Client Name: BASF India Limited Project Name: Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9005 Date 23-Apr-12 Page 1 of 13

LOW VOLTAGE MOTOR CONTROL CENTRE

Project Document No: G3IR-1050-65-SP-9005

Unit: Discipline: Document Type:

Infra Electrical Specification

Document Title: SPECIFICATION FOR LV MOTOR CONTROL CENTRE (For Mechanical Packages Only)

DISCLAIMER THIS DOCUMENT DEVELOPED BY FLUOR DANIEL INDIA PRIVATE LIMITED, IS THE PROPERTY OF BASF INDIA LIMITED AND THIS DOCUMENT CANNOT BE REPRODUCED, COPIED, DISTRIBUTED DIRECTLY OR INDIRECTLY OR OTHERWISE USED WITHOUT EXPRESS WRITTEN PERMISSION OF BASF INDIA LIMITED FOR ANY PURPOSE OTHER THAN FOR THE PROJECT FOR WHICH IT IS FURNISHED.

ISSUED FOR DESIGN

06 Aug 2012

1 0 A Revision

30-Jul-12 23-Apr-12 16-Apr-12 Date

Issued for Design Issued for RFQ Issued for Review Purpose

HS HS HS Prepared By

NG NG NG Checked By

VP VP VP Fluor BASF Approved By

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Client Name: BASF India Limited Project Name: Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9005 Date 23-Apr-12 Page 2 of 13

LOW VOLTAGE MOTOR CONTROL CENTRE Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. A Date Description

16-Apr-12

Issued for Review

23-Apr-12

Issued for RFQ

30-Jul-12

Issued for Design

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Client Name: BASF India Limited Project Name: Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9005 Date 23-Apr-12 Page 3 of 13

LOW VOLTAGE MOTOR CONTROL CENTRE TABLE OF CONTENTS 1. GENERAL ...................................................................................................................................................... 4 1.1. SCOPE ......................................................................................................................................................... 4 1.2. SERVICE CONDITION ................................................................................................................................ 4 2. TECHNICAL REQUIREMENTS ..................................................................................................................... 4 2.1. GENERAL.................................................................................................................................................... 4 2.2. BASIC CONSTRUCTION ............................................................................................................................ 4 2.3. BUS BARS................................................................................................................................................... 5 2.4. INCOMER CIRCUIT BREAKERS ............................................................................................................... 6 2.5. MOTOR STARTERS AND CONTACTORS ................................................................................................ 7 2.6. OUTGOING FEEDERS................................................................................................................................ 7 2.7. CONTROL WIRING AND TERMINAL BLOCKS ........................................................................................ 8 2.8. REMOTE OPERATION ............................................................................................................................... 8 2.9. SPACE HEATERS....................................................................................................................................... 8 2.10. AUXILIARY SUPPLY ................................................................................................................................. 8 2.11. EARTH FAULT RELAYS ............................................................................... Error! Bookmark not defined. 2.12. INDICATING LAMPS ................................................................................................................................. 8 2.13. CONTROL AND SELECTOR SWITCHES ................................................................................................ 9 2.14. METERING AND INDICATION .................................................................................................................. 9 2.15. RELAY AND TIMERS ................................................................................................................................ 9 2.16. CURRENT TRANSFORMER ................................................................................................................... 10 2.17. VOLTAGE TRANSFORMER ................................................................................................................... 10 2.18. PADLOCKS AND LOCKING ................................................................................................................... 10 2.19. CABLE TERMINATIONS ......................................................................................................................... 10 2.20. EARTHING ............................................................................................................................................... 11 2.21. PAINITING AND FINISHING.................................................................................................................... 11 2.22. EQUIPMENT IDENTIFICATION............................................................................................................... 11 3. INSPECTION, TESTING AND ACCEPTANCE ........................................................................................... 11 4. DRAWINGS, INFORMATION AND CERTIFICATES .................................................................................. 12 5. ATTACHMENTS........................................................................................................................................... 13

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Client Name: BASF India Limited Project Name: Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9005 Date 23-Apr-12 Page 4 of 13

LOW VOLTAGE MOTOR CONTROL CENTRE 1. GENERAL 1.1. SCOPE 1.1.1. This specification prescribes the minimum technical requirements for motor control centres required for operation on a 3-phase, 4-wire, 50 Hz solidly earthed system. MCC shall be designed for operating voltages not exceeding 1000 Volts. The equipment shall be a complete, manufactured assembly consisting of enclosure, bus bar systems, motor starters, circuit breakers, contactors, and other items to make the installation complete.

