TECHNICAL SPECIFICATIONS FOR POWER DISTRIBUTION BOARD (PDB)

Design, Manufacture, Supply, Erection, Testing and

commissioning of 160 A Low Voltage Power Distribution Board with suitable
switch gears & accessories as specified in the BOQ Drawings

ELIGIBILITY CRITERIA FOR VENDORS:-

1) ELIGIBILITY : Only CPRI approved vendors offers will be considered,

hence all the vendors are informed to attach the CPRI certificate along
with their offer without fail, else the offer will be rejected.
2) PROOF OF CAPABILITY for PDB; The party should have manufactured
and supplied atleast 10 Power distribution board of similar rating and
above in last 5 years. The party should enclose the copy of above
particulars along with the quotation without fail, else the offer will be
rejected.

3) CATALOGUES,DRAWINGS,CERTIFICATES AND MANUALS:

While quoting the party should attach detailed catalogues, drawings of
PDB which they are quoting, certificates and manuals so that it is
possible to evaluate their offers.
Offered panel without Drawings of PDB will be out rightly rejected .
4) GURANTEE: The party should give a guarantee of eighteen months
from the date of dispatch or 12 months from the date of
commissioning of the panel at site.
5) The vendor shall have Design team for furnishing detailed design data &
drawing for calculation of Bus bar size , fault level etc & they shall
have in house facilities for testing of PDB before dispatch.
6) The bidder shall have rich experience in panel manufacturer satisfying
the following.
a) CPRI approval in appropriate class.
b) Shall have design team for furnishing detailed design drawing of
PDB with design data.
c) Shall have in house facilities for testing of PDB before dispatch.
7) If required, the vendor may visit site & acquaint himself of the site
conditions before submitting the offer.

Major Activities involved are as follows viz.,

1) Submission of detailed Design data & drawing of PDB unit for

approval.
2) Fabrication of the PDB unit after obtaining Department approval. PDB
vendor shall be CPRI approved in appropriate class of PDB.
3) Pre-dispatch Inspection of PDB at vendor premises.
4) Providing Scaffolding facilitating to work at heights in areas which
does not have permanent platform.
5) Assembly & Erection of PDB unit at site.
6) Testing & Commissioning of the PDB unit
7) Performance demonstration of the PDB unit for functional capability
and acceptance.

1) POWER DISTRIBUTION BOARD

1. SCOPE

Design, Manufacture, & Supply of 160A , 415 V 3 phase , Neutral Low

Voltage Power Distribution Board along with switchgears as specified in
the BOQ/Drawings .

2. CODES AND STANDARDS

The design, material, manufacture, inspection, testing and performance of low
voltage Power Distribution Board and cable shall comply with all currently
applicable statutes, regulations and safety codes in the locality where the
equipment will be installed. The equipment shall also conform to relevant
applicable IS.
 IS: 13947 Low voltage switchgear and control gear
IS: 722 Specification for AC Electricity meters
IS: 1248 Direct acting Electrical Indicating Analogue Electrical
Measuring Instruments and their accessories.
IS: 2705 Current Transformers
IS: 3156 Voltage Transformers
IS: 3231 Electrical relays for power systems protection
IS: 3043: Code of practice for earthing
IS: 5082 Wrought Aluminium and Aluminium Alloy bars, rods, tubes
and sections for electrical purposes.
IS: 7098, part-2 for XLPE, FRLS cable
IS: 5578 Guide for marking of insulated conductor
IS: 8623 Low voltage switchgear and control gear assemblies
IS: 11353 Guide for uniform system marking and identification
conductors and apparatus terminals
IS: 375 Marking and arrangement for switchgear bus bars, main
conductor and auxiliary wiring.
IS: 3072: Code of practice for installation and maintenance of Switchgear
IS: 1897 Copper strips for electrical purposes.
IS: 2147 Degrees of protection provided by enclosures for low voltage
switchgear and control gear.
IS 2516 AC circuit breaker requirements-voltages not exceeding 1000V
IS 4237 General requirements for switchgear and control gear for
voltages not exceeding 1000V AC.
IS 6875 Control switches for voltages up to and including 1000V AC
and 110V DC.
IS 10118 Code of practice for selection, installation and maintenance of
switchgear and control gear.
IS 12021 Control transformers for switchgear and control gear for
voltages not exceeding 1000V AC.

