Version 1/2008 Specification No.

EP-MS-P4/S2-010

QATAR GENERAL ELECTRICITY & WATER CORPORATION

ELECTRICITY NETWORKS AFFAIRS

SPECIFICATION NO. EP-MS-P4/S2-010

LV DISTRIBUTION FUSE BOARDS

1.0 FOREWORD

The purpose of this Specification is to provide a range of low voltage

distribution fuse boards for use in outdoor substations. It includes detailed
requirements for type tests on fuse carriers and routine tests on thumbscrews.

2.0 SCOPE

This Specification details distribution fuse boards of the following types for
use in electricity substations which supply low voltage, with separate neutral
and earth.

i) Pillar mounted fuse boards, cable connected, subsequently referred to

as FEEDER PILLARS.

ii) Transformer mounted fuse boards in cabinets, subsequently referred to

as FUSE CABINETS.

The fuse boards are for use on 3 Phase, 4 wire AC systems at a frequency of
50Hz and at a nominal voltage of 433 V between phases.

2.1 REFERENCES

This Standard makes reference to, or should be read in conjunction with, the
following documents :

IEC 60269/BS 88 Cartridge Fuses for Voltages up to and including

1000V AC and 1500V DC, Part 1, General
Requirements.

IEC 60439/BS 5486 Low-Voltage Switchgear and Control Gear

Assemblies.

BS 381C Specification for Colours for Identification, Coding,

and Special Purposes.

IEC 60269/BS 1361 Cartridge Fuses for AC Circuits in Domestic and

Similar Premises.

BS 1363 13A Plugs, Switched and Unswitched Socket-

outlets and Boxes.

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BS EN 22063:1994 Metallic and other inorganic coating.

Thermal spraying. Zinc, Aluminium and their
alloys.
BS 3382 Electroplated Coatings on Threaded Components.

ISO 272/4759/BS 3692 ISO Metric Precision Coatings on Threaded

Components.

IEC 60044-1(1996)/ Current Transformers.

BS 7626:1993

ISO 885/ISO 4759/1 ISO Metric Black Hexagonal Bolts, Screws and
Nuts.

BS 6001 Sampling Procedures and Tables for Inspection by

Attribute.

BS 6231:1998 Specification for PVC Insulated Cables for

Switchgear and Control Gear Wiring.

BS 6480/IEC 60055 Impregnated Paper Insulated Cables for Electricity

Supply.

IEC 60076 Power Transformers

BS 2562:1993 Specification for Cable Boxes for Transformer and

Reactors.

3.0 ENVIRONMENTAL CONDITIONS

The fusegear will generally be installed in outdoor situations in a tropical

climate having the following characteristics:

1. Altitude: Low lying, generally close to sea level - no point

exceeding 100 metres above sea level.

2. Temperature: Air maximum 50C

Air minimum 0C
Air maximum mean average 45C
Air minimum mean average 10C

Exposed sunlight 75C maximum.

3. Solar Radiation Peak 1030W/sq.m.

4. Humidity: Ranges between 30% and 100%, though 100% is

common throughout the year and may occur at air
temperatures in excess of 30C.

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5. Rainfall: Negligible for most of the year, though the Winter

season may bring infrequent but heavy rainstorms.

6. Sandstorms are not uncommon and have a salt content which is

extremely penetrating and corrosive.

7. General Atmospheric Conditions:

A hot atmosphere with very fine highly penetrating dust
particles present. Occasional mists occur which are salt
laden and highly corrosive.

4.0 TYPE AND DESIGN

4.1 Feeder Pillar

4.1.1 General

This Standard covers arrangements of feeder pillars, as described below,

suitable for use with:

a) 500, 800, and 1000 kVA Transformers

b) 1250 and 1600 kVA Transformers.

Transformers are oil filled and in general accordance with IEC 60076. LV
Interfaces are generally in accordance with BS 2562, specific detail being
provided in this Specification.

The feeder pillars shall be complete with supporting members as required on

which shall be mounted control equipment, busbars and instrumentation in
accordance with the arrangements specified below. The design shall be such
that the cables can be readily jointed from the front.

All parts of the distribution equipment shall, as far as practicable, be readily

accessible and replaceable without excessive dismantling.

Insulating materials shall be as nearly non-hygroscopic and resistant to

tracking as present good manufacturing technique permits.

All parts of equal size and rating shall be inter-changeable. The general
design shall be such that the number of joints shall be kept to a minimum. All
bolted joints shall be secured by corrosion proof steel bolts. All bolts and
studs shall be plated to BS 3382 and shall have corrosion proof locking
features. Each distribution unit position shall be drilled for mounting at 145
5 mm centres.

The feeder pillars shall be designed to take up the following arrangements:

Type A: 2500 A Busbars

2500 A incoming transformer unit:

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Nominal size of cables up to 800 sq.mm.

Six 630A outgoing distribution units.
Instrument panel.

The framework shall be arranged to accommodate the equipment in the

following order reading from the front, left to right :

Distributor units
Transformer unit
Instrument panel

Type B: 2500 A Busbars

2 x 2500 A incoming transformer units:

Nominal size of cables up to 800 sq.mm.

Four 630 A outgoing distribution units.
Two Instrument panels.

