< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

JOB NO.: 6261

ISSUED DATE: 18/04/2009 A

DHT PROJECT

DOC NO.: 6261-N-133A

PAGE NO. 2 OF 21

TABLE OF CONTENTS
Sl.No
1.0
1.1
1.2
1.3
1.4

General
Scope
Specific Job Requirement
Codes and Standards
General Requirement

2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19

Equipment Specifications
Constructional Features
Bus Bars
Air Circuit Breakers (ACB)
Air Break Switches
Fuses
Contactors
Starters
Thermal Overload Relays
Numerical Relays
Indicating Lamps, Push Buttons and Control Switches
Moulded Case Circuit Breakers (MCCB)
Instruments
Miniature Circuit Breakers (MCB)
Instrument Transformers
Internal Wiring
Terminal Blocks
Control Supply
Name Plates and Rating Plates
Painting

5
5
8
10
11
12
12
12
12
13
13
14
14
15
15
17
17
17
18
19

3.0

Interface With DCS

19

4.0

Interface With MMI/ SCADA

19

5.0

Inspection and Testing

20

6.0

Drawings and Documents

20

Title

Sheet No.
3
3
3
3
4

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

JOB NO.: 6261

DHT PROJECT

ISSUED DATE : 18/04/2009 A

1.0

GENERAL

1.1

Scope

DOC NO. : 6261-N-133A

PAGE NO 3 OF 21

This specification covers the general requirements for the design, manufacture,
inspection, supply and testing of Indoor, Fixed/ Draw Out type Medium Voltage
Switchgears, having rated voltage not exceeding 1000V, 3 Phase/ 3 Phase Neutral, 50
Hz.
1.2

Specific Job Requirement

Specific job requirements which are herewith attached cover modifications to this
specification, Purchasers special and/or local requirements, as well as specific job
requirements pertinent to this specification.

1.3

Codes and Standards

1.3.1 The design, manufacture and performance of Medium Voltage Switchgear shall comply
with all current statutes, regulations and safety codes in the locality where the
equipment will be installed.
The equipment shall also conform to applicable IS/IEC. In case of imported equipment,
standard of the country of origin can be accepted if these standards are equivalent or
stringent than the applicable Indian standards.
The relevant Indian standards are:
1.
2.
3.

7.

IS: 5 (2007)
IS 772
IS 1248 P1-(1993)
P2,4,6,7-(2003)
P3,4,5 -(1983)
IS 1897 (1983)
IS 2705
P1,2,3(1992)
IS 3156
P1,2,3,4(1992)
IS 2824

8.
9.

IS 3231 P2, 3(1987)

IS 3618 (1966)

10.

IS 4237 (1982)

11.

IS 5082 (1998)

12.

IS 5578 (1984)

4.
5.
6.

Colours for ready mixed paints and enamels.

AC Electricity Meters
Direct acting indicating analogue electrical measuring
instruments and their accessories
Copper strips for electrical purposes.
Current Transformers
Voltage Transformers
Method for determining the comparative tracking index of
solid insulating materials under moist conditions.
Electrical relays for Power system protection.
Phosphate treatment of Iron and Steel for protection
against corrosion.
General requirements for switchgear and control gear for
voltages not exceeding 1000V AC or 1200 V DC.
Wrought aluminums and aluminium alloy bars, rods, tubes
and sections for electrical purposes.
Guide for marking of insulated conductors.

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

JOB NO.: 6261

DHT PROJECT

ISSUED DATE : 18/04/2009 A

13.
14.

18.

IS 6005 (1998)
IS 6875 P3-(1980)
P1,2 (1973)
IS 8623
P1,2,3-(1993)
IS 9224 P1,2-(1974)
P4- (1980)
IS 10118
P1,2,3,4-(1982)
IS 11353 (1985)

19.

IS 12021 (1987)

20.

22.

IS 13703
(Part 2/ Part 1)1993.
IS 13947 (1993)
(Part 1 to part 5)
IEC 258

23.
24.
25.
26.
27.
28.

IEC 185(1987)
IEC 186 (1987)
IEC 947 (1989)
IEC 391
IEC 269
IEC 408

15.
16.
17.

21.

1.4

DOC NO. : 6261-N-133A

PAGE NO 4 OF 21

Code of practice for phosphating of iron and steel.

Control switches for voltages upto and including 1000V
AC and 1200V DC.
Factory-built assemblies of switchgear and control gear for
voltages up to and including 1000V AC and 1200V DC.
Low voltage Fuses - Part I, II, and IV.
Code of practice for selection, installation and
maintenance of switchgear and control gear.
Guide for uniform system of marking and identification of
conductors and apparatus terminals.
Control transformers for switchgear and control gear for
voltages not exceeding 1000V AC.
Low voltage fuses
Low Voltage Controlgear and Switchgear.
Direct acting recording electrical measuring instruments
and their accessories.
Current Transformers
Voltage Transformers
Low Voltage Switchgear and Control Gear PART 2
Marking of insulated conductors
Low Voltage Fuses
Low voltage air break switches, air break disconnectors,
air break switch disconnectors and fuse-combination unit

GENERAL REQUIREMENT

1.4.1

The offered equipment shall be brand new with state of art technology and proven
field track record, No prototype equipment shall be offered.

