SPECIFICATION P-48: 81

A,C AND D,C AUXILIARY SERVICES PANELS

PAKISTAN
WATER AND POWER DEVELOPMENT AUTHORITY
DESIGTN DEPARTMENT, NTDC

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 C O N T E N T S

0. Foreword

1. Scope

2. Services Conditions

3. General Requirements

4. Circuit Breakers

5. Instruments

6. Meters

7. Current Transformers

8. Relays and Contractors

9. Alarm Annunciation Equipment

10. Enclosure and Accessories

11. Spare Parts

12. Drawings and Descriptive Data

PRINTING HISTORY

First approved on 18th November, 1968

Second edition on 13th August, 1981.

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 SPECIFICATION P-48:81

A.C AND D.C. AUXILIALRY SERVICES PANELS

AMENDMENT NO.2 DATED 10TH MARCH, 1986

1. Sub-Clause 3.9.1 A.C. Portion, Page-6

Please read “Power Circuit Breaker Heaters” instead of “ 132 kV

and 66 kV Breaker heaters” at Sr. No.16 under the head of Circuit
labeling.

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 SPECIFICATION P-48:81

A.C AND D.C AUXILIALRY SERVICES PANELS

AMENDMENT NO.1 DATED 28TH FEBRUARY, 83

Sub Clause 5.2.1 Please read the following revised clause in

Place of clause 5.2.1.

“5.2.1 Indicating instruments shall be semi flush

mounted, back connected, dust proof switch
board type having a removable transparent dust
tight window cover with a dull black finish to
match in appearance with relays and meters and
having facility to change the scale with or
without opening the instrument. The normal
size of instrument unless otherwise specified
shall be 144mm x 144mm. Scale plates shall
have a permanent white finish with black
graduation and numerals and with the
instrument transformer ratio if applicable for
which instrument has been graduated
prominently marked. The zero adjuster will be
provided out side the instrument. All
instruments shall be tropicalised”

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 SPECIFICATION P-48:81

A.C AND D.C AULILIALRY SERVICES PANELS

0. FOREWORD

0.1 This specification has been prepared by the Design Department of

Power Wing WAPDA.

0.2 This specification describes standard types of auxiliary services

panels for the procurement and does not include all the necessary
provisions of a contract.

0.3 This specification supercede3s P-48:68.

0.4 This specification is subject to revision periodically as and when

required.

1. SCOPE

1.1 This specification covers A.C and D.C auxiliary services panels for
supplying A.C Power, D.C power and D.C emergency power to
substation equipment.

2. SERCICE CONDITIONS

2.1 Atmospheric Conditions

It may be assumed that the air is not normally heavily polluted by

dust, smoke, corrosive gases, or vapour. However at certain times
of the year severe dust storms may be experienced.

2.2. Ambient Temperature

Maximum 500C

Maximum mean over any 24 hours 450C

Mean in any year 300C

Minimum 100C

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2.3 Relative Humidity

Relative humidity may range upto 100%. The maximum values of

ambient temperature and humidity however do not occur
simultaneously. During the monsoons high humidity may persist
for many days at a time.

2.4 Altitude

Installation upto 1000 meter above sea level.

2.5 Supply System

2.5.1 A.C Supply

The distribution panels shall be suitable for installation in a 3-

phase, 4-wire LT distribution a.c, and system and 2-wire d.c,
system of the following characteristics:

Type of system 3-phase 4-wire, neutral

Solidly earthed

Normal voltage 240/415 V

Limits of supply voltage which an AC operating device or auxiliary

equipment shall be capable of operating correctly.

+ 10%
- 10%

Rated frequency 50 Hz

2.5.2 D.C Supply

Nominal system voltage 110 or 220 Volts

System highest voltage 140 or 280 Volts

2.5.3 The d.c, supply shall be 110V unless otherwise stated.

2.5.4 The neutral on the LT side is solidly grounded at the 11,000/415

Volts distribution transformer.

3. GENERAL REQUIREMENTS

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3.1 The A.C and D.C auxiliary services panels equipped with circuit
breakers for incoming and outgoing circuits, protective devices,
instruments, meters, C.T’s and auxiliary equipment to be used
with 200 kVA pad mounted transformer.

3.2 The cubicle for auxiliary services panels shall consist of three
separate portions with partitions of insulating material for
separating a.c, d.c, and d.c, emergency portions.

3.3 The panels shall be designed for indoor use and shall be mounted
on the floor. Each panels shall accommodate the equipment
specified in clause 3.9 and shall be self-contained and self-
supporting.

3.4 The panels shall be designed throughout to secure safety during

operation, inspection and maintenance.

3.5 The auxiliary panel shall consist of bus bars, three phase and
neutral for a.c., and positive and negative for d.c., main and
emergency supplies, appropriate connections, incoming and
outgoing circuit breakers, a.c. no voltage relay d.c under voltage
and battery earth fault relays, instruments, meters, annunciators,
cable glands and cable trays all mounted in a suitable metal
enclosure. The breakers, instruments and meters shall be flush
mounted.

3.6 The panel will be fed through LT underground cables which will be
connected directly to the a.c., and d.c, incoming circuit breakers
terminations.

3.7 The general appearance and the relative po9sitions of the

equipment to be mounted on the panel shall be as per drawing No.
PDW/TS-1981.

3.8 Requirements

3.8.1 Each panel shall be fitted with but not restricted to the following
circuit breakers, instruments, relays, and contractors.

3.8.2 A.C. Portions

i) One No. triple-pole 400 amps circuit breaker for incoming

circuit with one normally close auxiliary contract.
ii) One No. triple pole 60 amps circuit breaker with one
normally close auxiliary contract.