1.1.2.

1.2.

SERVICE CONDITION 1.2.1. MCC shall be designed for continuous operation at rated output for the following Voltage and Frequency a) Voltage b) Frequency 415 V 10 %, 3 phase 50Hz 5 %.

1.3.

REFERENCES 1.3.1. The MCC and its associated auxiliary equipment shall conform to the latest editions of following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for Purchase, unless noted otherwise. Refer section Requirements for Technical Design for standard details

2.

TECHNICAL REQUIREMENTS 2.1. GENERAL 2.1.1. The MCC shall have the short-time thermal rating of 36kA for 1 sec and shall be capable of carrying the through fault symmetrical current for the short-time specified and also withstand the dynamic stresses of the peak asymmetrical through fault current without damage or danger.

2.2.

BASIC CONSTRUCTION 2.2.1. 2.2.2. The MCC shall be metal-clad, free standing, floor mounting and arrange to form single structure with a common bus bar assembly. All MCC panels shall be of same height (max 2.3 m). Panels shall be bolted together to form a continuous flush front switchboard suitable for front of board operation. All switches, operating handles, meters shall be installed between 300mm to 1800mm from the bottom of base frame of MCC panel for ease of operation. For equipment heavier (e.g. withdraw able Circuit breakers, drawers) than 25 kg, a lifting device shall be provided. The MCC shall be designed for arc containment, such that a fault within the switchboard will not injure personnel standing in front of the equipment. Each assembly shall be suitable for future extension at each end. Removable endplates shall be provided for access to the horizontal bus bars and wireways.

2.2.3.

2.2.4.

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Client Name: BASF India Limited Project Name: Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9005 Date 23-Apr-12 Page 5 of 13

LOW VOLTAGE MOTOR CONTROL CENTRE Each shipping section shall have facilities for lifting, and base construction for rolling or skidding. 2.2.5. Vertical sections shall have horizontal and vertical wireways, and each vertical wireway shall have its own full-height hinged door or access panel. Doors shall be equipped with gaskets to exclude dust. Holes or slots in wireways, and other metal members for routing of wires, shall be provided with bushings or grommets. Provisions shall be included for supporting the cables from the gland plate to the individual MCC compartments. This may be tray or plastic trunking. Equipment compartments, bus compartments, cable compartments, and wire ways shall be completely isolated from each other by steel barriers or baffles. Safe access to each cable compartment shall be possible with adjacent circuits energised. Each incoming and outgoing switching device shall be housed in an individual compartment with internal separation. The MCC enclosure shall maintain a degree of protection of at least IP4X with cubicle doors closed, and IP20 with doors open and withdrawable units removed. All circuits shall be fully withdrawable. Spare requirement for outgoing feeders: At least one of each type or 20% of total feeders which ever is higher.

2.2.6.

2.2.7.

2.2.8. 2.2.9.

2.2.10. Cubicle doors shall be mechanically interlocked with isolating devices to prevent access to live equipment except for cubicles which do not have exposed live power conductors, where suitable warning labels, indicating that live terminals are present, shall be fitted. 2.2.11. All electrical or control function required for daily operation shall be located on the front of the panel door and operable without opening the doors. 2.2.12. Sheet steel used for fabrication shall be cold rolled, cold annealed. Minimum thickness of various members shall be as follows:Base Frame / Channel /Gland plate : 3 mm Load Bearing Members : 2 mm Internal Partitions : 1.6 mm Construction shall be rigid and robust. All steel work shall be flawless and have a smooth finish. 2.2.13. The equipment shall be designed and manufactured to facilitate inspection, cleaning, repair and maintenance and to ensure absolute safety during operation, inspection and maintenance. 2.2.14. Withdrawable units which are mechanically identical but electrically have a different function or size shall be non-interchangeable, e.g., it shall not be possible to install a motor starter unit into a space for plain feeder unit of the same size. 2.2.15. Electrically identical components shall be mechanically interchangeable. 2.3. BUS BARS 2.3.1. Main horizontal bus bars shall be completely isolated with both front and rear barriers.
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Client Name: BASF India Limited Project Name: Project GIR Project Number: G3IR

