ANNEXTURE-I

TECHNICAL SPECIFICATION OF PCC PANEL WITH GTP & BOQ

The design, construction, inspection and testing of the PCC Incomer Panel shall
comply with all relevant statutory regulations. The switchgear assembly should
conform to the following Indian Standards.

IS:13947 LV Switchgear & Control Gear part 1,2,3,4.

IS: 8623 Factory built assemblies of Switchgear and Control Gear.
IS:13703 Low Voltage Fuses.
IS:2705 Current Transformers.
IS:3158 Voltage Transformers.
IS:3231 Electrical Relay for Power System Protection.
IS:3842 Application Guide for Electrical Relay for AC System(Part 1 &2).
IS:13010 AC Electrical Meters.
IS: 5-1978 Colors for ready mixed paints and enamels.
IS:6005 Code of practice for phosphating of Iron and Steel.
IS:613 Copper rods and bars for Electrical Purposes.
IS:513 Specification for Cold Rolled Carbon Steel Sheets.
IS:5082 Wrought Aluminum.
IS:375 Marking & arrangement for Switchgear Busbar.
IS:694 PVC Insulated Cables and voltages upto 1100V.

Service and Environmental Conditions

The PCC shall in all respect, be suitable for operation under service conditions stated
on Electrical Standard Specification.
Maximum altitude above sea level 1000m
Maximum Ambient air temperature 48°C
Minimum ambient air temperature 2° C
Maximum relative humidity 98%.
Environment- Corrosive

Electrical System
The electrical arrangement of the PCC, protection, metering, control, interlocking,
inter-tripping etc. shall be shown on the PCC Single line diagrams.
The PCC shall be suitable for operation, without deleterious effect, with variations of
voltage and frequency. Transient voltage depressions down to 80% of rated voltage
shall not affect PCC performance. System voltage

415V, 3phase, 4 wire,50 Hz, 65KA AC with +/-10%V variation in voltage and +/-3%
variation in frequency.

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Fabrication Details
Low voltage Switchgear shall be fixed type, metal clad totally enclosed, floor
mounted, compartmentalized, modular with totally segregated compartments having
full side partition between the panel, busbar chambers, cable alleys modules etc
fabricated from 2mm thick CRCA sheet steel suitable for indoor installation. The LV
Switchgear shall be dust and vermin proof and the enclosure shall be provided a
degree of protection not less than IP54 as per IS:13947.

Each feeder should be fitted with individual door with thumb screws and quick release
cam type hinges. Where cables are connected to door mounted compartments they
shall be routed, suitably protected and dressed to cross the door hinges and allow the
door to fully open without subsequent cable damage.

Approx Size of Panel is Length-2600mm, Width-1800mm and Height

2380mm. The Final Size will be approved after visit of Panel
Engineer/Representative at site and based of GA Drawing Approval.

The Switchgear shall be assembled on either side by the addition of vertical sections.
It shall be possible to extend the switchgear, irrespective of the type of end panel and
the design shall be such as to permit addition of extension panels.
The switchgear shall be designed to ensure maximum safety, means shall be provided
to prevent shorting of power or control terminals due to accidental dropping of
maintenance tools etc inside the switchboard.

All load bearing and non load bearing members/frames shall be fabricated by using
minimum 14SWG cold rolled sheet steel.

The switchgear shall be provided with internal base frame ISMC75 for each vertical
panel to prevent corrosion of sheet steel cubicle and facilitate to cleaning of floor. All
base frames shall be painted with black paint.

All openings, covers and doors shall be provided with neoprene gaskets around the
perimeters to make the switchgear dust and vermin proof.

All hardware shall be corrosion resistant. All joints and connections of the panel
members shall be made by galvanized, zinc passivated or cadmium plated high
quality steel bolts, nuts and washers, secured against loosening.

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The Panel Should be fabricated in 02 Parts -Incomer Breaker Panel 01 & 02 with
suitable lifting hooks shall be provided on each panel or shipping section for ease of
lifting of PCC. These hooks when removed shall not leave any openings in the board.

