Spec For 415v MCC, MLDB

LPG BOTTLING PLANT , BATHINDA
Doc. No. 266763-000-SP-4004 Rev: B Page 1 of 37
Specification for 415 V PMCC, BUS DUCT, MCC, PDB & MLDB
Hindustan Petroleum Corporation Ltd 8 S.V. Marg, Ballard Estate Mumbai- 400 001
Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059
P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

List of Content
1 2 Introduction Location and Environmental Conditions 2.1 2.2 2.3 3 Plant Location Environmental Conditions Electrical System Data
Page No
5 6 6 6 6 6 6 9 9 10 10 10 10 10 10 11 11 11 11 11 12 13 14 15 16 16 16 17 18 18 19 20 20 21 21 21
Scope of Supply 3.1 3.2 3.3 Electrical Equipment & Material: Engineering Services Exclusions
Codes and Standards 4.1 4.2 General Conflicting Requirements
Technical Particulars: 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 Operating Philosophy: 415 V PMCC(000-PMCC-001) 415 V BPMCC (000-BPMCC-001) 415 V PDB (000-PDB-001) 415 V MLDB (000-MLDB-001) Motor Control philosophy. Motor Feeder Requirement: Construction: Busbars: Air Circuit Breakers (ACB): Moulded Case Circuit Breakers (MCCB): Contactors: Over Load Relays & Timers: Control Switches, Indication Lamps, Push Buttons & Control Fuses: Indicating Instruments & Meters: Current Transformers: Potential Transformers: Wiring and Identification: Control Supply: Space Heaters and Cubicle Illumination: Earthing: Busduct Terminations: Cable Entry and Terminations:

5.19 5.20 5.21 5.22 5.23 5.24 6 7 8
Capacitor Bank : Nameplates: Makes of Components Tropical Protection Painting Quality assurance:
21 21 22 22 22 22 23 24 25 25 25 25 25 25 26 27 30 31 32 34 35 36 37
Inspection and testing: Vendor documentation: Spares and special tools: 8.1 8.2 Spares Special tools
9 10 11 12
Installation and commissioning: Packing and transportation: Statutory Approval: Guarantee:
Appendix-A: Table of Compliance. Appendix-B: Electrical System Data Appendix-C: Codes & Standards. Appendix-D: Requisition for Engineering Documents Appendix-E: Guaranteed Technical Particulars Appendix-F: Electrical Drawings. Appendix-G: Control Schematics drawings. Appendix-H: Technical Specification for 415 V Bus Duct.

Introduction
This specification is intended to cover the design, manufacture, assembly, testing at manufacturer's works, supply & delivery, properly packed for transport F.O.R. site of 415V PMCC, MCC, Bus Duct, PDB & MLDB complete with all accessories for efficient and trouble-free operation for the LPG Bottling Plant project at Bathinda of Hindustan Petroleum Corporation Limited, India. The scope of work shall also include, the supervision of erection, testing, commissioning and putting into successful commercial operation of the switchgear furnished under this specification Following are the definitions: Company/Client/Owner Shall mean Hindustan Petroleum Corporation Limited (HPCL), Consultant Shall mean Mott MacDonald Consultants India Pvt. Ltd. (MMCI). Supplier of 415V PMCC, MCC,Bus duct, PDB, MLDB etc. This is to be understood as mandatory in relation to the requirements of this document. This is to be understood as a strong recommendation to comply with the requirements of this document. This is to be understood as vendor supplied equipment with all accessories.
Manufacturer / Vendor
Shall
Should
Equipment
The Vendor shall ensure that the design complies with the requirements of this specification and its referenced specifications, data sheets & standards. The Guaranteed Technical Particulars, Appendix F, which forms part of this specification, shall be completed by the Vendor. Deviation if any should be specifically brought out at the offer stage in the Table of Compliance, Appendix A. Without the compliance table and Guaranteed Technical Particulars can cause rejection of the offer. Failure to clearly identify specific deviations if any shall be assumed by the Purchaser to be total compliance with the specification. This specification does not relieve the Vendor from final guarantee as to materials, apparatus, workmanship and performance of the equipment supplied.

2
2.1
Location and Environmental Conditions

Plant Location
The Plant is situated at Village Phulo Khari, Taluka Talwandi Sabo, District Bathinda Punjab. PMCC/MCC/Bus Duct /MLDB listed in scope of supply shall be located in the MCC Room within plant complex.
2.2
Environmental Conditions
50 C
0 0
Design ambient temperature for Electrical Equipment (Indoor):
Design ambient temperature for Electrical Equipment (Outdoor): 55 C For other details Refer EIA Report for Site Enviormental condition.
2.3
Electrical System Data
Refer Doc No.: 266763-000-SP-4004BX [in Appendix B] for details.
Scope of Supply
The following equipments shall be supplied, in accordance with this specification; standards stated herein & enclosed appendices.
3.1
Sr. No.
Electrical Equipment & Material:

Item Description Unit Quantity Remarks
415V PMCC/MCC/Bus duct/ PDB/MLDB as per following details:
1.0
000-PMCC 001 ( 415 V PMCC) 415V, Double Front, Compartmentalised Draw out type, floor mounted, AL Bus bar PMCC as per following details & attached Single Line diagram Dwg. No 266763-000-410-002D. Rated voltage Highest system voltage Rated Bus-bar current Short time withstands current No. of outgoing feeders Control supply Voltage 415 V 433 V 1600 A 50 kA for 1 Sec. As per SLD Refer Appendix B
Set
2.0
000-BPMCC 001 ( 415 V MCC) 415V, Double Front, Compartmentalised Draw out

type, floor mounted, AL Bus bar; Bottling Plant MCC as per following details & attached Single Line diagram Dwg. No 266763-000-410003D. Rated voltage Highest system voltage Rated Bus-bar current Short time withstands current No. of outgoing feeders Control supply Voltage 415 V 433 V 400 A 50 kA for 1 Sec. As per SLD Refer Appendix B
Set
3.0
000-BD 001( 415 V Bus Duct ) 415V AL, non-segregated phase Bus Duct as per following details & attached Annexure H for specification of LV Bus Duct : Rated voltage Highest system voltage Rated Bus-bar current Short time withstands current 415 V 433 V 1600 A 50 kA for 1Sec. set 1
Exact bus duct length will be finalized during detail engineering stage. Vendor is advised to quote as on unit rate basis.
Ref. Dwg. No. 266763-000-425-006D.
4.0
000-PDB-001( 415 V PDB ) 415V, Compartmentalized, Floor mounting, single Front, and Fixed type auxiliary PDB as per following details & attached Single Line diagram Dwg. No. 269323-000-410-049D. Rated voltage Highest system voltage Rated Bus-bar current Short time withstands current No. of outgoing feeders 415 V 433 V 125 A 50 kA for 1 Sec. As per SLD Set 1
4.0
000-MLDB-001( 415 V MLDB )

415V, Compartmentalized, Floor mounting, Double Front, and Fixed type Main Lighting Distribution Board as per following details & attached Single Line Diagram Drawing No. 266763-000-410-004B.
Set
Rated voltage Highest system voltage Rated Bus-bar current Short time withstands current No. of outgoing feeders
415 V 433 V 400 A 50 kA for 1 Sec. As per SLD
5.0
Dummy Panel of following widths to account for floor beams that may foul with the cable entries: 800mm wide No. Quote unit rate Quote unit rate Quote unit rate
600mm wide
No.
400mm wide 6.0
No.
Unit rates for addition / deletion of:: Incomer Breaker Panel of each rating Quote unit rate Quote unit rate Quote unit rate Quote unit rate
6.1
6.2
Outgoing Motor feeder ( DOL) of each rating & each scheme type Outgoing Motor feeder ( STAR/DELTA) of each rating & each scheme type Outgoing Power feeders of each rating & each scheme type Empty Panel without feeders but complete with horizontal & vertical Busbars. Main Busbars rated for 1600A 400A 250A
6.3
6.4

Extension Box if required, for termination of cables shall be included at no extra cost.
Inspection and Testing as specified. Submission of documents as specified. Painting as specified. Preservation, preparation of shipment and delivery to site. List of Spares for two years normal operation. Start-up spares and commissioning spares. List of special tools required (Vendor to provide list with the bid). Any other items, required to make system complete.
3.2
Engineering Services
The Vendor shall provide engineering services, which shall include, but not necessarily be limited to, the following: Providing/coordinating detailed design of all equipment and components within the scope of supply. This will also include providing engineering/design layout of PMCC & Bus Duct matching the customers general arrangement of the substation. Resolving engineering queries related to the equipment and components within the scope of supply. Performing all relevant calculations pertaining to the equipment and components within the scope of supply. Providing progress reports etc. Providing expediting services for all sub-vendors, if any. Providing quality assurance, including all sub-vendors if any with respect to ISO 9000 or equivalent. Quality Assurance. Supervision of Installation/erection and commissioning. Training of clients personnel at site / Vendors shop.
3.3
Exclusions
Installation/Erection & commissioning.


4
4.1
Codes and Standards

General
The LV Switchgears shall meet the requirements of this specification and latest edition of applicable standards listed in enclosed Appendix-C
4.2
Conflicting Requirements
In case of conflict between documents relating to the enquiry or purchase order, the following priority of documents shall apply. First priority : This engineering specification along with attached drawings/ data sheets and subsequent purchase order & variations thereto. Relevant Indian /International standards.
Second priority
Note: Should any conflict arise either before or after order placement the Vendor shall immediately inform the Purchaser for technical resolution of the conflict.
5
5.1
5.1.1
Technical Particulars:
Operating Philosophy: 415 V PMCC(000-PMCC-001)
a) PMCC located in the MCC Room, will have two incomers; One from Grid Source through 1 MVA distribution transformer via bus duct and other from DG AMF cum Control Panel (Common for 2 nos. 500KVA DG Sets) by single core cables. For details Refer 415 V PMCC single Line diagram Dwg. No. 266763-000-410-002D. Under Normal condition, Incomer -I will be energized independently from Grid Source and feeding power supply to PMCC Loads. In case of failure of power supply at I, Incomer II will be fed from DG Panel & will supply the entire plant load. b) There shall be electrical interlocking among two incomers such that only one circuit breaker out of two shall be closed at a time. c) Under loss of grid mains power supply, DG-1 (500KVA) & DG-2 (500KVA) will start on AMF signal from Line PT. DG Incoming breaker at PMCC will be closed manually after getting close permisive from DG AMF Cum Control Panel. The running of DG-1 & /or DG-2 shall depend on the total load connected to PMCC which will be sensed & controlled by DG AMF Cum Control Panel. The two DGs will be synchronised at DG AMF Cum Control Panel. d) On resumption of grid power, Changeover from DG-Incomer to grid main power supply shall be done manually, with break in power supply (i.e. DGs shall not be paralleled with the grid at any time). However provision to be kept at the PMCC panel for automatic changeover by momentary paralleling between the two incomers on resumption of grid power without break in power supply. e) In case of loss of supply on both the incomers, the breaker status shall be maintained.

