Work Scope

The work scope includes design, engineering, manufacturing, fabrication, assembly, testing, and
inspection at the shop floor, packing , dispatch, transportation, delivery for site of planetary
gear reducer with an integral wet clutch system for belt conveyors as per your technical
specifications.

Supply of planetary reducer with wet clutch system along with cooling skid consisting of piping/flexible
hoses with fittings, heat exchangers, filters, input coupling, output coupling, brake, hydraulic pump, oil
control valves, holdback etc. required for complete trouble free operation of equipment as specified

Supply of CST Controller Panel /Filed Instruments/Auxiliary LT Motors for CST Drive as per your specified
features.

Supply of control cable kit for interconnecting the planetary gear reducer with integral wet clutch system PLC controller
with each of its hydraulic controls.

All other associated accessories like pipes, clamps, pipe supports, coupling guards, drive base frames, fixing fasteners,
foundation bolts, shim plates etc. which are not specifically mentioned but are required for smooth and trouble free
operation of the system and should also make the system complete in all respect

PLC application software copy with necessary rights to use it for routine and preventive maintenance of the CST system.
Provision for condition monitoring system shall also be provided as per specification.

The equipment shall be equipped with temperature gauges and resistant temperature detectors and
vibration sensors.
Output shaft key made of suitable material will also be provided along with planetary gear
reducer with an integral wet clutch system.
Work scope will also include supply of any consumables like lubricant/oil etc required for initial
operation .The indication of the specification of oil along with the quantity required will also
provided by us.
We follow good engineering practice in order to achieve fits and tolerance for all machined parts
for which are also not included in the drawing.
Supply of one set of special tools & tackles which may be required for operation , maintenance ,
inspection and repair will be supplied by us which should not be used for any other purpose.

Purchasers Obligation:
Purchaser should provide respective drive support floors for the equipments as shown in the
drawing.
You will provide us with 415V 3 phase, 3 wire or 240V 1 phase.

CST will provide Local Starter Panel near to CST drive unit for feeding 3Phase, 3Wire power supply to
cooling pump motor, oil heat exchanger.
Customer must provide Local Starter panel near the CST drive unit for 3 wired power supply to
run cooling pump motor and oil heat exchanger for the system.
Customer will terminate FO cable a CST controller for FO communication between CST controller
and plant PLC.
All power & control cables will be In customer ` supply expect special required for the
system& instructions.
 Codes & Standards:

.The design, selection and construction of the system, components and materials shall be to relevant AGMA standards
and also conform to relevant Indian standard specification and codes of practice incorporating the latest revisions.

The design, manufacture, inspection and testing of CST drive shall comply with all the currently applicable status,
regulations and safety codes in the locality where the equipment is to be installed. Other internationally acceptable
standards/codes, which ensure equal or higher performance than those specified, shall also be accepted.

Design Specification:

The planetary gear reducer with wet clutch system shall be suitable for 24 hours continuous duty cycle at full load
and shall be suitable for moderate shock loads. Wherever required, oil temperature rise over ambient temperature
shall be restricted to 40C temperature.

The service factor for the drive shall be minimum 1.6 of motor power factor for safe and trouble free operation.
The planetary gear reducer with wet clutch system shall dampen the belt tension spikes during starting condition to
protect motor and other conveyor components such as belt, etc.

The components of the drive system shall be of sufficient strength to withstand the most severe stresses
encountered during conveyor operation.

The transmission efficiency of the gears shall not be less than 0.99 per stage.

The material of gears, profile and geometry shall ensure high power-weight ratio with low volume.

The gears used shall be machine cut and case hardened and shall be in accordance with relevant AGMA standards
or equivalent IS codes (latest revision). The dimensions of the shaft end shall conform to IS: 3688 or its latest
revision. However, input and output shaft extension to be provided in line with other drive chain equipment.

The high speed shaft shall be so designed to accommodate electro-magnetic brakes and hold back devices of the
CST system..

Field adjustable S curve conveyor belt velocity. The belt ramp time to be adjustable type.

