Cairo Monorail 6th of October

SECTION 26 2413 - MAIN DISTRIBUTION BOARDS

PART I -GENERAL

1.01 RELATED DOCUMENTS:

A. Drawings and general provisions of Contract, including General and

Supplementary Conditions and Division-1 Specification sections, apply to
work of this section.

B. Division-26 "Electrical Basic Materials and Methods" and other sections

apply to work -specified in this section.

1.02 SUMMARY:

A. This section includes Main Distribution Board (MDB) work as indicated by

drawings and schedules. (Main distribution boards fed from emergency
supply are prefixed with letter "E").

1. Relevance to codes or standards of this Specification.

2. Work includes mounting frames, fittings, cable termination accessories,

gland plates and supports.

B. Types of MDB's specified in this section are including the following:

1. Circuit-breaker MDB's, floor mounted with withdrawable or fixed circuit

breaker arrangements.

2. MDB's with incorporated automatic transfer switches as shown on

drawings.

C. Related Sections: the following sections of division 26 contain

requirements that relate to this Section:

"Low Voltage Circuit Breakers"

"Disconnect Switches"
"LV Electrical Power Conductors and Cables"

"Earthing".

"Identification".

"Transfer Switches".

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1.03 SUBMITTALS:
A. Equipment Data: submit for approval detailed description of main
distribution boards and major components supported by manufacturers
catalogues, indicating compliance with the Standards, equipment
characteristics, details of construction, operating data, dimensions and
weights etc. Give details of miscellaneous items including incoming and
outgoing feeder terminal arrangement, connections at busbars, isolating,
earthing, interlocks, control devices, indicating and metering instruments
etc.
B. Tests and Certificates: submit complete certified manufacturers type and
routine test records, in accordance with the Standards.
C. Shop and Construction Drawings: submit drawings for approval including,
but not limited to the following:
1- Plans and elevations with indication of built-on equipment, exact
dimensions and weights.
2- Arrangement of boards inside rooms allocated, indicating spaces and
clearances.
3- Arrangement of equipment inside board.
4- One-line diagram of power system showing current ratings of switch
gear and busbars and types and locations of protective gear (relays,
instruments, CTs, VTs etc.) .
5- Schematic and elementary diagrams of control circuits.
6- Foundation details, grouting holes, installation details.
7- Arrangement of incoming and outgoing feeders, terminal fittings,
instruments, busbar connections etc.
D. Technical Literature: submit the following for approval prior to placing
orders for equipment manufacture.
1- Schedule of circuit breaker application, indicating type, range, features
and characteristics, short- circuit ratings, time-current curves etc.
2- Method of setting of protective devices for overload, short-circuit and
earth-fault currents as coordinated with upstream and downstream
systems based on specific coordination curves of protective devices
used and specific calculated prospective short-circuit currents at
various points
3- Test methods on site and references.

E. Selectivity Study
Submit to the Engineer a relay and C.B. selectivity study based on a fully
selective system.
The Current – time characteristics must be plotted on a log-log papers
showing that the choice of the C.B. settings are correct for full selective
system.

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F. Load Balance
Submit a detailed load list verifying the load balance across the phases.

1.04 SPARE PARTS AND TOOLS

A. Spare Parts: provide manufacturer's recommended spare parts for
emergency replacement and/or one year's maintenance including but not
limited to the following:
1. One set of fixed and moving contacts for every type of replaceable
contact set.
2. One operating motor and/or coil for each type of electrically operated
circuit breaker.
3. Two sets of each type and rating of indicating light, fuse, LED, control
switches, and similar devices subject to failure or breakage at any time.

B. Tools and Instruments: provide tools and instruments required for normal
routine inspection and maintenance and testing of circuit breakers and
protective devices as appropriate for type of switch gear supplied.

1.05 QUALITY ASSURANCE:

A. Manufacturer's Qualifications: firms regularly engaged in the manufacture
of main distribution boards, of types, sizes and capacities required, and
whose products have been in satisfactory use in similar service for not
less than 5 years.
B. Contractor's Qualifications: firm with at least 5 years of successful
installation experience on projects utilizing switchboard units similar to
those required for this project. .
C. Codes and Standards:
1. Standards

a. Switch gear and control gear are to comply as a minimum with IEC
439-1, IEC 60974 Factory-Built Assemblies of Low Voltage Switch gear
and Control Gear.

b. Circuit breakers are to comply with IEC 947-2 and as specified in

Section "L V Circuit Breakers".

c. Other components, where not otherwise specified, are to comply with

the relevant IEC standards.

