electrical scope of work - gailtenders.in

ELECTRICAL SCOPE OF WORK

TABLE OF CONTENTS

1.0 INTRODUCTION………………………………………………………………..

2.0 DESIGN CODES AND STANDARDS ......................................................

3.0 ELECTRICAL POWER SYSTEM .............................................................

4.0 ELECTRICAL SCOPE OF WORKS .........................................................

5.0 RESIDUAL ENGINEERING .....................................................................

6.0 PROCUREMENT ......................................................................................

7.0 CONSTRUCTION .....................................................................................

1.0 INTRODUCTION GAIL (India) Limited, is India's flagship Natural Gas company, integrating all aspects of the Natural Gas value chain (including Exploration & Production, Processing, Transmission, Distribution and Marketing) and its related services. In a rapidly changing scenario, GAIL is spearheading the move to a new era of clean fuel industrialization, creating a quadrilateral of green energy corridors that connect major consumption center in India with major Gas Fields, LNG terminals and other cross border gas sourcing points. GAIL is also expanding its business to become a player in the International Market. M/s. GAIL (India) Limited envisages to strengthen local gas grid network in various parts of India. M/s GAIL (India) Ltd. proposes to cater to the demand of various small consumers in construction of Pipelines & Associated Facilities for Supplying Gas to Consumers in the state of Karnataka, Goa and Maharashtra. 2.0 DESIGN CODES AND STANDARDS

M/s GAIL Pipelines and terminal facilities envisaged shall be Designed and Engineered primarily in accordance with the provisions of the latest edition of Codes, specifications, OISD & Standards for Electrical Systems for Design and Construction Requirements for Cross Country Hydrocarbon Pipelines and PNGRB and DGMS guidelines.

However, all facilities shall be Designed and Engineered with the provisions of the latest edition of Codes, applicable OISD and Director General of Mines Safety (DGMS) rule.

The equipment offered and its installation shall comply with the latest issue of the relevant Indian Standards and shall be Local Statutory approved.

In addition, requirements, as applicable to gas service of following codes / standards shall be complied with. IS:3043 : Code of Practice for earthing. IS:2309 : Code of Practice for the Protection of Buildings and Allied Structures against lightning. IS:9676 : Reference ambient temperature for electrical equipment. SP:30 : National Electrical Code (NEC) BIS Publication. IS:13234 : Guide for short circuit calculations in three phase AC systems. IS:5572 : Classification of hazardous areas having flammable gases and vapours for Electrical installations. IS:5571 : Guide for selection of electrical equipment for hazardous area. IS:4146 : Application guide for C. T. Application guide for V .T.

IS:6665 : Code of practice for Industrial Lighting. IS:3646 : Code of practice for Interior Illumination. IS:1944 : Code Of practice for Lighting of public thoroughfares. IS:13346 : General requirements for electrical apparatus for explosive gas atmospheres. IS:13408 : Code of practice for the selection, installation and maintenance of electrical apparatus for use in potentially explosive atmospheres. IS:3716 : Application guide for Insulation Coordination. IS:10118 : Code of practice for selection, installation and maintenance for switchgear and control gear. IS:7689 : Guide for Control of undesirable static electricity. IS:2309 : Code of practice for the protection of buildings and allied structures against lightning. IS:12360 : Voltage bands for electrical installations including preferred voltages and frequencies. IS:3961 : Recommended current ratings for cables. IS:7752 : Guide for improvement of power factor consumer's installations. IS:1646 : Code of practice for the fire safety of buildings – Electrical installation. IS:325 : Three phase induction motor specifications. IS:1554 : (Part‐1) Specification for PVC insulated heavy duty electrical cable for working voltage upto & including 1100 Volts. IS:7098 : (Part‐1) Specifications for XLPE insulated PVC sheathed cables for working voltage from 3.3 kV to 33 kV. IEEE 515 : Standard for Testing, design, installation and maintenance of Electrical Resistance Heating for industrial applications. BS 6351 : (Pt. 1,2, & 3) Electrical surface heating: Devices, Systems & code of practice In addition to above codes and NACE standards listed in Annexure-A shall also be referred. In case of conflict between the requirements of codes/Standards referred above, requirement of ASME, NEC, OISD & NACE standards shall govern.

3.0 ELECTRICAL POWER SYSTEM. Electrical required system to be installed as a part of this project shall be included and Engineered in accordance with the standards/codes referred in above section of this document.

Electrical Equipment’s & Earthing details. Lighting & Lightning Protection details. Main Power Supply & AC/DC UPS Power Supply details. Electrical Cables & cable accessories. Electrical Panels, DB’s & Convenience Socket Outlets. Electrical Equipment’s For Hazardous Area. Solar power Supply System Cathodic Protection System 4.0 ELECTRICAL SCOPE OF WORKS 4.1 Electrical works Design, detailed engineering, Supply, installation, testing and commissioning of electrical system comprising of: Design, detailed engineering, Supply, installation, testing and commissioning of Solar power system (2X50%) Including Solar panel modules, Charge controller, NI-CD Battery Banks, PDB and LDB for the power distribution system including JB’s & Control gears

4.1.1 Design, detailed engineering, Supply, installation, testing and commissioning of Electrical control & Power panels, PDB and LDB for the power distribution system including indoor & outdoor Electrical equipment’s, JB’s & Control gears. 4.1.2 Design, Supply, installation, testing and commissioning of all earthing and lightning protection system with material of complete earthing and lightning protection system of new earthing system at Station, comprising of copper plate & GI Pipe earth electrodes, Copper & GI strip, Lugs, connection wires of all Electrical, instrumentation/communication equipment, metering skid, piping, gate etc to the earth grid. 4.1.3 Design, Supply, laying (in trenches, buried cable trenches, pipes, road crossings, pipe-racks etc). & termination of all Control & power cables (all incoming & all Outgoing feeders) as per cable schedules, & directions of engineer-in-charge, as per attached standards and recommended practices. 4.1.4 Design, Supply, Installation, testing and commissioning of 1/2/3 KVA UPS along with DB, interconnection cables, nickel cadmium battery banks suitable for 12 hours backup time at full load as per specification and datasheet. 4.1.5 Design, Supply, installation, testing and commissioning of Indoor & outdoor lighting fixtures, lighting control DB’s, light poles, Wiring/cabling, Power sockets, ceiling Fans, Exhaust fans, chokes/Ballasts, lamps, switches, Glanding & terminations, conduit work, wiring for fixtures/mains/sub-mains etc. complete in all respects. 4.1.6 Design, Supply, installation, testing and commissioning of for Hazardous area Indoor & outdoor lighting fixtures, lighting control DB’s, light poles, Wiring/cabling, Power sockets, Exhaust fans, chokes/Ballasts, lamps, switches, Glanding & terminations for fixtures/mains/sub-mains etc. complete in all respects suitable for Hazardous area.. 4.1.7 Design, Supply, installation, testing and commissioning of all other items required to complete the job and hand over a fully functional system of the Works described in SOW/SOR

are included in the scope of supply of the Contractor 4.1.8 Only Main equipment’s estimated quantities are indicated in SOR. Unit rates quoted against each SOR item shall be applicable for any addition items required to complete the job also included in scope of works. 4.1.9 Any modification/rectification required in existing Electrical power system/panels/DB’s to complete the new job also included in scope of works. 4.1.10 Providing as built documentation for all work done including old systems where any integration has been done. All documentation to be provided as printed documents and computer files compatible with MS Office and Autocad. 4.1.11 All materials shall be approved by GAIL or its authorized representative before use by the Contractor. CATHODIC PROTECTION 4.2.1 General Pipeline and piping CP stations to be installed as a part of this project shall be designed and engineered in accordance with the standards/codes. Following CP System and material are in the contractor’s scope of supply in this tender. All equipment and materials including cables, CPTR/CPPSM units, various types of test stations, junction boxes, anodes, grounding equipment/items/anodes, polarization cells, polarization coupons, surge diverters, spark gap arrestors, bonding stations along with diodes, shunts and variable resistors etc. as required for Temporary cathodic protection & Permanent cathodic protection system of pipelines in line with standard specification, design basis and datasheet are included in the scope of supply of the contractor. 4.2.2 Cathodic protection system Design, detailed engineering, Supply installation, testing and commissioning of the temporary cathodic protection system using galvanic anodes to protect the external surface of the pipeline, against corrosion for minimum 2 year or till commissioning of permanent CP system whichever is later. Cathodic Protection system activities which are common for TCP and PCP (viz. protection of carrier pipe using zinc ribbon anodes for a design life of 30 years at all painted or coated cased crossings) are to be included in the scope of this contract. Scope also included measurement of soil resistivity for anode ground beds sizing, collection of cathodic protection related data along right of way of pipelines as per requirements. Interference detection and mitigation study & remedy’s for cathodic protection is also included in contractor scope of works. The contractor shall begin AC and DC interference detection survey immediately after the complete pipeline is buried and shall employ survey methods such as close interval potential logging survey, CAT survey, DCVG survey etc., conforming to the Data Sheets, and specifications. On completion of interference detection survey the contractor shall prepare a report clearly indicating the regions of interference, the reasons of the interference and the mitigation measures that will be employed as a part of the PCP implementation. The Client shall have the right to ask for additional investigations and the same shall be done by the contractor without extra cost. The mitigation measures must be vetted by the contractor’s CP consultant/specialist and approved by GAIL before implementation. NOTE: wherever interference is found on the pipeline the contractor shall deploy suitable equipment and trained manpower and the variations in the pipeline potential for at least 24 hours. This shall invariably be done in areas of railway traction, HV/EHV sub-stations, EHV line crossings, and crossings of foreign pipelines that are affected by interference. Permanent

cathodic protection system shall be done by impressed current method to protect the external surface of the pipelines. The construction of deep well anode ground bed of minimum depth 50 M and diameter 250 mm. The scope shall include disconnection of temporary cathodic protection system which does not form part of permanent cathodic protection system. CPTR/CPPSM units to be supplied shall be provided with remote SCADA monitoring/controlling facilities and current interrupter with GPS based timer. The contractor shall include the services of specialist agencies for doing interference survey and implementing mitigation measures against interference for CP system. The scope shall include to complete permanent cathodic protection system, including carrying out the soil of soil (at pin spacing’s of 10M, 30M, 50M, 80M and 100M) at locations for design of deep well anode ground beds, interference detection and mitigation, close interval potential logging survey, CAT survey, DCVG survey etc., conforming to the Data etc., CP NACE standards and specifications.

4.2.3 BONDING BETWEEN OLD AND NEW PIPELINES.

The contractor’s scope of work shall include bonding the new pipeline and the nearest existing pipeline. The bonding between the pipelines shall be done with the help of removable links inside CP test stations that will be installed for the new pipeline. The bonding connection from the old pipe shall be taken from the existing CP test stations. The test stations of the new pipeline must be located near to the test station for the old pipeline. However in case any pipe-to-cable connection is to be made on any old pipeline by means of pin-brazing/cad welding, the contractor shall take pipe thickness readings before making the pin-brazing/cad welding to ensure that the pipe thickness at the proposed location is adequate. The contractor’s responsibility shall include liaison with other agencies whose pipelines exist in the common ROU and obtaining their permission for carrying out bonding, pin brazing on their pipelines or any other activity that need the consent and permission of the other pipeline owners. All work related to bonding of the old pipe and new pipe shall be completed by the contractor at the TCP construction stage. The actual decision regarding the establishing the actual bond by connecting the link inside the CP Test Station shall be taken based on interference surveys to be done after the new pipeline section is lowered and buried. 4.2.4 Temporary Cathodic Protection system TCP Design & detailed engineering including the preparation of Design documents, drawings, BOQ, O & M Manuals. Supply, installation, testing and commissioning of all materials including spark gap arrestors/zinc grounding cell, insulating joints, test Stations of cathodic protection system of Pipelines for Design life of 2 year. Scope including all related civil works for completion of the system, collecting the CP system related data along the pipeline route by route survey, identification of various crossings, measurement of Soil Resistivity of Anode Ground bed by 4 pin - wenner method. Supply, installation, testing and commissioning of corrosion measurement probe, and interference detection and Mitigation study of the Pipeline and Monitoring of Cathodic Protection system up to the final commissioning. PCP & TCP works shall be carried out as per schematic drawing, specifications enclosed with contract, NACE Standard, approved procedures, approved drawings and instructions of Engineering-in-Charge. 4.2.5 Permanent Cathodic Protection system PCP scope of Design, detailed engineering including the Preparation of Design documents, Drawings, BOQ, O & M Manuals shall be as per corrosion survey, Soil Resistivity survey, NACE Standard, schematic drawings, specifications and route survey. Supply of all materials including but not limited to CPPSM/CPTR unit, reference cell, polarization cells, cables, corrosion coupons, spark gap arrestors/zinc grounding cell across all Pipeline, insulating joints & test

Stations. Design, Supply, installation testing & commissioning of works shall be based on collecting the CP system related data, measurement of Soil resistivity along pipe line of cathodic protection system of pipeline for design life of 30 years. Scope Including all related civil works for completion of the CP system of pipelines. All the CP System works shall be carried out as per specification & route survey including Identification of various Railway crossings, OHLs, Rivers & Roads crossings, measurement of soil resistivity. Interference detection, mitigation study remedy’s of the same and monitoring of cathodic protection system. CIPL, CAT, DCVG surveys shall be carried out after final commissioning of PCP system, as per schematic drawings, specifications, NACE Standard, approved procedures, approved drawings and instructions of Engineering-in-Charge.

5.0 RESIDUAL ENGINEERING Review / update the site data including collection of additional data / surveys, if required.

Compilation of all data / information collected/ generated by Contractor. Firming up of route survey drawings & rerouted sections and additional surveys, if any.

Preparation of Electrical construction drawing such as SLD, Data sheets for, various equipments.

Preparation of design documents, procedures, manuals, drawings etc. as referred in clauses of this document.

Carrying out Material Take Off for the entire Electrical system other than those materials supplied by Company. 6.0 PROCUREMENT Contractor shall procure and supply all materials other than Company supplied materials, required for permanent installation of Electrical system in sequence and at appropriate time. All equipment, materials, components etc. shall be suitable for the intended service.

Approved vendor list has been enclosed with the bid package for various items. For items which are not covered in the vendor list, Contractor shall obtain Company’s prior approval for the vendor. Equipment/ material offered shall be field proven. Equipment require specialized maintenance or operation shall be avoided, as far as possible

Stores management including receipt, warehousing, preserving the material in good condition, issue of material to construction site, reconciling/ handing over surplus material to Company for Company supplied items at Company’s storage yard.

Carryout proper documentation of inspection and quality assurance programmers for bulk materials duly approved by Company. Contractor shall maintain an accurate and traceable listing of procurement records for the location, quality and character of all permanent materials in the Project.

Contractor shall immediately report to the Company of all changes which will affect material quality, and recommend any necessary corrective actions to be taken.

Submit periodic manufacturing progress reports highlighting hold ups and slippages, if any, to Company and take remedial measures.

Interact with authorities such as GST, Sales tax, Octroi, Excise etc. as necessary and arrange for dispatch of materials to site.

All purchase requisitions including purchase orders shall be approved by Company.

Compliance with vendors and supplier’s instructions and recommendations for transportation, handling, installation and commissioning.

7.0 CONSTRUCTION All construction works shall be carried out as per “Approved for Construction” drawings, procedures, specifications and applicable codes and standards. Any changes at site shall also need prior approval from the Company and revision of drawings. Company has obtained most of the clearances, No objection certificates (NOC) for laying Cables for stations from concerned authorities. However, for some of the permissions, if not available, Contractor shall do the follow up with the concerned authorities to get the permissions to execute the job in time. However, all statutory payments required for such permissions shall be reimbursed by Company at actuals. Contractor shall obtain permits/clearance from concerned authorities before actual commencement of the job at site including preparation and establishment of safety procedures for laying Cables.

Immediately after award of work, Contractor shall make a visit to the site to establish the work setup and familiarize with the working conditions so as to plan for deployment of man and machinery.

Contractor shall barricade the working area for safety. Excavated trench & pits in residential area, area near heavy traffic and other areas for kept for movement of animals, shall not be left open without barricading. Contractor shall consider all these eventualities while bidding.

Contractor shall also inform all local authorities in advance and obtain all necessary approvals for crossing underground utilities/ cables wherever encountered along the pipeline route.

In some areas where mechanized excavation is not possible, Contractor shall have to do manual Excavation also. Contractor shall consider all these eventualities while bidding.

Providing schedules, progress reporting, organization chart at construction site, quality assurance plan and developing quality control procedures, as per requirements of the bid package.

Contractor shall be responsible for claims if any arising out of damage/ obstruction to public utilities like OFC lines of DOT, water pipelines etc. where the claims will cover the restoration costs as well as loss of revenue due to down time.

Providing all equipment’s, manpower, machinery, consumables, apparatus, tools and tackles for fabrication, installation, inspection, testing, pre-commissioning and commissioning complete as required including facilities for inspection and interpretation of testing results by Company/Company’s Representative personnel; providing all types of safety tools, tackles, devices and apparatus, equipment etc.

Coordination and supervising the work of sub-Contractors.

Transportation of appropriate materials to worksite, intermediate storage points, maintaining and operating an adequate material control procedure at worksite.

Fabrication of all structural components as per approved drawings.

All associated civil, structural, electrical, instrumentation; HDPE duct & OFC laying and telecom works shall be performed in accordance with relevant specifications and requirements enclosed elsewhere in the bid package.

Provide, maintain and operate all temporary facilities required for the construction related works and remove after completion of work.

All works related to testing, dewatering, swabbing, pre-commissioning and commissioning of the work tendered.

ELECTRICAL DESIGN BASIS

TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 DESIGN CODES AND STANDARDS

3.0 SCOPE .....................................................................................................

4.0 SITE CONDITIONS ..................................................................................

5.0 CLASSIFICATION OF HAZARDOUS AREAS ........................................

6.0 REGULATIONS ........................................................................................

7.0 ELECTRICAL DESIGN PARAMETERS ..................................................

8.0 CABLE SYSTEM. ......................................................................................

9.0 LOW VOLTAGE (LV) FEEDERS .............................................................

10.0ELECTRICAL EQUIPMENTS FOR HAZARDOUS AREA .......................

11.0ELECTRICAL INSTALLATION ...............................................................

12.0CATHODIC PROTECTION ......................................................................

13.0APPROVED VENDOR LIST

1.0 INTRODUCTION GAIL (India) Limited, is India's flagship Natural Gas company, integrating all aspects of the Natural Gas value chain (including Exploration & Production, Processing, Transmission, Distribution and Marketing) and its related services. In a rapidly changing scenario, GAIL is spearheading the move to a new era of clean fuel industrialization, creating a quadrilateral of green energy corridors that connect major consumption center in India with major Gas Fields, LNG terminals and other cross border gas sourcing points. GAIL is also expanding its business to become a player in the International Market. M/s. GAIL (India) Limited envisages to strengthen local gas grid network in various parts of India. M/s GAIL (India) Ltd. proposes to cater to the demand of various small consumers in construction of Pipelines & Associated Facilities for Supplying Gas to Consumers in the state of Karnataka, Goa and Maharashtra. 2.0 DESIGN CODES AND STANDARDS M/s GAIL Pipelines and terminal facilities envisaged shall be Designed and Engineered primarily in accordance with the provisions of the latest edition of Codes, specifications, OISD & Standards for Electrical Systems for Design and Construction Requirements for Cross Country Hydrocarbon Pipelines and PNGRB and DGMS guidelines. However, all facilities shall be Designed and Engineered with the provisions of the latest edition of Codes, applicable OISD and Director General of Mines Safety (DGMS) rule. In addition, requirements, as applicable to gas service of following codes / standards shall be complied with. IS:3043 : Code of Practice for earthing IS:9676 : Reference ambient temperature for electrical equipment. SP:30 : National Electrical Code (NEC) BIS Publication IS:13234 : Guide for short circuit calculations in three phase AC systems IS:5572 : Classification of hazardous areas having flammable gases and vapours for Electrical installations IS:5571 : Guide for selection of electrical equipment for hazardous area IS:4146 : Application guide for C. T. Application guide for V .T. IS:6665 : Code of practice for Industrial Lighting. IS:3646 : Code of practice for Interior Illumination IS:1944 : Code Of practice for Irghting of public thoroughfares. IS:13346 : General requirements for electrical apparatus for explosive gas atmospheres IS:13408 : Code of practice for the selection, installation and maintenance of electrical apparatus for use in potentially explosive atmospheres

IS:3716 : Application guide for Insulation Coordination IS:10118 : Code of practice for selection, installation and maintenance for Switchgear And control gear IS:7689 : Guide for Control of undesirable static electricity IS:2309 : Code of practice for the protection of buildings and allied structures against lightning. IS:12360 : Voltage bands for electrical installations including preferred voltages and frequencies. IS:3961 : Recommended current ratings for cables IS:7752 : Guide for improvement of power factor consumer's installations IS:1646 : Code of practice for the fire safety of buildings –Electrical installation IS:325 : Three phase induction motor specifications IS:1554 : (Part-1) Specification for PVC insulated heavy duty electrical cable for working voltage upto & including 1100 Volts. IS:7098 : (Part-1) Specifications for XLPE insulated PVC sheathed cables for working voltage from 3.3 kV to 33 Kv IEEE 515 : Standard for Testing, design, installation and maintenance of Electrical. Resistance Heating for industrial applications BS 635 : (Pt. 1,2, & 3) Electrical surface heating: Devices, Systems & code of practice NACE RP-0169 : Standard Recommended Practice Control of External Corrosion on nderground or Submerged Metallic Piping Systems NACE 10A 190 Measurement technique related to criteria for CP of Underground or Submerged Steel Piping System (as defined in NACE Standard RP0169-83). NACE RP-0177 Standard Recommended Practice Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems NACE RP-0286 Standard Recommended Practice The Electrical isolation of Cathodically Protected Pipelines NACE. 54276 Cathodic Protection Monitoring for Buried Pipelines. NACE TM0497 Measurement technique related to criteria for Cathodic Protection on underground submerged metallic piping system BS 7361 Part I Code of Practice for Cathodic Protection for land and Marine applications. IS0 15889-1 Cathodic Protection of pipeline transportation system

In addition to above codes and standards listed in Annexure-A shall also be referred. In case of conflict between the requirements of codes/Standards referred above, requirement of ASME, NEC, OISD shall govern.

i) iii) iv)

Equipment Design Temperature : Minimum ambient temperature : Design Relative humidity :

45oC 14°C 90%

3.0 SCOPE This document covers the details of Electrical work tendered, scope of Electrical work, scope of material supply pertaining to Electrical and associated facilities. All works and clauses of this document shall be applicable unless specifically mentioned otherwise.

This document shall be read in conjunction with List of Attachments, Schedule of Rates, specifications, standards, drawings and other documents forming a part of the Tender Document. This document establishes minimum Electrical Design Parameters and Basis for Design and Detailed Engineering of the Pipeline’s associated facilities covered under this project as defined briefly herein below. The scope of specification shall provide the minimum requirements & form the basis for carrying detailed design engineering for Electrical power system, sizing of various electrical equipment’s, their supply, installation, testing & commissioning of the Electrical system for New Pipeline & associated facility. This document also provides the general guidelines for preparation of Electrical specification, datasheets and other relevant documents. In case of conflicting requirement of tender documents, following priority shall govern in general. However, in case of conflict, it shall be referred to Client for clarifications and decision of Client shall be final and binding with or without any cost implications (as per project scope)

The requirements of any statutory body shall govern. Data Sheets, This specification / Basis of design, Job Specifications, Code & Standards, Safety to personnel and equipment, Reliability of service (smooth & efficient performance), Minimal fire and explosion risk, Ease of maintenance & convenience of operation Protection of all electrical equipment through selective relay system.

Utilization of equipment with adequate interrupting capacity, continuous carrying capacity and insulation levels, as per system voltages and capacities. 4.1 SITE CONDITIONS Equipment’s & materials shall be suitable for giving trouble free service under the environmental conditions given hereunder. Electrical equipment shall be specified for operation under the following site conditions: i) Maximum ambient temperature : 45°C

5.0 CLASSIFICATION OF HAZARDOUS AREAS Area classification for the plant shall be done in accordance with Petroleum Rules, DGMS Regulations and IEC60079-10 & IS 5572. Following factors shall be considered for proper selection of electrical equipment for use in hazardous area: i) Area Classification i.e. Zone ii) Gas Group.IIA/IIB/IIC. iii) Temperature Classification T3. iv) Atmospheric Pollution. The hazardous areas shall be classified as Zone 1 or 2 or 0 and shall be IIC for areas where hydrogen gas may be present and IIA for remainder of classified areas. Surface temperature

classification for all equipment for use in hazardous areas shall not exceed 200 deg. C (T3 Class). All electrical equipment installed in hazardous area shall be selected as per IS 5571 and IEC60079-10 and shall meet the requirement of relevant IS, IEC. All electrical equipment for hazardous area shall be certified by CIMFR (CENTRAL INSTITUTE OF MINING AND FUEL RESEARCH) / ERTL and DGMS approved for use in oil mines area as per the Oil Mines regulations. All electrical equipment for hazardous area shall have the valid DGMS approval at the time of installation and commissioning. Isolating devices for equipment located in hazardous areas shall switch all poles of the supply including the neutral. 6.0 REGULATIONS The electrical equipment / installation offered shall comply with requirements of the following rule /regulations as amended upto date : (a) Central Electricity Authority regulations 2010. (b) The Indian Electricity Act (c) The Indian Electricity Supply Act. (d) The Indian Factories Act, (e) The Petroleum Rules, (f) DGMS MSIHC Rules (g) CCE (h) Terms & Condition (i) Any other State Regulations in force The Contractor shall obtain the necessary clearance from the DGMS / Electrical Inspector/ Competent Authority for equipment supplied and installed. All necessary drawings, calculations, test certificates, etc. as required by DGMS / Electrical Inspector /Competent

Authority shall be furnished. Any modification/rectification as required by him shall be carried out by contractor free of cost. The fees required to be paid to the DGMS / Electrical Inspector / Statutory Authority for inspection shall be borne by Owner on production of documentary evidence. 7.0 ELECTRICAL DESIGN PARAMETERS.

Electrical power system to be installed as a part of this project shall be designed and engineered in accordance with the standards/codes referred in above section of this document. The supplied items/equipment’s shall be certified by ATEX/CMRI and CCOE. Copy of relevant certificate(s) shall be submitted along with the offe /bid.

7.1 Voltage and Frequency Variation for electrical Equipment

Equipment shall be capable of meeting its rated output continuously at 90% to 110% of system voltage at consumer terminals coincident with -2% to +2% of system frequency.

Voltage depressions to 90% of system voltage at the switchgear during motor starting shall

have no detrimental effect on equipment operation. 415 Volt, 50Hz. 25kA, 3 phase-3 wire supply will be provided. Individually, 1-ph load shall have 2 pole isolation provisions, 3-ph load shall have 3 pole isolation & 3-ph + N load shall have 4 pole isolation provisions

7.2 Voltage Drops

The maximum voltage drops in various sections of the electrical system under steady state conditions at full load shall be within the limits stated in the following table: System Element Maximum Permissible

Voltage Drop Cable between PCC and MCC or auxiliary switchboard 2%

Cable between MCC and Motors 5%

Circuit between lighting panels and lighting points 4%

DCDB to Control Room 2%

UPS outgoing circuit 2%

The maximum voltage drop at various buses during start-up of large motor shall be within the limits stated below:

System Elements Operating Conditions Max. Perm.

Voltage Drop

At the bus bar of the worst affected Switchboard (PCC

Start-up of large 415 V motor with other loads on the bus

10%

/MCC)

Cables between (PCC / PMCC / MCC and Motors

Motor start up 15%

7.3 System Earthing The 415V system neutral is resistance grounded type, The 415V system shall be solidly connected to earth via generator neutral point to earth. The earthing system shall conform to IS 732 and IS 3043. All non‐ current carrying metallic parts and enclosures of electrical equipment and metallic structures used for mounting electrical equipment shall be effectively bonded to earth throughout the terminal in accordance with IS 732, IS 3043 and IS 7689. All exposed conductive parts of equipment; piping, vessels and structural items shall be effectively bonded so as to prevent the accumulation of static charge. Every multicore power cable shall contain a separate equipment earthing conductor which is connected to the earth bar at the Switchgear / MCC, and which is connected to the utilisation equipment at the load end. This shall provide a

low impedance path for earth fault currents to permit rapid operation of protective devices a. All non – current carrying metal enclosures shall be bonded for earth continuity to the main earth Grid/earth bus. b. The minimum of two earth studs must be provided on the skid base, diagonally Opposite to each other, for connection to the main plant earth system. c. No. of earth pits shall be provided as per IS : 3043. All earthling materials shall be supplied as per Technical Specification. i) 600 x 600 x 3 mm thick copper plate earth electrodes for UPS, RTU, Telecom, Instrument Control Panel, metering panel. ii) 65 mm dia X 3000 mm (L ) GI Pipe electrode for other d. All equipment earthling· shall be carried out as per IS : 3043, Minimum size of earth conductor to be used shall be as given below: Equipment Conductor size Main Grid & equipment such as 50 X 6 mm GI Flat main Electrical Distribution Board, Switch Socket DB, UPS, DB, Lighting DB 25 x 6 mm GI flat / 16 sq. mm GI rope Mechanical equipment / Vessels, tanks, 50 X 6 mm GI Flat Pipe/cable racks, structure, fencing UPS, Telecom, RTU 10 Sq. mm Cu cable Field Instruments 2.5 sq mm copper PVC Wire 10 sq. mm Cu armored cable shall be used for Cu plate electrode interconnection of two earth pits e. Earthing electrode shall be GI pipe/ copper plate.

Minimum 2 Nos. Copper Plate Electrodes will be provided for RTU/SCADA/Control Panel equipment at new station. Minimum 2 Nos. Copper Plate Electrodes will be provided for Telecommunication System at new station. Minimum 2 Nos. Copper Plate Electrodes will be provided for UPS system at new station. GI pipe electrodes for new stations will be provided as per IS-3043 and as per site requirement, (2 Nos. near building & 2 nos. for process area and 2 nos. separate earthling for lightning protection system). All these earth electrodes will be interconnected. f. A board of 250 X 250 mm, 3mm thick GI plate shall be provided adjacent to all earth pits. Board shall display earth pit number, date of testing, test values & next due date, as per guide line of CEA.

7.4 Lightning Protection:

Lightning protection shall be provided to protect the terminal and equipment against lightning thunderstorms expected during monsoon season. The system shall be modeled to ensure that a

complete coverage to the Terminal is provided. Required number of lightning arresters shall be provided at the appropriate highest points and earthed individually. Dedicated earth pits shall be provided one for each down conductor running from the lightning arrester. The resistance of the earth pit shall not be more than 1 Ohm as per Indian Standards. The down conductors shall be copper and sized to carry the lightning energy safely down to earth without damaging itself or causing any harm to the surface on which it is supported. The down conductors shall not be run in conduits, ladders or other routes that are common to other electrical cables and services. The lightning earth pits shall not be connected to the other Terminal electrical earth grid system. A disconnection point at the earth pit shall be provided for testing the earth resistance of each pit. The sheet metal used for insulation cladding of the vessels shall not be used as the earth path for the lightning energy. Design of lightning protection system for structures provided with lightning protection shall be as per IS 732 and IS 2309. 7.5 DC Power Supply Any other instrument requiring 24 V DC power, shall drive from the 230 volt AC UPS being provided as a part of the project. 7.6 Emergency Power Supply The emergency power supply is not envisaged as a part of the project . 7.7 Uninterrupted Power Supply (UPS) Uninterrupted power supply system (230 V, AC, 1 Ph, N, Redundancy Parallel redundant UPS) along with nickel cadmium battery bank (VRPP/VRFP battery bank, as per specification and datasheet) suitable for sufficient backup time at full load shall be provided for meeting critical loads that cannot withstand even a momentary interruption in voltage. Following loads shall be connected to the UPS system:

Critical instrumentation and control Critical security equipment Annunciation panel Configuration:- i) 2 X 50 % KVA rating with bypass arrangement three/single phase UPS inparallel redundant configuration shall be charging the batteries @ 0.2C operating only on grid power is available ii) UPS system should be able to communicate the RTU’s on mod-bus protocol. iii) UPS protection class shall be IP-52 Solar Power System

Solar power system all units shall be (2X50%) rating capacity. Solar panel modules shall be latest higher efficiency & higher ratings, MPTC Charge controller(2 X 50%), pocket plate sintered NI-CD (2 X 50%) Battery Banks for three no sunny days autonomy power requirements, DC to AC (230 volt) Inverter, 2 nos. PDB for DC and AC (min, 10 outgoing feeders) Power distribution system including JB’s & Control gears. Final solar rating shall be calculated after considering all connected equipment’s de-ratings factors (solar panel modules, charge controller, battery banks, temperature, cable loss, and dusting) as per manufacturers recommendation, codes & standards. 7.8 Equipment Enclosures Equipment Enclosures shall be of heavy‐duty construction and shall provide the following minimum degrees of ingress protection.

Outdoor locations Local Control Stations IP55

Outdoor locations Lighting Fittings IP55

Outdoor locations Receptacles / Sockets / JBs IP55

Outdoor locations Electric motor IP55

The list is not exhaustive, therefore Contractor shall consider the above mentioned requirement in selection of equipment’s for the desired application. 8.0 CABLE SYSTEM. 8.1 Cables. All cables shall be 0.65 /1.1 kV grade PVC insulated, extruded inner sheath Tinned Copper wire, wire / flat armoured stranded annealed copper conductor FRLS PVC outer sheathed heavy duty cables manufactured in accordance with the IS: 1554 Part-1 (0.6 /1.0 kV grade as per IEC). Where cables have to be routed underground in the plant (e.g. for final connection to motor), they shall be protected by conduits & sealed to prevent ingress of hydrocarbons. Physical segregation shall be maintained between conductors carrying different voltage levels. Cable ladder/tray covers shall be provided on cable ladders/trays exposed to direct sun to protect the cable outer sheath from Ultra-Violet radiations. All the power and control cable which are going to be installed in the Hazardous area shall be DGMS approved type with valid DGMS approval certificates. Cable shall be marked permanently with legible words “MINING”, DGMS approval number in every three meters. Each conductor shall be identified with separate color such as Red, Yellow, Blue & Black. Vendor shall provide the valid Test certificate and DGMS approval certificate of the cable. Vendor shall provide the valid manufacturers guarantee certificate.

a. Power Cable Stranded Annealed Copper Conductor up to 10 mm2 Stranded Aluminum Conductor from 16 mm2 and above XLPE insulation- Type A Inner and outer Sheath will be extruded Inner sheath will be ST2 Steel strip/wire armoured Outer sheath of cable will be FRLS XLPE, ST2 Type Voltage grade- 1100 V IS 1554/7098 Part 1 b. Control Cable Stranded Annealed Copper Conductor 2.5 sq mm XLPE insulation type A. Inner and outer Sheath will be extruded Inner sheath and outer sheath will be ST2 Steel strip/wire armoured Outer sheath of cable will be FRLS XLPE, ST2 type Voltage grade - 1100 V

IS-1554/7098 Part I c. Lighting Cable/Wire in conduit 2.5 mm2 stranded Copper XLPE/PVC insulated wire in concealed PVC conduit will be used in Lighting fixtures/ flameproof fixtures. 4 core 6 mm2 stranded Copper will be used from outdoor lighting DB to junction box on the lighting poles. 3 core 2.5 sq. mm stranded copper cable (YWY} will be used from junction box on the lighting pole to lighting fixture. 8.2 Cable Sizing Cables shall be heat and oil resistant and suitable for service in the maximum environmental conditions described for the Platforms/Terminal and can be expected at the respective locations. All nominal power cable ratings shall be based on maximum ambient temperatures (design temperature) as specified under site conditions. De-rating factors shall be applied as necessary to take account of Installation configuration and variation in ambient temperature. Conductor current ratings for distribution board feeders shall be established on the basis of 125 % of the rated actual load current at the ambient temperature and de-rated for grouping and method of installation. Cables for emergency duty equipment shall have fire performance characteristics to lEC 332-3 Category A. Safety critical circuit cables, such as certain Fire and Gas and communication signals required to maintain integrity during a fire, shall be fire resistant type to the requirements of IEC 331. Control & Instrument multicore cables shall have 20% spare conductors (cores). 8.3 Cable Racking As far as possible the cables shall be installed in the existing cable ladders / trays. In case new cable trays are required, the same shall be of marine grade Aluminum (MGA) / or stainless steel (SS). Continuous Marine Grade Aluminum barrier strips may be used to separate power cables of different voltage grades. Cables shall be fitted with the removable, ventilated covers where there is exposure to chemical spillage, falling objects or direct sunlight. Cable trays / ladders shall be installed in accordance with the manufacturer’s recommendations and specially supported at each elbow. The overhead cable trays / ladders shall be installed at a minimum of 500 mm above ground level at on-shore facility. Single core cables shall be laid in trefoil group. All fasteners shall be made from Marine Grade Aluminum or Stainless Steel material. All cable trays / ladders supports shall be located to suit structural features and manufacturers recommendations. All cable trays / ladders shall be electrically connected to the earthing system. Cable ladder/tray covers shall be provided on cable ladders/trays exposed to direct sun to protect the cable outer sheath from Ultra-Violet radiations. 9.1 Cable Accessories: Each cable shall be provided with a number, which shall be tagged on the cable at regular intervals for easy identification. The numbering scheme to be adopted for the cables, shall match with the existing cable numbering philosophy. Cable sockets shall be heavy duty crimped type copper. These shall conform to the relevant standards. No cable shall be terminated directly without sockets. Provision shall be made to avoid bimetallic corrosion. 8.4 Cable Glands and Transit Frames All cables shall be fitted with FLP double compression type cable glands. All cable glands

and adopters shall be made of nonferrous/non-corrosive material and shall be fitted with soft sealing nylon washers. Fiber washers shall not be used. Flameproof double compression cable glands and flameproof plugs shall be certified by CIMFR. Such transit frames shall include at least 20% spare capacity for future use. 8.5 LIGHTING SYSTEM Plant lighting system shall comprise: a) Normal Lighting b) Emergency lighting Normal and emergency lighting shall be fed by AC supply 240 V, 2 phase system (specifically required by DGMS). Normal lighting system shall provide enough illumination so as to enable plant operators to move safely within the accessible areas of plant to perform routine operation include reading of field instruments, operation of all valves etc. and to carry out all the necessary maintenance and adjustment to equipment. Lighting requirements provided during the failure of power supply for normal lighting are broadly indicated here below: a) To facilitate carrying out of specified operations, for safe shutdown of the plant. b) To gain access and permit ready identification of firefighting facilities such as fire water pumps, fire alarm stations etc. c) Escape route for safe evacuation of operating personnel. Adequate number of self contained portable hand lamps and battery operated emergency lighting units shall be provided for immediate use for buildings where no DC supply Is available. LED Lamps shall generally be used for outdoor plant lighting. LED lamps shall be used for plant lighting & indoor lighting for non-process buildings and control room. Metal halide/Low pressure sodium vapour lamps shall not be installed in hazardous areas. All ballasts shall be with copper winding and capacitor for power factor improvement (to 0.95) shall be provided with fixtures as

applicable. Tall structures shall have aviation obstruction lighting as per statutory requirements. All outdoor lighting shall be automatically controlled by means of photo‐ switch or timers with manual control. The Lighting panels shall be provided with MCB as incomer and miniature Circuits Breakers (MCBs + ELCB) for outgoing feeders control and protection of lighting circuits. MCBs shall not be loaded beyond 80% of rated capacity. A minimum of 25% of miniature circuit breakers of each board shall be left as spares. Lighting Lux Level Lighting system design shall be based on minimum illumination levels as specified below Sr. Nos. Area/Location Lux Level

1 Roads & Tank Farms 10

2 Pumps House & Sheds 100

3 Main Operation Platforms 60

4 Ordinary Platforms 20

5 Process Area, Pipe Racks, Heat Exchangers, Heater, Cooling Tower, Separators

60

6 Switchgear Rooms, UPS Rooms 200

7 Battery Room 150

8 Ware‐House 100

9 Office 300

10 Control Room, Laboratory 400-500

Lighting design shall conform to relevant International Codes and Standards, IES Hand Book and shall take into consideration the requirements from point of view of safety and ease in operation and maintenance. A maintenance factor of 0.8 shall be assumed for lighting illumination level calculations for normal areas. However for dusty areas maintenance factor as per relevant codes and standards shall be considered. Wiring for lighting and convenience outlets in outdoor areas shall be carried out with PVC armoured cables run along the column / platforms and structures. The armoured cable shall enter lighting fixture / J8 through double compression gland for safe area, Ex(e) or Ex(d) equipment and through flameproof glands for Ex(d) equipment. Where required suitable mechanical protection shall be provided for lighting fixtures (e.g. wire guard).

Two pole MCB shall be used for controlling fixtures in hazardous areas to isolate phase as well as neutral.

9.0 LOW VOLTAGE (LV) FEEDERS Switchgear used for LV feeders shall incorporate the following protective devices: a) Short Circuit b) Earth fault Protective devices for the MCC and emergency panel feeders shall be housed within the low voltage MCC and emergency enclosure.

