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The design, material, construction, manufacture, inspection, testing and performance of the
LT switchboards shall comply with all currently applicable statutes, regulations and safety
The LT

switchboards and

standards Specified below.


components s hall
case of

conform to the latest


conflict between the standards

Specification, this specification shall govern.

Circuit Breaker

BS: 3659 / IEC: 56, 694 /IS: 2516

Switchboard General Requirements :

BS: 5486 / IEC: 947 / IS 13947

Factory Built Assemblies of SWGR and

Control gear for Voltages up to and including
1000 V AC & 1200 V DC

BS: 5486 / IEC: 439 / IS: 8623

Electrical Relays for Power System


BS: 142 / IEC: 255 / IS: 3231

Air Break Switches, Motor Protection :

Circuit Breaker

BS: 60947 / IEC: 9472 & 3 /IS:


Bus-Bar supports Insulators

BS: 3297 / IEC: 273, 168 / IS: 2544

Low voltage Fuses

BS: 1362 / IEC: 269-1 / IS: 13703


BS: 60947 -4 / IEC: 947-1/

IS: 13947

Control Transformers for switchgear and

Control gear voltage not exceeding :

IS 12021


BS: 60947-4 / IEC: 292-14/

IS: 13947

Current Transformers

BS: 7626 / IS: 2705

Voltage Transformers

BS: 7625 / IEC: 44, 186 /IS: 3156

Indicating Instruments

BS: 89 / IEC: 51 /IS: 1248

Marking and identification of conductor

And Apparatus Terminals

BS: 159 / IS: 11353

A.C. Electricity Meters

BS: 5685/IEC: 145,211/

IS: 722, 8530

and this

Degree of Protection

Guide for marking of insulated conductor :

IS: 5578

Guide for uniform system of marking and

Identification of conductors and apparatus :

IS: 11353

Selection, installation and maintenance of :

Switchgear and control gear

BS: 60529/IEC: 947-PI/IS: 13947

IS: 10118

Code of practice for phosphating Iron and


BS: 3189 / IS: 6005

Phosphate treatment of iron and steel for

Protection against corrosion

IS: 3618

Specification for copper rods and bars for

Electrical purposes

IS: 613

Material data for Aluminum Bus-Bars

IS: 5082


Following auxiliary supplies with +10% to -15% voltage variation, + 4% to -6% frequency
variations and +10% combined voltage and frequency variation are available:

Three (3) phase, 415V, Four (4) wire, 50 Hertz, effectively earthed AC supply.
220V ungrounded DC supply.



415V LT PCC, MCC, DBs as per Main SLD.

20% fully equipped spare feeder for each rating/each module shall be consider in each
LT switchgears are having two incomer with one bus coupler, the necessary interlocks will be
provided such that only two breakers/switch fuse units can remain closed at any given time.
The base channel frame of the switchgear/MCC/DB with hardware
Set of minimum accessories as detailed below:
i) Breaker lifting & handling truck
ii) Device for slow closing & opening of breaker
iii) Breaker racking in/out handle

Mandatory Spare parts



The switchgear shall be formed using distinct vertical sections each comprising the following
A completely metal enclosed horizontal busbar compartment running horizontally at
Individual feeder modules organized in multitier mode.
Completely enclosed vertical bus bars serving all feeder modules in the vertical section.
Cable termination compartment.
Perforated sheet steel/insulating material enclosed horizontal auxiliary bus way for
control, interlock, indication and metering wiring running horizontally.
The 415V switchboard shall comprise air circuit breakers & s hall be metal clad, indoor
type floor mounted (in fully

Draw out execution).Switchboard shall be in



Execution for incomers & bus couplers & two tiers for outgoing feeders.

Relative position of incomers shall be as per the equipment layout requirement.

Circuit breaker shall be mounted on fully draw out truck with service, test and isolated
positions and complete with following safety interlocks and safety shutters with padlock
It shall not be possible to move the truck in or out of cubicle when the breaker is closed.
CB compartment door shall be mechanically interlocked so that it will not be possible to
close the CB in plug position when the door is open.
It shall not be possible to push the truck in close position if either of the safety shutter is
not free and not in close position.
The position of various control s witches, pu sh button s, levers etc. requiring manual operation,
shall be at a height not less than 450mm and shall not exceed 1850mm from
The finished floor level.
Name plate for each incoming bus coupler, and outgoing feeder at front and back, both on
the fixed portion of the panel.
All panels shall have space heater with switch and cubicle illumination lamp with door

All breakers of similar rating shall be interchangeable.
Metal sheets shall be provided between two adjacent vertical panels running to the full width
of the wider panel and upto full useful height of the switchgear.
The front of the board shall comprise of individually enclosed Air Break Circuit Breakers,
starters, Fuse switch and switch fuse modules.
All auxiliary devices for control, indication, measurement and protection such as control
and se lector switches, indicating lamp s, a mmeters, voltmeters, e nergy meters, protective relays
shall be mounted on the front side of the respective compartment only.
The design shall be such that unless required for maintenance/inspection purpose, all power
on/off or start/stop and relay reset operations shall be performed without opening the panel

Rated short time withstand current not less than the system short circuit level specified for
1sec. Rated peak withstand current not less than 2.1 times the system short circuit level.

Derating of Equipment The current rating of all equipment specified in the Bill of Material are
the minimum standard current ratings required at a reference ambient temperature of 50C.
The Bidder shall indicate clearly the derating factors employed for each component and furnish
the basis for arriving at the se derating f actors duly considering the specified current rating and
ambient temperature of 50C.



The complete board shall be of coordinated design so that shipping groups of the board
are easily assembled together at site into a continuous lineup . Necessary standard connecting
material shall be supplied.
Name plates of elegant and durable design and quality shall be fixed to the individual
compartments, feeder modules etc.
The boards covered by this

enquiry s hall

accordance with the latest

revisions of

be designed, manufactured an d tested in

the relevant applicable standards listed

elsewhere in this document.

The framework of the boards shall be constructed of preformed steel channels, angles
and side sheets bolted together and suitably reinforced to form a rigid, self-supporting,
Compact assembly to function properly under both normal and short circuit conditions.