The framework shall be so arranged to accommodate the equipment in the

following order reading from the front, left to right :

Instrument panel
Transformer unit
Distributor units
Transformer unit
Instrument panel

Of the two transformer units one will normally be used for the incoming
transformer and the other will normally be used to supply a single large
consumer via single core cables. The two units are to be identical to allow
either to be used for either purpose, depending on site requirements.

Where live metal work is adjacent to the framework a sheet of bakelite or

other suitable low voltage insulating material shall be fixed to the inner side
walls of the feeder pillar and shall extend to at least 200mm above the red
phase (upper phase) top contacts and an equal distance below the blue phase
(lower phase) bottom contact. The width of the insulating sheet shall
approximate to that of the side walls of the feeder pillar and thickness shall
not be less than 2mm.

The sheet of insulating material shall be suitably fixed. The fixing shall not
incorporate metallic parts which protrude towards live metalwork. If
adhesives are used, the quality shall be such as to ensure proper adhesion
under the temperature/humidity levels described earlier.

4.1.2 Incoming Transformer Unit .

The rated normal current of the incoming circuit shall be as previously

specified.

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A pole operated isolator shall be provided in each phase of the incoming

transformer circuit . See Drawing EP-MS-P4/S2-010 Fig. 1.

The isolator contacts shall include a contact tightening device on both the top
fixed contact and the bottom hinged contact, designed to obviate slackening
when subject to vibration and good contact shall not depend on the natural
spring of the contact. Reasonably good contact shall be made on closing the
isolator so that current can be safely carried in the interval prior to the
tightening of the contacts.

The contact tightening device shall be pole operated by crank action using the
isolator operating pole; the same end of the operating pole shall be used for
tightening or slackening the contact tightening device as is used for opening or
closing the isolator blades. WHEN THE DEVICE IS BEING
TIGHTENING OR SLACKENED THE OPERATING POLE END
SHALL REMAIN IN THE DEVICE AND ISOLATING MOVING
BLADES SHOULD REMAIN IN ITS POSITION WITHOUT
DROPPING BY ITS OWN WEIGHT.

The total movement from full slackness to full tightness the device shall be
confined to angular rotation of not more than 140 in one movement.

An insulated pole shall be provided for operating the isolators and clips shall
be provided inside the pillar to store this when not in use. The amount of bare
metal on the pole shall be kept to a minimum.

Provision shall be made for padlocking the isolators in the open position by a
suitable insulated device.

Provision shall be made on each phase for one current transformer as specified
in Section 11 'Current Transformers'. It shall be possible to easily change
current transformers and should be securely fixed without touching the live
conductor.

A bolted link rated at not less than half the unit rating shall be provided for
disconnection of the neutral.

Insulated dividing barriers shall be provided between phase contact

assemblies and between phase and neutral contact assemblies.

Insulated dividing barriers shall be provided between the transformer units

and outgoing distributor units. The fixing of the insulated dividing barriers
shall be such that under normal operating conditions it is not possible for
contact to be made between live metalwork of different phases or between live
and earthed metalwork.

INCOMER SAFETY COVER SHOULD BE LOCKABLE BOTH IN

OPEN AND CLOSED POSITION.

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Screens shall be provided where necessary to permit safe access to all parts of
the instrument panel.

The design shall permit the use of the following arrangement :

7 single core 600/1000V stranded copper conductors either i) paper insulated,

lead sheathed PVC oversheath cables to BS 6480, or ii) XLPE insulated, PVC
oversheathed, to the nominal sizes as previously specified.

Cable termination arrangement shall be suitable for compression lugs.

Wooden cable cleats shall be provided adequate to support the cables in
normal service and when subject to the short circuit duty specified in Section
6.0.

4.1.3 Outgoing Distributor Units

The rated normal current of an outgoing unit shall be 630A.

Cable termination arrangements shall be suitable for accommodating upto and

including 300mm2 4 core copper conductor either i) paper insulated lead
sheathed double steel tape armour PVC oversheathed cables to BS 6480 or ii)
XLPE insulated, steel wire armoured PVC oversheath cable. Cleats suitable
for supporting and accommodating cables for 70 sq. mm to 300 sq.mm shall
be fitted before delivery.

The cables will be terminated using heat shrinkable materials using

compression lugs. The cable termination materials will be supplied by
KAHRA MAA.

Cable earths terminal will be terminated on the earth bar using suitable nuts
and bolts.

Bottom plate of the feeder pillar with cable entry holes, shall be divided into
two portions. By removing the front portion, it shall be suitable to connect or
disconnect any cable termination individually.

The phase cable side fuse contacts (see Drawing EP-MS-P4/S2-010 Fig 2)
shall be designed with long and short reach and shall be fitted with forward
projecting M16 captive steel studs, one per contact complete with a full nut.
A lockwasher or plain washer and lock nut shall be provided. The contacts
shall be so designed that they provide adequate spacing and are fully
interchangeable to permit terminating the phase conductors of a cable
whatever their lay. It shall be possible to change any single busbar or cable
contact without affecting other phases.

