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LPG BOTTLING PLANT , BATHINDA

Doc. No. 266763-000-SP-4004

Rev: B

Page 1 of 37

Specification for 415 V PMCC, BUS


DUCT, MCC, PDB & MLDB

Hindustan Petroleum Corporation Ltd

Mott MacDonald Consultants (India) Pvt. Ltd.

8 S.V. Marg, Ballard Estate

Kothari House, CTS No. 185

Mumbai- 400 001

Off Andheri - Kurla Road


Andheri (East)
Mumbai 400 059

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Rev: B

Page 3 of 37

List of Content

Page No

Introduction

Location and Environmental Conditions

2.1

Plant Location

2.2

Environmental Conditions

2.3

Electrical System Data

Scope of Supply

3.1

Electrical Equipment & Material:

3.2

Engineering Services

3.3

Exclusions

Codes and Standards

10

4.1

General

10

4.2

Conflicting Requirements

10

Technical Particulars:

10

5.1

Operating Philosophy:

10

5.1.1

415 V PMCC(000-PMCC-001)

10

5.1.2

415 V BPMCC (000-BPMCC-001)

11

5.1.3

415 V PDB (000-PDB-001)

11

5.1.4

415 V MLDB (000-MLDB-001)

11

5.1.5

Motor Control philosophy.

11

5.2

Motor Feeder Requirement:

11

5.3

Construction:

12

5.4

Busbars:

13

5.5

Air Circuit Breakers (ACB):

14

5.6

Moulded Case Circuit Breakers (MCCB):

15

5.7

Contactors:

16

5.8

Over Load Relays & Timers:

16

5.9

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

16

5.10

Indicating Instruments & Meters:

17

5.11

Current Transformers:

18

5.12

Potential Transformers:

18

5.13

Wiring and Identification:

19

5.14

Control Supply:

20

5.15

Space Heaters and Cubicle Illumination:

20

5.16

Earthing:

21

5.17

Busduct Terminations:

21

5.18

Cable Entry and Terminations:

21

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Page 4 of 37

5.19

Capacitor Bank :

21

5.20

Nameplates:

21

5.21

Makes of Components

22

5.22

Tropical Protection

22

5.23

Painting

22

5.24

Quality assurance:

22

Inspection and testing:

23

Vendor documentation:

24

Spares and special tools:

25

8.1

Spares

25

8.2

Special tools

25

Installation and commissioning:

25

10

Packing and transportation:

25

11

Statutory Approval:

25

12

Guarantee:

26

Appendix-A: Table of Compliance.

27

Appendix-B: Electrical System Data

30

Appendix-C: Codes & Standards.

31

Appendix-D: Requisition for Engineering Documents

32

Appendix-E: Guaranteed Technical Particulars

34

Appendix-F: Electrical Drawings.

35

Appendix-G: Control Schematics drawings.

36

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

37

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Rev: B

Page 5 of 37

Introduction

This specification is intended to cover the design, manufacture, assembly, testing at manufacturer's works,
supply & delivery, properly packed for transport F.O.R. site of 415V PMCC, MCC, Bus Duct, PDB & MLDB
complete with all accessories for efficient and trouble-free operation for the LPG Bottling Plant project at
Bathinda of Hindustan Petroleum Corporation Limited, India.
The scope of work shall also include, the supervision of erection, testing, commissioning and putting into
successful commercial operation of the switchgear furnished under this specification
Following are the definitions:
Company/Client/Owner

Shall mean Hindustan Petroleum Corporation Limited


(HPCL),

Consultant

Shall mean Mott MacDonald Consultants India Pvt. Ltd.


(MMCI).

Manufacturer / Vendor

Supplier of 415V PMCC, MCC,Bus duct, PDB, MLDB


etc.

Shall

This is to be understood as mandatory in relation to the


requirements of this document.

Should

This is to be understood as a strong recommendation to


comply with the requirements of this document.

Equipment

This is to be understood as vendor supplied equipment


with all accessories.

The Vendor shall ensure that the design complies with the requirements of this specification and its
referenced specifications, data sheets & standards. The Guaranteed Technical Particulars, Appendix F,
which forms part of this specification, shall be completed by the Vendor. Deviation if any should be
specifically brought out at the offer stage in the Table of Compliance, Appendix A. Without the compliance
table and Guaranteed Technical Particulars can cause rejection of the offer. Failure to clearly identify
specific deviations if any shall be assumed by the Purchaser to be total compliance with the specification.
This specification does not relieve the Vendor from final guarantee as to materials, apparatus,
workmanship and performance of the equipment supplied.

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Doc. No. 266763-000-SP-4004

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Page 6 of 37

Location and Environmental Conditions

2.1

Plant Location

The Plant is situated at Village Phulo Khari, Taluka Talwandi Sabo, District Bathinda Punjab.
PMCC/MCC/Bus Duct /MLDB listed in scope of supply shall be located in the MCC Room within plant
complex.

2.2

Environmental Conditions

Design ambient temperature for Electrical Equipment (Indoor):

50 C
0

Design ambient temperature for Electrical Equipment (Outdoor): 55 C


For other details Refer EIA Report for Site Enviormental condition.

2.3

Electrical System Data

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

Scope of Supply

The following equipments shall be supplied, in accordance with this specification; standards stated herein
& enclosed appendices.

3.1

Electrical Equipment & Material:

Sr. No.

Item Description

Unit

Quantity

Remarks

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

1.0

000-PMCC 001 ( 415 V PMCC)


415V, Double Front, Compartmentalised Draw out
type, floor mounted, AL Bus bar PMCC as per
following details & attached Single Line diagram
Dwg. No 266763-000-410-002D.
Rated voltage

415 V

Highest system voltage

433 V

Rated Bus-bar current

1600 A

Short time withstands current

50 kA for 1 Sec.

No. of outgoing feeders

As per SLD

Control supply Voltage

2.0

Set

Refer Appendix B

000-BPMCC 001 ( 415 V MCC)


415V, Double Front, Compartmentalised Draw out

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Doc. No. 266763-000-SP-4004

Rev: B

type, floor mounted, AL Bus bar; Bottling Plant


MCC as per following details & attached
Single Line diagram Dwg. No 266763-000-410003D.
Rated voltage

415 V

Highest system voltage

433 V

Rated Bus-bar current

400 A

Short time withstands current


No. of outgoing feeders
Control supply Voltage

3.0

Page 7 of 37

Set

50 kA for 1 Sec.
As per SLD
Refer Appendix B

000-BD 001( 415 V Bus Duct )


415V AL, non-segregated phase Bus Duct as per
following details & attached Annexure H for
specification of LV Bus Duct :
Rated voltage

415 V

Highest system voltage

433 V

Rated Bus-bar current

1600 A

Short time withstands current

50 kA for 1Sec.

set

Exact bus duct


length
will
be
finalized
during
detail engineering
stage. Vendor is
advised to quote
as on unit rate
basis.

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

4.0

000-PDB-001( 415 V PDB )


415V, Compartmentalized, Floor mounting, single
Front, and Fixed type auxiliary PDB as per
following details & attached Single Line diagram
Dwg. No. 269323-000-410-049D.

4.0

Rated voltage

415 V

Highest system voltage

433 V

Rated Bus-bar current

125 A

Short time withstands current

50 kA for 1 Sec.

No. of outgoing feeders

As per SLD

Set

000-MLDB-001( 415 V MLDB )

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Doc. No. 266763-000-SP-4004

Rev: B

Set

800mm wide

No.

Quote
unit rate

600mm wide

No.

Quote
unit rate

400mm wide

No.

Quote
unit rate

415V, Compartmentalized, Floor mounting,


Double Front, and Fixed type Main Lighting
Distribution Board as per following details &
attached Single Line Diagram Drawing No.
266763-000-410-004B.

5.0

Page 8 of 37

Rated voltage

415 V

Highest system voltage

433 V

Rated Bus-bar current

400 A

Short time withstands current

50 kA for 1 Sec.

No. of outgoing feeders

As per SLD

Dummy Panel of following widths to account for


floor beams that may foul with the cable entries:

6.0

Unit rates for addition / deletion of::

6.1

Incomer Breaker Panel of each rating

Quote
unit rate

6.2

Outgoing Motor feeder ( DOL) of each rating &


each scheme type

Quote
unit rate

6.3

Outgoing Motor feeder ( STAR/DELTA) of each


rating & each scheme type

Quote
unit rate

6.4

Outgoing Power feeders of each rating & each


scheme type

Quote
unit rate

Empty Panel without feeders but complete with


horizontal & vertical Busbars.
Main Busbars rated for
1600A
400A
250A
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Extension Box if required, for termination of


cables shall be included at no extra cost.

Inspection and Testing as specified.

Submission of documents as specified.

Painting as specified.

Preservation, preparation of shipment and delivery to site.

List of Spares for two years normal operation.

Start-up spares and commissioning spares.

List of special tools required (Vendor to provide list with the bid).

Any other items, required to make system complete.

3.2

Engineering Services

The Vendor shall provide engineering services, which shall include, but not necessarily be limited to, the
following:

3.3

Providing/coordinating detailed design of all equipment and components within the scope of
supply. This will also include providing engineering/design layout of PMCC & Bus Duct matching
the customers general arrangement of the substation.

Resolving engineering queries related to the equipment and components within the scope of
supply.

Performing all relevant calculations pertaining to the equipment and components within the scope
of supply.

Providing progress reports etc.

Providing expediting services for all sub-vendors, if any.

Providing quality assurance, including all sub-vendors if any with respect to ISO 9000 or
equivalent.

Quality Assurance.

Supervision of Installation/erection and commissioning.

Training of clients personnel at site / Vendors shop.

Exclusions

Installation/Erection & commissioning.


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Codes and Standards

4.1

General

Rev: B

Page 10 of
37

The LV Switchgears shall meet the requirements of this specification and latest edition of applicable
standards listed in enclosed Appendix-C

4.2

Conflicting Requirements

In case of conflict between documents relating to the enquiry or purchase order, the following priority of
documents shall apply.
First priority

This engineering specification along with attached drawings/ data sheets


and subsequent purchase order & variations thereto.

Second priority

Relevant Indian /International standards.

Note: Should any conflict arise either before or after order placement the Vendor shall immediately
inform the Purchaser for technical resolution of the conflict.

