DG SET-Technical Specs PDF
DG SET-Technical Specs PDF
DG SET-Technical Specs PDF
1.1 This specification covers the design, manufacture, assembly, shop testing, packing, despatch,
transportation supply, erection, testing, commissioning, performance and guarantee testing of
Silent type Diesel Generating Sets, complete in all respects with all equipment, fitting and
accessories for efficient and trouble free operation as specified here under including statutory
approvals.
General Scope of work shall include design, manufacture, shop testing, packing, despatch,
transportation to site, supply, erection, testing and commissioning of the following:
a) Diesel engine complete with all accessories, an Alternator directly coupled to the engine through
flexible/ rigid coupling complete with all CTs, PTs, etc as required or as per BOQ &
specifications, accessories for starting, regulation and control, including base frame, foundation
bolts etc, interconnecting piping and accessories, power and control cable glands and lugs.
b) AMF/Manual panel including various meters/Annunciation and other control components as per
standard practice, BOQ & specifications. Control panel cabling between bidders & local
equipments and special cables if any.
c) Equipments necessary for fuel storing and distribution, day oil tank, piping, valves, level
controller and indicators etc. Load sharing facility with Synchronization Panel.
d) Flexible connections and Residential type silencer of exhaust system, including thermal lagging.
e) Batteries with teak wood battery stand painted with acid proof black paint and battery charging
equipment, including their connections as necessary along with tools & accessories for battery
maintenance.
g) Preparing of all related shop drawings for approval from client/consultant and statutory bodies.
h) Obtaining approval of the installation of Diesel Generators by the Electrical Inspectorate and
Pollution
Control bodies and any other statutory bodies.
i) Minor civil works like chasing, grouting etc, for execution of jobs.
j) Carrying out performance and guarantee test i.e. full load test followed by 1 hour over load
including making arrangements for oil lubricants, other consumables and Electrical loads etc. as
required.
1.3.1 The equipment furnished under this specification shall conform to the following latest
standards, except where modified or supplemented by this specification.
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BS: 5514 : Specification for reciprocating internal combustion engine.
BS: 5000 : Rotating electrical machines of particular type or for particular applications.
IS: 1239 (Part-I & II) : Mild steel tubes and fittings.
IS: 1651 : Stationary cells and batteries lead acid type (with tubular positive plates).
IS: 9224 : Specification of low voltage fuses, General purpose.
IS: 4540 : Mono-crystalline semi-conductor rectifier assemblies and equipment.
IS: 5 : Colours for ready mixed paints.
IS: 4722 : Rotating electrical machines.
IS: 1248 : Specification for electrical indicating instruments.
IS: 10000 : Methods of tests for internal combustion engines.
IS: 10002 : Specifications for performance requirements for constant speed
compression
ignition (Diesel) engine for general purposes (above 20 KW)
IS: 2147 : Degree of protection provided by enclosure for low voltage switchgear and
control gear.
IS: 1600 : Code for type testing of constant speed IC engines for general purposes.
IS: 1601 : Performance of constant speed IC engines for general purposes.
ASME Power : Internal combustion engines.
Test Code PTC-17 : Codes of Diesel Engine Manufacturer's Association U.S.A.
1.3.2 The installation work shall conform to Indian Electricity act and Indian Electricity Rules as
amended upto the date of installation. The fuel oil installation shall meet all statutory require-
ments of Govt. of India as amended up to the date of installation. Any approval required from
statutory authorities shall be obtained by the contractor. Nothing in this specification shall not
be the limiting factor to relieve the contractor of their responsibilities.
1.3.3 The equipments furnished under this specification have to operate in a tropical climate and
shall be given tropical and fungicidal treatment as per relevant specification.
1.4 ENGINE :
1.4.1 Type :
The diesel engine shall be of stationary type four stroke with Vertical In Line or (V) Type
Cylinder arrangement, Turbo charged, cooled with radiators.
1.4.2 Rating :
a) Continuous BHP rating of the engine shall be such that the DG set can continuously deliver
the specified net electrical output while supplying power/driving all electrical and mechanical
auxiliaries connected to alternator terminals and engine shaft at specified site conditions and
ambient temperature of 45 deg C.
b) It shall also be capable of satisfactorily driving the alternator at 10% over load at the rated
speed for one hour in any period of 12 hours of continuous running.
The successful bidder shall have to furnish supporting calculations to arrive at the diesel
engine rating.
Speed shall be 1500 revolutions per minute. Speed governor/over speed protection shall be
provided. At due running conditions, speed shall be stabilized at plus or minus 2% nominal
speed, regardless of load. At transient condition, engine speed shall vary not more than 10%
plus or minus. Governor class shall be A0/G3 for normal application unless otherwise
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specified. The Governor of all DG set shall be of similar characteristics to enable
synchronization. The engine vibration level shall be with in the permissible limits.
1.4.4 Lubrication :
a) The engine shall have a closed cycle forced & splash lubricating system with positive oil
pressure and a crank chamber for collection/storage of the lubricating oil during circulation.