The bus compartments shall comprise of one main horizontal TPN bus unit with vertical
risers for connection to the individual modules.
The board shall be of totally metal enclosed ventilated multiple unit construction. End
units shall include provisions for future main bus extensions and installation of additional
units on either side with the framework suitably drilled to receive the additional modules
and the

bus bars fitted





associated hardware

enabling future

Extension without involving major fabrication works on the panel in service.

Functional units when working on those of adjacent un its. These barriers s hall have insulating
inserts as necessary for taking the interconnections etc.
Doors and covers shall be of sheet steel of thickness not less than 2.0 mm cold rolled and the
edges shall be reinforced against distortion by rolling/bending/ or by addition of
welded reinforcement member s. The doors shall have concealed type of hinges. Wherever the door
length is more than 600 mm, necessary stiffeners shall be provided.
Cut outs shall be true in shape and free from sharp edges.
The panel shall be provided with integral metal base channel 7 5 mm in

height for

Facilitating grouting on the floor.

Dust excluding gaskets of neoprene shall be used on all doors to ensure dust tightness
of the interior while the board is in service. Suitable ventilating louvers designed in such
a way as to prevent entry of falling dust shall be provided at the sides and top so that a
Free circulation of air through the equipment under thermal cycling conditions is ensured.
The louvers shall be

provided with fine-screened brass meshes to prevent entry

Vermin. If ventilation louvers are provided on top, suitable canopy / cover



Provided, with wire mesh inside the panel.

The hardwares shall be zinc plated & passivized; these shall be of the captive type to obviate loss
of these bolts / s crews etc., when the doors / covers are opened for servicing / inspection.
Cold Rolled Sheet Steel of 2.5 mm. thickness shall be used for all members, other than doors
and covers.
All c components including the busbars s hall be capable of being re moved from fro nt.
The cable alleys shall also be at the front of the board for MCCs. However, cable access
may be arranged at the rear side for ACB feeders.
All the doors for the feeder modules in the front shall have individual sheet steel hinged
doors with concealed hinges. These doors shall be capable of being physically lifted off
the main base s hell an d fixed back in position while the panel is i n service without
necessitating removal of any screws or welding etc. and with the adjacent modules in
service with their doors closed. The doors shall also have interlock facility, with defeat

provision, to ensure that the door is not opened when feeder is in ON position.
The bus bar chamber shall have screwed covers at the front, on the sides and on the top.
The panels shall be suitable for cable entry at bottom. Undrilled, removable gland plates
Shall be provided at the bottom for the switchboards to suit entry of the cables as furnished in
the schedules. Cable clamping arrangements shall be provided in the cable
The switchboards shall have uniform height of not more than 2 350 mm. The height of
the operating handle for the feeder modules, indicating lamps, instrument fuses etc., in
the topmost tier

which may need adjustment / replacement shall all be not more than

1850 mm from the finished

operating level

on the floor


that these

a re easily

accessible for the operating / maintenance personnel without having to take recourse to
ladders / steps etc.,
The minimum operating height of the switch handles shall not be less than 450 mm from
the finished floor level including the safety rubber mat.
All live parts shall be suitably shrouded with non-deteriorating Insulating barriers so as to
prevent any

accidental contact with these b y

the operating / maintenance


while the panel is in service and the modules are opened for inspection / servicing etc.,


The bus bars shall be of hard drawn high conductivity electrolytic grade ( 63401 W P)
Aluminum conforming to IS: 5082. The bus bars shall be of uniform cross section along
its entire length. No tapering of the bus bar cross section is allowed.
Horizontal and vertical bus bars shall be provided with PVC sleeves of high quality.
The joints in the bus bars s hall be of the bolted ty pe and its hall be ensured that the
following precautions are observed:

The contact pressure must be ample and this shall be maintained during the time the
panel is in service.
The surfaces of the conductors must be clean.
With flat conductors, the overlap should be equal to or greater than the width of the
bars or ten times the bar thickness whichever is greater.
The joints shall be treated by the application of joint compound to render the joint
For the joints, use bolts of cadmium plated high tension MS bolts and nuts.

All the bus bar joints / bolts should be silver plated for rating 1600 Amps and above and
shrouded with proper insulated material. The efficiency of the joints shall be preserved by
smearing the surfaces with oxide inhibiting grease just prior to making the joint.
The neutral bus shall be rated for the full short circuit current. Rating of horizontal buses
shall be same as that of incomer circuit breakers and vertical run shall be same as that of
outgoing breaker rating.
The switchboard shall be provided with power busbars for the 3 phases and neutral. The
Busbars fed by the incomer s hall r un continuously throughout the length of the switchboard.

The busbars shall have a short circuit withstand capacity of 50 kA for 1 Sec.
The busbars shall be phase identified by colour, throughout the length or identification of
busbars at regular intervals. Colour code shall be RED, YELLOW and BLUE for phase
buses and BLACK for the neutral. Busbars shall be rated for 40 C temperature rise over
an ambient of 50 C.
The cross section of the

bus bars s hall be uniform

throughout after

considering all

derating factor for PCC and MCCs.

Busbars shall be supported on tough, non-hygroscopic, resin bonded self-extinguishing
fire retardant insulators of SMC / D MC with ribbed construction to prevent tracking due
to dust accumulation an d

to have larger

c reepage path s. All the phases shall

Individually supported. I f a Common support is provided f or all


barriers s hall

be Incorporated. B usbars


the three phases, anti

and supports

shall withstand t he

Maximum stresses that are likely to be induced by the short circuit currents specified.

The necessary calculation for selecting size of bus bar and insulator shall be furnished
during detailed engineering for owners approval.
All busbar joints s hall be

Of the bolted type. Ring washers

shall be used for joints to

Prevent loosening of the nuts and overheating. Lock nuts shall be incorporated for the
bolts besides the main nuts. The bolts and nuts used in the current carrying paths shall
all be of steel cadmium

plated and the hardware s hall have

protective cadmium coating to obviate corrosion while

adequate cover of the

the board is in service. P roper

work space is required for tightening and checking the bolts and joints.
The bus bar


at the top s hall be to


compartments and rendered totally inaccessible under

segregated from the rest o f

Normal circumstances. No

Equipment / Instrument shall be mounted on the busbar chamber.