Technical Particulars:

5.1

Operating Philosophy:

5.1.1

415 V PMCC(000-PMCC-001)

a) PMCC located in the MCC Room, will have two incomers; One from Grid Source through 1 MVA
distribution transformer via bus duct and other from DG AMF cum Control Panel (Common for 2
nos. 500KVA DG Sets) by single core cables. For details Refer 415 V PMCC single Line diagram
Dwg. No. 266763-000-410-002D.
Under Normal condition, Incomer -I will be energized independently from Grid Source and feeding
power supply to PMCC Loads. In case of failure of power supply at I, Incomer II will be fed from
DG Panel & will supply the entire plant load.
b) There shall be electrical interlocking among two incomers such that only one circuit breaker out of
two shall be closed at a time.
c) Under loss of grid mains power supply, DG-1 (500KVA) & DG-2 (500KVA) will start on AMF signal
from Line PT. DG Incoming breaker at PMCC will be closed manually after getting close permisive
from DG AMF Cum Control Panel. The running of DG-1 & /or DG-2 shall depend on the total load
connected to PMCC which will be sensed & controlled by DG AMF Cum Control Panel. The two
DGs will be synchronised at DG AMF Cum Control Panel.
d) On resumption of grid power, Changeover from DG-Incomer to grid main power supply shall be
done manually, with break in power supply (i.e. DGs shall not be paralleled with the grid at any
time). However provision to be kept at the PMCC panel for automatic changeover by momentary
paralleling between the two incomers on resumption of grid power without break in power supply.
e) In case of loss of supply on both the incomers, the breaker status shall be maintained.

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5.1.2

Rev: B

Page 11 of
37

415 V BPMCC (000-BPMCC-001)

a) Bottling Plant MCC (130-BPMCC-001) located in the MCC Room, will have one incomer feeding
from PMCC supplying to the Bottling Plant loads. Refer Dwg. No 266763-000-410-003D for details.
5.1.3

415 V PDB (000-PDB-001)

a) Auxiliary power distribution board (130-PDB-001) located in the MCC Room, will have one incomer
feeding from PMCC, supplying to the auxiliary 415 V & 240V loads. Refer Dwg. No 266763-000410-049 for details.
5.1.4

415 V MLDB (000-MLDB-001)

a) Main Lighting Distribution board shall have two incomers. One Incomer form 415 V PMCC & Other
from the 250 kVA Emergency DG set (DG-3). Refer Dwg. No. 266763-000-410-004B for details.
b) Critical loads (viz. Jockey Air Compressor/Jockey pump motors) also will be fed from this
distribution board.
c) During normal operating condition it will be fed from the PMCC. In case loss of grid mains power
supply and DG-1 &/or DG-2 fail to start, DG-3 shall be started manually & feed the critical loads
including entire lighting loads.

5.1.5

Motor Control philosophy.

Refer control Schematic drawing no. 269323-000-410-050D. However above control schematic as referred
above is indicative only. Vendor shall develop the detail control circuits as required. Vendor is advised to
ensure that the following control philosophy will be taken care during their detail design.
a) The Start and normal Stop operation for all motors except VFD drives will be done from the local
control station manually by actuation of Start and Stop push buttons of the respective equipment.
The indications of Motor overload, Motor ON, Motor OFF will be displayed on the respective
MCC feeder with Amber Red, Green colored indicating lamps respectively.
b) PMCC/MCC /MLDB will have the emergency Stop Push button for all the drives.
c) Standby motors shall come in service manually during outage of working motors or as and when
required as per process requirements.
d) VFD fed motors shall be controlled from local control stations through contactor provided at VFD.

5.2

Motor Feeder Requirement:

5.2.1

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

5.2.2

Motor starters

a) The manufacturer shall wire the starters as per enclosed Motor starter schematic drawings.

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b) Motors up to and including 22 kW shall be with DOL starter and motors above 22kW shall be with
star delta starter unless otherwise specified. All motor feeders shall have electronic over current
relays except VFD Feeders.
c) Current transformers shall be provided for current indication in Local Control Station for all motors
rated 7.5 kW and above.
d) Circuit for motor space heating shall be provided for all outgoing motor feeder modules rated 30kW
and above. Separate 240 V AC busbar shall be considered which will be fed from a separate
source.
e) Feeders with Forward reverse motors shall have suitable control logic.

5.3

Construction:

5.3.1

Switchgears shall be totally enclosed, metal clad, sheet steel fabricated, dust & Vermin proof, free
standing, floor mounted type with self-supporting structure and provided with integral base frame
at bottom. Switchgears shall be in double-front, draw-out execution & fully compartmentalized. The
Panels shall have IP 4X degree of protection with gasketed doors. All doors shall be fastened to
the vertical section by means of concealed hinges. The sides, top & bottom of each vertical section
shall be covered with removable screw-on plates with formed edges all around.

5.3.2

The Switchgears shall be easily extensible on either side by the addition of vertical sections. It
shall be possible to extent the Switchgears, irrespective of the type of end panel and design shall
be such as to permit addition of extension panels of a type other than the type of end panel. It shall
be of unit construction suitable for splitting into sections for shipping to site and to be correctly reerected on prepared foundations without skilled supervision. The individual shipping section shall
comprise not more than three verticals. For each shipping section adequate lifting facilities such as
hooks for ease of handling on site shall be provided. These hooks when removed shall not affect
the degree of protection of Panels. Vendor shall supply accessories such as bus links, etc. for
connecting various shipping sections at site.

5.3.3

The Switchgears shall be fabricated preferably from CRCA sheet steel of minimum thickness
2mm. for load bearing members, 1.6 mm for non-load bearing members & 3mm for gland plates.
Removable type undrilled gland plates shall be provided at bottom of the panel.

5.3.4

The height of Switchgears shall be constant throughout the length, but not exceeding 2500mm.
The arrangement of feeders shall ensure that operating height of components shall be above
350mm & below 1800mm from finished floor level. Cable alley width shall be 300mm.

5.3.5

Busbars shall not be exposed when CB / Starter module is removed. Insulated and isolated
vertical busbars are required. Barriers shall be provided to separate the bus compartment from
wiring space at top, bottom and sides of each section and shall be adequate to prevent accidental
contact and restrict propagation of unit originated arc into the busbar compartment.

5.3.6

Starter Unit / CB shall be draw-out type. Each starter/CB compartment door shall be interlocked
with door mechanically so that it cannot be opened unless the Switch operating handle is moved to
the "OFF" position. However, the handle mechanisms of the Switch shall be so designed that a
qualified person can defeat the door interlock for purpose of inspection without interrupting power.

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5.3.7

Rev: B

Page 13 of
37

Each draw-out unit shall be equipped with a mechanical safety interlock such that:

a) A withdrawn unit with the Switch in the 'ON' position cannot be inserted into the vertical structure
and make contact with the vertical bus.
b) Units in the fully inserted position shall not be able to be withdrawn with the Switch in the 'ON'
(closed) position.
5.3.8

Front access shall be available to all components in each cubicle, which require adjustment,
maintenance or replacement. Checking & removal of components shall be possible without
disturbing adjacent equipment. All auxiliary equipment shall be easily accessible. Setting of relays
shall be possible without de-energizing other equipment. Access shall be available to all cable
glands & multicore terminal blocks by means of sheet steel hinged doors, designed to give the
maximum possible access to the cable terminations. The cable alley door shall be provided with
bolts, which can be opened with special keys but by authorized person. Plug-in stab construction
shall assure positive electrical and mechanical contact to the bus under all loads and rated fault
conditions.

5.3.9

All incomers, bus couplers & outgoing feeder shall be designated as per feeder list. Incoming
feeder shall be mounted in separate vertical section. The arrangement of feeders in the panel shall
take into consideration the number & size of cables required for the feeders. Extension box if
required for termination of cables shall be included.

5.3.10 Vendor shall provide partition between two power cable terminations of outgoing feeders. Vendor
shall provide FRP shrouds on outgoing feeder terminations.
5.3.11 Base frame:
Switchgears shall be provided with integral base frame which shall be bolted/welded on the cross
members provided by owner. Amply dimensioned oblong holes shall be provided on the base
frame. The base frame shall be of standard sections, re-rolled sections will not be acceptable.
Vendor shall give base frame details in foundation drawing. Cross members or foundation on
which base frame is mounted is excluded from Vendors Scope of supply.

5.4

Busbars:

5.4.1

The Busbars shall be made of Electrolytic grade high conductivity Aluminum with continuous rating
as required. All busbars & their main current carrying connections shall have same cross sectional
area throughout the length. All busbars shall be insulated with heat shrinkable PVC sleeves. All
busbars shall be colour coded such that on removal of any door the phases shall be identifiable.
All busbars shall be accessible for inspection & easily replaceable. Control & earth bus bar shall
be of copper bus.

5.4.2

Busbar size shall be determined by taking into consideration the specified continuous current
rating & fault level for 1 sec, without exceeding the busbar final temperature of 95C. The busbars
shall be supported by insulators of non-carbonizing material resistant to acid and alkali and having
non-hygroscopic characteristics and braced to withstand fault level specified. The main horizontal
busbars shall be located at the top. Size of neutral busbar may be half the size of main busbars.
Neutral busbar shall include taps for each outgoing cable connection in each vertical section. The
clearance between live parts & earth shall be as per IS/IEC.

5.4.3

Busbars and connections shall be secured in such a manner that the insulators are not subjected
to bending forces under short circuit conditions. Dynamic stresses shall be calculated on the basis
of peak short circuit current. For long Busbars, suitable expansion joints shall be provided.

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5.4.4

Separate set of vertical busbars shall be provided for front and rear sections. The vertical busbars
shall be sized to carry continuously at least the sum of rated currents of the connected circuit
breakers. Short time rating of vertical busbars shall be same as main busbars.

5.4.5

It shall be possible to extend the busbars at either end of the switchboard for addition of future
units. Both ends of busbars must be suitably drilled for this purpose.

5.4.6

Where busbars are taken through the partitions of adjacent cubicles, fireproof shrouding shall be
provided to prevent spread of fire from one unit to the next.

5.4.7

Thermal design of the busbars shall be based on installation of the switchgear in poorly ventilated
conditions. The cooling air volume shall take into account only the bus enclosure.

5.5

Air Circuit Breakers (ACB):

5.5.1

The Circuit Breaker shall be manually & electrically operated, triple pole, air break, and draw-out
type with solid manually detachable type neutral. Short circuit withstands capacity for ACBs shall
be same as that of switchgear. Breaker continuous current ratings shall be in panel ratings. No
external mean shall be provided for limiting temperature rise in panel box.

5.5.2

The charging mechanism of the circuit breaker shall be motor operated. The close / trip control
switch to be interlocked to trip before close. The closing and tripping circuits shall be self-opening
on completion of their respective functions irrespective of the position of the control switch.
Manual closing devices shall also be provided. Operating handle shall be provided for charging the
spring manually.

5.5.3

The Circuit Breaker shall be provided with mechanical ON/OFF, TRIP and SPRING CHARGED,
DISCHARGED indication, T/N/C control switch, mechanical trip push button, mechanical close'
push button, and padlocking facility.

5.5.4

The circuit breaker shall be electrically and mechanically trip free, with anti-pumping feature.

5.5.5

The breaker shall be provided with minimum 6 NO + 6 NC auxiliary contacts. However, the exact
requirement shall be as per the details given in the Scheme Specific Requirements. 20% auxiliary
contacts (Min. 3 NO + 3 NC) shall be provided for Owner's exclusive use. All spare contacts shall
be wired up to terminal blocks. Auxiliary contactor or relay shall be used to multiply contacts.