No moving part shall require lubrication by hand or any other external source either prior to
the starting of the engine or when it is in operation.
b) A lubricating oil filter shall be provided for operation under normal conditions for a period of
500 hours without the necessity of its replacement or cleaning.
c) In case lubricating oil coolers are required they shall be of the water cooled type and shall be
supplied as an integral part of the Diesel Generator Set.
d) Necessary temperature and pressure gauges and other instruments shall be supplied and fitted
on the lubrication system.
e) A lubricating oil level dipstick suitably graduated shall be provided and located in the
accessible position.
a) The engine shall be capable of running on all types of diesel fuel oil normally available in
India.
b) The fuel consumption of the engine at full, three quarters and half of its rated power output
shall be indicated by the Contractor in the bid.
c) A fuel service tank of capacity as specified in BOQ shall be provided on a suitably fabricated
steel platform. The tank shall be complete with level indicator marked in litres, filling inlet
with removable screen, an outlet, a drain plug, an air vent and necessary piping. The fuel tank
shall be painted with oil resistant paint. Service tank level switches (2 Nos. per tank) for
alarm & trip shall also be provided by the bidder. All pipe joints should be brazed/ welded.
d) A hand pump for pumping the fuel into the fuel service tank together with necessary pipes or
tubing shall be provided. The inlet of the pump shall be provided with 5 meters long
armoured hose with suitable filter.
The diesel engine shall be provided with special dry type air filters having low resistance to
air passage, high dust retaining efficiency and provision for easy cleaning. Filters shall be
suitable for achieving satisfactory engine operation and ensuring the engine life under tropical
humid conditions, with sulphur dioxide and trioxide fumes, abrasive dust and coal particles of
5 to 100 microns present in the atmosphere. The minimum efficiency of filters shall be 90%
down to 5 micron size.
1.4.7 Cooling :
The diesel engine should be air cooled with radiator system or fluid cooler.
The governor shall be A0/G3 type as per ISO 8528 part V. It shall have necessary
characteristics to maintain the speed substantially constant even with sudden variation in load.
However, a tripping shall be provided if speed exceeds maximum permissible limit. The
governor shall be suitable for operation without external power supply.
1.4.9 Turbo Charger :
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It shall be of a robust construction, suitable of being driven by engine exhaust having a
common shaft for the turbine and blower. It shall draw air from filter of adequate capacity to
suit the requirements of the engine.
a) Engine starting shall be by electric starting motor complete with manual/automatic starting
arrangement. The starter motor shall conform to IS-4722 and shall be of adequate power for
its duty and be of inertia or pre- engaged type. The pinion shall positively disengage when the
engine starts up or when the motor is de-energised. The engine cranking shall be only from
the panel and any engine starting devices etc, that are given as original fitment on the engine
by engine manufacturers shall be either removed or padlocking arrangement given for this so
that all normal start/stop operations could be done only from panel whether the set is AMF or
manual.
From the initial operation of the starting device, the engine shall start, run up to normal speed
and be capable of accepting 80% of full load within a maximum time of 25 seconds, and full
load within a further 5 seconds.
The set is intended to supply power only during an emergency for essential services and may
be idle for long periods except for periodic routine run once in a day for a short time. When
there is a total failure of mains power supply, the sets shall be required to operate
continuously at full load for a period which at times may exceed even 18 hours at a stretch. It
shall also be capable of satisfactorily running at 10% overload at the rated speed for 1 hour in
any period of 12 hours of continuous running.
i) Starting Duty :
This DG Set shall withstand and shall be able to take care of starting load of largest machine
and other running loads.
This D G Set shall be capable of running continuously on primary duty of about 100% of its
name plate rating.
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The instrument panel shall be mounted on engine using rubber dampers for vibration
isolation. The gauge dials shall have clear red marking to identify the limiting dangerous
levels, `Zone markings' on the scale to indicate the normal healthy & abnormal operating
zones for the parameters concerned. The metering could be either normal electro-mechanical
analogue type or electronic digital type, latter being preferred as manufacturers fitment only.
1.5 ALTERNATOR :
1.5.1 The alternator shall be brushless type with rotating field and static excitation circuit controlled
by field control unit suitably compounded for voltage and load current for a self excited self
regulated system.
1.5.2 The alternator shall be in Screen Protected Drip Proof (SPDP) enclosure, foot mounted with
ball and roller bearings on end shields.
1.5.3 The alternator shall conform to IS: 4722 / BS: 2613 and shall be suitable for tropical
conditions.
1.5.4 The alternator shall comply with the following specifications:
Rating As specified in the B.O.Q
Voltage 415 V
Speed 1500 RPM.
Frequency 50 Hz.
P. F. 0.8 lag
Waveform Distortion No Load <1.8%, Non Distorting Balanced Linear Load <5%
Enclosure IP: 23.
Insulation H grade
Excitation Self excited, self regulated with brushless system and static voltage control unit
suitably compounded for voltage and current to maintain terminal voltage constant at ± 5% at
all load for p.f. not less than 0.8.
