Khyber Pakhtunkhwa Cities

Improvement Project (KPCIP)

Kotal Township (KDA) Sewerage System

Particular Specifications

Volume 2- Proposed Sewage Treatment Plant

June 2021
 Table of Contents

Particular Specifications Sewage Treatment Plant Kohat

Specifications Section Title

General & Mechanical

1001 Particular and General Requirements

1002 Screening Equipment

1003 Wastewater Pumps

1004 Sludge Pumps

1005 Sump Pumps and Plant Drain Pumps

1006 Scraper Primary & Secondary Settling Tanks

1007 Scraper Sludge Thickener

1008 Aeration System (Blower, Diffusers, Air piping)

1009 Motorized Penstocks

1010 Manual Penstocks

1011 Valves

1012 Flow Meters for Wastewater and Sludge

1013 Overhead Crane

1014 Ductile Iron (DI) Pipes and Fittings

1015 HDPE Pipes & Fittings

1016 Commissioning Tests

1017 Operation & Maintenance Manual

1018 Laboratory Equipment

1019 Corrosion Protection

SCADA System

1101 Instrumentation and SCADA System

Electrical System

1201 Basic Electrical Materials and Methods

1202 Grounding and Bonding

1203 Conductor and Cables

1204 High Voltage Cable

1205 Packaged Engine Generator

1206 Medium Voltage Power Factor Correction Equipment

1207 High Voltage Oil Distribution Transformer

1208 High Voltage Switchgear

1209 Automatic Transfer Switch

1210 Medium Voltage Switchboards

Electrical Works BASIC ELECTRICAL MATERIALS AND METHODS

SECTION 1201

BASIC ELECTRICAL MATERIALS AND METHODS

PART 1 GENERAL

1.1 SCOPE

This section covers the furnishing of labor, materials and equipment under other sections of this
Contract; installation of all equipment, as may be furnished by the Client; and furnishing and
installation of all additional equipment and materials needed for the electrical requirements of this
Contract.

The scope of work includes, but is not limited to the following:

- Switchboard and Panel boards

- Interior Power and Lighting Systems

- Exterior Lighting

- Grounding and Bonding

- All other Electrical and Auxiliary Works

- Emergency and Security Lighting System

- Generators and Automatic Transfer Switch and Fuel Tanks

- All interconnecting wiring and cabling including cable glands, boxes, conduits, cable trays,
ladders, termination kits, etc.., underground cable ducts and manholes, trenches, supports,
steel poles, foundations and associated miscellaneous civil engineering works

- All necessary instruments for testing of switchgear, control gear and auxiliaries for
equipment, foundation bolts, fixings, locks, etc., any replacement fuses or devices required,
used during the Commissioning Period

- Spares and Special Tools for Maintenance

- The supply of Drawings, Operating and Maintenance Manuals and other Documentation in
accordance with this Specification

- Erection, Testing and Commissioning of all relevant equipment

Work shall include furnishing all labor, materials, tools, equipment and services to construct and
install, test and commission the complete electrical system as indicated on the drawings, specified
herein and subject to the requirements of the Conditions of Contract. For any deviations from the
contract drawings pertaining to the ratings of electrical equipment, due to the use of codes and
standards of the country in which the equipment is manufactured, it shall be the responsibility of
the Contractor to verify the precise requirements and to provide and/or adjust to their correct
settings or sizes, cables, circuit breakers, starters, overload heaters, relays, instrument
transformers, etc., this shall be at no added extra cost to the Client.

1.1.1 Contract Provision:

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The Contractor will be required to make provision for the following and his prices shall be deemed
to include for any cost arising there from:

- Transportation of labor and materials to and from the Site of Works

- Suitable accommodation for the storage of plant and materials

- All lifting tackle and gear required for the necessary execution of the Works

- Workshop facilities for the drilling of brackets, lighting, welding and light fabrication

- Supply and installation of any component of work whether or not shown on the drawings
and/or described in the Specifications and/or Bill of Quantities, but which can reasonably
be inferred as necessary for proper completion of the Work

The General and Special Provisions shall apply to all works under this Section.

1.1.2 Training of Technical Personnel:

A rate shall be included in the Schedule of Prices to provide for the training of selected members
of the Client's Technical Staff in the event of this option being taken up.

1.1.3 Related Works:

This Section covers the requirements for the installation of electrical equipment furnished under
other sections of this Contract.

1.1.4 Alternatives:

Redesign of or part of electrical or mechanical work, which is required due to the Contractor's use
of an alternate item, arrangement of equipment and/or layout other than specified herein; shall be
done only by the Contractor at his own expense, if approved by the Engineer. Redesign and
detailed drawings shall be subject to acceptance and approval of the Engineer. No additional
compensation will be provided for changes in the work, either his own or others, caused by such
redesign.

Alternate proposal shall only be permitted if equal to or better and only if with considerable savings
to the Client than what is specified herein and when deemed by the Client as of absolute necessity.
Contractor may proceed only upon concurrence by the Engineer and upon approval of all redesign
details, which may have direct or indirect impact on other disciplines. No additional cost will be
provided for changes in the work. Redesign or altered drawings, reviewed by the Engineer, shall
not relieve the Contractor of any or all of his contractual obligations and responsibilities with the
Client for proper and complete installation and operation of all materials and equipment, including
related accessories as required or detailed on the Contract.

Although substitution in general is forbidden, proposed alternatives may be submitted for approval.
The Contractor shall provide sufficient data to allow evaluation of proposed alternative and
determination of compliance with Contract documents. The Contractor shall list any proposed
deviation from these Contract documents.

1.2 REFERENCES

1.2.1 International Standards:

The design, manufacture, installation practices and testing of the materials, plant equipment and

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systems are to be supplied, constructed and rated in accordance with the standards or approved
International Standard of design or manufacture unless otherwise specified. In all cases, the latest
issue of Publications, Specifications, Standards and/or Codes of Practice shall apply.

Approved Standards include:

- The Regulations for the Electrical Equipment of Buildings (lEE)

- British Standard Specifications (BS)
- National Electrical Code (NEC)
- National Electrical Manufacturing Association (NEMA)
- International Electrotechnical Commission (IEC)
- Illumination Engineering Society (IES)
- Commission Internationale de l'Eclairage (CIE)
- National Fire Protection Association (NFPA)

1.2.2 National Local Codes:

The Work shall also consider local WAPDA / Pakistan Electric Codes, Regulations and Standards.

1.2.3 Regulations:

All supplies and services offered response to this specification shall conform to the latest standards.

The design, equipment and installation requirements shall comply with the standards and
recommendations laid down by the following:

- Regulations for Electrical Installations as issued by the WAPDA / Pakistan Electric Codes
for Transmission & Distribution lines

- Standards relating to Electrical Installations and equipment as issued by International

Electrotechnical Commission (I.E.C.) and British Standard Institute (BSI)

- Regulations for Telephone System Installation as issued by PTCL

- National Electrical Code issued by National Fire Protection Association (NFPA), Boston,
U.S.A.

- Rules of the RESCUE for Fire Alarm Installation

Where two or more applicable standards and/or the Specifications are on conflicts, the
most stringent shall apply.

The Contractor shall be responsible for ensuring that all items of electrical systems comply
with the requirements of these Governing Standards; that the manufacturers comply with
all the necessary instructions and that these instructions are included in the Operating and
Maintenance Instructions when submitted.

The Contractor shall be responsible for providing all electrical equipment with the
necessary, warnings signs and instructions. These shall cover maintenance, working,
operating and access or egress. All electrical equipment rooms shall have a notice
permanently secured to all doors stating "No Admittance to Unauthorized Personnel".
Where the noise level is in excess of 80 dbA, there shall be installed a warning notice on
all doors in accordance with the Governing Standards for reducing the exposure of noise
to operating personnel.

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All notices shall be permanently engraved with the text in both Urdu and English.

1.2 COORDINATION

The drawings indicate the extent and general location and arrangement of electrical equipment,
conduit and wiring, poles, manholes, trenches, etc.. All works shall be carefully laid out in advance,
coordinating electrical features with architectural, structural and mechanical features of
construction. Any conflicts which occur necessitating departures from the drawings shall be
submitted in the form of details of departures and reasons therefore as soon as practicable for
written approval.

Where any of the electrical work may interfere with the work of other trades, assist in working out
space conditions to make a satisfactory adjustment. If requested by the Engineer, the Contractor
shall prepare, scaled working drawings and sections which clearly show how the work is to be
installed in relation to the work of other trades.

1.3 SUBMITTALS

1.3.1 General:

All materials and equipment shall be submitted for review in accordance with the requirements set
forth at the Conditions of Contract. All submittals shall have a key identification number to facilitate
filing and retrieval. Submittals for each class of equipment such as panel boards, Transformer,
Generator, etc. shall be completed and shall cover all types in that class. Partial submittals shall
not be acceptable and shall be returned to the Contractor.

1.3.2 Shop Drawings:

Unless otherwise permitted by the Engineer all shop drawings shall be prepared on AO at least
scale 1:50 sheet and drawn to a suitable metric scale for plans and layout. Shop drawings shall be
submitted for installations and layout of but not limited to the following:

- Cables installation and routing

- Conduit and trunking installation and routing

- Receptacles (socket outlets) and light switches installation

- Boxes and fitting installation

- Lamps and luminaires installation and layout

- Disconnect switches and circuit breakers installation

- Motor starters and control equipment installation details and control diagrams

- Grounding (earthing) materials installation

- Panel boards installation

- Auxiliary and fire alarm systems equipment installation including control diagrams

- Lightning protection materials installation

- All other detail drawings as shall be required by the Engineer

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- Schematic for main and sub-main distribution

The working shop drawings shall be complete submittals including the manufacturer's drawings
and shall show the exact site conditions with specific dimensions, locations and arrangement of
the equipment itself, dimensions of mounting bases and pads working clearances from neighboring
equipment, external connections including the location, number and size of cables and conduits
connected to the equipment and the schematic and wiring diagrams showing interconnections of
all local and remote devices.

Submission of the manufacturer's working shop drawings and data shall include:

- Equipment wiring diagrams, schematic diagrams and certified dimension sheets for the
415V switchboards and 11 kV switchgear/substation, motor control centers, control
panels, safety switches, circuit breakers, transfer switches, power transformers, engine
generator sets, fire alarm system, telephone system, and panel boards with specific
descriptions of the standard electrical equipment used.

- Time-current characteristic curves for all circuit breakers and fuses.

- Complete working shop drawings showing the exact location and number of all the surface
or recessed mounted lighting fixtures, after the Contractor has done the coordination with
the type of the suspended ceiling actually installed and the location of equipment and
devices installed under other sections ofthese Specification.

The Contractor shall submit for approval number of specified in general condition copies of prints
of working shop drawing and detail drawings of the entire installation.

The working shop drawings shall be submitted early enough to get the approval as specified in
general conditions prior to any construction and not before getting the approval of the Engineer for
the equipment shown on the working drawings. This should be coordinated to conform to the
general program and schedules of work for all trades.

1.3.3 Progress Drawings:

Provide and keep o the job all times, one complete and separate set of black line prints of the
electrical work on which shall be clearly, neatly and accurately noted, promptly as the work
progresses, all architectural and electrical changes, revisions and additions to the work. Whatever
work is installed otherwise than as shown on the Contract Drawings, such changes shall be noted.

Indicate daily progress on these prints by coloring in the various conduit, ducts, trunking, cable
trays, fixtures, apparatus and associated installation works erected.

1.3.4 As-built Drawings:

The Contractor shall provide the as-built drawing, as approved by the engineers, in DXF format or
AutoCAD DWG format, either in floppy diskettes or in CD-ROM, as per the Project Documentation
requirement. The drawings shall be submitted not later than (2) months after completion of the
Project, or putting into operation, whichever is earlier. An addition, (3) sets of hard copy of all
relevant drawings, which will be required and maintenance, shall be supplied in bound book forms
immediately after the commissioning of the Project.

The Contractor shall supply, (3) sets of all operation and maintenance manuals in original, from the
manufacturer in bound book form, at least (2) weeks prior to commissioning of the equipment.
These shall also be supplied, in computer diskettes, based on popular Microsoft window based

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publishing software programs, along with the as-built drawings as mentioned above, as specified
in the Project Documentation.

1.3.5 Builders Work:

Lay electrical works in advance of pouring concrete slabs and construction of walls. Obtain
Engineer's approval before commencing builder's work in connection with electrical installation.
Related coordinated shop drawings shall be submitted for approval as per the related Clause 1.1.5
of this section. Materials approval shall be obtained as per procedure detailed in Clause 1.1.9
below. The Contractor shall make it certain that drawings property coordinated with other works
are submitted immediately after signing of the Contract and approval of drawings and the materials
are obtained at least one month prior to the commencement date of the construction.

Check with other trades to ensure equipment and material can be installed in space provided.

Provide other trades with information necessary for them to execute their work.

Details on drawings which are specific regarding dimensions and locations, are for information
purposes. Coordinate with other trades to ensure work can be installed as indicated.

1.3.6 Programs:

The Contractor shall produce a work program based on CPM or Bar chart form indicating the time
required for various operations to complete the Project in time. The following points shall be
highlighted in the program.

- Mobilization
- Drawing/submittals
- Approvals
- Equipment Delivers including Delivery periods from supply sources
- First fix
- Main/sub-main distribution equipment
- Second fix
- Fixing of light fittings
- Testing
- Commissioning and handing over

1.3.7 Materials/Manufacturer's Data:

On submittal sheet, the Contractor shall indicate the general classification of materials, e.g.
Raceways and Fittings; Luminaires; Panel boards; etc. Moreover, the Contractor shall attach a
product compliance sheet indicating the specifications provisions, the product specifications and
the deviation, if any.

"Submittals for each manufactured item shall be current manufacturer's descriptive literature of
catalogued products, equipment drawings, diagrams, performance and characteristic curves, and
catalogue cuts."

Publication Compliance: Where equipment or materials are specified to conform to industry and
technical society publications of organizations such as ANSI, ASTM, UL or IEC Standards, submit
proof of such compliance. The label or listing by the specified organization will be acceptable
evidence of compliance. In each of the publications referred to herein, consider the advisory
provisions to be mandatory, as though the word "shall" had been submitted for "should" wherever
it appears. Interpret references in these publications to the "authority having jurisdiction", or words
of similar meaning, to mean the Engineer. In lieu of the label or listing, submit a certificate from an

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approved independent testing organization, adequately equipped and complete to perform such
services, stating that the item has been tested in accordance with the specified organization's test
methods and that the item conforms to the specified organization's publication.

Certified Test Reports: Electrical equipment and materials shall be approved by an adequately
equipped, recognized, and independent testing laboratory of the country where the equipment has
been manufactured, indicating that the equipment is in conformance to the code requirements of
that country.

Certificates of Compliance: Submit manufacturer's certifications as required on products, materials,

finish, and equipment indicated in the technical sections. Certifications shall be documents
prepared specifically for this contract. Preprinted certifications and copies of previously submitted
documents will not be acceptable. The manufacturer’s certifications shall name the appropriate
products, equipment, or materials and the publication specified as controlling the quality of that
item.

1.3.8 Samples:

As specified elsewhere samples of the materials such as individual circuit breakers, luminaires,
cables, conduit, receptacles and switches, etc. shall be submitted.

1.3.9 Manuals:

Complete operations and maintenance data for all equipment furnished under Division 16,
Electrical, shall be submitted in accordance with the requirements set forth at the Conditions of
Contract. The manuals shall be prepared specifically for this installation and shall include all
required catalog cuts, drawings, equipment lists, descriptions, complete parts lists address of
vendors of relevant equipment etc., that are required to instruct operating and maintenance
personnel unfamiliar with such equipment.

Operation and Maintenance Manual:

Submit at least four (4) copies of manuals as required for systems and equipment indicated in the
technical sections and shall be in the English language. Furnish three copies, bound in hardback
binders or an approved equivalent. Furnish one complete manual prior to performance of systems
or equivalent tests, and furnish the remaining manuals prior to contract completion. Inscribe the
following identification on the cover the words: "OPERATION AND MAINTENANCE MANUAL",
name and location of the system, equipment, building, name of Contractor, and contract number.
Include in the manual the names, addresses, and telephone numbers of each sub-
contractor installing the system or equipment and the local representatives for the system or
equipment.

Include a table of contents and assemble the manual to conform to the table of contents, with tab
sheets placed before instructions covering the subject. The instructions shall be legible and easily
read, with large sheets of drawings folded in. The manual shall include:

- Internal and interconnecting wiring and control diagrams with data to explain detailed
operation and control of the system or equipment
- A control sequence describing start-up, operation and shutdown
- Description of the function of each principal item of equipment
- Installation and maintenance instructions
- Safety precautions.

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- Diagrams and illustrations.

- Testing methods.
- Performance data.

Spare Parts:

Provide sufficient spare parts submit to the Engineer a list of all spare parts to be required for a
further two years operation from the date of issue of the Maintenance Certificate.

Spare parts are required where quantities for each item or equipment is recommended by the
manufacturer.

Spare parts to be delivered to central Client stores.

Appendix: List of qualified permanent servicing organizations for support of the equipment,
including addresses and certified qualifications.

1.3.10 Closeout Submittals and Record Drawings:

As required under the Condition of Contract, the Contractor shall keep an accurate record of the
installation as work is carried out, including length, size, number, location and depth of all conduits,
pipe ducts, and cables installed therein, and connections to all machines, plant equipment, and
terminal boxes, including all internal connections. Cooperate with the suppliers of control centers,
and annunciators to enable them to provide accurate records of the internal connections and
functions of the equipment installed. Record drawings shall include, but not be limited to the
following:

- All amendments, additions, etc., to the location of outlets, equipment, and sizes and routes
of conduits and cables including lengths.

- Amended drawings of all detailed circuit diagrams and cabling diagrams, indicating
conductor sizes, conduit numbers, all terminal numbers, and sequence of operations.

- New drawings of any extensively modified detail in the original Contract drawings, and of
further details provided or obtained during construction.

- Schedules for all panel boards relating circuit breaker numbers to circuit function and
rating.

- Schedules for all terminal boxes and terminal strips relating terminal numbers to incoming
and outgoing wires and general function (power or control).

1.5 QUALITY ASSURANCE

1.5.1 Factory Tests and Inspection:

The Client reserves the right to witness factory testing and inspection of any equipment
furnished under these Division 16, Electrical specifications. The Contractor shall furnish
the Engineer with any sketches, test setups, and instrumentation and shall notify the
Engineer at least 20 days in advance of the time each shop test will be made.

1.5.2 Inspection of the Works:

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The Engineer shall perform inspections of the work as he requires from time to time, and
shall witness the tests performed by the Contractor as specified in Quality Control
paragraphs of this section. Any work not acceptable to the Engineer shall be removed and
redone at the Contractor's expense.

1.5.3 Coordination Study:

For the high-voltage and/or medium voltage switchgear manufacturer, the manufacturer
shall conduct a complete coordination study of relays, circuit breakers, and all other
protective devices. The coordination study shall include the entire distribution system
starting with the smallest 415/240 volt, 3-phase and/or single phase, 50 Hz circuits’
protective device on the load end, to the nearest protective device on the substation line
side.

The study shall include, but not be limited to, the following:

- A tabulation of circuit breaker trip settings

- Motor starting profiles for all motors sized 40 kilowatt and above

- Transformer damage curves and protection evaluated in accordance with IEC,

ANSI/IEEE C57.109 (if applicable)

The coordination study shall be bound in a standard paper size report. The study shall be
provided in accordance with the requirements set forth at the Conditions of Contract. Final
selection of all protective device settings or sizes shall be subject to review and acceptance
by the Engineer.

1.5.4 Standardization:

All materials and equipment supplied under this section of the works shall wherever
possible be standardized and of metric uniform design to facilitate maintenance and
operation and to limit storage of spare parts and tools. All materials of the same kind of
service shall be identical and made by the same manufacturer.

All components of the same size and rating used in the works shall wherever practicable
be interchangeable with one another. All circuit breakers, fuses, contactors, relays, etc.,
shall be of the same make and design unless particular location and duty make such
standardization impracticable.
1.5.5 Derating:

All ratings given in the Contract Documents are standard ratings.

For components and accessories for which no specific ratings or sizes are indicated, the
Contractor shall select rating and sizes that will be suitable for the site conditions. Twenty
percent (20%) shall be minimum derating factor for such items.

The cable and wire sizes indicated on the drawings are the design sizes required for the
site conditions and for the ratings of the specified equipment. Therefore, for the actual
equipment, the sizes of cables need further selections. For wires or cables where no
specific sizes are indicated, the sizes shall be determined by suitably derating the current
ratings of those wires and cables as per the rating factors indicated in the latest regulations
of the country of origin.

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1.5.6 Spare Capacity:

Spare capacity shall be provided to allow for future expansion and future loads. Where
required in the contract drawings, there shall be spares for conduits, spare space for
installing future equipment, and spare circuits at panel boards and switchgears. If during
the field-testing prior to handing over the Works, the required spare capacity is not
available, the Contractor shall replace or add to any component or equipment to the system
at no cost to the Client.

1.6 DELIVERY, STORAGE AND HANDLING

1.6.1 Delivery:

The equipment furnished under this section shall be prepared for shipment, delivered,
stored, and handled.

Deliver electrical materials and equipment in original cartons or containers with seals intact
as applicable. Unless otherwise specified, deliver conductors in sealed cartons or on
sealed reels, ends of reeled conductors factory sealed. Deliver large multi-component
assemblies in sections that facilitate field handling and installation.

1.6.2 Handling:

All exothermal welding materials and molds shall be stored and protected against
absorption of moisture. Welding charges, which show signs of moisture absorption during
storage or during installation, shall be discarded and replaced. Before making the first weld
of the day or after a delay between welds, it is expected that a charge may be fired in the
empty mold to condition the mold.

All grounding, insulating and electrolyte materials shall be protected from degrading by any
cause and from loss by any cause.

Handle materials and equipment in accordance with best industry practices and
manufacturer's recommendations. Lift large or heavy items only at the points designed by
the manufacturer. Use padded slings and hooks for lifting as necessary to prevent damage.

The contractor shall inform the Engineer by the receiving of equipment to inspect before
installation.

Store materials and equipment on the ground and under cover. Prevent corrosion,
contamination or deterioration. Unless the equipment item is specifically designed for
outdoor exposure in a non-operating mode, all items shall be stored in a protected area.

1.7 PROJECT CONDITIONS

1.7.1 Environmental Requirements:

All equipment and materials shall be suitable for use in an ambient temperature range
from soc to 55°C under severe marine environment with tropical and sandstorm
condition. Equipment and materials shall be sized so that their ratings will not be exceeded
nor their functional use degraded in any way under these ambient conditions. Motor
starters and other thermally-sensitive equipment that is installed outdoors where exposed
to sunlight shall be provided with a sun screen or other provisions to avoid false tripping or
damage due to solar energy. Moreover, equipment shall be protected against salt spray,
corrosion, and blowing sand and dirt.

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All services installed below grade on corrosive soil due to presence of moisture, salts, acids
and other substances that would cause corrosion, shall be protected with acceptable
treatment or encasement. Materials such as grounding cables, mats and plates where
meant to have electrical contact with earth shall be made of materials resistant to corrosion
while maintaining good electrical conductivity. Other means such as grounding pits with
provision for replaceable ground rods will be considered where deemed necessary.

All electrical equipment shall be rated for an ambient temperature of 55°C outside and
50°C inside the building. The ground temperature at 75cm depth varies from 20°C in winter
to 40°C in summer. It is the responsibility of the Contractor to take into account the effects
of any severe and arduous conditions in the design and utilization of all electrical
equipment.

1.7.2 Underground Service:

Underground service conductors shall be continuous from the service entrance equipment
to the indoor/outdoor power system connection at the transformer substations and/or low
voltage switchgear up to the main switchboard/panel board of the building. The
underground portion of the conduit shall be encased in a concrete envelope having a wall
thickness of not less than 76 mm.

Where a conduit enters through a concrete floor, the curved portion shall not be visible
above the finished floor and the entire conduit below the floor slab shall be encased in a
concrete envelope having a wall thickness of not less than 76 mm. Ends of the underground
conduit shall be protected by suitable caps until connections are made.
1.7.3 Electricity Supply:

The Supply Authority will make available, at the incoming terminals of each Main
Switchboard (Medium Voltage Panel) a 3 phase + Neutral, 4 wire, 415 V, 50 Hz supply of
adequate capacity and having the following tolerances:

- Voltage ± 6%
- Frequency ± 4%

Phase rotation of supply to B S 158

Neutral: Solidly earthed at transformer location

Obtain system: TNS
Obtain fault level and fault duration time from the Supply Authority (WAPDA).

Obtain confirmation from the Supply Authority of the size and number of cables
they will provide to Main Switchboard. Allow for adequate and appropriate cable
glands, lugs and boxes.

1.8 WARRANTY

All materials and equipment shall be warranted against workmanship defect or failure for
a period of time from date of acceptance as stipulated in the Conditions of Contract.

PART 2 PRODUCTS

2.1 MATERIALS

The materials used in all systems shall be new, unused and as herein specified. All

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materials where not specified shall be of the very best of their respective kinds in
accordance with the industry standard to which they are made.

2.1.1 Standard Products:

Materials and equipment to be provided by the manufacturers shall be essentially the

standard catalogued products of a manufacturer regularly engaged in the manufacture of
such products. Materials and equipment shall meet the applicable requirements of the
specification and shall essentially be in satisfactory use for at least 2 years.

Standard catalog items and IEC sizes, ratings, capacities, and voltages shall be given
preference.

2.1.2 Prohibited Materials:

Aluminum conduits, fittings, supports and conductors are not acceptable unless specially
approved for each use, or location, and manufacturer standards.

2.1.3 Equipment Enclosures:

All equipment shall be properly derated for ambient heat, altitude and similar climatic
conditions which shall affect the operation and performance

Outdoor electrical equipment enclosures (panels, luminaires, etc.) shall be corrosion

resistant, rainproof and dustproof, indoor electrical equipment enclosures shall be
dustproof, unless otherwise specified or indicated on related documents or drawings.
Minimum index of protection (IP) for outdoor wet areas shall be IP66 and for indoor IP30.

Equipment located in damp or wet locations shall meet exterior requirements. Refer to
environment conditions (Item 1.8 above).

2.1.4 Factory Finishes:

Unless otherwise specified in a specific technical provisions section, the sheet metal
surfaces of electrical equipment enclosures shall be electo-statically painted for interior
and exterior metal surfaces. the color shall be medium light gray or as per manufacturer's
standard. Hardware shall have a corrosion-resistant finish.

2.1.5 Ratings:

The required output ratings of all electric equipment shall be referred to a continuous duty
at a coolant temperature of 45°c, Class F, for insulation and Class B for temperature rise
unless particularly specified elsewhere.

2.1.6 Nameplates:

Shall be as per manufacturer’s standard, and of durable quality.

2.1.7 Common Requirements for Packaged Equipment:

Where two or more units of the same class of material or equipment are required, the
Contractor shall provide products of a single manufacturer.

2.1.8 Deviations:

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The requirements laid down in this specification, drawings or requisition orders, have to be
strictly followed. Any deviation, arising during tendering, and manufacturing of the relevant
equipment for any reasons, must be submitted for approval and confirmed in writing by the
Engineer.

Deviations in quality or quantity that are not listed or inspected shall in no way relieve the
Contractor from responsibility.

2.2 PERFORMANCE AND DESIGN REQUIREMENTS

2.2.1 Suitability to Environment:

Contractor shall be responsible to evaluate and assess all ambient conditions where
electrical equipment, devices and fixtures shall be installed. Contractor is not relieved of
the responsibility to replace any material with prior approval if found unsuitable for the
environment where it is to be installed.

2.2.2 Design Criteria:

The criteria for this project shall be taken as:

Ambient Air Temperature, 55 max

Ambient Ground Temperature, °C 45 max
Relative Humidity 90% max
Altitude, meters 0 (sea level)

Electrical services shall enter the facility at 12KV-415Y/214 volts, three• phase, four-wire,
50 Hz, unless otherwise specified or indicated on the drawings.

The main grounding (earthing) arrangement is a TN-S system.

2.3 ACCESSORIES

2.3.1 Nameplates:

Shall be as manufacturer's standard.

2.3.2 Danger Signs:

Provide danger signs on all electrical panel boards, switchboard, main distribution panel
board, and other live energized equipment.