1.4.2

Vendor shall ensure availability of spare parts and maintenance support services for
the offered equipment at least for 15 years from the date of supply.

1.4.3

Vendor shall give a notice of at least one year to the end user of equipment and PMC
before phasing out the product/spares to enable the end user for placement of order
for spares and services.

1.4.4

All equipment is intended for continuous duty operation, as per name plate rating
under the specified ambient temperature.

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

2.0

EQUIPMENT SPECIFICATIONS

2.1

Constructional Features

DOC NO. : 6261-N-133A

PAGE NO 5 OF 21

2.1.1

The switchboards shall be suitable for installation and satisfactory operation in a air
conditioned or pressurized Substation or in a substation with restricted natural air
ventilation in a tropical, humid and corrosive atmosphere. The switchboards shall be
designed for continuous duty and to operate under site conditions as specified in the
data sheet.

2.1.2

Metal enclosed switchgear shall be free standing, floor mounting type, unitized
vertical steel structure, dust and vermin proof, assembled to form a single structure
with a common bus bolted to withstand fault currents at least equal to the short circuit
capacity of the circuit interrupting devices.

2.1.3

The switchgear shall be of fully draw-out modular design, compartmentalized single /

double front and multi-tier construction as specified in data sheet. However circuit
breaker panels and fixed type switchboards shall be in single front execution only. It
shall consist of metal frame- work with the associated compartment doors and
covers. The cubicles shall be segregated by partition sheets into the following
functional compartments:(i)
Feeder compartments (Modules),
(ii)
Busbar compartments,
(iii)
Cable compartments (Alleys).

2.1.4

The switchgear frame shall be fabricated using mild steel structural sections or
pressed and shaped cold rolled Sheet Steel of thickness not less than 2.5mm.
Frames shall be enclosed by sheet steel of thickness not less than 2.0mm smoothly
finished, leveled and free from flaws. Doors and covers shall be of sheet steel of
thickness minimum 1.6mm; stiffeners shall be provided wherever necessary. All panel
edges and door edges shall be reinforced against distortion by rolling, bending or by
the addition of welded reinforcement members. Cable supports shall be provided
throughout the height of the cable alley to support the cables.
The removable gland plate shall be 3mm thick. In case of single core cables, gland
plate shall be of non-magnetic material.

2.1.5

The rear side doors / covers shall be hinged type of sufficient strength to hold the
door / cover weight continuously (Cast aluminium material is not acceptable). Bolted
covers shall not be acceptable.

2.1.6

Switchgear shall be provided with Neoprene gaskets all round the perimeter of
adjacent panels, all joints/openings, removable covers and doors and between panel
and the base frame.

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 6 OF 21

2.1.7

Panel space heater with thermostat having adjustable setting & DP Rotary switch &
fuse shall be provided in the wire way/cable alley of each panel. Supply to space
heater shall be 240V AC.

2.1.8

Suitable lifting hooks shall be provided on each panel or shipping section for ease of
lifting the switchboard.

2.1.9

All auxiliary devices for control, indication, measurement and protection such as
push buttons, control and selector switches indicating lamps, ammeters, voltmeters,
and protective relays shall be mounted on front side of the respective compartment
only. For ACB feeders, the relay /auxiliaries can be mounted in same/separate
vacant compartments in same/adjacent panel. However, current transformer with
buit in releases may be mounted on the breaker trolley.

2.1.10 The switchboard shall be dust and vermin proof and shall provide with a degree of
protection not less than IP-42. The switchboard shall be assembled out of vertical
sections of uniform height.
2.1.11 It shall be possible to extend the switchboard in either direction at a future date.
Ends of bus bars shall be suitably drilled for this purpose. Panels at extreme ends
shall have openings, which shall be covered with plates screwed to the panel.
Details
of drilled holes in bus bar and openings in the panels, provided for future
extension shall be clearly shown in the contractor drawings.
2.1.12 The panels shall be suitable for installation on a base frame supplied in one piece
along with foundation bolts or shall be suitable for tack welding.
2.1.13 Each vertical panel shall have a separate cable alley. The width of this cable alley
shall be sufficient to accommodate power & control cables of all feeders and shall
have free access for cable terminations. It shall not be less than 250 mm wide. Cable
alley shall be provided with a suitable hinged door. Sheet steel barriers shall be
provided between individual compartment and cable alley. This barrier shall be
provided with opening for power and control connections and it shall be possible to
safely carryout maintenance work on cable connections to anyone circuit in the alley
with the adjacent circuits live.
2.1.14 The vacant modules in the panel shall be fully equipped with hinged door and shall
be suitable to mount modules in future.
2.1.15 The outgoing feeders trolleys shall be fully draw out and shall have the following
features.
i.

