Professional Documents
Culture Documents
OF TECHNICAL REQUIREMENTS
FOR
A 20 CIRCUIT BREAKER
EED 50 47(EKM)
Apr 15
MATERIAL BRANCH
DIRECTORATE OF ELECTRICAL ENGINEERING
INTEGRATED HEADQUARTERS
MOD (NAVY)
‘D’ WING, SENA BHAWAN
NEW DELHI 110011
1
II. REVISION NOTE
No revision incorporated.
III. HISTORICAL RECORD
This standard supersedes the following: NIL.
2
INDEX
A 20 CIRCUIT BREAKERS
1. Introduction (Section1) 5
2. Reference Documents (Section2) 6
3. General (Section3) 7
4. Technical Parameters (Secion4) 89
5. Table 4.4 (Electrical Data for Breaker) 10
6. Circuit Breaker & Selection (Section5) 1112
7. Design of Air Circuit Breaker (Section6) 1315
8. Construction (Section7) 16
9. Inspection & Testing (Section8) 1720
10. Drawings & Documentation (Section9) 21
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SECTION 1
1. Introduction
1.2 Consideration to departure from the specification will be given when difficulties
are encountered during the construction of CBs but no departure may be made
without prior approval DQA (N) / DGQA or DEE / IHQ MOD (N).
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SECTION 2
2. REFERENCE DOCUMENTS. Following documents are referred while
formulating the EED :
(a) NES 530
(b) NES 511
(c) NES 534
(d) NES 532
(e) BR 2031
(f) JSS 55555 Ver 2012 and 50101
(g) NES 609
(h) IEC 363
(J) IS: 139472 / IEC 9472
(k) BS 4752
5
SECTION 3
3. General
3.1 Circuit Breakers used in the Indian Navy are normally type approved and their
manufacturers are registered with DQA (N), which have been adapted to meet
service requirements. The CBs shall be manufactured in accordance with the
specifications and in strict conformity to the approved drawings by Naval
Headquarters. Approval of IHQ MOD (N) / DEE shall be obtained in case of any
deviations whatsoever.
3.2. Any approved alteration or addition of a minor nature found necessary during
the construction of the CBs, are to be carried out by the manufacturer without extra
charges. The manufacturer is to keep in mind continuously the fact that, economy of
weight and space is of utmost importance.
3.3. Wherever items are described in specification and are not indicated in the
drawings or are indicated in drawings but not described in specifications; such items
are deemed to be the requirement of both specifications and drawings.
3.5. All components, fittings, fixtures etc. shall be of standard make (DQAN
approved) and their installation work shall be in accordance with the standard marine
practice and shall satisfy IHQ MOD (N) / inspecting Agency.
3.6. All parts, subassemblies and components shall comply with the requirement
of drawings and specification to the satisfaction of the IHQ MOD (N) / Inspecting
Agency.
3.7. No materials, parts, components or complete units which have been rejected
shall be retreated or adjusted without the approval of the IHQ MOD (N) / Inspecting
Agency.
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SECTION 4
4. Technical Parameter
4.1. Circuit Breakers (CB) are to be electrically operated; microprocessor based with
facility for emergency hand operation and should be suitable for electrical supply
characteristics onboard. Wiring in the circuit breakers should be LFH type. All CBs
are of withdrawal type on front side. Facility should be provided to disengage it from
fixed busbar connection with locking arrangement in service, isolated and
maintenance position. The following protections are to be incorporated in the CBs:
(a) Overload protection.
(b) Short Circuit protection.
(c) Earth fault protection.
(d) Over voltage protection.
(e) Under voltage protection.
(f) Current unbalance protection.
(g) Reverse power protection.
(h) Voltage unbalance protection.
4.2. All Circuits Breakers are to meet the requirements as per BS 4752. Where a
Circuit Breaker falls below this standard, approval of the IHQ MOD (N) / DEE must be
obtained before it is accepted for use. The succeeding clauses define the minimum
standards which are considered acceptable for such Circuit Breakers in addition to
following special service conditions :
(a) Ship motion.