5.1.2
415 V BPMCC (000-BPMCC-001)
a) Bottling Plant MCC (130-BPMCC-001) located in the MCC Room, will have one incomer feeding from PMCC supplying to the Bottling Plant loads. Refer Dwg. No 266763-000-410-003D for details. 5.1.3
415 V PDB (000-PDB-001)
a) Auxiliary power distribution board (130-PDB-001) located in the MCC Room, will have one incomer feeding from PMCC, supplying to the auxiliary 415 V & 240V loads. Refer Dwg. No 266763-000410-049 for details. 5.1.4
415 V MLDB (000-MLDB-001)
a) Main Lighting Distribution board shall have two incomers. One Incomer form 415 V PMCC & Other from the 250 kVA Emergency DG set (DG-3). Refer Dwg. No. 266763-000-410-004B for details. b) Critical loads (viz. Jockey Air Compressor/Jockey pump motors) also will be fed from this distribution board. c) During normal operating condition it will be fed from the PMCC. In case loss of grid mains power supply and DG-1 &/or DG-2 fail to start, DG-3 shall be started manually & feed the critical loads including entire lighting loads.
5.1.5
Motor Control philosophy.
Refer control Schematic drawing no. 269323-000-410-050D. However above control schematic as referred above is indicative only. Vendor shall develop the detail control circuits as required. Vendor is advised to ensure that the following control philosophy will be taken care during their detail design. a) The Start and normal Stop operation for all motors except VFD drives will be done from the local control station manually by actuation of Start and Stop push buttons of the respective equipment. The indications of Motor overload, Motor ON, Motor OFF will be displayed on the respective MCC feeder with Amber Red, Green colored indicating lamps respectively. b) PMCC/MCC /MLDB will have the emergency Stop Push button for all the drives. c) Standby motors shall come in service manually during outage of working motors or as and when required as per process requirements. d) VFD fed motors shall be controlled from local control stations through contactor provided at VFD.
5.2 5.2.1
Motor Feeder Requirement:

The manufacturer shall consider feeder rating, feeder type (Schematic), busbar rating, SFU rating, CT & ammeter requirements etc., from the respective Single Line Diagram & Schematic drawings. Manufacturer shall obtain the motor tag number and description from the feeder list for nameplates on each feeder. The SLD depict the minimum ratings of each equipment. The final rating will be as per Type -2 coordination as per IEC 60947 .
5.2.2
Motor starters
a) The manufacturer shall wire the starters as per enclosed Motor starter schematic drawings.

b) Motors up to and including 22 kW shall be with DOL starter and motors above 22kW shall be with star delta starter unless otherwise specified. All motor feeders shall have electronic over current relays except VFD Feeders. c) Current transformers shall be provided for current indication in Local Control Station for all motors rated 7.5 kW and above. d) Circuit for motor space heating shall be provided for all outgoing motor feeder modules rated 30kW and above. Separate 240 V AC busbar shall be considered which will be fed from a separate source. e) Feeders with Forward reverse motors shall have suitable control logic.
5.3
5.3.1
Construction:
Switchgears shall be totally enclosed, metal clad, sheet steel fabricated, dust & Vermin proof, free standing, floor mounted type with self-supporting structure and provided with integral base frame at bottom. Switchgears shall be in double-front, draw-out execution & fully compartmentalized. The Panels shall have IP 4X degree of protection with gasketed doors. All doors shall be fastened to the vertical section by means of concealed hinges. The sides, top & bottom of each vertical section shall be covered with removable screw-on plates with formed edges all around. The Switchgears shall be easily extensible on either side by the addition of vertical sections. It shall be possible to extent the Switchgears, irrespective of the type of end panel and design shall be such as to permit addition of extension panels of a type other than the type of end panel. It shall be of unit construction suitable for splitting into sections for shipping to site and to be correctly reerected on prepared foundations without skilled supervision. The individual shipping section shall comprise not more than three verticals. For each shipping section adequate lifting facilities such as hooks for ease of handling on site shall be provided. These hooks when removed shall not affect the degree of protection of Panels. Vendor shall supply accessories such as bus links, etc. for connecting various shipping sections at site. The Switchgears shall be fabricated preferably from CRCA sheet steel of minimum thickness 2mm. for load bearing members, 1.6 mm for non-load bearing members & 3mm for gland plates. Removable type undrilled gland plates shall be provided at bottom of the panel. The height of Switchgears shall be constant throughout the length, but not exceeding 2500mm. The arrangement of feeders shall ensure that operating height of components shall be above 350mm & below 1800mm from finished floor level. Cable alley width shall be 300mm. Busbars shall not be exposed when CB / Starter module is removed. Insulated and isolated vertical busbars are required. Barriers shall be provided to separate the bus compartment from wiring space at top, bottom and sides of each section and shall be adequate to prevent accidental contact and restrict propagation of unit originated arc into the busbar compartment. Starter Unit / CB shall be draw-out type. Each starter/CB compartment door shall be interlocked with door mechanically so that it cannot be opened unless the Switch operating handle is moved to the "OFF" position. However, the handle mechanisms of the Switch shall be so designed that a qualified person can defeat the door interlock for purpose of inspection without interrupting power.
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6

5.3.7
Each draw-out unit shall be equipped with a mechanical safety interlock such that:
a) A withdrawn unit with the Switch in the 'ON' position cannot be inserted into the vertical structure and make contact with the vertical bus. b) Units in the fully inserted position shall not be able to be withdrawn with the Switch in the 'ON' (closed) position. 5.3.8 Front access shall be available to all components in each cubicle, which require adjustment, maintenance or replacement. Checking & removal of components shall be possible without disturbing adjacent equipment. All auxiliary equipment shall be easily accessible. Setting of relays shall be possible without de-energizing other equipment. Access shall be available to all cable glands & multicore terminal blocks by means of sheet steel hinged doors, designed to give the maximum possible access to the cable terminations. The cable alley door shall be provided with bolts, which can be opened with special keys but by authorized person. Plug-in stab construction shall assure positive electrical and mechanical contact to the bus under all loads and rated fault conditions. All incomers, bus couplers & outgoing feeder shall be designated as per feeder list. Incoming feeder shall be mounted in separate vertical section. The arrangement of feeders in the panel shall take into consideration the number & size of cables required for the feeders. Extension box if required for termination of cables shall be included.
5.3.9
5.3.10 Vendor shall provide partition between two power cable terminations of outgoing feeders. Vendor shall provide FRP shrouds on outgoing feeder terminations. 5.3.11 Base frame: Switchgears shall be provided with integral base frame which shall be bolted/welded on the cross members provided by owner. Amply dimensioned oblong holes shall be provided on the base frame. The base frame shall be of standard sections, re-rolled sections will not be acceptable. Vendor shall give base frame details in foundation drawing. Cross members or foundation on which base frame is mounted is excluded from Vendors Scope of supply.
5.4
5.4.1
Busbars:
The Busbars shall be made of Electrolytic grade high conductivity Aluminum with continuous rating as required. All busbars & their main current carrying connections shall have same cross sectional area throughout the length. All busbars shall be insulated with heat shrinkable PVC sleeves. All busbars shall be colour coded such that on removal of any door the phases shall be identifiable. All busbars shall be accessible for inspection & easily replaceable. Control & earth bus bar shall be of copper bus. Busbar size shall be determined by taking into consideration the specified continuous current rating & fault level for 1 sec, without exceeding the busbar final temperature of 95C. The busbars shall be supported by insulators of non-carbonizing material resistant to acid and alkali and having non-hygroscopic characteristics and braced to withstand fault level specified. The main horizontal busbars shall be located at the top. Size of neutral busbar may be half the size of main busbars. Neutral busbar shall include taps for each outgoing cable connection in each vertical section. The clearance between live parts & earth shall be as per IS/IEC. Busbars and connections shall be secured in such a manner that the insulators are not subjected to bending forces under short circuit conditions. Dynamic stresses shall be calculated on the basis of peak short circuit current. For long Busbars, suitable expansion joints shall be provided.
5.4.2
5.4.3

5.4.4
Separate set of vertical busbars shall be provided for front and rear sections. The vertical busbars shall be sized to carry continuously at least the sum of rated currents of the connected circuit breakers. Short time rating of vertical busbars shall be same as main busbars. It shall be possible to extend the busbars at either end of the switchboard for addition of future units. Both ends of busbars must be suitably drilled for this purpose. Where busbars are taken through the partitions of adjacent cubicles, fireproof shrouding shall be provided to prevent spread of fire from one unit to the next. Thermal design of the busbars shall be based on installation of the switchgear in poorly ventilated conditions. The cooling air volume shall take into account only the bus enclosure.
5.4.5 5.4.6 5.4.7
5.5
5.5.1
Air Circuit Breakers (ACB):

The Circuit Breaker shall be manually & electrically operated, triple pole, air break, and draw-out type with solid manually detachable type neutral. Short circuit withstands capacity for ACBs shall be same as that of switchgear. Breaker continuous current ratings shall be in panel ratings. No external mean shall be provided for limiting temperature rise in panel box. The charging mechanism of the circuit breaker shall be motor operated. The close / trip control switch to be interlocked to trip before close. The closing and tripping circuits shall be self-opening on completion of their respective functions irrespective of the position of the control switch. Manual closing devices shall also be provided. Operating handle shall be provided for charging the spring manually. The Circuit Breaker shall be provided with mechanical ON/OFF, TRIP and SPRING CHARGED, DISCHARGED indication, T/N/C control switch, mechanical trip push button, mechanical close' push button, and padlocking facility. The circuit breaker shall be electrically and mechanically trip free, with anti-pumping feature. The breaker shall be provided with minimum 6 NO + 6 NC auxiliary contacts. However, the exact requirement shall be as per the details given in the Scheme Specific Requirements. 20% auxiliary contacts (Min. 3 NO + 3 NC) shall be provided for Owner's exclusive use. All spare contacts shall be wired up to terminal blocks. Auxiliary contactor or relay shall be used to multiply contacts. The auxiliary contact for the shunt trip shall be of advanced nature such that the auxiliary contact close before main contacts. The main and secondary isolating contacts of the circuit breaker shall be of self-aligning type. The main isolating contact shall have continuous rating equal to the rating of the breaker. The secondary isolating contact shall be of wiping contact type. The fixed portion of the circuit breaker shall have slide rail arrangement over which the chassis can move smoothly. The breaker shall have 3 distinct positions, such as "SERVICE", "TEST" and "ISOLATED", with padlocking facility in Test & Isolated position. Proper mechanical indication shall be provided to locate these three positions without opening the compartment door. It shall be possible to bring the circuit breaker to isolated position with the help of external lever without opening the compartment door. A stop block shall be provided on the slide rails to prevent the movement of the circuit breaker out of the compartment when it reaches the isolated position so that any accidental fall can be avoided. Wherever cut-outs are provided for the circuit breaker control box, proper continuous gaskets shall be provided. Provision shall be made for closing the cut-out provided for the control boxes when the C.B. is taken out of the compartment.
5.5.2
5.5.3
5.5.4 5.5.5
5.5.6 5.5.7
5.5.8
5.5.9

