Annexure # 1 EPPC Electrical 1

LV SWG Requirements

"LV Switchgear requirements"

Two LV switch-boards 3Ph/N/PE 400Volt 50Hz with series MANUAL operated bus-coupler
(bus coupler scheme for flexible interchangeability of downstream loads, bus coupler breaker
capacity will be similar to MCC1 & 2 incomer, arrangement to be provided so that no parallel
operation is possible between two incomers through bus coupler). Each incomer 5 runs of
cooper 630 sq. mm cable per phase, upstream incomers' capacities are 2000Ampere each. Load
shading scheme to be considered as an option.

General Requirements

 The 400V Switchgear shall be metal enclosed type with IP41 protection, Draw out type,
completely factory assembled.
 The switchgear shall have single end, copper single bus bar system. The switchboards shall be single
fronted.
 The outgoing feeders shall be standard modules, thus providing maximum
interchangeability.
 The 400V Switchgear is intended for installation indoors, inside RO unit.
 The painting system shall be selected so as to obtain a consistency of paint material, coat thickness
and surface compatibility (The electrical equipment shall be rated in due consideration of
geographical, meteorological and site conditions Altitude above sea level 1.6 m Atmosphere Highly
corrosive marine climate-humid, dusty and sulphurous (salty) atmosphere, incidence of sand storm
is very high). Painting system shall be suitable for the ambient conditions. The enclosure color shall
be selected by the manufacturer based on his standard. .
 Entries for incoming and outgoing cables shall be from the top with cable glands.
 The base frames (frameworks) are in the scope of supply of the switchgear supplier.
 The fastening at the base frame shall be carried out about screw-/ snap-in connections.
 Adjusting incomers cables are not permissible (cable joints), existing incomers location
to be respected Annexure #3 Switchboard room approx. dimensions.
 As much as possible existing feeders' location to be maintained to avoid any cables joints.
 The said enclosure shall be designed:
o To avoid any hazard to the operating personnel.
o To safely release pressure caused by short-circuit.
o To prevent any adverse effects on the adjacent compartments. Functional units and
cable compartments in the event of any short-circuit.
o To completely separate the switchgear, cable compartments and bus bar units (Form
3. According to IEC 60439).
o To ensure that the air circulation does not depend on bottom openings,
o To ensure that cable connections can be worked on while the switchgear remains
energized.

Construction of Boards

 The switchgears shall be of a least Form 3 construction according to IEC 60439 and shall consist of
vertical sheet metal cubicles. The single fields / cubicles are screwed together.
 Each horizontal section shall be equipped with the following devices:
o Bus bar compartment
o Circuit breaker module or motor starter modules or distribution feeder modules
o Cable termination compartment with terminals, cable fixation and cable entry suitable for Form
3
 Each board cubicle shall have separate partitions for circuit breaker / motor starter / bus bar / cable and
control compartments.

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LV SWG Requirements

 It is imperative that any accidental arc is restricted to its place of origin so that the adjacent
compartments/ boards will not be affected.
 Needed openings for connection of the withdraw-able units to the vertical bus bar shall be provided
with automatic shutters.
 Unused plug-in connections shall be touch proof covered
 A later reorganization of the cubicles during the operation shall be possible without use of special tools
and without weld, drill and cut.
 In principle the panels shall be established so, that these can be sent to the site ready to assemble
and connection, with the necessary withdraw-able units.
 The mechanical interlock of draw out air circuit breakers shall prevent moving of air circuit breakers
while they are closed and prevent closing/opening unless the circuit breaker is in SERVICE (primary
disconnecting devices are in full contact) or Test position(separated at a safe distance).

 It shall be possible to insert the withdrawal units and put in operation in any time in the
operating state of the switchgear.
 All doors shall open depending on the installation of neighboring cubicles (preferably the
opening shall be 160 degrees).
 The Low Voltage motor starters and outgoing feeder quantity shall include 10% fully equipped
spare with at least one typical motor starter or outgoing feeder from each type on each bus for
future use.
 The air circulation shall not be made depended by openings in the bottom. It must get in
consideration that the bottom is sealed up completely.
 The switch gears shall be able to perform without failure at a room temperature of +40 °C.
 If the inner thermal stability cannot be ensured by accumulation of heat sources an additional ventilator
shall be installed to raise the air-stream for the diversion of heat.
 The equipment compartments shall be all-round partitioned by sheet metals. Merely little openings for plug
devices, ventilators or air-compensation is permitted.
 The partition shall be executed so, that:
o Excess pressure by short-circuit currents are compensated without risk,
o To protect operating staff from danger
o No influences arise on neighboring compartments or fields.
 The bushing of the bus bars from equipment compartment to the bus bar compartment shall be executed internal
arc fault proof.

Bus bar System

 The bus bar system shall be produced of hard-drawn copper and cross section shall be designed so, that the
requirements correspond to electrical data.
 Cross section of horizontal busbars shall be uniform throughout the length of switchgear, bus bar joints shall
be silver plated. Bus bar joints shall be shrouded.
 The switchgears shall be equipped with the corresponding bus bar system depending on kind of the predefined
network to IEC 60364-3. 400/230V.AC distribution, TN-C-S system, 5 conductor system.
 Connection between PE and N bar shall be by a link that can be opened for measurements (inside incomer
cubicles).