(i) Roll : +/ 300
(ii) Pitch: +/ 100
(iii) Trim : 50
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120G, 8ms (vertical)
& 70G, 8ms (lateral)
(j) Endurance (number of operation cycle)
(q) EMI / EMC : Mil Std – 461E/F {OEM would be required to formulate an
EMI/EMC Acceptance Plan (EMI AP) post placement of order for approval of
IHQ MoD (N)/ NEC (MB). The EMI/EMC testing would be done as per test plan
vetted and stamped by NEC (MB)}.
4.3 Electrical Data for the breaker :
SI Parameters Rated Limit
Board Rated Parameters
(a) Voltage 175320 V
(b) Main circuit current 1500 A
(c) Voltage in control and signaling circuit 127 V 50 Hz 1Ф
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4.4 Electrical Data for the breaker:
Input Nomina Current Current Time of Settings Time of Time for Electrodynamic Maximum Maximum Thermal
Voltage l Settings Setting operation for operation operation Reserve Current Current that Reserve
(V) DC Current for for of short overload of of Maximum that is is allowed ITH2 tTH
(A) tripping Short circuit trip IOL overload tripping Current that is allowed through (KA2Sec)
IN coil (A) Circuit trip (times IN) trip tOL coil allowed through through contacts
IT Current tSC (Sec) (Sec) tTRIPCOIL contacts without contacts during Thermal
ISC (Sec) damage IMAX during making of Equivalent
(KA) dropping breaker impulse of
(times of breaker without short
IN) without damage circuit
damage IMAXMAKE current
IMAXDROP (KA) over time
(KA)
0.18
1250
175 0.38
1500 A 1500 2 8 1.55 2 4 12 0.04 110 45 70 3000
320 0.63
2000
1.0
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SECTION 5
5. Circuit Breakers Selection
5.1 Circuit Breaker is to be selected to suit the particular supply system requirement
in terms of rated voltage, current and fault handling capacity in accordance with the
methods described in NES 532 and IEC 363.
5.2. Temperature Rise.
5.2.1. The ambient air temperature surrounding the Circuit Breaker will be
determined by the heat dissipated within the board and the air flow through it, which
is again determined by the design. The maximum temperature rise for component
parts of Circuit Breakers is to be as shown in BS 4752 subject to be specified
temperature rise being reduced by Tc 40 degree C where Tc is the maximum
temperature of the air surrounding the Circuit Breaker when fitted in the board and
operating under the most adverse conditions of service.
5.2.2. The maximum temperature limit for any assembly or component fitted in a
Circuit Breaker which is not covered specifically by BS 4752 (eg. an electronic/
processor protection unit) is not to be exceeded.
5.3. Material.
5.3.1 Materials used in the construction of CBs are to be selected in the first instance
from the range shown in NES 507. Where the required material is not covered by
NES 507, approval of the DEE must be obtained before it is used.
5.3.2 High conductivity electrolytic grade copper bus bars are to be provided in
accordance with BS 1433. Bus bars are to be rated in accordance with BS 159.
5.3.3. Materials that could pose a health hazard are not to be used, eg asbestos
cadmium and all forms and compounds of these materials.
5.3.4 Plastic and similar combustible materials used for mouldings and insulation are
not to be used unless they have been tested for fire characteristics and approved for
use by the IHQ MOD (N) / DEE. Where there is doubt the details of the material
proposed are to be forwarded to the DEE for approval. The material should meet the
following main fire retardant characteristics:
(a) Oxygen Index : greater than 30.
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(b) Toxicity Index : less than 5.
(c) Smoke Index : less than 50.
(d) Fire Propagation Index: less than 12.
5.4 Painting and Finishing :
5.4.1 Painting and finishing to the manufacturer’s usual commercial standards will
normally be acceptable subject to the limitations on hazardous materials stated in
Clauses 5.3.4 above.
