TECHNICAL SPECIFICATION

FOR
2 X 1010 KVA, 1500 RPM, 415 V DG SETS

INDEX
S. NO.

SECTION

SUB HEAD

PAGE
NO.

SECTION - I

GENERAL SITE CONDITION

SECTION - II

SCOPE OF WORK

SECTION - III

TECHNICAL SPECIFICATION - DG SETS

SECTION - IV

12

SECTION - V

SECTION - VI

SECTION - VII

SECTION - VIII

GUARANTEED TECHNICAL PARTICULARS

- DIESEL ENGINE & ALTERNATOR
TECHNICAL SPECIFICATION - FOR DG
AUXILIARY PANEL
GUARANTEED TECHNICAL PARTICULARS
FOR DG AUXILIARY PANEL
TECHNICAL SPECIFICATION - FOR L.T. BUS
DUCT
LIST OF APPROVED MAKES

SECTION - IX

DRAWINGS

34

15
22
25
32

SECTION I

GENERAL SITE CONDITIONS

1.0

SITE CONDITIONS
-

Maximum Ambient temperature

Minimum Ambient temperature
Maximum Relative Humidity
Minimum Relative Humidity
Altitude above mean sea level

:
:
:
:
:

45 0C
9 0C
97%
30%
1000 mtr

IMPORTANT :
ALL MAJOR EQUIPMENTS LIKE ENGINE AND ALTERNATOR SHALL BE DESIGNED FOR
OPERATING TEMPERATURE OF 500C FOR ALL PRACTICAL PURPOSES. BIDDERS TO FURNISH
THE DERATION CALCULATION AT SITE CONDITIONS MENTIONED ABOVE IN VIEW OF THE
SUPPORT FOR THE CAPACITY/SUITABILITY OF THE EQUIPMENTS OFFERED. PLEASE NOTE
THAT OFFERS OF THE BIDDERS NOT SUBMITTING THE AFORESAID CALCULATIONS, SHALL NOT
BE CONSIDERED.

SECTION II

SCOPE OF WORK

GENERAL: Design, manufacturing, testing, supply, erection & commissioning of Emergency Generating
Set for prime power output of 1010 KVA at 1500 RPM, 415V + 5%, 3 Phase ,0.8 pf (lag) &
500 C ambient with complete accessories.

3.0

SCOPE OF WORK INCLUDED IN THE CONTRACT :

The scope of work in this tender shall include (but not limited to) Design, Manufacture,
supply, inspection before dispatch, delivery at site, installation, testing, commissioning &
handing over to CDRI the following :
a.
b.
c.

2 Nos. DG Sets & Accessories of rating 1010 KVA

DG aux. Panel
Modification and commissioning in existing DG Control panel.

Note:DG Panel & PLC synchronizing panel is already installed at site and provided with I/C
breakers for these new DGs. DG Panel consists of feeders for 6 nos. of DGs (2 nos.
existing 1010KVA, 2 nos. 437.5 KVA & 2 nos. new 1010KVA). However CTs & meter for
1010KVA feeders are provided with 800/5A rating. These CTs are to be replaced &
modification of control schematic for DG Panel / PLC Panel synchronizing is to be done by
supplier of new DGs.

EXCLUSIONS :
i.
ii.
iii.

Foundations of DG Sets, cooling towers, pumps, water pumps and trenches,

Foundation of Chimney / Stack of 30 meter height.
Earthing of DG Sets & Panels.
(However, foundation drawing, earthing layout alongwith size of earth bus to be
furnished by contractor.)

SECTION III
TECHNICAL SPECIFICATIONS
DIESEL GENERATOR SETS
1.

GENERAL
Work covered by this contract shall include design, manufacture, supply, transportation, delivery,
installation, testing and commissioning of Diesel Generator Sets and auxiliaries required for prime
power generation.
The generator set shall consist of a diesel engine directly coupled to an electric generator,
together with the necessary control panel, battery, diesel tank etc and accessories to provide
prime electric power for the duration of any failure of the normal AC source.

2.

STANDARDS
The equipment offered shall conform to the latest revision of relevant Indian or British Standard
(BSS) as indicated below and Codes together with the requirements of the Local Supply Authority.
Engine shall conform to BS 5514/IS:10000 and the alternator shall be in accordance with
IS:4722/BS:2613/IEC-34(Part-1).

3.
3.1

ENGINE AND ACCESSORIES :

DIESEL ENGINE : Diesel Engine of required bhp, stationary type, four stroke with V cylinder
arrangement shall be complete with integral air intake through suitable air filters and exhaust
system, speed regulation system, fuel injection system, lube oil system, cooling water system,
silencers, self contained piping, instruments, mounted on anti vibration mounts
The engine shall have the following characteristics :
Type
- Suitable for generating set application, turbo charged, multicylinder, 4-stroke, cold starting.
Cycle
- Four stroke
Speed
- 1,500 r.p.m.
Method of Starting
- Battery
Net site output
- This shall be the prime power output (exclusive of the power
requirements of auxiliaries deriving power with engines) at 1500
r.p.m. under site conditions.
Overload feature
- The engine shall have 10% overload capacity for one hour in
every 12 hours of operation.
Engine rating shall be stated in the tender in accordance with the standards above. The engine
should comply to CPCB emission guidelines and should be of emission optimized type. The
engine shall be installed in area where in it need be operated for long durations. Bidder need to
declare the max load factor for prime power continuous duty application.
ACCESSORIES :
EXHAUST SYSTEM :
Turbocharger
Silencers residential type
Stainless Steel Flexible Bellows.
COOLING SYSTEM :
-

Heat Exchanger
Cooling water centrifugal pump
Bypass Thermostat

FUEL SYSTEM :
-

Fuel pump
Fuel injectors
Fuel filter
Fuel hoses
Lube oil pump
Lube oil-priming pump.
Lube oil filter
Bypass filter

INTAKE AIR SYSTEM :

Air intake manifold
Air cleaner
Vacuum indicator
GOVERNOR :
Electronic EFC
Starting System
24 V DC Electric starter
Battery Charging Alternator
LUBE OIL SYSTEM :
COUPLING ARRANGEMENT :
Flexible coupling
Flywheel to suit flexible coupling
Flywheel housing
PROTECTION / WARNING
Engine:
Over Speed Shutdown
Low Lube Oil Pressure Warning /Shutdown
High Coolant Temperature Warning / Shutdown
Low Coolant Level Warning / Shutdown
Low Coolant Temperature Warning
Low And High Battery Voltage Warning
Weak Battery Warning
Dead Battery Shutdown
Over Crank Shutdown
Fail To Crank Shutdown

3.2

Fuel Consumption
The engine shall be suitable for satisfactory operation on H.S.D. as locally available.

3.3

Lubricating Oil Consumption

The tenderers shall state the lubricating oil consumption in gm/bhp-hr (ltr/hr) at rated load.

3.4

Governing
The governor shall be Electronic type confirming to Class A1 and shall be a self contained unit
capable of monitoring speed.

3.5

Frequency Variation :
The engine speed shall be so maintained that frequency variation at constant load including no
load shall remain within band of 1% of rated frequency.

3.6

Mounting and Foundations

The engine and direct coupled alternators shall be rigidly secured to common rigid base frames
fabricated from MS sections. The DG set shall be placed on concrete block with anti vibration
mountings.