BUSBARS

 Each section shall be provided with a main horizontal three phase bus at the bottom, N and PE horizontal bus
at the bottom.
 Each vertical section shall have three phase vertical bus + N to distribute power to the starters and feeder units
in the vertical section.
 The cross sections of vertical bus bars shall be rated to meet the specific requirements of short-circuit
rating and max. cubicle system load.
 When the draw-out modules have been removed, the vertical bus bars must be shock proof covered or be
provided with an automatic shutter.
 The neutral conductor shall have half cross section of the main phase conductors.

PROTECTIVE CONDUCTOR (PE)

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LV SWG Requirements

 The bar shall be adequately sized for Earth fault current accordingly to the classified size of switchgear.
Sizing calculations and / or Test certificates shall be provided.
 The protective conductor shall be conductive connected with the casing and base frame at three locations
(in the middle and at both ends) and the doors of switchgear by means of flexible.
 During removal, the withdraw-able units shall remain connected to the PE till all electrical connections to
live parts are severed.
 All hinged doors shall be connected to the PE bus with flexible connections.
 Sufficient holes for the PE-conductor connection including the required bolts, nuts, shims and spring washers.
 Earthing terminals of sufficient number and size shall be provided on the switchgear body / base frame, PE
bus bar to connect the switchgear to the main earthing system.
 Connection to main earthing system is envisaged with 90 sq.mm copper conductor, PVC insulated cable. Per
LV switchgear.

Cable Termination Compartment

 The cable termination compartment for the outgoing cubicle in principle shall be accessible from the front.
 The cable compartment shall be partitioned from bus bar compartment and adjoining cubicles.
 The cable compartment has to be formed with sufficient space and provided with a door at the outgoing
cubicles.
 It shall be possible to work in the cable compartment during the switchgear is in operation.
 Brackets with corresponding profiles to the fastening of the cables shall be assembled
 Cable compartment shall be intended for termination of power and control cables associated with each of the
withdraw-able unit.
 Connecting possibilities shall be provided according to the cross section of power cables indicated in the List
of LV switchgear documents.
 The motor cables shall be connected to permanently installed contact lugs.
 They shall be provided with shockproof covering (with connected cable).
 The said protection and the accessories required for cable connection such as lugs, wire end sleeves, bolts,
nuts, shims and spring washers shall be included in the scope of the switchgear supplies to consider the
specific material for Form 4 as per IEC 60439.
 Standard rails shall be used for fixing all cables in the cable compartment. Cable end fixation should be done
by metal cable clamps with PVC protection half shells.
 A wiring duct for internal interlocking and bus cables shall be provided in each cable compartment.
 Cable termination for large draw-out units (arranged in the lower cubicle section) shall be arranged beside
the upper part of the draw-out module to enable proper cable connection (big cross sections and big bending
radius).
 A parallel arrangement of a cable connection is also to be considered for consumer current above 55 kW (the
related consumer shall be specified later).

Control Voltage Supply for Incomers/Motor starters/Outgoing Feeders

For motor starters, outgoing feeders, the control voltage shall be 230V AC, (L+N+PE) supplied from the adequately
sized control bus bars connected to control voltage transformer (400/230V AC) with sufficient capacity located inside
the incomer cubicles. One transformer shall be provided for each bus bar section, with one secondary phase grounded.
The primary winding shall be controlled by a MCCB.

230V AC Switchgear Power Bus

A separate 230V AC power bus shall be provided for feeding the motor space heaters, switchgear space heaters.
230V AC, 1 phase incoming feeders shall be provided per bus section from Auxiliary power distribution board.
MCSs for protection and isolation purposes shall be foreseen

Description of Withdraw-able Units – General

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LV SWG Requirements

 Withdraw-able units shall be suited for replacement and the unit compartments shall be modifiable while
switchgear is energized.
 The withdraw-able units shall be total plug able for the main and auxiliary circuits for easily inserting
and removing without misalignment of contacts.
 The draw out units should have 3 positions - Isolated, Test and Service.
 All control circuit protection shall be by miniature circuit breakers.
 Solid state microprocessor based multifunction protection relays or electronic programmable release
shall be used for air circuit breakers. The protection device shall be an integral release with the Circuit
Breaker or separate numerical relay.
 The status of the circuit breaker (ISOLATED, TEST, SERVICE, ON, OFF, SPRING CHARGED) and
the status (category of trip) shall be clearly recognizable from outside the closed door.
 All circuit breakers (Withdraw-able) shall be equipped with mechanically acting push buttons for local,
testing and emergency operations
 Mechanical interlock shall be provided to prevent opening of Circuit Breaker compartment door when
the Breaker is in service position.
 Rating of incoming and bus tie breakers shall be as per Single Line diagrams. The breakers shall be
sized taking into account of the de-rating of the breaker nameplate rating for the design ambient
temperature and in panel installation. The breaker ratings indicated in the Technical data sheets and
Single line diagrams shall be suitably up-rated considering the de-rating for maximum ambient
temperature.
 Mechanical forced ventilation of breakers to achieve the specified rating will not be accepted.
 The auxiliary control, signaling and measuring devices shall be grouped to form sub-assemblies
assigned to the circuit-breakers
 Circuit breaker cubicles shall be provided with automatic shutters to cover the bus bar spouts.
 The circuit breaker contacts shall be self-aligning and the contact surface of main and auxiliary contacts
shall not be subject to corrosion by a polluted or corrosive atmosphere.
 Doors of all incomer and coupling circuit breaker cubicles shall be provided with padlocking facilities.
 The auxiliary contacts of the circuit breaker shall be wired on terminals so that a remote alarm can be
carried out.
 Spare NO and NC contacts (at least 2 per type) shall be provided in the incoming and bus tie circuit
breakers for client's use. These contacts shall be in addition to those required for control and interlocks

