110509 FRS Electrical Panel Spec EOI(1)

7/24/2019 110509 FRS Electrical Panel Spec EOI(1)

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GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

lR eso t r

FUNCTIONAL REQUIREMENT SPECIFICATION

FOR

MANUFACTURE & SUPPLY OF MODULAR AND FLEXIBLE

ELECTRICAL PANELS

RESEARCH DESIGNS & STANDARDS ORGANIZATIONMANAK NAGAR, LUCKNOW - 226 011


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FUNCTIONAL REQUIREMENT SPECIFICATIONFORMANUFACTURE & SUPPLY OF MODULAR AND FLEXIBLEELECTRICAL

PANELS

0.0 FORWORD:

This Specification defines the objective guidelines and requirement for the designmanufacture and supply of modular and flexible electrical panels & enclosures.

1.0

GENERAL:

1.0.1 The tenderer shall furnish the following information:-

1.0.2Name of manufacturer & country of manufacture.1.0.3Credentials of firm as manufacturer of panels.1.0.4Description of electrical panels installed during the last five years with thename of the parties/buyers to whom supplies was made, date of installation and

performance certificate thereafter.1.0.5Details of testing facilities at manufacturers works.1.0.6Whether manufacturer has technical collaboration with another firm, if soprovide details regarding the same.

1.2 The tenderer shall bring out clearly any additional feature which he deems fitto include to give a complete and comprehensive offer. He shall, however, explainreasons for offering such additional features/items in his proposal.

2.0 SCOPE:

The scope of supply & services shall include the design manufacturing, testing &supply of panels as per enclosed list.

3.0 CLIMATIC CONDITIONS:

3.1 The Panels should be manufactured accordance to covered all the followingmentioned conditions.

3.2 The climatic condition specified in this clause are average conditions, anyspecific conditions specified in the tender documents shall override these.

Atmospherictemperature

(a) Short term peak : +50C(b) Maximum on a 24Hours avg. : +35Cto 40C(c) Minimum temp. : -10C

Humidity 100% saturation during rainy season.

Referencesiteconditions

i) Ambient Temp. : 50 Cii) Relative Humidity : 50% at 40Ciii) Altitude: 1000m above sea level


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Rain fall Very heavy in certain areas.

Atmosphereduring hotweather

Extremely dusty and desert terrain incertain areas. The dust concentration inair may reach a high value of 1.6 mg/m.In many iron ore and coalmine areas, the

dust concentration is very high affectingthe filter and air ventilation system.

Pollutionlevel

Humid and salt laden atmosphere withmaximum. pH value of 8.5, sulphate of7mg per liter, max. concentration ofchlorine 6 mg per liter and maximumconductivity of 130 micro siemens/cm.

Wind speed High wind speed in certain areas, withwind pressure reaching 150kg/m

4.0 STANDARDS

The Panel shall conform to the following Indian / international Standards asamended /revised till date unless stated otherwise, as applicable:

S.No. Specification No. Description

1 IEC60051/ IS - 1248 For Direct acting indicating analogueselectrical measuring instrument

2 IEC60947/IS-13947 For Low-voltage switchgears & controlgear

3 IEC 60439-1 For Low voltage switchgear & controlgear assemblies.

4 IEC 60529 / IS13947 part 1

For Degree of protection provided byenclosures ( IP Codes )

5 EN 61641 For accidental arc conditions

6 DIN - 43671 For Bus-bar Current rating.

7 DIN - 3168 For climate control unit for distributionbox / concept testing marking.

8 DIN VDE 0100 For Outdoor panels painting.

9 DIN 50961-2000 andIS 1573-1986

For mounting plates.

10 DIN 43668 For cam lock with double-bit insert

11 IS : 5138 For quality of sheet steel

12 IS : 3072 For installation of switchgear

13 IS : 1554 For control wiring14 IS : 2516 For Air-circuit breaker

15 IS : 7098 (part-1) For LT Cables

16 IS : 2705 part-III 1964 For CTs

17 IS: 3043 For earthling

18 IS: 2384-1964 For capacitors

19 DIN EN ISO 1520,2815 & 2409

For Anodic dip coat priming.

20 DIN EN ISO 1520, For Textured powder coating


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2815 & 2409 &9227NSS

21 DIN 53 577 For Testing elastic foamed material.Determination of the compress strength

22 DIN 53 504 For Testing of rubber. Tensile test

23 DIN EN ISO 1798 For Flexible cellular polymeric materials-

determination of the tensile strength andelongation strength ( ISO 1798 : 1997);German version EN ISO 1798 : 1999

24 DIN 53 508 For Testing of rubber. Accelerated ageing

25 DIN75200 For Determination of burning behavior ofinterior materials in motor vehicles

26 EN ISO 1856 For Flexible cellular polymeric materials.Determination of the compression set

27 IEC 60255 For Electrical Relays

28 IEC 60255 / IS - 3231 For Electrical Relays

29 IEC 609473 / IS -13947

For On load isolators

30 IEC 60629 2 / IS13705

For Low voltage fuses

31 IEC 60439-1 / IS -8623

For Low voltage switchgear & controlgear assemblies.

