tender.tractebelindia.comtender.tractebelindia.com/BGRL/1000667302020/Technical Tender.pdf · S.NO....

ELECTRICAL WORKS FOR 2 NOS. OF CNG STATIONS AT EXISTING ROs FOR CGD PROJECT OF BILASPUR, HAMIRPUR & UNA GA IN THE STATE OF HIMACHAL PRADESH Project No.P.015682Document No. P.015682 G 11031 R034E Tender No.-1000667302020

Bharat Gas Resources Ltd,Mumbai | INDIA

RESTRICTED

12 Aug 2020

TECHNICAL DOCUMENTATIONTechnical, Volume II of II

S.NO. DOCUMENT / DRAWING NO. REV. NO PAGES PAGE NO.

I

1 SECTION - I INVITATION FOR BID (IFB)

2 SECTION - II INSTRUCTION TO BIDDERS (ITB)

3 SECTION - III GENERAL CONDITIONS OF CONTRACT (GCC)

4 SECTION - IV SPECIAL CONDITIONS OF CONTRACT (SCC)

5 SECTION - V FORMS AND FORMATS

6 SECTION - VI SCHEDULE OF RATES (SOR)

13

1 P.015682-G-11039-E002 0 5 1

2 P.015682-G-11040-E006 0 7 6

3 P.015682-G-11077-E050 0 10 13

4 P.015682-G-11077-E051 0 6 23

5 P.015682-G-11077-E052 0 16 29

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21 P.015682-G-11088-E100 0 4 147

22 P.015682-G-21080-E001 0 49 151

23 P.015682-G-21080-E002 0 24 200

24 P.015682-G-21080-E003 0 6 224

25 P.015682-G-21080-E004 0 12 230

26 P.015682-G-21098-E003 0 1 242

27 P.015682-G-21098-E004 0 1 243

28 P.015682- C- 20705- 101 3 1 244

29 P.015682- C- 20705- 103 3 1 245

TABLE OF CONTENTSPROJECT - CONSTRUCTION OF DAUGHTER BOOSTER STATIONS AT UNA, HAMIRPUR

AND BILASPUR GA IN THE STATE OF HIMACHAL PRADESH

TYPICAL EARTHING INSTALLATION DETAILS

TYPICAL CABLE TRAY INSTALLATION DETAILS

DESCRIPTION

VOLUME II OF II (TECHNICAL)

TECHNICAL DATA SHEET – UPS SYSTEM

TECHNICAL DATA SHEET – POWER & CONTROL CABLE

TECHNICAL DATA SHEET- POWER DISTRIBUTION BOARD

TECHNICAL DATASHEET –VRLA BATTERY

SCOPE OF WORK

VENDOR LIST-ELECTRICAL

0 117P.015682-G-11031-R034

VOLUME I OF II (COMMERCIAL)

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PTS – ELECTRICAL PACKAGE

PTS – CABLE AND ACCESSORIES

PTS – LOW VOLTAGE DISTRIBUTION BOARDS

QAP-DISTRIBUTION BOARD

PTS – UPS SYSTEM

PTS- BATTERY

TYPICAL LIGHTNING PROTECTION DETAILS

APPROVED LAYOUT PLAN - GURU NANAK BARUHI

PTS-FLAMEPROOF & WEATHERPROOF EQUIPMENT

FIELD INSPECTION, TESTING AND COMMISSIONING OF ELECTRICALINSTALLATION

QAP-VRLA BATTERY

QAP-UPS SYSTEM

QAP-POWER & CONTROL CABLES

SINGLE LINE DIAGRAM FOR CNG STATION - SHIVALIK HEIGHTS MEHATPUR

TYPICAL LIGHTING INSTALLATION DETAILS

PTS-EARTHING & LIGHTNING PROTECTION SYSTEM

PTS-LIGHTING SYSTEM

PTS-ERECTION, TESTING & COMMISSIONING OF ELECTRICALEQUIPMENT

TECHNICAL DATASHEET –FIRE FIGHTING EQUIPMENT

SINGLE LINE DIAGRAM FOR CNG STATION -GURU NANAK BARUHI

APPROVED LAYOUT PLAN - SHIVALIK HEIGHTS MEHAT PUR

Construction of CNG Station -Electrical Works Page 1 of 1

SCOPE OF WORK P.015682-G-11039-E002

BHARAT GAS RESOURCES LIMITED (BGRL)

CONSTRUCTION OF CNG STATION -ELECTRICAL WORKS

SCOPE OF WORKS

0 30.07.2020 Issued for Tender MCY MCY SME

A 24.04.2020 Issued for Review MCY MCY SME

Rev. Date Subject of revision Prepared By Checked By Approved By

1 of 246


Rev. 0 Construction of CNG Stations – Electrical Works Page 1 of 4

TABLE OF CONTENTS1.0 INTRODUCTION ................................................................................................................... 22.0 GENERAL REQUIREMENT .................................................................................................... 23.0 SCOPE OF WORKS ............................................................................................................... 24.0 INSPECTION AND TESTING ................................................................................................. 3

5.0 SITE ACCEPTANCE TESTING ................................................................................................ 36.0 CO-ORDINATION WITH OTHER VENDORS .......................................................................... 37.0 COMMUNICATION ............................................................................................................... 38.0 SAFETY ................................................................................................................................. 39.0 GUARANTEE ......................................................................................................................... 4

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1.0 INTRODUCTION

M/s. Bharat Gas Resources Limited (BGRL) (hereinafter referred as Owner), is executing the City GasDistribution project in the Geographical Areas (GAs) at Una, Hamirpur and Bilaspur district in the State ofMaharashtra.

Tractebel Engineering Pvt. Ltd. (TEPL) has been appointed as Project Management Consultant (hereinafterreferred as PMC), by BGRL for providing Design, Engineering & PMC services for a mentioned project.

Tractebel Engineering Pvt. Ltd. is now inviting tenders on Competitive Bidding basis for Supply, erection,testing and commissioning of Electrical Works for the 2 nos. daughter booster stations of the aforementionedGAs.

2.0 GENERAL REQUIREMENT

This document presents the scope of work for daughter booster station electrical works at two (2) numbers ofexisting retail outlets. This scope of work shall establish the minimum requirements for detailed design ofelectrical system as well as supply, erection, testing and commissioning of all equipment.

The design shall be based on the following factors:

(i) Safety to personnel and equipment,(ii) Reliability of service (smooth & efficient performance),(iii) Minimal fire and explosion risk,(iv) Ease of maintenance & convenience of operation(v) Protection of all electrical equipment as per codes and standards.

Utilization of equipment with adequate fault interrupting capacity, continuous current carrying capacity andinsulation levels, as per system voltages and capacities.

This document shall also provide the minimum requirements & basis for carrying out detailed designengineering for electrical power system, sizing of various electrical equipment, their supply, installation, testing& commissioning of the Electrical system for the aforesaid stations & associated facilities.

In case of conflicting requirement of tender documents, following priority shall govern in general:

(i) The requirements of any statutory body shall govern.(ii) Data Sheets,(iii) This specification / Basis of design,(iv) Job Specifications(v) Code & Standards

However, in case of conflict, it shall be referred to owner for clarifications and decision of owner shall be finaland binding without any cost implications (as per project scope).

3.0 SCOPE OF WORKS

To facilitate proposed daughter booster station, 415V switch board shall be considered, incomer cable shall befrom existing 415 V AC SEB terminal point. Detailed is described in respective specification documents.

3.1. Design, detailed engineering, supply installation, testing, commissioning and putting into successful commercialoperation of electrical system comprising of the following:

a) 415V switch board as per SLD,b) Incoming shall be from 415 V pole or pole mounted transformer and outgoing feeders & Outgoing cable

shall be from 415 V panel to station loads.c) 230 V, 1 Phase, 50 Hz, 3 kVA AC UPS.d) Sealed maintenance free (SMF) battery bank for 2 hours back up.e) UPS DB for the UPS loads.f) Earthing and lightning protection system.g) Outdoor & Indoor LED Lighting system.

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h) All power & control cablesi) Structural Steel, Cable trays, pipe/conduit and its accessories for cabling and miscellaneous items etc.j) Other Miscellaneous items as per Electrical BOQ

Providing as built documentation for all work done including old systems where any integration has been done.All documentation to be provided as printed documents and computer files compatible with MS Office andAutoCAD.

All materials shall be approved by Owner or its authorized representative before use by the Contractor.

3.2. Wherever testing and measurement is required, contractor shall propose a list of measurement and test equipment inhis procedure and shall demonstrate that sufficient equipment will be allocated for all concurrent tasks. Allmeasurement equipment shall be fit-for-purpose and, for each piece of equipment, the Contractor shall providedocumentation of current third-party calibration by a recognized independent certified testing house.

4.0 INSPECTION AND TESTING

Inspection and testing by Third party Inspection agency (TPIA) and Third-party test laboratory requirement formaterials as part of scope of this tender, shall be in scope of contractor. In addition, owner may also consideradditional agency / own personnel for such inspections review. Electrical distribution board and UPS systemshall be supplied with TPI inspection release report and Owners dispatch clearance. Bidder shall furnishminimum three TPIA agency name and then Owner/ Owner consultant will give clearance the agency name forinspection. For all other materials, Bidder shall inspect and provide the inspection report to owner/ownerassigned consultant for review and dispatch clearance.