5.5.10 The circuit breaker shall be provided with automatic safety shutters, so that before the breaker reaches `isolated' position the main isolating contacts are completely shrouded. When the circuit breaker compartment door is open it must not be possible to touch the live parts. All removable covers protecting live parts shall be clearly labelled with warning notices reading LIVE PARTS. ISOLATE ELSEWHERE BEFORE REMOVING COVER. 5.5.11 The circuit breaker compartment shall be so designed that hot gases produced during fault shall be lead away from the operator. 5.5.12 It shall be possible to readily remove the arc chutes for routine inspection of the contacts with the circuit breaker in the withdrawn position. 5.5.13 The protective relays and instruments shall be mounted in separate compartment. compartment shall be along side and immediately next to the controlled breaker. This
5.5.14 The CB shall be provided with microprocessor based direct acting protection releases for overload, short circuit & earth fault. The releases shall be programmable & adjustable type. 5.5.15 Circuit breakers shall be with communication unit for : a) Breaker status, alarm and maintenance information. b) Control commands & configuration settings. 5.5.16 The following interlocks shall be provided on the circuit breaker : a) It shall not be possible to withdraw the circuit breaker from the service position with the contacts of the breaker closed. b) It shall not be possible to close the circuit breaker unless any one of the three positions is located, the service position, a definitely located test position, or isolated position. c) It shall not be possible to open the compartment door when the circuit breaker is ON. d) The circuit breaker can be padlocked in OFF position with door interlock defeat facility. e) Castle key interlock shall be provided for incomers & bus couplers to prevent parallel operation where specified. 5.5.17 All the non-conducting metal parts of the circuit breaker trolley shall be bonded together and shall make perfect electrical connection to earth through substantial sliding contacts, at service and test positions. Such sliding contacts shall be arranged to make before power plug in and interrupt after power draw out. 5.5.18 All circuit breakers of same rating shall be identical in all respects and shall be interchangeable. However, breakers of different ratings shall not be interchangeable. 5.5.19 Breaker handling trucks / trolleys shall be included in the scope.
5.6
5.6.1
Moulded Case Circuit Breakers (MCCB):

MCCBs shall be of triple pole construction for panel mounting, operating mechanism shall be trip free, quick make quick break type. Short Circuit withstand capacity for MCCBs shall be same as that of switchgear. The MCCBs shall be provided with front operating handles & mechanical ON/OFF indicators. In case of trip handles shall remain in an intermediate position.
5.6.2

5.6.3 5.6.4
MCCBs shall be provided with releases as per schematic drawings. The releases shall be adjustable type. MCCBs in individual motor circuits shall be designed for application, in combination with motor starter units. They shall operate on the magnetic principle with accurate sensing element in each pole to provide short circuit protection. MCCBs shall have following accessories & features:
5.6.5
a) Auxiliary contact set of 1 NO + 1NC b) Fault signalling contact set of 1 NO + 1NC c) Insulation shields to isolate the connection between each pole. d) e) Finger protection plate to prevent accidental contact. The compartment door shall be interlocked with handle of MCCB.
5.7
5.7.1
Contactors:
The air break contactors shall be of electromechanical, triple pole type conforming to AC3 category of duty. However for motors in inching or reversing rotating service, utilization category AC4 shall be used. Contactors used for Capacitor bank application shall be suitable for Capacitor switching compitable. The auxiliary contactors shall have 4 NO + 4 NC contacts with at least 2 NO + 2 NC auxiliary contacts for owner's exclusive use. The spare contacts shall be wired up to the terminal block. The contactor coil shall be suitable for the specified control voltage. The coils shall have grade E insulation and shall be suitable for use in the ambient temperature specified elsewhere. The design of the contactor shall ensure easy access to auxiliary contacts and coil. Mechanical ONOFF indication shall be provided for the contactors. Wherever mechanical indications are not provided, indicating lamps shall be provided for ON indication of the contactor. The contactor shall pick up at 85% to 110 % of the control voltage and shall not drop out for voltage up to 45%. The contactor rating shall be chosen to provide Type-2 co-ordination as per IEC 60947. In case of Star-delta starter feeder, rating of all three contactors shall be identical.
5.7.2 5.7.3
5.7.4
5.8
5.8.1
Over Load Relays & Timers:

Motor Overload Protection Relays Overload protection relays shall be of Electronic type to be installed in all phases & shall have inbuilt Single Phasing Protection feature. Relay shall be temperature compensated type with manually reset facility on the front of the compartment door. Overload protection relays shall be direct line mounted upto 50A rating. Higher ratings shall utilize CTs. Relays shall be with adjustable trip class -10, 20, 30 as per IEC 60947.
5.8.2
Timers Timers shall have adjustable time setting of 0 - 60 secs. The time settings, where specified shall be accurately set before dispatch of the switchboard for all ON delay & OFF delay timers.
5.9
5.9.1
Control Switches, Indication Lamps, Push Buttons & Control Fuses:

Each Air circuit breaker shall be provided with trip-neutral-close control switch and local remote selector switch.

5.9.2
All circuit breaker operating switches shall be of the pistol grip type, spring return to neutral and lockable in neutral position. They shall be arranged to close the breaker by being turned clockwise. The trip, neutral and close positions shall be clearly indicated. The movement shall be such that the switch cannot be operated inadvertently and that it is mechanically interlocked to trip before close. The operating switch shall be located on the centre line at about 1.5 meters from the floor level. Two spare ways shall be provided on these switches. Ammeter selector switches shall have `make` before break feature on its contacts. The selector switch shall generally have four positions for reading three phase currents and the neutral current. The voltmeter selector switch shall also have four positions. Three shall be used to measure phase to phase voltages and the fourth shall be OFF position. Based on operational philosophy, if required, Auto / Manual selector switch shall be provided. Indication lamps shall be cluster of LEDs. Voltage rating of LED shall be equal to rating of control circuit voltage. The covers of the lamp shall be heat resistant. Indication lamps shall be provided for each feeder in Switchgear as per feeder schematics. Emergency Stop push buttons shall be mushroom headed, stayput type, with press to lock & twist to unlock (release) operation. Colour coding of Push Buttons & Indication Lamps shall be as follows:Push Buttons Start or On Stop or Off Alarm Reset Acknowledge O/L Reset Trip circuit healthy check Lamps (LED Type) Green Red Yellow Black Blue Black Push Buttons Running or On Stop or Off Fault Trip coil healthy Spring charged Breaker in Service DC Failure Control supply healthy White Lamps (LED Type) Red Green Amber White Blue Blue Red
5.9.3 5.9.4 5.9.5 5.9.5 5.9.6 5.9.7 5.9.8
5.10
Indicating Instruments & Meters:
5.10.1 All indicating instruments and meters shall be capable of carrying continuously their full load currents and full voltage across their pressure coils. They shall not be damaged by the passage of fault currents or the existence of over pressure on the primary side of their instrument transformers for the maximum permitted duration of fault conditions, which may occur during normal operation. All instruments and meters shall be back connected.
5.10.2 The type and quantity of the measuring instruments shall be as specified in schematic drawings.
5.10.3 All instruments shall be of the flush mounting type and shall have an enclosure with a degree of protection of at least IP 52. 5.10.4 They shall be equipped with non-glare, non-reflecting windows. Standardized dimensions shall be used in accordance with IEC 60473.

5.10.5 Indicating instruments shall be in accordance with the relevant IEC standards and have an accuracy class 1. Analogue meters should be of the square pattern type 96 x 96 mm, and mounted at a suitable height for easy reading from the front. Scales shall be in actual values. 5.10.6 Meters shall be installed on the door of the respective functional units. 5.10.7 Ammeters for motor current indication shall have suitable suppressed scale corresponding to motor starting current.
5.11
Current Transformers:
5.11.1 The CTs shall be Resin cast bar type. CT secondary shall be 1A. The minimum burden shall be 15VA. However, current transformers shall have sufficient capacity to operate with the burden imposed by the devices shown on drawings with their accuracy classification. Separate cores shall be used for metering and protection. 5.11.2 CTs for measuring instruments shall have an accuracy class 1.0 and accuracy limit factor less than 5.0. If a metering load is fed from a protection CT, suitable 1/1 or 5/5 ratio saturable interposing CTs shall be use. CTs for Protection shall have an accuracy class 5P and saturation factor less than 0. CTs for restricted earth fault protection shall confirm to class X. 5.11.3 The CTs shall be capable to withstand dynamic and thermal stresses originated by the fault current. 5.11.4 The CTs shall be suitably insulated and the mounting of the CTs shall facilitate easy maintenance. The CTs shall be mounted in stationary part of switchgear. 5.11.5 Shorting links shall be provided for the secondary of the CTs when wired to terminals. 5.11.5 One side of current transformer secondary shall be grounded in the compartment with the meters or relays which they serve and each CT group shall be grounded with a separate identified lead which may be disconnected for testing. 5.11.6 All motors rated 7.5 kW and above, the CT signal shall be brought out as shown in schematics for current indication at Local Control Station. CT terminals shall be suitable for termination of 4 sq.mm cable. 5.11.7 CT parameters shall be verified by vendor, based on connected relay make & relay manufacturers recommendation.
5.12
Potential Transformers:
5.12.1 The Potential Transformers shall be epoxy cast resin type. Potential transformers shall have sufficient capacity to operate with the burden imposed by the devices shown on the schematic drawings with their accuracy classification. 5.12.2 The Potential Transformers shall have an accuracy class 1.0 for voltmeter only. management / others, it shall have accuracy class of 3.0 For energy
5.12.3 The primary of the Potential Transformers shall be rated for 412 volts and the secondary for 110 volts. PTs shall have a continuous voltage factor of 1.2 with short time over voltage factors as below: a) 1.5 for 30 seconds in case of effectively earthed systems. b) 1.9 for 8 hours in case of non-effectively earthed systems. 5.12.4 The PT shall be provided with HRC fuse on the primary side and MCB on secondary side.

