Technical Specification

For

Electrical & Instrumentation Works

Volume II: Technical Specification for
Electrical &Instrumentation Works

TABLE OF CONTENTS
Sr. Description
No.
1 Scope of Work

2 Project Information/ Site Environmental Condition

3 Design Criteria for Electrical, Instrumentation & Control Equipment/ Systems

4 General Technical & Particular Requirements for Electrical, Instrumentation & Control
Equipment/ Systems
5 Safety Equipment’s/ Requirements and Miscellaneous Items

6 Installation, Testing & Commissioning – Electrical, Instrumentation & Control

Equipment/ Systems
7 Pre Commissioning Tests- Electrical, Instrumentation & Control Equipment/ Systems

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Volume II: Technical Specification for
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1. SCOPE OF WORK:

1.1. The scope of services covers the design, detailed engineering, preparation of
construction drawing, manufacture, acceptance testing at manufacturer’s works or
at any accredited agency, supply, packing, forwarding and delivery from
manufacturer’s works/ place of storage to erection site including transit insurance,
unloading, storage at site, assembly, erection, testing, commissioning &
performance demonstration and handing over along with all necessary spares of
original ratings & specifications on Design, Build& Operatebasis.Inland and
overseas transit insurance, transport, testing at site shall be Contractor scope.
Tender Bill of Quantities and Drawings are for reference purpose only which is the
minimum requirements for the water supply system including raw water Intake,
various Headwork/Sub-Headwork with/ or without water treatment facility as
applicable ;Contractor to ensure that design &equipment’s are as per specification
requirements.

1.2. The Contractor shall prepare design calculations based on parameters/ design
criteria indicated in the specifications. The Contractor shall prepare detailed
engineering and construction purpose drawings to make his/ her own estimate of
ratings & quantities (minimum requirements as per price schedule, technical data
sheets, reference drawings& other relevant details) for entire electrical &
instrumentation systems including all items, systems such as equipment’s, cables/
cabling system, lighting, ventilation, earthling, lightning protection, main & auxiliary
power distribution, instruments, civil works required for completion of Works.

1.3. Contractor shall take due care of the site Seismic conditions while design of all
equipment’s/ components used in entire electrical & instrumentation systems
covered in this specification. Contractor shall furnish list of additional design
parameters considered in design to fulfill above requirement.

1.4. Design and detailed engineering of the materials procured by Contractor is included
in scope. Contractor shall submit design drawings/ calculations of each system
which is included in scope to Purchaser/Purchaser’s representative for final review/
approval. All design documents/ calculations prepared by Contractor shall be as per
ISO documentation i.e. With duly singed by qualified authorities and stamped.
Design documents/ calculations prepared by Sub-Contractors shall be approved by
Contractor and stamped copy of approval along with no-deviation sheet from SUB-
ContractorshallbesubmittedbytheContractortoPurchaser/ Purchaser’s representative
for final review/ approval.

1.5. Expert or manufacturer supervision for Sub-Contractor supplied material shall be

provided by Contractor and included in offer.

1.6. Contractor shall be solely responsible for any shortages or damages in transit for
his supply scope, handling and/ or in storage of any materials and erection of the
equipment, supply of erection tools at site. Contractor shall ensure that it will not
affect any activity or project schedule. Any demurrage, wharf age and other such
charges claimed by the transporters, railways etc. shall be to the account of the
Contractor.

1.7. Contractor shall identify activities and mile stones of the work forecasted for next
month with optimistic and pessimistic dates of work completion. Contractor shall
prepare program evaluation and review techniques to identify critical path of project
and activity sequences. The project schedule shall be prepared and updated

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fortnightly in MS Project.

1.8. Nothing in this specification shall be constructed to relieve the Contractor of his/ her
responsibilities towards following best engineering practices established in the
country.

1.9. Obtaining approval including load sanction/ release from Himachal Pradesh State
Electricity Board (HPSEB), No Objection Certificates from HPSEB,Electrical
Inspector, relevant government agencies, statutory authority, as applicable is
included in Contractor’s scope.

1.10. All necessary legal fees required for various applications to HPSEB/ Electrical
Inspector, relevant government agencies, statutory authorities shall be paid by the
Purchaser. The HPSEB deposit required to be paid for load sanction/ release shall
also be borne by the Purchaser.

1.11. If found necessary, Contractor shall ensure to conduct measurement of soil

resistivity at site by Wenner’s four electrode method as per IS: 3043-
1987(Reaffirmed in 2006) at minimum four locations at site. The earthing shall be
designed for the actual mean soil resistivity value obtained.

1.12. Even if all components of a system included in this specification are not explicitly
identified and/ or listed herein, these shall be supplied under this contract to ensure
completeness of the system and facilitate proper operation and easy maintenance
of the plant. Any and all other works not indicated above but necessary/ required to
complete the system in all aspects, are included in the Contractor’s scope.

1.13. The Contractorshall include start up spares, essential spares, recommended spares
and a set of special tools necessary for operation, routine maintenance of
equipment supplied for a period as specified in this contract.

1.14. Whether specifically called for or not, all accessories required for normal and
satisfactory operation (as deemed by the Purchaser) of the equipment shall be
considered to be a part of the Contractor’s basic scope of supply and/ or work and
no claims whatsoever, for extra payment on these grounds, will be accepted.

1.15. Contractor should visit site and get him/ her ascertained regarding the scope of
work for the complete Electrical & Instrumentation works before submission of
quote/ offer.

1.16. Contractor’s scope shall include design, engineering, manufacture, supply, testing,
commissioning and handover of following electrical equipment/ systems as per
tender specifications, BOQ, reference drawings and other relevant details as per
the requirements of Engineer-in-charge.

1.16.1. Tariff metering equipments applicable (as per HPSEB requirement) & electric
supply connectionincluding necessary liaison works (Tariff metering equipment &
electric supply connection shall be provided by HPSEB for which necessary liaison
shall be done by the Contractor)

1.16.2. Switchyard Equipment (if required) -Two/ four pole structure (required to receive
incoming 11/ 33 kV power supply from overhead line/ cable and to extend out
required feeders), Bus bars, Isolators (GOD) with operating mechanism, Earth
Switches, Lightning Arrestors, Incoming point of supply Breaker/ Ring Main Units

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outdoor type (required where installed capacity of transformer(s) exceeds 800 kVA/
or as per statutory requirement) & Drop Out Fuses (wherever applicable for
transformer(s) being fed directly from incoming power supply)etcincluding
necessary civil works, fence & gate etc.

1.16.3. Oil type, ONAN, Dyn11, Power/ Distribution Transformer(s) with OCTC/ OLTC +
RTCC, AVR, Marshalling box.

1.16.4. 11/ 6.6 kV Metal Enclosed Switchgears indoor type with Vacuum Circuit Breakers/
Vacuum Contactors/ Load Break Switches fully draw out including necessary
control, metering & relaying devices.HVMotor Starters& necessary Capacitor Banks
as per system requirement.

1.16.5. 415 V Metal Enclosed Switchgears including Power & Motor Control Centre
(PMCC) including Starter Panels, PDBs, Sub DBs, Lighting DBs, Receptacles for
utilities. Local Start/ Stop Push Button Stations shall be provided near those motors
which are not controlled from a Local Console/ Panel.

1.16.6. 415 VCapacitor Banks with control panel consisting of automatic power factor
correction (APFC) relay to improve the plant power factor up to 0.99. APFC panels
shall be provided on both bus sections of the PCC/ MCC.

1.16.7. Cabling system shall consists of various HV/ LV grade, XLPE/ PVC insulated, multi-
stranded Al/ Cu, GI round wire/ flat strip armoured power, control & instrumentation
cables, GI ladder/ perforated type Cable Trays & associated accessories including
support structures.

1.16.8. Provision for continuous monitoring of electrical Power & Energy parameters like
Voltage, Current, Power Factor, Frequency, Kilo Watts, Kilowatt-Hours etc.

1.16.9. Earthing for HV/ LV equipments and lightning protection system for all buildings in
the plant premises. The general design shall be on the basis of following codes and
standards (their latest amendments) in line with design criteria &specification
requirements.

a) IS 3043- 1987,(Reaffirmed in 2006) : Code of practice for Safety Earthing

b) IS/ IEC 62305- 2013 : Code of Practice for the protection of

buildings and allied structures against
lightning.

c) CEA guidelines 2010 : Measures related to safety & electric supply.

1.16.10. Lighting system for all indoor & outdoor areas of plant(s). The lighting system will be
controlled by lighting panels installed in respective plant/ station areas, which will be
fed from the main lighting DB.

1.16.11. DC System:

a) 24/ 30V or 110V DC in built DC power pack unit shall be provided wherever
applicable.

b) 24/ 30V or 110V DC Battery & Battery Charger (with inbuilt DCDB) shall also be
provided wherever applicable.

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1.17. Contractor’s scope shall also include design, engineering, manufacture, supply,
testing, commissioning and handover of following Instrumentation & control
equipment/ systems as per tender specifications, BOQ, reference drawings and
other relevant details.

1.17.1. Wherever applicable, Programmable Logic Controller (PLC) based control &
monitoring system with HMIshall be implemented, covering the required functional
& operational requirements of the plant involving measurement, control, alarm &
interlocking functions.

1.17.2. All instruments & analysers as required for monitoring/ control/ alarm/ interlocking
functions involved in the process.

1.17.3. All erection hardware and accessories like branch cable trays from field sensors to
Junction boxes & from junction boxes to remote panel/ PLC cabinets, impulse tubes
with fittings & accessories, drain/ vent valves, root valves, cable glands, structural
frames/ supports, expander & reducer etc. as required for complete & proper
installation of the instrumentation & control equipment/ systems.

1.17.4. Instrumentation, control & any other special cables as required for entire system
under Contractor’s scope.

1.17.5. Electronic earth pits, as per applicable standard & also meeting automation
Contractor’s requirement and including supply & laying of earthing cables with
required accessories.

1.17.6. All necessary and supplementary items & equipment required for completeness,
safe & efficient operation of the system, even though these may not have been
mentioned in this specification. Spares & consumables for successful
commissioning, establishment of performance guarantee and five years of trouble-
free & safe operation of the plant.

1.18. Submission of drawings & documentation as specified under ‘’General Technical &
Particular Requirement’’ section for Electrical, Instrumentation & Control equipment/
systems.

1.19. Contractor’s scope shall also include all civil works required for electrical &
instrumentation equipment/ structure such as equipment foundations, indoor &
outdoor trenches, equipment support structures, two pole structures, flow meter
chamber, control rooms, all excavation works including those for earthing, cabling
etc, de-tanking area, soak pits, burnt oil pits, chamber etc.

1.20. It is not the intent to completely specify all details of design and construction herein.
Nevertheless, the Electrical, Instrumentation & Control system shall conform to high
standard of engineering, design and workmanship in all respects and shall be
capable of performing satisfactorily in continuous commercial operation under the
specified environmental conditions.

1.21. Purchaser reserves the right to issue addendum to the technical specification to
indicate modification/ changes in the requirements, if so required at a later date.

1.22. The pumping machinery shall be installed on a base plate designed and
manufactured by the principal manufacturer of the machinery The foundation of the
machinery should be properly designed with proper anchorage. All electrical

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Volume II: Technical Specification for
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equipments and accessories such as Starter, Soft starters , APFC panels, LT

Switchgears ,MCBS, ELCBS, AC distribution board, capacitor, ICTP switches. DC
battery including incoming and outgoing cable etc. shall conform to the following
reference codes and makes :-
Name of Reference Make
component of codes
Amp. IS:1248(Pa AE/L&T
Meter/Voltmeter/V rt-II)-1983
olt monitor relay
Frequency Meter IS:1248(Pa AE/L&T
rt-IV)-1983
Power factor IS:1248(Pa AE/L&T
meter rt-V)-1983
ICTP Switches IS:4064(Pa L&T/Havell/Crompto
rt-II)-1978 n
OCB IS:2516(Pa MEI/Kilburn
rt-II)-1985
M.C.B IS:2516(Pa Havell/ Kilburn
rt-II)-1985
M.C.C.B IS:2516(Pa Crompton/L&T/Havel
rt-II)-1985 l
E.L.C.B IS:2516(Pa Havell/Indetec/MDS
rt-II)-1985
E.L.R IS:2516(Pa Datar/Indetec
rt-II)-1985
Shunt Capacitor IS:2834- L&T/Asian/Crompton
1986
D.O.L IS:8544(Pa L&T/Siemens/Cromp
rt-I)-987 ton
Star Delta Starter IS:8544(Pa L&T/MEI/Crompton
rt-II)-987
Oil Immersed star IS:8544(Pa MEI/Kilburn
Delta Starter rt-II)-987
Auto Transformer IS:8544(Pa MEI/Kilburn
starter for motor rt-IV)-987
Rotor stator IS:8544(Pa MEI/Kilburn
starter for low rt-III)-987

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speed motor
/Pressure/Vacuu IS:3624- Feibig /Bouden
m Gauges 1979

1.23. PROJECT INFORMATION:

2.1. SITE/ ENVIRONMENTAL CONDITIONS:

2.1.1. Ambient temperature : 45ºC(site specific)

2.1.2. Relative Humidity : 5 - 95%

2.1.3. Area Classification : Non Hazardous / Hazardous

2.1.4. Seismic Data : As per IS 1893 (latest Issue)

2.2. NOMINAL SYSTEM VOLTAGE:

2.2.1. Incoming AC power supply voltage to the plant premises shall be 11 KV

2.2.2. Plant Power/ Control SupplyDistributionVoltage:

Plant Power Distribution Voltage: 11/ 6.6 kV, 3 Phase, 3 Wire, 50 Hz, AC

415V, 3 Phase, 4 Wire, 50 Hz, AC

General Lighting & Space Heating: 240V, 1 Ph, 2 Wire, 50Hz, AC

Control, Protection & Emergency Lighting: 24/ 30 or 110V, 2 Wire DC (as applicable)

2.2.3. VoltageTransformer Secondary:110 V, 3 Ph, 50 Hz, AC

2.2.4. Voltage Variation:  10%, Frequency Variation: 5%and Combined Voltage &
Frequency Variation: 10%

2.3. SYSTEM EARTHING:

2.3.1. 66 kV, 3 Ph AC system : Neutral Grounding Resister

2.3.2. 11kV, 3 Ph AC system : Neutral Solidly Earthed

2.3.3. 415 V, 3 ph, AC system : Neutral Solidly Earthed

2.3.4. 240 V, 1 ph, AC system : Neutral Solidly Earthed

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Volume II: Technical Specification for
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3. DESIGN CRITERIA FOR ELECTRICAL, INSTRUMENTATION & CONTROL

EQUIPMENT/ SYSTEMS:

3.1. GENERAL:

3.1.1. The design criteria, given below has to be followed by the Contractor for designing/
sizing of electrical, instrumentation & controlequipments covered under Contractor’s
battery limits; However it is to be noted by the Contractor that, following this design
criteria does not relieve the Contractor from adherence to the standards, regulatory
requirements & best engineering practices.

3.2. ESTIMATION OF LOAD/ MAX DEMAND: The following considerations are to be

followed to arrive at the maximum electrical demand.

3.2.1. Load Factor

a) Main motors : 0.9

b) Auxiliary load (valve actuators, Crane/ Hoist, etc.) : 0.4

c) Lighting load : 1.0

3.2.2. Diversity Factor

a) Main motors : 1.0

b) Auxiliary load (valve actuators, Crane/ Hoist, etc.) : 1.1

c) Lighting load : 1.1

3.2.3. Power factor of Motors : As per the Manufacture’s Data sheets

3.2.4. Efficiency of Motors : As per the Manufacturer’s Data sheets

3.2.5. Soft Starter – 3 times the rated current.

3.2.6. Wherever,HV supply (for load demand above 100 kVA/ or as per HPSEB rules
prevailing at that time) is envisaged, 100% stand-by shall be provided for
transformers.All the associated equipments/ accessories shall be provided for
stand-by transformer as well. In normal condition, both the transformers shall feed
their respective bus sections by keeping bus coupler open & in case of failure of
one transformer, the other transformer shall be able to take 100% load with bus
coupler in close position.

3.2.7. The Load losses and No-load losses of transformer shall be within the values given
in IS 1180-2014/ or latest applicable standards.

3.3. SWITCHGEAR SIZING/ SELECTION:

3.3.1. Switchgear shall be sized/ selected considering the following:

a) Rating suitable for carrying full load current of the equipment.

b) Suitability for Short Circuit Rating for 1 sec duration.

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c) Switchgear for motors shall be suitable for motor duty application.

3.3.2. Switchgear for all the motor feeders shall be as per Type-2 coordination.

3.3.3. Motor starter selection shall be done as follows:

a) Direct On Line (DOL) Starter – For motors rated up to 5.5 kW

b) Star- Delta Starter - For motors rated above 5.5 kW to 15 kW

c) Auto Transformer Starter (ATS) - For motors rated above 15 kW to 75 kW

d) Soft Starter – For all low/ medium voltage motors above 75 kW rating.

e) In-panel de-ration of minimum 20% or as provided in Manufacturer’s

catalogue, whichever is higher shall be considered.

3.3.4. Bus Bar Sizing:

a) The Contractor shall furnish calculations after award of contract, establishing

the adequacy of the bus bar sizes to meet the continuous and short time
current ratings as calculated.

b) The bus-bars shall be sized considering the following criteria:

i. Sleeving made of insulating material on all bus bars.

ii. Design ambient temperature 50⁰C.

iii. Final temperature of the bus-bars complying with requirements of IS

8623 & IEC 60947. Reduced temperature rise limit by 5K (for indoor
panels) & 10K (for outdoor panels) to that of mentioned in IS 8623 &
IEC 60947 shall be considered to satisfy the final temperature.

iv. Bus bars being inside the panel; De- ration for enclosure and ventilation.

v. Bus bar suitability for carrying rated current continuously.

vi. Configuration of bus bars and Proximity effect

vii. Bus bars shall withstand the short time rating of the panel for 1 sec
duration.

3.4. POWER FACTOR IMPROVEMENT: APFC Panel shall be sized considering

following design criteria:

3.4.1. Minimum 8 steps in an APFC relay shall be considered.

3.4.2. Capacitor shall be All Poly Propylene (APP), double layer type.

3.4.3. Fixed type capacitor bank, with manual & auto switching and components as
indicated in reference electrical Single Line Diagram(s) shall be provided in each
mains incomer (LV) panel for transformer no load compensation.

3.4.4. For each bus section of the Main LV PCC/ MCC panel, separate APFC panel-

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based on above design criteria to be provided. Other requirements of APFC panel &
its components shall be as per requirement provided in this specification.

3.4.5. Total capacity &capacitor bank sizes shall be as given in Table below:

Capacity 5 kVAr 10 kVAr 15 kVAr 25 kVAr 50 kVAr 100 kVAr

* kVAr # Nos. # Nos. # Nos. # Nos. # Nos. # Nos.

(*) = Contractor has to calculate the capacitor rating based on the system power
factor (0.85 or actual, whichever is lesser - to be corrected for 0.99. Rating of APFC
panel shall be based on 50% of running load on each bus section & not on the
connected load basis. Number of stages/ steps in a particular APFC panel shall be
decided by the Contractor such that minimum 8 steps & maximum 16 steps shall be
provided in a particular panel.CT changeover scheme when only one transformer is
running to be considered.

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3.5. CABLE SIZING: The Contractor shall ensure that cable and wires associated with
the power distribution and control systems, plant wiring and all other installations
throughout the Works are adequately rated for their use.

3.5.1. The following main aspects shall also be considered while deciding the final size of
the cables-

a) Supply voltage and frequency

b) All cables shall be selected to carry the corresponding full load current under
site conditions.

c) Route length and disposition of cables

d) Maximum allowable temperature rise under normal full load condition based
on the material of cable insulation (XLPE/ PVC).

e) Maximum short circuit current duration (fault clearing time) and final
temperature of cable during short circuit current flowing through the cable.

f) For Cables emerging from ACB outgoing, fault clearing time shall be
considered as 0.16 second (for Tie feeders if any it shall be 0.5 second)

g) For Cables emerging from MCCB outgoing, fault clearing time shall be
considered as 0.01 second

h) For the HV incomer cables (metering kiosk to HV switchgear/ transformer)

minimum fault clearing time shall be considered as 1 sec.

i) For cable from HV panel outgoing to transformer, fault clearing time shall be
considered as 0.16 second.

j) Cable from transformer secondary to PCC incomer, fault clearing time shall
be 1sec

k) Contractor to note that, the above fault clearing times are minimum to be
considered & fault clearing time shall be considered as per actual relay co-
ordination study.

l) Appropriate de-rating factors as per cable manufacturer’s catalogue and

enlisted below shall be considered for sizing the cable:

i. Ambient Air Temperature (minimum 50⁰C).

ii. Ambient ground temperature (minimum 40⁰C to be considered)

iii. Laid in Air/ ducts/ directly in ground etc.

iv. Depth of cable burial (minimum 750 mm for LT and 900 mm 11kV HV)

v. Thermal Resistivity of Soil (minimum 150⁰C Cm/ W to be considered)

vi. No. of cables in a group-touching each other or separated by a distance

vii. No. of cable trays in tier

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viii. Any other de-ration factors as applicable & as per Manufacturer’s

catalog.

m) Permissible voltage dips at the time of starting the corresponding motor/ load.
Contractor to ensure adherence to the Criteria-2 mentioned above.

n) In running condition, cumulative voltage drop (at 100% rated load) shall not
exceed 5% (measured at load end) for the LV loads.

o) HV cables shall be E/ UE grade (as per system requirement), multi-stranded

Al conductor, XLPE insulated, inner/outer extruded PVC sheath ST2,
galvanized steel flat strip armoured cables.

p) LV cables shall be 1.1 kV grade, multi-stranded Copper/ Al conductor, XLPE

insulated, colour coded, inner and outer extruded PVC sheathed, galvanized
steel round wire/ flat strip armoured cables.

q) Cables up to & including 4.0 sq.mm shall be Cu multi-stranded conductor with

galvanized steel round wire armoured& balance cables shall be Al multi-
stranded conductor with galvanized steel round wire/ flat strip armoured.

r) Single core cable shall have non magnetic material armouring.

s) Control cables shall be Cu multi-stranded conductor with galvanized steel

round wire/ flat strip armoured. For cables above 7 cores, minimum two spare
cores shall be considered.