2. Electrical Regulations/Code Compliance: comply with applicable local

regulations/code requirements of the authority having jurisdiction. This
will have precedence over other codes/standards nominated for the
project, J unless otherwise approved in writing.

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1.06 DELIVERY, STORAGE, AND HANDLING:

A. Deliver MDB's and components properly packaged and mounted on
pallets, or skids to facilitate handling of heavy items. Utilize
factory-fabricated type containers or wrappings for MDB's and
components, which protect equipment from damage. Install gravity
measuring meters in containers which indicates whether container has
been bumped or dropped. Return G-meters to manufacturer for reuse
upon delivery of MDB's. Inspect equipment to ensure that no damage has
occurred during shipment
B. Store MDBs in original packaging and protect from weather and
construction traffic. Wherever possible, store indoors; where necessary to
store outdoors, store above grade and enclose with watertight wrapping.

C. Handle MDBs carefully to prevent physical damage to equipment and

components. Remove packaging, including the opening of crates and
containers, avoiding the use of excessive hammering and jarring which
would damage the electrical equipment contained therein. Do not install
damaged equipment; remove from site and replace damaged equipment
with new.

1.07 SEQUENCING AND SCHEDULING:

A. Schedule delivery of MDB and accessories equipment which permits

ready building ingress for large equipment components to. their
designated installation spaces. Coordinate delivery of equipment with the
Installation of other building components.

B. Coordinate the size and location of concrete equipment pads. Cast

anchor bolt inserts into pad. Concrete, reinforcement, and formwork
requirements are, specified in Division 3.

C. Coordinate with. Other electrical work including raceways: electrical

boxes and fittings, and cabling/wiring work, as necessary to Interface
Installation of MDBs with other work.

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PART 2 –PRODUCTS

2.01 MANUFACTURERS:

A. Available Manufacturers: subject to compliance with requirements,

specifications, drawings and regulations.
B. For approved manufacturers refer to the recommended manufacturer
list.

2.02 GENERAL REQUIREMENTS:

A. Generally: main distribution boards are to be “BS standard” (Form 2b)

Metal Clad multi-cubicle, floor mounted, free standing, 1000 V rated
insulation voltage and 600 V, rated operational voltage with fixed or
draw-out switch gear , manually or manually and electrically operated, as
shown on the Drawings, with matching vertical sections to form a
continuous integral and rigid structure, wired and type tested at the
factory, ready for installation on the site.

B. General Construction: rigidly framed and bolted, with electro-galvanized

sheet steel enclosures, minimum thickness 2 mm, phosphatized, primed
with rust inhibiting primer and finished with thermal polymerized
polyester epoxy powder coating, grey colour (RAL 7703) to approval.
Switchgear is to be Vermin, dust and rodent proof, IP 42 protection to lEC
529 for indoor installations, with adequate lifting means and base-frames
and capable of being moved into position and directly bolted to floor
without additional sills.

C. Ventilation: compartments are to be Ventilated, where required, by

approved methods complying with the Standards.

D. All fastenings between structural members shall be bolted, not welded, to

provide flexibility during installation.

E. Extension of structure and busbars is to be possible end of switchboard.

F. Arrangement is to permit incoming. and outgoing busbars and cables to

enter enclosure as indicated on the Drawings and connect at respective
terminals without inconvenience to installation or maintenance.

G. Automatic transfer switches incorporated within switchboards are to be

as. shown on the drawings and to comply with section 26 3623.

H. Removing Circuit Breakers: suitable arrangements and equipment are to

be provided for extracting, lifting and unloading switchgear from
enclosures as appropriate for type of switchgear.

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I. Spare and space positions are defined as follows:

spare position: fully equipped enclosure with switchgear

space position: fully equipped enclosure ready to receive switchgear.