5.5.6

The auxiliary contact for the shunt trip shall be of advanced nature such that the auxiliary contact
close before main contacts.

5.5.7

The main and secondary isolating contacts of the circuit breaker shall be of self-aligning type. The
main isolating contact shall have continuous rating equal to the rating of the breaker. The
secondary isolating contact shall be of wiping contact type.

5.5.8

The fixed portion of the circuit breaker shall have slide rail arrangement over which the chassis can
move smoothly. The breaker shall have 3 distinct positions, such as "SERVICE", "TEST" and
"ISOLATED", with padlocking facility in Test & Isolated position. Proper mechanical indication
shall be provided to locate these three positions without opening the compartment door. It shall be
possible to bring the circuit breaker to isolated position with the help of external lever without
opening the compartment door. A stop block shall be provided on the slide rails to prevent the
movement of the circuit breaker out of the compartment when it reaches the isolated position so
that any accidental fall can be avoided.

5.5.9

Wherever cut-outs are provided for the circuit breaker control box, proper continuous gaskets shall
be provided. Provision shall be made for closing the cut-out provided for the control boxes when
the C.B. is taken out of the compartment.

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5.5.10 The circuit breaker shall be provided with automatic safety shutters, so that before the breaker
reaches `isolated' position the main isolating contacts are completely shrouded. When the circuit
breaker compartment door is open it must not be possible to touch the live parts. All removable
covers protecting live parts shall be clearly labelled with warning notices reading LIVE PARTS.
ISOLATE ELSEWHERE BEFORE REMOVING COVER.
5.5.11 The circuit breaker compartment shall be so designed that hot gases produced during fault shall
be lead away from the operator.
5.5.12 It shall be possible to readily remove the arc chutes for routine inspection of the contacts with the
circuit breaker in the withdrawn position.
5.5.13 The protective relays and instruments shall be mounted in separate compartment.
compartment shall be along side and immediately next to the controlled breaker.

This

5.5.14 The CB shall be provided with microprocessor based direct acting protection releases for overload,
short circuit & earth fault. The releases shall be programmable & adjustable type.
5.5.15 Circuit breakers shall be with communication unit for :
a) Breaker status, alarm and maintenance information.
b) Control commands & configuration settings.
5.5.16 The following interlocks shall be provided on the circuit breaker :
a) It shall not be possible to withdraw the circuit breaker from the service position with the contacts of
the breaker closed.
b) It shall not be possible to close the circuit breaker unless any one of the three positions is located,
the service position, a definitely located test position, or isolated position.
c) It shall not be possible to open the compartment door when the circuit breaker is ON.
d) The circuit breaker can be padlocked in OFF position with door interlock defeat facility.
e) Castle key interlock shall be provided for incomers & bus couplers to prevent parallel operation
where specified.
5.5.17 All the non-conducting metal parts of the circuit breaker trolley shall be bonded together and shall
make perfect electrical connection to earth through substantial sliding contacts, at service and test
positions. Such sliding contacts shall be arranged to make before power plug in and interrupt after
power draw out.
5.5.18 All circuit breakers of same rating shall be identical in all respects and shall be interchangeable.
However, breakers of different ratings shall not be interchangeable.
5.5.19 Breaker handling trucks / trolleys shall be included in the scope.

5.6

Moulded Case Circuit Breakers (MCCB):

5.6.1

MCCBs shall be of triple pole construction for panel mounting, operating mechanism shall be trip
free, quick make quick break type. Short Circuit withstand capacity for MCCBs shall be same as
that of switchgear.

5.6.2

The MCCBs shall be provided with front operating handles & mechanical ON/OFF indicators. In
case of trip handles shall remain in an intermediate position.

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5.6.3

MCCBs shall be provided with releases as per schematic drawings. The releases shall be
adjustable type.

5.6.4

MCCBs in individual motor circuits shall be designed for application, in combination with motor
starter units. They shall operate on the magnetic principle with accurate sensing element in each
pole to provide short circuit protection.

5.6.5

MCCBs shall have following accessories & features:

a) Auxiliary contact set of 1 NO + 1NC


b) Fault signalling contact set of 1 NO + 1NC
c) Insulation shields to isolate the connection between each pole.
d)

Finger protection plate to prevent accidental contact.

e)

The compartment door shall be interlocked with handle of MCCB.

5.7

Contactors:

5.7.1

The air break contactors shall be of electromechanical, triple pole type conforming to AC3 category
of duty. However for motors in inching or reversing rotating service, utilization category AC4 shall
be used. Contactors used for Capacitor bank application shall be suitable for Capacitor switching
compitable.

5.7.2

The auxiliary contactors shall have 4 NO + 4 NC contacts with at least 2 NO + 2 NC auxiliary


contacts for owner's exclusive use. The spare contacts shall be wired up to the terminal block.

5.7.3

The contactor coil shall be suitable for the specified control voltage. The coils shall have grade E
insulation and shall be suitable for use in the ambient temperature specified elsewhere. The
design of the contactor shall ensure easy access to auxiliary contacts and coil. Mechanical ONOFF indication shall be provided for the contactors. Wherever mechanical indications are not
provided, indicating lamps shall be provided for ON indication of the contactor. The contactor shall
pick up at 85% to 110 % of the control voltage and shall not drop out for voltage up to 45%.

5.7.4

The contactor rating shall be chosen to provide Type-2 co-ordination as per IEC 60947. In case of
Star-delta starter feeder, rating of all three contactors shall be identical.

5.8

Over Load Relays & Timers:

5.8.1

Motor Overload Protection Relays


Overload protection relays shall be of Electronic type to be installed in all phases & shall have inbuilt Single Phasing Protection feature. Relay shall be temperature compensated type with
manually reset facility on the front of the compartment door.
Overload protection relays shall be direct line mounted upto 50A rating. Higher ratings shall utilize
CTs. Relays shall be with adjustable trip class -10, 20, 30 as per IEC 60947.

5.8.2

Timers
Timers shall have adjustable time setting of 0 - 60 secs. The time settings, where specified shall
be accurately set before dispatch of the switchboard for all ON delay & OFF delay timers.

5.9

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

5.9.1

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

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5.9.2

All circuit breaker operating switches shall be of the pistol grip type, spring return to neutral and
lockable in neutral position. They shall be arranged to close the breaker by being turned
clockwise. The trip, neutral and close positions shall be clearly indicated. The movement shall be
such that the switch cannot be operated inadvertently and that it is mechanically interlocked to trip
before close. The operating switch shall be located on the centre line at about 1.5 meters from the
floor level. Two spare ways shall be provided on these switches.

5.9.3

Ammeter selector switches shall have `make` before break feature on its contacts. The selector
switch shall generally have four positions for reading three phase currents and the neutral current.

5.9.4

The voltmeter selector switch shall also have four positions. Three shall be used to measure
phase to phase voltages and the fourth shall be OFF position.

5.9.5

Based on operational philosophy, if required, Auto / Manual selector switch shall be provided.

5.9.5

Indication lamps shall be cluster of LEDs. Voltage rating of LED shall be equal to rating of control
circuit voltage. The covers of the lamp shall be heat resistant.

5.9.6

Indication lamps shall be provided for each feeder in Switchgear as per feeder schematics.

5.9.7

Emergency Stop push buttons shall be mushroom headed, stayput type, with press to lock & twist
to unlock (release) operation.

5.9.8

Colour coding of Push Buttons & Indication Lamps shall be as follows:Push Buttons

5.10

Lamps (LED Type)

Push Buttons

Lamps (LED Type)

Start or On

Green

Running or On

Red

Stop or Off

Red

Stop or Off

Green

Alarm Reset

Yellow

Fault

Acknowledge

Black

Trip coil healthy

White

O/L Reset

Blue

Spring charged

Blue

Trip circuit healthy check

Black

Breaker in Service

Blue

DC Failure

Red

Control supply healthy -

White

Amber

Indicating Instruments & Meters:

5.10.1 All indicating instruments and meters shall be capable of carrying continuously their full load
currents and full voltage across their pressure coils. They shall not be damaged by the passage of
fault currents or the existence of over pressure on the primary side of their instrument transformers
for the maximum permitted duration of fault conditions, which may occur during normal operation.
All instruments and meters shall be back connected.

5.10.2 The type and quantity of the measuring instruments shall be as specified in schematic drawings.
5.10.3 All instruments shall be of the flush mounting type and shall have an enclosure with a degree of
protection of at least IP 52.
5.10.4 They shall be equipped with non-glare, non-reflecting windows. Standardized dimensions shall be
used in accordance with IEC 60473.

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5.10.5 Indicating instruments shall be in accordance with the relevant IEC standards and have an
accuracy class 1. Analogue meters should be of the square pattern type 96 x 96 mm, and
mounted at a suitable height for easy reading from the front. Scales shall be in actual values.
5.10.6 Meters shall be installed on the door of the respective functional units.
5.10.7 Ammeters for motor current indication shall have suitable suppressed scale corresponding to
motor starting current.

5.11

Current Transformers:

5.11.1 The CTs shall be Resin cast bar type. CT secondary shall be 1A. The minimum burden shall be
15VA. However, current transformers shall have sufficient capacity to operate with the burden
imposed by the devices shown on drawings with their accuracy classification. Separate cores
shall be used for metering and protection.
5.11.2 CTs for measuring instruments shall have an accuracy class 1.0 and accuracy limit factor less than
5.0. If a metering load is fed from a protection CT, suitable 1/1 or 5/5 ratio saturable interposing
CTs shall be use. CTs for Protection shall have an accuracy class 5P and saturation factor less
than 0. CTs for restricted earth fault protection shall confirm to class X.
5.11.3 The CTs shall be capable to withstand dynamic and thermal stresses originated by the fault
current.
5.11.4 The CTs shall be suitably insulated and the mounting of the CTs shall facilitate easy maintenance.
The CTs shall be mounted in stationary part of switchgear.
5.11.5 Shorting links shall be provided for the secondary of the CTs when wired to terminals.
5.11.5 One side of current transformer secondary shall be grounded in the compartment with the meters
or relays which they serve and each CT group shall be grounded with a separate identified lead
which may be disconnected for testing.
5.11.6 All motors rated 7.5 kW and above, the CT signal shall be brought out as shown in schematics for
current indication at Local Control Station. CT terminals shall be suitable for termination of 4
sq.mm cable.
5.11.7 CT parameters shall be verified by vendor, based on connected relay make & relay manufacturers
recommendation.