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 iii) One No. triple pole 60 amps circuit breaker with earth-fault
protection.
iv) Two Nos. triple pole 30 amps circuit breakers each with one
normally close auxiliary contract.
v) Two Nos. triple pole 30 amps circuit breakers
vi) Two Nos. triple pole 16 amps circuit breakers
vii) Six Nos. double pole 16 amps circuit breakers.
viii) Ten Nos. double pole 16 amps circuit breakers.
ix) Three current transformers of 400/5 amps ratio for metering
purposes.
x) Three ammeters 0-400 amps, one in each phase.
xi) One voltmeter 0-500 volts to indicate busbar voltage.
xii) One seven position voltmeter selector switch for selecting
phase to phase, phase and “off” positions.
xiii) One 3-phase 4-wire, 415 volts, 400/5 amps kWh meter.
xiv) One No-volt relay.
xv) One four window annunciator unit with auxiliary relays and
flasher relays.

3.8.3 D.C Portion

i) One No. double-pole 100 amps circuit breaker for incoming

circuit with one normally close contact.
ii) Two Nos. double-pole 60 amps circuit breakers each with
one normally close contacts.
iii) Two Nos. double pole 60 amps circuit breakers.
iv) Five Nos. double pole 30 amps circuit breakers.
v) Two Nos. double pole 16 amps circuit breakers each with
one normally close contact.
vi) One No. double pole 16 amps circuit breaker
vii) One ammeter 0-100 amps alongwith shunt.
viii) One battery earth leakage relay to detect battery earth faults.
ix) One under voltage relay.
x) One double pole contractor 30 amps for emergency supply
xi) One four window annunciator unit with auxiliary relays and
flasher relays.
xii) D.C hooter.

3.8.4 D.C Emergency Portion

i) Four Nos. double pole 16 amps circuit breakers.

3.8.5 The busbars shall be of the following sizes:

i) 40 mm x 5 mm = for a.c., three phase and neutral busbars.

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 ii) 30 mm x 5 mm = for d.c., positive and negative, for main
and emergency busbars.

3.8.6. The minimum clearances for busbars, terminations and other

conductors shall be as under:

i) Phase to phase 50 mm
ii) Phase to neutral 50 mm
iii) Positive to negative 50 mm
iv) Phase to earth 25 mm

3.8.7 Brass cable glands for incoming cables shall be used and the solid
copper terminals strips shall be provided on incoming C.B’s for
connecting the incoming cables.

3.8.8 The terminal blocks for outgoing cables shall be suitable for the
following sizes of stranded aluminum cables for the C.B. ratings
given:

i) 60 amps CB’s = 70 mm2

ii) 30 amps CB’s = 35 mm2
iii) 16 amps CB’s = 16 mm2

3.8.9 The cable glands shall be suitable for the following sizes of PVC
insulated PVC sheated aluminum cables for connections to the
MCB’s of ratings given below:

i) 60 amps TP MCB’s = 70 mm2 4-core

ii) 30 amps TP MCB ‘s = 35 mm2 4-core
iii) 16 amps TP MCB’s = 16 mm2 4-core
iv) 60 amps DP MCB’s = 70 mm2 2-core
v) 30 amps DP MCB’s = 35 mm2 2-core
vi) 16 amps DP MCB’s = 16 mm2 2-core

3.9 Circuit breakers shall be labeled according to the following scheme

and as laid down in clause 10.1.11.

3.9.1 A.C. Portion

Sr.# Description C.B Rating Circuit Labeling

1 Incoming 400A T.P (+ N/C) A.C Incoming
2 Outgoing 60A T.P (+ N/C) Battery Charger
3 Outgoing 60A T.P (+E/F) Switchyard Power
Outlets
4 Outgoing 30A T.P (+ N/C) 132kV and 66 kV

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 breaker motors
5 Outgoing 30A T.P (+ N/C)
6 Outgoing 30A T.P Transformer No.1&2
7 Outgoing 30A T.P Cooling fans
8 Outgoing 16A T.P Transformer No.1&2
9 Outgoing 16A T.P Tap changers
10 Outgoing 30A D.P Control and relay
room power out lets
11 Outgoing 30A D.P Control room Air
12 Outgoing 30A D.P Conditioners
13 Outgoing 30A D.P Relay room Air
14 Outgoing 30A D.P Conditioner
15 Outgoing 30A D.P Telecom room air
cond.
16 Outgoing 16A D.P 132kV and 66 kV
17 Outgoing 16A D.P Breaker heaters
18 Outgoing 16A D.P 11kV breaker motors
19 Outgoing 16A D.P -do-
20 Outgoing 16A D.P Control and relay
panels
21 Outgoing 16A D.P -do-
22 Outgoing 16A D.P Control and relay
room
23 Outgoing 16A D.P Lighting
24 Outgoing 16A D.P Telecommunication
battery chargers
25 Outgoing 16A D.P Spare

3.9.2 D.C.Portion

1. Incoming 100A D.P (+N/C) D.C Incoming

2 Outgoing 60A D.P (+N/C) 132 kV and 66 kV
3 Outgoing 60A D.P Breaker motors
4 Outgoing 60A D.P Control & relay
5 Outgoing 60A D.P Panels
6 Outgoing 30A D.P 11 kV breaker
7 Outgoing 30A D.P Motors
8 Outgoing 30A D.P D.C Emergency bus
9 Outgoing 30A D.P
10 Outgoing 30A D.P Spare
11 Outgoing 16A D.P (+N/C) 11kV Switchgear
12 Outgoing 16A D.P Protections
13 Outgoing 16A D.P Spare
3.9.3 D.C. Emergency Portion

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 1. Outgoing 16A D.P Control building
2 Outgoing 16A D.P Lighting
3 Outgoing 16A D.P
4 Outgoing 16A D.P Switchyard lighting

3.10 Annunciation Scheme

3.10.1 The scheme consists of initiating visual indication by incandescent

lamps and audible alarm by d.c. hooter and a.c. bell for a.c. and
d.c. functions respectively.
3.10.2 The scheme shall include auxiliary relays flasher relay, signal
lamps, indicating unit, and push button for:

a) Acknowledgement
b) Reset
c) Lamp test

The indicating unit shall have transparent cover inscribed with

various trip functions.