5.0 SITE ACCEPTANCE TESTING

The contractor shall implement procedures and inspection test plans for site in accordance with tenderspecification along with the vendor documentation which will termed as Site Acceptance Testing (SAT)procedure. All equipment shall pass SAT and the contractor shall submit SAT documentation in order to obtainapproval of the engineer-in-charge to proceed for further installations commissioning.

6.0 CO-ORDINATION WITH OTHER VENDORS

Owner shall be engaging other equipment vendor or contractor for performance of other works associated withCNG composite works. It shall be the responsibility of contractor to communicate, co-operate, co-ordinate andprovide assistance to such Vendor/contractor and sort out all interface issues in consultation with engineer-in-charge, for carrying out scope of work of system. The contractor shall appoint a representative to meet weeklywith other vendor’s representatives in the presence of the owner. The contractor in meeting shall provide thelocations to determine programming for construction and commissioning activities such that the Owner’s needsfor co-ordination for other contractor is not disadvantaged by one contractor’s activities.

The contractor shall plan his activities requiring interfacing with other vendors/contractor well in advance andprovide details at least 10 days in advance so that all interface issues can be resolved prior to actual execution ofthe work. All delays on account of such interface problems arising out of non-co-operation / lack of coordinationby the Contractor shall be to contractor’s account.

7.0 COMMUNICATION

For effective communication with owner, the contractor shall establish a detailed project communicationprocedure in consultation with engineer-in charge, that will include as a minimum an organization chart anddetails of communications structure.

8.0 SAFETY

The Contractor shall be responsible for implementation of a project specific safety and health management planimmediately after award of work, in line with statutory requirements. The contractor shall be responsible for thesafety at all sites including all travel to the sites and any remote offices. The safety plan shall be in compliance toall local and government safety requirements, approvals and standards and Owner’s safety manual. Contractorshall depute experienced and sufficiently trained safety personal at site throughout the project phase.

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9.0 GUARANTEE

9.1. Manufacturer shall guarantee that the design, materials, manufacturing and testing of electrical items, comply withthe requirement of this specification and applicable codes and standards. Manufacturer shall replace all items whichwould result defective or fail during field testing or fail to perform satisfactorily due to inadequate engineering,substandard material and workmanship.

9.2. The manufacturer shall guarantee electrical items against any defect, failure or malfunctioning occurring during 12months from the date of commissioning or 24 months from the date of supply whichever is earlier.

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VENDOR LIST -ELECTRICAL P.015682-G-11040-E006


CONSTRUCTION OF CNG STATIONS – ELECTRICAL WORKS

VENDOR LIST - ELECTRICAL



Rev. Date Description Prepared By Checked By Approved By

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Rev.-0 Construction of CNG Stations – Electrical Works Page 1 of 6

LIST OF ACCEPTABLE MANUFACTURERS FOR ELECTRICAL ITEMS

SL No.

1 CABLE – FIRE ALARM & COMMUNICATION CABLES1.1 Cords Cable Industries Ltd.1.2 CMI1.3 Delton cables Ltd.1.4 ELKAY Telelinks1.5 KEI Industries Ltd.

2 CABLE – LT POWER & CONTROL(XPLE)2.1 Universal Cable Ltd2.2 Polycab Wires Pvt. Ltd.2.3 Industrial Cables (I) Ltd2.4 Cable Corporation of India Ltd.2.5 Gloster Cables Ltd. (Earlier Fort Gloster Cables)2.6 NICCO Corporation Ltd2.7 Torrent Cables Ltd.2.8 KEC (Earlier RPG Cables)2.9 Uniflex Cables Ltd., Andheri (W),

2.10 KEI Industries Ltd2.11 Ravin Cables,

3 CABLE GLAND3.1 Baliga3.2 Comet3.3 Flexpro3.4 FCG Flameproof control gear3.5 Electro Werke3.6 Dowels3.7 Cable Corporation of India

4 CABLE - LUGS4.1 Dowels4.2 Jainson4.3 Ismal

5 CABLE - TRAY5.1 Ercon Composites5.2 Yamuna Power & Infrastructure Ltd.5.3 Indeana Engineering

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5.4 Elcon Cable Tray5.5 Advance Power Products

6 EARTHING & LIGHTNING PROTECTION MATERIALS6.1 Rukmani Electrical & Components Pvt Ltd.6.2 Indiana Grating Pvt Ltd.6.3 Jef Techno Solutions Pvt Ltd6.4 Advance Power Products

7 FLAME PROOF LDB’S/ JB,S/CONTROL STATION/SWITCHES7.1 FCG Flameproof control gear7.2 Sudhir Switchgears Pvt. Ltd7.3 Prompt Engineering Works7.4 Flame Proof equipments pvt. Ltd.7.5 Baliga Lighting Equipments Pvt. Ltd.7.6 Flexpro Electricals Pvt. Ltd.

8 LIGHTING FIXTURES (NORMAL)8.1 GE Lighting Pvt. Ltd.8.2 Bajaj Electricals Ltd.8.3 Crompton Greaves Ltd.8.4 Philips India Ltd.

9 LIGHTING FIXTURES (FLAMEPROOF)9.1 Bajaj Electricals Ltd.9.2 Baliga Lighting Equipment Pvt. Ltd.9.3 Crompton Greaves Ltd.9.4 CEAG Flameproof Controlgear Pvt. Ltd.9.5 Flexpro Electricals Pvt. Ltd.9.6 Philips India Ltd.9.7 Sudhir Switchgears Pvt. Ltd.9.8 FCG Flameproof control gear

10 GI LIGHTING POLE

10.1 Bajaj

10.2 Transrail10.3 Wipro10.4 Utkarsh India

11 LOW VOLTAGE PCC/ MCC/ PDB/ MLDB/ LDB11.1 GE Power Control India Private Limited11.2 Larsen & Toubro Limited

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11.3 Schneider Electric India Private Limited11.4 Siemens Limited11.5 ABB Limited

11.6 BCH Electric Limited (Bhartia Industries Limited)11.7 Tricolite Electrical Industries Limited11.8 Controls & Schematics Limited11.9 C&S Electric

11.10 KMG ATOZ Systems Private Limited11.11 Unilec Engineers Limited, New Delhi11.12 Jaksons Limited11.13 Sudhir Power Ltd.

12 MINIATURE CIRCUIT BREAKERS (MCBS) AND MOLDEDCASE CIRCUIT BREAKER (MCCB)12.1 ABB12.2 Hagger12.3 Indo Asian Fusegear Ltd.12.4 Legrand12.5 MDS Switchgear Ltd.12.6 Schneider12.7 Siemens Ltd.12.8 HPL12.9 C&S Electric

12.10 L&T

13 CONTRACTORS – AC POWER13.1 Andrew Yule13.2 ABB13.3 BHEL13.4 C&S Electric13.5 L&T13.6 Schneider13.7 Siemens Ltd.13.8 Telemechanique

14 CONTROL TRANSFORMER14.1 Automatic Electric Ltd14.2 Indushree14.3 Intra Vidyut14.4 Kalpa Electrikals14.5 Transpower Industries Ltd.14.6 Siemens

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15 INDICATING LAMPS20.1 Alstom Ltd.20.2 BCH20.3 L&T20.4 Siemens Ltd.20.5 Vaishno Electricals

16 PROTECTION RELAYS - THERMAL16.1 BCH16.2 L&T Ltd.16.3 Siemens Ltd.16.4 Telemenchanique & Controls (India) Ltd.

17 PROTECTION RELAYS -NUMERICAL17.1 ABB17.2 Siemens17.3 Schneider17.4 L&T17.5 GE

18 PUSH BUTTONS18.1 BCH18.2 Schneider18.3 L&T18.4 Siemens Ltd.18.5 Telemenchanique & Controls (India) Ltd.18.6 Vaishno Electricals

19 SWITCHES - CONTROL19.1 BCH19.2 Easum Reyrolle Relays & Devices Ltd.19.3 Schneider19.4 Kaycee Industries Ltd.19.5 L&T19.6 Siemens Ltd.19.7 C&S Electric

20 SWITCHES – 5/15A PIANO/ PLATE, SWITCH SOCKET20.1 Anchor Electronics & Electricals Pvt. Ltd.20.2 Indo Asian20.3 North-West Switchgear Ltd.20.4 Surya Switchgear20.5 Legrand

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20.6 Havells

21 SWITCH SOCKET OUTLETS (INDUSTRIAL)21.1 Havells21.2 Best & Cromption Engineering Ltd.21.3 BCH21.4 Crompton Greaves Ltd.21.5 Essen Engineering Company Pvt. Ltd.

22 TERMINALS BLOCKS22.1 Connectwell22.2 C&S Electric22.3 Elmex Controls Pvt. Ltd.22.4 Essen Engineering Co. Pvt. Ltd.

23 UPS SYSTEM AND INVERTER23.1 VERTIV (Earlier DB POWER & Emerson)23.2 APLAB23.3 KELTRON23.4 HI-REL23.5 DUBAS23.6 Enertech

23.7 Synergy Systems

24 BATTERIES24.1 Amco Shaft Batteries Ltd.24.2 HBL Power Systems Ltd.24.3 Exide Industries Ltd24.4 Amara Raja

25 CHANGE OVER SWITCH25.1 CGM25.2 L&T25.3 Siemens25.4 Schneider25.5 C&S Electric

26 INDICATING METERS26.1 ABB26.2 AMCO26.3 AE26.4 Alstom Ltd.

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Notes:

1. Apart from the vendors detailed in the above list or items with no vendor list, the contractor may propose any othervendor having credentials for supply of respective items (for the same or higher size, schedule, capacity, etc asapplicable) in the last 5 years in oil & gas applications (except for items meant for fire water service). in such cases thebidder shall provide supply records viz. copy of PO, inspection reports, inspection release note, proven track record,experience details or any other documentary evidence to establish past supply, for Owner’s review and approval, asapplicable. the acceptance of the same is at the discretion of the owner.