It shall be possible to withdraw the trolley without having to unbolt or

unscrew any power connections to the equipment mounted on the with
drawable trolley.

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

ii.

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 7 OF 21

Both power and control connection shall be draw out type.

2.1.16 All power switches/MCCBs shall be lockable in both ON and OFF positions. The
switch/MCCBs shall be interlocked with the compartment door to prevent opening of
the door when the switch/MCCB is in ON position and to prevent switching ON
when the door is open. A defeat mechanism for this interlock shall also be provided.
2.1.17 Suitable supporting channels shall be provided for cables and cable termination. The
outgoing cables shall have bottom entry unless otherwise indicated. The cable
terminations shall be suitably sized for receiving specified number of cables per
termination. In case the total number of cables entering a particular panel cannot be
accommodated in the cabling compartment, an extension panel shall be added to
the cabling compartment for accommodating extra cables.
2.1.18 Automatic safety shutters shall be provided to ensure the inaccessibility of all live
parts after the breaker/module is drawn out.
2.1.19 Outgoing Motor feeder door shall have control supply switch, Motor space heater
switch, Ammeter, Stop PB, Thermal overload relay reset cord & indication lamp.
2.1.20 Control lyra contact at module end shall be male type while at panel body end shall
be female type so that no live parts is exposed when trolley is racked out.
2.1.21 Clearance and creepage distance shall not be lower than the value specified below
for any parts of the switchgear i.e. switches, fuses, contactors, thermal relays,
outgoing cable connections etc. and also for the bus bars.
a. Min. Clearance between phases - 25 mm.
b. Min. Clearance to earth - 19 mm.
c. Min. Creepage distance to earth - 28 mm.
d. Min. Creepage distance between two live conductors - 28mm
2.1.22 The clearance and creepage as specified above shall definitely be maintained in the
bus bar system. Adding of separators or barriers will not be acceptable in the bus
bar system to reduce the clearance for the value specified above.
2.1.23 In case if the above clearance is not possible to be maintained at the termination
points in the equipments i.e. switches, contactors, thermal relays etc. the phase
insulating barriers or PVC bolt caps shall be provided. All the links or terminals where
clearance is not possible to be maintained should be insulated or taped.
2.1.24 All insulating material shall be non-hygroscopic in nature.
2.1.25 Provision shall be made to route Power and control cables of upper module through
the barrier sheet.

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

2.1.26

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 8 OF 21

Auxiliary bus bars each of minimum size 18-mm2 coppers shall be provided for
following, depending on requirement.
- Panel space heater supply and motor space heater supply.
- Control supply for breaker tripping, closing and indication circuits.
- Control supply for breaker spring charging motors, motor starter control and
indication circuit.
- AC potential supply for energy meters, voltage operated relays etc.
- Tee-off connectors shall be used for distributing auxiliary supply to each vertical
panel. Rubber grommets shall be used for all wire entries to make die entries dust
and vermin proof.
- Provision to hook up of external DC control supply to be provided either in bus PT
panel or bus coupler panel.

2.1.27 All hardware shall be corrosion resistant. All joints and connections of the panel
members shall be made by zinc passivated cadmium plated high quality steel bolts,
nuts and washers
2.1.28 In case of MCC, PDB & LDBs (motor control centers with SFUs & contactor control)
with multi-tier construction, each module section in the cable alley shall be
segregated using non-conducting, fire resistant material (to prevent accidental
falling of tools) over O/G live circuit below. MCC incomers and bus couplers shall
be provided with Air circuit breaker having minimum continuous current rating of
800 Amps.
2.1.29 Danger stickers, Arc hazard labels to be given in breaker cubicle compartment, O/G
section compartment cover, Main bus bar chamber & other locations as per safety
standards.
2.1.30 The safe working distance limits in Breaker cubicle compartment & Outgoing
compartment shall be given along with the Personal protective equipments
proposed.
2.1.31 The maximum height of the operating handle/switches shall not exceed 1900 mm
and the minimum height not below 300mm
2.1.32

Motor starter and switch fuse modules shall not be accommodated at front and rear
of ACB incomer and bus coupler panel.

2.2

Bus Bars

2.2.1

Main bus bars shall be of uniform cross-section throughout the length of the
switchgear and up to the terminals of incomer circuit breaker/switch. The main buses
shall be capable of carrying the rated current and short circuit rating as specified in
datasheet without exceeding the allowable temperature rise, above the specified

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 9 OF 21

ambient temperature.
Auxiliary buses for control shall be of electrolytic copper, adequately sized and
supported. The control bus-bars shall also be insulated.
2.2.2

Phase and neutral bus bar size shall be same.

