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Sabarmati River Front Development Corporation Limited

ELECTRICAL PANELS FOR PUMPSETS

415 V SWITCHGEAR

1.1

Power-cum-Motor Control Centers (PMCCs) & Motor Control Centers (MCCs) Codes
& Standards
The design, construction, manufacture and performance of equipment shall conform to
latest applicable BIS standards and comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment will be installed.
The relevant Indian Standards are:

Title

Code No.

Switchgear General Requirements

IS13947/BS5486/IEC947

Factory Built Assemblies of Switchgear and

Control gear for Voltages up to and including
1000V AC & 1200V DC

IS8623/BS5486/IEC60439

Air Break Switches

IS13947-P3/BSEN60947/IEC60947-3

Miniature Circuit Breakers

IS8828/BSEN60898

Low voltage Fuses

IS13703/BS1362/IEC269-1

Contactors

IS13947/BSEN60947-4/IEC60947-1

Starters

IS13947/BSEN60947-4/IEC292-1 to 4

Control Switches / Push Buttons

IS6875/BSEN60947/ IEC60044

Current Transformers

IS2705/BS7626

Voltage Transformers

IS3156/BS7625/IEC60186

Indicating instruments

IS1248/BS89/IEC60051

Marking and Identification of Conductors and

Apparatus Terminals

IS11353/BS159

A.C. Electricity Meters

IS722, 8530/BS5685 / IEC 145, 211

Degree of Protection

IS13947/IEC947-P1

Selection, installation and maintenance of

switchgear and control gear

IS10118

Bus Bar

IS613

Relays

IS3231/IS3842/BSEN60947-5-1 /IEC60255

Push Buttons

IS6875/BSEN60947/BSEN60037/IEC60037

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1.2

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General
For uniformity of appearance all switchgear and control panels shall have a common
appearance and colour.
In order to reduce the spares holding to a minimum, electrical components of a
standardized approved make & type shall be used throughout the Works.

1.3

Features of Construction
The switchgear shall be metal enclosed, modular (compartmentalized) type suitable for
indoor, floor mounting and shall have following features:

1.4

Height shall not exceed 2350 mm including the integral base channel
Shall be single or double front execution and fixed or draw out type as specified.
Shall be provided with proper neoprene gasketing for removable covers, doors,
between panels and base frame and all around the perimeter of adjacent panels to
achieve required degree of protection.
The switchgear shall be divided into distinct vertical sections each comprising :
- A completely metal enclosed bus bar compartment running horizontally.
- Individual feeder modules arranged in multi-tier formation. It is essential that the
modules are integral multiples of the basic unit size to provide for flexibility in
changes, if any, at site.
- Enclosed vertical bursars serving all modules in the vertical section. For safety
isolation of the vertical bus bars, insulating barrier with cut-outs shall be provided
to allow the power stab contacts to engage with vertical bus bars.
- A vertical cable alley covering the entire height. The cable alley shall be minimum
300 mm wide for motor control modules and 500 mm wide for circuit breaker
controlled modules.
- A horizontal separate enclosure for all auxiliary power & control buses, as
required, shall be located so as to enable easy identification, maintenance and
segregation from the main power buses. Tap off connections from these buses
shall be arranged separately for each vertical section.
- The Switchgear shall be easily extendable on both sides by the addition of vertical
sections after removing the end covers.
- Operating devices shall be incorporated only in the front of switchgear.
- Each shipping section shall have metal sheets at both ends.
- Cable alley shall be provided with suitable hinged doors.
- Rear of single front switchgear shall be provided with removable doors/sheets with
captive screws.
- All doors shall be with concealed type hinges and captive screws
- Each vertical section shall be equipped with panel accessories as specified
elsewhere.

Withdrawable Components
Where removable or withdrawable components are specified they shall, where
appropriate, be provided with distinct locations for test and removed position.
Provisions shall be made to padlock the withdrawable part in each position.
Withdrawable parts shall not be withdrawn or re-inserted unless the main circuit has
been interrupted.
The degree of protection applying to the connected position shall be maintained in the
test and disconnected position and during transfer from one position to another.
Withdrawable parts shall be fitted with positive guides to ensure correct alignment of
the isolating contacts in whichever circuit or earthing position is selected.

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1.5

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Safety Shutters
A set of safety shutters shall be provided to cover each three phase group of
stationary isolating contacts. The shutters shall be opened automatically by a positive
drive from the circuit breaker moving portion and when closed shall prevent access to
the stationary isolating contacts. When the circuit breaker is withdrawn each set shall
be capable of being individually operated and of being padlocked in the closed
position.
To facilitate inspection and testing, a device shall be provided for propping (not
locking) the shutters in the open position and for releasing them into the closed
position. The device shall be arranged to be cancelled by the moving portion to ensure
the restoration of the automatic feature of the shutters.
Busbar shutters shall be coloured red and labeled BUSBARS in large white letters.
Circuit shutters shall be labeled with a large white arrow pointing in the direction of the
section of busbars to which the contacts are connected.

1.5.1

Interchangeability
All identical equipment and corresponding parts be fully interchangeable without any
modifications.

