Specification of LT

Core Green Sugars and Fuels Pvt. Ltd.
TECHNICAL SPECIFICATIONS OF SUGAR UNIT
LT TECHNICAL SPECIFICATIONS
1. LT PCC AND MCC BOARDS Power Distribution Panels and Sub-Power Distribution Panels shall be suitable for operation on 3 Phase/single phase, 415 volts, 50 cycles, neutral grounded at transformer. All Power Distribution panels shall be by a CPRI approved, reputed manufacturer. Distribution panels shall comply with the latest Relevant Indian Standards and Electricity Rules and Regulations. Specific requirement of each panel has been covered under single line diagram. 1.1 CONSTRUCTION FEATURES
All Main Power Distribution panels shall be designed for Totally Type Tested as per IEC 60439-1 for indoor/outdoor installation, dead front, floor mounting/wall mounting type and shall be form 3-b construction. The Power Distribution Panels shall be undergone internal ARC Test for different type of feeders, especially smaller rating feeders. The Power Distribution panels shall be totally enclosed modular construction 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. Power Distribution panel shall be suitable for the climatic conditions as specified in Special Conditions. Steel sheets used in the construction of Power Distribution panels shall be 2.5 mm for frame, 1.6 mm for doors and 2 mm for other sheet metal works 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 Power Distribution panels. A base channel of 75 mm x 40 mm x 5 mm thick shall be provided at the bottom for floor mounted panels. Minimum clearance of 275mm shall be provided between the floor of Power Distribution panels and the lowest unit. Power 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
S.V. Engineers & Consultants
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holes of appropriate size and number shall be provided in the Power Distribution panels in conformity with the location of cable/conduit connections. Removable sheet steel plates shall be provided at the top 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 minimum clearance between phase and earth shall be 20 mm and phase to phase shall be 25 mm. 1.2. BUS BAR CONNECTIONS
Bus bar and interconnections shall be of high conductivity electrolytic aluminum / copper alloy complying with requirement of grade E 91 E of IS: 50821981 and of rectangular cross section suitable for carrying the rated full load current and short circuit current without overheating of phase and neutral bus bars and shall be extendable on either side. Bus bars and interconnections shall be insulated with heat shrinkable sleeve of 1.1 KV grade and shall be colour coded. Bus bars shall be supported on glass fiber reinforced thermosetting plastic insulated supports at regular intervals to withstand the force arising from in case of short circuit in the system. All bus bars shall be provided in a separate chamber and all connections shall be done by bolting. Additional cross sectional area to be added to the bus bar to compensate for the holes. All connections between bus bars and breakers shall be through extended solid copper strips of proper size to carry full rated current and to receive the aluminium bus bar through bimetallic strip / washer. 1.2.1 TEMPERATURE - RISE LIMIT Unless otherwise specified, in the case of external surface of enclosures of bus bar system which shall be accessible but do not need to be touched during normal operation, an increase in the temperature rise limits of 25 C above ambient temperature shall be permissible for metal surface and of 15 C above ambient temperature for insulating surfaces as per IS 8623(Part-2) 1993. Continuous earth bus sized for prospective fault current shall be provided with arrangement for connecting to station earth at two points. Hinged doors/ frames shall be connected to earth through adequately sized flexible braids. 1.2.2 STANDARDS
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The design, manufacture and performance of equipment covered by this specification shall conform to the relevant Standards. The design, manufacture and testing of the various equipment covered by this specification shall comply with the latest issue of the following standards : IEC-144 : Degree of protection of enclosure for low voltage switchgears and control gear IEC-185 : Current Transformers IEC-186 : Potential Transformers IEC-255 : Electrical Relays IEC-269 : LV Fuses IEC-439 : LV switchgears and control gear assembly IEC-947 : LV switchgears and control gear IS:722 : AC Electricity meters IS:1248 : Specification for direct acting electrical indicating instruments IS:2147 : Degrees of protection provided by enclosures for low voltage switch gear and control gear IS:2705 : Specification for current transformer IS:3231 : Electrical relays for power system protection IS:5082 : Material data for aluminium busbars IS:5578 : Guide for making of insulated conductors IS:8623 : General requirement for factory built assembly upto 1000 V IS:8828 : Electrical accessories - circuit breakers for over current protection for house hold and similar installations IS:9224 : Low voltage fuses IS:10118 : Code of practice for selection, installation and maintenance of switchgear and control gear not exceeding 1000 V IS:11353 : Guide for uniform system of marking and identification of conductors and apparatus terminals IS:12021 : Control transformer for switchgear and control gear for voltages not exceeding 1000V AC IS:13947 : LV Switchgears and Control gear 1.3 COMPARTMENTS 1.3.1 CABLE COMPARTMENTS Cable compartment of adequate size shall be provided in the Power Distribution panels for easy clamping of all incoming and outgoing cables entering from the top/bottom. Adequate supports shall be provided in cable compartment to support cables.
