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Technical specification

L T Panel
1.0 Scope
This specification covers the requirements of design, materials, manufacturing, testing and inspection at
Contractor's works of Low Voltage switchgear with or without Auto Power Factor Correction Panel and Distribution
board.
2.0 Applicable Standards
The design, manufacture and performance of equipment shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall
be construed to relieve the Contractor of his responsibility.
The equipment shall conform to the latest edition of applicable Codes of Standards. In case of conflict between the
applicable standards and this specification, this specification shall govern.
Switchgear general IS : 13947 BSEN: 60947 IEC:
BSEN 60947-2
AC circuit breakers IS:13118 BS:3871(PI) IEC 947-2
MCCB
Factory built assemblies of switchgear and
IEC:61439
control gear for voltages up to and including BS:5486
1&2
1000v AC. & 1200 v DC
Air break switches IS:13947 BSEN:60947-3 IEC-947-3
Miniature circuit breakers IS:8828 BS:3871 IEC:
HRC cartridge fuses IS:13703(P2) BS:88 IEC-769
D type fuses IS:8187 BS: IEC:
Contactors IS:13947 BSEN-60947-1 IEC:9474-1
BSEN-60947-4-
Starters IS:13947 IEC:947-4-1
1
Control switches/push buttons IS:13947 BS: IEC:
Current transformers IS:2705 BS:7626 IEC:185
Voltage transformers IS:3156 BS:7625 IEC:186
Relays IS:3231 BS:142 IEC:255
Indicating instruments IS:1248 BS:89 IEC:51

Arrangement for bus bars main connections IS:5578


BS:159 IEC:
and accessories IS:11353
Ac electricity meters IS:8530 BS:37 IEC:
Degree of protection IS:13947(PI) BS: IEC:947-1
The performance of ac control gear
equipment rated up to 600 v for use on high IS: BS: IEC:
prospective fault current system
Code of practice for installation and
IS:10118 BS: IEC:
maintenance of switchgear
Climate proofing of electrical equipment IS: BS: IEC:
Code of practice for phosphating iron and
IS: 6005 BS: 3169 IEC:
steel
Wrought aluminum and aluminum alloys for
IS:5082 BS:2898 IEC:
electrical purposes
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Control transformer for switchgear and


control gear for voltage not exceeding 110v IS:12021 BS: IEC:
ac
3.0

CUIM/TEN/UTL/09 LT Panel R5
a. Constructional Features
The LV switchboards shall be modular construction type Symmetrical, welded frame construction, consisting of
single sheet folded construction with punched on a 25mm DIN pitch pattern. All profiles with rounded
edges,Horizontal sections, vertical sections with fixing levels for space saving interiors installation and should be
welded at corner . The switchboards and the associated equipment including switchgear, control gear, Bus bar
supports, Bus bar orientation, Bus bar links etc. shall be identical in construction to the assembly. The detailed
drawings of the type-tested assemblies shall be made available during technical specifications as per specs. Panel
shall be tested of design as per Seismic Zone 2.
The major parameters of the panel switchgear and other required features are given in data sheet and SLD. The
Contractor shall in his offer specifically conform compliance of these data in full. Deviation if any should be
specifically brought out in the schedule of Technical Deviation.
The switchgear shall be indoor, metal enclosed, floor mounted of uniform height not more than 2450 mm, made up
of the requisite vertical sections, dust and vermin proof construction with IP – 5X degree of protection, unless
otherwise stated. The colour shade shall be of RAL 9003 Textured.
Metal based PU gaskets between all adjacent units and beneath all covers shall be provided to render the joints
dust and vermin proof to provide a degree of protection of IP 5X as stipulated in schedule of quantities. The
unused openings within the switchboards shall be closed using suitable grommets.
Adjacent switchgear cubicles shall be provided with side sheets on either side to ensure complete isolation. The
switchgear shall be easily extendable on both sides by the addition of vertical sections.
The bottom of the switchgear shall be fully covered by sheet steel.
Removable gland plates shall be provided for power and control cables. The gland plates shall be 3mm thick.The
gland plates for single core cables shall be of non-magnetic material.
All sheet steel work shall be thoroughly cleaned of rust, scale, oil, grease, dirt and swarf by pickling, emulsion
cleaning etc. Nano-ceramic coating Bonderite NT-1 (replacing the commonly used phosphating process) should be
applied by High-pressure jets. This is used to achieve better long term protection of enclosures and ensuring an
eco-friendly result, which acts as a corrosion protection and provides an excellent base for powder coating. This
coating is environment-friendly as it is Phosphorous- and COD/BOD- free with no regulated or toxic heavy metals
(Fe & Zn Remnants in phosphating) and has very good quality aspects like high performance better
Forming properties after painting. There is no chipping thereafter since the nano-ceramic layer is less brittle than
phosphates and the coat.After that Electrophoretic Dip-coating, the parts on the conveyor after pre-treatment, are
immersed in a liquid bath containing a special EC paint as solid particles mixed with de-mineralized and ozonized
(bacteria-free) water. The paint is then electrolytically applied on the entire metal surface
Immersed in the bath. This process is termed as electro-phoresis . Formation of an even layer on all surfaces,
edges and cavities is ensured with this process creating a high degree of corrosion protection. The coating is
approximately 20 +/- 5 microns thick. On this surface over-painting is possible .The EC coating is free from any
heavy metals, chromates and silicone thereby ensuring that RoHS standards compliance is achieved of finished
synthetic enamel oven baked/stoved, paint shall be applied or powder coated. Each switchgear cubicle shall be
fitted with a label in the front and back of the cubicle. Each switchgear shall also be fitted with label indicating the
switchgear designation, rating and duty. Each relay, instrument, switch, fuse and other devices shall be provided
with separate labels. Operating devices shall be incorporated only in the front of the switchgear. No equipment
needing manual operation shall be located less than 250 mm above ground level.