1.6

Safety Earthing
Assemblies shall be provided with earthing facilities as follows:
For single compartment assemblies an earth stud shall be provided.
For multi-compartment assemblies a clearly marked continuous copper earth bar of
adequate size, 25 mm x 6 mm minimum, shall run the entire length of the assembly
and shall be provided with facility for connection to Plant earthing system conductor.
The short-time rating of the earth busbar and connections shall be not less than that of
the associated equipment or the maximum through-fault current of the power source.
The temperature rise of the busbar and connections under fault conditions shall not
cause damage to the connections of any equipment to which they may be connected.
No earth terminal bolts or studs shall be less than 8 mm diameter.
An earth bond of minimum size 4 mm2 shall be made to all enclosure doors where
electrical supply has been taken.

1.7

1.8

Safety Features
Electrical equipment shall be designed and constructed to provide a maximum
standard of safety for operating and maintenance personnel.
Access to any enclosure shall be possible only when the circuit isolator is open and
connections within the enclosure are isolated or fully shrouded against accidental
contact or when connections within the enclosure are not at a voltage exceeding 24 V.
Where a test facility exists for use with the enclosure door open, all live contacts shall
be shrouded to prevent accidental contact.
Isolators shall be pad-lockable in the OFF position only. It shall not be possible to
open the compartment door when the isolator is in the ON position.
Arrangement of Internal Components
Internal components shall be laid out in a logical manner in order to provide freedom
of access to terminations and to allow removal of any component without interference
to adjacent components.
Particular attention shall be paid to the location of heat dissipating equipment such as
power supplies etc in order that they do not have a detrimental effect on adjacent
cabling or components.

1.9

Miscellaneous Accessories for panels

The DC and AC auxiliary supplies shall be distributed inside the switchgear with
necessary isolating arrangements at the point of entry and with sub-circuit MCBs as
required.

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Space heaters of adequate capacity shall be provided inside each panel to prevent
moisture condensation within the enclosure. The space heater shall be suitable for
240V, 1 ph., 50 Hz supply and complete with MCB for isolation purpose and
thermostat to cut off heater at pre-set temperature.
Each switchgear panel shall be provided with 240 Volts, 1 phase, 50 Hz, 5 amps. 3 pin
receptacle with MCB located at a convenient position.
A 20 W F.T. L. interior illuminating lamp together with operating door switch and
protective fuse shall be provided for each panel at an appropriate location.

1.10

Design of Switchgear
The LV Switchgear shall be fuse-less type. i.e. Motor Protection Circuit Breakers
(MPCBs) and Moulded Case Circuit Breakers (MCCBs) shall be provided in place of
switch-fuse and fuse-switch combination.

1.11

Sheet Metal Work

Metal enclosure shall comprise rigid welded structural frame enclosed completely by
metal sheets, minimum 2.5 mm thick, hot rolled (HR) or 2.0 mm thick, cold rolled, cold
annealed (CRCA), smooth finished, leveled and free from flaws.
All sheet steelwork shall be phosphated in accordance with the following procedure
and in accordance with relevant standards for phosphating iron and steel.
Oil, grease and dirt shall be thoroughly removed by emulsion cleaning.
Rust and scale shall be removed by pickling with dilute acid followed by washing with
running water, rinsing with slightly alkaline hot water and drying.
After phosphating, thorough rinsing shall be carried out with clean water, followed by
final rinsing with dilute dichromate solution and oven drying.
The phosphate coating shall be sealed by the application of two coats of primer
suitable for finishing by powder coating.
After application of the primer, the fabricated sheet steelwork shall be subject to epoxy
based powder coating. Shade of powder coating is subject to approval by the
Engineer-in-Charge.
The final finished thickness of the coating on steel shall not be less than 100 microns
and shall not be more than 150 microns.
Each floor-mounted, free-standing panel shall be provided with its own base channel
of at least 50 mm height, providing rigidity to the entire assembly. The base channel
may be painted matt black.
Panel door shall be supported by strong hinges and braced in such a manner as to
ensure freedom from sagging, bending and general distortion of panel or hinged parts.
All the hardware such as nuts and bolts shall be of stainless steel.
All doors, panels, removable covers shall be gasketted all around with neoprene
gaskets. All louvers shall have screens and filters. Vent openings shall be covered by
fine mesh on the vertical face. The screens and grills shall be made of either brass or
galvanized iron wire mesh.
Separate removable gland plates with minimum thickness of 3 mm shall be provided
for power and control cables. The gland plate for the power cables shall be of nonmagnetic material.
Structure, buses and control wiring troughs shall be so designed and arranged as to
make future extensions readily feasible.
Lifting lugs shall be provided for installation purposes.

1.12

Degree of Protection provided by the enclosure

IP 54 for equipment mounted indoors. In exceptional cases, where heat dissipation
is an important consideration, degree of protection IP42 may be accepted by the
Engineer-in-Charge. However, this will be on case-to-case basis.
IP 55 for equipment mounted outdoors. In addition, a canopy shall be provided for
protection against direct rains.