3.10.3 On energisation of a function the associated auxiliary relays shall

operate the hooter or bell and at the same time cause the
respective signal lamp to begin to flash. The duration of flash shall
be sufficient for the inscription of the function to be read easily.
On pressing the alarm cancellation push button the hooter or bell,
will be silenced and the signal lamp will stop flashing and change
into continuous light which shall remain alight until the cause of
fault is removed. The reset push button shall then be pressed to
extinguish the signal lamp.

3.10.4 If a second function is energized before having the previous

function cleared the scheme shall refunction the same way as
described above.

3.10.5 The lamp test button shall be used to test when required all the
signal lamps of the unit simultaneously.

3.10.6 The indicating units for alarm functions shall have following
inscriptions:

A.C. Functions

Functions: Inscriptions:

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 i) Main Incoming MCB tripped Incoming C.B tripped
ii) Battery charger A.C MCB tripped Battery charger supply failed
iii) HV circuit breaker motor supply HV C.B motors supply failed
failed
iv) A.C No-Volt relay operated A.C No- Volt relay

D.C Functions

i) Main Incoming MCB tripped Incoming C.B tripped

ii) HV circuit breaker HV C.B motor supply failed
iii) 11 kV circuit breaker 11 kV protective supply failed
protective supply failed
iv) Under voltage or battery U/V or E/F operated
earth fault relay operated

4. CIRCUIT BREAKERS

4.1 General

The circuit breakers shall be moulded case, double pole, and triple
pole automatic air break with nominal voltage of 110 Volts d.c.,
220 Volts d.c., and 415 Volts a.c., and with auxiliary contacts as
specified. The circuit breakers shall be equipped with thermal and
magnetic over current releases and earth leakage protection as
required.

4.2 Enclosure

4.2.1 The enclosure shall be made of insulating material resistant to

heat, moisture, and fungus.

4.2.2 The enclosure shall b e so made as not endanger the operator by

the effect of gases or arcing.

4.3 Operating Mechanism

4.3.1 The circuit breaker shall be manually operated by a quick make

and quick break mechanism which shall operate by compressing
springs in the first part of the make or break operation, which
springs shall then assist in completing the operation independently
of the operator’s efforts. The operation shall be continuous and
the mechanism shall not hold in an intermediate position in any
case. The mechanism shall be so designed that a fault on one
pole, shall trip all the poles simultaneously.

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4.3.2 The circuit breaker shall be mechanically trip-free. Breaker
position identification shall be provided either by means of the
breaker handle position or mechanical “On” and “Off” indicators.
Circuit breaker shall be capable of being pad locked in the open or
closed position. Pad locks shall also be provided.

4.4. Contacts.

4.4.1 The contacts shall be heavy duty spring loaded type and shall be
silver faced. The temperature rise of any current carrying part
shall not exceed 400C.

4.5 Arc Chutes.

4.5.1 Arc chutes shall be provided for extinguishing of the arc.

4.5.2 Arc chutes shall be so situated that emission of flame or hot gases
or both will not cause electrical break-down or damage to
insulation of main and auxiliary circuits and will be directed away
from any place where an operator may have to be in the course of
his ordinary duties.

4.6 Terminals

4.6.1 Terminals shall be grouped in terminal blocks made of insulating

material of adequate mechanical strength. The shall be arranged
for rear connection.

4.6.2 The terminals shall ensure adequate and durable contact such
that there is no undue risk of loosening and over heating. The
terminals shall be such that the conductor which are held together
by two screws bite directly into the conductor shall not be
acceptable.
4.6.3 The incoming breakers shall be provided with terminals strips.
Lugs shall also be provided for connection of incoming stranded
aluminum conductor cables.

4.6.4 The terminal strips and lugs shall be made of copper or brass and
shall be tin or cadmium plated.

4.7 Rating

4.7.1 The standard ratings shall be as under:

Rating Triple Pole Double Pole Double Pole

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 i) Rated voltage 415 Volts 240 Volts
110 or 220
Volts
ii) Rated frequency 50 Hz 50 Hz -
iii) Rated nominal 16,30,60 & 16 & 30 16,30,60 &
current 400 Amps Amps 100 Amps
iv) Rated symmetrical 7500 Amps 7500 Amps 5000 Amps
breaking capacity
v) Rated making 13000 13000 Amps 8500 Amps
capacity Amps
vi) Rated short time 1 7500 Amps 7500 Amps 5000 Amps
sec breaking
capacity
vii) One minute power 2000 Amps 2000 Amps 2000 Amps
frequency
withstand voltage

4.8 Tripping and Auxiliary Devices

4.8.1 Each circuit breaker shall be equipped with two direct operating
over current releases. One shall be of the thermal type and other
shall be of the magnetic type. The releases shall be rated as
under:

Rating of Breaker Rating of Releases

16 Amps 16 Amps
30 Amps 30 Amps
60 Amps 60 Amps
100 Amps 100 Amps
400 Amps 300 & 400 Amps

4.8.2 The thermal release of circuit breakers shall preferably operate and
open the breaker within maximum and minimum times of which
the mean values are tabulated below. These opening times are
based while the circuit breaker is at the operating temperature.
The outgoing breakers shall however be coordinated with the
incoming breakers and the supplier shall submit the coordinating
curves.