The switchgear shall be divided into distinct vertical sections comprising of-
i. Individual feeder module which shall be integral multiples of basic module, containing all associated
equipment, enclosed in sheet steel enclosure on all sides and the rear except cable alley side and provided with
hinged door on the front.
ii. A completely metal enclosed, bus bar compartment running horizontally and a vertical bus bar
compartment serving all modules in vertical section.
iii. A vertical cable alley covering the entire height, except horizontal bus bar compartment with minimum
300 mm width for MCC modules and circuit breaker controlled modules, with adequate number of slotted cable
support arms.
iv. A horizontal separate enclosure or enclosures separated by Metallic sheets for power and control
buses with tap off connections to each vertical section.
v. For operator safety IP2X protection to be available even after opening of feeder compartment door
compartment to be used using metallic separator/Poly carbonate. Hylem& PVC shall not be used anywhere.
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The circuit breakers shall be fully draw out type. The circuit breakers shall have distinct service, test, isolated and
maintenance positions. In the test position the circuit breakers shall be capable of being tested for operation
without energising the power circuits. Four normally open auxiliary contacts shall be provided for each of the
services and test limit positions switches.
The test position should preferably be obtained without the need to disconnect normal control connections and use
extension cords for testing.

CUIM/TEN/UTL/09 LT Panel R5
For outgoing feeders ratings shall be as defined in the SLD.
The current transformers shall be mounted on the fixed portion of the switchgear but not directly on buses or the
breaker truck.
The draw-out contacts shall be made of copper/ copper alloy/aluminium faces, which shall be silver or tinplated.
If ventilating louvers are provided they shall be provided with fine-screened brass or GI meshes from inside to
prevent entry of vermin and dust.
Every vertical of a LT panel shall have rat catcher (glue pad) in cable compartment, cable alley or wherever
required inside LT panel. Rat catcher will be non-billable item. LT switch board shall be ready with
Ethernet(TCP/IP) communication i.e. Switchgears (ACB & MCCB) status (On/Off & Trip) and Multi-function meters
(MFM) parameters shall be readily available on Ethernet communication inside the LT Panel at EMS/SCADA level
In case of ACB/MCCB with communication port, the release metering data shall be available on ethernet
communication. Panel builder shall include all necessary hardwares in their scope to make LT panel ethernet
ready and submit communication test report during panel testing at shop floor. Communication hardwares should
be plug & play, non PLC type, with no programming requirement, with built-in web pages and only EMC/EMI
certified to be installed in electrical panels.
Communication architecture shall be tested & verified at panel builder premises and approved by switchgear
manufacture.
Load Managers (Multifunction meters) shall have LCD display and be provided for measurement Class 1 accuracy
IEC 62053-22 & metering of voltage, current, power, demand, energy (active, reactive,apparent), THD and
individual harmonics (up to 15th level harmonics as per IEC 61557-12 ), % unbalance, active load timer, meter
operation timer, run hours.Meter shall have high sampling rate of 64 samples per cycle.Test LED at the front panel
for test and calibration of the meter at site. Heart beat LED indicates the normal functioning of the meter and
communication status if connected to RS485 network.

Module Types
The various types of modules/feeders shall be as defined in the SLD.
Main and Auxiliary Buses
Busbars shall be of uniform cross section throughout the length of the switchgear, and upto the incoming terminals of
the incoming feeder circuit breaker/ switch.
All busbars, shall be insulated with close fitting sleeve, all bus taps, joints shall be insulated with moulded caps. If
insulating sleeve is not coloured, busbars shall be colour coded with coloured bands at suitable intervals.
Busbars shall be adequately supported on insulators. These shall withstand dynamic stresses due to short circuit
currents specified.
Busbars shall be of aluminium. They shall be provided with minimum clearances as per IEC standards and panels
supported by impulse voltages (12 KV) withstand test results. Panel shall be internal arc tested as per IEC 61641
65 KA for 0.4 second. Main Bus shall be installed on top horizontal bus.
Auxiliary Buses
Auxiliary buses for control power supply, space heater power supply or any other specified service shall be provided.
These buses shall be insulated, adequately supported and sized to suit specific requirements. The material of control
power supply buses shall be electrolytic copper. The material for space heater power supply buses shall be same as
that for the main power buses. Supply transformer(s), auxiliary busbars and necessary connections to the supply
transformers and associated circuits shall be in the CONTRACTOR'S scope.
Safety Interlocks and Features
Withdrawal or engagement of circuit breakers or switch (isolator) shall not be possible unless it is in the open
position.
Operation of circuit breaker shall not be possible unless it is fully in service positions or in test position or is fully
drawn out.
Circuit breaker cubicles shall be provided with safety shutters operated automatically by the movement of the circuit
breaker carriage, to cover the exposed live parts when the breaker is withdrawn.
Caution name plate with inscription "Caution - Live Terminals" shall be provided at all points where the terminals are
likely to remain live and isolation is possible only at remote end, e.g. incoming terminals.
A breaker of given rating shall be prevented from engaging with a stationery element of higher rating.
b. Circuit Breakers
Draw-Out Air Circuit Breakers (ACBs)
The incoming air circuit breaker (ACB) of the 415V switchgear shall be four (4) pole, electrically operated draw out
i.e. EDO type. They will be sized to cater for full rating of the transformer and designed short circuit level.
ACB’s of PCC feeders shall be 4P type EDO with microprocessor/EMD based overload, short circuit, earth fault
releases (Ics=Icu=Icw rating).( (Ics for 1 second)
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Circuit breakers shall be suitable for switching duty as per the Standard.
Circuit breaker along with its operating mechanism shall mounted on a wheeled carriage moving on guides, designed
to align correctly and allow easy movement.
There shall be ‘Service’, ‘Test’ and ‘Fully withdrawn’ positions for the breakers. In the ‘Test’ position, the circuit
breaker shall be capable of being tested for operation without energizing the power circuits i.e. the control circuits
shall remain undisturbed while the power contacts shall remain disconnected. Separate limit switches, each having a
CUIM/TEN/UTL/09 LT Panel R5
minimum of 2 ‘NO’ + 2 ‘NC’ contacts, shall be provided for both ‘Service’ and ‘Test’ positions of the circuit breakers for
Employer’s use. These contacts shall be rated for 10 amps, 230V AC and 10 amps (inductive breaking) at 30V DC.
Connection of the control / interlocking circuits between the fixed portion of the cubicle and the breaker carriage shall
be preferably by means of plug socket arrangement.
Self aligning disconnects shall have adequate number of contacts to meet the requirements of control and
interlocking scheme. Contact between the fixed and moving parts of the disconnects shall be established to enable
testing of breaker outside panel.
Plug and socket arrangement when provided shall have adequate number of pins to meet the requirements of
control and interlocking scheme. The plug and socket arrangement shall be so designed that it shall be possible to
insert the plug in the socket in one position only, thereby eliminating the possibility of faulty insertion and wiring. The
plug, after insertion, shall be secured in position by spring clamps, which need considerable force to operate. The
length of the plug chord will be such that the plug can be inserted into the socket only when the breaker is pushed
into the test position. Suitable interlock will be provided to permit further pushing of the breaker only if the plug is
inserted correctly into the socket. It shall not be possible to remove the plug when the breaker is in service position
and it shall be necessary to withdraw the plug from the socket before the breaker can be pulled out from the test
position to fully withdrawn position. 63 A and above all rating must be considered as MCCB with LSIG protection.
Switchgear shall be provided with testing facilities to test the operation of circuit breaker. A separate test position of
the breaker shall be provided in the cubicle / module.

