Part B
Electrical
Works
Section
I
General
Instructions
Section II Specification and
List of Make
Section III Item Specification
Section II
Specifications
and List of Make
Electrical Works – Specifications and List of Make
E- 2
Section II: Electrical Works - Specifications, Testing and Make of
Material
Contents
Part A – Electrical Specification .................................................................................................................... 3
E1.
Internal Wiring ............................................................................................................................... 3
E2.
Distribution Boards...................................................................................................................... 11
E3.
Cable Trench............................................................................................................................... 13
E4.
Cable Trays ................................................................................................................................. 13
E5.
Medium Voltage Cables .............................................................................................................. 24
E6.
Cable Termination....................................................................................................................... 28
E7.
Medium Voltage Panel Board / Mv Switch Gear ......................................................................... 28
E8.
Lighting Fixtures & Accessories .................................................................................................. 54
E9.
Earthing ....................................................................................................................................... 60
E10.
Street Lighting Poles: .................................................................................................................. 67
E11.
Telephone & Data Distribution .................................................................................................... 72
E12.
HT GOD& HT Work .................................................................................................................... 77
E13.
Diesel Generator Set................................................................................................................. 106
Part B: Testing .......................................................................................................................................... 123
Part C: Erection, Testing & Commissioning Of Electrical Installations ..................................................... 125
Part - D: List Of Approved Make For Electrical Materials ......................................................................... 129
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Part A – Electrical Specification
E1. Internal Wiring
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 outlet points, power socket outlet points etc. including fixing of light fixtures, ceiling fan, exhaust
fan, wall fan etc.
1.1
Standards
The following standards and rules shall be applicable:
Standard no.
Particular
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 : 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 layout 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.
1.2
Point Wiring
A point shall consist of the a switch as required, including the ceiling rose or pendant holder or swan
holder, or ceiling fan box or socket or suitable termination. A point shall include, in addition, the earth
continuity conductor / wire from the Switch 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
1.2.1.
Supply, installation, fixing of conduits with necessary accessories, junction / pull / inspection /
switch boxes and outlet boxes. ( Refer BOQ Item for Pipe Supply )
1.2.2.
Supplying and drawing of wires of required size including earth continuity wire.
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1.2.3.
Supply, installation and connection of flush type switches, sockets, cover plates, switch
plates, etc.
1.2.4.
The point shall be complete with the branch wiring from the Switch board to the outlet point,
Pre laid conduit with accessories, junction, pull, inspection boxes, control switch, socket,
outlet boxes, ceiling roses, button / swan holder, connector etc.
Point Rate
The rate per point shall include supply, installation, connection, testing and commissioning of point as
described under “point wiring”. The measurements of the points will be enumerated. Rate for the point
shall consist of wiring from the out let point to the switch board as required with a connector/ plate/ ceiling
rose fan box with hook socket with switch. The point rate shall include phase and neutral wire a PVC
insulated earth continuity wire from switch to outlet. The unit rate for the point shall consist of wiring from
switchboard to outlet point through switch and/or socket, switch board as required and including the outlet
points with connector, fan hook box or sockets etc…
1.4
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, copper conductor
FRLS wires laid through exposed (surface mounted) PVC conduits as directed.
1.5
General
The contractor shall submit for approval, the shop drawing of 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 prior to laying of conduits. Only after the drawings are approved, the contractor shall
proceed with the work of conduit laying.
Prior to laying and fixing of conduits, the contractor shall carefully examine the working drawings
prepared by him and approved by the Consultant indicating the layout, satisfy himself about the sufficiency
of number and sizes of conduits, location of junction boxes, sizes and location of switch boxes and
other relevant details. Any discrepancy found in the drawings shall be brought to the notice of the
Owner’s site representative. Any modifications suggested by the contractor shall be gotten approved
before the actual laying of conduits is commenced.
In laying of conduits it is important that not more than two right angle bends are provided for each circuit
and as far as possible. No junction box shall be provided in the entire length of conduit run for drawing of
wires. Only switch outlets, lighting fixture outlets, equipment power outlets and socket outlets shall be
considered for drawing of wires.
1.6
Material
1.6.1 PVC
Conduits
All non-metallic PVC conduits shall conform to IS: 9537. The conduit shall be plan and type as specified in
IS: 9537 and shall be used with the corresponding accessories (Refer IS: 3419 specification for fittings for
rigid non PVC metallic conduits). PVC conduits shall be rigid unplasticized, medium gauge having 1.6 –
1.8 mm. wall thickness up to 20 mm. diameter conduit and 1.8 - 2 mm. wall thickness for all sizes above
20 mm. diameter.
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1.6.2 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 sheets painted with two coats of red-oxide and then two coats
of enamel paints as called for. Colour of the paints shall be as approved by the client. 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. 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 fan shall be fitted with adequately
sized rod / hook to fix ceiling fan. The boxes shall be of minimum depth of 65 mm.
1.6.3 Cover Plate
The cover of the boxes to receive outlet points shall be of best anodized sheet cut to shape and size or
plate of approved manufacturers of switches.
1.6.4 Cables
The cables shall conform to IS: 694. For all internal wiring FRLS wires of 650 / 1100 volts grade, single
core shall be used.
The conductors shall be plain annealed copper conductors complying with IS: 1554.
The conductors shall be circular copper conductor.
The insulation shall be XLPE compound complying with the requirements of IS: 694. It shall be applied by
an extrusion process and shall form a compact homogenous body.
The thickness of XLPE insulation shall be as set out in the relevant standards
The cores of all cables shall be identified by colours 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.
Unless otherwise specified in the drawings the size of the cables used for internal wiring shall be as
follows:
In case of circuit wiring for lights, exhaust fans, convenience socket outlet points (P+N+E):
2 nos. of 2.5 mm² + 1 no. of 1.5 mm.²
-From MCB at Panel/DB to switch boards.
3 nos. of 1.5 mm.²
-From switch boards to outlet points
2 nos. of 4.0 mm.² + 1 no. of 2.5 mm.²
-From MCB at Panel/DB to 16/20 Amp socket.
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1.6.5 Switches
Switches shall conform 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 moulded type rated for 250 volt, and of
full 5 / 15 A 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 flush modular type the make of the switches shall be as indicated in the
drawings or BOQ or make of material or as suggested and approved by the client. 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.
1.6.6 Sockets
The sockets shall conform to IS: 1293. Each socket shall be provided with control switch of appropriate
rating. The sockets shall be moulded type, rated for 250 volts, and either of full 5 A or 15 A capacity, as
mentioned on the drawings.
Sockets shall be of three pin type, the third in 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 contacts and solid brass shrouded terminals to ensure positive
electrical connections.
The sockets shall be provided with automatic shutters, which open only when earth pit of the plug inserts
in the socket.
The socket shall be provided with three pin plug top suitable to the socket and of the same make as
socket.
1.6.7 Under Floor Raceways
The under floor duct for “in screed” system shall be “galvanized sheet” steel of 1.6mm thick with top and
bottom plates are double folded and spot welded together to give required rigidity and to prevent the
seepage of concrete and screed water. The duct must have two or three compartments to accommodate
cables of different voltage ratings ( Power , Data & Communication ). The standard length of the duct shall
be of 2.5 mtrs with a width of 100 / 200 /250 (or) 300 mm and with a height of 28 / 38 (or) 48mm.
Coupler have to be used to connect the standard sizes of the ducts in screed covered system. The end
cap should lock in to the duct with out additional accessories to protect against dust or other foreign
particles inside the duct. The riser bends should be easily mounted as well for quick entry of cables in the
under floor system.
Under floor Junction & Service Outlet Access Boxes
The floor boxes must be of high quality material and should withstand heavy load and should have
corrosion protection.
The Underfloor Junction and Service Outlet Boxes shall be robust in its construction with a base plate and
side walls manufactured from minimum 1mm thick galvanized steel and main leveling frames from diecast/extruded aluminium. Height of the Underfloor Service outlet and Junction Boxes shall be adjustable
from 70 to 125mm inline with the height of the screed level for higher screed structures. The Junction and
Service outlet boxes shall have suitable dimensions to eliminate congestion and to provide ample working
space within the box. Junction Box shall be supplied with crossover bridges for segregation of power,
voice and data cables. The sides of the Underfloor boxes shall be pre punched on all the sides for quick
and easy installation of Underfloor Ducts at site.
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The Frame cassette for Stone finished application shall be manufactured from Stainless steel cassette
with 10/15/20/25/30 & 40mm height options to support floor finishing stone of different heights. The
cassettes shall also be fitted with a 4mm thick sheet steel plate for ensuring maximum rigidity and
providing adequate load bearing capacity. The cassette shall be supported on the Underfloor boxes with
the help of four part cassette frame screwed on the underfloor box firmly in place. The frame shall also
house a square shaped gasket in single piece to prevent ingress of dirt and water through the gap
between the cassette and frame.
Installation:
Underfloor trunking system shall be installed strictly as per manufacturer’s instructions and to a level of
workmanship to ensure that all the underfloor boxes are consistently in level with the screed level and any
part of the boxes is not detected below and or above the floor slab. Failure to comply in this respect, the
affected boxes shall be re-installed by the contractor, as required by the engineer.
Cross-over bridges shall be installed at the junctions as required, to ensure that adequate segregation of
power, voice and data service cables is maintained.
Service outlets shall be installed within floor boxes after installation is completed and wiring is carried out,
on to cover plates which are provided with suitable blanks for installation of service outlets.
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1.6.8 Under Floor PVC Raceways
1.7
Drawing Of Conductors
The drawing and joining of copper conductor or wires shall be executed with due regard to the following
precautions, while drawing insulated wires into the conduits, care shall be taken to avoid scratches and
kinks which may cause breakage of conductors. There shall be no sharp bends.
Insulation shall be shaved off for a length of 15 mm at the end of wire like sharpening of a pencil and it
shall not be removed by cutting it square or ringing.
PVC insulated copper conductor wire ends before connection shall be properly soldered
(at least 15
mm length) with soldering flux / copper solder, for copper conductor. Strands of wires shall not be cut for
connecting to the terminals. The connecting brass-screws shall have flat ends. All looped joints shall be
soldered and connected through terminals block / connectors. The pressure applied to tighten terminal
screws shall be just adequate, neither too much nor too less. Conductors having nominal cross section
are exceeding 4 sq. mm shall always be provided with crimping type cable sockets. At all bolted terminals,
brass flat washer of large area and approved steel spring washers shall be used. Brass nuts and bolts
shall be used for all connections.
Only certified wire man and cable jointers shall be employed to do joining work.
For all internal wiring PVC insulated wires of 650 / 1100 volts grade shall be used. The sub-circuit wiring
for point shall be carried out in looping system and no joint shall be allowed in the length of the
conductors. No wire shall be drawn in to any conduit, until all work of any nature that may cause injury to
wire is completed. Care shall be taken in pulling the wires so that no damage occurs to the insulation of
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the wire. Before the wires are drawn into the conduits the conduits shall be thoroughly cleaned of
moisture, dust, and dirt or any other obstruction by forcing compressed air through the conduits.
Maximum permissible number of 1100 volt grade PVC insulated wires that may be drawn into rigid non
metallic or PVC Conduits are given below:
1.8
Size of wires Nominal Cross
Maximum
size(mm)
number
of
wires
within
conduit
Section Area (Sq. mm.)
20
25
32
40
50
1.5
5
10
14
--
--
2.5
5
8
12
--
--
4
3
7
10
--
--
6
2
5
8
--
--
10
--
3
5
6
--
16
--
2
3
--
6
25
--
--
2
4
6
35
--
--
--
3
5
Joints
The wiring shall be by looping back system, and hence all joints shall be made at main switches,
distribution boards, socket outlets, lighting outlets and switch boxes only. No joints shall be made inside
conduits and junction boxes. Joints where unavoidable, due to any specified reasons, prior permission
in writing shall be obtained from the client before making such connections. Joints by twisting conductors
are prohibited.
1.9
Load Balancing
Balancing of circuit in three phase installation shall be planned before the commencement of wiring and
shall be strictly adhered to.
1.10
Earthing
All earthing systems shall be in accordance with IS: 3043 - 1985 code of practice for earthing.
1.11
Testing Of Installation
Before a completed installation is put into service, the following tests shall be complied with
1.11.1
Insulation Resistance
The insulation resistance shall be measured by applying 500 volt megger with all fuses in places, circuit
breaker and all switches closed.
The insulation resistance in mega ohms of an installation, measured shall not be less than 50 mega ohms
divided by the number of points on the circuit.
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The insulation resistance shall be measured between
EARTH TO PHASE
EARTH TO NEUTRAL
PHASE TO NEURAL
PHASE TO PHASE
1.11.2
Earth Continuity Path
The earth continuity conductors shall be tested for electrical continuity and the electrical resistance of the
same along with the earthing lead but excluding any added resistance or earth leakage circuit-breaker
measured from the connection, with the earth electrode to any point in the earth continuity conductor in the
completed installation and shall not exceed one ohm.
1.11.3
Polarity Of Single Pole Switches
A test shall be made to verify that every no-linked, single pole switch is connected to one of the phase of
the supply system.
1.11.4
Completion Certificates
All the above tests shall be carried out in presence of client and the results shall be recorded in prescribed
forms. Any default during the testing shall be immediately rectified and that section of the installation shall
be re tested. The completed test result from shall be submitted to the client for approval.
On completion of an electric installation a certificate shall be furnished by the contractor, countersigned by
the certified supervisor under whose direct supervision the installation was carried out. This certificate
shall be in a prescribed form as required by the local electric supply authority.
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E2. Distribution Boards
Distribution Boards (DB’s) shall be suitable for operation on 3 Phase/single phase, 415/240 volts,
50 cycles, neutral grounded at transformer. The DB shall be minimum di-electric strength of 2.5 KV / Sec.
All Distribution Boards shall manufactured by a manufacturer listed in Appendix-I.
DB’s shall comply with the latest Relevant Indian Standards and Electricity Rules and Regulations and
shall be as per IS-13947-1993.
1.1
Construction Features
DB’s shall be IP 43 & made out of 1.6 mm thick high quality CRCA sheet steel and shall be pre-treated
and powder coated sheet steel used in the construction of DB shall be folded and braced as necessary to
provide a rigid support for all component. DB shall be suitable for indoor / outdoor installation, wall
mounting free standing type, in double door construction. The Distribution Boards shall be totally
enclosed, completely dust and vermin proof and shall be with hinged doors, Neoprene gasket, padlocking
arrangement. All removable/ hinged doors and covers shall be grounded by 4.0 sq mm tinned stranded
copper connectors. Distribution Boards shall be suitable for the climatic conditions. Joints of any kind in
sheet metal shall be seam welded, all welding, slag shall be rounded off and welding pits wiped smooth
with plumber metal. The general construction shall confirm to IS-8623-1977 (Part-1) for factory built
assembled switchgear & control gear for voltage up to and including 1100 V AC.
All panels and covers shall be properly fitted and square with the frame, and holes in the panel correctly
positioned. Fixing screws shall enter into holes tapped into an adequate thickness of metal or provided
with wing nuts. Self threading screws shall not be used in the construction of DBs.
Three phase boards shall have phase barriers and a wire channel on three sides. Neutral bars shall be
solid tinned copper insulated bars with tapped holes and chase headed screws. For 3 phase DB’s, 3.
Independent neutral insulated bars shall be provided. All DB’s shall be internally pre-wired using copper
insulated PVC wires brought to a terminal strip of appropriate rating for outgoing feeders.
Knockout holes of appropriate size and number shall be provided in the DB’s in conformity with the
location of cable/conduit connections. Detachable sheet steel gland plates shall be provided at the top /
bottom to make holes for additional cable entry at site if required.
Distribution Boards shall comprise of the following:
1.1.1. A panel for mounting where appropriate incoming supply circuit breaker & other auxiliaries for
Control & distribution as required.
1.1.2. Installation accessories shall be part of the DB for fixing conductor and rails for mounting MCB’s
and RCCB’s etc... Neutral bus bars & earthing bus bars required in the circuit. All bus bars in the
FDB shall be insulated type.
1.1.3. Service cable /interconnection shall be part of the Distribution Boards.
1.1.4. The board shall be installed at a height such that the operating is within reach of the normal human
height i.e. 1.2 to 1.8 meters from finish floor level.
1.1.5. Degree of protection shall be IP-52 for indoor application, IP-54 for kitchen & laundry and IP-55 for
outdoor application.
1.1.6. All three phase distribution boards shall have 4 rows and single phase distribution boards shall have
single rows for housing of MCB’s and RCCB’s unless noted otherwise.
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1.1.7. Phase segregation to be maintained in all three phase distribution boards.
1.1.8. Earthing shall be provided in each FDB’s.
1.2
Miniature Circuit Breaker (MCB)
Miniature Circuit Breaker shall comply with IS-8828-1996/IEC898-1995. Miniature circuit breakers shall be
quick make and break type for 240/415 VAC 50 Hz application with magnetic thermal release for over
current and short circuit protection. The breaking capacity shall not be less than 10 KA at 415 VAC. MCB’s
shall be DIN mounted. The MCB shall be Current Limiting type (Class-3). MCBs shall be classified (B, C,
D ref IS standard) as per their Tripping Characteristic curves defined by the manufacturer. The MCB shall
have the minimum power loss (Watts) per pole defined as per the IS/IEC and the manufacturer shall
publish the values. MCB shall ensure complete electrical isolation & downstream circuit or equipment
when the MCB is switched OFF.
The housing shall be heat resistant and having high impact strength. The terminals shall be protected
against finger contact to IP20 Degree of protection. All DP, TP, TPN and 4 Pole miniature circuit breakers
shall have a common trip bar independent to the external operating handle.
MCB should be having an integrated label holder with dual side din rail locking facility. Incoming &
Outgoing should have facility for termination of Busbar & Cable separately.
Cable termination facility should be up to 35 sq. mm.
1.3
Residual Current Circuit Breaker Current Operated Type ( RCCB)
I.
System Of Operation
Residual Current Circuit Breaker shall confirm to IEC 61008.RCCB shall work on the principle of core
balance transformer. The incoming shall pass through the torrodial core transformer. As long as the
currents in the phase and neutral shall be the same, no electro motive force shall be generated in
the secondary winding of the transformer. In the event of a leakage to earth, an unbalance shall be
created which shall cause a current to be generated in the secondary winding, this current shall be
fed to a highly sensitive miniature relay, which shall trip the circuit if the earth leakage current exceeds
a predetermined critical value. RCCB shall be current operated independent of the line voltage; current
sensitivity shall be of 30 / 100 mA at 240/415 volts AC and shall have a minimum of 20,000 electrical
operations.
It should provide full protection as envisaged by IE rules – 61-A, 71 – ee, 73 – ee, 1985 and also rule 50 of
IE rule1956.
Ii.
Mechanical Operation
The moving contacts of the phases shall be mounted on a common bridge, actuated by a rugged toggle
mechanism. Hence, the closing /opening of all the three phases shall occur simultaneously. This also
shall ensure simultaneous opening of all the contacts under tripping conditions.
Iii.
Neutral Advance Feature
The neutral moving contact shall be so mounted on the common bridge that, at the time of closing, the
neutral shall make contact first before the phases; and at the time of opening, the neutral shall breaks
last after allowing the phases to open first. This is an important safety feature which is also required by
regulations.
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MCB should be having an integrated label holder with dual side din rail locking facility. Incoming &
Outgoing should have facility for termination of Busbar & Cable separately.
Cable termination facility should be up to 35 sq. mm.
Iv.
Testing Provision
A test device shall be incorporated to check the integrity of the earth leakage detection system and the
tripping mechanism. When the unit is connected to service, pressing the test knob shall trip the ELCB /
RCCB and the operating handle shall move to the "OFF" position.
1.4
Earthing
Earthing shall be provided as per IS: 3043-1987.
1.5
Painting
All sheet steel work shall undergo a process of degreasing, pickling in acid, cold rinsing, phosphating,
passivaiting (seven tank processing) and then painted with electrostatic paint (Powder coating). The
shade of colour of panel inside/outside shall be of Siemens gray paint shade no. RAL-7032 of IS Code
No.5.
1.6
Labels
Engraved PVC labels shall be provided on all incoming and outgoing feeder. Circuit diagram showing the
arrangements of the circuit inside the distribution panels shall be pasted on inside of the panel door and
covered with transparent plastic sheet.
1.7
Testing
Testing of panels shall be as per following codes:
IS: 8623 (Part -I) 1977 for factory built assemblies of switch gear for voltages up to and including 1000
VAC.
IS: 13947: 1993 Degree of protection
1.8
Wiring
In wiring a distribution panel it shall be insured that total load of various distribution panel and/or
consuming devices is divided evenly between the phases and number of ways as per Consultants
drawing.
E 3 . C a b l e Tr e n c h
Not Applicable
E 4 . C a b l e Tr a y s
General Requirement:-
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Cable Tray and Cable Ladder systems are intended for the support and accommodation of cables and
possibly other Electrical equipment in Electrical/Instrumentation/Communication systems.
Design and Fabrication of Cable Trays / Ladders:The cable trays / ladders shall be fabricated according to the design specified by IEC 61537 and should be
tested for Safe Working Load (SWL). The relevant details of SWL and the load chart with respect to SWL,
supporting distance and the deflection should be according to the following chart.
Safe Working Load (SWL) with a span length up to 3 meters
Span length (in meters)
Side
Width
Description
Height
1.5m
2m
2.5m
3m
(in mm)
(in mm)
Permitted Load (in kg/meter)
35
50 - 300
125
90
50
-
60
50 - 600
150
100
50
-
85
100 - 600
175
110
50
-
100 / 110
100 - 550
185
130
75
60
45
200 - 600
180
140
100
55
60
200 - 600
-
225
150
100
100 / 110
200 - 600
-
310
200
140
Perforated Cable Tray
Cable Ladder
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Safe Working Load (SWL) with a span length up to 10 meters
Span length (in meters)
Side
Width
Description
Height
4m
5m
6m
7m
8m
9m
10m
(in mm)
(in mm)
Permitted Load (in kg/meter)
200 - 300
160
110
75
-
20
-
-
400 - 600
200
150
100
-
40
-
-
200 - 300
230
180
140
100
70
-
-
400 - 600
250
200
160
130
100
-
-
200 - 300
160
110
80
40
-
-
-
400 - 600
210
150
100
70
-
-
-
200 - 300
230
180
140
100
70
-
-
400 - 600
250
200
160
130
100
-
-
200 - 600
-
-
300
250
200
140
100
100 / 110
Perforated Cable Tray
for long span distance
160
100 / 110
Cable Ladder for long
span distance
160
200
Fabrication of Tray / Ladder and accessories at site and welding is not permitted. In unavoidable
circumstances, If any cut or holes are made in the trays/Ladder/accessories, zinc spray need to be applied
over the surface. The metal edge has to be protected by edge protection sleeves to avoid cable damage.
Edge of the supports has to be protected with plastic END caps. Screwed connections and internal fixing
Devices should not create any damage to the cable when correctly fixed. Sudden or jerky motions shall
not be used to tighten reusable screw connections.
Cables shall run in cable tray/ladder mounted horizontally or vertically on cable tray support system which
in turn shall be supported from floor, ceiling, overhead structures, trestles, pipe racks, trenches or other
building structures using mounting accessories
Cable Tray:The cable tray and all accessories shall be fabricated from sheet steel and has to be hot dip galvanized
against corrosion confirming to ISO 1461-1999 for installations in both indoor and outdoor applications &
should have a Base Perforation Class B according to IEC 61537. The cable trays shall be supplied in
standard lengths of 3000mm and the width of the tray shall be as follows.
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E- 16
Width: 50, 100, 150, 200, 300, 400, 500, 600, 750 & 1000 mm.
All the cable tray accessories like Bend’s, TEES’s, Cross over’s etc should be designed in accordance
with IEC 61537 and shall be factory fabricated. The accessories shall be from the same material as of the
tray and modular type, it should be connected with the trays by using fasteners. Typical details of trays,
fittings and accessories.etc are shown in the enclosed drawings.
For Cable trays designed, tested and confirming to IEC 61537, thickness of cable tray should be
according to the manufacturers catalogue. For locally fabricated and non tested tray, thickness should be
2 mm up to span length of 1.5 meter, 2.5 mm for span length between 2 to 3 meter and 3 to 4 mm for
span length between 4 and 10 meter
Cable ladder:The cable Ladder and all accessories shall be fabricated from sheet steel and has to be hot dip galvanized
against corrosion confirming to ISO 1461-1999 for installations in both indoor and outdoor applications &
should have a Free Base Area classification Y according to IEC61537. The cable ladders shall be
supplied in standard lengths of 3000/6000 mm and the width of the tray shall be as follows.
Width: 200 to 1200 mm in multiples of 100 mm
Maximum rung spacing in the ladder shall be 300mm. The rung’s should be made of C profiles suitable to
fix cables by special metal clamps according to the drawing. The ladder shall be of riveted and foldable
type for easy transportation and to avoid damage during transportation and storage. All the ladder
accessories like Bend’s , TEES’s, Cross over’s etc should be designed in accordance with IEC 61537 and
shall be factory fabricated . The accessories shall be made from the same material as of the ladder and
modular type, it should be connected with the ladder by using fasteners. The details of ladders, fittings and
accessories .etc are shown in the enclosed drawing.
For Cable Ladders designed, tested and confirming to IEC 61537, thickness of cable Ladder should be
according to the manufacturer’s catalogue. For locally fabricated and non tested Ladder, thickness should
be 2.5 mm up to span length of 1.5 to 2 meter, 3 mm for span length between 2.5 to 4 meter and 3 to 4
mm for span length between 5 and 10 meter
Cover for Cable Trays / Ladders:Cover for trays/ladders to protect the cable insulation from falling objects, water droplets, harmful effects
of ultraviolet rays and accumulation of dust. The cover shall be made either from Hot Dip Galvanized
sheet steel or superior quality Double Dip Galvanized Sheets. For Outdoor application, Double dip
Galvanized material shall be used. The covers should be fitted properly to the Ladder / Tray by using pre
fixed and tested locks which ensure that covers are fitted rigidly to Tray / Ladder. For outdoor application
in high wind areas, additional cross over beadings to be used for fixing the cover on tray / ladder of width
more than 500 mm.
Mounting Accessories (supports and Brackets):-
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Electrical Works – Specifications and List of Make
E- 17
The mounting accessories shall be fabricated from steel and has to be hot dip galvanized against
corrosion confirming to ISO 1461-1999 for installations in both indoor and outdoor applications and should
be of completely modular type.
All supports and Brackets should be factory made, hot dip galvanized after completing welding, cutting,
drilling, other machining operations and tested according to IEC 61537 according to the arrangements in
the enclosed drawing. The system shall be designed such that it allows easy assembly at site by using
Bolts and Nuts. The main support and brackets shall be fixed at site using necessary brackets, clamps,
fittings, bolts, nuts and other hard ware etc to form various arrangements required to support the cable
trays. Welding of the components at the site shall not be allowed.
Corrosion Protection:The cable tray / ladder/accessories shall be of HOT DIP Galvanized (ISO 1461-1999) for installations in
corrosive atmospheres both indoor and outdoor application. Sample tray / ladder / accessories / mounting
accessories and supports should be salt spray tested according to ISO 9227 for > 500 hours. (*550 hours
according to class 6 for Hot dip Galvanized surface as per ISO)
Testing and Certification:Cable tray / Ladder, bend, T Bend, cross, and all supports are to be tested for Safe Working Load (SWL),
deflections, Impact resistance, Salt Spray & Electrical continuity test according to IEC 61537. The cable
th
tray/ladder should not deflect more than 1/100 of the span length at SWL in Mid span and the transverse
th
deflection of all mounting accessories at SWL shall not exceed 1/20 of the length. The cable tray / cable
ladder should be tested up to 1.7 times SWL at minimum and maximum room temperature. The
temperature classification of cable tray system should be - 5 to + 150°C.
Marking, Documentation, Compliance and Inspection:Each system component shall be durably and legibly marked with:
-the manufacturer’s or responsible vendor’s name or trade mark or identification mark;
-a product identification mark which may be, for example, a catalogue number, a symbol, or the like.
When system components other than cable tray lengths and cable ladder lengths are supplied in a
package, the product identification mark may be, as an alternative, marked on the smallest package unit.
Marking shall be applied, by moulding, pressing, engraving, printing, adhesive labels, or water slide
transfers. Compliance is checked by inspection and, for marking on the product, by rubbing by hand for 15
s with a piece of cotton cloth soaked with water and again for 15 s with a piece of cotton cloth soaked with
petroleum spirit. Marking made by moulding, pressing, or engraving is not subjected to the rubbing test.
After the test, the marking shall be legible.
If a system component is stored and transported at a temperature outside the declared minimum and
maximum temperatures, the manufacturer or responsible vendor shall declare the precautions and the
alternative temperature limits. Compliance is checked by inspection.
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E- 18
The manufacturer or responsible vendor shall provide in his literature all information necessary for the
proper and safe installation and use of the cable tray system and cable ladder system. The SWL and
impact resistance is valid for the whole temperature classification declared. The information shall include
a. Instructions for the assembly and installation of system components and for the precautions
required to avoid excessive transverse deflection, which could cause damage to the cables.
b. Thermal Expansion properties and precautions to be taken, if necessary,
c. Material, Surface Treatment and Salt Spray Test certificate
d. Relative humidity if it affects the material and Surface Treatment
e. Information on holes or devices provided for equipotential bonding or to run Earth Bonding Bar
f. Precautions for transport and storage outside the declared temperature classification, where
applicable
g. Product dimensions
h. Torque setting in Nm for screwed connections and internal fixing Devices. These devices should
not create any damage to the cable when correctly fixed. Sudden or jerky motions shall not be
used to tighten reusable screw connections. To test the screwed connections, it shall be tightened
and removed.
i. End Span Distance
j. Position and type of coupling along the span
k. SWL in kg/m for the fittings when not directly supported
l. Fixing method for installing cable tray or cable ladder to the supports
m. SWL in kg/m for the cable tray lengths or the cable ladder lengths including joints for various Span
Distances. SWL information can be given in the form of a diagram, table or similar. Compliance is
checked by inspection
n. SWL in kg for cantilever brackets
o. SWL for pendants as a bending moment in kg and /or as a force in N
p. The appropriate material specification and environmental conditions, chemical environments or
aggressive agents for which the product is suitable
SPECIFICATION FOR WIRE MESH CABLE TRAY
GENERAL:Wire Mesh Cable Tray System intended for the support and accommodation of power, Instrumentation,
data network, voice, video and other low-voltage cables and possibly other Electrical equipment in
Electrical / Communication systems. The SYSTEM shall support commercial, industrial, and utility
applications and should be designed, constructed and tested according to IEC 61537.
Design and Fabrication of Mesh trays:The wire mesh cable tray shall be manufactured according to the design specified by IEC 61537 and
should be tested for Safe Working Load (SWL). The relevant details of SWL and the load chart with
respect to SWL, supporting distance and the deflection should be according to the following chart.
Safe Working Load (SWL) with a span length up to 2 meters
Span length (in meters)
Side
Width
Description
Height
(in mm)
(in mm)
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1m
1.5m
2m
Permitted Load (in
Kg/meter.)
Sign of Bidder
Electrical Works – Specifications and List of Make
35
Mesh cable tray
55
105
E- 19
50 - 150
25
11
10
200
30
14
10
300
75
22
15
50 - 150
25
12
8
200 - 400
60
28
25
500 - 600
75
38
25
100 – 200
80
55
37
300 – 400
110
75
53
500 – 600
125
85
60
Each section of mesh tray shall have a length of 3 meter of continuous, rigid, welded steel wire mesh.
Consecutive straight length of 3 meter mesh trays shall be connected without couplers or connecting tools
Screwed connections and internal fixing Devices should not create any damage to the cable when
correctly fixed. Sudden or jerky motions shall not be used to tighten reusable screw connections
Cables shall run in cable tray mounted horizontally or vertically on cable tray support system which in turn
shall be supported from floor, ceiling, overhead structures, trestles or other building structures using
mounting accessories
SURFACE TREATMENT:



Electro Galvanized confirming to DIN E 12329 with minimum 10 microns zinc coating for indoor
closed and dry atmospheric application
Hot Dipped Galvanized confirming to ISO 1461 – 1999 with minimum 60 microns zinc coating for
outdoor or open area applications
Stainless steel 304 for Food/Beverage/Pharmaceutical and clean room application
Stainless steel 316 for highly corrosive atmospheric areas like chemical plant & Offshore
platforms
According to area of application, Surface treatment of material can be selected. Eg. Electro Galvanised
cable tray and accessories should never be used in outdoor or open areas.
CONSTRUCTION:The Tray shall be constructed using 50 mm x 100 mm grid except for 50mm wide tray to ensure
maximum ventilation of cables and dissipation of heat. For 50 mm wide tray, the grid size should be 20
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E- 20
mm x 100 mm. All exposed fabricated edges shall be tapered to ensure safe handling and installation of
the product. One end of each straight section of formed wire mesh cable tray shall be of integrated
interlocking ends. The diameter of the steel wire shall be minimum 3.5 mm for trays up to 150 mm width
and minimum 4.5 mm for trays up to 600 mm width.
Screw less straight connection of mesh cable tray shall be made without couplers and special tools for
straight consecutive lengths.
All tray fittings (eg., change in direction) shall be constructed at site by using bolt cutters and fastened
using joint connectors, clamps & corner connectors with M6x20 bolt and combination nut. The connectors
and clamps should be same or higher corrosion resistance class of the tray.
Mounting Accessories (supports and Brackets):The mounting accessories shall be fabricated from steel and has to be hot dip galvanized against
corrosion confirming to ISO 1461-1999 for installations in both indoor and outdoor applications and should
be of completely modular type.
All supports and Brackets should be factory made, hot dip galvanized after completing welding, cutting,
drilling, other machining operations and tested according to IEC 61537 according to the arrangements in
the enclosed drawing. The system shall be designed such that it allows easy assembly at site by using
Bolts and Nuts. The main support and brackets shall be fixed at site using necessary brackets, clamps,
fittings, bolts, nuts and other hardware etc to form various arrangements required to support the mesh
trays. Welding of the components shall not be allowed.
Corrosion Protection Testing:Sample tray / accessories / mounting accessories and supports should be salt spray tested according to
ISO 9227 as below
#
Corrosion
class
resistance
Material Surface Treatment
Salt spray test duration
1
1
Electro Galvanised
24 Hours
2
6
Hot Dip Galvanised
550 hours
3
6
Double Dip Galvanised
550 Hours
4
9 A to 9 D
Stainless Steel
Not applicable
Testing and Certification:Mesh tray and all mounting supports are to be tested for Safe Working Load (SWL), deflections, Impact
resistance, Salt Spray & Electrical continuity test according to IEC 61537. The cable tray should not
th
deflect more than 1/100 of the span length at SWL in Mid span for mesh trays and the transverse
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Electrical Works – Specifications and List of Make
E- 21
th
deflection of all mounting accessories at SWL shall not exeed 1/20 of the length. The mesh tray should
be tested up to 1.7 times SWL at minimum and maximum Temperature. The temperature classification of
mesh tray system should be - 5 to + 150°C.
Marking, Documentation, Compliance and Inspection:The manufacturer or responsible vendor shall provide in his literature all information necessary for the
proper and safe installation and use of the mesh tray system. The SWL and impact resistance is valid for
the whole temperature classification declared. The information shall include
a. Instructions for the assembly and installation of system components and for the precautions
required to avoid excessive transverse deflection, which could cause damage to the cables.
b. Thermal Expansion properties and precautions to be taken, if necessary,
c. Material, Surface Treatment and Salt Spray Test certificate
d. Relative humidity if it affects the material and Surface Treatment
e. Information on devices provided for equipotential bonding or to run Earth Bonding Bar if
necessary for routing power cables
f. Product dimensions
g. Torque setting in Nm for screwed connections and internal fixing Devices. These devices should
not create any damage to the cable when correctly fixed. Sudden or jerky motions shall not be
used to tighten reusable screw connections. To test the screwed connections, it shall be tightened
and removed.
h. End Span Distance
i. Position and type of coupling along the span
j. SWL in Kg/m for the fittings when not directly supported
k. Fixing method for installing mesh tray or to the supports
l. SWL in Kg/m for the mesh tray lengths or the lengths including joints for various Span Distances.
SWL information can be given in the form of a diagram, table or similar. Compliance is checked
by inspection
m. SWL in KG for cantilever brackets
n. SWL for pendants as a bending moment in Kg and /or as a force in N
o. The appropriate material specification and environmental conditions, chemical environments or
aggressive agents for which the product is suitable
INSTALLATION
Prior to and during installation, refer to SYSTEM layout drawing containing all elements of the SYSTEM.
Installer shall comply with manufacturer’s installation procedures. Support and cable loading shall be done
in accordance with manufacturer’s load diagram.
1.0
Cable Trays shall be Galvanized and factory fabricated out of MS channels, angle iron, tee,
bends, sections, flats and perforated sheet for different loads and number and size of cables as given
below :
Cable trays shall be galvanized as per Specification given elsewhere.
a.
1500 mm wide
Runners 25 x 100 x 25 x 3 mm
Rungs 20 x 40 x 20 x 3 mm 250 mm C/C
Suspenders 2 Nos. 40 x 40 x 5 mm GI angle 1200 mm C/C
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b.
E- 22
1200 mm wide
Runners 25 x 100 x 25 x 3 mm
Rungs 20 x 40 x 20 x 3 mm 250 mm C/C
Suspenders 2 Nos. 40 x 40 x 5 mm GI angle 1200 mm C/C
c.
1000 mm wide
Runners 25 x 100 x 25 x 3 mm
Rungs 20 x 40 x 20 x 3 mm 250 mm C/C
Suspenders 2 Nos. 40 x 40 x 5 mm GI angle 1200 mm C/C
d.
750 mm wide
Runners 25 x 100 x 25 x 3 mm
Rungs 20 x 30 x 20 x 2.5 mm 250 mm C/C
Suspenders 2 Nos. 32 x 32 x 5 mm GI angle 1200 mm C/C
e.
600 mm wide
Runners 25 x 100 x 25 x 3 mm
Rungs 20 x 30 x 20 x 2.5 mm 250 mm C/C
Suspenders 2 Nos. 32 x 32 x 5 mm GI angle 1500 mm C/C
f.
450 mm wide
Runners 25 x 100 x 25 x 3 mm
Rungs 20 x 30 x 20 x 2.5 mm 250 mm C/C
Suspenders 2 Nos. 25 x 25 x 4 mm GI angle 1500 mm C/C
g.
Supply and fixing of perforated type cable trays of the following sizes of pre-galvanized iron.
600 x 100 x 100 x 2 mm thick
450 x 100 x 100 x 2 mm thick
300 x 100 x 100 x 2 mm thick
150 x 100 x 100 x 2 mm thick
Note: Suitable length of 8 mm dia. GI rod suspenders at 1200 mm intervals shall be included in the item
for perforated type cable tray.
2.0
Specification for hot dip galvanizing process for mild steel used for earthing, cable trays or
junction boxes for electrical installation
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1.2
General Requirements
I.
Quality Of Zinc
E- 23
Zinc to be used shall conform to minimum Zn 98 grade as per requirement of IS: 209-1992.
Ii
Coating Requirement
Minimum weight of zinc coating for mild steel flats with thickness up to 6 mm in accordance with IS:67451972 shall be 400 g/sqm.
The weight of coating expressed in grams per square metre shall be calculated by dividing the total weight
of Zinc by total area (both sides) of the coated surface.
The Zinc coating shall be uniform, smooth and free from imperfections as flux, ash and dross inclusions,
bare patches black spots, pimples, lumpiness, runs, rust stains bulky white deposits, blisters.
Mild steel flats / wires shall undergo a process of degreasing pickling in acid, cold rinsing and then
galvanizing.
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E- 24
E 5 . M e d i u m Vo l t a g e C a b l e s
1.1
Scope
This section shall cover supply of medium voltage cables.
1.2
Standards
The following standards and rules shall be applicable:
IS: 1554
PVC insulated electric cables (heavy duty).
IS: 1753
Aluminium conductors for insulated cables.
IS: 3961
Recommended current ratings for cables.
IS: 8130
Aluminium conductors for insulated cables
Indian Electricity Act and Rules.
1.3
Measurements
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.
1.4
General
The medium voltage cables shall be supplied, laid, connected, tested and commissioned in accordance
with the drawings, specifications, relevant Indian Standards specifications, manufacturer’s instructions.
The cables shall be delivered at site in original drums with manufacturer’s name, size, and type, clearly
written on the drums.
1.5
Material
The MV cables shall be cross linked polyethylene (XLPE) insulated PVC sheathed of 1100 volts grade
aluminium or copper conductor, armoured and unarmoured heavy duty, conforming to IS : 7098 Part I IS :
1988 Part I. as asked for in the schedule of quantities.
1.5.1. All XLPE Aluminium/Copper Power cables shall be 1100 Volts grade, multi core constructed as
per IS : 7098 Part-I of 1988 as follows :
a.
Stranded Aluminium /Copper conductor of high conductivity up to 4 mm.² size, the conductor
shall be solid and above 4 mm.², conductors shall be concentrically stranded as per IEC: 228.
b.
Cores laid up
c.
The inner sheath should be bonded over with thermo-plastic material for protection against
mechanical and electrical damage.
d.
Armoring should be provided over the inner sheath to guard against mechanical damage.
Armouring should be Galvanized steel wires or galvanized steel strips. (In single core cables
used in A.C. system armouring should be non-magnetic hard aluminium Wires/Strips. Round
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E- 25
steel wires should be used where diameter over the inner sheath does not exceed 13 mm;
above 13 mm flat steel armour should be used. Round wire of different sizes should be
provided against specific request.)
e.
The outer sheath should be specially formulated heat resistant black PVC compound
conforming to the requirement of type ST2 of IS: 5831-1984 extruded to form the outer
sheath.
1.5.2. Conductor shall be of electrolytic Aluminium/Copper conforming to IS : 8130 and are compact
circular or compact shaped.
1.5.3. Insulation shall be of XLPE type as per latest IS general purpose insulation for maximum
rated conductor temperature 70 degree centigrade.
1.5.4. In Inner sheath laid up cores shall be bonded over with thermoplastic
against mechanical and electrical damage.
material
for
protection
1.5.5. Insulation, inner sheath and outer sheath shall be applied by extrusion and lapping up process only.
1.5.6. Armouring shall be of galvanized steel wire/flat.
Galvanized steel flat strip / round wires applied helically in single layers complete with covering the
assembly of cores.
For cable size up to 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
1.5.7. Repaired cables shall not be used.
1.5.8. Current ratings of the cables shall be as per IS: 3961.
1.5.9. The XLPE insulated cables shall conform to latest revision IS read along with this
specifications. The Conductor shall be stranded Aluminium/Copper circular/ sector shaped and
compacted. In multi core cables the core shall be identified by red, yellow, blue and black coloring
of insulation as following.
Core identification:
Two cores
:
Red and Black
Three cores
:
Red, Yellow and Blue
Four core
:
Red, Yellow, Blue and Black
Single core
:
Green, Yellow for earthing
Black shall always be used for neutral.
1.5.10. The XLPE insulated 1100 Volts grade power cables shall conform to latest IS and shall be
suitable for a steady conductor temperature of 70 degree centigrade. The conductor shall be
stranded Aluminium/Copper as called for in the Schedule of quantities. The outer sheath shall be
as per the requirement of type ST-2 of IS: 5831 of 1984.
1.5.11. The cables shall be suitable for laying in racks, ducts, trenches, conduits and underground buried
installation with uncontrolled back fill and chances of flooding by water.
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1.5.12. Progressive automatic in line sequential marking of the length of cables in meters at every one
meter shall be provided on the outer sheath of all cables.
1.5.13. Cables shall be supplied in non returnable wooden drums as per IS: 10418.
Both ends of the cables shall be properly sealed with PVC/Rubber caps so as to eliminate ingress
of water during transportation, storage and erection.
1.5.14. The product should be coded as per IS: - 7098 Part-I as follows:-
1.6
Aluminium Conductor
A
XLPE Insulation
2X
Steel round wire armour
W
Steel strip armour
F
Steel Double round wire armour
WW
Steel Double strip armour
FF
Non-magnetic (Al.) round wire armour
Wa
Non-magnetic (Al.) strip armour
Fa
PVC outer sheath
Y
General
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 client.
The cable ends shall be suitably sealed against entry of moisture, dust, water etc. with cable compound as
per standard practice.
1.7
Testing
1.1.1 Finished Cable T ests At M anufacturer’s Works
The finished cables shall be tested at manufacturer’s 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 clients' representative.
a.
Voltage test
Each core of cable shall be tested at room temperature at 3 KV A.C. R.M.S. for duration of 5 minutes.
b.
Conductor 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.
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E- 27
Prior to dispatching cables and at the time of delivering the cables at stores, following tests shall be
carried out: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 Vendor 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 out in
the presence of the client and results shall be recorded in the prescribed forms.
1.8
Cable
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 ².
Manufacturer’s Name & year of manufacturing.
1.9
Sealing, Drumming & Packing
After tests at the manufacturer’s works, both ends of the cable shall be sealed to prevent the ingress of
moisture during transportation and storage.
Cable shall supply in length of 500 ± 10% meters on 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 manufacturer’s 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 manufacturer’s name and year of
manufacturing etc.
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E- 28
E 6 . C a b l e Te r m i n a t i o n
Not Applicable
E 7 . M e d i u m Vo l t a g e P a n e l B o a r d / M v S w i t c h G e a r
1.1
Scope
This scope shall cover design, manufacture, check test, and supply, installation, testing (Scope to assist
the Ele. Contractor for installation, all the sections of panels & Internal Control wiring should be done by
panel vendor on site ), testing and commissioning of various medium voltage Panel Board as described in
Bills of quantities and drawings. The Panel manufacturer should have a design validated by CPRI / ERDA
for breaking capacity of at least 100 KA for 1 Sec.
Medium voltage Panel Board will be installed indoor and is connected through the cables.
1.2
Service Conditions At Site
Ambient Temperature
:
Max. / Min. = 45° C. / 6° C.
Design temperature
:
50 Degree C.
Relative humidity
:
95% max.
Voltage
1.3
:
415+/- 10%, TPN
Frequency
:
50 Hz. + 3% to -6%
Neutral
:
Solidly / earthed neutral.
Fault level
:
15KA, Symmetrical at 415V solidly earthed.
Documentation
1.3.1. Vendor shall furnish drawings

General arrangement drawing indicating accessories and dimensions.

Foundation plan and loading.

Termination arrangement with dimensions.

Three phase wiring diagrams

SLD’s and control schemes

Terminal plans

Bill of quantity for each panel.
1.3.2. Documents to be submitted after placement of order, before starting of the Fabrication of the
Panels

As per above for comments and approval for manufacture.
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
E- 29
Schematic and sectional drawing.
1.3.3. Final documents - data and manuals in six sets along with equipment supplied.

As built drawings with RTP (Reproducible Tracing Paper).

Instruction and maintenance manual - Six copies.

Test certificates - Six copies.
1.4
General Specifications
All 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
grounded at transformer and short circuit level as mentioned in the drawings.
Degree of protection for following type of distribution panel enclosure shall be as per IS: 13947-1993.
a.
IP 52 for indoor panels.
b.
IP 54 for kitchen and laundry panels.
c.
IP 55 for outdoor panels.
The painting of all the metal part shall be with seven tank process followed by powder coating as per the
standard.
The Panels shall be designed to withstand the heaviest condition at site, with maximum expected ambient
temperature of 50° c., 95% humidity.
1.5
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:
Standard no.
Particular
IS : 4237
General requirements for switchgear and control gear for
voltages not exceeding 1000 V A.C. or 1200 V D.C.
IS : 5578
Guide for marking of insulated conductors.
IS : 11353
Guide for uniform system of marking and identification of
conductors and apparatus Terminals.
IS : 13947
Low voltage switchgear and control gear.
IS : 8197
Terminal marking for electrical measuring instrument and their
accessories.
IS : 2551
Danger notice plates
IS : 10118
Code of Practice for selection, installation and maintenance of
switchgear
and control gear.
IS : 8623
Specification for factory built assemblies of switchgear and
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Particular
control gear for voltage up to and including 1000 V A.C. and
1200 V D.C.
IS : 8828
Miniature circuit breakers.
IS : 9224
HRC fuse links
IS : 2705
Current transformer
IS : 3156
Voltage transformer
IS : 3231
Electrical relay for protection
IS : 1248
Indicating instrument
IS : 722
Integrating instrument
IS : 6875
Control switches and push buttons
IS : 1822
A.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 consultant at various stage of their manufacture such as
design, selection, construction, testing, shipping etc.
1.6
Construction
1.6.1 Cubical Type Panels
A.
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. The type of construction shall be 4b.
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: 51 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 units 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
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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. The entire
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.
A1.
Structure & Construction for IP 65 Panel / Feeder Pillar
Feeder Panels shall be lockable IP65 & 3 mm thick sheet steel cabinet for Outdoor installation, dead front,
floor mounting type and shall be form 3b construction. The Distribution panels shall be totally enclosed,
completely dust and vermin proof and shall be with hinged doors, Neoprene gasket, padlocking
arrangement and bolted back. All removable/ hinged doors and covers shall be grounded by flexible
standard connectors. Distribution panel shall be suitable for the climatic conditions as specified in Special
Conditions. Steel sheets used in the construction of Distribution panels shall be 3 mm thick and shall be
folded and braced as necessary to provide a rigid support for all components. Joints of any kind in sheet
metal shall be seam welded, all welding, slag shall be rounded off and welding pits wiped smooth with
plumber metal. The general construction shall confirm to IS-8623-1977 (Part-1) for factory built assembled
switchgear & control gear for voltage up to and including 1100 V AC.
All panels and covers shall be properly fitted and square with the frame, and holes in the panel correctly
positioned. Fixing screws shall enter into holes tapped into an adequate thickness of metal or provided
with wing nuts. Self threading screws shall not be used in the construction of Distribution panels. A base
channels of 75 mm x 40 mm x 5 mm thick & Suitable Size Stand with the 3 mm Sheet Cover the bottom
for floor mounted panels. Minimum clearance of 450 mm shall be provided between the floor of
Distribution panels and the lowest unit.
The Internal electrical switchboard (panel) shall be made up of high quality polycarbonate thermoplastic,
shock proof, anti-corrosive, acid & chemical resistant, fire retardant, self extinguishing, highly impact
resistant, halogen free, silicon free, recyclable, having internally embedded gasket. The switchboard
(panel) shall have provision for future expansion & shall be modular in construction. The bus bars shall be
connected with C type clamps without any drilling on the bus bars. The panel shall be in accordance with
IEC 60 439 – 1 (Fully TTA). The Degree of Ingress Protection shall be in accordance with IEC 60 529.
Panel Enclosure (Internal) has to be thermoplastic polycarbonate or of the material which has equivalent
or exceeds the inherent features of thermoplastic polycarbonate. Said enclosures, in addition to containing
the devices and components that constitute the electrical panel, must have certain properties and
characteristics that are specific for their practical use; for e.g. they must provide a suitable degree of
electrical insulation, have sufficient structural strength, be easy to handle, ensure adequate resistance to
the aggression of chemical and atmospheric agents, be self extinguishing, etc. It should be clean and
aesthetically appreciable.
Internal panel should be totally insulated FEEDER PILLAR PANEL made out of Modular Panel Box
System, Degree of Protection IP 65, in accordance with IEC 60 529, type tested in accordance with IEC
60 439 – 1.
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The manufacturer of board/panel shall submit a copy of CPRI test report of Degree of Ingress Protection
IP 65 in accordance with IEC 60529. The gasket material shall be Polyurethane; while the gasket shall be
internally embedded.
The manufacturer of board / panel shall submit a copy of type test report of a board made out of
Polycarbonate thermoplastic panel in accordance with IEC 60439-1. The report shall have mention of
following tests performed and passed out satisfactorily:
1.
2.
3.
4.
5.
6.
Temperature Rise.
Dielectric Properties.
Short circuit withstand current – Rated peak & short time withstand current and Rated Conditional
Short Circuit Current.
Effectiveness of Protective Circuits.
Clearance & Creep age Distance.
Mechanical Operation
For better safety the Polycarbonate encl shall be fire retardant & self extinguishing in accordance with IEC
60 695-2-11, DIN VDE 0304 Part 3, UL Subject 94 for Flammability V-2. It should be tested at Glow Wire
test for 960 deg. Cent.
The impact strength of polycarbonate enclosures / boards i.e. the Degree of Protection against
Mechanical load shall be in accordance with EN 50298-98 for IK 08.
The lid closing and opening shall be done by quick fastening spring mechanism latches.
Compactness of the boards is main criteria due to space constraints. The board / panel should be made
compact meeting the technical requirements in accordance with relevant standards and also keeping
adequate space for technicians to work. The MCB/ RCCB switching operations / accessing the MCB dolly
should be preferably by opening of a window flap. Window flap must be integral part of body of the box.
Window flap Additional screwing by cutting the front of the box for MCB or any accessories will not be
acceptable.
Note: The board manufacturer must submit the copy of type test reports for Polycarbonate Thermoplastic
Board only with final arrangements as per approved GA. Test Reports submitted of other material of
construction like MS, SS will not be applicable. Each Board shall have individual routine test report of the
manufacturer.
Internal Insulated enclosures of protection class II shall be made out of environment friendly, recyclable
polycarbonate thermoplastic, UV Resistant, halogen & silicon free, highly impact resistant, Anti Acid, Anti
corrosive : Resistant against demands caused by rains, water and corrosive atmosphere, Degree of
Protection against mechanical load IK 08 in acc. with DIN EN 50 102, Color Gray RAL 7032, fire retardant,
Glow Wire Tested at 960 deg. cent in acc. with IEC 60 695–2-1, DIN VDE 0304 Part 3. UL Subject 94, V –
2, Flame Retardant, Self Extinguishing, with transparent / opaque lids having tool operated / sealable /
hand operated / lockable quick fastening mechanism. Modular panel box doors especially for circuit
breakers should be the integral part of the top cover, Additional flap mounted on the box shall not be
allowed.
Incoming & Outgoing Cable from all the directions….
Mounting Type: Free Standing Type with Canopy of 3 mm thick CRCA Sheet.
Protection Measure: Totally Insulated
Degree of Protection: IP 65 in acc. with IEC 60 529
Rated Voltage: 690 / 1100 V
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Bus Bar System: electrolytic grade square type copper bus bars as per description with insulated
supports.
Interconnection between solid bus bars and equipment shall be connected by means of bus bar
connectors to avoid tapings on solid bus bars…
Temperature Resistance: - 40 deg. cent to + 120 deg. cent.
Distribution panels shall be of adequate size with a provision of spare switchgear as indicated on the
Single Line Diagram. Switches shall be arranged in multi-tier. Knockout holes of appropriate size and
number shall be provided in the Distribution panels in conformity with the location of cable / conduit
connections. Removable sheet steel plates shall be provided at the Bottom to make holes for additional
cable entry at site if required.
Every cabinet shall be provided with Trifoliate or engraved metal name plates. All panels shall be provided
with circuit diagram engraved on PVC sheet. All live accessible connections shall be shrouded and shall
be finger touch proof and minimum clearance between phase and earth shall be 20 mm and phase to
phase shall be 25 mm.
Sr.
No.
Criteria / Parameter
SMC required specification
1.
Material of Construction
of Main Feeder Pillar
Panel
Polycarbonate
2.
Degree
of
Protection
IP 65 in accordance with IEC 60
529
3.
Gasket
Material
enclosure
Sr.
No.
4.
Ingress
of
Vendor specification
Polyurethane
Criteria / Parameter
SMC required specification
Test
Report
The
Polycarbonate
Panel
manufacturer
shall
submit the test report
The
Polycarbonate
Panel
manufacturer shall submit the
test report for following type
tests.
Vendor specification
1. Temperature Rise.
2. Dielectric Properties.
3. Short circuit withstand
current – Rated peak &
short time withstand
current
and
Rated
Conditional Short Circuit
Current.
4. Effectiveness
of
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Protective Circuits.
5. Clearance & Creepage
Distance.
6. Mechanical Operation
B.
5.
Fire Retardant & SelfExtinguishing Test
The PC Enclosures shall be
tested for Glow Wire Test at 960
deg. cent. in accordance IOEC
60 695 – 2 – 11
6.
Impact Test
The PC Enclosure shall be rated
for IK 08 for mechanical impact
test in accordance with EN
50298-98
Protection Class
All the indoor Panels shall have protection class of IP : 51
C.
Painting
The painting shall be seven tank process followed by powder coating.
D.
Circuit 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 in `ON’ and `OFF’
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.
E.
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 switchgear / control gear,
busbar and connections.
F.
Busbars
The busbar shall be air insulated and made of high quality, high conductivity, and high strength Aluminium
/ Copper.
The busbar shall be of 3 phases and neutral system with separate neutral and earth bar. The size of
neutral busbar in all main panels or lighting panels and feeders for LDB shall be equal to phase busbar.
The busbar and interconnection between busbars and various components shall be of high conductivity
Aluminium / Copper. The busbar shall be of rectangular cross-section designed to withstand full load
current for phase busbars and half rated current for neutral busbars in case of APFCR panels only and
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shall be extensible on either side. The busbar size shall be as per drawing. The busbar shall have uniform
cross-section throughout the length.
The busbars and interconnections shall be insulated with epoxy coated bus sleeves. The busbar shall be
supported on bus insulators of SMC/DMC type at sufficiently close intervals to prevent busbars sag and
shall effectively withstand electromagnetic stresses in the event of short circuit capacity of 15 KA RMS
symmetrical for 1 sec.
The busbar shall be housed in a separate compartment. The busbar shall be isolated with 3 mm. thick
Bakelite sheet to avoid any accidental contact. The busbar shall be arranged such that minimum
clearance between the busbar is maintained as below:
Between phases
:
27 mm. minimum
Between phases and neutral
:
27 mm.
Between phases and earth
:
27 mm.
Between neutral and earth
:
20 mm. minimum
All busbar connections shall be done by drilling holes in busbars and connecting by chromium plated or
tinned plated brass bolts and nuts. Additional cross-section of busbar shall be provided in all Panels to
cover up the holes drilled in the busbar. Spring and flat washers shall be used for tightening the bolts.
All connections between busbars and circuit breakers / switches and cable terminals shall be through
aluminium / Copper 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.
Busbar shall be calculated on 50 deg. C. ambient temp. and 85 deg. C. for continuous and short time
rating. Busbar surrounding air temp. shall be considered 70 deg. C. for busbar calculation
All joint shall have non-flammable insulation shrouds for secondary insulation purpose
G.
Electrical Power And Control Wiring Connection:
Terminal for both incoming and outgoing cable connections shall be suitable for 1100 V grade, aluminium
/ copper conductor PVC 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 (PVC) 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.
Clip on type terminals shall be provided up to 10 sq.mm conductor and above 10 sq.mm bolt type
terminals shall be used.
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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; PVC 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.
H.
Terminals
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 and only one conductor may be connected in one
terminal.
I.
Wireways
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.
J.
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.
K.
Earthing
Copper earth bars of 25 mm  6 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.
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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.
L.
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.
M.
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.
Name plate shall be engraved in Gujarati language 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 send screws and not by adhesives.
N.
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 pretreatment 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, is of ISI certification mark.
O.
Internal Components:
The Panels shall be equipped complete with all types of required number of MCCB’s, contactors, relays,
fuses, meters, instruments, indicating lamps, push buttons, fittings, busbars, cable connectors etc. and all
the necessary internal connections / wiring as required and as indicated on relevant drawings.
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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.
1.7
Components
1.7.1 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 is ratings anticipated at prevailing site conditions.
1.7.2 Air Circuit Breaker
A.
Construction
The ACBs shall have following features:

Motorized with 230 V A.C. motor.