32 IEC 60947-2/IS13947-part 2.

For MCCB,

33 IEC 60898/IS 88828-1995

For MCB

34 IEC 60947-4-1 For Contactors

35 UL 489/ IEC 60947-2/ IS13947 -part 4.

For MPCB

36 DIN EN 13601 For material of copper Bus-Bars37 IEC 60439-1: 1999,

Annex D,

For guidelines for the differentseparation types

Other standards shall be applicable provided the stipulation of such astandard is at least equal to the requirement of the specified standards.

5.0 PANEL SPECIFICATION:

5.1 General :

Frequency - 50Hz.Voltage Variations - +10%.Frequency Variations - +3%.

5.2 System :

High Voltage Level - 33 kV.Medium Voltage Level - 11 kV.


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Low Voltage Level - 415V.Design Form - 3 Phase, 4-wire ( TPN )

5.3 Construction

5.3.1. Enclosure:Enclosure should be of Single sheet sturdy frame section construction of sheetsteel as per IS: 5138, consisting of folded rolled hollow frame section punching in25mm DIN pitch pattern. All profile edges are radiuses. The corners are stiffenedwith welded zinc die-cast corner connectors with load bearing capacity of 1.5 Tonsof static load.

5.3.2 Rear wall:Rear Panel /Rear Wall should be made with 1.5mm thick cold rolled sheet steel,with foamed-on seal which should be removable.

5.3.3 Roof panel:Roof panel should be made with 1.5 mm thick sheet steel with foamed-on seal andshould be removable.

5.3.4 Side panels:Side panel should be made with 1.5mm thick sheet steel, with a foamed-on sealand fixing screws. All parts should have been prepared for the attachment of earthstraps.

5.3.5 Surface finish:Sheets should be cleaned and Nano ceramic coated, electro-dip coat primed andpowder coated with textured polyester RAL 7035.

5.3.6 Doors:Doors should be made with 2 mm sheet steel, flush-mounted, with foamed-in seal,vertical perforated mounting strips fitted on both sides(door stiffeners) and screw-fastened hinges. Hinges can be fitted on the left or right for single-door enclosures,130 opening angle as per VDI (retrofittable to 180), cam lock with double-bitinsert as per DIN 43668

5.3.7 Mounting plate:The mounting plate should be as per DIN 50961 2000 and IS: 1573 1986, 2 - 3mm sheet steel with system punchings, depth-adjustable stud mountings, withoutspangles, zinc-plated @ 120 GSM (Gram per Square Meter).


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5.4 Busbar System

5.4.1 Bus bar & associated connections shall be constructed from 99.98% E-Cu(Electrolytic Grade of Copper) with tinning thickness of 4 to 5 microns as per DINEN13601 with bus-bar rating according to DIN 43 761 standard. Tiniing is done toavoid oxidation of copper.

5.4.4 The bus-bar support shall be of Polymide fiberglass reinforced with fireprotection corresponding to UL 94 V0.

5.4.5The bus-bar system shall be capable of withstand stress due to fault currentof up to.35kA for one second below 800A.

50kA for one second 800 1600A.75kA for one second 1600 3200A110 kA for one second for 4000A.

The bus-bar cover shall be complied with UL 94 V0. Tested under IEC60439.

5.4.6 Heat shrinkable sleeves should be provided for identification and protection.

5.4.7 Hardware used in bus-bar system should be of high tensile strength of grade8.8 or better.

5.5 Painting / Surface treatment

5.5.1 The manufacturer should have RoHS compliance for painting process &painting should comply with DIN EN ISO 1520, 2815 2409. Anodic dip coatpainting & textured powder coating performance shall be as per DIN EN ISO 9227NSS. Alternatively, Painting process should comply with IS 3618- class -c forphosphating (Tri catena zinc - phospahte)& Powder coating as per IS 101 & IS13871 and Coating weight to confirm the requirement of IS 2618. In order toensure optimum corrosion protection in all climatic zones, Aluminum orGalvanized/zinc plated metal with subsequent Nano-ceramic/zinc-phosphate &powder coating should be used with the materials that are specified to be intendedfor outdoor application.

5.5.2The thickness of paint should be 70 135 micron.

5.5.3 Properties of Powder Paint

5.5.3.1 External Applications The Polyester powder paint should be cured polyester powder paint; TriglycidylIsocyanurate (TGIC) should provide a wide range of desirable properties.

5.5.3.2 Indoor Applications


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For indoor applications, Epoxy painting should be used. Epoxy has excellentproperty for corrosion resistance but inferior in case of UV.