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1.13

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Electrical equipment proposed to be installed in hazardous (explosive) atmosphere

shall be provided with enclosure appropriate for the application such as Group/ Div,
zone as applicable. These equipment shall be CMRS certified.

Main and Auxiliary Buses

1.13.1 Main Busbars

Main busbars shall be of electrical grade aluminium alloy E91E of high conductivity
and non-segregated type.
Busbars shall be located in air insulated enclosures and segregated from all other
compartments of the cubicle. Direct access or accidental contact with busbars and
primary connections shall not be possible. To provide a seal between adjacent
cubicles, busbars shall be taken through FRP seal-off barriers.
All busbars joints shall be thoroughly cleaned and anti-oxide grease shall be applied.
Plain and spring washers shall be provided to ensure good contacts at the joints and
taps. Wherever aluminium to copper connections are required, suitable bimetallic
connectors or clamps shall be used.
Busbars shall be rated in accordance with the service conditions and the rated
continuous and short time current ratings specified in the SLD drawing. Maximum
temperature of the busbars and busbar connections, under operating conditions, when
carrying rated normal current at rated frequency shall not exceed 85 deg. C.
Busbars shall be adequately supported on insulators, to withstand dynamic stresses
due to short circuit current. Busbar support insulators shall conform to relevant
standards. Supports shall be of cast resin, DMC or SMC. Hylam or similar hygroscopic
material shall not be used for bus bar supports or shrouds.
The busbar clearances in air shall be suitable for the Basic Insulation Level (BIL) of
the equipment and the bracing shall be suitable for electro-dynamic forces during short
circuit.
Busbars shall not be painted and all performance characteristics specified shall be
obtained with unpainted busbars.
Switchgear shall be provided with three phase or three phase and neutral bus bars as
per SLDs enclosed.
Bus bars shall be of uniform cross section throughout the length of the switchgear, and
upto the incoming terminals of feeder circuit breaker / switch.
All bus-bars, bus-taps shall be insulated with close fitting heat shrinkable sleeve of
hard, smooth, dust and dirt free plastic insulation of high dielectric strength to provide
a permanent high dielectric non-ageing and non-tracking protection, impervious to
water, tropical conditions and fungi. The sleeve shall provide full insulation against
operating voltage. The insulation shall be non-inflammable and self-extinguishing and
in fast colours to indicate phases. The joints shall be insulated in such a way as to
provide for accessibility of contact bolts for maintenance. Suitable moulded caps shall
be provided at the joints. The dielectric strength and properties shall hold good for the
temperature range of 0 deg. C to 90 deg. C. If the insulating sleeve is not coloured
bus-bars shall be colour coded with coloured bands at suitable intervals.
Busbars shall be adequately supported and braced to withstand the stresses due to
the specified short circuit currents for the associated switchgear.
Separate supports shall be provided for each phase of the busbars. If a common
support is provided for all three phases, anti-tracking barriers shall be incorporated.
Busbar joints shall be complete with high tensile steel bolts and Belleville washers and
nuts. Busbars shall be thoroughly cleaned at the joint locations and suitable contact
grease shall be applied just before making a joint.
1.13.2 Auxiliary Buses

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Auxiliary buses for control power supply, space heater power supply or any other
specified service shall be provided. These buses shall be insulated, adequately
supported and sized to suit specified requirements. The material of control power
supply buses shall be electrolytic copper / aluminium.

1.14

Air Circuit Breakers

Air circuit breakers shall comply with IS 13947 (Part II) or BS EN 60947-2 or IEC
60947-3 and shall be suitable for breaking capacity of 50 kA.
Circuit breakers shall be withdrawable. These shall be 3 pole with isolable neutral or 4
pole, as specified.

1.15

Operating Mechanisms
All circuit breakers shall be provided with operating mechanisms as specified, the
selection being from the following types:
Hand charged spring with manual release
Motor charged spring with electrical release
All operating mechanisms shall have mechanical `ON' and `OFF' indicators and a
manual trip device fitted with means for locking. Hand charged and motor charged
spring mechanisms shall have mechanical indicators to show `Spring Charged' and
`Spring Discharged'.
Operating mechanisms of the hand charged and motor charged spring types shall be
arranged so that release of the springs to close the circuit breaker can only be
achieved by a deliberate action. It shall not be possible for vibration or mechanical
shocks to release the charged springs. Motor spring mechanisms shall be arranged so
that charging is initiated automatically following a discharge, and the necessary limit
stops and switches for the automatic control of the charge once initiated, shall form an
integral part of the mechanism. It shall be possible to hand charge a motor charged
spring mechanism in an emergency.
Spring operated mechanisms shall be provided with volt-free contacts to give
indication that the springs are charged.
To facilitate maintenance and adjustment of contacts, it shall be possible to `slowclose' the circuit breaker but this operation shall only be possible in the fully withdrawn
position. Any necessary operating handle, lever or tube shall be supplied.
The circuit breaker shall be mechanically and electrically trip-free.
The circuit breaker shall be provided with mechanical and electrical anti-pumping
feature.
The circuit breakers shall be provided with Service and Test position limit switches
for electrical indication of position of the circuit breaker as well as for interlocking
scheme.
Adequate number of auxiliary NO & NC contacts shall be provided for the circuit
breakers. These shall be used for indications and interlocking schemes as required. A
minimum of 2 NO + 2 NC contacts shall be made available for Purchasers use. Use of
contact multiplication contactors/relays shall not be permitted for this purpose.
Breaker closing coils shall be suitable for operation in range of 85-110% of rated
voltage and tripping coil in range of 70-110% of rated voltage.
Racking in and racking out operation of the circuit breakers shall be over telescopic
rails or similar mechanism for smooth movement and shall be controlled by a racking
handle. The mechanism shall have a stopper at fully withdrawn position.