Completely metal enclosed horizontal bus bar compartment shall run horizontally at
top, individual feeder modules organized in multi-tear mode. Completely enclosed
VERTICAL Al busbars serving all feeder modules in the vertical panel.

The switchgear shall be compartmentalized, modular construction. All equipment

associated with a particular circuit shall be housed in a separate and independent
compartment – marked for that particular circuit in the fixed portion of the vertical
panel. All auxiliary devices for control, indication, measurement and protection such
as Pushbuttons, control and Selector switches, indicating lamps, ammeters,
voltmeters shall be mounted on the front side of the respective compartment only.

Suitable AL Busbars Coupling Plates should be provided to Couple the

individual sections of PCC along with Couplers for top busbar at both side
for coupling of PCC with existing feeder panels and existing coupling with
incomer busduct at top coming from secondary winding 415V of 3MVA
Transformer.

Busbar Sizing, Connection and Supports

All Aluminium Busbars should be E91 Grade high conductivity, supported on insulators
made of non-hygroscopic, non-inflammable material. The main busbars should have
uniform current rating throughout their length. The current rating of the neutral shall
be half of the phase busbars throughout the length. Removable neutral links should be
provided on the feeders to permit isolation neutral of the busbars.
All busbars should be marked to indicate the phase coloring. An earth busbar shall be
provided along the full length of the PCC with provision of Earth Strips connections at
each end.

The busbars and supports should be capable of withstanding the short circuit currents.
Only zinc passivated or cadmium plated high tensile steel bolts, nuts and washers
should be used for all busbar joints and supports. All busbars should be supported
with SMC moulded insulators and 10% shall be kept spare for future requirement. The
maximum operating temperature of busbars at maximum design temperature should
not exceed 60C for normal operating condition. The short circuit withstanding
capacity should be 65KA RMS for 1 second and insulation level 2.5KV for 1 minute at
50Hz should be considered for designing the busbar.

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Three phase horizontal busbars should be uniformly rated with current density not to
exceed 0.80Amps/sqmm for AL and 1.20Amps/sqmm for Cu. The busbars should
have minimum clearance of not less than 50mm to earth and between phases in line
with IS.

All busbars should be PVC sleeved and colour coded by means of identifying colour.
Red, Yellow and Blue colour should be used for phase busbars and Black colour for
neutral busbars. Heat shrinkable PVC sleeves should be used.

Electrolytic Grade Cu Busbars should be used from Breaker Male Contact to

a suitable length to avoid heating of Breaker Male-Female Contacts and
after that AL Busbars to be used. All joints surfaces at aluminium to copper
joints shall be silver/tin plated and bimetallic plates should be use at
coupling of AL-Cu Busbar.

Interconnections between the main busbars and individual units shall be made by
using vertical Aluminium busbars of adequate rating. These interconnections and the
vertical busbars should be compartmentalized and fully shrouded.

All necessary coupling plates, bolts, nuts, locknuts and washers shall be provided to
give individual connection on each busbars.

Auxiliary Wiring and Terminals

The wiring for power, control protection and instrument circuits shall be as per IS :694.
PVC Insulated wires of insulation grade 1100V should be used. All control wiring shall
preferably be of 1.5Sq mm and that of CTs and ammeter be of 2.5Sqmm. The circuit
arrangement should be such that not more than one outgoing cable is connected to
any one terminal. An adequate number of neutral and earth terminals shall be
provided to comply with this requirement.

All wiring shall have crimped terminations and connect to rail mounted terminals
adequately rated for the respective duty. All terminals and cable ends should be
suitably and consistently identified with the approved permanent markers. Ferruling of
wires should be as per relevant IS. Inter-panel wiring between each shipping sections
shall be vendors responsibility. Terminal blocks on adjoining shipping sections and
jumpering wires to be provided.
All control wiring for control, voltmeter supplies etc that originate from the main and
sub-main busbars shall be connected to the busbars by means of HRC cartridge fuses

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suitably rated for the purpose. The maximum size of fuse shall not exceed 20Amps. A
minimum of 20% spare terminals shall be provided on each terminal block.