All nameplates, signs and other notices shall conform to the requirements of IEEE, or IEC
standards and shall be engraved (of durable quality) in both Urdu and English.

2.4 FABRICATION

2.4.1 Surface Preparation:

Remove all casting projections, weld flux or splatter, by hand scraping, hand impact tools,
etc., follow by wire brushing or power grinding. Sharp corners or sheared edges shall be
dulled and radiused with power grinder to improve paint adherence.

Exposed grooved surfaces shall be finished smooth by filling and thoroughly cleaned as

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Electrical Works BASIC ELECTRICAL MATERIALS AND METHODS

required to provide a smooth uniform surface for painting.

2.4.2 Shoo Painting:

Unless otherwise specified, all iron and steel surfaces, except copper and stainless steel
shall be shop primed with a vinyl primer and then given two or more shop coats of vinyl
base light gray enamel finish. The shop coating, including primer, shall have a dry film
thickness of at least 0.155 mm.

PART 3 EXECUTION

3.1 WORKMANSHIP

All materials and equipment shall be installed in accordance with the recommendations of
each manufacturer as approved by the Engineer to conform to the contract documents.
The installation shall be done by workmen skilled in this type of work. All electrical works
shall be installed in a neat, workmanlike manner. Exposed conduits shall be installed
straight, plumb and level, parallel to or perpendicular to beams and walls; where vertical
shall be installed plumb.

3.2 ACCEPTABLE INSTALLERS

3.2.1 Regulations for Electrical Installations:

The Contractor shall plan methods of wiring and installation of components into the Works
in compliance with all regulations, requirements and recommendations of the Governing
Standards, and shall comply with all local codes and ordinances. The Contractor shall be
responsible for the full compliance with the requirements of the applicable Standards and
IEC 364 "Electrical Installations in Buildings", NFPA 70, IEEE and ANSI C2, throughout
the installation of the Works including any temporary works required.

An installation or part thereof complying with the herein specified standards is one in which:

- Is suitable for its intended purpose

- Has a supply adequate for its maximum possible demand
- Comprises equipment suitable for the environment to which it will be
subjected
- Comprises equipment correctly selected as regards to compatibility and
maintainability
- Embodies protective measures for safety which remain effective over its
intended life
- Has been constructed or installed so as to facilitate an efficient and safe
operation
- Has been installed using good workmanship and proper materials
- Is constructed so that periodic inspection, testing, maintenance and
repairs can be readily and safely carried out
- Has been inspected, tested and certified as complying with the appropriate
standards and regulations

The Contractor shall ensure that his employees are familiar with requirements of the herein
specified Governing Standards and the requirements of the "Industrial Safety and Health"
Regulations.

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Electrical Works BASIC ELECTRICAL MATERIALS AND METHODS

3.3 PREPARATION

Before installing any materials, the Contractor shall make certain that there are accepted
shop drawings available in his files for the material being installed. All electrical equipment
furnished in this and other sections of the specification shall be connected according to the
schematic diagrams indicated on the drawings or on the accepted drawings furnished by
the manufacturer of the equipment.

3.4 INSTALLATION

3.4.1 Setting of Equipment:

All equipment shall be installed level and plumb. Sheet metal junction boxes, equipment
enclosures, sheet metal raceways, etc., mounted on water-bearing or earth-bearing walls,
shall be separated from the wall by corrosion-resistant spacers not less than 6mm.

3.4.2 Sealing of Equipment:

All distribution panel boards, power panels, disconnect switches, lighting control panel and
similar equipment shall be permanently sealed at the base, and all openings into
equipment shall be screened or sealed as required to prevent the entrance of rodents and
insects the size of wasps and muddaubers. Sealing material at the base shall be non•
shrink grout as specified in the Grout section. Small cracks and openings shall be sealed
from inside with silicone sealant.

3.4.3 Repair of Existing Works:

The work shall be carefully laid out in advance and where cutting, channeling, chasing, or
drilling of floors, walls, partitions, ceilings or other surfaces necessary for the proper
installation of supports or/and anchorage for electrical works. This work shall be carefully
done and any damage to building, piping or equipment shall be repaired by skilled
personnel of the trade involved, at the satisfaction of and at no additional cost to the Client.

3.4.4 Thermal Expansion:

Conduits and raceways crossing expansion joints or areas subject to difference in

temperatures shall be provided with approved factory-made fittings to compensate for
mechanical stress on raceways.
3.4.5 Use of Different Materials:

All metallic frames, structures and raceways used for electrical installations shall be made
of the same materials. Where deemed as of absolute necessity, only approved compatible
transition joints shall be used while maintaining the cross-section of the conduit system.

3.4.6 Ducts:
All ducts and conduit system shall be of the same materials. Where deemed of absolute
necessity only approved compatible transition joints shall be used while maintaining the
cross-section of the conduit system.

3.4.7 Wiring:
Install wiring for control systems, power feeder and branch circuits, lighting branch circuits,
communication and auxiliary systems such as fire alarm and security, in separate raceways
unless otherwise indicated. Install power system wiring for "Emergency", "Life

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Safety”,"Critical", systems in separate raceways.

3.4.8 Wet, Damp, or Dry Location Work:

Provide products as appropriate for wet, damp, or dry location as defined by NFPA 70.

3.4.9 Manufacturer Installation Instructions:

Install equipment in accordance with the manufacturer's Installation instructions and

recommendations.

3.4.10 Fire and Smoke Barrier Penetrations:

Install fire stopping to raceways, boxes and electrical equipment installed in or penetrating
fire - rated or smoked barrier assemblies, in a manner which maintains the fire resistance
rating or barrier intent.
3.4.11 Field Painting:

In a manner satisfactory to the Client, touch-up or refinish factory -applied paints or finishes
which are chipped, defaced, scratched, or in any other way disturbed due to handling,
installation or general construction work.

3.5 CONSTRUCTION

3.5.1 Sleeves and Forms:

The Contractor shall provide and place all sleeves for conduits penetrating floors, walls,
partitions, etc. Locate all necessary slots for electrical work and form before concrete is
poured.
Where exact locations are required by equipment for stubbing-up and terminating conduit
concealed in floor slabs, the Contractor shall request shop drawings, equipment location
drawings, foundation drawings, and any other data required by him to locate the concealed
conduit before the floor slab is poured.

Where such data is not available in time to avoid delay in scheduled floor slab pours, the
Engineer may elect to allow the installation of such conduit to be exposed. No additional
compensation for such change will be allowed.
All openings, sleeves, penetration, and slots shall be sealed as specified herein.

3.6 FIELD QUALITY CONTROL

3.6.1 Field Service:

All roughing in works for embedded items shall be subject to inspection to the Engineer
and cleared prior to concrete pouring, closing of shuttering or closure of walls, ceiling and
floors where electrical service shall be concealed or embedded. The Engineer has the
authority to stop any electrical work found to be non-compliant with the project
specification.

3.6.2 Field Tests:

In conjunction with the coordination study, the Contractor shall test and calibrate all
protective devices in accordance with the manufacturer's specification prior to making the
proper device setting before the initial energization of the conductors and equipment. Field
setting of adjustable protective devices shall be indicated on electrical drawings that show

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the proper wiring of the protective devices and the rating and wiring on nonadjustable
devices.

The Contractor shall provide all test equipment and personnel and submit written copies of
all test results. As an exception to requirements that may be stated elsewhere in the
contract, the Engineer shall be given 15 working days’ notice prior to each test.
3.7 PROTECTION

3.7.1 Care of Equipment:

During construction, all electrical equipment and cable insulation shall be protected against
absorption of moisture, and metallic components shall be protected against corrosion by
strip heaters, lamps, or other suitable means. This protection shall be provided immediately
upon receipt of the equipment and maintained continuous until the equipment is put into
operation.

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Electrical Works GROUNDING AND BONDING

SECTION 1202

GROUNDING AND BONDING

PART 1 GENERAL

1.1 SCOPE

This section covers the furnishing and installing of a complete grounding system for the
facility.

The words "earth" and "earthing" as used herein are synonymous with the words "ground"
and "grounding" and may be used interchangeably within this specification.

1.2 REFERENCES

1.2.1 Governing Standards:

Except as modified or supplemented herein, all materials required in this section including
their installation shall conform to the applicable requirements of the following standards.
Standards current at the time of tender shall be used.

American National Standards Institute

ANSI No.
C2 National Electrical Safety Code (NESC)
C135.3 Zinc-Coated Ferrous Ground Rods for Overhead or Underground
Line Construction

American Society for Testing and Materials

ASTM No.

B8 Concentric-Lay-Stranded Copper Conductors, Hard, Medium-

Hard, or Soft

Institute of Electrical and Electronic Engineers

IEEE No.

81 Guide for Measuring Earth Resistivity, Ground Impedance, and

Earth Surface Potentials of a Ground System

National Fire Protection Association

NFPA No.

70 National Electrical Code

International Electro-technical Commission (IEC)

British Standard (BS)

Egyptian Building Codes & Regulations

1.3 RELATED SECTIONS

The following Sections include requirements which relate to this section:

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00320 Geo-technical Report

16050 Basic Electrical Materials and Methods
16231 Package Engine Generator
16320 Distribution Transformer (Oil)

1.4 SUBMITTALS

Submit the following in accordance with Conditions of the Contract, Division-! Specification
Sections and Division-16 Section 16050 "Basic Electrical Materials and Methods".

- Grounding calculations detailed enough to reach the required overall

earthing resistance. However, the final test report results after installation
shall remain the effective proof of reaching the requested earthing
resistance value.

- The Contractor shall submit manufacturer's catalog sheets with catalog

numbers marked for the items furnished, which shall include:
• Exothermal welding materials
• Terminal Lugs and clamps
• Copper ground cable
• Ground rods
• Ground connection hardware

Shop drawings and data shall be submitted m accordance with the requirements forth at
the Conditions of Contract.

- Samples

- Post-installation test procedures

- Final test report

PART 2 PRODUCTS

2.1 MATERIALS

Ground Wires ASTM B8, soft drawn bare copper

Insulated Ground PVC or XLPE insulated copper in green and/or green-

yellow color and shall conform to IEC 502 and NEMA WC
7.

Ground Rod Rods made of copper clad steel shall conform to BS.
Ground rods shall be not less than 20 mm in diameter and
three 3.6 m in length.

Grounding plates copper, minimum 600 mm by 60 mm by 6 mm thick.

Exothermic welds Molds, cartridges, materials and accessories as

recommended by the manufacturer of the molds for items
to be welded. Molds and powder shall be furnished by
the same manufacturer.

Flexible braided cable strap Copper, 250 mm by 35 mm thick ground post clamps.
Clamps shall be of the anti-electrolysis type

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2.2 PERFORMANCE AND DESIGN REQUIREMENTS

2.2.1 Grounding and Bonding:

Grounding and bonding shall as a minimum be in accordance with the IEC. All exposed
non-current-carrying metallic parts of electrical equipment, metallic raceway systems,
metallic cable armor, grounding conductor of non-metallic sheathed cables, grounding
conductor in non-metallic raceways and neutral conductor of the wiring system shall be
grounded. Bonding shall be provided where necessary to assure electrical continuity and
the capacity to conduct safely any fault current likely to be imposed. Non-current-
carrying metal parts of service equipment shall be effectively bonded together. If available
on the premises of each building served, metal underground water pipe shall form the
grounding electrode system where it conforms to the IEC requirements. An additional
electrode as required by the IEC shall supplement the metal underground water pipe. If the
metal underground water pipe is coated with an insulation material or there is no
underground metal pipe, ground connection shall be made of driven rods or gradients
control mats on the exterior of the building.

A bonding jumper not smaller than 16 mm2 copper shall be connected between the
communication and power grounding electrodes where separate grounding electrodes are
used.

Equipment Criteria, Ground wires for substations mam panels and distribution panels shall
be annealed pure copper with 98 percent conductivity. Wires shall be as indicated or as a
minimum in accordance with the grounding requirements of IEC latest edition.

Grounding connectors shall be high strength, high conductivity copper alloy. Ground Rods:
Ground rods shall be copper clad (not less than 0.38 mm thick) steel not less than 20 mm
in diameter, 3.6 m long, with hardened tip and cap, driven full length into the earth and
where practicable below permanent moisture level. If the maximum resistance of grounding
system shown in paragraph "Grounding Resistance" cannot be attained, additional rods
shall be installed from those shown on drawings. If the resultant resistance exceeds these
values, measured not less than 7 days after rainfall, the Client's Representative shall be
notified immediately. Where multiple rods are installed, they shall not be less than 3.0 m
apart.

Grounding Electrodes: Grounding electrodes shall be provided for ground loop conductor
and located at the perimeter of the building. Extend driven ground rods into the existing
undisturbed earth for a distance of not less than three (3) meters. Ground rods shall be set
not less than 600 mm from the edge of walkways nor more than three meters from the
structure.

The completed installation shall have a maximum total resistance to ground using the fall-
of-potential method described in IEEE 81 of 5 ohms, under normally dry conditions when
a ground loop is not used. Use a ground loop when two of any three (3) ground rods, driven
not less than three meters into the ground, a minimum of three meters apart, and equally
spaced around the perimeter, give a combined value exceeding 50 ohms immediately after
having been driven. For ground loop a continuous 70 mm2 bare stranded copper cable (or
as shown on the drawings) or equivalent material having suitable resistance to corrosion
shall be installed. Lay ground loop around the perimeter of the structure in a trench not less
than 750 mm below grade, at a distance not less than 600 mm nor more than 3 000 mm
from the nearest point of the structure. Install a ground loop in earth undisturbed by
excavation, not earth fill, and do not locate beneath roof overhang, or wholly under paved

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areas or roadways where rainfall cannot penetrate to keep soil moist in the vicinity of the
cable. Make connections between ground conductors and grounds or ground loop, and
between ground loop and grounds electrically continuous. Where so indicated, provide an
alternate method for grounding electrodes in shallow soil by digging trenches radially from
the building. A 70 mm2 bare copper cable (or as shown on the drawings) arranged in a
star pattern with the structure at the center for radial systems shall be installed. Bury the
radials at least 750 mm below grade external to the structure.

PART 3 EXECUTION

3.1 INSTALLATION

All works below grade shall be thoroughly coordinated with all underground services and
structures. Grounding and bonding works must, in all circumstances prevent any dissimilar
metal contact that will cause galvanic corrosion. Bonding shall be made only after thorough
inspection of metal parts to be bonded. Grounding conductors shall be run with all three
phase feeders, and all single and three phase branch circuits.

3.1.1 Bonding:

Metallic raceway system shall have electrical continuity with equipment individually and
directly connected with the building ground, independent on a raceway system, as herein
specified. All raceways shall contain an appropriately sized green grounding conductor.

Enclosures to the panel boards shall be individually and directly connected to the building
ground. The grounding conductor shall be as indicated on the drawing and shall be
connected from the building ground to a copper ground bus terminal strip located in each
panel board.

Doors of panel boards, MCC's, switch disconnects, and other electrical equipment should
be bonded by suitable bonding jumpers.

Polarized receptacles, lighting fixtures, and equipment enclosures shall be grounded with
an identified (green color) insulated conductor not smaller than 4.0 mm2 connected with
the branch circuit ground-bus terminal strip. The ground-bus terminal strip in each panel
board enclosure shall be isolated and independent of the system neutral terminal strip.

Conduits stubbed-up below a switchboard or motor control center shall be fitted with
insulated grounding bushings and connected with the equipment ground bus.

Liquidtight flexible metal conduit m sizes 40 mrn and larger shall have bonding jumpers.

Grounding electrodes shall be driven as required. Where rock is encountered grounding

plates may be used in lieu of grounding rods.

All equipment enclosures, motor and transformer frames, conduits systems, cable armor,
exposed structural steel and similar items shall be grounded.

Exposed connections shall be made by means of grounding clamps. Exposed connections

between different grounding conductors shall be sealed with No• Oxide Paint Grade A or
equal. All buried or inaccessible connections shall be made by exothermic welding process
as specified herein.

All grounding conductors subject to physical damage shall be installed in steel conduits
and electrically bonded thereto on both ends.

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Electrical Works GROUNDING AND BONDING

Care shall be taken to ensure good ground continuity, in particular between the conduit
system and equipment frames and enclosures. Where necessary, jumper wires shall be
installed.

3.2 QUALITY CONTROL

3.2.1 Field Tests:

The completed equipment grounding system shall be subjected to megger test at the
service disconnect enclosure ground bar to ensure that the ground resistance does not
exceed 5 ohms. Certified test reports shall be submitted for review by the Client's
Representative.

All exothermal weld connections shall successfully resist moderate hammer blows. Any
connection which fails such test or which, upon inspection, indicates a porous or deformed
weld, shall be remade at no additional cost to the Client.

All exothermal welds shall encompass 100 percent of the ends of the materials being
welded. Welds which do not meet this requirement shall be remade.

Deficiencies: Where ground resistances exceed specified values, and if directed, modify the
grounding system to install and connect additional rods as directed by the Engineer until
the required value is obtained without any additional cost to the contract.

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Electrical Works Conductor & Cables

SECTION 1203

CONDUCTOR AND CABLES

PART 1 GENERAL

1.1 SCOPE

This section covers the furnishing and installation of all insulated wires and cables including
control/instrumentation cables for voltages 600 volts nominal or lower; except wire and
cable for special applications, such as low• level circuits for analog signals, data and
supervisory control, communication and telemetering systems.

1.2 REFERENCES

1.2.1 Governing Standards:

Cables and wires shall comply with the following stand are as appropriate:

BS 1442 Galvanized mild steel wire for armouring cables

BS 2484 Straight concrete clay ware covers

BS 2897 Aluminum strip armour for cables

BS 3506 Unplasticised PVC pipe for industrial purposes

BS 4066 (IEC 332) Tests on electric cables under fire conditions

BS 4660 Unplasticised polyvinyl chloride (PVC-u) pipes and plastic fittings of

nominal sizes 110 and 160 for below ground gravity drainage and
sewerage

BS 5308 Instrumentation cables

BS 5467 (IEC 502) cables with thermosetting insulation for electricity supply for
voltages of up to and including 600/1000 V and 19000/30000 V

BS 6004 (IEC 227) PVC insulated cables (non-armoured) for electrical power

BS 6007 Rubber insulated cables for electric power and lighting

BS 6207 (IEC 245) mineral insulated cables

BS 6234 Polythene insulation and sheath for cables

BS 6346 PVC insulated cables for electrical supply

BS 6360 (IEC 228) copper conductors for cables

BS 6500 (IEC 227) insulated flexible cords

BS 6622 (IEC 502) cables with extruded cross linked polyethylene insulation, for

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Electrical Works Conductor & Cables

rated voltage 3800/6000 Vup to 19000/30000 V

BS 6746 PVC insulation and sheath of electric cables

BS 6746C Color chart for insulation and sheath of electric cables BS 6899 Rubber
insulation and sheath of electric cables

BS 7671 Requirements for electrical installations

ISO 9000 Quality management and assurance standards

BS EN 29453 Soft solder alloys-chemical composition and forms

Cable terminations shall comply with the following specifications:

BS 1858 Bitumen based compounds for electrical purpose

BS 4579 Performance of mechanical and compression joints in electric cable and

wire connectors

BS 6121 Mechanical cable glands for elastomer and plastic insulated cables

BS 6910 Cold pour resin compound and heat shrink cable joints in the voltage
range up to 1000 V AC and 1500 V DC.

1.2.2 General Equipment

Stipulations: Section 01605, General Equipment Stipulations shall apply to all

equipment furnished under this section.

1.3 SUBMITTALS

Submit the following in accordance with the requirements set forth at the Conditions of
Contract.

1.3.1 Drawings and Data:

Descriptive literature, drawings and test reports for all cable materials shall be submitted.
Literature submitted should be marked to clearly indicate any particular specification
paragraph for which the material applies. Sheets or drawing showing more than the
particular item under consideration shall have crossed out all but the pertinent description
of the item for which review is requested.

Samples:

In addition to complete specifications and descriptive literature, a sample of the largest and
smallest size of each type of cable shall be submitted for review before installation. Each
sample shall have the manufacturer's full surface printing identification label.

The samples shall be retained until completion of the Contract. The Client's Representative
reserves the right to subject any of the samples submitted to tests and will be in no way
responsible for damage or breakage as a result of any such tests.

1.4 DELIVERY, STORAGE AND HANDLING

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Electrical Works Conductor & Cables

1.4.1 Delivery:

All cables shall be delivered to site with seals intact and bearing the manufacturer's label
indicating classification, size, description, length and grade. All labels shall be retained and
kept in a logbook to be available for inspection by the Client's Representative.

1.4.2 Storage:

Cables shall be stored at normal temperatures and out of direct sunlight. Cables not on
purpose-built cable reels shall be coiled neatly, allowing for any limitations of bend radius
and protected against mechanical damage. Cable ends shall be sealed to prevent ingress
of moisture.

Care shall be taken to ensure that all cables are adequately protected while stored on site
prior to erection. No damaged cable shall be used.

1.4.3 Handling:

Whenever possible, cranes shall be used with suitable spindle through the center of the
reel. In the absence of hosting equipment, temporary ramp shall be provided to move cable
reels to and from storage area. Cable reels that have been dropped will be subject to
rejection by the Client's Representative, because of flatting of the cable inner layers. Drums
shall be rolled in the direction of indicating arrows.

1.5 PROJECT CONDITIONS

1.5.1 Environmental Requirements:

As specified in Section 16050, Electrical Materials and Methods.

PART 2 PRODUCTS

2.1 MATERIALS

Wire and cable to be furnished shall conform to the detailed requirements specified herein.

Color identification of flexible cords IEC 173

Bare copper cables for earthing (grounding) IEC 228 Class 2

PVC insulated or PVC Sheathed cables, 0.6/1 kV IEC 502

XLPE insulated or PVC Sheathed cables, (90°C) IEC 502 0.6/1 kV

XLPE/SWA/PVC Direct Buried Armored Cable IEC 502

Cable glands for single and multi-core PVC BS 6121, BS 5467

Surge arrestors for cables IEC 99 Part 1

Cable conductor identification by color or numerals IEC 446

Stranded copper cable Conductors IEC 228 Part 1 and 2

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Electrical Works Conductor & Cables

Stranded copper wire IEC60227 and BS 6004

Cable joints, encapsulated resin type IEC 502 or IEC 455

Cable joints, heat shrink type IEC 502 or IEC 684

2.1.1 Rated Circuit Voltages:

All cable shall have minimum rated circuit voltages of 600/1000 volts. Wire shall be 450/750
volt.

2.2 PERFORMANCE AND DESIGN REQUIREMENTS

2.2.1 Cable Design Criteria:

All cables shall conform to the applicable provisions of the IEC and local standard.

Each type of cable used throughout the installation shall be supplied by one manufacturer
only.

Conductors above 3 mm2 shall be stranded copper.

Conductor Insulation: Unless specified or indicated otherwise, or required to be otherwise

by NFPA, all power and lighting and instrumentation cables shall be rated 600/1000 Volt,
type PVC/PVC 85 oc or XLPE cables (armored and non armored).

Cable Types: The following types of wiring systems shall be used for power circuits and
controls:

- 600/l000 V rated PVC insulated armoured cables.

• PVC/SWA/PVC cables: 600/1000 V Grade, to BS6346

• Conductor: Annealed high conductivity copper, stranded, shaped and laid

in an approved manner

• armour: Single layer of galvanized steel wires for multicore cables

• insulation: Color coded to BS 67 46C

• PVC for sheath and insulation to BS 6746

• cables shall be terminated with compression glands as specified below,

giving adequate mechanical support by locking on the armour and
ensuring a high earth continuity.

- PVC insulated PVC Sheathed (PVC/PVC) Cables

• to BS 6346, 600/1000 V Grade, or to BS 6004, 300/500 V Grade

• flat twin and three core cables shall be to BS 6004 and incorporate an
earth conductor placed between the red and black core for two core cables
and between the yellow and blue cores for three core cable.

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Electrical Works Conductor & Cables

• conductor: annealed high conductivity copper, stranded, shaped and laid

in an approved manner.

• insulation: Color coded to BS 6746C

• PVC for sheath and insulation: to BS 6746

- Single core PVC insulated Wires

• cable shall be to BS6004, rated 450/750 V, with high conductivity copper

conductors and PVC compound insulation. Color coding shall be in
accordance with table 51 A ofBS 7671.

• Wires shall be continuous from outlet and no splice shall be made except
within outlet and junction boxes. A separate neutral wire shall be provided
for each circuit. Wires shall be left sufficiently long enough (minimum 150
mm) to permit making final connections.

- Mineral Insulated Cables

• To BS 6207: Part 1, rated 600/1000 V

• cable shall comprise of a pressure packed magnesium oxide insulation

contained within a continuous soft ductile copper sheath and copper
conductors embedded in the dielectric in standard formation

• cable termination kit shall comprise of conductor insulation of neoprene

sleeving retained by cone shaped beads beneath a fiber sealing disc.
Each conductor shall be identified with regard to phase etc., by means of
sleeving placed over the neoprene insulation.

• cable seals shall comprise of screw-in-pot type seals, with brass ring
glands designed to accommodate the pot seal.

- Terminals

• for cable up to 6 mm2 : two screw pinching type

• for cable over 6 mm2 : grip lug type cable sockets

• brass saddles: purpose made, two fixing screw type

- Heat Resistant and High Temperature Cable

• to BS 6500, orBS 6004 300/500 V grade, designated EPR (ethylene

polypropylene rubber) insulated HOFR sheathed, 85 °C or EPR insulated
OFR sheathed, 60 °C. Conductor(s) shall be flexible class 5 tinned copper
to BS 6360. Insulation shall be type GP.1 to BS 6899. Outer sheath shall
be HOFR (heat, oil, fume resistant) or BS4066 Part 1, temperature rating
60 oc or 85 °C.

• high temperature cable shall be to BS 6500 or BS 6007, designated

300/500 V grade silicone insulated glass braided, 180 °C. Conductors
shall be flexible Glass 5 tinned copper to BS 6360. Insulation shall be

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Electrical Works Conductor & Cables

silicone rubber Type EI 2 to BS 6899. Outer sheath shall be treated glass

fiber braid temperature rating 180 °C.

- Flexible Cable

• to BS 6007, or BS 6500, rated in accordance with manufacturer's labels.

• flexible cables subject to excessive heat shall be insulated as (8) above,

(a) or (b) as per the Project Documentation required.

- 600/1000 V rated XLPE Insulated Cable

• to BS 5467, 600/1000 V grade, designated XLPE/SWA/PVC for armoured

multicore cable and XPLE/PVC for unarmoured cable

• conductors: plain annealed copper to BS 6360

• cable shall comprise of plain copper, stranded circular conductors

insulated with an adequate thickness of extruded cross linked
polyethylene.

• conductors shall be laid up together and warmed circular with suitable

performed fillers and warnings, bound with polythene terephthalate (PTP)
tape and covered with an extruded PVC sheath, minimum 1.4 mrn thick
for multicore cable.

• armourd multicore cable shall have steel wire armouring and extruded
sheath of black PVC.

• armoured single core cable shall have a luminium wire armouring and
extruded sheath ofBlack PVC

• outer sheath of single core cables shall be at least 2.5 mm thick

• conductor screen: non-metallic comprising either semi-conducting tape or

a layer of extruded semi-conducting material

• prevent void formation in insulation by careful control of its passage

through temperature graded water baths

• cable shall be terminated with compression glands as specified below,

giving adequate mechanical support by locking on the armour and
ensuring high earth continuity

- Instrumentation Cables - Analogue Signals

• to BS 5308 Part 2, Type 2300- 500 V

• single copper conductor 1/08 mrn

• polyethylene insulation

• individual screen of aluminum backed polyester tape with tinned copper

stranded drain wire

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Electrical Works Conductor & Cables

• collective screen of aluminum backed polyester tape with tinned copper

standard drain wire

• extruded PVC bedding

• galvanized steel wire armour

• PVC outer sheath, gray

• Core identification as BS 5308, Part 2.

- Instrumentation Cables -Digital Signals

• to BS 5308 Part 2, Type 2 300-500 V

• single copper conductor 1/0.8 mrn

• polyethylene insulation

• collective screen of aluminum backed polyester tape with tinned

copper stranded drain wire

• extruded PVC bedding

• galvanized steel wire armour

• PVC outer sheath, Gray

• Core identification as BS 5308 Part 2

Cable Sizing and Selection: The applicable IEC or local regulations for Electrical
Installations shall be used as the basis for sizing cables and conductors.