1.16

Interlocks and Test Operation Facilities

All circuit breakers shall be provided with interlocks to ensure that:
The circuit breaker cannot be plugged in or isolated whilst it is closed, attempted
isolation shall not trip a closed circuit breaker;
The circuit breaker cannot be closed until it is fully plugged in or completely isolated;
The circuit breaker cannot be closed in the service position without completing the
auxiliary circuits between the fixed and moving portions;
The circuit breaker cannot be `slow-closed' except in the fully withdrawn position;

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1.17

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With hand charged or motor charged spring mechanisms the springs cannot be
discharged until they have been fully charged or until the means for charging has been
fully removed and disconnected;
It shall be possible to padlock the circuit breaker in the fully isolated position or to
padlock the breaker to prevent closure in any position.
Where mechanical key interlocking is employed, tripping of a closed circuit breaker
shall not occur if any attempt is made to remove trapped key from the mechanism.

Protection
The circuit breaker shall incorporate an integral under voltage, short circuit and over
current - both phase and earth over current - protection release, micro-processor based,
offering facilities for site selection of inverse, very inverse and extremely inverse
characteristics.
The circuit breaker shall incorporate integral protection current transformers.

1.18

1.19

1.20

Molded Case Circuit Breakers

Molded case circuit breakers shall comply with BS EN 60947-2 and have a category of
duty P2.
They shall be of the low energy let through type and shall have interrupting capacity at
least equal to the switchgear rating specified.
MCCBs shall be of triple pole construction arranged for simultaneous three pole
manual closing and opening and for automatic instantaneous tripping on short circuit.
Maximum tripping time under short circuit shall not exceed 20 milliseconds. Operating
mechanism shall be quick-make, quick-break and trip-free type. The operating
knob/handle shall have three positive positions `ON', `OFF' and `TRIPPED' and the
same shall provide door interlocking facility with a defeat feature.
Tripping characteristics shall be ambient temperature compensated and selected
according to application, i.e., distribution, motor duty etc. Thermal magnetic releases
are considered acceptable. Auxiliary NO & NC contacts for MCCB status indication
and potential-free alarm contact on the release shall be provided as per the
requirements of the control schemes.
MCCB terminals shall be shrouded and designed to receive cable lugs for cable sizes
relevant to circuit ratings.
Motor Protection Circuit Breakers (MPCBs)
MPCBs shall be 3 phase devices suitable for direct connection to system having fault
level of 50 kA r.m.s. MPCBs shall be complete with inbuilt bi-metal overload
protection, short circuit protection and protection against single phasing.
Bi-metal overload protection shall have range suitable for motor F.L.C. These shall be
class 10 (normal duty) for normal applications such as pumps, agitators etc. and class
20 (heavy duty) for long time starting equipment such as centrifugal blowers. MPCBs
shall be tested for Type 2 coordination with contactors.
The protections shall provide at least 1 no. potential free output alarm contact for use
in control circuitry, alarm and signal to SCADA system.

Air Break Switches, Switch Disconnects and Fuse Switches

Where specifically allowed for use by Engineer-in-Charge, Air break switches and fuse
switches for use in distribution and motor circuits for voltages up to 1000 V ac shall
comply with IS 13947 or BS EN 60937-3
Switches for distribution circuit use shall be of utilization category AC 22.
Switches for motor circuits shall be of utilization category AC 23.
Utilization category shall be as defined in IS 13947 or BS EN 60937-3.
Provision shall be made for them to be locked in the `OFF' position. Operating handles
shall provide door interlocking facility with defeat feature.

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1.21

1.22

1.23

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Fuses and Links

Where specifically allowed for use by Engineer-in-Charge, Fuses used for the
protection of power circuits shall be of high rupturing capacity, HRC type. Fuses shall
comply with IS 13703 or BS 1362, 88.
Fuses and links shall be shrouded and positioned to enable easy removal of the fuse
and carrier without risk of contact with live parts.

Contactors
Contactors shall comply with IS 13947 or BS EN60947 or IEC 60947 They shall be
maintenance free and where possible allow replacement of the coil, without
disturbance to the wiring.
Contactors shall be suitable for AC3 utilization category. Adequate number auxiliary
NO & NC contacts shall be provided on the contactor, as required for the control
scheme with at least 1 NO + 1 NC spare contact for Purchasers SCADA system.
Auxiliary contactors with adequate number of NO & NC contacts shall be provided as
required for the control scheme and/or for interface with Purchasers SCADA system.
It shall be noted that DO devices in SCADA system may require interfacing contactors
for switching On large contactors.