230 V A.C closing and shunt trip coil

Drawout type with "service", "test", "isolated" and "maintenance" position.

Safety shutter of Fibre glass / polycarbonate sheet of 2mm thickess shall be provided

Mechanically trip free plus antipumping 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.
B.
Release

Microprocessor based release shall be direct acting type, tripping ACB mechanically.

Short circuit, overload and earth fault protection shall be provided.

Vendor to suggest release type for feeders of supply range characteristic and accuracy.
C.
Acb Performance

ACB performance inside panels at ambient 50 Degree.
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
The Symmetrical breaking, 50KA

Making capacity peak 87.5 KA

Short time rating , 1sec. 50KA
D.
E- 39
Incomer Acbs
All incomer ACBs shall have following additional protections other than mentioned above.

Under and over voltage

Under and over frequency

Restricted Earth Fault protection

Trip Circuit supervision with PS class CT’s.

Undercurrent, ( DG set only)

Reverse power ( DG set only)

Phase sequence reversal ( DG set only)

Load shedding and reconnection thru programmable contacts.

Release should display the Contact wear indication.
The release should provide local indication of actual %age loading at any instant. The release should be
able to communicate on MODBUS RTU protocol using inbuilt RS485 port and shall be integral part of
supply with trip unit.Parameters of the Protection Release should be changeable from Release as well as
thru communication network. Release should have graphical LCD for display of power parameters. The
release should provide comprehensive metering with the following parameters

Phase currents (running, avg & max) – All parameters in single window.

Release should be able to capture short circuit current on which ACB has tripped.The last ten trips
and alarms shall be stored in memory with the date & time stamping along with type of fault and
alarm. The sensing CT Should be Rogowsky type with measurement precision of 1%.

Release should be self powered .

Release should have facility to select different type of IDMTL protection(DT,SIT,VIT,EIT,HVF) for
better co-ordination with HT Breaker/Fuse.

Phase voltages (running, avg & max)

Energy & power parameters (active, reactive and apparent)

PF

Frequency

Maximum Demand ( KVA & KW)

Total Harmonics distortion
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O/G Acbs
All O/G ACBs shall have following functions.
Protection

The ACB control unit shall offer the following protection functions as standard:

Long-time (LT) protection with an adjustable current setting and time delay;

Short-time (ST) protection with an adjustable pick-up and time delay;

Instantaneous (INST) protection with an adjustable pick-up and an OFF

Position.

Current and time delay setting shall be indicated in amperes and seconds respectively

On a digital display.

Earth-fault protection with an adjustable pick-up and time delay shall be provided if indicated on
the appended single-line diagram.
Measurements

An ammeter with a digital display shall indicate the true rms values of the currents for each phase.
Release shall acknowledge the current & time delay settings done by user on the LCD display.

A LED bargraph shall simultaneously display the load level on the three phases.

A maxi meter shall store in memory and display the maximum current value observed since the
last reset. The data shall continue to be stored and displayed even after opening of the circuit
breaker.
Safety Features
i.
The safety shutter shall prevent inadvertent contact with isolating contacts when breaker is withdrawn
from the Cradle.
ii.
It shall not be possible to interchange two circuit breakers of two different thermal ratings. For Drawout breakers, an arrangement shall be provided to prevent rating mismatch between breaker and
cradle.
iii.
There shall be provision of positive earth connection between fixed and moving portion of the ACB
either thru connector plug or sliding solid earth mechanism. Earthing bolts shall be provided on the
cradle or body of fixed ACB.
iv.
The incoming panel accommodating ACB shall be provided with indicating lamps for ON-OFF
positions, digital voltmeter and ammeter of size not less than 96 mm x 96 mm, selector switches,
MCB for protection circuit and measuring instrument circuits.
v.
It shall be possible to bolt the draw out frame not only in connected position but also in TEST and
DISCONNECTED position to prevent dislocation due to vibration and shocks.
vi.
Draw out breakers should not close unless in distinct Service/Test/Isolated positions.
vii.
The insulation material used shall conform to Glow wire test as per IEC60695.
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E- 41
The ACB shall provide in built electrical and mechanical anti-pumping.
ix.
All EDO ACB`s Shall have Ready to Close Contact to ensure that the ACB gets a command only
when it is ready to close for applications of Remote Control, AMF, Synchronization and Auto Source
Change Over Systems.
1.7.3 Moulded 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 electromagnetic
short circuit protection device. 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 230 V A.C motor for closing and tripping / switching off for the feeders if indicated in
single line diagram.
MCCB should be with following:
i.
Free Alarming for O/L, Healthiness check of the Breaker, Fault Differentiation on front of the MCB
from Display / LED.
ii.
All MCCB should be Communicable & have all kind of communication accessories with in built
metering should support open / Modbus protocol.
iii.
MCCB should provide switch board display unit for panel cutout.
1.7.4 Fuse
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 15KA 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.
1.7.5 Miniature 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
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E- 42
fault current of MCBs shall not be less than 10KA at 230 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.
1.7.6 Contactors
The contactors shall meet with the requirements of IS: 13947 and BS: 771.
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.
1.7.7 Voltmeter
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.
1.7.8 Ammeter
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.
1.7.9 Current 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 up to date.
1.7.10
Push 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.
1.7.11
Indicating 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
:
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Red
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OFF indicating lamp
:
Green
TRIP indicating lamp
:
Amber
PHASE indicating lamp
:
Red, Yellow, and Blue
TRIP circuit healthy lamp
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:
Milky
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B.
Power Factor Correction System With Detuned Filter
1.1
Scope
Design, manufacture, supply, erection, testing and commissioning of Indoor type power correction
capacitor banks for power factor improvement as per specification given below:
1.2
Standard
Unless otherwise stated below, the capacitor shall comply with the following standards (and their latest
amendments): IS 13340-1993, IS 13341-1992, IEC 60831-1+2
1.3
Rating
50 KVAR (or less) capacitor units as specified in the BOQ shall be used to form a bank of capacitors of
desired capacity.
1.4
Enclosure
The panel shall be indoor type, free standing, and floor mounting with IP42 degree of protection. It shall
be completely made of CRCA sheet steel. The enclosure shall have sturdy support structure with angle
supports as necessary and shall be finished with powder coating in the approved colour shade/s to match
the colour of the other panels. The thickness of powder coating should be minimum 60-80 microns.
Suitable provisions shall be made in the panel for proper heat dissipation. Air aspiration louvers for heat
dissipation shall be provided as a necessary.
The front portion shall house the switchgear and the rear portion shall house capacitors and series
reactors. The enclosure is to be suitably sized to accommodate all the components, providing necessary
air clearance between live and non-live parts, providing necessary working clearance.
1.5
Apfc Relay / Controller
Microprocessor based IPFC relay (Intelligent VAr controller) shall sense the PF in the system and
automatically switch ON / OFF the capacitor unit or stage to achieve the preset target PF. The controller
shall have the following features:

Digital settings from all the 3 phases for parameters like PF, Switching time delay, Step limit etc.

Indication of PF, preset parameters.

Minimum threshold setting of 1% of CT current.

No-volt release.

Protective shut down in case of harmonic overload.

Indication for Failure to achieve the target PF, Harmonic overloading, Step failure etc.
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1.6
E- 45
Construction
Each basic unit of mixed dielectric extra low loss / All Poly Propylene (APP) / GAS Filled capacitor shall be
built with a number of elements. These elements shall be combination of capacitor tissue paper and
biaxially oriented polypropylene film impregnated with non PCB bio-degradable impregnant or Film Foil
capacitor manufactured using Poly propylene film placed between 2 layers of metal foil and winding. The
elements shall be connected to the external bus bars through these leads in a series parallel connection to
form a three phase unit.
The capacitor units shall be floor mounting type using minimum floor space. The container of capacitors
shall be made out of 2 mm thick M S sheet steel of polyester paint coated finish. Each standard unit shall
be provided with internal fuses (operation co-ordinate with case-rupture characteristics to avoid rusting).
Total Harmonic Distortion (THD) of up to 5% on voltage and current waveforms shall not affect the life of
capacitors. 660±10% variation in line voltage shall not affect the life of the capacitors.
1.7
1.8
Capacitors

General specifications: 3 phase, delta connected, 50 Hz.

Voltage: Must be designed to withstand system over voltage, increased voltage due to series
reactor and harmonics.

Capacitor type: Super heavy duty with double side metalized capacitor tissue paper. Gas Filled
and self-healing type with bi-axially oriented polypropylene film shall be fitted with pressure
sensitive disconnector in each individual capacitor cell.

Over voltage +10% (12h / 24h), + 15% (30m / 24h), + 20% (5m), +30% (1m) as per Clause 6.1 of
IS 13340-1993.

Over current : 2.5 x In

Peak Inrush current withstand : 350 x In

Total watt-losses including discharge resistors: < 0.45 W / k V Ar.

Temperature category: -25 deg. C to 70 deg. C.

Capacitor shall be self-heating type and oil impregnated for longer life. The impregnant shall be
non-PCB, biodegradable type, must be properly treated and de-gasified, so as not to have any
degeneration properties and shall be non-oxidizing.

The design shall be modular for simple mechanical assembly, no extra accessories / metal parts
to be required. Unit must be free standing with an IP 41 protection level.
Discharge Resistance
Capacitors shall be provided with permanently connected discharge resistors so that residual voltage of
capacitors is reduced to 50 volts or less within one minute after the capacitors are disconnected from the
source of supply.
1.9
Terminals
Each capacitor bank shall be provided with a terminal chamber and cable glands suitable for PVC
insulated aluminum conductor armoured cables as specified.
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1.10
E- 46
Earthing
Two separate earthing terminals shall be provided for earth connection of each bank.
1.11
Low Voltage Filter Reactor
Filter reactor shall be series type having a three phase, iron core construction suitable for indoor use. The
reactor shall be air cooled and the layout shall be in accordance with IEC 76. The complete unit shall be
impregnated under vacuum and over-pressure in impregnation resin and shall be suitable for temperature
class H operation. The reactor coils shall be wound with high grade aluminum / copper and termination
shall be provided with suitably designed copper bars.
1.12
Testing
The reactor shall be tested `using a separate source voltage test of 3 KV (coil to core) for one minute as
per IEC 76/3. The reactor shall be fitted with a temperature sensitive micro-switch in the centre coil
(normally open) for connection to trip circuit in case of high operating temperature.
1.13
Series Reactor
Application
LV Harmonic Filters shall be used with harmonic filter duty power capacitors to mitigate harmonics,
improve power factor and avoid electrical resonance in LV electrical networks.
Construction, Testing & Protection
The low voltage filter reactor shall be series type having a three phase, iron core construction suitable for
indoor use (IP 00). The reactor shall be air cooled and the layout shall be in accordance with IEC 60076.
The complete unit shall be impregnated under vacuum and over-pressure in impregnation resin and shall
be suitable for temperature Class H (T60/H) operation.
The reactor shall be tested using a separate source voltage test of 3.0kV (coil to core) for 1 minute as per
IEC 60076/3.
The permitted tolerance of inductance shall be + 3% of rated inductance value.
Reactor tuning factor shall be 13% and the current rating of the reactor shall include the effects of
harmonics and other possible over-currents.
The limit of linearity of inductance of the filter reactor shall be as follows 1.2 with L = 0.95 LN
The reactor shall be fitted with a temperature sensitive micro-switch in the centre coil (normally open) for
connection to trip circuits in case of high operating temperatures.
1.14
Switchgear & Protection
Incomer switchgear shall be TP&N breaker appropriate rating. Suitable contactor for each step shall be
used and must be capable of capacitor switching duty at each step for short circuit protection.
Busbars shall be suitably colour coded and must be mounted on appropriate insulator supports.
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Power cables used shall have superior mechanical, electrical and thermal properties, and shall have the
capability to continuously operate at very high temperatures up to 125 deg.C.
Internal wiring between main bus-bars, breaker, contactor and capacitors shall be made with 1100 V
grade, PVC insulated, copper conductor cable of appropriate size, by using suitable copper crimping
terminal ends etc.
Suitable bus links for input supply cable termination shall be provided.
1.15
Control Circuit & General Protection
The control circuit shall be duly protected by using suitable rating MCB.
An emergency stop push button shall be provided to trip the entire system (22.5 mm dia., mushroom type,
press to stop and turn to reset).
Wiring of the control circuit shall be done by using 1.5 sq.mm, 1100 V grade, PVC insulated, multistranded copper control wire.
Inspection terminal strip, number ferruling, labeling etc. shall be provided.
440 V caution board on the panel shall be provided.
1.16
Testing
The capacitor bank shall be subject to tests as specified in relevant Indian Standards at the factory and
the test certificates shall be furnished in quadruplicate.
1.17
Installation
Capacitors banks shall be installed as per installation manual of supplier and shall conform to
relevant Indian Standards.
All interconnections in the control panel shall be checked before commissioning.
Cable end boxes shall be sealed after cable connections to prevent absorption of moisture.
15 mm thick rubber matting of an approved make over a 100 mm high Timber platform shall be provided
in front of the full length of the capacitor bank and control panel.
1.18
T esting And Commissioning
i.
Insulation resistance shall be tested with a 1000 volts megger between phases and phase to
earth.
ii.
Residual voltage shall be measured after switching of the capacitors and the same shall not be
more than 50 volts after one minute.
iii.
Each discharge resistor shall be tested for its working.
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C
Lightning And Surge Voltage Protection
1.1
Scope
E- 48
The work required under this section shall include all material, labour and auxiliaries required to furnish
and install complete Surge Protection Devices at main LT Panel incoming feeders (Stage I / Class B) &
Distribution Boards (Stage II / Class C) for the protection of Building electrical and Electronics system from
the effect of Lightning discharges, line induced transient surge voltage or switching surges as per the
details.
1.2
Codes & Standards
The following standards & publications as referred in the various parts of this Specification shall apply.
1.3

IEC-61643-11, IEC-61643-12

IEC 60 364 – 5 – 5 53

IEC 62 305 - 4
Product Specifications
1.3.1 Surge Protector At Stage I / Class B (L T Panel Protector )
The Surge Protection Device (SPD) manufacturer shall offer a complete line of Surge Protection Devices
to support the requirements for Main LT Panel Incoming feeders. The surge protector at this stage shall
be provided to protect the downstream electrical and electronics against any lightning discharges surges
that may enter into the system through Mains panel.
The Protection unit shall be based on single arc spark gap technology and shall be able to withstand
10/350 microsecond surge currents associated with external lightning discharges.
1.3.2 Protection Network Configuration
The work required under this section consists of furnishing, installing and connecting SPD device as
specified and as asked for in BOQ. The SPD device shall be installed in a NETWORK configuration,
consisting of one set of SPD panel device at the service entrance of switchboard. All SPD devices in this
network configuration shall be of same manufacturer. All SPD devices shall be modular, mountable on 35
mm DIN rail.
Unit status indicator shall be provided to indicate the status of complete Protection unit.
Protection shall be manufactured for the specific type and voltage of the electrical Service and shall
provide clamping for both normal (L-N) and common (N-G) mode operation.
Protection shall be manufactured to withstand a maximum continuous operating voltage of not less than
115% of normal RMS Line voltage of 240 V.
The Protection shall be provided with safety MCB’s to be connected in series between Line/s to neutral &
neutral to earth as per the TNS configuration of wiring. It shall be testable on line for routine maintenance,
module failure and in order to prevent catastrophic failure modes.
Protection shall be a fail-safe type device, shall have a follow through current quenching capacity up to 25
KA r.m.s., shall have repeated surge capability state, shall be self restoring and be fully automatic in all
mode of operation.
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Protection shall comply with IEC 61643 and shall be approved for the location in which they are listed.
o
o
Protection shall have an operating temperature ranges from -20 C to 60 C.
1.3.3 Protection Criteria

The maximum continuous operating voltage (Rated Voltage) for SPD devices connected to phaseneutral shall not be less than the values shown in table:
Nominal Voltage Rating per phase
Maximum
Voltage
(Vrms)
(Vrms)
240
320
Continuous
Operating

Listing

The surge protective device and associated hardware must comply with IEC 61643-11.

The Protection voltage of the complete rail mount surge protective device shall be type test to the
figures as indicated in table below, which must not exceed the values shown.
Service Voltage / per phase
Protection Voltage @ In (Nominal
discharge current) / Protection Level
240 V
< 2.5 k V (between Line to Neutral)
1.5 kV (between Neutral to Earth)

Surge protective device application at Low Voltage AC main LT Panel incoming feeder surge
impulse current withstanding capacity as shown in table below.
Application Panel Location
Max. Single Withstand Surge Current
(of 10/350 μs Impulse)
Service Entrance (Main LT Panel)
25 KA, 10/350μs (between Line to
Neutral 100 KA, 10/350 (between
neutral to Earth)

Compliance to this specification must be provided in the form of a certificate from an independent
testing laboratory.

Response time of stage-I class –B arrester should not be < 100 ns.
1.3.4 Surge Protector At Stage II / Class C (Final Distribution Board
Protector)

The surge Protection manufacturer shall offer a complete line of surge Protection product to
support the requirements for the Distribution Board. The surge protector at this stage shall be
provided to protect the downstream electrical and electronics against any induced switching
surges that may be passed on to the downstream electrical & electronic system.

The Protection unit shall be based on Single High Capacity Metal Oxide Varistors (MOV), capable
of handling 8/20 μs surges and shall be able to give an indication in the event module failure and
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be pluggable to facilitate the in-service replacement without distributing the lines. One extra set of
replacement module shall be furnished to the job site.

Protection Network Configuration - The work required under this section consists of furnishing,
installing and connecting SPD device as specified and as shown in the drawings. The SPD
device shall be installed in a NETWORK configuration, consist of one set of SPD panel device at
the service entrance of switchboard. All SPD devices in this network configuration shall be of
same manufacturer. All SPD devices shall be modular, mountable on 35 mm DIN rail and be field
replaceable without interruption of electrical distribution circuit.

Unit status indicator shall be provided to indicate the status of complete Protection unit on the
product as well as provision for remote indication must be provided.

Protection shall be manufactured for the specific type and voltage of the electrical Service and
shall provide clamping for both normal (L-N) and common (N-G) mode operation.

Protection shall be manufactured to withstand a maximum continuous operating voltage of not
less than 115% of normal RMS Line voltage of 240 VAC.

The Protection shall be provided with internal safety fusing if required, to be connected in parallel
between Line/s to neutral & neutral to earth as per the TNS configuration of wiring. It shall be
testable on line for routine maintenance, module failure and in order to prevent catastrophic failure
modes.

Protection shall be a fail-safe type device, shall have no follow through current shall have
repeated surge capability, shall be solid state, shall be self restoring and be fully automatic in all
mode of operation. It shall have thermal disconnection and indication against overloading of the
device.
Protection shall comply with IEC 61643 standards.
o
o
Protection shall have an operating temperature ranges from -20 C to + 60 C.
Protection Criteria
The maximum continuous operating voltage (Rated voltage) for SPD devices connected to phase-neutral
shall not be less than the values as shown in table below:
Nominal Voltage Rating per phase
Maximum
Voltage
(Vrms)
(Vrms)
120
150
240
320
350
440
480
600
Continuous
Operating
Listing
The surge protective device and associated hardware must comply with IEC 61643-11.
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The Protection voltage of the complete rail mount surge protective device shall be type test to the figures
as indicated in table below, which must not exceed the values shown.
Service Voltage / per phase
Protection Voltage @ In (Nominal
discharge current) / Protection Level
240 V
1500 V
Nominal Withstand Surge Current.
Surge Protective device (including all fusing and over current protection) for application at sub-Distribution
Panels shall have a Nominal surge current withstand capacity as shown in table below. The failure or
operation of any fuse / over – current device during the test is not permissible.
Application Panel Location
Max. Single Withstand Surge Current
Of 8/20 µs Impulse)
Sub-Distribution Panel
10KA for 8 / 20 μs (between Line to Neutral)
Final Distribution Board
25 KA for
Earth)
10/350 μs (between Neutral to
Compliance to this specification must be provided in the form of a certificate from an independent testing
laboratory.
Response time of Class C arrestor should not be <25 ns.
- : Incoming ACB/MCCB/SFU
-: Back up fuse / MPCB / MCB for Surge Arrester
-: RYB and N Bus bar or looping after the incomer
- : Earth Bus bar in the panel
- : Surge Arrester to connect between Line and
- : SPD to connect between Neutral and Earth.
F4, F5, F6
R,Y,B and N
PE
SPD1,2,3
Neutral
SPD 4
B
F1
F2
F3
SPD 1
F4
F5
F6
SPD 3
Y
SPD 2
R
F1, F2, F3
Connection diagram for SPD for 3 phase 4 wire network
SPD 4
N
PE
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F1, F2, F3
- : Incoming ACB/MCCB/SFU
F4, F5, F6
-: Back up fuse / MPCB / MCB for Surge Arrester
R, Y, B and N
-: RYB and N Bus bar or looping after the incomer
PE
- : Earth Bus bar in the panel
SPD1, 2, 3
- : Surge Arrester to connect between Line and Neutral
SPD 4
- : SPD to connect between Neutral and Earth.
1.8
Shop
E- 52
Drawings
Prior to fabrication of the Panels the supplier / contractor shall submit for consultant’s approval the shop /
vendor 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 manufacturer’s catalogues of the electrical components installed in the Panels along with
the drawing.
The following shall be furnished as part of the Tender:
a) General arrangement showing plan, elevation and typical sectional views.
b) Technical literature on the various equipments.
c) The following shall be furnished after award of contract for Purchaser's approval :
i.
General arrangement showing plan, elevation and typical section views.
ii.
Foundation plan showing location of fixing channels, floor opening etc.,
iii.
Schematic wiring drawings for each feeder.
1.8.1
DOCUMENTATION :
1.8.1.1 Vendor 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
SLD’s and control schemes
Terminal plans
Bill of quantity for each panel.
1.8.1.2 Documents to be submitted after placement of order.
1.8.1..3
As per 2.1 above for comments and approval for manufacture.
Schematic and sectional drawing.
Final documents
-
As built drawings with RTP ( Reproducible Tracing Paper ).
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E- 53
Instruction and maintenance manual - Six copies.
Test certificates - Six copies
1.9
Inspection
At all reasonable times during production and prior to transport of the Panels to site, the supplier /
contractor shall arrange and provide all the facilities at their plant for inspection.
1.10
Test Certificates
Testing of Panels shall be carried out at factory and at site as specified in Indian standards in the
presence of consultant. The test results shall be recorded on a prescribed form. The test certificate for the
test carried out at factory and at site shall be submitted in duplicate to the consultant for approval.
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E8. Li ghti ng Fi xtur es & Accessor i es
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 Project
Manager.
Scope
1.1
Scope of work under this section shall include inspection at suppliers/manufacturer’s premises at site,
receiving at site, safe storage, transportation from point of storage to point of erection, erection and
commissioning of light fittings, fixtures and accessories including all necessary supports, brackets, down
rods and painting etc as required.
1.2
Standards
The lighting and their associated accessories such as lamps, reflectors, housings, ballasts etc., shall
comply with the latest applicable standards, more specifically the following:
General and safety requirements for Luminaires :

Part-1 Tubular flourescent lamps
-
IS – 1913 (Part-1)

Industrial lighting fittings with metal reflectors
-
IS - 1777

Decorative lighting outfits
-
IS - 5077

Bayonet lamp holders
-
IS - 1258

Bi-pin lamp holders for tubular fluorescent lamps

Electronic Ballasts for fluorescent lamps –

General & Safety requirement

Electronic Ballasts for fluorescent lamps –

Performance requirement
-
IS – 13021 (Part-2)

Ballast for HP MV lamps
-
IS - 6616

Tubular Fluorescent lamps
-
IS - 2418 (Part-1 to 4)

Luminaries – General requirement
-
IS – 10322 (Part-1)

Luminaries – Constructional requirement

Luminaries – Screw and Screwless termination

Luminaries – Methods of Tests

Particular requirement – General purpose Luminaries
-
IS–10322 (Part-5/Sec-1)

Particular requirement – Recessed Luminaries
-
IS–10322 (Part-5/Sec-2)

Particular requirement – Luminaries for Road and
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-
-
-
IS - 3323
IS – 13021 (Part-1)
IS – 10322 (Part-2)
-
-
IS – 10322 (Part-3)
IS – 10322 (Part-4)
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Street lighting
E- 55
-
IS–10322 (Part-5/Sec-3)

Particular requirement – Portable General purpose Luminaries
-

Particular requirement – Flood Lighting
-
IS–0322 (Part-5/Sec-5)

High pressure mercury vapour lamps
-
IS–9900 (Part-1)