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SECTION 6
6. Electrical and Mechanical Design of Air Circuit Breakers
6.1. Electrical Design of Air Circuit Breakers
6.1.1 Auxiliary switches, which mimic the operation of the main contacts, are to be
provided on the CB or cassette as required. Where these are cassette mounted, a
mechanical linkage is to be fitted to enable them to be operated when the CB is in
the “isolated” position. Auxiliary switches are to be readily accessible for maintenance
or replacement.
6.1.3. Over current protection fitted on the CB must be designed for maximum
reliability and provide the necessary monitoring arrangements to ensure integrity of
control lines. CB’s protecting incoming supplies when used with offbreaker
protection systems are to incorporate a direct acting backup device to provide
protection against short circuit in case of failure of normal control.
6.1.4. Connections to the CB for electrical control and auxiliaries are normally to be
by flying leads and approved sealed multipin connectors.
6.1.5. The A20 circuit breaker is to be operated as follows:
(a) Automatic switching on/off breaker from remote location.
(b) Automatic switching on/off breaker locally from battery post.
(c) Manually switching on/off breaker locally from battery post.
6.1.6. Provision is to be made for the fitting of a shunt trip and/or under voltage
release with time delay. Alternatively such devices may be incorporated in an
integrated protection system on or off the CB as stated in the SOTR.
6.1.7. All structural metal work in the CB is to be electrically continuous and is to be
bonded to the cassette framework via substantial earth strap. This strap must
provide continuity with the cassette when the CB is in either the “service” or “isolated”
undertaken with the CB fitted in the switchboard in the “maintenance” position.
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6.1.8. Contacts are to be of silver, silverfaced or approved equivalent and be
capable of making and breaking rated current without undue arcing, burning or any
tendency to weld. The main and arcing contact shall be of ample size and of such
form and disposition so as to ensure:
(a) A wiping or self cleaning action on closing.
(b) Efficient contact when closed for long periods of time under conditions of
considerable temperature changes which may occur in service.
(c) Satisfactory current breaking (45 KA) by limiting the fault current at the time
of breaking so that material damage to the main contacts is prevented.
(d) Should have a reasonably high MTBF.
6.1.9. Means are to be provided for adjusting the pressure of CB main contacts to the
correct value should changes occur during service. The main contact must be easily
accessible for cleaning and the arcing contact must be readily accessible and easily
renewable when in the ‘’Maintenance’’ position.
6.1.10. Insulation. F Class or of high grading to be used.
6.2. Mechanical Design of Air Circuit Breakers:
6.2.1. CB’s are to be of the withdrawable type designed as a self contained unit, eg.
including a housing or cassette. Means are to be provided to disengage it from the
fixed (busbar) connections and to lock it in the following positions within the cassette:
(a) “Service” connected to busbars and fully operational.
(b) “Isolated” disconnected from busbars but operational.
(c) “Maintenance” fully disconnected and withdrawn.
Position locks are to engage automatically as the CB is moved in either direction, and
be unlocked manually.
6.2.2 The CB should be of robust construction and capable of being handled by
Ship’s Staff using the appropriate handling gear under the most adverse conditions of
ship motion.
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6.2.3. The mechanical interlock is to be provided to ensure that the main contracts
are in the open condition before the CB connects to or disconnects from the fixed
(busbar) connections.
6.2.4. In the “maintenance” position the CB is to be adequately supported to allow
inspection and limited maintenance work to be undertaken. There is no requirement
for the CB or its supports to withstand the specified levels of mechanical shock in this
position.
6.2.5. The CB is to be fitted with clearly defined lifting points designed for attachment
of a frame or strap. Any such strap when in use is not to cause damage to
component parts of the CB.
6.2.6. In addition to the mechanical endurance requirements specified in BS 4752 the
CB is to be capable of 20,000 closeopen operations without damage or catastrophic
failure. This requirement assumes that the CB is not passing current and that
periodic routine maintenance and adjustment is permitted.
6.2.7. The CB is to be fitted with a counter to record the number of close open
operations. The counter is to be 5digit selfresetting to zero after 99999.