5.12.5 For proper relaying, one side of PT secondary shall be grounded at the transformer and the ground connection shall be identified and removable for testing. 5.12.6 Test terminals shall be provided for PT circuits.
5.13
Wiring and Identification:
5.13.1 All wiring for control signal, protection and metering shall be by PVC insulated, 650 Volt grade, copper stranded conductor wires of minimum 1.5 sq.mm section. For CT secondary circuit wires of 2.5 sq.mm copper conductors minimum shall be used. Wiring shall run in enclosed channel and shall leave at least 25% spare space for future use. Wires for connection between moving parts shall be flexible stranded copper conductors and the same shall be soldered at the ends before connections are made. 5.13.2 Terminal strips for connecting incoming control cables shall be channel mounted type of adequate size and shall be located conveniently for easy accessibility, without danger of contact with live part, ease of connection and shall be separated by barriers from power circuits. At least 20% spare terminals shall be provided in each terminal strips. CT secondary lead terminals shall be provided with shorting links. 5.13.3 All spare contacts of auxiliary relays, timers, contactors etc. shall be wired up to terminals block. Terminal Block shall be 600V grade 10 Amps rated. 5.13.4 Sufficient terminals shall be provided on each terminal strip to ensure that not more than one outgoing wire is connected per terminal. The wire shall be identified by numbered ferrules at each end, in accordance with the connection diagram. All ferrules shall be made of non-deteriorating materials. The ferrules shall be firmly located on each wire so that they cannot move or turn freely on the wire. 5.13.5 All inter-panel control wiring shall be done by the switchgear vendor. All wiring shall be properly bunched, cleated, & supported on a panel frame and shall run in plastic wire ducts. The inter panel wiring shall be taken through PVC sleeves or suitable rubber grommets. Colour Coding for internal panel wiring shall be as follows: Power Wires Control Wires Neutral Wires Ground Wires Red, Yellow, Blue for Phases. Grey. Black. Yellow & Green.
5.13.7 Each shipping section of each Switchgear shall be provided with one marshalling box. Wiring between individual modules to marshalling box shall be done by Vendor. Wiring from Switchgear to field controls like local PB Stations / Panels will be done directly from individual modules, however, interconnection between Switchgear and control room panels like DCS / PLC / Relay Panel will be done through this marshalling box. Vendor shall refer attached scheme drawings to estimate number of signals per module, up to marshalling box. Actual number of signals shall be confirmed at the time of drawing approval. Each marshalling box shall have two separate terminal blocks, one for outgoing signals to DCS / PLC / Relay Panel and other for incoming signals from DCS / PLC / Relay Panel. Vendor shall provide 25% spare terminals in each terminal block in marshalling box.

5.14
Control Supply:
5.14.1 Control supply for control, indication, space heater etc. shall be derived within the switchgear by vendor. Vendors shall provide auxiliary / control supply bus in the switchgear throughout its length for further distribution inside the switchgear. Vendors shall also provide suitable MCB for receiving, distributing & in each sub-circuit as per requirement. 5.14.2 Auxiliary Busbars of thick electrolytic tough pitch copper shall be provided for following applications. Exact number of bus bars shall depend on various controls, metering and auxiliary power distribution requirements. 5.14.3 ACB [spring charging motors], Panel / Motor space heater supply 240V AC, 1 ph, 50Hz, to be derived by vendor. 5.14.4 Control supply for Annunciators, ACB [indications, closing & tripping coils] 110V DC, from clients DC UPS. 5.14.5 Control supply for motor starter control circuits 110V AC via control transformer, to be derived by vendor. 5.14.6 Space Heaters 240 AC derived from Lighting DB. 5.14.7 Two number 110V DC power supply feeders shall be provided for each switchgear from owners DC UPS. Suitable DC control supply monitoring & selection scheme shall be developed by vendor. Any other intermediate voltage required in the panel shall be derived by providing suitable control transformer. 5.14.8 Control Transformer & Control Circuits: a) Control transformer shall be double wound, air cooled type with one leg of secondary earthed unless otherwise specified. b) VA rating of the Control transformer to be adequate to supply about 150% of the control loads of the switchgear. Voltage regulation of the Control transformer shall be limited to 4%. c) The control supply in Switchgear shall be derived from control transformer with 100% standby. The control transformers in each panel shall have power supply from each of the incomer. Out of the two control transformers one shall be working and other will be standby.
d) Auto-change over system shall be provided for control supply from working control transformer to standby control transformer and vice versa as per schematic drawings attached. 5.15 Space Heaters and Cubicle Illumination:
5.15.1 Adequately rated anti-condensation space heaters shall be provided in each breaker panel and in cable alleys of the MCC to maintain MCC inside temperature, 5 C above outside ambient temperature. 5.15.2 Space heater shall be strip type, rated for operation on 240V, single phase, 50 Hz. A.C. supply unless otherwise specified. 5.15.3 Each space heater shall be complete with a rotary type ON/OFF switch, MCB in the phase, neutral link in neutral and a control thermostat. 5.15.4 A separate DP isolator and MCB shall be provided in motor feeders for control of space heaters of motors. These shall be wired through a 'NC' contact of the contactor / circuit breaker for motor control.

5.15.5 Each vertical panel shall have fluorescent light fittings for internal cubicle illumination with door switch. 5.15.6 240V, 15A SPN Industrial socket outlet, complete with MCB & earth leakage protection shall be provided in each vertical panel.
5.16
Earthing:
5.16.1 An earth bus of at least 50mm x 10mm aluminium shall be provided. The earth bus shall be electrically continuous and shall run the full extent of each board. The earth bus shall be of same material as the main busbars. Each unit shall be constructed to ensure satisfactory electrical continuity between all metal parts not intended to be live and the earth terminals of the unit. 5.16.2 At each end of switchgear, suitable slots shall be provided on main earth bus for connection to Owner's Earth. The earth bus shall be accessible in each cable compartment either directly or through a branch extension to ground the cable armour and shields. 5.16.3 All doors and movable parts shall be connected to the earth bus with flexible copper connections. All non-current carrying metallic parts of the equipment shall be earthed. Earth bus shall be brought back to cable compartment and earthing bolts shall be provided to ground cable armours.
5.17
Busduct Terminations:
5.17.1 PMCC Incomer will be connected to Transformers by Non segregated Busducts (with Aluminum Busbars) from top. Vendor shall furnish flange details for Busduct connection.
5.18
Cable Entry and Terminations:
5.18.1 For Switchgears, opening with removable gland plate for cable entry shall be provided at the bottom for both incoming and outgoing cables. Terminals shall be located sufficiently away from gland plate to facilitate easy connection. Gland plate shall be minimum 3 mm thick. 5.18.2 All terminal blocks shall be furnished with white marking strips marked with terminal numbers in accordance with the wiring diagrams. The terminal blocks shall be physically grouped and located suitably for termination of the cables. Terminal block in all drawout units shall be furnished with pull apart terminals to connect all outgoing wires and shall be furnished with 20% spare terminals at least. 5.18.3 Suitable arrangement shall be made in cable alley for supporting incoming & outgoing cables. Terminal blocks shall not be used to support cables.
5.19
Capacitor Bank :
PMCC shall have capacitor bank for power factor correction. 300 kvAR Capacitor bank with suitable combination of basic unit size will be housed in the PMCC Panel along with the APFC (automatic power factor correction) relay. For Details, refer technical specification for Capacitor bank Document No. 266763-000-SP-4006.
5.20
Nameplates:
5.20.1 Permanent non-corrosive nameplate with engraved white letters on black background indicating the switchgear designation shall be fixed at the top of the central panel. A separate nameplate giving feeder details shall be provided for each feeder. 5.20.2 Name plates shall contain the following information:

a) Manufacturer b) Basic technical data such as rated voltage, rated current, etc. c) Country of origin. d) Certification data such as UL certificate number etc.
e) Each feeder shall be labelled giving following details Equipment number as per feeder list Description as per feeder list Feeder No. as per manufactures GA KW Rating as per feeder list Scheme reference.
5.20.3 Nameplates shall be provided for each equipment (lamps, push button stations, switches, relays, Auxiliary contactors etc.) mounted on the switchgear. Special warning plates shall be provided on all removable covers or doors giving access to high voltage cables / busbars and inside the switchgear wherever considered necessary. Danger labels shall have black letters on a yellow background. 5.20.4 Internal labels and components identifications shall correspond with identities or circuit references as shown on the schematic diagrams. All external labels shall be attached by screws or rivets only and not by adhesive.
5.21
Makes of Components
5.21.1 Manufacturer shall furnish standard list of components makes for the complete the 415V switchgear assembly. This list must be included with the offer. 5.21.2 Make of Numerical Relays shall be Areva / Siemens / ABB. Electronic overload relay shall be EOCR or equivalent type.
5.22
Tropical Protection
5.22.1 All equipment, accessories and wiring shall have fungus protection, involving special treatment of insulation and metal against fungus, insects & corrosion. 5.22.2 Screens of corrosion resistant material shall be furnished on all ventilating louvers to prevent the entrance of insects.
5.23
Painting
5.23.1 All metal surfaces shall be thoroughly cleaned and degreased, pickled and phosphatised. Thereafter, a coat of phosphate paint and a coat of zinc chromate primer shall be applied. After removing all imperfections, all metal surfaces shall be sprayed with two coats of final paint as per colour shade RAL 7032. Final coat shall be of epoxy based. All unpainted parts shall be plated to prevent corrosion.
5.24
Quality assurance:
5.24.1 The Manufacturer is expected to demonstrate that he has working Quality Assurance System which complies with ISO 9001 or may be appropriate to the type of contract and his product. 5.24.2 If the Vendor elects to sub-contract part of the work he shall ensure that only those sub-contractors or suppliers are used who can demonstrate that they operate Quality Systems based on ISO 9001

or ISO 9002 as applicable. The Vendor shall give his sub-contractors or suppliers assistance in attaining the required standard, if necessary. This shall not relieve the Vendor of his responsibility for the quality of the finished work. The Owner reserves the right to audit the Vendors Quality System. 5.24.3 The Vendor shall assign sufficient full time personnel to the Project to ensure the Quality Assurance / Quality Control System, documented in a Quality Assurance / Control Manual, is maintained and kept up-to-date throughout the duration of any purchase order. The Vendors Quality Assurance / Control System shall become an integral part of any Purchase Order. Vendor shall organize a prefabrication / inspection meeting with the Owner. Within 3 weeks from the date of Purchase Order the Manufacturer shall submit a Quality Assurance Plan for the review of the Owner.
6
6.1 6.2
Inspection and testing:

The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor. The Vendor shall specify all of the inspection and testing requirements in the quality plan which shall identify the activities requiring the Owners approval, review, witnessing etc. Inspection and testing requirements shall be in accordance with this specification, other All Equipment shall be inspected for compliances with: a) Requirement of Owners specification & correspondence therefore. b) Applicable codes, standards and specifications, which shall also include sub- referenced standards therein. c) Test and Inspection Plans produced by the vendor.
6.3 6.4
Inspectors have the right to request additional inspections or tests to ensure that the equipment complies with the specification and all relevant codes & standards. Manufacturer shall furnish valid Type Test Certificates of similar models along with the offer. Fresh type tests for the equipment are not needed, provided the Manufacturer can submit certificates that the equipment complies with all type tests as prescribed by IEC/IS Standard specifying the test requirements for that equipment. The routine tests shall include but not necessarily limited to the following: a) Operation under simulated service condition to ensure accuracy of wiring, correctness of control scheme & proper functioning of the equipment. b) All wiring and current carrying part shall be given appropriate High Voltage test. c) Primary current and voltage shall be applied to all instrument transformers. d) Routine test shall be carried out on all equipment such as circuit breakers, instrument transformers, relays, meters etc.
6.5
6.6
Routine tests on the equipment shall be carried out as per the relevant IS/IEC. Equipment offered for final inspection shall be complete and ready for shipment, with the possible exception of the final paint finish. Routine Test certificates to be submitted for Equipment and its all auxiliaries. Type test certificate of similar equipment shall be submitted.
6.7

6.8 6.9
Vendor to furnish required copies of test certificates, Ref Documents, Drawings, and Instruction Manuals before Equipment are dispatched. Factory acceptance test (FAT) is required to be done at no extra cost to the purchaser. The purchaser or his representative shall be advised of the tentative date for FAT at least 3 weeks in advance prior to the test date. Any defects found by the TPI or the Owners appointed Inspector shall be rectified in his presence. Where this is not possible or practical, check lists shall be prepared and signed by the Third Party Inspector stating all pending items. Copies of these lists shall be sent to the Owner to enable their subsequent checking. The equipment shall not leave the Vendor factory before all defects have been rectified and without the written permission of the Owner. All spare parts shall be subjected to the same inspection standards and full material certification as the main order. The equipment shall not leave the Vendor / Sub-Vendors factory before all discovered defects have been rectified and without the written permission of the Owner/Purchaser. Any acceptance or release of equipment following an inspection or test activity shall in no way relieve the Vendor of his contractual responsibility to provide guarantees as to the suitability of the materials, workmanship and performance of the equipment in accordance with this Specification. Owner/Consultant reserves the right to waive the inspection at any stage. Inspection shall be carried out only on receipt of Vendor's internal test report of the equipment offered and scrutiny of the same. In the event, on receipt of inspection call, the Owner/Consultants representative reaches the Vendor's works and finds the material not ready for inspection/incomplete/has short supply, the inspector will return to his base station and all expenses incurred by the inspector including to and from travelling expenses from his base station to place of inspection, boarding and lodging etc shall be reimbursed by Vendor.
6.10
6.11 6.12 6.13
6.14
7
7.1
Vendor documentation:
All information listed here is to be furnished along with the offer as a minimum. a) Clause wise comments / deviations on specification in `Table of Compliance [enclosed Appendix A]. If not furnished, compliance to all requirements in specifications will be binding on the Vendor. b) Duly filled up Guaranteed Technical Particulars [enclosed Appendix-F]. c) List of components & accessories with Makes. d) List of recommended spares for two years normal operation with itemised rates. e) Type test certificates. f) Technical Catalogues and brochures of major Components.
g) List of clientele for similar equipment in last 5 years. h) Complete list of special tools (if required) i) 7.2 Documents as per RED. The Manufacturer shall furnish the drawings and documents as per enclosed Requisition for Engineering Documents - RED Form [Appendix-D].

7.3
The Owner/Consultant will review drawings submitted by Vendor & return to the Vendor one copy of drawings with comments to carry out necessary changes, if any, during the engineering / manufacturing stage. The documents required by the Third Party Inspection Agency are not covered under this specification. The Vendor shall provide all the drawings and documents required by the Third Party Inspection agency in compliance with the applicable codes and standards.
7.4
8
8.1
Spares and special tools:

Spares
The Manufacturer shall furnish list of spares and provide all necessary spares for testing, precommissioning, commissioning. Any of the spares if used during testing/commissioning must be replenished at no extra cost to the purchaser. The Manufacturer shall also provide all consumables required during erection up to commissioning. In addition to above, Manufacturer shall quote separately for Spares required for two years of operation.
8.2
Special tools
The Manufacturer shall include any special tools, which are required for the installation, commissioning, operation and maintenance of the equipment being supplied. A list of special tools shall be supplied along with the offer
Installation and commissioning:
Vendor shall dispatch Installation and Commissioning instructions at least 2 weeks before the arrival of the equipment. Vendor shall provide qualified personnel to supervise the installation and carryout site testing and commissioning of all equipment supplied under this contract. Prices for these services shall be given separately.
10
Packing and transportation:
Packing, shipping and delivery of equipment at site and unloading requirements shall be as per relevant Standard. Vendor to submit the procedure & all the relevant necessary datas / informations along with offer. Preparation of the skids for shipment is a crucial step in the completion of this contract. The Vendor must take in to consideration that all equipment and the skid itself shall be prepared for land transportation.
11
Statutory Approval:
The Equipment supplied shall be acceptable to local Electrical Inspectorate and changes required, if any, shall be carried out by the vendor without any extra cost.

12
Guarantee:
Equipment shall be guaranteed to meet the specified performance at specified conditions in terms of power, air flow, thermal performance, design conditions etc. Equipment and its components shall be guaranteed against faulty design, defective / improper materials poor workmanship or failure from normal use during the guarantee period. Vendor shall make all necessary and desirable alterations, repairs and replacement free of charge in the even of mal performance or defects occurring in the equipment during guarantee period. Also refer to guarantee clause under Purchase Order.

Doc. No. 266763-000-SP-4004 Appendix-A: Table of Compliance. Rev: B Page 27 of 37
The Vendor shall confirm that clauses of the specification have been complied with/accepted or further clarifications are desired, or Vendor has taken a deviation with reason thereto.
CLIENT : M/s. Hindustan Petroleum Corporation Ltd LPG Bottling Plant project at Bhatinda. Spec. Clause No. 1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 4 4.1 4.2 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 Conforms Yes/No Alternative Yes/No
VENDOR REF.
Clarification

Doc. No. 266763-000-SP-4004 Rev: B Page 28 of 37 VENDOR REF.
CLIENT : M/s. Hindustan Petroleum Corporation Ltd LPG Bottling Plant project at Bhatinda. Spec. Clause No. 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 5.24 6 7 8 8.1 8.2 9 9.1 9.2 10 11 12 Appendix A: Appendix B: Appendix C: Appendix D: Conforms Yes/No Alternative Yes/No
Clarification

Doc. No. 266763-000-SP-4004 Rev: B Page 29 of 37 VENDOR REF.
CLIENT : M/s. Hindustan Petroleum Corporation Ltd LPG Bottling Plant project at Bhatinda. Spec. Clause No. Appendix E: Appendix F: Appendix G: Appendix H: Conforms Yes/No Alternative Yes/No
Clarification

Appendix-B: Electrical System Data
[Doc. No. 266763-000-SP-4004BX]

Doc. No. 266763-000-SP4004BX Rev: B Page 1 of 2
Appendix-B: Electrical System Data 1.0 System Voltages
Nominal system voltage Highest system voltage Frequency Lightning Impulse withstand voltage Power frequency withstand voltage for 1 minute
11 KV 12 KV 50 Hz 75 KV (peak) 28 KV (rms)
0.415kV 440 V 50 Hz -2 KV (rms)
2.0
Supply variations
System voltage Steady state voltage Steady state frequency Combined Voltage Frequency System fault level at rated voltage
11 KV 10 % (*) 5 % (*) 10 % ( *) 31.5 KA for 3s ( Hold (*)) Resistance Earthed
0.415 kV 10 % 5% 5 % (*) 50 KA for 1s Solidly Earthed
System Earthing
( *) HPCL to advice. Vendor to take confirmation from HPCL before final design. 3.0 Control Supply for Electrical System
HV Circuit Breakers for Incomer feeders Spring Charging Motors Closing Circuit Trip Coil Alarm Indication : : : : :
Voltage ( in Volts) 110V DC 110V DC 110V DC 110V DC 110V DC
P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004_BX.doc

Doc. No. 266763-000-SP4004BX Rev: B Page 2 of 2
Relay Auxiliary Supply Heaters in Panels LV Air Circuit Breakers (Applicable Incomers & Bus coupler as applicable) Spring Charging Motors Closing Circuit Trip Coil Alarm Indication Relay Auxiliary Supply Heaters in Panels LV Motor Starters (Contactor controlled) Control Voltage for
: :
110V DC 240V AC, SPN
: : : : : : :
240V AC, SPN 110V DC 110V DC 110V DC 110V DC 110V DC 240V AC, SPN
110V AC, SPN derived through control transformer. 110V AC, SPN
Indications Space Heater Circuit :
240V AC, SPN ( From MLDB Bus)
Indications PMCC/BPMCC Local Control Panel : : 110V AC, SPN 110V AC, SPN
P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004_BX.doc

Doc. No. 266763-000-SP-4004 Appendix-C: Codes & Standards. Rev: B Page 31 of 37
IS-1248 ( Part I to IX) :2003 IS-2419 :1979 IS-2705 ( Part I to IV) : 1992 IS-3156 (Part I to IV) : 1992 IS-3231 : 1986 (Part I) / (Part II) : 1987 IS-4146 : 1983 IS-4201 :1983 IS-4237 :1982 IS 4691 :1985 IS-4794 ( Part I & II) : 1968 IS-5082 :1998 IS-6236:1971 IS-6875 : Part I : 1973
: : : : : : : : : : : : :
Direct acting indicating analogue electrical measuring instruments and their accessories Dimensions for panel mounting indicating and recording electrical instruments Current Transformer Voltage Transformer Electrical Relays for Power System Protection Application guide for Voltage Transformers Application guide for Current Transformers General Requirements for Switchgear and Control Gear for Voltages not exceeding 1000V AC or 1200V DC Degree of Protection provided by enclosures Push Button Switches Wrought aluminium & aluminium alloy bars, rode, tubes and sections for electrical purposes. Direct recording electrical measuring instruments. Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages up to and including 1000V AC and 1200V DC. Specification for Low-Voltage Switchgear and Control gear Assemblies Low Voltage Fuses Code of Practice for Selection, Installation and Maintenance of Switchgear and Controlgear Guide for uniform system of marking and identification of conductors and apparatus terminals Specification for Low-voltage Switchgear and Controlgear Low Voltage Switchgear & Controlgear- Part 1 - General rules Low voltage switchgear and control gear Assemblies Part 1: Type-tested and partially type-tested assemblies.
IS 8623 : ( Part I to II) :1983 IS-9224: Part I ( 1979) IS 10118 :1982 IS-11353 : 1985 IS 13947 : 1993 IEC 60947 :2007 IEC 61439 :2009
: : : : : : :