3.7
3.8

Exhaust Piping
Exhaust System
Each engine shall be provided with residential type silencers so as to limit the sound level from the
DG set.
Exhaust piping shall be fabricated from Class C MS Black Pipe conforming to relevant IS
standard size suitable to limit back pressure to within permissible limit. The exhaust shall be
terminated as per pollution norms. Exhaust piping inside DG room shall be insulated with 75 mm
thick mineral wool and 26 gauge Al. cladding. Exhaust piping shall be connected to the engine by
means of flexible section or an expansion joint.

3.9

Turbocharger
Turbocharger mounted at the side of the engine for better conversion of energy of exhaust gases
resulting in more power, improved fuel economy, altitude compensation, lower exhaust
temperature, lower smoke and noise level

3.10

Air Filter
The engine air intake shall be fitted with dry type air cleaner with vacuum indicator facilitating
change of air filter.

3.11

Fuel And Lubricating Oil Filters

Filter for fuel and lubricating oil systems shall be of replaceable paper element type.

3.12

Lubricating Oil System

The engine shall be of the totally enclosed type and fitted with a positive pressure system of
lubrication to all working parts. Lubricating oil shall be circulated in the engine by an engine driven
pump. There shall be no moving part requiring lubrication by hand prior to the starting of the
engine or while in operation. It shall be so designed that when the engine starts after a long shut
down lubrication failure does not occur. Necessary priming pump for the lub oil circuit shall be
installed to keep bearings primed.

3.13

Safety Controls
Low Lubricating Oil Pressure
Pressure sensors shall be fitted such that in the event of a fall in the lub oil pressure and indication
shall be actuated. In addition, the engine shall be automatically shut down in the event of lub oil
pressure dropping to a pre-determined low value.

High Water Temperature

An indication shall be given if the water temperature exceeds the safe limits and the shall be shut
down when a pre-determined set water temperature is reached.

Over Speed
Speed control shall be so arranged that 12-13% increase over normal rated speed shall cut off fuel
supply, thus stopping the engine.

3.14

General
The DG sets shall be complete with all equipments, indications and controls required for fully
reliable and safe operation of the DG sets whether specifically stated in these specifications or not.
It is essential that the operation of all protection equipments be completely reliable in all respects.

4.0

Engine Mounted Instruments Panel (Electronic): The flexibly mounted instrument

panel on engine shall be complete with the following:

4.1

Digital Display to indicate :

Coolant Temperature
Lub Oil Pressure
Battery voltage
Engine speed
Engine Run hours

4.2

Engine and alternator protection : The electronic panel will display the fault
codes on the screen so that the necessary action can be taken. It should
also provide the engine protection features such as :

4.3

High Coolant Temperature

Over-speed
Low lube oil pressure

The DG Set shall be supplied with micro-processor based generator

monitoring, metering & protection features like :

Analogue & Digital AC output metering

Battery monitoring system to sense and warn against a weak battery condition.
Digital alarm & status message display
Overload
Overcurrent
Over voltage
Under voltage
Over frequency
Under frequency

5.0 GENERATOR:
Synchronous alternator of suitable capacity to generate 1010 KVA output at alternator terminal at 415
V, 50 Hz, 3 Phase, 4 Wire, 0.8 pf (lag) 1500 RPM and in accordance with BS:2613 / IS:4722/IEC34(Part-I) shall be of totally enclosed or screen protected dip proof and self air-cooled type driven by
the Diesel Engine. Generator shall be supplied along with its excitation system, AVR and include all
necessary auxiliaries.

Generator / Alternator shall have following characteristics:

Permissible voltage regulation (max.) in static condition + 0.5% Permissible over load of 10% for
one hour in every 12 hrs. of operation
Permissible voltage & frequency variation of + 0.5% & + 1 % respectively
Alternator shall be provided with QDCTs, RTD & BTD.

Excitation System:

The Generator shall be provided with brush less excitation system capable of supplying the excitation
current of the generator under all conditions of output from no load to full load.

Enclosure :

Alternator enclosure shall be Screen Protected Drip Proof (SPDP) conforming to IP-23.

Winding :

Class H Insulation shall be used for stator/rotor winding.

BATTERY :

Battery of voltage and capacity compatible with the engine, complete with battery charging equipment shall
be provided to energise electric starting equipment. Batteries shall be of lead-acid automotive type. The
charging unit shall be part of existing DG control panel.

DG Set Accessories

6.1.

DESCRIPTION OF WORK
Scope of works includes supply, installation, testing & commissioning of following items :a) Cooling Tower, Pumps & associated piping.
b) Exhaust Piping.
c) 360 AH Battery with accessories.
d) Any other item not specifically mentioned but required for satisfactory installation,
operation and maintenance of DG Set.
APPLICABLE CODES, STANARDS AND APPLICABLE PUBLICATIONS

6.2

6.2.1

SUBMITTALS

6.2.1.1

Drawings and Data

a) DG Set layout, showing exhaust piping, typical supporting arrangement for all piping,
Cooling Tower Layout.
b) P&I diagram for Cooling System & Fuel oil supply system.

6.2.1.2

Tests and Test Reports

a) Pump performance curves and power consumption with operating points duly
indicated shall be submitted and verified at the time of testing and commissioning of
the installation.

6.3

SPECIFICATIONS

6.3
6.3.1

FRP COOLING TOWER (DX- SERIES)

The Fibre glass Reinforced Plastic (FRP) cooling tower shall be efficient and of sturdy
design for long life. It shall be supplied in the colour shade as approved by the Engineerin-Charge. All hardware used shall be stainless steel. The supporting frame work for the
cooling tower shall be fabricated from galvanised steel with epoxy paint to protect from
varying atmospheric conditions. The cooling tower shall be complete with casing, water
basin, fan with suitable electric motor and supporting structure, sprinkler system and
fittings and a strong supporting framework so as to make the cooling tower a complete and
independent unit. The cooling tower shall be forced draft type. One cooling tower is
envisaged for each D.G. set. The cooling tower shall be located on terrace .
FRP Casing
FRP casing of the cooling tower shall be so designed that it is strong enough for the duty it
is providing. It shall be strong enough to withstand the wind pressure and vibrations. The
casing shall be of such design that it can be repaired easily in case of damages. Hot
water temperature and cooled water temperature shall be 43.3oC and 32.2oC
respectively. Design ambient wet bulb temperature shall be 28.5oC.
Cooling Tower Fan
The fan shall be of axial flow type, low noise and light weight. The fan shall be selected to
suit the cooling tower design. Suitable electric motor and supporting structure shall be
selected for the cooling tower fan. The fans shall be fibre glass with NASA Aerofoil design
Fans shall be direct driven with low RPM motors.
Water Basin
Water basin shall be of sufficient capacity so as to provide continuous flow of water. It
shall be of FRP construction. A drain shall be provided to facilitate easy removal of
accumulated dirt from the bottom of the tank.
Cooling Tower Supporting Structure
The supporting frame work for the cooling tower shall be fabricated from galvanised steel
with epoxy paint to protect from the varying atmospheric conditions. If directed by the
Engineer-in-Charge design calculations shall be furnished for approval.
Cooling Tower Internals
The cooling tank shall have filling of PVC, MM AQUA (munters make) resistant to
corrosion and with good heat exchange efficiency. The cooling tower shall have water
sprinkler system located centrally. The sprinkler head shall be fitted with suitable beam to
take care of thrust and radial loads.

6.3.2

6.3.3

6.3.4

6.3.5

6.3.6

6.3.7

Painting
The exterior and all steel (ferrous) surfaces of the tower shall be given two shop coats of
anti-corrosive paint of approved finish.