3.6. ILLUMINATION SYSTEM: Illumination for various indoor & outdoor areas shall be
conforming to the requirements mentioned below:

3.6.1. The illumination levels to be considered for the design of lighting system for various
areas shall be as following. These are the illumination levels achieved at Work
plane. Work plane height shall be considered as 0.76 m from FGL.
Area Illumination Level (Lux) - Average values

Office rooms 300

Switchgear rooms 250
Control rooms 300
Chemical and general stores 150
All other indoor areas 150
Outdoor platforms and walk ways 50
Outdoor plant areas 20
Switchyard & Transformer Area
- General 10
- On Equipment 30
Roads 15

3.6.2. Critical lighting shall be designed such that at all junctions, exit passages &
strategic locations the Lux level shall be maintained above 10 Lux. Installite fixtures
with built in battery backup shall be considered.

3.6.3. Lighting design shall be performed using DiaLux Software Version 4.5 or its latest
version/ Original Equipment Manufacturer (OEM) validated software. The Validation
Report along with software and data files shall be acceptable to Purchaser/

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Purchaser’s representative.

3.6.4. Various design factors shall be considered as following:

a) Maintenance Factor:
i) Outdoor area : 0.6 (0.7 for LED)
ii) Indoor areas : 0.7 (0.8 for LED)

b) Reflectance Factors:
i) Wall : 30%
ii) Ceiling : 10%
iii) Floor : 30%

c) Uniformity (Min. / Avg.) : 50% Minimum for indoor and 30% for outdoor

3.7. EARTHING &LIGHTNING PROTECTION SYSTEM:

3.7.1. The safety earthing and lightning protection system will be generally on the basis of
following codes and standards (including their latest editions).

a) IS 3043 -1987 (Reaffirmed in 2006): Code of practice for Safety Earthing.

b) IEEE 80 - 2000.

c) IS/ IEC 62305 - 2013: Code of Practice for the protection of buildings and
allied structures against lightning.

d) CEA guidelines - 2010: Measures related to safety & electric supply.

3.7.2. The fault levels considered shall be as follows:

System Voltage Fault level in kA

66 kV (*) kA for 1 sec
33 kV (*) kA for 1 sec
11 kV 18.4 kA for 1 sec
6.6 kV (*) kA for 1 sec
415 V * (50 kA) for 1 sec

(*) Contractor to design on the basis of actual impedance and adequacy

calculations for sufficiency of earth conductor size shall be provided.

3.7.3. Following factors shall be considered for sizing the earthling conductor:

a) Design Ambient Temperature : 50C

b) Allowable temperature rise for steel welded joints : 500C

c) Fault clearing time : 1 Second

d) Overall earthling resistance to be achieved as per : ≤ 1 Ohm for transmission

IEEE std 80 – 2000 substation.

≤ 5 Ohm for distribution

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substation.

3.7.4. Measurement of soil resistivity shall be done using Wenner’sfour (4) electrode
method as described in IS 3043 -1987(Reaffirmed in 2006) including its latest
amendment.

3.7.5. The soil resistivity of the plant area has not yet been measured; the same should be
carried out during detailed engineering by successful Contractor.

3.7.6. After soil resistivity measurement; length of conductor, number of earth electrodes
and no. of test pits shall be finalized based on these design criteria & the
requirements specified in earthling requirements.

3.8. INSTRUMENTATION & CONTROL SYSTEMS:

3.8.1. Instrumentation, Control & Automation (ICA) system shall be designed,

manufactured, installed and tested to ensure the high standards of operational
reliability.

3.8.2. The instruments complete with all the necessary mounting accessories shall be
designed to work at the ambient conditions of temperature, humidity, and chlorine
contamination that may prevail

3.8.3. Instruments mounted in field and on panels shall be suitable for continuous
operation of plant. Wherever required, lockable & tamperproof enclosure shall be
provided for all the field mounted instruments.

3.8.4. All electronic components shall be adequately rated and circuits shall be designed
so that change of component characteristics shall not affect plant operation.

3.8.5. The outdoor equipment shall be designed to withstand tropical rain. Wherever
necessary, space heaters, dust and water proof cabinets shall be provided.

3.8.6. Unless otherwise specified, the normal working range of all indicating instruments
shall be between 30% and 70% of the full scale range.

3.8.7. Unless otherwise stated, degree of protection for field mounted electrical and
electronic instruments shall be IP-67. All instruments of submersible type shall be
protected to IP-68.

3.8.8. Unless otherwise stated, overall accuracy of all measurement systems shall be ±1%
or better of the measured value.

3.8.9. Dual redundant SMPS shall be used for powering 24V DC Instrumentation, Control
& Automation equipment’s.

3.8.10. For all the field mounted transmitters, output signal shall be 4-20 mA DC isolated
with HART Protocol (version 6 & above) and field transmitters shall be provided with
the back lit LCD/ LED display.

3.8.11. Electronic instruments shall be of proven design and shall utilize solid state
electronic components, integrated circuits, microprocessors, etc.All digital outputs
from the instruments shall be volt free.

3.8.12. The relay/ switch contacts shall be rated for the voltage of the circuit in which they

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are to be wired.

3.8.13. All indicating meter shall be of the digital type with no moving parts. Zero and span
adjustments shall be provided for all instruments.

3.8.14. After a power failure, when power supply resumes, the instruments and associated
equipment shall start working automatically.

3.8.15. The instruments shall be designed to permit maximum inter-changeability of parts

and ease of access during inspection and maintenance.

3.8.16. The field instruments i.e. the instruments mounted outside the control panel shall be
mounted at a convenient height of approximately 1.2 meter above grade platform.

3.8.17. The instruments shall be given enough protection against corrosion and all the
wetted parts of the instruments shall be non-corrosive.

3.8.18. All field instruments and cabinets/ panel mounted instruments shall have tag
plates/name plates permanently attached to them.

3.8.19. The performance of all instruments shall be unaffected for the ±10% variation in
supply voltage and ±5% variation in frequency simultaneously.

3.8.20. Unless otherwise specified, double compression glands shall be used for glanding
the cable in field instruments and instrument control panel.

3.8.21. Electromagnetic Flow meter sizing shall be done such that velocity of fluid inside
flow tube should not be less than 0.3 m/s and not generally exceed 3.0 m/s. For
underground installation, Flow Meter Chamber shall be provided.

3.8.22. Inlet-outlet parameter measuring instruments of plant shall be compatible to GSM /

GPRS module interface.

3.8.23. Online process analyzers shall be of latest technology based and shall be reagent
free.

3.8.24. Unless otherwise specified, all instruments shall be tropicalized.

3.8.25. The monitoring and control system shall be designed & implemented through a
Programmable Logic Controller (PLC) with HMI, covering the required functional &
operational requirements of the plant involving measurement, control, alarm &
interlocking functions.

3.8.26. PLC system selected shall be Open Platform Communications (OPC) compatible.

3.8.27. Input/ Output philosophy for the PLC system shall be as follows:

a) Motor Digital Input:

Local/ Remote Selector-1 No
Run Feedback- 1 No
Stop Feedback- 1 No
Over Load Feedback- 1 No
Digital Output:
Start Command- 1 No

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Stop Command-1 No
Analog Input:
Speed Feedback (Applicable for VFD driven Pump)-1
No
Vibration Sensor Feedback (Applicable for MV Motor)-
6 Nos
Analog Output:
Speed Reference (Applicable for VFD driven Pump)-1
No
RTD Input:
Windings & DE/ NDE Bearings Temperature
(Applicable for motor having winding and bearing
RTDs )- 8 Nos
b) Pump/ Blower Analog Input:
Pressure Transmitter- 1 No (wherever continuous
Pressure monitoring is required)
Flow Transmitter- 1 No (wherever continuous Flow
monitoring is required)
c) Motorized Valve Digital Input:
Local/ Remote Selector-1 No
Open Feedback- 1 No
Close Feedback- 1 No
Over Load Feedback- 1 No
Torque Switch Feedback-1 No
Digital Output:
Open Command- 1 No
Close Command-1 No
Analog Input:
Position Feedback (Applicable for Modulated Control
Valve)-1 No
Analog Output:
position Reference (Applicable for Modulated Control
Valve)-1 No
d) Breaker Digital Input:
Local/ Remote Selector -1 No
ON Feedback- 1 No
OFF Feedback- 1 No
Master Trip Relay Operated- 1 No
Digital Output:
ON Command- 1 No
OFF Command-1 No
e) Transformer Digital Input:
Oil Level Low Alarm-1 No
Oil Temperature High-1 No
Oil Temperature Very High-1 No
Winding Temperature High- 1 No
Winding Temperature Very high-1 No
Buchholz Alarm-1 No
Buchholz Trip-1 No
Pressure Relief Device Trip -1 No
OLTC Fault-1 No
f) Sump/ Tank Digital Input:
Level Very High-1 No

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Level High -1 No
Level Low-1 No
Level Very Low-1 No
Analog Input:
Level Transmitter- 1 No (wherever continuous Level
monitoring is required)

3.8.28. PLC based control system shall be of latest industrially available configuration. PLC
system shall be provided with Operator& Engineering stations along with a printer,
peripherals & accessories, as required.

3.8.29. Unless otherwise specified, the PLC system shall be provided with hot redundant,
fault-tolerant features, redundancy in processor, power supply modules,
communication modules (I/O bus as well as HMI bus) and communication network,
bumpless switchover from the active system to the standby system in the event of a
fault.

3.8.30. The PLC I/O modules shall be hot swappable, i.e. card changeover, card wiring
removal or communication cable change shall be possible on-line (PLC running)
without causing any process interruption, bump or nuisance trip or any loss of
fidelity during such action.

3.8.31. In case of hot swap of I/O card or card wiring removal, the interruption shall be
limited to the subject card related inputs/ outputs only.

3.8.32. On line PLC programme modification shall be possible without stopping the
processor.

3.8.33. The I/O modules and processors shall be of same family and series. All analog
cards shall be differential type.

3.8.34. I/O modules shall have 3 levels of Isolation- a) Channel to Channel Isolation, b)
Channel to power Isolation & c) Channel to Ground Isolation.

3.8.35. Channel level diagnostic features shall be available in HMI.

3.8.36. The engineering station forms the focal point of the control system design and acts
as container of the complete control system application.

3.9. DRAWINGS/ DOCUMENTS FOR REFERENCE:

3.9.1. The electrical Single Line Diagram(s)/ PLC system architecture for water supply
project including raw water intake &various headwork/ sub-headworkwith/ or without
water treatment facility (as applicable) form part of this specification and should be
used for reference purpose only.

3.9.2. The equipment/ switchgear component ratings & requirements shown in the
reference electrical Single Line Diagram(s) are minimum requirements & after
award of contract, Contractor has to get approval for the equipment selection with
the approval for sufficiency calculations.

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3.10. CABLES &CABLING SYSTEM:

3.10.1. The scope shall be inclusive of supply, installation, testing & commissioning of
power, control and instrumentation cables, cable terminations, cable accessories,
stripping of cable insulation, supplying and fixing of Aluminium lugs for aluminium
cables & tinned plated copper lugs for copper cables and crimping the same to the
conductor, supply and fixing of double compression cable glands including all
labour supply and consumable material required for jointing/ termination. The rate
shall also include the laying of cable in ground/ in cable trays / cleating to structure
etc.

3.10.2. Applicable Standards:

The cables shall confirm to the latest applicable standards specified below. In case
of conflict between standards and this specification, this specification shall govern.

PVC insulated cables : IS: 694

(for voltage up to 1100 V)
HRPVC & PVC insulated cables : IS: 1554
heavy duty
Cross linked polyethylene insulated : IS: 7098
PVC sheathed cables
Low frequency cables and wires with : IEC: 189-1 &
PVC insulation and sheath IEC-189-2
PVC insulation and sheath of electric : IS: 5831
cables
Polyethylene insulation and sheath for : IS: 6474
electric cables
Conductors for insulated electric cables : IS: 8130
Methods of test for cables : IS: 10810
Specification for drums of electric cables : IS: 10418
Specification for PVC insulated cables : BS: 6346
for electricity supply
Specification for PVC insulation and : BS: 6746
sheath of electric cables

3.10.3. Constructional Features:

a) HV power cables shall conform to 11kV Earthed grade (E), three core,
stranded, Aluminium conductor, screened by extruded semi-conducting
compound, cross-linked poly ethylene (XLPE) insulated, cores screened with
non-magnetic metallic tape laid up with inner and outer extruded PVC sheath
compound Type-ST2 and galvanized steel strip armouring. The cables shall
generally conform to IS 7098-1985 with relevant parts thereof.

b) Armouring shall confirm to latest version of IS: 3975.

c) LV Power cables shall be 1.1kV grade, 4/ 3.5/ 3 Core, multi-stranded, Al/ Cu

conductor, XLPE insulated, extruded inner & outer PVC sheath compound
type ST2 and galvanized wire (up to 6 sq mm)/ steel strip(>6 sq mm)
armoured cables. All single phase, Lighting cables, UPS cables shall have
100% Neutral.

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d) All the control cables shall be 1.1kV grade, no. of cores (as per requirement/
application with minimum 2 spare cores for 7C & above) multi-stranded,
Copper conductor, XLPE insulated, extruded inner PVC & outer PVC FRLS
sheath compound type ST2 and galvanized steel round wire armoured.

e) All control cables shall be with following specific requirements:

i. Copper conductor stranded class 2.

ii. XLPE Insulated

iii. Provided with inner extruded PVC and outer PVC FRLS sheath of
extruded black PVC compound.

iv. Galvanized steel armouring in the form of GI round wire.

v. Core identification shall be by printed numerals.

vi. The insulation over the individual conductor core will be colour coded.

vii. Minimum 2 spare cores for above 7C.

f) The DC power supply cable shall be two core, multistranded copper

conductor, armoured cables with inner extruded PVC & outer PVC FRLS
sheath. All control wiring shall be PVC FRLS insulated.

g) All the power, control& instrumentation cables used in the Hazardous area
shall be flame proof type suitable for the intended application.

h) Earthing Cable shall be Single core multi-stranded Cu, 1.1 kV grade, XLPE
insulated, un-armoured green coloured outer sheath with yellow strips/ band
cable to be laid in trays, underground, trenches etc. as applicable.

i) Submersible Cables:Multi core flexible Cu conductor XLPE insulated & PVC

sheathed heavy duty cable suitable for submersible application (in case of
submerged pumps) shall be manufactured as per governing standards. High
purity electrolytic grade, annealed Cu conductor shall be used. Cables shall
be extruded inner & outer PVC sheathed. PVC compound shall be dielectric
grade & shall be impervious to water, oils & grease etc. Similarly double PVC
sheathing shall also be done as per IS: 5831/ 1984. Flexible inner sheath &
high abrasion resistant flexible outer sheath is required for these cables.
Double PVC sheathing shall be done so as to withstand abrasion & prevent
ingress of water along the interstices of the cable. Core identification shall be
by printed numerals. Conductors shall be as per IS 8130. Cable shall be
constructed as per relevant IS/ IEC standards.

3.10.4. Cable Colours:

a) All cable cores shall be colour coded throughout their length and shall be so
connected between switchboard, distribution board, plant and accessories,
that the correct sequence or phase colours are preserved throughout the
system.

b) The colour coding should be as follows:

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i. 3 phase Red, Yellow and Blue

ii. single phase or dc supply Red and Black

iii. earth Green/Green with Yellow coloured band

iv. control Gray (DC)

3.10.5. Cable Conductors;

a) Cables up to 4.0 sq.mm shall be Cu multi-stranded conductor with galvanized

steel round wire armoured& balance cables shall be Al multistranded
conductor with galvanized steel round wire/ flat strip armoured.

b) Single core cable shall have non magnetic material armouring.

c) Lighting final distribution circuits shall be of a minimum cross-section of 1.5

mm2.

d) Small control cables shall be of a minimum cross-section of 1.5 mm2.

e) Internal wiring of control panels shall be of a minimum cross-section of 1.5

mm2 flexible and multistranded.

f) Instrumentation and control cabling shall be of a minimum cross-section 1.5

mm2 for external use and 1.0 mm2 for internal use.

g) Cable Sizing shall be done as per design criteria specified in specifications.

3.10.6. Cable Numbering:All cables shall be allocated a unique number which shall be fixed
to each end of the cable using a corrosion resistant label. Necessary loop at both
ends shall be provided for future use and cables of different categories shall be
tagged with the following subscripts and three digit number.

HV power HV-P_ _ _
LV power P_ _ _
Control C_ _ _
Instrumentation I_ _ _
Protection PR_ _ _
Telecommunication T_ _ _

3.10.7. Cable Terminations:

a) Cable Lugs

i. Cable lugs shall be of tinned copper, solder less crimping type for Cu
cables & AL lugs for the AL cables.

ii. The current rating of the lugs shall be same as that of the respective
cable conductors.

iii. Bi-metal strip/ Bi-metallic lug shall be used whenever two different
metals are to be connected together.

iv. Double holes extended neck (long barrel neck) type lugs shall be used

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in case of cables above 185 sq. mm.

v. Anticorrosion/ anti-oxidation compounds shall be used for crimping lugs.

This shall especially be ensured for Al cable terminations & bimetallic
terminations shall be used wherever required.

vi. If termination is done with crimping tool employing crimping die then
forming dies shall be used to make the sector shaped conductor into a
round conductor before crimping the lugs on the conductor. The lug
must not be crimped directly on the sector conductor. Before crimping
the lug, the conductor shall be thoroughly cleaned and special jelly
applied over it to prevent further oxidation.

b) Cable Glands

i. Glands shall generally be of the double compression hexagonal type

brass glands. Earth continuity of brass glands shall be assured.

ii. Double compression type cable glands shall be used. Cable glands
shall be brass casting, machine finished and Nickel-plated to avoid
corrosion and oxidation. Rubber components used in cable gland shall
be of neoprene.

iii. For single core cables, gland shall be with brass ring.

iv. Glands for single core cables shall be constructed from non-magnetic
materials.

v. Cable glands shall be with metric threads.

vi. Where holes for cable entries are not provided it shall be the
responsibility of the Contractor to mark out and drill such holes. Burrs
and swarf shall be removed, care being taken to ensure that swarf and
filings, etc do not enter the equipment.

vii. For non-hazardous areas cable glands in situations where moisture may
be present shall be double seal weatherproof type, gland shrouds shall
be used and entry shall be sealed.

viii. Fordryindoor situations, standard industrial glands with shrouds are

acceptable.

ix. For hazardous areas, glands conforming to EEE standard shall be used
with double seal and shroud.

c) Trefoil Clamps for Single Core Cables:

i. All the single core cables shall be laid in trefoil formation only.

ii. The grouping & sequencing of three single core cables arranged in
trefoil formation shall be done in such a way to ensure balanced current
distribution.

iii. Trefoil clamp of suitable size & having non magnetic material shall be
used.

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iv. The Trefoil groups shall be held in trefoil clamps at an interval not
exceeding 3.0 meters.

v. In addition to trefoil clamps as mentioned above, the tre-foil groups of

cables shall be additionally tied by means of 3.0 mm dia. nylon cord
clamp at an interval not exceeding 750 mm.

d) Wherever applicable, supply & installation provision of bimetallic strip for

connection between Al to Cu strip & GI to Cu strip shall be provided.

3.10.8. Instrumentation Cables:

a) This specification covers the requirements for instrument signal cables,

thermocouple extension cables, RTD cables and power/ control cables.

i. Single pair shielded signal/ alarm cables shall be used between field
instruments / switches and junction boxes / local control panels.

ii. Single pair shielded thermocouple extension cables shall be used

between thermocouple head and junction boxes/ transmitters/ local
control panel mounted instruments.

iii. Single triad shielded signal cables shall be used between RTD head
and junction boxes/ transmitters/ local control panel mounted
instruments.

iv. For field bus compatible instrument single pair shielded cable shall be
used between instrument to junction box/ local panel and to control
room.

v. Foundation Field bus shall be Type-A cable. Construction of same shall

be as per IEC 61158-2. Trunk cable shall be used of 1 Pair, 5 Pair, and
12 Pair.

vi. Separate Multipair/ multitriad cables shall be used between junction

boxes/ local control panel and control room as per following
applications.

