Electrical Works Specifications

Electrical Works A Guide to Specifications Sewer Selection and Installation
ISSUE: 01 JANUARY 2007
PED/SDQS/EWS/SPEC/0507/003
Electrical Works Specifications
Electrical Works Specification

Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Low Voltage Switchboard and Components Specification Standby Generator Specification Small Power and Lighting High Tension Components Specifications Motor Specification Low Voltage Cable Specification & Installation Earthing, Lightning and Surge Protection
Electrical Works Specifications Issue 01 / Revision 01 February 2007
Page
Section 1 - Low Voltage Switchboard and Components Specification

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 Design and Construction Dimension Capacitor Bank Contactor For Capacitor Switching Busbars and Small Wiring Air Circuit Breakers Moulded Case Circuit Breaker (MCCB) Miniature Circuit Breaker (MCB) Residual Current Circuit Breaker (RCCB) Fuses In General Current Transformers Indicating Instruments Electronic Overload Relay Motor Starters Indicating Lamps and Fittings Push Buttons Anti-Condensation Heaters Labels Padlocks Cable Entries Junction Box Metal Treatment and Painting Procedures (ElectroGalvanised Metal Sheet) Appendix B Appendix C Appendix D Appendix E Appendix F Floor Mounted Switchboard Compartment Dimensions Typical Switchboard Drawings (Floor Mounted, Wall Mounted and Outdoor Type) Digital Protective Relay Standards Digital Protective Relay Operating Conditions Digital Protective Relay Metering Functions C-1 D-1 E-1 F-1 A-1 B-1 1-1 1-1 1-2 1-3 1-3 1-4 1-4 1-5 1-5 1-5 1-6 1-6 1-6 1-11 1-17 1-18 1-18 1-18 1-19 1-19 1-19
Appendix A -
ii
Appendix G Appendix H -
Digital Protective Relay Network, Machine and Switchgear Diagnosis Meaning of Colours from IEC 60073 and IEC 60204-1 G-1 H-1
Section 2 - Standby Generator Specification

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 General Engine Lubrication System Exhaust Fan Radiator Air Discharge Fuel System Engine Governing Engine Instrumentation Alternator And Exciter Voltage Regulation Voltage Waveform Starting System Fuel Supply System Protective Devices Control Panel Automatic Mains Failure (AMF) Switchboard Changeover Contactor Earthing System 2-1 2-1 2-1 2-1 2-2 2-2 2-2 2-2 2-3 2-3 2-3 2-3 2-4 2-5 2-6 2-6 2-8 2-9
Section 3 - Small Power and Lighting

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 Material Panel Distribution Board PVC Electrical Conduit and Fittings Spacer Bar Saddles Distance Saddle Ceiling Fan Light Fittings and Ancillary Equipment to Lamps Street and Perimeter Lighting Materials and Equipment 3-1 3-1 3-2 3-2 3-2 3-2 3-3 3-4 3-7
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Section 4 High Tension Components Specifications

1.0 2.0 3.0 4.0 11 kV / 22kV Vacuum Circuit Breaker Specification Specification for 11 kV Oil Immersed Natural Cooled Transformers Cast Resin Transformer 11 kV Cable Specification 4-1 4-6 4-11 4-17
Section 5 Motor Specification

1.0 2.0 Submersible Motor Surface Mounted Motors 5-1 5-2
Section 6 Low Voltage Cable Specification & Installation

1.0 2.0 3.0 4.0 5.0 6.0 7.0 Type of Cable and Application Cable Installation Requirements Cable Trench Cable Ducts Cable Termination and Jointing Cable Accessories 6-1 6-2 6-4 6-4 6-6 6-6 6-6
Section 7 Earthing, Lightning and Surge Protection

1.0 2.0 3.0 Common Earth Termination Network Surge Protection Lightning Protection 7-1 7-3 7-5
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Section 1
Low Voltage Switchboard and Components Specification
Section 1 Low Voltage Switchboard and Components Specification
Page

1.0 2.0 Design and Construction Dimension 2.1 2.2 2.3 2.4 3.0 4.0 Appearance Wall Mounted Floor Mounted Outdoor Type 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-4 1-4 1-5 1-5 1-5 1-6 1-6 1-6 1-6 1-7 1-7 1-8 1-8 1-9 1-9 1-10 1-10 1-10 1-10 1-10 1-11
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Capacitor Bank Contactor For Capacitor Switching 4.1 4.2 Up To 60 kVAr 400 V Greater Than 60 kVAr 400 V
5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0
Busbars and Small Wiring Air Circuit Breakers Moulded Case Circuit Breaker (MCCB) Miniature Circuit Breaker (MCB) Residual Current Circuit Breaker (RCCB) Fuses In General Current Transformers Indicating Instruments Electronic Overload Relay 13.1 13.2 Protection Relays Digital Protective Relay 13.2.1 General Design Requirements 13.2.2 General and Practical Operating Requirements 13.2.3 Installation and Requirements 13.2.4 Protection 13.2.5 Control and Monitoring 13.2.6 Metering 13.2.7 Network, Machine and Switch Gear Diagnosis 13.2.8 Relay Diagnosis 13.2.9 Programming and Configuration Software 13.2.10 User Machine Interface 13.2.11 Communication
14.0
Motor Starters 14.1 14.2 14.3 14.4 Direct-On-Line (DOL) Star Delta Auto Transformer Soft Starter 14.4.1 Performance Functions 14.4.2 Power Connection 14.4.3 Protection Functions 14.4.4 Sundry Features 14.4.6 Options 14.5 14.6 Variable Speed Drive Contactor for Motor Starters
1-11 1-12 1-12 1-12 1-12 1-13 1-13 1-13 1-13 1-14 1-14 1-17 1-17 1-18 1-18 1-18 1-19 1-19 1-19
14.4.5 Function Facilitating the Integration of Control System 1-14
15.0 16.0 17.0 18.0 19.0 20.0 21.0
Indicating Lamps and Fittings Push Buttons Anti-Condensation Heaters Labels Padlocks Cable Entries Junction Box Metal Treatment and Painting Procedures (ElectroGalvanised Metal Sheet)
Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Appendix G Appendix H -
A-1 B-1 C-1 D-1 E-1 F-1
Floor Mounted Switchboard Compartment Dimensions Typical Switchboard Drawings (Floor Mounted, Wall Mounted and Outdoor Type) Digital Protective Relay Standards Digital Protective Relay Operating Conditions Digital Protective Relay Metering Functions
Digital Protective Relay Network, Machine and Switchgear Diagnosis G-1 Meaning of Colours from IEC 60073 and IEC 60204-1 H-1
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SECTION 1 - LOW VOLTAGE SWITCHBOARD & COMPONENTS SPECIFICATION 1.0 DESIGN AND CONSTRUCTION
Switchboards, sub-switchboards, control panels, distribution board and all other equipment shall comply with the relevant current British Standard and IEC specification. Each item shall be enclosed in a vermin proof steel cubicle of rigid construction and made of sheet steel of such thickness that it is free from distortion and with no entries for insect whatsoever. Where two or more cubicles are fitted together they shall form a continuous flush front. All units shall be floor mounted unless otherwise specified. The door of the switchboard shall be hinged such that they can be operated through an arc of 180 degrees. A minimum of 3 hinges shall be chrome-plated and of a good quality. All switchboards, together with switch gears, control gears, etc. shall be capable of withstanding fault conditions of not less than 31 MVA at 415 V for 3 seconds as defined in IEC 60439-1 and off Form 3B. The cubicle framework shall be fabricated from rolled steel angle sections and shall be selfsupporting when assembled, uniform in height and depth from front to back. The rigid construction shall be designed to withstand without any sag, deformation or warping, the loads likely to be experienced during normal operating, maintenance or maximum fault conditions. Sheet steel used shall not be less than 2.3 mm anti-rust zinc. Cross-structs shall not be used. The manufacturer's name shall be incorporated on the switchboards. The interior and exterior of each cubicle shall be finished with light gray paint (ICI Ref. No: ICI 104 or OXYPLAST paint: FF160/8250/CS9. The cubicle shall be off electro-plated mild steel sheets. It shall be treated to prevent corrosion. Refer to Appendix A Metal Treatment and Painting Procedure (Electro-Galvanised Metal Sheet). All cubicles shall be dust, insect and vermin proof. The interior of each piece of equipment shall be clearly marked to show phases and to this end coloured plastic sleeving shall be employed. Plastic tape will not be permitted. Steelwork necessary for supporting the switchboards shall also be included.
2.0 DIMENSION
2.1 Appearance
2.3 mm and 90 m of paint thickness 2.3 mm and 90 m of paint thickness
Panel thickness Frame Thickness
Sec 1 - 1
2.2
Wall Mounted
Wall mounted switchboard shall not be more than 1.6 m height and located 0.2 m from floor. Where necessary, a step or a working platform that is insulated must be provided. For a range of up to 100 Amps switchboard:
Incoming compartment : 450 mm Subsequent compartment : 450 mm Cable compartment : 125 mm Cables to be glanded at bottom entry of the switchboard
2.3
Floor Mounted
Floor mounted switchboard shall not be more than 2.1 m height and located 0.2 m from floor. Where necessary, a step or a working platform that is insulated must be provided. Refer to Appendix B - Floor Mounted Switchboard Dimensions (up to 100 A, more than 100 A up to 400 A, 400 A and above)
2.4
Outdoor Type
The outdoor main switchboard shall be off self-contained, free standing or wall mounted weatherproof cabinets to be constructed of electro-galvanised metal plates. Control indication and alarm facilities shall be mounted on internal doors enclosing compartments housing electrical plant and equipment. Wall mounted outdoor weather proof control panel shall come with awning extended by at least 2 m from wall and floor mounted outdoor weather proof control panel shall come with roof awning extended 2 m from the panel. External doors with security locking facilities and double roofs on cabinets to reduce solar effects shall be provided. Refer to Appendix C Typical Switchboard Drawings (floor mounted, wall mounted and outdoor switchboard).
3.0 CAPACITOR BANK

The power factor (p.f.) of the assembly shall be design for 0.95 or better. Should it be less than 0.95, provision shall be made in the panel to incorporate additional power factor correction to improve the power factor to the minimum value required. Power factor regulation shall be of multiple steps, individual capacitors are allowed only if the load is lower than 5 kVAr. In any case the total power factor for the assembly shall not fall below 0.95. Where multiple steps are provided, in case of failure, the smallest step shall be duplicated to act as a back-up. Capacitors shall be protected with its individual capacitor switching contactors and MCCB.
Sec 1 - 2
4.0 CONTACTOR FOR CAPACITOR SWITCHING

4.1 Up to 60 kVAr 400 V
The contactors shall be specifically designed for capacitor switching. Particularly shall be included a set of contact and current limiting resistors which shall be switched off after initial switching peak current. The contactors shall comply with IEC 70 and IEC 831. All contactors will have the reference number on the front of the contactor. All contactors shall be climate proof as standard. The rated impulse voltage shall be 8 kV. The contactor shall work up to 55oC ambient temperature without derating. The coil operating range shall be between 0.85 and 1.1 times of the rated voltage (AC). All contactors shall be finger safe as standard or with adaptable covers and available in a variable composition for auxiliary contact. The safety clearance on the front of the contactor shall be less than 15 mm. The coil wire insulation shall be Class F. The contactors shall be cadmium free and built with recyclable materials. The contactor shall include a system to prevent resistor burning in case of abnormal pole operation. The switching contactors shall be of AC3 load switching.
4.2
Greater than 60 kVAr 400 V
The switching contactors shall be of AC4 load switching. All contactors shall incorporate air break or vacuum contactor rated for frequent duty in accordance with IEC 60947.
5.0 BUSBARS AND SMALL WIRING

Busbars marking and arrangement, connection and grade of copper shall all comply as appropriate with BS EN 13601. The switchboards shall be so arranged that the busbars run horizontally through each sectionalised length and shall comprise three or four bars as appropriate fabricated from hard drawn high conductivity copper rigidly mounted on non-hygroscopic insulators with connection from the busbars to the circuit breakers and switches effected by copper bars or cables securely clamped to the bars and identified by means of coloured plastic sleeving or painting to indicate the phase colours. All cable supports shall be non-hygroscopic. All small wiring shall be of adequate size to suit their current ratings but in any case not less than 1.5 square mm. in section for cables, insulated with PVC and shall be fixed securely without strain by cleats of the compression type. For the purpose of identification different insulant colours shall be provided to distinguish the various circuits and each connection shall terminate at an approved type of terminal block placed in an easily accessible position for testing at site with coded ferrules of an approved type at both ends of each connector. No connectors or soldered joints will be permitted in the wiring. The wiring shall be formed in a neat and systematic manner, with cables supported clear of panels and without cross-overs. Bushers shall be provided wherever necessary to prevent chafing of cables.
Sec 1 - 3
6.0 AIR CIRCUIT BREAKERS

All air circuit breakers used for the incoming shall be of four pole. All other air circuit breakers downstream shall be of triple pole. Association of Short-Circuit Testing Authority (ASTA) or Keuring Van Electrotechnische Materialen (KEMA) certified for a minimum rupturing capacity of 26 MVA at 415 V with a short time rating of 3 seconds. Air circuit breakers shall be used for all current ratings of 600 A and above. Units shall be hand charged spring closed with ratings and instrumentation as specified and of the horizontal draw-out isolation type so arranged that they may be completely isolated from the switchboard except that secondary circuits shall not be broken with the circuit breaker in the test position in order to permit test tripping or closing. Closing mechanism shall be of trip free type and incorporate mechanical "ON/OFF" and "SPRING CHARGED/SPRING FREE" indicators mechanically and positively coupled to the operating mechanism and mechanically interlocked to prevent:(i) Withdrawal or plugging of the circuit breaker in the closed position (ii) Closure unless either fully plugged or fully isolated (iii) Opening of cubicle door until breaker is isolated (iv) Prevent insertion of the racking handle when the cubicle door is open Contacts shall be of adequate rating to ensure that they can carry continuously full rated current without overheating, damage or deterioration and shall be individually spring loaded, hard silver plated of the magnetically "blown on" type so arranged that electro-magnetic forces arising under short circuit conditions do not tend to reduce contact pressure. The arc chutes shall be removable on site. No safety clearance shall be required around drawout circuit breakers. For fixed circuit breakers, 150 mm of free space shall be provided above the arc chutes to allow removal of the latter. Screening shutters actuated automatically with the circuit breaker isolated and withdrawn and capable of padlocking in the screened position. The arc chutes shall be equipped with metal filters to reduce effects perceptible from the outside during current interruption. The breaker shall have the option to install shunt trip coil energised through relay contacts, Close and Trip push buttons.
7.0 MOULDED CASE CIRCUIT BREAKER (MCCB)

Moulded case circuit breakers shall comply fully with BS 4752: Part 1 and the case shall be of moulded insulating materials of good mechanical strength and non-tracking properties. The tripping mechanism shall be calibrated in compliance with British Standards at the factory and the breaker shall be sealed to prevent tampering. MCCBs shall be used for all current ratings less than 600 A. MCCBs shall be rated at not less than 25 kA 0.3 sec. of below 100 A and 50 kA 0.3 sec. of above 100 A. MCCBs shall be of manual or automatic operation as required. The automatic type shall each incorporate a trip unit to provide overload and short circuit protection. The trip unit for each pole shall provide inverse time delay under overload conditions and instantaneous magnetic tripping for short circuit protection, with five adjustable trip setting. The trip units in all the circuit breakers shall be interchangeable.
Electrical Works Specifications Issue 01 / Revision 01 February 2007 Sec 1 - 4
The MCCB shall be so designed that when on tripped condition, the circuit breaker cannot be switched on again unless it has been reset by switching to OFF position first. The operating conditions (i.e. ON, OFF or TRIP) of the circuit breaker shall be clearly indicated. MCCBs shall be Single Pole and Neutral (SPN), Double Pole (DP) or Triple Pole and Neutral (TPN) type as required. However, MCCBs at the incoming shall be of Four Pole. The construction and operation of the circuit breakers shall be such that as a fault occurs, all the poles of the circuit breakers shall operate simultaneously to isolate and clear the fault efficiently and safely without any possible risk to the operator or to the installation. Each circuit breaker shall incorporate "trip-free" mechanism to ensure that the breaker cannot be held closed in fault conditions. The operating mechanism of the circuit breakers shall be hermetically sealed at the factory and all metallic parts associated with the operating mechanism shall be treated against rust and corrosion. The short-circuit breaking capacity of the MCCB shall not be less than the maximum prospective fault levels at the point where the MCCB is installed.
8.0 MINIATURE CIRCUIT BREAKER (MCB)

MCBs shall have a breaking capacity of not less than 5 kA (rms). They shall comply with BS EN 60947-2, BS EN 60898 or IEC 157-1, fully tropicalised and suitable for use on a 240/415 V, 50 Hz AC system and up to an ambient temperature of 400 C. MCBs shall be quick-make, quick-break and trip-free type complete with de-ion arc interrupters. The tripping elements shall be thermal magnetic type with inverse time delay over-current and instantaneous short circuit characteristics. They shall be able to respond to overload and the response shall be independent of variations in ambient temperature. MCBs shall be manually operated by means of toggle type handles having visual indication of whether the breaker is opened, closed or tripped. Multi-pole breakers shall be provided with common-trip mechanisms for simultaneous operation of all the poles.
9.0 RESIDUAL CURRENT CIRCUIT BREAKER (RCCB)

RCCBs shall be current operated type complying with IEC 61008-1. RCCBs shall be used for incoming rating of up to and including 60 A. They shall be either double pole or four pole type. The sensitivity, unless otherwise specified, shall not exceed 100 mA for double pole type and 300 mA for four pole type. Test push button and visual indication for ON and OFF shall be provided. They shall be equipped with screw clamping type cable terminals.
10.0 FUSES IN GENERAL

Fuses shall comply with BS 88. Unless otherwise specified all fuses shall be of the HRC type and of an approved make. Fuse bases and carriers shall be of the unbreakable type and shall be arranged for safe and easy replacement of fuses. All live connections including fuse base contacts shall be efficiently shrouded. The fuses fitted on a circuit shall be of such rating as to give maximum protection to the apparatus it supplies.
Sec 1 - 5
11.0 CURRENT TRANSFORMERS

Current transformer shall comply with BS 3938 and shall have short time ratings not less than that of the switch panels in which they are incorporated. Identification labels shall be fitted giving type, ratio, rating, output and serial numbers and duplicate rating labels are to be fitted on the exterior of the mounting chambers suitably allocated to enable reading without the removal of any cover or metal sheeting forming part of the structure of the switchboards. All current transformers shall be of Class 3, 5 VA for all metering circuits shall, unless otherwise stated. For all protection circuits, the current transformer shall be of 10P10 and a burden of 15 VA. For power factor regulation the current transformer shall be of Class and a burden of 15 VA.
12.0 INDICATING INSTRUMENTS

Indicating instruments on switchboards shall be flush mounted and shall generally be of the same pattern and appearance throughout. They shall be of a type giving no parallax error and their normal maximum reading shall be at about 60% full-scale deflection. Ammeters in motor starter circuits shall be capable of withstanding the starting current. All voltmeter shall have selector switches enabling any phase to phase to neutral voltage to be read. Indicating instruments shall be fitted with zeroing devices and shall be positioned with dial centres not more than 1.85 m and not less than 0.75 m above floor level. Indicating instruments shall comply with BS 89 and shall be of industrial grade accuracy. Panels with incoming 400 A and above, a digital power meter shall be provided.
13.0 PROTECTION RELAYS

13.1 Electronic Overload Relay
These relays shall have definite time characteristics: current threshold and time based function. The relay shall be functional in the case of long starting time or frequent starting. The relay shall provide protection at minimum for over-current, rotor locked and phase failure. The relay shall be incorporate individual adjustable trip time and delay time setting for staring, over-current and rotor locked. The over-current trip preset value for the relay shall be at minimum 110% of the operating current and with adjustable range. The relay shall incorporate LED indication light to assist fast diagnostic of status, operation and type of failure. The allowable error of the relay shall be 5% for current and time. The relay shall confirm to IEC 60255-6 and IEC 60947 standard. The degree of protection shall be IP20 and confirming to IEC 60529 standard. The relay shall be operation in temperature up to 60oC in normal operation without derating and confirming to IEC 60947-4-1 standard. The relay shall withstand surge up to 6 kV and confirming to
IEC 61000-4-5 standard. The sensing and control of the relay shall be through built-in current transformer and micro CPU.
13.2 Digital Protective Relay