Thermal Overload Relays

Thermal overload protection shall be provided by triple pole ambient temperature
compensated thermal overload relays with single phasing protection. The setting
range shall be properly selected in accordance with rating of the motor. Fuse sizes
shall be selected to ensure correct co-ordination with the overload relay such that the
relay will operate under stalled rotor conditions and also afford adequate protection to
the motor. The overload time constant of the overload device shall take into account
the motor run up time and shall ensure correct starting capability whilst maintaining
normal sensitivity during running.
Thermal overload relays shall be hand reset type.
Stop push button of the starter and hand reset device shall be separate from each
other.
Overload relay hand reset push button shall be brought out on the front of the
compartment door.
Overload relay shall be provided with at least one NO and one NC potential-free
contact.
Overload protection for drives rated less than 15 kW shall be provided by hand reset
thermal overloads providing differential single phase protection. Drives of 15 kW and
above shall be fitted with static type protection relays providing overload, earth fault
and phase current imbalance protection.

1.24

Single Phasing Preventers

Where specified, the relay shall be suitable for application to protect reversible and
non-reversible motors. The relay operation shall be independent of the motor kW
rating, the loading conditions prior to the occurrence of the single phasing and rpm of
the motor. The relay shall be of the fail-safe type and shall operate to trip the motor
when the relay internal wiring is accidentally open circuited. The single phasing
preventer should be negative phase sequence current sensing type.

1.25

Motor Control modes (Starters)

1.25.1 The selection of starters shall be made according to the rating

equipment. The selection shall be done as follows:
Up to & including 10 HP
:
Above 11 HP up to & including 50 HP
:
Above 50 HP
:

of the motor used with the

Direct On line Starter
Star-Delta tarter
Soft Starters

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1.25.2 At least 15% spare starter modules of each type and kW rating subject to a minimum of 1
No. shall be provided on each bus section of the MCC.
1.25.3 All the motor starters including VFDs shall be wired to communicate with PLC and SCADA
system as well as local control station. Each motor starter and VFD shall have following
minimum facilities Digital Input (DI) : Run and Stop from PLC. For maintained command, Run and
Stop can be common. For momentary commands, these shall be separate.
Digital Output (DO) : Running & Tripped feedback to PLC
Analogue Input (AI) : For VFDs only. From PLC 4-20 mA for speed reference.
Analogue Output (AO) : For VFDs only. To PLC as follows:
4-20 mA corresponding to speed.
4-20 mA corresponding to current
1.25.4 Ammeter shall be provided in the Y phase only for drives > 7.5 kW & < 55 kW. Drives of
55 kW or greater shall have the facility to measure all phase currents.
1.26

Motor Anti-Condensation Heaters

Where specified, provision shall be made to supply a motor anti-condensation heater
from its motor starter. The heater shall be energized from the cubicle isolator and
controlled by a normally closed auxiliary contact on the main contactor. The heater
circuit shall be protected by an internal miniature circuit breaker (MCB).

1.27

1.28

Direct on-line starters (DOL)

Direct on-line starters shall be suitable for Class AC 3 utilization category suitable for
type 2 coordination as specified in applicable standards. Each DOL starter feeder
shall be complete with Motor Protection Circuit Breaker (MPCB) with built in overload
relay and single phasing preventer, contactor, ON-OFF-TRIP indication lamps, StartStop-Reset push button, Local/Remote selector switch and MCB for control circuit.
Star-Delta Starters
Automatic Star-Delta starters shall comprise three sets of contactors one for the line,
one for the star point and one for the delta, and a timer relay to automatically change
the connections from star to delta.
Star-delta contactors shall be electrically interlocked to permit starting of the motor in
the proper sequence.
Start delta starters shall be suitable for Class AC 3 utilization category suitable for
type-2 coordination as specified in applicable standards.
Each starter feeder shall be complete with MPCB/MCCB as appropriate with built in
overload relay and single phasing preventor,3 nos. contactors, ON-OFF-TRIP
indication lamps, Start-Stop-Reset push button, Local/Remote selector switch and
MCB for control circuit.

1.29

Interface with PLC/SCADA system

The PMCCs & MCCs shall be wired for interface with PLC and SCADA systems. For
this purpose, Digital Inputs (DI), Digital Outputs (DO), Analogue Inputs (AI), Analogue
Outputs (AO) as applicable for individual starters shall be wired to a common
Marshalling compartment in the respective PMCC and MCC. 1 no. marshalling
compartment shall be provided for each transport section of the PMCC and MCCs.
Terminal blocks for High Level signals and Low Level signals shall be segregated for
ease of cabling. Multi-core cables shall be run from these marshalling compartments
to the PLC and SCADA system.