Terminal Box shall be suitable Rating of cable for terminating DG Sets of rating specified in
BOQ with Earthing studs.
a) The control panel shall be sheet steel enclosed and shall be dust, weather and vermin proof
providing a degree of protection of IP-52. Sheet steel used shall be cold rolled and at least 2.0
mm thick and properly braced and stiffened.
b) Control panel shall be provided with hidden hinged door(s) with pad locking arrangement and
suitable brackets/channels shall be provided for floor mounting.
c) All doors, removable covers and plates shall be gasketed all around with neoprene gaskets.
All accessible live connections shall be shrouded and it shall be possible to change individual
switches, fuses, ACBS without danger of contact with live metal.
d) All live parts shall be provided with at least phase to phase and phase to earth clearances in
air of 30 mm and 25 mm respectively.
e) Adequate interior cabling space and suitable removable cable gland plate shall be provided.
Necessary number of cable glands shall be supplied and fitted on to this gland plate. Cable
glands shall be screwed on type and made of brass.
g) All sheet steel work shall be degreased, pickled, phosphate and then applied with two coats of
finishing powder coating both inside and outside of shade Siemens Gray.
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1.6.2 Control of Diesel Generating Sets :
Auto Operation :
Necessary control equipments and system incorporating various function etc. shall be
provided to ensure following :-
When mains power is available, the healthiness of this power shall be monitored through a
mains voltage monitor. If voltage on the 3 phases are within limits, the monitor will send a
closing signal to the mains breaker and mains power will be connected to the load.
If the voltage drops on any phase or on all phases, the monitor shall sense this drop, and if this
drop persists for more than a pre-adjusted period of time (say 1 to 60 seconds) a signal is sent
to start the DG sets. While at the same time opening the mains supply breaker and
disconnecting load from mains as voltage is below acceptable limits.
The Command shall be sent for starting the engine through the starting solenoid. When the
engine is healthy, it starts up in a few seconds and the generator develops voltage and when
the voltage is developed, this give a signal to the generator breaker/contactor which closes
and connects the diesel generator to the load. Simultaneously, it sends a signal to de-energise
the engine starting circuit and the starter motor is disengaged. The engine protection circuits
for high water temperature and low lubricating oil pressure and engine over speed are also
energised.
b) Resumption of Supply :
If voltage from mains is resumed, the main voltage monitor will sense this voltage for
healthiness, i.e. for maintained correct voltage for a period of time (adjustable upto three
minutes) and then send a signal to the panel to stop the engine and to change over the
breakers from generator to mains and normal supply is resumed to the load. Provision shall
also be made for effecting the change over to normal supply through a selector switch.
c) Failure to Start :
A three attempt starting facility similar to using two impulse timers and a summation timer
for engine shall be provided and if voltage fails to develop within 30 seconds from receiving
the first start impulse, the set shall lockout automatically and a visual and audible alarm shall
be given in the remote panel. The panel shall receive "DG Trouble Alarm" (potential free
contacts to be provided).
Safeguards shall be provided and arranged when necessary to stop the engine automatically
by the following:
a) Energising a solenoid coupled to the stop lever on the fuel injection pump rack.
b) Deenergising "fuel on" solenoid or
c) Energising the "fuel - cut off" solenoid.
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The operation of the safeguard shall at the same time give individual warning of the failure by
illuminating an appropriate local visual indicator and remote alarm at generator panel.
The contactors, relays and other devices necessary for signal and control, for above purposes
shall be provided at Generator panel.
At the set at a easily accessible place an "EMERGENCY STOP" mushroom head stay put
type P.B shall be provided to stop the set in emergency mode.
The safe guards to "STOP THE SET" shall stop the set irrespective of mode selection of the
set viz Auto, Manual or test for following cases, with simultaneous isolation of alternator
circuit.
Emergency stop P.B's operation.
b) Over speed.
c) Low lube oil pressure.
d) Earth fault or restricted earth fault or differential faults of Alternator.
a) The battery shall conform to the requirement of IS-1651. Starting battery sets of 12 V, heavy
duty high performance approved make'/quality shall be provided to enable crank & start the
engine even in cold/winter morning conditions. Type/ voltage/AH capacity of same on 20
hour rated discharge period shall be indicated in the offer. The battery shall be capable of
performing at least eight (8) normal starts without recharging. Necessary battery calculations
shall be furnished at the time of bid.
b) The Battery shall be provided with good quality teakwood stand painted with acid proof black
paint with min 3 mm thick rubber mat below the battery.
c) Batteries shall be of lead container type only and not with PVC moulded sealed container so
that each individual cells are available for individual monitoring during its life span. Each cell
shall be provided with electrolyte filling cap with level floats for easy monitoring of
electrolytic level.
2. Small PVC mugs with handle - 2 Nos. (Red & white colour)
3. Hydrometer syringe type with float calibrated (not with zero markings only) with one spare
float.