Bolts and studs shall be of minimum ISO grade designation ISO 272, 885,
888/4759/1

There shall be no neutral link. The neutral conductor shall be terminated on to

a contact bar rated at 250A mounted at the bottom of the units between the

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neutral busbar and the insulated support strut. The bottom fixing of the
insulated support strut shall be mounted above the neutral contact bar so as to
allow the neutral core an unimpeded approach to the desired fixing position.
This neutral contact bar shall be drilled in two positions and fitted with a high
tensile M16 steel bolt and nut. A lock washer or plain washer and locknut
shall be provided.

Cable support shall be provided by a suitable cleat, as previously specified.

The centre line of this cleat shall be not less than 460 mm below the centre
line of the cable lug fixing of the neutral conductor. These cable supports
shall be adequate to support the outgoing cable in normal service and when
subject to the short circuit duty specified in Section 6.0.

There shall be one standard size of fixed contact assembly of one piece
construction which shall be suitable for accommodating a fuse carrier with a
92 mm terminal centre fuse-link type 'J' in accordance with BS 88. Fuse
carriers shall be supplied with the pillars. Each fuse carrier shall be suitable
for inserting in a phase of the unit by hinge action pivoted on the lower
contact and for withdrawing by snatch action. The contacts shall be arranged
to permit contact tightening and the contact surfaces shall be flat and
accurately aligned in pairs.

Contact assemblies shall be supported from the steel framework by means of

strips, rods, bars or moldings of insulating materials. The arrangement of
supports shall be such that mechanical stresses produced in service by the
temperature rise of connections shall not adversely affect the alignment of the
contact surfaces.

It shall be possible with care and safety when both busbar and outgoing
circuits are live to fit a current transformer ratio 500/5, 5VA output Class D
accuracy, of the design as supplied by the manufacturer, over any phase
contact of any outgoing unit, and to use a clip-on-ammeter over any fuse
assembly when a current transformer is not fitted.

Insulating dividing barriers shall be provided between phase contact

assemblies and phase and neutral contact assemblies which shall make it
impossible to insert a fuse link between contacts of different phases.

If the dividing barriers are fastened to live metal, the resulting live bolts or
fasteners shall not be exposed, without insulation on the lower side of the
barrier.

Provision shall be made on each outgoing unit to affix and padlock a suitable
insulated device to prevent fuse-links being installed or removed. Two such
devices shall be provided with each feeder pillar. The device shall not obstruct
the feeder pillar doors from closing when in position or when stored within
the feeder pillar. It shall be possible to fit the device safely whilst the feeder
pillar is alive and in normal service. The device shall be red in colour and
marked in white with the following wording in Arabic and English, which

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shall be clearly visible when viewed from the front with the feeder pillar doors
open:

"CAUTION - MEN WORKING - DO NOT INTERFERE WITH THIS

APPARATUS"

4.1.4 Busbars

Busbars shall be of hard drawn high conductivity copper. The rated normal
current of the phase busbars shall be 2500A as previously specified.

The neutral bar shall be rated at not less than half of the phase busbar rating.

The earth bar shall have a rating the same as the neutral bar.

Busbar shall be situated at the rear of the equipment.

Phase busbars shall be colour marked in sequence from top to bottom, red,
yellow, blue. The neutral busbar, mounted below shall be colour marked
black, and the earth busbar, mounted at the bottom shall be unmarked.

The colouring of the busbars shall not be continuous and shall be such that it
cannot be mistaken for an insulating covering.

A bolted connection of the same rating as the neutral bar shall be provided
between the neutral and earth busbars.

4.2 Fuse Cabinets

4.2.1 General

This Specification covers arrangements of fuse cabinets as described below

suitable for use with 500, 800 and 1000 kVA transformers to IEC 60076. The
fuse cabinets shall be complete with supporting members as required on
which shall be mounted an incoming transformer unit and outgoing distributor
units with busbars, and an instrument panel, in accordance with the specified
arrangements. The design shall be such that the cables can be readily jointed
from the front. All parts of the distribution equipment shall, as far as
practicable, be readily accessible and replaceable without excessive
dismantling.

Insulating materials shall be as nearly non-hygroscopic and resistant to

tracking as present good manufacturing technique permits.

Where live metal work is adjacent to the framework a sheet of bakelite or

other suitable low voltage insulating material shall be fixed to the inner side
walls of the feeder pillar and shall extend to at least 200mm above the red
phase (upper phase) top contacts and an equal distance below the blue phase

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(lower phase) bottom contact. The width of the insulating sheet shall
approximate to that of the side walls of the feeder pillar and the thickness shall
not be less than 2.0mm.

The sheet of insulating material shall be suitably fixed. The fixing shall not
incorporate metallic parts which protrude towards live metalwork. If
adhesives are used, the quality shall be such as to ensure proper adhesion
under the temperature/humidity levels described earlier.

All parts of equal size and rating shall be inter-changeable. The general design
shall be such that the number of joints shall be kept to a minimum. All bolted
joints shall be secured by corrosion proof steel bolts. All bolts and studs shall
be plated to BS 3382 and shall have corrosion proof locking features. Each
distribution unit position shall be drilled for mounting at 145 5 mm centres.

The fuse cabinets shall be designed to take up the following arrangement.

1600A Busbars
1600A incoming transformer units (horizontally mounted)
Four 630A outgoing distributor units.