Minimum wire size shall be 4 mm2 for power and lighting circuits; 6 mm2 for current
transformer secondary circuits; 3 mm2 for potential transformer, digital signal, relaying, and
control circuits; 1.5 mm2 for annunciator circuits, analog signal and alarm circuits.

Voltage drop on main distribution cables shall not exceed one and half percent (1.5%) and
on sub-circuits shall not exceed one percent (1%). These percentages may vary but the
voltage drop shall not exceed two and half percent (2.5%) from the source of supply to the
farthest end of any sub• circuit and/or originating from the nearest substation.

No cable shall be loaded to more than 80 percent of its current carrying capacity after
application of all the appropriate derating factors.

The spacing of cables shall be as determined in the calculation of the derating factors for
the current carrying capacity of cables.

When required, instrumentation cables shall be selected taking into account ofthe
following:

- Loop resistance shall be less than 50 ohms.

- The EMIIRFI environment through which the cable is to pass which will

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affect the screening and conduit requirements.

- Cable route to be used e.g. direct burial.

- Electrostatic interference sb.all be reduced by using a conductive screen around

the signal wires and grounding the screen at one location only.

Cable sizes shall not be less than the minimum size specified herein. Minimum cables
sizes for circuits outgoing from main switchboards, distribution panelboard, and main
distribution boards shall be in accordance with the schedule set forth in Table No. 1,
indicating the nominal cross section area ofPVC type cables.

Table No.1

Circuits connecting lighting, power and miscellaneous equipment shall be sized in

accordance with BS 6004 Governing Standards, but shall not be less than

PVC Cables 3 mm2 (7/.085mm Dia.)

Cables for motors above 2 kW, shall be sized to conform to the Governing Standards, so
that the current ratings is not less than 125 percent of the full load current of the motor and
that the cable is not smaller than

PVC Cables 4.0 mm2 (7/.085mm Dia.)

Remote control circuits 2.5 mm2 (7/.070rnm Dia.)

Cable and Conductor Identification

- Power Cables: All conductors shall be identified by colored insulation. Mains, sub-
mains and final sub-circuit phase cables shall be identified by using their respective
phase colors, i.e., red, yellow and blue. The neutral conductors shall be colored
black, the ground conductors shall be colored green and/or green-yellow.

Color coding shall be in accordance with Table SlA of BS 767

All conductors shall be identified in distribution and panel boards by their circuit
numbers. Neutral and ground cables shall further be identified by their respective
circuit number and phase letter, i.e. R, Y and B. This identification shall be made
by permanent clip-on or push-on plastic identification bands. In the case of larger
conductors the identification shall be by means of push-on numbers or a suitable
plastic bar that is tie• wrapped onto the cables.

At all outlet points, all phase and switch conductors are to be identified as specified
herein.

2.2.2 Cables in Conduits and Trunking:

All cables for lighting, smaller power, instrumentation and auxiliary services, including low
and extra low voltage services, shall be multistranded single core PVC, butyl, or silicone
insulated as required for 450/750 Volt grade as set forth in IEC and local specification
having stranded copper conductors. The minimum cable size shall be 1.5 mm2
(7/.050mm Dia.).

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All cables shall be color coded in accordance with Table SlA of BS 7679 and local
Standards.

Marker sleeves shall be fitted to each end of cables and at suitable distances along its
length. Sleeves and markers shall be of the proprietary type manufactured for the particular
applications, and they shall be of the correct size to ensure a tight fit on the cable. Where
cables changed direction, or are routed through conduits, cables identification sleeves shall
be fitted.

Cables shall be contained within a protective enclosure of a size not less than that
complying with IEC or local standards throughout its whole length.

Cables installed in conduits, trunking shall be so grouped that the cables of all phases and
the neutral, are drawn into the same conduit. The lead and return conductors shall always
be drawn into the same conduit. Not less than three single core cables shall be enclosed
in any one conduit or trunking compartment.

The grouping of cables fed from different distribution units shall not be permitted. Also the
grouping of cables of different service systems shall not be permitted.

Where cables are installed in trunking, they shall be grouped in their respective circuits or
services and taped or bound by means of nylon cable straps at one-meter intervals for
purpose of identification.

2.2.3 Cable Support Systems:

For above ground installations the method of fixing PVC/XLPE insulated and PVC
sheathed cables shall be either laid on cable trays or ladder rack or clipped to the building
structure by suitable cable clamp. All single core unsheathed cables shall be run in a
conduit or trunking system.

Fasteners: Cable clamps shall be of either non-ferrous metal, or plastic material, claw or
split clamp type suitable for the size and type of cable and shall be so selected so that all
clamps can be tightened down without exerting undue pressure or strain on the cables.

In the case of vertical cables, the clamps shall be so designed and of sufficient number to
grip the cable firmly to prevent creeping. No cable runs shall be without fittings. All cable
hangers and racks shall be submitted for inspection by the Client's Representative prior to
the installation of cables. Where cable routes are subject to numerous changes in level
and direction additional cable hangers shall be provided.

2.3 INSTALLATION INSTRUCTIONS

The following manufacturer's information shall be provided for each size, conductor
quantity, and type of cable furnished:

- Minimum bending radius, in millimeter for multiple-conductor cables, this

information shall be provided for both the individual conductors and the
multiple-conductor cable.

- Pulling tension and sidewall pressure limits, in kilograms.

- Upon request, compatibility of cable materials and construction with

specific materials and hardware manufactured by others shall be stated.

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Also, if requested, recommendations shall be provided for various cable

operations, including installing, splicing, terminating, etc.

2.4 TESTS, INSPECTIONS AND VERIFICATIONS

2.4.1 Cable Data:

Manufacture ofthe wire and cable shall not be started until all materials to be used in the
fabrication of the finished wire or cable have been approved by the Client's Representative.
Cable data shall be submitted for approval including dimensioned sketches showing cable
construction, and sufficient additional data to show that these specifications will be
satisfied.

Independent Tests:

The Client may at any time make visual inspections, continuity or resistance checks, and
insulation resistance readings. A cable's failure to pass these tests and inspections, or
failure to produce readings consistent with acceptable values for the application, will be
grounds for rejection of the cable. All cable installations that failed these tests shall be
replaced by the Contractor, at no cost to the Client.

Reports:

Results oftests made shall be furnished. No wire or cable shall be shipped until authorized.
Lot number and reel or coil number of wire and cable tested shall be indicated on the test
reports.

PART 3 EXECUTION

3.1 INSPECTION

The outside of each cable reel shall be carefully inspected and protruding nails, fastenings,
or other objects which might damage the cable shall be removed. A thorough visual
inspection for flaws, breaks, or abrasions in the cable sheath shall be made as the cable
leaves the reel, and the pulling speed shall be slow enough to permit this inspection.
Damage to the sheath or finish of the cable shall be sufficient cause for rejecting the cable.
Cable damaged in any way during installation shall be replaced by and at the expense of
the Contractor.

3.2 PREPARATION

3.2.1 Cable Protection:

Cables shall be carefully handled during installation to avoid damage of any kind. They
shall be unreeled or uncoiled slowly in order to prevent damage to the insulation or sheath
due to sudden bending. Repeated bending shall be avoided. Sharp links shall be avoided
in unreeling, uncoiling and pulling.

The pulling of cables into conduits or ducts shall be carried out with all possible care. The
cable reels or coils shall be positioned so that the cable may be trained into the conduit or
duct as directly as possible, with the minimum of changes of direction or of bending. The
cable end shall be provided with a suitable protector to guard against damage to the
insulation or sheath. Where several cables are contained in one conduit or duct, all cables
shall be pulled-in together.

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The pulling tension shall not exceed the maximum tension as recommended by the cable
manufacturer.

Long lengths of cable shall be laid using an adequate number of drum jacks, rollers and
other handling accessories. Make-shift-arrangements will not be acceptable. Care shall be
taken to break the rotation of the reel and cables shall not be dragged over loose earth,
concrete or any surface detrimental to the insulation. Cables shall not be stretched but shall
be adequately supported on rollers or manhandled into position.

Before cables are pulled through ducts, the ducts shall be checked for cleanliness and
smoothness. Where ducting is longer than two meters, a cable wire mesh cable stocking
shall be used to attach the cable to the draw• In rope.

The minimum bending radii shall be not less than that recommended but the cable
manufacturer and contra twisting shall be avoided.

Spacing between cables shall be suitable for the derating factors applied to the cable
installation design.

Cables shall be installed using the loop-in principle, unless otherwise specified no straight
through or tee joints will be permitted.

3.2.2 Cable Routing:

The general route of all cables shall be indicated on the drawings and/or as directed by the
Client's Representative if there are no drawings. The Contractor shall include for all
deviations required by the building structure and other services. The final routes of all
cables shall be submitted to the Client's Representative before any work in connection with
the cable installation is commenced.

Cable shall be installed with a minimum of 300 mm clearance of any equipment or pipework
including lagging associated with other services. Where this condition is or difficult to
maintain, the Client's Representative consent shall be obtained prior to the installation
being commenced.

Where cables are situated below floor level in sub-stations and switch rooms, they shall be
run either in formed concrete open ducts, PVC or under fire resisting access flooring. No
cables shall be buried directly in concrete flooring or foundations.

Where cables pass through holes in panels or other metalwork, they shall be protected by
rubber grommets, compression glands or their equivalent.

Where cables are run vertically heavy gauge sheet metal guards shall be supplied and
fixed where there is a possibility that the cable could sustain mechanical damage.

3.2.3 Segregation:

Cables of different voltages and duties shall be segregated and particular attention shall
be paid to the avoidance of induced 'spikes' or ' electrical noise' on adjacent circuits due to
high currents and/or switches surges.

3.2.4 Grounding:

All metal work which cannot be insulated as defined in the Governing Standards and is

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associated with cable runs shall be bonded to earth or to the cable armoring where this
latter methods is approved.

Where steel wire armoured cables are specified and the resistance of the armoring is
unsatisfactory, a supplementary earth (ground) cable shall be run with the affected cable.
This cable shall be sized to ensure compliance with the wiring regulations for earthing.

3.3 INSTALLATION

3.3.1 Cable Installation:

Cable shall be installed m accordance with IEC standards and local code.

Cables shall not be buried in solid or hard setting building finishes unless prior approval
has been given by the Client's Representative. The Contractor shall ensure that cables
when run in building finishes are immediately protected against mechanical or any other
damage. The Contractor shall also be in attendance when finishes are applied and shall
ensure that no damage or displacement occurs.

Cables shall be installed parallel to the building lines and shall not be run diagonally in
floor or ceiling finishes.

Single cable passing through walls and floors shall be protected by means of tubular PVC
or steel sleeves of sufficient size to give minimum 13 mm clearance all round the cable.
Sleeves passing through floors shall extend above the floor level a minimum of 40 mm.

Where passing through walls the sleeve shall finish flush with the finished surface. All
sleeves shall be tightly packed with suitable fire resistant materials of an approved type.
All cables rising from floor level to equipment or in other locations where accidental damage
may occur shall be protected.

Cables shall be straightened and dressed neatly on the runs by approved methods. All
bends shall have an inside radius of not less than that recommended by the cable
manufacturer and in no case shall it be smaller than the bending radii shown in the
appropriate standards.

Where multi-runs of cables occur they shall be fixed to cable trays.

Cables shall be tagged at both ends, inside each panel, and every 10 m of the run. Tag
shall be metal type and shall read both the cable size and the target panels or loads
(From/To).

Megger conductor phase-to-phase and phase-to-ground for continuation and insulation

tests before connecting the utilization devices for 100% feeders, branch circuit and motor
circuit.

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SECTION 1204

HIGH VOLTAGE CABLE

PART 1 GENERAL

1.1 SCOPE

This section covers the furnishing high voltage cables, including armored and unarmored
single and multiple conductor power cables.

1.2 DESIGN CRITERIA

The cables shall be designed for the following environmental conditions:

- Air ambient temperature at point of use (Refer to Section 16050)

- Relative humidity (Refer to Section 16050)
- Occasional sand storms
- Salty air
- Soil conditions vary from dry sand to wet silt or clay
- In some areas the soil is alkaline, in others it is acidic or salt

The cable shall be rated for 90°C continuous temperature, 130°C maximum emergency
temperature and 250°C short circuit temperature

1.3 REFERENCES

1.3.1 Governing Standards:

Except as modified or supplemented herein, all equipment and materials required in this
section including their installation shall conform to the applicable requirements of the
following standards. Standards current at the time of tender shall be used.

BS 1442 Galvanized Mild Steel Wire for Armoring Cables

BS 2484 Straight Concrete Clay Ware Covers

BS 2897 Aluminum Strip Armour for Cables

BS 3506 Unplasticised PVC Pipe for Industrial Purposes

BS 4066 (IEC 332) Tests on Electric CabLes Under Fire Conditions

BS 4660 Unplsticised Polyvinyl Chloride (PVC-u) Pipes and Plastic Fittings

of Nominal Sizes 110 and 160 for Below Ground Gravity Drainage
and Sewerage

BS 5308 Instrumentation Cables

BS 5467 (IEC 502) Cables with Thermosetting Insulation for Electricity

Supply for Voltages of up to and Including 600/1000 V and
19000/30000 V

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BS 6004 (IEC 227) PVC Insulated Cables (non-armored) for Electrical

Power

BS 6007 Rubber Insulated Cables for Electric Power and Lighting

BS 6207 (IEC 245) Mineral Insulated Cables

BS 6234 Polythene Insulation and Sheath for Cables

BS 6346 PVC Insulated Cables for Electrical Supply

BS 6360 (IEC 228) Copper Conductors for Cables

BS 6500 (IEC 227) Insulated Flexible Cords

BS 6622 (IEC 502) Cables with Extruded Cross Linked Polyethylene

Insulation, for Rated voltage 3800/6000 V up to 19000/30000 V

BS 6746 PVC Insulation and Sheath ofElectric Cables

BS 6746C Color Chart for Insulation and Sheath ofElectric Cables

BS 6899 Rubber Insulation and Sheath ofElectric Cables

BS 7671 Requirements for Electrical Installations

ISO 9000 Quality Management and Assurance Standards

BS EN 29453 Soft Solder Alloys-Chemical Composition and Forms

Cable terminations shall comply with the following specifications:

BS 1858 Bitumen Based Compounds for Electrical Purposes

BS 4579 Performance of Mechanical and Compression Joints m

Electric Cable and Wire Connectors

BS 6121 Mechanical Cable Glands for Elastomer and Plastic

Insulated Cables

BS 6910 Cold Pour Resin Compound and Heat Shrink Cable Joints in the
Voltage Range up to 1000 V AC and 1500 V DC

1.4 QUALITY ASSURANCE

1.4.1 Installer's Qualifications:

The Contractor shall submit data showing that he has successfully installed systems of the
same type and design as specified herein, or that the Contractor has a firm contractual
agreement with a subcontractor having not less than five years experience in the design
and installation of such systems. Data shall include names and location of at least two
installations of such systems, he or his referenced sub-contractors has installed. The
references shall indicate type and design of each system and certification that each system
has been performed satisfactorily in the manner intended for not less than three years.

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1.4.2 Engineer's Acceptance and Contractor's Responsibility:

The Engineer's acceptance of the Contractor's working drawings shall not relieve the
Contractor from responsibility for errors, omissions, or deficiencies in the work. The
Contractor shall verify actual conditions in the field and shall take all measurements
necessary for proper installation of this work.

1.5 SUBMITTALS

Submit the following in accordance with the requirements set forth at the Conditions of
Contract.

1.5.1 Data:

Equipment, performance and manufacturer's catalog data shall be provided for the
following items:

- Single core XLPE/SWA/PVC Direct Buried Armored Cable

- Multicore XLPE/SW A/PVC Direct Buried Armored Cable

- Single core XLPE/PVC Unarmored Cable

- Multicore XLPE/PVC Unarrmored Cable

1.5.2 Instructions:

Manufacturer's Instructions shall be provided showing the recommended sequence

and method of installation for the following:

- High Voltage Power Cable Systems

- Termination

1.5.3 Statements:

Listing of products installed shall be provided showing qualifications of Cable

Splicers to the Engineer's Representative prior to specified work.

1.5.4 Reports:

Test Reports for the following shall be in accordance with the paragraph entitled, "Field
Testing," of this section.

- Dielectric Absorption Tests

- High-Voltage Tests

- Radiographic Tests

1.5.5 Certificates:

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Certificates of Compliance shall be provided for the following showing that the cable
manufacturer has made the applicable factory• conducted tests on each shipping length of
cable. Certified copies of test data shall show conformance to the referenced standards
and shall be approved prior to delivery of cable.

- Conductor Resistance
- Thickness of Armour
- Ionization
- High-Voltage
- Flammability
- Mechanical Integrity
- Bending Test
- High-Voltage Time Test
- Dielectric Power Loss
- Power-Factor Tests
- Qualifications of Cable Splicers
- Dielectric Pothead Tests

1.6 SHIPMENT

Cable shall be shipped on reels such that the cable will be protected from mechanical
injury. Each end of each length of cable shall be hermetically sealed and securely attached
to the reel.

Minimum reel drum diameter shall be 14 times the overall diameter of the cable. A pulling
eye shall be installed by the manufacturer for each length of cable supplied for installation
in ducts, manholes, and utility trenches.

PART 2 PRODUCTS

2.1 CONSTRUCTION OF CABLES

Cable shall be armored type, rated 6350/11000 Volts, and shall comply with BS 6622.
Single core cable shall be designated 12 kV XLPE/AWNPVC. Multi-core cable shall be
designated 12 kV XLPE/SWNPVC.

Conductors shall be stranded aluminum complying with BS 6360, covered with a semi-
conducting screen extruded on to the conductors.

Insulation shall be extruded cross linked polyethylene suitable for continuous operation at
90 °C, able to accept a final temperature of 250 oc in the event of a short circuit, and
covered with a screen consisting of an extruded semi• conducting layer and a copper tape
layer.

Armored cables shall have secure bedding, over the core or core assembly, for the armor.
For single core cable, the bedding shall consist of a PVC sheath. For multi-core cable, the
bedding shall consist of non-hygroscopic fillers.

Single core cable shall have aluminum wire armor. Multi-core cables shall have galvanized
steel wire armor. Cable shall be covered with a red colored PVC sheath.

Electrical design stress at any point in the insulation shall not exceed 3 kV permm.

2.1.1 Conductors:

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The cable shall have single conductor of plain aluminum Class 2, of concentric strand
wires. The conductor shall be of compacted circular shape.

2.1.2 Conductor Screening:

Each conductor shall be covered with an extruded semi-conductive material layer. The
screening shall be tightly fitted to the conductor but shall be easily cold strippable. The
conductor screens shall bond thoroughly to the insulation but shall be easily distinguished
from it by its different color.

2.1.3 Insulation:

Each conductor shall have ozone-resistant layer or cross-linked polyethylene (XLPE)

extruded on the conductor screen.

2.1.4 Insulation Screening:

A semi-conductive material layer which shall have a different color from that of the main
insulation shall be extruded on the core. The screening layers shall be easily removable
without damaging or scratching the main insulation or leaving traces over it during splicing
or terminating the cable.

2.1.5 Copper Sheath:

On the core insulation, two screening flat copper tapes each having 0. 1 mm thickness
shall be helically applied and overlapped over the insulation shield.

The overlap for each tape shall be 2': 1/3 of its total width so that max. D.C. resistance of
cu screen at 20° per km of cables :S 0.65 ohm.

2.1.6 Filling and Inner Covering:

The three cores shall be assembled together, the interstice filled with non-hygroscopic;
non-conductive material which may be extruded or not so that the completed cable
assembly is of substantial circular cross-section.

The inner covering wrapping the three cores together shall be of extruded corrosion
resistant material.

The material is used for the filler and inner covering shall be suitable for the cable operating
temperature. The thickness of the inner covering shall be in accordance with the attached
table of dimensions.

2.1.7 Metallic Armour:

The metallic armour is of a double tape type and shall be of steel. The tapes shall be hot
or cold rolled of commercial quality. Special consideration shall be given to the possibility
of corrosion, not only for mechanical safety, but also for electrical safety. It shall be applied
on an inner covering in accordance with IEC 60502 standard.

The material and dimensions of the steel tapes shall be in accordance with IEC 60502
standard.

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The tape armour shall be helically applied in two layers so that the outer tape is
approximately central to cover the gap of the inner tape. The gap between adjacent turns
of each tape shall not exceed 50% of the width of the tape.

2.1.8 Outer Jacket:

The cable shall have an oversheath of extruded PVC st-2. The oversheath shall be non-
hygrosopic, sunlight resistant and suitable for soil conditions in Project Site.

The cable shall be marked throughout its length with the following items:

- Voltage rating
- Size
- Manufacturer's name
- Year of manufacture
- Customer's name
Intervals of marking shall not exceed one meter and each mark shall serially indicate the
length ofthe cable remaining.

2.2 IDENTIFICATION OF THE CABLE PHASES AND MARKING

Identification for phases shall be carried using colored plastic ribbon between the semi-
conducting layer and copper screen (RED, YELLOW, BLUE).

The cable shall be marked throughout its length with the following items:

- Voltage rating

- Size

- Number of conductors

- Manufacturer's name

- Year of manufacture

- Customer's name (Engineer)

Intervals of marking shall not exceed one meter and each mark shall serially indicate the
length ofthe cable remaining.

2.3 MULTIPLE-CONDUCTOR UNARMOURED CABLES

Cross-linked polyethylene insulated IEC 502:

Cross-linked Polyethylene With PVC Jacket: Multiple-conductor, cross• linked

polyethylene-insulated, red sheath polyvinyl chloride-jacketed unarmored cable shall
conform to IEC 502. Conductor screen shall be extruded, semi-conductor compound,
insulation screen (non-metallic part) shall be graphite layer with a lapping tape or
extruded semi-conductive material, and for metallic part shall be copper tapes 0.10
millimeter thickness. Taped bedding shall be used.

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2.4 MULTIPLE-CONDUCTOR, SWA CABLES

2.4.1 Cross-linked Polyethylene with PVC Jacket:

Multiple-conductor, cross• linked polyethylene-insulated, red sheath polyvinyl chloride-

jacketed steel wire armored (SWA) cable shall conform to IEC 502. Conductor screen shall
be extruded semi-conductor compound, insulation screen (non-metallic part) shall be
graphite layer with a lapping tape or extruded semi-conductive material and for metallic
part shall be copper tapes 0.10 millimeter thickness. Extruded PVC bedding shall be used.
Armour shall be galvanized steel tapes or steel wires applied helically over the PVC
bedding.

2.5 SINGLE-CONDUCTOR UNARMOURED CABLES

2.5.1 Cross-linked Polyethylene with PVC Jacket:

Single-conductor, polyethylene• insulated, red sheath polyvinyl chloride-jacketed

unarmored cable shall conform to IEC 502. Conductor screen shall be extruded semi-
conductor compound, insulation screen (non-metallic part) shall be graphite layer with a
lapping tape or extruded semi-conductive material and for metallic part shall be copper
tapes 0.10 millimeter thickness.

2.6 SINGLE-CONDUCTOR SWA CABLES

2.6.1 Cross-linked Polyethylene with PVC Jacket:

Single-conductor, polyethylene• insulated, red sheath polyvinyl chloride-jacketed SWA

cable shall conform to IEC 502. Conductor screen shall be extruded semiconductor
compound, insulation screen (non-metallic part) shall be graphite layer with a lapping tape
or extruded semi-conductive material and for metallic part shall be copper tapes 0.10
millimeter thickness.

2.7 CABLE SUPPORTS AND FITTINGS

Cable supports, related fittings, and accessories for use in corrosive underground
locations, such as manholes, shall be provided with a factory applied coating of polyvinyl
chloride of at least 0.51 millimeter thick. Polyvinyl chloride (PVC) coated items shall have
a uniform thickness and be free ofblisters, breaks, and holidays. PVC compound shall
conform to IEC.

Cable racks, cable tray supports and related fittings shall be IEC standard or heavy-duty
nonmetallic glass-reinforced nylon or polycarbonate.

2.8 SPLICE KITS

Approved connectors shall be provided for splices and terminal connections of all
aluminum conductors. The connector shall fit the conductor to which it shall be connected,
and the assembly shall have joint contact surfaces not less than 50%. (As recommended
in writing by the splicing kit manufacturer for specific sizes, ratings and configuration of
cable conductor and splices specified). Include all components required for complete splice
with detail instruction. Comply with IEC Code.

2.9 SOLID TERMINATIONS

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Termination for high voltage cable shall be in the switchgear or cable entrance
Compartment of transformers. Type of termination fitting shall be as required to match
conductor to equipment, built-up insulation and heat shrink stress cone as manufactured
by Raychem (or approved equal) for the type of cable specified.

PART 3 EXECUTION

3.1 INSTALLATION

High-voltage cables shall be installed in accordance with IEC.

Cable shall be installed in underground duct banks; in conduit above and below grade;
inside buildings; by open wire method; on insulator hooks; on racks; in wall and ceiling
mounted cable trays and manholes; and by direct burial.

Cables shall be secured with heavy-duty cable ties in trays mounted horizontally, where
cable rests on tray bottom. Cable ties shall be installed at minimum of3000-rnillimeter
intervals.

Cables shall be secured with PVC coated, metallic or non-metallic cable clamps, straps,
hangers, or other approved supporting devices, ceilings, and in cable trays mounted
vertically, where tray bottom is in a vertical plane. When field cuts or other damage occurs
to the PVC coating, a liquid PVC patch shall be applied to maintain the integrity of the
coating. After the installation is complete, an inspection shall be performed to ensure the
absence of voids, pinholes, or cuts.

Contractor shall ensure that all cable trays are properly secured and supported prior to
installing new armored cable. Contractor shall add new permanent and/or temporary tray
support devices as required to preclude cable tray failure during cable pulling or after cable
is installed.

Cable or conductors of a primary distribution system shall be rejected when installed openly
in cable trays or openly racked along interior walls; (in the same raceway or conduit with
ac/de control circuits or ac power circuits operating at less than 600 Volts; or in a manner
allowing cable to support its own weight).

3.1.1 Moisture-testing Before Pulling:

Contractor shall ensure that radii of bends, potheads, fittings, cable risers, and other
conditions are suitable for the cable and conform to the recommendations ofthe cable
manufacturer.

3.1.2 Protection During Splicing Operations:

Blowers shall be provided to force fresh air into manholes or confined areas where free
movement or circulation of air is obstructed. Waterproof protective coverings shall be
available on the work site to provide protection against moisture while a splice is being
made. Pumps shall be used to keep manholes dry during splicing operations. Under no
conditions shall a splice or termination be made with the interior of a cable exposed to
moisture. A manhole ring at least 150 millimeters above ground shall be used around the
manhole entrance to keep surface water from entering the manhole. Unused ducts shall
be plugged and water seepage through ducts in use shall be stopped before the splice is
started.

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3.1.3 Duct Cleaning:

Ducts shall be thoroughly cleaned before installation of power cables. A standard flexible
mandrel shall be pulled through each duct to loosen particles of earth, sand, or foreign
material in the line. Mandrel length shall be not less than 300 millimeter long, and shall
have a diameter 13 millimeter less than the inside diameter of the duct. A brush with stiff
bristles shall then be pulled through each duct to remove the loosened particles. Brush
diameter shall be the same as or slightly larger than the diameter of the duct.

3.1.4 Pulling Cables in Ducts and Manholes:

High-voltage cables shall be pulled into ducts with equipment designed for this purpose,
including power• driven winch, cable-feeding flexible tube guide, cable grips, and
lubricants. A sufficient number of trained personnel and equipment shall be employed to
ensure the careful and proper installation of the cable.

Cable reel shall be set up at the side of the manhole and above the duct, allowing the cable
to enter through the opening without reverse bending. Flexible tube guide shall be installed
through the opening in a manner that will prevent the cable from rubbing on the edges of
any structural member.

Cable shall be unreeled from the top of the reel. Payout shall be carefully controlled. Cable
to be pulled shall be attached through a swivel to the main pulling wire by means of a
pulling eye or suitable cable grip permitted only on cables less than 60 meter long and less
than 50 millimeter in diameter.