6.3.8

If these shop coats become marred during shipment or erection, the effected areas shall
be cleaned off with mineral spirits, wire brushed and spot primed, then coated with enamel
paint of matching shades.

6.3.9

RAW WATER PUMP

The pumping shall be suitable to cater to the requirement of DG set, including strainer,
fittings, valves, pressure gauges, controls, Instruments, accessories, high/low temperature
Audio-visual alarm etc. shall be provided. The pump shall be capable of delivery specified
liter/ minute of water against specified head and complete with squirrel cage indication
motor of specified H.P. with class F insulation. Water flow rates and head of the pumps
shall be in accordance schedule of quantities. Pump shall be mono block end-suction
design directly connected to motor. Impeller shall be hydraulically balanced and keyed to
shaft. Stuffing boxes shall be integral with casing and water sealed. Shaft sleeve shall be
of gun metal extending through stuffing boxes. Motor shall be drip and splash proof,
designed as integral part of pump. Motor shall be suitable for 415+5% volts 3 phase, 50
cycles AC power supply. All Pumps, Motors and bases shall be supplied with approved
finish. The cooling water pumps alongwith cooling tower fans shall be interlocked with DG
sets, so that they start automatically alongwith the DG set, to start cooling water supply.
There shall be provision for tripping the cooling water pump when the water level in
cooling tower sump is low.

6.4
6.4.1

6.4.2
6.4.3

6.4.4

6.4.5
6.4.6

6.5

6.6

Exhaust Piping
The exhaust silencer piping system shall be MS pipes confirming to Class- B. Suitable
length of flexible piping shall be used for connecting the exhaust piping to the engine as
per the recommendations of the manufacturer.
Exhaust pipe along with silencer inside the building shall be provided with mineral wool
insulation with chicken mesh wrapping and 26 SWG aluminium cladding.
All terminal connections and pipes joint shall be of welded construction. The terminals of
sizes 2" and above shall be butt welded, and of sizes 1.5" and below shall be socket
welded, complete with flanges, jointing and fasteners.
This welding shall be done as per relevant ASME/ASA codes. The Contractor will have to
indicate beforehand the welding procedure he proposes to use. After confirmation by the
Engineer-in-Charge the procedure which is finalised shall be strictly adhered to.
Water Piping And Oil Piping
Water Piping shall be Class - B M.S. pipe. Oil piping shall be MS pipe as per A106 Gr. B
Sch. 40 or provided flexible type of SS - 304. If M.S. pipe as per IS : 1239 heavy class is
used, it shall be " TATA " or any other make approved by the Engineer-in-Charge.
Alternatively, the piping shall be braided flexible of SS - 304 only.
SHOCK TREATMENT CHART
Shock treatment chart in English, Hindi and local language explaining the method of shock
treatment shall be provided duly framed in glass.
Testing and commissioning

SUPPORT SERVICES :
Throughout design, implementation, field installation the contractor shall supply consulting
assistance, as required by the buyer for site preparation, field installation and other areas where
technical support may be required.

TECHNICAL SUPPORT :
Consultation with contractors technical support personnel and trained field service personnel shall
be readily available on a short-term/long-term basis to assist the buyer in maintaining, expanding
and enhancing the installed setup.

INSPECTION :
Access to the contractors facilities during system manufacturing and testing and to any facility
where systems/equipments are being produced and tested shall be available to the employer.

DG TESTING :
TESTS AT MANUFACTURER'S WORK
The following tests shall be performed at manufactures works prior to packing and
dispatch to site, in the presence of Project Manager/Consultant. A weeks notice shall be
given. Nothing extra shall be payable. If witness is waived off the contractor shall have to
submit test certificate.
On DG Set
a. Maximum power load capacity.
b. Maximum motor starting capacity
c. Endurance test.
d. Fuel consumption at full load, 50% load, 75% load and 25% load.
On The Alternator
a. High voltage tests on stator and rotor windings.
b. Insulation resistance of stator and rotor windings.
c. Temperature rise test.
d. Stator voltage and current tests.
e. Stator phase sequence check.
On The Exciter
a.
b.
c.
d.

High voltage tests on stator and rotor winding.

Insulation resistance of stator and rotor windings.
Temperature rise test.
Measurement of losses.

On The Automatic Voltage Regulator

a.
b.

Sensitivity test.
Response time test.

All routine test as per IS/BS codes shall be conducted on alternator, exciter and AVR.
Moreover the engine and alternator supplied shall be duly tested and supported by the test certificates of
the respective manufacturer.
DRAWING & DOCUMENTATION TO BE SUBMITTED WITH BID
-

Filled-in Technical Particulars catalogue & literature for various

equipment.
Performance certificate of all major equipment.
Type test certificate of all major equipment.
List of Past supplier of all major equipment.
GA drawings of all major equipment.
Time frame of major activities including Bar chart.
Foundation drawings of DG sets.

DRAWING & DOCUMENTATION TO BE SUBMITTED BY SUCCESSFUL BIDDER AFTER AWARD OF

CONTRACT
-

11

Following information and documentations in addition to what has been

asked for in respective equipment specification shall be furnished by the
successful bidder after award of contract for approval/reference/record of
the purchaser.
Electrical layout drawing showing location of equipment, cable routing,
bus duct connections, water & fuel piping arrangement with fuel tank for
DG Set, exhaust system etc. Plan & Elevation drawing including
sectional details.
Single Line Diagram showing rating of components, metering and
protection for DG Panel/PLC Panel/Distribution boards etc.
Earthing layout showing connections to DG, panels (to be done by
others).
Modification of control schemes of existing DG panel/PLC panel with
DGs if any..
Wiring Diagram.
Write-up on control philosophy for complete emergency electrical system
containing starting & stopping sequence, interlocks, metering,
annunciation etc.
All required drawings/documents/technical information required during
various stages of works shall be submitted by the contractor as and
when required by the purchaser.
All drawings submitted by the Vendor/equipment supplier shall be in
sufficient detail to indicate the type, size, general arrangement &
foundation drawing, weight, the external connections, fixing arrangement
required, the dimensions required for installation and interconnections
with other equipment and materials, clearances and space required
between various portions of equipment and any other information
specifically requested.
The above document shall be furnished in 4 sets to EPI/CDRI one set
shall be returned with comments and approval. The document shall be
modified incorporating the comments indicated by EPI/CDRI and 4 sets
of corrected documents shall be given in 15 days time.

The contractor shall provided within 3 weeks of award of work a

complete bar chart based on the time period of the completion of
the project. The bar chart shall elaborate procurement, installation,
testing & commissioning of complete electrical system.

IMPORTANT INFORMATIONS TO BE PROVIDED BY THE BIDDER :

Duration calculation for the equipment at stated site conditions Warranty of the equipment to be
provided by the manufacturer. Local Service dealers address to be specified.
The acoustic
enclosure for the DG set shall be manufactured by the DG set supplier.