Circuit Breakers shall be provided with following accessories


Accessories as per OEM standard.
Mechanically operated targets to show 'Open', 'Closed', 'Service' and 'Test' positions of the circuit breaker.
Mechanically operated, red 'trip' push button, shrouded to prevent accidental operation.
Locking facilities in the 'Service', 'Test', and 'Isolated' positions. In test position the breaker will be tested without
energising the power circuits. The breaker shall remain fully housed inside the compartment in the test position.
Minimum 6 NO and 6 NC potential free auxiliary contacts, rated 10 A at 240V A.C. and 1A (inductive breaking at 220
V D.C.).
'Red', 'green' and 'amber' indicating lamps to show 'Closed' 'Open', and 'Auto-trip' conditions of the circuit breaker
when breaker operation is controlled by a control switch.
Closing and trip coil shall operate satisfactorily under the following conditions of supply voltage variation:
i. Closing coils - 85% to 110% of rated voltage.
ii. Trip coils - 70% to 110% of rated voltage.
When series trip circuit breakers are specified the following releases with adjustable settings shall be provided: (Oil
dash-pot type release is not acceptable):
i. Overload
ii. Short circuit
iii. Instantaneous
iv. Earth Fault
ACB Trip release features:

ACBs release shall have LCD display with Phase currents and voltages (running, average & max) and energy
parameters, It should be possible to store tripping history of last eight faults and the type of fault with values.
Release shall have percentage bar graph to show percentage loading of each phase.
The control unit shall have thermal memory throughout the range to store temperature rise data in case of
repetitive overload or earth fault for protecting the cables and loads.ACB release have individual fault indication of
Overload short ckt and earth fault.
All ACBs ON/OFF/Trip status and no. of operation counter of each ACB shall be available on ethernet
communication inside panel.
All ACBs should have built in Zone selective interlocking (ZSI) for logic discrimination to reduce
thermal/electrodynamics stresses in the event of short circuit and earth fault.
ACB shall have following protection setting options, as standard;
 Adjustable over load current (Ir) settings
 Over load time setting (tr) as field selectable curves.
 Short circuit setting (Isd) with adjustable Ir setting,
 Short circuit time delay adjustability
 Instantaneous (Ii) protection with an adjustable pick-up and an OFF position.
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 Earth fault setting adjustable in absolute Ampere with time delay settings

Incomer shall have additional feature as follows.


Main LT panel incomer ACBs trip release shall have additional information i.e. & power parameters (active, reactive
and apparent, power factor, power demand).
CUIM/TEN/UTL/09 LT Panel R5
Incomer ACB shall have additional protection/alarm of minimum & maximum voltage and frequency, voltage and
current imbalance, phase sequence, reverse power.
Incomer ACB shall have …
 Local 96X96 external display module /HMI shall be provided on the panel door which should have
following features.
 Display unit shall be connected to a release communication port and display required data by using
sensors & processed data at trip release
 Connection should be easy to use and requires no special software or settings. It is immediately
operational when connected to the COM option
 CT free distribution panels
 Analog, digital, bar graph metering (A, V, KW, Kwh, kVar, Power factor) for individual phases
 Load profile of individual ACB
 Remote/Local control option and status for ACB
 Local display of ACB trips and alarms history with date and time stamping

