E-15-01

September 2011

WATER SUPPLIES DEPARTMENT

STANDARD SPECIFICATION E-lS-Ol

HIGH VOLTAGE SWITCHBOARD

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September 2011

INDEX

Page No.

1. GENERAL

1.1 Scope 1

1.2 Standards 1-2

1.3 Type Test Certification 2-4

2. SWITCHBOARD DESIGN AND CONSTRUCTION

2.1 Standards 4

2.2 General Design Information 4-5

2.3 Panel Layout 5

2.4 Panel Steelwork 5-6

2.5 Panel Door Fittings 6

2.6 Switchboard Earthing 6

2.7 Reference Voltage 6

2.8 Bus Wiring 6-7

3. SWITCHBOARD EQUIPMENT AND AUXILIARIES

3.1 Busbars and Busbar Connections 7-8

3.2 High Voltage Circuit Breaker 8 - 14

3.3 Voltage Transformers 14 - 15

3.4 Current Transformers 15 - 16

3.5 Relays and Timers 16 - 17

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Page No.

3.6 Low Voltage Fuses 17

3.7 Indicating Instruments 18

3.8 Panel Auxiliary Equipment 18 - 19

3.9 Energy Meter 19 - 20

3.10 Summation Meter Cubicle 20 - 21

3.11 Power Supply Terminations 21

3.12 Cable Accessories 22

3.13 Spares and Tools 23 - 24

4. INSPECTION AND TESTING AT WORKS

4.1 General 24

4.2 Circuit Breakers 24

4.3 Switchgear Panels 25

4.4 Voltage Transformers 25

4.5 Current Transformers 25 - 26

4.6 Protective Relays and Instruments 26

4.7 Summation Meter Cubicle 26

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September 2011

WATER SUPPLIES DEPARTMENT

STANDARD SPECIFICATION E-lS-Ol

HIGH VOLTAGE SWITCHBOARD

1. GENERAL

1.1 Scope

This Specification covers the design, construction, inspection and testing

requirements of high voltage switchboard.

1.2 Standards

Equipment shall comply with the latest version of the relevant International
Electrotechnical Commission (IEC) I British Standard (BS) Specifications and
Codes of Practice.

The following standards, in particular, shall apply where appropriate :­

BS 88 Cartridge fuses for voltages up to and including

1000V a.c. and 1500V d.c.

BS 89 Direct acting indicating analogue electrical

measuring instruments and their accessories

BS 159 High-voltage busbars and busbar connections

BS 2692 Fuses for voltage exceeding 1000V a.c.

BS 5207 Sulphur hexafluoride for electrical equipment

BS 5311 High-voltage alternating-current

circuit-breakers

BS 6231 PVC-insulated cables for switchgear and

controlgear wiring

BS 7625 Voltage transformers

BS 7626 Current transformers

BS EN 60255 Electrical relays

BS EN 60298 A.C. metal-enclosed switchgear and

controlgear for rated voltages above lkV and
up to and including 52kV
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BS EN 60694 High-voltage switchgear and controlgear

standards

BS EN 60947-5-1 Electromechanical control circuit devices

BS EN 60947-7-1 Terminal Blocks for Copper Conductors

IEC 60099 - 4 Surge arresters - Metal-oxide surge arresters

without gaps for a.c. systems

IEC 60099 - 5 Surge arresters - Selection and application

recommendations

IEC 62053 - 21 Electricity metering equipment (a.c.)

Particular requirements - Part 21 : Static meters
for active energy (classes 1 and 2)

IEC 62053 - 23 Electricity metering equipment (a.c.)

Particular requirements - Part 23 : Static meters
for reactive energy (classes 2 and 3)

IEC 62056 - 21 Electricity metering - Data exchange for meter

reading, tariff and load control- Part 21 : Direct
local data exchange

IEC 62271 - 100 High-voltage switchgear and controlgear­

Part 100 : Alternating-current circuit- breakers

1.3 Type Test Certification

The switchboard shall be of a type tested model. The Contractor shall provide the
necessary certification to satisfy that the relevant type tests have already been
performed on essentially similar equipment.

Type test certificates of short circuit tests shall be issued by the Association of Short
Circuit Testing Authorities UK (ASTA) or other equivalent internationally
recognized authority. Type tests shall be carried out in accordance with the
requirements of the relevant British Standards. For SF 6 circuit breakers, all type
tests for current switching and dielectric strength shall be conducted at the lowest
permissible gas filling pressure.

The type test requirements for equipment are listed as follows :­

1. Circuit breakers to BS 5311

- Short-time withstand current and peak withstand current tests

- Short-circuit current making and breaking tests

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- Single-phase short-circuit tests

- Capacitive current switching tests

- Magnetizing and small inductive current switching tests

- Mechanical operation tests

- Dielectric tests

- Temperature-rise test

- Measurement of the resistance of the main circuit

- Rated current switching test at gas pressure of 1 bar

(SF6 circuit breakers only)

2. Metal-enclosed switchgear panels to BS EN 60298

- Dielectric tests

- Measurement of the resistance of the main circuit

- Short-time and peak withstand current tests

- Verification of making and breaking capacities

- Temperature-rise test

- Mechanical operation tests

- Pressure withstand and gas tightness tests of gas-filled

compartments

3. Voltage transformers to BS 7625

- Temperature-rise test

- Impulse tests on primary winding

- Determination of errors

- Short-circuit withstand capability test

4. Current transformers to BS 7626

- Short-time current tests

- Impulse tests on primary windings

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- Temperature-rise test

- Determination of errors

Complete details of the type test reports containing the test arrangement and test
results shall be submitted to supplement the test certificates when requested.

