SCJ (For Discussion)

REPORT ON
Electrical Assessment ( Rough for Discussion)

Our Ref: PQA/PP/SO/0013/19-20 (220120R1)
At
M/s. S.C.Johnson Products Pvt Ltd,

Unit6, Bamuniamaidan Industrial Area,
Guwahati- 781021. India.
Auditor : N.Prabakaran
Certificate no: AEA 278,
Mobile no: +919980600588
M/s VERTIV ENERGY PVT LTD,

1st floor, Nadathur Place, Plot No. 23, 16th Cross Road, 8th
Main Road,3rd Block, Jayanagar, Bengaluru,
Karnataka 560011, India.
(Headquarter Address: Plot no. C-20, Road no-19, Wagle Estate, Thane-Maharashtra-400604)
0.0 Table of Contents:
1.0 Introduction…………………………………………………………….…....02
2.0 Site Details………………………………………………………...............03
3.0 Locations of Monitoring…………………………………………………...04
4.0 Waveform and Graph Analysis…………………………………………..05
5.0 List of Abbreviations Used………………………………………………..15
Services: Power and Air audit, Harmonic Study, IR Scan, Facility Walkthrough, Energy Audit, Short 1
Circuit Co ordinations, ARC Flash analysis etc.
1.0 Introduction:
The Electrical Assessment at M/s S.C.Johnson Products Pvt Ltd, Unit6,
Bamuniamaidan Industrial Area,Guwahati- 781021, India is to minimize the ARC
Flash Incidental Energy in the work place as per earlier ARC FLASH Audit report.
Definition of Electrical Safety as per NFPA 70 E
NFPA 70E requirements for safe work practices to protect personnel by reducing
exposure to major electrical hazards. NFPA 70E helps companies and employees
avoid workplace injuries and fatalities due to shock, electrocution, arc flash, and arc
blast, and assists in complying with OSHA.
The Importance of Electrical Safety.

Almost everything in a workplace setting today operates on electricity. ... This
passage of electricity can cause great pain, burns, and even fatalities. To protect
workers, the Electrical installations should have necessary appropriate protections to
protect the human, equipment and ensure that the work environment is safe and free
of electrical hazards.
This report follows Indian standards and relevant international standards of IEEE,
IEC, NFPA to minimize the ARC Flash incidental energy level for safe operation.
Prevailing Electrical installations are installed in chemical handling places and have
more deviations with respect to safety and not comply with standards. The deviations
and the recommendations are given in the respective chapters.
Click here to go to Table of content
2.0 Standards for Evaluation:
M/s Vertiv Energy Private Limited subscribes to the industry wide standards used for
the evaluation of the electrical systems for computer installations, which include but
are not limited to: Institute of Electrical and Electronic Engineers Standard 1100-2005,
“Powering and Grounding Electronic Equipment”, (Emerald Book)
The standards conform to the requirements of the National Electrical Code (NFPA 70).
References:
1) IEEE 1100 :-1999 & 2005 Emerald Book
2) IEEE 446 :- 1995 Orange Book
3) IEEE 142 :- 1991 Green Book
4) IER 1946 Rules and Regulations
5) OSHA Standard for Human safety
6) IEC60601
7) IS 8623
Disclaimer: The Electrical Assessment is carried out at M/s. S.C.Johnson Products

Pvt Ltd, Unit6, Bamuniamaidan Industrial Area, Guwahati- 781021. India.
The comments and analysis are arrived based on the data collection and the
information collected from the client during the audit period. Any modifications done in
the facility after the audit period are not covered in this report. It is essential to take
into consideration, the effect of the additional loads and their interference in the
existing power distribution network. The recommendations are based on International
Standards and Guidelines and are applicable to any load in industry environment.
Further the retaining period of this record is for six months only.
3.0 Study on Electrical Demand:
3.1 Plant Load Analysis:
According to the Electricity bill, the contracted demand of the industry is 535 KVA
and the contracted load is about 630KW. The billable Demand is either actual
demand or contract demand whichever is higher. The Actual demand is maximum
about 286 KVA only. Consequently, the recurring losses for the industry is about 5.6
lac per annum by extra paying the money to the Electricity board Assam. The
Electricity bill details and the analysis is as below.
Contracted Actual Billable Excess billable Loss if 300 KVA is

Month Demand Demand Demand Demand contract Demand
in KVA in KVA in KVA in KVA in Rs
18-Jan 535 165.6 535 369.4 47000
18-Feb 535 159.2 535 375.8 47000
18-Mar 535 166.4 535 368.6 47000
18-Apr 535 164 535 371 47000
18-May 535 158.4 535 376.6 47000
18-Jun 535 164 535 371 47000
18-Jul 535 173.6 535 361.4 47000
18-Aug 535 287.2 535 247.8 47000
18-Sep 535 280 535 255 47000
18-Oct 535 183.2 535 351.8 47000
18-Nov 535 166.4 535 368.6 47000
18-Dec 535 161.6 535 373.4 47000
19-Jan 535 152.8 535 382.2 47000
19-Feb 535 156 535 379 47000
19-Apr 535 230.4 535 304.6 47000
19-May 535 216 535 319 47000
19-Jun 535 224 535 311 47000
19-Jul 535 232 535 303 47000
19-Aug 535 241.6 535 293.4 47000
19-Sep 535 188.8 535 346.2 47000
19-Oct 535 164 535 371 47000
19-Nov 535 164.8 535 370.2 47000
Form the above, the plant load is maximum of 286.4 KVA. Say 300 kVA. The
maximum required Electrical infra for the above load is 300 KVA. To save the
recurring expenses of 5.6 lakhs per annum, it is recommended to go for surrender of
excess demand.
3.2 Study on outdoor EB Structures and Transformers:
3.21 Outdoor Electricity Board Yard:
The industry is receiving 11 KV Electricity supply from Assam Electricity board
through two-part tariff metering. The 11-kV supply is step down to 433v by installing
two numbers of Transformers, rating of 500 KVA and 315 KVA.
11KV, XLPE 185 Sq. mm cable is laid from Electricity Board two pole structure which
is installed in back side of DG room and connected to the Electricity board metering
unit installed in the two-pole structure of the yard. Further the supply is connected to
two numbers of Transformers through drop out fuses and one more two pole
structure.
11 KV EB Line Two Pole Structure

XLPE Cable
Deviations:
Tree Branches are nearby the live lines, eventually there is possibility for short circuit
when the branches touch the line.
Rusted MS Supports are corroded and loos it strength to support for 11KV lines
11KV cable is inserted into PVC Pipe and there is no support
No lightening arrester installed.
No 11KV Breaker for CTPT Protection
3.22 Outdoor Transformers two pole structures:
Two numbers of Transformers rating of 500 KVA and 315 KVA are installed. There is
no record for 500 kVA installation and 315 KVA is installed on 2006. Both the
transformers are installed in outdoor. These transformers have no OLTC.
Fig 2 shows the outdoor yard; there is no High voltage breaker control to isolate the
fault within 1 sec. the calculated ARC FLASH LEVEL is above 40cal/cm2 which is
dangerous for Human and concern on Human safety. The ARC Flash Category is 4
The Air break switch is installed to isolate the Transformer and the mounting height
is nearer to 0.6 mtr. Eventually It is not easy to isolate the Transformer. It should be
1.06 mtr as per IER 1956.
The 315 KVA & 500 KVA Transformer Plinth height from the ground level is 1.0 mtr
and there are some chances for accident while doing maintenance and it should be
2.75 mtr from ground level as per IER 1956. Further the side wall clearance is also
lesser than 2.75 mtr.
The AB Switch (Air break switch) should be always in lock and key for safe
operation. There is no maintenance practice adopted in the structure to clean
regularly and structure supports are corroded and in weak conditions.
The lightening Earth bus connection should be supported by insulator as per
standard. And other earth bus should be supported/clamped.
Considering the above derivations with respect for modifications to comply rules and
regulations, it is recommended for Indoor units with all protection to minimize the
ARC FLASH category to NIL.
3.23 : 315 KVA Transformer 11Kv/433v:
The below picture shows the 315 KVA Transformer installation.
315 KVA Transformer
Fig 3
The secondary terminal of the Transformer is in open condition. As per IER 1956 the
live terminal should be in closed condition to avoid bird fault and safety operation.
Oil leak in the Transformer and spread out in the floors. Consequent upon this, there
is chances for fire accident, snake enter the yard to lead short circuit etc.
The cable and the Earth bus connections are not supported. It should be supported
by proper clamp.
Transformer has no OLTC and it could not regulate the voltage to meet the
requirement.
MCCB control is installed at the secondary @ 433v side, the operational height is
very low. The operating handle should be 1.6 mtr.
The load on the Transformer is less about 38% ( 120 KVA) as per PQA Audit Study
To do the modifications in the existing arrangements the proposed arrangement is in
the indoor arrangement in subsequent chapters.
3.24 : 500 KVA Transformer 11Kv/433v:
The below picture shows the 500 KVA Transformer installation.
500 KVA Transformer