Earthing Connections
All vertical panels shall be connected to an AL Earth Bus running throughout the
length of the MCC. The minimum size of earth bus should be 50X8mm. All doors and
movable parts shall be connected to the earthing jumpers which are coloured green.
Provision should be made to connect the earthing busbar to the plant earthing grid at
two ends. Minimum 2 Nos 3/8” holes shall be provided on earth bus with bolts and
nuts.

Labels and Notices

Identification labels should be provided for every item of switch/control gear and
instrumentation, giving clear details of its purpose. Where switchgear fuses of a lesser
rating than that of the rated switchgear are required, the actual fuse rating shall be
identified on the label.

Each section should be fitted with danger boards written in English/Hindi. All such
identification label shall be of Traffolyte or similar approved material with Black
characters on white background with 5mm high.
Warning notice shall be of Traffolyte with red characters on a white background in
English/Hindi language with a character minimum 8mm high.
All labels and notices should be securely fixed using round headed chromium plated
screws.

Painting
All metal surfaces should be thoroughly cleaned to remove oil scales, rust, grease and
dirt. Fabricated structure should be thoroughly cleaned chemically in a continuous
monitored and HOT NINE TANK SYSTEM.

The under surface shall be prepared by applying a coat of phosphate paint and coat of
zinc chromate primer. The under surface shall be made free from all imperfections
before undertaking the finishing coat.
After preparation of the under surface the MCC shall be Epoxy powder coated with two
coats not less than 50micron with RAL 7032 Shade. The finished panel should be free
from imperfections like pinholes, orange peels, runoff paint etc.

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Specific Requirements of PCC Panel.
AIR CIRCUIT BREAKERS
2Nos 6300Amps Incomer 3 Pole EDO Type ACBs should be L&T (U-Power) Omega/C-
Power conforming to IEC - 60947 (Part 1 & 2) IS/IEC - 60947 (Part 1 & 2), IEC 60695 -
2 – 1 suitable for harsh/corrosive environment. The ACB Should be equipped with
following features: -
1)Breaker Overcurrent/Short Circuit/Earth fault Release-Microprocessor based
releases.
2)Breaker Breaking Capacity-65KA.
3)Front accessible over current release settings, telescopic racking handle and various
racking interlocks; no need to open the panel door.
4)Unique ‘Maintenance position’ in drawout type ACBs to facilitate maintenance &
inspection without removing ACB from the panel.
5)Lockable sliding shutters to prevent unauthorized access to “TRIP” and “CLOSE”
push buttons.
6)In-built mechanical anti-pumping to prevent auto-reclosing of ACB on persisting
faults.
7)Safety shutters to prevent accidental contact with live cradle terminals.
8)Breaker Closing-Manual, Overcurrent/Earthfault Release Coil 110V DC for Tripping.
9)Spring Charging Motor-230V AC 50Hz.

HRC Fuses
All HRC fuses shall be of 500V totally enclosed cartridge type L&T Make HN or BS
Type having a category of duty 550A C80, and having class Q1fusing factor with the
exception of motor rated fuse links which shall be certified to 415AC80 and LV
underground cables which shall have class P1 fusing factor.

Current Transformers
Current Transformers shall be cast resin insulated type. Current transformers shall
conform to IS:393 with output accuracy and ratio as applicable for the duty. When
measuring the values of line currents, using a meter with a selector switch, it shall be
so connected that the current transformers are shorted out when not in use. This shall
be effected via the selector with the make before break contacts.

Measuring Instruments
Both the Incomer Breaker Feeders should have Ammeter & Voltmeters with SECURE
Make 0.2 Accuracy Class Energy Meters ELITE440.
The outgoing Feeders should have Ammeters & SECURE Make 0.2 Accuracy Class
Energy Meters ELITE440.