Field adjustable creep speed. The creep speed shall be adjustable type for design speed under no load conditions.
Field adjustable Max. Power (torque) limit for each drive to protect conveyor component (belt, pulleys. Idlers,
bearings) and the drive components (gears, bearings) from shock and excessive loads. The HVC drive shall send a
fault signal to controls when power exceeds the Max. Power set limit.

The main motor starting will be controlled by drive PLC controller system. For short stoppage of Conveyor belt, the
motors need not be turned off; the drive may simply be de-clutched.

The drives will have permanent magnetic drain plugs, oil level indicators, inspection window, metallic breather etc.

Gears & pinion will preferably be solid forged. Where forging is not possible forged steel gear rims shall be fitted on
steel centers to with stand shock loads.

All drive housings will be made of fabricated steel /Cast Steel and shall be so split as to enable easy maintenance.

Recommended oil grade will be compatible with gear internals like material of bearing, cages. Further, all gear
boxes shall have suitable breather plugs.

Necessary care (like hold back, brakes) shall be adopted for planetary gear reducer drive to prevent reverse
movement of the belt in case of power failure or breakdown, phase reversal, low voltage phase failure etc.
 Necessary cooling arrangement will be provided using a heat exchanger with a suitable fan arrangement for proper
cooling of lubricant to be achieved.
System is designed for cold commissioning or hot commissioning or belt laying or belt condition verification, belt will
run at slow speed (10% of conveyor speed approx.) for several hours.

All the shafts of rotating equipment will be properly aligned to those of the matching equipment to as perfect as
accuracy as practicable.
The equipment will be free from excessive vibration so as to avoid over-heating of bearings or other conditions
which may tend to shorten the life of the equipment.
Full-proof sealing devices willl be provided to prevent leakage of dust, water, lubricants and hydraulic fluid
including foreign materials for all the units and assemblies whereever applicable. The dust seal system will
have suitable protection to prevent against ingress of dust in the bearing and hydraulic oil to ensure longer life
of seal, bearing and hydraulic oil.

All running shafts and wheels running as fixed axles or pins will be fitted with suitable size anti-friction
bearings. Due allowance will be made for impact and side thrusts and where necessary, spherical, seating
and separate thrust bearings of suitable dimensions are used.

Life of bearings shall be minimum of 30,000 working hours.

All the electrical equipment/ Instruments and devices shall be suitable for 4C -50C ambient and dusty hot and humid
atmosphere in which it is required to operate.

Noise level will not be more than 85dB when measured at a distance of 1.5 metres above floor level in
elevation and 1 metre horizontally from the base of any equipment furnished.

SYSTEM OPERATION & CONTROL PHILOSOPHY

complete operation of the planetary gear reducer system shall be controlled through PLC system supplied
with control write up, block logic diagrams, I/ O list and all other details, which are needed to prepare the
software logic of the operation of the sampling system.
Our CST Controller will be suitable for control from Plant PLC as well as locally from CST controller.
Speed signal display at local & interface with Plant PLC will be provided in the system.

The drive system would work satisfactorily under the stipulated conditions under a specified guarantee
period

TESTS, INSPECTION & OTHER

No-load trial run test to be carried out at shop for checking of speed, temperature rise, noise and vibration
levels.
The following tests necessary part of in house QAP approval:-

a) In addition to checks for physical, chemical properties, hardness, microstructure as per relevant
standard, the shaft and gear, pinion forgings subjected to ultrasonic testing.
b) MPI to be carried out on gears/ pinions after machining. Case depth, hardness & MPI after hard
facing are checked to ensure free from defects.

c) No load shop trail run to be conducted on gear boxes which should include check for
i) No leakages, no abnormal sound.
ii) Noise and vibration level

d) Temperature rise will not exceed design values.

 e) Gear reducer shall be checked for reduction ratio, backlash and contact pattern.
f) Satisfactory performance of hold back devices (integral to gear box).
DRAWING / DOCUMENTS & INFORMATION Support:

Calculations in support of drive selection and its thermal capacity will be submitted along-with offer.