3. General Requirement of Panel:

a. The low voltage Power Distribution Board (PDB) shall be metal clad,
enclosed CRCA sheet steel cubicles and compartmentalized,
modular/fixed type, single front, floor mounted.
b. The Panel should be suitable for three Phase Neutral 415V AC and
control supply of 230Volts AC, 50 Hz.
c. LT switchboard shall be dust and vermin proof and provided with a
degree of protection not less than IP-42. The switchboard shall be
 assembled out of vertical sections of uniform height not exceeding
2190mm.
d. The LV Switchboard shall be designed to fulfil the following design
parameters:
i. Rated Voltage – 415 V
ii. Rated Frequency – 50 Hz
iii. Rated insulation level :
a. For power circuit – 2.5KV for 1 minute
b. For control circuit – 1.5 KV for 1 Minute
iv. Rated cont. current rating of main bus bar 160 A.
v. Fault level - 50 KA for 1sec.
e. The PDB shall be provided with suitable louvers
f. Incoming feeder is of SFU type, and outgoing feeders are of suitable
soft starter and Accessories.
g. The main I/ C supply shall be fed through cable only and suitable for
termination of terminating Aluminium XLPE Armoured Power cable of
size 3.5 C *95 Sqmm. No bus duct shall be used.
h. It should contain copper bus bar.
i. Individual feeder panel should be suitable for operation from front
side. Thickness of sheet steel shall be as follows:
i. Load bearing member – 3 mm
ii. Covers & partition – 2 mm
iii. Gland plate – 3 mm
j. The design and construction of each panel shall be such as to allow
extension at either end.
k. Cubicles should have individual front doors with sturdy hinges and
fitted with special non-deteriorating neoprene gasket. Similar gaskets
should be provided between all joints as required. Lifting lugs should
be provided on the top of panel.
l. If louvers are provided, they shall be backed up by fine wire mesh.
m. Each section of panel and feeder compartment shall be constructed,
such that failure of one equipment does not affect the adjacent units.
Between bus compartment and breaker compartment & breaker
compartment and cable compartment, non-perforated flame
retardant partitions shall be provided.
n. Suitable GI strip should be provided on the backside of the panel
with adequate holes with nuts, bolts and washers for making earth
connections for all panels and cables. Length of GI strip should be
same as panel length. Zinc plated and passivated double earthing
 studs with nuts, bolts and washers should be provided on the
earthing strips.
o. Danger plates (415 V AC) should be fixed on both front and rear of
panel including the bus-bar chambers.
p. Safety features: Caution name plate with inscription “Caution-Live
Terminals” shall be provided at all points where the terminals are
likely to remain live and isolation is possible only at remote end.
q. The panel should be suitable for ambient temp. of 45 degree and
relative humidity 95%. Panel should be of IP-42 protection.
r. Height of indicating instrument shall not be less than 300 mm or
shall not be higher than 2000 mm.
s. Relays, meters and control switches shall be located at height which
shall be convenient for monitoring and operating. Relays shall be
selected to ensure proper coordination with upstream relays.
t. Shrouding shall be done in the front and top of the terminal of each
feeder.
u. Bolted doors to cover front and back of Bus-bar alley shall also be
provided. Bus-bar alley shall be covered with screwed perforated sheet
to avoid direct access to the vertical bus bars on opening of the
busbar alley door. Doors of bus bar alley shall be fitted to board frame
with special screw / bolts such that same can be opened with special
key only. Vertical cable alley covering the entire height with hinged
door shall be provided.
v. All opening covers and doors shall be provided with neoprene
gaskets
w. Lifting lugs shall be provided on the top of all shipping sections.
x. Continuous current rating of various switchgear components/
busbars is in panel rating at full load condition for design ambient
temperature and site conditions. All hardware shall be zinc-passivated
or cadmium plated.
y. All hinged doors should be earthed with copper flexible loops / braids
as per IS-3043.
z. All the hardware should be of high tensile steel duly zinc passivated
for corrosion protection & fitted with proper sized heavy duty spring
washer & two nos. heavy duty flat washers.
4. Incoming & Outgoing Cable :

The Power cable for incoming & outgoing feeders shall be taken care
by the Department .