 4-20 mA signals (for conventional HART Transmitters)

 Foundation Field signals

 Thermocouple signals

 Resistance Temperature Detectors (RTD) signals

 Switch contacts/ Proximity switch contacts

 Gas detectors

vii. Instrument power cables shall be used between power supply

distribution boards and power consumers such as control panels, DCS/
PLC cabinets, any instruments requiring power supply, etc.

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viii. Instrument control cables shall be used for valves, feedback of feeders
etc.

ix. The cable design shall generally follow BS 5308 Part-1 for various
cables listed in clause-e as above.

x. Thermocouple cables design shall comply with ANSI MC 96.1.

xi. The power and control cables shall be generally as per BS 6346. For
these cables, equivalent IEC/IS specifications are also acceptable.

xii. The insulation grade shall be 1100 V AC for all cables.

xiii. The primary insulation shall be cross-linked Polyethylene with

temperature rating 70˚C conforming to BS- 5308/ IS 7098.

xiv. Inner and outer sheath/ jacket shall be made of extruded fire retardant,
low smoke, low halogen, low toxic, polymeric compound having physical
properties as per IS-5831-Type ST2.

xv. All cables shall be armoured and suitable for operation when installed
as follows:

 Directly buried in the ground

 Fastened to cable ladder rack or tray in the open air

 In underground ducts

 In overhead closed cable ducts

xvi. Running length of the cable shall be printed at least at every 5 metre
interval.

xvii. For Multipair/ multitriad cables, pair identification shall be provided with
numbers at interval of not more than 250 mm as per Contractor’s
standard.

xviii. Contractor shall ensure a minimum of 20% of quantity of each type of

cables supplied as spare including any special cable and in each
Multipair cable 20% pairs shall be kept as spare.

xix. A pair of communication wire shall be provided for Multipair/ multitriad

cables.

xx. Each wire shall be 0.5 mm 2 of plain annealed single or multi-strand

copper conductor with 0.4 mm thick 70˚C XLPE insulation.

xxi. All cables shall be fire retardant and low smoke.

b) Design and Testing Standards:

i. Instrument signal, RTD and thermocouple cables:

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Sr. Description Particulars

No.
1 Conductors BS 6360/ IS 8130 for instrument signal and
RTD cables and
ANSI MC 96.1/IEC-60584-3 for thermocouple
cables.
2 Insulation: XLPE Insulation shall be Cross-linked Polyethylene
(XLPE) as per BS 5308 / IS 7098.
3 Armour Round wire armour galvanized steel as per
IS 1554 Part 1
4 Inner & Outer Extruded Fire Retardant, Low Smoke, Low
Sheath-PVC Halogen,
Low Toxic, PVC having physical properties as
per IS
5831-Type ST2. Flammability and chemical
properties
shall be as follows:
 Oxygen Index: 30 (minimum) at room Temp
as perASTM-D-2863-77
 Temperature Index: 250 Deg C (minimum) at
Oxygen Index of 21 as per ASTM-D-2863.
 Light Transmission: 70% (minimum) as per
IEC1034.
 Flammability test: As per IEC 332 Part-1 &
Part-3Cat. A
 Corrosivity of combustion gases: pH-index>
4.3, Electrolytic conductivity < 100 micro S/cm
as per IEC 754-2
 Toxicity index: Maximum 05 Gases to be
extracted – HCL, HBr, HF, CO, CO2, NO,
SO2, HCN as per NES-713. HCL shall be first
gas to be extracted
Inner Sheath and outer sheath thickness: Min.
Inner sheath thickness and outer sheath
thickness shall be as per IS: 1554(P-1)1988
(should not be less than 0.5 mm).
Outer Sheath Colour: Blue
Inner Sheath Colour: Black
5 Testing of the BS 5308
instrument
Signal and RTD
cables.
6 Testing / Calibration ANSI MC96.1 / IEC-60584-2
of
Thermocouple
cables.
7 Dimensions BS 5308

ii. Instrument power and control cables:

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Sr. Description Particulars

No.
1 Conductors IS : 8130 / BS 6360
2 Insulation: XLPE Insulation shall be Cross-linked Polyethylene
(XLPE) as per BS 5308 / IS 7098.
3 Armour Round wire armour galvanized steel as per IS
1554 Part 1
4 Inner & Outer Extruded Fire Retardant, Low Smoke, Low
Sheath-PVC Halogen, Low Toxic, PVC having physical
properties as per IS 5831Type ST2.
Flammability and chemical properties shall be
as follows:
 Oxygen Index: 30 (minimum) at room Temp
as per ASTM-D-2863-77
 Temperature Index: 250 ˚C (minimum) at
Oxygen Index of 21 as per ASTM-D-2863.
 Light Transmission: 70% (minimum) as per
IEC 1034.
 Flammability test: As per IEC 332 Part-1 &
Part-3 Cat. A
 Corrosivity of combustion gases: pH-index>
4.3, Electrolytic conductivity < 100 micro S/cm
as per IEC 754-2
 Toxicity index: Maximum 05 Gases to be
extracted – HCL, HBr, HF, CO, CO2, NO,
SO2, HCN as per NES-713. HCL shall be first
gas to be extracted.

Inner Sheath and outer sheath thickness:

MinmumInnerSheath thickness and outer
sheath thickness shall be as per IS: 1554(P-
1)1988, should not be less than 0.5 mm.
Power Cables: Black
Control Cables: Blue with black bands (4 bands
at 90
apart)
5 Testing of the power IS : 1554 Part I, BS 6469 / BS 6346
and control cables.

c) Cable Construction:The various mechanical/ electrical parameters indicated

here are indicative and the Contractor shall be responsible to select/ design
the cables as per applicable standards.

i. Instrument Signal Cables (4 – 20 mA or Switch Contacts):

Sr. Description Particulars

No.
1 Conductor

i) Single / Multi Pair 7 stranded / 0.53 mm dia (1.5 mm²) stranded

annealed tinned copper conductors of
electrolytic grade copper.

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Sr. Description Particulars

No.

2 Insulation Cross-linked Polyethylene (XLPE) as per BS

5308/IS 7098.
3 Inner & outer sheath PVC, fire retardant, low smoke, low halogen,
low toxic, polymeric compound.
4 Pairs Two insulated conductors shall be uniformly
twisted together to form a pair at least 10 twists
per metre.
5 Maximum DC Shall not exceed 12.3 ohms/ km at 20ºC for
resistance cables with 1.5 mm conductor.
6 Mutual capacitance BS 5308 Part 1
7 L/R ratio of adjacent BS 5308 Part 1
cores
/pairs
8 Shield Shield shall be aluminium backed mylar/
polyester tape bonded together with the
metallic side down helically applied with either
side having 25% overlap and 100% coverage.
The minimum shield thickness shall be 0.05
mm in case of single pair and 0.075 mm in case
of multi pair cable.
9 Drain wire Drain wire shall be provided for individual pair
and overall shield with 0.5 mm²) multistranded
bare tinned annealed copper conductor
continuously in contact with aluminium side of
shield.
The drain wire resistance including shield shall
not exceed 30 ohm/km.
Electrostatic noise rejection ratio shall be over
76 dB.
10 Colour coding Individual pair core insulation: Blue & Black
Inner jacket : Black
Outer jacket: Blue for intrinsically safe
application and blue with black bands (4 bands
at 90˚ apart) for non IS applications.

ii. RTD cables:

Sr. Description Particulars

No.
1 Conductor
Single / Multi Triad 7 stranded / 0.53 mm dia (1.5 mm²) annealed
tinned copper conductors of electrolytic grade
copper.
2 Insulation Cross-linked Polyethylene (XLPE) as per BS
5308/ IS 7098
3 Inner & outer sheath PVC, fire retardant, low smoke, low halogen,
low toxic, polymeric compound.
4 Triads Three insulated conductors shall be uniformly
twisted together to form a Triad at least 10

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Sr. Description Particulars

No.
twists per metre.
5 Maximum DC Shall not exceed 12.3 ohms/ km at 20ºC for
resistance cables with 1.5 mm² conductor
6 Mutual capacitance BS 5308 Part 1
7 L/R ratio of adjacent BS 5308 Part 1
triads
8 Shield Shield shall be aluminium backed mylar/
polyester tape bonded together with the
metallic side down helically applied with either
side having 25% overlap and 100% coverage.
The minimum shield thickness shall be 0.05
mm in case of single triad and 0.075 mm in
case of multitriad cable
9 Drain wire Drain wire shall be provided for individual pair
and overall shield With 0.5 mm² multistranded
bare tinned annealed copper conductor
continuously in contact with aluminium side of
shield.
The drain wire resistance including shield shall
not exceed 30 ohm/km.
Electrostatic noise rejection ratio shall be over
76 dB.
10 Colour coding Core insulation: Red, Yellow and Blue
Inner jacket : Black
Outer jacket: Blue for intrinsically safe
application and blue with black bands (4 bands
at 90° apart).

iii. Thermocouple cables:

Sr. Description Particulars

No.
1 Conductor 16 AWG or 1.5 mm² solid conductors
Single pair cable Conductor material should be as follows:
K type T/C – Nickel/ Chromium; Nickel/
Aluminium (KX), Class 1.0
2 Insulation Cross-linked Polyethylene (XLPE) as per BS
5308/ IS 7098
Colour code: Nickel/ Chromium: Green
Nickel/ Aluminium: White
3 Pairs Two insulated conductors shall be uniformly
twisted together to form a pair at least 10 twists
per metre. The lay length of adjacent
pairs/Triads in case of Multipair cables shall not
be equal, to reduce cross-talk.
4 Mutual capacitance BS 5308 Part 1
5 L/R ratio of adjacent BS 5308 Part 1
triads
6 Core inductance Shall not exceed 4 mH /km. However, for J-type

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Sr. Description Particulars

No.
thermocouple inductance could be 8 mH/km.
7 Shield Shield shall be aluminium backed mylar /
polyester tape bonded together with the
metallic side down helically applied with either
side having 25% overlap and 100% coverage.
The minimum shield thickness shall be 0.05
mm in case of single pair and 0.075 mm in case
of multi pair cable
8 Drain wire Drain wire shall be provided for individual pair
and overall shield with 0.5 m m² multistranded
bare tinned annealed copper conductor
continuously in contact with aluminium side of
shield.
The drain wire resistance including shield shall
not exceed 30 ohm/km.
Electrostatic noise rejection ratio shall be over
76 dB.
9 Colour coding Outer sheath colour - Green
Inner sheath colour - Black

All thermocouple extension cable shall be matched and calibrated in

accordance with IEC-60584-2/ ANSI MC 96.1

iv. Instrument control cables:

Sr. Description Particulars

No.
1 Conductor 7 stranded / 0.53 mm dia (1.5 mm²) annealed
2 Core / Multi-core tinned copper conductors of electrolytic grade
type copper.
2 Insulation Cross-linked Polyethylene (XLPE) as per BS
5308 / IS 7098
3 Inner & outer PVC, fire retardant, low smoke, low halogen,
sheath low toxic, polymeric compound.
4 Maximum DC Shall not exceed 12.3 ohms/ km at 20ºC for
resistance cables with 1.5 mm² conductor
5 Core Identification IS : 1554/ BS 6746

v. Instrument power cables:

Sr. Description Particulars

No.
1 Conductor 7 stranded/ 0.67 mm dia (2.5 mm²) annealed
tinned copper conductors of electrolytic grade
copper.
The size of the conductor specified here is
minimum however; the exact size of the
conductor shall be selected based on the length
of cable and power consumption. For higher
conductor

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Sr. Description Particulars

No.
Sizes, aluminium can be considered.
2 Insulation Cross-linked Polyethylene (XLPE) as per BS
5308/ IS 7098
3 Core Identification IS-1554/ BS 6746
4 Colour coding Outer sheath colour –Black
Neutral wire insulation colour – Black
Phase wire insulation colour – Red
Ground wire insulation colour - Green

vi. Ethernet Cables:

 EIA/ TIA 568 A Category 5, 4 pair 0.5 mm2 (24 AWG) solid
conductors, with plastic foil wrapping.

 Overall screen to consist of aluminium bonded polyester tape and

tinned copper wire.

 Overall sheath shall be light grey PVC.

vii. Fiber Optic Cables:

 62.5/ 125 micron multimode, graded index, glass silica fibre core,
mechanical protection provided by round galvanized steel armour
with polyester laminated tape layered over inner sheath.

 Outer sheath shall be orange.

 HDPE conduit shall be orange colour.

viii. Any other special cables such as co-axial cable or cables with glass
insulation, required for instruments shall also be supplied as per
requirements.

ix. Contractor shall ensure that these cables are armoured type and shall
meet all other requirements specified above, as applicable.

3.10.9. Cable Drums:

a) Cables shall be supplied in non-returnable wooden drums. The wood used for
construction of the drum shall be properly seasoned and free from defects
and wood preservative shall be applied to the entire drum. All ferrous parts
shall be treated with a suitable rust preventive coating to avoid rusting during
transit or storage.

b) Before winding the cables on drums, Contractor shall obtain Purchaser’s

approval for the drum lengths. Cable ends shall be sealed by non-hygroscopic
sealing caps.

c) Contractor has to ensure reference of an arrow and suitable accompanying

wording which shall be stenciled on the sides of the drums indicating which
way it should be rolled. The number on each drum shall be either branded at

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the end of the drum or stamped on the metal attached to an end of the drum.
The cable shall be placed on the drum in such a manner that it will be
protected from injury during transit. Each end of the cable shall be firmly and
properly secured to the drum. The drum shall be securely blocked in position
so that the cable will not be displaced during transit. Cable ends shall be
sealed by non-hygroscopic sealing caps.

d) It shall be the Contractor’s responsibility to prepare the drum cutting schedule

so that cable wastage is minimum while cutting.

e) Contractor shall obtain Purchaser’s approval for the drum lengths.

f) The following information shall be given on the drums as a minimum:

i. Drum identification number

ii. Voltage grade

iii. Type of cable.

iv. Number of cores and cross-sectional area

v. Cable quantity

vi. Purchaser's order number and item number

vii. Total weight of cable and drum

3.10.10. Tests Before and After Laying of Cables at Site:Following Routine & acceptance
tests on each drums as per IS 10810, IS 7098 standard & other specified relevant
standards shall be performed by the manufacturer and witnessed by Purchaser/
Purchaser’s Representative.

a) For 1.1 kV Power & Control cables:

i. Dimensional & visual check

ii. Conductor resistance test

iii. Insulation Resistance Test

iv. High voltage test

b) For 11 kV power cables:

i. Design and visual check

ii. Conductor resistance test

iii. Very low frequency AC HV test (instead of DC test)

iv. Insulation resistance including P.I. at rated voltage

v. Capacitance and tan delta

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vi. AC leakage current

vii. Partial discharge measurement

c) All HV cables shall be subjected to DC or AC (preferably DC) high voltage test

after terminating but before commissioning as per Table 6.0 in IS: 1255 (Code
of practice for Installation & Maintenance of Power Cables up to and including
33kV).

d) Cables shall be checked for insulation resistance before and after jointing.
The voltage rating of the Megger for cables of different voltage grades shall
be as indicated below.

Voltage Grade Megger rating

1.1kV 500V
11kV 1000V
33kV 2500V

e) Following tests in the presence of Purchaser/ Purchaser’s representative shall

be carried out at site before commissioning of cables.

i. Insulation Resistance test between phases and phase to Neutral and

phase to earth.

ii. Continuity test of all the phases, neutral and earth continuity conductor.

iii. Sheathing continuity test.

iv. Earth resistance test of all the phases and neutral.

f) Instrument CableTesting:Contractor shall submit routine and Acceptance test

certificates, in original at the time of delivery of cables.

i. Type Test: Certificate from independent test house for the following
tests shall be furnished by the Contractor for the FRLS low halogen
sheathed cable.

 Flammability Test as per IEC 60332, Part-III, Cat A.

 Electrostatic noise Rejection test.

 Oxygen Index, Temperature rating, light transmission, pH Index,

electrical conductivity and toxicity index for the cable

ii. Routine Test and Acceptance test: Each of the following tests to be
carried out by Contractor during various stages of manufacturing.
Purchaser shall review the related documentations. In addition, the
following test shall be carried out for checking properties of low halogen
FRLS sheathing material.

 Light Emission test as per IEC-1034. Acceptance norms shall be

minimum 70%

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 Determination of the degree of acidity of gases evolved during

combustion as per IEC 754-2 (pH value to be minimum 4.3 and
conductivity to be maximum 100 micro Siemens/cms

 Toxicity Index as per NES-713. Value shall not exceed 5

 Tear Resistance as per BS 7655 Section 6.1

 Abrasion test method as per BS 6724 Annexure E

iii. All above tests shall be carried in presence of Purchaser or his

authorized representatives. Immediately after completion of the
electrical test the ends of the cable shall be sealed to prevent ingress of
moisture with suitable rubber/ PVC caps.

iv. Identification Marks on Instrument Signal Cables: Outer Embossing:

Following embossing should be in bold fonts at outer sheath at every
five (5) meter interval.

 Type of Cable i.e. Signal Cable

 No of Pairs i.e. 1, 6, 12 etc.

 Core Size i.e. 1.5 sq mm etc.

 Sequential meter marking shall be embossed at every one (1)

meter interval

 Individual pairs Embossing and identification: Core no shall be

printed on each core for identification at regular interval of 250 mm
or so.

 The pair numbers shall be available on individual pair by method of

polyester number tape also.

v. Identification marks on Instrument Control Cables: Following

embossing should be in bold fonts at outer sheath at every 5 meter
interval.

 Type of Cable i.e., Control Cable

 No of Cores i.e., 2, 4, 10, 12, 24 etc.

 Core Size i.e., 1.5 sq mm

 Sequential meter marking shall be embossed at every one (1)

meter interval

vi. Identification marks on Instrument Thermocouple Cables: Outer

Embossing: Following embossing should be in bold fonts at outer
sheath at every five (5) meter interval.

 Type of Cable i.e. T/C Cable

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 No of Pairs

 Core Size i.e. 16 AWG

 Temperature Range

 Sequential meter marking shall be embossed at every 1 meter

interval

 Individual pairs Embossing and identification: Each core of pair

shall be numbered for identification at regular interval of 250 mm or
so.

g) Cable Gland:

i. Cable glands required for glanding all cables at both ends shall be
supplied by Contractor.

ii. A minimum of 20% of cable glands shall be supplied as spare.

iii. Cable glands shall be of SS 316 and double compression type suitable
for armoured cables.

iv. All cable glands shall be weatherproof to IP-66. Flameproof glands

wherever required shall be supplied with Ex (d) certification suitable for
Gas Groups IIA / IIB / IIC.

v. All cable glands shall be with LSF shrouds.

vi. For all field items and junction box end, NPT threaded cable glands
shall be used and for control room / control panel end, cable glands
shall be ET threaded types.

h) Junction Boxes:

i. In order to make the most economic use of cable tray and trench
capacity, multicore / multipair cabling shall be utilised in order to connect
instrumentation groups by using suitably located junction boxes.

ii. The junction boxes shall have weather protection suitable for the area in
which they are to be installed and for the type of circuit.

iii. They shall be readily accessible for maintenance and clearly labeled.

iv. Junction box shall be constructed of die cast aluminium and provide
degree of protection IP 65.

v. Wires and terminals for the digital and analog signals shall be
segregated within junction boxes.

3.10.11. Drawings/ Documents Required:

a) As a part of the Bid, Contractor shall furnish the following :

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i. General information

ii. Principal technical data

b) After award of contract it shall be the responsibility of Contractor to work out a

detailed layout for the complete plant cabling system. The layout drawing shall
be furnished for the approval of Purchase/ Purchaser's representative before
commencement of installation including cable trays, cable racks/ trenches,
accessories, tray supports, conduits etc.

c) Contractor to submit following drawings/details after award of contract

i. Cable Sizing calculations

ii. Details of Installation of cables in trenches, on cable trays, directly

buried etc at all locations inside the plant.

iii. Cable routing lay out inside and outside the plant with route marker
provided at 30 meter interval.

iv. Bill of quantities of cables, lugs and glands.

v. HV Cable termination and mounting Kit Layout drawing.

d) Following Type Tests reports as per relevant standard to be submitted for the
same rating & type of Cables conducted in past for review of Purchaser/
Purchaser’s Representative by the Contractor at the time of inspection &
testing of equipment. Type test reports should be valid and not be older than
the 5 years.

i. Annealing test

ii. Tensile test

iii. Wrapping test

iv. Test for thickness of insulation & sheath

v. Physical test for insulation & sheath

vi. Tensile strength and elongation at break of insulation and sheath

vii. Loss of mass test

viii. Ageing in air oven

ix. Shrinkage test

x. Heat shock test

xi. Insulation resistance test

xii. High voltage test

xiii. Flammability test

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3.10.12. Cable Trays& Accessories:

a) Cable trays shall be of Galvanised Steel/ Fiber Reinforced Plastic and of

ladder/ perforated/ solid type, complete with all necessary coupler plates,
elbows, tees, bends, reducers, stiffeners and other accessories and hardware
as detailed in the relevant drawings. All hardware (i.e. bolts, nuts, screws,
washers, etc) shall be hot dip galvanized.

b) Cable trays of ladder and perforated types and the associated accessories
such as coupler plates, tees, elbows etc., shall be fabricated from 14 gauge
(2.0 mm thick) mild steel sheets. Cable tray covers shall be fabricated from 16
gauge perforated (1.60 mm thick) M.S. sheets.

c) The cable trays shall be supplied in standard lengths of 2500 mm and clear
inside widths of trays shall be as follows:

i. Perforated type trays: 150, 300, 450 and 600 mm.

ii. Ladder type trays: 300, 450, 600 and 750 mm

d) Cable trays, accessories and covers shall be painted with one shop coat of
red oxide zinc chromate primer and two site coats of aluminium alkyd paint for
indoor use.

e) For outdoor use, cable trays, accessories and covers shall be either
galvanized or made of aluminium as specifically mentioned in the layout
drawings.

f) For use in corrosive atmospheres both indoors and outdoors, the cable trays,
accessories and covers shall be as per serial no. (e) above.

g) The spacing of rungs for ladder type of trays shall be 250 mm unless
otherwise noted.

h) All finished cable trays and accessories shall be free from sharp edges,
corners, burrs and unevenness.