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1.3.2 Circuit Breaker Compartments Spring actuated and gravity operated safety shutters shall be provided for isolating the busbars and other live parts when the breaker is completely withdrawn. The design of compartment shall be such as to prevent movement of vermin from a particular circuit breaker compartment to any other portion of the panel when the breaker is withdrawn and the compartment door is closed. The circuit breaker compartment enclosure shall be IP31 with the circuit breaker in position or withdrawn from the compartment. The circuit breaker compartment shall be fully draw out, ie., bus side and outgoing power and control connections shall be through drawout contacts (it shall be possible to drawout the withdrawable trolley without having to unbolt or unscrew any power and control connections). Suitable guides shall be provided to facilitate easy withdrawal of the trolley. All identical feeder compartments shall be interchangeable without having to carryout modifications. The drawout breaker shall be earthed by means of a scraping earth system of silver plated copper such that the earth connection is broken after the breaker main contacts disengage during withdrawal and the earth connection is made before the main contacts engage during insertion. The earth connection shall remain connected in "test" and "isolated" positions also. The draw-out compartments shall have the following interlocks: Compartment doors shall be interlocked against opening when breaker is in closed or ON condition. However, it shall be possible to bypass this interlock for inspection purposes. It shall not be possible to push "in" a drawn out circuit breaker in closed condition or withdraw a circuit breaker in closed condition. It shall be possible to operate a circuit breaker only in the defined "Full In" or "Service" and "test" position inside the panel. It shall not be possible to operate the breaker in intermediate position while inserting or withdrawing a circuit breaker or while in "Full Out" position inside the panel. It shall be possible to open / close the circuit breaker in test position bypassing the closing interlocks. All the circuit breakers shall be provided with an TNC switch for local electrical operation and a Local / Remote selector switch for selecting the mode of operation. The breaker shall be of draw-out type and shall be suitable for motor / manual spring charged closing. Mechanical Castell key type interlocks shall be provided between feeders, wherever specified. Electrical interlocks shall also be deviced, wherever specified. Transducers in the ACB module shall be mounted in control compartment, not in power compartment.
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ON/OFF/TRIP feed back signals and ON / OFF control signals shall be arranged to connect with DCS system. 1.3.3 Feeder Modules The module shall comprise of the following : - Feeder MCCB with 3 poles and neutral link - Set of cluster type LED lamps for ON / OFF - Meters, as specified - Current transformers - Terminal blocks, interconnection bars / wires, ferrules etc., as per requirement Doors shall be mounted on adjustable and removable pin type concealed hinges and so arranged that unit doors may be removed without disturbing the unit doors above or below. The MCCB operating handles shall be capable of being padlocked in the `OFF' position. For the purpose of standardisation, similar components in the switch board shall be of the same make / brand, identical and interchangeable. Only the operating handle of the MCCB shall be accessible for operation with the related door closed. The doors shall be interlocked with the associated load break switch so that the door can be opened only when the switch is in the de-energised (off) position and the doors shall not be capable of being closed with the switch in the energised (on) position. Provision shall also be available to defeat the interlock. Each compartment shall have suitable nameplate, which shall be fixed on the cover in distinct colour to designate the feeder number, feeder designation, current rating and HP/kW of the related equipment. ON / OFF indication signals to be arranged to connect with DCS system. 1.3.4 Motor Feeder Starter Modules The starter modules shall comprise of the following : - Feeder switch with 3 pole MCCB, as applicable - Air-break contactor(s) - Bi-metallic over load relay below 100 HP and microprocessor based Motor protection relays for 100HP and above ratings.. - 4A MCB for the control circuits. - Set of cluster type LED lamps for ON / OFF / TRIP. - Timer set table upto 60 sec. for star-delta starters. - Analog type Ammeter shall be provided on door for the ratings above 10HP and as specified. - Current transformers for metering and protection.
