Volume 04

(A joint Venture of GOVT. of INDIA and GOVT.
of NCT of DELHI)
DESIGN VERIFICATION, DETAIL ENGINEERING, SUPPLY, INSTALLATION,

TESTING & COMMISSIONING OF ELECTRICAL AND MECHANICALSYSTEMS,
FIRE DETECTION, FIRE SUPPRESSION SYSTEM AND DG SETS OF CORRIDOR-
1 AND 2 OF ELEVATED STATIONS AND DEPOT OF PATNA METRO RAIL
PROJECT
CONTRACT NO.: PE-02
TENDER DOCUMENT
VOLUME-4
PARTICULAR SPECIFICATIONS
DELHI METRO RAIL CORPORATION LTD.
(A Joint venture company of Govt. of India & Govt. of NCT of Delhi)
Metro Bhawan, Fire Brigade Lane, Barakhamba Road, New Delhi - 110001
Website: www.delhimetrorail.com
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PART – A
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1. INTRODUCTION
1.1 GENERAL
1.1.1 The said contract is generally for the following works of DMRC Phase-IV MRTS being
executed by DMRC:
a) Supply, Installation, Testing and Commissioning of E&M, BMS, DG, Fire Detection, Fire
Suppression and HVAC Systems for 23 stations mentioned in this contract.
b) Supply, Installation, Testing and Commissioning of E&M, Fire Detection, Fire Suppression
and HVAC Systems for Mukundpur depot augmentation works mentioned in this contract.
c) Supply, Installation, Testing and Commissioning of Electrification works for PWD flyovers
Part 1 and 2 mentioned in this contract
1.1.2 The quantities taken in BOQ are cumulative requirement of all the metro stations, PWD
flyovers and depot.
1.2 SCOPE OF WORK
1.2.1 The scope of work under these specifications generally covers but is not limited to
supply, fabrication, installation/fixing, necessary touch up painting, testing and
commissioning of the items mentioned in the Bill of Quantities. The contractor shall carry
out and complete the said work under this contract in every respect in conformity with
the current rules and regulations of the Local Electricity Authority, the Indian Standard
Institution, Indian Electricity Rules and Act and with the directions of and to the
satisfaction of the Employer or his representative. The contractor shall provide all
required labour and install all materials, appliances, equipment (except those items
which will be supplied by the owner to the contractor at site) necessary for the complete
provision and testing of the installation as specified herein and shown on the drawings.
This also includes any material, appliances, equipment not specifically mentioned herein
or noted on the drawings as being furnished or installed but which are necessary and
customary to make complete installation properly connected and in working condition.
The work shall include all incidental jobs / minor civil works connected with installation
such as excavation in trenches and backfilling, cutting, drilling and grouting etc. The
following jobs shall be deemed to be included in the scope of work of relevant item
whether specifically mentioned or otherwise:
a) Conduiting, Wiring, Supply & Fixing of Modular type Switches etc. for Lighting
& fans etc.
b) Conduiting, Wiring, Supply & Fixing of Modular type Sockets and Switches
including Industrial Socket outlets wherever required and as per drawings.
c) External Lighting including its Feeder Pillar, Cabling, Poles all complete, High
Mast (as applicable).
d) Lighting Fixture for internal areas (including verification of lux level achievable
in various areas) and External Areas.
e) Fire Detection and Alarm System including associated Conduiting and Wiring.
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f) Safety Equipment as per requirement.
g) All panels & DBs including Main Distribution Board, Essential Power Panel, AC
Power Panel, Escalator Power Panel, Passenger Amenities Panel, Fire Pump
Panel, Water Pump Panel, Emergency Power Panel, Lighting Distribution Boards
etc. or other wherever applicable.
h) Various Distribution Boards / Panels as required with Automatic Source
Transfer System etc.
i) Power Supply for Signage.
j) DC Control Supply system as required.
k) Power Cables and Control Cables, Cable Trays, Raceways and Ducting etc.
l) Exhaust Fans, bracket fans, air circulator fans and Ceiling Fans.
m) Ventilation of Basement & Generator Room, Substation & Pump Room, Air-
Conditioning of Equipment Rooms and other areas as specified as per
requirement.
1.3 LIST OF STATIONS
1.3.1 List of 12 stations (all elevated) covered in this tender is as follows:
Corridor-1- (7 stations)
a) Danapur
b) Saguna More
c) RPS Chowk
d) Patliputra
e) Mithapur
f) Ram Krishna Nagar
g) Jaganpura
Corridor-2- (5 stations)
h) Malahi Pakri
i) Khemni Chak
j) Bhootnath
k) Zero Mile
l) New ISBT
1.4 STANDARDS
1.4.1 The work shall be carried out as per various standards & regulations which have been
detailed in each section/sub section of the technical specifications.
1.4.2 Applicable Codes and Regulations
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1.4.2.1 Electrical arrangement shall be based on BS: 7671 – 2001 “Requirements for electrical
installations. IEE Wiring Regulations – Sixteenth edition” or other internationally
recognized equivalent standard approved by the Employer’s representative example s
of which are:
IEA Indian Electricity Act
CEA Central Electricity Authority
BS British Standard
EN Euronorm Standard
ISO International Standards

Organization
NBC National Building Code
ASTM American Society for Testing and

Materials
IEC International Electro-technical

Commission
NEC National Electrical Code
NEMA National Electrical Manufacturers

Association
NFPA National Fire Protection Association
IS/BIS IS/BIS
1.4.3 Local Codes, Regulations and Standards

1.4.3.1 Unless otherwise stated, the electrical system shall be governed by all applicable local
codes, code of practices regulations and standards (all latest) issued by the local
agencies.
1.4.3.2 Local codes, regulations and standards shall take precedence where their standards
or requirements are more onerous than other national standards.
1.4.3.3 The Contractor shall ensure compliance with the regulations laid down by local
authorities
i.e., Government, Municipal, Chief Electrical Inspector Mumbai, and all other statutory
agencies including fire safety regulations, fire insurance regulations or other local
codes and obtain approvals from relevant authorities at appropriate stages of work as
required.
1.4.3.4 Updated and current standards shall be applicable irrespective of dates mentioned
with references/ standards in the tender documents.
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1.5 SERVICE LIFE OF EQUIPMENTS
1.5.1 The quality of the material, equipment’s, cables shall be so as to secure a minimum
service life as shown below:
Main Switch Boards 30 years
Sub-main switch boards / distribution 30 years

boards/ panels
Cables 30 years
Fire alarm main panel 30 years
Luminaires 10 years
Tray, trunking and supports 30 years
Lightning protection 30 years
Sub-assemblies and components 30 years
DG set 20 years
Batteries Life Over 10 years
VRF/VRV system 15 years
All other Equipment As Applicable
1.5.2 Above service life of the equipment is the normal life expectancy of the equipment
subject to its maintenance and preservations as per the recommended maintenance
practice. Contractor shall furnish manufacture’s certificate for secured service life of the
equipment
1.6 TECHNICAL REQUIREMENTS
1.6.1 The design, supply, installation, testing & commissioning of all items of equipment and
materials mentioned in BOQ shall be made in accordance with the particular
specifications, latest codes & standards specified in these documents.
1.6.2 Specifications shall find precedence over the relevant standards indicated. In case of
doubt or no mention of specification or standards, the CPWD specifications shall be
followed. However, the decision or clarifications of Employer's representative or the
Engineer on above shall be final & binding. No deviation from the agreed designs shall
be accepted unless specifically agreed to by Employer’s representative and notified.
1.6.3 Operating Parameters
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1.6.3.1 Operating parameters for electrical works shall generally be 3-phase, 4-wire, 415V,
50Hz unless specified otherwise.
1.6.4 Quality Control of Equipments, Components and Material
1.6.4.1 All major equipments and materials such as LV switchgear, distribution/sub-distribution
boards, switchboards, battery, battery chargers, change over switches, luminaries,
electronic chokes/drivers, street lighting poles, PVC/XLPE cables etc. as required for
the work shall be subject to Quality Assurance Programme to ensure proper supply
and use of raw materials, processes, installation/execution and tests.
1.6.5 The contractor shall furnish the Quality Assurance Programme prior to fabrication of
various assemblies and their supplies for installation. A well-documented quality plan
shall be charted indicating all the activities and interfaces relating to the sustained
check on quality of workmanship and materials used in various stages of the work.
1.6.6 The DG, systems shall be load tested at the time of commissioning. All the consumables
(diesel, oil etc), load banks, test equipments etc. required for the test shall be arranged
by the contractor.
1.6.7 All makes of components & accessories shall be got approved before use including
theenclosure design before fabrication. Progressive inspections shall be arranged as
desired by the employer's representative.
1.6.8 The Contractor shall incorporate adequate standardization to ensure minimum variety
and sizes of equipment, accessories, sub-assemblies, systems and practices.
1.6.9 Corrosion Protection
1.6.9.1 All ferrous components and fittings exposed to the atmosphere shall be hot-dip
galvanized unless specified otherwise.
1.6.10 Acoustic Criteria
1.6.10.1 Noise emanating from the equipment / service installations shall not exceed as per
provision given in the relevant international standards for each of the equipment.
1.7 STANDARDIZATION
a) Similar plant and equipment shall be replaceable/interchangeable, modular in

design, adaptable and extendable.
b) Equipment and accessories shall be provided with uniform standard spare
capacity,protection.
c) Piping, cabling etc. shall be suitably colour coded for identification and categorization
for each kind of use/type.
d) Maintainability of the plant and equipment shall be given due consideration.
1.8 SPACE FOR SITE OFFICE
1.8.1 A reasonable space at a centralized location for contractor’s site office/stores for the
duration of the contract shall be provided by DMRC. DMRC, however, reserve the right
to provide alternative space for the purpose, if so necessary, during the tenure of the
contract. Employer’s decision regarding location and size of space shall be final and
binding.
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1.8.2 The contractor has to build its own site office/store at each of the elevated stations for
keeping site related documents and storing its materials such as WRDs, site
measurement records, luminaires, cables, wires, pipes and fittings etc. locally. No
spare room will be provided by DMRC for the same.
1.9 TRANSPORTATION, STORAGE, INSURANCE etc.
1.9.1 The following shall be included but not limited to;
a) Loading, transportation and unloading.
b) Protection of stored materials/installed work against damage due to dirt, sun and rain
including providing tarpaulin/ PVC sheet covers as required.
c) Providing security arrangements/watch and ward for stored materials and installed works
to guard against pilferage including providing temporary covers on conduit outlets after
drawing of wires before fixing switches/fittings etc.
d) Comprehensive insurance with DMRC as beneficiaries against pilferage during
transportation/storage/installation valid till handing over (Refer GCC).
1.10 NAME PLATES AND CAUTION BOARDS
1.10.1 The contractor shall ensure the following:
a) Caution Boards: Affixing/pointing caution boards/danger plates as statutorily required for
electrical safety.
b) Name plates
Providing engraved anodized aluminum or approved equivalent name plates of suitable
sizes on Switchboards/panels/equipments etc
c) Circuit identification
All incoming and outgoing cables and wires shall be properly labeled as per the
layout/schematic drawings for easy identification. Details of circuits being fed from DBs
shall be affixed at the back of the door of each DB.
1.11 CIVIL WORKS, CLEANING and PAINTING
1.11.1 Items of civil works like foundations for major equipments, masonry trenches with
trench covers (excluding support structure for cables /pipes) etc shall be provided by
concerned civil contractor unless otherwise included in the scope of the E&M
contractor in BOQ.
1.11.2 Minor civil work items required for the work like making chases in walls/ceilings, making
holes and openings, providing inserts, grouting, sealing of cable trenches to prevent
water entry inside rooms etc including making good and painting the civil works shall
be deemed as included in the scope in case required.
1.11.3 Housekeeping
Housekeeping and clearing of work area during the tenure of contract shall be ensured
by the contractor.
1.11.4 Final Painting
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Providing final paint coat to all exposed fabricated steel work and providing matching
paint in approved manner over portions of factory painted equipment if damaged during
transportation/storage/installation before handing over shall be ensured by the
contractor.
1.11.5 Site Clearance
Demobilization and clearing of all temporary works/facilities after completion of work at
site and cleaning work shall be ensured by the contractor before handing over.
1.11.6 Water and electricity
Contractor shall make his own arrangement for water and electricity for working at the
site.
1.12 STATUATORY COMPLIANCES
1.12.1 The Contractor shall submit applications as prescribed with the appropriate Authorities
on behalf of DMRC and shall arrange for timely obtaining of the sanctions / permission
/ approvals / clearance as required. All expenses required to be incurred for obtaining
the statutory approvals shall be borne by the Contractor. Only Statutory fees shall
however be reimbursed by the DMRC against duly signed/stamped receipts.
1.12.2 Fire Detection System /Fire Suppression System
Obtaining approval of the proposal prior to commencement of work and clearance after
completion of work from the local Fire Control Authorities shall be within the scope of
the contract.
1.12.3 Electrical License
The tenderer shall be a licensed Electrical Contractor possessing a valid Contractor's
license of appropriate class in the state, employing licensed supervisors and skilled
workers having valid permits as per the regulations of Indian Electricity Rules and local
Electrical Inspectors requirements.
1.12.4 CMRS inspection
Complying with the any requirements of CMRS inspection shall be the responsibility of
the contractor. The contractor shall also be responsible to bear the cost of replenishing
any safety equipment which are subjected to destructive testing/are expensed during
the inspection.
1.12.5 Compliance of Statutory observation.
a) Complying with observations, if any, of nominated Electrical Inspector and/or
any other Statutory Authority after completion of work to start beneficial use
shall be Contractor’s responsibility.
b) In the event of the work being inspected by Chief Technical Examiner of CVC,
Govt. of India, complying with CTEs observations, if any, will be contractor’s
responsibility.
1.13 SUPPLY OF MANUALS, DRAWINGS etc.
1.13.1 Tender Drawings
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Tender drawings are for guidance of the Contractor. Work shall be executed as per
approved shop drawings. Exact locations, levels and distances etc. shall be governed
by dimensional parameters actually available at site.
1.13.2 Along with tender Particulars are required to be filled in by tenderers, along with
descriptive literature as required.
1.13.3 Shop drawings The Contractor shall submit shop drawings for all works as indicated in
the tender to Architects/DMRC for approval before commencement of work at
site/fabrication/ manufacture.
1.13.4 Completion documents
The Contractor shall submit completion documents comprising of the following at the
time of handing over:
a) 5 hard copies of Operating Instructions and Service Manuals for all equipment and
the installation along with CD for use by Owners operating staff. The Owners operating
staff shall also be instructed in proper operation of specialized equipments /systems.
b) 5 sets of test results of pre-commissioning tests carried out at site.
c) 5 sets of “As Built” completion drawings as detailed below.
1.13.5 Manufacturer Instruction
Where manufacturers have furnished specific instructions, relating to the materials used
in this job, covering points not specifically mentioned in these documents,
manufacturer’s instructions shall be brought to the notice of the DMRC for further
instructions in the matter.
1.14 INSPECTION AND TESTING
1.14.1 Material testing
The DMRC shall have full powers to require any material used in work to be tested by an
independent agency at the Contractor’s expense in order to prove its soundness and
adequacy.
1.14.2 Inspection at manufacturer’s Works
Prior to shipment of equipment, the DMRC reserves the right to inspect the equipment
at Manufacturer's Works. Contractor shall provide and secure every reasonable access
and facility at Manufacturer's Works for this inspection for the DMRC/ Authorized
representative.
1.14.3 Testing at Site before installation
All the System installed as part of this work shall be load tested and performance tested
at the time of commissioning. All the consumables, (diesel, oil etc.), load banks, test
equipments etc. required for the test shall be arranged by the contractor.
1.15 SAFETY REGULATIONS
1.15.1 The Contractors shall, at their own expense, arrange for safety provisions as per safety
codes of Indian Standards Institution, Indian Electricity Act and such other Rules,
Regulations and Laws as may be applicable, as indicated below, in respect of all labour,
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directly or indirectly employed in the work for performance of the Contractors’ part of this
agreement.
1.15.2 No inflammable materials shall be stored in places other than the rooms specially
constructed for this purpose in accordance with the provisions of Indian Explosives Act.
If such storage is unavoidable, it should be allowed only for a short period and in
addition, special precautions, such as cutting off the supply to such places at normal
items, storing materials away from wring and switch boards, giving electric supply for a
temporary period with due permission of Engineer-in charge shall be taken.
1.15.3 Protective and safety equipment such as rubber gauntlets or gloves, earthing rods, line
men’s belt, portable artificial respiration apparatus etc. should be provided in easily
identifiable locations. Where electric welding or such other nature of work is undertaken,
goggles shall also be provided.
1.15.4 Necessary number of caution board such as “Man on Line, Don’t switch on” should be
readily available in easily identifiable locations.
1.15.5 Standard first aid boxes containing materials as prescribed by the St. John Ambulance
Brigade or Indian Red Cross or as approved by the Engineer-in-charge. should be
provided in easily identifiable locations and should be readily available. Periodical
examination of the first aid facilities and protective and safety equipment provided shall
be undertaken and proper records shall be maintained for their adequacy and
effectiveness.
1.15.6 Charts (one in English and one in regional language ) displaying methods of giving
artificial respiration to a recipient of electrical shock shall be prominently displayed at
appropriate places.
1.15.7 A chart containing the names, addresses and telephone numbers of nearest authorized
medical practitioners, hospitals, Fire Brigade and also of the officers in charge shall be
displayed prominently along with the First Aid Box.
1.15.8 Steps to train supervisory and authorized persons of the Engineering staff in the First
Aid Practices, including various methods of artificial respiration with the help of local
authorities such as Fire Brigade, St. John’s Ambulance Brigade, Indian Red Cross or
other recognized institutions equipped to impart such training shall be taken, as prompt
rendering of artificial respiration can save life at time of electric shock.
1.15.9 No work shall be undertaken on live installations, or on installations which could be
energized unless one another person is present to immediately isolate the electric
supply in case of any accident and to render first aid, if necessary.
1.15.10 No work on live L.T. bus bar or pedestal switchboards should be handled by a person
below the\ rank of a Wireman and such a work should preferably be done in the presence
of the contractor’s Engineer supervising of the work. When working on or near live
installations, suitably insulated tools should be used, and special care should be taken
to see that those tools accidentally do not drop on live terminals causing shock or dead
short.
1.15.11 Before starting any work on the existing installation, it should be ensured that the
electric supply to that portion in which the work is undertaken is preferably cut off.
Precautions like displaying “Men at Work” cautions boards on the controlling switches
and locked switcheswith keys being kept with the person working on the installation, etc.
should be taken against accidental energization. “Permit to Work” should be obtained
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from the Engineer- incharge. No work on H.T. main should be undertaken unless it is
made dead and discharged to earth with an earthling lead of appropriate size. The
discharge operation shall be repeated several times and the installation connected to
earth positively before any work is started. E&M contractor shall obtain power block and
“permit to work” from the HT contractor, wherever required.
1.15.12 Before energizing on an installation after the work is completed, it should be ensured
that all tools have been removed and accounted, no person is present inside any
enclosure of the switch board etc. any earthing connection made for doing the work has
been removed, “Permit to Work” is received back duly signed by the person to whom it
was issued in token of having completed the work and the installation being ready for
re-energizing and “Men at Work” caution boards removed.
1.15.13 In case of electrical accidents and shock, the electrical installation on which the
accident occurred should be switched off immediately and the affected person should
be immediately removed from the live installation by pulling him with the help of his coat,
shirt, wooden rod, broom handle or with any other dry cloth or paper. He should be
removed from the place of accident to a nearby safe place and artificial respiration
continuously given as contained in BIS. Code and Standard prescribed by St. John
Ambulance Brigade or Fire Brigade. If needed the affected person should be taken to
nearest hospital without loss of time.
1.16 INDEMNITY
The Contractor shall be solely responsible for claims arising out of any accident at site
of work during the tenure of contract and shall cover such risks with suitable insurance.
The DMRC shall not be responsible for any direct or indirect consequence of such
accidents.
1.17 CERTIFICATES
On completion of the all installation a certificate shall be furnished by the Contractor
countersigned by the Licensed Supervisor, under whose direct supervision the
installation was carried out. This certificate shall be in the prescribed form as required
by the local supply authority.
1.18 WORKMANSHIP
Good workmanship is an essential prerequisite to be complied for this work. Entire work
shall be carried out in the most workmanlike manner by skilled workers under competent
supervision.
1.19 SERVICE/WORKING CONDITIONS
a) All the equipments, material shall be designed/ provided to suit/ work continuously under
conditions of ambient temperature of 50°C and relative humidity up to 90% for indoor
equipments and 50°C and 100% humidity for outdoor equipment’s unless specified
otherwise.
b) All the equipments shall be capable of continuous operation/use at rated output with
permissible overload under extremes of environmental and power supply conditions of
Voltage and frequency variation likely to be encountered at site.
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1.20 APPROVED MAKES
1.20.1 Contractor shall use the material/components / products of approved makes only as
approved by the Engineer -in charge. The Engineer-in charge’s approval shall also be
taken for low value items(irrespective of amount) such as screws, nuts and bolts,
gaskets, cable ties expansion bellows, anti-vibration pads etc.
1.20.2 Contractor shall also put on display one sample of each approved specimen at each
site along with method statement for installation.
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I. Reliability, Availability and Maintainability
a. Reliability, Availability and Maintainability (RAM) requirements shall be defined in

terms of Mean Time Between Failures (MTBF), percentage Availability and Mean
Time to Repair (MTTR) respectively.
b. The Contractor shall perform RAM analysis up to his scope of work
c. The Contractor shall submit Reliability, Availability and Maintainability Plan to the
Employer for review and approval. After system’s design has/have been
completed, the Contractor shall re-verify, that the reliability, availability and
maintainability requirements proposed by him in line with the contract
requirements, shall be met.
d. Delhi Metro Rail Corporation attaches the greatest importance to the attainment
of the highest possible ‘Reliability’ during service of all the equipment and systems
supplied and installed under this contract.
e. The design, manufacture, installation and commissioning of the equipment as also

the training of the operating and maintenance staff shall be such as to ensure near
‘Zero’ Failure performance.
II. Reliability Requirements:
a. Mean Time between Failure (MTBF) – It is the ratio of Total Operating Time
accumulated by the Total Population of a particular equipment to the total
number of failures of that particular equipment.
b. Failure –
Any independent failure in the equipment which results in loss of function

of that equipment caused by any of the following:
i. Fault in equipment of sub-system while operating within

its design and environmental specification limits;
ii. Improper operation, maintenance or testing of the
equipment as a result of documentation supplied by the
contractor;
iii. Any other fault as per the decision of Engineer-in-charge.
resulting in any one of the following:
i. Non-operation of that particular equipment, even though

stand-by system/redundancy, may be functional;
ii. Removal/repair of the equipment either on-site or off-
site;
iii. Degraded operation of the equipment and Non-
achievement of the desired design output or any other
performance parameter as defined in design or
specifications;
iv. Any unscheduled shutdown and/or maintenance of the
equipment;
v. Disruption of Revenue Services.
c. Reliability Targets –
i. Reliability Targets shall be calculated every month by the

contractor in coordination with nominated
representatives of DMRC.
ii. Such calculation shall be started after a stabilization
period of 3 months from ‘Taking Over’ or ‘Revenue
Operation Date’ (whichever is earlier).
iii. MTBF to be achieved for various Equipment is defined
below:
S. No. Equipment Min MTBF (in

hours/no of
switching
operation)
Automatic Transfer Switches(ATS) >1,60,000
1
(in hours)
ACB (MTBF data in min no of >5000
2
switching operations)
3 MCCB (MTBF data in min no of >10000
switching operations)
4 UPS (in hours) >50,000
5 Busduct (in hours) >45,000
6 LED lights (in hours) 50000
7 Processor 61,320
8 Annunciator 61,320
Fire Detection
Power supply 61,320
9 & Alarm
units
System
10 Loop cards 43,800
(in hours)
11 Detectors 35,040
12 Devices 35,040
13 Fire pumps (in hours) 17,500
14 Submersible Pumps (in hours) 17,500
Tunnel Ventilation Fans (TVF, TEF 150,000
15
and TBF)
16 Axial Flow Fans 150,000
MTBF to be achieved for following equipment is to be defined by

contractor for acceptance of the employer:
S. No Equipment Min MTBF in hours
1 Air Cooled Screw Chiller
2 Air Cooled Scroll Chiller
3 Air Handling Units
4 Fan Coil units
4 Pumps
5 Motorized Fire Dampers
7 Tunnel Ventilation Dampers
8 Air Compressor
9 Linear Heat Detection System
10 BMS Workstations
11 Programmable Logic Controllers
12 Clean Agent Gas Flooding System
d. The MTBF proposed by the contractor during design and as reviewed and
accepted by DMRC, shall have to be demonstrated by contractor during DLP. In
case of non-compliance of committed/agreed MTBF for a particular system/sub-
system/equipment, the contractor shall have to carry out required
changes/modifications in design, maintenance methodology/philosophy of all
system/ sub system/ equipment under the contract so that the desired MTBF is
achieved.
e. Disruption of Revenue Services as a result of equipment/system/sub-system’s

failure, would be looked upon very seriously by DMRC and penalty at the rate of
Rs. 5 Lakhs per incident shall be levied on the contractor, if such disruption is on
account of failure of the contractor.
III. Availability Requirements:
a. Availability shall be defined in terms of percentage availability.
Percentage Availability = [1 – {Downtime/Total Time}] * 100
Where:
i. Downtime is the total time spent on preventive &
scheduled maintenance during revenue hours plus total
time spent on corrective, breakdown maintenance &
repairs during revenue or non-revenue hours.
ii. Total Time is the time in hours in the assessment period
multiplied by the population of the equipment
commissioned.
b. Minimum availability Targets to be achieved are specified below:
S. No. Equipment Availability (Min

%)
1 Automatic Transfer Switches(ATS) 99.9%
2 ACB 95%
3 MCCB 95%
4 UPS 99.99%
5 Busduct 99.99%
6 LED lights 98.5%
7 Processor
8 Annunciator
9 Fire Detection Power supply units
99.99%
10 & Alarm System Loop cards
11 Detectors
12 Devices
13 Fire pumps 99%
14 Submersible Pumps 99%
Axial Flow Fans and Tunnel
15 99.99%
Ventilation Fans (TVF, TEF and TBF)
The availability targets for the equipment for which contractor is to propose the
MTBF values are to be defined by the contractor for acceptance of the employer.
c. Maximum Time to carry out any schedule of preventive maintenance shall not be
more than 4 hours.
IV. Maintainability Requirements:
a. Ease of carrying out Maintenance & Repair, of an equipment/system/sub-system,

is the most important aspect of DMRC. These criteria shall be taken into account
while designing of the system by Contractor.
b. It shall be made sure during design that maintenance tasks are achieved in
minimum time and using minimum manpower.
c. Components, systems and their sub-assemblies which require routine

maintenance, frequent attention shall be modular and easily accessible.
d. Mean Time to Repair (MTTR) – It is the ratio of ‘Cumulative time for repair’
(including time to access) to the total number of Failures.
e. Design shall be such that that the Mean Time to Repair (MTTR) is minimized
throughout the system.
f. The MTTR proposed by the contractor during design and as reviewed and
accepted by DMRC, shall have to be demonstrated by contractor during the DLP.
In case of non-compliance of committed/agreed MTTR for a particular
system/sub-system/equipment, the contractor shall have to carry out required
changes/modifications in design/mounting arrangements/maintenance
methodology/philosophy so that the desired MTTR is achievable.
INTERFACE MANAGEMENT DOCUMENT AMONG
ELECTRICAL SYSTEM CONTRACTORS
I N D E X
(Updated as on 25.06.2020)
S. DESCRIPTION PAGE VERSION
NO. NO.
1 Interface between Flexible OHE / EPC / Traction Contractor 1 May 2020 Rev.2
(FOCS) and Rigid Overhead Catenary System (ROCS) and
33 KV Auxiliary Network Contractor of Underground Section
2 Interface between Flexible OHE / EPC / Traction Contractor 5 Pg.5 (Rev.4)
and Elevated Stations & Depot E&M Contractors Pg.6 to 8 (Rev.2)
Table – Tentative List of SCADA Signals 9 June 2020 Rev.4
3 Interface between Flexible OHE / EPC / FOCS / ROCS / U/G 11 May 2020 Rev.2
Traction Contractor and Receiving Sub-Station (RSS)
Contractor
4 Interface between Rigid Overhead Catenary System (ROCS) / 16 May 2020 Rev.2
UG Traction Contractor and ECS & TVS Contractor in
Underground Station
5 Interface between Rigid Over Head Catenary System (ROCS) 17 May 2020 Rev.2
/ UG Traction Contractor and E&M Contractor in Underground
Stations
6 Interface between ECS / TVS / BMS Contractor and E&M 21 May 2020 Rev.2
Contractor in Underground Stations
7 Interface between E&M Contractor and RSS Contractor in 23 June 2020 Rev.4
Underground Stations
8 Interface between ECS / TVS / BMS Contractor and Lift & 23 June 2020 Rev.4
Escalator Contractor in Underground & Elevated Stations
9 Interface between SCADA Contractor and E&M Contractor in 23 June 2020 Rev.4
10 Interface between Elevator (Lift), Architect / DDC and 24 June 2020 Rev.4
Electrical (E&M) Contractors
11 Interface between Escalator, Architect / DDC and Electrical 27 June 2020 Rev.4
(E&M) Contractors
12 Interface between U/G Traction Contractor and E&M 30 June 2020 Rev.4
Contractor of Depot for Retractable Catenary (RCR) Works
13 Interface between E&M Stations & Depot Contractor and 30 June 2020 Rev.4
Signage Contractor
14 Interface between E&M Stations & Depot Contractor and DG 31 May 2020 Rev.2
Contractor
15 Interface between E&M Stations & Depot Contractor and Solar 32 June 2020 Rev.4
Project Developer (SPD)
(i)
FOCS E/M ELEV, ECS, TVS,
ROCS RSS UG E/M LIFT ESCAL SOLAR
SCADA DEPOT BMS
FOCS
-- 1 2 3 9
SCADA
ROCS 1 -- 12 3 4 5
E/M ELEV,
2 12 -- 10 11 15
DEPOT
RSS 3 3 -- 7
ECS, TVS,
4 -- 6 8 8
BMS
UG E/M 9 5 7 6 -- 10 11
LIFT 10 8 10 --
ESCAL 11 8 11 --
SOLAR 15 --
( ii )
Contract PE-02 – Particular Specification – E&M Work
DELHI METRO RAIL CORPORATION LIMITED

(A Joint Venture of Govt. of India & GNCTD)
MASS RAPID TRANSPORT SYSTEM – PATNA METRO
Design Verification, Detail Engineerring, Supply, Installation, Testing and

Commissioning of Electrical and Mechanical System, Fire Detection and Fire
Suppression System including D.G. Sets for Elevated Stations of Corridor-1 and
Corridor-2 and Depot of Patna Metro Rail Project
CONTRACT – PE-02
EMPLOYER’S REQUIREMENT
Volume - 4
PARTICULAR SPECIFICATIONS
E&M WORKS
Note: These specifications are the bare minimum requirement, PE-02 Contractor has to fulfil
while designing & executions. The final requirements of the specifications will depend upon the
Detailed Design and based upon that the contractor has to provide the material over and above
to these specifications which shall be finally approved by DMRC.
Page 1 of 401
PART – B
TECHNICAL SPECIFICATONS
Page 2 of 401
TABLE OF CONTENTS
ELECTRICAL SYSTEM ...........................................................................3
1 LV MAIN SWITCHBOARD INCLUDING DB .....................................4
2 MV CABLING .................................................................................51
3 CONDUIT WIRING& ASSOCIATED ACCESSORIES ....................69
4 LIGHTING & FANS ........................................................................89
5 PROTECTIVE EARTHING ...........................................................106
6 LIGHTNING PROTECTION..........................................................113
7 UNINTERRUPTED POWER SUPPLY (UPS) & INVERTER .........116
8 LV LIGHT BUS TRUNKING (BUS DUCT) & RISING MAIN ..........134
9 ADDRESSABLE FIRE DETECTION AND ALARM SYSTEM .......142
10 DG SETS .....................................................................................154
11 FIRESTOP TECHNICAL SPECIFICATION ..................................176
AIR-CONDITIONING AND VENTILATION SYSTEM ...........................179

1 GENERAL ....................................................................................180
2 BASIS OF DESIGN ......................................................................185
TECHNICAL SPECIFICATIONS..........................................................188
1 VARIABLE REGRIGERANT FLOW SYSTEM ..............................189
2 REFRIGERANT PIPEWORK........................................................193
3 SPLIT AIR CONDITIONERS ........................................................203
4 VENTILATION FANS ...................................................................206
5 DUCTWORKS, DAMPERS, DIFFUSERS AND ACCESSORIES .211
6 INSULATION ................................................................................225
7 ELECTRICAL WORK ...................................................................226
8 TESTING OF AIR-CONDITIONING SYSTEM ..............................229
9 NOISE CONTROL ........................................................................231
10 MODE OF MEASUREMENTS (AS APPLICABLE) .......................233
11 TECHNICAL DATA ......................................................................235
FIRE FIGHTING SYSTEM ...................................................................238
Part – B Page 1 of 401

1 FIRE HYDRANT & FIRE FIGHTING SYSTEM .............................239

2 CLEAN AGENT (NOVEC 1230) GAS BASED HIGH TEMPERATURE
POLYMER TUBE BASED PROTECTION SYSTEM ............................272
WATER SUPPLY PUMPS WORKS ....................................................276

1 WATER SUPPLY PUMPS ............................................................277
2 SCOPE OF WORK (Within Pump Room): ....................................277
4 VALVES AND OTHER ACCESSORIES .......................................284
5 GI PIPES and FITTINGS: .............................................................285
6 CPVC Pipes and Fittings: .............................................................287
7 PUDDLE FLANGE .......................................................................290
8 MOTORIZED VALVE: ..................................................................290
9 WATER METERS ........................................................................290
WATER SUPPLY PUMPS WORKS ....................................................276

2 SCOPE OF WORK (Within Pump Room): ………………………..277
EOT CRANE & AIR COMPRESSOR…………..…………………………281

STREET LIGHT AND MAST……………………………………………….313
BUILDING MANAGEMENT S……………………………….…………….354
Part – B Page 2 of 401

TECHNICAL
SPECIFICATIONS –
ELECTRICAL SYSTEM
Part – B Chapter – 1 Page 3 of 401

1 LV MAIN SWITCHBOARD INCLUDING DB

1.1 ABBREVIATION
AC Alternating current
ACDB Alternating Current Distribution Board
ACPP Air Conditioning Power Panel
AFC Automatic Fare Collection
AHF Active Harmonics Filter
AMF Automatic Mains Failure
ASS Auxiliary Substation
ATS Automatic Transfer Switch
CI Cast Iron
DB Distribution Board
DBT Dry Bulb Temperature
DC Direct Current
DCDB Direct Current Distribution Board
DFMD Door Frame Metal detector
DG Diesel Generator
DP Double Pole
ELCB Earth Leakage Circuit Breaker
EMC Electromagnetic Compatibility
EMLP Emergency main lighting panel
EPP Essential Power Panel
ESPP Escalator power panel
FCO Floor Clean Out Plug
FD Floor Drain
FFL Finished Floor Level
FPP Fire Pump panel
FRLSH Fire Retardant Low Smoke and low halogen
FRLSZH Flame Retardant Low Smoke Zero Halogen
FT Floor Trap
FWS Flushing water Supply
GI Galvanised Iron
HT High tension
HV High Voltage
HVAC Heating Ventilation & Air Conditioning
IEEE Institution of Electrical and Electronic Engineers
LDB Lighting Distribution Board
LEP Local Electrical Panel
LMCP Local Motor Control Panel

LT Low Tension
LV Low Voltage
LVDB Low Voltage Distribution Board
E&M Electrical & Mechanical
MCB Miniature Circuit Breaker
MCCB Moulded Case Circuit Breaker
MFM Multi-Function Meter
MLP Main lighting Panel
MPCB Motor Protection Circuit Breaker
MS Mild Steel
MV Medium Voltage
PVC Poly-Vinyl Chloride
PD Property Development
PSD Platform Screen Door
RCBO Residual Current Circuit Breaker with Overcurrent protection
RCCB Residual Current Circuit Breaker
RCC Reinforced Cement Concrete
RTU Remote Terminal Unit
RCD Residual Current Device
RH % Relative Humidity (percent)
S&T Signalling &Telecom
SCADA Supervisory Control and Data Acquisition.
SCR Station Control Room
SER Station Equipment Room
SP Single Pole
TB Terminal Block
TOM Ticketing Office Machine
UPS Uninterrupted Power Supply.
UPVC Unplasticised Poly Vinyl Chloride
VFC Volt Free Contact
WBT Wet Bulb Temperature
WPP Water Pump Panel
XLPE Cross link Polyethylene
1.2 GENERAL
1.2.1 Metro stations namely Rail corridor stations, elevated stations are provided with
Electrical Panels for receiving and distribution of power supply to various usages as
defined in various clauses at voltage level of 415 V / 50 Hz. The usages are generally
lighting, air conditioning system, PD area and all other type of E&M work which come
under stations coverage. Switch boards and panels as per following list are provided for
power supply distribution at Elevated metro stations / on grade stations.
1.2.2 The bidders shall refer the BOQ and drawing for incoming feeders, outgoing- feeders,

indications, metering, and protection details along with quantity and type of each.
1.2.3 The panels are generally named as follows:
a) Main Distribution Board (MDB)
b) Essential power panel (EPP)
c) Emergency Power Panel (EMLP)
d) Main Lighting Panel (MLP)
e) Fire pump panel (FPP)
f) Water pump panel (WPP)
g) Passenger Amenities Panel (PAP)
h) Distribution Boards (DB)
i) Active Harmonics Filter (AHF)
1.2.4 The manufacturing , testing , installation and commissioning of complete 415±10% V,
3 phase, 4 wire and 50±3% Hz low voltage main switchboard is as defined in IEC / EN
61439-1 & 2, built up from compartments to house the breakers, busbars , terminal
blocks, internal and control wiring, instrumentation, relays, interlock and padlocking
facility, emergency push buttons, equipment for BMS / SCADA / RS 485 / Mod bus
connectivity of communicable ACB / MCCB interface, indication lamps, control and
auxiliary switches, contacts, control power supply, air circuit breaker, MCCB, MCB, CTs
and PTs, and any other items considered necessary to deliver the functions of incoming
and outgoing power supply as detailed in BOQ and drawing.
1.2.5 The equipments installed in each of the Electrical Panel are defined in the BOQ.
1.3 GOVERNING SPECIFICATIONS
1.3.1 Electrical Panels along with equipments shall conform to the latest standard or
harmonize as per the respective standard as given below or specified along with the
equipment in the specification.
1.3.2 In case of any conflict between specifications & the standards, the instructions / decision
of the Engineer-In charge or Employer's authorized representative shall be binding.
1.4 STANDARDS:
1.4.1 Low voltage Electrical Panels shall satisfy the following requirements and shall also
comply with standards in force when Electrical Panel units are manufactured,
particularly which are in the following table (Unless otherwise stipulated in the
specification, the latest version of the standards shall be applicable).
STANDARD DESCRIPTION
ISO STANDARD
Quality systems- model for quality assurance in design /
ISO 9001
development, production, installation, and servicing
IEC STANDARD
IEC 60228 Conductors of insulated cables
IEC 60255 Measuring relays and protection equipment
IEC 60529 Degrees of protection provided by enclosures (IP Code)
Shunt power capacitors of the self-healing type for a.c.
IEC 60831
systems having a rated voltage up to and including 1000 V
Electrical accessories – Circuit-breakers for over current
IEC 60898
protection for household and similar installations
IS / IEC 60947-2 / EN Specification for low-voltage switchgear and control gear

60947-2 circuit breakers
Specification for low-voltage switchgear and control gear.
IS / IEC 60947-4 Contactors and motor-starters. Electromechanical
contactors and motor-starters.
Residual current operated circuit-breakers without integral
IEC 61008 over current protection for household and similar uses
(RCCBs)
Specification for residual current operated circuit -
IEC 61009 breakers with integral overcurrent protection for household
and similar uses (RCBOs)
Specification for low-voltage switchgear and control gear
assemblies. Particular requirements for low-voltage
IEC 61439-3
switchgear and control gear assemblies intended to be
installed in place.
Specification for low-voltage switchgear and control gear
IEC 61439 -1& 2
assemblies
Degrees of protection provided by enclosures for electrical
IEC 62262
equipment against mechanical impacts (IK code)
Enclosed low-voltage switchgear and control gear
IEC 61641 assemblies - Guide for testing under conditions of arcing
due to internal fault
IEC 61869 / BSEN
Instrument transformers
61869
IS STANDARD
ac Static Watt-hour Meters, Class0.5, 1 and 2-
IS 13010
Specification
Low-Voltage Switchgear and Control gear: Part 4 -
IS / IEC60947-4
Contractors and Motor-Starters
Low voltage switchgear and control gear, part 3: switches,
IS / IEC 60947-3 disconnectors, switch-disconnectors, and fuse
combination units
Low-Voltage Switchgear and Control gear, Part 2: Circuit
IS / IEC 60947-2
Breakers
Low-voltage switchgear and control gear, Part 1: General
IS / IEC 60947-1
rules
IS 5553 / IEC 60289 Reactors – Specification
Wrought Aluminium and Aluminium Alloy bars, Rods,
IS 5032 Tubes, Sections, Plates and Sheets for Electrical
Applications.
IS 3043 Code of practice for Earthing
BS STANDARDS
BS 381 C Colour chart
BS 4800 Colour
BSEN60742 / BS 3535 /
Isolating Transformers
BS 61558
Electrical earthing. Clamps for earthing and bonding.
BS 951
Specification
Code of practice for protective earthing of electrical
BS 7430
installations
BS EN 10025 Hot rolled products of structural steels
Electric cables. Low voltage energy cables of rated
BS EN 50525
voltages up to and including 450 / 750 V (U0 / U)
1.5 GENERAL AND TECHNICAL REQUIREMENTS OF ELECTRICAL PANELS

1.5.1 The Electrical Panel shall be same as low- voltage switchgear and control-gear
assemblies defined in IEC 61439-1 & 2 or EN 61439-1 built up from compartments
housing circuit breakers, control gear, relays, bus bars, controls and other equipment
as defined in BOQ.
1.5.2 All panels should be factory built of proven design with OEMs as well as switchboard
manufacturer approved as covered by IEC 61439-1 clause no. 3.10 as described below:
Switchgear manufacturer shall be fully responsible for proven design & verification.
1.5.3 The Electrical Panel shall pass the internal arc fault containment tests in accordance
with IEC 61641 for fault current ratings as defined incoming feeder / busbar fault current
rating in BOQ for a minimum time of 0.3 sec.
1.5.4 The degree of Ingress Protection for Electrical Panels shall be IP 54 for Elevated metro
stations unless otherwise specified in BOQ, as defined in IEC 60529 which shall not
deteriorate with time.
1.5.5 The Electrical Panels and the associated equipment, including switchgear and control
gear assemblies shall be certified for the category of duty specified as per Annexure A
of IS / IEC 60947-1.
1.5.6 The main circuit as defined in vide clause 3.1.3 of IEC 61439-1 shall have an insulation
voltage of 1000 V for ACB and 750V for MCCB or as specified in the BOQ.
1.5.7 The ambient temperature and relative humidity for Electrical Panel shall be +450C &
95% respectively. Temperature rise limit report shall be provided as per IEC 61439 part
1& 2 and the maximum temperature of the bus bars and the bus connections shall be
90 0C. However, temperature rise limit calculation report shall be provided at +450C
ambient temperature by Original manufacturer for Employer’s approval with type test
report as per IEC 61439-1 (clause 7.1.1 and 7.1.2 of IEC 61439-1) and Switchgear shall
be as per IEC 60947(Clause 6.1.1 and 6.1.3 of IEC 60947).
1.5.8 The secure service life of Electrical Panels shall be at least 30 years as defined in
General Scope of Work. The design features to secure the service life of 30 years shall
be submitted at the time of design approval.
1.5.9 The Electrical Panel shall have a rated short time withstand current of 50 kA, 35 kA and
25kA for 1 second as per BOQ. The LT panel shall be tested for the impulse withstand
voltage of 12 kV with ACB incomer, 8kV for MCCB incomer feeder.
1.5.10 The Electrical Panels shall be a minimum of Form 4b Type 5 in accordance with BS EN
61439-2 / IEC 61439-2 and Eiema’s Guide To Forms Of Separation.
1.6 ELECTRICAL PANEL CONSTRUCTION
1.6.1 The panels shall be of the approved design to suit local conditions as prevailing at
different metro stations.
1.6.2 The Electrical Panel (other than DB) shall be designed for indoor use in the form of free
standing, floor mounting extendible, self-contained, flush fronted cubicles and
sectionalized as necessary to face easy transportation and erection, containing all the
equipment indicated on the Drawing, BOQ and specified hereinafter.
1.6.3 The cubicle section shall be constructed of folded sheet steel or fully bolted construction
with all necessary removable covers. Removable lifting lugs shall be provided on the
top of the cubicles. Cubicle sections shall be provided with bolts or devices for ensuring
that they are correctly aligned when being coupled together. The bus bar chamber shall
be fitted with removable end cover plates secured by mild steel captive screws.
1.6.4 It shall be finished to provide a rigid shell type of enclosure in accordance with BS EN

10025.
1.6.5 The load bearing parts of the entire electrical panel assembly shall be 2 mm CRCA thick
sheet whereas other partition parts shall be constructed of minimum 1.6 mm CRCA
thick sheet steel. It shall be finished to provide a rigid shell type of enclosure. The frame
work shall be finished with standard two coats of epoxy powder coating of approved
colour shade after necessary chemical degreasing and primer coating as per standard
minimum 9 tank processes.
1.6.6 The Electrical Panels shall be mounted on a robust base frame made up of steel
channel with a minimum height of 100 mm and the maximum height of Electrical Panel
shall not exceed 2.450 meter including base frame. The base frame shall be able to
withstand the static and dynamic loads of the Electrical Panels. The steel channels shall
be painted with epoxy polyester paint. The main contractor shall ensure that the
maximum height of the Electrical Panel at the site of installation shall not exceed 2.65
meter including foundation if any.
1.6.7 Electrical panel shall have provision for top / bottom in-coming and bottom / top out-
going to suit site conditions of cable entries.
1.6.8 Aluminium gland plates should not less than 5 mm thick of suitable size and shall be
provided at the top and bottom of the LV main switchboards for the termination of
busduct or incoming and outgoing power cables of size 120 sq. mm or more and 3 mm
thick for cables of size less than 120 sq. mm. Where armoured multi- core cables
terminate inside the switchboard enclosure, glanding plates or glanding brackets shall
be provided for securing the cables to the switchboard.
1.6.9 Gland plates and extension boxes shall be removable and shall be of adequate size for
the particular cables to be terminated. The cables shall not put any stress on to the
glanding plate and shall be secured adequately.
1.6.10 All relays and indicating instruments shall be at least 300 mm and not higher than 1.8
m from the base frame. The clearance in front, back and side of all assemblies of
switchgear and control gear shall be as per NBC 2016 clause no. 5.3.6.8 and fig- 1 &
2.
1.6.11 Various units comprising a complete Electrical Panels shall be grouped in a multi- tier
arrangement including a cabling and wiring chamber of ample dimensions to
accommodate terminal blocks, cable boxes and gland plates.
1.6.12 The equipment shall be arranged within each compartment such that all normal
maintenance can be carried out through hinged access doors or removable covers, and
wherever possible from the front.
1.6.13 Adequate maintenance access shall be provided to equipment within the Electrical
Panels. Demountable panels shall be provided at the back of the Electrical Panels that
can be handled by a single person. Every demountable panel shall be provided with a
pair of handles for easy removal and fixing.
1.6.14 Front access door shall be fixed with concealed hinges and interlocked with the switch
mechanism. The door panel can be opened only if the switchgear is in the "OFF
position” or the switchgear should switch off if the panel door is opened.
1.6.15 Ventilating louvers along with filter, where required, shall ensuring compliance of IP of
panel. It shall be provided in such a way that it is easily accessible for cleaning or self-
cleaning filters shall be proved.
1.6.16 Anti-condensation heaters shall be provided at the rate of 60 W for each vertical of the
Electrical Panels, in case the volume is greater than 1 cubic meter of one vertical then
2x60 W heater shall be provided. The heaters shall be of an enclosed tubular pattern,

each of which is having separate MCB to energies the circuit. Each heater shall be
controlled by means of a step adjustable humidistat. Cable alley shall be having the
provision of LED fixture dually controlled by limit switch in the MDB, EPP, WPP and
FPP panels.
1.6.17 Adequate arrangements for air circulation shall be made within each compartment of
the Electrical Panels, if required. The Contractor shall ensure that the internal
temperature of the Electrical Panels will be well within the operating ranges as specified
by IEC 61439-1 of all electric components including switchgear, control gear, bus bars,
relays, wiring and timers inside the Electrical Panels.
1.6.18 All the incoming / outgoing terminations shall be extended via tinned Aluminium
connections into a separate termination chamber adjacent to the switchboard. When
busbars are used between switchboards, the internal busbars of the switchboard shall
be of tinned Aluminium bars, sizes of tinned Aluminium shall be as per tested design.
No linking of busbar or incoming / outgoing terminals with switchgears / functional units
shall be permitted with cable except in case of MCCBs / MCBs below or equal to 100 A
rating.
1.6.19 The switchgear assembly / sub-assemblies or panels shall be termite and rodent proof.
1.6.20 The switchboard shall have sufficient space to house all electrical equipment allowing
spare Space capacity of 10% for the future expansion.
1.6.21 Spare feeder shall be provided as per BOQ. Any Panel which comprises an assembly
of similar modules shall be constructed such that further similar modules can be added
at either end.
1.6.22 All similar items of the Electrical Panels and their component shall be interchangeable.
Spare parts shall be manufactured to originals and shall fit all similar items of the
Electrical Panels. Where machining may be needed before fitting renewable parts, the
machining fits and the associated tolerances shall be shown on the drawings
accompanying the instruction manuals.
1.6.23 The Electrical Panel shall operate without excessive vibration and with a minimum of
noise as per best of engineering practice and shall also operate without excessive
temperature rise at the rated load conditions.
1.6.24 The style and finish of the workmanship shall be consistent throughout the Works.
Unless otherwise specified, Engineer-In charge shall decide the final colours for all
paintwork and other finishes to be applied to the Electrical Panels.
1.7 ELECTRICAL PANEL EARTHING AND SAFETY ARRANGEMENT
1.7.1 All non-current carrying metallic components shall be permanently connected to earth.
1.7.2 Material used for the earthing busbar shall be same as the main busbar.
1.7.3 The aluminium earthing busbar inside & Bimetallic earthing busbar link outside the panel
shall have cross-sectional area as per IEC 60364.
1.7.4 A continuous earthing busbar shall be provided along the whole length of each Electrical
Panels and shall be provided with terminals for connection to the metal housing of
incoming busways, cable trunking and cladding or armouring of all incoming and
outgoing cables and to the substation earth.
1.7.5 Switchboards shall be provided with two earthing terminals, one at each end, for the
connection of external earth conductor for earthing. The earthing bars shall be fixed at
rear interior bottom portion throughout the length of the switchboard, bonding all gland
plates, and other component parts of the switchboard to a main earth point adjacent to
the intake position in accordance with BS 951 and BS 7430.

1.7.6 All terminals, connections, relays, and other components which may remain live when
access doors are open shall be screened. It shall not be possible to obtain access to
an adjacent cubicle when any door is opened.
1.7.7 Where several outgoing circuits occupy a common cabling chamber, all copper /
aluminium work, cable lugs, terminations and terminal blocks shall be fully segregated
by compartmentation to enable work on any one circuit to be carried out with other
circuits remain live.
1.7.8 Protection against shock in normal service shall be achieved by the provision of barriers
or enclosures both vertical and horizontal and between adjacent units to ensure
segregation and prevent accidental contact with live parts, or by complete insulation of
all live parts Control cables shall be segregated from primary conductors.
1.7.9 The protective earthing configuration shall be TN-S unless otherwise specified.
1.7.10 Each openable door of the panel shall be double earth with braided flexible copper wire
of minimum cross section 2.5 sq.mm.
1.8 EQUIPMENT INSTALLED INSIDE ELECTRICAL PANELS
Electrical panels consist of Low Voltage Switchgear, control wiring and all other parts
which are defined below:
1.8.1 Busbar
1.8.1.1 Busbars shall be of rectangular section hard drawn high conductivity, high strength
tinned aluminium alloy, grade E91E bare type conform to BIS 5082 / IEC or as per
BOQ, adequately rated for designed value and fault level of load and supported by
non- tracking moulded insulators spaced at suitable intervals. The complete assembly
shall be capable of withstanding the maximum mechanical stresses to which it may
be subjected to under fault conditions.
1.8.1.2 Bus bar rating shall be same throughout the length of panel and shall be as per BOQ
type tested design and recommendation of IEC 61439. The bus bar shall be designed
for easy extension in future at either end.
1.8.1.3 Busbars and busbar connections shall be constructed in accordance with the
requirements of IEC 61439-1. The short-time withstand current rating shall be as
mentioned in BOQ for 1 second at 415 V and shall be provided with suitable busbar
for aluminium cable termination. Aluminium lugs shall be fully placed on aluminium
busbar / spreader
1.8.1.4 Connection in Bus bars shall be made as approved and proven design of original
manufacturer.
1.8.1.5 The maximum temperature of the bus bars and the bus connections shall be 90 0C.
1.8.1.6 The main busbars shall be so positioned and arranged that all busbar risers and
droppers can be brought onto the main busbars without undue bending. Busbars shall
be and supported with appropriate clearances in air to the requirement of providing
full insulation.
1.8.1.7 Busbar chambers of similar rating shall be capable of coupled together using busbar
coupling links, in accordance with the manufacturer's recommendation. Coupling links
shall be approved by the Engineer-In charge before use.
1.8.1.8 Interconnecting conductors between busbar chambers and switchgear shall be as per
rating of switchgear and type tested design.
1.8.1.9 Switchgear shall be joined to busbar chambers by means of properly designed busbar
chamber connection flanges or male bushes. Connection flanges shall be
manufactured from galvanized sheet steel or CRCA and finished grey.

1.8.1.10 Busbars shall be coloured for phase identification at location of bus inspection points
with the approval of Engineer-In charge. The material for phase identification shall be
non-fading colour of proven design to be decided by the Engineer-In charge and use
of adhesive label shall not be acceptable.
1.8.1.11 The front cover and end plates of busbar chamber shall be removable and normally
held in position by non-ferrous metal screws.
1.8.2 POLARITY
1.8.2.1 The polarity of all apparatus shall be arranged as follows when viewed facing the front
of the Electrical Panels:
a) For two pole apparatus, phase pole and neutral pole when reading from top to bottom
or left to right.
b) For three or four pole apparatus, red, yellow, and blue phases and neutral when
reading from top to bottom or left to right.
1.8.2.2 All cables shall be so connected within the Electrical Panels such that the correct
sequences are preserved throughout.
1.8.3 Control supply
1.8.3.1 The control circuit shall be separated from other auxiliary circuits, i.e. indicating circuit,
heater, and lighting circuits, with dedicated circuit protective devices.
1.8.3.2 240V Volt sensing relay with potential free contacts shall be provided for sensing the
control supply for local and remote indication to BMS / SCADA.
1.8.4 Instrumentation
1.8.4.1 Electrical meters shall conform to IS 13010 / IEC - 1036, 687, 1286 suitable for single
phase / three phase supply system in all respects. Accuracy of meters shall be of
class as specified in BOQ. Accuracy of direct reading shall be class 0.5s for MDB
meters and class 0.5 shall be used in other panels. All meters shall be digital type and
multifunction meters should be with RS 485 connectivity to suit BMS System wherever
mentioned in BOQ. Suitable memory and software for logging the information along
with real time metering information must be available. The meters must have required
level of protection and sufficient number of auxiliary contacts.
1.8.4.2 Meters shall be suitable for continuous operation between 00C and +500C.
1.8.4.3 Meter shall be suitable for 3 phase, 4 wire systems, balanced as well as unbalanced
load. All instruments and associated apparatus shall be capable of carrying their full-
load current without undue heating. They shall not be damaged by the passage of fault
currents up to the rating of the associated switchgear through the primaries of their
associated instrument transformers. The instrument meter shall be earthed by a
copper conductor of not less than 2.5 mm2 cross-sectional area.
1.8.4.4 Energy meters shall be two / three element, switch board mounting type suitable for
unbalanced loads. In MDB, a summation C.T. shall be provided with the energy meter.
1.8.4.5 The display for meters i.e. ammeter, voltmeters or multifunction meter shall be auto-
ranging type. The display for single meter i.e. ammeter or voltmeter shall be 3.5 digits
as specified in BOQ.
1.8.4.6 Multi-function meter in MDB shall be provided with minimum following parameter:
Each phase current (A), Power factor, Voltage, THD, TOD, Hz, W, Wh, VA, Vah, VAR,
VARh, Max. Demand & Import / Export with RS 485 communication port. Other multi-
function meters shall provide Voltage, amperes, Hz, VA, Vah, Demand & Import /
Export parameters with RS 485 communication port.
1.8.4.7 Meter shall be flush mounting and shall be enclosed in dust tight housing. The housing

shall be steel or phenolic mould. Design and manufacture of meters shall ensure
prevention of fogging of instrument glass. Selector switches shall be inbuilt in
Voltmeter such that voltmeters can read voltages between phase to phase and phase
to neutral.
1.8.4.8 Ammeters shall normally be suitable for 5 A secondary of current transformers
1.8.4.9 Voltmeter circuits shall be provided with protection through MCB as required.
1.8.4.10 Separate current transformers for a feeder shall be provided for protection device and
for instrumentation.
1.8.5 Current Transformers (CTs) and Voltage Transformers (VTs)
1.8.5.1 CTs and VTs shall comply with IEC 61869 / BSEN 61869 and CTs shall be of the
epoxy resin encapsulated ring type, 100A and above split core type. The ratings
specified on the Drawings are indicative only and it shall be contractor / manufacturer's
responsibility to ensure that the ratings offered are adequate for the relays / meters
provided considering lead resistance, etc.
1.8.5.2 Current transformers shall comply with approved standard and shall be compatible
with and provide the necessary accuracy, over current factors, characteristics,
performance, and VA rating for the satisfactory operation of the relevant protection
devices, instruments and meters.
1.8.5.3 All CTs shall have a short-time current rating as specified in IEC 60044-1.
1.8.5.4 CTs for protection shall be compatible with the protection relays to ensure that the CTs
will not be saturated up to the maximum prospective fault current.
1.8.5.5 CTs designed for unit protection schemes shall be able to withstand a stability of not
less than the maximum through-fault of the units.
1.8.5.6 In balanced circuits, the spill current with maximum stability conditions shall not
exceed one quarter of the operating current of the relay.
1.8.5.7 CTs for use in conjunction with protection relays shall be of class 5P accuracy or
better. CTs for use in conjunction with measuring instruments shall be of Class 0.5s
for MDB with dual ratio and 0.5 for others. The product of rated accuracy limit factor
and rated output of the protection CTs shall not be less than 20 times the total rated
burden of the trip circuit including the relay, connection leads and O / C release where
applicable.
1.8.5.8 All CTs shall have output ratings adequate to cater for the burden connected to them.
The Contractor shall demonstrate to the satisfaction of the Employer’s representative.
By calculation or by test, that each group of the CTs, when installed and having the
secondary burden connected, is capable of operating the relays and other measuring
instruments in accordance with the manufacturer's published characteristics and the
requirements of the system, with a reasonable margin of safety.
1.8.5.9 Measuring CTs shall be connected to test terminal block. The test blocks shall be
provided with easily removable links and designed to facilitate connection of testing
instruments on load without open-circuiting the CTs.
1.8.5.10 The secondary circuit of each set of CTs shall be earthed at one point only through a
disconnectable copper link at a readily accessible position for testing.
1.8.5.11 Multi-ratio CTs (where used) shall have a label clearly indicating the connections
required for the alternative ratios. These connections shall be shown on panel wiring
diagrams.
1.8.5.12 Identification labels shall be fitted, mentioning type, ratio, rating, output and serial
numbers.

1.8.5.13 Instruments shall be similar in appearance throughout the whole of the Electrical
Panels. All instruments meters shall be of flush pattern, dust and moisture proof,
suitable for the environment in which they are installed.
1.8.5.14 All instruments and meters shall be completely segregated in instrument
compartments. Compartments containing these devices shall not contain any
terminals or equipment operating at higher voltages with the approval of Engineer-In
charge.
1.8.5.15 The housing shall be of steel or phenolic mould. Design and manufacture of meters
shall ensure prevention of fogging of instrument glass. Selector switches shall be
provided for ammeters and voltmeters used in three-phase system. This selector shall
be of built-in type with meters.
1.8.6 Relays
1.8.6.1 The relays are having in-built function with protective gears such as ACB, MCCB and
MCB and MPCB etc. In case any relay is required for additional protection as stated
in BOQ or otherwise, the same shall be provided to ensure full protection to the
system.
1.8.7 Emergency push button (EPB)
Emergency lock and key type push buttons shall be installed wherever required or
specified in BOQ to de-energize the Electrical Panels in the event of an emergency.
The EPB shall be button type with flat surface protection guard ring and pressed-in
design with key reset so that accidental triggering and vandalism shall be avoided as
far as possible. Transparent hinged cover shall be provided in front. Unless otherwise
specified on the Drawings, the EPB shall be mounted at 1300 + 100 mm above finish
floor level. The button design and the installation details shall be submitted for approval.
1.8.8 Interlock and padlocking facilities
1.8.8.1 Mechanical key interlocks shall be provided wherever applicable or as specified in
BOQ and shall be so designed as to avoid mal-operation at the point of manual
application. The scheme shall be such that attempts to remove a captive key shall not
result in tripping or opening of the device.
1.8.8.2 The tripping of the ACB(s) shall be via local hard wiring control and in Signal(s) shall
also be generated from circuit breaker(s) upstream of the corresponding Electrical
Panels and the switchboard interconnected section ACB.
1.8.8.3 Electrical interlocks on withdrawable equipment shall be so arranged that if the
equipments are withdrawn, the complete operation of the withdrawn equipment shall
be independent of the remote interlocking contacts. In addition, interlocks shall not be
defeated leading to damages or unsafe operations of Electrical Panels due to the
withdrawing of equipment.
1.8.8.4 Locking facilities shall be provided where appropriate for switches and isolators in
order that they may be locked in the open position. Switchgear cubicle access doors
shall be equipped with integral type locks, preferably incorporated in the handles of
the equipment.
1.8.8.5 Where locking facilities are of the integral barrel type, the key for each lock shall be
unique to the associated lock unless otherwise specified.
1.8.8.6 Two keys shall be provided for every lock supplied. The keys shall be fitted with rings
with identification labels, and cabinets with glazed front- opening doors shall be
provided. The cabinets shall be adequate in size and equipped with hooks to house
all keys when not in use, and shall be mounted in positions to be decided.
1.8.9 Internal and control wiring

1.8.9.1 All equipment shall have adequate provision for the entry and termination of all
associated power and auxiliary cables.
1.8.9.2 Cable entry shall in all cases, except where otherwise specifically approved, and be
at the base of the equipment. All cabling and wiring within the Electrical Panels shall
be neatly run and fitted in or upon such cable containments as may be appropriate to
the layout and equipment. Cable containments shall be non - metallic and shall be of
the low smoke halogen free material.
1.8.9.3 FRLSH Cables shall be as per cable specification. All internal and control wiring shall
be Fire retardant Low Smoke Halogen (FRLSH) copper conductor wires rated at 1100
V. All control wiring within the Electrical Panels shall be with single core minimum 2.5
mm2 for CT and balance as per approved manufacturer design. Insulation shall have
a glossy finish, be resistant to oil and be incapable of supporting combustion. Fire
survival cables shall be provided where required as per BOQ.
1.8.9.4 Wiring from the fixed part of the switchboard to the movable part such as hinged door
shall be enclosed by flexible tubing made of Fire-Retardant Low Smoke Halogen
material. Exposed live terminals shall be suitably shrouded or covered.
1.8.9.5 Wiring passing out to fully accessible positions shall be run in non-metallic low smoke
halogen free flexible tubes or conduits / trunking.
1.8.9.6 All internal wiring shall be neatly run and securely fixed in non-metallic cleats in such
a manner that, wherever practicable, wiring can be checked against diagrams without
removal of the cleats.
1.8.9.7 Access opening shall be fitted with a suitable long-life grommet where inter-panel
wiring passes through panel side sheets etc.
1.8.9.8 Bus-wires shall be fully insulated. Bus-wires terminals shall be fully accessible from
the point of entry to each enclosure. MCB and links shall be provided to enable all
control circuits within the Electrical Panels to be isolated from the bus-wires.
1.8.9.9 All control circuits shall be protected by a MCB.
1.8.9.10 There shall be no joint in conductors between terminal points.
1.8.9.11 Terminations for terminals shall be of the crimped-on ring type. Terminations of
stranded conductors to clamp type terminals shall be of the crimped-on solid rod type.
1.8.9.12 No more than one core of either internal or external wiring shall terminate on any
outgoing terminal. Where duplication of terminal blocks is necessary, suitable solid
bonding links shall be incorporated in the design of block selected.
1.8.9.13 Wiring for all known future equipment shall be provided and all wires shall be
terminated.
1.8.9.14 All wires between the terminals of two equipment shall be given a unique number
according to an approved system. A wire number shall not change solely by virtue of
passing through, say, a marshalling terminal block.
1.8.9.15 In the interests of uniformity, the wire-numbering system shall be approved by the
Engineer-In charge.
1.8.9.16 Identification markers shall be fitted to all wires and multicore cable tails within
enclosures in accordance with the diagram for apparatus concerned. Cable and core
makers shall be of insulation material, coloured according to the wire numbering
system with a glossy finish, be resistant to oil and be incapable of supporting
combustion. Numbers shall not be duplicated unless the corresponding wires are
directly in series or parallel
1.8.9.17 Different insulation colours shall be provided to distinguish the various circuits. All
wiring shall conform to the colour and ferrule codes to be approved by Engineer-In

charge.
1.8.10 Terminal blocks
1.8.10.1 Both incoming and outgoing cable shall have top or bottom entry depending on site
requirement.
1.8.10.2 Each terminal block compartment shall have not less than 20 % or 4 spare terminals
whichever is greater.
1.8.10.3 Terminal blocks for low voltage wiring shall be moulded from high-grade non-
hygroscopic melamine, comprise bank of rail-mounted blocks with all live parts fully
shrouded, screw- clamp, spring loaded insertion, solder-lug, or stud type terminals as
appropriate to the design and duty of the cables to be terminated. Pinch-type screws,
where the screw is in direct contact with the conductor, shall not be used.
1.8.10.4 Each terminal shall be provided with claw-type washers, crimp lugs or other approved
means for connection of the wires. Plain and spring washers, nuts and lockouts shall
be electro-tinned.
1.8.10.5 Terminals shall be assembled in banks and each terminal shall be complete with
marking tags to fit into moulded tag slots.
1.8.10.6 Terminations shall be grouped according to function and no more than two wires
Connected to one terminal. Labels shall be provided adjacent to the terminal block to
identify the function and voltage of each group.
1.8.10.7 All terminals to which 240 V or 415 V AC circuits are connected, where they are in
individual terminal blocks, shall be provided with a transparent insulated cover which
in addition to any other form of identification and shall have a label engraved suitably
indicating the voltage.
1.8.10.8 Terminals for the control supply which may be still alive when the main equipment is
isolated from the mains supply shall be suitably labelled to reduce the risk of accidental
contact.
1.8.10.9 All terminals shall bear a permanent identification number or letter.
1.8.11 Marshalling unit
1.8.11.1 In main distribution Electrical Panels separate marshalling chamber shall be provided
for BMS / SCADA interfaces terminals or wherever required as per BMS / SCADA
requirement.
1.8.11.2 Single location interface for different LV components of main distribution panel or
another Electrical panel where ever necessary or as per BOQ shall be provided
through marshalling chamber for BMS interface.
1.8.11.3 All interface terminals and ports for BMS shall be wired up to the marshalling chamber.
Necessary marking and ferruling shall be provided for individual termination.
1.8.11.4 Control command interface and other terminals having potential should have due
separation from potential free contact interface terminals. Control and signal cable
wiring from different relays, sensors, transducer, controller, and contactor releases
shall be through separate wiring bunch to avoid fault current or external magnetic /
electric interface.
1.8.11.5 Necessary multi dropping and single point interface provision shall be done through
suitable short links. Communicable devices using standard protocol communication
shall be looped as per BMS / SCADA requirement.
1.8.11.6 Marshalling chamber should have provided with necessary mounting arrangement or
space provision for BMS / SCADA remote I / O module / PLC equipment along with
its associated interface equipment and power supply unit or as per BOQ.

1.8.11.7 Junction box for control wires to suit four poles of ACB connection shall be provided
as per requirement.
1.8.11.8 Connecting cable with connector between ACB communication unit and junction box
shall be provided.
1.8.11.9 The communication of ACB / MCCB with SCADA / BMS system shall be provided the
suitable / required power source.
1.8.11.10 Panel manufacturers shall provide the required termination and interface detail for
BMS / SCADA work. In case of requirement of supervision and guidance during BMS
/ SCADA commissioning, same shall be inclusive to the panel manufacturer's scope
of work. It is the responsible of panel manufacturers to provide necessary interface
detail such as data point register address during BMS / SCADA commissioning or
supervise as appropriate during installation and testing of BMS / SCADA system.
1.8.11.11 Marshalling box shall comply with EMC (electromagnetic Compliance) and
protected from any electrical or magnetic interface. Required protection against any
BMS / SCADA or panel component has to be inclusive to respective contractor’s
scope of work.
1.8.11.12 Any specific interface requirement not specified here with shall be wired up to the
marshalling chamber interface terminal. Scope of work from potential free contact of
Marshalling box to RTU panel shall be in scope of SCADA vender. BMS / SCADA
interface point should only confine to marshalling box.
1.8.12 BMS / SCADA interface
1.8.12.1 Electrical contractor shall cross reference the requirement of BMS / SCADA remote
control and monitoring interface as required for electrical equipments and shall provide
the necessary volt free contact and remote-control interface for BMS / SCADA.
1.8.12.2 Serial interface as applicable for ACB / MCCB and digital meters or MFMs shall be
strictly on standard protocol communication (preferable with MODBUS-RTU, RS485,
2 wire communication). Necessary interface detail and drawing shall be provided to
BMS / SCADA contractor during commissioning.
1.8.12.3 All terminals and BMS / SCADA interface terminal and ports shall be wired to a
separate marshalling chamber with adequate number of ITBs and with proper marking
as per interface document.
1.8.12.4 No such change in contact or pseudo signal shall be provided for critical alarms control
interface.
1.8.12.5 BMS / SCADA and PLC interface for control command shall be pulse type close
contacts for single command output / double command output or a variable voltage /
current (i.e. 0V- 10V or 4mA - 20 mA) for analogue output command.
1.8.12.6 There shall be one interface for control open and one for control close operations. The
Contractor shall provide appropriate equipment to sense and latch the remote control
signal for performing the open / close control function. The BMS / SCADA digital
output (DO) & analogue output (AO) signal shall be as stipulated.
1.8.12.7 Contacts shall be rated to adequately make and break and carry continuously not less
than 5A at 250V AC or 2A at 11O V DC.Volt-free contacts for sequence of event (SOE)
and alarms shall firmly close and seat in position once activated. The contacts shall
not bounce or vibrate due to internal or external causes
1.8.12.8 Required data point as per BMS / SCADA requirement shall be configured in
respective controller or equipment by panel manufacturers as required with necessary
hardware and software for above said serial link communication.
1.8.13 Indicating lamps

1.8.13.1 Indicating lamps shall be multiple LED type. All indicating lamps shall be suitably rated
so that the indication is clearly visible from the side and front at a distance of not less
than 3 meter in a room.
1.8.13.2 The colours of indicating lamps for red, yellow, blue phases, ACB / MCCB ON, OFF
and TRIP shall be red, yellow, blue, red, green and amber only for incomer feeders
respectively and outgoing feeders shall be provided only ON, OFF & TRIP
indication lamp and colour shall be same as defined above.
1.9 LOW VOLTAGE SWITCHGEAR
1.9.1 Air circuit breakers (ACB)
1.9.1.1 ACB should be mechanically robust of compact design, air break horizontal and
withdrawable type, confirming to IS / IEC 60947-2 and EN 60947-2.
1.9.1.2 Air Circuit Breaker is provided in transformer incomer, outgoing feeder, Interconnector
Bus-Section and essential / semi-essential circuit breaker as defined in BOQ.
1.9.1.3 Manual charging as well as by 240 V AC motor with charged spring closing mechanism
complete with anti-pumping relay, discharge resistor, auxiliary switch, etc.
1.9.1.4 An under-voltage relay or release, when associated with a switching device, shall
operate to open the equipment even on a slowly falling voltage within the range
between 70% and 35% of its voltage as per clause 7.2.1.3 of IEC 60947-1.
1.9.1.5 240 V A.C shunt-trip coil shall be operable, within operational voltage range of 70% to
110% of rated control supply voltage as per Clause 7.2.1.4 of IEC 60947-1.
1.9.1.6 The operating mechanism shall be trip-free.
1.9.1.7 Maximum number of circuit breaker auxiliary switches, spare auxiliary switches to be
equally divided between normally open and normally closed. At least 4 spare pairs of
N.O. and N.C. volt free contacts shall be provided.
1.9.1.8 Indicating lamps for on, off, tripped on fault and trip supply healthy with all necessary
push buttons, panel wiring, bus wiring, terminals, fuses, etc.
1.9.1.9 Power and control cable terminals with undrilled gland plates for outgoing power
cables and multi-core cables.
1.9.1.10 Electrical connection between the breaker and switchboard shall be of plug and socket
type with automatic screening shutters. An interlock to prevent withdrawal when the
breaker is closed.
1.9.1.11 Number of Poles shall be as per BOQ.
1.9.1.12 Local / auto control selector switch shall be lockable in all positions. The automatic
control shall be defeated when the selector switch is put at local or OFF position as
per drawing and BOQ
1.9.1.13 Remote indication and alarm facilities shall be provided for Circuit-breaker open,
Circuit-breaker closed, Circuit-breaker tripped on fault, and Switch position of local /
remote control selector switch etc. as per interface requirement.
1.9.1.14 Control switch for air circuit breakers shall be as follows:
a) Air Circuit breakers shall be fitted with operative switches of the pistol grip type. The
handles of control switches for air circuit breakers shall turn clockwise for closing and
anti - clockwise for tripping.
b) The control switch shall be clearly labelled as CIRCUIT BREAKER OPEN - NEUTRAL
- CLOSE, with spring return to the neutral position. Mechanical interlock shall be fitted
to prevent repetitive closing without moving first to the trip position, and shall be
capable of padlocking in the neutral or trip position.

1.9.1.15 Set of terminals wired to provide for connection to the following:

a) Automatic changeover and interlocking as shown on the drawing
b) Operation of emergency push button as per requirement or as per BOQ.
c) Signal cables wired to terminal block for remote monitoring to SCADA.
1.9.1.16 Electrical Characteristics:
a) Rated Insulation Voltage: 1000 V
b) Rated Frequency: 50 Hz
c) Rated ambient temperature: As per Clause 6.1.1 and 6.1.3 of IEC 60947
d) Utilization category: B or as per drawing or BOQ.
1.9.1.17 Rated uninterrupted current: as shown on Drawings, however the contractor must
provide breaker after taking into account of the installation conditions and derating for
ambient temperature, based on selected make during preparation of working
drawings.
1.9.1.18 Current Ratings shall be as follows:
a) Rated short-time withstand current (lcw): 50 kA for 1 second (minimum)
b) Rated ultimate short circuit breaking capacity (Icu): 50 kA based on actual fault level
or as per BOQ.
c) Rated service short-circuit breaking capacity (Ics): 100% of Icu,
d) All ACBs shall have Icw=Icu=Ics for 1 second. Rated short-circuit making capacity:
shall be at least 2.1 times of ultimate short circuit breaking capacity at 0.25 power
factor or as per BOQ.
1.9.1.19 Protection: ACB shall have microprocessor-based protection releases for type of
faults with selective over current (long time, short time & instantaneous), Over voltage,
under voltage, unbalance temperature rise and earth fault protection, measurement of
electrical parameters and with communication capability with SCADA / BMS system.
Any other additional protection as mentioned in BOQ. ACB shall have an LED / LCD
display to show true RMS current in all the three phases and highest current among
these phases. The release shall be equipped with self-diagnostic feature with
indication. The release shall have zone selective interlocking (wherever required) and
be capable through Modbus over Serial (RS 485 port) communication as defined in
drawing where applicable. The overload and short circuit characteristics should be
front adjustable and password protected or suitable arrangement to prevent
unauthorised entry, with the approval of Engineer-In charge.
1.9.1.20 The release should have fault indication for faster fault diagnosis / self-diagnostic
feature is required.
1.9.1.21 The release should have fault indications by which discrimination of fault is possible.
1.9.1.22 Control relays and wiring for automatic changeover interlocking and other breaker
operation as shown on the Drawings.
1.9.1.23 Fire resistant transparent covers shall be provided over ACB’s to achieve IP-54
protection and door interlock so that ACB access door shall not open if ACB is ON
otherwise it will automatically OFF if Door is opened.
1.9.1.24 Electrical interlock for the two incoming circuit breakers and interconnector bus -
section circuit breaker to prevent paralleling of different power supply sources at any
one time as shown on the Drawings
1.9.1.25 Following shall be provided for ACB connected to the transformer incomer:

a) Four number Protection Current Transformers (three in panel, one in loose to be

mounted in transformer neutral), for Restricted Earth Fault Relay and Standby Earth
Fault relay as specified in the interface matrix related with high voltage switchgear.
b) Two ways inter-tripping relay shall be provided with the associated HV feeder circuit
breaker by interfacing with the Power Supply Contactor.
c) Voltage sensing relay and associated relays for automatic changeover and
interlocking operation as detailed on the Drawings.
d) Mechanical operation counter & door interlocking protection.
1.9.1.26 Interlocks and Test Operation Facilities
All ACBs shall be provided with interlocks to ensure that:
a) The ACB cannot be plugged in or isolated while it is closed.
b) The ACB cannot be closed until it is fully plugged in or completely isolated.
c) The ACB cannot be closed in the service position without completing the auxiliary
circuits between the fixed and moving portions.
d) With manual charged and motor charged spring mechanisms the springs cannot be
discharged until they have been fully charged and until the means for charging has
been removed or disconnected.
e) Facilities shall be provided for testing the ACB operation when in the isolated and
withdrawn positions by the normal means as in service.
f) Where control circuits are provided and interlock circuits are broken via plugs on
withdrawal of the ACB, a minimum of one jumper lead and plug assembly of each size
and type shall be provided to facilitate testing in the withdrawn position.
g) The neutral shall be rated for 100%.
h) ACB shall have auto / manual operation to avoid the continuous current to closing
coil in case of fault condition.
i) Release shall provide zone selective interlocking (wherever required) for short circuit
and earth fault protection zones to reduce thermal stress on the system. The release
should provide fault history including cause of fault as well as level of fault current. It
should be possible to store minimum 10 last trip histories and alarm data with non-
volatile memory. The release shall monitor the real current and shall record starting
current during switch ON. Additional features of release- Acknowlgement of settings
on release, self-powered trip unit, independent communication facility, making
current, phase sequence and reverse power protection (for DG set).
1.9.1.27 Safety Shutters
a) A set of shutters with padlocking facilities shall be provided to cover each three phase
group of stationary isolating contacts. The shutters shall be independent and operated
automatically by a positive drive from the ACB withdrawal mechanism
b) In order to prevent unauthorized operation, the withdrawable air circuit breakers shall
be provided with padlock facilities to secure them in their connected, test and isolated
positions.
c) The Arc chutes on each pole shall be designed to permit rapid dispersion, cooling and
extinction of arc. It should be possible to remove arc chutes. The insulation material
shall conform to Glow wire test as per IEC 60695.
1.9.1.28 Type Test Certificates
ACB shall be CE marked and shall be type tested and certified from NABL /
International lab accredited testing laboratories for compliance to IS / IEC 60947-2.

Supplier shall submit combine sequence test in the type test report for vendor
approval.
1.9.2 Moulded case circuit breakers
1.9.2.1 MCCBs shall comply with and be type-tested to IS / IEC 60947-2 or EN 60947-2.
Each MCCB shall be of fixed type, as specified in the BOQ and have all the mechanical
and live parts completely enclosed in an insulated moulded case. Withdrawable
pattern circuit breakers shall be designed that their electrical equipment can be safely
disconnected from or connected to the main circuit whilst the circuits are live.
1.9.2.2 MCCB shall be suitable for isolation as per Clause No. 7.1.2 of IEC 60947-2
1.9.2.3 MCCBs shall meet the following requirements:
a) Number of poles: triple-pole or four poles as specified on the Drawings or Design or
BOQ
b) Rated operational voltage: 415 V AC, as per drawing or BOQ
c) Rated insulation voltage: 750 V AC, higher voltage acceptable
d) Rated uninterrupted current (In): as shown on the Drawings or BOQ, but after taking
into account the installation conditions and temperature duration deration.
e) Rated frequency: 50 Hz,
f) Rated short-circuit making capacity (Icm): shall be at least 2.1 times of ultimate short
circuit breaking capacity at 0.25 power factor,
g) Rated ultimate short-circuit breaking capacity (Icu): as per BOQ.
h) Rated: service short-circuit breaking capacity (Ics): as per BOQ Further, Ics must be
equal to 100% Icu for the selected breaker,
i) Utilization category: A or B as appropriate,
j) Degree of protection: IP 3X to IEC 60529 or EN 60529, and
k) Rated ambient temperature: As per IEC 60947-2
l) Impulse Withstand Voltage - 8KV
m) 0 - t - CO - t - Co type of Duty i.e. Ics=lcu.
1.9.2.4 All MCCB's should have front adjustable microprocessor based releases with
adjustment in the range of 40 - 100% for nominal overloads and adjustable setting for
short circuit faults. MCCB's for network / feeder Protection shall have releases with
earth Fault Protection features, wherever and as indicated in Bill of quantities or
drawings.
1.9.2.5 In case of 4 pole MCCB, neutral shall be defined and capable of offering protection up
to full rating with possibility of adjustment at site in the neutral setting.
1.9.2.6 Mechanical endurance shall be as specified in latest IEC standard.
1.9.2.7 MCCB's shall have an electrical endurance operation cycles as per latest IEC standard
60947.
1.9.2.8 All MCCB's shall be arranged for padlocking in OFF positions with lock provided. A
shunt trip coil shall be provided to facilitate automatic tripping and local manual
tripping. The manual trip device shall be fitted with the means of padlocking. The shunt
trip coil shall be suitable for operation within a voltage range of 70% to 110% of the
rated AC power supply voltage.
1.9.2.9 Electronic trip units shall comply with the requirements as specified in Appendix F
(EMC / EMI Compatibility) of IEC 60947-2 or EN 60947-2.

1.9.2.10 The trip unit shall be easily replaceable in the same MCCB without changing the
MCCB.
1.9.2.11 The time delay on overload tripping shall be inversely proportional to the over current
up to a threshold value of approximately six to seven times the rated current at rated
working temperature.
1.9.2.12 Handle position shall give positive indication of 'ON' ‘OFF’ or 'TRIP', thus qualifying to
disconnection as per IEC 60947-3 indicating true position of all the contacts.
1.9.2.13 The operating mechanism of MCCB's shall be Independent of the operating speed of
the over centre toggle and the MCCB shall be of current limiting type and comprise of
Quick make and Quick break switching. Contacts shall be non-welding type. The
operating mechanism should be trip-free and provided with mechanical “ON", OFF"
and "TRIP” indication. The MCCB shall be designed for both vertical and horizontal
mounting, without any adverse effect on electrical performance.
1.9.2.14 Remote closing and tripping coil should be of suitable duty cycle. Wherever
interlocking or remote controlling required, all Motorised MCCB shall be considered
without any cost addition.
1.9.2.15 MCCB's shall have common field fittable auxiliaries for the entire range and above 63
A the accessories like copper spreaders and phase barriers should be the integral part
of the MCCB's.
1.9.2.16 MCCB protection releases should have
a) In-built thermal memory
b) In-built RMS sensing
c) Sensitive to improper termination
1.9.2.17 MCCB shall be CE marked and shall be type tested and certified from NABL /
International lab accredited testing laboratories for compliance to IS / IEC 60947-2.
Supplier shall submit the type test report for vendor approval.
1.9.2.18 MCCBs shall be provided with RS 485 communication ports for BMS / SCADA
(Building Management System) connectivity through MODBUS.
1.9.2.19 All MCCB shall have inbuilt LSIG protections.
1.9.3 Miniature circuit breakers (MCB)
1.9.3.1 MCBs shall comply with and be type-tested to IEC 60898 or EN 60898.
1.9.3.2 MCBs shall meet the following requirements:
a) Number of poles: single-pole, double-pole, triple-pole or four-pole as specified in the
BOQ or Drawings.
b) Protection against external influences: Enclosed-type.
c) Method of connection: Bolted type or clip-on type.
d) Rated operational voltage and frequency 240 / 415 V AC and 50 Hz.
e) Rated current: 6 A, 10 A, 16 A, 20 A, 25 A, 32 A, 40 A, 63 A, as shown on the
Drawings. Above 63A, MCCB as specified above must be used.
f) Range of instantaneous tripping current: MCB's shall be current limiting Type Class 3
with range of instantaneous tripping current B, C or D type as appropriate or as
specified.
g) Rated short-circuit breaking capacity: not less than 10 kA (M3) unless otherwise
specified in BOQ.

h) I2t characteristic: suitable for load and circuit being protected.

i) Degree of protection: IP-20 for MCB's.
j) Reference ambient temperature: as per IEC 60898.
k) MCB's shall have minimum power loss (Watts) per pole as per the IEC and should be
proven by published value by manufacturer.
1.9.3.3 The load handling contacts shall be silver / tungsten or proven material and the
contacts and operating mechanism shall be designed so as to give a wiping action
both at make and break. Breaker operating mechanism shall be of trip-free type. The
breaker operating dolly shall be clearly indicated for the "ON" and "OFF" positions. It
should be of Quick make and Quick break type.
1.9.3.4 Circuit protection against overload and short-circuit conditions shall be provided by
means of thermal-magnetic device. Double-pole, triple-pole, and four pole MCBs shall
be integral units and interlocked internally so that an over current through any pole
shall trip all the poles of the MCB simultaneously. An assembly of two or three or four
single-pole units mechanically strapped together is not acceptable.
1.9.3.5 Housing shall be heat resistant and having high impact strength. All DP, TP and FP
circuit breaker shall have a common trip bar and should be mechanically coupled
through a pin. It shall have an electrical endurance of the order of 10000 operation
cycle for current rating of up to 63A.
1.9.4 Residual current circuit breaker (RCCB)
1.9.4.1 RCCBs shall be double pole or four-pole current-operated, housed in a totally
enclosed moulded case, manufactured and tested in compliance with IEC 61008 or
EN 61008.
1.9.4.2 RCCBs shall meet the following requirements:
a) Number of poles: double-pole or four-pole as specified on the Drawings.
b) Rated current (In): as shown on the Drawings.
c) Rated residual operating current: 30 mA or 100 mA or 300 mA as shown on drawings
or as per approval of the Engineer-In charge.
d) Rated voltage: 240 / 415 V AC.
e) Rated frequency: 50 Hz.
f) Rated short-circuit capacity: not less than 1.5 kA unless otherwise specified in BOQ.
g) Operating characteristics in case of residual currents with DC components: as
specified.
h) Method of mounting: distribution board type.
i) Method of connection: connection shall be made with proper size of thimbles and
number ferruling for circuit identification,
j) I2t characteristic: suitable for equipment and circuit being protected.
k) Degree of protection: IP 2X as per IEC 60529 or EN 60529.
l) Reference ambient temperature: As per IEC 60898.
1.9.4.3 The tripping mechanism shall be of trip-free so that the unit cannot be held closed
against an earth fault. Tripping devices utilizing electronic amplifiers or rectifiers are
not acceptable.
1.9.4.4 Provision shall be made for testing the automatic earth - leakage tripping by an integral
test device. A device shall be fitted for prevention against reclosing after the device

has tripped on earth leakage.

1.9.5 RCBO (Residual Current Circuit Breaker with Over-current) protection
1.9.5.1 RCBOs shall be double pole or four-pole current-operated, housed in a totally
enclosed moulded case, manufactured and tested in compliance with IEC 61009 -1,
IS 12640(part 2) 2008 and ISI marked.
1.9.5.2 RCBOs shall meet the following requirements:
a) Number of poles: double-pole or four-pole as specified on the Drawings.
b) Rated current (In): as shown on the Drawings.
c) Rated residual operating current: 30 mA or 100 mA or 300 mA as shown on drawings
or as per approval of the Engineer-In charge.
d) Rated voltage: 230 / 415 V AC.
e) Rated frequency: 50 Hz.
f) Rated short-circuit capacity: 10kA.
g) Operating characteristics in case of residual currents with DC components: as
specified.
h) Method of mounting: distribution board type.
i) Method of connection: connection shall be made with proper size of thimbles and
number ferruling for circuit identification.
j) I2t characteristic: suitable for equipment and circuit being protected
k) Degree of protection: IP 2X.
l) Reference ambient temperature: As per IS 12640-1.
m) The tripping mechanism shall be of trip-free so that the unit cannot be held closed
against an earth fault. Tripping devices utilizing electronic amplifiers or rectifiers are
not acceptable.
n) Provision shall be made for testing the automatic earth - leakage tripping by an
integral test device. A device shall be fitted for prevention against reclosing after the
device has tripped on earth leakage.
o) A mechanical flag indicator on RCBO for faster identification of fault trip condition i.e.
earth leakage or over-current for faster fault diagnosis and preventive measures.
1.9.6 Discrimination
1.9.6.1 Selection of ACB, MCCB and MCB shall be of same make. Total discrimination up to
the design fault level must be available between the various elements of switchgear
(ACB, MCCB, MCB etc) selected. Supplier must provide test certificates from
acceptable, accredited and reputed laboratories or submit published discrimination
charts / tables to prove the same. In view of Standardization and Uniformity, mixing
of two series of switchgear (even from the same manufacturer) for either MCCB or
ACB will not be permitted.
1.9.6.2 In case higher frame sizes rating of switchgear (than those specified in the BOQ) is
required to be provided to achieve the above requirement, due to selection of a
particular make, the same shall be provided at no extra cost if other makes are able
to achieve the same with the specified frame size.
1.9.6.3 Total fault discrimination chart, duly vetted by OEM shall be submitted for approval at
the time of GA approvals of panels.
1.9.7 Remote monitoring

1.9.7.1 The following critical status and alarms for each Electrical Panels shall be sent to BMS
/ SCADA for remote monitoring via volt-free contacts or serial interface over standard
protocol communication as approved but not limited to:
a) Individual ACB / MCCB open / close status,
b) Common alarm for ACBs / MCCBs trip on fault / lock out,
c) Common alarm for any local / remote or local / auto selector switch in local mode
d) Control supply failure,
e) ACB ready to close indication.
f) Emergency push button (EPB) operated, and
g) Busbar voltage, current, frequency and energy parameter
h) Electrical Panels under voltage alarm and cause of tripping.
1.9.8 Motor starter
1.9.8.1 Every motor starter shall be designed to perform the following functions efficiently and
safety:
a) To start the motor without damage to the drive or driven equipment whilst regulating
the starting current to the satisfaction of the requirements of this Specification and
ensuring that at all stages of starting, the motor will develop sufficient torque to
accelerate the load.
b) To stop the motor.
c) To prevent damage to the motor due to overload, disconnection of one phase etc.
d) To prevent damage to reduced and danger to personnel due to resumption of the
electricity supply following a failure.
e) To prevent the damage to the motor due to stalling or internal electrical or mechanical
faults by quickly disconnecting the supply.
f) To prevent damage to the motor or the starter itself due to improper, unskilled or
hesitant operation or failure to complete a starting sequence once it is connected.
g) To enable the motor and starter to be completely isolated from the main supply and
from all control supplies for inspection and repairs by means of fixed type unit for each
starter circuit.
1.9.8.2 Each motor starter assembly shall comprise MCCB / MPCB, contactors, protection
relays, electronic circuitry, control switches, lamps and instruments and accessories
as specified hereinafter. It shall include control devices for automatic control systems.
The whole unit shall be enclosed in the cubicle, from which no access can be gained
to adjoining cubicles.
1.9.8.3 The specified starter types are based on estimated motor ratings. The final selection
of starter shall be based on the installed motor rating. Starters and associated over-
load devices shall be selected in accordance with the run-up time of the associated
motor driven load, the maximum thermal capacity of the motor and frequency of
starting, and the duty cycle. All starters shall have suitable protection for phase-to-
phase, phase-to-neutral and phase-to-earth faults, over-loads, and single phasing,
with additional protection measures as specified. Overload relays releases as
specified shall have inverse time delay characteristics compatible with the motor drive
to which they are applied for all protective devices the short-circuit capacity (Isc) shall
be capable of withstanding a fault current of the panel, as a minimum.
1.9.8.4 The specifications of incoming and other circuit breakers (ACB / MCCB etc.) shall be
as per clause 1.9, as relevant.

1.9.8.5 All starters shall be in accordance with section 7.2 of IEC 60947-4-1 or EN 60947-4-
1, and shall be adequately rated for conditions in which it shall operate.
1.9.8.6 All starters shall be type tested by a competent and internationally recognized testing
authority for type 2 co-ordinations in accordance with IEC 60947-4-1 or EN 60947-4-
1.
1.9.8.7 All contactors shall be electro-magnetic type with utilization category AC - 3 to IEC
60947-1.
1.9.8.8 All starter shall be of electrically held on pattern and shall not release until the over
voltage falls below 70% of nominal.
1.9.8.9 Control circuits shall generally be operated on main supply derived from the WPP,
FPP suitably protected by MCB type 2, as specified in clause 1.9. The control circuit
shall be of self-holding and latching design.
1.9.8.10 Where the control voltage is not 240V it shall be derived from transformers confirmed
to BS 3535 / BS 61558. Transformers shall be rated at the total control circuit load
plus a minimum of 10% spare capacity. Transformer primary windings shall be
protected by MCB's in the line connection(s) and a removable neutral link shall be
provided where the neutral is required. The supply shall be taken from downstream of
the main incoming Circuit Breaker. One end of the transformer secondary shall be
connected directly to the main earth bar. This connection shall be upstream of the
control circuit neutral link. The supply from the other end-of the winding shall be
protected by MCB.
1.9.8.11 The type of starters for other mechanical equipment such as plumbing, drainage, fire
services pump and other motor circuits shall be as specified in this clause subject to
rating of the motors selected during working drawing production as per clause 4.16.3.
The starters shall also comply with the requirements laid down in the Code of Practice
of electricity (Wiring) Regulations. Voltage for motors shall be 415V 3-phase or 240V
1-phase, as required. Motors rated 0.37kW and larger shall have a rated voltage of
415V, 3 phases, 50Hz. Motors rated smaller than 0.37 kW shall be operated at 240V
1-phase. Direct-online motor starters shall be used for motors up to and including 3.75
kW at 415 volts, 3 phases. All motors over this limit shall be equipped with soft starter
type as indicated in BOQ.
Motor size (M)Load Maximum starting current in multiple of full
load current (phase of motors)
M≤ 0.37 kW 6 (single phase motor)
0.37 kW < M< 3.75 kW 6 (three phase motor)
3.75 kW ≤ M 6-7 (three phase motor)
1.9.8.12 Tolerance in the above currents shall be of the order of ±20%

1.9.8.13 The direct-on-line starters shall be provided based on condition given in Clause
1.9.8.11 and shall include, but not be limited to, the following:
a) MPCB as specified,
b) Triple pole air break contactor,
c) MPCB wherever specified or required shall be provided with inbuilt Thermal /
Magnetic and single-phasing protection. MCCB, wherever specified / required shall
be of Electronic Trip Unit type with single phasing preventer unit.
d) All Current transformers with suitable ratio, output and accuracy for motor protection,
e) Local / off / remote control selector switch lockable in each position,

f) Set of start and stop push button,

g) Set of indicating lamps for motor running, off and trip on fault,
h) Set of digital input (dry contacts) interface wired to terminals for wiring connection to
station building services controllers,
i) One set of terminals wired to the following:
1) Emergency stop push button, effective in all positions of the local / remote switch
if any.
2) Remote start / stop of the motor, effective only in the remote position of the
selector switch.
3) Any other items required to affect satisfactory motor starting and control as
specified in this Specification, and
4) double pole contractor and motor protection unit for single phase DOL type starter.
j) Interposing relays / contactor for remote close and remote open whenever required.
1.9.8.14 All soft Starters shall be complying with class A for conducted and radiated emissions,
described in the Standard EN / IEC 60947-4-2. soft starters with a rated current not
exceeding 170 A, should have following additional provisions:
a) The Soft-starter shall comply with UL 508 and CSA "Industrial Control Equipment”.
b) All soft starters shall be equipped with motor current measuring means to ensure
engine protection. The soft starter should have a separate power control.
c) All soft-starter shall have setting of variable starting current.
d) The terminals of the board control shall be of plug type.
e) The soft starter shall be able to operate at design ambient temperatures from -10 to
+ 40 °C without derating, and between 40 and 60 ° C with suitable derating factor shall
be considered.
f) The maximum relative humidity will be 95% without condensation or dripping water
according to standards IEC60947-4-2.
g) The storage temperature can be between -15 °C to + 60°C.
h) Soft Starter Cooling should be managed automatically.
i) Voltage variation -15% to +10 %
j) Frequency Variation + / -5%
k) Starter shall be protected against Thermal overload, reverse phase network, loss of
phase, external faults, over current, short circuit faults, earth fault, dry run (for
Borewell Pumps).
l) Access of setting should be protected by password or other functions.
m) Starter shall be handle the by-pass of soft starter, manage the closure of the by-Pass
at end of acceleration time and open that by-Pass at end of stop sequence.
n) 3-Phase Soft-starter shall have thyristors (SCRs) in each phase for 3 phase motors
with RS 485 commincation port.
o) Starter shall be monitoring following information on screen:
i. Motor Current
ii. Active Power
iii. Current Status (acceleration, decelaration, etc.)

iv. Operating time.

v. The last fault occurred with time.
vi. By pass indication
1.9.8.15 Status / Alarm (Wherever Applicable)
a) Indicating lamps shall be provided on each phase of the main incoming supply.
b) All assemblies incorporating automatic control systems shall be equipped with
suitable status / alarm annunciation facilities. If these are not available directly from
the automatic control system then a separate status / alarm annunciator shall be
provided. Status / alarm annunciators shall provide indications for all starting devices
of 'ON', 'OFF ‘and 'TRIP' conditions.
c) The status / alarm annunciator equipment shall be mounted in the same cubicle as
the automatic controls. Volt-free contacts shall be provided for each condition in each
starter cubicle, which shall be wired internally to the status / alarm annunciator, via
terminals at each end.
d) The schematic diagrams as indicated in the Working Drawings shall be shown and
the operating status of all equipment shall also be indicated. Status indicating lights
shall exhibit run / stop or open / close and fault conditions. The Contractor shall
provide test buttons for the indicating lights.
e) Suitable interfaces shall be built into each channel to relay signals to remote locations,
by means of volt-free contacts.
1.9.8.16 Control Circuits
a) In each individual starter, the control circuit shall be provided with MCB, a neutral link,
a means of disconnection and, where specified, a disconnection over ride switch.
b) Neutral links shall comprise a solid copper link mounted in a white coloured fuse base
and carrier, which shall not be interchangeable with control or power fuse carriers.
c) The control circuit supply shall be connected via an auxiliary contact on the starter
isolator.
d) Where automatic changeover systems are specified for duty / standby operation, the
control circuit for the changeover controls shall be independent of both starters.
e) Start delay timers shall be incorporated for sequential operation of starters where
specified. The failure of one timer or starter to operate shall not prevent operation of
the remaining starters.
1.9.8.17 Auxiliary contacts
Two normally open and two normally closed auxiliary contacts shall be provided for
each starter as spares unless otherwise specified. These contacts shall be in addition
to contacts used for the control of the starter.
1.9.9 MPCB (Motor Protection Circuit Breaker)
1.9.9.1 Motor Protection circuit breakers shall comply with the general recommendations of
standard IEC 60947-1, -2 and -4-1.
a) The devices will be in utilization category A, conforming to IEC 60947-2 and AC3
conforming to IEC 60947-4-1.
b) Rated operational voltage of 690V AC (50 Hz).
c) Rated insulation voltage of 690V AC (50 Hz).
d) Isolation conforming to standard IEC 60947-2.

e) Rated impulse withstands voltage (Uimp) of 8 kV.

1.9.9.2 MPCB shall meet following requirement: -
a) Mounting:
The motor circuit breakers will be designed to be mounted vertically or horizontally
without derating Power supply will be from the top or from the bottom.
b) Contacts:
In order to ensure maximum safety, the contacts will be isolated from other
functions such as the operating mechanism, casing, releases, auxiliaries, etc, by
high performance thermoplastic chambers.
c) Operating mechanism
The operating mechanism of the motor circuit breakers must have snap action
opening and closing with free tripping of the control devices. All the poles will close,
open, and trip simultaneously.
d) Button:
The motor circuit breakers will be actuated by a rotary operator clearly indicating
the position ON (I), OFF (O), trip
e) Isolation:
In order to ensure isolation with clearly visible breaking conforming to standard IEC
60947-2 paragraph 7.2.7:
i. The mechanism will be designated so that the different types of operator will
only be in position (O) if the main contacts are physically separated,
ii. In position (0) the operating devices will indicate the isolated position.
iii. Isolation is enhanced by the double break of the main circuit.
f) Padlocking
i. Motor circuit breakers will accept a padlocking device in the "isolated" position.
ii. Trip.
iii. The motor circuit breakers will be equipped with a "PUSH TO TRIP" device on
the front enabling the correct operation of the mechanism and poles opening to
be checked.
g) Limitation, Durability
i. The motor circuit breakers will be current limiting for a mains voltage of 415 V,
the maximum let-through energy (I2Zt) on short circuit being extremely low.
ii. The motor circuit breakers will have a high electrical and mechanism durability
of at least 5 times that required by the standard.
h) Protection functions
1.9.9.3 General recommendations: The motor protection circuit breakers will be equipped with
releases comprising a thermal element assuring overload protection and a magnetic
element for short-circuit protection.
1.9.9.4 In order to ensure safety and avoid unwanted tripping, the magnetic trip threshold
(fixed) will be factory set to an average value of 12 Ir.
a) All the elements of the motor circuit breakers will be designated to enable operation
at an ambient temperature as per IEC without derating.
b) The thermal trips will be adjustable on the front by a rotary selector.

c) The adjustment of the protection will be simultaneous for all poles.