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LOW VOLTAGE MOTOR CONTROL CENTRE 2.3.2. The earth bar shall be located at the bottom and the neutral bus bar on top and in all vertical compartments of the assembly and shall be easily accessible. Sufficient connection points with adequate terminating facilities shall be provided for termination of cable earth conductors. Phase designation and rotation shall be R-Y-B. Phase R shall be located at the top and/or right when viewed from rear of equipment. Bus bars shall be fully insulated, hard drawn, Aluminium , and mechanically braced for the asymmetrical short circuit current. Bus bars shall have a continuous current rating for the calculated ampere capacity. Bus bar clearances and creep age distances between phases and phase-to-earth shall be as per standards. The main (phase) bus bars in the bus bar compartment shall be completely covered with insulation made from suitable material with a durability to withstand the mechanical, electrical and thermal stresses to which it may be subjected in service. The insulation shall be color coded for phase designation and shall be so constructed that it can only be removed by destructive measures. The insulation of the bus bar joints and branching points shall be of equal quality to that of the main bus bars and shall be removable for inspection and easily replaceable. The short circuit rating of the vertical bus bars shall be the same as the main bus bars. The neutral bus bar shall be rated to 100 % of the phase bus bar rating.

2.3.3.

2.3.4.

2.3.5.

2.3.6.

2.3.7.

2.3.8. 2.4.

INCOMER CIRCUIT BREAKERS 2.4.1. Incomer circuit breaker shall comply with IS/IEC 60947-2, utilisation category B and suitable for uninterrupted duty. Circuit breaker shall be 4 pole, air break type and of horizontal draw out construction. Automatically operated shutters with padlocking facilities shall be provided to screen bus bars and cable connections when circuit breakers are withdrawn. Circuit breakers shall have facilities for manual closing and tripping with mechanical indication. Operating mechanisms shall be trip free with anti-pumping devices. The closing mechanisms shall be either mechanical, solenoid or stored energy spring type. Springs shall be charged manually, and also by electric motor. The tripping mechanisms shall have a mechanical device and a dc shunt trip fitted with trip circuit supervision. If applicable, provision shall be made for remote closing and tripping of the circuit breakers from PLC. A 'local / remote' selector switch shall also be provided. Refer section 2.8 for details.

2.4.2.

2.4.3.

2.4.4.

2.4.5. 2.4.6.

2.4.7.

2.4.8.

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LOW VOLTAGE MOTOR CONTROL CENTRE 2.4.9. The breakers shall be provided with minimum 6 NO + 6 NC contacts, wired and available for owner use

2.5.

MOTOR STARTERS AND CONTACTORS 2.5.1. Motor starters and protective devices shall have been certified for Type "2" coordination with short circuit device protection as per IS 13947/IEC 60947-4-1. Control voltage shall be derived from "Y" phase and neutral in each starter, and protected by an MCB (or fuse) in phase conductor, and removable link in neutral. Wherever applicable, motor starters shall be equipped with an ammeter connected in the 'centre' (Y) phase. The ammeter shall have a compressed upper scale calibrated up to six times motor full load current. The basic control circuit detailed on the datasheets shall be applied to all starters so that any combination of manual and automatic control can be applied to a motor without affecting the starter control circuit. Contactors used in motor starter circuits shall conform to the requirement of both uninterrupted duty and intermittent duty Class 12 (12 operating cycles per hour at rated operational current) in accordance with IS 13947/IEC 60947-1. They shall have a mechanical durability level of one million no-load operating cycles. The utilization category AC-3 shall be applied for switching on and off squirrel cage motors during running. A utilization category AC-4 shall be applied for motors used for inching or reverse rotation services. Contactors shall be of the holding coil type with an operating voltage derived from Incoming supply through a suitably rated control transformer. Minimum number of contacts required for contactor coil shall be minimum 6 NO + 6 NC Starters shall include the following devices:

2.5.2.