5.5.3.3 Other PropertiesThe powder paint should resist any corrosion resulting from scratches, and nicks.Even without a primer coat, powder paint should provide excellent resistance tocorrosion. The paint should also offers excellent protection at sharp edges on metalfabricated items. Powder painting is stated to be the most flexible coating on themarket. The paint should not crack or lose adhesion when exposed to a bend witha radius of 1/8 inch or impact of 160 inch pounds. TGIC should have flexibilityproperties of the E-coating as well as withstand long-term exposure to heat up to300F. Corrosion resistance properly should be confirmed as per ASTM B-117.

5.6 Gasket

The gasket should be of tri functional (functioning as a sealant, elastic in natureand non- water absorbant), CFC free Polyurethane Gasket to provide maximum IPprotection & can withstand a temperature range of -40C to +90C.

It should comply with burning behavior According to DIN755200; also flexiblecellular polymeric materials should be used according to EN ISO 1856 and DIN ENISO 1798. Gasket should with stand Compress strength of 5 kPa to 200 kPa (at25% compression) according to DIN 53 577. Gasket should with stand tensilestrength up to 2 MPa [N/cm] according to DIN53 504. Gasket should be longlasting according to DIN 53 508. Gasket should be with stand high temperatureaccording to DIN 75200.

5.6.1 It should Capacity to withstand high temperature: PU gasket shouldwithstand 180 C/15 minutes.

5.6.2 High Adhesiveness:

Gasket should be with good quality of Adhesive or mixture of liquid Polyurethaneand Isocyanide (Resin & Hardener) & should be poured on the door/covers by aCNC machine. Upon drying the mixture should solidifies and gets bonded to thesurface of the part permanently.

5.6.3 It should have Hygroscopic feature that is Polyurethane gasket should be nonhygroscopic.

5.7 Control wiring

All control wiring, indication etc. shall be carried out using 650V grade 1.5 sqmm

copper conductor cables PVC insulated conforming to IS 1554 Part-I. CT wiringshall be with 4/2.5 sqmm copper conductor with suitable CT shorting links. Wiringshall be suitably protected within the switchboard. Runs of wires shall be neatlybunched and suitably supported and clamped. Means shall be provided for easyidentification of the wires. Identification ferrules shall be used at both the ends ofthe conductors.

5.8 Earthing


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The panel shall be provided with copper earth bus running throughout its length asper IS: 3043. Suitable earthing eyes/bolts shall be provided on the main earthingbus to connect the same to the earth grid at site. Sufficient no. of star washersshall be provided at joints to achieve earth continuity between panels and sheetmetal parts.

5.9 LT Cables

All cables shall be of suitable size copper & Aluminium Conductor, armoured,

XLPE insulated and rated for 1.1kV grade as per IS 7098 (part-1) 1998.

5.10 Terminals

All the control, instrumentation and protection wiring shall be provided withCOMPUTERISED Printed PVC ferrules at both ends for long life.

5.11 Name Plate

The panel as well as the feeder compartments door shall be provided with the nameplates giving the feeder description as required.

5.12 Basic Design Parameter

5.12.1The enclosure should be provided with a degree of protection as per IEC 60529 / IS: 13947 part 1, of not less than IP-54 for indoor and IP-55 with RainCanopy and Fan-Filter /outlet filter with Hood for all outdoor mounted panels.

5.12.2The enclosure should be provided with bus-bar cover (UL 94 V0) made ofPolymide (PA6.6) running all along the length of the switchgear in a separateenclosure & also It should compliance for any accidental arc conditions as per EN -

61641.

5.12.3Vertical Bus bars shall run at the middle of two adjacent panels to take offfor individual feeders. The Bus bars shall be fully shrouded with bus-bar cover (UL94 V0) heat shrinkable PVC sleeve to ensure safety of operation when rear doorsare opened.

5.12.14 The switchgear and distribution panels with ACBs & MCCB`s shall befront operated with Breaker operating knobs clearly indicating position of BreakerON / OFF / TRIP.

5.12.15 The switchgear and distribution panels shall be interlocked from doorsuch that only after tripping of the ACB`s or MCCBs the front door can be opened.

5.12.16 Even with the door closed, the test / service position of Breaker (ACB)shall be achieved. Rack in / Rack out of Breaker from above test to isolatedposition can be done with the door closed from outside. It shall have a lockingfacility to lock the Breakers in service & test positions.

5.12.17 The enclosure should be with insertion of an extended arm the Breakercan be fully drawn out from the compartment but remains mechanically attached


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to the panel so that routine inspection and maintenance checks can be easilycarried out.