Fig 4
The cable and the Earth bus connections are not supported. It should be supported
by proper clamp.
Transformer has no OLTC and it could not regulate the voltage to meet the
requirement.
ACB control is installed at the secondary @ 433v side, the operational height is very
low. The operating handle should be 1.6 mtr.
The load on the Transformer is very less about 9% (44KVA)
To do the modifications in the existing arrangements the proposed arrangement is as
follows.
3.25 : Recommendations
Prevailing installation needs more modifications to comply safety standards and safe
operations. Further the load of the industry is 300 KVA and one number of New 500
KVA with OLTC Transformer cater the entire factory demand.
Secondly one number High voltage breaker is required for 11 KV control to minimize
the ARC FLASH Category. The entire installation is proposed to install in the Indoor
hence the fire hazard is zero and the ARC Flash Category Level in cal/cm2 is also
nearer to zero.
500KVA Transformer Specifications:
TECHNICAL SPECIFICATION FOR INDOOR TYPE DISTRIBUTION
TRANSFORMER 500KVA, 11 kV/433, ONAN Indoor type with OLTC
This specification covers design, engineering, manufacture, assembly, stage testing,

inspection and testing before supply and delivery at site of oil immersed, naturally cooled
3 phase 11 kV/433, Delta Star transformers for indoor use.
It is not the intent to specify completely herein all the details of the design and
construction of equipment. However, the equipment shall conform in all respects to high
standards of engineering, design and workmanship and shall can perform in continuous
commercial operation, in a manner acceptable to the purchaser, who will interpret the
meanings of drawings and specification and shall have the power to reject any work or
material which, in his judgment is not in accordance therewith. The offered equipment
shall be complete with all components necessary for their effective and trouble free
operation. Such components shall be deemed to be within the scope of bidder’s
supply irrespective of whether those are specifically brought out in this specification
and / or the commercial order or not.
The transformer and accessories shall be designed to facilitate operation,

inspection, maintenance and repairs. The design shall incorporate every precaution
and provision for the safety of equipment as well as staff engaged in operation and
maintenance of equipment.
The materials shall conform in all respects to the relevant Indian/International

Standards, with latest amendments thereof unless otherwise specified herein. Some of
them are listed below:
Indian Title International and
Standard Internationally
recognised
standards
IS -2026 Specification for Power Transformers IEC 76
IS - 1180 Indoor Distribution Transformer
IS 12444 Specification for Copper wire rod ASTM B-49

IS-335 Specification for Transformer Oil BS 148, D-1473,
D-1533-1934
IEC Pub 296
IS - 5 Specification for colors for ready mixed paints
IS - 104 Ready mixed paint, brushing zinc chromate, priming
IS – 2099 Specification for high voltage porcelain bushing
IS - 649 Testing for steel sheets and strips and
magnetic circuits
IS - 4257 Dimensions for clamping arrangements
for bushings
IS - 7421 Specification for Low Voltage bushings
IS - 5484 Specification for Al Wire rods ASTM B - 233
IS - 9335 Specification for Insulating Kraft Paper IEC 554
IS - 1576 Specification for Insulating Press Board IEC 641
IS - 6600 Guide for loading of oil Immersed Transformers IEC 76
IS - 2362 Determination of water content in oil for
porcelain bushing of transformer
IS - 6162 Paper covered Copper conductor
IS - 6160 Rectangular Electrical conductor for electrical
machines
IS - 5561 Electrical power connector
IS - 6103 Testing of specific resistance of electrical
insulating liquids
IS - 6262 Method of test for power factor and dielectric
constant of electrical insulating liquids
IS - 6792 Determination of electrical strength of insulating oil
IS - 10028 Installation and maintenance of transformers.
Material conforming to other internationally accepted standards, which ensure equal or

better quality than the standards mentioned above, would also be acceptable. In
case the bidders who wish to offer material conforming to other standards, the bidder
shall clearly bring out the salient points of difference between the standards adopted
and the specific standards in relevant schedule.
SERVICE CONDITIONS:
The Distribution Transformers to be supplied against this Specification shall be

suitable for satisfactory continuous operation under the following climatic conditions
as per IS 2026 (Part - I) to suitable for the location of ASSAM.
Specification of 500 KVA Transformer.

Sl.No. Item Specifications
500KVA, 11Kv/433v with OLTC in buit HV

& LV cable boxes suitable for Indoor
application and its complete auxiliaries
1 System voltage (max.) 12 kV
2 Rated voltage HV 11 kV
3. Rated voltage LV 433 V
4. Frequency 50 Hz +/- 5%
5 No. of Phases Three
6 Connection HV Delta
7 Connection LV Star
8. Vector group Dyn-11
9. Type of cooling ONAN
10 Auxiliaries Conservator tank, Explosion vent,

Marshall box, Buchloz relay and
other standard auxiliaries
11 Transformer offline Tap setting (+) 10.0 % to (-)10.0 % in steps of
1.25%.
12 ON Load tap changer Copper windings
Range of taping + 5% to - 15% in
equal steps of 1.25% each on HV
winding.
13 Remote Tap Changer Control (RTCC) 1 set
14 ONLINE/OFF LINE BYPASS Arrangements in 1set along with OLTC
case of failure of OLTC
15 Marshall box with complete wiring 1set
The core should GRGO Materials, having property of low loss and withstand Voltage
Harmonics up to 5% and current Harmonic about 10%, coated with hot oil proof
insulation, steel laminations, bolted together & vibration or noise. The core shall be
stress relieved by annealing under inert atmosphere if required. The complete design of
core must ensure permanency of the core loss with continuous working of the
transformers. The value of the maximum flux density allowed in the design and grade
of lamination used shall be clearly stated in the offer.
The transformers core shall be suitable for over fluxing (due to combined effect of
voltage and frequency) up to 12.5% without injurious heating at full load conditions and
shall not get saturated. The bidder shall furnish necessary design data in support of this
situation.
No-load current shall not exceed 3% of full load current and will be measured by
energising the transformer at 433 volts, 50 Hz on the secondary. Increase of voltage of
433 volts by 12.5% shall not increase the no-load current by 6% (maximum) of full load
current.
WINDINGS Material:
HV and LV windings shall be wound from Super Enamel covered /Double Paper covered,
copper conductor/ foil for 500 kVA Indoor transformer
The winding construction of single HV coil wound over LV coil is preferable.
Inter layer insulation shall be Nomex /Epoxy dotted Kraft Paper.
Proper bonding of inter layer insulation with the conductor shall be ensured. Test for
bonding strength shall be conducted.
Dimensions of winding coils are very critical. Dimensional tolerances for winding
coils shall be with in limits as specified in Guaranteed Technical Particulars (GTP
Schedule I).
Current density for HV and LV winding should not be more than 2.8 Ampere per sq mm
for copper and 1.6 Ampere per sq mm for Aluminium Conductor.
The core/coil assembly shall be securely held in position to avoid any movement
under short circuit conditions.
Joints in the winding shall be avoided. However, if jointing is necessary the joints shall
be properly brazed and the resistance of the joints shall be less than that of parent
conductor. In case of foil windings, welding of leads to foil can be done within the
winding.
TAPS:
Tapping shall be provided on the higher voltage winding for variation of HV voltage
within range of (+) 10.0 % to (-)10.0 % in steps of 1.25%. b. Tap changing shall be
carried out by means of an externally operated self-position switch and when the
transformer is in de-energised condition. Switch position No.1 shall correspond to the
maximum plus tapping. Each tap change shall result in variation of 1.25% in voltage.
Provision shall be made for locking the taping switch handle in position. Suitable
copper anodised plate shall be fixed for tap changing switch to know the position
number of tap. c. There will be a provision to bypass the OLTC in case of its failure
and manual taping can be done during failure of OLTC.
On Load Tap changers (OLTC) are the most important equipment used to regulate
Voltage of transformer for changing the tap of a winding (to vary effective
transformation ratio of the transformer) whilst, the transformer is energized or is on
load. Performance requirements of these OLTCs for use in transformers and their
routine and type tests are described in IEC 60214-1.
Remote Tap Changer Control (RTCC) is a conventional equipment to control the