2.2.3

A horizontal grounding bus having minimum 50 x 6 sq.mm cross section of copper or

otherwise sized to carry current equivalent to the momentary short circuit rating of
the largest circuit breaker assembly shall be provided along the length of the
switchboard.

2.2.4

The maximum operating temperature of busbars and bare joints, at design ambient
temperature shall not exceed 95C for normal operating condition. For silver plated
joints the maximum operating temperature of 105 deg C shall be permissible.

2.2.5

Both horizontal and vertical bus bars, bus joints and supports shall be capable of
withstanding dynamic and thermal stresses of the specified short circuit currents for
1second. The short circuit capacity of the neutral bus bars shall be in line with
IS:13947.

2.2.6

All joint surfaces of Aluminium to copper joints shall be silver / tin plated, alternatively
bimetallic washers may be used.

2.2.7

Interconnections between the main bus bars and individual units shall be made by
using Aluminium/ Copper bus bars of adequate rating. These interconnections of the
vertical bus bars shall be in separate compartment and fully shrouded.

2.2.8

Buses and taps for each feeder shall be rated to carry the maximum rating of the
feeder switch / breaker and not for the feeder current transformer rating.

2.2.9

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

2.2.10 Each bus bar shall be insulated cased throughout with the colour coded heat shrunk
PVC sleeving and joints shall be fitted with insulated shrouds. Bus-bars shall be
adequately supported to withstand the stresses due to short circuits. Bus bar supports
shall be made of high impact, flame resistant, arc resistant, anti-tracking,
self-extinguishing, non-hygroscopic material.
2.2.11

The direction of Main Bus bars shall be marked with Red paint (Painted permanently
on the Rear covers) on the Bus coupler & Bus-riser panel rear covers.

2.2.12 Vertical earth bus shall be provided for earthing of all feeders. Drawout feeders shall
have scraping earthing facility.

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 10 OF 21

2.2.13 All doors and movable parts shall be connected to the earth bus with flexible copper
connections. Use star washers at earthing points.
2.2.14 Removable neutral links shall be provided on feeders to permit isolation of neutral
busbar.
2.3

Air Circuit Breaker (ACB)

2.3.1 ACB shall be fully drawout, air break and stored energy mechanism type. Spring
actuated and gravity operated safety shutters shall be provided for isolating the
busbars and other live parts when the breaker is completely withdrawn and
compartment door is closed. Provision shall be made for manual spring charging
incase failure of electric supply. The motor shall be automatically delinked
(mechanically), once the manual spring handle is
inserted.
Blanking plates shall be provided for each circuit breaker compartments, which would
be used after installation, to cover the opening in the event of taking out the breaker
outside the compartment
2.3.2

ACBs of the same rating wired up as identical scheme shall be interchangeable.

Attachments for special controls shall not be mounted directly on drawout type circuit
breakers to preserve the interchangeability.

2.3.3

ACBs shall have antipumping feature and shall be trip-free.

2.3.4

ACB shall have an interlock such that it shall not close unless the spring is fully
charged. Also shocks, vibrations or failure of springs shall not operate the breaker or
prevent intended tripping.

2.3.5

ACB draw out trolley shall have three positions. The breaker trolley shall remain
inside the cubicle even in the drawout position.
a) Service Position In this position both power and control circuit shall be
connected.
b) Test Position The power contacts shall be disconnected in this position but the
control connection shall not be disturbed, it shall be possible to
close and trip the breakers in this position.
c) Drawout Position Both the power and control shall be disconnected in this
position and breaker removed from the cubicle.

2.3.6

ACB shall be of the shunt trip type, with mechanical indications for Open, Closed,
Service and Test positions of the breaker. Electrical indicating lamps shall be of
the following colours:- Close - Red; Open - Green; Trip - Amber; Spring
Charged - Blue, Trip Circuit Healthy - White. Indicating Lamps shall be LED type,
with engraved lenses cover.

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 11 OF 21

2.3.7

ACB shall have mechanically operated, red coloured, shrouded trip push button.

2.3.8

ACB shall have following interlocks.

(a) It shall not be possible to plug-in a closed circuit breaker.
(b) It shall not be possible to operate a circuit breaker unless it is in fully plugged-in,
test or fully isolated position.

2.3.9

The ACB shall be provided with minimum 4 nos. normally open (NO) and 4 nos.
normally close (NC) potential free, spare auxiliary contacts made available on
terminal strip for purchasers use. If required nos. of spare auxiliary contacts are not
available, an auxiliary relays (not contactor) shall be used to multiply the available
spare auxiliary contact. The contact rating shall be of 10A, 415V, AC and 5A, 110V
DC.
The ACB shall be also provided with operation counter.