Tungsten filament general electric lamps
1.3
-
IS–10322 (Part-5/Sec-4)
IS - 418
Light Fittings-General Requirements:
a) Fittings shall be designed for continuous trouble free operation under atmospheric conditions
without reduction in lamp life or without deterioration of materials and internal wiring. Degree of
protection of enclosure shall be IP-65 for outdoor fittings except bulkhead fitting. Bulkhead fitting
shall be provided with IP-54 protection.
b) Fittings shall be so designed as to facilitate easy maintenance including cleaning, replacement of
lamps/ ballasts.
c) All fittings shall be supplied complete with lamps. All mercury vapour and sodium vapour lamp
fittings shall be complete with accessories like ballasts, power factor improvement capacitors,
starters, etc. Outdoor type fittings shall be provided with weather proof junction boxes (IP-55) and
IP-54 Control gear boxes.
d) Each fitting shall have a terminal block suitable for loop-out connection by 1100 V PVC insulated
copper conductor wires up to 4 sq.mm. the internal wiring should be completed by the
manufacturer by means of standard copper wire and terminated on the terminal block.
e) All hardware used in the fitting shall be suitably plated or anodized and passivated.
f)
Earthing: Each lighting fitting shall be provided with an earthing terminal. All metal or metal
enclosed parts of the housing shall be bonded and connected to the earthing terminal so as to
ensure satisfactory earthing continuity throughout the fixture.
g) Painting/Finish: All surfaces of the fittings shall be thoroughly cleaned and degreased and the
fittings shall be free from scale, rust, sharp-edges, and burns.
h) The housing shall be powder coated/stove-enameled or anodized as required. The surface shall
be scratch resistant and shall show no sign of cracking or flaking when bent through 90 deg. over
12 mm dia. mandrel.
i)
1.4.
Metal used in BODY of lighting fixtures shall be not less than 22 SWG or heavier if so required to
comply with specification of standards. Sheet steel reflectors shall have a thickness of not less
than 20 SWG. The metal parts of the fixtures shall be completely free from burns and tool marks.
Solder shall not be used as mechanical fastening device on any part of the fixture.
Light Fittings – Special Requirements
Assymetric Distribution
Flood Light Fittings
Flood light fitting shall be provided with Housing made of die-cast aluminium with powder-coated finish for
sturdiness and excellent corrosion resistance. The lamp compartment comprises of electrochemically
brightened, high purity, pre-anodized aluminium reflector for long life and superior reflectivity. Outstanding
glare suppression is secured by high grade asymmetric optics that achieve maximum intensity at around
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60 deg with accurate beam control and uniform light distribution. There should be no direct light above the
horizontal plane through the luminaire - As per the ICAO specs. Necessary supporting vertical grid
calculations to be provided. Heat-resistant toughened front glass fixed to the housing with the help of
specially designed stainless steel toggles with specially designed hinging mechanism for quick and easy
lamp replacement, with no, sky Pollution. Hot dip Galvanized MS mounting bracket with calibrated disk for
ease of mounting and aiming. Heat-resistant long life EPDM/Silicon gasket renders the luminaire dust tight
and jet proof with ingress protection classification of IP 65. The twin lamp version offers switching facilities
that permits tailoring to the user’s needs while allowing energy savings. Rugged all weather construction
designed for easy aiming, simple cleaning and speedy maintenance Horizontal mounting for optimum light
distribution is recommended with maximum rotational adjustment of 12 from the horizontal.
Symmetric Distribution Flood Light Fittings
Extremely high efficiency due to the ‘small’ lamp in combination with the patented coated reflector system:
to provide up to 35 % higher energy (W/m2) than other solutions. Excellent uniform light distribution with
an asymmetric beam (A-) or a bi-directional beam (-BD) to create outstanding illuminances on vertically
oriented objects. The CDM-TD 150 W with colour temperature 4200 K, in combination with the colour
rendering of 96, creates a daylight impression. Safety and minimum glare are assured, as the observer's
eyes are shielded from the burner by a patented louver system. More sparkle, because the bright,
compact burner is reflected on cars or glossy merchandise. Silicone gasket bonded to the housing
renders the luminaire. Should be dustproof and jet proof to IP65. Galvanised white-coated steel mounting
frame, for firm recessed fixing in cladding. Housing consists of an injection-moulded base plate, to which
deep-drawn aluminium hood in connected. Thermally hardened glass, enclosed by an IP65 siliconerubber sealing gasket. Finishing in white (WH)
Ballasts Specifications:
Impregnated electromagnetic ballasts of copper – iron construction for use in combination with external
ignitor with watt loss not more than 42 watts (400 watts) & not more than 21 watts (150 watts) and should
with stand a maximum winding temperature of 130 Degree. The Power factor should be >0.85 with mains
current not more than 2.15 A at stabilization. Ortho cyclic winding process for limited ballast coil volume
and reduced weight with minimum ballast losses. Compact size reduces space requirement within the
luminaire. Earthing-while-mounting facility. Ballast equipped with screw terminal blocks. Compliance with
IEC 922 (safety), IEC 923 (performance) standards. Semi – parallel ignition system in combination with
SN 58 ignitor ensures longer life for control gear components.
Box Channel Type Industrial Fittings
Box type slim line channel must be in screw less construction manufactured from M.S. CRCA sheet steel
powder coated with MS CRCA cover, powder coated white. Light reflection surface in Box/Channel type
fittings shall be in a POLYESTER PRECOATED STEEL having a reflection factor of not less than 80%.
SCREWLESS DESIGN & CONSTRUCTION Light fixtures shall be preferred due to their ease of
maintenance, especially for box/channel for box/channel type fixtures.
Moisture Proof Industrial Fittings
Surface mounted totally enclosed moisture proof fixtures must be in polycarbonate body and diffuser with
transparent prismatic interior and smooth exterior and frosted end. Fixture must be completely sealed
with polyerethane double gasket to achieve IP 65 protection. Fixture is complete with CRCA steel white
powder coated / enamelled finish reflector.
18 W / 36 W Fluorescent And 36 W CFL Low Glare Light Fittings
Recessed mounted, modular fluorescent lighting fixture made of CRCA Sheet steel powder coated (white)
housing, electro chemically brightened and anodised reflector, three dimensional cross louvers with
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2
concave contours, Fresnel top at louver saddle to increase efficiency. The luminance of <200 cd/M at 63
degree viewing angle in all directions so as to confirm Cat-2 classification of CIBSELG3
Highbay Industrial Fittings
Industrial Highbay luminaries shall be provided with pressure die cast housing along with all accessories,
orthocyclically woundopien construction ballast, and capacitor & semi parallel ignitor connected to terminal
block and mounted on the gear plate. The gear shall have side entry for ease in maintenance. The spun
aluminium reflector is suitable for narrows well as wide beam distribution. The luminaire will be suitable
for metal halide lamp HPI BU + 250 W which has 25500 lumens and 2.5 min restrike time (when operate
with son gear).
1.5
Accessories For Light Fittings Reflectors
The reflectors shall be made of CRCA sheet steel/aluminium /Silvered glass/Chromium plated sheet
copper as required. The thickness of reflectors shall be as per relevant standards. Reflectors made of
steel shall have stove enamelled/ vitreous enamelled/epoxy coating finish. Aluminium used for reflectors
shall be anodized/epoxy stove enamelled /mirror polished. The finish for the reflector shall be as specified.
The reflectors shall be free from scratches / blisters and shall have a smooth and glossy surface having
optimum light reflecting coefficient. Reflectors shall be readily removable from the housing for cleaning
and maintenance without use of tools.
1.6
Lamps
1.6.1 Tld
Lamp shall be environment friendly low pressure mercury discharge lamp with mercury content less than
or equal to 5 mg. The lamp shall have minimum lumen maintenance of 85 and CRI of 85. The lamp must
comply with ROSH (Restriction of Hazardous substances) and covered by WEEE. Lamp should be fully
re-cyclable. The lamp should be low on maintenance with life of 40 K hours in case of electromagnetic
ballast and 65 K hours in case of HF ballast up to 10% failure. The discharge glass shall be lead free.
TLD Lamps shall be minimum tri-phosphor type and have bi-pin bases. Colour spectrum of light shall be
equivalent to “PHILIPS colour 84 or colour 86 colour 82 or “OSRAM colour 21 or colour 11 or colour 41
(as required at site)”.
The fluorescent Tubes (TLD) should have cool daylight colour designation. But Architects reserve the
right to prescribe either Cool Daylight or Bright White or Incandescent Colour Designations for TLD. NO
extra payment will be made over the quoted rate of bidder for this. The 36 W fluorescent tubes will have
Nominal Luminous Flux of not less than 3350 lumens whether so mentioned in the Schedule of Quantities
or not.
T 5 – High efficiency eco-friendly lamps
T-5 lamp shall be environment friendly low pressure mercury discharge lamp with mercury content less
than or equal to 3 mg. lamp should have lowest CO2 emission compared to any other comparable light
source (40% less than a TL-D standard lamp, 26% less than TL-D / 80). T-5 lamp shall be 100% lead
free. T-5 lamp shall be designed for operation with electronic gear and well suited for dimming. Maximum
o
o
lumen output to be reached at approx 35 C in free burning position. T-5 lamp can be ignited from -15 C to
o
+ 50 C. Lamp should be fully recyclable and must comply with ROSH (Restriction of Hazardous
substances) and shall be covered by WEEE. T-5 shall have 16 mm in diameter service life of TL-5 lamp
should be 10% more than TL-D lamps. T-5 lamp shall have lumen efficacy of up to 104 Lux / W and shall
have excellent colour rendering to En 12464 (Ra 80 to 89).
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1.6.2 Compact fluorescent lamp shall have same luminous flux and power consumption as fluorescent
tubes but less than half the length and more compact than U-shaped and circulator lamps. CFL shall be
suitable for use with conventional control gear & standers and for HF electronic control gear. CFL lamp
shall be non integral type of OSRAM / GE / PHILIPS/ Havells Sylvania only.
1.6.3 150 W CDM-TD Lamp

Warm or cool white colour impression

Colour rendering good to excellent > 96.

Retrofit in double-ended luminaries for quartz metal halide lamps (MHN/W-TD), thereby allowing
to reduce operating costs and improve colour quality

Burning position horizontal +/-45°

Initial Lumen Output not less than 13250 Lumens.

Luminous efficacy should not be less than 84.
1.6.4 Lamp Specifications: 400W SON-T
Sont Pia Plus 400w

High pressure sodium vapour lamp with a specially designed integrated antenna to improve lumen
output and luminous efficacy for the source.

Initial lumen output should not be less than 56500 lumens

Initial luminous efficacy should not be less than 130 lumen per watt

The lumen maintenance at 5000 burning hours should be greater than 94% and at 10,000 burning
hours should not be less than 90%

The rated average life at 50% failure should not be less than 20,000 burning hours.
1.7
High Frequency Electronic Ballast
High frequency electronic ballast shall be used with fluorescent / Compact Fluorescent Lamps wherever
specified in the schedule of quantities. High frequency electronic ballast shall comply with the following:

IEC 927, IEC 928 for ≤10% total harmonic distortion.

EMI / RFI – Confirming to FCC / VDE Class A/B.

Line Transient as per IEEE C62.41.

Ballast Crest Factor C1.7%.

No Stroboscopic Effect

Constant Wattage / Light output between 240 V ± 10%.

Circuit protection for surge current and inrush current.

Short circuits, open lamp protection
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
PF > 70 for fluorescent / T5 lamp and CFL.

Deactivated lamp protection

Suitable for use with single and twin lamps

RFI < 30 MHz

Total Harmonic Distortion (THD) ≤10%

Immunity to interference
EN 61547

Safety
EN 60928 / IEC 928 / IS 13021 (Part I)

Performance

Vibrations & Bump tests

IEC 9001

Quality Standard

Environmental Standard

DC Operation
EN 60924

Emergency Lighting Operation
VDE 0108
EN 55015
EN 60929 / IEC 929 / IS 13021 (Part II)
IEC 68-2-6 FC
ISO 9001
ISO 14001
Total System consumption (lamps + ballast) for
1 x 36 W TLD, shall not exceed 40 W
1 x 28 W T-5, shall not exceed 32 W
1 x 35 W T-5, shall not exceed 40 W
1 x 14 W T-5, shall not exceed 16 W
1 x 18 W CFL, shall not exceed 20 W
1 x 36 W CFL, shall not exceed 40 W
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E9. Earthing
1.1
Earthing
The system shall be TNS with four wire supply system (R, Y, B, N and 2 Nos. E) brought from the main L
T Panel. All the non-current carrying metal parts of electrical installation and all metal conduits trunking,
cable sheaths, switchgear, distribution panels, light fittings and all other parts made of metal shall be
bonded together and connected by means of specified earthing conductors to an efficient earthing
system. All metal work such as pipe lines, ducts, cable trays, stair case railing etc shall be bonded to
earth.
All earthing shall be in conformity with IS: 3043 1987, and the basic system of earthing shall be TNS.
1.2
Earthing Conductors
Earthing conductors shall be of copper / GI as mentioned in schedule of quantities and shall be protected
against mechanical injury and corrosion.
1.3
Sizing Of Earthing Conductors
The cross sectional area of earthing conductor shall not be smaller than half of the largest current
carrying conductor subject to an upper limit of 80 Sq.mm. If the area of the largest current carrying
conductor or bus bar exceeds 160 sq.mm then two or more earthing conductors shall be used in
parallel, to provide at least half the cross sectional area of the current carrying conductor or bus bars. All
fixtures, outlet boxes, junction boxes and power circuits up to 15 amps shall be earthed with PVC
insulated copper wire.
All 3 phase switches and distribution panels up to 60 amps rating shall be earthed with 2 Nos. distinct
and independent 4 mm dia. copper / GI wires. All 3 phase switches and distribution panels upto 100
amps rating shall be earthed with 2 Nos. distinct and independent 6 mm dia. copper / GI wires. All
switches, bus bar, ducts and distribution panels of rating 200 amps and above shall be earthed with
minimum of 2 nos. separate and independent 25 mm x 3 mm copper / GI tape.
1.4
Connection Of Earthing Conductors
Main earthing conductors shall be taken from the earth connections at the main L T panel to an earth
electrode with which the connection is to be made. All joints in tapes shall be with four rivets and shall
be brazed in case of copper and by welding bolting in case of GI, wires shall be connected with crimping
lugs, all bolts shall have spring washers. Sub- mains earthing conductors shall run from the main
distribution panel to the sub distribution panel. Final distribution panel earthing conductors shall run from
sub-distribution panel.
Circuit earthing conductor shall run from the exposed metal of equipment and shall be connected to any
point on the main earthing conductor, or its distribution panel. Metal conduits, cable sheathing and
armouring shall be earthed at the ends adjacent to distribution panel at which they originate, or
otherwise at the commencement of the run by an earthing conductor in effective electrical contact with
cable sheathing. Where equipment is connected by flexible cord, all exposed metal parts of the
equipment shall be earthed by means of an earthing conductor enclosed with the current carrying
conductors within the flexible cord. Switches, accessories, lighting fitting etc. which are rigidly secured in
effective electrical contact with a run of metallic conduit shall not be considered as a part of the
earthing conductor for earthing purposes, even though the run of metallic conduit is earthed.
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The plate/pipe electrode, as far as practicable, shall be buried below permanent moisture level but in any
case not less than 2.5 M below finished ground level.
The plate/pipe electrode shall be kept clear of the building foundation and in no case, it shall be nearer
by less than 2 M from outer face of the respective building wall / column.
The plate electrode shall be installed vertically and shall be surrounded with 150 mm. thick layers of
Charcoal dust and Salt mixture.
19 mm. dia. G.I. pipes for watering shall run from top edge of the plate / pipe electrode to the mid level of
block masonry chamber.
Top of the pipe shall be provided with G.I. funnel and screen for watering the earth / ground through the
pipe.
The funnel with screen over the G.I. pipe for watering to the earth shall be housed in a block masonry
chamber as shown in the drawing.
The masonry chamber shall be provided with a Cast Iron hinged cover resting over the Cast Iron frame
which shall be embedded in the block masonry.
Construction of the earthing station shall in general be as shown in the drawing and shall conform to the
requirement on earth electrodes mentioned in the latest edition of Indian Standard IS: 3043, Code of
Practice for Earthing Installation.
The earth conductors (Strips / Wires copper / hot dip G.I.) inside the building shall properly be clamped /
supported on the wall with Galvanised Iron clamps and Mild Steel Zinc Passivated screws / bolts. The
conductors outside the building shall be laid at least 600 mm. below the finished ground level.
The earth conductors shall either terminate on earthing socket provided on the equipment or shall be
fastened to the foundation bolt and / or on frames of the equipment. The earthing connection to
equipment body shall be done after removing paint and other oily substances from the body and then
properly be finished.
Over lapping of earth conductors during straight through in joints, where required, shall be of minimum
75mm. long.
The earth conductors shall be in one length between the earthing grid and the equipment to be earthed.
Earth Leads And Connections
Earth lead shall be bare copper or Galvanised steel as specified with sizes shown on drawings. Copper
lead shall have a phosphor content of not over 0.15 %. G.I strips buried in the ground shall be protected
with bitumen and hessian wrap or polythene faced hessian and bitumen coating. At road crossing
necessary Hume pipes shall be laid. Earth lead run on surface of wall or ceiling shall be fixed on saddles
so that strip is at least 8 mm away from the wall surface.
The complete earthing system shall be mechanically and electrically bonded to provide an independent
return path to the earth source.
1.5
Prohibited Connections
Neutral conductor, sprinkler pipes, or pipes conveying gas, water or inflammable liquid, structural
steel work, metallic enclosures, metallic conduits and lightning protection system conductors shall not
be used as a means of earthing an installation or even as a link in an earthing system. The electrical
resistance measured between earth connection at the main L T panel and any other point on the
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completed installation shall be low enough to permit the passage of current necessary to operate or
circuit breakers, and shall not exceed 1 ohm. All switches carrying medium voltage shall be connected
with earth by two separate and distinct connections. The earthling conductors inside the building
wherever exposed shall be properly protected from mechanical injury by running the same in G I pipe of
adequate size. The overlapping in strips at joints where required shall be minimum 75 mm. The joints
shall be riveted and brazed in case of copper and by welding / bolting in case of GI in an approved
manner. Sweated lugs of adequate capacity and size shall be used for termination of all conductor wires
above 6 sq.mm size. Lugs shall be bolted to the equipment body to be earthed after the metal body is
cleaned of paint and other oily substances and properly tinned. Equipotential bonding of all metallic
structures shall be done.
1.6.
Earthing
The following must always be ensured in earthing system.

All earths must be interconnected at the earth pits. This includes generator neutrals, transformer
neutrals, transformer body, lightning protection system earths, UPS earths etc.

Extraneous conductive parts such as gas pipes, other service pipes and ducting risers and pipes
of fire protection equipment and exposed metallic parts of the building structure.
The Contractor shall get the soil resistivity test done at his own cost of the area where earthing pits are to
be located before starting the installation.
1.8
Resistance To Earth
The resistance of earthing system shall not exceed 1 ohm.
1.9
Specification For Hot Dip Galvanizing Process For Mild Steel
Used For Earthing For Electrical Installation
General Requirements
I.
Quality Of Zinc
Zinc to be used shall conform to minimum Zn 98 grade as per requirement of IS: 209-1992.
Ii.
Coating Requirement
Minimum weight of zinc coating for mild steel flats with thickness up to 6 mm in accordance with IS:67451972 shall be 400 g/sqm.
The weight of coating expressed in grams per square metre shall be calculated by dividing the total weight
of Zinc by total area (both sides) of the coated surface.
The Zinc coating shall be uniform, smooth and free from imperfections as flux, ash and dross inclusions,
bare patches black spots, pimples, lumpiness, runs, rust stains bulky white deposits, blisters.
Mild steel flats / wires shall undergo a process of degreasing pickling in acid, cold rinsing and then
galvanizing. Jointing of earthing tape shall be by welding. All joints and cut ends shall be properly painted
with aluminium paint.
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1.10 Chemical Earthing System – specification
Earthing system should offer a resistance of less than 2 ohms throughout the year. In places where Soil
resistivity is more, total length of the earthing rod has to be increased by adding 1m length rods (one over
the other) to achieve low and stable resistance value. In rocky places ,multiple earth rods have to be
installed and inter-connected to get the required value.
Solid Copper coated rods are recommended as earth electrode than a pipe due to the fact that solid rods
have much longer life and can be easily driven by electric/hydraulic hammers. Copper has much longer
life than all other materials as explained in IS 3043. Deep driven rods provide more stable and less Earth
Resistance. Doubling the length of the rod will reduce earth resistance up to 40 %, whereas doubling the
diameter will reduce the resistance by only 10 %, but may increase the cost by 4 times.Lower earth
resistance can also be achieved by increasing the number of earth rods. E.g. 40 % reduction in earth
resistance is possible if the rods are increased from 1 to 2. The minimum spacing between earth pits
should be equal to TWICE the length of the rod. Increasing the spacing between earth pits also reduces
the earth resistance significantly.
Need and importance of Earthing:

Human and Personnel safety.

Equipment protection.

Provides low impedance path for fault currents.

To ensure good quality power.

Protection against lightning and transient currents, noise reductions, Limitation of EMI.
References:
IEC 60364: Low Voltage Electrical Installations-Part 5-54: Selection & Erection of Electrical
Earthing arrangement & protective conductors.
equipment-
IEC 62561: Lightning Protection system Components. Part 1 to 7.
IEC 62305: Protection Against Lightning –Part 3: Protection of structures & life Hazards
IS 2309: Code of practice for protection of buildings & allied structures from lightning
IS 3043: Code of practice for earthing.
Components of earthing system:

Earth electrode

Connectors and fasteners

Inspection Chamber (Earth Pit)

Earth enhancement material

Connecting cable/tape/strip with accessories.
Earth Electrode:
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Copper coated Solid steel Rods shall be made of high tensile low carbon steel rod, molecularly bonded
with 99.9% electrolytic copper with minimum coating thickness of 250 microns as per IEC 62561 part -2:
Requirement for Conductor & Earth Electrodes. The length of the earth rod shall be 1 meter so that driving
into the ground is easier (scaffolding is not necessary). For dry areas, length of the rods can go up to
several meters by driving the rods one over the other. Earth rods should be of diameter 20 mm. These
rods should have facility to couple with hammer inserts so that they could be driven easily with an
electric/hydraulic hammer. Additional rods should be added without external couplers. The earth rods
should have peg & bore arrangement so that additional rods are added without external couplers.
Interconnecting Strips / Earthing Conductor: Copper coated steel strips / tapes should be used to
interconnect different earthing rods as well as horizontal earthing (Ring earthing). These strips should
have a coating thickness of minimum 70 microns.
Couplers / Connecting clamps:
Connectors/fasteners for connecting Electrode with Earthing conductor/strip should be of Stainless Steel
as it is compatible with all other materials viz Copper, GI etc. Fasteners should be made of Stainless steel
Inspection Chamber :
Should have an inner dimension of 250 mmX 250 mm X 250 mm made of FRP material. Flush Mounted,
removable cover of the earth pit should be able to withstand moderate loads. The area inside the
inspection chamber should be such that, the UNIVERSAL CLAMP/EBB/Bus bars not too deep inside the
inspection chamber or projecting out of inspection chamber. The chamber should have facility for marking
earth resistance and latest testing date by paint at the cover and previous recorded values inside the
cover.
Earth Enhancement material:
This is a conductive mineral compound to provide low resistance to the earth termination system. Earth
enhancing compound should contain minerals which in normal use is reliable and without creating any
hazards to persons and the surroundings. The material shall be chemically inert to sub soil and shall not
pollute the environment. It shall provide a stable environment in terms of physical and chemical properties
and exhibit low resistivity. It shall not be corrosive to the earth electrode itself. The material should have a
resistivity less than 50 Ohm meter
Installation:
Dig a pit of 1m* 1m * 0.5m depth.
At the center of the pit, Earth rod of 1 m has to be hammered electrically or hydraulically.
The number of Earth rods can be added one over the other to get the required length.
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Fill the dug up area with Earth enhancing compound mixed with water & soil to get slurry form in such a
way that the earth inspection pit is in flush with the earth surface.
Connect the connectors with fasteners & connect the down conductors.
Close the lid of earth inspection pit.
Inspection & maintenance:
Maintenance of the earthing system has to be done at least once in 6 months, preferably before the
monsoon period and a record should be maintained to verify earthing system conductors and
components, electrical continuity, earth resistance value, re-fastening of components viz-nuts, bolts etc.
1.11
Test
The entire earthing installation shall be tested as per requirements of Indian Standard Specification IS:
3043.
The following earth resistance values shall be measured with an approved earth megger and recorded.
1) Each earthing station
2) earthing system as a whole
3) Earth continuity conductors
4) Earth conductor resistance for each earthed equipment shall be measured which shall not exceed
5 ohm in each case.
Measurements of earth resistance shall be carried out before earth connections are made between the
earth and the object to be earthed.
All tests shall be carried out in presence of the client’s representative.
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E- 67
Street Lighting Poles:
The street light poles shall be fabricated from heavy duty cold-rolled steel tubes conforming to IS: 1239
and hot dip galvanized or painted as specified.
The street light pole shall be fabricated as per the details and dimensions shown in the drawing.
The street light poles shall have base plate, a Junction Box, and necessary fixture mounting bracket at
top.
The Junction box shall provide easy access to a multiway connector and MCB, to be mounted inside the
pole. The access shall be specially fabricated with adequate reinforcement and weather protection gasket
to prevent ingress of moisture and vandal proofed.
Poles shall have large diameter entries for incoming and outgoing cables and two earth studs & Spiral
earthing.
The poles fabricated shall conform to the drawings and where such drawing is not available, the contractor
shall make such drawing and have it approved before fabricated.
The pole shall house a multi way Wohner type terminal block and MCB as shown on the drawings. Poles
shall have concrete coping.
1.00
SCOPE:
The scope of this specification covers the manufacture, transport, installation, testing and commissioning
of the Raising and Lowering type of High mast Towers, Poles, including the Civil Foundation Works with
all items required for the safe and efficient operation and maintenance of the lighting system, including the
high mast, whether explicitly stated in the following pages or not, shall be included by the Contractor.
2.00
PRE-QUALIFICATION
The Supplier shall have own quality systems confirming to ISO 9001 for carrying out the job. Poles & High
mast manufacturing unit shall be ISO 14001 & ISO 18001 certified.
They shall also have enough experience in supply and installation of high masts & Poles in the country
and must have installed minimum of 100 similar masts & 1000 nos. of similar poles till date. Proof for the
experience shall be produced before issue of tender documents to the party.
The bidder shall produce proof of the following before issue of the tender documents to them.
a)
b)
c)
d)
e)
Contractor license for the state of Gujarat.
ISO 9001 certificate for High mast system and Poles.
ISO 14001 certificate for the manufacturing plant.
ISO 18001 certificate for the manufacturing plant.
Proof of completion of similar jobs in the port sector with single job value more than 2 crores.
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3.00 APPLICABLE STANDARDS:
The following shall be the Reference Standards for the loading of the High mast:
Code No.
Title
a). I.S.875 (Part III) 1987.
Code and practice for design loads for Structures.
b). BSEN 10025.
Grades of MS. Plates.
c). BS.ISO 1461.
Galvanizing.
e). TR. No.7 1996 of ILE, UK.
Specification for Mast and foundation.
3.1
LIGHTING POLES :
The street light poles shall be fabricated from heavy duty cold-rolled steel tubes conforming to IS:1239
and hot dip galvanized or painted as specified.
The street light pole shall be fabricated as per the details and dimensions shown in the drawing.
The street light poles shall have base plate, a Junction Box, and necessary fixture mounting bracket at
top.
The Junction box shall provide easy access to a multiway connector and MCB, to be mounted inside the
pole. The access shall be specially fabricated with adequate reinforcement and weather protection gasket
to prevent ingress of moisture and vandal proofed.
Poles shall have large diameter entries for incoming and outgoing cables and two earth studs & Spiral
earthing.
The poles fabricated shall conform to the drawings and where such drawing is not available, the contractor
shall make such drawing and have it approved before fabricated.
The pole shall house a multi way Wohner type terminal block and MCB as shown on the drawings. Poles
shall have concrete coping.
3.1.1
CONICAL POLES
Design
The Conical Poles shall be designed to withstand the maximum wind speed as IS 875. The top loading i.e.
area and the weight of fixtures are to be considered to calculate maximum deflection of the pole and the
same shall meet the requirement of BSEN 40-3- 1:2000, pr EN-40-3-3.
Pole Shaft
The pole shaft shall have circular cross section and shall be continuously tapered with single longitudinal
welding. There shall not be any circumferential welding. The welding of pole shaft shall be done by
Submerged Arc Welding (SAW) process.
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All conical pole shafts shall be provided with the rigid flange plate of suitable thickness with provision for
fixing 4 foundation bolts. This base plate shall be fillet welded to the pole shaft at two locations i.e. from
inside and outside. The welding shall be done as per qualified MMAW process approved by Third Party
Inspection agency.
Door opening
The conical poles shall have door of approximate 500 mm length at the elevation of 500 mm from the
Base plate. The door shall be vandal resistance and shall be weather proof to ensure safety of inside
connections. The door shall be flush with the exterior surface and shall have suitable locking arrangement.
There shall also be suitable arrangement for the purpose of earthing.
The pole shall be adequately strengthened at the location of the door to compensate for the loss in
section.
Material
Conical Poles shaft
: Conforming to grade S355JO.
Base Plate
: Fe 410 conforming to IS 226 / IS 2062
Foundation Bolts
: EN 8 Grade
Welding
The welding shall be carried out confirming to approved procedures duly qualified by third party inspection
agency. The welders shall also be qualified for welding the conical shafts.
Pole sections
The conical poles shall be in single section up to 12 mtr. There shall not be any circumferential weld joint.
Bracket Arm
The bracket will have a sleeve as cap of suitable diameter fitted with pinching bolts. The length of bracket
shall be as per illumination design.
Galvanization
The poles shall be hot dip galvanised as per IS 2629 / IS 2633 / IS 4759 standards with average coating
thickness of 70 micron. The galvanizing shall be done in single dipping.
Fixing Type
The conical poles shall be bolted on a pre-cast foundation with a set of four foundation bolts for greater
rigidity.
Top Mountings
The galvanized mounting bracket shall be supplied along with the conical poles for installation of the
luminaries
Pole Testing Facility
The manufacturing unit shall have in-house pole testing facility for validation of structural design data. The
pole testing facility shall conform to BS EN 40-3-2-2000 part 3-2.
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3.1.2
E- 70
Octagonal Poles
Design
The Octagonal Poles shall be designed to withstand the maximum wind speed of 160 km / hr. The top
loading i.e. the weight and the area of top luminaries are to be considered to calculate maximum
deflection of the pole and the same shall meet the requirement of BS: 5649 Part VI 1982.
Pole Shaft
The pole shaft shall have octagonal cross section and shall be continuously tapered with single
longitudinal welding. There shall not be any circumferential welding. The welding of pole shaft shall be
done by Submerged Arc Welding (SAW) process.
All octagonal pole shafts shall be provided with the rigid flange plate of suitable thickness with provision
for fixing 4 foundation bolts. This base plate shall be fillet welded to the pole shaft at two locations i.e. from
inside and outside. The welding shall be done as per qualified MMAW process approved by Third Party
Inspection agency.
Door opening
The octagonal Poles shall have door of minimum size of 250 mm X 65 mm at the elevation of 500 mm
from the Base plate. The door shall be vandal resistance and shall be dust proof to ensure safety of inside
connections. The door shall be flush with the exterior surface and shall have suitable locking arrangement.
There shall also be suitable arrangement for the purpose of earthing.
The pole shall be adequately strengthened at the location of the door to compensate for the loss in
section.
Material
Octagonal Poles
: Conforming to St 35 grade.
Base Plate
: Fe 410 conforming to IS 226 / IS 2062
Foundation Bolts
: 6.8 Gr. As per IS 1367
Welding
The welding shall be carried out confirming to approved procedures duly qualified by third party inspection
agency. The welders shall also be qualified for welding the octagonal shafts.
Pole sections
The Octagonal Poles up to the length of 11.5 meters shall be in single piece with single longitudinal
welding joint. There shall not be any circumferential weld joint. However, the pole with length of 12
meters and above shall be of 2 sections with telescopic fitment with minimum overlap of 1.5 times the
diameter.
Galvanization
The poles shall be hot dip galvanized as per IS 2629 / IS 2633 / IS 4759 standards with average coating
thickness of 65 micron. The galvanizing shall be done in single dipping.
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E- 71
Fixing Type
The Octagonal Poles shall be bolted on a pre-cast foundation with a set of four foundation bolts for greater
rigidity.
Top Mountings
The galvanized double / single arm shall be supplied along with the Octagonal Poles for installation of the
luminaries.
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E11.
1.1
E- 72
Te l e p h o n e & D a t a D i s t r i b u t i o n
Scope
This document defines the cabling system and subsystem components to include cable, termination
hardware, supporting hardware, and miscellany required to furnish, and to install a complete cabling
infrastructure supporting voice and video. The intent of this section is to provide pertinent information to
allow the vendor to bid the labour, supervision, tooling, materials, and miscellaneous mounting hardware
and consumables to install a complete system. However, it is the responsibility of the vendor to propose
any, and, all items required for a complete system whether or not it is identified in the specification,
drawings and bill of materials attached to this specification.
1.2
Applicable Documents:
The cabling system described in this specification is derived in part from the recommendations made in
industry standard documents. The list of documents below (or the latest revisions) has bearing on the
desired cabling infrastructure are incorporated into this specification by reference:
1) This Technical Specification and Associated Drawings
2) ANSI/TIA/EIA 568-B Commercial Building Telecommunications Cabling Standard – March 2001
3) ANSI/EIA/TIA-569-A Commercial Building Standard for Telecommunications Pathways and
Spaces - February, 1998
4) ANSI/EIA/TIA-606 Administration Standard for the Telecommunications Infrastructure of
Commercial Buildings - February, 1993
5) ANSI/TIA/EIA-607 Commercial Building
Telecommunications - August, 1994
2.0
Grounding
and
Bonding
Requirements
for
Conduits:
Conduits shall be as given below:
Indoor: medium gauge Rigid PVC conduit.
The conduit shall generally be as specified under section `CONDUIT WIRING'.
3.0
Cables And Wires:
3.1.
The type of cables and the services shall be as follows:

Indoor Multi pair, PVC insulated sheathed armoured and sheathed.

Inside Twin core PVC insulated with conduit twisted cores.
3.2. All multi core cables and wires shall be of tinned copper conductor of not less than 0.5 mm dia. and
shall be colour coded twisted pairs with rip cord.
3.3. The conductor resistance shall be less than 150 ohms per KM and the insulation resistance between
the conductor's not less than 50 mega ohms and the nominal capacitance of about 0.1 micro farad
per kilometre.
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E- 73
3.4. Cables lay underground or locations subject to dampness and flooding shall be filled with polyethylene
compound and shall have sufficient protection against moisture and water ingress.
3.5. All armouring shall be of galvanized steel wires and protected against corrosion by an outer sheath of
PVC in the case of indoor cables and polyethylene in the case of outdoor cables. Outer sheathing
must be fire retarding and anti-termite.
3.6. All unarmoured single core cables and inner sheath of armored cables shall be provided with rip cord.
3.7. All single pair cables for final extension to the telephone outlet box shall be unarmoured tinned copper
conductors of not less than 0.6 mm. diameter and shall be drawn in conduits. All telephone outlets
shall consist of 2 A 2 pair polythene connector in G.I box with 6 mm perspex cover with bevelled
edges and chromium plated brass hardware.
4.0
Tag Blocks
4.1. The telephone tag blocks shall be suitable for the multi core telephone cables and shall have two
terminal blocks, cross connect type. All incoming and outgoing cables shall be terminated on separate
terminal blocks and termination shall be silver soldered. The cross connecting jumpers shall be
insulated wires of same diameter and screw connected.
4.2. The tag blocks shall be mounted inside fabricated sheet steel boxes with removable hinged covers
and shall be fully accessible. The enclosure shall be painted with 2 coats of red oxide and stove
enamelled.
5.0
Installation
5.1. The installation of conduits shall generally be as specified under section `CONDUIT WIRING'.
5.2. All cables shall be on cable racks and neatly stitched together.
5.3. The connection at the tag blocks shall be silver soldered so as to achieve minimum contact
resistance.
5.4. The final branch connections with single pair cables in conduits and the maximum number of cables in
each conduit shall be as follows:
Conduit diameter
Max. No. of cables
inch
mm.
3/4"
20
2 Nos. single pair
1"
25
6 Nos. single pair
1¼"
32
12 Nos. single pair
1½"
40
18 Nos. single pair
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6.0
E- 74
Mode Of Measurement
6.1. The main telephone cables shall include supply and laying of multi pair cables on ceiling/wall/on cable
trays/racks including all supports and shall be measured and paid on running length basis. Cable
trays/racks shall be paid for separately.
6.2. The multi pair tag blocks shall consist of two telephone connector's strips, jumpered interconnections
silver soldered enclosure etc. and shall be measured and paid as one unit.
6.3. The conduit wiring for telephone shall include single pair 0.6 diameter cable in heavy duty rigid, PVC
conduits and shall include junction boxes, pull boxes, 2 pair 2 A connector in GI box, Perspex cover
etc. and shall from one point.
7.0
Cabling For Tv System
7.1. The Co-axial cable shall be of wideband type with operation capability up to 500 MHz
7.2. The ageing resistance of the co-axial cable shall comply with DIN 47252, Part 2, i.e. max. 5%
increase in attenuation at 200 MHz measured by artificial ageing (14 days at 80 deg. C)
7.3. Cables shall meet or exceed the following specifications.
Construction
RG-6 MATV Type
RG-11 MATV Type
a
Centre Conductor
18 AWG tinned copper
14 AWG tinned copper
b.
Dielectric
Foam Polyethylene
Foam Polyethylene
Nom. dia. 0.180
Nom. dia. 0.280
Foil - 0.003 AI. Tape
Foil - 0.003 AI. Tape
Braid - 34 AWG 4 end
Braid - 34 AWG 6 end
AL. 60% coverage dia. 0.212
AL.60%coverage dia. 0.314.
Black PVC flame-retardant
Black PVC flame retardant dia.
dia. over jacket 0.272 +
overjacket0.405+0.010
0.008 Min. spot 0.023
Min. spot 0.032.
c.
d.
Shield
Jacket
Electrical Properties
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a.
Dielectric Strength
E- 75
Conductor to shield
Conductor to shield
2000 VDC
1500 VDC
16.2 PF / FT. Nom
b.
Capacitance
16.2 PF / FT, Nom
c.
Impedance
75.0 + 3.0 ohms
d.
Attenuation
DB/100 ft.
e.
75.0 + 3.0 ohms.
DB/100 ft.
0.65 DB @
5 MHZ
0.35 DB @
0.76 DB @
10 MHZ
0.96 DB @
20 MHZ
1.28 DB @
100 MHZ
1.98 DB @
100 MHZ
1.78 DB @
200 MHZ
4.21 DB @
450 MHZ
2.20 DB @
300 MHZ
4.80 DB @
550 MHZ
6.49 DB @
1000 MHZ 4.30 DB @
0.94 DB @
2.75 DB @
5 MHZ
50 MHZ
450 MHZ
1000 MHZ
Velocity of
Propagation
82.0% Nom
82.0% Nom
f.
DCR
35.47 ohms / 1000 ft.
14.29 ohms / 10000 ft.
g.
SRL
30 DB (10 MHz to 300 MHz) 20 DB (5 to 450 MHz)
7.4. DIRECTIONAL COUPLERS
These shall be of Ultra Wideband type and of hybrid circuit design.
These shall have a near flat frequency response over the entire operating range.
These shall have aluminium cast housing for high frequency radiation resistance.
These shall have ‘F’ sockets for all input, output and branch ports.
The Tapoffs shall be available in one way, two way and four way configurations.
The splitters shall be available in two way, three way and four way configurations.
The Tapoffs shall be available in different tap values ranging from 11 dB, 15 dB, 20 dB, 25 dB and 30 dB.
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E- 76
These shall meet or exceed the following specifications
Tap off
Splitters
a.
Tap Loss
11-30 dB
b.
Through Loss
0.5-4 dB
4..0 - 8.0 dB
c.
Isolation
> 22 dB
> 22 dB
d.
Screening factor
> 50 dB
> 50 db
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E12.
HT GOD& HT Work
12.1
11 Kv Switchyard
1.1
E- 77
Two Pole Structure
The scope of work includes fabrication, supply, erection, painting as per the drawing and IS, and getting
the two pole as well as four pole structure approved from I.M & E department. The pole structure
comprising of following items.
All M.S. elements of channels, angles and flat shall be painted with two coats of primer and further painted
with two coats of Aluminium paint. All nut & bolts, washer etc. used shall be hot dip galvanized.
1.1.1. Vertical pole of minimum ISMB - 175 (175 mm x 90 mm) size of approximately 9.0 / 10.0 mtr. length
as indicated in the drawing, with 400 x 400 x 8 mm size base plate welded to one end of both the
joists.
1.1.2. Cross member of minimum ISMC - 100 (100 mm x 50 mm) size channels approximately 3.5 mtr.
each Length wherever required as indicated in the drawing.
1.1.3. Cross bracing angle of minimum ISA - 50 (50 mm x 50 mm x 6 mm) size of 4.5 mtr. each Length
wherever required as indicated in the drawing.
1.1.4. Side clamps, stay clamps, cleats, patties, etc. Fabricated from minimum 50 mm x 6 mm size M.S
flats as per actual requirement.
1.1.5. All nuts, bolts, washers etc. shall be of minimum 15 mm size.
1.1.6. Erection of poles and fixing of all structural members as per drawing and instruction of Site
engineer. The structure shall be erected in plumb, line level, properly facing the incoming and
outgoing lines. Cross member shall be firmly tightened.
1.1.7.
All members shall be fabricated to suit the mounting / fixing of GOD, L.A, DOF, DISC/PIN/POST
insulators, cable end termination kit / box etc. as per the drawing.
1.1.8.
All necessary hardware, nut-bolts, extra members, sundry items are included in the scope of
work.
1.1.9.
All M.S parts shall be painted with primer and aluminium paint.
1.1.10. Earthing terminal shall be provided by welding 12 mm size bolt / cleat of 50 x 6 mm size M.S flat
shall be fixed to each joist with a hole of 15 mm size and cadmium coated nuts, bolts, washers
shall be provided as earthing terminals. Fixing or joining of any members is allowed by nut and
bolt only welding is strictly not allowed.
1.1.11. Suitable M.S. flat supports and cleats shall be fixed to ISMB poles for supporting / fixing the
earthing protection strip in the manner approved by the Client.
1.1.12. All drawing shall be prepared and submitted to Industry Mines & energy Dept. for approval. Obtain
the approval from I.M. & E. Dept.
1.1.13. Vitreous enamelled caution boards or any other requirements shall be provided.
1.1.14. C.T.P.T. mounting channels, clamps, bracing angles, nut-bolts, hardware, etc. shall be supplied
and erected.
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1.2
E- 78
Air Break Sw itch
The air break switch should be constructed as per IS: 9920 / 1985. are provided with test certificate.
The A.B. switch should be triple pole type with movable centre pole. All the poles should be opened /
closed simultaneously by a lockable operating mechanism.
The porcelain insulator shall be sound free from defects, thoroughly vitrified and smoothly glassed.
Insulators shall have compressing type glassed with a good lustre and of uniform brown color.
The air break switch should be provided with 1 year guarantee and the test report.
The A.B. switch should be manually operated and shall be able to:

Carry rated current without excessive temperature rise.

Withstand the short circuit forces developed during fault.

Carry the inrush current of transformer.

Interrupt small inductive / capacitive current.
The contacts shall be of silver faced copper ensuring sufficient contact pressure. The male & female
contacts should be of self aligning type to ensure trouble free operation during opening and closing. Mild
steel arcing horn capable of breaking the magnetizing current shall be provided.
1.3
Drop Out Fuse
The D.O. Fuse assembly should be suitable for 33 KV supply and in accordance with IS 9385 / 1985 and
provided with a test certificate
The assembly shall be mounted on double pole structure complete with 3 fuse elements of required
ampere rating. The fuse link shall consist of iron channel base, stack insulator per phase, fuse carrier
bakelite tube, non-ferrous metal parts and spring loaded phosphor-bronze contacts. The insulator shall
comply with impulse voltage test in accordance with IS 3106.
1.4
Lightning Arrestor
1.4.1
Type And Rating:
Lightning arrestor shall be station class, heavy duty, and non-linear resistance type with rating as 33 KV.
The arrestor shall have adequate thermal discharge capacity for severe switching surges, long duration
surges and multiple strokes.
1.4.2
Constructional Features
The arrestor shall be single pole and hermetically sealed off. It shall be of robust construction with
excellent electrical and mechanical characteristics.
Insulators must be non-hygroscopic and shall be wet process porcelain, brown glazed and free from
imperfection. All metal parts and hardware shall be hot dip galvanized.
Creepage distance shall correspond to heavily polluted atmosphere. Grading ring if required shall be
provided to maintain voltage gradient within permissible limit.
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The arrestor shall be provided with pressure relief device if applicable to prevent shattering of approach in
case excessive gas pressure builds up.
1.4.3
Accessories
Lightning arrestor shall be furnished complete with insulating base, surge counter and anchoring hardware
for mounting on steel structure.
A surge counter shall be mounted at a convenient height for reading counter Terminals shall be such as to
permit connections with minimum bends.
A leakage current detector shall be furnished with the counter as an integrate part. This is for monitoring
the leakage to indicate any possible breakdown.
A suitable sized bypass shunt along with necessary terminals shall be furnished for bypassing the
discharge counter if required.
1.4.4
Terminals
All connection terminals shall be of corrosion resistant material and shall be provided with complete
connection hardware.
High voltage line terminal connector suitable for ACSR conductor.
1.5
Related Civil Work
Foundation require for two pole structure in switch yard area shall be carried out by vendor with respective
civil material as required to complete the job successfully as mentioned in our drawing.
12.2
H. T. VCB
1.1
VCB
Scope
Manufacturing, testing and supplying of integrated cubicle type metal clad, form 3 a, floor mounted and
draw out type free standing, front operated indoor type 11 KV switchgear as per specifications given
below:
System
The switchgear enclosure shall conform to degree of protection IP 4 X.
The switchgear shall be made from MS sheet steel 2 mm thick (CRGO) and shall be folded and braced as
necessary to provide a rigid support for all components.
The switchgear assembly shall form a continuous dead front line up of free standing vertical cubicles.
Each cubicle shall have a lockable front hinged door and a removable bolted back cover. All covers and
doors shall be provided with neoprene gaskets. Suitable arrangement for lifting of each cubicle shall be
provided. Design and construction of the switchgear shall be such as to permit extension at either end.
Vacuum Circuit breaker shall be provided with surge arresting device for protection against lightning and
switching over voltage. Two separate and distinct connections to earth shall be provided for each surge
arrestor.
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1.1.2
E- 80
Breaker Compartment
Vacuum Circuit Breaker shall be mounted in draw out truck with front plate which covers the cubicle when
the breaker is in service position. This front plate shall be provided with view glass to facilitate observation
of mechanical ON/OFF indication of Circuit breaker, spring charged / discharged indication and operation
counter. Necessary orifice shall be provided for manual charging of the springs. ON/OFF push button for
opening and closing of the circuit breaker shall also be provided.
All draw out circuit breaker trucks/trolley of the same rating for all outgoing breakers shall be identically
wired / equipped for complete interchange ability at site. `Service', `Test', `Draw Out' positions of the draw
out carriage of the switchboard shall be provided. Automatic safety shutters shall be provided to ensure
the inaccessibility of all live parts after the breaker is drawn out.
Dummy panels required for rear extensions for cable terminations or to mount the components shall be
included in the offer and details of each type of such panels shall be furnished along with offer.
1.1.3 Bus Bar Compartment
Bus bars of rectangular cross section of copper conductor supported by cast epoxy insulator to withstand
full short circuit currents up to 18.4 KA for one second for 11 KV systems shall be provided at the rear.
Bus bar chamber shall be provided with inter panel barriers with epoxy cast seal off bushings.
1.1.4
CT And Cable Compartments
At the rear of the panel sufficient space shall be available to accommodate three numbers epoxy CT’s of
double core and two numbers three core cable termination. The cable entry shall be from the top /
bottom.
1.1.5
Separate Compartments
Circuit breakers, instrument transformer, bus bars, cable etc shall be housed in a district different
compartments as required for form 3 a, compartmentalization. All relays, switches, lamps, etc. comprising
the control, indication and protective devices shall be housed in a separate compartment on the front of
the cubicle.
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1.1.6
E- 81
Technical Particulars Of Vcb Circuit Breaker
S.NO.
DESCRIPTION
6.6 KV
11 KV
22 KV
33 KV
A
Rated Current
400 A
400 A
630 A
630 A
B
Rated Voltage
7.2 KV
12 KV
24 KV
36 KV
C
Rated Frequency
50Hz
50 Hz
50Hz
50Hz
D
Rated Short Circuit breaking Current
18.4 KA
for
1
sec.
18.4 KA
for
1
sec.
26.3 KA
for
1
sec
26.3 KA
for
1
sec
E
Rated
(KAP)
50 KA
50 KA
66 KA
66 KA
F
Insulation level (KV rms/KVP)
20 KV /
60 KV
28KV /
75 KV
50 KV /
125 KV
70 KV /
170 KV
1.1.7
short circuit making current
Earthing Switch
Cable earthing switch shall be provided in the cable chamber and shall be operated from the front of the
panel. The ON/OFF position of switch shall be indicated by mechanical indicator. The earthing switch shall
be suitably interlocked with the breaker, so that it can be operated only when the breaker is in OFF
position.
Earthing switch shall also be provided on bus bar side. The ON/OFF Switch shall be indicated by
mechanical indicator. The earthing switch shall be suitably interlocked with the breaker, so that it can be
operated only when the breaker is in OFF position.
1.1.8
Isolating Contacts
The breaker isolating contacts shall consist of two parallel flat silver plated copper bars with ball point
contacts to give a vertical tolerance of ±10 mm.
1.1.9
Low Voltage Plug And Socket Connector
A twenty pin plug and socket connection along with flexible leads shall be provided to connect control
instrumentation and interlock circuits on the breaker truck and in the panel. The plug and socket assembly
shall be suitably interlocked with the truck positions like service and test/isolated position
1.1.10 Interlocks And Safety Devices
The following interlocks shall be provided:
a. The truck cannot be moved from either test to service position or vice versa, when the circuit
breaker is ‘ON’.
b. The circuit breaker cannot be switched ‘ON’ when the truck is in any position between test and
service position.
c.
Front part of the truck cannot be removed when the breaker in ‘ON’ position.
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d. The low voltage plug and socket cannot be disconnected in any position except test/isolated
position.
e. The truck cannot be moved inside the panel, when the LT plug and socket is disconnected.
f.
Earthing switch cannot be switched ‘ON’ when the truck is inside the panel.
g. The truck cannot be inserted when the earthing switch is ‘ON’.
1.1.11 Safety Devices
The following Safety devices shall be provided for the safety of the operating personnel:
a. Individual explosion vents shall be provided for breaker/bus bar/cable chambers on the top of the
panel to let out the gases under pressure generated in case of fault inside the panel.
b. Cubicle with front plate to withstand the pressure for internal arc fault as per PEHLA
recommendation.
c.
Circuit breaker and sheet metal enclosure shall be fully earthed.
d. Self locking shutters shall be provided which shall close automatically when the truck is withdrawn
to ‘Test position’ and no separate padlocking of the shutter shall be required.
1.1.12 Protective Earthing
The earthing connection between the truck and the cubicle shall be by means of sliding contacts so that
the truck is earthed in the isolated position when inserted and remains earthed when the truck is pushed
further into the connected position or when the truck is being withdrawn until the truck has moved part the
isolated position.
1.1.13 Current Transformer
I.
GENERAL REQUIREMENTS
Accommodation shall be provided in the circuit breaker panel, to mount one set of duel ratio CT. Access
to the CTS for cleaning, testing or changing shall be from the front, back or top of the panel.
II.
RATING
Duel ratio CTS of suitable burden (but each not less than 15 VA) shall be preferred with 5 amps
secondaries.
Instrument Security Factor (ISF) of each CT shall not be more than 5.
The CTs shall conform to relevant Indian Standards. The design and construction shall be dry type, epoxy
resin cast robust to withstand thermal and dynamic stresses during short circuits. CT terminals shall be
shorting type. Current & voltage circuits shall be laid in separate wire ways. Secondary terminals of CTS
shall be brought out to a suitable terminal block which will be easily accessible for terminal connections.
Test terminal block shall be provided in the front side of the panel for testing purpose.
CT’S shall have 2 Nos. of cores for following application:
Core -1
for metering
Core -2
for over current & earth fault protection.
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Class of accuracy of each winding
Metering class
1
Protection class
5P10
1.1.14 Potential Transformers
The potential transformers shall be confirming to IS 3156/ IEC 60185.The primary windings of the
potential transformers shall be insulated and shall be of the cast rest in type.
Potential transformer (PT’S) shall be mounted on a draw out trolley and housed in separate metal
compartment and shall have control fuses on the H.V. side and a miniature circuit breaker on the L.V.
side of the windings.HT HRC Control fuses shall be confirming to IS – 9385/ IEC –60282.Miniature Circuit
breaker shall comply with IS – 8828/ IEC – 60898.
Padlocking facilities shall be provided for both service and isolated position.
The potential transformer shall be as specified below:
Ratio
:
11000 V3/ 110/ V3/ 110 V
V A Burdan
:
100 V A for 100/V3 and 110 V winding
Class
:
CL –1 for both the windings.
Basic Insulation level
:
Same as mentioned for VCB in clause -6.
Over voltage factor
:
1.2 Continuous
Single phase PT’S shall be used and shall be connected in Star/ Star.
1.1.15 Protection And Tripping Arrangement & Devices
PROTECTION
All protection relay shall be numeric type of approved make.
The protection and tripping arrangement of circuit breaker shall be:
1) Numeric type instantaneous short circuit protection Device No.50 Range 500 – 2000% shall be
provided on all phases.
2) Numeric type back up over current protection for Phase faults Device No.51 Range 50 – 200%
shall be provided on all phases.
3) Numeric type ground fault protection Device No.50G. CT’s. Range 20 – 80% shall be provided.
4) Lockout and trip supervisory relays etc shall be provided with manual reset facility.
5) Auxiliary relay for transformer fault like OT & WT.
6) Surge Arrestor
BREAKER TRIPPING & CLOSING DEVICE
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E- 84
Breaker tripping and closing devices shall be operated on D.C. supply. The rated D.C. voltage shall 110 V
D.C. through power pack with storage facility for one tripping and one closing. The supply for breaker
opening, closing and indication devices shall be provided as under:

One D.C. feeder shall be provided for each bus section. The Bus coupler panel may be fed from
any of the two supplies.