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ON / OFF /TRIP indications signals and ON / OFF control signals to be arranged to connect with DCS system. - All starters rated above 75 kW shall be provided with an auxiliary contactor to transfer the ON/OFF signal from DCS. - The SLD shown are indicative and intended for general guidance of the panel supplier, for interfacing with DCS. The supplier shall develop detailed schemes for each motor feeder. - Supplier shall select the rating / burden of control transformer, semi-conductor fueses, PTs, CTs, Range of transducers, ammeter and speed indicators suitably. - Space heater supply shall be made available for all feeders rating 30kW and above. - Terminal blocks, interconnection bars / wires, ferrules etc., as per requirement. Only the operating handle of the MCCB/MPCB, Local/remote, DCS selector switches and Ammeter selector switches shall be accessible for operation with the related doors closed. The MCCB ratings and over load relays shall be suitably coordinated with the main contactor rating to meet type 2 requirement in accordance with IS:13947-4. Suitable AC3 duty rating of the contactor shall be selected. Heavy Duty Contactor shall be provided for all the fans, Conveyors and Blower Motor feeders. 1.3.5 Marshalling Compartments A common Marshalling compartments / cabinets, as an extension for the switchboards shall be provided, for connection of multi-core cables from DCS racks. A Marshalling Compartment of adequate size shall be provided in each 415V PCC / MCC / Distribution Board (common for all feeders in a particular switchboard) to house the interposing relays, contact multiplying relays. The terminal blocks shall be mounted in such a way that FIELD terminal blocks / terminations and DCS terminal blocks / terminations are coming on either side (Front and Rear). All inter-panel wiring between the individual modules, marshalling compartment shall be through metallic troughs with cover. The inter panel wiring between the individual modules and the marshalling compartment shall be done only with screened cables. Marshalling cabinets shall house terminal blocks and transducers for connection to 415V PCC, Auxiliary Switchboard and MCC compartments / DCS racks, as shown in the drawings. However, local push button stations and other field instrument cables shall be directly connected to the respective motor feeder compartments. The terminal block arrangement shall be arranged as below : All digital inputs (DIs) from different feeders to be terminated at a separate array of terminal blocks. All digital outputs (DOs) from different feeders to be terminated at a separate array of terminal blocks. All analog inputs (AIs) from different feeders to be terminated at a separate array of terminal blocks. All terminal blocks shall be identified with the respective feeder names.
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The communication port of all the Tri Vector Meters / kWH meters in the 415V PCC shall be connected in series through Screened, twisted pair cable of 0.5 Sq. mm. and a single point connectivity shall be provided in the marshalling compartment for hooking up these signals to the Energy Management System. However, there shall be an independent terminal block individually for all the Tri Vector Meter / kWH meter. 1.3.6 Control Supply Control Supply bus shall be of 240V for all the panel and this supply to be tapped from Mains from the incoming side of the Panel incomer. There shall be two control transformers in each panel with DP MCBs on incoming side and with a changeover switch at outgoing side of transformers to provide redundant control supply. 2 nos. 20A 2pin power sockets with 16A switch shall be provided in each panel for maintenance purpose. Control bus supply failure signal shall be arranged to connect it to DCS.
1.4
Low Voltage Air circuit-breakers
1.4.1 Conformity with Standards ACBs used in low voltage panels should conform to the International Standards IEC 60947, EN 60947, CEI EN 60947 and IEC 61000 and conform to the relevant EC directives: Low voltage directive (LVD) No. 73/23 EEC Electromagnetic Compatibility Directive (EMC) No.89/336 EEC 1.4.2 Functional characteristics - The circuit-breakers must have a rated service voltage of 690V a.c. and a rated insulation voltage of 1000V. - The circuit-breakers must have a rated impulse withstand voltage Uimp 12kV. - The circuit breakers shall enable short circuit protection with Icu 50kA up to 1600A rating and upto 65kA upto 3200A rating. - The circuit-breakers must be able to be supplied both from the top and bottom terminals without derating their performances and without jeopardizing their functionality. - The circuit-breakers with Higher Electrical & Mechanical life shall be preferred. 1.4.3 Environmental characteristics - Operating temperature: -25 C...+70 C (-13 F...158 F) - Altitude: operation without derating up to 2000m a.s.l.