2.3.10 Circuit breaker trip and closing coils in case of electrically operated breakers and trip
coil in case of mechanically operated breakers and circuit breaker indication shall be
suitable for satisfactory operation in a control supply system indicated in data sheets
& SLD.
2.3.11 The breaker trolley shall remain inside the cubicle even in the draw out position.
There shall be distinct overall door for the breaker compartment.
2.3.12 The earth connection shall make before the main power control contacts make and
break after the power/ control contacts are disconnected. Earthing connection through
a plug and socket connection shall not be acceptable.
2.3.13 Incomer & bus coupler breaker shall be mounted in a single tier execution. However,
the outgoing ACBs can be mounted in two tier execution. All the meters,
indication lamps, etc shall be mounted on the same front panel only.
2.3.14 All the breaker ratings shall be in-panel ratings with design ambient temperature as
specified.
2.4

Air Break Switches

2.4.1

Air break switches shall be heavy duty, load break, fault make type conforming
the latest applicable Indian Standard. It shall be suitable for AC23 duty.

2.4.2

Each switch shall be interlocked with associated compartment door such that:
(a) It shall be possible to open the door only when the switch is in OFF position.
(b) It shall not be possible to close the switch with door open.
Defeat interlock facility shall also be provided to defeat the above interlocks.

2.4.3

Solid links whenever used to connect switch and fuses & live parts of switch shall be

to

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 12 OF 21

shrouded.
2.4.5

All SFU switches, bus side sections shall be shrouded totally with transparent
insulating material of sufficient thickness (From all sides)

2.5

Fuses

2.5.1

Fuses generally shall be of HRC cartridge fuse-link type with rupturing capacity of
80KA at 440V with visible indication to show that they have operated.

2.5.2

Power Fuses shall be pressure fitted type to ensure good line contact.

2.5.3

It shall be possible to handle fuses during off load conditions with full voltage
available on the terminals. Wherever required fuse pullers shall be provided. The
fuses shall be located in the modules to permit insertion of fuse pullers and
removal of fuse links without any problem.

2.6

Contactors

2.6.1

Motor starter contactor shall be of the electromagnetic type rated for AC3 duty
unless otherwise specified, and shall have silver plated copper contacts. Each motor
starter contactor shall be with 2 NO and 2 NC auxiliary contacts.
Contacts shall be of double break, non-gravity, non welding type.

2.7

Starters

2.7.1

Direct-on-line/Automatic Star-Delta Starter shall be suitable for Class AC - 3

utilisation category.

2.7.2

Reversing starters shall be suitable for Class AC-4 utilisation category.

2.7.3

For re-acceleration duty, timers shall have adjustable setting of 0-60 secs. Timers
for auto-transfer schemes shall be with suitable time ranges.

2.7.4

Items constituting starters shall be chosen suitably to achieve TYPE-2 co-ordination.

2.7.5

All identical starter modules shall be interchangeable.

2.8

Thermal Overload Relay

2.8.1

Bimetallic thermal over load relays shall be provided for protecting the motors.

2.8.2

Bimetal relays shall be manually reset type with the reset push button with chord
brought out on the front of the panel. The reset push button with chord shall be
capable of being operated without opening the compartment door.

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 13 OF 21

2.8.3

Bimetal relays shall be positive acting ambient temperature, compensated type with
adjustable setting range.

2.8.4

Bimetal relays shall have built-in single phasing prevention feature which operate
even with 50% rated current at the time of single phasing.

2.9

Numerical Relays
An independent Numerical relay to be provided for Auto changeover schemes
(Protection & ATS schemes shall not be provided in a single relay). The required
information shall be collected from Other Incomer relays & bus relays through
potential free contacts.
For higher rating motors all protection relays shall be microprocessor based numerical
type providing all the required protection parameters in the same relay. It shall be
programmable type & shall be provided with RS-485 port at the output for serial
communication & in addition RS-232 port for taking individual data in laptop.
Alphanumeric display shall be provided on the relay to display various parameters.
For protection details refer SLD & data sheets. It shall be vendors responsibility to
select suitable relay for the motor feeders, so as to match the motor characteristics, to
be furnished by purchaser.
Numerical Relays shall have following features:
i) LCD display unit
ii) Programmable LEDs(for On/Off/Fault/Breaker Spring Charged/ Relay Available &
Relay Out of Service etc), Keypad for browsing and setting the relay parameters.
iii) Wide current adjustment range
iv) Test and Reset facilities
v) Starting delay time setting
vi) Required number of binary input/outputs based on scheme.
vii) Fault diagnostic features with time synchronization. i.e. Fault record, Event
Record.
viii) Event record with minimum 1ms resolution
All protective relays shall be suitable for flush mounting, and fitted with dust tight
covers.