J. Busbars: to be site rated for normal current as shown on the Drawings or

at least site rated to same rating as main circuit breaker size, and braced
for a symmetrical rms short- circuit duty equal to or higher than main
circuit breaker interrupting duty, for minimum of one second unless
otherwise specified or shown on the Drawings. Busbars are to be copper,
of sufficient size to limit temperature rise to allowable insulation or
equipment temperature ratings, and to a total maximum temperature of
90 deg. C. Connections and buswork are to be bolted with copper alloy
hardware and are to be accessible for inspection and maintenance.
Contact surfaces are to be electro-silver plated.

K. Connections from busbar to switch gear are to be rated to carry full

continuous current rating of switch gear frame and are to be insulated.

L. Full size neutral is to be continuous through all sections. Neutral bus is to

be insulated and separate from earth bus and connected to it with
removable links.

M. Earth bus is to extend full length of board, firmly fixed to each section in
accordance with the Regulations and Standards, complete with two main
earthing lugs ( one at each end), and required number of feeder
protective earth connectors.

N. Switchboard Type: switchboard(s) are to be of the following type(s):

1. Form 4b to IEC 439-1 with metallic separation, is to be front and rear

accessible, front and rear aligned with withdrawable main and tie
power air circuit breaker (PACB)) sections (type and rating as shown
in Schedules) and fixed or withdrawab1e individually mounted
outgoing P ACB & MCCB distribution section(s). ( type and rating as
shown in schedules).

O. Withdrawable metal enclosed circuit breaker section is to consist of

compartmented unit(s), stationary part with rear busbar and cable
connection compartments and front draw- out circuit breaker assembly.
Partitions between sections are to be bolted steel plate and partitions
between compartments are to be tough solid insulating removable bolted
barriers. Each unit is to have hinged lockable front door with grip-handle
and door mounted instrumentation.

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P. Drawout circuit breaker assembly is to have disconnecting contacts,

wheels and interlocks to prevent connecting or disconnecting circuit
breaker unless in the open position, and to prevent closing circuit breaker
while racking into any of the three positions ( connect, test, disconnect)
.Racking mechanism and rail assembly are to be approved worm and
lever mechanism. It is to be possible to close the unit door with breaker in
any of the three positions and when removed. External position indicator
is to be provided. Fixed disconnecting primary contacts are to be
accessible and replaceable from front and are to be silver plated copper.
Moving primary disconnect contacts are to consist of self- aligning, silver
plated,. spring pressure, finger-cluster copper contacts fitted on, line and
load studs of circuit breaker.
Q. Front and rear accessories, front and rear aligned, individually mounted
fixed or withdrawable PACB or MCCB distribution sections as basic
construction for form 3 and form 4 switchboards, are to be
compartmentalized construction, consisting of front modular circuit
breaker compartments, busbar system compartments and rear sable
termination compartments ( as per the form type selected), with
insulating barriers between front compartments and busbar
compartments and between rear compartments and busbar
compartments (removable for maintenance).MCCBs are to be closely
coupled to busbars (to minimize chances of bus -side faults), and to rear
cable terminals, through compatibly frame -sized insulated connectors.
MCCB modules are to be covered on the front, by recessed frame -type
bolted covers, 2 minimum thickness, to protect circuit breaker handles.
Top, sides and rear are to be covered with removable screw-on plates
having formed adages all around.
R. The Electrical installation has been designed to give load balance across
the phases as far as possible but it is the contractor's responsibility to
maintain or improve the balance when connections to bars etc.
S. When the final commissioning is to be completed the contractor shall
allow in his tender for checking loads and altering connections in order to
achieve as even a balance over the phases.
T. All busbar contact surfaces shall be electro-silver plated to a minimum
thickness of 0.0125 mm.
U. A special trolley shall be supplied together with the switchgear for
removal or installation of the air-circuit breakers from their compartment
for maintenance or repair.
V. The switchgear shall be provided with inlet air filtration.
W. In case of MDB main incoming C.B tripping due to either under voltage or
over voltage the C.B shall come back automatically after voltage stability.

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X. All incoming circuit breakers shall be equipped with under and over
voltage shunt trip relays.
Y. It is not permitted for Bus coupler to switch over between transformers
automatically.
Z. No paralleling of transformers shall be allowed, interlocking system to
insure this function.
AA. Main incoming circuit breakers shall be able to be controlled via the
B.M.S system.