The Digital Protective Relay shall comply with the most relevant national, international standards and recommendations for industrial electrical distribution (IEC, EN, UL, and CSA). The Digital Protective Relay shall be CE marked, conforming to European Low Voltage (73/23 EEC and 93/68 EEC) and EMC (89/336/EEC). Refer to Appendix D Digital Protective Relay Standards.
13.2.1 General Design Requirements
Technology and functionality:
The Digital Protective Relay design shall be based on a microprocessor technology and shall accommodate a hardware and software architecture consisting of a multifunction protection and control platform with logic/analogue inputs and outputs, including Protections, Metering, Control & Monitoring, User Machine Interface with alphanumeric display, Communication Interface, Network, Machine, Switch gear and relay diagnosis functionality.
Programming and configuration
The Digital Protective Relay shall be programmable and configurable with an appropriate userfriendly setting software using a MS Windows program running on a standard PC. The programming and configuration shall be carried out locally (front access) through a RS 232 port or remotely through a communication network, mainly an Engineering LAN (E-LAN) with adequate passwords to prevent any unwanted intrusion. Programming and configuration shall also be able to be prepared on a PC file directly (unconnected mode) and down-loaded locally or remotely into the relay.
Hardware and software architecture
The hardware and software architecture shall be modular and disconnectable to adapt the protection and control unit to the required level of complexity of the applications. The architecture shall allow future extensions by simple and easy hardware and firmware upgrading of the protection and control unit and shall be designed to enable upward compatibility between Digital Protective Relay of different generations of the manufacturer. The Protective Digital relay shall accommodate digital and isolated inputs/outputs. The inputs shall be used to monitor the status of the complete panel as well as receive external signal while the outputs shall be used for circuit breaker, inter-tripping between panels and remote alarms.
Sec 1 - 7
13.2.2 General and Practical Operating Requirements

The Digital Protective Relay shall operate according to the following conditions:
The circuit breaker control output relay contact shall be capable of withstanding a 30A DC current for 0.2 seconds and 2,000 operating cycles according to ANSI C37.90-Clause 6.7. Other logic output relay contacts shall be capable of withstanding a 8A DC/AC steady state current Logic input pilot voltage shall be rated as per the auxiliary power supply of external driven digital signals from the control system (RTU or PLC) and shall comply with IEC 60011-32. Current carrying terminal from current sensors shall be automatically short circuited when withdrawing current sensor modules. Provisions shall be made in the switchgear cubicle for testing and calibrating the relay by current injection using an external source, without disconnecting the permanent wiring. CT/VT and Trip coil supervision facilities shall be provided to check the wiring circuit continuity with relevant alarms and messages. The Digital Protective Relay shall be continuously rated and shall maintain the setting accuracy without setting drift over time and full range of auxiliary voltage variations as per the requisition. The Digital Protective Relay shall be capable of withstanding the output current of the associated current transformers corresponding to a primary current equal to the specified short circuit withstand current and time of the assembly ( 4 In permanent, 100 In 1 second).
Refer to Appendix E Digital Protective Operating Conditions.
13.2.3 Installation and requirements

The Digital Protective Relay shall be able to be flush mounted or mounted inside the Low Voltage compartment and shall have an IP52 mechanical protection degree according to IEC 60529. To operate properly and to achieve satisfactory operating quality, the Digital Protective Relay shall be installed so that it shall be protected against EMC, and the following points shall be required:
A single equipotential earth system used as the site potential reference A power distribution with TN-S earthing system Separation of different kinds of cables (power, power supply, auxiliary, data, measures) Use of screened cables for data and measure A power supply protection (filtering, over voltage protection) Equipment and installation protection against the indirect effects of lightning
Sec 1 - 8
13.2.4 Protection
The Digital Protective Relay shall integrate all the necessary ANSI code protections according to the different levels of applications and shall provide wide setting ranges mainly for current protections and a large choice of tripping curves through two setting groups (normal/back-up mode network) operated by logic input: Definite Time (DT) curve IDMT curves set by T time delay or TMS factor, including:IEC curves (SIT, VIT/LTI, EIT) IEEE curves (MI, VI, EI) Usual curves (UIT, RI, IAC) Customised tripping curve possibilities shall be available for specific Phase, Earth fault over current. ANSI code 50/51(Low, Mid-end solutions/applications) Tripping curve DT IDMT Is set point Threshold 0,1 to 24 In 0,1 to 2,4In Tripping time delay Inst: 0,05 sec to 300 sec 0,1 sec to 12,5 sec at 10 Is Inst: 0,05 sec to 300sec 0,1sec to 10 Is0
50N/51N(Low, Mid-end solutions /applications)
DT IDMT
Is0 set point
0,1 to 15 In0 0,1 to 1 In0
Overload protection shall be based on RMS current value (Minimum 13th Harmonic) and shall take the ambient temperature into account. Phase over current and earth fault protection shall have an adjustable timer hold to allow restriking fault detection Earth fault protection shall integrate a H2 Harmonic restraint for transformer start-up inrush current to be activated or inhibited Alternative over current setting groups shall be selectable by logical conditions through logic inputs, to adapt a fast protection plan change as well as setting facilities for thresholds and time delay adjustment. The Digital and protective Relay shall allow the use of upstream and logic discrimination in a cascading scheme or closed loop applications.
13.2.5 Control and monitoring

The Digital Protective Relay shall basically carry out all the ANSI code Control and Monitoring functions necessary to control the Circuit Breaker or Contactor for electrical operations. These operations shall be performed from pre-defined functions using logic inputs/outputs and shall be processed from internal and external data.
Sec 1 - 9
13.2.6 Metering
The Digital Protective Relay shall include accurate measurement processing functions and shall display the metering data on the User Machine Interface to operate the different applications and carry out commissioning and maintenance as per Appendix F Digital Protective Relay Metering Functions.
13.2.7 Network, machine and switch gear diagnosis

The Digital Protective Relay shall provide diagnosis facilities for process management and maintenance purpose as per Appendix G Digital Protective Relay Network, Machine and Switchgear Diagnosis.
13.2.8 Relay diagnosis

The Digital Protective Relay shall contain self-test diagnosis facilities to:
Detect internal relay failures that may cause nuisance tripping or failed fault tripping Set the relay in fail-safe position leading to a fall-back position to avoid any unwanted tripping if a major internal failure is detected. A Watchdog relay with change over contact (NO+NC) shall provide an alarm or information to activate a back-up protection. Any minor failure shall not interrupt the protection function operations and the relay shall operate in downgraded mode Inform for maintenance operation Detect unplugged connectors resulting in a major internal failure Check the hardware configuration:The absence or failure of a remote module shall be considered as a minor failure. The absence or failure of a Logic input/output module shall be considered as a major failure
13.2.9 Programming and configuration software

The Digital Protection Relay shall use a user-friendly setting and operating multi-lingual software in Windows environment
13.2.10 User Machine Interface
The Digital Protective Relay shall incorporate a User Machine Interface (or UMI) with an alphanumeric graphical LCD and back-light display screen indicating:Measurement values Operating messages in major international languages System maintenance messages
Sec 1 - 10
13.2.11 Communication
The Digital Protective Relay shall be communicating through one or two communication ports and integratable in communication architecture with information remote access. It shall be able to be interfaced to two types of communication networks providing access to data on each communication port, via:A multi-protocol based Supervisory Local Area Network (S-LAN) to supervise functions regarding the installation and the electrical network from a supervision system (SCADA or RTU). Modbus based Engineering Local Area Network (E-LAN) to configure, set up the relay, collect operating and diagnosis information, monitor the status of the electrical network and run diagnostics on electrical network incidents from the programming and configuration software.
14.0 MOTOR STARTERS

The starters shall be of the following types: (a) (b) (c) (d) (e) Up to 3.7 kW Above 3.7 and up to 7.5 kW Above 7.5 and up to 22 kW More than 22 kW 75 kW and above Direct-On-Line starters Star/Delta starters Auto-transformer starters Soft starter Variable Speed Drive
Motor starters shall be in accordance with IEC 60947-1 and IEC 60947-4-1 and equipped with overload and no volt protection. Where MCC are supplied as a stand alone unit, it shall comply with the switchboard specification. Single phase and earth leakage protection shall be deemed to be included. Starters shall be of the contactor type with coils wound for 230Volts 50 cycles operation. All starters shall be capable of at least 15 starts per hour at 100% full load torque. The motor starter shall be of rating to carry the full load current of its rated duty at its most severe load conditions All motor starters shall be of automatic and manual control type with Start/Stop/Reset" facility, MCCB mechanically inter-lockable with access door, independent control circuit with fuses/MCB and provision for remote control as required. Individual starters shall be provided for each equipment and housed in a separate compartment, which are mounted in switchboard cubicles. The starter cubicles shall be easily accessible for maintenance purpose constructed of ingress protection IP42. Unless otherwise approved, the metal surface of the cubicle wall adjacent to the contactors shall be protected by fireproof insulating material. All secondary wiring shall be so arranged and protected as to prevent it being damaged by arcing. Where draw-out patterns motor starter is specified, the starter shall be easily withdrawable and can be replaced with another spare starter of similar rating.
Sec 1 - 11
14.1 Direct-On-Line (DOL)

For DOL starters, an air-break tripole electromagnetic contactor starter with a normal open retaining auxiliary contact, shall be provided. The auxiliary contact shall be complete with one closing/holding coil 230 V, 50 Hz (no-volt coil inherent) and EOCR with resetting devices and auxiliary signal lamp contact. The reset push button shall be accessible from outside.
14.2 Star Delta

For Star Delta starters, an air-break triple pole electromagnetic LINE contactor fitted with necessary auxiliary contacts, closing / holding coil, EOCR, etc. shall be provided. The EOCR shall be connected in the Delta position and thus give automatic single phase protection. The starter shall contain an air break triple pole and neutral STAR contactor fitted with the necessary auxiliary contacts and an air break triple pole and neutral DELTA contactor fitted with the necessary auxiliary contacts. The Star Delta contactors shall be electrically and mechanically interlocked. The starter shall be complete with necessary time delay contacts to effect the correct sequence of operation.
14.3 Auto Transformer

Auto Transformer shall be fitted with multipole contactors which increase the supply voltage to the starter by changing out sections of the starting transformer tabs. The three phase, air cooled auto transformer shall be accommodated in a separate section mounted at the top within the switchboard cubicle of the starter. Tapping shall be provided at 40%, 60% and 75% of the voltage. The star point contactors and run contactors shall be mechanically interlocked. The starter shall be complete with timing relays. Where indicated, EOCR, earth fault and single phasing relays shall be provided. Auto transformer starter shall consist of three contactors with current rating similar to the peak current. All auto transformer shall be incorporated with thermal switch connected with control circuit.
14.4 Soft Starter

Soft Starter shall be a controller with 6 thyristors, which is used for the torque-control of soft starting and soft stopping of three-phase squirrel cage induction motor. The Soft Starter shall be housed in the respective MCC or Starter Panel Board. Adequate natural or forced ventilation shall be ensured for continuous operations at the maximum specified 50 oC (122 oF) ambient temperature. Harmful deposition of dust shall be excluded by suitable filters. All Soft Starters shall be sized to drive the duty motors in a particular group to which it is designated. The Power (kW) rating of the Soft Starters shall exceed the total driven load and shall make full allowance for the following: -
Sec 1 - 12
14.4.1 Performance Functions

Constant Current Mode and Current Ramp Mode. Constant control of the torque supplied to the motor during acceleration and deceleration period. Kickstart shall provide Extra Torque at the beginning of a start (High Breakaway Torque) but then accelerate freely with lower torque. Bypass contactor - shall retain Motor Protection & Current Monitoring Features Function. Wide frequency tolerance for generator set power supplies. The starter shall be able to connect to the motor delta terminals in series with each winding. Soft Stop Shall be able to automatically monitors & extends motor deceleration time and will provide optimum control of most application. DC Braking Greater Braking Torque shall be available for very high inertia loads by use of Soft Braking technique.
14.4.2 Power Connection

3 wires Configuration 6 wires Configuration Shall allow to control motors 50% larger than possible 3 wires connection Three phase voltage 230 V to 415 V50/60 Hz
14.4.3 Protection functions

Built in motor thermal protection Processing of information from PTC thermal probes Monitoring of the starting time Motor preheating function Protection against under loads and over current during continuous operation Phase Imbalance Sets the sensitivity of the Phase Imbalance Protection Phase Sequence Electronic Shearpin Auxiliary Trip Input Excess Start Time Protect the Soft Starter from being operated outside its rated start capacity Supply Frequency Shorted SCR Motor Connection Serial Interface Failure
14.4.4 Sundry Features

IP42 or IP54 - 253 Amps and below IP00 - 302 Amps and above Current Read out Motor Temperatures Read out Trip Log (eight (8) position ) Multiple Function Sets
Sec 1 - 13

Restart Delay sets the minimum time between the end of a stop and the beginning of the next start Pre-Start Tests shall have self diagnostic test Low current flag High current flag Motor Temperature Flag Auto-Stop Start Counter Function Lock / Password Protection Store / Restore Function Settings Thermal Mode Override
14.4.5 Function Facilitating the Integration of Control System

Minimum shall consists of 4 logic inputs, 2 logic outputs, 3 relay outputs and 1 analogue output. Plug-in I/O connectors. Function for configuration a second motor and easy to adapt settings Display of electrical values, the state of the loads and the operating time. RS 485 serial link for connection to Modbus.
14.4.6 Options

A remote terminal can be able to mount on the door of a wall fixing or floor standing enclosure. Advanced dialogue solutions such as power suite pocket PC with PPC type terminal and power suite software workshop. A range of wiring accessories for connection the starter to PLCs via a Modbus connection. Bus communication and Ethernet, DeviceNet and Profibus DP network communication options.
14.5 Variable Speed Drive

Variable Speed Drives (AC Drives) shall utilise a standard AC Squirrel Cage Induction Motor operating from a Variable Frequency Static Converter Speed Controllers. AC Drives shall operate in proportion to a measured Analogue Signal (0-10 V & 4-20 mA). The AC Drives shall be suitable for operation on a 380 500 Vac 3 Phase 50 Hz Power Supply with minimum Supply Tolerance -15% to +10% and shall provide a 415 Volt 3 Phase Variable Frequency Output suitable for driving a standard AC Squirrel Cage Induction Motors at high 50 oC (122 oF) ambient temperatures. The AC Drives shall be suitable for automatic control in response to 4-20mA Input Analogue Signal and its frequency output of 0-50 Hz via 4-20 mA Analogue Signal shall be in proportion to this signal range. The AC Drives shall operate on Pulse Width Modulation (PWM) principle either with the Control Method of Frequency Control (V/F) or Open Loop Vector Control (provide unequalled Motor Speed and Torque Control at low speed).
The current of the motor shall have a low content of harmonics to ensure high motor efficiency. Slip compensation shall be provided so that the speed holding accuracy shall be better than +/- 0.5. Each AC Drives shall be sized to drive all duty motors in a particular group to which it is designated. The Power (kVA) rating of the AC Drives shall exceed the total driven load. Operating frequency range 10 to 50 Hz. For each process control, the application listed below shall be made available:
Basic - Suitable for most purposes or applications. Standard - Basic, with more programming possibilities. Local / Remote Control - Two (2) external control plates. Multi-Step Speed Control - Intended for switching between 16 preset fixed speeds. PID Process Controller - Matching Pump/Fan speed to process requirements. Multi-Purpose Control - Most flexible of all. Pump and Fan Control - Control of up to five (5) pumps with Auto-Change. Can be used for controlling one (1) AC drives and a total of four (4) auxiliary AC Drives. Can detect Burst Pipe or Loss Of Prime. Full Motor Protection. Reduce Load Disturbance.
Shall have a built in Integrated AC Line Chokes (Reactors) to maximum protection and minimise any main disturbances (harmonics) and Integrated EMC/Noise Filter compliant with immunity to fulfill all EMC Immunity requirements. Emissions to EMC Class H complying with IEC61800-3 and shall have built in Input Line Fuses Fast Acting Semiconductor Fuses (for motor sizes 100 kW and above) and Integrated Braking Chopper. Shall allow for starting motors in cascade and assume starting current is not less than eight (8) times the motor full load current (FLC) and suitable for Multi-Motor drive system. Take account of Motor Power Factor and Efficiency with built in PFC with Autochange Function for Centrifugal Pumps and Fans. The Acceleration & Deceleration Time: 0 to 3,000 sec. The Relative Humidity: 0 to 95% RH: NonCondensing, Non-Corrosive, No Dripping Water. Shall allow for Constant Torque (Overload Factor: 1.5 x IH @ 50 oC) characteristics. High Starting Torque: > 200% (depending on motor and AC Drive sizing) with Low Ripple in the Torque. High Starting Current: 2.0 x IH. Full Torque Control at all speed all speed, including zero (0) speed or 0.0 Hz. The Torque Accuracy shall be less than 3%. Where the AC Drives controls more than one (1) motor, a standby AC Drives shall be provided.

Drive and Motor Input and Output Circuit Protection:Overvoltage and undervoltage Earth or ground fault, Main Supervision (Single Phasing) - Trips if any input phase is missing Motor Phase Supervision Trip if any output cables/phase is missing Drive Overtemperature Overcurrent Motor Phase Supervision Motor Overload Motor Stall Short-Circuit of +24 V and +10 V Reference Voltages.
Sec 1 - 15
Motor Underload - Loss Of Prime or Belt Damage, when the AC Drives has brought the motor up to speed, an adjustable Underload Setting will detect the loss of load due to Loss Of Prime Pump Application or Belt Damage Fan Application. Common Spare Parts:Same Human Machine Interface (HMI) for all models. Same Control Unit for all models. Adjustable Switching Frequency 1 to 16 kHz (Silent Motor Operation) Removable / Detachable Keypad & Alphanumeric Display Unit (RS232C c/w 3 m cables) mounted on the front side of panel door at approximately 1.5 m height from the floor. Intelligent and easily configurable Multilingual Control Keypad and Display. Inputs / Outputs (I/O) connections with simple quick connection terminal and Expandable Inputs / Outputs (I/O) configuration. All AC Drives are Constant Torque suitable for Pumps & Fans Application with PFC (Pump Fan Control) Autochange Function. Fixed Speed / Off / Variable Speed Switch for selection of control mode. Panel mounted facility for local setting of frequency manually in the event of a failure of the control signal. Digital indication of output voltage. Indication of output voltage. Drives Running / Failed indicator. Main Supply Isolating Switch.
The AC Drives unit shall include but not limited to the following protections:
Phase to Phase and Phase to Ground (Earth) Short Circuit Protection. Line Transient Protection. Three (3) Phase Short Circuit Protection at output terminals. Insensitive to incoming Power Phase Sequence. Built-in Thermal Relay for excessive temperature and shall be reset manually. Current Limiting feature.
Failure of the control signal shall stop the drive. Facilities shall be provided for indication of:
Control signal failure alarm. Variable frequency supply output failure alarm. Variable frequency control unit failure alarm.
A summary Alarm Volt-Free Contact and five (5) Inputs / Outputs Card Slots shall be provided to initiate an alarm to the SCADA System when any one or more of these alarms are on. Diagnostic fault indicators and messages in Alphanumeric (plain English) shall also be provided. The AC Drives shall be housed in the respective MCC or Starter Panel Board. Adequate natural or forced ventilation shall be ensured for continuous operations at the maximum specified 50 oC (122 oF) ambient temperature. Harmful deposition of dust shall be excluded by suitable filters.
Sec 1 - 16
The driven motor frame size shall be selected to ensure that the motor will operate correctly without overheating when fed from the Variable Frequency Drives (AC Drives) and operating over the speed range of 10 to 50 Hz. The AC Drives shall operate with an Input Power Factor not less than 0.95 throughout the speed range. Under any conditions of operation, the AC Drives shall not emit signals that may interface with Radio Transmission or Operation. The AC Drives shall meet the requirements of EMC Class: H IEC 61800-3 or higher regarding the emission of Radio Frequency Interference (RFI). Radio frequencies emitted by other equipment according to EMC Class: H IEC 61800-3 shall not hamper the correct operation of the AC Drives. The AC Drives shall not product Harmonics and Voltage Distortion that may affect the operation of other equipment connected to the MCC or Starter Panel Board. Voltage and Current Distortions produced by the AC Drives at the input side shall be limited to the values specified relevant Standards, which are applicable for industrial distribution system.
14.6 Contactor for Motor Starters