3.11. EARTHING &LIGHTNING PROTECTION SYSTEM:

3.11.1. Scope:

a) The scope includes collection of data, design of the system as per relevant
National/International Standards preparation of layout drawing supply of
earthing conductors, earth electrode, earthing strips installation and approval
to the satisfaction of electrical inspector under this tender specification.

b) Earthing system shall be provided to ensure equipment safety, personnel

safety and facilitate designed operation of protective switching during earth
fault conditions in the associated system.

3.11.2. Applicable Standards:Theearthing and lightning protection system shall conform to

the CEA guidelines and the latest applicable standards indicated below:

a) Code of Practice for Earthing : IS: 3043

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b) Code of Practice for the Protection of : IS: 2309

c) Building and allied structure against

d) Lightning.

e) Hot dip galvanizing : IS: 2629, 2633, 4759

f) Structural steel : IS: 2062 & 808

g) Welding : IS: 816

3.11.3. Earthing&Lightning system:

a) The design basis for designing earthing conductor is indicated under design
criteria for electrical system. Earthing system shall be provided for complete
plant i.e. pumping stations, switchyard and all electrical equipments as per the
latest edition including all official amendments and revisions of IS-3043 and
CEA guidelines.

b) All materials and fittings used in the earthing installation shall conform to the
relevant Indian Standards or shall be approved by the Engineer's
representative &HPSEB.

c) Contractor has to carry out soil resistivity test at,at least 4 locations for which
locations shall be provided by Purchaser’s representative. Testing to be done
at each site.

d) Soil resistivity shall be carried out by Wenner four electrode method as

described in IS 3043.Contractor has to carryout the test in presence of
Purchaser’s representative & test shall be carried out keeping electrode
spacing as 1, 2, 4, 6, 8, 10, 15, 25 M (each, along all 8 directions) as per
normal practice and report has to be submitted. Polar curves shall be used for
measurement of mean soil resistivity, which shall be used in finding earthing
resistance at a particular location. Mean soil resistivity values shall be
approved by Purchaser’s representative.

e) The Contractor shall base his earthing calculations on actual measurement

carried out by him in the presence of Purchaser/ Purchaser's Representative.

f) Galvanized Iron flat / wire shall be used as earthing conductor.

g) The conductor sizes & types shall be as per specified in the Technical
schedules in Volume- II, Section A3. Contractor to note that, the sizes
indicated are minimum required &earthing conductor sizes shall be approved
by the Purchaser/ Purchaser’s representative on the basis of adequacy
calculations submitted by Contractor.

h) The underground joints in the system shall be properly welded or brazed and
the bolted type connection shall be made with structures/ equipments.
Petroleum jelly shall be applied to contact surface of the bolted joints, which
will be covered with bituminous compounded and tapes.

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i) Earthing conductor shall be protected against mechanical damages

considering the installation conditions.

j) The earthing system shall comprise one or more earth electrodes, earthing
grid or a combination of these in order to obtain the required earth electrode
resistance of less than one (1) Ohms/ or as per IEEE Std 80 -2000.

k) For equipment earthing, two earthing leads will be used if rated voltage of the
equipment is 250 volts & above and one earthing lead will be provided for
equipment rated below 250 volts.

l) The earthing conductors in outdoor areas shall be installed at a minimum

depth of 600 mm below FGL.

m) For each 11 KV DP/ FP Structure, minimum 2 nos. of CI plate type earthing

electrodes shall be provided. The earth plate shall be buried in specifically
prepared earth pit- 3 mtr. below ground with alternate layers of charcoal and
salt, 40 NB GI pipe with funnel with a wire mesh for watering and bricks
masonry block and CI Cover complete as per IS 3043 with necessary length
of double GI earth flat 25x6 mm bolted with lug to the plate complete
connected to the required point of DP with end socket as per direction and
duly tested by earth tester conforming to IS as per drawing and specifications
complete with 600 x 600 x 6.0mm CI earth plate.

n) For each transformer neutral, minimum 2 nos. of Cu plate type earthing

electrodes shall be provided. The earth plate shall be buried in specifically
prepared earth pit 3 mtr. below ground with alternate layers of charcoal and
salt, 40 NB GI pipe with funnel with a wire mesh for watering and bricks
masonry block CI Cover complete as per IS 3043 with necessary length of
double Copper earth flat 25x6 mm bolted with lug to the plate complete
connected to the transformer neutral with end socket as per direction and duly
tested by earth tester conforming to IS as per drawing and specifications
complete with 600 x 600 x 3.15 mm Copper earth plate.

o) For other equipment & area, Earth electrodes shall be of heavy duty
galvanized mild steel of not less than 40 mm NB and minimum 3000 mm long.
Where multiple rods are used they shall be separated by a distance of not
less than the driven length.

p) Each earth electrode pipe shall be welded at the top to a mild steel plate to
which the earthing strips shall be connected.These connections shall each be
housed in individual inspection chamber set which shall project 100 mm
above the finished ground level and shall allow disconnection for testing of
individual electrodes.The chamber shall be permanently marked `Electrical
Earth'.

q) All materials used for the earth electrode installation shall be purpose made
for the application and site conditions and shall be approved by the
Purchaser’s Representative.

r) All civil works, such as excavation, boring, provision of charcoal & salt in
adequate quantity, backfilling for the installation of the earth electrodes and
the earth pit/ inspection pit shall be in the scope of Contractor.

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s) After the earth installation has been completed the Contractor shall
demonstrate to the Purchaser/ Purchaser’s Representative that the resistance
of the electrodes to earth and the continuity of the earth network are within the
limits specified. Any additional earth electrodes and test instruments required
for the tests shall be provided by the Contractor.

t) Main Equi-potential Bonding Conductor: Main equi-potential bonding

conductors shall be provided to connect the earth electrode system to
conductive parts forming the Works.

u) Circuit Protective Conductors: An independent circuit protective conductor

shall be provided for each circuit and may comprise one or any of the
following as appropriate:

i. a separate core within a multicore cable

ii. A separate conductor installed within a conduit or trunking. Steel conduit

or trunking shall not be used as a circuit protective conductor.

iii. The metal sheath of an armoured cable. The sheath shall be bonded to
the metal work of the apparatus and to the apparatus earth bar, if any.

iv. the copper sheath of a mineral insulated copper sheathed cable

v. An independent earthing conductor MS or GS run adjacent to the circuit

it protects.

vi. The size of the circuit protective conductor shall be calculated in such a
manner as not to take into consideration the contribution of any other
parallel or fortuitous earth paths.

vii. The armoring of the supply cable shall not form the sole means of
earthing a switchboard or large electrical load.

v) Instrumentation Earth:

i. An instrumentation earth bus shall be provided in each control panel.

This shall comprise a GI flat of cross section not less than 25 x 6 mm
and length to suit the number of connections. It shall be mounted on at
least two insulated supports and be provided with a single earth
connection to the control panel electrical power earth.

ii. If due to the physical size of a control panel more than one instrument
earth bar is required the additional bar shall be connected again with a
single earth connection to the same point as before on the control panel
electrical earth bar. In this fashion all instrument earths shall be
connected radial from the same earth point.

iii. All signal cable screens (analogue and digital) shall be terminated on to
the instrument earth bar. Signal cable screens shall be earthed at the
control panel end only. Screens at the field end shall be tied back and
insulated.

iv. Surge Protector Devices (SPDs) associated with the control and

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instrumentation system shall be earthed to the instrument earth in

accordance with the SPD manufacturer’s recommendations.

v. Separate electronic earthing system with dedicated earth pit shall be

provided by the bidder for I&C equipment.

3.11.4. Important Instructions for Earthing:

a) Each pole of lightning arrestors shall be earthed with separate earth pit.

b) Two-earth conductor shall connect outdoor CT secondary winding to earth

grid.

c) The switchyard fencing shall be earthed at every alternate block and the
switchyard gate shall be earthed with flexible GI wire.

d) All the earthing material with laying etc. shall be included in the scope.

e) The entire plant will have an earth grid laid in trenches/ trays/ buried in the
ground outside. The main earthing grid shall be embedded at a minimum
depth of 600 mm below FGL which shall be connected to earth electrodes.

f) All interconnections of the earthing grid conductors will have welded type
joints except at electrodes with disconnecting facility and at equipment with
bolted connections. All indoor earthing grids will be suitably interconnected to
the external earthing grid.

g) Each steel/ RCC column of the building will be interconnected to the floor-
earthing grid. Steel columns, steel strips / conduits, cable trays etc. will not be
used as earth continuity conductors.

h) Disconnecting type facility shall be provided between Earthing grid & each
earth electrode.

i) All connection between the conductors shall be welded/ brazed type. Metallic
pipe, conduit, structures shall be bonded to lightning protection conductors to
prevent the side flashover. But no metallic pipe, conduit, structure shall be
used as air termination conductor or down conductor.

j) The down conductors shall be fixed with embedded brass posts (on concrete
columns) with nuts & bolts used for fixing the saddle/ clamp (direct drilling of
down comer and fixing with screw shall not be acceptable).

k) Cleats for ‘earthing and lightning protection systems’ shall be of GI.

l) The lightning protective conductor shall not be connected with the earthing
above ground however both the systems shall be interconnected below
ground.

m) The earth pits may require boring & drilling in the soil & the same shall be
considered in Contractor’s scope.

n) Earth electrode with disconnecting facility shall be provided so that the

resistance of the independent earth electrode may be measured.

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o) Internal earth Bus of each panel shall be connected to both ends to the
earthing system by means of earthing conductor.

p) Metallic frames of all current carrying equipment, structures supporting and

adjacent to current carrying conductors, lightning protection system
conductors, metallic structures, metallic stairs, hand rails, fences shall be
connected to a single earthing system. Neutral points of various systems shall
be connected to the dedicated treated earth pits and these earth pits shall be
interconnected to each other below ground.

q) All connections in the equipment earth conductors buried in ground (or

otherwise) shall be cad welded/ brazed, whereas connection at equipment
end shall be of bolted type. All connections shall be of low resistance. All
bimetallic connection shall be treated with suitable compound to prevent
moisture ingression. For Bimetallic bolted connection, bimetallic washers shall
be used. All bolted joints shall have minimum two bolts to ensure proper
surface contact.Termination of stranded conductors at earth inserts shall be
with ring type/ lugs.

r) Galvanized conductors shall be touched up with zinc-rich paint where holes

are drilled at site for bolting to equipment/structure.

s) Suitable earth risers approved by the Engineer shall be provided above

finished floor/ ground level, if the equipment is not available at the time of
laying of the main earth conductor. The minimum length of such risers inside
the building shall be 200 mm and outdoor shall be 500 mm above ground
level.

t) Metallic conduits and pipes shall be connected to the earthing system unless
specified otherwise.

u) All cable trays will be earthed at minimum two places by suitable sized GI flats
to main earthing system earth conductor. The cable trays shall also be
earthed at a regular interval of not more than 10 meters by 25 x 3 mm GS flat

v) Earthing Pits:

i. Adequate number of earthing pits shall be provided in conjunction with

earthing grid for the earthing system. The minimum spacing between
two adjacent earthing pits shall not be less than length of the electrode
(minimum 3 m) and shall be kept 1500 mm away from footings of the
structure.

ii. Earthing pits shall be located in ground, which has a reasonable chance
of remaining moist. Arrangement comprising of GI pipe with top funnel
with wire mesh shall be made to facilitate pouring of water to keep
earthing pit wet.

iii. A galvanized iron strip of adequate size (as per calculations) shall be
provided from plate electrode to about ground level to facilitate jointing
with earth conductors. Each earth electrode ending at the pit shall be
connected to suitable linking strips to connect and disconnect the
earthing suitably.

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iv. Earthing chamber shall be of RCC/ brick chamber of 600 mm x 600 mm,
with removable 6 mm thick MS chequered plates. The covers shall have
holes for handling. Earthing pits (chambers) shall be painted Green and
the earth-pit number shall be marked on it.

v. Earthing cables crossing other metallic structures such as conduits

pipelines etc shall be minimum 300 mm away from such structures.

vi. Earthing conductors shall be protected against mechanical damage.

vii. All earth lead connections shall be as short and direct as possible and
shall be without kink.

viii. The main earth loop in plant area shall be generally routed along
cables. When equipments are located away from main earth loops,
suitable sub-loops shall be run up to them for deriving connections for
individual equipment. The entire earthing system shall fully comply with
the CEA guidelines and requirements.

ix. The Contractor shall have to carry out any changes as desired by the
Electrical inspector or the Engineer in charge, in order to make
installation conforming to the CEA guidelines 2010.

3.11.5. Lightning Protection:

a) The lightning protection system need will be established by calculating the risk
factor value of each building, structure etc. as per procedure given in IS 2309-
1989 and if found necessary the same shall be provided by the Contractor.

b) For Lightning protection of Civil Structures including RCC Buildings, fixing of

25x6 mm GI earth strip to roof as per IS/ IEC std, saddle clamp, down comer
connector etc. as required with all hardware shall be in Contractor’s scope.
Structural Columns (which are used as down comers for lightning protection
system) bottom shall be connected to the earth pit with 25x6 mm bare GI
strip.

3.11.6. Galvanizing:

a) Wherever galvanizing has been specified, the hot dip process shall be used.
The galvanized coating shall be of uniform thickness. Weight of Zinc coatings
for various applications shall not be less than those indicated below

Fabricated Steel
i. Thickness less than 2 mm, but not less than 1.2 mm 340 gms/ sq.m
ii. Thickness less than 5 mm, but not less than 2 mm 460 gms/ sq.m
iii. Thickness 5 mm and over 610 gm/ sq.m
Fasteners
i. Up to nominal size M10 270 gms/ sq.m
ii. Over M10 300 gms/ sq.m

b) Burrs shall be removed before galvanizing. Any site modification of galvanized

parts should be covered well by zinc rich primer and aluminium paint.

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c) Contractor shall ensure to use calibrated test equipment having valid

calibration test certificates from standard laboratories traceable to National
Standards.

3.11.7. Drawings/ Documents Required:

The Contractor should prepare Layout drawings, after award of contract and before
commencement of work for Purchaser’s approval, showing the location of earthing
grid, electrodes, interconnection grids and earthing leads to various equipment,
down comers, isolating links etc. should be accompanied by design calculations.

3.12. LIGHTING& VENTILATION SYSTEM:

3.12.1. Scope

a) The scope of the Contractor shall include design, supply and installation of all
equipment necessary for a complete lighting and receptacle system. The
lighting system includes Lighting fixtures (indoor/ outdoor), lamps, lighting
panels (LP), switchboards, Receptacles, JBs, cables/ wires for lighting/
receptacles, conduits etc. The supply of streetlight/ flood light poles as per IS
2713 or IS 3713 is also included in the Contractor’s scope.

b) The various types of lighting fixtures with lamps shall be installed based on
the mounting arrangement shown in the typical drawings enclosed with the
specification. Installation scope shall include all material to mount the fixtures
in proposed manner.

c) The various types of lighting fixtures as per specified in this specifications

shall be assembled, installed, tested & commissioned by the Contractor.

d) The type of lighting fixtures and receptacles, illumination level and

approximate quantity required shall be generally as per design criteria.

e) Lighting system installation shall be as per the tender specifications

f) It shall be the responsibility of the Contractor to work out complete detailed

requirement of lighting and receptacle system for the whole plant and staff
quarters including area lighting as per specification and accordingly procure
and install them.

3.12.2. General Requirements:TheLighting system includes following items.

a) Lighting fixtures complete with Lamps and accessories

b) Lighting system equipment

c) Light control switches, receptacle units with control switch units, lighting wires,
conduits, earth wires and other similar items necessary to complete lighting
system.

d) Lighting fixture supports, street lighting poles and flood light towers/ poles.

e) Lighting main distribution board, lighting panels

f) Multi core cables for street, boundary and flood lighting

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3.12.3. Lighting Layout:

a) It shall be the responsibility of the Contractor to work out a detailed layout for
the complete plant in order to provide the levels of illumination as indicated in
the relevant standards

b) The types of fixtures to be used in various areas are also indicated in the
above mentioned drawing. The Contractor shall be responsible for measuring
the levels of illumination and uniformity after installation and establish
compliance with the specification.

c) The lighting system will comprise the following:

i. Normal A.C Lighting: Normal lighting in all indoor and outdoor areas will
be operated on 230V, 1Phase, 50 HZ A.C supply

ii. Emergency Lighting:EmergencyLighting shall be designed such that at

all junctions, exit passages & strategic locations, Lux level shall be
maintained above 10 Lux. Emergency light fitting shall be 240 V self
contained 2 x 10 W fluorescent tube with built in Ni-Cd battery having
charging facility and six hours back-up time.The emergency light fittings
shall be provided at strategic locations of each house/ area. Emergency
fixtures shall come in service when AC supply fails. Pump room and
Electrical room shall be considered for Emergency lighting.

3.12.4. Applicable Standards:The design, manufacture and performance of equipment shall

conform to the latest standards specified below. In case of conflict between the
standards and this specification, this specification shall govern.

a) Lighting Fixtures & Accessories

Electrical lighting fittings general and : IS: 1913/ BS: 4533

safety requirements
Code of practice for industrial lighting : IS: 6665
Code of Practice for Interior Illumination : IS 3646
Code of Practice for Lighting of Public : IS 1944
Thoroughfares
Calculation of co-efficient of utilization : IS: 3646 (Part - III)
Industrial lighting fittings with metal : IS: 1777
Reflectors
Decorative lighting fittings : IS: 5077
Dust proof electric lighting fittings : IS: 4012
Dust tight electric lighting fittings : IS: 4013
Flood lights : IS: 10322/BS: 4533
Luminaries for street lighting : IS: 10322 Part 5
Water tight electric lighting fittings : IS: 3553/ BS: 4533,
5225(I)
Bayonet lamp holders : IS: 61184 / IEC: 61
Edison screw lamp holders : IS: 10276/BSEN 60238
Bi-Pin lamp holders for tubular : IS: 3323
fluorescent lamps
Starters for fluorescent lamp : IS: 2215/BSEN 60155
Holders for starters for tubular : IS: 3324/BSEN 60400
fluorescent Lamps

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Ballast for use in fluorescent lighting : IS: 1534 (Part 1)/

fittings BSEN 60920 & 60921
Transistorized ballast for fluorescent : IS: 7027
lamps
Ballast for HP mercury vapour lamp : IS: 6616
Capacitors for use in fluorescent, IS: 1569/BSEN 61048
HPMV & LP sodium vapour discharge & 61049 / IEC:
586
Circuits
Vitreous enamel reflector for tungsten : IS: 8017
filament lamp
Tubular fluorescent lamps : IS: 2418 (Part-1)/ BSEN
60081/ IEC: 81
High pressure mercury vapour lamps : IS: 9900/BS: 3677/ IEC:
188
Tungsten filament general electric lamps : IS: 418/IEC: 432
Cast acrylic sheets for use in Luminaries : IS: 7569
Screw less terminal and electrical : IS: 10322
connections for lighting fittings
High pressure sodium vapour lamps : IS: 9974
Emergency lighting units : IS: 9583
Ignition proof enclosures, dust-tight for : IS: 11005
elect. equipment
Luminaries : IS: 10322(Part I to V)

b) Lighting System Equipment:

Arrangement for busbars, main : IS: 5578/ 11353/ BS: 159

connections and auxiliary wiring and
marking
Enclosed distribution fuse boards and : IS: 2675/BSEN 60439
cutouts for voltages not exceeding
1000V
General requirements for switchgear : IS: 13947
and control gear for voltages not
exceeding 1000 V
Code of practice - installation and : IS: 10118/BS: 6423
Maintenance of switchgear BS 6626, BS 6867
Factory built assemblies of switchgear : IS: 8623/BS-5486/ IEC:
439
and control gear for voltages up to and
including 1000 V AC and 1200 V DC
Miniature air break circuit breakers for : IS: 8828/BSEN 60898
AC circuits
HRC cartridge fuse links up to 650 V : IS: 9224/BS: 88/
IEC: 269
‘D’ Type fuses : IS: 8187
Current transformers : IS: 2705/BS: 7626/
IEC: 185
Voltage transformers : IS: 3156/BS: 7625/
IEC: 186
Direct acting electrical indicating : IS: 1248/BS: 89/IEC: 51
Instruments
A.C. electricity meters : IS: 722/BS 5685

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Electrical relays for power system : IS: 3231/BS: 142/

protection IEC: 255
Switches for domestic and similar : IS: 3854/BS: 3676
Purposes
Three pin plugs and socket outlets : IS: 1293/BS: 546
Boxes for enclosure of electrical : IS: 5133(1)
Accessories
Rigid steel conduits for electrical wiring : IS: 9537/BS: 31
Accessories for rigid steel conduits for : IS: 3837/BS-31
electrical wiring
Flexible steel conduits for electrical : IS: 3480
Wiring
Rigid non-metallic conduits for electrical : IS: 9537/BS: 4607(2)
installations
Fittings for rigid non-metallic conduits : IS: 3419/BS: 4607(2)
PVC insulated cables for working : IS: 694
voltages up to and including 1100 V
Tubular steel poles : IS: 2713
Specification for copper rods and bars : IS: 613
for electrical purposes
Code of practice for phosphate iron : IS: 6005/ BS: 3189
and steel
Fittings for rigid steel conduits for : IS: 2667
electrical wiring
National Building Code of India (NBC) : NBC 2005

3.12.5. Other Design considerations for Lighting:

a) Lighting panels shall be provided in various areas and circuit wiring to the
lighting fixtures shall be made from lighting panels. Lighting panel shall
comprise of Four pole MCB + RCCB (100 mA) for incomer and SP MCB’s for
each outgoing single phase circuits.

b) The wiring for lighting circuits in indoor areas will be done by wires run in GI
conduits. For outdoor lighting, wiring will be done by using armoured cables.

c) Lighting cable from Main lighting DB (MLDB) to Lighting panels shall be Al

conductor, XLPE insulated, 1.1KV grade, laid in cable trays otherwise cleated
along the wall/ column/ beam.

d) For lighting fixtures (Pump room) 1100V grade, 4C x 2.5 sq. mm. PVC
insulated, multistranded copper conductor armoured/ unarmoured cables shall
be used.

e) For lighting fixtures (For Office, electrical room, toilets etc. areas) 1100V
grade, FRLS PVC, multi-stranded Copper conductor wires of area not less
than 1.5 sq mm laid in min. 20 mm dia GI conduit (above false ceiling) shall
be used.

f) For 5/15A decorative sockets (For Office, toilets etc. areas) 1100V grade,
FRLS PVC, multi-stranded copper conductor wires of area not less than 2.5/
4.0 sq. mm. Cu laid in minimum 20 mm dia. GI conduit shall be used.

