Ee Specifications

M&E WORKS SPECIFICATION
INDEX PAGE SECTION E.00 GENERALITIES SECTION ELECTRICAL WORKS E.01 L.V. SWITCHBOARS E.02 E.03 E.04 SECTION E.05 EXTERNAL ELECTRICAL INSTALLATION INTERNAL ELECTRICAL INSTALLATION ELECTRICAL MATERIAL & ACCESSORIES E.01 -01 E.02 -01 E.03 -01 E.04 -01 E.05 -01 : : : : : E.01 -45 E.01 -03 E.01 -11 E.01 -07 E.01 -07 E.00 -01 : E.01 -51
ALARM SYSTEM
SECTION E.06
LIGHTNING PROTECTION SYSTEM
E.06 -01
E.01 -02
SECTION E.07
EARTHING ARRANGEMENT
E.07 -01
E.01 -02
PROPOSED RECREATION CENTER
INDEX
M&E WORKS SPECIFICATION SECTION E.00
GENERALITIES
0.1 PRELIMINARIES DELETED 0.2. GENERAL SPECIFICATIONS
0.2.1. GENERAL PARTICULARS 0.2.1.1. General Requirements All works and materials to be used shall comply with requirements, regulations, recommendations and Codes of Practice of the latest editions of the following: (a) Regulations f o r E l e c t r i c a l I n s t a l l a t i o n s p u b l i s h e d b y t he I n s t i t u t e o f Electrical Engineers, London. (b) The Supply Companys Rules and Regulations (c) Regulations of the local Electrical authorities ,Fire Services Department, Public Works Department, Water Works Department, and to the satisfaction of the Engineer.
(d) The relevant British Standards and Codes of Practice. Short circuit test shall be by ASTA approved testing authorities. When equipment complying with other standards is offered, the Contractor shall satisfy the Engineer that the quality of the equipment offered is equivalent to or better than the appropriate British Standards. Any variations to the requirements of the following General Clauses will be detailed in the Particular Clauses. The specification r elat es t o, t he Cont r act or shall sup pl y a ll la bour and material necessary, and shall install, complete and make ready for use, the above Mentioned systems including the installation and wiring of miscellaneous equipment and devices, as indicated on the Drawings and as herein specified. The Contractor shall do the maintenance for a period of 12 months of the complete electrical installation as described in this specification and on the contracts drawings. 0.2.1.2. Basis of Design All electrical work shall be executed in accordance with the latest edition of the regulations for the Electrical Installation of Buildings as issued by the Institution of Electrical Engineers- U. K. and O.E.S Standards issued by Ministry of Electricity
PROPOSED RECREATION CENTER GEN -1
GENERALITIES
and Water, Oman. A copy of the regulations and O.E.S. shall be kept by the Contractor on site at all times. All works in general shall comply with any other local statutory regulations where applicable. The Contractor shall carry out the whole of the Electrical works in a workman like and substantial manner and in strict conformance with the codes, Standards and requirements listed in the following clauses, or approved equal. All equipment and material supplied for this Project shall be manufactured in strict compliance with the standards listed in the following clauses, or approved equal. If actual ratings of equipment supplied under other sections are different than the values indicated on the Drawings, the Contractor shall implement all necessary modifications at no extra cost, to the approval of the Engineer and relevant Local Authorities. 0.2.1.3. Interference and Erroneous Locations The Contractor shall verify on Site all data and final locations of work done under o t h e r Sections o f t h e S p e c i f i c a t i o n s , r e q u i r e d f o r a r r a n g i n g t h e Electrical Works. In case of interference with other works or erroneous locations with respect to equipment or structures, the Contractor shall supply all labour and materials necessary to complete the Work in an approved manner. 0.2.1.4. Climatic Conditions Materials and equipment shall be suitable in all respects for operation on electrical systems under following climatic conditions:Temperature - 52 degree C. Max. Relative Humidity - 100 percent Max. The Contractor shall be responsible to ensure that all works are carried out taking into account of the prevailing environmental conditions on site. 0.2.1.5. Protection of Electrical Equipment Electrical equipment shall be protected against mechanical damage and from the weather especially from water dripping or splashing upon it at all times during shipment, storage, and construction. Equipment shall not be stored outdoors, where equipment is installed or stored in moist areas, such as unheated buildings, open spaces, etc., it shall be provided with an acceptable means to prevent moisture damage. This may be a uniformly distributed source of heat to prevent condensation. Should any equipment or material be subjected to possible damage by water, it shall be dried out thoroughly and put through a special dielectric test as directed, at the expense of the Contractor or shall be replaced by the Contractor without additional charge. Should any equipment or material be subjected to possible mechanical damage, the Contractor shall repair or replace the damaged equipment at free of
GENERALITIES
cost as instructed by the Engineer. 0.2.1.6. Acceptance Tests Any work which is not in accordance with the Specifications or to the satisfaction of the engineer and/or local power authorities shall be removed and repaired at the Contractors expense. All material must be factory finished and/or painted to the approval of the Engineer. All electrical equipments should have been type tested in an independent and reputed test laboratory like ASTA, NEMA or any other authorities for the relevant duty conditions and the type test certificates shall be furnished for the Engineers approval
0.2.1.7. Local Electrical Authorities Requirements The Contractor shall attend to and afford all facilities to the Local Electrical Authorities and shall provide oil drainage pits, terminal cable pits, terminal boxes for cables, underground ducts, etc. to facilitate all main feeder work. The Contractor shall be responsible for foreseeing any requirement as requested by the above mentioned authorities, and shall follow the Engineers instructions on Site. The Contractor shall be responsible for preparing any shop drawings concerning transformer and electrical (meter) rooms, and feed-in routings, and shall consult the electrical authorities in accordance with the Engineers instructions, to seek the approval of these authorities. The Contractor shall also be responsible for follow up of the application for both electrical and Telephone connection. The application form shall be filled in by the Contractor who shall follow up with the concerned authorities for final connection to the project. The Contractor shall be required to assist the TRA-OMAN installers with respect to identifying conduit/ tray locations on site and providing drawings of the installed wire way for their use. 0.2.1.8. Modifications If during the work, the Contractor wishes to make changes or modifications, then these modifications shall be submitted in advance to the Engineer for approval. If these changes result in extra expenses in design and/or material, these expenses shall be borne by the Contractor. 0.2.1.9. L.V. Switchgear Switch boards Switchboards shall be manufactured, factory assembled and tested by a specialist switchboard manufacturer, and shall be identical in mechanical construction, except where modified by this Specification, to
GENERALITIES
the manufacturers standard range which shall have been type-tested by a competent testing authority to the fault conditions specified. Evidence of compliance with the above requirements, including makers literature, a list of contracts successfully completed for similar switchboards, and copies of test certificates, shall be submitted with the Tender. Flush fronted switchboards are generally required and they shall be of cubicle type construction, self supporting, with cubicle top, side panels and doors at least 1.5 mm thick sheet steel on a frame having members at least 2.5 mm thick to give a rigid construction without cross struts. Each switchboard shall be of uniform height and depth front to back, throughout its length. All hinges shall be concealed type. Each switchboard shall have circuitbreakers and fuse-switches arranged in tier formation with removable front access panels and bolted back plates and copper busbars suitably shrouded. Each switchboard shall, where specified, include a 100 mm channel iron plinth. Industrial type switchboards, where specified, shall be suitable for floor mounting. They shall be constructed of angle iron which shall be arranged to support all items of equipment. The switchboard shall comprise an incoming switch feeding onto a four pole busbar chamber, and fuses switches controlling outgoing circuits mounted above and below. All interconnecting cables and trunking, labels, cable boxes and glands shall be included. The framing shall be painted with two coats of aluminum paint on completion. The Contractor shall provide suitable testing equipment on site and carry out applied voltage tests. Each complete switchboard shall have the current rating specified. All fuseswitches shall be complete with high breaking capacity fuses having rupturing capacity of not less than the associated switchgear. A spare set of fuses shall be housed inside the cover of each fuse-switch. Fuse-switches shall be equipped with either a cable box, gland and clamp or XLPE or PVC. cable or an end plate suitable for drilling for MI cable gland or conduit entry. A copper earth bar shall be bolted to the main switchboard frame. Each switchboard shall incorporate storage facilities for space fuses. An ammeter and voltmeter shall be provided suitably scaled on the main incoming switch of each switchboard. Each meter shall be provided complete with a phase selector and off switch so that readings of all phases may be obtained including voltage between phases. The Contractor shall confirm with the switchboard manufacturers that the switchboards are complete with all cable boxes meters and ancillary equipment before the switchboard are certified completed for despatch at the manufacturers works, as no claims for variations will be entertained due to inadequate provisions being made. All switchgear shall be clearly labelled to indicate its position and purpose.
GEN -4
GENERALITIES
All switchboards and fuse-switches shall be dust-tight and the metal work must be finished to withstand local climatic conditions. All lids and removable panels shall be fitted with suitable gaskets to prevent the ingress of moisture and insects. All units shall include locking devices. Main busbar joints shall be achieved using threaded busbar rather than fully bolted joints. The layout of switchgear shown on the Contract Drawings is diagrammatic only. Drawings of all switchboards to a scale not less than 1:10 shall be submitted by the Contractor for the approval of the Engineer prior to commencement of manufacture. In order to minimize delay in the preparation of working drawings for approval, the Contractor, at the time of ordering the switchboards, shall acquaint the manufacturer with full details of the areas available in switch rooms and plant rooms, together with the proposed routes and details of all incoming and outgoing cables relative to switchboard entry. Busbars chambers shall run horizontally and shall contain triple phase and neutral busbars rated as shown on the drawings or specified elsewhere, of hard drawn high conductivity copper. The installation of cables passing through busbars chambers to interconnect items of switchgear or distribution equipment will not be permitted. Insulators, including busbar supports, shall be non-hygroscopic and nondeteriorating. The use of fibrous materials, oil, varnish, etc., is not acceptable. The various cubicles housing the respective switch/control units shall be so arranged as to gibe a multi-tier arrangement and shall include a cabling and wiring chamber of ample dimensions with provision for terminating armoured cables, where applicable. All secondary wiring shall be PVC insulated and not less than 1.5 mm2 stranded single core. Each connection for the secondary wiring shall terminate at an approved type of terminal block with a coded ferrule. Connectors or soldered joints shall not be permitted in the secondary wiring which shall, wherever possible, be grouped and laced together in a neat manner. The switchboard cubicles shall be solidly bonded by one continuous copper earth bar throughout the entire length of the switchboard. Provision shall be made at the end of the bar for connection to the main earthing system. The main earth bar, or tec-off connection shall be located convenient to the cable gland plates, to permit the earth bonding of all cable glands. The minimum size for main earth bars shall be 70mm copper. For switchboards protected by ACB, the main earth bar and tec-off connection shall be not smaller than
GENERALITIES
300mm2 and 150mm- copper respectively. The Contractor shall give the Engineer not less than 28 days notice of dispatch of cubicle switchboards from the manufacturers works.
0.2.1.10.
Fuse-Switch Units and On-Load witches
The units shall be of the air-break insulated, metalclad type and be designed to ensure safety to operating personnel. The fixed contacts shall be provided so that maintenance of the unit can be carried out in safety with the busbars live. The units shall preferably comprise fuse-switches having integral fuses, but manufacturers may offer the alternative of switch-fuses in which the air-break switch and connections from it to the associated fuse shall be designed to minimise the possibility of a phase-to-phase short circuit. in either case the switch shall be capable of breaking 3 times the normal rated current at 0.3 power factor and 110% rated voltage and making and carrying the system prospective symmetrical faultpower, but limited in magnitude and duration by the cut-off characteristic of the largest HRC fuse link that may be fitted to that unit. The rated normal current of the fuse-switch unit shall be as stated in the schedules forming part of this Specification or to suit the load stated therein. Interlocks shall be provided to ensure that the unit access door can only be opened when the associated switch is open and the switch cannot be closed until the access door is closed. All switches shall give visible ON/OFF position indicators and shall be lockable in both these positions. 0.2.1.11.High Rupturing Capacity (HRC) Fuses Fuses of the HRC type shall be provided and be such that the fuse carrier is easily with drawable for replacement of the fuse. All fuses shall be fitted with a visual device to indicate that the fuse has operated. Time/Current characteristics o f a l l f u s e l i n k s s h a l l b e p r o v i d e d w h e n requested by the Engineer. The current rating of fuse links shall be of sufficient capacity to afford short-circuit protection for the loads as stated in the schedules forming part of the Specification whilst remaining inoperative for such transient currents that may occur in the circuit. The rating where applicable, shall be such that the characteristic of the fuse link matches the characteristic of any contractor thermal device in the circuit.
0.2.1.12. Circuit Breakers
GEN -6
GENERALITIES
Air Circuit reakers: The Air Circuit Breaker shall comply to latest international standards IEC60947-2. The Air circuit Breaker shall be 4 Pole Motorised Drawout type capable of handling rated current upto in Panel temperature of 60 deg Celsius. The vendor shall furnish derating chart from the manufacturer in the submittals. The Circuit Breaker shall have electrical lockout feature. In the event of maintenance in d o w n s t r e a m , t h e o p e r a t o r s h a l l k e e p s h u n t t r i p c o i l energized to avoid unauthorized closing of the Circuit Breaker. It shall not be possible to either rack out or rack in the Circuit Breaker in closed position. The Circuit shall have suitable interlock to achieve the same. Draw out Circuit Breakers shall have three discrete positions Isolate/Test/Service positions. It shall have visual indication to show position. The Circuit Breaker shall have clear visual indication to show whether it is in closed or open condition. The closing mechanism shall be spring charged mechanism. It shall be possible to visualize whether spring is charged or discharged condition. The stored energy in the spring charged mechanism shall be sufficient to ensure that, it shall be possible to open a circuit breaker, reclose & open again. It shall not be possible to close the Circuit Breaker if the position of the Circuit Breaker is not one of the Isolate/Test/Service position. The Circuit Breaker shall be self diagnostic type. It shall check the following before closure. a. The Shunt trip should be in de-energised condition. b. The Under voltage release should be in energized condition. c. The breaker racked in fully to service/test/isolate condition. The Air Circuit Breaker shall have Service Short Breaking capacity of 65ka(Ics) at 440volts AC & short withstand current(Icw) of 65ka for 1 sec. The Circuit Breakers shall be capable of providing Total Discrimination. The Discrimination shall ensure availability of power supply to all other feeders except the feeder which is having a fault. With discrimination in the network it shall be possible for closest circuit breaker to clear the fault The protection release provided shall be microprocessor based release. The Air circuit breaker shall have adjustable Overload, Short circuit & Earth fault setting with time delay for each of the protection. Long-time (LT) protection with an adjustable current setting and time delay. Short-time (ST) protection with an adjustable pick-up and time delay. Instantaneous (INST) protection with an adjustable pick-up and an OFF position. The Protection Releases shall have built in Metering functions with metering of Voltage, Current, Power, Energy & Total Harmonic Distortions. The Protection releases shall have Residual current Protection. The Protection Releases shall display Main contact wear indication. The operating mechanism shall be of the Open/Closed/Open stored-energy type. The closing time shall be less than or equal to 70 milliseconds. The main
GENERALITIES
contacts shall be designed such that no maintenance shall be required under normal conditions of use. The Circuit breakers shall be equipped with a visual wear indicator that may be accessed by removing the arc chutes, for immediate main contacts assessment of contact wear without requiring measurements or specific tools. The arc chutes shall be removable on site. They shall be equipped with metal filters to reduce effects perceptible from the outside during current interruption. It shall be possible to disconnect the circuit breaker without having to open the door. The three possible positions (connected, disconnected and test) shall be indicated. Mechanical Indications shall be provided for the following conditions. a. Breaker On/Off b. Spring in Charged or Discharged condition. Before carrying out a disconnection or connection operation, the operator shall be required to press a release button located on the front of the chassis. It shall also be possible to discharge the spring before racking out the Breaker( With out closing the Circuit Breaker) Circuit breakers shall be designed in such a way that maintenance may be carried out as a function of their use. Without maintenance, Electrical endurance shall be greater than 10000 cycles up to 1600 A, 5000 cycles up to 4000A. Since the life of arcing contacts are very low & requires frequent maintenance, Arcing contact Technology in the main contacts construction is not acceptable. Moulded Case Circuit Breakers: The MCCBs shall comply to International Standards as per IEC60947-2. MCCBs shall deliver rated current at an ambient temperature of 50 Deg C. All MCCBs in the Main Distribution Board shall have Service short circuit breaking capacity of 50KA(Ics) at 440 volts. Service short circuit breaking capacity of MCCBs in Sub Main Distribution Boards shall be of 35 KA(Ics) at 440 volts. In the event considers lower fault level Circuit Breaker is considered, necessary documents shall be provided such that the fault level of the MCCB is enhanced to the above said rating with Cascading techniques. Vendor to provide corresponding supporting documents from the Manufacturer. The MCCBs shall be capable of providing Total Discrimination both Current & Time Discrimination. The MCCBs shall be Line/Load Interchangeable. The MCCBs shall have adjustable over load settings & adjustable short circuit settings for discrimination. The adjustable knob shall be accessible from the front of the MCCB. MCCBs upto 250A shall be of Thermo-magentic release. MCCBs above 250A shall be Microprocessor controlled release. MCCBs above 400A shall be of
GENERALITIES
category B type. The MCCBs upto 250A shall adjustable overload range from 80-100%. For ratings 400A & above adjustable range shall be 40100%. The MCCBs offered shall have trip free mechanism. The moulded-case circuit breakers shall be designed for both vertical and horizontal mounting, without any adverse effect on electrical performance. For maximum safety, the power contacts shall be insulated in an enclosure made of a thermosetting material from other functions such as the operating mechanism, the case, the trip unit and auxiliaries The operating mechanism of the moulded-case circuit breakers shall be of the quick-make, quick-break type with fault tripping overriding manual operation. All poles shall operate simultaneously for circuit breaker opening, closing and tripping. The moulded-case circuit breakers shall be capable of greatly limiting currents. For short-circuits, the maximum thermal stress I2t shall be limited to106 A2s for ratings up to 250 A, 5 x 106 A2s for ratings between 400 A and 630 A. Electronic and Thermal-magnetic trip units shall be adjustable and it shall be possible to fit lead seals to prevent unauthorized access to the settings. The moulded-case circuit breakers, the current ratings of which are identical with the ratings of their trip units, shall ensure discrimination for any fault current up to at least 35 kA rms, with any downstream circuit-breaker having a current rating less or equal to 0.4 times that of the upstream circuit-breaker. The electrical endurance of the moulded-case circuit breakers, as defined by IEC 947-2 standard, shall be at least equal to 3 times the minimum required by the standard The moulded-case circuit breakers shall provide class II insulation (according to IEC 664 standard) between the front and internal power circuits. This shall ensure power circuit fully insulated & no live parts shall be visible when front cover of the MCCB is opened. The operating mechanism shall be designed such that the toggle or handle can only be in OFF position (O) if the power contacts are all actually separated. Isolation shall be provided by a double break on the main circuit. Miniature Circuit Breakers: The Miniature Circuit Breakers shall comply to latest international standards BS EN 60898 and IEC 60898. MCBs shall be suitable for rated voltage of 240V AC for Single Pole & 415V AC for Multiple pole range. Short Breaking capacity Icn of MCBs shall be 9KA at 240volts AC. The Service short circuit breaking capacity Ics should be minimum of 6KA. The vendor shall submit Type test Certificates from Reputed Laboratories. The MCBs shall have minimum ON/OFF cycle of 20000 operations. The MCBs shall be as per DIN standards. Plug in MCBs are not acceptable. The Characteristics of MCBs shall be Type C. RCBO:
GENERALITIES
The RCBO shall have residual current sensitivity of 30ma & comply to international standards BS EN 61009/IEC 61009. The RCBO shall have short circuit breaking capacity of 10KA as per IEC 60898. RCCBs(ELCB): The RCCBs offered shall comply latest international standards BS EN 61008/IEC61008. The operating cycles(O-C) shall be minimum of 20000 operations. The RCCB offered shall provide protection against nuisance tripping due to transient voltages(Lightning, Switchgear switching in the network etc). 0.2.1.13. Final Distribution Boards
The Contractor shall supply and install the final distribution boards (DB, EDB) as indicated in the Schedules, where shown on the Drawings, and as herein specified. They shall include bus assembly, cabinet and front, circuit breakers and all necessary parts to install complete distribution boards. General lighting and power distribution boards shall be 500 volts grade metalclad pattern pre-treatment galvanized sheet steel rigid welded construction and shall be supplied complete with panel door, phase barriers, masking plates, earth terminal bar, miniature circuit-breakers with circuit charts. The Distribution Boards shall be as per IEC 60439 3 with short circuit withstand capacity of min of 15KA for 200ms. The Distribution boards shall have peak short time withstand capacity of 35KA. The ingress protection shall be IP31 as per IEC 60529. The Distribution boards shall be totally enclosed type, dust protected & vermin proof. Incoming isolators and/or residual current circuit breakers shall be double pole for SP & N distribution boards and four pole for TP and N distribution boards. All miniature circuit breakers shall be rated to withstand the fault currents of the circuits they protect without causing any interference in any other protective device associated with the distribution system. At the same time, the design of the circuit breaker shall be such that it will protect the circuit for which it is intended and not cause or allow other protective devices to operate when fault conditions apply. Plug in type MCBs are not accepted. Only DIN type MCBs shall be provided. The Distribution boards shall have hinged door which can be opened upto 180deg without any obstructions. Distribution boards with more than 8 ways shall have two locks in the door. All power socket outlets are to be equipped with RCBOs.(RCD) The Switchgear components used in the Distribution boards shall be of one make(MCBs,ELCBs, ISOLATOR, RCBOs shall be of one make only) & mix of various makes are not acceptable.
GENERALITIES
Each distribution board shall be clearly labelled indicating its service and all 3-phase distribution boards shall be fitted with white labels red engraved DANGER - and the appropriate 3-phase voltage. Good quality laminated Circuit charts shall indicate phasing, connected load and circuit-breaker or fuse rating. Single phase boards shall include phase colour identification discs. Distribution boards intended to be installed in plant areas shall be of weatherproof, industrial type construction, and those intended to be installed in office and residential areas shall be of appearance suitable for installation in these types of buildings. Both types shall be provided with top and bottom removable metal gland plates which shall be drilled to suit cable glands or conduit entry. Spare holes shall be provided, two each at top and bottom, and fitted with 32mm stopping plugs and locknuts.
Distribution boards shall be fitted with an integral incoming on-load switch. All distribution boards shall be fitted with a neutral busbar having facilities for terminating as many neutral cables as single-phase ways in the board. Neutral bar terminations shall reflect the circuits served, circuit No. 1 in Terminal No. 1 etc. Each distribution board shall be fitted with an earth stud located in an accessible position. All metal parts of the board except carrying parts shall be bonded together electrically and to the earth busbar. One earth terminal shall be provided for each earth cable terminated. Each distribution board shall be fitted with phase barriers of an oil and fire resisting insulating material whereby it is not readily possible for personnel to touch the phase busbars. Insulating barriers shall be fitted around the circuitbreakers such that only the front surface and toggIe of the circuit-breakers are showing. Each distribution boards shall be fitted with a card index of circuits contained in a suitable plastic pocket secured on the inside of the door panel. Contractor shall ensure that the distribution board and all the components are available in ex-stock with the proposed authorized local supplier.
0.2.1.14.
Contactors
Contactors shall be of the air-break type fitted with arc shields and be mechanically latched or electrically held in. All essential process drives for safe running or shutdown of the service will be controlled by contactors of the mechanically latched type. Only non-essential drives will utilise electrically held in contactors. Contactors shall comply with IEC 60947-4 and shall have a rating suitable for the
GENERALITIES
service required. The closing coil of mechanical latched contactors shall be suitable for operation from the d.c. power supply specified but shall operate satisfactorily, with a coil temperature of 50C, over a voltage range of 80-120% of nominal voltage. Contactors shall be of the air break type. They shall be rated for continuous duty, shall be category AC3 and have a no-load operating cycle of 1 million operations. All contactors shall be of the block type. Contacts shall be of the self-cleaning type and easily renewable. The design shall be such as to prevent welding in. All operating coils of contactors shall be able to operate on the appropriate control system voltage of the low voltage switchgear.
The shunt trip release coils of mechanically latched contactors shall be suitable for operation from the d.c. power supply specified but shall operate satisfactorily, with a coil temperature of 50C over a voltage range of 80 120% of nominal voltage. Butt contacts of the rolling self-cleaning type shall preferably be utilised and all portions likely to suffer from arcing shall be easily removable. If rocker type contacts are used they shall be fitted with electro-magnetic arc control devices. The nominal current rating of a contactor for direct start motor drives shall be not less than 120% of the nominal full load current of the motor. Minimum current rating of contactors shall be 30 amps. Unless otherwise specified, operating coils shall be suitable for single phase a.c. supply and switching facilities but fitted with rectified d.c. coil and separate fuse for the control circuit.
GEN -12
GENERALITIES
0.2.2. CABLES AND THEIR INSTALLATION Except where specified otherwise in the Particular Clauses or on the drawings, cables shall have copper conductors. Makers test certificates shall commencement of installation. be submitted to the Engineer prior to
Neutral conductors shall be full size throughout. 0.2.2.1. High Voltage Cables Standards The materials and components associated with high voltage cables shall comply with the latest issue including all amendments of the appropriate
British and European Standard Specifications. Particularly relevant Standard Specifications are as follows: BS EN 10257-1
GENERALITIES
Galvanised mild steel wire for armouring cables. BS 6469 Insulation sheaths of electric cables. BS 6622 Cables with extruded cross-linked polyethylene or ethylene propylene rubber insulation for rated voltages from 3800/6600 V up to 19000/33000 V. BS 6746 PVC insulation and sheath of electric cables. Materials High voltage cables shall be three core, 6350/11000 volt grade with stranded circular copper conductors. High voltage cables shall be manufactured by an approved cable maker. If required samples of the cables shall be provided and tests shall be carried out to confirm compliance with the relevant Standards by an approved independent laboratory. Conductors shall be screened with a layer of semi-conducting compound and insulated with extruded XLPE. Each core shall be screened with an extruded layer of semi-conducting compound, a semi-conducting tape and a plain copper tape in the form of a helix. The screened cores shall be laid up with suitable fillers to form a compact circular assembly with a suitable binder applied over the laid up cores. Bedding shall be an extruded layer of black PVC compound. The cable shall be armoured with galvanized steel wires with a coating of bitumen applied over the armour and over sheathed with an extruded layer of black PVC compound. Cable Terminations Cable terminations shall be made using an approved proprietary termination kit, shrouding kit and armour terminating gland. The termination kit shall include core cleaning materials, taped stress control materials, mastic tape for the crutch seal and self amalgamating tape. The shrouding kit shall include heat shrink shrouds for the crutch, cone and termination. Cable lugs shall be of the correct size and type and be jointed by means of a hydraulic crimping machine. Cable tails shall be of the correct length to allow the cores to be evenly spread and to avoid any unnecessary strain being applied to the cores during the termination process.
The armour terminating gland shall be complete with an earth tag, lock nut and shroud. A copper earth tape shall bond the gland to the equipment to which it is connected.
GENERALITIES
High voltage cables shall be terminated by operatives skilled in this activity to provide a termination that complies in every respect with the requirements of the manufacturer of the termination kit.
0.2.2.2. Low Voltage Cable