10

TECHNICAL SPECIFICATIONS OF ACOUSTIC ENCLOSURE

Silent DG Set container is of modular construction with the provision to
assemble and dismantle easily at site.
The enclosure is fabricated out of CRCA sheet of 14 SWG.
The sheet metal components are hot dipped seven tank pretreated.
Enclosure is polyester based powder coated (inside as well outside).
Nut, bolts & hardwares are Zinc coated.
The doors are gasketed with EPDM gaskets to avoid leakage of sound.
The door handles are lockable type.
Sound proofing of enclosure is done with high quality rock wool/mineral
wool confirming to IS 8183, of 100 mm thickness and density at 64
Kg/M3.
The rock wool is further covered with fibre glass cloth and perforated
powder coated m.s.sheet.
Specially designed attenuators are provided to control sound at air entry
to the container and exit from the container.
Adequate ventilation is provided to meet air requirement for combustion
and heat removal.
Temperature of enclosure does not exceed beyond 5-7C of ambient
temp.
The sound insertion loss shall be as per CPCB prescribed norms
applicable presently.

11

SECTION IV
GUARANTEED TECHNICAL PARTICULARS
FOR DIESEL ENGINE & ALTERNATOR
VENDOR SHALL FURNISH THE POINTWISE CONFIRMATION/INFORMATION AGAINST EACH POINT
DESCRIPTION

Sl.NO.
A.

Diesel Engine

1.

Rating :

QUOTED DATA

a)

Continuous duty rating of the Diesel engine

at site/NTP conditions in bhp/KW

b)

Maximum engine rating at site with 10%

over load in KW.

2.

Make of Engine and model no.

3.

Cylinders :
a)

Number of Cylinders

b)

Cylinder length

c)

Cylinder diameter

4.

Engine rpm

5.

Aspiration

6.

Cooling

7.

Type of Starting

8.

Type of fuel used

9.

Specific fuel consumption ( Guaranteed) in

KG/KWH
a)
At full load
b)

At 3/4th load

c)

At half load

d)

At 1/4the load

At site
condition

10.

Lube oil consumption in Grams/Hour

11.

Lube oil sump capacity in litres.

12.

Output at Site conditions after duration at Inlet

temperature 450C. of Engine.( As per BS649

variation +

:1958 ).

variation +

12

At NTP
condition

Sl.NO.

DESCRIPTION

13.

Governing characteristics :

14.

Minimum acceptable lube oil temperature at

start up.

15.

Maximum period for which the engine can

operate without raw cooling water supply.

16.

Jacket water system :

a)

QUOTED DATA

Make up tank capacity in liters.

17.

Type of Governor

18.

Overall dimensions ( LxBxH ), mm

19.

Weight (kg)

B.

Alternator

1.

Continues Rated Output of the

generator/alternator in - KW.

2.

Continues current rating in AMP.

3.

Site KW after deration

4.

Generated Voltage

5.

Number of phases

6.

Standard

7.

Class of Insulation for Alternator, Stator rotor.

8.

AC Power factor

9.

Rated speed (rpm)

10.

Make of Alternator

11.

Model No.

12.

Efficiency
a)

At full load

variation +

b)

At 3/4th load

variation +

c)

At half load

variation +

d)

At 1/4th load

variation +

13

Sl.NO.
DESCRIPTION
13. Type of Excitation
a)

Rated voltage

b)

Rated current

c)

Response ratio

QUOTED DATA

14.

Field current at rated output and voltage

15.

Temperature rise above ambient (500C )

a)

Stator

b)

Rotor

c)

Cores

16.

AVR - Type

17.

Degree of protection

18.

Full load losses

19.

Transient and sub-transient reactance (per unit)

variation +

a)

x d

variation +

b)

x d

variation +

20.

Short Circuit Ratio.

21.

Overall dimensions (LxBxH), mm

22.

Weight (kg)

14

SECTION V

TECHNICAL SPECIFICATIONS
FOR
DG AUXILIARY PANEL

15

1.

DESCRIPTION OF WORK
This section covers the detailed requirements for design, manufacture, inspection,
transportation to site, installation testing & commissioning of L.T. Panel suitable for 415
Volts, 3 phase, 50 HZ 4 wire system, in line with schematic diagram, schedule of quantities
and as specified.

2.

CODES AND STANDARDS AND APPLICABLE PUBLICATION

415V Switchboard shall conform to latest applicable IS, IEC standard as listed below and
other relevant standards / code as applicable.
IS : 13947 (Part I to V)
:
Specification for low-voltage switchgear.

3.
3.1
3.1.1
3.1.2
3.1.3

3.2

IS : 1248

Electrical measuring
accessories.

instruments

and

IS : 8623

Specification for low-voltage

Controlgear assembles.

IS : 3072

IS : 2705 (Part I to IV)

Code of practice for installation and maintenance

of switchgear.
Current Transformers

IEC : 61643-12

Surge Protection Devices for Power Lines.

IEC : 60947-7-1

Terminal Blocks

switchgear

their

and

SPECIFICATIONS
GENERAL
The L.T. panel shall comprise the following type of switchgear as specified. The panel
shall be capable of fault withstand capacity of 50 KA for duration of one second.
The panel shall be metal enclosed, indoor type having sectionalisation of incoming, and
outgoing switchgears as specified. The design shall be cubicle type as specified.
The panel shall be floor mounted free standing totally enclosed and extensible type. The
panel shall be with lockable arrangement with degree of protection IP - 54 and shall be
suitable for the climate conditions as specified. The design shall include all provisions for
safety of operating and maintenance personnel.
CONSTRUCTION

3.2.1

The panel shall be shall be fabricated out of CRCA sheet steel 2.0 mm thick. Wherever
necessary, such sheet steel member shall be stiffened by angle iron frame work. General
construction shall employ the principle of compartmentalization and segregation for each
circuit. Unless otherwise approved, incomer and bus section panels or sections shall be
separate and independent and shall not be mixed with sections required for feeders. Each
section of the rear accessible type board shall have hinged access doors at the rear. Overall
height of the board shall not exceed 2.40 meters. Operating levers, handle etc. of highest unit
shall not be at a height more than 1.8 m, and that of the lowest unit shall not be less than 300
mm above finished floor level. Multi-tier mounting of feeders is permissible. The general
arrangement for multi-tier construction shall be such that the horizontal tiers formed present a
pleasing and asthetic look. The general arrangement shall be got approved before fabrication.
Cable entries for various feeders shall be either rear or from the front through cable alleys
located in between two sections of minimum 300 mm width. There shall be separate gland
plate for each cable entry so that there will not be dislocation of already wired circuit when new
feeders are added. Cable entry plates shall therefore be sectionalized. The construction shall
include necessary cable supports for clamping the cable in the cable alley or in rear cable
chamber. All cable entries shall be from the top/bottom as specified. Gland plate shall be
minimum 3 mm thick.

16

3.2.2

Cable Termination / Bus Duct Terminations :

Panel shall be design for cable entry from bottom / top as required. Sufficient space shall
be provided for each of termination and connection. All provision and accessories shall be
furnish for termination and connection of power cables as per cable schedule including
removal gland plates, copper / aluminums lugs, double compression brass glands with
tapped washer and terminal blocks. Bus Duct connection shall be from the top. All
provision for Bus Duct connection with accessories shall be provided.

3.2.3

Instruments
All meters shall be Digital type flush mounted type conforming to class 1.0 for accuracy
and of size of 144 mm2 for incoming feeders and & 96 mm2 for outgoing feeders.

3.2.4

Indicator Lamps
ON/OFF and phase indicator lamps shall be provided suitable for operation on AC 230
Volts supply. Necessary filter G/Y/R/A shall be provided depending upon the function. All
lamps shall be protected by proper HRC fuses. All lamps shall be LED type.