2.10

Indicating Lamps, Push Buttons and Control Switches

2.10.1 Indicating lamps shall be LED type, low watt consumption. Bulbs and translucent
lamp covers shall be easily replaceable from the front. Every motor feeder shall be
given electrical
lamp indication for ON, OFF and TRIPPED by means of Red, Green and Amber

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 14 OF 21

coloured lamps.
2.10.2. Push buttons shall be momentary type, rated for 10A at 240V AC and 5A (inductive
breaking) at 110V DC fitted with self reset, 2 NO and 2 NC contacts. Each motor
feeder shall have STOP push button on the module red in colour. STOP PB shall
be mushroom head, stay-put, turn to release type.
2.10.3

The breaker control switch (Trip-Neutral-Close) shall be spring return rotary type,
unless otherwise specified and provided with pistol grip type handle. The control
switch for the circuit breakers shall be additionally fitted with lost motion devices and
sequencing devices, if required.

2.10.4 The selector switches shall be stay put rotary type and shall be provided with oval
shape handles.

2.11

Moulded Case Circuit Breakers (MCCB)

2.11.1 MCCBs in AC circuits shall be of triple/four pole construction arranged for

simultaneous three/four pole manual closing and opening and for automatic
instantaneous tripping on short circuit. If indicated in Data Sheet, power closing
device for remote operation may be provided. Operating mechanism shall be quickmake, quick-break and trip-free type. The ON, OFF and TRIP positions of the MCCB
shall be clearly indicated and visible to the operator when mounted as in service.
Suitable operating handle shall be provided on the front of the panel.
2.11.2 MCCBs shall be capable of withstanding the thermal stresses caused by overloads
and locked rotor currents of values associated with protective relay settings of the
motor starting equipment and the mechanical stress caused by the peak short-circuit
current of value associated with the switchgear rating. The maximum tripping time
under short circuit shall not exceed 20 milliseconds.
2.11.3 Under-voltage release, Overload inverse time & instantaneous release shall be
provided if specified in Data Sheet.
2.11.4 MCCB shall be provided with minimum 1 NO + 1NC auxiliary contacts.
2.12

Instruments

2.12.1

Indicating Instruments, Instrument Switches, Indicating Lamps and Protective Relays

shall be mounted on the front side of panels of the appropriate cubicle.

2.12.2

All the Ammeter & Voltmeter shall be 90 deflection type, unless otherwise specified.
Size of Ammeter & Voltmeter on Incomer/Outgoing breaker module shall be
96 x 96mm while on motors and other feeder it can be 72 x 72 mm. Class of Accuracy

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

DOC NO. : 6261-N-133A

JOB NO.: 6261

DHT PROJECT

PAGE NO 15 OF 21

of meter shall be 1.0.

2.12.3 All auxiliary equipment such as shunts Transducers, CTs, PTs, etc. as required shall
be included in the supply of the switchboard.
2.12.4 All AC ammeters and voltmeters shall be of moving iron type. Ammeters for motor
feeders shall have a non-linear compressed scale at the end to indicate motor starting
current and red mark for the full load current.
2.12.5

Each incomer feeder shall be provided with a voltmeter connected between R, Y, B

phases in line side and indicating lamps (LED type) shall be provided on bus side.

2.13

Miniature Circuit Breakers (MCB)

2.13.1 Miniature Circuit Breakers used in control circuits, shall comply with the
requirements of applicable standards,
2.13.2 MCB shall conform to IS: 8828 and shall be duty category M-9
2.13.3

It shall be provided with overload and short circuit protective devices in a heat
resistance housing.

2.13.4

Type test certificate for short circuit rating and current time tripping curve shall be
furnished along with the offer.

2.14

Instrument Transformers

2.14.1 Current Transformer

2.14.1.1 Current transformers shall generally conform to IS:2705. The short time rating shall
be equal to that of the breaker or switchboard. They shall be mounted on the
stationery part of the switchgear. The CT ratings shall be as shown in the data
sheet/SLD.
2.14.1.2 All terminals except wiping/sliding type control terminals shall be shrouded with
plastic covers to prevent accidental contact. Clip-on type shrouded terminals shall be
provided for direct termination.
2.14.1.3 All current transformers shall have both secondary leads terminated on shorting type
terminal blocks. All leads shall be properly terminated with compression lugs and
identified. Also test links shall be provided in both secondary leads of the CTs to
easily carry out current and phase angle measurement tests. The polarity of the C.T.
shall be clearly marked.
2.14.1.4 All current transformers shall be earthed through a separate earth link on the

