Technical Specifications

Section A: Scope of Work

1.0 SCOPE OF WORK

1.1 General
The works provided for by this Specification and drawings, required to be carried out by the
Contractor comprises the supply, delivery to site, installation, testing, commissioning and
maintenance thereafter of the Mechanical & Electrical Services for the following:
PROPOSED CONSTRUCTION OF TREATED WATER PUMP HOUSE AND PUMPING MAIN
FROM SUNGAI SELANGOR PHASE 1 (SSP 1) WTP TO BUKIT MAYONG BALANCING
RESERVOIR:
PACKAGE 1 – CONSTRUCTION OF NEW PUMP HOUSE AND OTHER RELATED WORKS

The systems shall be complete and functional in all respects and shall comply with the relevant
statutory requirements and include all items necessary for efficient operation.
The Contractor shall include all permit and inspection fees payable to all Authorities, overtime
payments and all other charges and costs necessary to complete the works within the submitted
construction program and obtain all necessary authority approval.

1.2 Extent of Works

The contractor shall supply all labour, materials, equipment and services for the complete
installation, setting to work, testing perfect operation of the complete Mechanical & Electrical
Services. The extent of works shall include, but not necessarily be limited to the following:

PUMP HOUSE

a) Main Pumps System

i) Vertical split casing constant speed pumps and associated pipeworks within pump
house only including valves, fittings and other necessary accessories.
ii) Pump control panel and cabling works including actuator, Motor Protection Relay
and all other necessary accessories.
iii) Telemetry and instrument panel c/w monitoring system of pump operation complete
with field devices, cabling works, 3G/4G uplink and other necessary accessories.
iv) Submersible drainage pumps c/w starter panel and cabling works and associated
pipe works within pump house and valve chambers.
v) Pump house pipe works, valves, fittings and other necessary accessories.
vi) The contractor shall make the necessary arrangements for the Client and
Consultant to witness factory acceptance test for the main pumps and motor control
centre. The Contractor shall allow up to 6 persons (not including contractor) all the
expenses incurred inclusive of transportation, accommodation and other necessary
arrangements for the witnessing of the factory acceptance test should the test
require prolong staying or be conducted overseas.

b) Overhead Crane
i) Electric overhead crane (capacity: 18 tons) complete with all machinery and
equipment necessary for the satisfactory operation of the system.

ii) Monorail crane with manual chain hoist and complete necessary accessories.

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 Technical Specifications
Section A: Scope of Work

iii) Electrical works consists of starter panel, power and signal cables.

iv) Supply and installation of brackets, support, saddles etc. which are required to
support girder and rails.

v) Testing and commissioning including JKK testing & issuance of PMA certification.

vi) Provision test load for JKKP testing

vii) 24 months comprehensive maintenance and attendance during the defects and
liability period.

c) Mechanical Ventilation
Ventilation system for pump house complete with exhaust fan system, fresh air fan
system, ductwork, starter panels, power & control wiring and other necessary accessories.

d) Fire Protection

Clean Gas System

i) Clean gas cylinders complete with fittings and charged with the relevant agent.

ii) Smoke/heat detectors

iii) Pipework, pipe fittings, valves, nozzle and hangers

iv) Fire curtain, evacuate lights, manual key switch

v) Control panel, power and signal cabling.

Fire Extinguishers

ABC/9kg and C02/kg portable fire extinguishers.

e) Air Conditioning & Mechanical Ventilation

Air Cooled DX Systems

Air cooled split DX systems complete with indoor unit, condenser unit, local starters,
switches, power and control wiring, wired remote control, timer, drain pipes, refrigerant
piping system complete with insulation, hangers, brackets and other necessary
accessories

Mechanical Ventilation System

Exhaust fan to pump room, HT room and consumer switchgear room complete with
ductwork, starter panel, power and control wiring.

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 Technical Specifications
Section A: Scope of Work

f) Cold Water Plumbing

Cold water distribution pipe tap from existing main water pipe termination point inside plant
to the fittings including excavation, brackets, valves and other necessary accessories.

g) Other Works
i) Preparation of shop drawings, as-built drawings, operation manual, and all other
related documents.
ii) Liaising with the related authorities to arrange for the inspection of the works, water
meter installation, etc.
iii) Making good, patching of holes and openings, and furring of incidental directly
undertaken by this contractor.
iv) Testing, providing services for testing and commissioning of all equipment and
services, including joint testing with all other subcontractors in stages as necessary
for Authority inspection and approvals.
v) 24 months comprehensive maintenance and attendance during the defects liability
period.
vi) Operation training of plant for 2 weeks to be provided for the client.

END OF SECTION

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 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

1.0 Treated Water Pump Details

Treated water pumps shall be of constant speed, vertical split casing type, single stage,
double entry volute centrifugal pumps. The speed of the rotation shall not exceed 1000
rpm for the treated water pumps. The pump vibration and noises shall be tested to the
requirement of JIS B 8301 and the running shall be smooth and free from excessive
vibration and extraordinary noises in any part. The total amplitude of vibrations during
testing at the manufacturer’s works shall not exceed the maximum values in accordance
with JIS B 8301 Part 9.4.

The pumps shall be installed at floor level of the pumping station with motors directly
coupled.

The design of the pumps and shafting and the associated pipework and valve, and the
selection of materials for construction shall be carefully carried out to obviate the effects
of the electrolytic action and corrosion action with due consideration to the water
analyses shown in Specification.

a) Pump casing

Pump casings shall be manufactured from close gained cast iron in accordance
with BS 1452 Grade 250 or better. The Tenderer may propose alternatives such
as the materials that are of greater tensile strength and more ductile than cast
iron or Meehanite such as spheroidal graphite cast iron in accordance with BS
2789 Grade 420/12.

The pump shall be of the double volute type and designed to produce a smooth
flow with gradual changes in velocity. The casing shall be split axially with the
suction and discharge nozzles and casing feet cast in the one casing half. The
interior of the pumps shall be easily inspected by removing the other half of the
casing without disturbing the pipe connections or pump alignment.

The flanges between the halves shall be machined on face and edge, and sealed
by a pre-cut gasket of approved materials. The two halves of the casing shall be
accurately located by the use of straight dowel pins to eliminate mismatch
between the two halves which would impair both hydraulic and mechanical
performance.

Each pump casing shall be fitted with a drainage cock at its lowest point and air
vent with cock at its highest point.

b) Pump shafts

Pump shafts shall be manufactured from stainless steel Type JIS SUS 316 or
better and shall be adequately sized and designed to minimize deflection.
Deflector plates of stainless-steel material shall be welded to each pump shaft
to prevent water seepage to the bearing housings. All wearing and immersed
surfaces shall be protected with renewable bronze sleeves.

c) Bearings

Pump bearings shall be designed for a minimum service life of 40,000 hours.
Bearings shall be of heavy duty of single or double row anti-friction type,
designed to withstand any thrust and axial loads.

The bearing at the coupling end shall be of the self aligning ball type while the
bearing at the opposite end shall be of the double thrust ball type to withstand
any thrust imposed on the bearing.

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 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

Bearings shall be grease lubricated type with readily accessible grease supply
and grease relief fittings.

Removable bearing housings shall be bolted and dowelled to bearing brackets

that are cast integrally with the pump half casing.

Bearing shall be of water-resistant type (with grease of water-resistant grade),

complete with the necessary bearing covers and compound rubber seals around
the pump shafts to eliminate water seepage to the bearings.

d) Wearing rings

The casing shall be fitted with removable bronze wearing rings designed to
provide a smooth flow of water into the impeller eye. The casing ring shall be
provided with a positive means of preventing rotation. The impeller shall also be
fitted with removable bronze wearing rings and held in place by set screws.

e) Water lubrication system

The Contractor shall supply and install a water lubrication system designed to
cool and flush the mechanical seals as specified in the Specification.

f) Impellers

Impellers shall be of double suction enclosed type, manufactured from stainless

steel Type JIS SCS14. Impellers shall be of smooth finish without any coating
and shall be statically and dynamically balanced on the spindle after assembly
and keyed to the shaft.

g) Motor coupling

The pump shall be directly couple to its driver by means of form flex coupling
type. The coupling and shaft shall be enclosed with an approved metal guard.

h) Pressure gauges

Both suction and delivery branches of the pump shall be fitted with pressure
gauges. Precautions shall be taken to ensure that the gauges cannot be
overstressed.

i) Motor Pedestal

Motor pedestal for the pump and the driving motor shall be of substantial cast
iron or stress-relieved fabricated steel and shall be supplied together by pump
manufacturer. They shall have machined landing for accurate alignment of
packings under the motor for maintaining alignment. The pedestal shall be
properly design to cater the load of motor

j) Pump and Motor Protection

Pump and motor shall be install and protect by Bearing RTD PT100 for both DE
and NDE.
Pump and Motor DE shall be installed with Vibration sensor to protect the
pumpset.

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 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

2.0 Water Lubrication System

2.1 General

The Contractor shall design, supply, install, test and commission the water lubrication
system for the treated water pumps. The system shall flush and cool the mechanical
seals at the pump stuffing boxes.

2.2 Water lubrication system for treated water pumps

The Contractor shall design, supply, install, test and commission a bypass line from the
pump discharge casing to the pump mechanical seals. The bypass line shall be of
stainless-steel tube, complete with stainless steel pipe sockets and connectors and shall
not be less than 25 mm in diameter. A sight glass shall be provided at each bypass line
for monitoring purpose.

3.0 Motors

3.1 Electric motor – general

All electric motors shall comply with the requirements of BS 4999 and BS 5000.

Constant speed AC motors shall be of the induction type suitable for operation on a 3-
phase supply and shall be capable of operating continuously, at rated torque, at any
voltage between +5 and –10 percent of the nominal valve, and nominal frequency +2
and –2 Hertz.

The maximum motor speed shall be 1500 rpm. All AC motors rated 0.18kW and above
shall be of the three-phase type.

Motors up to 2.2kW shall be of the squirrel cage rotor type suitable for direct-on-line
starting having a starting current not greater than 6 times the full load current.

Motors above 2.2kW and up to 75kW shall be of the squirrel cage type suitable for closed
transition auto-transformer type starting with the starting current limited to 250% of the
full load current.

Non-submersible motors above 75kW shall be of the slip ring wound rotor type suitable
for rotor resistance type starting with starting current limited to 150% of the full load
current.

Submersible motors above 75kW shall be of the squirrel cage type suitable for closed
transition autotransformer starting with the starting current limited to 250% of the full load
current.

Motors shall be designed for S1 duty to BS 4999.

All motors shall be capable of running continuously at a brake horsepower not less than
10% in excess of that absorbed by the driven equipment under any operating conditions.
The reserve power requirements shall be added to the calculated power prior to any
other adjustments e.g. high ambient temperature at Site. In addition, all motors shall be
suitable for 15 starts per hour for 415 volt rated motors.

The motors shall be commercially silent in operation and the overall A-weighted sound
pressure level shall not exceed 83 dBA at 1 metre. In addition, the motors shall run free
from vibration and their rotors shall be perfectly balanced both statically and dynamically
in an approved manner. The motor bearing vibration severity shall not exceed 20 microns
peak to peak when measured in the direction of the three mutually perpendicular axis at

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 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

the bearings and mounting points of the motor. Motors shall be balanced with the full key
in the keyways.

A proven track record shall be submitted with the Tender to demonstrate the motor
manufacturer’s past experience in the design and manufacture of high voltage motors of
comparable size and type required under the Contract.

3.2 Enclosures and methods of cooling

The enclosures of submersible pump motors shall afford a mechanical protection not
less than IP 68.

Enclosures for all motors shall afford a mechanical protection not less than IP 54 for
those installed indoor and IP 55 for those installed outdoor and in chemical or chlorine
plant areas. The method of cooling for these motors shall be to classification IC 411
(totally enclosed fan ventilated, plain or ribbed frame). The flow of cooling air shall be in
the direction of the driven equipment.

The maximum temperature of the motor casing, normally accessible by hand shall not
be more than 80ºC at an ambient temperature of 40ºC.

Thermoplastic fans and fan covers shall not be employed. All fans and fan covers shall
be made of metal and treated with a corrosion resistant coating.

Motors fitted with unidirectional fans shall be provided with an arrow permanently
indicating the direction of rotation. Indication by means of a painted or adhesive arrow is
not acceptable.

Totally enclosed motors shall be provided with suitable means of breathing and drainage
to prevent accumulation of condensation.

All motors shall be given corrosion resistant paint finishes and shall have corrosion
resistant parts.

All motor frames and bearing end shields shall be constructed of ferrous metals. Motor
frames made of aluminium alloy will not be accepted. Frame sizes shall be in accordance
with IEC 72 and IEC 72A.

3.3 Windings

Windings shall be made of copper and impregnated to render then non-hygroscopic and
oil resistant and shall be braced to prevent any movement of the coils during all
conditions of service.

All windings shall be adequately supported, braced and blocked to provide sufficient
rigidity and to limit end-winding vibration and subsequent cracking of the winding
insulation at the slot exists. Winding shall be capable of withstanding the dynamic forces
which result from system fault conditions.

Motors will be operating in an ambient temperature in the order of 40ºC. Motor insulation
shall be to BS 2757 Class F, with the temperature rise (by resistance method) limited to
80K, for both stator and rotor windings.

3.4 Bearings

Bearings shall be plain or rolling type as appropriate. Vertical shafts shall have approved
guide and thrust bearings incorporated in the motor body to carry the weight of the motor.

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 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

Bearings shall have a C3 internal radial clearance. The bearing temperature rise,
measured near the outer ring of the bearing shall never exceed 50K and the temperature
of the outer ring of the bearing shall never exceed 90K.

Bearings shall be designed to exclude the ingress of dust and water and sealed to
prevent leakage of lubricant along the shaft.

Motors up to 2.2kW and submersible motors of all ratings shall have sealed bearing
housing without lubrication nipples. The grease which shall be supplied by the
manufacturers shall be sufficient for at least 30,000 hours of continuous operation.

Each motor above 2.2kW shall have readily accessible lubricating valves which shall
enable the correct amount of lubrication (without over lubricating) when regressing whilst
the motor is running. The interval between lubrication and the requisite quantity and type
of grease shall be given on the lubrication plate which shall be mounted adjacent to the
motor name plate.

Excess and old grease shall be forced out through an opening in the outer bearing case.
Any surplus grease shall be ejected out of the motor casing to a separate container.
Spent grease retaining systems will not be accepted. The lubrication nipple shall be of
the conical type. Where necessary for accessibility, nipples shall be remotely mounted
at a point as close to lubrication point as practical and connected thereto by means of
double-walled copper brazed steel tubing. For large motors forced lubrication may be
provided as an alternative and details of the system shall be submitted with the Tender.
A flow indicator and/or pressure switch shall be provided on forced lubricating systems
to indicate failure of the system.

For submersible pump motors exceeding 37kW rating and non-submersible motors
exceeding 75kW rating, bearing temperature monitoring system employing RTDs shall
be provided. RTD sensors shall be suitable for connection of 3 wire instrument cables.
Dial type analogue indicators with trip and alarm contacts shall be provided for each
bearing on the respective starter panel.

3.5 Winding temperature detectors

Each 415-volt motor rated above 2.2kW shall be fitted with three PTC type thermistors
(one number per phase) and all the leads of these three thermistors shall be terminated
inside a separate terminal box with IP 55 degree of protection, where the thermistors
shall be connected in series. For 415-volt motors rated above 75kW, six PTC type
thermistors (2 numbers per phase) shall be provided.

Individual thermistor resistance shall be approximately 1000 ohms at the tripping

temperature appropriate to the insulation class of the motor. The control unit of the
thermistors complete with alarm and trip contacts shall be mounted in the respective
starter panel.

Motors with thermistors shall be fitted with a non-corrodible metal thermistor data plate
which shall include the following information:-

i. Thermistor manufacturer
ii. Type number
iii. Tripping temperature (ºC)
iv. Resistance of each thermistor at the tripping temperature
v. Number of thermistors embedded per winding

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 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

In addition to the above a stainless-steel warning plate with the inscription “WARNING”!
THERMISTORS INSTALLED. DO NOT MEGGER” shall be installed in a prominent
position on the thermistor terminal box.

3.6 Anti-condensation heaters

Anti-condensation space heaters shall be provided on all motors above 2.2kW unless
otherwise specified. The heaters shall be suitable for use on a single phase a.c. supply
and wired to a separate terminal box. A prominent warning label with the inscription
‘WARNING – CIRCUIT MAY BE LIVE’ shall be installed. Each heater shall be provided
with a switch in the respective starter and automatic control to disconnect it when its
motor is in operation. Each heater shall be sufficiently rated to maintain the temperature
above dew point when the motor is stationary.

3.7 Brushgear

The rotor current shall not exceed 600 Ampere.

On slip-ring and commutator motors, the brushgear shall be designed to operate without
injurious sparking, with the minimum need for adjustment or replacement of brushes.
Removable hinged covers shall provide access to the brushgear, slip-rings or
commutator.

Brush holders shall incorporate constant force springs to maintain optimum contact
pressure throughout the life of brushes. Constant force springs shall apply the designed
pressure at all times, independent of the length of the brush. Brushgear box length shall
be suitable to accommodate long length of brushes and to reduce the necessity for
changing brushes between scheduled shutdown periods.

The force which the spring exerts shall be fixed during its manufacture. Furthermore, to
reduce maintenance and to elimate mal-adjustment due to human error, all mechanical
fingers, pivots, rivets and hold-off devices which are otherwise necessary with
conventional brush holders shall be avoided. To provide positive identification each
spring assembly shall be clearly marked with the value of the force fixed during
manufacture.

The springs shall be of simple plug-in clip designs and shall allow easy access to brushes
for examination or replacement.

The Contractor shall ensure that the carbon brushes selected are readily available locally
a designed for long life.

3.8 Slip-rings

The slip-rings shall be placed adjacent to the bearing in the non-driving end and be of
the external type, separately enclosed and separated from the main motor frame. The
slip-ring space of motors with a degree of protection conforming to IP 54 shall be
screened off from other parts of the motor. A filter that can be easily removed and cleaned
shall be provided to collect the dust from the brushes.

3.9 Terminal and cable termination boxes

Separate individual cable terminal boxes with IP 55 degree of protection shall be

provided for stator, rotor, heater and thermistor cables.

Terminal boxes shall be positioned to accept adequately supported cables which rise
vertically from below, or alternatively angled in such a way as to accept cables from a
cable try without stress being introduced to the cable. The required positions of the cable
boxes shall be approved before manufacture.

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 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

Each terminal box of stator/rotor shall be fitted with an approved phase segregated cable
termination and sealing/spreading box, cable glands and all fittings necessary to
terminate the cables and cores. Phase segregation shall be provided by earthed metallic
barriers forming completely distinct individual phase compartments, so as to restrict any
electrical break down to an earth fault between phase to phase.

Terminal and cable termination boxes shall provide sufficient space for segregating the
cores and maintaining the minimum insulation clearances and creepage distances
applicable. Cable terminal and sealing/spreading boxes shall be suitable for a maximum
fault level of 50kA for 0.25 sec. on 415-volt system.

Terminal boxes shall be fitted with pressure relief diaphragm, so that products of an
electrical breakdown within the terminal box will be relieved outside the terminal box.
Pressure relief shall be located between the terminal box and the motor, so arranged
that potential for injury to personnel is minimised.

Cable sealing box to accommodate XLPE insulated cables shall be suitable for housing
heat shrinkable termination kits and shall be supplied with compression glands. Gland
plates and glands to be used for single core cables shall be made of non-magnetic
material such as brass or stainless steel.

Cable sealing box to accommodate PVCSWAPVC cable and mounted indoors shall be
air insulated, totally enclosed and sealed to exclude moisture and dust.

Clamping devices shall be provided inside the terminal box to separate and support the
cable conductors and to withstand the short circuit current. Material used for clamping
devices shall be non-hygroscopic.

Approved indoor/outdoor type glands shall be provided in accordance with the relevant
section of the Specification for termination of PVCSWAPVC cables.
Internal surfaces of terminal boxes shall be painted white to aid detection of dust and
other foreign matter.

Stud terminals mounted on terminal boards shall be provided in terminal boxes. Loose
or flying leads shall not be used. An earthing terminal shall also be provided in each
terminal box.

3.10 Name plate and instruction plates

Stainless steel nameplates and instructions shall be provided.

Information provided on the rating plate shall be in accordance with IEC 34-1. The values
provided should as far as possible be actually measured and shall be based on the
specified operating conditions. The rating plates shall include, but not limited to the data
stated below:

- Manufacturer’s name, serial number and year of manufacture

- Purchase order number
- Degree of protection of motor and terminal boxes.
- Winding connection
- Rated output and voltage
- Rated current
- Rated frequency
- Number of phases
- Rated speed
- Class of insulation
- Temperature rise

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 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

- Power factor at full load

- Efficiency at full load
- Locked rotor current at rated voltage and frequency
- Locked rotor torque at rated voltage and frequency

For motors with rated output exceeding 2.2kW, the following additional information shall
be provided on a separate rating plate.

- Bearing size
- Bearing type
- Clearance
- Type of lubricant
- Lubrication intervals, where applicable
- Minimum and maximum allowable quantity of lubricant for the DE and NDE bearings

3.11 Power factor of motors

All motors larger than 2.2kW shal be provided with power factor correction capacitors in
respective starter boards to correct the power factor of the motors to not less than 0.9
lagging under all operating load conditions.

3.12 Electric actuators

Electrically operated actuators for valves and penstocks shall be sized to guarantee
closure at the maximum possible differential pressure across the door. The safety margin
of motor power available for unseating the door shall be at least 50 percent in excess of
maximum closing torque at the nominal supply voltage. For valve sizes 300mm or greater
the closing and opening shall take approximately 2 minutes for each operation unless
otherwise specified. For valve sizes less than 300mm, the operating speed for closing
and opening shall be 300mm per minute. In addition, for valve sizes of 600mm and
above, the electric actuator shall include a pulsing timer assembly. The pulsing timer
assembly shall provide automatic inching operation of the valve over a pre-selected
portion of the valve travel to effectively achieve 2-speed valve movement. The point at
which change of speed shall occur shall be selected by setting of a limit switch in each
direction. The pulse timer shall incorporate an adjustable approximate starting period of
0-15 seconds and an adjustable approximate stopping period of 0-120 seconds per
pulse. The available pulses shall not be less than 20.

The electric motors shall be Class F insulated and tropicalised and conform with the
Specification with a time rating of 15 minutes or twice the valve/penstock stroking time,
whichever is longer. Duty rating shall S2 or S4.

Motor burn-out protection shall be provided by direct sensing of motor temperature by a

thermostat embedded in the motor winding. A changeover volt-free contact (monitor
relay) for remote indication of motor tripped shall be provided.

A space heater shall be provided in the electric actuator. The heater shall be suitable for
use on a single-phase a.c. supply and wired to the terminals compartment. The heater
shall be sufficiently rated to maintain the temperature above dew point when the actuator
motor is stationary.

The actuator gearbox shall be of totally enclosed oil bath lubricated type, suitable for
operation at any angle and provided with the appropriate filing and drain plugs. The drive
shall incorporate a lost motion hammerblow feature. The output shaft shall be hollow to
accept a rising stem. Thrust bearings of the ball or roller type shall be provided in such a
way that the gear case can be opened for inspection or disassembled without releasing
the stem thrust or taking the valve out of service.

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 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

A handwheel shall be provided for emergency operation and shall be arranged such that
when engaged the motor shall be automatically disconnected mechanically and
electrically and the drive being restored to power only after disengaging the handwheel
and by starting the motor. The handwheel and any gearing shall be such as to permit
emergency manual operation in a reasonable time and in any case shall not exceed one
hour. Clockwise operation of the hand wheel shall give closing movement of the valve
unless otherwise stated.

The actuator shall be furnished with a drive bushing easily detachable for machining to
suit the spindle or gearbox input shaft. The drive bushing shall preferably be positioned.

4.0 Motor Starters (Rotor Resistance)

Rotor Resistance (Reduced Voltage) A.C. starters shall be air-break electromagnetic

switching devices complying with the recommendation of BS 4941 Part 3.

Rotor resistance starters shall be rated for uninterrupted duty and intermittent duty Class
0.1 with on load factor of 60 % and utilisation category AC-3. The rated operational
voltage (Ue) and the rated insulation voltage (Ui)) shall be not less than 440V A. C.

The rated operational current (Ie) shall be not less than the full load current of the motor.
The corresponding rated thermal current (Ith) and the rated operational power with the
starter gear assembly shall be entered in the Technical Schedule.

Coordination with the short-circuit protective device (S.C.P.D.) shall be Type "b" as
defined in Appendix C of BS 4941 for a prospective short-circuit current not less than the
value stated in Particular Specification. For this purpose, the S.C.P.D. shall be the
suitably and motor circuit fuse.

Thermal overload relays shall be Type 2 and sensitive to phase failure. Time current
characteristics shall be supplied by the manufacturer on 28mm x 56mm logarithmic
decides. These curves shall have a tolerance not exceeding ±10%.

Starters shall be suitable for both automatic and non-automatic methods of control. When
opening by overload relay involves energizing an auxiliary relay from the control supply,
the pick-up voltage of this auxiliary relay shall be below the drop-out voltage of the main
contractor.

The rated control supply voltage (Ue) shall be equal to the nominal voltage of the A.C.
item specified.

Test certificates shall be supplied for the following type and special tests to BS 4941:
Part 4.

- temperature - rise limits

- Dielectric properties
- Change-over ability
- Characteristics overload relays
- Special test to verify that auto-transformer will withstand starting current for the
starting time (Ts)
- Special test to verify the type if coordination with the S.C.P.D. and certified by
ASTA, KEMA, PEHLA

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5.0 General Instrumentation Specification

5.1 Instrumentation Cabling

i) Twisted conductors shall be used in all signal leads, and shall be constructed with
26 - 33 twists per metre.

ii) The minimum cross-sectional area for low level signals shall be 0.65 square min
copper.

iii) An overall screen shall be included in signal cables for digital contact closure,
digital pulse, high level analogue and actuator drive signals.

iv) Individual screens for each twisted pair together with an overall screen shall be
included in signal for low level analogue signals.

v) Screening shall provide a minimum of 85 % coverage of copper braid or mylar

backed Aluminium foil. Individual shields in multicore shall be insulated from each
other and from the overall shield and armoring.

(vi) Insulation between conductors and earth shall not be less than 10 megaohms at
50OV.

(vii) The different types of signals shall be segregated from each other and shall be
contained in separate cables.

(viii) Multi-stranded cable of a minimum conductor size of 24/0.20mm plain copper to

BS 6360 shall be used.

Strict segregation shall be followed with not more than one type of signal run in any
multicore cable.

5.2 Ultrasonic Continuous Flow Rate/Level Measurement

The ultrasonic continuous measurement equipment for level measurement and open
demand flow shall be similar to the ultrasonic measurement equipment.

The equipment shall be capable of continuous measurement with a weatherproof

transducer and transmitter to IP 65 (IEC 529). The transmitter head shall be
encapsulated in PVC/Silicon rubber housing. The shielding megaphone housing the
transmitter and reference reflector shall be fibreglass reinforced plastic material. The
signal converter shall have a glass filled polyester base and a polycarbonate cover.

The maximum allowable separation between the signal converter and the transmitter
shall be 150m. Special coaxial cable between these two units shall be supplied by the
manufacturer.

The signal converter shall be to IP65, (IEC 529) and provide a 4-20 mA d.c. output signal
for remote indication. A suitable power supply unit shall be incorporated within it, so that
converter shall be operable from a 240V 5014z power supply. A built-in temperature
compensation to compensate errors due to variation of sound speed in air with
temperature shall be incorporated and suitable for the environment of installation. It shall
have solid-state modular plug-in printed circuit boards or equivalent for easy
maintenance. A minimum of 2 independent continuously adjustable set points and relays
(SPDT min. 4A 240V 50Hz resistive) shall be provided within the converter.

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For open channel flow measurement, a linearizer shall be incorporated and programme
with Q/h characteristic of the channel.

5.3 Level Measurement Piezo Type (Alternative)

The level sensor shall be the capacitor type located in a stilling chamber.

Output signal shall be 4-20 rnA D.C.

5.4 Level Control/Alarm Electrodes

This shall be of stainless-steel electrodes suspended in a stilling well, operating at low

Voltage.

Alternatively, this may be achieved by floats suspended in a stilling well.

5.5 Magnetic Flow Meter and Converter

The electromagnetic flow meter shall be suitable for continuous or intermittent

submergence up to 10m head of water.

The detector shall be of AISI stainless steel frame PTFE lining or other equivalent
approved lining and Hastelloy C electrodes. Flanges shall be carbon steel.

For metallic pipe which must be similarly earthed, the metering tube shall be effectively
bonded to the pipes.

The principle of operation shall be such as to be not affected by contamination of the

electrodes or an electrode cleaning unit shall be incorporated.

The metering tube shall have an external finish to be suitable for total continuous
submergence in water (i.e. IP68).

The signal converter shall be to IP65 protection or if to IP64 protection shall be provided
with a suitable weatherproof enclosure. It shall be suitable for the flow velocity ranges
used. Special cables between signal converter and the metering tube

shall be supplied by the manufacturer. The signal cable between the signal converter to
the indicator or receiving device shall be screened two core cable of appropriate size.

The design of the system shall be such as to allow a maximum separation between the
signal converter and the metering tube of 200m.

The signal converter shall have a 4-20 mA d.c. output signal for flow rate and a pulsed
(30ms pulse width) output signal for a remote counter indicator.

5.6 Orifice Plate

Orifice plates shall be of square edge concentric bore type manufactured from stainless
steel and shall comply with BS 1042 : Part 1.

The orifice plate shall be designed to obtain an optional range of not less than 2:1 and a
pressure loss of not more than 50 % of the differential pressure.

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5.7 Venturi Tubes

These shall be of Cast Iron designed to BS 1042. Internal surface shall be coated with
non-toxic epoxy. Flanges shall be made to suit the pipework in the system.

5.8 Transmitter

The transmitter to be used in conjunction with differential pressure sensing device shall
be similar to Electronic Differential Pressure Transmitter model 115DP manufactured by
Rosemount or equal approved.

Differential pressure (DP) transmitters shall be compatible with the primary sensors in
range and accuracy. For flow measurement, the DP transmitter shall incorporate inbuilt
square root extraction such that its 4-2OmA DC output signal is linearly proportional to
the flow rate.

The transmitter to be used in conjunction with pressure sensing devices shall be similar
to Electronic Gauge Pressure Transmitter model 115DP manufactured by Rosemount or
equal approved.

5.9 Transmission Sign

This shall be one of the following:-

Analogue : 4 - 20 mA

Pneumatic : 0.2 - 1.0 Kg f/cm2

5.10 Unit of Flow & Pressure/Level

The units of flow, pressure/level shall be as follows:

Flow rates : Litres per second, cubic metres/min. Megalitres per day

Quantities : Cu metres, Megalitres

Pressures : Metre head w.g. bar kgf/cm2

Water Levels : Metres

5.11 Accuracy of Measurement

Generally, the accuracy of a whole instrumentation system i.e. the sensor, transmitter,
indicator or other measured figure for a declared range, unless otherwise specified.

For non-linear measurement, the accuracy of a whole instrumentation system shall be

better or equal to +/- 2% of the full-scale deflection for a declared range, unless otherwise
specified.

If the declared range for the above guaranteed accuracy falls short of the specified range
of measurement, then the Contractor shall declare the minimum figure measurement
with + 0.2% accuracy. Alternatively, the Contractor shall declare the range for accuracy
up to +/- 0.2%, taking into consideration of the maximum figure specified to be measured.

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5.12 Indicators

Analogue signal operated circular type indicators shall be similar to cirscale pattern.

Analogue signal operated rectangular type indicators shall be Miniature Electronic 3

x 6 indicator series.

All circular indicators, except where otherwise stated shall be 150mm diameter. They
shall have black bexels, corporated a device for correct zeroing of the pointer and
designed to minimize parallax. They shall be suitable for flush mounting within the
panel, or pedestal, cubicle etc. as required. Other sizes where specified shall have
the same installation arrangement.

The maximum range of all instruments shall, unless otherwise specified, be not less
than 10% greater than the normal maximum indication.

5.13 Chart Recorders

Chart recorders shall be Circular Chart Recorder/Indicator type.

The selection, number of pens, chart speed and chart scale details shall be as specified
elsewhere.

5.14 Integrators

Integrators shall be either combined with the recorder/indicator specified in Clause 5.13.

The integrator shall be able to retransmit an output signal to a remote counter. The
integrator (either combined or separate) shall have a minimum 6-digit counter type with
the first right hand digit representing 0.01 megalitres/10 cu. metres as specified
elsewhere.

5.15 Alarms

Alarm conditions shall be annunciated on an alarm annunciator panel. The system shall
be designed to fail-safe, and alarms shall be initiated by the opening of a relay contact,
which shall be detected by the alarm annunciator system, which will sound and alarm
Maxon and illuminate the relevant alarm annunciator. These shall operate at 24 d.c.

Alarm annunciator panels, manufactured by Highland Electronic Ltd., 33-41 Dallington

Street, London ECIV 0131), i.e. similar approved shall be provided in the various control
panels as specified.

All alarm panels shall include "accept" and "test" pushbuttons and automatic resetting
shall be included. Alarms shall hold until accepted, initially being indicated by flashing
light which shall change to steady when the alarm in accepted. The alarm light has
cleared and the accept button has been pressed. Any flashing alarm annunciator shall
be accompanied by an audible which shall cancel when either the accept button is
pressed or the alarm condition clears.

These shall operate at 24V d.c. and where necessary the d.c. supply and the interposing
relay shall be supplied.

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5.16 High and Low Level Alarms

Alarm levels in pumping wells and water holding tanks shall be normally detected using
level electrodes, unless otherwise specified. The electrodes shall be manufactured from
stainless steel, and the electrodes heads shall be waterproof and shall allow an
adjustment in electrode level of at least 150mm to be made.

Alternatively, these may be extracted from the 4-2OmA signal of the level indicator via a
trip amplifier provided in this Contract.

5.17 Pushbutton Switches

Pushbutton switches for remote control shall be Series 03 illuminated switches as

manufactured by Highland Electronics Ltd., 33-41 Dallington Street, London ECIV, ODB,
or similar approved.

Twin illuminated pushbuttons shall be employed for motor starting and stopping. The
"start" pushbutton shall be illuminated green to show that the motor is ready to start and
the "stop" pushbutton shall be illuminated red to indicate that the motor is running.

These shall operate at 24V d.c. and where necessary the d.c. supply and interposing
relays shall be supplied.

5.18 Lightning Protection

Lightning protection to the approval of the Superintending Officer shall be provided as

necessary to protect solid state equipment from damage likely to be caused by lightning.
In particular protection shall be included for each analogue loop installed.

5.19 Instrumentation Circuit Routes

i. Signal cables shall not be run in the same conduit, duct or cable tray as power
cables.

ii. Conduits, ducting, cabling, cable tray etc. may be made of insulating or conducting
materials and where it is of the latter, all cable armour and screens shall be isolated
from conducting material. All cable armour and screens shall be isolated from the
insulating.

iii. Signal cables shall be routed to avoid sources of electromagnetic interference e.g.
electrically powered equipment, fluorescent lightning fittings, etc.

iv. All signal cables running from externally mounted items, i.e exposed to weather
shall be protected with al lightning protection device.

5.20 Instrument Cable Laying

i. Before and during installation up to the time of making off, all cables ends shall be
firmly supported and kept sealed off against ingress of moisture.

ii. The Contractor shall ensure that draw strain is taken on the armoring and the cable
is adequately protected where it enters a duct or pipe.

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iii. Where a change of cables direction is required the bending radius shall not be less
than 12 diameters except with the approval of the S.O.

iv. Where cables enter a building through foundation and or concrete flooring, these
shall be provided with a continuous pitch fiber or equal and approved l00 mm. duct
for cables of up to 70mm sq and 150mm ducts for cables above 70mm. sq to ensure
easy entry and minimum radius bends as recommended by the manufacturer of the
cable. These ducts will be provided by the Contractor.

v. Where cables pass through manholes or draw-pits they shall be supported and
spaced clear of the invert of the ducts at a point of entry so that any ground water
etc. finding its way into the duct may drain freely.

vi. Where cables pass through wet wells the duct work shall be of hot dip galvanised
mild steel heavy duty conduit.

vii. All joints where these have been approved by the S.0 shall be made in sealing
chambers of approved design and filled with a non-hygroscopic sealing compound
to be approved by the S.O.

5.21 Instrument Terminals

All terminations shall be of the serrated bar type as manufactured by Kippon Electricals
Ltd., Sheernees, Kent, England or equal similar approved.

5.22 Instrumentation Earthing

i. Earthing shall comply with the Regulations of the Institution of Electrical Engineers,
the requirements of the Supply Authority and conform to BS Code of Practice 10 13.

ii. The earthing arrangements shall, unless otherwise specified, comprise:-

a) Electrodes to provide adequate conductive capacity for the works systems.

b) Suitable inspection with concrete covers to allow ready access to the electrode
connections.

c) A protective conductor of adequate capacity between the switchboard earth bar

and the earth electrodes.

d) A bolted removable tinned copper link mounted in a suitably located link base
with porcelain carriers.

e) A bolted removable tinned copper link mounted in a suitably located link base
with porcelain carriers.

f) The earth resistance value shall be less than 0. 1 ohm.

iii. The earth electrodes shall be in the form of steel core copper rods suitably grouped
and connected.

iv. All metal work, other than current carrying parts of the electrical system, shall be
properly bonded to earth.

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Earthing screens of cables carrying signals shall be single point earthing established and
adhered to throughout the installation to avoid the production of "earth loops". Each cable
screen shall be earthed at the end nearest the central marshalling board only and
isolated from earth through the remainder of their length.

Armoring of cables shall be connected to the electrical distribution earth in accordance

with the Electricity Regulations.

6.0 Station Pipe Works & Valve

6.1 Pipeworks

Pipework shall be supplied to the general arrangements and limits indicated on the S.O.
drawings and shall include all necessary specials, jointing materials, flange adaptors,
etc. The layout and design of the pipework shall be such as to facilitate its erection and
the dismantling of any section for maintenance as follows :

a) All pipes and special shall be of mild steel and conforming to MS 708:1981 to BS
534:1981.
b) All mild steel pipes and specials shall be painted with one (1) layer of zinc chromate
and two (2) layers of gloss finish coating while ductile iron pipes and specials shall
be painted with two (2) layers of gloss paint.
c) All mild steel pipes shall be lined internally with concrete.
d) All flanges shall be machined and drilled to BS 4504 Table 16/11.
e) Flanged items shall be supplied complete with bolts, nuts and jointing materials.

Where a common manifold pipe is used, individual pump delivery branches unless
otherwise shown on the drawings shall be jointed to it in a horizontal plane and radiused
or angled to prevent sharp changes of flow. At joints in civil engineering structures,
flexibility shall be provided in pipework to accommodate differential settlement. Template
pipes, collars and cut pipes or flexible joints shall be provided in all pipe runs between
fixed points to accommodate construction tolerance in the civil structures.

All pipes of 50mm dia. or above connected to items of plant shall have flanged
connections. All pipes shall be checked for alignment and mating of flanges and
connections before being secured. Pipes shall not be sprung into position.

Adequate supporting and anchoring arrangements for all pipes shall be provided and
particular care shall be taken to ensure that pipework thrusts are, as far as possible, not
transmitted to machinery or other associated plant. Where concrete supports are
required, the Contractor shall indicate these on his drawings and the necessary work
shall be arranged by the S.O.

6.2 Delivery Pressure Gauge & Pressure Sensor

Each pump delivery branch and delivery main shall have provision for the fitting of a
pressure gauge to indicate generated head in metres and bars, the zero indicating
atmospheric pressure.

The gauge provided by Contractor shall comply with BS 1780 and the materials of
construction shall be bronze, stainless steel or other approved corrosion resistant
material other than aluminium.

Gauges shall be at least 150mm in diameter liquid filled type, fitted with an isolating cock
and snubber, and shall be securely attached to the pump discharge pipe above the floor
and easily visible.

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The full-scale range of the pressure gauge provided shall be approximately 30% above
the anticipated normal operating head generated by the pump.

The delivery main and each delivery branch also shall be installed with pressure sensor
to indicate the pressure at the delivery main. The reading shall be transmitted to pump
control panel.

The pressure sensor shall be IP65 protection type with 4 to 20mA output signal. The
accuracy shall be ±0.5%. The enclosure and wetted parts shall be acid resistant stainless
steel. The next operating pressure shall be at least 20 Bar.

6.3 Valves

6.3.1 Butterfly Valves

a) All butterfly valves shall conform to BS 5155 and shall be used for pipe
sizes above 250mm diameter.
b) The butterfly valve shall be fully designed for pressure rating of PN 16.
c) For butterfly valve with motorized gear, a suitable hand wheel for
headstock shall be provided.

6.3.2 Non-slam Type Check Valves

a) General
The non-slam check valve shall conform to BS 5155 and shall be with high
operating reliability and minimum pressure losses.
b) Design and Finish
i. The non-slam type check valve shall be designed to be of short
stroke, shock free closure and can be installed in any position i.e.
horizontal, vertical or inclined.
ii. The check valve shall also be designed such that the minimum
cross-sectional area of the pipe.
iii. The check valve shall be used for automatic operation by the use of
a direct spring-loaded closing element.
iv. The valve shall be with metal to metal seat and shall operate with
minimum wearing parts and minimum maintenance.
v. The valve shall be designed with the flow diffuser to minimize
pressure losses and shall be flanged and drilled to BS 4504 Table
16/11.

6.4 Electric Valve Actuator

a) General

Electric actuator for operating valves and penstock shall be of the heavy-duty type
and shall be made by reputable manufacturer with similar project references in
Malaysia. Contractor shall propose actuator manufacture that has a principal office

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located in Malaysia to ensure availability of after sales service as well as spare

parts for at least 10 years from date of commissioning.

The actuators shall be suitable for use on a nominal 415-volt 3 phase 50 Hz power
supply and are to incorporate motor, integral controls and terminals for remote
control and indication connections.

b) Ambient Temperature

The actuator shall be capable of functioning in an ambient temperature ranging

from -30c to 70c.

c) Motor

The electric motor shall be Class F insulated, with a time rating of at 15 minutes at
104 oF (40 oC) or twice the valve stroking time, whichever is the longer, at an
average load of at least 33% of maximum valve torque.

d) Gearing

The actuator gearing shall be totally enclosed in an oil-filled gear case suitable for
operation at any angle. All main drive gearing must be of metal construction.

e) Hand Operation

A hand wheel shall be provided to emergency operation, engaged when the motor
is declutched by a lever similar means, the drive being restored to power
automatically by starting the motor.

The handwheel drive must be mechanically independent of the motor drive and
shall be direct 1:1 ratio for emergency operation.

f) Limit and Torque Switches

Electric actuator shall be equipped with mechanical open and close torque and
position limit switches with separate changeover volt free contacts at each end of
travel for remote indication and interlocking.

Electronic means for actuator position and torque measurements is not acceptable.

g) Local Controls and Position Indication

A mechanical dial indicator shall be provided to show open / intermediate / close

position of the valve.

Digital LCD indicator that requires battery back-up during power outage is not
acceptable.

Integral to the actuator shall be local controls for open / close / stop and a local /
remote selector switch pad lockable in any one of the following three positions:
local control only, off (no electrical operation), remote controls plus local stop only.

h) Remote Valve Position / Actuator Status Indication.

Open / close limits switches shall be provided for remote indication of valve
position, with each contact rated at 5A, 250V AC, 30V DC.

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The limit switches shall be mechanically activated to ensure availability of remote

indication even when doing hand operation of the actuator during a power outage.

Contacts that are activated electrically requiring the use battery back-up during
hand operation when there is a power outage will not be acceptable.

6.5 Surge Suppression System

a) To counter water hammer, surge vessel shall be installed at the pump house.
b) Manufacturers are required to submit the complete sets of drawings, calculation and
etc. to DOSH for approval.

6.6 Schedule of Valves

The details of the sluice valve, butterfly valves and non-slam check valves to be supplied
and installed are tabulated below: -

Working Body Test

Type Size (mm) Qty Pressure Pressure
(Bars) (Bars)
Sluice Valve at suction line 700 6 nos. 16 24
Butterfly Valve at suction line 700 6 nos. 16 24
Butterfly Valve at delivery sides 600 6 nos. 16 24
Sluice Valve at suction line 600 6 nos. 16 24
Check Valve at delivery line 600 6 nos. 16 24

6.7 Pilots & Accessories

The normally closed pilot shall be of brass and bronze construction with a spring to adjust
the opening pressure.

The inner valve shall be of stainless steel 316 construction and the inner valve shall have
EPDM resilient compound for seating. The EPDM compound must be bonded
permanently to the inner valve and be ground flat and square to assure maximum
performance.

The pilot shall be self-cleaning by locating the inlet directly into the seat area through the
bottom of the pilot and the outlet ninety degrees to the inlet.

A separate port will sense pressure either upstream or downstream (subject to

application) to open the pilot and therefore the main valve when system pressure
exceeds the pilot set point.

6.8 Mechanical Spare Parts

Contractors are required to provide mechanical spare parts as follows:-

a) One (1) no. of Impeller

b) One (1) no. of Casing Wear Ring

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c) One (1) no. of Bearing set

d) One (1) no. of Shaft Sleeve
e) One (1) no. of Shaft
f) One (1) no. of Mechanical Seal
g) One (1) no. of O-Ring set

6.9 Nuts, Screws, Washers And Bolts

Bolts, screws, nuts and washers shall be stainless steel SS 316.

Stainless steel items shall be manufactured from Grade 316S31 steel complying with BS
970, Part 1 or BS 1449, Part 2. Bolt lengths shall be sufficient to ensure that nuts are
fully threaded when tightened in their final position.

6.10 Safety Chains

Safety chain shall be 8mm nominal and shall be of stainless steel.

Stainless steel safety chain shall be manufactured from Grade 316S31 steel complying
with BS 970, Part 1. Chain links shall be welded and have an internal length not
exceeding 5 mm and an internal width of between 12mm and l8mm. The fins caused by
welding shall be removed and the weld shall smoothly-finish all round. When tested in
accordance with Clause 7.3 of BS 4942, Part 2, each chain shall withstand a breaking
force of 30kN and a proof force of 15 KN.

6.11 Industrial Flooring And Stair Treads

Mild steel and aluminium alloy industrial type flooring and stair treads shall comply with
the relevant provisions of BS 4592.

After fabrication, mild steel flooring and stair treads shall be hot dip galvanised in
accordance with BS 729.

Flooring shall be open mesh or chequered plate type as specified.

Each floor panel shall be secured to the supporting members and adjoining panels with
proprietary clips.

The weight of any single panel shall not exceed 35 Kg, without the S.0's agreement.

6.12 Fixing Bolts

Fixing bolts, nuts and washers for concrete, brick or masonry shall be of stainless steel
Grade 316S31 to 13S 970 : Part 1 or BS 1449, Part 2. The bolts may be rag or indented
bolts to BS 1494 : Part 2, expansion bolts, or resin bonded bolts. The Contractor shall
submit details of the type he proposes to use, including manufacturer's specification
literature, for the S.O.'s approval.

Dimensions of holes and box-outs for fixing bolts shall be shown on machinery
foundations drawings.

When the bolts etc. are used for fixing aluminium items they shall be insulated from the
aluminium by a non-metallic sleeve and under-washer.

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The building-in material for use with rag or indented bolts, shall be a proprietary epoxy
non-shrink grout or a proprietary non-shrink mortar or caulking compound. Bolts shall not
be brought into service until they are effectively anchored and the building in material
has achieved adequate strength.

6.13 Safety Guards

All sections of the plant which constitute a safety hazard shall be covered by substantial
guards or barriers which shall comply with the Safety regulations.

All moving part of plant shall be adequately guarded to BS 5304.

All parts that in normal working are hotter than 60 degrees C or colder than -5 degrees
C shall either be adequately fenced or shall be lagged.

All live electrical conductors, including conductors forming part of electrical apparatus,
shall be either insulated or so fenced or placed as to prevent danger.

Guards shall be fabricated in mild steel wire mesh or expanded steel sheet, or should a
fully enclosed type be necessary, in mild steel sheet.

Guards shall be designed to provide ready access to bearings, greasing points,

thermometer pockets and other check points to allow routine observations to be made
by the operating staff without danger or the need to dismantle any part of the guard.
Hinged doors let into the guards with padlocking facilities shall be provided where
necessary to facilitate access to the check points.

Guards shall be bolted in position in such a way that they cannot be unintentionally
dismantled or removed.

All mild steel used in the construction of guards, including brackets shall be hot dip
galvanised unless otherwise specified.

Drawings of safety guard shall be submitted to the S.O.'s for approval before
manufacture.

6.14 Lubrication of Plant

The positions of all greasing and oiling points shall be arranged so as to be readily
accessible for routine servicing. Where necessary, to achieve this, suitable extension
pipes shall be fitted.

Manual grease lubrication points shall use hexagon headed nipples to BS 1486 : Part 1.
If more than one type of grease is required, a different size of nipple shall be used for
each type and labels to indicate the special lubricant required.
Dip sticks or level plugs shall not be used without the approval of the S.0's.

Automatic lubrication shall be provided where specified and full details of the system
shall be submitted to the S.O. for approval.

Where continual grease or oil feeding is required, the capacity of the reservoir shall be
sufficient for not less than seven days continuous service.

A complete schedule of recommended lubricants shall be included in the Operating and

Maintenance Instructions for the plant.

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6.15 Name Plates, Labels and Warning Notices

All equipment shall be suitable and uniformly labelled as to its operation, compatible with
the designation used on the appropriate electrical control cubicle.

Warning notices, whether statutory or otherwise, shall be provided in appropriate

locations to warn personnel of any potential hazard caused by the equipment.

Details of all labels and warning notices shall be submitted to the S.O. prior to
manufacture.

Labels and warning notices shall be of engraved plastic material and shall be screwed
or bolted in position. Adhesive bonding is not acceptable.

6.16 Paint Colors for Plant and Pipework

Unless otherwise specified, plant and machinery shall be finish painted to the following
colours:-

Standard Colour BS 4800 Ref

Plant (Water Supply)

General Plant including Motors Mild Blue 18E51

and Filter Vessels

Plant (Common)

Plant Mounting Bases and Light Grey 00A05

Structures

Machinery Guards Safety Red 04E53

Water Header Tanks Green 12D45

Runways and Overhead Cranes Yellow 08E51

Switchboards Grey 00A05

Rigid pipework shall be identified by colour in accordance with BS 1710:1984. Unless

otherwise specified, pipework shall be painted in the basic identification colour with any
banding colors repeated at junctions, at both sides of valves, at appliances, bulkheads,
wall penetrations and any other points where identification is necessary.

PVC pipework shall be unpainted but banding of the basic identification colour and the
appropriate colour codes shall be applied.

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7.0 Electrical Works for Station Pumps

7.1 General

This section covers electrical works to be carried out in association with the station
pumping system.

The equipment to be provided and installed at the Pump House includes but not limited
to the following:-

i. Pump Starter Board for constant speed pumps

ii. 415V Drainage Submersible Pump Starter Board

iii. Remote start/stop/emergency stop push button stations

iv. Cabling

v. Earthing

A Specialist Sub-Contractor engaged by the Contractor shall undertake all electrical

works. Single line diagrams for the proposed switchboards may not carry all the details
and the Contractor shall be guided by the requirements of the Works.

The Contractor shall be deemed to have visited the site and allowed for all necessary
cost. All electrical works, irrespective of the nature of the installation shall incorporate
value engineering in respect of energy saving and cost saving in ongoing maintenance,
etc.

This section shall be read in conjunction with all other sections describing the various
equipment of the works,

Unless specified elsewhere, all equipment, switchgear, apparatus, appliances and

accessories for low voltage electrical installation shall be rated for operation on 415/240
V, 3 phase, 4 wire and 50 Hz system with solidly earthed neutral.

7.2 6,600V Pump House Switchboard (Pump Starter Board) for Constant Speed Pump

Rotor resistance starter shall be provided and the starter shall comprise the following:

i. One suitably rated TPN, 4 pole motor protection MCCB with padlock and key for
locking in the off position.

ii. One four pole main contactor of the fail-safe type, having easily removable contacts,
arc chutes or pockets and inherent under voltage release or as required.

iii. One set protection and metering current transformers.

iv. One 90mm ammeter with suitably scaled and ammeter selector switch.

v. One power factor meter.

vi. One Motor Protection Relay of Microprocessor type or approved equivalent.

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vii. One solid state type rectifier device and sets of relays and controls for starting
complete with all auxiliary contacts for:

a. Auxiliary Controls
b. Signal Lamps
c. Delay timer to limit the starting frequency to less than 4 starts per
hour and 2 consecutive starts within 5 minutes in any hour

viii. One "Hour Run" meter.

ix. One set of auxiliary contacts for the motor starter heaters.

x. One anti condensation heater with thermostat automatically energized when the
motor is not running and de-energize them when the motor is running.

xi. One set of thermistor relays, provided by the motor supplier.

xii. One set of indicating lamps as follows:

"SUPPLY ON" - 3 lamps respectively RED, BLUE

and YELLOW for 3 phases
"MOTOR RUNNING" - RED

"MOTOR FAILED LOW LEVEL" - BLUE

"MOTOR FAILED OVERLOAD" - BLUE

"MOTOR FAILED LOW O/P" - BLUE for closed valve situation

"MOTOR - AMBER
FAILED OVERHEATING"

xiii. One set 'Start/Stop' push buttons.

xiv. One set Emergency Lockstop 'STOP/RESET' push button.

xv. One set terminal for remote 'Start/Stop'.

xvi. One set terminal for remote indication.

xvii. Pump low level cut off.

xviii. One local/remote selector switch.

xix. One duty selector switch.

xx. One MCB suitably rated for the starter anti condensation heater circuit.

xxi. One MCB suitably rated for the control circuit.

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xxii. Pump lubrication auxiliaries and controls.

xxiii. Power Factor correction capacitor banks complete with suitably rated MCCB,
contactors, automatic controller, etc.

Full details of the compartment’s fascia, starter components and control wiring shall be
provided for approval prior to commencement of manufacture.

7.3 415V Pump House Switchboard

This shall be the front and rear access type with Form 4 construction to BS5486. Cable
entry shall be, from the bottom.

Enclosure classification shall be IP54 to BS5490. It should be located in the pump house
as shown on drawing.

The components to be promoted shall be as follows:

i. Incomer

This shall comprise: -

1 - 4 poles TPN air circuit breaker (ACB) withdrawable type complete with
operating push buttons and indicating lights
1 - set supply "available" indicating lights

1 - set supply "on" indicating lights

1 - ammeter with ammeter selector switch
1 - voltmeter with voltmeter selector switch
1 - kWH meter

1 - power factor meter

1 - O/C and E/F device of IDMT type
1 - set current transformer for protection
1 - set current transformer for indication
1 - set current transformers for Tariff Metering
1 - set electrical and mechanical interlock
1 - anti-condensation heater complete with controls, thermostat, switch
and light
1 - cable box
ii. Busbars

This shall comprise:-

1 - set 1600 TPN 50 KA

1 - Tinned copper earth bar

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iii. Drainage Pump Starters

This starter shall comprise but not limited to the following:

i) One MCCB with door interlock.

ii) One three phase contactor with thermal overload relay.
iii) One set 'start' and 'stop/reset' push buttons.
iv) One set motor 'running', 'stop' and ‘failure' indicating lights.
v) One anti-condensation heater and thermostat.
vi) One set control relay.
vii) One Local/Off/Remote selector switch.
viii) Hours run meter

The power supply is 415 Volts, 3 phase, 50 Hz and shall be taken from the 415V
main switchboard.

All MCCB shall have door interlock. All the necessary interconnecting cables shall
be provided under this Contract.

7.4 Cabling and Other Requirements

7.4.1 Cabling

All cables inclusive of trenching, backfilling, road crossing trays, ladders, brackets,
supports and etc. for all equipment supplied under this contract shall be provided.

The Specialist Sub Contractor shall supply and install all cables from the Main
switchboard to the various other Boards and equipment specified and then to all
associated plant components. Some of the main feeders are indicated on drawings, as
guide only. The Contractor shall size cables and submit cable schedule for approval.

415 V cables shall be XLPE/SWA/PVC I OOOV grade copper.

For long low voltage cable routes, voltage drop shall be taken into considerations.

7.4.2 Pushbutton Station

Start/Latched stop local pushbutton control station shall be provided for each pump and
plant.

7.4.3 Earthing

i. Main Earthing System

Earthing systems shall comply with the requirements of BS 7430 Earthing, 1EE
Wiring Regulations, TNB and JBE as required.

The main ear thing systems shall consist of earth bars, circuit protective
conductors, equipotential bonding conductors, concrete electrode pits complete
with 15.6mm dia. x 5,467mm long (minimum), hard drawn copper or copper clad
steel earth electrodes and gunmetal clamps, interconnecting 25mm x 3.125mm
copper strips in 50mm diameter PVC pipes.

Page B / 26
 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

The earth resistance value measured at the Main Earth Bar shall not exceed I
ohm. The earth connections for all sections of each installation shall be
continuous throughout. Each individual earth systems shall achieve its required
earth resistance value before being interconnected with other earth systems.

ii. Equipment Earthing

All non-current carrying metal framework associated with the electrical

equipment, each item of electrical plant, casings and cable sheaths, etc shall be
earthed by means of 25mm. x 3mm tinned copper tape or copper conductors to
the earthing network comprising of a ring to be run around the electrical
perimeter of each location. The series earthing of one piece of equipment to
another utilizing the equipment casing will not be permitted.

The main bonding cables shall not be less than 16 sq. mm and supplementary
bonding of non-electrical plant not less than 10 sq. mm All connections shall be
made using compression type cable lugs, taped on completion to completely
sea] the lug and any bare copper from the atmosphere.

The earth network conductor comprising tinned copper tapes and/or cables shall
be securely supported and clamped in a neatly spaced manner on building
structures, cable trench walls all on cable trays, and neatly run vertically,
horizontally, parallel to adjacent walls, ceilings, beams, etc. appropriate. The
earthing installation shall be protected from any mechanical damage or
corrosion.

iii. Main Earth Bars and Earth Continuity Conductors

A main earth bar (complete with test links) shall be installed in a convenient
location preferably in cable trenches 600 mm above the finished floor level. The
main earth bar shall comprise a high conductivity copper bar supported on
porcelain barrel type insulators and wall mounted. The earth bar shall be of
sufficient length to accommodate bolted copper tape/cable connections to:

a. The earthing conductors between the earth bar and the earth
electrodes.
b. Circuit protective conductors between the earth bar and exposed
conductive parts.
c. Main equipotential bonding conductors between exposed and
extraneous conductive parts.
d. System neutral earthing conductors.

Earth studs shall have a minimum size of M8.

The size of the main earth bars for the 415-volt system the cross-sectional area
shall not be less than less than 150 sq. mm.

The main earth conductor shall also be provided with adequate number of spare
terminals including cable lugs, bolts, etc.

The sizes of earth continuity conductors for 415-volt system shall be as follows:

For cable sizes above 70 sq.mm : 25 mm x 6 mm tinned copper tape.

For cable sizes 35 sq. mm and up to : 25 mm x 3 mm tinned copper tape.
70 sq.mrn

Page B / 27
 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

For cable sizes less than 35 sq. mm : 13 mm x 1.6 mm tinned copper tape.

Earthing tape connections shall be run in approved positions and fixed in an

approved manner generally in square and symmetrical lines using gun metal
saddles of appropriate size for securing tapes at intervals not exceeding 900
mm. The copper tapes shall be supplied in long unbroken lengths to avoid
unnecessary jointing.

Particular care shall be taken on cable termination boxes to ensure that the cable
sheath and armour are adequately bonded to the frame of the item of plant to
which the cable is connected. The armour of the cable shall not be used as the
sole earth return path conductor. Cable armouring shall be bonded to earth at
both ends.

Where under special circumstances rigid or flexible conduit is incorporated into

the Works, an internal earth conductor shall be run which shall be securely
bonded to the terminating or intermediate apparatus by means of a special earth
terminal.

iv. Joints

Bar to bar tee joints and tape to tape joints (for underground connections) shall
be of 'Furseweld' or 'Cadweld' method to the approval of S.O. All earthing tape
connections to electrical apparatus shall be made by using a bolted connection
in a visible and accessible position. Before the connection is made, the tape
surfaces shall be tinned.

v. Earthling Points

Subject to determination by tests at site, earth electrodes shall be provided

comprising a system of vertical earthing rods interconnected with copper tape.
The electrodes shall be physically arranged and spaced to be electrically
independent and leads from each shall be interconnected to the next to form a
network.

The electrodes shall be grouped together providing an effective earth and

provide and earth loop impedance value not greater than five (5) ohm.

vi. Electrodes

Each earth point shall comprise an extensible type earth electrode of diameter
not less than 16mm, made of hard drawn steel cored copper rods with internal
screw and socket joint, hardened steel tip driving heads and connector clamps.
The rods shall have an electrolytically bonded layer of copper of not less than
0.38mm thickness. The Contractor shall determine the length and number of
electrodes required for each earthing, after the resistivity of the soil at the
particular location has been measured at site and witnessed by S.O. The
electrodes shall be interconnected by means 25mm x 3mm tinned copper tape
laid at a depth of 750mm below ground level.

Earth rods shall be driven by a 'Kango' hammer or similar, capable of delivering

a high rate of light blows to the driving head and the Contractor shall deemed to
be included in his Tender the use of such tools.
The minimum spacing between two adjacent electrodes shall be twice the length
of the longer electrode.

Page B / 28
 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

Where ground conditions make deep driving of single earth electrode impossible
to achieve the desired earth resistance, a matrix arrangement of electrodes
joined to one another by 25mm x 3mm tinned copper tape buried at a depth of
600mm shall be used to form an earth mat in order to achieve the desired earth
resistance value. The Contract Rates shall be deemed to include all the
necessary electrodes, tapes, interconnections, etc. required to achieve the earth
resistance value.

All joints shall be protected against corrosion and the ingress of moisture by the
application of two coats of an approved anti corrosion conductive paint.

vii. Earth Clamps and Inspection Chambers

At each earthing point an approved nonferrous clamp shall be provided for the
connection of the tinned copper tapes to electrodes. These connections shall be
housed in individual electrode inspection chambers at every earthing point with
a cover set flush to ground level. The inspection chamber shall be of 'Furse'
make type PT 205 or approved equivalent.

viii. Marker Posts

Marker posts shall be provided to mark the position of the electrodes adjacent to
the earth chambers. The marker posts shall be similar to those provided for cable
routes.

ix. Excavation of Trenches

All excavation of trenches for the installation of the copper tapes, earth
electrodes and the inspection chamber shall be carried out by the Contractor to
the requirement of the S.O. The Contractor shall be responsible for the backfilling
and reinstatement of the trenches, setting and alignment of the inspection
chambers to the satisfaction of the S.O.

x. Testing of Electrodes

The works shall also include for testing of all earth electrodes to the satisfaction
of the S.O. The test instruments required for the tests shall be provided by the
Contractor.

After the earthing installation has been completed, the Contractor shall
demonstrate to the S.O. that the resistance of the electrodes to earth and the
continuity of the earth network are within the limits specified. Any additional earth
electrodes, if required, shall be provided by the Contractor. Earth tests shall also
include measurement of the resistance value of each individual earth point.

Earth resistance testing shall also be carried once in the driest period or any time
which is deemed suitable by the S.O. during the Defects Liability Period. Should
the earth resistance value be less than the specified value, the Contractor shall
install additional earthing points in order to achieve the specified value. The
Contract Rates shall be deemed to have taken into account the additional
earthing points required and there shall be no claims for cost in this respect.

xi. Earthing and Grounding

Floating System to be implemented shall allow the installation to "float up",

preventing potential differences between the components installed. All power
cables and also the surge protection devices shall utilize a wiring practice known
as 'single point

Page B / 29
 Technical Specifications
Section 2: Station Main Pumps & Pipeworks

xii. Surge and Transient System

Scope of work

The Contractor shall supply, deliver, install and test a complete surge and
transient system for the individual instrument, equipment and system.

Main Incoming Surge Protection

The single mode power line shunt surge protection device shall be rated for
8OkA per phase, 8/20~ts single shot surge capacity (Imax). The unit shall
contain at least 160kA (8/20gs) of internal surge material providing robustness
and additional life for multiple numbers of smaller impulses. It shall be designed
for mounting at main power switchboards and distribution boards. Each phase
shall have individual module.

The protection device shall be virtually immune to the effects of 50/60 Hz

sustained over voltages, allowing fault voltages up to +15% of the nominal RMS
voltage (48OVrms) to be withstood. It shall be designed with high levels of
protection for both common and differential mode (L-N, N-E).

The device shall come with fast responsive Metal Oxide Varistors (MOV) and
diodes to provide effective surge protection with low let through voltage to protect
the sensitive electronics and electrical circuits. The rated voltage shall be 240 V
at 50Hz. Surge arrestors must be designed to operate within the temperature
rating of 10 to 60 deg. C.

Maximum claimed surge rating, maximum continuous operating voltage and

detail recommended fusing or isolation data specified shall be substantiated with
certified or testing result with actual detail test levels.

END OF SECTION

Page B / 30
 Technical Specifications
Section C: SCADA, Telemetry & Instrumentation

-As per attached Air Selangor ‘SCADA and Instrumentation System Specifications’ Rev. 2.0
dated 30.5.2017’

Page C / 1
SCADA AND INSTRUMENTATION
INSTRUMENTATION
SYSTEM SPECIFICATIONS
SPECIFICATIONS

Revision Date
Initial release 4.1.2010
1.0 8.8.2011
2.0 30.5.2017
 TABLE OF CONTENTS

1.0 INTRODUCTION
1.1 Type of Water Supply System…………………………………………. 5
1.2 Typical Diagram of SCADA and Instrumentation ………………... 7

2.0 DESIGN REQUIREMENTS

2.1 Standard of Compliance ……………………………………………… 8
2.2 General Design………………………………………………………..... 8
2.3 System Design…………………………………………………………... 10

3.0 SCADA SYSTEM – OUTSTATION

3.1 General ………………………………………………………………….. 13
3.2 Remote Terminal Unit…………………………………………..……... 13

4.0 COMMUNICATION SYSTEM

4.1 General ………………………………………………………………… 16
4.2 4G/LTE . Modem ….…………………………………………………. 16
4.3 Antenna ……………………….……………………………………….. 17
4.4 Signal Cable ………………………………….………………………. 17
4.5 Lightning Arrestor ………………………… …………...…………….. 17

5.0 INSTRUMENTATION
5.1 Ultrasonic Level Sensor……………..………………………………... 18
5.2 Pressure Transmitter……………………………………….………….. 20
5.3 Flowmeter……………………………………………………………… 22
5.4 Touch Panel ………... ……..…………………..……………………… 25

6.0 POWER SUPPLY SYSTEM

6.1 General………………….……………………………………………..… 27
6.2 Battery Charger……………………………………………………..…. 27
6.3 Solar Power system…………………………………………………… 27

Page 1 of 72
 6.4 Sealed Lead Acid (SLA) Battery…………………………………….. 28

7.0 DISTRIBUTION SYSTEM

7.1 General………………………………………………………………….. 30
7.2 Type of Cable………………………………………………….………. 31
7.3 Installation Method………………………..………………………….. 34
7.4 Excavation and Backfilling of Trenches………………………..…. 42
7.5 Cable Protective Covers……………………………………….…… 43
7.6 Record Drawings …………………………..……………….………….. 43
7.7 Cables Schedules ………………………………………………………. 44

8.0 EARTHING SYSTEM…………………………………………………….……….. 46

9.0 LIGHTNING PROTECTION SYSTEM

9.1 General……………………………………………..…………………… 51
9.2 Power Lines Surge Protector for Main Incoming Supply……….. 51
9.3 Power Line Surge Filter for RTU and Instruments…………..……... 52
9.4 Single Lines Surge Protector for Data Transmission & Control
System …………………………………………………………………….. 53
9.5 Earth Conductor for the Power & Signal Lines Surge…..………... 54

10.0 OTHERS
10.1 Control Relay……………..……………………………………………… 55
10.2 Interposing Relay……………………………....…………….………….. 55
10.3 Circuit Breaker.………………………………………………………… 56
10.3.1 General …………………………………….………...……………55
10.3.2 Miniature Circuit Breakers (MCB) ………………………….... 56
10.3.3 Auto-Reclosure Earth Leakage Circuit Breakers
(MCB)..……………………………………………………………...57

Page 2 of 72
11.0 INSTRUMENT PANEL
11.1 Design and Construction ………..……………………………….. 58
11.2 Component Arrangement ……………… ………………………. 59
11.3 Wiring and Cabling………...……………….………….…………… 60
11.4 Terminal Blocks ……….……..…………………..…………………… 62
11.5 Cable Terminations ………………………………………………….. 63

12.0 DEVELOPMENT
12.1 Requirement of Submission Process ……………………………. 68
12.2 Commissioning Test…………………………………………………. 24
12.3 Operation and Maintenance Instruction Manual …………… 71

Page 3 of 72
1.0 INTRODUCTION

This guideline serves to establish AIR SELANGOR minimum SCADA &

Instrumentation requirements for water supply systems.

The extent of the system to be implemented will be dependent on the

TYPE classification of the project as described below.

1.1 Types of Water Supply Systems

Table 1.0 and 2.0 show the different types of water supply systems. The
tables also show the primary instrumentation equipment requirements.

TYPE code of
Description of the Installation
installation

RESERVOIR

The following equipments are required:

• Ultrasonic Level sensor at Reservoir (RESLn).
• Flowmeter for each outlet of Reservoir (OUTFn).
• DC Sump pump for Flowmeter Chamber.
• Instrument Readings Display via RTU.

Additional parameters required connected to RTU:

1 • Battery Charger Status (AC FAIL, BATTERY LOW
& CHARGER FAIL.)
• Panel Door Open Status.
• CAT1 & CAT2 surge arrestor health status
• Flowmeter chamber flooding status.

A complete RTU system is required to monitor the

Service Reservoir(s) parameters by sending all
information back to master station at Command
Centre.

Table 1.0

Page 4 of 72
TYPE code of
Description of the Installation
installation

PUMP HOUSE

The following equipments are required:

• Pressure at inlet pipe to Suction Tank (INPn),
• Ultrasonic Level sensor at Suction Tank (SWLn),
• Flowmeter for each pumping main to Reservoir
(OUTFn).
• DC Sump pump for Flowmeter Chamber
• Pressure at pumping main to reservoir (OUTPn)
• Pump Status (ON,OFF,TRIP, Running Hour)
• Instrument Reading and Alarm Indicator Display
via RTU.

Additional parameters required connected to RTU:

• Battery Charger Status (AC FAIL, BATTERY LOW
& CHARGER FAIL.)
• Panel Door Open Status
2
• CAT1 & CAT2 surge arrestor health status
• Flowmeter chamber flooding status.

The instrumentations for Reservoir shall be displayed

at the respective Pump House.

In the case where the distance between the Pump

House and Reservoir is more than 500 meters,
additional RTU shall be provided from the same
manufacturer to provide standardization and
interchangeability of equipment but separately from
pump control system.

A complete RTU system is required to monitor both

the Service Reservoir(s) and Pump House
parameters by sending all information back to
master station at Command Centre.

Table 2.0

Page 5 of 72
 TNB Supply
240V AC
ELCB

LPU Cat 1 Battery

(Shunt)

24V DC SCADA & Instrumentation Panel

LPU Cat 2 Battery
(Series)
Charger

24V DC
MCB

Field Sensor
(2 wire system) 2 2 Fused Fused Fused
4C X 2.5mm 4C X 2.5mm
- Level LPU ( 4-20mA & Power )
LPU
- Pressure Power
Supply

ETHERNET CABLE 4G
Communication
Port RJ45 Modem
ETHERNET CABLE
< 1 Ohm
< 1 Ohm RJ45
LOW LOSS
Analog CABLE

Input HMI
Surge
4C X 2.5mm
2
4C X 2.5mm2 Touch Panel Arrestor
LPU (24 VDC ONLY) LPU
Digital
Field Sensor 4C X 2.5mm
2
4C X 2.5mm
2 Local Alarm Indicator
LPU LPU Input
- ( 4-20mA ONLY)
2
Flowwmeter 4C X 2.5mm
4C X 2.5mm
2
LPU LPU
(TOTALIZER ONLY) Digital
EXTERNAL
Output
TERMINAL ANTENNA
BLOCK

< 1 Ohm
Sump
Pump 4C X 2.5mm X PUMP
Flowmeter
Chamber

Control 2
4C X 2.5mm X PUMP (Optional)
Circuit
2
- Pump 4C X 2.5mm X PUMP

MT/2017/v2

FIELD FIELD FIELD POWER REMOTE

PROTECTION TERMINAL DISPLAY COMMS.
INSTRUMENT PROTECTION CABLING SUPLLY
UNIT

1.0 BLOCK DIAGRAM OF TYPICAL SCADA & INSTRUMENTATION SYSTEM

Page 6 of 72
2.0 GENERAL REQUIREMENTS

2.1 Standard of Compliance

All equipments/products must be registered and approved by at

least Suruhanjaya Perkhidmatan Air Negara (SPAN) or Air Selangor.