10.0 ELECTRICAL EQUIPMENTS FOR HAZARDOUS AREA Electrical Equipment’s The Electrical equipment’s for hazardous areas shall be selected as per IS: 5571 and petroleum rules. The minimum requirements are summarized below

Equipments Zone‐1 Zone‐2 Gas Gr. IIA, IIB Gas Gr. IIC Gas Gr. IIA, IIB Gas Gr. IIC LV Ind. Motors Ex‐d Ex‐d Ex‐d EX‐e HV Ind. Motors Ex‐d / Ex‐p Ex‐d / Ex‐p Ex‐d EX‐e Push Button Stations Ex‐d Ex‐d Ex‐d Ex‐d Motor Starter Ex‐d Ex‐d Ex‐d Ex‐d Plug Sockets Ex‐d Ex‐d Ex‐d Ex‐d

Welding Receptacles Ex‐d Ex‐d Ex‐d Ex‐d

Lighting Fixtures i) Lighting Fitting ii) Control gear Box

Ex‐d Ex‐d

Ex‐d Ex‐d

Ex‐d / Ex‐e* Ex‐d

Ex‐d Ex‐d

Junction Boxes Ex‐d Ex‐d Ex‐e Ex‐d Hand Lamps i) Light Fitting ii) Transformer Unit iii) Plug & socket

Ex‐d Ex‐d Ex‐d

Ex‐d Ex‐d

Ex‐d



Lighting Panels / Power Panels

Ex‐d Ex‐d Ex‐d Ex‐d

Break Glass Units (Fire Alarm System)

Ex‐d Ex‐d Ex‐d Ex‐d

11.0 ELECTRICAL INSTALLATION Electrical installation design shall be in accordance with IS 732. 11.1 Cable Laying: Cable shall be laid in the cable trays / ladders as specified under clause 6. Segregation / Separation (cables): Emergency and Instrumentation systems cables shall as far as practical be routed away from normal services systems. Special consideration shall be given to the routing and segregation of cables, to minimize the effects of fire on emergency and essential supplies and production operation. Wherever practicable the cables for duplicate feeds and equipment shall run via separate routes to increase security of supply. In addition the minimum distances between power / control wiring and electronic / signal wiring on prolonged cable routes shall be as follows

Power/Control Cables Minimum Distance from Electronic/Signal Cables

up to 125 V 250 mm

up to 300 V 500 mm

up to 1000 V 750 mm

above 1000 V 1250mm

11.2 Lighting and Small Power All exterior lighting and general area lighting shall be provided according to good engineering practice. LED fixtures shall be used for outdoor lighting. Perimeter lighting shall be provided using LED lighting fixtures with suitable spaced at an interval. The lighting fixtures and other equipment shall be suitable for the area of classification in which they are located. The illumination levels shall be as covered in the specifications & IS 6665.

11.3 Emergency/Critical Lighting: Emergency/critical lighting fixtures shall be provided with 4 hours backup battery banks. Emergency/critical lighting fixtures shall be automatically activated on loss of mains. Small Power:

3‐Phase and single phase socket outlet systems shall be provided in the facilities for: 240V, 50 Hz, 1 phase, neutral and earth, 16A, 5 pin, domestic type outlets for the living quarters and for general purpose use in the CCR, Switchgear rooms, local equipment rooms, offices and workshops. Socket outlets shall be provided in all switch rooms and CCRs for special test equipment. All single phase socket outlets shall be protected by 30 mA earth leakage circuit breakers. All other earth leakage protection requirements shall be identified on the basis of minimising earth leakage protection where not required by statutory requirements, standards, or regulations to minimize nuisance tripping, and where reduction of such protection does not degrade safety. Nameplates shall be installed at each receptacle clearly indicating source of supply, voltage and amperage. 12.0 CATHODIC PROTECTION 12.1 General Pipeline and piping CP stations to be installed as a part of this project shall be designed and engineered in accordance with the standards/codes . Following CP System and material are in the contractor’s scope of supply in this tender. All equipment and materials including cables, CPTR/CPPSM units, various types of test stations, junction boxes, anodes, grounding equipment/items/anodes, polarization cells, polarization coupons, surge diverters, spark gap arrestors, bonding stations along with diodes, shunts and variable resistors etc. as required for Temporary cathodic protection & Permanent cathodic protection system of pipelines in line with standard specification, design basis and datasheet are included in the scope of supply of the contractor. 12.2 Cathodic protection system Design, detailed engineering, Supply installation, testing and commissioning of the temporary cathodic protection system using galvanic anodes to protect the external surface of the pipeline, against corrosion for minimum 2 year or till commissioning of permanent CP system whichever is later. Cathodic Protection system activities which are common for TCP and PCP (viz. protection of carrier pipe using zinc ribbon anodes for a design life of 30 years at all painted or coated cased crossings) are to be included in the scope of this contract. Scope also included measurement of soil resistivity for anode ground beds sizing, collection of cathodic protection related data along right of way of pipelines as per requirements. Interference detection and mitigation study & remedy’s for cathodic protection is also included in contractor scope of works. The contractor shall begin AC and DC interference detection survey immediately after the complete pipeline is buried and shall employ survey methods such as close interval potential logging survey, CAT survey, DCVG survey etc., conforming to the Data Sheets, and specifications. On completion of interference detection survey the contractor shall prepare a report clearly indicating the regions of interference, the reasons of the interference and the mitigation measures that will be employed as a part of the PCP implementation. The Client shall have the right to ask for additional investigations and the same shall be done by the contractor without extra cost. The mitigation measures must be vetted by the contractor’s CP

consultant/specialist and approved by GAIL before implementation. NOTE: wherever interference is found on the pipeline the contractor shall deploy suitable equipment and trained manpower and the variations in the pipeline potential for at least 24 hours. This shall invariably be done in areas of railway traction, HV/EHV sub-stations, EHV line crossings, and crossings of foreign pipelines that are affected by interference. Permanent cathodic protection system shall be done by impressed current method to protect the external surface of the pipelines. The construction of deep well anode ground bed of minimum depth 50 M and diameter 250 mm. The scope shall included disconnection of temporary cathodic protection system which does not form part of permanent cathodic protection system. CPTR/CPPSM units to be supplied shall be provided with remote SCADA monitoring/controlling facilities and current interrupter with GPS based timer. The contractor shall include the services of specialist agencies for doing interference survey and implementing mitigation measures against interference for CP system. The scope shall include to complete permanent cathodic protection system, including carrying out the soil of soil (at pin spacings of 10M, 30M, 50M, 80M and 100M) at

locations for design of deep well anode ground beds, interference detection and mitigation, close interval potential logging survey, CAT survey, DCVG survey etc., conforming to the Data Sheets, CP NACE standards and specifications. 12.3 Bonding Between Old And New Pipelines The contractor’s scope of work shall include bonding the new pipeline and the nearest existing pipeline. The bonding between the pipelines shall be done with the help of removable links inside CP test stations that will be installed for the new pipeline. The bonding connection from the old pipe shall be taken from the existing CP test stations. The test stations of the new pipeline must be located near to the test station for the old pipeline. However in case any pipe-to-cable connection is to be made on any old pipeline by means of pin-brazing/cad welding, the contractor shall take pipe thickness readings before making the pin-brazing/cad welding to ensure that the pipe thickness at the proposed location is adequate. The contractor’s responsibility shall include liaison with other agencies whose pipelines exist in the common ROU and obtaining their permission for carrying out bonding, pin brazing on their pipelines or any other activity that need the consent and permission of the other pipeline owners. All work related to bonding of the old pipe and new pipe shall be completed by the contractor at the TCP construction stage. The actual decision regarding the establishing the actual bond by connecting the link inside the CP Test Station shall be taken based on interference surveys to be done after the new pipeline section is lowered and buried. 12.4 Temporary Cathodic Protection system TCP Design & detailed engineering including the preparation of Design documents, drawings, BOQ, O & M Manuals. Supply, installation, testing and commissioning of all materials including spark gap arrestors/zinc grounding cell, insulating joints, test Stations of cathodic protection system of Pipelines for Design life of 2 year. Scope including all related civil works for completion of the system, collecting the CP system related data along the pipeline route by route survey, identification of various crossings, measurement of Soil Resistivity of Anode Ground bed by 4 pin - wenner method. Supply, installation, testing and commissioning of corrosion measurement probe, and interference detection and Mitigation study of the Pipeline and Monitoring of Cathodic Protection system up to the final commissioning. PCP & TCP works shall be carried out as per schematic drawing, specifications enclosed with contract, NACE Standard, approved procedures, approved drawings and instructions of Engineering-in-Charge.

12.5 Permanent Cathodic Protection system PCP scope of Design, detailed engineering including the Preparation of Design documents, Drawings, BOQ, O & M Manuals shall be as per corrosion survey, Soil Resistivity survey, NACE Standard, schematic drawings, specifications and route survey. Supply of all materials including but not limited to CPPSM/CPTR unit, reference cell, polarization cells, cables, corrosion coupons, spark gap arrestors/zinc grounding cell across all Pipeline, insulating joints & test Stations. Design, Supply, installation testing & commissioning of works shall be based on collecting the CP system related data, measurement of Soil resistivity along pipe line of cathodic protection system of pipeline for design life of 30 years. Scope Including all related civil works for completion of the CP system of pipelines. All the CP System works shall be carried out as per specification & route survey including Identification of various Railway crossings, OHLs, Rivers & Roads crossings, measurement of soil resistivity. Interference detection, mitigation study remedies of the same and monitoring of cathodic protection system. CIPL, CAT, DCVG surveys shall be carried out after final commissioning of PCP system, as per schematic drawings, specifications, NACE Standard, approved procedures, approved drawings and instructions of Engineering-in-Charge. 13.0 APPROVED VENDOR LIST In addition to the codes/standards mentioned in documents, the latest edition of the below listed equivalent codes and standards shall also be used for design of proposed Electricals items. The listing includes, but is not limited to, the following:

LIST OF ATTCHEMENTS (ELECTRICAL)

TABLE OF CONTENTS

CONTENTS

1. LIST OF ATTACHMENTS ..............................................................................................

2. STANDATD DATA SHEETS ..........................................................................................

3. SPECIFICATIONS ...........................................................................................................

4. STANDARD DRAWINGS (ELECTRICAL) ...................................................................

5. PROJECT DRAWINGS & DOCUMENTS ......................................................................

1. LIST OF ATTACHMENTS

CONTRACTOR shall carry out all works strictly in accordance with the drawings/ documents/ specifications indicated in subsequent paragraphs. 2. STANDATD DATA SHEETS Sr. No

Data Sheet Number Description

1 DS-EL-001 DATA SHEET OF SOLAR POWER SYSTEM

2 DS-EL-002 DATA SHEET OF UNINTERRUPTED POWER SUPPLY SYSTEM

3 DS-EL -003 DATA SHEET OF HV & LV CABLES

4 DS-EL -004 DATA SHEET OF LV DISTRIBUTION BOARD

5 DS-EL -005 DATA SHEET OF STORAGE BATTERY

6 DS-EL -006 DATA SHEET OF LIGHTING FIXTURES & ACCESSORIES

7

DS-EL -007 DATA SHEET OF LIGHTING DISTRIBUTION BOARD & LIGHTING

PANEL

8 DS-EL -008 DATA SHEET FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

9 DS-EL -009 DATA SHEET FOR DATA SHEET OF IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM (PERMANENT) FOR PIPELINE

10 DS-EL -010 TECHNICAL DATA SHEET FOR MAIN ELECTRICAL DISTRIBUTION BOARD

11 DS-EL -011 TECHNICAL DATA SHEET FOR UPS SYSTEM

12 DS-EL -012 TECHNICAL DATA SHEET FOR POWER & CONTROL CABLES

13 DS-EL -013 TECHNICAL DATA SHEET FOR NICKEL CADMIUM BATTERY

3. SPECIFICATIONS

Sr. No

Specification number Description

1.

SP-EL-001 STANDARD SPECIFICATION FOR LOW VOLTAGE

SWITCHBOARD

2

SP-EL-002

STANDARD SPECIFICATION BATTERY CHARGER

3

SP-EL-003 STANDARD SPECIFICATION FOR STATIONARY

NICKEL CADMIUM BATTERIES

4

SP-EL-004

UPS POWER SUPPLY

5

SP-EL-005 STANDARD SPECIFICATION FOR SOLAR POWER

SYSTEM

6

SP-EL-006 STANDARD SPECIFICATION FOR FLAME PROOF

LIGHTINING AND POWER PANELS

7

SP-EL-007 STANDARD SPECIFICATION FOR LIGHTING

FITTINGS FOR HAZARDOUS LOCATIONS

8 SP-EL-008 STANDARD SPECIFICATION FOR CORROSION SURVEY

9

SP-EL-009 STANDARD SPECIFICATION FOR SACRIFICIAL ANODE

CATHODIC PROTECTION SYSTEM FOR PIPELINES

10

SP-EL-010 STANDARD SPECIFICATION FOR IMPRESSED

CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES

11

SP-EL-011 STANDARD SPECIFICATION FOR EQUIPMENT

AND MATERIALS FOR CP SYSTEM FOR UG PIPELINES

12

SP-EL-012 STANDARD SPECIFICATION FOR CATHODIC

PROTECTION TRANSFORMER RECTIFIER UNIT

13

SP-EL-013

STANDARD SPECIFICATION FOR CATHODIC PROTECTION POWER SUPPLY MODULE (CPPSM)

14

SP-EL-014 STANDARD SPECIFICATION FOR ELECTRICAL

EQUIPMENT INSTALLATION

15

SP-EL-015 STANDARD SPECIFICATION FOR CABLE

INSTALLATION

16

SP-EL-016 STANDARD SPECIFICATION FOR EARTHING

INSTALLATION

17

SP-EL-017 STANDARD SPECIFICATION FOR LIGHTING

INSTALLATION

18

SP-EL-018 SPECIFICATION FOR FIELD INSPECTION, TESTING

AND COMMISSIONING OF ELECTRICAL INSTALLATION

4. STANDARD DRAWINGS (ELECTRICAL)

Sr. No Standard Drawings Number Description

LIGHTING

1 SS-EL-001 FRONT PAGE

2 SS -EL-002 DRAWING INDEX

3 SS-EL-003 GENERAL NOTES - LIGHTING

4

SS-EL-005

TYPICAL SUSPENSION MOUNTING DETAILS OF INDUSTRIAL FLUORESCENT LIGHTING FITTING WITH

5 SS-EL-007 TYPICAL DETAIL OF CONCEALED CONDUIT WIRING

6

SS-EL-012

TYPICAL MOUNTING DETAILS OF STREET LIGHTING FITTING (WALL/COLUMN MOUNTED)

7 SS-EL-013 TYPICAL MOUNTING DETAIL OF STREET LIGHTING FITTING

8

SS-EL-018

TYPICAL MOUNTING ARRANGEMENT OF FLOOD LIGHT MOUNTED ON PLATFORM/WALKWAY

9

SS-EL-019

TYPICAL MOUNTING ARRANGEMENT OF FLOOD LIGHT MOUNTED ON STEEL/CONCRETE COLUMN

10 SS-EL-020 TYPICAL MOUNTING DETAIL OF 1 No. FLOOD LIGHTING FITTING

11

SS-EL-021

TYPICAL MOUNTING DETAIL OF 2Nos. INDUSTRIAL TYPE FLOOD LIGHTING FITTING

12

SS-EL-024

TYPICAL MOUNTING DETAILS OF FLAMEPROOF FLUORESCENT LIGHTING FITTING

13

SS-EL-031

TYPICAL DETAILS OF LOOPING BOX FOR STREET LIGHTING FITTING

14

SS-EL-032 TYPICAL DETAILS OF DUST/WEATHERPROOF ROUND JUNCTION BOX

15 SS-EL-033 TYPICAL MOUNTING DETAILS OF SINGLE PHASE SOCKET

EARTHING

Sr. No Standard Drawings Number

Description

1

SD-EL-101

FRONT PAGE

2 SD-EL-102 DRAWING INDEX

3

SD-EL-103

GENERAL NOTES - EARTHING

4 SD-EL-103 GENERAL NOTES - EARTHING

5 SD-EL-104 ELECTRODE FOR EARTHING SYSTEM

6 SD-EL-105 EARTH ELECTRODE IN TEST PIT

7 SD-EL-106 EARTH PLATES FIXING DETAILS

10 SD-EL-110 TYPICAL EARTH CONNECTION FOR STREET LIGHT POLE

12 SD-EL-113 TYPICAL EARTHING ARRANGEMENT FOR PROCESS EQUIPMENT

13 SD-EL-118 EQUIPMENT EARTHING SCHEDULE

14 SD-EL-119 TYPICAL DETAILS OF DIRECTLY BURIED EARTH ELECTRODE

15

SD-EL-120

TYPICAL DETAILS OF PLATE EARTH ELECTRODE

18

SD-EL-123

TYPICAL EARTHING DETAILS OF HV/LV SWITCHBOARD PANEL

CABLE TRAY

Sr. No Standard Drawgs Number

Description

1

SD-EL-201

FRONT PAGE

2

SD-EL-202

DRAWING INDEX

3

SD-EL-203 STANDARD DRAWING LADDER TYPE CABLE TRAY

4

SD-EL-204 STANDARD DRAWING PERFORATED TYPE CABLE TRAY

5

SD-EL-205

STANDARD DRAWING CABLE TRAY

6

SD-EL-206 STANDARD DRAWING CABLE TRAY ACCESSORIES

7

SD-EL-207 STANDARD DRAWING CABLE TRAY ACCESSORIES (FRP)

8

SD-EL-208 STANDARD DRAWING CABLE TRAY COUPLER

9

SD-EL-209 STANDARD DRAWING CABLE TRAY MOUNTING PLATE

CABLE TRENCH


Description

1

SD-EL-301

FRONT PAGE

2

SD-EL-302

DRAWING INDEX

3

SD-EL-303

RCC DUCT ABOVE FGL

4

SD-EL-304

ERC BELOW GRADE LEVEL

5

SD-EL-309 TYPICAL ARRANGEMENT FOR LAYING OF CABLES IN CABLE TRAYS

6

SD-EL-309 TYPICAL ARRANGEMENT FOR LAYING OF CABLES IN CABLE TRAYS

7

SD-EL-310 MARKING OF TRENCHES FOR ELECTRIC CABLES

8

SD-EL-311 TYPICAL SECTION OF CABLE TRENCH IN UNPAVED AREAS

9

SD-EL-312 TYPICAL SECTION OF CABLE TRENCH IN PAVED AREAS

10

SD-EL-313 CONDUIT OR CABLE SUPPORT ON CONCRETE BEAM OR COLUMN

11

SD-EL-316 STANDARD DRAWING CABLE TRENCH TYPE - 0504

12


13


14



Description

15


16


17


18


19


20


21

SD-EL-326 STANDARD DRAWING CABLE TRENCH TYPE 2/2015

22

SD-EL-327 STANDARD DRAWING CABLE IDENTIFICATION TAG

23

SD-EL-328 STANDARD DRAWING CABLE INSTALLATION PRACTICE FOR BOTTOM ENTRY TO SWITCH BOARDS/CONTROL PANELS

HAZARDOUS AREA

1

SD-EL-401

FRONT PAGE

2

SD-EL-402

DRAWING INDEX

3

SD-EL-403

GENERAL NOTES & LEGENDS FOR AREA CLASSIFICATION (ONSHORE OIL/GAS INSTALLATION)

4

SD-EL-404 DETAILS FOR AREA CLASSIFICATION (ON SHORE OIL/GAS

INSTALLATION)

5


INSTALLATION)

6


INSTALLATION)

7


INSTALLATION)

8


INSTALLATION)

9


INSTALLATION)

10


INSTALLATION)

11


INSTALLATION)

12


INSTALLATION)

13


INSTALLATION)

14


INSTALLATION)

15


INSTALLATION)

16


INSTALLATION)

17


INSTALLATION)

18


INSTALLATION)

CATHODIC PROTECTION

1

SD-EL-501

FRONT PAGE

2

SD-EL-502

DRAWING INDEX

3

SD-EL-503

CATHODIC PROTECTION SCHEMATIC DIAGRAM

4

SD-EL-504 TEST STATION CONNECTION SCHEME

5

SD-EL-505 TEST STATION WITH FOUNDATION DETAILS

6

SD-EL-506 GALVANIC ANODE INSTALLATION

7

SD-EL-507 DEEP WELL GOUNDED INSTLLATION

8

SD-EL-508 SHALLOW ANODE GROUND BED (PCP)

9

SD-EL-509 THERMIT WELD CONNECTION

10

SD-EL-510 TYPICAL CONSTRUCTION DETAIL OF HIGH SILICON CAST IRON

BED

11

SD-EL-511 ZINC REBBON ANODE FOR CASED CROSSINGS WITH

COATED/PAINTED CASING

12

SD-EL-512 PIPELINE GROUNDING THROUGH POLARIZED CELL AND

GALVANIC ANODE

13

SD-EL-513 ZINC GROUNDING CELL TWO PLATE TYPE

14

SD-EL-514 PERMANENT COPPER COPPER SULPHATE REFRENCE CELL AND

INSTALLATION DETAILS

15

SD-EL-515 PREPACKED MAGNESIUM ANODE

16

SD-EL-516 PREPACKED ZINC ANODE

17

SD-EL-517 CATHODIC PROTECTION SYSTEM ANODE JUCTION BOX

18

SD-EL-518 NEGATIVE DISTRIBUTION BOND BOX

19 SD-EL-519 CATHODIC PROTECTION SYSTEM EQUIPOTENTIAL BOND BOX

20 SD-EL-520 CATHODIC PROTECTION SYSTEM FOREIGN BOND BOX

21 SD-EL-521 CATHODIC PROTECTION SYSTEM TEST POST INSTALLATION AT ROAD CROSSINGS

22 SD-EL-522 CATHODIC PROTECTION SYSTEM HIGH TENSION LINE CROSSINGS JUNCTION BOX

SOLAR POWER SYSTEM

1

SD-EL-601 STANDARD DRAWING FOR SOLAR POWER SYSTEM

STANDARD SPECIFICATION FOR LOW VOLTAGE SWITCHBOARD

ABBREVIATION

BIS/IS: Bureau of Indian standards

IEC: International Electro-Technical Commission

BS: British Standards

IEEE: Institute of Electrical and Electronics Engineers

NEMA: National Electrical Manufacturers Association

OISD: Oil Industries Safety Directorate

CCE: Chief Controller of Explosive

DGMS: Director General Mines Safety

IE Rules: Indian Electricity Rules

CPRI: Central Power Research Institute

SWG: Switchgear

CRCA: Cold Rolled Cold Annealed

PCC: Power Control Centre

PMCC: Power and Motor Control Centre

MCCB: Moulded Case Circuit Breaker

MCB: Miniature Circuit Breaker

MCC: Motor Control Centre

CT: Current Transformer

PT: Potential Transformer PVC: Polyvinyl chloride

TABLE OF CONTENTS

SL NO. DESCRIPTION PAGE NO.

1.0 SCOPE ............................................................................................... 2.0 REFERENCE DOCUMENTS .............................................................. 3.0 DEFINITIONS ..................................................................................... 4.0 MATERIALS ........................................................................................ 5.0 DESIGN .............................................................................................. 6.0 FABRICATION .................................................................................... 7.0 INSPECTION AND TESTING.............................................................. 8.0 MARKING, PACKING AND SHIPMENT ..............................................

1.0 SCOPE This specification covers the requirements of design, manufacture, testing, packing and supply of Fixed / draw out type Low Voltage Switchboards.

2.0 REFERENCE DOCUMENTS

2.1 The equipment shall comply with the requirements of latest revision of following standards issued by BIS unless otherwise specified.

IS 5 : Colours for ready mixed paints and enamels IS 772: AC Electricity Meters IS :1248 : Direct acting electrical indicating instruments IS 2705: Current Transformers IS : 2824 : Method for determining the comparative tracking index of solid insulating materials under moist conditions IS: 3156 : Voltage transformers IS : 3231 : Electrical relays for power systems protection. IS : 3618 : Phosphate treatment of iron and steel for protection against corrosion IS : 5082 : Material data for aluminium bus bars. IS : 5578 : Guide for marking of insulated conductor. IS : 6005 : Code of practice of Phosphating of iron and steel. IS : 8623 : Factory built assemblies of switchgear and control gear for voltages upto and including 1000V AC and 1200V DC.Part -II particular requirements for busbartrunking systems (bus ways ). IS : 11353 : Guide for uniform system marking and identification of conductors and apparatus terminals. IS : 13703 : Low voltage fuses. IS : 13947 : LV Switchgear and control gear

2.2 In case of imported equipments, standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity Rules and other statutory regulations currently in force in the country.

2.0 In In case Indian Standards are not available for any equipment, standards issued by IEC/BS / VDE/ IEEE/ NEMA or equivalent agency shall be applicable.

2.1 case of any contradiction between various referred Standards / Specifications / Data Sheet and statutory regulations the following order of priority shall govern:

a. Local Statutory regulations b. Data Sheets c. Job Specifications d. Standards Specification e. Codes and Standards

3.0 DEFINITIONS For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows: OWNER / COMPANY OWNER of the particular Project (Project Specific). CONSULTANTThe party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management. BIDDER / SUPPLIER / VENDOR The party(s) which manufactures and / or supplies material, equipment, technical documents / drawings and services to perform the duties specified by Contractor. 4.0 MATERIALS 4.1 The frame, of individual vertical panels shall be fabricated using pressed and cold rolled

sheet steel. The sheet steel used for panel shall be of minimum 2mm (14SWG) CRCA except that the doors and covers may be made of 1.6mrn (16SWG) CRCA. Wherever required, stiffeners shall be provided to increase stiffness of large size doors and covers.

4.2 Bus bars shall be of high conductivity electrolytic aluminium /copper supported on insulators made of non-hygroscopic, non-inflammable material with tracking index equal to or more than that defined in Indian standards.

4.3 All hardware shall be corrosion resistant. All joints and connections of the panel members shall be made by zinc passivated cadmium plated high quality steel bolts, nuts and washers.

5.0 DESIGN 5.1 GENERAL REQUIREMENTS 5.1.1 The offered equipment shall be brand new with state of art technology and proven field track record. No prototype equipment shall be offered.

5.1.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment at least for 15 years from the date of supply.

5.1.2 Vendor shall give a notice of at least one year to the end user of equipment and Consulted before phasing out the product/spares to enable the end user for placement of order for spares and services.

5.2 TECHNICAL REQUIREMENTS

5.2.1 Low voltage switchboard shall be metal enclosed fully drawout, free standing, floor mounting, compartmentalized, modular type suitable for indoor installation.

5.2.2 The switchboard enclosure shall be dust and vermin proof and shall provide a degree of protection not less than IP-42.

5.2.3 The switchboard shall be assembled out of vertical panels of uniform height in single line up. 5.2.4 It shall be possible to extend the switchboards, in either direction at a later date. Ends of bus bars shall be suitably drilled for this purpose. Panels at extreme ends shall have openings, which shall be covered with plates screwed to the panel. Details of drilled holes in bus bar and openings in the panels, provided for future extension shall be clearly shown in the vendor drawings.

5.2.5 The switchboard shall be designed to ensure maximum safety during operation, inspection, connection of cables, relocation of outgoing circuits and maintenance, with the bus bar system energised and without taking any special precautions.

5.2.6 Adequate means shall be provided to prevent shorting of power and / or control terminals due to accidental dropping of maintenance tools etc. inside the switchboard. Checking and removal of components shall be possible without disturbing adjacent equipment.

5.3 SPECIFIC REQUIREMENTS OF AIR CIRCUIT BREAKER PANELS 5.3.1 The breaker panels shall have distinct bus bar, breaker and cable compartments. 5.3.2 The design of each compartment shall be such as to prevent movement of vermin from a particular compartment to any other compartment of the panel when the breaker is withdrawn and compartment door is closed.

5.3.3 Blanking plates shall be provided for each circuit breaker compartments, which would be used after installation, to cover the openings in the event of taking out the breaker outside the compartment.

5.3.4 In order to minimise accidental access and avoid accidents due to falling tools, all the outgoing links shall be shrouded.

5.3.5 Outgoing Air circuit breaker can be mounted in a maximum of two-tier execution while the incoming/bus coupler Air circuit breaker shall be in single tier execution only.

5.4 CABLE COMPARTMENT 5.4.1 Separate compartment totally enclosed from all sides shall be provided for cable termination, on the rear side. Access to cables shall be from the rear side after opening the cabling compartment door.

5.4.2 The incoming / outgoing cable termination shall be staggered for each circuit and barriers of sheet steel or insulating material shall be provided between termination of two circuits such that maintenance on one circuit could be carried out while the other circuit is live. Suitable clamping arrangements shall be provided for cables and cable termination. Terminal blocks shall not be used for supporting the cables.

5.4.3 The incoming supply for PCC/ PMCC panels shall be through top entry bus ducts or through bottom entry cables unless specified otherwise. The outgoing cables shall have bottom entry unless specified otherwise.

5.4.4 The cable terminations shall be suitably sized for receiving specified number of cables per termination and provision shall be made for terminating each outgoing cable with a separate bolted connection. In case the total number of cables entering a particular panel cannot be accommodated in the cabling compartment of the panels an extension panel of full height shall be added to the cabling compartment for accommodating extra cables.

5.5 CIRCUIT BREAKER COMPARTMENT 5.5.1 The circuit breaker compartment shall be fully draw out. Suitable guides shall be provided to facilitate easy withdrawal of the circuit breaker.

5.5.2 The current transformers for the ammeter/protection circuits shall be mounted on the fixed portion of the compartment. However, current transformers associated with built-in releases may be mounted on the breaker trolley.

5.5.3 All terminals except wiping/sliding type control terminals shall be shrouded with plastic covers to prevent accidental contact. For direct termination - clip on shrouded type terminals shall be provided.

5.5.4 There shall be three positions for the draw out trolley viz: a. "Service" position - In this position both power and control circuits shall be

connected. This shall be the normal operating position of the circuit breaker. b. "Test" position - The power contacts shall be disconnected in this position but the

control connections shall not be disturbed, it shall be possible to close and trip the breakers in this position.

c. "Drawout" Position - both power and control circuits shall be disconnected in this position and breaker removed from the cubicle.

The circuit breaker shall be lockable in "service” and "test" positions. Safety shutters shall be provided when the breaker is in withdrawn/drawout position.

5.5.5 The earth connection must remain connected in "Test" position; Earthing of the unit shall be done with a "pin" or with scrapping earth connections.

5.5.6 The earth connection shall make before the main power / control contacts make and break after the power /control contacts are disconnected. Earthing connection through a plug and socket connection shall not be acceptable.

5.6 INTERLOCKS Following interlocks shall be provided: 5.6.1 Compartment doors shall be interlocked against opening when breaker is in closed condition. However, it shall be possible to defeat this interlock for inspection purposes.

5.6.2 It shall not be possible to push "in" a drawn out circuit breaker in closed condition or withdraw a circuit breaker in closed condition.

5.6.3 It shall be possible to operate a circuit breaker only in the defined "Full in" or "service" and "test' position inside the panel. It shall not be possible to operate the breaker in intermediate positions while inserting or withdrawing circuit breaker.

5.6.4 Any unused circuit breaker compartment shall be fully equipped and provided with compartment door, vertical busbars and control terminals/wiring etc, such that the same could be used for housing outgoing breakers in future without any modifications to the panel.

5.7 SPECIFIC REQUIREMENTS OF NON-AIR CIRCUIT BREAKER FEEDERS 5.7.1 The design of drawout feeder modules shall not change for single front or double front execution. Separate vertical bus bars shall be provided for each front side modules.

5.7.2 All identical feeder modules shall be interchangeable. 5.7.3 Each vertical panel shall have a separate cable alley. The width of this cable alley shall be sufficient to accommodate all the cables and shall have free access for cable terminations and in any case shall not be less than 200mm minimum. Cable alleys shall be provided with suitable doors.

5.7.4 Sheet steel barriers shall be provided between individual compartments and cable alley. This barrier shall be provided with opening for power and control connections and it shall be possible to safely carryout maintenance work on cable connections to any one circuit in the cable alley with the busbars and the adjacent circuits live.

5.7.5 Maintenance and connection of cables to any modules shall be possible without having to take out the modules from its position from the panel.

5.7.6 The outgoing feeder trolleys for drawout type switchboard shall be fully drawout and shall have the following features.

a. It shall be possible to withdraw the trolley without having to unbolt or unscrew any power and control connections to the equipment mounted on the withdrawable trolley.

Both power and control connections shall be drawout type. All line and bus PTs shall be in drawout execution only. However, outgoing modules having size more than half of the useful vertical height of the panel may be in mixed combination of

drawout/fixed type.

b. Control supply transformer modules with burden higher than 2.5KVA may be in fixed execution.

c. The trolley withdrawal shall be by means of crank and screw arrangement. Alternatively movement on guided rollers may also be acceptable. Plug in operation shall be independent of manual force.

For drawout type feeders of size equal to or greater than half the useful vertical height of panel, positive clamping arrangement shall be provided on the top portion of the trolley in addition to clamping arrangement at the bottom, to ensure all round positive pressure on the power drawout contacts once the trolley is plugged in.

d. Power drawout contacts shall preferably be located towards the bottom portion of each trolley. The trolley shall be lockable in fully plugged in position and devices shall be provided to ensure positive plugging in. In test position, power contacts shall be totally isolated and a device shall be provided for indication of test position.

e. The incomer and bus tie feeders with load break switches rated 800A and above may be in fixed execution.

5.7.7 Various compartment sizes in a vertical panel shall be multiples of a basic dimension. However the minimum module size for switch fuse feeder and motor starter/contactor feeder shall not be less than that defined in Data Sheet/Job Specification. Vertical bus bars shall be pre-drilled at regular intervals for complete flexibility for changes in size of modules.

5.7.8 All switch drives other than rotary control switches, shall be lockable in both 'ON' and 'OFF' positions.

5.7.9 The Switches / Moulded case circuit breakers / MCB shall be interlocked with the compartment door to prevent opening of the door when the Switch/ Moulded case circuit breaker is in 'ON' position and to prevent switching on when the door is open. A defeat mechanism for this interlock shall also be provided.

5.7.10 The maximum height of the operating handle and switches shall not exceed 1900 mm and the minimum height not below 300 mm. Unused modules in the panel shall be fully equipped with hinged door, power and control terminals for starter modules and cradle for future use.

5.8 SWITCHGEAR MODULES Switchboard shall be completely lined up in one straight row with the type and quantities of feeders as defined in switchboard Data Sheet. Generally the feeders of three main categories are identified as circuit breaker, motor starters and switch-fuse,

5.8.1 Starter modules required for motor control shall be of following types and internal control wiring of all starter modules of each type shall be identical for all ratings.

FVNR Full voltage non -reversing starter with minimum 18 control terminals. FVR Full voltage reversing starter with minimum 24 control terminals. FVNR HD Full voltage non -reversing heavy duty starter with long starting time such as for compressors and fans etc, with minimum 18 control terminals.

5.8.2 Switch fuse /contactor feeder modules shall be of following types and internal control wiring of all modules of each type shall be identical for all ratings.

SFU Switch fuse modules with no control terminals. SFUC Switch fuse contactor modules with 18 control terminals.

5.8.3 Type of modules for fixed type switchboard shall be similar to above specified drawout modules except that the modules shall be of fixed type.

5.8.4 Minimum 2000 VA control transformer shall be provided for each bus section of the PMCC/MCC switchboard having contactor control feeders and each transformer shall be sized for the entire switchboard. For switchboard having two bus sections and coupled by bus tie shall have manual changeover switch for the control transformers.

5.8.5 To facilitate site modification due to changes in motor KW ratings and to minimise spares inventory, overload relays and power fuse links shall meet the following requirements.

a. All bimetal overload relays shall be separately mounted type with connecting links rated for the maximum rating of the contactor in a starter module.

b. Bimetal overload relays of various current ranges required for motors likely to be connected to a contactor must be identical in dimension for inter-changeability. In case offered relays are with different dimension for any particular starter module, special mounting plate suitable for mounting different relays shall be provided in all the modules of that size.

c. Heavy duty starters shall be provided with saturable type current transformer operated overload relays only, which shall be suitable for motor starting time of 15-60 seconds.

d. All contactor controlled starter feeders shall meet the requirements of type-2 co-ordination as per IS: 13947.

5.9 SWITCHGEAR COMPONENTS 5.9.1 CIRCUIT BREAKER

a. Circuit breakers shall be air break, 3 pole and drawout type. However Circuit breaker for generator incomer shall be with four poles unless specified otherwise.

b. The circuit breakers shall be provided with mechanically operated emergency tripping device. This device shall be available on the front of the panel. Mechanically operated 'closing' device shall be provided for all breakers. However mechanical closing shall be inhibited for all breakers in service position.

c. The circuit breakers shall be provided with minimum 4 NO + 4 NC contacts, wired

and available for Purchaser's use. d. Circuit breakers Open and closed positions; Service and test locations and spring

charged condition shall also be indicated mechanically in addition to electrical indications.

e. Unless otherwise specified, all circuit breakers in the switchboard shall be provided with electrical power operating mechanism. Wherever circuit breakers are provided in place of Isolators, Breaker can be manually operated type.

5.9.2 OPERATING MECHANISM a. Electric power operating mechanism shall be motor wound spring charged stored

energy type. However, manual-operating mechanism may be of the spring charging stored energy type or the spring assisted type. For circuit breakers with electrical power operating mechanism, provision shall also be made for manual spring charging. Closing time of circuit breakers with manual operating mechanism shall be independent of the speed of the operating handle.

b. All stored energy operating mechanism shall be equipped with following features. i. Failure of springs, vibrations or shocks shall not cause unintended operation of

breaker or prevent intended tripping operation. ii. Closing of circuit breakers shall be prevented unless the spring is fully charged.

c. All electrical power operating mechanisms shall be suitable for remote operation and shall be equipped with following features.

i. Provided with universal motor operable on AC or DC control supplies. ii. Provided with emergency manual charging facility. The motor shall be

automatically, decoupled (mechanically) once the manual-charging handle is inserted.

iii. Closing operation of circuit breaker shall automatically initiate charging of the spring for the next closing operation without waiting for tripping of circuit breaker.

iv. Closing operation shall be completed once the closing impulse is given and the first device in the control scheme has responded even though the control switch / Push Button is released provided no counter trip impulse is present.

v. Circuit breaker trip and closing coils in case of electrically operated breakers and trip coil in case of mechanically operated breakers and circuit breaker indication shall be suitable for satisfactory operation on a control supply system indicated in data sheets/job specification.

vi. Circuit breakers shall be provided with anti-pumping and trip free feature. vii. Circuit breakers shall be provided with operation counters.

viii. Releases are not required to be provided with breakers where relays are used. However breaker having AC control supply voltage shall be provided with under voltage release unless specified otherwise.

5.9.3 SWITCHES a. All switches or fuse switches shall be air break type provided with quick make/break

manual operating mechanism. The operating handle shall be mounted on the door of the compartment having the switch.

b. Rating of switches for starter module shall meet the requirements of AC-23 duty as per IS: 513947 and minimum rating shall be as specified in job specification/data sheets.

5.9.4 FUSES a. Fuses shall be non-deteriorating HRC cartridge link type. b. Power fuses shall be pressure fitted type and shall preferably have ribs on the,

contact blades to ensure good line contact. c. It shall be possible to handle fuses during off load conditions with full voltage

available on the terminals. Wherever required, fuse pullers shall be provided. The fuse base shall be so located in the modules to permit insertion of fuse pullers and removal of fuse links without any problem.

5.9.5 CONTACTORS a. The contactors shall be air break type, equipped with three main contacts and

minimum 1NO+1NC auxiliary contacts: The main contacts of a particular contactor for motor starter module shall have AC-3 or AC-4 ratings as specified in Data Sheet.

b. Unless specified otherwise, the coil of the contactor shall be suitable for operation on 240 V, I Phase, AC supply and shall work satisfactorily between 65 to 110% of the rated value.

5.9.6 THERMAL OVERLOAD RELAY a. Bimetal relays shall be provided for protecting the motor from thermal overload.

b. Bimetal relays shall be manually reset type with the reset push button brought out on the front of the panel. The reset push button shall be capable of being operated without opening the compartment door.

c. Bimetal relays shall be positive acting ambient temperature compensated type with adjustable setting range.

d. Bimetal relays shall have built-in single phasing prevention feature, which operate even with 50% rated current at the time of single phasing.

5.9.7 MOULDED CASE CIRCUIT BREAKERS a. MCCBs shall be provided with spring assisted quick make/ break manually operated

trip free mechanism. Wherever specified, MCCB shall be suitable for remote tripping operation and the tripping device shall be suitable for the specified control supply voltage.

b. MCCBs shall be provided tripping device with inverse time characteristic for over load protection and instantaneous characteristics for short circuit protection and MCCB rated above 125A shall preferably have adjustable settings.

c. 'ON' and 'OFF' position of the operating handle of MCCB shall be displayed and the operating handle shall be mounted on the door of the compartment housing MCCB.

d. Each MCCB shall be provided with minimum 1 NO + 1 NC auxiliary contact and 1NO contact for tripping indication/alarm for Purchaser's use.

e. MCCBs shall be provided with solenoid/ Motorised closing mechanism to make them suitable for remote closing operation if specified. The closing solenoid/motor shall be suitable for specified (control supply voltage).

f. MCCB's as part of motor starter module shall be current limiting type and type tested for type-2 coordination as per IS: 13947.

5.9.8 RELAYS a. Type of relay shall be numerical, static or electromagnetic type as specified in the

Data Sheet /Job Specification. b. All electromagnetic protective relays shall be back connected, of drawout type,

suitable for flush mounting, and fitted with dust-tight covers. Alternatively, "plug-in" type relays will also be acceptable. Auxiliary relays are acceptable in fixed execution.

c. The protective relay cases shall have provision at the front for "testing and calibration" purposes. It shall be possible to test the relays without disconnecting the wiring and without withdrawing the relays. The insertion of the test plug shall automatically short circuit the CTs and permit extension of external power supply to the relay.

d. Each protective relay shall be provided with minimum 2 nos. potential free contacts of required configuration.

e. Each tripping relay shall be lockout type with hand reset coil cut-off contact. The tripping relay shall be suitable for satisfactory operation from 50 % to 110 % of the specified control supply voltage.

f. Protective relays shall be preferably mounted on the front side and upper pail of the panel and mounting of relays on the lower portion shall be avoided.