The distributor units shall be mounted side by side with the red, yellow and
blue phase fuses mounted below one another.

4.2.2 Incoming Transformer Unit

The rated normal current of the incoming circuit shall be 1600A.

Hard drawn, high conductivity copper connections or other material approved

by the Purchaser, with provision for adjustment, shall be provided between the
transformer LV stems and the terminals of the isolators and neutral link.

These connections shall be suitable for connecting to the appropriate terminals

shown in Drawing EP-MS-02-010 Figs 4 and the 1600A connections shall be
arranged so as to be bolted at both the front and rear positions on the
transformer LV stems. The rated normal current of the phase connections
shall be 1600A as required, the neutral connection being rated at not less than
one half of that of the phase connections.

Each phase and neutral of the transformer unit shall be colour marked to
correspond with the busbars to which they relate.

1600A Incoming Transformer Units

A pole operated isolator shall be provided in each phase of the incoming

transformer circuit. See Drawing EP-MS-P4/S2-010 Fig 1.

The isolator contacts shall include a contact tightening device on both the top
fixed contact and the bottom hinged contact, designed to obviate slackening
when subject to vibration and good contact shall not depend on the neutral

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spring of the contact. Reasonably good contact shall be made on closing the
isolator so that the full current can be safely carried in the interval prior to the
tightening of the contacts.

The contact tightening device shall be pole operated by crank action using the
isolator operating pole; the same end of the operating pole shall be used for
tightening or slackening the contact tightening device as is used for opening or
closing the isolator. When the device is being tightened or slackened the
operating pole end shall remain in the device. The total movement from full
slackness to full tightness of the device shall be confined to angular rotation of
not more than 140 in one movement.

An insulated pole shall be provided for operating the isolators, and clips shall
be provided inside the cabinet to store this when not in use. The amount of
bare metal on the pole shall be kept to a minimum.

Provision shall be made on each phase for one current transformer as specified
in Section 11, "Current Transformers". It shall be possible to easily change
current transformers and should be securely fixed without touching the live
conductor.

A bolted link of not less than 800A rating shall be provided for disconnection
of the neutral.

The incoming transformer unit, which shall be mounted horizontally, shall be

fully shrouded with insulating material on the sides and at the front. The front
shall be hinged and be of transparent material. Facilities shall be provided for
locking the cover in position.

Insulated dividing barriers shall be provided between phase contact

assemblies and between phase and neutral contact assemblies.

4.2.3 Outgoing Distributor Units

The rated normal current of an outgoing circuit shall be 630A.

Cable termination arrangements shall be suitable for accommodating up to

and including 300mm2 4 core stranded copper conductors either i) paper
insulated lead sheathed double steel tape armoured PVC oversheath cables, or
ii) XLPE insulated, steel wire armoured, PVC over-sheathed cables.

The cables will be terminated using heat shrinkable materials using

compression lugs. The cable terminations material will be supplied by
KAHRA MAA.

Cable earth terminals will be terminated on the earth bar using suitable nuts
and bolts.

Cleats suitable for supporting and accommodating cables from 70 sq. mm to

300 sq. mm shall be fitted before delivery.

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Bottom plate of the feeder pillar with cable entry holes, shall be divided into
two portions. By removing the front portion, it shall be suitable to connect or
disconnect any cable termination individually.

The phase cable side fuse contacts (see Drawing EP-MS-P4/S2-010 Fig 2)
shall be designed with long and short reach and shall be fitted with forward
projecting M16 captive steel studs, one per contact complete with a full nut.
A lock washer or plain washer and lock nut shall be provided.

Bolts and studs shall be minimum ISO grade designation ISO 272, 885,
888/4759/1.

The contacts shall be so designed that they provide adequate spacing and are
fully interchangeable to permit terminating the phase conductors of a cable
whatever their lay.

There shall be no neutral link. The neutral conductor shall be terminated onto
the contact bar rated at 250A mounted at the bottom of the units between the
neutral busbar and the insulated support strut. The bottom fixing of the
insulated support strut shall be mounted above the neutral contact bar so as to
allow the neutral core an unimpeded approach to the desired fixing position.
This neutral contact bar shall be drilled in two positions and fitted with a high
tensile M16 steel bolt and nut. A lockwasher or plain washer and locknut
shall be provided.

Provision shall be made on each outgoing unit to affix and padlock a suitable
insulated device to prevent fuselinks being inserted or removed. Two such
devices shall be provided with each fuse cabinet. The devices shall not
obstruct the fuse cabinet doors from closing when in position or when stored
within the fuse cabinet. It shall be possible to fit the device safely whilst the
fuse cabinet is alive and in normal service. The device shall be marked with
the following wording in English and Arabic in white letters on a red
background, which shall be clearly visible when viewed from the front with
the feeder pillar doors open :

"CAUTION - MEN WORKING - DO NOT INTERFERE WITH THIS

APPARATUS"

Cable support shall be provided by a suitable cleat mounted at the bottom of

the cabinet in such a manner that the cable entry to the cabinet is sealed by the
cleat and that the cable is clear of any metalwork forming part of the base of
the cabinet.

The centre line of this cleat shall be not less than 460 mm below the centre
line of the cable lug fixing of the neutral conductor.