All major equipments must comply with the British Standards or

international regulatory bodies and local on products compliance
and approval. All equipments must pass all testing procedures and
certified by local or international regulatory bodies such as CE, SIRIM,
IEC, IEEE, CCITT and others.

Where materials are not covered by British Standards or where the

source of manufacture does not provide such compliance,
evidence must be provided with certification and certification test
report and proof of original copy if required.

2.2 General Design

The system design shall be an independent and separated system so

that a failure in any telemetry circuit shall have no effect on any other
system component functions (i.e. pumping system) unless otherwise
specified.

The whole SCADA/telemetry and instrumentation system shall consist

of, but not limited to the following sub-system:

2.2.1 System and Power Supply Unit

All equipments/devices supplied must be operated using 24V

DC power supply only and any equipment operated using AC
power supply is not acceptable.

2.2.2 Transmitting Elements

The transmitting element shall comprise of the transducer or

sensor, sensor cabling, transmitter or converter and its cabinet
or pedestal.

Page 7 of 72
 The different principle type to be employed for each category
of measurement shall be as follows:

• All level measurement : ULTRASONIC LEVEL SENSOR TYPE

• All pressure measurent : PIEZO-RESISTANCE PRESSURE TYPE
• All flow measurement : ELECTROMAGNETIC TYPE

Each parameter of measurement (level, pressure ad flow) shall

used standard unit as follows:
• All level measurement : in metres (m)
• All pressure measurent : in metres (m)
• All flow measurement : in metre cube per hour (m3/h)
• All totalizer measurement : in metre cube (m3)

2.2.3 Receiving Element

Unless otherwise specified, receiving elements shall be

provided in the form of:
• HMI Touch Panel
• Remote Terminal Unit (RTU)

2.2.4 Instrument Cabling

All instrument cables shall be installed individually from

instrumentation panel to the transmitting element and shall
overall screen, single galvanized wire armour and overall PVC
sheath.

Cable for AC, DC, control and signal shall be segregated and
shall not be mixed in the same multicore cable. Each cable
shall carry signals of only duty group and shall have separate
panel or junction box.

2.2.5 Lightning Protection System

2.2.6 Interface to Pump Control System complete with separate

panels, indicators, switches, etc.

Page 8 of 72
2.3 System Design

2.3.1 Working Life

Equipment shall be designed and constructed to give a

minimum operational life of 10 years continuous service when
operated on a 24 hours, 365 days per year basis.

2.3.2 Construction

Equipment shall be fully solid state and shall minimize use of

discrete components. The Equipment should preferably be of
plug-in modular design. All necessary cables, connectors and
materials for a complete installation shall be supplied together
with the Equipment and their costs included therein.

Equipment shall be fully tropicalized and suitable for working in

an ambient temperature of 10 deg.°C to 70 deg.°C with
relative humidity of up to 95% without any degradation in
performance and reliability, and shall be treated with
fungicides. The Equipment shall be dust and insect-proof.

Materials used in the equipment should generally be

incombustible. Should the use of combustible materials be
unavoidable, attention of the government must be drawn to
these, and the location and layout, in particular wiring, shall be
such as to minimize the risk of fire.

All components and printed circuit cards must be tested and

rugged in construction. It shall be designed with adequate
margins to withstand continuous services with a minimum of
maintenance.

Any component or assembly shall be capable of replacement

by one of an equivalent type, the characteristics of which fall
within the limits of the manufacturer’s tolerance, without
affecting the performance, reliability or stability of the system.

2.3.3 Labeling

All components, units, boards and their mountings shall be

submitted and sign written or marked to the satisfaction of the

Page 9 of 72
 Superintending Officer (S.O.) to permit easy identification and
cross reference to diagram. Components shall be individually
identifiable from layout diagram relating to individual boards
or units.

All such markings shall be readily visible without displacing any

component or wiring except that the marking of components
of units or sub-units that are normally removed from the
equipment for test or repair need only be visible when such
units or sub-units are removed.

Form positions shall be marked to show the supply voltage and

rating of the fuses fitted. All controls labels shall be clearly
marked in English.

2.3.4 Wiring and Cabling

All wiring and cabling within the equipment shall be of

adequate size and rating, neatly arranged and adequately
supported to minimize the risk for mechanical damage during
installation, operation or carrying out of normal maintenance
operations.

All wiring and cabling orientation shall have adequate space

to permit ease of maintenance and trouble shooting.

Where wiring of cable forms are adjacent, or attached to any

part of the metal framework, the framework shall be covered
with an approved insulating materials. Where a form passes to
the back of a panel, suitable insulating bushing shall be
provided to prevent cables from damage.

Wiring tags shall be so positioned that neither the tag, nor any
possible wiring conductor there on may come into contact
with any cover. Sufficient slack shall be left at the end of all
wires in forms, so as to permit replacement of components and
sub-assemblies without difficulty.

Tagging material shall be from cylindrical, hollow and white

ferrule type only with printable text on it. During installation, it
shall be secured by crimping together with cable lugs. Cable
lugs shall only be from cylinder type and to be crimped using
hexagonal crimping tool.

Page 10 of 72
Wiring of cable forms, feeding hinged frameworks carrying
apparatus shall be formed and run in such a manner as to
prevent rubbing action and possibility of breakage of wires.
The hinged mountings shall open and close without straining
the wiring.

Soldered termination shall be such that the wire may be

unsoldered and removed from the tag without undue risk of
breakage of the wire or tag. All cabling and wiring shall be
such that inductive interference is reduced to minimum.
Precautions shall be taken within the equipment to prevent
danger to personnel from contact with parts of the equipment
carrying main voltages.

Page 11 of 72
3.0 SCADA SYSTEM – OUTSTATION

3.1 General

Two (2) types of RTU shall be used for different type of function.

a) Type 1 – designed for installations at reservoirs

b) Type 2 – designed for installations at pump houses that require an
expandable feature such as pumps, additional instruments,
security features and many more.

Each type of RTU provided for the scheme shall be from the same
manufacturer to provide standardization and interchangeability of
equipment.

3.2 Remote Terminal Unit (RTU)

The Remote Terminal Unit (RTU) shall be of a modular design. It shall

comprise a separate power supply unit, a separate CPU module and
separate I/O modules that can be added onto the backplane on an
incremental basis. Failure to any module shall necessitate a change
of the faulty module only.

The RTU at pumphouse shall utilize modular input/output modules

only and be expandable to support up to 1024 I/O points. ‘Brick’ or
‘Compact’ type RTUs where the CPU and some I/Os are built into
integral units can be use at reservoir installation.

The communication protocol provided between RTU – master station

and RTU – RTU shall be DNP3.0 and the communication protocol
between RTU and smart sensors shall be HART as minimum
requirement. All communication protocols must ready for both serial
and IP based communication medium.

DNP3 protocol must be configured in Unsolicited & Report By

Exception mode in order to optimize data transmission.

The analogue input modules shall accept 4-20 mA DC from field-

mounted transmitters. The analogue inputs shall have minimum of a
12-bit resolution. Contact inputs shall be optically isolated and
protect input circuits from transients and surges up to 3 kV input-to-
logic.

Page 12 of 72
Analogue output modules shall convert data words into proportional,
isolated 4-20 mA DC analogue output signal to adjust gate positions
with minimum 8-bit resolution. The analogue power output shall be
able to drive up to 500 ohm maximum resistance load.

The digital input module shall be capable of accepting switching of

mechanical or solid state contacts. Protection rating of the input
circuits from transients and surges up to 3 kV input-to-logic. All points
must have configurable contact debounce features for noise filtering
to filter high frequency noise from plant.

The RTU shall be equipped Pulse Counter function which can be

assigned to any DI point. Its function is to accept any pulse
connected to it and counts incrementally inside memory, even in
sleep mode. It must be able to count for a maximum count of
999,999,999. The pulse counter shall also be able to be set to any
value and reset to zero.

The digital output modules shall be capable of providing solid-state

switches in either momentary (pulse), or latched mode to control AC
or DC powered loads. Isolation protection shall provide isolation up
to 3 kV input-to-logic. Digital output points switching current shall be
2A maximum.

RTU is recommended to have built-in surge suppressor of varistor type

to clamp the DC surge level up to 25% above the working voltage
for all I/O points.

The RTUs shall come with one TCP/IP Ethernet port, one HART port,
one RS-232 and one RS485 serial port as the port for RTU to RTU
communication using Master/Slave configuration and
communicating using HART protocol to sensors. Data signal from the
outstations shall be transmitted to the master station via the same
single communication network using VPN connection. An additional
industrial din-rail type switches need to be installed when more TCP/IP
Ethernet port is required.

RTU configuration software shall be provided to enable the RTUs to

be configured at site. The RTU configuration software shall run on a
notebook computer with Windows 7 minimum. It shall be possible to
perform field upgrades by downloading a file through the RTU
communication port locally or remotely via Operation Command
Center.

Page 13 of 72
The RTU shall be suitable for operation a single phase 240 V + 10%
50Hz supply with auxiliary power supplies at 24 V DC supply or 24 VDC
supply from a solar power system.

The RTU shall be of a low-power design. This is to allow easy and cost
effective installations using other power sources such as solar or
battery power. A low power design will also enhance reliability of the
CPU module.

The RTU programming shall be compliant with IEC 1131-3

programming language standard and shall support as a minimum:
• Ladder Diagram.
• Structured text.

The RTU CPU shall have an integrated watchdog timer and a

minimum of 16MB external RAM and shall use Flash/EEPROM/SD card
memory to support the RTU non-volatile storage of data logging,
parameter settings and instruction sets. The RTU CPU shall come with
a real-time clock. The crystal oscillator of the real-time clock shall
have a tolerance of no more than 10 parts per million to ensure
accuracy of time tagging of data.

When there is a real-time communication link with the master station,

the RTU shall be able to synchronize its real-time clock with the master
station clock via communication link and protocol.

The RTUs and all its associated equipment shall be designed to

function continuously in temperatures between 0 – 70˚C and
humidity between 0 to 95% relative humidity non-condensing.

All RTUs shall be configured to perform local automation functions at

the pumping stations independent of the master station and come
with report-by-exception (RBE) and solicited reporting features to
minimise the amount of unnecessary data transmitted to the master
station.

All conversion of raw engineering values shall be done in RTU logic

programming and only calculated engineering value will be sent to
Master Station. All changes to the conversion factor can be remotely
updated from Command Center directly via SCADA HMI interface
without using any programming tools.

Page 14 of 72
4.0 COMMUNICATION SYSTEM

4.1 General

Outstations RTU must be configured to use VPN over 3G/LTE network.

The data will be packeted and transmitted across the network using
3G/LTE to the nearby Base Stations and will then be forwarded to the
Internet Service Provider (ISP) and sent to SCADA Master Station
through IP based connection.

4.2 4G/LTE Modem

The modems shall be versatile, sensitive, reliable and able to operate

for 24-hours continuously over all the 4G/LTE bands available. The
downlink and uplink speed shall up to 100Mbps (max) and 50 Mbps.

The modem shall come with minimum of 1 TCP/IP Ethernet ports and
1 RS-232 / RS485 serial port as the port for communication.

The modem shall have built-in firewall and supports virtual private
network (VPN) for secure communication to M2M Gateway located
at Operation Command Center. L2TP, SSH or OpenVPN protocol are
acceptable.

The modem shall be designed to function continuously in

temperatures between -30 ºC to 75ºC with natural air circulation and
humidity between 5 to 85% relative humidity non-condensing. The
modem shall be suitable for power supply operation between 12 V
DC to 48 V DC supply.

The modem operation shall be transparent to RTUs and SCADA

software at Operation Command Center where it shall not
interfering, modifying, buffering, holding and removing the
communication data encapsulated within the communication
protocol.

The modems shall support communication mode using SMS as a

backup where data shall be generated and sent by SCADA system
in this format in the event of failure on the IP-based communication
channel.

Page 15 of 72
4.3 Antenna

The antenna shall be at least 10 dB high-gain, directional or omni

remote antenna with minimum 0.5 meter cable length. The antenna
must be installed at the highest location of the site and screw-type
based for secured/permanent installation for maximum signal reach-
out to nearby based station.

Selection of the antenna type is subject to the signal strength

acceptance by the modem at site minimum of 60% of full scale.

4.4 Signal Cable

The signal cable shall be a 50 Ohm RF Coaxial Cable (low loss type)
to reduce attenuation. Minimum specifications are stated below:

Impedance 50±3 Ohm

Nominal capacitance 82 pF/m
Velocity of propagation 82%
Insulation resistance >5000 Mohm.Km
Inner conductor resistance 6.8(10.5) Ohm/Km
Outer conductor resistance 14.1 Ohm/Km
Operating temperature range 40°C - +85 °C
Min.bending radius 38 mm

4.5 Lightning Arrestor

Minimum specifications are stated below:

Frequency Range DC~6000 MHz

Return loss 18dB Min.
Impedance 50 Ω nominal
Insertion Loss -0.5 dB (max.)
Spark-over voltage 230V
Surge life 10x3kV(1.2x50µs)
Max Surge 6㎲ , 6KV , 5KA
Residual voltage 5X20KA(8/20µs)
Operating Temp -30℃ ~ 70℃
Insulation resistance 5GΩ Min.
Port Connectors 10X20A 1sec @ 60H

Page 16 of 72
5.0 INSTRUMENTATION

5.1 Ultrasonic Level Sensor

Ultrasonic and level measuring instruments shall employ the principle

of measuring distance in term of time by the propagation of sound
waves in air from a transmitter and measuring the time interval
between transmission and reception of the reflected sound wave.

The transducer shall be sealed and coated with protective layer of

PVDF/ EPDM and shall be an corrosive proof. The design of the
enclosure shall suit the application and required characteristics of
the transmitted and reflected sound beam.

The sensor, which shall be a two wire system with power and output
analog signal on the same pair of line, minimum of 12-meter range
and positioned at least 250 mm above the high water level. It shall
contain an electro-dynamic transducer for the transmission and
reception of sound waves. The sensor shall support HART protocol.

The overall accuracy of each installation shall be within + 0.25% over

the complete working range including the linearity, repeatability and
hysteresis.

A timing unit shall be included for determining the time for the overall
travel and converting this time into distance. The reaction time shall
not be more than 5s.

Analogue to digital converters shall be incorporated for operating

the remote integrators. The output from analogue instruments shall
be 4-20 mA.The sensor shall be capable operating in temperatures
from -20ºC to +60ºC and shall be impervious to submersion and shall
have a high resistance to corrosive atmosphere.

The design and application of ultrasonic level meters shall take into
account the tank type, the material, size, shape, environment,
process fluid or material, the pressure of foam, granules, size etc. The
installation shall be chosen carefully in order to avoid any
degradation of performance from spurious reflections, absorption,
sound velocity variations, sensors detection area, temperature
fluctuations, shielding, stilling tube or other measures shall be
provided to avoid effects on the measurement.

Page 17 of 72
 7.5 TYPICAL INSTALLATION & WIRING OF ULTRASONIC LEVEL TRANSMITTER

Junction Box

Terminal Block (Fused

Type)

L
P
U
2.5 mm PVC
cable
Flexibble GI Conduit

Ultrasonic Level
Sensor

Panel Body (4C x 1.5mm

Panel Door amoured screen) Cable Gland Stainless Steel
Cable Gland Ring Bracket

6 mm PVC
cable

Cable Gland
Conduit

To Earth Field Cable to

Station RTU Panel

Rev v2 4/17

Page 18 of 72
5.2 Pressure Transmitter

All pressure measurements shall provide by means of gauge pressure

transmitters. The pressure measurement system shall consist of:

1 inch diameter directs tapping complete with polyethylene

pipe and isolating corks.

Venting valve to release pipe pressure during maintenance

Signal transmitter with LCD display.

The system shall be of the gauge pressure type and the transmitter
shall be a two wire system with power and output analog signal on
the same pair of line. The output of the system shall be linearly
proportional to the pressure and shall have a live zero 4 to 20 mA DC
against a load at least 600 ohms. Zero and span calibration shall be
non-interacting and shall be easily accessible to facilitate calibration
works.

The pressure transmitter shall utilize piezo-resistive method in the

measurement of water pressure in the pipes. Pressure from the pipe
shall be applied via a stainless steel 316 seal diaphragm and filling
liquid to a silicon pressure sensor whose diaphragm is then flexed. The
resistance change of the piezo-resistors in relation to the pressure
acting on the diaphragm is then amplified and converted into an
output current of 4 to 20 mA DC.

The pressure transmitter shall have an accuracy of +/-0.25%,

including hysteresis and repeatability and have a long-term signal
stability of at least +/-0.25% over a year with maximum span. The
pressure transmitter shall be suitable for an operating temperature
range of –30 to 85 deg Celsius.

The pressure transmitter shall come with stainless steel housing and
process connection. Ingress protection for the device shall be to IP65.

Page 19 of 72
 3.0 TYPICAL INSTALLATION AND WIRING OF PRESSURE TRANSMITTER

Padestal Terminal Block (Fused

Type)
LCD
I Pressure Transmitter
L N
P P
U
2.5 mm PVC
cable

Venting
Valve
(4C x 1.5mm
amoured screen cable)

Panel Body
Panel Door
Cable Gland Ring

Isolating Cork

6 mm PVC
cable

Cable Gland Poly-pipe

Conduit

To Earth Field Cable to Pressure from

Station RTU Panel Pipeline
Rev v2.

Page 20 of 72
5.3 Flowmeter

The flow measurement sensor shall be of low power consumption

electromagnetic induction full bore type. It shall be able to operate
fully on nominal 24V DC supply system. The sensor supplied shall
conform to the following standards:-

a) ISO 4064:2005
• Pt 1, Pt 2 and Pt3 – Measurement of Water Flow in closed
conduits – Meters for cold potable water

b) ISO 6817
• Measurement of conductive fluid flow in closed conduits
• Method of Using Electromagnetic Flow Meter

c) ISO 9104
• Test and Measurement of Fluid Flow in Closed Conduits For
Electromagnetic Flow Meters For Liquids

d) EN 60529
• Degree Of Protection By Housing (IP Code)

e) EN 61010
• Protection Measures For Electrical For Measurement,
Control, Regulation and Laboratory Procedures

f) EN 61326 (IEC 1326)

• Electromagnetic Compatibility (EMC Requirements)

The sensor shall be from a remote type (detachable from converter)

and can be connected to converter via IP68 cable and connectors
with maximum length of 30m. It shall be rated to IP68 (submersible up
to 10m) for ingress protection and be constructed of materials
suitable for outdoor/inside chamber installation. The sensor shall be
free of any external influences that can affect the flow meter
accuracy such as magnetic fields, electromagnetic fields
interference etc.

The sensor shall be of full or contoured bore design with ranges of

diameters from 25mm to 1500mm. The flow meter sensor body shall
be of flanged design and be rated to handle line pressures up to 16
bars.
The sensor body shall be made of carbon steel and the electrodes
shall be made from AISI 316 stainless steel. The lining shall be made
Page 21 of 72
from material suitable for potable water such as polypropylene or
ebonite.

The earthing rings shall be of stainless steel. Grounding termination for

both side meter (sensor) to pipe shall use minimum of 4 mm2 cable
and shall be connected to earth. The requirements of earthing ring
system are to follow the recommendation as according to
installation manual.

The sensor shall have a combined accuracy with converter for 0.25%
or better and repeatability of at least 0.5%. The sensor shall able to
measure bi-directional flow and come with empty pipe detection
feature. The sensor shall operate satisfactorily in ambient
temperatures up to 60°C.

Page 22 of 72
 4.0 TYPICAL INSTALLATION AND WIRING OF FLOWMETER

Padestal Terminal Block

(Fused Type)

L L L
P P P
U U U
2.5 mm2
PVC cable

1.5 mm2
amoured
screen
FLOW CONVERTER
Panel Body
Panel Door
Cable Gland Ring

6 mm2 PVC
cable Flowmeter
Chamber
Field Cable to GI Conduit
To Earth RTU Panel
Station Conduit

4 mm2 PVC
cable

Page 23 of 72
5.4 Touch Panel

5.4.1 General

The purpose of using Touch Panel is to combine and displaying the

analog readings and digital alarms into a single point of device at
pump house and reservoir.

The following parameters shall be incorporated as minimum

requirements:

• The water level of suction tank and reservoir.

• The pressure of inlet suction tank and pumping pipe at pump
house.
• The pumping and falling flow rate, the pumping and falling
totalizer at pump house and reservoir.
• The low, high and overflow alarm status of suction and
reservoir level (The I/O of the system shall be directly from the
RTU).

It shall also incorporate RESET and security features. The flow rate shall
have programmable scaling.

The Touch Panel shall be a HMI and programmable type. It shall have
supports for remote access via intranet or internet.

For maintenance, all data shall be automatic backup on SD card

and simple transfer of data to replacement device.

The Touch Panel shall supports connection of external devices (USB

flash drives, mouse, keyboard, etc.) via 2 integrated USB host
interfaces.

For security integrated features, the built-in software shall supports:

• Know-how Protection
- Algorithms can be protected against unauthorized access and
modifications.
• Copy Protection
- On the Memory Card, individual blocks are linked to the serial
number of the original memory card. This means that programs
cannot be copied. They will only run with the intended memory
card.
• Access protection
- Access protection functionality offers security against
unauthorized project-planning changes. Permission levels can be
used to grant separate rights to different user groups.
• Manipulation protection
- The system helps to protect the data being transmitted to the
controller from unauthorized manipulation. The controller
recognizes when a transmission of engineering data has been
changed or comes from an unknown source.

5.4.2 Technical Specifications

Description Pumphouse Reservoir

Display 7 inch 4 inch
Resolution (pixels) 800 x 480
Screen Type Touch
Supply voltage 24 V DC
Power / Input Current 0.5 A / 12 W
Processor Type X86 or ARM
Memory 12 MB
2 Ethernet ports
1 RS422 /485 (combine)
Interfaces
2 SD Card slots
USB port
Protocols Modbus TCP/IP, TCP/IP
Class of protection IP65
Operating Temperature 0 – 50 °C
Relative humidity 90 % ; no condensation

Page 25 of 72
6.0 POWER SUPPLY

6.1 General

Components shall be standardized as much as possible. Electrical

identical components shall be of one type and make. Components
installed shall be type tested in accordance with relevant IEC
specification and type test certificates shall be submitted.

6.2 Battery Charger

Battery charger shall have function to provide power to loads while

charging and to keep fully charged all backup batteries.

The charging system shall be 24VDC at 10A, continuous operating

type, combination of constant current & voltage and voltage
regulated switching system to be set (adjustable) at 2.25 to 2.3
volts/cell for float at 32ºC or as per recommendation by battery
manufacturer. It shall have minimum voltage settings for:

a) Low Voltage Disconnect - 19.45 V

b) Battery Low - 22.00 V
c) Float to Boost - 24.00 V
d) Boost to Float level - 26.50 V

It shall have separate terminal connection for battery and load. It

shall automatically switches from charging mode to float mode and
vice-versa depending on the battery voltage level/power capacity.
When battery is in fully charged state, it shall provide trickle charge
to maintain the backup battery power capacity.

It shall be provided with high temperature protection, resettable fuse

for over-current/low-voltage protection and over-voltage/over-
charging protection. The unit shall come with built-in voltmeter and
10A ammeter for load. It shall be equipped with individual dry
contact alarms of Battery Low, Charge Failure and AC Failed for
connection to SCADA system.

6.3 Solar Power Supply System

Solar system shall consist of the solar PV module, intelligent

charger/controller, trip/breaker, monitors/meters, SLA batteries,
connection/wires, solar panel mounting rack and battery for 24 VDC
operating voltage.
Page 26 of 72
 The charger controller shall be from MPPT and PWM type to extract
maximum power from PV. It shall come with LCD to display various
information i.e. charging current, load current, net current, PV
voltage. It shall able to select 12VDC or 24VDC system automatically
and rated at 30A maximum current load. It shall come with a
summary dry contact for charging failure, battery failure and PV fails.

The solar PV module shall be a monocrystalline type and the power

system sized is based on a 4-hour daily availability of daylight.

The solar panel shall be high efficiency, high quality and

weatherproof for outdoor installation. The solar panel shall be
reliable, safe, effective and with warranty for a guaranteed electrical
production for 10 years at 90% of rated power output and 25 years
at 80%.

It shall be moisture resistance, stable against UV and properly

insulated. The contractor shall state the guarantee period and
certification of warranty shall be issued on delivery.

The solar panels shall be water proofed and all the metallic part must
be corrosion free. It shall not lose its transparency after prolonged
exposure to high radiation, high temperature, dust, oil and
precipitation in the tropics.

The glass surface of the solar panels shall be tempered glass and able
to provide ultra-clear performance for excellent light transmission
and protects from wind and impact. Terminal enclosure on the solar
panel shall be designed for trouble-free field wiring and environment
protection.

The solar panel shall be installed at the top of the reservoir and shall
be fixed to a roof top or mounted on top of a minimum 3m GI pole
complete with arm, bracket and fixing accessories to avoid from
vandalism.

6.4 Sealed Lead Battery For Charger and Solar

The battery shall be from maintenance free Valve Regulated Lead

Acid (VRLA) or maintenance free Valve Regulated solar battery on
12V mono block. It must be spilled-proof and in high impact
container with low self-discharge current. The battery operating
voltage shall be up to 45ºC and shall have expectancy of lifetime for
10 -12 years.
Page 27 of 72
The battery size for the charger system shall be minimum of:

a) 12V/65AH and able to provide backup for 3 days without

charging for AC system.

b) 12V/100AH and able to provide backup for 5 days without

charging for solar system.

Page 28 of 72
7.0 DISTRIBUTION – CABLING

7.1 General Requirements

Cables and wires shall be supplied by an approved manufacturer

and as far as possible the same manufacturer shall be used for all
cables and wires. Each drum or coil shall be accompanied by a test
certificate stating the manufacturer’s name, rating of cable, result
and date of tests. Cables manufactured more than 12 months before
delivery will not be accepted.

All armoured cables shall be terminated with mechanical glands

which shall be of a type as to provide adequate mechanical support
by positively locking on the armour and shall at the same time give a
high level of earth continuity. The glands shall be provided with earth
tails for connection to earth nearby earth bar at RTU panel side only.

Cabling between the various items shall be the types as shown in the
Drawings.

a) Delivery

All cables shall be delivered on robust cable drums with cable

ends treated to form an effective seal. When a cable is cut
from a drum the cable end and the end left on the drum shall
be immediately sealed in an approved manner to prevent the
ingress of moisture.

b) Conductors

All cables comprise high conductivity stranded copper

conductors of the sizes and comply to BS 6360. The conductors
of single core cables shall be circular; those of multicore cables
shall be generally shaped. Multicore control cables shall have
a cross section not less than 2.5 sq. mm.

c) Insulant Colours

Insulant colours shall generally be in accordance with the

recommendation of the I.E.E. Regulations.

Page 29 of 72
 d) Rating

The Contractor shall ensure that each cable has sufficient

rating for its duty under both normal and possible fault
conditions. In assessing the rating and cross section required
for each cable the following factors shall be taken into
account:-

(i) Fault level and durations as governed by circuit

protection relays and MCCBs or MCBs.

(ii) Ambient air and soil temperature.

(iii) Allowable voltage drop under steady state (4% from

source main 415 volt switchboard to sub-switchboard or
MCC within a final sub-circuit) and transient (motor
starting) conditions.

(iv) Loading under steady state and transient conditions.

(v) Disposition of cables, whether in air or laid in the ground.

(vi) Method of laying.

(vii) Route length.

7.2 Types of Cable

a) Instrumentation Cable

i. PVC/PVC

Instrumentation cables specified as PVC insulated, non-

armoured and PVC sheathed. The cable shall be 300/500V
multi-stranded, overall screened and tested to BS 5308.

Page 30 of 72
 The cable shall be used for the exposed installation type and
shall not less than 1.5mm dia.

ii. PVC/PVC/SWA/PVC

Instrumentation cables specified as PVC insulated, armoured

and PVC sheathed. The cable shall be 300/500V multi-
stranded, overall screened and tested to BS 5308.

The cable shall be used for buried installation type and shall
not less than 1.5mm dia.

b) Power Cable – Low Voltage

DC power cables shall be from black and red color

meanwhile 240VAC power cable shall be brown, blue and
green.

C) PVC/SWA/PVC

The underground distribution cables shall have conductors of

annealed copper PVC insulated, steel wire armoured and PVC
sheathed adequately sized to carry the total power output
and lighting circuit required for the works and taking into
consideration voltage drop in accordance with I.E.E.
Regulations. PVC insulated armoured cables shall be
manufactured in accordance with the current B.S. 6346.

The voltage rating (EO/E) for the cable shall be 600V/1000V.

Power and control cables specified as PVC insulated,

galvanized steel wire amoured cable with an overall PVC
sheath are hereinafter referred to as PVC/SWA/PVC and shall
be manufactured and tested to BS 6346.

The cores of PVC/SWA/PVC cables shall be laid up to form a

circular cable and, where fillers are necessary for this purpose,
they shall be of PVC. Textile or other hygroscopic fillers are
prohibited.

There shall be no adhesion between bedding or sheath and

insulation. A polyethylene terephthalate (PTP) binder tape
over the laid iup cores shall be included by manufacturer.

Page 31 of 72
The amour bedding shall consist of an extruded layer of Type 6
or Type1 PVC compound complying with BS 6746. The radial
thickness shall be in accordance with BS 6346.

Amour shall consist of galvanized steel wires applied generally

in accordance with the requirements of BS 6346. Galvanizing
shall meet the requirements of BS 1442.

The outer covering the amour wires for all multicore control
cable shall consist of a black extruded PVC sheath which shall
comply with the requirements of BS 6746 for Type 1 compound.
The thickness shall be in accordance with BS 6346.

Conductors used for AC and DC systems shall not be mixed in

the same multicore cable. Control cables shall be made up of
the following standard numbers of cores : 4, 7, 12, 19, 27 and
37. All cores shall be coloured white and shall be identified by
black numbers arranged in sequence, e.g. 1,2,3,4,5,6, etc.

These numerals shall be lightly imprinted on the core insulation

at intervals of not more than 75 mm throughout the core
length. The shall be permanent in nature and not easily
removed without severe mechanical scraping. The figure ‘9’
shall be distinguished from the figure ‘6’, thus ‘9’.

Cables laid direct in the ground shall be laid in prepared

trenches not less than 600mm deep for L.T. cables and of
sufficient width to accommodate the number and size of
cables required. There shall be a layer of compacted sand not
less than 25mm thick as bedding. After the cables have been
laid, sand shall be spread over the cables covering the entire
length and width of the trench to a minimum thickness of
25mm above the largest cable and leveled.

The sand used shall be fine river sand with no stones included.
A layer of bricks shall be placed over the cables. Backfilling
shall be made with first quality material and well compacted
where cable trenches run across turfed area and roadways.

The turfing and reinstatement of the road shall be properly

carried out to the C&S Specification requirement. Wherever
possible cables shall be laid in continuous unjointed lengths for
the entire length of the cable route.
Page 32 of 72
 Where joining of cable is unavoidable, cables shall be properly
jointed using approved cable-joint box to ensure full
conductivity at rated current. The S.O. reserves the right to
reject cables in short lengths below 27.5 metres.

(ii) PVC

Power cables specified as single core PVC insulated are

hereinafter referred to as PVC cable and shall be
manufactured and tested to BS 6004. Such cables shall be
terminated as specified elsewhere.

(iii) PVC/PVC

Power cables specified as single core PVC insulated and

sheathed are hereinafter referred to as PVCPVC cable and
shall be manufactured and tested to BS Code 6004 or BS 6746
as appropriate. Such cables shall be terminated by
mechanical glands similar to that specified for PVC/SWA/PVC
cables.

7.3 Installation Methods

7.3.1 General

Cables which are to be run on walls, ceiling or other building

structures shall, unless otherwise agreed by the S.O., be
secured on cable trays or enclosed in GI conduit as
appropriate. All outdoor jointing (exposed to direct sunlight)
shall be covered with concrete and steel plate as illustrated in
Figure 1.0 below.

The concrete box size shall be at least 150mm x 150 mm x

150mm and made of concrete cement (grade 25), iron plate,
wall plug, screw and nut (stainless type). Each joint of the plat
and screw need to be soldered before installation.

The installation of concrete box is optional if the GI pipe

connection is 5 m higher than the ground and more than 2
meter away from reachable area.

Page 33 of 72
 25 Grade Cement

T6 Grade Iron
(Both-way)

GI pipe

Figure 5.0

Photo 6.0 (a) and (b) illustrates the typical installation of concrete box
at GI conduit jointing.

Photo 6(a)

Page 34 of 72
 Photo 6(b)

Every cable shall be neatly run vertically or parallel to adjacent walls,

beams or other structural members.

Where the building structure incorporates purpose-built covered

duct or trench systems for cables, power cables and control cables
shall be segregated and installed on separate trays, secured to the
walls and/or floor of the trenches. However, over short distances,
control cables may be run with the power cables, rated not more
than 600 volt with some spacing between the control and power
cables.

Where the structure incorporates general service ducts or trenches

containing pipework, chemical lines and other services, all cabling
shall be segregated from the other services and shall be run on the
trench walls, secured to cable trays. Crossover shall be kept to a
minimum and cabling shall be taken above wet service pipework.

Throughout the installation, due regard shall be paid to the spacing

of cables to maintain current rating, to prevent interference between
power and signal cables, and to avoid unnecessary crossovers and
deration.

Page 35 of 72
Cable hangers, cleats, saddles, brackets and similar supporting
devices shall be of an approved type and of adequate strength for
the cables they are supporting. They shall be treated to withstand
site conditions without corroding. Self-locking plastic buckle clips
and strapping shall not be used. Re-usable cable ties may however
be used. Cable ties shall be of nylon for indoor installations and
stainless steel straps covered with PVC/nylon for outdoor installations.
Nylon straps shall be of ultraviolet stabilized type.

Cables installed outside trenches, on the floor and walls shall be

provided with trunking covers to protect the cables against
mechanical damage.

Cables installed in areas of direct sunlight shall be covered with

cable tray trunking covers or GI conduits entirely up to instruments
cable entry holes.

All power cables shall be laid in a single layer and no bunching is

allowed. A minimum spacing of one time the cable diameter shall
be maintained for the power cables. Control/signal cables may be
bunched to a maximum or two layers.

Wherever it is necessary to remove the PVC sheath of a cable, eg.

At a joint, only the minimum length necessary shall be removed and
the exposed armour or copper sheath shall be neatly protected by

PVC tape or sleeves or other suitable means. Where cables pass

through walls below ground level, the Contractor shall ensure that
the point of entry is sealed against the ingress of moisture. Cables
shall be wrapped with “Denso-tape” or approved equal and any
remaining spaces around the cable filled with “Denso-mastic” or
similar approved materials.

Cables for high level signals, low level signals, resistance

thermometers and thermocouples, shall be segregated from each
other and each shall be separated from cables for power,
communications and other electrical services. Other cables run in
the vicinity of instrumentation cables shall be separated from
instrumentation cables by a distance of not less than 1% of the length
of any parallel run, with a minimum of 600 mm and a maximum of
4000 mm.

Page 36 of 72
Initiating devices for plant protection and personnel safety shall be
connected by individual cables direct to the tripping or safety
device and shall not be routed via any intermediate junction,
marshalling box, cabinet, relay, etc. The other sheaths of such
cables shall be coloured orange. Other circuits may, subject to the
provisions of the above paragraph, be grouped in multipair cables.
Terminals and glanding facilities shall be provided in junction boxes,
marshalling boxes, switchgear, etc. as appropriate.

7.3.2 Cable Tray

Cable tray shall be of the heavy duty, return flange perforated type,
fabricated out of electrogalvanised steel sheet and polyester power
coated.

The 37tilize37ed steel sheet shall be penetrated to remove oil, grease,

dirt, rust, millscale and the metal surface passivated before polyester
powder coating is applied and cured at 200° C. The polyester
powder coat shall not be less than 80 micron thick.

The thickness and support spacing of cable trays shall be as follows:-

Sheet Steel Support

Width Thickness Spacing (Max)
Up to 300 mm 1.5 mm 750 mm

above 300 mm
to 600 mm 2.0 mm 800 mm

above 600 mm to 2.5 mm 800 mm

900 mm

The height of the return flange shall not be less than 50 mm.

Loading on cable trays shall not cause at mid span a deflection

greater than 4 mm. All supports and tray work shall be a suitable for
withstanding a temporary weight of 125 kg.

The cable trays and accessories shall be sized to provide 25%

additional free space available after installation of the cables. The
minimum clearance behind the tray shall be sufficient to allow for
fixing of cables, which will relate to tray width, but shall not be less

Page 37 of 72
than 25 mm. Where trays are tiered, clear access shall be available
to all trays, with minimum 300 mm separation between trays.

Arms and supporting channels for cable trays shall be hot dipped
galvanized and shall be mill strut or approved equal. Fixings for cable
trays shall be disposed at regular intervals specified and not more
than 200 mm from bends to fix together adjacent sections of cable
trays and/or accessories.

7.3.3 Conduit

All conduits shall be of Class B hot dipped galvanized and screwed

steel type. Stove enameled conduit shall not be used without the
written permission of the S.O. Conduit fittings shall be of malleable
cast iron and be hot dipped galvanized. Fitting with covers shall
have a machined surface around the perimeter, mating with a
similar machined surface on the cover. The cover fixing screws shall
be of brass.

Conduit shall be run on the surface or sunk as specified and be neatly

arranged, and ways shall be provided for additional conduits at all
distribution boards. The sizes of conduit used shall be determined by
the number of cables to be drawn in as scheduled in the I.E.E.
Regulations or as specified for a particular position but in no case
shall conduit smaller than 20 mm diameter be used. Sunk and
concealed conduit systems shall support fittings independently or
any false ceiling. Conduit shall be supported by hot dipped
galvanized mild steel hangers fixed to walls/floors.

The conduits shall be screwed into spout outlets of conduit boxes or

where fixed to boxes drilled with properly sized clearance holes they
shall be secured by means of sockets and hexagon bushes. All
threads shall be cut clean and all burrs shall be removed with a
reamer. Exposed threads and plates where galvanizing has been
damaged, shall be cleaned and painted with two coats of an
approved metallic zinc based paint. The treatment applied as the
work proceeds.

Standard rectangular junction or adaptor boxes shall be provided at

all junctions and at sharp changes of direction in addition to any
other special positions where they are called for by the S.O. on Site.
Inspection couplers may be used in long runs to facilitate drawing in
cables, subject to the approval of the S.O.

Page 38 of 72
Particular care must be taken to ensure that no water is allowed to
enter the conduit at any time and all conduits shall be arranged with
adequate ventilation and drainage where necessary as directed by
the S.O. Inaccessible junction boxes will not be allowed.

Only continuous lengths of buried conduit shall be installed between

boxes, no joint boxes being allowed in the floor screeds. Conduits
crossing expansion joints shall be fitted with couplings of approved
manufacture with an earthing clip at each side of the coupling
connected by the correct size of tinned copper stranded wire.

The ends of conduits laid or set in formwork prior to concreting shall

be temporarily sealed off with a coupler and a solid brass plug.

Fixing to surfaces of walls shall be by means of galvanized steel stand-

off saddles or 25 mm aluminum strip saddles where more than one
conduit is run in parallel, securely fixed by brass screws and nylon
plugs. Conduits shall be supported at regular intervals not exceeding
75 mm on horizontal runs and 900 mm on vertical runs. Where
conduits are concealed or laid in constructional floors, they shall be
held in position with substantial fixings of a make and pattern the
approval of S.O.

A junction or adaptor box shall be provided in all conduit runs

exceeding 10 metre in length or containing more than two right
angle bends or the equipment, to facilitate the draw-in of wires.
Junction and adaptor boxes shall be made from galvanized steel
and be provided with gasketted flat covers secured with brass
screws.

Weatherproof boxes and accessories shall be used outdoors, where

agreed on Site by the S.O.

Conduit shall be installed such as to permit complete rewiring without

the need to remove false ceilings or carry out builders work.

Cables for drawing into conduit shall be single core PVC insulated,
non-sheathed, 1000 V grade and shall be supplied by an approved
manufacturer. Insulation shall be coloured to indicate phase and
neutral in accordance with the I.E.E. Regulations. Care is to be taken
in the number of cables in conduit and in no case shall conduits
enclose more cables than that set out in the I.E.E. Regulations. No
single conduit serving a single phase socket outlet, lighting point or

Page 39 of 72
switch shall contain more than one phase. Switch wires shall be white
in colour.

Wiring shall be carried out on the looping-in systems and no joints

other than at looping-in points will be allowed. Cables shall be only
drawn into the conduit after the conduit installation has been
completed.

All conduits before painting shall be washed with I.C.I Litho form or
approved material and shall then be primed with an approved
chromate primer followed by one undercoat and two coats of
approved gloss finish for general areas. In chemical building and
other corrosive areas such as chlorine building, the undercoat and
top coats shall be resistant to corrosion.

Flexible conduits shall be of steel with PVC over-sheath and a

separate earth wire shall be provided for earth continuity.

7.3.4 Trunking

Trunking shall only be used with the written consent of the S.O., where
large multiple parallel conduit runs occur.

The trunking shall be manufactured from electro-galvanized steel of

minimum thickness 1.5 mm, and shall be polyester coated. The
trunking shall have two return flanges for rigidity and removable
cover. The covers shall overlap the trunking and be made of the
same gauge. Each length shall be supplied with necessary
connection sleeves and joggled sides to allow flush fitting.

The number of cables installed in each trunking shall be such that

space factor of 45% is not exceeded. Separate compartments shall
be allocated using sheet steel barriers welded to trunking for circuits
requiring segregation.

The Contractor shall ensure that the size of the trunking is adequate
for the number of cables passing through it, but as a minimum the
size should be 50 mm x 50 mm. All bends, tees and intersections shall
be of the gusset type and manufactured by the maker of the trunking
and to a similar standard. The trunking shall be fixed to the ceilings
by means of a secure and permanent fastening to be approved by
the S.O.

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 Trunking shall be supported at intervals not exceeding 2 metre
horizontally of 2.5 metre vertically.

Where the trunking is installed in a vertical position insulated cable

supports shall be provided and packing shall be used at positions
where trunking goes through floor. Cables shall be retained in the
trunking when the cover is removed, by means of straps. Trunking
covers shall be fixed with centre and sideways captive screws or
spring-on type and no self-tapping screws will be accepted.

When trunking passes through a fire wall, a floor slab, a barrier of

adequate fire rating shall be installed to prevent the possible spread
of fire.

Cover plates shall be supplied in short lengths for easy removal. Every
entry to finished trunking shall be so placed as to prevent the ingress
of water. Cover plates shall be securely fixed after wiring is
completed.

For cables containing termite repellents, the drums shall bear a label
on the outside, warning that gloves shall be worn when handling the
cable.

Cable drums are to be non-returnable and are to be thoroughly

treated with cuprinol or equal insecticide and wood preservative.

7.4 Excavation and Backfilling of Trenches

The exact location of each cable trench will be settled on the Site by
the S.O. when the Contractor is ready to commence work.

Trenches shall be kept as straight as possible and shall be excavated

to approved formation and dimensions, and shall generally be 800
mm deep for cables of rated voltage up to 1000 V and 1000 mm
deep for cables of voltage grade above 1 kV up to and including 33
kV. Trenches shall have vertical sides and are to be timbered and
sheeted where necessary to prevent subsidence. The bottom of
excavated trenches shall be free of sharp stones and other
obstacles.

Where cables of different voltages are laid together, at the same

depth, vertical cable tiles shall be used to segregate the cables.

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Before the cables are laid, the bottom of the trench shall be lined
with sand to a thickness of 150 mm to form a bed. After the cables
are laid, the first 150 mm depth of cover backfill shall consist of sand,
over which shall be placed protective covers.

After all cables and protective covers have been laid, the trenches
shall be refilled in 150 mm layers, each layer being well rammed and
consolidated.

The surfaces of refilled trenches shall be temporarily reinstated and

maintained in a thoroughly safe condition until complete
consolidation of the soil is achieved.

The Contractor shall include for all materials and labour to reinstate
the ground to the same condition prior to excavation i.e turfing,
drains and roads, etc.

The excavation of trenches shall include, by way of amplification but

not of limitation, all timbering, pumping and bailing required and the
provision of all necessary labour, plant, tools, additional soil, fuel and
motive power for such purposes and the cost of the expendable
materials shall be included.

UPVC cable ducts shall be provided and installed at road crossings.

Only one cable shall be permitted in each cable duct. The external
diameter of cable duct shall be 150 mm for cables of overall
diameter 65 mm or more. 100 mm diameter ducts may be
considered for smaller cables. These ducts shall be encased in a
concrete jacket of 150 mm thick. The ducts shall be laid at a
minimum depth of 1000 mm.

Cables shall normally go under all obstruction such as mains, sewers,

drains, conduits and the like which cross the trench. The trench
bottom shall be ramped firm. Where it is not practical to go
underneath culverts and drains, cables shall at discretion of S.O. go
over them. The cables shall be adequately supported and
protected at the crossing. The type of support and protection
proposed shall be subject to the approval of S.O.

If an existing cable lies along the route, the Contractor shall generally
avoid excavating the existing tiles. If it becomes inevitable to move
the cable, the same shall be done after seeking permission from S.O.

Page 42 of 72
7.5 Cable Protective Covers

Protective cable cover tiles shall be of precast concrete type 1:2:4

mix complying with BS 2488 and engraved “Electrical HL or LT” or
according to the service. They are to be laid horizontally, interlocking
successively one with the other both vertically and laterally. Special
covers shall be provided, if required, for short radius bends.

The protective covers shall be of the following dimensions, unless

otherwise approved.

1000 mm long x 300 mm wide x 50 mm thick - for one circuit of

power cable

1000 mm long x 150 mm wide x 50 mm thick - for control and

instrumentation cables.

The protective covers shall be of such width as to extend beyond the

outer cables in the cable trench, on either side by at least 50 mm.
The supply and laying of cable protective covers shall be included in
rate for cable laying.

7.6 Record Drawings

Record drawings for cabling shall include cable route drawings,

block diagrams and cable schedules. Within buildings, record cable
route drawings shall show to scale the location of all items of
electrical plant, the route and method of installation of all cables e.g.
on tray, in trench, inducts, conduit etc. External cable route drawings
shall show:-

i) The route of the buried cable.

7) The depth of laying including any deviation to avoid local

obstruction encountered during installation.
iii) Position of marker posts.

iv) Position of joints, test terminal points, drawpits etc. located

from marker posts or other agreed key points.

v) Distances of cable runs from pipe runs or other buried

services.

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 vi) Position of earth electrodes, earth rods disconnecting
chamber and interconnecting earth tapes

7.7 Cable Schedules

A full cable schedule for all cables shall include:-

i) Cable tag number

ii) Cable type / construction

iii) Cross section of conductor(s) (conductor size)

iv) Number of cores

v) Start and finish point of cable

vi) Volt drop/amp/metre

vii) Route length

viii) Current rating of cable

ix) Rated voltage (voltage grade)

x) Load rating in KW

xi) Load current

xii) Installation method (in duct/buried underground).

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8.0 EARTHING SYSTEM

8.1 Main Earthing System

Earthing systems shall comply with the requirements of BS 7430–

Earthing, IEE Wiring Regulations, TNB and Suruhanjaya Tenaga as
required.
The main earthing systems shall consist of earth bars, circuit
protective conductors, equipotential bonding conductors, concrete
electrode pits complete with 15.6 mm dia. X 5,467mm long
(minimum), hard drawn copper or copper clad steel earth
electrodes and gunmetal clamps, interconnecting 25mm x 3.125mm
copper strips in 50mm diameter PVC pipes.

The earth resistance value measured at the Main Earth Bar shall not
exceed 1 ohm. The earth connections for all sections of each
installation shall be continuous throughout. Each individual earth
systems shall achieve its required earth resistance value before being
interconnected with other earth systems.

Upon installation of new equipment, existing earthing shall be

checked resistance. The new equipments can be connected to
existing earthing if it resistance is less than is within specification.
Otherwise, new earthing system must be installed and connected to
existing system with overall resistance shall within specifications.

8.2 Equipment/ Instrument Earthing

All non-current carrying metal framework associated with the

electrical equipment, each item of electrical plant, casings and
cable sheaths, etc shall be earthed by means of 25mm x 3mm tinned
copper tape or copper conductors to the earthing network
comprising of a ring to be run around the electrical perimeter of each
location. The series earthing of one piece of equipment to another
utilizing the equipment casing will not be permitted.

The main bonding cables shall not be less than 10 sq. mm and
supplementary bonding of non-electrical plant not less than 6 sq.
mm. All connections shall be made using compression type cable
lugs, taped on completion to completely seal the lug and any bare
copper from the atmosphere.

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 The earth network conductor comprising tinned copper tapes
and/or cables shall be securely supported and clamped in a neatly
spaced manner on building structures, cable trench walls all on
cable trays, and neatly run vertically, horizontally, parallel to
adjacent walls, ceilings, beams, etc. appropriate. The earthing
installation shall be protected from any mechanical damage or
corrosion.

The instrument earthing shall be by means of instrument earth cable

to draw earth resistance of less than one (1) ohm. The earth cable
shall be laid from the instrument to the shortest distance possible to
the earthing points/ chamber complete with the necessary fixing
accessories.

8.3 Main earth bars and earth continuity conductors

A main earth bar (complete with test links) shall be installed in any
convenient location preferably in cable trenches 600 mm above the
finished floor level. The main earth bar shall comprise a high
conductivity copper bar supported on porcelain barrel type
insulators and wall mounted. The earth bar shall be of sufficient length
to accommodate bolted copper tape/cable connections to:
- The earthing conductors between the earth bar and the earth
electrode
- Circuit protective conductors between the earth bar and
exposed conductive parts
- Main equipotential bonding conductors between exposed
and extraneous conductive parts
- System neutral earthing conductors

Earth studs shall have a minimum size of M8. The main earth
conductor shall also be provided with adequate number of spare
terminals including cable lugs, bolts, etc.
The size of earth continuity conductors shall be as follows:

For cable sizes above 70 sq. mm : 25 mm x 6 mm tinned

copper tape

For cable sizes 35 sq. mm and up : 25 mm x 3 mm tinned

copper tape to 70 sq.mm

For cable sizes less than 35 sq.mm : 13 mm x 1.6 mm tinned

copper tape

Page 46 of 72
 Earthing tape connection shall be run in approved positions and
fixed in an approved manner generally in square and symmetrical
lines using gun-metal saddles of appropriate size for securing tapes
at intervals not exceeding 900 mm. The copper tapes shall be
supplied in long unbroken lengths to avoid unnecessary jointing.

Particular care shall be taken on cable termination boxes to ensure

that the cable sheath and armour are adequately bonded to the
frame of the item of plant to which the cable is connected. The
armour of the cable shall not be used as the sole earth return path
conductor. Cable armouring shall be bonded to earth at both ends.

Where under special circumstances rigid or flexible conduit is

incorporated into the Works, an internal earth conductor shall be run
which shall be securely bonded to the terminating or intermediate
apparatus by means of a special earth terminal.

8.4 Joints

Bar to bar tee joints and tape to tape joints (for underground
connections) shall be of ‘Furseweld’ or ‘Cadweld’ method to the
approval of S.O. All earthing tape connections to electrical
apparatus shall be made by using a bolted connection in a visible
and accessible position. Before the connection is made, the tape
surfaces shall be tinned.

8.5 Earthing Points

Subject to determination by tests at site, earth electrodes shall be

provided comprising a system of vertical earthing rods
interconnected with copper tape. The electrodes shall be physically
arranged and spaced to be electrically independent and leads from
each shall be interconnected to the next to form a network. The
electrodes shall be grouped together providing an effective earth
and provide and earth loop impedance value not greater than one
(1) ohm.

8.6 Electrodes

Each earth point shall comprise an extensible type earth electrode

of diameter not less than 16mm, made of hard drawn steel cored
copper rods with internal screw and socket joint, hardened steel tip

Page 47 of 72
 driving heads and connector clamps. The rods shall have an
electrolytically bonded layer of copper of not less than 0.38mm
thickness. The Contractor shall determine the length and number of
electrodes required for each earthing, after the resistivity of the soil
at the particular location has been measured at site and witnessed
by S.O. The electrodes shall be interconnected by means 25mm x
3mm tinned copper tape laid at a depth of 750mm below ground
level.

Earth rods shall be driven by a ‘Kango’ hammer or similar, capable

of delivering a high rate of light blows to the driving head and the
Contractor shall deemed to be included in his Tender the use of such
tools.

The minimum spacing between two adjacent electrodes shall be

twice the length of the longer electrode.

Where ground conditions make deep driving of single earth

electrode impossible to achieve the desired earth resistance, a
matrix arrangement of electrodes joined to one another by 25mm x
3mm tinned copper tape buried at a depth of 600mm shall be used
to form an earth mat in order to achieve the desired earth resistance
value.

All joints shall be protected against corrosion and the ingress of

moisture by the application of two coats of an approved anti-
corrosion conductive paint.

8.7 Earth Clamps and Inspection Chambers

At each earthing point an approved non-ferrous clamp shall be

provided for the connection of the tinned copper tapes to
electrodes. These connections shall be housed in individual
electrode inspection chambers at every earthing point with a cover
set flush to ground level. The inspection chamber shall be of ‘Furse’
make type PT 205 or approved equivalent.

8.8 Marker Posts

Marker posts shall be provided to mark the position of the electrodes

adjacent to the earth chambers. The marker posts shall be similar to
those provided for cable routes.

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8.9 Excavation of Trenches

All excavation of trenches for the installation of the copper tapes,

earth electrodes and the inspection chamber shall be carried out by
the Contractor to the requirement of the S.O. The Contractor shall be
responsible for the backfilling and reinstatement of the trenches,
setting and alignment of the inspection chambers to the satisfaction
of the S.O.

8.10 Testing of Electrodes

The works shall also include for testing of all earth electrodes to the
satisfaction of the S.O. The test instruments required for the tests shall
be provided by the Contractor.

After the earthing installation has been completed, the Contractor

shall demonstrate to the S.O. that the resistance of the electrodes to
earth and the continuity of the earth network are within the limits
specified. Any additional earth electrodes if required (maximum of
five (5) matrix electrodes) shall be provided by the Contractor. Earth
tests shall also include measurement of the resistance value of each
individual earth point.

Earth resistance testing shall also be carried once in the driest period
or any time which is deemed suitable by the S.O. during the Defects
Liability Period. Should the earth resistance value be less than the
specified value, the Contractor shall install additional earthing points
in order to achieve the specified value. The Contract Rates shall be
deemed to have taken into account the additional earthing points
required and there shall be no claims for cost in this respect.

8.11 Earthing and Grounding

Floating System to be implemented shall allow the installation to

“float up”, preventing potential differences between the
components installed. All power cables and also the surge protection
devices shall 49tilize a wiring practice known as ‘single-point
grounding’. This technique incorporates a central point to which all
electrical system is bonded, before taken to earth ground with a
single ground connection.

Page 49 of 72
9.0 LIGHTNING PROTECTION SYSTEM

9.1 General

The power lines surge protection system shall be tested and

conformed to the one or more on following codes of practices:

i) AS 1768:2007 Cat A, B & C

ii) BS 6651:1999 Cat A, B & C
iii) IEC 61643-1:1998
iv) IEC 62305-4:2002

The data lines surge protection system shall be tested conformed to

the one or more on following codes of practices:

i) ITU (CCITT) IX K17

ii) AS 1768-2003 Cat A, B, C
iii) BS6651:1999 Cat C-high
iv) IEC61643-21

All surge protection devices must be submitted with third party

certification with test reports.

9.2 Power Lines Surge Protector for Main Incoming Supply (Category 1)

The power line surge protection for the Main Incoming Supply shall
be rated at 40kA (8/20µs) per conductor with per phase rating of
80kA (8/20µs). The unit shall be tested to 20kA (8/20µs) suitable for
robustness and suitable for severe lighting environment. The
protector must provide reliable protection status indicator of
electronic type for each phase.

The Protector shall be full mode with line to neutral, line to earth and
neutral to earth protection. The let-through voltage shall be less than
750Vrms when subject to 3kA (8/20µs) waveform or less than
1,200Vrms when subject to 20kA (8/20µs) waveform.

The protector shall be virtually immune to the effects of 50/60 Hz

sustained over voltages, allowing fault voltages up to +15% of the
nominal RMS voltage (480 Vrms) to be withstood. It shall be designed
with high levels of protection for both common and

Page 50 of 72
 differential mode (L-N, L-E). To avoid from component expulsion due
to overvoltage the protector shall be metal encased.
The protector shall come with fast responsive Metal Oxide Varistors
(MOV) to provide low let-through voltage to protect the sensitive
electronics and electrical circuits.

The rated voltage shall be 240 V at 50Hz, Surge arrestors must be

designed to operate within the temperature rating of -10ºC to 60º C.

Maximum claimed surge rating, maximum continuous operating

voltage and detail recommended fusing or isolating data specified
shall be substantiated with certificate and testing results with actual
detail test levels.

9.3 Power Line Surge Filter for RTU and Instruments (Category 2)

A power lines surge filter capable of carrying the full load current shall
be installed in series at the incoming power supply toward the final
circuit to the RTU and instruments in order to deliver efficient
protection against transient over voltages.

The surge filter shall be rated for 220-240 VAC, 50Hz, single phase, 10
Amps running current at 45 degrees C ambient, 0-90% working
humidity. It shall have minimum surge rating of 40kA (8/20µs) per
conductor. For the solar panel installation, the surge filter shall be
rated for 24V DC at 2 Amps running current.

The surge filter shall be specifically designed for filtering of low

frequency disturbance. The 2dB attenuation frequency shall not
exceed 2 kHz and shall preferably be below 2 kHz. The attenuation
at 40 kHz shall be at least 40dB. The surge protector shall be designed
to withstand multiple strikes and able to protect and survive in
tropical lightning intense environment.

The surge filter shall be able to provide protection in full mode:-

i. Phase to Neutral
ii. Phase to Earth

The surge filter ‘let-through’ voltage in full mode must not exceed
600V when tested to 6kV (1.2/50µs), 3kA (8/20µs) test waveforms. It
shall have a reliable visual indication and is recommend to be

Page 51 of 72
 housed in metal enclosure to prevent any package rupture or
expulsion of the Metal Oxide Varistor in the event of overload. The
protector shall be installed as near as possible to the equipment to
be protected to endure its effectiveness. It must have visible indicator
and dry contact to RTU to indicate it healthiness. The contact must
be connected to RTU for remote indication.

The surge filter shall specifically be designed for lightning and surge
protection on power lines. It should have 5 years manufacturing
defects from the manufacturer and has ISO 9002 certificate. The
surge protection should be provided with test report from local
independent bodies.

9.4 Signal Lines Surge Protector for Data Transmission and Control System

The signal lines surge protector shall be installed to provide transient

protection for balanced and unbalanced data lines, signal and
communications circuit used in instrumentation process control,
communications and computing applications.

The protector for data lines shall be able to provide protection in all
mode or full modes i.e. line to line and line to earth. The peak transient
‘let-through’ voltage shall not exceed twice its normal operating
voltage when subject to a test conducted in accordance to
AS1768:2007, BS 6651:1999 Annex C and IEEE C62.41:1991 location
category C and ITU (formerly known as CCITT IX K17) 10/700µs signal
lines test waveform. The protector shall have a peak surge rating of
20 kA on 8/20 microsecond wave shape on each protected wires.

It shall be designed to have working frequency of up to 10MHz. To

ensure minimum disruption and no signal losses the in-lines resistance
of the protector shall be less than 5 ohms.

The protector shall be series, in-line devices and shall have separate
plug and base design with provided facilitates ease of module
replacement. To avoid earth loops that can potentially interrupt the
low noise signal in the instrument, the connection between the base
of the protector and the earth terminal shall be separated with high
energy Gas Discharge Tube (GDT). The GDT will only allow
equipotential bonding under surge condition.

Page 52 of 72
 The protector shall be particularly designed to divert transients on
long-lines, high exposure lines and lines susceptible to power lines
and lightning induction. Thus, the overall transient protectors (cap
and base together) shall be a multistages design in order to provide
low let-through voltage.

The surge protectors shall be designed for temperature and tropical

field conditions over operating temperature range 10 deg C to 50
deg C and relative humidity up to 95%. Cable termination shall be
able to accommodate wire sizes up to 2.5mm².

The signal lines surge protector shall be designed to withstand both

common mode and differential (transverse) mode transients. The
overall protector shall be multi stages clamping type.

The protector shall be able to withstand and adequate/divert many

transients over a long period. They shall not be one shot of self-
sacrificing devices. The protector shall be effectively earthed using
high quality mechanical connections. They shall be earthed to the
earth of the equipment that they are protecting and to no other
earth.

9.5 Earth Conductors for the Power & Signal lines Surge Protection

Earth wires terminate at the all the power lines surge protectors shall
be at least 10 mm² in diameter. For all signal lines surge protectors
shall be at least 4.0mm² diameter. They shall be laid alongside
incoming cable pairs (dirty lines) and kept away or as far as possible
from equipment side cable (clean lines).

Since a transients barrier with primary and secondary protection is

necessarily a non-symmetrical device, great care shall be taken in
installation to ensure line-side and equipment connections are
correct and not reversed. Earth leads shall be as short and direct as
possible to minimize earth wire inductance.

Page 53 of 72
10.0 OTHER COMPONENTS

10.1 Control Relay

Relays shall be of either plug-in or block type. Relays shall be housed

in dust-proof and totally enclosed cases to BS5490, IP64. The cases
shall be of transparent plastic capable of being replaced. Plug-in
relays shall be fitted with transparent plastic dust-proof covers,
retaining clips, a base into which the relay plugs and external
connections shall be made using easily accessible screw clamp
terminals. Bases and relays shall be keyed to prevent relays being
plugged into incorrect bases. If mounted on DIN rails, blocking pins
shall be provided. Space and drillings shall be provided for a
minimum of 10% additional relays. Block type relays shall be totally
encapsulated.

Relays shall be fitted with neon or LED indicator connected across

the operating coil and easily visible when the compartment door is
open. Relays fitted with mechanical indicators will not be
acceptable.

DC relays shall be ringed with a diode (1200V, 1A).

Relays with different voltage coils or different configuration of

contact shall not be interchangeable.

Mixed voltages shall not be connected to different contacts of a

particular relay. If necessary, additional relays shall be used.

When voltages exceeding 55 volts to earth are employed in relay

compartments or non-door interlocked sections then such terminals
shall be shrouded, segregated and fitted with warning labels. Where
supply voltages from remote are used, then care shall be taken to
ensure relays associated equipment, terminal fuses etc. shall be
shrouded and segregated where possible.

10.2 Interposing Relay

All interposing relays shall be low voltage, plug-in and hermetically

sealed to ensure continuous and reliable service in the tropical
environment at Site.

Page 54 of 72
 The number of different contact configurations on relay shall be kept
to a minimum even if some relays have unused contacts, to assist in
keeping spares stock to a minimum.

Multi-contact interposing relays shall be incorporated into panel

circuitry where only one pair of initiating contacts is provided on the
plant being monitored, for the operation of different functions
simultaneously, e.g. a control initiation with alarm annunciation and
data logging. The relay contacts shall be so connected that a failure
in any one circuit shall have no effect on any other.

The use of spare contacts on interface relays fitted within annunciator

units or other secondary circuit equipment, or any other form of
cascade operation other than that controlled by plant contacts, in
which the performance of one circuit is dependent on the correct
operation of another, will not be accepted.

10.3 Circuit Breakers

10.3.1 General

Circuit breakers shall be capable of interrupting all faults up to their

maximum rating without damage to equipment or danger to
personnel.

Test evidence of the normal current rating and certification by an

independent switchgear testing authority such as KEMA or ASTA of
the symmetrical breaking capacity including the short time rating
temperature rise and creep age test shall be submitted.

10.3.2 Miniature Circuit Breakers

Miniature Circuit Breakers (MCBs) shall comply with IEC 947-2

and shall be of DIN rail mounted type. MCB shall not be used
for controlling 3 phase equipment unless prior approval has
been obtained from the S.O.

The breaking capacities of the MCBs shall be at least equal to

the prospective fault level at the point of the distribution system
where they are installed and the ultimate breaking capacity
(Icu) shall be minimum 10 kA.

Page 55 of 72
 Each pole shall be provided with ambient temperature
compensated bi-metallic thermal element for inverse time
delay protection and magnetic element for short circuit
protection. Where switching of neutral is required and for DC
circuits, the MCB shall be of double-pole type.

MCBs shall be trip free type and shall be capable of sustaining

20,000 switching operations.

The operating mechanism shall be quick make, quick break

and mechanically trip free so as to prevent the contacts from
being held closed against short circuit and overload
conditions. The operating mechanism shall be so constructed
to operate all poles in a multi-pole breaker simultaneously
during opening, closing and tripping conditions. The operating
handle shall be of the toggle type.

10.3.3 Auto Reclosure Earth Leakage Circuit Breakers (AR-ELCB)

All RTU panels installed at un-manned sites shall be equipped

with AR-ELCB. It will self-reclose for 3 times upon ELCB tripped
due to non-permanent fault i.e. lightning activities. This will
reduce the frequent visit by pump operator to just reclose
back a tripped ELCB.

The delay for activation of automatic reclosing shall be 30

seconds and shall be limited up to 3 times automatic reclosing
attempt. It operating temperature shall be up to 50 Deg. C with
18,000 numbers of operations.

Page 56 of 72
11.0 INSTRUMENT PANEL

11.1 Design and Construction

The instrument, local control and supervisory panel complete with all
associated equipment and terminal rack, etc shall generally be free
–standing floor-mounted cabinets of the cubicle.

Material shall be from mild steel sheets with 2mm minimum thickness
on walls and inside compartments. It shall be treated with phosphate,
primed and finished with coats of beige color polyester powder paint
to RAL7032 and shall be more than 80 micron of thickness.

A drawing pocket of minimum size 250 mm x 250 mm x 20 mm shall

be provided on the inside door of panel.

Control switches and pushbuttons shall be positioned below or

adjacent to any associated reading instrument. Panels for use in
locations other than control rooms shall have anti-vibration
mountings.

The panel shall be designed to ensure adequate ventilation and air

circulation without permitting the entry of vermin or the ingress of dust
as far as practicable by installing AC type exhaust fan (steel body
type). Panels installed in a dusty environment shall be provided with
non-combustible dust filters over the air circulation louvers.

All metal surfaces shall be treated against corrosion. Adequate

means shall be provided for cooling the equipment to prevent
overheating.

If electrical and non-electrical instruments are mounted in the same

panel, the panel shall be sub-divided internal to separate the
electrical and non-electrical sections. All connections shall be
arranged to ensure that no accidental damage to cabling or
electrical components can occur in the event of failure of any non-
electrical components or connection.

Each panel shall be adequately illuminated internally, as even and

as free from dazzle as possible, by fluorescent lighting controlled from
totally enclosed door operated switches. The lighting circuit shall be
independently fused and designed to allow lamps to be replaced
safely.

Page 57 of 72
 Outdoor panel shall have a non-flat roof type with angle more than
90 degree. All outdoor panel shall be installed with security features
illustrated in Figure 7© below.

11.2 Component Arrangement

Panel circuits shall be segregated into the following categories;-

Goup 1 : Power, control and very high level signal wiring (above
50V)
a) AC power supplies
b) DC power supplies
c) AC current signals above 50mA
d) AC voltage and control signals above 50 volts

Group 2 : High level signal wiring (6 to 50 V dc)

a) Signal from conventional electronic transmitters and controllers
(eg. 4-20mA)
b) Circuit to other solid state devices
c) Digital signals
d) Emergency shut-down and tripping circuits
e) On/off control circuits

Group 3 : Interconnecting wiring (between relays etc)

a) AC above 50 V
b) DC above 50 V
c) DC 50 V and below

Circuits supplied at 240V or above, between 240V and 110 VDC shall
also be segregated from each other and from other circuits. Access
to wiring and components of circuits having voltages exceeding
240V shall not be possible unless and until the circuit has been
isolated.

All wiring shall neatly and securely fixed by insulated cleats, bunched
and secured by approved plastic strapping, or run in approved
insulated wiring trunking or non-corrodible flexible tubing. Wiring for
future equipment shall be secured and terminated on the terminal
blocks. Inter-section wiring in multi-section cabinets shall be via a
terminal block in each section.

A terminal block shall be provided as an interface between

corresponding conductors of each internal and external connection.

Page 58 of 72
 Terminal blocks for analogue current signals shall permit the insertion
multimeter test leads without disconnecting any wiring.

Terminal blocks for circuits containing volt free contacts internal or

external to the cabinet shall permits the introduction of a test
continuity meter without disconnecting any wiring.

Each row of terminal blocks provided shall contain at least 25% spare
terminals over the number required for terminating all cores of
external cables in that row. All spare cores of external cables shall
be terminated in the terminal block and labeled accordingly.

A continuous copper earth bar of not less than 25 mm x 3 mm cross

section shall run the full length of each panel and be securely fixed
and bonded electrically to the main frame. The cable gland plates
and the earth bar shall be provided with suitable brass terminals of
not less than 8 mm International Standard screw thread for
connection to metal cladding or armouring of all incoming and
outgoing cables and to the station earthing system.

A second continuous earth bar of not less than 25 mm x 3 mm cross

section, electrically isolated from the steelwork of the panel and
metal cladding and armouring of cables, shall be provided for
earthing the signal earth connection of each instrumentation and
control device to the station earth mat. The earth bar shall have
sufficient brass terminals as specified above for each instrumentation
and control device and the screen of every shielded cable plus 25%
spare terminals.

Each instrument requiring a power supply shall be individually wired

and protected so that in the event of a failure of one circuit, the
remainder is unaffected. Power supply circuits shall be of sufficient
rating that any protective device mat operates without reducing the
voltage at the terminals of any other component to an
unacceptable level.

11.3 Wiring and Cabling

11.3.1 Small Wiring and Auxiliary Control Supply

Panel small wiring shall be carried out in copper multi –

stranded PVC insulated cable to BS 6231 with 1000 volt grade
and shall have a minimum cross-section of 0.75 sq. mm for
voltage circuits and 2.5 sq. mm for current circuits.
Page 59 of 72
Wiring shall be carried out in a neat and systematic manner
and securely fixed by insulated cleats or approved method
and arranged so that access to any apparatus or connection
point is not impeded. Where inter-panel wiring passes through
panel side sheets etc., the access hole shall be fitted with a
suitable grommet.

The wiring colour code shall be as given below:

Phases : Brown
Neutral : Blue
DC Circuit : Red & Black
Earth : Green
Connections to volt free contacts intended for external
connections shall be coloured white.

Wiring shall not be mounted direct to panel steel plates. Panel

wiring shall be run in neat looms and shall be installed vertically
and horizontally and not diagonally across. Any framing cable
looms shall be installed in PVC trunking. Not more than 70% of
the trunking shall be used.

Pre–insulated compression terminals or insulated sleeves shall

be tight fitted at the end of wirings. Terminals shall be
manufactured from high conductivity tin plated copper.
Insulated sleeves shall be of nylon or PVC and the latter shall
not be less than 0.8 mm thick. Sleeves shall be colour coded
for different ranges of conductors.

Sleeve type identification ferrules shall be fitted on all wires at

both ends; the numbers and letters used shall correspond with
the appropriate wiring diagram and shall read from terminal
outwards. Identification ferrules numbering shall not be
repeated. The wires shall not be jointed or broken between
terminal points.
Where duplication of terminal blocks is necessary suitable solid
bonding links shall be incorporated in the design of block
selected.

Small wiring used for extra low voltage and instrument signal
which are likely to be affected by interference shall be
screened and/or spaced from power cables to ensure no
distortion or mal- operation.

Page 60 of 72
11.3.2 Terminal Blocks

Terminal blocks for control wiring shall clamp the wire securely
and without damage between two plates by means of a
captive screw or by means of cage clamp. Terminals for
incoming and outgoing power connection shall be of the
bolted type with brass nuts and locknuts, each core being
fitted with a suitable lug.