Power shall be distributed to each module or compartment by a set of vertical busbars.
The vertical busbars shall run behind the modules.
All bu sbars s hall be PVC sleeved and adequately shrouded to prevent accidental contact. The
sleeve used shall be of the heat shrinks type.
The bus bars shall run horizontally in a separate enclosure but may run in an enclosure
located within the power busbar compartment.
Necessary tee off connectors shall be used for distributing auxiliary supply to e ach vertical
panel. Rubber grommets shall be used for all wire entries to make the entries dust and
vermin proof.



All 415V/240V AC an d 220 V DC loads of Main plant as well as BOP is to be catered

From the LT switchgears/MCCS/ DBs included under this specification. While tentative
feeder requirements are indicated, Bidder is to prepare feeder lists for BOP systems in
his scope and provide required PMCCs/PCCs/MCCs/DBs to cater for all the required LT
Loads. Bidder to s elect p roper equipment rating and substantiate the same

by proper

Justification / calculation during detailed engineering. The equipment shall be


as per the final requirement.

Certain switchgears with very long lengths s hall be sectionalized and physically separated for
ease of operation and maintenance. Interconnection of s uch sections by segregated phase busducts shall be in Bidders scope. Successful Bidder shall furnish preferred arrangement based on
general arrangement drawing.
In certain cases, switchgear may have to be arranged in L, C or U shape. Bidder shall
provide dummy panels required for such arrangements and also for floor beam crossing.
This being a lump sum turnkey contract. No additional payments will be applicable for all
such requirements.
415V switchgears s hall have spring charged A.C. Mo tor operated

stored energy type

Circuit breakers with integral manual spring charging handle. These breakers s hall be
electrically operated type and shall be provided with electrical and mechanical interlocks
to prevent paralleling of two different sources of supply.
All MCCs shall be of single front construction depending upon the space availability. All
Switchgears/MCCs shall b e Sectionalized. These shall
Provision s hall be made to

defeat interlock to enable


electrically Interlocked.

parallel operation i n case o f

The contractor shall furnish relay application checks / calculations to check adequacy of
the CTs / VTs as well as suitability of relay settings / setting ranges p roposed by the
Bidder. These checks / calculations shall be furnished during details engineering stage
for each and every feeder.



The Bidder shall supply all the material as required for completing the schemes. It may
be c learly noted t hat t he bidder s hall

offer A CBs, switches & c ontactors f or s tarters

covering the whole range upto 200 KW motor size in not more than six (6) sizes. Bidder
to select p roper eq uipment ra ting an d s ubstantiate th e same by p roper jus tification /

Sufficient s pace in

each mo dule s hall

be p rovided

for r epair a nd

maintenance work. Components i.e. contactors O/L relays, MCBs, MCCBs, PBs etc., to
be used in v arious Switchgears / MCCs should be of reputed make duly

approved by

Owner / Consultant.
All moto r f eeders ra ted b elow

30kW will be provided

Contactor & motor controller. Motor rated from

with MCCB

MPCB, Pow er

90 KW to 30kW shall be provided with

MCCB/MPCB unit, power contactor, motor controller with soft starter and DOL byp ass
etc., as per the requirement. The combination shall ensure type II coordination as per IS:

13947. Motors ra ted 90 K W a nd ab ove feeders t o be pr ovided with ACB s along with
protection re lays. All mo tor feeder mo dules s hall also be pr ovided w ith local / field /
remote selector switches on the module itself.
In all modules at least 2 NO + 2 NC spare contacts of main contactor shall be wired up to
the terminal block.
Each modu le shall have inde pendent

control s upply trans former of 415/240 V

suitable c apacity a nd protection at primary and s econdary s ide to


be pr ovided.


modules should have three distinct positions service / Test / Isolated.

Drawout type control module shall have self-aligning power/ control disconnects. All
disconnects shall be silver plated to ensure good contacts.
The module

shall hav e s ervice,

test and w ithdrawn p ositions. Adequate

s liding

contacts shall be provided in the control circuit to provide for all interlocks, start/stop
commands, control supplies and power supplies, etc.
The design s hall be such as to p ermit eas y withdrawal/reinsertion

of the un it


guide rails to ensure correct alignment.

Control Module shall house the control components for a circuit such as switch,
fuse, contactors, relays, push buttons, lamps etc.
The equipment lay out sha ll provide s ufficient w orking s pace in b etween t he components
and subject to Owner's approval.
Various mo dule/compartment size s sh all be multip le of one ba sic u nit to fa cilitate
modifications at site. Suitable provision for this purpose should also be incorporated
in the vertical bus bars.
Drawout ty pe c ontrol m odules of s ame s ize and t ype s hall be electrically and physically


LT s witchgear and PCC/MCC boards shall be of fu lly dra wout mo dular c onstruction.
ACDB / DCD B shall be of draw out type module. The switchgear shall comprise floormounted, self supporting with ISMC bas e frames or in-built kick plate of 75mm height,
dust tight sheet steel panels, with individual door for

each module. Main busbars shall

be accommodated in a horizontal busbar chamber running the full length of the board at
the top along with the neutral. The VBB will comprise of 3 phas e busbars in a busbar
chamber an d o ne neutral b us ba r and tes ted for

50 KA f ault le vel. C able alleys o f

adequate size (but not less than 250 mm) shall be provided in e ach vertical section for

ease of cable termination. Various feeders shall be arranged in individual compartments.

All feeders shall be wired out to th e terminals. Power cables connecting SS nuts bolts
and necessary cable supports in cable alley shall also be provided. Design shall be fully
compartmentalized an d m odular ty pe as c ommonly

used for Motor Control Centres.

Extension bus links properly s paced fo r termin ating single c ables of size 120 s q. mm
and above as well as for terminating multiple cables of all sizes Where more than one
cable h ave t o

be t erminated per unit, th e

arrangement s hall permit c onnection and

disconnection of i ndividual c ables s eparately

without d isturbing other c ables.Itsh all

conform to all applicable construction features specified herein for Switchgears / MCCs.
The panel boards shall be suitable for single front construction, floor mounting withfully
drawout design.
All AC and DC distribution boards and cabinets shall be complete with necessary neutral
links, earth bus, terminals, name plates, cable sockets, wiring, AC and DC distribution
boards shall have all s witches on front s ide of panels, operable from outside. Doors of
distribution boards and cabinets shall be lockable.