Appendix-D: Requisition for Engineering Documents RED Form Owner/Purchasers Office Hindustan Petroleum Corporation Ltd 8 S.V. Marg, Ballard Estate Mumbai- 400 001 Distribution Office Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059 Prints Documents shall be sent to: 4 4 FINAL The Purchasing Office via courier service The Purchasing Office via courier service TIMING FOR SUBMITTAL - for approval 2 weeks after order date
SPECIAL INSTRUCTIONS Production Schedule Manufacturing, inspection & testing sequence plan DRAWINGS OFF ER Approval drawings / Final drawings to be submitted under cover of an ADS form / FDS form respectively Submission of Following for each L V Switchgear, but not limited to: Guaranteed Technical Particulars General Arrangement Drawing showing masses, main dimensions Panel cross section details showing arrangement of auxiliary components, etc. Foundation Plan & Loading details Single line diagram, Feeder list Block Logic, Schematic & Connection Diagrams Bill of Material Soft starter schematic, component details, Block Logic diagram, connection diagrams, etc. Bus-bar sizing calculations Name Plate Drawing Make of Each Components Type Test, Routine Test Certificates Spares List for two Years Operation As Built Drawing SPARE PARTS DOCUMENTS ESPIR forms including 1 transparency TEST AND INSPECTION DOCUMENTS Documents to be submitted under transmittal Manufacturing report Test Report / Data Curves Calibration Certificates for testing Instruments. Bought out Equipments Certificates. Prints APPROV AL Prints
Required number for
Disk Prints - final issue 2 weeks after approval date Documents shall be submitted to:
2 2 -
4 4 4
2 2 2
4 4 4
2 -
4 4 4 4 4
2 2 2 2 2
4 4 4 4 4
2 2 2 -
4 4 4 4 4 4
2 2 2 2 2 2 2
4 4 4 4 4 4 4 Prints
Purchasing Office via courier service
Documents shall be submitted to: 1 1 1 1 4 4 4 4
Purchasing Office via courier service within 4 weeks of relevant test / inspection.

Doc. No. 266763-000-SP-4004 Rev: B Page 33 of 37 Purchasing Office via courier service not later than at time of dispatch of equipment. 1 1 1 4 4 4 Combine into one manual
OPERATING DOCUMENTS
Installation instructions Operating instructions Maintenance instructions ADDITIONAL REQUIREMENTS
1. Referenced standards / codes shall be the latest issue unless otherwise stated.
REMARKS Invoice must certify that the drawings and engineering documents specified above have been dispatched to all parties concerned. Any deviation from the timing for submittal of documents shall be notified to the Approval / Distribution Offices by fax or E mail. Shop fabrication shall not be started before the required approval drawings have been released for construction by the party concerned, unless otherwise stated on the "Approval Drawing Specification". Each document shall bear the item / tag and order reference number and be dispatched by air mail, unless other instructions are stated on the RED. Units / dimensions to be used on Engineering documents shall be SI. The documents shall be in English. Description on drawings and similar documents may be in other languages provided English translations are also given. Drawings and documents shall be suitable for microfilming and comply with accepted national or international standards for the preparation of technical drawings. Only the following standard sizes should be used: A4, A3, A2, and A1.

Doc. No. 266763-000-SP-4004 Appendix-E: Guaranteed Technical Particulars Rev: B Page 34 of 37
[Doc. No. 266763-000-SP-4004EX]

Doc No: 266763-000-SP-4004EX Rev: B Page 1 of 6
Appendix- E : GUARANTEED TECHNICAL PARTICULARS (* To be filled in by the Vendor) Note: Vendor shall submit guaranteed technical particulars separately for each L V Switchgear. It includes 000PMCC-001 (415 V PMCC), 000-BPMCC 001 (Bottling Plant MCC), 000-PDB-001(415 V PDB) & 000-MLDB001(415 V MLDB) Sr No A) 1) 2) 3) 4) 5) 6) B) 1) 2) 3) 4) 5) GENERAL Manufacturer Place of Manufacture Applicable codes & standards IAC classification for switchgear [as per latest IEC 62271-200] Type test certificate furnished Documents as per Specification furnished? ENCLOSURE Enclosure material Type & Execution Thickness of sheet metal Degree of Protection Paint Shade Inside Outside PMCC suitable for Busduct Incomer from Top Cable entry (Incoming & Outgoing) Minimum Cable alley width Material & thickness of gland plates Mounting height of components Minimum Maximum Overall dimension of Switchgear Busduct Entry Switchgear Heat Load for HVAC BUSBARS Rated continuous current [Main & Vertical] Short circuit rating [1 sec] Main Busbar location Busbar material Bus with insulating sleeves [Material of sleeves] Clearances Ph/Ph, Ph/n & Ph/earth Short circuit current rating for 1 sec Watts kA kA * mm mm mm mm * * mm * * * * * * * * * * * Description To be filled in by Vendor
6) 7) 8) 9) 10)
* *
11) 12) 13) C) 1) 2) 3) 4) 5) 6) 7)
* * * * *
mm kA
* *
P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004EX.doc

Sr No 8) 9)
Description Final Temperature of Busbars Horizontal Busbar size Phase Neutral Vertical Busbar size Phase Neutral Busbars support insulator make & voltage class Spacing between Busbar supports Shrouds on Joints & Tap-offs Inter panel barrier AIR CIRCUIT BREAKER Make Type Voltage, frequency & poles Rated current Short circuit rating Sym. interrupting capacity Total interrupting time Making current (Peak) Power Frequency Withstand Voltage Lightning Impulse Withstand Voltage Anti pumping feature provided Trip-free feature Provision for pad locking facility in the OFF position No. of auxiliary contacts for owners use Spring charging motor rating at 240V AC Time required to charge spring from fully discharged condition Control Supply voltage(DC) Maximum tripping coil consumption /ACB Maximum closing coil consumption /ACB MCCB Make Voltage, frequency & poles Rated current Short circuit rating Sym. interrupting capacity Total interrupting time A kA kA ms VA ms V VA VA A kA kA ms kA kV kV C mm
To be filled in by Vendor * *
10)
mm
11) 12) 13) 14) D) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12)
* mm * * *
* * * * * * * * * * * * * * * * * * *
13) 14) 15) 16) 17) 18) E) 1) 2) 3) 4) 5) 6)
* * * * * *

Sr No 7) 8) 9) 10) 11) F) 1) 2) 3) 4) 5) 6) 7) 8) 9) G) 1) 2) 3) 4) 5) H) 1) 2) 3) 4) 5) I) 1) 2) 3) 4) 5) 6) J) 1)
Description Making current (Peak) Operating mechanism Trip - free feature Provision for pad locking facility in the OFF position No. of auxiliary contacts for owners use SWITCHES Make Type Duty Rating Interlocking with Door + Defect Interlocking facility Padlocking in OFF position Shrouding of Incoming Terminal Rotary / Link Type Single Break / Double Break FUSES Make Type Rupturing Capacity Rating Control Fuse Make CONTACTORS Make Type Service Rating Duty OVERLOAD PROTECTION RELAY Make Type SPPR feature Trip class Reset facility CT operated from which rating onwards? EART FAULT PROTECTION RELAY Make A A A kA
To be filled in by Vendor * * * * *
* * * * * * * * *
* * * * *
* * * * *
* * * * * *

Sr No 2) 3) 4) 5) 6) K) 1) 2) 3) 4) 5) 6) 7) 8) 9) L) 1) 2) 3) 4) 5) 6) 7) 8) M) 1) 2) 3) N) 1) 2) 3) 4) 5) O) 1) 2)
Description Type Rating CBCT provided Timer provided Reset facility CURRENT TRANSFORMER Make Type & services Voltage & frequency Ratio Rated burden Accuracy class Short circuit current rating Class of Insulation Shorting link for secondary POTENTIAL TRANSFORMER Make Type & services Voltage & frequency Ratio Rated burden Accuracy class Short circuit current rating Class of Insulation PROTECTIVE RELAYS Make Type Control voltage INDICATING INSTRUMENTS Make Size Type Range for Incoming & Outgoing Burden WIRING Insulation Voltage class V VA V kA VA kA VA A
To be filled in by Vendor * * * * *
* * * * * * * * *
* * * * * * * *
* * * [To be filled for each type of instruments] * * * * *
* *

Sr No 3)
Description Size & Colour code Power Circuits CT secondary Control circuits ANNUNCIATION SYSTEM Make Applicable standard Type System Voltage [DC] No. of windows, Display device, Facia type and LED colour etc., Flash rate Response time Operational sequence (Alarm sequence) Power consumption Dimensions CONTROL SUPPLY Auxiliary Busbar size 110V DC 110V AC 240V AC Control transformer Ratio Rating Nos/Swgr Provision of standby control Transformer in each switchgear? Auto-change over provided between Control Transformers? Sleeving for control Busbars [Material of sleeves] SOFT STARTER Make Type of Solid state Soft Starter Frequency Range Starting capacity at maximum rated full load current Ir [* times Ir for * secs]. Allowable no. of starts per hour Overload capacity & duration Selectable Overload Class range Selectable Start/stop mode [Voltage / Torque ramp] Selectable range of Start Ramp Selectable range of Stop Ramp Control Type mm VA mm V
To be filled in by Vendor *
P) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) Q) 1)
* * * * * * * * * *
2)
3) 4) 5) R) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11)
* * *
* * * * * * * * * * *

Sr No 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) S) 1) 2) 3) 4) T) 1) 2) 3) 4)
Description Selectable Torque limit range Control of Soft starter with field bus provided Power circuit continuous Rating [SCRS] SCR peak inverse voltage SCR protection fuse rating Power Factor Efficiency (Converter with Output Filter) Transient voltage protection Total Harmonic Distortion (THD) Noise Level Type of cooling Bypass Contactor provided Protection provided For the Soft starter Requirement of Air-conditioning EARTHING Earth Bus Size Material Location Provision for Connection to Grid LOAD ON BATTERY ACB Closing Coils ACB Tripping Coils Burden of Auxiliary Relays (which will be on Battery) Annunciation system VA VA VA VA %
To be filled in by Vendor * * A V A * * * * * * * * * * * *
* * * *
* * * *

Appendix-F: Electrical Drawings.
01. 02. 03. 04. 05. 06.
Dwg. No. 266763-000-410-001B:- Overall Key Single Line diagram. Dwg. No. 266763-000-410-002B:- Single Line diagram for PMCC Dwg. No. 266763-000-410-003B:- Single Line diagram for Bottling Plant MCC Dwg. No. 266763-000-410-004D:- Overall Lighting Distribution Single Line Diagram Dwg. No. 266763-000-410-049D:- Single Line diagram for Power Distribution board. Dwg. No. 266763-000-425-006D:- Equipment Layout of MCC room & Transformer Cell.

Appendix-G: Control Schematics drawings.
01. 02. 03.
Dwg. No. 266763-000-410-050D:- Typical Control Schematics.-DOL ( Sheet 1) Dwg. No. 266763-000-410-050D:- Typical Control Schematics.-R-DOL ( Sheet 2) Dwg. No. 266763-000-410-050D:- Typical Control Schematics.- STAR-DELTA ( Sheet 3)

Appendix-H: Technical Specification for 415 V Bus Duct.