Terminal blocks at different voltages shall be segregated into

groups and distinctively labelled, and the voltage grouping
and terminal board layout shall correspond with the wiring
diagram. Only one wire shall be terminated on each terminal
block. Where duplication of terminals is necessary, purpose
made solid links shall be provided. Where approved barrier
pattern crew or stud-type terminal blocks are used covers of
transparent insulating material which does not sustain
combustion shall be provided. Insulating barriers when
provided between adjacent terminal blocks shall also allow
easy access, in addition to adequate protection.

Terminals which may be alive when the main equipment is

isolated from the mains supply shall be suitably labeled to
reduce the risk of accidental contact. All terminals shall bear a
permanent identification number or letter.

All the wires of a multi-core cable shall be connected to

terminal blocks including the spare wires.

Adequate number of spare terminals (at least 20%) shall be

provided for each group of terminal blocks. All spare core
cables shall be terminated to spare terminal blocks.

Removable DIN rail terminals shall be provided for all wiring,

mounted at an angle to provide ease of access, with centre
disconnecting link type terminals for analogue signal circuits,
isolation or test purposes, sufficient, suitably sized earth
terminals at the end.

Any exposed terminal of the terminal block shall have a clear

plastic clip-on cover covering the full length of the terminal to
prevent accidental contact.

Page 61 of 72
11.3.3 Cable Terminations

All cable boxes, glands, gland plates and all other apparatus
necessary to terminate all incoming and outgoing power and
control cables shall be provided. Non- magnetic gland plates
of not less than 6 mm thick shall be provided where single core
cables are terminated. For cable sizes 400 sq. mm above,
insulated cable glands shall be fitted.

All cable boxes shall be suitable for air insulated termination of

vertically ascending power cables. Cable glands suitable for
the sizes of cable used any support shall be provided with each
cable box. Suitable approved cable cleats shall be provided
to ensure that weight of the cable will not be carried by cable
gland.

Aluminum cable cores shall be terminated using approved

bimetallic connectors.
The panel shall, unless otherwise specified, be provided with
bottom cable entry. Cable gland boxes, with removable side
covers of at least 300 mm high above the base of the panel
shall be provided, to enable easy termination of cables. The
gland plates shall be gasketted.

In view of the substantial cable de-rating that is normally

applied, adequate terminals and cable termination space
shall be provided in the switchboards.

Each panel shall include all necessary copper down droppers,

terminal blocks and cable sockets. All terminals shall be
numbered and the numbering shall conform to schematic and
wiring diagram.

Page 62 of 72
 PVC TRUNKING
PVC TRUNKING
RTU & MODEM
COMPARTMENT

PVC TRUNKING ELCTRICAL

PVC TRUNKING
COMPONENT

PVC TRUNKING
CONTROL DC COMPONENT COMPARTMENT
COMPONENT COMPARTMENT 1
COMPARTMENT

PVC TRUNKING
PVC TRUNKING

AC SOCKET
TERMINAL BLOCK

PVC TRUNKING PVC TRUNKING

PVC TRUNKING

(OPTIONAL)
BATTERY
CHARGER
COMPARTMENT ELECTRICAL
COMPONENT
COMPARTMENT
2

BATTERY
COMPARTMENT INCOMING /
OUTGOIING
CABLE

CONCRETE BASE

Figure 7 (a) – RTU PANEL – COMPONENT & WIRING ARRANGEMENT

 20 cm
STEEL BAR

MOUNTING
10 cm 15 cm
TOUCH PANEL
SWL SWL RES RES SWL RES
HIGH LOW HIGH LOW OVF OVF

15 cm
SWL OUTP RES HMI TOUCH
0.00 M 0.00 M 0.00 M
PROTECTED
PANEL
STEEL BOX
INP OUTF1 OUTF2 2 NOS VERMIN PROOF
0.00 M 0.00 m3/H 0.00 M VENTILATION LOUVERS WITH
WIREMESH ON INTERNAL FACE
AND WEATHERPROOF COVER
ON EXTERNAL FACE
15 cm

HMI TOUCH

15 cm
PANEL

PROTECTED
STEEL BOX

10 cm 15 cm

15 cm
20 cm
STEEL BAR

CONCRETE BASE CONCRETE BASE

INDOOR PANEL INDOOR PANEL

(FRONT VIEW) (SIDE VIEW)

Figure 7 (b) TYPICAL RTU PANEL – INDOOR TYPE

Page 64 of 72
 20 cm
STEEL BAR
CLEAR
WINDOW FOR
10 cm 15 cm
TOUCH PANEL

15 cm
RES RES
0.00 M HIGH
HMI TOUCH
PROTECTED
PANEL
OUTF2 RES STEEL BOX
0.00 M OVF 2 NOS VERMIN PROOF
VENTILATION LOUVERS WITH
WIREMESH ON INTERNAL FACE
AND WEATHERPROOF COVER
ON EXTERNAL FACE
15 cm

HMI TOUCH

15 cm
PANEL

PROTECTED
STEEL BOX

10 cm 15 cm

15 cm
20 cm
STEEL BAR

CONCRETE BASE CONCRETE BASE

OUTDOOR PANEL OUTDOOR PANEL

(FRONT VIEW) (SIDE VIEW)

Figure 7 © TYPICAL RTU PANEL – OUTDOOR TYPE

Page 65 of 72
12.0 DEVELOPMENT

12.1 Requirement of Submission Process

12.1.1 Application and Proposal

The layout drawing must be done by an electrical consultant

and certified by a professional electrical/instrumentation
engineer, and it MUST comprise the following:

a. Site/Key Plan of the pump house /suction/service

reservoir showing the respective locations of all the
proposed instrumentations.
b. Block diagram of the proposed instrumentation system.
c. Cubicle diagrams of the proposed Instrumentation
panels and cabinets.
d. Drawing showing the detailed installation diagram of
RTU, level, pressure and flow measurement, etc.
e. Instrumentation cabling showing details of cable
marking (label), cable schedule, the cable laying route,
trenching as well as detailed dimensions and
construction of cable joints.
f. Lightning protection and instrument earthing system
showing the layout and the connection of the earth
continuity conductor to the main earth conductor. It
shall also include the layout and connection of the main
earth conductor to the earth electrodes as well as the
dimensions and construction of the earthing chamber.

12.1.2 Submission of Working Drawings Prior to Construction

The working drawings shall have the following items:

a. Full details of the equipment offered, copies of the

manufacturer’s specification to enable the nature,
quality and workmanship of the equipment offered to
be assessed.
 b. Fully dimensioned drawings showing the proposed
installation of the equipment.

12.2 Commissioning Test

After the satisfactory tests prior to setting to work and the

satisfactory and successful running of the works during the setting
to work period, the consultant shall confirm to the S.O. the date
that the whole work is ready for commissioning.

The minimum commissioning tests to be carried out by the

consultant is given in the following clauses. On completion of
these
commissioning tests, the consultant/contractor shall operate the
work permanently.

12.2.1 Testing instrumentation

The following inspections and tests shall be carried out

during commissioning at site.

• All instrument piping shall be tested for continuity any

leakage.
• All cables shall be tested for continuity and insulation
resistance.
• Electrical supply voltages shall be checked.
• The common mode D.C. voltage at each signal input
terminal shall be measured and recorded.
• The zero setting of each display instrument shall be
checked.
• The correct calibration of each item in each loop
shall
be checked by introduction of appropriate signals at
each source of the range for increasing and
decreasing
signals.
• Every item shall be visually inspected and any
damaged
part or deficiency made good.
• All safety devices shall be tested for correct
operation.
• Control sequences shall be checked with control
inputs
activated but outputs initially in a monitoring mode.

The consultant shall demonstrate the correct operation and

accuracy of all the equipment supplied in the manner
indicated below or as otherwise directed by or agreed with
the S.O :

a) Level instruments

The correct operation of level transmitters and level

operated devices shall be proved by actual level
variation or simulation at 25%, 50%, 75% and 100% full
scale for rising and falling levels to prove that a
correct output signal is produced at these values.

b) Pressure instruments

The correct operation of pressure transmitters and

pressure operated devices shall be proved by actual
pressure variation or simulation at 25%, 50%, 75% and
100% full scale for rising and falling pressures to prove
that a correct output signal is produced at these
values.

c) Flow instruments

Electro magnetic flowmeter converter and/or

amplifier shall be proved by applying a flow simulator
to the flow converter or amplifier at values
corresponding to 25%, 50%, 75% and 100% full scale
for increasing and decreasing flows. Any indicator
fitted on the flow converter or amplifier shall be
correctly calibrated and receiving instruments shall
be proved to repond correctly.

d) All pushbuttons, control switches and equipment

status
indicating lamps shall be shown to function correctly
utilizing the actual items of the Works concern
wherever possible.

Page 68 of 72
e) All alarms and trips shall be tested by operation of the
primarily initiating device.

All receiving instruments, analogue and digital

displays, mimic diagram and alarm indications,
control functions, etc and transmission systems shall
be shown to operate correctly utilizing the equipment
concerned. If line monitoring equipment is not
included in telemetry equipment, the consultant shall
provide such equipment and connect so that the
performance of the communication link may be
checked during the tests.

f) Operation of each function on each instrument

panel.

12.2.1 Test for telemetry

After the telemetry equipment has been installed at

the site, a system test shall be performed to verify the
integrity of the system. Some or all of the tests
performed during factory testing shall be repeated as
selected by the S.O. The system must be online (all
readings from site) for a minimum period of 7 days
before this tests. Continuous online without failure can
be verified via trending.

Before this test is started, the consultant shall satisfy

himself that the system is operating correctly with live
site data. Any malfunction during the test shall be
analyzed and corrections

made by consultant. The S.O. shall determine

whether any such malfunctions are sufficiently serious
to warrant a repeat of this test.

Any equipment supplied under the project that

requires readjustment, repair or replacement, again
be demonstrated by the consultant to the
satisfaction of the S.O.

All inputs, outputs and controls over telemetry system

shall be proved to operate correctly including the

Page 69 of 72
 correct display on the existing visual display and
logging equipment.

12.3 Operation and Maintenance Instruction Manuals

12.3.1 General

The Instruction Manuals shall cover the Commissioning,

Testing, Operation and Maintenance of the installation.
They shall be submitted as part of the Works and shall cover
each plant item associated with the Works whether
supplied by Contractor and shall be as specified herein.

The operation and maintenance instruction manuals shall

be regarded as an essential part of the plant to which it
refers. The supply and delivery of an item of plant will be
regarded as incomplete until the instruction manual is
supplied and approved. The data provided shall in all
respects be specified to the plant as installed.
The final manual (3 copies) in the form and detail specified
herein shall be supplied before the Works are handed over
to the S.O. Such manual shall be prepared and submitted
following receipt of the S.O.’s approval to the complete
previous submission plan.

The manual shall be in English, and volumes shall be bound

in hard covers with three post binders. It shall be prepared
for the particular plant application specified rather than for
general applications. Collection and compilation of
standard pamphlets of a general nature will not be
acceptable.

If manufacturer’s standard literature is used, non-

applicable material shall be removed or neatly deleted.
Original material is preferred, but photocopies will be
accepted provided the reproduction quality and in
particular, the reproduction of photographs, is satisfactory.

Photocopies shall be on ordinary bond paper as with the

Xerox process. Chemically treated or sensitized paper
photocopies will not be accepted. Supplied in volumes not
exceeding 50mm width at the spine. Text shall be submitted
on A4 sheets. Drawings shall be folded to A4 size in such a
way that their title block is clearly visible.

Page 70 of 72
 12.3.2 Spare Parts

At any time during prior to completion of commissioning,

the Consultant /Contractor shall deliver to the Site the
spare parts listed below or as specified elsewhere.

a) RTU – CPU module - 1 unit AND

AI /DI module - 1 unit each
b) Level Transmitter - 1 unit
c) Pressure Transmitter - 1 unit
d) LPU (Category 3) - 4 units
e) Battery (12V 65Ah) - 2 units

12.4 Maintenance During Defect Liability Period (DLP)

12.4.1 Communication Bills

The Consultant/Contractor shall bare the cost of

communication bills for such as Data and SMS until the
actual Defects Liability Period (DLP) ends.

12.4.2 Sim Card Change Ownership During Handover

All process of changing ownership for the communication

sim card shall be done by the Consultant/Contractor 6
months before DLP ends. Copy of the related documents
submitted to SYABAS during handover process.

Page 71 of 72
(This page is intentionally left bank)

Page 72 of 72
 Technical Specifications
Section D: Overhead Crane System

1.0 Overhead Crane

1.1 General

All sales taxes, import duties, permits and inspection fees payable to all authorities,
overtime payments and all other charges and costs necessary to complete the
installation within the time schedule shall be included in the Quotation. All equipment
and accessories to be supplied shall be fully tropicalized and shall be designed to
give full operation of the crane system as intended.

The layouts as shown in the accompanying drawings are to be considered as

diagrammatic and approximate only. The specifications and drawings are intended to
be mutually explanatory and complete but all work called for by one even if not by the
others shall be fully executed.

Tenderers shall note that the Specification and drawings are intended to set out the
basic and minimum requirements for the installation. Although equipment offered
shall not differ in basic type from that called for in the specifications, tenderers may
offer equipment which they consider both fulfill the basic requirements of the
Specification and also provides additional benefits in the form of greater ease,
simplicity or safety of operation or longer working life of the equipment provided no
other qualities are sacrificed to gain such benefits.

1.2 Standard & Regulation

The design, calculation, manufacture, installation and testing of the system shall be in
accordance with the best engineering practice, the latest relevant Standards and shall
comply with the latest Rules and Regulations of :

1. The Department of Occupational Safety & Health (JKKP or DOSH)

2. The Department of Electricity Supply and Gas (Suruhanjaya Tenaga)

3. Tenaga Nasional Berhad (TNB)

4. The relevant Malaysian Standards, British Standards (BS 2573 , BS 466) and
other Standards approved by Local Authorities

5. The Regulations of the Electrical Equipment of Buildings (Current Edition) as

issued by the Institution of Electrical Engineers, London

6. All other Authorities having jurisdiction over the Works.

1.3 Fabrication Requirements

The crane steel structure shall only be fabricated by the crane manufacturer with
Crane Fabrication License issued by Jabatan Keselamatan dan Kesihatan
Pekerjaan (JKKP).

Page D / 1
 Technical Specifications
Section D: Overhead Crane System

1.4 Welding Requirements

For welding process, the following minimum standards are used:

 Welding Procedure Specification – AWS D1.1 Approval testing of welding

procedure.
 Welder’s Certificate – AWS D1.1 Approval testing of welder’s working to approve
welding procedure

For Welding Procedure Specification (WPS), manufacturer must possess qualification

of 6GR as per AWS D1.1. All the WPS and Welder’s Certificate must submit to the
purchaser prior to fabrication

1.5 Crane Girder

Crane girder shall be designed to A4 as per BS466 1984. The maximum allowable
deflection shall be span/750.

Crane girder shall be double girder type and welded from steel plates to form boxes.
The design as regards to safety clearances, railing etc. are in accordance with
specified safety regulations of the local authority.

Maintenance platform with hand-rail shall be provided along one side of the girder for
maintenance platform. Platform shall be provided with toe plates having a minimum
height of 100mm above floor level. These shall have a minimum thickness of 6mm
and shall not be fixed to the floor.

1.6 End Carriages

End carriage shall be welded box design. Wheel base shall not be less than span/7. It
shall be designed so that the weight of the crane and its load is equally distributed
between the carriage wheels. The end carriages must be equipped with buffers at the
four ends.

Wheels shall be spheroidal graphite cast iron GGG70 which is low wear material due
to self-lubricating. All wheels are with anti-friction bearing and easy to change.

End carriage must be equipped with Limit Switch for long travel. In addition, anti-
collision device shall be provided for preventing the collision with the existing crane at
the same bay.

Travel motor shall be direct coupled to the driven wheels. Open-pinion drive is not
allowed. The travel motor shall be classified in FEM 4m and travel wheel shall be
classified to FEM2m.

1.7 Hoist

The hoist shall be electric driven wire rope hoist with modular design made of
standard series components. The individual components are optimally matched. The
hoist duty class shall be FEM 2m.

1.7.1 Hoist motor

Hoist motor shall be 3-phase A.C. squirrel-cage induction motor, 4 poles, with
cylindrical rotor and low flywheel mass, classified in group FEM 4m to FEM 9.682.
The motor shall ensure reliable starting even at under voltage and with high hoisting

Page D / 2
 Technical Specifications
Section D: Overhead Crane System

load and shall directly coupled to the gearbox without using coupling. The motor shall
be installed outside the wire rope drum for easy maintenance and better ventilation.

The motor shall be designed for heavy duty, 60% ED and 360 starts/hour, minimum
S4 duty high protection class IP 55 and temperature control with thermistor
temperature sensors to guard against overloading/overheating of motor.

Manual release shall be provided so that the breaking system can be released
manually in the event of failure in power supply.

1.7.2 Long-life brake

The motor brake shall be twin-disc magnetic disc brake encapsulated and has
asbestos-free brake lining with long service life of at least 1-2x106 braking operations.
Standard protection class IP55 to be supplied.

1.7.3 Gear

The gear shall be maintenance-free gear complete with enclosed housing with
highest accuracy and stability, gearing with high degree of flank hardness optimised
after hardening by honing (high service life, low noise). Lifetime oil lubrication is to be
provided.

1.7.4 Rope drive and drum

Designed for high safety and long service life, highly flexible special bright wire rope
or special galvanised rope, according to DIN 3063 and DIN 3067 with safety factor of
5.0 shall be supplied with the hoist. The hoist drum shall have fine machined drum
grooves to minimise wear on the rope. The return sheaves shall be resistant to wear.
Robust bottom hook block with low headroom, hook in forged ST52 steel shall be
provided.

1.7.5 Rope guide

Extremely wear-resistant rope guide in spheroidal graphite cast iron, high resistance
to diagonal pull shall be incorporated in the hoist drum and it shall not have
temperature limitations in its service life. No plastic material shall be used as rope
guide.

1.7.6 Drum bearings

The wire rope drum of the hoist shall be supported by anti-friction bearings of
standard type readily available from the market and they shall be the greased-for-life
type. The inner and outer races of the bearings shall form integral part of the bearings
and in no way shall the outer surface of the wire rope drum be used as inner race of
the bearing.

1.7.7 Overload Device

Reliable overload cut-off device shall be provided. Overload cut-off shall be electronic
device type and load measurement shall be taken at rope anchorage via load sensor.

1.8 Limit switch

Gear-type limit switch shall be provided as emergency hoist limit switch for cut-off in
top and bottom hook position. In addition, a further two switch elements are to be
installed to act as the operational hoist limit switch.

Page D / 3
 Technical Specifications
Section D: Overhead Crane System

1.9 Crab

The crab for the cross travel of hoist shall be designed to FEM standards.

The crab must equip with Limit Switch for cross travel. The crab shall cut off at both
ends of travels.

The material of the travel wheels shall be Spheroidal Graphite Cast Iron which
provides a self-lubricating effect to the rail surface.

Driven motor shall be direct coupled to the driven wheels. Open-pinion drive is not
allowed.

The travel motor shall be classified in FEM 4m, S4 duty and travel wheel shall be
classified to FEM2m.

1.10 Control

Contactors control shall be provided for all motors.

The control of the crane shall be by Pendant Station Mobile Along Crane Bridge. The
pendant shall comply the following features:

 Control voltage : 48VAC

 Type of enclosure : IP65
 Emergency stop button that actuates main contactor and stops all
movement
 Suspended with strain-relief control cable.

Control panels include main contactors, control transformer & control switchgears
shall be fitted on the crane girder.

Control panel for hoist and cross travel shall be fitted to the hoist unit. All control
panels shall be IP55 protection.

1.11 Speed Requirements

The following speeds shall be followed unless otherwise specified on the tender
drawings.

Hoisting: 5/0.8 m/min

Cross travel: 20/5 m/min
Long travel: 40/10 m/min

1.12 Motors

All motors must classified to minimum FEM 4m, S4 duty and 60%ED. Motors shall
have insulation class F and equipped with thermistor temperature sensors to guard
against overloading/overheating of motor.

1.13 Hoist power supply

Hoist power supply shall be via flat cable festoon system. All the cable carriages shall
be galvanised steel type. No plastic material is allowed.

Page D / 4
 Technical Specifications
Section D: Overhead Crane System

1.14 Long Travel Power Supply Line

The power supply feeding shall share with the PVC insulated 4 pole conductor
system. Current collector trolley for crane mobile power feeding shall be suitable and
able to fix to the conductor system.

1.15 Noise Limits

The crane and hoist shall be designed to minimise noise. The overall noise level for
this equipment shall not exceed 85dBA at 1 meter distance.

END OF SECTION

Page D / 5
 Technical Specifications
Section E: Air Conditioning and Mechanical Ventilation

1.0 Air Cooled DX Split Unit

1.1 General
Supply and install factory assembled a/c split packaged system to comprise but not
limited to :
a) Condensing unit
b) Fan coil unit
c) Refrigerant Piping and insulation
d) Condensate drain
Each fan coil unit is to be served by and individual compressor and completely
independent of the other fan coil/ compressors.
Fan coil units shall be complete with factory assembled remote 3 speed controls,
built-in starters and thermostats where possible.
For ceiling cassette units, all indoor units shall be complete with condensate drain
pump.

1.2 Condensing Unit

Air cooled condensing unit shall be factory assembled, tested, dehydrated and
charged to the following :
1.3 Air Cooled Condensers

Coils

a) Tubes : Seamless copper

b) Fins : Aluminium, mechanically bonded to tubes

Housing

a) Frame : angle iron

b) Casing : galvanised sheet iron
c) Supports : angle iron

Fans

a) Propeller or centrifugal type

b) Fan guard
c) Arranged for vertical and horizontal discharge

Motors

a) Totally enclosed , fan cooled coupled to fans

Corrosion Protection

a) Steel surfaces except fan shaft, to be galvanised

b) Fan shaft epoxy coated

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 Technical Specifications
Section E: Air Conditioning and Mechanical Ventilation

Control Cabinet

Factory mounted and pre wired with :

a) Terminals for interlocking to prevent compressor operation unless fan is running.

b) Refrigerant dual pressure switches with manual reset on high pressure cut out.

1.4 Refrigerant Accessories

Each circuit complete with :
a) Combination filter drier in liquid line with two replaceable cartridges, similar to
Sporlan Catchall replaceable core type.
b) Combination sight-glass and moisture indicator, similar to Sporlan See-All

2.0 Fans
2.1 General
Fans shall be of the type, size, arrangement and capacity as indicated in the
schedule and/or as shown on the drawings.
Fans and motors shall be selected to provide air flow rates of 10% more than that
specified against the corresponding increase in system resistance.
All motor/impeller rotors shall be satirically and dynamically balanced to International
Standard I.S.O. “Balance Quality of Rotating Rigid Bodies” and shall be free from
vibration at all operating speeds and during starting and stopping cycles.
Fan motors shall comply in all respects with the “Motors” clause in the section on
Electrical Works of this specification. Motor bearings shall be of the ball or roller type,
sealed for life or grease packed fitted with lubricant retaining and dust excluding seals
extended through the casing, and shall be selected for an operating life or not less
than 150,000 hours.
Fans shall not be operated in a partially completed system for any purpose whatever
and before start-up, all connected ductwork and equipment must be cleaned.

2.2 Axial Flow Fans

Axial fans shall have flanged hot dipped galvanised tubular casings extending over
the length of the fan and motor (unless specified otherwise) complete with an airtight
access door suitably placed for easy fan inspection. Fans 300 diameter or less may
have casings without access doors. Open fan intakes and discharges which are
accessible to personnel shall incorporate heavy gauge galvanised or bronze wire
mesh guards.
Non-overloading aerofoil fans shall have adjustable pitch cast aluminium alloy
impellers or may have adjustable pitch polypropylene impellers on fans up to 300
diameter and glass reinforced polyester resin impellers on fans up to 765 diameters.

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 Technical Specifications
Section E: Air Conditioning and Mechanical Ventilation

3.0 Electrical Works

3.1 General

This section of the specification covers the supply and installation of the electrical and
control requirements for the air-conditioning and mechanical ventilation services.

All controls shall be adjusted as necessary to achieve satisfactory operation of the plant
in accordance with the intent of this specification and to approval.

Where vibration is present, all materials, equipment, components and devices which
could be affected by vibration shall be protected in an approved manner.

3.2 Extent of Work

Supply and install the complete electrical installation as required for satisfactory
operation, control, maintenance and safety of the air conditioning plant and mechanical
ventilation systems, under all conditions of service and suitable for the working
environment.

In summary, the works to be supplied and installed shall include, but not necessarily be
limited to, the following items and equipment:

(a) All control wiring and connections between the switchboards, thermostats,
control valves and the like.

(b) Testing and commissioning of the entire installation.

(c) Supply of "as built" drawings prior to the issuance of a Certificate of Practical
Completion.

END OF SECTION

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 Technical Specifications
Section F: Fire Protection

1.0 Clean Gas System

1.1 General

The clean gas systems shall be in accordance with the rules and regulations of
National Fire Protection Association (NFPA 12) and (NFPA 2001) or other relevant
standards as may be approved by the S.O.

The manufacturer from the country of origin shall guarantee the performance and
selection of the components of the complete carbon dioxide extinguishing system and
complying with the specification and relevant codes.

Generally, the clean gas systems shall consist of but not limited to the following: -

(i) Cylinders of gases complete with discharge valves and discharge cables.
(ii) Manual discharge breakglass device.
(iii) Schedule 40 and 80 pipes complete with fittings, brackets and painting.
(iv) Gas discharge nozzles.
(v) Smoke and heat detectors for detection and actuation of the system.
(vi) Wiring in metal conduit.
(vii) Control panel complete with battery charger, booster charger, 24 V.D.C. Ni-Cd
battery, alarm bell, gas discharging system, ammeter, voltmeter, function
indicators and alarm test switches, etc. The control panel must be approved
by the Jabatan Perkhidmatan Bomba Malaysia.
(viii) Any necessary warning signs and instructions.
(ix) Red and green flashing indicator lights.

1.2 Type of System

Total flooding system shall be used unless otherwise specified. The clean gas system
shall be capable of developing a concentration as specified in NFPA.

1.3 Storage Containers

The containers shall be designed for holding gases in liquid form at ambient
temperatures. Containers shall not be charged to a filling density greater than as
specified in NFPA. Containers shall be distinctly and permanently marked with the
type and quantity of agent contained therein, together with the degrees of super
pressurization.
When using manifold, containers shall be adequately mounted and suitably supported
in a design for convenient individual servicing or content weighing. Automatic means
shall be provided to prevent agent loss from the manifold if the system is operated
when any containers are removed for maintenance.
A reliable means of indicating, other than weighing, shall be provided to determine
the pressure in refillable containers. The means of indication shall account for
variation of container pressure with temperature. In a multiple cylinder system, all
cylinder supplying the same manifold outlet for distribution of agent shall be
interchangeable and of one selected size and charge.
All containers shall be adequately protected with a steel enclosure to prevent
accidental damage to them. This enclosure shall not in any way hamper the proper
function or ease of service of the containers.

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 Technical Specifications
Section F: Fire Protection

1.4 Detection and Actuation Equipment

Automatic detection and actuation shall be used. An automatic detection shall be by
approved combination of ionisation smoke detectors and rate of rise heat detectors
capable of detecting and indicating conditions that are likely to produce fire. Multiple
detectors shall be wired in parallel.
Operating devices shall include clean agent releasing devices, discharge controls and
shutdown equipment and other necessary items for an efficient and reliable
performance of the system.
Operation shall be by approved electrical means and electrical detection shall be of
the normally open contact type. An adequate and reliable source of energy consisting
of nickel cadmium battery cells and normal electrical supply shall be used in the
detection and operation of the system.
All devices shall be located, installed or suitably protected so that they are not
subjected to mechanical, chemical or other damage, which would render them
inoperative.
All automatically operated valves controlling agent release and distribution shall be
provided with approved independent means for emergency manual operation
(breakglass type or pull-box with linkage type) and shall be easily accessible.
All devices for shutting down supplementary equipment shall be considered an
integral part of the system and shall function with the system operation.

1.5 Operating Alarms and Indicators (where applicable)

An alarm shall be sounded upon detection for the evacuation of personnel from the
hazard area pending gas discharge. Devices shall be incorporated in the system to
shutdown the mechanical ventilation fans (if any) upon detection pending discharge.
An alarm indicating failure of supervised devices or equipment shall give prompt and
positive indication of any failure and shall be distinct from alarms indicating operation
conditions.
Warning and instruction signs at entrances to and inside protected areas shall be
provided. RED, flashing indicating lights with the word "EVACUATE" shall indicate
pending carbon dioxide and AF11E gas discharge.

1.6 Power Supply

The Sub-Contractor shall supply, deliver install and maintain a 24-volt D.C. flat
nickel-cadmium battery complete with a charger located within the clean gas control
panel.
The capacity of the battery shall be such that in the event of mains supply failure, the
battery shall be capable of maintaining the system for 48 hours.

1.7 Wiring System

All wiring shall be carried out in metal conduits with PVC conductors of 1.5mm2
minimum strand for smoke detectors and 2.5mm2 minimum strand for alarm bells.
Refer also to the section on "Electrical Works" of this specification.
End of line resistors shall be provided for supervising the continuity of each fire alarm
group or zone.
The cable sizes must be provided so as to ensure that the voltage drop from the
battery terminals to any point on the system does not exceed 2.5% of rated voltage.
Voltage drop calculation of every point of the system with detailed wiring connection
must be submitted to the Engineer for examination.

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 Technical Specifications
Section F: Fire Protection

1.8 Control Panel and Alarm System

Control module complete with battery charger, 24V D.C. Ni-Cd battery, alarm, meters
and gas discharging system shall be supplied and installed.
Remote indication of alarm and fault conditions of the system shall be provided to the
Fire Alarm Panel.
The control panel shall be provided with but not be limited to the following: -
(i) Ammeter and battery test facilities.
(ii) Mains on, charger on, DC on indicating light.
(iii) Alarm reset switch.
(iv) Buzzer silence switch and indicating light.
(v) Bell silence switch and indicating light.
(vi) Fault indicating light.
(vii) Fuse indicating light.
(viii) Clean gas actuated indicating light and buzzer.
(ix) Clean gas cut off switch and indicating light.
(x) Heat zone of isolation/normal/fault/test fault/test amp isolation switch and
indicating alarm and isolated light.
(xi) Smoke zone of isolation/normal/fault/test fault/test amp isolation switch and
indicating alarm and isolated light.
(xii) Air conditioning or ventilation fan cut-off relays with separate alarm reset
switch.
(xiii) Mimic indication panel showing the floor plan and zoning layout where two or
more zones are controlled from a single panel.

1.9 Discharge Nozzles

Discharge nozzles shall be listed and approved for their intended use and discharge
characteristic. The discharge nozzle shall consist of the orifice and any associated
horn, shield or baffle. The size of the orifice shall be compatible with the design
discharge rate. Orifices shall be of corrosion resistant metal. Nozzles shall be
permanently marked to identify them and to show the equivalent single orifice
diameter regardless of shape and number of orifices.
Discharge nozzles shall be provided with frangible discs or blow-out caps where
clogging by foreign materials is likely. These devices shall provide an unobstructed
opening upon system operation.

2.0 Portable Extinguisher

2.1 General

Contractor shall supply and install the Portable Fire Extinguishers as shown in the
drawings. All materials shall be new and unused, be of best quality of items
respective kind, free from defects and approved for use by the Chief Inspectorate of
Fire Services, Malaysia.

It shall conform to M.S. 1179, M.S. 1180, M.S. 1181 M.S. 1182 and approved by Fire
Officers Committee.

Fire Extinguishers shall be supplied fully charged and with mounting brackets.

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 Technical Specifications
Section F: Fire Protection

2.2 Dry Chemical

Dry chemical powder shall capable of extinguishing class A, B and C fire.

The dry chemical shall be non-toxic, non-corrosive, non-abrasive and non-freezing. It

shall not solidify or evaporate and conform to B.S. 3465.

Dry chemical powder shall be expelled by compressed gas or air.

2.3 CO2 Extinguisher

Carbon dioxide shall be capable of extinguishing Class E fire and conform to B.S.
3326. It shall be supplied with horn, hose and valve assembly.

2.4 Details

Full details of the fire extinguishers installed shall be attached to each of the
extinguisher and a complete list given to the Owner on the day when the certificate or
practical completion is issued. Details required are:-

(i) Type, weight of extinguishers and location.

(ii) Operating instructions.
(iii) Jabatan Bomba dan Penyelamat Malaysia’s approval number.
(iv) Jabatan Bomba dan Penyelamat Malaysia last test dates and receipt of
testing fees.
(v) Manufacturer's name or trade mark and year and month of manufacture and
pressure test.

The above information will also be required to be displayed at each of the installed
fire extinguishers.

2.5 Approval

All portable extinguisher shall be tested and bear the certificate of approval by the
Jabatan Bomba Dan Penyelamat Malaysia. All fees in connection with testing and
approval shall be borne by the Contractor.

3.0 Electrical Works

3.1 General

This section of the specification covers the supply and installation of the electrical and
control requirements for the fire protection services.

All controls shall be adjusted as necessary to achieve satisfactory operation of the

plant in accordance with the intent of this specification and to approval.

All materials, equipment, components and devices which could be affected by

vibration shall be protected in an approved manner.

3.2 Extent of Work

Supply and install the complete electrical installation as required for satisfactory
operation, control, maintenance and safety of the fire protection equipment under all
conditions of service and suitable for the working environment.
In summary, the works to be supplied and installed shall include, but not necessarily
be limited to, the following items and equipment:

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 Technical Specifications
Section F: Fire Protection

1. All final power circuits between the switchboards and the various plant
components, including connections to boards and equipment.
2. Fire alarm panels and all control wiring works between the panel and field
devices.
3. Fire alarm signal wiring to the air-conditioning and mechanical ventilation services
switchboards and DDC system for fire mode operation.
4. Clean gas alarm panels and associated wiring.
5. Testing and commissioning of the entire installation.
6. Supply of “as-built” drawings prior to issue of a Certificate of Practical
Completion.

END OF SECTION

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 Technical Specifications
Section G: Cold Water

1.0 Pipeworks, Valves & Fittings

1.1 General
This section of the specification covers the supply and installation of all pipework systems
including valves and associated fittings.
The drawings indicate the sizes of pipes and the manner in which the various systems
are to be installed. They do not purport to show all minor pipework or bends, offsets and
the like which must be coordinated with other trades, measured on site or ascertained
from architectural drawings showing structural, plumbing, lighting and other features
normally encountered in this type of project.
All piping systems shall be complete with valves, fittings, vents, drains, expansions
facilities, anchors, supports and other items necessary for the satisfactory operation of
the systems as intended.
Connections to equipment shall be to the recommendations of the equipment
manufacturer and to approval.
Prior to installation all pipework shall be thoroughly cleaned and during installation all
open ends shall be kept covered in an approved manner to prevent the ingress of dust
and general building debris. Responsibility shall be accepted for all damage to
equipment due to dust and debris left in the pipework during installation.
All pipework shall be installed in an approved manner to meet structural and architectural
conditions and to achieve a neat and workmanlike appearance and shall be laid out with
adequate provision for concrete shrinkage, expansion, contraction, grading, alignment
and access for maintenance with not less than 50mm clearance between the external
surfaces of pipes (including insulation where applicable) and all adjacent services and
building structures. Provision shall be made for replacement of each piped service
without disturbing other services.
Tenderers shall include for cutting out welded joints or opening up other types of joints for
inspection and testing to a maximum of three type of joints in each particular system. If
any such joints are found to be defective an additional joint shall be cut -out or opened -
up for each defective joint. All joints cut-out or opened-up for inspection shall be made
good.
The word “pipework” shall mean all pipes, drains, tubes, fittings, nipples and reducers
including all hangers, brackets, anchors and expansion devices, sleeves and plates and
all accessories connected thereto for the complete installation.

Piping and Materials

The piping systems to be provided under this specification shall conform to the following
requirements:
System Material Pipe Size Design Design
Pressure
Temperature
Range
Cold Water Pipe
Tapping from HDPE PN 12.5 All 700 kPa 10C - 60C
existing pipe to the
fittings

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 Technical Specifications
Section G: Cold Water

All piping shall be of the best available quality and shall be supplied in clean full standard
straight lengths, free from any defects such as mill scale, rust, burns, dents, kinks, etc.
and with all ends sealed against the ingress of foreign matter and protected against
mechanical damage. All piping shall be kept in a clean condition at all times during
storage, fabrication, installation and testing.

1.2 Installation
All piping shall be run generally parallel to the axes of the building as close to the ceiling
or other construction as practical and free of unnecessary traps or bends. Bending or off
setting of finished piping connections and “cooking” of fittings or trim will not be permitted.
No pipes shall be installed so as to cause an unacceptable noise under normal
operations. If such a noise does occur, then the Sub-Sub-Contractor will alter the pipe
work as necessary and as directed by the Engineer.
Install piping clear of all doors, windows, access spaces, service areas, etc.
Where immersions thermostats or thermometer bulbs are installed in small piping, the
pipe shall be at least one size larger than the main straight run.
All cut pipes shall be reamed and filed to remove burrs.
All ends of pipes shall be capped with metal or PVC caps, or if not screwed, with wooden
plugs. Any other method will not be accepted.
Supply and install of all vents, stacks and other piping passing through the roof or walls a
stack counter flashing fitting, consisting of a overlapping coupling, caulked to the pipe
with poured lead, or screwed to the pipe with a water tight joint. The couplings shall
extend over a cylindrical flashing sleeve and be made watertight with Permaseal, or
similar compound.
Cover flashing shall be brazed all around and shall lap over the flashing a minimum
distance of four inches.

END OF SECTION

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 Technical Specifications
Section H: Painting & Identification

1.0 Painting & Identification

1.1 General

This section of the specification covers the painting and finishes requirements
pertaining to the installations covered by this specification.

Painting shall be carried out by capable and skilled tradesmen under the direction of
a competent painter foreman and under conditions that will not mar the finish. Paints
shall be applied evenly and strictly in accordance with the specific recommendation of
the manufacturer and on correctly prepared surfaces. Brushes, paint containers and
all other painting accessories shall be kept clean and in good condition at all times.

Where necessary, finished paintwork shall be protected during the progress of site
works by suitable dust covers.

Factory assembled steel components and pre-fabricated metal parts shall be painted
before dispatch with a good coat of zinc chromate or other anti-corrosive primer to
provide adequate protection against the action of dampness and weather during the
transport to site and subsequent erection.

Materials for site fabrication such as piping rolled steel sections and sheet metal shall
be supplied unpainted and primed after fabrication as necessary for protection
against corrosion.

1.2 Extent Of Work

Paint with first quality materials as specified in this section of all parts of the
installation covered by the work of this contract to approval.

The work shall include painting of all exposed work, equipment and machine bases,
supports and the following items but excluding normally bright and polished metal
components.

(a) Pipework, valves, fittings and hangers exposed to view

(b) Machine bases and plinths.
(c) All plant and equipment, which is not finished, painted to approval in the
factory.
(d) Switchboards, control panels, conduits, cable trays and electrical ducts.
(e) Fire tanks for sprinkler, hosereel and wet riser.

1.3 Material

Paints, fillers, temporary surface dressings and all other painting materials shall be
the products of an approved manufacturer and of the best quality in their respective
types. All painting materials shall be delivered to site in the original manufacturer's
sealed and labelled containers.

All paints shall be such that if applied in strict accordance with specific instructions of
manufacturer the finished surfaces will remain of true colour, will not fade, tarnish,
peel or otherwise deteriorate for a minimum of three years.

All sealers, primers, undercoats and finishing paints shall be of the type specified by
the manufacturer as appropriate for the particular application. Sealing compounds
shall be approved proprietary fillers.

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 Technical Specifications
Section H: Painting & Identification

1.4 Equipment and Metalwork

Equipment supplied in a factory finished condition will be acceptable provided that the
finish is of high standard, acceptable in colour, and does not require extensive
touching up. Otherwise factory finished equipment shall be cleaned, wire brushed and
painted on site with not less than two coats of approved finishing paint.

All other equipment and metalwork shall be painted with one coat of zinc chromate or
similar approved metalwork primer and two coats of full gloss enamel paint of the
specified colour.

All galvanised steel surfaces shall be cleaned of all oil and other protective coatings
used in manufacture and given one complete coat of approved type etching primer
before applying the finishing coats as above.

1.5 Pipework, Valves and Fittings

All pipework including fittings and valves shall be cleaned and painted externally with
one priming coat and two finish coats.

The final coat of paint on each piping service shall constitute the basic identification
colour or ground colour of the service. In addition to the basic colour all pipes shall
have identification colours painted on in the form of bands of colours in and lettering
to approval.

Alternatively, proprietary self adhesive labels may be utilized provided that a sample
is submitted for approval prior to installation.

1.6 Identification and Sign Writing

a) Identification

Identification colour bands and lettering shall be painted on pipelines or alternatively

pressure sensitive tape bands may be used.

Identification shall be applied at :-

i) 8,000mm intervals along pipe runs

ii) All branches in the system
iii) Each side of a safety band
iv) Each side of a partition through which the pipe passes

b) Sign Writing

The following sign writing shall be provided:-

i) Arrows indicating flow direction

ii) Lettering indicating Flow and Return on all services
iii) Lettering indicating piping content at the positions specified on pipes on both
sides of all valves.

Lettering codes shall be abbreviated (e.g. Sprinkler -SPR) and be in a contrasting

colour in vertical Bold Extended letters 12mm high on surfaces up to 32mm and
25mm high on larger surfaces.

All items of equipment such as exposed fans, air handling unit casings, and similar
items shall be labelled in accordance with the symbolism and equipment identification
used throughout this specification and drawings or otherwise to approval.

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 Technical Specifications
Section H: Painting & Identification

1.7 Concrete Bases

Where specified all concrete bases for mechanical equipment and switchboards shall
be first treated with one coat of linseed oil putty or other suitable sealer and then
painted with two coats of approved synthetic emulsion paint.

1.8 Cleaning and Polishing

Upon completion of painting the whole installation and the surrounding building
surfaces shall be thoroughly cleaned of all paint marks, grease, oil and dirt. Normally
bright metal parts of installation and all equipment identification plates shall be
polished to approval.

1.9 Labeling

All instruments, gauges, indicators, control equipment, valves and switchboard

equipment shall be clearly labelled using labels of the engraved plastic type except
otherwise specified. Lettering shall be upper case and black in colour on a white
background. Warning labels or installations pertaining to fire/safety equipment shall
utilise uppercase white letters on a red background. The height of lettering shall be
not less than 6mm in general and 3mm in switchboards and control panels.

Labels shall be attached using round head screws and glued to prevent distortion. On
valves, labels may be attached to hand wheels or spindles using key rings.

END OF SECTION

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 Technical Specifications
Section J: Testing & Commissioning

1.0 Testing & Commissioning

1.1 General

This section of the specification covers the testing and commissioning requirements for
the works.

Provide all necessary competent personnel and equipment to carry out testing and
commissioning of the installations covered by this specification. Balancing and
commissioning shall be carried out by personnel trained in that task and preferably
holding appropriate recognised qualifications.

All tests shall be carefully pre-planned and scheduled to ensure that they are co-
ordinated with the work of other trades involved and that they are carried out in a safe
and efficient manner with the minimum of inconvenience to all concerned.

Where the work is being carried out in an occupied or partially occupied building,
responsibility shall be taken to advise the owners and/or management of the building
regarding the nature of the tests and co-ordinate with them to minimise any possible
hazards or inconvenience that may arise due to the tests. Notification shall be given at
least three (3) days in advance of carrying out any tests so that a representative may
observe the test.

All tests required by statutory authorities such as the Local Fire Authorities and Health
Authorities shall be carried out to prove that the systems operate to their satisfaction and
in accordance with the appropriate Codes and Regulations.

1.2 Pre-Commissioning Procedures

Prior to commencement of the commissioning of the systems the following procedures

shall be carried out:

(a) Pressure and leak test all ductwork as outlined in "Ductwork, Air Outlets and
Fittings".

(b) Operate all air handling systems and fans with temporary filters installed.
Thoroughly clean out air handling units, filter chambers and air plenums.

(c) Thoroughly clean and flush out all water systems including all equipment which
forms part of and is connected to the systems.

Cleaning and flushing of pipework shall be carried out initially with coils and
valves by passed, in a power flush mode prior to cleaning of the equipment.

Flushing out shall be carried out using non-foaming detergent compatible with
the water treatment chemical used. A second flushing procedure shall then be
carried out using clean water only prior to final commissioning and chemical
dosing of the system. All strainers baskets shall be removed and cleaned out.

(d) Provide manufacturers' test certificates for all proprietary manufactured items.

(e) Test log sheets proposed to be used during the commissioning tests shall be
submitted for approval at least 1 week prior to the commencement of the tests.

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 Technical Specifications
Section J: Testing & Commissioning

1.3 Testing of Pipework

Progressive hydrostatic testing of all pipework shall be carried out as follows:

Clean Gas system - 2070 kPa (300psi)

Allowable pressure drops must not exceed 5% of test pressure during the initial
pump-up and shall hold constant thereafter for the test period of minimum 24 hours.
Welded joints which leak shall not be caulked but shall be cut out and re-welded. Any
other work shall be replaced.

1.4 Commissioning

Carry out all commissioning tests necessary to put the systems into commercial use and
to approval before Practical Completion is granted. Each item of equipment individually,
each sub-system and each complete system as a whole shall be checked and adjusted
to the design duties and generally as follows:

(a) Air Systems

All air systems shall be adjusted and balanced so that air flows at all points in
the system are within -0% to +10% of the specified flow rates.

Performance testing of the air systems shall be carried out with additional filters
or blanking plates installed to simulate the system operating conditions when
the air filters are 50% loaded.

In addition air distribution from supply air outlets shall be checked and adjusted
as necessary to ensure that the direction and "throw" of air is adequate for the
application, free from unacceptable draughts and generally uniform over the
face of each outlet.

Air flow adjustments shall be made in such a manner that pressure drops
through dampers at or near the faces of outlets are the minimum possible.
Pressure drops required for restricting flow rates in low resistance branches
such as short runs nearest to the fan shall be primarily achieved by means of
the dampers provided at branch take-off points at the main duct. Adjustable fan
drives, where provided, shall be used to obtain the correct air flow rates at the
minimum possible fan speed with the minimum use of the dampers in the
highest resistance run of ducting.

Outside return and relief air dampers where applicable shall be adjusted to
design air quantities at minimum and maximum positions and any intermediate
position.

Direct reading voltmeters may be used for preliminary balancing and

comparative adjustments of air flows at outlets but calibrated anemometers
shall be used for all final air flow measurements at outlets and at coils, air filter
banks, fresh air intakes, etc. where practicable.

For ceiling diffusers a discharge funnel of approved design shall be placed over
the outlets to direct all air in a downward direction to facilitate final
measurement and adjustment of the air flow rate. Pitot tubes or direct reading
voltmeters with pitot probes shall be used for measurement of air flow rates in
ducts where required and shall be based on the average of multiple readings at

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 Technical Specifications
Section J: Testing & Commissioning

not more than 300 centres and not less than one reading per 0.1m2 of cross-
sectional area of the duct.

(b) Water Systems

All pressure and flow actuated controls, relief devices, bleeds, vents and drains
shall be checked and proven to approval.

All temperature control valves shall be fully opened during balancing of water
flows. Final settings of all regulating valves shall be permanently marked in an
appropriate manner.

Flow measurements shall be undertaken across major items of plant to verify

the system performance.

Any major adjustment necessary to water flow rate shall be made by partial
closing of pump discharge valves when such valves are suitable for throttling.
Valves used to regulate final blows to equipment shall be clearly and
permanently marked in the balance position.

(c) Controls, Gauges and Instrumentation

All controls shall be adjusted and activated by competent personnel provided by

the manufacturer or his authorised agent. A complete log of the settings and
readings of all controls, gauges and instruments shall be maintained throughout
the commissioning period.

In addition, hand instruments shall be provided as necessary to check and log

readings for which permanent gauges or instruments may not have been
installed: -

(i) Ammeter readings for all motors.

(ii) Megger tests of all electrical equipment.

(iii) Voltage tests.

(iv) Air pressure drops through all filter banks, coils, etc.

(v) Speeds of all fans, motors, etc.

(vi) Ambient and internal dry and wet bulb temperatures.

(vii) Water flow rates in all equipment.

(d) Electrical Control Panels and Switchboards

The operation of all indicating and recording instruments and associated

equipment and the indicating lights and associated flashers and relays shall be
proved under full working conditions. Refer also to the "Electrical Works"
section of this specification for other electrical testing and commissioning
requirements.

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 Technical Specifications
Section J: Testing & Commissioning

(e) Fire Alarm System

The operation of all indicating lights and associated detector devices shall be
proved under simulated conditions. Detector devices that fail to operate
normally after two consecutive tests shall be rejected and replaced

1.5 Test and Installation Instruments

All instruments and appliances necessary to complete the performance tests specified
shall be supplied for the duration of the tests.

Gauges, instruments and thermometers provided as permanent parts of the installation

may be used during performance testing.

Test instruments proposed for use during performance testing shall all be checked for
accuracy by the manufacturer or an approved laboratory.

Calibration certificates shall be provided for each of the instruments to be used prior to
the commencement of tests.

All instruments provided as part of the installation shall be checked and calibrated as
specified above and again after 6 months of normal operation. Any instrument which
will not hold calibration shall be replaced.

1.6 Noise Measurement

If any excessive noise is evident, noise level measurements shall be taken in selected
and approved locations.

Measurement of sound pressure levels shall be taken during conditions of maximum

load of equipment or part load where directed otherwise by an approved organisation at
a time when the building is practically unoccupied. No measurement shall be taken
closer than 1500mm to any outlet, and not closer than 1000mm to any ceiling, wall or
floor surface.

Background noise levels during testing shall be below measured values by at least 6dB
in all octaves.

1.7 Commissioning and Performance Data

Copies of all data recorded during commissioning of the installation together with all
necessary inspection certificates from local authorities and appropriate manufacturer's
pressure test certificates and performance curves or tables for the following items shall
be provided.

(a) Chillers

(b) Fans

(c) Air Filters

(d) Pumps

(e) Cooling coils

(f) Other specific items of equipment.

Page J / 4
 Technical Specifications
Section J: Testing & Commissioning

Practical Completion will not be granted until all data, certificates and performance
curves etc. referred to above have been received and approved.

1.8 Handing Over

The following procedure shall be adopted prior to handing over the installation:

(a) All preliminary testing, checking, adjusting and balancing of the installation shall
be carried out before forwarding notification that the installation is considered to
have reached Practical Completion.

(b) After inspection, and when the Engineer is satisfied and agrees that the
installation is ready for handing over the plant shall be finally commissioned and
Installation Manuals together with post contract drawings shall be provided as
specified.

(c) Practical Completion will be certified only after the plant has been inspected
and approved and the above requirements fulfilled.

END OF SECTION

Page J / 5
 Technical Specifications
Section K: Maintenance & Servicing

1.0 Maintenance & Servicing

1.1 General

Routine maintenance and servicing shall be carried out for a period of 24 months (or
otherwise as specified in the Contract) from date of Practical Completion to the end of
the Maintenance and Defects & Liability Period.

Regular maintenance shall be carried out on a monthly basis and emergency service
shall be carried out on a 24 hour call out basis.

Maintenance procedures shall be as appropriate to ensure the safe and proper

operation of all systems and shall be in accordance with current standard requirements
of the relevant regulations and as specified herein.

1.2 Scope of Maintenance

The Contractor shall check, maintain and service the equipment regularly for proper and
efficient functioning of the equipment and systems according to the maintenance check
list for each service, generally or as described in this section for the duration of the
Defects Liability Period.

The Contractor shall ensure that all required works is carried out by trained personnel
with the experience and qualifications as required by the relevant authority. These
personnel shall also be acceptable to the Engineer.

All routine maintenance work is to be carried out on site during the operation of the
plant. In case of unforeseen large work on individual aggregates, the Contractor shall
carry out certain works in his own workshop or elsewhere.

The following consumable items shall be supplied as necessary during regular service
and maintenance.

i) Lubricants - grease and oil

ii) Carbon brushes in electric motors

iii) Electrical contact points

iv) Electrical fuses and indicating light bulbs

vi) Cotton rags, detergent and other cleaning materials

vii) Paint of correct colours for touching up

1.3 Conditions of Maintenance

During the duration of the maintenance period, no parts of the system shall be altered or
modified in any way by the Owner without the knowledge and agreement of the
Contractor. Maintenance service as provided under the maintenance period shall not
include labour, expenses and material necessary to repair damage to the equipment
caused by accident or abuse or arising from acts of third parties or any force of nature.

Page K / 1
 Technical Specifications
Section K: Maintenance & Servicing

Maintenance is to be carried out with the understanding that:-

i) The said routine maintenance service shall be rendered during normal business
hours.

Monday to Friday - 8.00 am to 1.00 pm

2.00 pm to 5.00 pm
Saturday - 8.00 am to 1.00 pm

ii) The contractor shall respond to all emergency calls and breakdown immediately
and endeavour to complete the remedial works within 24 hours basis all round
the year including weekend and public holidays.

iii) The duration of maintenance will be for twenty-four (24) months (or otherwise
as specified in the Contract) from the date of handing over to the end user.

1.4 Maintenance Schedules

Maintenance and service shall be carried out regularly as per manufacturer's

recommendation as well as the following, and a log book shall be kept with the
maintenance engineer. The maintenance engineer shall countersign each time any part
of Mechanical Services is attended to by the Contractor. A duplicate copy of each of the
service sheets shall be extended to the Owner each month. It is the responsibility of the
Contractor to ensure that the service sheet is countersigned by the maintenance
engineer as proof of maintenance.

1.4.1 Typical Items

i) Air Cooled Split DX Units (Monthly)

(a) Check all air `filters'; clean or replace filters as necessary
(b) Check monthly all seals and refrigerant pipe lines for leaks. Rectify as
necessary. Cooling coils shall be checked for cleanliness
(c) Check isolation valves for proper function
(d) Clean all fan and bearing and lubricate with grease as necessary
(e) Check all units for excessive noise and vibration. Rectify as necessary
(f) Clean all condensate drain pan as necessary
(g) Check for cleanliness, signs of rust, tightness of bolts and nuts
(h) Clean unit, fans and motor and touch up any rust spots with rust inhibitor and
corrosion resistant paint.
(i) Make appraisal of general condition.

ii) Electric Motors (MONTHLY)

a) Check all motor bearings; lubricate with grease as necessary.

b) Check safety devices fitted to all motors for proper operation; clean and adjust
as necessary.

Page K / 2
 Technical Specifications
Section K: Maintenance & Servicing

iii) Electrical Switchboards (MONTHLY)

a) Clean, adjust and lubricate pivots and moving parts as necessary.

b) Ensure that all indicator, meters and switches are in order.

iv) Instrumentation (MONTHLY)

a) Check all crankcase heaters, contactors, timers, holding relays, cut-off valves.
Adjust or replace as necessary.
b) Flow switches and thermostats shall be checked for correct operation.

v) Biannual Service

Check the performance of the complete air conditioning and mechanical ventilation
equipment.

1.4.2 FIRE PROTECTION

i) Ensure that all portable extinguishers are in the 'as-built' positions and that
they are not damaged impaired, leaking or in discharged condition.
ii) Ensure that all clean gas cylinders are fully charged and that all seal wires
are intact. The Contractor shall test each clean gas system under simulated
alarm condition and ensure that all indications on the control panel and also
the control mechanism work accordingly except that the gas will not be
released. The 'actuation' shall be by triggering of heat and smoke detectors
provided in the room.
iii) Check all Ni-Cd batteries and ensure that the battery water is filled up to
predetermined levels and that the terminals are clean.
iv) Ensure that all the battery chargers and associated components are in good
working condition. The Contractor shall record the condition of each set of
batteries in the logbook after each inspection.

1.5 Quarterly Report

A quarterly report shall be submitted to the Owner stating the condition of the equipment
including associated motors.

1.6 Biannual Report

A biannual report shall be submitted to the Owner stating the condition of the:

(a) Electrical equipment

(b) Equipment with motor
(c) Automation control equipment
(d) Conditions in air-conditioned areas.

END OF SECTION

Page K / 3
 Technical Specifications
Section L: Surge Vessel

1.0 SURGE VESSEL

(a) General

Each surge vessel shall be of the horizontally mounted cylindrically type with dished heads.

The vessel shall function to provide protection to the pumping facilities and pumping main against
the surges by limiting the pressure variation in the system to the minimum as caused by the
following:

i. Starting of pumps
ii. Normal and emergency stoppage of pumps
iii. Power supply failure

Each vessel shall be of butt-welded construction, amply proportioned and designed to withstand
separately or in combination the loads and forces exerted by:

i. The weight of the vessel

ii. An internal pressure equal to the design pressure
iii. The weight of a full vessel of water

The design, construction and testing of the vessel shall conform to the ASME Boiler and Pressure
Vessel Code, Section VIII Unfired Pressure Vessels. The vessel shall be approved by the local
authority. Corrosion allowance of 1.5 for the shell and the dish end shall be provided. The surge
vessel shall be internally and externally abrasive blast and lined with two (2) coats of non-toxic
epoxy and three (3) coats of epoxy paint respectively.

Surge vessel design calculations shall be performed with reputable design software and endorsed
by competent person then shall be submitted to consultant prior manufacturing of the vessel.
Manufacturer data report shall be furnished upon completion of fabrication and hydrostatic testing.

(b) Material

Steel plate for the pressure vessel shall conform to SA-516 Grade 70 to ‘Fine’ Grain Practice or
an equivalent steel having good notch toughness. Material for vortex plate, baffle plate, manhole
and so for the shall conform to that specified for the pressure vessel.

(c) Welding

All welding shall be in accordance with the current ASME Boiler for the Unfired Pressure Vessels.

All but welds shall be fully radiographed in accordance with the above code. Joints shall have a
maximum joint efficiency of 100% of that of the connecting plates. All the radiographs, including
location plans and interpretations shall be submitted to the S.O. for approval.

All nozzles necks, saddle supports, brackets and all other weld attachments shall be performed
with dye penetration test before hydrostatic testing. Certificates shall be provided to confirm the
result of shop fabrication procedures and welding test as required by the ASME specification.

Page L / 1
 Technical Specifications
Section L: Surge Vessel

(d) Supports

Each vessel shall b adequately supported on fabricated steel saddles, permanently fixed to the
vessel and designed to withstand the maximum load imposed thereon. Vessel saddle support shall
be suitable for right anchorage to the concrete floor with stainless steel holding down bolts.

(e) Accessories

The following accessories shall be furnished for each vessel:

i. Access manhole at least 600mm in diameter shall be provided in the shell of the vessel at
top and bottom.

ii. The main pipework valves shall be as generally shown on the drawings, flanges of
pipework shall be in accordance with BS EN 1092 and shall be drilled in accordance with
details shown in Appendix 3.1 Section 3 of Specification.

iii. Two safety valves to BS 1123 or ASME approved spring-loaded pressure relief valve with
stainless steel trim, suitable for air and water services shall be calibrated with valid
certificate provided for each vessel. The calibrated safety valve shall be set relieve at
pressure in excess of the design pressure. The valve shall not be less than 50mm diameter
and shall be installed such that it is accessible from the access platform. A spare safety
valve shall also be supplied under the Contract.

iv. A lubricated plug valve of the 3-way, 2 port, 2 position type rated to at least the design
pressure shall be furnished in order to select either of the two relief valves to service.
Piping between vessel and relief valve shall be furnished.

v. A sight glass gauge shall be furnished with an isolating cock which shall be shut
automatically in the event of breakage of the gauge glass. The gauge glass shall be
protected with a metal surround with the sides and back painted matt white. The front shall
have 12mm thick transparent armored glass providing not less than 50mm wide clear view
of the glass gauge. The assembly shall facilitate easy dismantling for cleaning and removal
of the gauge glass.

vi. Pressure gauges of the Bourdon type 200m dial diameter shall be provided, contained in
black aluminum case with stainless steel trim and suitably graduated to suit the test
pressure rating of the surge vessels and calibrated with valid certificates.

vii. An orifice plate of stainless steel type 316 construction suitable for insertion between pipe
flanges shall be provided.

viii. Galvanised mild steel ladders with safety cage and maintenance platforms complete with
handrails for access manholes, electrodes, pressure gauges, sight glass gauge, safety
valves, controls valves and all other appurtenances required shall also be provided.

ix. Surge vessel control

The control system shall maintain the water level in the surge vessels between two set
points (high water and low water level). Air is either released or pumped into surge vessels
to achieve this requirement.

Page L / 2
 Technical Specifications
Section L: Surge Vessel

Each surge vessel shall be provided with six level electrodes set to the following pre-
determined levels:

i. High-high water level

ii. High water level
iii. Normal water level
iv. Low water level
v. Low-low water level
vi. Common for earth

Only one set of electrodes from one of the surge vessels shall be used at a time to control
all the surge vessels. A selector switch shall be provided within the starter board to choose
the duty set of electrodes.

The acceptable water level in the surge vessel during the pumping operation shall be
between the high water level and low water level.

When the water level in the surge vessel rises above ‘high’ level, the electrical motorized
compressed air supply valve shall automatically open to supply compressed air to surge
vessel. When the water level drops below the ‘normal’ water level, the electrical motorized
compressed air supply valve shall automatically close. The period of air changing shall be
limited to 30 minutes for all the surge vessels.

When the pressure in the receiver drops below the compressor cut-in setting, the duty
compressor shall automatically start and shall continue to run until the pressure in the
receiver rises to cut-out setting. The period of air changing shall be limited to 30 minutes
for the air receiver.

When the water level drops below the ‘low’ water level, a suitably sized control electrical
motorized valve shall gradually open to release the air within the vessel to allow the water
level rise. When the water level rises above the ‘normal’ water level, the control valve shall
automatically close. The noise generated from the air being released shall not exceed 80
dBA at 3 meters away. A silencer shall be provided if required to reduce the noise level.

A delay timer shall also be provided to prevent frequent opening and closing the air inlet
and air release valves during surges and starting of pumps.

The pumps shall be prevented from starting when the water level is at the ‘high-high’ water
level, or the ‘low-low’ water level and if more than one (1) surge vessel is out of services.
Under any of these conditions a ‘Surge Vessel Abnormal’ signal shall be sent to each pump
starter panel. Facilities to override the ‘Pump Start Inhibit’ during the above conditions shall
be provided via a ‘Surge Vessel Abnormal’ override switch mounted within the air
compressor starter board.

Each surge vessel shall be provided with a continuous water level monitoring system,
comprising of a differential pressure transmitter, vertical edgewise bar graph indicator with
digital display at the starter board and associated relays and cabling.

Each differential pressure transmitter shall be of rugged construction, suitable for the
application and;

i. Have an electrical output of 4-20 mA proportional to differential pressure gauge or

absolute pressure as appropriate.

Page L / 3
 Technical Specifications
Section L: Surge Vessel

ii. Be capable of withstanding 100% overload (i.e. twice the pressure required for full
output) without sustaining damage.

iii. Have sensing elements and flanges of stainless steel or equivalent.

iv. Have independent span and zero adjustments.

v. Be operable non 2-wire system.

vi. Have an accuracy within +0.5% of span, repeatability of within +0.2% of span and
dead band not exceeding 0.2% of span.

Each application shall be supplied and installed complete with;

i. Sensing lines of stainless steel, grade 316S31 to BS EN 10088.

ii. Two isolating and one bypass valves for each transmitter.

The differential pressure transmitter for measuring the surge vessel water level shall have
the low pressure side filled to a reference level and a facility for topping up shall be
provided.

2.0 AIR COMPRESSOR FOR SURGE VESSEL

(a) General

The surge vessel provided shall be charged by the air compressor. The details of the two
(2) air compressor offered shall be provided by the tenderer as follows;

i. Manufacturer
ii. Type
iii. Speed
iv. Free air delivery
v. Delivery pressure
vi. Power absorbed

The contractor shall be required to supply and install the pipework, valves and fitting and
make the necessary connections to the air pipelines for air supply to the surge vessel.
Recharge time shall be less than 10 minutes.

All cabling, relays, contacts, etc. required for the air compressor power and control system
shall be included in the Contract Sum.

(b) Compressed Air Generation and Distribution

A complete compressed air generation and distribution system consists f air compressor,
compressed air storage tank, dryer, compresses air distribution pipework and compresses
air filter regulator, drain valve check valve and shut off valve.

Page L / 4
 Technical Specifications
Section L: Surge Vessel

The compressed air distribution pipework shall be designed based in a ring-main air
distribution system in order to obtain even distribution of pressure at different points of the
system. Rigid piping such as galvanized iron pipes shall be used for the ring-main air
distribution system.

Shut of valve shall be installed at necessary locations such as usage point, T-connections,
etc. for sectional shut down and maintenance purposes.

Condensate and water drainage valve must be available at the lowest point of every
distribution ring to facilitate condensate discharge. The drain valve must be electrical driven
auto discharge type.

Pressure gauge or sensors for monitoring of air distribution pressure must be provided for
every distribution ring at the furthest point from the main header.

Compressed air filter regulator is essential for pre-setting the air pressure and the
prevention of condensate water into the control equipment at each sub-station connected
to the ring-main.

The size of the G.I. pipes for the header assembly shall be 25mm DN whilst the ring main
shall be 20mm DN HDG pipe.

(c) Air Compressor

For compressed air generation, a piston or screw type compressor is requiring. The
compressor must be of an oil free type with piston or screw operation principle to guarantee
an air-preparation without using oil.

The maximum output pressure of the air compressor must not exceed 10 bar, but as a
minimum it should be able to deliver up to 8 bar pressure. Each pneumatic network shall
consist of at least 2 air compressors (1 duty / 1 standby) with each air compressor having
the capability to operate the pneumatic network system independently. Both the air
compressor mist work under alternating conditions. The sizing of the compressor shall be
based on maximum run-time of not exceeding 10 minutes/hour and shall not be lower than
1 cycle/hour.

The air compressor must be complete with simple control where it is able to auto start while
the air pressure is lower than the preset value and auto cut off when the desired maximum
pressure is achieved.

Each compressor must be complete with:

i. Non-return valve in the air circuit

ii. Pressure gauge
iii. Pressure switch On and OFF – adjustable up to max. 10 bar
iv. Switch and starting load rejection
v. Electrical driven auto condensing water drainage
vi. Pressure regulating and filtration service unit.

Page L / 5
 Technical Specifications
Section L: Surge Vessel

(d) Compressed Air Surge vessel

Standby compressed air stored in vessel / tanks is required as a buffer between the air
compressor and air supply network. Additionally, it works as a pre-separator for the
accumulating condensate. The average standby capacity of the surge vessel shall be of a
minimum of 2 hours supply to the pneumatic network.

The surge vessel shall be able to store compressed air with a pressure of up to 10 bar and
contractor is responsible for obtaining of the JKKP approval. Material for the surge vessel
shall be of welded steel with appropriate epoxy coating of minimum thickness 200 microns
to provide a guarantee of minimum service lifespan of 20 years.

Minimum test pressure shall be 1.3 x the nominal pressure. The surge vessel shall be
complete with the following equipment:

i. Mechanical safety relief valve

ii. Pressure switch for maximum pressure
iii. Pressure switch for minimum pressure
iv. Electrical driven auto drain valve for condensing water.

END OF SECTION

Page L / 6
 ELECTRICAL SERVICES
GENERAL SPECIFICATION
Page 1

TABLE OF CONTENT

ELECTRICAL SERVICES
TECHNICAL SPECIFICATIONS

SECTION TITLE

18000 SCOPE OF WORK

18001 SYSTEMS IDENTIFICATION

18002 QUALITY ASSURANCE, INSPECTION, TESTING AND

COMMISSIONING

18003 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,

HANDOVER PROCEDURE

18004 LIGHTING WIRING, POWER CABLING AND CONTROL WIRING

18005 CONDUIT, ‘RACEWAY’ TRUNKING, CABLE TRAY AND CABLE

LADDER

18006 600/1000V PVC SHEATED CABLES (NON-FIRE RESISTANT AND FIRE

RESISTANT)

18007 116.35kV XLPE SWA PVC CABLES

18008 SWITCHES AND SWITCHED SOCKET OUTLETS

18009 PROTECTION, METERING AND CONTROL

18010 DISTRIBUTION PANELS, AUXILIARY BOARD AND MARSHALLING

CABINETS

18011 415V METALCLAD SWITCHBOARDS AND DISCONNECTING

SWITCHES

18012 LOW VOLTAGE AC SWITCHBOARDS, MOTOR CONTROL CENTRE

AND ATS

18013 EARTHING SYSTEM

18014 LIGHTNING PROTECTION SYSTEM

END OF TABLE OF CONTENT

 SCOPE OF WORKS
SECTION 18000

PAGE 1

1.0 GENERAL

.1 DESCRIPTION

.1 Provide the work included in accordance with the Contract Documents.

.2 WORK INCLUDED

.1 Provide all labour, materials, equipment, tools, appliances, auxiliaries,

services, hoisting, scaffolding, support, supervision, and Project Record
Documents, and perform all operations for the furnishing and installing of
the complete electrical system, including but not limited to the work
described hereinafter.

.2 The electrical work shall be shown on the Shop Drawings to indicate the
general system arrangement and configuration. The work of this Division
shall include coordination with the work of other Divisions of the
Specifications and the Contract Documents so as to provide a complete
and operational system capable of being readily operated and
maintained, including approved rearrangement of the system and
equipment and rerouting of distribution services to enable the complete
system to fit within the confines of the allotted electrical spaces, all to the
satisfaction of the Employer's Representative or as directed by the
Employer.

.3 The work includes, but is not limited to the following:

.1 Local authority power supply intake services, cable ladders,
connection and metering
.2 415kV metalclad switchboards and Load break switch
.3 Dry type cast-resin transformers
.4 11 /6.35kV XLPE/ SWA / PVC cables
.5 Battery banks
.6 Battery and chargers
.7 DC distribution boards
.8 LV main switchboards and Essential Main Switchboard
.9 Low voltage capacitor banks
.10 Distribution panels
.11 Diesel engine driven generators and accessories
.12 Protection, metering and control
.13 Tap-off unit.
.14 600/1000V cables
 SCOPE OF WORKS
SECTION 18000

PAGE 2

.15 Cable conduits, trunkings, trays and ladders

.16 Underfloor trunking system
.17 Lighting and power wiring
.18 Lighting luminaries and aircraft warning lights
.19 Switches and switched socket outlets
.20 Fireman switch system
.21 Lightning protection systems
.22 Earthing systems
.23 Fire stops
.24 Equipment supports and miscellaneous steel for equipment
.25 Vibration isolation for equipment and installation
.26 Sealing of sleeves and all openings
.27 Power wiring to all BCS, FAS, BSS, etc. interface terminal strips
.28 Emergency power connection provisions to all BCS, FAS, BSS
etc. field panels
.29 Interfacing work with Air-Conditioning & Ventilation System,
Building Control System, Fire Protection System and other
applicable trade services.
.30 Protection Coordination and Setting
.31 Authorities approvals.
.32 Catalogues, technical and samples of equipment/components.
.33 Shop drawings, construction/installation drawings and installation
manuals/method statement.
.34 Establishing and maintaining a quality assurance and quality
control system.
.35 Packing delivery and storage notes of all equipment/components
delivered to site.
.36 Field painting.
.37 Tagging and labelling
.38 Cleaning
.39 Inspect and witness testing and site testing, adjusting,
commissioning, training of Employer's personnel and hand-over.
.40 As-built reproducible tracings, Auto CAD drawing files and
operation and maintenance manuals.

END OF SECTION
 SYSTEM IDENTIFICATION
SECTION 18001

Page 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Work of this Section shall conform to the requirements of the Contract

Documents.

.2 Provide fixed identification of all distribution equipment and conductors in

accordance with the Contract Documents.

1.2 WORK INCLUDED

.1 Mechanical Division

.1 Valve Tags

.2 Piping Identification

.3 Equipment Identification

.4 Duct Identification

.5 Charts and Schedules

.2 Electrical Division

.1 HV panels

.2 DC Supply Systems

.3 Transformers

.4 LV Main Switchboards, Motor Control Centres and Automatic

Transfer Switches

.5 Distribution Panel boards

.6 Auxiliary Boards

.7 Marshalling Cabinets

.8 Motor Starters

.9 Fuse Disconnecting Switches / Isolators

.9 Busbar Trunkings (Busways)

.10 Feeder Cables

.11 Cable Trunkings, Trays and Ladders

.12 Flush Floor Trunking Systems

 SYSTEM IDENTIFICATION
SECTION 18001

Page 2

.13 Switches and Socket Outlets

.14 Standby Generators

.15 Uninterruptible Power Supply System

.16 Public Address System

.17 Satellite Master Antenna System

.18 Earth Bars, Earth Points/ Test Points and Earth Chamber

.19 Firestops

1.3 SUBMITTALS

.1 Product Data: Manufacturer's latest published data for materials

equipment and installation including samples of valve tags, equipment
identification and piping identification, showing size of lettering, colour
charts and stickers: -

.2 Shop Drawings: Submit valve tag chart - pipe, duct, equipment labels,
paint and colour chart.