Mineral Insulated Cables All MI cables used shall be approved manufacture to BS 6207: 1987, with copper conductors and PVC sheathed over all, unless otherwise specified. Fire alarm cables shall be 500V grade. All other services shall be 750V grade. The ends of all MI cables shall be sealed by means of the cold screw-on pot type seals and associated glands. Cable gland plates for single core cables shall be slotted between each cable entry, All seals are to be of the "Earth tail seal" type. Where PVC served cables are specified cable glands shall be enclosed in suitable PVC shrouds. Where connections are to be made to busbars cone grip connecting lugs shall be employed. The ends of all MI cables shall be taken into earthed enclosures. No type of unfixed connector shall be used. The glands of MI cables shall be connected to fuse switches, distribution boards, and adaptable boxes by locknuts or where space is limited by means of smooth bore male brass bushes, compression washers and galvanized sockets for multicorecables. Non-ferrous sockets and locknuts shall be used for single core cables. All MI cable terminations shall be clearly marked with coloured sleeves. The insulation resistance of cables shall be tested immediately after installation and termination, using a 500V or 750 volts d.c. instrument as appropriate. Further tests shall be carried out not less than 24 hours after the cables have been sealed. Groups of cables shall be run on perforated cable trays, otherwise cables shall be secured by two screw fixing type copper saddles at 350mm centres on vertical runs and 220mm centres on horizontal runs. Saddles shall be PVC covered when used with PVC sheathed cables. Cable fixings on unplastered walls shall be provided with suitable distance pieces. Cable tray supports shall be fixed at intervals not greater than 1000mm. A through joint will only be permitted if a run of MI cable is of such length that is exceeds the maximum to which the cable can be manufactured. Such a joint
GENERALITIES
shall be made within an adaptable box, in which shall be fitted a fixed base mechanical clamp type connector of approved design. In such joints, all the cores forming a circuit shall be jointed in a common box. This applies both to single and multicore cables. Where MI cables cross expansion joints they shall be double set across the joint. A loop shall be introduced in an MI cable immediately before its entry into equipment subject to vibration or occasional movement A clear space, minimum 12mm, shall be maintained at the point in the loop where the cable passes over itself. All conduit fittings and accessories used in conjunction with MI cables shall be galvanized. Soldered, cone grip or approved crimped lugs shall be used for cables larger than 2.5mm2 which are connected to studs or pillar type terminals. PVC and XLPE Insulated Cables All sub-main circuit PVC and XLPE insulated and sheathed cables shall be 600/1000 volts grade. The cable core shall be readily identifiable by colours or numbers. Where numbers are used the intervals between adjacent numbers on the same core shall not exceed 75mm. Unless indicated otherwise armored cables shall be covered with a single wire layer of galvanized steel 2 wire. Multicore cables up to l6mm shall be PVC insulated. Cables above 16mm 2 shall be XLPE insulated. All outdoor cables shall be Steel Wire Armored type and Cable supports shall be in accordance with relevant manufacturers recommendations, 400mm horizontal and 500mm vertical maximum spacing. Cables shall be terminated by means of corrosion resistant brass glands with cone grip armour clamps. In outdoor situations the terminating glands shall be covered with plastic shrouds to give protection against moisture and corrosion. All cables drawn into conduit shall be PVC insulated 600/1000 volts grade with copper conductors. Conductors shall be stranded and none smaller than 2.5mm 2 will be permitted.
The cables shall be looped progressively from point to point and no joints will be permitted. Cables shall not be bunched or pass through the same conduits or draw boxes, if derived from separate distribution fuse-boards or fusesswitches. The cables for each section of the installation shall be confined to the conduit and draw box system for that particular section. Cables for separate sections may, however, pass through the same adaptable box provided the circuits are separated physically by means of fixed barriers within the box and separate covers are provided for each section thus formed.
GENERALITIES
The number of cables in any conduit shall not exceed the number stated in the local or International regulations. All cables shall be colour coded in accordance with local Regulations. Flexible cords shall be PVC insulated and PVC sheathed 300/300 volt or 300/500 volt grade as required. The colour of the PVC sheathing shall generally be white. Flexible cords shall not be used where they cannot be readily seen or inspected and shall not support lighting fittings without the Engineers prior approval in writing. No flexible conductor small than 0.75mm 2 shall be used. Core identification shall be phase/brown, neutral/blue and earth/green-yellow. Circuit protective conductors incorporated in PVC insulated and sheathed twin and multicore cables shall be sized to suit the circuit requirements and in any case shall be 1.5mm2 minimum. The materials and components associated with low voltage cables shall comply with the latest issue of the appropriate British and European Standard Specifications. Particularly relevant Standard Specifications are as follows: Galvanised mild steel wire for armouring cables. BS EN 10257-1 BS 3858 BS 4579-2, BS EN 61238-1 BS 5467 BS 6004 BS6121-1 BS EN 60702 BS 6346 BS6360 BS 6387 xBS 6724 BS6746 C BS 7629 BS7655 Specification for binding and identification sleeves for use on electric cables and wires. Performance of mechanical and compression joints in electric cable and wire connectors. Armoured cables with thermosetting insulation for electricity supply. PVC-insulated cables (non-armoured) for electric power and lighting. Metallic glands. Mineral insulated cables with a rated voltage not exceeding 750V. PVC-insulated cables for electricity supply. Conductors in insulated cables and cords. Specification for performance requirements for cables required to maintain circuit integrity under Specification for armoured cables for electricity fire conditions. supply having thermosetting insulation with low emission of smoke and corrosive gasesof when affected by fire. PVC insulation and sheath electric cables. Specification for thermosetting insulated cables with Specification insulating and sheathing limited circuit for integrity when affected by fire. materials for cables.
GEN -17
GENERALITIES
0.2.2.3. Cable Termination Cables shall be terminated in the cable boxes provided with the equipment covered by this Specification. New cable boxes for terminating cables in existing equipment shall be provided as required. All terminal boxes shall be fitted with screwed, tapered or stepped brass wiping glands. Earthing clamps shall be provided with cable boxes for all lead alloy sheathed cables. Provision shall be made for earthing the body of each cable box. Joints in PVC or XLPE cables shall not be carried out without the written approval of the Engineer. Low tension cable joints shall incorporate compression type ferrules with polyethylene tape insulation housed m a plastic joint box and sealed with cold pouring resin filling. The ends of each XLPE/SWA/PVC cable shall be terminated in brass compression type cable glands of the correct size which shall secure the cable inner sheath and ensure effective electrical continuity between the cable armouring wires and the metal enclosure on which the cable is terminated. A copper earth link shall be taken from the cable termination point to an associated sub-switchboard or main switchboard earth bar. XLPE cables shall be terminated similarly to PVC armoured cables. Where cables are required to be terminated in terminal boxes or other equipment supplied under another Contract, the Contractor shall be responsible for carrying out the terminations in accordance with the requirements specified above including the supply and jointing of tails where necessary and the testing to verify correct phasing of all cores. Where single core cables are used, all necessary precautions shall be taken to prevent hysteresis. Ferrous plates through which the cables pass shall be slotted and brass glands and sockets shall be used. Single core cables shall be very rigidly clamped to prevent distortion under short circuit conditions.
0.2.2.4. Cable Laying Wherever the installation involves the laying of certain sections of cable direct in the ground trenches prepared within the Contract, the Contractor shall protect the cables with reinforced concrete or approved PVC covers, all cables drawn into prepared pipes or ducts shall be effectively sealed where the cables enter substations or buildings to prevent the entry of water and vermin. Where required by the Engineer duct entries into manholes shall be suitably sealed, after the installation of all cabling. The invert levels of all pipes or ducts entering a building shall be such that the pipes or ducts slope away from the building. Should the pipe or duct entry into a building be below the water table puddle flanges shall be incorporated. Where cables are laid direct in the ground 75mm of sand or riddled earth shall
GENERALITIES
be placed at the bottom of the trench to form a bed for the cables. When the cables have been laid they shall be inspected and approved by the Engineer. They shall then be covered with similar riddled sand/earth which shall be punned around and over the cables to a level of 75mm above the top of the cables. Where more than one horizontal layer of cables is to be laid similar sand/earth bedding and cover shall be provided for each layer. Protective covers shall be placed centrally over the cables, each cover being closely butt jointed and interlocked with the adjacent covers throughout the length of the cable. No final filling in of trenches shall be commenced until the Engineer has approved the placing of the protective covers. After any cable has been laid and until the whole of the cables to be laid in the trench have been covered with protective covers, no sharp tools or other appliances shall be used in the trench or left in such positions that might result in damage to the cables if they fell into the trench. Any rollers used for the cable laying operation shall be free from all sharp projections liable to cause damage to the cables. The Contractor shall be solely responsible for ascertaining whether the soil is chemically active and for taking special precautions to protect the cables against chemical action. The Contractor shall take precautions to avoid electrolytic and/or electro-chemical action occurring in situations where the cable and accessories are likely to be installed in close proximity to other dissimilar metals in the presence of moisture. The arrangement of cables, all methods of laying and installation shall be agreed with the Engineer, which shall be planned to provide an orderly formation, free from unnecessary bends and crossings, permitting the removal of any one cable without undue disturbance to adjacent cables. Where ducts have been laid the Contractor shall ensure that they have been rodded and cleaned to remove all foreign matter before the cables are drawn in. After cables have been laid in accordance with requirements specified the trenches shall be filled in by the Contractor and the refilled trench shall be left and maintained in a thoroughly safe condition until the work of permanent reinstatement is carried out. Cable ducts shall be internally glazed vitrified clay with plastic flexible sleeve joints or PVC or pitch fibre type. Cables shall be identified in all manholes and at equipment by an insulated tag or tape with the circuit identification inscribed thereon. Cables shall have the phases and the number and sizes of cores identified with a letter or numerical designation in all manholes and switchboards. The designation shall be on noncorroding material which shall also be resistant to chemical degradation. Cables running through formed ducts shall be fixed with reinforced industrial nylon or aluminium alloy cable cleats bolted to vertical or horizontal mild steel channel supports embedded in the duct walls at 600mm fixing centres.
GEN -19
GENERALITIES
Cables passing under roads shall be drawn through full round ducts 600mm below ground level for cables up to 1 kV, 1000mm below ground level for cables up to 11 kV. Cables laid in direct ground shall be buried minimum 600mm for 1 kV rating and 800mm for 11 kV rating below ground level. Marker posts shall adequately (Every cable diversion& minimum 35mtr spacing shall be maintained for normal area) indicate the routes of all buried cables. They shall be reinforced concrete units fitted with lead inserts bearing cable sizes and references. The marker posts shall extend above ground level or shall be flush with the final ground level, as specified. 0.2.2.5. Cable Sizing Cables as specified are sized to take account of volt drop, grouping, protection and environmental conditions. major cable routes are indicated on the drawings and these shall be adhered to. Cable sizes for final circuits are based on direct routes from the distribution equipment to the respective loads, with due allowance made for routing around the structure and other services. All cables/wiring indicated as to be laid externally shall be armoured type Cables shall not be installed in or through thermal insulation except where they are required to pass through fire barriers. Any instance where the thickness of the fire barrier exceeds 300mm shall be brought to the attention of the Engineer prior to installation of the cables. In exceptional circumstances where the Contractor considers that the installation will be improved by installing cables in or through thermal insulation he shall submit full details to the Engineer for approval, including calculations showing the dating effect on cable sizes and relative costs. Any cable lengths indicated in the Contract Documents are shown only as a basis for design. It is the responsibility of the Contractor to ascertain actual cable lengths, include for the actual lengths in his tender and provide materials accordingly. If any cable length varies significantly from that indicated or implied in the Contract Documents, the Contractor shall provide the appropriate calculations to show that the cable is suitable for the intended load. Similarly, if any loads vary from those envisaged in the Contract Documents, the Contractor shall show that appropriate cables will be provided to suit. Each cable is sized in the Contract Documents on the basis that at no point along its length does the grouping exceed the maximum allowable for the conduit or trunking enclosing the cable along the major part of its length.
0.2.2.6. Cable Covers Cables laid direct in the ground shall, after being covered with approved filling, be covered by reinforced concrete or approved PVC cable covers, of suitable
GENERALITIES
size laid centrally above the cables they protect, adjacent covers being close butted and interlocked. The covers shall be adequate width to protect the cable or group of cables and provide a minimum overlap on each side of 50mm. This arrangement shall be maintained as far as is practicable at bends in the cable route. The covers shall be of approved design. Suitable lettering warning of Danger shall be cast in the upper surface of each cable tile in English and in the National language. Approved PVC warning tape shall be laid 300mm above the cable tiles and shall be 300mm below ground level. 0.2.2.7. Conduit Installation The number of wires and sizes of conduits indicated on the Drawings are a guide only and are not necessarily the correct number and sizes necessary for the actual equipment installed. The Contractor shall install as many wires and conduits as required and necessary for a complete electrical system, and shall provide adequately for the equipment actually to be installed Unless otherwise specified the whole of the various installations described shall he carried out in screwed heavy gauge welded steel conduit, or heavy gauge PVC conduit. No conduit less than 20mm diameter will be permitted. Where a conduit run passes from a concealed area to a surface area, the whole of that conduit run shall be carried out using galvanised conduit. Conduit runs shall, wherever possible, be concealed in ceilings, voids and walls, chases etc., and in rooms of secondary importance (with back outlet entries to switch boxes etc., especially on fair faced brickwork) otherwise the conduit shall be securely fixed to the surface of wall using heavy cast distance saddles. Where the system of wiring is concealed, the "looping-in" system of conduit shall be used. All steel conduit and accessories shall be heavily galvanised. Surface installed conduit shall be supported using distance pattern saddles fixed with nonferrous screws. A surface installation is defined as one where the conduit is installed on a surface of the building finishes and is normally visible. All other installations are described as flush or concealed. Where conduit risers are installed in multi-storey buildings, a substantial rightangle shall be interposed at every third storey, to ensure adequate support of the installed cabling preventing undue stress on the terminal connections. A separate insulated earth conductor, coloured green, shall be run in all conduits and earth facilities shall be provided at all terminal points.
GEN -21
GENERALITIES
Wherever the installation is specified as being flameproof, conduit runs entering these areas shall have a barrier box inserted in the run immediately before the conduit passes into the flameproof area. All conduit work inside the flameproof area shall be carried out with solid drawn galvanised conduit and all conduit fittings, sockets and accessories shall be galvanised and certified suitable for the hazard as specified. At the completion of wiring all machined faces of the accessories shall be thoroughly cleaned and greased prior to the screwing or bolting of all accessory cover plates into their final flameproof secured position. All exposed threads, bends and any damage to the galvanizing shall. be painted immediately after erection with a zinc rich cold galvanizing paint. PVC tube not exceeding 25mm in diameter shall be bent cold by means of the appropriate spring and the tube shall be saddled as quickly as possible after bending. When bending large sizes of tube, the tube must be heated in the approved manner until it is pliable. A normal 90 bend shall have a radius of not less than five time the outside diameter of the tubes. Joints between conduits and conduit fittings shall be watertight and shall be made by means of a solvent adhesive as recommended by the manufacturer. care should be taken to ensure that the tube is clean and free from damp and grease and in particular dust, mould and oil. The Contractor shall provide PVC tube ends and flexible covers to prevent ingress of concrete grout into the tubing and boxes. All bends are to be made on site to suit conditions and not more: than two right angle bends will be permitted without the interposition of a draw box. No tees, elbows, sleeves, either of inspection or solid type will be permitted. Generally long straight conduit runs from point to point shall have draw boxes installed at maximum intervals of 10 meters. Deep boxes or extension rings on standard circular conduit boxes shall be used where necessary in order to bring the front of each box flush with the surface of the ceiling or wall., Where conduits are laid direct on the shuttering of the reinforced slab construction conduit extension rings or deep boxes shall be used to raise the run of conduit to between the top and bottom reinforcing. PVC tape shall be installed around butt joints on extension rings to prevent the ingress of wet concrete. galvanized draw wires shall be provided where conduits are not to be wired on completion or are to be wired by others. All draw boxes and junction boxes shall be of ample size to permit the cables being drawn in and out. They shall be made of malleable iron with the jointing surface machined to ensure a dust tight joint. All circular boxes shall be provided with long spouts internally threaded incorporating a shoulder for the proper butting of the conduit and a solid brass earth terminal tapped and screwed into the base of the box. All conduit boxes shall be fixed to the structure of the building independently of the conduit by countersunk brass wood screws of appropriate size. Holes in
GENERALITIES
boxes should be adequately countersunk- to ensure the complete recession of the fixing screws. All inspection and draw-in boxes shall be provided with covers fixed by round head brass screws. Where conduits turn through walls back outlet boxes shall be provided. Conduits shall be fixed at 1750mm centres on vertical runs and 1500mm apart on horizontal runs unless specified otherwise in the Particular Clauses. Vertical conduit runs shall have saddles at 300mm maximum from their points of emergence from floors or ceilings, and the remaining saddles shall be fixed consistent with the requirement of spacing and appearance. Saddles shall be fixed on each side of every bend at 300mm maximum from the points of intersection of the centre lines of the conduits. All branches of conduit shall be taken off at right angles. Diagonal runs will not be permitted. Conduits in ceiling cavities shall be supported independent of the suspended ceilings. Where conduits cross expansion joints, the Contractor shall allow for the installation of expansion couplers at the position of the expansion joint and at right angles to it. He shall provide a bonding earth wire between each terminal fitted in the nearest conduit boxes each side of the coupler. All flexible metallic tubing shall be galvanized watertight pattern fitted with sweated brass adaptors. External earth conductors, wrapped around the tubing, shall be provided. Where conduits are laid in slab floors etc., the Contractor shall arrange for a competent person to be in attendance whilst the concrete pouring or screening operation is being carried out, in order to avoid damage being caused to the conduits and also to ensure that the conduit work is in sound condition, properly and efficiently maintained during this installation period. Particular care shall be taken when setting out conduit runs to outlet points which are to be fitted to furniture, kitchen fittings etc. The Contractor shall ascertain exact details of furniture and fittings constructions in order that all conduit work shall wherever possible be concealed. Conduits installed in, chases of walls and floors shall be firmly and securely fixed by wrought iron pipe hooks or crampets and these fixings shall in themselves be sufficient to hold the conduits in place. Conduits installed in chases shall be painted with one coat of bitumastic paint before erection and a further coat shall be applied to all accessible surfaces including the hooks and crampets after erection. Recessed conduit buried in plaster shall permit a full 6mm depth of cover over its entire length.
GENERALITIES
Provision shall be made for the tapping of condensed moisture. Care shall be taken to prevent water, dirt or rubbish entering the conduit system during erection. Screwed metal caps or plugs shall be used for protecting open ends. All conduit systems shall be erected completely with all conduit accessories connected, it shall then be offered for inspection and approval by the Engineer before any cables are installed. Conduit boxes shall be fixed to the structure of the building independently of the conduit except where drilling the box will break down any requirements for weatherproofing. In positions where the appearance of the conduit run is likely to be improved by the introduction of dummy lengths of conduits and where a more secure fixing for the suspension of fittings would be obtained, such dummy conduits and continuations shall be provided. Where a conduit is exposed to different temperatures (either by surrounding air conditions or by virtue of the surrounding medium with which it is in contact) at any particular time, the section of the conduit at the higher temperature shall be isolated from the section at the lower temperature by means of a conduit box filled with an approved permanently plastic compound, after completion and testing of all wiring. Such a condition would arise if a conduit running in a warmed building is run to exterior points. Where galvanised conduit is specified all conduit, accessories, switchboxes and all associated apparatus used in the installation must be galvanised (unless otherwise directed by the Engineer). Galvanised conduit shall be used when mounted outside a building, installed in floor trenches subject to dampriess or accidental flooding, or buried in the ground. The conduit system shall be weatherproof when erected outside a building. Exposed conduit threads shall be given a coat of zinc rich paint. Conduit buried in the ground shall be wrapped with Denso Tape half lapped. The taping shall extend for a distance of 150mm beyond the point where the conduit emerges from the ground. Joints in galvanized conduit systems shall be made watertight using lead, aluminum paint and hemp and/or gaskets. The joints shall be partially screwed up before the paint and hemp are applied to maintain continuity. All adaptable boxes shall be grey iron pattern unless otherwise specified. Where adaptable boxes are fitted flush, the cover plates shall be heavy gauge metal with l2mm overlap on all sides . All internal depth of a box shall not be less than 40 mm. Covers shall be secured by a screw at each comer and by additional screws as necessary to provide a maximum spacing of 300mm between adjacent screws.
GENERALITIES
Fixing screws shall be brass (round or cheese head). Covers for boxes shall be of the same material as the box. For boxes mounted in weatherproof situations, the cover shall have a machine surface around the perimeter mating with a similar machined surface on the box and shall be complete with gasket. Every flush outlet box to which a luminaire pull cord switch or similar is to be fitted shall, unless otherwise specified be fitted with approved type break joint ring. 0.2.2.8. General The contractor shall supply and install trunking for cabling as shown on the drawings and as herein specified. The system shall include, but not limited to standard rectangular trunking sections, bends, terminations, conversions, reducers, offsets, risers and all necessary parts to install a complete trunking system. Manufacturers standard fittings shall be used for all connections and changes in directions. Cutting and bending trunking to form flanges and attachments will not be permitted. Standard lengths of trunking used shall not be less than two meters. Cable retaining straps shall be fitted at intervals not exceeding 1 meter. Where trunking passes through walls, floors, and ceilings, non combustible, nonmetallic fire barriers shall be installed in the trunking. Metal Trunking Metal trunking shall be manufactured generally in accordance with the requirements of BS 4678:Part 1. Metal thickness for body and cover material shall be at least as stipulated in Table 1 of BS 4678. Trunking and connectors for internal use shall be finished with class 1 protection in according with BS 4678:Part 1. Where used externally, protection shall be class 3. Lengths of trunking shall be bonded to each other by using strip copper jinks not less than 12 mm wide x 1.65 mm thick and fixed with brass nuts, bolts and serrated washers. Lids shall be fixed at intervals not exceeding 1 metre by using quick release cam type fasteners. Steel screws and fasteners shall be protected against corrosion by a finish at least equivalent to zinc coating to BS 729 or BS 3382: Part 2. Trunking shall be bonded to earth at several point connections, as required. Vertical trunking shall be supplied with cable support unit with insulated pins at
Cable Trunking
GENERALITIES
intervals not exceeding 3 metre. Horizontal trunking sizes exceeding 100 mm x 50 mm shall be supplied with cable separators with insulated pins at intervals not exceeding 2 metres. All burrs rough edges caused due to any cutting or damage during erection shall be removed and the finish shall be made good. Corrosion patches if any, caused during storage and erection shall be removed and the affected area shall be treated with rust-proofing agent. Zinc rich epoxy primer of equivalent alternative shall be applied on the treated surfaces. In case of class 2 finishes this shall be followed by a coat of colour matching paint. Any fixing used for securing or fitting shall not cause any long term corrosion or electrolytic action. Where brackets are used, they shall be constructed of mild steel angle or channel iron finished to the same standard as the trunking. Connections to conduit, switchgear, junction boxes and distribution boards shall be made with flanged units. A trunking joint shall be made where a trunking crosses an expansion joints. The earth continuity links across such joints shall be of braided copper tape not less than 15 mm wide x 2 mm thick having a resistance from fixing to fixing equal to or less than the links used for standard trunking joints. PVC Trunking Construction of PVC trunking and its accessories shall comply with BS 4678:Part 4. Trunking shall be made from high impact rigid PVC of thickness not less than 1.5 mm. Concealed trunking shall be of medium classification (IP42) and surface trunking shall be of heavy classification (IP53). Lids shall be of the clip on type construction. All trunking accessories shall be of the same manufacturer. Site fabricated accessories shall not be acceptable. Where the trunking is installed in ambient conditions higher than 25 degrees centigrade, trunking joints shall accommodate 7 mm expansion for every 6 metres of trunking run. Protective conductor of not less than 2.5 mm2 with green and yellow insulation shall be installed throughout the length of the trunking, to allow looping in and out of metallic equipment and accessories. Installation Trunking shall be securely fixed to walls, ceiling or multibeam trunk to the approval of the Engineer. It shall be installed such that it shall not be obstructed by other trades. Adjoining sections shall be securely fastened together to provide a rigid joint. The sum of cross-sectional areas of all contained conductors shall not
GENERALITIES
exceed 20% of the interior cross-sectional area of the trunking. Trunking shall include all necessary cable retainers. Runs of trunking shall be parallel or perpendicular to walls and partitions. Supports Trunking when run horizontally shall be Securely supported at intervals not exceeding 1.5m, unless specially approved for supports at greater intervals, but in no case shall the distance exceed 3 m. All cables installed in trunking shall be laced and identified in an approved manner. Clips shall be at 600mm centres. vertical cable trunking shall be fitted with cable pin racks arranged to avoid any strain on the cables. All trunking shall be rust proofed, primed and painted, and fixed at intervals not greater than 1000mm.
0.2.2.9. Cable Tray
Cable trays shall be manufactured from cold rolled mild steel to comply with BS 5750. Cable trays shall have a perforated construction. All accessories used such as bends, intersections, risers, reducers, etc, used in cable tray installation shall be factory made and of the same manufacturer as that of the cable tray. Cables shall be laid in a single tier on the cable tray, unless otherwise approved and neatly installed. Cable tray shall only be cut along a line of plain metal (not through perforations). All cut edges shall be prepared and treated accordingly to original Finish of metal. Where welding had been employed in fabrication and also on galvanized tray, a zinc rich paint shall be used for this treatment. Holes cut in cable tray for the passage of PVC covered cables shall be provided with grommets or alternatively bushed and/or lined to prevent damage to the PVC covering. Cable tray shall be manufactured from perforated mild steel and shall have hotdipped galvanised finish. Cable trays shall have the following dimensions Width (mm) 100-150 225 300-450 600-100 Flange Height (mm) 13 13 20 20 Thickness (mm) 1.5 1.5 1.5 2.0
GEN -27
GENERALITIES