The equipment supplied shall be strictly in accordance with the design of the type
tested equipment.

2. SWITCHBOARD DESIGN AND CONSTRUCTION

2.1 Standards

Switchboard and switchgear panels shall be metalclad and comply with BS EN

60298.

2.2 General Design Information

2.2.1 Class and Rating

Rated voltage 12 kV, 7.2 kV, 3.6 kV

Number of poles 3

Earthing of system Solid

System frequency 50 Hz±2%

Installation type Indoor

Power supply for circuit breaker 1l0V d.c. ±15%

operation, controls and protection
Power supply for auxiliary equipment 220V ±10% I-phase 50 Hz ±2%

Degree of protection IP3X

Insulation class Class B

2.2.2 Site Operating Conditions

Altitude above sea level 1000 m

Maximum ambient temperature :­

Average over 24 hours

Peak over any 4 hours

Minimum ambient temperature

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Average yearly temperature

Relative humidity 98%

2.3 Panel Layout

Switchboards shall consist of free-standing panels fitted together to form a

continuous board of uniform height and shape when viewed from the front.
Switchboards shall be extensible at both ends.

Forced ventilation shall not be necessary under an ambient temperature of 40°C and
below. Ventilating grills, where required, shall not be located on the top of a panel.

The height of panels shall be not greater than 2700 mm.

Indicating and control instruments shall be positioned between 900-1800 mm above

floor level. Protective relays and instruments on the panel front shall be flush
mounted.

Control and auxiliary relays shall be mounted in a compartment with access through
a lockable hinged door. Any parts which generate vibration during operation e.g.
contactor coils and circuit-breaker operating mechanisms, shall be mounted such
that vibration shall not be transmitted to other parts of the panel.

The circuit breaker compartment shall be accessible through a hinged door fitted
with a perspex window for viewing the mechanical status indicator of the circuit
breaker. No equipment shall be fitted on this access door.

Busbars and current transformers shall be contained in separate chambers at the

upper section ofthe switchboard and shall be accessible through bolted covers only.

Apparatus on different panels with similar functions shall be located at a similar

physical position.

All functional equipment such as selectors, indicators and protective relays

associated with a panel shall be housed within that panel. Installation of such
components on a neighbouring panel is not acceptable.

Termination blocks for control wiring shall be located at least 150 mm from the
base ofthe compartment. Identification ferrules for cables shall be so arranged as to
be visible without the need to dismantle any other compartment cover or to remove
any adjacent panel component.

2.4 Panel Steelwork

Panels shall be made of steel sheet suitably braced to form a rigid structure.
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The panel steelwork shall be phosphate treated to BS 3189 prior to application of

epoxy powder coating. The paint work shall be of high quality in compliance with
ESI Standard 98-1 or equivalent. The minimum dry film thickness of the paint
coating shall be 50 microns.

The final paint coating shall be semi -matt of colour to BS 4800 shade 18B21 (light
grey).

2.5 Panel Door Fittings

The edges of hinged panel doors shall have deep return flanges for rigidity and
fitting of gaskets. Gaskets shall be of neoprene or rubber, continuous without joints
around corners and suitably arranged to minimize the transmission of vibration and
to prevent the entry of dust.

Hinged panel doors shall be fitted with chromium plated solid rod type detachable
hinges and chromium plated car door type lockable handles.

2.6 Switchboard Earthing

A tin-plated copper earthing conductor shall be provided running the length of the
metal-enclosed switchgear with rated short-time withstand current compatible with
the switchboard. The design current density shall not exceed 200Almm2 and its
cross-sectional area shall be not less than 30 x 6 mm with earth terminals of not
smaller than M8. All non-current carrying metallic parts shall be effectively
connected to the earthing conductor, including provision for bonding cables sheaths
and armouring.

2.7 Reference Voltage

The reference voltage for under-voltage and over-voltage relays shall be taken from
the load side of the voltage-transformer secondary fuses installed in the incoming
supply panel via bus wiring.

Where the switchboard consists of two or more incoming supply panels and
bus-section panels, the reference voltage bus-wires shall be linked through normally
open auxiliary switches on the bus-section circuit breakers and the incoming supply
circuit breakers such that the reference voltages from each voltage-transformer will
not be connected in parallel.

2.8 Bus Wiring

Bus wiring shall be used for auxiliary power supply and small wiring between
panels. Buswiring leads shall be PVC insulated copper cables terminated on
terminal blocks.

Minimum cable size shall be 4 mm2 . Cables connected to 32A fuses, 63A fuses and
80A fuses shall be of minimum 6 mm2 , 16 mm2 and 35 mm2 respectively.
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For auxiliary power supply, each set of terminals shall be segregated by plastic
barriers and provided with individual plastic covers.

Ends of buswiring for panels may be disconnected for transport. The manufacturer
shall provide wiring details for reconnection on site.

3. SWITCHBOARD EQUIPMENT AND AUXILIARIES

3.1 Busbars and Busbar Connections

3.1.1 Standards

The busbar system shall comply with BS 159. The enclosure and the assembly of
equipment shall comply with BS EN 60298.

3.1.2 Class and Rating

Busbars shall be three-pole and comprise separate sections for each circuit-breaker.

The rated current of bus bars shall be 630A, 1250A and 2000A.

The rating of busbars including busbar connections and primary isolating contacts
shall match the rating of the corresponding circuit breakers as detailed in Clause
3.2.2.