These cable supports shall be adequate to support the outgoing cable in

normal service and when subjected to the short circuit duty specified in
Section 6.0.

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There shall be one standard size of fixed contact assembly of one-piece

construction which shall be suitable for accommodating a fuse carrier fitted
with a 92 mm centre type 'J' fuse link in accordance with BS 88. Each fuse
carrier shall be suitable for inserting in a phase of the unit by hinge action
pivoted on the lower contact and for withdrawing by snatch action. The
contacts shall be arranged to permit contact tightening and the contact surfaces
shall be flat and accurately aligned in pairs. Fuse carriers shall be supplied
with cabinets.

Contact assemblies shall be supported from the steel framework by means of

strips, rods, bars or mouldings of insulated materials; the arrangement of
supports shall be such that mechanical stresses produced in service by the
temperature rise of connections shall not adversely affect the alignment of the
contact surfaces.

It shall be possible with ease and safety when both busbar and outgoing
circuits are live to fit a current transformer ratio 500/5, 5VA output Class D
accuracy, of the design as supplied by the manufacturer over the red phase
fuse contact of any outgoing unit, and to use a clip-on-ammeter over any fuse
assembly when a current transformer is not fitted.

Insulated dividing barriers shall be provided between phase contact

assemblies and phase and neutral contact assemblies which shall make it
impossible to insert a fuse link between contacts of different phases.

If the dividing barriers are fastened to live metal, the resulting live bolts of
fasteners shall not be exposed, without insulation on the lower side of the
barrier

4.2.4 Busbars

Busbars shall be of hard drawn high conductivity copper, of a size suitable

for the rating of the fuse cabinet.

The neutral bar shall be rated at not less than half of the rating of phase
busbars.

Busbar shall be situated at the rear of the equipment.

Phase busbars shall be colour marked in sequence from top to bottom, red,
yellow, blue, the neutral busbar, mounted below shall be colour marked
black, and the earth busbar, mounted at the bottom shall be unmarked.

The colouring of the busbars shall not be continuous and shall be such that it
cannot be mistaken for an insulating covering.

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5.0 CONSTRUCTION

5.1 Feeder Pillars

The shell of the feeder pillars shall be weatherproof and of robust construction
and shall be provided with a watershed tops. They shall be manufactured
from sheet steel.

Adequate ventilation shall be provided to permit natural circulation of air.

The ventilation apertures shall be suitably screened to prevent entry of vermin
and other foreign bodies. Degree of protection shall be IP44.

They shall be designed to ensure that adequate clearance, not less than the
clearance specified in Section 7.0 "Clearance", shall be provided to permit the
incoming transformer circuit isolators to be left in an open or closed position
and alive with the door closed and with the locking device in position.

The design of the feeder pillar shall be such that it is suitable for mounting on
a flat base or pier (at or slightly above ground level). However, it is required
that the pillars have enhanced clearance from the ground by incorporating a
"rooted" type framework, with a height of 400 mm. Provision shall be made
for fixing the pillar framework to the foundation by the inclusion of four
clearance holes for M16 foundation bolts. These bolts will be supplied by the
Purchaser. The "root" framework shall be equipped with bolt-on covers on the
front and sides to conceal the cables above ground level. Alternatively, the
sides may be solid, non removable.

Access to the front of the pillar shall be by means of hinged doors which
shall be fitted with a locking bar to secure it top and bottom. The locking bar
shall be operated by a central handle which shall be arranged to permit locking
by a padlock with a 52 x 49mm body and an 8.5mm diameter shackle having a
clear inside width of 29mm and inside length of 41 to 55 mm. The holes
provided for the shackle shall be not less than 10 mm diameter. The apron at
the front of the cabinet shall be removable. Rear access to the pillar shall not
be provided.

All ferrous surfaces and edges shall be cleaned of scale and rust by shot
blasting and shall then be treated on the same day, without outdoor exposure,
with a zinc spray. The zinc shall be applied by a flame gun process of a
thickness ZN4 in accordance with BS EN 22063:1994.

This treatment shall be followed by the application of one coat of zinc

chromate base priming paint, an undercoat and a final coat of durable oil and
weather resisting paint. The final coat shall be Dark Admiralty Grey, colour
632 to BS 381C.

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All feeder pillars shall be fitted with removable lifting devices mounted one at
each end and as near as possible to the balance line.

Overall approximate dimensions are :-

Width - 1600 mm.

Depth - 500 mm.
Hieght - 1750 mm.

The Foundation Bolts holes are outside.

Any equipment, which is not stable on its own supports, shall be fitted for
transit and storage with removable extension feet to provide stability.

A data plate shall be fixed to the feeder pillar detailing the following
information:

i) Serial Number
ii) Year of Manufacture
iii) Normal current rating of busbar
iv) Normal current rating of incoming unit
v) Normal current rating of outgoing units.
vi) Gross weight, when fully equipped (kg).
vii) Manufacturers name and reference number.
viii) Reference to this KAHRA MAA Specification and order number.

The gross weight is also to be stencilled externally.

5.2 Fuse Cabinets

The shells of the fuse cabinets shall be weatherproof and of robust

construction and shall be provided with a watershed tops. They shall be
manufactured from sheet steel.

Adequate ventilation shall be provided to permit natural circulation of air.