5. Detailed Description of Panel

a. INCOMER:
i. There will be 1(one) incomer , with 3 pole, 160A, 415V +/-10%,
SFU .
ii. All incoming and outgoing terminals of SFU should be fitted
with suitable links or brought out phase & neutral links of
aluminum in rectangular sections with hole. Zinc passivated
nut bolts with flat and spring washers for connection should be
provided for cable termination. The Neutral link rating should
be 100% of the phase bar rating. The Incomer should be
suitable for terminating Aluminium XLPE Armoured Power
cable of size 3.5 C *95 Sqmm .
b. Outgoing Feeders:
All outgoing feeder should be provided with SFU , followed by three
pole power contactors of AC3 class of duty with 240volts coil supply, Soft
starter , MPR of suitable rating of load as indicated in the SLD and a
bypass power contactor to by pass Soft starter during normal running of
the motor.
The outgoing feeder cable of suitable rating of single core multi-strand
cable has to be connected from contactors to terminal connector located
in cable chambers.
Disconnect Fuse Switches:
a) All switches or fuse switches shall be air break type provided
with quick make/break manual operating mechanism, the operating
handle shall be mounted on the door of the compartment having the
switch.
a) Rating of switches shall meet the requirements of AC-23 duty
as per IS-13947 and minimum rating shall be as specified in
SLD/data sheet.
Contactors:

a) The contactors shall be air break type, equipped with three main
contacts and required numbers of NO & NC auxiliary contacts, the
main contacts of particular contactor shall have AC-3 or AC-4 ratings
as specified in data sheet.
 b) Unless otherwise specified, the coils of the contactor shall be suitable
for operation on 240volts, single phase AC supply and shall work
satisfactorily between 65 to 110% of the rated value.

c. Metering/ Instrumentation for the Incomer:

All measuring instrument shall be of 96x96mm of 72x72mm square
pattern, flush mounting type for incomer and outgoing feeders.
All AC meters shall be of moving iron type with accuracy class of 1.5 as
pe IS-1248.
Selector switches shall have “make before break” feature on its contacts,
the selector switch shall generally have 4 positions for reading 3phase
currents and fourth position for OFF. The voltmeter selector switch shall
also have 4 positions. Three positions shall be used to measure phase-to
phase voltage and fourth shall be off.
• 01 No. of Digital Energy Meter of class-1, with RS 485 port.
• 01 No of Analog Voltmer (0-500V AC) with selector switch.
• 01 No of Analog Ammeter (0-250A) with selector switch of range.
Make- AE/RISHAB.
• CTs for metering & protection as per feeder capacity.
Make: KAPPA/Jyothi
• Control indication LED lamps for ON/OFF/TRIP indication.

• LED indication lamps for indication of ‘Supply ON’ (for R/Y/B phases),
‘ CB Off/CB On/Trip-OC/Trip-SC/Trip-EF As required.