2.03 CIRCUIT BREAKERS:

A. Except as otherwise indicated, provide circuit breakers and ancillary

components, of types, sizes, ratings and electrical characteristics shown
on drawings, which comply with manufacturer's standard design,
materials, components, and construction -in accordance with published
product information, and as required for a complete installation and as
approved by the Engineer.

B. Provide circuit-breakers as specified in Division 26 Section "Low Voltage

Circuit Breakers", of the following types:

1. Power Air Circuit Breakers (PACB's); electrically and mechanically

operated, 3 or 4 poles as shown on the drawings.

2. Moulded Case Circuit Breakers (MCCB's) meeting with specification of

“MCCB's for MOB's:
C. Provide the following accessories as required on drawings:

1. Electrical operator.
2. Control and interlocking functions.
3. Undervoltage release.
4. shunt trip coil.
5. alarm and auxil1ary switches.
6. padlocking device.
7. key lock device.

D. Non-fused current-limiting circuit breakers where high interrupting duty is

required for small normal current. ranges and with accessories as stated
above for MCCBs, as shown on drawings.

E. All components shall be installed in accordance with the instructions of

their manufacturers. This requirement does not negate the requirement
for type and routine testing as specified elsewhere in this specification.
F. Adjusting and resetting devices shall be easily accessible.

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G. All components shall be installed and wired such that their function is not
impaired by interaction such as heat, arcs, vibration, and fields or energy
present in normal operation.
H. Barriers for manual switching devices shall be designed such that arcs
caused by switching under normal operation or the interruption or making
of a fault current shall not present a danger to the operator.
I. All removable and withdrawable components shall be installed and
designed such that they can be safely disconnected or connected to
supply circuits while the associated conductors are live.
J. All spare contacts on relays, contactors, and the like shall be wired to
easily accessible terminal blocks, suitably positioned for future external
wiring.
K. Assemblies shall be provided with a spare set of fuses mounted on
polyethylene coated spring clips adjacent to the fuse chart on the doors
of a separate cubicle. A total of 20% of each size of fuse shall be
provided with a minimum 4 of each size. When commissioning is
complete the panel shall be handed over with this complete set of spare
fused. A fully detailed fuse chart shall be provided in the same cubicle as
the fuses.
L. Where moulded case circuit-breakers are installed they shall be fitted
with rotary action handles. The handles shall be lockable in the "ON" and
"OFF" positions.

2.04 METERING INSTRUMENTS

A. A microprocessor-based monitoring device that provide complete

electrical metering is to be provided for all the main incoming feeders.
B. The device is -provide reading of the items listed below with the following
accuracy:

current per phase : ± 0.5 %

Voltage per phase/line : ± 0.5 %
Power

Watts & Watts demand (min. & max.) : ± 1.0 %

Vars & Vars demand (min. &max.) : ± 1.0 %
V A & V A- demand (min. & max.) : ±: 1.0 %
Power consumption:
Watt -Hours : ± 1.0 %
Var –Hours : ± 1.0 %
VA –Hours : ± 1.0 %
Power factor : ± 2.0 %
Frequency : ± 1.0 HZ

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C. The device to be equipped with non- volatile storage of metered data at

time of last trip.

D. The device is to be provided in a draw -out case, which shall permit rapid
interchanging of the device with similar unit withdraw requiring panel
wiring change. Current transformers secondary shall be automatically
short - circuiting contacts shall be visible from the front.

E. Current and voltage transformer required for the operation of the device
are to be provided.

F. Current transformer (CT): indoor dry type, rated secondary current 5 A.

Rated primary current, core size and accuracy are to be determined in
accordance with nominal current of plant protected, short -circuit level
and burden.

G. Voltage transformer (VT): to be provided where required, complete with

primary and secondary fuses and disconnecting device.
H. Cable terminations and space for terminations shall be suitable for the
I. Terminal blocks shall be made of thermosetting melamine or polyamide
material with a low tracking index and good flame resistance, tested to
withstand a temperature rise of 90OC above ambient temperature.
Provision shall be made for permanent labels to be applied to each
terminal for identification purposes.
J. All terminals for control wiring shall have provision for plug-in test spills
and in addition be fitted with isolating links. Current carrying parts shall
be made of tinned brass or copper.
K. Completely shrouded terminals of the tunnel type shall be used for
cables up to 10mm2. The screw clamp connection shall be vibration
proof, self-locking and suitable for clamping two conductors.