3.1.3 Material

Main busbars shall comprise horizontally mounted, PVC-sheathed or epoxy

encapsulated, solid copper bars. Copper-clad or aluminium busbars will not be
accepted.

Porcelain type insulators shall not be used. Insulators shall be mechanically fixed
and not cemented into position to ensure rapid interchangeability in the event of
replacement.

Joints shall be insulated with moulded removable insulated covers. Designs

involving taping of joints or components shall not be accepted. The insulation
material and moulding shall be provided.

There shall be no visible corona discharge on the busbar system.

3.1.4 Busbar Joints and Supports

Jointing of sections of busbars shall be done by mechanical means. Soldered,

braced, welded or riveted joints shall not be used for bus bars.

Jointing faces of copper conductors shall be tinned or silver plated, or other

approved treatment to maintain effective conductivity of the joint.
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Busbar jointing bolts, nuts, and fixing accessories shall be provided for switchboard
installation. The recommended torque for tightening the bolts shall be stated in the
maintenance manual.

Extension busbar trunking shall be provided, where specified, to permit segregation

of the switchboard into sections.

3.2 High Voltage Circuit Breaker

3.2.1 Standards

High voltage circuit breakers shall comply with BS 5311.

3.2.2 Class & Rating

Circuit breakers shall be of triple pole and indoor type.

The rated current shall be 630A, 1250A and 2000A.

The other ratings shall be as follows :­

System voltage and 3.3 kV 3.3 kV 6.6kV 11 kV

fault rating 140MVA 225MVA 225MVA 380MVA
Rated voltage to 3.6kV 3.6kV 12kV 12kV
BS 5311
Rated lightning 40kV 40kV 75 kV 75kV
withstand voltage
(peak)
Rated transient
recovery voltage
(peak), parameters to 6.2kV 6.2kV 20.6 kV 20.6 kV
BS 5311 Table ITA

Rated short-circuit
breaking current 40 kA Is 50 kA Is 31.5kAls 31.5kAls
(r.m.s. a.c. or or or or
component) and 25 kA 3s 40 kA 3s 20 kA 3s 20 kA 3s
rated short time
duration
Min. rated current of
incoming supply and 1250A 2000A 630A 630A
bus-section circuit
breakers

Circuit breakers for pumpsets and power transformer feeders shall be capable of
breaking a minimum current of 20% of the rated operational current of the
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connected equipment with power factor 0.05 lagging (no-load magnetizing current
of the connected equipment).

3.2.3 Construction Features

3.2.3.1 Housing

The circuit breaker shall be ofthe vertical isolation horizontal drawout pattern truck
unit. The design shall be such that the truck will be located accurately in its housing
to ensure good alignment between the fixed housing and the contact assembly at the
truck.

3.2.3.2 Circuit and Busbar Earthing

Circuit and busbar earthing shall be effected by the circuit breaker without the
requirements of any loose attachments. The earthing connection shall be completed
by closing the circuit-breaker in the normal manner.

Selection of circuit or busbar earth position shall be possible only after the
circuit-breaker has been fully isolated and raising of the circuit-breaker shall be
possible only at the selected positions. It shall be by a fully interlocked and labelled
position selector which shall be designed to permit padlocking in any position.

Facilities shall be provided on all incoming and feeder circuit-breakers for earthing
the circuit side. However, only the incoming supply panels and bus-section panels
shall be provided with facilities for busbar earthing.

3.2.3.3 Circuit Testing

Facilities shall be provided for testing the circuit-breaker operation in the fully
isolated status and at any selected circuit position using normal control functions.
Where control circuits and interlock circuits are broken in the test position, a jumper
lead and plug assembly of each size and type necessary to connect all such circuits
shall be provided to facilitate testing. Jumper leads which only connect the tripping
and closing circuits shall not be acceptable.

3.2.3.4 Mechanical Interlocks

Mechanical interlocks shall be provided to cater for the following functions in any
selected positions:

(i) with the circuit-breaker in the closed position, the circuit-breaker

truck cannot be plugged in or withdrawn;

(ii) circuit-breaker cannot be closed until fully plugged in or completely

isolated;

(iii) tripping of circuit-breaker cannot be initiated by attempted operation

of any interlocked control;
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(iv) circuit-breaker cannot be 'slow-closed' except in the fully withdrawn

position;

(v) covers giving access to live parts of circuit-breakers cannot be

removed or opened unless the circuit-breaker is fully isolated and
withdrawn.

With the circuit-breaker plugged in and closed to an earth position, tripping shall
only be effected by the manual tripping button on the operating mechanism which
shall be lockable at the closed position.

3.2.3.5 Key Interlock

Key interlocks shall be provided at the switchgear panels as specified below:

(i) Incoming supply and bus-section panels

Where the switchboard consists of two or more incoming supply

panels, key interlock shall be provided, in addition to electrical
contact interlocks, in the incoming supply panels and bus-section
panels such that the incoming supplies shall not be permitted to
operate in parallel or to earth 'live' busbars.

The key interlock shall not prevent racking the circuit breaker into
service position. The interlocking function shall be effective on the
service and busbar earth positions but not on the circuit earth
position.

(ii) Station auxiliary transformer feeder panels

Key interlock shall be provided in the station auxiliary transformer

feeder panel to prevent opening the front and rear double-leaf doors
of the enclosure of the epoxy resin encapsulated type station
auxiliary transformer unless the associated circuit breaker is
withdrawn from the service position and closed to the circuit earth
position to earth the transformer supply cables.