In addition to the adjustable current setting range, short circuit releases shall be provided with at least four adjustable
time delay settings, If it is not possible to provide the specified adjustable current setting range for the short circuit
releases, shunt trip circuit breakers together with necessary protective relays shall be offered by the CONTRACTOR.
Each of the foregoing releases shall be provided with a single pole, double throw, and potential free alarm contact
rated for 0.5A, 220V D.C.
The breakers controlling motors shall operate satisfactorily under following conditions:
i. Direct-on-line starting of the specified motor.
ii. Breaking no load current of the specified motor.
iii. Operatable manually from outside without opening main door.
Spring Operated Mechanism
The operating mechanism shall be manually operated spring charging stored energy type or with motor, opening and
closing springs, limit switches for automatic charging and all necessary accessories. Facility for manual charging of
the closing spring shall be provided. The operating mechanism shall be trip-free and non-pumping electrically. An
antipumping relay to achieve electrical anti-pumping feature even if the breaker has provision for anti-pumping by
mechanical arrangement.
Power operated mechanism shall be:
Provided with facilities for remote panel closing and opening operations whenever required.
The control scheme will be as follows for remote control:
S. No. Breaker Position Service Test
Selector Switch Local Remote Local Remote
1.0 Switchgear Protection Tripping Yes Yes Yes Yes
2.0 Remote Interlock Tripping Yes Yes - -
3.0 Switchgear Manual Closing Yes - Yes -
4.0 Remote and Auto Closing through - Yes - Yes
Interlocks
5.0 Switchgear Manual Tripping Yes Yes Yes Yes
6.0 Remote Manual Tripping Yes Yes Yes Yes
7.0 Local P.B. Station of Motor (For breaker operated motors):
a) Closing for trial run Yes - - -
b) Tripping Yes Yes Yes Yes
Power operating mechanisms shall be provided with the following additional features:
i. Closing of the circuit breaker shall automatically initiate recharging of the spring ready for the next
closing stroke.
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ii. The motor shall be mechanically decoupled as soon as the emergency manual charging handle is
coupled.
c. Protection Coordination

CUIM/TEN/UTL/09 LT Panel R5
It shall be the responsibility of the Contractor to fully coordinate the overload and short circuit tripping of the circuit
breakers with the upstream and downstream circuit breakers/fuses/motor starters, to provide satisfactory
discrimination.
d. Motor Starters (If Required)
CONTACTORS
Motor starter contactor shall be of the electromagnetic type rated for uninterrupted duty and overload relays shall be
of electronic type.
Operating coils of contactors shall be suitable for operation on 230/100 V, single phase and 50 Hz suppl as indicated
in the SLD.
Class of coordination for starter module shall be class '2' as per IS-13947.
Direct-On-Line Starters
Direct-on-line starters shall be suitable for Class AC 3 utilization category as specified in applicable standards.
Automatic Star-Delta Starters
Automatic star-delta starters shall comprise three sets of contactors one for the line, one for the star point and one for
the delta, and a timer to automatically change the connections from star to delta.
Star-delta contactors shall be electrically interlocked to permit starting of the motor in the proper sequence, namely
star contactor closing, line contactor closing, timer energised after time delay, timer contact de-energising the star
contactor, and delta contactor closing.
Star-delta starters shall be suitable for AC 3 utilisation category as specified in applicable standards.
Thermal Overload Relays
Starters shall be complete with a three element, positive acting, ambient temperature compensated, time lagged
thermal overload relay with adjustable settings and built in single phasing preventer. The setting range shall be
properly selected in accordance with the rating of the motor.
Electronic overload relays shall be hand reset type,
'Stop' push button of the starter and hand reset device shall be separate from each other.
Overload relay hand reset push button shall be brought out on the front of the compartment door.
Switch And Contactor Ratings
Switch and contactor rating for various motor starter modules shall be selected by the Contractor and indicated in the
bid. as per type-2 co-ordination of OEM
Moulded Case Circuit Breakers
Moulded case circuit breakers (MCCBs) shall be provided as indicated in the SLD with defeat interlock with ROM.
The MCCBs shall conform to the latest applicable standards. All MCCB shall have spider links for termination of
aluminium cables.
MCCBs of LT panel shall be of four pole construction with microprocessor for 100A and above /EMD based overload,
short circuit and earth fault releases (Ics=Icu rating) for below 100A arranged for simultaneous four pole manual
closing and opening. power closing device for remote operation shall be provided. Operating mechanism shall be
quick-make, quick-break and trip-free type. The ON, OFF and TRIP positions of the MCCB shall be clearly indicated
and visible to the operator. Operating handle for operating MCCBs from door of board shall be provided.
The instantaneous short circuit release shall be so chosen by the CONTRACTOR as to operate at a current in
excess of the peak motor inrush current and a range of settings shall be provided for the PURCHASER'S selection.
MCCB terminals shall be shrouded and designed to receive cable lugs for cable sizes relevant to circuit ratings.
There should be total discrimination and co-ordination between upstream and downstream switchgear & protection
on devices i.e. ACBs, MCCBs ,MCBs etc. up to the service breaking capacity level as per IS/IEC-60947-2 for better
continuity of supply and fault localization. Manufacturer must provide both the discrimination tables ,let through
energy curves and report of all panels alongwith setting during technical evaluations, To achieve total discrimination
any change required in switchgear rating shall be considered by vendor without any additional price implication.