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 16 OF 21

terminal block to permit easy measurement of current transformer insulation

resistance. Earthing of the CT terminals shall be connected to earth busbar and not
directly to body of switchboard.
2.14.1.5 Current transformers shall be cast resin insulated type for feeders rated above 200A.
2.14.1.6 Minimum CT burden shall be 15VA.
2.14.1.7 Current transformers for instruments shall have an accuracy class 1.0 and accuracy
limit factor less than 5.0. However accuracy class of 3.0 is acceptable for CTs meant
for remote ammeters.
2.14.1.8 The current transformers in breaker feeders shall be capable of with standing the
applicable peak momentary short circuit and the symmetrical short circuit current for
1.0 second.,
2.14.2 Voltage Transformers
2.14.2.1 Each set of potential transformers and its protective fuses shall be assembled in
Separate compartment and so arranged that the unit can be withdrawn from the
operating position. Primary fuses shall have a
rupturing capacity equal to the
rupturing capacity rating of the associated switchgear. Fuses shall be provided in
each sub circuit.
2.14.2.2 Unless otherwise specified, the minimum performance requirements of voltage
transformers are as follows :Protective VTs - 100 VA per phase and accuracy class 3P
Measuring VTs - 100 VA per phase and accuracy class 0.5
Dual purpose VTs - 100VA and dual accuracy class 3P/0.5 for protection and
metering respectively.
All the secondary windings of voltage transformers including open delta windings shall
be rated for 110V per phase.
3
Voltage transformers shall have a continuous overvoltage factor of 1.2 and short time
over voltage factor of 1.5 for 30 seconds in case of effectively earthed system
2.14.2.3 The terminals of V.T. secondary and tertiary windings which are required to be
connected to earth shall be earthed through an isolating link.
2.15

Internal Wiring

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 17 OF 21

2.15.1 Internal wiring shall be carried out with 1100/650V grade, PVC insulated, FRLS type
multistrand copper conductor wires with minimum size of 4 sq.mm. for power circuits
and 2.5 sq.mm for control circuit
2.15.2 All control wiring shall be enclosed in plastic channels or neatly bunched together.
Horizontal wire way shall be provided for inter-panel wiring.
Ferrules for identification shall be provided according to the wiring diagram. The
ferrules shall be of yellow colour and engraved with black numbers and shall be fitted
to both ends of each wire.
2.15.3 Spare auxiliary contacts of all equipment shall be wired upto the terminal block.
Spare or Unassigned modules shall be complete with internal wiring.
2.15.4 Flexible multistrand copper cables shall be used for wiring inside the module with
FSU upto 125 Amp. Above this rating copper flat of suitable size shall be used.
2.15.5 Barrel type ferrules shall be used for all wiring. (Information to be printed on a single
sleeve). All trip wiring shall be identified with Red ferrule.
2.16

Terminal Blocks

2.16.1 Terminals shall be shrouded. Terminal blocks shall be grouped depending on the
circuit voltage.
Different voltage groups of terminal blocks shall be segregated.
A minimum 100mm clearance between two sets of terminal blocks shall be kept.
2.16.2 Terminals shall be adequately rated to carry the current of associated circuits. The
minimum rating of the terminal block shall be 10A. Minimum of 20% spare terminal
shall be provided. Terminals shall be numbered as per the wiring diagram.
2.16.3

Control terminals for external connections shall be suitable for terminating at least
two conductors each of 2.5 sq.mm. size.

2.16.4

Door mounted equipment shall have ring type lugs only. Pin type lugs are not
acceptable.

2.16.5

Each wire shall be terminated in separate terminals. Termination of two wires at a

single terminal shall be avoided.

2.17

Control Supply

2.17.1 Control supply for contactor control, indication circuit, and motor space heater shall be
240V AC & shall be tapped from Ph-N of individual module or from control
transformer as specified in data sheet. Minimum rating of control transformer for each

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 18 OF 21

bus section of PMCC/MCC shall be 2000VA. Control supply transformer modules with
burden higher than 2.5 kVA may be in fixed execution. Each transformer shall be
sized for the entire switchboard
Manual changeover switch shall be provided for control transformers in case
switchboard has two bus section & bus tie.
2.17.2 Control supply for breaker tripping, closing & indication circuits shall be as specified in
data sheet shall be provided at two points in incomer and bus-coupler panel. Further
distribution of control supply shall be in contractors scope.
2.17.3 Breaker spring charging Motor shall be rated for 110V DC and/or 240V AC or as
specified in data sheet, and shall operate satisfactorily at all values of rated voltage
between 80% to 110%. Spring charging motor shall be universal type, Operable on
AC or DC control supplies.
2.17.4 Supply to panel space heater and panel socket outlet shall be 240V AC.
2.17.5 Power supply to meters shall be 240V AC.
2.17.6 AC & DC control wire colors shall be different to avoid mix-up. Earth wire shall be
Green.
2.18

Name Plates and Rating Plates

2.18.1 Name plate with engraved letters shall be provided for both front and rear side of
switchgear, indicating the designation of each feeder cubicle and serial number of
cubicles. All front & rear covers shall have Panel numbers & Service Tag as given
name plates Riveted on the respective Module covers / Doors.
2.18.2 Non-corrosive name plates shall be manufactured in black anodized aluminium sheet
and engraving shall be with white letters. The name plates/labels shall be held in
position by self tapping screws.
2.18.3 All devices mounted inside the cubicle and instruments, etc. shall be identified by
marking the device numbers inside cubicle, as per the wiring drawing.
2.18.4 The switchgear shall have a rating plate fixed to the non-removable part of the
enclosure.
2.18.5 All electrical equipment like VTs, CTs, CBs, etc and all other electrical devices shall
be provided with rating plate made of stainless steel which can be easily seen.
2.18.6 The rating plates shall give all the relevant information as specified in relevant
standards.