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e) The battery shall be provided with 2 nos. cables, min 1.5 m long heavy duty rubber/PVC
insulated cabling with brazed tinned lug at one end and with brazed tinned brass terminal lug
at battery end - for connecting batteries to cranking system - with 0.25 m long inter battery
connecting cable.
f) The lugs shall be clearly stamped + or - and positive cable also red sleeved for easy
identification.
g) The batteries shall be supplied fully filled and charged ready to use.
a) Float rate charging and quick rate charging system shall be provided at the generator panel
with appropriate bridge charger system, LC network, rate selector switch and generously
rated charging transformer and silicon one rectifier bridge, so that the cranking battery system
can be kept fully charged at all times from E.B. supply network with quick charging rate
limited to 0.8 times rated discharge current with provision in control transformer and Silicon
rectifier present to enable boost charging the battery at 2 times rated discharge current in case
of emergencies. To this and in the mode selector switch boost charge position shall be present
which however shall be kept disconnected at mode selector switch normally.
b) Two DC ammeters to clearly indicate float charging current and quick/boost charging current
shall be provided with 0-250 or 0-500 mA range and 15-0-15 or 30-0-30 A range
respectively.
c) The float charging ammeter circuit logic shall be so as to bring in circuit only on demand
through a P.B. the R.S.S. (Rate selector switch) in it float charging mode to prevent damage
to the ammeter.
d) Dropper resistor network on the load side of battery charger system shall be provided so that
higher charger voltages in quick or boost conditions does not get impressed on the I/L and
contactor coils, which voltage shall remain well within +10% of rated voltage.
e) Battery charging subsystem shall be designed for continuous operation at cubicle ambient of
50 deg C corresponding to 45 deg C ambient outside and should be designed to operate at 1.5
times rated maximum current corresponding to boost charge current which can reach in
practice as high as 2.5 times or 3 times rated discharge current.
f) Any charger dynamo and dynamo charging current network present on the set shall either
have to be removed or made in operative so that both for AMF and manual application the
cranking battery system is kept charged from the charger at the panels at all times during or
shut down periods of the set.
The exhaust of DG set shall be routed through the residential type silencer. It is desired to
insulate the exhaust duct/chimney with insulation & appropriate support arrangement &
adequate trap door with feasibility of cleaning.
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The list of mandatory spares which are considered essential by the Supplier shall be indicated
in the bid for successful operation of DG Set for 3 years. Price may also be quoted separately
for these spares.
1.11 TESTS :
1.11.1 The alternator of each type and rating shall be type tested for the all tests as per IS:4722,
IEEE 115 & BS:5000. Required type test certificates shall be furnished for information.
1.11.2 The alternators and the starting motors shall be tested for the routine tests as per IS:4722 and
test certificates submitted for acceptance.
1.11.3 The control panels shall be tested/checked for following (but not limited to).
a) Compliance to drawing, data sheet and this specification.
b) Check for workmanship, wiring, conformity to functional requirements.
c) Calibration of instruments, meters C.T., P.T. etc.
d) H.V. Test
e) I.R. Test before and after HV test.
1.11.4 The acceptance and routine tests of battery shall be done as per relevant standard.
All civil works related to DG foundation etc are included in the scope of works under this
specifications.
1.13 NEUTRAL POINT : The winding of the alternator for 625 KVA shall be star-connected
and neutral side leads shall be brought out to a separate terminal box.
Client shall provide space for genset and its equipments. Contractor shall prepare and submit
to Architect/Consultant the following drawings in six sets for approval before commencing
the erection for construction work at Site -
The entire work of erection, testing and commissioning of equipment supplied under this
package shall be carried out by contractor and performance and guarantee tests to be conduct-
ed at site are also included under the scope of this specification. For this purpose the
contractor shall depute suitable qualified technical supervisor to site on advance intimation to
the Owner along with all special testing equipment required for testing and performance and
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guarantee tests. The supervisor(s) shall be responsible for the installation, testing,
commissioning checks and performance & guarantee tests mentioned in relevant clauses of
this volume and the checks recommended by the contractor.
The successful contractor shall submit sufficiently in advance the bio-data of the supervisor
giving details of his experience for Owner's approval.
The vendor shall ensure that the equipments supplied by him are installed in a neat workman
like manner such that they are leveled, properly aligned and well oriented. The tolerances
shall be established in Contractors drawings and/or as stipulated by the Owner.
All special tools and tackles and spares required for erection, testing and commissioning of
equipment shall be supplied by the contractor. The bid shall include a list of these special
tools, tackles and spares along with their item wise prices. The total cost for these tools,
tackles and spares shall be included in the bid price.
Erection, testing and commissioning manuals and procedures shall be supplied, prior to
dispatch of the equipment.
The contractor shall ensure that the drawings, instruction and recommendations are correctly
followed while handling, setting, testing and commissioning the equipment.
In addition to the checks and test recommended by the manufacturer, the contractor shall
supervise the following acceptance tests to be carried out on each set.
Load Test :
The engine shall be given test run for a period of at least 13 hours depending upon the actual
power factor of the load and set shall be subjected to the maximum achievable load without
exceeding the engine or alternator capacity.
This full load test is to be followed immediately by a 10% overload run for one hour. The
performance of the engine, alternator and exciter shall be satisfactory at the end of this
overload run. All the arrangements of factory visit of IUCAA engineers & consultant - three
engineers including stay-if required, shall be in the scope of DG vendor. At the end of the
full-load run, and again at the end of the over-load run, tests for temperature rise and
insulation resistance of the alternator as specified shall be taken.