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1.30

1.31

Page 10

Control Transformer
Each Bus section in the MCC shall be provided with a control transformer 415/110V,
single phase, dry type and of adequate VA rating to cater to loads of control circuitry of
the feeders connected to that bus. The transformers shall be adequately protected on
the primary side by an MCCB and on the secondary side by an MCB.
The secondary of the control transformer shall be taken to a control bus to be run
throughout the length of the MCC.

Instrument Transformers
The CTs and VTs shall be of cast resin type (insulation Class 'E'), and shall be able to
withstand the thermal and mechanical stress resulting from the maximum short circuit and
momentary current ratings of the switchgear. These shall be completely encapsulated.

1.32

Current Transformers
Current transformers shall comply with IS 2705 or BS 7626 or IEC 60044 and shall be
of the wound-primary, bar-primary or window type according to ratio required and
manufacturers standard.
Current transformers for metering purpose shall have rated VA burden adequate for
local as well as remote metering including lead burden where specified. For protection
core, VA burden as recommended by the protective relay supplier shall be provided as
a minimum. Minimum VA burdens are specified in the Tender SLD. In case of
deviation from this value, the Bidder shall take specific approval from the Engineer
with design calculations.
Current transformers shall be of Class 1 accuracy for use with measuring instruments
and Class 5P for use with protective relays. Rated secondary current of all current
transformers shall be 1 A preferably.
Class 5P shall be used for combined overcurrent and earth fault protection of the
inverse time overcurrent type. The Contractor shall ensure that the class and capacity
of the current transformers is correct for the meter or relay being supplied. Separate
current transformers/cores shall be used for metering & protection.
Class PS current transformers shall be used for special applications such as
differential and REF protections. Parameters of such CTs shall be subject to
Engineers approval. The Contractor shall furnish design check calculations for such
applications.
Each group of current transformers shall be earthed at one point via a removable test
link.
The accuracy limit factor selected for current transformers shall take due account of
the prospective short circuit current, connected burden and short time overload
capability of the meters connected.
CTs shall have polarity marks indelibly marked on each transformer and at the
associated terminal block. Facility shall be provided for short circuiting and earthing
the CT secondary at the terminal blocks.

1.33

Voltage Transformers
Voltage transformers shall comply with IS 3156 or BS 7625, IEC 60186.
Secondary and tertiary windings of voltage transformers shall be rated for three phase line
to line voltage of 110 V. Open delta connection, therefore, shall have voltage ratio of
*/(110/3)V.
Primary protection for high voltage windings shall be provided with current limiting fuses.
All other windings of voltage transformers shall be provided with HRC fuses or MCBs.
Primary fuses for voltage transformers shall be rated to interrupt short circuit current
corresponding to the switchgear rating.
It shall be possible to replace voltage transformer fuses easily without having to deenergize the main bus-bars.
Rated overvoltage factor and its duration shall be commensurate with system earthing and
according to the Standards mentioned above.

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1.34

1.35

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Protective Relays
All protective relays shall be Numerical type with programming facilities at site. The
relays shall be provided with facilities for communication with/ setting from a PC or
SCADA system. Necessary testing facilities shall be provided for testing of the relays
in-situ. The relays shall be provided with adequate number of potential-free output
contacts for use in control circuit and spare contacts for Employers use.
Relays shall comply with IS 3231, 3842, BS EN 60947-5-1, IEC 60255. They shall be
suitable for mounting on rail to BS 5584. Positive location being assured by a built-in
screw clamp or clip.
Terminals shall be numbered in accordance with BS 5472.
All protective relays shall be enclosed in rectangular shaped, dust proof cases.
All relays shall be suitable for flush mounting.
All protective relays shall be accessible for setting and resetting/programming from the
front. Access to setting/programming devices shall be possible only after the front
covers of the relays are removed. Resetting facilities shall however be accessible
external to the relay case.
All protective relays shall be of the draw out type. Where it is not possible to provide
protective relays of the draw out pattern, fixed type relays with facilities for plugging in
a portable test plug shall be provided. Necessary test plugs shall be furnished along
with the relays.
All protective relays shall be provided with positive action flag indicators or LEDs
visible from the front.
Tripping relays shall be rated to operate satisfactorily between 50% and 110% of the
rated voltage. Auxiliary relays shall be rated to operate satisfactorily between 70% and
110% of the rated voltage.
Auxiliary and tripping relays shall be electromechanical type, may be in fixed execution
and with adequate number of output contacts.

Indicating and Integrating meters

1.35.1 Analogue meters shall be 96 x 96 mm. size, taut-band or moving iron type as specified.
They shall have an accuracy class of 1.0 or better. Integrating meters such as kWh meters
shall be digital type. Kilowatt-hour meters shall comply fully with IS 722 or BS 5685 Class
2 and shall have industrial grade accuracy (2.5%). Three element units shall be used for
3 phase 4-wire systems. Two element units shall be used for 3 phase, 3-wire systems.
1.35.2 Digital meters shall be provided as specified. Wherever Load Managers or Multi-function
meters have been specified, they shall provide following minimum functions:

1.36

All line currents

All line and phase voltages

Frequency

Power Factor

kW, kVA & kVAR

kWh with Maximum Demand in Kva

They shall be provided with facilities for communication with PC/SCADA system

Control, Indication, Protection and Annunciation devices used in Switchgear &

Control gear
Instruments shall not be positioned above 2000 mm or below 500 mm and devices for
isolation and switching shall be accessible within the zone 500 mm to 1600 mm above
floor level.