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g) Wiring shall be concealed in wall below false ceiling with concealed switch
board. Minor civil work like chasing wall, cut outs for conduit, switch board,
Lighting Panel in wall, entries for tray, conduits etc. is in scope.

h) Lighting cable from MLDB to Lighting Panels and Lighting Panels to street
light fixtures, shall be Al conductor, XLPE insulated, armoured, 1.1 KV grade,
laid in cable trays otherwise cleated along the wall/ column/ beam and buried
in the ground.

i) The point wiring for lighting/ receptacle/ exhaust fan/ wall mounted fan/ ceiling
fan shall include conduits, conduit accessories, FRLS PVC insulated
multistranded Copper conductor wires and earthing wires, pull boxes, ceiling
rose, clamps, cleats, hardware, accessories, anchor fasteners etc. It shall
include wiring from lighting panel to switchboard and receptacles &
switchboard to lighting fixtures. Sheet metal switchboard embedded in wall
shall be considered for receptacles and lighting switchboards on wall shall be
considered for lighting.

j) For power sockets in wall/ furniture, PVC switch box of approved make with
switch plate & accessories and 16 Amp piano modular switches and 5/15A
sockets etc. as applicable shall be considered. For all types of point wiring the
receptacles with switches shall be included in the point wiring rate.

k) Lighting switchboard consisting of (*) no. of 6A piano switch without indicator,

1 no. 6A piano switch with indicator, 1 no. white coloured cover plate for (*)
module( 4/ 6/ 8/ 12 module), 1no. 2/ 3 pin shuttered socket of 5/15A and metal
flush box.

l) Decorative socket switchboard consisting of (*) no. of 16A piano switch with
indicator, (*) no. 2/3 pin shuttered socket of 5/15A and metal flush box, 1 no.
white coloured cover plate for (*) module( 4/ 6/ 8/ 12 module).

m) Lighting fixtures and fans will be grouped on the circuit wherever required.
However, separate circuits shall be used for receptacles wiring.

n) Lighting Control Philosophy as per mentioned below shall be observed. From

each switch –

i. Max. 2 (3 in case unavoidable) fluorescent luminaries (2x36W)

ii. Max. 4 (5 in case unavoidable) down lighters luminaries (2x18W)

o) All MH fixtures, High bay T5 fixtures, Street Light fixtures shall be controlled
directly from respective Lighting Panels, through MCB.

p) Each lighting panel/ Receptacle DB shall have minimum 2 spare circuits of

10/16A SPN outgoing feeders. A circuit consists of R, Y, and B Phase each.

q) Lighting for staircase shall be controlled with flushed modular switch. The
conduit for main staircase shall be concealed. Lighting for all staircases shall
be with 2 way switch

r) Contractor shall note that any chasing in walls or cutouts or openings such as
fixing of LPs, DBs, switchboards, concealing conduit in wall etc. in walls
required shall be made before plastering of brickwork wherever applicable

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and installation rates quoted shall be inclusive of chasing, cutting & making
the plaster as per standard practice.

s) Lighting for street light fixtures/ flood light fixtures and metal halide fixtures
shall be carried out with cables. The supply of cables, junction boxes, street
light poles & structural steel required for mounting fixtures/ LPs etc. are in the
scope of Contractor. The cable wiring shall include supply & installation of
cable required from LP to the junction box mounted on street lighting pole /
near indoor fixture and also between junction box mounted inside pole/near
indoor fixture to control gear box and same for flood lighting, supply and
installation of all termination accessories such as lugs, cable glands etc. DBO
Contractor’s scope shall also include excavation, preparation of soil bedding,
supply and installation of protection cover, back-filling, supply and installation
of cable route markers etc.

t) Point Wiring for lighting/ raw power receptacle/ emergency lighting:

i. Point wiring covers the wiring between a circuit of the lighting panel to
switchboard and then from switchboard to lighting fixtures connected to
that circuit of the lighting panel.

ii. For receptacle circuits point wiring shall cover wiring between circuit of
the lighting panel to receptacles connected to that circuit of the lighting
panel.

iii. The scope of the Contractor shall include the supply, erection, testing
and commissioning of the above LPs/ DB boards for supply of power to
the various sockets required for computers, raw power points etc. The
point wiring rate from these DBs shall include supply of wires, conduits,
cleats/ clamps etc. as may be required and shall be in the scope of
electrical Contractor.

iv. The conduit point wiring rate for exhaust fan shall include conduits/
casing capping, conduit/ casing capping accessories, Switch boards,
PVC insulated wires and earthing wires, pull boxes, ceiling rose,
clamps, cleats, hardware, sheet metal switchboards fabricated out of 16
SWG. sheet steel housing 5 Amp piano switches. It shall include wiring
from EXHAUST FAN DB/ RDB to switchboard & switchboard to exhaust
fan as applicable. Neutral for individual circuit shall be run separate from
DB to individual receptacles.

v. All mounting accessories like base channels, cross angles if required,

nuts, bolts etc. shall be supplied by the Contractorunder the scope of
this contract.

vi. Required no. of 1-Ph & 3-Ph, industrial receptacles with respective 2P/
4P ELCB (30mA) & 3/ 5 pin plug shall be provided for maintenance
purpose.

vii. Receptacle &its ELCB shall be mounted in prefabricated CRCA box of

16 SWG, epoxy painted with shade 631of IS-5. Earthing studs shall be
provided for connecting external earthing with receptacle box.

viii. The Configuration of Industrial receptacle units shall be as per following

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– Combination

 240V, 1-Ph, 50Hz, 3 pin, 15A Industrial receptacles with RCBO (30
mA).

 415V, 3-Ph, 50Hz, 32/63A Industrial receptacles with respective

RCBO (30 mA).

u) Lighting Fixtures and Accessories:

i. General

Normal supply voltage, phase 240 V, 1 ph, 2 wire, 50 Hz,

and frequency

Variation in supply
Voltage (AC & DC) ±10
Frequency ±5
Combined voltage & ±10
frequency
Design ambient air 500C
temperature

ii. The Luminaries shall be designed so as to facilitate easy maintenance,

including cleaning, replacement of lamps/starters etc.

iii. Connections between different components shall be made in such a

way that they will not work loose by small vibration.

iv. For each type of Luminaries the Contractor shall furnish the utilisation
factor tables to indicate the proportion of the light emitted by the bare
lamps which falls on the working plane.

v. All Luminaries shall be supplied complete with lamps suitable for

operation on a supply voltage and the variation in supply voltage,
frequency and combined voltage and frequency of 10%, 5% and
10% respectively.

vi. The Luminaries and accessories shall be designed to have low

temperature rise. The temperature rise above the ambient temperature
shall be as indicated in the relevant Standards.

vii. Fluorescent type luminaries shall be complete with accessories like

lamps, ballasts, power factor improvement capacitors, starters, re-
wirable fuse and fuse base. These shall be mounted as far as possible
in the luminaries housing only. If these cannot be accommodated
integral with the Luminaries then a separate metal enclosed control gear
box shall be included to accommodate the control accessories together
with a terminal block suitable for loop-in, loop out connections. Outdoor
type fixtures shall be provided with outdoor type weather-proof box.

viii. Fluorescent type Luminaries with more than one lamp shall be provided
with capacitors connected in lead-lag circuit for correction of
stroboscopic effect.

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ix. Each luminaries shall have a terminal block suitable for loop-in, loop-out
and T-off connection by 230/ 415 V, 1 core, FRLS PVC insulated
Copper conductor wires up to 4 sq. mm in size. In outdoor areas the
termination at the luminaries shall be suitable for 1100 V, PVC
insulated, Cu/ Al conductor, armoured cables of sizes up to 6/ 16 sq.
mm conductor. Terminals shall be of stud or clamp type. The internal
wiring should be completed by means of stranded Copper wire of
minimum 1 sq. mm size and terminated on the terminal block. Terminal
blocks shall be mounted with minimum two fixing screws.

x. Mounting facility and conduit knock-outs for the luminaries shall be

provided.

v) Earthing

i. Each luminary shall be provided with an earthing terminal suitable for

connection to the earthing conductor of 12 SWG GI wire.

ii. Where separate control gear box is provided for housing the
accessories the same shall be provided with an earthing terminal
suitable for connecting earthing conductor of 12 SWG GI wire.

iii. All metal or metal enclosed parts of the luminaries/control gear box shall
be bonded and connected to the earthing terminal so as to ensure
satisfactory earthing continuity.

w) Painting/ Finish:

i. All surfaces of the Luminaries/Control gear box housing accessories

shall be thoroughly cleaned and degreased. It shall be free from scale,
rust, sharp edges and burrs.

ii. When enamel finish is specified, it shall have a minimum thickness of 2

mils for outside surface and 1.5 mils for inside surface. The finish shall
be non-porous and free from blemishes, blisters and fading.

iii. The luminaire housing shall be stove-enamelled/epoxy stove-

enamelled-vitreous enamelled or anodised as indicated under various
types of fittings.

iv. The surface shall be scratch resistant and shall show no sign of
cracking or flaking when bent through 90 deg. over 1/2” dia. mandrel.

v. The finish of the luminaries shall be such that no brigHV spots are
produced either by direct light source or by reflection.

vi. External control gear box provided for housing accessories shall be
painted or galvanised.

3.12.6. Fluorescent Luminaries:

a) The luminaries shall be provided with CRCA sheet steel mounting rail with
reflector of minimum 20 SWG thicknesses and complete with all control
accessories mounted on it. The finish shall be vitreous enameled.

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b) Luminaries mounted recessed in false ceiling shall be with reflector housing

and spring loaded fixing arrangement for the diffuser/ louver frame. It shall be
possible to have access to the lamp and other accessories from below.

c) Luminaries shall be suitable for the number of lamps of specified wattage,

direct mounting on ceiling/ wall/ column/ pendent mounting.

d) The distribution of light shall be such that at least 80% of the total luminous
flux from the luminaries shall be in the lower hemisphere.

e) The luminous output of the luminaries with reflector shall not be less than 75%
irrespective of type of reflector used.

3.12.7. High, Medium and Low Bay Luminaries: T5 lamps

a) Luminaries selection on the basis of height shall be generally selected

considering following height criteria-

i. High Bay for mounting heights above 9 meter

ii. Medium Bay for mounting heights from 6 m to 9m

iii. Low Bay for mounting heights below 6 meter

b) High and medium bay luminaries shall be with cast aluminium/ stove
enameled housing, anodized aluminium mirror polished reflector, canopy with
eye bolt for suspension, cooling fins. Glass cover shall be provided. The
luminaries shall be suitable for metal halide lamp up to 400 W. The control
gear accessories shall be mounted integral with the luminaries.

c) Low bay luminaries may be with sheet steel/ cast aluminium enclosure, wide
angle distribution type polished reflector, acrylic cover and wire guard
complete with neoprene gaskets, mounting bracket etc. The luminaries shall
be suitable for metal halide lamp up to 125 watts. The control gear
accessories shall be mounted integral with the luminaries.

d) All luminaries used with metal halide lamps shall be of enclosed type.

3.12.8. Well glass luminaries:

Well glass luminaries shall be robust construction, cast aluminium/ vitreous

enameled housing, clear heat and shock resistant glass cover fixed with neoprene
gaskets for sealing. For mechanical protection to the glass cover, round steel wire –
guard with vitreous enameled finish shall be provided. Additional heavy gauge
vitreous enamel reflector shall be provided. The luminaries shall be suitable for
incandescent lamp up to 200 watts, mercury vapour up to 250 watts for suspension
mounting by conduit pipe, hook or strap.

Luminaries shall be with degree of protection IP 54 generally used indoor.

3.12.9. Flood Light Luminaries: General purpose flood light luminaries:

a) Flood light luminaries shall be of weather proof construction with cast

aluminium housing, anodisedaluminium mirror polished reflector, heat

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resistant, toughened glass cover and necessary neoprene gaskets to prevent

ingress of dust.

b) The housing shall be supported on a cast iron base and capable of being
swivelled in both horizontal and vertical directions and locked in any desired
position.

c) For focussing purposes, knobs, shall be provided along with sector plate
indicating the angle in degrees between 0 and 90 deg. in vertical direction.

d) The Luminaries shall be suitable for single and dual Metal Halide (MH) lamps
of 150W/ 250W/ 400 watts etc. as required. The same shall be mounted in a
separate sheet metal enclosed/ cast aluminium weather proof control gear
box.

e) The luminaries shall be provided with cable gland on the canopy in down ward
direction for cable connection.

f) It shall be possible to adjust the lamp position to achieve wide beam, medium
beam or narrow beam.

g) It shall be possible to replace the lamp from the canopy without opening the
front glass.

3.12.10. Outdoor/ Street Lighting Luminaries:

a) Fluorescent Luminaries

i. Street lighting fluorescent luminaries shall be outdoor weather proof

type for illumination of secondary roads, walkways, peripheral lighting of
buildings etc.

ii. The luminaries shall be of semi-cut off or non-cut off type, with CRCA
sheet steel housing, vitreous enamelled, plain or corrugated clear acrylic
cover, complete with integral mounted control gear, neoprene gaskets,
side pipe entry or top suspension type.

iii. The luminaries shall be suitable for 1x36 watts or 2 x 36 watts

fluorescent tubes and for mounting heights up to 4.5 metres.

b) MetalHalide luminaires:

i. Street light MH luminaries shall be outdoor weather proof type for

illumination of main roads, traffic islands etc.
ii. The luminaries shall be of semi-cut off with cast aluminium housing,
acrylic or prismatic cover, polished aluminium reflectors, complete with
integral mounted control gear, neoprene gaskets and with rear pipe
entry.
iii. The luminaries shall be suitable up to 150/ 250 watts MH lamps and for
mounting heights from 4 metres to 12 metres.

c) Post Top Lantern:

i. Post top lantern luminaries shall be generally outdoor weather proof

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type for illumination of walkways, gate posts, gardens etc.

ii. The luminaries shall have cast aluminium spigot finished with corrosion
proof paint for mounting, opal acrylic or high density polyethylene (HDP)
diffuser bowl, complete with integral mounted control gear, neoprene
gaskets, earthing terminal etc.

iii. The luminaire shall be suitable up to 125 W mercury vapour lamp or

70W sodium vapour lamp.

d) Bollard Luminaries:

i. Bollard luminaries shall be outdoor, weather proof type for illumination of

lawns, gardens, pathways etc.

ii. The luminaries shall be of FRP housing, clear acrylic cover, louvers for
directing light downwards and bottom cable entry.

iii. The luminaries shall be suitable for 9/ 11/ 18 W CFL.

3.12.11. High Mast Flood Light / Flood Light Towers (where applicable):

a) High mast shall be outdoor weather proof type for illumination of main roads
and area lighting, wherever found necessary.

b) The high mast shall be continually tapered, polygon cross section,

telescopically jointed steel fabricated construction. The mast shall be hot dip
galvanised internally and externally. Weather proof door shall be provided
near the base to permit access to winch, cables, plug, socket etc. The mast
shall be designed for wind speeds depending upon wind pressure and
direction as per relevant Indian Standards. Foundation bolts shall be included
in the scope of supply.

c) The moving platform shall be of steel construction hot dip galvanised and
designed to hold the number of flood light luminaires specified. The control
gear boxes shall be cast aluminium weather proof type mounted on the
moving platform. The moving platform shall be raised or lowered with the help
of winch, pulley system and stainless steel wire ropes. The winch shall be
suitable for hand operation or alternante by electric power.

d) The mast shall be suitable for mounting numbers of luminaires as required.

The standard mast heights are generally from 16 to 30 meters.

3.12.12. Emergency Light Luminaries:

a) Emergency light fitting shall be 240 V self contained 2 x 11 W fluorescent tube

with built in Ni-Cd battery having charging facility and six hours back-up time.
The emergency light fittings shall be provided at strategic locations of each
house / area.

b) Emergency fixtures shall come in service when AC supply fails.

c) Pump room and Electrical room shall be considered for Emergency lighting.

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d) In addition to above emergency fixtures, every pump station shall be provided

with two nos. of portable emergency luminary, which shall be with CRCA
sheet steel enclosure, complete with metalized mirror reflector, leak proof re-
chargeable battery rated for two hour discharge, battery charger, charger-on
lamp, push button switches, automatic changeover switch/relay, two metre
length cord with plug, mounting pads and other accessories required for
satisfactory operation of the luminaries.

e) The luminaries shall be suitable for connection to 240 V, 50 Hz single phase

supply. On failure of normal AC supply the luminary shall start automatically
and on restoration of AC supply the luminary shall switch off automatically.

f) The luminaries shall be suitable for up to 11/18 W CFL.

3.12.13. Accessories for Luminaries:

a) Reflectors

i. The reflectors shall be made of CRCA sheet steel/aluminium/silvered

glass/chromium plated sheet copper as indicated for above mentioned
luminaries.

ii. The thickness of steel/aluminium shall comply with relevant standards.

Reflectors made of steel shall have vitreous enamelled finish.
Aluminium used for reflectors shall be anodized/epoxy stove
enamelled/mirror polished. The finish for the reflector shall be as
indicated for above mentioned fittings.

iii. Reflectors shall be free from scratches or blisters and shall have a
smooth and glossy surface having an optimum light reflecting coefficient
so as to ensure the overall light output specified by the Contractor.

iv. Reflectors shall be readily removable from the housing for cleaning and
maintenance without disturbing the lamps and without the use of tools.
They shall be securely fixed to the housing by means of positive
fastening device of captive type.

b) Lamp/ Starter Holders:

i. Lamp holders shall have low contact resistance, shall be resistant to

wear and shall be suitable for operation at the specified temperature
without deterioration in insulation value. They shall hold the lamps in
position under normal condition of shock and vibration met with under
normal installation and use.

ii. Lamp holders for the fluorescent lamps shall be of the spring loaded bi-
pin rotor type. Live parts of the lamps holder shall not be exposed
during insertion or removal of lamp or after the lamp has been taken out.
The lamp holder contacts shall provide adequate pressure on the lamp
cap pins when the lamp is in working position.

iii. Lamp holders for mercury vapour and sodium vapour lamps shall be of
Edison Screw (ES) type.