General Arrangement & Load Data of complete drive-clutch system with base frame. General Arrangement
will indicate salient features viz. (KW) of Mechanical & Thermal rating, reduction ratio, material of
construction of major parts, GD values, weight, load data (static & dynamic) etc.
Maintenance clearance distances.
Weight of heaviest component to be handled.
Write up with brief description of all components.
Complete details of tests to be carried out.
Quality Assurance Programs.
Catalogues, Selection charts, etc.
List of field devices along with its mounting location/details and nomenclature will be furnished.
List of tools & tackles, if required, for assembly and maintenance of the equipment for reference.
USER Manual and Instrument Interconnect diagrams

Write-up and block logic diagrams, I/O list, field devices GA and data sheets, schematic/wiring/GA of motors,
local control panel and local push button stations including foundation details of all electrical items for
approval.

GA drawing of whole system and individual equipment which comprise the system in-line with the layout.
Characteristic curves

All drawings will be in metric/SI units. Drawings should be in scale and prepared in AutoCAD 2000/2002.

Instruction, erection, operational and maintenance manuals provided.

Performance test protocols for approval.

Inspection certificate and test certificates.
 .

Electrical & C&I Specification

Power Supply Information:

1 Nominal system Voltage 415V(+/-10%), 3Phase,3Wire System

2 Supply Frequency 50 Hz (-5% to +5%)
3 Highest Fault Level 50kA for 1 sec
4 System Earthing Solid earthed
5 Control Supply 110V AC
6 PLC Interrogation Volatge 24V DC

RELEVANT STANDARDS OF the System:

IS: 900 Code of practice for installation and maintenance of induction Motors.
IS: 8223 Dimensions and output ratings for foot mounted electrical machines with frame number 355 to 1080
IS: 1231 Dimension of three phase foot mounted induction motors
IS: 2223 Dimension of flange mounted induction motors
IS: 210 Frames for rotating electrical machines
IS: 1271 Classification of insulating materials for electrical machinery and apparatus in relation to their thermal
stability in service.
IS: 2253 Designation for type of construction and mounting arrangement for electrical machines
IS: 3043 Code of practice for earthing
IS: 4029 Guide for testing three phase induction motors
IS: 4691 Degree of protection provided by enclosures for electrical machinery
IS: 4722 Rotating electrical machinery
IS: 6362 Designation of methods of cooling for rotating electrical machinery
IS: 7816 Guide for testing insulation resistance of rotating machinery
IS: 12065 Permissible limits of noise level for rotating electrical machines
IS: 12075 Mechanical vibrations of rotating electrical machines
IS: 2147 Degree of protection provided by industrial enclosures
IS: 4729 Measurement and evaluation of vibration of rotating electrical machines
IS: 4889 Method of determination of efficiency of rotating electrical machines
IS: 8789 Values of performance characteristic for three phase induction motors
IS: 12824 Type of duty and classes of rating for rotating electrical machines
IS: 12802 Temperature rise measurement of rotating electrical machines
IS: 3003 Carbon Brushes for electrical machines
IS: 5 Colours for ready mixed paints and enamels

Technical Specification for Nigahi Coal Mines CST Drives

S.No. Description
1 Location TH-15 TH-16 TH-17
2 Conveyor C-27 C-28 C-29
3 Quantity 1 No. 1 No. 1 no.
4 Duty Continuous, 24 hours
5 Ambient Temperature Vary from 4C to 50C
6 Designed/Rated Capacity 1600/1920 TPH
7 Material Handled Coal
8 Lump Size,mm (-)300mm
9 Bulk Density of material 0.8-1.15 T/cu. m
10 Belt Width 1600/4
11 Drive pulley dia. With lagging 1600mm
12 Motor Rating,kW 420
13 Consumed power at motor shaft,kW 395 404 402
14 Comsumed power at drive pulley shaft,kW 370 379 377
15 Motor Rpm 1500
16 Drive Single
17 Conveyor Length (horizontal),m 400 552 825
18 Lift, m 40.3 33 16.5
19 Max. conveyor inclination 12
20 Actual Speed, m/sec 2.73
21 Speed, m/sec 2.5
22 Trough angle 35