(iii) Pump starter panels

Key interlock shall be provided in the pump starter panel to prevent

opening the door of the corresponding pump-motor power factor
correction capacitor panel unless the associated circuit breaker is
withdrawn from the service position and closed to the circuit earth
position to earth the motor and capacitor supply cables.

The keys and the locks shall be mass manufactured equipment of a proven design.
The keys shall not be interchangeable for different interlock applications. Tripping
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of a closed circuit-breaker shall not occur if an attempt is made to remove the key
trapped at the switchgear panel.

The Contractor shall submit for approval the detailed key interlock scheme together
with the technical brochures for all keys, interlocks and necessary key exchange
boxes within one month after award of Contract. Within one month after approval,
the Contractor shall deliver the keys and door interlocks specified below for passing
to the respective equipment suppliers for installation:

(i) for each station auxiliary transformer feeder panel, two extra keys
for the interlock at the switchgear panel, key exchange box, four sets
of keys and door interlocks for the transformer enclosure.

(ii) for each pump starter panel, two extra keys for the interlock at the
switchgear panel and one set of the door interlock for the power
factor correction capacitor panel

The Contractor shall however make available the interlock keys used at the
switchgear panels in order to verify the correct operation of the key interlock system
during the witnessed inspection and tests at works.

3.2.4 Components

3.2.4.1 Operating Mechanisms

The circuit-breaker operating mechanism shall be of stored energy operation by

means of a motor charged spring mechanism.

The mechanism shall be of the trip-free type. Operating mechanisms for the
interrupter units shall be positively coupled to ensure simultaneous operation of the
three phases.

The operating mechanism shall be provided with anti-pumping protection facilities.

The motor charged spring mechanism shall be provided with means for charging the
springs by hand and a lockable shrouded mechanical push button for releasing the
springs. Interlocks shall be provided to prevent simultaneous charging of the
operating springs by manual means and by the motor. A 'spring charged' and 'spring
free' indicator shall be provided.

Operating handles for lowering/raising, slow closing and manual spring charging of
the circuit breakers shall be provided.

Electrical tripping by the shunt trip coil shall be rendered inoperative when the
circuit breaker is closed at earth position.
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3.2.4.2 Operating Indicators & Manual Tripping Facility

Positively driven mechanically operated indicating devices shall be provided to

indicate whether a circuit-breaker is open or closed, in service, isolated or earthed
position. A 4-digit mechanical operation counter shall be provided at each circuit
breaker to register the number of mechanical operations.

An integral push-button for direct manual tripping of the circuit breaker shall be
provided. Pad-locking facility shall be provided to prevent unauthorized tripping of
the circuit breaker at the earth position.

3.2.4.3 Safety Shutters

Safety shutters shall be provided to cover each three phase group of stationary
isolating contacts. Shutters shall be automatically driven from the circuit-breaker's
rack-in or rack-out operation and when closed shall prevent access to stationary
isolating contacts. Shutters shall be capable of being individually operated and of
being padlocked in the closed position.

To facilitate high voltage and current injection testing via isolating contacts, a
device shall be provided for fixing (not locking) shutters in the open position and
for releasing them to the closed position. This device shall be arranged to be
disengaged as soon as the circuit-breaker is pushed into the service position to
ensure the restoration of the automatic features of the shutters in the event of an
operator failing to release the shutters before putting the circuit-breaker into the
service position.

Safety shutters shall be coloured and labelled with stencilled, white lettering of
minimum height 25 mm as follows :­

Feeder Orifice Busbar Orifice

Circuit Shutters Shutters
Background Character Background Character (White)
Colour (White) Colour
Incoming Red Danger Red Danger Busbars
Supply Incomer
Transformer Red Danger Red Danger Busbars
Feeder
Motor Yellow - Red Danger Busbars

Voltage Red Danger - ­

Transformer Incomer
Bus Section - - Red Danger
LH/RH
Busbars
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3.2.4.4 Primary Isolating Contacts

Isolating contacts fingers shall be of silver plated copper and self-aligned type.
Gauging devices shall be provided for checking the correct engagement of the
contact assembly with the stationary isolating contacts.

One set ofthree phase test plugs for current injection tests shall be provided for each
size of primary isolating contacts.

3.2.4.5 Auxiliary Switches

Auxiliary switches shall be of double-break type and shall be positively driven in

both directions.

The necessary auxiliary switches for the control functions specified shall be
incorporated with a minimum of two pairs of normally open and two pairs of
normally closed contacts (not change over contacts). The contacts shall be rated for
10A operational current, and shall be capable of breaking at least 2A at 110 d.c.
with a LlR time constant not less than 20 ms.

Auxiliary switches shall be used for tripping and closing interlocks. The use of
repeat relays for this purpose shall not be acceptable.

3.2.5 SF6 Circuit Breaker

SF 6 circuit breakers shall be metalclad, i.e. the gas tank shall be made of metal. A
pressure switch shall be provided on the SF 6 gas compartment to monitor the gas
pressure and to give a two-stage pressure low alarm and lockout feature. Local and
remote alarms shall be initiated and the breaker shall be inhibited from closing
whenever the gas pressure drops below the first stage preset level. The circuit
breaker shall be prevented from operation and a second alarm shall be initiated
whenever the gas pressure falls to the second stage level below which it is incapable
of performing its rated duty. A gas pressure gauge shall be fitted at the front of the
gas compartment to facilitate pressure checking without the need to dismantle any
cover. Means shall be provided in the gas compartment for gas topping up.