The ventilation apertures shall be suitably screened to prevent entry of vermin
and other foreign bodies. Degree of protection shall be IP44.

The cabinet shall be designed to ensure that adequate clearance, not less than
the clearance specified in Section 7.0 "Clearance", shall be provided to permit
the incoming transformer circuit isolators to be left in an open or closed
position and alive with the door closed and with the locking device in
position.

Provision shall be made for supporting the lower half of the cabinet by means
of two adjustable supports, which shall bear against the tank of the
transformer when the cabinet is in position. These supports shall be

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adjustable in length from inside the cabinet and shall have end caps to prevent
damage to the transformer tank paint finish.

Access to the front of the cabinet shall be via a door hinged on the left hand
side viewed from the front, fitted with a locking bar to secure it top and
bottom. The locking bar shall be operated by a central handle which shall be
arranged to permit locking by a padlock with a 52 mm x 49 mm body and an
8.5mm diameter shackle having a clear inside width of 29mm and inside
length of 41 mm to 55 mm. The holes provided for the shackle shall be not
less than 10 mm diameter.

The rear of the cabinet shall incorporate a short trunking piece of not less than
100 mm in length, which may be detachable. On all cabinets, this shall be
centrally positioned in relation to the sidewalls of the cabinet.

The thickness of the flange(s) of this trunking shall be strong enough to

support the weight of the cabinet and cables and should be adequate to ensure
a weatherproof seal when finally mounted onto the transformer and cabinet.
The flange as shown in Drawing EP-MS-P4/S2-010 Fig. 3 shall be suitable for
mounting on the transformer flange securing the low voltage bushing
mounting plate on ground mounted and unit substation transformers to
KAHRA MAA Specification. A gasket or gaskets of synthetic rubber bonded
cork not less than 5 mm thickness shall be provided for insertion between the
flange(s) of the cabinet and the transformer.

Access shall be provided as requested by the Purchaser for earthing

connections to be brought through the base of the cabinet.

The cabinets shall be of the following maximum dimensions.

External Width of Cabinet: Transformer unit

Horizontal (mm)

i) 4 outgoing ways 610 mm

From the horizontal centre line of the trunking:

i) To the top of the cabinet 460 mm

ii) to the bottom of the cabinet 1270 mm

All ferrous surfaces and edges shall be cleaned of scale and rust by shot
blasting and shall then be treated on the same day, without outdoor exposure,
with a zinc spray. The zinc shall be applied by a flame gun process of a
thickness ZN4 in accordance with BS EN 22063:1994.

This treatment shall be followed by the application of one coat of zinc

chromate base priming paint, an undercoat and a final coat of durable oil and
weather resisting paint. The final coat shall be Dark Admiralty Grey, colour
632 to BS 381C.

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All fuse cabinets shall be fitted with removable lifting devices mounted one at
each end and as near as possible to the balance line.

Any equipment, which is not stable on its own supports, shall be fitted for
transit and storage with removable extension feet to provide stability.

A data plate shall be fixed to the cabinet detailing the following information:

i) Serial Number
ii) Year of Manufacture
iii) Normal current rating of busbar
iv) Normal current rating of incoming unit
v) Normal current rating of outgoing units.
vi) Gross weight, when fully equipped (kg).
vii) Manufacturers name and reference number.
viii) Reference to this KAHRA MAA Specification and order number.

The gross weight is also to be stenciled externally.

6.0 SHORT CIRCUIT RATING

The distribution equipment contained in the fuse board shall be capable of

carrying without permanent distortion or deterioration the following 3 phase
or 1 phase currents for 0.5 seconds with an initial peak of 2.0 times this value.

i) with 1600A incoming transformer unit 33kA rms

ii) with 2500A incoming transformer unit 44kA rms

If the largest sizes of fuse-links limit the peak current and the clearance time
to lower values than these, such lower value may be substituted in respect of
the portions of the fuse board, which are protected by the fuses. Evidence
must be submitted that a complete distribution fuse board of the basic design
offered has been tested for compliance with this Clause.

7.0 CLEARANCES

For all connections in air, the clearance and creepage distances shall be not
less than 25 mm between conductors and 20 mm from conductors to earth.

Where special risks exist, adequate self-extinguishing solid insulation shall be

provided in addition to the above clearances.

8.0 TEMPERATURE RISE TESTS

Distribution fuse boards shall be so designed as to ensure that thermal

interaction does not unduly affect the performance of any of the components.

Evidence shall be submitted that temperature rise tests have been carried out
on complete distribution fuse boards of each type to demonstrate that they

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comply with this Clause. Tests of temperature rise shall be made with
alternating current at an average frequency not below 95 per cent of the rated
frequency.

Tests shall be made with the incoming circuit carrying its rated current and
with the minimum number of outgoing circuits connected to balance this. For
arrangements where exact balance is not possible, the outgoing circuit most
remote from the incoming circuit shall be arranged to carry only sufficient
current to obtain current balance.

The distributor units of the fuse board to be tested shall be jointed with
300mm2 copper conductor cable, approximately 3 metres in length.

The test current shall be applied for a period of 6 hours or such period as
necessary to reach steady state temperature conditions.