23 Tight side tension ,T1 during starting & runnng (kN) 235/222 241/227 239/226

24 Slack side Tension,T2 (kN) 86 88 88

25 Drive pulley dia. 1000 mm
26 Tail pulley dia. 800 mm
27 Snub pulley 800 mm
28 Lagging for drive pulley 12 mm
29 Lagging for non drive pulleys 10 mm
30 Gear ratio required 28.4
31 Pulley shaft dia at coupling 240
32 Starting Factor considered 1.05(bidder to conform)
DESIGN

Electrical
a) The motor will be of continuous duty (S1) and rating type in accordance with relevant code & motor shall be
Eff-2 category.
b) The temperature measuredo over the surface of the motor shall not exceed 0 oC over the ambient air for the
class of insulation B and 80 C for class F in accordance with relevant code.
c) The motor shall be designed to deliver rated output with the terminal voltage differing from its rated value by
not more than + 10%, frequency differing from its rated value by not more than -5% to + 5% and any
combination of these limited to 10%.
d) The motors shall be capable of withstanding the forces associated with the maximum in rush current, the
locked rotor torque and the pull out torque at the highest system voltage and at the upper limit of supply
frequency during starting.
e) The motors shall be capable of starting and accelerating to the rated speed along-with the fully loaded driven
equipment without exceeding the acceptable winding temperature even when the supply voltage is 80% of
rated voltage.
f) The motors shall be suitable for two cold starts in succession under the normal loading condition.
g) The motors shall withstand for 15 seconds without stalling or abrupt change in speed under gradual increase
of torque up to 1.6 times its rated value, the voltage and frequency being maintained at their rated value.
h) The accelerating torque at any speed with the lowest starting voltages shall be at least 10% of rated full load
torque.

Mechanical
a) The method of cooling for LT motors shall depend upon the system requirement.
b) The motor shall have IP55 protection in accordance with IS: 4961.
c) The motor vibration shall confirm to the requirements in accordance with relevant code.
d) The motor noise level shall confirm to the requirements in accordance with relevant code.

CONSTRUCTIONAL DETAILS
General
a) The motor and its components such as stator, rotor end shield, terminal boxes and the bearings shall be
designed to be readily inter-changeable as integral units for the same design and rating.
b) All non-metallic components used shall be resistant to flame propagation
c) All heavy parts of the motors shall be provided with necessary lifting arrangements.

Stator frames and shields

a) The stator frames and end shields shall be rugged and made of cast iron conforming to relevant code.
b) The frame holding the stator core and windings must be strong and rigid to withstand short circuit force
and unbalanced magnetic pull and minimize vibrations.

Cooling arrangements
a) LT Squirrel cage motors shall be Totally Enclosed, Fan Cooled, (TEFC) by a light weight cast Aluminium
fan of bi-directional design and very low inertia. The fan shall be keyed to the shaft.

Enclosures
The enclosure shall be totally enclosed fan cooled with suitable means for breathing and drainage. The drain
hole diameter shall not exceed 6 mm.

Stator
a) The stator core shall be built up of low loss high permeability steel laminations.
b) The winding shall be two layer type consisting of synthetic enameled copper conductors in Semi closed
slots.
c) Insulation shall be Class-F for 415V motors.
d) All winding overhangs and leads shall be adequately supported braced and blocked

Rotor
a) The rotor core shall be of similar construction to that of the stator
b) The cage bars for cage motors shall be of copper.
c) The complete rotor shall be dynamically balanced with the fan on the shaft for TEFC motors ensuring vibration
free smooth running.
Shaft
a) The shaft shall be manufactured from high grade steel, preferably C-40. The sustained deflection of the shaft
shall well below 10% of the air gap.
Bearings
a) The bearings shall be ball / roller type for 415 V motors
b) The bearings shall be self lubricated.
c) The bearings shall be in accordance with the relevant codes.
d) 415 V motors shall be grease lubricated.

Terminal box
a) Terminal boxes integral with the stator frame shall be provided with terminals for stator
leads. Additional terminal box shall be provided for slip ring motors.
b) Terminals shall be suitable for receiving single layer armoured Aluminium conductor
PVC/XLPE insulated cables.
c) Terminal boxes shall be suitable for top entry of cables.
Earthing terminals
Two independent earthing terminals shall be provided in accordance with I.E Rules on
diagonally opposite corners of the motor for bolted connection.