5.12

Potential Transformers:

5.12.1 The Potential Transformers shall be epoxy cast resin type. Potential transformers shall have
sufficient capacity to operate with the burden imposed by the devices shown on the schematic
drawings with their accuracy classification.
5.12.2 The Potential Transformers shall have an accuracy class 1.0 for voltmeter only.
management / others, it shall have accuracy class of 3.0

For energy

5.12.3 The primary of the Potential Transformers shall be rated for 412 volts and the secondary for 110
volts. PTs shall have a continuous voltage factor of 1.2 with short time over voltage factors as
below:
a) 1.5 for 30 seconds in case of effectively earthed systems.
b) 1.9 for 8 hours in case of non-effectively earthed systems.
5.12.4 The PT shall be provided with HRC fuse on the primary side and MCB on secondary side.
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5.12.5 For proper relaying, one side of PT secondary shall be grounded at the transformer and the
ground connection shall be identified and removable for testing.
5.12.6 Test terminals shall be provided for PT circuits.

5.13

Wiring and Identification:

5.13.1 All wiring for control signal, protection and metering shall be by PVC insulated, 650 Volt grade,
copper stranded conductor wires of minimum 1.5 sq.mm section. For CT secondary circuit wires
of 2.5 sq.mm copper conductors minimum shall be used. Wiring shall run in enclosed channel and
shall leave at least 25% spare space for future use. Wires for connection between moving parts
shall be flexible stranded copper conductors and the same shall be soldered at the ends before
connections are made.
5.13.2 Terminal strips for connecting incoming control cables shall be channel mounted type of adequate
size and shall be located conveniently for easy accessibility, without danger of contact with live
part, ease of connection and shall be separated by barriers from power circuits. At least 20% spare
terminals shall be provided in each terminal strips. CT secondary lead terminals shall be provided
with shorting links.
5.13.3 All spare contacts of auxiliary relays, timers, contactors etc. shall be wired up to terminals block.
Terminal Block shall be 600V grade 10 Amps rated.
5.13.4 Sufficient terminals shall be provided on each terminal strip to ensure that not more than one
outgoing wire is connected per terminal. The wire shall be identified by numbered ferrules at each
end, in accordance with the connection diagram. All ferrules shall be made of non-deteriorating
materials. The ferrules shall be firmly located on each wire so that they cannot move or turn freely
on the wire.
5.13.5 All inter-panel control wiring shall be done by the switchgear vendor. All wiring shall be properly
bunched, cleated, & supported on a panel frame and shall run in plastic wire ducts. The inter panel
wiring shall be taken through PVC sleeves or suitable rubber grommets.
Colour Coding for internal panel wiring shall be as follows:
Power Wires

Red, Yellow, Blue for Phases.

Control Wires

Grey.

Neutral Wires

Black.

Ground Wires

Yellow & Green.

5.13.7 Each shipping section of each Switchgear shall be provided with one marshalling box. Wiring
between individual modules to marshalling box shall be done by Vendor. Wiring from Switchgear
to field controls like local PB Stations / Panels will be done directly from individual modules,
however, interconnection between Switchgear and control room panels like DCS / PLC / Relay
Panel will be done through this marshalling box. Vendor shall refer attached scheme drawings to
estimate number of signals per module, up to marshalling box. Actual number of signals shall be
confirmed at the time of drawing approval. Each marshalling box shall have two separate terminal
blocks, one for outgoing signals to DCS / PLC / Relay Panel and other for incoming signals from
DCS / PLC / Relay Panel. Vendor shall provide 25% spare terminals in each terminal block in
marshalling box.

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Control Supply:

5.14.1 Control supply for control, indication, space heater etc. shall be derived within the switchgear by
vendor. Vendors shall provide auxiliary / control supply bus in the switchgear throughout its length
for further distribution inside the switchgear. Vendors shall also provide suitable MCB for receiving,
distributing & in each sub-circuit as per requirement.
5.14.2 Auxiliary Busbars of thick electrolytic tough pitch copper shall be provided for following
applications. Exact number of bus bars shall depend on various controls, metering and auxiliary
power distribution requirements.
5.14.3 ACB [spring charging motors], Panel / Motor space heater supply 240V AC, 1 ph, 50Hz, to be
derived by vendor.
5.14.4 Control supply for Annunciators, ACB [indications, closing & tripping coils] 110V DC, from clients
DC UPS.
5.14.5 Control supply for motor starter control circuits 110V AC via control transformer, to be derived by
vendor.
5.14.6 Space Heaters 240 AC derived from Lighting DB.
5.14.7 Two number 110V DC power supply feeders shall be provided for each switchgear from owners
DC UPS. Suitable DC control supply monitoring & selection scheme shall be developed by vendor.
Any other intermediate voltage required in the panel shall be derived by providing suitable control
transformer.
5.14.8 Control Transformer & Control Circuits:
a) Control transformer shall be double wound, air cooled type with one leg of secondary earthed unless otherwise specified.
b) VA rating of the Control transformer to be adequate to supply about 150% of the control loads of
the switchgear. Voltage regulation of the Control transformer shall be limited to 4%.
c) The control supply in Switchgear shall be derived from control transformer with 100% standby. The
control transformers in each panel shall have power supply from each of the incomer. Out of the
two control transformers one shall be working and other will be standby.

d) Auto-change over system shall be provided for control supply from working control transformer to
standby control transformer and vice versa as per schematic drawings attached.
5.15

Space Heaters and Cubicle Illumination:

5.15.1 Adequately rated anti-condensation space heaters shall be provided in each breaker panel and in
cable alleys of the MCC to maintain MCC inside temperature, 5C above outside ambient
temperature.
5.15.2 Space heater shall be strip type, rated for operation on 240V, single phase, 50 Hz. A.C. supply
unless otherwise specified.
5.15.3 Each space heater shall be complete with a rotary type ON/OFF switch, MCB in the phase, neutral
link in neutral and a control thermostat.
5.15.4 A separate DP isolator and MCB shall be provided in motor feeders for control of space heaters of
motors. These shall be wired through a 'NC' contact of the contactor / circuit breaker for motor
control.
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5.15.5 Each vertical panel shall have fluorescent light fittings for internal cubicle illumination with door
switch.
5.15.6 240V, 15A SPN Industrial socket outlet, complete with MCB & earth leakage protection shall be
provided in each vertical panel.

5.16

Earthing:

5.16.1 An earth bus of at least 50mm x 10mm aluminium shall be provided. The earth bus shall be
electrically continuous and shall run the full extent of each board. The earth bus shall be of same
material as the main busbars. Each unit shall be constructed to ensure satisfactory electrical
continuity between all metal parts not intended to be live and the earth terminals of the unit.
5.16.2 At each end of switchgear, suitable slots shall be provided on main earth bus for connection to
Owner's Earth. The earth bus shall be accessible in each cable compartment either directly or
through a branch extension to ground the cable armour and shields.
5.16.3 All doors and movable parts shall be connected to the earth bus with flexible copper connections.
All non-current carrying metallic parts of the equipment shall be earthed. Earth bus shall be
brought back to cable compartment and earthing bolts shall be provided to ground cable armours.

5.17

Busduct Terminations:

5.17.1 PMCC Incomer will be connected to Transformers by Non segregated Busducts (with Aluminum
Busbars) from top. Vendor shall furnish flange details for Busduct connection.

5.18

Cable Entry and Terminations:

5.18.1 For Switchgears, opening with removable gland plate for cable entry shall be provided at the
bottom for both incoming and outgoing cables. Terminals shall be located sufficiently away from
gland plate to facilitate easy connection. Gland plate shall be minimum 3 mm thick.
5.18.2 All terminal blocks shall be furnished with white marking strips marked with terminal numbers in
accordance with the wiring diagrams. The terminal blocks shall be physically grouped and located
suitably for termination of the cables. Terminal block in all drawout units shall be furnished with
pull apart terminals to connect all outgoing wires and shall be furnished with 20% spare terminals
at least.
5.18.3 Suitable arrangement shall be made in cable alley for supporting incoming & outgoing cables.
Terminal blocks shall not be used to support cables.

5.19

Capacitor Bank :
PMCC shall have capacitor bank for power factor correction. 300 kvAR Capacitor bank with
suitable combination of basic unit size will be housed in the PMCC Panel along with the APFC
(automatic power factor correction) relay. For Details, refer technical specification for Capacitor
bank Document No. 266763-000-SP-4006.

5.20

Nameplates:

5.20.1 Permanent non-corrosive nameplate with engraved white letters on black background indicating
the switchgear designation shall be fixed at the top of the central panel. A separate nameplate
giving feeder details shall be provided for each feeder.
5.20.2 Name plates shall contain the following information:
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a) Manufacturer
b) Basic technical data such as rated voltage, rated current, etc.
c) Country of origin.
d) Certification data such as UL certificate number etc.

e) Each feeder shall be labelled giving following details


-

Equipment number as per feeder list

Description as per feeder list

Feeder No. as per manufactures GA

KW Rating as per feeder list

Scheme reference.

5.20.3 Nameplates shall be provided for each equipment (lamps, push button stations, switches, relays,
Auxiliary contactors etc.) mounted on the switchgear. Special warning plates shall be provided on
all removable covers or doors giving access to high voltage cables / busbars and inside the
switchgear wherever considered necessary. Danger labels shall have black letters on a yellow
background.
5.20.4 Internal labels and components identifications shall correspond with identities or circuit references
as shown on the schematic diagrams. All external labels shall be attached by screws or rivets only
and not by adhesive.

5.21

Makes of Components

5.21.1 Manufacturer shall furnish standard list of components makes for the complete the 415V
switchgear assembly. This list must be included with the offer.
5.21.2 Make of Numerical Relays shall be Areva / Siemens / ABB. Electronic overload relay shall be
EOCR or equivalent type.

5.22

Tropical Protection

5.22.1 All equipment, accessories and wiring shall have fungus protection, involving special treatment of
insulation and metal against fungus, insects & corrosion.
5.22.2 Screens of corrosion resistant material shall be furnished on all ventilating louvers to prevent the
entrance of insects.

5.23

Painting

5.23.1 All metal surfaces shall be thoroughly cleaned and degreased, pickled and phosphatised.
Thereafter, a coat of phosphate paint and a coat of zinc chromate primer shall be applied. After
removing all imperfections, all metal surfaces shall be sprayed with two coats of final paint as per
colour shade RAL 7032. Final coat shall be of epoxy based. All unpainted parts shall be plated to
prevent corrosion.

5.24

Quality assurance:

5.24.1 The Manufacturer is expected to demonstrate that he has working Quality Assurance System
which complies with ISO 9001 or may be appropriate to the type of contract and his product.
5.24.2 If the Vendor elects to sub-contract part of the work he shall ensure that only those sub-contractors
or suppliers are used who can demonstrate that they operate Quality Systems based on ISO 9001
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or ISO 9002 as applicable. The Vendor shall give his sub-contractors or suppliers assistance in
attaining the required standard, if necessary. This shall not relieve the Vendor of his responsibility
for the quality of the finished work. The Owner reserves the right to audit the Vendors Quality
System.
5.24.3 The Vendor shall assign sufficient full time personnel to the Project to ensure the Quality
Assurance / Quality Control System, documented in a Quality Assurance / Control Manual, is
maintained and kept up-to-date throughout the duration of any purchase order. The Vendors
Quality Assurance / Control System shall become an integral part of any Purchase Order. Vendor
shall organize a prefabrication / inspection meeting with the Owner.
Within 3 weeks from the date of Purchase Order the Manufacturer shall submit a Quality
Assurance Plan for the review of the Owner.