Woven-wire cable grips shall be used to grip the cable end when pulling small cables and
short straight lengths of heavier cables.

Pulling eyes shall be attached to the cable conductors to prevent damage to the cable
structure.

Pulling eyes and cable grips shall be used together for PVC sheathed cables to prevent
damage to the cable structure.

Minimum bending radius shall be in accordance with the following:

Minimum Bending Radius

Cable Type Multiplier Times Cable Diameter
Armored cables 8
Unarmored cables with lapping tape 12

Cables shall be liberally coated with a suitable cable-pulling lubricant as it enters the tube
guide or duct. Grease and oil lubricants shall be used only on armored cables. unarmored
sheathed cables shall be covered with wire• pulling compounds when required which have
no deleterious effects on the cable. Rollers, sheaves, or tube guides around which the
cable is pulled shall conform to the minimum bending radius of the cable.

Cables shall be pulled into ducts at a speed not to exceed 0.25 meter per second and not
in excess of maximum permissible pulling tension specified by the cable manufacturer.

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Cable pulling using a vehicle shall not be permitted. Pulling operations shall be stopped
immediately with any indication of binding or obstruction and shall not be resumed until
such difficulty is corrected. Sufficient slack shall be provided for free movement of cable
due to expansion or contraction.

Cable splices made up in manholes shall be firmly supported on cable racks as indicated.
No cable splices shall be pulled in ducts. Cable ends shall overlap at the ends of a section
to provide sufficient undamaged cable for splicing. Cables to be spliced in manholes shall
overlap the centerline of the proposed joint by not less than 600 millimeter.

Cables cut in the field shall have the cut ends immediately sealed to prevent entrance of
moisture. Unarmored cables shall be sealed with rubber tape wrapped down to 75
millimeter from the cable end. Rubber tape shall be cover-wrapped with polyvinyl chloride
tape. Armored cables shall be sealed with wiping metal making a firm bond with the end of
the sheath or with a disk of lead fitted over the end and wiped to the sheath.

3.1.5 Direct Buried Installation:

Cable direct buried, unless otherwise specified furnish a bed of soft clean sand 100 mm
depth at the bottom of trench , and the same over cable. Install concrete tiles to the whole
route of the cable with 50 mm thickness and covering at least 200 mm over the outer edge
of the cable from both sides.

Then storing in backfilling with selected soil and reach to 95% compaction minimum. Before
reaching to the finished grade level by 300 mm install warning tape to cover the whole
routes indicating " DANGER ELECTRICAL CABLES". In both English and uRDU.

In road crossing, install UPVC pipe embedded in concrete encasement and install warning
tape and install spare pipes not less than 25 % of the same size.

Permanent markers shall be installed at each 50 m of the cable runs, changes in direction,
buried splices and cable ends.

Cables shall be installed as required by drawing and manufacturer's recommendation and

according to standard length of cable in case of long distance routes with one as a
maximum in certain route.

Use kits which are compatible with conductor size, material and type and according to the
manufacturer's recommendations.

Install terminations at ends of conductors and seal multi-conductor cable ends with
standard kits and glands.

3.1.6 Grounding:

The armouring of metal sheathed cables grounding connection's shall be made by means
of screw - type pressure connectors to grounding pads of connections provided on the
switchgear in accordance with IEC. All underground connections shall be made by
exothermic welding and then encapsulated in epoxy resin (Jointing). A separate protective
conductor shall connect the sheath, armouring, ground metal bodies of terminators, splices
and hardware according to manufacturer's written instructions and IEC codes.

3.2 INSPECTION AND TESTING

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3.2.1 ENGINEER reserves its right to carry out inspection during fabrication stages and to
witness the testing of cables.

3.2.2 Attendance of Engineer representative during fabrication stages and testing must not
relieve the manufacturer of his full responsibility for furnishing the cables in accordance
with the requirements of this specification, and shall not give him the right to invalidate any
claim which ENGINEER may make because of defective material or faulty workmanship.

3.2.3 Unless otherwise specified or approved in writing by Engineer all cables shall be tested at
the factory in accordance with the latest applicable issues of the IEC standards or approved
equivalent. All routine and type tests shall be performed by and at the expense of
manufacturer. The type and routine test certificates shall be delivered by Engineer.

3.2.4 Quality control procedure shall be submitted with tender documents.

3.3 GUARANTEE TABLES

The tenderer shall thoroughly fill in the attached guarantee tables (technical particulars and
performance).

3.4 MISCELLANEOUS

3.4.1 The cable length on each reel shall be as long as possible to minimize the number of joints
and as shown in the attached tables.

3.4.2 All cable ends shall be firmly secured to the reel and shall be covered by heat• shrinkable
end caps.

3.4.3 The cable drum shall be covered with wooden slabs of suitable thickness.

3.4.5 All cables shall be supplied on reels whose size is not to exceed 2.6 m diameter and 1.6
m width including protruded bolt length. The reels may be returnable as per agreement
between the tenderer and Engineer.

3.4.6 On each reel the following data shall be printed on both sides:

High Voltage Power Cables Manufactured by:

Voltage Class: kV

Number of Cores and Cross-section: mm2

Type of Insulation:

Length of Cable: Meters

Net Weight: kgs

Gross Weight: kgs

Reel No.:

Important Note:

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- The factory laboratory must be equipped with all modern instruments and
equipment required to perform all routine and special tests ofiEC 60502 with the
accuracies mentioned in IEC 60502

- Offers from tenderers having no such laboratories shall not be considered

- Dimensions shall be measured by digital and microscopic instruments.

The thickness of insulation at any place, may however be less than the specified nominal
value provided that the difference does not exceed 0. 1 mm + 10% of the specified nominal
value.

The measured smallest thickness of the PVC oversheath, at any point shall not fall below
80% of the specified nominal value by more than 0.2 mm.

- The thickness of insulation at any place may however be less than the specified
nominal value provided that the difference does not exceed 0.1 mm + 10% of the
specified nominal value.

- The dimension of the armour shall not fall below the specified nominal value by
more than 10%.

- The measured smallest thickness of the P.V.C oversheath, at any point, shall not
fall below 80% of the specified nominal value by more than 0.2 mm.

We certify that the above mentioned data are guaranteed for the offered cable.

FIELD TESTING

Each shall be subjected to dielectric-absorption and high-voltage tests after the installation
of power cables has been completed, including splices, joints, and terminations, and before
the cable is energized.

Test equipment, labor, and technical personnel shall be provided as necessary to perform
the electrical acceptance tests.

Arrangements shall be made to have tests witnessed and approved by the Engineer's
representative.

Each power-cable installation shall be completely isolated from extraneous electrical

connections at cable terminations and joints. Safety precautions shall be observed.

Each power cable shall first be given a full dielectric-absorption test with 2 500-Volt
insulation-resistance test set. Test shall be applied for a long enough time to fully charge
the cable. Readings shall be recorded every 15 seconds during the first 3 minutes of test
and at 1 minute intervals thereafter. Test shall continue until three equal readings, 1 minute
apart, are obtained. Minimum reading shall be 200 megohms at an ambient temperature
of 16 degrees C. Readings taken at other than 16 degrees C ambient temperatures
shall be corrected accordingly.

Upon successful completion of the dielectric absorption test, the cable shall be subjected
to a direct-current high-potential test for 5 minutes with test voltages applied in accordance
with IEC for cross-linked, polyethylene• insulated cable.

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Leakage current readings shall be recorded every 30 seconds during the first 2 minutes
and every minute thereafter for the remainder of the test. When the leakage current
continues to increase after the first minute, the test shall be immediately terminated and
steps taken to find and correct the fault. When a second test becomes necessary, this test
procedure shall be repeated.

Upon satisfactory completion of the high-potential test, the cable shall be given a second
dielectric-absorption test as before.

Results of the second dielectric-absorption test shall agree with the first test and shall
indicate no evidence of permanent injury to the cable caused by the high-potential test.

Test data shall be recorded and shall include identification of cable and location, megohm
readings versus time, leakage current readings versus time, and cable temperature versus
time.

Final acceptance shall depend upon the satisfactory performance of the cable under test.
No cable shall be energized until recorded test data have been approved by the Engineer's
Representative.

Radiographic tests shall be performed on all potheads at the discretion of the Engineer's
Representative to determine if voids exist in the pothead. Unacceptable terminations shall
be reworked at no additional expense to the Engineer.

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SECTION 1205

PACKAGED ENGINE GENERATOR

PART 1 GENERAL

1.1 SCOPE

This section covers the equipment, installation and testing of diesel engine and driven
electric generator units. The engine generator unit/s shall be installed as indicated on the
drawings.

The engine-generator unit shall be a skid-mounted, indoor type unit consisting of an

engine, an alternator, auxiliary systems, controls, and accessories as specified and as
required for a complete operating system.

Equipment furnished under this section shall be assembled, erected, and placed in proper
operating condition in full conformity to the specifications of the equipment manufacturer
unless exceptions are noted by the Engineer. The engine-generator unit shall be a
standard product of the manufacturer and shall be a packaged type unit, fully shop
assembled, wired, and tested, requiring no field assembly of critical moving parts.

1.2 REFERENCES

1.2.1 Governing Standards:

Except as modified or supplemented herein, all equipment and materials required in this
section including their installation shall conform to the applicable requirements of the
following standards. Standards current at the time of tender shall be used.

British Standards

BS No.

4999 Alternators
5514 Engines

Occupational Safety and Health Act OSHA No.

B 55514 Reciprocating Internal Combustion Engines Performances. International

Commission (IEC) Standard- IEC 34.1

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1.3 COORDINATION

All equipment specified in this section shall be furnished through a single manufacturer
who shall be responsible for the design, manufacture coordination, and proper installation
and operation of the entire system.

1.4 SUBMITTALS

Submit the following in accordance with the requirements set forth at the Conditions of
Contract.

1.4.1 Drawings and Data:

Complete descriptive and engineering data shall be submitted. These data shall consist of
drawings and photographs in sufficient detail that the construction of the equipment is
indicated, together with details, specifications, performance curves, installation drawings,
schematics, and wiring diagrams; and foundation drawing showing location detail and
size of anchor bolts. Data submitted shall include the following:

Engine Data

- Manufacturer
- Model
- Number of cylinders
- RPM
- Bore x stroke
- Rated capacity kW
- BMEP at rated kW (including any parasitic loads and generator efficiency)
- Make and model of governor
Generator Data

- Manufacturer
- Model
- RatedkVA
- Rated kW at 0.8 PF
- Voltage
- Temperature rise above 50 C ambient for Stator Field
- Class of insulation

Generator Efficiency Including Excitation Losses and at 80 Percent PF

- Full load
- 3/4 load
- 1/2 load
- l/4 load

Guaranteed Fuel Consumption Rate

- Fullloadliters/hour
- 3/4load liters/hour
- 1/2 load liters/hour
- 1/4load liters/hour

Engine-generator Unit and Accessories

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- Weight ofbase-mounted unit

- Overall length
- Overall width
- Overall height
- Exhaust pipe connection size and location
- Airflow required for combustion and ventilation, m3/min
- Heat rejected to room by engine and generator, Btu/hour
- Heat rejected to jacket water and lubricating oil, Btu/hour
- Height from bottom of base required for removing piston with connecting rod, also
for removing cylinder liner.

1.4.2 Test Reports:

Copies of the manufacturer's certified shop test record of the complete engine driven
generator. The engine-generator log test sheets and a performance review report shall
be signed by the engine tester and certified by the manufacturer. The report shall include
brief outlines of all test procedures and shall compare actual test results to the
requirements of these specifications by means of calculations, graphs, or charts.

Submit name and address of nearest factory authorized service and parts facility.

1.4.1 Operations and Maintenance Manuals/Charts and Spare Parts Data:

Complete operations and maintenance manuals/Charts including spare parts data and
wiring diagrams of all equipment furnished under this section.

1.5 PROJECT CONDITIONS

1.5.1 Power Supply:

The power supply for the engine-generator accessories will be 380Y/220 Volts AC, 50 Hz,
three-phase, 4-wire or as may be required by manufacturer’s standard.

1.6 DELIVERY, STORAGE AND HANDLING

1.6.1 Storage:

The Contractor shall acknowledge storage conditions at the time of submitting his Tender.
If the equipment will not be operational within 90 days after manufacture, the manufacturer
shall crate and prepare the equipment for export transportation and long-term storage.
Precautionary measures for prolonged storage shall be provided by the manufacturer at
the factory. The Contractor shall be responsible for storage and maintenance of the
protective measures as recommended and instructed by the manufacturer while stored at
the storage site. The manufacturer's warranty on units held in prolonged storage exceeding
three months shall be covered by special agreement reflecting the storage conditions.

1.6.2 Packaging:

In addition to the protection specified for prolonged storage, the packaging of spare units
and spare parts shall be similar to export packing and shall be suitable for long-term
storage in a damp location. Each spare item shall be packed separately and shall be

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completely identified on the outside of the container.

Instructions for the servicing of equipment while in long-term or prolonged storage shall
accompany each item of equipment. Advisement of enclosed instructions with each
package shall be noted on the exterior of the package in both Urdu and English.

1.7 SPARE PARTS

A list of all spare parts required for adjustment, operation, and maintenance of the
equipment shall be submitted in accordance with the requirements set forth at the
Conditions of Contract.

In addition, all special tools required for adjustment, operation, and maintenance of the
equipment plus the following spare parts shall be furnished with each unit:

- Five sets of air filter elements

- Five sets oflube oil filter elements
- Five sets of fuel oil filter elements
- One thermostat
One set of gaskets required for routine operational maintenance, but not limited to,
the following:

• cylinder head gaskets

• oil pan gaskets
• water pump gaskets
• exhaust manifold gaskets
• thermostat housing gaskets
- One set of hoses and belts including one of each different size and type
- Two complete fuel injection nozzles or ejectors

1.8 INSTRUCTIONS AND TRAINING ON OPERATION AND MAIN1ENANCE

Contractor shall provide instructions and training for the staff to be assigned in the
operation and maintenance of the equipment specified under this section. Training and
instructions shall be in accordance with the requirements set forth at the Conditions of
Contract.

PART 2 PRODUCTS

2.1 PERFORMANCE AND DESIGN REQUIREMENTS

2.1.1 Service Conditions:

The engine-generator unit shall provide standby electrical power. The unit shall
automatically start on closure of an "Engine Start" contact in automatic transfer switch and
when manually initiated from the control panel.

The engine-generator unit shall be designed to provide power for both initial and future
requirements as specified herein.

2.1.2 Design Conditions:

The engine and generator shall be directly connected, free from injurious torsional or other
vibrations, and shall be mounted on a steel sub-base. Each engine-generator unit shall be

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designed to operate under the following conditions:

Ambient Temperature in Summer (max) 55°C

Ambient Temperature in Winter (min) 2°C

Relative humidity 95%

Type, fuel supply diesel

Type, cooling system Water-cooled tropical radiator

Fluid Water with rust and scale inhibitor

2.1.3 Performance Requirements:

The engine-generator unit shall be capable of the following performance under the design
conditions above:

- Minimum continuous standby/k:W rating as indicated on the drawings

- For the following conditions:
• Frequency, Hz: 50
• Power factor: 0.8
• Terminal voltage: 415Y/240 Volts, 3-phase, 4-wire
Unless otherwise specified
• Maximum engine speed, rpm: 1500
• Units offered at ratings in excess of their published ratings
are not acceptable.
• The set shall be capable of 110% load for one hour under the
previously stated conditions at the rated speed .without over
heating of the engine or alternator and without mechanical or
electrical troubles.

2.2 ENGINE-GENERA TOR UNIT

2.2.1 Engine:

The engine shall conform to the following requirements:

- Cylinder arrangement V-type

- Aspiration Turbo-charged or turbo-charged and aftercooled

- Cycle 4

- Cooling Tropical radiator

- The engine shall have a net kilo Watt rating at least equal to actual requirements
at specified continuous power rating and at the specified conditions.

The engine shall be equipped with the following:

- Engine speed shall be an electronic governor for isochronous regulation from no

load to full load alternator output. Belt driven or velocity governors are not

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acceptable.

- Fuel system as specified and suitable for operation with specified fuel.

- Oil and coolant drains each piped to edge of skid with shutoffvalve or cap.

- Pressure lubrication system including a positive displacement oil pump, pressure

regulating valve, manual prelube pump and electric prelube pump, full flow filter,
oil cooler, level indicator or dipstick, and lubrication system as specified.

- Combustion air system as specified.

- Stainless steel flexible connections for all piping connections to the unit.

- Exhaust system as specified.

- Cooling system as specified.

- Starting system as specified.

- All field piping connections to the engine generator set, including oil drain lines,
shall be terminated with a flange. Flanges other than ANSI B16.5, Class 150,
raised face shall be furnished with companion flanges.

2.2.2 Alternator:

The engine-generator unit alternator shall be a 4 or 6 pole, revolving field design with
temperature compensated solid-state voltage regulator, brushless rotating rectifier exciter
system, and drip proof construction with amortisseur windings. The stator shall be two
bearing alternator. Only insulated bearings shall be used to prevent ground shaft
currents. Alternators shall be designed for service in severe desert environment.
The rotor shall be driven through a semiflexible driving flange to ensure permanent
alignment.

Frequency regulation under varying loads from no load to 100% load shall be 5%
(isochronous with electronic governor). The random frequency variation shall not exceed
±0.5% of its mean value for constant loads from no load to full load. Voltage regulation
shall be within plus or minus one (1)% under load from no load to 100% load, and for
constant loads from no load to 100% load shall not exceed ± 1% of its mean value. The
momentary voltage drop shall not exceed 25 percent without starter coils dropping out or
stalling the engine at any time when applying or starting the specified loads. Recovery to
stable operation shall occur within 2 seconds.

The alternator shall have Class H insulation as defined by NEMA MG 1-1.65 and
temperature rise shall be within NEMA MGl-22.40 definition at rated condition.

The combined generator, exciter, and regulator efficiency at full load shall be 95.0 percent
or better.

Generator leads shall be brought out to bushings mounted m a rigidly supported, dust tight,
oversize terminal box.

2.2.3 Lubrication System:

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Pressure system with gear driven oil pump, sump capacity sized to the engine
displacement requirements. The system shall be protected by at least one full flow
replaceable spin-in cartridge type oil filter.

The engine shall be furnished with an oil level regulator and a flowmeter. The level regulator
shall be float operated and shall be installed in such a position that it will maintain a
constant crankcase oil level as recommended by the engine manufacturer. The level
regulator shall visually indicate the oil level. The flowmeter shall be a positive displacement
type and shall indicate the oil delivered to the engine by the level regulator. The meter
accuracy shall be within one percent of indicated flow. The meter shall have a counter with
a totalizing register indicating up to full capacity liters in one (1) liter increments. Oil shall
be supplied by gravity to the flowmeter and level regulator from the oil supply tank.
Provisions shall be furnished for bypassing the flowmeter and level regulator for filling the
engine crankcase from the oil supply tank during oil changes.

A dial type differential pressure gauge shall be furnished with each engine oil filter. The
gauge shall be mounted on the filter housing and shall indicate when servicing of the filter
elements is required. The filter shall be mounted on the engine skid.

2.2.4 Combustion Air Filtration System:

An air filtration system shall be furnished to provide clean combustion air to the engine.
The filtration system shall include a dry type air cleaner, and all accessones and
appurtenances specified, or otherwise required for a complete properly operating
installation.

The air cleaner shall be heavy duty with a minimum of 17 tubular replaceable fiberglass
filter elements installed in a vertical position. The air cleaner shall be self-supporting, use
a high intake position with an integrated prefilter setting chamber and shall be suitable for
the future engine operating condition and performance with a pressure drop of no more
than 50 mm water column at the future combustion airflow rate. The filter shall include an
access hatch for easy servicing of filter elements. The filter shall be of steel construction.

Piping from the air filter to the engine is specified in another section.

2.2.5 Fuel System:

The engine-generator unit shall be furnished with a complete fuel system, including but not
limited to engine driven fuel pump, duplex type strainers, shutoff valves, check valves,
engine supply and return lines, and flexible connections, all as part of the package. All
items shall be suitable for the specified fuel.

The diesel fuel valve train for engine shall include a fail safe spring loaded DC power
operated valve for shutoff of the fuel supply with engine shutdown. The valve shall be
located upstream of the flexible connection in the fuel line and shall be activated from the
engine oil pressure sensor. The valve shall open on engine start initiation.

All parts of the fuel system shall be installed in full compliance with OSHA Standard
1910.106 Flammable and Combustible Liquids.

The engine shall be suitable for running on diesel oil as described below:

Specific gravity at 60F distillation (P.P. 123/40) 0.834

IBM 219 C

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10% 250 C
50% 276 C
90% 314 C
F.E.P. 342 C
Flash Point PME 189 C
Sulphur 1.1%
Calorific Value BTU/lb. Gross Carbon Residue 19750
0.01/wt Diesel Index 62
Viscosity Redwood Seconds at 100F 34

2.2.6 Day Tank:

The engine shall be provided with a separate self-supporting or integral day tank. The day
tank shall be provided with connections for fuel supply line, fuel return line, fuel overflow
line, local fuel fill port, gauge, vent line, drain line, and float switch assembly for control.
A fuel return line cooler shall be provided as recommended by the manufacturer and
assembler. The temperature of the fuel returning to the day tank shall be below the flash
point of the fuel. A temperature-sensing device shall be installed in the fuel supply line.
Each engine-generator set provided with weatherproof enclosures shall have its day tank
mounted within the enclosure. The fuel fill line shall be accessible without opening the
enclosure.

The day tank to supply fuel to the engine for an uninterrupted of minimum of 8 hour period
at 100 percent rated load without being refilled, plus any fuel which may be returned to the
main fuel storage tank. The calculation of the capacity of the day tank shall incorporate the
requirement to stop the supply of fuel into the day tank at 90 percent of the ultimate volume
of the tank.

Drain Line: The day tank drain line shall be accessible and equipped with a shut-off valve.
Self-supporting day tank shall be arranged to allow drainage into a 305 mm tall bucket.
The local fuel fill port on the day tank shall be provided with a screw-on cap.

Fuel Level Controls: The day tank shall have a magnetic float switch assembly to perform
the following functions:

- Start the supply of fuel into the day tank when the fuel level is at the "Low" level
mark, 75 percent of the total tank capacity.

- Stop the supply of fuel into the day tank when the fuel level is at 90 percent of the
total tank capacity.

- Activate the "Overfill Fuel Level" alarm at 95 percent of the total tank volume.

- Activate the automatic fuel supply shut-off fail safe spring loaded DC operated
solonide valve located on the fill line of the day tank and shut down the fuel pump
which supplies fuel to the day tank at 95 percent of the total tank volume. The flow
of fuel shall be stopped before any fuel can be forced into the fuel overflow line.

2.2.7 Main Fuel Storage Fuel Tank:

The Contractor shall supply and install a cylindrical diesel oil storage tank with a capacity
to operate the associated diesel generator set continuously on full load for 10 days, unless
otherwise specified in the Project Documentation.

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The tank shall be welded mild steel construction suitably protected from corrosion in
accordance wit BS 2594 and shall be installed in the location indicated on the drawings.

The storage tank shall be complete with pipes, fittings, feed lines, vents, etc.. The tank
shall be of the approved type located outside the diesel engine room. The tank shall be
provided with 600 mm inspection manhole with cover, 50 mm filling pipe with cooped
filling terminal, 50 mm air vent pipe with screen outlets, isolating valve, valved drain etc..

Electronic fuel indicator with an audio/visual alarm shall be provided for main fuel storage
tank.

Also the storage tank and its accessories must comply with the Pakistan Regulations for
generator installation.

2.2.8 Diesel Oil Pumping Set:

Provide packages type fuel oil pumping and straining set with a capacity of four Times the
total fuel consumption of the engine at full load.

Pump sets shall be factory assembled, piped, wired and tested. Pump shall be activated
automatically by a switch in the day tank.

Piping shall be complete to suction, discharge and return line connections. Provide gate
valves and unions arranged to permit removal of pump while the system is in operation.
Install check valves and relief valves on pump outlet and Gate valves prior to pressure
gauges.

Suction strainer shall be flanged connection type, one piece, cast iron body, and ASTM
A48 class 30, with 1.2 mm perforation brass baskets.

Oil pump shall be factory assembled on a structural steel channel beam base to include
pump, motor, flexible coupling and guards. Pump shall be suitable for diesel oil.

Suitable manually operated fuel pump shall also be provided.

2.2.9 Exhaust System:

The engine-generator installation shall include a critical exhaust silencer, exhaust piping,
expansion joints, stainless steel rain cap, hangers, and accessories as required for a
complete operating system. Exhaust piping and insulation shall be terminated with a single
pipe flange connection.

Hangs and supports shall be provided for the silencer and exhaust piping such that
essentially no load is transmitted to the engine exhaust connection.

The exhaust silencer shall be a chamber type, all welded steel construction, with suitable
bracket supports for vertical or horizontal mounting. The silencer shall be reinforced to be
able to withstand a horizontal force of not less than 2224 N at the inlet connection. The
silencer size shall be such that the silencer produces half the maximum allowable back
pressure at future operating conditions with inlet and outlet flanged connections. The
silencer shall be suitable for critical type silencing.

The silencer shall meet the following requirements:

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Mi dband Frequency, 31.5 63 125 250 500 1K 2K 4K 8K

Attenuation, dB 11.5 27 37 .5 6.5 31 27 27 28 0

3
Noise attenuation required are 55 dB (A) at one meter from air intake and outlet louvers.

Expansion joints shall be furnished in the engine exhaust piping as indicated on the
construction drawings. The expansion joint in the horizontal exhaust piping shall be the
double bellows type fabricated of stainless steel one-piece construction with welded ends.
The expansion joint shall be designed for 50 mm lateral offset, 38 mm axial compression.

The expansion joint in the vertical riser immediately above the engine exhaust connection
shall be bellows type, fabricated of all stainless steel with a flange on one end and a butt
weld connection on the other end and shall be designed for 6 mm lateral offset, and
vibration isolation.

A stainless steel rain cap shall be furnished and installed on the exhaust stack to prevent
the entry of dust and rain.

Insulation: Insulation for exhaust silencer and all interior exhaust piping is to be 100 mm
thick Calcium silicate molded block type of rigid hydrous calcium silicate with thermal
conductivity of 0.060 W/M-K. Outer covering shall be aluminum jacket, 0.4 mm inches thick,
and type 3003 or 5005 alloys with 4 mm corrugations. Jacket shall have a factory applied
vapor barrier on the inside with aluminum straps over transverse joints. Adjacent section
corrugations shall overlap.

2.2.10 Starting System and Control Power:

The engine-generator unit shall include an electric motor start system. The electric start
system shall include starting motors, 24 V DC Volt battery pack with rack and cables, and
battery charger. The unit shall be arranged for manual starting, stopping, and transfer of
load. The load shall be transferred to the diesel unit when it has attained rated frequency
and voltage. The engine shall be capable of starting solely from the heat of compression.
Intake and exhaust valves shall be heat-resisting alloy steel with high tungsten-chrome
alloy steel exhaust valve seat inserts.

Electric starting shall be accomplished by an engine-mounted, solenoid shift electric

starter, capable of withstanding four consecutive continuous cranking periods of ten
seconds duration each.

The engine starting control equipment shall be arranged to disconnect the battery charger
to prevent it from being over-loaded during starting. The starter motor shall be of adequate
power of its duty.

Batteries: Batteries for starting shall be of the nickel cadmium type, 24 V, heavy duty diesel
starting type and of sufficient capacity to provide continuous cranking of 1.5 minute duration
without recharging. Batteries should have sufficient capacity to provide three successive
starts.

The batteries shall be filled with electrolyte and installed on proper racks with cables and
clamp. A hydrometer shall be supplied with the batteries.

The batteries should be designed for diesel engine cranking service, and of a capacity as

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recommended by the battery manufacturer for cranking the engine furnished, for the
necessary break-away current as required and the spinning current for four consecutive
starts of 10 seconds of cranking on each start, or for 60 seconds of continuous cranking
without being recharged and with the ambient temperature (both engine and battery) of
0°C. The batteries shall be mounted in an insulated, protective enclosure on a floor or skid
mounted battery rack and suitable cables shall be provided.

Battery Charger: The battery charger shall be static type enclosed in an adequately
ventilated sheet steel case and incorporated within the control panel with its associated
instruments and controls mounted on front of panel.