1.9.10 Switch fuse units & disconnects / isolators (where applicable)
1.9.10.1 Switch fuse units shall have quick-make, quick-break silver plated preferably double
break contacts with operating mechanism suitable for rotary operation in the case of
cubicle mounting. All switches shall be rated according to the equipment schedule or
drawings and shall withstand the system prospective fault current let through. Cam
operated rotary switches with adequate terminal adaptors up to 25A are acceptable
but for all higher rating switch fuse units shall be heavy-duty type.
1.9.10.2 Fuses shall be HRC cartridge type conforming to IS: 13703 - 1993 with a breaking
capacity corresponding to system fault level. Fuses shall be link type with visible
indication. Screw type fuses are not acceptable for any ratings.
1.9.10.3 All disconnects shall consist of switch units quick-make, quick-break type with silver
plated contacts. The switches shall preferably have double breaks. The switches shall
preferably have sheet steel enclosure, which in turn is mounted on suitable angle iron
frame work. In wet locations enclosures shall be IP56 rated. Disconnects shall have a
minimum breaking capacity of 5KA at 415 Volts.
1.9.10.4 Switch contacts shall be designed with arc repelling features to extinguish the arc
quickly to provide long contact life.
1.9.11 Isolators
1.9.11.1 Isolators shall be fixed on wall, on self-supported galvanized angle iron frame work as
required and mounted as near to the motor as possible. Where several motors are
installed, isolators if required shall be provided at a central location on a common
frame work with prior approval at site. The Isolator shall be provided in IP 65
enclosures from the Isolator manufacturer only.
1.9.11.2 Painting, earthing and labels shall be provided as generally indicating for MV
Switchgear and as shown on drawings.
1.9.12 Contactors
1.9.12.1 Contactors shall comply with IS / IEC 60947-4-1 or EN 60947-4-1.
1.9.12.2 Contactors shall be electro-magnetically controlled, double air-break type. Contactors
shall be four-pole, triple-pole, double-pole or single-pole as shown on the Drawings.
1.9.12.3 The mechanical endurance of the contactors shall not be less than 3 million load
operating cycles.
1.9.12.4 Contactors shall be silver-faced.
1.9.12.5 The contactor should be modular in design with minimum inventory requirements and
built -in mechanically interlocked wherever required. They should be suitable for the
addition of auxiliary contacts and other electrical auxiliaries without any compromise
on the performance or the operation of the contactors. The contactors from 4KW to
400kW shall be associated with the same 10 auxiliary contact block range or as per
BOQ.
1.9.12.6 The control contactors for power factor correction equipment shall be of quick break
and have a high arc resistance during switching operation. Contactors shall be of
utilization category AC-6b for this application and specifically designed for switching
directly connected capacitor banks.
1.9.12.7 The contactors for other applications shall have an un-interrupted rated duty and
utilization category of at least AC3 at 415V±10% and 50 Hz. The contacts should be
of fast opening and fast closing type.
1.9.12.8 The making and breaking capacity values of the contactors should be as follows (as

per IEC 60947-4)

For AC3 duty:
a) Making capacity equal to or more than 10 Ie.
b) Breaking Capacity equal to or more than 8 Ie.
For AC4 duty:
a) Making capacity equal to or more than 12 Ie.
b) Breaking Capacity equal to or more than 10 Ie.
1.9.12.9 The contactors should be capable of frequent switching and should operate without
derating at 55°C for AC3 applications. They should be climate proof. The coil of the
contactor should have class H insulation to support frequent switching.
1.9.12.10 The rated insulation voltage shall be 690V. The rated Impulse voltage of the
contactor should be at least 8 KV.
1.9.12.11 Wherever DC control is required, the contactor should have wide range (0.7 to 1.25
Uc) DC coil with built in interference suppression as required.
1.9.12.12 The control and power terminals should be at separate layers preferably with colour
coding (black for power and white for control). All contactors power connection shall
be finger safe (IP 2X).
1.9.12.13 They should be capable of being integrated into automated system (PLCs) without
any interposing components in the minimum operating conditions.
1.9.12.14 Contactors should have surge suppressor.
1.9.13 Auxiliary switches and contacts
1.9.13.1 Auxiliary switches provided for indication, protection, metering, control, interlocking
supervisory purposes shall be readily accessible at the front of the Electrical Panels.
Adequate secondary contacts shall be included to enable the auxiliary switch to be
wired to the fixed portion of the equipment.
1.9.13.2 For each control compartment, spare auxiliary contacts with a minimum of two NO and
two NC contacts shall be provided and wired to suitably identify spare terminals.
1.9.13.3 Auxiliary contacts for all applications shall be rated at 240 V AC or 110 V DC with
contact rating of at least 6 A AC or DC and operating life of at least one million on on-
load operations at 0.4 power factor inductive load.
1.9.14 SURGE PROTECTION DEVICES (SPD)
Surge protection Devices shall confirm to IEC 61643-11: 2011 and NBC 2016. SPD
shall have mechanical health indication for Visual checking and potential free remote
monitoring feature. SPD shall be connected on DIN Rail: 35 mm channel. Device must
be tested and certified from KEMA / KEUR / VDE / UL / NABL.
Type-1 SPD for Entry Point After Transformer (Stage-1) / Main LT Panel
SL
Characteristics Parameter
No.
1 IEC test Classification Type-1 / Class-1
2 Technology Metal Encapsulated Spark Gap
Technology
3 Certification KEMA KEUR / VDE / NABL
tested as per IEC 61643-11 /
UL
4 Pluggability Pluggable for Safe and Easy

Type-1 SPD for Entry Point After Transformer (Stage-1) / Main LT Panel
SL
No.
Maintenance
5 Nominal Voltage Un 240 V AC (TN-S) / as per NBC-
2016
6 Max. Continuous operating Voltage 1.1*240 V AC / as per NBC-
Uc (L-N / N-PE) 2016
7 Impulse Discharge Current Iimp (10 25 kA
/ 350µs) (L-N)
8 Impulse Discharge Current Iimp (10 100 kA
/ 350µs) (N-PE)
9 Short Circuit Current rating ISCCR 50 kA for L-N & 100A for N-E
10 Voltage Protection Level Up (L-N) ≤ 1.5 kV
11 Temporary Over Voltage behavior at 440 V / 120 min-withstand mode
UT (L-N)
12 Temporary Over Voltage behavior at 1200V AC (200ms / withstand
UT (N-PE) mode)
13 Max. length from SPD to Earth bus 0.5 meter
bar in panel
14 Response time tA As per NBC-2016
Type-2 SPD for Sub-Distribution Panel (Stage-2)

(Essential Power Panel, Main Lighting, Emergency Lighting, Fire Pump Panel,
Water Pump, PAP & All Distribution Boards
SL
No.
1 IEC test Classification II / T2
Technology
L-N: MOV Technology
2
& N-PE: GDT Technology
Certification KEMA KEUR / VDE / NABL
3
tested as per IEC 61643-11 / UL
Pluggability Pluggable for Safe and Easy
4
Maintenance
5 Nominal Voltage Un 240 V AC (TN-S)
Nominal Discharge Current In (8 / 10 KA(L-N) & 20KA(N-E)
6
20µs) (L-N & N-E)
Maximum Discharge Current Imax (8 20 KA(L-N) & 40KA(N-E)
7
/ 20µs) (L-N & N-E)
8 Short Circuit Current rating ISCCR 25KArms (L-N) & 100Arms (N-E)
9 Voltage Protection Level Up (L-N) ≤ 1.5 kV
Temporary Over Voltage UT (L-N) 335 V AC (5s / Withstand Mode)
10
440V (120min–safe failure mode)
Temporary Over Voltage UT (N-PE) 1200 V AC (200ms / Withstand
11
Mode)
12 Max. length from SPD to Earth bus 0.5 meter
bar in panel
13 Response time tA As per NBC-2016

Type-3 (Stage-3) SPD for Sensitive Electrical and Electronic Equipment

SL
No.
1 IEC test Classification T3
2 Certification KEMA KEUR / VDE / NABL
tested as per IEC 61643-11 / UL
3 Pluggability Pluggable for Safe and Easy
Maintenance
4 Nominal Voltage Un 240 AC (TN-S)
5 Nominal Discharge Current In (8 / 3 kA
20µs)
6 Maximum Discharge Current Imax (8 / 5 kA
20) µs
7 Voltage Protection Level Up (L-N) ≤1.25 kV (L-N) / ≤1.5 kV (N-E)
8 Temporary Overvoltage UT (L-N) 335 V AC (5s / Withstand
Mode)
440V (120min–safe failure mode)
9 Temporary Overvoltage UT (N-PE) 1200 V AC (200ms / Safe failure
mode)
10 Response Time (tA) (L-N) As per NBC-2016
11 Short Circuit Current rating ISCCR 6 kA
1.9.14.1 SPD shall be with suitable rating of MCCB / MCB in series having the trip indication
on Panel. SPD shall be provided for Protection, maintenance etc. SPD shall be tested
by KEMA / VDE / NABL to ensure voltage protection level (Up) of 1.5KV to protect
the terminal equipment’s.
1.9.15 ACTIVE HARMONICS FILTER (AHF) up to 100A-415V-3Ph-4Wire System
1.9.15.1 Standards:
Code Description
ANSI / IEEE 519 - Guide for Harmonic Control and Reactive Compensation of
2014 Static Power Converters.
ASCE 7 Minimum Design Loads for Buildings and Other Structures
IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
EN 61000-6-4 Class EMI Electromagnetic compatibility (EMC)
A, EN 61000-6-2
ASTM E 329 Standard Specification for Agencies Engaged in the Testing
and / or Inspection of Materials Used in Construction
UL 508 Standard for Industrial Control Equipment
UL 1449 Standard for Transient Voltage Surge Suppressers
1.9.15.2 Performance Requirements:
a) Active harmonic filter (AHF) shall be defined as a power electronic device consisting
of power semiconductors known as insulated gate bipolar transistors (IGBT) that
switch into the AC lines to modulate its output to mitigate detrimental harmonic
current; correct the displaced reactive current (leading or lagging); and balance the
current (also known as negative sequence current) for the power source.
b) Converter design shall be a three-level design to optimize performance and minimize

heat losses.
c) Performance as defined assumes a properly sized AHF and impedance installed on
nonlinear loads. Impedance shall be 3% or larger on every nonlinear load
d) THD(v) shall be limited to not more than 5 percent as contributed by the loads at the
location of each AHF. A THD(v) set point may be set to optimize performance of the
AHF and maintain less than THD(v) set point. [Note: AHF cannot remedy THD(v) that
is caused by other electrical systems or devices that AHF is not connected to remedy.]
e) THD(i) shall be limited to 3% or less as long as AHF is 50% or more loaded and all
nonlinear loads have 3% or larger input impedance. A THD(i) set point may be set to
optimize THD(i) performance.
f) Displacement power factor (PF) shall be corrected to 0.95 or better at the location of
each AHF.
g) Displacement PF shall never go leading due to AHF performance or design.
h) Source current imbalance shall not exceed 2% phase-to-phase after correction.
(*Sizing should be done accordingly).
i) AHF shall be designed, considering three sources of supply i.e.; two source of Normal
supply and one source of Solar supply.
1.9.15.3 Service Conditions:
Active harmonic filter shall be suitable for the following conditions:
a) Operating Ambient Temperature Range: Up to 100A shall have an operating
temperature range of 0 °C to 50 °C.
b) Maximum Altitude: 3300 feet (1000 m) with derating at 1% per 100 meters
c) Relative Humidity: to 95 percent, non-condensing.
1.9.15.4 Equipment Sizing / Rating:
a) Active harmonic filter (AHF) shall be designed to operate from an input voltage of
380 V AC to 480 V AC, plus 10 percent, minus 15 percent at each nominal voltage.
AHF shall be designed to operate with an AC supply frequency of 50 Hz, + / - 3 Hz.
AHF heat losses shall not exceed more than 3 percent of the unit kVAR rating.
b) AHF ampere output ratings shall be 60, 100 amperes. Actual ratings required are
detailed in the electrical one-line drawings in this document. Up to 10 units of any size
combination shall be able to be paralleled to inject current according to the information
received from one set of supply current transformers (CTs) located at the source of
supply for loads and all active harmonic filter. This known as closed loop logic and
CT location.
c) When parallel units are employed, if one or more units is off line, the remaining units
shall adjust their total output to attempt to make up for the unit(s) off line. All units
operating in parallel shall have a common digital series communications connection
between all of them.
d) Each unit that receives the primary CT is considered a master unit. If any master is
off line, another master shall control the system. Units not receiving primary CT are
considered slaves. AHF that turns off all units when one is taken offline in the parallel
arrangement is not acceptable. AHF that shut off the nonlinear loads (i.e. VSD) when
AHF faulted is not acceptable.
e) All floor standing units shall provide incoming bus bar terminations for both top and
bottom entry. At least two cables per phase may be landed. AHF floor standing units
shall include a door-interlocked circuit breaker rated at 200,000 AIC (amperes of
interrupt capacity) at rated voltage up to 480 VAC.

f) An energy saving feature shall be provided to permit stopping AHF when load goes
below a desired set point (10% factory setting) and turn on at some higher set point
(15% factory setting)
g) Safety features include a dead front design where upon opening the enclosure door
on floor standing units. Extreme measures must be taken to bypass this safety dead
front design. To perform service the enclosure door should never be opened without
locking out the upstream feeder breaker.
h) Incoming power shall be connected to the input circuit breaker within a power cable
entry plenum. Once cable installation is complete and plenum covers are re-installed
there shall be no access to incoming cabling.
i) A service port is provided in the front cover of each unit chassis (IP00) such that with
power disconnected a USB connection from a laptop computer may examine past
performance and review all parameter set points and the event log. This may be used
for commissioning or service.
j) Engineer-in charge shall be approved, where AHF is to be installed.
1.9.15.5 Enclosure:
Provisions shall be made for locking disconnects in the off position. Provisions for
additional padlocking shall be made by the Employer using an approved lockout /
tag-out device. AHF shall be provided in minimum IP-20 enclosure with top / bottom
cable entry.
1.9.15.6 Function of AHF:
a) AHF shall monitor the total current of the loads under review utilizing two CT mounted
on the supply AC lines in MDB-1 for all three phase loads and all AHF. If
phase-to-neutral loads are connected (four wire system), three CT shall be required.
b) AHF shall analyze the content of the supply current for harmonics from the 2nd to the
51st harmonic and shall determine the reactive current content representing
displacement power factor and supply current balancing.
c) AHF shall inject cancellation for every harmonic order from 2nd to 51th order. AHF
with designs to inject less than all harmonic orders are unacceptable. To insure
optimum system performance, all nonlinear loads shall have input line reactors
included that are rated 3 percent or higher impedance (inductance).
d) AHF shall include an option to achieve optimized PF correction. Optimized PF
correction is designed to prevent correction when the system PF is better (closer to
unity) than the programmed PF setpoint. Any AHF that reduces the system PF to
attain a reduced set point are unacceptable.
e) AHF shall provide field selection as harmonic filter, reactive current correction, or
supply current balancing or any combination of the three modes. All modes shall be
required for this project.
f) AHF shall provide for current balancing of AC supply for harmonic and reactive
currents regardless of actual load distribution per phase. AHF shall have up to 30
seconds of logic ride-through in the event of power loss. AHF shall be designed with
a current limiting function to protect the IGBT. When the current limit level is attained
on any harmonic order, a message shall be displayed indicating the output capacity
is operating at maximum capacity. Operation shall continue indefinitely at this reduced
level without trip or degradation of AHF.
g) AHF shall have automatic restart capability upon power loss return and fault resets.
h) Fault trip limit shall occur after five restarts within a 5-minute period and provide
positive shut down and noticed. Upon occurrence of the fault trip limit, AHF shall stop

output current production and lock out restart until the fault is manually cleared. AHF
shall incorporate an over-temperature output roll back that shall reduce the total
output current to reduce power component heating in order to maintain maximum
current correction at the elevated temperatures within the electrical system.
i) AHF shall monitor the incoming air temperature and invoke a hard trip of the unit at
75°C.
j) AHF shall be compatible with SPD, EMC filters, SCR (thyristor) snubber circuits, and
switched mode power supplies (SMPS).
1.9.15.7 Operator Interface:
a) AHF shall have a door-mounted human machine interface (HMI) with touch screen
control rated NEMA 4-12 (IP65), dust-tight and liquid-resistant.
Note: HMI is not suitable for outdoor use.
b) HMI shall provide run / stop control from every screen. HMI shall provide an
oscilloscope feature to display specific parameters.
i. Three sets of data may be monitored at a time. Up to twenty predefined
parameters can be chosen for each curve.
ii. Performance trend curves shall be displayed for load total RMS current, load RMA
harmonic current per phase, AHF harmonic current output per phase, AC mains
voltage per phase, THDi, TDD, load RMS reactive current, and AHF RMS reactive
current output.
iii. Bar graphs shall be provided for display of the mains and load harmonic current
amplitudes per harmonic order.
iv. Selected internal curves shall be provided for diagnostic and performance checks
c) HMI shall display operating and setup parameters and event fault messages in plain
English, no cryptic codes or symbols are permitted on the display. HMI shall display
the mains voltage and CT current. Parameter adjustment shall be made via HMI and
shall be password protected. HMI shall record and display an event log with time and
date. Event log shall be cleared via the stop function or power-off. A minimum of
100 events shall be stored.
d) HMI shall provide external communications via an RJ45 connectors. Modbus TCP /
IP shall provide remote run / stop and display of operating parameters, set-up
parameters and diagnostic functions. HMI shall have a safety feature that shall lock
out all other forms of control during service and commissioning. After 15 minutes of
non-use the lockout shall clear and control functions shall revert to full functionality
and remote-control capability. HMI shall display a flashing warning screen in the event
of a fault. HMI shall download pertinent parameters to a USB memory device to permit
remote diagnostic evaluations and to save unit set up parameters.
e) HMI shall include, but shall not be limited to, an on-board commissioning guide with
automatic detection features. AHF shall automatically check for proper AC line phase
rotation. No specific phase rotation is required. AHF shall automatically test for CT
phase rotation and polarity. If installation is incorrect, AHF shall be able to rotate and
reorient CT’s through its own logic calculation. If proper alignment cannot be
achieved, a fault warning and lockout of operation shall occur. AHF shall automatically
calibrate the CT for optimum harmonic cancellation performance. AHF shall perform
at full capacity for a period of 15 minutes to validate components meet temperature
performance requirements in the installed location. In the event any of the above
cannot be reconciled, HMI shall lock out AHF function until commissioning agent
corrects, verifies, and clears each test.

1.10 DISTRIBUTION BOARDS

1.10.1 Distribution boards for miniature circuit breakers shall be of sheet steel construction with
minimum thickness of 1.6 mm, suitably braced to form a rigid structure. Exterior corners
and edges shall be rounded to give a smooth overall appearance. Hinged swing doors
shall be fitted with gaskets and shall be easily removable to simplify installation. DBs
shall be provided with suitable size of surge protection. DBs shall be fixed with bottom
at 1200 mm from finished floors. DB shall be provided with proper locking arrangement
to unauthorised access to DB’s internals. DBs shall be fixed properly, fitted square with
the frame and with holes correctly positioned. DBs shall be fastened to the walls with
suitable grouted studs of not less than 12-mm diameter.
1.10.2 IP ratings for distribution boards shall be IP 54 (used for Lights & small power,
Advertisement, Signage or any other purpose).
1.10.3 All boards shall be meggered phase to phase and to neutral using 1000 / 500V megger
with all switches in closed position. The megger value should not be less than 2.5 M
Ohm between phases and 1.5 M Ohm between phase and neutral. Testing of minimum
10 kA short circuit current otherwise specified in BOQ required.
1.10.4 Each distribution board shall be arranged for top and bottom cable entry and shall be
provided with ample cable termination plates and chambers to enable cables to be
neatly glanded with tails grouped and terminated on to appropriate internal terminations.
1.10.5 Distribution boards shall be wall mounted and shall, where specified, incorporate double
pole or triple pole all insulated switches as appropriate, which shall be front of panel
operated with an "ON" indicator. Distribution boards shall incorporate combinations of
single pole, double pole, triple pole and four pole miniature circuit-breakers (MCBs /
MCCBs) as specified.
1.10.6 Internal wiring shall be as per following table:
DB conductor Selection
S. From To Copper Conductor
No. Size in Sqmm.
1. Incomer cable MCCB / MCB 10
2. MCCB / MCB Busbar 10
3. Busbar DP feeders / 6
4. DP feeder Cable alley(Neutral 6
/ Non Timer
feeders
5. SP Feeder Cable alley 2.5
6. Control wiring 2.5
1.10.7 Neutral link and Earth link shall be separate for each phase.
1.10.8 Each bank of MCB's shall be clearly identified with its appropriate phase colours code,
and the mounting framework for the banks of MCB's shall be easily removable to
simplify installation. Adequate phase barriers and shields shall be fitted to ensure that
after installation and wiring, all bare terminals and wires are covered to prevent
accidental contact with live conductors during the normal procedure of resetting MCB's.
1.10.9 Each distribution board shall be supplied complete with a permanent circuit identification
chart, preferably mounted within the front door. This chart shall be permanently and
legibly filled in as circuits are completed, including the circuit description, the MCB rating
and the identification of upstream source of the distribution board.

1.10.10 Each distribution board shall be clearly labelled indicating its service and all 3- phase
distribution boards shall be fitted with standard labels as per relevant IS.
1.10.11 In the top and bottom, of each distribution board a 32 mm clear hole in addition to
other requirements shall be provided. These spare holes shall be fitted with 32 mm
stopping plugs and locknuts.
1.10.12 Spare MCB's shall be provided on the basis of one per four ways or part thereof for
every distribution board ensuring that spares are provided in numbers and rating
proportional to the numbers and ratings in the installation.
1.10.13 Distribution boards shall comply with best industry practice.
1.10.14 All busbars shall be of hard drawn tinned copper having ratings as specified
complying to relevant clauses given under clause 4.1 as relevant, and shall be electro-
tinned. Neutral busbars shall be of the same cross-sectional area as the phase busbars
and shall have adequate number of terminals for all outgoing circuits including spare
ways.
1.10.15 The configuration of the busbars, busbar supports and busbar mounting
arrangement) shall be rated at 415 V.
1.10.16 Multi-terminal connectors shall be provided within the distribution board for
connection of protective conductors of all outgoing circuits including spare ways.
1.10.17 Opening of front door shall be coordinated with site conditions or as approved by
Engineer- in charge.
1.11 FINISHES
1.11.1 Sheet Steel materials used in the construction of these units should have undergone a
rigorous rust proofing process comprising of alkaline degreasing, descaling in dilute
sulphuric acid and a recognized phosphating process.
1.11.2 The steel work shall then receive two dip-coats of oxide filler / primer before final
painting. Castings shall be scrupulously cleaned and fettled before receiving a similar
oxide primer coat. The manufacturer is required to have 9 tank treatment facility for this.
1.11.3 All exposed metal surfaces, both internal and external, shall be thoroughly cleaned of
all dust, oil, grease, scale, rust or any other contaminants and shall be epoxy powder
coated immediately at the manufacturer's factory. In case of any doubt, the painting
procedure, paint samples and process shall be approved prior to commencement of
painting.
1.11.4 The epoxy powder coating shall be not less than 80 microns thick and with colour in
accordance with BS 381C or BS 4800 as approved by Engineer-In charge.
1.11.5 Every care shall be taken to protect the surface of the panel from damages during
transportation and installation. In case, there is any damage, the same shall be made
good by the method as approved by the Engineer-In charge which may also include
change of the panel.
1.11.6 Size of the DB shall be optimized precisely by proper utilization of points on MCB.
Proper utilization of points reduces the space acquired by DB as well. If the numbers of
points are few on MCB then it shall be avoided by adjusting the same on other MCB
having sufficient free points. MCB rating shall be as per the number of points to be
included. Circuit for areas other than critical rooms e.g. SER, TER, SCR etc. shall be
clubbed according to the rating of MCB. While designing DBs, efforts shall be made in
such a way that each circuit shall have not more than 800 Watts connected load.
However, in case of LED Points where load per point may be less, number of points
may be suitably increased.

1.11.7 Moreover, Type – I DB for platform and Type – I DB for concourse can be of different
sizes & design. The under using idea is to reduce the size of DBs to the extent possible.
DBs Description
Type of DB Incoming Supply for DBs Purpose
Type - 1 (PF) Normal, UPS
Type - 1 (Concourse) Normal, UPS
Type – 2 Normal, UPS
Type – 3 Normal, DG, UPS
Type – 4 DG
Type – 5 Normal
1.12 NAMEPLATES AND LABELS

1.12.1 NAMEPLATES
Each Electrical Panels shall have permanently attached to it in a conspicuous position
labels upon which shall be engraved or stamped with the manufacturer's name, type
and serial number, date of manufacture, designation of each Electrical Panels, details
of the loading and duty at which the item of the Electrical Panels has been designed to
operate. Such labels shall be of non-hygroscopic material.
1.12.2 LABELS
a) Labels shall be provided for every panel to describe the duty of or otherwise identify
every instrument, relay or item of control equipment mounted externally and internally.
b) The designation on these labels shall be clear and shall, where applicable, incorporate
the device number along with concise descriptive wording in English.
c) Externally fitted panel labels shall be of Perspex or other approved transparent plastic
with letters and numbers rear engraved and filled with black.
d) Internally fitted panel labels shall be finished in white with engraved letters and numbers
filled with black, laminated material such as Trifoliate or rear engraved and filled plastic
may be used. Embossed materials and techniques will not be accepted or any latest
technology which provides same result as mentioned above shall be applicable.
e) Labels shall be provided in conformity with the above requirements or by other approved
means wherever necessary to designate panels or panel sections. To describe or
identify circuits or circuit components, to provide warnings or reminders of dangerous
or potentially dangerous circumstances and wherever called for elsewhere in this
Specification.
f) Safety labels "Danger 415 V” in both English and Hindi shall be provided on both the
front and rear of the Electrical Panels. The safety labels shall have graphic symbols
exactly as per IS standards. The design of all such signs shall be submitted for approval.
Similar labels shall be provided for other panels at different voltages.
g) Labels shall not be less than 45 mm high. Lettering shall be of not less than 10 mm
high. All labels shall be securely fixed to the panels by bolts and nuts.
h) Details of proposed inscription, including the English and Hindi wordings, and samples
of the labels shall be submitted for approval before any labels are manufactured.
i) Circuit labels, one on the front of the panel and one on the rear of the panel suitably

engraved.
1.13 FOUNDATION (IF REQUIRED) AND INSTALLATION

1.13.1 The location of each foundation shall be correctly set out in accordance with the
approved foundation layout drawing. Base channels shall be grouted, levelled in cement
concrete pad for switchgear and other cubicle panels, etc. with reference to a bench
mark in the building. Pedestal type panels and superstructures shall be erected by
grouting foundation bolts into the foundation in cured holes left in foundation blocks. For
concreting on existing floors, a proper bonding surface shall be made by chipping the
floor. The final finish to the surface of the floor shall be given after all equipment has
been installed. If floor is broken for installation of equipment, it shall be restored to
original finish after completion of installation.
1.13.2 The concreting shall be done in accordance with the provision of Indian Standard Code
of Practice for Plain and Reinforced Concrete, IS 456-2000. Concreting IS: 383-1970
Specification for coarse and fine aggregates from natural sources for concrete IS: 269-
1989 Specification for 33 grade ordinary Portland cement IS: 516-1959 Method of test
for strength of concrete
1.13.3 Suitable grooves or niches shall be provided in the foundation block at the time of
casting to enable embodiment of earth strips without calling for chipping of the blocks.
Subsequently conduits of appropriate size shall be embedded in the foundation blocks
for cabling, in the first instance, wherever required.
1.13.4 All foundations shall be cast in the presence of the Employer's representatives. All
foundation and grouted bolts shall be cured for a minimum period of 48 hrs.
1.13.5 Foundations shall be prepared as per manufacturers drawing, shall be levelled, checked
for accuracy and the switchboards installed. Busbar connections shall be checked with
a feeler gauge after installation. Tightness of accessible bolted bus joints shall be
checked using calibrated torque wrench. Sealing of cable and boxes to prevent moisture
entry shall be checked. Switchboard earth bars shall be connected to the earth grid.
1.13.6 Fabrication drawings of all panels shall be approved by the Employer's representative
before fabrication
1.13.7 The Electrical Panels shall be installed in the locations as approved by the Engineer-In
charge. Electrical Panels shall be secured, plumbed and levelled and in true alignment
with related adjoining work,
1.13.8 The rigid galvanized U-channels with adjustable levelling screws to ensure effective
fixing of the Electrical Panels on the uneven floor shall be provided.
1.13.9 Anchor bolts and anchorage items shall be provided where required and field checked
to ensure proper alignment and location. Templates, layout drawings, and supervision
on Site shall be provided to ensure correct placing of anchorage items in concrete.
1.13.10 Supporting members, fastenings, framing hangers, bracing, brackets, straps, bolts,
angles, shall be installed as required to set and rigidly connect the work.
1.13.11 Temporary bracing, gauge, or other devices shall be provided as required to
accomplish erection and to provide safety and stability until the ELECTRICAL PANELS
is in its final and approved position.
1.13.12 Erection tolerance requirements shall be controlled so as not to impair the strength,
safety, serviceability, or appearance as Approved.
1.13.13 After installations are complete, all places where the shop applied coating is abraided,

all bare steel, including bolts, nuts, washers, and welds shall be thoroughly cleaned.
Each item shall be painted with the same paint as used for shop coating in the
corresponding location.
1.14 OTHER PROVISIONS
1.14.1 The Electrical Panels shall be provided with all necessary cable lugs etc., fixed in
positions on mounting plates and straps, to suit the types and directions of entry of the
cables as shown on the Drawings or as specified.
1.14.2 Cable conductors for all circuits within the Electrical Panels shall be arranged in a tidy
manner and mechanically secured at regular intervals such that any movement
occurring to the conductors, either under normal operation conditions (e.g. thermal
expansion, vibration, etc.) or due to short circuit in any one of the circuits, shall not
cause any damage or short circuit to any healthy bare live parts in the Electrical Panels.
1.14.3 Each Electrical Panels shall be supplied complete with all operating handles, jigs, etc.
required for the normal charging, closing, opening, racking in and out operations of all
circuit breakers of the Electrical Panels and shall be properly fixed in a neat manner on
a board with brass hooks inside the switch room / plant room where the Electrical
Panels is installed.
1.14.4 Each Electrical Panels shall be provided with insulating mats of ribbed surface,
complying to IS 15652, laid in front of and at the rear of the switch board. The rubber
mats shall be continuous sheets of minimum thickness as per IS, each of same length
as the switchboard and minimum width of not less than 1000 mm or the width of the
space between the fronts or back of the switchboard to the adjacent wall.
1000 mm wide of required length as required for applicable voltage or as per approval
of Engineer-Incharge.
During factory acceptance test it must be ensure that time between vulcanization and
testing shall not exceed 2 months or at the most 3 months as per codal requirement, for
product test.
1.15 SPECIAL CONDITION:

1.15.1 The Switchboard shall be complete with all components and accessories, which are
necessary or usual for their efficient performance and satisfactory maintenance under
the various operating and atmospheric conditions. Such parts shall be deemed to be
included within the scope of supply whether specifically included or not in the
specifications or in the tender schedules. The contractor shall not be eligible for any
extra charges for such accessories etc.
1.16 RELIABILITY, MAINTENANCE, SPARES AND LIFE
1.16.1 The electrical panel shall be designed for reliable and safe working. It shall be designed
for a maintenance free secure service life of switchboards, sub-assemblies and
components for at least 30 years.
1.16.2 The manufacturer shall submit the list of spares which are required to be replaced as a
must change item along with interval.
1.17 MATERIAL AND MANUFACTURING:
1.17.1 All similar items of the Electrical Panels and their component interchangeable. Spare
parts shall be manufactured originals and shall fit all similar items of the Electrical
Panels. Where machining may be needed before fitting renewable parts, the machining
fits and the associated tolerances shall be shown on the drawings accompanying the
instruction manuals.

1.17.2 All parts which are susceptible to wear or contaminated by dust shall enclosed in dust-
proof housings.
1.17.3 The style and finish of the workmanship shall be consistent throughout the Works.
Unless otherwise specified, Engineer-In charge shall decide the final colours for all paint
work and other finishes to be applied to the Electrical Panels.
1.18 TESTING
1.18.1 The firm shall submit valid type test not more than 5 years old of the equipment
conducted at accredited / authorised / reputed / nominated by DMRC laboratory.
The type test shall be as per the governing specification.
1.18.2 DMRC will carry out Routine and factory acceptance tests as prescribed in the
specification with following additional test
1.18.3 The manufacturer shall not change the Bill of Material used in the manufacturing of
samples used for Type testing. In case the bill of material is changed then Engineer-in
charge may ask for the repetition of those type tests which he considers relevant.
1.19 INDICATIVE LIST OF ITEMS TO BE INCLUDED IN FAT PLAN FOR ELECTIRCAL
PANELS
(This list is an indicative List for the inspectors to be conducted during FAT of Power
Panels. However, the detailed FAT plan needs to be developed for the specific Panel
based on approved GADs and Contract Specifications and as per the tests defined in
Clause – 11 of IEC 61439 -1 (Routine Verification) / as per the relevant Standards as
applicable.)
S. Description Type of Check Remarks
No
GENERAL
A All items / components Visual Check & Obtain confirmation
(switchgears, cables, wires, meters, Certification before from Panel
relays etc.) used are as per the Call letter Manufacturer for
Approved Makes, Vendors and each Panel duly
ratings. verified by the Main
B Obtain the Factory Test reports of Verify Contractor.
Incoming / Raw Material
C Obtain the Internal Test reports / Review
Manufacturer Test Report of Internal
Quality Tests done on Panel offered
for Inspection as per ISO 9001.
D Confirmation from Panel For record
Manufacturer that Panel has been
manufactured strictly as per
approved GADs.
E List of tools required for Inspection Check for Validity
and copy of their Calibration
Certificates from independent Labs /
Authorities.
Note: All the above are to be made part of
this FAT report
Panel must be of Modular
construction as per PS. The
Inspection team shall carry the
approved GAD, approved Bill of
materials, Contract Specification,

relevant standards, copy of

Approvals and approved FAT Plan
from the office before proceeding for
the FAT inspection to the factory
promises.
Physical / Dimensional Checks (as per approved GADs).
1 Check the Length, Breadth and Measurement
Height of the complete Panel.
2 Check dimensions of each Sections Measurement
and Cubicles.
3 Check Number and dimensions of Measurement
Space for future additions as per
Specifications & BOQ.
4 Check dimensions of the Doors / Measurement
back Panels, etc. (Note: Back Panel
sections should not be too bulky to
handle by one individual. May be
taken care during GAD and checked
during FAT).
5 Check height / dimensions of all Measurement
front Mounting Accessories (such as
indicators. Measuring instruments,
knobs, etc.)
5.1 EPB (Emergency Push Button) at Measurement
1300 mm where applicable.
5.2 All Relays & indicating instruments Measurement
between 300 to 1800 mm
5.3 Max. Operating Height should not be Measurement
more than 1800 mm
5.4 Blank Space between the Floor of Measurement
Switch board and bottom unit (Min.
200 mm or as per PS)
6 Check size / height of Base Frame Measurement
(may be min. 100 mm. or as per PS).
6.1 The make of the manufacturer of
bought out items is clearly displayed
on the items where possible.
6.2 Check that all materials used in the
manufacturing of the electrical panel
are fire retardant, low smoke & low
halogen.
7 Verify Material and Thickness of
Certificate /
Load bearing and Non-Load Bearing
Member of Panel Enclosure: Measurement
7.1 Panel Structure
7.2 Bus bar Section
7.3 Cable Alley
7.4 Switchgear / feeder sections
7.5 Doors
7.6 Gland Plate
8 Check Quality of Sheet Metal Visual /
Painting and Colour used. It should Measurement
be as per the Specification /
Approved drawings.

9 Check for the Quality of Sheet Metal Visual

Workmanship. There shall not be
any sharp edges, burrs, dents, etc.
on the panel.
10 Check Number and Quality of the Visual
Door Hinges. Ensure that doors are
strongly supported and should not
have any unwanted deflection /
shakiness. When door is closed, it is
latched at adequate places with
adequate crushing of gasket on
metal frame.
11 Check Quality of the Door handles, Visual
Locks etc.
12 Check interlocking of Doors, Verify and Visual
Switchgears, incomers, outgoings Check
and couplers as per the design logic
and drawing
13 Check and compare the sealing Verify and Visual
arrangements all around the panel to Check
ensure intended ingress Protection is
achieved and compare with the Type
test reports.
13.1 Simple Paper insertion test for IP54.
Insert a paper in the gasket and
metal frame, close the door and pull
the paper. It should not pull out.
13.2 Check Quality of Gaskets / sealing
rubber, etc. for the Doors. The
arrangement shall be such that it is
replicable during maintenance.
13.3 Check Quality of Gaskets / sealing
rubber, etc., around the cut-outs for
Measuring & indicating instruments,
Switchgears, Relays etc.
13.4 Proper sealing of knock-outs / cut-
outs / gaps for control cabling bus
bar, etc., between different feeders /
sections within the Panels.
14 Check the Lifting arrangements Visual
(Hooks etc.) are provided.
14.1 Adequate Number of Lifting points /
Hooks
14.2 Adequate Strength of Lifting Points /
Hooks
15 Check proper identification Visual
markings, numbering labelling, tags
have been provided.
15.1 For the Panel
15.2 For each incoming and Outgoing
Feeders
15.3 For Measuring and indicating
instruments
15.4 Danger Plates / Signages

16 Visual
Check for rust, any sign of initiation
of corrosion, oxidation, etc., on the
support members / nut bolts / bus
bars / terminal points, etc. Initiation
is an indication of use of defective
material.
CABLE ALLEYS
1 Check for Cable Entry Arrangement Visual
(top entry / Bottom entry) as per
GADs.
2 Check for Maintenance / Working Visual /
space in Cable Alleys, etc. Measurement
3 Check for adequate Space for Visual /
accommodating Cable Loops, etc. Measurement
4 Provision for securing / clamping Visual
cables in Cable alley for proper
dressing of cables.
5 Check for Knock outs for Glanding of Visual
different smaller sizes of Cables in
Marshalling box (to be used for BMS
/ SCADA cables).
6 Thickness of Glanding Plates should Measurement
be minimum 5.0 mm & strong
enough to take the simultaneous
load / forces of cables glanded on
to it. The Cables shall be well
supported and not exert any force on
the glanding plate
7 Proper dressing / harnessing of Visual
internal control cables and wiring
within the Panel.
8 Provision of identification tags / Visual
ferrules on the internal control cables
and wiring within the Panel.
EARTHING ARRANGEMENT
1 Check that Material of Earth Bus Visual
provided in Panel is as per PS.
2 Check the Size of continuous Earth Measurement
Bus provided in the Panel as per IEC.
3 Check if the Earth Bus is properly Visual
supported and connected to the
outside terminals.
4 Check that proper earthing has been Visual
provided throughout the Panel and
all non-current carrying parts are
properly earthed.
5 All the Gland plates have been Visual
earthed properly
6 All Doors and openable sections Visual
must be earthed through flexible
wires / jumpers (dual if required as
per Specs)
7 Cases of all instruments and Visual

apparatus shall be earthed by a

conductor of suitable size (but not
less than 2.5 sq. mm)
8 Visual
Check that the Frame of Switchgear
is earthed, when racked in to the
Cubicle.
BUS BAR SECTION
1 Check Bus bar dimensions as per Measurement
Approved GAD (Only rectangular
Busbar is permitted)
2 Neutral bus shall be of full size Measurement
3 Material of the busbar shall be as per Visual /
approved specification Certificate
4 Quality (Conductivity) of the Material Certificate /
of the busbar (Copper / Aluminium) Measurement
shall be as per approved
specification
5 Check the quality of conducting Certificate /
material used for Bus bar and the Measurement /
Quality of Tinning on the Aluminium Visual
/ Copper Bus bar.
5.1 Factory tinned Bus bars to be used.
Obtain the Factory Test certificate
and attach the report.
5.2 Tinning of Bus Bar edges after
cutting / sizing also to be checked.
6 Check that the Bending of Bus Bars Confirmation &
should be on Rollers of adequate Cross-Check
diameter to avoid undue bending
stresses
7 Check the fixing / mounting Visual
arrangements of Main bus bar to
ensure that there are no undue
stresses due to misalignment of
fixing arrangements. (Focus on the
location where Panel is divided in to
different sections to ensure that the
Bus Bar sections match properly).
7.1 Check the proven design of bus bar
connections of OEM & its
compliance in the manufactured
product
8 Bus bar must be color coded for Visual
Phase identification
Note: In case, sleeve is to be
provided over the Bus bar for color
coding as per PS, then the material
of the sleeve must be as per the
relevant clauses of PS.
9 Check the distance between Bus bar Measurement
supports and compare with Type
tested assemblies / Approved
GADs.

10 Bus Bar Supports should be of Confirmation

approved material.
11 Measure minimum Electrical Measurement
clearances between the bus bars for
different Phases, Neutral and Earth.
(Main Bus as well as Tap off Bus
bars)
(Minimum clearance will be between
Live parts and Earth)
12 Check the interconnecting / Tap - Measurement
off links between Main Bus and bus
sections for proper tightness etc.
(connection with the double split cast
brass clamp is permitted)
13 Interconnection between Bus Bar Visual
and Switchgear - must be high
conductivity Copper Bar and must be
insulated and Colour coded
14 Proper compartmentation at Visual
locations where connecting Links
enter the Switchgear section, bus bar
sections and Cable Alley must be
ensured.
(Form - 4 b, Type - 5 to be ensured).
15 Proper Shrouding of Bus bar joints / Visual
tap off points to be ensured. Material
to be as per PS of the Contract.
16 Proper clearances and segregation Measurement
must be maintained between
Terminals / Tap - offs of different
feeders from Main Bus Bars.
INTERNAL WIRING, TERMINAL BLOCK
1 Check if the Wiring for all power and Verify Material Test
Control circuit is being provided as Certificate
per Approved GAD /
Specifications.
Note: - Internal Wiring in LT panels to
be FRLSH as per Specs for elevated
stations.
2 Termination arrangements
2.1 Terminal blocks should be of Non - Verify Material
Hygroscopic of Melamine
2.2 At terminal points - Plain and Spring Visual
Washers with electro - tinning to be
used
2.3 Check the tightness of wiring Visual
termination
2.4 Terminal should have test probe Visual
facility
2.5 All Live parts of Terminal blocks must Visual
be fully shrouded
2.6 Spare Capacity of Terminals Visual
2.7 Cable terminations should be with Visual
lugs of adequate size and with
proper crimping

2.8 No more than two wire to be Visual

connected to the Terminal
2.9 Terminals should have identification Visual
Labels.
2.10 All cables should have identification Visual
ferrules
2.11 Check if the adequate size of the Measurement
cables / wires is being used for the
control wiring
2.12 All the internal wiring shall be Visual
properly dressed and randomly
check the traceability of the wires
from the wiring diagram
2.13 Check Provision of Protection for Visual
Control wiring as approved
MARSHALLING BOX for BMS (if applicable)
1 Marshalling Box / Separate Visual
chamber for the BMS / SCADA
connection is provided as per the
Approved GAD
2 Check the BMS / SCADA points Visual
have been provided as per the
approved I / O schedule
3 Provision of Soft links points for the Visual
control shall be checked
4 Visual
All the terminals for the BMS /
SCADA shall be properly secured
and identification mark along with the
voltage level shall be provided
5 Randomly check voltage level at the Measurement
BMS / SCADA points for any
leakage voltage etc (at Potential free
contacts)
6 No power wiring / cable should pass Visual
through marshalling box
SWITICHGEARS, PROTECTIONS, INDICATIONS, ANNUNICATIONS AND
MEASURING INSTRUMENTS
1 Detailed Check list for these items of Factory Test
the Panel may be prepared based on Certificates and
the GADs / Contract Specifications Test during FAT
2 Test Certificates / Calibration Factory Test
Certificates for Measuring Certificates
instruments to be ensured
3 Check Surge Arresters (if applicable) Visual &
have been provided Manufacturer's
Test Reports
4 Separate CTs for Measurement and Visual &
Protection of relevant Class and Manufacturer's
Burden as per PS to be ensured Test Reports
5 Check Control Logics, Interlocks and Visual, Simulation,
Protections Schemes in detail as per Primary &
the approved plan / arrangement. Secondary
Injection etc

6 Check the working of Contractor Visual, Simulation,

based changeover and Controls Primary &
provided for safe operation. Secondary
Injection etc
MISCELLANEOUS
1 Check the lights, sockets, anti- Visual
condensation heaters and air
circulation means provided in the
Panels as per GADs.
2 All the Control and power wiring must Visual
per properly segregated.
3 Padlocks and interlock provision and Visual
Functions to be checked for the
safety for each.
4 Check for extendibility of the Panels Visual
(including Bus Bars) on either side.
5 Check provision of entry for Fire
Trace Tube and internally with in the
various cubicles and adequate
sealing arrangements.
6 Ensure that there are No Joints in the
cables used
7 The tests defined in Clause - 11 of
IEC 61439 - 1 (Routine Verification) /
as per the relevant Standards as
applicable are also to be performed
for which separate Test sheet may
be prepared.
8 The make of the manufacturers of
bought out items is clearly displayed
on the items where possible.
9 Check that all materials used in the
manufacturing of the electrical panel
are fire retardant, low smoke & low
halogen.

1.20 DATA SHEET

S.
Description Unit Values
No.
Length marking: Length shall be marked with number at one meter intervals on the
sheath.
*Bidder to furnish the data

2 MV CABLING
2.1 SCOPE
2.1.1 The Medium Voltage cables are used at an elevated station of the Delhi Metro for E&
M applications for power supply and control for various equipment. This specification
takes care of the design, manufacturing, testing and installation requirements of the
Cables. There are two types of cables namely PVC insulated as per IS: 1554 (Part-
1):1988 and XLPE insulated PVC sheathed as per IS 7098 (Part-1): 1988. XLPE cables
are generally used for power supply application and PVC insulated for control
application.
2.2 STANDARD
2.2.1 All equipment’s, components, materials and entire work shall be carried out in
conformity with applicable and relevant IS / BS / IEC Standards and Codes of
Practice. In addition relevant clause of Indian electricity act 2003 and Indian electricity
rule 1956 amended up to date shall apply.
2.2.2 It is to be noted that updated and current standards shall be applicable irrespective of
dates mentioned along with IS in the tender documents.
STANDARDS DESCRIPTION
IS:1554 (Part-I) – 1988 PVC insulated (heavy duty) electric cables: Part 1 For
working voltages up to and including 1100 V
IS:7098 Part-I 1988 Cross-linked polyethylene insulated PVC sheathed cables:
Part 1 For working voltage up to and including 1100 V
IS 1255 – 1983 Code of practice for installation and maintenance of power
cables up to and including 33 kV rating
IS 8130 – 1984 Conductors for insulated electric cables and flexible cords
IS 10418 –1982 Drums for electric cables
IS 10810 Methods of test for cables (All latest)
IS 3961 Recommended current rating for cables (All latest)
IS 5819 –1970 Recommended short circuit rating of high voltage PVC
cables
BS:7671 Requirements for electrical installations. IEE Wiring
Regulations
BS 4579 Specification for performance of mechanical and
compression joints in electric cable and wire.
BS 6121 Mechanical cable glands
IS 5831 PVC Insulation and sheath of electric cables.
2.2.3 All Codes and standards mean the latest. Where not specified otherwise the installation
shall generally follow the Indian standards / British Standards Codes of Practice / IEC
standards.
2.2.4 Cables up to size 10-sqmm conductor size shall be copper conductor & beyond size
10-sqmm shall be aluminium. All conductors shall be stranded.

2.3 ABBREVIATIONS
S. No. Abbreviation Description
1. FRLSH Flame Retardant Low Smoke and Halogen
2. FRLSZH Flame Retardant Low Smoke Zero Halogen
3. FS Fire Survival cable
4. GI Galvanized Iron
5. HV High Voltage
6. HT High Tension
7. LV Low Voltage
8. MV Medium Voltage
9. MS Mild Steel
10. PVC Poly-Vinyl Chloride
11. RCC Reinforced Cement Concrete
12. UPVC Unplasticised Poly Vinyl Chloride
13. XLPE Cross-Linked Polyethylene
2.4 TECHNICAL REQUIREMENTS

2.4.1 PVC Cables
2.4.1.1 Medium voltage cables shall be 1100 Volt grade aluminium / copper conductors, PVC
TYPE-C insulated, PVC sheathed with flame retardant low smoke and halogen
(FRLSH) compound and armoured conforming to IS: 1554 Part-l. Cables shall be rated
for 1100 Volts.
2.4.1.2 The insulation shall be of Type C PVC compound conforming to the requirements of
IS 5831.
2.4.1.3 The conductor of all cables shall be stranded. Sector shaped stranded conductors
shall be used for cables of 50-sqmm and above.
2.4.2 XLPE Cables
2.4.2.1 The cables shall be 1100 Volt grade XLPE insulated with PVC inner sheath, steel
armouring and with an outer protective sheath of flame retardant low smoke and
halogen(FRLSH) compound, conforming to IS: 7098 (Part I). Cables shall have high
conductivity stranded aluminium or copper conductors and cores colour coded to the
Indian Standards.
2.4.2.2 A common covering (bedding) shall be applied over the laid up cores by an extruded
sheath of unvulcanised compound. Armouring shall be applied over this extruded

sheath. The outer sheath shall be embossed the manufacturer's name, contact name,
DMRC monogram along with “DMRC” and trade mark at every one meter length.
Cores shall be provided with following colour scheme of PVC insulation
1 Core Red -RAL 3000 / Black-RAL 9005 / Yellow -RAL 1021 /
Blue-RAL 5015 and Green -RAL 6018
2 Core Red-RAL 3000 and Black-RAL 9005
3 Core(3-Phase) Red-RAL 3000, Yellow-RAL 1021 and Blue-RAL 5015
3 Core(1-Phase) Red-RAL 3000, Black-RAL 9005 Green-RAL 6018
3.5 / 4 Core: Red-RAL 3000 / , Yellow-RAL 1021, Blue-RAL 5015 and
Black-RAL 9005
The colour of the outer sheath shall be Black or as required by the Engineer-In charge.
2.4.3 Fire Survival Cable
All cables used for fire and life safety systems shall have a 3-hour fire survival capability.
These cables may be Special Fire Cables as per BS 7629. Mineral insulated or EPR
insulated with Glass Mica Taping or CWZ cables with special grade FRLSZH Inner and
Outer sheath and overall Steel Braiding. The Minimum withstanding Temperature of
Glass Mica Tape during fire should not be less than 950°C and shall be double layered.
(Manufacturer has to provide declaration on the usage of special mica tape of 950°C)
Cables shall be tested for fire survival duty and should pass all the fire tests as per BS:
6387-1994 and other relevant test certificates shall be furnished with each lot of supply.
2.5 DELIVERY, STORAGE AND HANDLING
2.5.1 Storage and handling shall conform to section 7 of IS 1255.
2.5.2 All cables shall be new without any kinks or damage, marked with contact name, DMRC
monogram along with “DMRC”, manufacturer's name, insulating material, conductor
size and voltage class on cable surface at every 1000 mm approx.
2.5.3 Cable drum conforming to IS: 10418 shall be stored on a well-drained, well-ventilated
area protected from sun and rain on hard surface, preferably of concrete, so that the
drums do not sink in ground causing rot and damage to the cable drum.
2.5.4 For transportation over long distance, the drums shall either be mounted on drum
wheels, trailers and pulled by ropes, unloaded preferably by crane and rolled down
carefully on suitable ramps. While transferring cable from one drum to another, the
barrel of the new drum shall have diameter not less than the original drum
2.6 INSTALLATION
2.6.1 While shortest practicable route shall be preferred, cable runs shall follow fixed
development such as roads, footpaths etc. with proper offsets so that future
maintenance and identification are rendered easy.
2.6.2 Whenever cables are laid along well demarcated or established roads, the LV / MV
cables shall be laid away from the line than HV cables.
2.6.3 Cables of different voltages and also power and control cable shall be kept in different
trenches with adequate separation. Where available space is restricted, LV / MV
cables shall be laid above HV cables.
2.6.4 Where cables cross one another, the cables of higher voltage shall be laid at a lower
level than the cables of lower voltage.
2.6.5 Power and communication cables shall be laid as far as possible, cross at right angles,
where power cables are laid in proximity to communication cables the horizontal and

vertical clearances shall not normally be less than 600 mm.

2.6.6 Cables shall be laid in the routes marked in the drawings. Where the route is not marked,
the contractor shall mark it out on the working drawings after deciding in consultation
with Engineer-In charge. Cables shall be laid in masonry trenches, directly on walls /
ceiling, inside shafts / cable trays, directly buried in ground or in pipes / ducts as
elaborated below. Cables of different voltages and also power and control cables shall
be laid, in different trenches with adequate separation. Wherever available space is
restricted such that this requirement cannot be met, medium voltage cables shall be
laid above HT cables as approved.
2.6.7 Cables shall be so laid that the maximum bending radius is 12 times the overall diameter
of the cable for medium voltage cables and 15 times the overall diameter for 11 kV
cables or in accordance with the manufacturer's recommendations whichever is higher.
2.6.8 In the case of cables buried directly in ground, the cable route shall be parallel or
perpendicular to roadways, walls etc. Cables shall be laid in an excavated, graded
trench, over a sand or soft earth cushion to provide protection against abrasion. Cables
shall be protected with brick or cement tiles as route shown on Drawings. Width of
excavated trenches shall be as per code of practice and drawings.
2.6.9 The general arrangement of cable laying shall be as per drawings. All cables shall be
full runs from panel to panel without any joints or splices.
2.7 CABLES LAID IN MASONRY TRENCHES
2.7.1 Wherever so specified, cables shall be laid in indoor / outdoor masonry / RCC
trenches with chequered plate / RCC covers to be provided by contractor. Cables shall
be laid on GI supports of approved design grouted in trench walls at intervals not
exceeding 600 mm. If required, cables shall be arranged in tier formation inside the
trench. Cables shall be dressed properly so that the clear spacing between the cables
shall not be less than the diameter of the cable. Suitable clamps, hooks and saddles
shall be used for securing the cables in position. Complete details of this support work
shall be shown in working drawings to be prepared by the Contractors and submitted
for approval of Engineer-In charge before execution. Works shall be carried out only as
per approved working drawing. Wherever so specified, trenches shall be filled with fine
sand.
2.8 CABLE LAID ON TRAYS / WALLS
2.8.1 Where numbers of cables are run, necessary perforated hot dipped galvanized cable
trays shall be provided wherever shown. Ladder cable trays shall be galvanized MS as
specified in the BOQ.
2.8.2 After laying and securing the cables in a cut-out, suitable water tight sealant shall be
applied as per requirement to prevent any ingress of water.
2.8.3 Cables shall be secured in position and dressed properly by means of suitable clamps,
hooks, saddles etc. Clamping of cables shall be at minimum intervals as below:
Type of Cables Size Clamping by Fixing
intervals
MV Up to and including Purpose made, approved 300 mm
25-sqmm flame retardant nylon 66
cable ties, flammability of
MV&HV 35-sqmm to 120- UL 94 V-0* 300 mm
sqmm
MV&HV 150-sqmm and SS 316 self locking type 300 mm
above of 0.2 mm thickness
having width of 12 mm#.

Note: 1. The fixing intervals specified apply to straight runs. In the case of bends,
additional clamping shall be provided at 30 cm from the centre of the bends on both
sides.
2. *- Tensile strengths as per SAE AS 3367.
3. # -Tensile strength of 210kg / sqmm………………...
2.9 BURIED DIRECTLY IN GROUND

2.9.1 Cables should be so laid that they will not interfere with underground structures.
2.9.2 All water pipes, sewage lines or other structures which become exposed by excavation
shall be properly supported and protected from injury until the filling has been rammed
solidly in places under and around them. Cables shall be laid and protected at such
locations.
2.9.3 Any telephone or other cables coming in the way are to be properly shielded as directed
by Engineer-In charge.
2.9.4 Surface of the ground shall be made good so as to conform in all respects to the
surrounding ground to the satisfaction of Engineer-In charge.
2.10 ROUTING OF THE CABLE RUNS
2.10.1 Before cable laying work is undertaken, the route of the cables shall be decided in
consultation with Engineer-In charge.
2.10.2 While shortest practicable route shall be preferred, cable runs shall follow fixed
development such as roads, footpaths etc. with proper offsets so that future
maintenance and identification are rendered easy.
2.10.3 Whenever cables are laid along well demarcated or established roads, the LV / MV
cables shall be laid further from the kerb line than HV cables.
2.10.4 Cables of different voltages and also power and control cables shall be kept in different
trenches with adequate separation. Where available space is restricted, LV / MV
cables shall be laid above HV cables.
2.10.5 Where cables cross one another, the cables of higher voltage shall be laid at a lower
level than the cables of lower voltage.
2.10.6 Power and communication cables shall as far as possible cross at right angles. Where
power cables are laid in proximity to communications cables the horizontal and vertical
clearances shall not normally be less than 600 mm
2.11 WIDTH OF TRENCH
2.11.1 The width of trench shall be determined on the following basis:
a) The minimum width of masonry trench for laying single cables shall be 350 mm or as
specified in BOQ.
b) Where more than one cable is to be laid in the same trench in horizontal formation, the
width of trench shall be increased such that the inter-axial spacing between the cables
except where otherwise specified shall be at least one cable diameter.
2.11.2 There shall be a clearance of at least 150 mm between axis of the end cables and the
sides of the trench.
2.11.3 The space between multiple cables laid in same trench shall be laid as prescribed by
the manufacturer of the cable or as recommended in standards.

2.12 DEPTH OF TRENCH

2.12.1 Where cables are laid in single tier formation, in ground the total depth of the trench
shall not-be less than 750 mm for cables up to 1.1 kV and 1250 mm for cables above
1.1 kV. When more than one tier of cables is unavoidable and vertical formation of laying
is adopted, the depth of trench shall be increased by 300 mm for each additional tier to
be formed.
2.13 EXCAVATION OF TRENCHES IN GROUND
2.13.1 The trenches shall be excavated in reasonably straight lines. Wherever, there is a
change in direction, suitable curvature of 12 times the overall diameter of the largest
MV cable and 15 times the overall diameter for 11·kV LT cable shall be provided. Where
gradients and changes in depths are unavoidable, these shall be gradual. Excavation
should be done by any suitable manual or mechanical means. Excavated soil shall be
stacked firmly by the side of the trench such that it may not fall back into the trench.
2.13.2 Adequate precautions shall be taken not to damage any existing cables, pipes or other
such installations during excavation. Wherever bricks, tiles or protected covers or bare
cables are encountered, further excavation shall not be carried out without the approval
of the Engineer-In charge. The Contractor shall use a cable detector along the route of
excavation and identify existing live cables along the route and exercise caution during
excavation.
2.13.3 Existing property exposed during trenching shall be temporarily supported or propped
adequately as directed by the Engineer-In charge. The trenching in such cases shall be
done in short lengths, necessary pipes laid for passing cables therein and the trench
refilled as required. If there is any danger of a trench collapsing or endangering adjacent
structures, the sides shall be well shored up with timbering and / or sheathing as the
excavation proceeds. Where necessary these may even be left in place when backfilling
the trench.
2.13.4 Excavation through lawns shall be done in consultation with the Engineer-In charge.
Bottom of the trench shall be level and free from stone, brick, etc. The trench shall be
provided with a layer of clean dry sand cushion of not less than 80 mm in depth before
laying of cables.
2.14 LAYING OF CABLE IN TRENCH IN GROUND
2.14.1 The cable drum shall be properly mounted on jacks or on a cable wheel at a suitable
location. It should be ensured that the spindle, jack etc. are strong enough to carry the
weight of the drum without failure and that the spindle is horizontal in the bearing so as
to prevent the drum creeping to one side while rotating.
2.14.2 The cable shall be pulled over rollers in the trench steadily and uniformly without jerks
or strains. The entire cable length shall, as far as possible, be laid in one stretch.
However, when this is not possible the remainder of the cable shall be removed by
flaking i.e. making one long loop in the reverse direction.
2.14.3 After the cable is uncoiled and laid over the rollers, the cable shall be lifted slightly over
the rollers beginning from one end by helpers standing about 10 meters apart and drawn
straight. The cable should then be taken off the rollers by additional helpers lifting the
cables and then laid in the trench in a reasonably straight line.
2.14.4 For short runs and cable sizes up to 50-sqmm 1.1 kV grade, the alternative method of
direct handling can be adopted with the prior approval of the Engineer-In charge. If two
or more cables are laid in the same trench, care should be taken to preserve relative
position. All the cables following the same routes shall be laid in the same trench.
Cables shall not cross each other as far as possible. When the cable has been properly
straightened, the cores shall be tested for continuity and insulation resistance. The

cable shall be measured thereafter.

2.14.5 Suitable moisture sealing compound tape shall be used for sealing of the ends of cables
laid in the trench. All the cables remaining in drums after laying shall be sealed in a dust
and moisture proof manner.
2.14.6 The trench shall be provided with a layer of clean dry sand cushion of not less than 80
mm in depth before laying of cables. Cable laid in trenches in a single tier formation
shall have a covering of clean dry sand of not less than 170 mm above the base cushion
of sand before the protective cover is laid. If additional tiers are formed each of the
subsequent tiers also shall have a sand cushion of 300 mm and the top most cable shall
have a final sand covering not less than 170 mm before the protective cover is laid. A
final protection to cables shall be laid to provide warning to future excavators of the
presence of the cable and also to protect the cables against accidental mechanical
damage. Such protection shall be with second class bricks of not less than 225 mm x
100 mm x75 mm (normal standard size) laid breadth wise for the full length of the cable
to the satisfaction of the Engineer-In charge. Where more than one cable is to be laid
in the same trench this protective covering shall cover all the cables and project at least
50 mm over the sides of the end cables. In addition bricks on edge shall be placed along
the entire run on either side of the cable run.
2.14.7 The trenches shall then be back filled with excavated earth free from stones or other
sharp edged debris and shall be rammed and watered in successive layers not
exceeding 300 mm. Unless otherwise specified a crown of earth not less than 50 mm
in the center and tapering towards the side of the trench shall be left to allow for
subsidence. The crown of earth should however not exceed 100 mm so as not to be a
hazard to vehicular traffic.
2.14.8 Where road berms or lawns have been cut or kerbstones displaced the same shall be
repaired and made good to the satisfaction of the Engineer-In charge and all surplus
earth and rocks removed to places as specified.
2.15 ROUTE MARKERS
2.15.1 Route markers shall be provided along straight runs of the cables at locations approved
and generally at intervals not exceeding 25 meters. Markers shall also be provided to
identify change in the direction of the cable route and also for location of every
underground joint.
2.15.2 Route markers shall be made out of 100mm x 100mm x 5mm GI / aluminium plate
welded or bolted onto 35 mm x 35 mm x 6 mm angle iron 600 mm long duly painted
with anti-corrosive paint / embossed. Such plate markers shall be mounted parallel to
and 300mm or so away from the edge of the trench / pipe / duct, or as directed at
site.
2.15.3 Plastic identification tags shall be provided at every 30m. Cables shall be identified at
end terminations indicating the feeder number and the Panel / Distribution board from
where it is being laid.
2.16 LAYING IN PIPES / CLOSED DUCTS
2.16.1 In locations such as road crossings, entry to buildings / poles in paved areas etc.
cables shall be laid in pipes or closed ducts. Spun reinforced concrete / GI pipes or
UPVC ducts shall be used for such purposes and the pipe shall not be less than 100
mm in diameter for a single cable and not less than 150 mm for more than one cable.
These pipes shall be laid directly in ground without any special bed. Unless otherwise
specified the top surface of pipes shall be at a minimum depth of 1000 mm from the
ground level when laid under roads, pavements etc.
2.16.2 The pipes for road crossings shall preferably be on the skew to reduce the angle of

bend as the cable enters and leaves the crossing. Pipes shall be continuous and clear
of debris or concrete before cable is drawn. Sharp edges at ends shall be smoothened
to prevent injury to cable insulation or sheathing.
2.17 LAYING OF CABLES IN FLOORS
2.17.1 Laying of cables directly in floors shall be avoided and GI pipes of adequate size shall
be used wherever necessary. However, if the cables have to be laid direct in the floor
specific written approval of Engineer-In charge shall be obtained and the Contractor
shall cut chases, lay the cables and make good the chases to original finish.
2.18 CABLE ENTRY INTO BUILDINGS
2.18.1 Cable entry into buildings shall be made through RCC pipes recessed in the floor. RCC
Hume pipes shall be provided well in advance for service cable entries. The pipe shall
be filled with sand and sealed at both ends with bitumen mastic to avoid entry of water.
Suitable size manholes shall be provided wherever required to facilitate drawing of
cables as per requirements. The Contractor shall submit a written request to Engineer-
In charge for inspection of following works for cabling:
a) On excavation and provision of sand bed at bottom of trench
b) On laying of cables, and provision of sand bed over the cables
c) On provision of protective cover & back filling
d) On commencing termination of cable
2.18.2 These requests shall be serially numbered and shall be in an approved format out of
one or two formats to be submitted by the Contractor.
2.19 CABLE LOOPS
2.19.1 At the time of the installation approximately 3 meters of surplus cable shall be left if the
cable laid below ground otherwise 1 meter loop should be left where cable is laid on
tray / beam / support as below or as directed by Engineer-In charge
a) at each end of the cable
b) on each side of underground straight through / tee / termination joints
c) at entries to buildings
2.19.2 This cable shall be left in the form of a loop. Wherever long runs of cable length are
installed cable loops shall be left at suitable intervals as specified by the architect /
clients.
2.20 TERMINATION / JOINTING OF CABLES
2.20.1 All cable terminations should be nut-bolt type; irrespective of the cable size and shall
have tinned copper / Aluminium / bimatelic compression lugs as required. The end
terminations shall be insulated with a minimum of six half-lapped layers of PVC tape.
Cable armouring shall be bonded at both ends.
2.20.2 Soldered jointing / termination shall be totally avoided. Solder-less terminations by
using crimping tools, suitable lugs and double compression brass glands shall be used.
In the case of aluminium conductors, it is to be ensured that the conductor oxidation is
cleaned by means of emery paper and then a thin coat of tin is applied before
termination.
2.21 MATERIAL AND MANUFACTURING
2.21.1 The material used in the manufacturing shall not deviate from the one used in the
manufacturing of sample piece of which the type test results submitted for vendor
approval.

2.21.2 The routine and acceptance test result shall not vary widely as compared to the type
test results.
2.21.3 The manufacturers shall be able to demonstrate to the inspecting official the sourcing
of material and process as per the system described in ISO document for continuous
quality control.
2.22 TESTING
2.22.1 Type test results as per the relevant standards mentioned herewith, and not more than
five-year-old shall be submitted along with the vendor approval request. In case the
Engineer-In charge so desires, a repeat of the type test from the accredited lab may be
asked for.
2.22.2 FRLSH, PVC insulated Cables shall be subjected to type tests and acceptance test as
per IS: 1554 Part-1 1988 carried out in accordance with appropriate parts of IS: 10810.
2.22.3 FRLSH, XLPE cables shall be tested as per IS: 7098 Part-1 and IS: 10810.
2.22.4 Acceptance Test for XLPE and PVC shall be carried as per the proforma given at
annexure A1 and A2 respectively of Paragraph 2.37 of this specification. The prescribed
values as per relevant IS and type test results as available on record shall preferably
filled by inspecting official before the inspection.
2.22.5 Test at Site after receipt and installation shall be carried out as per the proforma given
at annexure B. All type, acceptance and site test readings records shall form part of the
completion documentation. Underground Cable routes shall be got verified with the help
of cable detector.
2.22.6 Third Party Tests
2.22.6.1 During the execution stage, DMRC may conduct the Test on any type of fixture from
third party independent lab at its own cost, to ensure the quality of material supplies.
If any of the samples fail in the test, the cost of the test along with the complete
replacement of whole lot shall be borne by the Contractor.
2.22.6.2 If contractor represents, two random samples from the failed Lot shall be collected by
the contractor in the presence of DMRC representative and after duly sealing the
samples will be send to two different NABL accredited labs ( as approved by Engineer
Incharge) for conducting all those re-tests, which were conducted on the failed sample.
Cost of the testing including the collection of sample and transportation of sample will
be borne by the contractor.
2.22.6.3 If both the samples pass all the Tests, supplied lot will be deemed as accepted by
DMRC, but in case of failure of any of the samples collected by the contractor,
complete lot will be deemed as rejected and contractor will replace the whole Lot.
2.22.6.4 The delay, if any for the procurement of the replacement material due to failure, shall
be considered as non-compliance and applicable penalty shall be imposed on the
contractor.
2.23 CABLE TRAYS
2.23.1 Cable trays of sizes as per BOQ and drawings shall be of doubled bend channel design
unless otherwise stated. Cable trays shall be fabricated from minimum 2±0.02 mm thick
as per IS 1852, perforated hot dip galvanised sheet steel and shall be complete with
tees, elbows, risers, and all necessary hardware. Cable trays shall be hot dipped
galvanized as specified. Cable trays shall be erected in perfect level. Perforation should
not more than 17.5%. Galvanization shall be provided minimum 460 gm / sq. meter
coating thickness on all sides as per IS 4759. Galvanization surface shall be free from
blisters, roughness, sharp points and un-coated areas, flux residues, lumps and zink

ash.
2.23.2 The Cable tray / Ladders shall be fabricated according to the design specified by IEC
/ BS EN 61537 and should be tested for Safe Working Load (SWL). The relevant
details of SWL and Load chart with respect SWL, supporting distance and the deflection
should be according to IEC / BS EN 61537. Cable tray shall be hot dip galavanized.
Galvanized shall be confirm to IS 2629 & Zinc coating shall be confirming to IS 4759.
2.23.3 Widths of cable trays, thickness of steel, flanges of trays, and bends or tees, shall be
nominally as follows:
Width of Tray (mm) Thickness of Steel (mm) Flanges of Tray (mm)
300 & below 2.0 50 / 40
300-450 2.0 50 / 40
450-900 2.0 50 / 40
1000 2.0 50 / 40
Cable Tray Covers 1.6 20 / 10
2.23.4 Trays shall not have sharp edges, burrs or projections injurious to cable insulation.
Trays shall include fittings such as bends, risers etc. for changes in direction and
elevation. Each run of cable tray shall be completed before laying of cables. Cable trays
shall be exposed and accessible. All bends & tees should be factory made.
2.23.5 Trays shall be supported adequately at minimum 1 m distance from the building
structure by means of painted / galvanized (as specified) MS structural members
secured to the structure by dash fasteners or by grouting. This support should be
capable of withstanding the weight equivalent to 3 m length of the cables that can be
laid in the trays. Both ends of the bend and every turns the support has to be double.
The entire cable tray system shall be rigid. Cost of support arrangement shall be
included in the rates quoted for supply and installation of trays. Complete details of this
support arrangement shall be shown in working drawings to be prepared by the
Contractors and submitted for approval of Employer's representative before execution.
Works shall be carried out only as per approved working drawing. Minimum support
should be 40 X 40 X 5 mm GI angle. No customization (Cutting) is allowed at site for
installation of galvanized items like cable tray, angle, support etc or as approved by
Engineer-In charge. Anchor fasteners of suitable size to be provided.
2.23.6 All nut bolts shall be SS 304 for cable tray.
2.23.7 All bends and tees shall be used as factory made to the extent possible. In case of any
deviation; the same shall got approved by the Engineer-In charge before use.
2.23.8 Cable tray shall be required to be marked for identification as approved by Engineer-In
charge / employer’s representative.
2.24 CABLE TRAY EARTHING
2.24.1 Each Cable Tray joint shall have tinned copper / GI bond bolted to each adjacent tray
to ensure electrical continuity.
2.25 Termination
2.25.1 The terminating kits shall be suitable for termination of the cables on an indoor
switchgear or equipment. These shall be of proven design and shall be type-tested as
per relevant Indian or International Standards. Type test certificates shall be submitted.
The cable and wire terminations shall avoid any possibility of loose joint and wire
snapping. Cable conductor termination shall be by means of a heavy-duty solder less

cable lug for terminating aluminium cable to copper busbar or vice-versa. The lug shall
be of high conductivity copper, electro- tinned and applied to the conductor by means
of a hydraulic crimping tool. All such crimping should meet the requirements of BS 4579.
2.25.2 The cable sheath shall be clasped by means of a gland of compression type based on
BS 6121 or equivalent Indian standard with a compression washer, which will hold the
cable sheath securely. A cable shroud shall be fitted to cover the body of the
compression gland.
2.25.3 All wires shall be terminated with an approved type of connector.
2.26 CABLE GLANDS AND ACCESSORIES
2.26.1 Non-Armoured Cables
2.26.1.1 All cable glands and accessories shall be approved to BS 6121 or equivalent Indian
standard.
2.26.1.2 The cable glands shall have a watertight seal when fitted to a cable.
2.26.1.3 Each cable gland shall be supplied with a brass gland locknut and a flame retardant
low smoke halogen free outer gland shroud. The shroud shall totally enclose the gland
body and form an effective seal against the cable sheathing.
2.26.1.4 The Gland shall be flame proof.
2.26.2 Armoured Cables
2.26.2.1 All cable glands and accessories shall be approved to BS 6121 or equivalent Indian
standard.
2.26.2.2 The cable glands shall have a watertight seal when fitted to a cable.
2.26.2.3 Cables shall be terminated in a gland fitted with an armour clamp and an earth tag.
The gland body shall be provided with an internal conical seal to receive the armour
clamping cone, and a clamp nut, which shall secure the armour-clamping cone, and
conical armour seal. The spigot of the gland body shall be threaded to suit standard
conduit accessories. A flame retardant low smoke halogen free shroud shall be fitted
to cover the gland body.
2.27 CABLE TIES
2.27.1 Nylon 66 cable ties shall be flame retardant and ultra violet resistant with flammability
rating of UL 94 V0 and loop tensile strength as per SAE AS 3367. Following certicate
to be provided : a) flammability certificate shall be confirm to UL 94 V0 standard, b)
Loop tensile strength from NABL accrieted lab or equivalent, c) UV resitance test for
500 / 1000 hours as applicable as approved by Engineer-In-Charge.
2.27.2 Cable ties shall be self locking SS 316 grade and shall be corrosion resistant and
antimagenatic and solt spray resistant for 500 hours, having operating temperature
range -80 0C to 538 0C. High locking tensile strength of 105 / 210kg / sqmm as
approved by Engineer- Incharge. Following certificates :a) SS 316, b) Solt spray test, c)
Tensile strength.
2.28 CABLE IDENTIFICATION
2.28.1 Identification strips / tags of metal or plastic should be attached to the cable, particularly
if several are laid in parallel 8 to 10 m apart. Identification tags should also be attached
at every entry point into the buildings and at the cable end termination.
2.28.2 Cable identification shall be assembled from elliptical profiled low smoke halogen free
markers, carrier strip and cable ties.
2.28.3 Every single core cable and every core of a multi-core cable shall be provided with

identification at its terminations in the form of sleeves or ferrules of appropriate colours

or as specified for signalling cables.
2.29 Technical literature and test certificates to be furnished by Contractor before
execution of work at site.
2.29.1 Contractor shall furnish following minimum technical particulars:
a) Name of manufacturer
b) Standard governing specification
c) Manufacturer’s type designation
d) Rated system voltage in kV
e) Rated continuous current in amps
f) Max. permissible current in amps at 400C
g) Short circuit current for 1 sec. in kA
h) Minimum permissible bending radius in mm
i) Overall diameter of cable / wire in mm
j) Max. permissible length of cable in drum
k) Weight of cable and drum including cable
l) Resistance of Conductor / 100m length
m) High voltage with-stand test result in kV
n) Insulation resistance
o) Thickness and material of
i. Insulation
ii. Inner sheath
iii. Armouring
iv. Outer Sheath.
p) Compound used for FRLSH properties
q) Chemicals used for protection against rodent and termite attack.
r) Shelf life of cable accessories for the ambient temperature specified.
s) Catalogues and brochures giving technical and physical details of the cable such as
current rating, de-rating factors, etc.
t) Type test certificates and special test results for cables offered.
u) Type test certificates for cable & accessories.
v) De-rating factor with the proposed method of cable laying.
2.30 Material and Manufacturing
2.30.1 The material used in the manufacturing shall not deviate from the one used in the
manufacturing of sample piece of which the type test results submitted for vendor
approval.
2.30.2 The routine and acceptance test result shall not vary widely as compared to the type
test results.
2.30.3 The manufacturers shall be able to demonstrate to the inspecting official the sourcing
of material and process as per the system described in ISO document for continuous

quality control.

ANNEXURE
ANNEXURE-A1: Acceptance test report for XLPE cables:
Acceptance Test Report

Customer Name:
P.O. No. & Date:
Description:
Specification: IS 7098 Pt-1 & Data Specified Values Type Test Values Observed Values
Sheet
(Specified Values Type test Values

shall be as per IS shall be the same
Test Descriptions Unit 7098 Pt-1 and the as submitted at the DRUM No.:
S. Cable selected) time
No. of Vendor approval
Core Idenditification Red, Yellow, Blue & Red, Yellow, Blue & Red Yellow Blue Black
Black Black
Colour of Inner Sheath & Black / Black Black / Black Black / Black
Outer Sheath
Dimentional Check -
i) Thickness (Main) mm
1 (Neutral) mm
ii) Thickness of Inner Sheath mm
iii) Thickness of Outer mm

Sheath
iv) Overall Dia of Cable mm
Tests on Conductor (As per IS -
8130)
i) No. of Wires in -
Conductor (Class-
2)(M / N)
2
ii) Conductore Resistance at Ohm /
20 oC (M / N) Km
iii) Tensile strength (Before N/
ageing) mm2
iv) Wraping Test (Before -
ageing)
v) Annealing Test (Before %
stranding)
Test on Insulation (As per IS- -
7098-1)
i) a) Volume resistivity (at Ohm
27 oC) cm
b) Volume resistivity (at Ohm

90 oC) cm
3
ii) a) Tensile strength N/
(Before ageing) mm2
b) Elongation at break %
(Before
ageing)
iii) Hot set test (at 200+ 3 oC -
for 15 min.)
a) Elongation under load %
b) Permanent Elongation %
4 Test on Armouring (as per IS- -

3875)
i) Strip Dimension mm
ii) Armour Galvanization -
coating test
Test on Outer Sheath (as per -
IS- 5831)
5
i) a) Tensile strength N/
(Before ageing) mm2
(Before ageing)
Test on Complete Cable -
6
i) High Voltage Test ( for -
each connection)
Visual Inspection
7 i) Embossing over outer

Sheath
ii) Sequential Length
Marking at every
meters
8 Oxygen Index
9 Temperature Index
Date and Signature:
(Manufacturer) (Contractor) (DMRC Inspecting

officer)

ANNEXURE A2: Acceptance test report for PVC cables:

Customer Name:
P.O. No. & Date:
Description:
Specification: IS 1554 Pt-1 & Data Specified Values Type Test Values Observed Values
Sheet
(Specified Type test Values
Values shall be shall be the same
Test Descriptions Unit DRUM No.:
as per IS 1554 as submitted at
S.
Pt-1 and the the time
No.
Cable of Vendor
selected) approval
Core Idenditification Red, Yellow, Red, Yellow, Blue Red Yellow Blue Black
Blue & Black & Black
Colour of Inner Sheath & Black / Black / Black Black / Black
Outer Sheath Black
Dimentional Check -
i) Thickness (Main) mm
(Neutral) mm
1 ii) Thickness of Inner Sheath mm
iii) Thickness of Outer Sheath mm
iv) Overall Dia of Cable mm
Tests on Conductor (As per IS -
8130)
i) No. of Wires in Conductor -
(Class-
2)(M / N)
2 Resistance at Ohm / K
ii) Conductore
20 oC (M / N) m
iii) Tensile strength (Before N / mm2
ageing)
iv) Wraping Test (Before -
ageing)
v) Annealing Test (Before %
stranding)
1554-1)
i) a) Volume resistivity (at Ohm cm
27 oC)
b) Volume resistivity (at Ohm cm
90 oC)
3
ii) a) Tensile strength N / mm2
(Before ageing)
(Before

ageing)
iii) Hot set test (at 200+ 3 oC -

for 15 min.)
a) Elongation under load %
b) Permanent Elongation %
4 Test on Armouring (as per IS- -
3875)
i) Strip Dimension mm
IS- 5831)
5 i) a) Tensile strength N / mm2
(Before ageing)
(Before ageing)
Test on Complete Cable -
6
i) High Voltage Test (for -
each connection)
Visual Inspection
i) Embossing over outer
7 Sheath
ii) Sequential Length
Marking at every
meters
8 Oxygen Index
9 Temperature Index
Date and Signature:

officer)

ANNEXURE B
Cable Installation Checklist
1 Insulation Resistance(500 V)
(in MΩ)
R-Y
Y-B
B-R
R-N
Y-N
B-N
R-PE
Y-PE
B-PE
N-PE
2 Continuity
Yes / No
R
Y
B
N
PE
Visual Yes / No or
3
Inspection Remarks
a. No cracks and physical damage observed on cable
b. Proper hook, clamp and saddle provided as per spec.
c. Bending radius as per specification and provision of additional
support at bends
d. Proper offsets and loop provided for future maintenance
e. Proper distance maintained between the control and LV cables
f. Proper Phase sequence
g. Armour of the cable earthed properly at both ends
h. Route Marker provided as per specification
i. Distance between the LV / MV and HV cables, if exists together
j. Identification tags provided as per specification
k. Cable termination has been completed as per the specification
l. Underground cable routes verified with the help of cable detector
Verified
By(DMRC)
Checked By(Contractor)

3 CONDUIT WIRING& ASSOCIATED ACCESSORIES

3.1 SCOPE
3.1.1 The scope of the specification covers supply of wires / conduits / switch / sockets
etc, installation, testing and commissioning of the wire in conduit with related works,
earthing of distribution / sub-distribution boards, plug sockets, Conduit Fittings,
associated accessories etc.
3.2.1 Electrical wiring along with other related items shall conform to the latest standard or
harmonize as per the respective standard as given below or specified along with the
equipment in the specification.
3.2.2 In case of any conflict between specifications & the standards, the instructions /
decision of the Engineer-In charge' or Employer's authorized representative shall be
binding.
3.3 STANDARDS
3.3.1 All equipment, components, materials and entire work shall be carried out in conformity
with applicable and relevant IS / BS / IEC Standards and Codes of Practice. In
addition, relevant clause of Indian electricity act 2003 and Central electricity act 2010
amended up to date shall apply.
3.3.2 It is to be noted that updated and current standards shall be applicable irrespective of
dates mentioned along with standards in the tender documents
3.3.3 Codes and standards mean the latest where not specified. The installation shall
generally follow the latest Indian standards / British Standards / IEC standards.
IS 694:2010 Polyvinyl chloride insulated sheathed and unsheathed cables
with rigid and flexible conductor for rated voltages up to and
including 1100 V
IS 732 Code of practice for electrical wiring installations
IS / IEC 62305 Protection Against lightning
IS 5831 PVC insulation and sheath of electric cables
IS 8130 Conductors for insulated electric cables and flexible cords
NEC-2011 National Electrical Code-2011
BS 7671 Code of practice for electrical wiring installations
CPWD-General Specification for Electrical Work
3.4 ABBREVIATIONS
S. No. Abbreviation Description
1 PVC Poly-Vinyl Chloride
2 XLPE Cross-Linked Polyethylene
3 FR Fire Retardant
4 FRLSH Flame Retardant Low Smoke And Halogen
5 MS Mild Steel
6 GI Galvanised Iron

3.5 TECHNICAL REQUIREMENT

a) PVC Cables / Wires for rated voltages up to 1100 V.
b) Electrical wires shall confirm to IS 694-2010. Generally, there are three types of
electrical wires used in Metro system described at Clause No. 17, 19 and 20 of IS 694-
2010.
3.5.1 Clause No. 17 of IS 694-2010: Single core non-sheathed cables with flexible conductor
for general purpose (Maximum Conductor temperature of 85°C)
a) 1100 V grade
b) FR-LSH PVC insulated (Type C vide clause 5.1 of IS 694:2010). PVC shall confirm to
IS 5831.
c) Stranded Copper conductors class 5 as per IS 8130
d) Size and purpose
i. Light and Fans: 2.5 mm2 multi-strand copper conductors or as specified in BOQ
ii. 6 / 16 socket and group wiring of lighting and fan circuits: 4 / 6 mm2 multi-strand
copper conductors or as specified in BOQ.
3.5.2 Clause No. 19 of IS 694-2010: Single and Multi-core circular PVC insulated and
sheathed cables / cords with flexible conductor (Class 5) for general purpose
(Maximum Conductor temperature of 85°C)
a) 1100 V grade
b) FR-LSH PVC insulated (Type C vide clause 5.1 of IS 694:2010). PVC shall confirm to
IS 5831.
d) Sheath shall be PVC of type ST2 (HR) with 85ºC PVC compound confirming to IS 5831
Table 2
e) Size and purpose
i. Size: 4 to 300 mm2 as specified in BOQ
ii. Number of Core: 1,2,3,4 and 5 core as specified in BOQ
3.5.3 Clause No. 20 of IS 694-2010: Multi-core circular PVC insulated and sheathed cables
with flexible conductor (Class-5) for general purpose (For Maximum Conductor
temperature of 85°C)
a) 1100 V grade
b) FR-LSH-PVC insulated (Type C vide clause 5.1 of IS 694:2010). PVC shall confirm to
IS 5831.
d) Sheath shall be PVC of type ST2 (HR) with 85ºC PVC compound confirming to IS 5831
Table 2
e) Size and purpose
i. Size: 0.5 to 2.5 mm2 as specified in BOQ
ii. Number of Core: 6 to 25 cores as specified in BOQ
3.6 INSTALLATION REQUIREMENT
3.6.1 Wiring diagram

3.6.1.1 Before execution of works, the Contractor shall submit the copies of drawings which
are necessary to ensure correct supply of equipment, components, fittings and
materials & to enable correct erection of the installation for satisfactory and trouble
free performance as detailed in the specifications. All drawings for approval shall be
prepared and submitted by the Contractor in standard size, as approved by Engineer-
In charge, and multiples thereof, as required by the Engineer-In charge.
3.6.1.2 Revision and modification: Approval for any revision and / or modification in
job specifications shall be taken from the Engineer-In charge before implementation.
3.6.1.3 Change in construction reference drawings (CRD): Any change required during and /
or after approval of detailed construction drawings on account of functional
requirements or in the interest of efficient running of the system, keeping the basic
parameters unchanged, shall be carried out by the Contractor at no extra cost.
3.7 GUIDELINES FOR DRAWING OF WIRES
3.7.1 Bunching of Wires
3.7.1.1 Wires carrying current shall be so bunched in conduits that the phase and neutral
wires are drawn into the same conduit. Wires originating from two different phases
shall not be run in the same conduit.
3.7.2 Termination / Jointing Of Wires
3.7.2.1 Wiring shall be carried out in looping system. Joints shall be made only at distribution
board terminals, switches / buzzers and at ceiling roses / connectors / lamp
holder’s terminals of lights / fans / socket outlets. No joints shall be made inside
conduits or junction / draw / inspection boxes.
3.7.2.2 Wiring conductors shall be continuous from outlet to outlet. Joints where unavoidable,
due to any specified reasons shall be brought to the notice of Engineer-In charge and
made by approved connectors only with his permission. Specific prior permission from
Engineer-In charge in writing shall be obtained before making such joint.
3.7.2.3 Insulation shall be shaved off for a length of 15 mm at the end of wire and it shall not
be removed by cutting it square or wringing. Strands of wires shall not be cut for
connecting terminals.
3.7.2.4 Conductors having nominal cross-sectional area up to 10-sqmm shall be
cage clamped.
3.7.2.5 Heat-shrinkable sleeves of good quality of relevant standard as approved by the
Engineer-In charge shall be used on thimble connections.
3.7.2.6 At all bolted terminals, current carrying or non-current carrying shall be provided with
adequately sized flat and spring washer as per the requirements. Brass nuts and bolts
shall be used for all current carrying connections.
3.7.2.7 The pressure applied to tighten terminal screws shall be just adequate, and should not
dent or damage or cut any strand of the conductor.
3.7.2.8 Switches controlling lights, fans, socket outlets etc. shall be connected to the phase
wire of circuits only.
3.7.2.9 Only certified and licensed wire-men shall be employed to do wiring / jointing work.
3.7.2.10 Load Balancing - Balancing of circuits in three-phase installation shall be planned
before the commencement of wiring and shall be strictly adhered to. Distribution of
circuits in three phase installation shall be as per distribution chart indicated
in drawings by contractor.
3.7.2.11 Colour Code of Conductors· All wires shall be colour coded as follows:

PHASE COLOUR OF WIRE

R Red
Y Yellow
B Blue
N Black
Earth control, if any Green
3.8 PRECAUTIONS DURING DRAWING OF WIRES

3.8.1 The drawing of wires shall be executed with due regard to the following:
3.8.2 No wire shall be drawn into any conduit, until all work of any nature that may cause
damage to wires is completed. Care shall be taken in pulling the wires so that no
damage occurs to the insulation of the wire. Bushes shall be provided at conduit edges.
3.8.3 Before the wires are drawn, conduits shall be thoroughly cleaned of moisture, dust, dirt,
or any other obstruction by forcing compressed air through the conduits if necessary.
3.9 POINT WIRING
3.9.1 System of wiring
3.9.1.1 Group wiring shall be used for the lighting circuits except for individual rooms and other
small cubicles where light points may be wired individually. Each group shall cater for
a load of approximate 800 watts and wiring shall be done by Loop In- Loop out at each
fitting as per drawing.
3.9.1.2 The wiring shall be carried out strictly as per IE Rules / Indian Standard Code
of Practice for electrical wiring installation IS: 732-1989. The wiring shall be done
on distribution system with distribution and sub-distribution boards located
at convenient points.
3.9.1.3 Wires as specified above of nominal size 2.5-sqmm shall be used for wiring of single
light points, fans and 6 A plug sockets or as specified for group wiring of light points.
For 6 / 16 A sockets, the minimum conductor size used shall be 4-sqmm nominal.
3.9.2 Parameters
3.9.2.1 Point wiring shall be carried out as per following parameters in concealed / surface
conduit system unless otherwise stipulated.
3.9.2.2 Only looping system of wiring shall be adopted through-out. All accessories shall
be flush type unless otherwise stated.
3.9.2.3 For estimation of load, following loads per point shall be assumed:
1 Light points As per load of fixture
2 6 Amps socket outlet points 100 Watts
3 Fan points 60 Watts
4 Exhaust fan points 300 Watts or as specified
5 16 Amp socket outlet points 1000 Watts
3.9.2.4 Light points, fan points and 6-amp socket outlet points may be wired on a
common circuit. Each circuit shall have not more than 800 Watts connected load.
However, in case of LED Points where load per point may be less, number of points
may be suitably increased. Wiring from DB to the first switch in each such circuit is
defined as circuit wiring.

3.9.2.5 Power circuits shall normally have maximum two 16-amps socket outlet
unless otherwise stated. Separate circuit shall be run for each geyser, kitchen
equipment, window air conditioners and similar appliances.
3.9.2.6 Point wiring rates shall include cleaning of dust, splashes of colour wash or paint from
all fixtures, fans, fittings, etc. at the time of taking over of the installation.
3.9.3 LOOP IN LOOP OUT CABLE JUNCTION BOX / CONNECTION BOX AND
ACCESSORIES
3.9.3.1 All junction box with terminal box shall be suitable for 6 sqmm cross section cable
termination.
3.9.3.2 Junction box shall be fire retardant, minimum IP 55, and IK 07 with halogen free
product.
3.9.3.3 Junction box shall be thermoplastic / polycarbonate / hot dipped galvanized MS with
loop in loop out cable termination provision and having the one cable supply for lighting
fixture.
3.9.3.4 Junction box shall be complied to Glow wire test as per IEC 60695-2-11 at 6500C for
Box and glands and 8500C for insulating material like terminal block etc.
3.9.4 Inspection, checks and tests
3.9.4.1 Prototype tests on electrical wire shall be submitted by the vendor seeking approval.
Factory acceptance tests for wire shall be carried out by Contractor along with witness
by DMRC representative as per the proforma given at Annexure A.
3.9.4.2 Installation test of conduit wiring shall be carried out by Contractor along with witness
by DMRC representative during the process of installation and completion of the
installation as per the proforma given at Annexure B as stipulated in special conditions
of contract.

Annexure A:

Customer Name:
P.O. No. & Date:
Description:
Specification: IS 694:2010 & Data Specified Values Type Test Observed Values
Sheet Values
Test Descriptions Unit (Specified Values Type test DRUM / COIL No.:
shall be as per IS Values shall be
694:2010 and the the same as
S. No. Cable selected) submitted at
the
time of Vendor
Core Identification
Colour of Outer Sheath Black Black Black
1 Maximum size of Conductor mm
Conductor Resistance (ohms / -
2
km
corrected at 20 oC)
Annealing Test (for Copper
3
Wires After
stranding)
Thickness of Insulation mm
4
Thickness of Outer sheath mm
5
Overall dia of core mm
6
5831-1984)
Type of compound
i) a) Volume resistivity (at 27 Ohm
7 o
C) cm
b) Volume resistivity (at 90 Ohm
o
C) cm
ii) a) Tensile strength (Before N/
ageing) mm2
(Before
ageing)
IS- 5831-
1984)
Type of compound
8
i) a) Tensile strength (Before N /
ageing) mm2
(Before

ageing)
9 Routine High Voltage test at

R. temp.
FR Test -
10 i) Oxygen Index Test
ii) Temperature Index Test -
11 Flammability test
i) As per IS 10810 (Pt 53)
ii) Time of burning after
removal the
flame
Date and Signature:

officer)

Annexure B:
S.
DESCRIPTION REMARKS
NO.
Checks to be done before Drawing of Wire in Conduits as per the Specification for supply
& installation of conduits, associated fittings & accessories
1 Steel wire of 1.6 sqmm size shall be left in all conduit runs to
facilitate drawing of wires as per clause no. 3.9.1
2 Check for any mechanical stress on the conduit.
3 Check for use of approved quality metallic flexible conduits at
expansion joints of the building
4 Check allowance for running earthing wire as per clause no. 3.9.1
5 Conduit should be kept within 300mm of floors and ceiling when
running parallel to them
6 Ensure conduit runs must not exceed 8 m or have more than two
right angle bends.
7 Check conduits from different Distribution Boards must not be
connected to same junction box
8 Check the water tightness of the Conduit system as per the
‘Method Statement including Tests’ submitted by the contractor.
As per the specification of conduit.
9 Check the coupling used in conduit system, conduits must be
coupled using couplers or via boxes as per clause no. 3.9.3
10 Check the joints and terminations of the conduits, conduit-threads
must not be exposed and if unavoidable then must be treated as
per section 4(b) of the specification.
11 Check the conduit bends as per approval given by the Engineer-
In charge.
In Recessed Conduit and Outlet Boxes

1 Ensure minimum of 12mm of concrete must cover the conduit and
outlet box.
2 Ensure that the conduit must be tied to the reinforcement with
steel wire (dia 1.5 mm) at an interval of maximum 1 m.
3 Check the space between the concealed conduits entering the
draw-in box must be minimum 25mm
In Case of Conduit Recessed in Brick

1 Ensure 10 mm space must be available between conduits and
depth must be sufficient so that minimum thickness of plaster over
conduit is 6 mm
2 Check the Heavy-duty pressed steel clamps screwed to MS flat
strip saddled at maximum 600mm must be provided where chase
has been cut for conduiting
3 Ensure Galvanised Chicken wire mesh of 0.6 mm thick with 10 to
15 mm aperture must be provided for full length of the chase in
the plaster
4 Ensure that all boxes for accessories and draw / junction boxes
must have outer rim flushed in the finished surface, in case of
concealed conduits
In Case of Surface Conduiting

1 Check for approved make spacer saddle at an interval not
exceeding 600 mm and 300 mm from the fittings.

2 Good quality of workmanship must be ensured in case of surface

conduiting
3 Check that the loop earthing wire must be connected to a screwed
earth stud inside outlet boxes to make an effective contact with
the metal body.
4 Ensure that all outlets and switch boxes shall be provided with
temporary covers and plugs before plaster and concreting work
to safeguard against filling up with mortar / plaster etc.
5 Check entire conduit system including outlets and boxes must be
thoroughly cleaned after completion of erection and before
drawing of wires.
6 Check loop earthing is provided by means of insulated stranded
copper conductor wires of sizes as per BOQ laid along with wiring
inside the conduits for all wiring outlets.
Checks to be done after Drawing of Wire in Conduits as per the Specification for Conduit
Wiring of Elevated Stations
1 Check the phase and neutral must be drawn in the same conduit.
2 Ensure two different phases must not run in same conduit.
3 Check the wiring, no joint must be present in the conduits or
junction / draw / inspection boxes, except with prior written
approval from Engineer-In charge.
4 Check all bolted terminals, brass approved flat washer of large
area must be used.
5 Check that good quality heat shrinkable sleeves are used at the
terminations.
6 Check the switches controlling lights, fans, socket outlets etc.
must be connected to the phase wire of circuit only.
7 Ensure bushes must be provided at the conduit edges and proper
care must be taken so that no damage occurs to the insulation of
the wire.
8 Insulation resistance must be tested. This must not be less than
50 divided by the number of points in the circuit in mega ohms.
(50 / no. of circuits)
9 Check the earth continuity of various equipment installed.
10 Measure current and voltage of all the lighting circuits at the sub-
distribution board with all the lamps switched on to ensure that
these are within design values, in case of 3 phase the load must
be balanced reasonably.
11 Measure the minimum and maximum illumination levels after
installation of all the lamps along with the supplier of lamp /
luminaries and shall and shall comply with the designed value
12 Check the phase sequence to ensure correct phase sequence.
*Note: The test for insulation resistance must be carried out when all the equipment are
disconnected from the circuit.
Date & Sign
(Contractor) (DMRC
representative)

3.10 Supply and Installation of Rigid Steel Conduits, Associated Fittings and
Accessories:
3.10.1 Conduit is a part of closed wiring system of circular or non- circular cross-section for
conductors and / or cables in electrical installations allowing to draw them in and / or to
replace them. However, in this document the word ‘conduit’ shall refer to circular cross-
section only. Conduits shall be sufficiently closed- jointed so that the conductors can
only be drawn in and not inserted laterally. The conduits shall be rigid Steel type.
3.10.2 Conduit Fittings referred to in this document is a device designed to join or terminate
one or more portions of a conduit installation which shall be of metal (Galvanized Steel)
only.
3.10.3 Conduit Accessories are the parts other than fittings used in fixing steel conduits and
shall be provided by same manufacturer.
3.10.4 The specifications contained herein are applicable to Elevated etc.
3.11 GOVERNING SPECIFICATION FOR THE CONDUIT, ASSOCIATED FITTINGS AND
ACCESSORIES
3.11.1 The conduits, associated fittings and accessories shall satisfy the requirements given
below and shall also comply with standards mentioned particularly in the table below
unless otherwise stipulated in the specifications. The latest version of standards shall
be applicable.
Specification for Conduits for Electrical IS: 9537: Part I, 1980
Installations: Part I General Requirements, IS: 9537: Part II, 1981
Part II Rigid Steel Conduits
Specification for Accessories for Rigid Steel IS: 3837: 1976
Conduits for Electrical Wiring
Conduit Fittings for Electrical Installations: Part1 IS: 14768 Part-1, 2000
General Requirements
Part 2: Metal Conduit Fittings
IS: 14768 Part-2, 2003
Specification for Flexible Steel conduits for IS: 3480:
electrical wiring
Code of practice for electrical wiring installations IS: 732 / BS 7671
National Electrical Code, 2011 NEC-2011

National Building Code, 2016 NBC-2016
Central Electricity Authority (Measures relating to
Safety and Electricity Supply) Regulations, 2010
Plugs and Socket-Outlets of Rated Voltage up to IS: 1293: 2005
and Including 250 Volts and Rated Current up to
and Including 16 Amperes — Specification
Switches for domestic and similar purposes IS: 3854: 1997
General Requirements for Enclosures for IS: 14772:2000
Accessories for Household and Similar Fixed
Electrical Installations –Specification
Code of practice for electrical installation fire IS: 1646: 1997
safety of buildings

Recommendations on safety procedure and IS: 5216: 1982
practices in Electrical works
Specification for Hot-dip Zinc coating on mild steel IS: 4736: 1986
tube
Methods for Determination of Mass of Zinc IS: 6745: 1972
Coating on Zinc Coated Iron and Steel Articles
Plugs, Socket-Outlets and Couplers for Industrial IS: 60309-2
Purposes, Part 2: Dimensional Interchangeability
Requirements for Pin and Contact-Tube
Accessories
Degrees of protection provided by Enclosures (IP IS: 60529
Code)
Recommended Practice for hot-dip galvanizing of IS: 2629
Iron and Steel
Zinc Ingot- Specifications IS: 209
Hot Rolled Carbon Steel Sheet and Strip IS: 1079
Specifications
Standard Test Method for Surface Burning ASTM E84
Characteristics of Building Materials
Standard Test Methods for Fire Tests of Building ASTM E119
Construction and Materials
Standard Test Method for Fire Tests of ASTM E814
Penetration Fire stop System
Note: The latest edition of the standards shall be used. Wherever Indian Standards are
not available, relevant latest British and / or IEC Standards shall be applicable.
3.12 ABBREVIATIONS
 IS - Indian Standard
 IEC - International Electrotechnical Commission
 ERW - Electric Resistance Welding
 GI - Galvanized Iron
 MS - Mild Steel
 NEC - National Electrical Code
 NBC - National Building Code
 ASTM - American Society for Testing and Materials
Note: The term ‘Approved’ in this specification means that the approval of the Engineer-
in- Charge shall be taken.
3.13 REQUIREMENT
3.13.1 Rigid Galvanized Steel Conduits (IS: 9537, Part I & II)
3.13.1.1 These shall be galvanized steel with minimum wall thickness of 1.6 mm up to 32 mm
diameter and 2.0 mm for sizes above 32 mm diameter, electric resistance welded
(ERW), electric threaded type, with both ends screwed having perfectly circular tubing.
Conduits shall show no appreciable unevenness and shall be free from burrs, fins and
the like which may cause damage to cable insulation. These rough internal edges shall
be removed by means of a proper reamer. Conduits shall be precision welded and
shall be fabricated from tested steel strips of required thickness by electric resistance
welding. Welds shall be smooth and consistently of high quality to ensure crack proof
bending. The conduit shall be galvanized according to IS 4736-1986. All conduits used
in this work shall be marked according to IS: 9537 Part-2 and also with ISI certification
mark.