2.05 BUS BARS

A. All copper bus bars, switching devices and connections shall be of
sufficient sizes and silver plated at contact to limit the temperature rise
to 25OC over an average ambient temperature of 45 OC outside the
enclosure.
B. All bus bars and connections shall be accessible for inspection and
maintenance purposes.
C. Bus bars are to be of high conductivity copper and rigidly supported to
withstand the mechanical stress of a rated short-time withstand current
in accordance with IEC recommendation No. 60439-1.
D. Main bus shall be of continuous construction. Main bus joints and all top
connections shall be silver plated and tightly bolted to insure maximum
conductivity

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E. Bus bars shall be clearly marked with their respective phase colors and
shall be furnished for future extensions.
F. The main set of bus bars shall be housed in segregated chamber. Bus
bar top covers shall be capable of supporting a main weight without
deflection.
G. Incoming and outgoing supplies to switchgears shall be either busways
or cables as indicated on drawings.
H. A full-length ground copper bus shall be provided. The ground bus shall
be founded to the metal enclosure of each compartment and to
metering and relaying, transformers secondary windings. Lugs shall be
provided one at each end of the ground bus and one in each cubicle for
the user's copper ground cables.
I. The cross-sectional area of neutral bus bars shall not be less than of
the associated phase bars.
J. Access to bus bars and bus bar connections shall be possible only after
the removal of covers secured by bolts or studs. Such covers shall be
identified externally by engraved laminated labels bearing the
inscription “BUSBARS DANGER 380 VOLTS " in 30mm high black
lettering on a yellow background.
K. Connections from main and dropper busbars to the supply side of
functional units shall be by means of dedicated conductors. Conductors
installed on a loop in principle shall not be acceptable.
L. All neutral supply/load connections shall be made via the enclosure
containing the associated functional unit. Common neutral terminals
shall not be acceptable.
M. No diversity shall be used in busbar dropper sizing.

2.06 AUXILIARY WIRING

A. All non-screened auxiliary wiring, except that which is required to be

screened, shall be carried out on 600/1000V grade insulated, multi-
stranded flexible conductors.
B. The minimum conductor size shall be 1.5mm2
C. All auxiliary wiring shall be identified at both ends with numbered any
resistor color coded ferrules. These numbers shall be shown on the
control schematic wiring diagram.
D. All auxiliary wiring shall be contained within cabling trunking and totally
segregated from power wiring as far as practicable. Wiring of circuits at
different voltage categories, e.g. L.V. and ELV, shall be segregated.
Joints will not be permitted on wiring between devices.
E. Cable trunking shall be of the ventilated type with clip-on covers and
purpose made junctions and accessories. Cable shall not occupy more
than 40% of the trunking cross-sectional area.

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F. Wiring not contained within trunking shall be strapped in looms with

removable straps and held in place by sutiable cleats. Looms shall not
exceed more than 25 wires. Self-adhesive straps shall not be
acceptable.
G. All wiring connections from trunking and looms to devices shall be run
in straight lines, horizontally and vertically, and be neatly dressed.
H. Wiring to door mounted devices shall be flexible and provided with a
large enough loop to clear the edge of the opening. Protection against
abrasion shall be provided by means of flexible conduit or spiral
wrapping securely fixed at each end.
I. Where wiring passes through partitions it shall be protected against
abrasion by thermoplastic grommets and spiral wrapping.
J. Interconnections between functional units shall be contained within a
separate cabling chamber or trunking. All cables shall terminate on the
functional unit terminals within the cubicle.