d. Bus Bars
i. The main Bus bars shall be of high conductivity copper of uniform
cross–section throughout their length. The standard busbars and
supporting arrangement shall be designed and tested to withstand
a short circuit fault level of 50 kA for 1 second.
ii. The Busbars should consist of 1 set of hard drawn, high
conductivity, TPN (neutral equally rated to phase bars),
iii. The maximum operating temperature of busbars including joints,
at design ambient temperature shall not exceed 75ºC for normal
operating condition & 100ºC for short circuit condition.
iv. The bus bars shall be rigidly supported at equal intervals to
withstand the stresses due to full short circuit and also to take
care of thermal expansion.
 v. Only high tensile electro galvanized cadmium plated bolts, nuts
and washers shall be used. The washers shall be spring and plain
type. Both vertical and horizontal busbars shall be capable of
withstanding dynamic & thermal stresses of specified short circuit
currents for 1 sec.
vi. Bus chamber should be steel clad having front and rear bolted
covers.
vii. The Bus bar supported at sufficient intervals on non-hygroscopic,
non-inflammable SMC supports.
viii. All busbars shall be encased throughout with colour coded
insulated sleeving of 1100V grade and joints shall be fitted with
insulated shrouds. Red, yellow & blue colour shall be used for
phase busbars and black colour shall be used for neutral busbars.
Main busbars should be of full length as that of the panel.
ix. Vertical bus bars for feeding individual feeder should be full height
of the panel. Sufficient clearance should be maintained in the bus
chamber for proper cooling of the busbar. Busbar should be
extensible type to facilitate future extensions.
x. Removable links shall be provided on feeders to permit isolation of
the neutral bus bar.
xi. A separate GI horizontal earth bar of adequate cross section shall
be provided all along the length of the switchboard with necessary
terminating arrangement for connecting external earth conductor.
The earth bus shall be rated for faults withstand capacity of 50KA
for 1 sec having dimension 40mm × 6mm.
e. Panel wiring:
i. The entire control wiring is done with high grade bright copper
annealed multi strand PVC, FRLS flexible heat resistant
switchboard wires of minimum size 1.5 mm² Grey wire for control
circuits and 2.5 mm² for CT circuits, all doors are earthed with the
help of 1.5 sq.mm yellow green wire. Electronic Card signal wiring
is done with 1 sq.mm Shielded wire preferably be enclosed in
plastic channels or neatly bunched together. The wiring shall with
proper lugs. All wires and cable should have proper ferrule
numbers for easy identification.
ii. All wire termination except for Elmex type terminal blocks shall be
made with ring/fork tongue compression type connectors. Wires
 shall not be tapped in between terminal points. Type of lug shall
suit relevant application.
iii. The terminal block shall be grouped and segregated according to
circuit functions and different voltage levels, and shall have 20%
spare terminals. Individual terminals in each block in each group
shall be serially numbered in accordance with the drawings. Such
numbering shall be legible, permanent and indelible. Terminal
block for CTs shall be provided with drop out facility for testing
purposes for shorting and shall be segregated from other
terminals. Sufficient clear space shall be provided between gland
plate and terminal blocks.
iv. Inside the cubicles, the wiring for control, signalling, protection
and instrument circuits shall be done with BIS approved , PVC
insulated, flame retardant type, copper conductor multistrand wire
to be used.
v. The insulation grade shall be 650volts. The wiring shall be
enclosed in plastic channels or neatly bunched together.
f. Instrument Transformer:
a) Current Transformer shall generally confirm to IS-2705,
b) Current transformer for instrument shall have an accuracy class
1.0 and accuracy limit factor less than 5.0.
c) For all outgoing and incomer feeder, suitable rating of CT as
indicated in BOM with resin cast wound to be provided for
measuring the feeder current through analogue meter and for
connection to current transducer for all outgoing feeders.
g. Control Transformer:
For feeding control supply to the auxiliary systems and contactors
coils, control transformers with resin cast wound type to be
provided as indicated in the BOM. Control transformer shall be
provided with HRC fuses on primary side and miniature circuit
breakers with auxiliary contact on the secondary side.
h. Earthing:
1. All cubicles shall be connected to an earth bus bar running
throughout the length of the switchboard. The earth bus bar size
shall be minimum 50x6 mm² GI. Provision shall be made to
connect the same to the plant earthing grid at two ends.
2. Vertical earth bus shall be provided for earthing of all feeders.
 3. All doors and movable parts shall be connected to the earth bus
with flexible copper connections.
4. All non-current carrying metallic parts of the equipment and
components shall be earthed.
5. The main Earth bar available in cable duct in OPF sub-station to
be connected in the PDB panel by running earth bus along the
cable tray with suitable welding. Further running earth bus along
the cable tray up to the Electrical Plate Drier.
i. Painting:
LT switchboards shall be painted and the finishing shade shall be
light grey having shade No. 631 as per IS: 5.
All unpainted steel parts shall be cadmium plated or suitably
treated to prevent rust formation. If these parts are moving
elements, then they shall be greased.

6. INSPECTION, TESTING AND ACCEPTANCE

i. Only CPRI approved vendors offers will be considered, hence all
the vendors are informed to attach the CPRI certificate along with
their offer without fail, else the offer will be rejected.
ii. During fabrication, switchgear shall be subjected to inspection by
Department authorised representative to assess the progress work,
as well as to ascertain that only quality raw material used,
iii. All routine and acceptance tests shall be carried out at
manufacturer`s under his care and expense.
iv. Short circuit test shall be performed at CPRI or equivalent
approved testing agency and heat run test may be performed at
manufacturer`s work. Heat run test shall be performed at least
one outgoing feeder.
v. The successful bidder has to submit the QAP for the approval of
the purchaser before start-up the manufacturing process.
vi. Tests shall be carried out at the manufacturer’s works before
dispatch. All routine tests as specified by the applicable codes and
standards shall be conducted. Type test certificates for the
switchgear panel and circuit breakers shall be furnished during
detailed engineering.
vii. Acceptance tests shall be as follows