Miniature Circuit Breakers


Miniature circuit breakers for use on motor space heater control circuits shall comply with the requirements of
applicable standards, MCB shall be of the thermal and magnetic tripping type and shall comply with IEC 60898.
MCB shall be hand operated, air break, quick make, quick break type.
Operating mechanisms shall be mechanically trip-free from the operating knob to prevent the contacts being held
closed under overload or short-circuit conditions.
Each pole shall be fitted with a bi-metallic element for overload protection and a magnetic element for short-circuit
protection. Multiple pole MCBs shall be mechanically linked such that tripping of one pole simultaneously trips all the
other poles.
The short circuit rating shall not be less than 10kA.
e. Instrument Transformers
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The ratings of instrument transformers indicated in the SLD is tentative and Contractor shall workout the VA burden
based on system requirement. The CONTRACTOR shall ensure that the specified ratings are adequate for the
relays and meters furnished by him. If specified ratings are not adequate the CONTRACTOR shall offer instrument
transformers of required rating without additional cost.
The CTs and VTs shall be dry type and withstand momentary and short time current ratings of the associated
switchgear. For feeders with fuse, CTs shall have withstand capacity equal to let-through current of associated fuse.
CUIM/TEN/UTL/09 LT Panel R5
Unless otherwise specified minimum performance requirements of CT's & PTs shall be as follows.
Current Transformers
Measuring CTs - 10VA/15VA, accuracy Class 0.5 and ISF of 5 Protective CTs - 10 VA, accuracy class of 5P-20. CTs
rating shall be as per approved SLD. CTs shall be provided with test links in both secondary leads for carrying out
current and phase angle measurement.
Potential Transformer
The rating and class of accuracy shall be as indicated in the SLD.
Potential transformer shall have continuous over voltage factor of 1.2 and short time over voltage factor of 1.5 for 30
seconds for effectively earthed system and 1.9 for 8 hours for non-effectively earthed system.
Potential transformers shall be complete with suitable rated primary, secondary and tertiary fuses. Primary fuses
shall have a rupturing capacity equal to the rupturing capacity rating of the associated switchgear. Fuses shall be
provided on each sub circuit.
It shall be possible to replace voltage transformers without having to de-energise the main bus bars.
The terminals of P.T. secondary and tertiary windings which are required to be connected to earth shall be earthed by
an isolating link without a fuse.
f. Switchgear Accessories and Wiring
Switchgear shall be supplied completely wired internally upto terminal blocks ready for the PURCHASER's external
cable connections at the terminal blocks. Inter panel wiring between cubicles of same switchgear shall be routed
inside by the CONTRACTOR.
All auxiliary wiring shall be carried out with 1100 volts grade, single core, stranded copper conductor with PVC
insulation. The sizes of wire shall be not less than 2.5 mm² per lead of CT circuits and 1.5 mm² per lead of other
circuits.
Terminal blocks shall be of stud type, 1100 volts grade, 10 amps. rated complete with insulated barriers. Terminal
blocks for CTs and PTs shall be provided with test links and isolating facilities and CT terminals shall have short
circuiting and earthing facility.
All spare contacts and terminals of cubicle mounted equipment and devices shall be wired to terminal blocks.
Accuracy class for indicating instruments shall be 2.0 or better. Instruments shall be 96 mm square 90° scale for
semi-flush mounting with only flanges projecting.
Relays shall be suitable for semi-flush mounting with only flanges projecting.
The earth fault protection shall be provided with the use of Z-CT, ELR & shunt trip coil as indicated in the SLD.
All protective relays shall be in draw-out cases with built-in test facilities. Necessary test plugs shall be supplied loose
and shall be included in the CONTRACTOR'S scope of supply. All auxiliary relays and timers shall be supplied in
non-draw-out cases. All relays shall be of self reset type except lockout relay unless otherwise specified. Externally
operated hand reset flag indicators shall be provided on all relays and timers. Timers shall be of electromagnetic or
electronic type only.
Control and instrument switches shall be rotary type provided with escutcheon plates clearly marked to show
operating position and suitable for semi flush mounting with only switch front plate and operating handle projecting
out.
Breaker control switches shall be pistol grip black and selector switches shall be oval or knob, black. Breaker control
switches shall be 3 position spring return to neutral. Instruments selector switches shall be of the maintained stay-put
type. Contacts of the switches shall be spring assisted and contact faces shall be with rivets of pure silver. The
contact ratings shall be adequate to meet the requirements of circuit capacity in which they are used.
Push buttons shall be provided wherever specified. They shall be provided with inscription plates engraved with their
functions. Push buttons shall be rated for 10A at 240 AC and 10A at 220 VDC, with 2 NO and 2NC contacts. Start PB
shall be green in colour and stop PB shall be red coloured stay put type.
Indicating lamps shall be Cluster type LEDS. MCCB feeder shall use A/C power supply for indication
Space heaters of adequate capacity shall be provided inside each panel. They shall be suitable for 240 V, 1 ph, 50
cycles supply. They shall be complete with MCB , isolating switches and adjustable thermostat. Space heater shall
be controlled through humidity control switch.
Each switchgear panel shall be provided with 240 Volts, 1 phase. 50 cycles, 5 amps. 3 pin receptacle with switch
located in a convenient position.
The single phasing preventer relay shall be provided in all-star delta feeders.
i. Operate for supply voltage unbalance of more than + 5% and when relay internal wiring is open circuited.
ii. Not operate for 3 ph supply failure.
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iii. Instantaneous hand reset type


iv. Visual indication for operation
v. Suitable for reversible and non-reversible motors
Transformers For Control, Space Heating And Annunciator Supplies

CUIM/TEN/UTL/09 LT Panel R5
Adequately rated single phase, two winding, dry type transformers shall be provided for providing supply to the
switchgear control and alarm circuits, space heaters provided in plant equipment and space heaters in the
switchgear.
All transformers of 500 VA and above shall be controlled by MCBs/ switches on the primary and secondary side.
Common control transformer shall have fuses on all line leads of each winding and control transformer in individual
module shall have fuse in the line lead of only secondary winding. The fuses shall be of proper rating to protect the
control transformers against over loads and short circuits. The neutral or the earth lead shall have earth link instead
of fuses.
Window Type Alarm Annunciator
The alarm annunciator shall consist of flush mounted facia and shall have following features:-
Fault indication by steady lit window
Audible alarm on fault occurrence
Acknowledgement, resetting and test
Suitable for NC/NO initiating contacts
Facility for separate audio visual alarm on control supply failure
The alarm annunciator scheme operation shall be as follows:
Visual Audible
Alarm Alarm
-----------------------
Normal OFF OFF
On occurrence of fault -
First fault Flashing ON
Subsequent faults Flashing ON