Bends and tees shall. be made of the same material, finish and thickness as straight trays. At each end of the bends and tees, a minimum of 100mm straight run shall be provided. Cable trays shall be supported by mild steel galvanized brackets at regular intervals of 1,2mm maximum and at 255mm from bends and tees. Mushroom-headed steel roofing bolts and nuts shall be used for the installation and coupling of trays. Cable tray brackets shall be sufficient depth to provide access to the rear of the tray for easy installation of PVC saddle type fixings. All cables shall be secured to cable trays by means of PVC covered copper saddles of the two screw fixing type or PVC covered metal strip with noncorrodible cheese-headed screws and nuts. The shanks of the screws shall be protrude beyond the nut by more than three threads. Alternatively purpose made cable fixing devices may be proposed for consideration. Horizontal and vertical clearance between cables shall be such that no reduction in rating is necessary. A continuous run of 25mm x 3mm tinned copper strip shall be installed to the full length of the trays to ensure earth continuity. Jumper links shall be provided for all breaks in cable tray and at connections. A complete run of tray shall be earthed using 25mm x 3mm tinned copper strip as necessary. Unless otherwise specified, the contractor shall be responsible for selection of the correct grade of cable tray to meet the site conditions and the requirements of these specifications. Joining of various sections of the cable tray and its accessories shall be done in accordance with the recommendations of the manufacturer, or alternatively by using rustproof mushroom head roofing bolts, nuts and washers. Cable tray and its accessories shall have a hot-dip galvanized finish to BS 729. Any damage caused to the tray during installation and/or storage, shall be repaired by using zinc rich epoxy primer or equal alternative, followed by a generous existing metal coating. The joining bolts, nuts and washer shall be of galvanized steel. Brass shall not be used. A minimum clear space of 25 mm shall be kept behind all installed runs of cable tray. Cables shall be installed on the trays in a single layer leaving 25 percent spare space on the tray for future use. Cable trays shall provide direct support to the cables without cleats or saddles wherever practicable. Purpose made straps, cleats or saddles shall however be used to maintain a neat or regular disposition of cables. In vertical tray installation or where trays do not directly support the cables, load bearing cable cleats or saddles shall be employed and securely fixed to the tray. Manufacturers recommendations shall be followed in selection of cable cleats or saddles, on the basis of individual application.
GENERALITIES
Electromechanical continuity shall be maintained throughout the run of cable trays. Trays carrying LV cables shall be bonded to earth with green/yellow PVC insulated single core stranded copper cable. Trays carrying HV cables shall be bonded to earth with copper strip. HV and LV cables shall be installed on separate cable trays. MIC cables shall not be installed on galvanized cable tray.
0.2.3. GENERAL LIGHTING AND POWER 0.2.3.1. Alignment of Accessories The Contractor shall pay very particular attention to the method of fixing of outlet boxes so that they shall, when completed, be level and in an exact position relative to the finished surrounding surface to permit the cover plate to be fixed accurately. Where conduit work is to be concealed, the Contractor shall take full responsibility for the alignment of outlet boxes and shall ascertain a definite datum line from which all measurements can be taken, and also the thicknesses of wall, depths of finished plaster and final finishes of all relevant surfaces. Switches/sockets installed in the exposed, external areas, car parking area, plant rooms, pump rooms shall be of heavy duty metal clad industrial and weather proof IP56 Type switch/Socket Outlets. Socket Outlets These shall be switches, complying with BS1363-2:1995 and shall be installed in the position shown on the Drawings and shall be of the 13 amp flat pin, Double pole type. The socket outlets shall match the chosen lighting switches in that particular room or area. Switched socket outlets shall comply with BS1363-2:1995. The switched socket interior shall be mounted to the grid which shall have provision for both lateral and vertical adjustment. The grid shall be of 16 s.w.g. mild steel, zinc plated to a minimum of 5 microns thick.
GENERALITIES
The front cover plate shall be secured to the grid plate and switched-socket interior by countersunk screws finished to match the cover plate. For flush installations the cover plate shall overlap the box by 7mm and for surface installations it shall be the same size as the galvanized cast iron boxes which shall be employed in such locations. In plant rooms and similar areas the switch sockets shall be industrial pattern galvanized and on the roof all switch sockets shall be weatherproof Socket outlets shall be generally be of the DP switched 13 A 3 pin 220V shuttered patterned front plate with a fused plug top. Outlets shall be single or multigang as specified. Front plate shall be as specified. Socket outlets connected to 110 Volts a.c. supplies shall be of the round pin shuttered pattern fitted with D.P. switches and fully interlocked. They shall be non interchangeable with units of other ratings. Socket outlets mounted externally shall be galvanized water-resistant pattern fitted with machined joint and gasket, screwed brass plug top, screwed brass cover plates and securing chain , IP-56Type. Every socket outlet shall, unless otherwise specified, be provide with the appropriate plug top and fitted with a fuse of appropriate rating. Sockets outlets that are not supplied with fused plug tops shall be wired one socket outlet from an appropriately current rated fuse/MCB. Three phase socket outlets shall be four pole with earth connection and interlocked switch. Sockets outlets shall not be interchangeable for different voltage and each unit shall be effectively earthed and provided within an approved type plug. All 13 amp general purpose socket outlets shall be wired on the ring principle using a single core 4 sq.mm PVC stranded copper cable. Th e socket circuits are to be supplied from the MCB-boards and protected with 30A, 30mA, RCDs or ratings in accordance with the circuit lists.
Heavy duty mounting GI metal boxes shall be provided with earth terminals, an adequate number of knockouts and Adjustable lug complying with BS.4662. 0.2.3.2. 13 Amp Connection Unit (Spur Boxes) Wherever a 13 amp switch-socket is not suitable to tap-off a ring main or spur circuit, a connection unit shall be used. All such units shall be fitted with switches
GENERALITIES
and directly connected to the appliance served. Each connection unit shall contain a fuse of the appropriate current rating for the appliance it supplies, and the front plate shall be as specified and engraved with the name of the appliance. Connection units shall be connected into ring circuits wherever possible. 0.2.3.3. Switches Lighting switches shall generally be a.c. only" type capable of operating at their full rated capacity. Minimum rating of lighting switches shall be 20 A inductive. Switches shall be one way, two way or intermediate as required and where mounted together, they shall be fitted in a common box. For surface installations they shall be fitted with fixed grids and in flush installations the grids shall be adjustable with matching front plates as specified having a 6mm minimum overlap. Switches mounted externally shall be galvanized water resistant pattern fitted with machined box cover joint, neoprene seals and external fixings lugs. Switchboxes shall be suitably barriered and labelled where two or more phases are connected in the same box. Where d.c. lighting circuits are to be switched double pole quick make quick break switches with pillar type terminals and earthing straps shall be provided. Every switch controlling an appliance not visible from the switching position shall be engraved with the name of the appliance it controls, and where called for shall be fitted with 0.5 watt neon indicating lamp. Switches shall be 250 volt ac only rated with number of poles and amp ratings as indicated on the Drawings, to BS 3676 Part 1. Switches shall be fully rated for tungsten filament and fluorescent lamp loads, and up to 80% of rated capacity for motor loads. Switches shall be one gang or multi gang, 1-way, 2-way or intermediate as indicated on the drawings and to the approval of the Engineer. 20-Amp double pole switches shall incorporate a pilot light, and shall have the words "Water Heater" engraved on it when used for that propose. 30-Amp double pole switch shall incorporate the description indicating the purpose of its use. 45/50-Amp double pole switches shall incorporate a pilot light, and shall have the word "Cooker" engraved on it when used for that purpose. a) Switch Assemblies
GEN -31
GENERALITIES
Switch assemblies shall be of the grid switch system, comprising rockeroperated grid switches ,metal clad type and stainless steel cover plates, unless otherwise indicated. Switch assemblies shall comprise 20-amp lighting switches, and other units if so indicated on the Drawings. Switch assemblies shall have the words "Danger 415 volts" engraved in red in it. b) Dimmer Switch Dimmer switch shall provide separate dimming and switching function for the resistive and inductive loads to the approval of the Engineer. All electronic components shall be totally enclosed in a moulding. 400w Dimmer switch shall consist of a two-way 20-amp rocker switch and a rotary dimming control or Dimmer plate with electronic control. The rocker switch shall provide for independent on/off control at any level to which the rotary lighting control has been set. The dimmer switches shall comply with BS 800 for RFI suppression. The unit shall be fuse protected, and rated 415 watts at 240 volts and to the approval of the Engineer. 800W dimmer switch shall be suitable for flush mounting. The dimmer unit shall consist of a switch and a rotary dimming control with stainless steel cover plates or Dimmer plate with electronic control. The switch shall provide for independent on/off control at any level to which the rotary lighting control has been set. For Dimmer control plate above 1000 W the Dimmer power module shall be installed near the Final distribution boards, Only control wiring shall be provided to Dimmer control switch plate and the dimmer control plate shall be digital type with minimum 8 -scene setting facility. 0.2.3.4. Luminaires The Contractor shall provide, install and connect, including all necessary materials, all luminaires in accordance with the makes and types in the schedule of Luminaries, including lampholders, glassware, diffusers and ancillary equipment. Conduit or chain suspensions as specified shall be provided for all pendant fittings. The stem of conduit suspensions shall be screwed to ball and socket type dome lids with positive earth connection. Within plant rooms, ceiling mounted luminaires shall be complete with chain suspensions of adequate length to provide suitable illumination when all plant is erected. The final locations of luminaires within plant rooms shall be agreed on site with the Engineer to suit arrangement of plant.
GENERALITIES
White break joint rings shall be provided wherever necessary. Circuit cables shall not be routed through bulkhead or other fittings where the cables would be liable to undue temperature rise, but shall terminate in a fixed base connector in a conduit box mounted behind or adjacent to the fitting. Final connection to each fitting shall be carried out with silicone rubber or type 5 PVC high temperature insulated cable. Conduit terminations to all aluminium fittings shall be fitted with brass bushes to prevent corrosive action between the steel and aluminium components. Where PVC conduit is used the non-ferrous bushes may be replaced with an insulated pattern. Lamp-holders, with the exception of handlamps and fluorescent bi-pin units shall be of the nonferrous metal type. Lamp holders types E.S. and G.E.S. shall be so connected that the screw portion is in the neutral conductor. All fluorescent fittings shall be complete with quick starting control gear, power factor capacitors and lamps. The metalwork of all fittings and starting equipment shall be effectively earthed to the installation. Fittings without a shunt connected P.F. capacitor shaft incorporate a voltage dependent resistor to counteract surge voltages. All luminaires shall be cleaned using an anti-static cleaning fluid prior to final erection. The Contractor shall include for any modifications to the manufacturers standard luminaires to comply with the requirements relative to mounting height. in the event of extra long suspensions being required, these shall be ordered concurrent with the lighting fittings. Where lampholders are not supplied with the lighting fitting, the Contractor shall supply them and they shall be of an approved type and make. All fittings shall be suspended from or fixed to, a small B.S.S. conduit box, except where specified otherwise. Where lighting track is required for flexible display lighting or simple stage lighting it shall be complete with power supply box, connectors, fixing clamps, end plugs and spot-light adaptors. Each luminaire shall be complete with a lamp for each lamp way specified. Fluorescent lamps shall generally be white pattern. Tungsten lamps shall be clear type where enclosed and opal type where exposed. 0.2.3.5. Lamps All incandescent lamps, discharge lamps and fluorescent tubes shall conform to
GENERALITIES
the standard type of lamp cap required by each specific lighting fittings detailed. They shall all be of high quality manufacture, with each type of lamp used being in accordance with accepted standard of rated lamp life. All lamps of each type (e.g. tungsten, fluorescent) shall be by the same manufacturer.
0.2.3.6. Time Switches Time switches shall be self-contained units 24 hour or solar dial type as specified suitable for operation on the local low voltage a.c. supply. Solar dial type shall be complete with an automatic solar dial calibrated to applicable latitude, to permit accurate selection of switching times, selfstarting synchronous motor with a single pole fuse in the motor circuit, a 3-way terminal block and a 150 hours reserve. The switch shall be encased in a dust-tight metal. casing having a hinged front cover with a. clear perspex window. The casing shall be effectively earthed. Timer switches shall be 30 minute dial type, recess mounted with manual override switch. Switches shall have 20,000 switching cycles guaranteed life.
0.2.3.7. Safety Isolating Transformers Low voltage transformers with 55-0-55 V secondaries shall be double wound air cooled pattern contained in dust-tight cases. Separate windings shall be provided for the primary and secondary and the mid-point of the low voltage winding shall be earthed and an earthed screen provided between the windings.
0.2.3.8. Emergency Supplies Individual self-contained emergency lighting units shall be connected direct to the mains-supply and in the event of a failure the unit shall automatically connect to the battery housed within the unit. On restoration of the permanent supply the unit shall revert to mains operations. All units shall be surface pattern supplied complete with diffuser, rechargeable battery, changeover relay and silicone rubber covered cable interconnections. Each unit shall include solid state switching and the re-charge equipment shall enable a fully discharged battery to be fully re-charged within 14 hours. Facilities shall be included to prevent reverse polarity at low battery voltage. Each unit shall derive its supply from an unswitched circuit connected directly to the MCB or fuse serving the normal local mains lighting such that the battery is on automatic charge when the mains are healthy. 0.2.3.9. Mechanical Engineering Services Equipment All motors, fans, water heaters, thermostats, pump, chiller plant, kitchen
GENERALITIES
equipment, laundry equipment, boiler plant, filters, starters and associated plant control equipment will generally be provided under the mechanical engineering services section of the Specification. The Contractor shall include for the erection of electrical control equipment and final circuit wiring and connections to all mechanical services plant and equipment as detailed on the contract drawings. Final site commissioning and calibration of the mechanical engineering services installations will be carried out under the mechanical engineering services section of the Specification. The Contractor shall be responsible for ensuring that adequate instructions and connection diagrams are provided to enable the work to be completed. 0.2.3.10. Earthing The Earthing system shall be in full compliance with the requirements of the IEE Wiring Regulations, Local Authorities Practices and the Specifications. Any modification required by Local authorities shall be done at no extra cost. Unless otherwise specified all materials used for earthing shall be of copper or approved copper alloys, and shall be specially manufactured for the purpose. The complete earthing system shall be electrically and mechanically continuous to provide an independent fault current return path to the earthing source. Bolted connections shall be of the multiple bolt type. Bolts, washers and stop nuts shall be of high copper alloy. Ferrous hardware will not be accepted. Where earthing terminal connectors are brazed to equipment, the metal shall be thoroughly cleaned prior to brazing and the impaired surfaces repainted to prevent corrosion. The impedance of equipment (earth loop) at any point in the electrical wiring system shall be sufficiently low to limit the voltage to earth and to facilitate the operation of the circuit protective devices in the circuits, as required by the IEE Wiring Regulations. Otherwise earth leakage circuit breakers shall be used. Earthing Installation Two separate earthing installations shall be provided. One installation shall be the System earthing and the other shall be the Authorities Service Equipment Earthing. System Earthing The System Earthing shall consist of earthing pits connected in parallel if practicable, or shall consist of 95 mm2 ring (counterpoise) buried under ground at a depth of 1 meter minimum around the periphery of the building or substation if the latter is a separate structure.
GENERALITIES
Resistance of this earthing installation to earth shall not exceed 2 ohm. To this installation shall be connected: a) The neutral of the transformers) at the local authorities Low tension pillar or at the main distribution switchboard if the former is not provided. All Equipment earthing of the Electrical Works through a removable link at the Main Distribution Switchboard connecting the main earthing bus to the neutral bus. If no main switchboard is included in the works, a peripheral earth bus shall be provided in the Meters Room to which all the equipment earthing shall be bonded. The earthing bus shall in turn be bonded to the Local Authorities Low Tension Pillar neutral. The main earthing bus of the main and sub-main switchboard(s) if any shall be connected to the system earthing by a 95 mm2 bare copper cable via a 40 x 5 mm main earthing busbar fixed on the wall in an approved location. Service Equipment Earthing The service equipment earthing shall be a separate earthing installation consisting of earthing pits connected in parallel. These pits shall be at least 8 meters away from the system earthing if practicable otherwise the service equipment earthing shall be bonded to the system earthing and the combined resistance shall be less than 1 ohm. To this installation will be connected: the ring main unit earthing bar, the transformer(s) and HT switchgear tanks, HT cable sheaths, all exposed structural metal works including metal cable trays when the substation is situated above a basement. Connection material and sizes shall be as approved by the Local Authorities Equipment Earthing of the Electrical Works Equipment earthing of the Electrical Works shall consist of bonding all noncurrent carrying metal parts of the Electrical installation to the System earth ( TN-S system as per IEE Wiring Regulations, latest edition). Non-current carrying metal parts of the electrical installation shall include such items as cabinets, exposed metal parts of apparatus as well as enclosures, doors, grill, etc., protecting or shielding electrical equipment from direct access to unauthorized personnel. The series earthing of one piece of equipment to another will not be permitted. All equipment earthing connections shall be tapped from the applicable earth source. Unless otherwise specified or indicated on the Drawings, cable armour shall be accepted as equipment earthing conductors, provided they comply with the requirements of the Regulations.
GENERALITIES
All socket outlets, power apparatus, lighting fixtures and switches shall be earthed. No point on the neutral shall be connected to the earth system except as described under "System Earthing". Additional earthing pits may be shown on the drawings at different locations. These pits shall be bonded to the earthing bus of the relevant switchboards or panelboards as applicable in order to reduce the earthing resistance. Neutral at such points shall not be bonded to the earthing system. Joints and connection to the earthing system shall be so effected as to avoid undue reduction of the current carrying capacity and shall be approved. Special precautions shall be taken to ensure that the available contact area is fully utilised in all connections to plant and apparatus. The bonding connections to any gas or water services shall be made as near as practicable to the point of entry of these services into the building. Should there be an insulated section in the service run, the connection shall be made to the metalwork on the building premises side of the insulated section. These bonding connections shall be made with appropriate pipe clamps and precautions shall be taken to avoid damage to these pipes. The Contractor shall test every complete final circuit earth loop impedance comprising conduits, cable sheaths, core conductors, transformer windings and the general mass of the earth. Each of the entire conduit installations shall be electrically continuous throughout, forming completely bonded systems. The earthing rod shall be constructed from copper clad steel rod. Copper sheath shall be 99.9% pure electrolytic copper. The steel core shall be of carbon steel, with tensile strength min 97,000 psi yield strength at 0.2% offset 85,000 psi, proportional limit 57,000 psi, percent of elongation 13%. Rod shall be cold drawn. For telecommunications system equipment, a separate grounding / bonding conductors systems shall be provided and ended by its own earth electrodes which will be interconnected to the main earthing electrodes network. Any additional requirement for modifying the earth/soil resistivity in line with the requirements of the telecommunication suppliers requirements will be added in the specifications at a later stage.
0.2.3.11.
Bonding
The Contractor shall make provision to ensure that conductive parts which are simultaneously accessible to other conductive parts, are bonded to ensure that in the event of an earth fault, the voltage between all simultaneously
GENERALITIES
accessible parts are of such magnitude and duration as not to cause danger. This requirement shall include consideration of portable appliances connected from socket outlets. Where necessary, supplementary equipotential bonding shall be provided. In areas where the system of wiring is concealed, the supplementary bonding conductor shall also be concealed up to the point of termination. Tests shall be carried out during the construction to ensure that where supplementary bonding conductors are required, they can be installed within the construction programme and without the need to disturb finishes. The electrical continuity of mechanical services ductwork, pipes and plant is required under the Mechanical Services Section of the Specification. Under this section of the Specification, the Contractor shall complete the bonding to bring the mechanical services installation to an equipotential level with simultaneously accessible conductive parts. On completion of the installation, tests shall be carried out by the Contractor to verify compliance with this Clause. 0.2.3.12. Electric Shaver Outlets
Shaver outlets shall be insulated pattern, connected from local lighting circuits using the appropriate current rated cable size. Outlets shall be universal type with a dual voltage (230 or 110 Volt) output. Each outlet shall incorporate a double wound isolating transformer to provide an earth free supply and the primary circuit shall include a self-resetting thermal overload trip. Outlets shall be suitable for use in bathrooms.
0.2.3.13.
Mounting Heights
Equipment shall generally be installed in accordance with the following mounting heights and the measurement indicated shall be the distance between the finished floor level and the bottom edge of each unit. Any variations to the general mounting heights will be detailed on the drawings UNIT Lighting Switches (General) Sockets outlets Sockets outlets (Plant Room Areas) Sockets outlets in Kitchen above work surface. Fire alarms contacts Fire alarm bells MOUNTING HEIGHT (mm) 1350 450 1000 250 above work surface 1350 2200
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GENERALITIES
Fire alarm detectors mounted. Telephone outlets (Wall type) Distribution Boards
Isolators Flex-outlet plates (General) Bracket lighting points (General) Timer switches
Ceiling mounted 450 1800mm to Top approx. dependant on height of false ceiling. 1000 450 1900 -2200mm 1900
Note: Mounting arrangements of various switching accessories for Fron of House area shall be as per the latest ID details.
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GENERALITIES
GENERAL TECHNICAL REQUIREMENTS
0.2.4.
STANDARDS
Except where modified by this Specification, equipment and materials shall be in accordance with lEC (International Electrotecnical Commission), ISO (international Organization for Standardization) and BSS (British Standards Specification) recommendations, If relevant lEC, ISO and BSS recommendations are not available then relevant national standards shall apply, and such national standards shall be proposed by the Contractor for approval by the Engineer. When lEC or ISO or BSS recommendations, or national standards are referred to the Edition shall be that current at the date of Tender, together with any amendments issued to that date. If requested by the Engineer, the Contractor shall supply at his own expense three copies in English and one in the original language of any national standards which are applicable to the Contract. The whole of the electrical installation shall comply with the requirements of the current edition of the Regulations for Electrical Installations issued by the I.E.E. (Institution of Electrical Engineers), London, UK including the latest amendments thereto.
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GENERALITIES
0.2.5.DESIGN AND STANDARDISATION The Contract Works shall be installed to facilitate inspection, cleaning and repairs, and for operation in which continuity of service is the first consideration. All material and apparatus shall be of the best quality, designed to ensure satisfactory operation under the atmospheric conditions prevailing at the Site and under such sudden variations of load and voltage as may be met with under working conditions. The installation shall incorporate every reasonable precaution and provision for the safety of all those concerned in the operation and maintenance of the Contract Works and of associated works supplied under other Contracts. All apparatus shall operate without undue vibration and with the least practicable amount of noise. Operating boxes, kiosks, cubicles and similar enclosed compartments forming part of auxiliary equipment shall be adequately ventilated to restrict condensation and, where environmental conditions require, suitable integral lowtemperature heaters shall be provided. All contractor or relay coils and other parts shall be suitably protected against corrosion. All outdoor apparatus shall be so designed as to avoid pockets in which water can collect. Accessible means shall be provided for the easy lubrication of all bearings, mechanisms and moving parts. Grease lubricators shall be fitted with hexagon nipples. All mechanisms shall, when necessary, be constructed of stainless steel, brass or gunmetal to prevent sticking due to rust or corrosion. All connections and contacts shall be of ample section and surface for carrying continuously the specified currents without undue heating, and shall be secured by bolts or set screws of ample size, fitted with locking devices of approved type and material. All apparatus shall be designed to obviate the risk of accidental short circuit due to animals, birds and vermin. Openings in ventilated enclosures shall be so constructed to prevent the entry of vermin and insects. All apparatus incorporating doors shall be erected so that the doors can be opened to at least 90 after adjacent equipment has been installed.
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GENERALITIES
0.2.6. MANUFACTURERS STANDARDS Except where specified otherwise, all materials and equipment associated with the installation shall be handled and installed strictly in accordance with the manufacturers recommendations by workmen who have had previous experience of the equipment and materials and who have, where necessary, attended a manufacturers course on use and installation. The Contractor shall ensure that any special tools recommended by manufacturers for the installation of their materials and equipment are used by the workmen.
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GENERALITIES
0.2.7. GALVANISING Galvanizing shall be applied by the hot dipped process. The preparation for galvanizing a n d t h e g a l v a n i z i n g p r o c e s s s h a l l n o t a d v e r s e l y a f f e c t t h e mechanical properties of the material being coated. Pre-site drilling, punching, cutting, bending and removal of burrs shall be completed before galvanizing. Surfaces in contact with oil shall neither be galvanized nor cadmium plated, unless finished with an oil resisting varnish. The average thickness of the zinc coating shall be equivalent to not less than 0.6 kg/m2 of zinc for all surfaces, except steel wires. The thickness of the zinc coating for steel wires shall be in accordance with a national standard and shall be approved by the Engineer. 0.2.8. LABELS AND NUMBER PLATES
All equipment shall be clearly and permanently labelled, to the approval of the Engineer, in English. Where labels are provided for making clear the method of operation of apparatus, they shall be concise and preferably diagrammatic in form. Duplicate labels in the national language shall be provided whenever applicable. Labels shall be of the engraved traffolite type. Labels for similar equipment shall be of uniform appearance and size, and all labels shall be fixed by screws. Each item of equipment shall be marked with its function, manufacturers name or trade mark and the code or type number, together with the batch or serial number. Danger notices shall have red lettering on a white background. All other labels and number plates shall have black lettering on a white background. Generally lettering for danger notices shall be 10 mm high and all other lettering 6 mm high. All outdoor switchgear shall be clearly and permanently identified by number plates and phase discs of appropriate colours. The rating and circuit identification of each fuse shall be marked adjacent to the fuse base. The Contractor shall submit a schedule of labels for approval by the Engineer before engraving is carried out.
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GENERALITIES
0.2.9.
FIXINGS
Fixings to brickwork and block work shall be made in the bricks and blocks and not in the bond. Wood screws shall be zinc coated and machine thread screws shall be solid brass and greased before installation. Accessories mounted in fixed equipment shall incorporate adjustable slotted fixing holes. Heavy equipment shall be fixed with approved purpose-made clamp brackets, ragbolts or patent fixing bolts. Shot plugs or bolts shall not be used without the written approval of the Engineer. No structural steelwork shall be drilled for any purpose without the written approval of the Engineer. In general all fixings to steelwork shall be by means of studs welded to the stee1work or by clamp-brackets or hook bolts. Exterior steelwork fixings shall be galvanised. The supply and fixing of all supports, brackets, clamps and spacers and any other steelwork whether or not shown in detail on the drawings required for the proper and effective fixing of any equipment, shall be considered to be included in the material and labour covered by the supply and fixing of that equipment. Bolts and studs for electrical connections shall preferably be of brass M6 size minimum. Alternatively, size M5 may be used, but these must be of phosphor bronze or high tensile brass. Nuts shall be locked in position with lock nuts or lock washers, or castle-nut and split pin, or other devices if approved. Lock washers shall not be used above M24 size except when a spring type is specially approved. Bolts, nuts and washers on outdoor equipment shall be of non-corroding material where they are in contact with non-ferrous parts in conductor clamps and fittings and elsewhere if specially required. Suitable special spanners shall be provided for bolts and nuts which are not properly accessible by means of an ordinary spanner. 0.2.10. BUILDERS WORK Unless indicated elsewhere in this Specification, all builders work, cutting away and making good shall be carried out by the Main Contractor. The Contractor shall indicate where cutting away is required and will be held responsible for any extra costs incurred due to incorrect or inadequate marking out. Plugging of walls, floors and ceilings for the fixing of conduits, fitting and accessories shall be carried out by the Contractor. Details of all foundations for apparatus, construction of ducts, sumps, chases, etc,, structural steelwork, cutting away and making good in walls, floors, ceilings, etc., not detailed by the Engineer on the tender drawings shall be the responsibility of the Contractor who shall provide such drawings for approval by