Rated current Operating time in Secs. Of thermal release for

multiple circuit breaker rating of
300A 100A 60A 30A 16A
2.0 300 60 30 15

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 5.0 30 18 12 6
10.0 10 4 3 2

4.8.3 The magnetic release shall be of the instantaneous type and shall
open the circuit breaker in less than 40 ms complying with the
following requirements:

Breaker Rating Maximum Trip Current

16 Amps DP 5000 Amps
30 Amps DP 5000 Amps
60 Amps DP 5000 Amps
100 Amps DP 5000 Amps
16 Amps TP 7500 Amps
30 Amps TP 7500 Amps
60 Amps TP 7500 Amps
400 Amps TP 7500 Amps

4.9 Mechanical and Electrical Life

4.9.1 The circuit breaker shall be capable of make and break operations
given below without damage. The electrical operations shall be
made at rated continuous current, rated voltage and at rated
frequency and with a lagging power factor of 0.75 to 0.80. The
mechanical operations shall be made at no load and with rated
voltage. During the test cleaning, tightening and lubrication of
parts if required may be carried out after every 500 cycles.

Electrical operation 500 cycles

Mechanical operation 8000 cycles

4.9.2 The frequency of operations shall be not less than 20 in 10

minutes or 100 in an hour. At the end of the test, the circuit
breaker shall be capable of meeting its continuous current voltage
ratings, and one opening test at rated short circuit current.

4.10 Rating Plate

4.10.1 The following information shall be marked on the name plate of

each LT breaker.
1) Rated current
2) Voltage
3) Interrupting rating
4) Thermal setting
5) Magnetic setting

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 4.11 Tests

4.11.1The following type and routine tests shall be carried out:

Type Test

1) Making capacity, breaking capacity and short time current

test to verify the ability of a breaker to meet its making,
breaking ad short time current rating.

2) Mechanical and Electrical Life test to determine the service

life of breakers. The number of make and break operations
shall be as given in clause 4.9.1. This test shall be made at
rated control voltage without repair or replacement of any
part.

3) Temperature rise test to determine the temperature limits

specified in clause 4.4.1 are not exceeded.

4) Voltage test to determine that the insulating parts have

sufficient insulation resistance.

Routine Tests

1) Visual Inspection. All parts of circuit breaker shall be

checked visually and they shall comply with all the
requirements laid down in the specification.
2) Operation Test.. For verifying the correct operation of the
breaker and trip.
3) Power Frequency Voltage Test. The test voltage shall be
applied between phases with the circuit breaker closed,
between phases and earth, and across the terminals with
circuit breaker open. The test voltage shall be alternating of
frequency 50 cycles per second and approximately of sine
wave form.
4) Milivolt Drop Test. Milivolt drop test or equivalent
resistance measurement shall be made across circuit
breaker contacts and between terminals for comparison with
the temperature rise test at the rated normal current.

4.11.2 The circuit breaker used for type tests to be carried out by the
manufacturer shall be identical in all essential details with those to
be supplied.

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4.11.3 Certificates of all the type tests shall be supplied by the
manufacturer, together with a record of any alternation which have
been made to the circuit breakers subsequent to type tests. The
tests shall be carried out by a recognized authority.

4.11.4 All breakers shall be subjected to routine tests by the WAPDA

Inspector.

4.11.5 The manufacturer shall be required to indicate the duty cycle and
the designation and number of the national standard to which the
breaker is manufactured. This shall be subjected to approval by
WAPDA. All test shall be carried out in accordance with test
methods laid down in the approved standard. A copy of national
standard in English Language shall be provided with the bid.

5. INSTRUMENTS

5.1 General

5.1.1 The instruments shall be manufactured and tested in accordance

with International Electro technical Commission Publication 51
(1973) and the requirements listed herein.

5.2 Constructional Requirements.

5.2.1 Indicating instruments shall be semi flush mounted, back

connected dust proof switch board type, having a removable
transparent dust tight window cover with a dull black finish to
match in appearance with relays and meters. The normal size of
instruments unless otherwise specified shall be 144 mm x 144
mm. Scale plates shall have a permanent white finish with black
graduations and numerals and with the instrument transformer
ratio if applicable for which instrument has been graduated
prominently marked. The zero adjuster will be provided outside
the instrument. All instruments shall be tropicalized.

5.2.2 Ammeters shall be suitable and robust enough to withstand the

momentary large current arising in the circuits during short circuit
conditions without damage or loss of accuracy. Shunts used with
d.c., meters shall be rated 50 mv.

5.2.3 Terminal Markings.

5.2.3.1 The marking of terminals of instruments intended for use with

instrument transformers should preferable be the same as those of

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 the terminals of the instrument transformer in which they are to
be connected.

5.2.4 Diagram of Connection

A diagram of connection giving the following particulars shall be

supplied with the instrument.

1) The correct disposition of the connections carrying current to

and from the instrument.
2) Diagram explaining internal working of the instrument.

5.2.5 Damping of Instrument.

The damping of the instruments shall comply with clause 8.1 of

IEC Publication 51.

5.2.6 Continuous Load and Overload Capability.

5.2.6.1 All instruments, together with their accessories, shall comply with
the requirements appropriate to their accuracy class when they are
continuously loaded at their upper measuring limit under the
reference conditions specified in Table III and IV of IEC Publication
51.

5.3 Accuracy Class.

The accuracy of instruments shall be of class 1.5 for ammeters and

voltmeters.

5.4 Scale Ranges

5.4.1 Ammeters.

The preferred full scale values of ammeters for use with or without
current transformers shall be as follows:

Rated primary current of CT or Full scale value

circuit current

100 120

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 400 500

5.4.2 Voltmeters

The preferred full scale values of voltmeters shall be as follows:

Nominal system voltage Full scale value

110 V or 220 V 150 V or 300 V

415 V 500 V

5.4.3 Scale Marking

The scale plates shall clearly define the corresponding CT ratio if

applicable and the CT ratio wording shall be prominently marked
on the dial plate. For d.c., instruments the circuit current or
voltage shall be marked. The scale marking shall be evenly
distributed between 10 percent and 100 percent of the scale range.