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- Suitability for being used in hot humid ambient. To this regard, the circuit-breakers must undergo a Tropicalization process which makes them suitable for use in a hot-humid ambient, in accordance with the international IEC 60068-2-30 Standards. 1.4.4 Construction characteristics - All the models should be available in 3 and 4 pole versions both in fixed version and withdrawable versions - The circuit-breaker structure must be made of steel sheet. - In order to ensure maximum operator safety it is necessary to have total segregation between the power circuit and control circuit, thus making double insulation necessary. - Total segregation between the phases should be guaranteed for safety reasons. - Key locks or padlock devices should be provided in order to control enabling of opening and closing operations and/or racking in and out.(wherever specified) - The main contacts should be separate from the arc-breaking contacts. - It should be easily possible to inspect the arcing chamber and the wear of the main contacts of the air circuit-breaker in its racked-out position, by removing the arcing chambers. - All the circuit-breakers in the range should have the same depth and height with the aim of standardizing the support structures of the switchboards and the switchboards themselves as much as possible. - On the front, the circuit-breakers must indicate the exact position of the main contacts and the condition of springs charged/discharged by means of certain and reliable signals. - Tripped on fault flag/popup shall be there along with separate reset button on the front other than OFF button. - Potential free trip signaling contact and remote electrical reset arrangement are must for all EDO type ACBs. - The operating mechanism should be of the stored energy type, operated using pre-charged springs and fitted with an anti-pumping device. The springs are charged manually by operating the front lever or using a motor operator. - The entire range of air circuit-breakers should be equipped with microprocessor-based over current protection releases and the releases should be provided with rating plug.
Particular details for withdrawable versions - There must be three positions of the moving part in relation to the fixed part: - Connected - test (main contacts isolated, auxiliary contacts connected) - isolated
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- The circuit-breakers in the withdrawable version must be fitted with anti-racking-in locks to prevent a moving part with a different nominal current being racked-into a fixed part. - In the case of a withdrawable version, the presence of a device will prevent racking out or racking in with the circuit-breaker closed. - The withdrawable version circuit-breaker must allow racking out and racking in of the circuitbreaker into its fixed part with the switchboard door closed. - Insulating shutters must be provided on the main input and output circuits so that the energized parts are suitably segregated with the circuit-breaker withdrawn of under test. When in the closed position, these shutters can be closed with a padlock. 1.4.5 Accessories The following accessories must be common to the whole range. - Shunt opening/closing release - Control/Monitoring Test Unit, allows continuity of shunt opening release to be checked - Under voltage release - Time delay device for under voltage release, used for allowing delayed trip of the release with adjustable preset times - Geared motor for automatic charging of closing springs - Mechanical and electrical signaling of over current trip units tripped - Auxiliary contacts which enable the state of the circuit breaker to be signaled - Current transformer for the neutral conductor outside the circuit-breaker. - Interlocks between circuit breakers, for interlocking two or three circuit breakers both in horizontal and vertical position using flexible cables 1.4.6 Protection release functions - The trip unit should not require an external power supply, being self powered using the current transformers installed on the circuit-breaker. - Release must be of self-diagnostic type which can sense wrong connections at CT, trip coil and rating plugs. - The releases should have integrated LED fault indication for each type of protection i.e. for L, S, I & G. - The releases should allow: inverse long time-delay trip overload protection (L) and instantaneous short-circuit protection (I), while in addition (wherever specified) the release should have: - short-circuit protection with adjustable delay (S) - earth fault protection with adjustable delay (G) Main Protection functions & Setting Values
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Function L - Overload Protection S Selective short-circuit Protection I Instantaneous short-circuit protection G Earth fault protection N Neutral Protection Trip Threshold 0.4 to 1 x In 1 to 10 x In 1.5.12 x In 0.21 x In 50 - 200 % Trip time 3s.18s 0.05s0.5s Instantaneous 0.1s0.8s
All the Protection functions except the one for protection against overload must be excludable.
1.5 MOULDED CASE CIRCUIT BREAKER (MCCB) MCCB shall be Current Limiting and comprise of Quick Make - break switching mechanism, preferably Double Break Contact system, arc extinguishing device and the tripping unit shall be contained in a compact, high strength, heat resistant, flame retardant, insulating moulded case with high withstand capability against thermal and mechanical stresses. All MCCBs shall be capable of defined Variable overload adjustment. All shall be provided with electronic trip unit / releases. The trip command shall override all other commands. MCCB shall employ maintenance free double break contact system to minimise the let thru energies and capable of achieving discrimination upto full short circuit capacity of downstream MCCB. The manufacturer shall check and provide suitable switchgear to achieve total discrimination.