All contactor starters shall incorporate air break or vacuum contactor rated for frequent duty in accordance with IEC 60947-1 and IEC 60947-4-1. Contactor shall be rated to make and break according to Category AC3 of IEC 60947-4-1. All contactors shall have the reference number on the front of the contactor. All contactors shall be climate proof as standard. The rated impulse voltage shall be at least 6 kV. The contactor AC3 current shall work up to 55oC ambient temperature without derating. All contactors shall be finger safe as standard or with adaptable covers. The safety clearance on the front of the contactor shall be less than 15 mm. The coil wire insulation shall be Class F. The contactors shall be cadmium free and built with recyclable materials. The Starters shall be incorporated to detect failure of any phase (single phasing or reverse polarity or voltage and current unbalance) to interrupt the circuit when the contactor is de-energised. All starters shall incorporate triple pole MCB. Overcurrent, Phase Sequence and earth leakage protection relays shall be incorporated as later specified together with all necessary auxiliary relays, contactors, timers, MCB, wiring and terminals. Controls system and indication facilities shall be provided on each starter and incorporate with single pole MCB as specified. All medium voltage starters shall incorporate a triple pole fully interlocked load breaking isolating switch capable of breaking the stalled motor current and suitable for use on a 230/415 Volt, 50Hz, AC system.
15.0 INDICATING LAMPS AND FITTINGS

The indicating lamp shall enclosed type and complies with IP40. The indication light size shall be 25 mm in diameter. Lamps shall be easily removed and replaced from the front of the panel by manual means not requiring the use of extractors. The lamps shall be cluster LED type and fitted into an accepted standard form of lamp holder. The rated lamp voltage shall be 24 V DC/1A (resistive).
Sec 1 - 17
The bezels of metal or other approved material holding the lens shall be of an approved finish and easily removed from the body of the fittings so as to permit access to the lamp and lens. The lens shall be in standard colours, red, green, blue, white and amber. The colour shall be in the lens and not an applied coating and the different coloured lens shall be fully interchangeable. The lens holder shall incorporates a reflector ideally designed to eliminate light loss and marking plate serves as a filter to diffuse the light effectively, ensuring a clear illumination face. The service life at nominal voltage and at an ambient temperature of 25oC shall be 100,000 hours. Indicating lamps fitted to the facias of switch and instrument cubicles or panels shall be adequately ventilated. Refer to Appendix H - Meaning of Colours from IEC 60073 and IEC 60204-1.
16.0 PUSH BUTTONS

All stop push buttons whether forming part of a switchboard or supplied as a separate control station, shall be of the stay-put pattern arranged to permanently open a circuit until deliberate reset action has been carried out. All emergency push buttons shall have red mushroom headed pushes of the stay-put pattern, shall be connected in control circuits such that they are effective under all conditions and shall be positioned in the immediate vicinity of the associated pump motor. The start push buttons shall be effective only in selected circuits, primarily hand control circuits only. Emergency push buttons located next to equipment (outdoor) shall be of weather proof type.
17.0 ANTI-CONDENSATION HEATERS

A thermostatically controlled anti-condensation heater shall be provided at the back of the floor mounted switchboards and starter boards together with an over-riding rotary isolating switch. As a general rule the heaters shall be placed in a separate compartment at the bottom in such a way that the viscosity of oil in any dashpot is not affected and the thermostats shall be adjustable over the range of at least 21 C to 50 C. The heaters shall operate at 230 volts and the supply is therefore to be taken from one phase and neutral of 415 Volt system.
18.0 LABELS
Internally fitted labels shall be finished white engraved letters and numbers filled with black laminated material such as Traffolyte may be used on rear engraved and filled plastic. Externally fitted labels shall be of perspex or other approved transparent plastic with letters and numbers rear engraved and filled with black. The back surface of each label shall be finished with a first coat of aluminium paint and a second coat of paint of the same colour as the panel external finish.
19.0 PADLOCKS
Padlocks and keys shall be minimum of the Yale type in an incorrodible metal.
20.0 CABLE ENTRIES

All switchboards, starter panels and TNB meter panel shall unless otherwise specified, shall have cables glanded at bottom entry of the switchboard. Removable glands plates shall be mounted at least 300 mm above the base of the panels. If gland plates are provided inside the switchboards/starter panel cubicle entries in the base of the cubicle shall be made dust-proof in an approved manner. Refer to Appendix I Switchboard Plinth and Cable Trench Design Drawing.
21.0 JUNCTION BOX

The junction box or enclosures shall be IP66, dust/damp proof according to IEC 529. It shall be with high mechanical impact up to 55 N/mm2. It shall good resistance to UV radiation. Able to withstand temperature range up to 75C. It shall resistance to chemical, detergent solvent, grease and oil. It shall also non-hygroscopic (does not absorb moisture) type. Can be made of high quality thermoplastic (industrial grade), ABS thermoplastic or polyurethane. All the cable entries are must from bottom and enclosed with watertight coupler. The gasket piece used must from polyurethane for a continuous seal to maximise the IP rating. The junction boxes shall be watertight surface mounting type. The screws used shall be type self-tight screws and made of the same material as the box.
Sec 1 - 19
Appendix A - Metal Treatment and Painting Procedures (Electro-Galvarnised Metal Sheets)
Appendix A
Metal Treatment and Painting Procedures (Electro-Galvarnised Metal Sheets)
Section 1: Appendix A Metal Treatment and Painting Procedures (Electro-Galvarnised Metal Sheets)
APPENDIX A
A-2 ELECTRO-GALVANISED METAL SHEETS
PROCESS 1
Metal parts are soaked in alkaline degreaser TANK 1 (ALKALINE DEGREASER) Chemical Dilution Chemical Required Methods Time Tank Material : SPU 8 - 30 Alkaline Liquid Degreaser : 1: 5 parts of water : 140 litres : Immersion : 15 - 30 minutes : Stainless Steel 316
PROCESS 2
Water spray gun - To clean the alkaline residue
PROCESS 3
The metal treated should be left for air dry prior for powder coating
PAINTING PROCESS
- Selection of color of epoxy powder paint and filled up in the spray tank. - Parts are hung up in the spray booth - The parts are electrostatically sprayed with the epoxy powder paint. - Sprayed parts are removed from the booth and placed in an infrared oven. - Parts are then baked in the oven at 180 degree Celsius for a minimum of 30 minutes - Cured parts are then removed from oven. Quality Checks: - Painted parts are checked for the quality of paint. - Dry film thickness are checked with an elcometer - Dry film thickness should be a minimum of 45 micron as standard. Dry film thickness of 60 - 80 microns are non standard and available on request. - Rejected parts are to be reworked.
App: A - 1
Appendix B - Floor Mounted Switchboard Compartment Dimensions
Appendix B
Floor Mounted Switchboard Compartment Dimensions
Section 1: Appendix B - Floor Mounted Switchboard Compartment Dimensions
APPENDIX B
Up to 100 Amps (MCCB) Incoming : 450 mm Subsequent Compartment : 450 mm Cable Compartment : Behind More Than 100 Amps and Up To 400 Amps (MCCB) Incoming : 550 mm Subsequent Compartment : 500 mm (Until last compartment) Cable compartment : Behind 400 Amps and Above 2 panels : 1. MSB 2. MCC MSB Incoming : 600 mm Subsequent compartment : 450 mm MCC
Subsequent compartment : 450 or 500 mm
Cables shall be glanded at bottom entry of the switchboard
Floor Mounted Switchboard Compartment Dimensions
App: B - 1
Appendix C - Typical Switchboard Drawings (Floor Mounted, Wall Mounted and Outdoor Type)
Appendix C
Typical Switchboard Drawings (Floor Mounted, Wall Mounted and Outdoor Type)
App: C - 1
App: C - 2
App: C - 3
App: C - 4
App: C - 5
App: C - 6
A/T
A/T 30A TPN MCCB 10KA (HANDLE LOCK)
A/T 30A TPN MCCB 10KA (HANDLE LOCK) RYB3
A/T 30A TPN MCCB 10KA (HANDLE LOCK) RYB12 RYB4 60A TPN MCCB 25KA 3X6A MCB
DOL 30A TPN MCCB 10KA (HANDLE LOCK)
DOL 16A TPN MCCB 10KA (HANDLE LOCK) RYB8 60W T/H ON/OFF SWITCH ON/OFF SWITCH
DOL 16A TPN MCCB 10KA (HANDLE LOCK) RYB9 6A 1P MCB 6A 1P MCB
DOL 16A TPN MCCB 10KA (HANDLE LOCK) 16A TPN MCCB 10KA (HANDLE LOCK) 60A TPN MCCB 25KA 32A 2POLE MCB
RYB1
RYB2
RYB6
RYB7
RYB10
RYB11
R13
PFR &PF RYB1 RYB2 RYB3 RYB4
PANEL HEATER N PH N
15A TP MCCB 20A TP SWITCHING CONTACTOR R 5 KVAR CAP. BANK
2xEXHAUST FAN
4 STEP CAPACITOR BANK PANEL SINGLE LINE DIAGRAM
FOR 200A AND ABOVE IDMT, OC / EF SHALL BE USED
UUU 3x6A 1P MCB PF 3X100/5A CL.3 5VA CT 100/5A ZCT ELR S/T COIL 6A 1P MCB
4-6MM x 25MM TINNED CU. BUSBAR (RYBN)
3x6A 1P MCB PH. SEQ. RELAY PSR VS V 1-100/5A CL.1 15VA CT AS R 0-500V Y B TO CONTROL
0-100A
3x60A FUSE+N
SURGE PROTECTOR
100A 4P MCCB 50KA (HANDLE LOCK)
App: C - 7
App: C - 8
App: C - 9
App: C - 10
App: C - 11
A/T 30A TPN MCCB 10KA (HANDLE LOCK) RYB6 RYB1 5MM X 25MM TINNED CU. BUSBAR (RYBN)
A/T 30A TPN MCCB 10KA (HANDLE LOCK) RYB2 30A TPN MCCB 10KA 3X6A MCB
DOL 15A TPN MCCB 10KA (HANDLE LOCK) RYB4
DOL 15A TPN MCCB 10KA (HANDLE LOCK) RYB5 6A 1P MCB ON/OFF SWITCH R7 3x6A 1P MCB PH. SEQ. RELAY PSR 3x6A 1P MCB VS V PH 1-60/5A CL.1 15VA CT AS R 0-500V Y B TO CONTROL 30A 2P MCCB 10KA (HANDLE LOCK)
PFR &PF RYB1 RYB2 RYB3 RYB4
PANEL HEATER N
10A TP MCB 20A TP SWITCHING CONTACTOR R 2 KVAR CAP. BANK
10A TP MCB
EXHAUST FAN
20A TP SWITCHING CONTACTOR R 3 KVAR CAP. BANK
UUU PF 3X60/5A CL.3 5VA CT RCCB 63/0.3A 4P RCCB
60W
T/H
0-60A
60A 4P MCCB 25KA (HANDLE LOCK)
App: C - 12
App: C - 13
App: C - 14
S/D
S/D 20A TPN MCCB 10KA (HANDLE LOCK)
S/D 20A TPN MCCB 10KA (HANDLE LOCK) RYB3
S/D 20A TPN MCCB 10KA (HANDLE LOCK) RYB12 RYB4 200A TPN MCCB 35KA 3X6A MCB
S/S 30A TPN MCCB 10KA (HANDLE LOCK)
S/S 60A TPN MCCB 25KA (HANDLE LOCK) RYB8 60W T/H ON/OFF SWITCH ON/OFF SWITCH
VSD 60A TPN MCCB 25KA (HANDLE LOCK) RYB9 6A 1P MCB 6A 1P MCB
VSD 200A TPN MCCB 35KA (HANDLE LOCK) 200A TPN MCCB 35KA (HANDLE LOCK) 100A TPN MCCB 25KA 30A 2P MCCB 10KA (HANDLE LOCK)
RYB1
RYB2
RYB6
RYB7
RYB10
RYB11
R13
PFR &PF RYB1 RYB2 RYB3 RYB4-6
PANEL HEATER N PH N
MCCB TO SUIT DESIGN STEP TO SUIT DESIGN STEP (SWITCHING CONTACTOR) R CAP. BANK
2 x EXHAUST FAN 3X400/5A CL.3 5VA CT DPM 4-400/5A CL.10P10 15VA CTS 3x60A FUSE+N IDMT EF/OC S/T COIL 6A 1P MCB 400A 4P MCCB 50KA (HANDLE LOCK)
UUU 3x6A 1P MCB PF 1-100/5A CL.1 15VA CT 6A MCB
4-6MM x 50MM TINNED CU. BUSBAR (RYBN)
3x6A 1P MCB PH. SEQ. RELAY PSR TO CONTROL
SURGE PROTECTOR
App: C - 15
Appendix D - Digital Protective Relay Standards
Appendix D
Digital Protective Relay Standards
Section 1: Appendix D - Digital Protective Relay Standards
APPENDIX D DIGITAL PROTECTIVE RELAY STANDARDS

Requirements Protection relays Electro Magnetic Emission tests Compatibility (EMC) Disturbing field emission Conducted field emission Immunity tests Radiated disturbances radiated fields electrostatic discharge to power magnetic fields at network frequency Conducted disturbances RF disturbances fast transient bursts Standards IEC 60255 IEC 60255-25 EN 55022 IEC 60255-25/EN 55022 Level
IEC 60255-22-3 IEC 61000-4-3 ANSI C37.90.2 IEC 60255-22-2, ANSI C37.90.3 IEC 61000-4-8
III
damped oscillating waves surges voltage interruptions
IEC 60255-22-6 IEC 60255-22-4 IEC 61000-4-4 ANSI C37.90.1 IEC 60255-22-1, ANSI C37.90.1 IEC 61000-4-5 IEC 60255-11 IEC 60255-21-1 IEC 61000-2-6 IEC 60255-21-2 IEC 60255-21-3 IEC 60255-21-2 IEC 60255-21-2 IEC 60255-21-2 IEC 60529 NEMA IEC 60695-2-11 IEC 61131-2 IEC 60255-5 IEC60255-5, ANSI C37.90 IEC 61068-2-1 IEC 61068-2-2 IEC 61068-2-78 IEC 61068-2-52 IEC 61068-2-60
III A and B IV
III
Environmental Mechanical constraints
In operation vibrations shocks earthquakes De-energised vibrations shocks jolts Enclosure tests Mechanical protection degree Fire withstand Electrical tests earth continuity 1.2/50s impulse wave dielectric at network frequency
2 Fc 2 2 2 2 2 IP52 Type 12
Safety
Climatic conditions
In operation to cold to dry heat to damp heat salt mist corrosion influence/Gas test
Ad Bd Cab Kb/2
App: D - 1
Section 1: Appendix D - Digital Protective Relay Standards
In storage temperature variation to cold to dry heat to damp heat
IEC 61068-2-14 IEC 61068-2-1 IEC 61068-2-2 IEC 61068-2-78 IEC 61068-2-30 Standards EN 50263 Harmonised Standard European Directive UL508 CSA C22.2 IEC 60364 IEC61508
Nb Ab Bb Cab Db Level
Requirements Certification (*) CE UL CSA GOST
Low Voltage electrical installations Functional Safety of electronic safety related systems Communication Data transmission industrial protocol: Modbus RTU Between protective relay and control system inside a power station For power substation automation inside the substation
IEC 61158 Field Bus Foundation EC 870-5 series and IEC 870-5-103 DNP3 IEC 61850
App: D - 2
Appendix E - Digital Protective Relay Operating Conditions
Appendix E
Digital Protective Relay Operating Conditions
Section 1: Appendix E - Digital Protective Relay Operating Conditions
APPENDIX E DIGITAL PROTECTIVE RELAY OPERATING CONDITIONS

Temperature: External auxiliary power supply: - For Low and Mid-end solutions/ applications - For High-end solutions/applications: Current sensors: - 25C to +70C
From AC/AC UPS system or dual battery charger 24V-250V DC and 110V-240V AC (50Hz/60Hz) 24V-250V DC In/1A or In/5A current transformers, Core Balance CTs or interposing ring CT 100V, 110V, 100V/ 3, 110V/3 and voltages as per IEC 60 255-6
Voltage sensors:
App: E - 1
Appendix F - Digital Protective Relay Metering Functions
Appendix F
Digital Protective Relay Metering Functions
Section 1: Appendix F - Digital Protective Relay Metering Functions
APPENDIX F DIGITAL PROTECTIVE RELAY METERING FUNCTIONS

Designation Low-end solutions / Applications Current or Voltage Phase current I1, I2, I3 RMS Calculated residual current I0 Demand current I1, I2, I3 Peak demand current IM1, IM2, IM3 Measured residual current I0, I0 Voltage U21, U32, U13, V1, V2, V3 Residual voltage V0 Positive sequence voltage Vd/rotation direction Negative sequence voltage Vi Frequency Active power P, P1, P2, P3 Reactive power Q, Q1, Q2, Q3 Apparent power S, S1, S2, S3 Peak demand power PM, QM Power factor Calculated active and reactive energy(Wh,VAR) Active and reactive energy by pulse counting (Wh,VAR) Temperature Mid-end solutions/ Applications

(P) (Q) (S)
App: F - 1
Appendix G - Digital Protective Relay Network, Machine and Switchgear Diagnosis
Appendix G
Digital Protective Relay Network, Machine and Switchgear Diagnosis
Section 1: Appendix G - Digital Protective Relay Network, Machine and Switchgear Diagnosis
APPENDIX G DIGITAL PROTECTIVE RELAY NETWORK, MACHINE AND SWITCHGEAR DIAGNOSIS

Designation Switchgear Diagnosis CT/VT supervision ANSI 60/60FL Trip circuit supervision ANSI 74 Auxiliary power supply monitoring Cumulative breaking current Number of operations, operating time, charging time, number of racking out operations Low-end solutions / Applications Mid-end solutions/ Applications
Network and Machine Diagnosis Tripping context Tripping current Trip I1, I2, I3, I0 Phase fault and earth fault trip counters Unbalance ratio / negative sequence current Ii Phase displacement 0, 0, 0 Phase displacement 1, 2, 3 Disturbance recording Thermal capacity used Remaining operating time before overload tripping Waiting time after overload tripping Running hours counter / operating time Starting current and time

App: G - 1
Section 1: Appendix G - Digital Protective Relay Network, Machine and Switchgear Diagnosis
Designation Start inhibit time Number of starts before inhibition Unbalance ratio / negative sequence Ii
Low-end solutions / Applications
Mid-end solutions/ Applications
App: G - 2
Appendix H - Meaning of Colours from IEC 60073 and IEC 60204-1
Appendix H
Meaning of Colours from IEC 60073 and IEC 60204-1
Section 1: Appendix H - Meaning of Colours from IEC 60073 and IEC 60204-1
APPENDIX H
COLOURS MEANING EXPLANATION ACTION BY OPERATOR
Red
Emergency
Hazardous condition
Immediate action to deal with hazardous condition (e.g. by operating emergency stop) Monitoring and/or intervention (e.g. by re-establishing the intended function) Optional
Yellow
Abnormal
Abnormal condition impending critical condition
Green
Normal
Normal condition
Blue
Mandatory
Indication of a condition that requires action by the operator
Mandatory action
White
Neutral
Other conditions; may be used whenever doubt exists about application of Red, Yellow, Green & Blue
Monitoring
App: H - 1
Appendix I Switchboard Plinth and Cable Trench Design Drawing
Appendix I
Switchboard Plinth and Cable Trench Design Drawing
SWITCHBOARD
CABLE GLAND
WALL
1000mm PLINTH
GLAND PLATE 1000mm
2100mm
WALL
200mm
CABLE TRENCH CABLE
SPECIFICATION AND DESIGN OF SWITCHBOARD PLINTH AND CABLE TRENCH
App: I - 1
Section 2
Standby Generator Specification
Section 2 Standby Generator Specification
Page Section 2 - Standby Generator Specification 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 General Engine Lubrication System Exhaust Fan Radiator Air Discharge Fuel System Engine Governing Engine Instrumentation Alternator And Exciter Voltage Regulation Voltage Waveform Starting System Fuel Supply System 13.1 13.2 13.3 14.0 15.0 16.0 17.0 18.0 Fuel Tank Fuel Transfer System Fuel Supply Piping 2-1 2-1 2-1 2-1 2-2 2-2 2-2 2-2 2-3 2-3 2-3 2-3 2-4 2-4 2-4 2-5 2-5 2-6 2-6 2-8 2-9
Protective Devices Control Panel Automatic Mains Failure (AMF) Switchboard Changeover Contactor Earthing System
SECTION 2 - STANDBY GENERATOR SPECIFICATION 1.0 GENERAL