output of the Transformer from the OLTC unit fitted in the transformer. The desired
voltage will be achieved accordingly by controlling the OLTC with respect to the tap
position through RTCC system.
The insulating oil shall comply with the requirements of IS 335 or BS 148. Use of
recycled oil is not acceptable. The specific resistance of the oil shall not be less than 2.5
X1012 ohm-cm at 27 0C when tested as per IS 6103.
Oil shall be filtered and tested for break down voltage (BDV) and moisture content
before filling. The oil shall be filled under vacuum. The design and all materials and
processes used in the manufacture of the transformer, shall be such as to reduce to
a minimum the risk of the development of acidity in the oil.
CABLE BOXES:
HV terminations are to be made through cables the transformer shall be fitted with
suitable cable box on 11 kV side to terminate one 11kV/ 3 core aluminium conductor
XLPE cable up to 185 sq. mm. For LT 433v side the box should be suitable to terminate
3x300 sq mm cable. HT Cable box so as to prevent the ingress of moisture into the box
due to rain water directly falling on the box.
TERMINAL MARKINGS:
High voltage phase windings shall be marked both in the terminal boards inside the tank
and on the outside with capital letter 1U, 1V, 1W and low voltage winding for the same
phase marked by corresponding small letter 2u, 2v, 2w. The neutral point terminal
shall be indicated by the letter 2n. Neutral terminal is to be brought out and connected
to local grounding terminal by an earthing strip.
The following standard fittings shall be provided :

Rating and terminal marking plates, non-detachable.
Earthing terminals with lugs - 2 Nos.
Lifting lugs for main tank and top cover
Terminal connectors on the HV/LV bushings (For bare terminations only).
Thermometer pocket with cap - 1 No
Air release device
HV bushings - 3 Nos.
LV bushings - 4 Nos.
Pulling lugs
Stiffener
Radiators - No. and length may be mentioned (as per heat dissipation calculations)/
corrugations.
Arcing horns or 9 kV, 5 kA lightning arrestors on HT side - 3 No.
Prismatic oil level gauge.
Drain cum sampling valve.
Top filter valve
Oil filling hole having p. 1- ¼ ‘’ thread with plug and drain plug on the conservator.
Silicagel breather
Base channel 75x40 mm for up to 100 kVA and 100 mmx50 mm above 100 kVA, 460
mm long with holes to make them suitable for fixing on a platform or plinth.
4 No. rollers for transformers of 200 kVA and above.
Pressure relief device or explosion vent.
All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the
appropriate Indian Standards for metric threads, or the technical equivalent.
Testing:
At least 10% transformers of the offered lot (minimum of one) shall be subjected to the
following routine/ acceptance test in presence of purchaser’s representative at the place
of manufacture before dispatch without any extra charges. The testing shall be carried out in
accordance with IS:1180 and IS:2026.
Checking of weights, dimensions, fitting and accessories, tank sheet thickness, oil
quality, material, finish and workmanship as per GTP and contract drawings.
Physical verification of core coil assembly and measurement of flux density of one unit of each
rating, in every inspection with reference to short circuit test report
Temperature rise test on one unit of the total ordered quantity
Bill of Materials for 11 KV Transformer
Brief description of the Transformer for placing order:
Slno Item 11 kV Distribution
Transformers
500KVA, 11Kv/433v with OLTC inbuilt HV & 1 set
LV cable boxes suitable for Indoor
application and its complete standard
auxiliaries.
1 System voltage (max.) 12 kV
2 Rated voltage HV 11 kV
3. Rated voltage LV 433 V
4. Frequency 50 Hz +/- 5%
5 No. of Phases Three
6 Connection HV Delta
7 Connection LV Star
8. Vector group Dyn-11
9. Type of cooling ONAN
10 Auxiliaries Conservator tank,

Explosion vent,
Marshall box,
Buchloz relay and
other standard
auxiliaries
11 Transformer offline Tap setting with lockable (+) 10.0 % to (-)10.0 %
system & lock in steps of 1.25%.
12 ON Load tap changer copper winding in the Range of taping + 5% to
HV system. - 15% in equal steps of
1.25% each on HV
winding.
13 Remote Tap Changer Control (RTCC) 1 set
14 ONLINE/OFF LINE BYPASS Arrangements in 1set along with
case of failure of OLTC OLTC
15 Marshall box 1 set
Price for Supply, installation and Rs 18,00,000 + GST
commissioning
24c x 1.5 sqmm copper ar PVC 1.1 kv cable Rs 50,000/+ GST
app 100 mtr & terminal blocks& glands LS
Earth bus bar GI 25mm x 6mm for body Ls 50,000+GST
earth 100 mtr + 25mm x 12mm app 100mtr
Welding, bolt & connection to be connected
in existing earth pits
4.0 11kv Indoor Breaker:
11KV HV Indoor Breaker Specifications:
11 KV, 3 phase, 50 Hz, 3wire, 630 amps Bus Bar Indoor type floor mounted, non-
extensible, having hinged arc proof cable doors, Cable termination from the front,
breaking capacity 21kA Sec. Panel have Vacuum Circuit Breaker/Isolator having
IP67 degree of protection.
Service conditions:
Panel shall can operate normally within the following temperature range:
Maximum air temperature: + 45° C & Minimum air temperature: - 5° C
Suitable for operation in indoor locations.
Technical Particulars of VCB Circuit Breaker
S.NO DESCRIPTION 11 KV
.
A Rated Current (Minimum) 630 A
B Rated Voltage 12 KV
C Rated Frequency 50 Hz
D Rated Short Circuit breaking Current 18.4 KA for 1 sec.
(Minimum)
E Rated short circuit making current (KAP) 50 KA
F Insulation level (KV rms/KVP) 75 KV
System Parameters
Network Three phases - Three wires
Rated Voltage 12 kV
Service Voltage 11 kV
System Frequency - Hz 50 Hz
Bus bar Rating- A 630
Min Gas pressure - BarG 0.05
System Paramètres
Filling pressure- BarG 0.3

Min operating temperature – Deg c - 25
IP Rating IP 3X / 67
Internal Arc test IEC62271
Lightning Impulse withstand Voltage 95 kV Peak
Power Frequency withstand voltage 28 kV RMS - 1 min
Rated Normal Current
Incomer Load Break 630 A
Switch Feeder Circuit- 630A
breaker
Rated Short time current withstand ( 1 21 kA
sec )
Rated Short circuit making capacity of 52.5 kA peak at Rated Voltage
line switches
and earthing switches
Rated load interrupting current
Incomer Load Break Switch 630 A rms
Rated cable charging interrupting
current 30 A
Incomer Load Break Switch
Rated magnetizing interrupting current
Incomer Load Break Switch 16 A
The switchgear should have the minimum degree of protection (in accordance with
IEC60529)
IP 67 for the tank with high voltage components