Mounting
The motors for crushers, pumps, compressors, fans, and blowers shall have the mounting
B3 and the motors for conveyors shall have the mounting B5 in accordance with DIN 42950
or as specified elsewhere in this tender.

Technical Parameters

IS : 325

Ambient Air Temperature Maximum 50oC

Maximum upto 1000M above MSL
Heavily polluted with coal dust medium
Rated voltage (with percent variation) 4 1 5 V +/- 10 %
Frequency( with percent variation) 50 Hz (-5% to + 5%)
Continuous (S1),Eff-2 Type
Continuous
Class F limited to Class B
Temperature rise allowed over the ambient air 70 C over ambient for class B
Type of enclosure of motor TEFC
Degree of protection for enclosure of IP 55

Degree of protection for terminal box IP 55

TEFC/CACA
Lithium grease for roller and thrust
bearings, oil for pedestal bearings
Horizontal foot (B3)/Flange or
Face (B5)/ as per requirement
Squirrel cage
4/6/8/10
5 Percent
Three
Minimum efficiency at full load 90% for motors above 18.5 kW
Maximum value of locked rotor current as 650%, subject to tolerance as
percentage of full load current given in IS:325
Minimum value of locked rotor torque as 185% for motors above 18.5 kW
percentage of full load torque
Minimum value of pull out torque as percentage 200% for motors above 18.5 kW
Clearance between phases at terminal box 10 mm for 415 V motors
Clearance between phases to earth at terminal 10 mm for 415 V motors

Fault withstand level for terminal box 31 MVA for 415V motors
Particular of test requirements
Certificate for Type tests issued by a test house Required
of repute conducted on one motor of a lot
having identical Specification.
Certificate for Routine tests issued by a test Required
house of repute conducted on each motor
having identical specification. The certificate
shall bear the serial number of the motor
identical to that appearing on the rating plate

.
Junction Boxes Specification:

Junction Box/cable joint boxes with IP: 65 degree of protection, shall comprise a case and a
detachable cover or hinged doors constructed out of cold rolled steel sheet of minimum
thickness 2 mm. Top of the boxes shall be arranged to slope towards rear of the box. Gland
plate shall be 3 mm thick sheet steel with neoprene/synthetic rubber gaskets. All junction
boxes shall be suitable for mounting on walls, columns & structures. The boxes shall
include brackets, bolts, nuts, screws, glands, lugs, earthing stud required for erection.
Terminal blocks inside a junction box shall be of 660 volts grade. It shall be complete with
insulating barriers, clip-on-type terminal numbering for wiring diagrams & arranged to
facilitate easy termination. Twenty percent spare terminals shall be provided ineach
terminal block.

Zero Speed Switch Specification :

One no. zero speed switch shall be provided for each crusher. Zero speed switch shall be
non-contact (proximity) type electronic switch. Mounting arrangement/ location shall be such
that operation, effective sensing distance, sensitivity etc. shall not be effected by
accumulation of dust on rotating part or surface of probe. Adequate mechanical protection
by means of non-metallic shields shall be provided on top of the switch to prevent any
damage due to falling coal / metallic pieces etc. In built initial start up delay and nuisance,
tripping delay through timers shall be provided. Each switch shall have two NO and two NC
contacts wired out to the terminal blocks. The contact of the switches shall be rated for at
least 10 Amps. Breaking at 240 VAC at 0.3 p.f. lagging. The monitoring unit shall have cast
qualizin body having IP-65 degree of protection. A separate terminal box with a separate
cover, which shall be totally sealed from main box, shall be provided. Terminal blocks shall
be suitable for terminating 2.5 mm sq. standard copper cable. Power supply voltage shall be
110V AC +/-10% Voltage Variation .The probe housed in robust cast aluminium enclosure of
protection class IP-65 shall be installed either radially or axially. The controller unit shall be
dust & water tight, corrosion resistant and shall be mounted separately. The interconnecting
cable length shall not be less than 5meters. Following features shall be provided.
1. Speed setting accuracy : Within 5% of desired value
2. Repeatability : Within 1%
3. Differential : Within 5% of set value
4. Output Contact rating : 2 NO+2 NC, 10A, 240V AC