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SECTION 7
7. Construction
7.2. Shock Standard. The CBs shall withstand shock standard NSS1 (INHERENT)
in conjunction with BR3021.
7.4. Limiting Dimensions. The estimated overall dimensions of the CBs are not to
exceed the dimensions specified below:
7.5. Due to small opening of the submarine hatch, circuit breaker panel is
required to be dismantled and individual components are to be reassembled to
form the circuit breaker at the required location. Based on the location of the
circuit breaker, the assembly would be undertaken to cater for a form fit.
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SECTION 8
8. Inspection and Testing:
8.1 Quality Assurance.
(a) The supplier is required to submit draft Quality Assurance Plan (QAP)
& Drawings to the field unit of DQAN & ATP to IHQMoD (N) for approval
within 01 months of placement of order. The approving authority reserves the
right to amend/ modify the QAP/ ATP. The approved QAP will form basis for
inspection/quality check/ acceptance of items/ equipment’s. The equipment
supplied by the vendor would be accepted subject to evaluation and clearance
by team comprising of reps from the DGQA and IHQ MoD (N)
(b) The list of all bought out/ imported items which are sourced from OEM/
subcontractors and delivered in "asitis" condition would be approved by IHQ
MoD (N). The items would be accepted based on functional checks (as per
ATP/ FATs document approved by IHQ MoD(N), scrutiny of CoCs endorsing
the standards to which the items comply, physical values of test conditions the
items have been subjected to and the values obtained thereof (for ET,
EMI/EMC & ESS) and conduct of Burnin testing.
(c) Burn in test would be conducted in accordance with guidelines issued
vide 66301/Policy10/DQA(N)/QA10 dated 14 June 13.
(d) The items should be of the latest manufacture conforming to current
production standard.
8.2 Inspection.
(a) Inspection Authority. Directorate of Quality Assurance (Naval) or IHQ
MoD (N) nominated.
8.3. Trials and Tests
8.3.1 Type Testing: The CBs should be type approved or to be submitted for type
testing after placement of order if not tested earlier.
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8.3.2. Type Test. Following type tests are to be carried out as specified in NES
511:
(a) Withstand voltage test.
(b) Insulation Resistance test.
(c) Short circuit test.
(d) Temperature rise test.
(e) Thorough fault test.
(f) Operation of protective devices.
(g) Mili volt drop test.
(h) Functional test to prove the correct operation of safety devices.
(j) Tripping characteristic with rise in temp (IS: 139472/IEC 9472).
(k) Electrical Endurance (IS: 139472/IEC 9472).
(l) High Voltage Test. (As per NES511)
8.3.3. Environmental Tests. A list of limited environmental tests (which do not drive
the equipment to yellow banding) required to be conducted on CBs are as per table
given below:
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exposure variation from 20degC to 35degC, RH95 Test
Condition A, 7Cycles, Dwell time 12hrs
(g) Mould Growth JSS 55555 Ver 2012, Test No.21 29degC,
(Representative RH90, 28days
samples)
(h) Corrosion salt JSS 55555 Ver 2012,Test No.9, Procedure 2
(Representative
sample)
(j) Shock test JSS 55555 Ver 2012,Test No.24 NSS Grade
I (for equipment fitted below waterline)
120G, 8ms (vertical) and 70G, 8ms (lateral)
(k) Inclination/Tilt CL 0563 Sec19
8.3.4. FATs and HATs. The supplier is to offer the system for FATs and HATs as
per schedule provided by the OEM and approved by IHQ, MoD (N).
(a) Functional Tests of complete system
(b) Verification of design, especially firmware and software
(c) Test equipment used, calibration requirements
(d) Pass/Fail criteria
(e) Expected duration and time schedule
8.3.6. The FATs schedule after being formulated by the supplier should be
forwarded to IHQ, MoD (N) for vetting and approval at least 02 months prior to the
trials.All EMI/EMC and Environmental Qualification tests need to be completed prior
to FATs.