The charger shall be complete with all necessary relays, cut-outs, controls switches and
instruments for automatic charging of batteries. The charger shall automatically control the
charging rate to suit state of battery thus charging at high rate following a period of use of
battery and, when battery nearly fully charged, reverting to trickle charging automatically.

An ammeter and voltmeter in the control panel shall indicate the state of the battery and its
charging rate.

2.2.11 Cooling System: shall include:

Radiator: Built-in type with sufficient capacity to dissipate the total joules per hour rejected
by the engine cooling system at 110% full load.

Blower Fan: To have sufficient pressure to circulate required quantity of air for engine
cooling. The fan shall be provided with a suitable guard. DIG room inside temperature
should not exceed 56°C.

Jacket Water Heaters: To be provided on engme to facilitate quick starting under low
ambient conditions.

The Cooling System: Shall be capable of keeping the temperature of cooling water at safe
limits at all conditions of load required in the specifications. Maximum temperature of
cooling water after 10 hours of continuous running at full load at worst Pakistan climatic
conditions shall not exceed the maximum temperature limits of the diesel engine.

The cooling system shall include an engine shaft driven circulating water pump. The water
jacket of the engine cylinder shall be so constructed that the water in the jacket can be
drained completely.

The Radiator Finned Tubes: Shall have a common inlet and common outlet headers.

Drain Valve and Filling Valve: Shall be provided to the radiator for flushing and quick
filling.

Cooling Water Piping: Complete with all necessary supports, control valves, flanges and
fittings, thermometers, pressure gauges, relays, etc.., shall be supplied and installed to
form a complete engine water cooling line. Piping shall be as of BS 1387.

Water Pump Discharge Valve: Shall preferably be a globe valve, the other valves shall be
(sluice) gate valve.

2.2.12 Control Panel: The engine shall be furnished with a control panel mounted on the package
baseplate.

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The control panel shall have adequate clearance from the engine for engine maintenance
without moving the control panel.

The control panel shall be fabricated from not less than 2 mm steel. The panel shall be
equipped with an approximately full-size gasketed door with chromium-plated or stainless
steel three-point latch and piano type hinges. The panel shall be reinforced as required to
support the control devices. The finished panel shall be thoroughly cleaned and given a
rust-inhibiting primer coat inside and out. The panel shall be given not less than two finish
coats of enamel or lacquer of a color selected from paint samples which shall be furnished
to the Engineer.

The control panel shall include at least, but not be limited to, the following:

- Engine oil pressure gauge

- Engine oil temperature gauge
- Jacket water temperature gauge
- Jacket water pressure gauge
- Combustion air pressure gauge
- Fuel pressure gauge
- Running time meter
- Voltage adjustment rheostat (plus or minus 5 percent)
- Emergency stop push button
- Lubricant oil pressure gauge
- Exhaust gas temperature gauge
- Exhaust turbo-blower pressure guage
- EngineRPM
- System DC volt
- Generator AC volt
- Generator AC amp.
- Generator frequency
- Eight system diagnostic codes.

The system diagnostic codes shall be designed to entrance the system protection
and to allow for trouble shooting by untrained personnel.

These signals shall be:

- Loss of engine speed

- Invalid engine control switch
- Internal circuit fault
- Loss of coolant temperature
- Loss of data sending unit
- Unscheduled engine shutdown
- Invalid programming switch position
- Loss of failure of program setting

All gauges shall have metric scales with ranges approximately twice the normal gauge
reading.

Nameplates shall have white letters not less than 5 mm high on black bakelite, and
shall read both in Urdu and English.

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The following Control Systems shall be included:

- Generator over speed monitoring

- Generator under frequency protection
- Generator under voltage protection
- Generator over voltage protection
- Generator reverse power protection
- Overload monitoring (100% load, load reduction)
- Generator winding protection
- Generator bearing protection
- Generator cooling air output temperature protection
- Engine control switch
- Ammeter -voltmeter phase selector
- Emergency stop
- Indicator/display test switch
- Voltage adjust potentiometer

Pressure and Temperature Switches: Pressure and temperature switches shall be NEMA
Type 4, with adjustable range and differential. Required switches shall be as follows:

- A separate pressure switch shall be furnished and installed for the following:

• Lube oil pressure - low alarm

• Lube oil pressure - low shutdown

Pressure switches shall have normally open SPST contact to make on falling pressure.

- A separate temperature switch shall be furnished and installed for the

following (for each engine):

• Jacket water temperature -low alarm.

• Jacket water temperature - high alarm.
• Jacket water temperature - high shutdown
• Lube oil temperature - high alarm.
• Lube oil temperature - high shutdown.

Temperature switches shall be complete with capillary tubes, bulbs, well unions, and
normally open SPST contact to make on rising temperature for high temperature trips and
to make on falling temperature for low temperature trip.

The remote-mounted liquid level indicators for the fuel day tanks and lube oil tanks shall
be mounted near the oil transfer pump assembly.

Thermometers: Thermometers shall be liquid filled industrial type and shall be furnished
and installed on the engine or piping to indicate inlet and outlet temperatures of the jacket
water and lubricating oil. All thermometers are to be installed in thermowells to permit their
removal and replacement without the loss of liquid from the system.

Thermometers shall have metric (centigrade) scales with ranges equal to approximately
twice the normal reading.

2.3 ACCESSORIES

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2.3.1 Heaters: Automatic thermostatically controlled heaters rated 240 Volts, single
phase shall be provided to maintain 40°C jacket water and lubricating oil temperatures.

2.3.2 Base: The engine generator unit shall be mounted on a heavy skid type base. The unit
shall be capable of being moved with disassembly. The unit shall be bolted to a concrete
pad.

2.3.3 Customer Interface Module: A Customer Interface Module (CIM) shall be provided to
decode serial link data from the Electronic Control Panel and translate alarm, fault, and
status conditions to a set of relay contacts. Contacts shall represent conditions of

- Engine diagnostic fault system not in automatic alarm

- High coolant temperature alarm
- Low coolant temperature alarm
- High coolant temperature fault/shut down
- Over crank fault/shut down
- Over speed fault/shut down

Loss of serial data link to the CIM shall cause all relays to energize every two seconds.

Relays shall be individually fused, with single-pole, double-throw, and gold plated dry
contents. Systems shall be capable of reliable operation 1000 feet from the engine.

2.3.4 Customer Communication Module:

The Customer Communications Module (CCM) shall provide bi-directional communication

between BMS and the generator set Electronic Control Panels. Necessary outputs shall be
available for BMS to control and monitor the points as listed below. CCM output shall be
compatible for either direct connection or connection via a Hayes compatible modem.
The module shall include a digital display to indicate the status of communications
and fault conditions. The adapter shall be microprocessor based 100% solid state. It shall
operate in -40°C to 70°C ambient and be suitable for switchgear or similar mounting. The
CCM shall allow BMS to:

Control

- Engine start!stop
- Fault conditions reset
- Idle/rated speed switch for electronic governors
- Circuit breaker shunt trip
- Cool down
- Timer override
Monitor

- Coolant temperature
- Speed
- Service hours
- Generator three-phase voltage and current
- Frequency
- Battery voltage
- Position of engine control switch
- All alarms
- Shutdowns

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- Engine control panel relays

- Three customer inputs
- Diagnostic codes

Alarm Module

- One (1) Alarm module with four (4) alarm lamps, push to test, high coolant
temperature, low coolant temperature, and low fuel level.
- One (1) alarm hom
- One (1) hom silencer switch

2.4 SOURCE QUALITY CONTROL

2.4.1 Shop Tests:

The manufacturer shall shop test the engine-generator set to determine whether the
equipment conforms to the specified requirements for load capacity and starting duty.

The engine-generator shall be shop tested in accordance with IEEE 115 with its respective
generator control panel. Tests for the generator shall be sufficient to assure that the unit
will operate successfully and meet its guarantees and shall include, but not be limited to,
the following:

- Insulation resistance of all windings

- Polarity of field coils
- High potential on all windings
- Open circuit saturation
- Regulation (with regulator)
- Voltage and current balance

Test neutral grounding resistor for:

- Current transformer polarity and ratio

- Resistor continuity and resistance
- Ground resistance at point of connection to resistor

Testing Procedures: The procedure for the shop test of the diesel engine shall follow the
Diesel Engine Manufacturers Association's standard practice, and shall also include at
least, but not be limited to, the following:

Preparation: Prior to all starts during initial tests and all starts after new running parts have
been installed, the engine shall be connected to a separately driven lubricating oil pump
and filtered oil circulated through all the engine channels. The engine shall be thoroughly
inspected for oil leaks.

The engine shall be prelubricated for a sufficient period of time to ensure adequate
lubrication.

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The fuel system shall be thoroughly flushed with clean shop fuel.

The engine jacket water shall be treated with suitable chemicals, to ensure water that is
free of scale-forming and corrosive characteristics. Softening engine jacket water is not
sufficient treatment. A chemical corrosion inhibitor, which does not contain chromates,
shall be added in amounts as recommended by the vendor. The engine shall be tested
with its closed cooling system.

The engine shall be tested with the governor intended for permanent use on the engine.

Air filter or cleaner shall be used for the supply of combustion air during all testing.

The engine shall be given a suitable wearing-in run at reduced speed, after which it shall
be brought up to its full rated speed, and load applied in increments and at time as
recommended by the manufacturer. Before recording any readings, all operating
temperatures and pressures shall have become stabilized and be within the recommended
limits for good operation.

Prior to the above eight-hour test run, the engine shall be wiped clean so that any oil leaks,
etc., may be readily located. Any leaks which develop shall be properly corrected and the
engine given a check run at full load to assure that all required deficiencies have been
properly corrected.

Testing: After the wearing-in run, the engine-generator set shall be given a heat run for at
least the time indicated at the following loads, and performance readings taken and
recorded at 15 minute intervals starting after running 15 minutes at the new load rating.

One hour at 25 percent of full load rating required for the engine. One hour at 50 percent
of full load rating required for the engine. One hour at 75 percent of full load rating required
for the engine. Four hours at 100 percent of full load rating required for the engine. The
following items shall be monitored:

- AC voltage
- AC line current
- Exciter field voltage
- Exciter field current
- Output frequency
- Kilowatt output
- Temperature rise
- Engine lube oil temperature and pressure
- Engine coolant temperature and pressure
- Engine fuel consumption rate
- Engine exhaust gas temperature

Acceptance Tests: The factory acceptance test shall also include the following:

- Start cycle test

- Adjustment and calibration of fuel control and governing modules for
generator output frequency regulation and transient response
- Speed transient test
- Testing and calibration of all malfunction and safety devices and circuitry
- Testing of all control and logic circuitry
- AC metering calibration check

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Clean-up: After completion of all testing, the following is required:

- All filters and strainers shall be thoroughly cleaned and disposable elements
replaced with new units
- All entrapped water shall be drained, and proper protection applied, to prevent
the entry of water during shipment or a long period in storage

- The engine shall be given proper treatment for its protection for a long period of
storage
- All field connections shall be sealed

PART 3 EXECUTION

3.1 INSTALLATION

Equipment and accessories installed under this section shall be assembled, erected, and
placed in proper operating condition in full conformity with specifications, engineering data,
instructions, and recommendations of the equipment manufacturer unless exceptions are
noted by the Engineer.

The complete engine-generator unit shall be grouted in place on a level concrete pad.
Anchor bolts shall be supplied by the generator unit manufacturer.

3.2 FIELD QUALITY CONTROL

3.2.1 Field Supervision and Tests:

The Contractor shall include a minimum ofthree 8 hour working days allowance for the
services of a competent manufacturer's technical representative to check the installation,
make all necessary adjustments and, in the presence of the Engineer, perform acceptance
tests on the engine• generator unit to determine whether the equipment conforms to
specified requirements for load capacity and starting duty.

As part of the field test, each of the automatic shutdown devices shall be made to be
operated and the respective values recorded at which the devices actually stopped the
engine. Any adjustments required shall be made in the devices to make the operating
values correspond to those recommended by the engine manufacturer.

Before running the field test, submit a copy of the proposed log sheet on which shall be
recorded the load and all corresponding temperatures and pressures as well as the total
quantity of fuel consumed during the test. The test shall consist of operations under a load
bank at the specified power rating for four continuous hours.

Readings shall be taken and recorded at 15-minute intervals over the four• hour test period.

The Contractor shall furnish the fuel, lubricants, load bank, instruments and all other
devices necessary for the tests.

3.3 GROUNDING

Provide equipment grounding connections for diesel engine - as shown on the drawing
details of grounding refer to section .

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SECTION 1206

MEDIUM VOLTAGE POWER FACTOR CORRECTION EQUIPMENT

PART 1 GENERAL

1.1 RELATED DOCUMENTS

Drawings and general provisions of Contract including General Conditions, Conditions of

Particular Application and Division- I Specification Section, apply to this section.

1.2 SUMMARY

This section specifies capacitor-type power factor correction equipment for use in electrical
power systems rated 600 Volts and less.

1.3 REFERENCE STANDARDS

The design, manufacture, installation practice of plant equipment as a part of main medium
tension panel shall be in accordance with one or more of relevant publications of the
following standards:

BS 88 Cartridge Fuses for Voltage up to 1000 Vac

BS 1650 Capacitors for Connection to Power Frequency Systems
BSEN 60949 Control Gear for Voltage up to 1000 Vac

1.4 STANDARD PRODUCTS

Material and equipment to be provided by the manufacturer shall be essentially

the standard cataloged products.

Standard catalogue items and IEC (or NEMA) sizes, ratings, capacities and voltages shall
be given preference.

Products and manufacturer shall be nationally "listed", "labeled" and "approved"

from local concerned authority.

1.5 SUBMITTALS

Submit the following according to Conditions of Contract and Division 1 Specifications:

1.5.1 Product Data: For products specified, include data on features,

components, ratings and performance.

Include dimensioned plan, elevation views of enclosure and details of control panels.

Show access and working space requirements.

1.5.2 Three (3) complete original sets of operation and maintenance manuals.

Each set shall include:

- Lists of spare parts for 3 years and replacement to be stored at the site for ready

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access.
- Detailed Operating instruction covering operation under both normal and
abnormal conditions.
- Detailed installation construction manuals

1.6 EXTRA MATERIALS

Furnish extra materials suitable for interconnection, commissioning and operation

matching all products installed and identified with labels describing contents.

1.7 SUBSTITUTION OF MATERIALS AND METHODS

In case of any proposed deviation or alternatives, provide sufficient data to allow evaluation
of proposed offer.

1.8 SAFETY SIGNS

All access panels to the electrical equipment shall have appropriate warning labels
conforming to Section 16195.

1.9 WARRANTY AND PRODUCT QUALITY

Two (2) years warranty after the date of Substantial Completion, for the power factor
correction equipment shall be provided, for the materials and manufacturing quality control.

Contractor shall agree to repair or replace the equipment that does not comply with the
requirements or fails in work.

PART 2 PRODUCTS

2.1 GENERAL DESCRIPTION

The system shall consist of a power factor correction unit(s) installed in its own enclosure
to correct the power factor within range 0.9 lagging to unity as required by the design. IP
43, for indoor installation, and shall be an integral part of Medium voltage panel board.
System includes a separately mounted current transformer sensing current in the power
circuit being corrected and providing input to the system controls. Capacitor shall be of the
dry type and shall be capable of withstanding twice its rated voltage for 10 seconds at rated
frequency between terminals and container. Capacitor shall also withstand 3 kV for 10
seconds, capacitor losses shall be less than 0.5 W/KVAR.

2.2 SYSTEM CONFIGURATION

The basic types of power factor correction equipment used to incorporate the capacitor
cells may include:

- Automatic Systems: System includes integrally mounted, factory wired major

components incorporating:

• Individual capacitors shall be self-healing utilizing polypropylene as a

dielectric with vacuum deposited conductors on the polypropylene as
electrode.
• Each three (3) phase capacitor shall be furnished with an approved

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pressure sensitive interrupter. The interrupter shall disconnect all three

(3) phases at the same time to maintain a balanced circuit.
• Capacitors shall be contained in hermetically sealed metal cans to prevent
atmospheric contaminants from shortening the useful life.
• Dielectric material shall be low loss, less than 0.5 Watts per KVAR.
• Dry cells encapsulation medium shall be a thermoplastic material which
allows out gassing to engage the pressure interrupter.
• Terminal bushings shall withstand 10 KVAC to ground and be rated 30 kV
or greater.
• Nominal design life of individual capacitor cells shall be 10 years.
• Individual capacitor cells shall be covered by a five (5) year warranty.
• All capacitor cells shall have threaded terminals for wire connection.
• To reduce line transients on system no stage shall switch more than
20 KVAR and no capacitor cell shall exceed 50.0 KVAR.
• Multiple fused capacitor banks dry metallized dielectric, self-healing type.
• Multiple contactors that connect capacitor banks selectively to the output
circuit. Contactors should be 660 V rated for the repetitive high-inrush-
switching duty presented by the capacitor loading, and should be of the
fast opening and closing type.
• Solid-state microprocessor-based controls that switch the banks on and
off to suit the amount of power factor correction needed as load conditions
change in the distribution system served.
• Discharge resistors to discharge safely and automatically the stored
energy in the capacitors. Discharge shall be within 1 minute after
disconnection from the supply. Resistor shall be chosen to ensure 20
years minimum life.
• Potential transformer needed for the undervoltage relay.
• Undervoltage relay that interrupts capacitor switching for power supply
interruption longer than 15 ms.
• "Advance" and "Retard" pushbuttons on the control panel shall permit
manual sequencing of capacitor switching.
• On-off switch.
• Knob to adjust range 0.75 P.F to 1.0 P.F inductive
• Current transformer shall measure the overall current of loads and
capacitors mounted on the incoming of the main switchgear and
interconnected to the control switching.
• Air-core Type inductors coil mechanically braced to withstand short• circuit
current (S.C.C.) and installed in capacitor circuit may be used to limit
switching surges within Contactor ratings.
• Indicating lights LEDs to designate energized capacitor banks.
• Power factor meter.
• Blown fuse indicators, three (3) "push-to-test" blown fuse piolet lights, one
per phase, door mounted to indicate a blown fuse condition.
• Main circuit breakers
• Fuses to provide for major, fault protection, line fuses shall be provided
on all three (3) phases of each switched stage and fixed bank.

Line fuses shall be current limiting, recognized Class T type or equivalent,

minimum interrupting ratings shall be 200 000 Amps. for fuses of30 Amps.
and above.

Fuses shall be designed for capacitor applications and shall be rated not less than
200% capacitor current rating.

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• The equipment must comply with BS 800 with respect to Electrical

Interface
• All power and control cables used within the capacitor bank enclosure
must be in accordance with BS 6231 Type BK.

2.3 FAULT CURRENT CONSIDERATIONS

Air-Core Type inductors and power buswork in the power factor correction units shall
withstand the mechanical forces that occur when large short• circuit currents flow.

These currents shall be limited by the appropriate protective means, and the bracing of
these components shall withstand symmetrical short-circuit current (S.C.C.) ofthe
system.

The switching device should be sized to exceed the capacitor nominal current as follows:

- Moulded Case Breakers 150%

The switching of capacitor units on each section of switchgear must be controlled by a

single relay.

The relay shall:

- Have stage indication

- Be fitted with hand/off/auto controls for each capacitor unit
- Have a time delay between the switching of stages
- Be capable of switching all fitted capacitor units and have provision for switching
at least one additional capacitor unit
- Be fitted within the capacitor bank enclosure
- Have provision to switch all capacitors out of circuit when the essential alternator
is operating, by operation of a remote relay contact

Switching contractors must have a minimum duty category AC4 to BS EN 60947 and a
minimum current rating of 1.3 x the current consumed by the capacitor bank (See BS 1650).

The wire sizes shall match the switching devices rating.

2.4 PERFORMANCE REQUIREMENTS

The controls shall continuously sense the power factor on the circuit being corrected and
when it differs from the target settings for more than 10 seconds, system shall bring the
corrected circuit power factor closer to the target setting.

Only one capacitor bank shall be switched at a time.

2.5 WITHSTANDING TRANSIENTS

The construction of the system should give excellent withstanding capability to current
transients resulting from frequent switching of the stages of a multi stage capacitor bank.

PART 3 EXECUTION

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3.1 INSPECTION

Examine conditions under which centralized automatic power factor capacitor assemblies
are to be installed. Notify Engineer in writing of conditions detrimental to proper completion
of the work. Do not proceed with work until unsatisfactory conditions have been corrected.

3.2 INSTALLATION

Install centralized automatic power factor capacitor assemblies as indicated in accordance

with manufacturer's written instruction, requirements of applicable standards, NECA' s
"standard of Installation", or equal and in accordance with recognized industry practices to
ensure that installation complies with requirements and serves intended function.

Coordinate as necessary to interface installation of centralized automatic power factor

capacitor assemblies with other work.

Mount the switchboard assembly on flush steel aligning channels elevated above floor level
by a concrete pad and as noted on Drawings. Provide aligning shims to achieve level
installation where channels cannot be provided.

Ensure that centralized automatic power factor capacitor assemblies are shipped in
sections which will be fitted through the available structures and openings available.

Bond together the centralized automatic power factor capacitor assemblies structure,
sections and all conduits terminating at the same with a 120 mm2 bare copper earth
(ground) cable, and connect to the switchboard earth (ground) bus and to the earthing
(grounding) grid as required. Provide conduits terminating at centralized automatic power
factor capacitor assemblies with earthing (grounding) Wedges of the required size.

Tighten electrical connectors and terminals, including screws and bolts, in accordance with
equipment manufacturer's published torque tightening values for equipment connectors.

Provide 6.35 mm minimum thick x 60 em wide insulation mat in front of centralized

automatic power factor capacitor assemblies and rear of freestanding equipment
and extend 30 em beyond ends.

Provide protective covering during construction.

Touch-up marred or scratched surfaces to match original finish.

Provide control fuses, with five spare fuses for each rating. Adjust operating mechanism
for free mechanical movement. The following documentation shall be provided detailing:

- Type test certificate

- Routine test certificate
- Maintenance requirements
- Fault diagnosis
- Part list with part numbers and recommended spares
- Commissioning instructions
3.3 FIELD QUALITY CONTROL

Upon completion of installation of equipment and after circuitry has been energized, test
equipment to demonstrate compliance with requirements. When possible, field-correct
malfunctioning units, then retest to demonstrate compliance.

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Prior to energization of switchboards and centralized automatic power factor capacitor

assemblies:

- Perform insulating resistance test on each pole, phase-to-phase and phase• to-
earth for one (1) minute. Minimum test voltage to be 1 000 Volts D.C. with a
minimum resistance of 100 megohms.
- Check centralized automatic power factor capacitor assemblies for continuity
and for short circuits.
- Notify Engineer of any abnormalities.

After assemblies are energized, demonstrate functioning in accordance with

manufacturers requirements.

3.4 MAINTENANCE

All maintenance and inspection on the capacitor assembly shall be done with the system
disconnect device in the open position.

Maintenance and inspections (before handing over of the installation) should be limited to
15 minutes or less so not to affect utility billing.

An annual inspection of the capacitor cell (before the handing over of the installation) shall
be done to identify failing capacitor cells (a bulged cover is the symptom to watch for).

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SECTION 1207

HIGH VOLTAGE OIL DISTRIBUTION TRANSFORMER

PART 1 GENERAL

1.1 RELATED DOCUMENTS

Drawings and general provisions of the Contract, including General Conditions, Conditions
ofParticular Application and Division-1 Specification Sections, apply to work of this Section.

1.2 DESCRIPTION OF WORK

This section covers the work of distribution transformers as required by the Contract.

The Contractor is responsible to obtain the approval before delivering manufacturer for the
type, voltage, losses, etc. from electrical distribution company. Any additional requirements
shall be considered without any extra cost to the Contract.

1.3 REFERENCE STANDARDS

Except as modified herein, the equipment shall be designed, manufactured and tested in
accordance with IEC Standard publication No. 76, Parts 1 to 5 inclusive, latest edition.

The oil shall conform to the relevant IEC Standard No. 296/1969 and Amendment1.

1.4 SUBMITTALS

Submit the following in accordance with Conditions of the Contract and Division- I
Specification Sections:

- Materials list and manufacturer's data

- Shop drawings and wiring diagram of transformers
- Rooms layout with all equipment inside
- Certificates of compliance
- Spare parts data
- Materials and equipment manuals
- Post-installation test procedures
- Final test report

1.5 TESTING

1.5.1 The following tests shall be performed in the presence of the Engineer or his
representative:

- Resistance measurements of all windings on rated voltage connection of each

transformer and at extreme taps
- Ratio tests on rated voltage connection and on all tap connections
- Polarity or phase relation tests on the rated voltage connection
- Short circuit, impedance and load loss at rated current and rated frequency on the
rated voltage connection
- Insulation resistance test between windings and between windings and earth
- Induced over voltage withstand test
- Accessories test

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- Excitation loss at rated voltage

- Excitation current at rated voltage
- Audible sound level tests
- Oil dielectric test.

Prior to shipment the assembled transformer shall be liquid-filled and pressure tested for
at least 8 hours at the maximum operating pressure for detecting the presence of leaks.

A certificate for the following type tests shall be submitted:

- Impulse voltage test

- Measurement of maximum temperature rise of oil and windings

1.6 DELIVERY, STORAGE AND HANDLING

Transformers (with bushings installed) shall be crated, as required. All pipe connections
shall be provided with sealing devices and valves. Auxiliary devices shall be designed for
easy installation on Site and shall be packed and shipped separately.

Store transformers protected from weather, and so condensation will not form on or in
transformers components. Provide temporary heaters in accordance with manufacturer's
recommendations to prevent condensation.

Handling shall be in accordance with manufacturer's instructions. Use factory

installed lifting provisions.

1.7 RELATED SECTIONS

The following sections include requirements which relate to the work of this section:

16010 Basic Electrical Requirements

16124 High-voltage Cables

16060 Grounding

PART 2 PRODUCTS

2.1 OIL TRANSFORMERS

2.1.1 General:

Materials and equipment shall be new and completely assembled, wired and tested at the
factory. Distribution transformers shall be designed for 3-phase, 50 Hz continuous
operation. Insulating oil shall be high-quality mineral oil and shall contain an inhibitor to
extend its oxidation life. Rating and stipulated capacity shall be continuous Site-rated
capacity under all encountered environmental and climatic conditions.

2. 1.2 Characteristics:

Distribution transformers shall be oil-immersed hermitically sealed without conservator,

natural air-cooled. Insulating liquid shall be oil. Copper conductors shall be used for
primary and secondary voltage windings.

Winding temperature rise by resistance shall not exceed 60°C and oil temperature rise
shall not exceed 55°C.

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Taps shall be provided on high voltage winding with two (2) 2.5% above and four (4) 2.5%
below. Distribution transformers shall be equipped with externally operated off load tap
changer suitable for de-energized operation. Tap changer shall be gang-operated and be
capable of withstanding full transformer short-circuit current without damage. Tap
changer shall have at any tap position a position indicator visible from base level.

Permissible overload capacity without undue heating shall be 20% for 1-1Yz hours.

Primary voltage 12 kV as shown on Drawings, 50 Hz, secondary voltage 450/240 Volt;

ambient temperature 55°C.

For the windings with rated voltage 12 kV, the basic impulse withstand voltage shall be 75
kV (peak).

The vector group for the transformer shall be m general Dyn 11 or as indicated on
Drawings.

2.1.3 Terminations:

High voltage terminations shall be complete with cable glands as necessary. Medium
voltage termination shall be suitable for feeder busways or cables as shown on the
drawings.

High and Medium voltage bushings shall be of highest quality glazed porcelain.

2.1.4 Core:

Distribution transformer's core shall be built up from grain-oriented stress relieved cold-
rolled silicon sheet-steel laminations, insulated on both sides.

2.1.5 Windings:

Windings shall be constructed of copper conductors with low losses as per electrical
company requirements for each rating insulated with high dielectric strength tapes having
very good temperature stability and be firmly braced so as not to be loosen due to short
circuits.

The insulation of windings shall be Class "H" insulation and shall consist of materials or
combination of materials such as mica, glass, porcelain, quartz and asbestos with or
without organic binder. Other materials may be included if tests prove their capability of
operating.