In charge) for conducting all those re-tests, which were conducted on the failed
sample. Cost of the testing including the collection of sample and transportation of
sample will be borne by the contractor.
contractor.
3.13.1.6 Metallic Flexible Conduits (IS: 3480)
3.13.1.7 The usage shall be restricted to only those areas where it is not possible to use rigid
steel conduits. All final connections shall be made through flexible conduits with PVC
coated (Halogen Free) with required accessories like coupler, elbow etc. Flexible steel
conduits shall be as per latest edition of IS: 3480 and IEC 61386. Where flexible steel
conduit is employed, the length shall not exceed 2.5 metres and shall be provided with
an earth continuity conductor of copper size not less than 2.5 mm². Colour of flexible
conduit shall be approved by Engineer -in-charge before use.
3.13.2 Galvanized Steel Bends (IS: 14768)
3.13.2.1 Large right-angle bends (as per IS: 14768 but more than 75mm radius) or non-right-
angle bends (as per IS: 14768) in conduits runs shall be made by means of conduits
bending machines carefully so as not to cause any crack in the conduit. Small right-
angle bends in conduits runs can be made by standard conduit accessories (solid /
inspection bends / elbows). Facilities such as draw-in boxes must be provided so that
cables are not drawn round more than two right-angle bends or their equivalent. The
radius of bends must not be less than the standard normal bend. Bends in multi runs
of conduits shall be parallel to each other and neat in appearance, maintaining the
same distance as between straight runs of conduits.
3.13.3 Standard Fittings & Accessories IS: 3837 & IS: 14768, Part-1 and Part-2.
3.13.3.1 Heavy duty Class Galvanized (IS 4736 & IS 6745) standard conduit fittings and
accessories like standard / extra-deep circular boxes, looping in boxes, junction boxes,
solid / inspection elbows, solid / inspection tees, couplers, nipples, saddles, check
nuts, earth clips, bushes etc. shall be of superior quality and of approved makes. The
covers screwed with approved quality screws shall be used that can withstand hard
use or wear. Samples of all conduit fittings and accessories shall be got approved by
Engineer-in-Charge before use. Conduit fittings and Accessories shall be as per IS:
3837 and IS: 14768, Part-1 and Part-2.
3.13.3.2 Conduit boxes and covers shall have a minimum degree of protection as follows:
Description Against Corrosion Enclosure Surface or
Concealed
Outside buildings Heavy Protection both IP 54 Surface
inside and outside
Plant rooms and service Heavy Protection both IP 41 Surface
ducts, Switch Rooms, inside and outside

Description Against Corrosion Enclosure Surface or

Concealed
Store Rooms, Ceiling
Voids
Below Ground Heavy Protection both IP 44 -
inside and outside
All other locations Heavy Protection both IP 41 Concealed
inside and outside
3.13.3.3 The contractor shall submit for approval the ‘Method Statement including Tests’ to
ensure above degree of ingress protection. In case no testing facility is available, the
contractor shall comply with this clause by submitting design and installation features.
3.13.4 Fabricated Fittings & Accessories
3.13.4.1 Wherever required, outlet / junction boxes of required sizes shall be fabricated from
1.6 mm thick MS sheets except ceiling fan outlet boxes which shall be fabricated from
minimum 3 mm thick sheets. The outlet boxes shall be galvanized and of approved
quality, finish, and manufacture. Suitable means of fixing connectors etc., if required,
shall be provided in the boxes. A screwed brass stud shall be provided in all boxes
except circular junction boxes as earthing terminal.
3.13.5 Outlet Boxes for Light Fittings
3.13.5.1 These shall be minimum 75 mm x 75 mm x 50 mm deep and provided with required
number of threaded collars for conduit entry. For ceiling mounted light fittings, the
boxes shall be provided 300 mm off center for a 1200 mm fitting and 150 mm off center
for a 600 mm fitting so that the wiring is taken directly to the down rod. 3 mm thick
Perspex / hylam sheet cover of matching colour shall be provided.
3.13.6 Outlet Boxes for Ceiling Fans
3.13.6.1 Outlet boxes for ceiling fans shall be fabricated from minimum 3 mm thick MS sheet
steel and galvanized. The boxes shall be hexagonal in shape of minimum 100 mm
depth and 60 mm sides. Each box shall be provided with a recessed fan hook in the
form of one 'u' shaped 15 mm dia rod welded to the box and securely tied to the top
reinforcement of the concrete slab for a length of minimum 150 mm on either side. 3
mm thick Perspex / hylam sheet cover of matching colour shall be provided. Interface
with civil contractor has to be ensured for installation of outlet box in Ceiling.
3.13.7 Boxes for Modular Wiring Accessories
3.13.7.1 Boxes for housing modular wiring accessories (switches, switch socket outlets,
telephone / computer / TV outlets, bell pushes, electronic fan regulators etc.) shall be
fabricated from minimum 1.6 mm thick MS sheets provided with rust inhibiting
galvanization. The MS boxes shall be suitable for a grid plate being fixed over it for
mounting wiring accessories leaving ample space at the back and on the sides for
accommodating wiring conductors, MS boxes shall be provided with a brass earth
terminal. The MS boxes shall have knockout holes for conduit entry which shall be
secured in position by check nuts and provided with bushes.
3.13.7.2 In case the number of switches in one box is not tallying with that available in standard
manufacturer range, the box accommodating the next higher number of switches shall
be provided without any extra cost.
3.13.8 Wiring Capacity of Conduits
3.13.8.1 Conduits shall be of ample sectional area to facilitate simultaneous drawing of wires
and permit future provision also. Total cross section of wires measured overall shall
not normally be more than half the area of the conduit. No cables installed in conduits
shall be laced. Maximum number of wires which could be drawn in various sizes of

conduits shall be as given in table below:
Note: The above table shows the maximum capacity of conduits for a simultaneous drawing in
of cables as per DMRC’s requirements.
a) The columns headed ‘S’ apply to runs of conduits which have distance not
exceeding 4.25 m between draw in boxes and which do not deflect from the straight
by an angle of more than 15 degrees. The columns headed ‘B’ apply to runs of
conduit, which deflect from the straight by an angle of more than 15 degrees.
b) Conduit sizes are the nominal external diameters.
3.13.9 Modular Cover Plated Mounted Wiring Accessories
3.13.9.1 Switches
All 6 A, 16 A and 20A switches shall be of the modular enclosed type flush mounted
240-volt AC of the best quality and standard approved by Engineer-in- Charge. The
housing of switches shall be made from high impact resistant and flame retarding
plastic material. The switch controlling the light point shall be connected on to the
phase wire of the circuit. Lighting switches used on AC supplies shall be of “AC only”
type and not de-rated when used with fluorescent or inductive loads. Every switch
controlling an appliance shall be labelled with the name of the appliance it controls
and shall be fitted with an indicating lamp. The switch shall govern to 240 V grade as
per IS 3854 and IS 1293 respectively.
3.13.9.2 Moulded Cover Plates
Switches, receptacles and telephone system outlets in wall shall be provided with
moulded cover plates of shape, size and colour approved by the Engineer- in- Charge
made from high impact resistant, flame retarding and ultra violet stabilized engineering
plastic material, and secured to the box with counter sunk round head chromium plated
brass screws. Where two or more switches are installed together, they shall be
provided with one common switch cover plate as described above with notches to
accommodate all switches either in one, two or three rows.

One and two gang switch cover plate, telephone outlet cover plate, 6 A and 16 A
switched / unswitched plates, shall have the same shape and size. Three and four
gang switch cover plates shall have the same shape and size. Six and eight gang
switch cover plates shall have the same shape and size. Nine and twelve gang switch
cover plates shall have the same shape and size. Wherever five switches, seven
switches, ten switches and eleven switches are to be fixed the next higher sizes of
gang switch cover plate to be used and openings shall be provided with blank-off
covers at no extra cost.
3.13.9.3 Wall Socket Outlets
All 6 / 16 A wall sockets outlets unless otherwise mentioned on the drawings shall be
switched, with round pins and fitted with automatic linear safety shutters to ensure
safety from prying fingers. All 6 / 16 A wall socket outlet shall be of three pin type.
The socket outlets shall be made from high impact resistant, flame retardant and ultra
violet stabilized engineering plastic material. Socket outlets mounted externally or in
damp areas shall be weatherproof and shall have a degree of protection of IP54.
The switch and sockets shall be located in the same plate. The plates for 6A switched
/ unswitched plugs and telephone outlets shall be of the same size and shape. All the
switched and unswitched outlets shall be of the best standard. Mounting boxes shall
be galvanized steel. The switch controlling the socket outlet shall be on the phase wire
of the circuit. An earth wire shall be provided along the cables feeding socket outlets
for electrical appliances. The earth wire shall be connected to the earthing terminal
screw inside the box. The earth terminal of the socket shall be connected to the earth
terminal provided inside the box.
3.13.9.4 Industrial Socket Outlets
Industrial plugs, connectors, socket outlets and appliance inlets shall be provided to
meet IS 60309-2. Heavy- duty three phase socket outlets shall be 32A along with DP
MCB, complying with IS 60309-2. For interior use such as technical room unit shall be
rated to IP44. Externally or in wet environments level the protection shall be IP66.
3.14 CONDUIT INSTALLATION (IS: 732 AND RELEVANT CLAUSES OF NEC, 2011)
3.14.1 System
3.14.1.1 The whole conduit system shall be installed to comply fully with relevant provision
in Indian Standard Specifications, National Electrical Code. Conduits shall be laid
either recessed in walls and ceilings or on surface on walls and ceilings or partly
recessed and partly on surface, as required. Same rate shall apply for recessed and
surface conduiting in this contract. Steel wire of 1.6 mm2 size to serve as a fish wire
shall be left in all conduit runs to facilitate drawing of wires after completion of
conduiting. No conduit shall be under mechanical stress. When crossing through
expansion joints in building, the conduit sections across the joint shall be through
approved quality metallic flexible conduits (as per IS 3480) of the same size as the
rigid conduit. Allowance shall be made for running an earth wire of size not less than
the largest conductor contained between each terminal fitted in the nearest conduit
boxes on each side of the telescopic / flexible conduit joint.
3.14.2 Layout
3.14.2.1 Conduits layout and routes shall be submitted for Engineer-In charge approval prior
to execution. Allowance for adjustments due to site conditions shall be provided with
no extra cost.
3.14.2.2 Conduit routes shall be chosen for easy, straight runs with a minimum of bends and
crossing. Generally, they shall follow the structure of building, running at right angles
or in parallels to floors and ceiling. Conduit shall be kept within 300 mm of floors and

ceiling when running parallel to them.

3.14.2.3 Outlets boxes for housing accessories shall be used as draw boxes. The total
number of draw boxes shall be kept to a minimum and shall be provided so that
conduits runs do not exceed 8 m or have more than two right angle bends.
3.14.2.4 Conduits from different distribution boards shall not be connected to the same
junction box. Each run of conduit shall be assembled complete with draw in wires.
3.14.3 Joints and Terminations
3.14.3.1 Conduit threads shall be thoroughly cleaned and the conduits tightly screwed. The
conduit system shall be watertight after installation. The contractor shall submit for
approval the ‘Method Statement including Tests’ to ensure the above requirement.
3.14.3.2 Conduits shall be connected using couplers or via boxes. With a coupler, the ends
of the conduit shall be butted close together and the running coupler is screwed tightly
on and tightened by a locknut.
3.14.3.3 Conduits terminating into boxes provided with spouts shall be threaded so that
there are no exposed threads. For boxes with no spouts, the termination shall be made
using a brass bush and a coupler. The conduit is pushed through the knockout or
drilled entry and the bush is screwed tightly onto its end. The coupler is screwed to
butt firmly against the exterior wall of the box.
3.14.3.4 Where conduits are not jointed or terminated in boxes, they shall be terminated in
a screwed brass bush.
3.14.3.5 In all joints and terminations, conduits threads shall not be exposed. Where this
cannot be avoided as in a running coupler, the exposed threads shall be treated as
given in clause no. 3.14.3.3 of this specification.
3.14.4 Bends (IS: 14768-2)
3.14.4.1 Conduits shall be bend cold with an approved type of bending block or bending
machine, without altering the dimensions of their sections. The approval for the
bending block or bending machine proposed to be used at site shall be taken from the
Engineer-In charge.
3.14.4.2 All conduits bends shall be such as to permit compliance to the requirements for
bends in the IS regulations.
3.14.4.3 Bends shall be made with as large a radius as the position of the conduit within the
building permits. Where the bend is more than 90 degree, circular or rectangular
junction boxes shall to be used for connecting conduits.
3.14.5 Recessed Conduiting
3.14.5.1 Conduits recessed in concrete members shall be laid before casting, in the upper
portion of slabs or otherwise as may be instructed, so as to embed the entire run of
conduits and ceiling outlet boxes with a cover of minimum 12 mm concrete. Conduits
shall be adequately tied to the reinforcement with steel wire of not less than 1.5 mm
diameter to prevent displacement during casting at intervals of maximum 1 metre. No
reinforcement bars shall be cut to fix the conduits. Suitable flexible joints shall be
provided at all locations where conduits cross expansion joints in the building. Spacing
between concealed conduits entering the draw-in boxes shall not be less than 25 mm
to allow concrete aggregate to pass and set between conduits.
3.14.5.2 Conduits recessed in brick work shall be laid in chases to be cut by electrical
contractor in brick work before plastering. The chases shall be cut by a chase cutting
electric machine.
3.14.5.3 The chases shall be of sufficient width (minimum 10 mm spacing between adjacent

conduit) to accommodate the required number of conduits and of sufficient depth to

permit full thickness of plaster (minimum 6 mm) over conduits.
3.14.5.4 The conduits shall be secured in the chase by means of heavy-duty pressed steel
clamps screwed to MS flat strip saddles at intervals of maximum 600 mm. The chases
shall then be filled with cement and coarse sand mortar (1:3) and properly cured by
watering. Galvanized chicken wire mesh of 0.6 mm thick with 10 to 15 mm aperture
shall be provided for the full length and width of the chase in the plaster to prevent
cracking.
3.14.5.5 Junction boxes intended for facilitating drawing of wires in conduiting system shall
be located in accessible locations to permit redrawing of wires in future. Open ends of
conduits laid in slabs and walls shall be suitably plugged before pouring concrete /
plastering to prevent ingress of water / debris in to the conduits.
3.14.5.6 Entire recessed conduit work in concrete member and in brick work shall be carried
out in close coordination with progress of civil works. Conduits in concrete member
shall be laid before casting and conduits in brick work shall be laid before plastering.
If it becomes necessary to embed conduits in already cast concrete members, suitable
chase shall be cut in concrete for the purpose. For minimizing this cutting, conduits of
lesser diameter than 25 mm and outlet boxes of lesser depth than 50 mm could be
used by the contractor for such extensions only after obtaining specific approval from
Engineer-in-Charge. For embedding conduits in finished and plastered brick work, the
chase would have to be made in the finished brick work. After fixing conduit in chases,
chases shall be made good in most workmanlike manner to match with the original
finish.
3.14.5.7 Cutting chases in finished concrete or finished plastered brick work for recessing
conduits and outlet boxes etc. shall be done by the Contractors without any extra cost.
3.14.5.8 In the concealed conduit system, all boxes for accessories & draw / junction boxes
shall be installed such that outer rim is flush with the finished surface of the wall.
Sockets near skirting level shall be fed from the floor above rather than the floor below,
because in the latter case it would be difficult to avoid traps in the conduit
3.14.5.9 Where surface mounted distribution boards are used with a sunk conduit, a flush
adaptable box shall be fitted in the wall behind the distribution board and to take the
flush conduits directly into it. Holes can be drilled in the back of the distribution board
and bushed. Spare holes should be provided for future conduits. Distribution boards
must be bonded to the adaptable boxes and unused holes should be sealed.
3.14.6 Surface Conduiting
3.14.6.1 Wherever so desired, conduit shall be laid in surface over finished concrete and /
or plastered brickwork. Suitable spacer saddles of approved make and finish shall be
fixed to the finished structural surface along the conduit route at intervals not
exceeding 600 mm (except from fitting where 300 mm).
3.14.6.2 Fixing of standard bends or elbows shall be avoided as far as practicable and all
curves maintained by bending the conduit pipe itself with a long radius which will
permit easy drawing-in of conductors.
3.14.6.3 Holes in concrete or brick work for fixing the saddles shall be made neatly by electric
drills using masonry drill bits. Conduits shall be fixed on the saddles by means of good
quality Galvanized steel clamps meant to withstand hard use and wear screwed to the
saddles by counter sunk screws.
3.14.6.4 Neat appearance and good workmanship of surface conduiting work is of particular
importance. The entire conduit work shall be in absolute line and plumb. Conduits
above false ceiling shall be fixed on suitable hangers supported from structural ceiling.
3.14.6.5 All surface conduits shall be run in a vertical or horizontal direction. Diagonal runs

shall not be permitted.

3.14.7 Penetration in Walls
3.14.7.1 Where proprietary cable transits are required, they shall be installed strictly in
accordance with the manufacturer’s recommended procedures. Where cables pass
through walls, floors, or fire partitions, sleeves shall be installed to facilitate installation
and subsequent withdrawal of the cable.
3.14.7.2 After installation of the cables, the hole(s) through which the cables pass shall be
sealed with fire resisting material to achieve the fire rating as the structure through
which they pass. Details of the proposed sealing method shall be submitted for
approval prior to implementation. Cables passing through external walls shall
additionally be sealed with appropriate additional weather protection to prevent the
ingress of water.
3.14.7.3 The fire resisting material shall intumesce to form a hard char that tightly seals
penetrations against flame spread, smoke and toxic fumes. The fire resisting material
shall be tested according to ASTM E119, ASTM E814 and ASTM E84. Test
certification and test report shall be submitted.
3.14.7.4 The materials shall not emit toxic gases on exposure to fire. The materials shall be
easy to dismantle and replace in case of rearrangement and also withstand vibration
due to rail operation and seismic tremor.
3.14.8 Fixing of Conduit Fittings and Accessories
3.14.8.1 For concealed conduiting work, the fittings and accessories shall be completely
embedded in walls / ceilings leaving top surface flush with finished wall / ceiling surface
in a workman like manner.
3.14.8.2 Loop earthing wire shall be connected to a screwed earth stud inside outlet boxes
to make an effective contact with the metal body.
3.14.9 Protection of Conduit
To safeguard against filling up with mortar / plaster etc. all the outlet and switch boxes
shall be provided with temporary covers and plugs, which shall be replaced by sheet /
plate covers as required. All screwed and socketed joints shall be made fully water tight
with white lead paste.
3.14.10 Cleaning of Conduit Runs
The entire conduit system including outlets and boxes shall be thoroughly cleaned after
completion of erection and before drawing in of cables. For cast in-situ conduits, it shall
be checked for freedom from blockage and continuity as soon as the shuttering is
removed. All conduits shall be swabbed through before wiring is commenced and
cables shall not be drawn into any section of the system until all conduits and draw
boxes for that particular section are fixed in position. The contractor shall submit for
approval the ‘Method Statement including Tests’ to ensure the above requirements of
cleaning of conduit runs.
3.14.11 Loop Earthing
Loop earthing shall be provided by means of insulated stranded copper conductor wires
of sizes as per bill of quantities laid along with wiring inside conduits for all wiring outlets
and sub mains. Earthing terminals shall be provided inside all switch boxes, outlet boxes
and draw boxes etc. To satisfy requirements for earth fault loop impedance, the layout
of conduit, trunking and ducting and routing of cables, contractor shall ensure that the
maximum circuit lengths allowable are not exceeded.
3.15 ADDITIONAL REQUIREMENTS

3.15.1 All conduits shall be electrically and mechanically continuous and substantially water
tight after installation. Electrical continuity and resistance of steel conduit systems
intended to be encased in concrete shall be tested immediately prior to pouring.
3.15.2 Where an exposed galvanized surface has been cut or otherwise damaged, it shall be
repaired by application of a zinc rich epoxy primer with a generous overlap on the
existing sound metal coating. Exposed threads and connections shall be similarly
treated. The epoxy primer shall be used strictly in accordance with the manufacturer’s
instructions.
3.15.3 The use of inspection elbows and tees shall be avoided, as there is insufficient room for
drawing in cables and, in addition the installation presents a shoddy appearance. Round
boxes in accordance with relevant Indian Standards may be used. For conduits up to
25 mm diameter, the small circular boxes should be used. Circular boxes are not
suitable for conduits larger than 32 mm, and for these larger sizes rectangular boxes
should be used to suit the size of cables to be installed.
3.15.4 All circular boxes shall be provided with long spouts, internally threaded, incorporating
a shoulder for the proper butting of the conduit.
3.15.5 An indelible display shall identify the cables laid along with the conduits at each conduit
junction / termination etc. for identification during any future handling.
3.15.6 The contractor shall submit ‘Method Statement’ for Installation, Testing and
Commissioning of the conduit system as per the requirements of this specification. The
‘Method Statement’ shall also cover the aspect of quality and safety during Installation,
Testing and Commissioning of the system.
3.15.7 All boxes and conduit accessories shall be fully weatherproof when used in outdoor
locations. Weatherproof boxes and conduit accessories shall also be used in locations
other than outdoors where specified.
3.15.8 Covers for external application shall have machined faces, and shall be provided with
neoprene type gaskets. No box shall be fixed in such a position as to be inaccessible
on the completion of the building structure or other services.
3.16 SAFETY
3.16.1 The conduit system shall follow the relevant clauses of Central Electricity Authority
(Measures relating to Safety and Electricity Supply) Regulations, 2010, National
Building Code 2016 and National Electrical Code, 2011 for the safety precautions to be
adopted. In addition to this, following conditions should be adhered to:
3.16.1.1 All conduits shall be kept clear of gas and water pipes. In particulars, conduits shall
be at least 150 mm away from gas pipe. Where proximity to these pipes is
unavoidable, they shall be effectually segregated e.g. using rubber or other insulating
material to prevent appreciable voltage difference at possible points of contact.
Segregation from extra low voltage circuits and telecommunication circuits shall also
apply unless these are wired to that same voltage requirement as lighting and power
circuits.
3.16.1.2 The materials used in the conduit system shall be fire retardant, shall not emit toxic
gases and smoke on exposure to fire. The materials shall be easy to dismantle and
replace in case of rearrangement and also withstand vibration due to rail operation
and seismic tremor.
3.16.1.3 No timber or inflammable material shall be used for any supports.
3.16.1.4 No sharp edges or portion shall be present which may cause injury during handling
or installation.


4 LIGHTING & FANS

4.1 LED Lights
A. General
a. The scope of work shall cover the supply, installation and testing and commissioning of
the lighting system. Relevant codes and standards up to latest revision shall be
applicable. This specification covers the LED lighting that shall be used for general
lighting in DMRC.
b. ABBREVIATION
FRLSH Fire Retardant Low Smoke and low halogen
FRLSZH Flame Retardant Low Smoke Zero Halogen
LED Light Emitting Diode.
EPC Engineering, Procurement and Construction
OEM Original Equipment Manufacturer
NABL National Accreditation Board for Testing and Calibration

Laboratories
LPD Lighting Power Density
ECBC Energy Conservation Building Code
CCT Correlated color temperature
CRI Color Rendering Index
R Number Registration Number
SMD Surface Mounted Device
COB Chip On Board
RoHS Restriction of Hazardous Substances
CISPER International Special Committee on Radio Interference
AC, DC Alternating Current , Direct Current

EMC/EFT Electromagnetic compatibility/ Electrical Fast Transient /

/ESD Electrostatic Discharge
IEC/BIS International Electrotechnical Commission / Bureau of Indian

standards
IP Ingress Protection
SDCM standard deviation in colour maintenance
THD Total Harmonic Distortion
PMMA Poly Methyl Methacrylate
CRCA Cold Rolled Close Anneal
UGR Unified Glare Rating
PCB Printed Circuit Board
c. LED Standards
a. Latest revision of all codes and standards are to be followed wherever specified
otherwise for installation and requirements, Indian standards codes of practice or the
relevant British Standard codes of practice is to be followed, in absence of any
standards.
b. The luminaries shall have conformation standard of luminaries as per IEC 60598 / IS
10322 and shall have electrical safety as per IEC 61000, 61547, 61347, 62471, 60958,
62560, 60838-2-2, IEC 62262.
c. IEC 62471 or IS 16108-Standard for Photobiological Safety of lamps and lamp
systems.
d. IEC 62031-Safety Standard for LED Module for general lighting-safety specifications.
e. IEC 61347-2-13-or IS 15885 (Part 2/Sec 13) Standard for particular requirements for
DC or AC supplied electronic controlgear for Led Drivers.
f. IEC 60838-2-2-Standard for Particular Requirements- Connectors for LED- modules.
g. IEC 62384 or IS 16104-DC or AC supplied electronic control gear for LED modules -
Performance requirements
h. EC DIRECTIVE 2002 / 95 / EC and Related Commission-Restriction of the use of
certain hazardous substances (RoHS) in electrical and electronic equipment including
lighting.
i. IEC 61000-3-2 or IS 14700-3-2 "Electromagnetic compatibility (EMC) - part 3-2: limits
- limits for harmonic current emissions (equipment input current ≤ 16A per phase)"
j. IEC 61000-3-3-(EMC) for limits on voltage changes, voltage fluctuations and flicker.
k. IEC 61547 Standard for Equipment for general lighting purposes-EMC immunity

requirements.
l. CISPR 15. Limits and Methods of Measurement of Radio Disturbance Characteristics
of Electrical Lighting and Similar Equipment. (applicable on type A luminare specified
in Table A below and all fixtures having wattage greater than 50 watts ).
m. IEC 61000-4-11 Electromagnetic compaitability, Testing and measurement techniques-
voltage dips, short interruptions and voltage variation immunity tests.
n. LED Characteristics standards- LM-80, TM-21.
o. Luminaire Standard -LM 79, LM 70 and B50.
p. IEC 60068/2/78 or IS 9000 / Part IV : for damp heat test.
q. IEC 61086 : for conformal coating
r. IS 1239: Part 1: 2004 Steel Tubes, Tubulars and Other Wrought Steel Fittings -
Specification - Part 1: Steel Tubes.
s. IS 1239: Part 2: 1992 Mild steel tubes, tubulars and other wrought steel fittings, Part 2
Mild steel tubulars and other wrought steel pipe fittings
.
d. Environmental conditions
Sr.No Description Value
a Ambient temperature 0.60 to 47.20C
b Maximum relative humidity 100%
c All equipment must be designed for Vibration Level of 3g in X,Y and Z

directions.
e. Third Party Tests

a. During the execution stage, DMRC may conduct the Test on any type of fixture from
third party independent lab at its own cost, to ensure the quality of material supplies. If
any of the samples fail in the test, the cost of the test along with the complete
b. If contractor represents, two random samples from the failed Lot shall be collected by
c. If both the samples pass all the Tests, supplied lot will be deemed as accepted by
DMRC, but in case of failure of any of the samples collected by the contractor, complete
lot will be deemed as rejected and contractor will replace the whole Lot.
d. The delay, if any for the procurement of the replacement material due to failure, shall
contractor.
f. Guarantee / Warantee Criteria
a. For ensuring the guaranteed life from the EPC contractor/OEM, “Luminaries shall have

warranty of five and half year from the date of delivery and the EPC Contractor shall
submit the BG of 10% of the actual invoiced value of supply of LED fixtures or 10% of
60% of BOQ cost before completion of DLP period for the remaining guarantee/
warantee period left. For this, the EPC contractor shall have to enter into separate
Supplementary Agreement with DMRC after completion of DLP.”
b. One month prior to expiry of BG, 10 samples each of Type A-Suspended/Surface
mounted LED trunk fixture, Type G -Flood Light and Type J-Street light (refer Table A
below for Type of luminare) light fixture shall be collected jointly from site by EPC
contractor and DMRC’s representative. The sample shall be sent to third party NABL
accredited lab/ UL lab for testing of lumen output, as per choice of Engineer-Incharge.
The testing may be witnessed by Engineer-Incharge representative.
a) Criteria for Acceptance
The lumen output of the tested fixture for each Type of light fixture shall not be less than
70% of the declared value, at the time of approval. If more than 50% of sample of
particular type of light fixture fails in testing, the proportionate amount BG will be
forfeited. The decision of Engineer-in-charge in this regard will be final.
Apart from above, Engineer-Incharge reserves the right to test any other type of
supplied luminaries.
c. Lighting layout along with details of selection of approved light fittings, is to be submitted
by the contractor for review and approval of Engineer-Incharge. The final submitted
layout dialux reports (with IES file of all luminare and other parameters) should duly
comply the lux level design criteria given in the lux chart. The lighting design shall also
meet the best level of uniformity ratio.
d. The kW loading and LPD (Light Power Density) in W / m 2 shall comply with the latest
NBC / ECBC requirements.
e. The tolerances in the wattage / efficacy / harmonics and other parameters shall be as
per the latest IEC / IS.
f. The light fittings or its paint shall not emit toxic / corrosive gases in case of fire and shall
be non-combustible and fire-resistant type.
g. The emergency lighting installation shall fully comply with NBC or other relevant safety
standards.
h. Each luminaire and driver should be BIS certified and related “R” Number of BIS should
be printed on the Luminaire / driver.
i. The lighting fixtures and accessories shall give continuous trouble free operation during
the defined life and their performance, shall not deteriorate with time.
j. DMRC reserves the right of testing of products for its conformity in accordance with
mentioned specifications.
k. Driver of luminaire shall be preferably in separate compartment other than luminaire
compartment. Mock-up of fixture and driver installation maintenance shall be given by
OEM.
l. Platform lighting arrangement shall be straight or as per platform profile. Contactor shall
interface with civil contactor for complying the same.
m. Out of total light fixtures instalLED, at least 30% of the total lights, all uniformly
distributed shall be connected to emergency power source i.e. UPS/DG Set supply.

B. LED MAKE AND SPECIFICATIONS

1. The approved makes for the LED chips are Nichia, Philips-LumiLEDs, Osram and
Cree or as approved by DMRC. The LED Chip manufacturers should have registered office
In India. The OEM should provide letter of undertaking from LED supplier indicating the
led make , type and quantity supplied for the lot to be delivered.
2. LED shall have an SDCM (standard deviation in colour maintenance) of less than or
equal to 5.
3. The LED efficacy shall be more tha 85% at a junction temperature of 850C
4. Manufacturer has to submit the TM 21, LM-80 report along with relevant documents.
C. LED DRIVER AND CONTROL CIRCUIT SPECIFICATIONS
1. LED driver shall be marked as per latest Standards.
2. The LED driver shall be constant current type.
3. Potted driver with silicon based compound shall be provided for Type A-Suspended/
Surface mounted LED trunk fixture and all outdoor luminaries (refer Table A).The
potting material should have atleast thermal conductivity of 0.8 W/mK. It should be
moisture resistance and should be fire retardant. An unpotted sample of the driver also
needs to be submitted at time of inspection. MSDS of potting material to be submitted.
4. For the balance type of luminaries, which do not have potted drivers, the PCB should
have conformal coating complying to IEC 61086.
5. Over temperature protection / Thermal fold back should be provided in all luminaries
drivers.
6. Industrial grade or higher grade components should be used for manufacturing of driver.
7. The driver shall be able to withstand surge (EFT+ESD interference) of minimum 4KV of
1.2 / 50 microseconds voltage waveform (IEC 61000-4-5 ) for all indoor luminaries.
Outdoor Luminaires shall have surge protection of minimum 10 KV in common as well
as differential mode.
8. The driver shall have under voltage, over voltage and short circuit protection and auto
recovery mode.
9. Output current ripple content shall be less than or equal to 10% on load.
10. Output current regulation shall be +/- 5% of the rated current.
11. Output voltage ripple shall be within 3%.
12. Total harmonic distortion shall be less than or equal to 10%.
13. The LED driver of Type A-Suspended/ Surface mounted LED trunk fixture , and all
outdoor fittings (wattage > 50 W ,refer Table A) should comply to CISPR 15 for limits
and method of measurement of Radio Interference Characteristics.
14. The control gear shall be compliant to IEC 61347-2-13 or IS 15885-Part 2/Sec 13.
15. The driver shall have an efficiency > 85% at rated nominal voltage and at full Load.
16. It shall have a power factor > 0.95. at rated nominal voltage and full load
17. It should give consistent performance in the input voltage range of 165V-270V at 50 Hz
. The driver should have nominal voltage of 240 V.The output voltage of the driver shall
be designed to meet the power requirement for the system.
18. The driver shall be able to withstand 440 V for 8 hrs for all luminaries. After the
application of high voltage, the performance parameters namely THD, PF, regulation
and efficiency should not deteoriate.

19. The OEM shall submit damp heat test report confirming to IEC 60068/2/78 or IS 9000 /
Part (IV).
20. The driver should have facility for cut off at over voltage.
21. The driver shall have inbuilt inverse polarity protection.
22. The Current Waveform Shall be Compliant to EN 61000-3-2.
23. The equipments shall comply with IEC 61547 for EMC immunity requirements.
24. The driver should be designed for ambient temperature , Ta = 40 degree celcius and
the life of the driver shall be 50000 hrs (at full load and failure rate of less than 10%).
Accordingly Tc (case temperature) is to be decided by OEM.
Measurement of Tc to be recorded during inspection after placing luminare in ON
condition in thermal chamber at Ta=40 0C, after temperature has stabilization . Tc
should not be more than specified value.
25. Driver should be paired with luminarie that uses 20% less wattage than the maximum
rated wattage of the driver.
D. LED LUMINAIRE SPECIFICATIONS
1. The system luminous efficacy (Actual lumen coming out of LED Luminaries) of the led
luminaries (of the system) shall be as per Table-A:
2. The product shall be available in the colour temperature range of 4000K-5700K.
3. Manufacturer has to submit the LM-79, LM 70 and B50 test report along with relevant
documents and IES file of all luminaires.
4. It shall have CRI >80 for indoor except tunnel, flood light and high bay and CRI> 70 for
outdoor applications.
5. The fixture shall be surface suspended or recessed type depending on the application
area.
6. The housing & diffuser shall be robust and conforming to relevant standards and shall
have UV and corrosion resistance protection.
7. The luminaries shall have a high quality clear toughened glass or non-yellowish
polycarbonate or PMMA diffuser with diffused reflection having a maximum
transmissivity of 85% with fire retardant feature.
8. For the outdoor applications it shall have a clear toughened glass.
9. It shall have a proper thermal management to dissipated heat. The heat sink should be
made of extruded aluminium/die cast aluminium having high conductivity except Type
B fittings (Refer Table A) which can be made up of CRCA.
10. The fixture shall be suitable to work in diverse atmospheric condition like humidity, dust,
corrosive etc.
11. The fixture shall have a minimum ingress (IP) and impact protection (IK) rating
depending upon the area of application as per Table-A.
12. The power factor of the overall system shall be > 0.95 at full load
13. Manufacturer shall have in-house laboratories for carrying out acceptance tests and
shall have NABL accredition for in-house laboratories to perform all applicable
photometric tests.
14. Provision shall be made in the fixture for incoming power supply termination, preferably
directly at the back of housing.
15. All the internal wiring of the fixture shall be of FRLSZH type, copper conductor.

16. All screws should be SS 304 or higher grade.

17. Each Type-A fixture shall be provided with 1-meter long FRLSH cable PVC insulated,
PVC sheathed, of minimum 1.5 sqmm, 3 core, copper conductor with suitable gland
and terminations.
18. Connectors used for input AC and output DC connections must be screw type
connector. Makes of connectors to be used : Phoenix, WAGO and Harting.
19. SMD chip shall be in single length (PCB) for Type A, 4’ fixtures, for IP 54 Trunking
Fixtures (Refer Table A). The solder shall be RoHS compatible for being environment
friendly. LED / LED PCB shall be mechanically fixed (not to be glue fixed).
20. Extruded aluminium housing shall be robust, heavy duty & anodized and shall have
minimum thickness of 1.1 mm (preferably ribbed).
21. Type A fitting (refer Table A) must have adjustable height arrangement provision and
shall have click fix arrangement between luminaire and trunk (if required) for easy
installation and alignment feature.
22. Luminaire shall be embossed or screen printed with manufacturer Name and logo. Also
the following information shall be marked on durable adhesive sticker as per IS code:
Type of fitting/Manufacturer name/ Manufacturing year and month /wattage /Lumen/
Efficacy/ R number/IP/IK/ambient temp/CCT/CRI.
23. The lumen maintenance of the LED fittings (of the system not chip) shall not be less
than 70% after 50000hrs.
24. Additional following reports are to be submitted by the manufacturer, from NABL
accredited third party or UL/ILAC listed lab :
a) The luminaire should be tested as per IS 10322/IEC 60598 standards and following
test reports should be submitted: Heat Resistance Test, Thermal Test, Ingress
Protection Test, Electrical / Insulation Resistance Test, Endurance Test, Humidity
Test.
b) Should be compliant to LM-79-8/IS 16106: approved method for the Electrical and
Photometric Measurements of Solid-State Lighting Products LM-79 testing of the
complete luminaire.
c) Should be compliant to LM-80 IESNA: Approved Method for Measuring Lumen
Maintenance of LED Light sources and LED lumen depreciation time to L70 based
on LM-80 data to estimate lifetime based on performance data collected from IESNA
LM-80.
Table-A -Minimum Parameters of LED luminaire

Type
Fixture Lumen Efficacy Type of IP IK Outdoor
of Description Out put Lm / W
CCT CRI
Body Rating Rating /Indoor
Fitting
4', Suspended
/ Surface 4000 - Extruded
Type-A mounted, LED
4000 140
5700K
80
Aluminium
54 5 Indoor
trunk fixture
2'x2' Recessed
4000 -
Type-B Mounted LED 3600 120 80 CRCA 54 2 Indoor
5700K
fixture
4', Suspended
4400 / 4000 - Extruded
Type-C / Surface
2000
120
5700K
80
Aluminium
54 2 Indoor
mounted, LED

Table-A -Minimum Parameters of LED luminaire

Type
Fixture Lumen Efficacy Type of IP IK Outdoor
of Description Out put Lm / W
CCT CRI
Body Rating Rating /Indoor
Fitting
Batten
Pressure
4000 -
Type-D Downlighter 1800 120 80 Die-Cast 20 2 Indoor
5700K
Aluminium
Suspended /
Pressure
Surface 14000 / 4000 - Outdoor
Type-E mounted, High 7200
120
5700K
70 Die-Cast 66 5
/Indoor
Aluminium
bay fixture
Pressure
4000 - Outdoor
Type-F Bulkhead 750 70 70 Die-Cast 66 6
/Indoor
5700K
Aluminium
Pressure
4000 -
Type-G Flood Light 7200 120
5700K
70 Die-Cast 66 7 Outdoor
Aluminium
Pressure
4000 -
Type-H Flood Light 14000 120
5700K
Aluminium
Pressure
4000 -
Type-I Street Light 3600 120
5700K
Aluminium
Pressure
4000 -
Type-J Street Light 7200 120
5700K
Aluminium
Pressure
4000 - Die-Cast
Type-k Street Light 11000 120 5700K
70 66 7 Outdoor
Aluminiu
m
Pressure
High Mast 4000 - Die-Cast
Type-L 28800 120 5700K
70 66 7 Outdoor
Light Aluminiu
m
E. Area wise lux requirement for different activity centers:
TABLE-B
APPLICATION AVERAGE QUALITY UGR
DESIGNED CLASS OF
LUMINANCE DIRECT GLARE
(LUX) LIMITATION
Passenger Area
Circulating and Parking Area

30 2 25
Entrance / Exit / Stairs / Escalators /
Customer Care / Ticketing 225-250-275 2 25
Concourse / Corridor / Passages
175-200-225 2 25
Platform
175-200-225 2 25

APPLICATION AVERAGE QUALITY UGR

DESIGNED CLASS OF
LUMINANCE DIRECT GLARE
(LUX) LIMITATION
Platform Edge
225-250-275 2 25
Trainway, walk-ways and walking
surfaces 10 2 25
Lift -Lobby
125-150-175 2 25
Toilet
175-200-225 2 25
Operation rooms
Staff working area / Control room /
OCC 225-250-275 1 19
Tunnel
20 2 25
Signalling and Telecommunication /
UPS / Battery / Pump / Auxiliary
175-200-225 2 25
Substation / TSS / DG Room / LT
panel etc. (All plant room)
F. Failure Rate
The period of first six months from the date of energisation of light fixtures or from
revenue operation, whichever is earlier, will be considered as stabilization period. The
failure of the luminaire during this period will not be counted. Thereafter, failure rate of
luminaire should not exceed 5 % of the total luminaire installed, till the end of warranty
period.
4.2 EXTERNAL LIGHTING

A. General
The steel / Galvanized Octagonal street lighting poles used for lighting of approach
roads, traffic lanes and walkways in the circulating area, shall be erected at a distance
of 300 mm from the edge of the road / walkway. This shall be done by the Contractor
as a part of the contract work as per the approved drawing. The pole with its base plate
shall be grouted in the foundation which shall be provided with muffing. Galvanized
down pipes / sleeves of suitable diameter shall be embedded in the concrete for the
incoming and outgoing feeder cables. Contractor should follow CPWD specification for
mounting of MCBs.
B. Street and Flood Lighting Fixture
In addition to the specifications given above the external luminaire should have
minimum of IP-65 protection impact protection of rating min 05 i.e. IK-05, UV stabilized
clear polycarbonate cover or clear toughened glass. The light fixture construction shall
be of die-cast / extruded aluminium.
C. High Mast lighting luminaries
1. High Mast Lighting Luminaries suitable for LED light fixtures with Nos. Luminaires as
per BOQ for rotationally symmetric distribution. Complete with accessories including

appropriate gear and fixing arrangements, confirming to IS 10322-1987. The luminaries

shall be sturdy, having die-cast / extruded aluminium housing and black plate, corrosion
resistant high purity aluminium reflector, electromechanically brightened and anodized
heat resistant and toughened glass cover, high resistant silicon rubber marked
appropriate disc facilitating proper aiming of the luminaire, suitable stainless steel
togged as specified as required. The luminaire shall be suitable for fixing on lantern
carriage of high mast.
2. The lamp & Luminaries shall generally follow the specification under section ‘LIGHT
FIXTURES.
D. Street Lighting Poles
a. Steel Pole
1. The lighting poles shall be octagonal type poles as per BS EN 40-3-1&3, hot dip
galvanized as per drawings and as specified. The pole shall have a base plate, a large
access panel, and necessary fixture mounting bracket at top & inbuilt Bakelite sheet
with MCB’s, connectors to be mount inside the pole and 2 nos. 1.5m length of 40mm
diameter bent GI pipes for cable loop-in loop-out to be provided. The access panel shall
provide easy access to a multi-way connector, to be mounted inside the pole. The
access shall be specially fabricated with adequate reinforcement and weather proof
gasket to prevent ingress of moisture and vandal proofed. Poles shall have large
diameter for entries incoming and outgoing cable and two earth studs. The pole
fabrication shall conform to the drawings and where such drawing is not available; the
contractor shall make drawing and have it approved before fabrication.
2. The octagonal poles shall be made from steel of minimum tensile strength 490 N / mm2
as per BS EN 1025-510C.
3. Grade of foundation bolts shall be EN 8 & confirming to IS: 1367 (Part-III) – 2002.
4. Foundation – adequate size M30 grade RCC foundation with 100mm raft including
excavation are included in the rates of street light poles. Contractor shall submit design
calculation in support of size of RCC foundation for external lighting poles.
5. The pole shall have 2 no’s studs for earthing with 8SWG wire.
b. GLASS REINFORCE POLYMER (GRP) Pole
1. The GRP poles shall be manufactured by CNC filament technology, having minimum
glass content 60%, thermoset polyester / epoxy resin system, shock proof, totally free
from corrosion as well as nonconductive, flame retardant as per IS 6746. Resin shall be
UV resistance and pigmented. A highly weather resistant polyurethane coating shall be
applied to the pole with properly paint after primer system. Minimum coating thickness
shall be 80-100microns. Deflection of pole shall not exceed more than 10% of the length
of pole for given load.
2. The GRP pole shaft shall be conical in shape with standard diameter and thickness for
a particular length and shall be single section designed in conformance with BS EN 40-
7-2004.
3. Pole shall be provided with a bracket and arm pipe with tilt suitable for luminaire
mounting and with desired length. The arm shall be designed as per BS EN 40-2-2004.
4. Pole testing shall be confirmed to ASTM standards for varies properties glass, resin
content, tensile and flexural strength, barcol hardness and water absorption.
5. The pole fabrication shall conform to the drawings and where such drawing is not
available; the contractor shall make drawing and have it approved before fabrication.
6. GRP shall be non‐conductive, thereby reducing the possibility of electric shocks.

7. Poles should not deteriorate in salty air climates, acid rains or acid soil.
8. Poles shall be engineered to withstand the specified winds with the calculation of its
wind load conforming to AASHTOLTS‐21985.
9. Poles should be semi‐textured finish, which shall be uniform & almost as pleasant as a
typical smooth finish.
10. Pole surface should be free from crack / bubbles or damage. Any exposed fiber and
smooth surface shall be uniformly coloured. Pole length tolerance not exceeding 0.1m
per 10m.
11. Deflection of the pole as per the ASTM D 4923 will not exceed a 10% of the length of
the pole above the ground line when subject to maximum wind loading & will not have
more than 1% permanent deflection.
12. Pole should be provided with Anchor Base (Minimum Size 300mm X 300mm &
thickness 12 mm) and it should be heavy duty, mild steel Material duly painted with
Epoxy paint.
E. Junction Boxes and Connecting Cable
1. Each pole shall be complete with a junction box of fitted inside the pole. The junction
box shall have a water proof lockable hinged cover (IP65) of size 300 x 100 mm with L-
Key facility for safety against theft. It shall be fitted with 6A, DP, MCB and 8-way, 20A
connector strip, a neutral link, earthing studs and suitable down pipes for the incoming
and outgoing cable-lead. The junction box shall generally comply with the requirements
of IS: 2675-1983. The supply of pole shall be complete with 3 x 4mm2 FRLSH copper
cable, PVC insulated, PVC sheathed drawn from the junction box to the luminaire
terminal.
2. Pole shall have a concrete coping of 200mm height in M30.
F. Cable laying
1. Cabling shall be generally as specified in the section ‘CABLING.’
2. Cables shall be terminated in an 8-way terminal block inside the pole.
3. Cable route shall be as per approved drawings or the contractor shall mark out the route
and lay the cables only upon approval of the route.
G. Earthing
1. All street light fixtures and poles shall be earthed as specified under section
‘EARTHING.’ Every lighting pole shall be earthed by connecting it to the continuity earth
of the feeder cable from the feeder pillar. In addition, every 7th pole shall be connected
to locally provided earth electrode as per approved drawing.
H. Feeder pillars (as applicable)
1. Suitable feeder pillars, 3-phase 415 V outdoor type, with a fixed canopy shall be
provided for automatic control and power distribution to masts & streetlights. The feeder
pillar shall have IP: 66 degree of protection. It shall be provided with weather-proof
lockable door, incoming and outgoing cable gland plates, earthing studs and other
accessories.
I. Testing and commissioning
1. The lighting installation shall be tested as per approved schedule and the instructions
of Engineer and shall include but not be limited to the following:
a) Insulation resistance of each circuit shall be measured without the lamps being in
place. It should not be less than 500000 ohms to earth.
b) Current and voltage of all the outdoor lighting circuits shall be measured at the Main

Distribution Board with all the lamps switched on to ensure that these are within
designed values and in the case of 3-phase circuits, the load shall be balanced if
required.
c) Earth continuity shall be checked for all the circuits.
4.3 HIGH MAST LIGHTING
A. Scope
This specification deals with the design, fabrication / manufacture, testing, supply, and
erection of outdoor high lighting equipment including 12- 20 Mtr. high mast with mobile
lantern carriage, luminaries and associated accessories, fittings, etc. to be installed for
lighting of circulating and parking area outside the station.
B. Codes and standards
1. Design, manufacture, and performance of the mast shall comply with all currently
applicable statutory regularities and safety codes and standards in the locality where
the equipment will be installed and generally in accordance to the following:
a) British Code of Practice CP3: Chapter V Part 2: 1972
b) PLG 7 of lighting professionals (ILP):2013
2. The work shall be done to a high degree of workmanship in accordance with approved
drawings and in conformity with this specification and the relevant specifications and
code of practice of the bureau of Indian Standards, including the following:
a) Indian Electricity Rules
b) Code of Practice for fire safety of buildings (general); Electrical Installations – IS:
1646-1982.
c) Code of Practice for installation and maintenance of power cables up to and
including 33 kV rating – IS: 1255 – 1983.
d) Regulations laid down by the Chief Electrical Inspector.
e) Any other regulations laid down by the Local Authorities.
C. Design
12-20 Meters high mast suitable for fixing luminaries as specified, in C sections, with
confirm carriage and all accessories required to complete the supply and erection of
High Masts at designated locations high mast shall be manufactured as for PLG 7 by
ILP (latest edition) by the institution of lighting engineers and as per specification of high
masts given in this document.
D. General constructional features
1. The mast shaft shall be made with the best steel grade, in compliance with BS EN
10025 Fe 510C, having the following guaranteed characteristics:
a) Minimum Yield Strength = 355N / sq.mm for thickness < 30 mm
b) Tensile Strength ranging from 490 to 630 N / sq. mm
c) Minimum elongation for thickness between 3 mm and 30 mm: 22%
2. The steel grade for accessories shall be BS EN 10025 Fe 430A or equivalent, having
the following guaranteed characteristics:
a) Minimum Yield Strength = 275N / sq. mm for thickness < 30 mm
b) Tensile Strength ranging from 410 N / sqmm

c) Minimum elongation for thickness between 3 mm and 30 mm: 26%

d) All holding bolts are hot dip galvanized to BS: 729.
E. Mast design criteria
1. The high mast and the lowering system with the required number of floodlights and lamp
control gears etc. in place shall be capable of withstanding a sustained basic wind
speed of 180 km / h with 3 seconds gust.
2. The design shall be in such a manner that it is capable of withstanding external forces
exerted by wind pressure and should have a minimum wind load factor of 1.25 and
material factor of 1.15. Design life of mast should be at least 25 years.
The mast shall be designed in accordance to the table below. Contractor need to
provide the technical data for high mast as asked below:
By contractor:
Maximum Loading on
High Mast (Height as applicable)
Foundation
Shear Force
Overturning Moment
Torsion Moment
Axial Load
Max. Deflection
Max. Base Flange O. D.
F. Mast structure and construction

1. Each mast section to be delivered to site shall have a minimum length of 9.0 meter. The
sections shall not be circumferential welded through slip joint of multiple short sections.
Detailed instructions relating to site assembly shall be provided.
2. The top section shall have a flange plate / welded for bolted connection to the head
frame.
3. The base shall have a flange plate for fixing the high mast onto the concrete foundation
by anchor bolts.
4. The mast shall be fabricated as per PLG 7 of institution of lighting engineers. It will be
butt welded longitudinally to form a tapered section with (one) longitudinal seam weld
is permissible. All welding shall be to AWS D1.1 having the following basic
requirements:
5. Mast sections to base flange and longitudinal weld within 150 mm of the female slip
joints areas shall have: -
a) Full penetration between plates of all thickness.
b) No fissures.
c) No undercutting.
d) No blow holes, porosity or spherical beyond 5% on the minimum thickness. No
detectable angular inclusion.
e) Longitudinal welds along the mast shaft shall have: - 60% minimum penetration
between plates.

f) No fissure on the inside and outside surface. No undercutting on the outside

surface.
g) No blow holes.
6. Ultrasonic testing procedures shall be considered as minimum permissible testing
method.
7. The wall thickness of each section shall be designed to withstand the loads to which
the high mast will be subjected to but shall not be less than 3 mm.
8. Unless otherwise specified connection between the various station shall be achieved
by telescopic slip joints, the overlapping length being at least equal to 2.0 times the
inside diameter of the female section. Slip joint assembly shall be performed at site.
Shaft section shall not be joint by circumferential weld or bolting.
9. The base plate shall be free from lamination and shall be single flange constructed with
holes jig drilled for anchor bolt passage. The bottom of the base mast section shall be
securely welded to the base plate by complete penetration butt welding or fillet welding.
The welded connection of the base plate to the mast section shall fully develop the
strength of the section.
10. The base section shall be equipped with a hinged service door. The service door
opening shall be completed with a close fitting weatherproof and equipped with a vandal
resistant lock. The service door shall not be smaller than 1400 mm X 300 mm. The
opening shall be reinforced by a thick steel door frame.
11. Base plate dimensions, thickness and the diameter, size and the placement of anchor
bolts shall be determined by calculation and indicated in the drawings.
12. Anchor bolts shall be deformed steel reinforcement bars having the following minimum
guaranteed characteristics:
a) Specified characteristic strength = 460N / sq.mm
b) Tensile strength= 490N / sq.mm
13. Welding of two or more anchor rods of shorter lengths to achieve the design length shall
not be permitted. No welding shall be allowed on the anchor rod body.
14. Adequate earthing and earthing terminal shall be provided within the access door area
of each high mast. Details shall submit to the Engineer-In charge for approval.
15. All high mast shall be hot dip galvanized, in accordance with British Standard 729 /
1971(1986).
16. All mast components shall be hot dip as per BS 729 galvanized after completion of
fabrication. The galvanized of sections having overall length of up to 14m shall be
achieved in a single dip operation. Double dipping of any mast section is strictly
prohibited. Galvanising shall be inspected for adhesion, mass of zinc coating and
uniformity of coating
G. Lantern carriage
1. The mobile luminaries ring shall be of steel construction and manufactured in three
segments. Bolted flanges shall join the unit. All mobile components of the system shall
be located on the mobile part in order to allow visual inspection during each operation.
Proper luminaries’ carriage ring support arms shall be provided for supporting the
luminaries’ carriage ring when the latter is lowered for maintenance of luminaries.
2. The mobile luminaries’ carriage shall be designed to carry the assigned no. of
luminaries and control gears and shall be evenly balanced. Nylon Paddle Guide Ring /
PVC buffer shall be incorporated as a buffer arrangement between mobile luminaries
carriage and mast shaft. This is to prevent damaged to mast surface during raising and

lowering operation of mobile luminaries’ carriage.

3. The complete mobile components shall be hot dip galvanised in accordance to BS 729.
4. The steel grades used for construction of the head frame assembly and mobile part
shall be in compliance with BS EN 10025.
5. Lantern carriage shall be of latching type, latched at the top to ensure the complete load
of carriage is transferred to mast instead of wire rope.
H. Raising and lowering mechanism
For installation and maintenance of luminaries and lamps, it shall be necessary to lower
and raise the mobile luminaries’ carriage by means of a suitable winching arrangement
at the base of the mast. The speed of the raising and lowering of lantern carriage ring
shall be at least 3.0m per minute.
I. Winch
1. The winching system with the drive unit shall remain permanently inside the mast. Drive
unit may be removal without affecting winch mechanism. Each mast shall be provided
with a double drum winch suitable for raising and lowering the luminaire carriage ring.
2. The winch must be robust design and completely self-sustaining type without the brake
- shoe, springs, or clutches. It can be removed from the mast for maintenance if the
need arises in future. The reduction gear of the winch shall be of endless worm gear.
Operating in an oil bath. The minimum safe working limit of the winch shall be not less
than 750Kg and shall be verify by NABL accredited certification.
3. The capacity and operating speed of the winch shall be clearly marked on an indelible
label together with the specification of the recommended lubricant.
4. A minimum 6 turns of wire rope shall be on the grooved drum when the mobile luminaire
ring is fully lowered to rest on the supporting arms.
5. The winch is entirely self-sustaining under all normal circumstances and it is not depend
on the brake or restarting device that uncontrolled or dangerous runaway speeds will
occur in the event of the total failure and report to be submitted.
6. Test certificates in support of the safe working limit to be provided from reputed institute
such as IITs.
J. Head frame Escalation
1. The head frame duly hot dip galvanized shall include a pulley system accommodate 3
stainless steel hoisting wire rope at any one time and separate pulley for the passage
of flat electrical cables.
2. The pulleys shall be of non-corrosive material and shall run on self-lubricating gun-metal
bearing with stainless steel axles.
K. Hoisting and suspension wire ropes
1. The high mast shall be fitted with flexible stranded stainless-steel hoisting wire ropes of
7 x 19 constructions. The combine lifting capacity of the hoisting wire rope shall have a
factor of safety not less than 5 times the safe working load (SWL) of the winch and shall
be entirely suitable for the design application.
2. A transition plate shall be incorporated to connect the suspension wire ropes to the two
stainless steel winching wire ropes ensuring ensure even distribution of loads between
the two stainless winching-wires by means of an equaliser with a provision to fix
electrical cables.

L. Electrical cables
1. Electrical cable shall be anti-twisting flexible 2.5 mm2 cable suitable for small bending
radius. minimum 10 core (double circuit of 3P-N-E) flexible electrical cable with 2.5 mm2
conducting area shall be providing for connecting of power supply to the light source
and shall terminate at the stationary connecting board in the base compartment with a
multiple 10-pin weather proof plug and socket coupler fitted with locking levers or as
approved by Engineer -In charge.
M. Winch driving power tool
1. The winch drive unit shall be complete with a 415V, 3-Phase, 50 Hz squirrel cage,
reversible weather resistance, IP 55 protection, min. class F insulation induction motor,
a coupling flange for winch to facilitate detachment and attachment on several masts in
succession.
2. For safety reasons and final precision docking of lantern carriage ring to the head frame,
the winch must have a provision to operate manually by using external crank device
without removing the drive motor from the winch unit.
N. Control panel
1. Control of raising and lowering operation shall be carried out by means of Outdoor
Feeder Pillar with Push Button Arrangement located at least 3 Meter away from the
mast or a distance more than Outermost Carriage Diameter of High Mast.
2. The control panel shall be usable on all masts and shall be equipped with Emergency
stop button and Push button for raising and lowering of the mobile part.
3. The push buttons shall operate on the 'dead man' principle i.e. action shall cease as
soon as the button is released. Control panel shall also include housing for control
switches and relays. The control panel shall be equipped with safety devices such as
electronic torque control in case of overload or overheating of the hoist motor.
O. Statement of Compliance
1. The base offer shall comply with the specification. The Tenderer shall confirm for each
and every paragraph of the technical specification that the Tenderer is able to meet the
specified requirements. The statements shall be in accordance to the numbering
reference adopted in the technical specifications.
P. Testing and Commissioning
2. Insulation resistance of each circuit shall be measured without the lamps being in place.
It should not be less than 5 Mega ohms to earth.
3. Current and voltage of all the outdoor lighting circuits shall be measured at the Main
designed values and in the case of 3- phase circuits, the load shall be balanced, if
required.
4. Earth continuity shall be checked for all the circuits.
4.4 PLUG-SOCKETS
1. The 3-pin 6A / 16A plug Universal socket shall be combination socket and switch and
switch (on the live side) suitable for use with either 6A plug or 16A plug. The switches
and sockets shall be enclosed type flush mounted switches of 230-volt ac grade. These
shall be provided with approved poly carbonate modular cover plates, secured to the
box with counter sunk screw. Where more than one switch occurs in same location,

they shall be installed in gangs under one cover plate.

4.5 TIME SWITCHES
1. Astronomical electronic time switches shall be suitable for operation on a 230-volt 50Hz
ac supply and shall have auto / manual ON, OFF, season mode, day-light saving time
etc. which will reserve the power for clock to continue the function for a period of at least
minimum 100 hours with or without the supply. Minimum 2 nos. switching contact shall
be provided. Switch contacts shall be rated at minimum 16 amperes
2. Astronomical electronic time switch shall be capable up to 28 / 56 programs and having
unique software and data key.
4.6 Ceiling, Wall Fans & Exhaust fans
1. Ceiling fans shall be energy efficient highest BEE rated of latest notification of 1400 mm
/ 1200 mm sweep conforming to IS: 374-1979 complete with fan suspension stem,
canopies, and regulators. 30-cm suspension stem shall be standard accessory and
stems shall be heavy-duty steel tubes to IS: 1239-2004. The stem shall be painted with
enamelled paint. The fan shall have a junction box with MS hook of minimum size 150-
mm diameter fixed in recess of ceiling and covered with sun-mica sheet of minimum 3-
mm thickness.
2. The fan clamp shall be fabricated from new metal and shall be as close fitting as
possible. The suspension rod shall be seamless steel tube. Mounted on a pre-
embedded hook with hard rubber isolator. Regulators shall be step type mounted in the
switch box. The box in all such cases shall be large enough to accommodate the
regulator and switches. Air circulators of suitable size & sweep as specified, 1440 rpm,
suitable for 230 V, 1-phase, Low noise level of 80-90dB or as stipulated in Indian
Standards and approved shall be provided at suitable location.
3. Exhaust fan – The exhaust fan shall be of size 300 / 380 / 450 / 600-mm as specified
and required and minimum 900 rpm and shall conform to IS: 2312-1967 (as reaffirmed
in 2005). The fans shall be robust, having double ball bearings and low noise.
4. Pedestal fan – The exhaust fan shall be of size 400-mm as specified and required and
900 rpm and shall conform to IS: 1169-1967. The fans shall be robust, having double
ball bearings and low noise.
4.7 Inspection & tests
1. Prototype tests / routine tests as required shall be carried out by the contractor and
witnessed by employer’s representative as stipulated in Special Conditions of contract.

5 PROTECTIVE EARTHING
5.1 Scope of work
5.1.1 The scope of work shall cover the Earthing Stations (Earth Mat, earth electrodes), soil
resistivity testing, laying copper / GI earth strip and connecting the power panels, DBs,
switch boards and other equipment such as pumps, PLCs, BMS etc.
5.2 Detailed description and Application
5.2.1 The earthing protection is an integral part of any electrical system and is required to:
i. Protect personnel and equipment from electrical hazards.
ii. Achieve a reduction in potential to the systems neutrals.
iii. Reduce or eliminate the effects of electrostatic and electromagnetic interference on
the Signalling and Telecom equipment arising from auxiliary electrical systems.
5.2.2 There are several types of earthing systems such as Earth Mat, Plate Earthing & Pipe
Earthing which could be used in an elevated station. The selection of a particular type
of earthing system depends upon several factors such as:
i. Availability of Land.
ii. Type of Soil.
iii. Resistivity of Soil.
5.3 Governing Specifications
IS:3043 – 2018 Code of Practice for earthing
IEC 62561-1 to 8 Lightning protection system components

(LPSC)
IEEE 837 Qualifying Permanent Connections Used in

Substation Grounding
IEEE 80: 2013 Guide for Safety in AC Substation

Grounding
NBC-2016 National Building Code -2016
Indian Electricity Act and Central electricity act 2010
5.4 Requirements
5.4.1 Earth Mat
Earth mat shall be constructed as per IEEE 80 – 2013 and IS 3043-2018. Low carbon,
high tensile steel molecularly bonded with 99.9%pure electrolytic grade copper
thickness of minimum 250 microns tested by CPRI based Copper bonded MS round /
flats should be used for constructing earth mat of adequate size (horizontal and vertical
conductors) and at depth of 700 – 1000 mm from ground as per drawings. Adequate
number of risers shall be brought from earth mat for further connection to ASS
equipment and downstream equipment. Main earth terminals shall be provided in ASS,
SER, TER, S&T UPS, SCR, Lift, DG, and pump room as required. The resistance of the
earth mat should not be more than 1Ω.

a) Vertical electrode shall be installed in 200-diameter bore hole and should not
hammering on vertical electrode.
b) All the joints below ground level used for the interconnection of rods and for
connecting earth rod with the earthing conductor shall be exothermically welded.
Also, all the riser joints connected from the earth grid shall be exothermically
welded.
c) Exothermic weld material shall be UL listed and tested as per provisions of IEEE
837 by NABL accredited lab. Weld powder material should be moisture proof and
tamper free.
5.4.2 Plate Earthing

i. The earthing station shall be as shown on the approved working drawing. The earth
electrodes shall not less than 600 x 600 x 6.3 mm GI plate / 600 x 600 x 3.15 mm
copper plate electrode as required. The earth resistance shall be maintained with
a suitable soil treatment and watering arrangement as per approved working shown
on drawings or as directed at site. Excavated soft soil shall be thoroughly mixed
after ground enhance material in 100 mm trench which having maximum 0.12ohm-
meter resistivity material and filled in the earth pit. Independent earth shall have
same specification subject to meeting the earthing value criterion for
communication system.
ii. The earth lead shall be connected to the earth plate through copper / brass bolts
as per approved working drawings.
5.4.3 Pipe Earthing
i. The pipe earth shall be as shown on the approved working drawing and shall be
used for equipment earth grid. The earth electrode shall be 3.0 m long, 50 mm
diameter, Heavy duty (Class-C) thick galvanized steel pipe. The earth resistance
shall be maintained with a suitable soil treatment as shown on approved working
drawings and as per clause no.5.3.5.
ii. The earth lead shall be fixed to the pipe with a clamp and safety set screws. The
clamps shall be permanently accessible.
5.4.3.1 In all cases the relevant provision of rule no. 33, 61 & 67 of the Central Electricity Act
2010 as amended shall be complied with. Metallic covers or supports of all medium or
HT apparatus or conductors shall, in all cases be connected to not less than two
separate and distinct earth electrodes.
5.4.4 Location of Earth Electrode
The following guidelines shall be followed for locating the earth electrodes
i. An earth electrode shall not be situated less than 3 meters from any building. The
excavations for electrode shall not affect the column footings or foundations of the
buildings. Entrances, pavements and road ways shall not be used for locating the
earth electrode. In such cases electrode may be further away from the building.
ii. Earth mat locations – Earth mats shall be constructed at a suitable place in the
station area as near to ASS as possible.
iii. The location of the earth electrode / mats shall be such where the soil has
reasonable chance of remaining moist, as far as possible.
5.4.5 Method of Installation & Watering Arrangement

In the case of plate earth electrode, a watering pipe of 50 mm diameter of medium

class GI Pipe shall be provided and attached to the electrode. A funnel with mesh shall
be provided at the top of this pipe for watering the earth. The watering funnel
attachment shall be capable of load bearing capacity and testing shall be done as per
IEC 62561-5 with heavy duty parameters. The material of Earth Electrode inspection
housing shall be Poly plastic and shall be capable to handle minimum 8-ton load. A /
cover having identity mode “EARTH” and having locking arrangement shall be suitably
embedded in the enclosure.
a) Earth electrode (Vertical electrode) shall be back filled by soil in 200 mm diameter
bore hole when earth resistivity is 30 ohm-meter.
b) If earth resistivity is more than 30 ohm-meter, ground enhance material shall be
used instead of soil in 200 mm diameter bore hole.
5.4.6 Plate & Pipe Earthing shall have 200 mm surrounding layer of ground enhance material
having less than 0.12 ohm-m resistivity and shall be confirmed to IEC 62561-7 for tests
and materials.
5.4.7 Earth leads and connections
i. The copper bonded MS rod / strip earthing leads shall be connected to the Earth
Electrode / Earth mat at one end and to the main equipment at the other end. The
earthing lead shall connect to the earthing network in the installation.
ii. Earth lead shall be copper bonded Mild steel as specified with sizes shown on
approved working drawings. At road crossings necessary Hume pipes or UPVC
Pipes shall be laid. Earth lead run on surface of wall or ceiling shall be fixed on
saddles or wall so that the strip is at least 8 mm away from the wall surface.
iii. All earth strips shall be jointed as follows:
Copper : Copper riveting with 80 mm fish plate and brazing with at

least 80 mm brazing as a lap joint along the length
Galvanized : Lap welding with 50 mm minimum lap Steel: Overlay - not

less than 50 mm in all cases.
iv. Strip earthing leads shall be of copper bonded MS rod / Copper coated strip and as
per specifications.
v. The buried strip earthing lead shall be in trench not less than 0.5 m deep. If
conditions necessitate use of more than one earthing lead, they shall be laid as
widely distributed as possible, preferably in a single straight trench or in a number
of trenches radiating from one point.
vi. In the case of plate earth electrode, the earthing lead shall be securely bolted to
the plate with two bolts, nuts, check nuts and washers as required by IS 3043:2018.
All materials used for connecting the earth lead with electrode shall be GI in case
of GI Pipe and GI plate earth electrodes or tinned brass in case of Copper plate
electrode.
5.4.8 Connection of Earthing Conductors
i. Main earthing conductors shall be taken from the earth connections at the
substation to the earth bar at the main switch boards in the TN-S configuration and
the earth bar may also be directly earthed as in Indian TN-S.
ii. Sub-mains earthing conductors shall run from the earth bar at the main switch
board to the sub-distribution boards and to the final distribution boards.
iii. Loop earthing conductors shall run from the final distribution boards and shall be

connected to any point on the main / sub-main earthing conductor, or its distribution
board.
iv. Metal conduits, cable sheathing and armouring shall be earthed at the ends
adjacent to switch boards at which they originate, or otherwise at the
commencement of the run by an earth bonding conductor in effective electrical
contact with cable sheathing. Switches, accessories, lighting fitting etc shall be
effectively connected to the Loop Earthing Conductors. A metallic conduit shall not
be considered as the only protective earth conductor.
v. Point wiring for lights, fans, ceiling fans, exhaust fans, 6A & 16A sockets and the
like and sub-main wiring, shall all have an earth continuity conductor (ECC) with
the same cross section and type of wires used, the minimum in this case being 2.5-
sqmm copper.
5.4.9 Prohibited Connections
Neutral conductor, sprinkler pipes, or pipes conveying gas, water, or inflammable liquid,
structural steel work, metallic enclosures, metallic conduits, and lighting protection
system conductors shall not be used as a means of earthing an installation or even as
a link in an earthing system. However, these are to be effectively earth bonded.
5.4.10 Resistance to Earth
The electrical resistance measured between earth connection at the main switchboard
and any other point on the completed installation shall be low enough to permit the
passage of current necessary to operate fuses or circuit breakers. The combined earth
resistance of the earthing system should less than or equal to 1 ohm.
5.5 Additional Requirements
5.5.1 All apparatus and equipment transmitting or utilizing power shall be earthed as per the
drawings.
5.5.2 The earth continuity conductor may be drawn inside the conduit in which case, it should
be insulated.
5.5.3 Indian TNS system of earthing as shown on IS: 3043 – 2018 shall be followed for the
entire installation under the scope.
5.5.4 All the non-current carrying metal parts of electrical installation shall be earthed
properly. All metal conduits, cable trays, trunking, cable sheaths, switchgear,
distribution fuse boards, light fittings and all other parts made of metal shall be bonded
together and connected by means of specified earthing conductors to an efficient
earthing system. All earthing shall be in conformity with Indian Electricity Rules.
5.5.5 Metallic conduit shall not be accepted as an earth continuity conductor. A separate
insulated / bare earth continuity conductor of size related to phase conductor shall be
provided. Non-metallic conduit shall have an insulated earth continuity conductor of the
same size as above. All metal junction and switch boxes shall have an inside earth stud
to which the earth conductor shall be connected. The earth conductor shall be distinctly
coloured (green) for easy identification.
5.5.6 Armoured cables shall be earthed by 2 bonding earth connections to the armouring at
both the ends and the size of connection being as above. In multiple cables entering a
panel / DB, the cable joints shall be bonded together using a bonding wire selected on
the basis of the largest size of cable in the group. In the case of unarmoured cable, an
earth continuity conductor shall either be run outside along the cable. Three phase
power panels and distribution boards shall have 2 distinct earth connections of the size
correlated to the incoming cable size. In case of single phase DB’s a single earth
connection is adequate. Similarly, for 3-Phase and 1-Phase isolating switches there

shall be 2 and 1 earth connections respectively, sizes being correlated to the incoming
cable.
5.5.7 Three Phase motors and other 3-Phase apparatus shall have 2 distinct earth
connections of size equal to incoming feeder size. For 1-Phase motor and 1-Phase
apparatus, the single earth connections shall be provided of the above size.
5.5.8 Metallic covers or supports of all medium or HT apparatus or conductors shall, in all
cases be connected to not less than two separate and distinct earth electrodes.
5.5.9 Materials used for the protective system shall be resistant to corrosion or be adequately
protected against corrosion. Adequate margin for corrosion should be taken for the
selection of the size. The material shall be as specified in the schedule of quantities
BOQ and shall comply to the following requirements:
5.5.10 Copper - When solid or stranded copper wire is used it shall be of the grade ordinarily
required for commercial electrical work generally designated as being of 98%
conductivity when annealed, conforming to Indian standard specifications.
5.5.11 Galvanized Steel - Galvanized steel used shall be thoroughly protected against
corrosion by hot dipped Zinc coating and shall be confirming to IS 3043:2018 / IS 2629
and testing as per IS 2633.
5.5.12 The strips to be used shall be in maximum lengths available as manufactured normally
avoiding unnecessary joints.
5.5.13 All three-phase equipment shall have two separate and distinct body earths and single-
phase equipment shall have a single body earth. Earthing of transformer neutral, DG
set, S&T equipment (clean earth electrodes only), BMS equipment, other items shall be
carried out as per drawings. All the earthing strips shall be buried in floor (In ASS only)
prior to the floor epoxy coating work executed by civil contractor or wall as required and
all the fastening (by nut bolts) of earthing strips shall be tag welded as well.
5.5.14 Exothermic Welding shall be done by qualified welder having necessary required
certificates minimum qualification of welder is ITI trained from reputed institutes.
5.6 Material and manufacturing
5.6.1 Quality Assurance and Controls: The Contractor’s Management Systems shall
emphasize quality assurance and controls. The programme shall be adequate to ensure
an acceptable level of quality of the equipment supplied. The concept of total quality
assurance shall be based on the principle that quality is a basic responsibility of the
Contractor’s organization, and shall be visible by:
i. Firm procurement and job performance specifications.
ii. Firm procedures for transmission of information and data to their Subcontractors
and ensuring their compliance.
iii. Adequate testing to ensure repetitive product conformity to design requirements
and Total programme of surveillance and verification of physical performance and
configuration accountability.
iv. Adequate records shall be kept by the Contractor to provide evidence of quality and
accountability. These records shall include results of inspections, tests, process
controls, certification of processes and personnel, discrepant material, and other
quality control requirements.
5.6.2 The manufacturer shall ensure use of best manufacturing practice like quality of bends,
no sharp corners, and no metallic parts with sharp edges, use of quality gasket at
appropriate loss to damp vibrations and sealing etc.

5.6.3 The manufacturer shall study the environmental pollution data prevailing near the Metro
Station where its equipment is going be installed. The manufacturer shall take adequate
precaution either during manufacturing or installation to prevent any damage to the
equipment or loss of life arising due to prevailing pollution level.
5.6.4 Ground enhancement Material
Earth / Ground enhancement material is a superior conductive material that improves
earthing effectiveness, especially in areas of poor conductivity (rocky ground, areas of
moisture variation, sandy soils etc.). It improves conductivity of the earth electrode and
ground contact area. It shall be tested from third party NABL accredited lab and confirm
to the requirements of IEC 62561-7 having following characteristics:
 Shall be carbon based with min. 99% of fixed carbon content premixed with cement to
have set properties. Cement shall not mix separately & shall not have bentonite.
 Shall have resistivity of less than 0.12 ohms -meter.
 Shall have high conductivity, improves earth’s absorbing power and humidity retention
capability.
 Shall be non-corrosive in nature having low water solubility but highly hygroscopic.
 Shall be suitable for installation in dry form or in a slurry form.
 Shall not depend on the continuous presence of water to maintain its conductivity.
 Shall be permanent & maintenance free and in its “set form,” maintains constant earth
resistance with time.
 Shall not dissolve, decompose, or leach out with time.
 Shall not require periodic charging treatment neither replacement nor maintenance.
 Shall be suitable for soils of different resistivity.
 Shall not pollute the soil or local water table and meets environmental friendly.
Marking: The Earth enhancement material shall be supplied in sealed, moisture proof
bags. These bags shall be marked with Manufacturer’s name or trade name, quantity
etc.
5.7 Testing
5.7.1 Earthing material shall be confirmed to IS and IEC 62567 Part-1 to 8 as applicable.
5.7.2 The following earth resistance values shall be measured with an approved earth megger
and recorded.
i. Each earthing station / mat
ii. Earthing system as a whole
iii. Earth continuity
iv. Ground Enhance Material
a. Leaching Test
b. Corrosion test
c. Resistivity Test
d. Sulphur test
v. Exothermic Powder as per IEEE 837 as per table 1 etc.
a. Mechanical Test
b. Sequential test
5.7.3 Third Party Tests for Earthing Strips, Ground enhancement Material

contractor.

6 LIGHTNING PROTECTION
6.1 Detailed description and Application
6.1.1 The external Lightning Protection system is intended to intercept direct lightning flashes
to the structure, including flashes to the side of the structure and conduct the lightning
current from the point of strike to the ground. It should also disperse this current into the
earth without causing thermal or mechanical damage. The scope of work shall cover
supply, installation and testing of air and earth terminations and down conductors.
Protection of buildings against lightning shall be done to include the provision of a
parallel path lightning system complete with air terminal conductors, ground terminals
interconnecting conductors and other fittings required for the complete system.
6.2.1 The Lightning Protection system shall comply with standards mentioned particularly in
the table below unless otherwise stipulated in the specifications. The latest version of
standards shall be applicable.
IS / IEC-62305 Protection against lightning
IS: 3043 – 2018 Code of practice for earthing
NBC-2016 National Building Code -2016
All codes and standards mean the latest. Where not specified otherwise the installation
shall generally follow the Indian Standard Codes of practice or any other relevant
standard.
6.3 Requirements
6.3.1 Air terminations: Air termination systems can be composed of any combination of the
following elements:
i. Rods
ii. Meshed conductors
The individual air termination should be connected together at roof level. The air
termination shall be single point type of stainless steel (SS-316) material. The stem and
multi-point head shall be erected on the roof with a 150 x 150 x 6 mm stainless steel
(SS) base plate with a threaded socket of the same material welded to it. The base plate
shall be embedded in a concrete block to hold the elevation rod in a vertical position.
Air termination shall be one single rod without any joints.
6.3.2 Positioning of Air-terminations
Air termination components installed on a structure shall be located at corners, exposed
points, and edges in accordance with one or more of the following acceptable methods:
i. Protection angle method
ii. Rolling sphere method
iii. Mesh method
6.3.3 Down Conductor
The down conductors should be of SS-304 and to be arranged such that:
6.3.3.1 The down conductor shall follow the most direct path possible between the air
termination and the earth termination and several parallel current paths exist.

6.3.3.2 The down conductor shall be free of sharp bends, upturns and kinks and clamped to
the stem of the air termination by means of clamps. Each down conductor shall have
an independent earth termination and length of the current paths is kept to a minimum.
6.3.3.3 The roof conductor shall be clamped without puncher the roof.
6.3.3.4 The down conductor shall be clamped to the building outer wall at 600-mm centers.
All joints shall be lap welded. Welding shall be done by qualified welder having
necessary required certificates minimum qualification of welder is ITI trained from
reputed institutes.
6.3.3.5 Welding electrode samples to be approved by Engineer- In charge before execution.
6.4 Additional Requirements
6.4.1 A testing link shall be provided for each exposed down conductor, No need of test link
for concealed down conductor.
6.4.2 The entire lightning protective system shall be mechanically strong to withstand the
mechanical forces produced in case of a lightning stroke.
6.4.3 Horizontal air terminations shall be coursed along contours such as ridges, parapets
and edges of flat roof, and where necessary over flat surfaces in such a way as to join
each air termination to the rest and should themselves form a closed network. Also, the
entire conductor on roof and wall shall be connected over the conductor holders at every
1 meter as per IS / IEC 62305.
6.4.4 All metallic finials, chimneys, ducts, vent pipes, railings, gutters, metallic flag staff etc.
on or above the main surface of the roof of the structure shall be bonded to, and form
part of the air-termination network. If portions of a structure vary considerably in height,
any necessary air termination or air termination network of the lower portions shall be
in addition to their own conductors, be bonded to the down conductors of the taller
portions.
6.4.5 Each down conductor shall have an independent heavy-duty earth pit (Civil scope of
work). The interconnection of all the earth termination and the bonding with Earth mat
through non reversible diode / spark gap shall be done as approved by Engineer-In
charge. The material of Earth Electrode inspection housing shall be Poly plastic and
shall be capable to handle minimum 8-ton load. A / cover having identity mode “EARTH”
and having locking arrangement shall be suitably embedded in the enclosure.
6.4.6 An expansion piece shall be used as approved by Engineer-In charge in order
compensate the expansion and contraction due to weather conditions.
6.5 Maintenance and life:
i. The service life of the system shall be at least 30 years.
ii. The manufacturer should also submit Annual Maintenance cost rates for the full-
service life of the system.
6.6 Material and manufacturing
i. Firm procurement and job performance specifications.
ii. Firm procedures for transmission of information and data to their Subcontractors

iii. Adequate testing to ensure repetitive product conformity to design requirements

iv. Adequate records shall be kept by the Contractor to provide evidence of quality and
6.6.2 The manufacturer shall ensure use of best manufacturing practice like quality of bends,
6.6.3 The manufacturer shall study the environmental pollution data prevailing near the Metro
6.7 Testing
6.7.1 The entire installation shall be tested in accordance with the Indian Standard Code (IS
/ IEC62305, NBC-2016) and the ground resistance values shall be recorded for each
earthing Terminal.
6.7.2 The whole of the lightning protective system shall have a combined resistance to earth
not exceeding 10Ω.
6.7.3 Third Party Tests for SS 304 strip
contractor.
6.8 Training
6.8.1 On completion of installation, the manufacturer shall supply two sets of well bound
handing over manuals duly approved by Consultants / Engineer-in-charge. Each set
shall include: -
i. As Built Drawings.
ii. Do’s and Don’ts for the maintenance and operating staff.
iii. Extracts of the warrant / DLP.
iv. Soft copy of the entire documents.

7 UNINTERRUPTED POWER SUPPLY (UPS) & INVERTER

7.1 SCOPE
7.1.1 The scope of work shall cover supply, erection, testing, and commissioning of a static
Uninterrupted Power System meeting the performance criteria under equipment
schedule.
7.2 DETAILED DESCRIPTION
7.2.1 This section specifies the manufacture, supply, testing, and installation and
commissioning of Uninterruptible Power Supply System, hereafter referred to as UPS.
The UPS system shall consist of the UPS unit; Input and Output switch gear and Battery.
The UPS systems shall maintain a continuous AC Power supply to the loads classified
as of Emergency category loads for the Metro station in all possible power failure
scenarios.
7.2.2 The UPS, Battery and Input / output power supply switchgear are in the scope of different
vendors and come in the category of Vendor approval for the Contractor.
7.2.3 The UPS system in general shall consist of the following
i. Input / Output power supply panel
ii. Rectifier / Charger.
iii. Battery System.
iv. Battery Circuit Breaker.
v. Inverter.
vi. Static Bypass Switch.
vii. Built In / External Manual Bypass Switch.
viii. Control Units and Interconnections between different UPS Elements.
ix. Data logger, Digital Display, and annunciation.
7.2.4 This is only for guidance and may vary with technological advancements.
Specification for Uninterruptible power systems
IEC 62040 – 1,2 and 3 or latest
(UPS)
IEC 61643-1 or latest Surge Protective Devices
EN 61000-4-3 or latest EMC - Immunity
IEC 61000-3-2 / 61000-3-3 or EMC - Emission
latest Electromagnetic compatibility Testing and
IEC 61000-4 or latest Measurement Techniques
Source ISO 3746-2010 or latest Sound Level of Noise
IEC 60695-11-20 or latest Flammability Tests
BS 55014-1 or latest Radio frequency interference (RFI) levels
Low Voltage Switchgear and Panels
IEC 61439 or latest
Low-voltage Switchgear and Control gear
IEC 60947 or latest
Assemblies
BS 7671 or latest IEE Wiring Regulations
BS 7430 or latest Code of practice for Earthing
7.4 REQUIREMENTS
7.4.1 Functional Requirements

7.4.1.1 Features: The UPS shall be a true parallel redundant, (Clause 3.1.35 of IEC 62040-3)
Double Conversion (Clause 3.2.16 of IEC 62040-3) (VFI technology Online type.) and
shall configure to A.3.2.2 of the IEC 62040-3 as Parallel Redundant with bypass. The
UPS system shall consist of the components as defined under clause 3.1 of IEC 62040-
3.
7.4.1.2 The loads are generally linear to clause 3.2.6 of IEC 62040-3 but shall cater to nonlinear
loads to clause 3.2.7 of IEC 62040-3. UPS shall be compatible to take non-linear loads
and capable to handle high crest load. The UPS shall be suitable for taking unbalanced
load vide clause 3.5.22 of IEC 62040-3. UPS shall be provided with input power factor
correction features.
7.4.1.3 Capacity: The capacity of the UPS shall be as per the BOQ. However, in general the
Ratings of UPS standardized for Delhi Metro applications are 20 kVA, 30 kVA, 60 kVA
and 80 kVA.
7.4.2 Modes of Operation
The UPS shall operate in the following modes: -
7.4.2.1 Normal Mode (Mains Up) Clause No. 3.2.13 of IEC 62040-3
7.4.2.2 Stored Energy Mode (Mains Down) Clause 3.2.14 of IEC 62040-3
7.4.2.3 Battery Recharge (Mains Restored)
i. When mains supply is restored from failure or restored via automatic supply
changeover switch, the rectifier / charger shall resume the supply of DC power to the
Inverter and batteries. During this period, no interruption or disturbance shall be
caused to the inverter output.
ii. When the battery system is fully charged, the rectifier / charger shall automatically
adjust the output voltage to float charge the battery system.
7.4.2.4 Automatic By-pass Mode (Static By-pass Switch) as defined vide clause 3.2.15 of
IEC 62040-3 and also as following:
i. In the event of overloads exceeding system capabilities (short-circuits, heavy inrush
current or battery capacity being exhausted upon rectifier / charger supply down) or
the detection of internal faults, the static by-pass switch shall instantaneously
synchronize with the inverter output and transfer the loads to the bypass supply
source without load interruption.
ii. Retransfer of the load to the UPS shall be accomplished, after the restoration and
stabilization of the output power modules to the specified tolerances, without
disturbance to the load. In both these transfers, UPS output voltage and frequency
tolerances must remain within the specified limits.
7.4.2.5 Built In / Manual By-pass Mode (Maintenance) as defined vide clause 3.2.15 of IEC
62040-3 and also as following:
i. The external independent manual bypass switch shall be manually operated to
Perform, make-before-break switching of the UPS load to either the UPS or the
Mains supply source without load interruption, for UPS maintenance purposes. On
UPS load being connected to by-pass supply, full access to the UPS input / output
Equipment shall be possible.
7.4.2.6 Maintenance of Batteries
i. For maintenance purposes, it shall be possible to isolate the battery system from the
rectifier / charger and the Inverter by means of a circuit breaker. In such a case, the
UPS shall continue to supply the load as specified herein, except in the event of
mains supply outage.
7.5 SUB COMPONENTS OF UPS SYSTEM

7.5.1 Rectifier / Charger

7.5.1.1 The input of the rectifier / charger shall be protected by a circuit breaker with adjustable
settings. A walk-in circuit shall be provided at the rectifier / charger input to eliminate
sudden inrush current from the mains supply or changeover of supply source. The
current walk-in shall take place to allow a gradual increase in the loading in the mains
supply source.
7.5.1.2 The UPS shall have IGBT rectifiers to remove harmonics. The converter should be solid
state PWM converter with IGBT rectifiers. The converter should have the following
important features.
i. Power Conversion
ii. Battery Charging
iii. Power Factor Improvement
iv. Current Harmonic Reduction
v. Voltage Regulation
vi. Transient Recovery
vii. Automatic Synchronization
viii. Over-current Protection
ix. Over Temperature Protection
x. Control Power Failure Protection
xi. Short Circuit Protection
xii. Current limiting function of battery charging to prevent the battery from being
damaged.
7.5.1.3 The rectifier / battery charger shall provide a regulated DC output for the inverter and
the battery. The rectifier / charger regulation shall ensure that the DC output voltage
fluctuations are less than 1% of rated value, irrespective of load and mains supply
voltage variations.
7.5.1.4 The rectifier / charger shall be equipped with a filter limiting the DC ripple voltage to a
value less than 1% of the DC voltage.
7.5.1.5 The rectifier / charger shall have sufficient capacity to enable simultaneous supplying of
full load to the inverter and recharging a fully discharged battery to 100% rated value
within 10 hours.
7.5.1.6 A protective circuit shall be provided to prevent battery overcharge. After the rectifier /
charger has recharged the battery to 100% capacity, the rectifier / charger shall float
charge the battery.
7.5.1.7 Provision shall be made to prevent the battery from over-charging due to battery charger
rectifier fault. An adjustable battery current limiting device shall limit the battery recharge
current to the maximum value recommended by the battery manufacturer. The rectifier
/ charger shall be electronically current limited to protect the connections to the Inverter
input and to prevent damage to the battery.
7.5.1.8 The battery low-volt cut-off shall be set to suit the battery manufacturer's
recommendation to ensure the battery is not damaged by a deep discharge.
7.5.1.9 The rectifier / charger unit shall be equipped with an over-voltage protection device.
7.5.2 Inverter
7.5.2.1 The inverter shall be a solid-state device with proven Pulse Width Modulation technique
utilizing Insulated Gate Bipolar Transistors and microprocessor controls, capable of

accepting the output of the rectifier / charger or the battery system and provide a 3-
phase alternating current output complying with the performance requirements.
7.5.2.2 The inverter shall utilize the latest and reliable technology to achieve high efficiency and
reliability, and to cope with non-linear loads. The inverter should incorporate following
essential features:
i. Voltage Regulation
ii. Transient Recovery
iii. Automatic Synchronization
iv. Over-current Protection
v. Over Temperature Protection
vi. Short Circuit Power Protection
vii. High Speed switching
viii. Frequency Control
ix. Inverter Output Voltage Harmonic distortion
x. Inverter Overload protection
xi. Each inverter leg shall be protected from over-current to prevent damage to the
solid-state devices in the inverter bridges.
7.5.2.3 The inverter output shall be electronically current limited.
7.5.2.4 The inverter shall be protected against over voltage and under voltage surges
introduced at the output of the uninterruptible supply system by load switching and
transfer to the bypass. If the bypass AC line deviates by more than 50 Hz ± 3%, the
inverter logic shall automatically revert to 50 Hz ± 1 Hz and initiate an alarm condition
the time taken to recover from transient to normal voltage shall not be more than 20
milliseconds.
7.5.3 Automatic Static Bypass Switch
7.5.3.1 The UPS shall be provided with a static by-pass switch (make before break type) which
is synchronized with the UPS. In the case of inverter failure, sub-circuit failure, load
start-up inrush or battery capacity being exhausted upon rectifier / charger supply down,
the static bypass switch shall transfer the load to the mains automatically within 4 milli-
seconds. The UPS shall withstand the switching transient or fault energy produced
during operation of the static bypass switch parallels two different supply sources. Full
protection discrimination shall be achieved on the bypass circuit. In case of a single
sub-circuit fault, the capacity of the static by-pass switch shall withstand the fault energy
until the protective device of the sub-circuit clear the fault. The continuous capacity of
the Static bypass switch shall be equal to the 100% continuous rating of the inverter.
The overload capacity shall be equivalent to the overload characteristics of the UPS.
The current handling capacity of switch shall be 10 times for 20 milliseconds.
7.5.3.2 The means of operation shall ensure an uninterrupted transfer of load to or from the by-
pass supply source under both automatic and manual mode of operation.
7.5.4 Transfer conditions
7.5.4.1 The static bypass switch shall transfer from the inverter to the by-pass supply source
under the following conditions:
i. Inverter under voltage (less than 90 % of nominal),
ii. Inverter over voltage (greater than 110 % of nominal),
iii. Inverter overload,

iv. Inverter shut down for any reason (including failure)

v. Manual signal.
vi. DC circuit under voltage or over voltage.
vii. Final end voltage of the system battery is reached.
7.5.4.2 At the same time, the inverter output shall be isolated to prevent the bypass supply
source from back feeding power to the inverter.
7.5.5 Retransfer to Inverter
7.5.5.1 The static by-pass switch shall be capable of automatically retransferring the load back
to the Inverter after the Inverter has returned to normal voltage and stabilized for a
period of time or the overload due to short-circuit or high inrush current has
disappeared. The system shall only retransfer the load to the inverter provided all the
following conditions are met:
a) The inverter and the bypass supply source are synchronized.
b) Inverter voltage is within ± 5% of nominal for 2 to 30 seconds (adjustable).
c) Manual transfer signal off.
d) The overload current disappears within 1 to 10 minutes (adjustable).
7.5.6 Independent Manual By-Pass Switch
7.5.6.1 A manually operated mechanical manual bypass switch shall be provided for the for
maintenance on UPS and battery. The transfer scheme shall be make-before break
uninterrupted transfer of the load from the static bypass switch output to the external
manual bypass supply source or vice versa. The switching arrangement shall be
designed to electrically isolate the UPS from the distribution board. The current
switching capacity of the manual bypass switch shall be at least four times the UPS
rated output current. Key interlock between external manual bypass switch and the
inverter switch shall be provided such that the inverter output cannot be changed over
with the external manual bypass supply source directly.
7.5.6.2 In addition, the manual bypass switch shall be pad-lockable.
7.6 VRLA BATTERY SYSTEM
7.6.1 Twin Battery banks supplying 100% rated load suitable for half hour back up with each
UPS i.e. two banks of 30 minutes backup for a set of UPS over its full-service life complete
with heavy duty, high discharge valve regulated lead-acid type batteries, battery racks
and interconnecting cables shall be provided.
7.6.2 The battery capacity shall be designed for long life (Design life of 10 years) for 2V SMF
VRLA with uniform charging and discharging rates. Recombination cells, thus obviating
the specific need for flameproof equipment in the UPS room.
7.6.3 The overall capacity of the battery system shall be such as to meet the specified
performance and technical requirements throughout the life of the battery. The battery
capacity shall be designed for long life with uniform charging and discharging rates. In
calculating the battery capacity, an ageing and de-rating factor, advised by the supplier
shall be taken into account, this factor shall not be more than 0.8. Battery sizing
calculations shall assume an ambient temperature of up to 40ºC and room temperature
of 25ºC. The battery cell shall be heavy duty, rechargeable, valve regulated lead acid and
maintenance free type and the performance shall comply Battery shall be in conforms to
IEC 60896-21&22 having an intended design life of at least 10 years.
7.6.4 The charging of the battery to be done by the supplier at site. All equipment like charger
and material required for charging should be provided by the supplier.

7.6.5 Contractor shall provide design calculations for selection of battery sizing & capacity in
VAH duly considering ageing factor of 0.8, end cell voltage 1.75 and, load power factor
of 0.8, & 10 % design margin.
7.6.6 On restoration of grid power, the converter should automatically reactivate and provide
DC power to the inverter, simultaneously recharging the system battery in boost mode
and automatically switch to float mode after full charge recovery of the battery.
7.6.7 VRLA Battery shall be fitted in mild steel rack module as VRLA Cells require to maintain
compression. The rack shall be designed to provide easy access to all components for
maintenance and to minimize floor space requirements.
7.6.8 The battery shall have sufficient capacity and discharge characteristic to meet the
requirement listed. The battery shall be suitable for the following charging duties: A fully
discharged battery shall be charged to 75 % of its rated capacity within 8 hours under
float charge conditions.
7.6.9 A fully discharged battery shall be charged to 100 % of its rated capacity within 10 hours
under boost charge conditions
7.6.10 VRLA battery container shall be flame retardant polypropylene Opaque type and
shrouded terminals shall be provided.
7.6.11 VRLA batteries come with sleeved connectors and terminal shrouds on the terminals, so
that no base metal is exposed. Hence no isolation is required and can be in operation
with complete safety. As stated, isolation is not required in VRLA batteries which comes
in modules and fully protected from any exposure to electricity. Further a fully enclosed
cabinet with doors will not allow air circulation which will affect the thermal management
of the VRLA batteries thereby affecting life.
7.6.12 Racks shall be made of mild steel and a coating of non-conductive and fire-retardant
material for ex- paint is required.
7.7 TUBULAR BATTERY
7.7.1 DETAILED DESCRIPTION AND APPLICATION
7.7.1.1 This specification covers the design, manufacture, testing at manufacturer’s works,
packing, supply, and delivery to site of Tubular type lead-acid stationary batteries in
Monobloc container and associated accessories for indoor installation. Supervision of
erection and commissioning of the battery bank shall have to be undertaken on mutual
acceptance as per the terms and conditions for the same, if required.
7.7.2 GOVERNING SPECIFICATIONS
7.7.2.1 The tubular batteries shall comply with the governing specification, as given in the table
below:
TUBULAR BATTERIES
Stationary lead acid batteries (with tubular positive IS- 13369-1992 or latest
plates) in monobloc containers
Water for storage batteries IS-1069 or latest
Sulphuric acid for storage batteries IS-266 or latest
Specification for rubber and plastics container for lead IS-1146 or latest
Acid storage batteries
Synthetic separator for lead acid batteries IS-6071 or latest
7.7.3 Requirements

7.7.3.1 All the requirements shall be as per IS 13369. Any additional or specific requirements
are as follows:
a) Constructional Requirements
Type: The battery shall be lead acid Tubular type in Monobloc container. The cells of the
batteries shall be similar in type and shape. The batteries should preferably be of 12 volts.
b) Cell Lids:
It should be easily removable, if the need arises. The material shall confirm to IS-1146.
c) Connectors and fasteners (Flexible):
i. Connectors should be adequately designed to carry maximum duty cycle as
specified and shall offer minimum resistance. While considering the terminal voltage
of the cell at the time of Testing for discharge, the voltage drop due to inter-row and
inter-cell connectors shall be considered.
ii. Connectors shall be adequately designed to withstand various stresses due to
temperature changes, attack of acid and dynamic forces that could occur during the
operation of the battery. Fasteners should be made of suitable material such as
copper, brass, stainless steel, or any to prevent corrosion.
d) Electrolyte
Required quantity of electrolyte for the initial filling with 10% extra quantity shall be
supplied in non-degradable acid resistant strong plastic containers.
e) Terminal Post
All metal parts of the terminals shall be of lead coated type. Bolts, heads and nuts, except
seal nuts, shall be lead coated. The junction between terminal posts and cover and
between the cover and container shall be adequately sealed to prevent any seepage of
the electrolyte. All terminals shall be provided with insulated covers.
f) Ampere – Hour Rating
The rating assigned to the cell or battery shall be the capacity expressed in ampere hours
(after correction to 25 degree C) stated by the manufacturer, to be obtainable when the
cell or battery is discharge at the 10-hour rate to the end voltage of 1.80 volts per cell.
Expected life of battery under Normal operation & maintenance 10 Years
Condition
g) Temperature Correction
The capacity of the cell shall be corrected to 25˚C using the proper temperature correction
factor pertaining to the type of the cell and the rate of discharge. The temperature
correction should be made using factors supplied by the manufacturer but shall generally
conform to some national or international standard for the similar type of cell.
h) Design margin
The design margin for the battery shall be 10%.
i) Ageing factor
An ageing factor of 25% shall be considered.
7.7.4 Additional Requirements
a) Service condition
The battery is required to work at ambient temperatures up to 45-degree C.

b) Battery rack
The battery racks shall be constructed from good quality of high strength good quality
mild steel sections. These battery racks shall be painted with two coats of acid / alkali
resistant paint of approved make. The racks shall be of Single tier / two tier construction
depending on the final layout based on space availability.
c) Marking:
i. Each cell shall be marked to meet the requirements of relevant Indian standards. In
addition, each cell shall be legibly numbered serially to identify the cell during
manufacture, testing, installation, and operation of battery to identify after having
assembled into battery bank in battery racks.
ii. The marking shall be provided as per IS 13369. A set of loose stickers shall be
provided to mark the cells position in the assembled battery bank at site so that a cell
removed for maintenance can be put back in original position.
iii. The bidder should Provide onsite replacement warranty for 60 months including Free
Preventive & corrective Maintenance for the warranty period.
7.7.5 Safety
7.7.5.1 Battery Protection and charge controller
a) The battery bank shall be protected from internal fault by a circuit breaker. The
battery circuit breaker installed at the battery room should be complete with a metal
enclosure conforming to an Ingress Protection Classification of IP 54.
b) The UPS shall be automatically disconnected from the battery bank when the
discharge limits of volts per cell are reached, or when signalled by other control
functions.
c) Temperature monitoring equipment shall be incorporated in the UPS system to
optimize the charger voltage as a function of battery room temperature, to generate
alarm in case of room temperature exceeding the pre-set permissible temperature
and to predict the battery backup time.
7.7.6 System efficiency shall be as per IS 13369.
7.7.7 Reliability
The service life of batteries shall be 10 years. The manufacturer shall submit details of
maintenance required by batteries to ensure long service life.
7.7.8 Special condition
A representative from the side of battery manufacturer should be present during
commissioning of UPS and battery bank so as to ensure that the DC link voltage set by
the UPS manufacturer is as per the requirement of battery bank. The battery
manufacturer shall also certify that whether commissioning done at site is satisfactory.
7.7.9 Testing
a) The manufacturer of the batteries must have type test certificates, from an accredited
third party, for all the tests specified IS 13369 and shall not be more than five years
old.
b) In case, these are not available, manufacturer will be required to get these tests
executed from an accredited third party.
c) The factory acceptance tests shall be done in accordance with IS 13369.The
equipment shall be dispatched after testing in presence of authorized representative
of purchaser.

d) The manufacture representative shall be available at the time of commissioning of

batteries at site. The manufacture shall issue a certificate to the affect that the
batteries have been installed and commissioned as per his approved scheme for the
purpose.
7.8 ENVIRONMENTAL CONDITIONS
7.8.1 All equipment shall be capable of withstanding any combination of the following external
environmental conditions without any mechanical or electrical damage or degradation /
deterioration in performance:
a) Operating ambient temperature: 0ºC to 45ºC
b) Relative humidity: Up to 95 %
c) Storage temperature 0ºC to 50ºC
d) Operating altitude: As per IEC 62040-3.
7.8.1 The equipment shall be designed to provide rated output at the extreme environmental
conditions specified above.
7.9 PERFORMANCE REQUIREMENTS
7.9.1 Input Parameters
a) Input Voltage: - 415 V (AC) / 240 V (AC) (As per requirement). Each with input voltage
tolerance of (–10% to + 10%).
b) Wiring: - 3-phase, 4 wire and earth for Three Phase input / Single phase and Neutral
for Single Phase input.
c) Input Frequency: - 50 Hz ± 5%
d) Input Power Factor: - The total power factor of UPS as a load shall be from 0.99
lagging to unity, with rated load, fully charged battery, and input voltage within (10%
to + 10%) of the nominal value.
e) Harmonics on Input Voltage: - Input voltage distortion factor shall not exceed 0.08
and harmonic components shall not exceed values given in IEC 62040-3, Clause
5.2.1 d
f) Reflected Input Current Harmonics: - The rms value of all harmonics in the input
current waveform contributed by UPS shall be less than 5%.
g) Current Limiting: -The system shall be provided with inrush current limiting to 125%
of the rated UPS load current
7.9.1 Output Parameters
a) Rated voltage: 415 / 240V, 3 Phase 4 wire / single phase respectively.
b) Steady state voltage regulation: ± 1% for a load between 0 and 100% of full Rated
value, irrespective of value of the normal mains supply voltage and DC Voltage,
provided these voltages are within the limits specified.
c) Transient voltage regulation: Should be less than 3%.
d) Output Voltage harmonic distortion: An output filter to be provided to limit total
distortion to less than 5% with no single harmonic greater than 3%, irrespective of
load and normal mains supply, provided these are within the limits specified.
e) Steady state voltage unbalance (difference between phase voltage and the
arithmetic average of the three-phase voltage): ±1% maximum for balance load, ±

3% maximum for 50% unbalance load.

f) Phase displacement: 120°±½° for balanced load; 120°±1° for 50% unbalanced load.
g) The output voltage shall not dip more than 20% in case of any fault on the load side
of UPS.
h) Output Frequency shall be as following: -
i. Rated frequency: 50 Hz.
ii. In normal operation, the output frequency of the inverter shall be synchronized to
that of the bypass supply source within the limits of 3% (settable)
iii. For frequency variations exceeding these limits, the inverter shall switch over to
free-running mode, with regulation, providing an output frequency to within 1 Hz
of the rated value without switching to batteries.
iv. Frequency slew rate: 2 Hz / second minimum maximum.
i) Load Current Crest Factor: A crest factor up to 3:1 for the load current shall be
anticipated.
j) Load Unbalance Capacity: -The UPS shall have the capability to accept up to 50%
load unbalance with the ratio of current in the most loaded phase to the current in
the least loaded phase not exceeding 2, provided that the most loaded phase current
does not exceed the rated line current.
k) Overload Capability: -The UPS shall be able to supply 110% for 60 minutes, 125%
rated load for at least 10 minutes and 150% rated load for at least 1 minute
l) Output power factor: - 0.9 and above.
7.9.2 Noise Level
7.9.2.1 Noise emanating from the UPS during operation shall not exceed at a distance of 1.5 m
from the enclosure, over a load range of 10% to 100% of the rated full load and
measured as per the standard. It should be possible to change the internal parameters
of the UPS (initially set by the manufacturer) in order to vary the output parameters, if
required. The UPS shall automatically analyse the condition of the battery string on a
programmable period. It shall detect and enunciate the battery failure condition locally
and remotely. The periodic test shall not impair the battery readiness in case of normal
supply outage
a) 70 dBA for 80 kVA UPS
b) 65 dBA for 60 kVA & 30 kVA UPS
c) 55 dBA for 20 kVA and below UPS
7.10.1 Diagnostics
7.10.1.1 The UPS shall be fitted with a Microprocessor based Supervision and Diagnostic
System, which monitors all aspects of the UPS operation. The system shall aid in the
rapid identification of internal faults.
7.10.1.2 UPS shall be provided with RS 485 compatibility for remote monitoring and to extend
alarm & status indications, annunciation, and metering to BMS System located in
Station Control Room. It shall be provided to communicate with an external computer
for remote monitoring and diagnostics. The communication protocol shall be clearly
documented and submitted for approval by the Engineer. Contractor must interface with
the BMS Contractor regarding this

7.10.1.3 All the necessary software and hardware accessories shall be provided at the Station
for the monitoring and diagnostics of the UPS via the RS 485 data interface.
7.10.2 Display
7.10.2.1 All the modules and accessories shall be integral part of the main cubical and provide
controls, metering & monitoring system, and self-fault diagnostic / annunciation system
for healthy / faulty status through LEDs, data logger with LCD display suitable display
and power monitoring software for operational status locally. The UPS shall be fitted
with an integral control and indication panel.
7.10.3 Instrumentation
7.10.3.1 The UPS shall be provided with, digital instrumentation to indicate, as a minimum, the
following information. All readings shall have an accuracy of at least ± 0.5% of true value
and the settling time shall be less than 1 second. If certain meter is used to display more
than one parameter, a manual selector switch shall be provided for reading selection.
a) True RMS voltage
i. UPS input voltage with phase selection
ii. Rectifier output voltage
iii. DC battery voltage, and
iv. UPS output voltage with phase selection
b) True RMS current (crest factor – 3:1)
i. UPS input current with phase selection
ii. DC battery charge / discharge currents
iii. UPS output current with phase selection and
iv. By-pass source current with phase selection.
c) Frequency
i. Mains frequency, and
ii. UPS output frequency
d) Power (kW)
i. UPS output power with phase selection
e) Power Factor
i. Inverter output power factor
ii. Elapsed operating time.
7.10.4 Indications and alarms
7.10.4.1 The UPS shall include a mimic diagram with LED suitable display indication for the UPS
equipment status and audible and visual alarm alerting annunciation. The status
indication and alarm annunciation with the associated protection and control circuits
shall include, but not be limited to, the following status and alarms.
a) Equipment Status Alarms
i. UPS Input Voltage
ii. UPS Output Voltage
iii. Dual Supply, Healthy Status
b) Rectifier / Charger

i. Rectifier Normal / Failure

ii. Rectifier Failure
iii. Boost / Float Charge
c) Battery
i. Battery Charging / Discharging
ii. Circuit Breaker Open
iii. Battery Test Run
iv. Battery Discharging
v. Battery Low Voltage
vi. Battery Earth Fault
vii. Battery Test Fail
viii. DC Over voltage
d) Inverter
i. Inverter Normal / Failure
ii. Inverter Failure
iii. Inverter Overloaded
iv. Output over voltage / under voltage.
e) Static By-pass
i. By-pass Normal / Failure
ii. Load on Inverter / Bypass
iii. By-pass Failure
iv. Synchronous Failure
v. Static switch on manual
f) Manual Bypass
i. Load on UPS / Bypass
ii. Manual Bypass Off / On
iii. Transfer Inhibited
g) Ventilation
i. Fan Normal / Failure, or
ii. Over temperature alarm / shutdown (two stages)
iii. Fan Failure, or
iv. Over temperature alarm (adjustable)
v. Over temperature shutdown (adjustable)
h) Emergency Pushbutton
i. UPS On / Emergency Shutdown
ii. Emergency Shut Down with protective cover.
i) Common Alarm

i. Alarm triggered - Common Alarm

7.10.4.2 Also, the following control should be present:
a) Alarm test / reset push buttons
i. Lamp test / reset push buttons,
ii. Alarm silence push button.
7.10.4.3 There should be an alarm upon the occurrence of any faults or failures as mentioned
above, along with an indication at the remote BMS panel. Audible and visual
annunciation shall be activated at the indication panel when an alarm has occurred.
Such annunciation shall be latched on alarm occurrence and shall be such that it can
only be cleared by pressing a manual reset button.
7.10.4.4 The alarm state indications on mimic diagram shall remain until a manual reset switch
is operated and the alarm state has been cleared.
7.10.4.5 Remote monitoring status: - The following critical status and alarms of UPS shall report
to Station Building Management System (BMS) controller for remote monitoring via volt-
free contacts rated 24 V DC, 1A provided in the UPS modules:
a) Supply A normal / failure
b) Supply B normal / failure
c) Load on inverter / bypass
d) Battery charging / discharging
e) Manual bypass off / on
f) UPS (rectifier / charger / inverter / bypass switches) common alarm
g) Battery common alarm
h) Fan normal / failure or Over temperature alarm / shutdown
i) UPS on / emergency shutdown.
7.10.4.6 Remote Control: - There will be no remote control for the UPS except Emergency
shutdown push buttons in readily accessible locations, fitted with non-lockable covers
or shrouds.
7.10.4.7 There should be a system of communication provided with the UPS for transferring the
Battery run test and inverter failure data to mobile telephone of OCC in the elevated
stations.
7.11 SAFETY
7.11.1 UPS shall be designed for low impedance, less than 50V touch voltage and limited ripple
content. Two independent and distinct earth electrodes connections shall be provided for
earthing of UPS connections comprising 50 x 4 mm Copper strips / 50 x 6 mm GI strips
or as required / approved. Surge protective devices shall be provided at the inputs and
output of the UPS to protect the UPS and the load equipment against any power surge
due to lightning, switching, etc
7.11.2 The UPS system shall be equipped with an interlocking system to prevent parallel
operation of any non-synchronized sources activated either by any manual switches or
automatic switches. The UPS output shall be supplied via means of isolation with suitable
protection, sufficient to supply the full rated output load. The module shall be designed
such that if there is a single fan failure or over temperature, an alarm shall sound, but it
will in no way produce degradation of performance. In case of unavoidable shutdown due
to excessive temperature rise, a warning alarm shall be given out before the shutdown.