2.5.3.

2.5.4.

2.5.5.

2.5.6.

2.5.7.

2.5.8.

2.5.9.

MCCBs for protections of power circuits. MCBs for control circuits. Thermal overload protection relay and reset. Earth fault protection (above 22 kW motors) Current transformer for remote ammeter wherever applicable. Stay put type mushroom headed start/stop push buttons. Indicating lights for motor running (red), motor stopped (green), and fault trip (amber). Note: Please refer datasheet for details

2.6.

OUTGOING FEEDERS 2.6.1. MCCBs shall comply with IS 13947/IEC 60947, have utilisation category "A", and be suitable for uninterrupted duty. MCCB feeders incorporating contactors and protective devices shall have been certified for Type "2" co-ordination with short circuit device protection as per IS 13947/IEC 60947-4-1.

2.6.2.

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LOW VOLTAGE MOTOR CONTROL CENTRE 2.6.3. MCCB feeders shall be housed in individual compartments, along with the respective starter. MCCBs shall be interlocked with the compartment door and be padlock able in the "off" position.

2.6.4.

2.7.

CONTROL WIRING AND TERMINAL BLOCKS 2.7.1. Internal wiring shall be stranded copper PVC insulated, minimum cross section of 2.5 mm2, except where it is subject to movement, where flexible cable in flexible conduit shall be used. Wires shall have numbered ferrules to match associated terminal numbers and either crimped lugs or connected pressure clamp type terminals. Terminals for different voltages shall be segregated and terminals for service above 50V shall be shrouded. Cable compartments shall be designed to allow safe access to a compartment with all other compartments energised. Where single core cable is terminated, glands plates shall be non magnetic.

2.7.2.

2.7.3.

2.7.4. 2.8.

REMOTE OPERATION 2.8.1. If applicable, the LV MCC shall be provided with one local-remote selector switch for incomer breaker which shall energise auxiliary contactors for local or remote mode. Note: Package vendor shall prepare a scheme/block diagram as to how the MCC shall be integrated with PLC and shall send it to Companys review.

2.9.

SPACE HEATERS 2.9.1. Adequately rated anti-condensation space heaters shall be provided in each breaker panel and in cable alleys of the MCC to maintain MCC inside temperature. Each heater shall be complete with a rotary type ON/OFF switch.

2.9.2. 2.10.

AUXILIARY SUPPLY Auxiliary supply for control, indication etc. shall be 240V AC and shall be obtained using control transformer and it shall be sized for the entire board. Supplier shall provide adequate rated switch / MCB to receive these supplies. And suitable switch and MCB in each subcircuit as per requirement. The space heater supply shall be derived by the manufacturer and distributed throughout the switchboard in the similar manner.

2.11.

INDICATING LAMPS Lamps shall be LED type. Lamp covers shall be provided with interchangeable coloured lenses of perspex or equivalent unbreakable material. It should be noted that lenses should not get discoloured in course of time, due to the heat generated by the lamps. The colour of indicating lamp shall normally be the following unless otherwise specified :Red Green C.B. 'ON' C.B. 'OFF'
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Client Name: BASF India Limited Project Name: Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9005 Date 23-Apr-12 Page 9 of 13

LOW VOLTAGE MOTOR CONTROL CENTRE White Amber White RYB 2.12. 'Trip circuit Supervision' Auto Trip 'Spring Charged' When specifically called for Potential Indication

CONTROL AND SELECTOR SWITCHES 2.12.1. Control and selector switches shall be of rotary type, provided with nameplate engraved with switch operating positions /switch description. 2.12.2. Breaker control switch shall be of pistol grip type spring return, with position indicator sequence interlock and normal after closing (NAC) contact (when specifically called for). 2.12.3. Selector switches shall have stay put positions with oval handle.