2.1.6 Static Shield:

A static shield shall be applied where needed to distribute impulse voltage uniformly
throughout the winding and prevent undue concentration of electrical stresses in tum
insulation and coil section insulation.

2.1.7 Tank and Base:

Transformer tank shall incorporate cooling fins. Final finish shall take the form of sand
blasting to bare metal, followed by at least two coats of suitable primer and two final coats,
medium grey colour or any other color recommended by the supplier.

Transformer tank shall be welded steel construction, suitable for vacuum filling (300 mm
vacuum) oil and able to withstand all stresses during transport and operation including full
short circuit.

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Gasketted joints for tank and cover, bushings and other bolted attachments shall be so
designed that gaskets shall not deteriorate due to weathering.

Transformer base shall be designed to permit skidding in directions parallel to either

centerline.

2.1.8 Standard Accessories:

Each distribution transformer shall be equipped with the following accessories:

- Magnetic oil level gauge with alarm contacts; one (1) normally open and one(1)
normally closed (NO, NC).
- Dial-type thermometer with maximum indicating points and alarm contacts (2NO,
2NC).
- Combination drain and lower filter valve and oil sampling valve.
- Upper filter valve and vacuum pump connection.
- Facilities for lifting core and coil assembly from tank without draining oil from
transformer.
- Lifting lugs for complete transformer.
- Skid base with jacking and pulling provisions.
- Two grounding pads on diagonally opposed sides for the tank base with bolt type
cable clamp adjustable for copper ground cables ranging from 95 mm2 to 240 mm2
for tank grounding. One of the pads shall be located at the side where the
secondary neutral bushing is mounted.
- Fill hole fitted with plug.
- 4 Bi-directional rollers DIN42561
- Diagrammatic weatherproof stainless steel engraved or etched nameplate. The
nameplate shall show full rating of transformer, voltage and tap ratios, impedance,
weight, gallon of oil, operational pressure, withstand pressure, vector diagram, etc.
and shall bear a connection diagram showing studs, tap changers and other parts.
Nameplate shall be in English.
- Explosion diaphragms, to relieve sudden pressure from severe internal fault and
sudden pressure protective relay (DgPT2) or equivalent.
- In addition to items listed hereinbefore provide relaying and protection as
manufacturer's standard practice.
- Buchholz relay

PART 3 EXECUTION

3.1 INSPECTION

Inspect each transformer and related accessories for damage, defects and completeness
before installing. Inspect previously installed related work and verifY that it is ready for
installing instruments and equipment.

3.2 PREPARATION

Transformer room shall contain no water, soil ptpmg or ventilation ductwork.

Provide a sump pit of sufficient size to retain the liquid capacity of the transformer. The
floor shall be sloped to drain any transformer seepage to the sump pit. Curb retention will
also be considered.

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Ventilation shall be automatically controlled in accordance with the transformer

manufacturer's recommendations and/or national and local codes.

Ensure that installation areas are clean and that construction operations are completed
prior to installing equipment. Maintain the areas in a broom-clean condition during
installation operations.

3.3 ELECTRICAL WORK

Perform all interconnecting wiring and grounding as indicated, specified and required
including cables, conductors, terminals, connectors, wire markers, conduits, conduit
fittings, supports, hardware and all other required materials. Provide electrical materials
and complete required electrical installations in accordance with the requirements specified
in Division-16 Specification Sections.

3.4 INSTALLATION SUPERVISION

Furnish the service of an approved engineer, at no additional cost to the Employer,

specially trained and experienced in the installation of the equipment to: (1) supervise the
installation in accordance with the approved material and equipment manuals and (2)
inspect, check and adjust as necessary until all troubles or defects are corrected and the
installation and operation are acceptable.

3.5 SYSTEM VALIDATION

Provide the services of approved trained and field experienced engineers, at no additional
cost to the Employer. This is to validate each system and verify that each system is
operational and performing its intended function within system tolerances as specified
hereinafter and detailed in the approved post• installation test procedures. Validate each
system by simulating inputs.

Simulate malfunctions to sound alarms. Check all systems thoroughly for correct operation.
Test equipment for this function shall be furnished by the Contractor.

Immediately correct all defects and malfunctions disclosed by tests. Use new parts and
materials as required and approved and retest. Provide a report certifying completion and
validation of each system.

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SECTION 1208

HIGH- VOLTAGE SWITCHGEAR

PART 1 GENERAL

1.1 RELATED DOCUMENTS

Drawings and general provisions of the Contract, including General Conditions,

Conditions of Particular Application and Division-1 Specification Sections, apply to this
Section.

1.2 DESCRIPTION OF WORK

This section covers 12 KV metal clad switchgear as required by the Contract and shall
include the following items:

- Circuit Breakers
- Metering and Relay Panels
- Auxiliary Equipment

The high voltage switchboard is fed through two independent feeders via switchgear unit.
The load shall be normally shared on these two feeders, however, each feeder can carry
the total load whenever troubleshooting exists for the other one.

1.3 REFERENCE STANDARDS

Except as modified herein, the equipment shall be designed, manufactured and tested in
accordance with VDE 0670, Part 6 (5/1976) and IEC publication 298 and other relevant
Codes and Standards listed in Section 16010.

1.4 SUBMITTALS

Submit the following in accordance with Conditions of the Contract and Division-!
Specification Sections:

1.4.1 Product Data

Materials list and manufacturer's data Certificate of Compliance

1.4.2 Shop Drawings:

Shop drawings and schematic and wmng diagrams including time-current characteristic
curves of protective devices plotted on logarithmic transparencies for relaying coordination
study application. Also include installation instruction, and wiring diagrams to facilitate
reassembly of switchgear which divided into shipping sections

Rooms layout diagrams and general arrangement showing dimensions and weights

Single line diagram for the complete high voltage network indicating earthing interlocking
scheme.

1.4.3 Operation and Maintenance:

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Spare parts list for normal operation and maintenance for 3 year recommended by
manufacturer

3 complete sets of operation and maintenance manual for each panel and its internal
component (i.e. relays, bus bars, metering, etc.)

1.4.4 Tests

Post-installation test procedure Final test report

1.5 TESTING

The Contractor shall carryout the following test in presence of Engineer and Client's
Representative, Schedule of Tests to be submitted to the Engineer at least one week
before test start for his review and approval.

1.5.1 Factory Tests:

All components shall be thoroughly inspected and factory• tested to ensure alignment and
adequacy of all functions.

1.5.2 Field Tests:

The Contractor shall prepare test procedures for all field tests which should include, but
not limited to the following tests:

- Earthing system should be completed and satisfactory tested before start any life
test.
- Tightening torque, check for all bus-bars joints assembled on site as well as
measuring each joint resistance to minimize the voltage drop through the bus-bar.
- Primary injection test for power bus-bar after being assembled on site.
- Primary injection test for all current transformers
- Secondary injection test for all protection relays to verifY each one
characteristic curve.
- Phasing check for all incoming and outgoing feeders.
- Insulation resistance test and transformation ratio check for
potential transformers.
- Check of pulse polarity for current transformers.
- Dielectric (Hi-pot) test of complete assembled switchgear

1.5.3 Test Certificate:

Submit for the Engineer approval all field test results, test results shall not be accepted if:

- Not witnessed by the Engineer

- Not performed according to the approved test forms and procedures
- The results are less than the min. accepted value by the Reference Standards
and/or Specifications.

1.6 DELIVERY, STORAGE AND HANDLING

Shipments shall be securely packed for delivery with a waterproofed type providing
protection against excessive heat, humidity, water or damage. When material must be
bundled due to excessive size, each bundle shall have a metal tag securely tied on with
heavy gauge wire. Purchaser's markings shall be die stamped on the tag.

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Equipment, relays and other components with moving or fragile parts shall be properly
blocked, tied or packed to prevent damage.

Any component shipped separately shall be clearly marked with description use and
installation instructions.

All components that must be disassembled for shipment shall be properly match-marked
and provided with dowel pins or bolts (if required) to ensure realignment in the field.

All packages shall be marked with equipment tag number for identification when shipped
and when received at Site.

Sections shall be grouped in not more than 5 sections per crate.

Each shipping unit shall be equipped with shipping angles or lifting lugs for handling by
crane. Refer to Section 16010 for delivery, storage and handling.

1.7 RELATED SECTIONS

The following sections include requirements which relate to this section.

16010 General Electrical Requirements

16124 high Voltage Cables

PART 2 PRODUCTS

2.1 GENERAL

Materials and equipment shall be new and completely assembled, wired and tested at the
factory requiring only field installation and connection of power and control circuits to place
the equipment in service.

Switchgear and auxiliaries shall be designed for 12 KV, 3-phase, 50 Hz, power supply.
Ambient conditions shall be as specified in Section 16010.

Switchgear shall be installed inside an enclosure with all feeder and control wiring entering
the switchgear from below.

Switchgear line up shall contain all equipment indicated in the single line diagram,
Drawings and in Specification or as required by the manufacturer's standard practices.

Arrange for continuous integrated mimic bus on front of switchgear line up in single line
diagram format, using symbols consistent with Drawings to produce a concise visual
conception of the principle switchgear components and connections. To represent the bus
and components, use metallic strips fixed to panels with countersunk corrosion resistant
screws.

All ratings shown on single line diagrams are the required operational equipment ratings.
It shall be the Contractor's responsibility to ensure that equipment furnished satisfies the
ratings shown.

The Contractor shall assume all responsibility for mechanical and electrical coordination of
equipment and devices required by Drawings and Specifications.

Interrupting capacities and short circuit ratings shall be as shown on Drawings.

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The minimum rating for the integrated mam medium voltage (12 kV) switchgear assembly
shall be as follows:

Voltage 11 kV, 3-phase, grounded wye

Short Circuit-Interrupting 50 kA, 3 phase symmetrical at 11 kV
Short Time Current (r.m.s.) 50 kA for 1 second
Peak Making Current 75 Ka

Rates shall be referred to withstand short circuit for 1 second.

2.2 SWITCHGEAR

2.2.1 Apparatus:

The switchgear assembly shall be metal clad type, consists of the following units and as
shown on Drawings:

- SF6 circuit breaker cubicles for incoming and outgoing

- Bus riser unit
- Bus Coupler SF6 circuit breaker
- Accessories, metering, relays, etc. as indicated on single line diagrams and
other Drawings.

The switchgear shall be of the indoor true metal-clad type according to IEC 60298
standard.

The circuit-breaker, current transformer and H.V. cable connection, busbar,

M.V. devices shall be arranged inside four different compartments.

Each compartment shall be fully segregated by metallic partitions which must be

permanently electrically bonded together to a common copper earthed conductor for the
entire switchgear. Conductors.

Passage between different compartments shall be via insulating bushings (flower-boxes)

in order to allow for electrical connection between circuit• breaker and cable compartment
and electrical connection between circuit• breaker and busbar compartment

The flower-box bushings will also act to provide accurate positioning of the withdrawable
circuit breaker contacts without adjustment

All auxiliary equipment, transition sections and other necessary components required for
complete installation and proper operation, although not specifically listed herein, shall be
furnished and included in the switchgear assembly.

Protection shall be as shown on Drawings, required by Specifications and in accordance

with manufacturer's standard practice.

All non-segregated phase bus ducting, together with all of the necessary components
required for complete installation and proper operation, shall be furnished.

The switchgear shall consist of individual cells, each cell housing one circuit breaker
mounted on a horizontal withdrawable truck self rolling on the floor.

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The switchgear shall allow future extension from both ends. Preference shall be given to
the switchboard with minimum width to allow any future extension within the same room.

According to IEC requirements, the circuit-breaker compartment shall be separated from

both cable and busbar compartments by two permanently earthed upper and lower metallic
shutters to give safety against electrical shocks. Non metallic shutters will be rejected.

Shutters shall be operated by a positive drive mechanism linked to the circuit-breaker truck
position. Mechanisms that use gravity fall of the shutters will be rejected.

When shutters are closed, they shall be automatically and mechanically locked in position.

Upper and lower shutters must be differently color coded such that cable side shutter can
be differentiated from busbar side shutter.

The metallic shutters must be equipped with padlocking facilities to enable locking of the
two shutters in the closed position.

The design of the switchgear shall not facilitate manual handling of the shutters by the
operating staff even if the circuit breaker is removed.

It is a must that the command of all necessary devices for operation must be done from
the front of the panel in particular :

- Closing and opening of the circuit-breaker.

- Closing and opening of the earthing-switch.
- Metering, control and protection relays

The withdrawable circuit-breaker truck shall have three distinguishable positions,

- Connected-Position: The circuit breaker is engaged to main circuit

- Test-Position: The circuit breaker is disengaged from main circuit but can be
electrically tested for proper operation
- Disconnected-Position: The circuit breaker is totally disconnected from main and
control circuits

Each position shall be clearly visible from a distance not less than 5 meters.

When the circuit-breaker truck is either in "test" or "disconnected" position,the breaker

should be out the front of the switchboard and the metallic shutters shall be closed.

The switchgear degree of protection shall be IP 3X according to IEC-60529.

The switchgear shall be designed in such a way to prevent access to any live part during
service, as well as during maintenance operation.

The switchboard shall be mounted on appropriate civil engineering iron rails.

2.2.2 Cable Incoming Feeders:

Where incoming power feed is shown as cables, solderless pressure-type lugs, with stress
cones as required, shall be provided for the termination of shielded power cables whose
sizes and type shall be determined in coordination with power supply company. Lugs, bolts,
washers and ancillaries shall be furnished by the switchgear manufacturer for type and
size of cables installed.

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The Contractor shall make such coordination.

Sufficient space shall be provided in the cable incoming compartment for glands for number
and size of cables as determined by supply Company.

2.2.3 Outgoing Circuit:

Outgoing circuits shall be cable-installed in trenches and shall exit the switchgear from
underneath.

Sufficient space shall be provided in cable outgoing compartments for glands and number
and size of cables as shown on one line diagram.

A means of exiting the switchgear from underneath shall be provided for cables.

2.2.4 Switchgear Enclosure and Structure:

All enclosure doors and panels shall be provided with neoprene or equivalent gaskets and
shall be tightly assembled. Removable sheet metal bottom gland plates of thickness not
less than 3 mm shall be in all cubicles. All ventilation openings shall be covered with 6 mm
steel mesh provided with dust prooffilter.

Removable panels and doors shall be fastened as per manufacturer's standard. All
hardware and fasteners shall be steel with a heavy coating of zinc or

chrome or manufacturer's equivalent.

Each cubicle shall include an integral steel frame suitable for installation on a concrete or
steel floor.

All structures and enclosures shall be thoroughly cleaned to remove dust, mill scale and
dirt and painted inside and outside with manufacturer's standard color. No lead pigment
paint shall be used.

Any approved modifications to the manufacturer's standard enclosure for the purpose of
compliance with Specification shall be factory assembled by the manufacturer.

The entire switchgear assembly shall be tropic proofed.

2.2.5 Bus Work:

The main bus shall be horizontal, 98% conductivity, electrolytic, copper, of full capacity for
the entire length of the switchgear assembly; have provision to maintain firm contact at
bolted joints and have provisions for extension on either end. All bolted joints shall be
silver plated.

Bus shall be enclosed to prevent accidental contact and prevent propagation of arcing from
one cubicle to the next. The main bus shall have flame• retardant insulation.

Bus support insulators shall be track resistant and have the highest quality cast resin.

The main bus shall be sized to carry the continuous current indicated on Drawings,
withstand 55°C temperature rise above 55°C ambient temperature and be braced for the
RMS symmetrical short circuit current indicated.

Copper ground bus, of sufficient size to support cable lugs, shall be rigidly bolted to the
lower part of each cubicle frame. The ground bus shall be continuous for the entire length
of each shipping section. Provisions shall be made to join all the ends of the ground busses

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together for all shipping sections to form a continuous full length bus when the switchgear
line up is completely assembled in the field. The end of the ground bus in end cubicles of
the switchgear line up shall be drilled and provided with pressure-type solderless lugs for
use with 16 mm2 through 240 mm2, stranded, bare, copper, ground cable.

2.2.6 Circuit Breakers:

Circuit breakers shall be SF6 type; they shall not need any special maintenance or refilling
with SF6 during their whole life time (i.e. to be of the sealed pressure system according to
IEC 60056 appendix EE).

In order to insure high electrical endurance the circuit breaker must have two sets of
internal contacts, one set acting as primary contacts and a second set acting as arcing
contacts.

All circuit breakers of the same type and rating shall be interchangeable. However circuit
breakers of different ratings must not be allowed to be inserted in the position of another
circuit breaker that has a higher rating.

To achieve maximum safety for operating personnel, the circuit breaker must be equipped
with a safety membrane, which upon failure of the breaker shall rupture to release the hot
gases in the inside direction of the cubicle.

Built-in interlocks shall prevent any mishandling and provision for key locking shall
be made.

It shall be impossible to:

- Insert or withdraw the circuit breaker when it is in a closed position

- Close the circuit breaker unless it is located in service or test position
- Insert the circuit-breaker truck into the cubicle without connecting the MV control
plug
- Disconnection of the MV control plug while the circuit-breaker truck is in the
Connected-position

The life expectancy shall be at least 25 years. The circuit breaker enclosures shall be made
of molded epoxy resin casing.

For maximum safety, should the SF6 gas falls to zero relative pressure the breaker must
still be able to break at least for one time 60% of its rated short circuit current. The
manufacturer must be able to prove this by providing suitable type testing certificates

Periodic mechanism lubrication shall require at the most not less than every 5000 cycles
or five years.

The design of circuit breaker mechanism shall enable checking the degree of wear of
arcing contacts without opening the breaker poles.

Circuit breakers shall be equipped with an electrical spring stored energy operating
mechanism, including at least:

- One electrical motor, recharging the mechanism as soon as the breaker is

closed or opened
- One anti-pumping relay to prevent the closing the breaker if the closing coil being
fed continuously while the opening coil is energized.

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- One shunt trip opening coil

- One closing coil

Circuit breakers shall be fitted with a mechanical operation counter.

On the front plate of the circuit breaker, indication and control devices shall be provided as
follows:

- Mechanical indication of the position of the circuit breaker, positively driven in both
open and close positions.
- Mechanical indication of the state of the motor charged spring, this shall
clearly show whether the spring is charged or not.
- Provision shall be made for local manual tripping and closing of the breaker and at
the front of the cubicle, a plate shall bear all the indicating and control devices
necessary to cany service operations.
- Local manual spring release.
- Emergency hand operated local spring charging device.

The circuit breaker shall be equipped with a 2 NO and 2 NC of auxiliary contacts. They
shall be positively driven in both positions and to be mounted in such a way as to facilitate
maintenance and inspection.

The circuit breaker shall be equipped with SF6 pressure switch. Should the SF6 pressure
falls below a standard manufacturer set pressure value, the pressure switch will ensure
circuit breaker is tripped and blocked in OPEN position.

Each basic circuit breaker unit shall consist of a re-strike free, withdrawable SF6 circuit
breaker 630 A which shall be a 120 VAC motor operated charging mechanism. The circuit
breaker shall be electrically and mechanically tripfree.

Circuit breaker shall be rated at 500 MVA at 12kV rating nominal 3-phase class with a
normal continuous current rating as sown on Drawings bus. Breaker shall be rated at least
40 kA RMS symmetrical at 12 KV and shall have a closing and latching capability of 60 kA.
Rates shall be referred to withstand short circuit for one (1) second. Operating cycle shall
be open, 15-second time delay, closelopen,(0-15 sees-CO). Automatic reclosure shall not
be required.

2.2.7 Instrument Transformers and Control Switches:

Instrument transformers shall be sized for burden requirements of connected meters with
accuracy Class as follows:

- Current Transformers (CT's): Class 0.5 for metering and 1.0 for protection
10 ratio as shown on the Drawings.
- Potential Transformers (PT's): Metering- Class 1

All potential transformers shall be provided with current limiting fuses. Voltage rating for
the secondary winding shall be of ratios:

12000 / 415 / 240

--J 3 --J 3 --J3

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for metering and protection. The thermal rating of the transformers shall be sufficient to
provide the total current required to operate the burdens on the secondaries without
exceeding the rating of transformer as indicated on nameplate. PT's (1 per phase) shall
be installed either as a unit drawout assembly or with an isolating switch in a separate
compartment so that the transformers, primary fuses and secondary circuits may be
inspected and tested in a completely de-energized condition.

CT's shall have mechanical and thermal rating equal to the rating of the circuit breaker
and LBS. Secondary rating shall be 5 amperes and primary ratings shall be as shown on
one-line diagram. Transformer shall be capable of carrying 120 percent of rated current for
one hour. Ground current sensing transformers shall have a one ampere secondary
current.

All instrument transformers (current and voltage) must be installed in the cable
compartment.

In the event of primary fuse blow-out of the potential transformer it shall be possible to
replace the primary fuses without interrupting the switchgear accordingly the potential
transformers must be movable to allow for the replacement of fuses.

Incoming cells should have their movable instrument transformers located at the incoming
cable compartment

2.2.8 Earthing switch:

Each incoming or outgoing cell must be equipped with integral earthing switch.

The earthing switch shall be located in the cable compartment while it should be operated
from the front of the cubicle.

To prevent human error, the position of the earthing switch must be easily seen from both
the front and the back of the switchgear by means of mechanical indicators.

Mechanical interlocks shall be provided to avoid any wrong operation such as:

- Closing of earthing switch if the breaker is not totally withdrawn outside its cubicle
(disconnected position)
- Inserting of a breaker if the earthing switch is in a closed position

Padlocking facilities shall be fitted to enable the earthing switch to be locked in both
positions "closed" and "open". The position of the integral earthing switch shall be clearly
visible from the front of the switchboard as well as from behind to prevent mistakes during
maintenance works.

The position of the earthing switch should be positively driven (i.e. to be directly linked to
the earthing blades and not to the operating handel) such that in case of mismatch between
the earthing switch operating handle and the position of the earthing blades the indicator
will only reflect the actual position of the earthing blades

The Earthing switch operating handle shall have a direct acting mechanism such that the
handle shall never break in the event that the earthing switch blade are stuck in a certain
position. (switchgears utilizing mechanisms having gears or weak links will be rejected)

Special notes for Incoming Cells:

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- Each incoming cell shall be equipped with one capacitor divider per phase fitted at
the incoming cable connection point.
- Each capacitor divider shall be connected to a neon indicator lamp located at the
front side of the panel (one lamp per phase).
- A facility for external avometer connection shall be provided at the neon indicator
lamp holder to directly measure the output voltage of each capacitor divider directly
to test the operation of the neon lamps.
2.2.9 Wiring:

All switchgear control wiring shall be as per-manufacturer's standard. Switchgear wire

shall be rated 90°C, flame resistant.

All wiring shall be neatly and compactly arranged and cross section area not less than 1.5
mm2.

All terminals, auxiliary devices, internal wiring troughs, and miscellaneous materials
necessary for a complete installation shall be provided.

All wires and terminals shall be marked with permanent wire markers corresponding to
Drawings.

Wiring and interconnection diagrams between cubicles, compartments and sections and
between shipping sections of the switchgear assembly shall be provided.

Wiring terminal blocks shall be extra heavy duty phenolic type, or equal, rated at least 600
V AC with solderless tubular clamp type contacts for power circuits. Locking spade tongue
crimp connectors shall be used for instrument and control circuits. Provide 20 percent
spare terminals.

Protection for control circuits shall be by circuit breakers, with the exception of 12 KV
potential transformer primaries which shall be protected with current limiting fuses.

Indicating lights shall be installed as shown on Drawings and required by IEC. All indicating
lights shall be "Press-to-Test" type.

2.2.10 Measuring and Recording Devices:

Measuring instruments shall be flush type and of suitable dimensions. They shall be of the
precision industrial type of approved make and fine finish. Their accuracy shall not be
affected by variation of ambient temperature. The Contractor shall guarantee their degree
of accuracy and submit official test certificates for all measuring and recording instruments
as shown on Drawings. Scale range shall be as shown and as required for accurate actual
load conditions.

Approval shall be made after reviewal of complete manufacturer's detailed information

which shall be submitted by the Contractor.

All meters must be digital with LCD display and ready for future connection to building
management system

2.2.11 Digital Protection Devices:

Protection must be insured by a fully microprocessor based digital relay. The protection
functions must be as shown on the drawings.

The protection relay must be equipped with LCD display with back-light.

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Electrical Works HIGH- VOLTAGE SWITCHGEAR

The protection relay must allow easy configuration to its settings by use of interface
software (the software must be supplied).

It should be easy to configure the outputs to be of latching type or self reset as per
requirements oflocal electrical utility company.

All relays within the switchgear must be connected together to form a logic selectivity
scheme (as well as zone-selective-interlocking).

Any relay installed on a feeder circuit that may act as incoming or outgoing must have two
tables of settings so that the appropriate table of setting may be activated depending on
direction of flow of energy (incoming or outgoing)

All relays must have an internal watchdog protection to detect internal failure of the relay
circuitry.

In case that shunt trip release method is specified then the protection relay must have a
trip circuit supervision function.

Protection relays must show on their screen English messages indicating of fault, reason
for trip and value at which the protection trip was initiated.

The protection relay must have trip value accumulation function so that it can be easily to
statistically verify the state of the circuit breaker contacts depending on the accumulated
value of interrupted currents seen by the breaker.

Protection relays must be able to be connected to 1 or 5 Amp current transformer

secondary

2.3 ACCESSORIES

Furnish without any cost to the contract. The following in addition to all standard
accessories:

- Additional hand cranking lever per switchgear line up.

- One high-voltage hot line detector with hot stick handle.

All indicating lamps used in the switchboards should be semi-conductor LED diodes. Use
of neon or incandescent indicating lamps is not acceptable.

All indicating lamps and pushbuttons should be chromated metallic base and body.

2.4 SPARES

Provide the following spares in addition to those previously specified:

- One (1) set of potential transformer current limiting type fuses for each
potential transformer installation.
- Ten (10) carton of indicating lamps.

Spare parts for 3 years of operation and maintenance recommended by manufacturer. The
list shall be provided for approval during the bidding stage.

PART 3 EXECUTION

3.1 INSPECTION

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Electrical Works HIGH- VOLTAGE SWITCHGEAR

Inspect each switchgear assembly and related accessories for damage, defects,
completeness and ensure that all devices are in correct operating condition before
installing. Inspect previously installed related work and verify that it is ready for installation
of instruments and equipment.

3.2 PREPARATION

Ensure that installation areas are clean and that construction operations are completed
prior to installing equipment. Maintain areas in a broom-clean condition during installation
operations. The area or enclosure in which the switchgear is to be located shall be
continuously clean. Assure that all energized areas are locked to prevent access by
unauthorized personnel.

3.3 ELECTRICAL WORK

The Contractor shall perform all interconnecting wiring and grounding as indicated,
specified and required and shall include cables, conduit fittings, supports, hardware and all
other required materials. Provide the electrical materials and complete all required
electrical installations in accordance with the requirements specified in Division-16
Specification Sections and as shown on Drawings and one line diagrams. For busbars
joints assembled on site and after completing the required tests, apply joint insulation for
each joint the material and method of application must be provided and/or as
recommended by manufacturer.

3.4 LABELING

Identify components as required by codes and manufacturer's standards and according to

Section 16010 11General Electrical Requirements 11 •

3.5 INSTALLATION SUPERVISION

Furnish the service, at no additional cost to the Employer, of an approved engineer

especially trained and experienced not less than 10 years in the installation of equipment
to: (1) supervise the installation in accordance with the approved material and equipment
manuals and (2) inspect, check, adjust as necessary in accordance with Specifications
until all trouble or defects are corrected and the installation and operation are acceptable.

3.6 SYSTEM VALIDATION

Prepare a Post Installation Test Procedure and submit for approval. These procedures
must include all tests and commissioning required by the manufacturer as specified above.

Provide the services, at no additional cost to the Employer, of trained and field experienced
approved engineer(s) to validate each switchgear system to verify that each system is
operational and performing its intended function as specified and detailed in the approved
Post-Installation Test Procedures. Validate each system by simulating inputs. Switchgear
assembly shall be given conditional test to assure correct polarity connections between
transformers (current and/or potential) and protective relays.

Simulate malfunctions to sound alarms. Check all systems thoroughly for correct
operation. Test equipment for this function shall be furnished by the Contractor.

Immediately correct all defects and malfunctions disclosed by tests. Use new parts and
materials as required and approved and retest. Provide a final test report certifying
completion and validation of each system.