2.07 LABELS
A. All enclosure containing functional units shall be clearly labeled with a
circuit, unit reference and current rating.
B. All labels shall be of the engraved type made from suitable multi-layer
laminate and shall be fixed with zinc plated cheese head instrument
screws. No other type of label will be acceptable.
C. Every functional unit shall be labeled separately from all others. External
labels shall have letters not less than 5mm in height and internal labels not
less than 3mm. the letters shall be black in color on a white background.
D. All covers/doors not fitted with interlocked switched disconnectors
enclosing unshrouded live equipment shall be fitted with warning labels
inscribed "DANGER 380V ISOLATE BEFORE OPENING".
E. Warning labels shall have black letters on a bright yellow background
wherever possible, letters shall be not less than 30mm in height. On small
covers and doors letters of 20mm or 10mm in height shall be used.
F. Cable boxed shall be clearly labeled both externally and internally with the
circuit and functional device number.
G. All terminal blocks shall be labeled relative to the respective functional unit.
H. Every control and metering device, selector switch, pushbutton and
indicator light shall be clearly labeled to indicate its purpose.
I. Main identification labels shall be provided on the assembly together with a
rating plate.
J. Fixed and withdrawable portions of equipment including fixed and plug-in
devices shall be labeled with withdrawable portions cross-referenced to
their fixed part.
K. Proposed engraving details shall be submitted for comment prior to
engraving.

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2.08 EARTHING
A. Each assembly shall be provided with a continuous copper earth bar
running the whole length sized for the prospective short-circuit current.
B. Discrete terminals shall be provided for connection to all the protective
conductors. Each individual section of the assembly shall be separately
bonded to the main earth bar.

2.09 SELECTOR SWITCHES/PUSH-BUTTONS/INDICATOR LAMPS

A. The manufacturer's range shall include fully interchangeable contact
blocks and lamp holder blocks which can be fitted to all actuators including
switches and push-buttons.
B. Selector switches shall be of the rotary type, with lever or key operated
actuators.
C. Pushbuttons shall be of the flush type.
D. Pushbuttons used for emergency stop purposes shall be of the mushroom
head type, with a twist to release action or key reset.
E. Contact blocks shall have double break silver plated contacts, in "No" or
"NC" configuration rated at not less than 5A resistive at 220V 50 HZ.
F. Indicating lamps shall be of the flush type 22mm diameter with removable
colored lenses, allowing lamps to be changed from the front and shall be
provided with a push to test facility.
G. Indicating lamps on control circuits shall be equipped with completely
sealed dual wound safety isolating transformers and in-built test relay.
H. Fuse failure lamps shall be of the neon type with current limiting device.

2.10 POWER FACTOR (PF) CORRECTION

A. Generally: multi-step PF correction system complete with multi-step
capacitor bank, regulator, anti-harmonic protective reactors and HRC
fuses is required to bring up power factor of LV system to better than 0.93.
Each transformer is to be provided with a separate multi-step power factor
correction system as shown on the Drawings.
B. Location of Capacitor Bank: is to be indoor type as close as possible to
nominated switchboard requiring PF improvement, and to be totally
enclosed in sheet metal cabinets with appropriate ventilation.
C. Capacitor Bank is to be prefabricated, complete with capacitors,
anti-harmonic reactors, contactors, busbars and power factor regulator, to
effect automatic control and sensing of power factor for switching in and
out the number of steps required to improve PF to at least the figure
indicated above, and discharge resistors to enable discharge of capacitors
after disconnection. The total rating and minimum number of steps of each
capacitor bank is indicated on the Drawings.

D. Steps are to be rated at maximum 50 KVA, 3-phase, operating for loads

between 100 KVA and 1800 KVA having PF below 0.93. Details and
ratings of capacitor steps and anti-harmonic reactors of each system are to

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be calculated by the Contractor based on the final ratings and

characteristics of the selected equipment and taking into consideration the
various operating schemes. Calculations are to be submitted for approval.

E. Capacitors are to be dry-type, operating on rated low voltage, made of

metalized polypropylene (self-healing dielectric) foils coated with
thermosetting resin, or equal construction, proved in operation for at least
5 years, under prevailing ambient conditions. Capacitors are to comply
with IEC 381-1 & IEC 831-2, with a loss factor not exceeding 0.3x10(-3) (a
consumption of about 0.4 watts per KVAr). Capacitor with plastic
polypropylene dielectric, impregnated with vegetable non-PCB
impregnated (fire point >= 300 deg C biodegradable, in aluminum casing is
also acceptable.
F. Switching of Capacitors is only to be performed by the fast closing
contactors on capacitor bank units (with surge limiting reactors as
necessary). Switching arrangement of capacitors is not to allow excessive
transient capacitive switching at source, i.e. circuit breaker feeding the
bank.
G. Anti-harmonic reactors are to be connected in series with the capacitors
and properly tuned to limit the harmonic currents in order to avoid
overloading the capacitors. The reactor rating at 50 Hz is to be not less
than 7% of power capacity to be protected.
H. Accessories: each capacitor is to have its own connection terminals, HRC
fuses, contactor, indicator lamp and set of discharger resistors.
I. Regulator is to be housed IP31 sheet steel enclosure, and is to have
setting knob for PF selection between 0.8 and 1.0, manual control position,
and signal lights.
J. Instrument Transformers are to be provided at incoming circuit breaker(s)
of MDB.