2.13.

METERING AND INDICATION 2.13.1. Metering and indication shall be provided as shown on the data sheet. 2.13.2. Supplier shall provide moving iron type analog ammeter and voltmeter on the incomer of each panel. 2.13.3. Outgoing power feeder having rating 125A & above shall be provided with CTs and ammeter. Only ammeters used for motor feeders shall have a compressed overload scale and shall be provided for motors above 22 kW. 2.13.4. Meters shall be flush mounting and fitted on the front of the MCC. 2.13.5. Unless otherwise specifically indicated meters shall be 96mm square type for incomers and bus bar indications and 72mm square type for feeders. External zero adjustment shall be possible on all indicating analogue instruments to facilitate adjustment without dismantling the instrument. 2.13.6. Ammeters shall be scaled such that full load corresponds to between 50 and 80% of the angular deflection. Ammeters for motors (where applicable) shall have a compressed overload scale and a red line shall indicate motor full load current. 2.13.7. Meters and relays shall be capable of withstanding without damage the secondary currents associated with the MCC rated fault current flowing in the primary of current transformers taking into account current limiting effects of protective devices. 2.13.8. Unless indicated otherwise low voltage equipment voltmeters and voltage coils shall generally be direct connected. Ammeters and voltmeters shall be class index 1.5. Watt-hour meters and maximum demand meters shall be class index 2.5 for indication and class index 1 for measuring supplies to/from third parties.

2.14.

RELAY AND TIMERS 2.14.1. Relays and timers shall have dust proof covers. Relay bases shall be keyed to ensure correct contact alignment and shall include retaining clips for the relay. 2.14.2. Where similar relays and timers are used for different coil operating voltages they shall be non interchangeable.

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LOW VOLTAGE MOTOR CONTROL CENTRE 2.14.3. Relays shall have a means of visually indicating they are energised. Timers shall have indication that they are energised and that the timing is in progress. 2.14.4. The coil voltage shall be as specified with the minimum voltage to pull in and maintain no lower than 85% of the nominal control voltage. The relay shall not drop out at any voltage above 60% of the nominal control voltage. 2.14.5. Protection relays shall have hand-reset facilities and clear operating indication, e.g. light emitting diodes. Non-tripping relays may be self-resetting if an indication of operation remains until hand reset. 2.14.6. Relays with multiple trip and alarm functions shall have separate operating contacts for each function wired out to separate terminals. 2.14.7. Test blocks for injection testing of relays and measuring devices shall be provided on each panel. Current injection test blocks shall be provided with short circuiting links. 2.15. CURRENT TRANSFORMER 2.15.1. Current transformers shall conform to latest edition of relevant Indian Standards. The design and construction shall be sufficiently robust to withstand thermal and dynamic stresses due to maximum short circuit current, available at the point of installation of current transformer. 2.15.2. Accuracy class shall be 1.0 and burden and other requirements shall be as per requirements. 2.15.3. The current transformers shall have the insulation level and thermal and dynamic ratings corresponding to that of the circuit breaker. 2.15.4. Secondary terminals of the C.T. shall be brought out suitably to a terminal block which will be easily accessible for testing and external connections. 2.15.5. Terminals shall be marked in accordance with IS 2705. A rating plate as per IS 2705 shall be provided on each current transformers. 2.15.6. Current transformers shall preferably be capable of being left open on the secondary side with the primary circuit carrying rated full load current without overheating or damage. 2.16. VOLTAGE TRANSFORMER Voltage transformers shall comply to IS 3156, rated to ensure satisfactory operation of the connected devices and shall be of Class 3. Secondary circuits of voltage transformers shall be earthed. 2.17. PADLOCKS AND LOCKING All ACBs & MCCBs shall be padlock able. Mechanical key interlock systems shall be fitted as and where required to ensure safe switching sequences. 2.18. CABLE TERMINATIONS 2.18.1. Cable entry to MCC shall be from top of the MCC. G3IR-1050-65-SP-9005_R0
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LOW VOLTAGE MOTOR CONTROL CENTRE 2.18.2. Ample space shall be provided in the cable compartment to accommodate PVC insulated aluminium conductor cables. The termination arrangement of multiple cables shall permit connecting and disconnection of individual cables without disturbing the other cables. 2.18.3. Removable undrilled gland plate shall be provided for termination of cables. 2.18.4. Access for cabling shall be from the rear/front. The cubicle width shall be adequate for a cable jointer to enter and work within the cubicle during cable joining. 2.19. EARTHING 2.19.1. A main GI strip shall run the complete length inside the switchboard, sized for a bolted earth fault of the short time rating of the switchboard. 2.19.2. Individual units shall be bonded to the main earth bar, with earthing straps to compartment doors and gland plates. 2.20. PAINITING AND FINISHING The painting process shall be governed by seller standard but shall be got approved by the company. 2.21. EQUIPMENT IDENTIFICATION All warning, identification and instruction labels shall be inscribed in both the English and local languages. Labels shall be engraved, laminated plastic secured by screws. Duty labels shall have black characters on a white background and warning labels shall have black characters on a yellow background. Labels shall be installed for the following: MCC title - top/centre. Circuit nameplate - front and rear (if accessible), on each unit. Rating plate - inside each unit, indicating nominal and maximum rating. Instrument nameplate - on incomers. Component nameplate - in compartments having duplicated items such as fuses. Busbar phasing Year of manufacture Order Item No.