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1.38

Page 12

Control & Selector Switches

Control and instrument selector switches shall be rotary type provided with escutcheon
plates clearly marked to show operating position and suitable for semi-flush mounting
with only switch front plate and operating handle projecting out.
Breaker control switches shall be pistol grip, black and selector switches shall be oval
knob and black. Breaker control switches shall be three position spring return to
neutral type. Instrument selector switches shall be maintained stay-put type.
Contacts of the switches shall be spring assisted and contact faces shall be with rivets
of pure silver. The contact ratings shall be adequate to meet the requirements of
circuit, in which they are used. Local/ Remote selector switches shall have adequate
number of poles as required for control circuit with at least 1 no. spare pole for SCADA
interfacing.

Push Buttons

1.38.1 All push buttons shall have two normally open and two normally closed contacts, unless
otherwise specified. The contacts shall be able to make and carry 5 A at 110V AC/DC and
shall be capable of breaking 1 A inductive load at 110V DC. They shall be provided with
inscription plates engraved with their functions.
1.38.2 Colours of push buttons shall generally comply with IS 6875 and in particular shall be as
follows:
Stop, emergency stop

Red

Start

Green

Jogging/inching

Black

Reset (when not also acting as a stop)

1.39

Blue

Lamp test

Blue

Override/alarm accept

Yellow

Indicating Lamps

1.39.1 Indicating lamps shall be panel-mounting type cluster LEDs. The wattage of lamps shall
be 2.5 watts.
1.39.2 Lens colours shall comply with BS EN 60037 as follows:
Power On

Red

Running

Red

Stopped

Green

Tripped/alarm

Amber

Status (open, closed etc)

position)

Blue (or Green for safe position & Red for unsafe

Ready to start

Blue

Warning (no imminent danger) Amber

Note:
1.40

*white may be used where doubt exists as to which other colour to use.

Auxiliary Supply Control

Provision shall be made for receiving, distributing, isolating and protection of auxiliary
D.C. and A.C. supplies for controls, space heating etc. The fuse/MCB ratings shall be
so chosen as to ensure selective clearance of sub circuit faults. Auxiliary buses of
minimum 6 x 3 mm copper shall be run throughout the length of the switchgear for
auxiliary supplies such as AC/DC control supply, space heating supply.

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1.41

1.42

1.43

Page 13

Miniature Circuit Breakers (MCBs)

Miniature circuit breakers shall comply with IS 8828 or BS EN 60898. They shall be
type C with a breaking capacity of at least 9 kA at 240/415 V. They shall be complete
with Thermal Overload (O/L) and Short Circuit (S/C) protections. The operating knob
of the MCB shall clearly indicate On, Off and Tripped positions.
Miniature circuit breakers for DC circuits shall provide a double break (one pole
protected plus one switched).

Facia Annunciators
The alarm annunciation scheme, wherever specified in control wiring drawings, shall
incorporate the following features :
Visual indication of the fault by means of flashing alarm window.
Audible alarm on the occurrence of the fault.
Red facia units to differentiate trip alarm from non-trip alarms.
Acknowledgement of occurrence of fault with Accept push button. This shall silence
the audible alarm and the flashing window shall become steady.
Resetting the scheme after the faults have been cleared. This shall be with a Reset
push button.
Facility to test the healthy condition of the lamps with a Test push button (excluding
units indicating existing faults).
Prevention of mal-operation of the scheme when the push buttons are pressed
incorrectly or in a wrong sequence.
Initiation of the complete sequence of audio-visual alarms in the event of a new fault
occurring at the time of accepting an existing fault.
Suitable for operation on DC supply with a supply voltage variation between 80% and
110% of the rated voltage.
Suitable for operation for fleeting (15 milli sec. duration) as well as the persistent faults
and for normally open or normally closed (site selectable) indicating contacts of
either hand or self reset type.
Facility for a separate audio-visual alarm to indicate Alarm supply failure.
Facility for duplicating the audio-visual alarm at a second location.
Window alarm annunciators shall incorporate the following constructional features :
Facia annunciator system shall be static, microprocessor based
Flush mounted facia units, each of which is provided with two lamps and a series
resistor and a ground glass plate in front of the inscription. Facia window of minimum
size 35 mm x 50 mm
Plug in relays (where required) mounted behind the facia units.
The alarm annunciation scheme shall comprise the following equipment:
a facia unit complete with relays (where required) for each fault.
Common alarm bell/hooter preferably electronic type, separate for Trip and NonTrip alarms with different tones, adjustable at site.
Accept Reset and Lamp Test push buttons.
Alarm supply failure, Accept and Reset push buttons.
Adequate number of windows shall be provided specifically for annunciation of
troubles associated with submersible pumps.