5.12.18 The Panel should be Form 1 for LT distribution Panels below 800A as per

IEC 60439-1: 1999, Annex D

5.12.19. The Panel should be Form 4a for LT distribution Panels above 800A as perIEC 60439-1: 1999, Annex D,

5.12.21 Incomer shall have facility to receive emergency stop push button fromfield. These buttons through relay contacts shall be wired to incomer shunt trip ina way that it trips the breaker whenever emergency push button pressed in field.Incomer all have operating handle at the outside of that door and an emergencystop push button.

5.12.22 Incomer shall have RYB lamp indication, On Off & Trip indication, &Digital ammeter shall be operated through CT and suitably rated PT shall beprovided for Digital Voltmeter

5.12.23 All bus-bar shall be made with Electrolytic Grade of Copper E-Cu 99.98%purity as per DIN EN 13601with current rating acc. to DIN 43 761.

5.12.24All cable shall be FRP type with copper conductor.

5.12.25CTs wherever used shall be resin cast type.

5.12.26 The selection of components shall be made in accordance with feederrating keeping 20% extra.

5.12.27 There shall be suitable provision for termination of cable Cu. / Al. fromfield.

5.12.28 There shall be separate bus-bar chamber at the top for horizontal bus-bar.

5.12.29 Minimum 300mm clearance shall be maintained between floor & lastterminal row.

5.12.30 MCC shall have 3 phase 4 wire 50 Hz system i.e. TPN.

5.12.31 In future MCC should have provision to get expended at both ends.

5.12.32 The Panels shall be of single front, double access type having feeder

controls located in the front and vertical Bus bars and cable chamber located in therear. Control and selector switches, Push Buttons, indicating instruments, lampsprotective relays, single phasing relays shall be mounted on the front doors of therespective compartments. Current Transformers and Circuit Breaker controlcircuits shall be mounted on the fixed portion of the compartment; CTs shall not bedirectly mounted on the Buses.

5.12.33 Suitable liberally designed barriers shall be placed between CircuitBreakers and all control protective and indication circuits, equipment includingInstrument Transformers. External cable connections shall be carried out in a


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separate cable compartment. Separate cable chambers shall be provided for Power& Control cables.

5.12.34 After isolation of the power and control connections of a circuit, it shall bepossible to safely carry out maintenance in a compartment with the Bus bars andadjacent circuit in `live' condition.

5.12.36 All the assembly or installation for Low-voltage switchgears & controlgears assemblies should be as per IEC 60947 or IEC 60439 1, & IS : 3072.

5.12.37 All the enclosure climate control unit, like panel AC, etc, if requiredshould be as per DIN 3168.

5.13 Cable Entry

5.13.1.1 Cable entries in the Cabinets/ SCADAs, /Power/Control cubicles &other equipments shall be sealed with EPDM Modular based Cable sealing

system with technology based on Multidiameter.

5.13.1.2 The EPDM Modules should be "Low Smoke Index, Halogen free cross-linkable rubber compound based on EPDM (Ethylene - Propylene DieneTerpolymer).

5.13.1.3 One single module should seal a cable of several different diameters.

5.13.1.4 The system should ensure foolproof protection against hazards inducedby" Water, Dust, Humidity, & Rodents. The sealing system must have built inspare capacity i.e. option for adding more cables in to the same system.

5.14 SwitchgearThe typical requirements of switchgear required to be housed in the electricalpanels are given as under:5.14.1 ACB

5.14.1.1 Air circuit breaker shall be suitable for a continuous current rating asspecified for each type of panels. Air circuit breakers shall be with microprocessorrelease of O/L, S/C, E/F conforming to IS2516. The typical requirements for a1600 A ACB are as follows:-

Rated service voltage: 600 VACRated insulation voltage: 1000 VACRated impulse withstand voltage: 12 kVContinuous rated current: 1600 A

Capacity of the neutral pole: 1600 AShort circuit breaking capacity: 42 kA minShort circuit making capacity: 80 kA minOperating temperature: [C] -25+70Frequency: f [Hz] 50 - 60Version: Electrically operated drawout type.Protection: O/L, S/C & E/F

5.14.1.2 Necessary isolating plugs and sockets.


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5.14.1.3 Necessary independent manual spring closing mechanism withmechanical ON/OFF indicator as well as electrical ON/OFF indication to beprovided at front panel.5.14.1.4 Necessary set of auxiliary switches and indication, metering requirementssuch as ON/OFF indication, selector switches fuses.5.14.1.5 ACB shall have motor operated charging system and suitable undervoltage relay.5.14.1.6 Whenever two or more supplies are available /ACB's shall be electrically& mechanically interlocked by providing suitable control circuit& devices.5.14.2 MCCB