5.5. Marking and Symbols

Marking and symbols of instrument transformers shall be in

accordance with clause 10 of IEC Publication 51.

5.6 Name Plate Data

A name plate showing the following shall be attached with the

instrument.

1. Rated values
2. Specification number
3. Manufacturer’s name with country of origin and year of
manufacture
4. Percentage error.

6. METERS

6.1 kWh meters shall be of 3-elemet 3-phase 4-wire induction type,

class 1.0. The meter shall always be equipped with maximum
demand indicator. The current coils of the meters shall be of 5/10
amps rating.

6.2 The meters shall be supplied and tested in accordance with

WAPDA Specification P-9 & P-42.

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7. CURRENT TRANSFORMERS.

7.1 The current transformers shall be single pole, single ratio of 400/5
amps, output of 5 VA, standard accuracy class of 0.5 and suitable
for metering purposes at the rated frequency of 50 Hz.

7.2 The current transformers shall be generally manufactured and

tested in accordance with WAPDA Specification P-99: 74.

8. RELAYS AND CONTRACTORS

8.1 General

8.1.1 Relays and contractors shall be tropicalised and shall be suitable

for satisfactory operation under service conditions specified in cl.2.

8.1.2 Relays shall be so designed and constructed that reasonable

mechanical shock or external vibration does not operate or damage
them.

8.1.3 Relays shall be of the back connected, dust proof, flush mounted,
switchboard type, having a removable cover, with a transparent
window and having provision for sealing. The relay finish shall be
dull-black. The relays shall preferably be of the type which can be
withdrawn from the front.

8.1.4 The draw out and plug-in units of relays shall be such that any
person inserting or withdrawing the units with reasonable care
cannot come into contact with live parts. The draw out case shall
be so arranged that it is not possible to caused inadvertent tripping
signals either during the process of withdrawing the removable
part or reinserting it.

8.1.5 Manufacturing tolerances for relays shall be such that chassis or

plug-in units of similar design can be inserted in any case of
corresponding design.

8.1.6 The rated error of all the protective relays shall be 7.5 percent.
The relay characteristics shall not change by more than + 7.5
percent wit changes in ambient temperature of + 10 0C from the
reference temperature, which shall be 25 0C.

8.1.7 Setting adjustments shall be inaccessible until the case or the

cover is removed. The values of the setting shall be clearly marked
and shall be visible when the relays case is closed.

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8.2 A.C. NO- VOLT RELAY

8.2.1 The a.c., No-Volt relay shall be used to energise d.c., emergency
supply through d.c., contactor in case of a.c., supply failure.

8.2.2. A.C. No-Volt relay shall be electromagnetic with coil rated at 240
Volt a.c., and two pair of normally closed contacts.

8.2.3. The relay shall close its contacts at fall of voltage to 70% value and
open the contacts when the voltage rises to 85% value.

8.2.4 The relay shall b e equipped with two pair of contacts rated at 10
Amps making or breaking at 110 V to 220 V d.c.

8.3 D.C. CONTRACTOR

8.3.1 The contactors shall be electromagnetic, plunger type, two pole,

with double breaker main contacts and auxiliary contacts for
indication of its operation.

8.3.2 The coil shall be rated 110 V or 220 V d.c., and contacts rated for
30 Amps making and breaking at 110 V or 220 V d.c.

8.4 Under Voltage Relay

8.4.1 The under voltage relay shall be electromagnetic with coil rated at
110 V d.c., and two pairs of normally closed contacts and flag
indicator.

8.4.2 The relay shall close its contacts at fall of d.c., voltage to 70% value
and open the contacts when the voltage rises to 95% value.

8.4.3 The relay shall be equipped with two pair of contacts rated at 10
Amps making or breaking at 110 to 220 V d.c.

8.5 Battery Earth Fault Relay

8.5.1 The relay shall be used to detect ground faults in the station
battery and provided with plug indicator.

8.5.2 The relay shall have polarized electromagnetic coil which will
energise when the leakage current exceeds 1 MA. The drop out to
pick-up ratio will be 80%.

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8.5.3 The pair of contacts shall be provided each rated at 10 Amps at
110 V to 220 V d.c.

8.5.4 The relay burden shall not exceed 3 w.

8.6 Tests

8.6.1 Relay and contactors shall be subjected to routine tests at the

manufacturer’s works. Tests results for the type tests perfomed by
the manufacturer shall also be furnished.

8.6.2 The following routine tests shall be performed by the manufacturer

and test results to be furnished:

i) Limits of error
ii) Resetting value test
iii) Insulation resistance test with 2000 V meggor.

8.6.3 The relays and contactors shall withstand a test voltage of 2000
volts r.m.s. for 1 minute. All insulated parts and terminals shall be
tested to earth.

9. ALARAM ANNUNCIATION EQUIPMENT

9.1 Annunciator Unit

9.1.1 The annunciator unit shall consist of annunciator relays,

indicating units, and push buttons all wired to meet with the
requirements of clauses 4.4.3 to 4.4.5. The annuciator unit shall
either be self contained with all the components in one unit or with
separate relays and indicator units.

9.1.2 The annunicator relays shall be electromechanical with at least

four change over two way contacts or alternatively with at least
four normally open and four normally closed self reset contacts.

9.1.3 The relay coil shall be rated 110 V D.C. or 220 V for D.C
annunciator units and 240 V AC for AC annunicator units for the
supervision circuits. The relay contacts shall not be rated less than
5 Amps at 150 Volts.

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9.1.4 The indicating unit shall be molded plastic, flush mounting type
with transparent or opaque covers fitted with lamps, and push
buttons. The dimensions of each window shall be approximately 65
x 30 mm.