Inspection and testing:

6.1

The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor.

6.2

The Vendor shall specify all of the inspection and testing requirements in the quality plan which
shall identify the activities requiring the Owners approval, review, witnessing etc.
Inspection and testing requirements shall be in accordance with this specification, other All
Equipment shall be inspected for compliances with:
a) Requirement of Owners specification & correspondence therefore.
b) Applicable codes, standards and specifications, which shall also include sub- referenced
standards therein.
c) Test and Inspection Plans produced by the vendor.

6.3

Inspectors have the right to request additional inspections or tests to ensure that the equipment
complies with the specification and all relevant codes & standards.

6.4

Manufacturer shall furnish valid Type Test Certificates of similar models along with the offer. Fresh
type tests for the equipment are not needed, provided the Manufacturer can submit certificates
that the equipment complies with all type tests as prescribed by IEC/IS Standard specifying the
test requirements for that equipment.

6.5

The routine tests shall include but not necessarily limited to the following:
a) Operation under simulated service condition to ensure accuracy of wiring, correctness of control
scheme & proper functioning of the equipment.
b) All wiring and current carrying part shall be given appropriate High Voltage test.
c) Primary current and voltage shall be applied to all instrument transformers.
d) Routine test shall be carried out on all equipment such as circuit breakers, instrument
transformers, relays, meters etc.

6.6

Routine tests on the equipment shall be carried out as per the relevant IS/IEC. Equipment offered
for final inspection shall be complete and ready for shipment, with the possible exception of the
final paint finish.

6.7

Routine Test certificates to be submitted for Equipment and its all auxiliaries. Type test certificate
of similar equipment shall be submitted.

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6.8

Vendor to furnish required copies of test certificates, Ref Documents, Drawings, and Instruction
Manuals before Equipment are dispatched.

6.9

Factory acceptance test (FAT) is required to be done at no extra cost to the purchaser. The
purchaser or his representative shall be advised of the tentative date for FAT at least 3 weeks in
advance prior to the test date.

6.10

Any defects found by the TPI or the Owners appointed Inspector shall be rectified in his presence.
Where this is not possible or practical, check lists shall be prepared and signed by the Third Party
Inspector stating all pending items. Copies of these lists shall be sent to the Owner to enable
their subsequent checking. The equipment shall not leave the Vendor factory before all defects
have been rectified and without the written permission of the Owner.

6.11

All spare parts shall be subjected to the same inspection standards and full material certification as
the main order.

6.12

The equipment shall not leave the Vendor / Sub-Vendors factory before all discovered defects
have been rectified and without the written permission of the Owner/Purchaser.

6.13

Any acceptance or release of equipment following an inspection or test activity shall in no way
relieve the Vendor of his contractual responsibility to provide guarantees as to the suitability of the
materials, workmanship and performance of the equipment in accordance with this Specification.

6.14

Owner/Consultant reserves the right to waive the inspection at any stage. Inspection shall be
carried out only on receipt of Vendor's internal test report of the equipment offered and scrutiny of
the same. In the event, on receipt of inspection call, the Owner/Consultants representative
reaches the Vendor's works and finds the material not ready for inspection/incomplete/has short
supply, the inspector will return to his base station and all expenses incurred by the inspector
including to and from travelling expenses from his base station to place of inspection, boarding
and lodging etc shall be reimbursed by Vendor.

Vendor documentation:

7.1

All information listed here is to be furnished along with the offer as a minimum.
a) Clause wise comments / deviations on specification in `Table of Compliance [enclosed Appendix
A]. If not furnished, compliance to all requirements in specifications will be binding on the Vendor.
b) Duly filled up Guaranteed Technical Particulars [enclosed Appendix-F].
c) List of components & accessories with Makes.
d) List of recommended spares for two years normal operation with itemised rates.
e) Type test certificates.
f)

Technical Catalogues and brochures of major Components.

g) List of clientele for similar equipment in last 5 years.


h) Complete list of special tools (if required)
i)
7.2

Documents as per RED.


The Manufacturer shall furnish the drawings and documents as per enclosed Requisition for
Engineering Documents - RED Form [Appendix-D].

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7.3

The Owner/Consultant will review drawings submitted by Vendor & return to the Vendor one copy
of drawings with comments to carry out necessary changes, if any, during the engineering /
manufacturing stage.

7.4

The documents required by the Third Party Inspection Agency are not covered under this
specification. The Vendor shall provide all the drawings and documents required by the Third Party
Inspection agency in compliance with the applicable codes and standards.

Spares and special tools:

8.1

Spares

The Manufacturer shall furnish list of spares and provide all necessary spares for testing, precommissioning, commissioning. Any of the spares if used during testing/commissioning must be
replenished at no extra cost to the purchaser.
The Manufacturer shall also provide all consumables required during erection up to commissioning.
In addition to above, Manufacturer shall quote separately for Spares required for two years of operation.

8.2

Special tools

The Manufacturer shall include any special tools, which are required for the installation, commissioning,
operation and maintenance of the equipment being supplied. A list of special tools shall be supplied along
with the offer

Installation and commissioning:

Vendor shall dispatch Installation and Commissioning instructions at least 2 weeks before the arrival of the
equipment.
Vendor shall provide qualified personnel to supervise the installation and carryout site testing and
commissioning of all equipment supplied under this contract. Prices for these services shall be given
separately.

10

Packing and transportation:

Packing, shipping and delivery of equipment at site and unloading requirements shall be as per relevant
Standard. Vendor to submit the procedure & all the relevant necessary datas / informations along with
offer.
Preparation of the skids for shipment is a crucial step in the completion of this contract. The Vendor must
take in to consideration that all equipment and the skid itself shall be prepared for land transportation.

11

Statutory Approval:

The Equipment supplied shall be acceptable to local Electrical Inspectorate and changes required, if any,
shall be carried out by the vendor without any extra cost.

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Guarantee:

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

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Appendix-A: Table of Compliance.

The Vendor shall confirm that clauses of the specification have been complied with/accepted or further
clarifications are desired, or Vendor has taken a deviation with reason thereto.

CLIENT :

VENDOR REF.

M/s. Hindustan Petroleum Corporation Ltd


LPG Bottling Plant project at Bhatinda.
Spec. Clause
No.

Conforms
Yes/No

Alternative
Yes/No

Clarification

1
2
2.1
2.2
2.3
3
3.1
3.2
3.3
4
4.1
4.2
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
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CLIENT :

Page 28 of
37
VENDOR REF.

M/s. Hindustan Petroleum Corporation Ltd


LPG Bottling Plant project at Bhatinda.
Spec. Clause
No.

Conforms
Yes/No

Alternative
Yes/No

Clarification

5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
6
7
8
8.1
8.2
9
9.1
9.2
10
11
12
Appendix A:
Appendix B:
Appendix C:
Appendix D:
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CLIENT :

Page 29 of
37
VENDOR REF.

M/s. Hindustan Petroleum Corporation Ltd


LPG Bottling Plant project at Bhatinda.
Spec. Clause
No.

Conforms
Yes/No

Alternative
Yes/No

Clarification

Appendix E:
Appendix F:
Appendix G:
Appendix H:

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Appendix-B: Electrical System Data

[Doc. No. 266763-000-SP-4004BX]

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Page 1 of 2

Appendix-B: Electrical System Data


1.0

2.0

System Voltages

Nominal system voltage

11 KV

0.415kV

Highest system voltage

12 KV

440 V

Frequency

50 Hz

50 Hz

Lightning Impulse withstand voltage

75 KV (peak)

--

Power frequency withstand voltage


for 1 minute

28 KV (rms)

2 KV (rms)

11 KV

0.415 kV

Steady state voltage

10 % (*)

10 %

Steady state frequency

5 % (*)

5%

10 % ( *)

5 % (*)

31.5 KA for 3s
( Hold (*))

50 KA for 1s

Resistance
Earthed

Solidly
Earthed

Supply variations

System voltage

Combined Voltage Frequency


System fault level at rated voltage

System Earthing

( *) HPCL to advice. Vendor to take confirmation from HPCL before final design.
3.0

Control Supply for Electrical System

HV Circuit Breakers for Incomer feeders

Voltage ( in Volts)

Spring Charging Motors

110V DC

Closing Circuit

110V DC

Trip Coil

110V DC

Alarm

110V DC

Indication

110V DC

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Relay Auxiliary Supply

110V DC

Heaters in Panels

240V AC, SPN

Spring Charging Motors

240V AC, SPN

Closing Circuit

110V DC

Trip Coil

110V DC

Alarm

110V DC

Indication

110V DC

Relay Auxiliary Supply

110V DC

Heaters in Panels

240V AC, SPN

110V
AC,
SPN
derived
through
control transformer.

LV Air Circuit Breakers (Applicable


Incomers & Bus coupler as applicable)

for

LV Motor Starters (Contactor controlled)


Control Voltage

Indications
Space Heater Circuit

110V AC, SPN


:

240V
AC,
SPN
( From MLDB Bus)

PMCC/BPMCC

110V AC, SPN

Local Control Panel

110V AC, SPN

Indications

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Appendix-C: Codes & Standards.

IS-1248 ( Part I to IX)


:2003

Direct acting indicating analogue electrical measuring


instruments and their accessories

IS-2419 :1979

Dimensions for panel mounting indicating and recording


electrical instruments

IS-2705 ( Part I to IV) :


1992

Current Transformer

IS-3156 (Part I to IV)


: 1992

Voltage Transformer

IS-3231 : 1986 (Part I)


/ (Part II) : 1987

Electrical Relays for Power System Protection

IS-4146 : 1983

Application guide for Voltage Transformers

IS-4201 :1983

Application guide for Current Transformers

IS-4237 :1982

General Requirements for Switchgear and Control Gear for


Voltages not exceeding 1000V AC or 1200V DC

IS 4691 :1985

Degree of Protection provided by enclosures

IS-4794 ( Part I & II) :


1968

Push Button Switches

IS-5082 :1998

Wrought aluminium & aluminium alloy bars, rode, tubes and


sections for electrical purposes.

IS-6236:1971

Direct recording electrical measuring instruments.

IS-6875 : Part I : 1973

Control switches (switching devices for control and auxiliary


circuits including contactor relays) for voltages up to and
including 1000V AC and 1200V DC.

IS 8623 : ( Part I to II)


:1983

Specification for Low-Voltage Switchgear and Control gear


Assemblies

IS-9224: Part I ( 1979)

Low Voltage Fuses

Code of Practice for Selection, Installation and Maintenance of


Switchgear and Controlgear

Guide for uniform system of marking and identification of


conductors and apparatus terminals

Specification for Low-voltage Switchgear and Controlgear

Low Voltage Switchgear & Controlgear- Part 1 - General rules

Low voltage switchgear and control gear Assemblies Part 1:


Type-tested and partially type-tested assemblies.