These shall be of bunched LED type. The lamps shall have red, blue, green, amber and
white caps as specified.
All Indicating lamps s hall be c luster

LED typ e with removable c over and s hould have

LVGP protection.
Electrical indications with colours as given below shall also be provided.


a) Breaker 'ON'

Red Lamp

b) Breaker 'OFF'

Green Lamp

c) Breaker 'Auto Trip'

Amber Lamp

d) Trip circuit healthy

White Lamp

e) Spring Charged




Service Position


The panel shall be connected to an earth busbar running throughout the length of the
switchboard. The mi nimum ear th bus s ize s hall be 50x6 mm copper. A ll doors an d
movable parts shall be c onnected to the earth bu s w ith flexible c opper connections.
Provision shall be made to connect the earthing busbar to the p lant earthing grid at two ends.
All non-current carrying metallic parts of the mounted equipment shall be earthed.

With dr awable un its pro vided with self-aligning, spring loa ded, silver plated c opper
scrapping earth contacts of make before/break after type ensuring earth continuity from
service to the test position. Hinged doors earthed through flexible earthing braid.

The b reakers shall be of th ree pole

type, unles s

otherwise s pecifically men tioned

elsewhere (4 pole in case of DG power incomer) and all the breakers shall be of drawout type.
The operating me chanism s hall

be of

motor operated s pring c harged type unl ess

otherwise s pecifically men tioned, where it s hall b e of

manual wound s pring c harged

The circuit breakers shall be provided with mechanically operated emergency tripping /
closing device. This device shall be available on the front of the panel.
All circuit breaker shall be microprocessor based intelligent type direct acting O/C, S/C
& E/F release with measurement control & data transfer facility.
The release unit of bre akers (incomers, bus coupler & outgoing) shall have the facility for
taking input from a separately mounted NCT for earth fault protection.
The operating range of shunt trip coils of all breakers shall be minimum from 55-110%
(126-253V ac) of the rated 230V ac voltage. This is for reliable operation of the shunt trip
during single phase to ground fault on any phase.
The circuit breakers shall be provided with 6 NO + 6 NC minimum, convertible from NO to
NC and v ice versa at site. The spare auxiliary contacts shall be wired and available for f
uture us e. If spare auxiliary co ntacts are not available, lock-out relay of approved make &
type shall be used to multiply the available spare auxiliary contact.
Circuit Breaker positions shall be indicated electrically. The following indicating colours
shall be used.

Breaker 'Close' Red

Breaker 'Open' Green
Breaker 'Auto Trip' Amber
Breaker in service Clear
Trip circuit healthy Blue

Breaker Spring Charged White

Circuit Breaker positions (Open & Close), location (service and test) and spring charged
conditions shall also be indicated mechanically.
The breakers s hall b e trip free. If av ailable a s a m anufacturers s tandard f eature, the
breakers shall be provided with a release to trip the breakers instantaneously if closed on to
a fault.
The circuit breakers shall be provided with an antipumping feature. If an electrical relay
is us ed f or t his f eature, t he relay s hall be l ocated on the breaker c hassis. Th e anti
pumping feature shall be maintained even if the bus voltage disappears during a fault.
Circuit breaker trip and closing coils shall be rated for satisfactory operation under the
following conditions of supply voltage variation.

Trip coil: 55% to 110% of rated voltage

Closing coil: 85% to 110% of rated voltage.
Rated coil voltage shall be 220V DC



The ci rcuit breaker co mpartment sh all be fu lly draw o ut, tha t is, bus sid e & outgoing
power and control connections shall be through drawout contacts (it shall be possible to
drawout the withdraw able troll ey without h aving to unbolt or un screw

any po wer and

control connections). Suitable guides shall beprovided to facilitate easy

withdrawal of

the trolley. All identical feeder compartments shall be interchangeable without having to
carryout modifications.
Spring actuated and gravity operated safety shutters shall be provided for isolating the
busbars and other live parts when the breaker is completely withdrawn. The design of
compartment shall be such as to prevent movement of vermin from a pa rticular circuit
breaker compartment to any other portion of the panel when the b reaker is withdrawn

The earth connection shall remain connected in test and service' positions also.
The draw-out compartments shall have the following features and interlocks:
Compartment doors shall be interlocked against opening when breaker is in closed
or ON condition. However, it shall be possible to bypass this interlock for inspection
It shall not be possible to push 'in' a drawn out circuit breaker in closed condition or
withdraw a circuit breaker in closed condition.

shall be p ossible to

operate a c ircuit b reaker only in the d efined " Full In" or

"Service" and "test" position inside the panel. It shall not be possible to operate the
breaker in in termediate position while inserting or withdrawing a cir cuit breaker or
while in "Full out, position inside the Panel.
Castell key

type in terlocks

shall b e p rovided b etween

fe eders, w herever specified.

Electrical interlocks shall also be deviced, wherever specified.


Electrical p ower operating me chanism shall be motor w

ound s pring c harged s tored

energy type . How ever, manu al o perating me chanism ma y be o f

the s pring c harging

stored energy type or the s pring assisted t ype. Prov ision s hall

be m ade f or manual

spring charging also. Closing time of circuit breakers with manual operating mechanism
shall be independent of the speed of the operating handle.
All stored energy operating mechanisms shall be equipped with following features:

Failure o f springs, v ibrations or shocks shall n ot c ause u nintended op eration o f

breaker or prevent intended tripping operation.

Closing of circuit breaker shall be prevented unless the spring is fully charged.
All electrical power operating mechanisms s hall be s uitable for remote op eration
and shall be equipped with following features:
Provided w ith

emergency ma nual

automatically, (me chanically) de li nked


fac ility.

The mo tor

once t he

ma nual c harging h andle

shall b e

Closing operation

of c ircuit bre aker sl hautomaticallyl i nitiate

charging of the

spring for the next closing operation.