All cabinets shall be solidly bonded to earth in accordance with BS 7430 using adequate
section of cable or bus bar. The earth connection at the cabinets / enclosures shall be
made to the frame earth provided or alternatively to a substantial part of the basic frame
rather than a bolted - on panel.
7.11.3 Circuit Protection
7.11.3.1 Means of isolation with suitable protection shall be provided at both input and output
within the UPS, which fully discriminate with upstream and downstream circuit breakers.
The system shall be provided with component protection, to minimize damage and
downtime in the event of component failure, against:
a) AC Supply voltage transients and transfers.
b) Internal faults.
c) Sustained overload.
d) Load switching transients.
e) Current surges.
7.11.3.2 The system shall be provided with interlocks to prevent accidental damage to the UPS
during maintenance or normal operation.
7.11.3.3 UPS system shall be designed with protection & annunciation system for monitoring the
following:
a) Phase sequence.
b) Overload and short circuit trip.
c) Earth fault.
d) Reverse Power Flow.
e) Low battery voltage.
f) Fault indication alarm through suitably designed hooter.
g) Self-diagnostic annunciation system.
h) Ventilation Failure
i) Temperature monitoring
7.11.3.4 The manufacturer shall provide the scheme of operation of various protective devices
for the above-mentioned conditions.
7.11.4 Emissions in case of fire
7.11.4.1 The equipment shall produce low smoke and no toxic emissions in case of internal or
external fire / over-heating. The equipment shall not have any component which bursts
with smoke or toxic emission. The AC and DC capacitors used shall have over pressure
safety device or disconnector. Cables, wires & insulating materials used, shall be fire
retardant, low smoke and zero halogen material.
7.12 SYSTEM EFFICIENCY
7.12.1 The efficiency of the proposed UPS shall be at least 90% and above from 25% load to
full load. The life and efficiency is of prime importance. The manufacture may offer UPS
with any new proven technology having advantage of life and energy efficiency without
compromising on other parameters of specification.
7.13 RELIABILITY, MAINTENANCE, SPARES & LIFE

7.13.1 The system shall have high operating efficiency, front access, and self-diagnostic
features. There shall be sufficient redundancy in all vital parts to achieve a breakdown
free operation of the system. The reliability shall be greater than 99.9%. The
manufacturer shall provide data confirming to the required reliability.
7.13.2 The UPS shall be designed for maintenance free working. The conditioning monitoring
system through sensing of all parameters of working equipment’s shall be designed to
take care of incipient faults to undertake any unscheduled repairs without causing
consequential damages.
7.13.3 Equipment shall be designed and manufactured in modular manner to facilitate the fault
diagnosis and replacement of each modular part. Each module shall be capable of being
interchanged with other modules of the same type without affecting the rest of modules
in place
7.13.4 The service life of the UPS system shall be at least 20 years. The manufacturer shall
submit the list of those items whose life does not match with the service life of UPS. The
life of such spares shall be advised with a certificate from the manufacturer of the spares.
The firm shall provide purchase specification of these items.
7.13.5 The manufacturer shall submit a list of all the spare parts with price list to be kept after
the expiry of defect liability period.
7.13.6 The vendor shall provide the Annual Maintenance cost of UPS system (including
batteries) for their full-service life, in blocks of 5 years or year wise.
7.14 MATERIAL AND MANUFACTURING
7.14.1 Quality Assurance and Controls the Contractor’s Management Systems shall emphasize
quality assurance and controls. The programme shall be adequate to ensure an
acceptable level of quality of the equipment supplied. The concept of total quality
a) Firm procurement and job performance specifications.
b) Firm procedures for transmission of information and data to their Subcontractors
c) Adequate testing to ensure repetitive product conformity to design requirements
d) Adequate records shall be kept by the Contractor to provide evidence of quality and
e) Complaint handling and commitment towards customer satisfaction.
7.14.2 ISO certifications to which the quality standards are complied
7.14.3 Materials and Workmanship Requirements
7.14.3.1 All materials and processes to be used, whether incorporated in equipment at the
manufacturer’s works or used for installation at site, shall comply with the requirements
of this M&W Specification and shall conform to good modern practice. The following
requirements shall be the minimum requirements and they shall not relieve the Supplier
from ensuring that his designs are fit for purpose, and that all materials and processes
are suited to their intended purposes and environments. The basic workmanship and
manufacturing principles shall be visible during visual inspection such as no sharp
corners, sizing of screws / bolts, cable layout and identification, bedding and rubbing of

parts, clearances, user friendly switches and indication panel etc.

7.14.3.2 All equipment and components supplied under the Contract shall have proven reliability
and shall be designed, manufactured, and installed to meet the specified and / or
relevant international or national standards. The Contractor shall submit to the Engineer
for approval, a list of all supplied equipment and components with a declaration of
conformance to standards.
7.14.3.3 The manufacture shall supply information about the bill of material used in the
manufacturing of the product if the Engineer so desire to satisfy himself about the use
of quality material.
7.14.4 Mounting and Enclosure
7.14.4.1 UPS shall be free standing and mounted as a whole on a heavy-duty fabricated steel
base frame constructed from folded channel sections with suitable mounting pads. All
air entries shall be protected with cleanable filters. The cabinets shall be vermin and
dust proof with IP 20-degree protection.
7.14.4.2 The Cabinet shall be constructed with material of thickness 1.6 mm for non-load bearing
members and 2.5 mm for load bearing members and suitably braced to form a rigid
structure. Full substantiation of mechanical strength shall be provided for approval to
demonstrate that the cabinet is free from distortion when equipment is mounted and
support on floor. All metallic cabinets shall have treatment for corrosion protection and
painted with epoxy polyester paint.
7.14.4.3 The dimensions of the cabinets shall be optimally sized without requiring excessive floor
space.
7.14.4.4 The equipment shall be constructed in modular units, which shall be installed in metal
enclosures designed for floor mounting. Each module shall be constructed on a rigid
base frame. Sub-assemblies and components shall be mounted on pull out and / or
swing out trays. Cable connections to the cable ladder and trays shall be of sufficient
length to allow for easy access to all components.
7.14.4.5 The UPS cabinet shall have a clear area of at least 900 mm in front to allow the doors
to be opened fully and maintenance to take place. Doors shall be fitted with lockable
handles or other approved means of fastening and shall be provided with locking bars
and guides to prevent distortion. Cabinet shall be arranged so that access doors or
panels into compartment can only be opened when the locking device is in the unlocked
position. Two sets of keys shall be provided for each lock.
7.14.4.6 Each Cabinet shall be fitted with metallic gland plates for entry of cables and an earth
terminal. Foundation bolts and lifting hooks or eyes shall be provided as necessary for
handling purposes.
7.14.4.7 It shall be fitted internally with a nameplate, which shall state the manufacturer’s name,
address, telephone and e-mail address, serial number, rating, and year of supply.
7.14.4.8 Danger warning notices with red letters on a white background shall be fitted to covers,
which give access to live terminals or conductors at and above 110 volts. The danger
board should be provided as per Indian Electricity Rules.
7.14.4.9 Circuit and function labels shall be provided. All labels shall be in one language as
approved by Engineer. All switches or control unit provided for operation by Operating
Staff shall be labelled with prominent display by letter size of minimum 6 mm.
7.14.4.10 The modules shall be designed to be transported in a horizontal and / or vertical
mode as may be necessary to enable installation of the modules in the positions
designated on Site.
7.14.4.11 Each of the items shall be adequately packed and protected against damage in
transit from the manufacturer’s work area to the Site. Similarly, after delivery to Site,

each cubicle shall be properly protected from damage until work is completed.
7.14.4.12 The mechanical and electrical design of all cabinets shall be submitted for approval
by the Engineer.
7.14.4.13 Each cubicle shall be fitted with a designation label to show voltage rating and duty
on the front and rear of the cubicle.
7.14.4.14 Each cubicle shall be provided a space for keeping operating manual along with other
documents related to the UPS with suitable labelling.
7.14.4.15 Electronic Components and Sub-Assemblies: Each plug-in module or printed circuit
board shall be securely plugged into the main unit with guiding construct to hold the
module in place. Printed edge connector shall not be used.
7.14.4.16 Printed circuit boards shall have sufficient thickness to ensure its mechanical rigidity
and to eliminate the risk of damage during installation and maintenance. Dip switches
shall be avoided as far as possible. Jumper wire is not allowed.
7.14.4.17 Printed circuit boards shall be designed and manufactured to the accepted
standards, which shall include standards for conductor thickness, width and spacing.
Different standards shall be applied to equipment operated under different conditions if
applicable.
7.14.4.18 All plug-in modules shall be clearly and unmistakably identified. Labelling with
module name, part number, serial number and revision number shall be provided.
7.14.4.19 LED shall be provided with each plug-in module or printed circuit board to indicate
the power supply and component fault status. They shall be easily visible without any
obstructions.
7.14.4.20 The rated voltage of insulated terminal blocks shall be 415 V between terminals, 240
V to earth. Insulated terminal blocks shall comprise brass tubular connectors with screw
connections contained within a moulded block suitable for working temperature up to
100°C.
7.14.4.21 Terminals shall be designed to clamp the conductor between metal surfaces with
Sufficient contact pressure but without causing damage to the conductor. With the
largest recommended conductor in position, and tightly clamped, there shall be at least
two full thread pitches of the screw engaging in the connector.
7.14.4.22 All materials and parts comprising the module system shall be new and of current
manufacture of a high grade and free from all known defects and imperfections.
7.14.4.23 All active electronic devices shall be solid state. All semi-conductor devices shall be
hermetically sealed. Vacuum tubes shall not be used for any purposes.
7.14.4.24 Terminals shall be supplied suitable for the cables being used to make the power
connections. Terminals shall be provided for connecting the remote alarm contacts.
7.14.4.25 All power semi-conductors shall be fused in a manner to prevent cascaded or
sequential semi-conductor failures. Indicator lamps denoting blown fuse conditions shall
be located such as to be readily observable without removing panels or opening of the
cabinet doors.
7.14.4.26 Isolating switches shall be of the load type with ON / OFF indication and lock
attachment. Critical isolating switches essential for continuity of the load power shall be
pad-lockable.
7.14.4.27 Contactors if any shall have Contactor coils suitable for use on direct current.
Rectifiers shall be of the selenium type and terminals shall be provided to external
control of the contactors on the AC side of the rectifier.
7.14.4.28 Relays shall be of the plug-in type and shall be housed in dust tight enclosures.

7.14.5 Electrical Works and Accessories

7.14.5.1 All electrical equipment in the UPS, including MCCB, MCB, cable connector, trunking,
conduit, and other electrical accessories, shall comply with, the sections and clauses of
the M & W Specifications, relevant to these items. All the cables and wires used must
be of Low Smoke Zero halogen type.
7.14.6 Testing & Commissioning
7.14.6.1 The manufacturer of the UPS must have type test certificates, from an accredited /
reputed third party, for all the tests specified IEC 62040 – 3 and shall not be more than
five years old.
7.14.6.2 In case, these are not available, manufacturer shall arrange to get these tests executed
in their factory as per clause 6.6 of IEC 62040-3 in the presence of third party NABL
certified body. The DMRC official may call for repeat of all or some of the tests during
factory acceptance test.
7.14.6.3 Manufacturer will be required to carry out the routine and optional tests as specified in
IEC 62040 – 3.
7.14.6.4 The UPS shall be thoroughly checked for correct operation and load tested in supplier
works before dispatch. All faults created for check on satisfactory function of protection
system, control functions, workmanship and site load conditions shall be simulated,
checked, and proved. The equipment shall be dispatched after testing in presence of
authorized representative of purchaser.
7.14.6.5 The manufacture representative shall be available at the time of commissioning and
testing of UPS at site. The manufacture shall issue a certificate to the affect that the
UPS has been installed and commissioned as per his approved scheme for the
purpose.

8 LV LIGHT BUS TRUNKING (BUS DUCT) & RISING MAIN

8.1 GENERAL
8.1.1 This specification is intended for design, manufacture, transporting, installation, and testing
at site of compact sandwich type Aluminium / Copper conductor LT Bus Bar Trunking
system (Bus duct) suitable for indoor / outdoor installations as specified in the attached
data sheet.
8.1.2 415 V, 3 Phase, 50 Hz, self-cooled, sandwich construction Al / Cu bus duct as per the
specific requirements shall be supplied. The bus bar systems offered shall be complete
with all necessary accessories like elbows, off sets, reducers etc.
8.2 STANDARDS
8.2.1 Updated and current Indian Standard Specifications and Codes of Practice will apply to the
equipment and the work covered by the scope of this contract. In addition, the relevant
clauses of the following standards as amended up to date shall also apply. Wherever
appropriate Indian Standards are not available, relevant British and / or IEC Standards shall
be applicable.
Low voltage switchgear and controller assemblies: Part-
IS 8623 (Part-1) 1993 1 Requirement for type tested and partially type tested
assemblies
IS 8623 (Part-2) 1993 2 Particular requirement for busbar trunking system (bus
ways)
IS 8623 (Part-3) 1993 3 Particular requirement for equipment where unskilled
persons have access for their use
Low-voltage switchgear and control gear assemblies -
IEC 61439-6
Part 6: Busbar trunking systems (busways)
Low-voltage switchgear and control gear assemblies -
IEC 61439-1
Part 1: General rules
IEC 60529 Degrees of protection provided by enclosures (IP Code)
Indian Electricity Act 2003
Indian Electricity Rules
1956
National Building Code
1994
National Electric Code 1985
Code of Practice for Fire
Safety of Building (general)
IS 1641 General Principal and Fire Grading
8.3 TECHNICAL REQUIREMENT
415 V, 3 Phase, 50 HZ, self-cooled, sandwich construction, Aluminium / Copper (as
specified) bus duct as per the following specific requirements shall be supplied -
8.3.1 BUS BARS
a) For Aluminium Bus duct, Bus bar shall be fabricated from aluminium and the conductors
shall be continuously tinned Aluminium suitably plated for the entire length. Rating of
busbar shall be as per data sheet, and it shall be 3Phase +100% Neutral+ 50% integral
earth including bends.
b) Busbar conductors shall be insulated with single / multilayer of insulation of class F. Electric

connection shall be made at joints by single / multi bolt joint construction which ever suited.
Joints shall be realized by a torque spanner (wrench) and shall be set as per the
manufacturer design. To prevent the joints to be damaged during transport, they shall be
protected by plastic caps, which shall be removed before installation. Standard or designed
locking system shall be put in place to prevent loosening of any screw and requiring any
tightening schedule during maintenance. The design should have a provision to identify
unravelling of the screw / nut by a degree and a marker to indicate, if the bolt has shifted
from net position.
c) Each busbar shall be jointed to the adjacent section by single / multi bolt-joint clamps
without drilling the busbar. Joint between two sections shall be such that a complete sub
assembly is removable so that isolation of individual sections is possible without disturbing
other sections.
d) Inspection windows shall be provided over the joints to check tightness.
e) Flexible connections shall be provided by braided or multi leafed conductors for termination
8.3.2 ENCLOSURE
a) The enclosures of Bus Ducts shall be totally enclosed non ventilated type.
b) Ingress protection for the enclosures shall be IP 54 for indoor Busduct and IP 65 for outdoor
busduct as per IEC 60529. The enclosure of Bus Trunking System shall be fabricated by
minimum 1.5 mm thick CRCA sheet steel / GI / Extruded Al and shall be powder coated to
colour shade RAL 7032 after regress metal treatment process. Enclosure shall be rendered
dust proof and vermin proof by adequate gasketing etc. to provide ingress protection of not
less than IP 54 for Indoor Busduct and IP 65 for Outdoor Busduct as per IEC 60529.
c) The busbar Trunking System shall be manufactured in convenient section to facilitate easy
transportation and installation.
d) The sections shall be connectable to form vertical or horizontal runs as required. Each
section shall be provided with suitable support arrangement from walls / ceilings as
required.
e) Expansion joints may be provided as per manufacturer’s design and recommendation.
8.3.3 FLANGED END BOX
a) Flanged end box shall be provided to accommodate flange end for connecting the bus
trunking with the flanges of panels and transformers etc. through flexible connections.
b) Phase matching of bus trunking with equipment shall be done prior to installation.
8.3.4 EXPANSION JOINTS
a) The bus bar system shall be equipped with standard expansion joints or with expansion
bolts in each unit length to compensate thermal elongation of the bus bar. As per local
conditions permit, the longest bus bar unit lengths shall be used to minimize electrical
losses at the butt or bolted connections of the bus bars.
b) The bus bar junction points shall be suitably marked for identification.
8.4.1 RISING MAIN PLUG –IN TAP OFF BOXES FEATURES
a) Tap off Provision
Rising Mains shall have provision to install tap off boxes minimum 3 locations in standard
length of 3 m. Plug in points shall have a hinged sheet metal that provides IP protection
Similar to the specified for Bus Duct. There shall be Provision for up to 3 plugs in tap off
boxes. Rating of plug in tap off boxes shall start from 100 ampere and shall be up to and
including 400 amperes. Plug in tap off boxes shall have an electrical interlock mechanism
which also ensures that plug in tap off box cannot be removed mechanically from the
busbar when the box is at ON position. Tap off boxes shall be suitable for any brand of
MCCB. Tap off boxes shall be manufactured of Similar material and colour as main Bus
Duct. Tap off boxes shall be plug in type with earth contact to make first and break last.
Tap off boxes shall have spring loaded contacts for uniform contact pressure on busbars.
Tap off boxes shall be provided with door interlocking and interlocking with bus trunking to
ensure plug in and plug out possible on in OFF condition. All tap off boxes shall be
compatible with all rating of bus trunking and shall be suitable for interchanging between
sandwich / air insulated trunking. Tap off outlets shall be available as required by the
system design. Tap off outlets shall have safety shutters to prevent access to live busbars
when not in use. Degree of protection in the open conditions of with shrouding shall be IP
2X to offer personal safety protection.
8.4.2 THRUST PADS
a) Thrust Pads shall be provided in the raising main systems for necessary support to the
rising mains and to prevent busbar expansion in down ward direction.
8.4.3 ACCESSORIES
a) Bus trunking system shall be complete with all accessories like bends, busduct, expansion
joints, flexible connections etc to suit site requirements. Bus trunking systems shall be
complete in all respects. All accessories shall be deemed and to be included in the unit
rate of straight length of the busduct and rising mains.
8.5 TERMINAL ARRANGEMENTS
8.5.1 Suitable arrangements shall be available for cable terminations so that the cable weight
does not come on the terminals. The terminal on HV & LV shall be suitable for receiving
copper flexible cable and termination with cable gland and anodized hard wire for the cable
termination.
8.6 SAFETY
8.6.1 SAFETY FACTOR
a) The contractor will submit the Bus duct support calculation incorporating safety factor not
less than or equal to 3 and dead weight of the bus duct along with hanging arrangement
detail.
8.6.2 GROUNDING
a) Bus trunking system shall be provided with two independent earthing GI conductors size
of at least 50x6 (mm) / as suitable throughout the length of the system. The earth flats shall
be effectively connected to the enclosure by riveting / bolting. End covers shall be provided
as required. Neutral shall have same cross section as phases.
b) All parts of the bus enclosure, supporting structures and equipment frames shall be bonded
to the ground bus.
8.6.3 EARTHING
a) Internal earthing need not be provided as integral earthing to be provided where enclosure
will work as earth.
8.6.4 MAINTENANCE AND LIFE
a) The LT bus duct should be designed for maintenance free best service life in the industry
and not less than 30 years for all types of installation & under prescribed environmental
conditions.
8.7 TESTING
8.7.1 TYPE TEST
a) LT Bus Bar Trunking System (Bus Duct) offered shall comply to verification and type test

requirements of IEC 61439-6. Type Testing Shall be conducted from NABL accredited Lab.
Copies of the test Certificate for same rating shall be submitted at the time of vendor
approval. These shall not more than 5 years old.
8.7.2 ROUTINE AND ACCEPTANCE TESTS
a) Testing at manufacturer’s works shall be conducted before dispatch as per routine
verification requirements as per IEC 61439-6.
8.7.3 TESTING AT SITE
a) Physical check including checking damage / crack in any components, tightness of bolts
and connections etc.
b) Insulation test after installation according to manufacturer’s test procedures.
c) Testing earth continuity.
8.8 INSTALLATION
8.8.1 Installation of the Bus Duct / Rising Main shall be carried out as per manufacturer’s
instruction and installation shall be verified by the manufacturer before energising.
8.8.2 For Bus Duct horizontal runs, horizontal expansion units shall be provided at Suitable
intervals at least every 40 m and at expansion joints of the building structure and the system
shall be supported at every 1.5 m.
8.8.3 Annular space around or Bus Ducts while crossing walls shall be filled up by sealing
material by contractor in accordance with the manufacturer’s instruction. No extra claim
shall be entertained, for the same.
8.9 DATA SHEET FOR BUS DUCTS
DESCRIPTION RATED CURRENT OF 1600A
S.NO
1 Type Compact Sandwich
2 Supply System 3 Phase ,4 Wire, AC 415V,50HZ
a Busbar Conductor Aluminium
4 Insulation Class F
5 Rated insulation 1000 V
6 Power Frequency Withstand 2.5KV
7 Short-Circuit Rating 50 KA for 1 Sec
8 Current Rating 2500A,3P, +100%N, +50% Integral Earth
9 Temperature Rise* As per IEC Standards
10 Degree of Protection IP65 for Outdoor use, IP54 for Indoor use
8.9.1 The Bus Duct Systems offered shall be completed with all necessary accessories like
elbows, offsets, reducers etc.*Design Data in support of temperature rise being within
permissible limits shall be furnished along with the tender as per IEC Standards.
8.9.2 OEM should provide the test certificates as per IEC 61439 with following format of quality
plans.

MANUFACTURING QUALITY PLAN FOR

Manufacturers name & Address
BUSTRUNKING / DUCT
QAP Customer:
No.
Item: Purchase Order No.
Rev.
Rating: No. Project:
Dated Work Order No.

Extent of check
Agency
Acceptance norms
Characteristics to
For Manufacturer
Remarks
Components &
For customer /
S. No.
Manufacturer.
Customer /
inspecting
inspecting
Operation
Format of
Method
agency
agency
Record
verify
I Incoming inspection
Press / Sheet Dimension & Material
Metal / Painted Spec.
Fabricated /
1 forged / casting Surface Finish
/ machined &
moulded parts /
Rubber parts
Busbars (copper Visual inspection
/ Aluminium) Dimensions
Copper-IS-1897 Tensile strength
2
Aluminium-IS- Percentage Elongation
5082 Chemical composition
Conductivity (Minimum)
Glass mica Thickness
sheet /
3 Polyester Insulation Resistance
sheet High voltage
Polyester tape ThicknessWidth

4
High voltage with stand
Joint Assembly Dimensions & Mat.
Spec.
5 Surface finish
HV withstand
Insulation Resistance
Switchgear Make, Rating, Type
6
items Model
II In process Inspection
A Insulation
Placing of Glass Mica
1
sheet
Wrapping of polyester
2
sheet

Total width, overlap and

3
should be wrinkle free
III Final Inspection
Routine Test Overall finish
Name plate / Marking /
Labels
Screwed / Riveted
connections
Polarity of conductors
1
Continuity of main circuit
Phase busbar size
Neutral busbar size
Earth busbar size
Enclosure Dimension /
Thickness
Electrical Test Insulation resistance
High Voltage test
2
Protective earth test
Clearance & Creepage
Type Test Short Circuit
3 Bus trunking Temperature rise test
Degree of Protection
Manufacturer Seal & Name & Sign of Approved Authority &

signature Seal
8.10 LOW POWER LIGHTING BUS TRUNKING SYSTEM

a) The bus trunking system shall be halogen free air insulated; simple, compact &
maintenance free design. The operating voltage / insulation voltage of bus trunking system
shall be 415+-10% volts max with insulation voltage minimum 690 V respectively. The short
circuit current withstand capacity of the bus trunking system shall be 2.5 kA min for 0.1 sec
(Icw). ingress protection of bus trunking system shall be IP 55 and therefore resistant to
the ingress of dust & water. Bus bars in the bus trunking system shall be adequately placed
in the insulating channel throughout their length to keep bus bars in position and avoid any
possible chance of short circuiting. Provision of six plug in holes to be made in the standard
length of 3 meters. for 8 wire system with accessibility on both sides. The copper
conductors used shall be electrolytic with 99.9% purity.
b) The enclosure shall be made of stainless steel / hot galvanized steel with excellent
mechanical strength to take the weight of luminaries etc. The bus trunking system shall
have integral earth system through body enclosure which shall be tightened with screw
through the length of the body or braided wire connection to enclosure earth continuity. The
earth shall be tapped through the pin configuration in the by tap 0ff boxes to be connected
to the load. The Protective earth (PE) should be connected first to make an electrical
connection and last to be disconnected when unplugged.
c) Impulse withstand voltage should be minimum 6kV.
d) The bus way system shall be assembled together to give excellent electro mechanical
characteristics and heat dissipation properties. the tap off boxes shall be of plug in type, it
shall be possible to replace the tap off boxes on to the bus trunking system without shutting

off the power supply. The plug outlet should be provided with captive / unlosable covers so
that it ensures IP 55 protection and in case of non-usage of the outlet it remains in that slot.
e) The tap off boxes shall be mechanically locked and to be plugged in and out from live bus
bar. Tap off outlets shall be provided with safety shutters to prevent access to live bus bars
when not in use. the bus trunking system shall be completely type tested and shall comply
the IS / IEC standards to confirm short-circuit withstand capacity, temperature rise,
dielectric properties, insulation resistance, degree of protection, clearance & creepage and
mechanical operation.
f) All bus duct shall be type tested and certified from NABL accredited / Third party
international testing laboratories for compliance to IS / IEC 61439-6.
8.10.1 Bus Trunking
a) The housing shall be of galvanized steel sheet / SS with epoxy-based paint to provide
maximum protection against corrosion from water and other contaminants normally
encountered during construction. All hardware shall be Electro-plated to prevent corrosion.
b) The bus-way which runs from electrical room to shaft or to the next electrical room shall be
feeder type. The bus-way run along an electrical shaft to feed power to each floor shall be
plug-in type.
c) Bus bars shall be suitably electro-plated at all joints and contact surfaces.
d) All insulation material shall be NEMA class B.
e) For the plug-in type bus-way, the housing shall completely enclose the switching device
and shall be of sheet steel furnished in grey enamel over a rust inhibitor. A ground slab to
engage the grounding tab on bus-way shall be provided. A means for padlocking cover and
operating handle in "OFF" position shall be provided. All current-carrying parts shall be
suitably electro-plated.
f) For the plug-in type bus-way, a releasable cover interlocking shall be provided to prevent
opening cover except when switch is in "OFF" position. A releasable interlock preventing
closing switch with cover open shall also be included, as well as an interlock to prevent
insertion or removal from bus-way when in "ON" position.
8.10.2 Fittings
a) Tie bolts shall brace aluminium housing and bars to withstand, without damage or
permanent distortion, short-circuit currents of the magnitude shown on the drawings when
tested in accordance to UL standard. All parts of the bus enclosure, supporting structures
and equipment frames shall be bonded to the earth bus. Bus-way shall be finished in grey
enamel.
b) Joints shall be of the one-bolt removable / isolatable type with through-bolts that can be
checked for tightness without de-energizing the system. It shall be possible to make up a
joint from one side in the event the bus-way is installed against a wall or ceiling. The joint
shall be so designed as to allow removal of any length without disturbing adjacent lengths.
Springs shall be provided to give positive pressure over complete contact area. Plug-in and
feeder shall use identical parts, and all multi-stacks shall be phase connected.
8.10.3 Third Party Tests & Certificates
8.10.3.1 During the execution stage, DMRC may conduct the Test on any type of fixture from third
party independent lab at its own cost, to ensure the quality of material supplies. If any of
the samples fail in the test, the cost of the test along with the complete replacement of
whole lot shall be borne by the Contractor.
8.10.3.2 If contractor represents, two random samples from the failed Lot shall be collected by the
contractor in the presence of DMRC representative and after duly sealing the samples

will be send to two different NABL accredited labs ( as approved by Engineer Incharge)
for conducting all those re-tests, which were conducted on the failed sample. Cost of the
testing including the collection of sample and transportation of sample will be borne by
the contractor.
8.10.3.3 If both the samples pass all the Tests, supplied lot will be deemed as accepted by DMRC,
but in case of failure of any of the samples collected by the contractor, complete lot will
be deemed as rejected and contractor will replace the whole Lot.
8.10.3.4 The delay if any for the procurement of the replacement material due to failure, shall be
considered as non-compliance and applicable penalty shall be imposed on the contractor.

9 ADDRESSABLE FIRE DETECTION AND ALARM SYSTEM

9.1 General
9.1.1 This Section specifies the scope of work, manufacture, supply, design and installation,
testing, commissioning of the Fire Alarm and Detection System.
9.1.2 The system shall be an intelligent addressable fire alarm and detection system. NFPA-
72-2019 / NBC-2016, EN 54 & IS 2189 shall be used as the guiding standard for the fire
alarm and detection system for Elevated stations and the system shall be designed in an
integrated manner in accordance with NFPA-72-2019 / NBC-2016 / EN54 / IS 2189 / UL.
For Elevated stations, NBC & IS 2189 shall be used as guiding standard and design of
the Fire alarm System.
9.2 Abbreviation
FACP Fire Alarm Control Panel
BS British Standard
IS Indian Standard
EN European Norms
ISO International Organization for Standardization
NFPA National Fire Protection Association, USA
TAC Tariff Advisory Committee
UL Underwriter’s Laboratory
LPCB Loss Prevention Certification Board
FACP Fire Alarm Control Panel
AC Alternating Current
DC Direct Current
Hz Hertz
LCD Liquid Crystal Display
PVC Poly Vinyl Chloride
FS Fire Survival
mm Milli Meter
IP Ingress Protection
ECS Environmental Control System
SCADA Supervisory Control and Data Acquisition
DG Diesel Generator
HVAC Heating, Ventilation and Air Conditioning
ISMS Integrated Station Management System
LED Light Emitting Diode

C Centigrade
GI Galvanized Iron
RI Response Indicator
CO Carbon Monoxide
Ni-Cd Nickel Cadmium
NEMA National Electrical Manufacturer Association
NO Normally Open
NC Normally Closed
ASS Auxiliary Sub Station
LSZH Low Smoke Zero Halogen
ITB Interface Terminal Box
ISCS Integrated Supervisory Control System
ASD Aspiration based Fire Detection System
9.3 Scope of Work

9.3.1 The scope of the work is to supply, installation, testing and commissioning of intelligent
addressable fire alarm and detection system in compliance with codes and standard
mentioned in this specification, Outline design Criteria and International best practices
for all elevated stations etc.
9.3.2 The Addressable Fire alarm system will comprise of the following:
a) Microprocessor based Fire Alarm Control Panel (FACP) complying to UL 864 10th Edition
/ EN 54.
b) Sub Alarm Panel / Repeater Panel.
c) Addressable Multi-sensor Detector, smoke detectors, heat detectors, Duct detector,
Beam detector etc. complying to UL 268, 7th Edition / EN 54.
d) Addressable manual call points.
e) Addressable Hooter cum strobe (either addressable or made addressable through control
module).
f) Batteries and charger.
g) Electrical wiring, conduits, trunking, and accessories.
h) Communication driver at the FACP for interfacing with the BMS / SCADA.
i) Voltage free fire alarm signals through voltage free normally close contacts from the fire
alarm system to the BMS / other system and connecting cables between the fire alarm
system and BMS / other system for all interfaces.
j) The Addressable Fire Alarm Control Panel will be minimum 2 loop for Elevated Stations
with a Loop capacity of minimum number of detector and devices per loop varies from
128 per loop, 99 Smoke Detectors, 99 Devices and 159 Detectors and 159 Devices as
per IS 2189 and as per approval with UL 7th edition / EN54 or latest amended up to date.

FACP should be equipped with 20% spare capacity with each loop. The panel will be
located in the station control room and will have LCD / LED / Coloured TFT minimum
240-character backlit alphanumeric display.
k) The fire alarm control panel will have the capability to process and evaluate incoming
signals from addressable devices such as smoke detectors, heat detectors, duct detector,
combined optical and heat detectors, beam detectors, manual call point and I / O modules
etc., via Fire Survival Cables confirming to BS 7846:2015, BS 6387 CWZ having
withstand capability of 3 hours at 950 deg. C.
l) The Fire Alarm System will be provided with input modules for interface with flow switches
and relay module for interface with the BMS / other system and Output Module to Hooter
cum strobe, Lift, PA, Escalator, AFC, BMS / SCADA, Fire pump monitoring.
m) Fire Alarm System shall be capable of integration with:
i. Public address and voice alarm system
ii. Stoppage to lifts to next determination level
iii. Stoppage of all Escalators
iv. ON / Tripping of ECS / HVAC system
v. Input signal from Fire Pumps operation status through pressure switches &
monitoring of main delivery and suction line valves of firefighting.
vi. To provide signal for dis-alarming of AFC (automatic fare collection) gates
vii. To be seamlessly interfaced with BMS / SCADA system
viii. Audio and strobes signal to areas in the station building in case of alarm
9.4 Technical and Installation Requirements
9.4.1 Quality Control

a) Provide equipment that are products of manufacturers who have made these
products for a period of at least ten years, Complete System shall be the latest
developed products, which have been approved by UL (latest edition) / EN54.
The system components such as control panel, detectors & devices, line break
isolator, response indicators, repeater panel, modules, battery, or all fire alarm
detectors & devices shall be of the same manufacturer and under one family
design duly approved / listed by UL / EN 54 with latest Edition. All Fixing
accessories like back-boxes etc. shall either be of the same manufacturer or of
superior quality duly certified by OEM and approved by Engineer-In charge.
b) Sticker showing detector / device number and loop number should be pasted at
each device / detector by contractor. Sticker should be of 3M or equivalent make.
9.4.2 Fire Alarm Control Panel (FACP)

9.4.2.1 The fire alarm control panel (FACP) shall be multi-zone control panel of the intelligent
analogue addressable type, complete having power supply with surge protection
device, battery charger, batteries.
9.4.2.2 The Fire Alarm Control Panel shall be located within the Station Control Room (SCR)
or DCC, capable of interface with a Workstation for the Fire Detection & Suppression
system. All the fire detectors, alarm devices and interfaces to other systems shall be
connected via this panel.

9.4.2.3 The FACP shall be analogue addressable in a lockable housing with illuminated function
keys and capable of full “stand-alone” operation. The FACP housing shall be to a
minimum protection rating of IP 54.
9.4.2.4 The FACP shall be for Elevated Stations loop control panel with loops expandable
feature for all stations and of intelligent addressable type, complete with all alarm loop
cards and input / output control interface, at least 240 LCD / LED / Coloured TFT
character display or greater, easily operable with acknowledgement, reset and silence
facility.
9.4.2.5 Detection devices shall be connected via loops with a maximum acceptable length of
1.2 km for 1.5 sq. mm. copper cable or suitable length as per NFPA-72-2019 / NBC-
2016 / IS / EN 54. The FACP shall have indicators for information, isolation (including
device isolated), alarms and faults (including system fault, device fault, and external
fault and processor fault).
9.4.2.6 Activation of Manual call points or detectors shall be identified on the FACP identifying
the loop number and detector address number including the associated Fire Alarm
zone. This information shall be provided via a textual message on screen integral to the
FACP. Fire alarm panels shall be lockable with alarm / reset functions; On / Off controls
and alarm disable controls. A facility shall be provided to allow operating access to
authorized personnel. This shall be via alphanumeric key for the field programming and
control of the fire alarm system or password access.
9.4.2.7 The FACP shall be self-checking and shall have the facility to identify faulty /
contaminated devices or system malfunctions such that faulty status / condition shall
not be confused with fire alarms. The loss or failure of any detector or alarm device shall
be identified and displayed within 60 seconds.
9.4.2.8 The processor shall be capable of polling all field devices on a loop within three seconds.
9.4.2.9 A facility shall be provided to isolate a single device on a loop or a group of devices on
a loop on a temporary basis. An illuminated warning indication shall be provided on the
FACP, which shall remain lit until the isolation is removed.
9.4.2.10 The FACP shall have an integral clock, which shall be synchronized with the Station
centralized clock system (provided by others). A facility shall be provided to allow an
external logging printer to be connected. The station FACP shall be equipped with
monitoring / relay points to relay status and alarm messages to the BMS / SCADA
system.
9.4.2.11 Relays points shall be provided for:
a) FACP healthy signal,
b) Fire alarm condition,
c) Fire zone of such alarm condition,
d) Fire condition link to PA automatic messaging,
e) Non-synchronizing clock.
9.4.2.12 These relay signals shall be connected to the station communications equipment under
the signalling and communications contract.
9.4.2.13 FACP shall be capable of interfacing with other systems including but not limited to:
a) Ventilation Control System: The FACP shall send signals to the Ventilation Control
Panel advising of zones in FIRE condition. The operation of dampers and fans etc.
in the event of a fire in a particular zone / s shall be carried out by the ventilation
control system.

b) Sprinkler Systems: The system shall monitor water flow switches for wet stand
pipes etc. as required. The FACP shall receive signals from the sprinkler flow
switches to identify activation.
c) Clean Agent Based Panel & Transformer Flooding System: The FACP shall
receive signals from the individual Gas suppression system control panels to
identify activation of clean agent-based panel / transformer flooding system.
d) FACP shall also interface with Public address and voice alarm system, lifts,
Escalators, AFC gates, Electrical rooms, ECS / HVAC, Fire pumps, BMS / SCADA
system, and all other systems as per requirement.
e) FACP shall be capable to communicate with BMS/SCADA.
9.4.2.14 The response to alarms from various combinations of the detectors, flow switches, or
manual call points shall, via the dedicated microprocessor, shall be capable of initiating
performance of such other functions as required like:
a) Alert Station staff,
b) Alert Station controller,
c) Initiate operation of Fire Suppression Equipment,
d) On confirmation of Station Manager, initiate operation of Automatic Public Address
System message,
e) Release Smoke stop doors held open,
f) Allow any emergency exit fastenings to open on transmission of the Evacuation
signal,
g) Initiate illumination of Station No – Entry signs on transmission of the Evacuation
signal (via SCR and Telecommunications),
h) Initiate closure of Fire shutters,
i) Initiate smoke extraction measures,
j) Capable to initiate signal for operating any other emergency devices as per
requirement.
9.4.2.15 All detector and bell circuits shall be continuously monitored and a fault on any of these
shall be indicated in the Main Fire Alarm Panel.
9.4.2.16 The FACP shall be capable of control and monitoring of flow switches for Fire sprinkler
system and control and monitoring of Gas suppression system.
9.4.2.17 Each system shall provide at least 20 % spare capacity for future expansion.
9.4.2.18 Access rights for Fire Alarm Control Panel with all necessary Hardware & Software to
be provided to DMRC for any change, addition / deletion, or modification in the system.
The access shall be unconditional and manufacturer to provide necessary support to
DMRC including training to DMRC personnel for the same. Any hardware required for
software access shall be a part of the system without any cost implication and without
any requirement for periodic renewal. The manufacturer is required to provide all
software upgradations free of cost to DMRC during the entire life of the product.
9.4.2.19 For unmanned doors with magnetic lock, the fire alarm control panel shall be capable
for monitoring & controlling the doors / entry / Exit.
Manufacturer or their approved channel partner shall do the installation and
commissioning of the FACP. The manufacturer will also be required to ensure overall

supervision of the fire detection cabling and detector / device fixing works. Manufacturer
should minimum visit and report to employer during 25%, 50%, 75%, 100% of
installation of detector & devices if installation is done by channel partner.
9.4.3 Battery Charger and Batteries
9.4.3.1 A 24 V DC trickle type battery charger and batteries shall be provided. The unit shall
incorporate Trickle charger assembly, Rotary type selector switch, suitably rated double
pole fuse, Sealed Maintenance Free battery as per manufacturer recommendation &
approved by engineer- in charge, Rectifiers and DC output voltage stabilizer as
required.
9.4.3.2 The unit shall be suitable for use on a 240 V AC single-phase power supply and shall
automatically maintain the 24 V DC batteries in a state approximate to full charge and
at the same time to compensate for the standing load. The charger shall cater for re-
charging the battery from fully-discharged condition to fully-charged condition in not
more than 24 hours.
9.4.3.3 Battery shall be of sealed maintenance free battery requiring no maintenance
throughout the normal life of the battery and shall be of capacity capable of maintaining
the system in normal working condition for at least 48 hours without recharging and
subsequently operating in the "alarm" condition continuously for at least one hour.
9.4.3.4 48 hours back up shall be provided to the indication lamp of the “Panel power loss”.
9.4.3.5 In selection of battery capacity, a deterioration factor of 0.9 minimum shall be applied.
9.4.4 Break-glass Units / Pull down type Manual Call Point
9.4.4.1 Manual call point shall comply with NFPA-72-2019 / NBC-2016 and shall be UL / EN
54-11 approved / listed. They shall be addressable type and shall be arranged to
operate automatically upon pressing call point switch. The cover shall be locked in
position with a special key and the glass / fibre panel shall be clipped firmly into place.
It shall be manufactured in bright red compliant material. Measurement of MCP shall be
as approved / required by engineer.
9.4.4.2 The surface of the Manual call point shall be provided with a LED indicator. It shall light
up upon activation of the Manual call point. The operation of any call point connected
to the system shall cause the station FACP to enter the alarm state within three
seconds.
9.4.4.3 Contacts shall be of silver or approved non-deteriorating alloy, for normally close / open
system. The voltage and current ratings of the contacts shall be marked within the unit.
9.4.4.4 The units shall be of the flush / surface mounting type and suitable for direct connection
to the type of wiring system there in specified without the addition of unsightly surface
boxes, glands, and adaptors. Special boxes compatible with the conduit system shall
be provided where necessary for installation of the call points.
9.4.4.5 Manual call point shall be positioned at a height of 1.2 m or as per NFPA / NBC (IS) at
strategic points throughout the station such that they are clearly visible from front and
sides as practicable and manual call point shall be located so that one is within 30
meters of any point in the station. At every entrance and in public areas manual call
point as per NFPA / NBC (IS) have to be provided. Provide flush plates for the recess
mounting units.
9.4.4.6 The Sounder / Hooter Cum Strobe units shall actuate upon receipt of a fire alarm signal
from any of the Manual call points or detection systems.
9.4.4.7 The operating temperature range shall be from 00 C to 490 C. Relative Humidity (Non
condensing) range for performance parameters shall be between 0 to 93%.

9.4.4.8 Each Manual call point shall be resettable type complete with built-in testing slot, such
that testing can be carried out by insertion of the test key without removing the front
cover of the unit.
9.4.4.9 Manual call point of Pull-down type units (applicable for Pull down type), completely
encased in a MS / Polycarbonate housing, as per BOQ with provision for cable or
conduit coupling. Operation shall be via a plastic membrane (non-breakable) with
wording on method of operation in white lettering. The cover shall be etched in black
lettering in English “FIRE,” the letters measuring not less than 10 mm high. The Manual
Call Box Station shall be fully addressable with its own set code and operated by signals
sent from the Panel. The operating temperature range shall be from 00 C to 490 C.
Relative Humidity (Non condensing) for performance parameters shall be 93%. It should
also comply to Clause no. 9.4.4.2 to 9.4.4.7.
9.4.5 Detectors with associated base
9.4.5.1 General
a) Unless otherwise specified, smoke detectors shall be of multi sensor type.
b) Detectors shall be UL 7th Edition / EN54 or latest amended up to date approved,
multi-sensor. The internal circuits shall be of solid-state device and shall be
hermetically sealed to prevent their operation from being impaired by dust, dirt,
humidity, corrosion, or mechanical shock. All circuitry shall be protected against
typical electrical transients and electromagnetic interference.
c) Each detector shall carry a built-in address.
d) There shall be a built-in magnetic test / any other mock test facility in each
intelligent device.
e) Built-in testing facility shall be provided based on NFPA-72-2019 / NBC-2016 /
EN54.
f) The detector base shall have a positive mechanical means to hold the removable
portion of the device. However, such provision shall provide a simple means to
remove the detector from the base, either by hand for accessible devices or by the
use of a special tool that can plug-in and / or remove the detector head from a
distance of up to 6 m above floor level. Required tool to be provided by vendor
(one for 6 stations).
g) Detector base shall be compatible for connection of all types of analogue
addressable detectors and shall have the facility to drive a remote visual alarm
indicator which shall be provided for all concealed detectors. Remote indicator
shall be compatible with the detector so that the operation of the indicator will not
impair or affect the brightness of the detector’s built-in LED.
h) There shall be LEDs on the detector head so that alarm condition of the detector
can be seen clearly from any direction or angle.
i) The designed operating range of detectors shall be between 0oC and 490C and up
to 93% RH non-condensing or as per NFPA-72-2019 / NBC-2016 (IS).
j) There shall be at least 3 levels (high, medium and low) of sensitivity, as approved
by the agency listed or by Fire authority, which can be selected at any time at the
FACP control panel or by automatic day / night sensitivity change over program
which shall be built into the FACP control panel.
k) Detector shall be low profile, no more than 60 mm in height or as approved by
Engineer including the base to minimize dust accumulation at detector head,

resulting from the pattern of airflow.

l) Detectors shall either have inbuilt Isolator / Isolator Base or Isolator Module / pair
of isolators in every zone shall be provided for UL / EN system.
m) The remote indicator with labelling shall be provided for all detectors installed
above false ceiling as specified in clause (g) of this Specification.
n) Labels shall be provided adjacent to all detectors with appropriate letters indicating
the corresponding address.
9.4.5.2 Multi-Sensor Detectors
a) The multi sensor detector shall be a microprocessor based and operate on light
scattering principle, containing an emitter and photo sensor. The scattered light
reaching the photo sensor shall be proportional to the smoke density inside the
detection chamber. It will combine both optical smoke and heat detector
technology to detect clear burning fire products, which hitherto could only be easily
detected by ion-chamber detectors. The detectors shall also operate on a
temperature alone. It shall be UL 7th Edition / EN54 or latest amended up to date
approved.
b) The detector shall utilize advanced algorithms with time-based analysis to provide
early warning and an accurate analysis of alarm situations.
c) Under normal ambient conditions, the optical detector will behave as a normal
optical detector. Only when a rapid rise in temperature is detected, the sensitivity
of the detector shall increase together with the presence of smoke shall confirm a
fire condition, which will be transmitted as a fire alarm level.
d) The detector will be fully compensated for temperature, humidity, and barometric
changes in the environment. All electronic components shall be hermetically
sealed to prevent their operation from being impaired by dust, dirt, humidity,
corrosion, or mechanical shock.
e) All circuitry must be protected against typical electrical transients and
electromagnetic interference. The detector will be fully operable between 0oC and
49oC and 93% relative humidity non-condensing or as specified by NFPA-72-2019
/ NBC-2016(IS) / EN54.
f) The Sensitivity shall be adjustable by means of a pre-set control accessible by use
of a special tool / inbuilt feature. Built-in wind-shields will be provided to ensure that
air velocity of up to 10 meters / second do not affect the proper operation of the
detector.
9.4.5.3 Heat Detectors
a) Heat detector shall be an analogue addressable type designed to raise an alarm
when the temperature is at a rate-of-rise of 8 °C per minute or better or at a fixed
alarm temperature of 57 °C. It shall be UL 7th Edition / EN54 or latest amended up
to date approved and approved by Fire authority.
b) The detector shall employ two matching thermal sensing elements in a bridge
configuration to give a response, which depends both on absolute temperature and
rate of change of temperature. The reference and sensing thermal sensors shall
be fabricated under identical conditions to ensure good matching and tracking with
both temperature and ageing.
9.4.5.4 Probe / Duct Type Smoke Detectors
a) Probe / Duct type smoke detectors shall be UL 7th Edition / EN54 or latest

amended up to date approved and installed in the supply or return air duct of all
AHU / PAU and ventilating fans as stipulated in the relevant Specification, and / or
as shown on the Drawings.
b) Installation details shall comply with NEMA and NFPA standards for Stations &
NBC (IS) for Elevated stations.
c) An audible and visual alarm signal shall be provided at the Station Control Room
of the respective station which upon receipt of a signal from the probe type smoke
detector shall initiate the audible and visual alarm on the Fire Alarm control panel
and shut off the corresponding ventilating fans, fan units of the AHU and / or fan
units of PAU.
d) Detectors shall be supplied with multi-sensor or photo-electronic detector heads
and complete in all respects with all required components and accessories.
e) Each smoke probe / Duct unit shall comprise a perforated inlet tube across the
inside of the duct at 900C to the airflow and an expansion chamber containing an
ionization or photo-electronic smoke detector.
f) The smoke probe / Duct unit shall contain a clear polycarbonate cover for
convenient visual inspection.
g) The smoke probe / Duct units shall be of the same addressable analogue type.
The whole assembly shall be suitable for monitoring air movement of up to 25 m /
s.
h) The complete assembly (smoke detector with duct adapter) shall be supplied as a
single unit.
i) Connection of remote indicator shall be also available and compatible with the
smoke probe unit so that the operation of the indicator shall not impair or affect the
brightness of the detector’s built-in LED.
9.4.5.5 Addressable sounder / Hooter cum Strobe (either addressable or made
addressable through control module)
a) All the areas of Underground station, elevated station, depot & RSS shall be
provided with sounder cum visual strobe units and Control of Sounder and Strobe
should be possible.
b) The unit shall be wall mounted, approved colour, suitable for operation on 24V with
following features.
c) Visual Characteristics: The visual strobe shall consist of Xenon flash tube / LED
with associated lens / reflector. The feature selectable candela outputs (minimum
15, 15 / 75, 30, 75 or 110). The flash rate shall not exceed two flashes per second
(2Hz) and nor less than one flash per second (1 Hz) throughout the listed operating
range of appliances or as per NFPA-72-2019 / NBC-2016 (IS) and UL / EN.
d) The light pattern shall be disbursed so that it is visible above and below the strobe
and from a 90-degree angle on both sides of the strobe.
e) Sounder pulse rate and decibel level above the ambient shall comply with NFPA /
NBC (IS) standards.
f) Strobe shall be placed wall mounted in corridors no more than 4570 mm (15 feet)
from the end of a corridor with 30.48 m (100 feet) maximum distance between
strobes or as per NFPA-72-2019 / NBC-2016 (IS). Where there is an obstruction
to the viewing path in the corridors, such as a cross-corridor door or ceiling
elevation change, consider the obstruction as defining a new corridor.

g) Each flashing unit shall consist of Xenon / LED or better and shall be fitted with all
necessary flashing and control provisions. The unit shall be suitable for 24 V DC
operations.
h) Flashing light unit installed outdoor shall be of weatherproof type.
9.4.6 Fire Alarm Cables

9.4.6.1 For stations, Detector cable loops shall be fire survival screened cables complying with
BS 7846:2015; BS 6387 CWZ and it shall be “Class A” wiring as per NFPA 72-2019 /
EN54. The Contractor shall submit calculation on the overall current consumption and
voltage drop in each detection loop in normal and alarm condition to substantiate their
equipment selection.
9.4.6.2 All detection loops / network wiring / 24V DC power supply lines shall be minimum size
of 1.5 mm2 Copper conductor, twisted pair screened fire survival cables complying with
BS 7846:2009, BS 6387 CWZ having withstand capability of 3 hours at 950 deg. C.
9.4.6.3 Manufacturer shall provide cable sizing for all detector & devices in each loop with
relevant document.
9.4.7 Interfacing Relay Module
Signals to control other systems by means of dry contacts shall be equipped with a 24V
DC relay, with dry contact rated at not less than 1A 240 VAC / 1A 24V DC. The relay and
terminal block shall be housed in covered galvanized steel or stove enamel steel / fire
rated polycarbonate box with adequate size to house all relays but in no case smaller
than 110 mm by 100 mm by 50 mm or as approved by Engineer-In charge. Terminals
shall be labelled clearly by means of silk screened or engraved lettering in metal or plastic
plate.
9.4.8 Monitor Modules
Addressable contact monitoring module shall communicate via the detection cable loop
with the FA control panel for continuous monitoring of any NO or NC dry contacts
connected including break glass, flow switch and repeating dry contact signals from gas
flooding system and gas detection system. LED indication shall be provided to show the
status of the module.
9.4.9 Control Modules
9.4.9.1 Control module shall provide an addressable output for a separately powered alarm
indicating circuit or for a control relay and housed in covered galvanized steel or stove
enamel steel box with sufficient size to house all modules.
9.4.9.2 The control module shall provide a supervised indicating circuit where indicated on the
Drawings. Any open / short circuit fault shall be detected / highlighted / displayed at the
FA control panel. Subsequent fire alarm signals shall activate the appropriate controls
and signalling devices despite of the fault conditions.
9.4.9.3 The control module shall act as a control relay where required.
9.4.9.4 The control module shall contain a LED which blinks upon being scanned by the FA
control panel. Upon activation of the module, the LED shall be latched on.
9.4.9.5 Status of control module shall be fed back to FA control panel.
9.4.10 Fault Isolator Modules / isolator
9.4.10.1 Fault isolator modules shall detect and isolate a short-circuited segment of a fault-
tolerant loop.

9.4.10.2 The module shall automatically detect a return-to-normal condition of the loop and
restore the isolated segment.
9.4.10.3 Modules shall be provided for every 20 field addressable devices to limit the extent of
devices affected in the event of a short-circuit. A minimum of two fault isolator modules
shall be provided for one detection line loop. For EN system every field addressable
device to limit the extent of devices affected in the event of a short-circuit.
9.4.11 Repeater Panels

9.4.11.1 Remote repeater panels for repeating all alarm status indication with LCD / LED display
shall be provided at the specified location.
9.4.11.2 The repeater panel shall be fully stand-alone complete with power supply, charger /
batteries. The Repeater Panel will have its own microprocessor, software, and memory
capabilities and provide indication for alarmed and troubled / faulted condition in each
loop. All software (i.e. Programs and data system configuration) will be held in non-
volatile ROM / EPROM.
9.4.11.3 The repeater panel shall be provided with warning buzzer which shall activate when an
alarm occurs in the fire control room and a push switch shall be provided for silencing
the warning signal. Lamp test control switch shall also be provided in the panel.
9.4.11.4 The panel shall contain an integral backlit LCD / LED display of minimum 240 characters
as per this Specification. LCD / LED display shall be viewable through the panel door.
IP rating of the panel shall be IP 54.
9.4.11.5 The repeater panel enclosure shall be flush mounted and all electronics shall be
contained in the enclosure. Access to the repeater panel switches shall be protected by
key-switch.
9.4.11.6 One repeater panel has to be provided at firemen’s staircase or as per location
suggested by Engineer-In charge.
9.4.12 Response Indicator
9.4.12.1 Response indicator of LED type shall be provided for above false ceiling and below false
floor detectors and these shall be mounted outside / inside the rooms wherever asked
for by the Contractor / Employer representative for indication of fire through detector in
the room. The design & colour shall be as per the standard.
9.4.13 Aspiration based Fire Detection System (ASD)
a) For areas in Stations etc. where ceiling height is very high i.e. double height & triple
height areas, aspiration-based Fire Detection system may be provided.
b) Aspiration system shall be UL / EN approved with regulated Power supply having
in-built battery back-up, ASD should inform to FACP in case of power failure.
Aspiration system shall be integrated with the mail Fire Alarm Control Panel.
c) The detector shall be capable of vertical mounting with sample air inlet port(s)
directed up toward the ceiling (normal mounting) or down towards the floor
(inverted mounting).
d) The detector shall be capable of mounting directly to a wall using screw fasteners
or by using a stainless-steel mounting bracket.
e) Where a mounting bracket is used, it shall be marked or engraved with the correct
locations of inlet port sample pipe(s) and cutting guide and electrical conduit
locations.

f) The capillary sampling network shall comply with the following requirements:
I. Where false ceilings are installed, the sampling pipe shall be installed
above the ceiling, and Capillary Sampling Points shall be installed on the
ceiling and connected by means of a capillary tube.
II. The typical internal diameter of the capillary tube shall be 5 mm or 3 / 8”,
the maximum length of the capillary tube shall be 1.5 meter unless
otherwise specified in consultation with the manufacturer.
III. The Capillary tube shall terminate at a Ceiling Sampling Point specifically
designed and approved by the manufacturer. The performance
characteristics of the Sampling Points shall be taken into account during
the system design.
IV. Manufacturer shall provide the spare parts e.g. chamber assembly
sampling module, filters as required.
V. Pipe, Hole, battery backup for 48hr & System design calculation duly
vetted by manufacturer shall be submitted for approval.
g) Fire Retardant CPVC PIPEs of 25 mm OD complete in all respect with Tees, Bends
complete as per system requirement.
h) The entire installation shall be as per relevant NFPA / EN54 / BS guidelines.
i) The aspiration system shall have chamber auto cleaning facility.
j) The ASD shall sit directly on the loop without any module.
k) Sensitivity of ASD should be best available in market and as per UL / EN.
9.4.14 Intelligent High Sensitivity Photo Smoke Detector
The intelligent high sensitivity photo smoke detector shall be a spot type detector that
incorporates an extremely bright high sensitivity diode and an integral lens that focuses
the light beam to a very small volume near a receiving photo sensor. The scattering of
smoke particles shall activate the photo sensor.
a) Shall be designed to meet UL268, 7th Edition / Vds Latest.
b) The high sensitivity detector shall have conductive plastic so that dust
accumulation is reduced significantly.
c) The intelligent high sensitivity photo detector shall have nine sensitivity levels and
be sensitive to a minimum obscuration of 0.02 percent per foot.
d) The high sensitivity detector shall not require expensive conduit, special fittings, or
PVC pipe.
e) The high sensitivity photo detector shall not require other cleaning requirements
than those listed in NFPA 72. Replacement, refurbishment, or specialized cleaning
of the detector head shall not be required.
f) The high sensitivity photo detector shall include two bicolour LEDs that flash green
in normal operation and turn on steady red in alarm.

10 DG SETS
10.1 SCOPE OF WORK
10.1.1 The scope of work should cover Design, Manufacture, Supply, Installation, testing and
commissioning including Integral testing & commissioning with systems of Diesel Engine
Alternator sets including AMF Panel, Power and Control Cabling from DG set to AMF
Panel (with necessary cable end terminations), all the necessary meters & Relays,
Control wiring, earthing, Day Oil Fuel Tank along with fuel piping, Exhaust Piping,
Silencer(s), Sound proof Enclosure and Fire Safety system, etc.
10.1.2 Models of DG sets offered should be strictly as per latest CPCB norms (latest prevalent
at the time of supply of the DG sets).
10.1.3 All minor civil works, electrical and other works associated with erection, installation and
commissioning of the set shall be carried out by the contractor. The contractor should
quote for the complete lot to be executed under Indivisible works contract.
10.1.4 Scope of work under this tender will include: -
a) Design, Manufacture, Supply, including all transportation, arranging access to site,
storage, loading / unloading, insurance, installation, testing, commissioning, including
Integral testing & commissioning with systems and safe custody till handing over of the
following of each sound attenuated Diesel Generator set: -
i. Sound attenuated weather proof enclosures.
ii. Ventilation and illumination system for acoustic enclosure.
iii. Alternator and Engine with Radiator.
iv. Residential / Critical / Hospital grade silencer.
v. Bank of starting batteries along with battery charger for trickle and boost charging
of battery bank.
vi. Auto – Mains Fail (AMF) Panel for DG set operation.
vii. Power cable from Generator to AMF Panel (with necessary cable end terminations).
viii. All necessary control wiring from Generator to AMF Panel.
ix. Approval of the Installation from EIG for its operation.
x. Anti-vibration mounting pads.
xi. All piping system between engine and radiator.
xii. Piping system for fuel line from Engine to Day Oil fuel tank. The pipes shall be Mild
Steel (MS) pipes of 25 mm dia. with two coats of primer & two coats of paint or
braided flexible (If Required).
xiii. Calibrated Day Services Tank minimum capacity of 990 litres or as per CPWD
norms for operation of DG sets. The tank shall be made out of 14 SWG thick MS
sheets with all accessories such as oil level indicator, drain plugs, manhole and
painting etc. complete as required by Indian Explosive Rules and Regulations.
xiv. Provision of necessary signals for Local and remote monitoring and recording of
parameters through Building Management System (BMS).
a. Provision of making two independent earth stations for Neutral Earthing as per
IS 3043:2018 & IEEE-80 (Ground Enhancement Material) / NBC-2016 complete

in all respect including masonry enclosure, and connecting the Earth strips to
the Earth stations / Station Earthing as per clause no. 5.4.5 of specification.
b. Provision of two independent risers from station Earth Mat for DG enclosure,
AMF panel, GCU Panel and associated cable tray to be done.
xv. Provision of making cable trenches / or supplying and laying of GI / HDPE pipes to
accommodate all cables, earthing strips and fuel pipe lines as utility to DG set.
xvi. Supply and fixing of hot air exhaust duct of 22 SWG GI sheet with DG canopy to
remove hot air (if required).
b) Exhaust piping system including MS pipes, bends, flanges, reducers etc. connection to
silencers and lagging the exhaust pipe as per specifications.
c) All the MS supports for the Exhaust pipe should be bolted type instead of being welded,
so as to facilitate easy removal / replacement.
d) As per the CPCB guidelines the Chimney / Stack height has to be higher than the building
height, therefore suitable Lightning protection system on the Exhaust pipe has to be
provided which should be duly approved by Engineer In-charge.
e) All wiring and connections including but not limited to between: -
i. Engine control panel and AMF Panel.
ii. Starting battery bank and engine control.
iii. Engine mounted alternator to static battery charger.
iv. Electrical panel etc.
v. Battery charger to batteries.
f) All necessary wirings & connections to make DG Set system fully functional.
g) Supply laying and commissioning of earthing from Earth stations (or existing station
earthing system) to D.G. Body and neutral and AMF panel separately by GI earthing
Strips. The fixing arrangement of Earth strips should ensure all safeguards against
vandalism and theft.
h) Alarms and Protection system should be got approved from employer. It should include
all parameters for safe operation and safety of equipment & personnel. AMF should be
PLC or microprocessor based with suitable interface for monitoring and recording of all
parameters by BMS / SCADA.
i) Interfacing with Station Building Contractor
j) Testing and commissioning (including arranging suitable consumables and testing
equipment) of the DG sets at site.
k) All other work, not specifically mentioned but required for satisfactory completion of work.
l) Automatic Gas flooding of AMF Panel, using linear heat sensing tubes- Fire trace or
equivalent.
m) All Cables (Power and Control cables) for Elevated stations will be FRLSH only.
n) DMRC may need operation of DG sets before Revenue Operation date. For such sets,
all consumables, maintenance of DG set and the DG set operator will have to be arranged
by the DG set contractor. For this, DMRC will make the payments as per the items
provided in Bill of Quantities.
o) The contractor should go through all the site conditions of the DG set installation before
submitting the installation approval of the section / schedule. The requirements for the
installation at the above sites may vary & contractor has to coordinate with the different

civil contractors for the foundation and other requirements for the DG set Installation. The
contractor has to make all the arrangements for the movement of the inventory and his
equipment’s from Delhi to NCR region, has to make arrangements along with all the
approval requirements as per the place of installation of the DG sets.
10.2 TENDER CONDITIONS, SPECIFICATION AND SCHEDULE
10.2.1 For any discrepancy between Technical Specifications and Bill of Quantities, provision of
Bill of Quantities shall prevail.
10.2.2 Any item shown in Bill of Quantities and not called for in the Specifications or vice versa
shall be provided as if called for in both.
10.2.3 Wherever it is mentioned that the Contractor shall perform certain work or provide certain
facilities, it implies that the Contractor shall do so at his cost.
10.2.4 Wherever the Technical Specifications stipulate requirements in addition to those
contained in the applicable Indian Standard Specifications / Codes- these additional
requirements shall also be satisfied, the Contractor shall do so at his cost.
10.2.5 At some elevated stations the DG sets are required to be installed below the staircase
(Road to Concourse Level Staircase) as per the layout. The contractor has to co-ordinate
with the civil contractor for its requirements of Air circulation / Exhausts, cabling, and
foundations etc. The contractor should study each location of installation and submit the
detail report for approval to the Engineer- in charge before the installation of DG set. The
space and access requirements for the DG set transportation, de-loading, access to the
room, installation etc. should be interfaced with the civil contractor at the time of the
construction of the Staircase by the DG set Contractor.
10.3 INTERFACING WITH DESIGNATED CONTRACTOR
10.3.1 The employer has appointed a DDC for Civil works, Electrical works of stations & Depot.
The contractor will be required to interface with the DDC for all the design related
activities, associated with this tender.
10.3.2 Civil works are being executed by Civil Contractor. The contractor will be required to
interface with the Civil Contractor for ensuring provisions, required for installation of DG
sets at stations. While the foundation will be done by Civil Contractor, minor civil works
like grouting, chipping etc. are in the scope of the E&M contractor.
10.3.3 Contractor will be required to provide at least Six Potential Free Contacts in AMF panel.
10.3.4 Employer is providing Building Management System in admin building of depot. DG set
Contractor is required to provide signals for the BMS / SCADA. All signals (digital as well
as continuous / analogue) should be available from PLC of AMF panel or microprocessor
through RS – 485 ports. All the information for the BMS should be compatible with MOD
– BUS protocol. All energy related parameters shall be made available through a RS 485
port.
10.3.5 DG sets are expected to run at light load / No load. The DG set offered, shall be suitable
for operation under light load / No load, without any adverse impact on the service
performance or life of the equipment. Stations are provided with independent reliable
sources for power supplies and DG sets would be required to operate for a very small
duration and after large period of idling. DG set should be designed to work satisfactorily
even after prolonged idling period.
10.3.6 Approximately 60 percent of the load shall be non – linear, DG set should be designed to
operate under non – linear load environment. DG set should be so designed that the
ripples are not created in the energy generated and EMI and RFI are within acceptable
limit, specified by standards.

10.3.7 (Requirements of EMI / EMC due to Single – phase A.C. traction should be taken care)
10.3.8 During the Integrated, Testing and Commissioning of the DG set, the set will be tested
for the actual linear and non – linear loads at site and the test report furnished.
10.3.9 Equipment offered shall comply with latest pollution norms as notified by the Government
and other statutory bodies at the time of delivery of the DG sets at the site.
10.3.10 All drawings and other documentation including design calculations shall be submitted
in hard copy format as well as in soft copies in latest version of MS word latest version
and PDF formats.
10.4 APPROVAL OF PROTO TYPE RATING
10.4.1 Contractor will manufacture one prototype DG set of each rating (or more if required by
Engineer-In charge) in the scope of work under this contract, with complete equipment
(DG set inside the Sound proof enclosure and with AMF Panel) for capacity / rating as
specified of the Engine Alternator set or more if required by Engineer-In charge. The proto
type will be inspected and tested at factory premises by the Employer. Once the Proto
types is approved by the Employer, the firm will subsequently, manufacture and supply
the DG sets
a) Complete DG Sets of each capacity size shall be made available for prototype testing at
Manufacturer works.
b) A complete DG Sets system in addition to the controller shall be assembled on a test
bench to undergo a comprehensive running and functional testing in accordance with the
accepted test specification to verify compliance with the Specification.
c) Proto type DG sets shall be tested at varying loads at manufacturer’s works prior to
dispatch of DG sets to site. The performance tests at the works shall be carried out in
presence of the authorised representative from the Engineer- in– charge. Due notice for
the programme of performance testing at works shall be given to the Engineer- In charge
to enable them to arrange for their representatives for this inspection to be at
manufacturer works for this inspection & testing. The cost for the arrangement shall be
borne by the contractor.
10.4.2 The performance test on the DG sets shall be of minimum 8 hours duration.
10.4.3 All instruments, material, consumables (fuel oil, lube oil etc.) load and labour required for
carrying out of the test shall be provided by the contractor.
10.4.4 Following test acceptance criteria shall be applicable.
1. Fuel consumption at 50%, ± 5% of guaranteed performance. Actual
75% and 100% load alternator efficiencies as determined in the
manufacturer works tests shall be used as
the basis of calculation of specific fuel
consumption ratio.
2. Voltage regulation from no ± 0.5%
load to
full load
3. Frequency regulation from no ± 0.5%
load
to full load
4. Maximum water temperature ± 5% of guaranteed performance
5. Maximum lube oil ± 5% of guaranteed performance
temperature
6. Maximum lube oil pressure ± 5% of guaranteed performance

The tests shall include the following minimum requirements:

a) Verification of the suitability of the system, its efficiency, etc.
b) Performance testing of DG set for 8 hours.
c) Capacity testing of the DG set.
d) Any additional testing as required as per relevant standards.
e) Fuel consumption of the DG set.
f) Complete functional tests.
g) Testing of the Sound Acoustics enclosures.
h) Fault Simulation and testing of control & protection devices.
10.4.5 Copies of all the documents of routine tests & type test certificates of the equipment
carried out at the manufacturer premises shall be furnished to the Engineer In charge
along with the supply of the equipment and these are as below:
a) Routine Test: -
i. Engine separately
ii. Alternator Separately
iii. DG Set
b) Type test certificates.
i. Engine.
ii. Alternator.
iii. Pumps.
iv. Meters.
v. Governors.
vi. All major components.
10.5 OPERATING CONDITIONS
10.5.1 The Engine Alternator is to be installed in Delhi / National Capital Region and shall be
capable of working at any ambient temperature between 0ºC and 50ºC and relative
humidity up to 95%.
10.6 PERFORMANCE REQUIREMENT
10.6.1 The working kVA rating at site condition after accounting for de – rating shall be obtained
at 0.8 power factor.
10.6.2 Period of Operating: - The set may be idle for a long period except for routine test
periodically. When there is an electrical supply failure it will be required to work
continuously at variable load with average load factor of 80% as per ISO 8528.
10.6.3 Overload: - The set shall be capable of taking 10% overload for a period of one hour
during any 12 hours period while operating as per above conditions.
10.6.4 Shaft Speed: - Rotational speed shall not exceed 1500 rpm.
10.6.5 Loads: - The set shall be capable of operating in conjunction with non-linear and
harmonics generating electronic loads including the UPS System.

10.7 STANDARDS
STANDARDS DESCRIPTIONS
BS: 5514, BS: 649 Diesel Engines
IS: 4722 Alternator
IS: 8183 Sound Insulation
BS: 4552 Fuel Filters
BS: 7226 Air Filters
IS: 3043 Earthing System
ISO 8528 Genset
Latest CPCB norms for Noise Level, Height of Stack / Chimney & Emission levels
The set shall conform to following standards with latest amendments.
10.8 DIESEL ENGINE:

10.8.1 Construction
a) The Engine shall be internal combustion type direct injection, cold start suitable for diesel
fuel, 1500 rpm, turbocharged, with electronic governor suitable for auto synchronisation,
4- stroke of suitable rating with provision of 10% overload for 1 hour in every 12 hours of
running. Engine shall be multi-cylinder of “in – line” or “V” configuration and complete with
basic accessories.
b) Engine shall be built to comply with BS 5514 The engine shall be complete with cooling
fan drive, lubricating oil filters, air cleaners, starter motor / exciter, fuel injector, fuel control
solenoid, fuel lift pump, engine speed adjustment, other standard / operational
accessories and protective devices including Genset controller.
c) The Diesel Engine is designed for operation on HSD oil Grade a conforming to IS –1460.
DG sets will be operated on Diesel, commercially available in the NCR region, this aspect
should be duly taken care in the DG sets being offered and any variation in the
performance of DG set on account of this should be clearly indicated / brought out.
d) The engine shall be fitted with a heavy, dynamically balanced flywheel suitable for
constant speed generator duty to meet the cycle variation requirements. An electronic
speed governor shall be fitted to maintain engine speed at all conditions of load in line
with the requirements of BS: 5514.
e) Cylinder Housing and heads shall be provided along with other accessories.
f) Crankshaft shall be truly balanced.
g) Pistons shall be of aluminium alloy and provided with necessary compression and
scrapper rings and a fully floating gudgeon pin.
h) Connecting rods shall be H-section steel stampings. Camshaft shall be gear driven (fly-
wheel end) and easily removable.
i) Lubrication system shall be complete with necessary gear pump, piping and drilled oil
passage strainer, oil cooler and relief valve, etc.
j) DG set shall be able to start automatically even in cold condition without any adverse
effect on its performance and capable to take full load within 30 seconds (wake up time)
of failure of normal supply.
k) DG set shall be designed for low specific fuel consumption. Specific fuel consumption at
rated load should not be more than as per ISO 3046 / BS 5514. During testing of DG
set, consumption will be checked and recorded at 25%, 50%, 75% and 100% of rated

loads.
l) The DG set shall be suitable for continuous operation inside the acoustic enclosure under
all the ambient conditions without any adverse effect on its performance.
m) The DG set shall be suitable for continuous operation inside the acoustic enclosure under
all the ambient conditions up to 50 degree C ambient without any adverse effect on its
performance.
n) The AMF panel shall be connected & provided with suitable interlocking arrangements to
ensure automatic starting of the DG set in case of failure of supply from both the sources
and interlocking arrangement to avoid any incident of paralleling of normal power supply
with DG set supply.
10.8.2 Cooling
a) The engine shall be complete with suitable radiator for cooling the machine in tropical
ambient temperatures of 50 degree C, with engine-driven blower type heavy duty cooling
fan and radiator core.
b) Water cooled with fan and radiator, with engine driven circulating water pump, thermostat,
and temperature gauge with high temperature alarm / trip. Cooling water circuit shall be
fitted with corrosion inhibitors and coolant supplied by manufacturer. Need of corrosion
inhibitors shall be examined during design stage, based on recommendations of Engine
Manufacturer.
c) A thermostatic valve should by-pass the coolant in the primary circuit until a pre-set
operating temperature is reached.
d) The design shall take into account compensation for possible ingress of dirt, which may
normally clog the fins. The choice shall take into account the place of installation and the
flexibility available for locating cooling system, air circulation and smoke exhaust.
10.8.3 Fuel Tanks
a) A fuel Day tank shall be as per CPWD norms. Diesel Storage Capacity complete with
mechanical fuel oil level indicator to indicate ‘High’ and ‘Low’ levels and isolation valves.
Marking should be there to check the fuel level. Rotary hand pump with flexible hose shall
be supplied for pumping and storing Fuel oil from barrels to ‘Day Tank’ as necessary.
b) Also, the Fuel Diesel Tank shall be inbuilt under frame in such a way that allows correct
suction pressure to the Fuel lift pump of the Generator set when the fuel in the tank is at
any level between low level and high level.
c) The tank shall be constructed from Mild Steel of not less than 14 SWG thickness in
accordance with relevant IS standards. It shall be complete with filter, breather unit and
drain plug. The associated fittings shall be constructed from materials which are suitable
for long terms contact with diesel fuel and shall not include yellow brass, low grade of
copper and zinc, lead, and galvanized metals. The fuel piping and tanks shall be designed
to be free from leakage and airlocks. The fuel tank shall be supplied with a level gauge
to indicate the oil level in the tank in litters. The following fittings shall be included:
i. Direct reading level indicated (gauge).
ii. Drain pipe situated at lowest point in tank complete with isolating valve.
iii. Outlet pipe complete with manually operated isolation valve and mechanically
operated isolation valve (for fire shut-down).
iv. Fuel inlet pipe from the filling point at the top of the tank, Fuel return inlet pipe
connection (from the generator set).
v. Electronic level switch with display for High and Low Alarm purpose.

10.8.4 Filtration
a) The engine shall have replaceable fuel oil filters. Lube oil filtration, air filtration shall also
be through replaceable filters.
b) Fuel Filters
i. A supply line fuel filters shall be fitted and shall be of twin replaceable elements type.
c) Air filters
ii. The engine shall be fitted with dry type air filters with replaceable elements.
d) Twin heavy duty air intake filters in accordance with BS 7226 suitable for operating in
dust- laden atmospheres shall be fitted. Breathers shall be fitted with washable filters,
which are easily accessible for maintenance.
10.8.5 Engine Exhaust
a) The engine exhaust piping shall be amply sized for minimum back pressure and
connected to the engine manifold through flexible connection or an expansion joint on
one side and to a silencer on the other side along with pipe. The silencer shall be package
type with adequate attenuation for urban use, constructed from heavy gauge galvanised
steel.
b) The sound absorbent infill shall be non-hygroscopic, vermin proof, non-combustible
material. Engine shall be provided with Residential / critical / hospital – grade silencers
so as to achieve sound attenuation of more than 25 dBA from the DG set as per CPCB
norms.
c) The exhaust piping from the silencer onward shall be laid up to the specified / approved
level and discharged through a rain cowl. Entire exhaust piping and silencer shall be
Class ‘Medium’ MS pipe and shall be rock wool insulated with 50 mm thick 64 Kg / cum
density. The insulation shall be held in position with 0.63 mm dia, 20 meshes, galvanised
steel wire mesh and finished neatly with 24SWG Aluminium cladding.
d) The generator set shall be provided with an exhaust system incorporating residential /
critical / Hospital – grade silencers. If possible, the silencers shall be contained entirely
within the Generator building / on acoustic enclosure.
e) As per the CPCB guidelines for DG sets the Stack Height / Height of Chimney shall be
worked out as per the formula given below: -
H = h + 0.2 x SQROOT (KVA).
H = Total height of Stack in meter.
h = Height of the building in meters where the generator set is installed. KVA = Total
Generator capacity of the set in KVA
Based on the above formula the minimum stack height to be provided with different range
of Generator sets may be categorized as follows: -
Capacity of Generators Sets Total Height of Stack in meter
50 KVA Ht. Of the building + 1.5 meter.
50 – 100 KVA Ht. Of the building + 2.0 meter.

In case of any different regulation by the state Pollution Control Board, the more stringent
of norms shall be applicable at no extra cost payable to the contractor.
f) Similarly, for higher KVA ratings a stack height can be worked out using this formula.
g) The Exhaust Pipe is to be provided keeping in view the CPCB guidelines. Nothing extra
shall be paid on account of the suitable support structure to be provided for the Exhaust
pipe (suitable support structure should be part of DG set exhaust pipe item).
h) Flanged connection to the silencer and between pipe sections shall be made. Minimum
wall thickness of pipes and the silencer shall be 3 mm. A stainless-steel bellows unit shall
be provided for connection onto the engine.
i) Exhaust pipes within the building shall be lagged and guarded to prevent accidental
contact up to a height of 2.5 m. No part of any exhaust system installed outside the
building shall be less than 3 m from ground level. Passage of exhaust pipes through
walls or the roof shall be sleeved and shall be shrouded to prevent ingress of rain or of
vermin. Exhaust emission control shall be as per CPCB norms.
j) Exhaust piping shall be fabricated from class ‘Medium’ MS pipes conforming to IS 1239
of size suitable to limit backpressure to within permissible limit. The insulation thickness
stipulated in the schedule of quantities shall be checked by the tenderers to achieve a
maximum temperature of 60ºC on the outside surface of the insulated pipe and
supporting calculations for back pressure shall be furnished, the measurement of the
back pressure will be checked during proto type testing.
k) Flanged joints in the exhaust piping shall be covered with removable insulation at
suitable intervals for permitting access to the joint, as and when required. All flanged
joints shall have sprigged high temperature gasket. The piping shall be installed with
necessary thermal expansion facility as required. Exhaust piping shall be connected to
the engine by means of flexible section or an expansion joint and shall also be graded
to a drain pocket inside the building. The pocket shall be fitted with a drain cock.
10.8.6 Retro-fit Emission Control System
a) DG set shall have retro-fit emission control system as per Statutory Authorities
recommendations to achieve minimum specified particulate matter capturing efficiency
of 70%.
b) Retro-Fit emission control system shall be tapped in Exhaust stack and shall have dual
outlet with pressure relief valve, by-pass valve and other safety precautions to ensure no
damage to the engine operations under any circumstances. The retro-fit emission control
system to be closely coupled with the engine exhaust so that 100% of the exhaust passes
through it.
c) Exhaust coming out from the DG set will be routed through the pipe towards the oxidation
chamber for oxidation of pollutants like particulate matter etc. This device shall aid
passive regeneration of particulate matter (PM) trap. This system shall capture soot
particle or particulate matter and then release exhaust air. This trap is designed to ensure
back pressure are kept in limit and required PM reduction efficiency is met.
d) Safety system to be provided to safeguard engine from higher back pressure and any
malfunction.
e) Technology of retro-fit emission control system shall be tested by one of the CPCB
approved institutions / labs with at least 70% Particulate Matter capturing efficiency.

f) Any amendment in emission limits by Statutory Authorities at the time of vendor approval
shall be binding upon the Contractor.
g) Life of the product should be at least minimum 10,000 operational hours.
h) Retrofit emission control device manufacturer & contractor should interface with DG set
manufacturer during installation of Retrofit device and during installation, Testing &
Commissioning of DG set for successful installation testing and commissioning of this
device with DG set.
10.8.7 Sound attenuating acoustic enclosure

Design
a) The sound attenuation enclosure should be designed keeping into account the latest
norms of the CPCB as applicable at the time of Delivery.
b) Sound Attenuating Acoustic Enclosure should have pleasant and aesthetic looks and
should be designed to achieve the Final sound level of 75 dB (maximum) at a distance
of one meter from the Acoustic enclosure as per ISO 8528 part 10 (The latest CPCB
guidelines will have to be complied, during the execution of the contract). For testing, the
measurement of dB shall be done at different points all along the enclosure and then
averaged as per ISO 8528 part 10 mentioned in CPCB compliance procedures.
c) The sound attenuating enclosure shall be meticulously designed and its design,
construction etc. should be decided based on ventilation requirement and should be
completely weather proof.
d) In design, proper care should be taken for engine heat rejection in order to have safe
working temperature inside the enclosure by provision of fans etc., as required. The
design aspect should ensure free and uninterrupted flow of suction and exhaust air in
order that the temperature rise of the enclosure with respect to the ambient is less than
7°C.
10.8.8 Construction features
a) STRUCTURE: Enclosure shall be made in modular design and can be dismantled /
assembled at site. It shall be made out of heavy gauge mild steel sections and reinforced
with fabricated structure; the supporting frame work shall be of 2.0 mm thickness. Outside
covers & doors shall be fabricated in 2.0 mm thick CRCA sheet. Inside cover or perforated
sheet should be used. The base of Acoustic Enclosure shall be made from suitable size
of M.S. sheet / Channel. There should be provision of lifting-hooks on the enclosure to
ensure easy lifting. “CAP – ON” type Acoustic Enclosure shall not be accepted.
b) ACCOUSTIC INSULATION (walls, Roof and Doors): Fire retardant Foam / rock wool
slab of minimum density & thickness confirming to IS 8183 and covered by fire resistant
fibre tissue confirming to AWWA C – 203 specifications.
c) For DG sets up to 250 KVA Fire Retardant Foam can be used & above 250 KVA Mineral
Rock wool can be used as per the requirement, and confirming the Latest CPCB norms
as applicable at the time of delivery.
d) AIR INLET & AIR OUTLET: Specially designed sound attenuators at Suction & Exhaust
ends.
e) PAINTING: Outer surface of Acoustic Enclosure shall be painted with Polyurethane paint
or powder coated but painting should be done after corrosion treatment of sheet by 7
tank treatment process (or latest available) & synthetic enamel paint on the internal
surface. All nuts & bolts shall be zinc coated. The colour of the Enclosure should be got
approved from the Employer. Enclosure should be suitably coated to withstand arduous
temperature conditions of Delhi region.

f) WIRING AND LIGHTING: Suitable lighting arrangement with integrated door interlocking
limit switch to be provided in all compartments of Sound attenuating Acoustic Enclosure
i.e. ENGINE / ALTERNATOR set, AMF Panel with PVC FR copper wire of minimum 2.5
mm2, 1100 V grade concealed in flexible conduit / channel & MCB.
g) EXHAUST OF ENGINE: The Engine Exhaust shall consist of suitable dia. ‘Medium’ class
M.S pipe (Insulated) along with smooth bends & supported. This pipe shall be suitably
brought out at the top of enclosure with suitable arrangement at the outer end for
preventing water to enter in pipe as required. The Exhaust Muffler with insertion loss of
25 dB shall be provided. For the Engine Exhaust detailed specifications as per clause
10.8.5. Are to be complied. Rain cowl should be provided to prevent entry of rain water,
birds etc.
h) PROVISION FOR NEUTRAL / BODY EARTHING: Suitable bus bars have to be

provided outside sound Attenuating Acoustic Enclosure for neutral / Body earthing
separately. The neutral terminals shall be connected to the neutral of Alternator with
flexible copper wire insulated braided strip. All the Equipment’s inside the Acoustic
Enclosure shall be connected together with suitable size strip / flexible braided wire and
then connected to the Body Earthing bus bars. DG canopy door to be connected with
suitable size braided wire for Earthing
i) VENTILATION & AIR CIRCULATION: The system shall be designed to provide air inlet
/ exhaust acoustic louvers for efficient air circulation under all loading conditions. The
ventilation may be natural / forced cooling. The temperature rises of the enclosure with
respect to the ambient should be less than 7°C. In case of forced ventilation there should
be specially designed circuitry to ensure that the fan(s) starts when the Genset is in
operation and when the Genset has been switched off the fan(s) automatically switches
over to main supply and runs for 5 – 15 minutes (programmable) before stopping to
ensure that set is ready to start in case of another failure.
j) SPECIAL FEATURE: Fuel tank shall be provided at suitable place (nearest to ENGINE
/ ALTERNATOR set) outside the sound attenuating enclosure. Provision should be there
to fill this tank from outside as in automobiles and this should be with a lockable cap.
k) The batteries shall be accommodated in the sound attenuating enclosure in battery tray.
l) Engine Control Panel as well as engine instruments panel shall be inside the sound
attenuating enclosure with free frontal access.
m) AMF panel should be located inside in the DG room, the equipment layout for each DG
room is to be got approved from the Employer, prior to the execution of work. As far as
possible the control panel shall be placed adjacent to the enclosure to have minimum
length of cable.
n) The sound attenuating enclosure shall be provided with residential / critical / hospital –
grade silencers insulated from inside with rock wool having minimum insertion loss as
specified in the Latest CPCB norms.
o) The sound attenuating enclosure should be as compact as possible with good aesthetic
look.
p) From continuous running of engine, the temperature inside the sound attenuating
enclosure shall be maintained within 7°C of ambient and canopy shall be provided with
temperature safety device to shut down engine if canopy temperature exceeds 60°C.
q) The measurement of difference of temperature shall be as per the prescribed procedure
specified by the C.P.C.B.
r) The sound attenuating enclosure shall be complete with ducting & radiator bellow.

i. The sound attenuating enclosure shall have built in receiving tray at base of the
Genset for any oil spillage.
ii. The sound attenuating enclosure shall have provision of emergency shutdown from
outside the container.
iii. The sound attenuating enclosure door shall be gasket with high quality EPDM
gaskets to avoid leakage of sound. The door handles should be provided with durable
weather – proof locking system.
iv. All the doors of the sound attenuating enclosure shall be lockable and theft proof.
10.8.9 Safety systems
10.8.9.1 Governor
a) The performance of the governor under load conditions shall be to Class A1 in
accordance with BS 5514: Part 4 (ISO 3046).
b) The governor shall meet the following performance requirements:
i. Steady state speed band: + 1% or + 0.25% of nominal speed,
ii. Transient frequency changes on application or rejection of 60% load: ± 5%,
iii. Recovery time to steady state speed band on application of 60% load: 10 seconds,
c) Maximum speed drop: 5%
d) The electrical over speed trip provided shall operate at 120% of the rated speed and shall
be reset only by hand.
e) Other safety controls and indicating instruments shall be as shown in Data Sheet.
10.8.10 Engine starting
a) The starting system shall comprise a 12 / 24 V heavy duty suitable capacity high
discharge lead acid battery of reputed make as required, and electric starting motor. The
battery shall be sized to give not less than ten consecutive starts of the engine at 0°C to
50°C.
b) The starting system shall be complete with necessary relays, solenoid valves for fuel,
control and indicating panels as specified and required.
c) A main powered battery charger shall be provided, with sufficient capacity to maintain the
battery in a condition to fulfil the starting requirements.
d) The mains powered charger shall be suitable for operating on 240 V, single phase, 50
HZ supply and shall be complete with the following indications and features:
i. Battery charge / discharge current,
ii. Boost charge / trickle charge selector, On / off switch
iii. Fault indication,
iv. Protection Auto cut off feature to safeguard batteries from over charging,
v. DC ammeter and voltmeter,
vi. Annunciation panel for battery charging indication.
e) The input voltage to battery charger may vary between 180 V to 240 V; therefore, the
battery charger should be capable of charging the battery to the desired voltage level
with the above input Voltage range.
f) The battery charger shall have a selector switch by which the rate of charging the
batteries can be selected.

g) If the equipment does not start within three starting cycles with appropriate interval
between each attempt, the starting circuit shall be locked and audio-visual alarm shall be
given.
10.8.11 Mounting and installation
a) The engine shall be complete with suitable radiator for cooling the machine in tropical
ambient temperatures, with engine-driven blower type heavy duty cooling fan and
radiator core.
b) A common rigid bed plate shall be provided for the engine and alternator which shall be
directly coupled. The coupling must be done after ensuring proper alignment of generator
and engine shafts.
c) The entire set shall be housed in sound attenuating enclosure mounted on suitable
Rubber- in-shear type vibration mounts with 6 mm static deflection for isolating the
building floor / foundation. A nominal base concrete pad (if required) shall be provided
over which the engine set with its own base frame and vibration mounts shall be mounted.
It is to be ensured that minimum vibrations are transmitted to the surface on which set is
resting.
10.8.12 Radio Interference
All equipment’s, provided under the scope, shall be so designed that they shall not cause
interference with radio equipment. In the event of the inherent characteristics of the
equipment being such that radio interference is possible, efficient devices to nullify the
same shall be provided.
10.9 ALTERNATOR
10.9.1 Type & Rating
a) Alternator shall be 3 phase, 4 wire 50 cycles 415 volt, totally enclosed, brush-less screen
protected drip proof with self-contained excitation system and self-regulating and
conforming to IS 4722 & continuously rated. The alternator should have the rated capacity
at 0.8 PF. The alternator shall be designed to suppress radio interference in conformity
with BS 800. It shall be of heavy-duty single / double bearing design, adaptable for direct
coupling with diesel engine including excitation system, automatic voltage regulator,
voltage adjusting potentiometer [to adjust nominal voltage over a range of approximately
(+) or (-) 5%] and low speed protection, to reduce voltage proportional to the driven speed
in order to protect both alternator and V / F sensitive loads.
b) The supply interlocks shall be provided to supply the electricity after stabilisation only.
The excitation system shall provide an exceptionally rapid response to load change and
alternator shall be designed for high motor starting capabilities.
c) The alternator shall be tropically insulated with H class insulation and windings shall be
impregnated with thermosetting insulated varnish to use in tropical climates. Ample
ventilation shall be provided by shaft mounting fan as per manufacturer design.
i. The neutral point shall be brought out separately and earthed permanently.
ii. The band of voltage regulation shall be + / - 0.5% from no load to full load and under
varying load conditions.
iii. The overload capacity shall be 150 – 300 % for 10 seconds limitation, if any, shall be
highlighted by the manufacturer.
iv. The Alternator shall be suitable for taking unbalanced load, limitation, (if any), shall
be highlighted by the manufacturer.

d) The alternator shall be of fabricated steel construction conforming to minimum IP-23 class
specified (test certificates conforming to the specified IP class should be produced by the
contractor), dynamically balanced rotor with single / two bearings and damper windings.
The unit shall be with a large terminal box for outgoing cable connections specified.
Necessary adapter box shall be provided if the terminal box is not adequate to receive
the cables.
e) Alternator rotor shall be salient pole type with a damper cage and dynamically balanced.
Insulation shall be to class ‘H’ (BS 2757 / 1957). All winding shall be fully impregnated for
tropical climates with high quality or epoxy varnish.
f) Ventilation to the alternators shall be by means of fans fitted on the rotor.
g) It shall handle 10% overload in one hour in every 12 hrs. of operation without exceeding
the permissible possible temperature rise for the class of insulation provided.
10.9.2 Excitation system
a) The main exciter shall receive power from a permanent magnet generator through
separate auxiliary windings on stator via Automatic Voltage regulator. The AVR shall be
of solid-state circuitry and shall provide regulated voltage to the exciter compensating for
all normal variations. The main exciter output is fed to the main motor windings via a
rotating 3-ph bridge rectifier assembly which shall be protected from voltage surges, short
circuit, and overload and diode failures. The AVR and control gear shall be mounted in a
component box on the side of the machine. Electrical connections to the AVR shall be
taken through a multi way plug and socket.
b) Voltage regulation shall be within half percent under all conditions of load, power factor
and temperature including cold to hot variation. There shall be no radio or television
interference. Line voltage wave form shall be as true as possible with a total harmonic
distortion not exceeding 3% on 3-Ph load.
c) The excitation system and engine governor should be such that the alternator is capable
of starting up induction motors having a starting kVA of not less than 1.8 times the
alternator rated kVA. Manufacturer should indicate the voltage dip and duration under
such conditions as required under equipment data.
d) The highest capacity of induction motor to be started for elevated stations will be 75HP.
e) The neutral of each generating set shall be earthed solidly to ground with facility for
isolation through a fully rated contactor.
10.9.3 Automatic Mains Failure (AMF) operation
a) The AMF panel shall be capable of starting the DG set automatically in the event of
unhealthy conditions of the main power supply including power (mains) failure, single
phasing or voltage going below 85% or 360 V at the bus bar of MDB or Essential power
panel and shall switchover essential load from the main supply to DG set. The voltage
on both the incoming mains shall be continuously monitored through adjustable voltage
monitor on all the three phases. AMF shall be of at least IP 54.
b) To avoid unnecessary frequent starting and stopping of the DG set caused by momentary
unhealthy condition, an adjustable timer with setting 1 to 10 seconds shall be
incorporated in the control system. The DG set shall start automatically within 30 seconds
of main supply failure. It shall be idle for three minutes after making change over from
DG set supply to main supply, to ensure that the main supply has stabilised. The
manufacturer shall specify the adjustable range in both the cases.
c) The DG set Contactor or breakers shall have 4 poles (3 phase and 1 neutral) electrically
interlocked. The interlock logic will be got approved from DMRC and necessary
interfacing with E&M contractor will be done by DG set contractor.

d) The AMF logic must be achieved through a PLC or microprocessor-based circuitry to

monitor engine controls with an ON line mimic giving status of Engine running, voltage
built up & other status as required & specified. AMF shall have 3 modes of operations
viz. automatic, manual & test. The set shall be capable of starting and taking up the load
within the time stipulated in the data sheets.
e) The sequence of Automatic Mains Failure (AMF) operation shall be as follows:
a. Upon main power failure, the generator shall receive 3 kick-starts and the
generator breaker shall close only after building up of requisite voltage.
b. Hold the Mains Contactor or Breaker open.
c. On restoration of power, AMF logic should make change over from DG set to main
supply and trip the engine after a present time delay.
f) The AMF Panel should therefore comprise:
a. 4 Pole MCCBs, contactor of adequate rating to be electrically and mechanically
interlocked.
b. Battery charger with normal and trickle charging facility and an isolating switch.
Over load and E / F protection for the generator set.
c. For DG sets of Elevated stations, 2 outgoing breakers shall be provided – one for
EPP, One for Fire Fighting Panel.
g) AMF panel shall have RS 485 communication port for BMS system for providing the
controlling and monitoring the perameters.
10.10 PROTECTION / ANNUNCIATION
10.10.1 Protection and annunciation system confirming to latest standards like BS / IEC or IS
with soft control and touch resets shall be designed and provided comprising of following
but not limited to: -
a) Overload and short circuit trip for main in-comer
b) Overload and short circuit trip for the DG set
c) Over and under voltage protection
d) Over and under frequency protection
e) High temperature for cooling water trip
f) Alarm in case the DG set is not run for 15 days at a stretch.
g) Earth fault
h) Loss of sensing
i) Low battery voltage
j) Fault indication alarm through suitably designed Annunciator with inbuilt hooter
k) High Temperature in Canopy / DG room
l) Over speeds Trip
m) Field overload
n) Over current
o) Any other alarm as specified.
10.11 METERS AND INDICATORS AS FOLLOWS
10.11.1 Meter Generator as given in Specifications and data sheets

a) Battery
i. 0 - 24V Voltmeter
ii. 0 - 5A Ammeter for charge
iii. 0 - 75mA ammeter for trickle charge
b) Indication and Alarm annunciation
Engine side as given in Specifications and data sheets
Additional Indication Alarm
Battery Charger ON Yes -
High / Low battery Yes Yes
voltage
Failed to start Yes Yes
Lack of Fuel oil Yes Yes
Low lubricating oil Yes Yes
pressure
High oil temperature Yes Yes
Gen. ON Yes -
Enclosure Temp. High Yes Yes
Over Speeds Yes Yes
c) Auto Manual Selector Switch
Start-Stop Reset Buttons
Alarm Reset Buttons
Lamp testing Buttons
10.12 BATTERY SYSTEM

10.12.1 There shall be a 12 / 24V lead acid stationary battery with an AH capacity suitable for
10 (ten) cranking attempts of (10 seconds each) (suitable design to be submitted by the
firm for each capacity of DG set and to be got approved from DMRC) plus all indicating
lamps and alarm before the cell voltage goes down by 1.8V. Battery shall be complete
with necessary angle iron stand and multi strand flexible copper leads. The battery
charger in the AMF Panel shall be capable of floating the battery with quick and trickle
charging facility to maintain a cell voltage of 2 Volts. The battery stand and the canopy
failure should be provided with suitable safeguards against battery Acid.
10.13 CONTROL SYSTEM
10.13.1 The control system shall work on suitably supplied DC / AC operated system with
provision of alarm and operation status available on auxiliary terminal board so as to
enable it to extend alarm and operation status to operation control centre & station control
centre. The metering system shall be based on digital indication with status on auxiliary
contacts. The control system and metering panel shall provide for the following:
a) Metering / Indication
i. Voltmeter
ii. Phase sequence indication
iii. Ammeter
iv. KW meter, kWh meter, Frequency, Power factor meter or Multifunction Meter
v. Battery Voltmeter

vi. Common Fault Alarm Signal

vii. ON, OFF, TRIP for all incoming and outgoing feeders.
b) Counters
i. Hours Run Counter
c) Controls
i. Emergency Stop Button
ii. Run / Off-Reset / Auto Control Switch
iii. Lamp Test / Reset Push Button
iv. 3 Attempt Start Timer
v. Terminals for Remote / Emergency Stop
vi. Interface to Remote Annunciator
vii. Voltmeter Phase Selector Switch,
viii. Ammeter Selector Switch
Note: For Metering, Indication and Control, above or equivalent system shall be designed &
provided as per the latest industrial standards, after getting explicit approval of the
Employer.
10.14 FINISH
10.14.1 The generator shall be thoroughly cleaned and primed with two coats of industrial primer
and finished in two coats of industrial high gloss paint.
10.15 TESTING & COMMISSIONING
10.15.1 The complete Diesel generator set shall be thoroughly checked for correct operation
and load tested in supplier works before dispatch. All fluid seals, faults, control functions
and site load conditions shall be simulated, checked, and proved.
10.15.2 After installation each DG set shall be tested and the specific fuel oil consumption will
be checked. The values of the oil consumption noted at the time of testing will be the
basis for the penalty, if any on the DG set manufacturer as per Appendix-F Annexure 4
of ITT, on the successful commissioning. Each DG set shall be run for a minimum period
of 30 minutes continuously on no load. On satisfactory completion of the no-load run the
set shall be run for a period of 6.5 hours at 100% full load and followed by 60 minutes
operation at 10% overload. All consumables including fuel, lubricating oil and load banks
required for commissioning the set shall be supplied by the contractor. Test readings
together with an hourly log of the running test shall be furnished.
10.15.3 The trial shall be conducted in the presence of the Employer Representative / Project
Manager and the test results shall be recorded in an approved format. Any abnormal
condition occurring during trial run of the DG set shall also be recorded. Test results shall
be recorded at 30 minutes intervals. All facilities, labour, instruments, materials, and
consumables including fuel and lubricating oil required for the test shall be provided by
the contractor at his cost.
10.15.4 Tests proving the satisfactory performance of all operating gear, safety functions and
controls shall be carried out.
10.15.5 Performance test at site shall include (but not limited to) the following test acceptance
criteria:

Voltage variation ±1% or ± 0.25% (as applicable)

Voltage regulation ± 0.5%
Frequency regulation ± 1% or ± 0.25% (as applicable)
Maximum water temperature ± 5% of guaranteed performance
Minimum lube oil pressure ± 5% of guaranteed performance
Temperature rise in the Acoustic Not to exceed 7ºC above Ambient
Enclosure
Noise Measurement
75dB for 1 meter
Should comply with CPCB guidelines.
Muffler / Silencer Test Test certificate from Independent lab to
be submitted
Fuel Consumption at 100% load ± 5% of guaranteed performance
Measurement of Vibration around the DG set Enclosure
Testing of all Trips and Alarms, and data logging and monitoring systems
10.15.6 Contractor shall be required to carry out any further tests / trials that the DMRC
Engineer-In charge may desire to satisfy themselves that the Generator Sets and
Associated equipment fully comply with the conditions as set out in these Specifications.
Co-ordination with EIG for inspection shall be the responsibility of contractor.
10.16 DG SET DATA SHEET
1. Engine
Minimum Engine Rating Matching the DG set rating.
Altitude (m) Less than 1000m above mean sea level
Air humidity 95% Max.
Minimum 0
Air temperature (°C) Maximum 50
1.1
Average 40
Prime Power rating duty at specified
maximum ambient air Temperature of 50°C.
Duty (Suitable for Continuous operation at
variable load with average load factor of
80% as per ISO 8528).
1.2 Standard BS 5514, ISO 3046, & ISO 8528 (all parts)
Overload capacity for one
hour in 12 hours of 10% over the continuous rating.
1.3 continuous running.
Governor Electronic type
Starting Method Electric
1.4 No. of auto start 3(three)
Selectivity Auto / Manual / Test
Cooling System
1.5
i) Radiator Yes
Exhaust System 1 No. or more as required of Critical grade.
Silencer 1 No. for each exhaust pipe near the engine.
1.6 Nil.
Flexible connection
Scrubber Nil.
1.7 Safety Controls & Trip @ 20% over speed - Normal Audible &

Instruments visible alarm

Over speed Governor Trip engine-Audible & visible alarm
One -point thermostat Yes,
Low oil pressure Required,
Fuel level low Yes,
Oil Pressure gauge Required,
Hour counter
Yes
Sundry fittings Yes,
Vibration mounts Rubber in shear or any other type with 6 mm
minimum static deflection on load.
1.8
Electric pump for fuel filling
from barrels & draining Not Required
engine oil etc.
2. ALTERNATOR
125 kVA (100 kW),
160 kVA (128 kW),
180 kVA (144 kW),
200 kVA (160 kW),
Rating at 50 Deg. C 300 kVA (240kW),
2.1 (Ambient air Temp.)
Continuous duty : 350 kVA (280 kW),
380 kVA (304kW),
500 kVA (400kW),
Y-neutral brought out
10% over load for 1 hour in 12 hours
2.2 Minimum efficiency % 91.0
2.3 Alternator IP – 23 (IEC) & IS 4691
2.4 Enclosure To be suitable for outdoor Installation
2.5 AMF panel IP 54
2.6 Winding Class H
2.7 Cooling IC 01 IS-6362
Excitation System Brush less exciter with rotating diode
2.8
assembly
2.9 Over speed % 120
Transient response & Max. 20% dip on application of full load at
2.10
Response voltage dip stated P.F and recovery in 20 cycles.
Sustained short circuit Min. 300% of full load current FLC for 3
2.11
secs.
2.12 Terminal Box Suitable for cables as specified.
3. Fuel Oil Facility
3.1 Day tank (14 SWG steel) 990 Litres or as per CPWD norms.
3.2 Hand Pump-Portable Oil Filling pump (one
Pump
per station)
3.3 Piping From day tank to engine set
4. COOLING Radiator cooled
5. ENCLOSURE DETAILS

MS Press bent 1.6 mm (minimum) with

Structure
suitable reinforcement
Type Steel Fabricated double wall insulated panels
Suitable thickness as per type approval
Panel Thickness
Certificate of CPCB
Outer Sheet 1.6 mm thick CRCA Sheet
Inner Sheet 0.2 mm thick CRCA Perforated Sheet
Frame & Stiffener 1.6 mm thick CRCA Sheet
Type of Material Foam / rock wool of reputed make.
As per IS 8183
Thickness of Acoustic Suitable thickness as per type approval
Certificate of CPCB
Density Suitable thickness as per type approval
Certificate of CPCB
AIR CIRCULATION SYSTEM
1. AIR Intake (As per Proto type / Design approved by DMRC)
Type Axial Flow fans*
Make Technomac or Equivalent
RPM 1440 / 2800
Motor KIRLOSKAR or Equivalent
B) Air Exhaust System (Will be applicable for DG room only).
Type Axial Flow Fan
Make Reputed Make
Speed 1400 / 2800 RPM
Motor KIRLOSKAR or Equivalent
Qty. Minimum 1 No. Or more as required For Air
Exhaust
AIR SCREEN For Radiator Exhaust
INSULATED HOOD At Canopy Air Exhaust
SILENCER HOOD INTAKE
Type Air Intake Hood
Qty 1 Nos.
Design With Acoustic Splitter & Baffles Insulated
Hood Cover
FINISHING Weather Proof “POLYURETHANE PAINT” or
“POWDER COATED” Paint
Sound Reduction (min) 25 dB (A) at one meter.
Notes:
1. The DG set Data Sheets are guidelines to meet with requirements of the Design of the
DG set and its enclosure. Any minor changes in the above will be acceptable at the time
of Design approval of the DG sets, with the confirmation that the changes made will not
have any variation in the performance parameters and the requirements of the CPCB
norms as prevalent.
2. Silencer shall be of Residential / Hospital / Critical grade.
3. Engine and Alternator ratings shall be for the operating conditions and altitude specified
and Not NTP ratings.