BREAKING CAPACITY: Short time with-standing capacities & breaking capacities for different ratings of MCCBs shall be as specified in the SLD or as per the table below if not specified in the SLD. o Upto and including 250A 25kA Ics at 415V o 251A to 630A 35kA Ics at 415V
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LT TECHNICAL SPECIFICATIONS o > 631A 50kA Ics at 415V
Preferably (Ics) shall be equal to (Icu) or all breaking capacities shall be considered for (Ics). Fixing or removal of accessories should not affect the above breaking capacity. It should be possible to remove and replace all the accessories at site from the point of servicing and maintenance. ) RELEASES:
Unless otherwise specified all MCCBs up to and including 250A shall be provided with Thermal Magnetic releases & MCCBs of rating greater than 315A shall be provided with Microprocessor based releases. All MCCBs with Thermal magnetic releases shall be provided with adjustable overload & fixed short circuit releases. Thermo magnetic releases shall be fitted with protection threshold against overload and with protection threshold against short-circuit. All MCCBs with Microprocessor based releases shall be provided with adjustable overload & short circuit releases. The over current releases must be self-supplied. They must be unaffected by electromagnetic interference in compliance with the EMC directive on the matter. Wherever earth fault module is required it shall be inbuilt with other releases, i.e. separate module for E/F is not preferred.
The MCCBs shall be provided with rotary handle operating mechanism. The handle position shall give positive indication of ON, OFF or Tripped thus qualifying to Disconnection as per the IS/IEC indicating the true position of all the contacts. In case of 4 pole MCCB the neutral shall be defined and capable of offering protection. The MCCBs shall be provided with extended spreader terminals to provide proper termination to use with Aluminium Bus Bars. 1.6.1 MOTOR PROTECTION CIRCUIT BREAKER (MPCB)
Motor circuit breakers shall conform to the general recommendations of standard IEC 947 -1,2 and 4 (VDE 660, 0113 NF EN 60 947-1-2-4, BS 4752) and to standards UL 508 and CSA C22-2 N 14.
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The devices shall be in utilization category A, conforming to IEC 947-2 and AC3 conforming to IEC 947-4. MPCB shall have a rated operational and insulation voltage of 690V AC (50 Hz) and MPCB shall be suitable for isolation conforming to standard IEC 60947-2 and shall have a rated impulse withstand voltage (Uimp) of 6 kV. The motor circuit breakers shall be designed to be mounted vertically or horizontally without derating. Power supply shall be from the top or from the bottom. In order to ensure maximum safety, the contacts shall be isolated from other functions such as the operating mechanism, casing, releases, auxiliaries, etc, by high performance thermoplastic chambers. The operating mechanism of the motor circuit breakers must have snap action opening and closing with free tripping of the control devices. All the poles shall close, open, and trip simultaneously. The motor circuit breakers shall accept a padlocking device in the isolated position. The motor circuit breakers shall be equipped with a PUSH TO TRIP device on the front enabling the correct operation of the mechanism and poles opening to be checked. The auxiliary contacts shall be front or side mounting, and both arrangements shall be possible.The front-mounting attachments shall not change the breaker surface area. Depending on its mounting direction the single pole contact block could be NO or NC.All the electrical auxiliaries and accessories shall be equipped with terminal blocks and shall be plugin type. The motor circuit breakers shall have a combination with the downstream contactor enabling the provision of a perfectly co-ordinated motor-starter. This combination shall enable type 1 or type 2 co-ordination of the protective devices conforming to IEC 60947-4-1.Type 2 coordination shall be guaranteed by tables tested and certified by an official laboratory: LOVAG (or other official laboratory). The motor circuit breakers, depending on the type, could be equipped with a door-mounted operator which shall allow the device setting. The motor circuit breakers shall be equipped with releases comprising a thermal element assuring overload protection and a magnetic element for short-circuit protection. In order to ensure safety and avoid unwanted tripping, the magnetic trip threshold (fixed) shall be factory set to an average value of 12 Ir. All the elements of the motor circuit breakers shall be designated to enable operation at an ambient temperature of 50 C without derating.The thermal trips shall be adjustable on the the front by a rotary selector.The adjustment of the protection shall be simultaneous for all poles.Phase unbalance and phase loss detection shall be available.Temperature compensation (-20 C to +60 C) 1.7 Switch Fuse Units, Disconnecting Switches and Fuses All switches shall be load double break, heavy duty air break type provided with quick make break manual operating mechanism. The operating handle shall be mounted in the door of the compartment having the switch. Switches shall be designed to carry the rated current continuously without overheating.