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iv. The starter holders shall be so designed that they are mechanically
robust and free from any operational difficulties. They shall be capable
of withstanding the shocks met within normal transit, installation and
use.

c) Ballasts:

i. The ballasts shall be designed to have a long service life and low power
loss. The ballasts shall be of the inductive, heavy duty type copper wire
wound, filled with thermosetting, insulating, moisture repellent polyester
compound filled under pressure or vacuum. Ballasts shall be provided
with taps to set the voltage within the range of variation in supply
voltage of ±10% of 240 V. End connections and taps shall be brought
out to a suitable terminal block rigidly fixed to the ballast enclosure.
Ballasts shall be free from hum and such of those which produce hum
shall be replaced by Contractor free of cost.

ii. Ballasts shall be mounted using self locking, anti-vibration fixings and
shall be easy to remove without demounting the fittings. They shall be in
dust tight, non combustible enclosures.

iii. All the luminaries other than Flood Light Fixtures shall have integral
control gear.

iv. All type of fluorescent light fittings shall be provided with high frequency
electronic ballast of proven design with less than 10% THD, fully wired
up to the connector block. The electronic ballast shall be suitable for
operation with input voltage variation between 180-260V to give a
constant light output.

v. All gas discharge/ MH type lamps shall be provided with control gear,
with Copper wound and polyester filled low loss ballast, igniter and PF
correction capacitor.

vi. Contractor to provide comprehensive technical details of the luminaries

and the lamps being offered. The details must be sufficient to take in to
consideration maximizing of energy efficiency and minimizing overall
shop power consumption.

vii. In Crane bays, lighting fixtures shall be mounted with the minimum 500
mm clearances above overhead crane clearance level as asked by
Crane Manufacturer.

viii. All the outdoor purpose luminaries, including Street light luminaries shall
be with ingress protection of IP 65 minimum.

ix. All the Mid Bay &Highbay fixtures, street light fixtures shall be provided
with the toughened Glass covers.

x. In case of Hazardous areas, if any- Flame proof luminaries (complete

with suitable lamp & accessories) in line with the requirements of IS
5572 shall be provided by the Contractor.

d) Starters:

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i. Starters shall have bimetal electrodes and high mechanical strength.

ii. Starters shall be replaceable without disturbing the reflector or lamps

and without the use of any tool.

iii. Starters shall have brass contacts and radio interference capacitors.

e) Capacitors:

i. The capacitors shall have a constant value of capacitance and shall be

connected across the supply of individual lamp circuits.

ii. The capacitors shall be suitable for operation at specified supply voltage
conditions and shall have a value of capacitance so as to correct the
power factor of their corresponding lamps circuit to the extent of 0.95 lag
or better.

iii. The capacitors shall be hermetically sealed preferably in a metal

enclosure to prevent seepage of impregnate and ingress of moisture.

f) Lamps:

i. Lamps shall be capable of withstanding small vibrations and the

connections at lead in wires and filaments/ electrodes shall not break
under such circumstances.

3.12.14. Drawings/ Documents Required:

a) As part of proposal, the Contractor shall furnish relevant descriptive and

illustrative literature & drawings/ data for the respective lighting fixtures &
accessories with manufacturer’s catalogue numbers.

b) It shall be the responsibility of the Contractor that, on award of contract to

work out a detailed lighting layout for the complete plant in order to provide
the levels of illumination as indicated under Design Criteria and shall be
furnished for the approval of the Purchaser's representative before
commencement of installation.

c) Detailed Room wise Lighting Layout with Type of fixture details, mounting
detail arrangement and Circuit diagram showing phase wise load distribution
and interconnection between switches, fixtures, Lighting panel, receptacles
etc.

d) Conduit layout showing room wise routing of wires from lighting panel to
lighting fixtures covering primary & secondary point wiring, receptacles etc.

e) Internal road Lighting and Area lighting layout with type of mounting details
and fixture details.

f) Street Light pole details with Foundation details

g) General arrangement of lighting panel &lighting distribution board showing

plan, elevation and typical section views.

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3.12.15. Lighting System Equipment:

h) Main Distribution Boards and Lighting Panels:

i. Main Lighting distribution board (MLDB) shall have MCCB as incomer &
outgoing feeder with thermal magnetic release for O/L+S/C+E/F
protections.

ii. This MLDB shall feed to different Lighting Panels/ Lighting DBs for
further distribution.

iii. Where ever MLDB is not applicable, lighting feeder of appropriate rating
shall be derived from the local distribution board. This feeder will feed to
local LP catering to lighting requirements of that particular area.

i) Constructional Features:

i. Boards and panels shall be sheet steel enclosed and shall be fully dust
and vermin proof, providing a degree of protection of IP-54 for indoor.
Outdoor panels shall in addition be completely weather-proof with a
sloping canopy for protection against rain and providing a degree of
protection of IP-55. The sheet steel used for frame, frame enclosures,
doors, covers and partitions shall be cold rolled 2.0 mm thick.

ii. The lighting panel for outdoor lighting shall have a programmable timer
for automatic control of lighting along-with contactor, MCB, auto/ manual
selector switch.

iii. All boards and panels shall be provided with hinged doors for access to
equipment. Doors shall be gasketed all round with neoprene gaskets.

iv. A slotted metallic sheet shall be provided inside. Only the MCBs
operating knobs shall project out of the metallic sheet slots for safe
operation and neat appearance. Incomer to lighting panels shall be
provided with Four pole MCB + RCCB

v. All accessible live connections/metals shall be shrouded and it shall be

possible to change individual MCBs from the front of the boards/ panels
without danger of contact with live metal.

vi. For floor mounting type distribution boards, adequately sized mounting
channels shall be supplied and for wall/column/structure mounting type
panels suitable mounting straps shall be provided.

vii. Adequate interior cabling space and suitable removable cable entry
plates shall be provided for top/bottom entry of cables through glands
and or conduits as required. Necessary number of glands to suit the
specified cable sizes shall be provided. Cable glands shall be screwed
on type and made of brass.

viii. Two earthing terminals shall be provided to suit the earthing conductor.

ix. All sheet steel parts shall undergo rust-proofing process which should
include 7 tank processing. The steel works shall then be painted with

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two coats of Zinc - chromate primer and two coats of final epoxy based
finish paint of colour 63I as per IS 5.

j) Busbars:

i. Busbars shall be of copper conductor of hard drawn (HD) and high

conductivity.

ii. Busbars shall be provided with at least the minimum clearances in air as
per applicable standards.

iii. Busbars shall be adequately sized for the continuous current rating such
that the maximum temperature of the busbars, busbar risers/droppers
and contacts does not exceed 85 C under site reference temperature.

iv. The busbars, busbar connections and busbar supports shall have
sufficient strength to withstand thermal and electro-mechanical stresses
of the MCB’s let through/cut-off current associated with the specified
short-circuit level of the system.

v. Busbar supports shall be SMC type. Separate supports shall be

provided for each phase of the busbars.

vi. The neutral bus of the main 3 phase, 4 wire distribution board shall be
100% of the phase busbars.

k) Panels/ Boards’ Component &Lighting Accessories:

i. MCB/ ELCB :

 MCBs shall be C curve type for lighting panels.

 For all the lighting panels RCCBs shall be with 100 mA sensitivity &
for all receptacles RCBO sensitivity shall be 30 mA.

ii. MCCB :

 MCCB requirements shall be as per specified in the LV switchgear

requirements & as specified above.

iii. Indicating Instruments and Meters:

 Whenever required, instruments and meters shall be of the flush

mounting type. They shall be suitably mounted so as to provide for
easy access to CTs and small wiring.

 Instruments shall be of minimum 96 mm square size, shall have

provision for zero adjustment outside the cover and black numerals
on white dial.

 Ammeter/Voltmeter selector switches having 3 positions and off,

with stay-put contacts rated 10A shall be provided when specified.

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 Potential fuses shall be provided at the tap-off point from the bus
bars for the voltmeters.

iv. Instrument Transformers:

 Current and voltage transformers shall be of cast resin type, with

insulation class B, & accuracy class 1.0 unless otherwise specified,
it shall be the responsibility of the Contractor to ensure that the VA
burden of the instrument transformer is adequate for the meters
connected to it.

 Test links shall be provided in both secondary leads of the CTs to

easily carry out current and phase angle measurement tests.
Facilities shall be provided for short-circuiting and grounding the
CTs at the terminal blocks.

 Voltage transformers shall be provided with suitably rated primary

and secondary fuses.

v. Indicating Lamps:

 Indicating lamps shall be of the clustered LED type, low watt

consumption.

vi. Internal Wiring

 Panels/ boards shall be supplied completely wired, ready for the

external connections at the terminal blocks. Wiring shall be carried
out with 1.1 kV grade, FRLS PVC insulated, multistranded Copper
conductors. Conductors of adequate sizes shall be used to suit the
rated circuit current.

 Cross Ferruling i.e., engraved identification ferrules, marked to

correspond with the wiring diagram shall be fitted at both ends of
each wire.

 All wiring shall be terminated on terminal blocks. Terminal blocks

shall be one piece moulded rated 500 V, of reputed make of
approved list, preferably stud type for higher current ratings such
that wires are connected by cable-lugs and complete with nuts and
washers. Terminals shall be adequately rated for the circuit current,
the minimum rating shall be 20 A.

 Terminals for circuits with voltage exceeding 125 V shall be

shrouded.

 Terminals shall be numbered and provided with identification strip

for identification of the circuit.

 Terminal blocks for CT secondary lead wires shall be provided with

shorting and disconnecting/earthing facilities.

vii. Labels & Diagram Plate:

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 All door mounted equipment as well as equipment mounted inside

the switchboard/panels shall be provided with individual labels with
equipment designation/rating. Also the boards/panels shall be
provided on the front with a label engraved with the designation of
the board/ panel.

 Labels shall be made of non-rusting metal, 3-ply lamicoid or

engraved acrylic

 Inside the door of the 1 phase ways lighting panels a circuit

diagram/ description shall be fixed for reference and identification.

viii. Conduits:

 Rigid steel/ non-metallic conduits and their associated fittings as

required shall conform to applicable standards. The minimum size
of conduit shall be 20 mm for surface installation and 25 mm for
concealed installation.

 Steel conduits shall be seamed by welding and hot dip galvanised.

They shall be supplied in standard lengths of 5 metre.

 Supply of conduits shall include all associated fittings like couplers,

bends and tees as required for lighting system installation work.

ix. Junction Boxes:

 Junction boxes with terminals shall be supplied for branching and

terminating lighting cables when required for outdoor areas, three
(3) phase receptacles etc.

 The junction boxes shall be dust and vermin proof and shall be
fabricated from 14 SWG sheet steel and shall be complete with
removable cover plate with gaskets, two earthing terminals each
with nut, bolt and washer. Boxes shall be additionally weather proof.

 The boxes shall have provision for wall, column, pole or structure
mounting and shall be provided with cable/conduit entry knock outs,
terminal blocks, and HRC fuses as required.

 The terminal blocks, with specified number of terminals, shall be

mounted securely on brackets welded to the back sheet of the box.
The terminals shall be 600V, grade, one piece construction
complete with terminals, insulation barriers, galvanised nuts, bolts
and washers and provided with identification strips of PVC. The
terminals shall be made of Copper alloy and shall be of box clamp
type.

 The boxes shall be painted with one shop coat of red oxide zinc
chromate primer followed by a finishing coat of paint.

x. Lighting Poles and Flood Light Pole Mounting:

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 Lighting poles for street lights and flood lights shall be of stepped
tubular steel poles construction as per applicable standard. These
poles shall be coated with bituminous preservative paint on the
inside as well as embedded outside surface. Exposed outside
surface shall be painted with one coat of red lead oxide primer.
After completion of installation two coats of aluminium paint shall be
applied.

 Poles for mounting flood lights shall be supplied whenever required

and as per typical attached drawing. Unless otherwise specified,
poles shall be painted with red lead oxide primer and two coats of
aluminium paint. One steel ladder shall be provided separately. The
length of each step of the ladder shall be at least 300 mm and
spacing between two adjacent steps not more than 300 mm.

 The supply of poles shall be complete with fixing bracket/necessary

pipe reducer for fixing the fitting and also include the necessary
associated pole mounted junction boxes.

 The required sizes of poles and the junction box shall be as

indicated in the attached drawings.

 Outdoor JBs shall be minimum IP 55 protected.

 Cable entry for street lighting junction boxes shall be from bottom.

 Rain water canopy shall be provided at the top for the outdoor JBs.
Terminal strip shall be provided for looping loop out of cables.

 Street lighting JB shall consist of terminal strip (3 ways) for looping

in & loop out of cables. The JB shall be provided with 6A MCB(C-
Curve type) for isolation of lighting fixture, as well as sufficient
arrangement (earthing studs) for termination of 2 nos. earthing
connections.

xi. Ceiling Fans/ Wall Mounted Fans:

 Ceiling/ Wall mounted fans shall be suitable for operation on 240 V,

1 phase, 50 Hz supply and shall be complete with standard
mounting accessories such as suspension rods, top and bottom
caps etc for ceiling fans and easy accessibility for wall mounted
fans.The fans shall be supplied with appropriate speed regulators.

 Exhaust fans, where ever required shall also be provided. The

exhaust fan with all parts shall be according to IS: 2312- 1967 & its
latest amendment with IP-55 specification. The exhaust fan shall
have epoxy powder coating with specially pretreated components
for better resistance to corrosion and acid alkali flumes. The
exhaust fan shall have totally enclosed highly efficient heavy duty
motor with pressure die cast aluminum rotor mounted on two ball
bearings.

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 The fans shall generally conform to the applicable standards

indicated in Tender. Details regarding blade sweep and suspension
requirements shall be as per Project layout drawing/price schedule.

5. SAFETY EQUIPMENTS/ REQUIREMENTS AND MISCELLANEOUS ITEMS:

5.1. Following safety procedure and practice should be provided by Contractor in

switchgear room/ sub-station as per latest edition of I.S. 5216.

5.1.1. 900 mm wide antiskid insulating mat as per IS 15652 and of reputed make to be
spread in front of the 11kV, 415V switch gear panels & power DBs, DCDB etc.

5.1.2. First aid box with all the standard contents.

5.1.3. First aid chart made of cloth for electrical shock treatment printed in English, Hindi
and Gujarati duly framed with front glasses.

5.1.4. Charts/ drawings duly framed with front glass.

5.1.5. HV and LV power supply single line diagrams in adequate sizes approved by
Purchaser/ Purchaser’s representative & in line with the local electrical inspector.

5.1.6. Routine maintenance schedule for High Voltage Switchgear, Distribution

Transformers, Low voltage Switchgears, APFC panels, Fire Alarm System, UPS
system etc.

5.1.7. Provision of portable type Class A, B, C, and D type fire extinguishers at various
locations in line with the statutory requirements.

5.2. FIRE SAFETY:

5.2.1. The requirement of hand appliance in switchgear room, electrical equipment room
shall be provided as per Clause 4.0 of Fire Protection Manual by Regional Tariff
Committee, 10th edition 1988.

5.2.2. Water Sealing & Fire Barriers at appropriate locations as specified in this
specifications & good engineering practices.

5.3. DEGREE OF PROTECTION:

5.3.1. The enclosures of the control cabinets, junction boxes and Marshalling boxes,
panels etc. to be installed shall provide minimum degree of protection as detailed
here under

a) Installed outdoor – IP 55

b) Installed indoor – IP 54

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5.3.2. The degree of protection shall be in accordance with IS 13947 (Part I)/ IEC 947
(Part I)/ IS 2063/ IEC 529

5.4. ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS:The electrical equipments

for hazardous areas shall be selected as per IS 5572. Following factors shall be
considered for proper selection of electrical equipments for use in Hazardous Area.

5.4.1. Area Classification (Zone)

5.4.2. Gas Classification (Group) – The characteristics of the gas or vapour involved in
relation to the ignition or energy and safe gap data

5.4.3. Temperature Classification- The ignition temperature of the gas or vapour involved
or lowest value of the ignition temperature, if more than one combustible material is
present.

5.4.4. Environmental conditions – In which apparatus is to be installed. The selected

electrical apparatus shall be adequately protected against corrosive and solvent
agencies water ingress, thermal and mechanical stresses as determined by the
environmental condition.

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6. INSTALLATION,TESTING& COMMISSIONING – ELECTRICAL EQUIPMENT:

6.1. GENERAL:

6.1.1. In accordance with the specific installation instructions, as shown in Contractor’s

drawings or as directed by the Engineer In Charge the Contractor shall unload,
erect, install, wire, test and place into commercial use of all electrical&
instrumentation equipment included in the contract. Equipment shall be installed in
a neat manner so that it is level, plumb, and properly aligned and oriented.

6.1.2. The Contractor shall furnish all supervision, labour, tools, equipment, rigging
materials and incidental materials such as bolts, wedges, anchors, concrete inserts
etc. required to completely install, test and adjust the equipment.

6.1.3. Drawings, instructions and recommendations shall be correctly followed in handling,

settling, testing and commissioning of all equipment and care shall be exercised in
handling to avoid distortion to stationary structures, the marring of finish, or
damaging of delicate instruments or other electrical parts.

6.1.4. The Contractor shall erect and commission the equipment as per the instructions of
the Purchaser/ Engineer In Charge and shall extend all co-operations to him.

6.1.5. In case of any doubt/ misunderstanding as to correct interpretation of drawings or

instructions, necessary clarification shall be obtained from the Engineer’s
Representative. The Contractor shall be held responsible for any damage to the
equipment consequent to not following instructions correctly.

6.1.6. The Contractor shall move all equipment into the respective buildings through
regular doors or floor openings provided specifically for the equipment. The
Contractor shall make his own arrangement for lifting of equipment.

6.1.7. Where assemblies are supplied in more than one section, the Contractor shall make
all necessarymechanical and electrical connections between sections including the
connections between busbars/wires.TheContractorshallalsocarryoutthe
adjustments/alignments necessary for proper operation of the circuit breakers.All
insulators and bushings shall be protected against damage during installation.
Insulators or bushings chipped, cracked or damaged due to negligence or
carelessness shall be replaced by the Contractor at his own expenses.

6.1.8. The Contractor shall take utmost care in handling instruments, relays and other
delicate mechanisms.Wherever the instruments or relays are supplied separately,
they shall be mounted only after the associated control panels have been erected
and aligned. The blocking material/mechanism employed for the safe transit of the
instruments and relays shall be removed after ensuring that the panels have been
completely installed and no further movement of the same would be necessary.Any
damage to relays and instruments shall be immediately reported to the Engineer In
charge.

6.1.9. Equipment furnished with finished coats of paint shall be touched up by the
Contractor if their surface is spoiled or marred while handling.

6.1.10. Foundation work and grouting of fixing bolts or channels for all transformers,
switchgear, motors, and control panels shall be carried out by the Contractor.

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6.2. POWER/ DISTRIBUTION TRANSFORMERS:

Inspection, storage, installation, testing and commissioning of transformers shall be

in accordance with the latest Indian Standards Code of Practice IS: 10028. All
commissioning tests as applicable, vide Appendix B of IS: 10028 (Part II) shall be
carried out. Fire Wall of 4 Hr fire rating shall be provided between two transformers.

6.3. HV/ LV SWITCHGEAR CONTROL PANELS:

6.3.1. Switchgear control panels shall be installed in accordance with the latest Indian
Standard Code of Practice 10118. The switchgear panels shall be installed on
finished surface or concrete or steel sills. The Contractor shall be required to install
and align any channel sills which form part of the foundations. Tape or compound
shall be applied where called for.The base of outdoor type units shall be sealed in
an approved manner to prevent ingress of moisture.

6.3.2. Following minimum clearances shall be observed while finalizing the HV/ LV panel
layouts-

a) Minimum clearance of 1.0 meter shall be maintained from the rear of the
panel to the nearest wall /structure.

b) Minimum clearance of 2.0 meter between panels facing opposite to each

other.

c) Side clearance for LV panels shall be either ≤ 200mm or ≥ 800 mm.

d) For HV metal enclosed, indoor panels, Minimum 1 meter clearance from all
sides & 1.5 meter in the front.

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6.3.3. Emergency Exit doors shall be provided forelectrical room, complying with the
requirements of NBC 2005 latest edition.

6.3.4. After installation of all power and control wiring, the Contractor shall perform
operating tests on all switchgear and panels to verify the proper operation of
switchgear/panels and the correctness of the interconnections between various
items of equipment.This shall be done by applying normal a-c or d-c voltage to the
circuits and operating the equipment. Megger tests for insulation, polarity checks on
the instrument transformers, operation tests on equipment, and installation tests
shall be carried out by the Contractor who shall also make all necessary
arrangements for proper functioning of the equipment.

6.4. EARTHING AND LIGHTNING PROTECTION SYSTEM:

6.4.1. The Contractor shall install copper/ steel conductors, braids, etc., required for the
system and individual equipment earthing.All work such as cutting, bending,
supporting, painting/coating, drilling, brazing/soldering/welding, clamping, bolting
and connecting onto structures, equipment frames, terminals, rails or other devices
shall be in the Contractor’s scope of work. All incidental hardware and
consumables such as fixing cleats/clamps, anchor fasteners, lugs, bolts, nuts,
washers, bituminous compound, welding rods, anti-corrosive paint as required for
the complete work shall be deemed to be included by the Contractor as part of the
installation work.

6.4.2. The quantities, sizes, material of earthing conductors and electrodes to be installed
as per requirement. Routes of the conductors and locations of electrodes shall be
shown in the earthing layout drawings,which are to be prepared by Contractor&
approved by Purchaser’s representative.

6.4.3. The work of embedment of earthing conductor in RCC floors/walls along with
provision of earth plate inserts/pads/earth risers shall be done by the Contractor
when the floors are cast or during construction of walls. Contractor’s scope of
installation shall also include, laying the conductors in position with 60 mm concrete
cover, making welded connections to inserts/pads/risers above the floor near the
equipments.The embedded conductors shall be connected to reinforcing rods
wherever necessary.

6.4.4. If the tap connections (earthing leads) from the floor embedded main earthing grid
to the equipment are more than 500 mm long then the same shall be embedded in
floor by the Contractor where required, together with associated civil work such as
excavation/chasing, concreting and surfacing.The concrete cover over the
conductor shall not be less than 60 mm.