Components shall be marked with their ratings and any other essential data. Where current transformer rating plates are not visible when installed, a duplicated plate shall be installed in a suitable position. 3. INSPECTION, TESTING AND ACCEPTANCE MCC shall be subject to inspection/testing by the Owner / Owners Consultant or by an agency authorised by the owner. Manufacturer shall furnish all necessary information concerning the supply to Owners inspectors.

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LOW VOLTAGE MOTOR CONTROL CENTRE 3.1. Type Tests: Type test certificates to be provided by the seller and shall include-Temperature-rise test - Dielectric properties making and breaking capacities - Degree of protection of enclosed equipment 3.2. Acceptance Tests: Acceptance tests shall be as follows: - A general visual check shall be carried out. This shall cover measurement of overall dimension, location, number and type of devices, location and connection of terminals etc. - Manual and electrical operation of Circuit Breakers / Relays shall be checked under the worst conditions of auxiliary supply voltage. - Dry insulation test with power frequency voltage shall be conducted for the main and auxiliary circuits. - Insulation resistance of the main and auxiliary circuits shall be checked before and after power frequency voltage withstand test. - Interchange ability Test - Secondary Injection Test - For equipment bought from other sub-suppliers, certified test reports of tests carried out at the manufacturers works shall be submitted. 3.3 All routine and acceptance tests shall be carried out at manufacturer's work under his care and expense.

4.

DRAWINGS, INFORMATION AND CERTIFICATES Following drawings shall be furnished for company approval: - General Arrangement Drawing showing front view, plan, foundation plan, floor cutouts and trenches for external cables, elevations, transport sections with weights. - Sectional drawings of various types of feeder, panels showing general constructional features, mounting details of various devices, busbars, current transformers, cable boxes, terminal boxes for control cables etc. - Schematic and control wiring diagrams for each type of feeder and protection, including indicating devices, metering instruments, alarms, space heaters etc. - Terminal plans showing terminal numbers, ferrules markings, device terminal numbers, function etc. - Relay wiring diagrams. - As Built drawings shall be submitted after installation and commissioning. The information furnished shall include the following:- Technical literature giving complete information of the equipment. - Erection, operation and maintenance manual, complete with all relevant information, drawings and literature for auxiliary equipment and accessories, characteristics for relays etc. - A equipment list with detailed specification.

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LOW VOLTAGE MOTOR CONTROL CENTRE 5. ATTACHMENTS Attachment 1: Low Voltage MCC Datasheet.

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