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All measuring instruments shall have a compatible appearance, size and finish and
shall be mounted on as near as possible to the associated equipment. All ammeters
and voltmeters shall be of the moving iron type with external zero adjustment. They
shall be flush mounted and housed in a pressed steel or plastic case with escutcheon
plate.

When reading currents on all the phases, ammeters shall be provided with selector
switches to enable all three currents to be read and neutral out of the balance current.
These switches will incorporate an OFF position. Ammeters shall have a maximum
burden of 3VA at full scale of deflection. When reading on all three phases, voltmeters
shall be provided with selector switches for reading all phase and line voltages and
the voltage of the neutral. These switches shall be incorporated an OFF position.
Voltmeters shall be scaled 0-500 with a suppressed zero and continuously rated.
Control Transformer
2 Nos Control Transformer of 415V/110V, 2.0KVA should be provided for 110V AC 50Hz
control supply of the MCC panel with 32A SFU and Fuse arrangements.

Control Switches
All control switches shall be rotary, back connected type, having a cam operated
contact mechanism. Preferably phosphor bronze contacts shall be used on the control
switches. They shall have pistol grip handles for circuit breaker control and knob type
handle for other applications. Ammeter selector switches shall have make before
break feature on its contacts. The selector switch shall generally have 4 positions for
reading 3 phase currents and fourth position OFF. The voltmeter selector shall also be
used to measure phase to phase voltage and fourth shall be OFF position.

Indicating Lamps
LED Indicating lamps shall be suitable for 110V AC. Lamps shall be provided with
translucent covers Red for ON Indication, Green for OFF Indication and Amber colour
for TRIP Indication.

Alram Annunciator
The PCC Panel should have annunciator panel for alarm/trip for:-
Trafo Oil Tempt High-Alarm
Trafo Wdg Tempt High-Alarm.
Bucholz Relay-Alarm.
Bucholz Relay Trip.
Trafo Oil Tempt High-Trip.

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Trafo Wdg Tempt High-Trip.
PRV-Trip
Oil Level Low (MOG)-Alarm
Makes of Brought Out Items
All the switchgears i.e MCCB, Power and Control Contactors, Fuse Switch Unit with
fuses, Overload Relays, Timers, Control Fuses should be of L&T make Only. Other
components like CT/PT, MCB, Indicating Lamps, Selector Switches, Terminal Blocks,
Ammeters & Voltmeters and Energy Meters should be of L&T or Reputed Make as
given in Annexure-II.

Sctions & Shipping Arrangement

PCC Panel should be provided in 02 Sections keeping view of the space
limitation for entering the Panel in PCC Room.

AL Coupling Busbars
Suitable Aluminium Coupling Plates to be provided for Coupling of Top
Busbars & Incomer Busbars of All Sections, for coupling of Busbars at both
side with Existing Panel and top Busduct Incomer Busbars.

General
PCC shall be provided with minimum 01 Set of Extra Rack-in/Rach-out Handle.

TESTS
1)The equipment offered should have been successfully type tested at NABL accredited
laboratories for following tests in line with the relevant standard and technical
specification. The design of circuit breaker shall be proven through all the routine and in
accordance with IEC 62271-100 / 200 / IS 13118: 1991 and any amendment thereof.

2)The bidder shall be required to submit complete set of the following type test reports
before dispatch which will be witnessed by OPM Representative: -

TESTS ON CIRCUIT BREAKER

Circuit breaker shall be fully type tested as per IEC 62271 - 100/200, including the
following tests:
a) Short time and peak withstand current test.
b) Short circuit breaking capacity and making capacity.
c) Capacitive current switching test.
d) Dielectric test i.e., power frequency withstand and impulse withstand test.
e) Temperature rise test.
f) Mechanical Endurance Test at ambient temperature.

g) Measurement of resistance of the main circuit.

h) Internal arc test.

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CURRENT TRANSFORMER
a) Short Time Current Test.
b) Temperature Rise Test.