Silent features :
1. Red LED for Supply On
2. Green LED for Relay On
3. Display of present speed
4. Display of speed set
 5. Alarm facility with indication
6. Initial bypass time delay

PLC SPECIFICATION
MICRO-PROCESSOR CONTROLLER
The system shall have micro-processor controllers for inter-acting with the starter panels of the
drives with or without inter posing relays. These controllers shall also interact with various control
instrumentation provided for monitoring of drives and shall basically consist of a regulated power
supply unit and plug-in type cords for easy maintenance. The controller shall comprise a central
processing unit, solid state memory, digital input modules with optical isolation with potential free
contracts, digital output modules for generation of control output. The microprocessor memory
shall contain software which shall achieve all logical processing by executing instructions in the
CPU. FO converter unit shall be provided by bidder inside CST Controller
Panel for communication between CST Controller & PLC through FO cable
communication.

Protocol for communication will be confirmed during detail engineering. It shall be the
sole responsibility of the vendor to supply additional hardware at CST PLC end, if
required, for establishing the smooth communication.

PLC processor
The processor unit shall be capable of executing the following functions :

Receiving binary and analog signals from the field and operator intimated command
from the control panels.

Implementing all logic functions for control & protection of the equipment and system

Issuing control commands

Providing alarm and status information.

Performing self-monitoring and diagnostic functions

Providing log output

The controller shall provide all basic functions, operations, storage, counting, timing,
logging and transfer operations and comparison functions. The programmable system
shall be delivered completely programmed for the complete and reliable operation of
the LSP.

The PLC memory capacity shall be sufficient for the complete system operation with
provision for at least 20% expansion in future. Programmed operating sequences and
criteria shall be stored in nonvolatile memories. All dynamic memories shall be
provided with buffer battery backup which shall be for at least 360 Hours. The
batteries shall be lithium or Ni-Cd type. The PLC system shall be provided with
necessary hard-
ware for inter connection with Purchaser's/Other-way. Cont
Facility shall be provided for changing the states of inputs and outputs, timers and
flags to facilitate fault finding and other testing requirements. It shall be possible to
display the signal flow during operation of the program

A NORMAL/TEST/PROGRAMME/OFF lockable selector switch shall be provided on

the control panel or processor.

Priority of different commands shall be as follows:

Manual intervention shall be possible at any stage of operation. Protection commands
shall have priority over manual commands and manual commands shall prevail over
auto commands.

INPUT/OUTPUT:
The PLC system should be designed according to the location of the input/output cabinets.
Individually output circuits with fuse blow indicator shall be provided. All input/output
points shall be provided with status indicator. Input circuits shall be provided with
fuses preferably for each input, alternatively, suitable combination of inputs shall be
done and provided with fuses such that for any fault, fuse failure shall affect the
particular drive system without affecting other systems. All input/output cards shall
have quick disconnect terminations allowing for card replacement without
disconnection of external wiring. The Bidder shall provide the following monitoring
features :
Power supply monitoring
Contacts bounce filtering
Optical isolation between input and output signals with the internal circuits In case
of power supply failure or hardware fault the critical outputs shall be automatically
switched to the fail safe mode. The fail safe mode shall be decided during approval
stage.
There shall be at least 20% spare capacity available on input, output and memory
modules, over and above the system requirement. Output module shall be capable
of switching ON/OFF inductive loads like solenoid valves, auxiliary relays etc.
without any extra hardware. Further, multiplication if required shall be done in PLC.
All input field interrogation voltage shall preferably be 24V DC only. In case of loss
of remote I/O communication link with the main processing unit, the remote I/O shall
be able to go to pre-determined fail safe mode with proper annunciation. This shall
be decided in approval stage.

Specification for CST Controller Panel

The panel frame shall be fabricated using suitable mild steel sections of pressed and
shaped, cold-rolled sheet steel of thickness not less than 2.0 mm. Frames shall be
enclosed in cold-rolled sheet steel of thickness not less than1.6 mm. 3.0mm gland plates
shall be provided and shall be of removable type. CST controller panel shall be IP-65.