.3 Maintenance Manuals: Provide valve tag charts for inclusion in

maintenance manuals.

.4 Identification procedures shall be noted and scheduled on the applicable

shop drawings.

1.4 QUALITY ASSURANCE

.1 Piping identification to be in accordance with local practice or BS 1710

and BS 4800 (latest edition), as to sizes, colour, lettering and background
colour.

.2 Except as modified by governing codes and by the Contract Documents,

comply with the latest applicable provisions and latest recommendations
of acceptable industry standards.

2.0 PRODUCTS

2.1 EQUIPMENT IDENTIFICATION

.1 Identify electrical and mechanical equipment by means of nameplates

permanently attached to the equipment including control panels. Provide
black surface, white core laminated bakelite with engraved letters (upper
case letters). Minimum size plates 80mm long by 25mm wide white letters
10mm high.

.2 Identify electrical and mechanical equipment by means of nameplates

 SYSTEM IDENTIFICATION
SECTION 18001

Page 3

.3 Identification plates for equipment supplied by the emergency supply shall

be red surface, white core laminated bakelite with engraved letters (upper
case letters). Minimum size plates 80mm long by 25mm wide white
letters 10mm high.

.4 All identification plates must be engraved and must be secured with rivets
or brass/cadmium plate screws. The use of Dymo type or the like is
unacceptable.

2.2 DUCT IDENTIFICATION

.1 Stencil system number and service (supply, return, exhaust) onto ducts at
strategic locations. Provide arrows to show direction of flow.

2.3 VALVE TAGS

.1 Tags shall be minimum of 80mm long by 60mm wide, fabricated of

aluminium or shatterproof plastic material.

.2 Attach tags to the valves with chain or split ring as appropriate.

2.4 PIPING IDENTIFICATION

.1 Identify pipes with colour bands in accordance to local practice or BS

1710 and BS 4800.

2.5 CHARTS & SCHEDULES

.1 Provide two diagrammatic charts or schematic diagrams of all piping

systems, identifying location, numbers and types of all valves, framed with
glass cover for mounting. Legend to show service (chilled water, pump,
etc.) and valve number assigns number by floor.

.2 Provide electrical schematic diagrams for each control panel, identifying

the switchgear, controls, starters, circuit breakers, etc.

2.6 SIGNAGE AND LABELING (applicable for Mechanical Services)

.1 To provide safety precautions and emergency procedures indication and

signage within the rooms, exterior walls or access doors.

.2 The information and instruction appeared on the signage shall be in text

form or combination of text, graphic and flow charts presentation with
different colour to the background panel to show clear indication of
information and instruction to the operators, users and public.

.3 The material and method of construction for signage panels shall be

based on the following schedule minimum requirement:
 SYSTEM IDENTIFICATION
SECTION 18001

Page 4

Services Systems Background Panel

and Method of
Construction

Fire Protection Sprinkler Zone Flow  Perspex minimum

Switch and Range Pipe 4mm thick with
Drain Valves embossed or hot
stamping signage

 Hanging or fixed to
ceiling

Rooms with Fixed CO2  Perspex minimum

and Clean Agent 4mm thick with
System embossed or hot
stamping signage

 Fixed to wall or door

Fire Breeching Inlets  Perspex minimum

4mm thick with
embossed or hot
stamping signage

 Fixed to wall

Sprinkler Alarm Valves  Perspex minimum

and Water Operated 4mm thick with
Gongs embossed or hot
stamping signage

 Fixed to wall

Fire Pump Rooms  Perspex minimum

4mm thick with
embossed or hot
stamping signage

 Fixed to wall or door

Lift Inside Car  Stainless Steel

minimum 1.5mm thick
with engraved
signage

 Fixed to wall or door

 SYSTEM IDENTIFICATION
SECTION 18001

Page 5

Services Systems Background Panel

and Method of
Construction

Motor Room  Perspex minimum

4mm thick with
embossed or hot
stamping signage

 Fixed to wall or door

Lift Pit  Perspex minimum

4mm thick with
embossed or hot
stamping signage

 Fixed to wall

Car Top  Perspex minimum

4mm thick with
embossed or hot
stamping signage

 Fixed to wall

Natural Gas Gas Main Valves  Perspex minimum

Station 4mm thick with
embossed or hot
stamping signage

 Fixed to wall or
fencing or hanging to
shelter ceiling

Development Boundary  Perspex minimum

Isolating Valve 4mm thick with
embossed or hot
stamping signage

 Fixed to wall, door or

hanging to floor slab

Building’s Main Service  Perspex minimum

Valves (main solenoid 4mm thick with
valves assembly) embossed or hot
stamping signage

 Fixed to wall or door

 SYSTEM IDENTIFICATION
SECTION 18001

Page 6

Services Systems Background Panel

and Method of
Construction

Service Gas Meter  Perspex minimum

4mm thick with
embossed or hot
stamping signage

 Fixed to wall

Air Conditioning and Hex Room and Chilled  Perspex minimum

Ventilation Water Pump Rooms 4mm thick with
embossed or hot
stamping signage

 Fixed to wall or door

Fire Dampers  Perspex minimum

4mm thick with
embossed or hot
stamping signage

 Hanging or fixed to
ceiling or fixed to wall

Domestic Water and Pump Rooms and Pits  Perspex minimum

Sanitary Plumbing 4mm thick with
embossed or hot
stamping signage

 Fixed to wall or door

or hanging to floor
slab

Irrigation Pump Rooms  Perspex minimum

4mm thick with
embossed or hot
stamping signage

 Fixed to wall or door

or hanging to floor
slab

.4 Text font size and colour selection samples shall be submitted to E.R. for
approval. However, the minimum text size shall be based on reasonable
and acceptable viewing distance to E.R. approval as well as in
compliance with relevant and approved British Standard.

.5 The following schedule is the applicable colour coding and systems

identification requirements for Mechanical Services:
 SYSTEM IDENTIFICATION
SECTION 18001

Page 7

SERVICES SYSTEM BACKGROUND TYPE OF BAND ARROW AND REMARKS

SYSTEMS CODE COLOR IDENTIFICATION COLOR TEXT COLOR

ACMV SYSTEMS
Chilled Water CHWS N/A  Pipe Band Dark Blue Black or
Supply Pipe White
 Service
Identification
Text
 Arrow
Chilled Water CHWR N/A  Pipe Band Light Blue Black or
Return Pipe White
 Service
Identification
Text
 Arrow
Plant Rooms EA N/A  Service N/A Black or
and Car Park Identification White
Ventilation Text
(Exhaust)
 Arrow
Plant Rooms SA N/A  Service N/A Black or
and Car Park Identification White
Ventilation Text
(Supply Air)
 Arrow
Kitchen KEA N/A  Service N/A Black or
(Exhaust Air) Identification White
Text
 Arrow
Kitchen KSA N/A  Service N/A Black or
(Supply Air) Identification White
Text
 Arrow
Toilet TEA N/A  Service N/A Black or
(Exhaust Air) Identification White
Text
 Arrow
Toilet (Supply TSA N/A  Service N/A Black or
Air) Identification White
Text
 Arrow
Smoke Spill SSE N/A  Service N/A Black or
(Exhaust Air) Identification White
Text
 Arrow
Smoke Spill SSA N/A  Service N/A Black or
(Make-up Air) Identification White
Text
 Arrow
Air/Cond ASA N/A  Service N/A Black or
(Supply Air) Identification White
Text
 Arrow
Air/Cond AFA N/A  Service N/A Black or
(Fresh Air) Identification White
Text
 Arrow
 SYSTEM IDENTIFICATION
SECTION 18001

Page 8

SERVICES SYSTEM BACKGROUND TYPE OF BAND ARROW AND REMARKS

SYSTEMS CODE COLOR IDENTIFICATION COLOR TEXT COLOR

ACMV SYSTEMS
Air/Cond AEA N/A  Service N/A Black or
(Exhaust Air) Identification White
Text
 Arrow
Air/Cond ARA N/A  Service N/A Black or
(Return Air) Identification White
Text
 Arrow
Staircase SPA N/A  Service N/A Black or
Pressurisation Identification White
Text
 Arrow
Lobby LPA N/A  Service N/A Black or
Pressurisation Identification White
Text
 Arrow
FIRE PROTECTION SYSTEMS
Sprinkler Main SP Fireman Red  Service N/A White  To include
Pipes and Identification system
Risers Text stage code
 Arrow
Sprinkler Drain SP-D Fireman Red  Service N/A White  To include
Pipe Identification system
Text stage code
 Arrow
Sprinkler SP-T Fireman Red  Service N/A White
Transfer Pipe Identification
Text
 Arrow
Wet Riser WR Fireman Red  Service N/A White  To include
Main Pipes Identification system
and Risers Text stage code
 Arrow
Wet Riser WR-R Fireman Red  Service N/A White  To include
Return Pipe Identification system
Text stage code
 Arrow
Wet Riser WR-T Fireman Red  Service N/A White  To include
Transfer Pipe Identification system
Text stage code
 Arrow
DOMESTIC WATER AND
SANITARY PLUMBING
Domestic CW-IN Blue  Service N/A Black or BAND is
Water main Identification White required with
incoming pipe Text background
to Tank colour code for
 Arrow ABS or other
plastic
polymer pipe
 SYSTEM IDENTIFICATION
SECTION 18001

Page 9

application

SERVICES SYSTEM BACKGROUND TYPE OF BAND ARROW AND REMARKS

SYSTEMS CODE COLOR IDENTIFICATION COLOR TEXT COLOR
DOMESTIC WATER AND
SANITARY PLUMBING
Domestic CW-T Green  Service N/A Black or BAND is
Water Identification White required with
Transfer Pipe Text background
To Break or colour code for
Rooftop Tanks  Arrow ABS or other
plastic
polymer pipe
application
Domestic CW-F Blue  Service N/A Black or BAND is
Water Identification White required with
Distribution Text background
Pipe from colour code for
Tanks to  Arrow ABS or other
Service Area plastic
(Flush Valve) polymer pipe
application
Domestic CW-S Blue  Service N/A Black or BAND is
Water Identification White required with
Distribution Text background
Pipe from colour code for
Tanks to  Arrow ABS or other
Service Area plastic
(General) polymer pipe
application
Domestic CW-D Black  Service N/A White BAND is
Water Tank Identification required with
Drain, Over Text background
Flow, Scour colour code for
and Warning  Arrow ABS or other
Pipes plastic
polymer pipe
application
Sanitary SW-T Brown  Service N/A Black or
Sewerage Identification White
Transfer Pipe Text
 Arrow
Basement WW-T Black  Service N/A White
Waste Water Identification
Transfer Pipe Text
 Arrow
Sanitary Soil SWP N/A  Pipe Band Brown Black  To include
and Waste Stack Code
main  Service
discharge Identification
pipes and Text
droppers
 Arrow
Sanitary Vent VP N/A  Service Brown Black  To include
pipes Identification Stack Code
Text
Sanitary Stack STP N/A  Service Brown Black
Pipes Identification
Text
 SYSTEM IDENTIFICATION
SECTION 18001

Page 10

SERVICES SYSTEM BACKGROUND TYPE OF BAND ARROW AND REMARKS

SYSTEMS CODE COLOR IDENTIFICATION COLOR TEXT COLOR

NATURAL GAS
Gas supply NG Yellow  Service N/A Black or to
and service Identification Gas Malaysia
pipe Text requirements

 Arrow
IRRIGATION SYSTEMS
Irrigation IW-IN N/A  Pipe Band Dark Green Black or
Water main White
incoming pipe  Service
to Tank Identification
Text
 Arrow
Distribution IW-S N/A  Pipe Band Dark Green Black or
Pipe for White
Irrigation  Service
Water Identification
Text
 Arrow

.5 The following schedule is the applicable colour coding and systems

identification requirements for wiring containment (e.g. conduit and
trunking) with respect to Mechanical Services:

SERVICES SYSTEMS BACKGROUND TYPE OF BAND TEXT COLOR REMARKS

COLOR IDENTIFICATION COLOR
BUILDING CONTROL N/A  Conduit/Trunking N/A Including Cable
SYSTEMS Band Ladder, Cable Bridge
and Cable Tray
FIRE PROTECTION N/A  Conduit/Trunking N/A Including Cable
SYSTEMS Band Ladder, Cable Bridge
and Cable Tray
ACMV SYSTEMS N/A  Conduit/Trunking N/A Including Cable
Band Ladder, Cable Bridge
and Cable Tray
DOMESTIC WATER N/A  Conduit/Trunking N/A Including Cable
AND SANITARY Band Ladder, Cable Bridge
PLUMBING and Cable Tray

LIFT N/A  Conduit/Trunking N/A Including Cable

Band Ladder, Cable Bridge
and Cable Tray
NATURAL GAS N/A  Conduit/Trunking N/A Including Cable
Band Ladder, Cable Bridge
and Cable Tray
IRRIGATION N/A  Conduit/Trunking N/A Including Cable
SYSTEMS Band Ladder, Cable Bridge
and Cable Tray
 SYSTEM IDENTIFICATION
SECTION 18001

Page 11

2.7 SIGNAGE AND LABELING (applicable for Electrical Services)

.1 Lettering heights unless otherwise noted must be as follows:

Item Lettering
HV Cable Ladder 100mm
HV Panels 25mm
DC Supply Systems 25mm
Transformers 25mm
LV Main Switchboards, Motor Control Centres 25mm
and Automatic Transfer Switches
Distribution Panel boards 12mm
Auxiliary Boards 12mm
Marshalling Cabinets 12mm
Motor Starters 12mm
Fuse Disconnecting Switches / Isolators 12mm
Busbar Trunkings (Busways) 25mm
Feeder Cables 12mm
Cables Trunkings, Trays and Ladders 12mm
Flush Floor Trunking Systems 12mm
Switches and Socket Outlets 5mm
Standby Generators 25mm
Uninterruptible Power Supply System 25mm
Public Address System 25mm
Satellite Master Antenna System 25mm
Earth Bars, Earth Points/ Test Points and 25mm
Earth Chamber
Firestops 12mm
Ballasts (Greater than 415 volts) 12mm

.2 Cable tags must be flameproof secured with flameproof non-metallic

cord.

.3 Identification plate inscriptions must bear the name and number of

equipment to which they are attached as indicated on the Contract
Document. The Employer's Representative reserves the right to make
modifications in the inscriptions as necessary.

.4 The Employer's Representative reserves the right to request additional

nameplates at time of review of shop drawings and upon site
observations. These shall be furnished at no additional cost to the
Employer.

.5 The following schedule is the applicable colour coding and systems

identification requirements for wiring containment (e.g. conduit and
trunking) with respect to Electrical Services:
 SYSTEM IDENTIFICATION
SECTION 18001

Page 12

SERVICES SYSTEMS CONDUIT FACTORY PRE- BAND COLOUR HOT DIP GALVANISED
COLOUR PAINTED

ELECTRICAL Orange  Conduit Orange band Cable Ladder, Tray and

(NORMAL) Trunking

ELECTRICAL Orange with  Conduit Orange band and Cable Ladder, Tray and
(ESSENTIAL) Red band Red band Trunking

ELECTRICAL (UPS) Orange with  Conduit Orange band and Cable Ladder, Tray and
Yellow band Yellow band Trunking
PA SYSTEM White  Conduit White band Cable Ladder, Tray and
Trunking
SMATV SYSTEM Pink  Conduit Light Blue band Cable Ladder, Tray and
Trunking

.6 Coloured bands shall be of painting type with etching primer and two coat
of approved type colour paint.

.7 Work method statements for coloured bands shall be submitted for

Employer’s Representative approval.

3.0 EXECUTION

3.1 EQUIPMENT

.1 Attached nameplates in a permanent manner in a location that will be

clearly visible after installation is complete.

.2 Mask all labels prior to field painting of equipment. Labels that are
painted over will be replaced at no extra cost to the Employer.

3.2 DUCTWORK

.1 Stencilling to be done after insulation and other duct coverings are

completed.

.2 Minimum text font sizes shall be 50 mm height complete with directional

arrow. The labelling distance shall be based on the following interval:

.1 Horizontal at 6.0m intervals and at any directional change, wall or

floor penetrations, fittings and overlapping.

.2 Vertical at 3.0 m intervals and at any directional change, wall or

floor penetrations, fittings and overlapping.

.3 Systems on which duct identification has been covered or is otherwise not

visible will not be accepted.

3.3 PIPING SYSTEMS

.1 Identify positions of the colour coded bands as local practice or BS 1710

and BS 4800 to the piping systems. Bands shall be placed at strategic
points, such as valves, items of equipment, changes in pipe direction, wall
penetrations and every 6.0 m of straight run and 3.0 m of vertical rise.
 SYSTEM IDENTIFICATION
SECTION 18001

Page 13

.2 Each set of bands shall consist of the following: -

.1 One (1) band on which one name of the service with directional
arrow and text font size not less than 36mm height.

.2 Provide bands with backgrounds of different colours from the

various service group.

3.4 CHARTS & SCHEDULES

.1 Prepare the diagrammatic charts, valve charts and schematic diagrams of

the piping systems and the control panels in a frame mounting with clean
perspex sheet for protection.

.2 Laminated control and circuit diagram shall be provided for all control
panels.

3.5 SWITCHBOARDS, TRANSFORMERS AND MOTOR CONTROL CENTRES

.1 Furnish and install a master identification plate on the top of each

switchboard, transformer and motor control centre labelled with the
equipment identification indicated in the approved drawing / Contract
Document.

.2 Provide on each circuit breaker cubicle an identification plate centrally

mounted at the top of the cubicle.

3.6 DISTRIBUTION PANELBOARDS AND MARSHALLING CABINETS

.1 Furnish and install an identification plate for each distribution panel board,
marshalling cabinet and TNB tariff metering kiosk labelled with the
identification indicated in the approved drawing / Contract Document.
Mount at the top of each board or cabinet.

.2 For distribution panel boards, after installation is completed, provide and

mount under sturdy transparent shield in the directory frame of each door,
a neat, accurate and carefully printed directory properly identifying the
lighting, switched socket outlets, and equipment each protective device
controls.

.3 For marshalling cabinets, after installation is completed, provide and

mount under sturdy transparent shield in the directory frame of each door,
a neat, accurate and carefully printed directory properly identifying the
terminal blocks, circuit descriptions, equipment connected and the
originating points.

.4 Include in the directory the distribution panel board or marshalling cabinet

identification, the cable and cable tray/trunking, size of panel feeder, and
the feeder originating point.
 SYSTEM IDENTIFICATION
SECTION 18001

Page 14

3.7 BUSBAR TRUNKING (BUSWAYS)

.1 Furnish and install identification plates for busbar trunkings labelled with
busbar trunking designations. Install at each busbar trunking in every
electrical closet, route changes and on straight horizontal runs at not
more than 15 metre intervals. Where busbar penetrates a wall, floor, etc.,
provide identification plate on busbar within one metre on each side of
wall, floor, etc.

3.8 DISCONNECTING SWITCHES (ISOLATORS)

.1 Furnish and install an identification plate for each disconnecting switch

labelled with the equipment designation, which the disconnecting switch
serves, the source of supply and the size and type of cable.

3.9 AUTOMATIC TRANSFER SWITCHES

.1 Furnish and install a red identification plate for each automatic transfer
switch. Labelling shall indicate the switch number, the load served, and
the sources of normal and standby generator power and the size and type
of cables (emergency and normal).

3.10 MOTOR STARTERS

.1 Furnish and install an identification plate for each motor starter and those
in a motor control centre, etc. Labelling must indicate the motor served
and the source of supply.

3.11 FEEDER/TRANSFORMER/MOTOR SWITCHES

.1 Furnish and install for each feeder/transformer/motor switch including, but

not limited to those in switchboards, tap-offs at busbar trunkings, those in
motor control centres, etc. an identification plate indicating the load
served, the size and type of cable and tray/trunking etc.

3.12 DC SUPPLY SYSTEM

.1 Furnish and install an identification plate on each battery charger, DC

distribution board and battery bank. DC distribution boards shall be
provided with information on the directory frame.

3.13 SWITCHES

.1 Furnish and install an identification plate for each switch controlling loads,
which are not local to the switch. Labelling shall be as directed by the
Employer's Representative.

3.14 EARTH BARS AND EARTH TERMINALS

.1 Furnish and install an identification plate on each earth bar and earth
terminal. Engraving must indicate earth bar/terminals; functions e.g.
power riser earth, telecommunication earth and power transformer
neutral.
 SYSTEM IDENTIFICATION
SECTION 18001

Page 15

3.15 LUMINAIRES

.1 Where connected to other than 415/240 Volt circuit, provide each

fluorescent or high intensity discharge fixture with the ballast voltage
labelled on the ballast cover in letters not less than 12mm high.

3.16 TRUNKING SYSTEMS

.1 Furnish and install an identification plate on each section of trunking

labelled with the system designation e.g. BCS, Security, Fire Alarm, etc.
Install on all vertical trunking at each floor level and on horizontal trunking
at not more than 1.5 metre intervals and within 1 metre on both side of
wall penetrations.

END OF SECTION
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

The quality assurance, inspection, tests and commissioning procedures shall be

carried out upon placing of contract for the electrical facilities.

1.2 WORK INCLUDED

.1 Provide Quality Assurance Manual (QAM), Works Quality Assurance

Programme (WQAP), Field Quality Assurance Programme (FQAP) and
Quality Plan.

.2 Tests at manufacturer's works.

.3 Provide assistance and testing equipment for witnessed site inspection

and tests.

.4 Perform site tests and commissioning for all mechanical and electrical
equipment and plant

1.3 SUBMITTALS

.1 After Contract Award, submit the following: -

.1 Quality Assurance Manual (QAM)

.2 Works Quality Assurance Programme (WQAP)

.3 Field Quality Assurance Programme (FQAP)

.4 Quality Plan

.2 For inspection and testing, submit inspection and testing procedures,

programme, record sheets applicable at each hold point.

.3 After completion and testing submit test records, packaging, transportation

and storage instructions and methods.

.4 For site installation and commissioning submit installation methods or

procedures, notification and procedure for pre-commission and
commissioning.

.5 After commissioning submit site test records, as-built drawings, etc.

1.4 QUALITY ASSURANCE

.1 The Contractor shall refer to the appropriate parts of ISO 9001:2000

series as guidelines for implementation of the quality programmes.

.2 All equipment and components shall be designed, manufactured and

tested to Malaysian, IEC or British Standards. Where these standards are
not applicable then other national standards shall apply e.g. Australian,
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 2

American, Japanese or German Standards. The order of preference shall

be as follows: -

.1 British Standards

.2 IEC Recommendations

.3 Malaysian Standards

.4 Australian, American, Japanese or German Standards

.5 Other relevant standards

.3 Contractor to maintain a full set/photocopies of all relevant Standards in

the Site Office.

2.0 PRODUCTS

Not used

3.0 EXECUTION

3.1 QUALITY ASSURANCE CONCEPT AND CONTROL

.1 Minimum requirements for establishing and implementing a quality

assurance programme shall be applied to all aspects of the work
necessary for carrying out the Contract. Quality assurance shall extend to
material parts, components, systems and services as a means of
obtaining and sustaining the reliability of critical items, operating
performance, maintenance and safety.

.2 Acceptance of the Contractor's quality assurance programme does not

relieve the Contractor's obligation to comply with the requirement of the
contract document. If the programme is found to be ineffective or
inadequate in providing for quality assurance or control, then the
Employer's Representative reserves the right to request for necessary
revisions of the programme.

.3 The Contractor is required to produce readily identifiable documentary

evidence covering the extent and details of both his own and his sub-
contractors' quality assurance system

.4 The documentary evidence should take the following form: -

.1 Quality Assurance Manual (QAM)

.2 Works Quality Assurance Programme (WQAP)

.3 Field Quality Assurance Programme (FQAP)

.4 Quality Plan

.5 These documents shall be prepared separately and submitted to the

Employer's Representative at the time of tendering.
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 3

.6 Quality Plan and Manual shall be prepared by the Contractor for all items
and services to be supplied, after the Contract has been placed, but
before commencement of fabrication, and shall be subject to evaluation
and acceptance by the Employer's Representative before start of works.

.1 Quality Assurance Manual (QAM)

.1 The QAM shall be a general comprehensive document

outlining the Contractor's basic organization, policies and
procedures. The information to be given the QAM shall
include but not limited to:

.1 Quality policy

.2 Quality assurance programme

.3 Organization structure showing inter-relationships

.4 Functional responsibilities and levels of authority

.5 Lines of communication

.6 Customer relations

.7 Laboratory facilities

.2 Works Quality Assurance Proqramme (WQAP)

.1 The WQAP shall detail the Contractor's quality assurance

programme at works applicable throughout all phases of
Contract performance including design, procurement,
manufacture, inspection and testing. It shall identify each of
the programme elements to be designed, developed,
executed and maintained by the Contractor for the purpose
of ensuring that all supplies and services comply with this
Specification.

.2 The information to be given in the WQAP shall include but

not limited to:

.1 Organisation and Responsibility

.2 Contract Review

.3 Designs and Document Control

.4 Procurement Control

.5 Controls on Sub-contractors

.6 In-process Quality Control and Trace-ability

.7 Production Control
QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 4

.8 Inspections and Testing

.9 Controls of Non-conformances

.10 Corrective Actions

.11 Control of Inspection, Measuring and Test

Equipment

.12 Handling, Storage, Packaging and Delivery

.13 Records

.14 Quality Audits

.15 After-sales serving

.3 Field Quality Assurance Programme (FQAP)

.1 The FQAP shall detail the Contractor's Quality Assurance

programmme at site applicable throughout site construction,
erection and commissioning. It is the underlying philosophy
that the quality built into the product at works shall be
maintained throughout the construction and commissioning
stages.

.2 While, in principle, the FQAP shall include the items

discussed in WQAP, it shall, however, be approached
differently to take into account site conditions.

.3 The FQAP shall include, but not limited to the following

information:

.1 Organisation and Responsibility

.2 Controls of Drawings and Documentation

.3 Product Checklists

.4 Control and Trace-ability of Purchased materials

and services

.5 Receipt Inspections of Materials at Site

.6 Material Storage Control

.7 Inspection and Examination Procedures

.8 Controls of Painting and Insulation Works

.9 Pre-commissioning

.10 Commissioning
QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 5

.11 Controls of Non-conformances

.12 Corrective Actions

.13 Control of Inspection, Measuring and Test

Equipment

.14 Records

.15 Quality Audit

.16 Personnel Training

.17 Servicing during Defects Liability Period

.4 Quality Plan

.1 The Contractor shall be required to prepare manufacturing

and construction/erection quality plans for all equipment
items and services. The quality plan shall also define the
involvement of the Employer's Representative in the
inspection and test programmes.

.2 The Quality Plan shall incorporate as appropriate:

.1 Charts indicating flow of materials, parts and

components through manufacturing quality control,
inspection and test to delivery and erection.

.2 The charts shall indicate the location of hold points

for quality control, inspection and test beyond which
manufacture shall not continue until the action
required by the hold point is met, and the
documentation required is generated.

.3 The control documents associated with each hold

point, i.e. drawings, material specification, Works
Process Schedule (WPS), Process Quality Records
(PQR), quality control methods and procedures and
acceptance Standards.

.4 These control documents should also include

Process Contract Document Sheets, Inspection
Procedure Sheets, Site Fabrication Specification,
Cleaning and Protection Application Sheets and
Purchase Specifications (for Sub-Contract jobs).

.5 These documents shall detail the procedures and

approvals with which the process complies.

.6 An indication of the organization responsible for the

quality activities covered.
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 6

.7 Reference to quality assurance procedures, goods inward procedures and

nonconformance procedures.

.8 The Contractor shall submit his subcontractor’s quality plans. The

Contractor shall determine and agree with the Employer's Representative
the control to be exercised over the sub-Contractors and the degree of
surveillance that will take place.

.9 The Contractor shall prepare education and training programmes as

required for the indoctrination of his quality assurance and quality control
personnel. Where personnel are required to be certified by this contract
documents, e.g. skilled wiremen, the Contractor shall keep an up-to-date
register which will be subject to examination by the Employer's
Representative.

3.2 REPAIR PROCEDURES

.1 The Contractor shall prepare a Repair Procedure based on the

specification requirements and approved Standards. The procedure shall
take into account Site conditions, and be detail enough to include, for
example, equipment to be used, methods of repair, acceptance / rejection
criteria, inspections required, etc. The repair procedure shall cover
painting etc. but shall not cover components, which shall be replaced if
they are faulty.

3.3 OTHER DOCUMENTS

.1 The Contractor shall submit to the Employer's Representative one copy of

other relevant documents, such as manufacturer's instructions, technical
papers, etc., where such documents are being referred to in the
documents.

3.4 SITE QUALITY CONTROL SECTION

.1 The Contractor's Quality Control (Q.C.) Section shall be headed by an

experienced Quality Control Engineer. He shall be assisted by other
supervisors. The Section shall be an independent one, reporting to the
Contractor's Site Manager only on administrative matters, but otherwise
under full control by the Contractor's Corporate Quality System
Management.

.2 The Contractor's Q.C. Section shall liaise closely with the Employer's
Representative in charge of Quality Assurance / Quality Control, and to
whom it shall give fullest cooperation. It is the underlying principle of this
contract document that while the Contractor's Q.C. Engineer implements
the Contractor's quality programme, the adequacy and effectiveness of
that implementation shall be audited by the Employer's Representative at
Site whose recommendations on improving or maintaining quality shall be
acted upon promptly by the Contractor's Q.C. Section.

3.5 INSPECTION AND TESTING

.1 General
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 7

.1 All equipment and components supplied shall be subjected to

inspection and tests by the Employer's Representative during
manufacture, erection / installation and after completion. The
inspection and tests shall include but not be limited by the
requirements of this contract document. Prior to inspection and
testing, the equipment shall undergo pre-service cleaning and
protection.

.2 Third Party Certification

.1 The Employer shall arrange for an independent third party

insurance classification organization to certify the design, materials
and construction of the equipment in his scope to comply with
statutory requirements and for insurance purposes. The
certification shall include all pressure vessels and lifting equipment
and shall cover both fabrications at the manufacturer's works and
at the site.

.2 The classification organization shall be approved by, and

registered with, the Malaysian Factories and Machinery
Department / Department of Occupational Safety and Health
(DOSH) and shall be approved by the Employer. All costs
associated with the third party certification shall be borne by the
Contractor.

.3 Guarantees

.1 Tenderers shall state and guarantee the technical particulars listed

in the Schedule of Technical Data. These guarantees and
particulars shall be binding and shall not be varied without the
written permission of the Employer's Representative.

.2 No tolerances shall be allowed other than the tolerances permitted

in the relevant approved Standards shall apply unless otherwise
stated.

.4 Rejection

.1 If the guaranteed performance of any item of equipment is not met

and/or if any item fails to comply with the specification requirement
in any respect whatsoever at any stage of manufacture, test or
erection, the Employer's Representative may reject the item, or
defective component thereof, whichever he considers necessary,
and after adjustment or modification as directed by the Employer's
Representative, the Contractor shall submit the item for further
inspection and / or test.

.2 All repair procedures shall not be performed without the prior

approval of the Employer's Representative. In the event of a defect
on any item being of such a nature that the specification
requirements cannot be fulfilled by adjustment or modification,
such item shall be replaced by the Contractor, at his own expense
to the entire satisfaction of the Employer's Representative. Any
item of plant repaired to an approved procedure shall not be
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 8

accepted as a part of the Works as a permanent solution or

replacement unless the Contractor guarantees in writing that the
repaired plant or component shall have the same service life and
efficiency as the component originally manufactured.

.3 The approval of the Employer's Representative of inspection

and/or test results will not prejudice the right of the Employer's
Representative to reject an item of equipment if it does not comply
with the contract document when erected or prove completely
satisfactory in service.

.5 Sub-Contracts

.1 The contractor shall be responsible for the timely transmission of

the relevant and appropriate sections of the contract document to
sub-Contractors and other manufacturers and the proper
execution of all tests on work or plant or materials carried out or
supplied by sub-Contractors, wherever such tests may be carried
out, to the same extent as if the tests on work, plant or materials
were carried out or supplied by the Contractor himself.

3.6 TESTS AT MANUFACTURER'S WORKS

.1 General

.1 Where no specific test is specified then the various items of

materials and equipment shall be tested in accordance with the
acceptable Standards. Where no acceptable standard is available,
tests shall be carried out in accordance with the manufacturer
Standard practice, subject to the prior approval of the Employer's
Representative. In all cases, works tests shall include electrical,
mechanical and hydraulic tests in addition to any test called for by
the Employer's Representative to ensure that the equipment being
supplied fulfils the requirements of the contract document. Where
applicable test must comply the latest requirements of JKKP.

.2 If considered necessary by the Employer's Representative, any

mufti-part assemblies shall be fully erected in the Works prior to
packing and dispatch to Site.

.3 All tests to be performed during manufacture, fabrication and

inspection shall be agreed with the Employer's Representative
prior to commencement of the work. The Contractor shall prepare
the details of the schedule and submit these to the Employer's
Representative for approval. It must be ensured that adequate
relevant information on the design code/Standard employed, the
manufacture/ fabrication/ assembly procedure and the attendant
quality control steps proposed are made available to the
Employer's Representative. The Employer's Representative will
mark in the appropriate spaces his intention to attend or waive the
invited tests, or inspections.

.4 A minimum of twenty-one (21) days notice of the readiness of

equipment for test or inspection shall be provided to the
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
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Employer's Representative by the Contractor (whether the tests be

held at the Contractor's or sub-Contractor's works). The subject
items should remain available for Employer's Representative
inspection and test up to a minimum of 10 days beyond the agreed
dates of witnessing the test. Every facility in respect of access,
drawings, instruments and manpower will be provided by the
Contractor and his sub-Contractor to enable the Employer's
Representative to carry out the necessary inspection and testing of
the Plant.

.5 No plant shall be packed, prepared for shipment, or dismantled for

the purpose of packing for shipment, unless it has been
satisfactorily inspected, all tests called for have been successfully
carried out in the presence of the Employer's Representative or
approved for shipment, or alternatively inspection has been waived.

.6 Functional electrical and mechanical tests shall be carried out on

completed assemblies in the Works. The extent of these tests and
method of recording the results shall be submitted to, and agreed
by, the Employer's Representative in sufficient time to enable the
tests to be satisfactorily witnessed, or if necessary for any changes
required to the proposed programme of tests to be agreed.

.7 All instruments and apparatus used in the performance of the tests

shall be supplied by the Contractor, to the approval of the
Employer's Representative and shall be calibrated to an agreed
Standard at SIRIM (Malaysia), or equivalent centres approved by
the Employer's Representative. Calibration Tests Certificates shall
be submitted in respect of each and every instrument and
apparatus. All calibration shall be conducted within 6 months
before the date of the actual tests and the corresponding tests
certificates shall be issued and submitted to the Employer's
Representative at least 1 month before commencement of the test.
Calibration done and Certificates issued outside the period
aforementioned shall not be valid and the Contractor shall arrange
for the recalibration of the instrument or apparatus at no extra cost
to the Employer's Representative.

.8 The Employer's Representative reserves the right to visit the

Manufacturer's Works at any reasonable time during fabrication of
equipment and to familiarize himself with the progress made and
the quality of the work to date.

.2 Material Tests

.1 Representative samples of all plates, bars and pipes, etc., which

form components of the equipment shall be tested as required by
the relevant approved Standard. All test pieces shall be prepared
and supplied by the Contractor at his own cost. If any test piece
fails to comply with the requirements of the specifications for the
material in question, the Employer's Representative may reject the
whole of the material represented by that test piece.

.3 Acceptance Tests
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.1 Acceptance tests shall be carried out by random sampling of

manufactured equipment. The results of tests shall be recorded
and verified by the Employer's Representative. Three copies of the
test results shall be submitted to the Employer's Representative.
The same set of test results shall be included in the Operation and
Maintenance documentation.

.4 Test Certificates

.1 Within 30 days of the completion of any test, three (3) sets of all
principal test records; test certificates and correction and
performance curves shall be supplied to the Employer's
Representative.

.2 These test records, certificates and performance curves shall be

supplied for all tests, whether or not they have been witnessed by
the Employer's Representative or not. The information given on
such test certificates and curves shall be sufficient to identify the
material or equipment to which the certificate refers and should
also bear the Contract reference title.

.3 When all equipment has been tested, the test certificates from all
Works and Site tests shall be compiled by the Contractor into
volumes and bound in an approved form complete with index and
four copies of each volume shall be supplied to the Employer's
Representative.

3.7 TYPE TESTS

.1 Type tests are required on all equipment whether specifically noted or not
to prove the general design of the equipment in accordance with the
relevant acceptable Standards and the Contractor may submit test
certificates of tests, which have been carried out on identical equipment.
Notwithstanding any provision in a Standard, the Employer's
Representative shall have the right to accept or reject such certificates in
lieu of the specified type tests.

.2 The type tests prescribed shall be carried out at the Contractor's cost in all
cases where such certificates are not available or are rejected.

.3 Notwithstanding the above one type of each rating of equipment shall be

type tested under this Contract, to the relevant acceptable Standard, and
test certificates submitted to the Employer's Representative.

3.8 ROUTINE TESTS

.1 All equipments and components shall be subjected to visual, dimensional,

material, non-destructive, hydraulic, functional and performance tests at
the manufacturer’s works. The tests to be carried out shall be strictly in
accordance with the relevant approved standards. All relevant material
and works certificates shall be available at the time of test and the tests
shall be carried out against approved drawings.
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3.9 TESTS AT SITE

.1 General

.1 All equipment and assemblies shall pass site tests to prove

compliance with the contract document independently of any tests
which may have already been carried out at the Manufacturer's
Works.

.2 The Contractor shall check the electrical and mechanical

connections to all equipment and assemblies supplied under the
Contract before they are brought into commission and shall be
responsible for the correctness of such connections in accordance
with the contract document.

.3 In particular all functional and pressure tests on fully assembled

and complete items of equipment and assemblies, which have not
been carried out at the manufacturer's works, shall be carried out
at Site.

.4 All instruments and apparatus used in the performance of the tests

shall be supplied by the Contractor and shall be to the approval of
the Employer's Representatives and shall be calibrated to an
approved Standard at SIRIM (Malaysia) or equivalent centres
approved by the Employer's Representatives. Calibration Tests
Certificates shall be submitted in respect of each and every
instrument and apparatus. All calibration shall be conducted within
6 months before the date of the actual tests and the corresponding
tests certificates shall be issued and submitted to the Employer's
Representative at least 1 month before commencement of the test.
Calibration done and Certificates issued outside the period
aforementioned shall not be valid and the Contractor shall arrange
for the recalibration of the instrument or apparatus at no extra
costs to the Employer's Representative.

.5 The Contractor will be responsible for the submission to the

Employer's Representative for Site inspection and tests of all
equipment under this contract.

.6 The Contractor shall submit a written programme of tests and

checks for the approval of the Employer's Representative.

.7 The Contractor shall provide experienced test personnel subject to

the approval by the Employer's Representative (CV's shall be
submitted) and conditions imposed by the Electrical Supply
Regulations issued by the Suruhanjaya Tenaga, Ministry of Energy,
Water and Communication; and any regulations ruling at that time
on such practices.

.8 The testing shall be carried out during normal working hours as far
as is practicable.

.9 The Contractor shall advise the Employer's Representative in

writing at the time of commencement of site erection of the site
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
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supplies which will be required for the operation of the test

equipment.

3.10 ERECTION AND INSTALLATION

.1 During the course of erection, the Employer's Representative shall have

full access for inspecting the progress of the work and checking its
accuracy by witnessing such checks as may be required by him.

.2 The Contractor shall provide all temporary scaffolding, ladders, platforms

with adequate and safe flooring and handrails essential for proper access
of the Employer's Representative to carry out inspection.

.3 The Contractor shall provide all labour, materials and instruments and
other resources necessary for the use of the Employer's Representative
for checking, setting out of the Works, for the periodic measurement of the
works executed and for the aforementioned Site inspections and tests.

.4 On completion of erection, tests on all equipment shall be carried out by

the Contractor and witnessed by the Employer's Representative to
demonstrate adequately that the equipment as erected on Site is entirely
suitable for operation.

.5 The Contractor shall provide all erection check lists for the Works, copies
of which are to be provided to the Engineer after signing at each stage of
inspection.

.6 The Contractor shall record the results of the tests clearly, on an approved
form and with clear reference to the equipment and items to which they
refer, so that the record can be used as the basis for maintenance tests
by the Employer during the working life of the equipment. The required
number of site test result records shall be provided by the Contractor to
the Engineer as soon as possible after completion of the tests. Both the
Employer and his representative require this information before the plant
will be accepted for initial energizing.

.7 No tests as agreed under the programme of tests shall be waived except

upon the instruction or agreement of the Employer's Representative in
writing.

.8 The Contractor shall submit to the Employer's Representative for his

approval a list of recommended settings for all protection and other types
of automatic equipment, not less than three (3) months before such
equipment is required in service. Where the settings involve discrimination
with settings of TNB's network or plant, the relevant information shall be
supplied to the Contractor.

.9 The Contractor's test equipment shall be of satisfactory quality and

condition and shall be appropriately calibrated by an approved authority or
standard at the Contractor's expense. Details of the test equipment and
instruments used shall be noted in the test sheets in cases where the
instrument or equipment characteristics can have a bearing on the test
results.
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3.11 PAINTING INSPECTION METHODS

.1 The various inspection methods included in the various parts of the

specification shall provide a reference base for the contractor to ensure
that all coating related activities and the final coating film conform to the
requirements as laid down in this specification.

.2 Approved inspection procedures shall be used singly or in conjunction

with each other - as circumstances may warrant - to resolve disputes
related to application condition, film, thickness, degree of cure, adhesion
to the substrate or between coats, determination of the correct time
between coats, etc. and to determine whether individual coating films or
the total coating system meet the acceptance criteria specified.

3.12 CLEANING AND PROTECTION OF PLANT AND EQUIPMENT

.1 General

This section covers mechanical and chemical pre-service cleaning and

protection of the plant items and equipment that are not subsequently to
be painted.

Cleaning of fabricated component items shall be carried out after

fabrication and final heat treatment or welding at manufacturer's works or
at Site as appropriate.

Mechanical cleaning as opposed to alternative chemical cleaning is the

preferred method for works cleaning except where this is precluded by
design or access considerations.

Mechanical cleaning is preferred for plant items constructed from

materials other than stainless steels. Stainless steel plant items shall be
chemically cleaned with a mixed nitric-hydrofluoric acid formulation to
the Employer's Representative approval. Alternatively approved
proprietary paste formulations may be used for this purpose.

Machined surfaces shall be protected during the cleaning operations.

In the event of the surfaces not being cleaned to the Employer's

Representative satisfaction, such parts of the cleaning procedures or
agreed alternatives as are deemed necessary to overcome the
deficiencies shall be carried out at the Contractor's sole expense.

For recleaning small areas, hand cleaning by wire brushing may be

permitted. Wire brushes used on austenitic materials shall have austenitic
steel bristles.

Austenitic stainless steels, copper and aluminum alloys, cast iron,

bimetallic and metallic/plastic items, and components fabricated by spot
welding or riveting shall not be chemically cleaned. All weld areas shall be
suitably stress relieved before chemical cleaning.
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The date and place at which works cleaning will be carried out shall be
notified to the Employer's Representative at least two weeks in advance
for witnessing and inspection.

At an appropriate time, but not less than six months prior to

commencement of any Site cleaning, the Contractor shall submit a
detailed programme covering all procedure, and supporting calculations
giving velocities, chemical solutions, silencing, draft factors, pipework
forces and movements imposed during Site cleaning operations.

.2 Mechanical Cleaning at Manufacturer's Works

Mechanical cleaning shall preferably be carried out by abrasive blasting.

The Employer's Representative is prepared do consider alternative
method provided they achieve the necessary surface condition.

.1 Surface Condition

The metal surfaces shall be clean and free of mill scale, rust, dirt,
grease and any other deleterious matter.

Where metal surfaces are to. be painted the surface profiles shall
conform with the painting specification requirements.

Where this does not apply, surfaces shall have a surface texture
not coarser than Grade 80 abrasive paper.

.2 Abrasives

Abrasives containing silica, silicates or slag residues shall not be

sued or water/steam side surfaces of plant except for cleaning
sand castings where hydro-blasting with sand may be used.

For austenitic materials only abrasives containing 98% or more of

alumina Al203 shall be used.

.3 Removal of Abrasive and Debris

After cleaning, abrasive and debris shall be thoroughly removed

from components.

.3 Chemical Cleaning at Manufacturers Works

.1 General

The procedure shall comprise pretreatment, acid treatment,

neutralisation, rinsing and drying to achieve cleanliness equivalent
to that specified for mechanical cleaning. The procedure to be
adapted shall be to the Employer's Representative approval.

.4 Site Cleaning Procedure

.1 General
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In interpreting the following requirements, no plant items

incorporating copper or aluminum or their alloys, or zinc coatings
shall undergo any chemical cleaning other than flushing or manual
cleaning as agreed with the Employer's Representative.

The Contractor shall take all necessary precautions to ensure that

the internal surfaces of all plant are kept clean and free from
injurious matter during erection.

When all plant has been erected and lagged or at such other time
as may be agreed with the Employer's Representative for
subassemblies, the installation shall undergo a procedure for Site
cleaning in accordance with the requirements and associated
Schedules as specified herein.

.2 Piping and Vessels

All piping and vessel shall be flushed with air or oil, or steam or
deionised, distilled, potable or sea water, as deemed appropriate
by the Employer's Representative to remove loose debris.

.3 Cleaning and Flushing of Oil System

Before any machine is run on Site, the oil systems shall have been
thoroughly cleaned and flushed. The complete system shall be
flushed, excluding such items as bearings and control valves etc.
Temporary strainers shall be incorporated in the flushing
arrangements to collect foreign matter and debris, and to indicate
when a satisfactory state of cleanliness has been achieved.

All unalloyed ferrous lubricating oil pipes shall be pickled and

passivated prior to oil flushing. The Site flushing procedure shall
be submitted to the Employer's Representative for approval. The
oil shall be circulated in the flushing procedure at a temperature
satisfactorily in excess of any emergency operating conditions
likely to occur.

Once the strainer have appeared free from debris the circulation of
flushing oil shall continue for a further three hours, and the
strainers again checked to confirm satisfactory cleanliness of the
system. All flushing oil, temporary pipework, strainers, and any
other materials required for the Site flushing procedure shall be
supplied under this Contract. Both hot and cold flushing shall be
carried out.

.5 Inspection

At the end of the plant cleaning operations at Site the plant shall be made
available for inspection. In the even that the surfaces are not cleaned to
the Employer's Representative satisfaction such parts of the cleaning
procedure or agreed alternatives as are deemed necessary to overcome
the deficiencies shall be carried out at the Contractor's sole expense.

.6 Programme for Site Cleaning

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At an appropriate time not less than six months prior to commencement of

any Site cleaning, the Contractor shall submit a detailed Site cleaning
specifications and programme including procedure details supporting
calculations giving cleaning times, velocities, chemical solutions, silencing,
drag factors, pipework forces and moments imposed during Site cleaning
operations.

.7 Disposal of Waste Effluents at Site

The Contractor will be responsible for satisfactorily disposing of all waste

effluent liquors and materials and treating them to render them suitable for
discharge to waste in accordance with regulations prevailing at Site
regarding disposal of waste effluents.

3.13 PRE-COMMISSIONING CHECKS AND COMMISIONING PROCEDURES

.1 General

.1 The Contractor shall be responsible for the safe and efficient

setting to work of the whole of the plant and equipment in its
supply. The methods adopted shall be to the approval of the
Employer's Representative on site, and shall be in accordance
with any safety and permit regulations in force on the site.

.2 The Contractor shall give sufficient detail in the programme as

required in this Contract Document to satisfy the Employer's
Representative that the sequence and duration of the proposed
commissioning activities are logical and realistic. Details of the
Contractor's commissioning staff necessary to achieve the
programme shall be given.

.3 It shall be necessary to coordinate the commissioning tests and all

trades contractors shall be required to cooperate in this activity.

.4 The Contractor is required to cooperate with the Engineer by

organising and setting-up the assigned inputs of the Building
Control System, Fire Alarm System and if required the Standby
Generator Control System and in the production of application
programmes for logs and displays, for the periods of pre-
commissioning, and commissioning.

.5 At least four months before commencing the commissioning of any

plant or equipment, the contractor shall submit for approval full
comprehensive procedures of pre-commissioning checks as
applicable to each item of the plant and equipment provided.
These procedures shall then be used during pre-commissioning as
guide to the methods to be followed and to record the actual
activities carried out with the appropriate date, together with details
of all work yet to be completed, variations and modifications to
design conditions. The procedures should describe the
prerequisites for that particular test: -
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.1 Test which should have been previously satisfactorily

completed.

.2 Systems which must be live, or charged.

.3 Special precautions required e.g. safety, or erection of

temporary equipment.

.4 Reference to relevant drawings.

.6 Each procedure shall be accompanied by a checklist. The

checklist shall include as a minimum the following: -

.1 Contract title.

.2 Plant item/system name.

.3 Schedule of checks to be carried out.

.4 Space for data obtained during checks to be entered and

initialed.

.5 Space for date and names of persons carrying out and

witnessing tests.

.6 Item/system data e.g. expected range of results.

.7 Space for remarks.

.7 The Contractor shall provide at site the necessary certified

standard instruments and gauges and any other equipment
necessary for checking the installation as and when required and
shall operate the plant and carry out the tests to the satisfaction of
the Employer's Representative.

.8 Each activity on the pre-commissioning procedure, when

completed to the satisfaction of the Employer's Representative,
shall be signed and dated by the Contractor. The schedules shall
be countersigned by the Employer's Representative as necessary.

.9 The Contractor shall also submit for approval schedules of

commissioning procedures that he proposed to follow when
bringing into service groups of plant items during the
commissioning period. These schedules shall detail the tests
necessary to ensure the complete and satisfactory commissioning
of each section of plant and shall detail all operational limitations.
The schedules shall be used during commissioning which shall
only commence when the relevant pre-commissioning check
schedules have been completed. The procedures and check lists
in the commissioning schedules shall take the same format and
layout as described above for pre-commissioning.

.10 Each activity on the commissioning procedure schedules when

completed to the satisfaction of the Employer's Representative,
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shall be signed and dated by the Contractor and shall be

countersigned by the Employer's Representative as necessary.

.11 The commissioning procedures shall ensure that the

commissioning of any section of the Works does not interrupt the
normal operation of any previously commissioned sections(s) or
other running plants in the building.

.12 The Contractor shall remain fully responsible for the operation,
maintenance and cleaning of equipment as necessary throughout
the commissioning period up to the time takeover.

.13 The Employer's Representative may introduce a coordinated

'Permit to Work' system during the course of the site works in
order to establish control over the safe access to all plant that has
been commissioned, charged, made live or energized, and to sure
both personnel safety and security of plant operation.

.14 The Contractor shall comply fully with such safety procedure and
permit systems and shall accept and accommodate the resulting
limitations on access to his plant without claim on the Employer.

.15 When the commissioning of each section of the Works is complete

and before the thirty (30) days Reliability Run is commenced, the
Contractor shall carry out such preliminary tests as are necessary
to establish that the plant is functioning correctly and efficiently,
and shall make any adjustments required.

.16 The Contractor shall supply all test equipment, paper charts,
continuous stationery, and magnetic tape and disc, tools,
chemicals, lubricating oils and grease and other materials required
for the aforementioned operations.

.17 The Contractor shall make available load for the purpose of these
tests but gives no guarantee that the availability will be continuous
or non any specific load, but every endeavor will be made to give a
load as near as possible to the rating of the machines.

.18 The timing for implementing the tests shall be mutually agreed
between the Contractor and the Employer's Representative.

.19 Within two months of the completion of commissioning tests the

Contractor shall submit a comprehensive commissioning report
with a completed set of signed check sheets and procedures.

.20 For purposes of this Contract, the provisions of this Section shall
apply also to works and installation supplied from sub-contractors.

.2 Contractor's Site_Superyisory Staff

.1 During the commissioning and subsequent testing of any item of

works and installation, the Contractor shall provide for the services
of any special supervisory staff necessary for the purpose of
ensuring proper commissioning and the satisfactory completion of
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all tests. Test cost of such services is deemed to be part of the

tendered price.

3.11 WELDING QUALITY ASSURANCE

.1 Welding Manual

.1 It is a specific requirement of this Specification that the Contractor

shall produce a separate Welding Manual covering all aspects of
welding and welding controls at works and Site. This manual shall
be submitted to the E.R. for evaluation and acceptance after the
Contract has been placed, but before start for any welding.

.2 The Manual shall cover in detail all the welding processes to be

employed in this project, their normal and special requirements
and the quality controls to be implemented.

.3 Furthermore, the part on Site welding shall incorporate as a

minimum, all items discussed in the Site Welding Documents and
Site Welding Control.

.2 Site Welding Control

.1 In order to monitor and maintain welding quality on Site, the

Contractor shall establish within his Site Organisation an
independent Quality Control Section, whose function would solely
to enforce the Contractor's field quality assurance programme and
Site Quality plans. Among areas where the Contractor shall
exercise greater controls, in order to achieve the desired quality,
are control of welders and control of welding activities, control
of welding consumables and control or NDT.

.3 Control of Welders

.1 The Contractor shall employ only experienced welders. However,

all welders, with or without previous qualifications, shall be tested
to agreed Test Procedures as discussed in Clause 3.1.6.3 of this
Specification. Holders of current welding certificates from DOSH,
Malaysia, shall not be exempted from sitting the test. However,
the Employer's Representative at Site may, at his discretion, allow
these welders to work if they can demonstrate their skill on five
production joints, the sizes and locations of them shall be selected
by the Employer's Representative, without any defects as revealed
by visual inspection and radiography. The same rule shall apply to
bonafide welders from the Contractor's manufacturing works.

.2 All welders qualification test shall be conducted, at Contractor's

expense, and witnessed by the Employer's Representative and
from whom final decision as to the suitability of the welders shall
be obtained.

.3 In cases where the Statutory requirement requires the welders to

be registered with DOSH, Malaysia, and if it deems necessary by
the Inspectors of the Department that the welder's qualification test.
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be conducted in their presence, then it is the responsibility of the

Contractor to arrange for the Inspector's attendance.

.4 The Contractor shall monitor the performance of his welders

throughout the project. The Employer's Representative may
require a welder to be re-qualified if he deems the all of the
welder has deteriorated, and the Contractor shall promptly remove
the said welder from the job.

.5 At the discretion of the Employer's Representative, the re-

qualification test may be in the manner of the original test or
in a different form that more resemble the actual production joints
condition for example, if a welder consistently produces bad welds
in the furnace region, the re-qualification test may not be just
welding a single test piece of appropriate size in 6G positions,
but may be welding five parallel tubes and in the vertical position
at a pitch distance. All costs of re-qualification tests shall be borne
by the Contractor.

.6 It is a specific requirement of this Specification, that welders

welding on attachments, such as thermocouple pads, tube-fins,
lugs, etc., on pressure parts shall be qualified pressure part
welders. In addition such welders shall be required to do a mock-
up welding of the attachments to the pressure parts in order for the
Employer's Representative to assess that such welding can be
successfully done by the said welders.

.4 Control of Weldinq Activities

.1 The Contractor shall at all times control its welding activities in a

manner whereby the quality requirement of its FQAP is never
compromised, but at the same time no delay to the welding
progress is experienced. The Contractor shall draw up a working
procedure to accommodate the Employer's Representative at Site
participation in accordance with Table 1.

.2 In all cases, the Contractor's scope shall be 100%. In cases

where the Employer's Representative participation is also 100%,
such inspection may be done jointly at the same time when the
Contractor does his inspection. However, the Employer's
Representative may insist that the Contractor does his
inspection initially and correct whatever defects found before
calling for the Employer's Representative participation.

.3 The Contractor shall liaise closely with the Employer's

Representative and keep him inform of the status of welding on
hand. The Contractor shall submit a daily return of welding works
indicating the distribution of welders, the number and identification
of joints welded, the number and. identifications of joints needed to
be NDT and PWHT.

.4 The Contractor shall prepare all check sheets for the inspections,
the format of them shall be agreed with the Employer’s
Representative at Site. Such check sheets must be signed by the
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relevant parties immediately at the end of each inspections. The

Contractor shall compile these check sheets and hand them in
bound volumes, appropriately titled, to the Employer's
Representative at the end of Site construction.

.5 The radiographic films, after review by the Employer’s

Representative at Site, shall be returned to the Contractor who
shall then compile, catalogue and store them in appropriately
labelled boxes in clean, dry, pest-free air-conditioned room. The
Contractor shall keep the films in such good conditions for at least
five years after end of construction period. The Employer’s
Representative shall have access to these films at any time during
the storage period.

TABLE 1

Item Activities Employer’s Representative

Scope
1 Material receiving checks 100% checking
2 Cleaning of components Spot checking
3 Alignment of components 100% checking
4 Fit-up checks 100% checking. The
Contractor shall not proceed
to weld the joints until
Employer’s Representative
approval is obtained
5 Issue of electrodes/filler Spot checking
material
6 Inspection during welding Spot checking, but the
Employer’s Representative
approval is obtained.
7 Visual inspection after 100% checking. The
welding Contractor shall not proceed
to NDT or other work until the
Employer’s Representative
has given approval.

.5 Control of NDT

.1 The Contractor shall be responsible to control all NDT activities

under his Contract, even when he sub-Contracts the job to a NDT
specialist company.

.2 He shall ensure that his NDT equipments are reliable, modern,

calibrated and comply with all relevant requirements of the agreed
Standards.

.3 The Contractor shall only employ mature and experienced NDT

operators. He shall ensure that the NDT operators hold current
and relevant certificates from approved Certification bodies.
Notwithstanding such a certificate, he shall promptly arrange for
the demonstration of the skill of his NDT operators to the
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Employer’s Representative, should the Employer’s Representative

may so request.

.4 In the case of radiography, the Contractor shall comply with all the
requirements of the Act 304 of the Government of Malaysia -
Atomic Energy Licensing Act 1984. Radiographic works shall only
be carried out after normal working hours, from 7 p.m. to 7 a.m.
the next day. However, the Employer his Representative may
delay permission to start radiography or suspend it for any
duration during the permitted hours if urgent construction works
and/or plant operational activities need to proceed without
interference.

.5 If the Contractor desires to sub-Contract part or the whole of the

NDT works under his scope, he shall first obtain the approval from
the Employer’s Representative at Site. He needs to prove to the
satisfaction of the Employer’s Representative that his quality of
inspection will not be compromised even though he sub-Contracts
the inspection work.

.6 The Contractor shall arrange for NDT works to be done promptly

after completion of welding, but in any case not later than 72 hours.
Where welds require PWHT, the NDT shall be done after the
PWHT.

3.12 NON-DESTRUCTIVE TESTINGS OF WELDS

All underground pipeworks shall undergo 100 % non-destructive test

(radiography test.). 10 % of aboveground welded pipework shall undergo non-
destructive test (radiography test.). The techniques to be employed, the
equipments to be used, the testing routines and the acceptance/rejection criteria
shall be as per the approved Codes and Standards, and in any case, shall not be
less than specified in the relevant clauses of contract document. Where there is
a conflict in the requirements of the approved Codes and Standard and the
relevant Clauses of the Specification, the stricter of the requirements shall prevail.

.1 Pressure-containing Welds

.1 For butt welds in pipes buried underground, the entire

circumference of all welds shall be examined radiographically. For
pipes/tubes aboveground, the entire circumference of 10% of the
welds made each day by each welder (or group of welders, if the
weld is welded by more than one welder) with a minimum of two
welds per welder (or group of welder) shall be selected at the
discretion of the Employers’ Representative for radiographic
examination.

.2 When one or more failures occur in a sampling examination, for

example in 10% radiography, than the failure(s) shall be repaired
and re-radiographed, and a further 10% radiography sampling is to
be taken. If there is further failure(s), the new failure(s) shall be
repaired and re-radiographed, and additionally now, all the
remaining unexamined welds shall be radiographed and repaired,
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 23

if necessary, and re-radiographed until all the welds are confirmed

to be without defects.

3.13 HYDROSTATIC TESTS

.1 All cast, forged or fabricated pressure vessels or enclosures and all

completed pipes, bends and fittings which are to be subjected to an
internal pressure or vacuum during operation shall be subjected in the
maker’s works to a hydrostatic test. The test pressure shall be maintained
for a minimum of 24 hours or longer at the discretion of the Employer’s
Representative to permit complete examination by the Inspector.

.2 All hydrostatic tests shall be carried out prior to surface coating or painting
and cast iron enclosures may be subjected to hammering as required by
the Employer’s Representative.

.3 Hydrostatic test of equipment manufactured from austenitic steels should

be carried out using water having chloride content less than 30 ppm.

.4 The manufacturer shall supply labour and appliances for such testing as
may be carried out on his premises. Failing facilities at his own works the
manufacturer shall make arrangements for carrying out the tests
elsewhere.

.5 The testing shall include, but not be limited to, the following: -

.1 Each sections of the compressor casing, control valves and

emergency stop valves shall be tested as defined in the relevant
Standard for a minimum of 2 hours duration.

.2 Each completed part of the heat exchanger shall be hydrostatically

tested at room temperature at the manufacturer’s works as define
in the relevant Standard. Pressure vessels shall be tested in
accordance with the appropriate design code and to the approval
of the Employer’s Representative.

.3 Pipework shall be hydrostatically tested in accordance with the

relevant Standard. The test pressure shall not be less than one
and one half times the normal working pressure. Any expansion
bellow shall be tested together with an adjacent section of pipe.
Satisfactory arrangements must be made to protect bellows from
damage during the test.

.4 The body of each valve of fitting shall be tested to not less than
one and one half times its design pressure and where appropriate
the latest requirements of JKKP, shall apply. In the particular case
of safety valves the seats shall be blanked and the hydrostatic
pressure applied only the part of the body at the inlet valve.

.5 With the exception of the following items and items which may
suffer internal damage e.g. bellow operated instruments, etc., each
assembled fitting shall be tested to not less than one and one half
times its design pressure.
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 24

.1 Assembled safety valves

.2 Tubular glasses for water gauges

.3 Sub-assemblies containing the glasses of water gauges of

the through vision or reflex glass type

.6 Pressure gauges shall be tested in accordance with the relevant

approved Standard.

.7 All prefabricated tanks operating at atmospheric pressure shall be

tested by filling to maximum level and being subjected to an
additional superimposed hydrostatic pressure of 15 mbarg. All
tanks shall be tested in accordance with approved Standard.

.8 Pumps casings shall be hydrostatically tested in accordance with

an approved Standard.

3.14 PERFORMANCE TESTS AT MANUFACTURER’S WORKS

.1 All equipment shall be subjected to routine performance tests at the

Manufacturer’s Works in accordance with the relevant ANSI, ASME or
ASTM Standard including operating tests of complete assemblies to
ensure correct operation of apparatus and components. A strip-down
internal inspection of pumps, compressors, motors as required by the
Employer’s Representative shall be carried out.

.2 Each item of main and auxiliary Plant shall be subjected to a performance

test to prove that reliability and operation and performance conform to the
requirements of this Specification. Plant items and equipment shall be
fully assembled and complete in every respect prior to the
commencement of Works performance tests.

.3 Pumps, fans, compressors and other rotating equipment shall be given full
load tests, and run to 15% over speed for 5 minutes to check vibration.
main and auxiliary gear boxes shall be subjected to shock load tests and
a six-hour endurance run at rated speed and maximum torque.

.4 The Contractor shall submit single line diagrams including the layout of
the plant together with the location of test instrumentation and the
principal dimensions of the layout. All calculations to derive performance
data shall be made strictly in accordance with formula given in the
approved Standards. Any alterations or deviations form the approved
Standard test layout or formula shall be subjected to the prior approval of
the Employer’s Representative.

.5 The formula used for correcting test results to Site conditions shall be
subjected to the Employer’s approval and be given with the test results
together with calibration details of any measuring instruments.

.6 All pressure gauges, flow meters, venturi tubes or ducts, orifice plates and
other instruments to be sued for works tests shall be subjected to routine
calibration against Standard instruments. Calibration records shall be
available for inspection by the Employer’s Representative.
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 25

.7 Wherever possible, Plant items shall be tested with the driving motor
specifically purchased for the respective item. Where such an
arrangement is not practical then it will be permissible to utilities a test
motor providing fully technical performance details are available for
scrutiny by the Employer’s Representative.

.8 The Tenderer shall demonstrate the Plant he is proposing for this Contract
is of a satisfactory proven type in commercial operation. In such a case,
at his own expense, he will arrange for one representative each from both
the Employer’s Representative and the Employer’s organisation to visit
such units and to meet with responsible representative of the respective
owners/operators.

.9 Each completed rotating unit shall be subjected to a dynamic balance test.

A check balance test shall be carried out after the item has been
subjected to any overspeed or performance test. The Standards for
dynamic balance shall be specified by the manufacturer and agreed by
the Employer’s Representative.

.10 All pumps shall be tested in accordance with AS2417 or equivalent

approved ANSI and ASTM Standards. Prior to any test taking place, the
Contractor shall submit for the Employer’s Representative approval, a test
procedure showing the layout of the testing equipment with the position of
pressure measurement points, flow measuring device and relevant datum
lines for measuring fluid heads. In addition, details of the calibration of the
flow measuring device, the motor power vs. efficiency curve, a specimen
of the test records sheet and details of the performance calculations shall
be provided.

.11 The performance test shall be conducted over the full operating range of
the pump to a closed valve condition and a minimum of five measurement
points covering the full range shall be taken. Curves indicating Quantity
vs. head, Quantity vs. Power absorbed, and Quantity vs. Pump efficiency
shall be provided. In additional curve of the NPSH required vs. Quantity
shall be provided except when the suction conditions do not require this
test. Any proposal for the omission of this test shall be to the approval of
the Employer’s Representative.

.12 On completion of the tests the Contractor shall submit a report showing
the test results obtained together with the curves corrected to the Site
operating conditions.

.13 The Tenderer is to state his normal practice with regard to the testing of
turbine components, the trial erection of the turbine, and the steaming of
the turbine assembly in works to prove the satisfactory mechanical
operation prior to dispatch to Site.

.14 Air compressors shall be tested in accordance with the requirements of

the relevant Standard and the particular test procedure to be applied to
each compressor shall be agreed with the Employer’s Representative.

.15 All inspection, testing, marking and certification for Air Receivers shall be
performed to the appropriate ANSI, ASTM and ASME Standards.
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 26

.16 The vessels shall be constructed and tested under the supervision of a
third party inspector approved by the Employer’s Representative. Safety
valves, bursting discs and other fittings shall be tested in accordance with
the requirements of the appropriate ANSI, ASTM and ASME Standards.

.17 The Contractor shall carry out at his Works, tests as required by ANSI,
ASTM and ASME Standards to prove the capacities of the lifting
equipment. Test Certificates shall be provided and shall include the
material of fabrication, welding and non-destructive testing, electrical
equipment, wire ropes, hooks, chain blocks, shackles, runway beam, eye
bolts and any other related items which are provided.

.18 All tests shall be carried out in the presence of the E.R. and the
nominated third party inspector. Upon completion of the tests, the
equipment shall be clearly marked with the equipment’s safe working load
(SWL) and any marking that the E.R. may require. A permanent
nameplate shall be attached containing the following information: -

Date of manufacture
Date of test
Load applied

.19 The testing of storage tanks shall conform to the appropriate ASME and
ANSI Standards.

.20 Subject to the approval of the E.R., radiographic or ultrasonic examination

may be applied to 1% of the total length of vertical and horizontal butt
welds in each tank. Selected spots shall include 5% of the junctions of
vertical and horizontal joints if more than one procedure or more than one
welder is employed.

3.15 PIPEWORK TESTING

.1 Preliminaries

.1 The Contractor shall be responsible for conducting pressure tests

but these shall be witnessed by the Employer's Representative to
his satisfaction and approval.

.2 On completion of erection, the interior of all pipes, valves, fittings

and other associated equipment shall be flushed and free from
loose mill scale, welding slag, temporary protective coating and
other foreign matter.

.3 Mechanical equipment and pressure relieving devices shall be

blanked off or removed from the line during pressure testing.

.4 Instruments, filters and similar equipment for which the maximum

permissible cold test pressure is lower than the test pressure
applied to the system, shall be removed or blanked off or removed
from the line before testing. Such equipment shall be inspected
during commissioning.
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 27

.5 Provision shall be made for the automatic relief of excess pressure

caused by thermal expansion.

.2 Hydrostatic Testing

.1 The completed piping system shall be tested to a pressure of at

least one and one half times the design pressure.

.2 The test pressure shall be maintained for a period of at least 24

hours. After correction for variation caused by temperature
changes, the initial and final test readings shall not differ by more
than 1%.

.3 Temporary vents shall be located at high points in the system or

section thereof to be tested, in order to ensure complete
displacement of air.

.4 All testing equipment such as temporary pumps, strainers,

pipework, valves, instrumentation etc. shall be included under this
Contract.

.3 Repeat Testing

.1 Upon failure of the pressure test results to meet the above

requirements the Contractor shall check the installation for leaks
and other defects and carry out rectification work accordingly to
the Employer's Representative. He shall fully inform the
Employer's Representative of all rectification works. The pressure
test shall then be repeated. This procedure shall be repeated until
satisfactory results are obtained. The Employer's Representative
may, at his discretion, review the test requirements in accordance
with Site conditions.

.4 Welded Pipework

.1 All butt welds shall be tested by radiographic methods and/or other

form of NDT as required by the Employer's Representative aver
their entire circumference.

.2 All butt welds to valves or other forging or casting shall be tested

by radiographic methods and/or other forms of NDT as required by
the Employer's Representative aver their entire circumference.

.3 In event of any test prescribed not meeting the requirements for

welding the defects in the welds represented by those tests shall
be rectified and the approved inspecting authority may call for an
increase in the number of tests required until such time as a
satisfactory Standard is achieved.
3.17 ELECTRICAL EQUIPMENT TESTS

.1 General Checks

.1 A general check of all the main switchgear and ancillary equipment

shall be made and shall include a check of dimensions, location
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 28

and routing, and the completeness, correctness and condition of

earth connections, labeling, clearances, painted surfaces, cables,
wiring, pipe work, blanking plates and all other auxiliary and
ancillary items.

.2 HV Dielectric Tests

.1 All electrical equipment shall be subjected to comprehensive

insulation tests at an appropriate voltage level.

.2 All high voltage cables, the main and auxiliary circuits in switch
gear and bus systems shall be subjected to a high voltage test at
the appropriate voltages.

.3 During these tests the following precautions shall be observed:

.1 Voltage transformers shall be isolated.

.2 Current transformers secondary shall be short circuited and

earthed.

.3 Cables shall be isolated.

.4 Circuit breaker frames shall be earthed.

.4 All instruments and apparatus used in the performance of the tests

shall be supplied by the Contractor and be to the approval of the
Employer's Representative. If required by the Employer's
Representative, the equipment shall be calibrated at SIRIM or an
equivalent Authority approved by the Employer's Representative.
Calibration test certificates shall be submitted in respect of each
and every instrument and apparatus. Certificates issued more than
1 year before date of test shall not be valid, and the Contractor
shall arrange for the recalibration of the instruments or apparatus
at no extra cost to the Employer.

.5 All electrical equipment shall be subjected to comprehensive high

voltage tests and insulation tests in accordance with the
requirements of the relevant Standard.

.3 Tests on the 415/240V system shall comply with BS 7671 (formerly IEE
Wiring Regulations 16th Edition). In this respect detailed inspection of the
installations shall be carried out prior to the tests being performed. The
sequence of performance of site tests shall be:

.1 Verification of continuity of protective conductors.

.2 Verification of continuity of ring final circuit conductors, if any.

.3 Insulation resistance measurement between live conductors and

between live conductor and earth. Electronic devices shall be
disconnected.
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 29

.4 Insulation resistance measurement of any exposed-conductive

parts to live parts.

.5 Verification of protection provided against direct contact.

.6 Polarity checks.

.7 Earth fault loop impedance measurements.

.8 Earth electrode resistance measurements.

.9 Operation of residual current operated devices.

.4 Protection System

.1 The protection system and its ancillary components shall be tested

as follows:

.1 Secondary Injection

.1 Secondary injection shall be carried out on all

protection relays, using voltage and current of
sinusoidal wave form and at rated power frequency
to confirm satisfactory operation and range
adjustment.