Doc. No. 266763-000-SP4004HX Rev: B Page 1 of 13
Specification for LV Busduct

(Appendix H to Specification for 415V PMCC, Bus duct, Aux. PDB, MLDB, Spec No. 266763-000SP-4004)
List of Contents 1. 2. 3. 4. Introduction Scope of Supply Bill of Material for Busducts Technical Particulars: 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 4.7. 4.8. 4.9. 4.10. 4.11. 4.12. 5. 6. 7. Construction Busbars Busbar Supports Space Heater: Earth Bus: Termination at the ends of Busduct Special Chambers Marking for Reassembly Name Plates Busduct Supporting Arrangement Makes of Component Painting
Pages 2 2 2 4 4 5 6 6 6 6 6 7 7 7 7 8 9 10 12
Codes & Standards Requisition for Engineering Documents Guaranteed Technical particulars
P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004 HX, Rev-0.doc

Introduction
This specification covers the minimum requirements for the Design, Manufacture, Material procurement, Assembly, Painting, Inspection at manufacturers works, and Delivery to site, supervision of Erection of Non-Segregated Metal Enclosed three Phase Neutral Busduct This specification is to be read in conjunction with Specification for 415V PMCC, Bus duct, MCC, PDB, MLDB, Spec No. 266763-000-SP-4004.
Scope of Supply
The following LV Bus duct shall be supplied, in accordance with this specification; standards stated herein.
1. 2. 3. 4. 5. 6
Busduct No. Voltage Grade (Volts) Rating (Amp) PMCC Transformer No. Location
000 -BD-001 415 1600 000-PMCC-001 000-DT-001 MCC Room
3
3.1
Bill of Material for Busducts

The 415V Bus ducts shall be supplied with Materials listed below:
Sl No. a. b. c. d. e. f. g.
Description of Parts Straight Length (Indoor) Straight Length (Outdoor) 90 Degree Bend - Horizontal / Vertical Adaptor Chamber (at Switchboard End) Adaptor Chamber (at Transformer End) TPN Copper Flexible Set for Transformer End Connection TPN Copper Flexible Set for Switchboard End
Quantity (approximate) 4 Meter. 10 Metre. 5 Sets. 1 No. 1 No. 1 Set 1 Set

Doc. No. 266763-000-SP4004HX Connection h. i. j. k. l. m. n. o. Phase-cross over assembly (as required by manufacturer) Aluminium Flexible (if required) Rubber Bellow at transformer end (if recommended by manufacturer) Wall Frame Assembly with Seal of Bushing Silica gel Breather (if recommended by manufacturer) Fire Barrier 240V Space heater +Thermostat Set with junction box Supporting Structure (galvanized) with hardware as required 3.1.1 Vendor to Estimate the actual quantities during execution Notes to Vendor: 1 Set 1 Set 1 Set 1 Set. 1 No. As required. 1 Set 1 Lot Rev: B Page 3 of 13
a) Indoor and Outdoor Lengths indicated are tentative. These lengths are given only to give an idea about approximate length of Busduct. Vendor shall accept the changes in Busduct route, length & accessories till final drawing approval. To arrive at the total length of Busduct, it will be measured along the centre line of the Busduct which will include bends and phase cross over chambers. b) Vendor shall manufacture Busducts as per final approved drawings and bill of material shall be treated as basis for final invoice c) Following drawings shall be furnished to successful vendor for Busduct engineering in the event of order. i. Equipment Layout ii. Vendor Drawing for Transformer
The Scope shall also include

3.1.2 Inspection and Testing at manufacturers works, as specified. Submission of documents as specified. Painting as specified. Preservation, preparation of shipment and delivery to site. Supervision of Erection at site. List of Spares for two years normal operation. Start-up spares and commissioning spares. List of special tools required (Vendor to provide list with the offer). Any other items, required to make system complete. Exclusions Installation/Erection & commissioning.

4
4.1
4.1.1
Technical Particulars:
Construction
The Busduct shall be of box frame construction of Sheet Steel enclosure suitably braced to withstand the maximum mechanical and electrodynamic forces. The Busduct enclosure shall be fabricated from 2 mm thick Sheet Steel. Eddy current heating, if applicable, shall be taken into account. The section of the Busduct shall be rectangle & non-phase segregated. The degree of protection shall be IP-55.The Busduct shall have fire barriers inside. The Busduct enclosure shall be suitable for indoor/outdoor installation as specified. The outdoor portion of Busduct shall be suitable for outdoor installation without any additional protection from owners end. However, rain hood shall be provided as an additional protection for outdoor installation. Canopy and proper fixing arrangements shall be provided for the same. The Busduct shall be provided with removable top covers fitted with gaskets secured by sufficient number of nuts, bolts to ensure that these covers are dustproof. All joints and covers shall be provided with non-deteriorating type gaskets of neoprene between joints. These covers shall be of suitable length for ease of removal and shall be arranged to give complete accessibility to the busbars, joints, bends and supports, etc. The entire busduct shall be dust and vermin proof. Louvers shall not be provided. The design of Busduct enclosure shall be such that it will withstand the operating conditions arising out of the following:
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
(a) Normal operating conditions (b) Momentary short circuit currents (c) Rigours of adverse weather conditions, and
(d) Combinations of above.

4.1.7 The busduct shall be provided with flanged ends to connect the busduct to transformer at one end and switchgear at other end. These flanges shall match with corresponding flanges in the equipment to which these are connected. Vendor shall provide suitable termination arrangement at 415V switchgear and transformer ends. Proper alignment and co-ordination between the busduct and power transformer / switchgear terminations shall be the responsibility of the busduct supplier. The purchaser will furnish the drawings required by the vendor. The busduct shall be supplied complete with all the hardware necessary for making the terminations 4.1.8 All hardware shall be hot dip galvanised/Cadmium Plated. The bolts shall be full threaded and high tensile quality. Belleville washers for all current carrying conducting parts of the busbars and plain washers for enclosure and covers shall be provided for every bolt.

Doc. No. 266763-000-SP4004HX 4.1.9 Rev: B Page 5 of 13
Filter type drain holes shall be provided for draining out condensed moisture. The filter element shall be such that it will allow escape of moisture but prevent ingress of dust. This shall be removable type for cleaning purposes.
4.1.10 Bolted inspection cover shall be provided throughout length of Busduct. At the wall crossing of the busduct, there should not be removable type inspection cover. 4.1.11 Proper wall sealing arrangements shall be provided at the wall where bus duct enters the substation building. Busduct with wall mounting flange will be acceptable for the sealing arrangement. 4.1.12 Top covers of the busduct shall be so located that they will not fall within the wall crossing section. Busduct shall be supported from overhead hangers inside the substation. 4.1.13 The enclosure shall be provided with suitable mounting lugs at suitable interval. The mounting lugs shall be suitable for hanger type supports. Vendor shall design and indicate the supporting arrangement for busduct. 4.1.14 The Busduct shall be designed for an ambient temperature of 50 Deg Centigrade. (For indoor) & 0 55 C for outdoor. Under Normal operating conditions, the surface temperature of the enclosure shall not exceed 80 C (i.e., the temperature rise shall be limited to 30 Deg centigrade.)
4.2
4.2.1
Busbars
The busbars shall be of electrical grade Aluminium flats adequately sized to carry maximum specified continuous current & short circuit current for 1sec, at maximum site temperature specified. The final temperature of busbars and connectors at joints between connector and busbar should not exceed 95 C when carrying rated currents. Also the final busbar temperature shall not exceed 250 C when specified short circuit current for 1sec duration flows through. Current density of Busbars shall be 0.8 Amp/mm2 max. All busbars shall be insulated with heat shrinkable PVC sleeves. All busbars shall be colour coded such that on removal of any inspection cover the phases shall be identifiable. Busbar clamps shall be provided to maintain the busbars in position. These clamps shall be made out of fully heat treated magnesium silicate aluminium alloy to IS: 5082, 1998. The clamp design shall be such that it holds the busbar firmly and also allow sliding movement of busbars without generating internal stresses to accommodate expansion during operation at rated current. For fixing the busbars to the busbar supports, cadmium plated bolts, nuts and washers shall be employed. Wherever required for long run of busduct, expansion joints with flexible strips shall be provided to allow for expansion and contraction due to temperature variations arising out of normal continuous current flow and short circuit current flow for specified duration. Minimum one expansion joint shall be provided for each 3000 mm long straight length of busduct. In case this is not provided, Vendor shall substantiate the same with Calculations.
4.2.2
4.2.3
4.2.4

Doc. No. 266763-000-SP4004HX 4.2.5 Rev: B Page 6 of 13
Suitable Bimetallic strips shall be provided wherever copper to aluminium connections are envisaged.(For flexible jumpers at expansion joint & end terminations) All the hardware for connections both at transformer end & the PMCC end shall be in scope of supply.
4.2.6
4.3
4.3.1
Busbar Supports
The busbars shall be supported by non-deteriorating type (non-hygroscopic, non-carbonising, Corrosion resistance) Solid core resin cast epoxy insulators of requisite electrical / mechanical strength. The mechanical strength shall be sufficient to withstand forces arising out of peak short circuit current. Each shipping section shall meet this requirement separately. Adequate Creepage distance shall be available on insulator to operate under high humid conditions and effects of condensed moisture due to variations in temperature within busduct due to different conditions of loading. The spacing of the insulating supports shall be decided on the basis of the fault withstand capacity
4.3.2
4.3.3
4.4
Space Heater:
Busduct shall be provided with anti-condensation space heaters with controlling thermostats of adequate capacity to maintain internal temperature above dew point to prevent moisture condensation in busduct. Space heaters shall be rated for 240V, single phase, 50 Hz AC supply. Space heater shall be provided on both sides of the fire barrier.
4.5
Earth Bus:
Earth bus of 50 mm x 8 mm aluminium shall run on the external side of the busduct through the whole length of the busduct and shall be positively connected to the body of the busduct enclosure. At both ends of the earth bus provision shall be made to connect it to main earthing system.
4.6
4.6.1
Termination at the ends of Busduct

The busduct shall be provided with flexible at both ends for connecting it with transformer at one end and 415V switchgear at other end. The Flexibles shall be made of thin copper strips. The ends of the flexible shall be clamped by copper plate. The ends of flexible shall be tin plated.
4.6.2
4.7
Special Chambers
To match the phase sequence of the two equipments connected by busduct, a suitable phase cross over chamber shall be provided; if required, at suitable location. This chamber shall generally be located in transformer yard.