2. At the time of PO placement, proposed Vendor/ Supplier shall not be in holiday list.

26.5 Conzerv/Schneider26.6 Elecon Measurement Pvt. Ltd.26.7 HPL Electric & Power Pvt. Ltd.26.8 MECO Instruments Ltd.26.9 Minilec

26.10 Rishabh Instruments Pvt. Ltd.26.11 Trinity energy system26.12 kaycee26.13 Salzer26.14 Secure meter

27 DG Set27.1 Jakson27.2 Mahindra Powerol27.3 Koel Green27.4 Sterling & Wilson27.5 Sudhir Genset

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PTS – ELECTRICALPACKAGE P.015682-G-11077-E050


CONSTRUCTION OF CNG STATION – ELECTRICAL WORKS

PTS – ELECTRICAL PACKAGE



Rev. Date Subject of revision Prepared By Checked By Approved By

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TABLE OF CONTENTS

1.0 GENERAL ........................................................................................................................................... 1

2.0 SCOPE OF DESIGN AND ENGINEERING .............................................................................................. 1

3.0 SCOPE OF SUPPLY, ERECTION, TESTING AND COMMISSIONING ....................................................... 1

4.0 CODES AND STANDARDS .................................................................................................................. 2

5.0 REGULATIONS ................................................................................................................................... 3

6.0 SITE CONDITIONS .............................................................................................................................. 3

7.0 AREA CLASSIFICATION AND EQUIPMENT SELECTION ........................................................................ 3

8.0 ELECTRICAL DESIGN PARAMETERS. ................................................................................................... 4

9.0 ENCLOSURE PROTECTION OF EQUIPMENT ........................................................................................ 4

10.0 SYSTEM EARTHING............................................................................................................................ 5

11.0 LIGHTNING PROTECTION: ................................................................................................................. 5

12.0 DC POWER SUPPLY............................................................................................................................ 5

13.0 EMERGENCY POWER SUPPLY ............................................................................................................ 5

14.0 UNINTERRUPTED POWER SUPPLY (UPS). .......................................................................................... 5

15.0 ELECTRICAL EQUIPMENT CLEARANCE ............................................................................................... 5

16.0 CABLING SYSTEM .............................................................................................................................. 6

17.0 LIGHTING SYSTEM ............................................................................................................................. 7

18.0 DISTRIBUTION BOARD ...................................................................................................................... 7

19.0 OTHER MISCELLANEOUS ITEMS ........................................................................................................ 8

20.0 ELECTRICAL EQUIPMENTS FOR HAZARDOUS AREA ........................................................................... 8

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Rev-0 Construction of CNG Station- Electrical works Page 1 of 8

1.0 GENERAL

M/s. Bharat Gas Resources Limited (BGRL) (hereinafter referred as Owner), is executing the City GasDistribution project in the Geographical Areas (GAs) at Una, Hamirpur & Bilaspur district in the State ofHimachal Pradesh.

This document presents the design criteria for CNG station Electrical Works at two (2) numbers of existing retailoutlets. The design criteria shall establish the minimum requirements for detailed design of electrical system andequipment.

The contractor shall carry out electrical works based on tender drawings, project and general specification /standards, documents etc. enclosed with this tender document and, instruction of Owner / Owner’sRepresentative and other provisions of Contract document.

The design shall be based on the following factors:

• Safety to personnel and equipment,

• Reliability of service (smooth & efficient performance),

• Minimal fire and explosion risk,

• Ease of maintenance & convenience of operation

• Protection of all electrical equipment through code and standard.

• Utilization of equipment with adequate interrupting capacity, continuous carrying capacity and insulationlevels, as per system voltages and capacities.

2.0 SCOPE OF DESIGN AND ENGINEERING

This document establishes minimum Electrical Design Parameters and Basis for Design and DetailedEngineering of CNG station & associated facilities covered under this project as defined briefly herein below.

This document shall provide the minimum requirements & basis for carrying detailed design engineering forelectrical power system, selection & sizing of various electrical equipment of the Electrical system for CNGstation. This document also provides the general guidelines for preparation of Electrical specification, datasheetsand other relevant documents.

All materials shall be approved by Owner or its authorized representative before use by the Contractor.

Scope shall include detailed design and engineering of electrical system comprising of the following


shall be from 415 V panel to station loads.c) 230 V, 1 Phase, 50 Hz, 3 kVA AC UPS.d) Sealed maintenance free (SMF) battery bank for 2 hours back up.e) UPS DB for the UPS loads.f) Earthing and lightning protection system.g) Outdoor & Indoor LED Lighting system.h) All power & control cablesi) Structural Steel, Cable trays, pipe/conduit and its accessories for cabling and miscellaneous items etc.j) Other Miscellaneous items as per Electrical BOQ

3.0 SCOPE OF SUPPLY, ERECTION, TESTING AND COMMISSIONING

The Contractor’s Scope of Work for each CNG refuelling station shall consist of but not limited to the following:

Supply installation, testing and commissioning of Electrical system comprising of the following

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shall be from 415 V panel to station loads.c) 230 V, 1 Phase, 50 Hz, 3 kVA AC UPS.d) Sealed maintenance free (SMF) battery bank for 2 hours back up.e) UPS DB for the UPS loads.f) Earthing and lightning protection system.g) Outdoor & Indoor LED Lighting system.h) All power & control cablesi) Structural Steel, Cable trays, pipe/conduit and its accessories for cabling and miscellaneous items etc.j) Other Miscellaneous items as per Electrical BOQ

To facilitate proposed CNG station, 415V switch board shall be considered, incomer cable shall be from stateelectricity board power supply terminal point.

Any other work not specifically mentioned herein but required for the satisfactory completion / operation / safety/ statutory / maintenance of the works shall also be covered under the scope of work and has to be completed bythe Contractor within specified schedule at no extra cost to Owner.

4.0 CODES AND STANDARDS

The equipment offered and its installation shall comply with the latest issue of the relevant Indian Standards, IECand IEEE.

However, as a guideline, as applicable to gas service, following codes /standards shall be complied:

∑ IS:3043 Code of Practice for earthing.

∑ IS:2309 Code of Practice for the Protection of Buildings and Allied Structures against lightning.

∑ IS:9676 Reference ambient temperature for electrical equipment.

∑ IS:13234 Guide for short circuit calculations in three phase AC systems.

∑ IS:5572 Classification of hazardous areas having flammable gases and vapours for Electrical installations.

∑ IS:5571 Guide for selection of electrical equipment for hazardous area.

∑ IS:6665 Code of practice for Industrial Lighting.

∑ IS:3646 Code of practice for Interior Illumination.

∑ IS:13346 General requirements for electrical apparatus for explosive gas atmospheres.

∑ IS:13408 Code of practice for the selection, installation and maintenance of electrical apparatus for use inpotentially explosive atmospheres.

∑ IS:3716 Application guide for Insulation Coordination.

∑ IS:10118 Code of practice for selection, installation and maintenance for switchgear and control gear.

∑ IS:7689 Guide for Control of undesirable static electricity.

∑ IS:12360 Voltage bands for electrical installations including preferred voltages and frequencies.

∑ IS:3961 Recommended current ratings for cables.

∑ IS:7752 Guide for improvement of power factor consumer's installations.

∑ IS:1646 Code of practice for the fire safety of buildings –Electrical installation.

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∑ IS:325 Three phase induction motor specifications.

∑ IS:1554 Specification for PVC insulated heavy duty electrical cable

∑ IS:7098 Crosslinked polyethylene insulated PVC sheathed cables.

∑ IS:8623 Low Voltage Switchgear and Control gear Assembly.

∑ IS: 2705 Current Transformers

5.0 REGULATIONS

Offered electrical equipment / installation shall comply with requirements of the following rule /regulations as amended up to date:

a) Central Electricity Authority regulations 2010.

b) The Indian Electricity Act

c) The Indian Electricity Supply Act.

d) The Indian Factories Act.

e) The Petroleum Rules,

f) CCOE/ PESO

g) Any other State Regulations in force

h) PNGRB Guidelines

i) Oil Industry Safety Directorate

j) Director General of Mines Safety

k) American Petroleum Institute

l) Central Mines Research institute

The Contractor shall obtain the necessary clearance from the Electrical Inspector /Competent Authority forequipment supplied and installed. All necessary drawings, calculations, test certificates, etc. as required byElectrical Inspector /Competent Authority shall be furnished. Any modification/rectification as required by himshall be carried out free of cost. The fees required to be paid to the Electrical Inspector /Statutory Authority forinspection shall be borne by Owner on production of documentary evidence.

6.0 SITE CONDITIONS

The equipment shall be designed for the following site conditions.

ß Max / Min. Temperature - 50°C/ 0∞C

ß Design Temperature - 50 ∞C

ß Max/Min Region Relative Humidity- 100%/ 5%

ß Altitude above Sea level - Less than 1000 Meters

ß Atmospheric pollution - Tropicalized to withstand the site Conditions, dust, vapour etc.