5.14.2.1 All the MCCBs shall be rated for at least 35 kA and from the approvedmakes.5.14.2.2 Operating mechanism shall be Quick-make, quick-break, trip free.5.14.2.3 This shall be independent of manual speed of operation. Contacts shallnot be teased into position, nor can the breaker be held closed under faultconditions.5.14.2.4 Shall have Clear indication of ON, OFF and TRIP position.5.14.2.5 All MCCBs shall be provided with operating handles to be fixed on the

panel door.5.14.2.6 Facility to push to trip to verify healthiness of mechanism shall be inbuilt.5.14.2.7 All parts of circuit breaker shall be enclosed in heat resistance insulatingmaterial housing5.14.2.8 Silver alloy contacts should have long electrical life and there should beno arcing on the current carrying part of the contact5.14.2.9 Terminals shall have large dimensions to accept links or cable lugs areseparated by insulated barriers with adequate clearances.5.14.2.10 The MCCBs shall comply with the requirements of IEC 60947-2/IS13947 -part 2.

5.14.3 Capacitors

5.14.3.1The capacitor shall be of heavy duty suitable for 3ph, 440V, 50Hz as perIS 13340/1993and shall be available in 5, 10, 15, 20 and 25 KVAR capacities. . The capacitorsabove 15 KVAR Module shall be hermetically sealed and assembled easily in sheetsteel containers with Stud type Terminals. Capacitors shall be suitable for Indooruse up to ambient temp. of 55 degree C. Sealed in strudy corrosion proof, sheetsteel Containers and impregnated with non-inflammable Synthetic liquid. Thecapacitors above 15 KVAR Module shall be hermatically sealed and assembledeasily in sheet steel containers with Stud type Terminals.

5.14.4.2 Capacitors shall be hermitically sealed in sturdy corrosion proof, sheet

steel containers and impregnated with non-inflammable synthetic liquid. Thecapacitors shall withstand voltage of 2500V (power frequency test voltage). Theinsulation resistance shall not be less than 50 megohm when tested with 500Vmegger.

5.14.4 MPCB


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5.14.4.1 There should be manual and local control, when the motor circuit-breaker is used on its own, and automatic and remote control when combined witha contactor5.14.4.2 Motor protection should provided by thermal-magnetic devices built intothe circuit-breaker5.14.4.3 No live parts should be accessible to direct finger contact5.14.4.4 The addition of an undervoltage trip enables the motor circuit-breaker tobe tripped if voltage is lost5.14.4.5 The addition of a shunt trip should enable remote control of tripping5.14.4.6 The control for the open or enclosed motor circuit-breaker should belocked in the N/C" position using 3 padlocks5.14.4.7 The MPCB should comply with the requirements UL 489/ IEC 60947-2/IS13947 -part 4.

5.14.5 MCB

5.14.5.1 The fault current of MCBs shall not be less than 10KA at 230 V. TheMCBs shall be flush mounted and shall be provided with trip free manual operatingmechanism.

5.14.5.2 The circuit breaker dollies shall be of the trip free pattern to preventclosing the breaker on a faulty circuit.

5.14.5.3The MCB contacts shall be silver nickel and silver graphite alloy and tipcoated with silver. Proper arc chutes shall be provided to quench the arcimmediately.

5.14.5.4 MCBs shall be provided with magnetic fluid plunger release for overcurrent and short circuit protection. The overload or short circuit device shall havea common trip bar in the case of DP and TPN miniature circuit breakers. All theMCBs shall be tested and certified as per Indian Standards, prior to installation.

5.14.5.5 The MCB should comply with the requirements IEC 60898/IS 88828-1995

5.14.6 Contactors

5.14.6.1 The contactors shall have minimum making and breaking capacity inaccordance with utilization category AC3 and shall be suitable for minimum ClassII intermittent duty.

5.14.6.2 If the contactor forms part of a distribution board then a separateenclosure is not required, but the installation of the contactor shall be such that itis not possible to make an accidental contact with live parts.

5.14.6.3The Contactor should comply with the requirements IEC 60947-4-1.

5.14.7 Current Transformer

CT s should be cast resin type. They shall be of accuracy class 10 P 10/5 P 10 ( asper requirement) of IS 2705 part-III 1964, Where ammeters are called for C.T.sshall be provided for current measuring. Each phase shall be provided withseparate current transformer of accuracy Class I and suitable VA burden foroperation of associated metering and controls.


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5.14.8 Push ButtonsThe push button unit shall comprise of the contact element, a fixing holder, and apush button actuator. The push button shall be momentary contact type. Thecontacts shall be of silver alloy and rated at 10 Amps. continuous current rating.The actuator shall of standard type and colour as per its usage for ON, OFF andTRIP. Wiring for Remote ON, OFF push button is to be required.

5.14.9 Indicating Lamps

Indicating lamps assembly shall be screw type with built in resistor having nonfading color lens. LED type lamps are required. Wiring for Remote ON, OFF, TRIPindicating lamp is required.