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Barriers shall be provided to prevent interphase arcing and live terminals shall be shrouded to avoid accidental contact. The switches shall be rated for AC23A duty. Auxiliary switches shall be provided with a minimum of two NO contacts, rated for 5A, 230V AC. Fuses shall be non-deteriorating HRC cartridge link type. Diaze fuses are not acceptable. The fuses shall be provided with operation indicator which shall be visible without removal of fuses from service. Fuses shall be pressure fitted type and shall preferably have rims on the contact blades to ensure good line contact. It shall be possible to handle fuses during off load conditions with full voltage available on the terminals. Wherever required, fuse pullers shall be provided. 1.8 Contactors The contactors shall be air break type, equipped with three main contacts and minimum 2 NO + 2 NC auxiliary contacts. The main contacts of a particular contactor shall have AC3 ratings for general AC motor circuits, AC4 for RDOL feeders and AC5a for AC lighting circuits as per IEC 60947. The auxiliary contacts shall be rated for minimum 5 Amps at 230 V AC and 110 V DC. Unless specified otherwise, the coil of the contactor shall be suitable for operation on 110V AC supply and shall work satisfactorily between +10% and -15% of the rated voltage. The contactor drop-off voltage shall be between 30% to 65% of the rated coil voltage. Auxiliary contactors shall generally be used for interlocking and multiplying contacts. Auxiliary contacts shall be capable of carrying the maximum estimated current, but not less than 5A at 230V AC. 1.9 Over Load Relays Overload relays will be of bi-metallic thermal overload type or electronic type as specified in the drawings. Bi-metallic Over Load Relay, three element type directly mounted, front adjustable, ambient temperature compensated bimetallic devices of suitable range to match with the rating / Output of the motors connected to the related starter and complete with hand resetting device. The relays shall be provided with minimum 1 NO + 1 NC contacts with a rating of 5 Amps at 240 V, 1PH, 50 Hz AC and 1.3 Amps at 110 V DC (Inductive load). The bi-metallic relays shall have double slide mechanism for single phase failure detection even at partial load conditions. Microprocessor based earth fault relay shall be additionally provided with CBCT wherever specified. Microprocessor type overload relays shall have motor stalling, single phasing, locked rotor, earth fault and overload protections, as a minimum and shall be suitable for the ambient that will be prevalent in the switchboard. Necessary core balancing current
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transformers, as required for earth fault protection shall be arranged. The relay shall have inbuilt time delay setting facility for tripping. The relays shall preferably be of CT operated type. Class 20 relays shall be considered wherever the starting time is expected to be very high.
1.10 INDICATING PANEL All meters and indicating instruments shall be in accordance with relevant Indian Standards. The meters shall be flush mounted type. Indicating lamps shall be of LED type, and shall be backed up with MCB / MPCB.
1.11 WIRING In wiring the single phase loads of a power distribution panel it shall be insured that total load of various panel and/or consuming devices is divided evenly between the phases and number of ways. 1.12 ANTI-CONDENSATION SPACE HEATERS 1 No. 100 W, 240 volts, single phase, 50 Hz AC Anti Condensation space heaters controlled by thermostat and protected by 6 amps SP MCBs/MPCB shall be provided in each vertical section of Main LT Panel synchronizing panel Power Distribution Panel, MCCs and 1 No. 60 watt Anti Condensation space heater shall be provided in each cable alley of main distribution boards and sub distribution boards. Supply and control equipment for the above shall be provided by the vendors. 1.13 EARTHING Earthing shall be provided as per IS:3043-1987. 1.14 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 confirming to IS Code No.5.