INSPECTION:
1)The inspection may be carried out by the OPM Representative after manufacture before
dispatch of panel.
2)The manufacturer shall grant free access to the purchaser's representative/s at a
reasonable notice when the work is completed.
3)Inspection and acceptance of any equipment under this specification by the purchaser
shall not relieve the supplier of his obligation of furnishing equipment in accordance with
the specification and shall not prevent subsequent rejection if the equipment is found to be
defective.

4)The supplier shall keep the purchaser informed in advance, about the manufacturing
program so that arrangement can be made for stage inspection if required.

PERFORMANCE GUARANTEE:
All equipment supplied against this specification shall be guaranteed for a period of 18
months from the date of receipt at the consignee’s stores centers or 12 months from the
date of commissioning, whichever is earlier.

DRAWINGS & DOCUMENTATION

1)The manufacturer has to submit complete drawings before start of manufacture. If any
modifications are required on these, the same will be conveyed to the supplier who shall
modify the drawings accordingly and furnish final drawings for approval.
2)List of Drawings
a)GA of Incomer PCC Breaker Panel..
b)Sectional view of incomer, bus coupler & feeder panels.
c)Foundation details of Incomer Breaker Panel.
d)Typical single line diagram for Power & Control Circuit.
e)DC control circuit of Breaker Panel.
f)Protection Circuit for Breaker Panel.
g)Metering circuit for Breaker Panel with indication & Annunciator scheme.
h)Terminal block details for Complete Panel.
i)Bill of material for complete switchgear.
j)Technical particulars of Switchgears.

3)The manufacturing of the equipment shall be strictly in accordance with the approved
drawings and no deviation will be permitted without the written approval of OPM.

4)04 set of final drawings, bill of materials, wiring schedules, technical literature and
commissioning manuals shall invariably be forwarded to the consignee alongwith the
panel consignment.

5)All drawings shall preferably be of A3 size.

6)In case the supplier fails to furnish contractual drawings and manuals even at the time
of supply of equipment, the date of furnishing of drawings/manuals will be considered as
the date of supply of equipment.

PACKING AND FORWARDING

1)The equipment shall be packed in crates suitable for vertical/horizontal transport as the
case may be and the packing shall be suitable to withstand handling during the transport
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and outdoor storage during transit.

2)The supplier shall be responsible for any damage to the equipment during transit, due to
improper and inadequate packing.

3)The easily damageable materials shall be carefully packed and marked with the
appropriate caution symbols.

4)Wherever necessary, proper arrangement for lifting, such as lifting hooks etc. shall be
provided.

5)Any material found short inside the packing cases shall be supplied by the supplier
without any extra cost.

6)Consignment shall be accompanied by a detailed packing list containing the following

information:-
a. Name of the consignee
b. Details of consignment.
c. Destination
d. Total weight of consignment
e. Sign showing upper/lower side of the crate.
f. Handling and unpacking instructions.
g. Bill of material indicating contents of each package.

COMMISSIONING
1)The scopes of Installation/Commissioning are as below:-

OPM CSU SCOPE:-

a) Unloading of material at stores.
b) Lifting & Shifting of Panel to Location.
c) Obtaining Any statutory Approval of Installations third party Electrical Inspector.
d) Dismantling of Existing panels.
e) Shifting of dismantled panels from site location to the designated location.
f) Installation of base frame required for Panel.
g) Laying & Termination of Control cable outside the supplied panels.
h) Gate Pass permission for contractor's manpower as well as ABB Staff.
i) Provision of External AC & DC Supply.

SUPPLIER SCOPE:-
a) Erection/ Installation of new PCC Incomer Panel.
b) Busduct Bus-bar coupling & Top Busbar Coupling at Both sides of Existing Panel.
c) Implementing the protection settings of ACBs
d) Testing of all Auxiliary Relays for proper function and proper pickup voltage.
e) IR Test for panel.
f) Checking of CB mechanical & electrical operation closing and tripping.
g) Mechanism critical setting and adjustments.
For Installation/Commissioning the Supplier will be provided with separate service order in
addition to material supply order as required.