IP 2X for the front covers of the mechanism
IP 3X for the cable connection covers
EARTHING OF METALLIC PARTS
There shall be continuity between the metallic parts of the switchboard and cables
so that there is no electric field pattern in the surrounding air, thereby ensuring the
safety of people.
The substation frames shall be connected to the main earth bus bar without
dismantling any bus bars.
EARTHING OF THE MAIN CIRCUIT

The cables & feeders shall be earthed by an earthing switch with short-circuit making
capacity, in compliance with IEC 60129 standard. The earthing switch can only be
operated when the main Load break switch / Circuit Breaker is open.
The earthing switch shall be fitted with its own operating mechanism and manual
closing shall be driven by a fast-acting mechanism, independent of operator action.
Mechanical interlocking systems shall prevent access to the operating shaft to
avoid all operator errors such as closing the earthing switch when the switch is
closed.
They shall be fully mounted and inspected in the factory.
An operating mechanism can be used to manually close the circuit breaker and
charge the mechanism in a single movement.
It shall be fitted with a local system for manual tripping by an integrated push button.
There will be no automatic reclosing.
Doors can be opened only with the Earth Switch in Closed position.
A cable test rod has to be provided which can be fixed on the terminations to facilitate
testing.
Termination boots shall have a proper opening to facilitate the same. The opening
shall be covered by means of removable protection cap.
MECP / Raychem or boots used in terminations must

have this facility.
In case of front door opened, it shall not be possible to operate the load break
switches / isolators or breaker.
The cable cover door shall be pad lockable and shall be Tamper and Arc proof as
per IEC 62271.
Cable charge indication shall be provided for Each RMU.
Provision for cable door interlocks such that the doors cannot be opened unless the
Earth switch is closed
There shall be provision of hinged doors Panel.
They should confirm to the following standards:
IEC 60068-2-6, IEC 60068-2-9 & IEC 60529 : Mechanical Test
IEC 60950 : Electrical Security
IEC 1000-4 and IEC 1000-6 : EMI / RFI
IEC 1000-4-2 : Air Discharges
They should have CE marking.
BUS BARS
Bus bars for the connections to the switch or circuit breaker shall be of copper and
shall be suitable for the 3 single phases. The bus bar shall be integrated in the cubicle
Bus bars shall be rated to withstand all dynamic and thermal stresses for the full
length of the switchgear.
CABLE SWITCH
It shall be a switch-disconnector and earthing switch using VCB as an arc-quenching

medium. The switch positions are closed – open – earthed. In the open position the
switch satisfies the disconnector requirements.
EARTHING SWITCH
Earthing switches shall be rated equal to the switchgear rating.
Earthing switches shall be quick make type capable of making Rated Fault Current.
Earthing switch shall be operated from the front of the cubicle by means of a removable
handle.
THE MECHANISMS
All mechanisms shall be situated in the mechanism compartment behind the front
covers outside the SF6-tank.
The mechanism for the switch and the earthing switch shall operate both switches
via one common shaft. The mechanism shall provide independent manual operation
for closing and opening of the switch, independent closing of the earthing switch and
dependent opening of the earthing switch.
The mechanism for the T-off switch and earthing switch shall operate both switches
via one common shaft. The mechanism shall have stored spring energy and provide
independentmanualoperation for closing and opening of the switch, independent
closing of the earthing switch and dependent opening of the earthing switch. The
mechanism has fuse tripping device.
The mechanism for the vacuum circuit breaker (VCB) and disconnector-earthing
switch shall operate the VCB and the disconnector-earthing switch via to separate
shafts. The mechanism for the VCB shall have stored spring energy and provide
independent manual operation for closing and opening of the VCB. The mechanism
shall have a relay with related CT’s and/or remote tripping device. The mechanism
for the disconnector-earthing switch shall provide independent manual operation for
closing and opening of the disconnector, independent closing of the earthing switch
and dependent opening of the earthing switch.
CABLE COMPARTMENT
It shall be possible to terminate up to a maximum of two single core HV cables per

phase.
The access to the compartment will be possible by removing the cable cover, bolted
to the main frame.
Removable steel covers shall close the cable compartments. Arc proof cable covers
shall be available as option. Each module shall have a separate cable compartment
that is segregated from each other by means of a partition wall. A partition wall shall
be fitted to divide the cable compartment from the rear side of the switchgear. In case
of an arc inside the tank, followed by the opening of the pressure relief, the partition
wall shall prevent the hot gases flowing out from the pressure relief to enter the cable
compartments. All covers shall be removable. The ground continuity shall be achieved
when the covers are in place by means of bolted connections.
POWER CONNECTION
The cables are installed in the dedicated compartment below the mimic front cover.
At the bottom of the cable compartment, an earthing bar system made of copper with
a minimum cross section of 150 mm2 shall be fitted. In each compartment the
earthing bar shall be fitted with 4 screws M10. The earthing system is connected to
the tank by a copper bar, which rises up to the connecting point of the tank behind
the rear partition wall on the middle of the switchgear.
INTER LOCKING
The mechanism for the cable switch shall provide a built in interlocking system to
prevent operation of the switch when the earthing switch is closed, and to prevent
operation of the earthing switch when the switch is in the closed position.
The mechanism for the T-off switch shall provide a built in interlocking system to
prevent operation of the switch when the earthing switch is closed, and to prevent
operation of the earthing switch when the switch is in the closed position. In addition
an interlocking device allows access to the fuses only when the earthing switch is in
the earthed position and opening of the earthing switch is only possible when the fuse
cover is closed and secured.
The mechanism for the VCB and the dis-connector-earthing switch shall have a built
in interlocking system to prevent operation of the dis-connector-earthing switch when
the VCB is in the closed position.
CURRENT TRANSFORMERS
All current transformers shall comply with IEC 60185.
Current transformers shall be of dry type, with ratings and ratios as required.
Instrument Security Factor (ISF) of each CT shall not be more than 5.
The CTs shall conform to relevant Indian Standards. The design and construction
shall be dry type, epoxy resin cast robust to withstand thermal and dynamic stresses
during short circuits. CT terminals shall be shorting type. Current & voltage circuits
shall be laid in separate wire ways. Secondary terminals of CTS shall be brought out
to a suitable terminal block which will be easily accessible for terminal connections.
Test terminal block shall be provided in the front side of the panel for testing purpose.
CT’S shall have 2 Nos. of cores for following
application: Core -1for meteringCore -2 for
protection. Class of accuracy of each winding Metering
class 1
Protection class 5P20
POTENTIAL TRANSFORMERS
The potential transformers shall be confirming to IS 3156/ IEC 60185.The primary

windings of the potential transformers shall be insulated and shall be of the cast rest
in type.
Potential transformer (PT’S) shall be mounted on a draw out trolley and housed in
separate metal compartment and shall have control fuses on the H.V. side and a
miniature circuit breaker on the L.V. side of the windings.HT HRC Control fuses shall
be confirming to IS – 9385/ IEC 60282.Miniature Circuit breaker shall comply with IS
– 8828/ IEC – 60898.
Padlocking facilities shall be provided for both service and
isolated position. The potential transformer shall be as
specified below:
Ratio : 11000 / V3/ 110/ V3V A Burden

: 100 V A for 100/V3 and 110 V winding
Class : CL –1 for both the windings.
Basic Insulation level : Same as mentioned for
VCB in clause -6.
Over voltage factor : 1.2 Continuous
Single phase PT’S shall be used and shall be connected in Star/ Star.
CONTROL WIRING
The control wiring shall be carried out with minimum 2.5 sq. mm. PVC insulated
copper conductor Low Smoke Zero Halogen Free (LSZHF) cables. The wiring shall
be securely fixed and neatly arranged to enable easy tracing of wires. Identification
PVC ferrules shall be fitted to all wire terminals to render easy identification and
facilitate checking in accordance with IS 5578 and 11353.
METERING INSTRUMENT PANEL ACCESSORIES
Metering
Digital type Load manager of approved make (EEM) shall be provided on the incomer
feeder. and shall be communication capable and ready with RS485 port and MODBUS
protocol.
Specification of the meter shall be as follows:
Accuracy : Class 1, compliant to revenue class certification.