4.8
Marking for Reassembly

All busduct parts like enclosure, adaptor box, rain hoods, enclosure covers, supports, busbar and busbar fish plates shall be identified distinctly by clear numbers. These shall be indicated in drawing.
4.9
Name Plates
Permanent non-corrosive nameplate with engraved white letters on black background shall be fixed on each Busduct with its designation & service description. The nameplate shall indicate the following: First line : Equipment Item No. Equipment Description System voltage. Equipment Continuous & short Circuit Rating.
Second line: Third line: Fourth Line:
4.10
Busduct Supporting Arrangement
4.10.1 Busduct supplier shall quote separately unit rate for busduct supports with details of the supporting members and quantity being offered. 4.10.2 The supports offered shall be as specified below. (a) (b) (c) Supporting structure shall be fabricated from standard steel sections and shall be hot dip galvanised after fabrication. Support structures shall be designed to withstand the dead weight of the busduct and the short circuit forces under maximum fault conditions. Support structures shall include support members like brackets, hangers, vertical / longitudinal beams, channels, nuts, bolts, washers and other hardware required for erection and support of entire busduct. Indoor portion of the busduct may be supported from wall or ceiling as per layout furnished. Outdoor portion of the busduct shall be supported from ground below on suitable foundations in ground.
(d)
4.11
Makes of Component
4.10.2 Manufacturer shall furnish standard list of components makes for the complete the 415V
Busduct assembly. This list must be included with the offer.

4.12
Painting
All metal surfaces shall be thoroughly cleaned and degreased, pickled and phosphatised. Thereafter, a coat of phosphate paint and a coat of zinc chromate primer shall be applied. After removing all imperfections, all metal surfaces shall be sprayed with two coats of final paint as per colour shade RAL 7032. Paint thickness shall be 100 microns. Final coat shall be of epoxy based. All unpainted parts shall be plated to prevent corrosion. Inside surface of Busduct enclosure shall be painted with black matt colour for heat dissipation.

Codes & Standards : Specification for Low Voltage Switchgear and Control gear Assemblies: Particular Requirements for Busbar Trunking Systems. Specification for Low Voltage Switchgear and Control gear Wrought Aluminium and Aluminium alloy bars, rods, tubes and sections for electrical purposes. Guide for making of Insulated Conductors. General Requirements for Switchgear and Control Gear for Voltages not exceeding 1000V AC or 1200V DC Degree of Protection provided by enclosures
IS-8623 (Part 2), 1993
IS-13947, 1993 IS-5082, 1998 IS-5578, 1984 IS-4237, 1982 IS -4691, 1985
: : : : :

Requisition for Engineering Documents

RED Form Owner/Purchasers Office HI-TECH CARBON, (A unit of Aditya Birla Nuva Ltd.) Murdhwa Indl. Area, P.O. Renukoot, Dist. Sonebhadra (U.P.), Pin-231 2127 Distribution Office
Mott MacDonald Consultants (India) Pvt. Ltd. Kothari House, CTS No. 185 Off Andheri - Kurla Road Andheri (East) Mumbai 400 059 SPECIAL INSTRUCTIONS Prints Documents shall be sent to: Production Schedule 4 The Purchasing Office via courier service Manufacturing, inspection & testing sequence plan 4 The Purchasing Office via courier service Required number for TIMING FOR SUBMITTAL DRAWINGS OFFE R Prints APPRO VAL Prints FINAL Disk - for approval 2 weeks after order date
Prints - final issue 2 weeks after approval date Documents shall be submitted to:
Submission of Following for each 415V Busduct, but not limited to: Guaranteed Technical Particulars with values filled up. General Arrangement Drawing with cross sectional view of bus duct with details of Insulator, busbar clamps, spacing of busbar phases and spacing of Insulators and cross section & length of flexible Plan View of busduct connecting two equipments with dimensions from centre to centre equipments Side elevation of busduct with all levels or dimensions marked. End View of busduct with busbars and flexible connecting the transformer with clearances between bolt/Nut of adjacent phases and same for PMCC End. Design Calculation for: (i) Busbar sizing (ii) Final Temp.of busbars when carrying rated current Continuously in still air. (iii) Final Temp.of busbars when 3 phase SC Current flow for one second (iv) Final Temp.of busbar enclosure for conditions (ii) & (iii)
2 2
4 4
2 2
4 4
4 4
2 2
4 4 Purchasing Office via courier service

Doc. No. 266763-000-SP4004HX (v) Temp. rise Calculation (vi) Busbar Support Calculations under short circuit conditions. (vii) Surface Temp.of enclosure under normal operating conditions. Flange details of connecting adaptors at both ends Wall sealing frame Name Plate Drawing Make of Each Components Type Test, Routine Test Certificates Spares List for two Years Operation As Built Drawing SPARE PARTS DOCUMENTS Rev: B Page 11 of 13
2 2 2 -
4 4 4 4 4 4 4
2 2 2 2 2 2 2 2
4 4 4 4 4 4 4 4 Prints Documents shall be submitted to:
TEST AND INSPECTION DOCUMENTS Documents to be submitted under transmittal Manufacturing report Test Report / Data Curves Calibration Certificates for testing Instruments. Bought out Equipments Certificates. 1 1 1 1
4 4 4 4 Purchasing Office via courier service within 4 weeks Of relevant test / inspection. Purchasing Office via courier service not later than at time of dispatch of equipment.
OPERATING DOCUMENTS
Installation instructions Operating instructions Maintenance instructions ADDITIONAL REQUIREMENTS
1 1 1
4 4 4
Combine into one manual
1. Referenced standards / codes shall be the latest issue unless otherwise stated.
REMARKS Invoice must certify that the drawings and engineering documents specified above have been dispatched to all parties concerned. Any deviation from the timing for submittal of documents shall be notified to the Approval / Distribution Offices by fax or E mail. Shop fabrication shall not be started before the required approval drawings have been released for construction by the party concerned, unless otherwise stated on the "Approval Drawing Specification". Each document shall bear the item / tag and order reference number and be dispatched by air mail, unless other instructions are stated on the RED.
Units / dimensions to be used on Engineering documents shall be SI. The documents shall be in English. Description on drawings and similar documents may be in other languages provided English translations are also given. Drawings and documents shall be suitable for microfilming and comply with accepted national or international standards for the preparation of technical drawings. Only the following standard sizes should be used: A4, A3, A2, and A1.

Guaranteed Technical particulars

(* To be filled in by the Vendor)
Sr. No A) 1) 2) 3) 4) 5) 6) B) 1) Description GENERAL Manufacturer Country of Manufacture Applicable codes & standards List of Type test certificates furnished List of Routine tests offered Documents as per Cl. 5 of Specification furnished? CONSTRUCTION Busduct Enclosure a) Enclosure material b) Thickness of Enclosure c) Degree of Protection Indoor / Outdoor[without canopy] Type & Execution Paint Shade a) External Paint Shade b) Internal Paint Shade Dimensions: Width x Length x Height Slopping Canopy for outdoor portion a) Material of Canopy b) Thickness of Canopy Number of Bends Provision for phase Crossover Chamber Location of phase Crossover Chamber Type of Gasket used for Joints and Covers Wall Frame Assembly(for Sealing) Provision of drain plug to remove condensated moisture Busduct Top Cover removal provision Provision of Space Heaters Provision of Fire Barrier RATINGS Continuous current rating Fault Current withstand capacity for 1 sec. Voltage Grade Design Ambient Temperature Maximum Temperature rise above Design Ambient Temperature of a) Busbar At rated continuous current At rated short circuit current b) Enclosure Derating Factors considered for busbar sizing mm * * * * * * To be filled in by Vendor
mm
* * * * * *
2) 3)
4) 5)
mm
* * * * * * * * * * * *
6) 7) 8) 9) 10) 11) 12) 13) 14) C) 1) 2) 3) 4) 5)
Amps kA Volts Deg.C Deg.C
* * * *
6)
* * * * *

Doc. No. 266763-000-SP4004HX Sr. No D) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) Description BUSBARS Busbar Material Busbar Type (Cross-Section) Number of Busbars per Phase Size of Busbar Current Density of Busbars Neutral Busbar Cross Sectional Area Earth Busbar Material Earth Busbar Size Earth Busbar Location w.r.t. Enclosure Busbar Insulation: a) Material b) Thickness c) Class Busbar Colour Identification Heat shrinkable sleeves for Busbars Minimum Air Clearance Between a) Phase - Phase b) Phase - Neutral c) Phase - Enclosure Provision for Busbar Expansion Joints Internal of Busbar Expansion Joints Flexible Connections provided at a) Number of Flexible Connections per phase b) Material of Flexible Connections BUSBAR SUPPORTS Type of Busbar Supports (Material) Distance between Busbar supports BUS DUCT SUPPORTS Type of Busbar Supports (Material) Distance between Busbar supports mm * * * * * * * * * * * * * * * * * * * * * * * mm * * * Rev: B Page 13 of 13 To be filled in by Vendor
mm 2 A/ mm Sq.mm mm
11) 12) 13)
14) 15) 16)
E) 1) 2) F) 1) 2)
mm

Spec For 415v MCC, MLDB

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LPG BOTTLING PLANT , BATHINDA

Doc. No. 266763-000-SP-4004 Rev: B Page 1 of 37

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

Codes and Standards 4.1 4.2 General Conflicting Requirements

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LPG BOTTLING PLANT , BATHINDA

5.19 5.20 5.21 5.22 5.23 5.24 6 7 8

Installation and commissioning: Packing and transportation: Statutory Approval: Guarantee:

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

Location and Environmental Conditions

Design ambient temperature for Electrical Equipment (Indoor):

Electrical System Data

Refer Doc No.: 266763-000-SP-4004BX [in Appendix B] for details.

Electrical Equipment & Material:

415V PMCC/MCC/Bus duct/ PDB/MLDB as per following details:

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

Ref. Dwg. No. 266763-000-425-006D.

000-MLDB-001( 415 V MLDB )

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

415 V 433 V 400 A 50 kA for 1 Sec. As per SLD

400mm wide 6.0

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

Installation/Erection & commissioning.

LPG BOTTLING PLANT , BATHINDA

Codes and Standards

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

415 V BPMCC (000-BPMCC-001)

415 V PDB (000-PDB-001)

415 V MLDB (000-MLDB-001)

Motor Control philosophy.

Motor Feeder Requirement:

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

5.4.5 5.4.6 5.4.7

Air Circuit Breakers (ACB):

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

Moulded Case Circuit Breakers (MCCB):

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

Over Load Relays & Timers:

Control Switches, Indication Lamps, Push Buttons & Control Fuses:

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

5.9.3 5.9.4 5.9.5 5.9.5 5.9.6 5.9.7 5.9.8

Indicating Instruments & Meters:

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

LPG BOTTLING PLANT , BATHINDA

LPG BOTTLING PLANT , BATHINDA

Wiring and Identification:

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

11 KV 10 % () 5 % () 10 % ( ) 31.5 KA for 3s ( Hold ()) Resistance Earthed