5.9.9 INSTRUMENT TRANSFORMERS (CTS/PTS) a. Current transformers shall generally conform to IS : 2705 and any special

requirement with respect to Numerical relay shall be taken care by the Vendor. b. For general guidance the Vendor shall note that the protective current transformers

shall have an accuracy class "5 P" and an accuracy limit factor greater than "10 ". However CTs for restricted earth fault shall be of class "PS". Vendor shall co-ordinate the knee point voltage, magnetising current for PS class CTs to avoid saturation and mismatching of CTs provided at other end by other Vendor.

c. Current transformers for instruments shall have an accuracy class 1.0 and accuracy limit factor less than 5.0. However accuracy class of 3.0 is acceptable for CT's meant for remote ammeters.

d. The current transformers in breaker feeders shall be capable of withstanding the applicable peak momentary short circuit and the symmetrical short circuit current for

1.0 second. e. The voltage transformers shall be cast resin type transformers and PT shall

generally conform to IS : 3156. PT shall be provided with HRC fuses on primary side and Miniature circuit breakers with auxiliary contact on the secondary side.

5.9.10 MEASURING INSTRUMENTS a. All measuring instruments shall be of 96 x 96, mm and 72 x 72 mm square pattern,

flush mounting type for incomer and outgoing feeders respectively in the switchboard.

b. All auxiliary equipment such as shunts transducers, CT's PT's etc. as required shall be included in the supply of the switchboard.

c. All AC ammeters and voltmeters shall be of moving iron type with accuracy class of 1.5 as per IS: 1248.Ammeters for motor feeders shall have a non-linear compressed scale at the end to indicate motor starting current and red mark for the full load current.

d. The KW/KWH meters shall be suitable to measure unbalanced loads on 3 phases 4-wire system. Test terminal block shall be provided for KWH meters. The accuracy class of KW/KWH meters shall be a minimum of 2.5.

e. Digital meters shall be provided if specified in Job Specification/Data Sheets. All digital meter shall be high reliable, accurate, compact and self powered. Digital meter data shall be saved in case of power failure. Field programming from front of the meter shall be possible and shall be RS232/485 port in case specified in the Job Specification/Data Sheet.

5.9.11 CONTROL SWITCHES a. All control switches shall be rotary type, having a cam operated contact mechanism.

Switch shall have pistol grip handles for circuit breaker control and knob type handle for other applications.

b. Ammeter selector switches shall have make before break feature on its contacts. The selector switch shall generally have 4 positions for reading 3 phase currents and fourth position for off. The voltmeter selector switch shall also have 4 positions, Three positions shall be used to measure phase to phase voltage and fourth shall be OFF position.

5.9.12 PUSH BUTTONS: Push button colours shall be as follows:

a. Stop /open/emergency : Red b. Start/close : Green c. Reset/test : Yellow / Black /white

5.9.13 INDICATIONS a. Clustered LED type indicating light with minimum 8mm diameter size shall be

provided for indications. b. Breaker positions (Close, Open, spring-charged, test position, service position)

electrical indications, with colors as given below, shall also be provided: Breaker `Close' : Red lamp Breaker 'Open' : Green lamp

Breaker auto-trip : Amber lamp Trip circuit healthy : White lamp Spring charging : Blue lamp

c. Outgoing feeder (Close, Open, trip) electrical indications, with colors as given below, shall also be provided:

'Close' : Red lamp 'Open' : Green lamp `Trip' : Amber lamp

5.9.14 AUXILIARY RELAYS/CONTACTORS Auxiliary relays/contactors shall generally be used for interlocking and multiplying contacts. Auxiliary contacts shall be capable of carrying the maximum anticipated current.

5.9.15 TIMERS For re-acceleration duty, timers unless otherwise stated, shall be pneumatic type and shall have adjustable time setting of 0-60 seconds, Alternatively static timer may be considered. The time settings, where specified, shall be accurately set before dispatch of the switchboard. Timer provided for control of capacitor feeder shall have minimum setting of 0-5 minutes.

5.9.16 MINIATURE CIRCUIT BREAKER a. MCB shall provide high mechanical and electrical life, reliable protection of circuits

against overload and short circuit and shall have minimum breaking capacity of 9KA unless otherwise specified. Positive ON/OFF indication shall be provided.

b. Earth leakage circuit breaker shall have earth sensitivities range 30mA to 300mA unless otherwise specified.

6.0 FABRICATION 6.1. All identical equipment and corresponding part shall be fully interchangeable. 6.2 The frame, of individual vertical panels shall be fabricated using pressed and cold rolled sheet steel. The sheet steel used for panel shall be of minimum 2mm (14SWG) CRCA except that the doors and covers may be made of 1.6mm (16SWG) CRCA. Wherever required, stiffeners shall be provided to increase stiffness of large size doors and covers. The switchboard shall be provided with integral base frame for each vertical panel. The switchboard integral base frame shall be suitable for tack welding.

6.3 All openings, covers and doors shall be provided with neoprene Gaskets. Removable blanking plates shall be provided to cover the openings in the event of withdrawing the feeder modules. Number of blanking plates shall be 10% of each module size with a minimum of one number.

6.4 All hardware shall be corrosion resistant. All joints and connections of the panel members shall be made by zinc passivated cadmium plated high quality steel bolts, nuts and washers.

6.5 Suitable removable type eyebolts shall be provided for the lifting of the panel/shipping section. These bolts, when removed shall not leave any opening in the panels.

6.6 Non-magnetic cable gland plates shall be provided for termination of single core cables. 6.7 The switchboard shall be formed using distinct vertical panels each comprising of following compartments.

6.7.1 A metal enclosed horizontal bus bar compartment running at top unless otherwise specified. Individual feeder modules in multitier mode.

6.7.2 Vertical bus bars serving all feeder modules in the vertical panel. 6.8 CABLE TERMINATION COMPARTMENT 6.8.1 Perforated sheet steel/insulating material enclosed horizontal auxiliary bus bars for control, interlock, indication and metering wiring running horizontally.

6.8.2 Metal sheets shall be provided between two adjacent vertical panels running up to full useful height of the switchboard.

6.8.3 MCC shall be of single/double front execution as specified in Data Sheet/Job Specification. However Circuit breaker panels and fixed type switchboard shall be in single front execution only.

6.8.4 Motor starter and switch fuse modules shall not be accommodated at front and rear of ACB Incomer and bus coupler panel.

6.8.5 All metering and protection equipment associated with a particular circuit as specified in Data Sheet shall be housed in separate and independent compartment earmarked for that particular circuit and in the fixed portion of the vertical panel in case of breaker panels.

6.8.6 All auxiliary devices for control, reset, indication, measurement and protection such as push buttons, control and selector switches, indicating lamps, measuring instruments and protective relays shall be mounted on the front side of the respective compartment. The design shall be such that all power on/off or start / stop and relay reset operations shall be performed without opening the panel door.

6.9 SPACE HEATERS

6.9.1 The switchboard panels shall be provided with space heaters to prevent moisture condensation. The space heater shall be located in the bottom part of each panel and shall be supplied from 240 V AC auxiliary bus for space heater. The space heater shall be provided with a thermostat having adjustable setting and double pole miniature circuit breaker.

6.10 AUXILIARY BUS BARS 6.10.1 Auxiliary bus bars each of minimum size 18-mm2 copper shall be provided for following applications. Exact number of bus bars shall depend on various control, metering and auxiliary power distribution requirement.

6.10.2 Panel space heater supply and motor space heater supply. 6.10.3 Control supply for breaker tripping, closing and indication circuits. 6.10.4 Control supply for breaker spring charging motors, motor starter control and indication circuit. AC potential supply for energy meters, voltage operated relays etc.

6.10.5 Tee-off connectors shall be used for distributing auxiliary supply to each vertical panel. Rubber grommets shall be used for all wire entries to make the entries dust and vermin proof.

6.10.6 Provision to hook up of external DC control supply to be provided either in bus PT panel or bus coupler panel.

6.11 BUS BAR 6.11.1 Bus bars shall be of high conductivity electrolytic aluminium /copper supported on insulators made of non-hygroscopic, non-inflammable material with tracking index equal to or more than that defined in Indian standards.

6.11.2 The main bus bars shall have uniform current ratings throughout their length as specified in Data Sheet/Job Specification. The current rating of the neutral shall be half that of the phase bus bars, Removable neutral links shall be provided on feeders to permit isolation of the neutral bus bar.

6.11.3 Both horizontal and vertical bus bars, bus joints and supports shall be capable of withstanding dynamic and thermal stresses of the specified short circuit currents for 1 second, The short circuit capacity of the neutral bus bars shall be in line with IS:l3947.

6.11.4 Only zinc passivated or cadmium plated high tensile strength steel bolts, nuts and washers shall be used for all bus bar joints and supports. The hot spot temperature of bus bars including joints at design ambient temperature shall not exceed 95° C for normal operating conditions.

6.11.5 The current rating as defined for switchboard and components in Data Sheet/Job Specification are for design ambient temperature at site conditions and for being inside the cubicle at fully loaded condition. The Vendor shall suitably derate the nominal rating to suit the above condition.

6.11.6 All bus bars shall be insulated with heat shrunk PVC sleeves of 1100 V grade. Red, yellow and blue colour shall be used for phase bus bars and black colour shall be used for neutral bus bars, Removable type shrouds shall be provided for joints.

6.11.7 Minimum clearance between live parts, between live parts/neutral to earth shall be 19 mm, However clearances between terminals at components shall be as per applicable individual standards for components.

6.11.8 Interconnections between the main bus bars and individual units shall be made by using aluminium bus bars of adequate rating. These interconnections of the vertical bus bars shall be in separate compartment and fully shrouded.

6.11.9 Vertical bus bars for circuit breaker panels shall be sized depending upon the rating and number of breakers per vertical panel. However Vertical bus bars of all other panels shall be of uniform cross section, Size of vertical bus bars shall not be less than 500 mm2 aluminium per phase or equivalent copper for panels rated above 25kA.

6.12 WIRING AND TERMINALS 6.12.1 Inside the cubicles, the wiring for control, signalling, protection and instrument circuits shall be done with BIS approved, PVC insulated, flame retardant type, copper conductor wire. The insulation grade shall be 660 V. The wiring shall preferably be enclosed in plastic channels or neatly bunched , together.

6.12.2 PVC insulated copper conductor of cross section 1.5 mm2 may normally be used provided the control fuse rating is 10 amps or less. For 16 amps control fuse circuit 2.5mm2 copper conductor shall be used. Each wire shall be terminated at a separate terminal. C.T. Circuit wiring shall be done with 2.5mm2 Copper conductor.

6.12.3 Shorting links/suitable-shorting arrangement for shorting CT. secondary shall be provided. Each wire shall be identified at both ends by PVC ferrules.

6.12.4 Inter panels wiring within each shipping section shall be switchboard Vendor's responsibility. For wiring between shipping sections, Vendor shall provide terminal blocks on adjoining shipping sections and supply suitable jumpering wires. Interpanel wiring shall be taken thorough PVC sleeves or rubber grommets.

6.12.5 A minimum of 10% spare terminals shall be provided on each terminal block. 6.12.6 Conductors shall be terminated with adequately sized compression-type lugs for connection to equipment terminals and strips. Stranded conductors shall be soldered at the ends before connections are made to the terminals. Sufficient terminals shall be provided on each terminal block to ensure that not more than one outgoing wire is connected per terminal.

6.12.7 Terminal strips shall preferably be separated from power circuits by metal barriers or enclosures. All spare contacts of auxiliary relays, timers, etc shall be wired up to the terminals.

6.13 EARTHING

6.13.1 All panels shall be connected to a tinned copper / GI earth bus bar running throughout the length of the switchboard.

6.13.2 The minimum earth bus size shall be 30x6 mm2 copper for fault level up to 31.5kA and 50x6 mm2 copper for fault level above 31.5kA,

6.13.3 All doors and movable parts shall be earthed using flexible copper connections to the fixed frame of the switchboard. Provision shall be made to connect the earthing bus bar to the plant earthing grid at two ends.

6.13.4 All non current carrying metallic parts of the mounted equipment shall be earthed. Minimum 4 nos, 10 mm diameter bolts with nuts shall be provided on the earth bus for

termination of fourth core of cable per vertical panel.

6.14 NAME PLATE 6.14.1 A nameplate with the switchboard designation shall be fixed at the top of the central panel. A separate nameplate giving details for each feeder compartment of all panels shall be provided.

6.14.2 The nameplates for feeder compartments shall be in two parts. One part shall have necessary details pertaining to the compartments number of vertical panel of the switchboards, The other parts shall be removable and shall contain all details regarding the feeder number for drives/equipment controlled by the particular module as per approved single line diagram.

6.14.3 Blank nameplates shall be provided for all spare and vacant modules. 6.14.4 Nameplate or polyester adhesive stickers shall be provided for each equipment mounted inside the switchboard, Special warning plates shall be provided on removable covers or doors giving access to cable terminals and bus bars.

6.14.5 Special warning labels shall be provided inside the switchboards also, wherever considered necessary. Identification tags shall be provided inside the panels matching with those shown on the circuit diagram.

6.14.6 Engraved nameplates shall preferably be of 3 ply (Black-White Black) lamicoid sheets or anodised aluminium. However back engraved Perspex sheet nameplates may also be acceptable. Nameplates shall be fastened by screws and not by adhesives.

6.15 PAINTING 6.15.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid, The under surface shall be prepared by applying a coat of phosphate paint and coat of yellow zinc chromate primer, The under surface shall be made free from all imperfections before undertaking the finishing coat.

6.15.2 After preparation of the under surface, the switchboard shall be spray painted with two coats of epoxy based final paint or shall be powder coated.

6.15.3 Colour shade of final paint shall be 631 as per IS:5 unless otherwise specified.

6.15.4 The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint etc. Vendor shall supply final paint (1 litre per switchboard) in non-returnable container for final touch up at site. All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust formation. If these parts are moving elements then they shall be greased.

7.0 INSPECTION AND TESTING 7.1 During fabrication, switchgear shall be subject to inspection by Consultant / Owner or by an agency authorised by the Owner. Manufacturer shall furnish all necessary information concerning the supply to Consultant / Owners inspectors.

7.2 All routine and acceptance tests shall be carried out at Manufacturer's work under his care and expense.

7.3 Type tests, if specified shall be performed. Short circuit test shall be performed at CPRI or equivalent approved testing agency and heat run test may be performed at manufacturer's works. Heat run test shall be performed at least on one incomer and two outgoing vertical panels of the ordered switchboard.

7.4 Type and shop tests shall be witnessed by an inspector of Consultants / Owner or of an agency authorised by the Owner. Prior notice of minimum 4 weeks shall be given to the Inspector for witnessing the tests.

7.5 ACCEPTANCE TESTS Acceptance tests shall be as follows: 7.5.1 A general visual check shall be carried out. This shall cover measurement of overall dimension, location, number and type of devices, location and connection of terminals etc,

7.5.2 Manual and electrical operation of Circuit Breakers. / Relays shall be checked under the worst conditions of auxiliary supply voltage.

7.5.3 Dry insulation test with power frequency voltage shall be conducted for the main and auxiliary circuits.

7.5.4 Insulation resistance of the main and auxiliary circuits shall be checked before and after power frequency voltage withstand test.

7.5.5 Operation check shall be carried out for every control function /interlocks as per the schematic diagrams by manually simulating fault conditions and operation of control switches/relays etc.

7.5.6 For equipment bought from other sub-suppliers, certified test reports of tests carried out at the manufacturers works shall be submitted. Normally all routine tests as specified in the relevant standards shall be conducted by the sub-supplier at his works.

7.5.7 Interchangeability of similar modules shall be checked on a random basis. This may be done on one module of each size.

8.0 MARKING, PACKING AND SHIPMENT 8.1. All the equipment shall be divided into several shipping sections for protection and ease of handling during transportation .The equipment shall be properly packed for selected mode of transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polyethylene sheets before being placed in

8.2 wooden crates /cases to prevent damage to the finish. Crates /cases shall have skid bottoms for handling. Special precaution notations such as Fragile, This side up, center of gravity, weight, Owner's particulars, Purchase number etc. shall be clearly marked on the package together with other details as per purchase order.

8.3 The equipment may be stored outdoors for long periods before installation. The packing should be suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agree.

STANDARD SPECIFICATION FOR BATTERY CHARGER

ABBREVIATION



BS: British Standards

IEEE: Institute of Electrical and Electronics Engineers

NEMA: National Electrical Manufacturers Association

OISD: Oil Industries Safety Directorate

CCE: Chief Controller of Explosive

DGMS : Director General Mines Safety

IE Rules: Indian Electricity Rules

CPRI: Central Power Research Institute

DCDB: Direct Current Distribution Board

CRCA: Cold Rolled Cold Annealed

PCB: Printed Circuit Board

VRLA: Valve Regulated Lead Acid

LED : Light Emitting Diode MCCB: Moulded Case Circuit Breaker

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE ...................................................................................... 2.0 REFERENCE DOCUMENTS ..................................................... 3.0 DEFINITIONS ............................................................................ 4.0 MATERIALS .............................................................................. 5.0 DESIGN..................................................................................... 6.0 FABRICATION .......................................................................... 7.0 INSPECTION AND TESTING .................................................... 8.0 MARKING, PACKING AND SHIPMENT………………………….

1.0 SCOPE This Specification covers the design, manufacture, testing at manufacturer's works, packing and supply to site of Battery Chargers and Distribution Boards.


2.1 The equipment shall comply with the requirements of latest revision of the following Standards issued by BIS (Bureau of Indian Standards), unless otherwise specified:

IS 5 : Colours for ready mixed paints and enamels.

IS 1248 : Direct acting indicating analogue electrical measuring instruments and (Parts-1, 2,8, 9) accessories. IS 3700 : Essential rating and characteristics of semi-conductor devices (Parts-1 to 11). IS 3715 : Letter symbols for semi-conductor devices (Parts-1 to 4). IS 4411 : Code of designation of semi-conductor devices. IS 5001 : Guide for preparation of drawings for semi-conductor devices and integrated (Parts-1, 2) accessories. IS 5469 : Code of practice for the use of semi-conductor junction devices. (Parts-1 to 3) IS 6619 : Safety code for semiconductor rectifier equipment. IS 7204 : Stabilized power supplies dc output (Parts-1 to 4). IS 12021 : Control transformers for switchgear and control gear for voltages not exceeding 1000V AC. IS 13703 : Low voltage fuses for voltages not exceeding 1000VAC or 1500VDC. (Parts-1 to 4). IS 13947 : Low voltage switchgear and control gear. (Parts-1, 3, 4, 5). IEC 60146 : Semiconductor converters.

2.2 In case of imported equipment, the Standards of the country of origin shall be applicable if these Standards are equivalent or more stringent than the applicable Indian Standards.


2.4 In case Indian Standards are not available for any equipment, Standards issued by IEC/ BS/ VDE/ IEEE/ NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred Standards/ Specifications Data Sheets and statutory regulations, the following order of decreasing priority shall govern:

a. Statutory Regulations b. Data Sheets c. Job Specifications d. Standard Specification e. Codes and Standards.

3.0 DEFINITIONS For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows: OWNER / COMPANY - OWNER of the particular Project (Project Specific). CONSULTANT- The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management. BIDDER / SUPPLIER / VENDOR - The party(s) which manufactures and / or supplies material, equipment, technical documents / drawings and services to perform the duties specified by Contractor. 4.0 MATERIALS 4.1 The Chargers, DCDB and Cell Booster enclosures shall be fabricated from structural/ CRCA sheet steel. The frames shall be fabricated by using minimum 2mm thick CRCA sheet steel while the doors and covers shall be made from minimum 1.6 mm thick CRCA sheet steel.

4.2 PCBs used in the chargers shall be made of glass epoxy material. 4.3 Power cables shall be with aluminum/ copper conductors and control cables shall be with copper conductors.

5.0 DESIGN 5.1 GENERAL REQUIREMENTS 5.1.1 The offered equipment shall be brand new with state of the art technology and a proven field track record. No prototype equipment shall be offered. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least 15 years from the date of supply.

5.1.2 Vendor shall give a notice of at least one year to the end user of equipment before phasing out the product/ spares to enable the end user to place order for spares and services.

5.1.3 The Battery Charger system shall be an integrated system comprising of static rectifiers,

DC Distribution Board, isolating and protection devices and all other equipment/ accessories required for completeness of the system. whether specifically mentioned herein or not, but necessary for completeness and satisfactory performance of the system. The Battery Charger equipment shall be properly coordinated with the selected Battery to ensure complete compatibility.

5.1.4 All equipment and components shall be of excellent quality and reliability for providing secure DC power required for vital equipment performance, controlling, monitoring and safeguarding functions in continuously operating process units and utility installations of petroleum refineries, petrochemical and gas processing facilities and other industrial plants. Components shall be capable of withstanding the thermal and dynamic stresses resulting from internal and external short circuits and circuit switching operations etc. The design of the equipment shall be such as to minimize the risk of short circuits and shall ensure personnel and operational safety.

5.1.5 The Vendor shall be responsible for design, engineering and manufacturing of the complete system to fully meet the intent and requirements of this Specification and attached Data Sheets.

5.1.6 The Battery shall meet the requirements of Data Sheets and Specifications attached with the Material Requisition/ Bid document.

5.2 TECHNICAL REQUIREMENTS 5.2.1 INPUT POWER SUPPLY

a. The Battery Chargers shall be suitable for input power supply as defined in the Data Sheet. If not specified therein, they shall be suitable for the following input power supply:

Voltage 415V ± 10% Frequency 50 Hz ± 5% b. In addition to the above variations, the input voltage may be subject to transient

variations comprising of voltage dips up to 20% of normal voltage during motor start-up, voltage interruptions during short circuits as well as frequency variations due to large motor start-up. The Battery Chargers shall operate satisfactorily with a total harmonic distortion of up to 5% in the input power supply.

c. The Battery Chargers shall also be designed to operate satisfactorily while drawing input power from an emergency diesel generator set. The incoming power supply to the Battery Charger system shall be provided by 2 independent feeders. One feeder shall supply power to each rectifier.

5.3 BATTERY CHARGER 5.3.1 DESIGN BASIS

a. The Battery Charger system shall have two chargers (Charger-1 & Charger-2). Both chargers shall be of identical design and rating. The battery to be connected to the chargers shall be of Nickel Cadmium/ flooded electrolyte Lead Acid/ VRLA type as indicated in the Data Sheet. Battery Chargers for flooded Lead Acid and Nickel

Cadmium batteries shall be sized to provide quick charging of the battery within duration of 10 hours, unless specified otherwise. Battery Chargers for VRLA battery shall be sized to provide quick charging of the battery up to 90% of rated Ampere hours within duration of 24 hours and to 100% within 4 days. Each charger shall be sized for the most stringent of the following duty conditions, whichever is higher:

i. Offline quick charging of the battery assembly. The charger shall be sized as under: Charger rating in Amps. = 0.14 Ah (C10) of battery (for Lead Acid battery) = 0.2 Ah (C10) of battery (for VRLA battery) = 0.2 Ah (C5) of battery (for Nickel Cadmium battery) ii. Online float charging of the battery assembly while feeding the complete DC load. The charger shall be sized as under:

Charger rating in Amps. = 1.15 x Average DC load + float charging current (Average DC load = Area under the battery duty cycle/ battery duty cycle duration).

iii. Initial charging of the uncharged battery assembly to fully charged condition. b. Each charger shall have a 3 phase full wave, controlled rectifier bridge with protective

devices. c. Independent current limits shall be provided for charger load current and battery

charging current. Subsequent to a discharge cycle and completion of quick charging, when battery is connected to charger under float mode, the battery current shall be monitored, controlled and limited to set value automatically irrespective of the value of load current. Fast acting semi-conductor fuses shall be provided for protection against internal short circuits. In case of external short circuits, the chargers shall be protected by rapid shutdown of the semi-conducting power devices. The high speed semi-conductor fuses used for rectifier protection shall be complete with trip indication.

d. Filter circuits consisting of smoothing choke and condenser, complete with protection to limit the ripple content at the output, shall be provided.

e. Silicon blocking diodes shall be provided in the charger output circuit to prevent back-feed from battery into the charger and filters.

f. Protection against reverse battery connection and DC earth fault relay for earth leakage protection shall be provided.

g. Silicon blocking diodes (min. 4 nos.) connected to 80% tap of the battery bank shall be provided to maintain continuity in the DC supply to the load.

h. Internal cooling of the charger unit shall preferably be by natural ventilation. If forced air cooling is necessary, a redundant air cooling fan shall be provided for each service. The charger components shall be capable of delivering their rated output with one forced air cooling fan out of service. Under this condition, maximum continuous temperature of components shall not exceed the permissible limits. In case of chargers with forced cooling, loss of ventilation alarm/ trip with override facilities shall

be provided. i. Selection, sizing and suitability of all components used for various applications shall

be Vendor's responsibility and the rating of components shall be increased, if required, to suit associated components during execution of the order without any claim for extra price or time. All electronic power devices including thyristors, transistors, diodes etc. shall be rated under operating conditions for at least 150% of the maximum current carried by the device. All electrical components such as transformers, reactors, contactors, switches, bus bars etc. shall be rated for at least 125% of the maximum required rating. No electronic device shall experience a PIV greater than 50% of its rated value.

j. The DC system shall be unearthed, unless mentioned otherwise in the Data Sheet. However, a high impedance earth fault relay shall be provided for the protection of the battery.

k. Each charger shall be galvanically isolated from the input power supply by providing a double wound transformer at its input. The transformer shall be natural air cooled, dry type suitable for location inside a panel.

l. Suitable protection shall be provided in the control circuits to guard against the instability of the controlled rectifiers due to electrical oscillations which may be present in the input supply as caused by an emergency DG set.

m. An R.F.I. filter shall be provided to suppress the radio frequency interference to permissible limits. The production of radio frequency interference voltages shall not exceed the value of suppression grade N' as defined in VDE-0875. The performance of the Battery Charger system shall not get affected or in any way be degraded by the use of portable radio transmitter receivers in the vicinity of the chargers.

n. Transient/ surge protection devices shall be provided in the input circuit of chargers to protect them against surges & voltage spikes.

o. The Chargers shall be designed to draw power from main supply at a minimum power factor of 0.85 lag while sharing the rated load in normal operating configuration.

The chargers shall be designed to ensure that the harmonic component in the input currents are limited so as not to cause undue harmful effects on other sensitive equipment operating on the same supply bus. Suitable filters/ harmonic traps shall be provided, as required, for this purpose.

p. All breakers shall be adequately rated for the required continuous rating and breaking capacity as applicable. Paralleling of breaker/ switch Contactor poles to achieve the required current rating is not acceptable. All output isolating devices shall be double pole type. The DC contactors shall be operated with a DC control supply using ON/ OFF selector switches and not push buttons. All DC contactors must have a tested/ published DC rating equal to or exceeding the most stringent current carrying and breaking requirements while considering adequate design margins.

q. All the thyristors, diodes and other power electronic devices shall be protected with high speed semiconductor fuses. I2t co-ordination between fuse and semi- conducting power devices shall be ensured. The Battery Chargers shall be specifically designed

to limit float and quick charging voltages to the battery to limits recommended by the battery manufacturer. Output voltage shall be limited to maximum +10% of nominal system voltage when the battery is float charged while feeding the load. Vendor shall specifically ensure that the charger output voltage does not exceed the recommended limits of operation under any conditions of internal/ external fault or operation, including:

i. Filter capacitor fuse failure of either charger. ii. DC output switch OFF of either charger. iii. DC output fuse blown of either charger.

r. Other specific current/ voltage limits during normal charging/ operation of the chargers shall also be incorporated in the design of the chargers.

5.3.2 OPERATION AND PERFORMANCE a. Operation

i. Normal operation requires that the battery assembly shall be float charged simultaneously by both Chargers-1 & 2 while feeding the DC load, the chargers thus operating in parallel and equally sharing the total load.

ii. However in case of failure of either of the chargers, the other charger shall float charge the battery while feeding the complete DC load. Faulty charger shall automatically get disconnected from the healthy system.

iii. In case of AC mains failure, the battery shall continue to supply the load.

iv. The process of changeover from float to quick charging and reverting from quick to float charging shall be selectable in Automatic or Manual mode by means of an Auto/ Manual selector switch. In Automatic mode, the changeover from float to quick charging shall be initiated through a current sensor, set at a preset value. Similarly, the changeover from quick to float charging shall also be automatic based on current sensing. In Manual mode, both changeovers from float to quick charging and from quick to float charging shall be performed manually using push buttons. When quick charging mode is selected, the battery charger shall Initially charge the battery under constant current mode followed by constant voltage (finishing charging) mode or as per the battery manufacturer's recommendation. Changeover from constant current to constant voltage (finishing charging) mode shall be fully automatic. A backup synchronous or digital timer shall also be provided for initiating the changeover to float mode by default after a preset time period. The timer range shall be 0 to 24 hours or the nearest available as per manufacturer's standard range.

v. In the event of failure of the charger feeding the load, when battery is being quick charged by the other charger, continuity in DC supply shall be maintained from the battery to the load through 80% tap of the battery bank followed by full battery supplying the load through contactor.

vi. Interlock shall be provided to ensure that when either of the chargers is selected in quick charging mode, it will be disconnected from both the DC load and the other

charger operating under float charging mode. vii. The chargers shall have facility for manual mode of operation in the event of failure

of controller under closed loop control. The selection shall be done through Auto/ Manual selector switch.

viii. Energisation of contactor for DC critical lighting shall be initiated by means of an AC mains failure relay complete with Auto/ Manual selector switch, on/ off push buttons etc.

ix. Facility for initial charging of the uncharged battery shall also be provided b. Performance

i. Both chargers shall be of solid state design, constant voltage and current limit type. The output voltage shall be stabilized to within ±1% of set value in float charging mode for mains steady state voltage and frequency variation of ±10% and ±5 % respectively, and load variation of 10 to 100% at any temperature up to the design ambient temperature specified in the Data Sheet. However, the variation in output voltage can be up to ±2% for chargers with rated output voltage up to 24V.

ii. Under constant current boost charging condition, the DC output current shall be maintained within ±2% of set value.

iii. The output voltage dynamic response of the charger unit with battery disconnected shall not vary more than ±10% of nominal output voltage in the event of step load of up to 50% of the rated output. The output voltage shall be restored to a value within the steady state limits within 250 msec. Voltage feedback shall generally be derived from charger output while current feedback from the DC ammeter.

iv. The maximum allowable RMS ripple voltage, with battery disconnected, shall be equal to or less than 2% of the nominal output voltage.

v. The maximum noise level from the chargers measured at 1 meter distance in any position, at any load between 0- 100% with all normal cooling fans running shall not exceed 75 dB(A).

c. Controls i. Controls shall include but not be limited to the following: -ON/ OFF control switch for AC supply to charger (push buttons are not acceptable). -Push buttons for float/ quick charging mode selection -Potentiometers under float mode for voltage and current adjustment -Potentiometers under quick mode for voltage and current adjustment -Auto/ Manual selector switch to select mode of operation -Others as required.

d. Panel Metering and Indication These shall include but are not limited to the following: i. Meters Charger-1 -AC input Voltmeter with selector switch -AC input Ammeter with selector switch

-DC output Voltmeter -DC output Ammeter -DC Voltmeter with selector switch (battery voltage) -DC Ammeter (battery) -DC Earth Leakage Ammeter (mA). Charger-2 -AC input Voltmeter with selector switch -AC input Ammeter with selector switch -DC output Voltmeter -DC output Ammeter. DC Distribution Board -DC Voltmeter -DC Ammeter. ii. Lamps Chargers-1 & 2 - AC power ON (1 lamp for each phase) - Float charger ON - Quick charger ON - Charger fault. DC Distribution Board

-DC power ON -Outgoing feeder ON (for each outgoing feeder). All indicating lamps shall be provided with series resistors. Clustered/ Jumbo LEDs of minimum 10mm diameter may be provided in place of lamps subject to their having at least equal luminance.

e. Annunciation i. Static type audio-visual enunciator with annunciation windows, acknowledge, test and reset push buttons and hooter shall be provided on each charger for the following annunciations. Any additional relays/Components, including DC under voltage relay and current sensors, required for this purpose shall be provided in the chargers. Facility for bypassing the audio alarm on each charger shall also be provided. - DC under voltage - DC overvoltage - DC earth leakage - AC incoming power supply failure - AC input fuse blown-off - Thyristor/ diode failure - DC output fuse blown-off

- DC battery fuses blown-off - Filter Capacitor fuse blown-off - Load on Battery (using current direction sensing with time delay) - Battery under voltage/ Disconnected during discharge (using zero current sensing) - Cubicle fan failure/ cubicle temperature high (for chargers with forced cooling). -One summary alarm potential-free contact each for Battery, Charger-1 and Charger-2 shall be wired to terminal block for remote annunciation. f. Printed Circuit Boards (PCBs)

i. PCBs used in the chargers shall be made of glass epoxy material. Components shall be properly mounted without undue stress, torsion, bends, twists etc. All PCBs shall be provided with a transparent epoxy coating on both sides for environmental/ anti-fungus protection and tropicalisation. Industrial grade components shall be used in the PCBs and electronic circuits. PCBs shall preferably be wave soldered. Copper strips/ prints on PCBs shall have smooth edges free from hair line cuts and shall be provided with tin coating. Plug-in PCBs shall preferably be mounted in a standard rack and shall be suitable for easy replacement. They shall be located away from heat sources. The rack shall have PCB guides which shall allow the insertion of PCBs smoothly without requiring undue force. The rack shall l be mounted on hinged pivots to enable it to be turned for access to the back side terminals. The PCBs shall be firmly clamped in position so that vibration or continued usages do not result in loose contacts. All PCBs shall be fitted in a manner to avoid replacement of a PCB by a wrong spare card. The PCBs shall be provided with visual light emitting diode (LED) status indications, monitoring points/ test connections and setting potentiometers in a readily accessible location which is visible without removing the PCBs. Visual fault diagnostics shall preferably identify faults up to various sections in the card. ii. Vendor shall provide adequate protection to the system, even if not specifically mentioned. 5.3.3 CELL BOOSTER

a. Cell booster shall be suitable for charging one to six cells within the time duration specified. It shall be suitable for charging not only new cells before being introduced to the battery bank but also for any treatment to be given to individual weak cells. Cell booster shall be suitable for 240 V ± 10%, 50 Hz ± 5% SPN input power supply. Cell booster output voltage shall be in the range of 0-18V and 0-12V for Lead Acid and Nickel Cadmium batteries respectively. Cell booster shall be sized as under:

For Lead Acid battery = 0.14 x AH (C10) of cell For VRLA battery = 0.2 x AH(C 10) of cell For Ni-Cd battery = 0.2 x AH (C5) of cell.

b. Cell booster shall have a heavy duty switch fuse or MCCB on both AC incomer and DC output sides, along with AC voltmeter, DC ammeter, DC voltmeter and indicating lamps for AC/ DC power ON. The output voltage and current of cell booster shall be manually controlled using a suitably rated variac or a full wave controlled rectifier bridge. Suitable interlock shall be provided so as to ensure that the variac / controlled rectifier is at its minimum position while switching on the cell booster. Cell booster shall be portable type with wheels. Each cell booster shall be supplied with 5 m long flexible

copper conductor PVC insulated braided cables for both AC incoming power supply and DC output connection to the battery. An industrial type 3 pin 15A plug shall be provided on AC incoming cable end and lugs shall be provided on DC outgoing cable end.

5.3.4 RELIABILITY

a. All necessary care shall be taken in selection, design, manufacture, testing and commissioning of the equipment for ensuring high system reliability. The following design considerations shall be taken into account to ensure maximum availability of the system. There shall be no common device between the two units, the failure of which could cause shutdown of more than one charger.

b. It shall be possible to attend to any individual power circuit for maintenance without affecting the total DC supply. Series-parallel combination of smaller devices to achieve specified rating shall not be acceptable. All the components used shall be time tested and standardized. Vendor shall state the safety factors used in selecting such items as semi-conductors, electrolytic capacitors, transformers etc.

6.0 FABRICATION

6.1 Each Battery Charger and DC distribution board shall be housed in a separate free standing cubicle. All panels shall be of the same height so as to form a panel lineup which shall have good aesthetic appearance. Chargers-1 & 2 shall be installed side by side whereas DCDB may be located separately and interconnected to the charger through cables. The DCDB shall accommodate outgoing feeders as specified in the Data Sheet. Each panel shall be provided with an 11W CFL light with a door operated switch and a thermostatically controlled MCB protected space heater.

6.2 Unless specified otherwise in the Data Sheet, the DCDB shall be compartmentalized with each outgoing feeder housed in a separate compartment. Cable alley of minimum 200mm width with suitable supports shall be provided for the termination of cables for each vertical arrangement of outgoing feeders in DCDB.

6.3 The Chargers, DCDB and Cell Booster enclosures shall be fabricated from structural/ CRCA sheet steel. The frames shall be fabricated by using minimum 2mm thick CRCA sheet steel while the doors and covers shall be made from minimum 1.6 mm thick CRCA sheet steel. Wherever required, suitable stiffeners shall be provided. The panels shall be provided with suitable louvers for ventilation backed by wire mesh. They must be suitable for use in a tropical climate. Hinged doors shall be provided at the front and back as required. Interpanel sheet steel barriers shall be provided.

6.4 The charger panels and DC distribution board shall be provided with minimum IP-42 degree of ingress protection as per IS-13947 (Part-1).

6.5 Bus bars shall be colour coded and live parts shall be shrouded to ensure complete safety to personnel intending routine inspection by opening the panel doors. All the equipment inside

the panel and on the doors shall have suitable nameplates and device tag numbers as per the schematic diagram. All wires shall be ferruled and terminals shall be numbered. 6.6 The DCDB incomer and main bus bars shall be rated based on the maximum load current considering an additional 10% design margin for contingencies. The rating shall be selected from standard available ratings and shall be adequate for the expected short circuit current. The bus bar voltage shall be higher than the recommended boost voltage for the system. The insulation for all equipment where provided shall be heat resistant, moisture proof and tropicalised. All power and control switches shall be rotary/ cam operated type. All power switches shall be air insulated load break type. Vendor shall ensure that all equipment/ components such as incomer switches, outgoing DC switches, MCCBs, push buttons, indicating lamps, charger mode selector switches, voltage control switches, annunciator windows etc. are suitably located on the charger and distribution board door such that they can be operated without opening the front door. Power switches shall be provided with a door interlock. In case of difficulty in installation on the charger front panel door, the AC incoming power switches, DC outgoing switches and MCCBs may be installed within the panel provided that they are operable after opening the front panel door. However, all other selector/ control switches, push buttons, indicating lamps, annunciators, meters etc. shall necessarily be installed on the front panel door as specified above.

6.7 All instruments shall be switchboard type, back connected and (72 x 72) mm square size. Accuracy class of all meters shall be 1%. Digital meters capable of displaying different parameters can be considered subject to Owner's/ Consultant approval. Analogue instrument scales shall have a red mark indicating maximum permissible operating rating.

6.8 All fuses shall be link type and shall be located inside the panel. Diazed fuses shall not be accepted.

6.9 All power and control wiring connections within the panels shall be carried out with 660V grade, PVC insulated, BIS marked wires having stranded copper conductors. However, copper strip connections shall preferably be used for currents exceeding 100A. Wires of 1.5mm2 size shall normally be used for control circuits with fuse rating of 10 Amps. or less. For control circuits with fuse of 16 Amps. or more, 2.5 mm2 size wire shall be used. Control wiring for electronic circuits/ components shall be through flat ribbon cable or copper wire of minimum 0.5mm diameter. All control wiring shall be enclosed in PVC channels or otherwise neatly bunched together. Each wire shall be suitably identified at both ends by PVC ferrules. Ferruling of wires shall be as per relevant IS.

6.10 For all cabling external to panels, power cables shall be with aluminum/ copper conductors and control cables shall be with copper conductors. All cable connections shall be from the bottom of the panel, unless specified otherwise in the Data Sheet. Removable bolted undrilled gland plates shall be provided along with single compression type nickel plated brass cable glands for all external cable connections. Clamp type terminals shall be used for connection of wires up to 10mm2. Bolted type terminals suitable for cable lugs shall be provided for wire sizes above this. Separate test terminals shall be provided for measuring and testing the equipment to check performance. All panels shall be supplied complete with tinned copper

cable termination lugs.

6.11 All potential free metallic parts shall be earthed using soft drawn copper conductor wire. A suitably sized earth bus shall be provided at the bottom of the panels running through the panel lineup with provision for earth connections at both ends to Owner's main earth grid. The minimum size of earth bus shall be (25 x 6) mm copper (or equivalent aluminum). All potential free metallic parts of equipment shall be suitably earthed to ensure safety.

6.12 The maximum height of the operating handles/ switches shall not exceed 1800 mm and the Minimum height shall not be below 300 mm.

6.13 All components/devices/ feeders shall be provided with screwed nameplates. Nameplates shall Be 3 ply white-black-whites 2 colour laminated plastic type. Lettering shall be of minimum 6 mm Height and edges shall be beveled at 45°.

6.14 The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of zinc oxide/ phosphate primer. The under surface shall be free from all imperfections before undertaking the finishing coat. After preparation of the under surface, the panels shall be either spray painted with two coats of epoxy paint or epoxy powder coated to a uniform thickness suitable for rugged industrial use.