Accept fault -
First faults Steady OFF
Subsequent faults Steady OFF
Reset - Faults cleared OFF OFF
Faults not cleared Steady OFF
Lamp test Steady OFF
g. Cable/Bus Duct Termination
Incomers of LV switchboard shall be suitable for cable/bus duct connection. Glands shall be of heavy duty brass
castings, machine finished and complete with check nut, washers, neoprene compression ring etc. The lugs shall be
tinned copper/aluminum depending on cable conductor and of solder less crimping type. Bimetal shall be used
whenever copper and aluminum connect.
h. Local Push Button Stations
The local P.B. stations shall be metal enclosed, provided with IP-55 protection, and made up of diecast aluminium or
2 mm thick sheet metal.
The P.B. station shall be suitable for wall or structure mounting, provided with lables, earthing terminals, suitable lugs
glands.
Push buttons shall be fitted with 2 NO and 2NC contacts (10A at 220V DC and 10A at 240V AC) with stop PB of stay
put type and red in colour. Other PB's shall be green in colour.
PB station shall be of one of the following types
Type A - Three PB's forward-reverse-Stop for reversible motors
Type B - Two PB's start-stop for non-reversible motors
Type C - One PB STOP for emergency
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i. LT Panel
The 415 V LT Panel will be 3-phase, 4 wire, free standing/ floor mounted, modular, rear/ front access, switchboards
shall be modular construction type Symmetrical, welded frame construction, consisting of single sheet folded
construction with punched on a 25mm DIN pitch pattern. All profiles with rounded edges,Horizontal sections,
vertical sections with fixing levels for space saving interiors installation and should be welded at corner . The
CUIM/TEN/UTL/09 LT Panel R5
switchboards and the associated equipment including switchgear, control gear, Bus bar supports, Bus bar
orientation, Bus bar links etc. shall be identical in construction to the assembly. metal enclosed design and shall
have compartmentalized construction. All modules except air circuit breakers on the switchgear will be non-draw out
fixed type. The panels shall be of sealed version and vermin, corrosion, dust & damp proof with degree of protection
IP54. The cable entry shall be from top or Bottom .
The PCC will feed the shop distribution boards in the production/ shop area & utilities like Ventilation and Lighting
through 1100V grade Bus ducts/Sandwich Bus Trunking/ cables run overhead/ underground trenches. The
connections to individual machine control panels will be derived from these shop distribution boards.
Load Managers will be provided for LT Panel incomer and outgoing feeders as indicated in the SLD and the same
shall be integrated with energy management system through SCADA..
Entire 415V power system will be fuse less type. For all shop distribution boards incomer ACB’s shall be TPN EDO
and microprocessor based O/C, S/C & E/F releases (Ics=Icu=Icw rating). Outgoing ACB’s shall be TPN MDO and
static O/C, S/C & E/F releases (Ics=Icu=Icw rating).
For all manufacturing equipment, power supply will be given up to the power panel of equipment/ system. Further
engineering shall be in the scope of equipment/ system Contractor.
j. Bimetal Strip
Bimetal strip sections shall be used where different metals need to be connected for example connection of Cu and
Al joints.
1. Bimetal strip shall be made up of Copper (Sheet metal) clad on pure Aluminum (Base metal).
2. Composition- 70:30 (70% Aluminium and 30% copper)
3. Thickness- 2 mm
4. Bimetallic strip shall be fire proof and resistant to chemicals.
5. It shall be installed at places-
 It will be installed at Bus duct and transformer connection, bus duct and LT panel connection where Cu
flexible shall be connected with Aluminium bus bar.
 Sandwich Bus Trunking and Panel connection
 For lugs above 25sq mm connected with different metal.
This item will be part of end termination and will not be billable item.
k. Label
Suitable size Legend plate shall be provided for the name of panle and all other lights switch and devices
on the Panel door. The Legend plate shall be White Acrylic with Engraved black letters. Below are the items which
shall be mentioned-
LT Panel Name
Each outgoing feeders
Danger plate
SLD strip on front of LT panel (Mimic)
Cable alley
Relay, meter, indication lamp, switches and all installed items on door
4.0 Earthing
Equipment earthing shall be provided at the bottom and extended throughout the length of the Panel. shall be
bolted to the frame work. All non-current carrying metal work of the Panel shall be effectively
bonded to the earth bus. Hinged doors shall be earthed through flexible earthing braid. Each panel shall be
provided with double earthing.
For all equipment earthing with suitable size strip or wire shall be done at two locations.
The earthing for equipment shall have to be connected to nearest earth pit or nearest Earth Grid.
The Earthing for equipment shall be in the scope of Contractor. However in case a separate unit rate item
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is available in the Bill of Quantities than it shall be payable as per unit rates of Bill of Quantity.
5.0 Cables & Cable Trays
The interconnection of the DC System and panels shall be done by the Contractor.

CUIM/TEN/UTL/09 LT Panel R5
The Electrical Cable and cable trays for the same are in the scope of Contractor. However in case a separate unit
rate item is available in the Bill of Quantities than it shall be payable as per unit rates of Bill of Quantity.
6.0 Painting
PAINT PROCESS
The components are loaded on a Wagon of a Power & Free Conveyor System continuously moving at a pre-
determined speed of 5.0 meters/minute. No Manual handling takes place after the loading station right till the
unloading station. The whole process is designed for energy efficient and low effluent causing operation with
maximum recycling of chemicals.