5.14.10 Indicating Instrument & Metering

5.14.10.1All electrical indicating instruments shall be of digital type with 25mm,3 digital display as per IS : 1248 or IEC - 60051. The size of the meter shall be 96Sq.mm and shall be suitable for flush mounting with only flanges projecting on

vertical panels. Instruments shall conform to latest IS and shall have accuracyclass of 1.0. All meters of reputed make and approved by the Corporation shall besupplied.

5.14.10.2Wattmeter shall be of static type with accuracy Class of 1.0 type.

5.14.10.3Voltage and Current circuits shall be arranged in such a way that theydo not appear in adjacent terminal blocks.b. Care shall be taken to see that no block shall have more than two wires in aterminal.

5.14.10.4KWH meter shall be of 3 Phase microprocessor based of accuracy class

0.5, suitable for measurement of unbalanced loads in 3 Phase, 4 wire circuits.Ammeter, voltmeter and wattmeter shall be of reputed make and approved byCorporation.

5.14.11Terminals

5.14.11.1 Terminal blocks (both for power and control circuits) shall be of the650V grade stud type, links between each pair of studs, washers, nuts & locknuts. The studs shall be securely locked within the mounting base to prevent theirturning. Insulated barriers shall be provided between adjacent terminals.

5.14.11.2 Terminal blocks shall be adequately rated to carry the current of theassociated circuit.

5.14.11.3 Terminal blocks shall be arranged with at least 50mm Clearancebetween two sets of terminal blocks,

5.14.11.4 Control terminals for external connection shall be suitable forterminating at least conductors each of 2.5Sq.mm size.

5.14.12 Space Heaters & Lighting Outlets


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Space heaters of capacity 60W suitable for connection to the single phase A.Csupply shall be provided inside all Cubicles, Panels and Switch boards at thebottom to prevent condensation of moisture. Wiring connected to the space heatersin the cubicle shall have porcelain beaded insulation over a safe length from theheater terminals. All switchboards, cubicles etc., shall be provided with suitablylocated lighting outlets and 15A, 3 pin powers plugs with sockets. The lightingswitch shall be provided inside each entrance door at the back of the panels.

5.14.13 Name & Identity Plates

5.14.13.1 Name & identity plate should be 25mm wide white/black Aluminiumplates.

5.14.13.2 All components (i.e. MCCBs, MCBs, Fuses, Contactors, auxiliarycontactors, relays, switches etc.,) inside the panel and out side the panel shall belabeled with the above mentioned plastic plates and fixed permanently on the panelbeneath each component.

5.14.13.3 All labels shall comprise of black letters on white background. Labelsshall be made of 3ply lamicoid. They shall be properly fixed, with provision toprevent distortion due to expansion. Size of labels and lettering are subject toCorporations approval.

5.14.14Ventilation

The rear enclosing sheets, and all front covers for the Breakers of heavy capacity ifconsidered necessary, shall be provided with Fan-Filter and outlet filter unitcombination to prevent entry of dust and vermin into the panel and giving IP

54 protection.

5.15 Make of Components

The make of the components to be used in the Electrical panel should be from theCEEs approved list of the concerned zonal railway. In case, the item doesnt featurein the list then it should procured from sources having proven design in similarapplications

6.0 SCHEDULE OF TESTS

6.1.0 GENERAL

6.1.1 Only after all the designs and drawings have been approved andclearance given to this effect by RDSO, the manufacturer shall takeup manufacture of the prototype unit.

6.1.2 The contractor shall submit a detailed test plan, for approval ofRDSO, consisting of test procedures, schematic/circuit diagrams,items/parameters to be checked and values required as perspecification for each of the tests and the number of days required to


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complete all the tests at one stretch. The schedule shall also indicatethe venue of each of the tests.

6.1.3 The routine/acceptance/type tests to be carried out on the panels, aspart of above inspection, are given in para 6.2.0 below.

6.1.4

Prototype inspection shall be witnessed by RDSO as per the approvedtest plan. RDSO reserve the right to witness the complete or part ofthe tests at their discretion.

6.1.5

During the process of type testing or even later, the DG/EM/RDSO,Lucknow, reserves the right to conduct any additional test(s), besidesthose specified in the test plan herein, on any equipment/item so asto test the equipment/item to his satisfaction.

6.1.6 The tests shall be conducted on the prototype Panel at the works ofthe manufacturer or at any NABL/Government approved test houseor laboratory in the presence of authorized representative ofDG/EM/RDSO. Contractor shall submit the complete test reportconsisting of full details of the tests and test parameters.

6.1.7

On successful completion of the tests prototype approval certificateshall be issued.

6.1.8 Series manufacture shall start only after issue of prototype approval

by RDSO. Acceptance tests, as per the approved test plan, on thebalance quantity shall be done by the authorized representative of theIndian Railways as per purchase order.