During the load test half hourly records of the following shall be taken:
a) Ambient temperature
b) Exhaust temp. when exhaust thermometer is fitted.
c) Lubricating oil temperature when an oil cooler is fitted.
d) Lubricating oil pressure
e) Speed
f) Voltage, wattage and current output.
g) Oil tank level
h) Stored diesel oil temperature
Regulation Test :
The automatic and manual regulation of the alternator load at half and full rated load shall be
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tested for a nominal volts of 240 volts, between phase to neutral and at 0.8 p.f. to verify the
requirements of voltage and frequency variation as per IS:4722.
The speed of the engine shall be verified to ensure that it conforms to the requirement of
BS:5514.
Vibrations :
The vibrations shall be measured during full load test as well as during the overload test and
the limit shall be limited to 250 microns.
Check of Fuel Consumption : A check of the fuel consumption shall be made throughout the
test run of full load and overload.
On completion of the engine tests, the insulation of each unit of local wiring in the control
cubicles and other components of the engine set, shall be tested with a 500 V insulation tester.
The insulation resistance shall not be less than one mega-ohm. between wires in a cable and
engine set frame of cable sheath.
Functional Tests :
a) Protective equipment on the engine against excessive cylinder temperature and low
lubrication oil pressure.
b) Type of starting provided for the engine.
c) Pilot and fault indication lamps.
1.15 DATA SHEET FOR D.G. SETS (To be filled by the Vendor along with the
bid)
2.0 ENGINE :
2.1 Type :
2.2 Make :
2.3 Model :
2.4 BHP :
2.5 RPM :
2.6 No. of Cylinder :
2.7 Specific Fuel Consumption Liter/Hr. :
2.8 Type of Cooling :
2.9 Type of Starting :
3.0 ALTERNATOR :
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3.1 Make :
3.2 Type of Enclosure :
3.3 Mounting :
3.4 KW Rating :
3.5 KVA Rating :
3.6 Insulation :
3.7 Excitation :
3.8 Terminal Box Provided (Yes/No) :
3.9 Earthing Studs :
7.1 Type :
7.2 Make :
7.3 Ampere Hour Rating :
8.1 Type :
8.2 Facilities provided (bidder to furnish
Details & brief description) covered :
a) Monitoring :
b) Startup :
c) Changeover :
e) Operation :
f) Protection & interlocks & safeguards :
8.3 Cable entry :
8.4 Weight :
8.5 Dimensions :
The framework shall be made out of suitable sheet steel with anti corrosive paint. Specially
designed
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acoustic doors shall be provided with glass window for visibility of the DG sets from outside. These
doors shall have a proper sealing arrangement to ensure that there is no sound leakage.
The enclosure shall be provided with suitable ventilating/exhaust fans for fresh air & hot air exhaust
with all accessories required. The ventilation system shall be designed so that the temperature rise in
acoustic enclosure shall be less than 15 Deg Cent. above ambient.
The enclosure shall be supplied with necessary anti vibration pads between DG & Enclosure and also
between enclosure & foundation.
Noise level – average of 75dB right around measured at a distance of 1 meter from the enclosure.
10.0 EXECUTION :
Vendor shall give necessary inputs for designing the foundations & shall be responsible for
design, erection shall happen after completion of foundation works (done by other agencies).
Vendor shall co-ordinate with other agencies like electrical contractors, civil contractors etc.
Further to erection, testing and commissioning of the DGs, the termination of cables at DGs,
Between DGs and Main LT panel end shall be done by the main electrical contractor.
Calibration of CTs, approval from statutory authorities like electrical inspectorate, PCB etc
shall be the responsibility of the DG supplier. DG supplier shall coordinate with main
electrical contractor for necessary control & power cable termination.
11.0 Auto Synchronizing & Auto Load Sharing Panel for 2 x 625 KVA DG Sets :
The panel includes Motorized ACB FP 1000A 50 KA with O/C,S/C & E/F as Incomer 1 to 2
from the DG set # 1 to 2. The ACB should be equipped with U/V, O/C, S/C and E/F
protection. R-Y-B indication, ON, OFF, Trip indication, and Load Manager for measurement
of ampere, voltage, Kw, kwh and frequency, and Max Demand with PC Compatible port.
Microprocessor- based Relay with AMF, Auto Synchronizing &Auto Load Sharing and Auto
shut off facility. It should have capability to manually synchronize the DG’s. The panel
should be suitable to handle 2 x 625 KVA DG set load. Load Manager for measurement of
ampere, voltage, Kw, Kwh and frequency, and Max Demand with RS 232 / RS 485 port. The
panel should have the following feeders:
2 Nos. 1000 Amp FP ACB 50 kA for with ON/OFF/TRIP indication & 01 No. 2000 A, 65 kA
FP ACB, Busbar 2500 Amp, 65 kA
The panel shall be vermin proof and dustproof, having chemical surface treatment and
finishing shall be of 2-coats of synthetic enamel, RAL – 7032
All internal wiring shall be of FRLS 1.1 KV grade, PVC wires. CT shorting links are to be
provided for Ammeter and protection circuit
STANDARDS :
Following equipments shall conform to the requirements as per the latest revisions of the
following standards:-
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1. Air Circuit Breaker(ACB) : IS 13937- 1.2 / IEC 947 - 1.2
2. Moulded Case Circuit Breaker (ACB) : IS 13947 - 1.2/ IEC 947 - 1,2
3. Contactors- : IS 13947-1,4
4. Miniature Circuit Breaker(MCB) : IS 8828- /IEC898
The switchboard shall be metal clad, totally enclosed, rigid, compartmentalized design, floor
mounting, air insulated, extensible cubicle type, CNC fabricated for use on medium voltage
power, 3 phase 4 wire 50Hz system. The overall construction shall meet Form-4
constructional requirements.