This section describes the specification of diesel generator set. The set shall comprise a diesel engine directly coupled to a 3 phase alternator with auxiliary equipment as further described below and shall be capable of maintaining a continuous output of not less than the kVA specified at 0.8 lagging power factor, 415 volts, 3 phase, 4 wire, 50 Hz supply. Under the operating conditions specified hereafter and within a guaranteed range of frequency and voltage fluctuations after making full allowance for all internal losses and power consumed by ancillaries. The operating conditions shall be:
Total baromatic pressure Air temperature Relative humidity
: 750 mm Hg. : 40 C : 95%
2.0 ENGINE
The engine shall be multi cylinder, vee/in line configuration, 2/4 stroke, naturally aspirated/turbo charged, air-cooled or water cooled with fan and radiator, instant starting and in general compliance with BS 5514 as minimum requirements. Engine speed shall be 1500 rpm. and capable of producing continuously the service power not less than that required by the alternator for the generation of the required output under the specified operating conditions. The engine shall be able to withstand an overload of 10% for 1 hour in any period of 12 hours consecutive running. Engine base mounting shall be fabricated steel channel base frame complete with spring type vibration damper.
3.0 LUBRICATION SYSTEM

The engine shall be complete with enclosed force-feed lubricating system by gear type oil pump with full flow replaceable paper element type oil filter. Oil pan shall be of the sump type.
4.0 EXHAUST FAN

The engine shall be provided with a suitable exhaust system capable of carrying exhaust gases from the engine and dissipate them to the atmosphere as quickly and silently as possible. The piping and fitting shall have minimum thickness of 3 mm and shall be suitably protected from corrosion by application of heat resistant paint. A suitable flexible connection shall be made between the section of piping fixed to the engine and the piping fixed to the building structure.
Sec 2 - 1
The exhaust system shall incorporate an efficient residential type silencer of the absorption-type capable of reducing the exhaust noises of the engine to an acceptable level. Exhaust piping inside the Generator Room shall be fully lagged with minimum 20 mm thick asbestos rope that in turn sheathed with tinfoil. Silencer shall be lagged with minimum 35 mm thick fibre glass section. A metal thimble guard shall be installed where the exhaust pipe passes through the wall.
5.0 RADIATOR AIR DISCHARGE

Unless otherwise dictated by room design, engine radiator discharge air shall be directed outdoors through an approved discharged duct that connects the engine radiator to an opening in an external wall. The duct shall be as short as possible. A length of flexible duct shall be provided between the radiator and the fixed air discharge duct. Shall provide an aluminium automatic self-opening and self-closing shutter complete with aluminium frame to be mounted on the wall opening. The automatic shutter shall be self-closing when the engine is not in operation. When the engine starts the shutter shall be opened outwards by air discharged from the radiator. The automatic shutter system shall be so designed as to keep the noise level to a minimum. In the case of an air cooled engine, air discharge ducting system complete with aluminium automatic shutter as above shall be provided.
6.0 FUEL SYSTEM

The engine shall be capable of operating on 'Class A' fuel to BS 2869. The fuel pump shall be of the gear type complete with governor and throttle and capable of fuel delivery to injectors under all power conditions of the engine. The pump shall be self- adjusting for wear and fuel viscosity. Fuel filter shall be of heavy duty, replaceable and paper element type.
7.0 ENGINE GOVERNING

The governing accuracy of the engine shall be in accordance with BS 5514 part 4, 'Class A1'. The speed droop shall be less than 5%.
8.0 ENGINE INSTRUMENTATION

The instruments and gauges shall be flush mounted on the metal clad panel and shall include but not limited to the following:
Elapsed hours running meter Lubricating oil pressure gauge Cooling water temperature gauge Tachometer
Sec 2 - 2
9.0 ALTERNATOR AND EXCITER

The alternators shall be of screen protected, drip-proof, revolving fields, brushless, salient pole type, directly coupled to the engine and fitted with an exciter to comply in all respects to BS 4999 and BS 5000. Insulation shall conform to BS 2757 Class 'F'. The rotor or armature shall be of one piece, four pole type with lamination pressed and keyed to the shaft. The stator shall be of the multiplicity type for high or low voltages in 'Star' or 'Delta' connections. Damper windings shall be provided in the pole faces. The alternator of brushless type shall be continuously rated not less than the manufacturer's rated kVA specified at 0.8 power factor lagging when wound for 415 volts, 3 phase, 4 wire, 50 Hz supply.
10.0 VOLTAGE REGULATION

The voltage regulation shall be of solid state transistor amplified type capable of providing voltage regulation Grade VR 2.21 of BS 4999 part 40. The alternator, when driven its rated speed and operating with its normal excitation control system, shall be capable of maintaining the voltage under steady state conditions within + 2.5% of rated voltage for all loads between no-load and rated load at rated power factors. Following transient changes the voltage shall restored to within these limits in less than 10 seconds. When alternator, driven at rated speed and giving its rated voltage on no load under its normal excitation control system is switched on to a symmetrical load which would absorb 60% of rated current at rated voltage at a power factor between 0.4 and zero lagging, the initial voltage drop shall be limited to 15% of rated voltage and the voltage shall recover to at least 97% of rated voltage in less than 1.5 seconds. The transient rise in voltage after a sudden rated load rejection at rated power factor and constant speed shall not exceed 20%. Normal voltage shall be variable by means of voltage trimmer within +5% of rated voltage.
11.0 VOLTAGE WAVEFORM

The voltage waveform shall approximate closely to a sine wave both at no load and full load with a lagging power factor of 0.8 and shall not exceed the limits as stated in BS 4999 part 40.
12.0 STARTING SYSTEM

Each engine shall be fitted with electric starting system with a 24 volt heavy duty nickel cadmium battery of sufficient capacity to provide a minimum of six (6) successive abortive starts of the engine without recharging. The minimum cranking period for each abortive starts shall be 15 seconds. The battery shall be connected to the starter motor starting and stopping circuit complete with indicating or signal devices. Capacity of the nickel cadmium battery shall be as recommended by the battery manufacturer for particular make and model of the generator set that required to operate the dc indicating, tripping and control circuits. Battery shall be housed in a rack or crate located beside the generator set and covered on top by a removable wooden cover with sufficient ventilation. The battery charger shall be of automatic constant potential type with two rates of charging complete with ammeters, voltmeters, main isolators, indicating lights for `Mains On', `Trickle Charge', `Boost Charge', ÀC Failure' and etc.
Sec 2 - 3
It shall employ fixed resistance charging and transistor switched relay to switch in the boost charge resistor when the battery voltage falls below a predetermined level recommended by the battery manufacturer. After the boost period, the relay shall be de-energised automatically and the circuit reverts to trickle charge condition. A milliammeter and an ammeter of suitable range shall be provided to indicate trickle and boost charge currents respectively. The battery charger shall be incorporated in the generator switchboard. The starter motor for the engine shall be automatic type to be controlled by the automatic starting and stopping system. In the event of more than one generator sets are installed then each engine shall be provided with its own nickel cadmium battery and battery charger as above.
13.0 FUEL SUPPLY SYSTEM

13.1 Fuel Tank
A fuel tank having a capacity for a minimum of 8 hours continuous operation at full load or 1,000 litres capacity whichever is larger supported by suitable angle irons to permit gravity feed to the engine pumps. The fuel tank shall be fabricated from 2.5 mm thick mild steel sheet construction, not galvanised but painted inside and outside with oil resistant prime and externally finished with undercoat and topcoat. A dial type level indicator calibrated in litres shall be provided. A breather is to be provided. The breather opening must be adequate to vent gases and air from the fuel tank without back pressure. The fuel pump suction line shall pick fuel about 30 mm from the bottom of the fuel tank complete with fuel strainer. The fuel return line shall be so located so as to allow separation of the fuel and vapour or gases in the expansion space above the normal fuel level and shall be pointed away from the breather and suction area. A drain valve complete with padlock shall be provided at a low point in the fuel tank in an accessible location to allow periodic removal of water condensation and sediment. If more than one generator sets are installed in the Generator Room, a common fuel tank may be used unless otherwise specified. However, the common fuel tank shall be off sufficient capacity, or otherwise specified elsewhere, to run the generator sets simultaneously for a minimum of 8 hours continuous operation at full load. Shall supply a full tank of fuel at the time of handing over. Fuel required to carry out all tests including work test and site tests shall be supplied and shall be additional to the full tank of fuel mentioned above.
13.2 Fuel Transfer System

Fuel transfer system for transferring fuel from drums into the fuel tank shall be supplied and installed. The fuel transfer system shall consist of hand operated pump installed in parallel with an electric motor-driven pump.
Sec 2 - 4
A filler pipe shall be installed from the inlet point of the fuel tank to the outlet point of the fuel transfer pumps. A suitable length of flexible transparent oil resistant hose shall be connected from the inlet of the fuel pumps for off-loading from drums. The fuel transfer pumps shall be installed as close to the fuel tank as possible. The electric motor driven pump shall be of the self-priming type and shall have sufficient suction lift to deliver a transfer rate of 50 litres per minute. The electric motor driven pump shall be suitable for operation from single phase, 230 V, 50 Hz supply. To carry out wiring in galvanised steel conduit from the electric starter point on nearby wall to the electric motor-driven pump.
13.3 Fuel Supply Piping

Fuel piping and plumbing shall be of black iron pipe or 'steam' pipe. The diameter of the pipe shall be as recommended by the generator set supplier. Seamless synthetic rubber flexible hose shall be used for connection to the engine fuel inlet and return outlet. Must keep the number of bends to a minimum. Feeding fuel pipe from the fuel tank shall be with a shut-off valve near the fuel tanks for maintenance purposes. Facilities shall be provided to padlock the shut-off valves in open position. Overflowing fuel from the engine shall be fed back to the fuel tank by means of fuel pipe complete with check valve near the fuel tank. Keys alike shall be provided for the padlocks used for shut-off valves of the fuel feeding pipe and the padlocks used for drain valves of the fuel tank. Fuel pipes where required to be distinguished from pipelines of other services shall be brown as a basic identification colour in compliance with BS 1710.
14.0 PROTECTIVE DEVICES

The generator set shall be provided with protective devices to provide warning and automatic shutdown under the following conditions:
Low oil pressure - warning and trip High jacket water temperature - warning and trip Fail to start - warning and trip Over speed - trip Low fuel level (1st.stage) - warning Low fuel level (2nd.stage) - trip
The low oil pressure warning and shut-down and the high jacket water temperature warning and shutdown protective devices shall be set at the manufacturer's recommended pressures and temperature respectively. The overspeed shutdown protective devices shall also be set at the speed recommended by the manufacturer. The `failure to start' warning and shut-down protective devices shall operate if the engine should fail to start within a adjustable pre-set time and stop the automatic starting cycle to avoid successive depletion of the battery charge. The time shall be set to allow for 6 attempts in starting each with a rest interval of half the time setting of the attempt to start. Under any of the above conditions, a common alarm bell of 250 mm diameter installed at the control panel shall sound. In addition, indication lamps showing operation of each engine protective devices shall also be provided. Shall arrange for simulation tests of the above on completion of the generator set erection.
15.0 CONTROL PANEL

A generator set control panel housing control switches and buttons, relays, timers, indicating lights, indicating instruments, selector switches, alarms and etc. shall be supplied and installed. The control panel shall be cubicle construction suitable for floor standing. All control wiring shall be properly labelled with number sleeves. The following facilities shall be incorporated as minimum requirements:
Indication lamps showing operation of each engine protective devices A lamp test button Alarm bell indicating operation of each engine protective devices with Àlarm Silence' button Selector switch giving Àuto', `Test', Òff', and `Manual', operation modes. The function of each mode is as follows:Auto mode Test mode This places the generator set in its normal standby mode To test the auto-start by simulating TNB power failure without actually changing over the load from the TNB supply to the generator set. However if TNB supply fails during `Test' mode, load connection to the generator set must operate. To cut out the starting circuit so that the engine cannot be started. To permit manual operation of the generator set.
Off mode Manual mode
A timer (t1) adjustable up to 15 seconds for starting the generator set; a timer (t2) adjustable up to 60 seconds for load connection to the generator set after starting up the generator set; a timer (t3) adjustable up to 5 minutes before the automatic changeover contactor changes to TNB supply after a mains failure; a timer (t4) adjustable up to 10 minutes for shutting down the generator set after load connection to TNB supply on restoration of TNB supply. All timers shall have calibrated scales in seconds or minutes as appropriate complete with an adjustable knob and pointer. `Start' and `Stop' push buttons Self-latching mushroom head type 'Emergency Stop' button (One to be provided at the control panel and another one in the vicinity of the generator set to be decided on site)
16.0 AUTOMATIC MAINS FAILURE (AMF) SWITCHBOARD

The generator switchboards shall be of the self-contained cubicle type, free standing floor mounted, metalclad, flush fronted suitable for front and rear access housing switchgear and controlgear, protective relays, meters, indicating lamps, cable terminating boxes, and all other necessary items of equipment. Whether specified hereinafter or on the drawings or not it shall be suitable for operation on a 415/230 V, 3 phase, 4 wire, 50 Hz system with solidly earthed. Unless otherwise specified elsewhere, the generator switchboards shall be in general compliance with BS 5486 Part 1 and capable of withstanding without damage fault condition of not less than 31 MVA at 415 volts for 1 second.
Sec 2 - 6
The framework of the switchboard shall be fabricated from rolled steel sections and shall be selfsupporting when assembled, uniform in height and depth from front to back. The rigid construction shall be designed to withstand without any sag, deformation or warping, the loads likely to be experienced during normal operating, maintenance or maximum fault conditions. The front shall be provided with covers/doors of box formation. The rear shall be provided with hinged removable doors of box formation. The rear doors shall be of double-leaf type with rebated edges and each leaf should preferably not be wider than 450 mm. Each leaf of door shall have 2 pairs of approved hinges. The door shall be fitted with approved type of surface- mounted espagnolette or cremate bolts complete with approved locking device operated by a satin chrome lever handle at the centre fixing. The top and sides shall be of removable panels. All panels, covers and doors shall be fabricated from electrogalvanised metal plates of thickness not less than 2.3 mm with paint thickness of 90 m. The interior and exterior of each cubicle shall be finished with light gray paint (ICI Ref. No: ICI 104 or OXYPLAST paint: FF160/8250/CS9 and so constructed as to provide a clear, flush and pleasing appearance. The panels, covers and front doors shall be secured to the enclosure by means of chrome type of screws with cylindrical knurled head complete with retaining clips. Welded cross struts shall not be used. Refer to Appendix A Metal Treatment and Painting Procedure (Electro-Galvanised Metal Sheet). The generator switchboard shall be dust and vermin proof. All covers and doors shall be provided with grommets and seals to exclude dust and dirt. Louvres shall be provided at the sides and back for adequate ventilation. The whole cubicle shall undergo de-rusting treatment, followed by anti-rust treatment and with the exterior be finished semi-gloss enamel grey and interior finished matt white. Busbars shall be tinned hard drawn high conductivity copper of adequate rectangular cross section to carry continuously the rated normal current at a rated frequency of 50 Hz with a temperature rise in accordance with the requirements of BS EN 13601. The busbar rating shall be based on the current density of not more than 1.5 A/sq. mm. Busbars shall be arranged and rigidly mounted on nonhygroscopic insulators so as to withstand any mechanical forces to which they may be subjected under the maximum fault conditions. Where multiple parallel bars are used, they shall be separated by tinned copper spacers at spacing equal to the bar thickness. The main busbars shall be run for the full length of the generator switchboard without reduction in size and shall be arranged in the horizontal plane and in the order Red phase, Yellow phase, Blue phase and Neutral from back to front. In each panel, connections shall be Red phase, Yellow phase, Blue phase and Neutral from left to right, viewed from the front of the panel. The neutral busbar shall be of full size and full length as that of the phases. Tinned copper earthing bar of 6 mm x 25 mm cross section shall run to the full length at the base of the generator switchboard. Busbars shall be identified with standard colour code Red, Yellow, Blue, Black and Green at appropriate points to distinguish the phases, neutral and earth respectively. Connections from busbars to the switchgears shall be effected by means of copper bars or copper insulated conductors and shall be identified by means of coloured plastic sleeving or painting in accordance with the standard colour code. All connections shall be made up with bronze or other copper alloy bolts and nuts utilizing tension washers on both outer faces. Precautions shall be taken to prevent overheating through hysteresis and Eddy current losses. All secondary wiring shall be of not less than 1.5 sq. mm. section insulated with PVC and shall be fixed securely without strain by cleats of the compression type. All secondary wiring shall be properly labelled with number sleeves. Flexible protective conductor of not less than 2.5 sq. mm section insulated with PVC shall be fixed securely between the lids, doors, cover plates and etc. with electrical equipment attached to them and the main cubicle to ensure continuity of the protective circuits.
Sec 2 - 7
All switchgear, controlgear, indicating and measuring instruments, measuring transformers, protective relays and etc. provided shall comply with the relevant specifications. Automatic changeover contactors shall be as specified hereinafter. Refer to 13.2 Electronic Protection Relay (Section B Low Voltage Switchboard and Components Specification). One number anti-condensation heater shall be installed for every two (2) panels at the generator switchboards. Each heater shall be complete with automatic thermostat, control switch and indicating lamp. A tool compartment of sufficient size shall be provided at the base of the generator switchboard for storage of tool kit used for the generator set. The door for tools compartment shall be hinged type complete with lockable handle with keys. Engraved labels with white lettering on a black background made of laminated materials shall be provided and fastened on the front panels of each switchgear and items of equipment. Wording shall be clear and coincide. Rubber mat of width 1,000 mm and thickness 12 mm shall be provided in front of the generator switchboard. It shall extend to the full length of the generator switchboard.
17.0 CHANGEOVER CONTACTOR

The automatic changeover contactor, unless otherwise specified, shall be bar mounted type with fixed bar and moving shaft made of steel and bearing supports made of aluminium/bronze alloy. They shall be mechanically held, mechanically and electrically interlocked, double air-break, quick-make and quick-break type complying fully with IEC 60947. They shall be dust-proof, rust protected, fully tropicalised and suitable for use on 230/415 V, 50 Hz AC system. The operating coil shall be 230 V/415 V, 50 Hz AC type and shall operate satisfactorily when the voltage at the coil terminals is between 85% and 110% of the nominal voltage. The electromagnet shall be of laminated type. The automatic changeover contactors shall be four pole types. Each pole shall comprise three main parts:
The main contacts shall be of 'butt-contact' pattern without sliding or rolling and shall operate with absolute minimum contact bounce. The blow out coil shall be rated to carry the total current flowing through the main pole and according to the thermal rating of the contactor. The arc chute shall be De-ion type or the type having 'arc splitter' for rapid extinction of electric arc. Each arc chute shall have a steatite disc on its internal faces for preventing rapid erosion of the chute by the effect of arcs. The arc chutes shall be easily removable to allow inspection of the main contacts and where necessary their replacement. The main contacts shall be able to carry continuously the rated current without damage in an enclosure having an ambient temperature up to 40 degrees Celsius. They shall be of category AC 4 as defined in IEC 60947. Unless otherwise specified, a minimum of four normally close and four normally open auxiliary contacts shall provided. A transparent protection screen of full compartment size shall be provided in front of the automatic changeover contactor.
Sec 2 - 8
18.0 EARTHING SYSTEM

Independent earthing system shall be provided for each generator set. Earthing to earth Resistance not exceeding one (1) Ohm () shall be effected by 3 mm x 25 mm copper tape and 16 mm diameter copper jacketed steel core rods. The copper jacket shall be of minimum thickness 0.25 mm and shall be permanently bonded to the steel core to ensure that the copper jacket and steel core are not separable. Earth chambers and covers used for earthing rods shall be reinforced concrete type. Each generator set earthing point shall be identified by permanent label legibly marked with the words 'GEN-SET EARTH' permanently fixed to the point of connection of every earthing conductor and the earth electrode.
Sec 2 - 9
Section 3
Small Power and Lighting
Section 3 Small Power and Lighting
Page Section 3 Small Power and Lighting 1.0 2.0 3.0 4.0 5.0 6.0 7.0 Material Panel Distribution Board PVC Electrical Conduit and Fittings Spacer Bar Saddles Distance Saddle Ceiling Fan Light Fittings and Ancillary Equipment to Lamps 7.1 7.2 7.3 7.4 7.5 7.6 8.0 8.1 8.2 8.3 8.4 8.5 9.0 9.1 9.2 9.3 9.4 Light Fittings for Use with Tubular Fluorescent Lamps Flexible Cords Installation of Fluorescent Light Fittings Self-Contained Emergency Lights Light Fittings to be Supplied and Installed LUX Levels Scope of Works Light Distribution Street Lighting Lanterns High Pressure Sodium Vapour (HPSV) Lamp Columns and Bracket Arms General Ballast Ignitors Service Fuse / Cut-Outs. 3-1 3-1 3-2 3-2 3-2 3-2 3-3 3-3 3-3 3-3 3-3 3-4 3-4 3-4 3-4 3-4 3-5 3-5 3-6 3-7 3-7 3-7 3-7 3-7
Street and Perimeter Lighting
Materials and Equipment
SECTION 3 SMALL POWER AND LIGHTING 1.0 MATERIAL PANEL