6.15 Colour of final paint shall be shade 631 as per IS 5, unless specified otherwise. The finished panels shall be dried in stowing ovens in dust free atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, run off paint etc. All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust corrosion.

7.0 INSPECTION AND TESTING

7.1 During fabrication, the equipment shall be subjected to inspection by Consultant / Owner or by an agency authorized by the Owner. Manufacturer shall furnish all necessary information concerning the supply to Consultant / Owner's inspector. Tests shall be carried out at manufacturer's works under his care and expense.

7.2 Each Battery Charger/ DCDB/ Cell Booster shall be tested in accordance with applicable standards. The following acceptance tests shall be performed on each Battery Charger and DCDB as a minimum. Detailed test schedule and procedures shall be formulated by the vendor and submitted for Consultant / Owner's approval. Vendor shall indicate the maximum allowable tolerance against each test parameter in line with applicable standards. All tests shall be witnessed by Owner or his authorized representative and 4 weeks prior notice shall be given before the date of commencement of tests. In case the equipment fails to meet any requirements of the Specifications, necessary modifications/ corrections shall be made by the Vendor to ensure compliance to the Specifications, and the equipment shall be retested before acceptance. Test certificates indicating the test results shall be submitted to Owner.

7.3 INSULATION TESTS 7.3.1 Insulation tests shall be performed as per IEC 60146-1-1.

7.3.2 The insulation tests shall be carried out using an AC power frequency voltage or a DC voltage at the choice of the manufacturer. In the case of AC power frequency voltage test, the test voltage at the frequency available in the test facility or at the rated frequency, but not exceeding 100 Hz, shall be increased to the full value shown in the following table in not less than 10 seconds continuously or in maximum steps of 0.05 p.u. of the full value starting at a maximum of 0.5 p.u. The unit on test shall withstand the specified voltage for 1 minute. In case DC voltage is used for the test, the value of DC voltage shall be equal to the crest value of the test voltage specified in the table.

V p / √ 2 (Vp is the highest crest voltage to be expected between any pair of terminals)

Test Voltage (AC RMS value)

≤60V 500V ≤ 125 V 1000 V ≤250 V 1500 V ≤ 500 V 2000 V

7.4 PRINTED CIRCUIT BOARDS PCBs and other electronic circuits shall undergo a burn-in test for 96 hours at 50°C at a voltage varied between the maximum and minimum supply voltage. In case of failure of any component during testing, the tests shall be repeated after replacement of the faulty component.

7.5 HEAT RUN TEST Prior to execution of functional tests, each of the two chargers of each Battery Charger set shall be subjected to a Heat Run test performed at rated load and voltage for a period not less than 8 hours. The other charger of the set shall be energized under zero load current condition throughout the test period. The temperature of electronic power devices shall be measured and the device junction temperature shall be calculated. The calculated value shall be at least 10-20°C lesser than the maximum rated junction temperature of the device with proper ambient temperature correction applied.

7.6 FUNCTIONAL TESTS Functional tests shall be performed on each charger. If during execution of functional tests, an electronic component of the charger is required to be replaced, e.g. due to charger malfunction or failure of the unit to fulfill the performance requirements of the Specification, then the heat run test shall be repeated at rated current following which functional tests shall be carried out.

7.7 CHARGER TESTING AT CONSTANT OUTPUT VOLTAGE

Measurements shall be carried out in the float charging mode and in the quick charging mode. In each mode, measurements shall be carried out at nominal AC input voltage and at zero, 50% and 100% of rated output current. Measurements at 100% rated load current shall be repeated at 90% and 110% of nominal AC supply voltage. Measurements shall include input AC phase voltage, frequency, current and power and DC output voltage, current and output voltage ripple.

7.8 CHARGER TESTING AT CONSTANT OUTPUT CURRENT LIMIT Measurements shall be carried out both in the float charging and quick charging mode. In each mode, measurements shall be carried out when the charger is operating under DC current limiting conditions with DC output voltage between zero and set value corresponding to constant voltage operation. Measurements shall include DC output voltage and current.

7.9 AUXILIARY EQUIPMENT AND CONTROL CIRCUIT TESTS The correct functioning of all measuring instruments, alarms, indications, protections and controls mentioned in the Specification shall be verified. 7.10 PARALLEL OPERATION Parallel operation of both chargers, sharing of the load and automatic isolation of faulty charger shall be checked.

7.11 CHARGER EFFICIENCY This shall be determined by measurement of the active power input and output at 50%, 75% and 100% load.

7.12 AUDIBLE NOISE TEST Audible noise shall be measured around each charger at 1 meter distance in at least 4 to 5 positions and its value shall be within the permissible limits.

7.13 SITE ACCEPTANCE TEST The Battery Chargers, DCDB and Cell Booster shall be tested at site along with the battery. Vendor shall furnish a Site Acceptance Test (SAT) procedure for Owner's approval and all tests shall be performed as per the approved SAT procedure.

8.0 MARKING, PACKING AND SHIPMENT

8.1 All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/ rail or trailer. It shall be wrapped in polythene sheets before being placed in crates/ cases to prevent damage to finish. The crates/ cases shall have skid bottoms for handling. Special notations such as `Fragile', `This side up', 'Center of gravity', `Weight', `Owner's particulars', 'PO no.' etc., shall be clearly and indelibly marked on the packages together with other details as per

purchase order.

8.2 The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed.

STANDARD SPECIFICATION FOR STATIONARY NICKEL CADMIUM BATTERIES

ABBREVIATION

BIS/IS Bureau of Indian standards IEC International Electro-Technical Commission BS British Standards IEEE Institute of Electrical and Electronics Engineers NEMA National Electrical Manufacturers Association OISD Oil Industries Safety Directorate CCE Chief Controller of Explosive DGMS Director General Mines Safety IE Rules Indian Electricity Rules CPRI Central Power Research Institute DC Direct Current Ah Ampere hour PVC Poly Vinyl Chloride

TABLE OF CONTENTS

SL NO. DESCRIPTION .

1.0 SCOPE ...............................................................................

2.0 REFERENCE DOCUMENTS ..............................................

3.0 DEFINITIONS ....................................................................

4.0 MATERIALS .......................................................................

5.0 DESIGN ..............................................................................

6.0 FABRICATION ...................................................................

7.0 INSPECTION AND TESTING .............................................

8.0 MARKING, PACKING AND SHIPMENT .............................

1.0 SCOPE

The intent of this Specification is to define the design, manufacture, testing & supply of stationary Nickel Cadmium batteries for DC power system /AC UPS application.


2.1 The equipment shall comply with the requirements of the latest revision of the following Standards issued by BIS (Bureau of Indian Standards) unless otherwise specified.

IS-10918: Specification for Vented type Nickel Cadmium batteries 2.2 In case of imported equipment, Standards of the country of origin shall be applicable if these Standards are equivalent or more stringent than the applicable Indian Standards.


2.4 In case Indian Standards are not available for any equipment, Standards issued by IEC/ BS/ VDE/ IEEE/ NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred Standards/Specifications/Data Sheets and statutory regulations, the following order of priority shall govern:

a. Statutory regulations. b. Data Sheets. c. Job Specification. d. Standard Specification. e. Codes and Standards. 3.0 DEFINITIONS

For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows:

OWNER / COMPANY - OWNER of the particular Project (Project Specific).

CONSULTANT - The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management. BIDDER / SUPPLIER / VENDOR

The party(s) which manufactures and / or supplies material, equipment, technical documents / drawings and services to perform the duties specified by Contractor.

4.0 MATERIALS

4.1 The terminal posts shall be of nickel plated steel. The terminals shall be suitable for short circuit current and specified discharge current without damage to the cell as a result of terminal heating.

4.2 Stationary Nickel Cadmium cells shall be designed to withstand the mechanical stresses encountered during normal transportation and handling.

5.0 DESIGN 5.1 GENERAL REQUIREMENTS 5.1.1 The offered equipment shall be brand new with state of the art technology and proven field track record. No prototype equipment shall to be offered.

5.1.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least 10 years from the date of supply.

5.1.3 Vendor shall give a notice of at least one year to the end user of equipment before phasing out the product/ spares to enable the end user to place order for spares and services.

5.2 TECHNICAL REQUIREMENTS 5.2.1 The Nickel Cadmium cell/battery shall be suitable for float duty operation with a constant voltage permanently applied to its terminals which is sufficient to maintain it in a state close to full charge and shall be designed to supply load in the event of normal power supply failure. Type of plate construction for batteries shall be as per the Data Sheet.

5.2.2 The standard rated ampere hour capacity of the cell/ battery shall be at a reference temperature of 27°C, constant current discharge at 5 hours rate (C5) and an end cell voltage of 1.0 V/cell.

5.2.3 Ampere hour of the battery shall be selected based on the following: a. Minimum site ambient temperature of 10°C or as defined in the Data Sheet. b. Discharge duty cycle. c. End cell voltage. d. Ageing factor of 0.8 e. Design margin of 10%, if not defined in the Data Sheet f. Capacity rating factor. 5.2.4 Number of cells and end cell voltage shall be decided by the Vendor on the basis of maximum permissible voltage to the load when batteries are float charged while feeding the Load and minimum DC system voltage. However the number of cells and end cell voltage shall be as per the Data Sheet, unless otherwise specified. .

5.2.5 The battery shall be suitable. For being boost charged to fully charged condition from fully discharged condition within 10 hours, unless otherwise specified.

Battery assembly shall be supplied dry and uncharged. Dry electrolyte and required quantity of electrolyte liquid with 10% extra shall be delivered with the battery in suitable non returnable sealed containers, unless otherwise specified.

5.2.6 Each cell shall have a separate container. The cell container shall be of high strength alkali resistant material and designed to withstand mechanical stresses, shocks and vibrations. The cell container shall be translucent/transparent.

5.2.7 The terminal posts shall be of nickel plated steel. The terminals shall be suitable for short circuit current and specified discharge current without damage to the cell as a result of terminal heating.

5.2.8 Stationary Nickel Cadmium cells shall be designed to withstand the mechanical stresses encountered during normal transportation and handling.

5.2.9 Flame arrestor shall be mounted on the cell so that all the vented gases diffuse through the arrestor to the outside environment. The construction of the arrestor shall be such that hydrogen burning on the external surface of the arrestor shall not propagate back into the cell to cause explosion.

5.2.10 The following information shall be permanently marked on the cell. a. Nominal voltage b. Name of manufacturer/model reference c. Rated capacity in ampere hours (Ah) with End Cell Voltage d. Voltage for float operation at 27°C with tolerance of ±1%, Month and year of manufacture e. Polarity Marking. 5.2.11 Each set of battery shall be supplied with all the accessories, including, but not limited to the following:

a. Battery stands in formation as per Data Sheet. Mild steel stand pretreated and epoxy painted /PVC coated. b. Inter cell, inter row and interbank connectors and end take offs. These shall be of tin plated copper/flexible-insulated copper cable. c. Stand insulator. d. Cell number plates, Lugs for cable termination, as required. e. Other accessories and their quantity as per Data Sheet. 5.3 PERFORMANCE Nickel Cadmium batteries shall have been type tested to meet the performance requirements for each design and Ah rating of cells as per Standards IS-10918.

6.0 FABRICATION

6.1 Flame arrestor shall be mounted on the cell so that all the vented gases diffuse through the arrestor to the outside environment. The construction of the arrestor shall be such that hydrogen burning on the external surface of the arrestor shall not propagate back into the cell to cause explosion.

6.2 Each cell shall have a separate container. The cell container shall be of high strength alkali resistant material and designed to withstand mechanical stresses, shocks and vibrations. The cell container shall be translucent/transparent.


7.1 Batteries shall be subject to inspection by Consultant/Owner or by an agency authorized by the Owner to assess the progress of work. The manufacturer shall furnish all the necessary information concerning the supply to Consultant/Owner's representative.

7.2 Consultant/Owner’s Representative shall be given free access in the works from time to time for stage wise inspection and progress reporting. Four weeks advance notice shall be given to witness the final routine tests and other tests as agreed upon.

7.3 Following tests shall be carried out as a minimum for each Ah rating of cells/battery:

a. Routine test i. Physical examination test. ii. Polarity and absence of short circuit. iii. Dimension, Mass and layout. iv. Marking and packing. b. Acceptance test i. Marking and packing. ii. Verification of dimensions. iii. Test for Ah capacity iv. Test for voltage during discharge v. Internal resistance test. c. Type test i. Verification of constructional requirement. ii. Test for voltage during discharge. iii. Test for Ah capacity.

iv. Test for charge retention/loss of capacity if specified in the data sheet. v. Air pressure test. vi. Ampere hour and Watt-hour efficiency test.

7.4 Battery duty cycle test to meet the load cycle requirement shall also be performed at site

after installation as part of commissioning unless otherwise defined in the Data Sheet.

8.0 MARKING, PACKING AND SHIPMENT 8.1 All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases to prevent damage to finish. Crates/cases shall have skid bottom for handling. Special notations such as 'Fragile', 'This side up', 'Centre of gravity', 'Weight', `Owner's particulars', 'PO nos.' etc., shall be clearly marked on the package together with other details as per purchase order.

8.2 The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature, unless otherwise agreed.

STANDARD SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY

ABBREVIATION

BIS/IS Bureau of Indian Standards

IEC International Electro-Technical Commission

BS British Standards

IEEE Institute of Electrical and Electronics Engineers

NEMA National Electrical Manufacturers Association

OISD Oil Industries Safety Directorate

CCE Chief Controller of Explosive

DGMS Director General Mines Safety

IE Rules Indian Electricity Rules

CPRI Central Power Research Institute

CRCA Cold rolled cold annealed

UPS Uninterrupted Power Supply

DCS Distributed Control System

IGBT: Insulated Gate Bipolar Transistor

SMPS Single Mode Power Supply RMS Root Mean Square LCD Liquid Crystal Display

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE .........................................................................................................

2.0 REFERENCE DOCUMENTS ........................................................................

3.0 DEFINITIONS ...............................................................................................

4.0 MATERIALS .................................................................................................

5.0 DESIGN ........................................................................................................

6.0 FABRICATION .............................................................................................

7.0 INSPECTION AND TESTING .........................................................................

8.0 MARKING, PACKING AND SHIPMENT ........................................................

1.0 SCOPE

1.1 The scope of this Specification is to define the requirements of design, manufacture, testing, packing and dispatch of static Uninterrupted Power Supply (UPS) system.

1.2 Deviation from this specification shall be acceptable only when the manufacturer shall inform the deviation in quotation before placing the order & shall take the necessary written approval for deviation from the Consultant / Owner. In absences of a list of deviation, it will be assumed that the Manufacturer complies fully with this specification.

2.0 REFERENCE DOCUMENTS 2.1 The equipment shall comply with the requirements of latest revision of following Standards

issued by BIS (Bureau of Indian Standards) unless otherwise specified: IS: 5: Colours for ready mixed paints and enamels IS: 1248: Direct acting indicating analogue electrical measuring

(Part 1, 2, 4 and 9) instruments and their accessories IS: 2147: Degree of protection provided by enclosures for low voltage Switchgear and control gear. IS: 3700: Essential ratings and characteristics of semi-conductor (Part I to 11) devices. IS: 3715: Letter symbols for semi-conducting devices. (Part 1 to 4) IS: 4411: Code for designation of semi-conductor devices. IS: 5001: Guide for preparation of drawings of semi-conductor devices (Part I & 2) and integrated circuits. IS: 5469: Code of practice for the use of semi-conductor junction (Part 1 to 3) devices IS: 7204: Stabilised power supplies D.C. output (Part 1 to 4) IS: 12021: Control transformers for switchgear and control gear for voltages not exceeding 1000V AC IS: 13314: Solid state inverters run from storage batteries IS: 13703: Low voltage fuses for voltage not exceeding 1000V AC or (Part 1 to 4) 1500V DC IS: 13947: Specification for low voltage switchgear and control gear (Part-4 / Sec-1)

2.2 In case of imported equipments Standards of the country of origin shall be applicable Standards are equivalent or stringent than the applicable Indian Standards.

2.3 The equipment shall also conform to the provisions of Indian electricity rules and other statutory regulations currently in force in the country.

2.4 In case Indian Standards are not available for any equipment, Standards issued by IEC/BS/VDE/IEEE/NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred Standards/Specifications/ Data Sheet and statutory regulations, the following order of priority shall govern:

a. Local Statutory Regulations b. Data Sheets c. Job Specification d. This Specification e. Codes and Standards

3.0 DEFINITIONS For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows: OWNER / COMPANY - OWNER of the particular Project (Project Specific). CONSULTANT - The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management. BIDDER / SUPPLIER / VENDOR The party(s) which manufactures and / or supplies material, equipment, technical documents / drawings and services to perform the duties specified by Contractor 4.0 MATERIALS

4.0 UPS panels, ACDB and cell booster enclosures shall be fabricated from Structural/CRCA sheet steel. The frames shall be fabricated by using minimum 2mm thick CRCA sheet steel while the doors and covers shall be made from 1.6mm thick CRCA sheet steel. Wherever required suitable stiffeners shall be provided.

4.1 The panels shall be free standing, fitted with suitable louvers for ventilation and cooling fans as required. Hinged doors shall be provided at the front and back with dust tight gaskets. Interpanel sheet steel barriers shall be provided. The enclosure shall provide minimum IP-42 degree of protection, if not specified otherwise in the Data Sheet. The maximum and minimum operating height of the switches shall be 1800 mm and 300 mm respectively.

5.0 DESIGN 5.1 GENERAL REQUIREMENTS 5.1.1 The offered equipment shall be brand new with state of art technology and proven field track record. No prototype equipment shall be offered. 5.1.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least 15 years from the date of supply.

5.1.3 Vendor shall give a notice of at least one year to the end user of equipment before phasing out the product/spares to enable the end/user for placement of order for spares and

services.

5.1.4 The UPS system shall be an integrated system comprising static rectifiers, battery, static inverters, static switches, auto / manual by pass switch, AC distribution board, voltage stabiliser in bypass, isolating and protection devices and all other equipment/ accessories required for completeness of the system whether specifically mentioned herein or not, but necessary for completeness and satisfactory performance of the system.

5.1.5 The UPS system shall be suitable to feed all loads connected to the output which are primarily instruments, (DCS), computers, disc drives and other SMPS equipment leading to high crest factor of the load.

5.1.6 The inverter shall be thyristor / transistorised (IGBT) type or with the latest proven technology. All components shall be of a high quality and reliability that satisfy with the requirements of a secure AC power to vital equipment with respect to performance, controlling, monitoring and safeguarding function in continuously operating petrochemical process units, petroleum refineries, gas processing facilities, utility and other miscellaneous industrial plants. Components shall be capable of withstanding the thermal and dynamic stresses resulting from internal and external short circuits and switching surges etc.

5.1.7 The design of the UPS shall be such as to minimize the risk of short circuits and shall ensure human and operational safety.

5.1.8 The vendor shall be responsible for design, engineering and manufacturing of the complete system to fully meet the intent and requirements of this specification and enclosed data sheets. Selection, sizing and suitability of all equipment and components used for UPS system shall be Vendor's responsibility.

5.1.9 The UPS shall be single phase or three phase system as indicated in the Data Sheets. 5.1.10 For the Batteries detail see technical requirement cl. no. 5.2.3. 5.2 TECHNICAL REQUIREMENTS 5.2.1 INPUT POWER SUPPLY

a. The UPS shall be suitable for input power supply as defined in the Data Sheet. If not specified therein the UPS shall be suitable for the following input power supply. Voltage 415V ± 10% Frequency 50 Hz ± 3%

b. In addition to above variations, the input voltage may be subjected to transient variations comprising voltage dip to 20% of normal voltage during motor start-up as well as voltage variations due to fault condition.UPS system shall be designed to operate satisfactorily while deriving the input power from an emergency diesel generator set.

c. UPS system shall also operate satisfactorily on input power supply having: i. the ratio of negative to the positive sequence components not exceeding 5%

and ii. Total harmonic distortion of not more than 5%.

d. Total Harmonic Distortion is the ratio in percentage of r.m.s.value of the harmonic content to the r.m.s. value of the fundamental component of alternating quantity.

e. The incoming power supply to UPS will be provided by 2 Nos. feeders. one feeder shall feed the rectifier(s) while other shall supply power to stabilized bypass supply.

5.2.2 UPS CONFIGURATION AND OPERATIONAL REQUIREMENTS The UPS system shall have one of the following basic configurations as specified

in Data Sheet and drawings:

a. Single UPS with Bypass i. In UPS system having this configuration a single rectifier and inverter shall be

provided. Under normal conditions when AC mains power is available, the rectifier shall simultaneously feed DC power to inverter as well as for float/rapid charging of the battery. The AC supply to loads shall be fed from inverter output. In case of any fault in the inverter, the load shall be automatically transferred to stabilized bypass supply and retransfer of load from stabilized bypass supply to the inverter shall be possible in auto as well as in manual mode.

ii. In case of AC input power failure or battery charger failure, the battery shall supply power to inverter without any interruption. The charger shall be designed for simultaneously feeding complete inverter load and for float/rapid charging the battery to its rated capacity. Charger shall be equipped with 'On Line' automatic as well as manual charging facility.

b. Parallel Redundant UPS with bypass i. In UPS system having this configuration two sets of rectifiers and inverters

shall be provided. Under normal conditions, when AC mains power is available, both the rectifiers shall operate in parallel and supply DC power for float/rapid charging the battery and simultaneously to inverters. In case of failure in one rectifier, the other rectifier shall feed the complete load and the battery without any interruption. In case of incoming supply failure or failure of both rectifiers the battery shall feed the inverters without any interruption. Each rectifier shall be designed for simultaneously feeding complete inverter load and float/rapid charging of the battery to its rated capacity. Each rectifier shall be equipped with 'On Line' automatic as well as manual charging facility.

ii. Normally both inverters will be synchronized with each other and with stabilized bypass supply. Both inverters shall operate in parallel and share the load equally.

When a disturbance/fault occurs in any one of the inverters, the faulty unit shall automatically get disconnected and the entire load shall be fed from the

other inverter. In case both the inverters develop a fault, the complete load shall be transferred to stabilized bypass supply through the static switches and retransfer of load from stabilized bypass supply to the inverter shall be possible in auto as well as in manual mode.

c. Hot stand-by Redundant UPS with bypass i. In UPS system having this configuration, the arrangement of

rectifiers/inverters and the operating philosophy is same as described above, except that only one inverter shall be operating at one time. The other inverter shall not be sharing the load but shall be synchronized with the running inverter and stabilized bypass supply and remain ready to accept the load in case of fault in the running inverter. Retransfer of load from stabilized bypass supply to the inverter shall be possible in auto as well as in manual mode.

ii. In all UPS configurations, the facility for uninterrupted manual transfer in either direction through static switches shall also be provided.

iii. For ease of maintenance, it shall be possible to isolate inverters and static switches from load through manually operated make before break switches. In case of larger rating UPS, where it is not possible to provide one power switch with make before break feature, combination of breakers with the control scheme having make before break logic may be provided which ensures momentary paralleling before tripping of selected breaker.

5.2.3 UPS DESIGN AND PERFORMANCE REQUIREMENTS a. Incoming AC supply shall be converted to DC through three phase full wave

controlled rectifiers. The rectifiers shall operate according to the constant voltage current limiting principle and shall incorporate a "Soft Start" feature to gradually accept load on initial energizing.

b. The rectifier section of the UPS system shall be capable of precise regulation to prevent damage to the battery. The output voltage of rectifier's DC bus without the battery shall be stabilized to within ± 1% of set value during load variation between 0 to 100% of the rectifiers and specified mains input supply voltage variation.

c. Suitable protection shall be provided in the control circuits to guard against instability of phase controlled rectifiers due to electrical oscillations which may be present in the input supply as caused by emergency DG set.

d. The UPS system including the stabilized by-pass shall be galvanically isolated from input power supply system by providing double wound transformers. All transformers shall be natural air cooled, dry type suitable for location inside the panel. All rectifiers shall also have a double wound transformer at its input.

e. An RFI filter shall be provided. The production of radio frequency interference voltage shall not exceed the value of suppression grade N' as defined in VDE-0875. The performance of UPS system shall not get affected or in any way be degraded by the

use of portable radio transmitter receiver in the vicinity of the UPS system and or UPS room.

f. Transient/surge protection circuit shall be provided in the input circuit to rectifiers to protect the UPS from surges & voltage spikes.

g. The UPS system shall be designed to draw power from mains supply at a minimum power factor of 0.85 while working at rated load in normal operating UPS configuration.

h. The UPS shall be provided with automatic sequence and power walk in circuit(s) with time delay of upto 15 sec. such that the rectifiers and inverters can start operating automatically when incoming AC power is restored allowing the UPS to be loaded automatically.

i. Facility for initial charging of batteries shall also be provided. The inverters may be disconnected during initial charging of the battery.

j. For battery sizing, the following factors shall be considered unless specified otherwise in the Data Sheet:

i. Load Power Factor of 0.8. ii. Minimum ambient temperature as specified in Data Sheet. Inverter rated KVA x Rated load p. f. iii. Battery Current = Inverter Efficiency* x End cell voltage x No. of cells

*At 50 % load on each inverter for parallel redundant UPS. iv. Aging factor of 0.8. v. Back up time of 8 / 10 / 12 hours in case of mains power failure unless specified

otherwise in Data Sheet. vi. Minimum end cell voltage for lead acid / VRLA battery 1.85 V per Cell and 1.0 V

per cell for Ni-Cd battery. vii. Battery state of charge factor of 0.95. k. The rectifiers/chargers shall be designed to completely charge the Lead acid and

Nickel cadmium batteries in a maximum time of 8 / 10 / 12 hours after complete discharge. Facilities shall be provided to initiate battery rapid charge operation by manual & automatic means. An auto charging sequence should be provided for the rapid and float charging based on current sensing. Battery charger for VRLA battery shall be sized to provide boost charging of the battery up to 90% of rated Ampere hours within duration of 24 hours and to 100% within 4 days. In addition to above, the charging shall he transferred from rapid to float mode after a preset time adjustable through 0-24 hours timer as back up protection against overcharging.

l. The rectifiers shall be sized based on the maximum inverter input load when inverter is delivering its rated output at 0.8 p.f. lagging and recharge the battery to nominal rated capacity of the battery. The DC load imposed by the inverters shall

be considered under the most severe operating conditions where only one rectifier is operating but the UPS load is equally shared by all the inverters. The rating of each rectifier shall be not less than the value calculated as follows:

For Lead Acid Batteries = Inverter input current + 0.14Ah (10 hr. Rating of the battery) For Nickel Cadmium Batteries = Inverter input current + 0.2Ah (5 hr. Rating of the

battery) For VRLA Batteries = Inverter input current + 0.2Ah (10 hr. Rating of the battery) Rated KVA capacity of UPS x Load power factor Where Inverter input current =

Battery charging voltage x Inverter efficiency m. The DC rectifiers shall sense the battery charging current and adjust the DC bus

voltage to maintain the charging current to preset level. A separate current limit circuit shall also be provided for adjustment of battery current. The rectifiers shall be protected against reverse battery connection at DC link voltage bus. Subsequent to a discharge cycle when battery is connected to rectifier, the battery current shall be monitored, controlled and limited to set value automatically irrespective of the inverter input current.

n. The battery may be taken out of service for maintenance, during which period it shall be possible for the inverter to continue operation by drawing power from the rectifier. Ripple content at the DC link shall not exceed 2% even with battery disconnected.

o. Battery / D.C. link shall be provided with a sensitive earth leakage protection. p. The inverter shall be of the current limiting type (short circuit proof) and have

nominal output voltage and frequency as specified in the data sheet. The inverter output voltage and frequency shall not exceed the operational tolerances, as measured at the output terminals of the unit during the following conditions of UPS loading:

i. Load variations between 0-100% of the rated output of UPS ii. Load power factor over the range of 0.7 lagging to unity. iii. Load current waveform having a relative harmonic content varying between zero

and 50% the latter waveform having a crest factor not exceeding 2.5 and individual harmonics not exceeding the following values :

- 3rd harmonic- 44% of fundamental - 5th harmonic- 33 % of fundamental - 7th harmonic- 1.8 % of fundamental - 9th harmonic- 7% of fundamental - 11th harmonic-10% of fundamental iv. The Relative harmonic content is the ratio of the r.m.s. value of the harmonic

content to the r.m.s. value of the total non-sinusoidal periodic waveform i.e. relative harmonic content =

Rms value of the fundamental component of the current or voltage √ [1- (----------------------------------------------------------------------------------------- ) 2 Rms value of total waveform of current or voltage v. The UPS output voltage waveform shall be pure sine wave under linear load

conditions, and not exceeding 5% under the non-linear load conditions specified above.

q. The inverter shall control the output voltage of the UPS such as to maintain synchronism with the mains bypass voltage during variations in mains frequency up to the limits specified.

During variations in mains frequency exceeding these limits, the inverter shall revert to internal frequency control.

r. It shall be possible to vary the inverter output voltage steplessly within ± 5% of the specified output voltage. This adjustment shall be possible to be made when the inverter is in operation.

s. The steady state output voltage and frequency (free running) variation of inverters shall not exceed ± 1% from the set value for specified input power supply conditions from no load to full load condition and load power factor variation from 0.7 lag to 1.0.

t. The UPS system shall be able to operate satisfactorily on rated loads (in KVA) with power factors in the range of 0.7 lag to 1.0. The overall efficiency of the UPS system shall not be less than 80% at rated load and 0.8 p.f.

u. The UPS shall have capacity to deliver a minimum overload of 125% for 10 minutes and 150% for 10 sec. UPS shall be provided with current limit circuit to avoid excessive loading beyond its permissible overload withstand capability.

v. The inverters shall be 'phase locked' to the stabilized bypass power supply as long as stabilized bypass supply frequency remain within ± 4% of nominal. When bypass supply frequency variation, exceeds the above limits, the inverters shall be delinked from mains. Free running frequency tolerance limit shall not exceed ± 1%. Facility shall also be provided for adjustment of range of synchronizing frequency.

w. Unless otherwise specified, the UPS system output voltage variation shall not exceed ± 10% and complete recovery to normal steady state shall be within 0.1 Sec. The above requirement shall be complied for following transient disturbances.

i. 100% step load and unload (For single UPS and hot stand by UPS) ii. 50% step load ( for parallel redundant UPS) iii. Momentary interruption in power supply iv. Load transfer to stabilized bypass supply v. Complete load transfer to other healthy inverter when one of the two

parallel inverters develop a fault. x. For 3 phase UPS system, the maximum output voltage and angle variation

between the phases should not exceed 5% and 3 degrees respectively even under the condition of 100% unbalanced loading of the 3 phase output.

y. UPS system shall be suitable for floating output in case of single phase system. z. The stabilized bypass supply shall be designed to regulate the output voltage

within ±2% of the rated voltage over complete range of load from no load to full load and for specified input supply voltage variation. The type of Voltage stabilizer in stabilized bypass supply shall be as indicated in data sheet.

aa. The stabilized bypass supply shall have a continuous current rating equivalent to the rated output of the UPS unit and be capable of conducting a current ten times the rated output for the duration more than the fault clearing time of the type of fuse provided. The load transfer devices shall comprise of continuously rated static elements in both inverter and stabilized bypass supply.

bb. Adequately rated static switches in required number & configuration shall be provided in the inverter(s) output and stabilized bypass supply to ensure positive isolation of faulty inverter section such that the other inverter and bypass circuits do not feed into the fault leading to under voltage / trip. The short time rating of all the static switches shall be at least 10 times the rated output for the duration more than the fault clearing time of the type of fuse provided.

cc. Facility shall be provided to manually and automatically initiate transfer of the load from inverters to the stabilized bypass supply and from stabilized bypass supply to the inverters. Under voltage and over voltage sensing levels to initiate transfer shall be adjustable. The maximum transfer time between inverters and bypass supply shall not exceed 4 msec and 20 msec in synchronous and asynchronous mode respectively.

dd. The criteria for load transfer:

i. Load transfer from inverter to the stabilized bypass supply shall be as follows: - The load transfer shall only be possible when: The stabilized bypass output voltage is within ± 5% of rated UPS output voltage and the mains bypass frequency is within ± 4%. Auto-transfer of the load from inverter to stabilized bypass supply shall be inverted when: The inverter output voltage drops below 95% of nominal output voltage under steady state condition and/or if the inverter output voltage falls below 90% of the nominal value under transient conditions. OR The inverter output voltage exceeds 105% of the nominal output voltage under steady state condition and/or if the inverter output voltage reaches 110% of the nominal value under transient conditions. OR The inverter output current exceeds its tolerable limits. ii. Retransfer of load from stabilized bypass supply to the inverter shall be as follows: - The load transfer shall be possible when: The inverter output voltage is within ± 5% of nominal output voltage for more than 5 sec. and

Inverter output and stabilized bypass supply are synchronized. Retransfer of load from stabilized by pass to the inverter shall be done manually only unless otherwise specified in the Data Sheet. If automatic retransfer of load to the inverter is specified in the Data Sheet, then the retransfer of load to the inverter shall be inhibited following four automatic transfers of load to stabilize by pass within a period of 5 minutes.

ee. All breakers shall be adequately rated for continuous rating as well as breaking capacity as applicable. Paralleling of breaker/ switch/ contactor poles to achieve the required current rating is not acceptable. All output isolating device shall be double pole type.

ff. All electronic power devices including thyristors, transistors (IGBTs), diodes etc. shall be rated under operating conditions for approximately 200% of the maximum current carried by the device. All other electrical components such as transformers, reactors, breakers, contactors, switches, bus bars etc. shall be rated for at least 125% of the maximum required rating. No electronic device shall be subjected to PIV greater than 50% of its rated value.

gg. All the thyristors, power transistors, diodes and other electronic devices of UPS shall be protected with high speed semiconductor fuses. I²t co-ordination between fuse and semi-conducting power devices shall be ensured.

hh. The outgoing circuits of ACDB shall be protected by semiconductor fuses. Each inverter shall be designed to clear a fault in any of the branch circuits upto a maximum rating of 25 % of the system capacity without the assistance of the stabilized bypass supply. In case of any fault in branch circuits, the load connected to the healthy circuits shall not get affected. The fault clearing time shall be less than 4 msec.

ii. All PCBs shall be provided with a transparent epoxy coating for environmental protection and tropicalisation. They shall be suitably located away from heat sources.

jj. All electronic control and monitoring printed circuit cards shall be installed in Standardized electronic equipment frames and shall be fitted with suitable means for easy removal. The frames shall incorporate guides for PCBs to facilitate correct insertion of PCB's and shall allow access to the wiring side of the connectors. All PCBs shall be placed in a manner to avoid replacement of a PCB by a wrong spare PCB. Monitoring points shall be provided on each of the PCBs and the PCB shall be firmly clamped in position so that vibration or long usage does not result in loose contacts. Failure of each PCB shall be indicated by visual alarms. Visual fault diagnostics shall preferably identify faults up to various sections in the card.

kk. Forced ventilation of panel, if provided, shall be supplemented by 100% redundant fans. In normal operation, normal & redundant fans shall run together. The power supply for the fans shall be tapped from the inverter output. However, the rating of the UPS as specified in the Data Sheet shall be the net output of UPS after deducting power consumption for fans etc. However in case of non-operation of 50% of running fans the UPS output shall not be affected. The fans shall be arranged to facilitate removal of faulty fan for maintenance without requiring system shutdown.

i. Maximum noise level from UPS system at 1 meter distance, under rated load with all normal cooling fans shall not exceed 75 dBA.

5.2.4 CELL BOOSTER

a. Cell booster shall be suitable for charging one to six cells within a time duration as specified. It shall be suitable for charging not only the new cells before being introduced to the battery bank but also any treatment to be given to the individual weak cells. Quantity of such boosters shall be as defined in the MR. Cell booster shall be suitable for 240 V ± 10%, 50 Hz ±3% SPN input power supply. Cell booster output voltage shall be in the range of 0-18V and 0-12V for Lead Acid and Nickel Cadmium batteries respectively. Cell booster shall be sized as under: I. For Lead Acid battery = 0.14 x Ah of cell (10 hr. Rating of the cell) II. For VRLA battery = 0.2 x Ah of cell (10 hr. Rating of the cell) III. For Ni-Cd battery = 0.2 x Ah of cell (5 hr. Rating of the cell) b. Cell booster shall have heavy duty switch fuse or MCCB on AC incomer and DC output, AC voltmeter, DC ammeter and voltmeter, indicating lamp for AC/ DC power ON. The output voltage and current of cell booster shall have manual control using a suitably rated variac or a full wave controlled rectifier bridge. Suitable interlock shall be provided so as to ensure that the variac/controlled rectifier is at its minimum position while switching on the cell booster. Cell booster shall be portable type with wheels. Each cell booster shall be supplied with 5 m long flexible copper conductor. PVC insulated and braided cable for AC incomer power supply and DC output connection to the battery.

5.2.5 A.C. DISTRIBUTION BOARD a. Sheet steel enclosed AC distribution board shall be provided as part of the complete UPS package. It shall accommodate AC feeders as indicated in the Data Sheet. The distribution board shall be floor mounted fixed type with compartmentalized construction unless otherwise indicated in the Data Sheet. It shall be possible to operate the switches without opening the doors. Switches shall be provided with door interlock. Vertical cable alley of minimum 200mm width with suitable supports shall be provided for the termination of outgoing cables. Suitable supports shall be provided for supporting incoming and outgoing cables. All outgoing switches shall be air insulated load break type. Fuses on outgoing feeders shall be fast acting semiconductor type and cable entry shall be from bottom. The gland plate of the distribution board shall be non-magnetic type where single core cables are used as specified in the Data Sheet. Cable glands shall be of brass and single compression type and cable lugs shall be of tinned copper.

5.2.6 ALARM, CONTROL, INDICATION AND METERING REQUIREMENTS If not specified otherwise in the Data Sheets, following schedule shall be followed for alarm, control, indication and annunciation. Any additional devices/features considered necessary for reliable operation and maintenance shall also be included in various panels and same shall he highlighted separately.. An illuminated one line diagram indicating operational status shall be provided on the front of the panel, metering, indications, audio- visual alarm shall be provided. Parameters/ information indicated shall be available in LCD panel or by other means directly or indirectly.

a. Metering i. Rectifier - Incoming line voltages (For all the three phases).

- Input line currents.(For all the three phases). - D.C. voltage at each rectifier output. - Battery current. ii. Inverters - AC voltage at each inverter output (AC voltages for 3 phase inverter) . - AC current at each inverter output (AC currents for 3 phase inverter). - Frequency meter at each inverter output. iii. Stabilised bypass supply - Frequency meter for incoming supply. - Voltmeter with selector switch for incoming supply. - Ammeter with selector switch for incoming supply. iv. ACDB Following shall be provided for each of the ACDB incomers: - Voltmeter (voltmeter selector switch shall also be provided for 3 phase inverter). - Ammeter (ammeter selector switch shall also be provided for 3 phase inverter). - Power factor meter. b. Indications All indication lamps shall be provided with series resistors. Clustered/Jumbo LED's of minimum 10mm dia. may be provided in place of lamps subject to their having at least equal illumination. - AC mains 'ON' - Rectifier. - AC mains `ON' - Bypass. i. Rectifiers (for each rectifier) - Rectifier output 'ON' - Battery on float charge - Battery on rapid charge ii. Inverters (for each inverter) - DC input 'ON' - Load on inverter - Inverter synchronized with mains iii. Load on bypass c. Audio-Visual Alarm (separately for each circuit) - Mains failure - Battery charger failure - Battery fault - Inverter temperature high - Low voltage from inverter - Load on bypass - Inverter overloaded - All power Fuse failures i. 2 nos. changeover contacts shall be wired to the terminal strip, 1 no for common remote alarm of 'UPS fault' in owner's panel and 1 no. for load on bypass supply annunciation.

d. Controls - All the switches for starting, shut down and testing sequence. - Primary input circuit breakers for feeding chargers, bypass line and dc bus from battery including backup protection. - Inverter ON/OFF switch (to initiate inverter operation). - Static switch transfer test Push Button.

5.2.7 RELIABILITY All necessary care shall be taken in selection, design, manufacture, testing and commissioning of the equipment for ensuring high system reliability. Following design consideration shall be taken into account to ensure maximum availability of the system.

a. There shall be no common device, between main and redundant units (e.g. master oscillators etc.) in order to ensure that the fai lure of the same does not cause shutdown of more than one unit.

b. It shall be possible to take out any individual power circuit for maintenance without affecting the total UPS supply.

c. Series-parallel combination of smaller devices to achieve required rating shall not be acceptable.

d. Vendors shall offer their nearest higher Standard size that will meet the requirement of the specified UPS rating.

5.2.8 FAULT DIAGNOSTIC UNIT a. If specified in the Data Sheet, each UPS set shall have provision for adding

microprocessor based 'ON line' fault diagnostic unit. This shall supervise the UPS operation continuously. It shall identify and locate faults immediately so that corrective action can be taken. Fault Diagnostic unit shall be compatible to hook up with Owner's PC through RS232/RS485 interface. The software shall be provided on a CD ROM.

b. The fault diagnostic unit shall have provision for automatic print out facilities for time, input/output voltages, currents, frequency as a minimum under the following conditions.

- UPS power source changeover from mains to battery. - UPS power source changeover from battery to mains. - Changeover from inverter to stabilized bypass supply and vice versa. - Changeover from one inverter to other inverter. - Changeover time in case of inverter to stabilized bypass supply and from one inverter to other inverter. - UPS failure. - Type of failure incident along with diagnostic report. c. In addition to the above, any other feature which vendor feels may be useful shall be provided and highlighted separately. d. If any additional equipment (e.g. bin connector, adaptor cards etc.) are required for connecting this unit with UPS system as well as with Owner's PC. The same are also to be included in the vendor's scope.