6.4.5. Installation of earth conductors in outdoor areas, buried in ground, shall include
excavation of earth up to 600 mm deep 450 mm wide, laying of conductors at 600
mm depth, brazing/welding as required, of main grid conductor joints as well as
risers of length 500 mm above ground at required locations and then backfilling
material to be placed over buried conductor shall be free from stones and other
harmful mixtures. Backfill shall be placed in layers of 150 mm, uniformly spread
along the ditch, and tampered utilizing pneumatic tampers or other approved
means. If the excavated soil is found unsuitable for backfilling, the Contractor shall
arrange for suitable material from outside.

6.4.6. Installation of earth connection leads to equipment and risers on steel

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structures/walls shall include laying the conductors, welding/cleating at specified

intervals, welding/brazing to the main earth grids risers, bolting at equipment
terminals and coating welded/brazed joints by bituminous paint. Galvanized
conductors shall be touched up with zinc rich paint where holes are drilled at site for
bolting to equipment/ structure.

6.4.7. Electrodes shall be installed in constructed earth pits, and connected to main buried
earth grid, The scope of work shall include excavation, construction of the earth pits
including all materials required for construction of earth pits, placing the rod and
fixing test links on those pipe/rod/plate electrodes in test pits and connecting to
main earth conductors.

6.4.8. Installation of lightning conductors on the roofs of buildings shall include laying,
anchoring, fastening and cleating of horizontal conductors,grouting of vertical rods
wherever necessary, laying fastening/ cleating/ welding of the down comers on the
walls/columns of the building and connection to the test links to be provided above
ground level.

6.4.9. Installation of the test links shall include mounting of the same at specified height on
wall/column by suitable brackets and connections of the test link to the earth
electrode.

6.4.10. Whenever main earthing conductor crosses cable trenches, they shall be buried
below the trench floor.

6.4.11. Suitable earth risers shall be provided above finished floor/ ground level. If the
equipment is not available at time of laying of the main earth conductors, the
minimum length of such riser inside the building shall be 200 mm and outdoors shall
be 500 mm above ground level. The risers to be provided shall be marked in project
drawings.

6.4.12. Earth leads and risers between equipment earthing terminals and the earthing grid
shall follow as direct and short a path as possible.

6.4.13. An earthing mat shall be provided under each operating handle of the isolator and
operating mechanism of HV breakers. Operating handle of the isolator and
supporting structure shall be bonded together by a flexible connection and
connected to the earthing grid.

6.4.14. A separate earth electrode bed shall be provided adjacent to structure supporting
lightning arrestors. Each connection shall be as short and as straight as practicable.
For arrestors mounted near transformers, earth conductors shall be located clear off
the tank and coolers.

6.4.15. Wherever earthing conductors passes through walls, galvanized iron/PVC sleeves
shall be provided for the passage of earthing conductor. The pipe ends shall be
sealed by the Contractor by suitable water proof compound.

6.4.16. Earthing Connections:

a) All connections in the main earth conductors buried in earth/concrete and

connection between main earthing conductor and earth leads shall be of
welded type.

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b) Connection between earth leads and earthing terminal provided on the

equipment shall be bolted type.

c) All bimetallic connections shall be treated with suitable compound to prevent

moisture ingression.

d) Metallic conduits and pipes shall be connected to the earthing system.

e) Lightning protection system down conductors shall not be connected to other

earthing conductors above ground level. Also no intermediate earthing
connection shall be made to lightning arrester and transformer earthing leads
which shall be directly connected to pipe electrode.

6.4.17. Earth Electrodes:

a) Electrodes shall as far as practicable, be embedded below permanent

moisture level.

b) Test pits with concrete covers shall be provided for periodic testing of earth
resistance. Installation of pipe electrodes in test pits shall be suitable for
watering. The necessary materials required for installation of test pits shall be
supplied and installed by Contractor.The installation work shall also include
civil work such as excavation and connection to main earth grid.

c) Earth pits shall be treated with salt and charcoal. In case found necessary,
then with the approval of Purchaser’s representative,Back fill compound of
suitable composition may be used. Back fill material shall not be water soluble
& shall retain moisture & enhance conduction around electrode.Back fill
compound shall be low resistance & non corrosive earth enhancement
compound which shall provide safe discharge path to fault current &lightening
current.

d) Ohmic value shall be within safe limits & it shall be stable & not fluctuating.

e) Soil, salt and charcoal placed around the electrode shall be finely graded, free
from stones and other harmful mixtures. Backfill shall be placed in layers of
250 mm thick uniformly spread and compacted. If excavated soil is found
unsuitable for backfilling, the Contractor shall arrange for a suitable soil from
outside.

6.5. INSTALLATION OF CABLE RACKS AND CABLE TRAYS:

6.5.1. General

a) Lines and grade for trays may be measured from building steel and finished
floor elevations. Change in line or grade, or the addition of offsets by means
of cutting standard tray sections and inserting additional tray fittings to match
with the existing arrangement shall be considered as a normal part of the
work.

b) Where embedded steel inserts in concrete floors/ walls for welding the
supports for cable racks/ trays are not available, Contractor shall provide
suitable anchor fasteners at no extra cost.

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c) Cable shall be clamped to the cable trays at every 750 mm distance.

d) Flexible metallic conduits shall be used for termination of connection to

equipment such as motors, limit switches and other apparatus.

6.5.2. Cable Trays: All the cable tray shall be hot dipped galvanized with minimum
galvanization thickness as per mentioned in this specifications.

a) Cable tray shall be of perforated sheet steel with formed flanges and of
minimum thickness not less than 1.25 mm for trays up to 100 mm width, not
less than 1.5 mm for trays from 100 mm to 150 mm width and not less than
2.0 mm for trays from 150 mm to 300 mm width.

b) All the cable trays above 300 mm width shall be of ladder type with minimum
thickness of 2.5 mm.

c) Cable tray for use in areas where chlorine gas may be present shall be
constructed from U-PVC or GRP. Cable tray supports shall be of a compatible
finish with the associated cable tray.

d) All cable trays tees, intersection units, bends, turns and sets shall be
prefabricated (made by the manufacturer) and shall be of a matching design
to the main section of cable tray.

e) Tray shall only be joined by couplers supplied by the manufacturers. The joint
shall be secured in accordance with the manufacturer’s instructions.

f) Cable tray supports supplied by a manufacturer or made up on Site shall have

adequate strength to maintain rigid support to the fully laden cable tray along
its entire length and shall ensure that the deflection of any one section does
not exceed 15 mm at mid span.

g) Wherever possible, cable trays shall be installed in full lengths without cutting.
Should it be necessary to cut or drill a length of tray, the bared ends or
damaged section of the tray shall immediately be given a coat of zinc rich cold
galvanized paint. All site manufactured accessories, supports and metal
fittings required to ensure correct installation of the cable trays shall be
similarly treated.

h) All cables shall be firmly secured to the tray using purpose made saddles, as
approved by the Purchaser’s Representative, together with proprietarynylon
fasteners and/or cable cleats. Following installation of cables, the tray shall
remain rigidly supported and the deflection of any section shall not exceed 15
mm at mid span. All brackets and tray work shall be suitable for withstanding
a temporary weigh of 125 kgs.

i) Cable trays shall not be cut to allow the passage of cables through the
surfaces of the tray

j) The sizing of the cable tray shall provide a minimum of 20% spare capacity.

k) The tray shall be run at least 300 mm clear of plumbing and mechanical
services.

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l) Bends in the installation shall take account of the minimum bending radii of
cables to be installed.

m) All the cable trays shall be supplied with cable tray supports (of adequate
size) at no more than 1.2 meter interval.

n) Other cable tray details & cabling system shall be as per typical drawings
attached with the specifications.

6.5.3. Cable Trunking – Metal:

a) Cable trunking shall be manufactured from mild steel of not less than 1.25 mm
and shall be hot dipped galvanized. The Contractor shall ensure that the size
of the trunking is adequate for the number of cables to be installed together
with 50% spare capacity and shall in any case be 50 mm x 50 mm minimum
size.

b) Segregation of cables shall be carried out if required using continuous sheet

steel barriers with the bottom edge welded to the trunking.

c) The trunking shall have two return flanges for rigidity. Where necessary,
additional strengthening straps shall be fitted internally. The cover shall
overlap the trunking and be made of the same gauge. Fixing screws for
covers shall be recessed and be of the self retaining `quick fix' type. All
bends, tees and intersections shall be of the gusset type and shall, wherever
possible, be purpose made by the manufacturer and of a matching design to
the main trunking.

d) Cables shall be retained in the trunking when the cover is removed by means
of straps. Internal connecting sleeves shall be fitted across joints in the
trunking and earth continuity ensured by bonding each section of trunking to a
continuous earth wire.

e) Non-flammable fire barriers shall be inserted where the trunking passes

through walls or floors. Conduit connections to trunking shall be made by
flanged couplings and male bushes.

f) Trunking shall be supported at intervals not greater than 2 meter horizontally

or 2.5 meter vertically.

g) Crossings over expansion joints shall be made in flexible conduit.

h) Should it be necessary to cut or drill a section of trunking or a trunking fitting

the bared ends shall immediately be given a coat of zinc rich cold galvanizing
paint.

i) Cable and conduit/ trunking runs shall be determined by the Contractor and
agreed by the Purchaser’s Representative before any work is started. The run
shall be at least 300 mm clear of plumbing and mechanical services.

j) Conduit/ trunking systems erected outside a building shall be weatherproof.

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6.6. CABLE INSTALLATION:

6.6.1. General:

a) Cable installation shall be in accordance with IS 1255: 2001- latest edition.

b) Cables shall be installed in such a way that the minimum bending radii are not
reduced when installed or during installation. Cables shall not be installed in
ambient temperatures below that recommended by the cable manufacturer.

c) Cables grouped together shall have insulation capable of withstanding the

highest voltage present in the group.

d) Cables of different categories shall be installed so as to maintain satisfactory

clearances for safety and in order to reduce the possibility of electrical
interference. The following Table details the distances in mm that shall be
maintained between the different categories of cable.

Table of Separation Distances in mm between different Categories of Cable

Cable HV Power LV Power C&I/ Tele-

Category Protection communication
HV Power N/A 300 600 600
LV Power 300 N/A 300 300
C&I/ Protection 600 300 N/A 200
Tele- 600 300 200 N/A
communication

e) These separations are minimum and special circumstances such as the

presence of high current flows, or harmonic content may necessitate larger
separation distances.

f) A distance of minimum 300mm shall be maintained between the cables to be

laid on trays/ conduits carrying low voltage AC and DC signals and a distance
of minimum 600 mm shall be maintained between cables carrying HV and LT
signals.

g) In order to make economic use of the cable support system, cables shall be
arranged in groups of 50 mm maximum overall diameter. These groups shall
be securely tied to the cable support system at intervals not exceeding 900
mm for horizontal runs and 300 mm intervals on vertical runs.

h) In order to make the most economic use of cable tray and duct capacity,
multicore cabling shall be utilized in order to connect instrumentation groups
by using suitably located sub-distribution junction boxes. The junction boxes
shall be suitable for the area in which they are to be installed and for the type
of circuit. They shall be readily accessible for maintenance and clearly labeled
junction boxes shall be constructed of die cast Aluminium and provide degree
of protection IP 65.

i) Instrumentation cables shall be continuous without any joints. Separate

cables shall be used for digital and analogue signals at all times.Digital and
analogue signals shall be segregated within junction boxes.

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j) Cables shall be laid in a manner such that any electrical interference between
cables shall not have a detrimental effect on the life and operation of Plant.

k) Where practical a separate cable support system shall be provided for power
and non-power cables. Where this is not practical a separation as per
indicated in above table shall be maintained between power and non-power
cables when run on the same support system.

l) Heavy duty galvanized iron cable tray and ladder racking shall be used for
cable support systems. FRP/ GRP cable support systems shall be used in
areas used for the storage and handling of chlorine. These systems shall be
used to route cables around walls and within cable trenches. Cables shall be
securely fixed to the support systems. Bundling of cables shall be permitted
where allowance for this practice has been made in sizing the cables.

6.6.2. Laying of Cables:

a) Each instrumentation and power supply cable shall be terminated to individual

panel/ terminal box.

b) Identification of each cable shall be by proper ferrules at each junction as per

cable schedule to be prepared by Contractor.

c) Cables shall be laid in accordance with layout drawings and cable schedule
which shall be prepared by Contractor and submitted for approval.

d) All cable routes shall be carefully measured and cables cut to the required
lengths, leaving sufficient amount for the final connection of the cable to the
terminals on either end.

e) Various cable lengths cut from the cable reels shall be carefully selected to
prevent undue wastage of cables.

f) A loop of 1.0 meter shall be left near each field instrument before terminating
the cable.

g) Cables shall be complete uncut lengths from one termination to the other.

h) Separate cables shall be used for digital and analog signals.

i) All cables shall be identified close to their termination point by cable numbers
as per cable interconnection schedules.

j) Identification tags shall be securely fastened to the cables at both the ends.

k) Cable shall be rigidly supported on structural steel and masonry, using

individually cast or malleable iron galvanized clips, multiple cable supports or
cable trays.

l) The Contractor shall take the actual measurement of the cables and the
associated accessories such as cable trays, conduits etc required at site, prior
to the placement of order on the cables.

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6.6.3. Cables Laid Direct in Ground:

a) Buried cable up to 1.1 kV shall have a laid at a minimum depth of 750 mm

measured from FGL to the top of the highest cable. On crossing roadways the
cable shall be run through a PVC-U duct of minimum diameter 100 mm with a
minimum of 1000 mm cover and encased on all sides by 150 mm of concrete.

b) Cables of greater than 1.1kV shall be buried at a minimum depth of 1 meter.

c) The bottom of the cable trench shall be freed of sharp stones and such like
and 75 mm of sieved sand laid below the cable. After cable laying 75 mm of
sieved sand shall be laid above the cable. For HV cables sand bedding shall
be of 150 mm & cables shall be covered with half round Hume pipes of twice
the diameter of cable.

d) Interlocking cable protective covers, minimum 1 m long x 300 mm wide,

marked ‘Danger-Electric Cable' in English and the vernacular shall be laid on
top of the sieved sand. Covers shall extend the whole length of the cable
trench and shall overlap cables by a minimum of 50 mm.

e) Warning tape shall be laid a minimum of 200 mm above the protective covers.

f) Cables are to be installed without tees or through joints unless otherwise

approved by the Purchaser’s Representative. Single core cables shall be run
in trefoil formation.

6.6.4. Cables Laid in Underground Ducts:

a) Underground ducts shall be constructed of impact resistant PVC-U and laid at

a minimum depth of 750 mm, ducts shall be surrounded by at least 75 mm of
sieved sand except at road crossings where it shall be 1.0 meter deep and
encased on all sides by 150 mm of concrete.

b) The Contractor shall ensure that sufficient draw-in points have been provided
and that adequate room has been allowed for installation of cables.
Drawstrings shall be provided in all ducts to enable additional cables to be
installed when required.

c) Where cables pass in or out of any duct entries into or within buildings such
entries, together with any spare ducts shall be sealed against the ingress of
moisture by means of duct stoppers and bituminous compounds or by any
other method approved by the Purchaser’s Representative. The stopper shall
have a fire resistance of at least 30 minutes. Single core cables in trefoil
formation shall pass through the same duct and shall not be separated.
However, for two different trefoil formations, they shall be laid in separate
ducts.

6.6.5. Cables installed in Conduit:

a) Conduits shall be galvanized heavy gauge solid drawn or welded screwed

steel type and be in accordance with IS 9537, Part 2 or BS 4568. Accessories
shall either be malleable cast iron screwed type or pressed steel and
galvanized.

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b) A space factor of 40% shall not be exceeded, but in any case conduit of less
than 20 mm diameter shall not be permitted. The tubing shall be perfectly
smooth inside and out and free from flaws and imperfections of any kind. Both
ends of every length of tubing shall be properly reamed with all sharp edges
removed before erection.

c) Where a number of conduits converge, malleable cast iron or heavy gauge

sheet steel adaptable boxes shall be employed in order to avoid crossings.
Conduits shall be connected by means of male brass bushes and couplings.

d) Where conduits are greater than 25 mm, straight through joint boxes shall be
of the trough type. Where conduit and/ or fittings are attached to equipment
casings, the material or case of the casing shall be tapped for a depth of not
less than 10 mm or male bushes and flanged couplings shall be used.

e) Heavy hexagonal lock nuts shall be used at all positions where running joints
are required and care shall be taken to ensure that they seat firmly and evenly
on to the mating faces of coupling or other adjacent accessories. All junction
boxes, draw-in boxes, and inspection fittings, shall be so placed that the
cables can be inspected and, if necessary, withdrawn and re-wired throughout
the life of the installation.

f) Generally not more than two bends or offsets or one coupling will be permitted
without a suitable inspection accessory. Fish wires shall not be left in conduits
after erection. The whole of the installation shall be arranged for a loop-in type
of system with joints being carried out at switches, isolators, etc. Intermediate
joints in the cable will only be allowed by arrangement with the Purchaser/
Purchaser’s Representative.

g) Ends of conduits which are liable to be left open for any length of time during
building operations shall be plugged to prevent the ingress of dirt, cement,
etc. and covers, either temporary or permanent, shall be fitted on all boxes.

h) Generally, conduits shall not cross expansion joints of buildings, but where
they cannot be installed in any other manner then a flexible conduit shall be
used across the expansion joint. A total 150 mm movement shall be allowed.

6.6.6. Surface Installation:

a) Surface conduits shall be secured and fixed by means of distance spacing

saddles or approved purpose made clips at every 500mm, which allow the
conduits to be taken directly into accessories without sets or bends. Conduits
shall be run in a square and symmetrical manner. An efficient means shall be
adopted to provide for the drainage of condensation and the runs shall be
properly ventilated. All surface conduit runs shall be marked out for approval
by the Purchaser’s Representative before the installation is carried out. Where
large multiple parallel conduit runs would occur, use may be made of
galvanized cable trunking. Conduits installed on structural steelwork shall be
secured at spacing not exceeding those for surface conduit by girder clips,
otherwise fixing shall be as for surface conduits on walls, drilled and tapped to
the metalwork. Power driven fixings shall only be used with the express
permission of the Purchaser’s Representative. Any drilling or access which is
required through any structural memberof the building shall be agreed with
thePurchaser/ Engineer in Charge before carrying out the work.

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b) Exposed threads and places where galvanizing has been damaged shall be
cleaned and then painted with two coats of an approved metallic zinc based
paint. This treatment shall be applied as the work proceeds.

6.6.7. Concealed Installation:

a) Concealed conduits shall be securely fixed to prevent movement before laying

of screeds, floating of plaster, casting of columns or other building operations
necessary after the conduit installation. Crumpets or similar fixings shall be
used for attaching the conduit to blockwork, etc. Building nails will not be
accepted.

b) At least 15 mm cover shall be allowed for finishes over the conduit. Where
this cover cannot be maintained then expanded metal shall be fitted with the
conduit. Conduit cast into reinforced concrete floors shall be fixed to the steel
reinforcing with binding wire and the conduit boxes filled with expanded
polystyrene or enclosed in a plastic bag to prevent the ingress of concrete
when poured. Where possible, the conduit boxes shall be fixed to shuttering
to give a flush finish.

c) Conduit installed in voids, false ceilings, and other concealed routes shall be
installed as specified for the surface conduits. Wiring shall be carried out after
the false ceiling or permanent ducts have been completed. Conduit installed
in floors shall be sealed against ingress of moisture.

d) The conduit installation shall be inspected by the Purchaser’s Representative

before the building operation conceals the work.

6.6.8. Cable Installed in Flexible Conduit:

a) Flexible conduit shall be of the waterproof galvanized type or PVC wire-wound

type with cadmium plated mild steel couplings. Lengths of flexible conduits
shall be sufficient to permit withdrawal, adjustment or movement of the
equipment to which it is attached and shall have a minimum length of 300
mm. Flexible conduit shall not be used as a means of providing earth
continuity. A single earth conductor of adequate size shall be installed
external to the conduit complete with earth terminations.

b) Where conversion from rigid conduit to flexible metallic conduit is to be made,

the rigid conduit shall terminate in a through type box and the flexible conduit
shall extend from this box to the equipment, the earth continuity cable shall be
secured to the box and to the piece of equipment by properly designed
earthing screws. The use of lid facing screws, etc., will not be permitted.
Adapters shall incorporate a grub screw or a gland to prevent the flexible
conduit becoming loose.

6.6.9. Cable Clipped Direct:

a) All cable hangers, clips, cleats and saddles shall be of an approved type and
appropriate to the type and size of cable installed. Their spacing shall be such
as to ensure a neat appearance and prevent sagging of the cables at all times
during their installed life.