Provision shall be made in the panels for the installation of the meters by TNB. Sufficient length of cable shall be provided for termination of cables at the meters.
2.0 DISTRIBUTION BOARD

The boards shall be provided with Miniature Circuit Breakers (MCB) and arranged in such a manner that the incoming cables to the MCB is connected direct to the other MCB terminal. It shall be so designed that the MCB can be replaced without disturbing or removing the adjacent units and busbar connectors. All boards shall incorporate a main isolator of appropriate rating, which shall be positioned at the lower part of the panel along the centerline. The interior of the panel shall be provided with a removable internal shroud, giving access to the MCB dollies, but covering the reminder of the interior for neat appearance after wiring. The internal shroud shall be off the same finish as the exterior of the board. Labels for phase and circuit identification and current ratings shall be fixed on this internal shroud either above or below the dollies. On the outside face of each board cover, a black Perspex label with the number of the distribution board and engraved in the white on chrome-yellow lettering shall be provided and fixed thereon. For TPN type distribution boards, bearing the letters: DANGER 415V; 3-PHASE SUPPLY engraved in red color thereon shall be installed. Isolators used shall be of the heavy duty ON LOAD type and of a approved make. All distribution boards shall be fitted with suitable means for terminating incoming and outgoing cables and final subcircuit wiring. The distribution board shall be of totally enclose type construction and be suitable for installation on walls or be recessed in walls of buildings. All boards shall be rated for the intended voltage and be in accordance with relevant British Standard. Busbars for the main shall be of copper and sized in accordance with the relevant British Standard. Unless otherwise noted full size neutral busbars shall be provided. Busbars shall be braced throughout to conform to standard practice governing short circuit stresses in distribution boards. Spare ways shall be installed with MCBs and be fully wired and labeled. For those not exposed to the sewage emitted vapors and gases, the distribution board panel thickness shall be of 2 mm and 60 m of paint thickness. However for distribution boards in contact with the sewage emitted vapors and gases shall be of 2.3 mm in thickness and 90 m of paint thickness.
Sec 3 - 1
3.0 PVC ELECTRICAL CONDUIT AND FITTINGS

The PVC Electrical Conduit and Fittings shall be of proven durable and effective for years maintenance free performance in exposed and encased applications in accordance with NEMA TC-2 Specification. All conduit and its fitting materials shall comply to the following: Rigid Non-metallic Conduit: Schedule 40, high impact PVC with 5,000 psi tensile strength at 73.4 degrees F and approved for 90 degrees C rated by UL Standard 651. Corrosion Proof : Resistant to most chemicals Properties make shall be of PVC fire resistant. Non-Magnetic and Non-Galvanic: Properties shall be of good insulation and No power loss or conductor heating.
4.0 SPACER BAR SADDLES

Spacer bar saddles and bases shall be of Rigid Non-metallic, Schedule 40 high impact PVC with 5,000 psi tensile strength at 73.4 degrees F and approved for 90 degrees C rated by UL standard 651. Saddle bases shall be 3 mm deep and may be solid or pressed from PVC of not less than 1 mm thick. Saddle tops shall be fluted. The screw holes shall be of either slotted or keyhole pattern to permit the assembly and removal of the saddle top without removal of the retaining screws. Retaining screws shall be 2 BA in size and be of brass or steel and zinc plated to comply with BS 3382: Part 2. Retaining screws shall engage not less than 1.5 full thread in bases pressed from steel.
5.0 DISTANCE SADDLE

Distance saddle shall be of Rigid Non-metallic, Schedule 40 high impact PVC with 5,000 psi tensile strength at 73.4 degrees F and approved for 90 degrees C rated by UL Standard 651. Saddle bases solid or pressed from PVC of not less than 1 mm thick. Saddle bases shall be of such depth that the nominal clearance of 6 mm between the conduit and the wall of surface to which the saddle are fixed is provided. Retaining screws for saddle tops shall be of brass complying with BS 3382.
6.0 CEILING FAN

Ceiling fans shall be 1,524 mm sweep model fitted with capacitor type motor suitable for operation on 240V 50Hz AC single-phase and supplied complete with down rods to suit mounting heights and speed regulators.
Sec 3 - 2
7.0 LIGHT FITTINGS AND ANCILLARY EQUIPMENT TO LAMPS

7.1 Light Fittings for Use with Tubular Fluorescent Lamps
All fluorescent tubes shall comply with MS 619 or relevant British Standard and be of 26 mm diameter. They shall be switch-start, white light with a correlated color temperature of 3,000K and have average life span of 15,000 hours. The lamp lumens shall be 3,200. Lamp holders shall be bi-pin, spring loaded, designed to retain positively the lamp caps independently of the contact springs and of robust construction complying with BS 5101. Power factor correction capacitors shall be of the metal foil type enclosed in a metal case with two insulated connections, safety discharge resistor and impregnated with Arcolor or other approved medium. Power factor shall be corrected to capacitors shall comply with the relevant British Standard or MS 279. Ballast for fluorescent lamps shall be polyester vacuum impregnated, built-in, switch-start type, having a hot loss of 8 W (for 36 W lamp) and comply with BS 2818. Diffusers depend on type of fittings.
7.2
Flexible Cords
Flexible cards for use with light fittings employing tubular fluorescent lamps, or apparatus operating at normal room temperature shall comply with BS 6500 and shall have conductor of plain copper.
7.3
Installation of Fluorescent Light Fittings
All fluorescent light fittings shall be supplied complete with tubes, lampholders and control gear. They shall be completely wired and fully tested to ensure reliable performance and quality. All internal wiring shall be neatly arranged and taped with intermediate terminals provided with external connection. All wiring shall be of heat resistant type and be PVC insulated. Brass earthing screws with spider washers shall be provided for earthing the fittings. The cutting of down rods or the provision of extended down rods to suite mounting height shall be undertaken. Where fluorescent light fittings are to be installed on the underside of the ceilings, suitable spacers which shall be inserted between the top of the fittings and underside of the ceiling in such a manner as to allow a minimum clearance of 12 mm shall be provided.
7.4
Self-Contained Emergency Lights
The unit shall be designed such that the cover can be readily removed for ease of installation. The unit shall be suitable for mounting on walls or on ceiling as required. The diffuser shall be of clear acrylic.
The unit shall be equipped with nickel cadmium sealed cells and an automatic charger main failure relay and shall be maintenance free. The emergency duration shall not be less than 3 hours for a fully charged battery. Illumination shall be provided by one 300 mm 10 W fluorescent lamp. The unit shall be equipped with LED to indicate mains on and a test switch to simulate main failure.
7.5

Light Fittings to be Supplied and Installed

2 x 36 W fluorescent fitting c/w acrylic prismatic diffuser corrosion resistent recessed mounted. 2 x 36 W fluorescent fitting c/w acrylic prismatic diffuser corrosion resistent surface mounted. 150 W sodium vapour explosion proof floodlight lamps. 150 W sodium vapour weatherproof floodlight lamps. 1 x 70 W high-pressure sodium street lighting fitting c/w single arm and 3 m pole and accessories.
7.6
LUX Levels
The lighting for the various location listed below shall be as follows: (a) (b) (c) Pump room, blower room, switchboard room, workshop, equipment rooms and other enclosed work areas 500 Lux Office, Administration Area 350 Lux Toilets, pantry, corridors, walkways, staircase and etc. 250 Lux
8.0 STREET AND PERIMETER LIGHTING

8.1 Scope of Works
The works shall be consist of the supply and delivery to site of lanterns, fittings, switch-gears, bracket arm, columns, bases, cable, feeder pillars and all necessary ancillary equipment for the assembly, erection, connection, testing and commissioning of the complete street lighting system. The work shall also include the supply and delivery of one hydraulic working platform.
8.2
Light Distribution
The light distribution for all the street lanterns shall be of cut-off. It could be either semi-cut-off or fully cut-off. The specification of the lighting scheme shall conform to the following: The road shall be assumed with an average road luminance factor of 0.08, a specular factor of 0.37 and maintenance factor of 0.7.
Sec 3 - 4
The light distribution shall consist of: (a) (b) (c) Minimum average road surface luminance of 30 Lux Minimum average perimeter luminance of 150 Lux Uniformity of luminance i.e. L min/L av. of 0.4.
8.3
Street Lighting Lanterns
All lanterns shall be new, totally enclosed, dustproof, insect proof and watertight and shall be tested in accordance with BS 4533 part 2. All exposed parts shall be of non-corrosive stainless steel materials. The lanterns shall provide the required light distribution with the size and type of lamp specified. The light distribution shall be semi cut-off or cut-off. Each lantern shall be supplied complete with all the necessary integral control gear fully wired and ready for erection. The lantern wiring shall be of the size and insulated with materials that will more than effectively withstand the current, voltage and temperatures expected within the lantern during both the starting and operating model in the ambient temperature of the site. The lamp compartment of the lantern shall be accessible via a hinged, glazed acrylic bowl which shall, in the closed position, bed firmly upon a soft resilient neoprene gasket shall be positively secured in the lantern housing and shall be of weather resistant type. The bowl and its frame or housing shall be secured firmly to the lantern body, by means of stainless steel clips and hinge pins. In the lowered position of the bowl it shall be restrained from becoming detached or being blown against the other portion of the lantern or the column arm. The polar curves of the lanterns in both horizontal and vertical planes shall be smooth and free from any abrupt variations so that the luminous intensity diminished smoothly and progressively from the maximum. The lantern shall incorporate high intensity aluminium mirrors, chemically anodized to yield optimum reflection of light distribution.
8.4
High Pressure Sodium Vapour (HPSV) Lamp
All lamp supplied shall be of a High Pressure Sodium Vapour (HPSV) type and shall have a colour temperature of approximately 2100K and 5000K respectively. The majority of the light output shall fall within the 560-610 nanometre waveband i.e. Yellow/Orange range for the HPSV. The lamp shall have an initial luminous efficiency of approximately 83 lumens per watt.
Sec 3 - 5
8.5
Columns and Bracket Arms
All Columns and bracket arms shall be manufactured to comply with BS 1840: 1972. The columns and bracket arms shall be manufactured from steel conforming to BS 4360: 1976 Grade 43C or Grade 50C. The columns shall be of continuously tapered octagonal sections, connected together by forced fit slip joints. Each column shall have a base compartment and a weatherproof door, measuring 600 mm x 130 mm, with a tamperproof column and be flush with the column, providing a watertight fitting against a non-perishable resilient gasket. Door keys shall be supplied at the completion. The columns shall be supported connected by flange plates on concrete footings. Flange plates shall be of at least 18 mm thickness. Concrete footings shall be cast with appropriately sized holding down bolts as recommended by the column manufacturer and have lead-in / lead-out ducts and shall be responsible for the size of the concrete footings depending on soil conditions. A 16 mm thick Tufnol baseboard, measuring 600 mm x 130 mm, shall be included in the base compartment. The baseboard shall be securely fixed in position inside the column by countersunk screw to hidden treaded bushes. No part of this fixing shall protrude through the column. All metal parts of each column shall be earthed and the column and bracket arms shall be electrically continuous. A corrosion resistant electrical earthing terminal in the form of a stud of not less than 6 mm in the diameter and 20 mm long shall be attached close to the door opening within each column. Two suitable sized washers and two nuts shall be fitted. All columns shall be erected in to a perpendicular position with the door on the opposite side to the oncoming traffic except at the parapets of bridges and retaining walls. In each run of columns of five or more, every fifth column shall be checked for vertically with a theodolite. If less than five columns are erected in line than one column shall be so checked. Shim washers may be use to achieve vertically where necessary. The bracket arms shall be of the safe shape and finish as the column. The smaller end of the curve arm finish with a spigot, suitable for the safe mounting of the lantern to be installed. Individual sections of each column, bracket arm and flange plate shall be protected against corrosion by hot-dip galvanising internally and externally in accordance with BS 729: 1971. All welding work shall be done prior to galvanising. The joining of two parts by welding after galvanising shall not be permitted. The treatment prior to galvanising shall include degreasing, rinsing, pickling, then rinsing and fluxing. Post treatment such as chromating or phosphating shall then be applied. The minimum average zinc coating weight shall conform to the recommendations of BS 729.
Sec 3 - 6
9.0 MATERIALS AND EQUIPMENT

9.1 General
Items of equipment and material shall have makers specification agreeing with those of British Standard. The equipment offered shall be suitable for continuous trouble free operation under adverse conditions.
9.2
Ballast
Only ballast manufactured for high-pressure sodium vapour lamp applicants shall be used. The combination of MBF control gear and retrofit sodium vapour lamp shall not be acceptable. The ballast shall be an open style polyester resin filled type. It shall be enclosed in the suitable steel canister, encapsulated and finished in white enamel. The windings shall be dual polyester amide / amide copper wire, and both windings and core insulation materials shall be Class H. The ballast shall be designed to operate over a range of main voltage from 200 to 250 volts by means of suitable tapings.
9.3
Ignitors
Ignitors for the HPSV lamps shall be rated with the appropriate voltage. The unit shall be capable of operating from a range of voltage from 200 to 250 volts. The ignitor shall be highly efficient, housed in a cylindrical aluminium canister and provided with wither pin terminations of flying leads. The ignitor shall be of the Pulse Transformer type incorporating electronic circuitry and suitable for the type of ballasts and lamp to be installed. The output pulse shall be substantially independent of both supply voltage and ballast parameter. A cut-out circuit shall be incorporated so that pulsing will cease after approximately two minutes, in the event of no ignition.
9.4
Service Fuse / Cut-Outs.
The service fuse / cut-outs shall be of an approved equivalent. Service fuse unit for each lantern shall be of the correct rating and of HRC type. The unit housing has high mechanical and dielectric strength, and shall be suitable for use in the tropics.
Sec 3 - 7
Section 4 - High Tension Components Specifications
Section 4
High Tension Components Specifications
Page Section 4 - High Tension Components Specifications 1.0 11 kV / 22 kV Vacuum Circuit Breaker Specification 1.1 1.2 1.3 General Design Features and Construction 1.2.1 Cubicles Main Components 1.3.1 Incoming circuit breaker 1.3.2 Outgoing feeder circuit breaker 1.3.3 Bush bar Chamber 1.4 Description 1.4.1 Circuit breaker compartment 1.4.2 Metering compartment 1.4.3 Bus bar compartment 1.4.4 Potential Transformer 1.4.5 Metal Treatment 1.4.6 Tests 1.5 1.6 Required Technical Parameters Specification for Panels 1.6.1 Incomer Panels 1.6.2 Outgoing Panels 2.0 Specification for 11 kV Oil Immersed Natural Cooled Transformers 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 General Standards and Approval Transformers Type of Transformer Voltage Ratios Winding Connections and Vector Group Impulse Withstand Voltage Impedance Voltage Flux Density Tapping Range and Method Limits of Temperature Rise Class of Winding Insulation 4-1 4-1 4-1 4-1 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3 4-4 4-4 4-4 4-4 4-4 4-5 4-6 4-6 4-6 4-6 4-6 4-6 4-7 4-7 4-7 4-7 4-7 4-8 4-8
2.13 2.14 2.15 2.16 2.17 2.18 3.0 3.1 3.2 3.3
Cooling System Fittings Terminal Marking and Rating Plates Oil Earthing Transformer Room Scope Standards Description 3.3.1 Magnetic Core 3.3.2 LV Windings 3.3.3 HV Windings 3.3.4 MV Winding Support Spacers 3.3.5 HV Connections 3.3.6 LV Connections 3.3.7 HV Tapping
4-8 4-8 4-9 4-9 4-9 4-10 4-11 4-11 4-11 4-11 4-11 4-12 4-12 4-12 4-13 4-13 4-13 4-14 4-14 4-14 4-15 4-15 4-15 4-15 4-16 4-16 4-17 4-17 4-17 4-17 4-18
Cast Resin Transformer
3.4 3.5 3.6 3.7
Accessories and Standard Equipment Thermal Protection Metal Enclosure Electrical Protection 3.7.1 Protection relay 3.7.2 MV surge arresters 3.7.3 RC filters (repetitive switching operations)
3.8 3.9 4.0 4.1 4.2 4.3 4.4
Climatic and Environmental Classifications Fire Behaviour Classification Types Of Cables Cable Trench Cable Ducts Cable Marker
11 kV CABLE SPECIFICATION
ii
Section 4 - High Tension Components Specification
SECTION 4 - HIGH TENSION COMPONENTS SPECIFICATIONS 1.0 11 kV / 22kV Vacuum Circuit Breaker Specification
1.1 General
This specification covers the technical details of operating requirement, constructional details and provides some guidelines for testing of 11 kV Vacuum circuit breaker and panel. The panel shall be made out of 2 mm. CRCA steel sheet, dust & vermin proof, duly painted with red oxide & powder coated with steel grey paint after pretreatment of acid/alkali wash with a provision for incoming side cable entry & outgoing bottom cable entry. This specification shall be applicable for indoor installed switchboard connected to control incoming supply and to primary side of power transformers. All circuit breakers shall be arranged for Solenoid closes and shunt tripping, both operating from 110 V.D.C. source. The close/trip control switch shall be of pistol grip type. The closing and tripping circuits shall be self-opening on completion of their respective functions irrespective of the position of the control switch. A readily identifiable mechanical trip device shall be provided with each breaker. The mechanism shall be trip-free at any position of the closing stroke. A visual ON/OFF indicator shall be provided positively coupled to the operating mechanism. Manual charging facility of the spring and manual tripping arrangement shall also be provided. Anti-pumping facility shall be provided.
1.2
Design Features and Construction
1.2.1 Cubicles
Each unit shall be housed in a 2 mm thick MS steel sheet cubicle having the bus-bars, C.T.'s, main and control cable c/w terminals, nations, all at the rear and accessible by removing detachable panels. A lockable hinged lift off type front door shall enclose the truck and shall carry the control switches, indicating instruments and lamps. Fuses shall be mounted on the fixed part of the cubicle, preferably at the rear. The ammeter shall have red mark at full load rating. Protection relays shall be mounted on a separate swing panel above the cubicle frame work. The panel should conf. to IP54 degree of protection.
Sec 4 - 1
1.3
Main Components
1.3.1 Incoming circuit breaker

This shall be provided with protective and instrument panel. This shall be drawn out type with vertical isolation and bus bar chamber for inter-trunking with other breakers. Incoming cable box shall be provided with provision for spare cable entry.
1.3.2 Outgoing feeder circuit breaker

This shall be provided with protective and instrumental panel. This shall be draw out type with vertical isolation and bus bar chamber for inter trucking with other breakers. Outgoing cable box shall be provided.
1.3.3 Bus bar Chamber

Adequately rated potential transformer/current transformer Complete with protection fuses Indicating and measuring devices Protective relays Trip free operating mechanism Safety interlocks Wiring for control circuit, measuring, indicating and protective devices Frame earthing Operation counters "ON" and "TRIP" push button Pressure release vent Test terminal blocks
1.4
Description
1.4.1 Circuit breaker compartment

This compartment shall consist of a truck carriage on rollers on which the circuit breaker shall be mounted. The raising and lowering mechanism shall be designed so as to enable the breaker to be plugged in or out with minimum physical strain. The mechanism employed shall enable the breakers to be self-supporting at all positions. Positive interlocks shall be provided to ensure that the circuit breaker is taken out from or put into service position only when it is in OFF" position. Further more, circuit breaker shall be operable only when it is in "FULL SERVICE" position or in "TEST" position. The circuit breaker shall be provided with a manually charged spring assisted stored energy closing mechanism with electrical tripping and switching device. The following mechanical and electrical interlocks shall be provided in the spring charging mechanism.
Sec 4 - 2
When the breaker is in "ON" position it will not be possible to charge the main spring. It will not be possible to close the circuit breaker if the spring is not fully charged. Rapid opening of the breaker will be ensured.
1.4.2 Metering compartment

Each unit should have its own metering chamber with hinged door, centralized wiring and fuses. The meters provided should be flush type and mounted on floor.
1.4.3 Bus bar compartment