6.0 FABRICATION 6.1 Rectifier/charger and inverter, stabilized bypass supply and static switch sections shall be suitably housed in sheet steel panels complete with all interconnections.

a. UPS panels, ACDB and cell booster enclosures shall be fabricated from Structural/CRCA sheet steel. The frames shall be fabricated by using minimum 2mm thick CRCA sheet steel while the doors and covers shall be made from 1.6mm thick CRCA sheet steel. Wherever required suitable stiffeners shall be provided.

b. The panels shall be free standing, fitted with suitable louvers for ventilation and cooling fans as required. Hinged doors shall be provided at the front and back with dust tight gaskets. Interpanel sheet steel barriers shall be provided. The enclosure shall provide minimum IP-31 degree of protection, if not specified otherwise in the Data Sheet. The maximum and minimum operating height of the switches shall be 1800 mm and 300 mm respectively.

6.2 Power cables shall be with aluminum / copper conductors and control cables shall be with copper conductors. All the cable connections shall be from bottom and front of the panel, if not specified otherwise in the Data Sheet. A removable bolted gland plate shall be provided along with single compression type nickel plated brass cable glands for external cable connections. Clamp type terminals shall be used for connection of all wires up to 10 mm2. Bolted type terminals suitable for cable lugs shall be provided for wire size above this. Tinned copper lugs for all external connections shall be provided with the panels.

6.3 Bus bars shall be used in all power circuits which are rated minimum 100 Amp. Copper conductor PVC insulated cables or wires of 660V grade shall be used for power circuits rated less than 100 Amp. Bus bars shall be colour coded and live parts shall be shrouded to ensure complete safety to personnel intending routine inspection by opening the panel doors. All the equipment inside the panel and on the doors shall have suitable name plate and device tag numbers as per the schematic diagram. All wires shall be ferruled and terminals shall be numbered.

6.4 MCCBs and load break power switches shall be mounted inside the panel. The control switches shall be rotary type, mounted on the door and shall be externally operable. An 11 W CFL lamp controlled through a door switch shall be provided for illumination in each panel. All instruments shall be analogue/digital, switchboard type, back connected, (72x72) mm. square (Analogue type) of reputed make. Analogue instruments scale shall have red mark indicating maximum permissible operating rating. Separate test terminals shall be provided for measuring and testing of the equipment to check the performance.

6.5 A suitably sized earth bus shall be provided at the bottom of the panels including ACDB running through the panel’s line up with provision for earth connection at both ends to purchaser's main earth grid. The minimum size of earth bus shall be (25x3) mm copper (or equivalent aluminum). All potential free metallic parts of various equipment shall he earthed suitably to ensure safety. 6.6 All panels shall be of same height so as to form a panel lineup which shall have good

aesthetic appearance.

6.7 Inside the panels, the controls connections shall be done with 660V grade PVC insulated wires having stranded copper conductors: 1.5 mm2 size wire shall normally be used for circuits with control fuse rating of 10 Amp. Or less. For control circuit having fuse of 16 Amps., 2.5 mm2 size wire shall be used. Control wiring for electronic circuits shall he through flat ribbon cable or through copper wire minimum of 0.5 mm dia.

6.8 All control wiring shall preferably be enclosed in plastic channels or otherwise neatly bunched together. Each wire shall be identified at both ends by PVC ferrules. Ferruling of wires shall be as per relevant IS.

6.9 All metal surfaces shall be thoroughly cleaned and de-greased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The undersurface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under-surface shall be made free from all imperfections before undertaking the finished coat.

6.10 After preparation of the under-surface, the panels shall be spray painted with two coats of epoxy-based final paint or shall be powder-coated. Spray painted finished panels shall be dried in stowing ovens in a dust-free atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint, etc. The vendor shall furnish the painting procedure along with the bids.


7.1 During fabrication, the equipment shall be subjected to inspection by Consultant/Owner or by an agency authorized by the Owner. Manufacturer shall furnish all necessary information concerning the supply to Consultant’s/Owner's inspector. Tests shall be carried out at manufacturer's works under his care and expense.

7.2 UPS system shall be tested in accordance with applicable Standards. The following acceptance tests shall be performed on each ups system as a minimum. All tests shall be witnessed by Owner or its authorized representative and 4 weeks prior notice shall be given before the date of commencement of tests. The tests certificates indicating test results shall be furnished.

Following system acceptance tests shall be conducted on each UPS system: 7.2.1 INSULATION TESTS a. Insulation tests shall be performed as per IEC 60146-1-1. b. The insulation tests shall be carried out using an AC power frequency voltage or by using DC Voltage at the choice of the vendor. In case of AC power frequency voltage test, the test voltage at the frequency available in the test facility or at the rated frequency, but not exceeding 100 Hz, of the full value starting at a maximum of 0.5 p.u. The unit on test shall withstand the specified voltage for 1 minute.

c. In case DC voltage is used for the test, the value of DC voltage shall be equal to the crest value of the test voltage specified in the table.

Vp/√2 (V*, is the highest crest voltage to be expected between any pair of terminals)

Test Voltage (AC rms value)

≤60 V 500 V

≤125 V 1000 V

≤250 V 1500 V

≤500 V 2000 V

7.2.2 INTERCONNECTION CABLE CHECK The interconnection cable are to be checked for correct wiring, insulation and quality of the terminations

7.2.3 A.C. INPUT FAILURE TEST The test is performed with the test battery and carried out by tripping a.c. incoming circuit breakers or by switching off rectifiers and bypass supply at the same time. Output voltage and frequency variations are to be checked for specified limits.

7.2.4 A.C. INPUT RETURN TEST The test is performed by closing A.C. incoming circuit breakers or is simulated by energizing rectifiers and bypass supply. Proper operation of rectifiers starting and voltage and frequency variations of output are to be checked.

7.2.5 SIMULATION OF PARALLEL REDUNDANT UPS FAULT The test is applicable for UPS with parallel redundant configuration. Fault of rectifier or inverter are to be simulated and output transients are to be recorded.

7.2.6 TRANSFER TEST Transients shall be measured during load transfer from inverter to bypass supply caused by simulated fault and load retransfer after clearing the fault.

7.2.7 REGULATION TEST a. This test shall be carried out by measuring input voltage, input current, output voltage, output current, DC link voltage, output distortion, input active power, output active power and frequency at no load, 50% load and 100% load at 0.7 and 0.8 p.f. b. Following parameters of rectifiers and inverters are to measured: i. Measurement shall be carried out in the rectifier float charge mode and in rapid charge

mode. Measurement shall be at nominal A.C. voltage and at no load, 50% load and 100% of rectifier full load. Rectifier measurement shall comprise of : - - Input voltage, frequency, phase current and input power. D.C. output voltage and current. - Ripple current at the DC link bus shall be recorded after isolating the test battery. ii. Inverter measurement shall also be at no load, 50% load and 100% load of inverter rated output current and shall be repeated for inverter D.C. input voltages corresponding to battery float charge operation as well as rated inverter maximum and minimum input D.C. voltage. Measurement shall comprise of : - Input voltage, input current. - Output voltage, frequency and waveform distortion, output power and current.

7.2.8 UPS EFFICIENCY This shall be determined by the measurement of the active power input and output at rated p.f. for 50%, 75% and 100% load.

7.2.9 CURRENT DIVISION IN PARALLEL UPS Load sharing between UPS units shall be measured with a dummy load under parallel redundant UPS configuration.

7.2.10 LIGHT LOAD TEST The test is to verify that all functions of the UPS system operate properly. The load applied is limited to some percentage of rated loads. The following points are to be checked.

a. Output voltage and frequency and correct operation of meters. b. Operation of all control switches and other means to put UPS system into operation. c. Functioning of protective and warning devices 7.2.11 BURN-IN TEST FOR PRINTED CIRCUIT BOARDS PCB's and other electronic components sub assemblies shall undergo a burn- in test for 96 hours at 50°C at a voltage varied between the maximum and minimum supply voltage. In case of failure of any component during testing, the tests shall be repeated after replacement of the faulty component. 7.2.12 CONTINUOUS FULL LOAD TEST AT 0.8 POWER FACTOR WITH TEMPERATURE RISE MEASUREMENT

a. The test is required to be performed by connecting resistive load or resistive and inductive load to the UPS system output. The load shall be placed outside the test room to avoid influences of its heat upon UPS ventilation. b. UPS system in this test shall undergo a complete full load test for 32 hours at 0.8 power factor. Out of these 32 hours, each inverter section shall be subjected to full load test for 8 hours. Both invertors sections operating in parallel shall be subjected to full load test for 8 hours and the

for remaining 8 hours, the bypass section shall be subjected to full load test. Steady state temperature of rectifier transformer, Rectifier set, D.C. choke, inverter set, static switch etc. shall be recorded during the test. The temperature of all UPS panels is also to be recorded.

7.2.13 AUXILIARY EQUIPMENT AND CONTROL CIRCUIT TESTS The correct functioning of all measuring instruments, alarms, indications, protection devices and controls are to be verified. The functioning of auxiliary devices such as lighting, cooling fans, annunciation etc. should be checked.

7.2.14 SYNCHRONIZATION TEST Frequency variation limits of inverter are to be tested by feeding bypass supply incoming line by variable frequency generator and inverter synchronization limit is to be checked as specified.

7.2.15 UNBALANCED LOAD TEST (FOR 3 PHASE UPS ONLY) Unbalance load at specified limits is applied to the UPS system. The specified voltage and phase angle variation may be checked for compliance with specified values.

7.2.16 OUTPUT VOLTAGE UNBALANCE (FOR 3 PHASE UPS ONLY) Output voltage unbalance shall be checked under symmetrical load conditions and unbalance load conditions. Phase to phase and phase to neutral output voltage are to he observed. The voltage unbalance is the ratio of highest phase volta ge minus lowest phase voltage to the average value. Phase angle variation may be measured for phase to phase and phase to neutral voltages

7.2.17 OVERLOAD CAPABILITY TEST Specified values of short time overload are to be applied for specified time interval. Values of output voltage and output current are to be recorded.

7.2.18 SHORT CIRCUIT CURRENT CAPABILITY TEST Specified short circuit current capability is to be tested by application of a short circuit to UPS output if necessary via a suitable fuse. Short circuit curr ent is to be recorded.

7.2.19 SHORT CIRCUIT FUSE TEST Fuse tripping capability of the UPS system is to be tested by short circuiting the UPS system output via a specified rating of fuse. The test is carried out at an appropriate UPS load under normal operation.

7.2.20 RESTART Manual restart to be tested after complete shutdown of UPS system.

7.2.21 OUTPUT OVER VOLTAGE Operation of output over voltage protection is to be checked. 7.2.22 DYNAMIC RESPONSE TEST Output recording at different loads and operating condition to be done. 7.2.23 HARMONIC COMPONENTS Harmonic components of output voltage are to be recorded at no load, 50% load and 100% load conditions. Harmonic voltages caused by UPS system components in the A.C. incomer side shall be recorded at site.

7.2.24 EARTH FAULT TEST An earth fault is to be applied to the output terminal of UPS system. UPS output transients are to be measured. An earth fault is also to be applied to the battery terminal and UPS system output transient shall be measured.

7.2.25 AUDIBLE NOISE TEST a. The audible noise is required to be measured at 1 meter distance from UPS system in at least 4 to 5 locations and its value shall be within permissible limit. b. The detailed test schedule and test procedure shall be formulated in line with above. Before giving call for the witness of the tests, vendor shall get Consultant approval on the test procedures. Vendor shall also indicate the max. Allowable tolerance for each test result along with the test procedures. c. If tests show that certain requirements of the specifications are not met, 'Vendor' shall make necessary corrections to the equipment so that it satisfies all the requirements before acceptance is made.

7.2.26 SITE ACCEPTANCE TESTS Vendor shall furnish Site Acceptance Tests procedure to be followed. Final acceptance testing along with the batteries shall be done at site. It shall be Vendor's responsibility to arrange necessary instruments and tools as required by their commissioning engineer for these tests.

8.0 MARKING, PACKING AND SHIPMENT All the equipment shall be divided in to several shipping sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets before being placed in wooden crates /cases to prevent damage to the finish. Crates /cases shall have skid bottoms for handling Special notations such as Fragile', 'This side up', ' center of gravity', `weight', 'Owner's particulars', `PO nos.' etc. shall be clearly marked on the package together with other details as per purchase order. The equipment may be stored outdoors for long periods before installation.

The packing shall be suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed.

STANDARD SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM

ABBREVIATION

BIS/IS Bureau of Indian standards IEC International Electro-Technical Commission BS British Standards IEEE Institute of Electrical and Electronics Engineers NEMA National Electrical Manufacturers Association OISD Oil Industries Safety Directorate CCE Chief Controller of Explosive DGMS Director General Mines Safety IE Rules Indian Electricity Rules CPRI Central Power Research Institute VRLA Value Regulated Lead Acid Ni-Cd Nickel Cadmium AH Amphere hour MCCB Moulded case circuit breaker SCR Silicon Controlled Rectifier

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE .........................................................................................................


3.0 DEFINITION .................................................................................................

4.0 DESIGN ........................................................................................................

5.0 FABRICATION .............................................................................................

6.0 INSPECTION AND TESTING .......................................................................

7.0 MARKING, PACKING AND SHIPMENT ......................................................

1.0 SCOPE 1.1 This Specification provides the minimum requirements for the design, manufacture, testing and supply of the Solar Electric Power System to be installed. The Solar Electric Power System shall independently meet the power requirement of continuous loads as defined in Data Sheet.

1.2 The exact number of solar electric power systems along with loads connected to each system and the load rating of each system shall be as indicated in the equipment Data Sheet.

1.3 Each solar electric power system when installed in accordance with Vendor's instructions shall form self-sufficient power system to meet the power requirements of continuous loads.

2.0 REFERENCE DOCUMENTS 2.1 The equipment supplied shall comply with the requirements of the latest revision of the relevants standards of

NEC National Electrical Code NEMA National Electrical Manufacturers' Association NFPA National Fire Protection Association API American Petroleum Institute ANSI American National Standards Institute ASTM American Society for Testing and Materials BIS Bureau of Indian Standards IEC International Electro-technical Commission

2.2 Any other recognized international codes or standards may be used in lieu of the above, subject to the approval of the Company.

3.0 DEFINITION 3.1 For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows: 3.2 OWNER / COMPANY - OWNER of the particular Project (Project Specific). CONSULTANT - The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management. BIDDER / SUPPLIER / VENDORE : The partys which manufactures & / or suppliers materials, equipment, technical documents / drawings and services to perform the duties specified by contractor 4.0 DESIGN 4.1 POWER SYSTEM 4.1.1 Power system shall include the following equipment. Photovoltaic solar cell array (solar panels). Battery bank solar power controller the solar power system shall be self sustained type. The photovoltaic solar cell array (solar panels) and the solar controller shall be sized to meet through battery back-up, the load cycle requirements of the connected loads with the solar energy availability at site under worst weather conditions the load requirement per day shall be determined on the basis of load data specified in the Data Sheet.

4.2 SOLAR PANELS 4.2.1 The photovoltaic solar panel array shall consist of required number of individual solar panels. The individual photovoltaic elements shall be connected in suitable series- parallel combinations to obtain the required voltage and current rating of a solar module. Individual solar modules shall be connected in suitable series parallel combinations to obtain the required voltage and current rating of a solar panel. Solar panel array shall consist of required number of panels in series-parallel combination to meet the System requirements.

4.2.2 The Solar panels will be mounted on steel support structure of suitable height on the control room roof top.

4.2.3 The solar panel array shall be designed based upon isolation data (to be gathered by contractor from metrological department) and following design conditions:

a. Output current to be considered at operating point based on following operating conditions: i. Cell temperature while delivering current corresponding to P max point on the I-V curve at specified ambient temperature.

ii. Operating voltage considering: - Charging voltage of the battery. - Voltage drops in cables between solar array and solar, controller and solar controller and

battery. - Voltage losses in solar controller. - Negative tolerance, if any, on the output voltage at solar controller.

4.2.4 After working out the output current at operating point, the following deratiing factors shall be applied:

a. Deterioration factors over life span or 15% whichever is higher. b. Losses due to dust deposit or 1% whichever is higher. c. Losses due to module/branch mismatch or 2% whichever is higher. d. Losses due to line resistance cables (panel to controller). e. Losses in field wiring and array wiring. Losses in solar controller. f. Battery charge/discharge efficiency or 93% whichever is lower. g. Any other de-rating factor considered essential for satisfactory and guaranteed performance of Solar Power System (e.g. negative tolerance on nominal rating of solar panels) h. Derating factor of 2% or as applicable (whichever is higher) to account for panel orientation other than the specified one as per insulation data. i. The solar panels shall be able to fully charge the battery bank after "3 NO SUN DAYS" cycle from the surplus power available from the solar panel in next 14 days with 70% Depth of Discharge of battery.

4.3 BATTERYBANK 4.3.1 BATTERY CELLS a. The battery bank shall be charged from the surplus power available from the solar panel when the sunlight is available and will supply/supplement the solar electric power from the solar panel when the sunlight is inadequate under cloudy condition and during nights. The battery cells shall be low self discharge (up to 3% at 27°C per month) Ni-Cd suitable for photovoltaic application. The battery cells shall be provided with flame arresting type catalytic caps or ceramic plugs. The type

of battery cells shall be as specified in equipment Data Sheet. b. The battery shall incorporate the following features: i. High charging efficiency. ii. Good cycle life even for deep discharge. iii. Extended life expectancy. iv. Long maintenance interval Maintenance free for VRLA battery cell. v. Large electrolyte reservoir. c. The type, AH capacity and no. of cells in the battery bank shall be decided on the following basis: i. Geographical and climatic conditions prevalent at site. ii. Back-up during low insulation periods considering the de-rated solar panel output and insulation data. iii. Unless specified otherwise, the system voltage shall be 12 V (Nominal).

iv. Battery suitable for 4000 or more charge-discharge cycle for 10% depth of discharge and for 1600 or more charge discharge cycle for 70% depth of discharge. v. 70% Depth of Discharge. vi. Minimum 3 days back up to independently feed the load, plus, losses, if, any. vii. Design ambient temperature minimum and maximum site temperatures as given in Specification -“Site Conditions and Climate". viii. Deterioration-factor over the life span (Actual or 20% whichever is higher). ix. Weight of individual cell shall be of the order of 55 Kg x. Self discharge during low insulation periods considering average ambient temperature of 30°C.

4.3.2 The battery shall be able to fully charge after ”3 no sun days” cycle from surplus power available from the solar panel in next 14, days with 70% depth of discharge.

4.3.3 General requirements and performance for Ni-Cd batteries shall be as per manufacturer data available in market.

4.4 SOLAR POWER-CONTROLLER 4.4.1 TECHNICAL REQUIREMENTS a. The solar power controller shall regulate the charge of the battery and shall monitor the charging current from the solar array power from the battery set shall be routed through the solar controller. b. The controller shall be provided with low loss type, high efficiency, tested and

tropicalized components with overall loss of the solar controller not exceeding 10%ofthe rated load. MCCBs and MCBs shall be used for the circuit or device protection in place of fuses. However, semiconductor grade fuses shall be used for diodes, SCRs etc.

c. Unless specified otherwise, the solar controller shall be wall mounted type with hinged and gasket door in the front .The cable entry shall be from top or bottom (to be decided at the time of detailed engineering.) through glands and access to all inside equipments shall be from the front only.

d. The supply system shall be suitable for both negative earthed and unearthed system as

required. The provision of negative earthing shall be through an isolating link.

e. Apart from required control elements, the following components/ features shall be provided in the controller as minimum requirements:

i. A 2-Pole MCCB with shunt trip to isolate the solar panel from the solar controller/battery on receipt of 60% LEL signal from the gas detection panel.

(The signal will be in the form of a normally open potential-free contact). ii. The battery bank shall be automatically disconnected from the solar panels when the state of charge of the battery reaches 110% or maximum permissible charge level (as indicated by the battery manufacturer) and from the load when the depth of discharge reaches 70%. The battery bank shall be automatically reconnected to the Solar Panel when the state of charge of the battery drops to 100%. iii. Ammeters to measure load current and solar array current. iv. An array fault indicator to indicate solar array failure. v. Voltmeter to indicate system output voltage and Battery voltage. vi. Charge-discharge Ammeter. vii. Battery deep discharge alarm and indication. viii. Control circuit fail alarm and indication. ix. Switches mounted on the front to disconnect all alarms and indications. x. Necessary transducers for providing two wire 4-20 mA signals for the following parameters: - Battery voltage - Solar array current - Battery charging current - Load current - Solar panel fault indicators xi. Current limiting features with active elements. xii. Voltage regulator shall be switching mode type. xiii. Digital Ampere hour meter. f. Protection features to take care of faults in DCDB bus, solar controller, solar panel, battery circuit etc.

4.5 GENERAL REQUIREMENTS 4.5.1 BUS BARS Bus bars shall be sufficiently sized and adequately braced for the supply conditions specified in data sheet. The bus bars shall be electrolytic copper and shall be sleeved with 1100V grade flame retardant PVC. Bus joints shall be bolted type and insulated by flame-retardant insulation tape.

4.5.2 EARTHING An earth bus bar made of electrolytic copper shall be provided, running the complete length of the solar controller. All non current carrying parts shall be bonded with flexible copper wires with the earth bus. The earth bus shall have provisions at both ends for connecting it to earth grid conductor.

4.5.3 SEGREGATION All electrical devices and live parts in the solar controller panel shall be segregated by means of metallic screens. All power connections in case of solar controller shall be segregated from one another and from the electronic circuits

4.5.4 CABLING All interconnecting cables between various solar panels and main JBs, included in scope of supply, shall be Flame Retardant Low Smoke (FRLS) type. Cables of sizes, as specified, connecting JBs to solar controller, solar controller to battery shall be supplied by contractor.

Adequate space shall be provided for termination of external cables. All required Nickel Chromium plated brass double compression cable glands and tinned copper lugs shall be included in the scope of supply.

4.5.5 MATERIALS AND FINISH All materials shall be selected and finished to resist the site conditions and climate specified.

All electronic circuit boards shall be tropicalised to prevent corrosion and fungus growth. Painting shall be suitable for the requirements specified in Specification.

4.5.6 IDENTIFICATION All solar panels, batteries, solar controller and related devices and materials shall have permanent tags in contrasting colours affixed on them and lettering of at least 12 mm size. The tag inscription shall be in line with the equipment number list.

5.0 FABRICATION 5.1 PANEL CONSTRUCTION 5.1.1 The Solar modules shall have suitable encapsulation and sealing arrangements to protect the Silicon elements (Cells) from the environment. The arrangement and material of encapsulation shall be compatible with the thermal expansion properties of the silicon cells and the module framing arrangement/material. The encapsulation arrangement shall ensure complete moisture proofing for the entire life of the solar modules.

5.1.2 The solar panel shall have suitable supporting arrangement complete with adjustable mounts, solar module fixing accessories, inter-module connections, cable termination arrangement, double compression, nickel/chromium plated, brass cable glands and all other necessary equipment and hardware. The supporting arrangement shall be such as to utilize minimum space on the control room roof top. Unless specified otherwise width of the walkway is 1600mm. The panel dimension and its supporting structure shall be so sized as to leave a clear walking space of minimum 750mm. Materials used in the construction of panel frame to support the solar modules, supporting structure and all other accessories shall be suitable for location in extremely corrosive, dusty environment to be encountered. The solar module framing

shall be copper free aluminum alloy. Arrangement, such as, vertical stainless steel rods or flexible rods shall be provided to prevent bird landing on the panels. Each panel shall be provided with a weatherproof Junction box with minimum IP 55 enclosure with removable gasket front cover for termination of external cables. The electrical terminals in the junction box shall be corrosion proof and anti-loosening type. Suitable bypass diodes shall be provided for partial shadowing of modules, if recommended by manufacturer.

6.0 INSPECTION AND TESTING 6.1 All tests shall be carried out as per relevant Standards at Vendor's works. 6.2 The Consultant/Owner reserves the right to have a representative to witness the final testing and inspection. Prior intimation of at least 20 days shall be given to enable the Consultant/Owner depute its representative to witness the tests.

6.3 Testing and inspection shall include but not necessarily limited to the following: 6.3.1 GENERAL (FOR ALL ITEMS) a. A quantitative check to ensure that all items in specified quantity are present. b. A visual inspection to check workmanship and compliance with submitted drawings. c. Dimensional checks. 6.3.2 SOLAR PANELS a. Following environmental tests shall be carried out on photovoltaic modules on sampling basis. Minimum 2% of ordered modules or 1 no. Module, whichever is higher, shall be subjected to following tests and performance of module before and after each test shall be tabulated and furnished. The tests shall be carried out sequentially on each module selected for testing and the tested module shall be discarded after tests. b. In case on account of testing: i. The overall deterioration in the performance of the tested modules after test exceed 5% of rated performance, or ii. The tested module exhibits any open circuits and or ground faults, or iii. The tested module develops cracks or mechanical damage, or iv. The tested module fails to pass the electrical isolation tests c. The entire ordered lot of modules shall be rejected. S.No Test Test Details 1. Cold Temp. : (-) 40°C

Duration : 16 Hrs. 2. Rapid Change of

Temperature Low Temp.: (-)40°C High Temp:+ 85°C

No. of cycles :10 Duration of Exposure:30 Min.

3. Dry heat Temp. : 85°C Duration : 16 Hrs.

4. Salt mist Temp. : + 35°C Duration : 48 hrs. 5. Wind Pressure equivalent to an air velocity of 280km/hr. 6. Rain Test as required in the mentioned Standards 7. Dust Test as required in the mentioned Standards 8. Composite

/Humidity Test Test as required in the mentioned Standards.

9* Mould Growth 84 days 10* Hail Storm test Test as required in the mentioned Standard 11 * Shock Test Peak Acceleration : 490m/sec 2 Duration : 11

msec.

* Vendor shall submit the test procedure for Owner's review. Vendor shall indicate test conditions like temperature limits and duration etc. and also mention the name of the applicable standards.

d. The following design qualification tests shall also be conducted: i. Earth continuity test. ii. Electrical isolation test. iii. * Hot spot endurance test.

NOTE: Type test certificate can be accepted for the tests marked with asterisks (*). 6.3.3 SOLAR CONTROLLER Tests in the following order shall be conducted for the panel : a. General b. Earth Continuity Test c. Functional Tests d. Insulation Resistance Measurement e. Heat Run Test f. Insulation Resistance Measurement g. Functional Test

6.3.4 Burn out tests for 120 hrs. On the complete system in one assembly.

7.0 MARKING, PACKING AND SHIPMENT The offered equipments along with accessories shall be shipped to site packed in wooden crates. They shall be wrapped with polythene sheets, before being placed in the crates to prevent damage to finish. Crates shall have skid bottom for handling.

STANDARD SPECIFICATION FOR

FLAME PROOF LIGHTING AND POWER PANELS

ABBREVIATION

BIS/IS Bureau of Indian standards IEC International Electro-Technical Commission BS British Standards IEEE Institute of Electrical and Electronics Engineers NEMA National Electrical Manufacturers Association OISD Oil Industries Safety Directorate CCE Chief Controller of Explosive DGMS Director General Mines Safety IE Rules Indian Electricity Rules CPRI Central Power Research Institute TPN Triple Pole Neutral SPN Single Pole Neutral FRP Fiber Reinforced Concrete SS Stainless Steel

GI Galvanized Iron

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE .........................................................................................

2.0 REFERENCE DOCUMENTS .......................................................

3.0 DEFINITIONS ...............................................................................

4.0 MATERIALS ................................................................................

5.0 DESIGN .......................................................................................

6.0 FABRICATION .............................................................................

7.0 INSPECTION AND TESTING .......................................................

8.0 MARKING, PACKING AND SHIPMENT ......................................

1.0 SCOPE This Specification covers the requirements of design, manufacture, testing, packing and supply of flameproof Lighting and Power panels/ accessories suitable for installation in locations handling flammable liquids and gases.


2.1 The equipment shall comply with the requirements of latest revision of the following standards issued by BIS (Bureau of Indian Standards), unless otherwise specified:

IS-5: Colours for ready mixed paints and enamels.

IS-1248 (Parts 1 & 2): Direct acting indicating analogue measuring instruments and their accessories. IS-2148: Flameproof enclosures for electrical apparatus. IS-5571: Guide for selection of electrical equipment for hazardous areas

IS-8828: Specifications for Circuit breakers for Over current protection for household and-similar installations

IS-12640: Residual current operated circuit breakers. IS-13346: General requirements for electrical apparatus for explosive gas atmosphere.

IS-13408 (Part-1): Code of practice for the selection, installation and maintenance of electrical apparatus for use in potentially explosive atmospheres (other than mining applications or explosives processing and manufacture).

IS-13947 (Parts 1 & 5): L.V. Switchgear and Control gear. 2.2 Imported equipment shall conform to the International Standards such as IEC/ BS/ VDE/ NEMA or equivalent.


2.4 In case Indian Standards are not available for any equipment; Standards issued by IEC/BS/VDE/ NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred Standards/ Specifications/ ata Sheet and statutory regulations, the following order of decreasing priority shall govern:

a. Statutory Regulations b. Data Sheets c. Job Specification

d. Standard Specification e. Codes and Standards. 3.0 DEFINITIONS

3.1 For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows:

OWNER / COMPANY OWNER of the particular Project (Project Specific).

CONSULTANT The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management.

BIDDER / SUPPLIER / VENDOR The party(s) which manufactures and / or supplies material, equipment, technical documents / drawings and services to perform the duties specified by Contractor. 4.0 MATERIAL

4.0 The enclosures of the lighting and power panels shall be made of cast light metal alloy and shall be free from frictional sparking hazard. The magnesium content in the alloy shall be as per IS-13346.

5.0 DESIGN 5.1 GENERAL REQUIREMENTS 5.1.1 The offered equipment shall be brand new with state of art technology and proven field track record. No prototype equipment shall be offered.

5.2 POWER SUPPLY 5.2.1 Unless otherwise specified, lighting and power panels shall be suitable for 415V, 50Hz, three phase and neutral (TPN) incoming supply and outgoing circuits for 240V, single phase and neutral (SPN).

5.2.2 For lighting and power panels falling under the jurisdiction of DGMS, the following additional requirements shall apply:

a. The phase-to-phase voltage shall not exceed 250 volts. b. The panels shall have 415V, three phase, 4-wire system. c. Earth leakage protection shall be provided for all outgoing circuits, which shall isolate both poles.

5.3 TECHNICAL REQUIREMENTS

5.3.1 COMPOUND SPECIFICATION

a. Busbars in the lighting and power panels shall be made of high-conductivity copper and shall be supported by non-hygroscopic insulators. Busbars shall be colour coded for identification of phases and neutral.

b. Unless otherwise specified, the incomer shall have one no. 4 pole 40A MCB isolator (without overload and short-circuit release) and one no. 4 pole ELCB. ELCB’s shall have a maximum sensitivity of 30mA.

c. Unless otherwise specified, the outgoing feeders shall be provided with double pole 10A MCBs having overload and short-circuit releases.

d. Unless otherwise specified, all MCBs (except isolators) and ELCBs shall be with 9kA (M9. category) interrupting capacity.

e. The ELCB. shall be hand reset type one no. door mounted reset push button shall be provided.

f. The operating knobs (ON/ OFF/ RESET) shall be. provided with a suitable rack and pinion arrangement for operating them smoothly from outside.

5.3.2 TERMINAL & WIRING

a. The panels shall be provided with sufficient number of terminals. More than 2 wires per terminal shall not be permitted. If required, additional terminal with shorting link may be used. Unless otherwise specified, the terminals for termination of incoming and outgoing external cables shall be suitable for termination of upto 70 mm² and 6 mm² copper conductors respectively. Terminals shall be suitable for termination of solid conductors upto 6 mm² and stranded conductors above 6 mm². Wherever lugs are required for cable termination, tinned copper type lugs shall be provided.

b. All internal wiring in lighting and power panels shall employ adequately sized, 660V grade, PVC insulated copper conductor wires, colour coded for phase, neutral and earth, with minimum conductor sizes as below:

i. Incomer 16 mm² ii. Outgoing 2.5 mm²

6.0 FABRICATION

6.1 The enclosures of the lighting and power panels shall be made of cast light metal alloy and shall be free from frictional sparking hazard. The magnesium content in the alloy shall be as per IS-13346. The temperature of external surfaces shall be limited to 200°C, unless otherwise specified. The enclosures shall be sized to facilitate easy maintenance and heat dissipation.

6.2 The panels shall be suitable for use in outdoor open locations and shall have IP-55 degree of protection. They shall preferably be provided with integral canopy. However, where the enclosure has been certified without integral canopy, a separate canopy can be accepted. The separate canopy shall be made of at least 14 SWG (2mm) galvanised sheet steel or FRP. The canopy shall be suitable for providing protection against rain from top and two sides.

6.3 The lighting and power panels shall be provided with gaskets made of non- inflammable and self-extinguishing material.

6.4 The enclosures shall be treated and prepared for painting with two coats of epoxy paint with final colour shade (both internal and external) as below:

Flame proof (Gas groupIIA/IIB) : Dark admiralty

grey shade 632 of IS-5 Flame proof (Gas group IIC) : Light yellow

shade 355 of IS-5

6.5 A warning inscription "Isolate power supply elsewhere before opening" shall be provided on each enclosure. The warning inscription shall be embossed on the enclosure or a separate warning plate with above inscription shall be fixed to the enclosure with screws. The warning shall be of nickel plated brass or stainless steel. accessories like nuts, bolts, washers etc. shall be made of stainless steel SS-304.

6.6 All the non-current carrying metallic parts of the panel shall be inherently bonded together. Each lighting and power panel shall be provided with two earthing studs with lugs on the exterior of the panel enclosure suitable for termination of 10 mm dia GI wire rope.

6.7 Each outgoing feeder shall be provided with distinct terminals for phase, neutral and earth. The terminal block enclosures shall be adequately sized to properly terminate the cables by taking into account the required bending radii of cable cores and shall have the following minimum gland to terminal distances.

Conductor size

Up to 2.5mm² Above 2.5mm²

& up to 10mm²

Above 10mm²

& up to 35mm²

Above 35mm² &

upto 70mm²

Distance 40 mm 60 mm 100 mm 150

6.8 The panels shall be provided with suitably sized cable entries at the bottom/ sides, for incoming and outgoing cables. Panels shall be complete with double compression type nickel plated brass flameproof cable glands. Flameproof nickel plated brass sealing plugs shall be supplied, for plugging the unused cable entries. The quantity of sealing plugs shall be equal to 20% of the total number of outgoing cable entries.

6.9 The panels shall have external fixing lugs for mounting on wall or column. The holes, provided on these lugs shall be of oblong type.

6.10 A nameplate indicating TAG No. shall be provided on each panel Nameplates shall also be provided for each incoming and outgoing feeder Separate nameplate shall also be provided to indicate the details of testing agency (CIMFR or equivalent), test certificate no. with date, statutory approval no. with date and agency (PESO/ CCE/ DGFASLI/ DGMS), BIS license

number and date, applicable gas group etc. The nameplates shall be engraved on 3 ply black white black lamicold Sheds using square cutters. Black engraved perspex sheet nameplate shall also be acceptable. Nameplates shall be fixed by screws and shall not be pasted. In case the standard details given above are embossed on the enclosures, the same need not be repeated on the name plate.


7.1 During fabrication, the equipment shall be subjected to inspection by Consultant/ Owner -or by an agency authorised by the Owner, if specified/ agreed in Inspection Test Plan. Manufacturer shall furnish all necessary information concerning the supply to Consultant / Owner's inspector. All routine/ acceptance tests shall be carried out at manufacturer's works under his care and expense. .

7.2 Type test certificates from CIMFR or equivalent test house, applicable PESO/ CCE/ DOFASLI/ DGMS approval, certificates, BIS license and original drawings referred in type test Certificates shall be shown to the inspection agency on demand during inspection. The certificates and BIS license must be valid at the time of despatch.

7.3 Test certificates of bought out components shall be shown to the inspection agency on demand during inspection.

7.4 All equipments shall be subjected to various acceptance tests as per standards but not limited to the following:

a. General visual inspection b. Dimensional inspection c. Verification of electrical operations d. Dielectric tests e. Routine pressure test as per IS-2148 f. Any other routine and acceptance test as per applicable Standards. 7.5 Type tests shall be carried out if specified in Data Sheet/ job Specification. 7.6 CERTIFICATION 7.6.1 The equipment shall have test certificates issued by recognised independent test house (CIMFR/ CPRI/ ERTL/ Baseefa/ LCIE/ UL/ FM or equivalent). All indigenous equipment shall conform to Indian standards and shall be certified by Indian testing agencies. All equipment (indigenous & imported) shall also have valid statutory approvals as applicable for the specified location. All indigenous flameproof equipment shall have valid BIS license and parking as required by statutory authorities.

8.0 MARKING, PACKING AND SHIPMENT

8.1 All the equipment shall be divided into several sections for protection and ease of

handling during transportation. The equipment shall be properly packed for the selected mode of transportation, i.e. by ship / rail-or trailer and shall be wrapped in polythene sheets before being placed in crates/ cases to prevent damage to finish. The crates / cases shall have skid bottom for handling. Special notations such as `Fragile', This side up, `Center of gravity', `Weight', `Owner's particulars', `PO no.' etc, shall be clearly marked on the packages together with other details as per Purchase Order.

8.2 The equipment may be stored in a covered shed for long periods before installation. The packing should be suitable for such storage.

STANDARD SPECIFICATION FOR LIGHTING FITTINGS FOR HAZARDOUS LOCATIONS

ABBREVIATION

BIS/IS Bureau of Indian standards IEC International Electro-Technical Commission BS British Standards IEEE Institute of Electrical and Electronics Engineers NEMA National Electrical Manufacturers Association OISD Oil Industries Safety Directorate CCE Chief Controller of Explosive DGMS Director General Mines Safety IE Rules Indian Electricity Rules CPRI Central Power Research Institute CIMFR Central Institute of Mines and Fuel Research MSL Mean Sea Level

TABLE OF CONTENTS

SL NO. DESCRIPTION .

1.0 SCOPE ...........................................................................................................................

2.0 REFERENCE DOCUMENTS .........................................................................................

3.0 DEFINITION ...................................................................................................................

4.0 DESIGN .........................................................................................................................

5.0 FABRICATION (TECHNICAL REQUIREMENT) ............................................................

6.0 INSPECTION, TESTING & ACCEPTANCE ...................................................................

7.0 PACKING & SHIPMENT ................................................................................................

1.0 SCOPE

1.1 The intent of this specification is to define the requirements of lighting fixtures and accessories suitable for installation in classified hazardous locations.


2.1 In general the equipment covered by this Specification shall, unless otherwise specified, conform to the latest edition of Indian Standards/International Standards but not limited to the following:

a. IS-2148 Flameproof enclosures for electrical apparatus

b. IS-5572 (Part-1) Classification of

hazardous area (other than mines) for electrical

installation.

c. IS-5571 Guide for selection of electrical equipment for hazardous areas. d. IS-8239 Classification of maximum surface temperature of electrical

equipment for use in explosive atmosphere. e. IS-6381 Construction and testing of electrical apparatus with type of protection IS-8289 Electrical equipment with type of protection 'n'.

IS-2206 (Part 1 to 4)

Flameproof electric lighting fittings (well glass and bulk head type, fittings using glass tubes).

IS-8224 Electrical lighting fitting for division 2 areas.

IS-1913 (Part-I)

General and safety requirements for Luminaires.

Wherever the requirements in this specification are in conflict with any of the above Standards, the requirements under this specification shall be binding.

3.0 DEFINITION


OWNER / COMPANY OWNER of the particular Project (Project Specific). CONSULTANT The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management.

BIDDER / SUPPLIER / VENDOR


4.0 DESIGN 4.1 GENERAL 4.1.1 The equipment shall be suitable for installation and satisfactory operation in classified hazardous locations in tropical, humid and corrosive atmosphere as prevalent in refineries/petrochemical plants or as specified in Material Requisition / Data Sheet. If not specifically mentioned therein, design ambient temperature of 40°c and altitude not exceeding .1000 m above MSL shall be considered.

4.1.2 Unless otherwise specified, equipment' shall be suitable for 220 - 250 volts, single Phase and neutral, 50Hz. +3% power supply.

4.1.3 All equipment shall be tested and certified by independent authority for use in specified gas group locations. Certification number/data and gas group/temperature classification must be indicated on the manufacture’s name plate on each item. All flameproof equipments shall have BIS marking which must be indicated on the manufacturer’s name plate. All equipment for use in hazardous area shall be approved by CCE/DGMS as applicable.

4.1.4 POWER SUPPLY Unless otherwise specified, equipment shall be suitable for 220 – 250 volts, single phase and neutral, 50Hz + 3% power supply.

5.0 FABRICATION (TECHNICAL REQUIREMENT)

5.1 All equipment shall be suitable for use in outdoor open locations and shall have IP55 degree of protection.

5.2 The body of the lighting fixtures, control gear box and junction boxes shall be of cast aluminium LM-6 alloy and shall be free from frictional sparking hazard. The temperature rise of external surfaces shall be limited to 200°c, unless otherwise specified.

5.3 LIGHTING FIXTURES 5.3.1 The construction of lighting fixture shall be such that replacement of lamp or any normal maintenance of fixture shall not affect their suitability for use in classified area.

5.3.2 Glass used for lighting fixture shall he clear suitable for use under conditions involving exceptional risk of mechanical damage. 5.3.3 Well glass lighting fixture for zone-2 classified area shall meet requirement of IS 6381. Mechanical strength of well glass shall satisfy requirement of IS-2206 (for type A glass) for flame proof lighting fixtures and IS-6381 for Div.2 lighting fixtures. All well glass fixtures shall he provided with a galvanised steel wire protective cage having mesh dimensions not exceeding 50mm.