: Real time measurement per
phase & average V, I, PF,
KW, KVAR, KVA
: Peak demand, sliding window. Protected.
: V & I unbalance Phase reversal
: Time
Multiport Communication : One each of RS 485 and RS 232

ports.
Instrument Panels
The instrument panel shall be part of the housing. Relays, meters and instruments
shall be mounted as per general arrangement drawings to be submitted by the
vendors. They shall be of flush mounting type.
Instrumentations
Digital type Voltmeter of class 1.0 accuracy and 96 x 96 mm square in size as per
IS-1248 shall be provided at incomer panel, with selector switch. The instrument
shall be calibrated for the ranges specified.
Digital type Power factor meter of class of 1.0 accuracy conforming to IS : 1248 shall
be provided at incomer panel.
Digital type Ammeter of specified range to class 1.0 accuracy and 144 x 144 sq mm in
size as per IS- 1248 shall be provided at both incomer and outgoing panels along with
necessary selector switches.
Digital type frequency meter class of 1.0 accuracy conforming to IS:1248 shall be
provided at incomer panel.
The following minimum indication lamps shall be provided in the front of cubicle.
Breaker open / closed / tripped, spring charged trip circuit healthy and control
supply healthy. Lamps shall be clustered LED type and trip circuit supervision
scheme shall be of continuous supervision type.
After meeting all necessary control and indication requirements 2 nos. NO

and 2 nos.. NC auxiliary of the breaker shall be made available for the owner,
wired up to terminal block.
Separate MCB’s shall be provided for lamps, heaters and other

instrumentation etc. on each panel.
Anti-condensation space heaters suitable for operation on 240 V single phase,

50 Hz A.C. for each cubicle and with thermostat control one incandescent lamp
with switch and 3 pin 5 amps plug socket.
MOTOR OPERATOR ACCESSORY FOR ELECTRICAL OPERATED DRAWOUT

TYPE CIRCUIT BREAKERS (EDO)
The mator operator accessory shall provide a means to remotely opne, close and
reset a circuit breaker. Electrical operation
With the breaker and the motor operator in the OFF position, on pressing the ON
button, it shall energize the motor and close the breaker. When the breaker handle
reaches the ON position, the control circuit shall be disabled by an internal limit
switch.
The OFF button shall energize the motor and open the breaker. After the handle
reaches the OFF position, the control circuit shall be disabled by an internal limit
switch.
When the circuit breaker trips automatically, there shall be no external trip indication
unless a separate bell alarm accessory is installed to actuate a warning device. It shall
be necessary to press the OFF button to reset the breaker before it can be closed
after a trip.
Automatic Reset
An auxiliary switch shall be available as an accessory to automatically return the

breaker to the OFF/RESET position after it has tripped. The switch shall be mounted
inside the breaker and wired in parallel with the OFF button. When the breaker trips
the switch shall also close, moving the breaker handle to the OFF/RESET position.
After the motor operator accessory has resent the breaker, the limit switch shall open
the circuit. Bill of materials to place order is as below
VCB make Megavin/Siemens/ABB Motorized draw out type CT for Monitoring & Protection : 50/5A, burden : 5VA PT
with Digital Multifunction meter for remote monitoring : 11kv/110v, burden: 50VA, Aux relay for Transformer
protection, cable entry bottom, Drawout type, Indoor
Conserv EM6436H Panel meter, 110V, CDG 31 relay for
type,
protection 2 O/C + 1 E/F;E/F SETTING - 0.5 - 2 Amps,
Manual, diagram etc
Network Three phases - Three wires
Rated Voltage 12 kV
Service Voltage 11 kV
System Frequency - Hz 50 Hz
Bus bar Rating- A 630
Min Gas pressure - BarG 0.05
System Parameters
Filling pressure- BarG 0.3
Min operating temperature – Deg c - 25
IP Rating IP 3X / 67
Internal Arc test IEC62271
Lightning Impulse withstand Voltage 95 kV Peak
Power Frequency withstand voltage 28 kV RMS - 1 min
Rated Normal Current

Incomer Load Break Switch Feeder 630 A
Circuit-breaker 630A
Rated Short time current withstand ( 1 sec ) 21 kA
Rated Short circuit making capacity of line switches 52.5 kA peak at Rated Voltage
and earthing switches
Rated load interrupting current
Incomer Load Break Switch 630 A rms
Rated cable charging interrupting current
Rated magnetizing interrupting current
Price Rs 8,00,000 +GST
3c x 185 sqmm, 11 kV XLPE aluminum ar cable with Rs 2,00,000/- + GST

earthing app mtr 60m tr and 5nos termination kit
4.0 MV Panel:
Two numbers of Electrical panels are installed in the Power House/Room, namely
PCC 01 & PCC02. PCC01 is getting supply from Transformer rating of 315 KVA and
PCC02 is getting supply from Transformer no:02, rating of 500 KVA. In addition to
that failed stabilizers with multiple change overs are also in line. The breakers are
MCCB in both Pcc01 and PCC02. The arrangement is as follows.
PCC 01
PCC 02
Note: The above panels are not dust and vermin proof and the door gaskets are in
damaged condition. All the breakers have no ELR with CBCT, adjustable OL, SC &
EF settings. Act as isolator. In case of any fault, there is much delay in tripping
eventually there is more damages, accidents etc. The live line of the bus bars is not
covered and the cables are not supported properly. There is no segregation between
two compartments in the panel.Considering the above the ARC Flash category goes
to level 3 and the panels are not complied with IER1956 rules and regulations.
Existing feeders in Transformer no:01: 315 KVA Feeders:
Feeder Name Electrical Protection system
PCC01 Incoming 400A 4p MCCB
outgoings: all are 4p
Power capacitor 250A MCCB
spare 100A MCCB
MCC PANEL 7(DG ROOM) 100A MCCB
ETP PANEL 100A MCCB
SPARE 100A MCCB
L580 LIGHT 100A MCCB
DB NO2LV2 100A MCCB
MCC PANEL 3 250A MCCB
DB NO:05 63A MCCB
SPARE 63A MCCB
COMPRESSOR UPS 250A MCCB
COMPRESSOR 100A MCCB
CANTEEN/FIRE HYD 100A MCCB
HEATER 63A MCCB
MDB4 63A MCCB
STREET LIGHT 63A MCCB
MDB 38 : QC LAB 100A MCCB
MDB 41: ENGINEERING 100A MCCB
Note: The above MCCBs are act as isolator and has no adjustable protection system
of OL, SC, EF & ELR
Existing feeders in Transformer no:02: 500 KVA’s feeders:
Slno Feeder Name Electrical Protection system

PCC02 Incoming 800A 4p MCCB
outgoings: all are 3p
1 Capacitor Panel
2 MCC8 (L580) 400A, 3P
3 MCC2 (FORMULATION) 160A, 3P
4 MDB 23 (UPS ROOM) 100A,
5 BLOTHERM 63A, 3P
6 SPARE 63A, 3P
7 AC OUTDOOR 63A, 3P
8 MDB 22 63A, 3P
Note: The above MCCBs are act as isolator and has no adjustable protection system
of OL, SC, EF & ELR and the breakers should have 4 pole.
Recommendations:
Considering the above deviation and High ARC FLASH LEVEL 3, it is
recommended to replace the old panels of PCC1, PCC2, AVR Changeover panels,
AVRs by a single panel as per the following specifications.
Item Description
MV Panel incomer: 800A, 4P MCCB, 50KA. Outgoing : 400A,25KA - 1no.
250A, 25KA - 3nos, 100A,25KA : 10nos & 63A,25KA : 10 nos, All are 4P
All MCCBs are Schneider make : NSX Model. OL, SC & EF Protection +
Shunt coil, Minilec ELR + CBCT. Bus connection : appropriate Aluminum
Indoor type. Each feeder should be separate by metal, flush type panel IP54
protection, Mainframe, door, cover mounting plate thickness
2mm. Base frame : MS Channel ISMC 75. paint by black colour. Panel power
coated & siemens grey colour
feeder Panel meter Digital Ammeter at the outgoing. Incoming Multifunction
meter Conserv EM6436H Panel meter with appropriate CTs
Incomer: indication lamps. Control circuit control: 6A MCB.
Specifications of Proposed MV Switch gears:
Main Distribution Panels, Sub-Distribution Panels and Final Distribution shall be