CURRENT TRANSFORMER (CT)

 The current transformers shall be of the dry type and cast resin.
 All current transformers shall be capable of carrying the potential fault current at the panel or section in
which they are mounted without injurious heating or mechanical/electrical damage.
 Current transformers for protection shall be of 5P20 class

VOLTAGE TRANSFORMER (PT)

The voltage/potential transformers shall be of single phase dry type. The secondary wiring shall be installed short
circuit proof by providing miniature circuit breaker (MCB) on the secondary side. The primary of the Voltage
transformers shall be connected to the main buses through MCCBs.
The Motor feeder modules shall have three positions, namely ISOLATED, TEST and SERVICE. In ISOLATED
position, both the power and control moving contacts of the module shall be isolated from the fixed contacts of
the switchgear. In TEST position, the control contacts shall be connected and the power contacts shall remain
isolated.

Motor Management relay:

 All essential protection and operating functions, recording of measured and counted values,
annunciation function and communication shall be realized by an integrated programmable intelligent
motor management system with soft link interface.
 The flexible modular motor management system shall combine all functions necessary for a motor
feeder. The system shall protect and monitor the motor feeder completely.
 The motor management relay shall have programmable Digital inputs for connection of Local Control

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LV SWG Requirements

Switch (LCS) and other hardwired inputs. The motor management relay shall also have programmable
digital outputs
 The LCS will have a spring return ON push button and spring return OFF push button.
 Motor feeder shall be switched ON only if "Start Permissive" interlocks signal (external dry
contact/potential free contacts) is received, all safety interlocks are satisfied and motor has not tripped
on fault.
 The control supply for the motor management relay shall be 230V AC from the control supply bus. The
interrogation voltage from the relay to the field motor control switch (for the digital inputs) shall also be 230V
AC. The motor control switch shall be connected to the Motor management relay with multi-core copper
conductor, PVC insulated, unarmored control cable of cross section 1.5 sq.mm or 2.5 sq.mm. Supplier has
confirmed to achieve the desired functionality.

Factory acceptance testing

Factory Acceptance Testing will include the following:

- Visual control of Supplier Documentation and Test Certificates,
- Visual Inspection (completeness, dimensions, conformance to spec., etc.),
- Functional/Performance Inspection and Test (routine test)
The inspection shall include all tests as indicated and the results shall be recorded

Any defects found by the inspector/EPPC shall be rectified in his presence. Where this is not possible, check lists of all
pending items shall be prepared from EPPC inspector and signed by both parties.

Inspection of Assembly

 Measurement of Insulation Resistance

 Test certificates (copy of origin)
 Certificate for insulation rating, AC voltage test
 Certificate for withstand the rated peak current, rated short time current
 Certificate for making and breaking capacity
 Internal arc test certificate
 Test certificate for mechanical function
 Certificate for degree of protection

Site Tests

Verification with Drawing and Dimension Check Yes

Verification of Workmanship Yes
Verification of Coating and Painting Yes
Verification of Surface Yes
Verification of Labeling and Identification Yes
Verification of settings and parameters for protection relay and Yes
composite meter
AC High voltage test of main circuits Yes

High voltage test of auxiliary and control circuits Yes

Insulation Resistance measurement of main circuit Yes

Insulation Resistance measurement of auxiliary and control circuits Yes

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LV SWG Requirements

Contact resistance test for bus bar joints Yes

Contact resistance test for breaker contacts Yes

Test of the mechanical function Yes

Test of Electrical Function Yes

Test of Software Function if any Yes

Wiring inspection Yes
Test of Protection devices Yes
By means of secondary injection of current (Omicron) if required

Special tools / test kits if required for above testing shall be arranged by supplier for testing purpose. All handling costs
shall be included in the site testing charges.

SPARE PARTS:

Spare parts for pre-commissioning, commissioning and start-up

Pre-commissioning and commissioning spare parts are required to safeguard the operation of equipment during the
running-in period and start-up period of the plant.
Supplier shall quote pre-commissioning and commissioning spare parts for a period of at least one (1) year. The spare
parts list shall be specified by supplier during detail engineering

2-Years spare parts

A recommended spare parts list for 2 years operation shall be specified.