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8.3.8 EMI / EMC. Compliance to Environment and EMI/EMC test specifications
would involve conduct of physical tests or scrutiny of test reports.
8.4 Description of Tests.
8.4.1. Insulation Resistance Test. All CBs are to be tested for insulation
resistance and minimum insulation resistance shall not be less than 2 Mega Ohms.
The test voltage is to be 500 volts. The test for measuring, insulation resistance is to
be carried out after withstand voltage test.
8.4.2. Short Circuit Test. All the circuit breakers are to be tested for time of
operation by actually passing short circuit current. Where practical, the test shall be
made on the complete assembled equipment and not on the individual parts, unless
special instructions are given by the naval authority.
8.4.3. Functional Test. Function, control and performance of all control circuits
indicating lamps, alarms etc are to be demonstrated.
8.4.4. Protection Relays . Performance of all protective relays is to be demonstrated
throughout their range of setting and recorded.
8.4.6 Burn in Test. Burn in Test is to be conducted on the breaker by continuous
operation for a period of 168 hrs at room temperature or 48 hrs at +55 deg elevated
temperature prior to shipment. Burn in test is to undertaken on 10 % of the breakers
being supplied. If one batch of supplies undergo burn in test successfully, the
additional batches / supplies under repeat order are to be exempt from Burn in
Testing.
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SECTION 9
9. DRAWINGS AND DOCUMENTATION
9.1 Documents, as per JSS 025101, are to be submitted to IHQ MOD (N)/DEE.
Manufacturing drawing and other document are to include the following:
(a) Drawing and Document list.
(b) General Arrangement and associated illustrated parts catalogue.
(c) Wiring Diagram.
(d) Busbar arrangement.
(e) Schedule of services.
(g) Detailed drawing of all component including part list parts.
(h) Production Test Specification.
(j) Type Test Reports.
(k) Cable Gland Diagram.
(l) List of Recommended Spares.
(m) Instruction and Maintenance Manuals for Proprietary Equipment.
(n) Drawing of special Jigs, Tools and Fixtures required for manufacture of
modular parts.
(p) Drawing comprising three clear prints of the out line of the equipment
showing overall dimension, fixing arrangement and estimated weight.
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SECTION 10
10. SPARES.
10.1 Spares. The onboard spares, base and depot spares and test equipment is to
be recommended by the supplier. Such recommendations are to be commensurate
with the reliability of critical components and component use in the system. Special
tools and test equipment is to be supplied for onboard maintenance.
10.2. Onboard spares. An itemised list of OBS, special tool and special test
equipment, which will be supplied with the main equipment, is to be furnished along
with the quotation for the main equipment. The OBS are to cater for all of the ships’
staff onboard maintenance routines and possible repair requirements. The OBS
should include the following:
(a) All spares required for exploitation up to 2 years.
(b) One set of generalpurpose maintenance tools.
(c) One set of special tools required for disassembling / assembling of
components to effect repair by replacement.
11. Installation . The supplier shall supply one set of installation and
commissioning spares. The manufacturer is required to provide the necessary
representative(s) to assist in carrying out inspection and supervise the work that is
done on the equipment, during the following phases:
(a) Onboard erection and connections.
(b) Setting to Work.
(c) Harbour and sea trials.
(d) Final machinery trials.
(e) Inspections on completion of CSTs (if applicable)
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12. Warranty. The equipment with associated controls/instrumentation is to be
guaranteed for stipulated performance for 24 months after commissioning. The
equipment supplied shall be warranted from defects, manufacturer and performance
for the said period and cover all the defects arising from malfunction through design
faults, inappropriate material, bad production and nonconformance to specifications.
Any expense on account of repair/supply of spares against guarantee defects is to be
borne by the supplier.
Interface Definition
14.1. The manufacturer shall provide all information required for integration of the
equipment onboard the ship. The equipment shall be designed and constructed so
that it can be fully integrated with the subsystem to which it interfaces. All
components shall be compatible in order that the functional performance of the
equipment is not degraded as a result of its integration within the system as a whole.
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