a) CRCA-Sheet steel enclosed, indoor floor mounted free standing cubicle type & CNC
fabricated.
b) Made up of the requisite vertical sections which when coupled together shall form
continuous
switchboards.
c) Dust, vermin and damp proof and enclosure protection not less than IP 42 for indoor &
IP55 for
outdoor applications and IP:32 for Battery Chargers or as specified elsewhere.
d) Each feeder/instrument compartment shall be provided with a hinged door interlocked
with ACB/LBS inside the compartment such that door can only be opened when ACB/ in
off position.
e) Readily extendable on either sides by the addition of vertical sections after removal of the
end
covers.
f) Switchboards shall have access to the feeders, bus bars, cable termination, cable alley,
etc. as
required.
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g) All CTs for metering/protection shall be mounted in respective feeder compartments
either in front or on the rear side of the same compartment for easy maintenance without
disturbing other feeders.
i) All CT wiring shall be done with CT terminal block with shorting facility mounted in the
metering compartment.
j) Wherever control wiring is done between the shipping sections, terminal blocks shall be
provided on both sides of shipping sections with TB diagram pasted near to the TBs.
k) The total height of the panel shall not be more than 2200mm unless otherwise specified
and maximum height of switch operating handle shall not be more than 1800mm from
FFL. The maximum shipping section shall be of 2000mm width. The total depth of the
panel shall be adequate to cater for proper cabling space.
Where ever single core cables are used, 3mm thick aluminium gland plate shall be
provided. All sheet steel work forming the exterior of switchboards shall be smoothly
finished, leveled and free from flaws. The corners should be rounded.
n) Components forming part of the switchboards shall have the following minimum
clearances:
o) All insulating material used in the construction of the equipment shall be of non-
hygroscopic
material treated to withstand the effects of high humidity, high temperature and tropical
ambient service conditions.
p) Functional units such as circuit breakers, fuse switches, ACBs, etc. shall be arranged in
multi-tier formation except that not more than two air circuit breakers shall be housed in a
single vertical section.
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r) Cable terminations of one functional unit, when working on those of adjacent unit/units.
s) All covers providing access to live power equipment/circuits shall be provided with tool
operated fasteners to prevent unauthorized access.
t) Provision shall be made for permanently earthing the frames and other metal parts of the
switchgear by two independent distinct connections.
v) All capacitor control panels shall be of compartmentalized design. All capacitors &
reactors shall have individual compartments. Exhaust fans shall be provided for
ventilation purpose.
w) The complete panel shall be designed such that it’s rating is as per SLD without de-rating
considering ambient temperature & temperature rise as per IS/IEC. De-rating of
ACBs/ACBs or the whole panel shall not be accepted. Panel shall be provided with
necessary ventilation arrangements to meet the above requirement.
a) A front framed structure of rolled/folded CRCA sheet steel angle section rigidly bolted
together. This structure shall house the components contributing to the major weight of
the equipment such as circuit breaker cassettes, fuse switch units, main horizontal bus bars,
vertical risers and other front mounted accessories.
b) The structure shall be mounted on a rigid base frame of folded CRCA sheet steel of
minimum 6 mm thickness and 100 mm height or ISMC100. The design shall ensure that
the weight of the components is adequately supported without deformation or loss of
alignment during transit or during operation.
c) A cable chamber housing the cable end connections and power/control cable
terminations. The design shall ensure generous availability of space for ease of
installation and maintenance of cabling and adequate safety for working in one vertical /
horizontal section without coming into accidental contact with live parts of the adjacent
section.
d) A cover plate at the top of the vertical section, provided with a ventilating hood wherever
necessary. Any aperture for ventilation shall be covered with a perforated sheet having
less than 1mm diameter perforations to prevent entry of vermin.
e) Front and rear doors fitted with dust excluding neoprene gaskets with fasteners designed
to ensure proper compression of the gaskets. When covers are provided in place of doors
generous overlap shall be ensured between sheet steel surfaces with closely spaced
fasteners to preclude the entry of dust.
a) After fabrication the panel shall under go 7 tank treatment/sand blasting for removing
grease, Rust etc. The panel shall be coated with zinc chromate primer(Applicable for
outdoor panels).
c) After coating of primer, the panel shall be coated with Epoxy based paint (powder
coating/spray paint). Paint shade shall be as specified by the client/consultant during
drawing approval.