ß Hazardous Area classification - Zone-1/Zone-2, Gas group IIA/ IIB for Plant, Temp. Class - T3

ß Control Room/ Electrical room/

Guard Room/ DG Area - Safe area

7.0 AREA CLASSIFICATION AND EQUIPMENT SELECTION

Area classification for the plant shall be done in accordance with Petroleum Rules/PNGRB Regulations andAPI500, IEC60079-10 & IS 5572. Following factors shall be considered for proper selection of electricalequipment for use in hazardous area:

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i) Area Classification i.e. Zone

ii) Gas Group IIA/IIB/IIC.

iii) Temperature Classification.

iv) Atmospheric Pollution.

The hazardous areas shall be classified as Zone 1 or 2 or 0 and shall be IIC for areas where hydrogen gas may bepresent and IIA/IIB for remainder of classified areas. Surface temperature classification for all equipment for usein hazardous areas shall not exceed 200 deg. C (T3 Class). All electrical equipment installed in hazardous areashall be selected as per IS5571 and IEC60079-10 and shall meet the requirement of relevant IS, IEC.

All electrical equipment for hazardous area shall be certified by CMRI/PESO or equivalent independent testingagency. All electrical equipment for hazardous area shall have the valid approval at the time of installation andcommissioning. Isolating devices for equipment located in hazardous areas shall switch all poles of the supplyincluding the neutral.

8.0 ELECTRICAL DESIGN PARAMETERS.

CNG station to be installed as a part of this project shall be designed and engineered in accordance with thestandards/codes referred in above section of this document.

Equipment shall be capable of meeting its rated output continuously at variation +/- 10% of system voltage atconsumer terminals coincident with -5% to +5% of system frequency.

Voltage depressions to 80% of system voltage at the switchgear during Motor starting shall have no detrimentaleffect on equipment operation.

415 Volt, 50Hz, 25kA/10kA, 3 phase-4 wire supply will be provided by Owner. However, Cable and its layingfrom State electricity board pole to PDB shall be in scope of Bidder. Individually, 1-ph load shall have 2 poleisolation provisions, 3-ph load shall have 3 pole isolation & 3-ph + N load shall have 4 pole isolation provisions.

The maximum voltage drops in various sections of the electrical system under steady state conditions at full loadshall be within the limits stated in the following:

a) Cable between PCC and MCC or auxiliary switchboard shall be 2%

b) Cable between MCC and Motors shall be 5%

c) Circuit between lighting panels and lighting points 4%

d) DCDB to Control Room 2 %

e) UPS outgoing circuit 2 %

f) Cable between Auxiliary Switchboard / LDB and Lighting Panel 1 to 1.5%

9.0 ENCLOSURE PROTECTION OF EQUIPMENT

9.1. Enclosure ProtectionThe electrical equipment installed outdoor shall have the following enclosure protection:

ß All equipment: IP 55 with vermin and Weatherproof

The equipment installed indoor shall have the following enclosure:

ß Switchboards: IP 52 and vermin proof type

ß UPS – IP 42

The above enclosure protection shall be in accordance with Indian Standard.

9.2. Safety enclosures in hazardous areasThe types of enclosures that shall be used in the plants are the following:

ß Flame proof (Ex-d)

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10.0 SYSTEM EARTHING

The earthing system shall conform to IS 732 and IS 3043. All non-current carrying metallic parts and enclosuresof electrical equipment and metallic structures used for mounting electrical equipment shall be effectivelybonded to earth throughout the terminal in accordance with IS 732, IS 3043 and IS 7689. All exposed conductiveparts of equipment; piping, and structural items shall be effectively bonded so as to prevent the accumulation ofstatic charge.

Resistance of the earth pit shall not be more than 1 Ohm as per Indian Standards.

∑ No. of earth pits shall be provided as per IS: 3043. All earthing materials shall be supplied as per TechnicalSpecification.

∑ 600 x 600 x 3 mm thick copper plate earth electrodes for UPS, RTU, Telecom, Instrument Control Panel,metering panel.

∑ 100 mm dia X 3000 mm (L) GI Pipe electrode for other.

∑ All equipment earthing· shall be carried out as per IS: 3043, Minimum size of earth conductor to be usedshall be as given below:

Equipment Conductor size

Main Grid & equipment such as main Electrical Distribution Board 50 X 6 mm GI Flat

Switch Socket DB, UPS, DB, Lighting DB 25 x 3 mm GI flat /16 sq. mm GI rope

Compressor 50 X 6 mm GI Flat

Pipe/cable racks, structure, fencing 25 x 3 mm GI flat

UPS, Telecom, RTU 25 x 3 mm Cu flat/10 Sq. mm Cu cable

Field Instruments 2.5 sq mm copper PVC Wire

Electronics Earthing Electrode shall be provided as per IS-3043.GI pipe electrodes for new stations will beprovided as per IS-3043 and as per site requirement.

A board of 250 X 250 mm, 3mm thick GI plate shall be provided adjacent to all earth pits. Board shall displayearth pit number, date of testing, test values & next due date, as per guideline of CEA.

11.0 LIGHTNING PROTECTION:

Design of lightning protection system for structures provided with lightning protection shall be as per IS 2309.

12.0 DC POWER SUPPLY

Any other instrument requiring 24 V DC power within this tender, shall drive from the 230 Volt AC UPS beingprovided as a part of the project.

13.0 EMERGENCY POWER SUPPLY

The emergency power supply shall be fed from existing Emergency panel through Diesel Generator. SLD to bereferred.

14.0 UNINTERRUPTED POWER SUPPLY (UPS).

Uninterrupted power supply system (minimum 3 kVA, 230V, AC, 1 Ph, N) along with Sealed maintenance freeVRLA battery banks, as per specification and datasheet, suitable for sufficient 2 hours backup time at full loadshall be provided for meeting critical loads.

Uninterrupted power supply system shall be provided, (as required) for meeting critical loads that cannotwithstand a momentary interruption in voltage (e.g. critical instrumentation, control etc.). Separate battery bankshall be provided for UPS system.

15.0 ELECTRICAL EQUIPMENT CLEARANCE

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The substation building shall be sized to maintain adequate clearances between equipment for ease ofmaintenance as per IS, IEC and IEEE standard.

16.0 CABLING SYSTEM

16.1. Cables

All cables shall be 1.1 kV grade XLPE insulated, extruded PVC inner sheathed, wire / flat armored, strandedannealed copper conductor FRLS PVC outer sheathed heavy-duty type. Cables shall be manufactured inaccordance with the IS:1554 Part-1/7098(Part -1) (0.6 /1.0 kV grade as per IEC). Where cables have to be routedunderground in the station (e.g. for final connection to motor), they shall be protected & sealed to prevent ingressof hydrocarbons.

Physical segregation shall be maintained between conductors carrying different voltage levels.

Cable ladder/tray covers shall be provided on cable ladders/trays exposed to direct sun to protect the cable outersheath from Ultra-Violet radiations. All the power and control cable which are going to be installed in theHazardous area shall be certified by competent authority. Each conductor shall be identified with separate colorsuch as Red, Yellow, Blue & Black. Vendor shall provide the valid manufacturers guarantee certificate.

a. Power Cable

∑ Stranded Annealed Copper Conductor up to & including 16 mm2.

∑ Stranded Aluminum Conductor from 25 mm2 and above

∑ XLPE insulation- Type A

∑ Inner and outer Sheath will be extruded

∑ Inner sheath shall be PVC ST2 type

∑ Steel strip/wire armoured.

∑ Outer sheath of cable will be FRLS PVC, ST2 Type

∑ Voltage grade- 1100 V

∑ IS 7098 Part 1

b. Control Cable

∑ Stranded Copper Conductor

∑ XLPE insulation- type A.

∑ Inner and outer Sheath will be extruded

∑ Inner sheath will be PVC ST2 type

∑ Steel strip/wire armoured

∑ Outer sheath of cable will be FRLS PVC, ST2 type

∑ Voltage grade - 1100 V

∑ IS-7098 Part I

16.2. Cable Sizing

Cables shall be heat and oil resistant and suitable for service in the maximum environmental conditionsdescribed for the Platforms/Terminal and can be expected at the respective locations. All nominal power cableratings shall be based on maximum ambient temperatures (design temperature) as specified under site conditions.De-rating factors shall be applied as necessary to take account of Installation configuration and variation inambient temperature. Conductor current ratings for distribution board feeders shall be established on the basis of125 % of the rated actual load current at the ambient temperature and de-rated for grouping and method ofinstallation. Cables for emergency duty equipment shall have fire performance characteristics to lEC 332-3Category A. Safety critical circuit cables, such as certain Fire and Gas and communication signals required to

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maintain integrity during a fire, shall be fire resistant type to the requirements of IEC 331. Control & Instrumentmulticore cables shall have 20% spare conductors(cores).

16.3. Cable Glands, Cable Accessories and Transit Frames

Each cable shall be provided with a number, which shall be tagged on the cable at regular intervals for easyidentification. The numbering scheme to be adopted for the cables, shall match with the existing cablenumbering philosophy. All cables shall be fitted with FLP double compression type cable glands. All cableglands and adopters shall be made of non-ferrous/non-corrosive material and shall be fitted with soft sealingnylon washers. Fiber washers shall not be used. Flameproof double compression cable glands and flameproofplugs shall be certified by competent authority.