.2 The fault setting checks for the type of protection

shall be established by secondary injection, where it
is impracticable to ascertain this value by primary
injection. Injection shall be made across the
appropriate relay bus wires with all associated
relays, setting resistors, and CT's connected.

.2 Primary Injection

.1 Primary current injection tests shall be carried out

by the Contractor and the methods employed for a
particular installation shall be agreed with the
Employer's Representative.

.2 Tests shall be carried out as follows: -

.1 Local primary injection to establish the ratio

and polarity of current transformers as a
group, care being taken to prove the identity
of current transformers of similar ratio.

.2 Overall primary injection to prove correct

interconnection between current transformer
groups and associated relays.

.3 Fault setting tests, where possible, to

establish the value of current necessary to
produce operation of the relays.
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 30

.5 DC Operations

.1 Tests shall be carried out to prove the correctness of all DC

polarities, the operating levels of DC relays and the correct
functioning of DC relay schemes, selection and control-switching,
indications and alarms. The correct functioning of all isolation links
and fuses shall also be checked.

.6 On Load Tests

.1 On load checks shall be made after the protective gear has been
placed in service to ensure that all connections and test links have
been replaced and test leads removed, as well as to confirm the
integrity of the current transformer circuits. Where necessary
voltage readings shall be taken at the terminals on each relay to
ensure that loop connections between the relays are complete.

.7 Other Tests

.1 Other tests that are specified in the respective equipment

specifications shall be carried out.

3.16 RELIABILITY RUN

.1 After the Contractor has notified the Employer's Representative that the
plant is ready for commercial service, and providing the Employer's
Representative is satisfied that the works and installation is ready for
commercial service, the plant with all its auxiliaries is required to operate
under the various modes of operation as stipulated by the Employer's
Representative and under the working condition of the station within the
limits of output specified and either continuously or intermittently, as may
be more convenient for the working of the station without failure or
interruption of any kind for a period of 30 days.

.2 The plant will be operated by the Contractor under the supervision of the
Employer's Representative during the reliability test period, but the
Contractor shall be allowed to make any minor adjustments which may be
necessary, provided that such adjustments do not in any way interfere
with or prevent the commercial use of the plant by the Employer's
Representative or result in reducing the output or decreasing the
efficiency.

.3 The work 'supervision' here shall mean that the Contractor

Representative/s shall be physically present at Site for 24 hours during
the reliability run. The Contractor may arrange for the representative to
work on shifts.

.4 All operating expenses shall be borne by the Contractor during the

Reliability Run Period.
 QUALITY ASSURANCE, INSPECTION, TESTING AND COMMISSIONING
SECTION 18002

PAGE 31

.5 During the Reliability Run the Employer's Representative shall have the
right to request the Contractor to repeat certain operational tests or
maneuvers performed during the commissioning test to prove the integrity
of the plant including the Control system, and the Contractor shall comply.

.6 Should any failure or interruption occur in any portion of the plant due to,
or arising from, faulty design, material, workmanship or omission or
incorrect erection, sufficient to prevent safe and full commercial use of the
plant, the reliability run shall be considered void and the reliability test
period of 30 days shall recommence after the Contractor has remedied
the defects. All adjustments made by the, Contractor shall be recorded by
him in a manner to be specified by the Employer's Representative.

.7 Within one month of the completion of the reliability run, the Contractor
shall submit one report covering the observations, adjustment made
during the period.

.8 As soon as practicable following the satisfactory completion of 'the 30

days reliability trial, the performance test shall be carried out. A certificate
shall be issued after completion of a satisfactory Reliability Trial. The
requirements of the contract shall apply.

END OF SECTION
 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
HANDOVER-PROCEDURE
SECTION 18003

PAGE 1

1.0 INTRODUCTION

.1 The importance of the management of the test and adjust/commissioning/

handover - employer acceptance procedure must be emphasized.

.2 Successful operation of a completed facility involves a staged sequence

of testing, witnessing, training and information delivery to the employer by
the contractor. The end result is a completed facility with an employer
being confident of the proper installation of operating system, meeting the
full intent of the contract drawings and specifications; such systems
successfully operated and demonstrated; and operating personnel fully
trained with detailed as-built drawings and operation and maintenance
manuals on hand allowing confidence in the ability to operate and
maintain the facility.

.3 The accompanying information presented is in the form of a

"Commissioning Manual".

.4 The "Commissioning Manual" is intended to provide a common framework

of standards and employer expectations across the project. It is not
substitute for individual project specification requirements. It is, however,
a minimum standard that all contractors must recognize as
complementing the specifications, providing a framework for facility
completion and employer Certificate of Practical Completion.

.5 This manual, with its suggested minimum requirements and handover

procedures, is required of each contractor.

2.0 TASK DEFINITIONS

.1 Task Description

.1 Commissioning Manager - The Contractor shall appoint a qualified

and experienced Commissioning Manager for the management,
planning, coordination and implementation of the process
described in this Manual. Contractor to submit his C.V. to the
Employer’s Representative for approval.

.2 The Commissioning Manager shall prepare a detailed and

comprehensive commissioning programmed and event schedule.
The schedule shall be submitted not later than ten months prior to
the contract completion date. The schedule shall be based on the
input of the trade contractors and sub-contractors own detailed
programme and schedules. The overall schedule shall include (for
each trade) main activity items and duration identified within the
major components of:

.1 Pre-commissioning / installation testing as required by

Specification and by the Local Authorities.
.2 Final snagging/defect clearance.
.3 Commissioning (system operation, test and adjust).
.4 Employer and Operator Training/Documentation Submittal.
.5 Hand over.
IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
HANDOVER-PROCEDURE
SECTION 18003

PAGE 2

.3 Progress measured against this schedule shall be monitored by

the Commissioning Manager and shall identify critical path network
items by other trades which could impact/delay progress. Such
impact / delay shall be highlighted on the event schedule with the
schedule revised as necessary to maintain progress.

.4 The Commissioning Manager shall call regular commissioning

team meetings. The meetings shall be minuted with action items
and responsibility clearly identified. Weekly meetings shall be
required for the final six months of construction for each facility.
Meeting minutes (and progress against the event schedule) shall
be reported to the Employer’s Representative.

.5 The Commissioning Manager shall ensure each major trade

contractor appoints a person responsible for progressing
commissioning. Such a person may typically be the trade
contractor's project manager. In any event, such person shall have
the authority to progress decisions taken within the text of
commissioning. Each trade contractor's designated commissioning
manager's name shall be reported to the Employer’s
Representative.

.6 The Commissioning Manager shall be responsible for and shall

maintain the snagging/defects tracking system from contract
initiation to completion.

.7 The Commissioning Manager shall coordinate with the Employer’s

Representative.

.8 The Employer's Representative shall be invited to attend all

commissioning team meetings called by the Commissioning
Manager.

.9 The Commissioning Manager shall obtain from Employer’s

Representative the Employer's designated operations personnel
names and responsibilities prior to the start of required system
training and coordinate the training schedule with the Employer's
Representative.

.10 Commissioning Specialist - A trade contractor may elect to source

start-up and handover by a specialist commissioning company. In
some cases, at least a portion of the commissioning work (air and
water balance for instance) is required to be performed by
independent contractors.

.11 If a trade contractor elects to hire a specialist company, the details

of such company must be reported to the Employer’s
Representative prior to such company starting work. Details to be
submitted include personnel with relevant project experience,
previous similar assignments, scope of work to be undertaken on
this assignment, company resources and equipment.
 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
HANDOVER-PROCEDURE
SECTION 18003

PAGE 3

.12 Use of a Commissioning Specialist by a trade-contractor shall not

relieve the Commissioning Manager of his obligation to name one
of his own employees as the person responsible for progressing
commissioning.

.13 The Commissioning Manager shall

.1 Inform the Employer’s Representative the required

witnessing of installation and commissioning tests at least
24 hours before hand.

.2 Submit the commissioning documentation, as-built

drawings operation and maintenance manuals, test data,
etc. for Employer’s Representative to review.

.14 Trade Contractor

.1 The trade contractor shall appoint a responsible manager

for the implementation of the commissioning process
described in this Manual. He shall prepare a trade specific
commissioning programme and event schedule for
submission to the Commissioning Manager. He shall work
closely with the Commissioning Manager to help develop
the-overall commissioning programme.

.2 Progress against his trade specific schedule shall be

reported to the Employer’s Representative prior to each
scheduled commissioning team meeting. Slippage shall be
reported with the intended means to recover to the
Employer’s Representative. Commissioning delay without
an intended work programme to recover the delay is not
acceptable.

.3 The trade contractor commissioning manager charged with

the responsibility to fulfill the obligations imposed by this
commissioning manual.

.2 Documentation Example

.1 Trade Specific Commissioning Programme

2.1 TYPICAL ACTIVITIES TO BE DESCRIBED WITHIN A COMMISSIONING

PROGRAMME

.1 Important Note

.1 The following list is NOT EXHAUSTIVE. It is intended to highlight

some of the main items required to be included in the
commissioning/handover programme.

.2 The list shall be expanded by the Contractor to cover the specific

detailed needs of individual buildings and their systems.
 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
HANDOVER-PROCEDURE
SECTION 18003

PAGE 4

.3 The following lists are indicative of activity main items required to

be included for each facility commission / handover programme.
Although not specifically listed, such programmes are required for
site work utilities and area development work packages.

.2 Electrical Services

.1 Electrical Systems

.1 Power to Employer HV Systems

.2 Power to LV Systems
.3 Power to Mechanical Plant
.4 Power to Building Control System
.5 Power to Elevator Installation
.6 Power to Fire Alarm System
.7 Power to Security System
.8 Test/Commission Bus bar Systems
.9 Test/Commission MCCs
.10 Generator Load Testing
.11 Emergency Systems Tests
.12 Generator Fuel System Tests
.13 Earthing Tests
.14 Lightning Protection System Tests
.15 PA System
.16 SMATV System
.17 UPS System

.3 General Activities

.1 Employer Training Date (By System)

.2 Power on Dates (By System)
.3 Employer Witnessing/Demonstration (By System)
.4 Operating and Maintenance Manual Submission
.5 Statutory Inspections
.6 Insurance Certification
.7 Drainage System Tests
.8 Environmental Tests

3.0 TESTING, ADJUSTING AND BALANCING

.1 Required Action

.1 Specific Testing During Construction

.1 Contractor to schedule, notify the Employer’s

Representative prior to specified test.

.2 Employer’s Representative shall confirm schedule after

being notified by the Commissioning Manager.

.3 The Employer’s Representative shall be the witness. The

Commissioning Manager to sign documentation.
IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
HANDOVER-PROCEDURE
SECTION 18003

PAGE 5

.4 Commissioning Manager to log and maintain signed Test

Certificates. One copy to Contractor for inclusion in
Operation and Maintenance Manuals.

.2 Local Authorities Testing

.1 During construction.

.2 After commissioning to prove performance to code

requirements.

.3 Contractor to provide preliminary schedule, notify

Commissioning Manager prior to scheduled
test/demonstration.

.4 For completed system, prior to scheduling the Local

Authorities, the Contractor shall furnish a "Certificate of
Compliance" to the Commissioning Manager. The
Commissioning Manager may then confirm the schedule.

.5 Commissioning Manager to confirm schedule, notify all

parties. Notify and confirm schedule with Local Authorities
after Employer’s Representative approval that test /
performance demonstration may proceed.

.6 Commissioning Manager and Employer’s Representative

to attend with the Local Authorities. Commissioning
Manager to provide and secure Local Authorities signature
on required document.

.3 Commissioning / Start-Up / Test / Adjust / Balancing

.1 Contractor to verify system is completed, disengaged and

ready for test and balance. Contractor to submit to the
Employer’s Representative (through the Commissioning
Manager) detailed proposals for test and balance
procedures four (4) weeks prior to scheduling such tests.
Reporting formats outlined in this Manual shall be used.

.2 Commissioning Manager to field verify Contractor's

verification of system completeness. Commissioning
Manager to notify Contractor to proceed.

.3 Contractor to schedule, notify Employer’s Representative

prior to schedule testing / balancing.

.4 Commissioning Manager to notify Employer’s

Representative that procedure is ready to proceed.

.5 Employer’s Representative to witness Contractor is doing

properly.
 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
HANDOVER-PROCEDURE
SECTION 18003

PAGE 6

.6 Commissioning Manager to log and maintain signed test

and balance data. One copy to Employer’s Representative
for verification and approval for inclusion in Operation and
Maintenance Manual.

.2 Test Equipment

.1 General Requirements

All field test instruments to be used on the works shall comply with
the following:

.1 Be complete with calibration certificate not more than 6

months old and issued by a recognized independent
testing authority.

.2 Copies of calibration certificates together with instrument

serial numbers shall be submitted to the Employer’s
Representative prior to their use on site.

.3 Be free from damage, or if damaged during use shall be

recalibrated.

.4 Be complete with all manufacturer's instructions.

.5 Instructions shall be carried at all times by the personnel

conducting the test/balance procedure.

.6 The following schedules indicate the suggested basic types

of equipment required for testing of air and water systems,
The Contractor shall provide detailed inventories of all
equipment held at site (prior to use) to the Commissioning
Manager. Such inventory lists shall be submitted by the
Commissioning Manager to the Employer’s Representative
for approval prior to use.

.3 Documentation Examples

.1 Local Authorities Testing

.1 During Construction

.2 After Commissioning to Prove Compliance with Local

Authorities Requirements

.2 Commissioning / Start-up / Test / Adjust and Balance

.4 Local AuthoritiesTesting

.1 During Construction

.2 After Commissioning Requirements

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.5 Commissioning / Start-up / Test / Adjust and Balance

4.0 IMPLEMENTATION/DESCRIPTION

.1 The snagging system shall be maintained by the Commissioning Manager

from contract initiation to completion.

.2 All input to this system shall be coordinated through the Commissioning

Manager.

.3 Additionally each snagging report, regardless of whoever generated shall

be copied to the Employer’s Representative. The Employer’s
Representative shall periodically check that all snags have been properly
documented by the Commissioning Manager.

.4 The snagging system also is used to define outstanding/incomplete work.

Thus the snagging report becomes the single document allowing the
Employer’s Representative to monitor progress towards completion.

.5 Additionally, a thorough log allows the Employer’s Representative a

rational basis to judge both the progress of the work and payment for
same.

4.1 TASK DESCRIPTION

.1 Commissioning Manager

.1 The Commissioning Manager shall maintain the overall Defect

Control Log. All input to the system shall be coordinated through
him.

.2 He shall maintain the log and report on a regular basis to the

Employer’s Representative.

.3 No defect shall be cleared from the report log until it has been
signed by the Contractor, the organization initiating the snag, and
the Employer’s Representative.

.4 Two defect logs shall be maintained. The main log showing all
defects shall be maintained in a complete form.

.5 A supplement log shall be maintained which is printed from the

main log.

.6 Provide an outstanding defects list.

.7 Print out the defects by trade.

.8 The Commissioning Manager shall ensure that disengaging is

accomplished by the responsible trade contractor. The
Commissioning Manager shall hold regular review meetings with
each trade contractor's project manager. The defect log shall be
 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
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reviewed with the trade contractor and specified dates agreed for
defect clearance.

.9 If a trade contractor becomes seriously arrears in his defect

clearance, the Commissioning Manager shall report such to the
Employer’s Representative.

.10 Defect clearance performances should be incorporated into the

Contractor's recommendation for each trade contractor's monthly
application for payment.

.11 Handover procedures to the Employer’s Representative shall not

be implemented by the Commissioning Manager until that trade
contractor's outstanding defects list has been reduced to a
minimum.
.
5.0 OPERATION AND MAINTENANCE

.1 General

.1 The Trade Contractors shall provide the specified number of O&M

Manuals.

.2 The manuals shall be submitted to the Commissioning Manager

initially in draft format for employer review a minimum of ten (10)
weeks before intended demonstration / handover. The final version
to be available - a minimum of six (6) months before intended
demonstration / handover.

.3 The Contractors shall ensure that the necessary information is

requested from all other parties in adequate time for the above
requirements to be met.

.4 The manual cover shall be stiffened PVC / Rexine covered 4 ring

clip binders in an agreed colour. The manual cover and spine tab
shall contain the project name, title etc., generally as set out in the
attached sample format.

.5 The manual page size shall be ISO size A4.

.6 Each section and sub-section within the manual(s) shall be

subdivided with colour coded and numbered dividing tabs.

.7 The Contractors O&M Manuals shall also incorporate

manufacturers’ technical literature, spare parts manuals and
warranty certificates.

.8 Additionally all test certificate, balancing and adjusting reports,

Local Authorities compliance documents shall be included in the
O&M Manual.

.9 Attached to this procedure is a typical operation and maintenance

manual index, which will need fine tuning to suit individual building
 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
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needs. In all cases the Commissioning Manager shall obtain the

draft manual from the Trade Contractors and submit for
Employer’s Representative review within the above listed time
frame.

.10 It is likely that some sub-sections of the manual will need to be a

complete manual in their own right; however the format, cover,
number system etc. must coordinate with other manual(s) to form
a comprehensive set.

.11 Documentation Examples

.1 Draft Cover
.2 Draft Tab.
.3 Sample Format.

6.0 AS-BUILT/RECORD DRAWINGS

.1 Requirements

.1 Generally all works shall be installed as per the approved shop

drawings. Where on-site revisions are necessary to overcome
coordination problems, such revisions shall be incorporated into
marked-up copies of the working drawings on a regular basis
throughout the course of the works. These marked-up prints will
form the basis of as-built / record drawing production.

.2 All soft copy as-built / record drawings shall be in the form of CD.

.3 The contractor shall submit a schedule of his proposed as-built

drawings when submitting his draft O&M manual.

.4 All drawings shall be clearly marked "As-Built / Record Drawings"

in minimum 10mm high lettering. All submittals of "As-Built /
Record Drawings shall be made via the existing drawing control
system.

.5 All manufacturer supplied drawings shall also be provided with the

standard project title block and issued as an "As-Built" drawing
generally as set out as above.

.6 A typical format for as-built drawing title blocks based on Project

Procedures Manual Standard is included within this section.

.7 The quantities and types of print and tracing to be issued for "As-
Built" use are the same as for normal document issues, as set out
in the Project Procedures Manual.

.8 All existing revision information on working drawings shall be

removed prior to their issue for "As-Built" status. A new series
starting "R1 " shall be instituted for first "As-Built" issue.
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6.1 SAMPLE FORMAT - TYPICAL INDEX TO OPERATION AND MAINTENANCE

MANUALS

.1 Important Note

The following list is not exhaustive. It is intended to highlight some of the

main items required to be included in the operating and maintenance
manuals. The list will need to be expanded to cover the specific detailed
needs of the individual buildings and their system.

Sec. Description Sub-Sections

.1 GENERAL .1 Introduction
.2 Services Identification
.3 List of Abbreviations
.4 Schedule
.5 Directory of Suppliers
.6 Warranty Contacts (list all
major equipment with
warranty beginning and end
dates)

.2 ELECTRICAL SYSTEMS .1 High Voltage Systems

.2 Low Voltage Systems
.3 Power Generation
.4 Emergency Lighting
.5 Lightning Protection
.6 Earthing

.3 WATER SYSTEMS .1 Fill and Pressure Test (by

sections)
.2 Initial flushing
.3 Re-fill and Chemically Clean
.4 Drain, Flush, Re-fill and
Water
Treatment Dosing
.5 Pre-Commissioning Pumps
.6 Commission Pumps
.7 Check Controls Interface

.4 PLUMBING .1 Domestic Water Systems

.2 Drainage Systems
.3 Interceptor Systems
.4 Storage Facilities

.5 OPERATING .1 General
PROCEDURES .2 Initial Set-Up
.3 Routine Inspection Charts
.4 Equipment Start-Up /Shut
Down
Procedures
.5 Filling-Up
.6 Draining Down
.7 Lubrication Charts
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.8 Filtration Charts
.9 Preventative Maintenance
.10 Lead/Lag Arrangements
.11 Fault Finding

.6 EMERGENCY .1 General
PROCEDURES .2 Health and Safety
.3 Failure of Electrical Supply
.4 Failure of Water Supply
.5 Failure of Gas Supply
.6 Refrigerant Leaks
.7 Water Leaks
.8 Fuel Oil Leaks
.9 Fire Situations on MEP
Systems
.10 First Aid Procedures

.7 MANUFACTURERS' DATA .1 Factory Test Certificates

.2 Certified Drawings
.3 Nameplate Date
.4 Specific / Specialized
maintenance
Recommendations
.5 Performance Curves
.6 Catalogue Cut

.8 SPARES .1 Recommended Spare

Schedules
.2 Spares Policy
Recommended
.3 Schedule of Spares Supplied
At Handover

.9 TEST CERTIFICATES .1 Pressure Tests

.2 Environmental Tests
.3 Chlorination Certificates
.4 Chemical Cleaning
.5 Commissioning Checklists
.6 Snagging Sign-Offs
.7 Tank Test Certificates
.8 Electrical Safety
.9 Generator Tests

.10 SYSTEM SCHEMATICS .1 Wiring Diagram (HV)

.2 Wiring Diagram (LV)
.3 Valve Charts
.4 Water System Schematics
 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
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7.0 OPERATING TRAINING

7.1 TRAINING TO EMPLOYER AND BUILDING OPERATORS

.1 General

.1 This section defines the general scope and content of Employer

and Building Operators training.

.2 Given the requirements of the Health and Safety at Work Act and
the need to maintain warranty conditions it is an absolute
prerequisite that full training occurs prior to handover of any
equipment or systems.

.3 The Commissioning Manager shall coordinate all training

proposals into a comprehensive training schedule. This schedule
is to be submitted to the Employer’s Representative for review and
agreement. The Commissioning Manager shall incorporate all
reasonable requirements into a final training programme and
arrange attendance of the required training personnel.

.4 As a general matter of policy the Employer’s Representative will

require training on equipment to be carried out by engineers /
instructors of the original equipment manufacturer (OEM)
supplemented by the Trade Contractors as necessary.

.5 In submitting a comprehensive training schedule the

Commissioning Manager must confirm the following:

.1 Name and title of persons carrying out training

.2 Name of company employing trainers

.3 Proposed location of training i.e. job site, classroom or

factory.

.4 Details of training aids to be used, i.e. manual, audiovisual

etc.

.5 Details of any spares/tools to be provided

.6 For each training session a training agenda shall be provided,

generally set out as per the attached standard format.

.7 The contractor shall arrange to digital record the training session

and provide a copy of the VCD/DVD for Employer’s
Representative retention.

.2 Training Periods

.1 The following schedule sets out for each facility, the general
systems / equipment requiring demonstration/training and also
IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
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gives minimum duration and responsibilities; unless otherwise

noted in the specifications:

System / Minimum Duration Who Carried

Subject (Hours) Out Training

.1 General Mechanical 4 Mechanical Trade Contractor

.2 Plumbing and Drainage 3 Mechanical Trade Contractor

.3 Pumps 3 Equipment Manufacturer

.4 General Electrical 4 Electrical Trade Contractor

.5 Fuel System 2 Installation Contractor

.6 Motor Control Systems 4 Electrical Trade Contractor

.7 LV & Power Factor 4 Equipment Manufacturer

Board

.8 Lighting and Controls 4 Electrical Trade Contractor

.9 High Voltage 4 Equipment Switch gear

Manufacturer

.10 Transformers 2 Equipment Manufacturer

.11 Standby Generator 4 Equipment Manufacturer

.12 UPS 4 Equipment Manufacturer

.13 P.A. System 4 Equipment Manufacturer

.14 SMATV 4 Equipment Manufacturer

.2 Where more than 1 manufacturer supplies a given type of

equipment or system, the duration given above applies to each
individual manufacturer.

.3 Additional training courses to those noted above may be required

to cover specific items of equipment in a particular building.

.4 Documentation Examples

.1 Training Seminar Agenda

.2 Sample Format

.3 Training Seminar Agenda

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Building : Contractor:

Date of seminar

Time of seminar

Location of seminar

.4 Title of Seminar

.5 Attendance List

.6 Opening Introductions by Chairperson

.1 Introductions of Instructors
.2 Introductions of Owners Representatives
.3 Introductions of Manufacturers Specialists
.4 Presentations of Course Training Aids
.5 Statements of Course Aims/Scope

.7 Training (Classroom)

.1 Descriptions of System and Equipment

.2 Inter - Relationship with other Systems
.3 Recommended Maintenance Requirements
.4 Preventative Maintenance Check List and Recommended
Spare Parts
.5 Health and Safety Precautions

.8 Field Training

.1 View Equipment at Location

.2 Demonstrate Maintenance Access
.3 Review of Overall System and Associated Interfaces with
Other System
.4 Demonstrate Actual Start - Up Procedures
.5 Demonstrate replacement of Common Spare Parts

.9 Review of O&M Documentation and Spare Parts List

.1 Site Review to Compare with Actual Installation of

Accuracy

.2 Review Description of Systems and Certified

Manufacturers Drawings
 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
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8.0 SPARE PARTS

.1 General

.1 The Contractor shall coordinate the supply of all specified spare

parts to the owners operations staff.

.2 The information for a given project shall be organised by system

and shall include the following: -

.1 A list of spare parts, special tools, lubricants etc. for each

item equipment which has been purchased as part of the
relevant trade contract.

.2 Similar list to (a) above covering spare parts etc. for all
other equipment for each spare parts have not been
included in the Trade Contract.

.3 A list of spare items for standard systems i.e. fuses,

gaskets etc.

.4 The above lists shall be based on manufacturers

recommendation and cover a period of two (2) year from
handover of equipment/system to employer.

.5 Standard spare parts schedules shall provide the following

information as a minimum: -

.1 Manufacturers part name

.2 Manufacturers name, address, phone and fax
numbers
.3 Manufacturers part number
.4 Quantity recommended for two (2) year
.5 Unit
.6 Lead time
.7 Shelf life
.8 Alternative suppliers of parts
.9 Local stockist(s) name, address, phone and fax
number

.6 Preliminary list of spare parts, tools etc. shall be submitted

a minimum of 60 days prior to intended system handover
for Employer’s Representative review. The employer’s
Representative reserves the right to add to, reduce, or omit
entirely the recommendations contained on these lists.

.7 Upon approval by the Employer’s Representative of the

spare lists either original or amended form the Contractor
shall instruct the Trade Contractors to supply those items
covered by the relevant trade contracts.
 IMPLEMENTATION OF TESTING AND ADJUSTING, COMMISSIONING,
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.8 Those items so supplied shall be in manufacturer's original

packaging and shall be tagged with a unique number
coordinated with the relevant handover schedule.

.9 These parts shall be available for handover to owners

operations personnel at least thirty (30) days prior to
handover of the associated systems.

9.0 DESCRIPTION OF THE HANDOVER PROCESS

.1 Introduction

.1 As buildings reach the final stages of completion the Employer will

require operations to take over areas and systems as they are
almost complete. This initial phase is part of the inheritance of the
Buildings by operational management who will control security and
access to the areas and systems prior to the acceptance into
service and practical completion. This is the first step towards the
acceptance into service.

.2 The Documentation Summary is a required document to be

maintained by each building's Employer assigned Commissioning
Manager. It lists each system proposed to be handed to operations.
The proposed systems shall be agreed with the Commissioning
Manager at an early date and shall be transmitted to each trade
contractor as a requirement.

.3 The take over confirmation is an internal document of operations

recording the steps leading to areas/system being offered to
operations.

.2 Takeover Confirmation Systems

This certificate is based on a checklist extracted from the M&E

Commissioning and Handover Procedures Manual.

.3 O&M Manuals and Test Certificates

This information may be presented in draft form but the content must
encompass all aspects relating to the operation and fault finding areas.

.4 As-Built or Record Drawings

The suppliers’ recommended spare list should be provided in the O&M

Manuals although further revisions may be incorporated in the final issue
with operations agreement.

.5 This training will take place after receipt of the draft documents and with
the agreement of the Building Manager or Building Services Manager in
respect of content, time scale and dates for training.
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.6 Current Snags List

The snag list will consist of items both in numbers and content that are
considered manageable by the Building Manager. The attachment of the
list at this time does not deem to represent or limit the scope for adding
items that arise through the operation of areas and system by operations
throughout the defects liability period. A status report of the current snag
list will be provided with the certificate of readiness.

.7 Keys

All door keys are to be presented to the Building Manager from the Project
Executive in an orderly manner at a mutually acceptable time. This will
also include all keys associated with engineering items of plant and
equipment.

.8 Authority

The Building Manager is the authorised representative for operations and

will issue the certificate.

.9 Warranty and Maintenance

These items are covered by the narrative for the Certificate of Practical
Completion and do not from part of this procedure.

.10 Certificate

.1 The Certificate of Practical Completion is initiated by the

Commissioning Manager, signed by the Employer’s
Representative before a signature of agreement by the authorised
representative of operations. The distribution of the completed
certificate to be arranged by operations as required.

.2 A list of plant that is operational in the building must be provided

with the certificate.

.3 A status report on the current snag list as the date of issue of the
certificate will also be attached.

.4 Documentation Examples

.1 Owner/Construction Manager Documentation Summary

.2 Takeover Confirmation

END OF SECTION
 LIGHTING WIRING, POWER CABLING AND CONTROL WIRING
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PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 To install, test and commission lighting wiring, power cabling and control wiring in
accordance with the Contract Documents

1.2 WORK INCLUDED

.1 Wiring of lighting circuits

.2 Cabling of power circuits

1.3 SUBMITTALS

.1 Tender Stage

.1 Company's proven track record

.2 Wiremen competency certificates

.3 Technical data and products catalogues

.2 Construction Stage

.1 Construction drawings showing the circuitry and conduits, cable trays,

trunking and raceways layouts

.2 Catalogues and samples of cables and accessories if requested by

Employer's Representative

.3 Site Installation

.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.4 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals
 LIGHTING WIRING, POWER CABLING AND CONTROL WIRING
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.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Standards To Comply

.1 Except as modified by the Contract Document, comply with the latest

applicable provisions and latest recommendations of the following:

.1 IEC 60364 – Low Voltage Electrical Installations of Buildings

.2 BS 7671 - Regulations for Electrical Installations (formerly IEE

Wiring Regulations 16th Edition)

.3 BS 6004 – For cable size 1.5mm², 2.5mm² & 4mm² insulated

cable used for final sub-circuit.

.2 Workmanship

.1 Contractor shall have a proven track record and the wiremen shall have
at least 10 years experience in wiring for commercial building and hold a
PW4 Wiremen Certificate.

2.0 PRODUCT

.1 General requirement

.1 Installation works shall conform to this specification and conform to the

best principle of modern installation practice and be carried out by fully
competent tradesmen of appropriate grade.

.2 The workmanship shall be of first grade quality and shall be complete for
satisfactory operation, control, maintenance and safety under all
conditions of services.

.2 Composite wiring diagrams

.1 The electrical Trade shall furnish all data and wiring diagrams for those
items of equipment where there is joint coordination and responsibility for
the wiring and interface between the Electrical Trade and the BSS and/or
BCS Contractors. Such items shall include but are not limited to the motor
starters, fire pump and controllers, domestic water pumping units,
terminal units, water chilling unit control panels, emergency generator,
transfer switches, fire alarm system (point location, point type
 LIGHTING WIRING, POWER CABLING AND CONTROL WIRING
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identification), etc. the data and wiring diagrams furnished to the BSS and
BCS Contractors shall indicate those terminals which have been provided
for the use of the BCS and BSS Contractor. The diagrams shall first be
submitted to the BSS Contractor who, upon completion of marking up the
drawings showing BSS interfaces and connections, shall forward them to
BCS Contractor.

.2 The BCS Contractor shall create a composite wiring diagram indicating

the control and/or monitoring of the motors, dampers, and other items of
equipment. The completed diagram shall include all line and low voltage
wiring between temperature control items, motor start/stop and/or hand-
off-auto stations, control relays, pumps, controllers, end switches, etc.

.3 Provide one composite drawing for each item of equipment indicating the
wiring in its entirety including interlocks. Any omissions or errors noticed
by the BCS Contractor shall be brought to the electrical trade and BSS
Contractor or relevant parties immediately.

.4 Identify each line (wire) termination by a termination number or symbol. In

addition, index each line (wire) termination to identify the termination
location of the other end of the line (wire).

.5 Include all internal wiring of panels (in detail) in the composite wiring
diagram. For items such as motor starters and etc. all jumpers added or
removed shall be clearly indicated as being “added” or “removed”.

.6 Include in the composite wiring diagrams a description of the interlock

sequence of operation. The description shall include complete
identification of each item shown (relay motor controller, etc.) and each
item’s exact operation shall be related to the interlock sequence.

.7 Complete the composite wiring diagrams and return the diagrams to the
Electrical trade who will verify that the composite wiring drawings are
correct. Any corrections required shall be made by the BCS Contractor.

.8 Provide composite wiring diagrams in a sturdy hardcover loose-leaf

binder separate from other shop drawing submittals and documentations.

.3 Examination of documents

.1 Prior to starting, the contractor shall familiarize himself/herself with all

conditions affecting the proposed installation of equipment requiring
electrical connections. Failure to comply with the intent of this paragraph
shall in no way relieve the contractor of performing all necessary work
required for final electrical connections and equipment and the
coordination thereof.
 LIGHTING WIRING, POWER CABLING AND CONTROL WIRING
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.2 Connections shall be made in accordance with the manufacturer’s

recommendations and approved shop/installation drawings and
installation methods.

.4 Cables used for wiring

.1 All cables used shall be of the appropriate grade complying with the
relevant standards BS 6004 & BS 7671 and to the approval of the latest
electricity Supply Regulations and local authority.

.2 Cables shall be of PVC insulated cables, and where indicated XLPE

cables shall be used for power circuits. Cable sizes shall be as indicated
in the design drawing, or otherwise comply with BS 7671. They shall be
correctly coloured coded, black for neutral, green for earth, red-yellow-
blue for phase.

.3 Conductors shall be of adequate size and rating for the particular duties
and terminations.

.4 All cables shall be installed in one continuous length between the points
of connection and no joints of any description, other than those required
for terminating the cables, shall be allowed.

• All cables shall be multi-stranded type. It shall be minimum 7 strand.

.5 Method of wiring

.1 The wiring shall be drawn into the conduits after the conduits have been
completely fitted.

.2 The wiring system will be of the loop-in type and connections will only be
allowed in switches, lamp fittings and switched socket outlets.

.3 No connections will be allowed in conduit boxes.

.4 No exposed wiring are allowed unless otherwise indicated.

.5 The maximum numbers of PVC insulated cables drawn into any conduit
must comply with BS 7671.

.6 Wires shall be kept clear of auxiliary components. The method of clipping

shall be such as to prevent damage to the insulation. Adhesive tape shall
not be used for clipping or looping of wires.
 LIGHTING WIRING, POWER CABLING AND CONTROL WIRING
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.7 A fixed two terminal connector block with an earth terminal adjacent or

integral shall be provided near the incoming cable entry of each
fluorescent fitting.

.8 Lighting and small power circuits shall be in conduit or on raceway.

.9 The lighting circuit and power circuit will have their own separate conduits
and raceways where applicable.

.10 Power wiring to motors shall be on trays. Cables on tray shall be

clamped. No cable straps are acceptable in this contract.

.11 Wiring to motors shall be tagged at bends and termination ends.

.6 Motor control wiring

.1 Motor Control Interface Wiring with BCS (Building Control System)

.1 Wiring shall be provided between the motor controller and terminal

strip within the BCS marshalling kiosk located next to the
associated motor control centre to enable the BCS to stop/start
control the motor when the motor is in the auto mode only. When
the BCS closes a momentary contact across the ‘ON’ terminals
the motor shall be started and when the BCS opens a contact
across the ‘OFF’ terminals the motor shall stop. Provide additional
relays in the motor control circuit such that:-

.2 The motor will remain ‘ON’ when the momentary ‘ON’ contact is
re-opened..

.3 The motor will stop even when the momentary ‘OFF’ contact is re-
closed and

.4 Following a loss of power to the controller, the motor shall not re-
start until the momentary contact across the start terminals is
closed.

• Additional terminals shall be used for the terminal of the screens

on the wiring to the motor control relays. Relays shall be rated for
a minimum of ten (10) million mechanical operations and 500,000
electrical operations. Relays shall be located within the motor
controller cubicle of the terminal strip enclosure.

.2 Motor Speed Control

.1 Where variable motor speed controllers are fitted, a pair of

terminals at the terminal strip shall be wired to the motor control
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such that a BCS generated control signal of 0 to 10V dc or 4 to

20mA at these terminals will modulate the motor speed from
minimum to maximum speed. One additional terminal shall be
used for the termination of the screen on the wiring to the fan
motor terminals.

.3 Motor Status Monitoring

.1 A pair of terminal shall be wired such that when the BCS detects
an open contact it shall indicate that the motor is ‘OFF’ and when
the BCS detects a close contact the motor is ‘ON’.

.4 Alarm Status Monitoring

.1 A pair of terminals shall be wired such that when the BCS detects
‘close’ contact and at the same time an open contact on status
monitoring then the motor is in ‘alarm’ condition.

.2 The load on the motor starter side of the terminal strip shall be
such that the BCS relays required to execute the various control
and monitoring function shall not require a rating greater than 5
amps 240V.

.3 The electrical contractor shall provide all wiring, relays, etc. as

necessary to provide a fully functioning interface which shall
enable the BCS without modifications to the work of this contract
to undertake the monitoring and control requirement as detailed
herein.

.4 The electrical contractor shall provide all necessary wiring

diagrams, guidance and documentations to the BCS Contractor to
enable the BCS to undertake the monitoring and control functions
as detailed herein.

.5 The terminal strip shall be housed in a local panel mounted

adjacent to the each motor control panel. All terminal strips shall
be property arranged and numbered. All control wiring
terminations shall be ferruled and numbered.

.6 All wiring shall be screened and shall be terminated as detailed

above. Test shall be performed to ensure that the screen is not
earthed at any point between the instruments and motor controller
and the terminals strip.

.7 Details of the terminals strips are to be submitted in the shop

drawings. All BCS terminal interface strips for motor controllers
furnish under this contract shall be the same.
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.7 Motor Contractor Interface Wiring with FAS (Fire Alarm System)

.1 The Contractor shall provide a terminal strip housed in a separate

metalclad enclosure, to which the Fire Alarm system (FAS) Contractor
shall interface for override controls on selected motors. The terminal
strips shall be shown on the motor control design drawings.

.2 The Contractor shall provide all wiring, and relays, etc. as necessary to
provide a terminal strip interface as detailed herein to which the FAS
interface so as to undertake override stop control and also status of the
motor.

.3 The terminal strip shall be wired so as to enable the following FAS

interface: -

• Motor ‘OFF’ Control

A pair of terminals shall be wired such that when the FAS closes a
relay contact across the terminals then the motor stops regardless
of the position of the motor controller HOA switch and regardless
of the status received by the BCS. When the relay contact is
opened the FAS shall not cause the motor to start but it will not
inhibit the motor from being started. An additional terminal shall be
provided for the termination of the screen between the controller
and the terminal strip.

.2 Motor Status

A pair of terminals shall be wired such that when the FAS detect
an open contact it shall indicate that the motor is ‘OFF’. An
additional terminal shall be provided for the termination of the
screen on the wiring between motor controller and the terminal
strip.

.3 Provide a minimum of 4 spare terminals.

Other conditions related to BCS terminal strips and wiring also

apply to this section of specification.

3.0 EXECUTION

3.1 TESTS

.1 Site Tests
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Every installation shall be inspected and tested during erection and/or on

completion before being put into service. A report recording all the test results
shall be submitted to the Employer’s Representative.

.2 Visual Inspection

.1 Insulation of cables is not damaged.

.2 Check if the routing of cables is in safe zones or within mechanical

protection provided.

.3 Check for proper connection of conductors.

.4 Check the circuits; fuses, switches and terminals are labelled.

.5 Core identification of conductors.

.6 Presence of fire stopping material.

.7 Presence of separation between power cables and communication

cables.

.3 Continuity Test

.1 Continuity of protective conductors (including main and supplementary

bonding conductors).

.2 Continuity of ring final circuit conductors.

.4 Insulation Resistance Tests

Between phase/neutral and between phase/neutral against earth, with the

remaining phase/neutral earthed.

.5 Polarity and Phase Sequence Checks

3.2 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Review O & M Documentation and Test Results.

3.3 HANDING-OVER AND EMPLOYER’S ACCEPTANCE

.1 Endorse defects list.

END OF SECTION
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1.0 GENERAL

1.1 DESCRIPTION

.1 Manufacture, test at works, deliver to site, install and commission of conduit,

'raceway' trunking, cable tray and cable ladder systems in accordance with the
Contract Document.

1.2 WORK INCLUDED

.1 Galvanised steel conduit.

.2 Flexible galvanised steel conduit.

.3 Hot dip galvanized steel 'raceway' trunking.

.4 Hot dip galvanized steel cable trays.

.5 Hot dip galvanized steel cable ladders.

.6 Conduit, 'raceway’ trunking, cable tray and cable ladder fittings and accessories.

.7 Outlets and junction boxes.

1.3 SUBMITTALS

.1 Tender Stage

.1 Technical data and product catalogues.

.2 Construction Stage

.1 Shop drawings/construction drawings.

.2 Catalogues and samples of conduit, 'raceway' trunking, cable tray, cable

ladder, fittings and fixing accessories.

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance tests.

.2 Acceptance test reports after tests.

.3 Packing, transportation and storage notes.

.4 Site Installation
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.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.5 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Except as modified by the Contract Documents, comply with the latest applicable
provisions and latest recommendation of the following: -

.1 MS 275 Specification for Steel Conduits and Fittings with

Metric Threads of ISO Form for Electrical
Installations.

.2 BS 31 Specification for Steel Conduit and Fittings for

Electrical Wiring.

.3 BS 476 Fire Tests on Building Materials and Structures.

Pt. 4 Part 4 - Non-Combustibility Test for
Materials.

.4 BS 476 Fire Tests on Building Materials and Structures.

Pt. 7 Part 7 - Method for Classification of the
Surface Spread of Flame of Products.

.5 BS 476 Fire Tests on Building Materials and Structures.

Pt. 8 Part 8 - Test Methods and Criteria for the
Fire Resistance of Elements of Building
Construction.

.6 BS EN ISO- Hot Dip Galvanized Coatings on Fabricated

1461:1999 Iron and Steel Articles. Specification and Test
Methods.
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.7 BS EN 61386 Specification for Conduit System for Cable

-1:2004 Management. General Requirements.

.8 BS 3382 Specification for Electroplated Coatings on Pt.1

Threaded Components. Part 1-Cadmium on Steel
Components

.9 BS 4568 Specification for Steel Conduit and Fittings with

Metric Threads of ISO Form for Electrical
Installations.

.10 BS 4652 Specification for Metallic Zinc-rich Priming Paint

(Organic Media).

.11 BS 4678 Cable Trunking.

.12 BS 6946 Specification for Metal Channel Cable Support

Systems for Electrical Installations.

.13 BS 7671 Requirements for Electrical Installations.

.14 BS EN 1562 Founding for Malleable Cast Irons.

:1997

.15 BS EN 1774 Zinc and Zinc Alloys. Alloys for Foundry

Purposes. :1998 Ingot and Liquid.

.16 BS EN 12844 Zinc and Zinc Alloys. Castings. Specifications.

: 1999

.17 JIS G 3131 Hot Rolled Mild Steel Plates, Sheets and Strips.

.18 NEMA VE1 Metal Cable Tray Systems.

.2 PRODUCT

2.1 CONDUIT

.1 Conduit shall be concealed using galvanized type where indicated and

specified in the tender drawing. Surface run conduit may run on walls,
ceilings and structure steel as may be required. Surface mounted conduit
will be run truly horizontal or truly vertical. Where these requirements
cannot be met conduit runs shall follow the buildings lines.
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.2 All conduit shall be heavy gauge galvanized, class B, screwed steel type
complying to BS 31 or other relevant BS standards.

.3 All conduit fittings, cover lids and accessories shall be of the galvanized
type or of the equivalent quality proprietary fitting made of aluminium die
casting. Prefabricated conduit bends, elbows, draw boxes and etc. shall
conform to the relevant BS standards.

.4 Draw in boxes shall be provided to give access to all conduits for the
drawing in of cables. The draw in boxes shall be approximately sized so
as to allow neat diversion of cables from one conduit to another without
cramping. Cable joints are not allowed in draw in boxes under any
circumstances. Where conduit is to be installed in point to point runs draw
in boxes shall be installed in every 9 meter. No box shall be installed so
as to be inaccessible after completion of the structure or other services.

.5 Conduit ends and terminations into conductive enclosures shall be fitted

with brass bushes to the relevant BS standards. Conduits terminating in
non-conductive or insulating enclosures may be fitted with an all insulated
type plastic bush.

.6 Couplers shall have dimensions associated with the diameter ‘D’ of the
conduit as follows: -

• Overall length ‘D’ + 12 mm nominal

• Diameter of flange ‘D’ + 12.7 mm nominal

iii. Thickness of flange 3.175 mm nominal

.7 Spacer bar saddle shall be used for all exposed conduits.

.8 Where it is not possible or practical to terminate a conduit at the supplied

enclosure or equipment a flexible conduit of an approved type and
conforming to the relevant regulations will link the fixed conduit and the
enclosure or equipment. Flexible conduit shall be of galvanized steel and
manufactured to BS EN 61386-1:2004. The total maximum length of each
flexible conduit installation shall be limited to two meters.

.9 Flexible conduit adaptors shall be malleable cast iron complying with BS

EN 1562:1997 and shall be provided with external earthing lugs.

.10 The maximum number and size of the installed cable within a conduit will
be such that a space factor of 40% is not exceeded. The Contractor is
required to substantiate the conduit sizes with technical calculation on
conduit capacity.
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.11 All conduits exposed and run above false ceiling shall be pre-painted from
factory with etching primer and two coat of approved type colour paint.
Conduit for essential and UPS circuit shall complete with additional 50mm
width painted colour band at 1.5m intervals.

2.2 STEEL TRUNKING

.1 Where it is found that several surface-run conduit cable runs are grouped
together, thereby utilizing extensive space on walls or steel structural
works, the Contractor may, with the Employer’s Representative approval,
use steel trunking in lieu of conduit for PVC cables runs.

2 The number of PVC cables to be installed in steel trunking shall be such

that a space factor of 45% is not exceeded. Under no circumstances shall
circuit cables from different distribution boards be run in the same
trunking. The Contractor is required to substantiate the trunking sizes with
technical calculation on trunking capacity.
.3 The trunking shall be manufactured from hot-dipped galvanized steel
trunking complying to BS EN ISO-1461:1999, of 1.6mm for cross-section
sizes of up to and including 300mm x 100mm for sizes exceeding 300mm
x 100mm, 2mm sheet steel shall be used.

.4 Steel trunking shall be supplied in standard length, with each length being
provided with a sleeve-type coupling and external earth bonding link of
copper size 35 mm sq.. All trunking shall have a smooth interior with
cover plates overlapping the sides of the trunking. In general, the trunking
shall be designed for exceptional strength and rigidly with trunking length
fitted with “butt-up” joints form the necessary runs. Suitable adaptors shall
be utilised for any change in cross section of trunking runs. All such
adaptors, bends, tee pieces and stop bends used in the trunking
installation shall be pre-fabricated. All accessories including tee pieces,
bends, intersections and other similar accessories shall be purpose made
by the trunking manufacturer. The Contractor shall be required to submit
technical calculation to justify the structural integrity of the support
requirement on cable trunking.

.5 Earth link shall be provided externally between lengths of steel trunking to

maintain electrical continuity throughout the entire run. Earth links shall be
copper tape with minimum cross sectional area of 35 sq. mm and be fixed
using screws, washers and lugs.

.6 In horizontal and vertical trunking runs, insulated type cable support and
retaining clips shall be fitted to support the weight of the cables.

.7 Trunking may be suspended from the underside of floor slabs, on column

or wall supports or on floor mounted structure. All suspension supports
and hangers shall be galvanized, placed adequately for the trunking
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support on them. In any event, the maximum support spacing shall not
exceed that defined in Table 4D of the 16th edition of the IEE wiring
regulations. No sagging of any trunking will be permitted. All such
suspension units, angle supports to or structures shall be of hot-dipped
galvanized.

.8 Trunking lids shall be lipped and fixed at intervals not exceeding 1m by

quick release spring type cam fasteners.

.9 Where conduit is taped off trunking, suitable brass and smooth-type

bushes shall be fitted at all conduit terminations. The use of all insulated
type, plastic, fibre or bakelite bushes for this purpose shall not be
permitted.

.10 Where vertical trunking runs pass through floors of the buildings, fibre-
resisting barriers with individual sleeve mouldings (this material shall be
approved by the Jabatan Bomba Malaysia), shall be fitted in the trunking
at individual floor levels. All such fire barriers shall have a minimum fire
rating of 3 hours.

.11 For all trunking, a 50mm width painted colour band at 1.5m intervals to be
used for all installation.

2.3 CABLE TRAYS

.1 Wherever cable trays are required for use in the contract works, the
Contractor shall supply and install perforated type: hot-dipped galvanized
complete with all necessary bends, tee pieces and adaptors for changes
in width of trays where required. The trays shall be of heavy-duty
construction from at least 1.6 mm sheet steel for trays to 300 mm in width
and 2 mm sheet steel for trays in access of 300mm.

.2 All accessories including tee pieces, bends, intersections and other

similar accessories shall be purpose made by the tray manufacturer.

.3 Cable trays may either be suspended from the underside of floor slabs or
roof structural work on column of wall supports, or installed on floor-
mounted. All such suspension units, angle supports to or structures shall
be of hot-dipped galvanized.

.4 Cable-tray supports, hangers and structures shall be spaced adequately

apart to cater for the weights of the cables and tray supported on them. In
no case shall cable trays and cables be permitted to sag. Any sag found
on installation works shall be replaced by the Contractor at his own cost.
The spacing shall not exceed 1.2m and support shall be provided not
more than 150mm from any bend, tee, intersection or riser. The
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Contractor shall be required to submit technical calculation to justify the

structural integrity of the support requirement on cable trays.

.5 In the event of a single layer of cable trays being insufficient to cater for
the cables to be laid thereon, the Contractor shall install two or more
layers of cable trays on a common set of hangers. The supports or
structure shall be sufficient robust construction to cater for the additional
weights of the trays and cables.

.6 Fixing clips or cleats for cables on trays shall be installed by means of

non-corrosive metal screws (for bolts), washers and nuts.

.7 Cable trays shall be installed with the greater dimension in the horizontal
plane unless otherwise agreed with the Employer’s Representative.

.8 All cable tray systems shall be fully earth equipotential bonded throughout
using 25mm X 3mm copper tape with square clamp installed on the
jointing connection of copper tapes.

.9 Provision of cable tray telecommunication requirement shall be as

indicated in the tender drawing.

.10 The colour of paint applied shall comply with TM’s requirement. For all
other services, painted colour band shall be in the form of a 50mm width
at 1.5m intervals or a minimum of one band per section.

2.4 FLUSH FLOOR TRUNKING SYSTEM

.1 General

.1 Flush floor trunking system will be used for floor distribution and
shall be supplied and install complete with all necessary trunking,
junction boxes with fly over, services outlet boxes, reducers,
elbow box, vertical access box, end cap, trunking support bracket
and adaptor junction boxes for connection to under floor trunking
system.

.2 The system shall be catered for routing of telecommunication,

data and power in three-compartment and the following
compartment usage will be adopted.

- Compartment 1 - Power to UPS supply s/s/o

- Compartment 2 - Telephone and Data
- Compartment 3 - Power to Normal supply s/s/o
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.2 Flush Floor Trunking

.1 Trunking shall be modular design in equal section to facilitate

installation and subsequent removal and interchanged of cover
and services boxes.

.2 It shall have three compartments separated by a removable

sectionalised separator between compartments for the entire
length of the trunking. The compartment dividers shall be easily
removed and readily reinstated without using special tool or
modification or parts.

.3 The flush floor trunking shall be firmly fixed to floor slab with
galvanized sheet steel floor fixing with bracket and screws
manufactured from the same manufacturer.

.4 Any screws or bolts/nuts used in any part of the trunking,

particularly for the joint of each trunking and the earth link, shall be
corrosion resistant, smooth and should not cause any damage to
the wiring during installation.

.5 Where there is no service outlet box located at the floor trunking

the compartment divider shall be of full height to the trunking
height.

.6 Manufacture of trunking shall comply with BS 4678 Pt 2: 1973 and

BS EN ISO-1461:1999.

.7 Additional supports shall be required on the flush floor trunkings to

maintain its structural integrity against any deflection if the overall
width of the trunking is more than 400 mm. The related cost for
such additional support shall deemed to be bonded by the
Contractor.

.3 Junction Box and Elbow Box

.1 Appropriate size floor junction box and elbow box shall be

provided and installed as required.

.2 Where tee-junction boxes are indicated, the compartment for

telephone and data services routing shall have 100% cable
handling capacity throughout as the main trunking without
obstructed by fly over. The tee flyover must be able to convert
from “left to right tee” or “right to left tee” without the use of special
tool. Fixed type tee flyover is not acceptable.
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.4 Services Box

.1 The services outlet boxes shall be concealed type and each

module shall be similar in size with the modular trunking covers for
interchangeability.

.2 The service outlet boxes frame and cover shall be manufactured

from high-pressure zinc alloy die-cast materials. All visible and
exposed parts should be epoxy coated to protect against rust.
There shall be facilities to adjust the box frame and trap to suit the
finishing floor level.

.3 The hinge for the coverlid of services box shall be of the robust
material and the construction of opening manoeuvred of the
coverlids shall be of long-lasting type.

.5 Material

.1 The trunking, junction boxes, modular services outlet boxes,

vertical access boxes and etc. shall be constructed from hot-
dipped galvanized sheet steel to BS 4678 Class 3. The thickness
of trunking body, compartment separators, flanges and junction
boxes shall not be less than 1.6mm and all covers shall not be
less than 3.0mm thick.

.6 Earthing

.1 The cover of the services outlet box shall be provided with a brass
earth terminal and shall be earthed to the main trunking body.

.2 Copper earth links (of minimum cross section area 35 mm sq.)

shall be used for each joint to maintain electrical earth continuity
and shall be installed at the internal side of the trunking. All
electrically conductive parts shall be properly earthed and the
entire trunking system shall be earth continuity maintained.

.7 Test

.1 The flush floor trunking system shall be able to withstand the

following minimum load test requirement.
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.1 Loading requirements The flushed trunking system shall be able to withstand the
following loading test requirements. Whilst it is recognised
that there is currently no test conducted on the existing
flushed floor trunking construction to these loading. It is the
absolute contractual requirement of the successful flushed
floor trunking supplier to have the loading tests to be
conducted by an independent testing laboratory such as
SIRIM within 1.5 months from the confirmation of selection.

All types of flushed floor trunking components shall pass the

test otherwise it is the responsibility of the supplier to
increase the lid/cover sheet metal thickness or modify the
design (whatever necessary to meet the loading
requirements)

Take note that this is a performance specification

requirement and the acceptance of the product is subject to
the passing of the loading requirements stated below.

.2 Concentrated load not less than 4.5 kN/300mm² and

not less than 3.0 kN/25mm²

The test loads shall be applied for 24 hour duration.

The maximum deflection shall NOT exceed 2mm for these

loadings.

2.5 UNDER FLOOR TRUNKING SYSTEM

.1 General

.1 The under floor trunking system shall be suitable for use in the
distribution of power, telephone and data services within concrete
or floor screeds and finishes in accordance with the layouts shown
in the Drawings and as specified herein.

.2 The under floor trunking system supplied shall be from a

proprietary system complete with all necessary trunking, junction
boxes, service outlet boxes, service outlets accessories, plates,
vertical access boxes, pedestal outlet boxes, outlets boxes, duct
outlets, fly over units, radius bends, jointing sleeves, fixing clips
and all other accessories necessaries to bring about a complete
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working system. The method of installation of the under floor

trunking system shall comply to the manufacture’s instructions and
shall be as appropriate for cast-in-situ system or floor screed
systems. The type of system i.e. cast-in-situ or floor screed shall
be as shown in the drawing.

.2 Under floor Ducting

.1 Under floor ducting shall be constructed from pre-galvanized

sheet steel with thickness not less than 1.6mm. The top and
bottom plates shall be double folded and spot welded together to
the full height of the ducting. Metal jointing sleeves with locking
screws for grounding purposed must be provided.

.3 Junction Box and Service Outlet Box

.1 Appropriate size floor junction and outlet boxes be provided and

installed for various floor trunking as required. All boxes shall be
installed flush with the various floor finishes.

.2 All junction and outlet boxes shall be equipped with appropriate

cover plates, which will matched with the floor, wall or column
finishes. The Contractor shall verify the exact depth of floor
finishes and required height of the junction boxes on site and shall
coordinate with the works of interior floor finishes.

.4 Junction Box

.1 The junction boxes shall be flushed with the final finished floor
level and the junction box base frame and pillar supports shall be
manufactured of zinc alloy die-cast in one piece to give the base
unit the mechanical strength. The junction box lid and metal fly
over shall be zinc alloy die-cast heavy load bearing materials. The
trap cover with 6mm recess, suitable for vinyl tile, ear par or
ceramic tile floor finish, shall be installed for the junction box. The
junction box shall be provided with overlapping flanges for
securing onto the floor slab, and flyovers for segregation of
intersecting cables. Knockout trunking outlets trap cover
supported by the frame and height adjustable pillar screws shall
be provided with neoprene rubber gaskets to prevent noise and
ingress of moisture and dust.

2.6 SERVICE OUTLET BOX

.1 The service outlet boxes frame and cover shall be manufactured of zinc
alloy die-cast heavy load bearing materials and the base frame and pillar
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support shall be zinc alloy die-cast in one piece, complying with BS EN

1774:1998 AND BS EN 12844:1999.

.2 The trap lifting handle shall be retractable into the trap cover without the
need of cutting the floor finish materials and it shall not protrude from the
trap cover. The lid, frame and accessories plate shall be epoxy coated for
protection and against corrosion.

.3 The junction boxes and concealed outlet floor boxes shall be supplied
with disposable screeding lids, so that the traps will not be covered with
cement or concrete during screeding or casting of concrete and the traps
shall only be installed after screeding and/or casting.

.4 Generally the service outlet box shall be supplied with multiple lids for 2
compartments service outlets and 1 lid for 3 compartment service outlet.

3.0 EXECUTION

3.1 INSTALLATION OF CONDUIT, TRUNKING, TRAY AND LADDER

.1 General

.1 Rigid conduits, trunking, trays and ladders shall be run truly vertical,
horizontal or parallel with the features of the building and in accordance
with BS 7671. The Contractor shall be responsible for coordinating the
routing with other specification Divisions.

.2 Galvanised coating damaged by excessively rough treatment during

transit and erection shall be renovated using at least two coats of good
quality zinc-rich paint complying to BS 4652.

.3 The maximum size of damaged area for which such repairs is acceptable
shall be in compliance with BS EN ISO-1461:1999.

.2 Conduit Installation

.1 Conduits shall be concealed where possible by laying in the concrete

slabs or screeds of floors or chases in walls which are to be plastered or
panelled, or in ceiling voids or in concrete or services ducts.

.2 Conduits buried in concrete shall be securely fixed to prevent

displacement and shall have 40mm depth of cover over its entire length.
Conduits buried in plaster shall be securely fixed and shall have 6mm
depth of cover over its entire length.
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.3 Conduits shall not be laid across expansion joints and where these occur
in the run of a line of conduits, the conduits shall be brought below the
expansion joint and a length of flexible conduit installed, sufficient to allow
for a total movement of +/-10mm.

.4 Where conduits buried in concrete crosses the expansion joint in the

concrete it shall be wrapped with waterproof building paper or half lapped
PVC self adhesive tape for a distance of 300mm on each side of the
joints.

.5 The cut section shall be renovated using at least two coats of good quality
zinc-rich paint complying with BS 4652.

.6 Inspection type elbows, bends or tees shall only be used with the written
consent of the Employer's Representative.

.7 A draw-in box shall be provided in all conduit runs exceeding 9 meter in

length or containing more than two right angle bends or the equivalent.

.8 Conduits shall be supported with saddle at regular intervals not exceeding

1200mm on horizontal runs and 1500mm on vertical runs.

.9 Conduit boxes shall be fixed to the structure of the building independently

of the conduits.

.10 The length of thread on the ends of the conduits shall suit the length of
internal thread in the end of the fitting accessory. Excess length of thread
shall not be permitted.

.11 Spanners or purpose made tools shall be used to tighten hexagonal

bushes. Pliers and toothed wrenches shall not be used.

.12 Conduits shall be so arranged that it is impossible for water to lodge at

any point. Where this is not practical drain holes 3mm diameter shall be
drilled at the lowest points in the conduit runs or boxes.

.13 Conduit runs on the surfaces of buildings or ducts shall be fixed by means
of saddles and with colour band, unless otherwise specified.

.14 Three piece conduit unions should be used. At the discretion of the
Employer's Representative, running couplings with hexagonal locknuts
may be used, the exposed threads being given a coat of zinc paint.

.15 Conduit terminating at boxes, trunking or accessories not provided with

spout or tapped entries shall be made mechanically by means of a
flanged coupler and bush with male thread. Exposed conduit threads
shall be given a coat of zinc paint.
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.16 All free ends of conduits shall be fitted with approved bushes.

.17 Conduits to all motors, with drawable or removable items of equipment,

and all items of equipment where vibration may reasonably be expected,
shall be of flexible type.

.18 The ends of flexible conduits shall be connected to the fixed conduit
system and the equipment by means of approved adaptors. A stranded
copper earth wire of section complying with BS 7671 shall be run
internally between motor and starter and connected in an approved
manner.

.3 Trunking Installation

.1 Trunking shall be run neatly on the surface of the building and at least
150mm clear of plumbing and mechanical services.

.2 Manufacturer's standard fittings shall be used. Trunking joiners shall be

used to connect trunking to each other. They shall be fixed by flathead
screws without drilling of holes.

.3 The practice of cutting and bending the material of the trunking to form
attachments shall not be accepted.

.4 Connections between trunking and apparatus shall be by a screwed

coupler and bush or a standard flanged coupling or an adaptor neck,
fabricated or cast. Direct attachment of trunking to apparatus will only be
permitted if cable entries are provided with smooth bore bushes or
grommets and the return edge of the lid of the trunking is left intact.

.5 Conduit connectors shall be used to connect conduits to the trunking.

Holes shall not be punched or drilled into the trunking for conduit
connection.

.6 Trunking supported by hangers shall be provided with a proprietary-make

hanger system.

.4 Cable Tray and Cable Ladder Installation

.1 Cable trays and cable ladders shall not be cut at site. Instead, they shall
be supplied in different lengths from the factory for assembly at site.

.2 Splice connector plates shall be located according to manufacturer's

recommendation. Where necessary the trays or ladders shall be cut at
site to suit splice locations.
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.3 The splice connector plates shall be located outside of tray side rails.
The adjacent tray or ladder sections shall be bolted using nuts and
washers, on the outer side of the tray. The torque nuts used shall be to
manufacturer's specified value.

.4 Expansion splices shall be positioned properly with the connector

fasteners securely locked to permit the tray or ladder to expand and
contract freely.

.5 Trays and ladders shall be securely anchored to supports. They shall be

secured such that the tray or ladder system will not move during cable
installation.

.6 Holes shall be punched or drilled in the side rails or troughs only as

needed for splicing of sections cut at site.

.7 Where cables are to be installed across dividers, divider strip protectors

shall be installed. Where cables are to pass over the tray edge, a sheath
edge with compassable material similar to the cable sheath shall be
installed.

.8 Holes for attachment of conduit to blind end-plates shall be punched at

site.

.9 All trays damaged during installation or cable pulling shall be restored to

new condition or replaced.

.10 Cable trays and ladders shall be installed above piping and other
obstructions to meet the required headroom. The minimum clearance
from the top of the tray side rails shall be 300mm.

.11 The side of the cable tray facing the wall shall have a clearance as per
manufacturer's recommendation. The other side of the cable tray shall
have a minimum clearance of 100 mm.

• Bends, elbow, hinged splices, etc. shall be proprietary and shall not be
fabricated at site.

3.2 INSTALLATION OF CABLE TRAY AND CABLE LADDER SUPPORTS

 CONDUIT RACEWAY TRUNKING CABLE TRAY AND CABLE LADDER
SECTION 18005

PAGE 16

.1 Horizontal and vertical supports shall provide at least 30mm bearing length from
each rail and shall have provisions for hold-down clamps and fasteners.

.2 The side rail shall bear on the support. Where necessary, shims shall be used to
elevate the trays or ladders and provide bottom clearance to the supports. The
trays or ladders shall not bear on the support.

.3 Vertical straight lengths shall be supported by wall mounted supported brackets

at intervals as dictated by building structure but this shall not exceed 1 metre.

.4 Horizontal trays and ladders shall be supported by either wall mounted support
brackets or hanger rod system. The intervals between support shall be as
recommended by the manufacturer but this shall not exceed 1 metre for wall
mounted support brackets and 1.2 metres for hanger rod system.

.5 The hanger rods shall be positioned and installed according to the

manufacturer's recommendation. The selection of the rod size shall be
determined based on the total loading of the support system. The Contractor
shall be required to submit technical calculation to justify the structural integrity of
the support requirement on cable trays and ladders.

.6 Sloping trays and ladders shall be supported at intervals not exceeding those
used for the horizontal trays and ladders of the same design.

.7 Cable tray supports shall be installed at each cable-drop-out.

.8 Cables shall be supported by proprietary make hanger system and cable clamps
on the cable tray and ladder. Cable straps are not acceptable in this Contract.

3.3 INSTALLATION OF CABLE TRAY AND LADDER SPLICE CONNECTORS

.1 Splice connectors shall be located as recommended by the manufacturer.

.2 Splice connectors shall be attached by round head bolts with nuts and washers
located on the outside of the tray or ladder.

.3 Thermal expansion splices shall be installed wherever expansion joints occur.

• Where space constraint demands, reducer plates shall be required. The

structural straight and deflection of the tray shall be mentioned using a
supplementary permanent framing.

3.4 INSTALLATION OF CABLE EXITS FROM CABLE TRAY AND LADDER

 CONDUIT RACEWAY TRUNKING CABLE TRAY AND CABLE LADDER
SECTION 18005

PAGE 17

.1 Conduits shall be attached to the side rail with conduit clamps and brackets.
Holes shall not be made in side rail for conduit attachment.

.2 The minimum bending radius of cables exit from trays or ladders shall be
maintained using drop-out plates, vertical riser elbow fittings, or other
accessories designed to control bending.

.3 Cable tray and ladders edges and flanges at locations of cable exit from trays
shall be suitably sheathed to prevent injury to cable insulation.

3.5 INSTALLATION OF CABLE TRAY AND LADDER DIVIDER STRIPS

.1 These divider strips shall be installed where different system wiring is installed in
a common tray or where shown in the design drawings.

.2 Divider strips shall be anchored to every ladder rung using fasteners, which
attach to the tray without the need for drilling or punching at site.

.3 The fastener shall attach to the tray without the need for any drilling or punching
of hole at site. The fasteners shall also present minimum exposure to the cables
by having rounded exposed parts.

3.6 INSTALLATION OF FIRE BARRIERS AND FIRE PROOF ENCLOSURE

.1 Fire stop seals shall be provided where cable raceways, trays or ladders pass
through floors or walls.

.2 Fire stop installation shall be as specified in Section 16190: FIRESTOPS.

.3 For cable ladders and cable trays passing through the floor slabs and walls, the
installation of fire stop shall only be carried out after the utility or services
provider has completed their cabling installation works.

3.7 EARTHING

.1 All cable trays, ladders and interconnecting trunking and conduit shall be earthed
as described in the earlier paragraphs.

.2 Earth links shall be used to electrically interconnect joined sections of the cable
trunking, cable tray and cable ladder system. The resistance measured between
adjacent sections shall not exceed 0.01 Ohms.

3.8 PACKING, TRANSPORT, HANDLING, DELIVERY AND STORAGE AT SITE

.1 Conduits, trunkings, trays, ladders, fittings and accessories shall be separately

packed and delivered in approximately labelled packing in accordance with the
 CONDUIT RACEWAY TRUNKING CABLE TRAY AND CABLE LADDER
SECTION 18005

PAGE 18

manufacturer's recommendations. All articles shall be securely packed to

prevent any movement and damage during transport. To avoid wet storage
staining, transportation of galvanised articles shall avoid damp and/or badly
ventilated conditions.
.2 Manufacturer shall provide information for unpacking and safe handling
of articles.

.3 On arrival at site, the consignment shall be checked against the delivery notes.

.4 On delivery to site, the products shall be stored indoor, in a clean, dry and well
ventilated place. Galvanised articles shall not be stored on clinkers or ashes.

3.9 TESTS

.1 Type Tests

.1 Type tests shall be carried out on conduits, fittings and components as

recommended in MS 275. This shall include: -

.1 Test for durability of markings

.2 Test of mechanical properties

.3 Test for resistance to corrosion

.4 Requirements for the efficiency of the conduit/fitting conducting

path

.5 Test for malleable cast iron fittings

.2 Type tests shall be carried out on trunking as recommended in BS 4678.

This shall include: -

.1 Test for durability of markings

.2 Test for knockouts

.3 Test for resistance to corrosion

.4 Electrical continuity test

.3 Cable trays and ladders shall be type-tested to NEMA VE1 standard as

follows: -
.1 VE 1-3.01 Destruction load test
.2 VE 1-3.02 Deflection test
.3 VE 1-3.03 Electrical continuity of connections
 CONDUIT RACEWAY TRUNKING CABLE TRAY AND CABLE LADDER
SECTION 18005

PAGE 19

.4 Provide complete type test reports

.2 Acceptance Tests at Manufacturer’s Works

.1 Conduits, ‘raceway’ trunkings, cable trays, cable ladders, their fittings and
accessories and fire resisting trunking shall be subjected to the following:
-

.1 Visual inspection

.1 Correct types of conduits, trunkings, trays and ladders

.2 Correct markings

.3 Dimension checks

.4 Damage on conduits, trunkings, trays and ladders

.5 Damage on galvanising

.6 Material and accessories are proprietary type

.2 Inspection and testing of galvanising for compliance with BS EN

ISO-1461:1999

.1 Determination of coating weight

.2 Uniformity of coating

.3 Deflection tests

.4 Electrical continuity of connection tests

.2 Provide complete acceptance test reports

.3 The manufacturer test shall be verified and witnessed by the Employer

Representative’s and his representatives.

.3 Inspection and Testing at Site

.1 Upon delivery to site, check the condition as follows: -

 CONDUIT RACEWAY TRUNKING CABLE TRAY AND CABLE LADDER
SECTION 18005

PAGE 20

.1 Damage on conduits, trunkings, cable trays, ladders and their

fittings.

.2 Damage on galvanising.

.3 Material and accessories are proprietary type.

.4 Store indoor.

.2 Repair/replacement of damaged products and renovation of damaged

galvanised coating areas.
.3 At completion of installation, visual inspection and verification of: -

.1 Correctness of location and mounting

.2 Labelling and markings

.3 Damage on conduits, trunkings, cable trays, ladders and fittings

.4 Damage on galvanising

.5 Earthing of metal conduit, trays and ladder system

.4 At completion of installation carry out electrical continuity test to the

manufacturer's recommendation.

3.10 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Review O&M documentation and test results.

3.11 HANDING-OVER AND EMPLOYER’S ACCEPTANCE

.1 Endorse defects list.

END OF SECTION
 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Manufacture, test at Works, deliver to site, install, test and commission the
following for low voltage cables in accordance with the Contract Documents: -

.1 600/1000V fire-resistance mineral-insulated and low smoke halogen free

(LSH) cables.

.2 600/1000V XLPE/AWA/PVC cables

.3 600/1000V XLPE/SWA/PVC cables

.4 600/1000V PVC/AWA/PVC cables

.5 600/1000V PVC/SWA/PVC cables

.6 600/1000V PVC/PVC cables

.7 600/1000V PVC cables

.8 600/1000V XLPE/PVC cables

.9 450/750V PVC cables

1.2 WORK INCLUDED

.1 Single-core 600/1000V fire resistant mineral-insulated and low smoke halogen

free (LSH) cables.