GENERALITIES
the Engineer. The information shall be provided in sufficient time to allow the work generally to progress in accordance with the Contract program, but the Contractor shall be entirely responsible for the accuracy of the information given. 0.2.11. CLEANING AND PAINTING All ungalvanised ferrous surfaces, such as black steel pipe work, brackets etc. shall be painted one coat of anti-corrosive primer immediately after erection, and a further two coats of gloss finish on completion. The paint specification for all equipment supplied with a works finish shall be to suit the particular application, and shall be to the approval of the Engineer. 0.2.12. OIL AND GAS Unless otherwise specified sufficient oil or gas shall be supplied to fill oil or gas filled equipment provided under this Contract. The oil or gas shall be of appropriate type and suitable in all respects for use in the equipment when it is operated under the condition laid down in this Specification. The design and all materials and processes used in the construction of the equipment shall be such as to reduce to a minimum the risk of development of acidity in the oil or gas. Special measures such as nitrogen sealing or the use of inhibited oils are not required unless specified by the Engineer. 0.2.13. FIRE PRECAUTIONS All apparatus, connections and cabling shall be designed and arranged to minimise the risk of fire and any damage which might be caused in the event of fire. 0.2.14. RADIO INTERFERENCE All equipment shall be designed so as to minimize radio interference in the frequency range 0.15 MHz to 30 MHz by means of suppression at source. 0.2.15. PADLOCKS Padlocks or other approved locking devices for circuit-breakers isolating devices, control switches, valves, marshalling kiosks, cubicles, screened enclosures and other equipment shall be supplied under this Contract. All padlocks and other locks shall be provided with two identical operating keys. Each key shall have an engraved durable identification label. It shall be impossible to open any lock or padlock with the key of any other lock or padlock provided under this Contract. Locks or padlocks shall be in suites or areas provided with group master key facilities to the requirements of the Engineer.
GENERALITIES
Keys and locks shall be impressed with the manufacturers special serial number. Wall mounting cabinets with glazed doors suitable for the accommodation of keys, shall be provided and mounted in approved positions and shall be labelled in a similar manner to the keys, with a labelled hook arrangement for each key. The engraving on all labels shall be in accordance with an approved scheme. 0.2.16. TOOLS Where specified the Contractor shall supply in steel boxes, complete with keys, any special tools that may be required for making adjustments to equipment during normal operation or maintenance periods. All tools shall be of alloy steel and stamped with an approved identification. 0.2.17. EXPANSION JOINTS Building expansion joints may occur throughout the building works. Wherever the drawings indicate that such joints are installed the Contractor shall ensure that all pipes, ducts, conduits and cables crossing the joints are suitably sleeved, set and flexibly coupled across the expansion joint, adequately fixed each side of the joint and properly bonded. 0.2.18. EQUIPMENT DOCUMENTATION All documentation shall be in English and shall be provided by the Contractor. The number of copies and the dates of submission of the documentation shall be provided in accordance with the requirements of the Specification. All drawings, manuals, specifications, component lists, etc., shall have an issue or revision number and a record of modification. Equipment instruction manuals shall include circuit diagrams for each unit, plug in board and integrated circuit used in the complete equipment. 0.2.19. CONTRACT DRAWINGS The Contract Drawings are schematic and are intended to enable the Contractor to prepare his estimates and submit a tender. Where runs of piping, ducts, cable ways etc., are shown, they do not necessarily indicate exact locations within the confines of the building area concerned. The final locations of all such services, one with another and each with the building, shall be determined by the Contractor in the preparation of his Installation Drawings. Allowance shall be made in the preparation of Tenders to cover such deviations between Contract and Installation Drawings. 0.2.20. D R A W I N G S PREPARED BY THE CONTRACTOR FOR CONSTRUCTION (WORKING DRAWINGS) This section is to be read in conjunction with the Architects/Engineers to be
GENERALITIES
applied. Contract and requirements. The more onerous specification/requirement is Refer to the Architects/Engineers requirements for timing of submissions and for penalty clauses for non-compliance. Construction drawings shall be prepared based on the contract design (tender) drawings, Local authority requirements and contract specification for the consultant/ client approval prior to any installation works at site. Further to the Schedule of Drawings submitted with the Tender, the Contractor shall, within two weeks of the order to commence work, confirm the detailed schedule of all Installation and Builders-word Drawings to be prepared by the Contractor for the purpose of constructing the Works. The Schedule shall indicate the dates on which the individual drawings shall be submitted to the Engineer for checking, date for final issue and distribution and the date on which the work covered is due to commence on site in accordance with the overall Construction Program. Relevant dates for commencement of manufacture of plant items shall be included. Checking of the Contractors Installation and Builderswork Drawings by the Engineer, shall not relieve the Contractor of his responsibilities for compliance with the designs intent, co-ordination or with any other obligations and requirements under the Contract. The Contractor shall allow in his Tender for providing three copies of each drawing and schedule to the Engineer for checking and four copies including reproducibles for final distribution. All drawings prepared by suppliers, manufacturers and/or Contractors shall be endorsed with the Contractors own name title block and drawing number and the Contractor shall take full responsibility for such drawings in accordance with his obligations under the Contract. The scale and format of all drawings shall be to the approval of the Architect/Engineer. All drawings shall be prepared on AutoCAD, Release 14, by the Contractors ON-SITE CAD OFFICE. 0.2.21. RECORD DOCUMENTS AND DRAWINGS This section is to be read in conjunction with the Architects/Engineers conditions of contract and requirements. The more onerous specification/requirement is to be applied. Refer to the Architects/Engineers requirements for timing of submissions and for penalty clauses for noncompliance. The Contractor shall supply to the Engineer, as a pre-requisite to Practical Completion of the Works, comprehensive record documents finalized in detail and approved by the Engineer. The Contractor is advised that great importance will be placed upon the quality, accuracy, clarity and completeness of the record documents and upon their being made promptly available.
GENERALITIES
Within two calendar months of completion of the work, the Contractor shall prepare and hand over to the Engineer two sets of As Fixed drawings and operating and maintenance instructions for approval. On receipt of such approval, the Contractor shall issue to the Engineer three final sets of drawings, comprising one complete set of translucent negatives and two sets of white dyeline prints, and three sets of operating and maintenance instructions strongly bound in flexible covers and suitable for heavy usage over a long period. The final set of documents shall also be presented on CD ROM format. A practical completion certificate for the works will not issued to the Contractor until such operating and maintenance instructions and drawings are received and approved by the Engineer. A) The Contractor shall keep a full set of white prints on site showing the progress of all work in connection with this Contract. Such prints shall be kept up to date and all pipe work, ductwork, conduit and cable runs, outlets positions, equipment etc. shall be marked on the prints as they are installed. When any equipment comprises a complete installation in itself (e.g. fire alarm system), a separate set of drawings relating to that installation shall be included. In addition to these, additional copies of detailed layouts of main plant chambers, circuit diagrams, valve charts, and relevant plant information shall also be provided suitably framed and fixed in the respective plant chambers.
B) Operating and maintenance instructions shall be provided by the Contractor and shall comprise the following as applicable written to be read in conjunction with the Record Drawings: B1) A general description of the scope, purpose and manner of working to each system or apparatus forming part of the Works. B2) A detailed description of the scope, purpose and manner of working of each system of automatic controls and/or monitoring instruments. B3) Data on general design parameters operating temperatures, pressures the commissioning tests. and associated normal etc., based on
B4) Clear and comprehensive instructions for the starting up, running and shut down of each system or apparatus. B5) Instructions in respect of any precautionary measures from time to time necessary (e.g. against freezing or corrosion). B6) Instructions in respect of the care of apparatus normally subject to
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GENERALITIES
seasonal disuse B7) Instructions as to the nature, extent and frequency of servicing necessary properly to maintain the Works in good condition and as to the materials to be used for the purpose. This information may be supported in detail, but not replaced by maintenance instructions provided by the suppliers of particular component apparatus. B8) A list of recommended factory specified spare parts plus the names and addresses of suppliers of all major components of the Works as may potentially be required to obtain spare parts or replacements. C) Copies of manufacturers data with respect to the nature, type and method of operation of individual pieces of equipment together with their detailed maintenance instructions shall also be supplied. Such data, in the form of individual booklets and the like, shall be indexed and crossreferenced to the operating and maintenance instructions and presented, suitably protected in box files or folders. The Contractor shall demonstrate from time to time as required by the Engineer throughout the execution of the Works, that adequate and accurate records are being kept such as will ensure the ultimate completeness and accuracy of the record documents and that the record documents are themselves being progressively complied as the work on site proceeds. The record documents shall be adequate for the following purposes C1) To record clearly the arrangements of the various sections of the Works as actually installed and to identify and locate all components parts thereof. C2) To make it possible to comprehend the extent and purpose of the Works and the method of operation thereof. C3) C4) To set out clearly the extent to which maintenance and servicing is required and how, in detail, it should be executed. To provide sufficient and readily accessible information properly to facilitate the ordering of spares and replacements.
0.2.22. FAMILIARISATION The Contractor will be deemed to have, prior to tender, studied the full working drawings of the buildings, visited the site and to have acquainted himself with all relevant details affecting his work. Claims arising from neglect of this clause will not be entertained.
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GENERALITIES
0.2.23. PROTECTION OF UNFINISHED WORK All unfinished work shall be left in a safe condition, and any temporary supports necessary to give adequate protection from unauthorized interference shall be provided. When it is necessary to store any heavy equipment on the site the most suitable position shall be ascertained from the Main Contractor and the equipment shall be stored in such a manner as to prevent it falling or slipping. All trench or duct covers etc., shall be replaced on leaving the site or the immediate vicinity, and the ducts or trenches shall be adequately guarded to prevent accident. No responsibility for protection of the works can be under-taken by the Employer.
0.2.24. APPROVAL OF EQUIPMENT AND MATERIAL All plant and material is subject to the approval of the Engineer, and the Contractor must submit full details, including samples where required, before placing any orders or making any deliveries to site. All literature submitted for approval shall contain only relevant data. All fire protection and prevention equipment shall be to the approval of the Ministry of the Interior Civil Defence Department/ ROP. All equipment shall be installed in strict accordance with the makers recommendations, and where appropriate shall be factory assembled and tested.
0.2.25. PROGRAMME OF WORK Immediately after receiving instructions to proceed, the Contractor shall produce in agreement with the Main Contactor a time and progress schedule. The Contractor shall prepare his program on PRIMAVERA Project Planner P3 and fully integrate his program with that of the main Contractor. Copies shall be provided for the Engineer and the Employer, and a copy shall be kept on site and update his program as necessary to maintain a completion date target program; also as and when required by the main Contractor and/or when required by the Architect/Engineer.
0.2.26. L I A S O N WITH OTHER PARTIES a) TRA-OMAN
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GENERALITIES
It is the responsibility of the Contractor to liaise with the requirements of the local Telecommunication Authority for Telecommunications System. Prior to installation of any telephone ducts, manholes, conduits or trunking, etc. The Contractor shall obtain written approval of the system and relevant drawings. b) Electricity It is the responsibility of the Contractor to liaise with the requirements and regulations of the local Electricity Authority which includes the submission of a completed application form and all necessary documentation. All drawings and equipment shall be approved by the local electricity authority prior to commencement of work and all time and expenses incurred in gaining approvals shall be included in the tender. c) ROP Civil Defence Authority It is the responsibility of the Contractor to liaise with the requirements and regulations of the local Civil Defence Authority. All relevant drawings and equipment shall be approved by the Civil Defence prior to commencement of work and all time and expenses incurred in gaining approvals shall be included in the tender.
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L.V. SWITCHBOARS
GENERAL The supply voltage will be 415/240V AC. 3-phase, 50Hz 4-wire. The installation, generally, shall be in accordance with the Regulations for Electrical Installations, sixteenth Edition, issued by the Institution of Electrical Engineers, United Kingdom, and shall conform with all Statory Requirements, including the appropriate section of the following: current appropriate British Standards relevant Public Authority for Electricity and Water.
together with all Regulations and Codes of Practice applicable to such installations. All equipment shall be suitable for an ambient temperature of 50 0C and relative humidity of 95%. MAIN DISTRIBUTION BOARDS / LOW VOLTAGE PANELS GENERAL This Specification covers the general requirements for design, manufacture, testing and supply of Main Distribution Boards (MDB / L.V. Panel). The specific requirements and details of the main distribution board(s) or L.V. Panel(s) required are given on the drawings. The Contractor shall install the Main Distribution Boards (MDB / L.V. Panel) as shown in the drawings and in full compliance to this specification, the international standards specified in the following section & the local authority regulations. In case of difference between this specification and the specified international standards and the local authority regulations, the more stringent requirements in compliance with local authority regulations shall prevail. The low-voltage switchboards shall have a rated insulation level of 1 000 V AC the low-voltage electrical switchboards shall comply with standard IEC 68.2.30 (hot and damp climates) and with standard IEC 68.2.11 (salt mis APPLICABLE STANDARDS Unless specified otherwise Main Distribution board / L.V. Panel shall conform in design, material, construction and performance to the latest editions of the International recommendations (IEC standards) and its corresponding British / European standards (BSEN standards) and in particular to the following publications:
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Low Voltage Switchboard-IEC 60439 Degree of protection-IEC 60529 the degree of protection in compliance with standard IEC 529 shall be: IP 42 with door; IP 54 with door and gasket kit.
In addition to the above listed standards, the local authority regulations shall also be adhered to. SITE CONDITIONS For general climatic conditions, refer and comply the specified project site conditions. The main distribution boards shall comply and perform satisfactorily at the below listed special design conditions as minimum: Ambient temperature Relative humidity : : 50C 95% (at 55C)
DESIGN CONSIDERATIONS The main distribution boards shall be of standard, natural air cooled, well tested and proven design which ensures maximum safety to personnel, maximum service reliability and economic operations for a lifetime of at least 20years. Design and construction shall be simple, well laid-out and shall provide good accessibility to components and parts. Unless specified otherwise, the form of construction for the main distribution board shall comply with Form-4, Type-6 requirements of IEC 60439-1. Unless specified otherwise, the main distribution board shall be fixed version, main incoming switching devices shall be withdrawable type and the outgoing switching devices shall be fixed type. However the actual requirements for the version of the distribution board and the switching devices shall be as shown in the drawings. Main distribution boards shall be rated on the basis of voltage, current, frequency and the symmetrical breaking capacity of incorporated switching devices.
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The electrical system for all main distribution boards shall be 415 / 380V, 50Hz 3phase and neutral, 4-wire solidly earthed. The main distribution boards shall be suitable for operating voltage up to 1000V. Unless specified otherwise, the fault level withstand capacity of the main distribution board busbar system rated up to 2500Amps s shall have a permissible asymmetric short-circuit current of up to 85 kA for 1 second. The busbars shall be designed for mounting on insulated supports that are sufficient in number to accept the electrodynamic forces resulting from the flow of the peak asymmetric short-circuit current (187 kA peak). The breaking capacity of the switching devices shall be 65KA as minimum standard The type test certificate shall be submitted for consultant engineer verification, to prove the fault level withstand capacity of the main distribution boards. Even under extreme conditions of short circuit or mal-operation there shall be no danger to persons in the vicinity of the assembly. All equipment and components of the main distribution boards shall be capable of continuous operation at their full current and voltage ratings and without detriment or malfunction at system continuous deviation of up to and including the following percentages of the normal values. Voltages Frequency 10% 5%
All components shall be capable of withstanding the dynamic, thermal and dielectric stresses resulting from prospective short circuit currents without damage or injury to personne CONSTRUCTION REQUIREMENTS General The main distribution boards shall be assembled by an approved panel builder, who shall pre-qualify and comply with requirements specified under panel assembler prequalification of this specification. The panel builder / assembler, who do not fully comply pre-qualification clause of this specification are not approved and cannot be accepted as a manufacturer / assembler / supplier for main distribution boards. The main distribution boards shall be assembled by the same panel builder / assembler, who shall also assemble the sub-main, Motor control centre and final distribution boards. the busbars shall be made of electrolytic copper, (type Cu ETP as defined by standard ISO 1337).
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Unless specified / approved otherwise, enclosure system, the switching devices and other components used for assembly of the main distribution boards shall be from franchised manufacturer. Different manufacturer for the main distribution board enclosure and switching devices will not accepted/approved. Enclosure system for all main distribution boards and motor control centers rated up to 5000A to be of same model from one manufacturer. Unless specified otherwise, the main distribution board shall be of fixed version in Form-4, Type-6 construction. Type test certificates shall be available for the proposed type of enclosure and the busbar system. The type test certificates shall be clearly state type, model and main characteristics of the assembly, references of the standards applied for the tests, results obtained and the observations made during & after the tests. The test report shall also contain the documents such as records, drawings, photographs, etc. Main distribution board shall fully comply with requirements of TTA equipment (Type Tested Assemblies). PTTA equipment (Partially Type Tested Assemblies) will not be approved for the main distribution board. Main distribution board shall restrict the internal arcs faults within the compartment to ensure maximum safety to the operating personnel and also to minimize the down time for replacement and repairs. Type test certificate shall be carried out to verify the arc containment within the compartment as per AS 3439-1 standards. Certificates shall be submitted for consultant verification. Design drawings, component catalogues and type test certificates shall be submitted for consultant approval prior to placement of order for the main distribution boards.
General Arrangement & Assembly L.V Panel shall comprise of free standing enclosure, bus bar system, switching devices such as ACB/MCCB, metering equipments, all necessary current transformers and the like as required. Panel shall be assembled in a systematic manner such as Transformer Incomer section, Generator Incomer section (if applicable), Bus coupler section (if applicable), Incomer Metering / Indication section and Outgoing section. Unless otherwise specified the panels shall be designed to accept bottom entry of cables and shall be of rear access type. The rear access shall only be provided for access for termination of cables, all other equipments shall be accessible / operable from the front of panel. Where front access type is specified, the panel shall be designed completely for front access only.
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Each panel section (cable compartment) shall be provided with thermostatically controlled panel heater. Each section shall be arranged typically as described below and as per the details shown in the drawings: Incomer section (Transformer Incoming) Transformer Incomer panel shall be a 3compartment enclosure with Top & Bottom compartment dedicated for metering / controls and the Middle compartment shall be dedicated for the circuit breaker. It shall comprise of but not limited to the following: Bottom Compartment Incomer supply cables
Middle Compartment Main Incoming circuit breakers with rating and type as per the drawing.
Top Compartment Any control component for Incoming circuit breaker. Digital power meter to indicate various electrical parameters Phase indication lamps (R,Y,B) wired to the line side of the circuit breaker. Power factor meter (If required as per local authority requirement). KWH energy meter (If location of KWh is approved by local authority).
Incomer section (Generator Incoming) (If applicable) Generator Incomer panel shall be a 3compartment enclosure with Top & Bottom compartment dedicated for metering / controls and the Middle compartment shall be dedicated for the circuit breaker. It shall comprise of but not limited to the following: Bottom Compartment Incomer supply cables
Middle Compartment Main Incoming circuit breakers with rating and type as per the drawing.
Top Compartment Any control component for Incoming circuit breaker. Digital power meter to indicate various electrical parameters Phase indication lamps (R,Y,B) wired to the line side of the circuit breaker. KWH energy meter (If shown in the drawings).
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Bus coupler / Bus Tie section (If applicable) The Bus Tie / Bus Coupler Panel shall be a 3compartment enclosure to match with the incomer panels. The Top & Bottom compartment can be used for accommodating the common controls of the incoming and the bus tie circuit breakers. The Middle compartment shall be dedicated for the circuit breaker. It shall comprise of but not limited to the following: Notes: Where ACBs are used as incoming or bus coupler, the front face of the ACB shall be accessible for operation from the front without opening the front door. Where MCCBs are used as incoming or bus coupler circuit breakers an extended operating handle shall be provided at the front face of the panel front door for operation. All such door handles shall be door interlocked wherever required.
Outgoing section(s) The outgoing section(s) enclosure shall accommodate the outgoing circuit breakers which shall be arranged in a systematic and symmetrical manner. It shall comprise of but not limited to the following: Each panel shall have various fixed compartments with individual doors for each compartment and each compartment shall accommodate the following: Notes: All circuit breakers and other controls pertaining to a feeder shall be accommodated in its own compartment, which shall have its own lockable door. Keys for all such door shall be common. Moulded case circuit breaker in each compartment shall be equipped with an extended operating handle extended to the front face of the door for operation. All such door handles shall be door interlocked, wherever required. Air circuit breaker front face shall be accessible without opening the door. Circuit breakers and other control components shall be fully accessible after opening the panel door; however no live parts shall be exposed. - All the bus bar connections / terminations to the outgoing circuit breakers shall be taken from the rear side of the circuit breaker, which
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Circuit breakers with rating and type as specified in the drawings. Any other controls, which may be part of the outgoing circuit breakers.
L.V. SWITCHBOARS
shall be shrouded properly using metallic / poly carbonate sheets. All the mccb terminals shall be fully shrouded with original terminal shrouds from the mccb manufacturer, in such a that way no live parts are exposed, when the front door is opened. - Opening of the front door shall give access to the circuit breaker for rating adjustments etc. - Maximum 2nos. air circuit breakers shall be installed in one enclosure, provided that sufficient space for cable termination is provided and derating of circuit breaker is carried out as per manufacturer recommendations. - Maximum 2nos.moulded case circuit breakers, rated at 800Amps shall be installed in one enclosure, provided that sufficient space for cable termination is provided. - Maximum 9nos. of moulded case circuit breakers (rated less than 250Amps) shall be installed in one enclosure, provided that sufficient cable termination is provided. - All Partitioning and shrouding shall comply the requirements of Form-4, Type-6 construction as per IEC standards. Enclosure manufacturing Main distribution board enclosure shall be a branded catalogue product from approved manufacturer. Enclosure shall be made out of electro galvanized steel sheets conforming to international specification. Zinc coating shall be provided on the sheets, which shall prevent rust formation during storage and handling for processing, in addition to giving corrosion protection to the finished product. The sheets have a fine surface finish, which gives good presentation to the painted components of the enclosure. The steel sheet used for enclosure manufacturing shall pass through the pretreatment process for surface treatment. The process shall be a complete 7stage zinc phosphating spray treatment system and shall include the following process: Degreasing Surface conditioning Zinc phosphating Passivation Dematerialized water rinses Intermediate rinses
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The enclosure shall be powder coated to an approved color. The painting process shall include removal of moisture on the sheet steel surface using and applying thermosetting polyester powder using automatic guns. Polymerization of the powder shall take place when the components are cured at about 200C, forming a continuous integrated coating. A fairly uniform coating of atleast 70-80 microns shall be provided. The pretreated and powder coated sheet steel components shall be atleast tested randomly at regular intervals for coating thickness measurement, adhesion test, bend test, impact test, hardness test, salt spray test etc. Enclosure construction Main distribution board enclosure shall be a branded catalogue product from approved manufacturer. The assembler shall assemble the prefabricated elements of the enclosure system, busbar system, switching devices and other equipment to complete the main distribution board. Main distribution board enclosure shall be fabricated of minimum 2mm thick electrogalvanized sheet steel folded and welded construction. The enclosure shall be of simple and robust construction designed for a variety of dimensions obtainable by means of standardized basic elements. Main distribution board shall consist of several enclosures of equal height and depth mounted side by side to form a composite board of uniform assembly. Each section of main distribution board shall be made up of 4 distinct functional spaces: Vertical and horizontal busbars, switchgear components, cable connection and auxiliaries. Enclosure structure composition shall be based on a supporting frame consisting of cross members, vertical members and panels fastened one another by means of bolts and rivets. The basic structure shall be completed by the addition of a compartment for the connections which may be located at rear or at side depending on the access. A single-piece base shall allow anchoring of the unit to the floor. The complete assembly shall be rigid self-supporting structure which is deformable and unaffected by shocks. The structure shall be completed by a metal partition made of one or more pieces between two sections depending on the depth of the compartment. The lower part of structure shall be closed by means of bolted plates that can be removed whenever the assembly of cable glands is required. The switchgear components contained in sections shall be installed on mounting plates. Each door panel shall be equipped with integral key lock and the key shall be common for all such locks. All door hinges to be of concealed type and it shall be possible to remove the door panel whenever required. All doors, bold on cover, partitions, mounting plates and metallic shrouds shall be effectively connected to earth. Flexible earth wires shall be used for removable covers and hinged doors.