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6.6.10. Cable Installed in Internal Floor Trench:

a) In shallow trenches (maximum depth 500 mm)

b) In shallow trenches used for electrical services only, cables may be laid in a
neat and orderly manner on the floor of the trench. One layer only shall be
allowed. Additional cables shall be installed on the walls of the trench in an
acceptable manner & such a way that, in no case the distance between two
different types of cable shall not be less than the separation distance
tabulated above.

c) Where the trench is shared by other services, cables shall be installed on the
walls of the trench in an acceptable manner & such a way that, minimum
separation distance of 300mm shall be maintained.

d) All other trenches including walk through service ducts

e) Cable trenches & cable installation shall be in accordance with the attached
typical cabling system drawings.

f) Where other services are present the cables shall be segregated from them
by separation distances as mentioned above and wherever possible kept
above `cold' wet services. Cables should not be run if at all possible above or
in close proximity to `hot' services.

g) The cabling shall be installed in such a manner as to allow access to the other
services for normal maintenance without disturbance of the electrical
installation

6.6.11. Cable Terminations and Joints:

a) Power Cable Terminations

i. Power cables shall be terminated in suitable boxes arranged for bolting

to switchgear, motor starters and motors.
ii. Cores shall have either crimped lugs or sleeves to match either post
terminals or bolted clamp terminals.
iii. Each cable entry into a terminating box shall be made through a
suitable gland, which shall have provision for securing the armour where
applicable. Where single core glands are required these shall be of the
non-magnetic type and the associated box bottom plate, where the core
passes through, shall not have a continuous magnetic path.
iv. Adequate provision shall be made to bond the cable armouring to the
box and/or switchgear casing of a suitable size to withstand the
prospective short circuit fault current of the system, glands shall be fitted
with earth bonding tags where intimate screwed contact between gland
and cable box is not possible.
v. Where cable glands are exposed to the weather these shall be
protected by heat shrink plastic sleeve or purpose moulded sleeves
covering the gland continuously from overall sheath to the gland neck.
vi. Where terminations of multicore type have to be made on to items of
Plant which have to be dismantled for maintenance, these shall be
made off through glands into an adaptable box containing terminals and
flexible single cores taken into the equipment via flexible waterproof

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plastic covered conduit, and a separate earth core linking the box to the
equipment.
vii. Where single core cables are glanded to or pass through cabling plates
the gland plate or cabling plate shall be constructed of non-magnetic
material.

b) Power Cable Joints:

i. Through joints shall only be allowed with the approval of the Purchaser’s
Representative. Where such joints are necessary in thermoplastic and
elastomeric cables, the cables shall be jointed with epoxy or acrylic
resin cold setting compound, which has been premeasured and pre-
packed ready for use. The boxes shall preferably be of split, moulded
plastic type with filling vents for compound. Bonding straps shall be
fitted with armour clamps across the joint and inspected by the
Purchaser/ Purchaser’s Representative prior to filling the box with
compound. Wrapped pressure type joints will not be accepted.

c) Multi-core or Control Cable Terminations:

i. A sufficient number of terminals shall be provided to terminate all cable

cores. For control and auxiliary wiring an additional 20% of this number
shall be provided as spares.
ii. Not more than one core of internal or external wiring shall be connected
on any one terminal. Where duplication of terminal blocks is necessary,
purpose-made solid links shall be incorporated in the design of the
terminal blocks.
iii. Terminals which remain energized when the main equipment is isolated
shall be suitably screened and labeled.
iv. Terminal blocks for different voltages or circuit type shall be segregated
into groups and distinctively labeled.

6.6.12. Cable Fixings:

a) Ties and strapping shall be suitable for securing cable and cable groups to
cable tray or ladder. They shall be resistant to chemical and marine corrosion.
Plastic coated metal ties used in order to obtain corrosion resistance shall not
be acceptable. Nylon ties shall be resistant to the effects of ultra-violet light
and shall be self-extinguishing.

b) Large single cables shall be secured with cable clamps or cable cleats.

6.6.13. Cable Identification:

At each end of each cable, in a uniform and visible position a label shall be fixed on
the cable in accordance with the cable schedule. Labels shall be made of PVC and
shall be indelibly marked to the approval of the Purchaser’s Representative. The label
shall be retained using proprietary nylon strips passing through two fixing holes at
either end of the label. If the cable gland is not normally visible, then the label shall be
fixed inside the panel by means of screws.

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6.6.14. Marking Locations of Underground Cables:

a) The location of all underground cables shall be engraved on brass or other

non-corrodible plates to be fixed to the exterior surface of all walls of buildings
300 mm above ground level and directly above the point where cables pass
through the wall.

b) Cable route markers as per the attached drawing shall be installed at an

interval not more than 30 meter & at bending/ road crossings the interval shall
be at every 10 meter.

c) The minimum depth for laying of underground cable route markers shall be as
per indicated in the typical drawings attached with this tender.

6.6.15. Additional Requirements for Cable Installations:

a) The Contractor shall install, test and commission the cables specified in the
specification. Cables shall be laid directly buried in earth, on cable racks, in
built up trenches, on cable trays and supports, in conduits and ducts or bare
on walls, ceiling etc. as per drawings, which are to be prepared by
Contractor& approved by Purchaser’s representative.Contractor’s scope of
work includes unloading, laying, fixing, jointing, bending, and termination of
the cables & all related accessories. The Contractor shall also supply the
necessary materials and equipment required for jointing and termination or
the cables.

b) All apparatus, connections and cable work shall be designed and arranged to
minimize risk of fire and any damage which might be caused in the event of
fire. Wherever cables pass through floor or wall openings or other partitions,
suitable bushes of an approved type shall be supplied and put into position by
the Contractor.

c) Standard cable grips and reels shall be utilized for cable pulling. If unduly
difficult pulling occurs, the Contractor shall check the pull required and
suspend pulling until further procedure has been approved by the Engineer’s
Representative. The maximum pull tension shall not exceed the
recommended value for the cable measured by the tension dynamometer. In
general, any lubricant that does not injure the overall covering and does not
set up undesirable conditions of electrostatic stress or electrostatic charge
may be used to assist in the pulling of insulated cables in conduits and ducts.

d) After pulling the cable, the Contractor shall record cable identification with
date pulled neatly with waterproof ink in linen tags. Identification tags shall be
attached securely to each end of each cable with non-corrosive wire. The said
wire must be non-ferrous material on single conductor power cable. Tags
shall further be attached at 10 meter intervals on long runs of cables on cable
trays and in pull boxes. Cable and joint markers and RCC warning covers
shall be provided wherever required.

e) Sharp bending and kinking of cables shall be avoided. The bending radius for
various types of cables shall not be less than those specified below:

i. 11 kV, XLPE insulated, multicore : 15 times the overall dia of

the cable armoured cables

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ii. 1.1 kV, XLPE insulated, multicore : 12 times the overall dia of
the cablearmoured cables

iii. (If shorter radius appears necessary, no bend shall be made until
clearance and instructions have been received from the Purchaser/
Engineer in charge)

f) Power, control and instrumentation cables shall be laid in separate cable

racks/trays.

g) Where groups of HV, LV and control cables are to be laid along the same
route, suitable barriers to segregate them physically shall be provided.

h) Where cables cross roads and water, oil, gas or sewage pipes, the cables
shall be laid in reinforced spun concrete or steel pipes. For road crossings
the pipe for the cables shall be buried at no less than one meter depth.

i) Cables laid in ground shall be laid on a 75 mm riddled earth bed. The cables
shall then be covered on top and at their sides with riddled earth of depth of
about 150 mm. This is then gently filled up to a depth of about 100 mm above
the top of uppermost cable to provide bedding for the protective cable covers
which are placed centrally over the cables. The protective cable covers for LV
cables may be of earthenware and for HV cables of reinforced concrete. The
RCC covers shall have one hole at each end, to tie them to each other with GI
wires to prevent displacement. The trench is then backfilled with the
excavated soil and well rammed in successive layer of not more than 300 mm
in depth, with the trenches being watered to improve consolidation wherever
necessary. To allow for subsidence, it is advisable to allow a crown of earth
not less than 75 mm in the centre and tapering towards the sides of the
trench.

j) In each cable run some extra length shall be kept at a suitable point to enable
one or two straight through joints to be made, should the cable develop a fault
at a later date.

k) Cables on cable racks, on cable trays and conduits shall be formed to avoid
bearing against edges of trays, racks, conduits or their supports upon entering
or leaving trays, racks or conduits. Cables shall be racked or laid directory into
cantilevered cable trays where practicable, but in some cases it may be
necessary that cables are pulled or threaded into trays. To facilitate visual
tracing, cables in trays shall be laid only in single layers and unnecessary
crossing of cables shall be avoided. Cables on trays shall finally be clamped
in an approved manner.

l) Cable splices will not be permitted except where permitted by the Purchaser/
Purchaser’s Representative. Splices shall be made by Contractor for each
type of wire or cable in accordance with the instructions issued by cable
manufacturer’s and the Engineer’s Representative. Before splicing, insulated
cables shall have conductor insulation stepped and bound or penciled for
recommended distance back from splices to provide a long leakage path.
After splicing, insulation equal to that on the spliced conductors shall be
applied at each splice.

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m) Jointing of cables shall be in accordance with relevant Indian Standards

Codes of Practice. Materials and tools required for cable jointing work,
including cold setting bituminous compound shall be supplied by the
Contractor.Cables shall be firmly clamped on either side of a straight through
joint at a distance of not more than 300 mm away from the joints. Identification
tags shall be provided at each joint at all cable terminations.

n) At cable terminal points where the conductor and cable insulation will be
terminated, terminations shall be made in a neat, workmanlike and approved
manner by men specialized in this class of work.

o) Control cable termination shall be made in accordance with wiring diagrams,

using colour codes established by the Purchaser’s Representative for the
various control circuit, by code marked wiring diagram.

p) When control cables are to be fanned out and cabled together with cord, the
Contractor shall make connections to terminal blocks, and test the equipment
for proper operation before cables are corded together. If there is any
question as to the proper connection, the Contractor shall make a temporary
connection with sufficient length of cable so that the cable can be switched to
another terminal without splicing. After correct connections are established
through operating the equipment, cables shall be cut to their correct lengths,
connected to terminals in the specified manner, and corded together where
necessary to hold them in place in a workmanlike manner.

q) Cable seals shall be examined to ascertain if they are intact and that cable
ends are not damaged. If the seals are found to be broken the cable ends
shall not be jointed until after due examination and testing by the Purchaser/
Purchaser’s Representative.Before jointing is commenced, insulation
resistance of both sections of cables to be jointed shall be checked by
megger.

r) After installation and alignment of motors, the Contractor shall complete the
conduit installation, including a section of flexible conduit between motor
terminal box and trench/ tray. The Contractor shall install and connect the
power, control and heater supply cables as per equipment manufacturer’s
drawings.

s) Metal sheath and armour of the cable shall be bonded to the earthing system
of the station.The size of conductor for bonding shall be appropriate with the
system fault current.

6.7. LIGHTING SYSTEM INSTALLATION:

6.7.1. This covers the requirements of installation of the following:

a) Lighting fixtures complete with lamps and accessories

b) Main Lighting distribution board

c) Lighting panels

d) Receptacles and lighting control switches

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e) Point wiring

f) Street lighting poles and flood light towers

g) Multi core cables for street and boundary lighting

h) Maintaining equipment/ materials during storage and being responsible for the
equipment/ material until they are handed over to Purchaser.

i) Installation, testing and commissioning shall be carried out in accordance with

the drawings and as stipulated in this specification.

6.7.2. Applicable Standards for lighting system installation

Electrical wiring installations : IS: 732

(System voltage exceeding 650 V)

Code for practice for interior illumination (Part-1) : IS: 3646/ BS: 8206

Code of practice for street lighting installation : IS: 1944

Code of practice for industrial lighting : IS: 6666

Code of practice for fire safety of building : IS: 1646

Boxes for enclosure of electrical accessories : IS: 5133(Part-1)

Guide for safety procedures and practices in : IS: 5216

electrical work

Ceiling roses : IS: 371

6.7.3. Lighting Fixtures:

a) The installation of lighting fixtures shall be based on the mounting

arrangement shown in the drawings.The rates quoted for installation shall
include all materials required to mount the fixtures. Hooks in RC slabs for
suspension of high bay fixtures shall be provided wherever not already
provided. Cost of supply and installation of such hooks shall be included in the
cost of installation of lighting fixtures. Rate for installation of lighting fixtures
shall include cost of installation of control gear box wherever applicable.

b) Installation of receptacles and switches shall be carried out suitably. Switch

shall be mounted in flush with the front cover plate.Cost of supply and
installation of necessary hardware shall be included in the lump sum rates
quoted for installation of receptacles/ switches.

c) Lighting distribution boards shall be installed at the suitable location.

Installation shall include supply and installation of base channels, foundation
bolts, etc.

d) Outdoor lighting distribution boards shall be installed on a concrete plinth. The

top of plinth shall be 1000 mm (min.) above the grade level.Cost of

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construction of concrete plinth shall be included in Contractor’s scope. No

cement and steel will be supplied by Purchaser.Installation cost of lighting
distribution board shall include cost of installation of earthing conductor from
LDB to the nearest earthing grid.

6.7.4. Point Wiring:

a) Contractor has to prepare the detailed conduit layout drawing showing

primary & secondary point wiring points. Point wiring also covers the wiring of
the associated control switches of lighting fixtures/control switches of
receptacle units.

i. Primary Point Wiring:

Primary point wiring covers the wiring between a circuit of the lighting
panel to the junction box of the first lighting fixture/receptacle unit and
between junction boxes of the subsequent lighting fixture connected to
that circuit of the lighting panel. In some cases where there are junction
boxes, the primary point covers the wiring between junction box and the
first lighting fixture/receptacle unit in that circuit.

ii. Secondary Point Wiring:

Secondary point wiring covers the wiring of the remaining lighting

fixtures/receptacle unit other than that covered under primary point of
that circuit in the lighting panel. Secondary point wiring also covers the
wiring of the associated control switches of lighting fixtures/control
switches and control switches of receptacle units.

b) Supply and Installation of Conduit Point Wiring:

i. The point wiring shall include supply of necessary materials for the
conduit wiring such as galvanized rigid steel conduit, galvanized M.S.
fixing saddles with spacer plates, nylon/fiber fixing plugs, galvanized
M.S. fixing screws, 12 SWG galvanized steel earthing wire, FRLS PVC
insulated Copper conductor wires, control switches and pulling,
termination of the earthing/ FRLS PVC insulated wires as required,
installation of control switches, drilling holes in brick walls/RCC roof
slabs for taking the wiring conduits and refinishing and any other
works/material necessary for making point wiring complete in all
respects.

ii. Wires used for conduit point wiring of lighting fixtures/ceiling fans, 5A
receptacles and receptacles above 15A shall be 1.1 kV grade, FRLS
PVC insulated, single core, multistranded Copper conductor wires of
sizes not less than 1.5 sq. mm and 2.5 sq. mm respectively. Wires shall
conform to IS: 694 and shall bear the ISI mark.

iii. Contractor shall take into consideration necessary galvanized MS fixing

clamps when the wiring conduits are to be supported from steel roof
truss/structural members.

c) Supply & Installation of cabling for Street and Flood Lighting

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i. Work includes supply and installation of cables required between LDB

and junction box mounted on street lighting pole/flood lighting tower and
also between junction box mounted on flood light tower to metal
enclosed control gear box located near flood light fixture, supply and
installation of all the termination accessories such as crimping type
cable lugs and double compression cable glands at each junction box
and fixture, termination, testing and commissioning of cables.
Contractor’s scope of work also includes excavation, preparation of
riddled soil bedding, supply and installation of protective covers over the
cable, backfilling, ramming, supply and installation of route markers,
supply and installation of HDPE / Hume pipes for road crossing, etc,
supply and installation of necessary cleating arrangement for cabling on
flood light tower, supply of labour, supervision, welding equipment, all
tools and tackles and testing equipment as required.

ii. Contractor shall plan and cut the cables in such a way that there is no
wastage and no cable jointing is required in any run. However, should
any joint become necessary the same shall be provided by the
Contractor and a joint marker shall also be provided at no extra
cost.Earthing of street light pole/flood light tower, lighting fixtures, etc.
are included under Contractor scope.

d) Point wiring shall also include/hold good for the following :

i. Supply and installation of lighting control switches and switchboxes

complete with fixing accessories.

ii. Drilling holes in brick/RCC wall and roof for taking cable or conduit,
sealing and refinishing with cement plaster.

iii. Testing, commissioning and handing over the lighting system in

commercial working condition.

iv. Marginal shifting of any fixture/accessory from the location indicated in

the lighting layout drawings.

6.7.5. Outdoor Lighting (Street and Flood Lighting):The following shall be deemed to be
included as part of the installation work for outdoor lighting point wiring.

a) Installation of multicore/ single core cables between LDB and junction box
mounted on street light pole/flood lighting tower, from junction box to metal
enclosed control gear box.

b) Supply and installation of crimping type cable lugs, double compression type
cable glands at each junction box and fixture, termination, testing and
commissioning of cables.

c) Contractor’s scope shall also include excavation and preparation for buried
cables. Supply and installation of route markers, supply and installation of
HDPE/Hume pipes for road crossing shall also be included in the scope of
installation of point wiring.

d) Supply and installation of necessary cleating arrangement for cabling on flood

light poles.

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e) Contractor shall provide necessary foundation for erecting street light

pole/flood light tower and install the same. Contractor shall prepare foundation
drawings with necessary details &Purchaser Representative’s approval shall
be obtained.

f) Contractor shall plan and cut the cables in such a way that there is no
wastage and no cable jointing is required in any run. However, should any
joint become necessary, the same shall be provided by the Contractor and
joint marker shall also be provided at no extra cost.

g) Earthing of street light pole/flood light tower, lighting fixtures, control gear
boxes, junction boxes, etc. are also included in the scope of installation of
point wiring. Contractor shall earth street light pole/flood light poles and
junction box with 25x3 mm G.S. flat tap off from the 25x3 mm M.S. flat
earthing grid along the street lighting included in scope. The Contractor shall
interconnect earthing grid to plant main earthing grid at first and last pole of
each feeder circuit and at one intermediate pole.

h) Installation of lighting Poles and Towers for Outdoor Lighting (Street and
Flood Lighting)-

i. Work includes supply and installation of street light poles and flood light
towers including associated junction boxes with fuses, links and
terminals for junction boxes and junction boxes near each flood light
fixtures.

ii. All street light poles and towers shall be painted with one shop coat of
red oxide oil primer followed by two coats of aluminium alkyd paint.

6.7.6. Installation of Lighting Distribution Board, Lighting Panels (AC & DC), 230 V, AC 1-
Ph Distribution Boards.

Installation of above items shall include necessary foundation channels, bolts/ nuts,
etc. for grouting lighting distribution boards, iron brackets/ grouting brackets,
bolts/nuts for wall/ column mounted panels and associated civil works.

6.7.7. Details of work requirements are covered in lighting installation notes and details
and typical drawings which form the part of specification. Any changes, if
necessary due to site conditions/requirements shall be carried out after obtaining
approval of Purchaser/ Purchaser’s Representative. The changes carried out shall
be marked clearly in the layout drawings by Contractor and ‘AS BUILT DRAWING’
shall be prepared by the ‘Contractor’ and this shall be forwarded to Purchaser’s site
/ design office.

a) Wiring

i. Wiring shall be carried out strictly as per project drawings and technical
specification.All exposed conduit wiring shall have provision for easy
inspection. Where cable wiring is specified cable shall be cleated on to
the wall as close to the ceiling as possible. In all types of wiring due
consideration shall be given for neatness and appearance.

ii. Wherever DC emergency lighting is provided, emergency lighting wires

shall run in a separate conduit. Colour of the wires used shall be as

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follows; white for positive, black for negative.

iii. Wherever lighting system has three phase distribution, separate

conduits shall be used for different phases.For easy identification of
phases and neutral wires the following colour wires shall be used.

R - Phase - Red
Y - Phase - Yellow
B - Phase - Blue
N –Neutral - Black

b) There shall be a circuit breaker on each live conductor of supply mains at the
point of entry.

c) Conductors not arranged for connection to the same system or supply

different phases of the same supply, shall be kept apart throughout their entire
run.

d) Receptacles and lighting fittings in general shall be fed from different Circuits.
Five amps receptacles for toilet or small rooms can be fed from the lighting
circuit with proper isolating arrangement.

e) Each final sub-circuit from a lighting panel shall be controlled by a single pole
switch connected to the live conductor.

f) For long conduit wiring runs, inspection/ pull boxes shall be provided at
intervals not exceeding 10 meter. Such facilities shall also be provided at
conduit bends.

6.7.8. General Practices for lighting:

a) All receptacles and switches to be installed in offices and control rooms shall
be flush mounted within the wall and those in other areas shall be wall or
column mounted.

b) Ceiling roses shall not embody fuse terminals as an integral part.For voltages
exceeding 250 volts, a ceiling rose or any similar attachment shall not be
used.

c) All exposed metal parts of the plug, when the plug is in complete engagement
with the socket outlet, shall be in effective electrical connection with the
earthing pin.

6.7.9. Earthing for lighting:

Conduits and fittings shall be earthed by 12 SWG GI wires run along the length of
the conduit and secured by means of suitable clamps efficiently fastened to conduit
tip. To achieve perfect electrical continuity, the conduits shall be bonded effectively
on either end of a coupling and other joints.

a) Conduits shall be earthed at the ends adjacent to switch boards at which they
originate or otherwise at the earth clip, clamp or gland, in effective electrical
contact with the conduit.

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b) For outdoor lighting poles & mast 8 SWG GI earth wire shall be run buried in
ground at a depth of 600 mm along-with lighting cables and shall be
terminated up to the junction box on the pole and 12 SWG wire shall be taken
up to the pole fitting. In case of lighting poles where the main earth grid is far
away from the pole, local pits shall be provided for pole earthing.

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