4. Engine BHP shall be selected for alternator kW output at emergency loading Condition.
After 3 Auto Starts, Engine to lock Shut
* Shall be provided with the DG sets without any extra cost, in case DG set is not able to
meet with the “temperature criteria” for enclosure temperature of less than 7ºC.
(May not required to be provided if the Engine driven radiator fan is adequate to meet the
“temperature criteria” of enclosure temperature less than 7ºC).
10.16.1 DATA Sheet AMF PANEL
1. SYSTEM 415V 3 Ph 4W effectively earthed neutral
system
2. BUSBARS Aluminium
3. LOCATION & TYPE Indoor cubicle dead front
4. ENCLOSURE IP 54 (IEC)
5. CIRCUIT BREAKER PANELS
5.1 Usage Generator Breaker
5.2 Number 1(One)
5.3 Type MCCB / ACB
5.4 Pole 4P
5.5 Closing With 12V / 24V DC
5.6 Opening closing coil 12 / 24V DC shunt trip coil
5.7 Current rating (A) as applicable
5.8 Breaking Capacity (KA) 35 KA (minimum).
5.9 Meters As Applicable
5.10 Kilowatt hour meter (kW hr) 1-3Ph 4 wire unbalanced load
5.11 Voltmeter, Ammeter 0-500V as per rating of DG sets and with
suitable rating CT’s
5.12 Power factor meter Lag 0-1-0 lead (Digital type)
6 PROTECTION
6.1 O / C & EF 2# O / C &
Type 1# REF (Restricted Earth Fault)
IDMT 1.3 Sec. or static relay
(Electric Numerical Relay)
Setting range Auxiliary OC: 50-200%, REF: 10-40%, Under
Voltage Relay, Alarm Relay
7 INSTRUMENT TRANSFORMERS
7.1 CT’s for measurement Set of 3
Burden Ratio 15 VA
Class Cl-0.5
CT’s for Protection As per the ratings of DG sets.
Burden 15VA
Ratio Accuracy / Class 5P10
CT Numbers 4+1 Neutral CT
7.2 Phase indication lamp 1 No. for Each R-Y B
Sundry Fittings
ON-OFF-TRIP 1 No. for Each for ON, OFF, Trip
LED Indicating lamps
10.17 B-TEST SCHEDULE
B-Check schedule should include following items:

1. Lube oil
2. Oil filter
3. Fuel Filter
4. By-pass filter
5. Water Separator
6. Air Filter
7. Radiator Cleaning
8. Any other test suggested by OEM

11 FIRESTOP TECHNICAL SPECIFICATION

11.1 REFERENCES
11.1.1 The publications listed below shall be used as reference for firestop work at project.
ASTM INTERNATIONAL (ASTM)
 ASTM E 814 : Standard test method for fire test of Through Penetration fire
stops.
 ASTM E 84 : Standard test method for Surface burning characteristics of
building materials.
UNDERWRITERS LABORATORIES (UL)
 UL 1479 : Fire Test of Through Penetration firestops
 UL 723 : Test for Surface burning Characteristics of building materials
 UL 2079 : Standard for tests for fire resistance of building joint systems.
 UL Fire Resistance- Fire Resistance Directory
11.2 SYSTEM DESCRIPTION

11.2.1 General
Furnish and install tested and listed Firestopping systems, combination of materials or
devices to form an effective barrier against the spread of flame, smoke, and gases, and
maintain the integrity of fire resistance rated walls, floors, and ceiling-floor assemblies,
including through-penetration.
a) Through -penetration includes the annular space around pipes, tubes, conduit, wires,
cables, and vents.
b) `Fire sealing of gaps up to 200 mm (Less than or equal to) from service to ceiling / wall
is in scope of this work
11.2.2 Firestopping Materials
Provide firestopping materials from manufacturer consisting of commercially
manufactured, asbestos free, non-toxic, UL Listed, for use with applicable construction
and penetrating items, complying with following minimum requirements: -
11.2.2.1 Fire Hazard Classification
Material shall have a flame spread tested in accordance with ASTM E84 or UL 723.
11.2.2.2 Toxicity
Material shall be non-toxic, should not contain hazardous chemicals and not harmful to
humans at all stages of application and during fire conditions.
11.2.2.3 Fire Resistance Rating
Firestop Systems shall be UL Fire Resistance listed approved with “F” rating at least
equal to Fire rating of wall or Floor in which penetrated openings are to be protected. Fire
rating of 2 hours or more. It should also pass hose stream test.
a). Through Penetrations
Firestopping materials for through -penetrations, as described in paragraph system
description, shall provide F, fire resistance ratings in accordance with ASTM E814 or UL
1479.

11.2.2.4 Material Performance

All firestop materials are subject to these minimum standards of –
a) Firestop materials shall be capable of installation at temperatures of 5 to 40 degrees
Celsius.
b) Firestopping material must convey a manufacturer’s written document guaranteeing the
performance of material for the sustainable lifetime of structure.
11.2.3 Submittal Requirements
A) Submit detail drawings including manufactures descriptive data, typical details
conforming to UL Fire Resistance testing laboratory, installation instructions & UL listing
details for a firestopping assembly in lieu of fire -test data or report. For those
applications for which no UL tested system is available through a manufacturer, a
manufacturer’s engineering judgement, derived from similar UL system designs and
based on IFC (International Fire council) guidelines shall be submitted for review and
approval before installation of firestop. Submittal shall indicate the firestopping material
to be provided for each type of application.
B) Submit certificates attesting that firestopping intumescent material complies with the
specified requirements- For all firestop material used in through penetration systems,
manufacturer shall provide certification from UL of passing the “Ageing and
Environmental Exposure Testing” as per clause 9 of UL 1479. All the 3rd party type test
certificate should be submitted which should be tested at reputed Lab.
C) Submit documentation of training and experience of installer.
11.3 QUALITY ASSURANCE
11.3.1 INSTALLER
Engage an experienced installer who is: -
a) FM research approved in accordance with FM 4991, operating as a UL Certified
Firestop contractor, or
b) Certified or otherwise qualified by the firestopping manufacturer as having the
necessary staff, training, and a minimum of 2 years’ experience in the installation of
manufacturer’s products in accordance with specified requirements. The installer shall
have been trained by a direct representative of the manufacturer (not distributor or
agent) in the proper selection and installation procedures. The installer shall obtain the
manufacturer written valid certification of training and retain proof of certification for the
duration of installation.
c) Installer should be deployed after approval of Engineer in charge.
11.4 DELIVERY, STORAGE AND HANDLING
Deliver materials in the original unopened packages or containers showing name of
manufacturer and the brand name. Store materials off the ground, protected from
damage. Materials should be stored at required temperature as mentioned by
manufacturer on product labels.
11.5 INSPECTION
11.5.1 General Requirements
Before installation of firestop material, installer should submit detail site survey report
along with relevant UL tested system drawings or Engineering Judgements as mentioned
in Para 11.2.3 for review by contractor and client. This is to ensure that UL Tested system

/ Engineering Judgment’s should comply with site conditions.

The client and contractor representative along with Installer representative shall inspect
the applications initially to ensure that adequate preparations (clean surfaces suitable for
application etc.) and periodically during the work to assure that completed work has been
accomplished according to the manufactures written instructions and the specified
drawing requirements. Manufacturer should make minimum visit site at 25%, 75%, 100%
of work is done and submit report to Employer, if the work is done by their authorized
agency.
Submit written reports indicating the locations of and type of penetrations and type of
firestopping material used at each location. Each location to be marked with Printed
Stickers mentioning the firestop material and UL Listed or Engineering judgements
drawing no. along with name of Installer firm and person and fire rating provided.

AIR-CONDITIONING AND
VENTILATION SYSTEM

1 GENERAL
1.1 ABBREVIATION
HVAC Heating Ventilation & Air Conditioning
DBT Dry Bulb Temperature
WBT Wet Bulb Temperature
RH Relative Humidity
ACPH Air Change Per Hour
FCU Fan Coil Units
IDU Indoor Units
ODU Outdoor Units
VRV / VRF Variable Refrigerant Volume / Flow
PPM Parts Per Million
EER Energy Efficiency Ratio
ISEER Indian Seasonal Energy Efficiency Ratio
COP Coefficient of Performance
CFM Cubic Feet per Minute
OD Outer Diameter
UL Underwriters Laboratories
TEFC Totally Enclosed Fan Cooled
VCD Volume Control Dampers
MFD Motorized Fire Dampers
CRC Central Remote Controller
UV Ultra Violet
IE International Efficiency
1.2 SCOPE OF WORK
Scope of work under this contract shall include but not limited to the design, manufacture,
testing at manufacturer’s workshop, supply, storage, erection, site testing and
commissioning of the Air-conditioning & Ventilation System, training of DMRC staff mainly
comprising of:
a) VRV / VRF air-conditioning system along with refrigerant piping etc.
b) Ventilation fans
c) Air distribution system
d) Drain Piping
e) Electrical & control works
1.2.1 Any other item required to complete the work except the specified items mentioned under
para “works & services to be arranged by other than HVAC Contractor.”
1.2.2 Scope of work shall also include the following:
a) De-mobilisation, clearing of all temporary works and facilities after completion of job.
b) The Contractor shall include the supply of entire materials in accordance with this
specification and the whole of the work necessary for the complete installation as set
down in this Specification and with the accompanying schedules and drawings. Materials

and components not specifically stated in the specifications and / or bill of materials or
noted on the drawings but which are necessary for satisfactory installation and operation
of the system shall be deemed to have been included in the scope of work.
1.3 QUALITY ASSURANCE OF MATERIALS AND WORKMANSHIP
1.3.1 Materials
a) The contractor will supply the equipment as indicated in the list of approved makes in the
tender.
b) Furthermore, all equipment must strictly conform to the relevant IS code specified in the
tender document or as required. However, the contractor shall submit Vendors data in
the approved format.
c) The contractor shall furnish test certificates of the materials procured for the work. Testing
of materials shall also have to be done at contractors cost as and when necessary and
required by the Engineer. If the test result of any material does not comply with the results
stipulated in the relevant latest IS code, the materials shall be rejected and no claim shall
be entertained on any account what so ever. All the rejected material should be removed
from the site of work, without delay.
d) Where manufacturer have furnished specific instructions relating to the materials used in
this job and covering points not specifically mentioned in these documents,
manufacturer’s instructions shall be followed.
1.3.2 Quantum of Materials to be ordered
The Schedule of Quantities shall not be used as a basis for ascertaining the quantum of
materials to be ordered and these are for guidance only. The Contractor shall assess the
quantities of materials to be ordered as per requirement and shall be entirely responsible
for the same. The design / drawings of the layouts / system shall be approved from the
employers’ representative.
1.3.3 Manufacturer Instruction
Where manufacturers have furnished specific instructions relating to the materials and
equipment used in this project, covering points not specifically mentioned in these
documents, such instructions shall be followed in all cases.
1.4 INSTALLATION, INSPECTIONS & TESTING
1.4.1 When the installation is deemed by the Contractor to be complete, he shall arrange with
the Engineer’s In-charge for inspection and testing of the installation. Test results shall
be recorded in the format approved by the Engineer’s In-charge. An installation shall not
be accepted until the Engineer is satisfied about its compliance with the requirements of
the specifications and performance of the system. The Contractor shall cause interim /
stage inspection during execution of the works as and when so called for and carry out
any rectification / modification as may be suggested by the Engineer’s In-charge.
1.4.2 Soon after the work is completed, the Contractor shall inform in writing to the Engineer’s
In-charge for getting the complete system including all sub-systems and instrumentation,
control panels etc., thoroughly inspected and tested for satisfactory performance. After
satisfactory completion of tests of the system, the Contractor shall carryout all start up
trials of the system provided by him.
1.4.3 Any defect noticed during these tests shall be speedily rectified for testing and shall be
the responsibility of the contractor.
1.4.4 All instruments and materials including consumables required for testing shall be the
responsibility of the Contractor.

1.4.5 Balancing of all air and other fluids systems and all tests shall be carried out by the
contractor in accordance with the specifications and relevant local codes if any.
Performance test shall consist of seven days operation of system for each season.
1.4.6 Tests shall be carried out in peak summer and monsoon season.
1.4.7 The results for summer / monsoon and winter air conditioning in duplicate shall be
submitted for scrutiny. Two copies of the certified manufacturer’s performance curves for
each piece of equipment shall be submitted along with the test results. The contractor
shall also provide two copies of record of all safety and automatic control settings for the
entire installation.
1.4.8 The contractor shall arrange all necessary balancing and testing equipment’s,
instruments, materials, accessories, refrigerant and the requisite labour. Any defects in
materials and / or in workmanship detected in the course of testing shall be rectified by
the contractor, to the satisfaction of the Engineer’s In-charge.
1.4.9 The installation shall be tested again after removal of defects and shall be commissioned
only after approval by the Engineer’s In-charge. All tests shall be carried out in the
presence of the representatives of the Engineer’s In-charge.
1.5 STANDARD OF WORK
1.5.1 The work shall be carried out to the satisfaction of the Engineer’s In-chargeand in
accordance with the regulations of the concerned Authority, Electricity Rules and other
local Regulations and the enclosed specifications.
1.6 SHOP DRAWINGS
1.6.1 Before proceeding with the work, the Contractor shall submit for approval, general layout
and assembly drawings and such additional assembly and sub-assembly detailed
drawings as necessary to demonstrate fully that all parts of the apparatus to be furnished
will conform to Specifications. These Drawings will include plant room layouts, required
to complete the project as per specifications and as required by the Engineer. These
drawings will contain details of construction, size, and arrangement, operating
clearances, performance characteristics and capacity of all items of equipment, as also
the details of all related items of work by other Contractors. Each item of equipment
proposed shall be as per standard catalogue product of an established manufacturer as
per specifications.
1.6.2 When the Engineer makes any amendments in the above drawings, the Contractor shall
supply fresh sets of drawings with the amendments duly incorporated, along with the
drawings on which corrections were indicated.
1.6.3 The Contractor shall furnish for checking and scrutiny advance sets of prints of the layout,
assembly, and erection drawings. No modifications shall be made in the drawings after
they have been approved by the Engineer without his prior consent. All drawings
necessary for assembly, erection, maintenance, repair, and operation of the equipment
shall be furnished. Different parts shall be suitably numbered for identification and
ordering of spare parts.
1.6.4 No material or equipment may be delivered or installed at the job site until the Contractor
has in his possession, the approved Shop Drawings for that particular material or
equipment.
1.6.5 The Shop Drawings shall be submitted for approval sufficiently in advance of the planned
delivery and installation of any materials, to allow the Engineer ample time for scrutiny.
No claims for extension of time shall be entertained because of any delay in the work due
to his failure to produce Shop Drawings at the right time, in accordance with the approved
program

1.6.6 Approval of Drawings by the Engineer shall not relieve the Contractor of any part of his
obligation to meet all the requirements of the Contractor of the correctness of his
drawings. The Contractor shall be responsible for any pay for all alterations of the works
due to discrepancies in the drawings or other particulars supplied by him, whether such
drawings have been approved by the Engineer or not.
1.6.7 The drawings prepared, and the allocated position for equipment’s represents a feasible
scheme in the machine room and equipment room. The layout in the machine room and
the equipment room may be rearranged only in the allocated space, subject to the
approval of the Engineer.
1.6.8 Where the work of the Contractor has to be installed in close proximity to, or will interfere
with the work of other trades, the Contractor shall assist in working out space conditions
to make a satisfactory adjustment. If so, directed by the Engineer, the Contractor shall
prepare composite working drawings and sections at a suitable scale, clearly showing
how his work is to be installed in relation to the work of other trades. If the Contractor
installs his work before coordinating with other trades, or so as to cause any interference
with work of other trades, he shall make all the necessary changes without extra cost to
the Employer.
1.7 VIBRATION ISOLATION AND NOISE LEVEL
1.7.1 All equipment shall operate under all conditions of load without any sound or vibration
which is objectionable in the opinion of the Engineer. In case of rotating machinery,
sound, or vibration noticeable outside the room in which it is installed, or annoyingly
noticeable inside its own room, shall be considered objectionable. Proper provision shall
be made for vibration isolation for the required equipment. Abnormal vibration and noise
level conditions shall be corrected by the Contractor at his own expense.
1.8 GUARANTEE
1.8.1 The contractor shall guarantee that all the material, machinery and components supplied,
fabricated, designed and installed by him shall be free from defects due to fault design
material and / or workmanship, that the plant shall perform satisfactorily specifically the
successful performance of the system in monsoon and summer and the efficiency of the
system and all the components shall not be less than the values laid down in the
specifications and the capacities shall be within ± 5% of the specified values, in case of
deviation greater than ± 5%, the contractor shall replace the necessary components.
1.9 MAINTENANCE & TRAINING
1.9.1 The Contractor shall associate, during the erection and during the Defects Liability Period
with the DMRC staff to familiarize them with the operation and maintenance of the plant.
1.9.2 If required by the Engineer’s In-charge the Contractor shall agree to train members of the
purchaser maintenance staff either at his or manufacturer’s work or at such other place
or places as may be considered suitable by the Engineer.
1.9.3 On completion, supply of two sets of well bound handing over manuals duly approved by
Consultants / Engineer. Each set shall include “As Built Drawings”
1.10 TECHNICAL DATA
1.10.1 The tenderers must submit the technical data along with catalogue, literature, and
manufacturer’s manual for all items as listed in tender (Technical specifications) in the
indicated format, and submit along with their tenders.
1.10.2 Failure to furnish technical data with tenders may result in summary rejection of tenders.
1.11 WORKS & SERVICES TO BE EXECUTED BY OTHER AGENCIES

The following associated works and services are excluded from scope of this contract
and shall be executed by other agencies in accordance with contractors approved shop
drawings.
1.11.1 Major civil works like foundations for the equipment, cut-outs for pipes and ducts.
However minor openings and finishing shall be carried out by Air- conditioning contractor.
1.11.2 Horizontal drain pipes in floor up to nearest drain point & tap-off point near each IDU for
drain connection.

2 BASIS OF DESIGN
2.1 CODES & DESIGN STANDARDS
a) NBC-National Building Code – 2016
b) ISHRAE – Indian Society of Heating Refrigeration and Air Conditioning Engineers.
c) ASHRAE – American Society of Heating Refrigeration and Air Conditioning Engineers.
d) ECBC- Energy Conservation Building Code-2017
e) ASME- American Society of Mechanical Engineers
f) ANSI- American National Standards Institute
g) ASTM-American Society for Testing and Materials
h) National Electrical Code (NEC)
i) Bureau of Indian Standard (BIS)
j) BS- British Standard.
k) AMCA –Air Movement and Control Association
l) ASTM B280-08 – Standard Specification for seamless copper tube.
2.2 DESIGN PARAMETERS
2.2.1 CLIMATIC CONDITIONS
Location : New Delhi (India)
Latitude : 28.34 °N
Altitude : 216 Meters. above mean sea level.
2.2.2 OUTDOOR CONDITION:
Dry Bulb Temp REFERENCE
Seasons Wet Bulb Temp (°C)
(°C)
Summer 43.3 23.9 ISHRAE Handbook
Monsoon 35.0 28.3
2.2.3 INSIDE CONDITIONS & STAND BY AC REQUIREMENTS:

Inside Temp AC STAND BY
Area Description RH %
(°C) UNIT AC UNIT
Telecom Equipment Room (TER) 24±1 <60% √ √
Signalling Equipment Room
24±1 <60% √ √
(SER)
UPS Room (S&T / E&M) 24±1 <60% √ √
Station Control Room (SCR) 24±1 <60% √ √
Ticket operating Machine (TOM) 24±1 <60% √
Crew Control Room, Rest room 24±1 <60% √ √
2.2.4 VENTILATION REQUIREMENTS:

AREA DESCRIPTION VENTILATION RATE REFERENCE
(ACPH)
Toilets 10 ACPH

Mess room 10 ACPH

Cleaners room / janitor Room 10 ACPH
Auxiliary Substation (ASS) 20 ACPH National Building Code of
India-2016
Pump Room 15 ACPH
STP Rooms 30 ACPH
2.2.5 LIGHTING LOAD:

AVERAGE REFERENCE
AREA DESCRIPTION
LIGHTING LOAD
TOM, Technical Equipment ‘s 0.5 W / Sq. ft. Energy Conservation Building
Room Code-2017 (Building Area
Method – Table -6.3)
2.2.6 EQUIPMENT LOAD:
AREA DESCRIPTION EQUIPMENT LOAD

Signalling Equipment Room (SER) 1.5 KW
Telecom Equipment Room (TER) 1.5 KW
UPS Room (S&T and E&M) 4.0 KW
Station Control Room (SCR) 1.0 KW
Ticket operating Machine (TOM) 1.0 KW
2.2.7 DESIGN PARAMETER FOR DUCTS:
Air conditioning
Maximum flow velocity in ducts, if any : 305 metres. / min (1000 ft. / min)
Maximum friction : 0.1-inch WG / 100 ft. run
Maximum velocity at Supply air grille / 152 metres. / min (500 ft. / min)
:
diffuser, if any
Ventilation
Maximum flow velocity in ducts : 600mtrs / min (2000 ft. / min)

Maximum friction : 0.1-inch WG / 100 ft. run
Maximum velocity at Supply air grille 183 metres. / min (600 ft. /
:
min)
2.2.8 DESIGN PARAMETER FOR 3 PHASE VENTILATION FANS:
Maximum fan outlet velocity for fan up to &
: 9.2 m / sec
including 450 mm dia.
Maximum fan outlet velocity for fan above 450
: 12 m / sec
mm dia.
Maximum fan speed for fans up to including 450
: 1440 RPM
mm dia.
Maximum fan speed for fans above 450 mm dia. : 1000

2.3 SYSTEM DESCRIPTION

 The area mentioned above for air-conditioning shall be catered through central Variable
refrigerant volume / Flow system at each station. Some area shall be air-conditioned
through Inverter based split AC system also wherever connection with central Variable
refrigerant volume / Flow system is not possible due to location.
 The outdoor units of central Variable refrigerant volume / Flow system, which are placed
at platform or other shaded location shall be provided with cowl duct to throw the hot air
outside. The cowl duct shall be provided with 1 coats of primer and 2 coats of paint of same
colour as of outdoor units.
 The refrigerant pipes shall be provided with insulation and finally provided with mechanical
protection through aluminium sheet cladding as per BOQ.
 The non-air-conditioned enclosed area shall be provided with ventilation fan for exhaust
purpose and the intake air shall be taken through door transfer air grille as shown in the
drawings.
 The exhaust fans in toilets area shall be provided with timer based controlling system for
operation as per commuter’s frequency to minimize the operational hours of the fans.
Contractor shall provide complete solution including timer with auto-manual controlling
system and control cabling etc. to make the system operational.
 The fans in toilets and other office area shall of fire-retardant ABS plastic construction and
provided with inbuilt mounting frame, gravity louvers and bird screen etc. or as per engineer
in-charge.
 The exhaust fans in utility rooms shall be of heavy-duty metallic constructions. The
ventilation fans in ASS room shall be provided with 2 nos. Co2 cum Temperature based
sensor. Two / three fans shall be interlocked through one Co2 sensor. The CO2 sensor
shall be provided with inbuilt relay, relay output through NO / NC contact. Contractor shall
provide necessary Auto / Manual switch, on-off push button with enclosure box and
necessary control cabling for automatic operation of the fans.

TECHNICAL
SPECIFICATIONS

1 VARIABLE REGRIGERANT FLOW SYSTEM

1.1 Variable Refrigerant Volume / Flow (VRV / VRF) type Air- conditioning system to be
provided at the elevated stations (Rail Corridor) of DMRC. Generally, the following rooms
of the stations shall be air- conditioned:
a) Station Control Room
b) Ticket Office
c) Signalling Equipment Room
d) Telecom Equipment Room
e) UPS (S&T) Room
f) Crew Control Rooms if any.
1.2 The scope of work related to Variable Refrigerant Flow Air-conditioning System shall
generally comprise of but not limited to the following:
a) Manufacturing
b) Testing at manufacturer’s works
c) Supply and storage
d) Installation at station
e) Site testing and commissioning
f) Training of DMRC staff
1.3 The VRF type air-conditioning system shall generally consist of:
a) Outdoor and Indoor units along with refrigerant piping, its insulation with aluminium
cladding and control cables. Each refrigerant circuit from Outdoor Unit to Indoor Unit will
run on cable tray. Refrigerant piping of each circuit shall be provided with proper tagging
(engraved aluminium Tag) at regular interval for easy identification. Identification mark
(in red colour) to be done at each joints of refrigerant pipe.
b) Air distribution system, Drain Piping, Electrical & control works.
c) Materials and components not specifically stated in the specifications and / or bill of
materials or noted on the drawings but which are necessary for satisfactory installation
and operation of the system. No separate payment is to be made for such items.
The VRF type air-conditioning system shall comply with standards mentioned particularly
in the table below unless otherwise stipulated in the specifications. The latest version of
standards shall be applicable.
ASHRAE latest standard and guidelines.

UL-94- V0
Indian Electricity Rules- 2005
ASTM B280
ISHRAE Guidelines for Testing and Rating of VRF systems
1.5 Requirements
The VRF system shall be designed to meet the minimum requirements on the design
parameters mentioned in Basis of Design.

1.6 Functional Requirements

1.6.1 The Variable Refrigerant Flow (VRF) System should be air cooled, consisting of modular
condensing outdoor units connected to multiple indoor units. Each indoor unit shall have
the capability of individual set point control. Each modular condensing unit should have
inverter compressors to obtain 10% to 100% step less capacity control to match the air-
conditioning load.
1.6.2 The VRF unit shall be capable of operating within a wide range of temperatures. The
condensing units should be capable of working with an ambient temperature of -5 deg. C
to 52 deg. C DB. The system shall be designed for automatic cyclic operation for a bank
of VRF units with settable time feature including providing all related microprocessor,
cabling. The refrigerant used should be environmental friendly and latest. The
manufacturer shall take a note of the ambient air pollution prevailing in Delhi / NCR region
and shall provide proven protection against corrosion to all the components of VRF
module like copper coils, fins, and other electronic components. The VRF air conditioning
system shall consist of the following sub-systems:
1.6.3 OUTDOOR UNIT
The outdoor unit shall be a factory assembled unit housed in a sturdy weather proof
casing constructed from rust-proofed mild steel panels coated with a baked enamel finish.
There should be no scaling, corrosion, or any other physical deformation on the body of
Outdoor unit. The outdoor unit shall be modular in design and thickness of the sheet used
for manufacturing the body shall be such that it shall not deform during handling and may
use corrugation to strengthen the body structure. It should be possible to place the ODU’s
side by side. The ODU must deliver the rated capacity at 43.3°C outside condition and
24°C inside condition within the acceptable tolerance of ± 5%. The minimum ISEER
should be as below: -
ODU Capacity ISEER (Minimum)
Up to 10 HP 30
12HP to 14 HP 25
16HP & Above 21
The outdoor unit should be able to operate even in case of breakdown of one of the
compressors (for above 16 HP units). The Outdoor unit shall at least have the following
sub-components: -
1.6.3.1 Compressor
The compressor shall be highly efficient 100 % inverter based hermetically sealed scroll
/ T w i n rotary design and capable of capacity modulation with inverter
technology. Each ODU should have minimum one nos. variable compressor up to 16
HP, 2 nos. variable compressors up to 32 HP capacity and 3 nos. variable compressors
up to 48 HP capacity.
1.6.3.2 Heat Exchanger
a) The heat exchanger shall be constructed with copper tubes mechanically bonded to
aluminium fins to form a cross fin coil. The heat exchanger and condenser fins must be
coated with Anti-corrosive treatment. The fins, copper coil, joints of the ODU shall be
coated with aluminium pigmented polyurethane coating of minimum 25 microns
thickness on aluminium fins and 120 microns thickness on copper coil and joints or
Silane based hybrid coating of minimum 15 microns thickness on aluminium fins and

40-50 microns thickness on copper coil and joints or 80-90 microns ( Base coat- 50-
60 micron Hybrid epoxy + Top coat 20-30 micron Silane Hybrid) thickness on copper
coil and joints & Silane based hybrid coating of minimum 15 microns thickness on
aluminium fins to offer an inhibiting as well as sacrificial protection of metals against
corrosion, Sulphur and other chemical contaminants present in the air. Coating should
be done at manufacturing stage only in presence of OEM representative. The coating
shall be carried-out by the certified applicator of coating manufacturer. The coating
should be in consultation of OEM, so that there is no effect on equipment COP. Third
party certificated from NABL accredited laboratory must be produced for salt spray test
for minimum 3000 hours for the coatings. The coating must be have life of at least 2
years, if there is any maintenance required during this period, contractor shall provide
necessary solution without any extra cost. OEM shall provide technical documents of
coating and applicator details to engineer in-charge for approval before application of
coatings. /
1.6.3.3 Fan Motor Speed Control
The condensing unit fan motors to have at least two speed operations to maintain
constant head pressure control at all ambient temperatures and modes of operation.
The fan should have external static pressure of minimum 4 mm WG for cowl duct
extension.
1.6.3.4 Refrigerant Circuit
The refrigerant circuit shall include an accumulator, liquid and gas shut off valves and
a solenoid valves or pulse width modulation valve. The equipment must have inbuilt
refrigerant stabilization control for proper refrigerant distribution.
1.6.3.5 Oil Recovery System
Each unit shall be equipped with an oil separator to ensure stable operation with long
refrigerant piping.
1.6.3.6 Unit Control Board
a) The Units shall be provided with surge protection device suitable for minimum 8KV
Impulse.
b) There should be no ingress of water in control board enclosure during wet maintenance.
c) The PCB should have Conformal Coating as per IEC-61086.
1.6.4 INDOOR UNIT
Indoor unit shall be Wall mounted / Ceiling mounted / floor mounted (as per requirement)
with metallic body except cassette units, each complete with coil, pre-filter, etc. including
necessary steel supporting structure. Indoor unit should have flexibility for duct extension
(if required). CFM shall be as below:
CEILING SUSPENDED IDU Capacity CFM (Minimum)

1.5TR 600
2.0 TR 800
2.5 TR 1000
3.0 TR 1200
4.0 TR 1350

CEILING MOUNTED IDU (Cassette Type)

Capacity CFM (Minimum)
2.0 TR 600
2.5 TR 800
3.0 TR 1000
Note: The CFM of indoor units may vary as per actual equipment’s ADP, meeting the
design requirements.
b) It shall have electronic control valve to control refrigerant flow rate in response to load
variations of the room. The fan shall have highly efficient BLDC (Brushless Direct Current)
motor and statically and dynamically balanced direct driven DIDW multi-blade type
blowers, to ensure low noise and vibration free operation.
c) The system should be designed such that in case of failure / trip of one indoor unit, the
working of ODU and other indoor units should not be affected. The indoor unit fan shall
be direct driven. The indoor unit casing shall be fully insulated and sealed to prevent
condensation. Each indoor unit shall have the capability of individual set point control.
d) All the ceiling suspended indoor unit’s body & parts should be of metallic construction.
The cassette type indoor units having some parts in non-metallic construction must be
UL-94- V0 certified.
e) The indoor unit should be provided with corded remote control as a standard accessory.
The address of the indoor unit shall be set automatically in case of individual and group
control. In case of centralized control, centralized remote controller shall set it.The fins,
copper coil, joints of the IDU shall be coated with aluminium pigmented polyurethane
coating of minimum 25 microns thickness on aluminium fins and 120 microns thickness
on copper coil and joints or Silane based hybrid coating of minimum 15 microns thickness
on aluminium fins and 40-50 microns thickness on copper coil and joints or 80-90 microns
(Base coat- 50-60 micron Hybrid epoxy + Top coat 20-30 micron Silane Hybrid) thickness
on copper coil and joints & Silane based hybrid coating of minimum 15 microns thickness
on aluminium fins to offer an inhibiting as well as sacrificial protection of metals against
corrosion, Sulphur and other chemical contaminants present in the air. Coating should
be done at manufacturing stage only in presence of OEM representative. The coating
shall be carried-out by the certified applicator of coating manufacturer. The coating should
be in consultation of OEM, so that there is no effect on equipment COP. Third party
certificated from NABL accredited laboratory must be produced for salt spray test for
minimum 3000 hours for the coatings. The coating must have life of at least 2 years, if
there is any maintenance required during this period, contractor shall provide necessary
solution without any extra cost. OEM shall provide technical documents of coating and
applicator details to engineer in-charge for approval before application of coatings.
1.6.4.1 / Electronic Expansion Valve
Each indoor unit shall be fitted with an electronic expansion valve to control the
refrigerant flow in response to the load variations in the room. The electronic expansion
valve is to be controlled via a sensing the return air temperature, refrigerant inlet, and
outlet temperatures. During the cooling operation the electronic expansion valve shall
control the refrigerant superheat degree at the evaporator.
1.6.4.2 Cooling Coils
Shall be direct expansion, constructed from copper tubes expanded into aluminium fins
to form a rigid mechanical bond.

1.6.4.3 Unit Control Board

The indoor unit shall have a printed circuit board complete with, address switches for a
variety of operation controls, emergency operation switch and fault / operation indication
LED’s. The fan motors shall be thermally protected. The PCB should have Conformal
Coating as per IEC-61086.
1.6.5 CENTRALIZED SYSTEM REMOTE CONTROLLER
1.6.5.1 A multifunctional compact touch screen centralized system remote controller shall be
provided with the system. The System Controller shall provide proven air conditioning
management system to give complete control of VRF air conditioning equipment. It
should be user friendly.
1.6.5.2 It should be able to control at least 50 indoor units; the centralized system remote
controller shall perform the following minimum functions:
a) Starting / stopping of Air conditioners as a zone or group or individual units.
b) Temperature setting for each indoor unit or zone.
c) Switching between temperature controls modes, switching of fan speed and direction of
airflow, enabling / disabling of individual remote controller operation.
d) The address of the indoor unit shall be set automatically in case of individual and group
control.
e) Monitoring of operation status such as operation mode & temperature setting of
individual indoor units, maintenance information, trouble-shooting information.
f) Scheduling of both Indoor and Outdoor units as per the requirement.
g) Display of actual room temperature.
h) The controller shall have user friendly colour LCD Touch screen display. The centralized
system controller should be able to control the indoor unit with control wiring up to a
total distance of 1 km.
1.6.6 In case of power fluctuation or power failure, the addressing and other settings such as
temperature of individual indoor units should not be affected. Alpha- numeric addressing
of each indoor unit should be possible to facilitate the location of individual indoor unit.
2 REFRIGERANT PIPEWORK
2.1 All interconnecting pipe-work between the condensing unit & indoor units shall have
seamless copper tubes with brazed connections and the appropriate distribution joints and
headers shall be used. The piping should be routed at site in such a manner, that brazed
joints in the Refrigeration Piping are kept to a minimum. All interconnecting piping joints
and U bends shall be painted with two coats of coating for protection against corrosion
from ambient air pollution.
2.2 Each coat shall have dry film thickness of minimum 25micron.The coating shall be strong,
flexible, and durable. It shall have good adhesive and abrasion resistance. It shall be
resistant to moisture, UV, acid alkali and other chemicals.
2.3 All suction & liquid lines of the Refrigerant pipe work shall be insulated with Nitrile rubber
pipe sections as specified to avoid condensation.
2.4 The pipe insulation shall be Aluminium cladded with minimum 0.63 mm thickness. The
refrigerant pipe shall be thermally insulated by proven materials having low thermal
conductivity, high mechanical strength, non-combustible, resistance to Fungi, ozone, UV,
and any other environmental pollutant. Moulded joints of thermal insulating material shall
be used at bends, y-joints, T-joints etc.
2.5 The refrigerant piping shall be extendable up to minimum 165 m with 50 m level without

any oil trap. Distribution refrigeration pipe joints and headers shall be installed in an
appropriate orientation to enable correct distribution of refrigerant. The Distribution joints
shall be factory insulated. All pipe-work must be kept clean and free from contamination to
prevent breakdown of the system. All pipe ends shall be kept sealed until immediately prior
to making a joint.
2.6 Refrigerant charge must be calculated based on the actual length of the refrigerant pipe
work. The refrigerant charging process must be carried out with an appropriate charging
station and under supervision of manufacturer / OEM or his representative.
2.7 The insulated refrigerant piping and control wiring (in conduit) shall run on GI tray properly
supported by GI rods. The exposed tray shall be covered by openable GI covers.
2.8 Bend of copper piping shall be done by proper mechanical bending machine.
2.9 The copper tubes shall be of two types: Soft Annealed (O) and Half hard (1 / 2 H). The
chemical composition will confirm to grade C12200 designated as “Phosphorus Deoxidized
High Residual Copper” grade having minimum Copper % of 99.9 % with Phosphorus % of
0.015 to 0.040%.
2.10 The Mechanical properties should also as per the ASTM B280.
2.11 The OD & wall thickness of copper refrigerant piping shall be as follows:
Toleranc
Toleranc
Thickne e
Size e Specification
ss (Thicknes
(Día)
s)
0.762 ± 0.08 ± 0.051
6.35 mm (1 / 4 in) C12200T-O (ANNEALED)
mm mm mm
0.813 ± 0.08 ± 0.051
mm mm mm
12.70 mm (1 / 2 0.813 ± 0.08 ± 0.051
C12200T-O (ANNEALED)
in) mm mm mm
0.889 ± 0.11 ± 0.051
mm mm mm
± 0.11 ± 0.025 C12200T-1 / 2 H (HALF-
19.1 mm (3 / 4 in) 1.07 mm
mm mm HARD)
± 0.11 ± 0.025 C12200T-1 / 2 H (HALF-
22.3 mm (7 / 8 in) 1.14 mm
mm mm HARD)
± 0.13 ± 0.038 C12200T-1 / 2 H (HALF-
25.40 mm (1 in) 1.27 mm
mm mm HARD)
28.6 mm (1 1 / 8 ± 0.13 ± 0.038 C12200T-1 / 2 H (HALF-
1.27 mm
in) mm mm HARD)
34.9 mm (1 3 / 8 ± 0.14 ± 0.038 C12200T-1 / 2 H (HALF-
1.40 mm
in) mm mm HARD)
41.3 mm (1 5 / 8 ± 0.15 ± 0.051 C12200T-1 / 2 H (HALF-
1.52 mm
in) mm mm HARD)
/
/
/
/

/ /
/ /
/
/ /
/ /
/ /
/ /
2.12 The size of the pipe may vary depending on the site conditions / OEM recommendation.
2.12.1 The copper tubes shall be supplied with end Caps at both ends.
2.12.2 The copper tubes must be packed & sealed to protect them from any atmospheric
degradation / contamination.
2.12.3 All copper tubes shall be 100% eddy current tested.
2.12.4 All the Tubes shall be RoHS (Restriction of Hazardous Substances) complied and each
lot of supply shall be provided with routine test certificate.
Testing Max. Permissible Content Limit (PPM)

Cadmium (Cd) 100 ppm
Lead (Pb) 1000 ppm
Mercury (Hg) 1000 ppm
Chromium 1000 ppm
2.12.5 Third Party Tests for Copper Pipe:
third party independent lab at its own cost, to ensure the quality of material supplies. If
any of the samples fail in the test, the cost of the test along with the complete
DMRC, but in case of failure of any of the samples collected by the contractor, complete
lot will be deemed as rejected and contractor will replace the whole Lot.
contractor.
2.12.6 All joints in copper piping shall be sweat joints using low temperature brazing and or silver
solder. The piping shall be continuously kept clean of dirt etc. while constructing the joints.
Subsequently, it shall be thoroughly blown out using nitrogen.

2.12.7 Copper pipe fittings shall be of same manufacturer and of same thickness as refrigerant
pipe.
2.12.8 Following marking should be provided on copper Pipes:
a) Manufacturer Name
b) Standard of manufacturing
c) Dimension
d) Application
e) For DMRC Projects
2.12.9 Site Acceptance Test:
Each lot of the copper tubes shall be inspected physically for any physical defects and
the sizes shall be checked as per specification.
2.13 DRAIN PIPING

The indoor units shall be connected to vertical insulated cPVC drainage pipe. The vertical
pipes shall be concealed in the wall & drop down up to floor level and connected to the
horizontal pipe running in the floor without any extra cost. The pipes shall be laid in proper
slope for efficient drainage of condensate water. Drain pipes carrying condensate water
shall be insulated with 6 mm Nitrile rubber insulation as specified. The joints shall be
properly sealed with synthetic glue to ensure proper bonding of the ends.
2.14 NOISE LEVEL
The Noise level of outdoor unit shall not be more than 68 dB(A) at normal operation. The
Noise Level of indoor unit shall not be more than 42 dB(A) for non ductable and not more
than 49dB(A) for ductable units. The noise level shall be measured at a distance of 1m
away (horizontally) and 1.5 m above ground.
2.15 INPUT VOLTAGE & FREQUENCY
All the outdoor unit shall be suitable for operation with 415 V ±10%, 50±3% Hz, 3Ph 4
wire AC supply, whereas all indoor units should be with 240V± 10%, 50Hz±3 % Single
Phase supply.
a) The control / communication cable between indoor and outdoor units shall run in GI
conduits.
b) The insulated refrigerant piping and cable between indoor and outdoor unit shall run in
a Galvanized Steel raceway / Cable tray with proper supporting arrangement. The
exposed refrigerant pipe near ODU’s shall run in covered cable tray or in raceway.
c) All galvanized support beams, galvanized legs, galvanized hangers, anchor bolts,
vibration isolators, and ductworks shall be provided for the installation of the units,
assembly, and its sub-assembly.
d) The VRF type air conditioning units shall be mounted on vibration isolators and installed
in accordance with the manufacturer’s recommendation such that no disturbing
vibration or noise is being transmitted to the nearby structure.
e) The centralized system Controller shall be located in a properly sized box with lock and
key facility along with its battery / adapter unit. The power supply cable for the controller
shall be taken in a conduit from the nearest 240V socket. A guidance manual of the
controller shall be located in this unit.

f) Joints in refrigerant piping should be minimized. Half Hard / Hard copper pipes up to
dia. 18 mm should be bended and not use elbow at the locations having bends of 90
deg.
2.17 SAFETY
2.17.1 All necessary safety devices shall be provided in the indoor and outdoor units to ensure
the safety operation of the system. The design of the safety system shall be such that the
equipment is protected and defect of one unit shall not lead to consequential damage to
any other units. The safety and protection design shall be submitted with the offer and
shall be a part of the training course to DMRC official.
2.17.2 The following safety devices shall be part of the outdoor unit:
a) High Pressure Switch
b) Low Pressure Switch
c) Fan Motor Safety thermostat
d) Over Current Relay
e) Fuse
f) Overload protection
g) Protection for indoor fan motor.
h) All the material used in the manufacturing of VRF system shall be fire retardant. The
indoor unit shall be in conformance to UL-94 guidelines. The manufacturer shall submit
UL compliance certificate with the offer.
2.18 ENERGY EFFICIENCY
2.18.1 Only the best manufacturing practices i.e. the units with maximum ISEER as per ISHRAE
will be accepted. The contractor shall study the best available design and offer the best
ISEER available in industry. However, the VRF unit should provide a minimum ISEER as
mentioned above.
2.18.2 The formula used for the calculation of ISEER shall be as follows:
ISEER= [(0.06* COP at 100% loading) + (0.48*COP at 75% loading) + (0.36*COP at 50%
loading) + (0.10* COP at 25% loading)] * 3.41
2.18.3 The vendor shall provide the model no. of the proposed units and provide the actual
capacity of same units at AHRI and site condition also. The Minimum EER & IEER Value
should also comply as per ASHRAE.
2.19 MAINTENANCE AND LIFE
2.19.1 The service life of the VRF system shall be at least 15 years, with average 16 hours
working per day during the year.
2.19.2 The manufacturer shall submit the list of those items whose life does not match with the
service life of VRF. The life of such spares shall be advised with a certificate from the
original manufacturer of the spares. The firm shall supply purchase specification of these
items.
2.19.3 The manufacturer should also submit Annual Maintenance cost rates of the system.
2.19.4 The manufacturer shall provide free service and guarantee for 24 months from the date
of taking over the metro station by the purchaser.
2.19.5 The Contractor shall provide additional coat of corrosion protection as mentioned above
in the last month of the DLP.

2.20 SPECIAL CONDITION

a) Firm procurement and job performance specifications.
b) Firm procedures for transmission of information and data to their Subcontractors and
ensuring their compliance.
c) Adequate testing to ensure repetitive product conformity to design requirements and
Total programme of surveillance and verification of physical performance and
d) Adequate records shall be kept by the Contractor to provide evidence of quality and
controls, certification of processes and personnel, discrepant material, and other quality
control requirements.
e) Complaint Handling and commitment towards customer satisfaction.
f) The manufacturer shall ensure use of best manufacturing practice like quality of bends,
g) The manufacturer shall study the environmental pollution data prevailing near the Metro
2.21 TESTING
2.21.1 The unit shall be tested for capacity and ISEER as per ISHARE conditions at
manufactures premises or at an accredited laboratory. The capacity of ODU and IDU’s
shall be as per the BOQ and rated 100% capacity within the acceptable tolerance of +5
% at design condition i.e. at minimum 43.3 °C outside condition. The OEM shall also
submit the unit’s actual capacities at AHRI condition for the same unit.
2.21.2 The manufacturer shall also submit the deration graph for different ambient conditions in
the performance of their VRF system starting from the maximum ambient temperature
conditions as tested.
2.21.3 The refrigerant piping system shall be pressure tested using dry nitrogen gas prior to
insulating the joints at a pressure of 4.0 MPaG (580 PSIG). Pressure of 4.0 MPaG (580
PSIG) shall be maintained in the system for at least 24 hours for test of leakage.
2.21.4 After satisfactory testing, the refrigerant pipe shall be evacuated and dehydrated to (-755
MM HG) and held for one to four hours depending on the pipe length. When the gauge
indicator does not rise, the test will be considered successful. If the gauge indicator rises,
there may be moisture remaining or a leak in the circuit.
2.21.5 After completing the vacuum drying, the refrigerant shall be charged in a liquid state.
Digital scale shall be used for measuring the additional refrigerant quantity.
2.21.6 The FAT plan for VRF equipment shall be as per Annexure-A.
2.22 TRAINING
2.22.1 The contractor shall ensure training of DMRC staff as decided by DMRC at DMRC
workplace or at his workplace as considered necessary.

2.22.2 On completion of installation, the manufacturer shall supply two sets of well bound
handing over manuals duly approved by Consultants / Engineer-in-charge. Each set shall
include: -
a) As Built Drawings.
b) Do’s and Don’ts for the maintenance and operating staff.
c) Working details of VRF system.
d) Operating manual.
e) Extracts of the warrant / DLP.
f) Details of service center.
g) List of staff trained on the said design of the VRF.
h) The first page of the booklet shall be signed by the manufacture, contractor and DMRC
Engineer.
i) Soft copy of the entire documents.
ANNEXURE-A
FAT PLAN FOR VRF EQUIPMENT (MINIMUM PARAMETERS)
PHYSICAL PARAMETERS TO BE CHECKED
COMPONENT PARAMETER Requirement Remarks
1. OUTDOOR UNIT Casing Weather proof casing
constructed from rust-
proofed mild steel panels
coated with a baked enamel
finish
Compressor 1 no. variable compressor
up to 16 HP and minimum 2
no. variable compressor for
above 16HP and up to 32
HP.
2. INDOOR UNIT Component Electronic Expansion Valve
Insulation fully insulated and sealed
3. HEAT EXCHANGER Construction The Condenser fins must be
coated with Anti-corrosive
treatment.
4. REFRIGERANT Component Accumulator
CIRCUIT
Component Liquid and gas shut off valve
Component Solenoid valves
5. OIL RECOVERY Component Oil Separator
SYSTEM
6. SAFETY DEVICES Component High Pressure Switch
Component Low Pressure Switch
Component Fan Motor Safety
Thermostat

Component Over Current Relay

Component Fuse
7. FAN MOTOR Component Thermal protection relay.

TECHNICAL PARAMETERS TO BE CHECKED
S. COMPONENT PARAMETE REQUIREMENT REMARK

No. R
1. OUTDOOR UNIT Cooling 100% cooling capacity at
capacity Outdoor ambient temperature
as per ISHRAE (within the
acceptable tolerance as
specified ISHRAE Guidelines
for Testing and Rating of VRF
systems)
Noise level 68 dB(A)at normal operation
measured horizontally 1m away
and 1.5m above ground.
COP / ISEER As per ISHRAE Guideline
Conditions
Maximum As per ISHRAE Guideline
temperature Conditions
operating test
Operation The unit operation at maximum
outdoor temperature of 52°C.
2. INDOOR UNIT Noise level NOISE Level < 42dB for non
ductable type and <49 dB for
ductable unit
3. REFRIGERANT Length Extendable minimum 165 m
PIPING with 50 m level without any oil
trap.
4. FAN MOTOR Speed At least two speed operation to
Control maintain constant head
pressure control at all ambient
temperatures
5. CENTRALIZED Operation Starting / Stopping of Air-
REMOTE conditioners as a zone or group
CONTROLLER or individual unit
Operation Temperature setting for each
indoor unit or zone
Operation Switching between
temperature control modes
Operation Switching of fan speed
Operation Control direction of air-flow
Operation Enabling / disabling of

individual remote controller
operation
Operation Monitoring of Operation status
Operation Maintenance information
Operation Trouble Shooting information
Operation Temperature setting of

individual indoor units

2.23 COMMISSIONING
2.23.1 After installations are completed, all air-conditioning system shall undergo test run. During
test at site, a report forms to contain following minimum data listings shall include design
and actual conditions for each Item mentioned below:
a) Date and time of test.
b) Outside conditions (DB and WB)
c) Air-conditioning unit make, type, name, and serial number.
d) Fan rpm.
e) Fan motor amperage
f) Rated motor amperage, starter number and ampere rating.
g) Fan CFM
h) Entering air coil conditions (mixing) (DB and WB)
i) Leaving air coil conditions (DB and WB)
j) Room temperature & Humidity (DB and RH %)
k) Settings to be checked of centralized controller after power supply failure.
l) Running condition of each circuit after switching-off of one indoor unit from MCB in each
circuit.
2.23.2 During test run, the air filters of testing sets shall be used.
Note: Additional tests may be conducted based on the requirement of the employer’s
representative.

3 SPLIT AIR CONDITIONERS

3.1 GENERAL
a) The contractor shall supply and install split system air conditioner with highly efficient
inverter compressor. The system shall be complete in all respects and comply with the
specifications as given.
b) All split units shall be eco-friendly type.
3.2 CONDENSING UNITS
a) Each condensing unit shall be complete unit with high EER hermetic inverter type scroll
/ rotary compressors, air cooled condenser, condenser fans with motors, internal piping,
switches, and internal wiring and shall be enclosed in weather proof outdoor type
housing.
b) The compressor shall be hermetic, with enclosed gas cooled motor. The compressors
shall be suitable for R410A / R32.
c) The condenser coil shall be air cooled type with aluminium sine wave fins and copper
tubes and necessary refrigerant connections. The copper tubes shall not be less than 1
/ 4” O.D.
d) The condenser air fans shall be propeller type direct driven, each complete with motor.
The air quantity and area of the condenser shall be adequate for working in the specified
outdoor conditions.
e) The casing shall be fabricated from galvanized steel and finished with powder coated
paint. The casing shall make the whole unit fully weather proof. Suitable for outdoor
installation.
f) The unit shall include a remote-control assembly with thermostat and starter and speed
switches.
g) The necessary charge of refrigerant gas and lubricated oil shall be provided to run the
system.
h) The fins, copper coil, joints of the IDU / ODU shall be coated with aluminium pigmented
polyurethane coating of minimum 25 microns thickness on aluminium fins and 120
microns thickness on copper coil and joints or Silane based hybrid coating of minimum
15 microns thickness on aluminium fins and 40-50 microns thickness on copper coil and
joints or 80-90 microns ( Base coat- 50-60micron Hybrid epoxy + Top coat 20-30 micron
Silane Hybrid) thickness on copper coil and joints & Silane based hybrid coating of
minimum 15 microns thickness on aluminium fins to offer an inhibiting as well as sacrificial
protection of metals against corrosion, Sulphur and other chemical contaminants present
in the air. Coating should be done at manufacturing stage only in presence of OEM
representative. The coating shall be carried-out by the certified applicator of coating
manufacturer. The coating should be in consultation of OEM, so that there is no effect on
equipment COP. Third party certificated from NABL accredited laboratory must be
produced for salt spray test for minimum 3000 hours for the coatings. The coating must
have life of at least 2 years, if there is any maintenance required during this period,
contractor shall provide necessary solution without any extra cost. OEM shall provide
technical documents of coating and applicator details to engineer in-charge for approval
before application of coatings.
/ /
3.3 COOLING UNIT
a) Indoor unit shall be Wall mounted / Ceiling mounted (as per requirement) with metallic
body except cassette units. The cooling unit shall be matched to the respective

condensing unit and shall consist of cooling coil, blower, filters, outer casing, drain pan,
accessories etc.
b) The cooling coil shall have copper tubes of not less than 1 / 4” O.D. and continuous
aluminium sine wave fins with integral collars. The tubes shall be staggered in the
direction of the air flow.
c) The fan section shall comprise of 1 Nos. statically and dynamically balanced centrifugal
blower, motor, drive package, mounting arrangement etc.
d) The unit casing shall be made of galvanized steel, the casing shall be insulated to lower
the noise level and eliminate condensation. The Cassette type indoor units having some
parts in non-metallic construction must be UL-94-Vo certified.
e) CFM requirement shall be as follows.
Unit Capacity CFM (Minimum)
1.5TR 600
2.0 TR 800
Note: The CFM of the indoor units may vary as per actual equipment’s ADP, meeting the
design requirements.
3.4 REFRIGERANT PIPING

The condensing unit and evaporator unit shall be interconnected by type `L’ seamless
refrigerant liquid and suction lines using flared or brazed fittings. Necessary accessories
shall be incorporated in the circuit:
a) The suction and liquid line shall be insulated with 13 mm thick Nitrile rubber insulation
and the discharge / gas line shall be insulated with 19 mm thick insulation.
b) Necessary chases and holes in walls and floor etc. for laying the piping work shall be
done by contractor, after completion of work necessary repair work shall be done by
contractor and brought to its original finish to the satisfaction of Engineer’s-in- charge.
c) The insulated refrigerant piping and control wiring (in conduit) shall run on GI tray properly
supported by GI rods. The exposed tray shall be covered by openable GI covers.
3.5 MISCELLANEOUS
a) The unit shall have control panel, housing the starting switches, contactor, relays
etc. Isolation pads shall be provided under the units.
b) Insulated drain line shall be provided from indoor unit up to drain trap. (To be priced
separately).
c) Suitable galvanized M.S. channel supporting frame shall be provided for the condensing
unit and supporting arrangement for the indoor units.
d) Interconnecting power and control cabling shall be provided between condensing unit
and evaporator unit.
e) Aluminium cladding of 0.63 mm shall be provided to cover the insulated refrigerant piping
from indoor to outdoor units.
f) Compressor current should not flow through indoor unit.
g) Inbuilt protection in indoor unit against electric fault to be provided.
3.6 INSTALLATION
3.6.1 The split type air conditioner shall be mounted on vibration isolators and installed in

accordance with the manufacturer’s recommendation such that no disturbing vibration or

noise is being transmitted to the nearby structure.
a) All the insulated refrigerant pipes shall be cladded with 0.63 mm thick Aluminium
cladding.
b) Anti-corrosion protective coating on refrigerant pipes, Bents, Joints of indoor & outdoor
unit to be done to avoid leakages.
3.6.2 All galvanized support beams, galvanized legs, galvanized hangers, anchor bolts,
vibration isolators, duct works and shall be provided for the installation of the units.
3.7 TESTING AND COMMISSIONING
After installations are completed, all air-conditioning system shall undergo test run. Any
adjustments that are needed shall be made to assure that all air-conditioning system will
operate at the required performance. Report forms to contain following minimum data
listings shall include design and actual conditions for each Item mentioned below:
a) Date and time of test.
b) Air-conditioning unit make, type, name, and serial number.
c) Fan rpm.
d) Fan motor amperage
e) Rated motor amperage, starter number and ampere rating.
f) Fan CFM
g) Outside conditions (DB and WB)
h) Entering coil conditions (mixing) (DB and WB)
i) Leaving coil conditions (DB and WB)
3.7.1 During test run, the air filters of testing sets shall be used.
3.8 MAINTENANCE AND LIFE
a) The service life of the system shall be at least 10 years, with average 16 hours working
per day during the year.
b) The manufacturer shall submit the list of those items whose life does not match with the
service life of Split AC. The life of such spares shall be advised with a certificate from the
original manufacturer of the spares. The firm shall supply purchase specification of these
items.
c) The manufacturer should also submit Annual Maintenance cost rates of the system.
d) The manufacturer shall provide free service and guarantee for 24 months from the date
of taking over.
e) The Contractor shall provide additional coat of corrosion protection in the last month of
the DLP, same as mentioned above.

4 VENTILATION FANS
4.1 GENERAL
a) This Section specifies the manufacture and installation of all ventilation fans as shown
on Drawings.
b) The fan external total pressure resistance figures specified on the Equipment Schedules
and / or Drawings are for guidance and information only and are calculated based on
assumed resistance figures of equipment. The exact fan total pressure based on the duct
run and the offered equipment shall be carefully checked and re-calculated for each fan
before ordering the equipment. Calculation shall be submitted for Approval. No
modification to the ductwork system shall be allowed without prior Approval. Any
additional cost for the modification of the system (fans, motors, switchgears, cables,
panel boards, switchboards, etc.) necessary to meet the specified duties, spatial
conditions and the offered equipment shall be provided at no extra cost to the Employer.
c) Allowance shall be made for the effects on fan performance of all installation conditions
including coils, eliminators, sound attenuator, plenums, enclosures, inlet, and discharge
arrangements so that actual installed fan performance equals that specified.
d) Proprietary bell mouth and wire guard shall be provided for fans without ductwork
connection. Bell mouth is not required for propeller fans.
4.2 QUALITY CONTROL
a) Reference Codes and Standards
i. AMCA Standard 210: Laboratory Methods of Testing Fans for Rating
ii. BS 848: Fans for General Purposes
iii. IS / IEC 60034 for design, performance, and efficiency of motors
iv. ISO 5801: Industrial Fans – Performance Testing using Standardized Airways.
b) Codes and regulations of the jurisdictional authorities.
c) All fans, drives and accessories shall be designed, constructed, rated, and tested
in accordance with the recommendations and standards of AMCA / ISO.
d) Fan tests shall conform to the requirements of AMCA Standard 210 or ISO 5801
or to an Approved equal standard.
e) Sound ratings shall conform to AMCA standard test code for sound rating of air
moving devices or BS 848: Part 2.
4.3 TECHNICAL AND INSTALLATION REQUIREMENTS
4.3.1 DESCRIPTION
a) Fans shall have non-overloading characteristic, except for forward curved centrifugal,
over their entire operating range. The characteristic curves shall be such that the fan
operating point falls between the no flow static pressure and the maximum mechanical
efficiency. The fan characteristic shall also be such that for a 15% increase in total
pressure over the specified value, the fan shall deliver not less than 85% of the specified
air volume flow rate. The stability of fan operation shall not be affected under such
situation.

b) All axial flow fans shall have a minimum efficiency of 70%. The manufacturer’s best
efficient fans shall be selected through manufacturer’ software by engineer in charge
during approval.
c) Each fan unit including motor and drive shall be supplied from the manufacturer as a
completely factory-assembled package and all guarantees and test certificates shall be
deemed to apply to the entire assembly.
d) All fans shall be capable of withstanding the pressures and stresses developed during
continuous operation at the selected duty. Additionally, all belt driven fans shall be
capable of running continuously at 15% in excess of the selected duty speed.
e) Lifting eye / Flanges shall be provided on all the axial fans.
f) All fans shall be statically and dynamically balanced.
g) Motor speed shall not exceed 1450 rpm unless otherwise specified. The fans installed in
ASS and pump room shall be heavy duty propeller fans.
h) Nominal motor nameplate rating shall be higher than the peak operating power of the
selected fan curve for non-overloading characteristic. The motor rating shall be a
minimum of 15% higher than the motor operating point at design conditions unless
otherwise specified.
i) All fans and motors offered shall be of minimum vibration and noise level during
operation. Should the vibration and noise level be excessive and not within acceptable
standards, additional vibration isolation and sound attenuation shall be provided at no
extra cost to the Employer to the satisfaction of the Engineer.
j) All fans are required to be hot dip galvanised / galvanised.
k) Wherever required Fan inlet and outlet connections shall be by means of flexible canvas
connections having flexibility and slackness as per relevant IS Codes.
4.3.2 PROPELLER FANS
a) The impeller shall be designed to give maximum volume with minimum noise level and
minimum power consumption.
b) The exhaust fan shall be of size 300 / 380 / 450 / 600-mm as specified and required and
minimum 900 rpm and shall conform to IS: 2312-1967 (as reaffirmed in 2005) / CE
certified in accordance to EN 60034-1:2010 Standard. The fans shall be robust, having
double ball bearings and low noise.
c) The fan installed for services rooms shall be heavy duty application type and made of
steel or aluminium alloy. The hub shall be heavy welded steel construction with grey stove
epoxy finish or aluminium alloy. Fan blades and hub assembly shall be statically and
dynamically balanced at the manufacturer’s works.
d) The following accessories to be provided with metallic propeller fan:
i. Wire guard on inlet side
ii. Heavy gauge gravity louvers and bird screen on the outlet side.
e) The fan installed for common rooms / toilets shall be made of fire-retardant ABS plastic
with factory fitted louver & bird screen or metallic construction type with speed regulator
and shall be provided with louver & bird screen as per direction of engineer in-chargeThe
fan shall be complete with anti-vibration Mount.
f) The motor shall be dust and moisture protected to IP54 and of a totally enclosed
construction with permanently lubricated ball bearings suitable for running in ambient
temperatures of up to 50°C and relative humidity of up to 100%. Motors for fans shall be
suitable for 240 ± 10% volts, 50 cycle’s single-phase power supply.

g) Fan shall be provided with accessories like Louvers made from aluminium blades and
steel frame, Mounting plate, Bird screen etc.
h) Wire guards made of heavy gauge steel wire or rod with all joints and crossings welded
shall be fitted at one side and louvers with bird screen at outer side of the metallic
propeller fans.
i) Propeller fans shall be diaphragm mounted on mounting plate with stove epoxy grey
finishes.
j) Fans shall be provided with seal permanently lubricated bearings.
4.3.3 INLINE FANS
4.3.3.1 Circular Inline Fans
a) Circular inline Centrifugal duct fan shall be a straight through radial fan. It should be
compact.
b) The fan shall cope with high pressure and long duct runs, whilst still operating at an
acceptable sound level.
c) The circular inline fans should be moisture resistant and should be approved for
installing in humid or damp environments. The fans should be rated IP-44 when installed
in a duct system. The casing should be manufactured from pre galvanized steel & the
fan shall be provided with spigot connections. Automatic thermo – contact shall open
up if the temperature within the motor windings becomes excessive. Motors shall be
with Class F insulation wired to an externally mounted weather proofed terminal box.
The fan motors shall be suitable for 240 ± 10% volts, 50 cycle’s single-phase power
supply.
4.3.3.2 Cabinet Inline Fans
The Cabinet of the cabinet inline fans shall be manufactured from zinc coated (minimum
220 gsm on both side) pre-galvanized steel sheet complete with inlet and outlet spigots.
All other metal parts shall be hot dip galvanized. The Mounting brackets and access
panel should be fitted as per manufacturer standard. The impeller of the fans should be
with high efficiency forward curved DIDW / SISW type. The scroll of the fans should be
fabricated with galvanized sheet steel. The motor of the fans shall be Squirrel cage
induction type with bearings sealed for life. The motor shall be suitable for single phase
electrical supply. The fan capacity 600 CFM and above shall be cabinet type. Fan shall
have directly driven forward curved centrifugal impeller, running in a metal scroll
balanced to give quiet and vibration free operation. Fan motor assembly shall be
statically and dynamically balanced. The fan motors shall be suitable for 240 ± 10%
volts, 50 cycle’s single-phase power supply.
4.3.3.3 Performance Data
a) All fans shall be selected for the lowest operating noise level. Capacity ratings, power
consumption, with operating points clearly indicated, shall be submitted, and verified at
the time of testing and commissioning of the installation. Fan should be equipped with
single phase asynchronous motor as per latest standard. The Fans should be AMCA
certified for air & sound performance.
4.3.3.4 Testing
a) Capacity of all fans shall be measured by an anemometer. Measured air flow capacities
shall conform to the specified capacities and quoted ratings. Power consumption shall
be computed from measurements of incoming voltage and input current.
b)
4.3.4 AXIAL FLOW FANS (VANE / TUBE TYPE)

4.3.4.1 Provide axial flow, direct drive aerofoil fans as specified on the Equipment Schedules
and / or Drawings.
4.3.4.2 FAN CASING:
a) Casing shall enclose the motor and impeller.
b) Fan casings shall be fitted with matching flanges on the inlet outlet ends with spigots for
attachment of flexible connections.
c) Inspection doors or sight ports to enable direction of rotation to be established shall be
provided.
d) Terminal boxes welded to the casing shall be provided for electrical connection using
metallic flexible conduits to fan motor complying with BS 4999: Part 20 for dust and
weatherproof conditions.
e) Grease nipples shall be brought to the outside of the casing in the most accessible
position and fitted with lubrication tube made of copper or other Approved material.
f) Gasketed access doors shall be provided in each fan housing or connecting ductwork,
suitable for access to adjust or replace blades. For smoke extraction fans, the gaskets
shall be suitable for continuous operation in an air stream temperature of 250 °C for not
less than two hours.
g) Casing shall be hot dip galvanized with minimum 220 GSM Zinc Coating.
4.3.4.3 IMPELLER
a) Impellers shall be of die-cast aluminium alloy.
b) For hub size of 315mm (dia.) and above, blades shall be manual adjustable without
removing the wheel.
c) Positive locking shall be provided for securing the impeller blades into the hub. Spun
aluminium hub caps shall be fitted.
d) The blades shall be counter-balanced and mounted on a thrust bearing for vertically
installed fans.
i. Except smoke extraction fans and unless otherwise specified, drive motors shall be
of class F insulation (BS 4999 and BS 2757) totally enclosed type and rated for
continuous operation in ambient temperature of 50 °C. Performance and rating shall
comply with BS 5000 and IEC 34-1 with protection to IP55. All motors shall be of
efficiency class IE-3.
ii. Factory bell mouth shall be provided where no duct connection is required. Fans
shall be fitted with bell mouth inlets. Flow cores and bell mouth inlets shall be
fabricated in steel and provided with flanges drilled and rigidly bolted to the fans.
iii. Provide wire guards on fan outlet / inlet not connected to ductwork and shall be
made freely accessible for maintenance.
iv. Fans shall be provided with mounting feet and spring isolators.
v. The bearing life of the fan motor assembly shall be of 40,000 hours (L-10 life).
vi. Stationary, curved guide vanes shall be located on the outlet side of the fan to
straighten the motion of the air leaving the blades to improve operating efficiency if
required.
vii. For smoke extraction fan, adequate clearance shall be provided between blade tips
and housing at all points to allow for expansion and contraction over a continuous
operation in an air stream temperature range from 0 °C to 250 °C without
developing interference to the specified flow capacity. The fabrication / shop

drawings shall show the clearance at over a continuous operation in an air stream
temperature range from 0 °C to 250 °C as well as any point of minimum clearance
in between. The motors in case of smoke extraction fans shall be fire rated for
250°C, 2 hours.
viii. Motor: shall be squirrel-cage, totally-enclosed, fan cooled, standard frame, constant
speed, continuous duty, single winding, suitable for 415±10% volts, 50 cycles, 3
phase AC power supply. Motor shall be specially designed for quiet operation. Fan
total efficiency should not be less than 70 % and noise level should not be more
than 85 dB(A) @ 1 m distance when measured in hemispherical reverberant room
conditions.
ix. All the High temperature Fans should either be EN-12101-3 or UL tested for High
temperature (UL Power & smoke Ventilation listed) for a minimum of 250 Deg. C
for a minimum of 2 Hrs.
4.3.4.4 INSTALLATION
a) All belts, pulleys, chains, gears, couplings, projecting set screws, keys and other rotating
parts shall be adequately guarded so that any person can safely come in close proximity
thereto.
b) Fit fans and appurtenances to the space provided and make readily serviceable.
c) Provide support beams, support legs, platforms, hangers, and anchor bolts required for
the proper installation of equipment as shown on the Drawings or as recommended by
the manufacturer and Approved by the Engineer.
d) Provide permanently attached lifting eyes of sufficient number for on Site installation
and future dismounting of fan units.
e) Provide factory inlet bells and other accessories for fan units as shown on the Drawings
or otherwise required for a complete and efficient installation.
f) Where corrosion can occur, appropriate corrosion resistance materials and installation
methods shall be used including isolation of dissimilar metals against galvanic
interaction.
g) Thoroughly clean the entire system before installing filters or operating the fans.
h) For systems containing filters, install filters and permanently seal the filter frame air-tight
before operating the fans. Replace all dirty filters and filter media before handing over
the system to the Employer.
i) Means of protection against overcurrent in the motor shall be incorporated in the control
equipment when the motor rating exceeds 0.37 kW.
j) A hole in the blanking off plate shall be provided for the cables leading to the fans. The
hole shall be sealed around the cables with material suitable for sealing the hole
effectively and continuously exposed to an air stream temperature of 250 °C for not less
than 2 hours rating if the fans are used for smoke extraction
DATA SHEET FOR AXIAL FLOW FANS
Type Vane / Tube Axial (Long Casing Type)
Reference Code / Standard AMCA 210, ISO5801, BS848
Capacity As per BOQ
Flow Unidirectional
Noise 85 dBA at 1 meter
Total Pressure As per BOQ
FAN
Blade Aerofoil Construction, Dynamically Balanced

Material Aluminium alloy

Bearings Totally sealed type Ball Bearing
Hub Cast Aluminium Alloy
Casing Rolled Steel Sheet, Heavy Gauge
Shaft Solid Steel
Mounting Shaft Key and Positive Locking Device
Drive Arrangement Direct Drive
Motor
Type TEFC, IE-3, Induction Motor, Continuous Duty
Design As Per IEC 60034
Three Phase, 415 V, 50 Hz, AC Power Supply
Power Supply
IP 55 Protected
Mounting Arrangement Suitable Bracket for Ceiling Suspension
Lifting Eye at Suitable Location and Number or
Lifting Arrangement
as per manufacturer standard.
Synthetic Paint (Not required in case of 275
Paint
GSM or above, as per standard)
1. Lifting eyes / Flanges shall be provided for the lifting of fans.
2. Should be provided for spring isolators & to install fans as per manufacturer
standard.
3. Flanges on the fans have sufficient strength to lift the fans.
4. Fans shall be provided with Flexible connections (Fire Rated) with spring
washers on both the side.
5 DUCTWORKS, DAMPERS, DIFFUSERS AND ACCESSORIES
5.1 GENERAL
5.1.1 DESCRIPTION
a) This Section specifies the manufacture and installation of ductwork, diffusers, registers,
grilles, dampers, guide vanes, louvers, cleaning of air system, access panels and
accessories.
b) All ductwork and distribution accessories delivered to Site shall be new and indelibly
stamped to identify different grades, materials, and manufacturers.
c) Provide all ductwork, diffusers, registers, dampers, and grilles generally in accordance
with the Drawings to be performed during final design stage.
d) Diffusers, registers, and grilles shall be selected to meet the requirements of noise control
as described elsewhere in this Specification.
5.2 QUALITY CONTROL
a) Relevant Codes and Standards
i. HVCA, DW / 144: Specification for Sheet Metal Ductwork, Low, Medium and High
Pressure / Velocity Air Systems
ii. IS 277: Galvanized steel sheets (plain and corrugated) - Specification
iii. BS 476: Fire Tests on Building Materials and Structures
iv. BS 729: Hot Dip Galvanised Coatings on Iron and Steel Articles
v. UL 555: Fire Dampers
vi. UL 555S: Leakage Rated Dampers for Use in Smoke Control Systems

b) SMACNA: HVAC Duct Construction Standards, metal and Flexible and Rectangular
Industrial Dust Construction Standards (Note: SMACNA standards shall be applied only
if any parts of the duct installation standards are not covered by DW / 144).
c) Technical and installation requirements.
5.3 SHEET METAL DUCTWORK
a) All sheet metal and stainless-steel ducting shall be constructed to the recommendations
of DW / 144. The pressure class rating shall also be in accordance with DW / 144.
b) Ductwork shall be constructed of galvanised steel sheets complying with DW144 for sheet
thickness and IS: 277 for galvanization requirements. The galvanization requirements as
per IS:277 are as follows:
Thickness of sheet (mm) Galvanization (GSM)
0.18 to 0.28 (both inclusive) 200
0.30 to 0.55 (both inclusive) 220
0.63 to 1 (both inclusive) 275
Above 1 350
c) Provide volume control dampers, complete with adjusting handle or similar device to all
branches of the supply air ducts to regulate air flows along the main duct and the branch
ducts. Provide opposed blade type volume control dampers to all branch.
d) Provide flexible connectors of not less than 150 mm long between primary air handling
units / air handling units / fans and related ductwork to prevent transmission of vibration
to adjacent elements. Flexible connectors shall also be provided at building / station
expansion and movement joints.
e) The material used for the flexible connections shall withstand the specified conditions of
temperature and air pressure, and shall comply with the standards of air-tightness. The
material shall be fire resistant.
f) Provide flanged joints to plant and elsewhere as necessary to facilitate maintenance.
g) All flanged joints in ductworks shall be made up with rubber gaskets or suitable mastic
material. These joints should also be connected with suitable material for earthing. Proper
sized electrical continuity jumpers (min. 2 per joint) are required to be provided for making
the duct work continuous. The gaskets provided should be fire retardant and should not
emit toxic gases in case of fire.
h) Apply sealant, adhesives, and tapes to joints for sealing. All such material shall comply
with the requirements of DW / 144.
i) Balancing dampers of appropriate types shall be provided for air balancing.
j) Short radius rectangular and square elbows in air ducts shall be equipped with double
thickness turning vanes. Long radius elbows shall be used wherever possible.
k) The transition ductwork between silencers and fans shall be constructed of not less than
1.2mm thick galvanised steel sheet. The transition shall be aligned with the fans and shall
be connected with angle flanges.
l) The ducts and supports in the stations must be adequate for minimum 100 mm WG.
Static pressure or the system pressures whichever is higher.
m) Duct crossing for duct strength at 450 mm or as per SMACNA.

DATA SHEET FOR NON-FIRE RATED DUCT MATERIAL AND DUCT WORK
Duct Material Galvanized Sheet Steel of Lock Forming Quality
Zinc Coating As per IS277
Duct Construction DW 144 / SMACNA (only for
Reference codes / Standards
parts not covered in DW144), IS277
Duct All Duct Sections Will Be Cross Broken
At All the Bends to Be Made from The Same
Guide Vanes
Material as The Duct
Thickness of Sheet and Type of
As per DW144
Joint for Rectangular Duct
Traverse Joint
Large side up to 1000 mm TDF type Flange
Large side 1000 mm and above Slip on Flange
Indicative support arrangement is given in
Bracing / Support tender drawing, final drawing shall be approved
by engineer in charge
Duct Accessories
For Joints Hexagonal Nuts – Bolts / Washers Zinc Coated
Rivets Galvanized Iron / Magnesium Aluminium Alloy
Gaskets Fire retardant– size as per flange requirement
Screws Self-Tapping Screws Will Not Be Used
Support Arrangement As Per SMACNA / DW144
Anchor Fastener of Required Rating Not Less
Support from Wall / Ceiling
Than 2.5 Times the Load of the Duct
Flanges and Supports Treated for Corrosion
Paint and Painted with Zinc Rich Paint of Approved
Quality
Flexible Connection circular Fire Proof Material to Be Screwed or Clip Band
Spigots with Adjustable Screw or Toggle Fitting
Fire Proof Material to Be Flanged and Bolted
Flexible Connection Rectangular
with Backing Flat or Bolted to Mating Flange
Ducts
with Backing Flat
Flexible Connection 150 Length Between Two Faces (Minimum)
5.4 FLEXIBLE DUCTS
a) Flexible ducts shall be neatly fixed and adequately supported.
b) Flexible ducting used to connect the air distribution accessories and main ductworks shall
comply with Part 7 of DW / 144.
c) Flexible duct length shall not exceed 3.7m in length. Sheet metal duct branch off shall be
provided in case the maximum length of flexible duct permitted is not long enough to
reach the air terminal.
d) Bending radius shall be sufficient to prevent undue tensioning of the outside of the bend
and restriction of the throat likely to cause deformation and / or leakage. The ratio
between the bending radius and the duct diameter shall be less than 2. In no case shall
flexible ductwork be used to connect misaligned ducts.

e) Flexible duct shall consist of flexible corrugated metal tubing of stainless steel, aluminium,
tin plated or aluminium coated steel and suitable for an operating temperature range of –
5 to 9°C.
f) The frictional resistance to air flow per unit length of flexible duct shall not exceed 150%
of the frictional resistance per unit length of galvanised steel duct of similar diameter.
g) Flexible duct shall be insulated and wrapped with a minimum 25 mm thick 24kg / m3
density fibre glass blanket.
h) Flexible duct shall not be used for any system which is designed for handling smoke or
being part of a smoke control system.
5.5 FUSIBLE LINK FIRE DAMPERS (FLFD)
a) Provide fire dampers in air ducts where ducts penetrate fire compartments.
b) Fire dampers shall fully comply with the requirements of DW / 144.
c) Fire dampers shall be constructed to the same standards of air tightness as the rest of
the system.
d) Fire damper casings and blades shall be constructed of galvanised sheet (275 GSM) and
provided with a galvanised steel angle frame to each side of wall or floor.
e) Fire damper casings shall be flanged to suit the ductwork which they are fitted and the
cross-sectional area shall not be less than that of the ductwork.
f) Blade and fusible link shall be accessible for servicing through air-tight inspection doors
placed upstream or downstream of the air path whichever provides the better access.
g) Provide UL Listed fusible link set at 68°C / 74°C or else as approved to all fire dampers
unless otherwise specified. Fusible link shall be arranged in an exposed position and at
upstream of the damper.
h) Details and position of all fire damper and associated access doors shall be submitted
for Approval prior to installation on Site.
i) Provide all necessary fixing frameworks for the installation of fire dampers.
j) Provide fire rated material to seal off the clearance between the fire dampers and wall.
DATA SHEET FOR FIRE DAMPER
Type Fusible Link Snap Acting (FLFD)
Reference Code / Standard UL 555 BS 476 Part 20., UL Classified
Fire Rating Two Hour @ 2500 C
Fusible Link Rated @ 680 C / 740 C
Service Continuous Duty
Mounting Horizontal or Vertical
Construction In Single / Two Module
Differential Pressure 1000 Pascal
Damper Free Area 80 % Of Damper Face Area
Damper Operating Mounting As per manufacturer standard complying UL555
Bracket
Open / close Indication Limit Switch with Each Module
Leakage Max 5% of the Rated Air Flow Across Damper in Open
Position
Frame Construction As per manufacturer standard complying UL-555

DATA SHEET FOR FIRE DAMPER

Blade
Pressure Drop 38 Pascal @ 10 Meter. / sec. Air Velocity
Construction Material As per manufacturer standard complying UL-
555
Design – Aerofoil Design OR 3V-Type Design
Type Opposed / parallel Blade as per requirements
Blade Thickness For Aerofoil Design – Min 1.6 mm
For 3V-Type Design – Min 1.5 mm
Both complying UL-555
Linkages As per manufacturer standard complying UL-555
Shaft As per manufacturer standard complying UL-555
Bearing As per manufacturer standard complying UL-555
5.6 PAINT / COVERING FOR FIRE RATED DUCTWORK (AS APPLICABLE)

a) Wherever required / shown on the Drawings, fire rated ductwork or equipment enclosure
shall be fabricated from fire rated material to the requirements of BS 476 Part 24 or ISO
6944.
b) The construction of the ductwork or enclosure shall take into account the structural
strength, noise isolation as required and the requirements of Class C duct in accordance
with DW / 144.
c) All necessary supports, and other accessories required for the complete installation of
fire rated ductwork, Sealant, Gasket, including additional material for fire stopping at wall
/ ceiling penetration, shall be supplied by the same manufacturer as the fire rated duct
material and shall be assembled in accordance with all the manufacturer’s
recommendation regarding all aspects of construction and installation shall be certified
by the manufacturer.
d) The applicable smoke temperature shall be 250 deg. C. The ductwork system shall be
fire-rated for two hours and shall maintain mechanical stability, fire resistant integrity, and
thermal insulation criteria to BS 476: Part 24 as per the ISO Cellulosic Fire Curve at
temperature of 1029 C, for both vertical and horizontal duct arrangements, for both
inside and outside fire exposures. Restriction of the duct due to twisting or buckling after
the fire test shall not cause 25 % or more reduction in cross-sectional duct area.
e) The performance shall not be affected by moisture absorption. Mechanical strength shall
be maintained and the fire resistance material shall not de-laminate or the fire resisting
properties shall not deteriorate even under water saturation. The material shall also be
"Class-One" surface spread of flame as defined in BS 476: Part 7. Additional insulation,
if required, shall be used as per the manufacturer’s recommendation.
f) Whether BS 476 thermal insulation criterion is applicable or not, fire rated air-conditioning
supply, return, and exhaust ductwork shall be complete with thermal insulation and
vapour barrier.
g) The fire-resistant material shall not attract pests and shall not rot or support the growth
of mould.
h) All fire-resistant ductwork or enclosure, apart from its fire resisting quality, shall be
capable of resisting accidental damage and shall require to pass the hard body impact
test section of BS 5669: Part 1 / BS EN 1128 with the weight being dropped through not
less than 1m.
i) Smoke extraction system ductwork shall be made from suitable material with adequate

thickness. Rivets or self-sealing screws used shall not be of aluminium. Where ductwork
(including sealant, flexible connection, gasket and accessories) for smoke extraction /
purge systems penetrate the fire compartment walls or floors of the room which they
serve, the portion of the ductwork that traverses outside of the compartment wall or floor
shall have a fire rating equal to the fire rating of the compartment wall or floor which it
traverses through or of not less than two hours whichever is the higher.
j) Fire resistant and acoustically sealed access panels shall be provided in the above-
mentioned enclosures for the access and maintenance of equipment and fire dampers.
DATA SHEET FOR FIRE RATED DUCT MATERIAL AND DUCT WORK
Duct Material Galvanized Sheet Steel of Lock Forming Quality
Zinc Coating As per IS :277
Reference codes / Duct Construction BS 476 PART 24, ISO 6944.
Standards
Duct All Duct Sections Will Be Cross Broken
Guide Vanes At All the Bends to Be Made from The Same Material
as The Duct
Thickness of Sheet and As per DW144
Type of Joint for
Rectangular Duct
Traverse Joint
Large Side up to 1000 mm TDF Type
Large Side 1001 – 2250 Slip on flange
mm
Bracing Indicative support arrangement is given in tender
drawing, final drawing shall be approved by engineer
in charge
Duct Accessories
For Joints Hexagonal Nuts – Bolts / Washers Zinc Coated
Rivets Galvanized Iron / Magnesium Aluminium Alloy
Gaskets Material Fire Rated For 2500 C 2 hours
Thickness As per flange requirements
Screws Self-Tapping Screws Will Not Be Used
Joint Strength Should with Stand 1.5 Times the Operating Pressure
with Out Deformation or Failure
Joint Strength Should with Stand 1.5 Times the Operating Pressure
with Out Deformation or Failure
Support from Wall / Ceiling Anchor Fastener of Required Rating Not Less Than
2.5 Times the Load of the Duct
Paint Flanges and Supports Treated for Corrosion and
Painted with Zinc Rich Paint of Approved Quality
Flexible Connection Fire Proof Material to Be Screwed or Clip Band with
circular Spigots Adjustable Screw or Toggle Fitting
Flexible Connection Fire Proof Material to Be Flanged and Bolted with
Rectangular Ducts Backing Flat or Bolted to Mating Flange with Backing
Flat

Flexible Connection 150 mm Length Between Two Faces (Minimum)

Duct Material Fire Rated to Comply with BS – 476 Part 24 And ISO
– 6944
Reference Standard BS 476 Part 24, ISO – 6944
Flame and Fire Spread Class O (BS 476 Part 6 & 7)
Fire Duct Work Manufactured to HVCA Standard DW-144
Function Smoke Extraction
Duct Material Resistant to Water Impingement from Any Sprinkler
System
Impact Resistance BS EN 1128
Stability and Integrity Must Retain at least 75% of its overall Cross-
Sectional Area
(BS – 476 Part 24 (1987)
Leak Test HVCA Specification DW – 143
Sealant Flame Retardant
Duct Accessories
Supports and Angle Should Have 8000 C Melting Point and Tensile Stress
be 15 N / mm2 for min 2Hour
Hangers and Stiffeners
Flanges
Gasket and Nut / Bolts
Duct Work Seals As Per BS – 476 Part 24, ISO – 6944
5.7 MOTOR OPERATED FIRE DAMPERS (MOFD)

a) All motor operated dampers shall be suitable for installation in either a vertical plane or a
horizontal plane.
b) The dampers shall be operated by electric actuators and shall be readily assembled on
Site from modular panels. Each motor operated damper panel shall be of the multiple-
parallel-blade type, with an independent channel frame; and shall be factory-assembled
complete with frames, blades, shafts, bearings, seals, linkage, and all accessories
required to erect the panels into composite dampers. Motor operated dampers shall be
provided with all structural support members and hardware required for installation with
additional framing or trims as required to complete the installation.
c) Motor operated damper actuator shall be mounted outside of the damper frame.
d) Spring-return type damper actuator shall be provided either to open or close damper as
required in the event of power failure.
e) All motor operated dampers shall be the product of a single manufacturer; and all like
components shall be provided by a single supplier.
f) Motor operated damper module assembly shall have a net free face area of not less than
80 % measured to the inside of the frames.
g) Dampers shall be based on standard air having a density of 1.20 kg / m3. This shall apply
to MOD and MSFD / MFD.
h) The motor operated damper manufacturer shall carry out factory tests to verify that when
the dampers are fully-closed and holding against a differential pressure of 1000 Pa, air

leakage through the damper will not exceed 8 CFM per square feet of net damper face
area.
i) When the dampers are in the fully-open position and air is flowing across the damper at
a uniform velocity of 10 m / s and the static-pressure drop across the damper shall not
exceed 38 Pa.
j) The motor operated dampers and their associated structural-supporting systems shall,
when the dampers are in the fully - closed position, be capable of withstanding a
differential pressure across the dampers of not less than 1.5 kPa.
k) The motor operated damper blade and shaft assemblies shall be supported at each end
by means of heavy duty, permanent self-lubricating bronze, or stainless-steel bearings.
l) All motor operated damper-blade seals and damper-frame seals shall be fabricated of a
flexible material suitable for the specified operating conditions as Approved. The seals
shall be factory-installed in dovetail grooves incorporated for this purpose in the design
of the blade and frames to facilitate a tight closure between the blades, and between the
blades and frame. All seals shall sit securely in the closed damper position. Alternative
design of the seals will be subject to the Approval of the Engineer. Noise due to
resonance of spring-type seals or any other source shall be rejected.
m) Each module of damper with only two operating positions should have one limit switch
with two contacts to monitor its open / closed status. If anyone module of the damper fails
to operate, the damper shall be considered not functioning properly. For each module of
damper with three operating positions, two or more limit switches shall be provided.
n) Motor operated damper linkage shall consist of stainless steel (SS-316), extending
through bearings inserted in brackets fabricated of stainless steel. The linkage bearings
shall be fabricated from bronze or other material suitable for the specified operating
conditions as Approved. The linkage brackets shall either be attached to the damper-
blade shafts or be side-mounted and mechanically inter-connected with the shafts. Set
screws shall not be used in the linkage assembly. The linkage for MFD shall be as per
manufacturing standard complying UL555 and UL555S.
o) Motor operated damper frames shall be a channel cross-section with not less than a 100
mm web and 40 mm flanges, and shall be fabricated of hot-dipped galvanised steel plate
(min. 275 GSM) to BS EN 10142. However, the web and frame for MFD shall be as per
manufacturing standard complying UL555 and UL555S. Reinforcing bosses and dove-
tail grooves for mounting frame seals shall be integral parts of the channel configuration.
The corners of the frames shall be either welded or reinforced by means of riveted gusset
plates.
p) All screws, bolts, nuts, washers, expansion anchors, and / or other hardware required to
complete the installation shall be fabricated from stainless steel grade 316, and all
intermediate supports, framing members, and hardware required for assembly /
installation of the damper shall be fabricated of hot-dipped galvanised steel to BS 729.
q) The motor operated dampers shall be installed using fastening devices and structural
support elements herein specified, and in accordance with the published instructions of
the damper manufacturer.
r) Motor operated damper blades shall have an aerofoil or 3V design with minimum
thickness of 2mm, and shall be fabricated of hot-dipped galvanised steel plate (min. 275
GSM) to BS EN 10142. The width of the blades, measured in the direction of airflow shall
not be less than 100 mm and shall not be greater than 200 mm. For MFD, blades shall
be aerofoil design (min 1.6 mm) or 3V design (min 1.5 mm).
s) Motor operated damper-blade shafts shall be fabricated of stainless-steel SS-316, The
design of the shafts shall incorporate the devices required for securely locking the blades

onto the shafts. For MFD, shafts shall be as per manufacturing standard complying
UL555 and UL555S requirements.
t) All VCDs, and MDs shall also comply with above specifications to the extent applicable.
VCDs shall have provision to set & lock the damper at any desired position, whereas,
MDs shall have a two-position set and lock facility only. These would be made of GSS
(275 GSM) with 2 mm frame and blades.
DATA SHEET FOR MOTORISED SMOKE & FIRE DAMPERS
Type Motorized Damper
Reference Code / Standard UL 555S, UL 555, BS 476 Part 20.
Service Continuous Duty
Mounting Horizontal or Vertical
Construction Each module With Dedicated Motor Actuator
Damper Free Area 80 % Of Damper Face Area
Damper Operating Mounting As per Manufacturing standard complying UL555
Bracket & UL555S
Open / close Indication Limit Switch with Each Module
Leakage Leakage as per Class 1 of UL555S
As per Manufacturing standard complying UL555
Frame Construction
& UL555S
Blade
38 Pascal @ 10 Meter. / sec. Air Velocity (As per
Pressure Drop
size)
Material - As per Manufacturing standard
Construction complying UL555 & UL555S
Design – Aerofoil Design OR 3V Design
Type Parallel / Opposed Blades
For Aerofoil Design – Min 1.6 mm
For 3V-Type Design – Min 1.5 mm
Blade Thickness
Both complying UL555 & UL555S

Linkages
& UL555S
Shaft
& UL555S
Bearing Self-Lubricated Sleeve Bearing
As per Manufacturing standard complying
Bearing Rating
UL555 & UL555S
Crank Arms
& UL555S
Actuator Assembly
Capacity 50% In Excess of The Rated Capacity
Temperature Rating of actuator As per Manufacturing standard complying
assembly UL555 & UL555S

Motor Type Single Phase, 240 ± 10 V, 50 Hz, AC Supply

Accessories Space Heater
Indication Power On – Off
Sleeve thickness of dampers shall be same as the frame thickness
5.8 GRILLS AND DIFFUSERS
a) All grills and diffusers shall be designed and rated in accordance with ASHRAE 32-7 /
ASHRAE 70.
b) All grills and diffusers shall be of pure polyester finish aluminium unless otherwise
specified. Colour of grills and diffusers shall be selected by the Engineer. Samples of
finishes shall be submitted for approval.
c) All supply, return and exhaust diffusers shall be complete with opposed blade dampers,
suitable for mounting with appropriate diffuser and shall be fitted with concealed
adjustment devices. Straightener grids are required before diffusers except for the last
diffuser on the route. Each supply air grille shall be complete with an opposed blade multi-
leaf damper. One set of tools for every 10 grilles or diffuser shall be provided for volume
adjustment.
d) The inside of all components and surfaces of all diffusers and grilles shall be painted matt
black. The drawings show provisional locations of diffusers and grilles but in each
instance, outlets shall be installed in accordance with the final detail drawings and
reflected ceiling plans.
e) Velocities, net airways, and distribution patterns shall give satisfactory air distribution and
temperature equalisation, be free of draughts stratification or noise nuisance. The
contractor shall make final adjustments to air patterns when balancing.
f) The sizes of the grilles (including linear grille) indicate on drawings imply the neck sizes
of the fittings. Whereas the sizes of ceiling diffusers on drawings imply overall external
dimensions.
5.8.1 Square ceiling Diffusers
a) Diffusers constructed of extruded aluminium shall be power coated polyester finish to a
colour approved by the Engineer.
b) Diffusers with removable cores shall have square necks or alternatively round necks.
Diffuser sizes are shown on the drawings.
c) Provide aluminium or steel opposed blades volume control dampers of black colour with
concealed adjustment lever. In general, dampers will not be required for fan coil unit
system having supply diffuser.
d) Provide galvanised steel sheet painted black at the front view to seal off dummy parts of
diffuser.
e) Diffusers ring or frames shall be compatible with the ceiling construction in which they
are installed. A transition piece shall be provided to connect the diffuser to the duct. All
edges exposed to view shall be rolled or otherwise stiffened and rounded. Internal parts
shall be removable to permit cleaning of the diffuser and provide access to the duct.
f) Baffles, turning vanes or other devices shall be provided for the required air distribution
pattern. Equalising grids shall be provided for ceiling diffusers.
g) Volume control dampers shall be equipped and factory fabricated by the diffuser
manufacturer. The adjustment position shall be easily accessed.

h) Square and rectangular diffusers shall comply with the following performance
requirements at design flow:
i. Maximum pressure drops: 30 Pa
ii. Throw: 4m
iii. Noise criteria: NC 30
iv. Maximum air velocity at diffuser neck: 4 m / s
v. Maximum terminal velocity: 2.54 m / s
DATA SHEET FOR GRILLS AND DIFFUSER
Function Air Distribution
Standard Air Diffusion Council
Requirement For Supply Air, Return Air and Air Extraction
Grills Linear Flow / Double Deflection Registers
Diffuser Four Way Rectangular / Square / Round
Construction Material Aluminium
As per manufacturer standard
Flange Suitable for Continuous Joint with Alignment
Strips
Design Extruded section
Blade / Louvers Adjustable Front and Rear
Bars
Front Aluminium
Rear Aluminium
Damper
Type Adjustable Lever Operated
Fire Rating Non-Fire Rated
Finish / Material Black Anodized aluminium
Material Duly Treated for corrosion And Anti
Paint
Corrosive Paint
Noise Generation Should Have Very Low Air Noise Generation
5.9 SUPPLY AND TRANSFER AIR GRILLES AND REGISTER FOR GENERAL USE. (FOR
DUCTED SUPPLY AIR APPLICATION)
a) Double deflection supply air grilles / register shall be tapped from top or bottom of ducts
with provision for tamper proof adjustment of air pattern spread along its width. Adjusting
tool shall be provided by the manufacturer. Grilles / register shall have a minimum of 80%
free area.
b) Provide grilles / registers to meet the size and capacities as shown in the drawings
required to connect ducts to grilles and registers.
c) Grilles and register shall be factory assembled with opposed blade volume control
dampers operable through the grilles face. The adjustment shall be by a key through the
face of the register and the volume control damper shall be group operated or opposed
blade type. The operating mechanism shall not project through any part at the register
face.

d) Diffusers constructed of the extruded aluminium shall be pure polyester finish and colour
approved by the Engineer.
e) All grille cores shall be capable of being removed easily from the duct work of access to
dampers.
f) All edges exposed to view shall be rolled or otherwise stiffened and rounded. All edges
shall be equipped with air tight, non-combustible neoprene or sealing stipes to prevent
leakage. The register ring of frames shall be compatible with ceiling construction in which
they are installed.
g) Multi-blade volume extractors shall be of the air deflecting and air straightening type with
blades spaced a maximum of 50 mm apart.
h) Supply air registers shall comply with the following performance requirements at design
flow as:
i. Maximum pressure drops: 30 Pa
ii. Throw: 4m
iii. Noise criteria: NC 30
5.10 SUPPLY / RETURN / EXHAUST GRILLES AND REGISTERS FOR GENERAL USE
a) Grilles shall have single set of fins which shall be vision proof to effectively mask the
return opening. Grilles shall have 450 inclined fins spaced approximately 19 mm apart.
b) Free area of grille core shall be at least 80%.
c) Grilles and registers will be fixed type.
d) Return air diffusers shall match the supply diffusers in appearance and shall be
constructed of the same material and identical in surface finish as approved by the
Engineer.
e) Register rings or frames shall be compatible with the ceiling construction in which they
are installed.
5.11 VENTILATION LOUVERS
a) Ventilation Louvers shall be made of powder coated extruded aluminium. Ventilation air
intake louvers for interior application shall be suitable for high free area and low air flow
resistance. The louvers for external wall application shall be drainable type louvers with
bird screen made of 12 mm mesh in 1.6 mm steel wire held in angle or channel frame.
The blades shall be inclined at 45°on a 40 mm blade pitch to minimize water ingress.
The lowest blade of the assembly shall extend out slightly to facilitate disposal of rain
water without falling in door / wall on which it is mounted. All the louvers, bird screen shall
be made of extruded aluminium construction.
b) The Louvers for fresh air intake in ASS rooms shall be provided with washable type dust
filter section made of non-woven synthetic media supported by Al. mesh on one side and
finished with HDPE mesh on the other side. The filter shall be provided with Aluminium
frame. The filter shall be of G3 category and have minimum efficiency of >80 % down to
20-micron dust particle. The fresh air louver shall have provision to fit-out the filter panel
in such manner that it can be easily removed form louver for cleaning purpose.
5.12 DUCTWORK INSTALLATION
a) Provide complete ductwork systems and ensure that the installation can be adjusted to
the designed flow rates to the satisfaction of the Engineer.
b) Check all the Drawings provided in regard to structural requirements and other finishes
before detailing the ducting system. Allowance shall be made for the detailed
development and on-Site co-ordination.

c) Submit all drawings to indicate the fabrication and installation of ductwork for Approval
before fabrication commences.
d) Replace damaged ductwork and other appurtenances at no additional cost to the
Employer.
e) Provide hangers and supports (Slotted rail), fabricated of hot-dipped galvanised steel, for
the proper installation of ducts in accordance with DW / 144. Hanger rods shall be 10 mm
or 13 mm in diameter, depending on size of duct. All such hangers shall be provided with
screwed lengths on lower end for adjustment of ducting runs to level. All nuts shall be
provided with washers and with lock-nuts, and projecting ends of bolts shall be cut off.
f) Supports shall not be riveted or bolted to the air ducts.
g) Install dampers and splitters in a manner so that they can be adjusted at any time after
completion of the work.
h) Install dampers without strain or distortion of any part of the dampers.
i) Adjust moving parts to move freely without binding.
j) Caulk dampers airtight around frames.
k) Adjust dampers and splitter adjusting rods to operate freely, between the open and closed
position.
l) Install flexible connections in accordance with Part 7 of DW / 144.
m) All ductwork shall be manufactured according to the dimensions taken on Site. Provision
shall be allowed to accommodate any discrepancies between the Drawings and the Site
dimensions.
n) All branches and openings in ducts shall be purpose made prior to erection of the
ductwork.
o) Cross-breaking will be permitted on low velocity ductwork only and in no case where rigid
external insulation shall be applied.
p) Internal roughness, sharp edges or obstructions to air flow shall not be allowed.
q) External edges and corners formed from cleated joints shall be neatly dressed down with
air tight joints.
r) Provide at least 75 mm clearance from ductwork to walls, ceiling, and obstructions where
a high standard of cleanliness shall be maintained.
5.12.1 AIR DUCT CLEANING POINTS
The Contractor shall supply and install air duct cleaning points access doors at suitable
locations to the duct work system. The cleaning points shall be installed at fully accessible
locations. The contractor shall also supply proprietary type compressed air lance,
disinfection application lance and ambling probe which shall be suitable for use with the
cleaning points. All joints must be air / water tight to prevent leakage.
5.13 MOFD INSTALLATION
a) Each damper shall be installed so as to provide smooth operation, opening, and closing
without shock in accordance with the manufacturer’s recommendations.
b) Undue flexing or bending of connecting rods and linkage will not be acceptable. Such
connecting rod or linkage shall be replaced with a corrected design, higher strength
material or increased size of such a component at no extra cost to the Employer.
c) Dampers shall be supported independently of the ductwork.

d) Wall and floor mounted dampers: All slight, unavoidable spaces and purpose-provided
spaces between the damper frames and the structure shall be sealed as required or as
Approved. Blanking-off plates for such purpose shall be considered as part of the damper
assembly and shall be provided at no additional cost to the Employer.
e) Damper module installations shall be fully sealed by gaskets between the module frame
and the mounting frame. The gasket material for MSFD / MFD shall meet the continuous
operation in an air stream temperature of 250°C for not less than one-hour criteria.
Identification of damper position is required on easy visible and accessible position, and
the damper setting position after balancing shall be marked in a permanent manner.
5.14 DIFFUSERS, REGISTERS AND GRILLES INSTALLATION
a) Install diffusers, registers, and grilles so that they can be key adjusted from the face
directly without special tools.
b) Unless otherwise specified, install vanes, volume control dampers and multiple-blade
extractors so that they can be removed through the diffusers and registers for access to
the duct.
c) Install diffusers, grilles, registers, and louvres with frame connected to the ductwork and
provide soft gaskets inserted under the frame or otherwise so arranged so as to avoid air
leakage around the diffusers and grilles.