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The structure and the partitions shall be protected by a durable scratch resistant textured paint finish, epoxy powder polymerized at high temperatures to an approved color. Unless specified otherwise, the main distribution board shall be with ingress protection rating of IP42 as per IEC standards as minimum. Unless specified otherwise, Main distribution boards shall be designed for front access for the purpose of operation and access to all components and shall suit front or rear access for cable connections and top or bottom for cable entries. Wherever required, enclosure shall be suitable for busduct entry at the top. The access and entries shall be provided as per site requirements. Adequate care shall be taken while designing the main distribution board connection spaces for the external cables. Sufficient cable supports shall be provided for routing the cables inside the enclosure. Wherever single core cable enters, the gland plate shall be of aluminum material. Enclosure system shall effectively dispose the heat produced by the main circuits and shall integrate a high performance natural ventilation system which shall be aimed at regulating the internal temperature based on the actual capacities of the components. Enclosure shall be readily suitable for future extension on either side without any modifications (after installation at site). Form-4 construction assembly shall provide protection against contact with internal live parts and components. Busbars, functional units and cable termination shall be segregated from each other as given below: Busbars shall be separated from functional units; Functional units / switching devices shall be separated from each other; Cable termination and functional units / switching devices shall be separated from each other; Incoming and outgoing terminals shall be separated from each other. Busbars shall be accommodated in a separate chamber/alley with metallic shrouds and partitions to avoid accidental external contacts. Incoming switching device shall be located in separate section and outgoing switching devices in other sections, wherever applicable. Each switching device shall be segregated from each other and located in individual compartment with hinged door.
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External cable termination to the switching device terminals shall be outside the functional unit / switching device compartment. Segregation shall be made between the switching device terminal and the switching device within its compartment by means of rigid barriers and partitions. All segregation shall be achieved by means of rigid metallic sheet partitions. Segregation and partition shall ensure protection against contact with live parts and limitation of the faults within each of the functional unit compartment. A cable alley shall be provided either at rear or at the side of each section as per site conditions and requirements to facilitate the switching device cable glanding. Cables shall be glanded on the bottom plate of common cable alley/chamber. External cable termination shall be carried out in an enclosed individual termination compartment for each switching device, which is external to but separated from functional unit compartment. The cable termination compartment shall be provided with cable entry shrouds at the cable entry in to the compartments. Supports shall be provided to fasten the power and control cables inside cable alley/chamber. Busbars The busbar system shall be designed as per the pre-defined guidelines provided by the original manufacturer. The busbar system shall be type tested by the manufacturer at reputed laboratory for short circuit withstand capacity. The neutral and earth busbars shall also be type tested for the short circuit withstand capacity. The fault level rating of the busbar system shall be as per the drawings however the minimum short circuit withstand capacity shall be 50KA RMS for 1second. Neutral busbar shall be able to withstand a thermal stress of atleast 60%, corresponding to the main phase busbar rated short circuit withstand capacity. The busbars shall be high grade electrolytic tin plated copper (with 99.9% conductivity), rectangular and rigid construction. The phase busbars and neutral busbars shall be arranged systematically in a busbar chamber/ alley. The busbars shall be color sleeved throughout the length for phase identification (except for the distribution busbars of the withdrawable sections). The busbars shall be shrouded completely using metallic partitions and/or polycarbonate shrouds as applicable. The busbar assembly shall be shrouded (at least IP20) by shrouds so that no live parts are accessible. Phase identification shall be done systematically. Use of bakelite sheets for shrouding will not be permitted.
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The busbar system shall be supported adequately at regular intervals as per manufacturer guidelines based on the type test results on a specially designed busbar supports. The supports shall be independently fixed to structure to strengthen the busbar arrangement. Wherever required additional intermediate supports shall be provided between the busbars. All vertical droppers shall also be adequately supported as per the manufacturer guidelines and the test results. The distribution busbars shall be connected to the main busbars by suitable sized and graded bolt & nut and contact washers. Clamp type arrangements for connections will not be permitted. Connections to the switching devices to the main or distribution busbars shall be carried out using rigid bars of adequate and standard sizes. It shall be possible to replace the switching devices with different rating with same frame sizes without changing the interconnection busbars. Distance between the busbar supports for busbar system and the distance between different phases of busbar system shall be as per manufacturer guidelines based on the type test results. The main busbars shall be accommodated on a separate busbar chamber running horizontally at top or bottom or middle of the panel. Main busbars running behind the functional units (the switching device mounting plates) will not be permitted. Distribution busbars are permitted at the back of the switching device compartments only where withdrawable versions are used. The dimensioning of the busbar system shall be as per the rated current of the main switching device, the short circuit current, the maximum rated permissible temperature at permanent operation and the ambient temperature around the busbars. The selection of busbars shall be supported by calculations and recommendations from the original manufacturer. The main phase and neutral busbars shall be of same size through out the panel irrespective of the ratings and load distribution. Earth busbars shall be half the size of the phase busbars. Several copper bars may be used for each phase and neutral, however such parallel running bars of each phase / neutral shall be spaced evenly with a minimum gap of 5mm between the bars. Busbar system shall be standardized with 5mm thick main busbars, distribution busbars and interconnection busbars for better heat dissipation. The neutral busbar shall run along with the phase busbars and shall outgoing switching devices neutral connection terminal shall be provided with in the switching device compartment. Neutral busbar running at bottom or in the cable chamber/alley will not be accepted in case of Form4 construction.
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Earth busbar shall be running throughout the panel fitted directly on to the structure for connection of the protective conductors to provide equipotential bonding of exposed conductive parts. Earth busbar shall be located at the bottom of the panel and in the cable chamber/ alley to facilitate easy connection of protective conductor. Hardware used for busbar connections shall be zinc plated, yellow passivated / bi-chromated steel of 8.8grade. Tightening of busbar bolts shall be done as per manufacturer recommendations and pre-defined guidelines using calibrated torque wrenches. Labeling The main distribution board shall be labeled systematically in English to describe the designation of the incoming and outgoing switching devices as referenced in the drawings. A main label shall be fixed to the front face of the main distribution board. The label shall be of special white pvc material front engraved for the desired text. The text shall be black in color. The label shall be fixed to the door using a special pvc rivets. Each metallic and polycarbonate(pc) shrouds shall be provided with engraved warning labels indicating Danger 415V Live Bus Inside Isolate Main Supply Before Opening This Cover at the front face. All such warning labels shall be riveted to the shroud plates. The line side of the incoming circuit breaker and its bus bar shall be shrouded separately with removable metallic front plates to prevent accidental access to bus bars. Such shrouds shall be provided with engraved warning labels indicating Danger 415V Live Bus Inside Isolate Supply Else Where Before Opening This Cover at the front face. All such warning labels shall be riveted to the shroud plates. Permanent labels shall be provided inside the main distribution board for phase identification of the incoming and outgoing switching devices. Identification labels shall be provided for neutral and earth connections. A drawing pouch / pocket shall be provided inside each main distribution board and approved load schedule (laminated) and the as-built drawings for the motor control centre shall be provided. Testing
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Type test The main distribution board and the components as applicable shall be type tested in accordance with the IEC standards to verify the specified fault level withstand capacity from a reputed and approved type testing laboratory and certified by an competent authority. The following 7 type tests as specified in IEC 60439-1standards to comply with requirements of TTA equipment shall be carried out at recognized test laboratories and certificates from approved test witnessing authority shall be provided for each type test: 1. 2. 3. 4. 5. 6. 7. Verification of temperature-rise limits (IEC Clause 8.2.1); Verification of the dielectric properties (IEC Clause 8.2.2); Verification of short-circuit withstand strength (IEC Clause 8.2.3); Verification of the effectiveness of the protective circuit (IEC Clause 8.2.4) Verification of clearances and creepage distances (IEC Clause 8.2.5); Verification of mechanical operation (IEC Clause 8.2.6); Verification of the degree of protection (IEC Clause 8.2.7).
Type test certificates shall be submitted to the consultant engineer for verification. Routine test The panel assembler shall perform the routine test and provide the test certificates as defined in IEC standards. The routine test shall include but not limited to the following: 1. Inspection of the assembly including inspection of wiring and electrical operational test (IEC Clause 8.3.1); 2. Dielectric test & Insulation resistance test (IEC Clause 8.3.2 & 8.3.4); 3. Checking of protective measures and of the electrical continuity of the protective circuits (IEC Clause 8.3.3) 4. Functional test as per the approved test procedure.
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Routine test certificates and test readings shall be submitted to the consultant engineer for verification. SUB MAIN DISTRIBUTION BOARDS GENERAL This Specification covers the general requirements for design, manufacture, testing and supply of Sub Main Distribution Boards (SMDB / SDB). The specific requirements and details of the sub main distribution board(s) required are given on the drawings. The Contractor shall install the Sub Main Distribution Boards (SMDB / SDB) as shown in the drawings and in full compliance to this specification, the international standards specified in the following section & the local authority regulations. In case of difference between this specification and the specified international standards and the local authority regulations, the more stringent requirements in compliance with local authority regulations shall prevail. APPLICABLE STANDARDS Unless specified otherwise Sub Main Distribution boards shall conform in design, material, construction and performance to the latest editions of the International recommendations (IEC standards) and its corresponding British / European standards (BSEN standards) and in particular to the following publications : - Low Voltage Switchboard - Degree of protection - L.V Circuit Breaker & Switch-Disconnector - Earth Leakage Circuit Breaker - Earth Leakage Relay IEC 60439-1 IEC 60529 IEC 60947-1 to 5 IEC 61009-2-2 / IEC 61008 IEC 60755 & IEC364-4 & 5
In addition to the above listed standards, the local authority regulations shall also be adhered to. SITE CONDITIONS
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For general climatic conditions, refer and comply the specified project site conditions. The sub main distribution boards shall comply and perform satisfactorily at the below listed special design conditions as minimum: Ambient temperature Relative humidity : : 50C 95% (at 55C)
DESIGN CONSIDERATIONS The sub main distribution boards shall be of standard, natural air cooled, well tested and proven design which ensures maximum safety to personnel, maximum service reliability and economic operations for a lifetime of at least 20years. Design and construction shall be simple and well laid-out and shall provide good accessibility to components and parts. The construction of sub main distribution board shall comply with Form-2 requirements of IEC 439-1. The electrical system for all sub main distribution boards shall be 415v , 50Hz 3phase and neutral, 4-wire solidly earthed. The sub main distribution boards shall be suitable for operating voltage up to 690V and insulation voltage up to 1000V respectively. Unless specified otherwise, the fault level withstand capacity of the sub main distribution board busbar system shall be 35KA RMS for 1Second as minimum standard. The breaking capacity of the switching devices shall be 25KA as minimum standard. The type test certificate shall be submitted for consultant engineer verification, to prove the fault level withstand capacity of the sub main distribution boards. Even under extreme conditions of short circuit or mal-operation there shall be no danger to persons in the vicinity of the assembly.
All equipment and components of the sub main distribution boards shall be capable of continuous operation at their full current and voltage ratings and with out detriment or malfunction at system continuous deviation of up to and including the following percentages of the normal values. Voltages Frequency 10% 5%
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All components shall be capable of withstanding the dynamic, thermal and dielectric stresses resulting from prospective short circuit currents without damage or injury to personnel. CONSTRUCTION REQUIREMENTS Enclosure construction Sub main distribution board enclosure shall be original from approved manufacturer. The sub main distribution board shall be a branded catalogue product and the assembler fit the standard type tested busbar assembly and switching devices of the original manufacturer to the sub main distribution board enclosure. Sub main distribution board enclosure shall be fabricated of minimum 1.5mm thick electro-galvanized sheet steel folded and welded construction. The enclosure shall be of simple and robust construction. The sub main distribution board enclosure shall mainly consist of a back box, a specially designed bracket assembly to accommodate the busbar system, a front cover and a hinged door. The distribution board back box shall easily allow and accommodate the standard busbar assembly, switching devices and power & control components by means of specifically designed brackets. The back box shall have key hole mounting slots for fixing to the walls, pre-punched fixing holes for accommodating the front cover and a safety earth stud for bonding purpose. Sheet steel front cover with standard cutouts shall form the front cover assembly, which shall be screw fitted to the back box assembly. The front cover assembly shall cover all the component and busbar of the distribution board. The front cover shall be provided with standard cutouts on it, to provide access only to the toggles and front face of the switching devices. Standard hinged door shall be fixed to the front cover or back box using concealed type of hinges and thus the door shall form a protective cover for the outgoing switching devices against accidental access. The door shall have a standard self-latch type of lock with an optional feature of having a key lock, wherever required. The complete enclosure assembly shall be coated with durable scratch resistant textured paint finish, epoxy powder polymerized at high temperatures to an approved color. Unless specified otherwise, the sub main distribution board shall be with ingress protection rating of IP41 as per IEC standards as minimum.
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The sub main distribution board shall have standard width and various heights as per the number of ways and the incomer switching device current ratings. General arrangement of the distribution board shall be arranged in such a way that the incoming switching device is positioned vertically at the bottom center of the distribution board after leaving sufficient space for incomer cables below the switching device. The pan assembly design busbar assembly shall be arranged to be positioned above the incoming switching device and shall be linked to it with suitable busbar links. The outgoing switching devices shall be fitted on both the sides of the busbar assembly with sufficient cabling spaces on either side for outgoing cables. The neutral busbar shall be positioned on one side of the incoming switching device and earth bar shall be positioned on the other side of the incoming switching device without obstructing the cable space. The distribution boards shall have minimum optimized cable space of minimum 80mm for outgoing feeders. Additional space for main cable termination shall be provided by including an extension box from the original enclosure manufacturer. Wherever required, a metering compartment shall be provided at the top of the sub main distribution board to accommodate the metering equipments as shown on the drawing. The metering compartment shall be similar to the extension box and shall be original from the manufacturer. The sub main distribution boards within its range shall accommodate the manufacturer incoming and outgoing switching devices without any modifications.
Busbars The busbar system shall be original from the manufacturer designed to accept the manufacturer standard switching devices. The busbar system shall be type tested by the manufacturer at reputed laboratory for short circuit withstand capacity. The fault level rating of the busbar system shall be as per the drawings however the minimum short circuit withstand capacity shall be 35KA RMS for 1sec. The busbars shall be tin plated copper, rectangular and rigid construction. The phase busbars shall be arranged and assembled one above the other
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using specially designed insulators to form a pan assembly design. The busbars shall be protected pvc shrouds from all sides. After assembly of the switching devices on to the busbar assembly, the complete assembly shall be in compliance to the requirements of Form-2, Type-2 construction as per IEC standards. The busbar assembly shall be fully shrouded (at least IP20) by original shrouds, so that no live parts are accessible. Phase identification shall be done systematically for the incoming and outgoing ways. The incoming switching device and the busbar links between the incoming switching device and the main busbar assembly shrouded by screw fitted metallic shroud plate to avoid any accidental access to the busbars. The busbar system and the specially designed brackets inside the sub main distribution boards shall be designed in such a way that any switching device can be fitted or removed on to the distribution board without disturbing the already installed switching devices. The pvc busbar shrouds shall form an integral part of the busbar assembly and it shall not be possible to remove the shroud without switching the main power supply and dismantling the complete busbar system. Tin plated copper neutral busbar shall be located on the side of the incoming switching device, with sufficient no. of terminal provided on the busbar for cable termination. Each feeder shall have its own neutral termination facility. Neutral busbar shall be provided with a suitable termination facility for connecting the main neutral cable on it. Neutral terminal shall be provided with identification label. Tin plated copper earth busbars shall be located on the side of the incoming switching device without disrupting the other cable terminations. It shall have sufficient quantity of terminals to facilitate termination of earth cables on to it. Earth busbar shall be provided with a suitable termination facility for connecting the main earth cable on it. Extra terminals shall be provided on the earth bar for bonding purpose. The ratings of the main busbar assembly shall be to suit the incoming switching device rating, however for the purpose of standardization it shall be categorized in to two groups as 250Amps and 630Amps, irrespective of the incoming switching device rating. For distribution board main circuit rated up to 250A, the busbar shall be rated for 250Amps and for distribution board main circuit rated above 250A, the busbar shall be rated for 630Amps.
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The busbar assembly shall be available in different combinations of no. of outgoing ways to suit the requirement. The typical nos. of TP outgoing ways shall be 2, 4, 6, 8, 10, 12, 14, 18 & 20. Busbar assembly shall be of standard type and size to accept the manufacturer MCCBs up to 35KA rating as outgoing feeder without any modification to it. The busbar assembly shall readily accept the manufacturer 1Pole or 3Pole MCCBs. Busbar assembly shall readily accept the manufacturer MCCB or Isolator rated up to 250 / 630A (as per the rating shown on the drawing) as main incoming switching device without any modification to it. Busbar assembly shall readily accept the manufacturer MCCBs rated up to 250A, 3pole or 1pole version (as per the rating shown on the drawing) as outgoing switching device without any modification to it. Future space for outgoing switching devices shown in the drawings shall be readily available in all respects to install the breaker in future without any modifications to the busbar assembly or the sub main distribution board.
MOTOR CONTROL CENTRES ((Form-4 Type-6, Fixed Version) GENERAL This Specification covers the general requirements for design, manufacture, testing and supply of Motor Control Centre (MCC). The specific requirements and details of the motor control centre(s) required are given on the drawings. The Contractor shall install the Motor Control Centre (MCC) as shown in the drawings and in full compliance to this specification, the international standards specified in the following section & the local authority regulations. In case of difference between this specification and the specified international standards and the local authority regulations, the more stringent requirements in compliance with local authority regulations shall prevail.
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MANUFACTURER & PANEL BUILDER / ASSEMBLER: PREQUALIFICATION Motor Control Centre shall be assembled only by a franchisee of the original manufacturer and approved by the consultant. Panel builder / assembler shall have a minimum experience of 15years in the field of switchgear assembly. APPLICABLE STANDARDS Unless specified otherwise Motor Control Centre shall conform in design, material, construction and performance to the latest editions of the International recommendations (IEC standards) and its corresponding British / European standards (BSEN standards) and in particular to the following publications: - Low Voltage Switchboard - Degree of protection IEC 60439-1 IEC 60529
In addition to the above listed standards, the local authority regulations shall also be adhered to.
SITE CONDITIONS For general climatic conditions, refer and comply the specified project site conditions. The motor control centre shall comply and perform satisfactorily at the below listed special design conditions as minimum: Ambient temperature Relative humidity : : 50C 95% (at 55C)
DESIGN CONSIDERATIONS The motor control centre shall be of standard, natural air cooled, well tested and proven design which ensures maximum safety to personnel,
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maximum service reliability and economic operations for a lifetime of at least 20years. Design and construction shall be simple, well laid-out and shall provide good accessibility to components and parts. Unless specified otherwise, the form of construction for the motor control centre shall comply with Form-4, Type-6 requirements of IEC 60439-1. Unless specified otherwise, the motor control centre enclosure system shall be of fixed version. Main incoming and outgoing switching devices and starter units shall be accommodated in individual compartments of the motor control centre. The motor control centre shall be assembled using various combinations of enclosure to form a uniform and composite panel. The general external appearance and construction of fixed version enclosures shall be similar. It shall be possible to assemble various combinations incoming switching devices, starter feeders, distribution feeders etc. easily. Motor control centre shall be rated on the basis of voltage, current, frequency and the symmetrical breaking capacity of incorporated switching devices. The electrical system for all motor control centre shall be 415 / 380V, 50Hz 3phase and neutral, 4-wire solidly earthed. The motor control centers shall be suitable for operating voltage up to 1000V. Unless specified otherwise, the fault level withstand capacity of the main distribution board busbar system rated up to 2500Amps s shall have a permissible asymmetric short-circuit current of up to 85 kA for 1 second. The busbars shall be designed for mounting on insulated supports that are sufficient in number to accept the electrodynamic forces resulting from the flow of the peak asymmetric short-circuit current (187 kA peak). The breaking capacity of the switching devices shall be 65KA as minimum standard The type test certificate shall be submitted for consultant engineer verification, to prove the fault level withstand capacity of the main distribution boards. Even under extreme conditions of short circuit or maloperation there shall be no danger to persons in the vicinity of the assembly
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All equipment and components of the motor control centre shall be capable of continuous operation at their full current and voltage ratings and without detriment or malfunction at system continuous deviation of up to and including the following percentages of the normal values. Voltages Frequency 10% 5%
All components shall be capable of withstanding the dynamic, thermal and dielectric stresses without damage or injury to personnel. Unless specified otherwise, the motor control and protection combination of conventional starter assembly and/or electronic starter assembly shall comply with Type 2 coordination as per IEC standards. The motor control and protection combinations shall be tested under conditions defined by IEC standards and certified by reputed certifying company. CONSTRUCTION REQUIREMENTS General The motor control centre shall be assembled by an approved panel builder, who shall pre-qualify and comply with requirements specified under panel assembler pre-qualification of this specification. The panel builder / assembler, who do not fully comply pre-qualification clause of this specification are not approved and cannot be accepted as a manufacturer / assembler / supplier for motor control centers. The motor control centre shall be assembled by the same panel builder / assembler, who shall also assemble the main and sub-main distribution boards. Unless specified / approved otherwise, enclosure system, the switching devices and other components used for assembly of the motor control centre shall be from franchised manufacturer. Different manufacturer for the motor control centre enclosure and switching devices will not accepted/approved. Type test certificates shall be available for the proposed type of enclosure and the busbar system. The type test certificates shall clearly state type, model and main characteristics of the assembly, references of the standards applied for the tests, results obtained and the observations made during &
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after the tests. The test report shall also contain the documents such as records, drawings, photographs, etc. Motor control centre shall fully comply with requirements of TTA equipment (Type Tested Assemblies). PTTA equipment (Partially Type Tested Assemblies) will not be approved for the motor control centre. Motor control centre shall restrict the internal arcs faults within the compartment to ensure maximum safety to the operating personnel and also to minimize the down time for replacement and repairs. Type test certificate shall be available to verify the arc containment within the compartment as per AS 3439-1 standards. Certificates shall be submitted for consultant verification. Design drawings, component catalogues and type test certificates shall be submitted for consultant approval prior to placement of order for the motor control centre. General Arrangement & Assembly MCC shall comprise of free standing enclosure, bus bar system, switching devices such as ACB/MCCB, Starter assemblies, metering equipments, all necessary current transformers and the like as required. Panel shall be assembled in a systematic manner such as Incomer section, Incomer Metering / Indication section, Outgoing feeder and starter sections. Unless otherwise specified the MCC shall be designed to accept bottom entry of cables and shall be of rear access type. The rear access shall only be provided for access for termination of cables, all other equipments shall be accessible / operable from the front of panel. Where front access type is specified and/or required, the MCC shall be designed completely for front access only. Each panel section (cable compartment) shall be provided with thermostatically controlled panel heater. Each section shall be arranged typically as described below and as per the details shown in the drawings: Incomer section
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Incomer panel shall be a 3compartment enclosure with Top & Bottom compartment dedicated for metering / controls and the Middle compartment shall be dedicated for the circuit breaker. It shall comprise of but not limited to the following: Bottom Compartment Incomer supply cables
Middle Compartment Main Incoming circuit breakers with rating and type as per the drawing. Top Compartment - Digital power meter to indicate various electrical parameters - Phase Indication lamps (R,Y,B) wired to the line side of the circuit breaker. - Any control component for Incoming circuit breaker. Note: Wherever the main incoming switching device ratings is not exceeding 630A, The main switching device may be accommodated as part of outgoing panel / section in a separate compartment. The metering equipment shall also be located in a separate compartment with hinged front door. Metering compartment shall be located as the top most compartment of the panel / section and incoming feeder compartment shall be located just below the metering compartment. Outgoing section(s) The outgoing section(s) enclosure shall accommodate the outgoing circuit breakers and starter feeders which shall be arranged in a systematic and symmetrical manner. It shall comprise of but not limited to the following: Each panel shall have various fixed compartments with individual doors for each compartment and each compartment shall accommodate the following: Circuit breakers with rating and type as specified in the drawings. Starter assembly to suit motor rating as specified in the drawings. Any other controls, which may be part of the outgoing circuit breakers.
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Notes: - All circuit breakers and other controls pertaining to a feeder shall be accommodated in its own compartment, which shall have its own lockable door. Keys for all such door shall be common. - Moulded case circuit breaker in each compartment shall be equipped with an extended operating handle extended to the front face of the door for operation. Unless specified otherwise, the handle shall be interlocked with the door; however it shall be possible to defeat and/or remove the door interlock whenever required. - Air circuit breaker front face shall be accessible without opening the door. - Circuit breakers and other control components shall be fully accessible after opening the panel door; however no live parts shall be exposed. - All the bus bar connections / terminations to the outgoing circuit breakers shall be shall be shrouded properly using metallic / poly carbonate sheets. All the mccb terminals shall be fully shrouded with original terminal shrouds from the mccb manufacturer, in such a that way no live parts are exposed, when the front door is opened. - All control & reset pushbuttons, selectors, metering and operating handle for the circuit breaker shall be fitted to the hinged door of the compartment. - Opening of the front door shall give access to the circuit breaker for rating adjustments, starter components etc. - Maximum 2nos. air circuit breakers shall be installed in one enclosure, provided that sufficient space for cable termination is provided and derating of circuit breaker is carried out as per manufacturer recommendations. - Maximum 2nos.moulded case circuit breakers, rated at 800Amps shall be installed in one enclosure, provided that sufficient space for cable termination is provided. - Maximum 12nos. of moulded case circuit breakers (rated less than 250Amps) shall be installed in one enclosure, provided that sufficient cable termination is provided. - Starter compartment rated up to 5KW D.O.L shall be in a compartment at least of 200mm height and starter rated more than 5KW shall be in compartment of not less than 200mm height.