2.11 WIRING
A. Arrangement: wiring is to be modularly and neatly arranged on. master
terminal boards with suitable numbering strips and appropriate cartridge
type fuses where required.
B. Connections are to be made at front of terminal board and with no live
metal 'exposed.
C. Metal cases of instruments, control switches, relays etc. are to be
connected, by copper conductors not less than 2.5 mm2 section, to
nearest earthing bar.
D. Control Wiring: copper, PVC insulated, 85 deg. C, 600 V grade, and PVC
sheathed. for multi-core cables. Finely stranded copper conductor, silicon
rubber insulated cables are to be used in proximity to higher temperature
components and as flexible cable.
E. Ferrules: wires are to be fitted with numbered ferrules of approved type at
each termination.

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2.12 MISCELLANEOUS

A. Schematic and wiring diagram is to be provided suitably located within

each cubicle.

2.13 WORKS TESTS

A. All assemblies shall be tested in accordance with the requirements of IEC
60439 standards part 1, plus requirements of associated standards.
B. TYPE TESTED ASSEMBLIES (TTA)
TTAs are specified, certification shall be provided for all type and routine
tests to IEC 60439 standards.
C. TYPE TESTED ASSEMBLIES
TTAs are specified, compliance with the test requirements of IEC 60439.
Verification of the Type Testing Certification or the appropriate
extrapolation calculations shall be provided. Certificates shall also be
provided for routine tests.
D. Works tests shall include inspection of all wiring and a complete electrical
functioning test.
E. Protection relays shall be tested by primary current injection with currents
equal to overload, short-circuit and earth fault conditions.
F. Works tests shall be done in the presence of the engineer.

2.14 FIELD TESTING

A. ASSEMBLES
All assemblies shall be subjected to the routine tests as defined in IEC,
60439 standards. after installation on site. Test certificates shall be
provided.
B. FUNCTIONAL UNITS
All functional units shall be checked for correct mechanical operation.

C. PROTECTION CIRCUITS
All protection circuits in with relays used shall be tested for correct
operation by secondary injection of test currents. This shall be carried out
at currents equivalent to overload, short-circuit and earth fault conditions.
D. CURRENT TRANSFORMERS
Protection circuits using current transformer (CT) operated relays shall be
tested by primary injection of current to prove the transformer ratio.

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2.15 COMMISSIONING
A. Following the satisfactory conclusion of inspections and tests on
completed sections of the works, each switchgear assembly shall be duly
commissioned and left in full working order. The term "Commissioning"
shall be deemed to include:
(1) The energizing of functional device circuits and equipment which have
previously been inspected, tested found to be satisfactory and capable of
being energized with compete safety.
(2) The starting up of all electrically powered plant and equipment, including
that supplied and installed under other contracts, and as specified in the
schedules.
(3) The verification of the performance of each switchgear assembly relative
to all such plant and equipment by the carrying out where required, of
further tests and the making of all necessary adjustments or as to obtain
optimum performance.
(4) The proving of all interlock operations in all possible combinations and
the operation of all control systems, metering and indications to meet the
performance requirements specified.

PART 3- EXECUTION
3.01 EXAMINATION:
A. Examine areas and conditions under which switchboards and components
are to be installed, and notify Engineer in writing of conditions detrimental
to proper completion of the work. Do not proceed with the work until
unsatisfactory conditions have been corrected in a manner acceptable to
the Installer.