Wiring

1.43.1 Panel Power Wiring

Power wiring shall be carried out with stranded, copper conductor, PVC insulated,
1100 V grade, wires liberally sized for the application. Aluminium links of adequate
sizes may be used for higher current applications.
1.43.2 Panel Control Wiring

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Switchgear shall be supplied completely wired internally up to equipment and terminal

blocks and ready for external cable connections at the terminal blocks. Inter-panel
wiring between cubicles of same switchgear shall be provided.
All auxiliary wiring shall be carried out with 660 volts grade, single core, stranded,
super-flexible, copper conductor with PVC insulation. The size of wire shall be not
less than 1.5 mm2.
Current transformer secondary circuits shall have a minimum cross-sectional area of
2.5 mm2. Earth wires for meters, doors etc shall have a minimum cross-sectional area
2
of 2.5 mm .
The wiring colour code shall be as follows:
Phases Red, Yellow, Blue
Neutral Black
Control Grey (DC), Black (AC)
Earth Green/Yellow
The wiring shall be neatly laced and cleated to the switchboard structure or contained
within purpose designed plastic trunking and arranged so that access to equipment is
not impeded. No wire shall be directly terminated on the equipment terminal or
terminal block irrespective of type of terminal used. Suitable pin/eye type crimping lugs
shall be used for this purpose.
Wiring within the switchboard/ control panels shall be marked with ferrules at each end
for identification. The letters and numbers used shall correspond with the assembly
wiring diagram. Cross ferruling system shall be adopted. The ferrules shall be nonloosening type and shall not slip-off when the wire is removed/disconnected from the
terminal.
Wiring between cubicles or panel sections, for inter-panel wiring, shall be terminated in
terminal blocks at each end.
Control wiring shall be completely segregated from power circuit.

Terminal blocks
Power terminals shall be liberally sized suitable to take power cables derated to 70%.
Adequate phase-to-phase clearance or inter-phase barriers shall be available for safe and
trouble-free operation.

1.44.1 Control Terminal Blocks

Control terminal blocks shall be of the screw clamp, rail mounted type to IS : 13947,
2
VDE 0611 : Part 1 for connection of copper conductors up to 2 x 1.5 mm on either
side and shall be 650 V grade, 10 amps. rated.
Each terminal rail and each individual terminal shall be indelibly marked with a unique
number corresponding to the schematic diagram terminal numbering system.
No more than two cables shall be terminated per clamp. Cross connections (shorting
links) shall be used to link adjacent terminals where multiple wire connections are
required.
Earth terminals shall be coloured green/yellow and shall clamp to the fixing rail in
order to provide earth continuity.
Terminals of different sizes and for different voltage terminations shall be partitioned.
Terminal blocks for CTs and VTs shall be provided with test links and isolating
facilities.
In any terminal arrangement, adequate space shall be provided for neat and logical
termination of the incoming wiring. At least 15% spare terminals shall be provided, in
addition to those used. In addition, terminal rails shall have provision for installation of
at least 10% additional terminals.
Terminals within cubicles and enclosures shall not be obstructed and shall be easily
accessible for installation and testing purposes, without removal of equipment.
1.44.2 Terminal Arrangements
Cables entering and leaving an assembly shall do so via suitably positioned terminals.
Terminals shall be arranged in function groups as follows:

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Supply outputs to field devices

Signal inputs from field devices
Control output to starter sections
Signal inputs from starter sections
Within each group terminal shall be arranged in subgroups as follows:
Voltage
Energized with panel door open
De-energized with panel door open
Terminals for circuits at voltages greater than 24 V that are not de-energized when the
assembly door is open shall be screened and labeled accordingly.
They shall be completely segregated from power terminations.

Labels and Nameplates

Each switchgear cubicle shall be fitted with a label in the front and rear of the cubicle.
Each switchgear shall also be fitted with label indicating the switchgear designation,
rating and duty. Each relay, instrument, switch, fuse and other devices shall be
provided with separate labels.
Caution name plate, 'Caution Live Terminals' shall be provided at all points where the
terminals are likely to remain live and isolation is possible only at remote end, i.e.
incoming terminals of main isolators.
All door mounted equipment as well as equipment mounted inside the
switchboard/panels shall be provided with individual labels with equipment
designation/rating. Sizes of the labels and the inscribed label height shall be
appropriate for the application.
Labels shall be made of non-rusting metal, 3-ply lamicoid or engraved PVC and shall
be fixed with countersunk screws. Paper stickers with stencilling shall not be used as
labels.

1.46

Switchboard Ancillary Equipment

The following ancillary articles shall be supplied with each switchboard.
1 No black fluted rubber safety mat of appropriate voltage grade, IS marked, running
the length of the switchboard.
Operating handles, racking/withdrawing handles, fuse-pullers, panel keys, tools etc. in
lockable wall mounted steel or wooden cabinet.

1.47

Inspection and Testing

All Routine Tests according to IS or IEC shall be carried out on completely assembled
switchgear assembly at the manufacturers works and the same shall be witnessed by
the Employer or his authorised representative and the Engineer.
Routine Test Certificates of all major items such as circuit breakers, CTs, VTs,
protective relays and meters shall also be furnished to the Employer.