MAHARASHTRA INDUSTRIAL DEVELOPMENT

( A GOVT. OF MAHARASHTRA UNDERTAKING)

ITEM NO. 8
Bay Marshalling Box.
Providing, erecting, testing and commissioning of following types of Bay
Marshalling Boxes complete as per detail technical specification.
Item No. 8.1

120 terminal Bay Marshalling Box.

Item No. 8.2

60 Terminal Bay Marshalling Box

TECHNICAL SPECIFICATION
1.0

SCOPE
The scope of this specification covers the design, manufacture, galvanising
or painting as specified, inspection & testing before dispatch, packing &
forwarding to site Marshalling Kiosks for use in EHV switchyard for
connection of control cables coming form various switchyard equipment and
the control room.

2.0

STANDARDS
The marshalling Kiosk offered shall conform to the latest revisions of
relevant standards, rules and codes. Some of these standards are listed below:
Sr.
No.

Standard No

IS

: 13947

Degree of protection provided by enclosure for low voltage

switchgear and control gear

IS

: 4007

Terminals for equipment

IS

: 13703

HRC cartridge fuse links

IS

: 6005

Code of phosphating for Iron and Steel

IS

:5

Colour of ready mix paints

3.0

TITLE

IE Rule - 1956

PRINCIPAL PARAMETERS

CONTRACTOR

EXECUTIVE ENGINEER

MAHARASHTRA INDUSTRIAL DEVELOPMENT

( A GOVT. OF MAHARASHTRA UNDERTAKING)

The equipment covered in this specification shall meet the following technical
particulars and the general technical requirement of the marshalling box
furnished at 4.0 below:
Sr.
No

Particulars

Requirement
120 Ways

60 Ways

1.

Installation

Pedestal mounted

Pedestal mounted

2.

Type

Out door type

Out door type

3.

Electrical clearances

AS per IE rule

AS per IE rule

4.

Minimum
dimensions

4.1

Height

1200

800

4.2

Width

750

750

4.3

Depth

300

300

5.

Thickness of sheet steel

2.5 mm (min)

2.5 mm (min)

6.

Degree of protection

IP - 55

IP - 55

7.

Terminal Block

7.1

Size

Suitable to connect
10 sq. mm aluminum
or 2.5 sq. mm.
copper conductor

Suitable to connect
10 sq. mm aluminum
or 2.5 sq. mm.
copper conductor

7.2

Type

M5 Clip on with
melamine body and
poly
carbonate
cover.
Elmex/Connectwel

M5 Clip on with
melamine body and
poly
carbonate
cover.
Elmex/Connectwel

7.3

Normal Current

30 A

30 A

7.4

Rated voltage

1100 V

1100 V

Sr.
No

Particulars

inside

Requirement
120 Ways

7.5

CONTRACTOR

Insulation Level

3.5 kv for 1 minute

60 Ways
3.5 kv for 1 minute

EXECUTIVE ENGINEER

MAHARASHTRA INDUSTRIAL DEVELOPMENT

( A GOVT. OF MAHARASHTRA UNDERTAKING)

7.6

Minimum
clearance
between terminal block
and cable gland

150 mm

150 mm

7.7

Minimum
clearance
between two rows of
terminal blocks

150 mm

150 mm

8.

Fuses

8.1

Type

HRC NS cartridge

HRC NS cartridge

8.2

Normal current

16 A

16 A

8.3

Rated voltage

415 V

415 V

8.4

Insulation Level

3.5 kV
minute

for

one

3.5 kV
minute

for

one

4.0

GENERAL TECHNICAL REQUIREMENT

4.1

The marshalling box shall have the arrangement of terminal columns as under:

4.1.1
with

120 Way marshalling box shall

40 terminals.

4.1.2

60 Way marshalling box shall have three columns of terminal blocks each with
20 terminals.

4.1.3

The installation of terminal blocks shall commence from top of the column,
bottom side of the column shall be kept without terminals for installation of
additional terminal blocks if required, in future.