IS 10118 :1982
IS-11353 : 1985
IS 13947 : 1993
IEC 60947 :2007
IEC 61439 :2009

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Rev: B

Appendix-D: Requisition for Engineering Documents


RED Form
Owner/Purchasers Office

Distribution Office

Hindustan Petroleum Corporation Ltd


8 S.V. Marg, Ballard Estate
Mumbai- 400 001

Mott MacDonald Consultants (India) Pvt. Ltd.


Kothari House, CTS No. 185
Off Andheri - Kurla Road
Andheri (East)
Mumbai 400 059
Prints Documents shall be sent to:

SPECIAL INSTRUCTIONS
Production Schedule
Manufacturing, inspection & testing sequence plan
DRAWINGS

Approval drawings / Final drawings to


be submitted under cover of an ADS
form / FDS form respectively
Submission of Following for each L V
Switchgear, but not limited to:
Guaranteed Technical Particulars
General Arrangement Drawing
showing masses, main dimensions
Panel cross section details showing
arrangement of auxiliary components,
etc.
Foundation Plan & Loading details
Single line diagram, Feeder list
Block Logic, Schematic & Connection
Diagrams
Bill of Material
Soft starter schematic, component
details, Block Logic diagram,
connection diagrams, etc.
Bus-bar sizing calculations
Name Plate Drawing
Make of Each Components
Type Test, Routine Test Certificates
Spares List for two Years Operation
As Built Drawing

4
4

The Purchasing Office via courier service


The Purchasing Office via courier service

Required number for

TIMING FOR SUBMITTAL

OFF
ER

APPROV
AL

Prints

Prints

2
2

4
4

2
2

4
4

2
-

4
4
4

2
2
2

4
4
4

4
4

2
2

4
4

2
2
2
-

4
4
4
4
4
4

2
2
2
2
2
2

4
4
4
4
4
4

SPARE PARTS DOCUMENTS


ESPIR forms including 1 transparency

FINAL

Disk Prints - final issue 2 weeks after approval


date
Documents shall be submitted to:

TEST AND INSPECTION DOCUMENTS


Documents to be submitted under transmittal
Manufacturing report
Test Report / Data Curves
Calibration Certificates for testing Instruments.
Bought out Equipments Certificates.

- for approval 2 weeks after order date

Purchasing Office via courier service

Prints
Documents shall be submitted to:
1
1
1
1

4
4
4
4

Purchasing Office via courier service


within 4 weeks
of relevant test / inspection.

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Rev: B

OPERATING DOCUMENTS

Installation instructions
Operating instructions
Maintenance instructions

Purchasing Office via courier service


not later than at time of dispatch of
equipment.
1
1
1

4
4
4

Combine into one manual

ADDITIONAL REQUIREMENTS
1. Referenced standards / codes shall be the latest issue unless otherwise stated.

REMARKS
Invoice must certify that the drawings and
engineering documents specified above have been
dispatched to all parties concerned.
Any deviation from the timing for submittal of
documents shall be notified to the Approval /
Distribution Offices by fax or E mail.
Shop fabrication shall not be started before the
required approval drawings have been released for
construction by the party concerned, unless
otherwise stated on the "Approval Drawing
Specification".
Each document shall bear the item / tag and order
reference number and be dispatched by air mail,
unless other instructions are stated on the RED.

Units / dimensions to be used on Engineering


documents shall be SI.
The documents shall be in English. Description on
drawings and similar documents may be in other
languages provided English translations are also given.
Drawings and documents shall be suitable for
microfilming and comply with accepted national or
international standards for the preparation of technical
drawings. Only the following standard sizes should be
used: A4, A3, A2, and A1.

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Appendix-E: Guaranteed Technical Particulars

[Doc. No. 266763-000-SP-4004EX]

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Doc No: 266763-000-SP-4004EX

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Page 1 of 6

Appendix- E : GUARANTEED TECHNICAL PARTICULARS


(* To be filled in by the Vendor)
Note: Vendor shall submit guaranteed technical particulars separately for each L V Switchgear. It includes 000PMCC-001 (415 V PMCC), 000-BPMCC 001 (Bottling Plant MCC), 000-PDB-001(415 V PDB) & 000-MLDB001(415 V MLDB)
Sr
No

Description

To be filled in by Vendor

A)
1)

GENERAL
Manufacturer

2)

Place of Manufacture

3)

Applicable codes & standards

4)

5)

IAC classification for switchgear [as per


latest IEC 62271-200]
Type test certificate furnished

6)

Documents as per Specification furnished?

B)

ENCLOSURE

1)

Enclosure material

2)

Type & Execution

3)

Thickness of sheet metal

4)

Degree of Protection

5)

7)

Paint Shade
Inside
Outside
PMCC suitable for Busduct Incomer from
Top
Cable entry (Incoming & Outgoing)

8)

Minimum Cable alley width

mm

9)

Material & thickness of gland plates

mm

10)

mm

11)

Mounting height of components


Minimum
Maximum
Overall dimension of Switchgear

mm

12)

Busduct Entry

13)

Switchgear Heat Load for HVAC

Watts

C)
1)

kA

2)

BUSBARS
Rated continuous current
[Main & Vertical]
Short circuit rating [1 sec]

kA

3)

Main Busbar location

4)

Busbar material

5)

6)

Bus with insulating sleeves


[Material of sleeves]
Clearances Ph/Ph, Ph/n & Ph/earth

mm

7)

Short circuit current rating for 1 sec

kA

6)

mm

*
*

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Doc No: 266763-000-SP-4004EX

Sr
No
8)

Rev: B

Description

Page 2 of 6

To be filled in by Vendor

Final Temperature of Busbars

mm

mm

12)

Horizontal Busbar size


Phase
Neutral
Vertical Busbar size
Phase
Neutral
Busbars support insulator make & voltage
class
Spacing between Busbar supports

13)

Shrouds on Joints & Tap-offs

14)

Inter panel barrier

D)
1)

AIR CIRCUIT BREAKER


Make

2)

Type

3)

Voltage, frequency & poles

4)

Rated current

5)

Short circuit rating

kA

6)

Sym. interrupting capacity

kA

7)

Total interrupting time

ms

8)

Making current (Peak)

kA

9)

Power Frequency Withstand Voltage

kV

10)

Lightning Impulse Withstand Voltage

kV

11)

Anti pumping feature provided

12)

Trip-free feature

*
*

13)

Provision for pad locking facility in the


OFF position
No. of auxiliary contacts for owners use

14)

Spring charging motor rating at 240V AC

VA

15)

ms

16)

Time required to charge spring from fully


discharged condition
Control Supply voltage(DC)

17)

Maximum tripping coil consumption /ACB

VA

18)

Maximum closing coil consumption /ACB

VA

E)
1)

MCCB
Make

2)

Voltage, frequency & poles

3)

Rated current

4)

Short circuit rating

kA

5)

Sym. interrupting capacity

kA

6)

Total interrupting time

ms

9)

10)

11)

*
mm

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Sr
No
7)

Making current (Peak)

8)

Operating mechanism

9)

Trip - free feature

10)

Provision for pad locking facility in the


OFF position
No. of auxiliary contacts for owners use

11)

Description

To be filled in by Vendor
kA

F)
1)

SWITCHES
Make

2)

Type

3)

Duty

4)

Rating

*
*

6)

Interlocking with Door + Defect Interlocking


facility
Padlocking in OFF position

7)

Shrouding of Incoming Terminal

8)

Rotary / Link Type

9)

Single Break / Double Break

G)
1)

FUSES
Make

2)

Type

3)

Rupturing Capacity

4)

Rating

5)

Control Fuse Make

H)
1)

CONTACTORS
Make

2)

Type

3)

Service

4)

Rating

5)

Duty

I)
1)

OVERLOAD PROTECTION RELAY


Make

2)

Type

3)

SPPR feature

4)

Trip class

5)

Reset facility

6)

CT operated from which rating onwards?

J)
1)

EART FAULT PROTECTION RELAY


Make

5)

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Page 4 of 6

Sr
No
2)

Type

3)

Rating

4)

CBCT provided

5)

Timer provided

6)

Reset facility

K)
1)

CURRENT TRANSFORMER
Make

2)

Type & services

3)

Voltage & frequency

4)

Ratio

5)

Rated burden

6)

Accuracy class

7)

Short circuit current rating

8)

Class of Insulation

9)

Shorting link for secondary

L)

POTENTIAL TRANSFORMER

1)

Make

2)

Type & services

3)

Voltage & frequency

4)

Ratio

5)

Rated burden

6)

Accuracy class

7)

Short circuit current rating

8)

Class of Insulation

M)

PROTECTIVE RELAYS

1)

Make

2)

Type

3)

Control voltage

N)

INDICATING INSTRUMENTS

1)

Make

2)

Size

3)

Type

4)

Range for Incoming & Outgoing

5)

Burden

O)

WIRING

1)

Insulation

2)

Voltage class

Description

To be filled in by Vendor
*
A

VA

*
*

kA

VA

*
*

kA

*
*

*
[To be filled for each type of
instruments]
*

VA

*
V

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Sr
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3)

Rev: B

Description

Page 5 of 6

To be filled in by Vendor
*

P)

Size & Colour code


Power Circuits
CT secondary
Control circuits
ANNUNCIATION SYSTEM

1)

Make

2)

Applicable standard

3)

Type

4)

System Voltage [DC]

5)

6)

No. of windows, Display device, Facia type


and LED colour etc.,
Flash rate

7)

Response time

8)

Operational sequence (Alarm sequence)

9)

Power consumption

VA

10)

Dimensions

mm

Q)

CONTROL SUPPLY

1)

mm

R)

Auxiliary Busbar size


110V DC
110V AC
240V AC
Control transformer
Ratio
Rating
Nos/Swgr
Provision of standby control Transformer in
each switchgear?
Auto-change over provided between
Control Transformers?
Sleeving for control Busbars [Material of
sleeves]
SOFT STARTER

1)

Make

2)

Type of Solid state Soft Starter

3)

Frequency Range

4)

5)

Starting capacity at maximum rated full


load current Ir [* times Ir for * secs].
Allowable no. of starts per hour

6)

Overload capacity & duration

7)

Selectable Overload Class range

8)

9)

Selectable Start/stop mode


[Voltage / Torque ramp]
Selectable range of Start Ramp

10)

Selectable range of Stop Ramp

11)

Control Type

2)

3)
4)
5)

*
*
*

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12)

Rev: B

Description

Page 6 of 6

To be filled in by Vendor

Selectable Torque limit range

*
*

14)

Control of Soft starter with field bus


provided
Power circuit continuous Rating [SCRS]

15)

SCR peak inverse voltage

16)

SCR protection fuse rating

17)

Power Factor

18)

Efficiency (Converter with Output Filter)

19)

Transient voltage protection

20)

Total Harmonic Distortion (THD)

21)

Noise Level

22)

Type of cooling

23)

Bypass Contactor provided

24)

Protection provided For the Soft starter

25)

Requirement of Air-conditioning

S)

EARTHING

1)

Earth Bus Size

2)

Material

3)

Location

4)

Provision for Connection to Grid

T)

LOAD ON BATTERY

1)

ACB Closing Coils

VA

2)

ACB Tripping Coils

VA

Burden of Auxiliary Relays (which will be


on Battery)
Annunciation system

VA

VA

13)

3)
4)

*
%

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37

Appendix-F: Electrical Drawings.