One complete c losing o peration s hall b e c ompleted o nce t he
given and the first device in

closing impulse is

the control scheme has responded even though the

control switch / PB is released provided no counter trip impulse is present.




The c ontrol unit

shall be interchangeable

on s ite

for adaptation to c

hanges in t


Sensors shall b

non-magnetic or

of th e

Ro gosky type for

accurate c urrent

The control unit shall measure the true RMS value of the current.
The control unit shall comprise a th ermal memory to store temperature-rise data in the
event of repeated overloads or earth faults. It shall be possible to disable this function if

The control unit shall offer the following protection functions as standard: Longtime (LT) protection with an adjustable current setting and time delay; Shorttime (ST) protection with an adjustable pick-up and time delay; Instantaneous
(INST) protection with an adjustable pick-up and an OFF position. Earth-fault
protection with an adjustable pick-up and time delay.

Current and time-delay settings shall be indicated in amperes and seconds respectively
on a digital display. Acknowledgement that the setting change should translate to the trip

An ammeter with a digital display shall indicate the true RMS values of the currents for
each phase.
An LCD Screen should continuously display the most heavily loaded phase apart from the
load level on the three phases.
A maximeter shall store in memory and display the maximum current value observed since the
la st r eset. The da ta s hall c ontinue t o b e stored and displayed e ven after opening of the
circuit breaker.
The control unit shall measure voltages and calculate power and energy values.
These v alues s hall be d isplayable o n t he sc reen and updated ev ery second. The minimum
and maximum values shall be stored in memory.


The circuit breaker shall be capable of communicating the following data through a bus:
Circuit-breaker s tatus (op en/closed, c onnected/disconnected/test, trip ped on a fau lt,
ready to close)





parameters. Tripping causes

The measurements processed by the control unit: cur rent, voltage, frequency & power
active & reactive).
It shall be possible to remotely modify circuit-breaker settings:
Settings within the range defined by the switches on the front panel of the control
unit; Settings of the protection functions and the alarms.
It shall be possible to remotely control the circuit breaker of identified feeders only.(Viz. all
incomers & bus couplers)

Communications functions shall be independent of the control unit.



Trolley for transportation / replacement / handling of the circuit breaker- 1 No for each
switchboard shall be supplied, The trolley shall have an arrangement of lifting / lowering
of the t rolley platform with a gear operated handle and s elf l ocking p rovision at th e desired
level with the help of a ratchet.



Fuse switch modules shall be fully drawn out type.
Fuse switch modules shall be provided with components, as specified. The module shall
comprise of the following:

Feeder switch with TP/TPN/FP with HRC fuses and neutral

link Set of cluster type LED lamps for ON / OFF




specified Current transformers

Terminal blocks, interconnection bars / wires, ferrules, etc. as per requirement

The switch modules shall have doors made out of 1.6 mm steel or heavier. Doors shall be
mounted on adjustable and removable pin type concealed hinges and so arranged that
unit doors may be removed without disturbing the unit doors above or below.
The switch operating handles shall be capable of being padlocked in the 'OFF position.
For the purpose of standardization, similar components in th e switch board shall be of the
same make / brand identical and interchangeable.
Only the operating handle of the load break switch shall be accessible for operation with
the related door closed.
The doors shall be i nterlocked with the associated load break switch so that the door can be
ope ned only when the switch is in the de-energized (off) position and the doors shall not be
capable o f being c losed with th e s witch in t he en ergized ( on) po sition. Provision shall also
be available to defeat the interlock.
Each compartment shall have suitable name plate which shall be f ixed on the cover in
distinct colour to designate the feeder number, feeder designation, current rating & HP /
kW of the related equipment.



Types of starters for various ratings & applications shall be as below:


--- Direct online (DOL)/Soft starter


--- Reversible DOL (RDOL)

Lighting panels/heaters --- Feeders with MCCB/switch fuse unit

The s tarter modules s hall be of a pproved quality a nd mak e and c omprise of t he
Starter module shall be fully drawn out type.
Feeder switch with 3 poles with HRC fuses /MCCB/ ACB, as applicable
Air-break contactor(s)
Bi-metallic over load relay
HRC fuses for the control circuits.
Selector switch,
Set of cluster type LED lamps equipped with Low Voltage Glow Protection for ON /
OFF / TRIP. OPENED / CL OSED lamps shall b e made a vailable additionally fo
valve feeders.
Set of pilot devices comprising of Oil tight 'RESET' button complete with actuator and
necessary linkages.
Meters & transducers,
Current transformers for metering and protection
Terminal blocks, interconnection bars / wires, ferrules, etc. as per requirement

The starter modules shall have doors made out of 1 .6 mm steel or heavier. Doors shall be
mounted on adjustable and removable pin type concealed hinges and so arranged that
unit doors may be removed without disturbing the unit doors above or below.
Only the operating handle of the load breakswitch set, an d the RESET push buttons
shall be accessible for operation with the related doors closed.

The fuse ratings in the load-break switch fuse units/MCCB and over load relays shall be
suitably c oordinated with the mai n c ontactor ratin g to meet typ e '2' re quirements in
accordance with IS:13947. The selected switch ratings at AC23B duty shall be not less than
the corresponding fuse/MCCB rating, in all the cases.
Following colour coding to be used for panel wiring:
Power Circuit - Red / Yellow / Blue / Black





sleeve.) AC control wire - Grey colour

DC control wire - White
Earth wire - Green


MCBs shall be used in all the AC control circuits and DC c ontrol & lighting feeders, as
specified. However, control fuses may be used in the ACB feeders for DC circuit.
The MCBs sha ll be s uitable fo r
under o verload

manual c losing a nd o pening

and s hort c ircuit c onditions. They

and automatic trip ping

s hall op erate on Hammer Tr ip

principle. They shall be provided with trip-free mechanism.

The minimum s hort circuit breaking c apacity of

MCBs shall b e 9KA r .m.s. at 0.55

The c ontractor s hall b e r esponsible to check an d coordinate the

p. .

MCB c haracteristics

with the back up fuse provided in the LDB.