8.1 Feeder Pillars

Any temporary connections for tests shall be such that their temperature rise is
not less than 35oC or not less than the actual temperature rise of the adjacent
current carrying parts under test if this should be below 30C.

The temperature rise of the cable terminals shall not exceed 30C relative to
the ambient temperature outside the switchboard.

Note: This implies that when the temperature is 50C outside the feeder
pillar, the temperature of the cable terminals will not exceed 85C.

The test shall be carried out with the base of feeder pillars closed and the
doors shut as in normal service.

8.2 Fuse Cabinets

The incoming temporary connections shall be copper busbars not more than
12.5 x 63 mm cross-section, bolted to the transformer unit connections with
the steel bolts, nuts, spring washers and clamping plates provided for bolting
the transformer terminal stems. These incoming connections and any
temporary connections shall be arranged such that their temperature rise is not
less than 30C.

Temperatures shall be continually monitored by means of thermocouples

attached to the following points.

i) The incoming temporary connections at a distance of 300 mm from the

point of connection.

ii) The interconnecting point (where the fuse-cabinet is normally

connected to the transformer).

iii) The top contact of each phase of the transformer units.

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iv) The top fuse contact of each phase of the distributor units.

v) All cable sockets.

vi) Air temperatures at the top and 300 mm from the bottom of the fuse
cabinet.

The temperature rise at any point shall not exceed 35C relative to the ambient
temperature outside the cabinet.

The test shall be carried out with the base closed, door(s) shut, and the mouth
of the throat piece, through which pass the incoming connections, effectively
blanked off.

9.0 FUSE AND FUSE CARRIERS

9.1 Fuses for Distributor Circuits

9.1.1 Fuse Links

Fuse Links shall be in accordance with BS 88. They shall be of the cartridge
type and shall have 92 mm terminal centres. Fuse links are to be supplied by
the Purchaser.

9.1.2 Fuse Carriers

A through grip shrouded fuse carrier of high quality, non inflammable and
non-hygroscopic DMC insulating material approved by KAHRA MAA shall
be provided on each phase. Each carrier shall be complete with two insulated
contact tightening thumbscrews. Reasonable good contact shall be made by
wedge action on inserting the fuse carrier so that current can be safely carried
in the interval prior to the tightening of the contact tightening thumbscrews.
Wedge action material shall be of brass and screws shall be of anti corrosive
material. There shall be one standard size of fuse-carrier which shall carry a
92 mm terminal centre fuse-link as specified previously.

9.2 Fuses for Auxiliary Supply

Fuse carriers for auxiliary circuits shall be of the withdrawable handle

insulated type with a rating of 60A and shall accommodate cartridge type
fuse-links of 15A, 30A and 60A ratings. The fuse links shall be of the end
cap type with dimensions in accordance with type 11a fuse detailed in BS
1361 : 1971.

10.0 NEUTRAL AND EARTH CONNECTIONS

In all units separate neutral and earth bars shall be provided. They shall be
solidly bolted together. The earth bar shall be mounted level with the cable
support cleats and the neutral bar shall be mounted above.

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The centre lines of the two bars shall be not less than 460mm apart. The
neutral shall be insulated from the framework and shell or cabinet. The earth
bar shall be bolted to the shell or cabinet and a sideways projecting M 12 x
50 mm captive stud complete with washer, nut and lock nut connected to the
earth bar shall project outwards from the shell or cabinet.

Studs shall be steel of minimum ISO grade designation ISO 272, 885, 888.

11.0 CURRENT TRANSFORMERS

Three current transformer shall be provided on each transformer unit as

follows:-

For 1600A Units 1600/5

For 2500A Units 2400/5

The current transformers shall be mounted on the incoming side of the unit.
The CT should be removable. They shall be encapsulated in epoxy resin
within moulded cases and comply with the requirements of BS 7626 and IEC
60044-1 and shall be of 5 VA output Class 1 accuracy. Thermal circuits not
less than class-'B'.

They shall be suitable for the operation of thermal demand ammeters.

12.0 INSTRUMENT PANELS AND AUXILIARY SUPPLY

CIRCUITS

An instrument panel suitably wired shall be provided to accommodate three

thermal demand ammeters with instantaneous pointer having a 20 minute time
lag and with direct reading scales. The scales reading shall be 0-1920 for C.T.
ratio 1600/5 and 0-2880 for C.T. ratio 2400/5.

The cable connections shall be of sufficient length to allow for the removal of
the indicators from the front panel.

The following additional equipment shall be provided:-

1-13A switched socket outlet to BS 1363.

1-60A fuse base and carrier for fuse-pillar socket outlet, substation
supplies and earth fault indicator reset supply.

Where requested, accommodation and mounting arrangements together with

wiring shall be provided for a voltage transformer for use in conjunction with
an earth fault indicator. The supply to be taken from the 60A fuse-carrier.

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The instrument panel shall be mounted in such a position that neither cable
installation nor jointing are impeded. Where it is mounted in front of the
cables it shall be removable.

See Drawing EP-MS-P4/S2-010 Fig. 5 for wiring diagram for auxiliary

circuits.

13.0 SMALL WIRING

Small wiring shall be carried out in PVC insulated cable coloured black to
BS 6231 Type B, with 7/0.67 mm conductors and with cores ferruled.