5.3.4 Glass used for aviation and navigational lighting fixture shall be coloured in itself. Painted glass shall not be accepted.

5.3.5 Glass shall be of approved make or as specified in Material Requisition. 5.3.6 The fixing parts of the enclosure which is to be opened for replacement of bulb shall be so fastened that they can be unfastened only with special tools. All fixtures shall carry a special warning inscription in English "Isolate supply elsewhere before opening".

5.3.7 All lighting fixtures which are not certified as flameproof construction but approved for use in Zone-2 area shall have approved enclosed break lamp holder and complete enclosure certified as having restricted breathing type construction. Lamp holder shall he screw type.

5.3.8 All lighting fixtures suitable for .discharge lamps shall be provided with one 3/4 "ET threaded entry and supplied with .approved type double compression nickel plated brass cable gland.

5.3.9 All lighting fixtures suitable for incandescent lamps shall be provided with two 3/ "ET threaded entry. Two entries shall be used 'for looping of circuit 'wherever required. The fixtures shall be supplied with approved type two double compression nickel plated brass cable glands and one threaded plug for sealing unused entry.

5.3.10 The top of all well glass lighting fixtures shall be identically drilled / threaded to facilitate the installation on pole/column or ceiling.

5.3.11 All flood lighting fixtures shall be supplied with adjustable mounting arrangement both in horizontal and vertical plane.

5.4 CONTROL GEAR BOX 5.4.1 Lighting fixtures suitable for discharge lamps shall be provided with power factor, correction capacitor, choke starter to be housed .in separate control gear box. The choke shall be copper wound. .The complete control gear shall have power factor not less than 0.9. All components shall be of approved make or as specified in Material Requisition.

5.4.2 Control gear box shall be provided with three 3/4 ET threaded entry (Incoming supply to lighting fixture and for looping to other Fixture/Control gear box). The control gear box shall be supplied with approved type three double compression nickel plated brass cable glands and one threaded plug for sealing unused entry. 5.4.3 Control gear box for flame proof fixtures shall be flameproof type and for div.2 or increased safety fixtures shall be increased safety type unless specified otherwise in the material requisition.

5.5 JUNCTION BOXES 5.5.1 The junction boxes shall be 3 way or 4 way type as specified in material requisition. All junction boxes for looping of single phase lighting circuits using cables upto 4mm shall he minimum 100mm dia in size. Each junction box shall be complete with requisite number of ET

threaded cable entries and with approved type double compression nickle plated brass cable glands and one threaded plug for sealing unused cable entry.

5.6 TERMINALS & WIRING 5.6.1 All equipments shall he provided with sufficient number of terminals. More than 2 wires per terminal shall not be permitted. If required, additional terminal with shorting link may be used. Each terminal for external cable connection shall be suitable for termination of 4mm2 copper conductor or as specified in material requisition using crimped type tinned copper lugs. All terminals shall be of nonsparking, anti-loosening design such that they do not produce any arc or spark in normal operation.

5.6.2 Flexible wires used for internal wiring shall be minimum 1.5mm2 copper conductor and connections, shall he done using crimped type tinned copper lugs.

5.6.3 Terminals shall .be of approved make or as specified in Material Requisition. 5.6.4 All equipments on single phase supply shall be provided with an independent earth terminal inside the enclosure for connecting the earth core of the cable and shall have facility for looping.

5.6.5 All the hardwares shall be cadmium plated whereas clamps and supporting brackets shall be hot dip galvanised. The galvanising shall be 610gms/m for clamps and 900gms/m2 for supporting brackets. All gaskets shall be of neoprene.

5.6.6 External surfaces of all the equipments shall be treated and prepared for painting with two coats of epoxy paint to shade 632 as per IS-5.

6.0 INSPECTION, TESTING & ACCEPTANCE

6.1 During fabrication, the equipment shall be subjected to inspection by Consultant / Owner or by an agency authorised by the Owner. Manufacturer shall furnish all necessary information concerning the supply to Consultant / Owner's inspector. Tests shall be carried out at manufacturer's works under his care and expense. 4 weeks prior notice shall be given before date of commencement of test for witnessing by Consultant / Owner's authorised representative. The test certificate indicating test result shall be furnished. 6.2 CMRS test certificates along with CCE/DGFASLI/DGMS approval certificates as applicable shall be furnished for each type of fixture. All equipments shall be routine tested as per applicable Indian standards.

6.3 During inspection, facility shall be provided for impact testing of random sample. One well glass of each fixture type from each lot shall be tested for impact strength

7.0 PACKING & SHIPMENT 7.1 The equipment shall he shipped to site packed in wooden crates. They shall be wrapped in polyethylene sheets before being placed in crates to prevent damage to the finish. The crates

shall have skid bottoms for handling.

STANDARD SPECIFICATION FOR CORROSION SURVEY

ABBREVIATION

ROU Right of Use EHC Extra High Voltage HV High Voltage

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE .........................................................................................


3.0 DEFINITION .................................................................................

4.0 GENERAL ....................................................................................

5.0 SOIL RESISTIVITY SURVEY .......................................................

6.0 TESTS ON SOIL SAMPLES ........................................................

7.0 ADDITIONAL DATA COLLECTION .............................................

8.0 REPORT ......................................................................................

1.0 SCOPE

1.1 The Specification covers the requirements for corrosion survey including measurement of soil resistivity, chemical analysis of soil / water and collection of other cathodic protection related data along ROU of the pipelines.

2.0 REFERENCE DOCUMENTS 2.1 Equipment and measurement techniques shall unless otherwise specified, conform to the requirement of latest revisions of following applicable Standards:

- BIS Specifications - BS Specifications and codes of practice - NACE publications 2.2 The work shall be carried out in compliance with all applicable local laws and regulations.

2.3 In case of any contradiction between various referred Standards/Specifications/Data Sheet and statutory regulations the following order of priority shall govern:

- Statutory regulations - Data Sheets - Job Specification - This Specification - Codes and Standards. 3.0 DEFINITION


OWNER / COMPANY OWNER of the particular Project (Project Specific). CONSULTANT The party which is doing engineering, procurement, construction, pre-commissioning and assistance for

commissioning, monitors and controls the overall project management.



4.0 GENERAL

4.1 This Specification defines the basic guidelines for carrying out the corrosion survey. Contractor shall be responsible for providing necessary data interpretation based on corrosion survey measurements, which is intended to form a basis for design of cathodic protection system for the pipeline.

5.0 SOIL RESISTIVITY SURVEY 5.1 Unless otherwise specified the soil resistivity measurements shall be carried out at intervals of approximately 500 m along the ROU. Where soil resistivity is less than 100 ohm. m and two successive readings differ by more than 2:1 then additional soil resistivity readings in between the two locations shall be taken.

5.2 To carry out the soil resistivity measurement Wenner's 4 pin method or approved equal shall be used. The depth of resistivity measurement at each location shall be at around 1 m and at the burial depth of the pipeline accounting for the cuttings /fillings or 2 m approximately whichever is higher. At locations where multi layer soil with large variation in resistivity / corrosiveness is expected and /or locations specifically advised by Owner or his representative resistivity measurements at additional depth of up to 3 m (approx) or more shall be taken. In general the resistivity of soil, which shall be surrounding the pipe, shall be measured. Hence the depth of measurement / electrode spacing may vary depending on topography and strata at the area.

5.3 At places where ROU has not yet been cleared, measurements shall be made right over the centre line of pipeline route surveyed accounting for the cuttings /fillings also.

5.4 Observations shall be made enclosing the soils adjoining the trench wherever pipeline trenching has already been done.

5.5 The observations shall be made enclosing the soil immediately surrounding the pipeline route where ROU has been cleared but trenching has not been done.

5.6 All measurements shall be taken at right angles to the ROU unless otherwise asked by Owner or his representative at site.

5.7 At places in ROU where other pipelines are already existing care shall be taken to precisely locate such pipes line and take such precautions that observations are not adversely affected by presence of such pipelines.

5.8 Care shall also be taken that the observations are not influenced by presence of other earth currents in the area especially in the vicinity of EHV/HV lines and plants using earth return in their source of power etc.

5.9 Wherever possible / advised by Owner or his representative, depth of water table shall be determined by resistivity observations. 5.10 All measurements shall be made and recorded in metric units. While recording the data

reference to the nearest intersecting point shall be made. To provide visual representation of variations in the resistivity along ROU, values shall be plotted on semi log graph sheets. The resistivity graph shall also indicate the resistivity at additional depths measured at various locations and depth of water table.

6.0 TESTS ON SOIL SAMPLES

6.1 Soil/water samples shall be collected along the ROU for analysis. Samples shall be collected on an average at one location for every 10 km along ROU with minimum at two locations. Exact locations shall be decided at site depending on the type of soil, soil resistivity and in consultation with Owner or his representative. At each location the soil samples shall be collected at 1 m, 2 m depth and at expected depth of pipeline if it is more than 2 in at the location.

6.2 The collected soil/water shall be analysed to determine presence and percentage of corrosive compounds including carbonates, bicarbonates, nitrates, chlorides, oxygen activity, moisture content and pH value.

7.0 ADDITIONAL DATA COLLECTION 7.1 The following data shall be collected with a view to generate design data for evaluation of cathodic protection interaction possibilities due to presence of other services in ROU and its vicinity:

7.2 Following information regarding foreign service/pipeline in or around the ROU (for existing and those, which are likely to come up during contract execution).

7.2.1 Types of service / pipeline and year of laying. 7.2.2 Diameter and pipeline coating in case of pipeline. 7.2.3 Parallel running / crossing. 7.2.4 Year of laying / commissioning. 7.2.5 Depth of laying. 7.2.6 Type of existing cathodic protection systems (impressed-current / sacrificial). 7.2.7 Location and type (Deep well / surface) of anode ground bed. 7.2.8 Rating of impressed current type of anode ground bed. 7.2.9 Location of existing CP power supply units and their output voltage, current, pipe to soil potential readings.

7.2.10 Location of existing test stations.

7.2.11 Remedial measures existing on foreign service/pipeline to prevent interactions. 7.2.12 Graphical representation of existing structure / pipe to soil potential records. 7.2.13 Possibility of integration/isolation of CP system of the foreign service/pipeline with that of the proposed pipeline, which may involve negotiations with owner's of foreign services.

7.2.14 Where, pipeline is likely to "pass close to any existing ground bed (with in 100 m approx), anode-bed potential gradient survey shall .be carried out, to verify possible interference with the CP system of the pipeline covered under this project..,

7.3 Voltage rating, phases and sheathing details of cables running parallel or crossing the ROU.

7.4 Existing .and proposed DC/AC power sources and systems using earth return path such as HVDC substations/ earthing stations fabrication yards with electric welding etc. in the vicinity of the entire pipeline route

7.5 Crossing and parallel running of electrified and non-electrified traction (along with information regarding, operating voltage, AC/DC type etc.) as well as abandoned tracks near ROU having electrical continuity with the tracks in use.

7.6 Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead overhead power lines along with details of voltage, AC/DC type etc.

7.7 Voltage rating, phases, sheathing details of underground power cables, along ROU or in its vicinity.

7.8 Any-other relevant information that may be needed in designing and implementing of proper cathodic protection scheme for the proposed pipeline.

8.0 REPORT 8.1 On completion of all the field and laboratory work an interim report incorporating results generated from surveys, additional data collected, results of test carried out, etc, shall be submitted for comments / approval. The report shall also highlight any adverse impact on performance of sacrificial anodes due to the percentage of corrosive compounds including carbonates, bicarbonates, nitrates, chlorides present in the soil and pH value of the soil noticed during the survey. The final report incorporating comments/missing data shall be furnished for records. The report along with various drawings, graphs etc. prepared in connection with the work shall be submitted along with six prints by the Contractor.

STANDARD SPECIFICATION FORSACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES

ABBREVIATION

AC Alternating current


BIS Bureau of Indian Standards

CP Cathodic Protection

CP TR Cathodic Protection Transformer Rectifier unit.

CMRI Central Mining Research Institute.

CTE Coal To Enamel

DC Direct Current

EHV Extra High Voltage

FBE Fusion Bonded Epoxy

HDD Horizontal Directional Drilling

HV High Voltage

HVDC High Voltage Direct Current

MOV Motor Operated Valve

NACE National Association of Corrosion Engineers

PE Polyethylene

SV Sectionalizing Valve

ROW Right Of Way

HV High Voltage

CIPS Close Interval Potential logging

DCVG Direct Current Voltage Gradient

Cu / CuSo4 Copper / Copper sulphate reference electrode

Ag / AgCl Silver / Silver chloride reference electrode

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE ........................................................................................

2.0 REFRENCE DOCUMENT ............................................................

3.0 DEFINITION.................................................................................

4.0 DESIGN .......................................................................................

5.0 MATERIAL ..................................................................................

6.0 INSTALLATION ...........................................................................

7.0 INSPECTION, TESTING AND COMMISSIONING .......................

8.0 INTERFERENCE MITIGATION ...................................................

9.0 SYSTEM MONITORING ..............................................................

10.0 CLOSE INTERVAL POTENTIAL LOGGING SURVEY (CIPS) ....

1.0 SCOPE

1.1 This Specification defines the requirements of design, engineering, installation, testing and commissioning of sacrificial anode cathodic protection system for external surface of cross country onshore underground pipelines / structures including supplementing of corrosion survey, investigation for interference / interaction problems and mitigation of the same.

1.2 This Specification defines the basic guidelines to develop a suitable sacrificial anode cathodic protection system for the pipelines / structures required to be protected. All data required in this regard shall be taken into consideration to develop an acceptable design and for proper engineering of the system.

1.3 Compliance with these Specifications and / or approval of any of the Contractor's documents shall in no case relieve the contractor of his contractual obligations.

2.0 REFRENCE DOCUMENT

2.1 The system design, performance and materials to be supplied shall conform to the requirements of the latest revision of following Standards as a minimum: NACE Standard RP-0169: Standard Recommended Practice Control of External Corrosion on Underground or Submerged Metallic Piping Systems

NACE Publication 10A 190 Measurement technique related to criteria for CP of Underground or Submerged Steel Piping System (as defined in NACE Standard RP0169-83).

NACE Standard RP-0177 Standard Recommended Practice Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems

NACE Standard RP-0286 Standard Recommended Practice The Electrical isolation of Cathodically Protected Pipelines

NACE Publication No. 54276 Cathodic Protection Monitoring for Buried Pipelines.

NACE TM0497 Measurement technique related to criteria for Cathodic Protection on underground submerged metallic piping system

BS 7361 Part I Code of Practice for Cathodic Protection for land and Marine applications.

IS0 15889-1 Cathodic Protection of pipeline transportation system 2.2 In case of imported equipments Standards of the country of origin shall be applicable if these Standards are equivalent or stringent than the applicable Indian Standards.

The equipment shall also confirm to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country.

2.3 In case of any contradiction between various referred Standards / Specifications / Data Sheet and statutory regulations the following order of priority shall govern:

a. Statutory regulations.

b. Data Sheets.

c. Job Specification.

d. This Specification.

e. Codes and Standards.

3.0 DEFINITION 3.1 For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows:

Owner / Company OWNER of the particular Project (Project Specific). Consultant The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management. Bidder / Supplier / Vendor The party(s) which manufactures and / or supplies

material, equipment, technical documents / drawings and services to perform the duties specified by Contractor.

Anaerobic Lack of free oxygen in the electrolyte adjacent to a metallic structure Blistering (of paint film) Formation of swelling on the surface of an unbroken

paint film by moisture, gases or the development of corrosion products between the metal and paint film.

Cathodic disbanding Failure of adhesion between a coating and metallic surface that is directly attributed to cathodic protection conditions and that is often initiated by a defect in the coating system, such as accidental damage, imperfect application or excessive permeability of the coating. Current Density The current to or from a unit are of electrode surface. Foreign structure Any metallic structure that is not intended as a part of a system under cathodic protection Holiday A defect in a protection coating at which metal is exposed. This may, in some cases, be small as possible. Instantaneous off potential

The structure-to-electrolyte potential measured immediately after the synchronous interruption of all sources of applied cathodic protection current

DESIGN

Unless otherwise specified in the Data Sheet, following parameters shall be used for design of cathodic protection system.

4.0 SYSTEM IMPLEMENTATION 4.0.1 All work to be performed and supplies to be effected as a part of contract shall require specific review by Owner or his authorized representative. Major activities requiring review shall include but not be limited to the following:

a. Corrosion survey data interpretation report and. design basis for CP system.

b. CP system design package. (Including calculation for CP system)

c. Detailed engineering package

d. Field testing and commissioning procedure,

e. Procedures for interference testing and mitigation.

f. Close interval potential logging survey and system monitoring procedures:

g. As built documentation

4.1 CORROSION SURVEY 4.1.1 The details of corrosion survey including soil resistivity data along ROW and other data required for CP design if available with the Owner shall be included as part of project Specification / Data Sheet. However, verification of its veracity and adequacy shall be the entire responsibility of the contractor. Contractor shall also carry out soil resistivity survey at sacrificial anode ground bed locations for proper design of ground beds as specified in Data Sheet. Wenner's 4-pin method or approved equal shall be used for such measurements. Survey instruments shall have maximum AC and DC ground current rejection feature.

4.1.2 Care shall be taken to ensure that the resistivity observations are not influenced by the presence of foreign pipelines / structures, and earth currents in the vicinity of EHV / HV lines and installations using earth return in their power system etc.

4.1.3 Where specified in the project Specification / Data Sheet, the contractor shall carry out corrosion survey along the ROW of the pipeline conforming to the Specifications included in the tender document.

4.2 ADDITIONAL DATA TO BE COLLECTED 4.2.1 The following data shall be collected to generate design data for evaluation of interaction / interference possibilities due to presence of other services in ROW / in vicinity. Owner shall provide assistance for liaison work to the extent possible.Route and types of foreign service / pipeline in and around or crossing the right of way (including those existing and those which are likely-.to come up during contract execution).

4.2.2 Diameter, wall thickness, pressure, soil-cover, and coating scheme used, type of cathodic protection system provided, if any and year of laying / commissioning in case of foreign pipelines.

4.2.3 Details of the existing cathodic protection systems protecting the services i.e. type of protection, location, type, rating of anode beds, test station locations and their connection schemes. Present output current and voltage readings of the CP power supply units.

4.2.4 Remedial measures existing on foreign pipelines / services to prevent interaction. Graphical representation of existing structure/ pipe to soil potential records.

4.2.5 Possibility of integration/isolation of CP systems, which may involve negotiations with owners of other services.

4.2.6 Information on existing and proposed DC/AC power sources and systems using earth return path such as HVDC substations/ earthing stations, fabrication yards with electric welding etc. in the vicinity of the entire pipeline route.

4.2.7 Crossing and parallel running of electrified and non electrified traction (along with information regarding operating voltage; AC / DC type etc) as well as abandoned tracks near ROW having electrical continuity with the tracks in use.

4.2.8 Crossing or parallel running of any existing or proposed 11 KV and above AC / DC overhead power lines along with details of voltage, AC / DC type etc.

4.2.9 Voltage rating phases sheathing details of-underground power cables running along ROW or in its vicinity.

4.2.10 Any other relevant information that may be needed in designing and implementing proper protection.

4.2.11 Contractor shall conduct necessary potential gradient surveys for any existing anode ground beds that may interfere with the CP system of the pipelines covered under this project.

4.3 REPORT 4.3.1 On completion of all fieldwork, a report incorporating all the results generated from surveys and details of additional data collected shall be prepared. The report shall also contain detailed interpretation of survey results and resistivity data enclosed, probable interference prone areas etc. to form design basis for the scheme of cathodic protection. This report shall also include various drawings prepared in connection with the above work. The soil resistivity values shall be plotted on semilog graph sheets.

4.4 CATHODIC PROTECTION DESIGN PARAMETERS 4.4.1 Unless otherwise specified in the Data Sheet, following parameters shall be used for design of cathodic protection system.

4.4.2 Where the cathodic protection system is specified for temporary protection, those parts of sacrificial anode cathodic protection system, which will be integrated, with the permanent CP system shall be designed based on permanent CP parameters.

4.5 PROTECTION CURRENT DENSITY 4.5.1 Pipelines having coal tar enamel (CTE) coating with two / three layers of reinforcement

Pipeline surrounding

Minimum protection Current Density

Temporary CP (µ A/m2)

Permanent CP (µ A/m2)

Soil resistivity more than 100 ohm/m 40 200

Soil resistivity 10 ohm m to 100 ohm/m 75 300

Soil resistivity less than 10 ohm/m 500 2000 Sea water 1000 5000

4.5.2 Pipelines having fusion bonded epoxy coating

Pipeline surroundings


Temporary CP (µ A/m2)

Permanent CP (µ A/m2)

Soil resistivity more than 100 ohm/ m 25 90

Soil resistivity 10 ohm m to 100 ohm/ m 35 125

Soil resistivity less than 10 ohm/m 125 500

4.5.3 Pipelines having polyethylene (PE) coating



Temporary CP

(µ A/m2) Permanent CP (µ A/m2)

Soil resistivity more than 100 ohm/m 10 35

Soil resistivity 10 ohm /m to 100 ohm/m 15 50

Soil resistivity less than 10 ohm/m 35 125

4.5.4 The above current density values for temporary CP system are applicable for CP system design life up to two years

4.5.5 Actual current density to be adopted shall be decided based upon soil and other environmental conditions, current drainage survey data (where included in Contractor's scope), proximity of foreign pipe lines/structures and other interference areas affecting the installation. Where considered necessary for satisfactory protection of pipeline the current density shall be suitably increased by contractor.

4.5.6 The pipe protection Current Density indicated as above shall be applicable where the temperature of the fluid transported by the pipeline / the surface temperature of the buried portion of the pipeline does not exceed 30° C, the protection Current Density shall be increased suitably in consultation with the Owner / Company.

4.5.7 At HDD (Horizontal Directional Drilling) crossing, the pipe protection current density applicable for marshy area shall be considered.

Safety factor for current density 1.3 Anode utilisation factor 0.85 for solid anodes 0.6 for ribbon anodes

Pipeline natural potential (-) 0.45V.

4.5.8 Unless otherwise specified in Data Sheet the design life of temporary CP shall be two year and that of permanent CP shall be 30-years

4.5.9 Along the ROW Where soil resistivity is higher than 100 ohm / m temporary CP for the pipeline may not be provided after obtaining specific approval from the Owner.

4.6 CATHODIC PROTECTION DESIGN CRITERIA 4.6.1 Cathodic protection system shall be designed to meet the following criteria: 4.6.2 The pipe to soil potential measurements shall be between (-) 0.95 V (ON) and (-) 1.5 V (ON) for polyethylene coated pipe lines between (-) 0.95 (ON) and (-) 1 7 V (ON) for fusion bonded epoxy/coal tar coated pipe lines with respect to a copper / copper sulphate reference electrode.

4.6.3 A positive potential swing of 100 milli volts or more shall be considered sufficient to indicate the presence of an interaction / interference situation requiring investigation and incorporation of mitigation measures by the Contractor.

5.0 MATERIAL

The system shall include the following major equipment / sub-systems unless otherwise specified in project Specifications.

a. Sacrificial anodes and anode ground beds

b. CP system at cased crossings

c. Test stations

d. Surge diverter and polarisation cell

e. Permanent reference cells

f. Electrical resistance probes

g. Interconnecting cables

h. Cables to pipe connections

All equipment shall be new and procured from approved manufacturers. Equipment offered shall be field proven. Equipment requiring specialised maintenance or operation shall be avoided as far as possible. Prototype equipment shall not be accepted.

Equipment shall conform to the relevant Specifications enclosed with the tender document. All equipment including test stations, anode lead junction boxes etc. shall be located in safe non-hazardous areas.

Where it is essential to install the equipment in hazardous area, such equipment shall be flame proof type and shall meet the requirement of IS: 2148 or equivalent international Standard and shall be suitable for gas group IIB, temperature class T3 (200°C). Indigenous equipment shall be certified by CMRI or any other recognised testing body and shall be approved by the concerned statutory authority. All flameproof equipment shall carry the BIS license marking as per the requirement of

statutory authorities.

All Imported equipment for hazardous area may be tested and certified by an independent certifying agency of country of equipment origin and shall be approved by the concerned statutory authority in India.

5.1 ANODE GROUND BEDS 5.1.1 Along row where soil resistivity predominantly remains low, ranges from 0-10 ohm/ m and pH value is within 9, zinc anodes may be provided.

5.1.2 Anodes of type I as per ASTM-B 418 Standard shall be used for seawater, brackish water or saline electrolyte application and anode of type II as per ASTM-B 418 Standard shall be used for fresh water, back fill and soil applications. Along ROW where soil resistivity is predominantly in the range of 10 ohm/m to 30 ohm/ m, low potential (1.55V) magnesium anodes may be provided.

5.1.3 Along ROW where soil resistivity is predominantly in the range of 30 ohm/m to 50 ohm/m high potential (1.75V) magnesium anodes may be provided.

5.1.4 At high resistivity area where resistivity is of the order of 50 ohm/m and above magnesium ribbon anodes may be provided.

5.1.5 Where magnesium anode is used for protection of polyethylene coated pipelines, the anodes shall preferably of low potential (1.55V) type.

5.1.6 Anodes shall be installed along the pipeline at suitable intervals as per pipeline protection voltage attenuation calculations and ground bed resistance / current output of anode installations. At high resistivity area the magnesium ribbon anodes shall be installed all along the pipeline by the side of the pipeline in the pipeline trench.

5.1.7 Suitability of the selected sacrificial anodes for the soil conditions with particular attention to carbonates, bicarbonates, phosphates and nitrates, shall be checked for proper operation by the Contractor. The anodes shall be laid in proper type of back fill, such that the effect of soil is minimum on the anode effectiveness and life. Suitable safe guards against anode passivation in prevailing soil shall be taken by the Contractor.

5.1.8 At the temporary CP anode ground-bed, the leads of all the anodes shall be joined together in a junction box filled with epoxy and buried. A single cable shall be routed from the junction box to test station.

5.1.9 For sacrificial anode ground bed which as intended for permanent CP system and / or which is to be integrated with permanent CP system, the leads of all the anodes shall be brought up to the test station and shall be terminated individually.

5.1.10 The number of anodes at each ground bed shall be sufficient for providing the specified pipe protection current density taking into consideration the ground bed resistance, cable resistance, etc. For permanent cathodic protection system, Contractor shall prepare a table for number of anodes required at different soil resistivities to produce the specified protection current for the specified designed life. For Temporary Cathodic Protection system, an indicative design data for sacrificial anodes ground bed in tabular form is given in Data Sheet. The number of anodes for ground bed, spacing of ground beds based on the applicable soil resistivity, size of pipeline, type of coating for the pipeline shall be chosen from the table after necessary verification by the CP contractor. Any deficiency in the protection system if noticed during commissioning or

during monitoring shall be corrected by the CP contractor by suitably augmenting the system with additional anodes without any cost / schedule implications. 5.1.11 For the portion of the pipeline for which the CP system has been specified based on the permanent CP system parameters the contractor shall ascertain the requirement of the cathodic protection current density indicated above. Where specified in the project Specification / Data Sheet the requisite current density test / survey shall be conducted by the contractor to establish the adequacy of CP current requirement and number of anode ground beds. 5.2 TEST STATIONS 5.2.1 Test stations shall be provided along the pipeline ROW for monitoring the performance of the cathodic protection system at the following locations. Test stations shall be provided at additional locations, if required, so that distance between any two adjacent test stations does not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like forest / deserts.

a. Al the locations of anode ground beds.

b. At vulnerable locations with drastic, changes in soil resistivity

c. At both sides of metalled road crossings

d. At locations of surge diverters, pipeline grounding through polarisation cells, zinc and magnesium anodes.

e. At EHV/HV AC/DC overhead line crossings and selected locations where EHV/HV overhead line is in the vicinity of the pipeline.

f. At railway line crossings and at selected locations along lines running parallel to the pipeline.

g. At both sides of major river crossings.

h. At EHV/HV cable crossings or along routes where EH/HV cables are running in parallel.

i. In the vicinity of DC networks or grounding systems and HVDC grounding systems where interference problems are suspected.

j. At crossings of other pipelines/structures.

k. At the locations of reference cell and Electrical Resistance probe installation m) at both sides of cased crossings.

l. Locations, where interference is expected.

m. At locations of Sectionalizing Valve (SV) stations.

n. At any other locations considered necessary by Owner / Owner's representative.

5.2.2 Test stations used for sacrificial anodes shall have shunt for measurement of anode current, provision for resistance insertion to limit the anode current output and anode disconnecting link. 5.2.3 Test stations for bonding shall be provided with shunt and resistor as a means to monitor and control current flow between the pipeline and foreign pipelines or structures that may exist in common ROW.

5.2.4 Test station with current measuring facility shall be provided at interference prone areas, on both sides of major river crossings, near marshy areas and minimum one for every 10 km max. along the pipeline.

5.2.5 The test stations shall be installed with the face of the test station facing the pipeline. The nameplate of test stations shall carry the following minimum information

a. Chainage in km.

b. Test station connection scheme

c. Distance from pipeline in meters.

d. Direction of product flow.

5.2.6 Terminals and different schemes of wiring shall be provided as per the test station connection scheme. Minimum twenty percent spare terminals shall be provided in each test

5.2.7 Minimum two cables shall be provided from the pipeline at any test station 5.2.8 The location of all the test stations shall be marked with their connection schemes and other relevant information on alignment sheets. A detailed test station schedule shall be prepared.

5.3 PERMANENT REFERENCE CELLS 5.3.1 High purity copper-copper sulphate reference cells with proven high reliability shall be provided for stable coupon to soil potential measurement at the locations of polarisation coupons.

5.3.2 The reference cells shall be of silver / silver chloride type in place of copper / copper sulphate cells, at marshy area locations, where water table is high and chloride ion concentration is more than 300 ppm for marshy area in saline soils high purity zinc may be considered as an alternative to silver / silver chloride.

5.3.3 The life of reference cells shall be minimum 10 years under burial-conditions. 5.3.4 The test station connection scheme inside the test station shall clearly indicate the type of reference cell (Cu CuSO4 /Ag AgCI).

5.4 ELECTRICAL RESISTANCE PROBE 5.4.1 Where specified in Data Sheet electrical resistance probes (E/R probes) utilising the electrical resistance technique shall be provided along the pipeline at marshy areas and at vulnerable locations to monitor the external corrosion activity on the pipeline.

The lead wires of the probe shall be connected to pipeline through test station and terminated inside test station enabling periodic resistance measurement of the probe using a portable measuring instrument.

5.4.2 The E/R probes shall be provided preferably at the bottom portion of pipeline. The number of ER probes, the location of their installation and the number of portable ER probe reading instruments shall be as specified in the project Specification/Data Sheet.

5.5 SURGE DIVERTER AND POLARISATION CELL 5.5.1 SURGE DIVERTER Explosion proof type spark gap surge diverter shall be connected across each insulating joint to protect it from high voltage surges.

5.5.2 POLARISATION CELL Where ever the pipeline is either crossing or running in parallel, with overhead EHV/HV transmission lines of voltage grade 66kV and above, it is mandatory that the pipeline shall be grounded to discharge any accumulated potential / singe that may appear in case of transmission line faults, as

per below

The pipeline shall be grounded through polarization cell with zinc galvanic anodes of minimum 20kg net weight each at location where pipeline crosses EHV/HV transmission lines.

The pipeline shall be grounded at regular intervals of maximum 1 km where EHV/HV transmission lines run parallel within 25 m of the pipeline

Locations along pipeline where continuous induced over-voltage due to other overhead transmission lines / underground cables of voltage grade below 66kV is expected or observed during commissioning, the pipeline shall be grounded through polarization cell to the earth system of the EHV / HV tower causing the voltage induction or to a separate earthing system of zinc anodes through polarization cell.

The polarization cell shall be installed inside test station of suitable size. Type of polarization cell shall be as specified in Data Sheet.

The total system including cable, cable termination, surge diverters / polarization cells / anodes shall be suitable for the anticipated fault current at the location of its installation

The surge diverter, polarization cell and anode system shall be suitable for the design life of permanent CP system. The grounding system shall have minimum resistance to earth to restrict the pipeline voltage as per NACE / VDE criteria but shall not exceed 5 ohms. The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.

Motor operated valves where located on the cathodically protected portion of the pipeline shall be grounded by a zinc or magnesium anode of 20 kg net where the type of anode provided for the CP system of the pipeline is zinc or magnesium respectively. The MOV power supply cable armour shall be insulated (by cutting and taping with insulation tape) at MOV end to avoid armour carrying CP current.

The above ground cathodically unprotected pipeline at intermediate SV stations, pigging stations etc. and terminals shall be earthed with GI earth electrodes, The resistance to earth of grounding shall be limited to 5 ohms max.

5.6 CP AT CASED CROSSING 5.6.1 At cased crossings where casing is coated, the casing shall be protected by sacrificial anode installations, provided at both ends of casing. The anode installation shall be sized based on the permanent CP design parameters and design life of permanent CP system. At cased crossings where casing is painted or uncoated, additional protection for casing pipes may not be provided.

5.6.2 The carrier pipe inside the painted or coated casing shall be protected by zinc ribbon anodes weld connected to the outer surface of bottom of carrier pipe extending up to hour hand positions of 4 and 8 O'clock. The anodes shall be placed at close intervals as per design

5.6.3 Calculations with minimum one number of anodes installed between every two supports provided between carrier and casing. The anodes shall be sized based on the permanent CP design parameters for marshy area and design life of permanent CP system.

5.6.4 Where casing is bare (i.e. uncoated or unpainted), additional protection for carrier pipe may not be provided.

5.7 REFERENCE CELL ACCESS POINTS 5.7.1 Reference cell access points shall be provided near insulating joint locations and at SV stations, where the ground is paved, for measurement of pipe to soil potentials. A perforated PVC pipe filled with native soil and buried at the location shall be provided for the purpose. The length of the PVC pipe shall be adequate to reach the native soil below the paving.

5.8 CABLES 5.8.1 Cables shall be with annealed high conductivity stranded copper conductor, PVC insulated, 650/1100V grade, armoured, PVC sheathed conforming to IS: 1554 Part -I except for the cables for reference cells and pipeline for potential measurement. The size of the copper conductor shall be 6 sq.mm for anode tail cable from anode to buried junction box or test station (incase of permanent CP anode ground bed), 10sq.mm from buried junction box to test station and a 10 sq.mm. from test station to pipe line. The size of cable for bonding, polarisation cell, grounding anodes and surge diverter connections shall be suitable for the maximum fault current subject to Minimum 25 sq.mm. The length of anode tale cable shall be sufficient for routing from anode to buried junction box or test station for anodes for temporary CP or permanent CP respectively.

5.8.2 The cables for reference cells and pipeline potential measurements shall be of 4 sq.mm copper conductor, PVC insulated, Aluminium backed by Mylar / polyester tape shielded, PVC sheathed, armoured PVC overall sheathed type. 6.0 INSTALLATION 6.1 CABLE LAYING 6.1.1 Cables shall be laid in accordance with the layout drawings to be prepared by the Contractor. No straight through joint shall be permitted. Cable route shall be carefully measured and cables cut to required length. Minimum half meter cable slack shall be provided near anodes, pipeline and test stations to account for any settling

6.1.2 All cables inside station / plant area shall be laid at a depth of 0.75 M Cables outside station / plant area shall be laid at a depth of minimum 1.5 m Cables shall be laid in sand under brick cover and back filled with normal soil. For cables laid outsider the station / plant area, polyethylene warning mats shall placed at a depth of 0.9 m. from the finished grade to mark the route

6.1.3 In case of above ground cable, all armoured CP cables shall be laid in GI conduits of sufficiently large size up to accessible height for protecting against the mechanical damage.

6.1.4 All underground armoured cables including anode tail cables shall run through PE sleeves. The cables routed along the pipeline shall be carried at the top of the carrier pipe by securely strapping it at intervals with adhesive tape or equivalent as required.

6.1.5 PVC pipes of proper size shall be provided for all underground cables for road crossings

6.1.6 Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and final take off to equipment is facilitated.

6.1.7 The cables for reference cells and pipeline potential measurement shall be routed in a separate trench other than the trench provided for the rest of the CP system cables, AC cables for CPTR units, etc.

6.1.8 The armour of all the cables from pipeline to test station (potential measurement, reference cell cables, cathode cables, etc) and test station to ground bed (anode cable) shall be earthed only at test station end of the cable to avoid armour carrying CP current. The cable armour shall be insulated by cutting and taping with insulation tape.

6.2 PERMANENT REFERENCE CELLS 6.2.1 The permanent reference cells shall be installed in natural soil conditions as per the recommendations of the cell manufacturer. Installations in highly acidic / alkaline soil and soil contaminated by hydrocarbons shall be avoided.

6.3 CABLE TO PIPE CONNECTIONS 6.3.1 All cable connections to the new pipeline shall be made by an approved exothermic process or by pin brazing. However, cable connection to charged pipelines shall be made by pin brazing. Exothermic welding shall be adopted for water pipelines. The resistance of the cable to pipe at the connection point shall not exceed 0.1 ohm. Coating shall be repaired after connection of cable conductor to pipeline. The coating repair material shall be compatible with the original coating and shall prevent ingress of water along the cable, surface and at the interface of coating repair with the original pipe coating

6.4 GROUND BED FENCING 6.4.1 Where specified in project Specifications / Data Sheet a chain link fencing shall be provided around the location of each ground bed, designed based on the permanent CP design

7.0 INSPECTION, TESTING AND COMMISSIONING 7.1 SYSTEM TESTING AT SITE 7.1.1 Field tests as per the reviewed field testing and commissioning procedures prepared by the Contractor shall be carried out on the equipment / systems before these are put into service. Acceptance of the complete installation shall be contingent upon inspection and test results

7.1.2 Before the CP system facilities are put into operation, necessary tests shall be carried out to establish that all equipment, devices, wiring and connection have been correctly installed, connected and are in good working condition as required for the intended operation. Owner / Owner's representative may witness all tests. Intimation shall be given at least one week before commencing the tests.

7.1.3 All tools, equipment and instruments required for testing shall be provided by Contractor. Generally, the following minimum tests must be carried out and recorded.

a. Cables

I. Cable No. II. Voltage grade. III. Conductor cross section.

IV. Continuity check. V. Voltage test. VI. Insulation resistance values between each core & earth, between cores. All cables shall be tested by 500 V megger.

b. Insulating joint

I. Location. II. Pipe to soil potential of both protected and non protected sides of the insulating joint before and after energisation of CP system

c. Surge diverter

I. Location / Identification number rating II. Type III. Explosion proof enclosure check for healthiness. IV. Check for proper connection.

d. Polarisation Cell

I. Location / Identification number. II. Ratings. III. Check for wiring IV. Check standby current drain after CP system energisation. (Current drain with respect to voltage across the cell shall be recorded). V. Details of grounding provided for the polarisation cell

e. Anode Ground Bed

I. Location / Station II. Vertical / horizontal III. Check for actual layout and compliance with drawings. IV. Current output of ground bed. V. Current output of each anode (in case of permanent, CP anode ground beds)

f. Reference Cell

I. Location II. Type of cell III. Potential reading IV. Installed on top/bottom level of pipeline

g. E/R Probe I. Location / Identification number II. Checking of wiring as per schematics III. Resistance reading of probe

IV. Installed on top / bottom / side of the pipeline 7.2 COMMISSIONING 7.2.1 Natural potential of pipe to soil for the complete pipeline and casing pipeline at the locations of cased crossings shall be measured at all the test station locations, recorded prior to connecting anodes to pipe line and casing pipeline respectively.

7.2.2 The anode shall be connected to pipeline in the test station and the pipe to soil potential observation shall be made after allowing sufficient time for polarisation. The current output of each anode at permanent CP anode ground bed or the total current output of anode bed at temporary CP anode ground bed shall also be measured to ensure that it does not exceed the output current capacity of the anodes. In case the anode output current exceeds the rated capacity, it shall be controlled by insertion of resistance element in the anode circuit inside test station and the pipe to soil potential shall be rechecked for adequacy of protection. At locations of polarisation coupons the coupon 'OFF' potential shall be measured by switching off the reed switch. Additional anodes shall be provided where required to achieve desired level of protection and to keep the anode output current within the rated value. In case pipe to soil potential exceeds the specified value, suitable resistance shall be inserted in the anode circuit to limit the potential.

7.2.3 Anode installation shall become individually operational as above. 7.2.4 At the locations of cased crossings where anode installations are provided for the protection of the casing pipe, these anode installations shall be commissioned as per the procedure detailed in clause 7.2.2. above.

7.2.5 After connecting all the anode ground beds to pipe line, measurement of pipe to soil potentials shall be taken at each test station to ensure conformity to protection criteria.

7.2.6 In case of insufficient protection as per the CP design criteria on any portion of the pipeline / casing pipeline (at cased crossings where casing is cathodically protected) Contractor shall carry out necessary additions / modifications to the provided protection in consultation with the Owner / Owner's representative.

7.2.7 Resistance readings of the probe shall be taken at all the locations of electrical resistance probes.

8.0 INTERFERENCE MITIGATION

8.1 Investigations shall be made for stray current electrolysis of the pipeline, mutual interference between the pipeline and foreign pipelines / structures, interference on foreign pipelines / structures due to the CP of the pipeline and ground bed, AC induction on pipeline due to 11 KV and above overhead HV/EHV line, interference due to high voltage DC line, HVDC groundings, electric traction etc.