3.2.5

Wiring
All wiring controls, indication etc. shall be with minimum 2.5 sq. mm suitable stranded
copper conductor cables PVC insulated. Wiring shall be suitably protected within the
switchboard. Runs of wires shall be neatly bunched and suitably supported and clamped.
Means shall be provided for easy identification of the wires. Identification ferrules shall be
used at both ends of the wires. All control wiring meant for external connection are to be
brought out on terminal board. Brass/Copper thinbles, insulation tape etc. shall be
provided at joints & terminations as required.

3.2.6
i.

Terminal Blocks
All control terminal blocks shall be unbreakable and IP 20 compliant. The metal parts of
the terminal block including the captive screw shall be of Cu. Alloy and its housing shall be
Polyamide class V0/V2 as per UL94. It shall be suitable for mounting on both C&G type
rail and shall be capable to withstand vibration level upto 5g.
High current carrying terminal blocks suitable for 25-240 sq. mm wire shall contain
individual terminal sleeve cover on each termination which is also individually separatable,
to avoid accidental touch. It housing material shall be Polyamide as per UL 94 and shall
be separated from each other by separating/partition plate.

ii.

3.3

Bus Bar & Bus Bar Chambers

i.
Bus Bar and Connections
a.
The bus bar shall be of high conductivity Aluminium alloy of E 91 grade and of
adequate section. The bus bar system shall comprise a system of totally enclosed
main horizontal bus bars run at the top and vertical bus bars serving all modules in
vertical section on either side in cable entries. In case of rear access, horizontal
bus system shall run suitably either at the top or bottom. All connections to individual
circuits from the bus bar shall be with solid connections. All horizontal bus bar,
vertical bus bar and connections shall be suitably sleeved with PVC sleeves or
suitably insulated in an approved manner.
b.

The bus bar temperature should not exceed 90o C i.e. 40oC temperature rise over
50oC ambient. The calculation for temperature rise and bus bar sizing should be
furnished along with shop drawing for approval.

c.

Wherever copper bus bar and Aluminium bus bar are connected to each other,
bimetallic strip shall be used.

17

ii.

Bus Bar Supports and Attachments

Bus bar shall be firmly fixed on supports constructed from SMC (glass fibre
reinforced thermosetting plastic). The supports shall be sufficiently robust to
effectively withstand electro-mechanical stresses produced in the event of short
circuit.

iii.

Connection to Bus Bars

Connections to bus bars shall be made with bolts and nuts. Holes drilled into the bus
bars may be made.The bolts and nuts used for connections to bus bars shall be of
Aluminium alloy, tinned forged brass or galvanised iron. Suitable precaution shall
be taken against heating due to bi-metallic contact.
Further for tapping off
connections from bus bars, PVC insulated wire may be used for current capacities
upto 100 amps and for higher current capacities solid conductors/strips suitably
insulated with PVC sleeves/tape shall be used.

iv.

Clearances
The minimum clearances to be maintained for open and closed indoor air insulated
bus bars/electrically non-exposed and working at system voltages upto 600 volts
shall be as follows :
-------------------------------------------------------------------------------------------Between .................................................Minimum Clearances

v.

Phase to Earth .............................................

20 mm
Phase to Phase .............................................
25 mm
-------------------------------------------------------------------------------------------Bus Bar Markings
The colours and letters (or symbols) for bus bars :
Main bus bar connections and auxilliary wiring etc. shall conform to relevant Indian
Standard. A brief from I.S. 375 (revised) is given below:
For AC bus bars and Main connections
-------------------------------------------------------------------------------------------S.No.
Bus Bar &
Colour
Letter/Symbol
Main Connection
-------------------------------------------------------------------------------------------1.
Three Phase
Red,
R,Y,B.
Yellow,
Blue.
2.
Two Phase
Red, Blue
R,B
3.

Single Phase

Red

4.

Neutral Connection

Black

5.

Connection to
earth

Green

6.

Phase variable
(Such as connections
to reversible motors)

Grey

Gy.

18

vi

Phase Sequence and Polarity

Bus bars and main connections, when marked shall be marked in accordance with
the following table to indicate the order in which the voltages in phases reach their
maximum values.
-------------------------------------------------------------------------------------------System
As indicated by
Phase sequence
Colours or letters
as indicated
Vectorially
-------------------------------------------------------------------------------------------Three Phase
Red, Yellow, Blue
R, Y, B.
Two Phase
Red, Blue
R, B.
--------------------------------------------------------------------------------------------

vii.

Arrangement of Bus bars & Main Connections :

Bus bars and main connections which are substantially in one plane shall be
arranged in order given as follows :
a. A.C. System

b.

The order of phase connections shall be Red, Yellow and Blue.

ii

When the run of the conductors is horizontal, the red shall be on the top or
farthest away from the centre line as viewed from the front.

iii

When the run of the conductor is vertical, the red shall be on the extreme
left.

iv

When the system has a neutral connection in the same plane as the phase
connections, the neutral shall occupy an outer position.

Unless the neutral connections can be readily distinguished from the phase
connections, the order shall be red, yellow, blue and black.
Terminations
Incoming terminals shall be suitable for receiving cables.

3.4.1

PROTECTIVE DEVICES
Suitable Surge Protection Devices shall be provided at the input of Panel, conforming to
IEC-61643-12 (Stage-I/Class B). The device shall be mountable on standard DIN Rail. It
shall have the capability to arrest external lighting surges (of 10/350 waveform) up to 50
KA between Line to Neutral & 100 KA between neutral to earth. The wiring shall be as per
TT configuration of wiring.
Protective devices shall be provided as specified in the schedule of quantities.
There shall be not less than 4 N/O and 4 N/C auxiliary contacts rated 5 amp on each
breaker. The auxiliary contacts blocks shall be so located as to be accessible from the
front. The auxiliary contacts in the trip circuits shall close before the main contacts have
closed. All other contacts shall close simultaneously with the main contacts. The auxiliary
contacts in the trip circuits shall open after the main contacts open.All current carrying
parts shall be silver plated and suitable arcing contacts with proper arc chutes shall be
provided to protect the main contacts. The heat generated in the contacts due to tripping
under fault conditions shall be very nominal.

19

3.4.2

MOULDED CASE CIRCUIT BREAKERS

3.4.2.1

Moulded case circuit breakers shall comply with the latest Indian Standards and IEC
standards. They shall have the voltage and current ratings, rated duty, rated short circuit
service breaking capacity and rated short-time withstand current as indicated.
3.4.2.2 MCCB's shall be of the independent manual closing air-break type, rated for an
uninterrupted duty, unless otherwise indicated.
3.4.2.3 Each MCCB shall have a facility for padlocking in the "OFF" position.
3.4.2.4 MCCB shall have front operating Extended door operating handle.
3.5

CURRENT TRANSFORMERS
Current Transformers shall be cast resin type.
a) All phases shall be provided with current transformers of accuracy Class I and suitable
VA burden to operate associated metering.
b) Separate C.T's shall be used for protective devices.

3.6

VOLTAGE TRANSFORMER :
Voltage transformers shall be cast resin type with accuracy class of 1.0.

3.7

RELAYS :
The contractor shall furnish, install and co-ordinate all relays to meet the requirement of
protection, interlock and bus transfer scheme as indicated in BOQ, Drawing, Specification
and system requirement. Relays shall be Microprocessor type.

3.8

EARTHING
All components, frame etc. shall be properly earthed. Al. earth bars of 50 mm x 6 mm
shall be provided for the LT panel for the full length of the panel and connected to the
frame work. Provisions shall be made for connection from this earth bar to the main
earthing bar on both sides of LT Panel.