i. A general visual check shall be carried out. This shall cover

measurement of overall dimensions, verification of BOM,
 location, number and type of devices, terminal boxes,
location and connection of terminals etc.
ii. Manual and electrical operation of Circuit breakers / Relays
shall be checked under worst conditions of auxiliary supply
voltage.
iii. Dry insulation test with power frequency voltage shall be
conducted for the main and auxiliary circuits.
iv. Insulation resistance of the main and auxiliary circuits
shall be checked before and after the high voltage withstand
test.
v. Operation check shall be carried for every control function
as per the schematic diagram by manually simulating fault
condition and operation of control switches, relays etc.
vi. For equipment bought from other sub-suppliers, certified
test reports of tests carried out at the manufacturer’s works
shall be submitted to the Engineer in-charge.
Erection and commissioning:

1. The vendor shall have to supply detailed design and dimension drawing for
foundation/Erection of the PDB. Necessary site data as required will be
provided by the purchaser if required.
2. Construction of minor foundation and other civil engineering work as per
design drawing shall be carried out by the vendor
3. The vendor shall indicate in the erection drawing the requirement of power
and various services facilities like water any special requirement, the same
will be provided by the purchaser.
4. The scope of vendor includes unloading, alignment and positioning of the
PDB in the place provided by the purchaser
5. Erection work will be carried out by the vendor, necessary manpower and all
the tools etc are to be brought by the vendor on returnable basis duly
making entry in the main gate.
6. Engineers of the vendor engaged in erection, commissioning work may
make their own lodging arrangement.
7. Vendor shall follow IE rule/other safety guidelines by department, apprise
themselves of it and shall not jeopardize theirs and other`s safety while
working.
 DATA SHEET
Bidder’s
Sl. No. Particulars of equipment Units Purchaser’s requirement Response /
compliance

GENERAL DATA

1. Equipment description Vacuum Distillation furnace

Roots pump & mechanical pump
motor PDB

2. Supply Voltage V 415V ± 10%

3. System Frequency Hz 50

4. System Neutral grounding Solidly ground

5. No. of Phase 3 phase 4 wire

6. Individual feeder details As indicated in the tender

specification

7. Location Indoor

8. Painting Shade No. 631 as per IS 5,

RATING

9. Rated operational voltage V 415

10. Rated impulse withstand voltage KV 2.5

11. Main Circuit V 415

12. Auxiliary Circuit V 230

13. One minute Power frequency KV 2.5 KV / min for Power Circuit and
withstand voltage 1.5 KV / min for control circuit.

14. Rated short time current withstand KA 50

capacity for 1 sec.

CONSTRUCTION

15. Type Floor mounted, Metal Clad, Draw

out Type

16. Degree of protection IP 42

17. Material of Construction CRCA SHEET STEEL

18. Front Single front

19. Cable entry Top

20. Thickness of sheet steel

A Frame/Door/Covers Min 2mm

B Gland Plates Min 3mm

C Load bearing member Min 3mm

21. Dimension of the panel VTS

BUS BAR

22. Bus bar material Copper

23. Grade Electrolytic grade

24. Bus bar to be sleeved Yes, R-Y-B colour coded heat

shrinkable ,PVC sleeves

25. Shrouding of Bus bar joints Yes

26. Materials of shrouds FRP

27. Insulators SMC

28. Earth bus copper

A Short Circuit withstand capacity for 1 50kA

sec.

29. Materials GI (Hot dipped )

30. Panel space heater Not Required

31. Control supply 230 V AC

32. Control transformer Class H, Dry type, Air cooled,

vacuum impregnated

33. I/C SFU , 160 Amps

34. No. of I/C One

35. Indication and meter required on I/C Yes

36. O/G Feeders Four with suitable rating of Soft

starters with all accessories

37. SFU

A Make L&T/SIEMENS

B No of poles 03 Poles (Incoming)

C Incoming power entry Through 3 ½ C, 95.mm, Top cable

 entry.

D Rating for one second 50 KA

38. CT

A construction Cast resin wound

B Accuracy class For metering 1.0, for protection

5P,

39. MPR with inbuilt protection

A Type MPR 300 of L& T make

B Details of protection O/l ,Locked rotor ,NPS,E/f ,Under

current

40. Metering All O/G and I/C feeders as

drawing.

41. Indication lamp LED

42. Deviation If any VTS

VTS: vendor to specify