9.1.5 The push buttons shall at least be rated for 10 Amp making and
breaking at 140 Volts. The push buttons for alarm acknowledge,
lamps test and alarm reset shall respectively be colored red, green
and orange.

9.2 Lamps

9.2.1 Lamps shall be easily removed and replaced from the front of the
panel by manual means. The lamp fittings shall allow adequate
ventilation and shall not incorporate material subject to
deterioration under high ambient temperature.

9.2.2. The indicating lamps shall be of screw type with base E-10 and
length 40 mm. The rating shall be 5 W at 140 V.

9.2.3 The supervision lamps shall be of neon type with screwed base of
E-10 and rated at 5 W at 140 Volts/ 280 Volts.

9.3 Alarm Bell and Hooter

9.3.1 The alarm bell and hooter shall be substation type with coils rated
230 volts for a.c. bell and 110 V or 220 V for d.c. hooter.

9.3.2 The bell and hooter shall be suitable for giving loud clear
penetrating signals. The electromagnetic system shall be encased
in tough plastic or metallic casing. Arrangement for interference
suppression shall also be provided.

9.3.3 The a.c. bell shall have a flat gong of about 150 mm in diameter
and the d.c. hooter a trumpet of about 200 mm. The sound levels
shall not be less than 100 decibels at a distance of 1 meter.

9.4 Tests

9.4.1 The component parts of the annunciator system shall be

completely wired together and connected to a 110 Volts or 220 Volt
d.c. or a.c. supply as the case may be and tested for correct overall
electrical and mechanical operation adjustment including test for
correct operation at under voltage specified. Annunciator wiring

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 shall be given a point to point check. The wiring shall be subjected
to the standard dielectric test of 2000 V for one second.

9.4.2 All plug-in modules or printed circuit boards shall be pulled out
before applying high potential tests.

10. ENCLOSURES AND ACCESSORIES

10.1 Enclosure.

10.1.1 The auxiliaries services panels shall be completely assembled wired

and tested at the factory. Shipment will be as a complete unit.

10.1.2 The housing shall be fabricated according to drawing No. PDW/TS-

1981 with bolted and welded construction.

10.1.3 The dimensions of overall enclosure shall be based on

requirements of space for the installation of the equipment
specified, ventilation space for circuit breakers and bus bars and
insulation and clearance for bus bars and cable connections. The
panels shall have dimensions of 2200mm height, 600mm depth
and 1200 mm width. The panel shall be provided with removable
front and bottom plates, double leaf hinged back doors and lifting
hooks. All live parts, including circuit breakers, current
transformers, bus bars connections etc. shall be enclosed in the
panel.

10.1.4 Access to bus bars, circuit breakers, terminals, current

transformers, bus bars connections, terminal blocks etc. shall be
through doors with locking facilities provided in the rear of the
panel. Circuit breaker operating handles, instruments and relays
etc., shall be accessible from the front of the panel.

10.1.5 The circuit breakers shall be mounted at a lowest level of 600mm,

from bottom. The bus bars shall be adjusted vertical at a suitable
height from the bottom and at a sufficient clearance from back
doors. The terminal blocks for outgoing circuits shall be placed
horizontal at level of about 450mm from bottom and sufficient
clearance from the back door shall be provided for ease in cable
installation, and connections. Directly attached terminations shall
be provided for the incoming A.C and D.C circuit breakers. Cable
glands shall be provided in the detachable bottom plates.

10.1.6 The enclosure shall be made from leveled high grade sheet steel
3mm in thickness as indicated in the above mentioned drawing
with edges formed into a rectangular pattern, rigidly bolted or

24
 welded to shapes so that each section is rigid and self supporting.
Panels shall be so constructed as to make them completely vermin
proof with special regard to the danger of flashover both in service
and isolated positions.

10.1.7 Two hinges per door of rugged design shall be provided to prevent
sag or misalignment. The hinges shall be designed to suit the
gasket in the back door.

10.1.8 Suitable screwed type lifting hooks shall be provided for lifting the
complete panel by means of slings. The ho9les of the lifting eyes
shall have a minimum diameter of 40 mm.

10.1.9 Panels shall be provided with adequate louvers in the back door
upper part and on from lower part for ventilation of t5he panel
equipment. Brass wire gauze shall be bolted inside the louvers to
prevent ingress of insects.

10.1.10 Cutouts for circuit breakers, instruments, relays annunciators,

lamps etc. shall be cold punched and properly rubber gasketed.

10.1.11 Each circuit breaker shall have provision for identification of the
circuit being protected. Plain plastic sheet of black colour with 3
mm thickness shall be provided for each circuit breaker and
engraved as shown in drawing No. PDW/TS-19082. The size of
labeling sheet be about 60 x 40 mm.
10.1.12 A pocket shall be provided inside the rear door for keeping the
panel drawings. The size of the pocket shall approximately be
250 x 350 x 40 mm.

10.1.13 Necessary holes shall be provided for grouting of the panels by

means of M12 bolts.

10.2 Terminal Blocks

10.2.1 Terminals blocks shall be made of high grade melamine with

terminal sleeve, screws and fixing arrangement.

10.2.2 The terminal block shall be rugged and non flexible so that after
being fixed, shall not come out of the fixing device in applying
moderate pressure in tightening the terminal screws.

10.2.3 Terminal blocks suitable for following sizes of stranded aluminum

conductors shall be provided:

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 i) 70 mm2
ii) 35 mm2
iii) 16 mm2

10.2.4 The terminal tube shall be rectangular pressure plate type made of
nickel plated cooper zinc alloy. The terminal sleeve shall be
provided at each end with nickel plated zinc alloy screws and
captive washers to prevent its removal from the block. The
terminal should not work loose even if exposed to seismic
vibrations.