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- All Partitioning and shrouding shall comply with the requirements of Form-4 Type-6 construction as per IEC standards. Enclosure manufacturing Motor control centre enclosure shall be a branded catalogue product from approved manufacturer. Enclosure shall be made out of electro galvanized steel sheets conforming to international specification. Zinc coating shall be provided on the sheets, which shall prevent rust formation during storage and handling for processing, in addition to giving corrosion protection to the finished product. The sheets have a fine surface finish, which gives good presentation to the painted components of the enclosure. The steel sheet used for enclosure manufacturing shall pass through the pretreatment process for surface treatment. The process shall be a complete 7stage zinc phosphating spray treatment system and shall include the following process: Degreasing Surface conditioning Zinc phosphating Passivation Dematerialized water rinses Intermediate rinses
The enclosure shall be powder coated to an approved color. The painting process shall include removal of moisture on the sheet steel surface using and applying thermosetting polyester powder using automatic guns. Polymerization of the powder shall take place when the components are cured at about 200C, forming a continuous integrated coating. A fairly uniform coating of atleast 70-80 microns shall be provided. The pretreated and powder coated sheet steel components shall be atleast tested randomly at regular intervals for coating thickness measurement, adhesion test, bend test, impact test, hardness test, salt spray test etc. Enclosure construction Motor control centre enclosure shall be a branded catalogue product from approved manufacturer. The assembler shall assemble the prefabricated elements of the enclosure system, busbar system, switching devices and other equipments to complete the motor control centre.
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Motor control centre enclosure shall be fabricated of minimum 2mm thick electro-galvanized sheet steel folded and welded construction. The enclosure shall be of simple and robust construction designed for a variety of dimensions obtainable by means of standardized basic elements. Motor control centre shall consist of several enclosures of equal height and depth mounted side by side to form a composite board of uniform assembly. Each section of motor control centre shall be made up of 4 distinct functional spaces: Vertical busbars, horizontal busbars, switchgear components and cable connection / auxiliaries. Enclosure structure composition shall be based on a supporting frame consisting of cross members, vertical members and panels fastened one another by means of bolts and rivets. The basic structure shall be completed by the addition of a compartment for the connections which may be located at rear or at side depending on the access. A single-piece base shall allow anchoring of the unit to the floor. The complete assembly shall be rigid self-supporting structure which is deformable and unaffected by shocks. The structure shall be completed by a metal partition made of one or more pieces between two sections depending on the depth of the compartment. The lower part of structure shall be closed by means of bolted plates that can be removed whenever the assembly of cable glands is required. The switchgear components contained in sections shall be installed on mounting plates. Each door panel shall be equipped with integral key lock and the key shall be common for all such locks. All door hinges to be of concealed type and it shall be possible to remove the door panel whenever required. All doors, bold on cover, partitions, mounting plates and metallic shrouds shall be effectively connected to earth. Flexible earth wires shall be used for removable covers and hinged doors. The structure and the partitions shall be protected by a durable scratch resistant textured paint finish, epoxy powder polymerized at high temperatures to an approved color. Unless specified otherwise, the motor control centre shall be with ingress protection rating of IP42 as per IEC standards as minimum. Unless specified otherwise, Motor control centre shall be designed for front access for the purpose of operation and access to all components and shall suit front or rear access for cable connections and top or bottom for cable entries. Wherever required, enclosure shall be suitable for busduct entry at the top. The access and entries shall be provided as per site requirements.
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Adequate care shall be taken while designing the motor control centre connection spaces for the external cables. Sufficient cable supports shall be provided for routing the cables inside the enclosure. Wherever single core cable enters, the gland plate shall be of aluminum material. Enclosure system shall effectively dispose the heat produced by the main circuits and shall integrate a high performance natural ventilation system which shall be aimed at regulating the internal temperature based on the actual capacities of the components. Enclosure shall be readily suitable for future extension on either side without any modifications (after installation at site). Form-4 construction assembly shall provide protection against contact with internal live parts and components. Busbars, functional units and cable termination shall be segregated from each other as given below: Busbars shall be separated from functional units; Functional units / switching devices shall be separated from each other; - Cable termination and functional units / switching devices shall be separated from each other; - Incoming and outgoing terminals shall be separated from each other. Busbars shall be accommodated in a separate chamber/alley with metallic shrouds and partitions to avoid accidental external contacts. Incoming switching device shall be located in separate section and outgoing switching devices in other sections, wherever applicable. Each switching device shall be segregated from each other and located in individual compartment with hinged door. External cable termination to the switching device terminals shall be outside the functional unit / switching device compartment. Segregation shall be made between the switching device terminal and the switching device within its compartment by means of rigid barriers and partitions. All segregation shall be achieved by means of rigid metallic sheet partitions. Segregation and partition shall ensure protection against contact with live parts and limitation of the faults within each of the functional unit compartment. A cable alley shall be provided either at rear or at the side of each section as per site conditions and requirements to facilitate the switching device cable glanding. Cables shall be glanded on the bottom plate of common
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cable alley/chamber. External cable termination shall be carried out in an enclosed individual termination compartment for each switching device, which is external to but separated from functional unit compartment. The cable termination compartment shall be provided with cable entry shrouds at the cable entry in to the compartments. Supports shall be provided to fasten the power and control cables inside cable alley/chamber. Busbars The busbar system shall be designed as per the pre-defined guidelines provided by the original manufacturer. The busbar system shall be type tested by the manufacturer at reputed laboratory for short circuit withstand capacity. The neutral and earth busbars shall also be type tested for the short circuit withstand capacity. The fault level rating of the busbar system shall be as per the drawings however the minimum short circuit withstand capacity shall be 50KA RMS for 1second. Neutral busbar shall be able to withstand a thermal stress of atleast 60%, corresponding to the main phase busbar rated short circuit withstand capacity. The busbars shall be high grade electrolytic tin plated copper (with 99.9% conductivity), rectangular and rigid construction. The phase busbars and neutral busbars shall be arranged systematically in a busbar chamber/ alley. The busbars shall be color sleeved throughout the length for phase identification (except for the distribution busbars of the withdrawable sections). The busbars shall be shrouded completely using metallic partitions and/or polycarbonate shrouds as applicable. The busbar assembly shall be shrouded (at least IP20) by shrouds so that no live parts are accessible. Phase identification shall be done systematically. Use of bakelite sheets for shrouding will not be permitted. The busbar system shall be supported adequately at regular intervals as per manufacturer guidelines based on the type test results on a specially designed busbar supports. The supports shall be independently fixed to structure to strengthen the busbar arrangement. Wherever required additional intermediate supports shall be provided between the busbars. All vertical droppers shall also be adequately supported as per the manufacturer guidelines and the test results. The distribution busbars shall be connected to the main busbars by suitable sized and graded bolt & nut and contact washers. Clamp type arrangements for connections will not be permitted. Connections to the switching devices to the main or distribution busbars shall be carried out using rigid bars of adequate and standard sizes. It shall be possible to replace the switching devices with different rating with same frame sizes without changing the interconnection busbars.
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Distance between the busbar supports for busbar system and the distance between different phases of busbar system shall be as per manufacturer guidelines based on the type test results. The main busbars shall be accommodated on a separate busbar chamber running horizontally at top or bottom or middle of the panel. Main busbars running behind the functional units (the switching device mounting plates) will not be permitted. Distribution busbars are permitted at the back of the switching device compartments only where withdrawable versions are used. The dimensioning of the busbar system shall be as per the rated current of the main switching device, the short circuit current, the maximum rated permissible temperature at permanent operation and the ambient temperature around the busbars. The selection of busbars shall be supported by calculations and recommendations from the original manufacturer. The main phase and neutral busbars shall be of same size through out the panel irrespective of the ratings and load distribution. Earth busbars shall be half the size of the phase busbars. Several copper bars may be used for each phase and neutral, however such parallel running bars of each phase / neutral shall be spaced evenly with a minimum gap of 5mm between the bars. Busbar system shall be standardized with 5mm thick main busbars, distribution busbars and interconnection busbars for better heat dissipation. The neutral busbar shall run along with the phase busbars and shall outgoing switching devices neutral connection terminal shall be provided with in the switching device compartment. Neutral busbar running at bottom or in the cable chamber/alley will not be accepted in case of Form4 construction. Earth busbar shall be running throughout the panel fitted directly on to the structure for connection of the protective conductors to provide equipotential bonding of exposed conductive parts. Earth busbar shall be located at the bottom of the panel and in the cable chamber/ alley to facilitate easy connection of protective conductor. Hardware used for busbar connections shall be zinc plated, yellow passivated / bi-chromated steel of 8.8grade. Tightening of busbar bolts shall be done as per manufacturer recommendations and pre-defined guidelines using calibrated torque wrenches. Labeling
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The motor control centre shall be labeled systematically in English to describe the designation of the incoming and outgoing switching devices as referenced in the drawings. A main label shall be fixed to the front face of the motor control centre. The label shall be of special white pvc material front engraved for the desired text. The text shall be black in color. The label shall be fixed to the door using a special pvc rivets. Each metallic and polycarbonate(pc) shrouds shall be provided with engraved warning labels indicating Danger 415V Live Bus Inside Isolate Main Supply Before Opening This Cover at the front face. All such warning labels shall be riveted to the shroud plates. The line side of the incoming circuit breaker and its bus bar shall be shrouded separately with removable metallic front plates to prevent accidental access to bus bars. Such shrouds shall be provided with engraved warning labels indicating Danger 415V Live Bus Inside Isolate Supply Else Where Before Opening This Cover at the front face. All such warning labels shall be riveted to the shroud plates. Permanent labels shall be provided inside the motor control centre for phase identification of the incoming and outgoing switching devices. Identification labels shall be provided for neutral and earth connections. A drawing pouch / pocket shall be provided inside each motor control centre and approved load schedule (laminated) and the as-built drawings for the motor control centre shall be provided. Testing Type test The motor control centre and the components as applicable shall be type tested in accordance with the IEC standards to verify the specified fault level withstand capacity from a reputed and approved type testing laboratory and certified by an competent authority. The following 7 type tests as specified in IEC 60439-1standards to comply with requirements of TTA equipment shall be carried out at recognized test laboratories and certificates from approved test witnessing authority shall be provided for each type test:
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1. 2. 3. Verification of temperature-rise limits (IEC Clause 8.2.1); Verification of the dielectric properties (IEC Clause 8.2.2); Verification of short-circuit withstand strength (IEC Clause 8.2.3);
4. Verification of the effectiveness of the protective circuit (IEC Clause 8.2.4); 5. 6. 7. Verification of clearances and creepage distances (IEC Clause 8.2.5); Verification of mechanical operation (IEC Clause 8.2.6); Verification of the degree of protection (IEC Clause 8.2.7).
Type test certificates shall be submitted to the consultant engineer for verification. Routine test The panel assembler shall perform the routine test and provide the test certificates as defined in IEC standards. The routine test shall include but not limited to the following: 1. Inspection of the assembly including inspection of wiring and electrical operational test (IEC Clause 8.3.1); 2 .Dielectric test & Insulation resistance test (IEC Clause 8.3.2 & 8.3.4); 3. Checking of protective measures and of the electrical continuity of the protective circuits (IEC Clause 8.3.3) 4. Functional test as per the approved test procedure. Routine test certificates and test readings shall be submitted to the consultant engineer for verification. COMPONENTS SPECIFICATION Air Circuit Breakers The Air Circuit Breaker shall comply to latest international standards IEC60947-2. The Air circuit Breaker shall be 4 Pole Motorised Drawout type capable of handling rated
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current upto in Panel temperature of 60 deg Celsius. The vendor shall furnish derating chart from the manufacturer in the submittals. The Circuit Breaker shall have electrical lockout feature. In the event of maintenance in down stream, the operator shall keep shunt trip coil energized to avoid unauthorized closing of the Circuit Breaker. It shall not be possible to either rack out or rack in the Circuit Breaker in closed position. The Circuit shall have suitable interlock to achieve the same. Draw out Circuit Breakers shall have three discrete positions Isolate/Test/Service positions. It shall have visual indication to show position. The Circuit Breaker shall have clear visual indication to show whether it is in closed or open condition. The closing mechanism shall be spring charged mechanism. It shall be possible to visualize whether spring is charged or discharged condition. The stored energy in the spring charged mechanism shall be sufficient to ensure that, it shall be possible to open a circuit breaker, reclose & open again. It shall not be possible to close the Circuit Breaker if the position of the Circuit Breaker is not one of the Isolate/Test/Service position. The Circuit Breaker shall be self diagnostic type. It shall check the following before closure. a. The Shunt trip should be in de-energised condition. b. The Undervoltage release should be in energized condition. c. The breaker racked in fully to service/test/isolate condition. The Air Circuit Breaker shall have Service Short Breaking capacity of 65ka(Ics) at 440volts AC & short withstand current(Icw) of 65ka for 1 sec. The Circuit Breakers shall be capable of providing Total Discrimination. The Discrimination shall ensure availability of power supply to all other feeders except the feeder which is having a fault. With discrimination in the network it shall be possible for closest circuit breaker to clear the fault The protection release provided shall be microprocessor based release. The Air circuit breaker shall have adjustable Overload, Short circuit & Earth fault setting with time delay for each of the protection. Long-time (LT) protection with an adjustable current setting and time delay. Short-time (ST) protection with an adjustable pick-up and time delay. Instantaneous (INST) protection with an adjustable pick-up and an OFF position. The Protection Releases shall have built in Metering functions with metering of Voltage, Current, Power, Energy & Total Harmonic Distortions. The Protection releases shall have Residual current Protection. The Protection Releases shall display Main contact wear indication. The operating mechanism shall be of the Open/Closed/Open stored-energy type. The closing time shall be less than or equal to 70 milliseconds. The main contacts shall be designed such that no maintenance shall be required under normal conditions of use. The Circuit breakers shall be equipped with a visual wear indicator that may be accessed by removing the arc chutes, for immediate main contacts assessment of contact wear without requiring measurements or specific tools.
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The arc chutes shall be removable on site. They shall be equipped with metal filters to reduce effects perceptible from the outside during current interruption. It shall be possible to disconnect the circuit breaker without having to open the door. The three possible positions (connected, disconnected and test) shall be indicated. Mechanical Indications shall be provided for the following conditions. a. Breaker On/Off b. Spring in Charged or Discharged condition. Before carrying out a disconnection or connection operation, the operator shall be required to press a release button located on the front of the chassis. It shall also be possible to discharge the spring before racking out the Breaker( With out closing the Circuit Breaker) Circuit breakers shall be designed in such a way that maintenance may be carried out as a function of their use. Without maintenance, Electrical endurance shall be greater than 10000 cycles up to 1 600 A, 5000 cycles up to 4000A. Since the life of arcing contacts are very low & requires frequent maintenance, Arcing contact Technology in the main contacts construction is not acceptable . Moulded Case Circuit Breakers The MCCBs shall comply to International Standards as per IEC60947 -2. MCCBs shall deliver rated current at an ambient temperature of 50 Deg C. All MCCBs in the Main Distribution Board shall have Service short circuit breaking capacity of 50KA(Ics) at 440 volts. Service short circuit breaking capacity of MCCBs in Sub Main Distribution Boards shall be of 35 KA(Ics) at 440 volts. In the event considers lower fault level Circuit Breaker is considered, necessary documents shall be provided such that the fault level of the MCCB is enhanced to the above said rating with Cascading techniques. Vendor to provide corresponding supporting documents from the Manufacturer. The MCCBs shall be capable of providing Total Discrimination both Current & Time Discrimination. The MCCBs shall be Line/Load Interchangeable. The MCCBs shall have adjustable over load settings & adjustable short circuit settings for discrimination. The adjustable knob shall be accessible from the front of the MCCB. MCCBs upto 250A shall be of Thermo -magentic release. MCCBs above 250A shall be Microprocessor Based release. M CCB s ab ove 400A sh all b e of cat egory B t yp e . The MCCBs upto 250A shall adjustable overload range from 80-100%. For ratings 400A & above adjustable range shall be 40-100%. The MCCBs offered shall have trip free mechanism. The moulded-case circuit breakers shall be designed for both vertical and horizontal mounting, without any adverse effect on electrical performance. For maximum safety, E.01-34
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the power contacts shall be insulated in an enclosure made of a thermosetting material from other functions such as the operating mechanism, the case, the trip unit and auxiliaries The operating mechanism of the moulded-case circuit breakers shall be of the quickmake, quick-break type with fault tripping overriding manual operation. All poles shall operate simultaneously for circuit breaker opening, closing and tripping.
The moulded-case circuit breakers shall be capable of greatly limiting currents. For short-circuits, the maximum thermal stress I2t shall be limited to 106 A2s for ratings up to 250 A 5 x 106 A2s for ratings between 400 A and 630 A 14. Electronic and Thermal-magnetic trip units shall be adjustable and it shall be possible to fit lead seals to prevent unauthorized access to the settings. The moulded-case circuit breakers, the current ratings of which are identical with the ratings of their trip units, shall ensure discrimination for any fault current up to at least 35 kA rms, with any downstream circuit-breaker having a current rating less or equal to 0.4 times that of the upstream circuit-breaker. The electrical endurance of the moulded-case circuit breakers, as defined by IEC 947-2 standard, shall be at least equal to 3 times the minimum required by the standard The moulded-case circuit breakers shall provide class II insulation (according to IEC 664 standard) between the front and internal power circuits. This shall ensure power circuit fully insulated & no live parts shall be visible when front cover of the MCCB is opened. The operating mechanism shall be designed such that the toggle or handle can only be in OFF position (O) if the power contacts are all actually separated. Isolation shall be provided by a double break on the main circuit. Miniature Circuit Breakers The Miniature Circuit Breakers shall comply to latest international standards BS EN 60898 and IEC 60898. MCBs shall be suitable for rated voltage of 240V AC for Single Pole & 415V AC for Multiple pole range. Short Breaking capacity Icn of MCBs shall be 9KA at 240volts AC. The Service short circuit breaking capacity Ics should be minimum of 6KA. The vendor shall submit Type test Certificates from Reputed Laboratories. The MCBs shall have minimum ON/OFF cycle of 20000 operations. The MCBs shall be as per DIN standards. Plug in MCBs are not acceptable. The Characteristics of MCBs shall be Type C. RCBO
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The RCBO shall have residual current sensitivity of 30ma & comply to international standards BS EN 61009/IEC 61009. The RCBOs shall have short circuit breaking capacity of 10KA as per IEC 60898. RCCB ELCB ) s(
The RCCBs offered shall comply latest international standards BS EN 61008/IEC61008. The operating cycles(O-C) shall be minimum of 20000 operations. The RCCB offered shall provide protection against nuisance tripping due to transient voltages(Lightning, Switchgear switching in the network etc). Final Distribution Boards The Distribution Boards shall be as per IEC 60439 3 with short circuit withstand capacity of min of 15KA for 200ms. The Distribution boards shall have peak short time withstand capacity of 35KA. The ingress protection shall be IP31 as per IEC 60529. The Distribution boards shall be totally enclosed type,dust protected & vermin proof. The Distribution boards shall have hinged door which can be opened upto 180deg without any obstructions. Distribution boards with more than 8 ways shall have two locks in the door. All power socket outlets are to be equipped with RCBOs. The Switchgear components used in the Distribution boards shall be of one make(MCBs,ELCBs, ISOLATOR, RCBOs shall be of one make only) & mix of various makes are not acceptable.
Electronic soft starters.
1. This specification relates to 3-phase controlled progressive electronic starters, i.e. 6 thyristor type. 2. The starter assures the starting and stopping of 3-phase asynchronous squirrel cage IEC or Nema type motors. The possible stopping modes will be: freewheel, braked or decelerated. 3. The electronic starter will have to be developed and qualified in conformity with international standards and, in particular, with the product standard EN/IEC 60947-4-2 for starters. 4. The starter will have to be CE marked in accordance with the harmonised standard EN/IEC 60947-4-2. 5. With regards to electromagnetic compatibility, the starter will have to conform to the class A level for radiated and conducted emissions as detailed in the product standard EN/IEC 60947-4-2, and this applies to all available standard functions
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within the starter. Class B will be obtainable with additional accessories and only applies to starters with a nominal current not exceeding 170 A. 6. The starter will have to be UL 508 and CSA certified Industrial Control Equipment. 7. The manufacturing plant of the electronic starters and associated design activities will have to be ISO 9001 version 2000 and ISO 14001 certified. 8. 18 months warranty will be offered from the date of delivery or 24 months from the date of manufacture. Product description: 9. The operating principle of the starter will not have to rely simply on motor current limitation during the transitory phases or on a voltage ramp, but on motor torque control. The starter will have to provide a torque ramp throughout the accelerating phase. Therefore, it will be able to control the torque throughout the entire starting phase and, if necessary, provide a constant motor torque throughout the accelerating phase. 10. For pumping applications, the deceleration will have to be made on a torque ramp. 11. All starter ratings will have to have the same control card. This control card will have to be identical for all applications and also, the same starter will be able to be used on a crusher, a pump or a conveyor (taking into account the dimensioning). 12. All the starters will have to incorporate means whereby the actual current is measured in order to ensure protection of the motor. 13. The incoming power supply terminals will have to be positioned at the top of the starter and the terminals for connecting the motor will be at the bottom (through wiring). 14. All ratings of starter will have to have connection terminals for the starter bypass contactor. The current measurements will have to be maintained when the starter is bypassed by the contactor. 15. The starter will have to have a separate control supply. The Vendor to offer Soft Starters with Type 2 Co-ordination as per IEC60947-4-2. 16. The control terminal block for logic and analogue commands will have to be removable. Environment:
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L.V. SWITCHBOARS
17. The starter will have to be capable of operating, without derating, at an ambient temperature range between 10 and +40C and between 40 and 60C with a derating factor of 2% per degree C above 40C. 18. The maximum relative humidity will be 95%, without condensation or dripping water, conforming to the standards IEC 60947-4-2. 19. The storage temperature range can be between -25C and +70C. 20. The maximum operating altitude will be 1000 metres (3280 feet). Above this, the starter will be derated by 2.2% per 100 metre increase. 21. The manufacturer will have to indicate the noise level of the starter, which must not exceed 65 dBA. 22. If the starters incorporate fans for cooling, their continuous operation will have to be avoided. They will have to be switched automatically in relation to the temperature of the heatsink. 23. The maximum ambient degree of pollution will be degree 3 conforming to IEC 60664-1 (or IEC 60947-4-2). 24. The supplier will have to provide the wiring diagrams of the starters. 25. The supplier will have to make available motor starter combination tables comprising circuit-breakers, fuses, contactors and starters in order to assure type 1 or type 2 coordination. Electrical characteristics of the starter: 26. The utilisation category of the starters will be AC 53a conforming to the product standard EN/IEC 60947-4-2. 27. The supplier will have to be capable of offering starters in one or several ranges to cover supply lines of 208 to 690 V (208 15% to 690 V +10%). 28. The current range of the starters will be comprised between 17 and 1200 A. 29. The starter will have to automatically adapt to 50 or 60 Hz, with a tolerance of +/5%. By configuration, it will have to be capable of operating at a supply line frequency that can vary by +/-20%. 30. Logic inputs; the starter will have to include a minimum of 4 x 24 V isolated logic inputs. 31. Outputs; the starter will have to include a minimum of 3 relays with a N/O contact. Maximum switching capacity on inductive load: 1.8 A at 230 V a.c. and 30 V d.c. Minimum switching capacity: 10 mA for 6 V d.c.
E.01-38
L.V. SWITCHBOARS
32. Outputs; the starter will have to include a minimum of 2 x 24 V logic outputs. 33. Analogue outputs; the starter will include 1 analogue output with either a 0 - 20 mA or 4 - 20 mA signal. This signal will be able to be scaled. 34. The starter will have to include its own 24 V power supply for the logic inputs/outputs. 35. The supplier will have to offer a starter selection table for 2 types of dimensioning: - Dimensioning 1: From cold state (motor duty S1): 1 start at 3 In for 46 seconds. Cycle comprising starting (motor duty S4), with a load factor of 50% and 10 starts per hour, or an equivalent thermal cycle: 1 start at 3 In for 23 seconds. - Dimensioning 2: From cold state (motor duty S1): 1 start at 4 In for 48 seconds. Cycle comprising starting (motor duty S4), with a load factor of 50% and 5 starts per hour, or an equivalent thermal cycle: 1 start at 4 In for 25 seconds. Protective functions: 36. The starter will have to incorporate PTC probe processing. 37. The starter will have to continuously calculate the heating of the motor from the actual current measured (the current having to be measured and not estimated). Several classes of thermal protection will have to be offered conforming to the standard EN/IEC60947-4-2: classes 10A, 10, 20, 30 as well as the intermediary classes; one inferior to class 10A, one between classes 10 and 20 and one between classes 20 and 30. The calculation of the thermal protection must be performed even when the starter is not being supplied. 38. The starter will have to be protected against thermal overloads. 39. The starter will have to detect an underload from the motor torque information. The detection threshold as well as the allowed duration of the underload will have to be adjustable. This protection will be able to lead to either a fault on the starter or simple indication in the form of an alarm via a logic output. 40. The starter will have to detect an overload from the motor current information. The detection threshold as well as the allowed duration of the overload will have to be adjustable. The duration of the overload will be able to be adjusted from 0.1 seconds. This protection will be able to lead to either a fault on the starter or simple indication in the form of an alarm via a logic output.