All bus bars shall be air-insulated, PVC encapsulated, amply rated and shall be fitted in the top rear position. The bus bars and their main current carrying connections shall have the same sectional area through out their length. Where bus bars are taken through the partitions of adjacent cubicle, sealing shall be provided to prevent spread of fire from one unit to the next. The bus bar shall be of hard drawn copper and these shall be supported on suitable insulating materials at sufficiently close intervals to prevent bus bar sag and to effectively withstand electromagnetic stresses in the event of short circuit. Provision for the interconnection of the circuit breakers by trucking arrangement and through terminal box shall be provided. Each group of bus bar feeder spouts shall be fitted with automatically operated safety shutters. All incomer panels, sectionaliser and other feeders shall be provided with:
One set of 3 single phase bar primary current transformer for instrumentation of panel (Accuracy Class 0.5) One set of 3 single phase bar primary current transformer for protective devices (Accuracy Class 5 P 10)
The switchgear shall be provided with cable sealing hoses to in terminate the incoming and outgoing cables.
1.4.4 Potential Transformer

All incomer panels and sectionliser shall be provided with adequately rated 3 phase, 11 kV/110 Volts, 200 VA potential transformers with current limiting resistors and H.T. & L.T. fuses for protection. These shall be used for all measuring instruments proposed in the Technical Parameters and to provide control circuit actuation of all the panels of the switchboard. The potential transformers shall be core type air insulated and housed in sheet steel cubicles. Indoor plugs shall be provided for simulation disconnections of both primary and secondary winding of the transformer. Causing of the potential transformers shall be efficiently earthed.
Sec 4 - 3
1.4.5 Metal Treatment

Enclosure shall undergo rigorous rust proofing process comprising of alkaline degreasing, pickling, phosphate coating of primer and finally standard approved colour to provide an elegant and enduring finish.
1.4.6 Tests
Shall ensure that the tests mentioned in BS 2037, BS 116 or relevant have been performed.
1.5
Required Technical Parameters

: Indoor : 11 kV / 22 kV : 12 kV / 24 kV : 3 (three) : 50 HZ : Non effectively Earthed system : Vacuum Circuit Breaker : 26.2 kA corresponding to 500 MVA : 26.2 kA : One minute power frequency : 28 kV RMS : With standard full wave : 75 kV Peak :B : 800 AMPS : Electrolytic copper : 50 degree C
Service Nominal System Voltage Highest System Voltage No. Of phases Frequency System Earthing Type Symmetrical breaking capacity Short Time breaking capacity Rated insulation Levels Withstand voltage Impulse withstand test voltage (1.2/50 microsecond wave) Class of Insulation Bus bar capacity Bus bar material Maximum ambient temperature
1.6
Specification for Panels
1.6.1 Incomer Panels

No. Of units required Nominal rated current Purpose C.T Ratio Incoming Cable Size Potential Transformer : One No. : 630 AMPS : To control the incoming power supply : 100-50/5+5 having 15 VA burden per core & accuracy Cl.:0.5 for meter & 5 P 10 for protections : 1 No.11 kV x 3 x 120 sq.mm XLPE Copper conductor cable : 1 No. 11 kV/110 V, 200 VA per phase & Cl.: 1 accuracy for metering & protective Relays
Sec 4 - 4
Protections
Measuring Instruments Indicating Lamps
: - Numerical Type, Microprocessor based, one 3 Ph. - IDMT and high set instantaneous relay consisting of three overload units (Range 50% to 200%) one earth fault unit (range 5% to 80%) & three high set instantaneous units - 1 Single pole instantaneous relay for heavy earth fault with setting 5-80% - Over voltage Relay : - Ammeter with selector switch (Duel Range) - Voltmeter with selector switch (Range 0 - 15 kV) : - GREEN for breaker 'OFF' - RED for breaker 'ON' - AMBER for breaker 'AUTO TRIP' on fault - WHITE for TRIP CIRCUIT HEALTHY
1.6.2 Outgoing Panels No. Of units required

Nominal rated current Label Reading Purpose C.T. Ratio Outgoing cable size
: 3 Nos. (Three)
: 630 Amps : Transformer Feeder. : Control of supply to transformer : 30/5+5 Amps having 15 VA burden per core & accuracy Cl.:0.5 for meter & 5 P 10 for protections : 1 No. 11 kV x 3 C x 120 sq.mm XLPE Copper Conductor Cable for each panel.
Measuring Instruments Protections
: Ammeter with selector switch (Range 0-30 A) : - Numerical Type, Microprocessor based, combined
IDMT and high set instantaneous relay consisting of three overload units (Range 50% to 200%) one earth fault unit (range 5% to 80%) & three high set instantaneous units. - Over Voltage Relay : - GREEN for breaker 'OFF' - RED for breaker 'ON' - AMBER for breaker 'AUTO TRIP on fault. - WHITE for TRIP CIRCUIT HEALTHY
Indicating Lamps
Sec 4 - 5
2.0 Specification for 11 kV Oil Immersed Natural Cooled Transformers

2.1 General
This section of the Specification describes and specifies requirements for 11 kV / 415 V distribution transformer.
2.2
Standards and Approval
The transformers shall comply with the latest relevant British Standard Specifications, Malaysia Standard or IEC.
2.3
Transformers
The transformers shall be suitable for continuous operation on 3 phase, 50 Hz electrical power distribution system with neutral earthing conditions and maximum phase fault levels as follows : 11 kV 350 MVA6.6kV 150 MVA3.3 kV 75 MVA415V 31 MVA
They shall be fully tropicalised and suitable for continuous operation at an ambient temperature up to 40 degree Celsius, relative humidity up to 100%, isoceraunic level up to 200 days per-annum and altitude up to 1,000 meters above sea level.
2.4
Type of Transformer
The transformers shall be oil-immersed natural cooled and hermetically sealed type complying with BS 171 or IEC 76 and suitable for indoor duties. Unless otherwise specified, they shall be low loss, step-down type of distribution transformers fitted with skid type bases.
2.5
Voltage Ratios
The standard voltage ratios at no-load shall be as: (a) (b) (c) 11000/433-250 V, so as to deliver load at the declared voltage of 415/240 Volts, 3 phase, 4 wire system with the neutral solidly earthed. 11000/3300 V 6600/433-250 V
Sec 4 - 6
2.6
Winding Connections and Vector Group
Unless otherwise specified, the winding of all 3 phase step-down transformers shall be connected as follows:Higher Voltage Delta Lower Voltage - Star Vector Group - Dyn11
2.7
Impulse Withstand Voltage
Completed transformers arranged for service but with arcing horns removed shall be capable of withstanding the following negative polarity 1.2/50 microseconds impulse voltage on the higher voltage windings:Nominal System Voltage Impulse Withstand Voltage (Volt rms) (kV peak) 3300 6600 11000 45 60 75
All impulse shall be carried out in accordance with the provisions of BS 923 BS 171 or IEC 76.Type test certificates may be accepted in lieu of separate impulse tests at the discretion of the IWK/JPP
2.8
Impedance Voltage
For the purpose of protection against short circuit stresses, the minimum value of impedance voltage at 75 degrees Celsius rated current shall be as follows: -4.75% for transformer up to 1,000 kVA. 5.5% for transformer between 1,000 1,500 kVA 6.0% for transformer between 1,500 - 2,000 kVA.
2.9
Flux Density
The maximum flux density at any point in the magnetic circuit when the transformer is connected on the principal tapping and operating at normal voltage and frequency shall normally be in the region of 1.55 to 1.65 Tesla, but at the time of tendering alternative designs employing higher flux densities may be may be submitted. However with such higher flux densities for consideration the magnetic circuit shall not unduly saturate during system over voltage conditions.
2.10 Tapping Range and Method

Tapping shall be provided on the higher voltage winding for a variation of the no-load voltage of + 5.0%, + 2.5%, 0%, - 2.5% and-5.0%. All tap changing shall be carried out with the transformers off circuit by means of an externally operated tapping switch with tap position indications. The operation handle shall be mounted on the tank side and provision shall be made for padlocking in any tap position. Padlocks of any approved type shall be supplied.
Sec 4 - 7
2.11 Limits of Temperature Rise

The transformers shall be designed for continuous operation at their rated power without exceeding the temperature rise limits as follows: In Top Oil In Inding : 50 degrees Celsius : 55 degrees Celsius
2.12 Class of Winding Insulation

The Class of winding insulation shall be Class A to BS 2757.
2.13 Cooling System

Cooling tubes or fins shall be fitted on the sides of the transformer. The arrangement of the tubes or fins shall be such that all painted surfaces can be readily cleaned and painted in position. The tubes or fins shall be designed to allow free circulation of oil and to prevent any accumulation of moisture.
2.14 Fittings
Unless otherwise stated in the in the specification transformers covered by this specification shall be provided with the following standard fittings:
Terminal Marking and Rating Plates Lifting Lugs Jacking Lugs Earthing Terminal (two numbers on opposite side) Oil Level Indicator Oil Temperature Indicator Thermometer Pocket Winding Temperature Indicator Drain Valve Filter Valve Pressure/Vacuum Bleeding Device Pressure/Vacuum Relief Device Pressure/Vacuum Gauge
Sec 4 - 8
2.15 Terminal Marking and Rating Plates

The terminal marking plate shall show a plan view of the terminals with the characters of terminal markings as per Appendix D of BS 171 or IEC 76 engraved thereon. It shall also show the tappings in a tabulated form. The rating plate shall indicate the following:
Manufacturer's name and address Transformer Specification Reference Manufacturer's Serial Number Year Of Manufacture Rating in kVA Volts at no-load on normal tapping :High Voltage Low Voltage Current at rated load on normal tapping :High Voltage Low Voltage Number of phases Frequency Vector Group Symbol % Impedance Voltage at Normal Tapping at 75 degrees Celsius
The terminal marking and rating plates shall be of a durable and corrosion resisting material and the markings thereon shall be permanently legible. The two plates may be combined into a single plate.
2.16 Oil
Transformers shall be supplied filled with oil and hermetically sealed. The oil shall meet the requirements of BS 148 and shall be completely free from PCB.
2.17 Earthing
The neutral point of the low voltage system of the transformer shall be solidly earned to achieve an earth resistance not exceeding one ohm. The frameworks and all non-current carrying metal parts of the transformer shall be earthed similarly to achieve an earth resistance not exceeding one ohm. An earth bar of flat hard drawn copper with dimension not less than 25 mm x 6 mm shall be installed around the four walls of the transformer room at a height of 300 mm from the finished floor level. The earth bar shall be bolted to the frame earth of the transformer. All joints of the earth bar shall be tinned and bolted. The earth bars shall be painted with approved green enamel. Unless otherwise specified, the neutral earth and the frame earth of the transformer shall be separately connected to its own group of earth electrodes. The neutral earth and the frame earth shall be connected to its electrodes by means of two numbers green PVC insulated copper cable of cross sectional area not less than 70 sq.mm.
Sec 4 - 9
The two groups of earth electrodes after having been hang verifies by the IWK/JPP. Each of earth resistance not exceeding one ohm, shall be linked together by means of PVC cables as mentioned above unless otherwise specified. At least two points of the frame earth system of the transformer shall be connected to the earth electrodes. Earth electrodes shall be of copper jacketed steel core rods with 16 mm diameter and supplied in 2.4 m length and shall have provision for screw coupling with another standard length. The copper jacket shall be of minimum thickness 0.25 mm and shall bi-metallically bonded to the steel core to ensure that the copper jacket and steel core are not separable. Where the desired earth resistance value cannot be driven, sufficient number of sets of earth electrodes shall be installed outside the resistance area and linked together by PVC copper cables as mentioned above until the required value is reached. Each set of earth electrode shall be provided with brass connecting clamp and approved type of precast heavy duty concrete inspection chamber with removable cover. The earthing points shall be identified by permanent label legibly marked with the words `Transformer Frame Earth' or `Transformer Neutral Earth' permanently fixed at the point of connection of every earthing conductor to an earth electrode.
2.18 Transformer Room

Approved type of rubber mat shall be provided around the transformers. The rubber mat shall extend to the full length and width of the transformer and shall be of thickness not less than 12 mm and width 1,000 mm. `BAHAYA' sign, `DILARANG MASUK' sign, sign indicating `Substation No:' and shock treatment chart shall be installed to the requirement of the Suruhanjaya Tenaga. ` DILARANG MEROKOK ' sign shall also be installed. All trenches in the transformer rooms shall be filled up with clean sand to a level above cable ducts. As fitted layout plans, schematic wiring diagrams, and plans showing cable routes and positions of earthing point with reference to easily recognizable buildings and structures shall be suitably framed up in the transformer room. These plans and diagrams shall be in addition to the four sets of prints required to be submitted to the IWK/JPP. All main High voltage switch room, Transformer room shall be fitted with automatic triggered release CO2 system, controlled by heat and smoke sensor. .
Sec 4 - 10
3.0 Cast Resin Transformer

3.1 Scope
Three-phase transformers of cast resin type, Class F insulation system with natural (AN) cooling for indoor installation, destined for use in three-phase HV/LV distribution systems. If required forced cooling (AF) to increase the rated power up to 40%.
3.2
Standards
These transformers will be in compliance with the following standards: IEC 60076-1 to 60076-5: power transformers IEC 60076-11 : Dry type transformers CENELEC Harmonisation Documents HD 464 S1 : 1988 + / A2 : 1991 + / A3 : 1992 for dry-type power transformers HD 538-1 S1 : 1992 for three-phase dry-type distribution transformers 50 Hz, from 100 To 2500 kVA with highest voltage for equipment not exceeding 24 kV. IEC 905: 1987 - Load guide for dry-type power transformers.
These transformers will be manufactured in accordance with: A quality system in conformity with ISO 9001 An environmental management system in conformity with ISO 14001, both certified by an official independent organisation.
3.3
Description
3.3.1 Magnetic Core

This will be made from laminations of grain oriented silicon steel, insulated with mineral oxide and will be protected against corrosion with a coat of varnish. In order to reduce the power consumption due to transformer no-load losses, the magnetic core is stacked using overlapping-interlocking technology, with at least 6 overlaps. In order to reduce the noise produced by the magnetic core, it is equipped with noise-damping devices.
Sec 4 - 11
3.3.2 LV Windings
The LV winding is produced using aluminium or copper foils (according to the manufacturers preference) in order to cancel out axial stress during short circuit ; this foil will be insulated between each layer using a heat-reactivated Class F pre-impregnated epoxy resin film The ends of the winding are protected and insulated using a Class F insulating material, covered with heat reactivated epoxy resin The whole winding assembly will be polymerised throughout by being autoclaved for 2 hours at 130C, which will ensure: High level of resistance to industrial environments Excellent dielectric withstand Very good resistance to radial stress in the instance of a bolted short circuit.
3.3.3 HV Windings
They will be separated from the LV windings to give an air gap between the MV and LV circuits in order to avoid depositing of dust on the spacers placed in the radical electrical field and to make maintenance easier. These will be independent of the LV windings and will be made of aluminium or copper wire or foil (according to the manufacturer's preference) with Class F insulation. The HV windings will be vacuum cast in a Class F fireproof epoxy resin casting system composed of: An epoxy resin An anhydride hardener with a flexibilising additive A flame-retardant filler.
The flame-retardant filler will be thoroughly mixed with the resin and hardener. It will be composed of trihydrated alumina powder (or aluminium hydroxide) or other flame-retardant products to be specified, either mixed with silica or not. The casting system will be of Class F. The interior and exterior of the windings will be reinforced with a combination of glass fibre to provide thermal shock withstand
3.3.4 MV Winding Support Spacers

These will provide sufficient support in transport, operation and during bolted short circuit conditions as well as in the case of an earthquake. These spacers will be circular in shape for easy cleaning. They will give an extended tracking line to give better dielectric withstand under humid or high dust conditions.
Sec 4 - 12
These spacers will include an elastomer cushion that will allow it to absorb expansion according to load conditions. This elastomer cushion will be incorporated in the spacer to prevent it being deteriorated by air or UV.
3.3.5 HV Connections
The HV connections will be made from above on the top of the connection bars. Each bar will be drilled with a 13 mm hole ready for connection of cable lugs on terminal plates. The HV connection bars will be in rigid copper bars protected by heat shrinkable tubing. HV connections in cables are not allowed, in order to avoid all risk of contact, due to cables flapping. The HV connections will be in copper.
3.3.6 LV Connections
The LV connections will be made from above onto bars located at the top of the coils on the opposite side to the HV connections. Connection of the LV neutral will be directly made to the LV terminals between the LV phase bars. The LV connection bars will be in copper or in tinned aluminium (according to preference of the manufacturer). The output from each LV winding will comprise a tin-plated aluminium or copper connection terminal, enabling all connections to be made without using a contact interface (grease, by-metallic strip). These will be assembled according to current practices, notably using spring washers under the fixings and nuts. Devices in the 630 to 2,500 kVA range will be easy to connect using factory-built electrical ducting through an optional interface. Stress withstand in the instance of a bolted short circuit on the connector will be guaranteed by the manufacturer.
3.3.7 HV Tapping
The tapping which act on the highest voltage adapting the transformer to the real supply voltage value, will be off-circuit bolted links. Tapping with connection cables are not allowed. These bolted links will be attached to the HV coils.
Sec 4 - 13
3.4
Accessories and Standard Equipment
These transformers will be equipped with: 4 flat bi-directional rollers lifting lugs haulage holes on the underbase 2 earthling terminals 1 rating plate 1 "Danger Electricity" warning label (T 10 warning) 1 routine tests certificate 1 instruction manual for installation, commissioning and maintenance in English.
3.5
Thermal Protection
These transformers will be equipped with a thermal protection device which will comprise: 2 sets of 3 PTC sensors, one sensor for "Alarm 1", one for "Alarm 2" per phase, installed in the coils of the transformer. They will be placed in a tube to enable them to be replaced if ever necessary. An electronic converter with two independent monitoring circuits equipped with a changeover switch, one for "Alarm 1" the other for "Alarm 2". The position of the relays will be indicated by different coloured indicator lights. A third indicator light will indicate the presence of voltage. These three indicator lights will be on the front of the converter. The electronic converter will be installed away from the transformer. A plug-in terminal block for connection of the PTC sensors to the electronic converter. The PTC sensors will be supplied assembled and wired to the terminal block fixed on the upper part of the transformer. The converter will be supplied loose with the transformer, packaged complete with its wiring diagram.
3.6
Metal Enclosure
On request, these transformers will be equipped with a metal enclosure for indoor installation comprising an integral IP31 (except the base which may be IP21) metal enclosure, that can be dismantle on request, with: an anti-corrosion protection in the manufacturer's standard colour lifting lugs enabling the transformer and enclosure assembly to be handled a bolted access panel on the enclosure front to allow access to the HV connections and to the tapping. This will be fitted with handles, it will have one "Danger Electricity" warning label (T 10 warning), a rating plate and a visible braid for earthling blanked off holes for fitting Ronis ELP 1 or alternatively Proflux P1 type key locks on the bolted access panel to enable it to be locked
Sec 4 - 14
2 undrilled gland plates on the roof: one on the HV side, one on the LV side (drilling and cable gland not supplied) 1 plate at the right HV side on the bottom of the enclosure for the HV cables for connections from the bottom as an option, a HV cables clamping system shall be provided when the cables are coming from the bottom
3.7
Electrical Protection
3.7.1 Protection relay

The installation must have a protection relay to protect the transformer from: overload, short circuits (internal or external), earth faults, overflow.
3.7.2 MV surge arresters

It is advisable to check that the installation will not be subjected to over voltage of any kind (atmospheric or switching over voltage). If there is a risk, the transformer should be protected by phase-earth surge arresters installed directly on the MV connection terminals (top or bottom). Phase-earth surge arresters are absolutely essential in the following cases: If the lightning impact level Nk is greater than 25. The risk of direct or induced atmospheric over voltage is directly proportional to Nk. During the occasional switching (less than 10 operations a year) of a transformer with a weak load, or during a magnetisation period.
They are highly recommended in the following case: If the substation is supplied by a network including overhead parts, then a cable which is longer than 20 m (for example, an overhead-underground network).
3.7.3 RC filters (repetitive switching operations)