The standing type panels shall be provided with hinged doors (within built locked
arrangement and handle). It shall be possible to open the door through 100 degree. The
doors, cut-outs and covers shall be equipped with approved type of synthetic/rubber all
round and sufficient number of latches/bolts shall be provided to achieve a degree of
protection of IP.65 as per IS: 2147.

All equipment mounted on the front face of the panels shall be flush or semi-flush type.
Detailed internal arrangement drawing of the control panel indicating spacing between
different components shall be submitted for Purchaser's approval.

The PLC panel shall be free standing vertical type separate from control desk. The
equipment shall be rack mounted and arranged in clearly defined sections or I/O devices,
processors, power supplies etc. About 20% space shall be left for future expansion in each
section. A cable marshalling section shall be included.

The PLC panels shall be provided with perspex/glass doors in front to facilitate monitoring
of the LED indication of various cards mounted in the card rack. All components shall be
clearly and unambiguously marked for proper identification and easy maintenance. Readily
accessible and clearly marked test points shall be provided in all important modules and
circuits.

I/O racks and processor cabinets shall be provided with door switches which shall provide
proper annunciation on control desk in case doors are open. Removable eye bolt or lifting
lugs shall be provided on all panels to facilitate easy handling.

We ensure that the control panels are vermin proof, and all surplus holes in the gland plates
shall be tightly closed by rubber plugs.

Name plates and label

Each panel shall be provided with prominent, engraved identification plates for all front mounted
equipment. Panel identification name plates shall be provided at front and rear. All name plates
shall be of non-rusting metal with white engraved lettering on black back ground. Inscription and
lettering sizes shall be subject to Purchaser's approval. For easy identification of all equipment
inside the panel, they shall be marked with suitable, clear, indelible paint markings. Labels for
fuses shall also clearly indicate current ratings of the respective fuses.

Terminal blocks
Terminal blocks shall be of 650 Volts grade, rated for 10 Amps and in one piece molding.
They shall be complete with insulating barriers, clip-on-type and identification strips.
Terminal blocks for CT and VT secondary leads shall be provided with test link and isolating
facilities. Terminals for CT secondary leads shall also be provided with short circuiting
earthing facilities.

All terminal blocks on which external cables are connected shall be suitable for terminating
at least 2 nos. of 1.5 mm2 of stranded copper wire. Not more than two(2) wires shall be
connected to any terminal.

All terminals shall be numbered for identification and grouped according to the function.
Terminal blocks shall have minimum clearances of 200 mm to cable gland plates, and of
150 mm to adjacent terminal rows, panel sides and other equipment. Twenty (20) percent
spare terminals shall be provided, distributed over all terminal blocks.

Wiring
All inter panel wiring and connections between adjacent panels including all bus wiring for
AC and DC supplies, shall be provided by the Bidder. All internal wiring shall be carried out
with 650 V grade single core, 1.5 mm2 or larger, stranded copper wires having color-coded,
PVC insulation. Space heater circuits shall have wires having adequate current carrying
capacity, but not less than 2.5 mm2 Copper. Internal wiring between electronic cards shall
be as per the standard practice of manufacturer.

Engraved core identification ferrules marked to correspond with panel wiring diagrams, shall
be fitted at both ends of each wire. Jumper wires between two terminal blocks shall also be
ferruled at both ends. Spare contacts of relays, timers and switches shall be wired out to the
panel terminal blocks only as required by the Purchaser, during approval stage.

Necessary transformer/power packs shall be provided by the Bidder. The equipment power
supply unit shall be mounted as an integral part of the enclosure and provide all voltages
necessary to power the central processor and I/O cabinets. For separately mounted I/O
racks separate power supplies shall be provided. Power supply module shall be of ample
capacity to supply all modules.

Additionally, about 20% spare capacity for future use shall be provided. The components
shall be suitable for the supply voltage variation of + 10% of the rated voltage and suitable
for withstanding a momentary supply voltage rise upto 70% for about 10 secs. Above the
nominal system voltage. Necessary constant voltage transformers or voltage stabilizers will
be provided