E.01-39
L.V. SWITCHBOARS
41. The starter will have to have protection against supply line phase inversion and also against phase failure of the supply or motor. 42. The starter will take into account management of an external fault. When the contact is open, the starter goes to fault mode. 43. The protective functions will have to be maintained even when the starter is bypassed by a contactor. Communication: 44. The starter will have to include a multidrop serial link for its direct connection on Modbus. All Parameters shall be accessible from SCADA station. 45. The starter will have to be able to be connected to Ethernet and other networks, with connection to communication bus as an option. 46. The communication will have to provide access to the control, to the adjustment and to the supervision of the starter. Main functions: 47. The starter will be able to start and decelerate several motors in cascade. 48. A second set of motor parameters will be able to be switched to by a logic input. 49. In order to protect the motor against condensation when stopped for long periods, the starter will have to have a pre-heating function that does not involve rotation of the motor. The pre-heating current will have to be adjustable. 50. The starter will have to pilot the starter bypass contactor: control closing of the bypass contactor on completion of start-up and opening on receipt of the stop instruction. This function will have to be compatible with the stop modes: freewheel, braked and decelerated. 51. The starter will be able to control the line contactor. The contactor will have to close following the start instruction and open when the motor has come to a stop. 52. Access to the settings will be able to be code locked. The monitoring parameters will have to remain visible. Supervision: 53. The standard starter will have to have a dialogue screen and programming keys. As an option, a remote programming terminal kit will have to be available. 54. The following information will have to be accessible on the dialogue screen:
E.01-40
L.V. SWITCHBOARS
Motor current Motor torque Thermal state of motor Cosine Active power Current status (accelerating, decelerating, etc.) Elapsed operating time of starter Last fault detected
55. The following information will have to be accessible on the analogue output: - Motor current - Motor torque - Thermal state of motor - Cosine - Active power 56. The starter will include optional evolved dialogue solutions, such as: - software workshop for PC in order to prepare, store, download and print the settings, - terminal with display, clearly showing the parameters.
LV Capacitor Banks GENERAL This article specifies the requirements for the design , manufacture , testing of low voltage power factor correction sets with all necessary ancillary equipment. Three phase automatic power factor correction sets shall be installed indoor. Installation will be carried out by others and all relative information to enable the installation to be carried out efficiently shall be provided. APPLICABLE STANDARDS The design of the low voltage capacitor bank and accessories shall comply with the requirements of the latest current edition of following standards and with the specific requirements of this specification. IEC 60831 : Part 1&2- Shunt power capacitors of the self healing type for a.c systems having rated voltage up to and including 1 kV. IEC 60439-1 : Low Voltage Switchgear and Controlgear Assemblies. IEC 60947 : Low Voltage Switchgear DESIGN CONDITIONS
E.01-41
L.V. SWITCHBOARS
Ambient temperature The LV capacitor banks shall be designed for the following ambient temperature inside the electrical room : Maximum : 50C Average over 24 hours : 45C Annual average : 45C . In case of higher temperature, the components must be overrated. Altitude The LV capacitor bank shall be designed to be installed at a maximum of 2000m. Humidity The humidity withstand by the equipment shall be according to IEC 60439-1. Site pollution conditions The site pollution conditions shall be maximum class 3 according to IEC 60815 ELECTRICAL SYSTEM CHARACTERISTICS Low voltage network system Nominal system voltage : 415 V Voltage tolerance ( 415 V ) : +/-10 % Rated frequency : 50 Hz
Harmonic pollution The capacitor bank shall be designed to withstand harmonic pollution and avoid harmonic amplification. The following rules shall be taken into account. Capacitors rated 400/415 V ( for 400 V network ) shall be used if the power of harmonic generating loads in kVA is lower or equal than 15 % of the power of the transformer. Capacitors rated 470 V ( for 400 V network ) shall be used if the power of harmonic generating loads is between 15 and 25 % of the power of the transformer. Capacitors rated 470 V with Reactors tuned to 215 Hz shall be used if the power of harmonic generating loads in kVA is between 25 and 50 % of the power of transformer.
CAPACITORS The capacitors shall be low-losses units, tested in accordance with IEC 60831 part 1&2. Each element is to be of a dry self healing metallised polypropylene film and to be housed in an individual case. A protection system shall be fitted to each element which shall comprise an HRC cartridge, an integral discharge resistor and an overpressure disconnect device.
E.01-42
L.V. SWITCHBOARS
Each element forming the three phase capacitor shall be fitted with an internal discharge resistor to ensure that the capacitor is discharged to a voltage not exceeding 50 V measured at the capacitors terminals, one minute after disconnection from the power supply. The use of polychlorinated biphenols ( PCB ) and oil as capacitor impregnation is not acceptable. The capacitor losses in Watts shall not exceed 0.7 W/kvar,discharge resistor included. Enclosure and connection The group of elements forming a three phase capacitor unit shall be installed in a plastic enclosure. The capacitor shall be indoor type. Each capacitor shall be provided with three terminal pads and shall not require earth connection. Certification The three phase capacitor shall be designed and manufactured in an ISO 9001 and ISO 14000 certified plant.
Technical data Tolerance on capacitance value :
0, + 10 %.
Insulation level : 50 Hz , 1 minute withstand voltage : 6 kV 1.2 / 50 s : 11 kV Temperature class : - 25 / D Surrounding temperature : Maximum : 55 C Average over 24 hours : 45C Annual average : 35C Admissible current overloads : 30 % Admissible voltage overloads : 8 h in any 24 h period : 10 % 30 min in any 24 h period : 15 % 5 min in any 24 h period : 20 % 1 min in any 24 h period : 30 %
POWER FACTOR CONTROLLER The power factor controller shall be of the electronic type capable of switching capacitor contactors in 12 steps. The technical specification should be as follows : Connection type : Line to line or Line to neutral . Connection features : Insensitive to CT direction / Insensitive to phase rotation polarity Voltage input : 220 / 240 V Voltage measurement : Frequency : 50 Hz ( +/- 1 Hz ) Current input : CT ../ 5 A class 1 .
E.01-43
L.V. SWITCHBOARS
Step output contacts : 12 volt free contacts Alarm output contact : 1 volt free contact Momentary no voltage function : Disconnection of all steps. Once Voltage is restored (for more than 15 ms), automatic reconnection shall be made. Step configuration programming : Fixed / Auto / Not used . It shall provide the following information :
Cosine phi Connected steps Period before switching Step output status ( capacitance loss survey ) Load and reactive current Total voltage harmonic distortion Voltage , temperature, Power ( S,P,Q) Voltage harmonic spectrum ( 3,5,7,11,13 )
It shall provide the following Alarms and warning : Low power cosine phi Hunting Abnormal cosine phi Overcompensation Frequency not detected Over current Under voltage Over voltage Over temperature Total voltage harmonic distortion Capacitor overload Power factor setting : Digital , 0.8 ind to 0.9 cap C/K setting : Automatic search or manual setting Accuracy class : 1.5 % Display : 7 segments LED Temperature : Working state 0 to 50C
CONTACTORS Contactors shall be used to switch capacitors in or out of service. They shall comply with IEC 60947-4 and shall have a rating suitable for the service required. Specially suitable Capacitor Switching Contactors, which include a current limiting device , with a proven track record should be used . FUSES
E.01-44
L.V. SWITCHBOARS
Each step of the capacitor bank shall be protected by fuses. Fuses shall be of the HRC cartridge approved type to IEC 60269. Fuse shall be correctly sized according the type offered. REACTORS Detuned reactors shall be used in case of harmonic pollution. The detuned reactor shall be three phase iron core with copper winding. The reactor shall comply with IEC 60289.
E.01-45
EXTERNAL ELECTRICAL INSTALLATION
E.02.01 1.
GENERAL The installation, generally, shall be in accordance with the Regulations, for Electrical Installations, sixteenth Edition, issued by the Institution of Electrical Engineers, United Kingdom, and shall conform with all Statutory, Requirements, including the appropriate section of the following: current appropriate British Standards relevant Public Authority for Electricity and Water
Together with all Regulations and Codes of Practice applicable to such installation. 2. All equipment shall be suitable for an ambient temperature of 50 0C and relative humidity of 95%. The Sub-Contractor shall, if requested, submit at no extra cost for approval samples or any other information required on any of the materials proposed to be used in the Contract. ARMOURED CABLES LAID DIRECT IN THE GROUND Underground cables shall be laid at a minimum depth of 800mm for LV and 1000mm for H.V. cables. They shall be protected by cable warning covers, provided and erected by the Contractor. The bottom of the trenches shall be cleaned of all rocks, stones and hard objects, and covered with 100 mm of lightly compacted layer sifted soil, sand or gravel, of lightly compacted sifted soil, sand or gravel to a depth of 100 mm and this layer shall be covered with the cable covers. Warning location tape shall be provided. This location tape shall be yellow in colour, 150mm wide heavy gauge polythene strip printed with the words DANGER ELECTRIC CABLES BELOW in Arabic and English. Underground cables shall run in many cases in common services zones or common trenches with other services. It is essential that in these cases the minimum clearance between other services is kept as indicated on the Drawings. Where more than on cable is installed in the same trench, the minimum spacing between them will be twice the overall diameter of the largest cable. E.02.03 ARMORED CABLES LAID DIRECT IN THE GROUND ( CONT D) The Sub-Contractors attention is drawn to the minimum internal bending radius of cables laid down by the I.E.E. Wiring Regulations. The Contractor shall ensure that this minimum value is strictly observed and special care should be taken during the installation of the cables.
PROPOSED RECREATION CENTER E.02-1
3.
E.02.03
E.02.04
CABLE MARKERS Suitable cable markers shall be provided to permanently indicate route of the underground cables. The markers shall be provided every change of direction and at 40 meters intervals along the route. The cable markers shall be 200 x 200mm concrete posts complete with suitable lead inserts to demote the voltage and reference of the cable. The full details regarding the markers shall be agreed with the Engineer prior to manufacture and installation.
E.02.05
CABLE TERMINATION For armoured cables, termination with suitable compression glands of the type which provide an anchorage and a cross joint bonding of the armouring shall be made. The glands shall them be fitted with PVC shrouds which completely encase them.
E.02.06 1.
CABLE ROUTES The cable routes shall be generally as indicated on the drawings, the cables shall mainly be installed in areas which can easily be excavated to allow cable servicing. Where this is not possible, the cables shall be installed in ducts or trenches. Where the cables are installed in ducts, the latter shall be 150mm dia asbestos pipes encased in light concrete. All cables installed under hard surfaces, concreted areas, tarmacted areas and buildings shall be installed in ducts. Where cables cross roads, the contractor shall provide additional spare ducts. CABLES All cables shall be XLPE/SWA/PVC(Cross-Linked Polyethylene Insulated Steel Wire Armoured Polyvinyl Chloride Sheathed Cables).
2.
3.
4. E.02.07 1.
2.
Each cable shall be manufactured in one complete length and no through joints will be allowed on new cables without written authorisation from the Engineer. EARTH WIRE ALL XLPE/SWA/PVC cables shall be installed with an external PVC earth wire which shall have a minimum cross-sectional area in accordance with table 54F of the IEE Wiring in Regulations 16th
E.02.08
E.02-2
Edition. E.02.09 1. CABLE JOINT Contractor shall provide all necessary material including labour to make straight through joint of the new 11KV XLPE/SWA/PVC copper cable to the existing 11KV XLPE/SWA/PVC aluminium cable. The materials use shall be an approved standard manufacturer. SPIKING The Contractor shall include in this prices for jointing necessary costs for identifying the H.T. Cables/Phases and also for spiking of the cables prior to connecting the new copper cable with the existing 11KV cable.
2. E.02.10
E.02-3
INTERNAL ELECTRICAL INSTALLATION
E.03.01 1.
GENERAL The installation, generally, shall be in accordance with the Regulations for Electrical Installations, sixteenth edition, issued by the Institution of Electrical Engineers, United Kingdom, and shall conform with all Statutory Requirements, including the appropriate section of the following: current appropriate British Standards. relevant Public Authority for Electricity and Water.
together with all be Regulations and Codes of Practice applicable to such installations. 2. All equipment shall be suitable for an ambient temperature of 500C and relative humidity of 95%. The Contractor shall, if requested, submit at no extra cost for approval samples or any other information required on any of the materials proposed to be used in the Contract. The extent of the work includes the following: (a) (b) The supply and installation of all cables and wiring. The supply and installation of the lighting system, including all luminaires, lamps and accessories and emergency lighting luminaires. The supply and installation of socket outlets and other motive power points. The supply and installation of all wiring power and control panels to items associated with the mechanical engineering services.
3.
4.
(c)
(d)
E.03.02 A. 1.
CABLE INSTALLATION GENERAL REQUIREMENTS The routes of all cables shall be approved by the Engineer or his Representative before the installation is commenced. GENERAL REQUIREMENTS (Cont'd) The cables shall be so arranged that neither they nor their support come into contact with the pipes of any other services. They shall be run in a neat orderly manner, with easy sets and bends.
E.03-1
A. 2.
3.
All main and sub-main cables used on three phase circuits shall be clamped or bound in trefoil groups throughout their length. All main, sub-main and multicore cables shall be marked with noncorrosive labels, bearing the cable reference by the Engineer or his Representative. The labels shall be provided at each cable joint, at each end of ducts, at each termination and at intervals of 30 metres on straight runs. All labels shall be approved, a sample being submitted to the Engineer prior to installation. Cables and flexible cords other than those specially designed for high temperatures shall not be installed in conditions where the ambient temperatures attained are likely to exceed those set out in the latest editions of the Regulations for Electrical Installations. The cables may be installed in a number of ways. These may include: (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) Direct in the ground In piped ducts in concrete trenches On hangers On racks with porcelain or die cast cleats On cable tray, or cable ladder In trunking In conduit Saddled to the building structure. (This method will be allowed only in special cases).
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5.
6.
E.03-2
C. 1.
CABLES ON HANGERS OR RACKS The Contractor shall supply and install tier type iron hanger racks with die cast cleats or racks with porcelain cleats together with all fixings, rag bolts, raw bolts or girder clamps or other specialist fixing as required. Where hangers or racks are to be fixed to walls, sides of trenches and other concrete or block structures, the Contractor shall be responsible for cutting away, fixing and grouting in rag bolts and making good. The hangers and racks shall be spaced at no more than 750mm centres. They shall be designed to give at least 25mm clearance between the cable and the face to which it is fixed and, for multiple runs of cable, 75mm between cables. Multiple hangers shall have two or more fixing holes. Where cables pass through floors, they shall be protected by a section of duct which shall project 75mm above finished floor level. Where the cables pass through a slot formed in the floor a 75mm upstand shall be formed slot. All the free space in the ducts and also slots shall be packed firmly with asbestos yarn from falling through the duct or duct or slot. CABLES ON TRAY The Contractor shall provide and install all cable trays and supporting steelworks. Cables shall not be installed in more than one layer and 25% spare capacity shall be left on each tray for future development. All cables shall be saddled at not more than 750mm centre. Where cables are routed off the tray they shall be protected from any cut edges by lead flashing or other approved method. Different types of cables run on the same tray shall be kept separate. CABLES IN TRUNKING
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D. 1.
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4. E.
1. The complete trunking system in any section shall be installed and tested for electrical continuity before cables are drawn-in. All entries to the system shall be so placed as to prevent the ingress of moisture.
E.03-3
2.
Cables used for system voltages below 200V shall be run in a separate compartment from cables used for system exceeding this voltage. Where cables pass through compartment carrying cables at a different voltage, they shall be enclosed in conduit. The number of cables installed in trunking shall be such that a space factor of 45% is not exceeded. The cables shall be secured by the cable retaining clips provided. When the trunking rises vertically, the cables shall be mechanically secured at intervals of 1800mm. CABLES IN CONDUIT The complete conduit installation shall be erected and tested for electrical continuity before any cables are drawn-in. Cables of separate system, e.g. mains, lighting, low voltage lighting, power, auxiliaries, etc, shall be run in separate conduits. The number of cables drawn into any conduit shall be in accordance with the recommendation given in the sixteenth Edition of the Regulations with the exception that not more than eight cables shall be drawn into any conduit unless otherwise agreed with the Engineer.
3.
F. 1.
2.
3.
The cables shall be installed on the loop-in system, no joints or connections being allowed other than at the designed outlet positions. Cable forming the lead and return of a circuit shall be run in the same conduit. Under no circumstances cables shall be drawn into conduits until after the conduits have been screeded or buried in the structure, except that this shall not apply to surface conduit installations. Where length of cables pass through draw-in boxes, a sufficient length of slack shall be left in the cable to facilitate inspection or alteration.
4.
G. 1.
CABLE JOINTS AND TERMINATIONS The Contractor shall be responsible for terminating all cables and for checking that such terminations are in accordance with the diagrams provided. He shall provide all materials required for this work. No through joints will be followed in any cable without the prior approval of the Engineer.
E.03-4
G. 2.
CABLE JOINTS AND TERMINATIONS (Cont'd) PVC insulated PVC sheathed mains cable terminations shall be made with an approved type of compression gland. The gland shall be complete with armour clamp where required and where the armour is PVC sheathed, a PVC shroud which encloses the glands. The cores shall be terminated in sweated cable lugs or an approved type of compression lug. PVC insulated PVC sheathed multicore cable terminations shall be made with compression glands as described for main cable. The cores shall be terminated in sweated lugs crimped washers. At junction of cables inside buildings, the cables shall be terminated with compression glands in junction boxes. The cable cores shall be connected to a fixed terminal block having stud connectors of not less than 6mm diameter. Not more than one core shall be terminated on each stud, interconnections between studs being made with copper links. Telephone cable terminations shall be made with compression glands as described for mains cable. Where the cables are terminated at items of equipment, tag types terminal blocks shall be provided and the cable cross sweated to the tags. At junction boxes. The cable cores shall be terminated by the use of Ross Courtney washers and connected to a fixed terminal block. Not more than one core shall be terminated on each stud, interconnections between studs being made with copper links. For PVC insulated cables, no joints or connections shall be made in the cables other than at outlet positions where the wiring is connected to flexible lamp holders via a heat resisting flexible cable or cord. These connections shall be made in a ceiling rose or in a base fixed connector block with two brass pinching screws for each connection. The connector block shall be enclosed in a conduit box, due regard being given to the Regulations in respect of shrouding live terminals. Where the cable feeds equipment other than lighting fittings, the conduit box shall have a suitable outlet for flexible cable. Silicone insulated cables shall be as PVC insulated above, with the addition that the braiding shall be stripped back for at least 12mm from the end of the insulation at every termination.
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E.03-5
G. 7.
CABLE JOINTS AND TERMINATIONS (Cont'd) No joints or connections shall be made in coaxial cables other than at outlet positions, except where an aerial lead is to be split into two or more branches. CABLE TRAY, CABLE TURNKING & CONDUIT SYSTEMS CABLE TRAY Cable trays shall be used on multicore runs of XLPE/SWA/PVC cables, PVC multicore and PVC sheathed telephone cables unless specified otherwise. All cable trays shall be galvanised. The tray shall be manufactured of not less than 18 gauge mild steel unless otherwise stated and each length of cable tray shall be finished with a minimum of 12mm return on both edges. The cable tray shall be of adequate width for disposing the cables at single depth, with a 25% width allowance for spare cables. All cut edges of galvanised cable trays shall be prepared and treated with zinc rich paint. Site fabrication of accessories shall be kept to a minimum and manufacturers standard items shall be used where possible. Where special sections are required, the material thickness and finish shall be as adjoining section. A minimum clear space of 20mm shall be left behind all cable trays. Fixings for cable trays shall be disposed at regular intervals not exceeding 1.2 metres and at 225mm from bends and intersections. Fixing brackets shall be fabricated from mild steel flat bar. All fixing brackets shall be galvanised. All cable trays shall be electrically continuous by means of suitable fixing saddles or cleats. All cable trays shall be electrically continuous by means of 25mm x 3mm copper links across each joint in the system. STEEL CABLE TRUNKING Cable trunking shall be of minimum gauge 18 s.w.g. steel, zinc coated with a stove enameled finish in interior dry locations. In all situations where galvanised conduit is specified, but where trunking is permitted in lieu, the trunking shall be galvanised. All trunking shall be of the lipped pattern, single or multi compartment as necessary, with a copper earth continuity link mounted on each side
E.03-6
E.03.03 A. 1.
2.
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4.
5.
6.
7. B. 1.
2.
of the trunking at all joints. This earth continuity link shall be affixed to the trunking by means of cadmium plated screws with captive shakeproof washers. Copper earthing straps shall be supplied and fitted at all joints including T joints, through joints, right angle joints, etc. 3. The cover to the trunking shall be overlapping and of minimum 16 gauge steel with the same finish as the trunking itself and each length of cover shall be fitted by means of at least two coin actuated buttons complete with retaining spring. In lengths exceeding one metre fixing buttons shall be provided at intervals not exceeding 750mm. In all cases trunking shall be oversized to permit the addition of further cabling with at least 20% free space remaining when the installation is complete. Where joints are made in the trunking the jointing surfaces shall initially be free of enamel to ensure satisfactory earthing continuity and after the joint is made it shall immediately be coated with two coats of grey metallic paint. The modular covers shall have quick release fastener clamps moulded from zinc alloy. The screws used shall be stainless steel. The segmented partitions shall have PVC gaskets on flange edges. The unit rates for trunking quoted shall include for cross, tees, elbows, vertical access box, reducers, adapters, etc., all manufactured by the main trunking manufacture. Service outlet module manufactured from 2.5mm thick galvanised sheets shall have trap frame and trap covers made from high pressure zinc alloy die-cast materials. STEEL CONDUIT WORKS All conduit shall be welded heavy gauge screwed and enameled or galvanised with all necessary couplings and malleable iron draw-in and terminal boxes. Each point, switch, or switch socket shall be enclosed in to British Standard Specification to which a ceiling rose or fitting may be directly attached, shall be provided and fixed. Bends, tees or elbows shall not be used and the number and positions of boxes and the sizes of conduits shall be arranged to permit the cables being draw-in easily after all conduits are fixed. All draw-in and terminal boxes shall be provided with belled or bushed spouts tapped for conduit. Where conduits are connected to distribution boards, trunking or fittings not tapped for conduit entry, connections shall be made by means of male hexagon headed brass bushes and flanged machined face couplings.
E.03-7
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7. 8.
9.
C. 1.
2.
3.
4.
Conduits crossing expansion joints in the building shall be fitted with couplings with earthing clip at each side of the coupling, connected by 6mm2 copper wire. Conduits shall be not less than 20mm diameter and not more than six cables shall be run in any 20mm conduit. In no case shall the number of cables installed in any conduit exceed the number specified in Regulations 522-08 and Appendix 4A of the Regulations. All conduits shall be smooth in bore, true in size and all ends where conduits are cut shall be carefully remade. All joints between lengths of conduit or between conduits and fittings, boxes, etc shall be threaded home butted. Running thread connectors and locknuts shall be provided in long lengths of surface conduit to permit easy disconnection if required. Sets and bends shall be made without indentation and the bore shall remain full and free throughout. Oil shall not be used when cutting screw threads on conduit. All screw threads shall be lightly painted with metallic lead paint ground in linseed oil before being connected up.
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6.
7.
8.
C. 9.
STEEL CONDUIT WORKS (Cont'd) All conduit runs, particularly where fixed on the surface of walls and ceilings, shall be symmetrical and evenly spaced and surface conduits shall be fixed by spacer bar saddles of approved make. Conduits and fittings fixed externally or on the surface in plant rooms, switch rooms, tank rooms, and other areas likely to be subject to moisture shall be galvanised. All conduits buried in concrete or other solid building materials shall be painted with two coats of black bituminous paint. Conduits and accessories in ground floor slabs or screeds shall be galvanised. Any lighting point boxes connected to conduits concealed in voids above ceiling shall finish flush with the underside of the ceiling and all necessary extension and break joints rings shall be provided and fitted. Where direct conduit entry to equipment is not possible or desirable, as in the case of motors or equipment where adjustment of position may be necessary, the conduit shall terminate at an agreed position adjacent to the equipment and the wiring shall be continued in flexible metallic tubing fitted with brass split clamp adapters and shall be provided with separate earthing wire.
10.
11.
12.
E.03-8
13.
Not less than 450mm of flexible a conduit shall be installed unless otherwise specified and a separate earth conductor shall be run within or external to the conduit, connected to earth terminals on the connection box on the motor, starter, etc, and to the fixed conduit run. The flexible conduit will not be considered as an earth connection. All conduit work shall be erected complete with distribution boards, main switches, etc connected and shall be inspected and approved before any cables are installed. Prior to drawing-in cables all conduits shall be cleaned through with a swab. Conduits recessed in walls shall be fixed in chases cut in the wall at a depth to permit a full covering of cement and sand before plastering. All conduit drops fixed on wall surfaces shall be truly vertical and horizontal conduits shall be fixed with a slight fall to drainage holes so that any moisture which might collect in sections of conduits which are not sealed is allowed to drain away.
14.
15.
C. 16.
STEEL CONDUIT WORKS (Cont'd) Conduit runs on the surface shall be fixed by saddles at 900mm centres for 20mm conduits and at 1200mm centres for 25mm and over. Saddles shall be fixed by raw plugs and screws. Sunk conduits shall be secured in positions by crampets driven into wood plugs. All conduit and trunking throughout the contract shall be supplied by one manufacturer. Draw-in boxes shall be provided to give access to all conduits for the drawing-in or out of any cable after the installation is completed. Conduit runs rising more than two right angle bends or more than 10 metres long must have draw-in boxes. In all cases the locations shall be approved by the Engineer. The draw-in boxes must be of ample size to enable the cables to be neatly diverted from one conduit to another without undue cramping. Joints will not be allowed in draw-in boxes under any circumstances. Where draw-in boxes are required in floors, the boxes must be grouped in positions approved by the Engineer and covered by suitable floor traps. The Contractor shall include in his Tender for the supply, delivery and fixing of these traps. The floor trap covers shall be filled by the Contractor with a material to match the floor surfaces.
17.
18.
D.
P. V. C. CONDUIT WORKS 1. Plastic conduits shall be rigid PVC, super high impact Class A; conduits. All paragraphs for steel conduit above shall also apply to this clause where the method of installation is recognised as being similar for both steel and PVC conduits.
E.03-9
2.
All boxes and other conduit fittings shall be supplied from the same manufacturer as far as possible. The conduit shall be solvent welded to all fittings. The wiring shall be continuously and effectively protected along its whole length, with the conduits mechanically continuous throughout. The conduits shall be of sufficient large sections to allow cables to be easily drawn-in or out and shall not be less than 20mm diameter. The conduit work shall be concealed in floors, walls and roof slabs. No Surface PVC conduit will be allowed within false ceilings, but steel conduit shall be used instead.
3.
4.
D. 5.
P. V. C. CONDUIT WORKS(Cont'd) All corners shall be turned by easy sets or bends made cold without altering the section of the conduit. Bends shall be formed using bending springs supplied by the conduit manufacturer for the size, class and gauge of conduit. Standard 50mm centre circular boxes with steel insert clips shall be used throughout unless stated otherwise in this Specification or on the Drawings. Where conduits terminate at fusegear, switch and socket outlet boxes, etc the connection shall be made by means of female threaded adapter welded to the end of the conduit and a smooth bore threaded male bush. All conduits necessarily exposed to the weather during building operations shall be protected against the ingress of moisture by means of conduit and caps or other approved means. A suitably sized green PVC insulated circuit protective conductor shall be drawn-into all conduits, connected to an earthing terminal at all connection boxes and accessories. WIRING SYSTEMS Unless otherwise shown on the Drawings, or otherwise specified, the general method of wiring to lighting switch socket outlets, power point, auxiliary switches, etc. shall be carried out in one of the following methods. (a) PVC insulated cables in high impact grade heavy gauge PVC conduits concealed within wall, floor slabs or screeds for lighting and power. All conduits surfaces within false ceilings shall be galvanised steel. PVC insulated cables in steel trunking and steel heavy gauge screwed conduits in the plant rooms and similar locations.