One separate 240 V AC supply shall be provided for space heater, motor auxiliary supply etc.
Mechanical indication for breaker positions such as ON, OFF, spring charged, test position/Service
position shall be provided. Various Electrical indications with colours are indicated below shall be provided.
a)
Breaker `ON'
-
Red lamp
b)
Breaker `OFF'
-
Green Lamp
c)
Breaker `Auto Trip'
-
White lamp
d)
Trip circuit healthy
-
White lamp
e)
DC fail
-
Blue lamp.
f)
Red phase ON
-
Red
g)
Yellow phase ON
-
Yellow
h)
Blue phase ON
-
Blue
1.1.16 Control Wiring
The control wiring shall be carried out with minimum 2.5 sq. mm. PVC insulated copper conductor cables.
The wiring shall be securely fixed and neatly arranged to enable easy tracing of wires. Identification PVC
ferrules shall be fitted to all wire terminals to render easy identification and facilitate checking in
accordance with IS 5578 and 11353.
1.1.17 Metering Instrument Panel Accessories
i.
METERING
Digital type Trivector meter of approved make (Smart demand controller) shall be provided on the incomer
feeder. Specification of the meter shall be as follows:
Accuracy
:
Class 0.5, compliant to revenue class certification.
:
Real time measurement per phase & average
:
V, I, PF, KW, KVAR, KVA
:
Peak demand, sliding window. Protected.
:
V & I unbalance Phase reversal
:
Time of Use (TOU)
Power Quality Measurement:
Total Harmonics
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E- 85
Logging & recording for all measurements:
Alarming
:
Interval or event-based, 32 channel measurement & recording
:
Event logging
:
“Bust” data recording
:
Min/ Max recording
:
Over & under measurement detection by 24 set point Functions.
Multi port Communication
ii.
:
One each of RS 485 and RS 232 ports.
INSTRUMENT PANELS
The instrument panel shall be part of the housing. Relays, meters and instruments shall be mounted as
per general arrangement drawings to be submitted by the vendors. They shall be of flush mounting type.
iii.
INSTRUMENTATIONS
a. Digital type Voltmeter of class 1.0 accuracy and Suitable in size as per IS-1248 shall be provided
at incomer panel, with selector switch. The instrument shall be calibrated for the ranges specified.
b. Digital type Power factor meter of class of 1.0 accuracy conforming to IS: 1248 shall be provided
at incomer panel.
c.
Digital type Ammeter with Inbuilt Selector Switch of specified range to class 1.0 accuracy and
Suitable in size as per IS - 1248 shall be provided at both incomer and outgoing panels along with
necessary selector switches.
d. Digital type frequency meter class of 1.0 accuracy conforming to IS: 1248 shall be provided at
incomer panel.
e. Digital Type Load Manager of Schneider makes PM 210 with RS 485 port.
iv.
The following minimum indication lamps shall be provided in the front of cubicle Breaker open /
closed / tripped, spring charged trip circuit healthy and control supply healthy. Lamps shall be
clustered LED type and trip circuit supervision scheme shall be of continuous supervision type.
v.
After meeting all necessary control and indication requirements 2 nos. NO and 2 nos. NC auxiliary of
the breaker shall be made available for the owner, wired up to terminal block.
vi.
Separate MCB’s shall be provided for lamps, heaters and other instrumentation etc. on each panel.
vii.
Anti-condensation space heaters suitable for operation on 240 V single phases, 50 Hz A.C. for each
cubicle and with thermostat control one incandescent lamp with switch and 3 pin 5 amps plug socket.
viii.
Earthing Conductor of 30 x 6 mm should be provided in continuous length of the panel.
1.1.18.
Drawings/Documents Required For Review/Approval
Following drawings documents shall be submitted by the manufacturer for approval.
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E- 86
1) General arrangement (GA) of equipment layout.
2) Equipment list.
3) Relay and metering system schematics.
4) Supply and erection schedule.
5) Catalogue and specification sheets.
1.1.19.
Inspection And Testing
After manufacturing of switchgear panels tests shall be carried out on the equipment as per relevant IS
and Electricity Regulations.
1.1.20.
Quality Assurance
Vendor shall submit in substantial detail a quality assurance plan indicating all activities step by step at
various manufacturing/fabrication stages to meet the requirement of this specification and various
standards/regulations/practices to enable comprehensive assessment of its merits and reliability.
1.
Technical Data For Switchgear Cubicle Type With
Breaker
VCB
Tenderer must fill in the following technical data
VCB
1.1
1.2
Switchgear cubicle
i.
Make
ii.
Type
iii.
Reference Standard
iv.
Voltage (System/Rated)
v.
Phase/Frequency
vi.
Short Circuit Rating
a.
Interrupting Symmetrical
b.
Short time for 1/3 sec.
Construction
i.
Draw out feature for Circuit Breaker with Service
Test & Disconnected
ii.
Minimum clear space required at:
a.
Front for breaker withdrawal
b.
Rear
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iii.
1.3
1.4
E- 87
Overall dimension & Operating weight
BUS BAR
i.
Material & grade (Cu. Only)
ii.
Reference standard
iii.
Cross sectional area size
iv.
Continuous current at 40 deg C
v.
Max temp rise over for 40 deg C
vi.
Short time current for 1/3 sec.
vii.
Min clearance of bare bus bar & connection
a.
Phase to phase
b.
Phase to ground
Circuit breaker
i.
Make
ii.
Type
iii.
Rated voltage
iv.
Rated frequency
v.
No. of poles
vi.
Rated current
a.
Continuous at 40 deg C & within
b.
Short time current for 1 sec/3 sec
1.5
Max. temp rise over 40 deg C ambient
1.6
Rated operating duty
1.7
Interrupting capacity at rated voltage and operating duty
cubicle
a. Symmetrical
1.8
Rated making current
1.9
No. of breaker operations permissible
Without requiring inspection for refilling
SF6 gas replacement of contacts & other main parts
a.
Not Applicable
At 100% rated current
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b.
1.10
1.11
1.12
1.13
1.14
E- 88
At 100% rated short circuit current
Type of contacts
a.
Main
b.
Arcing
Min clearance in air
a.
Between poles
b.
Between live parts & ground
Operating mechanism
a.
Type
b.
No. of breaker operations stored
c.
Trip free or fixed trip?
d.
Antipumping features provided
Closing Coil
a.
Voltage
b.
Permissible voltage variation
c.
Power required at rated voltage
Breaker/breaker cubicle provided with the
following:
a.
Mech. safety interlocks
b.
Automatic safety shutter
c.
Emergency manual trip
d.
Mech. ON/OFF indicator
e.
Operation counter
f.
Spring charge/discharge indications
g.
Manual spring charging facility
h.
Mechanical Antipumping
1.15
Net weight of the breaker
1.16
Impact load for foundation design
1.17
Overall dimensions in mm
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12.3
1.1
E- 89
DRY Type Transformers With Off Load Tap Changer
Scope
Design, manufacture, testing, supplying and commissioning of 11 KV/433 volts step down, transformer
complete with all the accessories and fittings for efficient and trouble free operation.
1.2
CODES And ST ANDARD
Transformer shall Conform to Indian Standard IS: 2026-1977 (Part I to IV), IS: 11171 - 1985 IEC 60726,
ECBC-2007.
1.3
Rating
Transformer shall be suitable for continuous operation and maximum rating shall be as given in the
schedule of quantities.
1.4
Connections And Vector Group
Delta on High Voltage side and star on low voltage side with neutral terminal brought out for solid earthing
corresponding to the Vector Symbol Dyn - 11.
1.5
System Of Supply
3 phase, 50 Cycles, 33 KV earthed system.
1.6
Tappings
Off load tap changing on HV side. The tapings to be provided for variation on HV side from +7.5% to 7.5% in steps of 2.5 % each.
1.7
Temperature Rise
o
Continuously rated for full load, temperature rise not exceeding 90 C corresponding to Class “H".
1.8
Type
Outdoor type.
1.9
Terminals
The cable box with glands on H T side shall be suitable for 3 core XLPE cable of specified capacity.
Flanges with cable box / bus duct on LT side shall be suitable for aluminium conductor armoured cables /
LT bus duct of size mentioned in BOQ. All cable glands shall be earthed.
1.10
Cooling
Air Cooled
1.11
Insulation
Glass fibre reinforced epoxy and class `H'.
1.12
Earthing
Two earthing terminals shall be provided at the bottom on both sides.
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1.13
E- 90
Fittings And Accessories
The following fittings and accessories shall be provided.
a. Transformer shall be provided with 4 Nos. bi-directional rollers fitted on cross channels to
facilitate the movement of the transformer in both direction.
b. Lifting lugs
c.
Diagram and rating plate shall be provided indicating the details of transformer, connection
diagram, Vector group, tap changing diagram etc.
d. Thermistors for Alarm and Trip.
e. HV Cable terminating facility for XLPE cable.
f.
LV Cable terminating facility /bus duct termination flange.
g. Winding Temperature Relay unit.
h. Winding Temperature indicator.
i.
1.14
Disconnecting chamber shall be provided for cable termination.
Iron Core
The core shall consist of grain oriented laminations which shall be insulated on both sides for low losses.
1.15
Winding
High Voltage and Low Voltage windings shall be made of copper and insulation shall be of class F. High
voltage and low voltage windings, shall be completely impregnated and cast under vacuum into moulds.
This process shall form the insulation system of uniform glass fibre epoxy laminate of highest
electrical and mechanical quality, into which windings shall be voidlessly embedded.
Both the high voltage and low voltage windings of each phase shall be separately cast as one rigid tubular
coil.
1.16
Enclosure
The transformer shall be housed in 2 mm thick CRCA sheet steel enclosure mounted on bi-directional
rollers. Enclosure shall be provided with metal screen at top and bottom for ventilation. Degree of
protection of enclosure shall be IP-43.
1.17
Draw ings And Leaflets
Three copies of manual giving complete instructions for the installation, operation and maintenance with
circuit diagram, foundation and trenching details shall be provided with the transformer.
1.18
M aximum Allow able Pow er T ransformer Losses
Maximum allowable losses for Oil type distribution transformers with highest voltage for equipment up to
50 KV, at 50 % and 100 % of the load.
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E- 91
TRANSFORMER
CAPACITY KVA
MAXIMUM
ALLOWABLE
LOSSES AT 50% KVA OR
LOAD (%)
MAXIMUM ALLOWABLE
LOSSES AT FULL LOAD /
RATED KVA (%)
100
1.88
2.44
160
1.61
2.07
200
1.50
1.90
250
1.36
1.73
400
1.19
1.51
500
1.12
1.45
630
1.06
1.40
1000
0.90
1.20
1600
0.79
1.05
2000
0.75
1.00
Measurement And Reporting Of Transformer Losses
Tests

All routine tests as per IS2026-1977 / IS: 11171-1985 which is applicable shall be carried out at
the factory and copies of test reports shall be submitted for approval and records.

Heat Run Test shall be carried out at an approved test lab as per IS: 2026-1977 at no extra cost.

Impulse test shall be carried out at an approved test lab as per IS:2026-1977

Measurement of winding resistance.

Ratio polarity and phase relationship.

Impedance voltage.

Load Losses.

No-Load losses and no-load current.

Insulation resistance.

Induced over voltage with-stand.

Temperature rise.
1.19
Testing
The transformer shall be subject to the following tests at the factory before dispatching the same and test
certificates shall be furnished.
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E- 92
a. Measurement of winding resistance.
b. Ratio polarity and phase relationship.
c.
Impedance voltage.
d. Load losses.
e. No-load losses and no-load current.
f.
Insulation resistance.
g. Induced over voltage withstand.
h. Separate - source voltage withstand.
i.
Temperature rise.
1.20
Draw ings/Documents Required For Review /Approval
Following drawings documents shall be submitted by the manufacturer for approval.
a. General arrangement (GA) of equipment layout.
b. Equipment list.
c.
WTI schematics.
d. Supply and erection schedule.
e. Catalogue and specification sheets.
1.21
Inspection And T esting
After manufacturing of switchgear panels tests shall be carried out on the equipment as per relevant IS
and Electricity Regulations.
1.22
Quality Assurance
Vendor shall submit in substantial detail a quality assurance plan indicating all activities step by step at
various manufacturing/fabrication stages to meet the requirement of this specification and various
standards/regulations/practices to enable comprehensive assessment of its merits and reliability.
1.23
Technical Data For Transformer
Tenderer must fill in the following technical data
S. No. Technical Parameters
Dry Type
Transformer
1.
Type and class of insulation
2.
Output in KVA (Continuously rated)
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3.
4.
E- 93
Rated Voltage
a.
HV (Volts)
b.
LV (Volts)
Rated Current
a.
HV (amps)
b.
LV (amps)
5.
No. of phase
6.
Type of cooling
7.
Frequency
8.
Winding Connection
9.
Tapings
10.
Vector Group
11.
Ref. Ambient temperature
Temperature rise winding
Class of insulation
12.
13.
Physical Dimensions
a.
Length (in mm)
b.
Width (in mm)
c.
Height (in mm)
% Impedance
S. No. Technical Parameters
14.
X/R ratio
15.
Iron losses at normal voltage ratio
16.
Copper loses at normal voltage ratio
Dry Type
at full load
17.
Efficiency at unity power factor
a.
Full load
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12.4
b.
75% load
c.
50% load
18.
Regulation at unit power factor
19.
Regulation at 0.8 power factor
20.
Approximate weight
a.
Core & winding (Kgs.)
b.
Total Weight (Kgs.)
E- 94
Ht Cable
11 / 11 Kv Grade XLPE
1.1
General
Cables shall be aluminium conductor, cross linked polyurethane construction and shall be
supplied, inspected, laid, tested and commissioned in accordance with drawings, specifications, relevant
Standard Specifications and cable manufacturer's instructions.
1.2
Material
a.
Conductor
The Conductor shall be made from electrical purity aluminium stranded wires compacted
together.
b.
Conductor Screen
The conductor screen shall consists of an extruded layer of thermosetting semi-conducting
compound which shall be extruded simultaneously with the core insulation
c.
Insulation
High quality TROPOTHEN - X (XLPE) unfilled insulating compound of natural colour shall be used
for insulation. Insulation shall be applied by extrusion process and shall be chemically cross
linked in continuous vulcanization process.
d.
Shielding
Cables shall be provided with conductor shielding as well as insulation shielding and shall consist
of extruded semi-conducting compound, additionally insulation shield shall be provided with semiconducting and metallic tape shield over the extruded insulation shield. XLPE insulation and outer
core shielding shall be extruded in one operation.
e.
Armouring
Armouring shall be applied over the inner sheath and shall comprise of flat steel wires (strips).
f.
Outer Sheath
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Tough outer sheath of heat resisting PVC compound shall be extruded over the armouring in case
of armoured cables or over extruded over the armouring in case of armoured cables or over inner
sheath in the case of unarmoured cables.
Cable Marking
g.
Embossing of outer sheath:
The PVC outer sheath shall be legibly embossed with the legend: "ELECTRIC CABLE
3300/33000 VOLT"
The letter and figures shall be raised and shall consist of upright block characters. The maximum size of
the characters shall be 13 mm and the minimum size 15 % of the cable circumference or 3 mm whichever
be the greater. The gap between the end of one set of embossed characters as above and the beginning
of the next shall not exceed 150 mm.