10.2.5 The terminals tube shall be capable of accommodating on each end

at least two wires each of cross section mentioned above.

10.2.6 Terminals blocks shall be fixed to assembly rail of 30 mm base.

The rail shall be made of galvanized, chromatised or zinc
passivated steel. The assembly rail shall be fixed to the panel by
means of steel brackets and studs. The assembly rail shall be
according to DIN standard 46277.

10.2.7 Terminal blocks strip shall be mounted horizontally at an easily

accessible position to the side of the panel approximately 300mm
from the panel base and equipped with barriers, terminal strips
and colour coded strips of the same material as that of the
terminal block. A.C. D.C. current and potential transformer
circuits shall be physically segregated in groups. The A.C 240/
415 Volt circuit terminals shall be fitted with non inflammable
transparent plastic covers to prevent accidental contact with live
parts.

10.3 Cable Trays

10.3.1 The cable tray shall be made from wrap proof, PVC in two parts,
the base channel and the cover. The U-shaped channel shall have
side slots for wire outlets and shall be fixed on metallic brackets to
the panel by means of studs. The cover shall be removable and
fixed to the channel by simple push on, no screws or bolts be used.

10.3.2 Horizontal and vertical cable trays shall be used to carry wires
from terminal blocks to the circuit. The cable trays shall be
arranged to allow minimum lengths of hanging wires.

10.3.3 The size of cable trays shall be chosen so that only 70 percent of
the cable tray space is occupied.

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10.4 Bus Bars and Supports.

10.4.1 A set of eight bus bars, three for phases, one for neutral, two for
d.c., main and two for d.c., emergency supply made of high
conductivity copper of at least 98% IACS conductivity, and of
rectangular cross section shall be provided.

10.4.2 The bus bars shall be air insulated and mounted on insulators
placed at suitable intervals so that they are rigidly mounted. The
bus bars shall be completely covered with insulation capable of
withstanding the full line to line voltage.

10.4.3 The size of the bus bars shall be 40 x 5mm for a.c., supply and 30
x 5mm for d.c., supply.

10.4.4 All bus bars at joints shall be tin plated and firmly jointed. A
drawing showing clearly the details and methods of jointing shall
be provided by the manufacturer.

10.4.5 The maximum temperature rise of the bus bars at their

connections and joints shall be 30 0C.

10.5 Wiring

10.5.1 All wires shall be PVC insulated with tinned copper conductor
rated 1000 volts. Following wire sizes shall be used:

i) 70 mm2, 4-core
ii) 35 mm2, 4-core
iii) 35 mm2, 2-core
iv) 16 mm2, 4-core
v) 16 mm2, 2-core

10.5.2 All wiring shall be carried insulated in cable trays as far as

possible which will provide easy access for inspection and
replacement of wiring. Each wire shall be properly protected where
it leaves the cable tray.

10.5.3 Exposed wiring shall be kept to a minimum but where used shall
be formed into compact flat groups suitably turned together and
properly supported.

10.5.4 There shall be no splices in the wiring and all connections shall be
made at terminal studs or terminal blocks. Wiring to all the screw
studs or terminal blocks. Wiring to all the screw terminals shall be
made by means of toothed lock washers. Connection across

27
 portions with flexible wires which shall be supported on both sides
to avoid stress on terminals due to bending of wires.

10.5.5 Ends of each wire shall be identified by a machine lettered

permanent fiber or plastic ferrule securely attached to the
conductor with no possibility of detachment under normal
handling.

10.5.6 Suitable provision shall be made for supporting incoming cables

from the point of entrance into the panel to the termination on
terminal blocks or device terminals.

10.6 Eearthing

10.6.1 All metal parts of the panels shall be efficiently bonded together.
Hinged doors shall be connected to the panel body by means of
flexible copper earthing straps and the hinges shall not be relied
upon for effective earthing.

10.6.2 In case panel two independent external earthing facilities shall be

provided. Earthing terminals shall accommodate 95-120mm2
stranded copper wire for connection to the earthing system.

10.7 Painting

10.7.1 All interior and exterior surfaces of the enclosure shall be

thoroughly cleaned to prepare the metal surface for painting.

10.7.2 Three coats of paint shall be applied. The first coat shall be a
primer of zinc chromate and iron oxide or any other primer which
has equivalent weather resistance and rust inhibiting properties.

10.7.3 The second coat shall be based on synthetic resin with suitable
properties for resistance to weathering.

10.7.4 The third finish coat shall also be based on a synthetic resin and
shall have a hard durable surface and excellent weathering
properties.

10.7.5 Alternative paint system having equivalent durability and

resistance to weathering may be allowed if approved. Full details
shall be supplied for approval.

10.7.6 The total paint thickness shall be at least 0.10 mm, Finish shall
be white inside and light green outside, to the approval of
Engineer.

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11.8 Tests

11.8.1 Tests for the main equipment such as circuit breakers,

instruments and meters, C.Ts relays and annunciation equipment
are described in the relevant section. Tests for the completed
panel and accessories are described hereunder.

11.8.2 Mechanical: All contacts of all circuit breakers, relays devices and
accessories including mounted equipment and such devices
furnished as un-mounted and spare parts, shall be tested for
correct operation. Device markings, name plate markings,
conductor identifications, terminal blocks with designations and
the scales of meters and instruments shall all be checked against
the approved shop drawings. Each auxiliary services panel shall
be checked for alignment of circuit breakers, instruments, meters
and devices, for rigidity of structures, and for adequacy of
fastenings and supports. The dimensions of panel’s sheet
thickness and part thickness shall be checked.

11.8.3 Electrical: Panel wiring shall be given a point-to-point check.

Relays shall be given an operational test to check the operation of
all protective and alarm circuits. Other equipment shall be given
an operational test as far as the auxiliary services panel mounted
devised permit and as may be required by the Engineer.