covered under this section. Panels/Boards shall be suitable for operation on 3
Phase/single phase, 415/240 volts, 50 cycles, 4 wire system with neutral grounded
at transformer. All Distribution panels shall be CPRI tested design and
manufactured by an approved manufacturer. CPRI certificate shall be made
available. Distribution panels shall comply with the latest Relevant Indian Standards
and Electricity Rules and Regulations and shall be as per latest edition of IS- 8623.
Distribution panels shall be 2 mm thick sheet steel cabinet for indoor installation,
dead front, floor mounting/wall mounting type and shall be form 3b construction. The
Distribution panels shall be totally enclosed, completely dust and vermin proof and
shall be with hinged doors and folded covers, Neoprene gasket, padlocking
arrangement and bolted back. All removable/ hinged doors and covers shall be
grounded by flexible standard connectors. Distribution panel shall be suitable for
the climatic conditions as specified in Special Conditions. Steel sheets used in the
construction of Distribution panels shall be 2 mm thick and shall be folded and
braced as necessary to provide a rigid support for all components. Joints of any kind
in sheet metal shall be seam welded, all welding, slag shall be rounded off and
welding pits wiped smooth with plumber metal. The general construction shall
confirm to IS-8623-1977 (Part-1) for factory built assembled switchgear & control
gear for voltage up to and including 1100 V AC.
All panels and covers shall be properly fitted and square with the frame, and holes
in the panel correctly positioned. Fixing screws shall enter into holes tapped into an
adequate thickness of metal or provided with wing nuts. Self threading screws shall
not be used in the construction of Distribution panels. A base channel of 75 mm x
40 mm x 5 mm thick shall be provided at the bottom for floor mounted panels.
Minimum operating clearance of 275 mm shall be provided between the floor of
Distribution panels and the lowest operating height.
Distribution panels shall be of adequate size with a provision of spare switchgear

as indicated on the Single Line Diagram. Feeders shall be arranged in multi-tier.
Knockout holes of appropriate size and number shall be provided in the Distribution
panels in conformity with the location of cable/conduit connections. Removable
sheet steel plates shall be provided at the top to make holes for additional cable
entry at site if required. Every cabinet shall be provided with Trifoliate or engraved
metal name plates. All panels shall be provided with circuit diagram engraved on
PVC sheet. All live accessible connections shall be shrouded and shall be finger
touch proof and minimum clearance between phase and earth shall be 20 mm and
phase to phase shall be 25 mm. Panels with ACB shall necessarily have front and
rear access as per requirement whereas panels with all MCCB breaker may be
provided with only front access with sufficient clearance.
BAR CONNECTIONS
Bus bar and interconnections shall be of high conductivity electrolytic grade
aluminum / copper as indicated in the drawings complying with requirement of IS :
5082 – 1981 and of rectangular cross section suitable for carrying the rated full load
current and short circuit current and shall be extendable on either side. Bus bars
and interconnections shall be insulated with heat shrinkable sleeve of 1.1 KV grade
and shall be colour coded. Bus bars shall be supported on glass fiber reinforced
thermosetting plastic insulated supports at regular intervals to withstand the force
arising from in case of short circuit in the system. All bus bars shall be provided in a
separate chamber and all connections shall be done by bolting. Additional cross
sectional area to be added to the bus bar to compensate for the holes. All
connections between bus bars and breakers shall be through solid copper /
aluminium strips of proper size to carry full rated current and insulated with
insulating sleeves. Maximum current density for the bus bars shall be 0.8 A/sq.mm
for aluminium and 1.4A/sq.mm for copper bus bars.
Maximum allowable temperature for the Bus bar to be restricted to 85 deg C
1.1 Temperature - Rise Limit

Unless otherwise specified, in the case of external surface of enclosures of bus bar
compartment which shall be accessible but do not need to be touched during normal
operation, maximum temperature rise limits of 25° C above ambient temperature
shall be permissible for metal surface and of 15° C above ambient temperature for
insulating surfaces.
All main distribution panels and sub distribution panels shall be provided with MCCB
of appropriate capacity as per Single Line Diagram. All final Distribution boards shall
be provided with Miniature Circuit Breakers. Final Single Phase Distribution boards
shall be connected to the incoming supply through double pole MCB units & earth
leakage circuit breakers. All wiring for final distribution boards shall be concealed
behind 5 mm thick Bakelite sheet or M S sheet cover. All Distribution boards shall
be completely factory wired, ready for connection. All the terminals shall be of
proper current rating and sized to suit individual feeder requirements. Each circuit
shall be clearly numbered from left tonight to correspond with wiring diagram. All
the switches and circuits shall be distinctly marked with a small description of the
service installed.
Continuous earth bus sized for prospective fault current shall be provided with
arrangement for connecting to station earth at two points. Hinged doors/ frames
shall be connected to earth through adequately sized flexible braids.Cable
Compartments
Cable compartment of adequate size shall be provided in the Distribution panels for
easy clamping of all incoming and outgoing cables entering from the top/bottom.
Adequate supports shall be provided in cable compartment to support cables.
2. AIR CIRCUIT BREAKERS (ACB)

The ACB shall conform to the requirements of IEC 60947-2 / IS 13947-2 and shall
be type tested & certified for compliance to standards from–CPRI, ERDA/ any
accredited international lab. The circuit breaker shall be suitable for 415 V + 10%,
50 Hz supply system. Air Circuit Breakers shall be with moulded housing flush front,
draw out type and shall be provided with a trip free manual operating mechanism
or as indicated in drawings with mechanical "ON" "OFF" “TRIP” indications.
The ACB shall be 3 or 4 pole with modular construction, draw out, manually or
electrically operated version as specified. The circuit breakers shall be for
continuous rating and service short Circuit Breaking capacity (Ics) shall be as
specified on the single line diagram and should be equal to the Ultimate breaking
capacity(Icu) and short circuit withstand values(Icw) for 1 sec.
Circuit breakers shall be designed to ‘close’ and `trip' without opening the circuit
breaker compartment door. The operating handle and the mechanical trip push
button shall be at the front of the breakers panel. Inspection of main contacts should
be possible without using any tools. The ACB shall be provided with a door interlock.
i.e. door should not be open when circuit breaker is closed and breaker should not
be closed when door is open.
All current carrying parts shall be silver plated and suitable arcing contacts with
proper arc chutes shall be provided to protect the main contacts. The ACB shall
have double insulation (Class-II) with moving and fixed contacts totally enclosed for
enhanced safety and in accessibility to live parts. All electrical closing breakers shall
be with electrical motor wound stored energy spring closing mechanism with
mechanical indicator to provide ON/OFF status of the ACB.
All Switchgear module front covers shall have provision for locking.
Switchgear operating handles shall be provided with arrangement for locking
in ‘OFF’ position. Protections The breaker should be equipped protection with
complete flexibility and shall offer complete over current protection to the
electrical system in the following four zones:
Long time protection
Short time protection with intentional

delay Instantaneous protection
Ground fault protection
The typical setting range of release shall be generally as follows:
Type of Setting Range Of Release

Protection Pick-Up Current Time Delay
Long Time 0.4 to 1.0 times In (Ir) 0.5 to 30 sec at 6 Ir
Steps: 0.4, 0.5, 0.55, 0.60, 0.65, Steps 0.5,1, 2,4, 6, 8,12,18,24 and
0.70, 0.75, 0.80, 0.85, 0.90, 0.95, 30 secs
1.00.
Tolerance: Corresponding to
Operating Limit : 1.05 to 1.2 times ±10% of current.
Ir
Short Time 2 to 10 times Ir 20 ms to 600 ms
Steps : 2,3,4,5,6,7,8,9 & 10 Steps 20,60,100,160,200,260,300