Identification of Manufacturer & year of manufacture
An identification of the manufacturer and indication of the year of manufacture shall be embossed at
regular intervals on the PVC outer sheath. This shall not affect the spacing between repetitions of the
legend as given above.
1.3
Tests
Cables shall be type tested and routine tested in accordance with IS: 7098 (Part II).
a.
Conductor resistance test.
b.
Partial discharge test.
c.
High Voltage test.
The following tests shall be carried out at site for insulation between phases and between phase and earth
before and after cable laying.
a.
Insulation Resistance Test.
b.
Continuity resistance test.
c.
Sheathing continuity test.
d.
Earth test.
e.
High Voltage test.
Cables shall be laid with a clearance of at least 75 mm between two cables.
1.4
End Termination Of Ht Cable
Pre-moulded cable terminations for XLPE cable shall be used as per manufacturer’s instructions. The
steel cone of Push-On shall consist of highly track resistant insulating section vulcanized to a semiconducting section. The pad material shall have cold-flow properties and shall be flame retardant.
Each end terminal shall undergo Hi Pot Test.
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1.5
E- 96
Laying Of Ht Cables
Direct In Ground
The work shall involve excavation of trench and laying of cable(s) as indicated in drawing and Schedule of
Quantities.
The depth of the excavation shall not be less than 900 mm for 6.6 / 11 KV and 1050 mm for 22 / 33 KV
plus radius of cable, from the upper surface of ground. Where more than one multi core cable is laid in the
same trench, a horizontal inter spacing of 250 mm shall be left in order or reduce mutual heating and also
to ensure that fault occurring on one cable will not damage the adjacent cable.
Cable shall be laid in cement pipes encased in concrete or hume pipes at all road crossing. Cables shall
be laid in trenches over rollers placed inside the trenches. After the cable has been properly laid and
straightened, it shall be covered with 80 mm thick layer of sand. Cable shall then be lifted and placed over
this sand cushion. Again, the cable shall be covered with an 80 mm layer of
sand. Over the sand a
layer of cable protection tiles shall be placed by overlapping 50 mm on either side. Trenches shall then be
back-filled with earth and shall be consolidated. Suitable cable markers made of cast iron with aluminium
paint indicating the voltage grade and direction of run of the cables shall be installed at regular intervals.
12.5 Compact Sub Station / Unitise Sub Station
1.1
SCOPE
This scope shall cover design, manufacture, check test, and supply, installation, testing
and commissioning of Compact Package Substation as described in Bills of quantities
and drawings.
1.2
CODE & STANDARDS:
All equipment and material shall be designed manufactured and tested in accordance
with the latest applicable Indian Standard / IEC standard.
Equipment and material confirming to any other standard which ensures equal or better
quality may be accepted. In such case copies of English version of the standard adopted
shall be submitted.
The electrical installation shall met the requirement of Indian Electricity Rules as
amended up to date relevant IS code of practice and Indian electricity act.
The Compact Secondary Sub-station offered shall in general comply with the latest issues
including amendments of the following standards but not restricted to it.
Title
High Voltage Low Voltage Pre-Fabricated Substation
Indian
Standards
IEC:1330
11 / 11 kV Switchgear cubicles
IS:13118,
IS:3427, IEC:694.
IEC:298
Ring main unit 11 / 11 kV grade
IS:9920, IEC:265
Code of practice for selection, installation and maintenance of
Switchgear
Distribution Transformer
IS:10118
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IS: 2026
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1.3
E- 97
Dry Type Power Transformer
IS:11171
Colour for ready mix paints
IS:5
Enamel synthetic, exterior a)Undercoating b) finishing
IS:2932
Indian Electricity Rules
1956
Indian Electricity Act
1910
DESIGN CRITERIA
Compact Secondary Sub-station consisting of 11kV Non-Ext Compact SF6 RMU(1no. SF6 circuit
Breaker) + Transformer + L.T. Switchgear with all connection accessories, fitting & auxiliary equipment
in an Enclosure to supply Low-voltage energy from high-voltage system as detailed in this specification.
The complete unit shall be installed on a substation plinth (base) as Outdoor substation located at very
congested places. The HT Circuit Breaker shall be used to control and isolate the 11kV/433V Distribution
transformer. The transformer L.T. side shall be connected to L.T. switchgear. The connection cables to
Feeder Pillars shall be taken out from the L.T. switchgear.
The prefabricated-Compact Secondary substation shall be designed for a) Compactness,
installation, c) maintenance free operation, d) safety for worker/operator & public.
b) fast
The Switchgear and component thereof shall be capable of withstanding the mechanical and thermal
stresses of short circuit listed in ratings and requirements clause without any damage or deterioration of
the materials.
For continues operation at specified ratings temperature rise of the various switchgear components shall
be limited to permissible values stipulated in the relevant standard and / or this specification.
1.4
Service Conditions:
The equipment offered shall be suitable for continuous satisfactory operation in tropical area of
Installation.
1.5
Enclosure:
The Enclosure, High Voltage switchgear-control gear, Low Voltage switchgear-control gear & Transformer
of the Compact Secondary substation shall be designed to be used under normal outdoor service
condition as mentioned. The enclosure should take minimum space for the installation including the
space required for approaching various doors & equipment inside. The enclosure construction shall be
such that it fully protects ingress of rain water &rusting .For this purpose, construction without welded joint
is preferred.
1.6
SPECIFIC REQUIREMENT
The main components of a prefabricated-Compact Secondary substation are Transformer, High-voltage
switchgear-control gear, Low-voltage switchgear-control gear, corresponding interconnections (cable,
flexible, bus bars) & auxiliary equipment. The components shall be enclosed, by either common enclosure
or by an assembly of enclosure. All the components shall comply with their relevant IS/IEC standards.
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1.7
E- 98
Ratings:
Description
Value
Rated Voltage/ Operating Voltage
11 kV rms
Rated frequency & Number of phases50Hz & 3nos.
Rated maximum power of sub-stationAs given in B.O.Q.
Rated Ingress protection class of Enclosure
IP-23D for substation enclosure and
IP:54 for LT Switchgear & HT
Switchgear enclosure
HV Insulation Level
Rated withstand voltage at power
frequency of 50 Hz
50 kV rms
Rated Impulse withstand Voltage
125 kV peak
HV Network & Busbar
1.8
Rated current
400 Amp
Bus Bar current density (Cu)
1 Amps/sq. mm
Rated short
current
18.4 kA rms/1sec
time
withstand
Making capacity for switchdisconnector & earthing switches
52.5 kA peak
Breaking capacity of Isolators
(rated full load)
400 A
Tap off Breaker
400 A
LT Network
1 No. ( rating As per BOQ ) , 4P, 50 /
65 kA ACB with micro-processor
based release as incomer with
Communicable Accessories with 1
no. of 160 Amp. TP MCCB with
Capacitor duty Contactor with time
delay relay with 50 KVAR Gas Field
Capacitor & Metering as shown in
SLD
Outdoor enclosure:
The enclosure shall be made of Galvanized Iron tropicalised to Indian whether conditions.
The metal base shall ensure rigidity for easy transport & installation.
The structure of the substation shall be capable of supporting the gross weight of all the equipment & the
roof of the substation compartment shall be designed to support adequate loads.
The protection degree of the Enclosure shall be IP54 for LT & HT switchgear compartment & IP23D for
Transformer compartment. Proper / adequate ventilation aperture shall be provided for natural
ventilation by way of Louvers etc.
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The doors shall be provided with proper interlocking arrangement for safety of operator.
The H.V. & L.V. outgoing of the transformer are to be connected to HT Breaker & incomer of the L.V.
1.9
Internal Fault :
Failure within the Compact Secondary substation due either to a defect, an exceptional service condition
or mal-operation may initiate an internal arc. Such an event may lead to the risk of injury, if persons are
present. It is desirable that the highest practicable degree of protection to persons shall be provided.
1.10
Covers & Doors :
Covers & doors are part of the enclosure. When they are closed, they shall provide the degree of
protection specified for the enclosure. Ventilation openings shall be so arranged or shielded that same
degree of protection as specified for enclosure is obtained. Additional wire mesh may be used with proper
Danger board for safety of the operator. All covers, doors or roof shall be provided with locking facility or it
shall not be possible to open or remove them before doors used for normal operation have been opened.
The doors shall open outward at an angle of at least 90° & be equipped with a device able to maintain
them in an open position.
1.11
Earthing :
All metallic components shall be earthed to a common earthing point. It shall be terminated by an
adequate terminal intended for connection to the earth system of the installation, by way of flexible
jumpers/strips & Lug arrangement. The continuity of the earth system shall be ensured taking into account
the thermal & mechanical stresses caused by the current it may have to carry. The components to be
connected to the earth system shall include:
a)
b)
c)
d)
e)
The enclosure of Compact Secondary / prefabricated substation,
The enclosure of High voltage switchgear & control gear from the terminal provided for the
purpose,
The metal screen & the high voltage cable earth conductor,
The transformer tank or metal frame of transformer,
The frame &/or enclosure of low voltage switchgear,
There shall be arrangement for internal lighting activated by associated switch for HV,
Transformer & LT compartments separately.
1.12
Labels :
Labels for warning, manufacturer’s operating instructions etc. & those according to local standards &
regulations shall be durable & clearly legible.
1.13
Cleaning & Painting :
i) The paints shall be carefully selected to withstand tropical heat rain. The paint shall not
crinkle or be removed by abrasion due to normal handling.
scale off or
ii) Special care shall be taken by the manufacturer to ensure against rusting of nuts, bolts and fittings
during operation. All bushings and current carrying parts shall be cleaned properly after final painting.
1.14
11kV Non-Ext RMU: ( Refer HT VCB Spects Also )
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E- 100
The requirement of 11kV Switchgear is as under.
VCB Non-extensible Units with HT Circuit Breaker comprising of panel as indicated below:
VCB (Feeding to transformer) complete with operating mechanism, protection system and One
Number of cable box accessible from the front suitable for terminating of suitable size XLPE cables
(Details to be frozen while detailed engineering)
The above Breaker , Busbars should be mounted inside a robotically welded sealed for life , stainless
steel tank of 3 mm thick sheet metal. The degree of protection for gas tank should be IP67.
The VCB is required to control 11 kV/433 volts distribution Transformer of suitable rating and relay
settings shall be selected accordingly.
1.14.1 General Finish: Totally enclosed, metal clad, vermin and dust proof suitable for tropical climate
use as detailed in the specification.
1.14.2 Ratings: The busbars shall have continuous rating of 630 Amps. The isolator shall have a
continuous rating of 630 Amps VCB Breaker shall have a continuous rating of 400 Amps. in accordance
with relevant IS / IEC standard
1.14.3 Breaking & Making Capacity : The VCB, Breaker shall be capable of having rupturing capacity
of 26.3kA symmetrical at 11000 volts three phase.
1.14.4 Busbar: Switchgear shall be complete with all connection, bus-bars etc. Copper busbars
continuous rating shall be 630 Amps.
1.14.5 Remote Operation: Provision of remote operation of the RMU’s Isolators & Breaker CB shall be
possible using Motors fitted to the operating mechanism. It shall be possible to fit the motors either directly
in manufacturing plant or on site as & when required. Installation on site shall be possible (optional – all
required provisions to be made)
1.14.6 Switchgear :
The RMU shall be Sealed for life, the enclosure shall meet the “sealed pressure system” criteria in
accordance with IEC:298 (a system for which no handling of gas is required through out service life of
approximate 25 years.) There shall be no requirement to ‘top up’ the SF6 gas. In addition, manufacturer
shall confirm that maximum leakage rate is lower than 0.1% per year. It shall provide full insulation,
making the switchgear insensitive to the environment. Thus assembled, the active parts of the switchgear
unit shall be maintenance free.
The switchgear & switchboard shall be designed so that the position of different devices is visible to the
operator on the front of the switchboard & operation are visible as well. The switchboard shall be designed
so as to prevent access to all live parts during operation without the use of tools.
RMU should be tested for internal arc fault test.
1.14.7 Isolator :
The Isolators offered shall conform to IEC60129. The isolator shall be triple pole, spring assisted, hand
operated, non-automatic type with quick break contacts. The operating handle shall have three positions
‘ON’, ‘OFF’ and ‘EARTH’ which shall be clearly marked with suitable arrangement to padlock in any
position. A safety arrangement for locking shall be provided by which the isolator operation shall be
prevented from ‘ON’ position to ‘EARTH’ position or vice versa in a single operation.
1.14.8 VCB:
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E- 101
The Unit shall consist 400 A Tee-off spring assisted, three pole VCB circuit Breaker, with integral fault
making / dead breaking earth switch. The function shall be naturally interlocked to prevent the main &
earth switch from being switched ‘ON’ at the same time & the CB not allowed to trip in ‘Earth On’ position.
The selection of the main/earth switch lever on the panel, which is allowed to move only if the main or
earth switches in the off position. The lever shall be able to pad locked in either the main or earth position.
The manual operation of the circuit breaker shall not have an effect on the trip spring. This should only be
discharged under a fault (electrical) trip condition, the following manual reset operation should recharge
the trip spring & reset the CB mechanism in ‘main off’ position.
1.14.9 Protection :
Protection Relays: The CB shall be fitted with microprocessor based self powered relay inside the front
cover to avoid any tampering.
1.14.10 Cable Box :
Every isolator / VCB shall be provided with suitable and identical cable boxes for connecting 3 core, 11kV
cable from vertically below. The cable boxes shall be so located at convenient height to facilitate easy
cable jointing work. The Cable termination shall be done by Heat shrinkable Termination method so
adequate clearances shall be maintained between phases for Termination. Access to all the cables should
be possible form the front of RMU.
1.14.11 Locking Arrangement : Suitable padlocking arrangements shall be provided as stated below…
a)
b)
c)
CB manual operating handle in the “OFF” position.
Each feeder Panel operating handle in ‘Closed’ ‘Open” or ‘Earth’ position.
Each isolator operating handle in ‘Closed’, ‘ Open’, or ‘Earth’ position.
1.14.12 Ratings :
Non-Extensible switchgear with VCB
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
a)
b)
c)
d)
e)
f)
Switchgear Data
Service
Type
Number of phases
Voltage
Rated Frequency
Rated Current
Short Circuit rating
i) Breaking
ii) Short time withstand for 3 Sec.
iii) Rated S/c making
Short duration power frequency
Insulation Level
System earthing
Breaker
Type
Rated voltage
Breaking current
i) Load breaking
Making current
Rated current
No. of poles
Consultant : JIT Engineering Services Consultant
Outdoor but inside Enclosure
Metal clad
3
11 KV
50 Hz
400 Amp
18.4 kA rms for Breaker
28.3 kA rms
52.5 kA peak for Breaker
50 kV
125 kV peak
Solidly earthed at substation
VCB in SF6 tank
11 KV
18.4 kA rms.
52.5 kA peak
400 Amps.
3
Sign of Bidder
Electrical Works – Specifications and List of Make
g)
Operating mechanism.
a)
b)
c)
Busbars ( If any)
Material
Type
Rated Current
E- 102
Trip free & free handle type with mechanically
operated indication & pad locking.
Copper
SF6 insulated
400 Amps
1.14.13 Tests For Breaker: Each type of 11 / 11kV Switchgear shall be completely assembled,
wired, adjusted and tested at the factory as per the relevant standards i.e. IS : 9920, IS :
3427, IS : 13118, IEC : 265, IEC : 298 and during manufacturing and on completion
Routine Tests : The tests shall include but not necessarily limited to the following a) Operation under simulated service condition to ensure accuracy of wiring, correctness
of control scheme and proper functioning of the equipment.
b) All wiring and current carrying part shall be given appropriate High Voltage test.
1.15
DISTRIBUTION TRANSFORMER
ONAN Type Transformer :
1.15.1 Requirement: 11 / 0.433 KV DRY Type , ( KVA as per B.O.Q.) KVA, AN cooled suitable for
installation at outdoor in Enclosure for ground mounting.
1.15.2 Voltage Ratio : No load voltage 11000/433 volt within tolerance as stipulated in IS.
1.15.3 Rating : The transformer shall have a continuous rating as specified at any of the specified
tapping position and with the maximum temperature rise specified.
1.15.4 Magnetic Core : The Core will be made from Laminations of grain oriented silicon steel, insulated
with mineral oxide and will be protected against corrosion with coat of varnish.
The choice and grade of steel and the cutting pattern and method of assembly minimizes the loss level
and the no load current with the effect of a very low noise level.
1.15.5 Fittings / Accessories
1)
2)
3)
4)
5)
6)
7)
8)
2 nos. earthing terminals
Rating and diagram plate
1 no. Winding temperature indicator
Off circuit tapping links +/- 10 % in 2.5% step
4 nos. flat bi-directional rollers
Lifting lugs
Cooling fans
Marshalling box
Technical Particulars of Transformer
Description
Unit
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Value
Sign of Bidder
Electrical Works – Specifications and List of Make
Service
Type
Rating
Rated frequency
Number of Phase
HV Side
LT Side
Rated Voltage
HV Side
LT Side
Vector Group
Type of Cooling
Class of Insulations
Insulation Level
1
2
3
4
5
6
8
9
10
a) Power Frequency withstand
Impulse Withstand
Method of earthing-LT
Duty
Taps
a) range
b) No. of Steps
c) In steps of
d) Tapping provided on HV Side
Tap Changer Type
Impedance Voltage at 75°C
a) At Principal tapping
Temperature Rise above 50°C
ambient
11
12
13
14
15
16
a) Winding by Resistance
Terminals
a) HV Side
b) LT Side
Losses (at 75°C and principle
Tapping) (IS Tol.)
a) No Load at rated Voltage and
Frequency
17
18
b) Load loss at Rated Current
c) Total Loss at maximum Rated
Power
Efficiency at 75°C and unity P.F.
a) At Full Load
b) At 75% Load
c) At 50% of Load
Hot spot temperature of winding
limited to
19
20
kVA
Hz
Outdoor
AN Type
As per B.O.Q
50
3 phase 3 wire
3 phase 4 wire
kV
kV
kV
rms
kV
Peak
11
0.433
DYN-11
AN
CLASS H
50KV
125KV
INDIAN TNS
Continuous
%
%
+10% to -10%
9
2.5% each
Yes
OFF Load
%
As per IS Code ±10%
°C
65°C for Class H
Cable Box
Flexible Copper connection
KW
KW
KW
Should be less than allowed in ECBC2007.
Should be less than allowed in ECBC2007.
Should be less than allowed in ECBC2007.
%
%
%
Should be better than allowed in ECBC.
Should be better than allowed in ECBC.
Should be better than allowed in ECBC.
°C
90°C for Class F/ 115°C for Class H
Reference Standards
21
1.16
E- 103
IS-2026, IS-11171, IEC 60726, ECBC2007
ISOLATOR PANEL :
System:-
Declared voltage :– 3 Phase,415V (±10%) 50 Hz,
Neutral :– Solidly earthed at substation.
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E- 104
1.16.1
General finish :- Tropical, totally enclosed, metal-clad, weather-proof, vermin and dust proof.
1.16.2
Enclosure :- Type of enclosure shall be able to provide the degree of protection IP : 4X .
1.16.3 Circuit Ways for kVA ( as per B.O.Q.) CSS :
Incoming of 1 No. rating as per BOQ, 4P, 50 / 65 kA ACB with micro-processor based release as incomer
with Communicable Accessories with 1 no. of 160 Amp. TP MCCB with Capacitor duty Contactor with time
delay relay with 50 KVAR Gas Field Capacitor & Metering as shown in SLD. Cable connection box should
be at least 750 mm above from Gland Plate with necessary space to terminate 4 nos. of 400 Sq. mm. x
3.5 C Cables.
1.16.4 Construction :
The terminals shall be of sufficient mechanical strength and shall provide adequate electrical contact for
the appropriate size of cable used. They shall be capable of receiving appropriate size of Aluminum
conductors / Bus Duct. They shall be provided with stainless steel nut bolts, plane washers and spring
washers for cable connection.
The enclosure of LT Shall be constructed using 2mm CRCA sheet steel.
No contact pressure shall be transmitted through insulating material & the gripping of the conductor shall
take place between metal faces.
1.16.5 Earthing :
Earthing arrangement shall be provided for earthing each cable / Bus Duct, PVC cable gland, neutral
busbar, chassis and frame work of the cubicle with separate earthing terminals at two ends. The main
earthing terminals shall be suitably marked .The earthing terminals shall be of adequate size, protected
against corrosion, and readily accessible. These shall be identified by means of sign marked in a legible
manner on or adjacent to terminals.
Neutral bus bar strip shall be connected to Earthing terminal with help of copper strip of suitable capacity
& nut-bolt arrangement.
1.16.6 Accessories: The following accessories shall be supplied duly mounted.
One incandescent lamp (with necessary fuse) to illuminate the fuse board internally.
1.16.7 Metering : As per BOQ & SLD
1.17
SHOP DRAWINGS
Prior to fabrication of the Panels the supplier / contractor shall submit for consultant’s approval the shop /
vendor 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 manufacturer’s catalogues of the electrical components installed in the Panels along with
the drawing.
The following shall be furnished as part of the Tender :
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Electrical Works – Specifications and List of Make
E- 105
(a)
General arrangement showing plan, elevation and typical sectional views.
(b)
Technical literature on the various equipments.
(c)
The following shall be furnished after award of contract for Purchaser's approval :
1.18
i.
General arrangement showing plan, elevation and typical section views.
ii.
Foundation plan showing location of fixing channels, floor opening etc.,
iii.
Schematic wiring drawings for each feeder.
TYPE / ROUTINE TEST ON COMPACT SECONDARY SUBSTATION :
Type Tests:
The offered Compact Secondary substation should be fully type tested as per the IEC-1330
Routine Tests :
The routine tests shall be made on each complete prefabricated substation.
a) Voltage tests on auxiliary circuit.
b) Functional test.
c) Verification of complete wiring.
Test Witness:
Routine test shall be performed in presence of Owner’s representative if so desired by the Owner.
The Contractor shall give at least fifteen (15) days advance notice of the date when the tests are
to be carried out.
1.19
Test Certificates:
Test report for the test mentioned under Type tests clause shall be submitted along with offer.
Certified reports of all the tests carried out at the works shall be furnished in three (3) copies for
approval of the Owner.
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Sign of Bidder
Electrical Works – Specifications and List of Make
E13.
E- 106
Diesel Generator Set
2.0
Uninterruptable Power Supply
2.1
General Requirements
2.1.1. The scope of work for supply and installation of UPS system shall include design manufacture,
supply, installation, testing and commissioning of all related equipments together with all
accessories and auxiliaries as per specifications.
The system shall be fully operational and shall comply with the specified codes and standards.
The contractor shall be responsible for providing all materials, equipments and engineering services
specified or which are required to fulfil the intent of ensuring reliability of the total work covered
under these specifications within his quoted price.
2.1.2. Supply and installation of the UPS system covered under this specification shall conform to the
latest editions of codes and standards mentioned below and all other applicable Standards.
a)
IEEE Standard 446-1987
:
b)
IEEE Standard 450-1975
:
c)
IEEE Paper 4-177:
Some discharge characteristics of lead acid batteries.
d)
IEC 60140-3
e)
IEC 60140-2
:
Electro Magnetic Compatibility
f)
IEC 60140-1
:
Safety
e)
ANSI C 37.90a,
:
Emergency and standby power systems.
UPS Performance
IEEE Standard 472
:
Surge withstand capability test.
f)
ANSI C 34.2
:
Practices and requirements for semiconductor power rectifiers.
g)
ANSI C 37.90
:
Relays and relay system associated with electrical
apparatus.
h)
NEMA PE-1-1983
:
Uninterrupted Power System Standard
i)
IS 2208 & IS 9224
:
Cartridge fuses for voltages up to and including 650 V
power
(Part 1 & Part 2) (I.E.C. 269)
j)
IS 9224 (Part - 4)
:
Fuses for protection of semiconductors.
k)
BS 2709 (I.E.C 119)
:
The Electrical Performance of Semiconductor Rectifiers. (Metal
Rectifiers)
l)
BS 4417 (I.E.C 146)
:
Semi-conductor Rectifier Equipments.
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Electrical Works – Specifications and List of Make
E- 107
m)
IS 13947: 1993 :
Specification for Low voltage Switchgear & Control gear
n)
IS 3961(Part 2):1967
:
Recommended current rating for PVC insulated Cables
o)
IS 1652 & IS 1652
:
Lead-acid stationary cells and batteries.
p)
BD 9720
:
Custom-built transformers and inductors of assessed quality.
q)
IP20
:
Degree of protection.
r)
IEC
:
Semi Conductor Convertor Standards.
s)
JEC
:
Standard of the Japanese Electro technical committee
t)
JIS
:
Japanese Industrial Standard.
u)
JEM
:
The standard of the Japan Electrical Manufactures Association.
v)
ISO 9001 approved
2.1.3.
The vendor shall submit his offer for UPS systems as indicated in the tender document.
2.1.4. All components of the UPS equipment shall have Surge Withstand Capability (SWC) to meet
the requirements of ANSI C62.41-1980. ANSI C 37.90a, IEEE Standard 472-1974.
2.1.5.
All components of UPS system shall withstand short circuit current without any damage.
2.1.6.
Following general requirements shall be met for ensuring proper circuit protection.
a. Fuses shall not be larger than 125% of the transformer primary circuit current where the
secondary circuit fuse protection has not been provided.
b. Where the secondary fuses are sized not larger than 125% of the secondary current of the
transformer, fuses shall not be required in the primary circuit, provided the primary feeder fuses
are not larger than 250% of the transformer primary current.
c.
All the neutral conductors in three phase UPS systems shall be sized equal to at least 150% of
the maximum phase current. In addition, all the isolators and circuit breakers used in three phase
UPS system shall also to be rated such that the neutral poles shall take at least 150% of the
maximum phase current.
d. All control shall be designed and positioned such that possibility of inadvertent or
operations is eliminated.
accidental
e. All UPS system cabinets, frames and power equipment shall be double earthed.
2.1.7. The UPS design shall ensure that a single component/ device failure shall not result in failure of the
entire UPS system. The design of UPS System shall be modular to permit easy maintenance.
2.1.8. The various overload capacities of inverters, static switch, and step down transformer/voltage
stabilizer as specified herein are the minimum requirements. However, if the Contractor’s
offered system has better overload capacities for the above devices, the same shall be highlighted
by the Bidder in his bid.
2.1.9. The UPS system offered by the contractor shall be suitable for operating continuously at the
rated capacity indicated in tender with in ambient temperature 0-40 deg.C and relative
humidity of 0 to 95%. Also the UPS system shall be suitable for operation as per full rating up
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Electrical Works – Specifications and List of Make
E- 108
to 1000 meters above sea level without derating. The Contractor shall furnish a certificate
towards compliance on ambient conditions permissible.
2.1.10. The UPS system to be supplied by the contractor shall have maximum humming noise level of 65
DB one meter away from the UPS cabinets. Shall not exceed 69 dBA measured 5 feet from surface
of the UPS.
2.1.11. Suppression of Radio Interference shall be provided to meet statutory requirements.
2.1.12. Detailed literature should be provided showing Quality Assurance Procedure adhered to.
2.1.13. The contractor shall submit detailed item by item compliance statement along with the tender.
2.2
Functional
Requirements
2.2.1.
Contractor shall furnish On-Line Uninterruptible Power Supply (UPS) system of continuous duty of
the ratings mentioned in Bill of Quantities. Each UPS shall give regulated filtered & uninterruptible
power supply as described in the specifications.
2.2.2.
Contractor shall note that the KVA ratings of the UPS systems shall be guaranteed at 40 deg.C
ambient temperature. In case contractor’s standard UPS KVA rating are based at a lower
temperature, the contractor must consider a derating factor of at least 1.5% per deg.C for arriving
at the specified UPS capacity at 40 deg.C ambient temperature.
2.2.3.
In case the calculated /specified UPS capacity is not the same as one of the standard KVA ratings
of the UPS manufacturer, the next higher standard KVA rating shall be selected. UPS of non
standard rating shall not be acceptable.
2.2.4.
UPS system supplied by the contractor shall be the latest state of the art technology system fully
digitalized using microprocessor controlled full wave rectification and IGBT inverter.
2.2.5.
Batteries shall be valve regulated lead acid specially ment for UPS application.
2.2.6.
Monitoring and control system shall also be state of the art technology LCD touch panel type
providing all relevant data described in this document.
2.2.7.
The monitoring and control system shall be capable of RS485 with MODBUS protocol input
software for connecting to customer’s computer system for data display and monitoring.
2.2.8.
All necessary components required for protecting UPS equipment and connected inputs and
outputs shall be furnished by the Contractor as an integral part of the UPS system.
2.2.9.
The control logic power supply shall have redundant power supply AC input and the system
battery as power sources.
2.2.10. The UPS systems shall include but not be limited to the following equipment:
a. UPS system including 100% capacity float-cum-boost charger with 100% sealed valve regulated
lead acid batteries with guaranteed battery life of 5 years.
b. Suitable factory built battery cabinet for housing the batteries, including terminal isolator / breaker
and power disconnect device. The enclosure shall conform to IP 20 as minimum.
c.
All cables, connectors, accessories like turning, cable trays, conduits etc. required for connection
between battery and the UPS unit.
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3.
Static Converter
3.1
General
E- 109
The static converter (rectifier) shall be a multi-functional converter providing functions of power
conversion, battery charging and shall have the additional functions of input power factor improvement
and current harmonics reduction. The converter equipment shall include all necessary control circuitry
and device to conform requirements like voltage regulation, current limiting, wave shaping, transient
recovery, automatic synchronization etc. as given below.
The converter shall be a solid state static PWM converter utilizing utilize Insulated Gate Bipolar
Transistors (IGBT) or Intelligent Power Module (IPM) transistors and shall include intelligent features like
the drive circuitry, over current protection, over temperature protection, control power failure protection
and short circuit protection.
The IGBT / IPM transistors shall enable high speed switching at 6 KHz thus reducing the heat dissipation
in the UPS and thereby providing high efficiency.
The PWM converter shall utilize the above and achieve unity power factor and reduce input current
harmonics as given earlier and thus improve the overall power factor of the converter achieving input KVA
savings.
During any step inverter load change (0-100%) the converter shall only supply 100% current to the
inverter. The battery shall not be cycled at any time during this step load changes.
3.2
Input Current Limit
The converter logic shall provide input current limiting by limiting the DC output current. Two (2) line-side
current transformers shall be employed as a means of sensing the current amplitude. The converter logic
shall also be capable of providing auxiliary current limited when the logic is signalled to do so via an
external dry contact closure (e.g. UPS fed from generator). The converter shall be capable of supplying
overload current in excess to the full load rating. It shall also have sufficient capacity to provide power to a
fully loaded inverter while simultaneously recharging the system battery to 95% of full capacity within 10
times the discharge time. The DC output current limit values shall be as follows:

Rectifier output current (maximum) 100%.

Rectifier output current (aux.) 25% - 100% variable.
Note: 100% current shall be under the battery recharging mode.
3.3
Battery Charge Current Limited
The converter logic shall provide current limiting function of battery charging to prevent the battery from
damage. The following battery current limit and protection shall be provided.

Battery charge current limit 10% of battery Ah rate.

Over-current protection at 120% of above item.
3.4
Voltage Regulation
The rectifier / charger output voltage including variation effects of input voltage does not deviate by more
than +/- 1% of the nominal output voltage, due to the following conditions:

From 0 to 100% loading.
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3.5
E- 110

Rectifier input variations of voltage and frequency within the limitations set in Section 3.10.

Environmental condition variations within the limitations set in Section 3.10.
Automatic Input Current Walk -In
The converter logic shall employ circuitry to allow a delayed and timed ramping of input current.
Subsequent to energizing the converter input, the ramping of current shall be delayed by a maximum of 3
seconds. Upon starting the walk-in process, the ramping of current is timed to assume the load gradually
within 1 through 60 seconds (every 1 second selectable).
3.6
Input Overload Protection
The A/C input fuses shall be provided at the converter input as a means of overload protection.
The AC maximum current shall be controlled by the Converter.
3.7
Equalizing Charge Timer
The UPS logic shall provide an electronic automatic equalize charge timer which shall be selectable 24
hours for Lead Acid type or 8 hour for alkaline type batteries. The timer circuit, once activated shall
provide a high rate equalizing charge voltage to the system battery for the selected time. The circuit shall
also be capable of manual activation via the LCD touch panel mounted on the front door. The level of
equalizing voltage shall be equal to that stated by the battery manufacturer. Upon completion of the timer
count, the converter output voltage shall automatically return to the specified float voltage.
3.8
Step Load Change
During any step inverter load change (0-100%), only the converter shall supply 100% current to the
inverter. The batteries SHALL NOT is cycled at any time during these step load changes.
3.9
Input Voltage
The converter shall be fed from the Normal Power Supply source.
The converter shall meet the following specifications in addition to other requirements stated herein:
Nominal Voltage
:
415V, 3 Phase, 3 Wire
Voltage Range.
:
+ 15% / - 30% AC
Normal Frequency
:
50 Hz + 8 %
Frequency Range
:
+ 8% (+ 4 Hz)
Input Power Factor
:
0.9 lagging or more at full load
(PF improvement)
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Input Harmonic Current THD
E- 111
:
3% typical at 100% load
6% maximum at 50% load
Duty
:
Continuous at 40 deg.C
Cooling
:
Forced cooling using fans with thermal
relays using a latched cut out for resetting as protection for cooling fans.
Each individual fan shall have its own
thermal relay.
Ambient operating temperature range
:
Operating - 0 to 40 deg.C maximum.
Storage & Transport -20C to 70C
Operating Relative Humidity
:
0-95% non-condensing.
Operating Altitude
:
Altitude Operating: to 3,000 ft. (1,000
meters) above Mean Sea Level.
Derated for higher altitude applications.
Storage/Transport: to 40,000 ft. (12 200
meters) above Mean Sea Level
Magnetized sub-cycle in rush current
:
Typically 8 times normal full load current
Converter Walk-in time
:
1 through 60 seconds (every 1 second
selectable, (0 to 100% rated load)
Input
:
Suitable terminals shall be provided for
termination of cables from the AC
distribution board.
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4.
Static Inverter
4.1
General
E- 112
The static inverter shall be of solid state type using proven Pulse Width Modulation (PWM) technique.
The inverter equipment shall include all necessary control circuitry and devices to conform requirements
like voltage regulation, current limiting, wave shaping, transient recovery, automatic synchronization etc.
as given below.
The inverter shall utilize Insulated Gate Bipolar Transistors (IGBT) or Intelligent Power Module (IPM)
Transistors which shall provide intelligent features like the drive circuitry, over-current protection, over
temperature protection, control power failure protection and short circuit protection.
The IGBT / IPM transistors shall enable high speed switching of 6 KHz thus reducing the heat dissipation
in the UPS and thereby providing high efficiency.
The UPS shall utilize both Voltage and Current feedback control circuits so that the inverter shall act not
only as a constant voltage source but also as a load required current source. This shall enable the
inverter to quickly adapt to the changing load current value and wave shape.
4.2
Voltage Regulation
The inverter output voltage shall not deviate by more than + 1% RMS due to the following steady state
conditions:
4.3

From 0 to 100% loading

Inverter DC input voltage varies from maximum to minimum.

Environmental conditions variations within the limitations set in the section 4.8.
Frequency Control
The inverter output frequency shall be controlled by an oscillator internal to the UPS module logic. It shall
be capable of synchronizing to an external reference (e.g. the bypass source or another UPS module) or
operating asynchronously. The oscillator shall maintain synchronization with the external reference within
the limitations set hereunder. The inverter shall operate on self run mode without synchronism if the
bypass frequency exceeds the set value. The oscillator, while running asynchronously, shall maintain the
frequency as 50 Hz + 0.01% (or + 0.005 Hz). Automatic adjustment of phase relationship between
inverter output and standby bypass source shall be gradual at a controlled slew rate which shall be
adjustable at the rate of 0.5, 1.0, 2.0, 3.0 Hz / second. (Default 2.0 Hz / second).
The inverter output frequency shall not vary during steady state or transient operation due to the following
conditions:
4.4
a.
From 0 to 100% loading.
b.
Inverter DC input varies from maximum to minimum.
c.
Environmental condition variations within the limitations set in section 4.8.
Output Voltage Harmonic Distortion
The inverter output shall limit the amount of harmonic content to the values stated in section 4.9. The use
of excessive or additional filtering shall not be required to limit the harmonic content thus maintaining a
high level of efficiency, reliability and original equipment footprint.
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Output Overload Capability
The inverter output shall be capable of providing an overload current while maintaining rated output
voltage to the values stated in section 4.8. An LED indicator shall be located on the control panel to
identify this condition. If the time limit associated with the overload condition expires or the overload is in
excess of the set current amplitude, the load shall be transferred to the bypass source without interruption.
4.6
Inverter Current Limit
The inverter output shall be limited to 150% of rated load current. The two sensing locations shall operate
separately and independently thus providing redundancy and, in the event of a failure, preventing
unnecessary damage to power transistor components / fuses. Load current above 150% shall cause an
immediate transfer of the load to the bypass source for fault clearing.
4.7
Inverter Overload Protection
The AC output from the inverter shall utilize fuses for overload protection. The inverter shall utilize a
contactor to isolate the inverter output from the critical bus.
The inverter fuses shall be the fast acting semiconductor type.
The inverter output isolation contactor shall be located in the UPS module and shall be controlled by the
internal UPS module system logic.
4.8 Inverter Specifications
The inverter shall meet the following specifications in addition to other requirements stated herein:
Voltage Input
:
Three Phase UPS :
Nominal 360 V DC (Range 290 V to 414
V DC to maximum DC bus voltage
during charging the batteries).
415 V + 1% AC 3 Phase, 4 Wire
Nominal Voltage Output
:
Inverter Capacity
:
Voltage Regulation
:
a.
:
< + 1%
:
< + 1%
:
< + 1%
For 0 to 100% loading
b.
Inverter DC input voltage vary
from maximum to minimum
c.
Environmental
given below
conditions
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Transient Voltage Regulation
:
a.
AT 100% step load change
:
< + 3%
b.
At loss or return of AC input
:
< + 1%
:
< + 3%
:
20 milli seconds
:
50 Hz
:
+ 0.01%
:
49 Hz to 51 Hz.
d.
Field adjustment range for
above
:
50 + 0.25 Hz to 50 + 1.5 Hz
Total voltage harmonic distortion
:
< 2% THD for 100% linear load
c.
At load transfer from bypass to
inverter
Time to recover from transient to
normal voltage
Wave form
a.
Normal frequency
b.
Frequency regulation for all
conditions of input supplies, loads and
temperature occurring simultaneously
or in any combination (automatically
controlled)
c.
Synchronization
limits
for
synchronism between the inverter and
standby AC source.
4.9
< 4% THD for 100% non-linear load
Duty
:
Continuous
Cooling
:
Forced cooling using fans.
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Ambient operating temperature range
:
0 to 40deg.C maximum continuous.
Operating relative humidity
:
0-95% non-condensing.
Operating altitude.
:
Sea level to 1000 meters.
Output
:
Suitable terminals are provided for
termination of cables for connecting
inverter output to AC distribution board.
Built-In Isolation Transformer
This shall provide neutral separation which shall mean that output neutral will be independent of incoming
neutral, hence critical load shall be isolated from the problems like incoming neutral open or, short or,
variations in neutral to earth voltage due to sudden loading in neighbouring installation.
4.11
Reverse Phase Sequence Protection
In the event of Phase sequence reversal at the input, UPS system shall continue to work on the main
power supply, or UPS systems shall go into battery mode, and shall not trip the UPS system.
5.
Bypass And Static T ransfer Sw itch
5.1. A bypass circuit shall be provided as an alternate source of power other than the inverter. A high
speed switch and wrap-around contactor shall be used for the critical load during automatic transfers
to the bypass circuit. The static switch and wrap-around contactor shall drive power from an upstream
bypass feed circuit breaker internal to the UPS module provided for overload protection. The wraparound contactor shall be electrically connected in parallel to the static switch and shall at the same
time as the static switch, energize and upon closure, maintain the bypass source. The static switch
shall only be utilized for the time needed to energize the wrap-around contactor thus increasing
reliability. The bypass circuit shall be capable of supplying the UPS rated load current and also
provide fault clearing current. The UPS system logic shall employ sensing which shall cause the static
switch to energize within 150 microseconds thus providing an uninterrupted transfer to the bypass
source when any of the following limitations shall exceed:

Inverter output under voltage or over voltage.

Overload beyond the capability of the inverter

DC circuit under voltage or over voltage

Final end voltage of system battery is reached.

Bypass source present and available

System failure (e.g. Logic fail, fuse blown, etc.)
5.2. Keeping the above requirements in view, the static switch shall have the following minimum rating.
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
Capacity continuous equal to 100% of continuous rating of the inverter.