The circuit breaker shall be capable of interrupting its rated normal current with SF 6
gas at atmospheric pressure. The sealing of the gas compartment shall be designed
so that SF 6 gas shall not need replenishment within the service life of the circuit
breaker. The gas leakage shall not exceed 1% per annum at site ambient
temperature.

Facilities shall be provided to enable checking the extent of contact wear, e.g. an
external contact indicator, without the need to dis-assemble the gas compartment.
Means shall also be provided to allow access to the contacts of the interrupter units
for necessary inspection and maintenance. All contact assemblies shall be
replaceable. Safeguards shall be provided to prevent incorrect replacement of
contacts.
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The designed electrical and mechanical life shall be at least 5,000 and 10,000
cycles, respectively. The circuit breaker shall be capable ofundergoing 40 cycles of
fault breaking operations at 50% rated short-circuit breaking current or equivalent
without any need of opening up the tank for inspection or contact replacement.

Instructions for post-fault maintenance, gas top-up, frequency of checking contact

wear, contact and seal replacement shall be clearly detailed in the manual.

3.2.6 Vacuum Circuit-Breaker

The vacuum circuit-breaker shall be designed in compliance with lEC 62271 - 100.

All exposed live conductors in the circuit breaker truck shall be fully insulated or
separated by insulated partition sheets.

The circuit-breaker shall be capable of interrupting rated short-circuit fault currents

for at least 20 times without the need of maintenance or interrupter replacement.

Visual contact wear indicator or equivalent to monitor the severity of the main
contact erosion of circuit-breaker shall be provided.

The chopping current of circuit-breaker shall not exceed 5A.

Surge suppression devices shall be installed in each pump starter panel for
suppression of steep voltage rise and spikes generated due to motor switching. The
surge suppression devices shall be of metal-oxide without gaps in compliance with
lEC 60099-4. The ratings of the surge suppression devices shall be in compliance
with the selection and application recommendations specified in lEC 60099-5.

3.3 Voltage Transformers

3.3.1 Standards

Voltage transformer (VT) shall comply with BS 7625.

3.3.2 Class and Rating

The secondary voltage shall be 110V.

The rated output per phase at a power factor 0.8 lagging shall be not less than
1OOVA. The minimum output shall be capable of supplying all panels in the
system.

The rated voltage factors shall be 1.2 continuous and 1.9 for 30- second duration.
Ratings of the VT shall be as follows :­
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System nominal voltage 3.3 kV 6.6kV 11 kV

Rated highest equipment voltage 3.6kV 7.2kV 12kV

One minute power frequency test 10kV 20kV 28kV

voltage (r.m.s.)

VT shall have a measuring accuracy class 0.5 and a protective accuracy class 3P.

3.3.3 Construction Features

Each VT shall have a rating plate marked with all data recommended in BS 7625.

VT shall have separate windings for primary and secondary and shall be dry-type
cast resin encapsulated and natural air cooled.

The primary winding shall be protected by fuses to BS 2692. These fuses shall be
removable only when the VT is at the isolated position. Secondary circuit fuses
shall be provided and shall be readily accessible for replacement.

A set of safety shutters shall be provided to automatically cover the opening

accessible to the fixed isolating contacts when the VT is withdrawn. Particulars of
shutters shall be identical to those for circuit-breakers. Means shall be provided to
padlock the shutters in the closed position.

Padlocking facilities shall be provided to lock the VT in the service position.

Access to the RV live parts shall not be possible in this position.

3.4 Current Transformers

3.4.1 Standards

Current transformers (CT) shall comply with BS 7626.

3.4.2 Class and Rating

CT shall be rated for 50 Rz operation and compatible with the circuit breaker's
ratings.

3.4.3 Design Features

The rated secondary current shall be lA or 5A.

The rated primary currents in amperes shall be (10), 12.5, (15), (20), 25, (30), 40,
(50),60, (75) and their decimal multiples. The preferred values are those given in

brackets.

Measuring CT shall be l5VA Class 1 and protective CT shall be 5P 10 15VA.

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For dual ratio CT, all the secondary terminals shall be wired to a terminal block and
clearly identified.

The secondary circuits of each CT shall be earthed at one point only. Bolted copper
link at readily accessible position shall be provided for CT earthing. Each earth
wire shall be terminated on separate terminals.

CT shall be of epoxy resin encapsulated type.

CT rating labels shall be fitted on the CT and on a prominent place on the exterior of
the CT chamber. For dual ratio CT, the ratio in use shall be clearly indicated on a
label.

3.5 Relays and Timers

3.5.1 Protective Relays

Protective relays to BS EN 60255 shall be provided.

Protective relays and trip circuit supervision relays shall be of withdrawable type
housed in cases unless otherwise specified. The relays shall be flush mounted. For
current operated relay, a feature shall be incorporated to short circuit the secondary
terminals of the CT when it is withdrawn from the case.

For solid-state or microprocessor based relays such as overcurrent and earth fault
protection relays which are not of withdrawable type, test blocks shall be installed
adjacent to the relays to facilitate testing.

For electromechanical type IDMT overcurrent and earth fault protection relays, the
three single phase elements shall be in one horizontal plane and accommodated in a
common case. The design ofplug setting selection shall be such that the plug setting
can be changed on-load without open-circuiting the CT, and the highest current
setting shall be automatically selected when the plug is removed.

Operation indication shall be provided for each protective element and within the
same relay. The relay shall have a common hand-reset device operable without
opening the relay access cover.