400,500 and 600 ms
Tolerance : ±10%
Tolerance : ±10% or 20ms
whichever is higher
Instantaneou 2 to 12 times In
s
Steps : 2,3,4,6,8,10,12
Tolerance : ±10%
Ground Fault 0.2 to 0.6 time In 100 ms to 400 ms
Steps : 0.2,0.3,0.4,0.5,0.6 Steps : 100,200,300,400ms

Tolerance: +10% or 20 ms
Tolerance : ±10% whichever is higher.
The MCCB should be current limiting type with trip time of less than 10 msec under
short circuit conditions. The MCCB should be either 3 or 4 poles as specified in
design drawings. MCCB shall comply with the requirements of the relevant
standards IS13947 – Part 2/IEC 60947-2 and should have test certificates for
Breaking capacities from independent test authorities CPRI / ERDA or any
accredited international lab.
MCCB shall comprise of Quick Make -break switching mechanism, arc

extinguishing device and the tripping unit shall be contained in a compact, high
strength, heat resistant, flame retardant, insulating moulded case with high
withstand capability against thermal and mechanical stresses
The breaking capacity of MCCB shall be as specified in the schedule of quantities.

The rated service breaking capacity (Ics) should be equal to rated ultimate breaking
capacities (Icu).MCCBs for motor application should be selected in line with Type-
2 Co-ordination as per IEC-60947-2, 1989/IS 13947-The breaker as supplied with
ROM should meet IP54 degree of protection.
2.1 Current Limiting & Coordination
The MCCB shall employ maintenance free minimum let-through energies and
capable of achieving discrimination up to the full short circuit capacity of the
downstream MCCB. The manufacturer shall provide both the discrimination tables
and let-through energy curves for all.
Protection Functions
Protection settings shall apply to all poles of circuit breaker.Earthing shall be provided
as per IS:3043-1987.
3. PAINTING
All sheet steel work shall undergo a process of degreasing, pickling in acid, cold
rinsing, phosphating, passivaiting (seven tank processing) and then painted with
electrostatic paint (Powder coating). The shade of colour of panel inside/outside
shall be as per design drawings confirming to IS Code No.5.
4. LABELS
Engraved PVC labels shall be provided on all incoming and outgoing feeder. Circuit
diagram showing the arrangements of the circuit inside the distribution panels shall
be pasted on inside of the panel door and covered with transparent plastic sheet.
All voltmeters and indicating lamps shall be through MCB’s.
Meters and indicating instruments shall be flush type.
All CT’s connection for meters shall be through Test Terminal Block (TTB).
5. CURRENT TRANSFORMERS
The CTs shall confirm to relevant Indian Standards. The design and construction
shall be dry type, epoxy resin cast/ Flame Retardant resin filled Nylon type robust
to withstand thermal and dynamic stresses during short circuits. Metering CTs, shall
have inbuilt bus bar mounting arrangement. Secondary terminals of CTs shall be
brought out suitable to a terminal block which shall be easily accessible for testing
and terminal connections. The secondary terminal should be covered with insulation
cap/cover so that there should not be any possibility of touching the live terminal.
The protection CTs shall be of accuracy class 5P10 and measurement CTs shall be
of accuracy class 1.
6. POTENTIAL FREE CONTACTS

Potential free contacts shall be provided for connection to Building Automation
System in panels indicated in Schedule of Quantities.
7. INDICATING PANEL
All meters and indicating instruments shall be in accordance with relevant Indian
Standards. Meters shall be flush mounted type. Indicating lamps shall be of low
burden, and shall be backed up with 2 amps MCB/MPCB as per relevant fault level
and toggle switch.
8. SELECTOR SWITCH
Where called for selector switches of rated capacity shall be provided in control
panels, to give the choice of operating equipment in selective mode.
Proposed Panel :
Bill of Material to place order:
Item Description : 800A Indoor Panel as per IS 8623 standard
Main frame: 2.00mm/14 gauge CRCA TATA Steel, Doors: 2mm thick CRCA
Sheet, Gland plate :3mm thick, Base frame : 75MM MS Channel
Earth strip double runs of 40mm x 10mm GI strip, Degree of protection: IP 54,
Dust and vermin proof, flush mounted, Siemens grey painting 7 tank process
of powder coating. Compartment physically segregated by sheets and live
bus connection should covered by Hylam/FRP supports. Minimum bus
clearances :Phase to phase clearance : 27mm and Phase to neutral
clearance : 27 mm and Phase to Earth clearance : 25mm. busbar support :
FRP.
MV Panel incomer: 800A, 4P MCCB, 50KA. Outgoing : 400A,25KA - 1no.
250A, 25KA - 3nos, 100A,25KA : 10nos & 63A,25KA : 10 nos, All are 4P
All MCCBs are Schneider make : NSX Model. OL, SC & EF Protection +
Shunt coil, Minilec ELR + CBCT in cable.
Indoor type. Each feeder should be separate by metal, flush type panel IP54
protection, Mainframe, door, cover mounting plate thickness
2mm. Base frame : MS Channel ISMC 75. paint by black colour. Panel power
coated & siemens grey colour
Feeder Panel meter Digital Ammeter at the outgoing. Incoming Multifunction
meter Conserv EM6436H Panel meter with appropriate CTs, kalpa make.
Incomer: indication lamps. Control circuit control: 6A MCB. Earthing : GI Strip
Double earth for all switch gears & panel. Door earth suitable copper wires
2.5 sqmm
Price Rs 19,00,000+ GST
5.0 DG Panel:
The prevailing DG panel consisting of two numbers of Electricity board supply of 315
KVA & 500 KVA & three numbers of DG sets rating of 500KVA – 2nos & 160 KVA –
1no. The configuration is as below.
The DG sets have Compact genset controller for gensets operating in multiple island
and/or parallel to mains mode (together with Mains Compact NT) and it has the
features of Active Load and VAr sharing, Full gen-set monitoring and protection, True
voltage and current RMS measurement, 3 phase generator voltage and current
measurement, 3 phase bus bar voltage & Power measurement etc. And the DG set
breakers have over load and short circuit protection to protect the DG set from Over
load and short circuit from the loads. There is no EF relay to protect the DG set from
Earth fault relay.
Electricity Board supply through Transformer have Over load, Short circuit, Earth
fault protection. The feeder details are as below.
Feeders at the DG Panels:
Slno Feeder Name Electrical Protection system

800A, 4P Motorized ACB, schneider make,
1 ASEB 315 KVA OL,SL,GF,Inst setting
Minilec UV & single phase preventer. ESD1 & VSP 2
relay. Model Eassy Pact
400A, 4P Motorized MCCB, schneider make, Io,Ir &
Isd. Intelic Compact system for parallel operartion &
2 DG - 4 320 KVA, AMF and neutral isolation by contactor 225A
Intelic Compact system for parallel operartion & AMF
Neutral isolation by contactor 225A
3 DG - 2 320 KVA, AMF & Neutral isolation by contactor 225A
Intelic Compact system for parallel operartion & AMF
4 DG - 2 160 KVA, AMF, Neutral isolation by contactor 225A
800A, 4P Motorized ACB, schneider make,
5 ASEB 500 KVA OL,SL,GF,Inst setting
Minilec UV & single phase preventer. ESD1 & VSP 2
relay.
500A Contactor, 3pole, Auto manual Switch, ON/OFF
6 bus coupler button & Neutral link. ( TPN)
7 PCC Panel 1 MCCB Not openable
8 Pcc Panel 2 MCCB Not openable
9 Spare – 2nos MCCB
Recommendations:
Absence of Earth fault relay in the DG set feeder, will leads major damage in case of
earth fault in the loads, cables. Further in the back side of the panels the live bus
bars are not covered. The doors also need repairing. Hence it is recommended to
install Earth fault relays in the existing system and cover the live bus bar by hylam
sheets. The bill of material is as follows.
slno Item Description qty Costing RS
Supply & Installation of CDG 11 relay in two
numbers of existing 500 KVA DG set panel EF
Setting 0.2 to 5, flush type Alstom/Avera make with
protection CT rating of 500/5A, burden
1 2nos 100,000
Live bus bar covering by Electrical hylam sheet
6mm thick, door reparing, identification marking
Labour charges
2 LS 50,000
Total cost 1,50,000 + GST
6.0 MCC2 & Formulation Panel:
In the 1st floor MCC2 and formulation panels are installed at the chemical handling
and storage area. The label pasted in the Tank is as below. And it is confirmed that
the stored chemical is flammable.
Hence it is recommended for the following.
1. To Shift the MCC 2 to the ground floor.