17.0 LIGHTING SYSTEM

Plant lighting system shall comprise:

a) Normal Lighting

b) Emergency lighting

LED Lamps shall generally be used for outdoor plant lighting as well as for indoor area.

All outdoor lighting shall be automatically controlled by means of photo sensor with manual control.

The Lighting panels shall be provided with MCCB as incomer and miniature Circuits Breakers (MCBs + ELCB)for outgoing feeders control and protection of lighting circuits. MCBs shall not be loaded beyond 80% of ratedcapacity. A minimum of 25% of miniature circuit breakers of each board shall be left as spares.

17.1. Lux level in the plant area for calculation of lighting fixtures shall be as per below:

Lux level - As per IS-6665/OISD

Utilisation Factor - As per manufacturer’s catalogues.

Maintenance Factor - 0.6 for Outdoor / 0.7 for Indoor

Note: Illumination level of other areas not mentioned here shall be as per IS: 6665. Lighting design shall confirmto relevant International Codes and Standards, IES handbook and shall take into consideration the requirementsfrom point of view of safety and ease in operation and maintenance. Bidder shall submit illumination calculationto Owner/Owner’s Engineer for approval during detail engineering.

Wiring for lighting and convenience outlets in outdoor areas shall be carried out with XLPE armored cables runalong the column / platforms and structures. The armored cable shall enter lighting fixture / JB through doublecompression gland for safe area, Ex(e) or Ex(d) equipment and through flameproof glands for Ex(d) equipment.Where required suitable mechanical protection shall be provided for lighting fixtures (e.g. wire guard).

Two pole MCB shall be used for controlling fixtures in hazardous areas to isolate phase as well as neutral.

18.0 DISTRIBUTION BOARD

ß Power Distribution Board (PDB)/ LT Panel/ Emergency Panel with changeover switch

- Shall be Floor mounted, Stand-Alone type with cable alley and bus chamber- Shall have one incomer with suitably rated MCCB for PDB

- Shall have two incoming power sources (one from LT panel and other from DG with changeover

switch) with suitably rated MCCB for Emergency Panel.

- Shall have Outgoing feeders with suitably rated MCCB as per feeder requirement.

- Motor Feeder if any shall be selected as per Type 2 coordination chart

- Shall have spare feeders min 10% of each rating or one of each type, whichever is greater- Single Phase Load (If any) shall be equally distributed on each phase

ß Normal LDB for Outdoor lighting

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- Shall be floor/wall mounted, recessed type

- Shall have one incomer with suitably rated MCCB with RCCB (Residual Current Circuit Breaker), fedfrom LT Panel

- Shall have Outgoing feeders with suitably rated MCB as per feeder requirement for Indoor and Outdoor

lightings.

- Single Phase Load shall be equally distributed on each phase

- Photo sensor with manual for controlling

- Shall have spare feeders’ min 10% of each rating or one of each type, whichever is greater.ß Switchgear used for LV feeders shall incorporate the following protective devices:

a) Short Circuit

b) Overload

c) Earth fault

19.0 OTHER MISCELLANEOUS ITEMS

Remaining electrical items’ dimensions and other design parameters shall be considered as per BOQ andrelevant Codes & Standard.

20.0 ELECTRICAL EQUIPMENTS FOR HAZARDOUS AREA

Electrical Equipment’s

The Electrical equipment’s for hazardous areas shall be selected as per IS: 5571 and petroleum rules. Theminimum requirements are summarized below

Equipments Zone-1 Zone-2LV Induction Motors Ex-d Ex-dPush Button Stations Ex-d Ex-dMotor Starter Ex-d Ex-dPlug Sockets Ex-d Ex-dWelding Receptacles Ex-d Ex-dLighting Fixtures, Lighting Fitting,Control gear

Ex-d Ex-d

Hand Lampsi) Light Fittingii) Transformer Unit iii) Plug &socket

Ex-d Ex-d

Lighting Panels / PowerPanels

Ex-d Ex-d

Break Glass Units (FireAlarm System)

Ex-d Ex-d

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PTS – CABLE ANDACCESSORIES P.015682-G-11077-E051


CONSTRUCTION OF CNG STATION – ELECTRICAL WORKS

PTS – CABLE AND ACCESSORIES



Rev. Date Subject of Revision Prepared By Checked By Approved By

23 of 246


Rev-0 Construction of CNG Stations – Electrical Works Page 1 of 5

TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................................. 2

2.0 STANDARDS .................................................................................................................................. 2

3.0 GENERAL CONSTRUCTION ......................................................................................................... 2

4.0 TESTING AND INSPECTION ......................................................................................................... 3

5.0 PACKING AND MARKING ........................................................................................................... 5

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1.0 SCOPE

This specification covers the requirements for design, engineering, manufacturing, testing atmanufacturer works, properly packing, transportation and the supply of XLPE insulated power &control cables and cable accessories at site.

2.0 STANDARDS

The cables and its associated materials/parts shall be designed, manufactured & tested conforming tolatest editions of the applicable Indian Standards, including the below mentioned standards:

IS: 1554 - PVC insulated (heavy duty) electric cables

IS: 5831 - PVC insulation and sheath of electric cables

IS: 7098 - Cross-linked Polyethylene insulated PVC sheathed cables

IS: 8130 - Conductors for insulated electric cables and flexible

IEC: 60227 - PVC Insulated Electrical Cables

IEC: 60502 - Extruded solid dielectric insulated power cables for rated voltages from

1 kV up to 30 kV

IEC: 60885 - Electric Test methods for Electrical Cables

3.0 GENERAL CONSTRUCTION

These cables shall be suitable for laying in trays, trenches, ducts, conduits and underground buriedinstallation with uncontrolled backfill and possibility of flooding by water. Extra PVC/Rubber endcaps for each XLPE Cable size shall be supplied. The terminating and straight through joint kits forthe cables shall be suitable for the type of cables offered and for storage without deterioration up to50 Deg. C ambient temperature. All the cables shall be of improved fire performance type suitable forCategory C2 (Appendix A of IS 7098 Part-I Reaffirmed 2005). Outer PVC sheath of cables shall be flameretardant type conforming to category AF as per IS:10810.

3.1. CABLES

3.1.1. Cables shall be suitable for use with conductor temperature rise up to 90 degree Celsius undernormal operation and 250 degree Celsius under short circuit condition.

3.1.2. All the power cables of 25 sq. mm. and above shall be of aluminium and power cables up to 16 sq.mm. shall be of copper.

3.1.3. Power cables shall be with XLPE insulated, PVC inner sheathed, armoured and overall FRLS PVCsheathed.

3.1.4. The construction of the conductors shall be stranded and compacted circular for all cables.

3.1.5. The power cables with voltage grade 3.3 kV and above, shall be provided with both conductorscreening and insulation screening. The conductors shall be provided with non-metallic extrudedsemi-conducting shielding.

3.1.6. The core insulation shall be with cross-linked polyethylene unfilled insulating compound. It shall befree from void and shall withstand all mechanical and thermal stresses under steady state andtransient operating conditions.

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3.1.7. The insulation shielding shall consist of non-metallic extruded semi-conducting compound incombination with a non-magnetic metallic screening of copper. The insulation screen shall bestrippable without application of heat. The copper screen shall be capable of carrying the single lineto ground fault current of 1 kA for a duration of one (1) second.

3.1.8. The conductor screen and insulation screen along with insulation and sheath shall all be extruded inone operation by “Triple Extrusion” process to ensure perfect bonding between the layers. The coreidentification shall be coloured strips or by printed numerals.

3.1.9. The inner sheath shall be applied over the laid-up cores by extrusion and shall conform to therequirements of Type ST2 compound of IS:5831. The extruded inner sheath shall be of uniformthickness of size not less than 0.7 mm for all sizes of cables.

3.1.10. For multicore cables, the armouring shall be by galvanized steel strips armouring whereas for singlecore cables, armouring shall be done with hard-down aluminium round wire.

3.1.11. The outer sheath for the cables shall be made by extrusion over the armouring and shall be of PVCcompound confirming to the requirements of Type ST2 compound of IS: 5831. To protect cableagainst rodent and termite attack, suitable chemicals shall be added into the PVC compound of theouter sheath.

3.1.12. All cables shall be designed to have minimum Oxygen index of 29 at 27 + 2 degree Celsius and minimumtemperature index of 21 at a temperature of 250 degree Celsius & maximum smoke density of 60% as perASTM D2863. The cables shall have a low smoke property and the minimum average value of lighttransmittance shall be 60% as per ASTM D2843.

3.1.13. All cable shall be marked with manufacturer’s name, year of manufacturer, conductor cross section, typeof insulation, type of sheathing material at each meter length of the cable.

3.2. CABLE ACCESSORIES

The termination kit and straight through joint kits shall be suitable for the type of cables offered asper this specification. The termination and joints shall be supplied in kit form. The kit shallinclude all insulating and sealing materials apart from conductor fitting and consumable items. Aninstallation instruction shall also be included in each kit. For low voltage system, separate doublecompression brass glands and copper/aluminium lugs shall be provided.