8.2 Where transmission lines cross the pipeline or run in parallel within or more than 25m

from the pipeline, AC voltage measurements shall also be made on the pipeline to find out continuous induction of voltage. In case of induced voltage being beyond safe limits, the pipeline shall be grounded in line with clause no.5.5.2 above.

8.3 Measurements including pipe / structure to soil potential and pipeline/structure current etc. on the pipeline / structure being CP protected and on foreign pipelines / structures shall be made to investigate the current discharge and pickup locations. In case of fluctuating stray current, investigations shall be made continuously over a period of time and if required simultaneously at different locations to find out the stray current source(s). For measurements over longer durations, recorders shall preferably be used.

8.4 Where foreign pipelines (unprotected or protected by independent CP system) run in parallel to the pipeline in same trench or very near to the pipeline, and are not bonded to the pipeline then investigation shall be made for current discharge points on both the pipelines.

8.5 Mitigation measures shall be provided depending on type of stray current electrolysis / interference. These shall include installation of bond with variable resistor, diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment relocation (if possible) of offending interference source, provision electrical shield .etc. depending on the type of interference.

8.6 Bonding with foreign pipeline / structure, as a mitigation measure shall be provided where the Owner of the foreign pipeline/structure has no objection, otherwise alternative mitigation measure shall be provided. Where bonding is provided for mitigation, the bonding resistor shall be adjusted for optimum value for minimum/no interference. Galvanic anodes installed as a mitigation measure shall be sized for the design life specified for permanent CP.

9.0 SYSTEM MONITORING

9.1 Where the CP provided is temporary, the CP system shall be monitored at all test stations once in a month for healthiness / adequacy of protection hit commissioning of permanent CP or for design life of temporary CP specified, which ever is less, During this period if any deficiency / interference in protection system is noticed, the same shall be rectified / augmented by providing additional anodes as required. The monitoring report shall be submitted regularly to Owner for his review / information.

10.0 CLOSE INTERVAL POTENTIAL LOGGING SURVEY (CIPS) 10.1 Where specified in project Specification / Data Sheet, contractor shall carry out a close interval potential survey over the entire length of pipeline by computerised potential logging method and identify the under protected / over protected area, any major coating damage on the pipeline, after the back-filling has been consolidated sufficiently and CP system has stabilized. Contactor shall provide required mitigation measures and rectify the under / over protected zones, identify if any, the major pipeline coating defects required to be repaired. During the survey the reference cell shall be calibrated minimum once in 24 hours.

10.2 Where specified in the project Specification / Data Sheet, additional tests for detailed

identification of coating defects shall be conducted by the contractor.

STANDARD SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION

SYSTEM FOR PIPELINES

ABBREVIATION

AC Alternating current


BIS Bureau of Indian Standards

DNV Det Norske Veritas

CP Cathodic Protection

CP TR Cathodic Protection Transformer Rectifier unit.

SACP Sacrificial Anode Cathodic Protection

ICCP Impressed Current Cathodic Protection

CMRI Central Mining Research Institute.

CTE Coal Tar Enamel

DC Direct Current

EHV Extra High Voltage

FBE Fusion Bonded Epoxy

HDD Horizontal Directional Drilling

HV High Voltage

HVDC High voltage Direct Current

MOV Motor Operated Valve

NACE National Association of Corrosion Engineers

PE Polyethylene

ROW Right of Way

CPPSM Cathodic Protection Power Supply Module

SV Sectionalizing Valve

Cu/CuSo4 Copper / Copper Sulphate reference electrode

Ag/AgCl Silver / Silver chloride reference electrode

Kg/AY Kilogram / Ampere year

MMO Mixed Metal Oxide

TABLE OF CONTENTS

SL NO. DESCRIPTION =

1.0 SCOPE .........................................................................................


3.0 DEFINITION .................................................................................

4.0 DESIGN .......................................................................................

5.0 MATERIALS ................................................................................

6.0 INSTALLATION ...........................................................................

7.0 INSPECTION TESTING AND COMMISSIONING ........................

8.0 INTERFERENCE MITIGATION ....................................................

9.0 CLOSE INTERVAL POTENTIAL SURVEY ..................................

1.0 SCOPE

1.1 This Specification defines the requirements of system design, engineering, installation, testing and commissioning of an impressed current cathodic protection system for cross country onshore underground pipelines / structures including, supplementing of corrosion survey, close interval potential logging survey, investigations for interaction / interference problems and mitigation of the same.

1.2 This Specification provides the basic parameters to develop a suitable impressed current cathodic protection system for the pipelines / structures requiring protection. All data required in this context shall be taken into consideration to develop an acceptable design and for proper engineering of the system.

1.3 Compliance with these Specifications, and / or approval of any documents submitted by contractor shall in no case relieve the contractor of his contractual obligations.


2.1 The system design, performance and materials to be supplied shall conform to the requirements of the latest revision of following Standards as a minimum:

NACE Standard RP-0169 Standard Recommended Practice Control of External Corrosion on Underground or Submerged Metallic Piping Systems NACE Publication 10A 190 Measurement technique related to criteria for CP of Underground or Submerged Steel Piping System (as defined in NACE Standard RP0169-83) NACE Standard RP-0177 Standard Recommended Practice Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems NACE Standard RP-0286 Standard Recommended Practice The Electrical Isolation of Cathodically Protected Pipelines. NACE Publication No. 54276 Cathodic Protection Monitoring for Buried Pipelines. NACE Standard RP-0572 Standard Recommended Practice Design, Installation, Operation and of Impressed Current Deep Ground beds IS 8062 Recommended Practice ICCP for Underground Piping IS: 1554 Part I PVC insulated (heavy duty) cables. BS 7361 Part I Code of practice for cathodic protection for land and marine application. VDE 0150 Protection against corrosion due to stray current from DC installations.

2.2 In case of imported equipments Standards of the country of origin shall be applicable if these Standards are equivalent or stringent than the applicable Indian Standards.

2.3 The equipment shall also confirm to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country.

2.4 In case of any contradiction between various referred Standards / Specifications / Data Sheet and statutory regulations the following order of priority shall govern:

a. Statutory regulations. b. Data Sheets. c. Job Specification. d. This Specification. e. Codes and Standards. 3.0 DEFINITION


Owner / Company - Owner of the particular Project (Project Specific).

Consultant - The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management. Bidder / Supplier / Vendor

The party(s) which manufactures and / or supplies material, equipment, technical documents / drawings and services to perform the duties specified by Contractor .

Anaerobic : Lack of free oxygen in the electrolyte adjacent to a metallic structure Anode : Electrode through which direct current enters an electrolyte. Anodic area : That part of metal surface which acts as an anode.

Blistering (of paint film)

Formation of swelling on the surface of an unbroken paint film by moisture, gases or the development of corrosion products between the metal and paint film.

Cathode: Electrode through which direct current leaves an electrolyte. Cathodic area : A means of rendering a metal immune from corrosive attack by causing direct current to flow from its electrolytic environment into the entire metal surface. Cathodic disbanding : Failure of adhesion between a coating and metallic surface that is directly attributed to cathodic protection conditions and that is often initiated by a defect in the coating system, such as accidental damage, imperfect application or excessive permeability of the coating. Current Density : The current to or from a unit are of electrode surface.

Coating breakdown factor The ration between the surface area of exposed metal due to coating breakdown and the total surface area under consideration. This factor is used to determine the average current density on coated metal from current densities compared with that for bare steel.

Electrolyte : A liquid or the liquid component in a composite material such as soil, in which electric current flows by the movement of ions. Foreign structure : Any metallic structure that is not intended as a part of a system under cathodic protection Groundbed : One or more anodes installed below the earth’s surface for the purpose of supplying current used for cathodic protection. Holiday : A defect in a protection coating at which metal is exposed. This may, in some cases, be small as possible.

Instantaneous off potential

The structure-to-electrolyte potential measured immediately after the synchronous interruption of all sources of applied cathodic protection current

Natural Potential : The practical structure-to-electrolyte potential measured when no cathodic protection is applied and polarization caused by cathodic protection is absent. On Potential : The practical structure-to-electrolyte potential measure when while the cathodic protection system is continuously operating. Polarisation : The deviation from open circuit potential of an electrolyte resulting from the passage of current Protection current : The current made to flow into a metallic structure from its electrolytic environment in order to effect cathodic protection of the structure. Reference electrode : An electrode whose open circuit potential is constant under similar condition of measurement, which is used for measuring the relative potentials of other electrodes. Stray current : Current flowing in soil or water environment of a structure arising mainly from cathodic protection, electric power or traction installations an which can pass from the environment into the structure vice versa. Utilization factor : The proportion of anode material on an anode that may be consumed before the anode ceases to provide a current output as required in the design.

4.0 DESIGN 4.1 SYSTEM IMPLEMENTATION (DESIGN DOCUMENTS) 4.1.1 All work to be performed and supplies to be effected as a part of contract shall require specific review by Owner or his authorized representative. Major activities requiring review shall include but not be limited to the following:

a. Corrosion survey data interpretation report and plot plans for land acquisition.

b. Basic engineering package. c. CP System design including calculation of current requirements, pipeline attenuation,

resistance and current output of groundbeds. d. Detailed engineering package including Anode sizing calculation, Power supply

sizing calculation, A summary of the used formula and standards, schematic diagram of the proposed cathodic protection system.

e. Bill of material including material and equipment specifications f. Field testing and commissioning procedures. g. Procedures for interference testing and, mitigation. h. Close interval potential logging survey procedure. i. Operation and maintenance instructions. j. As built documentation.

4.2 CORROSION SURVEY 4.2.1 GENERAL

a. Unless otherwise specified in the project / job specification, corrosion / pre-design survey shall be performed to collect essential information on soil resistivity, geographical factors, likelihood or existence of stray current and other important features require for the design of CP system. The site survey shall be carried out as per guidance given below.

b. The details of corrosion survey including soil resistivity data along ROW and other data required for CP design if available with the Owner shall be included as part of project Specification / Data Sheet however, verification of its veracity and adequacy shall be the entire responsibility of the contractor. In addition, contractor shall have to generate/collect additional data as per clause 4.2.4 below required for completeness of the job.

c. Contractor shall carry out soil resistivity survey at anode ground bed locations for design of ground bed. Where specified in the Data Sheet, Contractor shall carry out corrosion survey along the ROW of the pipeline conforming to the Specifications included in the tender document.

d. To carry out soil resistivity measurement Wenner's 4-pin method or an equivalent method approved by Owner shall be used. Survey instruments shall have maximum AC and DC ground current rejection feature.

e. Care shall be taken to ensure that the resistivity observations are not influenced by the presence of foreign pipelines / structures, and earth currents in the vicinity of EHV/HV lines and installations using earth return in their power system etc.

4.2.2 SOIL RESISTIVITY SURVEY AT IMPRESSED CURRENT ANODE GROUND BED PLOT a. Each selected anode bed plot shall be sub divided into sub plots. Sizes of sub plots shall

depend upon the expected depth for soil resistivity investigations. Each of these sub plots shall be investigated for resistivity data individually. Sufficient observations shall be taken at each of these sub-plots as required and desired by Owner / Owner's representative to obtain sufficient information about sub soil stratification and, wherever possible, to establish the depth of water table. The number of subplots at each ground bed plot shall be decided at site in consultation with Owner / Owner's representative.

b. Number, location, demarcation and size of sub-plots and number of sets of resistivity observations required for each sub plot shall be individually decided for each ground bed plot location.

c. One or more ground bed plots may be required to be selected and surveyed at each CP station to form a suitable ground bed.

4.2.3 TOPOGRAPHIC SURVEYS a. Cathodic protection stations consisting of anode ground bed, CP station, etc. as applicable, along with all associated cabling up to pipeline and any other related equipment and accessories for CP station shall be demarcated on the ground. Ground plots so demarcated shall be surveyed for all other topographical and cadastral features and topo-sheets shall be developed by the Contractor, which shall be suitable for use in land acquisition etc.

4.2.4 ADDITIONAL DATA TO BE COLLECTED

a. The following data shall be collected to generate design data for evaluation of interaction / interference possibilities due to presence of other services in ROW or in its vicinity. Owner shall provide assistance for liaison work to the extent possible.

b. Route and types of foreign service / pipeline in and around or crossing the right of way (including those existing and those which are likely to come up during contract execution).

c. Diameter, wall thickness, pressure, soil cover and coating scheme used, type of cathodic protection system provided, if any, year of laying / commissioning in case of foreign pipelines.

d. Details of the existing cathodic protection systems protecting the services i.e. type of protection, location, type, rating of anode beds test station locations and their connection schemes. Present output current and voltage readings of the CP power supply units.

e. Remedial measures existing on foreign pipelines / services to prevent interaction. f. Graphical representation of existing structure / pipe to soil potential records. g. Possibility of integration / isolation of CP systems, which may involve negotiations with

Owners of other services. h. Existing and proposed DC/AC power sources and systems using earth return path such as

HVDC substations / earthing stations, fabrication yards with electric welding etc. in the vicinity of the entire pipeline route.

i. Crossing and parallel running of electrified and non-electrified traction (along with information regarding, operating voltage, AC/DC type etc.) as well as abandoned tracks near ROW having electrical continuity with the tracks in use.

j. Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power lines along with details of voltage, AC/DC type etc.

k. Voltage rating, phases, sheathing details of underground power cables along ROW or in its vicinity.

l. Any other relevant information that may be needed in designing and implementing proper cathodic protection scheme for the proposed pipeline.

m. Contractor shall conduct necessary potential gradient surveys for any existing anode ground beds that may interfere with the CP system of the pipelines covered under this project.

4.2.5 REPORT a. On completion of all field work, a report incorporating all the results generated from surveys and details of additional data, collected shall be prepared. The report shall also contain detailed interpretation of survey results and resistivity data, probable interference prone areas, selected locations for anode ground beds, etc., to form a design basis for the scheme of cathodic protection. This report shall also include various drawings prepared in connection with the above work. Soil resistivity values shall be plotted on semilog graph sheets.

4.3 CATHODIC PROTECTION DESIGN PARAMETERS A distinctly independent impressed current cathodic protection system shall be provided to protect the external surfaces of the complete pipeline / structure installation as specified.

Unless otherwise stated in the Data Sheets, the following parameters shall be used for design of permanent cathodic protection system:

4.3.1 PROTECTION CURRENT DENSITY RANGE Pipelines having coal tar enamel (CTE) coating with two/three layers of reinforcement.


Minimum Protection Current Density* (µA / m2)

Soil resistivity more than 100 ohm. m 200 Soil resistivity 10 ohm m to 100 ohm. m 300 Soil resistivity less than 10 ohm. m 2000 Sea water 5000

Pipe lines having fusion bonded epoxy (FBE) coating:



Soil resistivity more than 100 ohm. m 900

Soil resistivity 10 ohm m to 100 ohm. m

125

Soil resistivity less than 10 ohm. m 500

Pipe lines having polyethylene (PE) coating:



Soil resistivity more than 100 ohm. m 35 Soil resistivity 10 ohm m to 100 ohm. m 50 Soil resistivity less than 10 ohm. m 125

* Actual current density to be adopted shall be decided based-upon soil and other environmental conditions, current drainage survey: data, proximity of foreign pipelines / structures and other interference area affecting the installation where considered necessary for satisfactory protection of pipeline the current density shall be suitably increased by contractor.

4.3.2 At HDD (horizontal directional drilling) crossing, the pipe protection current density applicable for marshy area shall be considered.

4.3.3 The pipe protection Current Density indicated above shall be applicable where the temperature of the fluid transported by the pipeline/ the surface temperature of the buried portion of the pipeline does not, exceed 30° C. Where this temperature exceeds 30° C, the protection Current Density shall be increased suitably in consultation with the Owner / Consultant.

Safety factor for current density: 1.3 Anode utilization factor: 0.85 for centre connected anode. 0.6 (For high silicon cast iron anode) for end connected anode. Anode surface current density: 15 Amp./sq.m (max.) (For high silicon cast iron anode, for shallow anode for continuous operation) ground bed 10 Amp. /sq. m (max.) for deep well anode ground bed Anode consumption rate: 0.2 kg./Amp. (-) 0.45 V (For high silicon cast iron anode) Pipeline natural potential: (-) 0.45V Design life of CP system: 30 years, unless specified otherwise in the Data Sheet. Anode ground bed loop resistance Including anode to ground resistance, Anode and cathode cable resistances: 1 ohm (max.). (The output voltage rating of the CPTR unit / CPPSM shall in minimum be adequate to drive the specified end of life cathodic protection current with safety factor, considering the total anode ground bed loop resistance as the sum of the resistance specified in this clause and pipe to earth resistance).

4.3.4 For mixed metal oxide coated titanium anodes the anode utilization factor, anode surface current density and anode consumption rate etc. shall be as per the guaranteed values published by the manufacturer and supported by test certificates / field proven ness.

4.3.5 CURRENT DEMAND

a. Sizing of cathodic protection system is based on the total current demand calculations. Contractor shall carry out detailed current demand calculation by multiplying the total surface area of the structure, relevant current density and coating breakdown, as applicable.

b. All item lead to significant current drain on the cathodic protection system shall be included in the surface area and current demand calculations.

c. Earthing system shall also be taken into consideration while designing the cathodic protection system. Effect of all earthing electrode connected to the protected structures shall be included in current demand calculations.

4.4 CATHODIC PROTECTION DESIGN CRITERIA 4.4.1 Cathodic protection system shall be designed to meet the following criteria: 4.4.2 The pipe to soil potential measurements shall be between (-) 0.9V (OFF) and (-) 1.18V (OFF) with respect to a copper/copper sulphate reference electrode.

4.4.3 In rare circumstances, a minimum polarization shift of (-) 100 millivolts may be accepted as an adequate level of cathodic protection for the pipeline with the approval of Owner.

4.4.4 A positive potential swing of 100 millivolts or more shall be considered sufficient to indicate the presence of an interaction/interference situation requiring investigation and incorporation of mitigation measures by the Contractor.

5.0 MATERIALS 5.1 SYSTEM DETAILS 5.1.1 The system shall include the following major equipment / sub-systems unless otherwise specified in project Specifications:

a. CPTR units / cathodic protection power supply modules (CPPSM). b. Anode ground beds and anodes c. Anode junction box d. Cathode junction box e. Test stations f. Permanent reference cells g. Electrical resistance probes h. Polarization cell and surge diverter i. Polarization coupons j. Remote monitoring system. k. CP system at cased crossing l. Bond Stations m. Cables

5.1.2 All equipment shall be new and procured from approved reputed manufacturers. Equipment offered shall be field proven. Equipment requiring specialized maintenance or operation shall be avoided as far as possible. Prototype equipment shall not be accepted.

5.1.3 All equipment / materials shall conform to the relevant Specifications, included in the tender document.

5.1.4 All equipment including CPTR unit, CPPSM, test stations, anode lead junction boxes etc. shall be located in safe non-hazardous areas.

5.1.5 Where it is essential to install the equipment in hazardous area, such equipment shall be flameproof type and shall meet the requirement of IS- 2148 or equivalent international Standard and shall be suitable for gas group IIB, temperature class T3 (200°C). Indigenous equipment shall be certified by CMRI or any other recognized testing body and shall be approved by the concerned statutory authority. All flameproof equipment shall carry the BIS license marking as per the requirement of statutory authorities.

5.1.6 All Imported equipment for hazardous area may be tested and certified by an independent certifying agency of country of equipment origin and shall be approved by the concerned statutory authority in India.

5.2 CATHODIC PROTECTION STATIONS 5.2.1 The number and exact locations of CP stations shall be worked out based on the corrosion survey data collected. In addition, the following guidelines shall be followed for selecting the locations:

5.2.2 Number of CP stations and their selected locations shall ensure that these remain valid and are adequate for the full design life of the system after considering all foreseeable factors.

5.2.3 As far as possible, the availability of nearby low resistivity areas for location of associated ground beds must be ensured while selecting the locations of CP stations. 5.2.4 As far as possible, locations of intermediate CP stations shall coincide with the locations of SV stations.

5.2.5 The proposed locations of CP stations and anode ground bed current ratings are detailed in project Specifications / Data Sheets. The same shall be verified for adequacy by the contractor. The requisite current drainage tests / survey shall be conducted by the contractor to establish the adequacy of CP current requirement indicated in clause 4.3 above and adequacy of number, ratings of CP stations for permanent CP system indicated in the Data Sheet. The minimum end of life pipe protection current requirement shall be considered as the current requirement indicated in the clause 4.3 above or 3 times the current density value measured by the current drainage survey for polyethylene coated pipeline and 4 times the current density value measured by the current drainage survey for fusion bonded epoxy, coal tar enamel with reinforcement coated pipeline, whichever is maximum.

5.3 CP TRANSFORMER RECTIFIER UNIT/CPPSM 5.3.1 If specified in project Specifications / Data Sheet, the supply, installation, testing and commissioning of cathodic protection power supply module (CPPSM) / indoor type Cathodic Protection Transformer Rectifier Unit (CPTR unit) / outdoor type CPTR unit installed in kiosk along with kiosk shall be included in contractor's scope. The CPTR units shall be provided at CP stations where reliable AC power supply is available. CPPSM shall be provided at other CP stations where reliable DC power supply instead of reliable AC power supply is available. The CPTR unit / CPPSM shall be installed in non-hazardous (safe) area as specified in Data Sheets.

5.4 ANODE GROUND BEDS 5.4.1 Each CP station shall have an independent anode ground bed, which may be of shallow or deep well construction depending upon the data collected by the contractor. Deep well ground beds may also be used in the congested locations where availability of suitable land for spread out ground beds is restricted.

5.4.2 Ground bed shall be located electrically remote from the pipeline and foreign pipeline / other buried metallic structures. Nearest part of the anode bed shall at least be 100 meters away from the pipeline and foreign pipeline/other buried metallic structures. The anodes installed in the ground shall be located in perennially moist strata, wherever possible. Horizontal ground beds shall be at right angles to the pipeline as far as possible.

5.4.3 The location of ground bed shall be checked and ensured for remoteness from the pipeline and ether buried foreign pipelines / structures, buildings foundations, switchyards, electrical earthing systems, etc.

5.4.4 Unless otherwise agreed, anodes shall be of high silicon cast iron type or mixed metal oxide coated titanium anodes. 5.4.5 Sheet steel anode canisters of adequate size shall be provided for each anode. Anode canisters shall be filled with petroleum coke breeze. In case of deep well ground beds non-canistered anodes with petroleum coke breeze in the well surrounding the anodes shall be provided.

5.4.6 Each shallow anodebed shall contain anodes with canisters positioned horizontally or vertically in the soil with suitable backfill. The depth of anodes (depth of top of anode in case of vertically laid anodes) shall not be less than 2 meter from grade level

5.4.7 Layout of anode installation in anode bed shall be detailed out in drawings showing anode installation details, anode grouping, anode wiring, anode cable routing, etc. The deep well anode ground bed details shall include the details of anodes, deep well casing, anode positioning, anode cable supporting, deep well gas venting, active, passive portions of the ground bed, etc.

5.4.8 Anodes shall be supplied complete with tail cables, which shall be long enough for termination on their associated anode lead junction boxes without intermediate joints. Exact lengths and termination details shall be indicated in construction drawings.

5.4.9 Potential gradient around the anode bed shall be within safety requirements with regard to interference on foreign structures and its effective boundary shall be defined.

5.4.10 In case of two parallel pipelines running in the same ROW, the anode ground beds of the respective pipelines shall be located on the respective sides of the pipelines.

5.5 ANODE JUNCTION BOX 5.5.1 Depending on the size and configuration of anode ground beds, one or more anode junction boxes shall be provided at each ground bed. All cable tails from individual anodes shall be terminated onto the respective anode junction boxes, which shall be further connected to the main anode junction box (where applicable). The main anode junction box shall be connected to the cable coming from CP power source. Each outgoing circuit in main junction box (where applicable) and each anode circuit in junction shall have provision for measurement and control of individual circuit / anode current.

5.6 CATHODE JUNCTION BOX 5.6.1 Where output of the CP power supply unit is connected to multiple pipelines a cathode junction box shall be provided near the pipelines at the location of connection of the negative drainage cable to the pipelines.

5.6.2 The negative of the CP power source shall he connected to the incoming circuit of the cathode junction box. The junction box shall have separated out going circuit one for each pipeline to collect the negative drainage currents from each of the parallel pipelines. 5.6.3 The incoming circuit shall have a current measurement facility. Each out going circuits shall have provision for measurement and control of current.

5.7 TEST STATIONS 5.7.1 Test stations shall be provided along the pipeline ROW for monitoring the performance of the cathodic protection system at the following locations. Test stations shall be provided at additional locations, if required, so that distance between any two adjacent test stations does not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like forest / deserts:

a. At all insulating joints. b. At both sides of metalled road crossings. c. At vulnerable locations with drastic changes in soil resistivity. d. At locations of surge diverters, pipeline grounding through polarization cells, zinc and

magnesium anodes. e. At EHV/HV AC/DC overhead line crossings and selected locations where EHV/HV overhead

line is in the vicinity of the pipeline. f. At railway line crossings and at selected locations along lines running parallel to the pipeline. g. At both sides of major river crossings.

h. At EHV/HV cable crossings or along routes where EHV/HV cables are running in parallel. i. In the vicinity of DC networks or grounding systems and HVDC grounding systems where

interference problems are suspected. j. At crossings of other pipelines/structures. k. At the locations of reference cell, electrical resistance probe and polarization coupon

installation. l. At the location of computerized test stations. m. At both sides of cased crossings. n. Locations where interference is expected. . o. At locations of sectionalizing valve (SV) stations. p. At any other locations considered necessary by Owner/Owner's representative.

5.7.2 Test stations for bonding shall be provided with shunt and resistor as a means to monitor and control current flow between the pipeline and foreign pipelines or structures that may exist in common ROW.

5.7.3 Test stations with current measuring facility shall be provided at each CP station drainage point (to measure pipeline current on any one side of pipeline from drainage point at intermediate CP station and towards protected side of the pipeline at starting, end point CP stations), at interference prone areas, on both sides of major river crossings, near marshy areas and minimum one for every 10 km max. along the pipeline.

5.7.4 Test stations shall be installed with the face of the test station facing the pipeline. The nameplate of test stations shall carry the following minimum information:

a. Chainage in km. b. Test station connection scheme c. Distance from pipeline in meter. d. Direction of product flow.

5.7.5 Number of terminals and different schemes of wiring shall be as per the test station connection scheme. Minimum twenty percent spare terminals shall be provided in each test station.

5.7.6 Minimum two cables from the pipeline shall be provided at any test station. 5.7.7 The location of all the test stations shall be marked with their connection schemes and other relevant information on alignment sheets. A detailed test-station schedule shall be prepared.

5.8 PERMANENT REFERENCE CELLS 5.8.1 High purity copper/copper sulphate reference cells with proven high reliability shall be provided for stable pipe to soil potential measurement at CP stations, polarization coupons and computerized test station locations along ROW.

5.8.2 Silver / Silver Chloride reference cells in place of copper / copper sulphate cells shall be provided at marshy area locations, where water table is high and chloride concentration is more than 300 ppm. For marshy area in saline soil, high purity zinc may be considered as an alternative to silver/silver chloride. The test station connection scheme shall clearly indicate the type of the reference electrode (Cu CuSO4/Ag AgCI) at these locations.

5.8.3 The life of the reference cells shall be minimum 10 years under the installed conditions.

5.8.4 The cable from reference cells shall be provided up to CP power source at CP stations and up to test stations at the locations of polarization coupons, computerized test stations. The cable up to CP power source shall be routed through test stations near pipeline. 5.9 ELECTRICAL RESISTANCE PROBE 5.9.1 Where specified in project Specification / Data Sheet electrical resistance probes (E/R probes) utilizing the electrical resistance technique shall be provided along the pipeline at marshy areas and at vulnerable locations to monitor the external corrosion activity on the pipeline. The lead-wires of the probe shall be connected to pipeline through test station and terminated inside test station enabling periodic resistance measurement of the probe using a portable probe measuring instrument.

5.9.2 The material of the E/R probe element shall be of the same alloy as of the pipeline material. The probes shall be provided preferably at the bottom portion of pipeline.

5.9.3 The number of E/R probes, the locations of their installation and the number of portable E/R probe reading instruments shall be as specified in the project Specification/Data Sheet.

5.10 POLARIZATION CELL AND STAGE DIVERTER 5.10.1 Wherever the pipeline is either crossing or running in parallel with overhead EHV/HV transmission lines of voltage grade 66kV and above, it is mandatory that the pipeline shall be grounded to discharge any accumulated potential/surge that may appear in case of transmission line faults, as per below.

5.10.2 The pipeline shall be grounded through polarization cell with zinc galvanic anodes of minimum 20kg net weight each at location where pipeline crosses EHV/HV transmission lines.

5.10.3 The pipeline shall be grounded at regular intervals of maximum 1km where EHV/HV transmission lines run parallel within 25m of the pipeline.

5.10.4 Locations along pipeline where continuous induced over-voltage due to other overhead transmission lines/underground cables of voltage grade below 66kV is expected or observed during commissioning, the pipeline shall be grounded through polarization cell to the earth system of the EHV/HV tower causing the voltage induction or to a separate earthing system of zinc anodes through polarization cell.

5.10.5 Polarization cell shall be installed inside test station of suitable size. 5.10.6 Type of polarization cell shall be as specified in Data Sheet. 5.11 SURGE DIVERTER 5.11.1 Explosion proof spark gap surge diverter shall be provided across each insulating joint to protect it from high voltage surges. Surge diverters shall be suitable for installation in classified areas.

5.11.2 The total system including cables, cable termination, anodes/surge diverters, polarization cell shall be suitable for the anticipated fault current at the location of installation.

5.11.3 The surge diverter and polarization cell system shall be suitable for the design life of permanent CP system. The grounding system shall have minimum resistance to earth to restrict the pipeline voltage as per NACE / VDE criteria but shall not exceed 5 ohms.

5.11.4 The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.

5.11.5 Motor operated valves where located on the cathodically protected portion of the pipeline shall be grounded by a zinc anode of 20 kg net. Magnesium anodes grounding, if any, provided during temporary CP system shall be disconnected. The MOV power supply cable armour shall be insulated (by cutting and taping with insulation tape) at MOV end to avoid armour carrying CP current.

5.11.6 The above ground cathodically unprotected pipeline at terminals, intermediate SV stations, pigging stations, etc. shall be earthed with GI earth electrodes. The resistance to earth of grounding shall be limited to 5 ohms Max.

5.12 POLARIZATION COUPONS 5.12.1 Where specified in the project Specification / Data Sheet Steel coupons of pipeline material shall be provided along the pipeline to monitor the adequacy of the CP system to polarize / protect coating holidays. Coupon shall be installed at CP station drainage points, predicted cathodic protection mid points along the pipeline, at locations where the pipeline is bonded to foreign pipeline/structures, interference prone areas, marshy areas and at other locations such that minimum one coupon is installed maximum every 10 km approximate or the maximum interval specified in the project Specification/Data Sheet, along the pipe line.

5.12.2 Coupons shall be installed at bottom 1/3rd portion of the pipeline and 250 mm away from the pipe surface.

5.12.3 The coupons shall be constructed from the pipeline material and shall have uncoated surface of 100 mm x 100 mm exposed to soil. Two cables one for connection to pipeline for protection and other for potential measurement shall be provided for each coupon. The protection cable shall be connected through a magnetic reed switch inside the test station to enable measurement of coupon 'OFF' potential.

5.12.4 A permanent reference electrode shall be installed adjacent to the coupon in a manner so as to measure the representative potential of the coupon.

5.12.5 Magnets for operation of reed switch shall be provided as specified in the project Specification/Data Sheet. 5.13 REMOTE MONITORING SYSTEM 5.13.1 If specified in the project / Job specification, suitable remote monitoring system shall be provided for the complete cathodic protection system. Remote monitoring system shall include a minimum of four reference electrodes distributed around the area of influence of each power supply unit as required by design. The following shall be provided for remote monitoring as minimum:

a. Output voltage

b. Output current c. Structure-to-electrolyte potential, as applicable d. Failure alarm for AC input, as applicable

5.13.2 The power supply units shall have suitable provision to communicate with the remote computer. Contractor shall provide complete details of the remote monitoring system indicating the following Owner / Consultant approval.

a. Type of hardware utilized b. Type of communication proposed c. Details of software d. Details of data / information provided

5.13.3 Scope of supply for remote monitoring unit shall be as per Project / Job specification. 5.14 CP AT CASED CROSSING 5.14.1 At cased crossings where casing is coated, the casing shall be protected by sacrificial anode installations provided at both ends of casing. The anode installation shall be sized based on the permanent CP design parameters and design life of permanent CP system. At cased crossings where casing is uncoated or painted, additional protection for easing pipes may, not be provided.

5.14.2 The carrier pipe inside the painted or coated casing shall be protected by zinc ribbon anodes weld connected to the outer surface of bottom of carrier pipe extending up to hour hand positions of 4 and 8 O'clock. The anodes shall be placed at close intervals as per design calculations with minimum one number of anodes installed between every two supports provided between carriers and casing. The anodes shall be sized based on the permanent CP design parameters for marsh area and design life of permanent CP system.

5.14.3 Where casing is uncoated or unpainted additional protection for carrier pipe may not be provided.

5.15 REFERENCE CELL ACCESS POINTS 5.15.1 Reference cell access points shall be provided near insulating joint locations and at SV stations, where the ground is paved, for measurement of pipe to soil potentials. A perforated PVC pipe filled with native soil and buried at the location shall be provided for the purpose. The length of the PVC pipe shall be adequate to reach the native soil below the paving.

5.16 CABLES

5.16.1 Cables shall be with annealed high conductivity stranded copper conductor, PVC insulated, 650/1100 V grade, armored, PVC sheathed conforming to IS 1554 part-I, except for the cables for anode tail, reference cells and pipeline for potential measurements. The size of

the copper conductor shall be minimum 35 mm2 for anode and cathode cables, 6 mm2 for current measurements, 10 mm2 for anode tail cables and polarization coupon protection cables. The size of cable for bonding, polarization cell, grounding anodes and surge diverter connections shall be suitable for the maximum fault current subject to minimum 25 mm2.

5.16.2 The anode tail cables shall be PE insulated, 650V grade, unarmored, PVC sheathed and length shall be sufficient for termination on anode lead junction box without any joint in between.

5.16.3 The cables for reference cells, coupon and pipeline potential measurements shall be of 4 sq.mm copper conductor, PVC insulated, Aluminum backed by Mylar/polyester tape shielded, PVC sheathed, armoured, PVC over all sheathed type.

5.16.4 The CPTR unit incomer cable shall be minimum 4 sq.mm Copper conductor, 650/1100 V grade, PVC insulated, armoured, PVC sheathed. The cable shall be of 3 core types for single phase CPTR units and of 4 core type for 3 phase CPTR units.

5.16.5 The cables for connecting various transducers from CPTR unit/CPPSM to telemetry interface junction box shall be twisted pair with individual pair shielded and overall shielded with aluminum hacked by Mylar/polyester tape, PVC sheathed, armoured, PVC over all sheathed type.

6.0 INSTALLATION 6.1 CABLE LAYING 6.1.1 Cables shall be laid in accordance with layout drawings to be prepared by the contractor. No straight through joint shall be permitted. Cable route shall be carefully measured and cables cut to required length. Minimum half meter cable slack shall be provided near anodes, anode junction box, and pipeline and test stations to account for any settling.

6.1.2 All cables inside station/plant area shall be laid at a depth of 0.75 meter. Cables outside station/plant area shall be laid at a depth of minimum 1.5 meters. Cables shall be laid in sand under brick cover and back filled with normal soil. For cables laid outside the station/plant area, polyethylene warning mats shall be placed at a depth of 0.9 meter from the finished grade, to mark the route.

6.1.3 In case of above ground cables, all unarmoured CP cables shall be laid in GI conduits of sufficiently large size, up to accessible height for protecting against the mechanical damage. 6.1.4 All underground unarmoured cables including anode tail cables shall run through PE sleeves. Distant measurement cables and permanent reference cell cables routedalong the pipeline shall be carried at the top of the carrier pipe by securely strapping it at intervals with adhesive tape or equivalent as required.

6.1.5 PVC pipes of proper size shall be provided for all underground cables for road crossings

6.1.6 Cables shall be neatly arranged in trenches in such a manner that crisscrossing is

avoided and final take-off to equipment is facilitated.

6.1.7 The cables for reference cells and pipeline potential measurement shall be routed in a separate trench other than the trench provided for the rest of the CP system cables, AC cables for CPTR Units etc.

6.1.8 The armour of the cables from CP station to test station (potential measurement, reference cell & drainage cables etc.), CP station to, ground bed (anode cable) and test station to pipeline shall be earthed only at CP station end and test station end respectively of the cables. The cable armour shall be insulated (by taping with insulation tape) to avoid armour carrying CP current.

6.2 PERMANENT REFERENCE CELLS 6.2.1 The permanent reference cells shall be installed in natural soil conditions as per the recommendations of the cell manufacturer. Installations in highly acidic/alkaline soil and soil contaminated by hydrocarbons shall be avoided.

6.3 CABLE TO PIPE CONNECTIONS 6.3.1 All cable connections of other than cathode drainage cables to the new pipeline shall be made by an approved exothermic process or by pin brazing. However, cable connection to charged pipelines shall be made by pin brazing. Exothermic welding shall be adopted for water pipelines. The resistance of the cable to pipe at the pin, brazing, and connection point shall not exceed 0.1 ohm.

6.3.2 The cathode drainage cable shall be connected to a bolt welded to a metal plate, which is weld connected to the pipeline. The material of the plate shall be same as that of the material of the pipeline.

6.3.3 Pipe coating shall be repaired after connection of cable to pipeline. At cathode drainage point the cable joint including the bolt metal plate and the exposed portion of the pipeline shall be covered by the coating repair material against ingress of water/moisture. The coating repair material shall be compatible with the, original coating and shall prevent ingress of wter along the cable surface and at the interface of coating repair with the original pipe coating.

6.4 GROUND BED (IMPRESSED CURRENT) 6.4.1 The location and the soil resistivity of groundbed site shall be verified to confirm the design. During construction, test result may require some modifications in the design, e.g. anode depth, location etc. Prior to installation, impressed current anodes shall be inspected for defects, conformance with the anode specification, size and length of anode cable tails, and to ensure that anode caps, if used, are secured. Care must be exercised to avoid damage to the anodes during handling and installation. Cable tail should be visually inspected for defects in insulation. Care must be taken to avoid damage to the cables or cable insulation. Each anode

shall be tagged with a unique number or code.

6.4.2 Anode should never be handled, lifted or lowered using the anode cables, unless specifically allowed by manufacture in installation instructions (e.g. stringed anodes).

6.4.3 Impressed current anode shall be installed in carbonaceous backfill. If the backfill material is supplied loose. It should be compacted properly so that there are no voids around the anodes.

6.4.4 Contractor shall submit detailed installation procedure for both surface and deep grounbeds for Owner / Consultant approval prior to the installation.

6.4.5 Where specified in, project Specifications/Data Sheet chain link fencing shall be provided around the location of each ground bed/anode lead junction box.

6.5 INSTALLATION PROCEDURE 6.5.1 Full construction details and installation procedures for various equipment of the cathodic protection system shall be submitted to Owner / Consultant for review and approval.

a. Written procedure for the installation of DC voltage sources, groundbeds, cables, test facilities and all civil works.

b. Procedure for cable connection to the structures. c. A time schedule for the installation of the system. d. Written procedure for all tests require to be carried out at site e. All relevant construction drawings including but not limited to plot plan, location of

cathodic protection stations and test facilities, cable routing, single line diagram and schematics, wiring diagram, groundbed construction and civil works.

f. Written procedure to ensure safe working practices during installation. 6.5.2 The installation of the cathodic protection system shall start only after approval of the installation procedure by Owner / Consultant. 7.0 INSPECTION TESTING AND COMMISSIONING

7.1 Field tests as per the reviewed field testing and commissioning procedures prepared by the contractor shall be carried out on the equipment/systems before these are put into service. Acceptance of the complete installation shall be contingent upon inspection and test results. Field testing shall include but not be limited to the following:

7.2 Contractor shall carry out pre-commissioning operations after completion of installation of the system including all pre-commissioning checks, setting of all equipment, control and protective devices. All site tests, reliability and performance tests shall be carried out by Contractor.

7.3 Before the electrical facilities are put into operation, necessary tests shall be carried out to establish that all equipment and devices have been correctly installed, connected and are in

good working condition as required for the intended operation. Owner/Owners representative may witness all tests. At least one week's intimation notice shall be given before commencing the tests.

7.4 All tools, equipment and instruments required for testing shall be provided by Contractor. Generally, the following minimum tests must be carried out and results shall be recorded:

Visual inspection Comparison with drawings, Specifications, detailed physical inspection and, if necessary, by taking apart the component parts. Testing Simulation tests of equipment to determine its operational fitness.

7.4.1 Cables a. Cable No. b. Voltage grade. c. Conductor cross section d. Continuity check e. Voltage test. f. Insulation resistance values between each core & earth, between cores (between core

and earth for single core cable). All cables shall be tested by 500 V megger.

7.4.2 E/R probe a. Location / Identification number b. Checking of wiring as per schematics c. Resistance reading of probe d. Installed on top/bottom/side of the pipeline

7.4.3 Reference cell a. Location b. Type of cell c. Potential reading d. Installed on top/bottom level of pipeline

7.4.4 Insulating joint a. Location b. Pipe to soil potential of both protected and non-protected sides of the insulating

7.4.5 Surge diverter a. Location/identification number. Rating b. Type c. Check for healthiness. 7.4.6 Polarization cell

a. Location identification number b. Rating

c. Check for wiring d. Check standby current drain after CP system energisation. (Current drain

with respect to voltage across the cell shall be recorded). e. Details of grounding provided for the polarisation cell.