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 19 OF 21

2.18.7

Danger boards, caution boards, operating instruction plates, shall be fixed to each
switchgear cubicle as per the Standard Engineering Practice and regulations.

2.19

Painting

2.19.1

All sheet steel work / enclosure shall be painted using POWDER COATING.

2.19.2 The switchboard shall be painted with shade 631 as per IS 5 on interior and exterior
unless otherwise specified in the data sheet.
2.19.3 All other parts such as handles, levers and fasteners that are not stainless steel shall
be tin, cadmium, nickel or chrome plated.
3.0

INTERFACES WITH DCS.

3.1

Provision shall be made in MV Switchboards for signal interface with DCS as detailed
below:
a) Running signal of all motors
b) Fault signal of all motors
c) Motor stop.
d) Start / Stop command from DCS/PLC.

3.2

Additional remote annunciation to DCS for Auto / Manual position of Auto / Manual
selector switch shall be provided wherever specified.

3.3

Commands from DCS in the form of Auto start, Auto Stop & Start Permissive shall
be implemented in the wiring schematics of the motor feeders wherever applicable.
All external interlocks / start / stop contacts coming from DCS/PLC shall be potential
free.
Voltage induction / Voltage build up due to capacitance effect longer cable length in
case of AC control supply should be suitably taken care.

3.4

Marshalling compartment (at least one no. on each bus section of MCC) shall be
provided for interface with DCS / PLC.

4.0

INTERFACE WITH MMI / SCADA

The switchboards shall be hooked up with MMI / SCADA system. As per
SCADA/ECS specification 6261-N-201 and its attachment
Separate Digital & Analogue Output compartment on each bus section for interfacing
with SCADA system shall be provided in each switchgear.

Also separate compartment shall be provided for the following .

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 20 OF 21

A. All Running indication & Trip indication going to DCS/PLC shall be wired in
separate compartment.
B. Internal wiring for Auto changeover & other scheme.
C. All Digital output contacts coming to Switchgears.
Approach & sufficient clearances shall be provided to Access/remove/fix any wire
without any difficulty / disturbing other circuits.
5.0

INSPECTION AND TESTING

5.1

During fabrication, switchgear shall be subject to inspection by PMC/ Owner or by an

agency authorized by the owner. Manufacturer shall furnish all necessary information
concerning the supply to PMC /owners inspectors.

5.2

Routine tests shall be carried out at works in the presence of PMC/Owners

representatives, as per relevant IS/IEC Standards.

5.3

Contractor shall furnish type and routine test certificates for all bought out
components for the switchgear, as per relevant standards.

5.4

Test certificates for type test carried out on similar equipment of identical design, shall
be submitted along with the offer, including Oscillographic test records for closing and
tripping timings of the breakers.

5.5

Type tests, if specified shall be performed. Short circuit test shall be performed at
CPRI or equivalent approved testing agency and heat run test may be performed at
manufacturers works. Heat run test shall be performed at least on one incomer and
two outgoing vertical panels of the ordered switchboard.

6.0

DRAWINGS AND DOCUMENTS

6.1

Contractor shall prepare and submit to the Owner before completion of fabrication
and assembly of the equipment, prints of following for Owners approval.
(a)
(b)
(c)
(d)
(e)

(f)

Front and rear view plan and sections of switchgear.

Complete assembly drawing showing details of bus, connections, terminals and
other equipment.
Bill of material.
Schematic wiring diagrams for switchgear control, protection and metering
including CTs and PTs with polarity markings.
Complete wiring and interconnection diagrams showing connection for all
devices, such as relays, meters, switches, transformers etc. and terminal strips
(for information).
Termination schedule for each switchgear cubicle for interphasing and interpanel
wiring (for information).

< Security Level 2 >

ENGINEERING SPECIFICATION
MV SWITCHGEAR
TOYO ENGINEERING INDIA LTD.

ISSUED DATE : 18/04/2009 A

(g)
(h)
6.2

JOB NO.: 6261

DHT PROJECT

DOC NO. : 6261-N-133A

PAGE NO 21 OF 21

Foundation plan showing floor plan and openings for power cables and control
cables.
Busbar sizing calculations.

Contractor shall furnish following documents & drawings for information.

(a)
(b)
(c)
(d)
(e)
(f)
(g)

Loading data (weight)

Wiring Diagram
Spare Part list (commissioning and 2 years operational spares)
Special Tools list
Inspection & Test record
Installation, Operation & maintenance manual
Type, rating & details of all accessories along with leaflets.

6.3

Final drawing/As built drawings shall be furnished after the equipment is

commissioned incorporating all changes along with reproducible for Owners records.

6.4

Manual for erection, maintenance, testing and commissioning of all equipment shall be
furnished.