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Electrical Works AUTOMATIC TRANSFER SWITCHES

SECTION 1209

AUTOMATIC TRANSFER SWITCHES

PART 1 GENERAL

1.1 SCOPE

This section covers the furnishing, the installing, and the placing in operation of the
Automatic Transfer Switch.

1.2 REFERENCES

1.2.1 Governing Standards:

Except as modified or supplemented herein, all equipment and materials required in this
section including their installation shall conform to the applicable requirements of the
following standards. Standards current at the time of tender shall be used.

National Electrical Manufacturers Association NEMANo.

ICS 1 Industrial Controls and Systems

ICS 2 Industrial Control Devices, Controllers and Assemblies
ICS 4 Terminal Blocks for Industrial Use
ICS 6 Enclosures for Industrial Control and Systems

National Fire Protection Association NFPANo.

70 National Electrical Code

99 Standards for Health Care Facilities
110 Emergency and Standby Power Systems

Underwriters Laboratories, Inc. ULNo.

1008 Automatic Transfer Switches

1.3 QUALITY ASSURANCE

1.3.1 Installer's Qualifications:

The Contractor shall submit data showing that he has successfully installed systems of the
same type and design as specified herein, or that the Contractor has a firm contractual
agreement with a subcontractor having not less than ten years experience in the design
and installations of such system. Data shall include names and location of at least two
installation he or his referenced subcontractors has installed such systems. The
references shall indicate type and design of each system and certification that each
systems has performed satisfactorily in the manner intended for not less than three years.

1.3.2 Client's Acceptance and Contractor's Responsibility:

The Client's acceptance of the Contractor's working drawings shall not relieve the
Contractor from responsibility for errors, omissions, or deficiencies in the work The
Contractor shall verify actual conditions in the field and shall take all measurements
necessary for proper installation of this work

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1.4 SUBMITTALS

Submit the following in accordance with the requirements set forth at the Conditions of
Contract.

1.4.1 Drawings and Data:

One line diagram of ATS assembly and elementary or schematic and wiring diagram of
the unit in plastic lamination permanently secured to the inside of the front enclosure door.
An interface equipment connection diagram showing all conduits and wiring between the
ATS all other related equipment. The one-line diagram shall show interlocking provisions
and cautionary notes, if any.

It shall also general arrangement and complete dimensional layout of the equipment.

Above drawings shall show components description, technical ratings of equipment and
materials.

1.4.2 Certificates:

Test certificates shall be executed and submitted prior to final inspection and acceptance
in accordance with the requirements of NEMNIEC standards. The certified tests reports
shall show date, time and duration of the overload, endurance and temperature tests, and
that the unit under test was not de-energized during the test sequence. Three certified
copies of each test certificate shall be submitted to the Client's Representative.

1.4.3 Test Plan:

Test plan and test procedures for the acceptance tests. The test plan and test procedures
shall explain in detail, step-by-step actions and expected results to demonstrate
compliance with the requirements specified. The procedure shall also explain methods for
simulating the necessary conditions of operation to demonstrate system performance.

1.4.4 Acceptance Tests:

Test reports in booklet form showing all field tests are performed to adjust each
component and to prove compliance with the specified performance criteria, upon
completion and testing of the installed system. The reports shall include the manufacturer,
model number, and serial number of test equipment used in each test. Each report shall
indicate the final position of controls and operating mode of the system.

1.4.5 Operations and Maintenance Manuals/Charts and Spare Parts Data:

Complete operations and maintenance manuals/charts including spare parts data and
wiring diagrams of all equipment furnished under this section.

1.5 DELIVERY, STORAGE AND HANDLING

1.5.1 Storage:

Supplementing the storage requirements described in Section 01605, General

Equipment Stipulations the manufacturer shall acknowledge storage conditions at the time
of submitting his Tender. The equipment may not be operational within 90 days after
manufacture, and the manufacturer shall crate and prepare the equipment for export
transportation and long• term storage. Precautionary measures for prolonged storage
shall be provided by the manufacturer at the factory. The Contractor shall be responsible

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Electrical Works AUTOMATIC TRANSFER SWITCHES

for storage and maintenance of the protective measures as recommended and instructed
by the manufacturer while stored at the storage site.

In addition to the protection specified for prolonged storage, the packaging of spare parts
shall be prepared for export packing and shall be suitable for long-term storage in a damp
location. Each spare item shall be packed separately and shall be completely identified on
the outside ofthe container.

Instructions for the servicing of equipment while in long-term or prolonged storage shall
accompany each item of equipment. An enclosed instruction with each package shall be
noted on the exterior of the package and shall be in the Arabic and English languages.

1.5.2 Verification of Dimensions:

The Contractor shall become familiar with the details of the work and working conditions,
shall verify dimensions in the field, and shall advise the Client's Representative of any
discrepancies before performing the work.

1.5.3 Warranty:

The Maintenance Period for the equipment and appurtenances shall begin when the
performance test on the equipment and appurtenances has been successfully completed
and preliminary accepted as stipulated in the Conditions of Contract.

1.5.4 Spare Parts:

All lists of all spare parts required for adjustment, operation, and maintenance of the
equipment for a period of three years from the date of the certificate of completion shall be
provided in accordance with the requirements of Section 01605, General Equipment
Stipulations.

1.6 INSTRUCTIONS AND TRAINING ON OPERATION AND MAINTENANCE

Contractor shall provide instructions and training for the staff to be assigned in the
operation and maintenance of the equipment specified under this section. Training and
instructions shall be in accordance with the requirements set forth at the Conditions of
Contract.

PART 2 PRODUCTS

2.1 AUTOMATIC TRANSFER SWITCH (ATS)

ATS shall be double throw, electrically operated, mechanically held, fully protected,
complete with voltage sensing relay. ATS is mechanically held and electrically operated
by a single solenoid mechanism energized from the source to which the load is to be
transferred. ATS shall be suitable for use in emergency or standby systems described in
NFPA 70. ATS shall be UL listed or any other European Standard, and test reports are
approved as being equivalent of test results and certified test reports as those determined
and reported by UL or any other European Standard. ATS withstand symmetrical short
circuit RMS is 50 kA except that the ATS shall not be equipped with either overload or fault
current protective devices and shall be designed and manufactured to prevent stops in an
intermediate or neutral position during transfer by the use of electrical actuators and stored-
energy mechanisms.

Automatic Transfer Switch (ATS) shall have a continuous phase or main current rating
equal to or exceed the rating shown but, in no case, less than 125 percent of the full load

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Electrical Works AUTOMATIC TRANSFER SWITCHES

rating of the emergency power source, 415 Volts, 4P, 50 Hz and 50 kA symmetrical
minimum interrupting capacity, or as shown on the drawings

No circuit breaks system shall be allowed.

2.1.1 Override Time Delay:

Time delay to override monitored source deviation shall be adjustable from 0.5 to 6
seconds and factory set at 1 second. The device shall detect and respond to a sustained
voltage drop of 30 percent of nominal voltage between any two of the normal supply
conductors, and initiate transfer action to the emergency source and start the engine-
driven generator set after the set time period. The pickup voltage shall be adjustable
between 90 to 100 percent of nominal and factory set 90 percent. The dropout voltage
shall be adjustable from 65 to 70 percent of the pickup value, and factory set at 70 percent
of nominal voltage.

2.1.2 Transfer Time Delay:

Time delay before transfer to the emergency power source shall be adjustable from
0.2 to 120 seconds and factory set at 10 seconds. The device shall monitor the
frequency and voltage of the emergency power source and transfer when frequency and
voltage is stabilized at or above 90 percent of rated values. The pickup voltage shall be
adjustable from 85 to 100 percent of nominal, and factory set at 90 percent. The pickup
frequency shall be adjustable from 90 to 100 percent of nominal and factory set at 90
percent.

2. 1.3 Return Time Delay:

Time delay before return transfer to the normal power source shall be adjustable from 2 to
30 minutes and factory set at 30 minutes. The time delay shall be automatically defeated
upon loss or sustained undervoltage of the emergency power source, provided that the
normal supply has been restored.

2.1.4 Auxiliarv Contacts:

Two normally opened and two normally closed auxiliary switches shall operate when the
transfer switch is connected with the normal power source, and two normally opened and
two normally closed switches shall operate when the transfer switch is connected with the
emergency power source.

2.1.5 Control Panel:

The transfer switch shall be equipped with a microprocessor based control panel. This
panel will perform the operational and display functions of the transfer switch. The panel
digital display shall be accessible without opening the door of enclosure and can be
connected to BMS system via serial or parallel ports to transfer all data by implementing
Ion, backnet, modulus protocol.

2.1.6 Supplemental Features:

The ATS shall also be furnished with the following:

- Engine start contact

- Pilot lights to indicate switch positions
- Alternate source monitor
- Test switch

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Electrical Works AUTOMATIC TRANSFER SWITCHES

- Close differential protection

- Three-position selector switch "STOP", "TEST", "Automatic"

2.1.7 Motor Starter Control:

Undervoltage and timing relays, including any auxiliary relays required, shall be installed
in the ATS enclosure to provide an adequate number and type of properly rated contacts
to control the operation of remote motor controllers or starters shown. Devices and wiring
in an external to the ATS shall cause motors to be de-energized for an adjustable period
of time before the operation of the ATS in either direction and, subsequently, to cause
motors connected to the ATS load bus to be energized immediately after transfer at time
intervals shown. The time range shall be approximately from 1 to 15 seconds and factory
set at 3 or 5 seconds.

2.1.8 Operator:

A manual operator, conforming to the applicable provisions of UL 1008, shall be provided

to permit manual operation ofthe ATS without opening the ATS enclosure, and incorporate
features to prevent operation by other than authorized and qualified personnel. The ATS
shall be designed for use of the manual operator under no load conditions in the usual
instances, but with the capability of operation under load conditions when necessary.

2.1.9 Override Switch:

The override switch shall by-pass automatic transfer controls so the transfer switch will
transfer and remain connected with the emergency power source, regardless of the
conditions of the normal power source. If the emergency source fails and the normal source
is available, the transfer switch shall automatically retransfer to the normal source.

2.1.10 Green Indicating Lights:

A green indicating light shall supervise the normal power source and shall have a
nameplate engraved NORMAL.

2.1.11 Red Indicating Lights:

A red indicating light shall supervise the emergency power source and shall have a
nameplate engraved EMERGENCY.

2.2 ENCLOSURE

ATS and accessories shall be in a wall mounted, free-standing or floor• mounted IP 43,
Type 1, smooth sheet metal enclosure constructed in accordance with UL 1008. Intake
vent shall be screened and filtered. Exhaust vents shall be screened. Gauge of the
metal shall be not less than 2 mm. Doors shall have suitable hinges, locking handle latch,
and gasketed jambs. Enclosure shall be equipped with at least two approved size and type
of grounding lugs or bar for the purpose of grounding the enclosure using at least 16 mm2
copper conductors to the facility ground system. A thermostatically controlled heater shall
also be provided within the enclosure to prevent condensation over the temperature range
stipulated in paragraph SERVICE CONDITIONS. Factory wiring within the enclosure and
the Contractor's field wiring terminating within the enclosure shall comply with NFPA 70. If
wiring is not color coded, wires shall be permanently tagged near the terminal at each end
with the wire number shown on approved detail drawings. Terminal blocks shall conform
to NEMA ICS 4. Terminal facilities shall be suitably arranged for entrance of external

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Electrical Works AUTOMATIC TRANSFER SWITCHES

conductors from the top or bottom of the enclosure or from the top and bottom, as shown.
Main switch terminals, including the neutral terminal, shall be of the pressure type and
suitable for the termination of the external copper conductors shown. Extension of bars
can be connected to the terminal to accept the conductors.

2.2.1 Construction:

Enclosure shall be constructed for convenient removal and replacement of contacts, coils,
springs and control devices from the front without the disconnection of external power
conductors or the removal or disassembly of major components. Enclosure housing
of ATS shall be constructed to protect personnel from energized components.

2.2.2 Finishing:

Painting required for surfaces not otherwise specified and finish painting of items only
primed at the factory shall be as manufacturer's recommendations

2.3 TESTING

2.3.1 Laboratory Testing:

Testing shall be completed on the ATS to be supplied under these specifications, or shall
have been completed on a previous, randomly selected standard production ATS unit
having the same model number and capacity as the ATS specified. Endurance and
temperature tests shall be conducted in that sequence and within the shortest practicable
period of time on the same ATS without de-energization of that ATS under test. The test
sequence for the ATS listed below shall be followed. No deviation will be granted that is
less stringent. Approval will not be granted to deviate from the endurance and temperature
test sequence.

- General
- Normal Operation
- Overvoltage
- Undervoltage
- Endurance
- Temperature rise
- Dielectric Voltage - Withstand
- Contact Opening
- Dielectric Voltage - Withstand (Repeated)
- Withstand
- Instrumentation and Calibration of High Capacity Circuits
- Closings
- Dielectric Voltage - Withstand (Repeated)
- Strength of Insulating Base and Support
2.3.2 Factory Testing:

In addition to other factory tests, each completely assembled ATS unit shall be subjected
to dielectric and operational tests, and withstand tests.

Withstand Test

in Excess of UL 1008 Requirements: The ATS shall be tested and rated to withstand an
available fault or short-circuit current of 30 KA symmetrical minimum interrupting capacity,
or as shown on the drawings.

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Electrical Works AUTOMATIC TRANSFER SWITCHES

Dielectric Tests:

Tests shall be performed in accordance with NEMA ICS 1. Wiring of each control panel
shall be subjected to voltage surge tests as stipulated in IEEE C37.90. 1. Impulse withstand
rating tests shall be performed in accordance with the requirements ofNEMA ICS 1.

Operational Tests:

Tests shall be performed and shall demonstrate that the operational sequence of each ATS
unit conforms to the requirements of the specifications with regard to operating transfer
time, voltage, frequency, and timing intervals.

PART 3 EXECUTION

3.1 INSTALLATION

The ATS shall be installed as indicated and in accordance with approved manufacturer's
instructions.

3.2 OPERATIONAL TESTING

Following completion of the installation of each of the ATS, the Contractor shall perform
operational tests in accordance with the written instructions of the manufacturer after
having made proper adjustments and settings to demonstrate that each of the ATS
functions satisfactorily and as specified. The Contractor shall advise the Client's
Representative not less than 5 work days prior to the scheduled date or dates for
operational testing, and shall provide certified field test reports to the Client's
Representative within 2 calendar weeks following successful completion of the operational
tests. The test reports shall describe all adjustments and settings made and all
operational tests performed.

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Electrical Works MEDIUM VOLTAGE SWITCHBOARDS

SECTION 1210

MEDIUM VOLTAGE SWITCHBOARDS

PART 1 GENERAL

1.1 RELATED DOCUMENTS

Drawings and General Provisions of the Contract, including General Conditions,

Conditions ofParticular Application and Division-1 Specification Sections, apply to work of
this Section.

1.2 DESCRIPTION

This section covers medium voltage metal enclosed switchgear as indicated on the
Drawings and required by the Contract and shall include the following items:

- Switchboard
- Distribution Boards
- Branch Circuit Panelboards

1.3 RELATED SECTIONS

The following sections of work contain requirements that relate to this Section:

16010 General Electrical Requirements

16060 Grounding and Bonding
16415 Automatic Transfer Switches
16450 Enclosed Bus Assemblies

1.4 SUBMITTALS

Submit the following in accordance with the Conditions of the Contract and Division-1
Specification Sections.

1.4.1 Materials Lists, Manufacturer's Data and Descriptive Literature

- Shop drawings, schematic and wiring diagrams

- Room Layout diagrams and general arrangement showing dimensions and
weights
- Certificates of compliance
- Spare parts list recommended by the manufacturer for normal operation and
maintenance of 3 years
- Material and equipment manuals
3 complete original sets of manufacturer operation and maintenance manuals for
each board
- Provide thermal stress limitation checks for all breakers and cables as per
manufacturer's data
- Short circuit and voltage drop calculations
- Provide full discrimination and relay coordination studies for all breakers as per
manufacturer's data according to the requirements shown on the single line
diagrams

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Electrical Works MEDIUM VOLTAGE SWITCHBOARDS

- Standard and optional factory tests

- Post-installation test procedure
- Final test reports
- Load balance

1.4.2 Equipment Data/Shop Drawings:

The equipment data to be provided by the Contractor prior to ordering any material
covered by this Section shall include but not be limited to:

Complete technical data on circuit breakers, contactors and other switchgear protection
and switching devices, including data on operating characteristics, compliance to
standards, dimensions and weights and detailed description of operating mechanism.

Complete technical data on instrument transformers protective and auxiliary relays,

measunng instruments, including manufacturer's catalogue operating characteristics -
operating curves with detailed description.

- Complete technical data on the construction of switchboards with bus• bars,

equipment plug in arrangement, access doors, provision for expansion
including detailed descriptive manufacturer's catalogues.
- Complete technical data on miscellaneous items including indicating lamps,
control and instrument wiring, outgoing and incoming power terminals and wiring
labels, locks grouting, bracing, etc.

1.4.3 Contractor's Shop/Construction Drawings:

The Contractor's shop/ construction drawings for installations covered by this Section
shall include but not be limited to:

-Plans, front, rear and side elevations, with indication of all face-mounted
equipment exact dimensions and weights.
- Drawings of arrangement of equipment inside the board.
- One line schematic diagram of circuits.
- Control circuit diagram, showing all auxiliary contacts remote control, if any, and
remote indication.
- Indication of arrangement of main incoming feeders and outgoing feeders (bus-
bars or cables).
1.5 REFERENCE STANDARDS

The following standards are referred to in this Section:

BS 88, BS EN 60127 Cartridge fuses

BS142 Electrical protective relays
BS 159, BS EN 60439-2 Busbar and connection
BS7354, BS EN 60439, BS EN 6094 Electrical power switchgear
BS 7626, IEC 185 Current transformers
BS4794, Pt. 2 IEC 337-2 Control devices
BS37, Pt.l Electricity meters general
BS89, IEC 51 Direct acting indicating electrical
measuring instruments
BS 5685, IEC 521 Electric meters

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Electrical Works MEDIUM VOLTAGE SWITCHBOARDS

BS EN 60529, IEC 529 Degree of protection of enclosures

BS 4752, IEC 157-1, BS EN 60439 Switchgear and control gear
BS EN 60947-3, IEC 408 Air break switches
BS EN 60947-4, IEC-1 & 1A Contractors
BS 5472, BS EN 60439 Low voltage switchgear and control gear
BS 6231 PVC insulated cable for switchgear
BS EN 60439, IEC 439 Factory built assemblies LV

1.6 DELIVERY, STORAGE AND HANDLING

Shipments shall be securely packed for delivery and transit, protected against excessive
heat and humidity and waterproofed for protection against water damage. When material
must be bundled due to excessive size each bundle shall have a tag, made of metal,
securely tied on with heavy gauge wire. Purchaser's markings shall be die-stamped on the
tag.

Equipment, relays, and other components with moving or fragile parts shall be properly
blocked, tied or packed to prevent damage.

Any component shipped separately shall be clearly marked with description, use and
installation instructions.

All packages shall be marked with equipment tag number for identification when shipped
and when received at site.

Sections to be grouped in not more than 3 sections per crate.

Each shipping unit shall be equipped with shipping angles or lifting lugs for handling by
crane.

PART 2 PRODUCTS

2.1 GENERAL

Materials and equipment shall be new and completely assembled, wired and tested at the
factory requiring only field installation and connection of power and control circuits to place
the equipment in service, except for multi-unit switchgear which could be divided into
shipping section after being completed and tested at the factory.

Manufacturer design and arrangement details of the equipment shall be subject to the prior
approval of the Engineer.

Switchgear and auxiliaries shall be designed for continuous operation at 415/240 volt, 3-
phase, 5 wire, 50 Hz, solidly grounded neutral power supply. Ambient conditions shall be
as specified by Section 16010 "General Electrical Requirements".

Switchgear with an incoming circuit breaker rated above 1OOOAmp shall be metal
enclosed, form (4) types as per BS EN 60439 or IEC-439, complete with stationary
structure, have complete bussing and front access apparatus described herein.

Unless otherwise specified in the project documents, main switchboards for general
purpose indoor uses, shall be constructed to comply with form (2) Types as per BS EN
60439.

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Electrical Works MEDIUM VOLTAGE SWITCHBOARDS

Provide a dead hanged front panel behind the door of a distribution board, to allow safe
operation. This front panel shall carry the required tags of equipment to show function of
each breaker inside or any push-button, etc.

The Contractor shall make sure that the space for each switchboard is available in
accordance with the requirements for the installation and operation and maintenance of
the equipment as specified and supplied by the Manufacturer, and as per IEC 364, 439.
Any inaccuracy in the building shall be corrected as required and directed by the Engineer,
and at no extra charge to the Employer.

Ratings are shown on the one-line diagrams and the panel details and should be checked
based on the actual loads at no extra cost to the Employer.

The switchgear shall contain equipment with ratings as indicated on the one line diagram,
panel details, and in this Specification.

All equipment designated as "spare" shall be fully equipped with all of the necessary items
required to make the equipment operable by connecting to the outgoing power and control
leads.

Switchgear shall have additional"space" for at least 20% of its outgoings for future
extension. Equipment shall have a blank front cover and shall be equipped with horizontal
and/or vertical bussing complete with the necessary screens required and circuit breaker
cassette for the future addition of a circuit breaker suitable or a combination of breakers
within the space factor limits.

Approved barriers between adjacent sections of switchboard shall be provided.

Switchgear shall be suitable for future extension on both ends. Unequipped space units
will be furnished only as required to balance the switchgear assembly.

All ratings shown on the one line diagrams are the required operational equipment ratings
at the ambient temperature. It shall be the Contractor's responsibility to ensure that the
equipment furnished satisfy the ratings shown without any extra cost to the Employer.

The Contractor shall assume all responsibility for mechanical and electrical coordination of
equipment and devices required by the Drawings and Specifications.

Interrupting capacities and short circuit ratings shown on the Drawings are for guidance
only, Contractor shall submit calculation for actual levels to the Engineer for approval.

The prospected short circuit current (Isc) value indicated at each bus-bar on drawings shall
represent the maximum 3-phase symmetrical r.m.s. kA, and it is the rating that all
switchboard components (i.g. bus, bars, bolts, circuit breakers, etc. shall withstand.

Buses shall be 99.8% electrolytic copper of sufficient size to limit temperature rise to 45°C
or an additional derating would be necessary.

Crowded bus-bar arrangement to fit maximum possible number of branch circuit breakers
in a distribution board, shall not be accepted.

Stacking of circuit breakers inside the switchboard shall be in accordance to original

manufacturer design tables in accordance with temperature rise type tests.

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Electrical Works MEDIUM VOLTAGE SWITCHBOARDS

Any switchboard column housing a number of circuit breakers summing more than
3000Amp of name-plate ratings should be fitted with a top heat extraction fan and a bottom
ventilating louver fitted with a front filter to maintain the switchboard protection degree.

The phase arrangement on 3-phases buses shall be R.S.T from front to back, left to right,
or top to bottom from the front of the switchboard.

All switchboard components shall be of the same manufacturer and must be tested
according to IEC standards. The assembly must be type tested and fully coordinated. All
design must be in accordance to temperature-rise type test.

All switchboard doors shall have a key lock and indicating lamp for ON/OFF-READY, in
addition to the necessary equipment for security identification.

All indicating lamps used in the switchboards should be semi-conductor LED diodes. Use
of neon or incandescent indicating lamps is not acceptable.

All indicating lamps and pushbuttons should be chromated metallic base and body.

All panel access doors shall be provided with a master key for maintenance and operation.

The panel shall be designed to permit continuous operation of all components mounted
therein with panel ambient temperatures of up to 55°C for indoor installation and 60°C for
outdoor installation.

2.2 SWITCHGEAR

2.2.1 Apparatus:

All auxiliary equipment, transition sections, bus duct, and other necessary components
required for complete installation and proper operation, under TN-S distribution system,
although not specifically listed herein, shall be furnished and included in the switchgear
assembly.

All circuit breakers of the same type and rating shall be completely inter• changeable
between compartments and between units at different locations on the site.

All doors, panels and cubicles in general, shall be sealed with neoprene or equivalent
gaskets. Enclosure shall be dust and vermin proof. Provide a directory of circuits on inside
cable compartment.

Fuses (if applicable) shall be of the same manufacturer, dual elements current limiting type.

Overload relays shall be of the anti single phasing type.

Bolted covers on compartments incorporating live connections shall bear a suitable

warning label.

All live conductors behind doors should be protected against accidental contact by use of
transparent plexi-glass sheet marked with an electrical shock warning label.

Fuses or miniature circuit breakers shall be provided so that relays, controls and
instruments may be isolated whilst other essential circuits are kept energized. Accordingly
the control circuit should be divided into two separate circuits (indicators circuit) and
(circuit breakers control circuit).

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Supply of any control shall be via a suitably sized control transformer (at least three times
the VA rating of all connected devices). Control circuits which are fed directly from the
busbar will not be accepted. The control transformer shall be protected at its primary and
secondary sides by HRC fuses of suitable size.

2.2.2 Main Bus:

The main bus shall be made of 99.8% pure copper and shall be continuous current ratings
as indicated on the Drawings or shall be of equal rating to the maximum setting of the
protective device on the incoming side whichever is greater.

The bus-bars and all its shall be fully rated and extend with the same size along the entire
length of the switchgear assembly.

All horizontal bussing shall have provisions for future extension on either end.

All main bus connections shall be tight and tin plated, corrosion-free and with sufficient
bolts to withstand the symmetrical fault currents indicated on the Drawings.

The bus-bar supports shall be formed of high strength, low moisture absorbing, high impact
material with ample creepage distance between bus• bars. Bus-bars shall be braced to
withstand the symmetrical fault currents indicated. All busbar bracing materials should be
of a non-magnetic material.

All bus-bars and tap connections shall be connected in such a manner that initial contact
pressure remains substantially undiminished at bus temperatures ranging from indicated
rated ambient to rated full load temperatures, to maintain minimum contact resistance for
the full service life of the equipment.

2.2.3 Vertical Bus:

All vertical bus-bars shall be of same material ofmain bus and shall have sufficient capacity
to supply all installed circuit breakers and each vertical section shall have full height and
depth, fire stop barriers of approved fire resistant material.

Vertical bus compartment shall be completely enclosed and isolated from other
components.

All vertical bus connections shall be tight, corrosion free and be able to withstand the
symmetrical fault currents indicated.

2.2.4 Neutral Bus:

Neutral buses shall be sized for the same capacity of the main bus and shall be of copper.

The neutral bus shall be separate and isolated from the ground bus and completely
insulated from ground. A removable bus link shall be provided for grounding the neutral
bus as shown on Drawings.

All neutral bus connections shall be tight and corrosion free.

2.2.5 Ground Bus:

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A solid copper ground bus shall extend along the full length of the switchgear and rigidly
bolted to the switchgear lower part compartments, frame and all sections of structure.

The ground bus shall be sized at least 50% of the main or vertical bus or 300 mm2
whichever is greater.

2.3 INCOMING SUPPLY AND OUTGOING CIRCUITS

2.3.1 Source:

Incoming supply shall be 415 volts, 3-phase, 5 wire, 50 Hz, with symmetrical fault current
level available at the incoming line terminals as indicated on Drawings.

The connections from the incoming line terminals to the main bus shall have the same
capacity as the main horizontal bus.

Connections to the switchgear shall be by bus-way system, cables in conduit or on cable

trays as indicated on Drawings.

In case of bus-way connection then the bus way should be manufactured by the same
manufacturer of the circuit breakers so that a coordination table between the main circuit
breakers and the bus way can be present.

If the incoming power supply is shown as cables a removable metallic gland plate with
thickness of not less than 5 mm shall be fixed to the top or bottom or both sides of the
panel depending on the direction of the cables. A non• ferrous material must be used in
case of single core conductors. Pressure lugs shall be provided for the termination of
cables, whose sizes are as shown on the one line diagrams.

2.3.2 Outgoing Circuit by Cables:

All outgoing feeder sizes shown on Drawings are considered a minimum and the
Contractor shall adjust without any additional cost to conform to the IEC-364 Regulations
after final equipment selection, same gland plates mentioned above will be applicable.