If the installation is likely to be subjected to repetitive switching operations (e.g. connected with a process), it should be protected from the resulting surges, which are particularly harmful to the transformer. The ideal solution for protecting the installation completely from these surges (with high frequency oscillations), consists in fitting an RC damping filter between the phases and the earth.
Sec 4 - 15
This RC filter should be placed as close as possible to the transformers primary terminals. This gets rid of the high frequency phenomenon, and limits voltages at the transformer terminals. The filter should consist of 3 units, 50 Ohm resistors (of the RWST type), and 3 units, 0.25 F capacitors, insulation level 24 kV. It may be placed either in a separate metal enclosure or, preferably, inside the metal enclosure of the transformer.
3.8
Climatic and Environmental Classifications
These transformers will be of climatic Class C2 and of environmental Class E2 as defined in Appendix B of HD 464 S1: 1988 / A2 : 1991. C2 and E2 Classes will be indicated on the rating plate. The manufacturer must produce a test report from an official laboratory for a transformer of the same design as those produced. The tests must have been performed in accordance with Appendix ZA and ZB of CENELEC HD 464 S1: 1988 / A3: 1992.
3.9
Fire Behaviour Classification
These transformers will be of Class F1 as defined in article B3 of CENELEC HD 464 S1: 1988 / A2: 1991. F1 Class will be indicated on the rating plate. The manufacturer must produce a test report from an official laboratory on a transformer of the same design as those produced and on the same transformer which have initially passed the here above Climatic and Environmental tests. This test must have been performed in accordance with Appendix ZC of CENELEC HD 464 S1: 1988 / A3: 1992.
Sec 4 - 16
4.0 11 kV CABLE SPECIFICATION

4.1 Types of Cables
The cable to be supplied under this specification shall be manufactured and tested in accordance with BS 6480: Part 1: 1969 and shall be of XLPE type to a voltage rating suitable for continuous operation on a 11 kV, 3-phase, 50 Hz distribution system.
4.2
Cable Trench
Cable trenches shall be 750 mm deep. The trenches shall be of sufficient width to enable provision of adequate spacing between cables but in any case shall not be less than 450 mm wide. Trenches shall be kept as straight as possible and shall have vertical sides which shall be timbered where necessary so as to avoid subsidence and damage. The bottom of the trenches shall be firm and of smooth contour and any other objects likely to damage the cable sheathing shall be removed. The material excavated from the trenches shall be placed or removed so as to prevent nuisance or damage to adjacent areas or buildings. The trench excavation and filling in shall be so executed that all roads, walls, sewers, drains, pipes, cables, structures etc. shall be reasonably secured against risk of subsidence damage. Provision shall be made, during excavation and until interim restoration has been completed, for reasonable access of persons and vehicles to the areas of buildings adjacent to the trenches. The Electrical Contractor shall provide pumps and other appliances for the necessary pumping required for the disposal of water so as to prevent any risk of the cables and other materials to be laid in the trenches being detrimentally affected. Where necessary, bailing shall be provided. Where trenches pass from a footway to a roadway or at other position where a change of level is necessary, the bottom of the trench shall rise or fall gradually.
4.3
Cable Ducts
At road crossings, sewerage pipe crossing, water pipe crossings, paved areas, concrete areas and where specified cables shall be protected by galvanized steel pipes buried to a depth of 900 mm below finished ground level. The pipes shall be of heavy duty type, complying with BS 1387 and complete with screwed and socket joints. Unless otherwise specified the pipes shall be 150 mm in diameter. Where it is necessary to cross drains, culverts or similar obstruction which is too deep for the cables to be buried below, galvanized steel pipes as specified above shall be provided. The pipes shall be supported at each end in a concrete block and shall project through the blocks into the ground at a depth of at least 750 mm. All ducts shall be extended at least 600 mm beyond paved areas, concrete areas, drains, road crossing, pipe crossings etc. Cable entering a building shall be protected by pitch fiber ducts of 150 mm diameter, complying with BS 4108, completed with bend pieces, buried to a depth of 900 mm and encased with 75 mm of concrete all round. The ducts shall be installed with a gradient so as to drain away any water in the ducts. All ducts passing through walls shall be effectively sealed and made water-tight. The number of cables installed in each duct shall be such that the space factor shall not be less than 60%. A draw wire shall be provided for each duct. Unless specified to be provided by others, the above galvanized steel pipes and/or pitch fiber ducts shall be provided.
Sec 4 - 17
4.4
Cable Marker
Cable markers shall be of heavy duty reinforced concrete construction. The cable marker shall be of trapezoidal block with 100 mm square top face, 150 mm square bottom face and 400 mm in height. The top face shall be indented with bold lettering `H.V.' and directional sign indicating the direction/directions of the cable route.
Sec 4 - 18
Section 5 - Motor Specification
Section 5
Motor Specification
Section 5 Motor Specification
Page Section 5 Motor Specification 1.0 2.0 Submersible Motor Surface Mounted Motors 2.1 2.2 2.3 General Indoor Type Motor Outdoor Type Motor 5-1 5-2 5-2 5-3 5-3
SECTION 5 MOTOR SPECIFICATION 1.0 SUBMERSIBLE MOTOR

The electric motor shall be a 3 phase, squirrel-cage induction type running at not more than 1,500 rpm suitable for 50 cycles, 415 V and complying with BS 5000 or BS 4999. The motor shall be built for submersible operation, Class IP68 according to IEC. The motor shall be able to withstand a minimum depth of 20 m submergence. The motor stator shall be shrunk fit into an air-filled watertight stator casing. Externally mounted screws that may cause leakage into the motor shall not be used. The motor casing and sealing arrangements shall be designed waterproof to Class IP68. Motor bearing and shaft shall all the loads induced by the short-coupled i.e. pump impeller and mixer propeller. The motor shall be capable of operating continuously with full load without overloading throughout the operation. It shall be able to tolerate voltage variations of up to 10% of the rated voltage of 415 V without overheating. The motor shall operate at voltage imbalance of up to 2% between phases and current imbalance of up to 4% between phases. The motor shall start by direct on-line, star-delta, auto transformer, soft starter and variable speed drive in accordance with the size of the motors. The motor shall run continuously or intermittently with a maximum of 15 evenly spaced starts per hour. The motor shall be tested in accordance to IEC 34-1. The stator shall be moisture-resistant and triple-varnished and shall be insulated to Class F (IEC publication) capable of withstanding temperatures up to 155oC (to confirm the spec.), however the maximum temperature rise shall not exceed 80oC. The motor shall have a terminal box capable of sealing off the junction box completely from the stator casing to prevent leakage through the junction box into the stator housing. The cable entry water-seal design shall be such that the cables are sealed off by a compressible rubber bush and fitted with cable strain relief clamps. The design shall preclude specific torque requirements to ensure a water tight and submersible seal. Epoxies, silicon resin or other secondary sealing systems shall be used. The stator shall incorporate three thermal switches connected in series for monitoring purposes. Thermal sensors shall protect the stator from overheating in the case of asymmetric phase loading or voltage, continuous dry run or excessive temperatures in the medium itself. For motor rating of 37 kW and below, a minimum motor protection shall incorporate a leakage sensor at the seal chamber and a PT 100 or better in the stator winding. For motor rating of 37 kW and above, a full monitor motor protection shall be incorporated. The leakage sensor shall be located at the upper terminal area, lower motor area and seal chamber. The thermal sensor shall be located at the upper and lower bearing housing and stator winding. Power to the motor is supplied by one or several flexible cable(s) that connect to the motor through a sealed inlet to a connection box. The cable is supplied to specified length by the manufacturer.
Sec 5 - 1
The cables contain a sufficient number of leads for motor start and operation as well as for control impulse transmission. The motor is dimensioned for cooling submergence in the pumped liquid. For dry installation, cooling is provided by liquid circulating in a cooling jacket or by other means of heat transfer into the pumped liquid.
2.0 SURFACE MOUNTED MOTORS

2.1 General
Electric motors shall be manufactured and shop tested to BS 4999 and BS 5000. Motors shall be tropicalised 3 phase squirrel cage induction type. Both indoor and outdoor surface mounted motors shall comply with IEC 34-1 Electrical and IEC 72-1 Mechanical Specification. The motor shall be tested in accordance to IEC 34-1. 3-phase cage rotors shall be robust in design and construction and capable of running continuously for prolonged periods with minimum attention. Motor bearing and shaft shall carry all the loads induced by the short-coupled i.e. pump impeller and mixer propeller. The motor shall be manufactured in a one-piece stator frame casing. The feet shall be integrally cast into the stator frame. For most frames the terminal box shall be mounted on the top as standard. The terminal box can be rotated so that cables can be connected from the right and left. All shaft diameters shall be machined to IEC 60072 for ease of fitting, removing or securing fitments, a tapped hole in the drive end shaft. Tolerances on main performances parameter shall comply with IEC 60034-1 specifies allowable tolerances for efficiency, power factor, speed, locked rotor torque, pullout torque, starting current and moment of inertia. Ball bearings shall be used for motors having aluminium frames. Motors with cast iron or fabricated steel frames shall have ball or roller bearings. Ball bearings shall be grease lubricated. Working thrust loads shall not be placed on the motor bearing. The motor fan shall be made of light aluminum alloy. The motor shall start by direct on-line, star-delta, auto transformer, soft starter and variable speed drive in accordance with the size of the motors. Motors shall be equipped with their own starters and shall run at not more than 1,500 rpm, unless specified otherwise. Motor starters shall be fitted with a no-volt release and thermal overload in each phase. Motors and their associated starters shall be suitable for operation on a 415 V, 3-phase and 50 Hz supply. Motors shall be capable of continuously running and shall be able to tolerate voltage variations of up to 10% without overheating in accordance with BS 5000 S1 designation. The motor shall operate at voltage imbalance of up to 2% between phases and current imbalance of up to 4% between phases.
Sec 5 - 2
PT 100 or better shall be built into the motor windings for motors above 3.75 kW. It shall act either to give an alarm or to stop the motor. The stator shall be moisture-resistant and triple-varnished and shall be insulated to Class F (IEC publication) capable of withstanding temperatures up to 155oC, however the maximum temperature rise shall not exceed 80oC, Class B.
2.2
Indoor Type Motor
The types of motor enclosures and degree of protection for electric motors to be used in different areas shall be as follows: Totally Enclosed Fan Cooled Type (TEFC) to be used in damp and dusty indoor areas and shall have a service factor of not less than 1.15 or greater.
2.3
Outdoor Type Motor
The types of motor enclosures and degree of protection for electric motors to be used in different areas shall be as follows: Motors shall be with Class F insulation and IP55 enclosure. Motors shall be single speed Totally Enclosed Fan Cooled (TEFC) and rated for continuous use. It shall have a service factor of not less than 1.15 or greater.
Sec 5 - 3
Section 6 - Low Voltage Cable Specification & Installation
Section 6
Low Voltage Cable Specification & Installation
Page Section 6 Low Voltage Cable Specification & Installation 1.0 Type of Cable and Application 1.1 1.2 2.0 2.1 2.2 3.0 3.1 3.2 4.0 4.1 4.2 4.3 5.0 6.0 7.0 Type of Cables Application of Cables Cable Laid Direct In Ground Submerged Cable Colours Conductors Cables in Pre-Cast Concrete Trenches Cables on Walls and Under Floor Slabs Surface Cabling 6-1 6-2 6-2 6-2 6-2 6-3 6-4 6-4 6-4 6-4 6-5 6-5 6-5 6-6 6-6 6-6 6-7 6-7 6-7 6-8 6-8 6-8
Cable Installation
Requirements
Cable Trench
Cable Ducts Cable Termination and Jointing Cable Accessories 7.1 7.2 7.3 7.4 7.5 7.6 Metallic And Non-Metallic Conduits Cable Trays Clipped Direct Cable Fixings Cable Glands Cable Marker
SECTION 6 LOW VOLTAGE CABLE SPECIFICATION & INSTALLATION 1.0 TYPES OF CABLE AND APPLICATION
1.1
(i)
Type of Cables
PVC/SWA/PVC CABLE
Cable shall be manufactured and tested in accordance with MS 274 or BS 6346 and shall have high conductivity plain copper stranded conductors insulated with PVC suitable for a voltage of 600/1000 V laid together and bedded with PVC, armoured with galvanised steel wires and sheathed with PVC.
(ii) XLPE/SWA/PVC CABLE
Cable shall be manufactured and tested in accordance to BS 5467 or IEC 60502 and shall have high conductivity plain copper stranded conductors, insulated with cross-linked polyethylene (XLPE), suitable for a voltage of 600/1000 V laid together and bedded with extruded PVC, armoured with galvanised steel wires and sheathed with PVC.
(iii) XLPE/AWA/PVC CABLE
Cable shall be manufactured and tested in accordance to BS 5467 or IEC 60502 and shall have high conductivity plain copper stranded conductors, insulated with cross-linked polyethylene (XLPE), suitable for a voltage of 600/1000 V laid together and bedded with extruded PVC, armoured with aluminium wires and sheathed with PVC.
(iv) XLPE/PVC CABLE
Cable shall be manufactured and tested in accordance to BS 5467 or IEC 60502 and shall have high conductivity plain copper stranded conductors, insulated with cross-linked polyethylene (XLPE), suitable for a voltage of 600/1000 V laid together and bedded with extruded PVC and sheathed with PVC.
(v) PILCDSTAS CABLE
Cable shall be manufactured and tested in accordance with BS 6480 Part 1 and shall have high conductivity plain copper stranded conductors, insulated with strong long fibre paper, uniform in texture, free from metallic particles, mass impregnated with non-draining insulating oil compound suitable for a voltage of 600/1000 V, lead alloy sheathed, double steel type armoured and served. Refer to Appendix 01 Abbreviation.
Sec 6 - 1
1.2
Application of Cables
Cables shall be segregated into the following categories: (i)

Power (less than 1,000 V phase to phase)
PVC/PVC multicore cable to BS 6346 installed in floor ducts or conduits. PVC single core non-sheathed (600/1 000 V) to BS 6231 installed as internal wiring within switchgear and control assemblies. PILCDSTAS Cable shall be manufactured and tested in accordance with BS 6480 Part 1 and shall have high conductivity plain copper stranded conductors, insulated with strong long fibre paper, uniform in texture, free from metallic particles, mass impregnated with nondraining insulating oil compound suitable for a voltage of 600/1000 V, lead alloy sheathed, double steel type armoured and served.
Instrumentation/telemetry
(ii)
PE/PSCR/OSCR/PE/SWA/PVC. Plain annealed multistranded copper conductors, solid polyethylene insulation with aluminium-mylar pair screening including drain wire, with collective aluminium mylar screen including drain wire, solid polyethylene bedded steel wire armour with an outer sheath of flame retardant PVC. PVC sheath to be blue colour for intrinsically safe circuits, black for AC and DC non-intrinsically safe circuits, 300/500 V grade to BS 5308: Part 1, Type 2.
(iii)
Control Digital
PE/OSCR/PE/SWA/PVC. Plain annealed multi stranded copper conductors, solid polyethylene insulation collective aluminium mylar screen including drain wire, solid polyethylene bedded steel wire armour with an outer sheath of flame retardant PVC. PVC sheath to be blue colour for intrinsically safe circuits, black for AC and DC non-intrinsically safe circuits, 300/500 V grade to BS 5308: Part 1, Type 2.
2.0 CABLE INSTALLATION

All cables shall be handled, laid and installed according to BS 7671, cable manufacturer's recommendations and ERA Reports by using proper installation equipment and tools. Cables shall be laid in a manner such that any electrical interference between cables shall not have a detrimental effect on the life and operation of equipment installed within the installation. As a general rule the following minimum clearances shall be adhered to wherever practical. There shall be a minimum separation of 300 mm between all cables. Unless otherwise permitted by the JPP/IWK Representative no cable shall be laid and covered up in the absence of the JPP/IWK Representative. Cables shall be installed in such a way that the minimum bending radius is not reduced when installed or during installation. Cables shall not be installed in ambient temperatures below that recommended by the cable manufacturer.
The minimum internal bending radius of the cable shall not be less than 12 times the overall diameter of the cable. Wherever cables are cut, the ends shall be immediately sealed in an approved manner unless; it is intended to proceed with cable jointing for termination straight away. For groups of more than one cables laid in the same trench, they shall be spaced by the horizontal clearance between adjacent cables of at least twice the overall diameter of the adjacent largest size cables. Cables grouped together shall have insulation capable of withstanding the highest voltage present in the group. Where practical a separate cable support system shall be provided for power and non-power cables. Where this is not practical a separation of 150 mm shall be maintained between power and non-power cables when run on the same support system. In order to make economic use of the cable support system, cables shall be arranged in groups of 50 mm maximum overall diameter. These groups shall be securely tied to the cable support system at intervals not exceeding 900 mm for horizontal runs and 300 mm intervals on vertical runs. Refer to Appendix 01 Abbreviation.
2.2 Submerged Cable

Cable shall be manufactured and tested in accordance with DIN VDE 0282-4. They fulfill the requirements specified for cables used in contaminated water. The cables shall have a high conductivity copper finely stranded, Class 5 to DIN VDE 0295 and IEC 60228 insulated with special rubber compound, EPR (Ethylene Propylene Rubber) base suitable for a voltage of 450/750 V sheathed with: (i) Single-sheath This is provided with all single-core cables and for all multicore cables with conductor crosssections up to and including 10 mm2. Special synthetic rubber compound, minimum specifications as for compound types EM2 and 5GM3 to DIN VDE 0207-21. Thickness to DIN VDE 0282-4. (ii) Two-sheath This is to provide for multicore cables with conductor cross-sections of 16 mm2 and more. Inner sheath shall be of a special rubber compound, EPR base, and minimum specifications as for EM1 and GM1b to DIN VDE 0207-21. Sheath thickness to DIN VDE 0282-4. Outer sheath shall be of a special sythentic rubber compound, minimum specifications as for compound types EM2 and 5GM3 to DIN VDE 0207-21. Sheath thickness to DIN VDE 02824.
Sec 6 - 3
3.0 REQUIREMENTS
3.1 Colours
The colour coding shall be in accordance to IEEE latest edition. The following shall serve as a guide: i. ii. iii. iv. 3-phase Single phase or DC Earth Control Red, Yellow and Blue Red and Black Green/Yellow Blue (DC), Red (AC)
3.2
Conductors
Copper conductors shall comply with BS EN 60228. The size of conductors shall be made reference to Section 1 Low Voltage Switchboard and Components Specification and Section 3 Small Power and Lighting.
4.0 CABLE TRENCH

Unless otherwise specified, cable trenches shall be 750 mm deep. The trenches shall be of sufficient width to enable provision of adequate spacing between cables but in any case shall not be less than 450 mm wide. Trenches shall be kept as straight as possible and shall have vertical sides which shall be protected where necessary so as to avoid subsidence and damage. The bottom of the trenches shall be firm and of smooth contour and any other objects likely to damage the cable sheathing shall be removed. The material excavated from the trenches shall be placed or removed so as to prevent nuisance or damage to adjacent areas or buildings. The trench excavation and filling in shall be so executed that all roads, walls, sewers, drains, pipes, cables, structures etc. shall be reasonably secured against risk of subsidence damage. Provision shall be made, during excavation and until interim restoration has been completed, for reasonable access of persons and vehicles to the areas of buildings adjacent to the trenches. The trench excavation shall provide pumps and other appliances for the necessary pumping required for the disposal of water so as to prevent any risk of the cables and other materials to be laid in the trenches being detrimentally affected. Where necessary, bailing shall be provided. Where trenches pass from a footway to a roadway or at other position where a change of level is necessary, the bottom of the trench shall rise or fall gradually. Refer to Appendix B Laying of Underground Cable Drawing
Sec 6 - 4
uPVC cable protective covers shall be of polyvinylchloride without plasticiser type with specific density between 1.37 g/cm3 to 1.42 g/cm3. The uPVC cover shall be resistant to aggressive soils and of dimension 150 mm wide and 1,000 mm long. The covers shall be single coloured orange and top side shall be embossed with standard danger sign and bold letters BAHAYA! KABEL ELEKTRIK DI BAWAH. The covers shall be provided with male and female interlocking device. An orange coloured, multistrand nylon rope of minimum 6 mm diameter shall be laid at along the trench to identify the cable route. Refer to Appendix B Laying of Underground Cable Drawing
4.1
Cables in Pre-Cast Concrete Trenches
Cable tray specification shall be made reference to 7.2 Cable Trays. In the case of single core cable, non-ferrous saddle shall be used. The cable tray shall be supported by mild steel brackets. The bracket shall be hot dipped galvanised. All brackets shall be securely fastened with steel raw bolts and nuts. All cable tray joints shall be bridged by means of tinned copper tape of dimension not less than 25 mm x 3 mm. All saddles for cables on cable trays shall be installed by bolts, washers and nuts. All cable tray tees, intersection units, adaptor units etc. shall be factory manufactured.
4.2
Cables on Walls and Under Floor Slabs
Cable tray specification shall be made reference to 7.2 Cable Trays. Cable run on walls and under floor slabs shall be mounted on cable trays. Method of installation of the cables shall be in accordance with Method 11 and 12 of BS 7671 Table 4A. The construction and finished of the cable trays and the way of installation of the cables on the cable trays shall be made reference to 4.1 Cable in Pre-Cast Concrete Trenches. The cable trays shall be suspended from floor slabs by hangers or mounted on wall by brackets at 600 mm interval. The material and finishes of the hangers, brackets and other suspending and supporting structures shall be made reference to 4.1 - Cable in Pre-Cast Concrete Trenches. Where cable trays pass through floors or fire resistant walls, the surrounding hole shall be sealed to full thickness of the floor or wall with non-hygroscopic fire-resisting material of minimum 2 hour fire rating approved by Jabatan Bomba Dan Penyelamat Malaysia.
4.3
Surface Cabling
Surface cabling shall be carried out with PVC insulated PVC sheathed cables of 300/500 V grade to MS 136 and 600/1000 V grade to MS 274. The conductors shall be of stranded plain annealed copper
Sec 6 - 5
to MS 69 and MS 280. The insulation shall be suitable for continuous operation at a maximum cable temperature of 70 0C and comply with MS 138. The cables shall be run on the surface of the walls, floor slabs and in the ceiling spaces. The cables shall be secured by lead alloy saddles. Cables crossing metal surface shall be enclosed in PVC conduit. Saddles shall be fixed by brass nails and spaced at not more than 150 mm apart.
5.0 CABLE DUCTS