3.9

PAINTING
All steel work used in the construction of the LT panels shall have undergone a rigorous
metal treatment process as follows :i)

Effective cleaning by hot alkaline degreasing solution followed by cold

water rinsing to remove traces of alkaline solution.

ii)

Pickling in dilute sulphuric acid to remove oxide scales & rust formation, if
any, followed by cold water rinsing to remove traces of acidic solution.

iii)

A recognized phosphating process to facilitate durable coating of the paint

on the metal surfaces and also to prevent the spread of rusting in the
event of the paint film being mechanically damaged. This again, shall be
followed by hot water rinsing to remove traces of phosphate solution.

iv)

Passivating in de-oxalite solution to retain and augment the effects of

phosphating.

v)

Drying with compressed air in a dust free atmosphere.

20

vi)

Primer coating with two coats of a highly corrosion resistant primer,

applied wet on wet and stove dried under strictly controlled conditions of
temperature and time.

vii)

Finishing treatment shall be by powder coating with 60 micron minimum

thickness.

3.10

LABELS
Anodised Aluminium labels shall be provided on all incoming and outgoing feeder
switches. Circuit diagram showing the arrangement of the circuit inside the LT panel shall
be pasted on inside of the panel door and covered with transparent laminated plastic
sheet. Caution notice place shall be affixed at the back of each vertical panel.

3.11

SPACE HEATER AND PLUG SOCKET :

Each vertical panel shall be provided with thermostat controlled space heater and 5A 3
pin plug socket. Separate transformer for space heating supply has to be arranged.

4.

TESTING & COMMISSIONING

4.1

TEST AT MANUFACTURERS WORK

All routine tests specified in IS : 8623: shall be carried out

4.2

Test witness
Tests shall be performed in the presence of the Engineer-in-Charge. The contractor shall
give at least fifteen days advance notice of the date when the tests are proposed to be
carried out.

5.

SUBMITTALS
Following data, drawing & manual shall be submitted :-

5.1

5.2

To be submitted with bid.

a)

Single Line Diagram.

b)

Filled in Guaranteed Technical Particulars.

To be submitted for approval.

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)

General arrangement drawing showing space required in front for withdrawls,

power and control cables entry points, bus duct / cable entry details.
Technical particulars for each panel.
Single Line Diagram
Modification of control wiring diagram along with electrical interlock scheme.
Bill of material indicating quantity, rating and make of all component.
Foundation plan and loading.
Type test certificate from CPRI on identical panel.
Technical literature of each component / equipment.
Bus bar sizing calculations along with supporting document.
Routine test certificates carried out on the panel.
Type test certificates for any equipment if so desired by the owner.

21

SECTION - VI
GUARANTEED TECHNICAL PARTICULARS FOR DG AUXILIARY PANEL
(Separate GTP to be submitted for each size & type of panel).
Sl. No.
Description
Quoted Data
1.0
Assembly
1.1
Make
1.2
Type
1.3
Reference standard
1.4
Voltage (Nom./Max), Volt
1.5
Phase, frequency
1.6
Short circuit rating for 1 sec (KA)
1.7
Insulation level (KV)
1.8
Enclosure
a) Degree of protection
b) Minimum thickness of sheet metal (mm)
2.0
2.1
2.2
2.3
2.4
2.5
2.6
3.0
3.1
3.2
3.3
3.4

3.5

3.6
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10

Construction
Completely compartmentalized
Working height limits from floor level (mm)
Minimum clear space required at front for
breaker (mm)
Minimum clear space required at rear (mm)
Overall dimensions (LxBxH) mm
Approximate weight (Kg)
Busbar
Make
Material & grade
Reference standard
Cross sectional area
a) Main busbar
b) Vertical busbar
Continuous current (at site condition, 50oC)
a) Main busbar (A)
b) Vertical busbar (A)
Short time current for 1sec (KA)
Circuit Breaker
Make
Type
Reference standard
Rate voltage, KV
No of poles
Rated current
Short time current for 1 second (KA)
Total closing time
No of breaks per pole
Spring charging motor
a) Rating (W)
b) Voltage (V)

22

4.11

Closing coil

Sl. No.

4.13

Description
a) Voltage
b) Closing current (A)
Tripping coil
a) Voltage
b) Trip current (A)
Overall dimension (LxBxH)

5.0
5.1
5.2
5.3

MCCB
Make
Type
Reference standard

6.0
6.1
6.2
6.3

Fuse
Make
Type
Reference standard

7.0
7.1
7.2
7.3
7.4
7.5

Condactor
Make
Type
Reference standard
Duty class
Utilization category

8.0
8.1

Control & indications

Push buttons
a) Make
b) Type
LED
a) Make
b) Type

4.12

8.2

9.0
9.1
9.2
9.3
9.4
9.5
9.6

Quoted Data

Current transformer
Make
Type
Reference standard
Ratio
VA rating
Class
a) Relaying CT
b) Metering CT

23

10.0
10.1
10.2
10.3

Control transformer
Make
Ratio
VA rating

11.0
11.1
11.2
11.3
11.4
11.5
11.6
12.0
12.1
12.2
13.0
13.1
13.2
13.3
13.4

Voltage transformer
Make
Type
Reference standard
Voltage ratio
Accuracy class
VA burden
Relays
Make
All relays furnished as per BOQ, specification
& drawing?
Meter
Make
Type
Reference standard
Size

14.0
14.1
14.2
14.3

Secondary wiring
Voltage grade
Conductor size & material
Type of insulation

15.0
15.1
15.2
15.3

Terminal block
Make
Type
Voltage grade

16.0
16.1
16.2

Space heater
Wattage
Voltage

24

SECTION VII

TECHNICAL SPECIFICATIONS
FOR
L.T. BUS DUCT

25

TECHNICAL SPECIFICATION FOR L.T. BUS DUCT

1.

SCOPE
This section covers Design, manufacture, inspection, transportation to site, installation,
testing and commissioning of Low tension bus duct for connection between DG sets and
DG panel.

2.

GENERAL
The layout of the bus ducts shall be in line with the drawings/site conditions and shall be
got approved by Engineer-in-charge
All parts and accessories shall have appropriate match mark and part numbers for easy
identification and installation at site.

3.

STANDARDS
The bus duct works shall conform to up-to date amendments and relevant standards/code
as applicable:

4.

DESIGN
Bus duct shall be Non-segregated phase suitable for 415 volts, 3 Phase& Neutral, 50 Hz,
AC supply and indoor, outdoor installation as per the requirement.
Bus duct shall be designed to withstand the fault level of 50KA for 01 second.
Bus duct shall be designed for continuous current rating as per the current rating given in
the BOQ/SOQ.

5.

CONSTRUCTION

5.1

ENCLOSURE
All the three phases shall be enclosed in a weather proof, dust tight enclosure, Outdoor
section of the bus duct shall be completely rain proof. Weather resistant type
circumferential gaskets shall be provided for making the joints with adjacent enclosures
dust proof and impervious to moisture suitable inspection opening with gaskets shall be
provided for access to support insulator, lugs joints etc.
Bus duct enclosure shall be made of 14 swg. (2mm) CRCA sheet steel, for bus rating
below 3000A.
The degree of enclosure protection shall be IP 52 for indoor application and IPW-55 with
canopy for outdoor section of the bus duct.
All ventilation openings shall be screened and drains shall be filtered to prevent entrance
of dust and vermin.
The portion of bus duct at DG end may be subject to vibration. Suitable means shall be
provided to isolate the transformer vibration from rest of the bus duct.
For continuous operation at specified ratings, temperature rise of the bus duct and
auxiliary equipment shall be limited to the site permissible values stipulated in relevant
standards and/or this specification.