.2 Single-core 600/1000V XLPE/AWA/PVC cables

.3 Multi-core 600/1000V XLPE/SWA/PVC cables

.4 Single-core 600/1000V PVC/AWA/PVC cable

.5 Multi-core 600/1000V PVC/SWA/PVC cables

.6 Single-core 600/1000V PVC/PVC cables

.7 Multi-core 600/1000V PVC/PVC cables

.8 Single-core 600/1000V PVC cables

.9 Multi-core 600/1000V PVC cables

 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 2

.10 Single-core 600/1000V XLPE/PVC cables

.11 Multi-core 600/1000V XLPE/PVC cables

.12 Single core 450/750V PVC cables

.13 Connectors and Terminations

1.3 SUBMITTALS

.1 Tender stage

.1 Manufacturer's catalogue, and specifications for cable and terminations

.2 Letter of approval from local authority for fire resistant cables

• Where appropriate, for imported cables, letter of approval from local

authority for importation of cable.

.4 Type test certificates on fire resistance and halogen free content from
internationally recognised independent testing laboratory.

.2 Construction Stage

.1 To repeat the above tender stage submission.

.2 Construction drawings of cables and terminations

.3 Catalogues and samples of cables and accessories

.4 Cable rating tables, temperature, group derating factors, DC and AC

resistance, reactance, weight, dimensions, minimum bending radius and
etc.

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance test

.2 Acceptance test reports after test

.3 Packaging, transportation and storage notes

.4 Site Installation
 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 3

.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.5 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Standards to Comply

Except as modified by the Contract Documents, comply with the latest applicable
provisions and latest recommendations of the following:

.1 IEC 60228 Conductors of Insulated Cables

.2 IEC 60287 Calculation of the Continuous Current Rating

.3 IEC 60331 Tests on Electric Cables Under Fire Conditions

.4 IEC 60332 Tests on Electric Cables Under Fire Conditions

.5 IEC 60446 Identification of Conductors by Colours or

Numerals

.6 IEC 60502 Power Cable with Extruded Insulation and their

Accessories for Rated Voltages from 1 kV up to
30 kV

.7 IEC 60754 Test on Gases Evolved During Combustion of

Electric Cables

.8 IEC 60811 Common Test Methods for Insulating and

Sheathing Materials of Electrical Cables

.9 IEC 60885 Electrical Test Methods for Electric Cables

 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 4

.10 IEC 61034 Measurement of Smoke Density of Cables Burning

Under Defined Conditions

.11 BS 6004 Specification for PVC insulated cables (non-

armoured) for electric power and lighting

.12 BS 6346 Electrical Cable, PVC Insulated, Armoured Cables

for Voltages of 600/1000V and1900/3300V

.13 BS 6387 Specification for Performance Requirements for

Cables Required to Maintain Circuit Integrity Under
Fire Conditions.

.14 BS 7671 Requirements for Electrical Installations

.15 BS 7846 Electrical Cables 600/1000V Armoured Fire

Resistant Cables having Thermosetting Insulation
and Low Emission of Smoke and Corrosive Gases
when Affected by Fire

.16 BS EN 10244 Steel Wire and Wire Products. Non-Ferrous Metallic -

2:2001 C oatings on Steel Wire. Zinc or Zinc Alloy Coatings

.17 BS EN 10257 Zinc or Zinc Alloy Coated Non-Alloy Steel Wire for
-1:1998 Arranging either Power Cables or
Telecommunication Cables. Land Cables

.2 Manufacturing Experience

.1 Manufacturer shall have at least 10 years experience in the manufacture

of 600/1000V cables of similar construction.

2.0 PRODUCT

.1 600/1000V Non fire resistant cables

.1 All cables for the internal wiring distribution of the building, including the
external underground cable distribution submain, shall be supplied and
installed by the Contractor.
 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 5

.2 External cables shall be of the multi-core XLPE/SWA/PVC and/or

PVC/SWA/PVC as detailed in the tender drawings. All electric cables
supplied by the Contractor for the Contract works shall be provided with
high-conductivity multiple stranded annealed copper conductors.

.3 The insulation shall be XLPE compound complying with IEC 60502 or

PVC compound with the insulation thickness complying with the above
Standards.

.4 Core identification for power cable shall be made by means of a coloured

insulation. The 3-core and 4-core cables shall be coloured red-yellow-
blue and red-yellow-blue-black, respectively.

.5 For multi-core cable, an inner covering of suitable material is to be

extruded over the laid-up cores with the interstices substantially filled up
by the either PVC, PE or XLPE fillers so that the complete assembly is
formed into a circular shape. The direction of the cores shall be right
handed. A binder tape shall be applied over the circular assembly.

.6 For control cables having more than seven (7) cores, the direction of lay
shall alternate for each successive layer.

.7 For multi-core cable, sheath or bedding shall be applied over the laid up
cores. It shall be compatible with the operating temperature of the cable
and the thickness shall comply with IEC 60502.

.8 Metallic Armour (where specified) shall consist of hot or cold rolled

commercial quality, galvanized steel tested in wires compliance with BS
EN 10244-2:2001. For single core cable, non-magnetic material e.g.
aluminium shall be used. The armour shall be able to withstand the
normal electromechanical stresses expected in cable installation and
during services.

.9 The cable shall be provided with an extruded, continuous black PVC

compound outer sheath treated with repellent and shall be compatible
with the operating temperature of the cable. The thickness of the outer
sheath shall comply with IEC 60502.

.10 The outer sheath of large cables shall be impressed or embossed with
the rated cable voltage, cable size, year of manufacture and name of
manufacturer.

.11 For 1.5mm2, 2.5mm2, 4 mm2 and 6 mm2 PVC insulated cable used for
final sub-circuits (lighting, 13A switched socket outlets and others loads
from distribution board), compliance to BS6004.
 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 6

.12 For 10 mm2, 16 mm2 and 25 mm2 2core or 4core PVC/PVC insulated
cable used for sub-main, compliance to BS 6346, unless otherwise
specified in drawing.

.13 For 25 mm2 and 35 mm2 2core or 4core XLPE/PVC insulated cable used
for sub-main, unless otherwise specified in drawing, compliance to BS
6346. For 50 mm2 and above 1core XLPE/PVC insulated cable used for
sub-main, compliance to BS 6346.

.2 600/1000V Fire resistant mineral-insulated and low smoke halogen free cable

.1 All single and multi-core double insulated fire resistant cables shall
comply to standard BS6387, 1994 Category CWZ with extension of
600/1000V test, IEC 60331 and IEC 60332 part 1, IEC 60332 part 3
Category A, B and C, IEC 61034 and free from halogen acid gases when
tested in accordance with IEC 60754-2.

.2 The cables shall be rated at 600/1000V. The thickness shall comply with
IEC 60502. A gas mica fire resistance tape shall apply over the conductor
to meet the fire resistance test requirement. The sheath shall be a robust
extruded mineral insulated low smoke halogen free type complies with
IEC 60754-2.

.3 All fire resistant cables shall be installed strictly in accordance with the
manufacturer’s recommendation. Cables shall be laid in straight and neat
manner. Clipping of the cables to the trays and cable ladders shall be
done in accordance to the manufacturer’s recommendation and with
metal galvanized type clips/straps/clamps. When single cored cables are
used, the cables shall be laid in three-phase group. Whenever bending of
the cable is required the work shall be done in strict accordance to the
cable manufacturer’s instruction. Cable bending radius shall be restricted
to a minimum of 6 times the cable diameter for single core cable and
multi-core cable during installation.

.4 The cable conductors shall consists of stranded plain annealed copper in

circular construction. For multi-core, Core shall be identified by coloured
insulation such as Red-Yellow-Blue-Black, 7 to 37 cores, which shall be
identified by printed number on a white core. The sheath colour shall be
in orange colour for identification.

.5 The certification of fire resistance cable shall include different range of

cable sizes from 1mm sq to 630mm sq for single core and 1mm sq to
16mm sq for multi-core in accordance to BS6387 CWZ, IEC 60331 and
IEC 60754-2.

.6 Where specified, armoured cable shall consist of a single layer of

galvanized steel wires complying with BS7846.
 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 7

.7 All fire resistant cables shall comply with local authority requirements in
all respects. All relevant test Certificates shall be from an internationally
recognised independent testing laboratory.

.3 PVC/SWA/PVC

.1 Power and control cables specified as PVC insulated and sheathed,

galvanised steel wire armoured cable with an overall PVC sheath are
hereinafter referred to as PVC/SWA/PVC and shall be manufactured and
tested to BS 6346.

.2 The cores of PVC/SWA/PVC cables shall be laid up to form a circular cable

and, their fillers are necessary for this purpose, they shall be of PVC.
Textile or other hygroscopic fillers are prohibited.

.3 The insulation shall comply to PVC compound Type TI 1.

.4 There shall be no adhesion between bedding or sheath and insulation. A

polyethylene therephthalate (PTP) binder tape over the laid up cores may
be included at the manufacturer's discretion.

.5 The armour bedding shall consist of an extruded layer PVC compound.

The radial thickness shall be in accordance with BS 6346.

.6 Armour shall consist of galvanised steel wires applied generally in

accordance with the requirements of BS 6346. Galvanising shall meet the
requirements of BS EN 10257-1:1998.

.7 The outer covering over the armour wires for all multicore control cables
shall consist of a black extruded PVC sheath, which shall comply to PVC
compound Type TM 1. The thickness shall be in accordance with BS
6346.

.8 Control cables shall be made up of the following standard numbers of

cores: 4, 7, 12, 27 and 37. All cores shall be coloured white and shall be
identified by black numbers arranged in sequence. The numbers shall be
lightly imprinted on the core insulation at intervals of not more than 75mm
throughout the core length. They shall be permanent in nature and not
easily removed without severe mechanical scrapping.

.9 All PVC/SWA/PVC cables shall be terminated with mechanical glands of a

type, which shall provide adequate mechanical support by positive locking
on the armour and shall at the same time give a high level of earth
 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 8

continuity. The glands shall be provided with earth tails for connection to
earth conductors and PVC shrouds.

3.0 EXECUTION

3.1 CABLE SEALING AND DRUMMING

.1 Immediately after the Works Tests seal both ends of each cable length against
the ingress of moisture, dirt and insects and protect the end projecting from the
drum against mechanical damage during handling and transit. For large size
cables and long lengths where drumming is necessary, the ends of the cable
shall be marked 'A' and 'Z' as appropriate. Each drum shall bear a distinguishing
number either printed on one flange or printed on a nameplate and attached to
the flange. Particulars of the cable i.e. voltage, circuit label, length, cable type,
conductor size, conductor material, number of cores, gross and nett weights etc.
shall be clearly shown on one flange of the drum. The direction of rolling shall be
conspicuously indicated by an arrow. Small size cables shall be coiled.

.2 The preferred lengths should be such that no joint shall be made on each cable
circuit.

3.2 CABLE INSTALLATION

.1 Install cable complying with BS 7671.

.2 Install cable on cable trays in appropriate spacing and allow for bending radius
larger than the minimum recommended by manufacturer. Where single-core
cables are used, in three-phase supplies, the three phase cables shall be laid in
trefoil.

.3 No joints are allowed.

.4 Do not expose cut cable ends but seal them until cable termination is made.

.5 After cable is pulled install cable on the cable tray immediately before pulling the
next cable.

.6 Cable Tensions: Do not exceed manufacturer's recommended cable tensions

during cable installation especially when cable is run vertically.

.7 Install cable as recommended by manufacturer of cable.

.8 Earth cable armour and sheaths near all terminals according to manufacturer's
recommendations.
 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 9

.9 Use metal typed cable cleats/fasteners at 1m intervals.

.10 Fire-seal around all cables at all penetrations of fire-rated walls and floors to
maintain fire rating.

.11 Appropriate colour sleeving shall be provided for all LV cables entering and
exiting the electrical risers before cable termination.

3.3 TERMINATIONS AND JOINTING

.1 Make all terminations in accordance with manufacturer's recommendations.

3.4 TESTS

.1 Type Tests

.1 Perform relevant type tests recommended in the IEC. In lieu of actually

carrying out type tests, type test reports certified by acceptable testing
authorities may be submitted for approval of the Employer's
Representative.

.2 Routine Tests

.1 Carry out at works all relevant routine tests in the IEC and provide routine
test report for all cables supplied.

.3 Acceptance Tests at Manufacturer's Works

.1 Cut one 15 metre long cable sample of the largest cross section from the
completed cables and subject it to the following tests: -

.1 Dimension checks

.2 Insulation resistance tests to IEC 60502

.3 Conductor resistance test to IEC 60228

.4 High Voltage test to IEC 60885-1

.5 Visual inspection and measurement of insulation thickness and

extruded covering to IEC 60502

.6 Where relevant, flame retardant test to IEC 60332

 6001000V PVC SHEATED CABLES
SECTION 18006

PAGE 10

.7 Where relevant, flame resistance test to IEC 60331

.2 A complete report of the above tests shall be provided.

.3 The manufacturer test shall be verified and witnessed by the Employer

Representative’s and his representatives.

.4 Site Tests

.1 The following tests shall be performed on each complete circuit of cable: -

.1 Insulation resistance test to IEC 60502

.2 A complete report of the above tests shall be provided.

3.5 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Review O&M Documentation and Test Results.

3.6 HANDING-OVER AND EMPLOYER’S ACCEPTANCE

.1 Endorse defects list.

END OF SECTION
 11/6.35KV XLPESWAPVC CABLE
SECTION 18007

PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Manufacture, test at works, deliver to site, install, test and commission 3-core
11/6.35kV XLPE/SWA/PVC cable for high voltage feeder circuits in accordance with
the Contract Documents.

1.2 WORK INCLUDED

.1 3-core 11/6.35kV XLPE/SWA/PVC cables

.2 Joints and Terminations

1.3 SUBMITTALS

.1 Tender Stage

.1 Manufacturer's catalogue drawings and specifi-cations for

cable, jointing kits and termination. Cable manufactur-er's recommendation for
jointing kits and terminations.

.2 Type test certificates for the cables, cable

termination and jointing accessories from an internationally recognised
independent testing laboratory.

.3 Submit certificate of qualified personnel for cable terminations / jointing works.

.2 Construction Stage

.1 To repeat the above tender stage submission.

.2 Construction drawings of cables, joints and terminations,

catalogues and samples of cables and accessories.

.3 Calculations of cable ratings, cable rating tables, temperature

and group derating factors, DC & AC resistance, reactance, weight, dimension,
and permissible bending radius and side-wall pressures.

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance test.

.2 Acceptance test report after testing

 11/6.35KV XLPESWAPVC CABLE
SECTION 18007

PAGE 2

.3 Packaging, transportation and storage notes.

.4 Site Installation

.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.5 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Standards to Comply

.1 Except as modified by the Con-tract Documents, comply with the latest

applicable provisions and latest recommendations of the fol-lowing:

.1 IEC 60228 Conductors of Insulated Cables

.2 IEC 60287 Calculation of the Continuous

Current Rating

.3 IEC 60332 Tests on Electric Cables Under Fire

Conditions

.4 IEC 60502 Power Cable with Extruded Insulation and

their Accessories for Rated Voltages from
1 kV up to 30 kV

.5 IEC 60754 Test on Gases Evolved During

Combustion of Electric Cables
 11/6.35KV XLPESWAPVC CABLE
SECTION 18007

PAGE 3

.6 IEC 60811 Common Test Methods for Insulating and

Sheathing Materials of Electric Cables.

.7 IEC 60885 Electrical Test Methods for Electric Cables

.8 BS EN 10244 Steel Wire and Wire Products. Non--2:2001

Ferrous Metallic Coatings on Steel Wire. Zinc
or Zinc Alloy Coatings

.9 BS EN 10257 Zinc or Zinc Alloy coated Non-Alloy -1:1998

Steel Wire for Arranging either
Power Cables or Telecommunication
Cables. Land Cables.

.10 BS 6622 Cables with Extruded Cross-Linked

Polyethylene or Ethylene Propylene
Rubber Insulation for Rated Voltages
from 3.8/6.6kV up to 19/33kV

.2 Skilled Labour

.1 Personnel performing terminations and joints shall be qualified, having

minimum 5years experience with 3-core 11/6.35kV XLPE cables.

.3 Manufacturer's Experience

.1 Manufacturer shall have at least 10 years experience in the manufacture

of 11/6.35kV XLPE cables of similar construction.

2.0 PRODUCTS

2.1 CONTINUOUS CURRENT

.1 Calculation of the continuous current rating of the cables shall be made according to
IEC 60287. Derating tables specifically for this installation method and cable
construction shall be provided by the manufacturer.

2.2 JOINTS AND TERMINATIONS

.1 Thermo-Kit Heat-Shrinkable Termination

.1 Provide thermo-kit heat-shrinkable termination.

 11/6.35KV XLPESWAPVC CABLE
SECTION 18007

PAGE 4

.2 Methods and materials shall be as recommended by cable manufacturer

for particular application.

2.3 DESIGN OF CABLE

.1 General

.1 Cable shall be a 3-core right hand lay cross-linked

polyethylene insulated cable, manufactured in accordance with IEC
60502.

.2 Conductors

.1 Conductors shall consist of stranded annealed copper wires in circular

compact construction, complying with IEC 60228.

.3 Conductor Screen

.1 The conductor screen shall consist of a layer of extruded cross-linked

semi-conducting compound(non-metallic in nature) applied over the
conductor. Material compatible with the conductor and insulation materials
shall be used. The screen shall be bonded to the insulation such that no
voids or discontinuities are present. The bond shall be capable of
withstanding electrical and mechanical stresses in service without
degradation or separation.

.4 Insulation

.1 The insulation shall be cross-linked polyethylene (XLPE) extruded in one

operation with the conductor and insulation screens.

.2 The highest possible purity of insulation material shall be used. Adequate

precautions must be taken to remove contaminants and to eliminate the
introduction of particles or contaminants during material handling of the
extrusion process.The cross linking process used shall be a dry
curing process and suitable for the maintenance of consistent
performance over a long life of the cable. The highest manufacturing
standard shall be used in the cross-linking process.

.3 The insulation thickness shall comply with IEC 60502.

.5 Insulation Screen

.1 A non-metallic semi-conducting part in combination with a metallic part

forms the insulation screen. The non-metallic part shall consist of semi-
conducting cross-linked compound extruded onto the cable insulation.
The non-metallic layer shall be readily strippable without the need for
 11/6.35KV XLPESWAPVC CABLE
SECTION 18007

PAGE 5

special tools or heat. The semi-conducting screen shall be triplex extruded

at the same stage as the conductor screen and insulation.

.2 The metallic part shall be applied directly over the semi-conducting part
and comprise annealed high conductivity copper tapes or concentric
layer of wires.

.6 Core Identification

.1 A coloured or letters printed on the semi-conducting tape of

the insulation screen as core identification shall be
provided.

.7 Cable Lay Up, Filler and Binder Tape

.1 An inner covering of suitable material shall be extruded over the laid-up

cores with the interstices substantially filled up by PVC, PE or XLPE fillers
so that the complete assembly is formed into a circular shape.The direction
of the cores shall be right-handed. A binder tape shall be applied over the
circular assembly.

.8 Inner Sheath (Bedding)

.1 A sheath or bedding shall be applied over the laid up cores. It may have
low smoke and low halogen emission characteristics and shall be
compatible with the operating temperature of the cable. The thickness
shall comply with IEC 60502.

.9 Metallic Armour

.1 The armour shall consist of hot or cold rolled commercial quality,

galvanised steel wires tested in compliance with BS EN 10244-2:2001. The
armour shall be able to withstand the normal electromechanical stresses
expected in cable installation and during service.

.2 The armour shall normally consist of two layers of steel tape, or

one or two layers of galvanized steel wire. For cables having
nominal diameter over the lead or lead alloy sheath not exceeding
12mm the armour shall consist of galvanized steel wire.

.10 Double Steel Tape Armour

.1 The steel tape shall have a tensile strength in the range of

300MN/m2. The thickness of the steel tape shall be in accordance
with the appropriate table with a tolerance of 10%.
 11/6.35KV XLPESWAPVC CABLE
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.2 Joints in steel tape shall be welded and surface irregularities

removed to give a smooth finish.

.3 The tape shall be coated on both sides with a preservative compound

before being applied to the cable. The two layers shall be laid on helically
with a left-hand lay so that the outer taper is approximately central over
the gap of the inner tape. The gap between adjacent turns of each tape
shall not exceed 50% of the width of the tape. The outer tape shall
overlap the inner tape on both sides by not less than 15% of the tape
width.

.11 Single-Wire Armour

.1 The armour shall normally consist of a single layer of galvanized steel

wires of the size specified in the appropriate table. The galvanized
steel wire shall comply with BS EN 10257-1:1998. Where joints in
armour wire are necessary, they shall be brazed or welded and any
surface irregularity shall be removed. A joint in any wire shall be not
less than 1 meter from the nearest joint in any other armour wire in the
completed cable. The direction of lay of the armour shall be left- hand.

.12 Double-Wire Armour

.1 When required by the purchaser, a double layer of armour wires shall be

provided. The size of wire used for both layers shall be the same as that
for single-wire armoured cable specified in the appropriate table. The
direction of lay of the inner layer of armour shall be left-hand. The
direction of lay of the outer layer of armour shall be right-hand except in
special cases when by agreement between the purchaser and the
manufacturer, it may be left-hand.

.2 There shall be a separator consisting of a layer of suitable compounded

fibrous material between the two layers of armour.

.13 Outer Sheath

.1 The cable shall be provided with an extruded, continuous

and flexible orange colour waterproof PVC sheath
treated with termite repellent. It shall have low smoke and low
halogen emission characteristics and shall be compatible
with the operating temperature of the cable. The thickness
of the outer sheath shall comply with IEC 60502.
 11/6.35KV XLPESWAPVC CABLE
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PAGE 7

.2 The outer sheath shall be impressed or embossed with the

rated cable voltage, cable size, year of manufacture and
name of manufacturer at 300mm intervals.

2.4 TERMINATION AND JOINTING ACCESSORIES

.1 Supply and deliver factory manufactured terminations, joints and their materials
and tools for the complete installation of the cable.

.2 Materials for termination and jointing shall be supplied complete in separate

packages. Each package shall have all the materials necessary for the completion
of a termination, with a list of the materials contained in it as well as their quantity.

.3 Instruction manuals for the termination and jointing shall be provided. Step by step
instructions shall be listed in the manual together with clearly illustrated drawings
to enable the terminations to be easily carried out.

.4 For the purpose of cable termination and jointing, tool kits for satisfactory
completion of the work shall be provided. Materials for cable termination and
jointing shall not be included in the tool kit but shall be supplied separately. The
tool kit supplied shall have a list of tools with the quantities stated.

.5 Terminations and joints are to be subjected to type approval tests. The impulse
voltage withstand level of these accessories shall not be less than the impulse
level of the cable and switchgear.

.6 Terminating accessories for stranded copper conductor cables shall be designed

for indentation ferrules. Cables terminating into transformers and switchgear shall
be fitted with insulated barriers between the transformer/switchgear body and the
cable screen/metal sheath. The insulated barrier shall be capable of withstanding
an HV test of 5kV DC for one minute.

.7 The preferred type of termination shall consist of heat shrinkable polymeric

components to provide electrical stress control, non-tracking exterior surfaces and
complete environmental sealing. They shall consist of high permittivity, high
resistivity, heat shrinkable stress control device, exterior heat shrinkable tubing
and skirts, fabricated from UV stable non-tracking material and heat activated
sealant material to prevent ingress of moisture and contaminants.

.8 All cables entering or leaving terminal boxes shall be provided with separate
terminations so that any cable out of a number of such cables can be removed or
replaced without disturbing the remainder.

.9 All glands shall be fitted with an earth bond terminal attachment.

 11/6.35KV XLPESWAPVC CABLE
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PAGE 8

.10 All cable lugs of compression type shall be provided as per manufacturers
recommendation

3.0 EXECUTION

3.1 ERECTION OF CABLES

.1 Before excavation the cable trenches, the Contractor should confirm with various
Authorities to confirm the exact location of the existing service pipes, ducts,
cables.

.2 Any damages caused by the Contractor to the existing service pipes, cables,
ducts, etc., as a result of excavation, shall be properly remedied and reinstated
to their original conditions by the Contractor at his own expense to the
satisfaction and approval of the Employer Representatives.

.3 Rates for erection of cables shall include the following: -

.1 All measuring, marking off and cutting to length.

.2 Temporary sealing of cable ends when necessary and testing of cut ends
prior to connection.

.3 Supply, delivery and erection of all supports, bushes and other items
required for erection and fixing of cables.

.4 Design, provision, erection and painting of all additional

supporting steelwork.

.5 Excavate all the necessary trenches, laying of the cables, making

good of the road and other damage service, ducts, etc.

.6 Forming of necessary bends, surface fixing at intervals as

specified herein.

.7 Tests at site during installation and on completion.

3.2 CABLE ROUTE

.1 The centre line of these routes will be pegged out by the Contractor and
approved by the Employer’s Representative. The costs for cable route survey
shall be borne by the Contractor.

.2 The cable route for underground cables shown in the drawing are approximate
only.
 11/6.35KV XLPESWAPVC CABLE
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PAGE 9

3.3 EXCAVATION OF TRENCHES

.1 The exact location of each cable trench will be settled on the site by the
Employer’s Representative when work is ready to commence.

.2 Trenches shall be kept as straight as possible and shall be excavated to

approved formation and dimensions, and shall generally be 750mm deep for
M.V. cable and 900mm deep for H.V. cable. Trenches shall have vertical sides
and are to be timbered and sheeted where necessary to prevent subsidence.

.3 The excavation of trenches shall include, by way of amplification but not of

limitation, all timbering, pumping and baling required and the provision of all
necessary labour, plant, tools, additional soil, fuel and motive power for such
purposes and the cost of this service and of the expendable materials shall be
included.

.4 Before the cables are laid, the bottom of the trench is to be lined with sand or
sifted soil, which is to be compacted to a thickness of 75mm depth or cover
backfill, shall consist of sand or sifted soil over which shall be placed protective
covers. Backfilling and reinstatement of open trenches after placing of the cable
protective covers shall also be carried out. Particular attention shall be taken to
ensure that trenches are evenly graded prior to placing the bedding material.
Cables passing under roadways shall be insulated in 100mm/150mm diameter
G.I. or steel pipes buried to a minimum depth of 900mm. Cables shall not cross
in straight runs of trench or in any other position except where a cross may be
permitted if it is impossible to void by advance planning of the lay of cables in a
trench.

.5 Routing and excavation of all trenches shall be carried out correctly and
satisfactorily and at such times and places to suit the programme of cable
installation work.

.6 Only enough ground shall be opened at a time such that cable laying and
backfilling may proceed without delay in order to avoid having trenches opened
for long periods. Excavations shall be carried out generally by mechanical
equipment or by hand. In cases where special care has to be taken of existing
structures etc. the excavation shall be carried out carefully by hand.

.7 It shall be strictly understood that the rates for excavation, inserted in the Bill of
Quantities shall cover all types of subsoil encountered, including weathered rock
and shale, but excluding solid rock and rock fill. Where solid rock or rock fill is
encountered during excavation for trenches is shall be removed by the use of a
pneumatic drill or blasting, borne by the Contractor. All excavated materials shall
be deposited alongside the trenches.
 11/6.35KV XLPESWAPVC CABLE
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PAGE 10

3.4 CABLE TRENCHES

.1 Trenches shall be backfilled with soil and shall be consolidated after every
150mm of backfill using a mechanical rammer. The finished surface shall be left
proud by 50mm to allow for subsidence and the contractor shall be responsible
for the removal of any surplus soil to a position indicated by the Engineer.

3.5 CABLE MARKERS

.1 Cable Markers, marked ‘H.T. Cable’ shall be installed at every 15m along the
route and at any changes in direction or as directed by the
Engineer.

3.6 CABLE DUCTS

.1 At road crossing, paved or concrete areas, the cable shall be

protected with 150mm diameter G.I. or steel pipes or any other types
approved by the Engineer, supplied by this contractor and buried to a depth of
900mm below final level.

3.7 CABLE SEALING AND DRUMMING

.1 Immediately after the Works Tests seal both ends of each cable length against the
ingress of moisture, dirt and insects and protect the end projecting from the drum
against mechanical damage during handling and transit using thermo-fit heat
shrinkable polymeric end-cap. The ends of the cable shall be marked 'A' and 'Z'
as appropriate. Each drum shall bear a distinguishing number either printed on
one flange or printed on a nameplate and attached to the flange.

.2 Particulars of the cable i.e. voltage, circuit label, length, cable type, conductor size,
conductor material, number of cores, gross and nett weights etc. shall be clearly
shown on one flange of the drum. The direction of rolling shall be conspicuously
indicated by an arrow.

.3 The preferred drum lengths should be such that no joint is to be made on each
cable circuit.

3.8 TERMINATIONS

.1 Make all terminations in accordance with manufacturer's recommendations.

Compression type cable lugs shall be used.
 11/6.35KV XLPESWAPVC CABLE
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PAGE 11

3.9 CABLE INSTALLATION

.1 Contractor shall be responsible for routing the cables in coordination with other
specification Divisions and installing cable on cable ladders in appropriate spacing
allowing for bending radius larger than the minimum recommended by
manufacturer or as detailed in the drawings.

.2 Cables shall be supplied in maximum lengths and no joints are allowed. If it is

inevitable to have joints, Employer Representative's approval is required.

.3 Install cable in riser shaft by lowering the cable from the upper floor to a
lower floor. Hoist cable drums and place them securely on designated upper floor.
Arrangement for hoisting shall be made with other specification Divisions.
Insulation resistance test cable prior to pulling. Prevent cable from uncontrollable
release from cable drum under its own weight by installing an appropriate braking
system. Pull cable down in the riser shaft guided by cable roller guide suitable for
holding the cable in position. Cable guide and roller shall be fixed at every floor.
Pull cable after placing cable stocking at the pulling end by a winch placed at the
lower floor. Excess length of cable shall be properly coiled and protected from
damage.

.4 Do not expose cut cable ends but seal using thermo-fit heat shrinkage material
until cable termination is made.

.5 After cable is pulled install cable on the cable ladder immediately before pulling the
next cable. Cable shall be held to cable ladders using proper metallic cable
fasteners at 1m intervals.

.6 Cable Tensions: Do not exceed manufacturer's recommended cable tensions

during cable installation especially when cable is run vertically.

.7 Use only pulling equipment during cable installation as recommended by cable

manufacturer.

.8 All cables shall be installed on cable ladder. They shall be spaced according to the
Contract Documents and shall be such that cables current carrying capacities are
not adversely derated. Appropriate coloured sleeving shall be used for H.T. cable
identification before cable termination.

.9 Fire-seal around cables at all penetrations of fire-rated walls and

slabs to maintain fire-rating.

.10 Earth cable armour and sheaths at all cable terminations according
to manufacturer's recommendations.
 11/6.35KV XLPESWAPVC CABLE
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PAGE 12

.11 Where cable sheaths are used as earth continuity conductors,

the glands must have necessary contact surfaces to provide a low
resistance path under fault conditions.

.12 Use metal type cable cleats/fasteners as recommended by cable

ladder manufacturer.

.13 Make measurements of cable lengths installed and submit all

installation records and test results to Employer's Representative.

.14 Cable identification, labelled ‘H.T. Cable‘ shall be installed at every

5m interval along the cable ladder.

3.10 TESTS

.1 Type Tests

.1 Perform relevant type tests recommended in the IEC. In

lieu of actually carrying out type tests, type
test reports certified by approved testing authorities
shall be submitted for approval of the Employer's
Representative.

.2 Routine Tests

.1 Carry out at works all relevant routine tests recommended in

the IEC and provide routine test report for all cables
supplied.

.3 Acceptance Tests at Manufacturer's Works

.1 Cut one 15 metre long cable sample of the largest cross-section from the
completed cables and subjected it to the following tests:

.1 Dimension checks

.2 Insulation resistance tests to IEC 60502

.3 Conductor resistance test to IEC 60228

.4 Capacitance test

.5 Partial discharge tests to IEC 60885

.6 Bending test to IEC 60502

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PAGE 13

.7 Power factor test to IEC 60502

.8 Heat cycle test to IEC 60502

.9 High Voltage test to IEC 60885

.10 Impulse withstand test and powerfrequency test to IEC 60502

.11 Measurement of insulation thickness and extruded covering to IEC

60502

.12 Outer sheath penetration test

.13 Flame retardant test to IEC 60332, if applicable

.14 Visual inspection e.g. cable construction, core identification,

cable identification,etc.

.2 A complete report of the above tests shall be provided.

.3 The manufacturer test shall be verified and witnessed by the Employer

Representative’s and his representatives.

.4 Site Tests

.1 The following tests shall be performed on each complete circuit of cable: -

.1 Visual inspection

.2 Method and equivalent used for installing cables.

.3 Cable routes.

.4 Voltage rating and type of cable.

.5 Bending radius, cable tension.

.6 Spacing of cables on trays and ladders.

.7 No cable joints.

.8 High voltage test to IEC 60885

 11/6.35KV XLPESWAPVC CABLE
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PAGE 14

.9 Conductor resistance test to IEC 60228

.10 Insulation resistance test to IEC 60502

.2 A complete report of the above tests shall be provided.

3.11 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Review O&M Documentation and Test Results.

3.12 HANDING-OVER AND EMPLOYER’S ACCEPTANCE

.1 Endorse defects list.

END OF SECTION
 SWITCHES AND SWITCHED SOCKET OUTLETS
SECTION 18008

PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Manufacture, test at Works, deliver to site, install and commission, switches and
switched socket outlets in accordance with the Contract Document.

1.2 WORK INCLUDED

.1 Switches and weatherproof switches.

.2 Switched socket outlets

.1 13 Amp surface flush mounted switched socket outlets

.2 13 Amp metalclad switched socket outlets

.3 15 Amp switched socket outlets

.4 Weatherproof switched socket outlets

.5 Grid switch system

1.3 SUBMITTALS
.1 Tender Stage

.1 Technical data and product catalogs for:

.1 Switches.

.2 Switched socket outlets

.3 Commando plug/ Combination plug/ socket

.4 Isolator

.5 Fireman switch

.2 Construction Stage

.1 Catalogs and samples of switches, switched socket outlets, commando

plug, isolator and fireman switch
 SWITCHES AND SWITCHED SOCKET OUTLETS
SECTION 18008

PAGE 2

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance test.

.2 Acceptance test report after testing

.3 Packaging, transportation and storage notes.

.4 Site Installation

.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.5 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Except as modified by governing codes and by the Contract Documents, comply

with the latest applicable provisions and latest recommendations of the following:
-

.1 IEC 60309-2 Plugs, Socket-Outlets and Couplers for Industrial

Purposes.

.2 IEC 60529 Degrees of Protection Provided by Enclosures (IP

Code)

.3 IEC 60669-1 Switches for Household and Similar Fixed Electrical

Installations

.4 IEC 60947-3 Low Voltage Switchgear and Controlgear-Part

3:Switches, Disconnectors and Fuse-Combination
Units

.5 BS 546 Two-pole and Earthing-pin Plugs,

 SWITCHES AND SWITCHED SOCKET OUTLETS
SECTION 18008

PAGE 3

Socket-outlets and Socket-outlet Adaptors.

.6 BS 1363-2 13A Plugs and Adaptors. Specification for 13A

BS 1363-4 Switched and Unswitched Socket-outlets

.7 BS 3676 Switches for Household and Similar fixed

Electrical Installations

.8 BS 4343 Specification for Industrial Plugs, Socket-Outlets

and Coupler for AC and DC Supplies.

.9 BS 4662 Boxes for Flush Mounting of Electrical

Accessories. Requirements and Test Method and
Dimensions.

.10 BS 5733

.2 Manufacturer's Experience

.1 Manufacturer shall have at least 10 years experience in the manufacture of

switches and switched socket outlets of similar construction.

2.0

2.1 GENERAL

.1 The Construction Drawings shall indicate the approximately position of lighting,

switches, switched socket outlets and other fittings. The actual positions of all
fittings and the wiring layout and cable route shall be agreed finally on site with
the Employer’s Representative.

2.2 SUB-CIRCUIT SWITCHES

.1 Sub-circuit switches unless otherwise shown on the drawings shall be of single

pole, quick-make and quick-break, silent switch action type with solid silver alloy
contacts and totally enclosed switch action for flush or surface mounting as
required and shall be suitable for indoor or outdoor service according to location.
The switches shall be housed in standardized-purpose manufactured aluminium
stove enamel finish boxes and complete with conduit knockouts.

.2 Switches shall be rated at 5, 10, 15 amp. As determined by circuit load which for
inductive lighting circuits shall be assessed at twice the steady state connected
load current, one way or two way as indicated in the Tender Drawings and fixed
generally at a height of 1500mm from floor level and where located in rooms, the
switch shall where possible be located on the inside of the room on the handle
side of the door. Measurement shall be to bottom of Switch.
 SWITCHES AND SWITCHED SOCKET OUTLETS
SECTION 18008

PAGE 4

.3 Switch cover plates for the office areas, lobbies and public areas shall be of the
flush type, plate colour, decorative typed to be selected by ID/architect.

.4 Switches for service areas shall be of the metal-clad type approved by the
Employer’s representative mounted in flushed conduit boxes as specified.

.5 Weatherproof type of switches shall be used for outdoor application and shall
have minimum IP54 protection.

.6 An earthing terminal connected to the earth continuity terminal shall be provided

and connected to the protective conductor at every lighting switch position.

.7 A single pole switches shall be connected to break the phase wire of the supply,
the neutral wire shall not be through switch boxes.

.8 Where group of switches, from the same source of supply are to be installed at
the same location. The Contractor may propose grid switch system subject to the
approval of Employer’s Representative.

.9 All switches supplied shall comply to BS3676 and relevant BS standards

2.3 SOCKET OUTLETS

.1 13A switched socket outlets (S/S/O) shall conform to BS 1363.

.2 13A S/S/O shall be 3 rectangular pin switch shuttered outlets, one or two gang
for indoor service except as otherwise shown on the drawings and either surface
or flush mounted according to location.

.3 S/S/O shall be the quick make, slow break type with silent, totally enclosed
switch action and solid silver alloy contacts. Switched socket outlet for office,
lobbies and public areas shall be housed in steel boxes finished aluminium
stoved enamel, to BS 3676 and BS 1363 with conduit knock-outs. Switches
sockets outlets for the plant room and other general non-public areas, where
specified shall be of the metal-clad type.

.4 Socket outlets located in exposed situations shall be non-shuttered single pole 3

round pin to BS 546, galvanised iron weatherproof type with ¾ inch E.T. screwed
conduit entry, rated at 5 amp. or 15 amp. Switched as the socket orifice when not
in use.

.5 Generally, socket outlets shall be positioned 300mm above finished floor level
except otherwise shown on the drawing where they shall be positioned 1500 mm
above finish floor level or 150mm above counters or benches whichever is
suitable, or as directed by the Employer’s Representative. Measurement shall be
to bottom of Switch Socket Outlet.
 SWITCHES AND SWITCHED SOCKET OUTLETS
SECTION 18008

PAGE 5

.6 Switched-socket outlets connected to normal power supply shall be white

faceplate colour. Those that are connected to essential power supply shall be
white faceplate with red coloured rocker. Those that are connected to
uninterruptible power supply shall be white faceplate with red coloured rocker
and complete with pilot lamp.

.7 Decorative typed and colour of faceplate for the office areas, lobbies and public
areas shall be selected by ID/architect.

.8 S/S/O and switches, where mounted in the same area, shall have consistent
profile and thickness.

.9 The above weatherproof switch socket outlet and plug shall be of IP 65 rating.

2.4 FIREMAN SWITCHES

.1 All fireman switches shall have cast die-aluminium IP65, weather proof
enclosures and are design to comply to IEC 60529 rating of IP65 Ingress
Protection.

.2 Switches shall be type tested to IEC 60947-3 and have utilization category of
AC23A with duty rating 240V/415V AC, 50Hz.

.3 Switches shall be of quick make and break type.

2.5 ISOLATOR OR DISCONNECTING SWITCHES.

.1 Isolators or disconnecting switches shall comply with IEC 60947-3. They shall be
of the on-load, rotary type and interlocked with the housing and provided with
means of operation from the front so that all enshrouded live parts can be made
dead with the switch off. All fixed contacts shall be shrouded. Isolators shall
comprise of a quick-make and break, positive action mechanism. Isolators shall
not be door-mounted.

3.0 EXECUTION

3.1 TESTS

.1 Type Tests

.1 Perform relevant type tests recommended in the IEC. In lieu of

actually carrying out the type tests, type test reports certified by
acceptable testing authorities may be submitted for approval of the
Employer’s Representative.

.2 Routine Tests
 SWITCHES AND SWITCHED SOCKET OUTLETS
SECTION 18008

PAGE 6

.1 Before the products leave the works, the manufacturer shall carry out the
relevant routine tests on the total assembly and on parts thereof when
delivered with time intervals and the results shall be recorded in a test
report.

.3 Acceptance Tests at Manufacturer’s Works

.1 Acceptance tests shall be carried out on the completely assembled units.

.2 The manufacturer test shall be verified and witnessed by the Employer

Representative’s and his representatives.

.4 Site Tests

.1 At the completion of installation, all switches and switched socket outlets

shall be tested. A report recording each item of the testing shall be
submitted to the Employer's Representative.

.1 Visual Inspection

.1 Check that mounting heights are consistent and in accordance

with the specification.

.2 Check for any defects and poor installation.

.3 Polarity checks.

.2 Tests

.1 Operation of safety shutters.

.2 Operation of ON/OFF switch.

.3 Connection and termination of Live, Neutral and Earth cable

3.2 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Review O&M Documentation and Test Results.

3.3 HANDING-OVER AND EMPLOYER’S ACCEPTANCE

.1 Endorse defects list.

END OF SECTION
 PROTECTION, METERING AND CONTROL
SECTION 18009

PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Manufacture, test at Works, deliver to site, install and commission, relays,

protection devices, metering, control, indicating devices and alarm schemes in
accordance with the Contract Documents.

1.2 WORK INCLUDED

.1 Relays

.2 Protection devices

.3 Metering devices

.4 Control circuits and devices

.5 Indicating lights

.6 Alarm schemes

1.3 SUBMITTALS

.1 Tender Stage

.1 Catalogue and manufacturer's data for all equipment/ components.

.2 Full point by point control diagrams.

.2 Construction Stage

.1 Short-circuit calculations and computer software used

.2 Relay characteristics and MCCB current-limiting let-through energy

characteristics

.3 Protection and control block diagrams

.4 Control/logic and interlocking diagrams

.5 Current transformer and voltage transformer design calculations

.6 Protection and control schematic/wiring diagram

.7 Cable schedules

18009_Protection, Metering and Control

 PROTECTION, METERING AND CONTROL
SECTION 18009

PAGE 2

.8 Catalogue and component technical details

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance tests

.2 Acceptance test reports after tests

.3 Packaging, transportation and storage notes

.4 Site Installation

.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.4 Protection grading report and relay settings

.5 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Except as modified by governing codes and the Contract Documents,

comply with the latest applicable provisions and latest recommendations
of the following:-

.1 IEC 60044-1 Instrument Transformers – Part 1 : Current

Transformers

.2 IEC 60051 Direct acting indicating analogue electrical

measuring instruments and their accessories.

18009_Protection, Metering and Control

 PROTECTION, METERING AND CONTROL
SECTION 18009

PAGE 3

.3 IEC 60073 Basic and Safety Principles for Man-Machine

interface, Marking and Identification-Coding
Principles for Indicators and Actuators.

.4 IEC 60255 Electrical relays.

.5 IEC 60269 Low-voltage fuses.

.6 IEC 60909 Short-Circuit Currents in Three-Phase A.C.

Systems

.7 IEC 60947-5-1 Low Voltage Switchgear and Controlgear-Part 5-

1:Control Circuit Devices and Switching Elements -
Electromechanical Control Circuit Devices.

.8 IEC 61008 Residual Current Operated Circuit-Breakers

Without Integral Over Current Protection for
Household and Similar Uses (RCCBs)

.9 IEC 61010-1 Safety Requirements for Electrical Equipment

forMeasurement, Control ad Laboratory Use.

.10 IEC 61326 Electrical Equipment for Measurement ,

IEC 61326-1 Control and Laboratory Use – EMC
Requirements.

.2 Manufacturer shall have at least 10 years experience in the manufacture of

similar equipment.

.3 Manufacturer/supplier shall have full parts back-up and service availability for the
equipment provided.

.4 Certification of compliance with IEC requirements shall be done by ASTA, KEMA

or a recognized third party independent testing laboratory.

2.0 PRODUCTS

2.1 SYSTEM PROTECTION

.1 Protection equipment shall be designed and applied to provide proper

discrimination between faulty and healthy circuits. They are to remain
inoperative during transient phenomena which may arise during switching or
other disturbance to the system. The design of the protection system shall not
be limited to individual equipment alone but shall be so coordinated such that
good performance can be achieved throughout the system starting from the TNB

18009_Protection, Metering and Control

 PROTECTION, METERING AND CONTROL
SECTION 18009

PAGE 4

incoming feeders to the individual final sub-circuits. The protection system

performance shall reflect good zone selectivity, relay stability, speed with proper
discrimination and reasonable sensitivity without any loss of reliability and
maintainability.

.2 The Contractor shall carry out all short-circuit calculations, check the adequacy of
all equipment short-circuit ratings, provide the best protective device and
coordinate all protective devices in the system. Where computer software is
used for carrying out protection coordination exercise, the Contractor shall
provide full details of the software and shall be responsible for all results
generated from the software.

.3 Protection for the various circuits shall be but not limited to the following: -
Circuit Type Protection Requirement

.1 TNB incoming 11 kV Overcurrent and earth fault

.2 Building 11 kV cables Overcurrent and earth fault

.3 11/0.433kV transformers Overcurrent, earth fault and

winding temperature

.4 Incoming to LV main Overcurrent and earth fault

switchboards

.5 Outgoing from LV main 800A and above OC/EF

switchboard to Above 200A and 800A OC/EF
sub-switchboards Above 60A and 200A ELR
or distribution board 60A and below RCCB
.6 Incoming to sub switchboard 800A and above OC/EF
or distribution board Above 200A and 800A OC/EF
Above 60A and 200A ELR
60A and below RCCB

2.2 RELAYS

.1 Relays shall be of types complying with IEC 60255 and shall have approved
characteristics and be flush-mounted in dust and moisture-proof cases with glass
fronts. Attention is particularly drawn to the tropical and humid climate and the
relay designs shall be entirely suitable for duty under these conditions. Bezels of
relays shall be of approved construction and shall be arranged so that
adjustments, testing and replacement can be effected with the minimum of time
and labour.

.2 Relays of the hand reset type shall be capable of being reset without opening the
case. Relays with provision for manual operation from outside the case, other
than for resetting, will not be accepted.

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.3 Relays shall be capable of withstanding the output current of the associated

current transformers corresponding to a primary current equal to the specified
short-circuit withstand current and withstand time of the assembly.

.4 Relay contacts shall be suitable for making and breaking the maximum currents
which they may be required to control in normal service but where contacts of the
protective relays are unable to deal directly with the tripping currents, auxiliary
contactors, relays or auxiliary switches shall be provided. Separate contacts
shall be provided for alarm and tripping functions. Relay contacts shall make
firmly without bounce and the whole of the relay mechanisms shall be as far as
possible unaffected by vibration or external magnetic fields.

.5 Relays, where appropriate, shall be provided with flag or light emitting diode
indicators, and phase coloured where applicable. Flag or light emitting diode
indicators shall be of the hand reset pattern. Where two or more phase elements
are included in one case, indicators shall be provided for each element.

.6 Relays which rely for their operation an external DC supply shall utilise for this
purpose the trip supply of the associated circuit breaker. This supply shall be
monitored and an alarm provided in the event of failure unless otherwise
specified.

.7 Relays, whether mounted on panels or not, shall be provided with clearly

inscribed labels describing their application and rating in addition to the general
purpose labels.

.8 Test facilities shall be provided for each current and voltage transformer
secondary circuit so as to give access for testing of protection relays and
associated circuits. The facilities shall comprise test terminals for front of panel
mounting. Alternatively the same may be accomplished by the use of test
sockets and plugs.

.9 Each current transformer circuit shall be earthed through a removable link at one
point only in the relay panel.

.10 Links shall be provided for isolation of protection trip circuits.

.11 Relays shall be of the draw-out type with automatic shorting of all current
transformer circuits when the relay is withdrawn or when the test links are moved
from their normal operating position.

.12 When specified, electrically reset tripping relays shall be provided where
necessitated by the system of control, such as for those circuits subject to remote
supervisory control.

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.13 The application, performance and testing of protective devices shall be in

accordance with the relevant IEC Recommendations.
Static relays are preferred.

.14 Time delay relay shall not be of the dashpot type.

.1 Static Type Relays

.1 All static protection relays shall be designed to withstand the impulse

withstand and high-frequency interference requirements.

.2 Static protection which require an independent low voltage DC supply

shall preferably use regulated DC/DC converter power packs for this
purpose. Separate power packs are preferred for each individual
discriminative relay unit.

.3 If the power pack is separately housed from the relay units which it is
supplying, care must be taken that the cabling between the power pack
and the relay units, and between relay units is adequately screened and
physically separate from all 'power type' circuits associated with the CT,
VT and DC tripping circuits. All interconnecting screened cables shall
preferably be terminated by plugs and sockets.

.3 The power supply shall be capable of providing a supply to the protection

relay equipment such that a complete break in the primary DC supply
connections to the power supply unit for a period of not less than 10 ms
does not cause any maloperation of the protection relay. Measurement
errors are, however, acceptable provided they do not exceed the stated
assigned error of the equipment.

.4 It shall not be possible to gain direct access by means of external

connection to any low voltage DC power supply without first removing an
appropriate protective cover suitably engraved with a warning that high
voltage tests shall not be applied. There shall be a degree of mechanical
segregation between the 'power type' circuits associated with the CT, VT
and DC tripping connections and the low voltage circuits.

.5 All input and output terminals of the power packs which are connected to
'power type' circuits shall be subjected to the same over-voltage, impulse
and interference tests as specified for static protection.

.6 The low voltage supply to each discriminative relay unit shall be

continuously monitored and an alarm shall be given whenever the voltage
is not within the limits for reliable protection operation.

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.7 In order to minimise the high voltage interference to acceptable levels, the

station multi-core cables shall be screened and earthed according to the
latest standards.

.8 Each relay or relay scheme shall be provided with an adequate number of

indications to facilitate fault analysis including identification of the faulted
phase and faulted zone. Mechanically operated output indications are
preferred but other methods of presentation are acceptable provided that:
-

.1 Long term storage of the indication is not dependent upon an

auxiliary supply.

.2 Means are provided to ensure that the indication are complete,

e.g. relays which are provided with lamp indicators must have
lamp testing facilities.

.3 Each indicator, whether of the electrical or mechanical operated

type, shall be capable of being reset without opening the relay
case.

.4 Each indicator shall be so designed that it cannot move before the

relay has completed its operation.

.5 Unless otherwise approved, indication shall only be given by the

protection which causes the fault to the cleared.

.6 All indications shall be clearly visible without opening of relay

cases or relay panel doors.

.9 Rectifiers used in association with protective relays shall preferably be of

the silicon type and appropriately rated for the application.

.10 Wherever practical, the design of the relay scheme shall be based on the
'fail-safe' principle. Care shall be taken to ensure that loss of DC supply
or an open circuit does not cause incorrect opening or closing of circuit
breaker.

2.3 PROTECTION DEVICES

.1 Inverse Definite Minimum Time Overcurrent and Earthfault Protection

.1 Inverse definite minimum time (I.D.M.T) over current relays (where

specified) shall be of the solid state or numerical type and have
adjustable operating settings from 40% to 400% of the normal full load
secondary current, with an adjustable time setting. These over current

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relays shall provide selectable alternative time/current characteristics and

high set definite time operation.

.2 I.D.M.T. earth fault relays (where specified) shall be of the solid state or
numerical type and have adjustable operating setting from 8% to 80% of
the normal full relays load secondary current, with an adjustable time
setting, these earth fault relays shall provide selectable alternative time
current characteristics and high set definite time operation.

.3 In cases where the individual over current and/or earth fault elements are
effectively combined into one relay, this relay shall still provide indication
to discriminate the reason the relay has operated (i.e.,I.D.M.T.) over
current or earth fault, high set over current or earth fault) and which phase
has faulted.

.4 Directional overcurrent and earth fault relays shall have directional

discrimination down to 1 percent of the normal voltage.

.5 Instantaneous overcurrent elements where specified shall have a

continuous current setting range of 400 to 1600 percent. Similarly,
instantaneous earth fault elements shall have a continuous current setting
range of 50 to 200 percent. The instantaneous element can be set on
infinity if not required.

.6 Directional overcurrent and earth fault relays shall have directional

discrimination down to 1 percent of the normal voltage.
.7 The Contractor shall provide full details of the relay characteristics and
ensure that they operate satisfactorily under all fault conditions.

.2 Transformer Winding Protection

.1 All necessary indications, tripping relays and alarm relays associated with
the winding temperature protection shall be provided and set into
operation under this Contract.

.3 Pilot Wire Relay

.1 Relays for use with pilot wires is to be of an approved type, employing

preferably not more than three pairs in a multipair pilot cable with 1/0.91mm
telephone conductors.

.2 The protection shall operate for phase faults and earth faults within the
protected zone and remain stable for through faults equal to the maximum
fault current ratings of the associated switchgear.

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.3 Phase fault and earth fault sensitivities should not be more than 120 percent and
40 percent respectively of the nominal rated current of the circuit.

.4 Generator Reverse Power Protection

.1 Generator reverse power protection shall be adequately sensitive to detect

a motoring condition on complete loss of input to the turbine.

.2 A time-delayed trip output shall be provided such that there shall be no risk
of incorrect operating caused for example by rotor swings accompanying a
system electrical fault.

.5 Generator Undervoltage Relays

.1 An undervoltage solid state relay shall be included to respond to the true

rms value of the generator voltage. This relay shall have an adjustable
pickup range of 75% to 100% of the nominal and an adjustable dropout of
80% to 95% of pickup. Dropout shall have zero differential for time delay
reset about the dropout setting.

.6 Generator Over voltage Protection

.1 A generator overvoltage relay shall be supplied to detect over voltages at

the generator terminals.

.2 The over voltage relay shall have an adjustable setting range up to 1.4
per unit rated voltage and shall have an adjustable time delay.

.7 Generator Under/Over Frequency Protection

.1 Generator under/over frequency protection shall consist of a minimum of

four frequency settings. The frequencies and time delays for the alarms
and/or trips shall be to the approval of the Employer's Representative.

.2 Full details of the relay and proposed settings shall be provided.

.8 Generator Negative Phase Sequence Protection

.1 The generator negative phase sequence protection shall comprise a two-

stage device.

.2 Stage 1 (alarm) shall have an adjustable setting to match the generator

continuous negative phase sequence capability and shall include an
adjustable definite time delay or a fixed time delay of not less than 3
seconds.

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.3 Stage 2 (trip) shall have an adjustable thermal characteristic capable of

being set to match the generator short time negative phase sequence
capability.

.9 Generator Loss-of-Excitation Protection

.1 Loss of excitation protection shall be provided in addition to any loss-of-

excitation devices included in the excitation system or automation voltage
regulator.

.2 The protection shall monitor the generator terminal impedance vector and
shall have a negative reactance offset mho (circular) characteristic with
adjustable offset and adjustable diameter.

.3 An adjustable time delay shall be provided.

.10 Tripping Relays

.1 Electrically reset tripping relays with hand reset flag indicators shall be
used and these are to be arranged for pushbutton re-setting where
appropriate.

.2 The operating time of all tripping relays shall be less than 10 milliseconds.

.3 All auxiliary relays necessary to ensure the correct sequence of trip relay
resetting shall be included.

.11 Frequency/Voltage Time Delay

.1 An adjustable time delay on drop out of both the Generator Voltage

Protective Relay and the Generator Frequency Protective Relay shall be
provided to override loading transients. Range of adjustability shall be 0.1
to 2.0 seconds. Repetitive accuracy shall be within +10%.

.12 Trip Flag Indication Relays

.1 Flag indication relays shall be hand-reset type. Trip flag indication relays
shall be current operated and shall operate in series with the appropriate
tripping relay.

.2. Alarm flag indication relays shall be shunt-operated.

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.13 Protection Incorporated In Air Circuit Breakers

.1 Where circuit-breakers are fitted with electronic trip units, adjustments on

these units shall be made using non-removable, discrete step, reliable
switching plugs for precise settings.
.2 A sealable, transparent cover shall be provided over the adjustments to
prevent tampering.

.14 Protection Incorporated In Moulded-Case Circuit Breakers and Motor Circuit

Protection

.1 Overcurrent releases shall be of the thermal and magnetic type with

approximate inverse time-current characteristic. MCCB's shall have
thermal and current limiting magnetic trips to give low let-through energy.

.2 MCP shall have magnetic trip adjustable from 7 to 10 times its rated
current together with adjustable thermal overload trips meeting the
heating characteristics of motors. Where motor protection requirements
available in MCB's are inadequate, additional motor protection relays
shall be provided.

.15 Fuses

.1 High breaking capacity (HBC) type fuse links with time characteristics in
accordance with IEC 60269 and having full range breaking capacities of
at least 50kA shall be used. The maximum rating shall be 630A.

.2 Fuses should be of the low loss type.

.16 Motor Protection Relays

.1 Motor protection relays shall preferably be of the integrated multi-function

static type incorporating all necessary protection functions. Motor
protection functions shall include but not limited to the following:-

.1 Thermal overload

.2 Phase unbalance

.3 Phase reversal

.4 Single phasing

.5 Excessive starting time

.6 Stalling

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.7 High set overcurrent and earthfault

.8 Rotor protection

.2 Thermal overload protection shall be provided in all phases. The relay

characteristics shall closely match the heating characteristics of the
motors they are protecting. The relays shall be of the temperature and
frequency compensated type where appropriate and shall be equipped
with manually reset facilities on the front of the compartment. (Resettable
without opening the assembly). An inadvertent reset action shall not trip
a circuit. A time-delay shall be incorporated to prevent the motor from
being immediately started after a trip.

.3 If bimetallic thermal relays are used, direct heating elements shall be

provided up to a nominal current of 40A. For nominal currents above
100A standard nominal 5A relays shall be used in combination with linear
current transformers. Between nominal currents of 40A and 100A either
direct heating elements or 5A elements connected via current
transformers may be used.

.4 Motor protection relays of the static type shall have selectable thermal
operating characteristics.

.5 The operating time of the unbalance protection shall be dependent on the

degree of unbalance.

.6 The stall protection shall operate in conjunction with a speed switch on

the protected motor.

.7 The single phasing protection shall have a fixed definite time delay.

.8 For motors with running up times in excess of 5 seconds saturable

current transformers in combination with a standard nominal 5A relay
shall be provided. Alternatively electronic protection relays with suitable
protection curve shall be supplied.

.9 Where wound rotor are provided in conjunction with resistance starting

methods, rotor protection may be provided for large motors to operate
instantaneously at a set value above the starting current of the motor.

.10 For motors with operating conditions beyond those covered by overload
relays, special protection systems may be considered, e.g. installation of
thermistor temperature sensors in the motor windings with its relay
installed in the switchgear compartment, bearing lubricating oil alarm and
trips etc.

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.17 Motor Overload Relays

.1 All motor feeders shall be provided with a three element, positive acting,
ambient temperature corrected, time adjustable, hand reset-type thermal
overload relay suitable for overcurrent protection, either direct acting or
CT operated, with 70% to 120% setting range, with current range, clearly
engraved.

.18 Motor Earth Fault Protection

.1 Where indicated in the design drawings, motors shall be fitted with core
balance type earth fault protection relays. Relays shall be manually
resettable after opening of the assembly compartment cover. The relays
shall only operate on an earth fault current of less than 3% of the rated
nominal motor current with a maximum of 6A. The relays shall be
equipped with a clear trip indication of the relay.

.19 Undervoltage Relay

.1 Undervoltage relays for motors shall be of the instantaneous type and

operate on reduced supply voltage.

.20 Residual Current Circuit Breakers

.1 Residual Current Circuit Breakers or Earth Leakage Circuit Breakers

(RCCB/ELCB) shall be of the instantaneous tripping type with sensitivity
as indicated in the design drawings.

.2 Residual current circuit breakers shall be of the core balance type

complying with IEC 61008-1.

.3 Residual current circuit breakers incorporating amplifiers or relays

requiring power supply shall operate on 240V 50Hz.

.4 Performance Criteria

.1 Coordination of Breaking Capacity

All RCCB shall be protected against short-circuits by means of

circuit breakers.

The manufacturer shall guarantee that the association of these

two devices is properly coordinated such that the rated
conditional short circuit current (Inc) is equal to the prospective
short-circuit current level as shown in the drawings.

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Details of the coordination shall be submitted to the Employer’s

Representative for approval. The details shall include the
manufacturer’s coordination tables showing MCB+RCCB and their
rated conditional short-circuit current values.

.2 Voltage Independent

The RCCB shall be current operated type and independent of

voltage. They shall not trip on the loss of supply voltage.

.5 Construction

.1 Protection against nuisance tripping

All general purpose RCCB shall be of Type A characteristics as

stipulated in IEC61008-1.

The construction shall be of surge-proof design with reinforced

immunity to current surge to eliminate unnecessary nuisance
tripping. The RCCB shall be able to withstand surge currents up to
3000A (8/20s current surge test) without tripping. Details of the
tests shall be submitted to the Engineer for vetting upon request.

.2 Operating mechanism

The operating mechanism shall be of the quick-make quick-break

type, with the speed of operation independent of the operator.

The contacts shall also be mechanically trip free from the

operating handle so as to prevent the contacts from being held
closed against an electrical fault.

A test button shall be incorporated to enable periodic checks on

the correct operation of the device to be carried out.

As an option, it shall be possible to fit on-site auxiliaries like shunt-

trip coil, ON-OFF indicator switch, trip indicator, motor operator,
etc to the RCCB when required.

3. Terminals

The RCCB shall have cable terminals with safety guards to protect
against misconnection.

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2.4 METERING DEVICES

.1 Digital Power Meters

.1 The power metering for the incomers shall be capable to monitoring all
the important electrical parameters including 3 phase current, voltage,
power factor, kWhr, KVARhr, harmonics and maximum demand.

.2 Kilowatt-hour and KVAR-hour meters shall be provided with maximum

demand indications arranged for half hour resetting.

.3 It shall be capable of logging and communicating with remote station and

shall be integrated and monitored with the Building Control System. It
shall be of microprocessor type.

.2 Ammeter, Voltmeter and Power Factor Meters

.1 All instruments shall be of the flush mounting type and shall have an
enclosure with a degree of protection of at least IP 52 and comply with
IEC 60051.

.2 All meters should be of the square pattern type 96 x 96mm bezel case,
and mounted at a suitable height for easy reading from the front. Scales
shall be in actual values and arranged in 90o . Where appropriate, meters
shall have facilities for external zero adjustments.

.3 Meters shall be installed in the associated functional units. Recording

instruments, if required, may be mounted in any other accessible location
or common panel provided that the equipment is properly labelled.

.4 Ammeter and voltmeter shall be of suitable range complete with selector

switches to allow reading of phase currents and voltages R-B, B-Y and R-
Y.

.5 Ammeters and voltmeters shall have accuracy class 1.5. Kilowatt hour
and maximum demand metres shall have accuracy class 2.5. Power
factor meter shall have a scale reading of 0.5 capacitive 1-0.5 inductive
with a class accuracy of 2.5.

.6 Ammeters for motor duty (if required) shall have a compressed overload
scale and shall be suitable to withstand the motor starting currents.

.7 Outgoing feeders to sub-switchboards with current ratings in excess of

300A shall be provided with an ammeter.

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.8 Motor starter units with a motor feeder cable of 4mm2 cross section and
more, (usually from 4kW and above) shall be equipped with a current
transformer for a remote ammeter. Motors connected with a feeder cable
of 2.5mm2 will use a direct reading remote ammeter.

2.5 CONTROL CIRCUITS AND DEVICES

.1 Circuit breakers shall be provided with electrical controls at the circuit breakers,
suitably mounted in the mechanism box or marshalling kiosk for use under
maintenance or emergency conditions. A multi-pole lockable changeover
selector switch shall be provided at the circuit breaker and labelled ‘LOCAL’ and
‘REMOTE’.

.2 Individual healthy trip lamps shall be provided and these shall be coloured white
and mounted adjacent to the associated circuit breaker control switches. Healthy
trip indicators shall be connected so as to give on demand only, supervision of
the trip circuit with the circuit breaker either open or closed, in order to minimise
drain on the station battery. A series resistance shall be provided so that a short
circuit of the lamp or relay shall not result in trip coil operation.

.3 Protection and control schemes should, in general, be based on the use of

stranded 2.5 sq mm cable cores. This Contract shall include the preparation of
schedule of cables and cable core allocations.

.1 Control Relays

.1 Control relay shall be of the heavy duty type, fully tropicalised

complying with IEC 60947-5-1 and shall have a high degree of
reliability with double interrupting contacts. They shall be suitable
for mounting in any position without derating.
.2 Control relays shall have contacts with minimum rating of 15A at
440V. Contacts shall easily be changed from normally open (N/O)
to normally close (N/C) and vice versa and be easily accessible.
Contact tips shall be of hard silver.

.3 Relays shall be supplied with the number of poles required by the

circuitry indicated in the Contract Documents plus one spare pole
for future use. The maximum number of poles shall be six.

.4 Where relays are used in the 11kV and 415V switchboard trip
circuits, they shall have single 30V DC and 240V AC coils,
respectively. All coils shall be continuously rated.

.5 The magnetic system shall consist of a fixed core and plunge-type

armature which actuate the contact bar direct. When the coil is
de-energised, the armature and contact bar shall return to their
original position by a spring.

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.6 Control relays shall be of the plug-in type with the plug-in bases
having facilities for rail mounting. The terminals of plug-in bases
shall be designed to accept two wires with cross-section of 2.5 sq.
mm.

.7 Control relays shall be provided with protective dust cover.

.8 Each control relay shall be provided complete with identification

label with self-adhesive paper designation strips and transparent
covers.

.2 Timers

.1 The timers for the motor circuits, shall be of the 'ON' delay 'OFF'
delay type, Electronic, Synchronous or Pneumatic timers as called
for by the application with 2 N/O and 2 N/C contacts, capable of
withstanding the thermal effect of switching and have very close
accuracies. They shall have variable setting and suitable for
mounting on normal contactor or for rail mounting within switch
panel.

.3 Selector Switches

.1 Selector switches shall comply with IEC 60947-5-1 and be of

positive-action rotary-cam switches incorporating double contacts.
They shall be of modular construction and suitable for extension of
twelve cells. It shall be possible to arrange the switches for four,
six or eight positions and operations shall be in either direction.

.2 Selector switch contacts shall be double-break and of hard silver

alloy. They shall have a minimum continuous current rating of 10
amps and be of a high breaking capacity.

.3 Connections shall be by large terminals with clamp screws of

5mm minimum size.

.4 Operating knobs shall be of the type which positively indicates the

position of the switch. The switch position shall be clearly marked
on an engraved legend plate which shall be made from
black/white/black traffolyte and the minimum character size shall
be 5mm.

2.6 INDICATOR LIGHTS

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.1 Annunciator 'window' and indications shall be incorporated as shown in

the design drawings and shall be of the 25 mm tile mosaic preferably of
light green or blue green with back engraved inscriptions. The
annunciator inscriptions shall be to the Employer's Representative's
approval.

.2 One set of 'Accept', 'Reset' and 'Test' buttons shall be provided for the
whole mimic.

.3 The Contractor shall submit a Schedule of Alarms together with layout

drawings of the annunciator windows for Employer's Representative’s
approval.

.4 Lamp indications shall be provided and these shall utilise the same button
for test as those provided for the annunciator.

.2 Indicating Lamps

.1 Indicating lamps shall comply with IEC 60073.

.2 Lamp fittings shall allow adequate ventilation and allow for easy removal
for replacement of the lamps without requiring the use of extractors.

.3 The rated lamp voltage shall be 10 volts in excess of the auxiliary supply
voltage, whether AC or DC. Alternatively, low voltage lamps with series
resistors will be acceptable.

.4 The lamp lens shall be in standard colours, red, green, blue, white and
amber to the Employer's Representative's approval. The colours shall be
in the lenses and not applied coatings. The different coloured lenses
shall be interchangeable.

.5 Lamp test facilities shall be provided so that all lamps on the panel can be
tested simultaneously by operation of a common key. Where alarm
facias are specified, all alarm and monitoring indications (apart from
circuit breaker isolator position indications) shall be incorporated in the
facia.

.6 Circuit breaker control switches shall be of the manually operated

discrepancy type spring loaded such that it is necessary to push and twist
the switch past its indicating position for operation. A lamp shall be
incorporated in the switch base so that it will illuminate "steady" when the
circuit breaker position is in discrepancy with the control switch indication.

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.7 When the circuit breaker is tripped on a fault condition the lamp will illuminate to
show discrepancy.

.8 All discrepancy indicators shall be complete with a light which shall illuminate
"steady" when at discrepancy. On hand dressing the indicator to the correct
position the light shall go out.

2.7 MONITORING AND CONTROL

.1 The Building Control System (BCS), Fire Alarm System (FAS) and Generator
Control System (GCS) shall interface to instrumentation and final control
elements (control relays, etc). The following is a list of the base building
electrical equipment and motors that will be controlled and/or monitored.

.1 chilled water system’s pumps

.2 chilled water metering stations

.3 all AHUs and outside air make-up units VAV terminal boxes

.4 general, toilet, pantry and smoke exhaust fans

.5 stairwell and vestibule pressurization fans

.6 special area AHUs and Fan Coil Unit (FCU)/DX units

.7 exhaust and supply fan serving the transformer and switchgear rooms

.8 electrical tariff metering at the HV switchboard

.9 emergency generator system including diesel oil system and supply /

exhaust fans

.10 automatic transfer switches

.11 UPS system

.12 tie-breakers and main 11 kV breakers

.13 main switchboard circuit breakers status and main switchboard circuit
breakers status and electrical reading of current, voltage, frequency /
power factor, etc

.14 supply and return temperatures, pressure and flow rates at building
chilled water take-offs

.15 interior and exterior lighting controls

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.16 water storage tank (water level alarms) and booster pumps

.17 sump and sewage pumps status and alarm

.18 fire alarms systems (monitoring)

.19 light status :on/off for outgoing circuits, and on/off & trip status for
incoming breaker of office lighting DBs

.20 Irrigation system and water features

.2 The Contractor shall incorporate in the electrical equipment supplied, under the
other building scope of work for other packages, all the necessary auxiliary
contacts, control relays, current transformers, potential transformers, etc. and
install all the wiring connections, between the said equipment and the respective
system panels including the provision of all terminal strips in the panels to enable
the equipment to be controlled and/or monitored as outlined above. The
Contractor has to determine from the above list those equipment under his scope
of work and furnish the required components and wiring accordingly.

2.8 ALARM SCHEMES AND REMOTE INDICATION

.1 Alarms shall be sub-divided into trip and non-trip functions and each arranged to
operate a common bell or buzzer unless otherwise specified.

.2 Means shall be provided for silencing audible alarms whilst leaving the bell or
buzzer free to sound if any other alarm circuit is energised.

.3 Power supply for activating alarms and operation of any auxiliary relay etc. shall
be 240V as appropriate.

.4 Alarm indicating lamps shall remain alight until cancelled by the resetting of the
devices initiating the alarms and the operation of a separate cancellation switch.

.5 For the purpose of transmission to the remote control centre, alarms shall be
mainly segregated into groups but with some individual alarms and the
Contractor shall include for all auxiliary switches and relays necessary to present
these signals to the supervisory equipment interposing relays.