2. To shift the formulation panel to the ground floor.
3. Replace the 5nos of wall mounting exhaust fan by flame proof exhaust fans
and other locations like Glowwarm room & chemical storage room
4. Replace the 6 nos single phase industrial socket by flame proof sockets.
Bill of Materials:
slno Particulars Qty Price in Rs
1 Prateek make Flameproof heavy-duty Exhaust 7 nos :
Fan having sweep size of 18” , having air
discharge capacity of 4000 CFM, complete with Rs. 12,500/-
0.25 HP, Single phase, 240v, 1440RPM capacity each
of motor duly approved and certified by CIMFR
Dhanbad for gas group IIA & IIB, Zone-1&2 GST Extra
2 Prateek Make’ Flameproof cum weatherproof 10nos Rs 8,550/each

Switch Socket Plug combined. The technical
details are as under. MATERIAL : Cast GST Extra
Aluminum Alloy LM-6.RATING : 16Amp,
230 volts i.e,2pin+Earth.with RCCB LOCKING
Having foolproof interlocking i.e. plug cant be
removed in ON Condition. ENTR 2Nos. of ¾
ETHARDWARESS316. CAT NO : PE/EX/SS/90.
3 2Rx4c x 25 sq mm Copper XLPE 1.1 KV armored 600Mtr Rs 3,60,000/-
cable mtr. From Power House to GR stair case
GST Extra
4 MCC2: Fire proof panel consisting of 1no Rs1,00,000/-
ON/OFF/Lockable emergency off buttons -- 12
sets with terminal blocks for connections. Circular
in size to be mounted in the wall. Enclosure
should be IP56
5 Fire proof panel consisting of ON/OFF/Lockable 1no Rs1,50,000
emergency off buttons -- 8 sets plus 5 nos of
Digital temperature meter size of 4 inches X 4
inches. with terminal blocks for connections
Circular in size to be mounted in the wall.
Enclosure should be IP56
6 2Rx24c x 1.5 sqmm copper ar 1.1 kv control cable 1oo mtr 1,00,000
from MCC2 to remote control & formulation panel
to Remote control
7 Accessories of cable glands, cable support earth LS 1,00,000
wires etc
8 INCA DC 6150 fire Retardant cable coating in LS 1,00,000
Indoor cable and outdoor cables
7.0 Proposal Exclusions:
The proposed Project costing exclusion is as follows.
All the civil works of new construction, digging, repairing, renovating, removal etc
Civil construction work for indoor Transformer room & indoor 11 Kv panel room in the
proposed location of existing scrap storage place near by the Transformer yard.
Paying additional charges to the Electricity Board for surrender of Maximum Demand
and apply for Indoor metering unit.
Cost for removing old Transformers and its connection.
Removal of old Panels of PCC1 and PCC2 and install new panel, Transformer and
11 KV Breaker
Connecting the old cables in the new panel and costing for Earth strip laying
Re installation of formulation panel & MCC2 and new cables from Panel room
Making new Drawing of physical layout, SLD, cable trench layout, Earthing Layout
for the proposed installation.
Supervision charges for installation and commissioning
8.0 Challenges and complexity:
The following expected challenges and difficulties are there in the site to execute the
above proposals.
Proposal Recommendations Challenges and complexity

1 Electrical Demand
Apply to Electricity board for reduction of Demand Coordination with the Assam Electricity
and maintain 300 KVA Board
1.1 Apply to Electricity for Indoor Metering unit. Coordination with the Assam Electricity
Board
1.2 Demolish the prevailing scrap yard and do shifting Getting Management approval
other location
1.3 Construction of new Power house Coordination with the supply of
Transformer & 11 Kv panel
1.4 Installation of New Transformer and 11 KV panel as Nil
per drawing with approved vendor
2.0 Installation of New MV Panel in place of the old MV Proper Plan and modification is
Panel as per drawing required. Complete plant shutdown is
required about 3 - 5 days
3.0 Shifting MCC2 & Formulation panel Plant shut down is required about 3
days
4.0 Coating fire retardant paint in the cables Nil
9.0 List of Abbreviations Used
___________________________________________________________________
END__________________________________
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Electrical Assessment ( Rough for Discussion)

M/s. S.C.Johnson Products Pvt Ltd,

M/s VERTIV ENERGY PVT LTD,

2.0 Site Details………………………………………………………...............03

3.0 Locations of Monitoring…………………………………………………...04

4.0 Waveform and Graph Analysis…………………………………………..05

5.0 List of Abbreviations Used………………………………………………..15

Definition of Electrical Safety as per NFPA 70 E

The Importance of Electrical Safety.

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“Powering and Grounding Electronic Equipment”, (Emerald Book)

1) IEEE 1100 :-1999 & 2005 Emerald Book

2) IEEE 446 :- 1995 Orange Book

3) IEEE 142 :- 1991 Green Book

4) IER 1946 Rules and Regulations

5) OSHA Standard for Human safety

Disclaimer: The Electrical Assessment is carried out at M/s. S.C.Johnson Products

Contracted Actual Billable Excess billable Loss if 300 KVA is

11 KV EB Line Two Pole Structure

315 KVA Transformer

500 KVA Transformer

This specification covers design, engineering, manufacture, assembly, stage testing,

The transformer and accessories shall be designed to facilitate operation,

The materials shall conform in all respects to the relevant Indian/International

IS 12444 Specification for Copper wire rod ASTM B-49

Material conforming to other internationally accepted standards, which ensure equal or

The Distribution Transformers to be supplied against this Specification shall be

Specification of 500 KVA Transformer.

500KVA, 11Kv/433v with OLTC in buit HV

10 Auxiliaries Conservator tank, Explosion vent,

The winding construction of single HV coil wound over LV coil is preferable.

Inter layer insulation shall be Nomex /Epoxy dotted Kraft Paper.

Remote Tap Changer Control (RTCC) is a conventional equipment to control the

The following standard fittings shall be provided :

Temperature rise test on one unit of the total ordered quantity

10 Auxiliaries Conservator tank,

Suitable for operation in indoor locations.

Technical Particulars of VCB Circuit Breaker

Filling pressure- BarG 0.3

IP 67 for the tank with high voltage components

EARTHING OF THE MAIN CIRCUIT

They shall be fully mounted and inspected in the factory.

MECP / Raychem or boots used in terminations must

Cable charge indication shall be provided for Each RMU.

There shall be provision of hinged doors Panel.

They should confirm to the following standards:

IEC 60068-2-6, IEC 60068-2-9 & IEC 60529 : Mechanical Test

IEC 60950 : Electrical Security

IEC 1000-4 and IEC 1000-6 : EMI / RFI

IEC 1000-4-2 : Air Discharges

They should have CE marking.

It shall be a switch-disconnector and earthing switch using VCB as an arc-quenching

Earthing switches shall be rated equal to the switchgear rating.

It shall be possible to terminate up to a maximum of two single core HV cables per

All current transformers shall comply with IEC 60185.

Instrument Security Factor (ISF) of each CT shall not be more than 5.

CT’S shall have 2 Nos. of cores for following

application: Core -1for meteringCore -2 for

protection. Class of accuracy of each winding Metering

Protection class 5P20

The potential transformers shall be confirming to IS 3156/ IEC 60185.The primary

Padlocking facilities shall be provided for both service and