4.2

The marshalling kiosk shall be sheet steel enclosed, dust, vermin weather
proof suitable for installation outdoors. Cold rolled sheet steel shall be used
for the box.

4.3

The box shall stand on base angle frame with a door, switchboard type handle
and locking arrangement & hooks for padlocking industrial lock at top and
bottom of the door. The door shall have three hinges for 120 way and two
hinges for 6o way box.
Holes of 23 mm diameter shall be provided for the foundation pad for fixing it on
the foundation. Foundation bolts of adequate size shall also be provided along
with each box.

4.4

Cable entry shall be from bottom. Removable steel sheet gland plate of at least
3.5 mm thick shall be provided for this purpose.

have three columns of terminal blocks each

4.5
A switch, HRC fuse, socket and holder suitable for 230 V lamp shall be
provided.

CONTRACTOR

EXECUTIVE ENGINEER

MAHARASHTRA INDUSTRIAL DEVELOPMENT

( A GOVT. OF MAHARASHTRA UNDERTAKING)

4.6

A sloping rain hood shall be provided to cover all the sides of the box. All doors
/ covers shall be designed with special shape and sections and provided with
adequate size of neoprene gaskets to prevent ingress of moisture and achieve
the degree of protection of IP 55.

4.7

Two nos. of earthing terminals shall be provided on the two sides of the
marshalling box for connection to the earth mat.

4.8

Gaskets shall be provided all round the doors and gland plates. Neoprene anti
vibration gasket of size 18 mm x 5 mm thk on door and 15 mm x 2 mm thk on
gland plate shall be provided.

4.9

All nuts and bolts including foundation bolts shall be electro galvanised in white
shade.

4.10

Terminal Blocks

4.10.1 The terminal block shall be M 5 clip on type, one piece moulded complete with
insulated barriers, stud type brass terminals, washers, brass nuts, brass lock
nuts and identification strips. Studs, screws and washers etc. shall be made of
brass and shall be nickel plated. The springs shall be made of non magnetic
stainless steel. The washer shall be of brass having minimum thickness of 0.5
mm and shall be nickel plated. The connectors shall be rated for 1100 V at 30
A continuous current.
4.10.2 The terminal blocks shall be mounted on electro galvanised C shaped steel
section at least 2 mm thick. Zinc coating shall be at least 20 microns. Each
column shall have provision for addition of at least five terminals if required.
4.10.3 Steel end clamps shall be provided to fix the terminal blocks in position at each
end of the row.
4.10.4 Heavy duty transparent unbreakable good quality clip on type polycarbonate or
equivalent covers shall be provided on the terminal block to prevent contact with
the terminals unless the cover is removed.
4.10.5 Each terminal block shall be so arranged that any individual terminal can be
connected / removed / replaced without disturbing the other.
4.10.6 Four PVC troughs shall be provided between columns of the terminal blocks to
receive wires for connection to individual terminals. The trough shall have PVC
cover.
4.11

Painting

4.11.1 All sheet steel work shall be phosphated by seven tank process in accordance
with IS 6005. Oil, grease, dirt shall be thoroughly removed by emulsion cleaning.
4.11.2 Rust and scale shall be removed by pickling with dilute acid followed by washing
with running water, rinsing with slightly alkaline hot water and drying.

CONTRACTOR

EXECUTIVE ENGINEER

MAHARASHTRA INDUSTRIAL DEVELOPMENT

( A GOVT. OF MAHARASHTRA UNDERTAKING)

4.11.3 After phosphating, thorough rinsing shall be carried out with clean water
followed by final rinsing with dilute dichromate solution and oven drying.
4.11.4 Phosphate coating shall be sealed by the application of the two coats of stoving
type epoxy primer. The first coat may be flash dried while the second coat shall
be stoved.
4.11.5 After application of the primer, two coats of finishing epoxy paint shall be
applied. The second finishing coat shall be applied after the completion of
tests. The panel shall have colour confirming to shade 631 as per IS 5 for
out side and inside of the box. Base frame shall be coloured black.
Thickness of paint shall not be less than 50 microns.
5.0

TESTS

5.1

The equipment offered should have been successfully type tested in line
with the relevant Indian Standards and technical specification. The successful
bidder shall submit two copies of the type test report for review and
record
along with
the submission drawings.
5.2

All acceptance and routine tests as stipulated in the relevant standards

be carried out in presence of purchasers representative.