6 INSULATION
6.1 SCOPE
Supply and fix thermal insulation for piping, ducting, and equipment’s as per the
specification described in this section.
6.2 MATERIALS OF INSULATION
The following insulating materials shall be used:
a) The thermal conductivity as per DIN EN 12667 / EN ISO8497 of the insulation material
shall not exceed 0.032 W / mK at 0 °C mean temperature. The density of the insulation
material shall not be less than 40 -60 Kg / cum. The product shall have temperature range
of -400C to +1050C as per EN 14706, EN 14707 and EN 14304. The insulation material
shall be fire rated for Class O as per BS 476 Part 6: 1989 for fire propagation test and for
Class 1 as per BS 476 Part 7, 1987 for surface spread of flame test. Water vapour
permeability shall be not less than 0.024 per inch (2.48 x 10-13 Kg / m.s.Pa i.e. µ>7000:
Water vapour diffusion resistance) as per EN 12086 & EN13469.
b) The material shall comply to CFC / HCFC free material as per US EPA 5021A-2003. The
material shall be Lead, mercury and asbestos free and should have zero Global Warming
Potential and Ozone depleting Potential. Thermal conductivity of insulation material shall
not be affected by aging as per DIN 52616 standards.
c) Each lot of insulation material delivered at site shall be accompanied with manufacturer’s
test certificate for density and thickness. Samples of insulation material from each lot
delivered at site may be selected by Owner’s site representative and gotten tested for
thermal conductivity and density at Contractor’s cost.
6.3 FOR REFRIGERANT PIPING:
a) All suction pipes and low temperature / pressure liquid pipes of the Refrigerant pipe work
shall be insulated with slip on Closed Cell Elastomeric Nitrile Rubber fire retardant Class
‘O’ pipe insulation having a thickness of not less than 19 mm for suction pipes & 13 mm
for discharge refrigerant pipe.
b) All joints of the insulation shall be sealed with 100 mm width x3 mm thick self-adhesive
tape of the same material as insulation and shall be of the same make as the basic
insulation material. Insulation material exposed to atmosphere shall be of the material as
described above and shall be provided with UV protective coating / lamination (wherever
metallic cladding not provided). The joint sealing tape shall also be provided with identical
UV protective coating / lamination. Where indoor refrigerant pipe work is located in roof
spaces or spaces where temperature may exceed 30 degree C and RH may exceed
80%, the thickness of pipe insulation shall be selected accordingly.
c) The insulated refrigerant pipe shall be cladded with 26 G thick Aluminium sheet between
each set of indoor and outdoor unit.
d) The drain pipe shall be insulated with same insulation material as used for refrigerant
pipe. The thickness shall be as per BOQ.
6.4 FOR DUCTING
a) Ducting insulation thickness shall be as per table below.
Ducting position Thickness

SA duct in RA path 13 mm
SA duct: 19 mm
Ducted return air system
RA duct: 13 mm
Both SA & RA exposed Both 25 mm

b) Clean the surface with a wire brush and make it free from rust and oil.
c) Apply two coats of synthetic glue to the surface.
d) Wrap the duct with insulation sheets of the thickness mentioned above.
e) The joints shall be sealed with synthetic glue to form a seamless bond. The duct joints
shall be additionally covered with a 150mm strip of insulation material.
Note: The Insulation manufacturer has to send their engineers at site and train the insulation
contractors ensuring proper application and workmanship of the insulation material.
7 ELECTRICAL WORK
7.1 GENERAL
These specifications cover all types of motors used for Fans, machines etc. The motor
installation, wiring, control shall be carried out strictly in accordance with the specification
here in after laid down.
7.2 MOTORS
a) This Section specifies the manufacture and installation of motors.
b) Unless otherwise specified or approved, all motors shall be of the totally enclosed fan-
cooled type with Class F insulation. Motors for fire services shall be of class H insulation
and of IP 55 construction. Motors for fire rated operation shall be designed for continuous
operation in an air stream temperature of 250°C for not less than two hour and shall be
totally enclosed squirrel cage induction, fan cooled guarded to IP55 with Class H
insulation. Insulation materials shall be suitable for the climatic conditions available in the
city. Particulars of all motors shall be submitted for Approval. Motors shall be with IE3
Class.
c) Motors shall be adequately rated to meet the service demands of associated driven units
under all conditions and as limited by electrical and mechanical protective devices. The
cooling fan of the motor shall be aluminium and protected by a metal fan cover.
d) The type, design and manufacture of all motors shall be subject to Approval. Motors
powered by AC shall comply with IS / IEC 60034 and shall be of squirrel cage, induction
type. Voltage for motors shall be 415V 3-phase or 240V 1-phase, as required. Motors
rated 0.37kW and larger shall be rated 415V, 3-phase, 50Hz. Motors rated smaller than
0.37 kW shall be operated at 240V 1-phase. Starters for motors shall include individual
unit control transformers. Direct-on-line motor starters shall be used for motors up to and
including 3.75 kW at 415 volts, 3 phases. All motors over this limit shall be equipped with
reduced voltage starters of the star delta or autotransformer, two-step, closed transition
type.
e) The starting current shall not exceed 6 times of the full load current when direct-on-line
starting at full voltage is applied.
f) All motors shall be capable of accelerating the driven plant from standstill to rated speed
with a terminal voltage of 80% of the nominal supply voltage at 50Hz in less than 4
seconds. All motors shall be capable of operating continuously or, for short-time rated
motors, for the duration of the short-time period, at rated torque at any supply voltage
between 90% and 110% of the nominal supply voltage at 50Hz. They shall be capable of
delivering the rated torque when running at 70% of the nominal voltage for a period of 10
seconds without injurious overheating and under these conditions the slip shall not
exceed 10%.
g) All motors shall be capable of operating continuously without injurious effect and capable
of driving the driven units at their rated output at any frequency between 48Hz and 52Hz
together with any voltage between 90% and 110% of the nominal voltage.

h) Vertically mounted motor shafts shall be supported by Approved thrust bearings.

i) All bare steel internal parts except bearings shall be painted unless otherwise protected
against corrosion.
j) Motors shall be designed for low shaft current and shall have adequate provision to
prevent bearing damage by shaft current.
k) An auxiliary marshalling box, electrically and mechanically separated from the power
supply terminal boxes, shall be securely mounted on the motor frame for marshalling all
small wiring for motor control or monitoring.
l) For axial fans, external copper grease leads shall be provided for lubrication of motor
bearings unless totally sealed bearings are used.
m) The maximum motor efficiency shall be at the normal operating condition. Motors in all
cases shall be entirely suitable for the duty intended. A margin of not less than 5% for
compressors, 15% for fans and 10% for water pumps shall be provided for equipment
over the continuous rating of the motor (without over-loading) under the normal operating
condition unless otherwise specified. The motor shall have efficiency class IE3.
n) The power factor of motors shall not be less than 0.85 lagging at the operating condition.
Otherwise suitable power factor correction facilities shall be provided to improve the
power factor. For two-speed fans, the requirement shall be achieved at both high speed
and low speed operating condition.
o) All steel works, supporting brackets and members, which are required for the pump motor
installation, shall be hot-dipped galvanized. Motors shall be factory-painted to the
appropriate finish. The paint used shall be capable of withstanding continuous operation
in an air stream temperature of 250°C for not less than two hours without emitting smoke
or toxic fumes.
p) Unless otherwise specification in this M&W Specified, in normal ambient conditions
bearings shall be designed for 40,000 hours operating service (L10 life, Anti-Friction
Bearing Manufacturer's Association) and provided with a grease outlet connection for in
service lubrication. Grease fittings shall be brought to outside of fan housing and provided
with covers which shall effectively exclude water and dirt. Grease outlet is not required if
totally sealed type bearings are used.
q) Motor terminals shall preferably be of the stud type, totally enclosed both from
atmosphere and from the motor winding and be fully insulated from the frame. Rubber
insulation shall not be used for connections between the windings and the terminals.
r) Each motor terminal box shall be fitted with sealing chamber, conduit gland or adaptor
plate, as required, together with the necessary fittings to suit the cable entry. Terminal
markings and rating plates shall be provided. The terminal box shall be large enough for
the specified cable sizes of the respective motor.
7.3 STANDARDS
a) Reference Codes and Standards
i. IS / IEC 60034 – for design, performance, and efficiency of motors
ii. IS 1271 / IEC 60085 / NEMA – For insulation class rating
7.4 TECHNICAL AND INSTALLATION REQUIREMENTS
7.4.1 General
a) Motors of intake and exhaust fans of the axial type taking in 100% outside air shall be
suitable for operation in atmosphere of up to 95% RH.
b) Noise level shall meet BS EN 60034-9.

c) The degree of protection of the motors shall confirm to IP55 with the following additional
requirements:
d) Motor frames shall be steel or aluminium alloy or cast iron for motors inside station areas
as appropriate.
e) Motor frames shall be cast iron for motors in tunnels and Ancillary Buildings.
f) Earthing terminal shall be provided.
g) Unless otherwise specified, red oxide zinc chromate primer with two finish coats of grey
paint shall be painted.
h) All motors shall be squirrel type and shall be suitable for DOL or reduced voltage starting
as specified on the Equipment Schedules and / or Drawings.
i) Termination boxes of adequate size shall be die cast aluminium alloy or cast iron
diagonally split type and suitably gasketed to prevent ingress of moisture and dirt with
the following additional requirements:
j) Rotatable in any of the four 90-degree positions;
k) Threaded holes suitable for mounting brass cable glands;
l) Stud type terminals for terminating electric cables as specified; and
m) Internal wiring connections to the main terminal boxes and auxiliary marshalling boxes.
n) Bearings shall be double shields and have the following additional requirements:
o) Ball or roller bearings with grease fittings and minimum pressure relief fittings for in
service lubrication. Totally enclosed type bearings are also acceptable.
p) Guide and thrust bearings for vertical motor drive units shall be subject to Approval.
q) Lifting eyes shall be provided for motors with a weight of 20kg and above.
r) Tests shall be carried out before shipment to demonstrate that the equipment complies
fully with specified requirements. Test certificates shall be provided for Approval.
7.4.2 Installation
a) Motors shall be installed as required by the driven equipment.
b) Lifting equipment shall be provided for the installation of motors.
c) Any additional steel works, supporting brackets and members which are required for the
motor’s installation shall be provided by the Contractor at no extra cost to the Employer.
d) The frames and supports shall be accurately set and levelled.
e) Each motor shall be provided with an emergency stop push button at the Approved
location. For outdoor installation, all emergency stop push buttons shall be of
weatherproof type.
f) All moving or rotating parts of motors, which can be accessed by personnel, shall be
properly covered by steel wire mesh guards.
7.5 SWITCHBOARD: SAME AS (ELECTRICAL WORKS)
7.6 ELECTRICAL CABLING: SAME AS (ELECTRICAL WORKS)

8 TESTING OF AIR-CONDITIONING SYSTEM

8.1 GENERAL
a) Routine and types tests for the various items of equipment shall be performed at the
manufacturer’s workshop by the contractor in presence of consultant and client and test
certificates shall be furnished. Functional tests shall be conducted at site.
b) The performance tests to determine whether or not the full intent of the specification is
meant shall be conducted by the contractor. After notification to the employers that the
installation has been completed and the plant has run continuously for a period of at least
two weeks, the contractor shall conduct under the direction of the consultants and in the
presence of the employer’s representatives tests such tests as specified to establish the
capacity of various equipment supplied and installed by the contractor.
c) The contractor shall operate, test, and adjust the air conditioning appliances including
adjustment of regulators, dampers etc.
d) All test equipment, labour, operating personnel, oil, and refrigerant required for these
tests shall be furnished by the contractor to enable the plant to be put in continuous
running test fora period of two days after all other tests and adjustments have been made.
e) The performance tests shall be conducted during peak summer and peak monsoon.
8.2 PROCEDURE
8.2.1 Design Conditions
The inside and outside conditions will be recorded for24 hours duration on hourly basis.
The outside and inside dry bulb shall be recovered by means of a digital thermometer.
The inside dry bulb temperature and relative humidity shall fall within the specified limits.
8.2.2 Capacity of the Air-conditioning System
The following aspects shall be checked before conducting the performance tests:
a) The outside conditions shall be as close to the design values as possible. The tests shall
be arranged during the peak summer and monsoon.
b) The internal loads of various spaces shall be close to the design values as far as possible.
Otherwise, internal loads shall be simulated to a value required to satisfy the design
condition.
c) Hourly readings of pressure, temperature, electrical current, voltage and power factor
shall be properly recorded. The capacity of the system and various other equipment and
accessories shall be ascertained as follows:
8.2.3 Cooling Coils of Indoor units
a) The flow of air over the cooling coil will be measured by recording the velocity of air across
each filter placed before the cooling coil. The velocity shall be measured by means of an
anemometer.
b) The wet bulb temperature of air entering the coil and that leaving the coil shall be
measured. The enthalpy of entering and leaving air shall be noted from the psychometric
chart, corresponding to the WB temperature recorded. Single thermometer shall be used.
c) Same pressure gauge and thermometer shall be used for different measurement of
pressure and temperatures. The capacity of the compressor shall be computed from the
performance chart supplied by the manufacturer. Bhp / ton of the compressor shall be
computed from above readings.
8.2.4 Air Balancing

After the desired inside conditions are achieved the quantity of air through every outlet
shall be measured. Air balancing should be done as per design conditions.
8.2.5 Functional tests
8.2.5.1 Electrical Equipment:
a) All the cables shall be tested for continuity and absence of cross phasing. Insulation
resistance between the phase conductors and the earth be measured shall with the help
of a 500-V megger.
b) Motors:
i. Starting current shall be recorded every time the motor is started.
ii. Starter operation shall be checked for single phasing by removing one of the
phases.
iii. Overload protection shall be checked by altering the starter thermal overload
setting.
8.2.6 Test reading
The following readings shall be recorded hourly during the tests and capacity of the plant
shall be computed.
Indoor Units:
Air velocity M / Hr (FPM)
Coil face area M2 (SFT)
Air quantity M3 / Hr (CFM)
Entering air temp. DB °C (°F)
Entering air temp. WB °C (°F)
Leaving air temp. DB °C (°F)
Leaving air temp. WB °C (°F)
Cooling capacity K Cal. / Hr (TR)
Motor
Rated horse power HP
Rated volts Volts
Rated current Amps
Actual current Amps
Actual volts Volts
The observations of the test shall be recorded for each item separately.

9 NOISE CONTROL
9.1 Scope
The scope of this section comprises of the supply, installation, testing and commissioning
of noise and vibration control equipment and accessories.
9.2 Standards
The testing of all noise control equipment and the methods used in measuring the noise
rating of air conditioning plant and equipment shall be in accordance with the relevant
sections of the following British Standards, unless otherwise stated:
BS4718: 1971 Methods of Test of Silencers for Air Distribution
Systems.
BS2750 Parts1-9:1980 Laboratory and Field Measurement of Airborne
Sound Insulation of Various Building Elements.
Recommendations for Field Laboratory
Measurement of Airborne and Impact Sound
Transmission in Buildings.
BS3638: 1987 Methods of Measurement of Sound Adsorption in a
Reverberation Room
BS4773 Part2: 1976 Acoustic Testing.
BS4856 Part2: 1976 Acoustic performance without additional ducting of
forced fan convection equipment.
BS4773 Part5: 1976 Acoustic performance with additional ducting of
forced fan convection equipment
BS4857 Part2:1978 Acoustic Testing and Rating of High-Pressure
(1983) Terminal Reheat Units.
BS4954 Part2:1978 Acoustic Testing and Rating of Induction Units
(1987)
BS5643: 1984 Glossary of Refrigeration, Heating, Ventilating and
Air Conditioning Terms
Note: British standards shall also be applicable for noise control.
All the standards shall be referred latest amended up-to-date.
9.3 General
Mechanical services shall generally be designed and installed with provisions to contain
noise and the transmission of vibration, generated by moving plant and equipment at
source where illustrated on the tender drawings and plant and equipment schedules to
achieve acceptable noise rating specified for occupied areas.
In addition to the provisions specified in the Specification, particular attention must be
given to the following details at time of ordering plant and equipment and their installation:
-
a) All moving plant, machinery and apparatus shall be statically and dynamically balanced
at manufacturers works and certificates issued.
b) The isolation of moving plant, machinery and apparatus including lines equipment from
the building structure.
c) Where duct work and pipe work services pass through walls, floors, and ceilings, or where
supported shall be surrounded with a resilient acoustic absorbing material to prevent
contact with the structure and minimise the outbreak of noise from plant rooms.

d) The reduction of noise breakout from plant rooms and the selection of externally mounted
equipment and plant to meet ambient noise level requirements of the Specifications.
e) Electrical conduits and connections to all moving plant and equipment shall be carried
out in flexible conduit and cables to prevent the transmission of vibration to the structure
and nullify the provisions of anti-vibration mountings.
f) All duct connections to fans shall incorporate flexible connections, except in cases where
these are fitted integral within air handling units.
g) Duct work connections to the fan inlets / outlets shall be concentricity aligned so that the
flexible connections are not subjected to any strain and not used as a means of correcting
base misalignment.
h) All resilient acoustic absorbing materials shall be non-flammable, vermin and rot proof
and shall not tend to break up or compress sufficiently to transmit vibration or noise from
the equipment to the structure.
i) Where practicable, silencers shall be built into walls and floors to prevent the flanking of
noise the duct work systems and their penetrations sealed in the manner previously
described. Where this is not feasible, the exposed surface of the duct work between the
silencer and the wall subjected to noise infiltration shall be acoustically clad as specified.
9.3.1 Anti-vibration mountings
a) All items of rotating and equipment shall be isolated from the structure by the use of anti-
vibration materials, mountings or spring-loaded supports fixed to either concrete bases,
inertia blocks or support steels as indicated.
b) Axial flow fans shall be mounted on steel legs as diaphragm plates supported on
neoprene in shear anti-vibration mountings, or suspended using spring loaded hangers
to suite the application.
c) The construction of the anti-vibration mountings shall generally comply with the following:
- Enclosed Spring Mounting (Caged or Restrained Springs)
d) The springs shall have an outside diameter of not less than 75%of the operating height,
and be selected to have at least 50%overload capacity before becoming coil bound.
e) The bottom plate of each mounting shall have bonded to a neoprene pad designed to
attenuate any high frequency energy transmitted by the springs.
f) Mountings incorporating snubbers of restraining devices shall be designed so that the
snubbing damping or restraining mechanism is capable of being adjusted to have no
significant effect during the normal running of the isolated machine.
9.3.2 Flexible connections
a) Flexible connections shall be provided on all duct work connections to fans, rotating plant
and equipment isolated from structure and anti-vibration materials or mountings. Pipe
work and duct work crossing building movement or construction joints shall be installed
with flexible connections.
b) Flexible connections on duct work to fans etc., shall be a minimum / maximum free length
of 100 mm-200 mm. respectively to minimise noise transmission and noise breakout.
They shall be completely free from stress and shall not be required to accept any weight.
c) Thickness and strength of flexible connection materials shall be suitable to withstand the
positive and negative fan pressures to which they will be subjected to and shall not allow
perceptible leakage. The materials shall be durable, non-flammable having food
acoustical quality.

10 MODE OF MEASUREMENTS (AS APPLICABLE)

10.1 Units Prices in the Schedule of Quantities:
a) The item description in the schedule of quantities is in the form of a condensed resume.
The unit price shall be held to include everything necessary to complete the work covered
by this item in accordance with the specifications and drawings. The sum total of all the
individual item prices shall represent the total price of the installation ready to be handed
over.
b) The unit price of the various items shall include the following:
i. All the labour required to supply and install the complete installation in accordance
with the specifications.
ii. Use of any tools, equipment, machinery, lifting tackle, scaffolding, ladders etc.
required by the contractor to carry out his work.
iii. All the necessary measures to prevent the transmission of vibration.
iv. The necessary material to isolate equipment foundations from the building structure,
wherever necessary.
v. Storage and insurance of all equipment, apparatus, and materials.
c) The contractor’s unit price shall include all equipment, apparatus, materials and labour
indicated in the drawings and / or specifications in conjunction with the item in question,
as well as all additional equipment, apparatus, material and labour used and necessary
to make in question on its own (and within the system as a whole) complete even though
not specially shown, described or otherwise referred to.
10.2 Measurements of sheet metal ducts, grilles / diffusers etc.
10.2.1 Sheet Metal Ducts:
a) All duct measurements shall be taken as per actual outer duct surface area including
bends, tees, reducers, collars& other fittings. Gaskets, nuts, bolts, vibration isolation pads
are included in the basic duct items of the BOQ. These shall be treated as ordinary duct
pieces with their length measured along their centre line.
b) The unit of measurements shall be the finished sheet metal surface area in metres
squares.
c) No extra shall be allowed for lapse and wastage.
d) No measurements of vanes, splitters, duct dampers, deflectors, access door etc. which
are required to be installed in duct shall be made and the same shall be deemed to be
part of duct work.
e) The unit duct price shall include all the duct hangers and supports, exposing of concrete
reinforcement for supports and making good of the same as well as any materials and
labour required to complete the duct frame.
10.2.2 Grilles / Diffusers
a) All measurements of grills / diffusers shall be the actual outlet size excluding the outer
flanges.
b) The square or rectangular grilles / diffusers shall be measured in plain Sqm.
c) All round diffusers shall be measured by their diameters in cm.
d) All linear diffusers shall be measured as per actual length in meters.
e) The grill / diffuser frame shall be constructedof16 gauge and blade shall be constructed
of 18 gauge of extruded aluminium sections either anodized or powder coated.

10.3 Measurements of piping, fittings, valves, fabricated items

10.3.1 Pipe
a) All pipes shall be measured in linear meter along the axis of the pipes and rates shall be
inclusive of all fittings E.G. tees, bends, reducers, elbows etc.
b) Exposing reinforcement in wall and ceiling and floors of possible and making good the
same or installing anchor fasteners and inclusive of all items as specified in specifications
and schedule of quantities.
c) Rates quoted shall be inclusive of providing and fixing vibration pads and wooden pieces,
wherever specified or required by the project coordinator.
d) Flexible connections, wherever required or specified shall be measured as part of straight
length of same diameter, with no additional allowance being made for providing the same.
e) The length of the pipe for the purpose of payment will be taken through the centre line of
the pipe and all fittings (E.G. tees, bends, reducers, elbows etc.) as through the fittings
are also presumed to pipe lengths. Nothing extra whatsoever will be paid for over and
above for the fittings.
f) Structural supports shall be measured as part of pipe line and hence no separate
payment will be made. Rates shall be inclusive of hoisting, cutting, jointing, welding,
cutting of holes and chases in walls, slabs or floors, painting supports and other items as
described in specifications, drawings and schedule of quantities or as required at site by
project coordinator.
10.3.2 Copper Connections for Indoor Units
a) Copper connection assembly for making connections to the indoor units shall be
measured, as part of the indoor unit’s price and shall include brass flare nuts, brass
straight connector, brass tees, brass reducer fittings, making connections and leak
testing, complete assembly as per specifications and drawings. Nothing extra shall be
payable on account of any variation in the length of copper pipe.
10.3.3 Insulation
a) The measurement for vessels, piping, and ducts shall be made over the bare uninsulated
surface area of the metal.
10.3.4 Pipes
The measurements for installation of piping shall be made in linear metres through all
flanges and fittings. Pipes / bends shall be measured along the centres line radius
between tangent points. If the outer radius is R1 and the inner radius is R2. The centre
line radius shall be measured as (R1+R2) / 2. Measured of all flanges and fittings shall
be measured with the running metre of pipe line as if they are also pipe lengths. Nothing
extra over the above shall be payable for insulation over flanges and fittings in pipe line /
routing. Fittings that connect two or more different sizes of pipe shall be measured as
part of the larger size.
10.3.5 Ducts
The measurements for insulation of ducts shall be made in actual square metres of bare
uninsulated duct surface through all dampers, flanges, and fittings. In case of bends the
area shall be worked out by taking an average of inner and outer lengths of the bends.
Measurements for the dimension for the connecting duct, nothing extra over the above
shall be payable for insulation over dampers, flanges, and fittings in duct routing.

11 TECHNICAL DATA
It is mandatory to fill given below data sheet at the time of tender quoting and at the time
of proposal.
11.1 VARIABLE REFRIGERANT VOLUME AIR COOLED UNITS
11.1.1 Outdoor Unit
a) Outdoor Units Make and Model
b) Type (Cooling or heat pump)
c) Dimension of unit (Overall)
d) Operating Weight of Unit (Overall)
e) Actual capacity (TR) at specified conditions
f) Permissible length of refrigerant piping
g) Type of compressor
h) No. of compressor (each unit)
i) No. of inverter compressor Electrical characteristics
j) Power consumption at ISHRAE conditions for each capacity
100%
75%
50%
25%
k) Additional coating material for corrosion protection
11.1.2 Indoor Unit
a) Manufacturer Type
b) Nominal capacity (TR)
c) Airflow Min / Max (CFM) Sound level (Hi / Lo)
d) Overall dimensions (L x W x H)
e) Unit weight (Kg)
f) Remote controller for each indoor unit (Yes / No)
g) Additional coating material for corrosion protection
11.1.3 Centralized Controller
a) No. of controllers
b) Features
c) Power consumption
d) Circuit Diagram of Total Connected units.
e) Technical brochures to be attached.
11.2 SPLIT AIR CONDITIONERS
11.2.1 General
a) Make

b) Indoor / Outdoor unit dimension (L x H x D) in mm

c) Weight in Kg
11.2.2 Compressor
Manufacturer -
Model -
Type -
Refrigerant -
Power consumption at 100 % load KW
Refrigeration Capacity Nominal TR
Refrigeration Capacity actual at 44°C TR
air entering
11.2.3 Cooling Coil
Tube diameter MM
Face area Sq. m
No. of rows No.
No. of fins / cm No.
Tube material -
11.2.4 Condenser
Face area Sq. m
No. of rows No.
No. of fins / cm No.
Tube material -
Fin material -
Tube diameter MM
Type & no. of fans No.
Fan motor rating KW.
11.3 VENTILATION FANS
a) FAN Make / Model / Type Name / No.
b) Fan speed RPM
c) Fan Motor rating (specified) KW
d) Fan Motor current drawn Amps
e) Motor insulation Class --
f) Line voltage Volt
g) Fan capacity (specified Air qty.) CFM
h) Fan capacity (computed Air qty.) CFM
11.4 GALVANISED STEEL SHEETS
a) Make
b) Thickness / Gauge
c) Class of Galvanizing

11.5 GRILLES / DIFFUSERS / DAMPERS / ATG

a) Make, material and gauge
b) Fire damper, rating, make of damper motor
c) Smoke damper, rating, make of damper motor
d) Grilles / Diffuser
e) Duct Damper
f) FA Damper
g) Access Panel.
11.6 INSULATION
a) Manufacturer
b) Duct insulation material & density
c) Pipe insulation material& density
d) Fire Rated Class of insulation.
11.7 ROOM CONDITIONS (For all areas)
a) Date:
b) Day:
c) Time:
d) Room Temperature
- Dry Bulb °C
- Wet Bulb °C
e) Ambient Temperature
- Dry Bulb °C
- Wet Bulb °C

TECHNICAL
SPECIFICATIONS –
FIRE FIGHTING SYSTEM

1 FIRE HYDRANT & FIRE FIGHTING SYSTEM

1.1 General
1.1.1 The scope of this section comprises the supply, installation, testing, and commissioning
of the entire firefighting system.
1.1.2 All Galvanized Iron pipes and other accessories shall be cleaned thoroughly before
application of enamel paint two coats. Two coats of primer shall be applied and thereafter
two coats of enamel paint shall be applied. Each enamel paint coat should be given
minimum 24 hours drying time. No thinner shall be used. The work shall be done in
professional manner and to the satisfaction of the Engineer In charge. No extra amount
shall be paid for this work and price may be included with the relevant item itself or as
per BOQ.
1.1.3 All items provided in this specification shall be provided by the Contractor and no extra
payment shall be made.
1.1.4 All power and control cables in the fire system shall be Fire Retardant Low Smoke low
halogen (FRLSH) cables.
1.1.5 The Contractor shall obtain approval from Local Fire Department. No extra amount shall
be paid for this work and price may be included in the rates.
1.1.6 All nuts, bolts, washers etc. shall be (IS-1364) of Stainless steel (SS-304) for fitment of
pipes, valves, and other accessories unless and otherwise approved by Engineer in
Charge.
1.1.7 Contractor shall be responsible to co-ordinate the equipment and services with all other
discipline and shall produce properly coordinated shop drawings to demonstrate the
installation & comply with the performance requirement with shop drawing, calculations,
and details.
1.1.8 Shop drawings shall take into account actual measurement and setting out dimensions /
levels obtained and determined by the Contractor on site, actual equipment / material
used, actual routing of services, co-ordination with all installation, and site conditions /
constraints.
1.1.9 The rates quoted shall be inclusive of all structural supports clamps and vibration
mounting etc. as per the approved design / specifications. Also include painting of all
exposed metal parts, pipes, fittings, vessels etc. with two coats of anticorrosive paint and
two coats of enamel of "Fire Red" shade 536 to IS: 5-2004 and brand irrespective of
whether mentioned or not.
1.2 Scope of Work
1.2.1 The scope of work shall cover supply, fabrication, installation, testing, and commissioning
of the firefighting (Hydrant & Sprinkler) system covering the following but not limited to:
a) Fire Hydrant electric pumps as shown in the BOQ, drawings and as required.
b) Jockey pump, electric driven as shown in the equipment schedule, drawings and as
required.
c) Hydrant mains, external ring, and yard hydrants.
d) Wet risers in the building as specified and shown on drawings.
e) Landing valves, hose reels, hose cabinets etc.
f) Fire brigade breaching, Siamese connections, and connections to pumps and
appliances.

g) The Fire Suppression System shall comprise the Fire Hydrants System, the Sprinkler
System (Wet type), Fire extinguishers, Gas flooding system etc.
h) The hydrant system and the sprinkler system, under normal conditions, shall be
pressurized by means of the electric motor driven Jockey Pump.
i) The hydrant system and sprinkler System shall be provided with two electric motor driven
main pump (1 Working + 1 Standby).
j) The starting and stopping of the Jockey pump shall be automatic based on the pressure
switches at pre-set low and high pressure.
k) The electric motor driven Hydrant Pump starts automatically at pre-set pressure by
means of a pressure switch. As soon as the Hydrant Pump starts, the Jockey Pump
stops. If for any reason the electric motor driven Hydrant Pump does not start at the pre-
set pressure or is unable to maintain the pressure, the stand by electrical driven Hydrant
Pump starts at the pre-set pressure.
l) The hydrant pump and standby pump shall be stopped only manually.
m) Contractor shall ensure that all false ceiling voids greater than 800 mm are provided with
sprinklers (Commercial spaces only / Property development).
n) Contractor shall ensure Hydro Testing for the complete system as per NBC. Hydrostatic
test as “a test of a closed piping system and its attached appurtenances consisting of
subjecting the piping to an increased internal pressure for a specified duration to verify
system integrity and system leakage rates.
o) The Contractor shall be fully responsible and shall carry out following activities: -
i.Submission of working drawing.
ii.Obtaining the approval of drawings.
iii.Arranging inspection of site by officials of the Authority.
iv.Obtaining the final no objection / completion certificate after submitting required
documents.
p) Any other statutory approvals required
q) The contractor shall include submission and obtain necessary approval of relevant
drawings, schemes and documents from local / fire authorities and also obtain all
necessary permissions and NOC for execution of work as well as getting final approvals
from the concerned fire officers along with relevant “NOC” for occupation of building. All
expenses on this account shall be borne by the Contractor.
1.3 Standards
1.3.1 The fire hydrant installation shall conform to and meet with the requirements set out by
the following:
NBC-2016 Part- National Building Code-2016

IV Part-IV: Fire and Life Safety System
IS –325 Three phase induction motors.
IS –1822 Motor starter for voltage not exceeding 1000 volts.
IS –732 Code of practice for electrical wiring and fitting of building.
IS –1520 Horizontal centrifugal pumps for clear, cold, fresh water.

IS: 5290 – 1993 Specification for landing valves

Code of practice for installation and maintenance of internal fire
IS: 3844-1989
hydrants and hose reel on premises.
ASTM A-536 Code of practice for Grooved fittings
UBBL-2016 Unified Building Bye Laws for Delhi 2016
IS: 12585-2003 Specification for Thermoplastic Hoses
IS:15683 - 2006 Specification for Portable fire extinguishers
IS: 884 - 2015 Specification for first-aid hose reel for fire fighting
IS –1239 Mild steel tubes, tubular and other wrought steel fittings.
IS –13095 Code of practice for Butterfly valves.
Code of practice for coating and wrapping of underground mild
IS –10221
steel pipe lines.
IS: 15105- 2007 Design and Installation of Fixed Automatic Sprinkler Fire Systems
IS – 902- 1992 Specification for suction hose couplings for firefighting purposes.
Specification for fire hose delivery couplings, branch pipe, nozzles,
IS – 903- 1993
and nozzle spanner.
Specification for two-way and three-way suction collecting heads
IS – 904- 1983
for firefighting purposes.
IS –926- 1985 Specification for fireman’s axe
IS –636 Non percolating flexible firefighting delivery hose.
IS –2930- 1980 Functional requirements for hose laying tender for fire brigade use.
Specification for coupling, branch pipe, nozzle, used in hose reel
IS –8090
tubing for firefighting.
CPWD Specification for Wet Riser system and sprinkler system
IS –1641 Code of practice for fire safety of building
IS –1644 Code of practice for fire safety of building
IS –9972 Specification for automatic sprinkler heads.
IS –11101 Specification for extended branch pipe for fire brigade use.
IS –12349 Fire Protection sign.
Code of practice for provision and maintenance of water supplies
IS –9668
and firefighting.
Recommendation for methods for measurement or fluid flow be
IS –2592
means of orifice plates and nozzles.
IS- 4947- 2006 Specification for gas cartridges for use in fire extinguishers.
Code of practice for selection installation and maintenance of
IS- 2190- 2010
portable first- aid fire extinguishers.
Note: - All the standards mentioned above as well as referred to in the document elsewhere
shall be latest.

a) The standards mentioned above as well as referred to in the document elsewhere shall
be latest.
b) WORKING REFERENCE DRAWINGS (WRD): -The contractor shall prepare and furnish
all WRD drawings in quadruplicate at no extra cost for approval by the Engineer-in-
Charge before commencing fabrication / manufacture of the equipment. Such shop
drawings shall be based on the architect drawings and requirements laid down in the
specifications and as per site conditions. The manufacture of equipment shall be
commenced only after the WRD drawings are approved in writing by the Engineer-in-
Charge. Such drawings shall be co-ordinated with all disciplines of work.
c) COMPLETION / AS BUILT DRAWINGS: - On completion of the work and before
issuance of certificate of completion, the Contractor shall submit to the Engineer-in-
Charge, General layout drawings, drawn at approved scale indicating layout of pump
house piping and its accessories “As installed ". These drawings shall in particular give
the following:
i. General layout of pump house including Panels, pumps and other equipment location
and sizes etc.
ii. Complete Schematic as installed.
iii. Location of hydrants, Fire Hose Cabinets, and fire extinguishers etc.
1.3.2 Documents
1.3.2.1 The Contractor shall submit to the Engineer-in-Charge, the following documents on
completion of the work and before issuance of completion.
a) Warranty for equipment installed.
b) Test certificates.
c) List of the equipment.
d) Catalogues.
e) Operation and Maintenance manuals.
f) All approvals and sanctions.
1.3.2.2 Sanction / approvals from statutory authorities / local fire department.
1.4 Fire Fighting Pump
a) The fire pump shall be single stage / multi stage suction centrifugal type and direct driven
conforming to IS: 1520 by electric motor. The pump rating and performance shall conform
to the equipment schedule and meet the TAC duty requirements. The pumps should be
with mechanical seal.
b) Pump casing shall be of close-grained cast iron (grade FG 200, IS 210) with bronze
impeller. The shaft sleeve shall be brass or SS 304 / SS410 and the trim shall be brass
or bronze.
c) Impeller shall be one-piece, phosphor bronze, and the bush of gun metal. The impeller
shall be hydraulically and dynamically balanced. Impellers shall be fully protected against
damage from reverse rotation.
d) Pump shall be capable of delivering 150% of the rated capacity at 65% of the rated head
and the no-delivery head shall be not more than 140% (150% in case of end suction type)
of the rated delivery head. The pump casing shall withstand 1.5 times the no-delivery
pressure or 2 times of the duty pressure whichever is higher.
e) The pump shall be electrically driven with direct flexible coupling.

f) Shaft size shall be selected on the basis of maximum combined shear stress.
g) Pump Motor shall be minimum IE-3.
h) The electric drive motor shall be squirrel cage induction conforming to IS: 325-1996 and
rated for continuous duty (S1). Motor shall have not less than class F insulation and
minimum enclosure of IP55. Soft starter shall be provided in all firefighting pumps.
i) Soft starter shall have following inbuilt feature: -
i. Protection of Over load
ii. Short circuit
iii. Single phasing
iv. Dry run
v. Earth Fault
j) Drive rating shall be based on the largest of the following: -
i. Rated pump discharge at rated head
ii. 150% of rated discharge @ 65% of rated head
iii. Maximum power absorbed by the pump in its operating range i.e. no-delivery to free
discharge.
k) The pumps shall be directly coupled to the motor shaft through a flexible coupling
protected by a coupling guard.
l) The pump and motor shall be mounted on a common base plate fabricated from mild
steel section. The base plate shall have rigid, flat and true surfaces to receive the pump
and motor / diesel engine mounting feet. The pump will be perfectly aligned with the motor
so as to avoid any vibration during operation.
m) The pump heads specified on the drawings and / or equipment schedules are for
guidance and information only are calculated based on assumed equipment pressure
drops. The Exact pump head based on the pipe run and the offered equipment.
Calculation shall be submitted for approval. No modification to the piping System shall
be allowed without prior approval. Any additional cost for modification of the system
(pumps, motors, switchgears, cables, panel boards, switchboard etc) necessary to meet
the specified duties, special conditions and the offered equipment shall be provided at no
extra cost to the Employer)
n) The pump shall be tested at the factory and test curve shall be submitted showing the
performance and horse power requirement based on this test before final acceptance.
o) Contractor shall provide necessary test certificates, type test certificates, technical data
sheets performance curves and NPSH curves of the pumps, dimension detail, foundation
detail from the manufacturer while submitting data sheet for approval.
p) The motor shall be designed not to draw starting current more than 3 times normal
running current. Motor for fire pump shall be at least equivalent to the horse power
required to drive the pump at 150% of its rated discharge and shall be designed for
continuous full load duty.
q) Marking: - Permanent marking of Fire pumps is to be done by using stainless steel plates
of appropriate size as approved by Engineer In charge.
r) Earthing should be flushed with foundation of pumps for good aesthetics.
s) Cabling of jockey pump should be done by using appropriate size copper cable only.

1.5 Pump Foundation

Foundation of pumps in Fire Pump rooms should be of considerable height so that these
are not submerged in case of overflow.
1.6 Accessories
1.6.1 The Fire Pumps shall be complete with the following accessories:
a) Suction and discharge eccentric reducers
b) Pump coupling guard
c) Common base frame, fabricated mild steel or cast iron.
d) Pressure gauge at discharge side between pump and the non-return valve.
e) Name plate indicating suction, delivery, head, discharge, stages, RPM, and direction of
rotation
1.6.2 Each pump shall have independent set of pressure switches.
a) Digital pressure switches shall be employed for starting and shutting down operation
of pumps automatically, dictated by line pressure. The Pressure Switch shall be analogue
output, stainless steel sensor, LCD display -4-digit, High accuracy, Wetted Part: Stainless
steel-316, Measuring range: 0-10 bar. The housing shall be in cast aluminium or
equivalent, IP 65 compliant weather proof enclosure suitable for wall / pipe mounting.
This instrument shall be built with high accurate piezo- resistive pressure sensor with SS-
316 diaphragm which is suitable for media like non-corrosive liquids and air.
b) Analogue Pressure Switch shall be snap action SP DT switch rated 10A @ 230 V
operated through a stainless-steel diaphragm. The switch shall have a pointer for manual
adjustment of set point, and all electrical connections shall be terminated in a screwed
terminal connector. The entire unit shall be encased in a cold drawn steel (heavy gauge)
enclosure. The diaphragm shall be designed for a maximum operating pressure of the
system. Each pressure switch shall be provided with a pressure gauge in parallel as
shown on the drawings and all gauges and pressure switches shall be mounted in an
instrument panel with necessary control piping and drainage facility.
1.6.3 Anti-vibration mounting
Suitable vibration mounting duly approved by Engineer in charge shall be employed for
mounting the unit so as to minimize transmission of vibration to the structure.
1.7 SYSTEM OPERATION: -
1.7.1 Working of Fire Pumps: -
a) The fire pump shall be started automatically on loss of pressure and the operation
sequence of the jockey and fire pumps shall be as follows:
i. The pump operating sequence shall be arranged in such a manner to start the pump
automatically but should be capable of being stopped manually by stop push buttons
only.
b) Operating Conditions for the Fire Pumps:
i. The Pressure Switches mounted on the pressure vessel would be set as under (all
figures in kg / sq.cm.).
Description Cut in Cut out
Operating pressure 7.0 Kg / sqcm

Jockey pump 5.0 Kg / sqcm 7.0 Kg / sqcm
Main Fire Electric Pump (Working) 4.0 Kg / sqcm Manual
Main Fire Electric Pump (Standby) 3.0 Kg / sqcm Manual
1.7.2 Property Development station: -

The fire pump shall be started automatically on loss of pressure and the operation
sequence of the Jockey and fire pumps shall be as follows:
Description Cut in Cut out
Operating pressure 9.0 Kg / sqcm
Jockey pump- Hydrant 8.0 Kg / sqcm 9.0 Kg / sqcm
Jockey pump- Sprinkler 8.0 Kg / sqcm 9.0 Kg / sqcm
Main Fire Electric Pump 7.0 Kg / sqcm Manual
Standby Pump (Electric / Diesel driven) 6.0 Kg / sqcm Manual
Main Fire Sprinkler Pump 5.0 Kg / sqcm Manual
It is thus to be noted that;

a) Jockey Pumps shall start and stop automatically through pressure switches.
b) Jockey Pumps shall stop when main pumps start.
c) Main and standby fire pumps shall start automatically when pressure falls below the
specified limits, but stopping shall be manual.
1.7.3 The motor starters (Soft Starter) shall consist of electrically actuated contactors. The
starter shall be complete with ON-OFF push buttons, timers and auxiliary contacts and
shall be fully automatic. There shall be an indicating lamp with each of the pumps and an
ammeter and selector switch with the fire pumps.
1.7.4 The starter along with isolator shall be housed in a 14 SWG MS box duly rust inhibited
through a process of degreasing and phosphating.
1.7.5 All cabling to and from the pumps to starter and control switch shall be carried out through
armoured PVC cables of approved makes. Cables shall be laid in accordance with
section "MV CABLING". The pump motors and panels shall be double earthed in
accordance with IS 3043- 1987 or as shown on drawings and as approved.
1.7.6 All power and control cables in the fire system shall be fire retardant Low Smoke low
halogen (FRLSH) cables.
1.7.7 Installation
a) The pump and motor assembly shall be mounted and arranged for ease of maintenance
and to prevent transmission of vibration and noise to the building structure or to the pipe
work.
b) The pump and motor assembly shall be installed on suitable RCC foundation. The length
and width of the foundation shall be such that 100 mm space is left all around the base
frame. The height of foundation shall be so decided that the total weight of foundation

block is 1.5 times the operating weight of the pump assembly. 65 X 65 X 4 mm Angle iron
frame of suitable size shall be provided on the top edges of the foundation. The
foundation drawing shall be approved bt Engineer in charge before execution.
c) More than one pump and motor assembly shall not be installed on a single base or
cement concrete block.
d) The suction / discharge pipe shall be independently supported and their weight shall not
be transferred to the pump. It should be possible to disconnect any pump for repairs
without disturbing the connecting pipe line.
e) A minimum clearance of 750 mm around the main pumps shall be provided.
1.7.8 Sump pumps
a) Drainage sump pumps shall be vertical type suitable for drainage and solids up to 12 mm
size. Pumps shall be wet pit / submersible type, grease lubricated. Impeller shall be cast
iron with open vanes.
b) Pumps shall be provided with necessary support plates and M.S. sections. Pumps shall
operate with high water level in sump and stop at low water level by means of an
electronic level controller or auto float.
c) Pump shall have all accessories suitable for operation on 415 V 3 phase, 50 Hz (As per
BOQ). AC supply complete with starter for automatic operation including water level
sensing device, inter connection with submersible cable etc. common electrical panel
with alternative operation of pumps including all cabling, wiring etc. The scope will also
include piping work including bend connectors, etc. for drainage, complete in all respects
d) The pump set shall include an automatic starter control panel including cycling operation
relays, contactors, copper control wiring, LED indications, push buttons etc. Minimum 5-
meter-long of power and control cabling (FRLSH) to be provided for both the pumps.
Sump Pump and the control panel shall be supplied / manufactured by the single OEM.
e) Each Pump shall be supplied and installed with non-return valve and isolation valve on
the delivery line and shall be equipped with low- and high-level controllers suitable for
automatic / manual operation.
f) Sump pit cleaning must be ensured by contractor before and after installation till the
completion of DLP period.
g) Sump pump should be integrated to local control panel installed in SCR.
h) Sump pump panel incoming supply shall be through FPP panel.
1.8 Fire hydrants and hose reels
1.8.1 Fire Hydrant Design
1.8.1.1 Various pipe sizes of dia. – 250 mm, 200 mm, 150 mm, 100 mm, 80 mm, 65 mm, 50
mm, 40 mm, 32 mm, and 25 mm shall be used and these are purely for contractor's
guidance. The contractor shall be responsible for selection of sizes as per detailed
engineering to be done by him and submit calculation (Hydraulic Calculation as per
standard) for approval to Employer / DDC. Plumbing design to be done by the contractor
shall incorporate the following:
a) Butterfly / sluice valves shall be provided at suction and delivery sides of pumps.
b) External hydrant
c) Fire service connection / inlet.
d) Test valve.
e) Drain connections.

1.8.1.2 For testing the system healthiness and automatic operation on daily basis, one test pipe
with butterfly / sluice valve shall be provided in common discharge header. For avoiding
wastage of water, this pipe shall discharge water in the tank. The location of test line
valve shall be approachable from ground level.
1.8.1.3 Non return valve shall be provided at the delivery of each pump and fire service inlet.
This shall be of double plate.
1.8.1.4 Air release valves with ball valve shall be provided in the piping system for venting
trapped air with a size of 25 mm for pipes up to 100 mm and 40 mm for larger pipes.
1.8.1.5 The Hydrant system shall be kept pressurized all the times.
1.8.2 Hydrants shall be provided internally and externally as shown on the drawings. Internal
hydrants shall be provided at each landing of and escape staircase and additionally
depending on the floor area as shown on drawings. Landing valve shall be single headed
SS (stainless steel) valve with 63 mm diameter outlets and 80 mm inlet conforming to IS
5290-1993. Landing valve shall have flanged inlet and instantaneous type outlets and
mounted at 1.0 m above the floor level. Instantaneous outlets for the hydrants shall be of
standard pattern approved and suitable for 63 mm diameter fire brigade hoses. The
landing Valve shall be fitted to a T connection of the Risers at the Landing in such a way
that the valves is in the centre of the internal hydrant operation. The valve base shall be
Vertical and the valve facing outside, so there should be no hindrance in the operation of
wheel. Wherever necessary, pressure reducing orifices plate shall be provided so as to
limit the pressure to 3.5 kg / cm2 or any other rating as required by the Local Fire Authority.
a) Each landing valve shall have a hose reels or as shown on drawings.
b) Landing valve with single 63 mm diameter outlet and 80 mm diameter inlet.
c) First-aid hose reel: -First-aid hose reel shall be with 45 m long 25 mm diameter high
pressure thermo plastic (IS: 12585 marked) with Ball Valve and 7 mm shutoff nozzle. The
entire assembly is mounted on a wall bracket and can swing 180 degree. The water inlet
is connected to the riser pipe by means of a socket and valves. Hose reel shall be tested
and certified by the manufacturer to withstand an internal water pressure of not less than
35 kg / cm2 without bursting. All metal part of hose reel (connection pipe) shall be SS-
304.
d) Hose Pipe: -The hose tube can be pulled out easily for the purpose of discharge of water
nos. 15-meter long 38 mm diameter synthetic hoses with SS IS marked instantaneous
couplings.
e) Branch Pipe and Nozzle: - Branch Pipes with nozzle are mounted at the end of hose
pipe. Branch pipe is properly finished and free from sharp edges. During operation a
fireman has to hold the branch pipe. One end of branch pipe is fixed with hose coupling
and the other end is threaded to fit the nozzle. Nozzle is tapered pipe with one end
threaded internally which is fixed on branch pipe. The size of another end i.e. nozzle shall
be 20 mm (nominal internal diameter).
f) The First Aid Hose Reel Drum pipe shall conform to IS: 12585 and be wound on a
heavy-duty circular hose drum confirming to IS: 884- 1985 with a bracket. The hose shall
be permanently connected on one end to the Wet Riser through a 25m ball valve with
necessary hose adapter and a SS-304 nozzle at the other end.
g) Hoses shall be in two lengths of 15 m each, of synthetic type (UL listed) with
instantaneous couplings, neatly rolled into bundles and held in position with steel
brackets. Hoses shall be tested and certified by the manufacturer to withstand an internal
water pressure of not less than 35 kg / cm2 without bursting.
h) Fire Hose Cabinet: -The internal hose cabinet shall be fabricated from 2 mm thick
stainless steel (SS-304) sheet. The cabinet shall have double flap-hinged doors with 5.5

mm clear glass and shall have necessary openings for riser main and brackets for all
internals. The cabinet shall be provided with suitable and robust locking arrangement;
the hose cabinet shall be of size to accommodate the following.
i. Landing valves (Single headed).
ii. Hose pipe (2 Nos.).
iii. Hose reel (45 meters.).
iv. Branch pipes, nozzles (1 set).
v. Fire Extinguishers
vi. Universal locking arrangement.
vii. Fire man’s axe
viii. Lock has to be provided by contractor without any extra cost.
ix. Fire hose cabinet drawing shall be approved by Engineer in Charge.
i) Fire extinguisher stand: - Fire extinguisher stand for portable fire extinguishers (suitable
as per size) made with SS-304, minimum 2 mm thick complete with SS-304 angle with
base plate and suitable holding arrangement complete as required and as per site
condition or as per instruction of Engineer In charge.
i. Size approximate 28"x10"x10"
ii. Size approximate 21"x9"x9"
j) External Hydrants: - External hydrants shall be as per IS: 5290 with hand wheel control
and an 80 mm diameter pipe stand post. Hydrants shall be located at least 2 m away
from and within 15 m from the building wall.
k) Each external hydrant shall be provided with a hose cabinet containing 2 x 15 m 38 mm
diameter synthetic hoses with couplings. The cabinet shall contain a branch pipe and
nozzle. The cabinet shall be 900 x 600 x 450 fabricated out of 2 mm thick mild steel. The
cabinet shall be wall-mounted or free standing with its own steel legs depending on the
site conditions and as shown on drawings and as approved.
i. Single headed yard hydrant.
ii. Hose pipe (2 lengths of 15 m).
iii. Branch pipes, nozzles (1 set).
iv. Universal locking arrangement fabricated from 2 mm thick MS sheet and postal red
coated with 6 mm thick plain glass in front.
v. Lock has to be provided by contractor without any extra cost.
l) The fire brigade connection shall consist of four headed inlets, as specified in BOQ, 63
mm diameter outlets with built-in check valve and drain plugs connected to a 150 mm
diameter outlet connection to the water reservoir or to the hydrant main. The fire brigade
collecting head shall conform material and performance to IS: 904-1983 “Specification
for 2-way & 4-way suction collecting heads for firefighting purposes”. These are provided
for connection of fire service hose pipes for either directly pressurizing the system with
their pumps or filling water in the tank from a distance. In the first case non return valve
with butterfly valve shall be provided for holding water pressure. Fire service inlet shall
be provided with each wet riser / down comer and the ring main. The typical arrangement
shall be as per CPWD specification part V (Wet Riser and Sprinkler System). These are
fixed to 150 mm dia. pipe and located in MS Box made of 2 mm thick mild steel sheet
with openable glass cover. These shall be as per IS 904. 2-way & 4- way cap shall be
polyamide material as approved by Engineer In charge.

1.8.3 Testing and commissioning

1.8.3.1 The Jockey & fire pump starting and stopping shall be tested by opening the test valve
and record the following and the valves should be as furnished below:
Jockey pump start / stop

System pressure at start-up
System pressure at stop
Time elapsed from start to stop
Hydrant / Sprinkler Main Pump
System pressure at start-up
1.8.3.2 Maintained system pressure while discharging the landing valve at the highest point.
Highest outlet 3.5 kg / cm2

1.8.3.3 All the operating tests shall be carried out to the satisfaction of Compliance with the
local fire brigade and the enforcing authorities as specifically laid down by the local fire
authorities.
1.9 PIPING FOR FIRE FIGHTING SYSTEM
1.9.1 Scope
The scope of work covers supply, fabrication, laying, testing, painting, and commissioning
of the entire piping system for the firefighting installation i.e. fire hydrant and sprinkler
systems.
1.9.2 Hydrant Mains
1.9.2.1 External
a) Pipes shall be galvanized steel tubes conforming to IS: 1239. G.I Heavy Duty pipes, when
laid underground, shall be protected against corrosion by a 4 mm thick bituminous tape
with minimum 12 mm overlap over the entire length including fittings. The grooved joints
shall be random selected for testing in consultation with the Engineer-in- charge. All
flanges shall be slip-on welded type to IS: 6392-1971 with a 3 mm fiber- reinforced EPDM
gasket and rated for 2.0 N / mm2.
b) G.I pipes up to 150 mm diameter shall be galvanized steel tubes conforming to I.S. 1239
(Part-I) of grade and class as specified and above 150 mm diameter shall be as per I.S.
3589 of minimum 6.3 mm thickness.
c) Galvanising: When tubes are required to be galvanized, the Zinc coating shall conform
to IS 4736. (Hot dip zinc coatings on steel tubes).
d) Manufacturing Process: Tubes are made from tested quality of steel manufactured by
any approved process Electric Resistance Welded (ERW),
e) The Galvanising shall conform to IS:4736, the hot dip zinc coating shall be uniform,
adherent reasonably smooth and free from such imperfections as flux, ash and drop
inclusions, bare patches, black spots, pimples, lumpiness, runs, rust strains, bulky white
deposits, and blisters. The pipes and sockets shall be cleanly finished, well galvanised in
and out and free from cracks, surface flaws laminations and other defects. All screw
threads shall be clean and well cut. The ends shall be cut cleanly and square with the
axis of the pipe.
f) The tolerances in wall thickness, temperature, pressure ratings and spacing of clamps
will be as per IS 1239 and as specified in manufacturer catalogues.

g) Underground mains shall be laid not less than 750 mm below the ground level. All
excavation for pipe laying shall be carried out with sufficient width for making proper
joints. Backfilling shall be done only after the piping is hydro-statically pressure tested.
Piping shall be constantly kept clean till tested.
h) All valves shall be housed in brick masonry chambers over 150 mm cement concrete
(1:3:6) foundation. The brick walls of the chamber shall be plastered inside and outside
with 20 mm cement sand plaster 1:4 with a floating coat of neat cement. Chambers shall
be 650 x 650 mm clear for depths up to 1200 mm and 1000 x 1000 mm for depths beyond.
Each chamber shall have a heavy duty RCC cover as approved by the Engineer in
charge.
i) Piping laid above ground shall be supported on cement concrete (1:2:4) pedestals raising
the bottom of the pipe at least 150 mm over the ground level and held to the pedestals
with galvanized clamps. Pedestals shall be made at 3.0m centre to centre and as shown
on drawings. Cement concrete 1:2:4 thrust anchors shall be provided at all tee-off points
and change of direction as shown on drawings and as required. Pipes laid on walls and
ceiling shall have galvanized steel brackets.
j) GI Pipe Shall be galvanized both the surface inner and outer.
k) All piping shall have (UL / FM Approved) grooved joints.
l) Welding shall be done by qualified welder having necessary required certificates
minimum qualification of welder is ITI trained from reputed institutes.
1.9.2.2 Internal
a) All internal pipes shall be, heavy duty galvanized steel tubes to IS: 1239 using wrought
steel heavy-duty fittings. Flanges shall be provided to match with valves and other
equipment and shall conform to IS: 6392. Flanges shall be rated for 2.0 N / mm2.
b) The installation shall be neat and tidy, with accurate spacing between pipes, valves, and
joints, whether running in straight routes or turning through bends.
c) Valves shall be suitable for external piping and grooved fitting.
d) All joints above 65 mm shall be grooved joints and below 65 mm shall be threaded joints
(UL / FM Approved).
e) All pipes shall be of approved make and best quality without rust marks. Pipes and fittings
shall be fixed in a manner as to provide easy accessibility for repair, maintenance and
shall not cause obstruction in shafts, passages etc. Pipes and fittings shall be fixed truly
vertical, horizontal or in slopes as required in a neat workmanship manner. Pipes shall
be securely fixed to walls and ceilings by suitable supports at intervals specified. Only
approved type of anchor fasteners shall be used for RCC ceiling and walls.
f) All pipes shall be adequately supported from ceiling or walls through structural supports
fabricated from Galvanized Iron support structures e.g. channels, angels and flats
generally as shown on drawings. Fasteners shall be shear type anchor fasteners in
concrete walls and ceilings and G.I wrought steel spikes of at least 75 mm long in brick
walls. All pipes support shall be painted with 1 coats of red oxide primer and two coats of
black enamel paint in case approved by Engineer in Charge.
g) All low point loops in the piping shall be provided with 25 mm Ball Valves for draining the
system. All valves shall have screwed brass caps. Likewise, 25 mm gunmetal air vents
shall be provided at all high point loops to prevent air locking.
h) All piping shall have grooved joints.

1.9.3 Pipe Jointing

1.9.3.1 Mechanical Grooved Joints
a) G.I. pipe for working temperature up to 820C of suitable wall thickness may be joined by
use of mechanical grooved pipe and couplings. Only jointing systems approved by the
Loss Prevention Council, Bureau Vertitas or other similar authorities are acceptable.
b) All Grooved fittings shall be UL Listed and FM Approved.
c) Installation shall be done by skilled staff duly trained by the OEM / manufacturer. The
coupling shall consist of a combination of coupling pieces, water sealing gaskets, special
nuts and bolts and grooves in pipe walls and shall be self-centering.
d) Grooves shall be properly cut or rolled at the pipe ends by machine and fully in
accordance with the manufacturer’s instructions and recommendations. Grooves shall be
dimensionally compatible with the coupling.
e) Joint assembly, support details and positions shall be made in accordance with the
manufacturer’s instructions / descriptive leaflets.
f) Bellow expansion joints shall be provided for expansion and contraction in the pipework
and also provided where the pipes cross construction expansion joints. The expansion
joints shall be capable of absorbing axial and lateral movements. Confirmation shall be
obtained from the proposed expansion joint manufacturer on the suitable choice of the
proposed joints.
g) Flanges and unions shall be faced true. Flanges shall be provided with Approved gaskets,
and made square and tight.
h) All pipes shall be provided with threaded / grooved joints. Hold tite shall be used for
sealing for threaded joints.
i) Joints between valves and G.I. pipes shall be made by providing a suitable flange.
j) Flanges shall have appropriate number of holes and shall be fastened with nuts, bolts,
and 1.5 mm thick EPDM gasket.
k) All nuts, bolts, washers etc. shall be of stainless steel for fitment of pipes, valves and
other accessories as approved by Engineer in Charge.
l) The piping system and components shall be capable of withstanding 150 % of the
working pressure including water hammer effects.
m) Galvanized steel flanges shall be in accordance with Table - 17 of IS: 6392 "Plate Flanges
for Welding" and flange thickness shall be as under. Gasket thickness shall not be less
than 3 mm.
Pipe dia Flange Thickness
250 mm 26 mm
200 mm 24 mm
150 mm and 125 mm 22 mm
100 mm and 80 mm 20 mm
65 mm 18 mm
40 mm and below 16 mm
n) Fittings shall be cast of ductile iron conforming to ASTM A-536, Grade 65-45-12 , forged
steel conforming to ASTM A-234, Grade WPB 0.375" wall (9,53 mm wall), or fabricated
from Std. Wt. Carbon Steel pipe conforming to ASTM A-53, Type F, E or S, Grade B.
Fittings provided with an alkyd enamel finish or hot dip galvanized to ASTM A-153. Zinc

electroplated fittings and couplings conform to ASTM B633. The fittings shall with stand
pressure of up to 21 kg / cm2.
o) Grooved Mechanical Couplings shall be manufactured in two segments of cast ductile
iron, conforming to ASTM A-536, Grade 65-45-12. Gaskets shall be pressure-responsive
synthetic rubber, grade to suit the intended service, conforming to ASTM D-2000.
Mechanical Coupling bolts shall be zinc plated (ASTM B-633) heat treated carbon steel
track head conforming to ASTM A-449 and A-183, minimum tensile strength 110,000 psi.
Couplings up to 12” should have an Angle Bolt Pad and No Torque should be needed
while tightening. Couplings above 12” should have Wedge Shaped Grooved. Installation
Ready Couplings & Fittings shall be used wherever applicable.
p) For Fittings below 50 mm should be of Ductile iron Confirming to ASTM A-536, Grade
65-45-12, BSPT threads with FM approval and UL Listed. Fittings should be anti-rust
coated in threading and anti-rust black finish.
q) For tappings of 50 mm / 40 mm / 32 mm / 25 mm from headers, mechanical tees
manufactured from ductile iron conforming to ASTM A-536, grade 65-45-12, with
synthetic rubber gasket, and heat-treated carbon steel zinc plated bolts and nuts
conforming to physical properties of ASTM A-183 / Reducing Tees shall be used
r) The Grooving machine shall be supplied by the same company as grooved fittings as to
maintain conformity of grooving.
Wherever two horizontal headers are to run side by side, the two headers shall be located
at different levels, if possible, so as to avoid unnecessary bends at tapping off from the
headers. Accordingly, the supports shall also be staggered to support pipes at two levels
1.9.4 Valves and other accessories
1.9.4.1 Gate Valves
a) Sluice / Gate valves shall be used for isolation of flow in pipelines. For sizes up to 65
mm, gate valves shall be outside screw non rising spindle type and shall be as per IS:
778 Class-I and Class-II, as applicable. For sizes 80 mm to 300 mm, gate valve shall
be as per relevant IS, PN-1.6 and shall be of inside screw and non-rising type and cast-
iron double flanged.
b) Gate valves shall be provided with a hand wheel, draining arrangement of seat valve
and locking facility (as required). Gate valves shall have back setting bush to facilitate
gland renewal during full open condition.
c) The Body, bonnet, Stuffing Box, cap, and hand wheel shall be of cast iron to IS: 210 -
1970, grade FG 200 / 260. The non-rising spindle shall be of stainless-steel SS AISI
316 construction. The Bonnet gasket shall be of EPDM rubber.
d) The Valve shall be PN 1.6 rated and shall be tested in accordance with relevant BS / IS
/ API standard. The ends shall be flanged. The batch number of the valve shall be
punched on the top of the flange. The spindle shall be removable type, and shall be
easily rotated.
1.9.4.2 Pressure Switch
a) Digital pressure switches shall be employed for starting and shutting down operation
of pumps automatically, dictated by line pressure. The Pressure Switch shall be analogue
output, stainless steel sensor, LCD display -4-digit, High accuracy, Wetted Part: Stainless
steel-316, Measuring range: 0-10 bar. The housing shall be in cast aluminium, IP 65
compliant weather proof enclosure suitable for wall / pipe mounting. This instrument shall
be built with high accurate piezo- resistive pressure sensor with SS-316 diaphragm which
is suitable for media like non-corrosive liquids and air.

b) Analogue Pressure Switch shall be snap action SP DT switch rated 10A @ 230 V
operated through a stainless-steel diaphragm. The switch shall have a pointer for manual
adjustment of set point, and all electrical connections shall be terminated in a screwed
terminal connector. The entire unit shall be encased in a cold drawn steel (heavy gauge)
enclosure. The diaphragm shall be designed for a maximum operating pressure of the
system. Each pressure switch shall be provided with a pressure gauge in parallel as
shown on the drawings and all gauges and pressure switches shall be mounted in an
instrument panel with necessary control piping and drainage facility.
1.9.4.3 Air Release Valve
Air Release Valve shall be gun metal / forged brass and minimum test pressure of 16
bar as per IS 14845-2010.
1.9.4.4 Pressure Vessel
a) The Pressure Vessel shall be provided to compensate for slight loss of pressure in the
system and to provide an air cushion for counter acting pressure surges whenever the
pumping set comes into operation. It shall be normally partly full of water, the remaining
being filled with air, which will be under compression when the system is in normal
operation.
b) Pressure vessel (IS-2825) shall be fabricated from minimum 8 mm thick MS plate with
dished ends and suitable supporting legs. It shall be provided with 50 mm diameter
flanged connections from pump, one 25 mm drain with ball valve, one water level gauge
and 25 mm sockets for pressure switches. The pressure vessel shall be hydraulically
tested as required.
c) The Pressure Vessel shall be for Hydrant Systems. The Pressure Switches shall be
mounted on the drain end of each Vessel. The Vessel shall also be provided with an air
release valve mounted at the top.
1.9.4.5 Pressure Gauge
a) Digital Pressure Gauge shall be Case: Stainless steel, Ingress Protection: IP 65,
Display: LCD-4 digit, Measuring range: 0-20 bar, Wetted Part: Stainless steel, Size
minimum 80 mm, all accessories. The shut off arrangement shall be by ball valve.
b) Analogue Pressure Gauge shall be constructed of die cast aluminium and stove
enamelled. It shall be weather proof with an IP 55 enclosure. It shall be a stainless-steel
Bourdon tube type Pressure Gauge with a scale range from 0 to 16 Kg / cm2 and shall
be constructed as per IS: 3624 - 1987. Each Pressure Gauge shall have a siphon tube
connection. The Shut off arrangement shall be by Ball Valve.
1.9.4.6 Ball Valve
a) The Ball Valve shall be made from forged brass and tested to 25 Kg / cm2 pressure.
The valve shall be internally threaded to receive pipe connections.
b) The Ball shall be made from brass and machined to perfect round shape and
subsequently chrome plated. The seat of the valve body- bonnet gasket and gland
packing shall be of Teflon.
c) The handle shall be of chrome-plated steel with PVC jacket. The handle shall also
indicate the direction of `open' and `closed' situations. The gap between the ball and
the Teflon packing shall be sealed to prevent water seeping up to 14 Kg / cm2 pressure.
d) The handle shall also be provided with a lug to keep the movement of the ball valve
within 90 degree. The lever shall be operated smoothly and without application of any
unnecessary force.

1.9.4.7 Non-Return Valve

a) Non-return valves shall be cast iron spring action dual plate type. An arrow mark in the
direction of flow shall be marked on the body of the valve. The valve shall be designed
as per API standard.
b) The Valve shall be of cast iron to IS: 210 Gr. FG 260 body.
c) The gasket shall be of high-quality rubber. At high pressure of water flow the flapper
shall seat tightly to the seat. The Valve shall be capable of handling pressure up to 15
kg / cm2.
d) Testing shall as per reluctant IS / BS / API Standard.
Ref standard Designed and tested as per API 594 and API 598
or equivalent standard
Pressure Rating 16 bars
Type Dual plate wafer type
Plates SS-316
Seal EPDM
Hinges and stop pin SS-316
Spring SS-316
1.9.4.8 Butterfly Valve

a) The Butterfly Valve shall be suitable for waterworks and tested to minimum of 16 kg /
cm2 pressure. The Valves shall fulfil the requirements of IS 13095.
b) The body shall be of cast iron to IS: 210 Gr. FG 260 in circular shape and of high strength
to take the minimum water pressure of 10 kg / cm2. The disc shall be SS-316.
c) The valve seat shall be of integrally moulded high-grade elastomer or EPDM. The Valve
in closed position shall have complete contact between the seat and the disc throughout
the perimeter. The elastomer rubber shall have a long life and shall not give away on
continuous applied water pressure. The shaft shall be of stainless-steel SS-316.
d) The Valve shall be fitted between two flanges on either side of pipe flanges. The Valve
edge rubber shall be projected outside such that they are wedged within the pipe flanges
to prevent leakage.
e) The Valves up to and including DN150 shall be lever operated and valves in excess of
DN150 shall be provided with gear operated.
f) The valve shall be supplied with manual gear operated opening.
g) Butterfly valves above 150 mm shall be wheel operated type.
1.9.4.9 Strainers
a) Stainless steel (Y type) strainers shall have minimum 1.6 mm thick screen with 3 mm
perforations. Strainers shall be provided with flanges.
b) The screen shall SS 316 material.
c) The flanged ends shall be confirming to ASME B 16.5.
1.9.4.10 Orifice Plates
a) For restricting pressure at lower levels in the sprinkler system, orifice plates of
appropriate sizes shall be fitted at different floor levels, at the branching points form
Riser Main. The Diameter of such orifice shall not be less than 50% of the dia of pipe
into which it is to be fitted, which shall not be less than 50 mm dia. These orifice plates

must be of stainless steel with plain central hole without burrs. Such orifice plate must
have a projecting identification tag.
b) The orifice plate shall fit not less than two pipes internal diameters downstream of the
outlet from any elbow or brand.
c) Contractor shall submit the design and identify location on drawing before installation
d) Orifice plate shall be made of AISI 304 stainless steel.
e) Contractor must provide measuring nozzle for pressure differential measurement.
1.9.4.11 Anchor / thrust block
a) Contractor shall provide suitably designed anchor blocks in cement concrete / steel
support to cater to the excess thrust due to work hammer and high pressure.
b) Thrust blocks shall be provided at all bends, tees and such other location as determined
by the Engineer. Exact location, design, size and mix of the concrete block / steel
support shall be as shown on the drawings or as directed by the Engineer prior to
execution of work.
1.9.4.12 Pipe supports
a) All pipes whether horizontal or vertical shall be suitably supported using GI clamps /
painted GI angles as approved by Engineer in Charge.
1.9.4.12.1 Vertical Pipes
a) The pipes running vertical shaft shall be supported by galvanized mild steel rigid clamps
fixed to wall with anchor bolts and studs.
1.9.4.12.2 Horizontal Pipes
a) Pipes running horizontal shall be supported from structural beam / slab by using
appropriate GI clamps / GI angles with anchor fastener, bolts etc as approved by
Engineer in Charge.
b) The spacing of supports shall be as follows:
IS: 15105 Table-11 Distance Between Pipe Supports
(Clause 10.3.10)
Sr. No. Pipe Diameter Spacing
1 Up to 65 mm 4.0 m
2 65 mm to 100 mm 6.0 m
3 100 mm to 250 mm 6.5 m
c) Supports for horizontal piping longer than 15m in a stretch shall be provided with swivel
clamps. Otherwise, the clamps shall be universal clamps or rigid clamps as required by
the project engineer-in-charge.
d) Fixing of clamps / rails etc. - All clamps, rails and accessories shall be fixed to the
structure (beam, slab, walls etc.) by using approved good quality anchor fasteners of
appropriate size.
e) Additional pipe support shall be provided at bend and drop location as per site
requirement or instructed by Engineer In charge.

1.9.5 Installation
a) The installation work shall be carried out in accordance with the detailed drawings / WRD
Drawing prepared by the contractor and approved by the Engineer In charge.
b) In pipe above ground level, expansion loops or joints shall be provided to take care of
expansion or contraction of pipes due to temperature changes.
c) Tee-off connections shall be through equal or reducing tees, otherwise ferrules welded
to the main pipe shall be used. Drilling and tapping of the walls of the main pipe shall not
be resorted to.
d) Open ends of piping shall be blocked as soon as the pipe is installed to avoid entrance
of foreign matter.
e) Piping installation shall be supported on or suspended from structure adequately. The
contractor shall provide clamps and hangers. Proper lines and levels shall be maintained
while installing exposed pipes.
f) Extra supports shall be provided at the bends and at heavy fittings like valves to avoid
undue stress on the pipes.
g) Pipe sleeves of diameter larger than the pipe by least 59 mm shall be provided wherever
pipes pass through walls and the annular spaces shall be filled with felt and finished with
retaining rings.
h) Vertical risers shall be parallel to walls and column lines and shall be straight and in
plumb. Risers passing from floor to floor shall be supported at each floor by clamps as
per site.
i) The space in the floor cut outs around the pipe work shall be closed using cement
concrete (1:2:4 mix) or steel sheet, from the fire safety considerations, taking care to see
that a small annular space is left around the pipes to prevent transmission of vibration to
the structure.
j) Riser shall have suitable supports at the lowest point.
k) Where Galvanized steel pipes are to be buried under ground the same shall be treated
in accordance relevant code before laying. The top of the pipes shall be not less than 750
mm below the ground level. Where this is not practicable, permission of the Engineer
shall be obtained for buried the pipes at lesser depth. Masonry (with 1:4 plaster i.e.
cements or sand) or C.C. (1:2:4 for cement, sand & concrete) blocks shall be provided
for supporting the pipes at interval as per site requirement. After the pipes have been laid,
the trench shall be refilled with the excavated soil in layers of 20 cm. and rammed and
any extra soil shall be removed from the site of work by the contractor.
l) Underground pipe shall be laid at least 2 m. away from the face of the building preferably
along the roads and foot paths. As far as possible laying of pipes under road, pavement
and large open spaces shall be avoided. Pipes shall not be laid under building and where
unavoidable, these shall be laid in masonry trenches with removable covers.
m) To facilitate detection of leak and isolation of defective portion of pipe, valves shall be
provided in underground pipe at suitable locations. As far as possible such valves shall
be provided over ground. If the valves are to be provided below ground, suitable masonry
chamber with cover plate shall be provided with the approval of the Engineer. Locations
where vehicles can pass shall be avoided for provision of valve below ground.
n) Pipe over ground shall be painted in red colour shade no. 536 of IS: 5. Suitable
identification shall be provided to indicate the run of underground pipe wherever the route
of underground pipe cannot be ascertained from the location of yard hydrant / isolating
valves.

o) It shall be made sure that proper noiseless circulation is achieved in the system. If proper
circulation is not achieved due to air-bound connections, the contractor shall rectify the
defective connections. He shall bear all the expenses for carrying out the above
rectification, including the tearing up and refinishing of floors, walls etc. as required.
1.9.6 Painting
a) All exposed piping for firefighting shall be distinctly painted `Fire red' shade 536 to
IS:5-2004. For Pipes shall first receive two coats of red oxide primer uniformly applied
and two coats of oil paint applied thereafter. All pipes support shall be painted black as
specified for support & clamps or as approved by Engineer in charge.
b) Painting Schedule - All equipment and piping shall be painted in accordance with the
following colour code:
c) Marking of all fire piping work and associated accessories shall be ensured by contractor
after obtaining approval of Engineer in Charge.
d) All surfaces to be painted shall be thoroughly cleaned with wire brush to remove
completely rust and other extraneous substances. Over the cleaned surfaces one coat of
red oxide primer shall be applied completely covering the exposed surfaces. Finishing
coat of enamel paint shall be applied one day after the prime coat, after ensuring that the
paint is dry. The second coat shall be done before the installation is handed over and
after approval to do so from the Engineer-in-charge.
e) Corrosion protection tape shall be wrapped on G.I. Pipes to be buried in ground. This
corrosion protection tape shall comprise of coal tar / asphalt component supported on
fabric of organic or inorganic fiber and minimum 4 mm. thick and conform to requirement
of IS: 10221-Code of practice for coating and wrapping of underground mild steel pipe
line. Before application of corrosion protection tape all foreign matter on pipe shall be
removed with the help of wire brush and suitable primer shall be applied over the pipe
thereafter.
f) The primer shall be allowed to dry until the solvent evaporates and the surface becomes
tacky. Both primer and tape shall be furnished by the same manufacturer. Corrosion
protection tape shall then be wound around the pipe in spiral fashion and bounded
completely to the pipe. There shall be no air pocket or bubble beneath the tape. The
overlaps shall be 15 mm. and 250 mm. shall be left uncoated on either end of pipe to
permit installation and welding. This area shall be coated in-situ after the pipe line is
installed. The tapes shall be wrapped in accordance with the manufacturer's
recommendations. If application is done in cold weather, the surface of the pipe shall be
pre- heated until it is warm to touch and traces of moisture are removed and then primer
shall be applied and allowed to dry.
S. No. Equipment Colour Distinguishing Mark
Fire Red Shade No.536
1 Pump motors
to IS: 5 -2004
2 Internal piping - do -
Landing valves & Hose reel
3 - do -
cabinets
4 External Hydrants - do -
5 Fire brigade connection - do -
6 Air vessel - do -
7 Break Glass Unit Fire Red
8 Hooters / Speakers Fire Red
9 Sprinkler pipes Fire Red

Fire Red Vinyl tape

10 Fire Hose Cabinet
50% front side
1.9.7 Testing & commissioning
a) All piping after installation shall be tested for a hydrostatic test pressure of 10.5 kg / cm2
or 1.5 times the working pressure (whichever is less) maintained for 24 hours. All joints
and valves shall be checked for leaks and rectified and retested. During testing all valves
except drain & air valves shall be kept fully open.
b) Piping repaired subsequent to the above pressure test shall be re-tested in the same
manner.
c) System may be tested in sections and such sections shall be securely capped.
d) Pressure gauges may be capped off during pressure testing of the installation.
1.9.8 Makes of materials
For makes of materials refer to list of approved makes of material.
1.9.9 Mode of measurement
a) All external piping shall be measured along the centre line of the pipe and paid per unit
length and shall include
i. All pipes & fittings (Threaded & Grooved)
ii. Bituminous coating
b) All internal piping shall be measured similarly but shall include for the pipe supports and
clamps.
c) All valves, air valves, drain valves together with flanges or tail pieces shall be measured
per unit.
d) All excavation and concrete supports and thrust blocks shall be measured as per drawing
and paid for per cum.
e) The cost of pipe supports described above form part of the rate quoted for piping and no
extra shall be payable on the account.
f) All painting shall form part of the cost of equipment piping etc. No separate payment shall
be admissible.
1.10 PORTABLE FIRE EXTINGUISHERS
1.10.1 Scope
The scope of work covers the supply and installation of portable fire extinguishers. The
following types are envisaged in these specifications and provided as shown in the
schedule of portable fire extinguishers.
a) Carbon-dioxide extinguisher
b) Water expelling type.
1.10.2 Standards
Portable Fire Appliances Requirement, Type and Location as per Delhi Fire
Authority:
The latest standards and rules and regulations shall be applicable:
Fire protection manual of the tariff advisory committee, Fire Insurance Association of
India

IS: 15683 Portable Fire Extinguisher Carbon Dioxide Type
1.10.3 Extinguishers
1.10.3.1 Carbon dioxide type
a) The discharge system shall be designed to expel 95% of the contents in continuous
discharge as follows:
Capacity (kg) Time (Sec.)

2.0 8 – 18
3.0 10 – 20
4.5 10 - 24
1.10.3.2 Water CO2 Fire Extinguishers

a) The extinguishers shall be rated for 2.0 and 4.5 kg by weight of carbon dioxide, unless
stated otherwise. The contents shall be with a filling ratio not exceeding 0.667.
b) The body shall be steel cylinder made according to IS: 7285 - 2002 and approved by
the chief controller of explosives.
c) The discharge head shall be simple and safe to operate conforming to IS: 3224 - 2002
with a safety release to IS: 5903 - 1970 set to 18.0 to 20.0 N / mm2. A syphon tube of
copper or PVC shall be fitted. A non-conducting discharge horn and a high-pressure
hose (27.5 N / mm2 pressure) shall be fitted with each extinguisher.
d) The extinguishing medium shall be primarily water stored under normal pressure; the
discharge being affected by release of carbon dioxide gas from a 60 gms cylinder.
e) The capacity of the cylinder when filled shall be 9 liters ± 5 %.
f) The cylinder shall be fabricated from MS sheet, welded at seams, with dish and dome,
being of same thickness and of size not exceeding the diameter of the body. The neck
shall be externally threaded with leaded tin bronze.
g) The cap shall be of leaded tin bronze. The siphon tube shall of brass or GI. The cartridge
holder, knob, discharge fittings and plunger shall be of leaded tin bronze and plunger of
stainless steel with spring also of stainless steel. The discharge tube shall be of braided
nylon, of 10 mm diameter and 600 mm length with a brass nozzle.
h) The extinguisher shall be treated for anti-corrosion internally and externally and painted
fire red externally. The cartridge shall be IS marked. The Extinguisher body shall be
tested to 25-bar pressure for 2 minutes. The Extinguisher shall be IS: 15683 marked.
1.10.4 General Requirements
a) All extinguishers shall be standard products approved by the Authority having
Jurisdiction and manufactured and tested strictly in accordance with the relevant Indian
Standard. All markings and test results shall be stamped in the appropriate colour
markings accordingly to the Indian Standards.
b) All extinguishers shall have a structurally designed galvanized steel handle and also a
suitable wall-mounting bracket.
c) All extinguishers shall be installed in readily accessible locations with the appliance
brackets fixed to wall by suitable anchor fasteners or by means of floor mounted
supports.

1.10.5 Mode of measurement

d) Each extinguisher with its mounting bracket shall be measured per unit and paid.
1.10.6 Makes of materials
e) For makes of materials refer to list of approved makes of material.
1.11 AUTOMATIC SPRINKLER SYSTEM
1.11.1 Scope
This chapter covers the general requirement of selection, design, installation, testing,
commissioning, and maintenance of automatic sprinkler system for firefighting in
buildings used for other than industrial and storage purpose.
1.11.2 Introduction
1.11.2.1 Firefighting installations are to be operated manually. Delay in undertaking manual
operation due to late detection and or response, may result in spread of fire. In
automatic sprinkler system, sprinkler heads are provided through out the areas to be
protected at specified locations such as roof or ceiling, walls, between racks, below
obstructions and fitted with water supply lines permanently charged with water under
specified pressure.
1.11.2.2 The sprinklers operate at pre-determined temperature to discharge water over the
affected area below and provide an adequate distribution of water to control or
extinguish fire. Only those sprinklers which are in the vicinity of fire that is those become
sufficiently heated operate. Operation of sprinkler results in flow of water which initiates
fire alarm. Thus, sprinklers perform two functions i.e. first to detect fire and then to
provide an adequate distribution of water to control or extinguish it. Water distribution
from ceiling level, cools down the hot gas which forms beneath the ceiling of enclosure
in which fire is developing. This will prevent spread of fire to adjoining areas and contain
damage to limited area.
1.11.2.3 It should not be assumed that the provision of sprinkler system entirely obviates the
need for other means of fighting fire and it is important to consider the fire precaution in
the premises as a whole. The system shall be installed only where there is no danger
of freezing of water in the pipes at any time. Typical layouts of sprinklers shall be as per
CPWD specification part V (Wet Riser and Sprinkler System).
1.11.2.4 Sprinkler “K” Factor shall be 80 L / min / (Bar)1\2 or 5.6 gpm / (psi)1\2, However Contractor
shall submit all calculations regarding the Finalization of “K” Factor before procurement
of Sprinkler.
1.11.3 Classification of occupancies
1.11.3.1 Sprinklers are provided in industrial and non-industrial buildings. The design of sprinkler
installation depends upon type of occupancy. Buildings are categorized under the
following classes for the purpose of designing the installations in IS 15105.
a) Light hazard class.
b) Moderate hazard class.
c) High hazard class.
d) Storage hazards.
1.11.3.2 All non-industrial buildings are classified under light hazard class with the condition “lf
any occupancy or block within light hazard risk is larger than 125 sq. m. in area or having
an area less than 125 sqm but not bound on all sides by masonry or RCC walls raised
up to roof, the building should be classified as moderate hazard. Airport terminal
buildings, car parking areas within building or basement, departmental stores / retail

shops are also classified under moderate hazard class. In order to satisfy above
conditions, all non-industrial buildings shall be designed under moderate hazard class.
Accordingly, these specifications cover moderate hazard class only.
1.11.4 Planning
1.11.4.1 Extent of Sprinkler Protection: - But for following exceptions, sprinklers shall be provided
in the entire building or Specified in Drawing.
a) Areas, rooms, or places where the water discharged from a sprinkler may pose a
hazard.
b) Stair case and lift well.
c) Wash rooms, toilets, W.C.
d) Rooms or compartments where electric switch gear, transformer, DG sets and A.C.
plants have been installed.
1.11.4.2 In areas under (a) alternative arrangement shall be made. Any part of the building not
provided with sprinkler protection shall be separated by walls (225 mm brick or 100 mm
RCC). Fire doors not less than 2 h in fire resistance shall be provided in the opening of
such walls.
1.11.4.3 Design, Density and Assumed Maximum Area of Operation (AMAO): - This is different
for different hazards classified for moderate hazard, water discharge shall be at least 5
Itrs. / Min / m2 Over an assumed area of operation covering 360 m2.
1.11.4.4 Sprinkler Spacing, Arrangement and Locations: - Sprinkler heads may be installed on
ceiling and or side walls. For selection of number of sprinkler and their location in' a
given area, following factors shall be considered.
a) Maximum Area Coverage per Sprinkler
i. Side wall sprinkler - 9 m²
ii. Ceiling sprinkler - 12 m²
b) Maximum Distance between Sprinklers.
iii. Side wall sprinkler - 3.4 m
iv. Ceiling sprinkler - 4 m
v. Minimum Distance between Sprinklers - 2 m
vi. Maximum distance between Sprinklers - 2 m and Boundary.
1.11.4.5 While designing sprinklers installation, the recommendation of sprinkler manufacturer
shall be considered. Typical layout of side wall sprinklers shall be as per CPWD
specification part V (Wet Riser and Sprinkler System).
1.11.4.6 Spacing below Sprinkler Heads: - Clear minimum space of 0.5 m shall be maintained
below the deflector of sprinkler head.
1.11.4.7 Location of Sprinkler in relation to Building Structure: -
a) Ceiling Sprinklers Deflector shall not be less than 150 mm and more than 300 mm below
the ceiling.
b) Side wall sprinkler defector shall· not be less than 100 mm. and not more than 150 mm.
below the ceiling.
c) If depth of a beam in an area is less than 450 mm. distance at (i) and (ii) shall be
maintained and provision of beam shall not be considered. If the depth of a beam in an
area is more than 450 mm, then the beam shall be regarded as a boundary.

d) Concealed Spaces: - Spaces between roofs and ceiling more than 0.8 m deep shall be
sprinkler protected as follows: -
i. Sprinkler heads shall be provided considering the space as any other area in the
building.
ii. Sprinkler heads may be connected individually with the range / distribution pipes
below, which shall be sized by taking the room and concealed space sprinklers
cumulatively.
iii. Sprinkler heads may be connected with independent range / distribution pipes
connected with common feed pipe. The common feed pipes shall be not less than
65 mm dia.
e) Obstruction below Sprinklers: -Sprinklers shall be fitted under the following types of
obstruction which are either:
iv. More than 0.8 m. wide and less than 150 mm. from the adjacent walls or partitions.
OR
v. More than 1 m. wide.
1.11.4.8 Pipe Sizing and Design: -Sprinkler heads shall be connected with pipe lines
permanently charged with water. Depending upon location of sprinkler heads and site
conditions, sprinkler heads may be connected with range and distribution pipes. The
pipes connecting the sprinkler heads are to be sized depending upon number of
sprinkler heads and arrangement of their connection. Main elements of a sprinkler
installation shall be as per CPWD specification part V (Wet Riser and Sprinkler System).
Various pipes connecting the sprinkler heads are termed as below:
a) Range Pipe.
b) Distribution Pipe.
c) Main Distribution Pipe.
d) Riser.
1.11.4.9 Sizes of pipes are to be calculated from various tables and hydraulic calculations given
in IS: 15105. Some guide lines are given below.
a) Pipe less than 25 mm. dia is not to be used.
b) There shall not be more than 6 (Six) sprinklers in any range.
1.11.4.10 Typical pipe sizes "for sprinkler installation" shall be as per CPWD specification part
V (Wet Riser and Sprinkler System).
1.11.5 Components of sprinkler system: - Following types of valves are used in the
installations:
a) Stop Valve.
b) Test Valve.
c) Drain Valve.
d) Check Valve.
e) Installation Valve and Alarm Valve.
f) Alarm Device.
g) Pressure Gauges.

1.11.6 The location of above valves shall be as under.

1.11.6.1 Main Stop Valve: -
a) Only one main stop valve shall be provided immediately after main alarm valve at a
location which is readily accessible.
1.11.6.2 Test Valve: -
a) For testing hydraulic alarm or electric alarm by drawing water from downstream side,
test valve shall be connected with downstream of the water flow alarm.
1.11.6.3 Drain Valve: -
a) For drainage of system, drain valve 50 mm. dia shall be provided down stream of installation
valve / stop valve or any subsidiary stop valve. A common valve can perform the
functions of test and drain. The outlet shall be connected with a 50 mm dia G.I. drain
pipe along with riser pipes shall be as per CPWD specification part V (Wet Riser and
Sprinkler System).
1.11.6.4 Check Valve: -
a) Check valve shall be provided where more than one water supply is available and same
shall be fitted on each water supply pipe.
1.11.6.5 Installation and Alarm Valve: -
a) A sprinkler installation shall be fitted with suitable main installation valve to control water
supply to the installation. The valve set shall comprise of following:
i. A main stop valves.
ii. An alarm valve.
iii. A water monitor alarm gong.
b) The main stop valve shall be placed in the vicinity of the main entrance of the protected
area at an easily accessible place. The valve shall be secured open by a pad locked
and protected against damage. A location plate shall be fixed near the valve bearing
the following words in raised letters: -
i. Sprinkler
ii. Stop valve
c) Alarm valve shall be fitted on the main supply pipe immediately after the main control
valve and before any connection is taken off to supply any part of the installation.
d) Alarm Device: -
i. Water monitor alarm suitable for sprinkler service shall be provided very close to
the installation and alarm valve. This alarm shall be provided on the outside of an
external wall. Strainer shall be fitted between the motor nozzle and the alarm valve
connection. The water outlet shall be positioned so that any flow of water can be
seen. The alarm device shall provide audibility level of 85 dB above the back ground
noise level.
1.11.6.6 Pressure Gauges: -
a) Pressure gauges shall be provided at each of the following points.
i. Immediately downstream of the alarm valve.
ii. Immediately up stream of the main stop valve.
b) Stop cock shall be provided before pressure gauges for removal without interruption of
water supply of the installation. Pressure gauges shall be as per IS:3624.

1.11.6.7 Pre action valve: -

a) Pre-action valve body, all threads, inlet & outlet shall be as per BS4504:16 / 11 R.F.
suitable for a maximum working pressure of 16 bar. Material of construction shall be
Cast Iron as per BS1452 Grade 260.
1.11.7 Sprinklers type
1.11.7.1 Sprinklers shall be as per IS: 9972 and following types.
a) According to type of discharge as per page 90 of CPWD specification part V (Wet Riser
and Sprinkler System).
i. Conventional pattern.
ii. Spray pattern.
iii. Side wall pattern.
b) According to mounting pattern.
i. Pendent sprinkler.
ii. Up right sprinkler.
iii. Horizontal sprinkler.
iv. Ceiling sprinkler.
c) According to Release Mechanism.
i. Fusible element sprinkler.
ii. Glass bulb sprinkler.
d) According to Orifice Size
i. 10 mm
ii. 15 mm.
iii. 20 mm.
e) According to Temperature Rating. Sprinkler shall have one of the following temperature
ratings and shall be correspondingly colour coded.
i. Fusible Link Type
Temp. Rating °C Colour code
68 / 74 Natural
93 / 100 White
141 Blue
182 Yellow
227 Red
ii. Glass Bulb Type

Temp. Rating °C Colour code
57 Orange
68 Red
79 Yellow
93 Green
141 Blue

182 Maroon
204 / 260 Black
1.11.8 Selection of temperature rating

Temperature rating of a sprinkler should not be less than 30° C more than the highest
anticipated temperature of the location of installation. Under glazed roofs or where there
are roof sheets of PVC or similar plastic material, sprinkler shall be rated 68 / 79°C.
1.11.9 Selection of orifice size
In moderate hazard applications, sprinklers of orifice size 15 mm. shall be used.
1.11.10 Inspection and test valve assembly
Inspection and testing of the automatic starting of the sprinkler system shall be done by
providing an assembly consisting of gunmetal valves, gunmetal sight glass, bye-pass
valve, and orifice assembly as per approved drawing.
1.11.11 Flow switch
Flow switch shall have a paddle made of flexible and sturdy material of the width to fit
within the pipe bore. The terminal box shall be mounted over the paddle / pipe through a
connecting socket. The switch shall be potential free in either NO or NC position as
required. The switch shall be able to trip and make / break contact on the operation of a
single sprinkler head. The terminal box shall have connections for wiring to the
Annunciation Panel. The flow switch shall have connections for wiring the seat shall be
of S.S to the Annunciation Panel. The flow switch shall have IP: 55 protections. The flow
switches work at a triggering threshold bandwidth (flow rate) of 4 to 10 GPM. Further, it
shall have a “Retard” to compensate for line leakage or intermitted flow. The contractor
to interface with Electrical Contractor for providing conduct for flow switch cable on
required.
1.11.12 Size of installations
The number of sprinklers in an installation (excluding sprinklers provided in concealed
spaces) shall not exceed 1000 Nos. As far as possible one area shall be controlled by
one installation and alarm valve. If the area is quite large, more than one installation and
alarm valves should be planned. Details of area controlled by installation valves shall be
exhibited near the installation valves. If there are more than one block in a campus, each
block shall be provided with different installation and alarm valve.
1.11.13 Protection of sprinklers
Any sprinkler installed in a position of risk or accidental damage shall be fitted with a
metal guard suitable for sprinkler service.
1.11.14 Water supply arrangement for sprinkler
Refer Pumps section of this chapter
1.11.15 Water Storage Tank
The water storage tank shall be combined for other firefighting system and sprinkler
installation.
1.11.16 Annunciation panel and alarm for sprinkler
Electrically operated alarm shall be provided for indication of operation of sprinkler in an
area. Water flow switches shall be installed in main distribution pipes which shall be wired
to sprinkler annunciation panel. In the event of operation of a sprinkler, the flow switch
will operate and give signal to the annunciation panel to indicate operation of sprinkler in

the area. This will initiate an electrically operated alarm. The system shall be independent
of fire alarm system.
Construction details
a) The Panel shall be fabricated out of not less than 1.6 mm thick MS sheet and powder
coated after 7 tank treatment process and shall be totally enclosed dust damp and vermin
proof. Suitable knockout shall be provided for the entry of cables. The panel shall be
designed such that the equipment for power supply, battery charging is housed in
independent compartments. Sealed maintenance free batteries shall also be
accommodated inside the panel.
b) Indicating lamps control switches, buttons and fuses shall be suitably located in. the front
and properly labelled.
c) The indicating lamps shall be LED type of following colours. The flow switch operation
conditions shall be indicated by twin lamps.
i. Red to indicate flow switch operation.
ii. Amber to indicate fault condition.
iii. Green to indicate healthy condition.
d) The test buttons to test the indication lamps shall be provided.
e) The panel shall be solid state type or microprocessor type as indicated in the tender.
f) The primary function of the panel shall be to respond automatically to the operation of
one or more flow switches to give alarm and to indicate area / areas where the device
has activated. The operation of one or more flow switches shall result in simultaneous
alarm given by the following: -
iv. External alarm hooter (s).
v. A visible indication on panel.
vi. Audible alarm on panel itself (common for all zones.)
g) The panel shall indicate the fault within the system and immediate fault warning shall be
given by an audible and visible signal on the panel in case of open circuit, short circuit,
and earth fault in cable between flow switch and annunciation panel.
h) The panel shall be complete with mimic diagram for the areas covered by different flow
switches. The layout of mimic diagram shall be got approved from Engineer.
i) Battery backup with trickle cum boost charger shall be provided for operation of the
system. Indication of mains failure and low battery voltage shall be provided. The
batteries shall be sealed maintenance free. The capacity of the battery shall be 12 Volt 2
Nos. 24 AH each. Both batteries of 12 V shall be connected in series to make it 24 V. All
standard accessories shall be provided.
1.11.17 Installation
a) The installation shall be carried out as per Article (Pipe work) and Article (Installation,
Testing and Commissioning). Following additional points are to be taken care for sprinkler
installations.
b) For fixing sprinkler heads, 15 mm. dia M.S. Socket is to be welded to range pipes at the
locations as per drawings. Dead plug shall be fixed in the socket.
c) If sprinkler head is to be provided away from range pipe, M.S. Pipe nipple of suitable size
be used to extend the sprinkler head and socket is welded at desired location.
d) After completion of work in sections, pressure testing at 7.5 kg / cm2 pressure shall be
carried out for 24 hrs.

e) After completion of the entire work, pressure testing of entire pipe work shall be carried
out for 24 hrs at a pressure of 7.5 kg / cm2. The drop of pressure up to 0.5 kg / cm2 shall
be accepted.
f) The lines shall be flushed before completion of building work so that any foreign matter
which might have entered the system is taken out. The pressurization pump (Jockey
Pump) be operated and valves opened at different locations.
g) During occupation of the building, sprinkler heads shall be provided in place of dead
plugs. Teflon tape shall be used on threaded portion. The sprinkler heads shall be
properly tightened in the socket.
h) When all sprinklers heads are installed, pressure is built up in the system by
pressurization pump slowly and in case no leak is found, desired pressure is developed
and maintained. In case any leak is detected, the same shall be attended before
pressurizing the system further.
1.11.18 COMMISSIONING
a) As soon as the work is complete, the system shall be commissioned and made available
for use.
1.12 INSTALLATION, TESTING AND COMMISSIONING
1.12.1 Scope
a) This chapter covers the requirement of Installation, testing, and commissioning of
firefighting system.
1.12.2 Preparation and approval of drawing
a) On award of the work, the contractor has to prepare working drawings and submit to the
Engineer for approval. The work is to be executed as per approved drawings. The stage
of approval of drawings is therefore very important. All drawings should be carefully and
critically examined before approval. The requirements of various components of
firefighting system have been described in previous chapters dealing with the
components. However generally following points are to be taken care while examining
and approving the drawings.
b) Site survey should be carried out in detail.
c) In addition to building plans, layout plan along with landscape plan / horticulture plan and
other services plans should be consulted while deciding route of underground pipes from
pump house and around the building.
d) As far as possible, underground pipes are not to be laid under road, pavement, building
and long open spaces. The locations along road, foot path in earth may be preferred.
e) The location of yard hydrants, fire service inlet and fire service connection are to be
decided based on distance required as per fire hazard norms. However necessary
adjustments are to be made so that these components do not become hindrance in
vehicular movement and entrance to the building. Requirement of other building services
are also to be given consideration. Symmetry should be maintained for aesthetic
considerations.
f) Electrical Panel: -Complete wiring drawing, layout etc. are to be examined to ensure that
provisions of agreement are incorporated in the drawing. Sizes of various panels and
mounting arrangement may be decided keeping in view ease of operation and aesthetic
consideration as well.

1.12.3 Installation
a) The following precautions are to be taken during execution of the work. The pump and
motor / engine are to be perfectly aligned on the base plate so that there is no vibration
during operation. All nuts, bolts, washers shall be of adequate size and galvanized.
b) The pipe supports should be decided in a way that the weight of pipes and valves are not
transferred to the pumps and supports do not cause hindrance in movement inside the
pump house. As far as possible, floor supports may be provided in pump house.
c) All valves shall be installed at a height and in a position that their operation by right hand
is conveniently possible.
d) All pressure gauges should be installed so that the dial is vertical and is visible while
entering the pump house.
e) Electrical panels should not be installed at floor level. The panels shall be sufficiently
raised above ground level. If panels are to be mounted on wall, an angle iron frame shall
be provided so that at least 75 mm space is left behind the panels. The panels shall be
easily approachable.
f) Cable trays are to be used for laying of power and control cable inside pump house. No
cable is to be laid at floor level / in trench. Cable tray layout should give neat appearance.
All cable tray shall be adequately supported from the ceiling / floor.
g) While excavating for laying of external pipes, suitable sign board / barricading shall be
provided to ensure that no person falls in the trench.
h) The width and depth of trench shall be adequate for laying "the pipe 1m below ground
level.
i) No earth or any other matter is to be allowed to enter the pipes. The ends shall be kept
closed always.
j) The anticorrosive treatment is to be applied on the entire length pipe & fittings. The
treatment is not to be damaged.
k) Pressure testing is to be carried out in sections before filling the earth back in the trench.
l) The earth filling is to be done in layers of 20 cm each and properly rammed so as to avoid
possibility of settlement. Surplus earth / malba shall be removed from the site by the
contractor.
m) Where pipes crossing road likely to have heavy traffic, additional protection over pipe
shall be provided to ensure that pipe is not damaged.
n) External hydrants and fire service connection / inlet shall be located parallel to the nearby
road / foot path so as to give proper appearance. Foundation shall be raised from below
ground level and shall be properly plastered in plumb. The hydrants shall be facing the
road / approach. There shall be no obstruction in. approaching the hydrants for operation.
o) Risers shall be parallel to the wall and in plumb. Adequate supports shall be provided
from the wall. Opening around the pipe in slab shall be filled with CC and finished with
plaster.
p) Internal hydrant shall be provided in the centre and facing outside for ease of operation.
Sufficient space shall be provided around the handle for operation. There shall be no
hindrance in moving the first aid hose reel.
q) Terrace pipes shall be supported on Cement Concrete (1:2:4 parts for cement, sand, and
aggregate) pedestals of adequate height. The pipe route shall be such as no hindrance
is created in movement at the terrace. Pipes shall be sufficiently raised above terrace. It
is to be ensured that water proofing is not damaged during laying of pipes.