26

Bus duct and auxiliary equipment shall be capable of withstanding the mechanical forces
and thermal stresses of the short-circuit currents without any damage of deterioration of
material.
The L.T. bus ducts shall be self cooled and shall not be equipped with blower or any other
type of forced ventilation.

6.

DETAILED SPECIFICATIONS

6.1

BUSBARS

6.1.1

Material
Bus bars shall be made up of high conductivity electrolytic quality aluminum as specified
in BOQ with maximum temperature limited to 85 deg. C (i.e. 35 deg. C rise over 50 deg. C
ambient).

6.1.2

Current density
The Aluminum bus bars shall be of sufficient cross section. The design current density of
1Amp/Sq. mm for aluminum bus bars shall be maintained. However, the design shall be
suitable for the 50 KA fault level.

6.1.3

Neutral bar rating

The rating of the neutral bar shall be minimum 50% of the phase bar.

6.1.4

Joints
Adequate contact pressure shall be ensured by means of two bolt connection with plain &
spring washers and locknuts.
All bus joints shall be silver plated.
Bimetallic connectors shall be provided for connections between dissimilar metals.
The bus conductor shall be designed for bolted connections throughout the run. Joints for
the bus bar shall be bolted but joints of construction with double cover fish plates and with
adequate contact area.

6.1.5

Insulation & supports

Bus bars and connections shall be fully insulated for working voltage with heat shrink
colour coded PVC insulating sleeves.
Bus insulators shall be flame-retardant, non-hygroscopic, track resistant type with high
creepage surface materials like fiber glass reinforced thermosetting plastic/ epoxy/ FRP.
The supports shall be made of single piece.
They shall withstand without any damage or deformation the thermal and dynamic
stresses due to short circuit currents.

6.1.6

Color coding
Bus bars shall be colour coded for easy identification (Red, Yellow, Blue for three phases
and Black colour for neutral for A.C 3 phase system). Heat shrinkable, colour coded PVC
insulation sleeve shall be used for this purpose.

27

6.1.7

Lay out sequence

They are so positioned that the sequence of R-Y-B-N bars shall be from left to right, top to
bottom or front to rear, when viewed from the front of switchgear assembly.

6.1.8

Clearances & creepage distances

As far as possible, large phase and ground clearances and creepage distances shall be
provided on the bus bar system to minimize possibilities of fault. The clearance mentioned
below shall be minimum and maintained even at the connection point.
1
2
3

6.2

Phase to Phase 35 mm
Phase to Neutral 28 mm
Phase to Earth 28 mm

HARD WARE
Zinc passivated or any other superior quality standard size hard ware to be used for all
joints/connectioins/terminations at switchgear & control gear, bus bars, ground bus , interconnections/ wiring etc.

6.3

Convenience of maintenance
The system shall be maintenance friendly. i.e. it should be possible to easily
connect/tighten/disconnect etc.

6.4

Inspection Covers
Inspection covers shall be provided at suitable intervals as required.

6.5

Disconnect Link
Removable bolted disconnect link shall be provided in the bus for the purpose of isolation.
Disconnect link shall consist of a removable section of conductor and shall be so
constructed as to permit easy removal or reinsertion without alignment difficulties.
The bus on both sides of the link shall be rigidly supported so that the disconnect link is
equal in mechanical strength to any other section of the bus.
A minimum clearance of 300 mm (12) shall be provided between the disconnected bus
sections with the link removed.

6.6

Ventilation
The bus duct shall be natural cooled.

6.7

Joints, Expansion/Flexible joints

The bus bar shall be supported in such a way that the expansion/contraction does not
have undue strain on the bus and at the terminals at both ends.
Circumferential neoprene gaskets shall be provided for dust tight joints with adjacent
enclosure section.
The bus enclosure shall have extended bellows or equivalent means to allow for
temperature changes and vibrations.

28

Flexible joints shall be provided in enclosures at all points where the bus duct terminates
at equipment to withstand vibration, expansion/contraction and at suitable intervals in any
straight run of the bus duct where expansion and contraction would otherwise result in
stresses in the supporting structures.
Flexible connections shall be provided between bus sections to allow for expansion and
contraction of the conductor. Flexible connection shall also be provided at all equipment
terminations.
All contact surfaces shall be silver plated to ensure an efficient and trouble free
connection.
6.8

Other points
Shipping length of the bus duct shall be not more than three (3) meters in length.
Filtered drains for drainage of condensate shall be provided at the lowest points and at
such locations where accumulation of condensate can be expected.

6.9

GROUND BUS
Two numbers of Earth bars shall run along the full length of bus duct made up of size 50
mm X 5 mm Aluminium, strip. This ground bus shall be fixed to the bus duct on the
external side. It shall have provision to connect main earth/loop earth conductors with
bolts, nuts, washers & spring washers. Metallic parts of the bus duct & associated
structures etc. shall be bonded to the ground bus for effective earthing.
One end of the earth bus shall be joined to the LT Panel side body earth lead and the
other end shall be joined to the transformer body earth.

7.

INSTALLATION
All supporting structures required for hanging and/or supporting the complete bus duct
shall be provided including related civil works. These include all types of supports,
brackets, beams, channels, rods, clamps, hardware, etc to support with wall, roof, truss
etc.
Bus ducts running along the wall should be supported at intervals not exceeding 1.5m. In
case of branching, there should be a support on all branches at a distance of 30 cms from
the point of branching. Support should not be less than 40mm X 40mm X6mm MS angle
secured in an approved manner. Supports may also be formed as brackets fixed to walls
where runs are along with walls. Supports shall be grouted on the walls.
In case of ceiling suspended bus ducts, supports made of 40mm X 40mm X6mm MS
angle iron shall be provided. The horizontal interval between two such supports should not
be more than 1200mm. However, additional supports to be given at the bends and
termination points. These duct supports shall be suspended from the C.I/MS. boxes or
suitable approved suspension device provided in the ceiling by means of 12 mm diameter
MS rods.
Where fish plates are available, the same can be used for busduct support works. Where
there is no such provision, good quality anchor fasteners of size not less than 8mm shall
be used in the ceiling.

29

Seal-off bushings complete with wall frame and support plates shall be provided where
the bus duct penetrates the building wall. The seal is to prevent free exchange of air
between two portions of the bus duct part of which is indoor while the other is outdoor.
Silica-gel breather shall be provided on both portions of the bus duct between the seal of
bushings.

CONNECTIONS & TERMINATIONS

All matching flanges, seal-off bushings, gaskets, fittings, hardware and supports required
for termination of the bus duct at the switchgears, transformers and other equipment shall
be provided.

Flexible connections both for conductor and enclosure shall be provided.

a)
b)

At all equipment termination to provide for misalignment up to 25 mm (1) in all

directions.
Between bus duct supported from building steel to prevent transmission of vibration.

The equipment terminal connections shall be readily accessible and shall provide
sufficient air gap for safe isolation of equipment during testing.
If the material of bus conductor and that of the equipment terminal connectors are
different then suitable bi-metallic connectors shall be furnished.
8.