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 BILL OF MATERIALS

DESCRIPTION Type/Ref. Qty

6300A 3P,100KA EDO ACB MP BASED WITH 1
INCOMER#1 ST35560OOOO
ADJUSTABLE O/L, S/C & E/F PROTECTION

UNDERVOLTAGE RELAY 415VAC CL90818DOOO 1

Lockable Trip Push Button CL00659OOOO 1

AUX.CONTACT RELAY 2NO+2NC CS94020 1

Auto-manual selector switch,6A 61151 1

TNC SWITCH 73257SEB03PGGB 1

Alarm Annunciator (12window) EAPL 1

HOOTER REPUTED 1

3Phase Over Current+Earth Fault Relay with 1

High Set & RS -485Port MC61CNX4000

MFM4410 LED meter Cl0.2 with RS485 WL441041OOOO 1

DIGITAL AMTMETER (0-6300A) WL111010OOOO 1

AMMETER SELECTOR SWITCH 61325SAB13TDYR 1

DIGITAL VOLTMETER (0-500V) WL112010OOOO 1

VOLTMETER SELECTOR SWITCH 61312SAB13TDYR 1

PHASE INDICATION LAMP R,Y,B EPL 3

INDICATION LAMP ON, OFF,TRIP EMN 3

6300/5A, CL0.2, 15VA TAPE WOUND CT KAPPA/EQV. 3

6300/5A, CL-5P10 TAPE WOUND CT FOR KAPPA/EQV. 3

PROTECTION

6 AMP MCB,10KA BB10060C 4

CONTROLTRANSFORMER
415/230VAC CONTROL TRANSFORMERCL.1, KAPPA/EQV 1
1KVA

9-13A, MPCB ST41914OOOO 1

20A, 2P 10KA MCB BB20160C 1

6300A 3P,100KA EDO ACB MP BASED WITH ST35560OOOO 1

INCOMER#2
ADJUSTABLE O/L, S/C & E/F PROTECTION

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 UNDER VOLTAGE RELAY 415VAC CL90818DOOO 1

Lockable Trip Push Button CL00659OOOO 1

AUX.CONTACT RELAY 2NO+2NC CS94020 1

Auto-manual selectors witch,6A 61151 1

TNC SWITCH 73257SEB03PGGB 1

Alarm Annunciator (12window) EAPL 1

HOOTER REPUTED 1

3Phase Over Current+Earth Fault Relay with High MC61CNX4000 1

Set &RS -485Port
MFM 4410 LED mete rCl0.2 with RS485 WL441041OOOO 1

DIGITAL AMTMETER (0-6300A) WL111010OOOO 1

AMMETER SELECTOR SWITCH 61325SAB13TDYR 1

DIGITA LVOLTMETER (0-500V) WL112010OOOO 1

VOLT METER SELECTOR SWITCH 61312SAB13TDYR 1

PHASE INDICATION LAMP R,Y,B EPL 3

INDICATION LAMP ON,OFF,TRIP EMN 3

6300/5A, CL0.215VA TAPE WOUND KAPPA/EQV. 3

6300/5A CL-5P 10 TAPE WOUND CT FOR KAPPA/EQV. 3

PROTECTION

6A SP MCB,10KA BB10060C 4

CONTROLTRANSFORMER.
415/230VAC CONTROL TRANSFORMER CL.1, KAPPA/EQV 1
1KVA
9-13A, MPCB ST41914OOOO 1
20A,2P 10KAMCB BB20160C 1

Dimension:W-2600,H-2380,D-1800MM (Approx)
LOAD BEARING:2.0MM
GLAND PLATE:3.0MM
BUSBAR :6300A, AL
(PH-4X150X12,N- 2X150X12)

Electrolytic Grade Cu Busbars

PH-4X150X10, N- 2X150X10.
(should be used from Breaker Male Contact)

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