A relay test plug for each type of relay casing shall be provided.

3.5.2 Control & Timer Relays

Control and timer relays shall be ofplug-in type, rack mounted, provided with cable
connection terminal and anchored by quick fastening vibration-proof devices.
Timers shall be of solid-state type.

Contacts shall be rated for one million on-load operational cycles at the following
rating :­
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Control relays

Breaking duty : 16A 220V a.c. 0.4 p.f. lagging

0.7A inductive CUR = IS ms),

lOA resistive 11 OV d.c.

Switching capacity : 14A single phase normally open contacts

2.SA inductive CUR = IS ms),
lOA resistive 11 OV d.c.

Timer relays

Thermal rating : 2A 220V SO Hz

Breaking duty : SA 220V a.c. 0.4 p.f. lagging

O.SA 110V d.c. UR = IS ms

3.6 Low Voltage Fuses

3.6.1 Standards

Fuses and fuse holders shall comply with BS 88 Part 2.

3.6.2 Class and Rating

The voltage rating shall be 41SV, SO Hz or SOOV d.c. The rated breaking capacity of
fuses shall be 80 kA at 41SV, SO Hz or 40 kA at SOOV d.c.

Current ratings for fuse link shall be 2, 4,6,8, 10, 12, 16,20, 2S, 32, 40, SO, 63, 80,
100, 12S, 160 amperes.

3.6.3 Components

Fuse bases and carriers shall be of plastic moulded insulating material of an

approved make. Ceramic materials will not be accepted. Fuse bases and carriers for
fuses of2-20A shall be 20A units.

Fuse bases and carriers shall be colour coded, white for isolating links, light green
for tripping control and black for other fuses.

3.6.4 Mounting

Fuses and links in the same circuit shall be mounted in adjacent positions in the
same row. Live terminals and contacts of fuse holders shall be effectively shrouded
such that no live parts shall be exposed when the fuse is withdrawn or when the
panel door is opened.
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September 2011

3.7 Indicating Instruments

The bezel size of all indicating instruments shall be 96 x 96 mm. The indicator shall
be finished in phenolic black and suitable for flush panel mounting.

The accuracy of ammeter and voltmeter shall be of class 1.5 and shall have a scale
length not less than 145 mm on 240 0 angular deflection. The ammeter for motor
starter panel shall have a compressed scale above the rated circuit current to cater
for motor starting current. Voltmeter shall have an elevated scale with range of
around 90-120% of the nominal value and the zero shall be marked.

Frequency indicator shall be scaled 48-52 hertz and of accuracy class 1.0. Power
factor indicator shall be suitable for any condition of load and of accuracy class 2.5.

3.8 Panel Auxiliary Equipment

3.8.1 Selector and Control Switch

The selector and control switch shall be of rotary type with minimum contact rating
of 30A thermal and 16A 220V a.c. 0.4 p.f. lagging. All function selector switches
shall have spade type handle and key lockable in any selected position. The locks
for the same function selector switch in all switchboard in a station shall use a
common key.

Handles of control switches for circuit-breakers shall turn clockwise for closing and
anti-clockwise for tripping and shall be of the pistol-grip type. Control switches
shall be clearly labelled as "trip-neutra1-close", with spring return to the neutral
position. A mechanical interlock shall be fitted to prevent repetitive closing
without moving first to the trip position, and the handle shall be capable of being
locked in the neutral position.

3.8.2 Hour-run Meter

Hour run meter shall be a synchronous clock device with a digital indicator
registering 9999.9 hours and connected to either the 220V 50 Hz or the 110V d.c.
control supply. The meter shall be fitted with a mechanical push-to-reset button.

3.8.3 Indicating Lamp

Indicating lamp shall be circular shape of diameter 32 mm with glass spherical lens.
It shall be flush mounted on panel with the lens tip not protruding more than 40 mm
from the panel surface. 220V a.c. lamp shall be fitted with step-down transformer
for 6.3V a.c. lamp bulb. The use of LED type indicating lamp is preferred.

"Running" or "On" indicator shall be positioned on the right side of the "off'
indicator when arranged in a row.
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September 2011

3.8.4 Pushbutton

Pushbutton shall be of matching shape with indicating lamp. It shall have not less
than 2 change-over contacts with a minimum contact rating of30A thermal and 16A
220V a.c. 0.4 p.f. lagging.

Emergency stop pushbutton shall have a red mushroom head of stay-put and
turn-to-reset type.

3.8.5 Anti-condensation Heater

Anti-condensation heaters shall be fitted to each switchboard panel and the

associated isolator switch and control thermostat shall be provided.

3.8.6 Locking Facilities

Padlocks and keys shall be supplied for the lockable devices of the switchgear
panels. The key shall be unique for each padlock and fitted with an identification
plate indelibly marked with the panel and function type reference. Two keys shall
be supplied for each lock.

A key and padlock cabinet shall be supplied for each switchboard with more than
three panels. Hooks shall be provided for all keys and locks each identified with the
key number. The key cabinet shall be fabricated from mild steel sheets complete
with lockable hinged doors.

3.8.7 Labels and Warning Notice

Each switchgear and relay panel shall be fitted with circuit labels on both the front
and the rear. Labels shall be fixed by screws on the non-detachable parts of the
panel at a height of 1350 mm or above. The characters on the panel labels shall be
10 mm high.

The components shall be individually labelled.

"DANGER - HV LIVE TERMINALS" warning notices shall be attached to the

access covers of the cable boxes, eT chambers and busbar chambers.