.6 The following shall be incorporated into the alarm and indication schemes for
transmission to the remote control centres: -

.1 11kV Circuit Breaker Panel

.1 Voltage indication (incoming only)

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 PROTECTION, METERING AND CONTROL
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.2 Digital Power Meter

.4 Circuit breaker ON/OFF/withdrawn status

.5 Earthing status

.6 Protection trip alarms (group)

.2 Load Break Switch

.1 Circuit breaker ON/OFF/withdrawn status

.2 Earthing status

.3 Transformers

.1 Winding temperature alarm

.2 AN/AF fan ON/OFF indication

.4 LV Main Switchboard (per Circuit Breaker Panel)

.1 Circuit Breaker ON/OFF/withdrawn status

.2 Digital Power meter

.3 Protection trip alarm (group)

.5 Motor Control Centres (per Circuit Breaker Panel)

.1 Circuit Breaker ON/OFF/withdrawn status

.2 Ammeter signal

.3 Voltage signal (incoming only)

.4 Protection trip alarm (group)

.6 Automatic Transfer Switch

.1 Changeover from normal to emergency

.2 Changeover from emergency to normal

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 PROTECTION, METERING AND CONTROL
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.3 ON/OFF/WITHDRAW status

.7 Individual Motor Starter Panel To building control system

.1 ON/OFF status

.2 Protection trip alarm (group)

.3 Remote start/stop

.4 Motor speed control (either 0 to 10V dc or 4 to 20mA)

.5 Motor speed monitor

.6 Motor running current

To fire alarm system

.1 Remote start/stop

.2 Motor status (ON/OFF) monitoring

To standby generator control panel

.1 Generator start/stop signals

.8 Distribution Board

.1 ON/OFF status

.2 Protection trip

.9 Air-Craft Warning Light

.1 ON/OFF status

.2 Protection trip

.10 DC Supply System

.1 Charger on float-charge

.2 Charger on quick-charge

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 PROTECTION, METERING AND CONTROL
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.3 Mains ON/OFF status

.4 Electrolyte level

.5 Charger output DC current

.6 Charger output DC voltage

.7 Mains failure alarm

.8 Charger failure alarm

.9 Earthfault alarm

.10 Low electrolyte level alarm

.11 Under-voltage alarm

.12 Over-voltage alarm

.11 UPS System

.1 Input Voltage

.2 Input current

.3 Inverter output voltage

.4 Inverter output current

.5 Inverter output KW

.6 DC Voltage

.7 Batter Current

.8 Inverter Fault

.9 Charger fault

.10 Emergency Shutdown

.11 Common Alarm

18009_Protection, Metering and Control

 PROTECTION, METERING AND CONTROL
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3.0 EXECUTION

3.1 GENERAL

.1 Protection and control schemes should in general, be based on the use of

stranded 2.5mm2 core cables.

.2 All control and relay equipment shall be flush mounted on panels. Equipment
and terminals, terminal blocks, and panel wiring shall be so arranged and
effected that they require a minimum of disturbance to associated and adjacent
equipment for access.

.3 Where relay movements and other sensitive equipment are mounted on hinged
front panels, these shall be designed to minimise shock and wiring shall be so
arranged as to impose no strain on the terminations. No equipment whatsoever
shall be mounted on the rear access doors.

.4 The arrangement and mounting of all indicating devices, control switches, relays,
and other apparatus shall be to the approval of the Employer's Representative.

.5 The Contractor shall submit for the Employer's Representative's approval the
total system protection coordination and grading including the setting values of
the protective devices. This shall be done 1 month prior to the commissioning
date.

3.2 PACKING, TRANSPORT, HANDLING, DELIVERY AND STORAGE AT SITE

.1 All protection, metering and control devices shall be fitted to their respective
switchboards and delivered to site as complete units. All sensitive and movable
parts shall be packed in suitable packaging material to prevent movement and
damage during shipment.

.2 They shall be adequately protected against the tropical climatic conditions

encountered during shipment.

.3 For instructions on storage at site refer to sub-clause on Storage in the relevant

switchgear/switchboard section.

3.3 TESTS

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 PROTECTION, METERING AND CONTROL
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.1 Type Tests

.1 Perform relevant type tests recommended in the IEC. In lieu of actually

carrying out the type tests, type test reports certified by acceptable testing
authorities may be submitted for approval of the Employer's
Representative.

.2 Routine Tests

.1 Before the products leave the works, the manufacturer shall carry out the
relevant routine tests in accordance with the IEC. Static relay electronic
components shall be heat soaked and burnt-in. Results of the tests shall
be submitted to the Employer's Representative.

.3 Acceptance Tests at Manufacturer’s Works

.1 Acceptance tests shall be carried out on the completely assembled units.

.2 The manufacturer test shall be verified and witnessed by the Employer

Representative’s and his representatives.

.4 Site Tests

.1 Refer to sub-clause on Site Tests for the relevant switchgear/switchboard

section.

3.4 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Provide training schedule and agenda and list of instructors from original
equipment manufacturer (OEM) and the trader contractor.

.2 Provide classroom training.

.3 Provide field training with demonstration on operation and maintenance.

.4 Review O&M Documentation and Test Results.

3.5 HANDING-OVER AND EMPLOYER’S ACCEPTANCE

.1 Endorse defects list.

END OF SECTION

18009_Protection, Metering and Control

 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Manufacture, test at Works, deliver to site, install and commission low voltage AC
distribution panels and marshalling cabinets.

1.2 WORK INCLUDED

.1 Low voltage AC distribution panels

.2 Auxiliary board

.3 Marshalling cabinets

1.3 SUBMITTALS

.1 Tender Stage

.1 Technical data and product catalogues

.2 All type test certificates of individual component from an internationally

recognized independent testing laboratory.

.2 Construction Stage

.1 Dimensioned shop drawings

.2 Single line diagrams for distribution panels

.3 Catalogue and samples

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance tests

.2 Acceptance test reports after tests

.3 Packaging, transportation and storage notes

.4 Site Installation

.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 2

.3 Pre-commissioning test records subsequent to testing

.5 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Except as modified by the Contract Documents, comply with the latest applicable
provisions and latest recommendations of the following:-

.1 IEC 60439-1 Low-Voltage Switchgear and Controlgear

Assemblies Part 1 - Requirements for Type-Tested
and Partially Type-Tested Assemblies.

.2 IEC 60446 Identification of Conductors by Colours or

Numerals

.3 IEC 60898-1 Electrical Accessories-Circuit-breakers for

Overcurrent Protection for Household and Similar
Installations-Part 1:Circuit-Breaker for A.C
Operation.

.4 BS EN 13601:2002 Copper and Copper Alloys. Copper Rod, Bar and

Wire for General Electrical Purposes

.5 BS 3900 Pt. E7 Methods of Test for Paints. Part E7 - Resistance to

Impact (Falling Ball Test).

.6 ASTM D3359-02 Standard Tests Methods for Tape Test Methods for
Measuring Adhesion by Tape Test ASTM
International

.7 BS 3900 Pt. F2

.8 BS 7079
 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 3

.2 Manufacturer shall have at least 10 years experience in the manufacture of

similar equipment.

2.0 PRODUCT

2.1 GENERAL

.1 The distribution panels, auxiliary board and marshalling cabinets shall be non-
ventilated, naturally cooled, metal-enclosed type, flush fronted and suitable for
front access and shall be built to comply with IEC 60439-1. All louvers shall be
covered with wire mesh.

.2 The distribution panels and auxiliary board shall be mounted and house
moulded-case circuit breakers, miniature circuit breakers, residual current
devices and busbars as indicated in the Contract Documents.

.3 The marshalling cabinet shall be suitable for wall or floor mounting as

appropriate.

.4 All necessary fixing material, mounting bolts, etc. shall be provided for the type of
mounting mentioned.

.5 All operating devices shall be mounted for installation, cable termination and
maintenance operation at the front of the panel.

.6 All distribution panel located outside riser and public area shall have key lock
handle.

2.2 EXTERNAL FEEDER PILLAR

.1 The construction of feeder pillar shall comply to local authority requirements. The
contractor shall obtain approval on the location and construction of the feeder
pillar from local authority's.

.2 The feeder pillar shall be Form 1 construction and manufactured from sheet steel
thickness of 2 mm thick minimum, anti-rust coated steel plate. The structure shall
be reinforced with angles or channel irons. The feeder pillar roof shall be a
“house” pattern and not flat.

.3 The feeder pillar shall rest on an angle iron frame where suitable holes have
been prepared to locate foundation bolts and to secure the feeder pillar onto a
concrete footing.
 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 4

.4 An earthing terminal in the form of a bolt of minimum dimension of 6mm in

diameter and 20mm long shall be welded onto the base frame for connection of
the earthing strip, where applicable.

.5 Doors for the feeder pillar shall be lockable with either wedge type locks
protected by screw plug or some other form of secret lock approved by the
Employer’s Representative. The doors shall be hinged internally to prevent
unauthorised access. Door hasp shall also be provided for additional padlock
security.

.6 The feeder pillar shall be self-ventilated and weatherproof and complying IP 65.
Anti-corrosive treatment shall be applied to the feeder pillar and shall be finished
with two coats of approved paint. A non-perishable resilient gasket shall be
provided all round the edge of the feeder pillar door.

.7 Additional 20% spares MCCB/MCB shall be provided. Socket outlet and lighting
shall be provided within the feeder pillar for night time maintenance.

.8 Contactor and time switch provided in the feeder pillar shall be approved type.
The activating coil of each contactor shall be wired up by means of a set of minor
fuses so that it can be energised by any of the following: -

.1 Main Road : “Photocell , By-pass and Timer”

.2 Local Road : “By-pass and Timer”

.9 A circuit identification chart sealed within a clear plastic laminate shall be

attached to the inside of the feeder pillar.

2.3 ENCLOSURE AND DEGREE OF PROTECTION

.1 The enclosure structure shall be fabricated from rolled steel angle sections and
shall be self supporting when assembled, uniform in height and depth from front
to back. Sheet steel used shall not be less than 2 mm thick, anti-rust coated steel
plate.

.2 The distribution panels, auxiliary board and marshalling cabinets shall be rigidly
constructed to be stand alone units without any danger of sagging, deformation
or warping.

.3 The front covers of the distribution panels, auxiliary board and marshalling
cabinets shall be of hinged-door type. The front doors shall be provided with
lockable push button typed. The doors shall be arranged to seal onto the board
 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 5

frame by means of a non-perishable duct-proof material. The sealing material

shall be synthetic rubber and not foam. Doors shall be effectively earthed to the
fixed enclosure by braided straps. Cover bolts or nuts shall be retained in place
when undone.

.4 For all internal DB, the degree of protection for the enclosures as per IEC 60529
shall at least be IP 41. When the doors are opened, the degree of protection to
all live parts shall at least be IP 20.

.5 Distribution panels and auxiliary board shall have Form 1 construction in

compliance with IEC 60439-1.

.6 The incoming and outgoing cable entry on the distribution panels and auxiliary
board shall be protected with rubber material to prevent cables damage.

2.4 SELECTION OF COMPONENTS

.1 All components shall be standardized as far as practical and shall comply with
relevant IEC publications.

.2 Busbars

.1 Busbars for the distribution panel and auxiliary board shall be of plain
hard-drawn, high conductivity, electrolytic copper bars in accordance with
BS EN 13601:2002 and of adequate rectangular cross-section to carry
continuously the specified current without overheating and shall be rigidly
mounted on insulators so as to withstand any mechanical force to which
they may be subjected under maximum fault condition.

.2 Busbars shall be coloured red, yellow and blue and black at appropriate
points to distinguish the phases and neutral. No tapes shall be used.

.3 Moulded-case circuit breakers

.1 For moulded-case circuit breakers, refer to section LOW VOLTAGE AC

SWITCHBOARDS.

• Typed test certificates shall be produced for the MCCB selected from
international recognized testing laboratory.

.4 Miniature circuit breakers

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SECTION 18010

PAGE 6

.1 Miniature circuit breakers shall comply with IEC 60898-1. They shall be
incorporated with overcurrent protection. Their selection for use shall be
matched as their operating characteristics.

.2 Typed test certificates shall be produced for the MCB selected from
international recognized testing laboratory.

.3 Performance Criteria

.1 Breaking Capacity

The rated short-circuit capacity, Icn, shall be higher or at least

equal to the maximum prospective short-circuit current at the
points of installation as stated in the single-line drawings.

The rated service short-circuit capacity, Ics, of 6kA and 10kA

breakers shall be 100%Icn and 75%Icn respectively.

.2 Co-ordination

All circuit breakers in the distribution boards shall be from the

same manufacturer and total discrimination with the upstream
breakers under over-current conditions shall be guaranteed.
Details of the operating characteristics and the coordination with
other protective devices shall be submitted to the Engineer for
approval. The details shall include the manufacturer’s full current
discrimination tables showing the over-current discrimination
levels.

Back-up protection is permitted when a current limiting circuit

breaker is installed in the upstream. Details of this coordination
shall be submitted to the Engineer for approval. The details shall
include the manufacturer’s back-up protection tables showing the
upstream/downstream devices and the coordinated level of
protection.

.3 Installation

The MCB shall be fully rated for uninterrupted continuous service

based on an ambient temperature of 30°C.

The MCB shall be of 35mm DIN symmetrical rail mounted type

and available in one, two, three and four poles version.

The MCB shall be suitable for mounting in any positions with no

de-rating.
 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 7

.4 Construction

.1 Trip Characteristics

The trip characteristics of the MCB shall be Type B, C or D as indicated in

the drawings.

.2 Operating mechanism

The operating mechanism shall be of the quick-make quick-break type,

with the speed of operation independent of the operator. In addition, the
breaker mechanism shall also be mechanically trip free from the
operating handle so as to prevent the contacts from being held closed
against short circuit and other abnormal conditions.

The operating mechanism shall be designed to operate all poles of a

multi-pole breaker simultaneous during opening, closing and trip
conditions. The individual operating mechanism of each pole of a multi-
pole MCB shall be directly linked within the MCB and not by the operating
handles alone.

All MCB shall be tested for isolating function as stipulated in IEC60898.

The isolation function shall guarantee that the breakers when in the open
position, should have an isolation distance in accordance with the
requirements necessary to satisfy the need for users’ safety.

Means of Positive Contact Indication to mimic the exact position of the

contacts shall be provided. The indication of the open and closed position
of the main contacts shall preferably be provided by the position of the
actuator. Color-coded bands and lettering on the actuator shall be
incorporated to aid identification.

The operating handle shall be of the toggle type with facility for installation
of padlock device.

All MCB shall have optional field installable accessories like shunt-trip
coil, under-voltage release, ON/OFF indications, alarm switch, etc. The
installation shall be flexible such that to allow for fitting of accessories to
either the left of right side of the MCB.

All MCB must be suitable for remote controlled on/off operations via an
electrical motor operator.
 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 8

.3 Terminals

The MCB shall have double function terminals to allow correct

termination of busbar and cable. The top terminal shall be suitable for PIN
busbars, the bottom terminals shall be suitable for both PIN & FORK
busbars.

The cable terminals shall be equipped with safety guards to protect

against misconnection. The safety guards shall function in a manner such
that there is only one possibility of cable insertion into the MCB terminals,
this will eliminate all possibilities of loose cable terminations because of
wrong insertions.

.5 Residual current devices

.1 Residual current devices shall be provided as indicated in the design

drawings and construction drawings.

.2 Refer to Section : PROTECTION, METERING AND CONTROL for

details.

.3 Typed test certificates shall be produced for the RCCB/ELCB selected

from an international recognized independent testing laboratory.

.6 Terminals for external conductors

.1 Terminals shall be suitable for copper conductors and of proprietary

design.

.2 As a standard, assemblies shall have facilities for the entry of cables from
the top and bottom. Cable entries, cable clamping, earthing facilities and
supporting devices shall be provided suitable for the type, size and
number of cables.

.3 Terminal blocks in the marshalling cabinets shall have individual

disconnecting links. All terminals connected to current transformers shall
have shorting links instead.

.7 Secondary cable and core identification ferrules

.1 Both ends of each conductor shall be provided with identification ferrules.

The ferrules shall be of insulating material which shall be unaffected by oil
or damp. Characters shall be suitably marked in black. The ferrules shall
be of the continuous ring type, not of the slip-on type. Marking shall be in
accordance with the related manufacturer’s drawings.
 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 9

.2 The minimum allowable cross-sectional area of control wires shall be

1.0mm². wires with a cross section of larger or equal to 1.5mm² shall
always be stranded.

.3 Current transformer secondary circuits with 5A rating shall be 2.5mm²

minimum.

.4 Colour coding of wiring shall be in accordance with IEC 60446. Earth

wires shall be green/yellow striped. Wiring between two terminals shall be
continuous, joints or interconnections are not allowed.

.5 Each wire shall be connected to each terminal connection.

.6 As a minimum requirement, use shall be made of rail-mounted terminals

(TS 32 rail assembly) of high-grade Melamine. Partitions shall be fitted
between terminals for different voltages.

.7 Wiring ends of stranded conductors which have to be connected into bus

type contacts of terminals, shall be provided with compression-type pre
insulated wire pins with insulation support. In general, when lugs, wire
pins, etc., are used, they shall be of the compression type.

.8 To accommodate and support the secondary wiring, covered plastic

channels, insulated tubes or plastic strips shall be used.

.9 Wiring shall never be mounted direct to metal. The filling factor for
channels shall be exceed 70%. Where supporting of a wire is not feasible,
the wire or part of it shall be as short as possible.

.8 Finishing and painting

• All metal structures and sheet shall be adequately protected against

corrosion. Preparation of surfaces for painting shall be made complying
with BS 7079. All mill scale, loose rust and welding slag, shall be
removed by hand tools and the metal surfaces shall be cleaned free from
dirt, oil, grease, wax and other contaminants.

.2 The sheet steel shall be zinc phosphate treated to a minimum thickness

of 3.0g/m² prior to the application of paint.

.3 The manufacturer’s standard is acceptable, if at least equivalent to using

the electrostatic spray process and oven-baked with:-

.4 One coat of stoving primer (zinc epoxy primer) of minimum thickness 30

microns.
 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 10

.5 One coat of melamine resin paint of minimum thickness 30 microns.

.6 One final top coat of melamine paint of minimum thickness 15 microns.

.7 Alternatively, the metal surfaces shall be coated with a layer of weather

resistant paint (epoxy polyacrylic for primer and top coat) via cathodic
electro deposition process. The dry film thickness shall be at least 35
microns.

.8 All panels shall have a consistent and matching paint finish. The final top
coat colour shall be light grey or manufacturer’s standard colour subject
to Employer representative’s approval.

.9 The assembly shall be treated in all respect to provide a lasting durability

under the specified services conditions.

.10 Repair painting shall be done when there is development of any

detrimental film irregularity such as lifting, loose, cracked, brittle or non-
adherent paint or discoloration after completion of painting.

.11 The equipment supplier shall submit detail of his painting system and
procedures for review and approval by the Employer’s Representative.

3.0 EXECUTION

3.1 INSTALLATION

.1 Distribution Panels

.1 All installation procedures shall follow manufacturer's recommendation.

.2 Records shall be kept of installation works and submitted to the

Employer's Representative.

.3 Complete incoming and outgoing power circuits and wiring shall be

installed.

.4 The completed installation shall contain no extraneous openings.

.2 Marshalling Cabinets

.1 When installing earth bars, ensure that the joint surfaces are clean before
tightening bolts of the correct size.
 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 11

.2 Complete and check power and control wiring prior to pre-

commissioning.

.3 Replace all cover and carry out pre-commissioning checks.

.4 All installation procedures shall follow manufacturer's recommendation.

.5 Records shall be kept of installation works and submitted to the

Employer's Representative.

3.2 PACKING, TRANSPORT, HANDLING, DELIVERY AND STORAGE AT SITE

.1 Distribution panels and marshalling cabinets shall be packed and delivered

appropriately labelled for easy identification at site. They shall be securely
packed to prevent any movement and damage during transport and against
tropical climatic conditions encountered during shipment.

.2 Manufacturer shall provide information for unpacking and lifting safely, including
details of any special lifting and positioning devices, if necessary.

.3 On arrival at site, the consignment shall be checked against the delivery notes.

.4 On delivery to site, the distribution panels and marshalling cabinets shall be

stored indoor in a clean, dry and ventilated place to prevent moisture
condensation and consequent damage and malfunction.

3.3 TESTS

.1 Type Tests

.1 Perform relevant type tests recommended in the IEC. In lieu of actually

carrying out the type tests, type test reports certified by acceptable testing
authorities may be submitted for approval of the Employer’s
Representative.

.2 Routine Tests

.1 Before the products leave the works, the manufacturer shall carry out the
relevant routine tests on the total assembly and on parts thereof when
delivered with time intervals and the results shall be recorded in a test
report.

.3 Acceptance Tests at Manufacturer's Work

 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 12

.1 The following checks and tests shall at least be carried out.

.2 Distribution panels shall be visually inspected for technical execution and

conformity with the latest issue of the approved drawings and with the
order. Spot checks shall be made to verify:

.1 Dimensions

.2 Degree of protection of the enclosure

.3 Panel layout and number of outgoing circuits

.4 Proper mounting of components

.5 Arrangement and correct wiring of main circuits

.6 The suitability of clamping, earthing and terminating

arrangements

.7 The availability of the earth bar in the panel

.8 The interchangeability of electrically identical components

.3 Insulating resistance test between phases/neutral and between each

phase/neutral against earth, with the remaining phase/neutral connected
to earth. The insulation resistance tests shall be carried out with all
manually operated and latched type, switching devices in the closed
position and all main fuses installed. The insulation resistance measured
shall be at least 5 mega - Ohms. The voltage applied shall be at least 1.1
times Un DC.

.4 Testing of the mechanical and electrical operation of a number of

functional units on random basis, including their control and protective
devices.

.5 Painting and finishing tests

.1 Measurement of paint thickness.

.2 Humidity (cyclic condensation) test to BS 3900 Pt. F2. Painted

panel shall withstand 1000 hours under test with no blistering of
film and corrosion of base metal.
 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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SECTION 18010

PAGE 13

.3 Adhesion test to ASTM D3359-02. Test tape shall not expose

more than one 3 mm2 of bare metal or underlaying coating.

.4 Impact resistance test to BS 3900 Pt. E7. Paint shall not chip off.

.5 The manufacturer test shall be verified and witnessed by the

Employer Representative’s and his representatives.

.4 Site Tests

.1 At the completion of installation, each panel shall be field tested by a

representative of the manufacturer. A report recording each item of the
tests shall be certified by the manufacturer and submitted to the
Employer's Representative.

.1 Visual inspection

.2 Metal work and paint work.

.3 Mounting of components.

.4 Internal wiring and cabling system.

.5 Clamping, earthing and terminating arrangement.

.6 Earthing system.

.7 Insulation resistance measurement

.8 Power frequency withstand voltage test

.2 Mechanical operation test of each disconnecting means under load

3.4 MISCELLANEOUS EQUIPMENT

Equip the Electrical Room (ER) with the following miscellaneous items: -

.1 All the requisite labels.

.2 Latest approved As-built drawings in A4 size lamination.

.3 Approved fire detection and fire fighting apparatus.

 DISTRIBUTION PANELS, AUXILIARY BOARD AND
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PAGE 14

.4 Earthing bar installation along the perimeter of the room connected to the
mainearthbed system.

3.5 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Provide training schedule and agenda and list of instructors from original
equipment manufacturer (OEM) and the trader contractor.

.2 Provide classroom training.

.3 Provide field training with demonstration on operation and maintenance.

.4 Review O&M Documentation and Test Results.

3.6 HANDING-OVER AND EMPLOYER'S ACCEPTANCE

.1 Endorse defects list.

.2 Provide all keys.

END OF SECTION
 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Manufacture, test at factory, deliver to site, install, test and commission 11kV
metalclad switchboards in accordance with the Contract Documents.

1.2 WORK INCLUDED

.1 415V metalclad switchboards complete with protective relays, metering and

control equipment.

.2 Disconnecting fuse switches.

1.3 SUBMITTALS

.1 Tender Stage

.1 Technical data of main equipment and components such as protective relays,

instruments, etc. and product catalogues.

.2 Type test certificates of circuit breakers, etc. to ASTA, UL, KEMA and
internationally recognised independent laboratory.

.2 Construction Stage

.1 To repeat the above tender stage submission.

.2 Dimensioned outline drawing of metalclad switchboard when fully assembled

(plans, section and elevations), identifying all principal fittings, parts to be
removed for transportation and total mass.

.3 Single line diagrams showing all the components used.

.4 Front panel component arrangements

.5 Schematic/wiring diagrams

.6 Protection and control wiring diagrams

.7 Shop drawings/construction drawings

.8 Catalogue and technical data to be resubmitted with shop drawings inclusive of

all associated components
 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 2

.9 Nameplate information

.10 Mimic bus arrangement

.11 Full load heat rejection in Btu per hour of each switchboard

.12 Data on structural supports, metal thickness, surface finish, provisions for
lifting and foundations etc.

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance tests

.2 Acceptance test reports after tests

.3 Packaging, transportation and storage notes

.4 Site Installation

.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.5 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Except as modified by governing codes and by the Contract Documents, comply with
the latest applicable provisions and latest recommendations of the following:

.1 IEC60044-1 Instrument Transformers-Part1:Current

Transformers

.2 IEC 60056 High Voltage Alternating-Current Circuit

Breakers
 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 3

.3 IEC 60071 Insulation Co-ordination

.4 IEC 60129 AC Disconnectors and Earthing Switches

.5 IEC 60186 Voltage Transformers

.6 IEC 60265-1 High Voltage Switches – Part 1:Switches for

Rated Voltages Above 1kV and Less than
52kV

.7 IEC 60269 Low-Voltage Fuses

.8 IEC 60282-1 High-Voltage Fuses-Part 1

.9 IEC 60445 Identification of Equipment Terminals and of

Terminations of Certain Designated
Conductors, including General Rules for an
Alphanumeric System

.10 IEC 60446 Identification of Conductors by Colours or

Numerals

.11 IEC 60529 Degrees of Protection Provided by

Enclosures (IP Code)

.12 IEC 60694 Common Specifications for High Voltage

Switchgear and Controlgears Standards

.13 IEC 60947-5-1 Low Voltage Switchgear and Controlgear-

Part 5-1 Control Devices and Switching
Elements-Electromechanical Control Circuit

.14 IEC61000-4-2 Electromagnetic Compatibility (EMC)-Part

2:Testing and Measurement Techniques-

.15 IEC 61000-4-3 Electromagnetic Compatibility (EMC)-Part

3:Radiated,Radio-Frequency,
Electromagnetic Field Immunity Test

.16 IEC 61000-4-4 Electromagnetic Compatibility (EMC)-Part

4:Electrical Fast Transient/Burst Immunity
Test

.17 IEC 62271-100 High-Voltage Swicthgear and Controlgear

Part 100:High Voltage Alternating-Current
Circuit-Breakers
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.18 IEC 62271-102 High Voltage Switchgear and Controlgear-

Part 102:Alternating Current Disconnectors
and Earthing Switches

.19 IEC 62271-105 High Voltage Switchgear and Controlgear-

Part 105: Alternating Current Switchfuse
Combinations

.20 IEC 62271-200 High Voltage Switchgear and Controlgear-

Part 200: Alternating Current Metal-
Enclosed Switchgear and Controlgear for
Rated Voltages above 1kV and up to and
including 52kV

.21 BS EN13601:2002 Copper and Copper Alloys Copper Rod, Bar

and Wire for General Electrical Purposes

.22 BS 381C Specification for Colours for

Idenfication, Coding and Special
Purposes

.23 BS 3900 Methods of Test for Paints. Part E7 –

Pt. E7 Resistance to Impact (Falling Ball
Test)

.24 ASTM D3359-02 Standard Test Methods for Measuring

Adhesion by Tape Test ASTM International

.25 BS 3900 Methods of Test for Paints. Part F2 –

Pt. F2 Determination of Resistance to
Humidity (Cyclic Condensation)

.26 BS 7079 Preparation of Steel Substrates before

Application of Paints and Related Products.

.2 Manufacturer shall have at least 10 years experience in the manufacture of

similar equipment.

.3 Each switchboard as a complete and finished product shall receive a single

integrated equipment rating by the manufacturer. The integrated equipment
short-circuit rating shall certify that all equipment is capable of withstanding the
thermal and magnetic stress of fault equal to the value specified on the Contract
Documents. Such rating shall be established by actual tests by the manufacturer
on similar equipment. This certification shall be permanently affixed to each
switchboard. Test data shall be submitted to the Employer’s Representative at
time of submission of Acceptance Drawings.
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.4 Manufacturer shall have full parts back-up and normal (within 1 day) service
availability for equipment provided.

2.0 PRODUCT

.1 This contract is to cover the manufacturing, supply, delivery, off loading,

installation and testing of indoor metal clad 11kV switchgear complete with
control panels and all required protection relays and equipment as specified.

2.1 QUALITY AND DESIGN EQUIPMENT AND CLIMATIC CONDITIONS

.1 The design, manufacturing and testing of the equipment offered shall be strictly
in accordance with this specification and the current editions of the Standard
Specifications and Codes of Practice.

.2 The equipment shall be designed to include all possible provisions for the
safety of those concerned in the operating and maintenance thereof.

.3 Where is it not possible to protect metal parts by painting or galvanizing, these

parts shall be constructed of stainless steel or brass.

• Control panels shall be designed to be rodent proof.

2.2 STATUTORY REQUIREMENTS

.1 Layouts of Equipment

.1 The contractor shall ensure that the layout of the equipment to be

supplied on this contract is such that in the operating condition it shall
comply fully with the regulations.

.2 Where equipment supplied on this Contract is to be positioned in

the proximity of existing equipment, structures or plant, the Contractor
shall establish beyond any doubt that the said Regulations shall not be
contravened by virtue of this proximity during the erection and testing

periods and in the final operating conditions. Any queries in this regard
must be submitted in writing to the Engineer.

.3 Where special inspection and testing are required the cost shall be
in the contract price for the equipment and the contractor shall be
responsible for the arrangement of such inspections and testing.

2.3 SAFETY AND RELIABILITY

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.1 Switchgear and controlgear shall be designed to minimize any risk of short

circuit and to ensure personnel and operational safety during all operating
conditions, inspections, maintenance, the connection of main, control and
auxiliary cables, and the equipping and commissioning of spare panels
whilst the switchgear is live and in operation.

.2 As a minimum requirement it shall be suitable for continuous operation at

full load for at least 27,000 hours without maintenance which would require
the busbar and associated systems to be de-energized.

.3 Even under extreme conditions of major short circuits or mal-operations

there shall be no danger to persons in the vicinity of the assembly.
Propagation of an internal fault from one compartment to another shall not
be allowed to occur.

.4 Enclosures shall comply with IEC 62271-200, with regard to their

mechanical strength in the event of an internal arc. The test performance
shall be in conformity with type A and the maximum allowable arc duration
shall be stated by the manufacturer.

.5 Internal arc tests shall be carried out on the panel(s).

2.4 PAINTING

.1 General

.1 The material shall be completely shaped, cut, drilled, countersunk,

welded, etc., before any paint work commences.

.2 Painting of non-galvanized steelworks

.1 Cubicles which contain wiring and other apparatus and are assembled in
the works shall receive the external-finishing coat of paint in the works.

.2 Before painting the parts shall be thoroughly cleaned by sand or shot-

blasting or metal brushes and acid bathed to remove all traces of rust,
scale or grease.

.3 Immediately after cleaning, all rough surfaces shall be filled.

.4 Paint finish shall be powder coat in excess of 40 microns. White chassis

plates shall be supplied.

2.5 LABELS
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.1 All equipment to be supplied in this contract shall be provided with clear and
concise descriptive labelling describing the function and the circuit number of the
apparatus concerned.

.2 In the case of open busbars, phase identification discs shall be fitted where
practical i.e. for strung busbars on the gantry beam below every string insulator
set and for solid busbars on post insulator support pedestals. These shall be
150mm diameter discs and shall be coloured red, yellow or blue according to
phase and shall be fitted to be visible from ground level.

.3 The indoor equipment such as black 60mm letter R, Y or B as relevant on the

coloured background.

.4 Each indicator lamps shall be labeled to indicate its function.

.5 Complete particulars of instrument transformers and surge diverters must be

labeled or stamped permanent weatherproof labels.

2.6 SPECIAL TOOLS

.1 Where special tools are required for effecting adjustment, for dismantling
purposes or for maintenance, a full kit of such tools shall be provided.

.2 The cost of the special tools shall be deemed to have been included in the price
of the device for which they are required, unless specially listed.

.3 These tools are not to be used during erection of equipment.

• A floor standing toolbox must be provided to house special tools.

2.7 OPERATING MECHANISM

.1 Motorised Operation

.2 Control switches shall be conveniently located on all switchgear.

.3 Provision shall be made for locking the mechanism in the open or closed position
by means of padlocks.

.4 Control switches must be arranged to operate in one direction when closing and
in opposite direction when opening. The control switches must be spring return
position. An approved method of locking the control switches in the neutral
positions must be provided.
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.5 Circuit breaker mechanisms shall be trip free as defined in IEC 62271-100. It is

recognized that it may be necessary for contacts to close momentarily prior to
opening to ensure satisfactory current interruption.

.6 In the event of the mechanism failing to latch in the closed position, the circuit
breaker shall be arranged to open at normal speed. Provision shall be made for
manual slow closing the circuit breaker for maintenance purposes, but it shall not
be possible to use this facility when the circuit breaker is in the 'SERVICE' position.

2.8 CHARGED SPRING MECHANISM

.1 The spring of spring operated mechanism shall be motor charged but it shall also
possible to charge the spring manually.

.2 The motor shall be operated from the substation battery supply, the voltage of
which shall be as specified.

.3 Two handle/lever for the manual charging of the spring shall be housed in the
mentioned toolbox.

.4 The spring release coil shall be suitable for operation from the substation battery
supply or any voltage between 80% and 120% of the nominal supply voltage
specified.

.5 The three phases of the circuit breaker shall be operated from a single drive
mechanism.

.6 Control of the spring close/open mechanism shall be possible from the local
control or from a remote source, depending on the position of the ‘local/remote’
selector switch.

.7 A mechanically operated device shall indicate whether the spring is charged or

free and this shall be visible.

.8 Suitable thermal overload protection must be provided for the motor.

.9 It shall be possible to charge the mechanism spring with the circuit breaker in
either the 'OPEN' or 'CLOSED' positions. It shall not be possible for the circuit
breaker to close unless the spring is fully charged. A visual indicating device,
preferably mechanical, shall be provided to indicate 'SPRING CHARGED' when
the spring is in a condition to close the circuit breaker and 'SPRING FREE' when
the spring is not in a condition to close the circuit breaker. If a charged spring is
released when the circuit breaker is closed, the circuit breaker shall not open and
neither shall such operation result in damage.
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.10 The mechanism shall be fitted with a local manual spring release, preferably a
push button, covered to prevent inadvertent operation and provided with means for
padlocking. In addition, an electrical spring release shall be required as specified.

.11 Motor charging of the spring mechanism shall be fitted with DC motor. Re-
charging of the mechanism operating spring shall commence immediately and
automatically upon completion of each circuit breaker closure. The spring shall be
fully charged in not more than 15 seconds. On motor charged mechanisms an
emergency hand operated charging device shall be supplied.

.12 The shunt trip coils and closing spring release coils fitted in the circuit breaker shall
be rated at the DC voltage specified.

2.9 INSTRUMENT TRANSFORMERS

.1 Voltage Transformers

.1 Plug-in contacts shall be used and provision shall be made for locking the
voltage transformers in the service or withdrawn position. Shutters shall be
fitted to the spouts and shall open and shut automatically by the insertion of
the voltage transformer. The secondary winding earth connection shall be
made before the primary connections are made. The spout shutters shall
be painted yellow or red depending on whether they are connected to the
circuit side or the busbar side of the circuit breaker and labeled 'VOLTAGE
TRANSFORMER' in white letters. The enclosure for the voltage
transformer shall be appropriately labeled 'BUSBAR VT' or 'CIRCUIT VT' in
red letters.

.2 The ratio, burden and class of the voltage transformers required shall be
as specified. 11,000/110 volt 3 phase voltage transformers shall comply
with the requirements of IEC 60186.

.3 The voltage transformers shall be totally encapsulated in epoxy resin or

other suitable material. The primary bushing shall be connected to either
the busbar-side or the circuit-side as specified.

.4 The secondary connections shall be fused at the voltage transformer.

.5 Separate set of voltage transformer shall be provided for local authority

metering purposes and consumer application.

.6 Depending on system requirement, the preferred winding connection are

as follows:-

.1 HV winding - star-connected, star point-earthed

.2 LV winding - star-connected, star point-earthed

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.7 The primary windings shall be connected to the busbar or feeder side of the
circuit breaker as specified through renewable fuses of adequate breaking
capacity with current limiting features. HRC type secondary fuses shall be
provided. These shall be so placed as not to be accessible to unauthorised
persons but shall be of suitable arrangement for safe removal and
replacement whilst the busbar is live.

.8 Connections to the voltage transformer primary fuses shall be capable of

carrying the circuit breaker rated short-time withstand current.

.2 Current Transformers

.1 The ratio, burden and class of the current transformers required shall be
as specified in the technical data sheets.

.2 The current transformers shall comply with the requirements of IEC

60044-1.

.3 Tenderers shall supply the magnetization curve details, saturation factors,

knee point voltages etc. Of the current transformers offered.

.4 Block type current transformers are preferred when resin encapsulated

current transformers are offered. No strain due to cable terminations shall
be exerted on the primary connections of the current transformers.

.5 Each current transformer shall be equipped with 5P20, class 0.2 for
metering and class 1.0 for measurement and burden windings are
specified.

.6 The primary windings shall have a short time current rating of not less
than that of the associated circuit breaker.

.7 All current transformers connections shall be brought out to spring loaded

terminals.

.8 The securing of the individual current transformers in the common

housing shall be such that vibration during service shall not damage the
windings.

.9 The tenderer shall ensure that the current transformers are suitable for
the protection relays or metering instruments with which they are to be
associated. Where the relays or instrument are to be supplied on a
separate contract the Engineer, on request, will provide the name of the
contractor concerned or the details of the relays or instruments.
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.10 Current transformer circuits shall be earthed via a removable link in the
control panel and this shall be the only earth point.

2.10 CONTROL, INDICATION AND PROTECTION

.1 The control panel shall be mounted on top of the switchgear panel. Make
up of a separate cubicles for each main circuit. The final panel arrangement must
have a continuous and uniform appearance.

.2 The panels shall be fabricated of steel of not less than 2mm thickness.

.3 The panel shall be capable of being extended at either end by the addition of
further cubicles.

.4 All relays and instruments shall be of the flush mounted type. Particulars of
relays and instruments required shall be as given in the technical data sheets.
The relay cases shall all be earthed.

.5 All relays and instruments must be labeled to indicate their exact function. Relay
type numbers only are insufficient.

.6 All panels shall be continuously earthed by means of 25 x 6 mm copper earth

bar.

.7 Adequate openings between panels shall be provided for any interconnection

wiring to prevent wires from being damaged.

.8 Degree of protection shall be to IP3X

2.11 CONTROL METHODS AND CONTROL SWITCHES

.1 Electrical control of circuit must be possible from the local or remote position - a
control switch marked local/remote on or at the circuit breaker shall determine
whether control shall be from the breaker or from a remote source.

.2 Open/Close control switches on the control panel and at the circuit breaker must
be arranged to operate in one direction for a close operation and in the opposite
direction for an open operation. The switches must be spring return to the neutral
position after being operated.

.3 The control and selector switches must be robust and shall be to the satisfaction
of the Engineer.

.4 All control methods shall be subject to all the necessary interlocks.

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2.12 RELAYS

.1 All protective relay shall be of the flush mounting type and shall be contained in
dust-proof case with an interior finish of aluminium or other approved material.
Relays of the hand reset type shall be capable of being reset without the
necessity for opening the case.

.2 It shall not be possible to operate any relay by hand to ‘trip’ without opening the
case.

.3 All protective relays shall, except where otherwise approved, be provided with
double contacts independent of each other, for controlling duplicate tripping
circuits if necessary.

.4 Contacts of relays shall be of silver, platinum or other approved material and

shall be capable of repeated operation with minimal deterioration.

.5 High speed tripping relays shall be self latching and, unless otherwise specified,
the coil circuit shall be broken by self contained contracts.

.6 All DC operated relays shall operate satisfactorily in a voltage range of minus

20% to plus 20% of the nominal battery voltage.

.7 All relays shall be marked with the function of the relay.

.8 Distance protection relays (where specified) shall be of the numerical type with
fault recording. They shall have switched, stepped zone tripping characteristics
which depend on the proximity of the fault. The distance covered by each zone
and trip delay(except zone 1which shall be instantaneous) shall be widely and
independently variable. The protection system shall operate correctly under
changing fault conditions such as the remote operation of a fault thrower or
power swing and must provide definite stability for reserve faulting the first two
zones. A following zone shall be provided which shall be non-directional with an
adjustable (definite) time delay. The relay shall be suitable for remote signal
tripping acceleration or blocking. Unless otherwise specified, over current starting
shall be suitable. The range of impedance setting shall suit relatively short
lines/cables and shall be to the approval of the Engineer. Trapezoidal
characteristics are preferred.

.9 Inverse definite minimum time (I.D.M.T) over current relays (where specified)
shall be of the solid state or numerical type and have adjustable operating
settings from 40% to 400% of the normal full load secondary current, with an
adjustable time setting. These over current relays shall provide selectable
alternative time/current characteristics and high set definite time operation.
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.10 I.D.M.T. earth fault relays (where specified) shall be of the solid state or
numerical type and have adjustable operating setting from 8% to 80% of the
normal full relays load secondary current, with an adjustable time setting, these
earth fault relays shall provide selectable alternative time current characteristics
and high set definite time operation.

.11 In cases where the individual over current and/or earth fault elements are
effectively combined into one relay, this relay shall still provide indication to
discriminate the reason the relay has operated (i.e.,I.D.M.T.) over current or
earth fault, high set over current or earth fault) and which phase has faulted.

.12 Restricted earth fault relays ( where required ) shall be instantaneous unless
otherwise specified. They shall be of the high impedance type and shall be stable
under transient and through-fault conditions.

.13 Where pilot wire feeder protection is specified, this may be required to match
existing equipment. Inter-tripping shall be effected by short circuiting the pilots. A
scheme which involves open circuiting the pilot wires will not be accepted. A
matching relay shall be supplied for use on the far end of the protected circuit.
Adequate transient protection shall be provided on the pilot wires (5kV) against
damage to any relays and/or relevant equipment.

.14 Biased Differential transformer Protection, (where specified) shall employ second
harmonic restraint to prevent operating during magnetization inrush, and shall not
required interposing CT’s for ratio correction.

.15 Pilot wire operated inter-trip receive (where specified) shall be provided with low
pass filters to prevent mal-operation as a result of imposed alternating voltages
of up to 5000 volts on the pilot wires. As a common pair of pilot wires will be
required for send and receive, contracts of the local inter-trip send relay must be
wired to open the local receive relay circuit. The master trip relay maybe used for
inter-trip send.

.16 All other relays specified, shall be to the approval of the Engineer.

.17 Relays that employ electronic sensing shall incorporate testing facilities to enable
the function of the relay to be tested without removing it from circuit, while the
primary circuit is on load.

.18 Power supplies for solid state relays must be provided with an alarm contact
which closes when the power supply fails. The primary sources of power shall be
the substation battery.

.19 Breaker fail current check required to initiate high speed back-up tripping
must be built into IDMT relay and shall be to the approval of the Engineer. The
AC circuit of the relay shall have instantaneous operating settings of 20 to 200%
of rated current and shall be continuously rated for at least twice rated current
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and for 30 times rated currents for 2 seconds. The DC circuit of relay shall be
continuously rated for the maximum substation voltage. It must be possible to set
the time delay over a range from 100 milliseconds to 200 milliseconds, The
actual setting being determined after consultation with the Engineer. The
accuracy of the time relay must be within 5% over the working temperature
range.

.20 No relay shall be mounted higher than 1600mm.

.21 Provision shall be made for the supply, installation and commissioning
of
remote end pilot wire protection relays unless otherwise specified.

2.13 INDICATION AND ALARMS

.1 Lamps indicating the switch condition shall be red for closed, green for open.

• The alarm scheme shall be such that whenever any circuit breaker is tripped for
any reason other than operation by means of control switch or a supervisory
control relay, a self-sealing, double-contact common alarm relay centrally
mounted on the control panel will operate. Cancellation of this alarm shall be by
means of a push-button in the sealing circuit of the common alarm relay. This
common alarm relay shall also be initiated by alarm relays such as trip circuit
supervision, if specified.

2.14 AUXILIARY SWITCHES

.1 The circuit breakers, isolators and earth switches shall be provided with all
necessary auxiliary and limit switches required for control, protection, interlocks,
alarm, local indication, supervisory indication and spares.

.2 Auxiliary switches must operate simultaneously with the main contacts (within =
20 milliseconds)

.3 The contacts of all auxiliary switches shall be adequately rated for the service
intended with a minimum rating of 10 amps continuous.

.4 Auxiliary switches shall be wired in series with the trip coil and special attention
shall be given to these to ensure correct timing and liberal rating for breaking
inductive currents.
.5 Auxiliary switches shall be wired in series with the close coil circuit and these
shall be liberally rated to suit the breaking of inductive currents.
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.6 The auxiliary switches shall be easily accessible, even when the primary circuit is
‘live’.

.7 In order to provide for connections to remote alarm and indicating devices, each
circuit breaker shall be provided with spare voltage-free auxiliary switches directly
operated by the operating mechanism for the following:-

.1 Circuit breaker ON/OFF/withdrawn status

.2 Remote ON/OFF/control of circuit breaker

.3 Earthing switch ON/OFF status

.4 Protection trip alarms

.8 The additional auxiliary switches shall at least consist of:-

.1 3 sets of double-gap 'make' switch elements, each with two

terminals

.2 3 sets of double-gap 'break' switch elements, each with two

terminals

.9 These contacts shall be completely wired up to the terminal blocks in the low
voltage compartment.

.10 The characteristics of all control circuit devices and switching elements shall at
least be in accordance with IEC 60947-5-1.

.11 The rated thermal current (Ith) shall be 10A. The utilisation category AC 11 and DC
11 shall be as follows: -

.1 AC 116 - 48V 6A
110 - 127V 5A

.2 DC 116 - 48V 3A
100 - 127V 1A
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2.15 LOW VOLTAGE COMPARTMENT

.1 The low voltage compartment located at the front of the panel shall house the
following: -

.1 Protective relays

.2 Instruments

.3 Indicator lights

.4 Test terminals and plugs

.5 Fuses

.6 Warning sign

.7 Circuit labels

.8 Secondary wiring

.9 Terminal blocks

2.16 CONTROL CABLES AND SECONDARY WIRING

.1 This contract includes the complete secondary wiring of all items of equipment
supplied on the contract. A secondary wiring compartment shall be provided along
the whole length of the switchboard. It shall be accessible at a suitable location
without having to intrude into any high voltage compartment. This compartment
shall be earthed.

.2 All multicore and low tension interconnecting cables, the installation, jointing and
termination of these shall be part of this Contract.

.3 The termination of multicore cables shall include glancing, stripping, marking of

cores, crimping of terminal lugs, connecting and stripping.

.4 All secondary cable in ducts and trenches shall be neat and orderly and to the
satisfaction of the Engineer. Cables shall not be allowed to hang freely for
distances in excess of 500mm, and shall be saddled to a rigid structure or
supported on cables trays as necessary.

.5 All terminal blocks for current transformers, relays and instrument connections
shall be neatly finished and readily accessible. Pinch type terminals in which the
screw bears directly on the wire strand will not be accepted. Each end of wire
shall be fitted with the crimp lug/connector suited to the type of terminal provided.
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.6 The design of the wiring cleats/strapping shall be such that only limited pressure
can be transmitted to the wires. Wiring for current transformer circuits shall have
a conductor cross section of at least 2.5mm2, whilst control and voltage circuits
shall be 1.5mm2

.7 Each end of each wire or control cable connection shall be provided with a ferrule
bearing a number corresponding to that on the diagram of connections.

.8 All cables shall be marked with a number tag and the number shall correspond to
the cable number on the cable schedule.

.9 All wire armours or screen of cables shall be earthed.

2.17 11kV INDOOR METAL CLAD SWITCHGEAR (VACUUM CIRCUIT BREAKER )

.1 General

.1 All indoor switchgear shall be capable of operating under full load and
fault conditions.

.2 The switchboards shall be of the indoor, totally enclosed, floor mounted

type and shall be vermin and dust proof, and shall be fully extensible on
both ends.

.3 Provision shall be made for lifting or slinging each panel.

.4 It shall be possible to set and reset all relays from a standing position in
front of the panel.

.5 Cable termination boxes/compartments shall be arranged to allow cables

to enter from the cable trench behind/and below the panel. It shall be
possible to make off all cables of any circuit without exposure to any
circuit with the busbar energized.

.6 All auxiliary wiring: Controls, CT’s VT’s, alarms and extra NO/NC contacts
shall be wired to control panel on top of switchgear panel.

.7 Doors shall have stops to prevent over swing when opening to prevent
interference with adjacent panels. The doors shall be suitably reinforced
to prevent distortion when open.

.8 All metal parts including door, relays, instruments, etc., mounted on the
switchgear shall be earthed through branch connections to the
switchboard earth bar.
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.9 Frames of the draw-out circuit breakers shall be connected to the earth bar
through a substantial plug type contact.

2.18 CIRCUIT BREAKERS

.1 Circuit breakers of the vacuum type shall incorporate contacts designed to ensure
a long contact life at all currents up to the rated making and breaking current
switching conditions. Contacts materials having low current chopping levels are
preferred to minimise the occurrence of excessive over-voltages when switching.

.2 All circuit breakers shall be of the triple-pole horizontal isolation draw-out

truck mounted type.

.3 The breakers shall be capable of interrupting all currents from zero to the
full asymmetrical rated fault currents at maximum system voltage.

.4 All circuit breakers closing mechanism shall be of stored energy type and shall
be manually or electrically charged. The closing operation shall be initiated
mechanically or electrically. The electrical tripping circuit shall be isolated when
the circuit breaker is in the earthing position. The mechanical close and trip
facility shall be of the lockable pistol grip type arranged for spring return to
neutral.

Note: Clockwise - close

.5 Circuit breaker spouts and sockets shall be such that all breakers of similar type
and current rating shall be interchangeable.

Note: It shall not be possible to insert a circuit breaker into a higher rated
circuit.

.6 Facilities shall be provided for padlocking the circuit breaker in the ‘racked in’
position.

.7 Circuit breakers shall be connected to the busbars and feeder circuit

through plug and socket type isolating devices. The devices shall be of the
off-load type but shall be suitable for operation whilst the busbars or feeder
circuits are live.

.8 The main circuit isolating devices and all auxiliary circuit isolating devices
shall be self-aligning and accessible for maintenance. The main isolating
contacts shall be silver plated, self-cleaning and shall be mounted in
porcelain or cast resin bushings.

.9 Adequate clearances and surface creepage distances shall be provided to

ensure satisfactory performance under service conditions.
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.10 Means for measurement of contact erosion without major dismantling shall
be incorporated and an appropriate gauge shall be provided.

.11 Any one interrupter unit should be able to be removed without having to
remove either of those on the other two phases.

.12 Each circuit breaker shall be suitable for duty periods of 27,000 hours
minimum, operating within their rated duties and under the specified
conditions without requiring major repairs or replacements and with
minimum attendance. The operating duty cycle is 0-3 min. -CO-3 min. -CO.
The minimum endurance shall be: -

.1 Electrical - 1,000 operating cycles

.2 Mechanical - 10,000 operating cycles

.13 It shall be possible to remove the circuit breaker completely from the panel
within the withdrawal distance. The circuit breaker truck shall have the
following:-

.1 3-pole circuit breaker

.2 Circuit breaker operating mechanism

.3 Manual closing/tripping buttons or switch

.4 Spring-charge indicator

.5 Open (green), close (red), isolated and earthed

position indicators

.6 Interlocking pins and level/carriage lock mechanism

.7 Trip counter

.8 A pair of handles

.9 Manual spring-charge socket

.10 Circuit breaker service position indicator

.11 Secondary control plugs

.14 The circuit breaker compartment shall be able to withstand internal pressures
arising from internal faults and it shall be incorporated with a pressure relief flap to
allow safe discharge of any excess pressure without endangering personnel within
 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 20

the vicinity of the switchboard. The compartment shall be completely sealed from
the busbar and cable compartments.

.15 Contact material properties shall be such that the specified dielectric strength
across open contacts is obtained at all times.

.16 Transmission of high mechanical stresses to the vacuum enclosures during

operation shall be reduced to the minimum possible level by the use of resilient
mountings. Features to prevent the application of abnormal stresses to the flexible
seals shall be incorporated.

2.19 CIRCUIT BREAKER PANELS

.1 Each circuit breaker panel shall consist of a metal-clad enclosure with all the
required control and ancillary equipment.

.2 Guides and self-alignment main contracts shall endure that the circuit breaker
and fixed panel contracts are properly aligned and correctly made when the
circuit breaker is racked into service or earthing position.

.3 Movement of the circuit breaker into and out of the service or earthing positions
shall be by mechanical driving system, which shall ensure positive location
without any possibility of damage to contacts or insulation components.

.4 All auxiliary plugs and sockets for making and breaking the circuit of the circuit
breaker shall be self-aligning with guide pins and contacts. In order to achieve
interchangeability, the position and control circuit function of these contacts shall
be the same on all categories of circuit breaker panels of the same rating.

.5 The circuit breaker panel shall have defined indication, clearly visible from the
front of the panel, to show the following:-

- Circuit breaker open and closed, which shall be visible with the circuit
breaker in position applicable.

- Circuit breaker racked in or out.

- Spring device charged or discharged.

2.20 DISCONNECTING SWITCHES

.1 The switches shall use low pressure SF6 gas for current interruption and shall
require no maintenance. The switch enclosure shall be mounted horizontally
within the cubicle and the position of the main and earthing contacts shall be
clearly visible from the front of the cubicle. The position indicator shall be placed
directly on the contact operating shaft. The switch enclosures shall be made of
cast epoxy resin.
 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 21

.2 The switches shall be of the high operating frequency type in accordance with
IEC 60265-1 recommendations. They shall have three positions (closed, opened
and earthed) and shall be fully assembled and tested before leaving the factory.
The relative pressure of the SF6 inside the enclosure shall not exceed 0.5 bars
(500hPa).

The pole unit enclosure shall be of the “ sealed pressure system” type as defined
by IEC 62271-200 recommendations with a service life of at least 30 years. No
refilling of the gas is required over this period.

.3 The operating mechanisms compartment shall include a switch and earthing

switch position indicator fixed directly to the shaft of the moving pole, thereby
satisfying the positive break criteria.

.4 This compartment shall also house the voltage indicators and the mechanical
‘fuse blown’ indicator for fuse-switch combination units.

.5 The compartment shall be accessible with the cables and busbars live, without
isolating the entire switchboard, and shall be designed for easy installation of
padlocks, key locks, auxiliary contacts, releases and the usual LV accessories.
The front cover of the operating mechanism shall be suitable for the application
of all symbols, mimic diagrams, nameplates and padlocking fixtures required by
the function implemented.

.6 The compartment shall allow addition of a motor mechanism without having to

change the operating mechanism. Operating mechanisms that must be replaced
for motorisation shall no be accepted. All switch and earthing operations shall be
carried out with an anti-reflex lever and shall be independent from the action of
the operator after charging the operating mechanism springs.

2.21 BUSBARS

.1 All busbars and droppers shall be of suitable cross sections with regard to
temperature rise at the specified altitude and of sufficient mechanical strength for
normal and fault conditions shall be fully insulated.

.2 All busbar shall be epoxy coated joints are to be tinned.

.3 Busbars shall be located in a separate compartment within the switchboard

enclosure. Busbar systems shall be air-insulated with individual solid epoxy resin
insulated busbars and connections. Taping is not acceptable. The insulating
material shall be flame-retardant, track resistant and capable of withstanding the
heating effects of the rated short-time withstand current without permanent
deformation and deterioration. Provisions shall be made at the bolted connections
to enable accessibility for maintenance and extensions when appropriate.
 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 22

.4 Where the busbar passes through adjacent compartments, it shall be supported on

suitable insulating pads. Supports shall cover busbar openings between housings
to provide a non-combustible fire wall. All busbars shall be phase-identified with
permanent marking and colour.

.5 The busbar insulation system shall be continued as far as practicable into the
breaker and/or cable compartments up to the next current protective device.

.6 Busbars shall be made of plain hard-drawn, high-conductivity, electrolytic copper in

accordance with BS EN 13601:2002.

.7 Busbars and connections shall be fully rated, braced and supported to withstand
the dynamic, thermal and dielectric stresses over the full length of the switchboard.
All busbar joints, splice plates and ends shall be silver plated to obtain self-aligning
high pressure contact.

.8 All bolted connections shall be made with high-tensile strength bolts effectively
secured against loosening.

.9 The busbar compartment shall be provided with pressure relief flaps that shall
positively and automatically open in a direction to discharge excess pressure
without endangering personnel within the vicinity of the switchboard in event of an
internal fault.

.10 Where transformer disconnecting switches are shown adjacent to the

transformers, the load side of the disconnecting switch shall be busbar connected
to the primary side of the transformer.

2.22 MECHANICAL INTERLOCKING AND SAFETY SHUTTERS

.1 To facilitate voltage detection, phasing-out and testing, a manually-operated latch

shall be installed to permit the opening and fixing but not padlocking of each set of
shutters in the open position. The latch shall be overridden by the circuit breaker
moving into place and the shutters shall cover the orifices automatically.

.2 The switchgear shall be fully interlocked against all possible mal-operation and
shall be so constructed to ensure that:-

- The circuit breaker cannot be raised/engaged or lowered/removed in a

closed position and attempts to do so will trip the breaker.

- Operation of the circuit breaker is only possible in the service and earthed
position.

- It shall not be possible to rack the circuit breaker until the truck is properly
located in the panel at the approved position.
 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 23

- Circuit and busbar shutters shall be arranged to operate independently

and it shall be possible to fix all shutters in the open position for testing
purposes.

- The busbars shutters shall be painted red and circuit shutters shall be
painted yellow. All shutters shall be clearly labeled in letters of the largest
possible size, indicating ‘Cable’ and ‘Busbars’.

Note: All safety shutter shall be provided with suitable arrangements for
padlocking the shutter in a closed position.

2.23 INTERLOCKS

.1 An interlocking system, which ensures safe operation of the equipment under all
service conditions shall be provided. The system shall be non-defeatable.

.2 Mechanical interlocking shall be effective at the point where hand power is applied
so that stresses cannot be transferred to parts remote from that point.

.3 Mechanical means shall be provided so that the circuit breaker shall positively
select the intended position at all times.

.4 For means of control, electrical interlocking shall also be provided to prevent

closure of the circuit breaker by interrupting the operating supply. The methods of
interlocking shall be to the approval of the Employer's Representative.

.5 Interlocking shall include but not necessarily be limited to the following: -

.1 Circuit breaker cannot be racked-in when

.1 control circuit plug is not connected to the correct socket

.2 it is closed

.3 earthing switch is closed

.4 it is of the incorrect rating and function

.2 Circuit breaker cannot be racked-out when it is closed

.3 Control circuit plug cannot be removed when circuit breaker is not

open or in the withdrawn position

.4 Circuit breaker cannot be closed when

 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 24

.1 it is not properly racked into position

.2 it is not open or in the withdrawn position

.5 Earth switch cannot be closed when

.1 circuit breaker is not in the open and withdrawn position

2.24 PADLOCKING FACILITIES AND KEY CABINET

.1 In addition to the interlocking facilities specified above, padlocking facilities

shall be provided as follows: -

.1 Circuit breaker and disconnecting switch mechanisms in the open

and closed positions.

.2 Access doors to circuit breaker and disconnecting switch

enclosures.

.3 Circuit breaker control switch in the neutral position.

.4 Shutters over the busbar, circuit and voltage transformer orifices.

.5 Earthing device in the open and close positions.

.2 Where a mechanism is to be locked in a specific position provision shall be

made at the part of the mechanism where the operating power is applied
and not at remote or ancillary linkages.

.3 All keys shall be housed in a lockable wall-mounted key cabinet provided

as part of the supply of the switchboard. All keys shall be unique and non-
interchangeable.

2.25 ISOLATING CONTACTS OF SECONDARY CIRCUITS

.1 Auxiliary and control circuit connections on with drawable switching devices

shall be made either with self-aligning plug and socket contacts or with
multi-conductor cable with plug and socket arrangement.

.2 The voltage-carrying part of the fixed gear shall be of the female type, while
the movable part of the switching device shall be of the male type.

.3 Connections shall be maintained or restored by special facilities, when the

With draw able part of the switching device is in the test position.
 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 25

3.0 EXECUTION

3.1 PACKING, TRANSPORT, HANDLING, DELIVERY AND STORAGE AT SITE

.1 All equipment shall be packed in a manner such that they are adequately protected
against the tropical climatic conditions encountered during shipment and storage at
site. All fragile parts are to be packed separately in an approved manner. All
equipment shall be labeled for easy identification at site. On arrival at site, the
consignment shall be checked against delivery notes and stored indoors.

.2 Co-ordinate with other specification Divisions to ensure the floor is adequately

level. Install foundation channels if necessary.

3.2 TESTS

.1 Type Tests

.1 Perform relevant type tests recommended in the IEC. In lieu of actually

carrying out the type tests, type test reports certified by any internationally
recognised testing laboratories shall be submitted to the Employer's
Representative for approval.

.2 Provide complete type test reports.

.2 Routine Tests

.1 Carry out all relevant routine tests at Manufacturer’s factory in

accordance to the IEC. Provide routine test reports for all breakers
supplied.

.3 Acceptance Tests at Manufacturer's Works

.1 The breakers shall be subjected to the following inspection

and tests: -

.1 Visual Inspection

.2 Dimension checks

.2 The degree of protection of the enclosure

.3 The degree of protection within the compartments

 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 26

.4 Damage on panel and painting work

.5 The effectiveness and reliability of safety shutters, partitions

and shrouds

.6 The effectiveness and reliability of operating mechanisms,

locks and interlock system

.7 The creepage distances and clearances

.8 The proper mounting of components

.9 The internal wiring and cabling system

.10 The correct wiring of main and auxiliary circuits

.11 The suitability of clamping, earthing and terminating

arrangements

.12 The correct labeling of functional units

.13 The completeness of the data on the nameplate

.14 The availability of the earthing system throughout the

switchgear

.15 The interchangeability of electrically identical components

.16 The non-interchangeability of mechanically identical but

electrically different components

.17 Power frequency withstand voltage test to IEC 62271-200.

.18 Dielectric test shall be carried out on the control and auxiliary circuits at 2 x
Un + 1000V (AC) with a minimum of 1500V for 1 second.

.19 DC resistance measurement of each CT secondary wiring.

.20 CT polarity and magnetisation curve, CT ratio and burden

measurements.

.21 Voltage transformer ratio, polarity, phasing and phase rotation check.
Perform test on the three phase voltage transformer to show that
energising each primary winding produces an output from only the
correct phase secondary winding. Measure total burdens connected to
all voltage transformer circuits.
 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 27

.22 Secondary injection test.

.23 Primary injection test.

.24 Functional (sequence) test including all DC operated circuits over the
permissible DC voltage limits.

.25 Mechanical operation test.

.26 Painting and finishing tests

.1 Measurement of paint thickness

.2 Humidity (cyclic condensation) test to BS 3900 Pt. F2.

Painted panel shall withstand 1000 hours under test with no
blistering of film and corrosion of base metal

.3 Adhesion test to ASTM D3359-02. Test tape shall not

expose more than one 3mm2 of bare metal or underlaying
coating

.4 Impact resistance test to BS 3900 Pt. E7. Paint shall not

chip off.

.5 The manufacturer test shall be verified and witnessed by the

Employer Representative’s and his representatives.

.6 Provide complete test report.

.4 Site Tests

.1 Upon delivery to site, check condition of panels and circuit breakers for

.1 Quantity

.2 Damage, rust and paint work

.3 Store indoors

.2 At the completion of installation, each panel shall be field tested by a

representative of the manufacturer. A report recording each item of the
testing shall be certified by the manufacturer and submitted to the
Employer's Representative.

.3 Visual inspection and verification of

 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 28

.1 Correctness of location and mounting

.2 Labeling, nameplate and phase markings.

.3 Damage on panel and paint work.

.4 Torque for all nuts and bolts on buswork.

.5 Cable bracing, both incoming and out-going, certifying that it is in

accordance with the manufacturer's recommendations.

.6 Safety shutters, partitions and shrouds.

.7 Circuit breaker trucks operating mechanisms, locks and interlock

systems.

.8 Mounting of components.

.9 Internal wiring and cabling system.

.10 Clamping, earthing and terminating arrangements.

.11 Earthing system.

.4 Power frequency withstand voltage test.

.5 Dielectric test shall be carried out on the control and auxiliary circuits
at 2 x Un + 1000V (AC) with a minimum of 1500V for 1 second.

.6 DC resistance measurement of each CT secondary wiring.

.7 CT polarity and magnetising curve, ratio and burden measurement

.8 Voltage transformer ratio, polarity, phasing and phase rotation check.

Perform test on the three phase voltage transformer to show that
energising each primary winding produces an output from only the correct
phase secondary winding. Measure total burdens connected to all voltage
transformer circuits.

.9 Secondary injection check

.10 Primary injection test

 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 29

.11 Functional (sequence) test

.1 Operation of all metering equipment.

.2 Operation of all alarm devices.

.3 Operation of all DC operated circuits e.g. interlocks, relays, etc.

over the permissible DC voltage limits.

.12 Mechanical operation test

.1 Operation of each disconnecting means under load.

.2 Operation of all key interlocks.

.13 Calibration and setting of protection devices

.1 The operating and resetting levels (current and/or voltage) and

timing of all relays shall be measured.

.2 The maximum torque angle and boundaries of operation/restraint

for directional relays shall be determined.

.3 Other relays shall be fully tested in accordance with the

manufacturer's recommendations or as advised by the Employer's
Representative.

3.3 MISCELLANEOUS EQUIPMENT

.1 Equip the HT room with the following miscellaneous items: -

.1 Danger sign, No Admittance signs etc.

.2 Artificial respiration (CPR) chart.

.3 Frame up latest approved As-Built schematic wiring diagram (A0 or

A1 size) of the panels.

.4 A 5mm thickness and 1000mm width rubber mat in front of the

entire length of the panels.

.5 All the requisite labels.

.6 Approved fire detection and fire fighting apparatus.

 METALCLAD SWITCH BOARDS AND DISCONNECTING SWITCHES
SECTION 18011

PAGE 30

.7 Earthing bar installation along the perimeter of the room connected

to the main-earth bed system.

3.4 SUBMISSION TO LOCAL AUTHORITIES

.1 The contractor shall obtain and prepare all necessary forms, documents and
drawings for submission and approval from local authority.

.2 The contractor shall obtain all endorsement from Employer’s Representative and
relevant parties.

3.5 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Provide training schedule and agenda and list of instructors from original
equipment manufacturer (OEM) and the Contractor.

.2 Provide classroom training.

.3 Provide field training with demonstration on operation and maintenance.

.4 Review O&M Documentation and Test Results.

3.6 HANDING-OVER AND EMPLOYER'S ACCEPTANCE

.1 Endorse defects list.

.2 Provide all keys.

END OF SECTION
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Manufacture, test at Works, deliver to site, install and commission low voltage AC
switchboards, motor control centres and automatic transfer switches.

1.2 WORK INCLUDED

.1 Low voltage AC switchboards.

.2 Motor control centres.

1.3 SUBMITTALS

.1 Tender Stage

.1 Technical data and product catalogues.

.2 Full type test certificates of switchboards from ASTA, UL, KEMA,

and internationally recognised independent testing laboratory.

.3 Type test certificates for Moulded Case Circuit Breaker, Air

Circuit Breaker from internationally recognised independent
testing laboratories, such as ASTA, UL, KEMA.

.2 Construction Stage

.1 To repeat the above tender stage submission.

.2 Short-circuit calculations and computer software used

.3 Dimensioned drawings (plans, sections and elevations)

.4 Single line diagrams

.5 Front panel component arrangements

.6 Schematic/wiring diagrams

.7 Control diagrams

.8 Shop drawings/construction drawings

.9 Catalogue and technical data of all components

 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 2

.10 Nameplate information

.11 Full load heat rejection in Btu per hour of each switchboard and
motor control centre

.12 Data on structural supports, metal thickness, surfaces finish and provisions
for lifting and foundations etc

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance tests

.2 Acceptance test reports after tests

.3 Packaging, transportation and storage notes

.4 Site Installation

.1 Installation methods/Work method statements prior to installation

work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.5 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Except as modified by the Contract Documents, comply with the latest

applicable provisions and latest recommendations of the following: -

.1 IECQ IEC Quality Assessment System for

Electronic Components.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 3

.2 IEC 60044-1 Instrument Transformers-Part 1:Current

Transformers
.
.3 IEC 60269-1 Low-Voltage Fuses-Part 1:General
Requirements

.4 IEC 60947-3 Low Voltage Switchgear and Controlgear-

Part 3:Switches, Disconnectors and Fuse-
Combination Units

.5 IEC 60439-1 Low-Voltage Switchgear and Controlgear

Assemblies Part 1 - Type-Tested and
Partially Type-Tested Assemblies.

.6 IEC 60445 Identification of Equipment Terminals and of

Terminations of Certain Designated
Conductors, including General Rules for an
Alphanumeric System.

.7 IEC 60446 Identification of Conductors by Colours or

Numerals

.8 IEC 60529 Degrees of protection provided by

Enclosures (IP Code).

.9 IEC 61000-4-2 Electromagnetic Compatibility (EMC)-Part

2Testingand Measurement Techniques-
Testing and Measurement Techniques
Electrostatic Discharge Immunity Test

.10 IEC 61000-4-3 Electromagnetic Compatibility (EMC)-Part 3:

Radiated,Radio-Frequency, Electromagnetic
Field Immunity Test

.11 IEC 61000-4-4 Electromagnetic Compatibility (EMC)-Part 4:

Electrical Fast Transient/Burst Immunity
Test

.12 IEC 60909 Short-Circuit Currents in Three-Phase A.C.

Systems

.13 IEC 60939 Passive Filter Unitsfor Electromagnetic

Interference Suppression

.14 IEC 60947 Low-Voltage Switchgear and Controlgear

 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 4

.15 IEC 60947-1 Low-Voltage Switchgear and Controlgear Part 1 –

General Rules

.16 IEC 60947-2 Low-Voltage Switchgear and Controlgear Part 2

- Circuit Breakers

.17 IEC 60947-4 Low-Voltage Switchgear and Controlgear Part 4

– Contactors and Motor-Starters.

.18 IEC 60947-6-1 Low-Voltage Switchgear and Controlgear Part 6 –

Multiple Function Equipment- Section One
Automatic Transfer Switching Equipment

.19 BS 1376 Specification for Colours of Light Signals

.20 BS EN 13601 Copper and Copper Alloys Copper Rod, Bar :2002
and Wire for General Electrical Purposes

.21 BS 3900 Pt E7 Methods of Test for Paints. Part E7 -

Resistance to Pt. E7 Impact (Falling Ball Test)

.22 ASTM D3359-02 Standard Tests Methods for

Tape Test Methods for Measuring Adhesion by
Tape Test ASTM International

.23 BS 3900 Pt F2 Method of Test for Paints. Part F2 - Determination

of Resistance to Humidity (Cyclic Condensation)

.24 BS 7079 Preparation of Steel Substrates before

Application of Paints and Related Products

.25 IEC 61641 Guide For Testing Under Conditions of Arcing Due
to Internal Fault

.2 Manufacturers shall have at least 10 years experience in the manufacture of

similar equipment.

2.0 PRODUCTS

2.1 SAFETY AND RELIABILITY

.1 Switchgear and controlgear shall be designed to minimise any risk of short circuit
and to ensure personnel and operational safety during all operating conditions,
inspections and maintenance. They shall also be so designed to allow safe
connection of main, control and auxiliary cables, and the equipping and
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 5

commissioning of spare panels whilst the switchgear is live and in operation. It

shall have a lifetime of at least 20 years.

.2 The assemblies shall be suitable for continuous operation at full load for at least
40,000 hours without maintenance which would require the busbar and droppers to
be de-energized.

.3 Even under extreme conditions of major short circuits or mal-operations, there shall
be no danger to persons in the vicinity of the assembly.

.4 The Contractor shall carry out all short-circuit calculations, check the adequacy of
all equipment short-circuit ratings, provide the best protective device and
coordinate all protective devices in the system. Where computer software is used
for carrying out protection coordination exercise, the Contractor shall provide full
details of the software and shall be responsible for all results generated from the
software.

2.2 DESIGN AND CONSTRUCTION

.1 General

.1 The LV switchboards and motor control centres shall be naturally cooled, self-
contained, metal-enclosed type, floor mounted, flush-fronted and suitable for
front and rear access and housing air circuit breakers, moulded-case circuit
breakers, ON/OFF switches, busbars, meters, protective relays, manually-
operated disconnecting switches, selector switches, indicating lamps, current
transformers, cable terminating boxes, anti-condensation heaters, padlocks,
interlocks and other necessary items of equipment. They shall be built to
comply with IEC 60439-1.

.2 All structural works shall be adequately protected against corrosion. The

basic materials shall be properly pre-treated before the final coats of resistant
finishing paint are applied.

.3 All materials, used in the construction and for primary insulation shall be non-
hygroscopic and have fire retardant properties and halogen free as practical.
Insulating materials shall have a high resistance to tracking.

.4 The switchgear shall be suitable for mounting on a concrete floor or plinth. All
necessary foundation or fixing bolts, channel bases and rails shall be
provided.