The M CBs shall be s uitable f or housing in the lightin g p anels

and f or c onnection of

standard copper / alumini um wires at both the incoming and outgoing ends by c opper
lugs or bus bars connection on the incoming end.
The terminals of MCB and ON and OFF positions shall be clearly and indelibly marked.
The MCBs shall generally conform to IS: 13947.
All MCCBs should have over load, short circuit element and earth fault protection that can
be adjusted by knob.

All fuses shall be of high rupturing capacity (HRC) cartridge plug-in type conforming to
IS:13703 IEC:269, Part 1, Part 2. No bolted type fuse shall be used.

Motor fuse characteristics and ratings shall be chosen so as to ride over starting period
and not operate during motor starting. They shall also not operate before the associated
motor thermal overload relay for 1.1 times the motor starting current. Fuse rating shall not
exceed associated switch rating.
Design of fuse mounting arrangement shall be such that it can be replaced with the help
of fuse puller even when the circuit is live.
Fuse ratings finally chosen for application in various circuits shall be subject to Owners
/ Consultants approval.
Non-hygroscopic ins ulating bar riers prefera bly of FRP o r s imilar materi al s hall be provided
between power fuses.

The contactors shall be air break type, equipped with three main contacts and minimum
2 NO + 2 NC auxiliary contacts. The main contacts of a particular contactor shall have
AC 3 r atings for general AC mo tor cir cuits, AC5a fo r AC ligh ting circu its, AC6b for
switching of capacitor banks and DC6 for DC lighting circuits, AC4 for bidirectional motor
inching facility, as per IS:13947.
The auxiliary contacts shall be rated for minimum 5 Amps at 240 V AC and 220V DC.
Unless specified otherwise, the coil of the c ontactor shall be suitable for operation on 240V
AC s upply and s hall work s atisfactorily bet ween +l0 % a nd - 15% of th e r ated voltage.

The contactor drop-off voltage shall be between 45% to 65% of the rated coil voltage.
Auxiliary c ontactors s hall generally be used for i nterlocking and mult iplying c ontacts.
Auxiliary contacts shall be capable of c arrying the maximum estimated current, but not less
than 5A at 240V AC.

Contactors shall not dropout when a fault occurs on an adjacent feeder.

All motor feeders shall be provided with auxiliary contactors as needed and to provide
adequate number of spare contacts.
The contacts of the auxiliary contactors and the auxiliary contacts of the main contactor shall
be rated for mak ing, carrying a nd b reaking 10A, 24 0V AC and 1 A, 2 20V DC (inductive
circuit). All spare contacts shall be independently wired to the terminal blocks.
Contactor c oil mo unting a rrangement shall be s uch tha t its rep lacement is possible
without disturbing any wiring connection.
Contactor shall be capable of closing on system prospective symmetrical fault c urrent
when backed up by the large HRC fuses appropriate to the rating of the contactor.
Reversing contactors s hould be provided with ele ctrical a nd me chanical inte rlocks between
forward and reverse contactor.



Over lo ad relays w ill be




of bi -metallic thermal overload


type or electronic type


specified in the drawings.

Bi-metallic Ov er Load R elay,

t hree el ement type d irectly m ounted, front


ambient temperature compensated bimetallic devices of suitable range to match with the
rating / o utput of the

motors c onnected to the r elated s tarter and c omplete

with hand

resetting device. The relays shall be provided with minimum I NO + I NC contacts with a
rating of 5 Amp s at 240 V I PH, 50 HZ AC and 1.3 Amps at 220V DC (Inductive load).
The bi-metallic relays s hall h ave
detection even at partial

double s lide m echanism f or

load conditions. Heav y d uty

r elays

single phase f ailure

shall be c onsidered,

wherever the starting time is expected to be very high.

The overload relays for all motor and valve feeders shall be three (3) elements positive
acting, a mbient tem perature

c ompensated, time lag

thermal bimetallic ty pe

adjustable settings. Thermal Overload Relay shall be provided with built in single phase
prevention fa cility. Th ey s hall

be h and reset with t he help of p ush b utton and reset


The range of thermal overload relay chosen shall be adjustable to 70 110% of full load
current of corresponding motor.
Thermal overload relay shall either have a pair of 1 N/O + 1 N/C potential free contacts or
a set of changeover hand reset type contacts.

The current transformers shall be of bar primary wound secondary cast resin type with
copper c oils and hav e a

short t ime withstand rating equal to tha

t of the as sociated

switchgear for one second. It shall be the responsibility of the vendor to co-ordinate the
burden of the CTs
associated with the

with the ac tual

requirements of relays , instruments, leads etc .,

particular CTs. The minim um requi rement s hall

be 10VA bur den,

accuracy class 1.0 and an instrument safety factor of 5. CTs with 0.5 accuracy clause
shall be provided, wherever specified.
The CTs shall be provided with the following:
Test links in both secondary leads to carry out phase angle & current
measurement tests.
Earth link to which the leads of the CTs shall be connected so as to facilitate easy
measurement of Insulation Resistance of the CTs.
Current transformers shall be des igned such as withstand open circuit secondary with
primary rated load for a short duration to be stated in the bid.
CTs s hall have polarity makings i ndelibly marked on e ach tr ansformer at t he l ead
terminations and at the associated terminal block. Facility shall be provided for s hort circuiting
and grounding the CT secondary at th e terminal blocks. Secondary terminals shall be provided
with protective cap.
CT ter minal block s hall be d isconnecting typ e a nd s uitable for round type lu gs with facility
for testing and short circuiting of individual CT.

All CTs shall be provided with supports independent of Busbars / Busbar supports.
The CTs s hall b e located in such a way that t hey c an b e eas ily appr oached fo r maintenance
without necessitating shutdown of adjacent feeders.


Voltage transformers shall be resin cast type with copper coils.

Current limiting HRC fuses shall be provided on the primary and secondary sides of the
VT. Facility for visual indication of rupturing of the fuses shall preferably be provided. It
shall be possible to r eplace a f use s afely

without ha ving to de-energize the m ain

busbars. The voltage transformer and fuses

shall be completely disconnected in fully

draw out position.