4.0 TESTING AND INSPECTION

The cables shall be tested and examined at the manufacturer’s works. All the materials employedin the manufacture of the cable shall be subjected, both before and after manufacture of the cable,to examination, testing and approval by Owner/Owner’s Representative. Manufacturer shallfurnish all necessary information concerning the supply to Owner/Owner’s Representative. TheOwner’s Representative shall have free access to the manufacturer’s works for the purpose ofinspecting the process of manufacture in all its stages and he will have the power to reject anywire or other material which appears to him to be of unsuitable description or of unsatisfactoryquality.

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4.1. Cables

4.1.1. After completion of manufacture of cables and prior to dispatch, cables shall be subjected to type,routine, acceptance and special tests as detailed below. Owner/Owner’s Representative reserves theright to witness all tests with sufficient advance notice from Bidder. The test reports for all cablesshall be got approved from the Owner’s Representative before dispatch of the cables.

4.1.2. The following tests shall be carried out on XLPE cables as per IS:7098.

4.1.3. Type Tests

The following shall constitute type tests:

a) Tensile testb) Wrapping testc) Conductor resistance testd) Test for armour wirese) Test for thickness of insulation and sheathf) Physical tests for insulationg) Physical tests for PVC sheath:h) Partial discharge testi) Bending testsj) Heating cycle testk) High voltage testsl) Insulation Resistance (Volume Resistivity) Testm) Dimensional Check

4.1.4. Acceptance Tests

a) Tensile test (for aluminium)b) Wrapping test (for aluminium)c) Conductor resistance testd) Test for thickness of insulation and sheathe) Partial discharge testf) High voltage testg) FRLS test

4.1.5. Routine Tests

a) Conductor resistance testb) Partial discharge test

c) High voltage test

4.2. Cable Accessories

Type tests shall have to be carried out to prove the general qualities and design of a given type oftermination/jointing system. The type test shall be conforming to the latest IEC:502-2, 466specifications.

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5.0 PACKING AND MARKING

Cables shall be dispatched in wooden drum of suitable barrel diameter, securely battened, with thetake-off end fully protected against mechanical damage. The wood used for construction of the drumshall be properly seasoned, sound and free from defects. Wood preservatives shall be applied to theentire drum.

On the flange of the drum necessary information such as manufacturer’s name, type size voltagegrade of cable, length of cable in meters, drum no. cable code, ISI Certification mark, gross weightetc. shall be printed. An arrow shall be printed on the drum with suitable instruction to show thedirection of rotation of the drum.

Permissible Drum Tolerance shall be +/-5% of standard drum length.

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PTS – LOW VOLTAGEDISTRIBUTION BOARDS P.015682-G-11077-E052


CONSTRUCTION OF CNG STATION-ELECTRICAL WORKS

PTS – LOW VOLTAGE DISTRIBUTION BOARDS



Rev. Date Description Prepared By Checked By Approved By

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Rev-0 Construction of CNG Station- Electrical works

TABLE OF CONTENTS

1.0 SCOPE ................................................................................................................................ 12.0 REFERENCE STANDARDS ................................................................................................... 13.0 AMBIENT CONDITIONS ...................................................................................................... 14.0 SYSTEM DETAILS ............................................................................................................... 25.0 DESIGN & CONSTRUCTIONAL FEATURES .......................................................................... 26.0 COMPONENT DETAILS ....................................................................................................... 67.0 ACCESSORIES .................................................................................................................. 108.0 PAINTING......................................................................................................................... 119.0 TESTS AND INSPECTION ................................................................................................. 1110.0 DRAWINGS AND DOCUMENT ........................................................................................... 1111.0 SPARES ............................................................................................................................ 1112.0 PACKING .......................................................................................................................... 1213.0 DEVIATIONS .................................................................................................................... 12

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1.0 SCOPE

Scope of work includes design, engineering, manufacturing, testing at manufacturer’s works, properlypacked for transportation, supply at site, installation, testing, commissioning and putting into successfulcommercial operation of low voltage distribution board.

2.0 REFERENCE STANDARDS

2.1. The design, manufacture and testing of the equipment shall comply with the latest issue of thefollowing Indian/International standards, unless otherwise specified:

∑ IEC 61439 : Low voltage switchgear & controlgear assemblies

∑ IEC 61869 : Instrument transformers

∑ IEC 60051 : Direct acting indicating analogue electrical measuringinstruments and their accessories.

∑ IEC 60255 : Electrical relays.

∑ IEC 60417 : Graphical symbols for use on equipment.

∑ IEC 60529 : Degrees of protection provided by enclosures. (IP Code)

∑ IEC 60688 : Electrical measuring transducers for converting AC andDC electrical quantities to analogue or digitalsignals.

∑ IEC 60715 : Dimensions of low-voltage switchgear and control gear.Standardized mounting on rails for mechanical support ofelectrical devices in switchgear and control gearinstallations

∑ IEC 60947 : Low-voltage switchgear and control gear.

∑ IEC 61000-4 : Electromagnetic Compatibility (EMC).

∑ IS 8623 : Low Voltage switchgear and control gear assemblies∑ IS 13947 : Low Voltage switchgear and control gear assemblies.

∑ IS 10118 : Code of practice for selection, installation andmaintenance of switchgear and control gear

2.2. The design and operational features of the equipment offered shall also comply with the provisionsof the latest issue of the Indian Electricity Rules and other Statutory Acts and Regulations. thesupplier shall, wherever necessary, make suitable modifications in the equipment to comply withthe above.

2.3. Wherever any requirement, laid down in this standard, differs from that in Indian StandardSpecification the requirement specified herein shall prevail.

3.0 AMBIENT CONDITIONS

Max/Min. Region Temperature - 50∞C / 0∞C

Max/Min. Design Temperature - 50∞C / 0∞C

Max/Min Region Relative Humidity - 100% / 5%

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Altitude above MSL- : Less than 1000 m

Atmosphere- : Tropicalized to withstand the site condition,

dust & Vapor

Location- : Indoor

4.0 SYSTEM DETAILS

The distribution board shall be suitable for operating at the specified rating continuously withthe specified voltage and frequency variations under the ambient conditions indicated inSpecification Sheet, without exceeding the permissible temperature rise and without anydetrimental effect on any part.

Voltage with ±% 415 V ± 10%Frequency with ±% 50 Hz ± 5%No. of phase & wire 3P + 1NFault level 25kA for 1 secEarthing mode Solidly EarthedControl supply & Auxiliary supply 230 V

If any other Voltage required, same shall bederived internally, by manufacturer. EPCshall take care the same during detailengineering

5.0 DESIGN & CONSTRUCTIONAL FEATURES

5.1. GENERAL

5.1.1. The distribution board shall consist of an assembly of a series of floor mounting, identical,metal clad, dead front type panels. The panels shall be placed side by side to form a compactassembly and shall be extensible on either side.

5.1.2. The complete assembly shall be dust, damp and vermin proof having minimum degree ofprotection equivalent to IP-52 as per IS:13947.

5.1.3. The framework of the cubicles shall be of bolted/welded construction. The minimum thicknessof steel shall be 2 mm for load bearing members, 1.6 mm for non-load bearing members and 3mm for base channel. The doors and covers shall be fabricated from cold rolled sheet steel.Suitable reinforcement, wherever necessary, shall be provided.

5.1.4. The door hinges shall be concealed type.

5.1.5. All external hardware shall be cadmium plated/zinc passivated. The hardware for fixing theremovable parts shall be provided with retaining devices.

5.1.6. The doors and the removable covers shall be provided with non-deteriorating neoprene gaskets.Gaskets without any discontinuity shall be preferred. Gaskets shall be held in position ingroove of shaped sheet steel work or these shall be of U type. Adhesive material, if used, shallbe of good quality so that the gasket do not come off during service.

5.1.7. All the components shall be accessible for inspection and maintenance without the necessityfor removal of the adjacent ones. In case of single front design all components shall be

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accessible from the front for maintenance and back opening doors/openable covers formaintenance shall not be acceptable.

5.1.8. The layout of the components inside a module shall be liberal to facilitate maintenance and theinterconnection of wiring between the components shall not be subjected to any undue stress atthe bends.

5.1.9. Mounting height of components requiring operation and observation shall not be lower than300 mm and higher than 1800 mm.

5.1.10. Inter panel barriers shall be provided.

5.1.11. Adequate arrangement for earthing shall be provided to safeguard the operator or otherpersonnel from electric hazards under all conditions of operation.

5.2. PANEL ARRANGEMENT

5.2.1. The distribution board shall be drawout/non-drawout type in single front/double frontconfiguration as specified in data Sheet.

5.2.2. Each Panel shall have its horizontal bus-bar chamber running on the top with multi-tier moduleunits in the centre and having vertical bus-bar chamber and cable alley on either side.

5.2.3. The modules shall be enclosed on all sides and shall be so arranged that larger ones are placedat the bottom portion of the panel. Fixed type modules shall be at least 300 mm from the basechannel.

5.2.4. The number of modules in the panel shall not exceed six for motor starter feeders and eight forswitch fuse/MCB/MCCB feeders. The minimum size of module shall be 300 mm and 200 mmfor starter and switch fuse feeders. The incomer and bus coupler module sizes for ratings upto400 A shall be half the panel size. For higher ratings they shall be housed in single panel.

5.2.5. The module door shall be so interlocked that it shall not be possible to open the door withswitch/MCCB in closed position. Defeat interlock facility shall be provided.

5.2.6. The relay, meters, switches/MCCB and lamps shall be flush mounted. All components of onemodule shall be mounted on the same module on a rigid sheet steel chassis. A 20 mm diarotating knob on the door shall be provided for closing and opening.