Warning labels with red inscription of "DANGER - eT TERMINATION" shall be

affixed to the terminals of eT circuits.

3.9 Energy Meter

The energy meter shall be a programmable polyphase integrated meter suitable for
recording and displaying the following parameters of the power supply system

Voltage and current

Power factor and frequency
kW, kVAr and kVA
kWh, kV Arh and kVAb
 - 20- E-15-01
September 2011

The accuracy for measuring active energy and reactive energy shall be Class 1 to
IEC 62053-21 and Class 2 to IEC 62053-23 respectively. The meter shall be
provided with four programmable digital/pulse outputs and four programmable
0-20mA d.c. analogue outputs for remote indications.

The meter shall be of transformer operated type. The reference voltage shall be
110V 50Hz 3-phase derived from the voltage transformers at the incoming supply
panels. The rated current shall be lA derived from the measuring current
transformers at the incoming supply panels or the pump starter panels.

Meter configuration, programming and data retrieval, which shall be multi-level

password protected, shall be made via an optical communication port using IEC
62056-21 protocol and with the use of a personal computer.

All necessary interface probe cable, licensed softwares for meter configuration,
programming, data retrieval and load profile data conversion to standard worksheet
application software shall be provided.

3.10 Summation Meter Cubicle

A meter cubicle shall be provided for each station for housing the summation
metering equipment where the power system has two or more incoming supplies. A
set of epoxy resin encapsulated summation current transformers of accuracy class
0.5, rated output of 5VA minimum and rated secondary current of lA, and voltage
selection relays shall be provided for the following summation meters :­

(i) Maximum demand meters for on-peak and off-peak period, and
(ii) Energy consumption meters for on-peak and off-peak periods.

The cubicle shall be fabricated from 2mm thick sheet steel, ofIP54 protection index
and suitable for wall-mounting. The cubicle shall be provided with epoxy
powdered coating. The final coat shall be semi-matt of colour BS4800 shade
18B21 (light grey). Detachable cable gland plate shall be provided. The cubicle
shall have a front access hinged door fitted with a glazed window.

The meters shall be mounted inside the cubicle with necessary mounting brackets to
facilitate viewing the meter display through the glazed window. The voltage
selection relays shall be flush mounted on the access door.

The maximum demand and energy consumption meters shall have flexible
programming capabilities for complex tariff configuration, which are based on daily
and weekly schedules as well as exceptional days, and shall have facilities for load
profile storage and remote meter reading. The data storage capacity shall be
sufficient to store one value every 30 minutes for 90 days viz. total 4320 values.
The meters shall be fitted with real time clock and calendar supported by an internal
battery. The registered data shall be transferred to non-volatile memory on power
failure. A sealable push-button shall be provided at the front of the meter for
resetting the maximum demand data.
 - 21 - E-15-01
September 2011

The terminals for current transformer connections shall be provided with short
links. The terminals for voltage supplies shall be provided with fuses and link.

3.11 Power Supply Terminations

3.11.1 Termination Provision

The cable termination box shall be suitable and have sufficient space for the
termination of the power supply cables specified in the Particular Specification. In
general, it shall meet the termination requirements of the following XLPE insulated
armoured copper conductor cables:

No. of Cable Sizes (mm2)

Cores 630A panel 1250A panel 2000Apanel
1-3c 300 - ­
2-3c 300 - ­
3-1c 300 1000 ­
6-1c 300 1000 1000
9-1c - 1000 1000

Cable lugs and cable glands shall be supplied to match the external cables. Insulated
glands shall be provided for single-core power supply cables. Where more than one
cable enters the cable box, the clearance between adjacent glands shall be sufficient
to permit satisfactory cable termination.

3.11.2 Cable Termination Box

The cable box for power supply cable shall be type tested to withstand the specified
fault level or certified by BEAMA or other equivalent internationally recognized
authority. The cable box shall be fabricated from mild steel and segregated from the
CT chamber and other parts of the panel.

The cable box shall be accessible from the rear of the panel through bolted steel
covers and suitable for cable termination using heat shrinkable termination kits.
Shrouds shall be fitted to the terminals.

The cable box shall be arranged for bottom entry of cables. The gland plate shall be
horizontal and at least 300 mm from the panel base.

For single core cables, provision shall be made on the cable box and gland plate to
minimize the effect of eddy current.
 - 22- E-15-01
September 2011

3.12 Cable Accessories

3.12.1 Terminal Bases and Bushings

Terminal bases and bushings shall be epoxy resin or glass-fibre polyester

high-pressure mouldings. Porcelain bushings shall not be accepted.

3.12.2 Terminal Sockets for Power Cables

Cable terminal lugs shall be fabricated from hard-drawn cadmium copper with the

socket portion locally annealed for crimping. The lug shall be tinned throughout.

Each socket shall be supplied with a piece of heat shrinkage tubing of sufficient

length to cover, when shrunk, both the crimped portion of the socket and cable to

effectively relieve any strain.

Fixing bolts, nuts and washers for the cable sockets shall be supplied.

Stud holes in the palm of cable sockets shall have nominal diameters compatible

with the bolts and to BS 91, Tables 1 and 2.

3.12.3 Mechanical Cable Glands

Cable glands for elastomeric or plastic insulated cables shall comply fully with BS

6121 type EIW. Suitable shrouds, slip-on earth tags and backnuts shall be supplied
with the cable glands.