11.8.4 Dielectric tests shall be performed to determine the adequacy of

the insulation of wiring. After the panels are comp0letely
assembled and wired, they shall be subjected to dielectric tests of
2000 Volts applied successively for one second between one
terminal and gr4ound of each isolated conductor. All necessary
precautions shall be taken to prevent damage to equipment not
designed or intended to withstand this test. All grounding
connections to the ground bus or panels shall be removed during
the test.

12 SPARE PARTS

12.1 General

12.1.1 The spare parts required in accordance with this specification are
intended to be ordered alongwith the supply of auxiliary services
panels. Prices of each spare parts shall be supplied.

12.1.2 All spares supplied shall be new, unused and strictly

interchangeable with the parts which they are intended to replace.

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12.2 Estimation of Requirements

12.2.1 The spare parts shall be divided into two categories. The first
category shall contain such spare parts as are normally required to
be replaced in the course of time due to wear and tear of the
equipment under normal service conditions. The second category
shall contain spare parts which may be required due to accidents,
malfunctioning of the equipment or other emergencies. Such spare
parts would be stocked to eliminate long shutdown of equipment.
The lists of spare parts falling in each category shall be prepared
separately and supplied.

12.2.2 For the guidance of suppliers, lists of the principal spare parts are
given in clause 11.4. The supplier shall prepare his
recommendations generally in line with these lists. He shall add to
these lists such other parts as he deems necessary to stock. If the
supplier considers that the provision made hereunder is
inadequate or is too great, he shall make recommendations
accordingly.

12.2.3 For the normal replacement of spare parts the supplier shall
prepare his own recommendations. In making these
recommendations he shall keep in mind that the climate
conditions shall be very severe which may cause more rapid
deterioration of heat sensitive parts such as gaskets. The
recommendations shall be made on the basis of 3 years
requirements of spare parts.

12.3 Packing

12.3.1 The spare parts shall be treated and packed for long storage under
the climate conditions specified in clause 3. Each spare shall be
clearly marked and labeled on the outside of its packing with its
description and purpose. When more than one spare is packed in
a single case or other container, a general description of its
contents shall be shown on the outside of such case of container
and a detailed list of enclose parts shall be given. All cases,
containers or other packages shall be marked and numbered in an
approved manner for purposes of identification.

12.3.2 All cases, containers or packages are liable to be opened for

examination and packings shall be designed to facilitate opening
and thereafter easy repacking.

30
12.4 List of Spare Parts.

12.4.1 Unit prices of the items should be stated against each.

i) Circuit breaker – each type

ii) Current Transformer
iii) Voltmeter – each type
iv) kWh meter
v) A.C No-volt relay
vi) Battery earth – leakage relay
vii) D.C contractor
viii) D.C under voltage relay
ix) Four window Annunciator unit complete
x) Annunciation auxiliary relay
xi) Flashing relay
xii) D.C hooter
xiii) A.C bell
xiv) Terminal block – each type
xv) Cable gland – each type

13 DRAWINGS AND DESCRIPTIVE DATE

13.1 Tender Drawings and Data

The following drawings, information and descriptive data shall be

supplied with the Tender and failure to supply the same may
subject the bid to disqualification.

13.1.1 Complete Auxiliary Services Panel

i) Overall assembly drawing showing front, side rear and plan

views with door closed and open. Sufficient cross-sections
and parts views shall be given to show clearly all the
equipment. All leading dimensions and clearances shall be
indicated.
ii) Details and the mountings of the bus bars, insulators and
methods of jointing of bus bars and insulators.
iii) Weight of complete panel

13.1.2 Circuit Breakers

i) Current, voltage and frequency rating of LT breakers

ii) Interrupting rating
iii) Time/ current characteristics curves for each rating of
breaker

31
 iv) Time/ current coordination curves for incoming and
outgoing breakers.
v) Catalogues of technical literature of the breaker giving
complete technical description of the breaker.

13.1.3 Relays

i) Outline drawings, photograph, descriptive sheets to clarify

the construction, operation and commissioning of protective
relays.
ii) Catalogues, descriptive data and drawings, showing
construction and operation of measuring, tripping indicating
and auxiliary supply units, if applicable.
iii) Characteristics curves for the relays for normal and limit of
conditions.

13.1.4 Current Transformers

i) Sketches showing outline, weight, dimensions, name-plate,

location and connections of CT’s in the arrangement scheme.
ii) Accuracy and burden etc.

13.1.5 Instruments and Meters

i) Outline drawings, catalogues, description and the accuracy

data on each type of instrument and meter to be supplied.

13.1.6 Alarm Annunciation Unit

i) Descriptive data, catalogues and schematic diagram

indicting operating of the annunciator relays and indicators
alongwith dimensional drawings.
ii) Catalogues, drawings and descriptive data of annunciator
relays, lamps, hooter, bell and push buttons.

13.1.6 Auxiliary equipment such as terminal blocks cable trays, bus bars
and supports, earthing etc.

13.1.8 Wiring and Terminations

i) Catalogue and descriptive data giving details and quality and

sizes of the wires and cables used.
ii) The method of installation and termination

13.2 The approval drawings shall include all the data requested above
in clause 12.1 and the details listed hereunder:

32
 i) Schematic drawings including annunciation scheme.
ii) Wiring diagram for auxiliary services panels
iii) Details of components, their characteristics, dimensional
drawings etc. for the protective relays, instruments, auxiliary
equipment and accessories.
iv) Details drawings showing the bus bar and ventilation
arrangement, terminal blocks, cable glands, cable trays,
supports and fixtures.

14. Enclosed Drawings:

1. Drawing No. PDW/ TS-1981.

2. Drawing No. PDW/ TS-1982.

33
34