Capacity overload equivalent to overload characteristics specified for UPS.
5.3
Nominal bypass input voltage
:
415 V / 240 V, 3 phase, 4 wire
Voltage Range
:
+ 10% of nominal
Nominal Frequency
:
50 Hz
Frequency range
:
+ 2%
Please refer to selectable range of Inverter
given in point 4.3 & 4.8
Output Fault Clearing :
Current
:
1000%
Duration
:
20 milli seconds
Ambient operating temperature
:
0 to +40 degree C continuous
Operating relative humidity
:
0-95% non-condensing
Operating altitude
:
Sea level to 1000 meters
Cooling
:
Natural Convection
Duty
:
Continuous
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Automatic Re-T ransfer
In the event that the critical load must be transferred to the bypass source due to an overload, the UPS
system logic monitors the overload condition and, upon the overload being cleared, performs an automatic
re-transfer back to the inverter output. The UPS system logic shall only allow a re-transfer to occur three
times within a ten minute period. Re-transfer shall be inhibited on the fourth transfer due to the likelihood
of a recurring problem at the UPS load distribution. The re-transfer a load to the inverter shall also be
inhibited due to the limitations set in section 5.3.
5.5
Manual Transfer
The UPS shall be capable of transferring the critical load to / from the bypass source via LCD touch panel.
When performing manual transfer to inverter or automatic re-transfers, the UPS system logic shall force
the inverter output voltage to match the bypass input voltage and then parallel the inverter and bypass
source providing a make-before-break transition allowing a controlled walk-in of load current to the
inverter.
5.6
Maintenance Bypass Switch (Mbs)
The UPS shall include as standard equipment, a zero energy maintenance bypass switch. Full UPS wraparound enables personnel to do work inside the UPS module or maintenance bypass switchboard without
danger for high voltage conditions.
6
UPS Battery System
a. The UPS system shall, as an integral part, provide battery system for backup time as specified in
the Schedule (Full Load) standby capacity.
b. The latest state of the art Valve Regulated Sealed Maintenance Free Lead Acid Batteries shall be
used with a 20 hours discharge rating.
c.
The battery system shall be sized to provide backup time as specified in the schedule of quantity
when the UPS is supplying 100% rated load at 0.8 load power factor.
d. An ageing factor of 15% shall be applied to the capacity arrived at, to allow for compensation
against capacity loss during float operation.
e. The battery system design shall be provided with necessary devices to prevent deep discharge
beyond recommended limits to prevent the batteries discharging beyond end cell voltage specified
by the battery maker. The connections from battery to battery shall be by using copper bus bar
strips and the entire battery system shall be used in IP20 steel cabinet enclosure and shall be
similar to the UPS enclosure.
f.
All batteries shall be clearly identified and identification numbers marked on the batteries and a
schematic diagram along with the complete calculations, including manufacturers supporting
curves, shall be submitted with the tender.
g. The UPS shall have a properly rated and sized circuit breaker to isolate it from the battery
7.
Operation
a. Under normal operation, the UPS load will be fed from the Inverter with the bypass switch inhibited.
The Converter, apart from providing DC power to the Inverter, also charges the battery under the float
charge mode. The battery charge system shall have float charge, equalising charge and recovery
charge modes, to replenish the batteries self-discharging part while the battery is fully charged,
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equalising the battery cell voltage to a constant value forcibly, and recharging the battery system to the
required values when the batteries have been used, respectively.
b. The Inverter shall constantly monitor the AC source frequency and shall be in synchronisation with the
AC input source till the frequency of the AC input source is within synchronising limit and if the
frequency of the standby source exceeds the synchronising limit the Inverter will work on its own
internal oscillator maintaining an output frequency of 50 Hz +/- 0.01% under all conditions of load.
When the Inverter operates on its internal oscillator, it shall continuously monitor the frequency of the
input source and when the input source frequency returns to within synchronisation limit, the Inverter
shall automatically synchronise itself with the input A/C source frequency and use it as a signal for
Inverter output frequency control.
c.
Battery Operation:
i.
When the A/C input voltage drops below specified limits or in case of a power failure the Inverter
continues to supply AC power of constant voltage and constant frequency utilising the battery
system as a power source until the input voltage returns to normal requirement. When the power
supply is resumed or the input voltage returns to limits, the Converter shall automatically start and
the load fed for normal operation status.
ii.
If the power failure continues beyond battery backup time or the battery voltage drops to the final
discharge voltage, the Inverter should automatically stop and at the same time transferring the
load to the bypass circuit. On resumption of power supply, the Converter shall automatically restart the operations and charge the batteries whereas the Inverter should inhibit automatic start
and should be started manually.
d. Bypass Operation:
When power is supplied from the Inverter in synchronisation with the bypass, it shall accomplish the
following:
i.
When the UPS output current reaches overload status it shall automatically transfer the load
to bypass circuit with no interruption and when the overload status is cleared it automatically
re-transfers the load to Inverter.
ii.
When the battery final discharge condition is reached, the load shall automatically be
transferred to the bypass circuit without interruption.
iii.
In case of failure of the UPS, the load shall be automatically transferred to the bypass circuit
with no interruption and when the failure is cleared, re-transfer the load to the Inverter shall be
done manually.
iv.
There should be provision made in the system to prevent, when necessary, asynchronous
transfer.
v.
When the UPS goes on bypass mode in any of the conditions described above and if at that
time there is no bypass power supply available due to power failure, the UPS shall remain in
standby mode and as soon as the bypass power supply is available will transfer the load to
bypass.
vi.
A maintenance bypass transfer switch shall be provided with lock and key arrangement and
should be manually done by authorised personnel only.
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Battery Monitoring System
a. The Battery Monitoring System shall provide for the automatic acquisition, trending, alarming and
storage of information from every cell or jar in a battery bank. It will have the interactive ability to first
identify and then provide an isolated equalizing charge current to any individual cell or jar that deviates
below a user-specified set point, from the cell average, within the same string or bank.
b. The Battery Monitoring System shall test the relative charge state and health of each individual cell or
jar by injecting a DC current, recording the magnitude of this current & comparing it to previous
benchmark values. Systems that require battery discharge for testing are not acceptable. The
system shall provide estimated backup time remaining during an actual discharge.
c.
The Battery Monitoring System shall monitor and maintain historical files for:

Individual cell or jar voltage

Total bank voltage

Discharge current

Ambient and pilot cell temperature

Relative current response value
d. Display shall be via local LCD display, with capability for viewing at a remote terminal. All files
shall be written to a fixed solid state disk within the enclosure. All functions shall be accessible via
modem using common communications software.
e. The system shall operate a “form C” relay contact when any parameter is in alarm. Alarm data
shall be written to a file in ASCII format for future retrieval.
f.
The system shall be capable of remote communications for remote access to all functions via
modem or ANSI terminal.
g. The Battery Monitoring System shall be capable of monitoring a minimum 264 jars per string, 9
parallel strings per system, and 6 cells per jar.
h. Resolution shall be 12 bit accuracy, with up to 10 per second channel test rate.
8.
i.
Cell voltage measurements must be made to within plus or minus 5 milli volts over the entire
operating and temperature range.
j.
Documentation. Manuals and installation documentation for the equipment shall be provided
which lists block diagrams, schematics parts list and theory of operating for each unique
component of the system. Installation drawings and documentation shall be site specific for each
string at this facility. Marked up building drawings shall be provided to show any changes to
building wiring including power wiring and communications cables.
k.
The system shall be factory tested fully and completely before shipment.
Cabinet And Enclosures
8.1
The entire UPS system, including all components like inverter, static switch, maintenance bypass,
shall be housed in free-standing steel type factory-finished enclosures complying with the protection
standards of IP20. The enclosure shall be open able using a special tool for internal access. The colour
shall be light grey.
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Ventilation
Forced air-cooling shall be provided to allow components to operate within their rated temperature
specified. The cooling fans shall have thermal relays protection using a latched cut fire re-setting, as a
protection for the cooling fans.
Similarly, the backup battery system shall also be housed as described earlier in an IP20 cabinet.
9.
Control And M onitoring
a. The UPS shall utilise state of the art full DDC control software driven Control and Monitoring System.
b. It shall be provided with LED displays.
Metering should display the following parameters on the control panel
1. Input AC voltage line-to-line and line-to-neutral for each phase
2. Input AC current for each phase
3. Input frequency
4. Battery voltage
5. Battery charge/discharge current
6. Output AC voltage line-to-line and line-to-neutral for each phase
7. Output AC current for each phase
8. Output frequency
9. Percent of rated load being supplied by the UPS
10. Battery time left during battery operation.
11. Bypass power available.
Following alarm messages to be displayed at the control panel:
a. Input power out of tolerance
b. Input phase rotation incorrect
c.
Incorrect input frequency
d. Charger in reduced current mode
e. Battery Charger Problem
f.
Battery failed test
g. Low battery warning (adjustable 1 to 99 minutes)
h. Low battery shutdown
i.
DC bus overvoltage
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j.
Bypass frequency out of range
k.
Load transferred to bypass
l.
Excessive retransfers attempted
E- 121
m. Static switch failure
n. UPS output not synchronized to input power
o. Input power single phased
p. Input voltage sensor failed
q. Inverter leg over current in X-phase
r.
Output under voltage
s.
Output overvoltage
t.
Output over current
u. System output overloaded
v.
Load transferred to bypass due to overload
w. Overload shutdown
x.
Control Error
y.
Critical power supply failure
z.
Load transferred due to internal protection
aa. External shutdown (remote EPO activated)
bb. Fan failure
cc. Over temperature shutdown impending
dd. Over temperature shutdown.
ee. Lamp test.
c.
The UPS logic should provide one set of normally open dry contact / relay output to allow interfacing of
UPS operating status to an external system and should be capable of providing, as a minimum, 10
numbers status and, should the UPS manufacturer’s standard product does not provide such
software, the bidder must add additional equipment and cost for the same.
d. The UPS shall also have an RS485 port with MODBUS interface card if required for interfacing to BAS
system or client's centralized computer network.
e. LCD touch panel (Optional)
i.
The UPS shall be provided with an operator friendly large scale LCD touch panel.
ii.
The LCD touch panel shall also include graphic measurement display, operational procedures
of each activity, fault status display and also have capability to record at least 50 faults.
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iii.
The touch screen panel shall clearly define specified areas for operational function, execution
and message display.
iv.
It should be possible to operate the entire UPS system and its components and obtain all
measurements and data through the touch screen operation. The measurement software
should provide capability to measure phase voltage, current in each phase, frequency, power
factor, available battery time etc.
v.
Under all operating conditions, the system software should have capability for displaying fault
alarm automatically. The tenderer should describe in detail the faults that would be displayed
under this mode.
UPS Testing
a. The Contractor shall perform the following tests, as a minimum, at site prior to handing over, to
confirm the functional and the performance specification of the UPS as specified. All required test
equipment like Digital Oscilloscope, Voltage Regulator, and Measurement Meters etc. shall be the
responsibility of the Contractor without any additional cost.
b. The Contractor shall demonstrate as a minimum the following features on site by providing all required
test equipment, such as power factor improvement, input current THD, output voltage THD, output
frequency and all other performance monitoring requirements detailed before as required by the
Owner.
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Part B: Testing
1.1
General
At the completion of the work, the entire installation shall be subject to the following tests in the presence
of the Owner’s site representative.

Wiring continuity test.

Insulation resistance test.

Earth continuity test.

Earth resistivity test.

Test as per Appendix `E' of IS:732 -1989
Besides the above, any other test specified by the local authority shall also be carried out. All tested
and calibrated instruments for testing, labour, materials and incidentals necessary to conduct the above
tests shall be provided by the Contractor at his own cost.
1.2
Testing Of Wiring
All wiring systems shall be tested for continuity of circuits,
before installation is energized.
1.3
and earthing after wiring is completed and
Insulation Resistance Test
The insulation resistance shall be measured between earth and the whole system of conductors, or any
section thereof, with all switches closed and except in concentric wiring all lamps in position of both
poles of the installation otherwise electrically connected together, a direct current pressure of not less
than twice the working pressure provided that it does not exceed 660 volts for medium voltage circuits.
Where the supply is derived from AC three phase system, the neutral pole of which is connected to
earth, either direct or through added resistance, pressure shall be deemed to be that which is
maintained between the phase conductor and the neutral. The insulation resistance measured as above
shall not be less than 50 divided by the number of points provided on the circuit; the whole installation
shall have an insulation resistance greater than one mega ohms. The insulation resistance between the
frame work of housing of power appliances and all live parts of each appliance shall not be less than
that specified in the relevant standard specification or where there is no such specification, shall not be
less than one a mega ohms. All equipments, cables shall be inspected at works by the Architect as per
relevant IS and testing commissioning of installation as per Appendix `E' of IS: 732-1989 shall be done
and all record to be maintained.
1.4
Testing Of Earth Continuity Path
The earth continuity conductor metallic envelopes of cables shall be tested for electric continuity
and the electrical resistance of the same, along with the earthing lead but excluding any added
resistance or earth leakage circuit breaker, measured from the connection with the earth electrode to
any point in the earth continuity conductor in the completed installation, shall not exceed one ohm.
1.5
Testing Of Polarity Of Non-Linked Single Pole Switch
In a two wire installation a test shall be made to verify that all non-lined single pole switches have been
connected to the same conductor throughout, and such conductor shall be labelled or marked for
connection to an outer or phase conductor or to the non-earthed conductor of the supply. In the three or
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four wire installation, a test shall be made to verify that every non-linked single pole switch is fitted to one
of the outer or phase conductor of the supply. The entire electrical installation shall be subject to the final
acceptance of the Owner’s site representative as well as the local authorities.
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Part C: Erection, Testing
Electrical Installations
1.1
E- 125
&
Commissioning
Of
Scope
The intent of this specification is to define the requirements for the installation, testing and commissioning
of the electrical system like transformer, M.V panels, Cables, earthing network, Internal and External
lighting, Light fixtures etc. Requirement of this project shall be as specified in bill of quantities / approved
drawings / general specifications or as per the battery limits fixed by the owner / consultant.
1.2
Standards
The work shall be carried out in the best workman like manner in conformity with this specification, the
relevant specification / codes of practice of the Indian Standards Institution, approved drawings and the
instructions issued by the authorised representative, from time to time. Some of the relevant Indian
Standards are listed elsewhere in this tender document.
In addition to the standards mentioned in 2.1, all works shall also conform to the requirement of the
following:
1.3

Indian Electricity Act and Rules framed there under.

Fire Insurance Regulations.

Regulations laid down by the Chief Electrical Inspector of the State / State Electricity Board /
Union Territory.

Regulations laid down by the Factory Inspector of the State / Union Territory.

Any other regulations laid down by the local authorities.

Installation & operation manuals of original manufacturers of equipment.
Equipment, M aterial And Accessories Specifications
This defines specifications and requirements mainly for the equipment and accessories, which are
generally supplied by the erection agency.
All materials, accessories, consumable to be supplied by the contractor shall be selected from the
list of specified make of material in consultation with the Client/Architect/Consultant without any
extra cost and shall conform to the specification given here under. The equipment shall be
manufactured in accordance with current Indian Standard specifications wherever they exist or
with the BS or NEC specifications, if no such IS standards are available. In the absence of any
specification & if any item not mentioned in the make of the material & anywhere else, the
materials shall be as approved by the owner / consultant or his authorised representative in
writing manner.
All similar materials and removable parts shall be uniform and interchangeable with one another.
Makes of bought out items selected by the contractor must be furnished by him as per the pro
forma given in elsewhere in this tender document. Tenderer should have to specify the list of
makes considered in the tender while quoting the rates in the tender, in covering letter of separate
letter enclosure. However, the final decision for accepting make specified by tenderer would be of
client/Architect/Consultants.
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Within a week of work order, the contractor shall submit the sample of each item / component of
above mentioned approved make for the approval of the Client/Architect/Consultant.
Bidder to submit authorization letter for supply of light fixtures and lamps only from regional sales
manager/director-sales of lighting company with duly signed and stamped with mentioning the
name of project, total quantity, type of light fitting etc. The letter should be submitted with valid
proof and original documents to consultant. These authorizations are to be obtained prior to
supply of material and should be approved by electrical consultant/architect.
1.3.1
Control Cables
Control cables for use on 415 V system shall be of 1100 volts grade, copper conductor, PVC insulated,
PVC sheathed, armoured and overall PVC sheathed, strictly as per IS: 1554 (Part-I) 1976. Unarmoured
cables to be used only if specifically mentioned in schedule of quantities.
The size of these cables shall be as specified in bill of quantities or as per approved drawing. The
minimum conductor size shall be 2.5 sq.mm. (Cu.).
1.3.2
Cable Trays
These shall be channel type, fabricated from structural steel, hot dip galvanised, complete with all
accessories such as bends, tees and reducers. Only aluminium flat clamps with G.I. / Chrome plated
bolts, nuts/screws to be used for clamping cables. Sizes of these trays shall be as specified in bill of
quantities or approved by client.
1.3.3
Cable Glands
Cable glands shall be heavy duty compression type of brass, chrome plated. These shall have a screwed
nipple with conduit electrical thread and check nut. These shall be suitable for armoured/Unarmoured
cables, which are being used.
1.3.4
Cable Connectors
Cable connectors, lugs/sockets, shall be of copper/aluminium alloy, suitably tinned, solderless, crimping
type. These shall be suitable for the cable being connected and type of function (such as power, control or
connection to instruments etc.).
1.3.5
Cable Indicators
These shall be self sticking type of 2 mm. thick lead strap for overall cable. PVC identification number,
ferrules shall be used for each wire.
1.3.6
G.I. Pipe For Cables
For laying of cables under floor, G.I. class “A” pipes shall be used. M.S. conduits are not acceptable for
this purpose. All accessories of pipes shall be threaded type. Size of pipe shall depend upon the overall
outer diameter of cable to be drawn through pipe. NO G.I. pipe less than 40 MM. I.D. shall be used for this
purpose. To determine the size of pipe, assume that 40% area of pipe shall be free after drawing of cable.
1.3.7
Push Button Stations
These shall be floor / wall mounted type as specified in bill of quantities. These shall be fabricated from
1.6 mm. thick stainless steel sheets (SS 304). In case of floor mounted station, these shall be supported
on 51 mm. “A” class G.I. pipe. Front cover shall be removable type with suitable rubber gaskets to make
them dust vermin and moisture proof.
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Each feeder shall be provided with “ON” (green) push button, “OFF” (red) push button, name plate (white
bakelite), indication lamp etc. Green & red push buttons shall have contact elements having 1NO + 1NC.
“OFF” push button shall be provided with lockable (key operated) arrangements to prevent accidental
starting. No. of feeders shall be specified in bill of quantities. The indication lamp can be combined with
“ON” push button.
1.4
Erection
The contractor shall make his own arrangement for safe transportation of all the items to the erection site
and also carry out complete loading / unloading during transportation. Equipment shall not be removed
from packing cases unless the floor has been made ready for installing them. The cases shall be opened
in presence of the client / consultant or his authorized representative. The empty packing cases shall be
returned to the stores and any document if found with the equipment shall be handed over to the client's
representative. Any damage or shortage noticed shall be reported to the client / consultant in writing
immediately after opening of packing cases.
1.5
General Notes For Street Lighting
For supplying and laying of cables, technical specification (wiring) shall be applicable reference shall be
made under heading Cable Work elsewhere in the tender.
For street light poles along roads, nearest finished road level shall be taken as ground level and for poles
along compound wall / away from roads, existing ground / finished ground shall be taken as ground level.
Distance of 1 mtr. shall be maintained between centre of pole and centre of kerb of road. For compound
wall poles, distance between compound wall and poles shall be 3 mtrs.
A loop of 1.5 mtr. of cable shall be provided near each street light pole for all incoming and outgoing cable.
1.6
Completion
Tests
After supply and installation of complete project or a particular building / area, following tests shall be
carried out by the contractor before switching on the power to installation and the results shall be recorded
and submitted to the Site-Engineer. If results are not satisfactory / as per standards set herewith, the
contractor shall identify the defects / short coming and shall rectify the same. Nothing extra shall be paid
for carrying out these tests and contractor has to arrange all necessary instruments.
1.6.1
Insulation Resistance To Earth
This is to be measured with all fuse links in place, all switches ON, all lamps and appliances in position by
applying a voltage not less than twice the working voltage (subject to a limit of 500 V). Insulation
resistance of the whole or any part of the installation to earth must not be less than 50 mega-ohms divided
by the number of outlets (points and switch positions) except that it need not exceed one mega-ohm for
the whole installation.
1.6.2
Insulation Resistance Between Conductors:
Tests to be made between all the conductors connected to one pole or phase conductor of the supply and
all the conductors connected to the middle wire or neutral or the other pole or phase conductors of the
supply. For this test, all lamps shall be removed and all switches put ON. The result of the test must be 50
mega-ohms divided by the number of outlets (points and switch positions) but need not exceed 1 megaohm for the whole installation.
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Sign of Bidder
Electrical Works – Specifications and List of Make
1.6.3
E- 128
Polarity Of Single Pole Switches:
Tests shall be made to verify that all non-linked single pole switches are on phase conductor (live) and not
on neutral or earth conductor. This can be done by connecting test lamps between two terminals of switch
and earth. If the lamp lights up when switch is ON and either terminal is touched, the switch is correctly
installed.
1.6.4
Resistance Of Metal Conduits / Sheets (Earth Continuity Test):
In case of cables encased in metal whether conduit of metallic sheathing, the total resistance of the
conduit or sheathing from the earthing point any other position in the completed installation shall not
exceed 2 ohms. This can be carried out by following circuit:
One end of the load is connected to the ECC and its connection with the electrode and the other to the
farthest point of the ECC. First, current through the circuit is measured with the resistance of 2 ohms short
circuited by the link. Next, current is measured through the two ohms resistance by disconnecting the two
leads from the ECC and joining them together. If current is more in the first case, the resistance of ECC is
less than 2 ohms.
1.7
Handing Over / Taking Over:
After completion of works and tests specified above, the various installations of the project can be taken
over by the employer as and when these are ready in all respects. The defect liability period of 24 months
shall start from the date, when all the installations of the project have been executed, tested as described
above, successfully commissioned and handed over.
The Contractor has to produce the Final As – Built drawings duly signed by Engineer In charge,
Consultant, Architect & Client before finalizing the Final bill. The cost for as built drawing to be borne by
the contractor.
Final bill will not be considered if as built drawings not provided by contractor as following.
Process of as built Drawings:
1 set of Hard copy & editable soft copy should be submitted to Engineer In charge.
After incorporating the comments received from Engineer in charge Final As built documents as
mentioned to be submitted.
Final As built documents
As built drawings with RTP (Reproducible Tracing Paper). : 1 Set
As built drawings with Coloured Print out: 4 Sets
Editable Soft Copy of the same: 6 Copies
Instruction and maintenance manual - Six copies.
Test certificates - Six copies.
Consultant : JIT Engineering Services Consultant
Sign of Bidder
Electrical Works – Specifications and List of Make
Part - D:
Materials
List
Of
E- 129
Appr oved
Make
For
Electrical
S. No.
Item
Approved Make
1)
Rigid PVC Conduit
( FRLS only )
Accessories for conduit
Precision Plastic Industries, Nihir, Finolex
Flexible Copper Wires
(FRLS)
Switches
R.R. Kable, Finolex Lapp Cable, Avocab, Poly Cab.
2)
3)
4)
5)
Use different colour switch
Accessories for Raw & UPS Power
Main Switch fuse up to
60 Amps - AC 23 duty
Same make as of pipe.
Legrand (Myrius), Gewiss, MK (Blenze), Schneider
(Opale)
&
Schneider MG, L&T, GE
6)
Above 60 Amps-A.C. 23 Duty
Schneider MG, L&T, GE
7)
HRC Fuses
Schneider MG, L&T, GE
8)
MCBs/ELCBs/ELMCBs / Contactor
Time Switch ( Timer )
Distribution boards IK 43
For TPN & SPN DB
Legrand (MDS-lexic), Schneider MG ( Multi 9)
For VTPN DB
Legrand (Lexic), Schneider MG
Factory fabricated. double door type, PPI only
with additional JB on both side
10)
Rewireable Porcelain Fuse
CPL, KEW.
11)
Telephone wires
Finolex, Delton, RR cable, Avocab, National, Poly Cab.
12)
Telephone cables
Jelly Filled
PVC tape
Finolex, Delton, GTCL, National, Avocb, Poly Cab.
14)
Main Cables down
Stream
XLPE armoured cable for 1.1 KV as per ISI 1554.
Finolex, Torrent, Avocab, Primecab, RR Kable, Poly Cab.
15)
Glands
Compression type, Heavy duty and deep threading
with rubber ring and double washers. HMI, Raychem
9)
13)
Hensel, Spelsberg, Legrand Flexi DB.
Steel grip, Anchor
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Electrical Works – Specifications and List of Make
E- 130
Sr. No
Item
Approved Make
16)
Cable Lugs
Dowells, 3-D, Raychem.
17)
Metal Clad Plugs
Indoor - MDS, Crompton, BCH.
Outdoor -Clipsal, Gewiss, RR PCE, MDS.
18)
Connectors
Technoplast, Porcelain.
19)
Anchor, CPL
20)
Button holder, Angle
holder, ceiling rose
M.S. Conduit ISI
21)
Anti vibration Ball
Aluminum (sample to be approved).
22)
M.S. Boxes
Fabricated out of 16 gauge continuously welded
(sample to be approved) with Powder coating.
23)
Telephone tag block
Krone.
24)
MCCB
With all kind of communication
accessories
Meter ( Analog Only )
Digital Meter
Steel Wire Rain Forced
PVC Flexible Hose
Schneider MG ( NSX ) , Legrand(MDS)
27)
Cable Tray
i) Ladder/Perforated - Hot deep GI - Legrand, OBO
Better man, Peaton
ii) Wired Cable Tray : Legrand, Obo Betterman
28)
TV Cable/CCTV Cable
Finolex, RR Cable, Avocab.
29)
Panel Fabricators
Peaton Electric, Schneider, Siemens.
30)
Changeover Switch
On load type – HPL, C &S, Havell's (Euroload)
31)
Fire Extinguisher
Should be of ISI approved - Safex,Firex,Safeline
32)
D G Set /Alternator with Engine Control
Panel
Cummins, Caterpillar, Kirloskar, Jackson.
25)
26)
BEC, Steel Craft, AKG
Rushabh, L &T,Conzerv, Schneider
Schneider, Conserve, Secure Meter, L&T
Flaxi - Hose
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Sign of Bidder
Electrical Works – Specifications and List of Make
E- 131
Sr. No
Item
Approved Make
33)
R G 6 / 11 wire
Finolex, RR Kable, Avocab
34)
Cat 6 Wire
Finolex, RR Kable, Delton, Legrand
35)
ACB
With all kind of communication
accessories
UPVC Cable truncking & Under floor
trunking
Schneider ( Masterpact - 6.0 Micrologic), L & T (U
Power - UNRS 2.5GL), Siemens (WL - ETU 75 B), Legrand.
Must be EDO type & Microprocessor base only
Legrand, OBO Betterman.
37)
Call Bell
Anchor
38)
DIGITAL meters, Load Manager
Schneider, Conserve, Secure Meter, L&T
39)
Light Fixture
38)
Lamps
( As specified in the BOQ & Sample to be approved ) No
other make will be allowed other than specified in
Tender
Philips, Osram
39)
Ballast
Philips, Vossloh, Tridonics
40)
LPI, Ashlok, OBO Betterman.
41)
Chemical Type Earthing
( Copper Road only )
Energy Meter
42)
CT
AE, Ashok, Kappa, C&S
43)
DWC Pipe ( Anti Rodent Type Only )
Tirupati Plasto, REX, Duraline
44)
45)
46)
Fan
PVC Junction Box
Contactor
Crompton, Usha, Havells, GE, Bajaj
Gewiss, Hensel, Spelsberg, OBO Betterman.
Telemechanique, L & T, Schneider, Legrand
47)
Panel Accessories
Telemechanique, L &T, Siemens
48)
Emergency Light
Sigma
49)
Water tight Plugs enclauser
Gewiss, Hensel, Spelsberg
50)
Compacy Sub Station
Schneider, Peaton, Crompton, Areva, Kirlosker, Siemens.
36)
L &t, Conserve, Schneider, Secure Meter
Consultant : JIT Engineering Services Consultant
Sign of Bidder
Electrical Works – Specifications and List of Make
E- 132
Sr. No
Item
Approved Make
51)
Oil/ Dry type Transformer
52)
54)
55)
H T VCB Breaker
Capacitor ( MPPH Gas Filled Type )
Thyristors, Reactors
Relay
Schneider, Voltamp, Kirloskar, Areva, Crompton, BHEL,
Danish.
Schneider, ABB, Areva, BHEL, Crompton, Siemens
L & T, Epcos, Neptune, Electronicon, Ducati, Areva.
56)
IPFC Relay
Conserve, Secure, Schneider, BCH, Ducati, Electronicon.
57)
PLC
Schneider, Siemens, ABB, Allen Bradley
58)
Surge Protector
Emerson, Obbo Betterman
59)
H. T. Cable
33 / 33 KV
Torrent, Finolex, Nicco, Polycab, Avocab, Gloster,
Universal, CCI, Ravin Cab
60)
RJ 11 telephone outlet
Same make as switch
61)
RJ 45 Data outlet
Legrand, D Link, Schneider
62)
Addressable Fire Detection System
Xtralis, OSID, GE, Notifier
63)
64)
Access Control System
CCTV
Schneider (Continuum) / Honeywell / Seimens
Pelco, Bosch, Honey well
65)
Monitors (Analogue & SVGA)
Samsung, HP, Sony
66)
P.A. System
As specified in tender
67)
Amplifier
Bosch, Philips, Bose, Aetis, Yamaha
68)
UPS
Should be on line UPS only
HT Cable Jointing KIT
Exhaust Fan ( Should be with louvers )
Timers
Octagonal / Conical Poles
Emerson, APC, DB Power
69)
70)
71)
72)
Alsthom, Siemens, Schneider, ABB, L&T.
Raychem
Usha, Havells, Crompton
Theben, Legrand, Schneider
Bajaj, BP, Schreder, Wallmont, PIGL
Refer Clause no. 1.3 of Part C- Erection Testing, & Commisioning of Electrical Installation before Quoting.
Consultant : JIT Engineering Services Consultant
Sign of Bidder