2.4 CIRCUIT BREAKERS

Main incoming and bus tie circuit breakers for main switchboard shall be four-pole, single-
throw, withdrawable air-type or molded case circuit breaker four (4) pole and continuous
current ratings as shown on the one-line diagram and wiring schedules.

All breakers above or equal to 1600A must be air-type.

As a general rule All breakers above 1600A must be electrically motorized unless otherwise
indicated on drawings.

Unless otherwise indicated all incoming and coupler breakers must be withdrawable air
type.

All automatic source change over (ATS) schemes must have mechanical interlocks in
addition to electrical interlocks.

Three (3) phase outgoing circuit breakers shall be molded case, miniature circuit breakers
or combined with residual current devices four (4) pole as shown in the single line diagram
or in panel schedules.

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All four (4) pole circuit breakers must have neutral protection accordingly their trip units
should be able to sense the current on all four (4) poles. The trip unit should allow a
separate setting for the neutral pole to select one of three settings (neutral unprotected) ,
(neutral protected at 50% phase current) and (neutral protected at 100% of phase current)

Circuit breakers shall be selected in line with this specification at the point of application in
accordance with the drawings, allocated spaces and the "Regulations" as applicable and
shall be suitably graded for 720 volt line service.

Circuit breakers serving as generator incoming must be fitted with a generator class trip
unit capable of achieving low settings suitable to generator applications.

Circuit breakers shall be totally enclosed in a molded case construction of approved

manufacturer and shall be provided with a front operated handle mechanism for manual
operation of the main contacts, in addition to the automatic operation under overload
current conditions. Multi-pole breakers shall have a single-handle mechanism for
simultaneous operation of all poles. Number of poles and its protection type shall be
suitable for TN-S grounding system.

Each pole of the circuit-breaker shall have an inverse-time delay over current protection
for small overloads and an instantaneous magnetic overcurrent trip element for operation
under short circuit conditions. All poles shall be constructed to open, trip or close
simultaneously.

Circuit breakers shall be provided with quick-make, quick break switching mechanism and
positive trip-free operation so that contacts cannot be held closed against excess currents
under manual or automatic operation. Contacts shall be non-welding silver alloy and
shall be adequately protected with effective arc-quenching devices.

The service short-circuit breaking capacity of the circuit breaker which is 100% of ultimate
short current shall be in accordance with IEC 947-2 and shall be equal to the same value
of short circuit level (I.e) indicated on Drawings. Switchboard and components
withstanding rating shall be equal to this short circuit level also.

The miniature circuit breakers shall be rated 10 kA breaking capacity as minimum unless
otherwise specified, with terminals capacity up to 25 mm2 .

All miniature circuit breakers should have protection shoulders against accidental contact
with their terminals.

Frame sizes (or continuous current ratings) indicated shall be the minimum accepted
ratings based on a fully-rated interrupting duty (non-current• limiting) as shown on the
drawings. The trip current rating (amps) indicates the nominal rating at which the thermal
overload element operates.

When tripped by either the thermal or magnetic elements, the handle shall automatically
assume a position midway between ON and OFF positions which clearly indicates a
"TRIPPED" position.

All poles shall be constructed so as to open, close or trip simultaneously.

Non-interchangeable trip breakers shall have their covers sealed and breakers with
interchangeable trips shall have the trip unit sealed to prevent tampering.

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Circuit breakers of 100 Amp frame size and larger shall have interchangeable over current
thermal-trip units and adjustable instantaneous trips unless otherwise indicated on the
drawings.

Thermal over current trips shall be ambient-temperature compensated to allow for an

ambient temperature at the breaker higher than at the protected circuit or device.

Combination of circuit breakers and ground fault circuit interrupters shall be used wherever
specified with a fault indicator lamp. It shall be instantaneous trip with a10 rnA, 30 rnA and
100 rnA sensitivity setting unless otherwise indicated.

All circuit breakers shall be derated according to climatic conditions and operating
temperature as per manufacturer standards.

All main circuit breakers to be provided with 4 auxiliary contacts 2 N.O. and 2 N.C. for
connection with BMS system.

All circuit breakers with ratings above 1OOOA (one thousand) should have a built in
ammeter on their trip units

2.4.1 Air Circuit Breakers:

To IEC 947-2 orBS EN 60947-2, suitable for triple pole service and shall have breaking
capacity of 50 kA symmetrical for 3 seconds at 415 Volts.

The Air Circuit Breakers (the conventional type and not moulded case circuit breaker) shall
be 500 V, 50 Hz, triple pole with neutral link for incoming and outgoing ACB or four poles
for bus tie ACB only with ratings as shown on the Drawings. They shall be air break, trip
free, draw-out type with mechanical and electrical ON/OFF indicators.

Where air circuit breakers are to be electrically operated by automatic motor wound spring
mechanism, a standby manual operating handle shall be provided for operating the circuit
breaker in case of power or motor failure.

The air circuit breaker shall be provided with over current, short circuit and earth fault
protection having the following characteristics:

- Adjustable long time delay current setting (50% - 150%) with varied tripping
time
- Adjustable short time delay current setting (400% - 1000%) with variable tripping
time
- Instantaneous tripping for heavier over current adjustable from 400% - 1600%
of base current
- Adjustable earth fault trip current setting (20% - 60%) with variable tripping
time

The circuit breaker shall have three position on the draw-out mechanism, namely service
position where all main and auxiliary contacts are made, test position where main contacts
are open but auxiliary contacts are closed and isolated position where all contacts are
open. An indicator shall clearly show these positions and provisions shall be made for
locking the breakers in any position. ON/OFF indicator shall be provided.

Mechanical Interlocks shall be provided to prevent withdrawing or inserting of the breaker

when it is "ON". Any attempt to do so shall trip the breaker automatically.

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The withdrawable part of the circuit breaker shall be effectively connected to earth through
scraping contacts that shall make before and break after the main and auxiliary contacts.

The moving contacts comprising the main and arcing contacts shall be of the spring loaded,
self aligning type. The arc contacts shall be arranged to make before and break after the
main contacts.

Each ACB shall be included but not limited with following components and accessones:

- Auxiliary Contacts
- Arc Chutes
- Folding Extension Rail
- Charging Handle
- Open and Close Push-buttons
- Over Current Trip Indicator
- Key Lock on Trip Button
- Spring Charge Condition Indicator
- Breaker Position Indicator
- Making Current Release
- Automatic Shutters for the BIB Terminal
- Carriage for Every Size of ACB exceeding 25 KG in Weight
- Operation Counter
- Shunt Trip Mechanism

The Man Incoming Circuit Breakers shall be provided with cable terminal boxes to suit the
incoming cables from the transformer/source supply.

Circuit breakers shall be tropicalised to operate continuously in an ambient temperature of

55°C and high relative humidity.

Type test certificate for each size of circuit breakers and MCCB from an internationally
recognized testing authority acceptable to the Engineer shall be provided.

2.4.2 Moulded Case Circuit Breakers:

Shall have a combination ofthermal and magnetic tripping giving an inverse time delay
protection against sustained overloads and instantaneous tripping under heavy overloads
and short circuits. Unless otherwise stated in the particular specification or drawings,
MCCB shall have a minimum short circuit rating of 25 kA.

Breakers shall have a quick make, quick break over center switching mechanism that is
mechanically trip free from the handle so that contacts con not be held closed against short
circuits and abnormal current.

Tripping due to overload or short circuits shall be clearly indicated by the handle assuming
a position mid-way between the manual ON and OFF position.

Latch surfaces shall be polished.

Poles shall be constructed to open, close and trip simultaneously. Ampere ratings shall be
clearly visible.

Breakers shall be completely enclosed in a moulded case to IEC No. 157-1A, suitable for
installation inside switchboard.

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Non-interchangeable trip breakers shall have the trip unit sealed.

Breakers with earth leakage relay protection shall be provided with shunt trips.

Frame sized shall be as per manufacturer's standard size and as approved by the
Engineer.

The magnetic trip shall be adjustable type for rating 200 Amp. and above, with 8 settings
from 1.5 to 10 times the rated current ofthe circuit breaker.

2.4.3 Miniature Circuit Breakers:

These shall be type C for general purpose uses, suitable for the load they feed, and shall
have short circuit of 9 kA, unless specified otherwise in the Project Documentation.

They shall be fault rated so that fuse backup protection is not required. They shall be rated
in accordance with BS EN 60898, IECG 898.

They shall include the following minimum features:

- Magnetic and thermal trip elements

- Trip-free mechanisms

Locking of facilities with detachable proprietary brackets and clearly marked ratings

2.4.4 MCB/ELCB:

Combined MCB/ELCB units shall be provided for final circuits supplying socket outlets,
water heaters and water pumps.

The units shall have a trip sensitivity of30 rnA.

2.4.5 Earth Leakage Circuit Breakers (ELCB):

Current operated earth leakage circuit breakers shall provide accident protection by
interrupting dangerous contact with voltage which may be present in faulty electrical
equipment as a result of frame faults, insufficient insulation or misuse.

The ELCB shall also provide a high degree of protection against earth leakage, fires and
electric shock and can withstand at least 9 kA or as specified in the Project Documentation.
The breakers shall generally comply with BS 4293, 1983 and the recommended
specification CEE 227 of the IEC on Rules for the approval of electric equipment.

The breaker shall consist of a core balance transformer, a tripping coil with contact
assembly, main supply contacts, ON/OFF switch, a test button and a trip free mechanism
all enclosed in a robust body of all insulated material.

Degree of Protection against earth leakage throughout the electrical installation shall be as
indicated on the Drawings. Unless otherwise indicated, ELCB shall have 30 rnA trip
settings.

The breaker protecting and or power circuits shall be mounted in the panel board
enclosure.

2.4.6 Overload Relays:

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Thermal overload relays shall be used for motors ratings up to and including 11 kW, giving
protection against:

- Over current unbalance

- Single phase
- Earth fault

Solid-state electronic protection relays shall be used for motors rated above 11 kW, having
the following protection features:

- Overload
- Over current
- Single phase
- Earth fault
- Under-voltage
- Over-voltage
- Plus, if required, digital indication of:
• Relay settings
• % of FLC that the motor is taking
• Continuous monitoring of thermal capacity of motor
• Thermal capacity used during start of motor
• If tripped, how much time before restart to take place
• Stall or short circuit trip
• Earth fault trip
• Starting

Documentary evidence must be produced showing the current/time characteristics of each

overload at its setting (hot/cold for the thermal overload) overlaid on the motor
manufacturers thermal stability time/current characteristics for comparison. Consideration
must be given as to the requested method of starting (DOL, star delta, etc..).

2.4.7 Fuses:

Fuses shall be the High Breaking Capacity (HBC) type to BS 88.

The fuse shall either include a suitable fuse carrier or it shall be capable of isolation. If the
fuse carrier is included it shall be such that when it is being withdrawn normally or when it
is completely withdrawn the operator is completely protected from accidental cont act with
any live metal of its fuse link fuse contacts and fixed contacts.

If the fuse is capable of isolation it shall be interlocked with the switch that isolation is
complete before the fuse enclosure can be opened further. The switch shall be prevented
from closing while the fuse-cover is open.

2.4.8 Fuse Switches:

To be metal clad, unless otherwise specified in the particular specification, with front
operated handles interlocked with enclosure door to prevent opening the door with the
switch in the "ON" position.

Switch shall have the door with "ON/OFF" indication and means of pad locking in the
"OFF" position.

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Fuse Switch and Switch Fuses:

- To BS EN 60967-3
- Fuses: to BS 88 bolted type, class Ql, 415 V and switches certified for AC-23A
duty, unless specified otherwise in the Project Documentation, rating as indicated
in the Project Documentation
- Fused switch carriages: withdrawable type
- Fuse switch: ASTA certified to 50 kA, or as otherwise indicated on the drawings

2.4.9 Isolating Switches:

Isolating switches shall be:

Same design as fuse switches and switch-fuses, with solid copper links in place of fuses.

Single pole and neutral, or triple pole and neutral, as indicated. Rating, as indicated.

2.4.10 Stop Lock-off Push Buttons:

Stop lock-off buttons for motors shall be mushroom headed red stay-put type with
automatic latching, the units having to be key operated to be released.

Push buttons shall be housed in a surface mounting weatherproof enclosure to IP 65.

Push buttons shall be UV stabilized.

2.4.11 Control Relays/Auxiliary Relays/Interposing Relays:

Relays shall be suitable for operation on nominal 240 or 110 V AC supply or in special
cases

24 V AC or DC (i.e. low voltage application), as per the Project Documentation. Relays

shall be suitable for operation at plus 10% and minus 25% of their nominal rated voltage.
Relays and contractors shall be selected for category AC 3 duty.

Relays shall be of the plug-in type only complete with plastic cover and shall be fitted with
normally open/normally closed or changeover contact combinations as necessary.

The contact material shall be suitable for their specific application and the Contractor must
supply this information during the mobilization period.

Mixed voltages must not be used on the different output contacts of a particular relay. If
necessary additional relays shall be used.

Coils shall be vacuum impregnated or guaranteed suitable for the local climatic conditions.

Terminations to the relay bases shall be of the front connected screw clamp type. The relay
mounting panel shall be drilled and tapped to accept future spare bases.

Relays shall be secured to their bases by retaining bar or clip to prevent malfunction due
to the relay loosened in its base.

Care shall be taken to ensure that relay contacts and associated wiring are suitably fuse
protected.

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AC operated relays shall have a neon indicator mounted within their clear covers which
shall be connected directly across the relay coil to indicate when supply is connected.
These indicators shall be easily seen when the relay compartment door is opened.

Relays having different contact configurations or different coil voltage shall under no
circumstances be interchangeable.

A permanent means of identification shall be affixed to both relay and base in line with the
circuit diagram reference.

Where remote supply voltages are used then care shall be taken to ensure that all relays
and any other equipment involved (terminals fuses, etc..) are completely shrouded and
where possible segregated. A warning label engraved in English and Arabic shall be fitted
onto or adjacent to any such equipment. Similarly where voltages exceeding 55 V to earth
are employed in relay compartments or non door-interlocked sections then shrouding
segregation and warning labels shall be applied.

2.4.11 Protection Relays:

Protection relays shall comply with BS 142.

Secondary injection shall be easily possible by means of purpose made voltage and/or
current plug-in type test terminal blocks which automatically open circuit or short circuit the
integral voltage transformers or current transformers respectively and provide termination's
for the test supply. Disconnection of any permanent wiring will not be acceptable.

2.4.12 Alarm System:

Auxiliary relays and auxiliary contacts and circuits breakers shall be provided as necessary
and if indicated to transmit alarm signals to remote control buildings.

Alarms shall be as indicated on the Contract Drawings and shall be selected from:

2.5 PANELBOARDS

Panelboards shall be factory assembled and type-tested, surface or flush mounted, as

shown on the Drawings and shall be deadfront, circuit breaker type with copper buses.

The panelboards shall be provided with main lugs, main breaker and number of breakers
as shown on the Drawings or panel schedule detail.

The panel boards should be manufactured by the same manufacturer of the circuit
breakers and must be designed in accordance with design guides based on results
obtained from temperature rise type-test

The panelboard enclosures shall be dustproof for indoor or dustproof and waterproof for
outdoor installation, unless otherwise indicated on Drawings.

The enclosures shall be provided with hinged covers and locks. All locks shall be keyed
alike.

Access to circuit breakers inside the panelboards should be restricted by use of dead front
plates which shall be of code gage sheet steel. Fronts shall be furnished with adjustable
trim clamps for securing the front to the box.

Each row of circuit breakers must have its own front plate, panel boards utilizing one front
plates for more than one row will not be accepted.

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Circuit breakers frame sizes shall be as indicated on the drawings. Panels shall be for
operation on voltage, number of phases, and number of wires as shown on Drawings.
Multiple phase circuit breakers shall be of the common trip type having a single operating
handle.

Each panelboard shall be equipped with full size neutral bus and ground bus of the same
length and cross-section as the neutral bus. The ground bus shall be bonded to the
enclosure.

Panels of 415/240 Volt shall have circuit breakers with an interrupting rating as shown on
the single-line diagrams and on Drawings.

A directory holder with protective covering shall be provided on the inside of each door.
The directory card shall provide a space at least 6 mm and 75 mm long for each branch
circuit. The card shall be completely typed to identify each connected and spare circuit,
and shall be bilingual, Arabic and English.

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All circuit breakers used must be as specified in the switchgear section 2.4 above.

All panel boards equipped with circuit breakers feeding single phase circuits must be
protected against the neutral conductor loss or disconnection so that to avoid feeding line
to line voltage to single phase loads.

All panel boards directly feeding sensitive electronic circuits or communication networks
must be protected with transient voltage surge suppressor (TVSS) to be installed at the main
circuit breaker.

2.6 DISTRIBUTION BOARD FOR OUTDOOR LIGHTING

When the photoelectric lighting control and timer unit switches on the triple pole contactor,
the outgoing phase lighting circuits shall be energized.

-Lighting Distribution Board: Shall contain the following:

• One main circuit breaker
• One triple pole lighting, ACI air-type contactor designed to withstand lamp
load inrush current and to carry full rated current on a continuous basis. It
shall be AC operated. A manual override switch shall be also provided and
connected
- Outgoing Circuit Breakers: The triple pole AC contactor shall be actuated by
means of a photo-electric lighting control unit mounted externally and a timer
module
- Photo-Electric Lighting Control Units: The distribution/control board shall be
controlled to switch on and off the outdoor lighting as a function of the ambient
daylight intensity by means of a photoelectric lighting control unit. The unit shall
be facing north nearest to distribution/control board and shall be connected to it by
means of finely stranded copper conductor flexible wires having 2 x 2.5 mm2 cross
sectional area and PVC insulation. Control unit shall be adjusted to respond
between 5 and 1000 lux and its response shall be delayed by 2 minutes to prevent
operation on momentary changes in daylight intensity. An additional
programmable timer shall be set to de-energize and energize the contactor in
selected periods of time.
- Selection switch and push buttons.
2.7 MOTOR CONTROL CENTERS

General: Provide the metal enclosed motor control centers as indicated, specified
and required.

The motor control centers shall be switchboard type construction as described for M.V.
cubicle switchboards excepts as modified herein.

The motor control centers shall be front access only.

Shipment shall be made in sections to facilitate field handling, and the shipped sections
shall be joined together to form a complete back-to-wall or back-to-back unit assembly as
indicated.

The motor control centers shall be free-standing or wall-mounted, as indicated in the

Project Drawings.

Construction: Vertical sections shall contain adequate space for connecting the incoming
power supply circuits, outgoing branch circuits, motor circuits and control circuits to
terminals, horizontal and vertical power bus bars, horizontal earth bus, circuit breakers,

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magnetic starters, contractors, control stations, pilot lights, timers, terminals,

transformers, panels, relays, ammeters, voltmeters, meter switches, earth leakage
protection, space heaters, thermostats, fans, vents, screens, filters and switches.

The vertical sections shall be fabricated from heavy gauge steel (minimum thickness of 1.5
mm), with uniform surfaces.

Unless otherwise indicated, the standard section shall be 800 mm wide (600 mm for
equipment and components, 200 mm for vertical wire way) by 600 mm deep.

Holes shall be provided in the structural base of each section for anchor bolts.

Sections shall contain wire ways, brackets, supports, plates, trims, barriers, gaskets, doors,
base channels, lifting angles and hardware.

Horizontal wire ways (top and bottom) shall extend through the width of each section.

Wire way openings shall be provided between sections with closing plates on the end
sections.

Each vertical section shall contain its own individual full height vertical wire way separated
from the vertical bus by a metal barrier, and also separated from the individual control units
by the side pan of the control unit.

Wire ties shall be furnished in the vertical wire ways to group and securely hold the
conductors in place.

A separate cover shall be provided on the vertical wire way.

Control units shall be isolated from one another by horizontal steel barriers. Front to rear
bracing shall not interfere with the cable entrance areas.

Hinged doors shall be equipped with screwdriver operated quarter turn latches that catch
automatically when the door is pushed closed. Large doors shall be equipped with
additional latches.

Provision shall be included to add a vertical section on either end of the line up in the future.

The power supply compartment shall be sized to accommodate the incoming power
conductors. The compartment shall be located at the top or bottom of the vertical section
as shown on the Drawings. The power compartment shall be covered by a hinged door
and shall be held closed with quarter turn pawl type latches.

Bus bars shall be provided for the power and earth systems. When shown on the Drawings,
provide full length full capacity and insulated neutral bus and cable connectors. Bus joints
shall be connected with bolts, nuts and spring washers. The main horizontal power bus
shall be located in the center or near the top of each section, jointed together to form a
continuous bus for the full length of the motor control center. The horizontal power bus
shall be copper and the current rating shall be as shown on the Drawings. The vertical
power buses shall be copper full height and rated for the section total load. The minimum
current rating for the vertical power buses shall be 300 amperes or as specified in the
Project Documentation. Small openings in the vertical barriers shall permit the plug-on
control unit contacts to pass through and engage with the vertical bus bars. Unused plug-
on openings in the vertical barriers shall be equipped with plastic snap-in closing plugs.

2.8 INSTRUMENTATION AND CONTROLS

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Instruments: The Measuring Instruments shall include ammeters, voltmeters, kWh

meters, selector switches and associated accessones as indicated on the Drawings and
described herein as follows:

- Ammeter, Voltmeter and Power Factor Meter r:

• The measuring instruments shall be moving iron vane type, flush pattern
with dust and moisture proof enclosure. Anti-glare glass front, anti-parallax
scales and whit faces with black numerals and marking shall be used. All
instruments shall be long scale 240 degree with full load indicating
approximately at 180°
• The dial size shall be 10 x 10 cm2
• Accuracy shall be one percent of full scale valves
• Moving elements shall be provided with zero adjustments located at face
of dial
• The ammeter shall be capable of withstanding twice of rated current for
10 minutes and overload sustained under fault conditions without damage
or loss of accuracy
• Voltmeter shall have a measuring range from 0 to 500 V and shall
withstand twice the rated full scale voltage for 1.0 minute without damage
• Three ammeters or a single ammeter with selector switch shall be
provided to read the current of each phase, as indicated on the Drawings
• The voltmeter selector switch shall be of the rotary type with cam operated
contractor and shall have (7) positions off, R-Y, Y-B, R-B, R-N, Y-N, B-N
• Single and poly phase power factor meters with associated current and
potential transformers shall be provided as required and specified herein
• Ammeters shall have maximum demand pointers

Current Transformers: Current transformers shall be of the bar primary type, air cooled and
suitably insulated. The current transformers shall be of Class X accuracy for restricted earth
fault protection and Class 1 accuracy for metering purposes, as stipulated in the WAPDA
Regulations.

Current transformers shall be rated not less than 5 VA and shall have thermal kWh meters.

The kWh meters shall be suitable for operation of 415/240 Volt, 3 phase, 4 wire, 50 Hz,
and shall conform to BS 37 Pat 1 and BS 5685.

The meters shall be dust-proof and vermin proof, protected from corrosion due to high
humidity and compensated against the effect of temperature up to 55°C.

The meters shall maintain their accuracy over many years service under Pakistan climatic
conditions. The counter shall be of the cycle meter type with six figures, the lowest figure
being unit. Pointer type counters are not acceptable.

The meter cover and cases shall be of metal .

Meters shall not have less than 5 mm diameter terminal holes and shall operated through
three current transformers and the counter of the meter should be calibrated to read the
primary kWh. The current transformers shall be selected from the standard sized stipulation
in WAPDA Regulations.

All meters shall be handed over the WAPDA for calibration prior to final installation and
connection.

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Restricted Earth Fault Protection: Restricted earth fault protection shall be provided
for main switchboards in accordance with the WAPDA Regulations.

Anti-condensation Heaters: Anti-condensation heaters shall be provided inside each

compartment in strategic positions. These shall be controlled by an internally mounted
humidistat and an external overriding ON/AUTO switch.

Heaters shall be of sufficient size to maintain the air temperature inside compartment at
least 10°C above the outside ambient.

2.9 TRANSIENT OVER VOLTAGE

Transient over voltage suppressor - shall be provided at the incoming supply side of main
medium voltage panel, as shown on the drawings. The contractor should select the proper
type which recommended by the supplier and submit to the Engineer fro approval
supported by calculations.

2.10 FACTORY TESTING

The switchgear shall be factory assembled and tested before shipping. Test reports shall
be furnished by the Contractor.

All components shall be thoroughly inspected and tested to ensure alignment and
adequacy of all functions.

PART 3 EXECUTION

3.1 INSPECTION

Inspect each switchgear assembly and related accessories for damage, defects,
completeness and correct operation before installing. Inspect previously installed related
work and verify that it is ready for installation of instruments and equipment.

3.2 PREPARATION

Ensure that installation areas are clean and that construction operations are completed
prior to installing equipment. Maintain the areas in a broom-clean condition during
installation operations.

3.3 ELECTRICAL WORK

The Contractor shall perform all interconnecting wiring and grounding as indicated,
specified and required and shall include cables, conductors, terminals, connectors, wire
markers, conduits, conduit fittings, supports, hardware and all other required materials.

Provide the electrical materials and complete all the required electrical installations in
accordance with the requirements specified in Section 16010 and Section 16050 and as
required by Drawings.

3.4 MOUNTING

The switchboards and panelboards (both surface and flush types) shall be installed so that
the height of the top edge will not exceed 1.80 m from the finished floor. Directories shall
be typewritten in English and Arabic to indicate load served by each circuit, and shall be
mounted in a holder behind protective coating. Contractor shall follow manufacturer's
installation instructions.

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For free stand panelboard either steel or concrete base should be made without any extra
cost to Employer.

Contractor shall submit to the Engineer for approval, an elevation mounting detail and plan
for each distribution board specially those mounted inside vertical service ducts, also
showing cable risers and racking to a scale of 1:10 or 1:50 before installation.

3.5 INSTALLATION SUPERVISION

Furnish the service of engineer especially trained and experienced in the installation of the
equipment to (1) supervise the installation in accordance with the approved material and
equipment manuals and (2) inspect, check, adjust as necessary in accordance with the
Specifications herein, until the installation and operation are acceptable. Include all costs
for services in the Contract Price.

3.6 FIELD TESTING

Contractor shall prepare in full details and submit for approval, post installation, test
procedures attached with test forms for all M.V. panels.

Switchgear installations shall be tested in accordance with BS 116, BS 162, BS 861, BS

3185 orBS 3659 as applicable (or corresponding IEC) for the type of equipment.

The tests shall be both electrical and mechanical to demonstrate satisfactory operation.
Where protection relays or adjustable over current trips are incorporated,
primary/secondary injection tests shall be carried out to demonstrate the correct setting of
the protection device and its satisfactory operation. Test certificates shall be issued by the
Contractor when primary injection tests are carried out.

Switchgear and Motor Control Center: The whole of the switchgear and control center shall
be tested as integral units based on the completeness of the circuits in the final
manufactured form within the manufacturer's works. Witnessed tests shall comprise
Routine Tests in accordance with BS 5496 Part 1 and BS 5424 Part 1, together with the
following:

- Primary injection tests to ensure correct ratio and polarity of CT's and to
demonstrate the correct operation of current operated protection relays and direct
acting coils over their full range of settings.
- Operation and through current stability tests on balanced earth fault protection
relays by primary current injection.

Correct operation of sequencing and control circuits indications and alarms at normal
operating voltages by operation of local control switches and simulation of operation of
remote control circuits and all protection devices.

- Circuit breakers shall be subject to routine tests together with checking of all
mechanical and electrical interlocks.
- Type test certificates and performance test data for identical panel types shall be
made available.
- Measure phase-to-phase and phase-to-ground insulations
to meet manufacturer's specified minimum resistance.
- Check electrical continuity of circuits and for short circuits.
- Coordinate tests with tests of generator and run them concurrently.
- Demonstrate interlocking and operational functions for at least 3 times.

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3.7 SYSTEM VALIDATION

Provide the services of trained and field experienced engineer(s) to validate each
switchgear system to verify that each system is operational and performing its intended
function as specified and detailed in the approved Post-Installation Test Procedures.
Validate each system by simulating inputs.

Immediately correct any and all defects and malfunctions disclosed by tests. Use new parts
and materials as required and approved and retest. Provide a report certifying completion
of validation of each system.

3.8 IDENTIFICATION PLATES

Identify components as required by codes and manufacturer's standards and according to

Section 16010 11General Electrical Requirements 11 •

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