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1.15 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. 1.16 METERS i. All voltmeters and indicating lamps shall be through MCBs. ii. Meters and indicating instruments shall be flush type. iii. All CTs connection for meters shall be through Test Terminal Block (TTB). 1.17 CURRENT TRANSFORMERS Current transformers shall be provided for Distribution panels carrying current in excess of 60 amps. All phase shall be provided with current transformers of suitable VA burden with 5 amps secondaries for operation of associated metering. The CTs shall confirm 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. Secondary terminals of CTs shall be brought out suitable to a terminal block which shall be easily accessible for testing and terminal connections. The protection CTs shall be of accuracy class 5P10 and measurement CTs shall be of accuracy class I. 1.18 PUSH BUTTONS, SELECTOR SWITCHES AND PILOT LAMPS
The push buttons shall be of shrouded type with actuator provided with escutcheon plates marked with its function on it. Control switches shall be of the heavy duty rotary type with name plates clearly marked to show the operation. They shall be semi-flushed mounting with only the front plate and operating handle projecting. Circuit breaker control switches shall be of the spring return to neutral type, while local / remote selector switches and instrument selector switches shall be of the stay-put type. The indicating lamps shall be of cluster LED type of low watt consumption. They shall be provided with series resistors. 1.19 LOW VOLTAGE 1.1 KV GRADE XLPE / PVC CABLES 1.19.1 GENERAL The LV cables shall be supplied, inspected, laid, tested and commissioned in accordance with drawings, Specifications, relevant Standard Specifications and cable manufacturer's instruction. 1.19.2 MATERIAL
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The LV cables shall be cross linked polyethylene (XLPE) insulated PVC sheathed of 1100 volts grade as asked for in the schedule of quantities. Cables upto 16 sq.mm shall be with copper conductor and 25 sq.mm and above shall be with aluminium conductor. 1.19.3 TECHNICAL REQUIREMENTS : 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 in case of 10 sq.mm. and above and solid conductor in case of 10 sq.mm. and below. 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 Galvanised steel wires or galvanised steel strips. (In single core cables used in A.C. system armouring should be non-magnetic hard aluminium Wires/Strips. Round 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. Conductor shall be of electrolytic Aluminium/Copper conforming to IS : 8130 and are compact circular or compact shaped. Insulation shall be of XLPE type as per latest IS general purpose insulation for maximum rated conductor temperature 70 degree centigrade. In Inner sheath laid up cores shall be bonded over with thermoplastic material for protection against mechanical and electrical damage. Insulation, inner sheath and outer sheath shall be applied by extrusion and lapping up process only. Armouring shall be of galvanised steel wire/flat. Repaired cables shall not be used. Current ratings of the cables shall be as per IS : 3961. 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. 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. 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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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. 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. 1.19.4 INSPECTION All cables shall be inspected by the contractor upon receipt at site and checked for any damage during transit. 1.19.5 JOINTS IN CABLES The Contractor shall take care to see that all the cables received at site are apportioned to various locations in such a manner as to ensure maximum utilization and avoidance of cable jointing. This apportioning shall be got approved by the Owners site representative before the cables are cut to lengths. Where joints are unavoidable heat shrinkable type joints shall be made. The location of such joints shall be got approved from the Owners site representative and shall be identified through a marker. 1.19.6 JOINTING BOXES FOR CABLES Cable joint boxes shall be installed with heat shrinkable sleeve and of appropriate size, suitable for XLPE armoured cables of particular voltage rating.
1.19.7 JOINTING OF CABLES All cable joints shall be made in suitable, approved cable joint boxes and the filling in of compound shall be done in accordance with manufactures' instructions and in an approved manner. All straight joints shall be done in epoxy mould boxes with epoxy resin. All cables shall be joined colour to colour and tested for continuity and insulation resistance before jointing commence. The seals of cables must not be removed until preparations for jointing are completed. Joints shall be finished on the same day as commenced and sufficient protection from the weather shall be arranged. The conductors shall be efficiently insulated with high voltage insulating tape and by using of spreaders of approved size and pattern. The joints shall be completely topped up with epoxy compound so as to ensure that the box is properly filled. 1.19.8 CABLE TERMINATIONS Cable termination shall be done in cable terminal box using crimping sockets and proper size of glands of double compression type with earthing facility.