3.12.4 Small Wiring

Wires shall be black for a.c. connections, grey for d.c. connections and yellow/green
for earth connections.

Each end of the wire shall be provided with a crimp lug. Wiring shall be run in a
neat manner and shall enable its being examined without the removal of cleats.

Numbered interlocking ferrules of white PVC with black characteristics shall be

provided for cable core identification. Ferrules shall be capable of being fitted
firmly to cable cores.

3.12.5 Terminal Blocks

Terminal blocks shall comply with BS EN 60947-7-1. It shall be single-level

feed-through, screw or screwless type connection, DIN rail-mounted, vibration and
corrosion resistant, and modular design suitable for harsh industrial environment.

All a.c. and d.c. supply bus wiring terminals shall be fully shrouded and identified.
Terminal blocks for current transformer secondary connections shall be provided
with maintenance shorting links and clamps.
 - 23 - E-15-01
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3.13 Spares and Tools

The following spare parts and tools shall be provided for each switchboard in
addition to other spares and tools recommended by the Contractor for 1 year's
servIce :­

1. A shunt trip coil of each circuit breaker rating.

2. A closing spring release coil of each circuit breaker rating.

3. 100% high voltage fuses of each type and rating used, subject to a
maximum of 3 for each size.

4. A wall mounted cubicle with front access door for housing the spare
fuses.

5. One set of operating and maintenance tools (including CB operating

handles) complete in a carrying case (Cl. 3.2.4.1).

6. One set of 3-phase RV test plugs of each switchgear panel rating

complete in a carrying case (Cl. 3.2.4.4).

7. Padlocks and keys in a cabinet (Cl. 3.8.6).

8. A relay test plug for each type of relay casing (Cl. 3.5.1).

9. One set of single- and multi- finger type test plugs complete with
plug links for the test block (where applicable).

10. One spring charging motor.

11. One spare circuit breaker truck for pump starter panel.

12. Portable SF 6 gas detector (where applicable).

If specified, the following non-consumable spares and tools shall be included in the
lists of recommended spares and tools:

13. 2 control relays of each type and rating used.

14. 1 timer relay of each type and rating used.

15. 1 three-phase set of protection CT for the incoming supply panel.

16. 1 three-phase set of protection CT for pump starter panel of each

rating.

17. 1 motor protection relay.

18. 1 probe interfacing cable for programmable energy meter.

 - 24- E-15-01
September 2011

19. 1 complete set of licensed programming and load conversion

software for the programmable energy meter (Cl. 3.9).

4. INSPECTION AND TESTING AT WORKS

4.1 General

The complete switchboard supplied under the Contract including spares, tools and
testing equipment shall be inspected and witness-tested at manufacturer's works
prior to shipment.

The scope of inspection shall in general cover the followings:­

1. General inspection checks including physical dimensions,

workmanship, quality, quantity, and standards.

2. Functional checks of correct operation, interlocks and setting of

equipment.

3. Routine tests as specified or as required under the relevant British

Standards.

4. Packing and protection checks.

Inspection and test reports/certificates together with test arrangement drawings,

circuits, calculations, and test results shall be submitted within one week after the
inspection and testing.

Type test reports on equipment and standard calibration test reports on instruments
used in the switchboard shall be available for verification during the inspection and
the same shall be incorporated in the instruction manual.

4.2 Circuit Breakers

The works tests shall include routine tests as follows. The test requirements shall be
in accordance with BS 5311.

1. Power frequency voltage withstand tests on the main circuit.

2. Voltage withstand tests on the control and auxiliary circuits.

3. Measurement of the resistance of the main circuit.

4. Mechanical operation tests.

5. Insulation resistance tests on the main circuit and auxiliary circuits.

6. Gas pressure check (for SF 6 circuit breaker).

 - 25 - E-15-01
September 2011

4.3 Switchgear Panels

The works tests shall include routine tests as follows. The test requirements shall be
in accordance with BS EN 60298.

1. Power frequency voltage tests on the main circuit.

2. Dielectric tests on auxiliary and control circuits.

3. Measurement of the resistance of the main circuit.

4. Mechanical operation tests.

5. Tests of auxiliary electrical, pneumatic and hydraulic devices.

6. Verification of correct wiring.

7. Verification of interlocking facilities and correct operation of

control circuitry.

4.4 Voltage Transformers

The following tests shall be carried out at manufacturer's works to BS 7625 and
need not be witnessed.

1. Verification of terminal markings.

2. Power frequency withstand test on secondary windings.

3. Power frequency withstand test on primary windings.

4. Partial discharge measurement.

5. Determination of errors.

6. Insulation resistance tests.

4.5 Current Transformers

The following tests shall be carried out at manufacturer's works in accordance with
the requirements ofBS 7626 and need not be witnessed.

1. Verification of terminal markings.

2. Power frequency tests on primary windings and measurement of

partial discharges (where applicable).

3. Power frequency tests on secondary windings.

4. Tests of intertum insulation.

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September 2011

5. Determination of errors.

6. Determination of magnetization curve, knee-point voltage and

secondary winding resistance. For dual ratio CT, tests shall be
carried out on both tappings.

4.6 Protective Relays and Instruments

The relays and instruments shall be tested at manufacturer's works for verification
of correct operation and calibration. The correct wiring and performance of the CT
operated protection circuitry shall be verified by primary current injection at rated
CT primary current.

4.7 Summation Meter Cubicle

The correct wiring of the programmable energy meter, summation CT and voltage
selection relays (where applicable) shall be verified at manufacturer's works.

- End of this Specification ­