PAINTING
Unless otherwise specified, the painting process shall be as follows:All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents, as
required, to produce a smooth surface free of scales, grease and rust etc.
The steel surfaces after cleaning shall be given on all sides proper coat of anti-corrosive
primer followed by two coats of powder coating painting.
The bus duct shall be finished with two coats of grey (IS 5 shade # 632) powder coated
paint.
Earth strip shall be painted with green colour enamel paint.
Where the painting is damaged during transit, installation etc., and touch up painting shall
be done at site.
All metallic parts involved in the installation like supports, beams, channels, brackets,
clamps, poles, hardware etc. shall be enamel painted.

9.

TESTS

9.1

Factory Test
The routine/acceptance tests shall be witnessed at the manufacturers works by CDRI
representative. Test shall be carried out as per IS.

30

9.2

TYPE TESTS
Bus duct shall be got manufactured by only reputed bus duct manufacturers having type
tested as per IS by CPRI or other govt. testing laboratory on similar bus duct (s) with
minimum 50KA short circuit current with stand capacity and the type test certificate shall
be produced to the CDRI inspector at the time of factory test.

9.3

SITE TESTS
In addition to the tests at manufacturers premises, all relevant pre-commissioning checks
and tests shall be done at site before energizing the bus duct.
The following tests are to be particularly done before cable jointing or connecting the bus
duct.
1. Physical inspection for breakages/damages/orderliness.
2. Insulation resistance test with 500 V Megger. The insulation resistance shall not be
less than 100 mega ohms.
3. Earth continuity test.
All test results are to be recorded and reports should be submitted to the department.

10.

COMMISSIONING
After the satisfactory installation & testing, the Bus duct shall be commissioned.

11.

Drawing, Data & Manuals :-

11.1

To be submitted with the bid.

11.1.1

Technical Particulars of each rating.

11.1.2

General arrangement drawing plan and section.

11.2

To be submitted after award of contract :-

11.2.1

Dimensional general arrangement drawings with cross sections of bus duct layout
including supporting arrangement.

11.2.2

Calculation for short circuit forces justifying the proposed arrangement and temperature
rise for bus and enclosure.

11.2.3

Detailed material list with part number.

11.2.4

Typical details of bus insulator assembly, rigid and flexible connections, grounding
provision, termination arrangement at equipment end etc.

11.2.5

Technical particulars of each rating.

Type test report.

31

SECTION VII
The following is the list of products and indicative makes. Bidder is free to propose any other equivalent
Make meeting Technical Requirements, Specifications alongwith required details in support of the same.
The same would be analyzed and accepted if found suitable after discussion between EPI and bidder. The
Makes shall be finalized during Technical evaluation prior to opening of Price-Bids.
Bidders are required to offer reputed equipment / component which is strictly meeting technical
requirements, enclosed specifications alongwith NIT and other relevant / latest applicable Standards &
Rules.
S.
No

Items

Indicative Makes

1.

Diesel Engine

Cummins/Caterpillar/MTU
/Mitsubishi/Perkins

2.

Alternator

Stamford/Cummins

3.

AVM Pads

Dunlop/GERB/ Resistoflex

4.

MS Pipes for Exhaust/water/fuel piping

Jindal/Tata

5.

Valves

Sant/Rama/Audco/Kirloskar

6.

Batteries

NICCO/Standard Furukawa/Exide

7.

Acoustic Enclosure

Jakson Engineers/Sudhir Engineers

8.

Cooling Tower

BELL / MIHIR / PAHARPUR

9.

Power Control Cables

CCI / Fort Gloster / Universal / Skytone

10.

Butterfly Valves, Strainer, NRV

C&R / Sant / Leader

11

Control wires

Finolex / national / havells

12

Water circulating monobloc pumps

Kirloskar / M&P / KSB

DG PANELS, DG AUXILIARY PANEL

AND RELATED ITEMS :
13.

MAIN DG PANELS / APFC PANEL/PLC

PANEL/ C&R PANEL / RTCC / MCCB
PANEL / UMDB/ DG AUXILIARY PANEL

TRICOLITE / JAKSON ENGINEERS / L&T /

SCHNEIDER / GE POWER / ABB / C&S /
SUDHIR
GENSETS
/
SIEMENS
/
ADVANCE (SIEPAN) / RST ELECTRICALS

14.

AIR CIRCUIT BREAKER

L & T / GE POWER / SIEMENS / ABB /

SCHNEIDER

15.

MOULDED CASE CIRCUIT BREAKERS

L & T / SIEMENS / SCHNEIDER/ GE

POWER / ABB / LEGRAND

16.

FUSE DISCONNECTOR
SWITCH FUSE UNITS

L & T / SIEMENS / SCHNEIDER / GE

POWER / ABB / C&S

17.

HRC FUSES

L & T / SIEMENS / GE POWER / ABB /

C&S / SCHNEIDER

18.

BUS DUCT

ADVANCE PANEL & SWITCHGEAR PVT.

LTD. / TRICOLITE / C&S / ADLEC.

SWITCH

32

19.

AMMETER, VOLTMETER

AE / MECO / UNIVERSAL / RISHAB / IMP /

CONSERV

20.

SELECTOR SWITCH, PUSH BUTTON

SWITCH / EMERGENCY SWITCH

KAY CEE / CONTROL & SWITCH GEARS /

L&T / GE POWER CONTROL / SIEMENS /
BCH.

21

LED INDICATION LAMPS

AE / C&S / EASUN / KAY CEE / SIEMENS

/ VAISHNOV / L&T

22.

CTS

AE / KAPPA / UNIVERSAL / KAYCEE /

IMP/ C&S / L&T / MECO.

23.

STARTERS

SIEMENS / L&T / CUTLER HAMMER / GE

POWER / ABB / C&S / SCHNEIDER

24.

SINGLE PHASING PREVENTOR

OVER LOAD PROTECTION UNIT

25.

RELAYS

L&T / AREVA / ABB / SIEMENS

26.

CHANGE OVER SWITCH

HH ELCON / C&S / INDO AISAN / HPL /

C&S

27.

CONTACTORS

L&T / GE POWER / BCH / SIEMENS / ABB

/ TC / C&S / SCHNEIDER

28.

KWH, PF, FREQUENCY METER

JAIPUR METER / AE / HAVELLS / L&T /

AREVA / SECURE / GENUS / CONSERV

29.

PUSH BUTTONS

L&T / SIEMENS / BCH / CON CORD / GE/

C&S

30.

TIMERS

L&T/ BCH / MDS / INDO ASIAN /

SCHNEIDER / SIEMENS / ADVANI
ORLIKON / GE POWER CONTROL

31.

TIME SWITCH

L&T / BCH / MDS / INDO ASIAN /

SCHNEIDER / SIEMENS / ADVANI
ORLIKON / GE POWER CONTROL.

32.

DIGITAL METERS

ENERCON / NEPTUNE / AE / L&T

33.

INTELLIGENT
DIGITAL METER

34.

PLC

ROCKWELL
SIEMENS

35.

UPS SYSTEM FOR PLC

MERLIN GERIN / EMERSON / GE DIGITAL

ENERGY /

36.

UPS BATTERIES

EXIDE / GLOBAL-YAUSA / PANASONIC

MULTIFUNCTION

L&T / GE POWER / SIEMENS / MINILEC /

ABB / SCHNEIDER

ENERCON / NEPTUNE / AE / L&T

33

AUTOMATION

L&T

SECTION - IX

DRAWINGS
SR. NO.

01

DESCRIPTION

MAIN SUBSTATION (21)

34