It should be possible to replace V.T.s without having to de-energize the main busbars.
Voltage transformer mounted on breaker carriage is not acceptable.
Sufficient VA ma rgin a nd ter minals s hall be p rovided for c onnection of re mote transducers for
customers DCS system.
Fuse failure relay shall be provided on the s econdary of v oltage transformer to monitor
LV fuses.


All protective relays shall be back connected, draw out type, suitable for flush mounting
and fitted with dust tight covers. All relays shall be mounted on the front of the panel and
shall be specified as per requirement. The current and the voltage coils shall be rated as
All protective relays shall be intelligent microprocessor based numerical type with IEC
61850 communication protocol capabilities &sequence of eve nt/disturbance recorders for
downloading on serial communication to SCADA.
Motor pr otection r elays

shall b e o f numeric/microprocessor type w ith self


facility, RS 485 communication port with suitable protocol for interfacing with PC / DCS,
software for da ta d ownloading and c onfiguration. Fe eder protection rel ays s hall hav e
IDMT ov er current &

e arth fa ult elem ents. Motor protection relays s hall

have over

Rated continuous, short time thermal and dynamic currents for coils shall be suitable for
service involved.
Rated continuous making and breaking currents for contacts shall be suitable for service
AC re lays shall be rated fo r op eration on 1A s econdary c urrent and 110V s econdary
voltage; number and rating of relay contacts shall suit the system requirements.
The Contractor shall furnish, install & co-ordinate all relays to s uit the r equirements of
protection, interlock and bus transfer scheme as broadly indicated in the annexures and



Control switches shall be of the heavy duty rotary type with name plates clearly marked
to s how the operation. The y s hall be semi-flushed mounting with only the fr ont plate
operating handle projecting. Circuit breaker control switches shall be of the spring return
to neutral typ e, w hile loc al / MCC / re mote s elector switches an d instrument selector
switches shall be of the stay-put type.
Control and s elector s witches s hall be


designated escutcheon plates c learly marked to s how

type and provided

operating pos itions.

with p roperly
To ggle

switch shall not be used for such applications.

Switch ratings shall be adequate for the purpose intended but shall not be lower than ten
(10) amperes making and continuous carrying, and breaking ten (10) A, 240V AC and 1A,
220V DC (inductive circuit) or the requisite circuit breaker operating coil currents at 220V

Circuit breaker control switches shall have required number of electrical ways and three
(3) p ositions ins cribed TRIP / NEUTRAL / CLOS E. The y s hall hav e s pring return to
neutral feature and shall be provided with lost motion device, sequence device and after
close and after trip contacts and pistol grip handle. These shall be Alstom type ODS or
Local / MCC/ remo te s elector s witch handles s hall be eit her s pade o r

pointer or oval

shaped. These shall have required number of positions and contacts.

All ammeter and voltmeter selector switches shall be four (4) position piano type integral
with the indicating me ters. Amme ter se lector s witches sh all ha ve ma ke before bre ak
type contacts so as to prevent open circuiting of CT secondaries when changing position
of the switch.


Marshalling compartments /

cabinets, as anextension for the s witchboards

shall be

provided, for connection of Hardwires from DCS racks.

Transducers and a uxiliary

c ontactors of the in dividual

m odules o f the

s witchboard,

whose outputs are required to be ho oked up for DCS interfacing, shall necessarily be
housed in the marshalling compartment with suitable arrangement of Hard wire scheme.
Marshalling c abinet s hall house terminal ocks,bl apart fro m auxiliary c ontactors a nd
transducers for c onnection to MCC c ompartments / DCS racks Ho wever, lo cal pus h
button station shall be directly connected to the respective motor feeder compartments.
The terminal block arrangement shall be arranged as below.
All digital inputs (DIs) from different feeders to be terminated at a separate array of
terminal blocks.
All digital outputs (DOs) from different feeders to be terminated at a separate array
of terminal blocks.
All analog inputs (AIs) from different feeders to be terminated at a separate array
of terminal blocks.
All terminal blocks shall be identified with the respective feeder name.
All incoming and outg oing motors feeders of LT switchboards shall have provision for
selection of local / remo te (DCS) facilityPotential. free I/O c ontacts f or St art / Stop

command ON, OFF& TRIP and feeder status signals shall be pre-wired and brought to
a common Marshalling chamber for DCS hookup.
All incoming and outgoing feeders of MCC/PMCC shall have spare contacts pre-wired and
brought to MCC DCS Marshalling chamber for status indication & control from DCS.



Energy mete rs s hall b e of elec tronic typwithe cla ss o f a ccuracy 0 .5 o r better. Th e

meters shall be capable of indicating all phase instantaneous parameters and recording
kWH. Th ese should be s uitable for 3 phas e, 4 wire 5 0 Hz

c ircuits with u nbalanced

All th e meter s


shall be

mic roprocessor bas

ed mu

ltifunction type

communication capabilities for downloading on serial communication to SCADA system.

The communication ports of all MFM & composite protection relays shall be integrated in
common data b us with data

concentration an d open pr otocol to have

soft in terfacing

with plant SCADA system.

Test terminal blocks shall be provided in the circuits, wherever static meter and energy
meters are provided.
The a nalog meters, wherever p rovided, s hall be of flu sh mo unting ty pe with s quare
pattern of size 144mm for incomer feeders and 96mm dial size for outgoing feeders. The
dial shall have black numerals with a white background and the scale / range of meter
shall be such that the rated value is indicated at around 70.
Ammeters shall be compatible with CTs of 5A secondary and read actual currents. For
motor feeders ammeters shall have suppressed scale upto 6 times of full load current after
1.2 times of full load current and shall have red mark on full load.


The t erminal blocks pro vided i n the sw itchboard sha ll be mounted vertica lly near the
bottom s ide of e ach module unit, in the c able chamber a t a s lightly up ward a ngle, to
provide clear and easy access to the terminals.
Each wire at the terminal blocks shall bear appropriate number / letter ferrules.


Wiring to the door shall be done by flexible cable & the cables shall be bunched, sleeved
and cleated so tha t no m echanical damage can occur to the c ables when t he d oor swings.

Not more than 2 wires shall be terminated at one control terminal.