5.3. BUS BARS AND CONNECTIONS

5.3.1. The bus-bar shall be suitable for the supply system specified in the Specification Sheet. Thebus-bar and connections shall be made of electrolytic copper or high conductivity aluminiumalloy conforming to Grade E91E of IS:5082.

5.3.2. The bus-bar shall be amply sized to carry the rated continuous current under the specifiedambient temperature without exceeding the temperature of 90oC. The bus-bars shall also bedesigned to withstand the system fault current for 1 second without exceeding the permissibletemperature rise. The minimum acceptable size of bus-bars shall be 250 Sq.mm (Al).Calculation for the bus-bar sizing shall be furnished for review.

5.3.3. In case of double front arrangement of distribution boards different sets of vertical bus-bars

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shall be provided. The vertical bus-bars shall be PVC sleeved or shrouded by insulatingbarriers which shall have cutouts to permit entry of power wires. It shall be possible to removethe shroud for inspection and maintenance. Neutral-bars shall be provided in this chamber.

5.3.4. Horizontal bus-bars shall be of same cross-section through out. Stepped bus-bars shall not beacceptable.

5.3.5. All bus-bars shall be arranged and colour coded according to IS:5578/11353.

5.3.6. The horizontal bus-bar shall run in a separate bus chamber located at the top shall haveseparate screwed cover for inspection purpose.

5.3.7. The bus-bars shall be rigidly supported at equal intervals to withstand maximum short circuitstresses. The supports shall be of moulded construction with built-in anti tracking barriers. Thesupport material shall be of fibre glass reinforced thermosetting plastic.

5.3.8. All joints shall be suitably treated to avoid oxidation of contact surfaces and bimetalliccorrosion. A minimum of two bolts with spring washers shall be used for horizontal bus-barjoints.

5.3.9. Horizontal bus bars shall be insulated with heat shrinkable PVC sleeves of reputed makes.Insulating shrouds shall be provided for all joints of insulated bus-bars.

5.4. CLEARANCE AND CREEPAGE DISTANCES

5.4.1. The clearance and creepage distances shall not be lower than the values specified below:

i) Minimum clearance between two live conductors -- 25 mm

ii) Minimum clearance between live part and accidentally -- 25 mm

dangerous part

iii) Minimum creepage distance -- 28 mm

5.4.2. The clearances and the creepage, as specified above, shall definitely be maintained in the bus-bar system. Provision of bus-bar insulations, separator or barriers shall not be considered toreduce the clearance from the values specified above.

5.4.3. At the termination points in the equipment, e.g. MCCB, switches, contactors, thermal relays,etc. it is realized that above clearance may not always be possible to be maintained. All suchpoints where above clearance are not possible to be maintained should, therefore, be insulatedor taped.

5.5. INSULATION

5.5.1. The insulation used shall be non-hygroscopic and may be of porcelain, Epoxy-resins or fibreglass moulded with plastic. It shall be of adequate electrical and mechanical strength to givetrouble free service during normal operation and short circuit conditions.

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5.5.2. The insulation shall be treated suitably to withstand the tropical conditions and atmosphericpollution as specified in Specification Sheet.

5.6. POWER WIRING

5.6.1. The connections from bus-bar including neutral to individual units on the modules shall consistof PVC insulated flexible copper cable or tapped copper strip.

5.6.2. The power wiring size shall be decided based on the rating of the switch, MCCB after using arating factor of not more than 50% over the current rating in free air. In any case the minimumsize of power wiring shall not be less than 4 Sq.mm copper.

5.6.3. The size of connection from incomer to horizontal bus-bar and from horizontal bus-bar to buscoupler shall not be less than the size adopted for horizontal bus-bar.

5.7. CONTROL WIRING

5.7.1. The switch board shall be completely factory wired and ready for external connections.

5.7.2. The wiring shall be carried out with flexible stranded PVC insulated copper conductor cablesof 1100 Volt grade. The size of wires shall be as follows:

C.T. Circuit -- 2.5 Sq.mm

V.T. and Control Circuits -- 1.5 Sq.mm

5.7.3. All wiring shall be provided with dependent both end marking as per IS:5578. Numberedferrules, reading from the terminals outwards, shall be provided at both ends of all wiring foreasy identification. These shall be interlocking type plastic ferrules.

5.7.4. Control wiring circuits, fed from a supply common to a number of feeders, shall be soprotected that failure of a circuit in one feeder does not affect the operation of the other feeders.

5.7.5. The wiring to the equipment mounted on the doors shall be carried out with flexible multistrand copper conductor cable and supported so that opening of the door, there is no unduestrain on wire leads.

5.7.6. The control cables shall be neatly arranged and properly supported.

5.8. EXTERNAL CABLE TERMINATION

5.8.1. All power and control cables shall enter the distribution board from the bottom unlessotherwise specified in data sheet. Sufficient space shall be provided for ease of connection andtermination of cables.

5.8.2. All cables shall be of 1.1 KV grade XLPE insulated armoured and FRLS PVC sheathed. Thenumber and sizes of cable shall be as indicated in Feeder details.

5.8.3. Compression type cable glands along with the cable lugs as required and shall be provided fortermination of cables.

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5.8.4. The cable glands shall be of rolled Aluminium or Nickel/Cadmium plated brass heavy dutydouble compression type and shall be mounted on a removable gland plate, provided at aminimum height of 75 mm from the bottom of the distribution board. Two numbers spareknockouts of size 20 mm shall also be provided on the gland plates for future use.

5.8.5. For all power cables crimped type aluminium lugs for aluminium cables and tinned copper lugsfor copper cables shall be provided.

5.8.6. Terminal Block for control cable are pressure clip type and Terminal Block for power cablesare bolted type. These shall be protected type and rated for 1100 Volts service. The minimumcurrent rating of terminal block shall be 16 Amp. The construction shall be such that after theconnection of cables by means of lugs, necessary clearance and creepage distance are available.

5.8.7. Where more than two cables in parallel are required to be terminated, a system of bus linksshall be provided with adequate clearance and spacing.

5.8.8. Suitable clamps to support the vertical run of cables shall be provided.

5.8.9. The terminal block shall be grouped according to circuit functions and suitably numbered. 20%extra terminals shall be provided in the terminal block.

5.8.10. For power connections, suitable marking on the terminals shall be provided to identify thephases.

5.9. FEEDER DETAILS

5.9.1. The requirements of incomer, bus coupler and outgoing feeders shall be as indicated in thesingle line diagram, feeder details and corresponding schematic diagram.

5.9.2. The bus coupler shall be so located that it is possible to maintain half of the bus-bars while theother half is still alive. Complete segregation of bus-bar connections to bus coupler shall beprovided.

5.9.3. Castle key type mechanical interlocks shall be provided between incomers and bus sectionmodules to avoid paralleling of incomers. In addition padlocking facilities shall be provided inOFF position.

5.9.4. Single phase loads shall be distributed as far as possible on all the three phases.

5.9.5. Suitable rated 415 V class surge arrestor shall be provided at the incomer of the electricaldistribution board.

6.0 COMPONENT DETAILS

The make of the components shall be as specified in the submitted data sheet and shall conformto type of coordination C as per IS:13947.

6.1. MOULDED CASE CIRCUIT BREAKERS

6.1.1. The MCCB shall conform to IS:13947 (Part 2) and shall having rupturing capacity as specifiedin data sheet.

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6.1.2. The MCCB shall be provided with quick make, quick break type manually operated trip freemechanism, thermal tripping devices of inverse characteristics, instantaneous short circuittripping devices, earth fault detection and instantaneous tripping devices due to earth fault,necessary auxiliary and alarm switches.

6.1.3. The thermal and short circuit tripping device shall be adjustable type.

6.1.4. In addition, under voltage trip shall be provided, if specified.

6.2. AIR BREAK CONTACTORS

6.2.1. The Air break Contactor shall be of AC3 category unless otherwise specified, conforming toIS:13947 (Part-4).

6.2.2. The dropout voltage shall not exceed 65% of rated voltage.

6.2.3. Each contactor shall be provided with auxiliary contacts as required. The rating of the auxiliarycontacts shall be 5 Amps. AC or 2 Amp. DC at the specified control voltages. The spareauxiliary contacts shall also be wired terminal block.

6.3. BIMETAL THERMAL OVERLOAD RELAYS

6.3.1. The contactor shall be provided with three pole bimetal thermal overload relays unlessotherwise specified. The bimetal relays shall be of suitable range, ambient temperaturecompensated and shall be separate mounting type. They shall be adjustable through graduatedscale and shall be provided with changeover contact.

6.3.2. Bimetal relays shall conform to IS:3231 and shall have built in single phasing preventor.

6.3.3. The bimetal relays shall be provided with a manual reset device resettable after opening thecubicle door. Auto reset thermal relays are not acceptable.

6.4. CURRENT TRANSFORMERS

6.4.1. The current transformers shall conform to IS:2705.

6.4.2. Current Transformers shall be cast resin. The Current Transformers shall be rigidly mountedand shall be easily accessible for maintenance and testing.

6.4.3. The Current Transformers shall be of min. 5 VA output or as specified in SLD/Data Sheet. Theoutput shall be adequate for the instrument and metering duties involved with sufficientmargin. The Current Transformers shall have the accuracy Class-1 for the metering duty.