6.1.9 Six copies of the following test certificates shall be submitted to thePurchaser for record:-6.1.9.1Type test certificate as issued by RDSO for the panels.6.1.9.2Acceptance test certificate for complete lot of the panels.6.1.9.3Routine test certificates for each panels.

6.1.10 Test certificates shall be completed with all the results. Purchasersapproval shall be obtained before dispatch of electrical panels.

6.1.11 Manufacturer shall advise the purchaser one month in advance whenthe panels shall be ready for inspection and tests, so that the lattersrepresentatives may be deputed to witness the test(s).

6.1.12 No material shall be shipped or dispatched until inspection and tests,upto the satisfaction of the purchaser, have been completed.

6.1.13Notwithstanding the successful completion of the tests as above, thecontractor shall be fully responsible for the satisfactory performanceof the panel as per the specification, without any prejudice to anyclaim, right or privilege of the purchaser arising out of use of defectivedesign, material or manufacturing by the contractor.

6.2.0 TESTS:

The test plan, including the sampling plan for various rating of panels, shall be gotapproved by RDSO before carrying out the test. Following tests shall be carried out

on the panel as a minimum:

S.No

General Test Conditions TypeTest

RoutineTest

AcceptanceTest

TestProcedureSub Clause (As per IEC60947-2 )

1 Performance Tests

1.1 Temperature-rise - - 8.3.2.5


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1.2 Tripping limits andcharacteristics

- - 8.3.3.1

1.3 Dielectric properties - - 8.3.3.2

1.4 Operational performancecapability

- 8.3.3.3

1.5 Overload performance (where

applicable)

- 8.3.3.4

1.6 Short-circuit breakingcapacities

- - 8.3.4 and8.3.5

1.8 Short-time withstand current(where applicable)

- - 8.3.6

1.9 Performance of integrallyfused circuit-breakers

- - 8.3.7

1.1 Mechanical operation 8.4.1

Tripping limits andcharacteristics

8.4.2

1.8 Dielectric properties - - 8.4.3

2 HV test on power & controlcircuits ( 2.0kV for oneminute )

3 Earth continuity test with alow voltage tester

4 Insulation test with 500Vmegger before & after H.V.test

5 Gasket test ( as per detailsgiven below

3

5.1 Shore 00 hardness for type 1

(Soft) enclosure 40 + 5

ASTM D2240-

975.2 Shore 00 hardness for type 2

(Hard) enclosure 55 + 5 ASTM D2240-97

5.3 Shore 00 hardness for type 3(Outdoor) enclosure 55 + 5

ASTM D2240-97

5.4 Shore 00 hardness for type S(Silicon) enclosure 55 + 5

ASTM D2240-97

5.5 Compression hardness

[N/mm] at 25% compression 0.02

0.01 /0.03 0.01

at 40% compression0.04 0.01 / 0.08 0.01 5.6 Min. tensile strength

(approximation)0.15- 0.2N/mm DIN 53504

5.7 Min. elongation at break75%

DIN EN ISO

1798

5.8 Max. water absorption 1-


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5%

5.9 Water penetration >2-4 h 5.10 Temperature resistance

30 minutes 180-300C

ASTM D2240-97

5.11 Max. change of Shore A(00

hardness +/- 20% DIN535045.12 Max. change of tensile strength+/- 20% after heat ageing

5.13 Heat ageing (168 hrs @ 100-200deg C)

DIN EN ISO1798

5.14 Compression set [%]

Measurement after 24h and50% compression, atcorresponding temperature

at T @ 70C = 10

at T @ -40C = 10DIN 53572AA-TL03-A 4

5.15 Confirmed continuoustemperature [C]

@ - 40 to 80C

6 Bus-Bar Support and MainBus-Bar Test ( as per detailsgiven below)

6.1 Temperature rise limits ace.chapter

Sub Clause (As per IEC60439-1 )

6.2 Dielectric properties ace.Chapter

8.2. 1

6.3 Short-circuit withstandstrength ace. chapter

8.2.2

6.4Effectiveness of protectivecircuit ace. chapter

8.2.3

6.5Clearances and creepagedistances ace. chapter

8.2.4

7 Paint Test ( as per detailsgiven below)

7.1

Flexibility(Mandrel bend) test5/8mm dia.