01.

Dwg. No. 266763-000-410-001B:- Overall Key Single Line diagram.

02.

Dwg. No. 266763-000-410-002B:- Single Line diagram for PMCC

03.

Dwg. No. 266763-000-410-003B:- Single Line diagram for Bottling Plant MCC

04.

Dwg. No. 266763-000-410-004D:- Overall Lighting Distribution Single Line Diagram

05.

Dwg. No. 266763-000-410-049D:- Single Line diagram for Power Distribution board.

06.

Dwg. No. 266763-000-425-006D:- Equipment Layout of MCC room & Transformer Cell.

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37

Appendix-G: Control Schematics drawings.

01.

Dwg. No. 266763-000-410-050D:- Typical Control Schematics.-DOL ( Sheet 1)

02.

Dwg. No. 266763-000-410-050D:- Typical Control Schematics.-R-DOL ( Sheet 2)

03.

Dwg. No. 266763-000-410-050D:- Typical Control Schematics.- STAR-DELTA ( Sheet 3)

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

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Page 1 of 13

Specification for LV Busduct


(Appendix H to Specification for 415V PMCC, Bus duct, Aux. PDB, MLDB, Spec No. 266763-000SP-4004)

List of Contents

Pages

1.

Introduction

2.

Scope of Supply

3.

Bill of Material for Busducts

4.

Technical Particulars:

4.1.

Construction

4.2.

Busbars

4.3.

Busbar Supports

4.4.

Space Heater:

4.5.

Earth Bus:

4.6.

Termination at the ends of Busduct

4.7.

Special Chambers

4.8.

Marking for Reassembly

4.9.

Name Plates

4.10.

Busduct Supporting Arrangement

4.11.

Makes of Component

4.12.

Painting

5.

Codes & Standards

6.

Requisition for Engineering Documents

10

7.

Guaranteed Technical particulars

12

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Rev: B

Page 2 of 13

Introduction

This specification covers the minimum requirements for the Design, Manufacture, Material procurement,
Assembly, Painting, Inspection at manufacturers works, and Delivery to site, supervision of Erection of
Non-Segregated Metal Enclosed three Phase Neutral Busduct
This specification is to be read in conjunction with Specification for 415V PMCC, Bus duct, MCC, PDB,
MLDB, Spec No. 266763-000-SP-4004.

Scope of Supply

The following LV Bus duct shall be supplied, in accordance with this specification; standards stated
herein.

1.

Busduct No.

000 -BD-001

2.

Voltage Grade (Volts)

415

3.

Rating (Amp)

1600

4.

PMCC

000-PMCC-001

5.

Transformer No.

000-DT-001

Location

MCC Room

Bill of Material for Busducts

3.1

The 415V Bus ducts shall be supplied with Materials listed below:

Sl
No.

Description of Parts

a.

Straight Length (Indoor)

4 Meter.

b.

Straight Length (Outdoor)

10 Metre.

c.

90 Degree Bend - Horizontal / Vertical

5 Sets.

d.

Adaptor Chamber (at Switchboard End)

1 No.

e.

Adaptor Chamber (at Transformer End)

1 No.

f.

TPN Copper Flexible Set for Transformer End


Connection

1 Set

g.

TPN Copper Flexible Set for Switchboard End

1 Set

Quantity (approximate)

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Rev: B

Page 3 of 13

Connection
h.

Phase-cross over assembly (as required by


manufacturer)

1 Set

i.

Aluminium Flexible (if required)

1 Set

j.

Rubber Bellow at transformer end (if recommended by


manufacturer)

1 Set

k.

Wall Frame Assembly with Seal of Bushing

1 Set.

l.

Silica gel Breather (if recommended by


manufacturer)

1 No.

m.

Fire Barrier

n.

240V Space heater +Thermostat Set with junction


box

1 Set

o.

Supporting Structure (galvanized) with hardware as


required

1 Lot

3.1.1

As required.

Vendor to Estimate the actual quantities during execution


Notes to Vendor:

a) Indoor and Outdoor Lengths indicated are tentative. These lengths are given only to give an idea
about approximate length of Busduct. Vendor shall accept the changes in Busduct route, length &
accessories till final drawing approval. To arrive at the total length of Busduct, it will be measured
along the centre line of the Busduct which will include bends and phase cross over chambers.
b) Vendor shall manufacture Busducts as per final approved drawings and bill of material shall be
treated as basis for final invoice
c) Following drawings shall be furnished to successful vendor for Busduct engineering in the event
of order.
i.
Equipment Layout
ii.

Vendor Drawing for Transformer

The Scope shall also include

Inspection and Testing at manufacturers works, as specified.

Submission of documents as specified.

Painting as specified.

Preservation, preparation of shipment and delivery to site.

Supervision of Erection at site.

List of Spares for two years normal operation.

Start-up spares and commissioning spares.

List of special tools required (Vendor to provide list with the offer).

Any other items, required to make system complete.

3.1.2

Exclusions
Installation/Erection & commissioning.

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Rev: B

Page 4 of 13

Technical Particulars:

4.1

Construction

4.1.1

The Busduct shall be of box frame construction of Sheet Steel enclosure suitably braced to
withstand the maximum mechanical and electrodynamic forces.

4.1.2

The Busduct enclosure shall be fabricated from 2 mm thick Sheet Steel. Eddy current heating, if
applicable, shall be taken into account.

4.1.3

The section of the Busduct shall be rectangle & non-phase segregated. The degree of protection
shall be IP-55.The Busduct shall have fire barriers inside.

4.1.4

The Busduct enclosure shall be suitable for indoor/outdoor installation as specified. The outdoor
portion of Busduct shall be suitable for outdoor installation without any additional protection from
owners end. However, rain hood shall be provided as an additional protection for outdoor
installation. Canopy and proper fixing arrangements shall be provided for the same.

4.1.5

The Busduct shall be provided with removable top covers fitted with gaskets secured by sufficient
number of nuts, bolts to ensure that these covers are dustproof. All joints and covers shall be
provided with non-deteriorating type gaskets of neoprene between joints. These covers shall be
of suitable length for ease of removal and shall be arranged to give complete accessibility to the
busbars, joints, bends and supports, etc. The entire busduct shall be dust and vermin proof.
Louvers shall not be provided.

4.1.6

The design of Busduct enclosure shall be such that it will withstand the operating conditions
arising out of the following:

(a) Normal operating conditions


(b) Momentary short circuit currents
(c) Rigours of adverse weather conditions, and

(d) Combinations of above.


4.1.7

The busduct shall be provided with flanged ends to connect the busduct to transformer at one
end and switchgear at other end. These flanges shall match with corresponding flanges in the
equipment to which these are connected.
Vendor shall provide suitable termination arrangement at 415V switchgear and transformer ends.
Proper alignment and co-ordination between the busduct and power transformer / switchgear
terminations shall be the responsibility of the busduct supplier. The purchaser will furnish the
drawings required by the vendor. The busduct shall be supplied complete with all the hardware
necessary for making the terminations

4.1.8

All hardware shall be hot dip galvanised/Cadmium Plated. The bolts shall be full threaded and
high tensile quality. Belleville washers for all current carrying conducting parts of the busbars and
plain washers for enclosure and covers shall be provided for every bolt.

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4.1.9

Rev: B

Page 5 of 13

Filter type drain holes shall be provided for draining out condensed moisture. The filter element
shall be such that it will allow escape of moisture but prevent ingress of dust. This shall be
removable type for cleaning purposes.

4.1.10 Bolted inspection cover shall be provided throughout length of Busduct. At the wall crossing of
the busduct, there should not be removable type inspection cover.
4.1.11 Proper wall sealing arrangements shall be provided at the wall where bus duct enters the
substation building. Busduct with wall mounting flange will be acceptable for the sealing
arrangement.
4.1.12 Top covers of the busduct shall be so located that they will not fall within the wall crossing section.
Busduct shall be supported from overhead hangers inside the substation.
4.1.13 The enclosure shall be provided with suitable mounting lugs at suitable interval. The mounting
lugs shall be suitable for hanger type supports. Vendor shall design and indicate the supporting
arrangement for busduct.
4.1.14 The Busduct shall be designed for an ambient temperature of 50 Deg Centigrade. (For indoor) &
0
55 C for outdoor. Under Normal operating conditions, the surface temperature of the enclosure
shall not exceed 80C (i.e., the temperature rise shall be limited to 30 Deg centigrade.)

4.2

Busbars

4.2.1

The busbars shall be of electrical grade Aluminium flats adequately sized to carry maximum
specified continuous current & short circuit current for 1sec, at maximum site temperature
specified. The final temperature of busbars and connectors at joints between connector and
busbar should not exceed 95C when carrying rated currents. Also the final busbar temperature
shall not exceed 250C when specified short circuit current for 1sec duration flows through.
Current density of Busbars shall be 0.8 Amp/mm2 max.

4.2.2

All busbars shall be insulated with heat shrinkable PVC sleeves. All busbars shall be colour
coded such that on removal of any inspection cover the phases shall be identifiable.

4.2.3

Busbar clamps shall be provided to maintain the busbars in position. These clamps shall be
made out of fully heat treated magnesium silicate aluminium alloy to IS: 5082, 1998. The clamp
design shall be such that it holds the busbar firmly and also allow sliding movement of busbars
without generating internal stresses to accommodate expansion during operation at rated current.
For fixing the busbars to the busbar supports, cadmium plated bolts, nuts and washers shall be
employed.

4.2.4

Wherever required for long run of busduct, expansion joints with flexible strips shall be provided
to allow for expansion and contraction due to temperature variations arising out of normal
continuous current flow and short circuit current flow for specified duration. Minimum one
expansion joint shall be provided for each 3000 mm long straight length of busduct. In case this
is not provided, Vendor shall substantiate the same with Calculations.

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Page 6 of 13

4.2.5

Suitable Bimetallic strips shall be provided wherever copper to aluminium connections are
envisaged.(For flexible jumpers at expansion joint & end terminations)

4.2.6

All the hardware for connections both at transformer end & the PMCC end shall be in scope of
supply.