6.4.4. All the Current Transformers shall be provided with terminals and shorting links. One of theterminals of C.T. shall be earthed. The polarity of the C.T. shall be clearly marked.

6.4.5. The C.T.s shall be capable of withstanding momentary open-circuit on the secondary sidewithout injurious effects.

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6.5. INSTRUMENTS AND METERS

6.5.1. All instruments shall be flush mounting type with square face and shall be tropicalized and dusttight.

6.5.2. The size of the instruments shall be 96 mm x 96 mm for full and half size modules and 72 mmx 72 mm for lower size modules.

6.5.3. Dials shall be parallax free with scale marked in black on white background and shall besuitable for direct reading.

6.5.4. Zero adjusters shall be provided for operation from the front of the cases.

6.5.5. All ammeters and voltmeters shall have 0 – 90o scale moving iron spring controlled type and ofClass 1.0 accuracy as per IS:1248 or digital type. The scale range of the ammeter and voltmetershall be as indicated in the feeder details.

6.5.6. In case of motor feeders, the ammeter shall be graduated uniformly upto C.T. primary currentand with a compressed end scale upto 6 times the C.T. primary current. Red pointer shall beprovided, which can be adjusted at site for indicating full load current.

6.5.7. KWH meter shall be 3 phase 4 wire type. These shall conform to the requirements of IS:722and shall be C.T. operated. The current coil shall be rated for 1/5 Amp.

6.5.8. All kWh meters shall be provided with test blocks for current and voltage coils for testing themat site without interrupting their recording while in service.

6.5.9. All numerical multifunction relay shall be communicable type and RS 485 port shall beprovided for serial communication.

6.6. PUSH BUTTON AND CONTROL SWITCHES

6.6.1. The switches and push buttons shall conform to utilization category AC 11 / DC 11 as perIS:13947 (Part- 5). The contact shall be rated to make, break and carry inductive current of 5Amp. At 415 V AC and 1 Amp at 220 V DC.

6.6.2. The control switches shall be spring return rotary type unless otherwise specified and providedwith pistol grip type handle. The control switches for circuit breakers shall be additionallyfitted with lost motion devices and sequencing devices.

6.6.3. The selector switches shall be stay-put rotary type and provided with oval shape handles.

6.6.4. The push buttons shall be of momentary contact spring loaded type with a set of normally closeand open contacts. The push button for ‘Start’ shall be shrouded type and coloured green, stoppush button shall be enshrouded type and coloured red and other push buttons shall beenshrouded type coloured black. The fixing ring shall be metallic white.

6.6.5. Emergency stop push buttons, if specified, shall be lockable in pushed position.

6.7. MINIATURE CIRCUIT BREAKERS

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6.7.1. The miniature circuit breakers shall conform to IS:13032 and shall be of duty category M-9.

6.7.2. It shall be provided with overload and short circuit protective devices in a heat resistanthousing.

6.7.3. A certificate of short circuit rating and current time tripping curve shall be furnished along withthe offer.

6.7.4. MCB feeders shall be derived. In this regard, supplier shall use current limiting MCCB at incomerto these MCBs, to limit the fault current 10 kA and subsequently MCB shall be 10kA rating

6.8. SIGNAL LAMPS

6.8.1. Signal lamps shall be provided to indicate the various circuit conditions as shown in schemedrawings. The colour of the lamps for various functions shall be as follows:

Red -- Switch/Contactor closed.

Green -- Switch/Contactor open.

6.8.2. The lamps shall be LED type having lumen output 200 milli-candella in axial direction.

6.8.3. It shall be possible to remove the globe from outside for replacement of lamps.

6.9. CIRCUIT BREAKER

6.9.1. The circuit breakers shall be of air break and of horizontal drawout construction, with 3 polesand isolable bolted neutral link.

6.9.2. Circuit breakers may be hand operated or power operated as called for in the data sheets. Theclosing mechanism of the circuit breakers shall be of one of the following types:

1. Hand operated, spring charged, independent manual type.2. Motor wound, spring charged with a provision of manual charging

6.9.3. The operating mechanism shall be mechanically and electrically trip-free and non-pumping.Anti-pumping feature may be built in or a separate anti-pumping relay may be provided. Amechanical closing device may be provided, if feasible.

6.9.4. A mechanical trip device suitable for front of board operation and a mechanical ‘ON-OFF’indicator shall be provided. Trip device should be shrouded to prevent inadvertent maloperation.

6.9.5. A series or shunt trip coil, as called for in the data sheets shall be provided for tripping thecircuit breakers. Wattage of shunt trip coils will be sufficiently high to prevent it from pickingup or holding on with specified number of indicating lights wired in series with the same.

6.9.6. Provision shall be made for remote closing and tripping of the circuit breakers, with electricallyoperated mechanism. A ‘local/remote’ selector switch shall also be provided wherever calledfor in the data sheets.

6.9.7. A maintenance closing device for slow closing and slow opening of circuit breakers shall also

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be provided, if feasible.

6.9.8. In case of spring charged mechanism, ‘Spring Charged’ indication (mechanical) shall beprovided.

6.9.9. Interlock shall be provided to prevent plugging in or withdrawal of circuit breaker trolleyunless it is open. Any attempt to do so shall trips the circuit breaker.

6.9.10. Interlock to prevent closing of circuit breaker, unless it is in ‘SERVICE’ or ‘TEST’ position,shall be provided.

6.9.11. Main contacts shall have ample area and adequate contact pressure to carry the rated and shorttime current without excessive temperature rise. The contacts shall be adjustable for wear andeasily replaceable. Main contacts shall open before and close after the arcing contacts, whenthese are provided. Arcing contacts shall be easily accessible for inspection and replacement.

6.9.12. The tips of main and arcing contacts shall be silver plated or shall be of suitable material, tominimize erosion of contacts due to arcing.

6.9.13. Auxiliary switches directly operated by the breaker mechanism shall be provided for controland interlocks. A minimum of six normally open and six normally closed contacts shall beprovided. The contacts shall be preferably convertible from NO to NC and vice versa. Thecontacts shall also be capable of adjustments to enable early closing or delayed opening withreference to breaker main contacts. The contacts shall be rated for 10 Amp. at 240V A.C. /D.C. All spare contacts shall be wired upto terminal block. Auxiliary contacts in the “trip”circuit shall close before the breaker main contacts close and shall open after the main contactshave opened. All other contacts shall operate simultaneously with the main contacts.

7.0 ACCESSORIES

7.1. SPACE HEATER

Each vertical section shall be provided with a thermostatically controlled space heater, rated for240 V, 50 Hz and controlled through double pole miniature circuit breaker.

7.2. NAME PLATES

7.2.1. The distribution board shall have large name plate. Each double front panel shall have nameplate both in front and back.

7.2.2. Each feeder shall be provided with name plate.

7.2.3. All control switches, push buttons, lamps, etc. shall have functional identification labels.

7.2.4. Name plate shall be of black lamicoid with white engraving text and of minimum 3 mm thick.

7.2.5. Any other accessories required, but not specified shall also be supplied to make the distributionboard complete in all respects to ensure safe and proper operation.

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8.0 PAINTING

8.1. The enclosure after degreasing, pickling in acid, cold rinsing phosphatising, passivating etc.shall be painted with two coats of anti-rust paint followed by two coats of anticorrosive paint.

8.2. Epoxy based paint shall be used, if not indicated otherwise in data sheet.

8.3. All paints shall be carefully selected to withstand tropical heat and extremes of weather. Thepaint shall not scale off, crinkle or be removed by abrasion due to normal handling.

8.4. Unless otherwise specified, the finishing shade shall be RAL 7032.

8.5. One litre of paint shall be supplied along with each board for touch up at site.

9.0 TESTS AND INSPECTION

9.1. The distribution board shall be subjected to routine test as per IEC 61439. Type test certificates ofnot more than 10 years old, shall be submitted for all type tests as specified in IEC 61439.

9.2. Additional tests, wherever specified, shall be carried out.

9.3. All the above tests shall be carried out in presence of purchaser’s representative. In addition, theequipment shall be subjected to stage inspection during process of manufacture at works and siteinspection.

9.4. These inspection shall however, not absolve the vendor from his responsibility for making goodany defect which may be noticed subsequently.

10.0 DRAWINGS AND DOCUMENT

10.1. All required drawings and document shall be submitted to owner/Owner’s representative forreview and approval. After getting approval of the same, contractor will start manufacturing of thepanel. Detailed single line diagram showing all protection and metering, schematic drawing ofeach type of feeder, general arrangement drawing with clear legend of each panel are theminimum requirement.

10.2. All drawings and documents shall have the following description written boldly:

-- Name of client

-- Name of Consultant

-- Enquiry / Order Number with Plant/Project Name.

-- Code No. and Description.

11.0 SPARES

11.1. Item wise unit prices for spare parts as listed in Annexure-I shall be offered along with mainequipment with recommended quantity for the period as stipulated in Specification Sheet.

11.2. Any other spare parts required, but not specified, shall also be offered.

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12.0 PACKING

12.1. The distribution board shall be properly packed before dispatch to avoid damage duringtransport, storage and handling.

12.2. The packing box shall contain a copy of the installation, operation and maintenance manual.

12.3. A sign to indicate the upright position of the panels to be placed during transport and storageshall be clearly marked. Also, proper arrangement shall be provided to handle the equipment.

13.0 DEVIATIONS

Deviations, if any, f

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