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F) BUS BARS :
a) The bus bars shall be made of high conductivity, Electrical grade Aluminium or copper
(As specified in SLD), suitable for 415 volts, 3 phase 4 wires 50 Hz,
b) The bus bars shall be suitably supported with non-hygroscopic supports to provide a fault
withstand capacity as specified.
c) High tensile (8.8 grade) bolts and spring washers shall be provided at all bus bar joints.
d) Fish plates of equal type and size shall be used at all joints.
e) The bus bars shall have uniform cross section throughout and shall be capable of carrying
the rated current at 415V continuously. The bus bars shall be designed to withstand a
temperature rise of 40 Deg. C above the ambient temp. of 50 deg. C. A current density
(Amp/Sq.mm) shall not exceed 1 A/sq.mm for copper & 0.8 A/Sq.mm for Aluminium.
f) The neutral bus bars shall have a continuous rating of at least 50% of the phase bus bars
unless otherwise mentioned.
g) Bus bars shall be fully sleeved using heat shrunk PVC sleeves appropriately color coded
to identify different phases and neutral bar.
h) All lighting & raw power panels/SMSBs shall be provided with neutral bus rated same as
the size of Phase Busbars unless otherwise specified in SLD.
i) MCCB/ACBs of rating 200A & above rating shall have copper spreaders on terminals &
then connected to main busbars.
j) All panels shall be provided with aluminium earth bus, which shall run throughout the
length of switch board at top or bottom as required. Following size of earth bus shall be
provided as per the switchboard rating:
Up to 100A 25x3mm
250A 25x6mm
315A 25x10mm
4000A 100x10mm
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G) POWER/CONTROL WIRING:
All control wiring shall be carried out with 1100/660 V grade single core PVC-FRLS cable
having stranded copper conductors with minimum cross section of 1.5 Sq.mm for potential &
control circuits and 2.5 Sq.mm for current transformer circuits. Control wiring for analog,
digital inputs/outputs shall be done with 1.5/1 Sq.mm screened copper cables. All power
cables shall be minimum cross section of 4 Sq.mm.
Wiring shall be neatly bunched, adequately supported and properly routed to allow for easy
access and maintenance. Wires shall be identified by numbered ferrules at each end. The
ferrules shall be of ring type and of non-deteriorating material. They shall be firmly located
on each termination so as to prevent free movement. All control circuit fuses/MCBs
shall be mounted in front of the panel and shall be easily accessible. All CT
wiring shall be done with CT terminal block with Shorting facility mounted in the
metering compartment.
Wherever control wiring is done between the shipping sections, terminal blocks shall be
provided on both sides of shipping sections with TB diagram pasted near the TBs. Control
wiring for analog, digital inputs/outputs shall be done with Screened cables & routed
separately to avoid EMI.
H) TERMINAL BLOCKS :
Terminal blocks shall be of 500 Volts grade and of stud/screw type. Terminal blocks shall
have a minimum current rating of 10 Amps and shall be shrouded. Provisions shall be
made for label inscriptions. At least 20% spare terminals shall be provided on each panel and
these spare terminals shall be uniformly distributed on all terminal blocks.
Terminal blocks for current transformer and voltage transformer secondary leads shall be
provided with test links and isolating facilities with disconnecting type TBs. Also current
transformer secondary leads shall be provided with Terminal block with short circuiting and
earthing facilities.
Terminal blocks for power feeders shall be of stud type with bolts & nuts.
There shall be a minimum clearance of 250mm between the first row of terminal blocks and
the associated cable gland plate. Also, the clearance between two rows of terminal blocks
shall be a minimum of 150mm.
I) CABLE TERMINATIONS :
a) Cable entries and terminals shall be provided in the switch board to suit the number, type
and size of aluminium conductor power cables and copper conductor control cable
specified in the detailed specifications.
b) Provision shall be made for top or bottom entry of cables as required. Generous size of
cabling chambers shall be provided with the position of cable gland and terminals such
that cables can be easily and safely terminated.
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c) Barriers or shrouds shall be provided to permit safe working at the terminals of one circuit
without accidentally touching that of another live circuit.
e) Cable risers shall be adequately supported to withstand the effects of rated short circuit
currents without damage and without causing secondary faults.
f) Sufficient height shall be provided between busbar & gland plate in case higher size cable
& more number of runs. Min. cable termination heights from gland plate shall be as
below:
Up to 35 Sq.mm : 200mm
50 to 95 Sq.mm : 250mm
120 to 185 Sq.mm : 350mm
240 to 400 Sq.mm : 550-600mm
A) CURRENT TRANSFORMERS :
a) Current transformer shall comply with the requirements of IS 2705. They shall have
ratios, outputs and accuracy as specified/required. All CT's shall be of resin cast type
unless otherwise specifically called for.
b) All CT’s shall be of bar type primary or suitable for the cable given type and size.
c) For all the CT's suitable type and size clamps are to be supplied for mounting in the
switchboards.
d) Polarities and terminal markings of primary and secondary shall be clearly marked on all
CT's.
1. Current Ratios :
ii.Secondary : 5A
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B) POTENTIAL TRANSFORMER :
a) All the Potential Transformers shall comply with the requirements of IS 3156 latest
edition. All PT’s shall be resin cast type and shall have Voltage ratios, output and
accuracy class as specified in SLD/Data Sheet.
b) All PT’s shall be single phase, dry type suitable for mounting inside the panel/cubicles.