3.02 INSTALLATION OF SWITCHBOARDS.

A. Install switchboards as indicated, in accordance with manufacturer's
written instructions, and with recognized industry practices; complying with
applicable requirements of applicable standards or codes approved.
B. Equipment Bases: ensure that concrete bases and foundations provided
for installation of equipment are constructed in accordance with approved
shop and construction drawings and equipment manufacturers' drawings
and that holes for fixing bolts and provisions for passage of cables etc. are
provided as required.
C. Built-in items: ensure that equipment supports, fixings and the like, and
sleeves for passage of feeders and cables which are to be built into
concrete foundations, bases, cable trenches or building structure are
provided as and when required and that they are properly installed.
D. Equipment: install on concrete bases etc., and assemble completely plumb
and level, before grouting in holding-down bolts.

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 Cairo Monorail 6th of October

E. Supports and Terminations: install all incoming and outgoing cable

supports, cable ends and termination fittings required for power and
control cables.
F. Relays: set in accordance with manufacturer's instructions and in
accordance with an approved scheme.
G. Make good damaged painted surfaces, clean and apply rust-inhibiting
prime coat and two finishing coats of approved enamel upon delivery of
equipment to site, or as required by the Engineer.
H. Tighten connectors and terminals, including screws and bolts, in
accordance with equipment manufacturer's published torque tightening
values for equipment connectors. Where manufacturer's torque
requirements are not indicated, tighten connectors and terminals to comply
with tightening torques specified in applicable standards.
I. Coordinate as necessary to interface installation of switchgears with other
works.
J. Fasten enclosures firmly to wall and structural surfaces, ensuring that they
are permanently and mechanically anchored. Provide all angle units and
accessories for proper mounting.
K. Provide properly wired electrical connections for switchgears within
enclosures.
L. Double lugging is not permitted.
M. Fill out switchgears circuit directory card upon completion of installation
work.
N. Provide equipment earthing connections sufficiently tight to assure a
permanent and effective ground for panelboards.
O. Provide 6.0 mm minimum thick x100 cm wide insulation mat in front of low
voltage switchgear and near of freestanding equipment and extend 50cm
beyond ends.

3.03 FIELD QUALITY CONTROL:

A. Equipment: inspect equipment upon delivery to Site and report any

damage to the Engineer.
B. Switch gear: inspect and check switch gear for completeness, component
ratings, types, sizes, and wiring connections. Check phasing of busbars,
contacts and clearances.
C. Tests: after installation and before handover, carry out all tests required
by the governing codes and any other tests the Engineer may require to
check compliance of installation with the Specification, including
insulation resistance tests and operational tests.
D. Main and Control Circuits: using 1000 V megger (2000 Megohm range),
check insulation resistance between phases, between phases and
earth/enclosure and between neutral and earth.

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E. Primary Injection Tests: provide portable test equipment to test time-delay

characteristics of circuit breakers by simulating an overload or fault
condition. Measure and record all test results and ambient conditions and
compare with manufacturer's data.
F. Instantaneous Trip Elements: test by high current primary injection, using
high- current primary injection test- sets and report all readings.
G. Routine tests on site are to be carried out on every main distribution board
in accordance with the Standard specified (IEC 439 or BS 5486: Part 1)
for FBAs assembled from standardized components outside the works of
the manufacturer. Routine tests are also to be carried out on every FBA,
delivered to site, if requested by the Engineer.
H. Prior to energization of circuitry, check all accessible connections to
manufacturer's torque tightening specifications.
I. Prior to energization of switchboards, check with ground resistance tester
phase-to-phase and phase-to-ground insulation resistance levels to
ensure requirements are fulfilled.
J. Prior to energization, check switchboards for electrical continuity of
circuits, and for short-circuits.
K. Equipment shall be tested and full type test certificate issued by an
approved independent test laboratory shall be submitted.
L. Adjust operating mechanisms for free mechanical movement.
M. After energization check phase balancing and adjust accordingly.
N. Touch-up scratched or marred surfaces to match original finishes.

3.04 ADJUSTING AND CLEANING:

A. Adjust operating mechanisms for free mechanical movement.
B. Touch-up scratched or marred surfaces to match original finishes.

3.05 EARTHING:
A. Provide equipment earthing connections for switchboards as indicated.
Tighten 1 connections to comply with tightening torques specified in
applicable standards to assure permanent and effective earthing.

3.06 DEMONSTRATION:
A. Subsequent to wire and cable hook-ups, energize switchboards and
demonstrate functioning in accordance with requirements. Where
necessary, correct malfunctioning units, and then retest to demonstrate
compliance.

END OF SECTION 26 2413

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