Loading of Component -
Enclosures, Flat parts (Doors, Rear Panels, Top & Bottom Covers, Gland Plates, Side Panels etc.), Compact
Enclosures (AE, KL, EB, etc. range) are loaded at this stage. All sheet Steels used are of CRCA “D” Grade /
Galvanized, which have a protective layer of anti-rust oil solution. The components during the loading are checked
for any rust or scaling Marks. Simple marks are first removed by emery before the parts travel to the pretreatment
tunnel.
Pre-treatment Stage - I
In this zone, all the oil, grease and foreign impurities are cleaned by high-pressure (2 bar) warm (50°C)
multidirectional jets using a chemical, which is mixture of Alkali Mono Metal (degreaser), activators and surface-
active agents. The jets impinge the components, which are fully cleaned of oil, grease and any other impurities due
to dynamic force.
Pretreatment Stage - II
This is done in different stages using water jets, which flush down all chemicals from stage -I on the surface or the
edges. The high pressure jetting technique ensures that no Sediments settle at the corners or curves of the
components.
Pretreatment Stage - III
This is done in different stages using fresh DM water jets, which flush down all chemicals from stage - II on the
surface or the edges. The high pressure jetting technique Ensures that no sediments settle at the corners or curves
of the components. No carryover
of previous stage chemicals to next stage.
Pretreatment Stage - IV
Here the components are uniformly coated with a special Nano-ceramic coating Bonderite NT-1 (replacing the
commonly used phosphate process) applied by High-pressure jets. This technology is used to achieve better long
term protection of enclosures and ensuring an eco-friendly result, which acts as a corrosion protection and
Provides an excellent base for powder coating. This coating is environment-friendly as it is Phosphorous- and
COD/BOD- free with no regulated or toxic heavy metals (Fe & Zn Remnants in phosphate) and has very good
quality aspects like high performance better forming properties after painting. There is no chipping thereafter since
the nano-ceramic layer is less brittle than phosphates and the coat
Pretreatment Stage - V
This is done in different stages using water jets, which flush down all dissolved salts on the surface or the edges.
The high pressure jetting technique ensures that no sediments Settle at the corners or curves of the components.
Pretreatment Stage - VI
In this final pre-treatment stage fresh de-mineral water jets are used which acts as a passivation and frees the
surface of any residual salts etc. which can cause creepage corrosion later. The whole pre-treatment process
provides the excellent base for the subsequent coatings which follow.
Electrophoretic Dip-coating
In this process, the parts on the conveyor after pre-treatment, are immersed in a liquid bath containing a special
EC paint as solid particles mixed with de-mineralized and ozonized (bacteria-free) water. The paint is then
electrolytically applied on the entire metal surface immersed in the bath. This process is termed as electro-phoresis
Formation of an even layer on all surfaces, edges and cavities is ensured with this process creating a high degree
of corrosion protection. The coating is approximately 20 +/- 5 microns thick. On this surface over-painting is
possible .The EC coating is free from any heavy metals, chromates and silicone thereby ensuring that RoHS
standards compliance is achieved.
Baking
The dip-coated component is then sent through an oven for baking at 180ºC for 10 minutes thereby achieving the
required coating thickness. This EC coating is highly corrosion resistant as well as has very good inherent
mechanical properties. This process is only used by Rittal amongst enclosure manufacturers. EC dip coating is the
commonly used painting process in the automobile industry where automobiles are required to stand outdoors all
the time. Although EC coating by itself is good, Rittal uses this layer as a primer for the final powder coating for the
external surfaces of the enclosures. The ovens use an automatic burner system set for LPG gas which is used as
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the fuel because it has a high calorific value and is very environment-friendly due to the very low emissions after
combustion. An automatic and accurate oven-temperature control is provided by controlling the gas flow in
the burner system.
Powder Coating
After EC dip coating and baking the conveyor with the parts can move into either of two automatic powder coating
booths. The Automatic booth 1 has powder-spraying guns to spray the positively charged powder on to the
CUIM/TEN/UTL/09 LT Panel R5
component, which is at ground potential. The guns have the facility of adjusting their distance from the object as
well as the spray velocity to control the thickness of the coating. The automatic spray mechanism ensures that the
paint thickness, texture and gloss level on the component are uniform. The second Automatic booth 2 is similar as
the first one but is used for special, customer Specific colors. The wagons are double-sided and carry the flat-parts
such as doors, side panels etc .Vertically on the conveyor throughout the entire pre-treatment, EC dip-coating and
powder Coating processes.
Baking
The powder-coated components are then finally sent for oven baking at 180ºC for 10 minutes and achieved a
required coating thickness in Microns. This oven is also similar to the EC oven described earlier. Powder coating
ensures high mechanical strength, very good corrosion protection and good resistance to contact with Mineral oils,
Lubricants, Machining emulsions, Temporary cleaning solvents, weak acids and alkalis etc. The powder
Coating also ensures good resistance to temperature variations and all types of weather. The coating is
approximately 80 microns thick. The overall thickness thus achieved in Rittal's painting process is approximately
100 microns.
Coating thickness on different parts:
Frames: 20 +/- 5 microns
Flat parts - Inner surface: 20 +/- 5 microns additionally with wrap around powder from. Flat parts - Outer surface:
Average 90 microns additionally with wrap around powder
from.
An equivalent paint process shall be applicable provided the unpainted structure and flat
7.0 parts has to be treated with galvanization prior to paint. The solvent being used at all Switchgear shall
be dust and vermin-proof. The color shade shall be RAL9003.