At road crossings, sewerage pipe crossing, water pipe crossings, paved areas, concrete areas, concrete areas and where specified, the cables shall be protected by galvanised steel pipes. The pipes shall be of heavy duty type, complying with BS 1387. Unless otherwise specified the pipes shall be 150 mm in diameter. Spare cable ducts of 150 mm diameter galvanized steel pipes shall be provided at all road crossings. Spare ducts to be provided with draw wires and temporarily sealed to prevent ingress of water. Cable entering a building shall be protected by heavy duty galvanised steel pipes complying with BS 1387 of 150 mm diameter completed with bend pieces.
6.0 CABLE TERMINATION AND JOINTING

Cable termination and jointing is not encouraged, however if required, all such termination and joints shall be provided for installations of more than 1,000 m of cable. All joints and termination shall have prior approval before commencements of works. A plastic laminated plate engraved with details such as size of cable, number of core, date of commissioning, date of jointing, length of cable, distance of cable joint and etc. shall be securely fixed near the termination. The heat shrinkable termination materials used shall be supplied in a complete kit to suit various sizes of cable and to provide stress control, non-tracking and environmentally sealed termination. It shall consist of high permittivity, high resistivity, heat shrinkable, stress control, UV stable, non-tracking polymeric materials and heat activated sealant to prevent ingress of moisture and contamination. The type of cable boxes, compound and jointing materials used shall be factory manufactured. Unless otherwise specified cast iron joint boxes shall be used, and all jointing kits shall be approved by the JPP/IWK Representative before joints being carried out.
Sec 6 - 6
7.0 CABLE ACCESSORIES

7.1 Metallic and Non-Metallic Conduits
Steel conduits shall be of galvanized, heavy gauge, Class B, screwed type complying with MS 275-1, IEC 60614-1, IEC 60614-2-1 and IEC 60423. All steel conduit fittings shall comply with MS 275-2, IEC 61035-1 and IEC 61035-2-1. The steel conduits shall be fitted with brass bushes at the free ends and expansion devices. The ends of each length of steel conduit shall be properly reamed. The termination to the distribution boards, consumer units, switchgears and outlet boxes shall be effected by brass type smooth-bore bushes. For cable size 25 mm and below junction box specification shall be made reference to Section 1 Low Voltage Switchboard and Components Specification. For cable 35 mm and above, junction box shall be 2.3 mm thickness electro-plated mild steel sheet with 90 m paint thickness. It shall be treated to prevent corrosion. The junction box shall be able to accommodate the cable size and the bending radius shall be taken into consideration. For non-metallic conduits and fittings, they shall be of rigid high impact PVC and approved by Jabatan Bomba Dan Penyelamat Malaysia for use in electrical installation. The colour of the conduit for concealed wiring shall be of orange. Unless otherwise for purposes of identification or distinguishing from another services, white coloured conduit shall be used for surface wiring. Rigid high impact PVC conduits shall comply with IEC 60614-1, IEC 60614-2-2 and IEC 60423 and fittings shall comply with MS 67, IEC 61035-1 and IEC 61035-2-2. All fittings for the rigid high impact PVC conduits shall be made and supplied by the same manufacturer for the rigid high impact PVC conduit. The ends of each length of rigid high impact PVC conduit shall be properly reamed. The termination to the distribution boards, consumer units, switchgears and outlet boxes shall be effected by adaptors and lock-rings. Flexible metallic and nonmetallic conduits shall comply with IEC 60614-1 and IEC 60614-2-5 and its fittings complying with IEC 61035-1 and IEC 61035-2-3. Steel saddles shall be used for steel conduits. Unless otherwise specified, steel conduits and steel fittings shall be used.
7.2
Cable Trays
Cable trays shall be fabricated from perforated hot dip galvanised sheet steel complete with all necessary bends, tee pieces, adaptors and other accessories. Minimum thickness for the sheet steel of the perforated hot dipped galvanised cable trays shall be 2.0 mm. All supports, hangers and structures shall be of hot dipped galvanised type, robust in construction and adequately installed to cater for the weights of the cables and trays supported on them so that cable trays and cables will not sag. The cable tray spacing shall be 300 to 600 mm depend on the size and numbers of the cables.
Sec 6 - 7
Fixing clips and cleats for cables on trays shall be installed by means of bolts, washers and nuts. All tees, intersection units, adaptor units etc. shall be the type manufactured by the cable tray manufacturer unless otherwise approved.
7.3
Clipped Direct
All cable hangers, clips, cleats and saddles shall be of an approved type and appropriate to the type and size of cable installed.
7.4
Cable Fixings
Ties and strapping shall be made of hot dip galvanized steel bends installed at intervals of every 600 mm. All bolts and nuts used shall be of hot dip galvanized steel.
7.5
Cable Glands
Glands shall generally be of the mechanical double compression hexagon type. Earth continuity of brass glands shall be assured. This may be achieved by the rigid clamping of the armour within the gland and the intimate contact between the threaded components of the gland and the equipment. Glands for single core cables shall be constructed from non-magnetic materials. Each gland shall be installed complete with a proprietary non-ferrous lock nut to secure the gland body to the equipment where the entry hole is plain, i.e. not tapped.
7.6
Cable Marker
Cable markers shall be of heavy duty reinforced concrete construction. The cable marker shall be of trapezoidal block with 100 mm square top face, 150 mm square bottom face and 400 mm in height. The top face shall be indented with bold lettering `L.V.' and directional sign indicating the direction/directions of the cable route.
Sec 6 - 8
Appendix A Abbreviation
Appendix A
Abbreviation
Section 6: Appendix A Abbreviation
APPENDIX A
ABBREVIATION
PVC SWA XLPE AWA PILCDSTAS OSCR PSCR PE Polyvinyl Chloride Steel Wired Armoured Cross Linked Polyethylene Aluminium Wired Armoured Paper Insulated Lead Covered Double Steel Tape Armoured and Served Overall Screened Pair Screened Polyethylene
App: A - 1
Appendix B Laying of Underground Cable
Appendix B
Laying of Underground Cable
GROUND SURFACE
GROUND SURFACE
EARTH EARTH 750mm 750mm
150mm uPVC CABLE PROTECTIVE COVER SAND CABLE 76mm
150mm
150mm
76mm
SAND
CABLE
450mm/min 450mm/min
a) SINGLE CABLE
b) DUAL CABLE (RUNNING PARALLEL)
Note:
Actual width of cable trench will depend On number of cables laid.
TYPICAL DRAWING FOR LAYING OF UNDERGROUND CABLE DIRECT TO GROUND
76mm
76mm
GROUND SURFACE
EARTH
750mm
150mm
150mm 914mm
CABLE
450mm/min
152mm
152mm GI PIPE
SAND
Note:
Number of GI pipes laid
TYPICAL DRAWING FOR LAYING OF UNDERGROUND CABLE USING G.I PIPE
Section 7
Earthing, Lightning and Surge Protection
Page Section 7 Earthing, Lightning and Surge Protection 1.0 Common Earth Termination Network 1.1 1.2 Requirements Specifications 1.2.1 Copper Tape Conductor 1.2.2 Ground Electrodes 1.2.3 Exothermic Welding 1.2.4 Inspection Chamber 1.2.5 Main Ground Bar 2.0 Surge Protection 2.1 2.2 Requirements Specifications 2.2.1 Surge Protection Device 7-3 7-4 7-4 7-1 7-1 7-2 7-2 7-2 7-2 7-3 7-3
2.2.2 Sub Circuit Circuit Connected To Sensitive Equipment E.G. Compact Plc, Plc. 7-5 3.0 Lightning Protection 3.1 3.2 Requirement Installation 7-5 7-5 7-6
Section 7 - Earthing, Lightning and Surge Protection
SECTION 7 EARTHING, LIGHTNING AND SURGE PROTECTION 1.0 COMMON EARTH TERMINATION NETWORK
1.1 Requirements
The purpose of the Common Earth Termination Network (CETN) is to eliminate potential difference between two or more earthing system within a facility, providing equipotential earthing system for all services, thus providing: Adequate path for earth fault return To ensure personnel safety from electrical shock hazard To prevent hazardous discharge of static electricity and fire risk To provide low impedance and resistance path for high frequency current discharge
It is important for the CETN to able to last for a minimum of 25 years, hence, it is important that all components required/necessary for the completion of CETN be of high quality. All services earth and metallic part of structure must be properly bonded to the CETN. CETN, when completed, shall form the common earth termination network system for: Direct Strike Lightning Protection System (LPS) Electrical Distribution Genset (Frame & Neutral) Supply intake (TNB) Electronics Telecommunications
The interconnection of all ground points shall be by means of flat bare copper tape conductor with dimension of not less than 25 mm (width) 3 mm (thickness). Flat bare copper tape conductor produces much less inductance compared to that of copper stranded cable. The copper tape conductor shall be bonded to ground points by means of Exothermic Welding only. Any other type of mechanical clamps, brazing is not acceptable as these method are subjected to corrosion, loosening, mechanical failure, electrical failure and disconnection. Main ground bars (MGB) shall be provided at suitable locations for termination of all metallic/conductive surface e.g. metallic enclosures, earthing of equipment(s) or surge protectors. MGB shall be wall mounted at a pre-specified height for termination convenience. Good, strong and permanent connections by means of Exothermic Welding must be provided for the electrically continuous connection of MGB and external/underground CETN. Each MGB shall have a minimum of two tinned copper conductor interconnection between MGB and external CETN.
Sec 7 - 1
Dimension & sizes of MGB, conductor shall be as per table below: Prospective earth fault currents (I) for 1s duration 40 kA < I 50 kA Main Ground Bar 50 mm x 6 mm MGB & CETN interconnecting conductor 2 mm x 25 mm x 3 mm
The following standards & regulations shall be adhered to for the works: BS 6651 BS 7430 IEEE Std 81.2 IEEE Std 837 UL/ANSI Lightning & Common earth termination network Earthing Measurement of Resistance/Impedance of Earth System Qualifying Permanent Connection Electrical Safety Standard
The earth resistance for the Common Earth Termination Network (CETN) shall be 1 Ohm () or less.
1.2
Specifications
1.2.1 Copper Tape conductor

Flat bare copper tape conductor shall be in compliance to BS 1432 for soft drawn conductor. Copper tape conductor shall have dimension not less than 25 mm (width) 3 mm (thickness). Copper tape conductor shall be buried at a minimum of 600 mm depth.
1.2.2 Ground Electrodes

Auxiliary ground electrode shall be of the molecularly copper bonded steel ground electrodes. Copper clad and jacketed type earth electrodes are not acceptable. Copper coating thickness on ground electrode shall be minimum 0.254 mm in accordance to UL & ANSI specifications. The ground electrode shall not be less than 14.2 mm (5/8) in diameter and 1,800 mm (6) in length. The ground electrode shall be extended to required electrode length using high strength electrode coupling. The ground electrodes shall have a minimum driven depths of not less than 3,600 mm and equally spaced (using the < 2 L formula as per BS 7430) to maximize each points potential.
1.2.3 Exothermic Welding

Exothermic welding materials shall be in compliance to UL for approvals of grounding and bonding products. Exothermic welding connections must also be tested to guidelines in accordance to IEEE Std. 837.
Sec 7 - 2
1.2.4 Inspection Chamber

Each ground electrodes point shall be provided with a heavy duty type inspection chamber with removable cover. The inspection chamber shall have a minimum dimension of 345 mm (width) 345 mm (length) 210 mm (depth). Lifting hook shall be provided for removable cover.
1.2.5 Main Ground Bar

The Main Ground Bar (MGB) shall be of high conductivity copper bar. MGB shall have a minimum of 6 M8 hole for termination of earth conductors. All termination to MGB shall be using stainless steel bolts & nuts and proper/suitable compression lug. The MGB shall not be less than 450 mm (length) 50 mm (width) 6 mm (thickness). The MGB shall be properly isolated from structure wall using high resistance insulators. A transparent protective cover of sufficient thickness and dimensions with label engraved and marked in red legibly with words Main Earthing Terminals Safety Electrical Connections Do Not Remove shall be installed to cover full length of the MGB. Two earthing conductors of tinned copper tae of dimension as indicated in table above shall be provided to connect the MGB to external CETN. The earthing conductors shall be protected, where necessary, by means of galvanized steel conduit and buried in the ground at a depth of not less than 450 mm below finished ground level. Interconnecting conductors between MSB/SSB and MGB shall be by similar earthing conductors to those between MGB & CETN. These conductors shall be mechanically protected using PVC rectangular channel flushed with the floor slab.
2.0 SURGE PROTECTION

2.1 Requirements
The lightning surge protection devices (SPD) shall be installed at specific locations for specific equipments and panels as per design, drawing and engineers specifications. The SPD shall be installed with care to minimize the amount of let through voltage into equipments. The SPD shall conform to various international standards for its surge handling capability, let-through voltage and short circuit current handling capability. All materials, equipment and components for a safe & durable lightning SPD must be UL certified. Standards & Regulations IEC 62305-4 Protection Against Lightning Part 4 Electrical & Electronic Systems within Structure
Sec 7 - 3
ANSI/IEEE C62.41 High Energy Lightning & Switching Standard IEC 61643 Surge Protection Devices connected to low-voltage distribution systems UL1449 Electrical Safety Standard
2.2
Specifications
2.2.1 Surge Protection Device

The surge protection device (SPD) shall be compatible with the system it is protected and shall provide phase-to-neutral, phase-to-earth and neutral-to-earth protection for either single phase or three phase power supply system. The normal operating voltage of the SPD for phase-to-neutral connection shall be 240 V and the maximum operating voltage is 275 V. SPD for phase-to-earth and neutral-to-earth connections shall be rated at 415 V and the maximum operating voltage of 475 V. The leakage current shall not exceed 3.5 mA. Unless otherwise specified, the type of SPD to be installed with respect to the location of switchboard shall be as in Table 1 below: Switchboard and/or distribution board receiving energy from main switchboard and or Sub switchboard located in the same building B High
Location of switchboard
Main switchboard or Sub switchboard receiving energy from licensee or other building C High
Location Category Exposure Level Peak Discharge Current (8/20 s test waveform) Peak Transient Let Through Voltage for all modes
40 kA 800 V (20 kV, 1.2/50 s and 10 kA, 8/20 s test waveforms)
20 kA 600 V (6 kV, 1.2/50 s and 3 kA, 8/20 s test waveforms)
Table 1 - Types of Surge Protection Device The peak transient let-through voltage or voltage protection level for all modes (phase-to-neutral, phase-to-earth and neutral-to-earth) shall be as in Table 1 above. Unless otherwise specified, the SPD shall be of the type complying with BS 6651 and/or IEC 61024-1 and IEC 61643-1, IEC 61312-1 and IEC 61312-3.
Sec 7 - 4
The surge protection device shall incorporate continuous indication of its protection status, via full protection present, reduced protection - replacement required and no protection - failure of protection. The connecting leads shall be as short as possible and not more than 1,000 mm in length, and shall be tightly bound together over throughout the whole length. Unless otherwise specified, four-pole moulded case circuit breaker or fuses of rating as recommended by the SPD manufacturer shall be provided to enable full isolation of SPD from the system for maintenance.
2.2.2 Sub Circuit circuit connected to sensitive equipment e.g. Compact PLC, PLC.
SPD shall be installed as secondary protection for sensitive electronics equipments to minimize the risk & danger of lightning surge current (let through voltage of MSB SPD). The power SPD shall have a minimum 16 kA 8/20s surge handling capability. The SPD shall be equipped with series LC filter to ensure low let-through voltage of not more than 600 V when tested using 3 kA 8/30s wave shape as per IEC 61643-1 Class II. Status indication of SPD shall be of either mechanical flag or LED. Surge protection shall be provided at the main incoming supply of the panels/switchboards where there is electronic devices are connected or those with incoming breaker ratings of 100 A and above. Protection shall be provided between live and earth as well as neutral and earth. Surge protection units shall be designed for multiple applications (as lightning consists of a number of pulses) and components shall be able to withstand the vibration caused by the pulses. Surge protection devices shall be designed so that alarm outputs can be retrofitted whenever required. The total surge rating in a 8/20 microsecond waveform shall not be less than 100 kA. The let-through voltage shall not exceed 900 V. The surge protection device shall comply with the following standards: IEC - 801 - 5 IEC - C -62.41 - 1991 BS EN 60099-1:1994 IEC 587 Category E IEC 1024 - 1 (Zone O)
3.0 LIGHTNING PROTECTION

3.1 Requirement
The lightning protection system (LPS) network shall comprise of the following (but not limited to): Aluminium air terminal Aluminium tape roof & down conductor Aluminium tape saddle Bi-Metallic connector
Sec 7 - 5
Copper tape down conductor Copper Plate type test clamp Earthing network termination system
The LPS network shall comply with the latest applicable provisions and recommendations of: BS 6651 BS 7430 IEC 62305 Code of practice for Protection of Structures Against Lightning Code of practice for Earthing Code of practice for lightning protection system
3.2
Installation
Air terminations shall be firmly secured by suitable mounting mast, fixing bolts, screws and clamps to establish good electrical continuity from air terminal to downconductor and to ensure they are securely held in position under the influence of mechanical stresses during the passage of lightning currents. All roof air terminations shall be of aluminium type material. The number of downconductor shall be in accordance with BS 6651. Downconductors shall be brought down from roof air termination using the least number of loops as possible. The aluminium downconductor shall be terminated at approximately 1,800 mm from finish floor level as indicated in the design drawing. Thereafter, Bi-Metallic connector shall be used to connect the aluminium downconductor to copper earth termination conductor. The copper earth termination conductor shall be embedded within the wall. The copper earth termination conductor shall be routed directly to ground point and terminated. Termination of the copper earth conductor to ground points (copper ground rods) shall be by means of Exothermic Welding connection for a permanent & long lasting termination as well as to prevent loosening & disconnection. The earth termination network shall consist of copper ground rods conductor with minimum driven depths of not less than 3,600 mm and equally spaced (using the < 2 L formula as per BS 7430) to maximize each points potential. Each ground points (ground rods) shall be interconnected using bare copper tape conductor buried underground with buried depth of not less than 600 mm. A complete lightning protection network shall be provided in accordance with MS 939:1984. All exposed non-conducting metal parts in the plant shall be bonded to earth. The lightning protection system shall comply with BS 6651 and shall take the form of a closed network and down conductors using aluminium strip. Conductors shall be fixed to the roof of any buildings in an approved manner. Waterproof barriers shall not be penetrated. Where fixings are required to pass through waterproof membranes, the approval of the Technical Committee of the Sewerage Services Department shall be obtained prior to the commencement of work.
Sec 7 - 6
Final connection to the earth electrode shall be made using aluminium strip installed in high impact heavy gauge PVC Class D conduit for below ground level installation. Wherever possible natural contact between dissimilar metals shall be avoided. Joints between copper and aluminium conductor shall be made as follows: Contact area of copper shall be tinned Contact area of aluminium shall be cleaned and coated with an oxide resisting paste Make off joint using copper rivets or purpose made clamps Joint to be liberally coated with bitumen paint and totally encased in a heat shrink sleeve
Sec 7 - 7

Electrical Works Specifications

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Electrical Works Specifications

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Electrical Works A Guide to Specifications Sewer Selection and Installation

ISSUE: 01 JANUARY 2007