Din EN ISO1519/ IS13871

7.2Cupping test 4mm

Din EN ISO1520

7.3Adhesion test (Scratch hatch)

DIN EN ISO2409

7.4

Impact resistance TEX

(ASTM D2794-69)/ IS13871

7.5Impact resistance Glossy/SG

(ASTM D2794-69)


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7.6 Corrosion resistance

ASTM B-117,Annex C of IS2075,DIN50961

7.7 Thickness IS 13871

7.8 Tests on Primer IS 2075

6.2.2 Tests on Cable Entry Sealing System-6.2.2.1 Following shall constitute the type tests

1. Water Ingress Test2. Pull Test

1

Water Ingress Testi) OBJECTIVE: To determine the water tightness of the Cable Transit System

when subjected to spray of water.

ii) TEST EQUIPMENT: A holding arrangement / fixture of sufficient dimensionto house the Cable Transit System.

iii) INITIAL EXAMINATION: The Cable Transit System shall be assembled withall its components like modules, stay plates, wedge etc. and a continuouscable passing through its any module.

iv) CONDITIONING: The cable transit system in its assembled condition shall besecured at holding arrangement / fixture. The water shall be sprayed with apressure of 12.5 l/min and the distance between nozzle & test item shall be2.5m to 3.0 m. at a normal room temperature. This test shall meet therequirement as per IEC 60529.

v) DURATION: The test to be done for a 3 min in all direction.

vi) FINAL EXAMINATION: The Cable Transit System shall be examinedexternally for any abnormality. The Cable Transit System shall be visuallyexamined at other side of system for any ingress of water.

vii)ACCEPTANCE: The Cable Transit System will be declared to have passed thewater ingress test in case there is no water vapour presents other side of thetransit system.

2 Pull Testi) OBJECTIVE: To check the strength and holding of the cable by module

inside the Cable Transit System.

ii) TEST EQUIPMENT: A holding arrangement / fixture of sufficient dimensionto house the Cable Transit System.

iii) METHOD: The Cable Transit System should be assembled with a longlength of cable so that it can be pulled to the required force of 80N to checkthe strength of module inside the Transit System.


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iv) ACCEPTANCE: The cable transit system will be declared to have passed thepull test in case there is no movement of cables or modules.

6.2.2.2 Following test shall be done to carryout the acceptance of the product.

1) Visual Examination- The Cable Sealing System shall be examined

physically for the workmanship and the design technology employed. Itshall be checked for any flaws defects, cracks visible to naked eye

2) Manufacturers Identity & Dimensional Range- Cable Sealing System shall

be examined visually to check the manufacturers trademark. The locationof the trademark on the system shall be matched with the concerneddrawing of system. Each module shall be visually checked for the range ofdiameters of cables it can hold & shall be verified by printed dimensionalrange mention on each module.

3) Compression of System - The Cable Sealing System shall be examinedvisually to check the proper compression of modules. The rays of lightshall not be come through system/ modules.

4) System Configuration - The Cable Sealing System shall be examined

visually to check configuration of modules with frame/system.

Configuration shall be verified with concerned drawing and BOM ofsystem.

5) Dimensional Test - Each Module is printed with dimensional range

showing the minimum & maximum cable diameters it can hold. TheModule shall be verified by placing the cables falls under thatdimensional range.

6.3.0 OTHER REQUIREMENTS

Only after approval of the original drawings incorporating changes, if any, as aresult of the prototype tests and clear written approval of the results of the tests onthe prototype is communicated by the Purchaser/DG (EM), RDSO, Lucknow, to the

successful tenderer/manufacturer, shall he take up bulk manufacture of thepanels. In no circumstances shall materials other than those approved in thedesign/drawings and/or during the prototype testing be used for bulk manufactureon the plea that they had been obtained prior to the approval of the prototype.

7.0 DRAWINGS:

Drawing in triplicate incorporating the detailed dimensional cross-sectionaldrawing of the panels following particulars shall be submitted with the tender forthe purpose of preliminary study. After award of the contract the successful

tenderer shall be required to submit reproducible copies of final drawings for thepanels ordered.

8.0 IDENTIFICATION AND MARKING

One name plate giving description of the MCC shall be affixed prominently on thetop of the MCC. Details will be furnished latter. The nameplates for individualfeeders shall carry the general information as mentioned below.


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Feeder No.Equipment ref. no. & descriptionRatingFor spares feeder blank labels shall be provided.

9.0 WARRANTY:

The panels must be guaranteed for satisfactory operation for a period of 12 monthsfrom the date of commissioning.

10.0 INFRINGEMENT OF PATENT RIGHTS

Indian Railways shall not be responsible for infringement of patent rights arisingdue to similarity in design, manufacturing process, use of similar components inthe design & development of this item and any other factor not mentioned hereinwhich may cause such a dispute. The entire responsibility to settle any suchdisputes/matters lies with the manufacturer/ supplier.

11.0 SCHEDULE OF GUARANTEED PARAMETERS

The following information shall be given by the tenderer in addition to any otherrelevant data:-

S. No. Description Certificate Test

1 IP Tests Yes Yes

2 Surface preparation & treatment test Yes No

3 Short circuit test Yes No

4 Bus-bar rating Yes No

5 Factory Acceptance No Yes

6 Third Party Inspection Yes Yes

7 Main Bus-Bar and Bus-Bar Support Yes Yes

Documents

110509 FRS Electrical Panel Spec EOI(1)