All terminations s hall b e of adequate current r ating and size to s uit in dividual f eeder
All the te rmination ends sha ll be pr ovided w ith ha rdwares like cad mium c oated bolts,
nuts, s pring washers a nd t win br ass washers o f 2mm thick and having an equiv alent
contact area of the terminating lug.
Outgoing po wer termi nations s hall bedsigned PVC alumi nium c ables. Suitab le provision
shall be made for termination of higher size cables.
Each control terminal block shaft has 20% spare terminals.
Inter module wiring in the same panel shall be through vertical cable alley.
The rating of the terminal blocks shall be minimum 10A.
Terminal blocks for all CT/VT connections to be of sliding contact type.



All s witchboards and panels shall be supplied c ompletely wired intern ally up to t he terminal
blocks; ready to receive Owner's cable shall be provided by others.
All inter-cubicle a nd inte r-panel w iring and connections b etween pan els of s ame switchboard
including all bus wiring for AC and DC control supplies and annunciation, space heating system
shall be provided by the Bidder.
All inter nal wiring s hall b e c arried out with 11 00 V g rade, s ingle c ore, 2.5 sq. mm or
larger stranded copper wires having colour-coded, PVC insulation. CT circuits shall be wired
with 2.5 square mm copper wires. Voltage grade and insulation shall be same as above.

Extra-flexible wires shall be used for wiring to devices mounted on moving parts such as
hinged doors. The wire bunches fro m the pan el ins ide to the doors s hall be properly
sleeved and cleated.

All wiring shall be properly supported, neatly arranged, readily accessible and securely
connected to equipment terminals and terminal blocks.
Internal terminations of stranded conductors shall be made with solderless crimping type
tinned copper lugs which shall firmly grip the conductor, or an equally secure method.
Similar lu gs s hall also be pr ovided at both ends o f components to c omponent wiring.
Insulating sleeves shall be provided over the exposed parts of lugs.
Engraved core ide ntification fe rrules marked to c orrespond with panel w iring diag ram
shall be

fitted at both

e nds of

each w ire. The

ferrule shall be "Nov oflex" typ e


equivalent. The wire number shall be in accordance with lS:5578. Red Ferrules should
be provided on trip circuit wiring.
Wiring for equipment

w hich may to b e

supplied by

the O wner a nd fo r w hich


Contractor has to provide mounting arrangement in his panels, shall also be provided by
the Contractor, upto the terminal blocks.
Spare auxiliary contacts of individual feeder shall be wired up to marshalling rack
All connections within individual m odules

rated 10 0 A an d abov e shall be by PV C

covered tinned copper/Aluminium links or fixable connections. The cable connections for
modules le ss than 100 A sha ll be s elected in such a way t hat t here

will not be any

melting/shorting. In case of a short circuit inside the module, the cable shall have current
rating to carry the let-through energy of the corresponding fuses in case of a fault.
The insulation of the cable and its cross section shall be decided considering the high
ambient temp erature

within t he mod ule. F or all

envisaged by the Co ntractor s pecific ap proval from the

modu les where

use of c able

O wner/Consultant regarding

cable details shall be taken.


Provision shall be made for tripping of incomer LT breaker on tripping of upstream HT
breaker. Provision for tripping of upstream HT b reaker on fault tri pping of LT inc omer
breaker shall also be provided.


Annunciator shall be static type.
Hooter and bell shall be provided for trip & alarm indication
respectively. Number of points shall be as per list.
Shall have facilities for test, reset and accept.


Shall con sists of annunciation windows,rel ay blocks w arning bell, emerg ency
hooter, push buttons etc.
All windows shall have two bunch LED in parallel.
All accessories including actuator (if respective scheme is in Contractor's scope)
shall be provided.
Sequence of operation shall be as follows :
On occurrence of fault
On accepting
On resetting (fault cleared)
On resetting (fault persists)



Steady ON
Steady ON


The tests shall include but not necessarily limited to the following.
Operation under s imulated s ervice c onditions to ens ure accuracy of wiring, correctness
of control scheme and proper functioning of the equipment.
All wiring and current carrying part shall be given appropriate HV test.
Routine test s hall be c arried out o n all equipment su ch a s CBs, switches / fuse
switches units / MCCBs, Contactors, relays, meters etc. Routine test shall include
measurement of insulation resistance.
Routine test shall be conducted in accordance to the relevant IS.


The supplier shall submit all type test certificates for verification and approval of owner.
The Owner reserves the right to witness any orall the tests, for which at least fifteen
(15) days of advance notice shall be given by the contractor.



The bidder shall supply mandatory spares





General arrangement drawing showing constructional features, space required in front for
withdrawals, disposition of v arious a ccessories and en try p oints of b us duct/cable etc.

Make, typ e and c atalogue n umber of different equipment an d ac cessories a long with
technical leaflets, data sheets, curves etc.
Type test certificates of similar equipment. In case type test certificates as per IS or IEC of
identical equipment of the offered items are not submitted, the Bidder shall have to
conduct the typ e b est on the o ffered equipm ent befo re delivery free o f charge to the
Owner or Bidders testing charges are to be mentioned.
Bill of materials.
Typical foundation plan.
Typical breaker control schematic, MCC control schematic.
Matching flange & terminals for bus termination.
Calculation of busbar size selection.


Dimensional general arrangement drawings with cross section showing the disposion of
various a ccessories, s pace requirement and

busduct/cable e ntry points for all

switchboards. (A)
Transport/shipping dimensions with weight for each equipment. (A)
Data Sheets. (A)
Cross section with part lists. (R)
Consolidated Bill of Materials. (R)
Drawing showing s pace req uired in fr ont for w ithdrawals and c able entry points o f
Single line diagram for each board. These are to be developed on the basis of inputs to
be given to the successful Bidder. (A)

Typical Control schematic and wiring diagrams of all SWGR/MCC/DB. (A)

Feeder wise

Control Sc hematics fo r

all boards (b ased on Purchasers b lock logic

diagram/operational write-up to be made available during detail engineering) showing all

external interlocks/hook-ups and connections/ disconnections within the panels that may
be needed to make typical control schemes suitable for any particular drive. (A)
Documents on motor protection relay

application c heck with b ack-up c alculation and

relay setting chart. (A)

All relevant equipment data sheet and catalogues. (R)