4.3

Busbar Supports

4.3.1

The busbars shall be supported by non-deteriorating type (non-hygroscopic, non-carbonising,


Corrosion resistance) Solid core resin cast epoxy insulators of requisite electrical / mechanical
strength. The mechanical strength shall be sufficient to withstand forces arising out of peak short
circuit current. Each shipping section shall meet this requirement separately.

4.3.2

Adequate Creepage distance shall be available on insulator to operate under high humid
conditions and effects of condensed moisture due to variations in temperature within busduct due
to different conditions of loading.

4.3.3

The spacing of the insulating supports shall be decided on the basis of the fault withstand
capacity

4.4

Space Heater:
Busduct shall be provided with anti-condensation space heaters with controlling thermostats of
adequate capacity to maintain internal temperature above dew point to prevent moisture
condensation in busduct. Space heaters shall be rated for 240V, single phase, 50 Hz AC supply.
Space heater shall be provided on both sides of the fire barrier.

4.5

Earth Bus:
Earth bus of 50 mm x 8 mm aluminium shall run on the external side of the busduct through the
whole length of the busduct and shall be positively connected to the body of the busduct
enclosure. At both ends of the earth bus provision shall be made to connect it to main earthing
system.

4.6

Termination at the ends of Busduct

4.6.1

The busduct shall be provided with flexible at both ends for connecting it with transformer at one
end and 415V switchgear at other end.

4.6.2

The Flexibles shall be made of thin copper strips. The ends of the flexible shall be clamped by
copper plate. The ends of flexible shall be tin plated.

4.7

Special Chambers
To match the phase sequence of the two equipments connected by busduct, a suitable phase
cross over chamber shall be provided; if required, at suitable location. This chamber shall
generally be located in transformer yard.

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4.8

Rev: B

Page 7 of 13

Marking for Reassembly


All busduct parts like enclosure, adaptor box, rain hoods, enclosure covers, supports, busbar and
busbar fish plates shall be identified distinctly by clear numbers. These shall be indicated in
drawing.

4.9

Name Plates
Permanent non-corrosive nameplate with engraved white letters on black background shall be
fixed on each Busduct with its designation & service description. The nameplate shall indicate the
following:
First line

4.10

Equipment Item No.

Second line:

Equipment Description

Third line:

System voltage.

Fourth Line:

Equipment Continuous & short Circuit Rating.

Busduct Supporting Arrangement

4.10.1 Busduct supplier shall quote separately unit rate for busduct supports with details of the
supporting members and quantity being offered.
4.10.2 The supports offered shall be as specified below.
(a)

Supporting structure shall be fabricated from standard steel sections and shall be hot dip
galvanised after fabrication.

(b)

Support structures shall be designed to withstand the dead weight of the busduct and the short
circuit forces under maximum fault conditions.

(c)

Support structures shall include support members like brackets, hangers, vertical / longitudinal
beams, channels, nuts, bolts, washers and other hardware required for erection and support of
entire busduct.

(d)

Indoor portion of the busduct may be supported from wall or ceiling as per layout furnished.
Outdoor portion of the busduct shall be supported from ground below on suitable foundations in
ground.

4.11

Makes of Component

4.10.2 Manufacturer shall furnish standard list of components makes for the complete the 415V

Busduct assembly. This list must be included with the offer.

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4.12

Rev: B

Page 8 of 13

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

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Rev: B

Page 9 of 13

Codes & Standards

IS-8623 (Part 2), 1993

Specification for Low Voltage Switchgear and Control gear


Assemblies: Particular Requirements for Busbar Trunking
Systems.

IS-13947, 1993

Specification for Low Voltage Switchgear and Control gear

IS-5082, 1998

Wrought Aluminium and Aluminium alloy bars, rods, tubes and


sections for electrical purposes.

IS-5578, 1984

Guide for making of Insulated Conductors.

IS-4237, 1982

General Requirements for Switchgear and Control Gear for


Voltages not exceeding 1000V AC or 1200V DC

IS -4691, 1985

Degree of Protection provided by enclosures

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Page 10 of
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Rev: B

Requisition for Engineering Documents


RED Form
Owner/Purchasers Office

Distribution Office

HI-TECH CARBON,
(A unit of Aditya Birla Nuva Ltd.)
Murdhwa Indl. Area, P.O. Renukoot,
Dist. Sonebhadra (U.P.),
Pin-231 2127

Mott MacDonald Consultants (India) Pvt. Ltd.


Kothari House, CTS No. 185
Off Andheri - Kurla Road
Andheri (East)
Mumbai 400 059
SPECIAL INSTRUCTIONS
Prints
Documents shall be sent to:
Production Schedule
4
The Purchasing Office via courier
service
Manufacturing, inspection & testing sequence plan
4
The Purchasing Office via courier
service
Required number for
TIMING FOR SUBMITTAL
DRAWINGS

Submission of Following for each


415V Busduct, but not limited to:
Guaranteed Technical Particulars with
values filled up.
General Arrangement Drawing with
cross sectional view of bus duct with
details of Insulator, busbar clamps,
spacing of busbar phases and spacing
of Insulators and cross section & length
of flexible
Plan View of busduct connecting two
equipments with dimensions from
centre to centre equipments
Side elevation of busduct with all levels
or dimensions marked.
End View of busduct with busbars and
flexible connecting the transformer with
clearances between bolt/Nut of
adjacent phases and same for PMCC
End.
Design Calculation for:
(i) Busbar sizing
(ii) Final Temp.of busbars when
carrying rated current
Continuously in still air.
(iii) Final Temp.of busbars when 3
phase SC Current
flow for one second
(iv) Final Temp.of busbar enclosure for
conditions
(ii) & (iii)

OFFE
R

APPRO
VAL

FINAL

- for approval 2 weeks after order


date

Prints

Prints

Disk

Prints - final issue 2 weeks after approval


date
Documents shall be submitted to:

Purchasing Office via courier


service

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Doc. No. 266763-000-SP4004HX
(v) Temp. rise Calculation
(vi) Busbar Support Calculations under
short circuit conditions.
(vii) Surface Temp.of enclosure under
normal operating conditions.
Flange details of connecting adaptors
at both ends
Wall sealing frame
Name Plate Drawing
Make of Each Components
Type Test, Routine Test Certificates
Spares List for two Years Operation
As Built Drawing
SPARE PARTS DOCUMENTS

Page 11 of
13

Rev: B

2
2
2
-

4
4
4
4
4
4

2
2
2
2
2
2

4
4
4
4
4
4

TEST AND INSPECTION DOCUMENTS


Documents to be submitted under transmittal

Prints
Documents shall be submitted to:

Manufacturing report
Test Report / Data Curves

1
1

4
4

Calibration Certificates for testing Instruments.


Bought out Equipments Certificates.

1
1

4
4

OPERATING DOCUMENTS

Installation instructions
Operating instructions
Maintenance instructions

Purchasing Office via courier


service within 4 weeks
Of relevant test / inspection.
Purchasing Office via courier
service not later than at time of
dispatch of equipment.

1
1
1

4
4
4

Combine into one manual

ADDITIONAL REQUIREMENTS
1. Referenced standards / codes shall be the latest issue unless otherwise stated.

REMARKS
Invoice must certify that the drawings and engineering
documents specified above have been dispatched to
all parties concerned.
Any deviation from the timing for submittal of
documents shall be notified to the Approval /
Distribution Offices by fax or E mail.
Shop fabrication shall not be started before the
required approval drawings have been released for
construction by the party concerned, unless otherwise
stated on the "Approval Drawing Specification".
Each document shall bear the item / tag and order
reference number and be dispatched by air mail,
unless other instructions are stated on the RED.

Units / dimensions to be used on Engineering documents


shall be SI.
The documents shall be in English. Description on
drawings and similar documents may be in other
languages provided English translations are also given.
Drawings and documents shall be suitable for
microfilming and comply with accepted national or
international standards for the preparation of technical
drawings. Only the following standard sizes should be
used: A4, A3, A2, and A1.

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Page 12 of
13

Guaranteed Technical particulars


(* To be filled in by the Vendor)
Sr.
No
A)
1)
2)
3)
4)
5)
6)
B)
1)

2)
3)

4)
5)

Description
GENERAL
Manufacturer
Country of Manufacture
Applicable codes & standards
List of Type test certificates furnished
List of Routine tests offered
Documents as per Cl. 5 of Specification
furnished?
CONSTRUCTION
Busduct Enclosure
a) Enclosure material
b) Thickness of Enclosure
c) Degree of Protection
Indoor / Outdoor[without canopy]
Type & Execution
Paint Shade
a) External Paint Shade
b) Internal Paint Shade
Dimensions:
Width x Length x Height
Slopping Canopy for outdoor portion
a) Material of Canopy
b) Thickness of Canopy

To be filled in by Vendor
*
*
*
*
*
*

mm

*
*
*
*
*
*

mm

*
*
*

6)

Number of Bends

7)

Provision for phase Crossover Chamber

8)
9)

Location of phase Crossover Chamber


Type of Gasket used for Joints and Covers

10)

Wall Frame Assembly(for Sealing)


Provision of drain plug to remove condensated
moisture
Busduct Top Cover removal provision
Provision of Space Heaters
Provision of Fire Barrier
RATINGS
Continuous current rating
Fault Current withstand capacity for 1 sec.
Voltage Grade
Design Ambient Temperature
Maximum Temperature rise above Design
Ambient Temperature of
a) Busbar
At rated continuous current
At rated short circuit current
b) Enclosure
Derating Factors considered for busbar sizing

*
*

11)
12)
13)
14)
C)
1)
2)
3)
4)
5)

6)

mm

*
*
*
Amps
kA
Volts
Deg.C

*
*
*
*

Deg.C
*
*
*
*
*

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Doc. No. 266763-000-SP4004HX
Sr.
No
D)
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)

11)
12)
13)

14)
15)
16)

E)
1)
2)
F)
1)
2)

Page 13 of
13

Rev: B

Description
BUSBARS
Busbar Material
Busbar Type (Cross-Section)
Number of Busbars per Phase
Size of Busbar
Current Density of Busbars
Neutral Busbar Cross Sectional Area
Earth Busbar Material
Earth Busbar Size
Earth Busbar Location w.r.t. Enclosure
Busbar Insulation:
a)
Material
b)
Thickness
c)
Class
Busbar Colour Identification
Heat shrinkable sleeves for Busbars
Minimum Air Clearance Between
a) Phase - Phase
b) Phase - Neutral
c) Phase - Enclosure
Provision for Busbar Expansion Joints
Internal of Busbar Expansion Joints
Flexible Connections provided at
a) Number of Flexible Connections per phase
b) Material of Flexible Connections
BUSBAR SUPPORTS
Type of Busbar Supports (Material)
Distance between Busbar supports
BUS DUCT SUPPORTS
Type of Busbar Supports (Material)
Distance between Busbar supports

To be filled in by Vendor
mm

mm
2
A/ mm
Sq.mm
mm

*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*

mm

mm

*
*

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC


PDB MLDB\266763-000-SP-4004 HX, Rev-0.doc