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1.19.9 BONDING OF CABLES Where a cable enters any piece of apparatus, it shall be connected to the casing by means of an approved type of armour clamp and gland. The clamps must grip the armouring firmly to the gland or casing, so that no undue stress is passed on to the cable conductors. 1.19.10 LAYING OF CABLES ON CABLE TRAYS Cables shall be laid by skilled and experienced workmen using adequate rollers to minimize stretching of the cable. The cable drums shall be placed on jacks before unwinding the cable. Great care shall be exercised in laying cables to avoid forming kinks. The relative position of the cables, laid on the cable tray shall be preserved and the cables shall not cross each other. At all changes in direction in horizontal and vertical planes, the cable shall be bent smooth with a radius as recommended by the manufacturers. All cables shall be laid with minimum one diameter gap and shall be clamped at every metre to the cable tray and shall be tagged for identification with aluminum tag and clamped properly. Tags shall be provided at both ends and all changes in directions both sides of wall and floor crossings. All cable shall be identified by embossing on the tag the size of the cable, place of origin and termination. All cables passing through holes in floor or walls shall be sealed with fire retardant Sealant and shall be painted with fire retardant paint upto one meter on all joints, terminations and both sides of the wall crossings by VIPER CABLE RETARD. 1.19.11 LAYING OF CABLES IN GROUND The minimum width of trench for laying single cable shall be minimum 350 mm. Where more than one cable is to be laid in horizontal formation, the width of the trench shall be workout by providing 200 mm gap between the cables, except where otherwise specified. There shall be clearance of 150 mm between the end cable and the side wall of the trench. The minimum dept of the cable trench shall not be less than 750 mm for single layer of cables. When the cables are laid in more than one tier the depth of the trench shall be increased by 300 mm for each additional tier. Excavation of trenches : The trenches shall be excavated in reasonably straight lines. Wherever there is a change in direction, suitable curvature shall be provided. Where gradients and changes in depth are unavoidable, these shall be gradual. The excavated soil shall be stacked firmly by the side of the trench such that it may not fall back into the trench. The bottom of the trench shall be level and free from stone, brick bats etc. The trench shall then be provided with a layer of clean, dry sand cushion of not less than 100 mm in depth. Prior to laying of cables, the cores shall be tested for continuity and insulation resistance. The cable drum shall be properly mounted on jacks, at a suitable location, making sure that the spindle, jack etc. are strong enough to carry the weight of the drum and the spindle is horizontal. Cable shall be pulled over rollers in the trench steadily and uniformly without jerks and strains. The entire drum length shall be laid in one stretch. However, where this is not possible the remainder of the cable shall be removed by `Flaking i.e. by making one long loop in the reverse direction. After the cable has been uncoiled and laid into the trench over the rollers, the cable shall be lifted off the rollers beginning from one end by helpers standing about 10 meters apart and laid in a reasonably straight line. Cable laid in trenches in a single tier
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formation shall have a cover of clean, dry sand of not less than 150 mm. above the base cushion of sand before the protective cover is laid. In the case of vertical multi-tier formation after the first cable has been laid, a sand cushion of 300 mm shall be provided over the initial bed before the second tier is laid. Finally the cables shall be protected by second class bricks before back filling the trench. Back Filling : The trenches shall be back filled with excavated earth free from stones or other sharp edged debris and shall be rammed and watered, if necessary, in successive layers not exceeding 300 mm. Unless otherwise specified, a crown of earth not less than 50 mm in the centre and tapering towards the sides of the trench shall be left to allow for subsidence. 1.19.12 CABLES INSIDE THE PLANT Cables inside buildings shall be laid on the cable trays. All cables passing through walls shall run through GI Pipes of adequate diameter 50 mm apart maintaining the relative position over the entire length. 1.19.13 ROUTE MARKER Route marker shall be provided along straight runs of the cables not exceeding 100 meters also for change in the direction of the cable route and underground joints. Route marker shall be of cast iron painted with aluminum paint. The size of marker shall be 100 mm dia with Cable and voltage grade inscribed on it. 1.19.14 CABLE TRAYS 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 1500 mm C/C b. 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 1500 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 1500 mm C/C
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d. 750 mm wide Runners 20 x 75 x 20 x 2.5 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 1800 mm C/C e. Supply and fixing of perforated type cable trays of the following sizes of pre-galvanized iron. i. 600 x 40 x 40 x 2 mm thick i. 450 x 40 x 40 x 2 mm thick i. 300 x 40 x 40 x 2 mm thick ii. 150 x 40 x 40 x 2 mm thick Suitable length of 8 mm dia GI rod suspenders at 2000 mm intervals shall be included in the item for perforated type cable tray. 1.20 SPECIFICATION FOR HOT DIP GALVANIZING PROCESS FOR MILD STEEL USED FOR EARTHING, CABLE TRAYS OR JUNCTION BOXES FOR ELECTRICAL INSTALLATION. 1.20.1 Quality of Zinc Zinc to be used shall conform to minimum Zn 98 grade as per requirement of IS:209-1992. 1.20.2 Coating Requirement Minimum weight of zinc coating for mild steel flats with thickness upto 6 mm in accordance with IS:6745-1972 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. 1.21 TESTING OF CABLES Cables shall be tested at works for the following tests before being dispatched to site by the project team. a) Insulation Resistance Test. b) Continuity resistance test. c) Sheathing continuity test. d) Earth test.(in armoured cables)
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e) Hi Pot Test. Test shall also be conducted at site for insulation between phases and between phase and earth for each length of cable, before and after jointing. On completion of cable laying work, the following tests shall be conducted in the presence of the Owners site representative. a) Insulation Resistance Test( Sectional and overall) b) Continuity resistance test. c) Sheathing continuity test. d) Earth test. All tests shall be carried out in accordance with relevant Standard Code of Practice and Electricity Rules. The Contractor shall provide necessary instruments, equipment and labour for conducting the above tests and shall bear all expenses in connection with such tests. All tests shall be carried out in the presence of the Owners site representative.
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