8.0 Tests and Certificate


All meters and other reference devices used for testing shall have valid calibration Certificate traceable to reputed
national laboratories/institutes. Inspection by Purchaser/Engineer will not be carried out unless the Contractor
confirms that such calibrated equipment are ready for proceeding with the tests.
Instruments and gauges to be used for testing and inspection of critical parameters as identified in the specification
shall have valid calibration and the accuracy traced to national standards.
The CONTRACTOR shall completely assemble install all the associated equipment including brought out items
mounted and wired and test each cubicle as per relevant standards.
Routine tests shall be carried out on completely assembled equipment as per relevant standards.
Functional tests shall be carried out to demonstrate the specified control and interlocks.
Copies of the test certificates for all brought out items shall be submitted for the PURCHASER’S approval before
dispatch of the switchgear. Bound copies of complete test results as specified in the distribution schedule shall be
furnished with the switchgear. These shall include complete reports and results of the routine tests as also certified
copies of type tests carried out on equipment of identical design.
The following routine tests shall be conducted at Contractor’s works.
a. Visual checks for dimensions and general arrangement.
b. Wiring checks.
c. Functional checks.
d. Voltage regulations for rated input supply for loads from 0-100%.
e. Load test to show the charger can deliver the rated duty without the
f. current limiter device operating.
g. Calibration of potentiometer vis-à-vis the DC output for float/boost
h. chargers.
i. Ripple measurement by oscilloscope at different loads.
j. Demonstration of guaranteed efficiency and power factor.
k. Insulation test (with 500 V megger)
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9.0 Drawings Required


The following shall be furnished as part of the tender:
a. General arrangement showing plan, elevation and typical sectional views.
b. Foundation plan showing location of fixing channels, floor openings etc.

CUIM/TEN/UTL/09 LT Panel R5
c. Schematic wiring drawings for each cubicle.
d. Technical literature on the equipment offered.
e. All drawings and data sheets shall be annotated in English.
f. Quality Assurance Plan.
10.0 DATA SHEET
DESCRIPTION DATA

Type Form-3B, Compartmentalize enclosure (Rittal)

Nominal Service Voltage : 415 V


Rated voltage class 1.1KV
Rated Frequency 50 Hz
Type of system: 3 Phase, 4 wire

Cable gland with external PVC hood Shall be integral part of panel

Cable entry/exit TOP


CT wiring 2.5 Sq.mm
Control wiring 1.5 Sq.mm
Control Supply 24V DC
No of pole in switchgear 4 Pole

Type of protection in the incomer As per SLD

Earth leakage minimum setting As per SLD


Horizontal earthing bus bar with multiple holes Required.
and extension in both side of panel for external
earthing connectivity

Modular construction
Make of panel Compartmentalized & Form 2B,3B or 4B
(Rittal –Ri -4 power ,Schneider, ABB )
Paint shade of enclosure RAL-9003 Textured finish

Dedicated control bus bar Required with segregation from main bus bar.

MFM (All MFM shall have data logging facility of


Metering in incomer and out goings all peak values and shall have communication
port)
Type of indication Clustrised LED
Auto/Manual , Local/Remote(Applicable for
Selector switch in each feeder
starter feeders)
Local/Remote, Auto/Manual selector switch,
Indication, metering ,selector switch, Push VSS, ASS, On/Off/Trip LED indication,
button in outgoing feeder Emergency trip push button, ON pushbutton.
(Applicable for starter feeders)

Rotary handle with defeat interlocking


Required
arrangement in each feeder
Page9

Drawing Pocket in the panel door of incomer Required

Acrylic sheet shroud for bus bar Required


Maximum height of panel 2200 mm

CUIM/TEN/UTL/09 LT Panel R5
height of integral base frame 100 mm
Terminal blocks Stud type non PVC
Type of Lug Ring type copper
Bus bar links Applicable for above 4 Sq mm of cable
Electronic operated motor protection relay Applicable for all motor starter feeders

% of empty feeders with switchgear As per SLD


Short time rating As per SLD
Type of Cooling Natural Air
Type of starter As per SLD
Control Terminals for future interlocks, LCS
Required.
connectivity and PLC integration
Centralized Marshalling Chamber to integrate
Required.
with RTU
Space for installation of RTU near Marshalling
Required.
Chamber with dedicated compartment
High Conductivity Electrolytic Grade E91E
Bus bar MOC
Aluminum

Type of CT Cast resin


Type of insulator supports SMC
Thickness of load bearing members 2.5 mm
Thickness of doors and partition sheets 1.6 mm
Thickness of paint (powder coated) 80 Microns
Thickness of gland plate 3 mm
7-9 Tank process + Nano coating +EC dip
Painting process
Coat+ Powder quoting
Current density of bus bar in bus duct 0.7A/Sq.mm
Current density of bus bar in PCC 0.7A/Sq.mm
Current density of bus bar in PDB 0.7A /Sq.mm
Type of construction Modular double front
IP-52 or 54 for indoor and IP-55 with double
IP protection
door for outdoor (Pure Polyester powder )
Space heaters Required in each cable alley
Required for each breaker compartment (Along
Forced ventilation in ACB feeder
with force ventilation calculation sheet )
First contact of breaker Copper
Number of tire in ACB feeder Single or Double
Spider terminals Required for all MCCB above 100A
Line side shrouds Required
ROM for MCCB/MPCB Required
Gasket PU(Polyurethane)
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Thermal Tape in each joint for temperature


Required
detection
shall be considered for neutral protection(For
Neutral CT
ACB)
11.0 Typical Single Line Diagram
CUIM/TEN/UTL/09 LT Panel R5
a. LT Panel –Type 1
b. LT Panel –Type 2
c. LT Panel –Type 3
d. LT Panel –Type 4
e. LT Panel –Type 5
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CUIM/TEN/UTL/09 LT Panel R5