1.12.4 Testing
1.12.4.1 Initial Testing
a) During laying of pipes, the same shall be subjected to 10 kg / cm2 hydraulic pressure
for a period of 24 hours, in sections.
b) After completion of the work, all valves / fittings shall be installed in position and entire
system shall be tested for 24 hours at a pressure of 10 kg / sqcm or 1.5 time the rating
pressure. The drop of pressure up to 0.5 kg / sqcm shall be accepted.
1.12.4.2 Final Testing
a) After completion, all operation checks (as per Para '2.4.1.14' of CPWD specification part
V - Wet Riser and Sprinkler System) shall be carried out for automatic operation of the
systems. For this purpose, landing valves may be opened at different locations. The
exercise shall be repeated couple of times to ensure trouble free operation of the
system.
b) Flow Test: -The design flow of pumps shall be checked. The pump shall be operated
after opening a number of landing valves at different locations. Design pressure is to be
maintained in the pump house. Water discharge is to be measured by drop in level in
UG tank for a certain period. All pumps shall be tested one by one. The flow rate shall
be not less than as specified while maintaining the design pressure in pump house.
1.12.5 Inspection by local fire officer
After completion of the work and testing to the entire satisfaction of Engineer, the
installation shall be offered for inspection by Chief Fire Officer or his representative.
Testing as desired by the Fire Officer shall be carried out. The contractor will extend all
help including manpower during testing. The observation of Chief Fire Officer which are
a part of agreement shall by attended by the contractor.
1.12.6 Pre-commissioning
On completion of the installation of all pumps, piping, valves, pipe connection, insulation
etc. The Contractor shall proceed as follows:
a) Prior to start-up and hydraulic testing, the Contractor shall clean the entire installation
including all fitments and pipe work and the like after installation and keep them in a new
condition. All pumping systems shall be flushed and drained at least once through to get
rid of contaminating materials. All pipes shall be rodded to ensure clearance of debris,
cleaning and flushing shall be carried out in sections as the installation becomes
completed.
b) All strainers shall be inspected and cleaned out or replaced.
c) When the entire systems are reasonably clean, a pre-treatment chemical shall be
introduced and circulated for at least 8 hours. Warning signs shall be provided at all
outlets during pre-treatment.
d) The pre-treatment chemical shall:
i. Remove oil, grease and foreign residue from the pipe work and fittings.
ii. Pre-condition the metal surfaces to resist reaction with water or air.
iii. Establish an initial protective film.
iv. After pre-treatment, the system shall be drained and refilled with fresh water and left
until the system is put in to operation.
v. Details and procedures of the pre-treatment shall be submitted to the Engineer for
approval.

vi. Check all clamps, supports and hangers provided for the pipes.
vii. Check all the equipment, piping and valves coming under hot water system and
operate each and every valve on the system to see if the vales are functioning
properly. Thereafter conduct hydro test of the system.
viii. Fill up pipes with water and apply hydrostatic pressure to the system as given in the
relevant section of the specification. If any leakage is found, rectify the same and
retest the pipes.
1.12.7 Fire Protection System
a) Check all hydrant valves by opening and closing: any valve found to be open shall be
closed.
b) Check all the piping under hydro test.
c) Check that all suction and delivery connections are properly made for all pumps sets.
d) Check rotation of each motor after decoupling and correct the same if required.
e) Test run each pump set.
f) All pump sets shall be run continuously for 8 hours (if required with temporary piping back
to the tank).
1.12.8 Commissioning and Testing
a) Pressurize the fire hydrant system by running the jockey pump and after it attains the
shutoff pressure of the pump then.
b) Open bypass valve and allow the pressure to drop in the system. Check that the jockey
pump cuts-in and cuts-out at the pre-set pressure. If necessary, adjust the pressure
switch for the jockey pump.
c) Open hydrant valve and allow the water to flow into the fire water tank in order to avoid
wastage of water. The main fire pump shall cut-in at the pre-set pressure and shall not
cut-out automatically on reaching the normal line pressure. The main fire ump shall stop
only by manual push button. However, the jockey pump shall cut-out as soon as the main
pump starts.
d) When the fire pumps have been checked for satisfactory working on automatic controls,
open fire hydrant valves simultaneously and allow the hose pipes to discharge water into
the fire tank to avoid wastage.
e) Check each landing valve, male and female couplings, and branch pipes, for compatibility
with each other. Any fitting which is found to be incompatible and do not fit into the other
properly shall be replaced by the Contractor. Each landing valve shall also be checked
by opening and closing under pressure.
f) Check all annunciations by simulating the alarm conditions at site.
1.12.9 COMMISSIONING
a) Flushing the System: - Before commissioning, the entire system shall be flushed to
ensure that any earth / foreign matters which might have entered during installation are
taken out. For this, pump may be operated and valves opened at different locations.
b) As soon as the work is complete, the system shall be commissioned and made available
for use. Requirement of firefighting installations is equally important during occupation of
the building. If the building is to be occupied in part, firefighting system of building
completed shall be commissioned by isolating the system of under construction portion
of the building.

c) The firefighting system shall be maintained and manned from the very first day of its
commissioning.
d) Any defects noticed during the warranty period shall be promptly attended by the
contractor and availability of the system at all time is to be ensured.

2 CLEAN AGENT (NOVEC 1230) GAS BASED HIGH TEMPERATURE POLYMER TUBE
BASED PROTECTION SYSTEM
2.1 CLEAN AGENT (NOVEC 1230) BASED FLOODING SYSTEM FOR ELECTRICAL
PANEL PROTECTION
2.1.1 General
a) The scope covers supply, installation, testing, and commissioning of automatic clean
agent-based flooding system complete for electrical panels with flexible fire detection
tubing, cylinder, valves, integration with main fire alarm control panel for status monitoring
etc. the scope of work includes, but not limited to the following.
i. Providing direct low-pressure panel gas flooding system with flexible fire detection /
discharge tubing inside the panels.
ii. Clean agent storage cylinder for flooding gas inside the panels.
iii. Audio-visual annunciation devices for indicating incidence of fire.
iv. Any other item required to the successful commissioning of the system.
v. The Cylinder must be filled in a UL / FM / PESO approved plant.
b) The electrical panel fire suppression system shall be complete with clean agent gas
storage cylinders for required capacities, extinguishing agent as specified, fire detection
tubing, filling and end-of-line adaptors, pressure switches, control equipment, clean agent
cylinder / valve assembly, cylinder mounting bracket and all necessary accessories to
protect the electrical panel in case of fire. The system will have an interface with main fire
alarm control panel in case of fire in the concerned panel, indication of fire / discharge
status should come in main fire alarm control panel. System provider / vendor has to
submit authorization for use of clean agent / gas from the manufacturer.
2.1.2 Design Requirements
a) All the detecting devices, alarm, indicating devices, containers and other related
equipment shall have required approvals & Authorization.
b) All installations shall conform to NFPA / LPCB requirements.
c) Clean Agent should be used with below mentioned properties
i. The Clean Agent should have Zero Ozone Depletion Potential. (ODP = 0)
ii. The Clean Agent should not have Global Warming Potential of more than 1.
iii. The Clean Agent should be a low-pressure agent.
2.1.3 System Equipment
2.1.3.1 Tubing should be UL Listed.
The tubing shall be installed throughout the electrical panel with one end connected to
the top of the clean agent container valve. The tubing shall be pressurized with dry
nitrogen to minimum 195 psig and maintains the system in the “OFF” position. The tube
shall burst at temp. 1000C-1200C. Tube should be marked with OEM name. The tubing
shall perform three functions:
a) Heat Detection,
b) System Activation and
c) Clean Agent discharge.

2.1.3.2 Clean agent Container

a) Design, fabricate, certify, and stamp containers in accordance with the requirements of
NFPA (DOT / TPED). Containers shall be standard model and size for ease of
replacement and addition.
b) Each storage container shall be equipped with a nickel–plated brass valve, a pressure
gauge to monitor container pressure, and an isolation valve that interfaces with the
detection tubing. The Isolation valve shall be kept closed at all times when the container
is not in service.
c) All container valves shall be equipped with a pressure relief valve (rupture disc) device
in compliance with DOT / TPED requirements.
2.1.3.3 Technical and Installation Requirements
a) Provide sufficient amount of extinguishing agent, inert to the micro environment being
protected, considering the following when computing volume to verify suitability and to
establish design limitations:
i. Volume of hazard area.
ii. Specific volume of Clean Agent.
iii. Discharge time and flow rates.
iv. Design concentration and design factors.
v. Detector / discharge tubing placement.
b) Interface system with main fire alarm control panel and BMS.
c) All doors and holes in the enclosed / equipment should be closed or sealed to maintain
the tightness of enclosure.
d) The clean agent based Pre-Engineered automatic direct fire suppression system / each
component shall be UL / FM / LBCP / VDS approved.
e) Each clean agent pre-engineered automatic system is equipped with its own detection
/ discharge tubing. Vendor to submit detailed drawings & calculations based on NFPA
& specifications for approval.
f) The unit shall be a self-contained and shall be equipped with its own non-electric
automatic detection system to detect the fire and agent release system into the electric
panel to suppress the fire.
g) The Clean Agent is to be stored in DOT / TPED steel cylinders as a liquefied
compressed gas, super- pressurized with Dry Nitrogen to min. 195 psig at 70°F. The
ambient operating temperature range for all system components should be 0-degree C
to 54-degree C.
h) Each container is equipped with a nickel–plated brass valve, a pressure gauge to
monitor container pressure, and a quarter-turn ball valve that interfaces with the
Detection Tubing. In addition, the container valve shall be equipped with a pressure
relief (rupture disc) device in compliance with DOT / TPED requirements.
i) Provide wall-mounted painted steel bracket to mount the container / valve assembly in
a vertical (upright) position. Each bracket should be equipped with at least two integral
quick-clamp straps as per manufacturer standard practice.
j) Install equipment as indicated on the approved shop drawings, and in accordance with
requirements of NFPA-70 and NFPA-2001.
k) All the necessary accessories required for operation of system shall be part of supply
from single manufacturer and the complete system shall have proven record of

accomplishment and international third-party approvals like UL, FM, LPCB, VDS or any
other reputed certification as applicable. The system shall be designed and endorsed
by OEM.
l) The installation and commissioning of the system should be by manufacturer or their
authorised channel partner. The final connections between equipment and system
detection tubing should be under direct supervision of factory trained and certified
representative of manufacturer.
m) It shall be so designed that it does not affect the IP ratings of electrical panels. The sub-
contractor has to coordinate with manufacturer of electrical panels for provision of holes
to run the tube and brackets for mounting the tube. The entry of tube inside the panel
shall be through suitable size of connector.
n) The tubing shall be manufactured from specially processed polymer material to achieve
the desired heat detection and delivery characteristics.
o) The tubing shall be capable of working even when contaminated with oil, dust, and
debris as long as the contamination will allow the heat to pass through the tube.
p) Distribution of detection tubing shall be ensured in each compartment of the panel viz.
busbar section, switchgear section and cable alleys etc. with routing on any two sides.
mounting / installation of the detection tube to be as per manufacturer’s design.
q) The authorised vendor / OEM shall be submitting all the relevant import documents for
components (if imported) of the system to ensure authenticity and traceability.
2.1.4 DETAILS OF PANELS IN WHICH SUPRESSION SYSTEM IS TO BE PROVIDED:
The following is an Indicative list of Panels for providing Fire suppression system -
S. No. Elevated Stations
1 MDB (Main Distribution Board)
2 EPP (Essential Power Panel)
3 FPP (Fire Pump Panel)
4 EMLP (Emergency Lighting Panel)
5 DG AMF Panel
6 Active harmonic filter Panel
2.1.5 Control Box

2.1.5.1 Each unit / cylinder of the gas flooding system shall be provided with separate control
box.
2.1.5.2 The control box shall be capable of giving audio and visual alarm in the event of gas
release and shall also be compatible for interfacing with existing station fire alarm
system. It shall relay the signal to the FACP in case of release of clean agent.
2.1.5.3 The control box enclosure shall be at least IP 54 rated.
2.1.5.4 Wiring of the Control Box shall be FRLSH as per IS 694 and shall be minimum 2.5
sqmm.

2.1.5.5 The control box shall be fire red in colour having 2 mm thick CRCA sheet with powder
coated finish. The unit shall contain indication for System Healthy, Mains Healthy and
Gas Release.
2.1.5.6 The unit shall also have signal silence button. All components such as hooter, strobe,
indication lamps, chip shall be of superior make subject to approval by Engineer-in-
charge.
2.1.5.7 Third party test reports for IP and Functionality of the system to be submitted before
approval. The system shall be supplied and certified by OEM of the flooding system or
their authorized vendor.
The control box shall be provided with UPS Power supply arrangement which is to be
provided by wiring / cable with MCB controlled.

TECHNICAL
SPECIFICATIONS –
WATER SUPPLY PUMPS
WORKS
Page | 276
1 WATER SUPPLY PUMPS

1.1 GENERAL:
1.1.1 The scope of this section comprises the supply, installation, testing, and
commissioning of the entire water Supply pumps.
1.1.2 All Galvanized Iron pipes and other accessories shall be cleaned thoroughly before
application of enamel paint two coats. Two coats of primer shall be applied and
thereafter two coats of enamel paint shall be applied wherever pipe shall be used.
Each enamel paint coat should be given minimum 24 hours drying time. No thinner
shall be used. The work shall be done in professional manner and to the satisfaction
of the Engineer In charge. No extra amount shall be paid for this work and price may
be included with the relevant item itself or as per BOQ.
1.1.3 All items provided in this specification shall be provided by the Contractor and no extra
payment shall be made.
1.1.4 All nuts, bolts, washers etc. shall be of SS 304 iron for fitment of pipes, valves, and
other accessories unless and otherwise specified.
1.1.5 Contractor shall be responsible to co-ordinate the equipment and services with all
other discipline and shall produce properly coordinated shop drawings to demonstrate
the installation & comply with the performance requirement with WRD drawing,
calculations, and details.
1.1.6 WRD drawings shall take into account actual measurement and setting out
dimensions / levels obtained and determined by the Contractor on site, actual
equipment / material used, actual routing of services, co-ordination with all
installation, and site conditions / constraints.
1.1.7 The Contractor is obliged to provide fully functioning works and systems in
conformance with the requirements of the contract. In the event certain items are not
fully described or indicated in the contract, but deemed essential by the Engineer In
charge (in all reasonableness) for the performance of the works and systems then the
provision of such items shall form part of the contractors scope of works at no
additional cost to the employer.
1.1.8 All water supply pipes, valves, pumps etc. shall be blue colour.
2 SCOPE OF WORK (Within Pump Room):
a) The general character and the scope of work but not limited to specified, to be carried
out under this contract is illustrated in the drawings, specifications, detailed
engineering, and system requirement. The Contractor shall carryout and completes
the said work under this contract in every respect in conformity with Engineer in
Charge. The contractor shall furnish all labour, supply, and install all new materials,
appliances, equipment necessary for the complete provision and testing of the
complete installation as specified herein and in accordance with relevant BIS codes.
This also includes any material, appliance, equipment not specifically mentioned
herein or noted on the drawings as being furnished or installed but which are
necessary and customary to make a complete installation.
b) Without restricting to the generality of the foregoing, the Water Treatment Plant
Installations shall include the following: -
Page | 277
2.1 WATER SUPPLY PUMPS:

a) Water Supply Distribution / Lifting Pumps (Domestic / Raw water).
i. Pumps, equipment’s, pipes, valves, and accessories
ii. Connections from Water Source to UG tanks including isolation valves, strainer,
and water meter etc.
iii. Distribution System including filling to domestic, raw overhead tank from water
lifting pumps delivery header located at plant room.
iv. Level controller for underground & overhead tank.
b) All incidental jobs connected with water supply pumps services installation such as
cutting chases in concrete and brick and making good, cutting / drilling holes through
walls, floors and grouting for fixing of fixtures, equipment foundation as per GA
Drawings, Structural supports & other supports as required at site shall be part of
Water supply pumps works for the material / equipment’s.
c) Pump Motor shall be minimum IE-3.
d) Contractor shall submit the samples / catalogues of each material / equipment giving
technical data. Only after written approval of samples / catalogues from Engineer In
charge, the Contractor shall place the order for the material equipment.
e) Preparation of WRD drawings - Contractor shall submit the detailed shop drawings
after coordinating with structural, architectural, and other services drawings. All
structural openings & pipe sleeves shall be identified.
f) Before starting the work at site, the contractor shall examine all services drawings
and report to architect / consultant for discrepancies and obtain clarifications. Any
work done without regard or consultation with other trades, shall be removed by the
contractor without additional cost to the client.
g) Contractor shall temporarily cover & protect all equipment’s and open pipe ends etc.
It is the responsibility of the contractor to protect all equipment’s until the time of
testing, commissioning & handing over to the clients.
h) Testing & commissioning of all systems including submission of test reports.
i) Contractor shall submit operation and maintenance manual for all equipment’s /
systems etc. Framed operating & maintenance instructions shall be provided in plant
room. Marking on water tanks, pumps and water pipe should be done by as per
approved design by Engineer In charge
j) Completion / As Built Drawing: On completion of the work the Contractor shall submit
to the Engineer-in-Charge, General layout drawings, drawn at approved scale
indicating layout of pump house piping and its accessories “As installed ". These
drawings shall in particular give the following:
i. General layout of pump room.
ii. Panels and other equipment location and sizes etc.
iii. Complete schematic of pump room with coordinated with civil layout pump foundation
etc.
iv. Location of earth pipes, and chambers etc.
Page | 278
v. Plumbing pipe line details of whole station including location of valves and water
meter etc.
2.2 Documents
a) The Contractor shall submit to the Engineer-in-Charge, the following documents on
completion of the work and before issuance of completion
i. Warranty for equipment installed.
ii. Test certificates.
iii. Catalogues.
iv. Operation and maintenance manuals.
b) The Contractor shall be fully responsible and shall carry out following activities: -
i. Submission of working drawing.
ii. Obtaining the approval of drawings.
iii. Obtaining the final no objection / completion certificate after submitting required
documents.
2.3 General Requirements:
a) All materials shall be new of the best quality conforming to specifications and subject
to the approval of Engineer In charge.
b) All equipment shall be of the best available as per approved make List.
c) All equipment shall be installed on suitable foundations, true to level and in a neat
workman like manner.
d) Equipment shall be so installed as to provide sufficient clearance between the end
walls and between equipment to equipment.
e) Piping within the pump house shall be so done as to prevent any obstruction in the
movement within the pump house.
f) Each pumping set shall be provided with a Ball Valve / butterfly valve on the suction
and delivery side and a dual plate type return (NRV) valve on the delivery side.
g) All delivery headers / hanging pipes within the pump house shall be floor / ceiling
support using GI supports and approved anchor fasteners.
3 WATER SUPPLY PUMPS
3.1 General
The various items of the water circulating system shall be complete in all respects and comply
with the specification given below.
3.2 Pump Sets
Pumps capacity shall be as per detail design requirement. Contractor shall submit the detail
design calculation for pump head etc and take approval from engineer in charge.
Page | 279
3.3 Vertical Inline Pumps

3.3.1 Scope:
This specification covers the design, materials of construction, features, performance, and
testing of the vertical In-line pumps. Pump shall be suitable for the purpose they are
intended.
3.3.2 Codes and Standards:
The design, material, construction, manufacture, inspection, testing, and performance of
vertical inline pumps shall comply with all currently applicable statutes, regulations, and
safety codes in the locality where the Equipment will be installed. The Equipment supplied
complies with the latest applicable Indian, American, or equivalent Standards.
Page | 280
IS 1200-1992 Mode of Measurement
IS 1172-1993 Code of Basic requirements for water supply drainage and sanitation
IS 2064- 1993 Selection, installation, and maintenance of sanitary appliances – Code

of practice
IS 2065 -1983 Code of practice for water supply in buildings
IS 15778 -2007 Code of practice for CPVC pipes
IS 2379-2006 Colour code for the identification of pipe lines.
IS 13095-2019 Butterfly Valves for general purpose
IS 10221-2008 Code of practice for coating and wrapping of underground mild steel
pipelines
IS: 2629 -1985 Recommended practice for hot dip galvanizing on iron and Steel.
3.3.3 General:
The pumps shall be single-stage, close-coupled, in-line suction and discharge ports of
identical Diameter with top-pull-out design. Hence, the rotating unit can be removed and
serviced without disconnecting the suction and discharge piping.
The pump and motor shall be factory assembled at the pump manufacturer’s facility.
Installation instructions shall be included with pump at time of shipment. The pump
manufacturer shall have complete unit responsibility.
3.3.4 Features of Construction:
a) Pump Casing:
i. Pump spiral volute casing shall be of in-line design robust construction with
integrally-cast base at bottom in order to transmit pipe load to the base and
foundation (Small pumps can be without base). Liquid passages in the casing
shall be smooth finish to ensure high Efficiency.
ii. Pump casing shall capable of withstanding 1.5 times the design pressure.
iii. Pump casing shall be of SS-316 and capable of withstanding to the maximum
pressure developed by the pump.
iv. Flange dimensions are in accordance with EN 1092-2 or ISO 7005-2. Pump
casing shall be fitted with bronze wear ring.
b) Impeller:
i. The impeller shall have SS-316 enclosed type with smooth surface finish for
minimum frictional loss. This ensures high Efficiency. Impeller shall be keyed to
the shaft and secured by impeller lock nut.
Page | 281
ii. All impellers are dynamically balanced to ISO 1940-1: Grade G6.3. The thrust
balancing can be of balancing holes or back vanes.
iii. The direction of rotation of the impeller shall be clockwise when viewed from the
drive end.
c) Shaft:
i. Pump shaft shall be austenitic stainless steels according to EN 1.4301 / AISI SS-
316 stub shaft and the same shall be ground and polished to final dimensions
and be adequately sized to with stand all stresses, hydraulic loads, vibrations and
torques coming in during operation.
ii. Shaft run-out shall be limited at the seal face and at the impeller to 0.05 mm.
Shaft shall be provided with mechanical seal as default fitment to provide leak
free operation.
d) Wear Rings:
i. A renewable type bronze wearing ring shall be provided in the pump casing to
maintain close running clearance and to minimize leakage and recirculation
losses and to ensure high pump efficiency.
e) Mechanical Seals:
i. The stuffing box cavity shall be sealed off at the pump shaft by an internally or
externally-flushed Mechanical seal with carbon / silicon carbide face material,
suitable for continuous operation up to140 °C.
f) Bearings:
i. As radial and axial forces are absorbed by the fixed bearing in the motor drive-
end, the pump requires no bearing. Bearing shall be effectively sealed to prevent
loss of lubricant or entry of dust or water.
g) Coupling:
The pump coupling should be of close-coupled type with stub shaft.
Stub shaft is a short rotating shaft that extends, cantilevered out past its
supporting bearings in the main structure of a power transmission subsystem.
Stub shafts are used as input and / or output connections, which allows for a
compact assembly where their short length provides just enough material for
attachment of a coupling
h) Motors:
i. Motor shall be a flange mounted, totally enclosed fan-cooled motors with main
dimensions according to IEC standards. Electrical tolerances are to IEC 60034.
Motor shall be high-efficient type. Motor shall be to with IP 55 enclosure. The
class of insulation shall be F with temperature rise limited to Class B.
ii. Motor shall be suitable for operation on a 415 V (± 10% variation), 50Hz ± 5%,
and 3 phase AC supply. Pump and motor shall be factory aligned, and shall be
realigned by the contractor as per factory recommendations after installation.
i) Name plates:
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Each pump shall be provided with a name plate indicating the following details:
i. Pump type designation
ii. Pump Model
iii. Rated flow
iv. Rated head
v. Pressure rating / max temperature
vi. Rated speed
j) Working pressure:
Maximum allowable working pressure for all the pressure containing parts shall in no
case be less than the maximum discharge pressure produced by the pump at shut off
(including tolerances), at the max suction pressure, for the maximum impeller
diameter and the maximum continuous speed. Pump shall be rated at actual required
working pressure but not less than 16 bar working pressure.
k) Painting:
The equipment shall be thoroughly cleaned and greased. All rust sharp edges and
scales shall be removed. All external and exposed cast iron parts of pumps have an
epoxy-based coating made in a cathodic electro-deposition (CED) process which is
high-quality dip-painting process and which would prevent rusting and corrosion. The
colour code for the finished product is NCS 9000 / RAL 9005. The pump shaft shall
not be painted.
l) Pump Foundation
Foundation of pumps in pump rooms should be of considerable height so that these
are not submerged in case of overflow.
3.4 Pump & Motor Selection:
The pumps shall be factory manufactured, assembled, and hydrostatically tested as
per Hydraulic Institute standards in an ISO 9001 approved facility. Motor should be
selected as non-over-loading type.
3.4.1 Inspection & Testing of Various Items:
Following inspections and tests as per relevant IS standards shall be carried out.
a) Hydrostatic Testing
b) Performance Test (Single point / Duty point)
c) Dynamic balancing for pump impeller.
3.4.2 Tender Drawings:
The following drawings shall be submitted by the Contractor:
a) Preliminary outline dimensional drawing of pump and motor (Suction and discharge
Connections)
b) Performance curves (capacity Vs total head, efficiency, NPSH and KW requirement)
ranging from zero to maximum capacity.
c) Technical data sheet for Pumps
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4 VALVES AND OTHER ACCESSORIES

4.1 Ball Valve
a) The Ball Valve shall be made from forged brass and tested to 25 Kg / cm2 pressure.
The valve shall be internally threaded to receive pipe connections.
b) The Ball shall be made from brass and machined to perfect round shape and
subsequently chrome plated. The seat of the valve body- bonnet gasket and gland
packing shall be of Teflon.
c) The handle shall be of chrome-plated steel with PVC jacket. The handle shall also
indicate the direction of `open' and `closed' situations. The gap between the ball and
the Teflon packing shall be sealed to prevent water seeping up to 14 Kg / cm2
pressure.
d) The handle shall also be provided with a lug to keep the movement of the ball valve
within 90 degree. The lever shall be operated smoothly and without application of
any unnecessary force.
4.2 Non-Return Valve
a) Non-return valves shall be cast iron spring action dual plate type. An arrow mark in
the direction of flow shall be marked on the body of the valve. The valve shall be
designed as per API standard.
b) The Valve shall be of cast iron to IS: 210 Gr. FG 260 body.
c) The gasket shall be of high-quality rubber. At high pressure of water flow the flapper
shall seat tightly to the seat. The Valve shall be capable of handling pressure up to
16 kg / cm2.
d) Testing shall as per reluctant IS / BS / API Standard.
Ref standard Designed and tested as per API 594 and API
598 or equivalent standard
Pressure Rating 16 bars
Type Dual plate wafer type
Plates SS-316
Seal EPDM
Hinges and stop pin SS-316
Spring SS-316
4.3 Butterfly Valve

a) The butterfly valve shall be suitable for waterworks and tested to minimum of 16 kg
/ cm2 pressure. The Valves shall fulfil the requirements of IS 13095.
b) The body shall be of cast iron to IS: 210 Gr. FG 260 in circular shape and of high
strength to take the minimum water pressure of 10 kg / cm2. The disc shall be SS-
316.
c) The valve seat shall be of integrally moulded high-grade elastomer or EPDM. The
Valve in closed position shall have complete contact between the seat and the disc
throughout the perimeter. The elastomer rubber shall have a long life and shall not
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give away on continuous applied water pressure. The shaft shall be of stainless-
steel SS-316.
d) The Valve shall be fitted between two flanges on either side of pipe flanges. The
Valve edge rubber shall be projected outside such that they are wedged within the
pipe flanges to prevent leakage.
e) The Valves up to and including DN150 shall be lever operated and valves in excess
of DN150 shall be provided with gear operated.
4.4 Strainers
a) Stainless steel (Y type) strainers shall have minimum 1.6 mm thick screen with 3
mm perforations. Strainers shall be provided with flanges.
b) The screen shall SS 316 material.
c) The flanged ends shall be confirming to ASME B 16.5.
5 GI PIPES and FITTINGS:

a) All pipes inside the pump room and where specified, outside the building shall be
galvanized steel tubes conforming to IS: 1239 of Class specified. When Class is not
specified, they shall be heavy duty.
b) Fittings shall be of malleable cast iron galvanized of approved make. Each fitting shall
have manufacturer’s trade mark stamped on it. Fittings for G.I pipes shall include
couplings, bends, tees, reducers, nipples, unions, bushes etc. Fittings etc. shall
conform to IS: 1879. (Part 1 to X) 1987.
c) Pipes and fittings shall be jointed with screwed joints using Teflon tape suitable for
water pipes. Care shall be taken to remove burr from the end of the pipe after cutting
by a round file. All pipes shall be fixed in accordance with layout and alignment shown
on the drawings. Care shall be taken to avoid air pockets. Necessary vents and drains
shall be provided at all high and low points respectively. G.I pipes inside toilets shall
be fixed in wall chases well above the floor. No pipes shall be run inside a sunken
floor as far as possible. Pipes may be run under the ceiling or floors and other areas
as shown on drawings.
5.1 Pipe Support:
a) All pipes clamps, supports, hangers, pipe support shall be factory made galvanized
MS steel or alternatively galvanized after fabrication to suit site requirement pipe
supports.
b) G.I pipes in shafts and other locations shall be supported by G.I clamps of design
approved by the Architect / Consultants. Pipes in wall chases shall be anchored by
iron hooks. Pipes at ceiling level shall be supported on structural clamps fabricated
from MS structural. Pipes in shafts shall be supported on slotted angles / GI channels
as specified / as directed.
5.2 Anchor Fasteners
a) All pipe supports, hangers and clamps to fixed on RCC walls, beams, columns, slabs,
and masonry walls 230 mm thick and above by means of galvanized expandable
anchor fasteners in drilled holes of correct size and model to carry the weight of pipes.
Drilling shall be made only by approved type of power drill as recommended and
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approved by manufacturer of the anchor fasteners. Failure of any fastening devices

shall be the entire responsibility and contractor shall redo or provide additional
supports at his own cost. He shall also compensate the Client for any damage that
may be caused by such failures.
5.3 Flanges:
a) Flanged connections shall be provided on pipes as required for maintenance / ease
in dismantling or where shown on the drawings, all equipment connections as
necessary and required or as directed by the architect / consultants. Connections
shall be made by the correct number and size of the SS 304 nuts / bolts as per
relevant IS Standards and made with 3 mm thick insertion rubber washer / gasket
5.4 PIPING INSTALLATION FOR GI PIPE:
a) Tender drawings indicate schematically the size and location of pipes. The contractor
on the award of the work shall prepare detailed working reference drawings, showing
the cross-section, longitudinal sections, details of fittings, locations of isolating and
control valves, drain valves and all pipe support, structural supports. He must keep in
view the specific openings in buildings and other structures through which pipes are
designed to pass.
b) Piping shall be properly supported on or suspended from clamps, hangers as
specified and as required. The contractor shall adequately design all the brackets,
saddles, anchors, clamps, and hangers and be responsible for their structural
sufficiency.
c) Pipe supports shall be of GI steel, adjustable for height. Where pipe and clamps are
of dissimilar materials a gasket shall be provided in between. Spacing of pipe
supports shall not exceed the following:
Sr. No. Pipe Size Spacing between Supports
1 Up to 12 mm 1500 mm (1.5m)
2 15 to 150 mm 2000 mm (2.0 m)
3 150 mm & over 2500 mm (2.5m)
d) Vertical risers shall be parallel to walls and column lines and shall be GI and plumb.
Risers passing from floor to floor shall be supported at each floor by clamps or collars
steel structural supports attached to pipe and with a 15 mm thick rubber pad or any
resilient material. Where pipes pass through the terrace floor, suitable flashing shall
be provided to prevent water leakage. Risers shall have a suitable clean out at the
lowest point and air vent at the highest point.
e) Pipe sleeves, 50 mm larger diameter than pipes, shall be provided wherever pipes
pass through walls and slabs, and annular space filled with fiberglass and finished
with retainer rings or as per approved by engineer in charge.
f) All pipe work shall be carried out in a workman like manner, causing minimum
disturbance to the existing services, buildings, roads, and structure. The entire piping
work shall be organized in consultation with other agencies work so that particular
area work shall be carried out in one trench.
g) Cut outs in the floor slab for installing the various pipes are indicated in the drawings.
Contractor shall carefully examine the cut outs provided and clearly point out
wherever the cut outs shown in the drawings, do not meet with the requirements.
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h) The contractor shall make sure that the GI clamps, steel structural supports, brackets,
GI clamp saddles and hangers provided for pipe supports are adequate. Piping layout
shall take due care for expansion and contraction in pipes, and include expansion
joints where required.
i) All pipes shall be accurately cut to the required sizes in accordance with relevant
codes and burrs removed before laying. Open ends of the pipes shall be closed as
the pipe is installed to avoid entrance of foreign matter. Where reducers are to be
made in horizontal runs, eccentric reducers shall be used for the piping to drain freely.
In other locations, concentric reducers may be used.
6 CPVC Pipes and Fittings:
CPVC Water Distribution System shall be CPVC (Chlorinated Polyvinyl Chloride)
Water Supply Piping System with pipe as per CTS SDR-11 at maximum working
pressure of 400 psi (28.1 Kg / cm2) at 23oC and 100 psi (7.03 Kg / cm2) at 82oC (from
½” - 2”), using solvent welded CPVC fitting i.e. Tees, elbows, couplers, unions,
reducers, bushing etc. including transition fitting (connection between CPVC and
metal pipe / G.I.) i.e. Brass adapter (both male and female threaded) all conforming
to ASTMD-2846 with only CPVC solvent cement conforming to ASTMF-493 - with
only Clamps / structural metal supports as required / directed at site including cutting
chases and filling the same with cement concrete / cement mortar as required. All
termination points for installation of faucets shall have brass termination fittings.
Installation shall be to the satisfaction of consultant / engineer in charge /
manufacturers of pipes and fittings.
Outside Diameters and Wall Thicknesses for CPVC 4120, SDR 11 Plastic Pipes
Nominal Size Outside Diameter, in. (mm) Wall Thickness, in. (mm)
(in.) (mm) Average Tolerance Minimum Tolerance
½ 15 0.625 (15.9) + 0.003 (+ 0.08) 0.068 (1.73) + 0.020 (+ 0.51)
¾ 20 0.875 (22.2) + 0.003 (+ 0.08) 0.080 (2.03) + 0.020 (+ 0.51)
1 25 1.125 (28.6) + 0.003 (+ 0.08) 0.102 (2.59) + 0.020 (+ 0.51)
1-1 / 4 32 1.375 (34.9) + 0.003 (+ 0.08) 0.125 (3.18) + 0.020 (+ 0.51)
1-1 / 2 40 1.625 (41.3) + 0.004 (+ 0.10) 0.148 (3.76) + 0.020 (+ 0.51)
2 50 2.125 (54.0) + 0.004 (+ 0.10) 0.193 (4.90) + 0.023 (+ 0.58)
Pressure Ratings for CPVC, SDR 11 Plastic Pipes

Nominal Size Pressure Rating, PSI (Kg / cm2)
o
(in.) (mm) 73.4 F (23oC) 180oF (82oC)
½ 15 400 (28.1) 80 (7.0)
¾ 20 400 (28.1) 100 (7.0)
1 25 400 (28.1) 100 (7.0)
1-1 / 4 32 400 (28.1) 100 (7.0)
1-1 / 2 40 400 (28.1) 100 (7.0)
2 50 400 (28.1) 100 (7.0)
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6.1.1 Joining CPVC Pipes and Fittings:
 Cutting:
Pipe shall be cut with either with a wheel type plastic pipe cutter or hacksaw blade,
and care shall be taken to make a square cut, which provides optimal bonding area
within a joint.
 Deburring / Bevelling:
Burrs and fillings should be removed from the outside and inside of pipe with a pocket
knife or file otherwise burrs and fillings may prevent proper contact between pipe
and fittings during assembly.
 Fitting / Preparation:
A clear dry rag / cloth should be used to wipe dirt and moisture from the fitting sockets
and tubing end. The tubing should make contact with the socket wall 1 / 3 or 2 / 3 of
the way into the fitting socket.
 Solvent Cement Application:
CPVC solvent cement conforming to ASTM - F493 should be used for joining pipe
with fittings. An even coat of solvent cement should be applied on the pipe end and
a thin coat inside the fitting socket, otherwise too much of cement solvent can cause
clogged water ways.
 Assembly:
After applying the solvent cement on both pipe and fitting socket, pipe should be
inserted into the fitting socket within 30 seconds and rotating the pipe 1 / 4 to ½ turn
while inserting so as to ensure even distribution of solvent cement with the joint. The
assembled system should be holded for 10 seconds (approximately) in order to allow
the joint to set up.
 Set and Cure Times: remake the joint to avoid potential solvent cement set and
cure times shall be strictly adhered to as per the below mentioned table.
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Minimum cure prior to pressure testing at 150 psi:

Ambient Pipe Sizes
Temperature During
½” - 1” 1 ¼” - 2”
Cure Period
Above 15 C 1 Hr 2 Hrs
4 - 15 C 2 Hrs 4 Hrs
Below 4 C 4 Hrs 8 Hrs
Special care shall be exercised when assembling flow guard systems in extremely
low temperature (below 4 C) or extremely high temperature (above 45 C) in
extremely hot temperatures, make sure that both surfaces to be joined are still wet
with cement solvent when putting them together.
a. Testing:
Once an installation is completed and cured or per above mentioned
recommendations, the system should be hydrostatically pressure tested at 150
psi (10 bar) for one hour. During pressure testing, the system should be filled
with water and if a leak is found, the joint should be cut out and replacing the
same with new one by using couplers.
b. Transition of flow guard CPVC to Metals:
When making a transition connection to metal threads, special Brass (Male and
female adapters) should be used.
c. Threaded Sealants:
Teflon tap shall be used to make threaded connections leak proof.
Solvent Cement:
CPVC solvent cement conforming to ASTMF 493 should be used for joining pipe
with fittings and valves. CPVC cement solvent have a minimum shelf life of 1
year. Solvent have a minimum shelf life of 1 year. Aged cement solvent will often
change colour or began to thicken and become gelatinous or jelly to like and
when this happens, the cement should not be used. The cement solvent should
be used within 30 days after opening the company’s seal and tightly close the
seal after using in order to avoid its freezing. The feezed cement solvent should
be discarded immediately and fresh one should be used.
d. Hangers and Supports:

Most hangers designed for metal pipe are suitable for flow ground. Hangers
should not have rough or sharp edges which come in contact with the tubing.
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Supports should be as per the below mentioned table:

Horizontal and Vertical Support
Spacing
Size of pipe 21 deg. C (70oF) 49 deg. C (120oF) 71 deg. C 82 deg. C
(160oF) (180oF)
Inch (mm) Ft. cm Ft. cm Ft. cm Ft. Cm
½” (15) 5.5 (167.7) 4.5 (137.16) 3.0 (91.44) 2.5 (76.2)
¾” (20) 5.5 (167.7) 5.0 (152.4) 3.0 (91.44) 2.5 (76.2)
1” (25) 6.0 (182.88) 5.5 (167.7) 3.5 (106.68) 3.0 (91.44)
1 ¼” (32) 6.5 (198.12) 6.0 (182.88) 3.5 (106.68) 3.5 (106.68)
1 ½” (40) 7.0 (213.36) 6.0 (182.88) 3.5 (106.68) 3.5 (106.68)
2” (50) 7.0 (213.36) 6.5 (198.12) 4.0 (121.92) 3.5 (106.68)
7 PUDDLE FLANGE
Contractor shall provide all inlets, outlets, drains, vents, overflows, control valves and all such
other piping connections including level indicator to water storage tanks as called for. All
pipes crossing through RCC work shall have puddle flanges fabricated from MS / GI pipes of
required size and length and welded to 6 / 8 mm thick MS plate. All puddle flanges must be
fixed in true alignment and level to ensure further connection in proper order. Puddle flanges
are fabricated item and have to be fabricated as per standard drawing provided in drawings
or as directed by engineer in charge.
Puddle flanges will be fabricated from GI heavy grade pipes or MS heavy grade pipes with
food grade epoxy coating over it as approved by engineer in charge.
8 MOTORIZED VALVE:
Motorized valve to be installed in all the main inlet line of the terrace roof tanks with
low-level and high-level sensing probes, pressure switch, solenoid sensors, actuator
with Control panels. Motorized valve shall be of proven quality and approved sample.
Motorized valve shall be electrically operated. Motorized valve must ensure that the
terrace roof tanks are always filled up and do not go dry. There will be a bypass circuit
to the motorized valve in the inlet water line for emergency. Motorized valve will have
a valve before and after it and a bypass to it with a valve. The motorized valve must
keep the entire operations on automatic mode. All schemes to be approved by
Engineer in Charge.
9 WATER METERS
Water meters of approved make and design shall be supplied for installation at
locations as shown. The water meters shall meet with the approval of local supply
authorities. Suitable valves and chambers or wall meter box to house the meters shall
also be provided along with the meters.
The meters shall conform to Indian Standard IS: 779 and IS: 2373. Calibration
certificate shall be obtained and submitted for each water meter.
Provision shall also be made to lock the water meter. The provision shall be such that
the lock is conveniently operated from the top. Where the provision is designed for
use in conjunction with padlocks, the hole provided for padlocks shall be a diameter
not less than 4 mm.
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9.1 Installation of Water Meter and Stop Cock

The G.I. lines shall be cut to the required lengths at the position where the meter and
stop cock are required to be fixed. Suitable fittings shall be attached to the pipes. The
meter and stop cock shall be fixed in a position by means of connecting pipes, jam
nut and socket etc. The stop cock shall be fixed near the inlet of the water meter. The
paper disc inserted in the ripples of the meter shall be removed. And the meter
installed exactly horizontal or vertical in the flow line in the direction shown by the
arrow cast on the body of the meter. Care shall be taken that the factory seal of the
meter is not disturbed. Wherever the meter shall be fixed to a newly fitted pipe line,
the pipe line shall have to be completely washed before fitting the meter.
*******
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TECHNICAL
SPECIFICATIONS –
EOT CRANES & AIR
COMPRESSED SYSTEM
Page | 292
1. EOT CRANES & AIR COMPRESSED

SYSTEM
1.1 EOT
CRANES
1.1.1 General description
The specification covers the design, manufacture, supply, installation,

testing and commissioning of Electric Overhead Travelling (EOT) Cranes
to be installed in the following Workshops of Depot: -
a) Workshop Bay
b) Electric Traction Unit (ETU) Bay
c) Under floor wheel lathe
(UFWL) building d) Inspection
Bay
The contractor shall interface with the structural contractor for exact
dimensions of long travel, cross travel and height and also during
installation, testing and commissioning.
1.1.2 Technical characteristics
The technical Characteristics of the EOT

cranes are:
a) The capacity (nominal load),

b) Operating speeds in all three directions at low speed (LS) and
high speed (HS), c) Dimensional characteristics,
d) The details of classification in accordance with standards are
indicated in
Appendix1 specify the classification for framework and mechanism.
e) The movements of hoisting, traversing and long travelling shall be
operable simultaneously
f) Pendant
control and g)
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Radio remote
control
1.1.3 Mechanical part
a) Crane Bridge
i. The crane should be rigid, robust and of sturdy construction.
The crane bridge shall comprise of double girders of the
plate box type. The connection between crane Girder and
End Carriages should be through High strength frictional grip
bolts with spacer washer. The inner faces of plate joints
containing spacer washers must be given one primer coating
with minimum 60 micron layer thickness.
ii. The crane bridge should be carried on end trolleys with
double-flanged
solid casted wheels of spheroidal graphite impregnated
material/ C55Mn75/ forged Steel. The minimum end
clearance on each side of the long travel wheels should be
7.5 mm. The wheels should be mounted inside the End
Carriage and can be conveniently removed, if required. For
Under slung type EOT cranes of Inspection bay, flangeless
wheels are to be considered for cross and long travel.
iii. Suitable jacking pads should be provided on each end
carriage for
jacking up the crane while changing track wheels. These
jacking pads should not interfere with replacement of long
travel track wheels.
iv. The end carriages should be fitted with suitable safety stops to
prevent the crane from falling more than 25 mm in the event of
breakage of track wheel, bogie or axle. These safety stops should
not interfere with the removal of track wheels.
v. The diameter of the motorised wheels and the steel grade must
be studied to obtain, in all load configurations, perfect braking
without any slide. Each end carriage shall be provided with rubber
stops adapted to the end buffers.
vi. The EOT Crane Bridge shall be single girder construction having a
end
carriage at each end, each fitted with rollers running on long
travel runways, which will be suspended along the steel structure on
the roof.
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vii. The bridge (Single) girders should be connected to the end carriages
by large gusset plates. Ground tight fit bolts in reamed holes should
be used for bolted connections.
viii. The crane bridge should be carried on end trolleys with wheels.
The wheels should be mounted on fixed axle or suitable anti-friction
spherical roller bearings, should be greases and sealed for life
End carriages should be designed to be strong enough to resist
all stresses likely to be imposed upon them under varied service
conditions, including collision & stops.
ix. End carriages should be fabricated from rolled steel sections or
plates, welded together. Under the loaded and unloaded conditions,
the crane should not loose balance and tilt.
x. The end carriages should be fitted with suitable safety stops to
prevent the crane from falling more than 25 mm in the event of
breakage of track wheel or axle. These safety stops should not
interfere with the removal of wheels. All butt welds on structural
members subject to tension should be radio graphically tested. All
other welds should be subjected to Magna flux or Dye Penetration
Test Connections in general should be as per Clause 26 of IS-800
(latest).
xi. Forward and reverse drive shall be provided by means of 2 motor
gear reducer-brake units, one at each end. These units shall be
mounted on the carriages. The diameter of the motor rollers and the
steel grade must be studied to obtain, in all load configurations,
perfect braking without any slide. The wheel diameter shall be 150
mm minimum for running on the runways with expansion joints.
b) Trolley frame and hoist

i. The trolley frame of all the double girder EOT cranes should be
welded rolled steel section, designed to transmit the load to the
bridge rails without undue deflection.
ii. The trolley wheels of all double girder EOT cranes should be double
flanged. The Wheel bearings should be either grooved ball bearing
or taper roller bearings or self-Aligning Spherical roller bearing
as per design specifications.
iii. The top of the trolley frame should be plated (chequered plate) all
over
at the top, except for opening(s) required for the ropes to pass
through. The opening in the trolley frame should be such as to keep
the ropes at a safe distance from any part of the trolley frame
or equipment, to prevent damage at all positions of the bottom block.
iv. The trolley should be fitted with substantial safety stops to prevent
the
Page | 295
trolley from falling more than 25 mm in the event of breakage of

track wheel, bogie or axle. These safety stops should not interfere
with the removal of wheel
v. The trolley frame/ hoist shall be provided with rubber stops designed to absorb the
kinetic energy in the event of a braking fault. Stops shall be designed for a trolley running
at high speed under a nominal load. The hoist shall be provided with manual brake release
in the event of power failure.
c) Hoist wheels
i. The hoist shall be fitted with cylindrical wheels for cross travel.
Rubber stops shall be provided to absorb the kinetic energy in the
event of a braking fault.
d) Hook
i. The lifting hook shall be secured to a pulley block system with
pulleys designed according to characteristics of the wire ropes. The
pulley block system casing shall be provided with two grips. The
hook shall be fitted with a safety catch, of spring-loaded type.
ii. The bottom block must be of enclosed design. The rope sheaves of
the
bottom blocks must be protected with covers, so that the operator’s
hand cannot be jammed between the rope sheaves and the rope. The
Rope sheaves should be self-adjustable type during Hoisting motion
to accommodate the Wire Rope.
e) Rails
i. The rails shall be designed with the consideration of building
expansion joints. The bridge rails shall be Square/ Rectangular bar
of EN8/ ST52
Material or rail section as per IS: 3443. Rail stops welded should
be provided to prevent creep in the longitudinal direction. These rails
to be directly welded on the Gantry Girders.
ii. Since Under slung cranes of Inspection bay travels on bottom flange
of
the runway beam, LT Rails are not required for these cranes.
However, the contractor should confirm the flange width and
thickness of the runway beams to the structural contractor at the
stage of building drawings approval.
f) Runways
i. The runways shall be designed with the consideration of building
expansion joints. ’I’ section Girder shall be installed by structural
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work contractor. Crane contractor will need to liaison with the

designated contractor.
g) Rail wheels
i. The rail wheels of all EOT cranes other than that of Inspection
bay should be double-flanged with straight tread. They shall be
capable of taking misalignments in span as per VDI 3576/ IS: 12843:
1989, Class II specifications. These wheels shall be of spheroidal
Graphite impregnated Cast Iron/ C55Mn75 forged steel material to
have minimum hardness of 22 HRC.
ii. The Wheel Blocks to be connected to End Carriage through Pin
connection & circlip locking/ L Block assembly. Wheels should be
with splined hub profile to DIN 5480/ keyed as per IS: 3177, Residual
flange indicator, Dampening element and protected internal
bearing arrangement featuring Tapered Roller/ Spherical roller
bearing. Wheel bearings to be lubricated for life.
h) Rope drums
i. The rope drum shall be designed to withstand the compressive
stresses caused by the wound on rope and the bending stress
due to beam action of the drum. The drum shall be designed to
take the entire length of the rope in a single layer. Free extra turns
shall also be provided. The drum shall be flanged at both ends.
ii. Cranes shall be designed with number of rope falls varying with
lifting
capacity Up to 15.0 tonnes - 4 falls in 4/2 reeving i.e. right and left
hand groove for true lift.
iii. Rope drums should be with Rope guide made of tough plastic
offering smooth rope lead-in by means of hardened pressure rollers
mounted on Anti-friction bearings. Inclined pull up to 4° without
touching the Rope guide should be possible.
i) Wire ropes
i. The Wire rope should be of reputed make and designed according
to FEM 9.661/ IS: 2266 with tensile strength more than 1570 N/ mm2.
Wire ropes should be Steel/ Steel core IWRC.
j) Gearing
i. The gearing in all motions should be of suitable case- carburising
low carbon alloy steels and should conform to relevant Indian/
International standards. They shall generally be in accordance with
IS: 4460-1967 (or latest) or relevant International standard like DIN.
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All gears and pinions must be made from forged blanks only. All
gears should be hardened and profile ground for longer life and
silent operation.
ii. At all stages only helical gears should be used, except in planetary
gearboxes, which can be spur type. Overhung or split gears and
pinions should not be used. In addition, worm wheels and bevel
gears must not be used.
k) Gearboxes
i. All gearboxes shall be of completely enclosed splash lubricated type.
All gearboxes shall be oil tightened sealed with compound or gasket.
All gear shafts shall be supported in bearings mounted in the
gearboxes. Gearboxes should be made either of high quality pressure
die cast aluminium alloy or of grey cast iron housing or fabricated
stress relieved housing of gear boxes. All gearboxes shall be stress
relieved. Adequate radial clearances between the gearbox inner
surface and outside diameter of the gears shall be ensured. The
facial clearance between the inner surface of the gearbox and
the face of the nearest gear/ pinions shall be at adequate.
ii. These should be of a modular, integral design. Motors may be
either flange-mounted or foot mounted, or a combination of the two.
In case of foot mounted motors, split type gearboxes shall also be
acceptable. The gearboxes should also be splash lubricated type.
Alternatively, VVVF controlled, directly coupled motors can also be
offered.
l) Drives
i. The wheels of each end carriage should be driven by independent
synchronized drive motors mounted near each end carriage. A
separate cross traverse motor should be used for cross traverse drive
through a suitable gearbox.
ii. Alternatively, Two Step Variable voltage variable frequency (VVVF)

control of adequate capacity for all the motions of the crane can also
be provided. Any alternative design of International standard may also
offer VVVF drives of Siemens, ABB, Demag, L&T, Allen Bradley,
Vectron shall be used.
m) Brakes
i. The hoisting motion shall be provided with fail-safe electro-hydraulic
thruster brakes/ Disc brakes. The LT & CT motion may have DC/
AC electro-magnetic disc brakes in case of flange mounted motors
where integral gearboxes are being offered, to derive the maximum
advantage in terms of compactness and weight, but if the motors
are not flange- mounted then thruster brakes should be used.
Page | 298
ii. In case of Thruster Brakes, the maximum braking torque to arrest

long travel and cross traverse motions should not less than 100% of
full load torque for each brake. For hoist motion, two brakes should
be used and the braking torque for each brake should not be less
than 125% of full load torque. One of the two hoist brakes shall be
applied with a time lag of 3 seconds in relation to the first.
iii. Thruster brakes should also be with Double shoe brakes for each
drive.
Brakes should be mounted on the input pinion shaft of all
gearboxes. The brake shoe should be of hinged type. Brake levers
should be forged and hinge pins should be provided with steel
bushes at the bearing points. Brake drums should be of forged
or cast steel and should be completely machined. Width of brake
drum should be about 10mm more than the width of brake shoe on
each side.
n) Couplings
i. In case of separate drive mechanism, motor shafts for MH/ AH shall
be connected to gearbox input extension shaft through flexible
gear coupling. For driving the hoist drum gear type flexible coupling
shall be used between, the ropes drum and hoist gear box, where the
hub should not be integral with the output shaft, so as to avoid
replacement of the whole shaft whenever there is wear and tear
in the coupling. Solid couplings should not be used.
ii. All couplings shall be of medium carbon steel and shall be designed
to suit the maximum torque that can be developed. Hardness of
geared portion in the gear coupling shall be more than 250 BHN.
Bolted connections shall be easily accessible for inspection and
tightening.
o) Rope sheaves
i. All sheaves should be of cast/ forged steel or as per relevant
standards, they should be identical, with the exception of the equaliser
sheave. The equaliser sheave should be mounted above the trolley
floor and should be easily accessible and removable from the trolley
floor level.
ii. The equaliser sheave should be arranged to turn and swivel in order
to maintain rope alignment under all circumstances. Sheave
grooves should be smooth finished for getting increased rope life. The
supplier should further ensure that wire ropes are parallel with each
other.
p) Bearings
i. Ball and roller anti-friction bearings shall be of only reputed makes
like
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NBC,SKF, FAG, NORMA, NRB, NTN and

KOYO.
ii. For long and cross traverse wheels, bearings should be either
grooved ball bearing or taper roller bearings or self-aligning
spherical roller bearings as per design specifications shall be
used. Bush bearings should not be used at any location.
iii. Rated life of ball and roller bearings should not be less than the
total life in working hours given in accordance for a particular class
of duty.
iv. Independent bearing housings on long shafts are split on the
shaft
centre line to permit easy removal of the shaft. The bottom surface of
all bearing pedestals should be machined, and should bear upon
a machined surface.
q) Lifting hook
i. The hook shall be secured to a pulley block system with
pulleys designed according to the characteristics of the wire ropes.
The pulley block system casing shall be provided with two proper
grips.
ii. Standard plain shank type trapezoidal section hooks should be used.
These hooks should conform to the relevant Indian
Standard
Specifications IS: 15560 (latest) / DIN standard
15401.
iii. Hooks should be mounted on grease lubricated anti-friction thrust
bearings and a protective skirt should be fitted to prevent rotation of
the hook. The hook block should have handle recess to provide
improved safety against hand crushing. The bottom block must be
of enclosed design. The rope sheaves of the bottom blocks must be
protected with covers, so that the operator’s hand cannot be jammed
between the rope sheaves and the rope. The Rope sheaves should
be self-adjustable type during Hoisting motion to accommodate the
Wire Rope. The hook shall be fitted with a safety catch of spring-
loaded type.
r) Buffer
i. Spring loaded or other suitable buffers should be fitted on the
four corners of the crane and also at the four ends of the bridge
girders. Buffers should be rigidly bolted in place, preferably along
the centre line of the crane rail or trolley rail as the case may be.
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ii. All buffers should have sufficient energy absorbing capacity to stop
the bridge or trolley in either direction when travelling at its rated
speed.
s) Lubrication
i. Individual/ Group lubrication, one for each of the end carriage and
one for the trolley platform, should be provided for all grease-
lubricated bearings, parts of the hoist, cross traverse and long travel.
The grease battery nipples should be located to facilitate regular
greasing by the operator with standard equipment.
ii. All gears and bearings enclosed inside gearboxes should be splash
lubricated. Bottom blocks and pedestal bearings should have
independent greasing points. All lubricating pipe work should
be securely fixed and protected from damage, and be
accessible throughout.
iii. A lubricating chart should be provided in the manual, indicating
all
lubrication points, the type of lubricants required and the
recommended frequency of lubrication. These details should
be repeated, and amplified, in the Maintenance Manual.
t) Maintenance Platform
i. Each Double Girder crane shall include one maintenance
walkway installed along the crane box girder structures &
one Short platform on other side of the crane. Walkway
shall be of a length equal to that of a box structure and
the other shall be of a length equal to that of the
traversing trolley.
ii. Crossover from one walkway to the other shall be via
a platform,
mounted on the hoist trolley. Plating shall be of the anti-
skid type. Walkways shall be provided with guardrails
designed in accordance with safety standards. Whereas for
under slung crane maintenance platform is not applicable.
1.1.4 Electrical part
The Contractor shall carry out all electrical work from power supply
switch to the cranes. The available electrical power supply is
415V±10%, 50 Hz±3%, three-phase,
4-wires. The equipment and gear to be supplied mainly includes:
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i. One latchable isolating switch

and MCCB, ii. Down shop leads,
iii. Electric switchboard and
control panel , iv. Various
motors,
v. power and
control wiring, vi.
Limit switches,
vii. The lighting (2Nos. LED under bridge lamps - 250W)- In
case of double girder cranes only,
viii. The control switch
a) Latchable isolating switch

i. It is provided for maintenance purpose and shall impede
any movement of the EOT Crane when Maintenance work
is in progress.
b) Down Shop Leads

i. The down shop leads shall be of enclosed type with copper
conductors.
ii. The conductor system shall be compact in construction
finger safe to IP-
23. The conductor material shall be insulated by a high
impact gloss finish PVC compound which shall have a
step/groove shrouded all along its length for effective
moulding of the conductor system.
iii. The conductor section shall be minimum four mtrs. in length
to be jointed with moulded joint of the same material as
the conductor and these conductors shall be supported
by way of a single piece moulding, four pole hanger with
single bolt fixing.
iv. The current collector trolley running inside the enclosure
should be with spring loaded sliding contacts offering
positive contact with copper conductor. The cable from
current collector trolley should be totally insulated, fully
enclosed and double insulated within the collector arm with
a proven performance.
v. Necessary wearing components for maintenance during DLP
shall be provided. The Contractor shall size the copper
section of the conductor in accordance with the necessary
power, and voltage drop requirements with the approval of
the Employer.
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vi. The bays are provided with power supply to the down
shop leads with four sets of power-on indicator lights. The
power supply for crane will be provided at workshop working
level through TPN MCCB.
vii. The cabling from TPN MCCB to down shop leads shall be in
crane scope of work. Down shop leads shall be connected to power
supply at single/ multiple points, as per the design requirements.
c) Switchboards and gear

i. Control gear shall be mounted in one or more switchboards
depending on the type of EOT Crane. The protection index shall be
IP 54.
ii. The trip circuit of the circuit breaker shall be designed such that it
should prevent the circuit breaker from being enclosed when main
contactor of any of the motions has failed to open, although the
corresponding controller has been brought to OFF position. Suitable
protective features to trip the circuit breaker with the operation of
limit switches and emergency push buttons shall also be provided.
iii. For protection of each drives, motor against over loads
adjustable
inverse time lag manually reset electro-magnetic, type relays shall
be provided for each motor. Alternatively, electronic type relays shall
be acceptable. These relays shall be mounted in respective
contactor panels and shall be set to trip the circuit of motion being
controlled when current exceeds 200% of normal value for more than
10 seconds. Each motor feeder shall be protected with no volt trip
device & short circuit, and with instantaneous trip current sensitive
type single phasing cum phase reversal preventer. Isolating
switches fitted with protection shall be provided for the following
branch circuits:
• Lighting and hand lamp socket outlets
• Control circuit.
iv. Each control circuit branch to every contactor panel shall be
provided with facility for isolation and protection against short
circuits and sustained high overloads by means of appropriately
rated miniature circuit breaker.
v. The electrical switchboard shall be key locked. The door shall include
a
3-position switch provided for no-load testing of control circuits and
shall be connected to the cabinet via an earth braid.
vi. All terminals and wiring shall be marked in accordance with the
electrical
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diagram.
d) Control Pendant
The controls shall be given from a push-button control pedant, which shall
be:
i. sealed, insulated to IP65 and unbreakable,
ii. be capable of moving along the EOT Crane independently from the
movement direction of the hook, be suspended with a stainless
steel wire
iii. The pendant control shall be capable of withstanding rough handling
without being damaged. The cover shall be firmly secured & made
out of Nylon fibre.
iv. The function of the push buttons shall be identified by means
of
engraved
labels.
v. Safety means shall be provided to prevent inadvertent operation
from floor while maintenance work is being carried out on the crane.
vi. Adequate guards shall be provided to prevent accidental contact of
pendant ropes or holding wire rope/ chain with cross traverse.
vii. released, not held, for all movements and for the hooters,
viii. held for switching on and lighting,
ix. Turn to unlock for the emergency stopping.
e) Radio Remote Control

i. The wireless control facility shall incorporate control of movements
in all directions, with speeds identical to those provided for the
pendent control.
ii. The facilities to be provided shall incorporate but need not to be
limited to the operations features listed below:
• Emergency stop button
• Emergency alarm button
• Normal ON/ OFF button
• Low/ High speed button
• Directional movement control buttons
• Radio/ Pendent control selection buttons
iii. Overall, weight of remote control hand set (transmitter) not to exceed
0.5 kgs. Approx. The system shall be so designed that in the event of
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malfunction it should be possible for the user to switch over to

pendent control through suitable by pass switch facility. The
general scope of supply Radio Remote Control equipment shall be
as follows:
• 1 no. Transmitter-Push button type
• 1 no. receiver
• 1 no. Antenna and cable
• Two sets of Alkaline battery size AA
iv. The transmitter shall be provided with a shoulder belt and shall be
in IP65 enclosed. The system shall be microprocessor based and
shall have watchdog circuit. The range of operation should be 40
meters minimum. The crane supplier shall be responsible for
commissioning the system.
v. Tenderer shall ensure adequate supply of spares and availability of
maintenance spares support within the country.
vi. Equipment supplied should be certified by internationally recognised
inspection
agency.
f) Contactors
i. All contactors shall be of AC 4 Class of duty with rating
sufficiently higher than the full load current of the respective motors
at the specified duty cycle. The directional contactors of all motions
shall be suitably interlocked for correct sequence of operation.
ii. Electrical & mechanical life of the contactors shall be indicated. For
AC 4
Class of duty Electrical life shall be minimum 2, 00,000 cycles
of operations. The contactors shall have high contact reliability
with preferably double break parallel bridge contact and facility of time
saving termination. All contactors shall be of Tele mechanique, ABB,
Siemens, L&T and Cutler Hammer make. Test certificate of the
manufacturers shall be submitted in support of life and rating of the
contactors.
g) Limit switches
i. All hoist motions shall be provided with limit switches to prevent
crane from over hoisting and over lowering. Limitation of the
motions at the upper and lower Hook positions should be effected
by Geared Limit switch, provided with 4 contacts. The design
should be such that the limits can be set as per the requirements
during crane installation at site.
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ii. Two stages Limit switch for hoist cross and long travel motion shall
be supplied installed and wired by the manufacturer.
h) Control panel
i. Variable voltage variable frequency control (VVVF) if considered,
should be of adequate capacity for all the motions of the crane
shall be provided. VVVF drive of Siemens, ABB, L&T, Allen Bradley
make shall be used. Independent AC variable frequency control for
main hoist, aux. Hoist, CT & LT shall be used by using independent
variable voltage variable frequency drives. However, common
controller for both the motors of LT may be used.
ii. The components inside the Control panel should be mounted in
such a
way that all the components are easily accessible. The
clearance between cable tray and each component should be
minimum 25mm.
iii. GA drawing of control panel should indicate internal layout of the
components. Instrument cut outs should be exact and without burrs
or unevenness. Location of outgoing terminals should be
minimum100 mm above the gland plate. Gland plate should be
sufficient to accommodate outgoing cables.
iv. Proper stiffeners should be provided to avoid buckling and
unevenness.
Control panel should have self-adhesive type gazetting arrangement.
Control panel box and base plate should have identification label
bearing details of project, electrical drawing number along with
revision number.
v. Minimum steel thicknesses to be used are:
• Base plate –2.0 mm
• Front Facia –2.0 mm
• Other sides –2.0 mm/1.6mm
• Frame –2.0 mm
vi. All power and auxiliary contactors, individual overload relay shall
be mounted in sheet steel cubical with lockable-hinged doors.
The door hinges shall be of such type that during the repair works
inside the panel the entire door can be lifted out and placed away
enabling better access inside the panel. A common panel with
separate compartment for each motion shall be acceptable. Interiors
of panel shall be dust and vermin proof. Panels shall be front wired
with readily accessible terminal blocks for making connections in the
external equipment. Panels shall be pre- wired into terminal strip.
Single core, copper conductor shall be used for control circuit wiring
in the panel.
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vii. All the equipment’s shall be so mounted in panel as to enable its

easy removal/ replacement from the front.
viii. All equipment’s inside the panel shall have permanent identification
labels in accordance with circuit diagram as also the power and
control terminals. Terminal blocks shall be of robust and of such
construction as to preclude possibility of cable connections getting
loose during vibration on crane. Contactor panels shall be well
braced to the crane structure and each panel shall be provided with
adequate number of lifting lugs. Updated and current Indian
Standard specifications and codes of practice will apply to the
equipment and the work. Wherever appropriate Indian standards are
not available, relevant British and/ or IEC standards shall be
applicable.
i) Interlocking
i. Suitable key locking arrangement shall be incorporated to ensure

that 25 kV supply on the particular track has been switched off
before working the EOT Crane. Also the arrangement shall be made
to ensure that 25 kV OHE cannot be switched on unless the crane
has been placed in the extreme position. (Crane is parked at the one
end of bay with hook in maximum position and cross travel also at
one end) and power supply to the crane switched off.
ii. Suitable electrical circuitry interlocking to be provided along
with mechanical interlocking operated with the help of a key. The
crane cannot be operated till the key is inserted. The key should
not be released until the crane is parked in extreme position (as
mentioned above) and power to crane is switched off. The
successful bidder is required to obtain approval from the engineer
in charge for detail electrical circuit diagram & mechanical locking
arrangement for the interlocking system.
j) Cabling
i. Control wiring and signal wiring should be separate as far as
possible.
Phase control wiring should be 1.5 Sq. mm grey while neutral wiring
should be black in colour. Power wiring should be minimum 2.5 Sq.
mm size and R, Y, B colour coated for R, Y, B phases. Maximum
loading of PVC cable should be 60% of cable tray capacity. Wire
bends should not be sharp to damage the conductors.
ii. Proper support for outgoing cables should be provided with proper
Ferruling. Wiring more than 5 cm length should not be exposed.
Wiring should be properly bunched or spiralled. Wiring should run
parallel only, no crossing of two wires is permitted. Common point of
star connected current transformers should be earthed.
Page | 307
iii. Where ever required, a separate instrument earth should be

provided, which is separate from main earth. Earthing can be done
as per cable size and application requirement, also creepage
distance could be decided as per IEC standard / switch gear
manufacturer requirement. Control and power links between the
EOT Crane Bridge and the hoist are made of flat cable, laid as a
garland, with appropriate carriers.
iv. Any cables exiting from a steel tube must be protected by an
insulating end fitting. Power cable shall be of FRLSH XLPE type.
Labels of permanent nature shall be provided on supports of all
switches, fuses, contactors, relays etc., to facilitate identification
of circuits and replacement. All panels, controllers, resistors etc.
shall be properly marked for each motion. All power control cable,
lighting and other cables shall be ferruled at both ends as per cables
numbers indicated in the supplier’s drawing. All equipment terminals
shall also to be marked likewise.
k) Emergency stop push button

i. A mushroom head type of push button shall be provided on pendent
so that the main incoming circuit breaker can be tripped under
any emergency conditions by pressing the operating head. A pilot
lamp incorporated in the control circuit shall glow when any of the
switches is operated.
l) Motors
i. Motors shall be of the asynchronous or squirrel cage type with a
built-in electromechanical or magnetic brake. The ingress protection
level of motors shall be IP54.
ii. Motor selection for lifting and travel applications should be

according to rule FEM 9.683/ IS: 3177. The motors must be suitable
for the operating conditions and ensure safe operation under related
conditions. All motors shall have insulation class B. The criteria
for motor selection should be as below:
• Required power – the thermal power is also included in these
required powers.
• Maximum rated torque and maximum acceleration torque.
• Cyclic duration factor.
• No. of cycles / hour.
• Type of control (type of braking)
• Speed regulation.
• Degree of protection.
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• Ambient Temperature.
iii. This brake shall be applied automatically in case of power failure
during lifting or travel.
m) Lighting
i. For all double girders EOT cranes other than that of Inspection
bay should have high bay light fitting with LED lamps of 250
W and associated control gear shall be securely fitted at two different
locations below the crane platform. These units shall be supplied
with 230 V via a contactor controlled from a switch on the
pushbutton pendant. A switch for the tubes shall be provided on the
walkway.
ii. Tool Receptacle shall be provided on crane platform – 2 Nos. sockets
(1
No. – Single phase, 20 Amps and 1 No. – ThreePhase,32 Amps)
to provide power supply for maintenance purpose.
n) Identification of circuit cables

i. Labels of permanent nature / ferruling shall be provided on supports
of all switches, fuses, contactors, relays etc., to facilitate
identification of circuits and replacement. All panels, controllers,
resistors etc. shall be properly marked for each motion. All power
control cable, lighting and other cables shall be ferruled at both
ends as per cables numbers indicated in the supplier’s drawing.
All equipment terminals shall also to be marked likewise.
o) Earthing
i. Earthing to the crane shall be effected through track rails of
crane structure. As such, all the electrical equipments mounted on
crane shall be connected to the crane structure by means of
earthing links. The crane structure in turn shall be made electrically
continuous by providing jumpers over bolted joints. Equipments fed
by flexible cables shall be earthed by means of spare core provided
in the flexible cable.
1.1.5 Protection and safety
In addition to the various recommendations enumerated in the previous

paragraphs, the Contractor shall include the protection systems scheduled in
the standards and consider the following recommendations:
i. all metal parts shall be earthed,
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ii. all movements (lifting, forwards/ reverse, traversing) shall include

limit switches, The lifting movement shall be fitted with:
• an over travel switch cutting off the power circuit

which may be reset from the crane walkway,
• a load limiter, which cuts off the power supply to
all movements except lowering
• a buzzer to warn the persons working near the
crane operating zone when crane is in working
condition.
1.1.6 Standards
The entire supply shall satisfy the requirements of Indian Standards

mentioned below or equivalent International/European/British
standards/ DIN Standards and regulations in force:
Indian Standard Code of practice for
IS 3177 :1999 EOT Cranes
Indian Standard code of practice for
design, manufacture, erection and
IS 807 : 1976 testing (structural portion) of
cranes and hoists
Indian Standard code for electric
IS 3938 : 1979 wire rope hoists
IS 2266 : 1976 wire ropes
IS 4460: 1967 Gears
specification for power driven
BS 466 overhead travelling cranes, semi-
goliath and goliath cranes for general
BS 2573 use
Part 1 & 2 - Rules for design of cranes
BS 5395 Stairs, ladders and walkways
DIN 15018 Crane classification
DIN 15401 Lifting hooks for lifting appliances
FEM 9.683 selection of lifting and travel motors
Rules for design of series lifting
FEM 9.661 equipment
DIN 15020 Principles relating to Rope Drives
Page | 310
1.1.7 Finish
a) Paintwork
i. Preparatory works prior
to painting:
• Outsides: brushing, degreasing, grit blasting.
Copper Slag blasting to the second quality finish
(Swedish Standard grade SA
2.5) and
blowing
clean.
• Hollow bodies: these areas shall be treated prior to
assembly by applying a coat of anti- corrosion paint.
• The thickness of this coat after drying shall not be
less than 180 microns.
ii. Painting of External parts and ancillary parts shall receive:
• Type: Primer cum
finish paint
• Make: Hempel fast dry 45410/ sigma cover 350/
intergrade 345
• Nos. of
coat: 2Nos.
• Gloss Level: Semi-Gloss (40-50%)
• Total DFT: 125 Micron

• The paints to be applied on walkways, access ladders
and handrails shall have a good abrasive resistance. All
equipment shall be painted golden yellow (RAL 1004).
On site, the Contractor shall touch-up paintwork which
may be made necessary by equipment installation.
b) Unpainted parts
• All friction parts or parts which must remain polished shall be
coated to protect them from corrosion until equipment start-
up.
c) Identification
i. Two identification plates shall be fixed to each crane on either side
of the main structure. These Identification plates shall indicate:
Page | 311
• Safe working load in Tonnes

• the year of manufacture,
• the unit item number.
ii. The Constructor’s identification plate may be affixed.
• All nuts, bolts, washers etc. shall be GI except where
provided otherwise.
1.1.8 Checks and tests
a) In-manufacturer’s-plant
i. During manufacture, and prior to delivery, verifications and checks
shall be carried out in order to ensure that the supply is in
accordance with the technical specification and with the approved
design documents.
ii. All quality checks shall be carried out, as required, during
manufacture on the Contractors or on the sub-contractors premises.
iii. The Contractor shall provide for quality check of supplies on his
sub- contractors premises prior to delivery of these supplies to his
workshops.
iv. Operation of safety and protection devices shall also be checked.
The
Contractor shall also carry out the following practical
tests:
• The various operating configurations with no load,
• I nsulation,
• Proper operation of dynamic tests including:
• V erification of speeds,
• Crane behaviour during start-up, acceleration, deceleration
and braking.
• In particular, the efficiency of the brakes, limit switches,
load limiters, good collection of power and the various
currents, heating of electrical and mechanical devices,
etc. shall be checked.
• These tests shall be carried out only on forward, reverse and
lifting movements. Traversing movements shall be tested on
the site.
b) At-Site
i. After assembly and erection of the EOT Cranes at site, all
tests mentioned in this chapter shall be carried out in presence of a
representative of the Employer.
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ii. In addition, the tests pertaining to the traversing movement

and the verification of the anti-collision devices shall be
carried out after assembly on the site along with the load
test at 100% loading and over load test at 125% loading for
determining crane Girder deflection. After these tests, the
load limiter shall be adjusted to its normal value and
tested. The Main contractor shall be responsible for
arranging loads at site for load testing.
1.1.9 Training
The contractor shall provide following training for operation and

maintenance staff for
EOT
• Four working days training for four staff on operation

of crane.
• Four Working days training for four staff for
maintenance of the crane.
• Two sets training material shall be provided to
the trainees.
1.1.10 Documents to be
provided
All documents shall be provided in English.
a) In the Bid
The Contractor shall provide, for each overhead travelling crane:
i. A detailed technical note including a description of the

equipment, main dimensions and total electrical power
required,
ii. Photographs or sketches of similar equipment with a list
of references, iii. General drawings substantiating the good
installation of the equipment, iv. References of the sub-
contractors,
v. The various speeds for each of the movements,
Page | 305
vi. The standards and specifications that the main

components used in the installation satisfy.
b) For Execution of Work
Prior to manufacture of equipment, the Contractor shall send the

following documents for approval:
i. Detailed dimensional drawing of the elements of the

machine, and dimensions of the cabinet,
ii. General, detailed assembly drawings and drawings of
mechanical parts, iii. A note, indicating that the provisions in
the civil work are compatible with
the equipment offered,
iv. Characteristics of the drum and the pulley
block system, v. Detailed calculation notes,
vi. References and characteristics of the main standard parts,
vii. Detailed electrical diagram for troubleshooting including
cable index, viii. Detailed electrical diagram for
troubleshooting including cable index,
ix. Electrical power required at each workstation, including
switchboard
equipment breakdown,
x. List of basic spare parts to be kept in stock for repairs, during
DLP,
xi. documentation, drawings, notes and references of sub-

contractors, xii. installation and commissioning
procedure,
xiii. Schedule of work and completion period.
c) At Completion of Work
The Contractor shall provide the entire documentation, up to date:
i. The general nomenclature of the supply including sub-contractors,

ii. Mechanical drawings and electrical diagrams required for
maintenance and troubleshooting of the machine,
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iii. Illustrated lists of mechanical and electrical parts itemised in

accordance with the diagrams and drawings mentioned above and
including the addresses of the various contractors,
iv. Two sets of maintenance and adjustment manual with summary
of circuits and functions and among other information, a lubrication
manual including location of lubrication points, type of lubricants,
frequencies and quantities,
v. Two sets of an operating manual including start up and
user’s instructions,
vi. Complete documentation on motors,
vii. Test reports or certificates for conformity of the
equipment, viii. List of recommended spare parts for two
years requirements.
1.1.11 Commissioning
After Completion of work, the crane shall be commissioned and all the
commissioning tests shall be jointly carried out by Contractor and approved by
Engineer Contractor and approved by The Engineer. All the equipment, tools
& tackles and measuring instruments shall be arranged by the contractor. All
consumables shall be arranged by The Contractor.
1.1.12 EOT crane for inspection bay general description and scope of supply
The specification covers the design, manufacture, supply, installation, testing and
commissioning of Electric Overhead Travelling Cranes to be installed for
handling of Rolling stock roof-mounted A/c units, pantograph and Vacuum circuit
breaker (VCB) in the Inspection Bay of Depot. The Inspection Bay is a covered
shed provided with 25 kV Over Head Electrification (OHE) contact wire system
at a height of about 5.4 m. I shaped girders supported at the roof truss
throughout the length of Inspection shed shall be provided by the civil contactor.
The E&M contractor supplying the cranes shall have to liaison with civil contractor/
structural contractor for furnishing the requirement of steel structure. The
Contractor shall supply and install the EOT cranes complete on the steel
structure. The down shop leads for the power supply shall be suitably fixed on
the steel girders by the crane contractor. The scope of supply shall cover and
down shop leads and all equipment and accessories that are required to
make the EOT Crane fully functional (this includes the rails for long travel,
arrangement of DG sets/ power backup for initial testing & commissioning by the
main contractor) and the cost of such accessories shall be included in the basic
price of the EOT Crane. First fill of the oil/ grease with sufficient quantity of
lubricants for commissioning of the EOT Cranes.
Page | 307
APPENDIX 1
FOR EOT CRANE OF 5T IN WORKSHOP CHARKOP DEPOT

MECHANICAL CHARACTERISTICS
Classification Speeds, in m/min

Crane Capa Frame
Ref. city work Mechanism Lifting Traversing Travelling
No. Location (Ton)
FEM Rating/ LS(m/ HS(m/ LS(m/m HS(m/ LS(m/m HS(m/mi
Group
IS:3177 M5 in) in) n)
min) min) min)
0.5/
EOT 1 Workshop bay 15/2 3 2m/M5 5/12.5 2 20 4 40
0.5
Workshop bay
EOT 2 5 3 2m/M5 0.5 12.5 2 20 4 40
(Common bay)
EOT 3 Inspection bay I 1.5 3 2m/M5 0.5 12.5 5 30 2 20
Pit wheel Lathe
EOT 4 5 3 2m/M5 0.5 12.5 2 20 2 20
Building
LS: Low Speed, HS:

High Speed
DIMENSIONAL CHARACTERISTICS
Crane Capacity Span of Clearance Hook level Level of Approximate Approximately

Reference (Ton) overhead under hook in “down” running ly length of space from
travelling way (m) running way running way
Number (m) position
crane (m) (0.00-FFL) (m) axis to face of
(Approximat adjacent
e ly) column (m)
EOT 1
15/2 18.48 5.10 -1.20 5.40 135 0.3
EOT 2
5 18.48 5.10 -1.20 5.40 135 0.3
EOT 3
1.5 3.00 5.80 -2.13 7.00 99 0.3
EOT 4
5 10.16 5.10 -1.05 5.40 22.5 0.3
Note: The contractor has to submit the design calculation for the approval
of DMRC before placing the procurement order.
Classification of lifting devices
NOTE: This classification must be defined according to European Union of

handling
Rules (F.E.M.)/ IS: 3177-1999.
Classification of Frame
works a) TABLE I: LOAD
STATUS
LOAD STATUS DEFINITION RELEVANT SPECTRUM

Device which lifts its rated
0 load only exceptionally p=0
(Very and which usually lifts very
light) light loads only.
Device which only seldom lifts
its rated load and
which usually lifts loads equal
1 to about one-third its rated p = 1/3
(light load.
) Device which rather
frequently lifts its rated load
and which usually lifts loads
2 Between one-third and two- p = 2/3
(average thirds its rated load.
) Device regularly loaded close
3 to its rated load. p=1
(heavy
)
b) TABLE II: CLASS OF USE
CLASS OFUSE FREQUENCY OF USE OF CONVENTIONAL

THE NUMBER
Occasional,
LIFTING
non-regular OFLIFTING
A MOTION
use, followed by extended CYCLES
6.3 x
idle 104
B periods
Regular use in intermittent duty 2 x 105
C Regular use in intensive duty 6.3 x
105
Use in severe intensive duty,
D for instance over 2 x 106
several
shifts
Note: The above factors in the table I, II can alternatively be as per IS: 3177 & IS: 807.
c) TABLE III: GROUP
(Deduced from tables I and II above)
Status of loads Class of use and conventional number of lifting cycles or of

or strain status strain cycles for one element
for one element
A B C D
0 (very 6.3x104 2x105 6.3X105 2x106
light) 1 2 3 4
1 (light)
p=0 2 3 4 5
p = 1/3
2
(average) 3 4 5 6
p =32/3
(heavy) 4 5 6 6
p=1
Classification of mechanisms
a) TABLE A: STRAINING STATUS
STRAININGSTATUS DEFINITIO
N there of which are
Mechanisms or elements
1 subjected only Exceptionally to their maximum strain
(p = 0) and which are usually subjected to markedly lower
2 Mechanisms or elements
strains. thereof which are
subjected to low, average and maximum strains for
(p =
3 Mechanisms
markedly equal or elements thereof which are
1/3)
mostly subjected to strains close to
(p =
2/3) maximum.
b) TABLE B: OPERATING CLASS
Assumed average Total theoretical time of

Operating class daily operating time, operation
V 0.25 in hours < 0.5 <, 800
in
V 0.5 > 0.5 and < 1 1,600
hours
V1 > 1 and < 2 3,200
V2 > 2 and < 4 6,300
V3 > 4 and < 8 12,500
V4 > 8 and < 16 25,000
V5 > 16 50,000
) TABLE C: GROUP
(Deduced from tables A and B above)
Operating
Straining
status classes
V 0.25 V 0.5 V1 V2 V3 V4 V5
1 1mB 1mB 1mB 1mA 2m 3m 4m
2 1mB 1mB 1mA 2m 3m 4m 5m
3 1mB 1mA 2m 3m 4m 5m 5m
1.1.13 DATA SHEET FOR THE EOT CRANE
S. No. Descriptio Remarks

n
01. Total weight of crane, including electrical

equipment
02. Safe working load in tonnes
Trolley
• Wheel span
03.
• Wheel base
Bridge
• Wheel span
04.
• Wheel base
Detailed wheel diameter calculation for long
05.
travel and cross traverse wheels.
Electrical details
of
• Motors
• Manufacturer, type & enclosure
• Rating, output in kw
• AC voltage across phases
• Speed in RPM
• Class of stator insulation
• Starting current, normal full load current
• Max. starts per hour for which motor
is suitable
• Class of duty (S1, S2, S3, S4 etc.)
6. • Suitable for voltage range
• Motor horse power calculation
• efficiency & power factor at ¾ load & ½
load
• Type of drive (Direct gear drive etc.)
• Control gear
• Rating of AC4 Contactors with min.
2,00,000 cycles of operation
• Protections for the motor like; Short circuit
• by HRC fuses, no volt & over volt trip,
instantaneous trip current sensitive Page | 285
single phase preventer
Make & type of the

following:
• Motors
• Cables
• Contactors
• Time relays
• Limit switches
• Overload relays
07. • Moulded case circuit breakers

• Resistors
• Control panels
Bidder to confirmDSL
• Shrouded following features
conductors of AC
& collectors
Drive: Inverter offered should be suitable for
• application
crane Thrusters brakes
for all motion
• Electrical isolators
Drive sizing should be done accurately
• Variable
considering typevoltage
of panelvariable
environment conditions
frequency drive
etc. the drive should be capable of taking 125%
overload for one minute at the slow speed of 20%
and at full speed as per crane IS standard.
Inverter offered should have slip
compensation feature in both UP/ Down
motions (even during regeneration)
08. Inverter offered should be with built in modes of
control strategies Viz. standard V/F, Open loop
vector
& flux vector so that the same inverter can be
Note: The bidder shall provide data of each type of EOT crane in separate sheets.
used for all motions selecting the control mode.
Inverter offered should be provided with
accurate brake coordination signals
Page | 286
1.2 AIR COMPRESSOR FOR WORKSHOP – 170 CFM
1.2.1 General Description
Air compressors are required for production of compressed air for the
Workshop at Depot. The specification covers the design, manufacture,
supply, installation, testing and commissioning of Air Compressors.
The compressor shall have high efficiency & low power consumption.
The supply shall comprise stationary type, electric motor driven, self-
lubricating Rotary Screw type complete with suction filter, air/oil
separator, air cooled after cooler, oil filter, oil cooler integrated
refrigerated air drier & moisture trap, microprocessor based control
panel all housed in silenced package provided on anti-vibration mounts.
The supply shall include air reservoir (01 no), air filters, pipes and
pipe couplings, electric controls, and all other accessories to make the
equipment
& installation fully functional. A set of service tools and special tools
shall also be supplied along with compressor. The compressor and
installations shall be designed considering ease of maintenance and
requiring minimum service in order to optimise down time.
1.2.2 Technical Characteristics
Technical
Particulars
Each compressor shall be capable of giving an output of 170 CFM

of air at an operating pressure of 10 Kg/cm2. Single compressors
shall work together in the system with full synchronisation and
redundancy. The compressors shall be provided with capacity control
system to reduce the load on motors at the time of start and to give
reduced output to match with the requirements. Arrangement shall also
be incorporated for automatic shutdowns in the event of prolonged
off-load operation. The compressor units shall be equipped with
condensate separator with both auto & manual drain. The compressors
shall be driven by adequate capacity TEFC squirrel cage type 3-
phase Induction motors (30 kw), having insulation class F, through
preferably a permanent alignment geared drive (any better arrangement
shall be explained with advantages in the offer). Star-delta type starter
with contactor relays and single-phase prevention shall be used. The
ingress protection of all motors shall be IP55. Pre wired connections
between the motor and starter should be provided. The compressor
shall be suitable for continuous and heavy-duty operation. The
contractor shall submit the compressor drive installed motor power (in
Page | 317
kW & hp). The manufacturer shall use all modern techniques of

vibro-acoustics optimisation for extremely low noise and vibration level.
The compressors permissible noise level measured at a distance of 1m
from the acoustic enclosure shall be less than 70 dbA. The compressor
shall be provided with integrated oil removal filter with filtration level of
0.01 ppm. The temperature of air leaving the compressor unit shall
not be more than 10ºC above the ambient. The contractor shall
submit equipment and piping layout drawing (preferably a 3
dimensional drawing) considering space available in the compressor
room & reservoirs outside. Depot layout drawing with compressor
room marked is enclosed.
All the equipment of the compressor package shall be mounted on a

common base frame for foundation less installation. The base frame
shall be made sturdy with facility for mobile crane & fork lifting
arrangement. A twin element suction air filter on the intake side of the
compressor, a compressed air-oil separator, oil cooler and a non-
metallic cartridge type oil filter shall be provided.
a) Suction filters
i. The dust filter (pre-filter) shall be capable of filtration up to 1
micron absolute with 99.5 % efficiency for solid particles. Heavy-
duty dry type intake air filter, conveniently located for quick and easy
replacement with cyclonic separation and arrangement for pre-filter
separation shall be provided.
b) Compressor
i. Single stage self-lubricated rotary screw compressor having
high efficiency and reliability shall be provided. It shall be equipped
with: -
• The air intake valve should be maintenance free
pneumatically controlled vacuum controlled without
spring Intake valve assembly for Load/ No load regulation.
• Non-return valve at element discharge.
• Automatic oil stop valve
• vacuum gauge adopter
c) Air & Oil separator
Page | 318
Compressor shall have air and oil separator which shall consist
of vertical design welded vessel that secure excellent oil
perspiration, oil separator element to provide clean quality air by
separating oil and the carry over is less than 1.5 ppm along with
minimum pressure valve, Safety valve, Delta Pressure sensor
before oil separator and oil draining arrangement.
d) Air after cooler & Oil cooler

I. The air after-cooler should be aluminium block type to cool
the compressed air and shall be high efficiency air cooled after-
cooler and oil cooler. A suitable capacity fan cooling
arrangement shall be provided.
II. Full flow type oil filter with thermostatic bypass valve (the TEV
should be stainless steel or cast iron and it may be integrated in the
oil filter housing to enable the compressor to reach its temperature
immediately after start up ) to avoid condensation and Oil
restrictor to regulate oil flow shall also be provided. The water
separator unit should be integrated in the after cooler and should
be capable of removing 100% condensate without any loss of air.
e) Capacity regulation system
The compressor shall be equipped with transducers to set discharge

air pressure to desired limits/ pressure band, Load/ No load system
with automatic start/ stop through solenoid control valves & timer,
moisture separation trap in the regulating line for separation of water
and control tubing.
f) Compressor control
I. Each compressor shall be provided with advance
microprocessor based graphical 3 to 5 inch high definition colour
display with clear pictograph and self-explanatory navigation
with real time operating
Page | 319
system with ergonomic user interface .The control shall have

following features:-
• Maximise energy efficiency by controlling the main drive
motor by regulating system pressure within predefined
pressure band (+/- 0.1 bar band).
• Simultaneous multiple compressor control from any of
the compressor control.
• Continuous monitoring of critical parameters including
service and warning indications, error detection,
compressor shutdown and maintenance scheduling.
• Using an ambient sensor to monitor the required dew
point suppression, the control shall start and stop the dryer
when the compressor has stopped thereby minimising energy
use and protecting the air system from corrosion due to
moisture.
• The compressor shall draw no starting current peaks and
shall have high power factor.
II. The general equipment shall include the following:
• Automatic (timer controlled) start-up and shutdown,
• Auto start facility after power failure,
• load indicator & an additional gauge (pressure gauge),
• emergency shutdown button,
III. Identification plate with the following information:
• Type, capacity and serial number of compressor,
• Type, capacity and serial number of motor.
IV. All electrical and electronic control, regulation and other items shall
be contained in a dust-tight cabinet, part of the compressor
package. It shall be designed such that all parts are easily
accessible for inspections, repairs and general maintenance.
g) Air dryer
I. The compressor shall have an integrated air cooled type
refrigerant dryer in the downstream of the compressor within the
same canopy & the design shall make the installation more
compact. The air drier shall stop working atomically when the
compressor stops functioning.
II. The output quality of air shall be 3ºC-7º C at dew point and
pressure
Page | 320
drop across the dryer should not be more than 0.2 bar-0.3 bar.
To ensure optimum removal of the water contained in the air it
shall have main design features like:-
• Compact size air to air & air to refrigerant heat exchangers
for maximum heat transfer and minimal pressure drop.
• Hermetically sealed refrigerant compressor. Type of
Refrigerant used shall be explained with advantages in the
offer.
• Shall be conceived as a sliding module
• Integrated water separator with automatic/manual drain.
• Digital display of lowest air temperature on the panel.
• Large capacity condensers to convert refrigerant gas in to
liquid for efficient cooling these dryers shall be installed on a
vibration- damped base.
• A pre-filter shall be fitted on the intake side of the dryer and
final filter on the outlet side of the dryer at the downstream
of the dryer, an oil trap filter (final filter) retaining oil aerosols
shall be installed. Its efficiency shall be 99.5% at 0.1 micron.
• This efficiency test should be carried out at manufacturer
site in presence of employer’s representative. The filter
element shall be made of thermo compressed glass micro
fibers or equally effective other material and the supplier
shall submit comparative advantages. The output pressure
sensor must be installed at the output of the compressor after
the refrigerated air dryer and shows the pressure after
considering the losses among the dryer.
h) Reservoir
I. The Contractor shall install 1500 litres reservoirs in an
area downstream of the dryers. The reservoirs shall be suitable
for service pressure of 10 Kg/cm2 and shall have an inspection
hole at the top as well as an automatic condensing bleeder. The
inlet and outlet pipe flanges shall be designed for the full rated
output of two compressors working separately. These shall be
equipped with a 0 to 15 Kg/cm2 pressure gauge as well as a
safety valve. One isolation valve should be provided at inlet of each
receiver tank to isolate the reservoir tank from each other.
II. Moisture trap unit should be provided at the bottom of the
reservoir.
There shall be no air loss due to condensate
drain.
Page | 321
i) Pipe connection
i. Stainless steel, quarter-turn ball type valves of sufficient
dimensions shall be provided. Compressor reservoir
connection shall enable flexibility in connecting the
compressors to the reservoirs. A schematic diagram shall
be provided for approval before execution.
ii. A valve shall be provided to enable isolation of each
compressor from
airline. One isolation cock between each workshop line,
inspection line, interior cleaning & Pit wheel lathe
building should be provided. Condensate drain taps unit
are required in each of the lines.
1.2.4 Electrical installation
Power supply: 360-440V, 50 Hz ± 3%, three-phase, 4 wires.
a) Electrical switchboard/ control cabinet shall comprise of:

i. A three-pole main isolating switch fitted with HRC fuses
or equivalent isolating device.
ii. A main circuit breaker, Star delta starter for each
compressor motor or equivalent soft starter, with over load
protection for both main and fan motor.
iii. Contactors for other appliances,
iv. Phase sequence relay to avoid operation of the motor
in reverse direction,
v. Thermal/ magnetic protection for each appliance,
vi. Single phasing protection,
vii. The location of this cabinet shall be proposed
according to its dimensions and the electrical power
supply distribution point.
It shall comply with the regulations in force and its front panel
shall have indication lamps (one orange lamp per phase). The
degree of protection of the cabinet shall be IP 55 and ventilation
shall be through louvers. The electrical supply to both
compressors shall be given at one point.
All terminal boards and power supply cables shall be marked in

accordance with the electrical schematic diagrams. The functions
of the main components shall be identified by engraved labels
Page | 322
whose contents shall be identical to the electrical schematic

diagrams.
b) Cabling
Each appliance shall have its own cabling and wiring from the
cabinet. The main cable should be FRLSH XLPE insulated.
All equipment shall be designed for operation in a railway environment.