The secondary wiring of the group of current transformers shall be connected

to earth at a single point. The earth connections shall be accessible from the
front of the fuse board.

Wiring shall be fixed and where wiring cleats are used they shall be of the
insulated limited compression type.

Both the main connection from the phase busbar to the fuse and the main
connection from the neutral busbar shall be hard drawn high conductivity
copper not less than 75mm2 cross section. Refer to Drawing EP-MS-P4/S2-
010 Fig 5.

14.0 CIRCUIT LABELS

A circuit label 75 x 50 mm made of insulating material shall be mounted on

the barrier between red and yellow phases of each circuit unit. This label shall
be securely held without the use of screws and it shall be possible to slot into
position and remove the label from the front of the barrier. The labels shall be
suitable for engraving with black letters on a white background.

15.0 H.V. TESTS

Each complete fuse board shall be subjected to high voltage tests in

accordance with the requirements of IEC 60439-1.

15.1 Type Tests

Type tests on fuse-carriers specified in 9.1.2, including their associated

wedge-operating thumbscrews, shall be carried out as set out below. Type
tests shall be carried out for each new design of fuse-carrier or thumbscrew
and for any change in material of either component.

The tests shall be made at an ambient temperature between 25 and 50C with
alternating current of approximately sinusoidal waveform at a frequency of

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between 25 Hz to 100 Hz inclusive. The test voltage of 3.75kV (rms) shall be

applied for 1 minute between:

i) Both of the fuse link terminals without a fuse-link being fitted.

ii) One of the fuse link terminals and metal foil which shall be wrapped
around such surfaces of the insulating material of the fuse carrier
including the thumbscrews, which can be touched during live
replacements or withdrawal of fuse-carriers. For this test, a fuse link
of the largest dimensions intended for the fuse carrier shall be fitted.

One pole of the testing transformer shall be earthed during parts (i) and (ii) of
the test, together with the metal foil in part (ii).

The voltage shall be applied at a low value and shall be brought up to the full
value as rapidly as is consistent with its value being indicated by the
measuring instrument. The test voltage shall be maintained at the steady
value for 1 minute and may then be rapidly reduced before switching off.

If the voltage cannot be maintained at the specified value or if there is visible

evidence of sparking or tracking, this shall be regarded as failure of the test.

Following the high voltage test, the fuse-carrier shall be placed in a humidity
cabinet for 48 hours in which the humidity is maintained between 91 per cent
and 95 percent and the temperature maintained within 2C of any convenient
value between 30 and 50C. Prior to being placed in a cabinet, the fuse carrier
shall be brought to a temperature within + 4C and -0C of the cabinet
temperature. Immediately after removal from the cabinet, and after wiping off
any drops of water resulting from condensation, the insulation resistance shall
be measured by the application of a dc. voltage of 500V between the points
specified above.

The insulation resistance shall not be less than 5 mega ohms.

15.2 Routine Tests

Routine tests on insulated poles for operating the isolator specified in 4.1.2
and 4.2.2 shall be carried out on a representative sample of poles.

Each pole shall be immersed in water to within 10mm of the base metal and
5kV a.c. shall be applied between the metal head of the pole and the mass of
water, for a period of 2 minutes without flashover occurring.

Routine tests on wedge-operating thumbscrews shall be carried out on

representative samples by subjecting them to a high voltage test at the
manufacturers works. Each thumbscrew under test shall have the major
accessible portion of the insulated section encased in conducting foam, and a
test voltage of 3.75kV, 25Hz to 100Hz a.c., applied for one second between
the metal insert of the thumbscrew and the conducting foam. The conducting

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foam shall be carbon loaded with a surface resistance of 10,000 ohms per
sq.mm. All traces of carbon must be removed after the test.

Sampling for routine tests shall be in accordance with BS 6001, using the
maximum Acceptable Quality Level (Normal Inspection). In the event of
electrical breakdown of any component on test it shall be examined for the
cause of failure. In accordance with the maximum AQL in BS 6001, 100
percent of that production batch shall be subjected to the routine tests.

16.0 TORQUE TESTS ON THUMBSCREWS

Type tests shall be carried out on six random samples of the insulated
thumbscrews, each complete with the wedge operating screw, to confirm the
mechanical strength of the thumbscrew. Each wedge operating screw shall be
placed in a vice and a torque applied in a clockwise direction to the insulated
thumbscrew using a torque spanner adapted as necessary. Each insulated
thumbscrews shall withstand a torque of 12Nm, without fracturing or turning
on the shank of the wedge operating screw.

This type test shall be carried out for each new design of thumbscrew or
wedge operating screw and for any change in material.

Drawings EP-MS-02-010 Figs 1 to 5 refer to this Specification.

17.0 DEVIATIONS FROM THE TECHNICAL SPECIFICATION

The Tenderers are required to attach a separate deviation list to their

Technical Offer and include it in the Technical Package if the offered
equipments do not meet the requirements of any clause of the Specification.

Offers without any deviation list attached to the Technical Offer and included
in the Technical Package shall mean that the offer meets the requirements of
the Specifications on all the clauses.

Offers with deviations listed out shall mean that the offer meets the
requirements of the Specification on all the other clauses not included in the
deviation list.

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