E.03-10
6.
7.
8.
E.03.04 1.
(b)
The installation shall be surfaced mounted. (c) PVC insulated cables within steel conduits concealed in floor slabs or screeds and within walls for Fire Alarm Services. PVC insulated cables in heavy gauge steel conduit generally as installed in (c) above, for Emergency Lighting. High impact grade PVC conduits concealed in floor slabs or screeds above the false ceilings and within walls housing cables for other auxiliary services. PVC insulated cables in heavy gauge galvanised water tight steel conduits in roof areas.
(d)
(e)
(f)
E.03.05
LIGHTING SWITCHES LOCAL LIGHT SWITCHES Light switches shall be rated at 10A and shall comply with BS 3676 and be suitable for operating on an inductive load. Lighting switches shall be, a. supplied by the Contractor and installed in the positions specified. b. mounted in sheet steel boxes of minimum 37mm depth fitted with adjustable grids to allow for variations in thickness of plastered walls. mounted in multi-gang assemblies where grouped. of the sunk type where used with concealed conduit or other wiring systems. of the type suitable for the nature of the supply to which they are to be connected, e.g. quick make and break for DC and AC.
c. d.
e.
The mounting height to the centre of the switch shall be 1250mm unless otherwise specified, and where the structure and furnishings permit, the distance from the edge of the architrave to the near edge of the switch shall be 150mm. Where several switches on one phase are shown at one position, a ganged box shall be used. Different phases shall not be ganged in one box unless each phase is segregated in a separate compartment which is covered by a separate internal warning plate.
ELECTRICAL MATERIAL & ACCESSORIES
E.04.01 1. 2. 3. 4.
GENERAL The supply voltage will be 415/240V a.c. 3-phase, 50Hz 4-wire. All material and accessories shall be suitable for an ambient temperature of 50C and relative humidity of 95%. All PVC materials and accessories exposed to sunlight or to be U.V. stabilized to ensure that no deterioration will occur. All materials and accessories shall be manufactured, built or assembled to conform or comply to the following: - current appropriate British Standards - relevant Ministry of Housing, Electricity and Water Regulations.
E.04.02 1.
GENERAL PURPOSE SOCKET OUTLETS These shall be switched, complying with BS 1363 and shall be installed in the position shown on the Drawings and shall be of the 13amp flat pin type. The socket outlets shall match the chosen lighting switches in that particular room or area. Switched socket outlets shall comply with BS 1363. The switched socket interior shall be mounted to grid which shall have provision for both lateral and vertical adjustment. The grid shall be of 16 s.w.g. mild steel, zinc plated to a minimum of 5 microns thick. The front cover plate shall be secured to the grid plate and switchedsocket interior by countersunk screws finished to match the cover plate. For flush installations the cover plate shall overlap the box by 7 mm and for surface installations it shall be the same size as the galvanised cast iron boxes which shall be employed in such locations. In plantrooms and similar areas the switch sockets shall be industrial pattern galvanised and on the roof all switch sockets shall be weatherproof. A radial final sub-circuit may be installed to serve a maximum of 6 socket-outlets in rooms other than kitchen and controlled by a 20AMP circuit breaker in the distribution board. A ring final circuit formed by looping into every socket on the ring all three conductors (phase, neutral and earth continuity) commencing and returning to the same way in the distribution board, may serve a maximum of 10 socketoutlets in rooms other than kitchen, no spurs shall be connected to a ring circuit. A ring circuit shall be controlled by a 30 AMP circuit breaker.
2. 3.
4. 5.
6.
E.04.03
FUSED CONNECTION UNITS All fused connection units shall be supplied and installed as shown on the drawings and manufactured in accordance with BS 5733. These shall match the chosen lighting switches and socket outlets in that particular room or areas required flush the outlet box shall be fitted with adjustable fixing lugs. Where fused connection units are detailed with integral pilot lights these shall be of the low current consumption type and incorporated in the outlet plate behind a red coloured plastic lens. Where detailed on the drawings these units shall be provided with a cable entry facility with provision for changing the cable. All fuses shall be of the cartridge type complying with BS 1362.
E.04.04
DOUBLE POLE SWITCHES All double pole switches shall be supplied and installed as shown on the drawings and manufactured in accordance with BS 3676. These shall match the chosen lighting switches and socket outlets in that particular room or area. Double pole switches shall be mounted in suitable sheet steel or iron clad boxes with conduit entries. Where units are required flush the outlet box shall be fitted with adjustable fixing lugs. Where double pole switches are required with integral pilot lights, these lights shall be of the low current consumption type and incorporate in the outlet plate behind a red coloured plastic lens. Where required these units shall be provided with cable entry facility with provision for changing the cable.
E.04.05
LOCAL ISOLATORS All local isolators shall be supplied and installed as shown on the drawings and shall be of the 500 volt duty type. Enclosures for isolators shall be fabricated from rust-protected sheet steel in stoved paint finish with gasketed doors and fitted with on/off indication and provision for internal fixing unless otherwise specified. The isolators shall have a protection rating of IP 65.
E.04-2
E.04.05
LOCAL ISOLATORS The isolator shall be suitable for padlocking in the off position. Interiors shall comprise porcelain bases fitted with non ferrous (brass) conducting components. Switches shall be of the quick make break type suitable for use on either AC or DC. Shields shall be fitted over both fixed and removable contacts. All equipment shall be tested to BSEN 60947-3 : 1992 category AC 23. Where isolators are to be weatherproof they shall generally be as described above and in addition shall be provided with cast iron enclosures fully gasketed to prevent the ingress of water and suitably finished to prevent the effects of corrosion. Stay put stop buttons operating on the control circuit of the motor starter shall not be used as the sole means of isolation of a motor and each starter shall be provided with an isolator. Where stay-put stop buttons are specified a warning notice shall be mounted adjacent to the button to read as following Emergency Stop- isolate and lock off at starter isolator in Arabic and English. Where stop buttons are provided for motors with assisted start type starters it shall only be possible to restart the motor in the motor in normal sequence.
E.04.06
45A COOKER CONTROL UNITS All cooker control units shall confirm in every respect with BS4177. they shall be of AC 250V type 45A double pole main switch socket outlet and pilot lamps.
E.04.07 1.
FLOOR BOXES Floor shall be multi-compartment galvanised heavy gauge steel, provide with a robust steel lid. Floor outlet boxes to be fixed to the bottom of the raised floor panels. All boxes shall be fitted with cable separators to segregate the mains and telephone cables and shall be provided with a cast frame and reversible recessed tray to cater for 12mm thickness of floor covering. Means of adjustment shall be provided to enable the lid to be accurately levelled. The boxes shall incorporate outlets as detailed on the Drawings. The cover plate shall be suitable for marble covering.
2.
E.04-3
E.04.08
ROOM THERMOSTATS/DETECTORS FOR A/C These shall be mounted on a BS 4568 terminal conduit box and shall be located as indicated on the drawings.
E.04.09
LOCALLY CONTROLLED EXTRACT FANS Locally controlled extract fans may be connected either to the lighting circuits or via a fused spur box power circuits, unless otherwise shown on the drawings provided the load does not exceed 2 amps. The final connection to the fan shall be made by means of white PVC insulated and sheathed flexible cable connected to a white 5 amp plug and socket which shall be mounted immediately adjacent to the fan.
E.04.10
ELECTRIC WATER HEATERS SWITCH All double pole switches shall be supplied and installed as shown on the drawings and manufactured in accordance with BS 3676. These shall match the chosen lighting switches and socket outlets in that particular room or area. Double pole switches shall be mounted in suitable sheet steel or iron clad boxes with conduit entries. Where units are required flush the outlet box shall be fitted with adjustable fixing lugs. Where double pole switches are required with integral pilot lights, these lights shall be of the low current consumption type and incorporate in the outlet plate behind a red coloured plastic lens. Where required these units shall be provided with cable entry facility with provision for changing the cable.
E.04.11
ELECTRICAL ACCESSORIES COVER PLATES Cover plates shall match the chosen lighting switches in that particular room or area.
E.04.12
LUMINAIRES The Contractor shall supply, install test and commission all the luminaires as listed in the drawings.
E.04.13 1.
CABLES POLYVINYL CHLORIDE (PVC) INSULATED CABLES AND FLEXIBLE CORDS. All PVC cables shall be 300/500 volt grade and shall conform to size, coverings and resistance as set out in BS 6004 PVC insulated cables
E.04-4
(non-armoured) for electrical power and lighting. Every flexible cable and flexible cord for use at low voltage shall comply with the British Standards listed below: BS 6500 Insulated Flexible Cords BS 6007 Rubber Insulated Flexible cables BS 6004 PVC Insulated Flexible Cables (non armoured) BS 6977 Rubber Insulated Flexible Travelling Cables for Lifts. In no case shall cables and flexible cords shall comply with requirements 514-07, and tables 51B of the IEE Regulation. The whole of the wiring shall be carried out in the looping-in system. Junction boxes and joints in cables shall not permitted. All cables shall be copper conductors unless otherwise specified. Conductors shall not be wrapped round stud terminals. Crimped lugs applied with a tool specifically designed to prevent inadequate criping shall be used to connect cables to stud terminals. The cable insulation shall not be trimmed back beyond the lug. PVC cables shall not be brought direct into luminaires but terminated in a connector block or plug in ceiling roses in false ceiling areas. 2. MINERAL INSULATED COPPER SHEATHED CABLES(MICS) The conductors shall be singled strand high conductivity annealed copper, insulated with a highly compressed mineral substance and sheathed with a solid drawn tube of annealed copper. All cables shall be 1000 volt grade except when specifically detailed otherwise in this Specification and manufactured to BS 6207 : 1991. 3. CROSS-LINKED POLYETHYLENE INSULATED STEEL WIRE ARMOURED POLYVINYL CHLORIDE SHEATHED CABLES (XLPE/SWA/PVC CABLES). 600/1000 Volt Grade Cables All XLPE/SWA/PVC cables shall manufactured in accordance with BS 5467: 1989 with copper conductors. Conductors shall be plain annealed stranded copper complying with BS and IEC 228. The insulation shall consist of cross-linked polyethylene applied by extrusion to form a compact homogenous layer. The bedding shall comprise either layers of non-hydroscopic tape compatible with the operating temperature of the cable or a layer of extruded PVC.
Armouring of multicoloured cables shall consist of a single layer galvanised steel wire complying with BS 1442 and served with extruded PVC over sheath , the external surface of which shall embossed with the voltage designation. Core identification shall provided by either colour code or by numerals on black insulation.
of an be be
Where unarmoured single-core XLPE/PVC cables are detailed on the drawings they shall be as described above where applicable. For armoured cables at all terminations and joints involving the severance of termination of the wire armour the conductivity of the wire armour throughout the system after bonding shall not be less than that of the original wire armour of the cables. Further, suitable precautions shall be taken to protect the bonds in such a way that the integrity of the bonds shall be assured throughout the life of the cable to the conductivity of the bond must not deteriorate due to oxidation or other causes. The tests detailed in BS 5467:1989 shall be carried out at the Manufacturers works and the results submitted in triplicate to the Engineer. Tests shall also be made on site following the installation of cables and in the event of failure to withstand the tests, replacement, making good and retesting shall be carried out at no additional expense until the cable withstands the tests. Each cable is to be manufactured in one complete length and no through joints will be allowed on new cables without written authorisation from the Engineer. 4. PVC INSULATED SWA/PVC SHEATHED CABLES PVC insulated armoured cables shall comply with BS 6346 PVC insulated cables for electricity supply with shaped cores and the neutral of the same cross section as the phase cores unless otherwise specified. PVC insulated single wire armoured PVC sheathed cables shall be 600/1000 volt grade cable and shall be terminated in approved glands supplied by the cable manufacturers which shall not leave any armouring exposed. The glands shall be covered with PVC shrouds. All cables shall be copper conductors and will comply with IEE Regulations Appendix 4.
5.
SINGLE CORE CABLES All single core cables shall have stranded copper conductors. When connecting or jointing cable the phase to phase colour coding as detailed herein shall be maintained.
E.04-6
E.04.14 1.
FUSED SWITCHES AND SWITCH FUSE Fused switches, switch fuses and isolator switches shall be of the type actuated by a quick-make-and-break movement, the spring being in tension or compression only during the operation of making or breaking contact. Switch contact clips shall be phosphore bronze and mounted on individual porcelain base, enclosed in case of cast iron or pressed steel with hinged dust tight lids interlocked with the switch section to prevent opening with the switch closed or closing the switch with the lid open, and suitable for conduit entry. Neutral links shall be of the bolted-down switched pattern type and enclosed in the same as the switch fuse or switch. All connection shall terminate in substantial mechanical clamps. All switch fuses and fuse switches shall be fitted with ASTA certified HRC standard cartridge fuse links to comply with BS88. SERVICE OUTLET NODES The contractor shall provide all electrical connections required to the service outlet nodes, where necessary and this equipment shall comply with the requirements set out in the Specification. The contractor shall provide detailed drawings of the ceiling mounted service nodes to the Engineer for approval, showing the proposed method of offering services to these boxes, in the manner described below. The contractor shall allow within the tender submission all associated costs to provide service connections to the ceiling mounted service nodes boxes, positions of which are shown on the drawings. Each service outlet node shall be capable of accepting the electrical service connections as indicated in the schedules and drawings.
2.
3. 4.
E.04.15 1.
2.
3.
The method of connection of services shall be as follows: 30A supplies shall be run in conduit, fixed directly to the underside of the structural slab and terminated within an adaptable box directly above the service outlet node. Flexible connections will emanate from the adaptable box and enter the top sections of the outlet node and terminate within the appropriate outlet.
E.04-7
FIRE ALARM SYSTEM
E.05.01
EXTENT OF CONTRACT The Contractor shall be responsible for the following: i) The supply and delivery to site digital Fire Alarm equipment, Fire Alarm cables and all necessary accessories and materials. Installation Testing and Commissioning Connection of the systems to the permanent mains supply and earthing as applicable. The provision of special tools and test equipment for maintenance. The supply of operational, maintenace manuals as required by the contract. and spare parts
ii) iii)
iv)
v)
vi)
Application to other authorities involved, for the approval of parts of the installation or equipment, as applicable. Any other works shown on drawings or described elsewhere or required for the completion and correct and safe operation of the installation. The provision of supervision and testing of the system by the system supplier or his trained representative. The Contractor shall make all necessary connections and provisions to the existing mimic panel and the main Fire Alarm panel in the Administrative Building.
vii)
viii)
ix)
E.05.02
STANDARD PRODUCTS All equipment supplied under this contract shall be the standard products of manufacturers, regularly engaged in the production of such equipment and shall be the manufacturers latest standard design.
E.05.03
POWER SUPPLY The voltage available is 240 V +/- 6%, 1-phase, 50 Hz.
E.05.04
I.E.E. WIRING REGULATIONS All electrical work apertaining to the works shall be executed strictly in accordance with the 16th Edition of the I.E.E. Wiring Regulations and any supplements, addenda or published revisions thereto.
E.05-1
FIRE ALARM SYSTEM
E.05.05
QUALITY AND STANDARDS All materials, devices and equipment used, shall be new, of high quality and in compliance with these specifications and to the last published issue of BS 5839 and BS 5306. Other standards of manufacture equivalent to BS may be accepted but sufficient technical information is required to be submitted together with the tender in order to verify the standards of manufacture as described in the paragraphs that follow.
E.05.06
TEST ON COMPLETION On completion of the works the Contractor, shall arrange for witness test to be carried out as required by the Engineer together with such other test as may be considered necessary by the Engineer in order to prove compliance with this Specification.
E.05.07
TEST ON COMPLETION The Contractor shall submit for the Engineers approval full details, of the procedure he intends to adopt and the measurements and readings he intends to take. The Contractor shall co-operate as necessary with other Contractors to ensure that all necessary preparations are made and that all equipment is ready in all respects for Site testing on the appropriate date. The cost of all such tests and inspections shall be borne by the Contractor. All testing instruments and apparatus are to be provided by the Contractor but the Engineer may if he so desires use his own instrument and apparatus as a check.
E.05.08 1.
TRAINING Tenderers shall indicate the avilability and means proposed to train Operator and Maintenance Staff. The cost of such training shall be borne by the Contractor. Operator The Contractor shall carry out operator familiarisation of the equipment for operators, qualified at the appropriate level, on site, at start up time.
2.
3.
Maintenance Staff The Contractor will be required to provide training for engineers and/or technicians in all technical aspects of the equipment being supplied under the Contract.
E.05-2
FIRE ALARM SYSTEM
The training shall be designed to give special emphasis to troubleshooting technique, fault diagnosis remedial and preventive maintenance. Where the equipment consists of various subsystem care should be taken so that the training proposed covers all subsystems in depth. Full details and contents of the training programme must be submitted with the Tender. The training must be scheduled to commence before the installation of the equipment. Tenderers should indicate the level of competence required for participation in the training programme, the outline of which and duration should be detailed. The training and associated literature should be in the English and Arabic language and the training documentation should be provided free of charge to the trainees during the training programme. E.05.09 LITERATURE Full and detailed description and technical specification for the porposed equipment and apparatus should be submitted in duplicate with the Tender. E.05.10 SAMPLES Samples of all items offered must be submitted on request. E. 05.11 DETAILED SPECIFICATION FOR THE SYSTEM For detailed specification for the above system refer. Section E 13.
E.05.12
WIRING Wiring shall be drown in galvanised trunking and galvanised conduits as indicated on the drawings. Cables in galvanised trunking & conduit Single core cables having themosetting insulation non armoured complying with BS 5467 & BS 7211.
1.
2.
Cables for prolonged operation Cables used for the interconnection of (a) control and indicating equipment (b) sounders, power supplies and remote transmission equipment with the control and indicating equipment (c) remote
E.05-3
FIRE ALARM SYSTEM
transmission equipment with telephone distribution cases, except of the parts running in plaster covered PVC conduit. (i) Comply with BS 6387 meeting at least the requirements for categorization as B; (Resistance to fire:7500C)
or (ii) Be in accordance with the requirements of BS5839:part 1:1988 Paragraph 17.6 - alternative cables (for prolonged operation) and at least equivalent to the cable described in (i).
3.
Manufacturers data - Test Certificates All Tenderers are required to submit at the stage of tendering all necessary manufacturers data to prove the compliance of the cables offered for prolonged operation with the requirements of the specification. Test certificates shall be submitted with the cable by the successful tenderer.
E.05-4
FIRE ALARM SYSTEM
APPENDIX NO. 1 MODEL CERTIFICATE OF TESTING OF A FIRE ALARM Certificate of testing of a fire alarm system at:
Protected
area: .............................................................................................................. .............................................................................................................. ..............................................................................................................
Address:
1.
The system is operational and has been checked and tested in accordance with BS 5839:Part 1:1988. Extensions and alterations to the existing system. Quarterly inspection test Annual inspection and test Servicing after a fire Servicing following a false alarm Servicing following excessive false alarm Servicing following a fault Othe non-routine attention ............................. ............................. ............................. .............................. ............................. ............................... ............................... ..............................
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Specify
.................................................................................................. ..................................................................................................
NOTE: 2.
............. Mark as applicable FINDINGS: .................................................................................................... ......................................................................................................................... .........................................................................................................................
E.05-5
FIRE ALARM SYSTEM
3.
REMARKS: .............................................................................................................. ......................................................................................................................... .........................................................................................................................
Signed ........................................... Status:............. Date: ............................ for and on behalf of Contractor.
Signed ............................................ Status:.................... Date: ............................ for and on behalf of the user.
E.05-6
FIRE ALARM SYSTEM
APPENDIX NO. 2 MODEL LOG BOOK FORWARD: It is recommended that this log book is maintained by a responsible executive who should ensure that every entry is properly recorded. An event should include fire alarms (whether real or false), faults, tests, temporary disconnections and the dates of installing or servicing engineers visits with a brief note of work carried out and outstanding. REFERENCE DATA Name and address: .................................................................................................. .................................................................................................. ..................................................................................................
Responsible person:
........................................................ Date:....................... ........................................................ Date:....................... ........................................................ Date:....................... ......................................................... Date:.......................
The system was installed by ...................................................................................... ..................................................................................................................................... and is maintained under contract by ............................................................................ .................................................................................................................................... Tel. No.:..............................................who should be contacted if service is required. EVENT DATE Date Time Zone Event Action req.Date Compl. Initials
E.05-7
E.06.01 1.
GENERAL The lightning protection system shall be in full compliance with BS 6651. The lightning protection system is detailed on the drawings and the Contractor shall follow closely this design which has been co-ordinated with the Architectural and structural elements of the building. To ensure an effective system and a satisfactory long term performance all fittings need to be mechanically robust and provide good corrosion resistance qualities in the environment 50OC and 95% relative humidity. All materials used shall be suitable for Lightning Protection Installation. AIR TERMINATION The air termination network is a combination of copper conductor in a 10 x 20m mesh. The copper conductor shall be high conductivity annealed copper. This shall be of minimum 70mm2 area. The conductor shall be fixed to the structure by means of metallic heavy duty saddles or clips. DOWN CONDUCTOR The down conductors shall be high conductivity P.V.C. covered copper tape with minimum size 70mm2 area. The down conductors shall provide a low impedance path from the air termination network, to allow the lightining current to be safely conducted to earth.
2.
3.
4. E.06.02 1.
2.
3.
E.06.03 1.
2. 3.
The down conductors shall be positioned as indicated on the drawings. The Contractors attention is drawn to the re-entrance loops, the length of the conductor forming the loop should not exceed eight times the width of the open side of the loop. Each down conductor shall be connected to the earth electrode through a purpose made Test Clamp which shall be positioned on within the Earth pit.6 EARTH TERMINATION NETWORK The resistance of the earthing network to the general mass of the earth shall not in any event exceed the value of 10 0hm.
E.06-1
4.
E.06.04 1.
2.
Each down conductor connects to an earth pit having one deep driven earth electrode 6.0 metre length. All these electrodes are connected with a strip electrode buried at 600mm depth. The earth rods shall be manufactured to BS 6651, these should be pure electrolytic copper, molecularly bonded into steel core minimum thickness 0.25 mm. This shall have a high strength steel driving head allowing power hammers to be used for deep driving. The top of each rod electrode shall be housed in a purpose made concrete pit to facilitate inspection. The pit shall be complete with a lid and the assembly shall be sunk flush with the ground level. BONDING TO AIR TERMINATION NETWORK All metal projections including masts,aerials, air conditioning units, handrails, water tanks, extract fans, pipes, etc. shall be bonded to the network.
3.
4.
E.06.05 1.
E.06-2
E.07.01 EARTHING ARRANGEMENT GENERAL 1. The consumers main earthing terminal shall be connected to an installation earth electrode by an earthing conductor. The earth electrode in this instance shall mean an earthing borehole to ensure a value of an earth resistance not greater than one ohms to meet the I.E.E. Regulations 16th Edition. The earthing borehole shall be deep enough to reach the water table or permanent moisture level in order to ensure that the specified value of resistance is met even at extreme weather conditons. The connection between the building main earthing terminal and earth electrode shall be made of PVC covered 25mmx3mm solid copper tape. All earthing and bonding installation and equipment shall comply with the requirements of the IEE Wiring Regulations 16th Edition and BS 7430 : 1991 Earthing. Descriptions of earth conductors or electrode locations are intended to define the minimum standards to which the installation shall conform. Reference to the cross sectional area conductors in this Specification and the Specification drawings relate to the minimum size of conductors that will be accepted. EARTHING TERMINALS The building Main earthing terminal will be located in the L.V. Switchroom and shall be a copper earth busbar mounted on the wall by means of ceramic insulators. This shall connect the following conductors to the earthing conductor: (i) (ii) circuit protection conductors main bonding conductors
2.
3.
4.
E.07.02
Provision shall be made in an accessible position for disconnecting the main earthing terminal from the means of earthing to permit measurement of the resistance of the earthing arrangements. This joint shall be such that it can be disconnected only by means of a tool, be mechanically strong and reliably maintain electrical continuity.
E.07-1
E.07.03
PROTECTIVE CONDUCTOR Protective conductors shall be supplied and installed in accordance with IEE Regulations 16th Edition Chapter 52 and Regulations 543. Types of protective conductor: (i) A cable containing a protective with the British Standard for that cable. (ii) In a final ring circuit the protective conductor must be arranged as a ring in the same way as the phase conductors with each end of the protective conductors connected to the earth terminal of the circuit. This does not refer to the metal cable covering or enclosure. Protective conductors formed by the metal enclosures of factory made switchboards, distribution boards and busbar trunking, etc. must be designed to satisfy to the need for (i) protection against detrimental mechanical, chemical or electrochemical effects (ii) have a conducting sectional area not less than that which is calculated by the previously mentioned formula, and (iii) have provision for connecting other protective conductors at all branch points on the assemblies. The sheath and/or armour or metallic covering of a cable used as a protective conductor must meet the requirements stipulated at items (i) and (ii) of item3. It is prohibited to use a flexible metal conduit as a protective conductor. A separate protective conductor must be fixed to the outside of the flexible conduit and terminated on the equipment at each end. The protective conductor should be calculated in accordance with BS Standard. Exposed metal enclosures of equipment must not be used as a protective conductor for other equipment. Conductive parts not forming part of the electrical installation must not be used as protective conductors. Permanently fixed and reliable extraneous metal parts may, however, be utilised for supplementary bonding. conductor must comply
(iii)
(iv)
(v)
(vi)
(vii)
E.07-2

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M&E WORKS SPECIFICATION

LIGHTNING PROTECTION SYSTEM

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

0.1 PRELIMINARIES DELETED 0.2. GENERAL SPECIFICATIONS

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

Fuse-Switch Units and On-Load witches

0.2.1.12. Circuit Breakers

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

0.2.2.2. Low Voltage Cable

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

0.2.2.9. Cable Tray

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

GENERAL TECHNICAL REQUIREMENTS

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER

M&E WORKS SPECIFICATION SECTION E.00

PROPOSED RECREATION CENTER