In particular, the equipment shall be protected from the detrimental
effects caused by:
a) Numerous interference phenomena caused by nearby high-
current equipment likely to frequently switch on and off,
nearby apparatus generating high frequencies (radio, telephone,
converters, etc.),
b) Miscellaneous interference noise, as well as against power
supply anomalies
such as high undulation rates, high over-voltages, slow
voltage variations,
c) The compressor should have inbuilt protection for high air oil
temperature should start giving warning of temperature at 110 degree
centigrade and will trip at 120 degree centigrade,
d) The compressor should have protection for all moving parts like pulleys,
belts, etc.
1.2.6 Standards
The entire supply shall comply with the requirements of the standards in force.
Work related to the production of the equipment shall comply with
the relevant Indian/European Standards, Codes of Practice and latest
statutory requirements of India including the following:
STANDARDS DESCRIPTIO
N
BSEN287 Approval testing of welders for fusion welding
Specification and approval of welding procedures
BSEN288 for metallic materials
BS5304 Code of practice for safety of machinery
Page | 323
Specification for coding of indicating devices

BSEN60073 and actuators by colours and supplementary
means.
Specification for degrees of protection provided by
BSEN60529
Enclosures (IP code).
1.2.7 Finish
a) Equipment (compressors, dryers, electrical cabinet)

All metal parts shall be painted & all bolting and fasteners shall be made of
high tensile steel.
b) Ventilation ducts and Electricity cableway
The ducts and all attaching parts (on the partitions or others)
shall be galvanised prior to assembly. After manufacture, the machined
components or duct parts shall be galvanised.
c) Partitions, floor.
The necessary paint touch-ups shall be executed on the walls and floor
of the room after erection of the installation.
d) Valves
Handles of normally open valves shall be painted green and Handles
of normally closed valves shall be painted red.
e) Piping
All the compressed air piping shall be MS. The MS pipe of various
sizes i.e.
100mm, 60mm, 25mm, 20mm, 15mm dia shall be provided wherever
required. The GI pipes shall conform to IS:1239 (PART I) “C” Class -
1979, IS 4736 and BS 3589 complete with all fitting such as elbows,
sockets, tees, unions, reducers, flanges, clamps, plugs and etc. with
threading, jointing and making connections including cutting holes in
wall/ floor/ slab and making good the same to its original finish. No sharp
bend shall be permitted. All the pneumatic piping up to the supply point of
UFWL machine shall be done with heavy duty pipe & and high quality
connectors , valves, gauges and all other accessories to
connect and supply for under floor wheel lathe machine. Wherever pipes
are passing through wall or floor etc. same shall be repaired after
completion of work and restored to original finish.
Page | 324
1.2.8 MS Pipe CONFIRMS TO IS: 1239 (PART I) “C” Class – 1979 and BS 3589
Nominal Outside Heavy (C-

Bore Diamete Class)
(MM) r (MM)
Thickness (MM) Weight (Kg/Mtr.)
3 10.32 2.65 0.493

6 13.49 2.9 0.769
10 17.1 2.9 1.02
15 21.43 3.25 1.45
20 27.2 3.25 1.9
25 33.8 4.05 2.97
32 42.9 4.05 3.84
40 48.4 4.05 4.43
50 60.3 4.47 6.17
65 76.2 4.47 7.9
80 88.9 4.85 10.1
100 114.3 5.4 14.4
125 139.7 5.4 17.8
150 165.1 5.4 21.2
1.2.9 Assembly and miscellaneous services
a) Connections to the appliances

Connections of piping to all appliances shall be such that removable parts can be
disassembled without requiring disassembly of the control systems, valves and
plugged accessories. It shall be possible to remove all piping elements placed
in the way of removable items.
b) Welding
Visual inspections and ultra-sonic inspections shall be carried out during and
after performance if necessary.
c) Reliability and maintenance
All component parts, and especially relays, shall be heavy-duty type providing
high reliability under normal machine operating conditions. All sub-assemblies
performing the same function shall be 100% identical and interchangeable.
d) Identification
All the following electrical and pneumatic equipment shall be marked by an
engraved plastic label indicating the function and the code number: -
Page | 325
• Appliances
• valves,
• cocks and fittings,
• Measuring and control equipment.
All symbols shall be in accordance with the standards and shall be marked on
the drawings, schematics and maintenance manuals.
The normal flow direction of the fluids shall be indicated with white,
black or conventional coloured arrows, depending on the background colour
so that satisfactory visibility is provided due to the contrast.
Presentation of
labels:
• white lettering on black background : minimum letter height
6mm,
• Attached by
rivets.
• Wherever possible, the labels shall be affixed to the
equipment itself.
• Labels for valves and special accessories and gear shall
be secured with a chain and by gluing.
a) In-manufacturer’s
plant
shall be carried out as per BS standards in order to ensure that the
supply is in accordance with the technical specification and with the
approved design documents.
manufacture on the Contractor’s or on the sub-contractors
premises. The Contractor shall arrange for quality checks on all
supplies on his sub-contractors premises prior to delivery of these
supplies to his workshops. The measure of FAD shall be carried
out as per ISO1217, Ed-3, and Annexure-C 1996. Operation of
safety and protection devices shall also be checked. All the checks
& tests carried out during FAT (factory acceptance test) shall be
recorded and shown for verification to the DMRC inspecting
engineer.
b) At-site
Page | 326
i. SAT (Site acceptance test) after installation of the equipment,

operating tests shall be carried out to check that equipment
design makes it suitable to fulfil the scheduled functions. The
purpose of the tests is to record and acknowledge that the
equipment is capable of performing regular service under different
operating conditions.
1.2.11 Spare parts
The contractor shall supply along with the machinery Spare Parts required
for two years after the expiry of defect liability period. The quantities of
spare parts shall be sufficient for the full operation of the machinery for the
first two years following the expiry of the Defects Liability Period for the
works. The list shall be provided in the offer.
1.2.12 Training
The contractor shall provide following training for operation and

maintenance staff
• One week training for four staff for operation of Compressor.
• One week training for four staff for maintenance of the
Compressor. (One week means six working days with eight
working hours)
All required training material should be provided for the intended training.
1.2.13 Maintenance
Page | 327
The contractor shall maintain complete installation during the Defect Liability
Period. It shall include labour, parts and consumables like oil, filters (air filter, oil
filter, and oil separator etc), various types of oils for top up etc. During DLP
each and every item including manpower etc shall be arranged by the contractor.
1.2.14 Documents to be provided
All documents shall be provided in

English.
1.2.15 For Execution of Work
Prior to manufacture of equipment, the Contractor shall send the following

documents for approval well in advance:-
a) Dimensional drawing of the foundations and anchoring of the elements

of the machine, and dimensions of the cabinet,
b) A detailed technical note indicating the weight of components and
removable parts, and including a list of all parts with the respective sub-
contractor’s references,
c) General equipment & piping layout drawings and detailed assembly
drawings, detailed drawings of mechanical parts, pneumatic diagrams,
detailed descriptive and operating note, detailed electrical diagram for
troubleshooting including cable index, connection diagram with markings,
documentation, drawings, notes and references of sub-contractors,
installation and commissioning procedure, Schedule of work and
completion period.
1.2.16 At Completion of Work
The Contractor shall provide the entire documentation, up to

date:
a) the list of general drawings and detailed drawings of electronic and

electrical diagrams with complete nomenclature, the general nomenclature
of the supply including sub-contractors, mechanical drawings,
electrical, electronic, pneumatic and hydraulic diagrams required for
maintenance and troubleshooting of the machine, illustrated lists of
mechanical and electrical parts itemised in accordance with the diagrams
and drawings mentioned above and including the addresses of the various
contractors two sets of maintenance and adjustment manual with summary
Page | 328
of circuits and functions and among other information, a lubrication manual

including location of lubrication points, type of lubricants, frequencies and
quantities,
b) two sets of operating manual (start up and user’s instructions),
• complete documentation of equipment from sub-contractors,
• Complete documentation on motors and major components.
1.2.17 Gunmetal ball valve
A ball valve is a valve with a spherical disc, the part of the valve which controls the
flow through it. The sphere has a hole, or port, through the middle so that when
the port is in line with both ends of the valve, flow will occur. When the valve is
closed, the hole is and perpendicular to the ends of the valve, and flow is blocked.
The handle or lever will be in line with the port position letting you "see" the valve's
position. Ball valves should durable and work to achieve perfect shutoff.
Page | 329
The details are

as under:-
a) Ports: 100 mm/65 mm/50 mm/25 mm/15 mm (BSPP,

BSPT & NPT). b) Body width: As per size.
c) Flow: 89-136 CFM.
d) Working pressure: 7-15
Kg/ Sqcm. e) Design
pressure: 38 Kg/ Sqcm.
f) Temperature:1 to 60 degree
centigrade. g) Body: Gun metal.
h) Ball: Stainless steel.
i) Handle: GI or
stainless steel. j)
Seats: Teflon.
k) Seal: Teflon.
l) Fully opening: 90 deg angle.
1.2.18 Auto drain valve
Auto Drain Valves help in purifying the air by getting it rid of the pollutants
periodically and automatically. These Drain Valves and air drain valves
are used to remove the condensate from the pneumatic piping.
The details
as under:
a) Material of construction:
Aluminium/ Brass. b) Media: Air/
Water.
c) Direct acting/ External pilot
type: 1/2” Inlet. d) On time setting:
0 to 99 sec Variable.
e) Off time setting: 0 to 99 Min settable & variable in steps of 1 min.
f) Pressure range: 1-15 kg/Sqcm.
g) Operation: Normally open/
normally closed. h) Seat:
VITON/Neoprene/Teflon.
Page | 330
i) Temperature: 2 degree centigrade to 60 degree

centigrade. j) Coil Enclosure: Fly lead/ Terminal
Box.
1.2.19 Pressure gauge
Bourdon type pressure gauges covering ranges between 0-15 Kg/ Sqcm
consist of `C' type/ helical type Bourdon Tubes made of nonferrous/ AISI
316 SS, closed at the upper end and the open end is soldered/argon
welded firmly to the connecting socket. Pressure causes the Bourdon
to expand or contract. The motion of the closed end of the Bourdon
tube is transferred to the pointer mechanism through rack and pinion
arrangement. Any backlash error is being completely eliminated by
providing suitable hair spring. The gauge with the Bourdon tube is
suitable under normal operating conditions for measuring Air.
The details
as under:-
a) Material: Sheet metal casing-

brass internal. b) Body dia: 150
mm.
c) Pressure: 0-15 Kg/ Sqcm.
d) Range: ± 2%.
e) Robust but lightweight.
1.2.20 Filter regulator
Filter regulator provides unsurpassed sensing, regulation and filtration performance

for pneumatic system. It can provide the clean dry air necessary to achieve
the peak performance required by fluid power system. The connectors should
simplify the plumbing of all components. Its innovative one touch fitting
technology provides dramatic time savings during the installation of both air
fittings and pneumatic flow controls.
The general features are

under:
a) Ports: 1/2” (BSPP, BSPT &

NPT). b) Body width: 60 mm or as
required. c) Flow: 89-136 CFM.
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d) Pressure: 7-15 Kg/Sqcm.

e) High efficiency 5 micron element.
f) Excellent water removal efficiency.
g) Robust but lightweight aluminium construction.
h) Positive bayonet latch to ensure correct & safe fitting.
i) Aspiration plus balanced poppet that provides quick response and
accurate pressure regulation.
1.2.21 Non return valve
Wafer type (Plate type) check valve/NRV has short face-to-face dimensions
and low weight allows a simple space saving installation between the companion
flanges. The valves are suitable to mounting between weld neck or slip on type
companion flanges of different standards. Opening and closing of the valve will
take place at an extremely low-pressure difference over the valve disc. The
eccentric disc shaft combination with the disc seat guarantees a positive shut
off returning media. It should be compact in design.
Feature
s
a) Body Type: Single Plate, Short

Type. b) Material: Cast steel.
c) Suitable For Horizontal and Vertical Mounting.
d) Shorter overall length, mounting requires minimum
space. e) Low Pressure Drop.
f) Maintenance Free.
g) End Connection: Wafer Type,
Flangeless. h) Size Range: 60mm to
100mm.
i) Pressure Rating: 15 kg/sqcm.
j) Seat Leakage: Zero Leakage, Tight Shut
Off. k) Temperature Range: 1 to + 70 C.
l) Mounting Between: ASA 150 flanges.
1.2.22 Cast Iron Body-Butterfly Valve
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The butterfly valve should suitable for isolating or regulating air flow. The closing
mechanism takes the form of a disk. It should be lighter in weight. The disc
should positioned in the centre of the pipe, passing through the disc is a rod
connected to an actuator on the outside of the valve. Rotating the actuator turns
the disc either parallel or perpendicular to the flow.
The butterfly should be a metal disc mounted on a rod. When the valve is closed,
the disc is turned so that it completely blocks off the passageway. When the
valve is fully open, the disc is rotated a quarter turn so that it allows an almost
unrestricted passage of the fluid. The valve may also be opened incrementally to
throttle flow.
The general features are as

under:
a) Type: Wafer type.

b) Material: Cast Iron PN16 IS: 210 FG
220. c) Test pressure: 15 Kg/ Sqcm.
d) Suitable For Horizontal and Vertical Mounting.
e) Suitable for ASA 150 standard
flanges. f) Temperature Range: 1 to +
70 C.
g) Low Pressure Drop.
h) Maintenance Free.
i) Size Range: 60 mm to 100
mm. j) Pressure Rating: 15 kg/
Sqcm.
k) Seat Leakage: Zero Leakage, Tight Shut Off.
1.3 AIR COMPRESSOR FOR PIT WHEEL LATHE & INTERIOR CLEANING – 21 CFM
1.3.1 General Description
Air compressor 1 no. is required for production of compressed air for the Pit
Wheel Lathe at Depot. The specification covers the design, manufacture, supply,
installation, testing and commissioning of Air Compressors. The compressor
shall have high efficiency & low power consumption. The supply shall comprise
stationary type, electric motor driven, and self-lubricating Rotary Screw type
complete with suction filter, air/oil separator, air cooled after cooler, oil filter, oil
cooler integrated refrigerated air drier & moisture trap. All compressor housed
in silenced package provided on anti-vibration mounts. The supply shall include
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air filters, pipes and pipe couplings, electric controls, and all other accessories to
make the equipment & installation fully functional. A set of service tools and special
tools shall also be supplied along with the compressor. The compressor and
installations shall be designed considering ease of maintenance and requiring
minimum service in order to optimise down time.
1.3.2 Technical Characteristics
The compressor shall be capable of giving an output of 21 CFM of air at an

operating pressure of 10 Kg/ cm2. The system shall be equipped with inlet air
filter, inlet check valve, compressor, oil separator element and minimum pressure
valve.
The compressors shall be single stage and self-lubricating, rotary screw type and
shall be mounted on steel deck suitable for 100 % continuous duty.
The system shall have heavy duty dry type inlet air filter, conveniently located for quick
and easy replacement with cyclonic separation and arrangement for pre filter
separation. The compressor unloading assembly shall be provided with piston type
unloader to release safe inside pressure. The unit shall have not-return valve at suction
element.
The compressor shall be provided with all the components required for a complete
installation & with first fill of oil & lubricants for integrated commissioning.
The supply shall include pressure regulation safety valve, pressure regulator outlet
valve, pressure gauge, periodic electronic condensate drain and pre piped. All
connections shall be optimized to minimize pressure drip & reduce and potential for air
leaks.
Arrangement shall also be incorporated for automatic shutdowns in the event of

prolonged off-load operation. The compressor units shall be equipped with condensate
separator with both auto & manual drain.
The compressor shall be driven by adequate capacity TEFC squirrel cage type 3-phase
Induction motors (5.5 kW), having insulation Class F, DOL type starter with contractor,
relays and single-phase prevention shall be used.
The ingress protection of all motors shall be IP 55. Pre wired connections between the
motor and starter should be provided. The compressor shall be suitable for continuous
and heavy-duty operation. The contractor shall submit the compressor drive installed
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motor power (in kW & hp). The manufacturer shall use all modern techniques of vibro-
acoustics optimisation for extremely low noise and vibration level. The compressors
permissible noise level measured at a distance of 1 m from the acoustic enclosure shall
be less than 70 dbA. The compressor shall be provided with integrated oil removal filter
with filtration level of 0.01ppm. The temperature of air leaving the compressor unit shall
not be more than 10ºC above the ambient. The contractor shall submit equipment and
piping layout drawing (preferably a 3 dimensional drawing) considering space available
in the compressor room & reservoirs outside. Depot layout drawing with compressor
room marked is enclosed.
All the equipment of the compressor package shall be mounted on a common base
frame for foundation less installation. The base frame including the tank shall be made
sturdy with facility for mobile crane & fork lifting arrangement. A twin element suction air
filter on the intake side of the compressor, a compressed air-oil separator, oil cooler
and a spin on type oil filter with internal NRV shall be provided.
a) Suction filters
The dust filter (pre-filter) shall be capable of filtration up to 1 micron absolute

with 99.5 % efficiency for solid particles. Heavy-duty dry type intake air filter,
conveniently located for quick and easy replacement with cyclonic separation
and arrangement for pre filter separation shall be provided.
b) Compressor
Single stage self-lubricated rotary screw compressor having high efficiency

and reliability shall be provided. It shall be equipped with: -
i. The air intake valve should be maintenance free

pneumatically controlled vacuum controlled without spring Intake
valve assembly for Load/ No load regulation.
ii. Vacuum gauge
adopter.
c) Air/ Oil Separator/ Oil cooler
The system shall have provision for oil reservoir, oil cooler, thermostatic
valve block and oil filter. The system shall have oil level indicator and oil
filling arrangement. Oil separator shall be mounted outside air tank,
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minimizing the oil carry over, integrated minimum pressure valve, safety
valve and oil draining arrangement. Oil cooler shall be equipped with high
efficiency block type cooled aluminium oil cooler. It shall have axial flow
fan for cooling, oil filter and oil restrictor to regulate oil flow. The
system shall consist electro pneumatic regulation system with air/ oil
receiver blow down mechanism to reduce No-load power consumption and
pressure switch to set discharge air pressure to desired limits.
All oil lines shall be of rigid steel pipe and with minimum number of high
temperature hoses.
d) Reservoir
The compressor package with electro pneumatic control panel shall be

mounted on a 200L air reservoir (ISI/ ASME approved as standard).The
reservoir shall be suitable for service pressure of 10Kg/ Sqcm. The
moisture trap shall be provided at the bottom of reservoir. There shall
be no loss of air due to condensate drain. The air compressor shall be
placed directly on firm floor near to the consumption point & needs no
foundation.
e) Pipe connection
Stainless steel, quarter-turn ball type valves of sufficient dimensions

shall be provided. Compressor reservoir connection shall enable flexibility
in connecting the compressors to the reservoirs. A schematic diagram
shall be provided for approval before execution. Condensate drain taps
unit are required in each of the lines.
1.3.4 Electrical installation
Power supply: 360-440V, 50 Hz ± 3%, three-phase, 4 wires. Compressor unit shall

be driven by V- belts with XPZ profile, coupled with 5.5 KW motor of Power supply
3 phase AC. Motor shall have TEFC square cage, F class insulation with IP 55
standard of likely make Siemens. Motor bearing shall be greased for life long.
a) Control Panel
The Control Panel shall comprise

of:
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i. DOL starter for each compressor motor or equivalent soft starter, with
over load protection for both main and fan motor,
ii. a three-pole main isolating switch fitted with HRC fuses or equivalent
isolating device,
iii. a main circuit breaker, iv.
Dryer ON/ OFF button, v.
Regulator with relays,
vi. Hour-meter to indicate total hours of operation,
vii. Start/ Stop button with lamp indicating compressor operation, viii.
Indicator for auto operation,
ix. Easy access for service points,
x. a phase sequence relay to avoid operation of the motor in reverse
direction,
xi. thermal/ magnetic protection for each appliance,
xii. Single phasing protection.
The location of this cabinet shall be proposed according to its dimensions and
the electrical power supply distribution point.
The degree of protection of the cabinet shall be IP 55 and ventilation shall be through
louvers. The electrical supply to both compressors shall be given at one point.
All terminal boards and power supply cables shall be marked in accordance with
the electrical schematic diagrams.
The functions of the main components shall be identified by engraved labels

whose contents shall be identical to the electrical schematic diagrams.
b) Cabling
Each appliance shall have its own cabling and wiring from the cabinet. The main
cable should be FRLSH XLPE insulated.
All equipment shall be designed for operation in a railway environment. In particular,

the equipment shall be protected from the detrimental effects caused by:
Page | 337
a) Numerous interference phenomena caused by nearby high-current equipment

likely to frequently switch on and off nearby apparatus generating high
frequencies (radiotelephone, converters, etc.),
b) Miscellaneous interference noise, as well as against power supply anomalies
such as high undulation rates, high over-voltages, slow voltage variations.
c) The compressor should have inbuilt protection for high air oil temperature it
should start giving warning at 110 degree centigrade temperature and will trip at
120 degree centigrade.
d) The compressor should have protection for all moving parts like pulleys, belts,
etc.
1.3.6 Standards
The entire supply shall comply with the requirements of the standards in force.
Work related to the production of the equipment shall comply with the
relevant Indian/European Standards, Codes of Practice and latest statutory
requirements of India including the following:
STANDARDS DESCRIPTIO
BSEN287 N
Approval testing of welders for fusion welding.
BSEN288 Specification and approval of welding procedures
for metallic materials.
BS5304 Code of practice for safety of machinery.
BSEN60073 Specification for coding of indicating devices and
actuators by colours and supplementary means.
BSEN60529 Specification for degrees of protection provided by
enclosures
(IP code).
1.3.7 Finish
a) Equipment (compressors, dryers, electrical cabinet)
All metal parts shall be painted & all bolting and fasteners shall be made
of high tensile steel.
b) Ventilation ducts and Electricity cableway
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The ducts and all attaching parts (on the partitions or others)
shall be galvanised prior to assembly. After manufacture, the machined
components or duct parts shall be galvanised.
c) Partitions, floor
The necessary paint touch-ups shall be executed on the walls and floor
of the room after completion of the installation.
d) Valves
Handles of normally open valves shall be painted green and Handles

of normally closed valves shall be painted red.
e) Piping
All the compressed air piping shall be MS. The MS pipe of various sizes i.e. 100 mm,
60 mm, 25 mm, 20 mm, 15 mm dia shall be provided wherever required. The GI
pipes shall conform to IS:1239 (PART I) “C” Class - 1979, IS 4736 and BS 3589
complete with all fitting such as elbows, sockets, tees, unions, reducers,
flanges, clamps, plugs and etc. with threading, jointing and making connections
including cutting holes in wall/ floor/ slab and making good the same to its
original finish. No sharp bend shall be permitted. All the pneumatic piping up to the
supply point of UFWL machine shall be done with heavy duty pipe & and high
quality connectors, valves, gauges and all other accessories to connect and supply
for under floor wheel lathe machine. Wherever pipes are passing through wall
or floor etc. same shall be repaired after completion of work and restored to
original finish.
1.3.8 MS Pipe CONFIRMS TO IS: 1239 (PART I) “C” Class - 1979 and BS 3589
Nominal
(mm)Bore Outside
Diamete Heavy (C-Class)
r Thickness Weight (Kg/ Mtr.)
(mm)
3 (mm)
10.32 2.65 0.493
6 13.49 2.9 0.769
10 17.1 2.9 1.02
15 21.43 3.25 1.45
20 27.2 3.25 1.9
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25 33.8 4.05 2.97

32 42.9 4.05 3.84
40 48.4 4.05 4.43
50 60.3 4.47 6.17
65 76.2 4.47 7.9
80 88.9 4.85 10.1
100 114.3 5.4 14.4
125 139.7 5.4 17.8
150 165.1 5.4 21.2
.3.9 Assembly and miscellaneous services
a) Connections to the appliances

Connections of piping to all appliances shall be such that removable parts
can be disassembled without requiring disassembly of the control
systems, valves and plugged accessories. It shall be possible to remove
all piping elements placed in the way of removable items.
b) Welding
Visual inspections and ultra-sonic inspections shall be carried out during
and after performance if necessary.
c) Reliability and maintenance
All component parts, and especially relays, shall be heavy-duty type
providing high reliability under normal machine operating conditions. All
sub-assemblies performing the same function shall be 100% identical and
interchangeable.
d) Identification
All the following electrical and pneumatic equipment shall be marked
by an engraved plastic label indicating the function and the code number:
-
•
Appliances
•
valves,
• cocks and
fittings,
• Measuring and control equipment.
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All symbols shall be in accordance with the standards and shall be marked
on the drawings, schematics and maintenance manuals.
The normal flow direction of the fluids shall be indicated with white,
black or
conventional coloured arrows, depending on the background colour so that
satisfactory visibility is provided due to the contrast.
Presentation of
labels:
• white lettering on black background : minimum letter height
6mm,
• Attached by
rivets.
• Wherever possible, the labels shall be affixed to the
equipment itself.
• Labels for valves and special accessories and gear shall
be secured with a chain and by gluing.
a) In-manufacturer’s plant
shall be carried out as per BS standards in order to ensure that the
supply is in accordance with the technical specification and with
the approved design documents.
manufacture on the Contractor’s or on the sub-contractors
premises. The Contractor shall arrange for quality checks on all
supplies on his sub- contractors premises prior to delivery of these
supplies to his workshops. The measure of FAD shall be carried
out as per ISO1217, Ed-3, and Annexure-C 1996. Operation of
safety and protection devices shall also be checked. All the checks
& tests carried out during FAT (factory acceptance test) shall be
recorded and shown for verification to the DMRC inspecting
engineer.
b) At-site
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i. SAT (Site acceptance test) after installation of the equipment, operating

tests shall be carried out to check that equipment design makes it
suitable to fulfil the scheduled functions. The purpose of the tests is to record
and acknowledge that the equipment is capable of performing regular
service under different operating conditions.
1.3.11 Spare parts
The contractor shall supply along with the machinery Spare Parts required for two
years after the expiry of defect liability period. The quantities of spare parts shall be
sufficient for the full operation of the machinery for the first two years following the
expiry of the Defects Liability Period for the works. The list shall be provided in the
offer.
1.3.12 Training
The contractor shall provide following training for operation and maintenance staff
• One week training for four staff for operation of Compressor.
• One week training for four staff for maintenance of the
Compressor. (One week means six working days with eight working
hours).
All required training material should be provided for the intended training.
1.3.13 Maintenance
The contractor shall maintain complete installation during the Defect Liability Period. It
shall include labour, parts and consumables like oil, filters (air filter, oil filter, and oil
separator etc.), various types of oils for top up etc. During DLP each and every item
including manpower etc. shall be arranged by the contractor.
1.3.14 Documents to be provided
All documents shall be provided in English.
1.3.15 For Execution of Work
Prior to manufacture of equipment, the Contractor shall send the following documents
for approval well in advance:-
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d) Dimensional drawing of the foundations and anchoring of the elements of the

machine, and dimensions of the cabinet,
e) A detailed technical note indicating the weight of components and removable
parts, and including a list of all parts with the respective sub-contractor’s
references,
f) General equipment & piping layout drawings and detailed assembly drawings,
detailed drawings of mechanical parts, pneumatic diagrams, detailed descriptive
and operating note, detailed electrical diagram for troubleshooting including
cable index, connection diagram with markings, documentation, drawings, notes
and references of sub-contractors, installation and commissioning procedure,
Schedule of work and completion period.
.3.16 At Completion of Work
The Contractor shall provide the entire documentation, up to

date:
c) The list of general drawings and detailed drawings of electronic and

electrical diagrams with complete nomenclature, the general
nomenclature of the supply including sub-contractors, mechanical
drawings, electrical, electronic, pneumatic and hydraulic diagrams
required for maintenance and troubleshooting of the machine,
d) Illustrated lists of mechanical and electrical parts itemised in accordance
with the diagrams and drawings mentioned above and including the
addresses of the various contractors two sets of maintenance and
adjustment manual with summary of circuits and functions and among
other information, a lubrication manual including location of lubrication
points, type of lubricants, frequencies and quantities,
e) Two sets of operating manual (start up and user’s
instructions),
• Complete documentation of equipment from sub-contractors,
• Complete documentation on motors and major components.
1.3.17 SPECIAL REQUIREMENTS
The system shall be designed to operate at the normal workshop

temperature arrangement shall also be incorporated for automatic shutdowns
in the event of prolonged off-load operation. The compressor shall be capable
of direct placement on firm floor near to the consumption point. High discharge
air temperature shut down system should be provided to limit the compressed
air temperature up to 120 deg C.
Page | 343
The sound level for the overall of the installation shall not exceed 70 dB at a
distance of one meter and shall, in no case whatsoever, create vibrations in the
ground or in the partitions.
Anti-Vibration Mountings shall be provided with sound proofing

treatment.
Page | 344
TECHNICAL
SPECIFICATION-
STREET LIGHT AND HIGH
MAST
2.1 EXTERNAL LIGHTING
A. Scope
The scope of work covers the supply, installation and testing of lighting poles, high
masts, weather proof Light fixtures, wiring to the fixtures, cable laying, earthing as
specified and shown on the drawing.
Page | 345
B. General
The octagonal/ round type street lighting poles used for lighting of approach roads,
traffic lanes and walkways in the circulating area, shall be erected at a distance of
300 mm from the edge of the road/ walkway. The foundation for the poles shall be
of 1:2:4 concrete. This shall be done by the Contractor as a part of the contract
work as per the approved drawing. The pole with its base plate shall be grouted in
the foundation which shall be provided with muffing. Galvanized down pipes/
sleeves of suitable diameter shall be embedded in the concrete for the incoming
and outgoing feeder cables. Contractor should follow CPWD specification for
mounting of MCBs.
C. Street and Flood Lighting Fixture.

In addition to the specifications given above the external luminaire should have
minimum of IP-65 protection impact protection of rating min 05 i.e. IK-05, UV
stabilized clear polycarbonate cover or clear toughened glass. The light fixture
construction shall be of die- cast/ extruded aluminium.
D. High Mast lighting luminaries.

1. High Mast Lighting Luminaries suitable for LED light fixtures for rotationally symmetric
distribution. Complete with accessories including appropriate gear and fixing
arrangements, confirming to IS 10322-1987. The luminaries shall be sturdy, having die-
cast/ extruded aluminium housing and black plate, corrosion resistant high purity
aluminium reflector, electromechanically brightened and anodized heat resistant and
toughened glass cover, high resistant silicon rubber marked appropriate disc facilitating
proper aiming of the luminaire, suitable stainless steel togged as specified as required.
The luminaire shall be suitable for fixing on lantern carriage of high mast.
2. The lamp & Luminaries shall generally follow the specification under section ‘LIGHT
FIXTURES.
E. Street Lighting Poles

1. The lighting poles shall be octagonal / round type poles as per IS 2713 (PART 2) –1980,
hot dip galvanized as per drawings and as specified. The pole shall have a base plate, a
large access panel, and necessary fixture mounting bracket at top and 2 nos. 1.5 m length
of 40 mm diameter bent GI pipes for cable loop-in loop-out to be provided. The access
panel shall provide easy access to a multi-way porcelain connector and fuse board, to be
mounted inside the pole. The access shall be specially fabricated with adequate
reinforcement and weather gasket to prevent ingress of moisture and vandal proofed.
Poles shall have large diameter entries for incoming and outgoing cable and two earth
studs. The pole fabrication shall conform to the drawings and where such drawing is not
available; the contractor shall make drawing and have it approved before fabrication.
2. The octagonal / round poles shall be made from steel of minimum tensile strength 490 N/
Page | 346
mm2.
3. Grade of foundation bolts shall be 6.8 & confirming to IS: 1367 (Part-III) - 2002.
4. Foundation - adequate size M30 grade RCC foundation with 100 mm raft including
excavation are included in the rates of street light poles. Contractor shall submit design
calculation in support of size of RCC foundation for external lighting poles.
5. The pole shall be provided with a 20 mm hole for wiring of street light pole and two nos. 20
mm studs are to be welded for earthing.
F. Junction Boxes and Connecting Cable.
1. Each pole shall be complete with an MS junction box of pole-mounting type/ fitted inside
the pole, manufactured from MS sheet of 14 sheet gauge painted with oil paint over red
oxide zinc chromate primer. The junction box shall have a water proof lockable cover of
size 500 x 100 mm. It shall be fitted with 6A MCB and 6-way, 20A connector strip, a neutral
link, earthing studs and suitable down pipes for the incoming and outgoing cable- lead. The
junction box shall generally comply with the requirements of IS: 2675-1983. The supply of
pole shall be complete with 3 x 4-mm2 copper FR / cable, PVC insulated, PVC sheathed
drawn from the junction box to the luminaire terminal.
2. Pole shall have a concrete coping of 200 mm height and 300 mm diameter in M30.
G. Cable laying
1. Cabling shall be generally as specified in the section ‘CABLING.’
2. Cables shall be terminated in a 6-way terminal block inside the pole or attached therewith
as shown on drawings.
3. Cable route shall be as shown on the drawings or the contractor shall mark out the route
and lay the cables only upon approval of the route.
H. Earthing
All street light fixtures and poles shall be earthed as specified under section
‘EARTHING.’ In each pole a through hole of 14 mm diameter shall be provided at
a height of 300 mm for earthing. Every lighting pole shall be earthed by connecting
it to the continuity earth of the feeder cable from the feeder pillar. In addition, every
7th pole shall be connected to locally provided earth electrode as per approved
drawing.
I. Feeder pillars (as applicable)
1. Suitable feeder pillars, 3-phase 415 V outdoor type, with a fixed canopy shall be
provided for power distribution to masts & street lights. The feeder pillar shall have IP:
65 degree of protection. It shall be provided with weather-proof lockable door, incoming
and outgoing cable glands, earthing studs and other accessories.
J. Testing and commissioning
1. The lighting installation shall be tested as per approved schedule and the instructions of
Engineer and shall include but not be limited to the following:
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a) Insulation resistance of each circuit shall be measured without the lamps

being in place. It should not be less than 500000 ohms to earth.
b) Current and voltage of all the outdoor lighting circuits shall be measured at
the Main Distribution Board with all the lamps switched on to ensure that
these are within designed values and in the case of 3-phase circuits, the
load shall be balanced if required.
c) Earth continuity shall be checked for all the circuits.
d) After inserting all the lamps and switching on all the circuits, minimum and
maximum illumination levels shall be measured in all areas and their
conformity with designed levels established. The test results shall be entered
in the approved pre-commissioning proforma and submitted to the Engineer
for approval before final commissioning.
2.2 HIGH MAST LIGHTING
A. Scope
This specification deals with the design, fabrication/ manufacture, testing, supply
and erection of outdoor high lighting equipment including 20 Mtr. high mast with
mobile lantern carriage, luminaries and associated accessories, fittings, etc. to be
installed for lighting of circulating area outside the station/ Depot.
B. Codes and standards

1. Design, manufacture and performance of the mast shall comply with all currently
applicable statutory regularities and safety codes and standards in the locality where
the equipment will be installed and generally in accordance to the following:
a) British Code of Practice CP3: Chapter V Part 2: 1972
b) Technical Report No.7: Second Edition, Section 2:1996 by the Institute of
Lighting Engineers.
2. The work shall be done to a high degree of workmanship in accordance with approved
drawings and in conformity with this specification and the relevant specifications and
code of practice of the bureau of Indian Standards, including the following:
c) Indian Electricity Rules.

d) Code of Practice for fire safety of buildings (general); Electrical Installations –
IS: 1646-1982.
e) Code of Practice for installation and maintenance of power cables up to and
including 33 kV rating – IS: 1255 - 1983.
f) Regulations laid down by the Chief Electrical Inspector.
g) Any other regulations laid down by the Local Authorities.
C. Design
20 Metres high mast suitable for fixing of luminaries (to achieve required lux
level), with lantern carriage and all accessories required to complete the supply
and erection of High Masts at designated locations high mast shall be
manufactured as for Technical Report No. 7 (latest edition) by the institution of
lighting engineers and as per specification of high masts given in this document.
Page | 348
D. General constructional features
1. The mast shaft shall be made with the best steel grade, in compliance with BS EN 10
025 FE 510C, having the following guaranteed characteristics:
a) Minimum Yield Strength = 355N/sq.mm for thickness < 30mm

b) Tensile Strength ranging from 490 to 630 N/sq. mm
c) Minimum elongation for thickness between 3mm and 30mm: 22%
2. The steel grade for accessories shall be BS EN 10 025 Fe 430A or equivalent, having
the following guaranteed characteristics:
a) Minimum Yield Strength = 225N/sq. mm for thickness < 30mm

b) Tensile Strength ranging from 340 to 470 N/sqmm
c) Minimum elongation for thickness between 3mm and 30mm: 26%
d) All holding bolts are hot dip galvanized to BS: 729.
E. Mast design criteria
a) The high mast and the lowering system with the required number of
floodlights and lamp control gears etc. in place shall be capable of
withstanding a sustained basic wind speed of 180 km/h with 3 seconds gust.
b) The design shall be in such a manner that it is capable of withstanding
external forces exerted by wind pressure and should have a minimum wind
load factor of
1.25 and material factor of 1.115. Design life of mast should be at
least 25 years.
The mast shall be designed in accordance to the table below:(Contractor
need to provide the technical data for high mast asked below:
By contractor:
Maximum Loading on Foundation 20m High Mast
Shear Force
Overturning Moment
Torsion Moment
Axial Load
Max. Deflection
Max. Base Flange O. D.
F. Mast structure and construction
1. Each mast section to be delivered to site shall have a minimum length of 9.0 m. the
sections shall not be circumferential welded through slip joint of multiple short
sections. Detailed instructions relating to site assembly shall be provided.
2. The top section shall have a flange plate for bolted connection to the head frame.
3. The base shall have a flange plate for fixing the high mast onto the concrete
foundation by anchor bolts.
4. The mast shall be fabricated as per technical report no. 7 of institution of lighting
Page | 349
engineers. It will be butt welded longitudinally to form a tapered section with (one)
longitudinal seam weld is permissible. All welding shall be to BS 5135 having the
following basic requirements:
5. Mast sections to base flange and longitudinal weld within 150 mm of the female slip
joints areas shall have :-
a) Full penetration between plates of all thickness.

b) No fissures.
c) No undercutting.
d) No blow holes, porosity or spherical beyond 5% on the minimum thickness.
No detectable angular inclusion.
e) Longitudinal welds along the mast shaft shall have: - 60% minimum
penetration between plates.
f) No fissure on the inside and outside surface. No undercutting on the outside
surface.
g) No blow holes.
6. Ultrasonic testing procedures shall be considered as minimum permissible testing
method.
7. The wall thickness of each section shall be designed to withstand the loads to which
the high mast will be subjected to but shall not be less than 3 mm.
8. Unless otherwise specified connection between the various station shall be achieved
by telescopic slip joints, the overlapping length being at least equal to 2.0 times the
inside diameter of the female section. Slip joint assembly shall be performed at site.
Shaft section shall not be joint by circumferential weld or bolting.
9. The base plate shall be free from lamination and shall be single flange constructed
with holes jig drilled for anchor bolt passage. The bottom of the base mast section
shall be securely welded to the base plate by complete penetration butt welding or
fillet welding. The welded connection of the base plate to the mast section shall fully
develop the strength of the section.
10. The base section shall be equipped with a hinged service door. The service door
opening shall be completed with a close fitting weatherproof and equipped with a
vandal resistant lock. The service door shall not be smaller than 1200 mm X 250
mm. The opening shall be reinforced by a thick steel door frame.
11. Base plate dimensions and thickness and the no. diameter, size and the placement
of anchor bolts shall be determined by calculation and indicated in the drawings.
12. Anchor bolts shall be deformed steel reinforcement bars having the following
minimum guaranteed characteristics:
a) Specified characteristic strength = 460N/sq.mm
b) Tensile strength= 480N/sq.mm
13. Welding of two or more anchor rods of shorter lengths to achieve the design length
shall not be permitted. No welding shall be allowed on the anchor rod body.
14. Adequate earthing and earthing terminal shall be provided within the access door
area of each high mast. Details shall submit to the engineer for approval.
15. All high mast shall be hot dip galvanized, in accordance with British Standard 729/
1971 (1986).
16. All mast components shall be hot dip as per BS 729 galvanized after completion of
fabrication. The galvanized of sections having overall length of up to 14 m shall be
achieved in a single dip operation. Double dipping of any mast section is strictly
prohibited. Galvanising shall be inspected for adhesion, mass of zinc coating and
uniformity of coating
G. Lantern carriage
1. The mobile luminaries ring shall be of steel construction and manufactured in three
Page | 350
segments. Bolted flanges shall join the unit. All mobile components of the system
shall be located on the mobile part in order to allow visual inspection during each
operation. Proper luminaries’ carriage ring support arms shall be provided for
supporting the luminaries’ carriage ring when the latter is lowered for maintenance
of luminaries.
2. The mobile luminaries’ carriage shall be designed to carry the assigned no. of
luminaries and control gears and shall be evenly balanced. Nylon Paddle Guide
Ring shall be incorporated as a buffer arrangement between mobile luminaries
carriage and mast shaft. This is to prevent damaged to mast surface during raising
and lowering operation of mobile luminaries’ carriage.
3. The complete mobile components shall be hot dip galvanised in accordance to BS
729.
4. The steel grades used for construction of the head frame assembly and mobile part
shall be in compliance with BS EN 10025.
H. Raising and lowering mechanism
For installation and maintenance of luminaries and lamps, it shall be necessary to lower and
raise the mobile luminaries’ carriage by means of a suitable winching arrangement at the
base of the mast. The speed of the raising and lowering of lantern carriage ring shall be at
least 3.0m per minute.
I. Winch
1. The winching system with the exception of the drive unit shall remain permanently
inside the mast. Each mast shall be provided with a double drum winch suitable for
raising and lowering the luminaire carriage ring.
2. The winch must be robust design and completely self-sustaining type without the
brake
- shoe, springs or clutches. It can be removed from the mast for maintenance if the need
arise in future. The reduction gear of the winch shall be of endless worm gear. Operating
in an oil bath. The minimum safe working limit of the winch shall be not less than 750 Kg.
3. The capacity and operating speed of the winch shall be clearly marked on an
indelible label together with the specification of the recommended lubricant.
4. A minimum 6 turns of wire rope shall be on the grooved drum when the mobile
luminaire ring is fully lowered to rest on the supporting arms.
5. The winch is entirely self-sustaining under all normal circumstances and it is not
depend on the brake or restarting device that uncontrolled or dangerous runaway
speeds will occur in the event of the total failure and report shall be submitted upon
request.
6. Test certificates in support of the safe working limit shall be provided upon request.
J. Head frame Escalation
1. The head frame duly hot dip galvanized shall include a pulley system accommodate
3 stainless steel hoisting wire rope at any one time and separate pulley for the
passage of flat electrical cables.
2. The pulleys shall be of non-corrosive material and shall run on self-lubricating
bearing with stainless steel axles.
K. Hoisting and suspension wire ropes
1. The high mast shall be fitted with flexible stranded stainless steel hoisting wire ropes
of 7 x 19 constructions with a minimum breaking strength of KGs. The combine
lifting capacity of the hoisting wire rope shall have a factor of safety not less than 5
times the safe working load (SWL) of the winch and shall be entirely suitable for the
Page | 351
design application.
2. A transition plate shall be incorporated to connect the suspension wire ropes to the
two stainless steel winching wire ropes ensuring ensure even distribution of loads
between the two stainless winching-wires by means of an equaliser with a provision
to fix electrical cables.
L. Electrical cables
Electrical cable shall be anti-twisting flat flexible 2.5 mm2 EPR cable suitable for small
bending radius. One standard 12 core flexible electrical cable with 2.5mm2 conducting area
shall be providing for connecting of power supply to the light source and shall terminate at
the stationary connecting board in the base compartment with a multiple 10-pin weather
proof plug and socket coupler fitted with locking levers.
M. Winch driving power tool
1. The winch drive unit shall be complete with a 415V, 3-Phase, 50 Hz squirrel cage,
reversible weather resistance, IP 55 protection, min. class B insulation induction
motor, a coupling flange for winch to facilitate detachment and attachment on
several masts in succession.
2. For safety reasons and final precision docking of lantern carriage ring to the head
frame, the drive motor must have a provision to operate manually by using external
crank device without removing the drive motor from the winch unit.
N. Control panel
1. Control of raising and lowering operation shall be carried out by means of Outdoor
Feeder Pillar with Push Button Arrangement located at least 3 m away from the mast
or a distance more than Outer Diameter of High Mast.
2. The control panel shall be usable on all masts and shall be equipped with
Emergency stop button and Push button for raising and lowering of the mobile part.
3. The push buttons shall operate on the 'dead man' principle i.e. action shall ceased
as soon as the button is released. Portable control panel shall also include a
portable panel for housing control switch and relays. The portable panel shall be
equipped with safety devices such as electronic torque control in case of overload
or overheating of the hoist motor.
O. Statement of Compliance
The base offer shall comply with the specification. The Tenderer shall confirm for each and
every paragraph of the technical specification that the Tenderer is able to meet the specified
requirements. The statements shall be in accordance to the numbering reference adopted
in the technical specifications.
P. Testing and Commissioning
2. Insulation resistance of each circuit shall be measured without the lamps being in
place. It should not be less than 5 Mega ohms to earth.
3. Current and voltage of all the outdoor lighting circuits shall be measured at the Main
designed values and in the case of 3 - phase circuits, the load shall be balanced, if
required.
4. Earth continuity shall be checked for all the circuits.
5. After inserting all the lamps and switching on all the circuits, minimum and maximum
illumination levels shall be measured in all areas and their conformity with designed
Page | 352
levels established. The test results shall be entered in the approved pre-
commissioning proforma and submitted to the Engineer for approval before final
commissioning.
Page | 353
TECHNICAL
SPECIFICATIONS –
BUILDING MANAGEMENT
SYSTEM
Page | 354
BUILDING MANAGEMENT SYSTEM

1. GENERAL
This Specification describes the minimum standards of the Building Management System (BMS)
for elevated stations of DMRC network. The Works to be executed under the Contract include
the design, development, manufacture, verification, delivery, installation, testing, commissioning
(including integrated testing and commissioning) and technical support for a complete BMS to
fully integrate the control, monitoring, and supervision of Low Voltage Power & Distribution,
Emergency Power Supply-DG sets and, Fire Alarm System, Hydraulic System (Bore Well Pumps
etc.), and other nominated HVAC Building Services Systems. The BMS shall also interface with
the requirements for control, monitoring, and supervision as required at the Operational Control
Centre (OCC) and also seamless integration with existing BMS system for other sections at
OCC. The BMS is to be designed manufactured, supplied, installed, tested and commissioned
by the Contractor and shall meet all performance and functional requirements as defined in the
Specification. This specification contains a description of the system concepts and major
components, and sections covering definitions, requirements for interfaces with other contracts,
general mechanical and electrical installation design/performance requirements, and testing
requirements. The emphasis is to explain the requirements of work, interfaces with other
contractors for achieving an efficient & safe working system commensurate to the best
international standards and practices. Every effort has been made to cite the design
requirements very clearly, however in this contract, the contractor shall follow acceptable
standards & design procedures akin to the best adopted practices in BMS system, wherever this
is not explicitly mentioned.
1.1 SCOPE
THE SERVICES TO BE PERFORMED BY THE CONTRACTOR SHALL INCLUDE,
BUT NOT BE LIMITED TO, THE FOLLOWING:
 Design, development, manufacture, verification, delivery, installation, testing,
commissioning (including integrated testing and commissioning) and technical support
for a complete BMS, including all PLC Equipment, CPU's, Modules, Sub Modules, Power
Supplies, Local Control Panels, PC Work Stations, Printers, Local Area Network (LAN),
Ethernet Hubs and Switches, Remote Fireman's Control Panel, electrical containment
and wiring systems, and other components, to fully integrate the control, monitoring, and
supervision of Low Voltage Power & Distribution including Energy Metering, remote relay
setting of ACBs, Diesel Generator System and strategic emergency power supply from
DG sets, UPS, Lighting Control System, Fire Alarm System, Lift and Escalators, Hydraulic
System (Raw Water pumps, Domestic water pumps and Fire Water pumps etc.) and
other nominated Building Services Systems, as required whether or not specified ,
necessary to deliver the requirements of this Specification. The scope has been further
given in detail as per I/O list with this document. The BMS shall also interface with the
requirements for control, monitoring, and supervision, as required at the Operational
Control Centre (OCC). The system should be capable of independent functioning as well
as seamless integration with centralized BMS system. Following scope of work but not
limited to be considered.
 Earthing of Programmable logic controller and Work Stations to the clean earth. Earthing
drawing will be submitted to the employer’s representatives for approval.
 Integration of BMS with other BMS at OCC.
Page | 355
 Presentations, reviews and audit support as specified in the Specification;

 Interface management as specified in the Specification;
 System operations and maintenance support services;
 Training for the Employer's Engineers and Training Instructors, operations staff,
maintenance staff and Engineering staff;
 Dismantling, removal and/or disposal of Temporary Works;
 Warranty period after commissioning.
 Transfer of Technology
 Warranty and Maintenance Support System-AMC
THE LIST IS NOT INTENDED TO BE COMPLETE AND THE CONTRACTOR SHALL

SUPPLEMENT IT ADEQUATELY FOR OBTAINING A SATISFACTORY WORKING
BMS SYSTEM.
1.1.1 Standardization
The Contractor shall, in establishing his design, follow the principles provided below in
the design and specification of all plant, equipment and components:
 Similar plant and equipment shall be replaceable/interchangeable, modular in design,
adaptable and extendable. The technical specifications and design standards shall be
uniform. Uniform standards for clear spaces, working clearances, protection of equipment
and physical dimensions of equipment and interfacing with other systems.
 Test standards and standardized equipment shall be selected or built or framedcarefully,
bench marked, designated and explicitly marked.
 A standard procedure shall be followed for identification of each category of equipment
explicitly (suffixing or prefixing while marking and numbering for each category of
equipment).
 The operating system shall be uniform for all systems/sub systems.
 Standards for maintenance planning shall be uniformly categorized.
 Uniform standards shall be designated for procurement, replacement stocking and
availability.
 Equipment and accessories shall be provided with uniform standard spare capacity,
protection.
 Conduiting, cabling etc. shall be suitably colour coded for identification and categorization
for each kind of use/type. The cable terminations should be tagged and numbered as per
the standards.
1.1.2 Quality Control of Equipment, Components and Material
The contractor shall furnish the following information for each item of equipment as
applicable:
 Manufacturer.
 Type and Model No. of equipment.
 Nominal capacity
Page | 356
 Power supplies i.e. Voltage & Frequency at which the equipment operates.
 Type of Frame and foundation required for the equipment.
 Space requirements
 Controls & Protection
 Indications/alarm/annunciation
 Standards
 Insulation class
 EMC Conformance and certification.
 Any other technical information related to the equipment.
The contractor shall provide a list of tools and test equipment for the installation, testing
and repair of any special apparatus and proposals for conducting system acceptance
testing and to support the extended period of trial running.
1.1.3 Submission of Drawing & Details
The contractor shall state the number and scales of all the drawings it intends to produce in
support of the works under this contract. The detailed/schematic drawings to be furnished by the
Contractor may include but not be limited to:
 Schematic drawings
 Interlock drawings
 Working drawings
 Wiring drawings
 As Built drawings
 Mode tables
 Containment details
 Tags and ferrule schedule
 BMS Equipment schedule including communication network devices.
 Field sensor schedule
 Data sheets for all BMS and communication equipment’s and cables
 Training manual on SCADA
 SCADA graphic sheets
 I/O Schedule and Cable Schedule
 A complete schedule of drawings to be produced by the contractor shall be submitted
 to the Employers representative within 6 months, of contract award.
1.1.4 Design Considerations
a) The complete installation shall be in strict accordance with the national and local
electrical codes.
 All system components are to be designed and built to be fault tolerant: Satisfactory
operation without damage at 110% and 85% of rated voltage and at (+)3 hertz & (-)1.5
Hz variation in line frequency.
Page | 357
 Static, transient, and short circuit protection on all inputs and outputs.
 Communication lines protected against in-correct wiring, static transients and
 induced magnetic interference.
 Communication ring should be established, so that any single device failure will
 not disrupt or halt bus communication.
b) All equipment, cables and wiring shall be designed, manufactured and installed so
as to secure a service life as shown below:
 Control Panels 30 Years
 Cables 30 Years
 Tray, trunking and supports 30 Years
 Sub-assemblies and components 30 Years
 All other equipment 20 Years minimum
c) Switchboards, equipment, and other control components shall be rated for operation in
ambient temperatures of 50°C and humidity up to 95% and shall have degree of protection IP-
54 for indoor devices and IP 65 for out door devices.
d) In the design of switchboards, local control panels, Cabinets of PLC, an allowance of 20%
spare space capacity shall be provided for possible future expansion and all panels shall be user
friendly, modular and aesthetic design, termite and vermin proof. Spare capacity of 20% shall be
provided for all I/Os, cable trays, trunking, wire ways, (raceways), and brackets, for future
expansion.
1.2 PATAMETERS FOR CONTROL AND MONITORING FOR THE VARIOUS
EQUIPMENT LOCATION
Functions PLC (Plant Room) SCR OCC
Condition Operation Status Alarm Remote

Data
Bore well Liquid level in Start Pump Low water Warning Warning
pumps at the level in goes OFF
station underground undergrou when
tank low. nd tank undergrou
nd tank full
(1+1) – Manual Log at PLC Red

Graphics
Main+ BypassSwitch
standby localor remote for local,grey
for
remote
Pump Running - Pump
Page | 358
Pump Failure - ON( OFF) Standby Warning

pump fail
warning
Water level in If full stop - - -

theUnderground Pumping
tank Log at PLC

Data
A defined time Alternating Standby

of pumping pump starts Pump is
completed ON
Hours of Log at PLC - Not run for Warning

operation more than (Not Run
a week, A for more
Pump than one
running for
more than
a defined
time
(Alarm)
Voltage Log at PLC - No Volt -

Warning
Pump Tripped Log at PLC warning warning
Raw water Liquid level in Low water Warning, warning

pumps at the raw water level in goes OFF
station tank low undergrou when
nd tank undergrou
(Raw) nd tank
(Raw
water) full
(1+1) – Manual Red

Main + Bypass Switch Graphics
Standby local or remote for local,
Page | 359
grey for
remote
Pump Running Pump
Pump Failure ON (OFF) Standby warning

pump fail
warning
Water level in If full stop

the Pumping
Underground Log at PLC
tank

completed ON

Data

a week, A for more
Pump than one
running for week)
more than
a defined
time
(Alarm)

Warning
Domestic Liquid level in Start pump Low water Warning,

water the Domestic level in goes OFF
pumps at water tank low Domestic when
station water tank undergrou
nd tank
Page | 360
(Raw
water) full
(1+1) – Manual Log at PLC Red

grey for
remote
Pump Running Pump
Pump Failure - ON (OFF) Standby Warning

pump fail
warning

the Domestic Pumping
water tank Log at PLC

completed ON

Data

a week, A for more
Pump than one
running for week)
more than
a defined
time
(Alarm)

Warning
Pump Tripped Log at PLC Warning Warning
Domestic Liquid level in Start pump Low water Warning, -
Page | 361

nd tank
(Raw
water) full
(1+1) – Liquid level in Log at PLC Low water Warning, -

Main + the Domestic level in goes OFF
Standby water tank low Domestic when
water tank undergrou
nd tank
(Raw
water) full
(1+1) – Manual Log at PLC Red - -

grey for
Remote
Domestic Liquid level in Start pump Low water Warning, -

nd tank
(Raw
water) full
Pump Running - Pump
Pump Failure - ON(OFF) Standby Warning

pump fail
warning

the Domestic Pumping
water tank Log at PLC

Page | 362
completed ON

Data

a week, A for more
Pump than one
running for week)
more than
a defined
time
(Alarm)

Warning
Pump Tripped Log at PLC - Warning Warning
Fire Hydrant Start the Warning Warning

Fighting Pressure fall Pump
Pump (Major)
(1+1) – -
Main +
Standby
Manual bypass Different

local or auto graphics
colour for
local or
auto
Pump Running - Pump 1/2

ON (OFF)
Pump Failure First Pump Warning
fail warning
Standby pump - Second Alarm

fail pump fail
Page | 363
alarm

completed ON

operation more than
a week.
Jockey Hydrant Start the - Warning -

Pump Pressure fall Pump
(Minor)

Data
Manual bypass Different - -

colour for
local or
auto
Pump Running - Pump -

ON (OFF)
Pump Failure - pump fail Warning

warning

operation more than
a week,
(Alarm)
DG set Incoming HT Bus Starting Warning Warning

supply to ASS Couplers the DG set supply
1&2 OFF, start failed
transformers DG set,
OFF load
breaker ON
Start DG - -
Page | 364
set, load
Start - --
breaker
command from
OFF
local
DG set running ON(OFF)
DG set OFF - -
Bus
couplers
ON
DG set failed Alarm Alarm

to start or
tripped
Hours of Log at PLC DG set Not run for Alarm

operation ON in more than
case not 15 days
running (Alarm)
more than
15 days
Starter Battery If low Log at Warning

Voltage PLC

Data
Lube oil Level Continuous Warning,

monitoring Maintenan
ce required
Fuel level Continuous
monitoring
Radiator water If low Log at

level PLC
Output voltage Log at PLC Within Alarm, if Out of

range, out of range
Indicate range alarm
on Load
Page | 365
Fire
Detection
and Alarm
System
All zones Alarm Signal at - Warning Warning

Situation FACP
All zones Alarm Signal at ON Warning Warning

Situation FACP
FACP System Fault Fault ON Warning Warning

Indication
External Fault Indication ON Warning Warning

Fault
Processor fault Fault ON Warning Warning

Indication

Data
Detector Fault Warning at Warning

Device fault/ Indication fixed
Device Alarm interval
isolated
Voltage Log at LDC No volt -

warning
Sprinkler Rise in Start Pump ON Warning Warning

Temperature
Hydrant Start Pump ON Warning
Electrical
Panels
Manual bypass Different

Colo
DB running - DB Warning Warning
Page | 366
ON(OFF) for No volt

in EPP
Energy Log at PLC Continuou Continuo

Consumption s us
monitoring monitorin
in decimal g in
value decimal
value
Voltage Log at PLC No volt

alarm
Trip Log at PLC Red Alarm

colour in
graphics
Communicat Log at PLC No volt Control

ion and alarm and
setting of setting of
ACB Relays ACB
relays

Data
Control Log at PLC No volt

Supply
alarm
failure
Escalators
Manual bypass - Different - -

Colour or
auto
Escalators DB Warning Warning

Running ON(OFF) for No volt
Graphics in ESPP
colour
shall be
Page | 367
green for
healthy
status
Voltage Log at PLC No volt

alarm
Log at PLC Red Alarm

colour in
graphics
No volt Control
alarm and
setting of
ACB
relays
1.2.1 The workstation pc with recent configuration and operating system shall be supplied and
installed in the station control room of each station. This shall be a standalone PC.
1.2.2 Programmable logic controller (PLC)
1.2.2.1 Necessary PLCs shal l be instal led to provide the most economic/ technical ly sui table
configuration based upon cost balances between PLC modularity and cabling costs, consistent
with the performance requirements of this specification.
1.2.2.2 Location of PLCs shall be chosen such that minimum length of cable will be required
between PLC and power DB.
1.2.2.3 PLC can be opened freely, so sufficient distance from the wall or obstruction will
be maintained.
1.2.2.4 Cables shall be kept at a distance of 300 mm from the power cable or should be
contained in metallic enclosures trunking /conduits at all places as entry/exit to
DB, PLC etc.
1.2.3 Hubs/switches — these will be installed in separate enclosures near the, PLCs/
workstation.
1.2.4 Repeaters-these will be installed in separate enclosure at a distance of 90 meter or
less from hub/repeater of the communication cable to boost the signal.
1.2.5 Field sensors- sensors will be located on, or adjacent to, that equipment which
is being monitored. For example, it could include sensing the electrical load,
water level etc. that changes within building.
1.2.6 Facility
1.2.6.1 The BMS system shall be centralized and comprise of a powerful central computer. This
shall run highly sophisticated programs, which operate in 'real - time'. Workstation shall
have continuous communication between the central or main operator station's central
Page | 368
processing unit (CPU) and the remote field processing units (PLCs). The CPU is
continuously updated with the conditions being monitored by, and control actions being
taken by, the PLCs. It shall therefore be able to implement global actions with the
minimum time delay, across the whole system. However, configuration of PC and
hardware components given insubsequent paras of this specification.
1.2.6.2 A central database management and communications system, to communicate with the
PLCs and local workstations over the communications link shall be provided and to
maintain a database regarding health and operation of all system points. The system
should be able to log the defective sub-systems, communication failures/ breaks and
also update the data on restoration of the fault.
1.2.6.3 Bulk data server facilities for software back up and historical data, including equipment
history of maintenance & frequent defects shall be provided at station & O.C.C. Maintain
equipment history of maintenance and frequent defects. The backup historical data shall
be available minimum for 6 months at a time and backup rate shall be fortnightly.
1.2.6.4 The BMS should activate designated alert for the attention of operations and
maintenance staff rapidly to equipment malfunctions, especially those likely to cause
uneasiness to the metro passengers (for example lighting system, escalators). SMS to
Mobile phones of DGM (O&M) and other designated officials of DMRC regarding high
priority alarms, energy audit reports and specific fuel consumption of DG sets.
1.2.6.5 Provide clear, comprehensive displays and printed logs of equipment status to each
operator workstation.
1.2.6.6 Provide comprehensive displays and printed logs based upon historical data, with the
option of overlaying data from earlier periods.
1.2.6.7 Time-tag all events detected by the BMS system, to one millisecond Resolution for
selected high-speed inputs, and to present this information in logs as a true system-
wide sequence of events.
1.2.6.8 Generate routine maintenance schedules automatically, based upon elapsed time and
equipment operation times. Also, record the maintenance activities carried out including
the maintenance block taken, persons attending or having access to the plant rooms.
1.2.6.9 Operating systems based on a Graphical User (GUI) format incorporating the widely used
WIMPs procedures (windows, icons, menus, and pointing device), where one display can
overlay another shall be provided. WYSIWYG (what -yousee- is-what-you-get) display
printing and print previewing features shall be provided.
1.2.6.10 The following primary facilities shall be available at each workstation:
 Visual and Audible Alarms and event logging and printing.
 Facility of Visual and Audible Alarms and event logging table should be
 converted in MS window Excel
 Operator acknowledgement of alarms.
 Selective display and printing of alarms and of events lists.
 User friendly group display on a single screen of various E&M systems.
 Execution of operator commands with access code security.
 Provision of user-friendly operator sequences.
 Operator entered text messages.
 Access to historical data files of plant status.
 Generation of tabular displays based upon spreadsheets.
Page | 369
 Generation of graphical displays based upon mimic diagrams.

 Generation of printed reports and printed copies of display pages.
 Utilities consumption monitoring and check metering.
 Operator entered data, including tagging, manually entering values and the
forcing of status points.
 Automatic logging of selected displays at specified times.
System timekeeping
2. SPECIFICATION/REQUIREMENTS FOR HARDWARE COMPONENTS

Off the shelf supplied items should be supported with AMC to cover the warranty period.
The terms should ensure prompt attention & not later than 12 hours. In case the standard
warranty terms do not provide such service then the contractor should build in suitable
mechanism for prompt attention.
2.1 Programmable Logic Controller (PLC)
2.1.1 The architecture shall be proposed with redundant PLCs and RIOs connected in hot
standby arrangement communicating over modbus communication or fiber optics to
implement BMS system.
2.1.2 PLC shall consist of main CPU, I/O modules, Power supply units and terminal blocks. It
collects data from the process, pre-processes and transmits the same, using suitable
protocol (MODBUS RTU or similar), to the SCR Workstation which in turn communicates
to the Central Server at the OCC via an optimized and event - based TCP/IP protocol.
2.1.3 PLC shall be an intelligent modular, compact system that allows suitable expansion,
minimum from 14 up to 1000 I/O’s using the same set of basic components having
functions for adjusting variables and for diagnostics which shall not require any prior
configuration or special software and it is possible to password-protect them. The use of
these functions must have no effect on the PLC scan time. The PLC shall be programmed
for local control by implementing specific logic in the PLC. Input and Output modules are
connected serially to make it a complete compact and modular data acquisition system.
The PLC shall communicate with SCR workstation through MODBUS Protocol/TCP IP,
using the RS232/485 Protocol/TCP IP port. PLC shall have a local 'intelligence' so that in
the event of a breakdown in communications with the CPU, the points connected to that
unit continue to be controlled according to the time schedules initially provided by the
CPU.
2.1.4 The Contractor shall ensure that the PLCs are compatible with the input/output signals
from the Workstation and other Subsystems. Power supplies for interrogation of volt-free
contract shall be provided as part of the PLC. The PLC modules should be hot swappable
type.
2.1.5 PLC terminals shall be of the clamp type preferably of cage -clamp and shall be provided
with isolating links
2.1.6 PLCs shall be supplied complete with 20% spare capacity for handling additional input and
output signals. Expansion by at least 50% shall be possible simply by adding more I/O
modules and reconfiguring the software. A further 100% expansion shall be possible by
adding additional interfacing equipment in additional cabinets, etc. and reconfiguration of
the software.
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2.1.7 A manual switch inside the PLC cabinet shall be provided as a hardwired facility to disable
the operation of control outputs. Change of switch status shall be registered as a system
event.
2.1.8 The Contractor shall establish the I/O requirements and provide the most economic
configuration of PLCs based upon cost balances between unitmodularity and cabling costs
for individual stations.
2.1.9 The PLCs shall be suitable for either wall or floor mounting and shall be suitably robust for
operation in Electrical switchgear room/ Pump room areas, to IEC529 IP65 enclosure
standard Wall mounting is prefer red. PLC shall be of the same make and type at all sites
and individual components shall be interchangeable between PLCs at different sites.
2.1.10The PLCs shall be suitable for operating in the environment described in the General
Specification clause.
2.1.11The PLCs shall be able to be interrogated fully and be fully reconfigured fromoperator
workstations. The Employer's personnel shall be able to re-configure fully the PLC
hardware and software after completion of the training courses provided under this
Contract. However, a nominated person with authorized password should have access for
making such change with using proper authorization from DGM/ Metro or OCC.
2.1.12It shall be possible to disable an individual PLC locally or from an operator workstation for
servicing or reconfiguring without affecting other PLCs. Whendisabled or enabled, a
change of status c ondition shall be announced on the Control Center monitor and the
changed log as an event.
2.1.13 PLC panel shall comprise of following-
 Min 32-bit Microprocessor base CPU
 Rack based Input and output interface modules suitable for a mixture of digital,
 analog inputs and outputs.
 Terminal for external cable termination
 Thermostat for temperature control
 Fan
 Power indication lamps
 Document holder
 MCBs for modules, Power supply unit, Fan, Tube lights
 LED Lights
 Door switches
 Fuses for digital output, input and analog input terminals
 Power supply unit
 Unit Door indication lamps for Critical, Warning and fail alarm.
 Battery backup for I/O Module 2 hours .
 Wiring diagram and contact detail chart
The PLC processor will have minimum Salient features as following:
 Min 4MB internal memory for user program RAMS and Flash.
 0.4 m sec/kb bit processing
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 Integrated ports: 2xMODBUS/1xMODBUS, ethernet port and USB port.

 2 interrupt inputs and 2 cyclic tasks.
 Direct access to I/O for fast response.
 Real-time clock.
 It shall have real time clock & time resolution of the clock should be ln sec.
 PLC shall have separate battery for the above clock. PLC shall be capable of
time
 stamping the event before communication to BMS.
 The event scanning resolution of PLC should be of 1msec.
 The PLC processor will have the capability to support the following language
 structures:
 Structured Text
 Sequential Function Charts
 Ladder Logic
 Function Block
The processor shall support the Advanced Instruction Set that includes basic and
advanced ASCII string instructions, and advanced math functions. The processor shall
support a system protection environment with passwords and privileges and support a
form of backup communications module. The controller platform shall have the ability to
change configuration online while the system is running normally without stopping the
process such as:
 Hot swap faulty IO modules without stopping the process.
• Adding the new control block.
• Deleting the unused control block.
• Change the parameters of the function block.
• CPU must support online Hardware configuration change.
2.1.14 PLC Interface Modules

The following hardware described will interface to the field mounted sensors and
equipment for control and monitoring.
Digital inputs:
 12 VDC, 24 VDC, 50 VDC, 110 VDC, 110 VAC, 240 VAC (5 kV isolation)
Digital Outputs (relay):
 Volt-free contact, 24 VDC, 30 VA
 Volt-free contact, 240 VAC, 125VA
 The outputs must be isolated in accordance with standard IEC 61131-2.
Analog inputs:
 0-10 VDC, 0-10 mA, 4 -20 mA with electrical isolation from ground
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 DC 12-bit resolution minimum

 >60dB interference rejection at 50Hz
Analog Outputs:
 0-10 VDC, 4-20mA
Pulse Inputs:
 12 VDC, 24 VDC up to 10 pulses/sec (2kV isolation)
Serial Link:
 RS 485, RS 232 / V24, RS422
 Base unit includes two isolated RS485 ports, two 10/100MB Ethernet ports,
USB Backup & Restore and Wi-Fi connectivity
2.1.15 PLC Hardware Requirements
PLC Operating Voltages: The PLC must be able to operate at 100% from the following
power sources:
 100 VAC — 250 VAC

 24 VDC — 100 VDC
Note: The PLC must operate at the nominal supply frequency of 50 Hz with a 15%
variation.
2.1.16 PLC Programming

 The PLC shall be programmed with manufacturer proprietary software, IEC
1131.3-
 compliant, mixable and reversible List language and Ladder language. The
software shall feature Windows-based editing functions and integrated online
help.
 An original copy of the latest manufacturer's proprietary software shall be
provided to DMRC upon completion and handover together with all generated
site-specific data.
 PLC should be remote programmable from SCR workstation.
 Optional connection to operator terminal, management station and via Web
browser with Web server device.
 Support SNTP/SNMP protocol.
 Freely Programmable.
 Flash ROM, real time processing and multi-tasking.
 32 bit or better processor system, minimum 4 MB program memory, Supply
voltage AC 230V +/-20% 50 Hz.
 Event driven data transmission.
 Automatic mains recovery
 Historical data memory storage
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 Software application stored in non-volatile memory

 PLC programming software should be supplied with software simulator to
check logic
 developed and download in simulator for debugging.
2.1.17 PLC communications
Although the PLC processor specified above will have the capability of communicating
directly with a BMS system via Modbus over TCP/IP protocol. In addition to the above,
the PLC shall have the capability to be monitored directly using the HTTP protocol.
2.1.18 Integration of 3rd Party Software and Exchange of Data
The system shall support the use of standard interfaces and drivers that make it easy
to integrate to 3rd party software directly at the management station level, or to make
common use of data from the system, eg via ODBC (Open Database Connectivity).
DDE (Dynamic Data Exchange)
2.1.19 LC Cabinet and Panel Internal Wiring

 PLC is compact and modular in design. All the components inside the panel
are dinrail mounted. PLC cabinets will be freestanding type and will have colour
matching with Electrical Panel.
 Control panel, switchboards and distribution boards wiring shall be clearly
identified in accordance with the Definitive Design Drawings using cable core
markers cable tags and ferrule Cable core markers shall read left to right or top
to bottom.
 Wiring shall be enclosed in FRLSH ducts or neatly loomed with nylon ties or
spiral binding as required. Wiring ducts shall be filled to a maximum space
factor of 50%.
 Where wiring is required to connect to devices mounted on doors it shall be
arranged such that opening and closing of the door is not impeded whilst
minimizing flexing of the wiring loom. The loom shall be effectively fixed at both
ends of the door opening with insulated saddles or clamps.
 Wire colors shall comply with the following requirements:
Phases Red, Yellow, Blue
Neutral Black
AC Control Grey
DC Positive Orange
DC Negative Lilac
Earth Green with Yellow trace
 Terminals shall be clearly numbered, and shall be rail mounted, adequately
sized tosuite wiring size and provided with 20% spare rail space. The bridging
of terminals shall be provided by the use of terminal bridging links as supplied
by the terminal manufacturer.
 Control wiring shall be terminated using pre-insulated pin or spade type crimp
lugs.Conductors terminating to study type terminals shall be fitted with spade
type crimp lugs.
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 A separate earth bar shall be provided for the termination of all earth wires.
Only one wire shall be connected into each termination point.
 Minimum conductor size shall be 1.5mm2.
 Cable glanding plates shall be earthed directly to the control panel earth bar.
 Panels shall be fitted with a suitable pocket to contain circuit diagrams and
other relevant Definitive Design Drawings. An "as installed" set shall be
provided with the panel.
2.2 Work Station
The central processing equipment shall comprise one high performance real time, digital
personal computer, rated with such application, complete with keyboard and mouse, one
colour graphic VDU, system Laser printer(s) to log all transaction and alarm printer(s). All
the equipment shall be suitable for the power supply voltage of 230VAC +-6% 50Hz +-2%.
The central equipment shall be located where shown on the plans and shall meet the
following minimum criteria.
2.2.1 Personal Computer
The Work Station shall be a personal computer (PC) based central server, with a minimum
32-bit Intel processor(i7/Xeon), min 8GB RAM, dual gigabit LAN ports, min 4 no. Hi-speed
USB ports, 4 No. parallel ports, 2TB HDD CD/DVD writer, memory key, keyboard/ mouse;
Optional Redundant Embedded Persistent Storage for Virtualization Hypervisor; iDRAC
with Lifecycle Controller, Open Manage Essentials.
2.2.2 Colour Monitor
The Work Station color monitor shall be 21-inch diagonal nonglare flat LED flat screen and
has minimum VGA resolution of 1920 pixels horizontal, 1080 lines vertical and minimum
16 based colors. Work stations shall include all accessories needed to comply with UL
requirements for listing under the appropriate standards as specified in UL864 and
UL916.Further, all accessories shall be included to satisfy the local authorities having
jurisdiction over the system. UL listed cards (originals preferred or photocopies) shall be
provided to support the documentation that such listing is in effect.
2.3 Notebook PC
The sub-contractor shall provide a colour note book with built -in modem for remote dialing-
in for use as a portable programming tool. The colour note book shall be Intel Core i5 with
latest generation or higher and be complete with min standard 8GB RAM, 1TB hard disk
capacity with high speed disk access, high speed DVDR/ RW, and with 82-key sculptured
keyboard (101-keyboard compatible). The note book shall come with a cordless USB
mouse (Optical) for user interacting. The overall weight for the note-book shall not be more
than 3 kg. To ensure hardware quality, computer clones shall not be acceptable. Note book
shall be with all necessary software preinstalled necessary for monitoring and controlling
and modifying the parameters of BMS system.
2.4 Printers
The sub-contractor shall provide printers as specified for recording alarms, operator
transactions and system reports. To ensure hardware quality, printers shall be
internationally branded, warranted, and technical support, spare parts and consumables
should be freely available from the manufacturers authorized distributors.
2.4.1 Laser Printer
A hard-copy multi-color graphics laser printer shall be provided for recording graphic
displays and associated dynamic data. Printer shall meet minimum requirements as
follows:
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 Print speed — Black: up to 20 ppm; color: up to 4 ppm

 First page out — 18 seconds black, 29 seconds color
 Resolution- 600 by 600 dpi
 Memory — 64 MB built-in SDRAM; expandable to 192 MB with one open
memory SDRAM DIMM slot
 Duty cycle — 30,000 pages per month
 Media — Media handling 125-sheet multipurpose tray 125-sheet multipurpose
tray, 250-sheet input tray 2 — Letter, legal, statement, executive, No. 10
envelopes, Monarch envelopes
 Output — 125 sheet face down bin
 Types Paper (plain, letterhead, pre-punched, bond, color, rough, preprinted,
recycled)
 Glossy Media, Cover Paper, Color LaserJet Transparencies, labels,
envelopes, and card stock
 Compatibility— Interfaces Hi-Speed USB 2.0 port, IEEE 1284-B compliant
parallel port
 Hi-Speed USB 2.0, IEEE 1284-B compliant parallel port
 Languages PCL 6 and Postscript level 3 emulation with automat ic language
switching
 Font capabilities — 80 TrueType TM internal scalable PCL 6 fonts; 80
TrueType internal scalable HP postscript fonts
 Client operating systems — Microsoft Windows 98, 2000, Me, XP, NT 4.0 Mac
OS 9.1, X v.10.1 and later; UNIX®, Linux, and OS/2 (limited functionality)
vista.
 Network operating systems — Microsoft Windows 98, 2000, NT 4.0 Me, XP;
Mac OS 9.x, OS X Vista
 Network protocols supported — TCP/IP
2.5 Network Switches, Modems, Hubs, Gateways
The switches which shall be used as an intermediate device to connect with the FOTS
system being provided by the telecom department shall be manageable Layer 2 switch
which shall be provided by the contractor and shall be managed by the telecom
department. The specifications of this switch shall also be approved by the telecom
department only.All modems, hubs, switches, gateways and other serial equipment to be
used inthe application of system networks must be of industrial grade quality to meet the
following criteria:
 Can tolerate up to -40 to 85C
 Can tolerate 5-95% humidity
 Provides vibration resistance (1E68-2)
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 Withstands power surges (IEEE-472)

 Provide easy DIN-rail mounting
 Are powered directly from 230V AC/110V DC
2.6 Communication
The suitable communication protocol shall be adopted for various communicationlinks. The
communication Protocol can be classified as per following requirements:
 The communication between E&M equipment to PLC: MODBUS Protocol
 The communication between PLC to the SCR Workstation: MODBUS Protocol
over TCP/IP.
 The communication between Multifunction Meters and Energy meters and
their communication to PLC/Workstation: MODBUS Protocol on RS 232/485 port.
 The communication between Light Control Panel, Fire Alarm Control Panel ,
and MDB & Electrical panels, Escalator Panels/MCCBs, AMF Panel CRC for
VRF etc to the PLC/SCR Workstation: MODBUS Protocol on RS232/485 Port.
 Communication between SCR Workstation to OCC: TCP/IP protocol on optic
fiber link through TER. Redundancy dual mode
2.6.1 Supply of the hardware essential to integrate all systems for communication link as above.
2.6.2 The communication link between SCR workstations and the OCC shall be done using
TCP/IP based protocol. All the SCR workstations and OCC shall be connected in LAN
TCP/IP that is being provided at TER by the main communication contractor.
2.6.3 Communication software in each PLC or workstation node on the network shall enable
peer-to-peer operation, such that failure of any node shall not affect other nodes on the
network.
2.6.4 The system should provide instant alarm to the operator about the communication failure.
2.6.5 The healthy operation of all PLCs shall be verified at intervals not exceeding 30 seconds.
PLC failure shall be displayed on the appropriate workstations as a system alarm.
2.6.6 In the event of a failure of the main communications system, local operation from control
panel at each station shall be maintained. Updating of the central database at the OCC
shall take place immediately on restoration of the communications link.
2.6.7 Operational changes and expansion will be made without shutdown the system.
2.7 Cables
All types of cables used in this project shall be Armoured.
2.7.1 Cables installed between PLC and DB/Sensors shall be Fire resistant low smoke Zero
Halogen (FRLSZH)
2.7.2 Cables installed between PLC and DB/Sensors shall be not less than 1.5 sq mm copper.
2.7.3 Ethernet cables for networking of PLCs and Workstation shall be provided.
2.7.4 Shielded cables (communication bus) shall be provided over RS232/485.
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2.8 Moxa card/ Router

2.8.1 For communication with RS 485 port of different panels Moxa card of minimum 8
ports/Router shall be installed with the BMS workstation.
2.8.2 Cables installed between PLC and DB/Sensors shall be not less than 1.5 sq. mm copper.
3. Specification/Requirement for BMS Software

3.2.1 The SCADA software shall consist of a human machine interface (HMI) system with support
for supervisory and process control, real-time data acquisition, alarm and event
management, historical data collection, report generation, local or remote telemetry
communications to PLC's and internet/intranet access. The software shall be easy-to-use,
with an object-oriented graphics development environment and shall have an open
architecture, supported on the latest Microsoft Windows Server and Client operat ing
systems.
3.2.2 The system shall have the built-in flexibility to permit easy configuration in accordance with
the specific end user requirements, as well as quick and easy modification by the end user
in the field.
3.2.3 The software shall consist of a suite of of f-the-shelf modular components from a single
software manufacturer that are tightly integrated together to perform all SCADA system
functions. The suite shall contain an HMI for process visualization, a real-time relational
database for historical data col lection with an open and accessible query interface, client
tools for trending and reporting both within the HMI and as standalone utilities.
Communication drivers for PLC’s shall be provided and supported by the software vendor.
3.2.4 The system shall be scalable so that a small, single, stand-alone application can easily be
expanded into a large distributed control network with either single or redundant database
servers, single or redundant communication servers providing information to multiple
workstation clients. The software shall also can easily interface with external databases,
modeling and simulation, Enterprise Asset Management (EAM), Condition Based
Monitoring (CBM), Maintenance Management Systems (CMMS), ERP, LIM and GIS
systems.
3.2.5 The software shall be able to communicate and interact with most common hardware and
software components of an industrial enterprise, including but not limited to, field I/O,
databases and enterprise business systems.
3.2.6 The software Development Environment shall utilize an object model to allow designing an
application which models the physical characteristics of the system, including geographical
topology, physical equipment and computer locations. The system shall use the concept
of Application Objects. These Objects may represent real world devices such as
computers, PID loops, Motors, Pumps, Valves, etc., or informational objects such as
external database readers and writers, XML readers and writers, etc. Application objects
shall closely model the physical representation of plant equipment and devices and not be
bound to a “tag -only topology. This shall include the ability to create complex, multi -
variable data structures.
3.2.7 The software shall provide an audit trail of the check-out, check-in and revision history for
each template or application object and shall include the user ID of the person making the
change(s), the time and date stamp, and a detailed summary of the changes made.
3.2.8 It is necessary to provide a time and date for alarms, which occur, and other significant
events, including operator commands.
3.2.9 Software will allow the database (points) and operating parameters (time, temperatures,
limits etc.) to be modified on-line, by the operator.
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3.2.10 When a binary contact goes from open to closed, or vice versa, the 'change of state' is
reported by the system.
3.2.11 Some alarms may, however, be critical and should never be locked out. It should be
possible to define these alarms when they are entered into the system in such a way that
it is impossible to lock them out.
3.2.12 On start-up of certain plant, it takes a finite time before stable conditions are reached and
the BMS should allow for automatic lockout of alarms for a preset period following start-
up.
3.2.13 If, either as a result of time programming, or an operator command, several large electrical
items are called to start at the same instant, this may cause overloading. BMS shall have
capability to overcome this by defining these items as 'heavy' electrical items, and
introduce a delay time to prevent starting of the next load until delay time has elapsed.
3.2.14 Logging of important status information will be provided. The list of such important items
shall be provided by contractor for approval of Engineer In charge
3.2.15 This should contain, in plain language, identification of the point, status and other data,
plus time, date etc.
3.2.16 It should be possible to call up logs for various 'levels'.
3.2.17 It should be possible to cancel logs under certain conditions.
3.2.18 Facility of summary logs, i.e. the ability to cal l for a print out, for example, of all points in
alarm, all points off normal, all motors which are running, all points which are locked out,
etc.
3.2.19 It should be possible to log system advisory messages, e.g. malfunctions within the
management system itself, such as hardware failures, power loss, failure of a point to
respond to a command, communication errors etc.
3.2.20 Operator will be allowed to define the engineering units, e.g. voltage, kWh, degrees
centigrade, etc., and the ranges over which they are to be measured.
3.2.21 An alarm should be reported in case of breaking the preset limit of analogue points such
as voltage, current etc.
3.2.22 To avoid nuisance alarm, the software should have flexibility to allow varying the
differentials or introducing time lag. For example, if a space temperature alarms at 25°C
high and has a 0.1°C differential, it will be constantly going in and out of alarm between
25°C and 24.9°C. It would probably just as acceptable to have a 2°C differential which
would reduce the number of alarms repor ted considerably and furthermore, when they
did occur, would be more meaningful to the operator.
3.2.23 It should be possible to lock out analogue alarms, both by the operator andautomatically,
during start-up maintenance operations if nuisance alarms are to be avoided.
3.2.24 It should allow start/stop commands to be set up at precise times, with daily variations as
well as allowing holiday programming.
3.2.25 The system will keep a record of how many hours a plant has been running or how long
a point has been running or how long a point has been in a normal or off-normal condition.
3.2.26 Limits to be set which can be used to alert the operator to the fact that maintenance is
necessary or perhaps can automatically switch from one pump to another after a present
period.
3.2.27 A record of consumption of things such as liters of fuel used, kWh etc. will be kept.
3.2.28 English language for both input and output will be accepted.
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3.2.29 The output information should be grouped in accordance with the make-up of the services
systems in the station building rather than the location of the field hardware.
3.2.30 Prompting feature will be provided, which takes the operator through the operation step
by step, prompting and teaching him as he does it.
3.2.31 Dynamic colour graphics will be used to show the schematic diagram of the system.
3.2.32 Different colours will be used to bring particular conditions to the attention of the operator.
The contractor should submit scheme in this regard for approval of Employer's
representative.
3.2.33 The operator will have the facility to generate or draw his own graphics on the VDU and
have a library of standard symbols available to him held in the memory of the system.
3.2.34 Password will restrict access to certain important areas, so it is necessary to control who
has access to a BMS, at what level and through which operator devices.
3.2.35 Number of characters of password will not be less than five.
3.2.36 Password time-out will be not more than half an hour.
3.2.37 Database save feature to copy the system database onto a separate storage medium,
usually a disk, will be provided.
3.2.38 Equipments will run on its requirement, in the rest time it will be possible to be switched
off to save the energy.
3.2.39 HMI software- On the front screen icons for all systems shall be shown. Healthy and
unhealthy status of these systems shall be shown by dynamic colour change of these
icons.
3.3 Scheduled Activities
 In addition to the ability to control events and activities through operator commands and
scripting languages, the SCADA software shall have a facility that allows the scheduling
of activities on a Calendar basis. This facility shall typically be used to perform routine
activities which help minimize power usage such as turning off lights and heating out -of-
hours and on public holidays.
 The solution offered shall seamlessly integrate with the SCADA software for data
acquisition via the SCADA Server I/O subsystem. It is not acceptable for the solution to
acquire or write data directly from the field devices, increasing both the network and
processing load for the field controllers.
 The scheduler functionality shall be configured from a Calendar view using simple point-
and-click configuration. It shall not be necessary to program code to configure the
scheduler. It shall support daily, weekly, monthly or annual recurring
 events. It shall support up to 20 special days during the year to account for irregular
events, such as public holidays. It shall support up to 200 different programs which can
each be called from multiple schedules. It shall be capable of interacting and adjusting
SCADA tags via expressions within a scheduled event.
 For testing and diagnostics purposes, it shall be possible to quickly and simply manually
initiate programs independently of the automated schedule. Manually triggered events
shall not interrupt scheduled events or programs.
3.4 Trend Display
 Trend displays shall comprise line graphs with time on a linear, continuous horizontal or
vertical axis and the trended value on the vertical or horizontal axis. Resolution of each
graph shall be to within 0.1% of full scale. Where more than one tag is graphed, the graph
of each tag and associated information shall be displayed in a different color.
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 Trend displays shall support both analog and digital pens on the same graph. Trend pen
assignments shall be user definable and retrievable in runtime to allow easy creation and
management of favorite trend groups.
 Each trend graph shall be capable of displaying up to 32 pens with adjustable time-base
to one second samples and reporting up to 10000 points with user-specifiable time
ranges, using the standard software. The graph shall be capable of viewing the entire
archived trend history for a group of pens on a single display.
 It shall be possible to trend multiple pens or multiple plots of the same pen over various
time spans.
 Each pen shall display individual ranges and engineering units. Each pen shall be
scalable for display purposes independently of other pens displayed on a page.
 The software shall include the capability to pan backward and forward within a selected
time range to read the exact value of any displayed tag, by selecting a point on the graph
or chart. The system shall display historical information as far back in time as desired,
with all information being displayed on average of 1 second.
 The trend display shall have a slide wire that can be moved over the page that will provide
indication of the date, time and value at the intersection of the slide wire and the trend
tags.
 The user shall be able to toggle the trend display between Local time and UTC time.
When in Local time, the trend display shall clearly indicate periods of daylight savings
transition.
 The software shall provide "zoom" and "pan" facilities for both the trended tag range and
the time axis range. The "zoom" facility shall allow an operator to compress or expand
the axis range whilst the "pan" facility shall allow an operator to shift the origin of the axis.
The software shall allow a user to define any zoom area by dragging a mouse across the
trend.
3.5 Reports
 The SCADA software shall perform all report generation, scheduling and management
internally and shall not require a third party package to perform these functions. With the
exception of very high speed accumulators, no long-term data or accumulators shall need
to be programmed in the PLC sub-system to deliver data to the SCADA for reporting
purposes. The SCADA shall have functions available for this purpose and shall not
require scripting to achieve such functionality
 The software shall permit reports to be scheduled for a specific time of day, on a periodic
basis, upon operator request, or event initiated (such as an alarm condition or end of
batch).
 The software shall support printing to the designated report printer. The software shall
also have the capability to log all reports to a disk file or database (SQL, ODBC and DBF)
or to a Web Server in a rich text file format such as HTML.
 The software shall have the capability to display all reports on the screen, in user
definable fonts and colors.
 The software shall permit reports to be defined based on archived data. Single point in
time reporting (online and historical) and time-range reporting are both essential, as is
the ability to report on an unlimited number of tags in one report.
 Reports shall include extensive calculations on both instantaneous and historical data,
and any other data from the system.
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 Reports shall have the ability to write to any tag in the system during the execution of the
report.
 Reports are to be automatically sent to a designated report printer. The software shall
provide for on-screen reporting. It shall also be capable of interfacing to third party report
generation packages, and importing data from or exporting data to external databases.
3.6 Alarms
 Alarms shall be detected and reported by an Alarm Manager service. The Alarm Manager
service shall support no less than two hundred (200) simultaneous alarm client displays.
In the event of an alarm storm (hundreds or thousands of alarms detected within one
second), the Alarm Manager shall report and the client shall be capable of displaying up
to one thousand (1000) new alarms within ten (10) seconds of the detection of the alarms.
 System shall provide the ability of shelving alarms in order to enable authorized operators
to temporarily remove selected alarms from the list of active alarms suppressing them for
a specified period. System shall request operators to enter a reason for shelving.
 System shall provide the ability to optionally suppress alarms based on selected plant
states in order to avoid displaying invalid nuisance alarms during specific states.
 The system shall have the ability to provide the total number of aggregated alarms of
each severity category (critical, high, medium and low) under each area level.
 The system shall be able to alarm system resources (CPU utilization, memory, etc.).
 Alarms shall be able to be logged to a Database Alarm events to be recorded shall include
alarm instantiation, alarm return-to-normal, and alarm acknowledgment. Items to be
logged in addition to the alarm event shall include date and time of alarm event, Alarm
Group, Alarm Tag name, Alarm Tag Type (real/integer/Boolean), Alarm Type (LoLo, Lo,
Hi, HiHi, ROC, Deviation, etc.), Operator Name , Operator Node of alarm
acknowledgement, and Alarm Priority.
 Alarms may be printed to a locally connected or network printer. The alarms printed from
a particular node may be all alarms, only unacknowledged alarms, only acknowledged
alarms, alarms from a particular alarm group or groups, alarms from a particular priority
to a particular priority or alarms from multiple alarm providers.
 Alarm Categorization: The system shall be able to categorize the alarms in 4 classes –
Critical, Warning, Attention and Normal.
 Alarm Escalation: The system shall support automatic Alarm Escalation upto 10 levels
for the alarms which has not been acknowledged by the operator. The escalation shall
be email / SMS based.
3.7 PLC programming
i. The PLC shall be application-software controlled, with the software assemble from
proven software modules, and shall be capable of the following function and facilities:
 Local time tagging of events.
 Alarm handling from discrete inputs derived parameters.
 Combining of digital inputs Boolean functions to give conditional outputs.
 The equipment shall be self-monitoring for fault conditions, and shall generate
an alarm on the appropriate operator workstations in the event of a fault
arising.
Page | 382
ii. PLC- software shall be capable of being reconfigured, under password control, either
locally from the portable-programming device to be supplied under the Contract, or
remotely over the communications links from operator workstations.
iii. Event processing shall have the following order of precedence, but shall be reconfigurable:
 Receipt of manual commands from operator workstations, each of which
 shall have an assignable level of command priority.
 Pre-defined control sequences.
 High-speed alarms.
 Normal alarms.
 Digital events.
 Clock synchronization (With the master clock at OCC).
 Analogue events.
4. Practical Considerations
4.1 Design
4.1.1 Design and performance requirements
Equipment or systems comprising several components shall be controlled through the BMS with
suitable control regimes to achieve desired operation manually and automatically but with
provision for manual intervention. The automatic operation shall conform to the operational,
functional and overall system needs as specified in this specification.
 The contractor shall prepare in clear and logical form documents describing the functions
transmitted and the operations carried out at the stations control room workstation and
that at OCC. The control and transmission scheme shall be submitted for the consent of
the Employer or his representatives.
 The equipment shall also have arrangements to log and record various parameters on a
regular basis and store the results for at least six months.
 The BMS supplier/ contractor may propose the use of a serial data link instead of voltage
free contacts. In this case the physical characteristics and data transmission protocol
proposed shall conform to an internationally recognized publicly available standard. If
there should be a match between the BMS supplier's proposal and the capabilities of the
electrical/mechanical equipment in the field for serial data link to be adopted with the
consent of the Employer. The contractor shall interface with other electrical and
mechanical equipment supplier, as per the interface matrix.
4.1.2 Design Coordination Requirements
The Contractor shall submit a list of all design review documents for the review of the
Employer's Representative.
4.2 Applicable Design standards
The following specifications in particular may be partially or wholly applicable, in
respect of BMS design:
SN Standard/ Title
Code No.
Page | 383
1 IEC 445 Identification of equipment terminals and of

terminations of certain designated conductors,
including general rules for an alphanumeric system
2 IEC 571-1 General Requirements and tests for electronic

equipments
3 IEC 571-3 Components, programmable electronic equipments and

electronic system reliability.
4 IEC 617-12 Binary logic elements-Graphical symbols to represent

dependency notation, combinative and sequential
element as well as complex function elements
5 IEC 801-3 Radiated electromagnetic field requirements.
6 IEC 870-1-1 Tele control equipment and systems-General

Considerations
7 IEC 870-2-1 Operating conditions
8 IEC 870-4 Performance requirements
9 IEC 870-5-4 Definition and coding of application information

elements-Transmission protocols
10 IEC 1082-1 Preparation of document (Signals, Diagrams)
11 ISO/IEC 4873 Information Technology ISO 8-bit code for information

interchange structure and rules for implementation
12 IEC 60848 Preparation of function charts for control systems
13 IEC 61175 Designations for signals and connections
14 IEC 61436 (All Industrial system installation, equipments and

parts) Industrial Products-Structuring principles and
reference designations
15 IEC 61850- Glossary

Part-2
16 IEC 61850- General Requirements

Part-3
17 IEC 61850- Communication networks and systems in substations
Page | 384
Part-4 system and project management
18 IEC 61850- Substation automation system configuration

Part-6 description language
19 IEC 61850-7-1 Basic communication structure for substation and

feeder equipment-Principles and models
20 IEC 61850-10 Conformance testing
21 BS 4737: Part- Specification for installed system configuration

2 description language
22 BS 4737: Code of practice for planning and installation

Section 4.1
23 BS 4737: Code of practice for maintenance and records

Section 4.2
24 BS EN 14908- Open data communication in building automation

1:2005 controls and building management, building network
protocol, protocol stack
25 BS EN 50090- Home and building electronic system-system overview,

2-1 Architecture
26 BS EN 50090- Home and building electronic system-system overview,

2-2 General Technical Requirements
27 BS ISO/IEC Information technology: Guidelines for the

6592 documentation of computer-based applications system
Code of practice for system design, installation,
commissioning and maintenance for fire detection and
alarm systems for buildings
28 BS 5839- Code of practice for system design, installation,

1:2002 68 commissioning and maintenance for fire detection and
Pages alarm systems for buildings
29 BS EN 54-2 30 Specifications for control and indicating equipment

Pages
30 BS 6266 38 Code of practice for fire protection for electronic data

pages processing installations
31 BS EN ISO Development, Supply, Installation and Maintenance of
Page | 385
9000-3 computer software
32 IS: 1765 Direct Current potentiometers
33 IS: 3043 Code of practice for earthing
34 IS: 3700 Essential Rating and Characteristics of semiconductor

device
35 IS: 4007 Part1 Terminals for electronic equipment- General

Requirements
36 IS: 5051 Part1 Relays for electronic and telecommunication

equipment- General Requirements
37 IEEE 802 Local Area Network

Series
38 ISO 3511 Process measurement control functions and instrument

symbolic representation-part 1 basic requirements
39 IEC-60947-7-1 Low voltage switch gear and control gear
40 IEC-61643, Lightning and surge protection.

62305,60364
41 EN: 60715-35 Din rail made thick layer passivated (ROHS) complaint
cold rolled carbon
4.3 Application of specification

The above specifications shall be applied in a manner altered, amended or supplemented
by this specification and the latest Indian Electricity rules whereve applicable.
4.3.1 Lightning
4.3.1.1 The contractor shall ensure that all equipments are fully protected against the effects of
mains surges and direct and indirect lightning strikes. Protection such as high voltage cut
outs or high current cut outs shall be applied to incoming mains power supplies and to
input and output signal lines to externally located sensors, transducers, actuating
equipment, etc. or to any other equipment likely to be affected.
4.3.1.2 Lightning protection systems shall be in accordance with BS 6651 —"Lightning
Protection" or an equivalent Indian/international standard.
4.3.1.3 All surge suppression equipment shall be self -contained and self-resetting.
4.3.2 Alarm
4.3.2.1 All alarms generated by the installation including processor alarms, power supply alarms,
and control equipment alarms, shall be sustained until cleared. Alarm handling shall be
implemented through the BMS system.
Page | 386
4.3.2.2 Alarms will flash on the present screen and be audible to the station controller; it will be
messaged to the mobile phone of the station controller and other concerned DMRC
authorities, as decided by the Employer.
4.3.2.3 The Alarm shall be in a form of a POP Up along with audio visual alarm the display
monitor positioned at SCR, near to the BMS system
4.4 Selection of equipments

4.4.1 The contractor should select the equipments, subsystems of the BMS keeping in view the
requirements given in this specification.
4.4.2 In their technical bid, the bidders should provide details of systems, its subsystem,
components etc.
4.5 Installation
4.5.1 It should be ensured that the noise within the communication links between the PLC and
the SCR Workstation is avoided.
4.5.2 Proper installation techniques should be employed to ensure adequate quality of signals
from analogue sensors (transducers) to PLCs.
4.5.3 Adequate measures shall be taken by the contractor to mitigate potential problems
confronted due to the various forms of interference.
4.5.4 A semi-rigid, shielded cabling, which is, to a certain extent, self -supporting, can be used
for signal and communication wiring.
4.5.5 The main contractor shall supply and install all materials including but not limited to cable
tray, brackets, and supports and execute all other works needed for supporting and routing
all cabling and wiring relating to BMS. The contractor shall interface with Building/ Civil
Contractors will make provisions in structures to accommodate the fastenings.
4.5.6 The PLCs should preferably be wall mounted. All floor mounted PLCs will be grouted in the
floor, so that vibrations due to metro train movement can be bourne. If the problem persists
then rubber AVMs can be used.
4.5.7 Separate tray, trunking and conduits will be used by the contractor for BMS cabling.
4.5.8 All cables will be laid in tray, trunking, and conduits as appropriate etc. Saddling of cables
on the wall shall not be permitted.
4.5.9 Dressing of cables will be done in such a manner that all cables will be laid parallel without
laying/ crossing on each other. All the cables shall be properly tagged and marked on both
ends and along the cable.
4.5.10 Bunching of cables near PLC entry, Power feeder entry and anywhere not permitted.
4.5.11 All trays, trunking and conduits will be marked with a definite colour and tray will be marked
clearly as ‘BMS Control'.
4.5.12 A separate team of experienced BMS installation engineer, Software engineer,
Electrician, Unskilled persons etc. will be kept for BMS work, for work completion as per
schedule in the contract. A list of such team will be submitted to the Employer's
representative 6 month before of the start of work.
4.5.13 Scaffold, welding machine, soldering iron and other tools/special tools &plants required
for execution of works under this project shall be arranged by the contractor.
4.5.14 Installation, testing schedule will be provided one month before start of work and weekly
progress will be submitted to the Employer's representative.
Page | 387
4.5.15 Without complete installation, tray marking, cable tagging and dressing etc., no test will
be allowed.
4.5.16 Where cables cross the track, wall or are in any part external to cable trough routes, then
they shall be suitably protected through conduits encased in concrete. Advantage shall
be taken, in consultation with the Civil Contractors, to incorporate such additional
protection into the basic construction of the concrete structures.
4.5.17 All cables except main power supply cables, entering or leaving equipment rooms and
wayside apparatus boxes shall be terminated in order of their core number on combined
terminal/disconnection or terminal/fuse links. Each wire shall be capable of being
disconnected and isolated without removing the wire itself. These links shall be easily
accessible for inspection and test. Each link or terminal shall be identified with the
designation of the circuit it carries.
4.5.18 All electronic equipment shall comply, as a minimum, with IEC 571 or equivalent
international specification. All components used shall be purchased from suppliers
complying with internationally recognized quality management and reliability certification
procedures. The Contractor shall declare in his offer the specifications to which he
proposes to comply.
4.5.19 Printed circuit boards shall be used to mount electronic components. The boards shall be
of sufficient thickness to ensure mechanical rigidity. They shall not be the sole support
for connectors, fascia panels, handles etc.
4.5.20 All components shall be identified either by carrying a manufacturer's designation or part
reference number or unique value in a standard format.
4.5.21 All metal enclosures shall be provided with an earthing terminal. The Contractor shall
ensure that all the equipments are properly and adequately earthed in accordance with
safety standards and its rules.
4.6 Testing and Commissioning

4.6.1 Testing General Requirements
4.6.1.1 There will be five type of tests-
 Factory Acceptance test for PLC, Workstation and Printer - During the test all logics shall
be demonstrated with simulator and sample PLC, Workstation and printer.
 Installation test- After delivery of the PLC at the site, this test shall be arranged to check
the physical healthiness of the hardware.
 Functional test- This test shall be arranged to test the functioning of PLC, workstation and
printer and communication network.
 System acceptance test- This test shall be arranged to test all automation and I/O list,
with integration of communication network.
 Integrated test- This test shall be arranged to test the integration of the BMSserver at
SCR with OCC and all workstations of different stations. However, indicative SAT
document shown in this specification, but it is contractor's responsibility to submit the
separate test document for each type of test to the approval of Employer's representative.
All tests shall be in sequence and on completion of previous test, next test shall be
arranged. Before installation test, all QA/QC document shall be submitted to the
Employer's representative for the approval.
Page | 388
4.6.1.2 Basic monitoring and control functions will be demonstrated on a point-by-point basis.
Checking out the software features is much more difficult and many of the programs will
only be proved correct or otherwise by closely monitoring the BMS operation over an
extended time period. The contractor shall provide necessary support till the time the
system is reasonably established.
4.6.1.3 A re-commission or check out of the operation of the BMS at the end of twelve months
shall be carried out.
4.6.1.4 The following requirements are intended to supplement and explain the General
Specification requirements without in any way limiting their application.
a) The testing philosophy for the BMS system shall ensure that the equipment functionality is
thoroughly verified and validated at the Contractor's premises before delivery and
commissioning. The test methodology shall be in line with the design methodology and the
two shall be developed in parallel.
b) The principle of testing shall be that, at stages throughout the work, formal tests shall be
performed and recorded against written test specifications, to provide a high level of
confidence to the Contractor and the Employer's Representative that subsequent stages can
proceed.
c) The responsibility for specifying, conducting and recording tests shall be with the Contractor,
but all aspects must be to the satisfaction of the Employer's Representative. The Employer's
Representative will at his discretion witness any tests. The degree to which the Employer's
Representative intervenes in the process will depend upon the level of confidence built up
during the project.
d) This document does not constitute a Test Specification or Test Procedure for any part of the
system; rather it sets out the stages at which tests are required and the subjects, location and
purpose of each stage. Inspection of incoming goods and components, and subassembly
testing, shall be undertaken by the Contractor in accordance with the procedures set out in
the Contractor's own Quality Management Plan and are not described here.
4.6.2 Responsibilities for Testing & Commissioning
4.6.2.1 All test documentation associated with a subsystem or system test shall be submitted for
review by the Employer's Representative at least 30 days prior to the scheduled
commencement of the associated test.
4.6.2.2 The Contractor shall revise and re-submit any documents to which the Employer's
Representative has raised an objection such that all test documentation associated with any
testing has achieved letter of no objection from the Employer's Representative prior to the
commencement of the corresponding testing.
4.6.2.3 The Contractor shall successfully carry out all pre-tests according to the finalized test
procedures and correct any errors prior to any (associated) witnessed acceptance tests.
4.6.2.4 The Contractor shall produce permanent records of all test progress and results in a
formal systematic manner and submit to the Employer's Representative for his review.
4.6.2.5 The Contractor shall carry out all remedial work and re-testing found to be necessary in
order that equipment shall pass the tests.
4.6.2.6 Each of the above responsibilities shall be discharged to the satisfaction of the
Employer's Representative, but no objection by the Employer's Representative shall not
imply any diminution of the Contractor's responsibilities.
4.6.3 Production Testing
4.6.3.1 Inspection - Inspection of incoming goods and component, and subassembly tests, shall
be performed in accordance with the Contractor's Quality Management Plan and shall
include software production and integration testing.
Page | 389
4.6.3.2 Product Inspection - Contractor's System Integration Testing - This is the contractors own
internal and un-witnessed testing on the complete BMS SYSTEM, including all simulation
programs necessary to prove the totality of functionality, prior to offering them up to the
customers witnessed test(s).
4.6.4 Acceptance
4.6.4.1 The Contractor shall complete all relevant Production testing before offering any
Item, Subsystem or the System as a whole for any witnessed acceptance test. All
documentation covering the results of Production tests shall be referenced in the notice
of witness testing submitted by the Contractor. The acceptance test stages follow the
requirements of the GS clauses of the contract.
4.6.4.2 All parts subject to wear, such as electromechanical peripherals, may be omitted from
the tests if agreed by the Employer's Representative. The printing and recording
equipment needed for conducting the test shall be run throughout the test. All refills
should be supplied during the period up to final handing over.
4.6.4.3 Tests shall be conducted to prove the individual and integrated functioning of the system
hardware and demonstrate performance in the face of various contingencies.
4.6.4.4 Integrated system tests shall be conducted to prove the functionality of all applications
software in the context of the complete integrated system, equipment and software
configuration. The contractor shall develop system test
4.7 Training
4.7.1 The contractor shall provide training to Employer's staff. The training should be designed
for few different levels of staff viz. operator of the system and engineers/technical
managers.
4.7.2 Contractor shall train the following minimum staff of DMRC.
Operator staff — 30 Nos.
Engineers/Managers- 5 Nos.
The Man weeks required for training of above staff shall be indicated by the BMS contractor
in their BID.
4.7.3 Operator training will be carried out on site and at the supplier's own training school, as
required.
4.7.4 Engineer/ Manager Training should concentrate on making them familiar with the
capabilities of the system so they he can take full advantage of the BMS in running
station building.
4.7.5 They should be trained for system administration i.e. allocating passwords and password
levels, adding points to, and deleting points from, the system, setting up management
reports on energy usage, cost and efficiency for major plant items, defining load shedding
priorities and so on.
5.2 Automation
5.2.1 When water level becomes lower than a predefined mark, pump will start to fill it.
5.2.2 When water level reaches to up-to-mark, pump will stop.
5.2.3 Fire water level will not be less than 90%, at such situation Tube well pump will start and
alarm will be generated.
5.2.4 If main water supply pump fails, then standby pump shall be started automatically.
Page | 390
5.2.5 Based on the detailed design, the Contractor shall develop a detailed BMS input/output
point list for all equipments to be monitored and/or controlled subject to the approval of the
Employer's Representative.
5.2.6 Control and monitoring shall be provided primarily at the SCR. It shall be possible,
however, to enable secondary control and monitoring of equipments from OCC
5.2.7 Description of basic functions is given in Table below:
Category Functions
Specified Categories Description
CRT- based supervision Window functions are available,

enabling display of plural
supervisory screen at the same
time.
Monitor and 1) Status display of units Displaying position symbol of

units
Supervision
with the shape, color, flickering
2) Fault Display Displaying position symbol of

units
with the shape, color,
flickering
3) Telemetry value display Display major telemetry

values of
voltage, current etc.
4) Ready for Graphics colour will be

command yellow
5) Running status Graphics colour for green
6) High/Low limit check Supervision and display

of deviation
of voltage, current and such
telemetry data from High/Low
setting values.
7) Trip Trip status of the breaker will be

shown by specific color (Red)
Control Local No control from BMS

workstation,
graphics colour will become
Red
Page | 391
Remote/Auto Workstation control available,

Graphics colour becomes
yellow. In
auto state controlled by
predefined
logic.
Record and 1) Reporting management Automatic collection of

various
Reporting
achievement data for editing
and
listing of operational
achievement
documents.
a) Daily Report Reporting and printing out a

daily
report of data arising from
hourly
telemeter and incidence
occurrence
b) Monthly Report Reporting and printing out a

monthly
daily
report
Category Functions
Specified Categories Description
Record and c) Annual Report Reporting and printing out a

annual
Reporting
Monthly
report
2) Message summary Reporting and printing out a

record message list, supported by
sorting
and editing functions based
on
specific factors, such as time
and
facilities.
Page | 392
a) Message list Record Reporting the contents of

equipment operation status
change
and alarming
b) Memo recording screen Reporting the contents of

equipment operation status
change
and alarming
Other 1) Change over remote Security protection by log-on

Functions control to manual password checks (operators,
control and vice versa system managers,
programmers)
2) Right of operation Setting up the scope of right-

of –
supervision and setting.
operation with a user name
a) Security Protection
to cover
b) Operation Privilege
supervisory control
setting objectives.
Page | 393
Page | 394
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INTERFACE MANAGEMENT DOCUMENT AMONG
ELECTRICAL SYSTEM CONTRACTORS
I N D E X
(Updated as on 25.06.2020)
S. DESCRIPTION PAGE VERSION
NO. NO.
1 Interface between Flexible OHE / EPC / Traction Contractor 1 May 2020 Rev.2
(FOCS) and Rigid Overhead Catenary System (ROCS) and
33 KV Auxiliary Network Contractor of Underground Section
2 Interface between Flexible OHE / EPC / Traction Contractor 5 Pg.5 (Rev.4)

and Elevated Stations & Depot E&M Contractors Pg.6 to 8 (Rev.2)
Table – Tentative List of SCADA Signals 9 June 2020 Rev.4
3 Interface between Flexible OHE / EPC / FOCS / ROCS / U/G 11 May 2020 Rev.2
Traction Contractor and Receiving Sub-Station (RSS)
Contractor
4 Interface between Rigid Overhead Catenary System (ROCS) / 16 May 2020 Rev.2
UG Traction Contractor and ECS & TVS Contractor in
Underground Station
5 Interface between Rigid Over Head Catenary System (ROCS) 17 May 2020 Rev.2
/ UG Traction Contractor and E&M Contractor in Underground
Stations
6 Interface between ECS / TVS / BMS Contractor and E&M 21 May 2020 Rev.2
Contractor in Underground Stations
7 Interface between E&M Contractor and RSS Contractor in 23 June 2020 Rev.4
8 Interface between ECS / TVS / BMS Contractor and Lift & 23 June 2020 Rev.4
Escalator Contractor in Underground & Elevated Stations
9 Interface between SCADA Contractor and E&M Contractor in 23 June 2020 Rev.4
10 Interface between Elevator (Lift), Architect / DDC and 24 June 2020 Rev.4
Electrical (E&M) Contractors
11 Interface between Escalator, Architect / DDC and Electrical 27 June 2020 Rev.4
(E&M) Contractors
12 Interface between U/G Traction Contractor and E&M 30 June 2020 Rev.4
Contractor of Depot for Retractable Catenary (RCR) Works
13 Interface between E&M Stations & Depot Contractor and 30 June 2020 Rev.4
Signage Contractor
14 Interface between E&M Stations & Depot Contractor and DG 31 May 2020 Rev.2
Contractor
15 Interface between E&M Stations & Depot Contractor and Solar 32 June 2020 Rev.4
Project Developer (SPD)
(i)
FOCS E/M ELEV, ECS, TVS,
ROCS RSS UG E/M LIFT ESCAL SOLAR
SCADA DEPOT BMS
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-- 1 2 3 9
SCADA
ROCS 1 -- 12 3 4 5
E/M ELEV,
2 12 -- 10 11 15
DEPOT
RSS 3 3 -- 7
ECS, TVS,
4 -- 6 8 8
BMS
UG E/M 9 5 7 6 -- 10 11
LIFT 10 8 10 --
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Volume 04

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(A joint Venture of GOVT. of INDIA and GOVT.

DESIGN VERIFICATION, DETAIL ENGINEERING, SUPPLY, INSTALLATION,

CONTRACT NO.: PE-02

DELHI METRO RAIL CORPORATION LTD.

(A Joint venture company of Govt. of India & Govt. of NCT of Delhi)

IEA Indian Electricity Act

CEA Central Electricity Authority

ISO International Standards

ASTM American Society for Testing and

IEC International Electro-technical

NEMA National Electrical Manufacturers

1.4.3 Local Codes, Regulations and Standards

Main Switch Boards 30 years

Sub-main switch boards / distribution 30 years

Fire alarm main panel 30 years

Tray, trunking and supports 30 years

Lightning protection 30 years

Sub-assemblies and components 30 years

Batteries Life Over 10 years

VRF/VRV system 15 years

All other Equipment As Applicable

a) Similar plant and equipment shall be replaceable/interchangeable, modular in

a. Reliability, Availability and Maintainability (RAM) requirements shall be defined in

b. The Contractor shall perform RAM analysis up to his scope of work

e. The design, manufacture, installation and commissioning of the equipment as also

II. Reliability Requirements:

Any independent failure in the equipment which results in loss of function

i. Fault in equipment of sub-system while operating within

resulting in any one of the following:

i. Non-operation of that particular equipment, even though

i. Reliability Targets shall be calculated every month by the

S. No. Equipment Min MTBF (in

MTBF to be achieved for following equipment is to be defined by

e. Disruption of Revenue Services as a result of equipment/system/sub-system’s

III. Availability Requirements:

a. Availability shall be defined in terms of percentage availability.

Percentage Availability = [1 – {Downtime/Total Time}] * 100

b. Minimum availability Targets to be achieved are specified below:

S. No. Equipment Availability (Min

IV. Maintainability Requirements:

a. Ease of carrying out Maintenance & Repair, of an equipment/system/sub-system,

c. Components, systems and their sub-assemblies which require routine

DELHI METRO RAIL CORPORATION LIMITED

Design Verification, Detail Engineerring, Supply, Installation, Testing and

AIR-CONDITIONING AND VENTILATION SYSTEM ...........................179

FIRE FIGHTING SYSTEM ...................................................................238

Part – B Page 1 of 401

1 FIRE HYDRANT & FIRE FIGHTING SYSTEM .............................239

WATER SUPPLY PUMPS WORKS ....................................................276

WATER SUPPLY PUMPS WORKS ....................................................276

EOT CRANE & AIR COMPRESSOR…………..…………………………281

Part – B Page 2 of 401

Part – B Chapter – 1 Page 3 of 401

1 LV MAIN SWITCHBOARD INCLUDING DB

Part – B Chapter – 1 Page 4 of 401

Part – B Chapter – 1 Page 5 of 401

Part – B Chapter – 1 Page 6 of 401

Part – B Chapter – 1 Page 7 of 401

Part – B Chapter – 1 Page 8 of 401