.5 All operating devices shall be mounted for operation at the front of the
switchboard.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 6

.6 Alphanumeric notation, generally in accordance with IEC 60445, shall be

used for identification and marking of phases, conductors and terminals.

.7 The switchgear and motor control centres shall fit within the area designated
on the Contract Documents with the clearances as indicated.

.2 Enclosure and Degree of Protection

.1 The enclosure structure shall be fabricated from rolled steel angle sections
and shall be self-supporting when assembled, uniform in height and depth
from front to back. Rigid construction shall be designed to withstand without
any sag, deformation or warping under the loads likely to be experienced
during normal operation, maintenance or maximum short-circuit conditions,
and shall comply with all requirements of IEC 60439-1 for normal mechanical
loads. Sheet steel used shall not be less than 2mm thick and anti-rust coated
steel plate. Welded cross-struts shall not be used.

.2 The front and rear covers of the switchboard shall be of hinged door type.
The front doors shall be provided with door latches; the rear doors shall be
provided with key locks. The doors shall be arranged to seal onto the board
frame by means of a non-perishable dust proof material. The sealing material
shall be synthetic rubber and not foam. Doors shall be effectively earthed to
the fixed enclosure by braided straps. Cover bolts or nuts shall be retained in
place when undone.

.3 The degree of protection for any assembly as per IEC 60529 shall be IP 41.
The floor shall not be considered as part of the enclosure.

.4 When the doors are opened, the degree of protection to all live parts shall be
at least IP20.

.5 Partitions or barriers for internal separation of assemblies shall be designed to

obtain Form 4B separation of compartments and shall comply with following
degree of protection: -

.1 between horizontal busbar IP 40

compartments and any other
compartment

.2 between incoming and IP 40

sectionalizer units

.3 between main busbar systems IP 40

of two separate sections

.4 between compartments of each IP 40

 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 7

functional unit and

other compartments

.6 It is acceptable that outgoing terminals of functional units are installed in

combined compartments provided that all terminations have a degree of
protection of at least IP 30.

.7 The switchgear enclosure shall be rodent and insect-proof. It shall be capable

of operating in tropical and humid conditions and provision shall be made for
electrical panel heaters to prevent condensation particularly when the
equipment is out of service.

.3 Anti-Condensation Heaters

.1 Power supply to electrical anti-condensation heater inside the assembly shall

be supplied from a separate source connected between system phase and
neutral. The heating system of each assembly section shall be separately
protected and switched for isolation purposes by means of a miniature circuit
breaker in combination with a residual current device of 30mA sensitivity.
When the heating system is live, this shall be indicated by means of a
prominently situated red light. The heating system shall be designed in such a
way that the heat is adequately distributed over all functional units.

.4 Temperature Rise

.1 The temperature rise limits as given in IEC 60439-1(all parts) shall not be
exceeded when the assembly is fully loaded.

.5 Protection Against Electric Shock

.1 All switchgear components requiring maintenance shall be easily accessible

from the front and rear.

.2 Exposed parts within the assemblies, which have to be accessible during

normal operation, maintenance or equipping of spare compartments, shall
either not be alive in the open position or shall be protected to a degree of
protection of at least IP 42. The terminals of the incoming and sectionalizer
switching devices can be alive when the device is in the off position. These
terminals shall always be protected to a degree of at least IP 42.

.3 HRC fuses and associated fuse carriers shall only be accessible when they
are fully isolated or when they offer a degree of protection to live parts of at
least IP 20 when the fuses are inserted, withdrawn or during withdrawal.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 8

.4 Terminals of equipment installed on a compartment door and which can be

alive when the door is opened, shall be shrouded to a degree of protection of
at least IP32.

.5 Compartment doors or covers shall be interlocked to prevent opening when

the isolating switch that includes ACBs and MCCBs is in the `ON` position.
The isolating device shall only be operable when the door is fully closed and
when the withdrawable unit is in the fully inserted position.

.6 When a withdrawable unit has been removed from the assembly, the live parts
inside the fixed compartment shall be protected against touch, with a degree
of protection of at least IP 20. When shutters are fitted to comply with above
requirement, they shall be mechanically operated by the movement of the
withdrawable unit and not dependent on gravity. Each set shutters shall be
capable of being individually operated and able to padlock in the closed
position. Shutters covering busbars or droppers shall be marked ‘BUSBAR’
and shutters covering the incoming supply, ‘INCOMING SUPPLY’.

.7 If a test position is provided (partly withdrawn unit) the degree of protection

shall be at least IP 42.

.8 Interlock systems shall be of a mechanical lever type and shall not rely on the
operation of springs or gravity.

.9 All practicable measures shall be taken to prevent danger to personnel

working on a disconnected functional unit with adjacent units still in
operation. Parts likely to be removed for maintenance shall have retainable
fastening means.

.6 Short-Circuit Withstand Strength

.1 Switchgear and its entire component shall be capable of withstanding the

thermal and dynamic stresses, resulting from the prospective short-circuit
current as shown on the design drawings, without the possibility of injury to
personnel.

.2 The whole busbar system, including the busbar conductors connecting the
main busbars to each outgoing unit, shall be arranged to withstand a short
circuit at any point.

.3 The switchgear shall be designed to withstand any external fault. In the event
of any internal arcing fault on a functional unit, the damage should be confined
to that unit, so that the busbars and all other functional units remain fit for
further service. However, the busbar conductors connecting the busbars to
the outgoing unit might be damaged by the internal arcing fault.
 LOW VOLTAGE AC SWITCHBOARDS,
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SECTION 18012

PAGE 9

.4 The time value of the rated short-time withstand current shall be 1 second.
The value of the rated peak withstand current shall in no case be less than 2.2
times the rated rms value of the rated short-time withstand current with a
power factor not higher than 0.2.

.5 For components of the switchgear protected by fuses or similar protective

devices, short-time and peak withstand current values shall be selected,
taking into account the limiting effects of the associated fuse or device on the
magnitude of the current and on its duration.

.7 Coordination of Short-Circuit Protective Devices

.1 In motor starter units, the coordination between starter and protective device
shall comply with type '2' as specified in Sub-clause 7.2.5 of IEC 60947-4.

.2 This generally implies that a starter is sufficiently protected by the short-circuit

protection that no damage will occur to the starter in case of a through-fault
current.

.3 The short circuit protection device inside each functional unit shall be
connected directly to the incoming supply from the busbars.

.8 Selection of Components

.1 All components shall be standardized as far as practical and shall comply

with the relevant IEC publications.

.2 The connections of the auxiliary circuits of withdrawable units shall be of the

plug-and-socket type, automatically operated by the unit.

.3 Incoming and sectionalising units shall be mounted in separate panels and

shall be provided with independent manually operated air break switches or
with circuit breakers. The utilization category as in Clause 4.3 of IEC 60947
shall be at least AC-22. Motor switches shall have utilization category of AC-
23.

.4 Switching devices shall switch all phases or poles (i.e. 4-pole type for 3
phase + neutral systems). For balanced systems, the neutral pole current
rating shall not be less than as specified for the neutral busbar.

.5 The switching devices shall have padlock facilities in the 'OFF' position.
Mechanical & electrical interlock systems between incoming and sectionalizer
units shall be provided to prevent paralleling of transformers. Components
and devices such as ACBs and MCCBs selected for services as automatic
transfer switches shall comply to IEC 60947-6-1.
 LOW VOLTAGE AC SWITCHBOARDS,
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SECTION 18012

PAGE 10

2.3 BUSBARS

.1 The busbars shall be of plain hard-drawn, high conductivity, electrolytic copper

bars in accordance with BS EN 13601:2002 and of adequate rectangular cross-
section to carry continuously the specified current without overheating and shall
be rigidly mounted on non-hygroscopic insulators so as to withstand any
mechanical force to which they may be subjected under maximum fault condition.

.2 Busbars shall be coloured red, yellow and blue and black at appropriate points to
distinguish the phases and neutral. No tapes shall be used. The main busbars
shall be arranged in a horizontal plane and in the order, red, yellow, blue and
neutral phases from back to front. On each panel connections shall be red,
yellow, blue and neutral phases from left to right viewed from the front of the
panel.

.3 The phase and neutral busbars should be located in the top compartments of the
switchboard.

.4 The busbar system shall be readily accessible for inspection, construction and
maintenance duties without the requirement of additional equipment. In case of
a busbar short circuit, it shall be possible to clean or to replace the busbars and
the support system without stripping the assembly.

.5 In the busbar compartment the phase busbars may not be fully insulated.
However, each phase busbar shall be able to withstand at least an applied AC
test voltage of 2.5kV for a period of 60 seconds.

.6 The droppers shall have full segregation by insulated materials. The insulation
of the busbar jointing and branching points shall be of equal quality to that of the
main bars and shall be removable and easily replaceable for inspection.

.7 The neutral bar may be not insulated in the busbar compartment but shall be
insulated at all other compartments with the same insulation level as the phase
busbars.

.8 The earth bar shall be located in the top or bottom compartment and in all cable
riser compartments of the switchboard and shall be easily accessible. Sufficient
connection points with adequate terminating facilities shall be provided for
terminating the cable earth leads. The earth bar shall be sized complying with
IEC 60439-1.

2.4 AIR CIRCUIT BREAKERS

.1 Circuit breakers shall be of the air-break type suitable for indoor use and
withdrawable complete with all necessary instruments, transformers, closing and
 LOW VOLTAGE AC SWITCHBOARDS,
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SECTION 18012

PAGE 11

tripping devices and protective instruments. They shall be easily accessible and
operable from the front and provided with padlocking facilities. Both phase and
neutral switching shall be required. Circuit breakers shall comply with IEC
60947-2 regarding their test performance and number of operating cycles, and
shall have a rated short-circuit making and breaking capacity specified in the
drawings and complying with IEC 60947-2 Table II. They shall be trip-free.

.2 Locking facilities shall be provided on the circuit breaker and control switch so
that, in any position, the circuit breaker can be prevented from being directly and
manually operated. Mechanical and electrical lockouts shall be provided to
prevent closing of the breaker after an overcurrent trip.

.3 All operating mechanisms shall have mechanical 'ON' and 'OFF' indicators.
'CLOSED', 'OPEN' and 'TRIPPED' indication lamps shall be provided. Hand
charged or motor charged spring mechanisms shall have mechanical indicators
to show 'SPRING CHARGED' and 'SPRING DISCHARGED'.

.4 All ACBs supplying loads from the main switchboards shall have motor charged
operating mechanisms, which shall be arranged so that release of the spring to
close the circuit breaker can only be done by deliberate action. It shall not be
possible for shocks to release the charged spring. Remote controlled switching
shall also be provided for motor charged operating mechanism ACBs.

.5 Closing and trip control switches shall turn clockwise for closing and anti-
clockwise for tripping and labelled 'OPEN-NEUTRAL-CLOSE' with spring return
to neutral.

.6 The shunt trip coil shall be operated by 240V AC supply unless otherwise stated
in the design drawings.

.7 All circuit breakers shall be provided with interlocks to ensure that: -

.1 They cannot be connected or withdrawn whilst it is closed.

.2 They cannot be closed until they are fully plugged in or completely

isolated.

.3 The spring charged mechanisms cannot be discharged until they are fully
charged.

.8 Mechanical & electrical interlocks shall be provided in cases where multiple

incoming supplies are not to be paralleled. Tripping of a closed circuit breaker
shall not occur if an attempt is made to remove the trapped key or when it is in
the withdrawn positions.
 LOW VOLTAGE AC SWITCHBOARDS,
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SECTION 18012

PAGE 12

.9 Facilities for operational tests of the circuit breaker shall be provided when in the
isolated or withdrawn position.

.10 Provide auxiliary contacts for remote monitoring of all incoming and
Sectionalizing breakers as well as all distribution breakers, on switchboards
supplied from the emergency power system.

.11 ACBs used for distribution on switchboards supplied from the emergency power
system shall have provision for remote operation (OPEN and CLOSE) for load
management.

.12 All protective relays and instruments shall be provided as shown in the design
drawings.

.13 Where specified in the design drawings, the circuit breakers shall have integral
solid-state trip units with built-in overcurrent and earthfault protection having
time-current characteristics. A combination of the following time-current curve-
shaping adjustments shall be provided: -

.1 Ampere setting.

.2 Long time delay.

.3 Short time pickup.

.4 Short time delay.

.5 Earth fault pickup.

.6 Earth fault delay.

.14 The solid-state trip-unit shall have a digital information system that provides
circuit current values and mode of trip indication (i.e. overload, short circuit, and
earth fault) with fault current levels displayed following an automatic trip
operation.

.15 All solid-state trip units shall be provided with test jacks for in-service functional
testing using a small hand-held test kit.

.16 Refer to Section 16145: PROTECTION, METERING AND CONTROL for

protection afforded by the electronic trip units.

2.5 AUTOMATIC TRANSFER SWITCHES

.1 Ratings and Utilization Category

 LOW VOLTAGE AC SWITCHBOARDS,
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SECTION 18012

PAGE 13

.1 The automatic transfer switches shall be provided as shown on the

design drawings and shall comply with IEC 60947-1 and IEC 60947-6-1.
All three phase, four wire transfer switches shall employ switched-neutral.
Switches used with earth fault equipment shall be the four-pole switched-
neutral type with all four poles on a common shaft. The neutral pole shall
have the same withstand and operational ratings as the other poles and
shall be arranged to break last and make first to minimize neutral
switching transients. Overlapping neutral contacts are not acceptable.
Switches serving 3 phase loads, which do not have a neutral condition,
shall be 3-pole type. The transfer switches shall be capable of switching
the classes of load specified and shall be rated for continuous duty when
installed in a non-ventilated enclosure. The automatic transfer switches
shall be capable of making, breaking and withstanding short-circuit
currents. It shall hence comply with Class PC according to IEC 60947-
61. The time value of the rated short-time withstand current shall be 1
second. The value of the rated peak withstand current shall in no case be
less than 2.2 times the rated rms value of the rated short-time withstand
current with a power factor not higher than 0.2. The utilization category
shall be AC-33B according to IEC 60947-6-1.

.2 Construction and Requirements

.1 The transfer switch shall be double-throw, actuated by a control

module and connected to the transfer mechanisms by a simple over-
centre type linkage with a total transfer time not to exceed 10 cycles. The
transfer switch shall be capable of transferring successfully in either
direction with 80 percent of rated voltage applied to the switch terminals.

.2 Inspections of all contacts (movable and fixed) shall be made from the
front without disconnecting the power cables or the linkages of the
operating mechanism. A manual slow opening and closing of the
contacts shall be provided for maintenance and inspection of the contacts
throughout the entire contact travel. Proper interlocks shall be provided
to prevent inadvertent transfer operation while in the maintenance/test
position.

.3 The normal and emergency contacts shall be positively interlocked

mechanically and electrically to prevent simultaneous closing. Main
contacts shall be mechanically locked in position in both the normal and
emergency positions without the use of hooks, latches, magnets, or
springs and shall be silver-tungsten alloy protected by arcing contacts,
with arc grids on each pole. Interlocked air circuit breakers, moulded
case circuit breakers or contactors are not acceptable.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 14

.4 The removal of access doors/covers shall not defeat the interlocking

mechanism.

.3 Operating Mechanism

.1 Transfer switches shall be electrically operated and mechanically

held. A single-solenoid mechanism shall be provided such that it shall
only be energized during switching operations to minimize power
consumption and heat generated. The switch shall be locked and
unaffected by voltage variations or momentary outages unless
directed by the control system.

.4 Control System

.1 The control system shall direct the operation of the transfer switch via
wire connections to the operating mechanism. The connections of
auxiliary circuits shall be of the plug-and-socket type, which shall
permit the disconnection of the control module for maintenance.

.2 The control unit shall be completely enclosed in a metal enclosed

compartment with a separate protective external cover and mounted
separately from the transfer switch and its operating mechanism.
Where the control unit is electronic or micro-processor-based, the
control system shall have high electromagnetic and radio frequency
interference immunity and shall not be affected by portable radio
transmitters etc, operated in the vicinity of the equipment. All
electronic devices shall be protected against transient voltage surge.
Electrical isolation of outgoing and incoming signals shall be provided
as appropriate. In this respect, IEC 61000-4-2, IEC 61000-4-3, IEC
61000-4-4, and IEC 60939 shall be complied as appropriate.

.5 Relays and Controls Requirements

.1 Relays provided in the control circuitry shall comply with the relevant
IEC and as far as possible be standardized. Relays shall be capable
of withstanding without damage 110% of the rated operating voltage.

.1 Close differential voltage sensing on all phases of normal system.

.1 Drop out field adjustable in 1% increments from 75 to

98%.Factory set at 80%.

.2 Pick up field adjustable in 1% increments from 85 to 100%.

Factory set at 90%.
 LOW VOLTAGE AC SWITCHBOARDS,
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SECTION 18012

PAGE 15

.2 Voltage sensing on at least one phase of emergency system.

.1 Pick up field adjustable in 1% increments from 85 to 100%. Factory

set at 90%.

.3 Frequency sensing of emergency system.

.1 Pick up field adjustable in 1% increments from 90 to 100%.

.4 Time delay of momentary normal source outages.

.1 Field adjustable from 0.5 to 6 seconds. Factory set at 1 second.

.5 Time delay on transfer back to normal.

.1 Field adjustable from 0 to 30 minutes. Factory set at 10 minutes.

.2 Immediate bypass and transfer to normal source if

.3 Shall cause a set of normally open contacts to close 10-15 seconds

prior to transfer back to normal for switches serving lift loads. This
shall be adjustable from 0-60 seconds and shall be set as required
by the lift vendor.

.6 Time delay of transfer to emergency.

.1 Field adjustable from 0 to 1 minutes. Factory set at 0 minutes.

.2 Where multiple transfer switches

are employed set time delay at 5 seconds apart between each
switch (i.e. 4 switches total transfer of last switch shall be 20
seconds). Switch priority assignments shall be determined.

.7 Engine Start Contacts.

.1 Two sets, one set to close the

other set to open upon failure of normal source.

.2 Signal to start respective generator

after time out of transfer to emergency relay as specified
above.

.8 Test switch.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 16

.1 Momentary type mounted through enclosure.

.2 Simulates failure of normal source.

.3 System to remain in test position

until delay on transfer back to normal has timed out.

.4 A test reset switch shall be included

and shall bypass the delay on transfer back to normal. It
shall not bypass the pre- signal specified above.

.5 During test conditions (operation of

test switch) a set of normally open contacts shall be caused to
close 10-15 seconds prior to transfer to emergency. The
signal shall be adjustable from 0-60 seconds and shall be set
as required by the vendor.

.6 Spare Contacts

.1 Four (4) spare auxiliary contacts, two (2) closed with switch in
emergency position, and two (2) closed with switch in normal position.

.7 Switch Indicating Lights

.1 Red when switch is in emergency position.

.2 Green when switch is in normal position.

.3 Lights shall be paralleled at remote annunciator panels.

2.6 MOULDED-CASE CIRCUIT BREAKERS AND MOTOR CIRCUIT PROTECTORS

.1 Moulded Case Circuit Breakers and Motor Circuit Protectors shall comply
with IEC 60947-2.

.2 MCCB and MCP should be of moulded insulating material of good

mechanical strength and non-tracking properties. The tripping mechanisms shall
be calibrated in compliance with IEC standards at the factory and the breaker
shall be sealed to prevent tampering.

.3 The MCCB and MCP shall be so designed that when on tripped condition, the
circuit breaker cannot be switched on unless it has been reset by switching it to
the OFF position first. The operating condition (i.e. ON, OFF or TRIP) of the
circuit breaker shall be clearly indicated. The construction and operation of the
MCCB and MCP shall be such that if a fault occurs, all the poles of the breaker
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 17

shall operate simultaneously to isolate and clear the fault efficiently and safely
without any possible risk to the operator or to the installation.

.4 Each MCCB and MCP shall incorporate a 'trip free' mechanism to ensure the
breaker cannot be held closed under fault conditions. The operating mechanism
of the circuit breaker shall be hermetically sealed at the factory and all metallic
parts associated with the operating mechanism shall be treated against rust and
corrosion.

.5 Bolt-in type solid neutral links shall be provided and fitted in the same
compartment together with the phase poles.

.6 Means shall be provided to padlock the MCCBs and MCPs in the 'OFF'
position. Mechanical 'ON'/'OFF' indicator operating in conjunction with the rotary
type operating handle of the circuit breaker must be provided.

.7 MCCBs supplying loads from switchboards connected to the emergency power

system shall be provided with facilities for remote operation (OPEN and CLOSE)
and auxiliary contacts for remote indication.

.8 Refer to Section 16145: PROTECTION, METERING AND CONTROL for

2.7 ISOLATORS OR DISCONNECTING SWITCHES

.1 Isolators or disconnecting switches shall comply with IEC 60947-3. They

shall be of the on-load, rotary type, able to padlock and interlocked with the
housing and provided with means of operation from the front so that all
enshrouded live parts can be made dead with the switch off. All fixed contacts
shall be shrouded. Isolators shall comprise of a quick-make and break, positive
action mechanism. Isolators shall not be door mounted.

2.8 CONTACTORS

.1 Contactors shall be the holding coil type with an operating voltage derived
from
phase and neutral.

.2 The contactors shall be suitable for making and breaking at 0.35 power
factor the
stall current of the associated motors which shall be assumed equals 8 times
full
load current of the motors.

.3 Contactors shall have facilities for rail mounting.

 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 18

.4 Contacts shall be renewable butt type, solid copper, hard silver faced, fully
shrouded main and auxiliary contacts and the designs shall be such as to ensure
effective freedom from contact bounce and sticking of the fixed and moving
portion of the magnet assembly.

.5 Auxiliary contacts necessary for remote monitoring and control by BCS,

Fire Alarm System and Standby Generator System shall be provided as indicated
on the Contract Documents.

.6 Contactor coils shall be fully tropicalised and wound for continuous

operation at
240V with Class E insulation. The coils shall be arranged such that they can be
removed without having to remove the contactor.

.7 Magnets shall be fabricated from silicon alloy riveted electrical steel sheet
with
shaded poles. Magnet/armature assembly shall be fully floating and
self- aligning.

.8 Arc chutes and magnetic blow out coils shall be fitted where appropriate
and to
manufacturer's requirement.

.9 With reference to IEC 60947-4, motor starters and contactors shall conform to
the requirements of both uninterrupted duty and intermittent duty class 0.1 (12
operating cycles per hour), at rated operational current and shall have a
mechanical endurance level of 300,000 no-load operating cycles.

.10 The utilization category AC-3 (starting of squirrel-cage motors, switching off
motors during running) shall be applied. For motors in inching or reversing
rotating service, utilization category AC-4 shall be used.

.11 For special loads such as transformers, capacitors, lighting, etc. a suitable
current rating and utilization category shall be selected by the manufacturer and
in compliance to IEC 60947-4-1.

.12 Position indication of contactors shall be fitted on the front of the compartment
by clear red light for 'ON' and clear green light for 'OFF'. The indication lights
shall be of the long life, low power consumption type, e.g. multi segment LED or
neon.

.13 In addition to the required number of auxiliary contacts needed for the control
and indication circuits, each contactor and motor starter shall be provided with at
least one make and one break contact element, double gap, potential free, and
wired up to the auxiliary terminal block of the compartment.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 19

2.9 CURRENT TRANSFORMERS

.1 Instrument current transformers and their connections shall be in accordance

with IEC 60044-1 with a saturation factor such that the instruments are not
endangered at maximum fault current.

.2 When analogue current transducers are required, they shall have an output
signal of 4-20mA.

.3 Accuracy class shall be in accordance with the design drawings. . The short-
circuit rating shall be at least 1 second if applied for short-circuit protection. The
wiring of the secondary circuits shall have a cross section of at least 2.5mm 2.
Secondary terminal shorting-links shall be provided for every current transformer.
.4 Secondary circuits of all current transformers shall be earthed.

.5 Facilities shall be provided in the incoming protection CTs so that primary

injection tests on the CTs can be made after the main cable have been
connected to the switch panel without the necessity of dismantling the switch
panel, such facilities shall include the terminal block complete with test socket
and test plug.

2.10 MOTOR PROTECTION

.1 The following motor protection devices where necessary, shall be provided as

appropriate. -

.1 Motor, starting protection relay (excessive start time or stalling).

.2 Motor thermal overload relay.

.3 Motor three-phase and earth fault protection relay.

.4 Unbalance or single-phasing relay.

.5 Undervoltage relay.

Integrated multi-function static relays may be used.

.2 Refer to Section 16145: PROTECTION, METERING AND CONTROL for details.

2.11 MEASURING, INDICATING AND CONTROL DEVICES

 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 20

.1 Where stated in the design drawings, the following measuring, indicating and
control devices shall be provided: -

.1 Digital Power Meter

.2 Kilowatt-hour meter

.3 Kilovar-hour meter

.4 Ammeter

.5 Voltmeter

.6 Power factor meter

.7 Indicating lamp

.8 Timer

.9 Control relay

.10 Selector switch

.2 Refer to Section 16145: PROTECTION, METERING AND CONTROL for details.

2.12 RESIDUAL CURRENT DEVICES

.1 Provide the type of residual current devices indicated in the Contract Documents.

.2 Refer to Section 16145: PROTECTION, METERING AND CONTROL for details.

2.13 TERMINALS FOR EXTERNAL CONDUCTORS

.1 Terminals shall be suitable for copper conductors.

.2 For main power circuit cabling, terminals allowing the conductors to be

connected without the use of cable lugs of any type are strongly preferred.

.3 In view of the substantial cable derating that is normally applied, adequate

terminals shall be provided for the main cabling.

.4 For bus wiring and outgoing control circuits, individual terminals shall be provided
for each external conductor. These terminals shall be of the non-loosening,
wedge type construction, obviating the use of cable lugs.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 21

.5 They shall be constructed in such a way that direct contact between screw, bolt
or nut and conductor is avoided. For the termination of internal control wiring,
push-on connections with insulation support of the compression type may be
used.

.6 Terminals shall be identified in accordance with the related wiring diagram. The
layout shall be consistent and logical.

.7 As a standard, assemblies shall have facilities for the entry of cables and busbar
trunkings from the top. Busbar trunking and cable entries, clamping, supporting
and earthing facilities shall be provided suitable for the type, size and number as
specified. Coordinate phase configuration of all busbar trunking connection to
switchboards.

.8 For wire-armoured cable without special earthing wires in or under the

armouring, metal gland plates and compression type cable glands shall be
provided for earth continuity.

.9 Cable glands for lead sheathed or armoured single-core cables shall allow for the
insulation of the lead sheathing or armouring from the gland plate. Moreover, the
gland plates and the individual cable soldering cones or glands or single-core
cables shall be of non-magnetic material.

.10 The main-switchboards shall be connected to the transformers by busbar

trunking for the LV phases and neutral. The busbars shall be suitably spaced
and positioned for connection to the flange end of the busway system.
Coordination shall be made with the transformer manufacturer.

2.14 SECONDARY WIRING, CORE IDENTIFICATION FERRULES AND TERMINALS

.1 Both ends of each conductor shall be provided with identification ferrules. The
ferrules shall be of insulating material which shall be unaffected by oil or
moisture. Characters shall be suitably marked in black. The ferrules shall be of
the continuous ring type, not of the slip-on type. Markings shall be in accordance
with the related manufacturer's drawings.

.2 For secondary wiring, PVC insulated interconnection wires shall be used. The
size and type of the wires to be selected shall be based on mechanical strength,
voltage levels and, especially for current circuits, on the prospective current
levels.

.3 The minimum allowable cross-sectional area of the wires shall be 1.0 mm2. Wires
with a cross section bigger 1.5 mm2 shall always be stranded.

.4 Current transformer secondary circuits with 5A rating shall be 2.5mm2 minimum.

 LOW VOLTAGE AC SWITCHBOARDS,
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SECTION 18012

PAGE 22

.5 Colour coding of secondary wiring shall be in accordance with IEC 60446. Earth
wires shall be green/yellow striped. Wiring between two terminals shall be
continuous. Joints or interconnections are not allowed.

.6 For the manufacturer's internal panel wiring, other than bus wires, no more than
2 wires shall be connected under one terminal connection. Bus wires shall have
only one wire connected to each terminal.

.7 As a minimum requirement, use shall be made of rail-mounted terminals (TS 32

rail assembly) of high-grade Melamine. Partitions shall be fitted between
terminals for different voltages.

.8 Wiring ends of stranded conductors, which have to be connected into bus-type

contacts of terminals, shall be provided with compression-type pre-insulated wire
pins with insulation support. In general, when lugs, wire pins, etc., are used, they
shall be of the compression type.

.9 For the termination of secondary wiring on components, compression-type pre-

insulated push-on connectors with insulation support may also be used.

.10 To accommodate and support the secondary wiring, covered plastic channels,
insulated tubes or plastic strips shall be used.

.11 Secondary wiring shall never be mounted direct to metal. The filling factor for
channels shall not exceed 70%. Where supporting of a wire is not feasible, the
wire or part of it shall be as short as possible.

.12 Termination compartments for auxiliary and control cables shall have adequate
dimensions, with ample accommodation for the required number of terminals.
Two or more conductor terminations on one terminal are not acceptable.

.13 Metal cable glands suitable for the cables specified shall be included in the
supply of the assembly.

.14 There shall be adequate marshalling space between the cable glands and the
terminal blocks.

.15 All current transformer terminals shall be provided with shorting links. Other
terminals shall be provided with disconnecting links.

.16 Test terminals and plugs shall be provided at the front of the protective relay and
instrument panel.

2.15 REMOTE MONITORING OF STATUS AND ALARMS

 LOW VOLTAGE AC SWITCHBOARDS,
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SECTION 18012

PAGE 23

.1 For the purpose of remote monitoring and alarms additional auxiliary contacts
shall be provided for each circuit of the following: -

.1 LV Main Switchboard (per Circuit Breaker Panel)

.1 Circuit breaker ON/OFF/withdrawn status.

.2 Protection trip alarm (group).

.2 Automatic Transfer Switch

.1 Normal supply.

.2 Emergency supply.

2.16 EARTHING

.1 Earthing shall be in accordance with BS 7430, colour coding of protective

conductors in accordance with IEC 60446.

.2 Equipment Earth Bar

.1 The equipment earth bar along the full length of the enclosure shall
consist of hard-drawn high conductivity copper. Where the substation
consists of 11kV switchgear, transformer and LV switchboard, the earth
bar shall be continuous along the full length of the substation. It shall be
connected to the main system earth bar at both ends using appropriate
size earthing bolts with nuts and spring washers. The cross-section of
the bar shall be sufficient to carry the rated short-time withstand current of
the switchgear for the allowable temperature rise and the time specified.

.3 Internal Branch Earth Connections

.1 Branch earth connections made from the equipment earth bar to the
components shall consist of adequately sized copper strips or
green/yellow striped PVC sheathed stranded copper conductor.
Termination lugs shall be of the compression type.

.4 Earthing of Metal Parts

.1 All metal parts including door, relays, instruments, etc., mounted on the
switchgear shall be earthed through branch connections to the equipment
earth bar.

.2 Frames of the draw-out circuit breakers shall be connected to the earth

bar through a substantial plug type contact.
 LOW VOLTAGE AC SWITCHBOARDS,
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SECTION 18012

PAGE 24

2.17 NAMEPLATES, CIRCUIT LABELS AND PHASE MARKING

.1 General

.1 Nameplates and their fixing materials shall be proven durable under the
service conditions specified for the switchboard, motor control centre and
automatic transfer switch. They shall be moisture and rodent proof and
provided with indelible inscriptions in the language specified.

.2 Labels

.1 Circuit labels shall be provided at the front and rear portion of the
switchgear, automatic transfer switch etc. in a prominent position.

.2 Each panel shall be provided with labels including, but not limited to, the
following: -

.1 Indicator light functions.

.2 Push button functions.

.3 Fuses.

.4 Instruments.

.5 Protective relays.

.6 Warnings

.3 Phase Marking

.1 All busbar and power cable terminals shall be provided with permanent
phase markings. No tapes are permitted.

.4 Material

.1 The nameplates and labels shall as a minimum be made of a corrosion-

resistant material such as Resopal or Traffolyte.

.5 Fixing

.1 Nameplates shall be fixed to the switchboard motor control centre and

automatic transfer switch and its components by means of proven durable
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 25

self-threading screws or rivets in a prominent position. Circuit label shall

not be fitted on detachable doors or covers.

.2 Holes for fixing shall not influence in any way the

protection degree of the enclosure.

.6 Colour

.1 Indicating labels shall be white.

.2 Instruction plates shall be yellow.

.3 Warning or caution plates shall be red.

.4 Inscriptions shall be black with the exception of the warning or caution

plates, which inscriptions shall be white.

2.18 FINISHING AND PAINTING

.1 All metal structures and sheet steel shall be adequately protected against
corrosion. Preparation of surfaces for painting shall be made complying with BS
7079. All mill scale, loose rust and welding slag, shall be removed by hand tools
and the metal surfaces shall be cleaned free from dirt, oil, grease, wax and other
contaminants.

.2 The sheet steel shall be zinc phosphate treated to a minimum thickness

of 3.0 g/m2 prior to the application of paint.

.3 The manufacturer's standard is acceptable, if at least equivalent to using the

electrostatic spray process and oven-baked with: -

.1 One coat of stoving primer (zinc epoxy primer) of minimum thickness 30

microns,

.2 One coat of melamine resin paint of minimum thickness 30 microns,

.3 One final top coat of melamine paint of minimum thickness 15 microns.

Alternatively, the metal surfaces shall be coated with a layer of weather

resistant paint (epoxy polyacrylic for primer and top coat) via cathodic
electro deposition process. The dry film thickness shall be at least 35
microns.

.4 All panels shall have a consistent and matching paint finish. The final top
coat colour shall be light grey or manufacturer's standard colour subject to
Employer Representative's approval.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 26

.5 The assembly shall be treated in all respects to provide a

lasting durability under the specified service conditions.

.6 Repairs painting shall be done when there is development

of any detrimental film irregularity, such as lifting, loose, cracked, brittle or
non-adherent paint or discoloration after completion of painting.

.7 The equipment supplier shall submit detail of his painting

system and procedures for review and approval by the Employer's
Representative.

2.19 LIGHTING INSIDE REAR PANEL

.1 1 x 18W fluorescent lighting complete with limit switch shall be provided

inside each compartment of LV Switchboards at the rear side (back access) for
maintenance purpose.

3.0 EXECUTION

3.1 LV SWITCHBOARD, MOTOR CONTROL CENTRE AND AUTOMATIC TRANSFER

SWITCHES INSTALLATION

.1 Prior to installation ensure that the room is free from construction debris and that
all cable ladders, HV cables, LV cables and control cables have been properly
installed in the switchboard room and ready for eventual connection to the
switchboards motor control centre and automatic transfer switches.

.2 Install the switchboard, motor control centre and automatic transfer switches in
accordance with this specification, the manufacturer's instruction and within the
designated switchroom as shown in the design drawings.

.3 Coordinate with other specification Divisions to ensure the floor is sufficiently

level. Provide any AC power supply required.

.4 Install foundation channels such that they are flush with the floor.

.5 Positions bolt securely each panel of switchboard and motor control centre on
the foundation channel according to manufacturer's recommendations. All
switchboards and motor control centres shall be installed level and plumb.
Fronts shall be lined up and must present a neat and orderly appearance.

.6 When installing main busbar and earth bars ensure that the joint surfaces are
clean before tightening bolts of the correct size. Provide permanent phase
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 27

identification on exterior of the enclosure matching the busbar phase

identification.

.7 For automatic transfer switches connect from auxiliary contact (closed before
switch returns to normal power) on transfer switch serving lift to each lift machine
room, which is served via the transfer switch. Terminate as and where required
by the lift vendor.

.8 For automatic transfer switches connect from auxiliary contact (closed before
switch moves to emergency position) on transfer switch serving lift to each lift
machine room, which is served via the transfer switch. Terminate as and where
required by the lift vendor.

.9 For automatic transfer switches connect from engine start contact on transfer
switch to emergency generator control panel.

.10 Insert withdrawable circuit breakers and check and adjust alignment. Check
alignment of auxiliary contacts.

.11 Complete and check inter-panel wiring and power and control wiring prior to pre-
commissioning.

.12 Upon completion of installation terminate all the respective, control cables, bus
ducts into the switchboard respective terminals.

.13 Replace all covers and prepare for pre-commissioning checks.

.14 Perform all inspections and tests as described in pre-commissioning tests.

.15 Certify that all the required tests have been performed and that the switchboards
and motor control centres are performing in accordance with the contract
requirements.

.16 Seal all the rear and top panel of the switchboard motor control centres and
automatic transfer switches using the prescribed seals.

.17 All installation procedures shall follow manufacturer's recommendation.

.18 Provide relay coordination curves.

.19 Records shall be kept of installation works and submitted to the Employer's
Representative.

.20 When terminating cable ensure that the joint surfaces are clean before tightening
bolts of the correct size with cable lugs.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 28

.21 Padlock all the circuit breakers in the off-position and keep keys in the lockable
key cabinet.

.22 Carry out touch-up work on the paintwork of the switchboard, motor control
centre and automatic transfer switches and clean all surfaces.

.23 Secure the room by padlocking all the access doors.

3.2 CABLE INSTALLATION AND TERMINATION

.1 All power cable installation works shall be carried out after studying and
coordinating the recommendations of the cable manufacturer and the
switchboard, motor control centre and automatic transfer switch manufacturer.

.2 Busbar cable termination and units shall be installed on switchboard, at the

manufacturers works with busbar connection to the termination and unit.

3.3 PACKING, TRANSPORT, HANDLING, DELIVERY AND STORAGE AT SITE

.1 Switchboards, motor control centres, and auto transfer switches shall be packed
and delivered appropriately labelled in accordance with the manufacturer’s
recommendations. Each packing shall be provided with the respective label as
shown in the contract drawings for easy identification at site. All interconnecting
busbars, earth bars and insulation material/components etc. shall be packed
separately. They shall be securely packed to prevent any movement and
damage during transport and against tropical climatic conditions encountered
during shipment.

.2 Lifting eyes shall be provided to facilitate lifting. Manufacturer shall provide

information for unpacking and lifting safely, including details of any special lifting
and positioning devices, which are necessary.

.3 Each switchboard, motor control centre and auto transfer switch shall be supplied
complete with: -

.1 Foundation channels
.2 Foundation bolts
.3 Interconnecting busbars and insulation materials, etc.
.4 Accessories

.4 On arrival at site, the consignment shall be checked against the delivery notes.

• On delivery to site, the switchboards motor control centre and automatic transfer
switches shall be stored indoor in a clean, dry and ventilated place. For
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 29

prolonged storage, panel anti-condensation heaters may have to be switched on

to prevent moisture condensation and consequent damage and mal-operation.

3.4 TESTS

.1 Full Type Tests

.1 Full type tests shall be carried out in accordance with IEC

60439-1 IEC 60947-1 and IEC 60947-6-1. Certificates issued by
approved independent testing laboratories shall be submitted to the
Employer's Representative.

Type tests include the following:-

a) verification of temperature-rise limits

b) verification of the dielectric properties
c) verification of the short-circuit withstand strength
d) verification of the effectiveness of the prospective circuit
e) verification of the clearances and creepage distances
f) verification of the mechanical operation
g) verification of the degree of protection

.2 Routine Tests

.1 Before the products leave the works, the manufacturer

shall carry out the relevant routine tests in accordance with IEC 60439-1 on
the total assembly and IEC 60947-1 and IEC 60947-6-1 parts
thereof when delivered with time intervals, and the results shall be
recorded in a test report.

.3 Special Test

.1 Carry out the following special tests recommended

in IEC 1641 Guide For Testing Under Conditions of Arcing Due to Internal
Fault, and the results shall be recorded in a test report.

.4 Acceptance Tests at Manufacturer's Works

.1 Acceptance tests shall be carried out on the complete

assembled switchgear motor control centres and automatic transfer
switches. Transportable units can be wired together instead of
completing busbar joints.
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 30

.2 The following checks and tests shall at least be carried out.

.3 Switchgear motor control centres and automatic transfer switches shall be

visually inspected for technical execution and conformity with the latest
issue of the approved drawings and with the order. Spot checks shall be
made to verify: -

.1 Dimensions.

.2 The degree of protection of the enclosure.

.3 The degree of protection within the compartments.

.4 The effectiveness and reliability of safety shutters, partitions and

shrouds.

.5 The effectiveness and reliability of operating mechanisms, locks

and interlock systems.

.6 The insulation of the busbar system.

.7 The creepage distances and clearances.

.8 The proper mounting of components

.9 The internal wiring and cabling system

.10 The correct wiring of main and auxiliary circuits

.11 The suitability of clamping, earthing and terminating arrangements

.12 The correct labelling of functional units

.13 The completeness of the data on the nameplate

.14 The availability of the earthing system throughout the switchgear

.15 The interchangeability of electrically identical components

.16 The non-interchangeability of mechanically identical but

electrically different components

.4 Dielectric tests shall be carried out in accordance with IEC

60439-1. The test voltage shall be at least: -
 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 31

.1 For main circuits 2500V (AC) for 1 minute.

.2 For control and auxiliary circuits 2 x Un + 1000 V (AC) with a

minimum of 1500V for 1 second.

.5 Testing of the mechanical and electrical operation of a number of

functional units on random basis, including their control and protective
devices.

.6 CT polarity, magnetization, ratio and burden measurements

.7 Secondary injection tests.

.8 Primary injection tests.

.9 Painting and finishing tests.

.1 Measurement of paint thickness.

.2 Humidity (cyclic condensation) test to BS 3900 Pt. F2. Painted

panel shall withstand 1000 hours under test with no blistering of
film and corrosion of base metal.

.3 Adhesion test to ASTM D3359-02. Test tape shall not expose

more than one 3mm2 of bare metal or under laying coating.

.4 Impact resistance test to BS 3900 Pt. E7. Paint shall not chip-
off.

.10 The manufacturer test shall be verified and witnessed by the

Employer Representative’s and his representatives.

.5 Site Tests

.1 At the completion of installation, each switchboard, motor control centre

and automatic transfer switch shall be field tested by a representative of the
manufacturer. A report recording each item of the tests shall be certified by the
manufacturer and submitted to the Employer's Representative.

.1 Visual Inspection

.1 Correctness of location and mounting.

.2 Labelling, nameplates and phase markings.

 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 32

.3 Verification of torque for all nuts and bolts on

busway.

.4 Observation of cable bracing, both incoming and

outgoing, certifying that it is in accordance with the
manufacturer's recommendation.

.5 Safety shutters, partitions and shrouds.

.6 Functional units, operating mechanisms, locks and

interlock systems.

.7 Mounting of components.

.8 Internal wiring and cabling system.

.9 Clamping, earthing and terminating arrangement.

.10 Earthing system.

.2 Dielectric tests shall be carried out in accordance with IEC 60439-1.

The test voltages shall be at least: -

.1 For main circuits 2500V (AC) for 1 minute.

2 For control and auxiliary circuits 2 x Un + 1000V (AC) with a

minimum of 1500V for 1 second.

.3 Power frequency withstand voltage test

.4 CT polarity, magnetization, ratio and burden measurement

.5 Secondary injection test

.6 Primary injection test

.7 Functional (Sequence) Test

.1 Operation of all relays and control devices.

.2 Operation of all indicating and metering devices.

.3 Operation of all alarm devices.

 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 33

.8 Mechanical Operation Test

.1 Operation of each disconnecting means under load.

.2 Operation of each auto transfer switch.

.3 Operation of all interlocks.

.4 Calibration and setting of protection devices

3.5 MISCELLANEOUS EQUIPMENT

Equip the switchroom with the following miscellaneous items: -

.1 Danger sign, No Admittance signs etc.

.2 Artificial respiration (CPR) chart.

.3 Frame up latest approved As-Built schematic wiring diagram (A0 or A1 size) of

the switchboards.

.4 A 5 mm thickness and 1000 mm width rubber mat in front and at the back of the
entire length of the switchboard, motor control and automatic transfer switch.

.5 All the requisite labels.

.6 Approved fire detection and fire fighting apparatus.

.7 Earthing bar installation along the perimeter of the room connected to the main-
earth bed system.

3.6 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Provide training schedule and agenda and list of instructors from original
equipment manufacturer (OEM) and the supply contractor.

.2 Provide classroom training.

.3 Provide field training with demonstration on operation and maintenance.

.4 Review O&M Documentation and Test Results.

3.7 HANDING-OVER AND EMPLOYER'S ACCEPTANCE

 LOW VOLTAGE AC SWITCHBOARDS,
MOTOR CONTROL CENTRE AND ATS
SECTION 18012

PAGE 34

.1 Endorse defects list.

.2 Provide all keys.

END OF SECTION
 EARTHING SYSTEM
SECTION 18013

PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Provide low impedance earthing systems and connections for equipment earthing in
accordance with the Contract Documents.

1.2 WORK INCLUDED

.1 Supply and delivery of earthing components to site, installation, connection of equipment

earth and testing of earthing systems.

1.3 SUBMITTALS

.1 Tender Stage

.1 Technical data and product catalogues.

.2 Construction Stage

.1 Material test certificates

.2 Dimensioned layout and routing diagrams

.3 Component arrangements, data and dimensions

.4 Construction/working/shop drawings

.5 Catalogue and samples

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance tests

.2 Acceptance test reports after tests

.3 Packaging, transportation and storage notes

.4 Site Installation

.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.5 Inspection and Commissioning Test

 EARTHING SYSTEM
SECTION 18013

PAGE 2

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

• As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Except as modified by the Contract Documents, comply with the latest applicable
provisions and latest recommendation of the following: -

.1 IEC 60364-5-54 Electrical Installation of Buildings Part 5 -54

Selection and Erection of Electrical
Equipment - Earthing
Arrangements and Protective Conductors and Protective
Bonding Conductors

.2 BS EN 13601:2002 Copper and Copper Alloys. Copper Rod,

Bar and Wire for General Electrical
Purposes

.3 BS 12451:1999 Copper and Copper Alloys. Seamless,

Round Tube for Heat Exchanges

.4 BS EN 12167:1998 Copper and Copper Alloys. Profile and Rectangular Bar

for General Purposes

.5 BS EN 13602:2002 Copper and Copper Alloys. Drawn, Round

Copper Wire for the Manufacturer of
Electrical Conductors

.6 BS 6360 Conductors of Insulated Cables

BS EN 60228:2005

.7 BS 7430 Code of Practice for Earthing

.8 BS 7671 Requirements for Electrical Installations

.2 Manufacturer shall have at least 10 years experience in the manufacture of similar

equipment/components.
 EARTHING SYSTEM
SECTION 18013

PAGE 3

2.0 PRODUCT

2.1 GENERAL

.1 The installation of the earthing system shall be comprising of the following:

.1 Bare stranded copper cables

.2 Earth cables concealed in columns (PVC insulated green in yellow strip

copper cables)

.3 PVC covered copper tape

.4 Exothermic welds

• Testing joints

.6 Earth points and earth test points

.7 Clamps and clips

• Copper rod electrodes

• Earth chamber

• Earth bars and disconnecting links

• Tape clips, saddles and clips

• Other components necessary to comoplete the earthing system

.2 Welding of Reinforcement Bar

.1 A minimum of two separate reinforcement bars shall be provided at each

connection point. The structural reinforcement bar to which the connection is
made shall be continuous steel bar extending a minimum of ten metres vertically
into the pile.

.2 For the bored pile reinforcement bars in the core area of the building, they will be
interconnected with a conductor loop to obtain a low resistance to earth.

.3 Earth Conductor

.1 Earth conductor laid in the earth or soil shall be bare type. Earth conductor shall
2
be soft drawn copper stranded wire of not less than 95mm . Allowance of five (5)
percent slack shall be provided before casting the concrete floor slab.
 EARTHING SYSTEM
SECTION 18013

PAGE 4

.2 PVC copper conductor shall be green in colour. If PVC copper conductor used
as neutral earth, it shall be black in colour.

.3 Bare copper tapes shall comply with BS EN 13601:2002.

.4 If PVC covered copper tape is used as neutral earth, it shall be black in colour.

.4 Earth Connectors, Clamps, Clips and Saddles

.1 Earthing connectors shall be high strength copper alloy interlocking clamps

equipped with silicon bronze bolt, nuts and lock washers or interlugs with Allen-
head set screws and one-hole tongue. Material used shall comply to BS EN
12167:1998 or BS 12451:1999. Earthing connectors
shall be corrosion resistant and provided for cable to flat surface connection on
equipment and structural steel.

.2 Clamps and connectors shall be connected tight to earthing conductor and

securely attached to equipment and earth rods with set screws, bolts and nuts. All
bonding shall be made on tinned copper surfaces.

.3 Direct buried earth connections shall utilise the exothermic welds.

.5 Exothermic Welding

.1 Exothermic welding connections shall be provided for all buried connections and
connection between copper stranded wire to steel reinforcement bar. The
method of welding shall be as follows: -

.1 Install the portion of copper conductor into a mould and fire the
powder in the crucible, which produce a super- heated flow of
molten copper into the mould.

.2 Where required, insulate the welded connections with self-

fusing electrical tape and cover vinyl plastic electrical tape to
a thickness equal to the conductor insulation.

2.2 SYSTEM EARTHING

.1 The system earthing shall be installed complying with the following criteria: -

.1 Lowest electrical resistance (in ohms).

.2 Good corrosion resistance.

.3 Able to carry the high current repeatedly.

 EARTHING SYSTEM
SECTION 18013

PAGE 5

.4 Reliable life span of at least 30 years.

.2 Earthing resistance measurements for individual systems shall be as follows: -

.1 HV & LV systems – not exceeding 1 ohm

.2 Lightning protection system – not exceeding 5 ohms

.3 Telephone system – not exceeding 1 ohm

.4 Computer system – not exceeding 1 ohm

.5 Bored Pile – not exceeding 3 ohms

.3 Earthing of Main Columns. The main structural columns shall be bonded with
exothermically weld and earthing leads will be taken to the above pits.

2.3 EARTHING SYSTEM

.1 The requirements of the earthing systems consists of manufacture, supply, install,

testing, commissioning and defects liability maintenance of all the complete earthing
detailed below:

.1 All HV 11KV and LV 415V/240V earthing for main switchboards, sub

switchboards, main distribution boards, distribution boards, all meter panels,
generator set (frame and neutral earthing), transformer (frame and neutral
earthing) and UPS (frame and neutral earthing).

.2 All earthing of trunking, cable trays, cable ladders, conduits, junction boxes,
lighting fittings, general socket outlets, equipment.

.3 All earthing for the telephone systems

.4 All computer systems earthing

.5 All main columns earthing

.2 The building earth-bed system shall consist of continuous loop connection of the
respective pile cap locations using buried bare copper stranded wire and exothermically
welded. The disconnection of earthing conductors from the earth-bed shall only be made
at the earth bars. All earth points shall be flushed to column surface for connection to
respective services.

.3 The groups of earthing points shall be interconnected with each other with a copper tape
to which all electrical plant and metal work is bonded. Connections to the earth
2
electrodes shall be by means of 95mm PVC insulated green copper cables. Each
earthing strip shall be extended by 25 x 3mm Hard Drawn High Conductivity copper
tapes connecting the non current carrying metal work of all ancillary apparatus supplied
 EARTHING SYSTEM
SECTION 18013

PAGE 6

under the works to the main earth bar. It shall be installed at a height of 300mm above
floor finishes level.

.4 Separate earth bar shall be provided for the building system earth. The method of
connection shall permit convenient disconnection by means of a tool for the purpose of
measurement and testing of earth loop impedance. No other joints should be allowed; if
the copper tape or stranded conductor is not adequate to complete the loop, exothermic
welds shall be used to joint two sections.

.5 Earth connections shall run in approved positions and fixed in an approved manner
generally in square and symmetrical line using gunmetal saddles of appropriate size for
securing tapes at intervals not exceeding 900 mm. The copper tapes shall be supplied in
long unbroken lengths to avoid unnecessary jointing, unless otherwise, all joints shall be
exothermic welded.

.6 The mating surfaces of all tapes at joints etc. shall be tinned before clamping and the
joints shall be tinned, riveted and soldered. All connections to electrical apparatus shall
be made by a bolted connection in a visible and accessible position.

.7 All joints in exposed sections shall be protected against corrosion and the ingress of
moisture by the application of two coats of an approved anti corrosion paint.

.8 The earthing systems shall include for measuring, making off, cutting, fitting and erecting,
the supply of necessary clamps and rag bolts complete with all fixing screws and rivets
for fixing and jointing the copper tape including the necessary lugs, installation material
and the use jointers tools.

.9 The earth connection for all sections of the installation shall be electrically continuous
throughout.

.10 All transformer and generator set neutral connections shall be brought directly and
connected to the plantroom main earth bars by exothermic welds such that
disconnection of the neutral can only be made at the individual transformers and
generator set. Neutral earthing conductors shall be insulated to distinguish from
frame earth conductors. Clear distinction shall be provided.

2.4 EARTHING POINTS (IF EARTH BED SYSTEM USING PILECAP NOT APPLICABLE)

.1 Each earthing point shall comprise and extensible type 15mm diameter hard drawn, solid
copper rod with internal screw and socket joint, hardened steel tip, driving head and
connector clamp.

.2 The combined resistance of the earth electrodes shall be less than one ohm and the
requirements of local authorities and/or utility providers shall take precedence.

.3 Contractor shall carry out soil resistivity tests on site and to ascertain the location and
number of earth points required, and allowance for such tests shall be made in the
Contract. The Contract sum for earthing shall cover any number of points or method
required achieving the required earthing resistance. The testing shall be carried out to the
 EARTHING SYSTEM
SECTION 18013

PAGE 7

satisfaction of the Employer’s Representative with a digital four-pole earth tester and
other relevant testing apparatus to be provided by the Contractor.

.4 Where more than two (2) electrodes are driven to form a group, the heads of the
electrodes in the group shall be bonded to each other by means of copper tape, laid at a
depth of 600mm in the ground.

.5 Where group conditions are favourable for the use of rods in parallel to form a group, the
distance between the rods should be at least equal to twice the driven length.

.6 Earth chamber c/w cover shall be provided. The Contractor shall include for the driving of
all earth electrodes, connecting to the main earth bar and testing to the satisfaction of the
Employer’s Representative.

2.5 THE ELECTRICAL DISTRIBUTION EARTHING SYSTEM TO BE PROVIDED SHALL CONSIST

OF THE FOLLOWING: -

.1 Plantroom Main Earth Bar System

.1 A looped earth conductor shall act as the main earth bar installed within the
electrical rooms or plantrooms. The main earth bar shall be sized to carry the
rated short-circuit current without creating any fire risk.

.2 Minimum two (2) copper tape conductor shall be extended in separate route from
the main earth bar to the equipment earth bar in each switchgear, transformer,
switchboard, motor control centre, generator set and other frame earth.

.3 Conductors from the main earth bar shall be provided as indicated in the design
drawings.

.2 LOCAL AUTHORITY Substation, Primary Switchgear, Main Switchboard and Motor

Control Centre

.1 Each section of the local authority substations, primary switchgear, switchboards

and motor control centres enclosure and service conduits entering same to the
respective equipment earth bar shall be bonded.

.2 Suitable earthing terminals shall be provided in all the switchgear enclosures,

relay and instrument casings and all other electrical metalwork for bonding to
earth.

.3 Where equipment earth bars are provided e.g. switchgear, main switchboards,
motor control centres, the respective circuit protective conductors shall be
connected to them. The sizes of circuit protective conductors shall be in
compliance with BS 7671.

.3 Dry-Type Transformer and Isolation Transformer

 EARTHING SYSTEM
SECTION 18013

PAGE 8

.1 Perform earthing in accordance with BS 7430 and BS 7671.

.2 Perform neutral connection and transformer core earthing separately.

.3 Install bonding jumper across flexible conduit from transformer enclosure to rigid
conduit.

.4 Generator Set

.1 Perform neutral connection and alternator earthing separately.

.5 Busbar Trunking (Busway)

.1 Where busbar trunking routes to switchboard, the integrated earth bar in the
busbar trunking shall be extended to the earth bar on the switchboards.

.2 Where busbar trunking are served via cable tap boxes; earth conductors from
earth bar in the busbar trunking shall be extended to equipment earth bar of
switchboard.

.3 All busbar trunking tap-offs and fuse devices shall have earth connection within
them for positive connection to earth bar of the busbar trunking.

.6 Cables

.1 Cable armour, cable metallic sheath, enclosures, frames, fittings and other metal
non-current-carrying parts that are to serve as earthing conductors shall be
effectively bonded where necessary to assure electrical continuity and the capacity
to conduct safely any fault current likely to be imposed on them. The armour or
metallic sheath of 3-core or 4-core cables shall be earthed at both ends. Any
nonconductive paint, enamel, or similar coating shall be removed at threads,
contact points, and contact surfaces or be connected by means of fittings so
designed as to make such removal unnecessary.

.7 Cable Trays

.1 Metallic paint systems shall not be used as principal earth return path in full
length. Separate earth conductor shall be provided.

.2 Jointing shall be made using exothermic welds or square clamp.

.8 Cable Trunkings

.1 Metallic paint system shall not be used as principal earth return path. Separate
link earth conductor shall be provided in the form of copper tape of minimum 35
mm sq. size.
 EARTHING SYSTEM
SECTION 18013

PAGE 9

.9 Conduit Connection to Electrical Equipment

.1 Earth conduits to metal framework of electrical equipment with double locknuts or

earthing bushings and bonding jumpers unless otherwise noted.

.2 Install bonding jumpers at all electrical equip-ment to provide continuous earth

return path through conduit.

.10 Underfloor Ducts

.1 Install bare copper bonding jumper between underfloor duct sections on both
sides of expansion joint using pressure type lugs with embedding type-bonding
screws.

.11 Flush floor Trunking

.1 Earth bonding links of 35 mm sq. shall be provided for jointing trunking to

maintain earth continuity; to be installed on one side of the trunking (the inner
side).

.12 Raised Floors

.1 All raised floors shall be electrically bonded for grid earthing purpose.

.2 25mm² PVC insulated earth cables and connectors from opposite ends of raised
floor shall be connected to panel board serving that area.

.13 Socket Outlets, Switches, Lighting Luminaries and Motors

.1 All socket outlets, switches and lighting luminaries shall be earthed by means of
a green/yellow PVC covered copper protective conductor.

.2 Install bonding jumpers between outlet box and socket outlet earthing terminal
except where contact device is provided for earthing purposes.

.3 Motors shall use the armours of the power supply cables as protective earth
conductors. Approved glands shall be provided for bonding. The armours shall
be sized to carry the prospective short-circuit currents. If the cross section of the
armour is inadequate, a separate protective conductor shall be used.

.4 Where motors or other utilization equipment are connected to electrical system

with flexible conduit, earth by one of the following:

.1 External jumper across flexible conduit.

.2 Flexible conduit contain integral earth wire.

.14 Telecommunication Earth

 EARTHING SYSTEM
SECTION 18013

PAGE 10

.1 Main telephone terminal board and riser terminal boards shall be earthed by
installing a bare copper tape riser between the building service earth and the last
riser terminal board. The design, routing and location of the telecommunication
earth riser, terminal bar and earth connections shall be similar to that of the
distribution earthing system. At each terminal riser board, one (1) copper wire
from the telephone riser earth shall terminate at the riser terminal board. The
method of bonding shall be similar to that of the distribution earth system.

.15 Electronic (Clean) Earth

.1 Electronic (clean) earth conductor shall be installed in a similar manner as the

distribution earthing system via the riser to the top-most utilisation floor.

.2 The riser shall be connected to earthing terminal.

.3 Facilities for the connection of the earth of electronic equipment at every floor
shall be provided for connection of earth conductors.

.16 Incoming Metal Pipe From Utilities Area.

.1 Make connection to earth connection.

.2 Do not damage pipe and other metal parts.

2.6 EARTH LABELS

.1 Label all the various types of earth at every floor. All the earth connection terminals and
earth test points shall be correctly labelled. Identification plates shall be white bakelite
plates with black engraved upper case letters enclosed by black border with bevelled
edge.

3.0 EXECUTION

3.1 TESTS

.1 Site Inspection, Bonding Resistance and Earth Electrode Resistance Measurement

.1 The measurement of the bonding resistance and earth electrode resistance of

each connection point to earth shall be carried out by the Contractor at the
following stages: -

.1 Before concreting of pile cap, on completion of securing the

reinforcement bar extensions on the pile cap location, and
 EARTHING SYSTEM
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.2 After concreting of pile cap.

.2 The method of measuring earth electrode resistance shall be in accordance with

BS 7430:1991 entitled “Earthing”. The Contractor shall provide all necessary test
equipment for performing of earth electrode resistance measurement.

.3 Sufficient prior notice shall be served to the Architect / Engineer for the
inspection of the welding of reinforcement extension prior to concreting of the pile
cap. Prior to testing, the methodology for testing shall be submitted to the
Architect / Engineer for approval. No testing is permitted without approval of
testing procedures.

.4 Full documentation of test results shall be submitted to the Architect / Engineer at

the completion of each phase of testing.

.5 The earth resistance at each bore pile shall be of the order of 3 ohms or less.
Should the resistance reading of any of the bored piles before concreting of pile
cap exceeds 3 ohms, additional bonding to the other starter bars of the bored pile
shall be provided, if instructed by the Architect / Engineer, to achieve lower
resistance to earth.

.2 Site Tests

.1 All site tests shall comply with the requirements of BS 7430 and BS 7671.

.2 Soil resistivity tests.

.3 Visual Inspection

.1 Condition and size of conductor.

.2 Check correct fastening of conductors and interval of clips.

• Completeness, tightness, material of earthing joints/connections and correct type

of clamps/joints and connections.

.4 Check exothermic welds.

.5 Condition and size of earth electrode and earth joint pit.

.6 Protection against mechanical damage to the conductor.

.7 Check provision and correctness of labels.

.8 Protection against corrosion.

.4 Earth Resistance Tests

.1 Measure earth resistance of each electrode and grid.

 EARTHING SYSTEM
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.2 Measure earth resistance of each earthing system.

.5 Continuity Test

.1 Check continuity of all connection.

3.2 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Review O&M Documentation and Test Results.

3.3 HANDING-OVER AND EMPLOYER'S ACCEPTANCE

• Endorse defects list.

END OF SECTION
 LIGHTNING SYSTEM
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PAGE 1

1.0 GENERAL

1.1 DESCRIPTION

.1 Provide all labour, materials and items of service required for the completion of a
functional and unobtrusive lightning protection system in accordance with the Contract
Documents.

1.2 WORK INCLUDED

.1 All materials, equipment and components for a safe and durable lightning protection
system in accordance with IEC 62305, BS 6651 and BS 7430.

1.3 SUBMITTALS

.1 Tender Stage

.1 Manufacturer's catalogue and specification for components.

.2 Construction Stage

.1 Installation and construction drawings, joints earth termination, bonding, etc.

.2 Systems drawings showing locations and routes of air terminations, down

conductors and test joints and earthing points, roof plans, elevation views.

.3 Components drawings, catalogues and samples

.4 Test certificates of components.

.3 Inspection and Acceptance Test

.1 Type test and routine test reports prior to acceptance tests

.2 Acceptance test reports after tests

.3 Packaging, transportation and storage notes

.4 Site Installation

.1 Installation methods/Work method statements prior to installation work

.2 Pre-commissioning test procedures prior to pre-commissioning testing

.3 Pre-commissioning test records subsequent to testing

.4 Method of ensuring effective bonding.

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.5 Inspection and Commissioning Test

.1 Site test reports prior to commissioning test

.2 Commissioning test reports after testing

.3 O&M manuals

.4 As-built AutoCAD drawings

1.4 QUALITY ASSURANCE

.1 Except as modified by the Contract Documents, comply with the latest applicable
provisions and latest recommendation of:

.1 IEC 62305-1 Protection Against Lightning –

Part 1 : General Principles

.2 IEC 62305-2 Protection Against Lightning – Part 2 : Risk

Management

.3 IEC 62305-3 Protection Against Lightning –

Part 3 : Physical Damage to Structures and Life Hazard

.4 IEC 62305-4 Protection Against Lightning –

Part 4 : Electrical and Electronic Systems with Structures

.5 BS 7430 Code of Practice for Earthing.

.6 IEEE C62.41-1999 IEE Recommended Practice for Surge Voltages in Low

Voltage AC Power Circuits

.7 AS1768 (Int):2003 Lightning Protection

.8 BS6651-1999 Code of Practice for Protection of Structures

Against Lightning - Appendix C

.9 CP33-1996 Code of Practice on Lightning Protection

.10 IEEE C62.41.2-2002 IEEE Recommended Practice on Characterization of

Surges in Low-Voltage (1000V and Less) AC Power
Circuits

.11 IEEE C62.41.1-2002 IEEE Guide on the Surge Environment in

Low-Voltage (1000V and Less) AC Power
Circuits
 LIGHTNING SYSTEM
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PAGE 3

.12 IEEE C62.45 IEEE Guide on the Surge

Testing for Equipment connected to Low-Voltage
(1000V and less) AC Power Circuits

.13 IEC 61643-1 Low Voltage Surge Protective –

Part 1 Surge Protective Devices connected to low-
voltage power distribution systems: Requirements and
tests

.14 IEC 61643-12 Low Voltage Surge Protective –

Part 12 Surge Protective Devices connected to low-
voltage power distribution systems: Selection and
application principles

.15 IEC 61643-21 Low Voltage Surge Protective –

Part 21 Surge Protective Devices connected to
telecommunication and signalling networks:
Performance requirements and testing methods

.16 IEC 61643-22 Low Voltage Surge Protective –

Part 22 Surge Protective Devices connected to
telecommunication and signalling networks: Selection
and application principles

.17 IEC 61643-331 Components for Low Voltage

Surge Protective Devices – Part 331: Specification for
Metal Oxide Varistors (MOV)

.2 Manufacturer shall have at least 10 years experience in manufacture of similar

equipment.

2.0 PRODUCT

2.1 GENERAL

.1 The lightning protection system shall be comprising of the followings:-

.1 Air Terminations (20mm diameter copper rods and 25mm x 3mm

copper tapes)

.2 Down conductors (25mm X 3 mm copper tapes and/or minimum 95 mm² copper

cables)

.3 Clamps and clips

.4 Test Joints
 LIGHTNING SYSTEM
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PAGE 4

.5 Earth Terminations

.6 Connections and bonding to external metallic curtain wall, parapet railing and
metallic parts located on the roofs and the sides of building.

.7 Surge Protection Devices

2.2 AIR TERMINATIONS

• Air terminations shall be firmly secured by suitable fixing bolts, screws and clamps to
establish good electrical continuity from lightning rods to roof conductors and to ensure
that they are securely held in position under the influence of mechanical stresses during
the passage of lightning currents. Roof conductors shall be secured by suitable clamps 1
meter apart. Part of the building structure, roof, parapet railing, metallic curtain walls and
other exposed metallic parts, etc. shall act as lightning air terminations. Special
consideration shall be given in the installation of air termination system in view of the
height of the building and the requirements of an aesthetically pleasing appearance but
without compromising inspection, performance and maintenance requirements.

2.3 DOWN CONDUCTORS

.1 The number of down conductor connecting the air termination and/or down conductor
shall be provided as shown in the design tender drawings. Down conductors shall be
brought straight down to its own earth termination with the least looping possible so as to
prevent unduly high electrical stresses during the passage of lightning currents. Each
down conductor, in the form of 95 mm sq. PVC copper cables indicated in the tender
drawings, shall be secured firmly by clamp to the bar within the building column at 1
meter intervals from the point of roof conductor connection to the earth termination and
shall be able to withstand mechanical stresses during the passage of lightning current.
For building height of more than 60 meter, tap-off points in the form of 25 m X 3 mm
copper tapes shall be provided at intervals indicated in the tender drawings, connecting
the metal parts of the building façade to each of the vertical down conductors. Such
connection shall protect against the in-direct flashing on the building.

2.4 BONDING OF METAL PARTS

.1 All external metal parts shall be effectively bonded to the lightning protection system.
Where metal parts are long, e.g. service pipes, metal sheaths, ladders, etc. bonding shall
be provided at their extremities. Attention shall be given to the bonding of metallic curtain
wall to prevent side flashing while acting as air termination.

2.5 CORROSION

.1 All materials selected for the lightning protection system shall offer resistance to
corrosion. Care has to be given to the contact of dissimilar metals such as copper and
aluminium. Proper friction-welded bimetallic connectors shall be provided.

2.6 TEST JOINTS

 LIGHTNING SYSTEM
SECTION 18014

PAGE 5

.1 Each down conductor shall be provided with a test joint in such a position that, while not
inviting unauthorised interference, it is convenient for use during testing. The down
conductor used to connect the test joint and the earth termination shall be of copper and
of the same dimensions as the upper down conductor.

2.7 EARTH TERMINATIONS

.1 An earth termination shall be connected to each down conductor. Each termination

should have a resistance to earth not exceeding by 5 ohms. All the earth electrodes shall
be interconnected by a ring conductor installed at least 0.6 meter below ground using 95
mm square bare stranded copper cable forming a closed loop. All joints except at the
earth chamber shall be exothermically welded.

2.8 MATERIAL

.1 All materials and components shall be similar to those used for the purpose of system
earthing.

2.9 SURGE PROTECTION DEVICES WITH MOV TECHNOLOGY

.1 General

.1 Surge Protection Devices shall be installed at main switchboards, sub

switchboards & distribution boards.

.2 Surge Protection Devices are required to provide protection for electronic

equipment against lightning & switching transients.

.3 Surge Protection Devices for MSB, SSB & DB shall be under one manufacturer
to ensure products compatibility.

.4 Third party test report on the let-through voltage and kA rating per phase is
mandatory to be submitted for performance review approval.

.2 Surge Diverters for Main Switch Boards(MSB), Essential Main Switch Boards (EMSB)
and AMF Board

.1 Surge Diverters for MSB, EMSB and AMF shall require minimum rating of
200kA(8/20us) per phase c/w status display and multiple redundant modes.

.2 Surge Diverters shall provide full mode protection (L-N, L-E & N-E)

.3 Surge Diverters shall have let through voltage less than 800V p (L-N,L-E & N-E),
when tested at 6kV (1.2/50us) and 3kA (8/20us) combination wave as per IEEE
C62.41 1999 and BS 6651: 1999 cat C test.

.3 Surge Diverters for Sub Switch Boards (SSB)

 LIGHTNING SYSTEM
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PAGE 6

.1 Surge Diverters for SSB shall require minimum rating of 80kA (8/20us) per
phase c/w status indicators.

.2 Surge Diverters shall provide full mode protection (L-N, L-E & N-E)

.3 Surge Diverters shall have let through voltage less than 600Vp (L-N, L-E & N-E),
when tested at 6kV (1.2/50us) and 3kA (8/20us) combination wave as per IEEE
C62.41 1999 and BS 6651: 1999 cat B test.

.4 Surge Diverters for Distribution Boards(DB)

.1 Surge Diverters for DB shall require minimum rating of 40kA (8/20us) per phase
c/w status indicators.

.2 Surge Diverters shall provide full mode protection (L-N, L-E & N-E)

.3 Surge Diverters shall have let through voltage less than 600Vp (L-N, L-E & N-E),
when tested at 6kV (1.2/50us) and 3kA (8/20us) combination wave as per IEEE
C62.41 1999 and BS 6651: 1999 cat B test.

3.0 EXECUTION

3.1 INSTALLATION

• The installation of all conductors and components shall be a such a manner that the
completed work is unobtrusive and does not detract the appearance of the building but
without compromising inspection, performance and maintenance requirements that are
necessary during the life of the building.

.2 All components shall have adequate electrical and

mechanical properties and shall be selected to achieve a minimum lifetime of twenty
(20) years. All the components shall be submitted for approval by the
Employer’s Representative.

.3 The design of the lightning protection system shall not only ensure the protection of the
buildings from downward flashes but upward flashes as well taking into consideration the
building height and high ceramic level experience at the location. The design shall
employ the Faraday Cage Principle to protect people and equipment within the building.
No side flashing shall be allowed.

3.2 TEST

.1 Site Tests

.1 All site tests shall comply with the requirements of BS 7430 and BS 7671.

.2 Visual Inspection

.1 Condition and size of conductor.

 LIGHTNING SYSTEM
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PAGE 7

.2 Check correct fastening of conductors and interval of clips.

.3 Completeness, tightness, material of joints/connections and correct type of

clamps/joints and connections.

.4 Check exothermic welds.

.5 Protection against mechanical damage to the conductor.

.6 Check provision and correctness of labels.

.7 Protection against corrosion.

.3 Continuity Test

.1 Check continuity of all connection.

3.2 TRAINING OF OPERATION AND MAINTENANCE STAFF

.1 Review O&M Documentation and Test Results.

3.3 HANDING-OVER AND EMPLOYER'S ACCEPTANCE

.1 Endorse defects list.

END OF SECTION