Clamps / brackets / supports required for the mounting shall be supplied along with PT.
d) Name plate indicating, voltage ratio, burden, accuracy class, type, Sr. No. Make and
Model etc., shall be provided.
e) A common earth terminal for earthing of core, bolts, clamps (non current carrying metal
parts) etc., shall be provided.
13.0 BREAKERS :
A) GENERAL:
The ACBs shall conform to IS 13947-1 / IEC 60947-1 for general rules and IS 13947-2/IEC
60947-2 for Circuit Breakers. The ACBs shall be suitable for 3 phase 415 Volts. All the
breakers shall have tropicalisation as a standard feature. ACBs shall meet the following
minimum parameters,
: 690V
Rated operational Voltage
Rated insulation Voltage : 1000V
Rated impulse withstand Voltage : 9kV
No. of mechanical operations : 25,000(up to 2000A)
15,000(above 2000A, up to 4000A)
No. of electrical operations : 10,000(up to 2000A)
5,000(above 2000A, up to 4000A)
B) CONSTRUCTION:
The Breaker shall be suitable for rear and vertical mounting and line load reversibility.
All ACBs shall be draw out type & shall be with service-test-isolated positions.
C) CONTROL UNITS:
The Control Units shall be housed in a separate enclosure and there shall be total insulation of
the control unit with respect to the power unit.
The Control Unit shall be of Microprocessor type & suitable to provide short circuit, overload
and earth fault protection.
The setting range of the short circuit protection shall be from 3 to 9 x In and 5 to 15 x In.
The overload settings shall be adjustable from 0.4 to 1.0 times the rated current.
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The breaker shall provide Earth fault protection from 0.2 to 0.7 times rated current.
D) ACCESSORIES:
The connection for the auxiliary shall be accessible from the front.
ACB shall be provided with following accessories, in addition to the item specified in Bill of
Quantities. Further these devices shall be fittable at site from the front and common for all
ratings.
E) INTERLOCKING:
F) BREAKING CAPACITY:
The ACB shall have minimum service breaking capacity of 65 kA. Preferably Ics shall be
equal to ultimate breaking capacity Icu or it shall be rated as specified in SLD. Original test
certificate of the ACB as per the IS shall be provided on request.
The Moulded Case Circuit Breaker shall be incorporated in the switchboard wherever
specified and shall be of the current limiting type. ACB shall conform to IS 2516, IS 13947-
1/ IEC 947-1 (part I & II / section 1) 1977 for general rules. It should be suitable for
Horizontal and Vertical mounting and line load reversibility. ACB shall be suitable either for
Single Phase AC 230V Or Three Phase 415V. The MCCB/ACB shall be available in four
pole versions for neutral isolation. It shall have tropicalisation as standard feature.
The ACB/MCCB cover and case shall be made of high strength heat-resistant and flame-
retardant thermosetting insulating material. The operating handle shall be quick make, quick
break, trip - free type. The operating handle shall have suitable `ON' `OFF' `TRIPPED'
indicators and in order to ensure suitability for isolation complying with IS 13947-2/IEC947-
2, the operating mechanism shall be designed such that the toggle or the handle can only be in
`OFF' position, if the main contacts are actually separated.
A) ACCESSORIES:
ACB shall be designed to have following accessories and it shall be fittable at site.
B) INTERLOCKING:
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ACB shall be provided with following interlocking devices for interlocking the door of a
switch board.
C) BREAKING CAPACITY:
Short time with-standing capacities & breaking capacities for different ratings of ACBs shall
be as specified in the SLD.
Preferably Ics shall be equal to Icu or all breaking capacities shall be considered for Ics.
D) RELEASES:
Unless otherwise specified all ACBs up to 250A (including 250A) shall be provided with
thermal magnetic releases & all ACBs of rating 315A & above rating shall be provided with
Microprocessor releases.
All ACBs with Thermal magnetic releases shall be provided with adjustable overload of
70/80-100% & fixed short circuit releases.
All ACBs with Microprocessor releases shall be provided with adjustable overload of 50-
100% & adjustable short circuit releases.
Wherever earth fault module is required it shall be inbuilt with other releases, i.e. separate
module for E/F is not recommended.
8) Wide array of time circuit for start delay, stop delay, mains restoration, recooling etc.
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9) Full engine safety function like :
9.2) DG fault like fail to start, fail to stop & low battery
9.5) Protection against engine faults like LLOP, SCT, Low fuel & over speed, phase reversal
etc
The Synchronization Controller relay should have programmable atleast 10 digital inputs, 18
analogue input, 8 output relays, 2 analogue output & communication port like RS 232, RS
485, USB & Bus communication & suitable converter for bacnet bus. It may also be
indicated whether Stand Alone SNMP protocol based communication interface is available
for the generator control panel. The controller shall be able to control/monitor following
alarms of engine & alternator:
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17) Battery charger alternator fault
1) mains/generator synchronization
3) Bus communication
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4) TCP/IP static address, for Ethernet/LAN control
8) insulated inputs
16) management of mixed systems with several mains and several generators
3. Battery : Exide
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LIST OF APPROVED MAKES
2 LT Cables Finolex/Polycab
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