6.0

INSPECTION

6.1

The inspection may be carried out by MIDC at any stage of manufacture and
also after the equipment is ready at manufacturers works. The manufacturer
shall grant free access to the purchasers representative at any reasonable time
when the work is in progress.

6.2

The supplier shall keep the purchaser informed of the time of starting and
of the progress of manufacture of the equipment in its various stages.

6.3

No material shall be dispatched from its point of manufacture unless the

material has been satisfactorily inspected and tested.

6.4

Advance information of the readiness of the equipment shall be given to MIDC

for arranging visit to manufacturers works for inspection.

7.0

Quality Assurance Plan

7.1

The successful bidder shall submit a detail quality assurance plan for
procurement of raw material, manufacturing and testing of the equipment
within a fortnight of receipt of Letter of Intent.

7.2

It shall also include following information :

a)

CONTRACTOR

shall

Statement of Raw materials, names of sub-suppliers, standards

according to which raw material is tested, List of tests normally
carried out on raw materials in the form of a quality assurance plan.

EXECUTIVE ENGINEER

MAHARASHTRA INDUSTRIAL DEVELOPMENT

( A GOVT. OF MAHARASHTRA UNDERTAKING)

8.0

b)

Copies of test certificates of all bought out items.

c)

List of manufacturing facilities available.

d)

List of testing equipments

Performance Guarantee
The equipment shall be guaranteed for satisfactory performance for a period of
24 months from the date of receipt of material at site or 18 months from the date
of commissioning whichever is earlier. In case of failure of the equipment within
this period, the supplier shall make good the faulty equipment at no extra cost to
the purchaser.

9.0

Drawings and documents

9.1

All the drawings shall conform to the international standards organization

(ISO) A series of drawing sheet. All drawings shall be Auto cad generated.
All the dimensions shall be in system international units.

9.2

The successful bidder shall on receipt of LOI submit four sets of following
minimum drawings along with bill of material and packing list for purchasers
approval. After receipt of purchasers approval, the supplier shall submit four
prints and a soft copy of the approved drawings.

9.2.1

General outline drawing showing outside dimensions, shipping dimensions,

weights and such other prominent details.

9.2.2

Sectional views showing the general constructional features of the

marshalling kiosk including door details and fixing of gaskets to achieve IP 55
feature .

9.2.4

Foundation plan including pedestal details.

9.3

Guaranteed technical particulars of the equipment in the format acceptable

to M S E B.

9.4

Approval of drawings by the purchaser shall not relieve the supplier of any
of his responsibility and liability for ensuring correctness and correct
interpretation of the drawings for meeting the requirements of the
applicable
standards, rules and code of practice.

10.0

Packing & Forwarding

10.1

The equipment shall be packed in suitable crates so as to withstand handling

during transport and out door storage. The supplier shall be responsible for any
damage to the equipment during transit, due to improper and inadequate
packing.

10.2

Each consignment shall accompany a detailed packing list.

CONTRACTOR

EXECUTIVE ENGINEER

MAHARASHTRA INDUSTRIAL DEVELOPMENT

( A GOVT. OF MAHARASHTRA UNDERTAKING)

11.0

Installation

11.1

The contractor shall arrange to transport the marshalling box to its location
& mount the marshalling boxes on steel frames as per MSEB norms &
approved drawings.

11.8

Following preliminary checks shall be conducted before commissioning of

circuit breakers.

12.0

1.

Check the tightness of bolts, clamps and connecting terminals.

2.

Check earthing connections.

3.

Check control wiring for correctness of connections , continuity and

IR values.

4.

Ensure doors are properly aligned .

Mode of Measurement
The measurement shall be made on per box basis.

CONTRACTOR

EXECUTIVE ENGINEER