7.4.7 Anode ground bed

a. Location/Station Check for actual layout and compliance with drawings. b. Resistance of each individual anode. c. Current dissipation by each individual anode. d. Total resistance of complete anode bed. e. Mutual interference.

7.4.8 Computerized Test station

a. Location/Identification number b. Checking of wiring as per schematics c. Checking programmed interval for 'collection of the field data by the, computer d. Type of reference cell

7.4.9 Polarization Coupons

a. Location b. Exposed area/size of coupon. c. Coupon to soil 'ON' and `OFF' potentials. d. Type of reference cell. e. Magnetic reed switch rating. f. Operation of magnetic reed switch with magnet.

7.5 CP COMMISSIONING PROCEDURE 7.5.1 A model commissioning procedure for a three stations CP system of a pipeline is given below for general guidance. It is mandatory for Contractor to develop detailed commissioning procedure as per this guideline.

7.5.2 On completion of installation of anode beds and other systems as envisaged in this Specification, they shall be individually checked, tested and compared against the agreed Specifications and procedure.

7.5.3 Electrical continuity of the entire pipeline shall be verified hi conformity with design. Input resistance of the pipeline at all the drainage points shall be checked and recorded.

7.5.4 All current measuring test stations shall be calibrated and recorded using portable battery, variable resistances, voltmeters, ammeters, etc. as required.

7.5.5 Temporary protection facilities provided (if any) which do not form part of permanent CP shall be disconnected from the system & removed unless agreed otherwise.

7.5.6 Anodes provided for grounding at the MOVs on cathodically protected portion of the pipeline shall be disconnected. Sacrificial anode where provided for the protection of the casing pipe at cased crossings shall be disconnected.

7.5.7 The pipeline shall be allowed to depolarize for at least 72 hours after switching `OFF' the protection (if any) of all other pipelines in the common ROW.

7.5.8 Before the pipelines are put on charge by switching `ON' any of the CP stations, natural pipeline to soil, casing pipe to soil and coupon to soil potential values at all the test stations of the system (coupon to soil potential at the locations of the coupon installations) shall be measured with respect to Copper/Copper Sulphate half cell.

7.5.9 CP station no.1 shall be energized with output potential adjusted to achieve a maximum pipe to soil potential (PSP) as specified, at the test station nearest to the drainage point. Observations on either spread of protected portion of pipeline and coupons under this CP station shall be taken for PSP 'ON' and PSP 'OFF' values at each of the installed test stations (coupon to soil potential at the locations of the coupon installations). The typical switching cycle of current interrupter shall be 12 seconds 'ON' and 3 seconds 'OFF'. The pipeline current values across the cross section of the pipeline shall also be determined at all the intended test stations influenced by this station.

7.5.10 CP station no.1 shall now be switched 'OFF', CP station no. 3 shall be switched 'ON' and measurement procedure as detailed in clause ix) above shall be repeated.

7.5.11 Similarly CP station no. 1 and 3 shall now be switched 'OFF', CP station no.2 shall be witched 'ON' and measurement procedure as detailed in clause ix) above shall be repeated.

7.5.12 All the CP stations of the system shall be switched 'OFF' and the pipelines shall be allowed to depolarize. All the three CP stations in the system shall then be simultaneously switched ON' and PSP values at the drainage points of pipeline shall be brought to a value of maximum PSP as specified and a complete set of observations shall be taken.

7.5.13 Another complete set of pipe to soil and coupon to soil observations shall be taken after lines have stayed on charge for 48 hours. If there are appreciable differences in these observations as compared to those of earlier set, a third set of observations shall be taken after 72 hours. Maximum drainage point protective potentials shall not be allowed to go beyond the maximum PSP values as specified, in any case.

7.5.14 Coupon to soil 'OFF' potential shall be measured at all locations of coupon installations by operation of magnetic reed switch in the test station. The PSP of the coupons shall be within the PSP range specified in clause 4.4 of this document.

7.5.15 The output of all CP stations shall then be so adjusted that the sites of occurrence of least negative protective potentials are not less negative than (-) 0.95V (OFF) and sites of occurrence of the most negative protective potential are not more negative than (-) 1.18V (OFF). A full set of pipe to soil, coupon to soil observations shall again be taken 72 hours after the adjustment of potentials and the protection system shall be left-in this state of operation.

7.5.16 Care shall be exercised to ensure that power supply remains uninterrupted during the

period of commissioning. In case of an interruption, the test in progress shall be repeated after allowing time for polarization. More sets of observations shall be taken in any of the steps specified above, if advised by the Owner/Owner's representative.

7.5.17 The zinc anodes for grounding of MOVs at the locations of MOVs on cathodically protected portion of the pipeline shall be reconnected to the MOVs.

7.5.18 At cased crossings where casing is protected, sacrificial anodes provided for the casing shall be connected to the casing pipe. The casing to-soil potential and anode out; put current shall be measured and recorded Where casing pipe protection is inadequate or the output current of the anode is more than the designed current, then additional anodes shall be provided as required.

7.5.19 PSP -values at each of the test stations of the existing pipelines shall be measured, plotted, where existing pipelines run in parallel to the new pipeline, mutual interference situations between the pipe lines shall be identified and necessary mitigation measures shall be provided. Interference situations shall also be identified and mitigated by comparing different sets of readings taken at same test stations at different intervals of time under identical conditions where positive potential swing is 100 mV or more.

7.5.20 Current readings at all the current measuring test stations shall be measured and recorded.

7.5.21 Where computerized test stations are provided the computer shall be initialized / started to collect and store the field data of potentials, current readings, etc as programmed.

7.5.22 After one month of starting the computers to collect the field data, the data stored by the computers at all the computerized test stations shall be retrieved/down loaded using the field data-retrieving computer. The data shall be analyzed with the help of a station main computer.

7.5.23 At the locations of the Electrical resistance probe installations the resistance readings of the probes shall be measured using, probe reader.

7.5.24 Original records of testing and, commissioning including graphical representation of final pipe soil potential readings shall be compiled with interpretation in consultation with Owner/Owner’s representative and submitted.

7.5.25 If any deficiencies are found in system, the same shall be rectified by the contractor, at extra cost or time schedule impact, to the complete satisfaction of Owner/Owner's representative. Such deficiencies shall include 'mitigation of stray current electrolysis and interference problems that may he found existing in the course of testing and commissioning. A set of PSP observations shall also be taken during the peak of the first year season after commissioning the system into regular operation. Any deficiency found in the protection of the pipeline shall be rectified by the contractor at his own cost.

7.5.26 If it is found during commissioning that the sites of occurrence of least negative or most negative protective potentials are less negative than (-) 0.95V (OFF) or more negative than (-) 1.18V (OFF) respectively even after 72 hours of operation, then the drainage point potentials shall be adjusted depending upon anode ground bed currents in consultation with Owner/Owner's representative. In any case, the protective 'OFF' potential values of pipeline and polarization coupons shall not exceed the PSP value range specified in cl. 4.4 of this document, at any location on the pipeline.

7.5.27 The reference cell shall be calibrated minimum once in 24 hours during the commissioning.

7.5.28 The current dissipated by individual anodes shall be measured from the anode lead junction box and corrected for equal dissipation to the extent possible keeping the total ground bed current same.

8.0 INTERFERENCE MITIGATION 8.1 Investigations shall be made for stray current electrolysis of the pipeline, mutual interference, between the pipeline and foreign pipelines/structures, interference on foreign pipelines/structures due to the CP of the pipeline and ground bed, interference on metallic structures which lie in between pipeline and ground bed or near to ground bed, AC induction on pipeline due to overhead EHV/HV, lines, interference due to high voltage DC dines, HVDC earthing system; electric traction, etc.

8.2 Measurements including pipe/structure to soil potentials and pipe/structure currents etc on the pipeline/stricture being CP protected and on foreign pipelines/structures, and ground potential gradient etc. shall be made to investigate the current discharge and pickup locations. In case of fluctuating stray currents, investigations shall be made continuously over a period of time and if required simultaneously at different locations to find, out the stray current source(s). Recorders shall preferably be used for long time measurements.

8.3 Wherever foreign pipelines which may or may not be protected by an independent CP system run in parallel to the protected pipeline either in the same trench or very near to the protected pipeline and are not bonded to it, investigations shall be performed for current discharge points on both the pipelines.

8.4 Mitigative measures shall be provided depending upon the type of stray current electrolysis/interference. These shall include installation of bond with variable resistor, diodes, installation of galvanic anodes for auxiliary drainage' of current, adjustment/ relocation (if possible) of offending interference source, provision of electrical shield etc. depending on the type of interference.

8.5 Bonding with foreign pipelines/structures as a mitigation measure shall be provided where the Owners of the foreign pipelines/structures have no objection. Otherwise alternative mitigation measures shall be provided. Wherever bonding is provided for mitigation, the bonding resistor shall be adjusted for optimum value for minimum/no interference. Galvanic anodes

installed as a mitigation measure shall be adequately sized for the life specified for permanent CP system.

8.6 Where overhead EHV/HV transmission lines/underground electric cables cross the pipeline run in parallel with in or more than 25m from the pipeline, A.C. Voltage measurements induced voltage being beyond the safe Limits, the pipeline shall be grounded in line above.

9.0 CLOSE INTERVAL POTENTIAL SURVEY

9.1 Where specified contractor shall carry out a close interval `ON/OFF' potential survey over the entire length of pipeline by computerized potential logging method and identify the under protected/over protected area, any major coating damage on the pipeline, after the backfilling has been consolidated sufficiently and CP system has stabilized. Contractor shall provide required mitigation measures and rectify the under/over protected zones, identify if any, the major pipeline coating defects required to be repaired. During the survey the reference cell shall be calibrated minimum once in 24 hours. Detailed procedures for running this survey shall be submitted for review.

9.2 Additional tests for detailed identification of coating defects shall be conducted by the contractor, if specified in the project Specification/ Data Sheets.

STANDARD SPECIFICATION FOR EQUIPMENT AND MATERIALS FOR CP SYSTEM FOR U/G PIPELINES

ABBREVIATION

AC Alternating Current BS British Standards BIS Bureau of Indian Standards CMRI Central Mining Research Institute CP Cathodic Protection CPPSM Cathodic Protection Power Supply Module CPTR Cathodic Protection Transformer Rectifier DC Direct Current HV High Voltage IS Indian Standards MMO Mixed Metal Oxide MOV Motor Operated Valve NACE National Association of Corrosion Engineers PE Polyethylene PVC Polyvinyl ROW Right of Way

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE .........................................................................................................


3.0 DEFINITION .................................................................................................

4.0 SITE CONDITION .........................................................................................

5.0 MATERIAL ...................................................................................................


7.0 MARKING,PACKING AND SHIPMENT .......................................................

1.0 SCOPE

1.1 This Specification covers the requirements for the design, manufacture, supply and testing of various equipment and materials for Cathodic Protection system for underground pipelines/structures.

1.2 These equipment and materials shall broadly include: a. Sacrificial Anodes b. Test Stations c. Anodes for impressed current CP system d. Anode junction boxes e. Cathode junction boxes f. Permanent reference cells g. Electrical resistance probes h. Polarisation cells and surge diverters/grounding cells i. Polarisation coupons j. Computerised test stations k. Cables

1.3 Requirement of Cathodic protection TR units (CPTR unit) and cathodic protection power supply modules (CPPSM) are covered in separate Specifications.

2.0 REFERENCE DOCUMENTS 2.1 All equipment and material covered in this Specification shall conform to the requirements of the latest revision of following Standards:

IS – 3043 : Code of practice for earthing NACE Standard RP0169

Standard recommended practice Control of corrosion on underground or submerged metallic piping system

BS 7361, Part-I Cathodic protection, code of practice for land and marine applications ASTM A518 M Corrosion resistant high silicon iron casting ASTM B418 cast and wrought galvanic zinc anode ASTM B338 Specification for seamless and welded Titanium and Titanium alloy tubes for condensers and heat exchangers. Magnesium Alloy Anodes for cathodic protection ASTM B843 IS 1554,part-1

PVC insulated (heavy duty)cables

2.2 In case of imported equipments Standards of the country of origin shall be applicable if these Standards are equivalent or stringent than the applicable Indian Standards. 2.3 The equipment shall also confirm to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country.


a. Statutory regulations. b. Data Sheets. c. Job Specification d. This Specification e. Codes and Standards

3.0 DEFINITION


OWNER / COMPANY OWNER of the particular Project (Project Specific). CONSULTANT The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management. BIDDER / SUPPLIER / VENDOR 4.0 SITE CONDITION


4.1 The equipment and materials shall be suitable for installation in locations having generally corrosive, warm and humid or dusty atmosphere. Service conditions shall be as specified in the project Specification/Data Sheet. If not specifically mentioned therein, a design ambient temperature 40°C and an altitude not exceeding 1000 M above mean sea level shall be considered.

5.0 MATERIAL

5.1 All equipment/material shall be brand new with state of art technology and proven field track record. No prototype equipment shall be offered.

5.2 Make and construction of all equipment/materials shall be subject to approval by Owner/Owners representative. 5.3 SACRIFICIAL ANODES 5.3.1 MAGNESIUM ANODE

The anode shall conform to the requirements of ASTM-B 843 Standard. The anode shall be of high manganese, magnesium alloy packed with special back fill. The metallurgical composition, potential and consumption rate of anode shall be as below.

a. Composition Element WEIGHT WEIGHT (High potential type) (low potential type) Manganese 0.5 – 1.3% 0.15 – 0.7% Copper 0.5 – 1.3% 0.15 – 0.7% Silicon 0.5 – 1.3% 0.15 – 0.7% Zinc - 2.5 – 3.5% Aluminium 0.5 – 1.3% 0.15 – 0.7% Iron 0.5 – 1.3% 0.15 – 0.7% Nickel 0.5 – 1.3% 0.15 – 0.7% Calcium 0.5 – 1.3% 0.15 – 0.7% Other metallic elements Each 0.5 – 1.3% 0.15 – 0.7% Total 0.5 – 1.3% 0.15 – 0.7% Magnesium Balance Balance Anode open circuit Potential 1.75 volts 1.55 volts Anode consumption rate 7.9 Kg/ (A Yr) max. 7.9Kg. / (A.Yr) Max. 5.3.2 ZINC ANODE The anode shall conform to the requirements of ASTM-B 418 Standard. The metallurgical composition of anode, potential and consumption rate of anodes shall be as below. Anodes of type I shall be used for seawater, brackish water or saline electrolyte application and anode of type II shall be used for fresh water, back fill and soil applications. The anode (other than ribbon anode) shall be packaged with special backfill. The type of ribbon anode inside the casing at cased crossing shall be suitable for the type of soil outside the casing.

a. Composition Element

Weight

Weight

(Type I) (Type II) Aluminium 0.1% to 0.5% 0.005% max. Cadmium 0.025-0.07% 0.003% max. Copper 0.005% max. 0.002% max Iron 0.006% max. 0.0014% max Lead 0.006% max. 0.003% max Others 0.01% max. - Zinc Remainder Remainder Anode open circuit potential 1.1 volts 1.1 volts Anode consumption rate Kg/A.Yr) mx

11.24 Kg/A.Yr) mx 11.24

http://casing.at/

5.3.3 The anodes shall be provided with cable tail of sufficient length to reach test station/ buried junction box, as applicable without any intermediate joint in the cable and with minimum of 0.5m cable slack provided at each anode and test station ends.

5.3.4 The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.

5.3.5 The anodes shall be suitable for the composition/conditions of soil in which they will be installed.

5.3.6 The other details of anodes shall be as shown in the applicable Consultant Standard drawings.

5.3.7 The anodes for grounding of cathodically protected above ground pipelines at intermediate SV stations, pigging stations, etc, groundings of motor operated valves on cathodically protected portion of the pipeline, grounding of pipeline through polarisation cell at EHV/HV line crossings or running in parallel, etc shall be of minimum 20 kg net weight each. The anode and cable terminations shall be suitable for the anticipated fault current at the location of installation. For pipelines protected by sacrificial anodes, the anodes for directly grounding the pipeline shall be of the same type as the one provided for the protection of the pipeline.

5.3.8 Special Backfill The composition of special back fill for anodes shall be as below

Gypsum 75% Bentonite 20%

5.4

Sodium sulphate TEST STATIONS

5%

5.4.1 Test stations shall be provided along the pipeline ROW for monitoring the performance of the cathodic protection system. Test station enclosure shall be made of sheet steel of at least 3 mm thickness and shall be suitable for GI pipe post mounting. Test stations shall have weatherproof enclosure having degree of protection IP-55 and hinged lockable shutter. The inner and outer surfaces of test stations shall be epoxy painted.

5.4.2 The resistors for control of current provided in the test stations, anode/cathode junction box etc shall be of variable, grid coil type. The resistors shall be suitable for operation over the design life for the permanent CP system specified in the project Specification/Data Sheet.

5.4.3 Number of terminals and different schemes of wiring shall be as per the applicable Consultant Standard drawing. Minimum twenty percent spare terminals shall be provided in each test station. 5.4.4 At locations where solid state polarisation cells are provided, the test station size shall be suitable for mounting the polarisation cell inside the test station.

5.4.5 A nameplate of anodised aluminium with black back ground and white letters shall be fixed to the inner side of the test station. The nameplate shall carry the following minimum information:

a. Chainage in km. b. Test station connection scheme. c. Distance form pipeline in meters. d. Direction of product flow. e. The constructional features of test stations shall be as per the applicable Consultant Standard drawings.

5.5 ANODES FOR IMPRESSED CURRENT CP SYSTEM 5.5.1 HIGH SILICON CAST IRON ANODES High silicon cast iron type anodes shall be center-connected hollow type or end connected solid type. Cable to anode joint shall be reliable and long lasting for total design life of anode. Composition of anodes shall be as below and shall also conform to ASTM A518 M-86 Gr. III.

Element Weight Silicon14.2 - 14.75% Manganese 1.5% max Carbon0.7 - 1.1% Chromium 3.25 - 5.0% Copper0.5% max. Molybdenum 0.2% max. Ironremainder 5.5.2 Surface current density rating of the anode for continuous operation shall be 15 amperes/sq.m (max.) for shallow anode ground bed and 10 amperes/sq.m (max.) for deep well anode ground beds.

5.5.3 Anode consumption rate shall not be more than 0.2 kg. /Amp. Yr 5.5.4 The design life of anode under burial condition, at the design operating current shall be in minimum the design life of the CP system specified in the project Specifications/Data Sheet.

5.5.5 For shallow anode ground bed sheet steel anode canisters of adequate size shall be provided for each anode. Anode canisters shall be filled with petroleum coke breeze with following Specification conforming to IS: 8502, Grade-A type.

a. Chemical composition Fixed carbon content by mass : 99% min. Ash by mass : 0.5% Moisture by mass : 0.1% Volatile matters by mass : 0.5% max. Bulk density : 800 kg. /M3 to 1200 kg./M3 Real density : 2.03 kg/litre min. Particle size : 1 mm max, dust free Resistivity : 0.1 ohm cm max at 150 PSI 5.5.6 For deep well ground beds, anodes shall be non canistered type. Calcined petroleum coke breeze slurry conforming above shall be supplied along with the anodes.

5.5.7 MIXED METAL OXIDE COATED TITANIUM ANODE a. Mixed metal oxide coated titanium anodes shall be of pure titanium having substrate composition of titanium of ASTM B-338, Grade I/Grade ll, over laid with mixed oxide of noble metals (MMO coated). These anodes shall be dimensionally stable. The anodes shall be centre connected & sealed tubular type. The design life of anode under burial condition, at the design operating current in minimum is the design life of the CP system specified in the project Specifications/Data Sheet.

The guaranteed design parameters of anode regarding current density, consumption rate, design life, rated current output, dimensions, shape, noble metal oxide coating thickness (gm/square meter), and their physical and mechanical properties shall be substantiated by manufacturer's published catalogues and backed up by type test reports. Each anode shall be supplied with anode lead cable connected to it. b. The anodes shall be provided with sheet steel canisters and coke breeze as per Data Sheet.

5.5.8 Each anode shall be supplied with anode tail cable connected to it, which shall long enough for termination on their associated anode lead junction box without intermediate joint. Anode cable tail shall be connected/jointed to the anode and the joint insulated at the anode manufacturer's shop before dispatch of anode.

5.5.9 For deep well ground beds steel pipe casing for active portion of the ground bed and non metallic pipe casing for the top inactive portion of the ground bed shall be provided. The top non metallic casing and the lower metallic pipe casing shall have threads for jointing each other. Anode supporting pipe, anode centralizers and gas venting pipes shall be provided for the ground bed.

5.6 ANODE JUNCTION BOX 5.6.1 Depending on the size and configuration of anode ground beds, requisite main and sub anode junction boxes (where required) shall be supplied for each ground bed. a. Each junction box shall have provision of termination of cable tails from individual anodes of the ground bed and provisions of connection of anode cable coming from main anode, junction box (in case of sectionalized ground bed) or from CP station power source. b. Junction boxes shall have sheet steel enclosure of minimum 3 mm thickness and hinged lockable shutters. Junction boxes shall be weatherproof with degree of protection IP55. It shall be epoxy painted on inside and outside surface Junction boxes shall have anode bus of copper with nickel/ silver-plated or tinned. Provision shall be made for measurement and control of individual out going circuit/anode current by providing suitable shunt and resistors of grid coil type. Disconnecting links shall be provided for each out going/anode circuit. 30% spare outgoing circuits shall be provided in each anode junction box. Terminals shall be of anti loosening type and provided with identification labels. Each outgoing circuit shall be labeled clearly to indicate the circuit/sub anode junction box to which it is connected. c. The constructional features of junction boxes shall be as per the applicable Conultant Standard drawing enclosed with the Data Sheet for impressed current cathodic protection system for pipelines. d. A nameplate of anodised aluminium with black back ground and white letters shall be fixed to the inner side of the junction box. The nameplate shall carry the following minimum information: I. Ground bed current rating II. Ground bed resistance III. Connection scheme. IV. Distance form pipeline in meters. V. Distance form CP station in meters. 5.7 CATHODE JUNCTION BOX 5.7.1 Where output of the CP power supply unit is connected to multiple pipelines a cathode junction box shall be supplied for providing near the pipelines at the location of connection of the negative drainage cable to the pipelines.

a. The junction box shall have a bus bar with an incoming circuit for connecting to negative of the CP power source and separate out going circuits for collection of negative drainage current from each of the pipelines. b. The incoming circuit shall have a current measurement shunt. Each out going circuits shall have isolation link, variable resistance of grid coil type and a current measurement shunt. One number spare outgoing circuit shall be provided. c. Junction box shall have sheet steel enclosure of minimum 3 mm thickness and hinged lockable shutters. Junction box shall be weatherproof with degree of protection IP-55. The inside and outside surfaces of the junction box shall be epoxy painted. The terminals shall be of anti loosening type. Proper identification labeling shall be provided for each terminal. Each outgoing circuit label shall clearly indicate the size and identification of the pipeline to which it is connected A nameplate of anodised aluminium with black back ground and white letters shall be fixed to the inner side of the junction box. The nameplate shall carry the following minimum information: I. Chainage in km II. Connection scheme III. Distance from the nearest pipeline in meters IV. Direction of product flow 5.8 GI EARTH ELECTRODES 5.8.1 For earthing of above ground cathodically unprotected pipelines at intermediate SV stations, pigging stations, etc. and at terminals GI earth electrodes shall be supplied. Earth electrodes shall be 100 mm dia, 3000 mm long, and 13 mm thick conformity to IS 3043.

5.9 PERMANENT REFERENCE CELLS 5.9.1 High purity copper/copper sulphate reference cells or Zinc reference cells as specified in project Specification/Data Sheets, with proven high-reliability shall be supplied for providing stable pipe to soil potential measurement reference at CP stations, at computerised test station locations and at locations of polarisation coupons along ROW.

5.9.2 Silver/silver chloride type reference cells shall be supplied for marshy area locations where water table is high and chloride ion content is more than 300 ppm.

a. The reference cells shall have high accuracy and stability and maintain the same over its design life. b. The permanent reference cells shall have a minimum design life of 20 years under installed/buried condition. c. The reference cell for high resistivity areas shall be: suitable for the prevailing dry soil conditions to give maximum service life. d. The reference cells shall be provided with cable tail long enough for connection to test station without any joint in between.

5.10 ELECTRICAL RESISTANCE PROBE 5.10.1 Electrical resistance probes utilizing the electrical resistance technique shall be suitable for use along the pipeline at marshy areas and at interference affected locations/vulnerable locations to monitor the external corrosion activity on the pipeline.

5.10.2 The material of the E/R probe element shall be of the same alloy as that of the pipeline material. Probe shall be provided with cable leads system and required for the probe resistance measurements.

5.10.3 Portable E/B .probe reading instrument shall be supplied by contractor, as specified in the project Specification Data Sheet the probe reading instrument shall be suitable for use in field and shall have IP55 weatherproof enclosure. The probe reading instrument shall be of digital type with 3.5 digit display. The instrument shall run on rechargeable batteries. The instrument shall be able to directly read out the resistance of probes

5.11 POLARIZATION CELL AND SURGE DIVERTER 5.11.1 POLARIZATION CELL a. Polarisation cell shall be a electrolytic type or solid state device as specified in project Specification/Data Sheets, designed to simultaneously provide isolation for DC current and low resistance path for AC current. The device shall require minimum maintenance. The solid state device shall have weather proof enclosure and shall be suitable for mounting inside a test station. b. Unless otherwise specified in project Specification / Data Sheet the DC blocking voltage shall not be less than 1.2 volts. The DC leakage current at 4.2 volt shall not be more than 0.5 mA. c. The device shall be suitable for continuously conducting maximum AC steady state current and short time AC short circuit current expected to flow through the pipeline under the normal operating condition/any kind of fault on the EHV/HV line at respective sites.

5.12 SURGE DIVERTER 5.12.1 The surge diverter when connected in parallel across the insulating joints shall protect the insulating joint against surges coming across it due to lightning strikes, electrical faults, etc, on the above ground portion of the pipeline. The surge diverter shall be of spark gap type. The device shall have weatherproof enclosure suitable for outdoor mounting. The surge diverters shall be of explosion proof type.

5.12.2 The minimum ratings of polarisation cells and surge diverters shall be as below unless otherwise specified in the project Specification/Data Sheet.

a. Polarisation Cell Type: solid state type/electrolytic type Minimum rated 50 Hz steady : 30A min at 28°C and min 2V DC State current (RMS symmetrical) AC fault current : 5 KA min for 1 cycle (RMS symmetrical) AC voltage under maximum Rated AC fault current : less than 10 V peak to peak b. Surge diverter Type : spark gap, explosion proof type Current, 8/20 micro second wave : 100 Kilo Amp Spark – over AC voltage 50 Hz : 1KV Impulse (1.2/50 micro second) : 2.2KV c. The polarisation cells, surge diverters, anodes, connecting cables, cable joints, etc, shall be adequately sized and suitable for the design life of permanent CP system. The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.

5.13 POLARISATION COUPONS 5.13.1 The polarisation Coupons shall be made from the material of the pipeline. The coupon shall have one side exposed area of 100 mm x 100 mm unless otherwise specified in project Specification/Data Sheet. Cable connection of 10 mm2 and 4 mints shall be provided to the coupon for connecting it to pipeline for cathodic protection and potential measurements respectively.

5.13.2 Connection of coupon to pipeline shall be through a vacuum sealed magnetic reed switch housed inside the test station. The magnetic reed switch shall be rated to carry and break minimum 50 mA at 50 V DC.

5.13.3 Magnet for operation of reed switches shall be provided as specified in project Specification/Data Sheet.

5.14 COMPUTERISED TEST STATION AND TEST STATION READER 5.14.1 COMPUTERISED TEST STATIONS a. The computer units for installing at computerised test stations shall be able to measure and record the field CP system parameters automatically at regular programmed intervals. The computer shall have required numbers of input ports for measurement of pipe to soil DC potentials, induced AC potentials, pipeline current, bond current, etc. In any case the number of input ports shall not be less than five. All the input measurement ports shall be protected against high voltage surges due to lightning/HV switching that may come from the pipeline. b. The computer shall have a real time clock and shall indicate the date and time of the data collection along with the data. The accuracy of the internal clock shall be +1, 0.1% or better. The input data measurement accuracy shall be +/- 0.5% or better. The measurement range for the input ports for pipe to soil measurement shall be (+) 5 V to (-) 5 V DC. The measurement range for the other input ports shall be decided based on the maximum value of the input parameters-measured. c. Unless otherwise specified in the job Specification/Data Sheet the computers shall be programmed to collect and store all the field parameters once daily. It shall be possible to reprogram the computer for the data collection interval/set/initialize the computers at field with the help of data retrieval computer. d. It shall be possible to designate a unique identification number incorporated in to the software of each computer for identification of the unit after down loading the field data from it. e. The computer shall have memory capacity suitable for storing the data measured at programmed intervals continuously for Six months without down loading the data. f. The battery provided in the computer shall be suitable for its operation including. Storing the measured data at field, as programmed for minimum 10 years without requiring the replacement/recharging of the battery g. The computer shall have provision/plug in arrangement for retrieval, of the stored data with a hand held data retrieval computer. h. The field computer shall have weatherproof enclosure. The test station housing the computer shall be of IP 55; weatherproof with locking arrangement.

5.14.2 THE DATA RETRIEVAL COMPUTER a. The data retrieval computer shall be of portable type suitable, for use infield. The computer shall be suitable for retrieving/down loading the data collected by the field computer, field programming/setting/initializing the field computer and estimating the field computer battery

capacity/life left over when connected to the field computer. Suitable plug arrangement shall be provided on the data retrieval computer so that it can be plugged in to the field computer for data transfer. The data retrieval computer shall have enough memory capacity for retrieving/down loading the data collected and stored by minimum ten field computers, each having collected the field data for minimum six months continuously. The battery provided in the data retrieval computer shall be suitable for this operation without any replacement/recharging the same during the operation. b. It shall be possible to down load the data collected by the data-retrieval computer to a station computer for further analysis of the data or directly to a printer. c. The data retrieval computer shall have IP 55, weatherproof enclosure. The unit shall be provided with a carry bag suitable for carrying in field.

5.15 MISCELLANEOUS REQUIREMENTS 5.15.1 The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under surface shall be free from all imperfections before undertaking the finishing coat. After preparation of the under surface, final spray painting with two coats of epoxy based paint shall be done. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint etc. 5.15.2 All unpainted steel parts shall suitably treated to prevent rust formation. Copper bus bars interconnection copper link shall be tinned or nickel/silver coated.Test station/junction box cabling. 5.15.3 Adequate space shall be provided inside the test station/junction box for termination of cables. Termination shall be performed using crimped lugs. The lugs shall be of tinned copper. Requisite cable lugs shall be supplied.

5.16 CABLES 5.16.1 Cables shall be of annealed high conductivity stranded copper conductor, 650/1100V grade PVC insulated, armoured, PVC sheathed conforming to IS-1554 part-I, except for reference cell, potential measurement and impressed current CP anode tail cables. The size of the copper conductor of the cables shall be as below:

a. Minimum 4 mm2 for potential measurement, reference cells, 6 mm2 for current measurement and 25 mm2 for bonding/grounding. b. For sacrificial anode CP system the cable size shall be minimum 6 mm2 copper for anode tail cable from anode to buried junction box and 10 mm2 copper from buried junction box to test station in case of temporary CP anodes. In case of sacrificial anodes for permanent CP system the size of anode tail cable from anode. To test Station shall be minimum 6 mm2 copper. c. For impressed current CP system the size of conductor of cables shall be based on the current to be carried, ground bed loop resistance and shall be minimum 35mm2 copper for positive, negative drainage cables and 10 sq.mm copper for anode tail cables. The size of CPTR unit AC incomer cables shall be of minimum 4mm2 copper conductor.

5.16.2 Impressed current CP anode tail cables shall be of minimum 10 mm2, annealed high conductivity stranded copper conductor, single core, 650 voltage grade PE insulated, unarmoured, PVC sheathed. Contractor may suggest cables with alternative insulation/sheathing having proven track record for impressed current anode ground bed application, for Owner's approval.

5.16.3 The cables for reference cells and pipeline potential measurements shall be of 4 mm2 copper conductor, PVC insulated, Aluminium backed by Mylar/polyester tape shielded, PVC

sheathed, armoured, PVC over all sheathed type. The tape shield shall be helically applied with metallic side down, with either side 25% overlap and 100% coverage. The minimum shield thickness shall be 0.05 min.

5.16.4 Cables for connecting various transducers from CPTR Unit/CPPSM to telemetry interface junction box shall be copper conductor, PVC insulated, twisted pair with individual pair shielded and overall shielded with Aluminium backed by Mylar/polyester tape, PVC sheathed, armoured, PVC over all sheathed type. 5.16.5 Cable conductor sizes indicated above are minimum only and where necessary for proper operation of the CP system higher sized cables shall be provided.Length of anode tail cables shall be sufficient for routing and terminating the cable inside anode junction box/buried junction box/test station as applicable without any intermediate joint.

5.17 EQUIPMENT FOR CLASSIFIED AREAS 5.17.1 Equipment for hazardous area shall be flame proof type and shall meet the requirement of IS: 2148 or equivalent international Standard and shall be suitable for gas group IIB, temperature classT3 (200°C). Indigenous equipment shall be certified by CMRI or any other recognised testing body and shall be approved by the concerned statutory authority. All flameproof equipment shall carry the BIS license marking as per the requirement of statutory authorities.

5.17.2 All Imported equipment, for hazardous area may be tested and certified by an independent certifying agency of country of equipment origin and shall be approved by the concerned statutory authority in India.


6.1 Unless otherwise agreed by the Engineer in Charge all the equipment/material shall be subject to inspection by Consultant / Owner or by an agency authorised by the owner. All necessary information concerning the supply shall be furnished to Consultant / Owners inspector. Two weeks notice shall be given to Consultant / Owner for witnessing the final testing.

6.2 Routine tests and final acceptance tests shall be carried out at manufacturer's works under his care and expense. Instruments and equipment required for testing shall be arranged by the manufacturer. Final acceptance shall be subject to successful testing. Type test certificates instead of conducting the tests may be accepted where specified in the project Specifications.

6.3 SACRIFICIAL ANODE 6.3.1 INSPECTION a. Visual inspection shall be carried out on all the anodes regarding surface finish excessive shrinkage, cracks, cable joint to anode cone, etc. b. Minimum 10% of number of anodes from each heat for conformity to dimension and weight c. The anode surface shall be free from cracks, which may reduce the performance of the anode d. Any cracks which follow the longitudinal direction of elongated anodes shall not be acceptable e. Small cracks in the transverse direction of elongated anodes and in anodes of other shapes may be accepted provided the cracks would not cause any mechanical failure during service of the anode considering that the combination of cracks and lack of bond to the anode core is detrimental.

f. For transverse cracks the acceptable limits shall be furnished by the bidders along with the offer. g. The anode shall be free from excessive shrinkage. The following limits shall be used. h. Maximum 10% of the depth of anode or 50% of the depth of the anode core whichever is less. The depression may be measured for the edges of one side. i. The surface of the anodes shall be free from coatings and slag/dross inclusions etc. j. The maximum deviation from straightness shall not exceed 2%. k. The weight tolerance of individual anode may be taken as + 5%. The total weight of the anodes shall not have negative tolerance Recommended dimensional tolerance shall be as follows: Length : ±2.5% Width/thickness : ±5% 6.3.2 One anode per heat shall be subjected to radiographic test completely to evaluate cracks, voids, slag inclusion, etc.

6.3.3 DESTRUCTIVE TESTING a. At least one anode per heat shall be subject to close inspection by destructive testing for slag inclusions, bond between the anode material and steel inserts. If the anode fails the test, two more anodes shall be tested. If the second lot of anodes also fails the test, all the anodes of the heat shall be rejected.

6.3.4 CHEMICAL ANALYSIS a. One anode sample per heat shall be subject to chemical analysis by spectrography. Sample shall be taken in the beginning for first heat, at the end for the second heat, at the beginning for the 3rd heat and so on. b. In case the chemical composition of the tested anode does not meet the requirements of this Specification, all the anodes of the heat shall be rejected. Vendor shall indicate specific method of spectrography for each element (eg.atomic absorption/emission/photometrics etc.).

6.3.5 ELECTROCHEMICAL TESTS a. One anode from the ordered lot shall be tested for I. Open circuit potential II. Consumption rate by weight loss method III. Visual examination of corrosion pattern (uneven consumption, inter granular attack, etc.) b. Where agreed by Owner type test certificate in lieu of actual conduction of electrochemical test may be accepted. c. The anode open circuit potential shall lie within (+) 10 MV and (-) 50 MV of the guaranteed value. The anode consumption rate shall not be less than the specified value. In case of anode closed circuit potential and/or the anode consumption rate do not meet the acceptance criteria all the anodes of the heat shall be rejected.

d. Manufacturer's test reports regarding reference cell calibration shall be furnished. The report shall also indicate the month and year of manufacture of reference cell.

6.4 IMPRESSED CURRENT ANODES 6.4.1 HIGH SILICON CAST IRON ANODE a. Visual inspection Visual inspection regarding surface finish, surface cracks & craters, shrinkage, cable joint, measurements of dimension, weight radiographic tests etc. shall be conducted. The anode acceptance criteria shall be as specified in the clause except that no crack in the anode shall be acceptable unless the cracks are only superficial

b. Destructive testing Destructive testing and acceptance criteria shall be as above. c. Chemical analysis Chemical analysis test and acceptance criteria shall be above. d. Electrochemical tests Electrochemical tests for anode consumption, visual examination of corrosion pattern and the anode acceptance criteria shall be as above.

e. Spectrographic analysis The anodes-from each heat shall be tested for chemical composition by spectrographic analysis and for homogeneity, dross inclusion, voids etc. by radiography. Destructive tests shall be carried out where asked by owner based on the radiographic test results.

6.4.2 MIXED METAL OXIDE COATED TITANIUM ANODE Contractor shall furnish list/details of the tests that will be conducted by manufacturer of anode and their acceptance criteria.

6.4.3 PETROLEUM COKE BREEZE AND SPECIAL BACK FILL The petroleum coke breeze material shall be tested for chemical composition, bulk density, real density, particle size and resistivity and test certificate shall be furnished. The special back fill material for the sacrificial anodes shall be tested for composition and test report shall be submitted

7.0 MARKING,PACKING AND SHIPMENT 7.1 All equipment/material for CP system along with one set of final drawings shall be dispatched to site packed in wooden crates

7.2 All the equipment shall be divided in to several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment call be wrapped in polyethylene sheets before being placed in

crates/cases to prevent damages to finish, Crates/cases shall have, skid bottom for handling. Special notations such as ‘Fragile', ‘This side up', `Centre of gravity', `Weight', `Owners particulars', `PO no’s, etc shall be clearly marked on the package together with other details as per purchase order.

7.3 The equipment may be stored out doors for long periods before installation. The package shall be completely suitable for outdoor storage in areas with heavy rain/high ambient temperature unless otherwise agreed

STANDARD SPECIFICATION FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

ABBREVIATION

BIS/IS Bureau of Indian standards IEC International Electro-Technical Commission BS British Standards IEEE Institute of Electrical and Electronics Engineers NEMA National Electrical Manufacturers Association OISD Oil Industries Safety Directorate CCE Chief Controller of Explosive DGMS Director General Mines Safety IE Rules Indian Electricity Rules CPRI Central Power Research Institute CPTR Cathodic Protection Transformer Rectifier CVCC Constant voltage constant current PSP Pipe to soil potential LED Light Emitting Diode SCADA Supervision Control And Data Acquisition PVC Poly Vinyl Chloride MTBF Mean Time Between Failure MTTR Mean Time To Repair HRC High Repturing Capacity

TABLE OF CONTENTS

SL NO. DESCRIPTION 1.0 SCOPE .........................................................................................................


3.0 DEFINITIONS ...............................................................................................

4.0 MATERIALS .................................................................................................

5.0 DESIGN ........................................................................................................

6.0 FABRICATION .............................................................................................


8.0 MARKING, PACKING AND SHIPMENT ......................................................

1.0 SCOPE

This Specification covers the requirements for the design, manufacture, testing and supply of Cathodic Protection Transformer Rectifier units (CPTR units) working on controlled rectification principle intended to supply power to cathodic protection system for underground pipelines/ structures.

2.0 REFERENCE DOCUMENTS 2.1 The system design, performance and materials to be supplied shall conform to the requirements of the latest revision of following Standards: IS: 1248 : Direct acting indicating analogue electrical measuring (Parts- 1, 2, 8 & 9) instruments and accessories. IS: 3700 : Essential rating and characteristics of semiconductor devices. (Parts-1 to 11) IS: 3715 : Letter symbols for semiconductor devices (Parts-1 to 4) IS: 4411 : Code of designation of semiconductor devices. IS: 5469 : Code of practice for the use of semiconductor junction devices. (Parts-1 to 4) IS: 6619 : Safety code for semiconductor rectifier equipment. IS:7204 : Stabilised power supplies DC output.(Parts-1 to 4) IS:12021 : Control transformers for switchgear and control gear for voltages (Parts-1 to 4) not exceedingl000 V AC. IS: 13703 : Low voltage fuses for voltages not exceeding 1000 V AC or (Parts-1 to 4) 1500 V DC. IS: 13947 : Low voltage switchgear and control gear. (Parts-4, section-1)

2.2 In case of imported equipment, Standards of the country of origin shall be applicable if these Standards are equivalent or stringent than the applicable Indian Standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country.


a. Statutory regulations. b. Data Sheets. c. Job Specification. d. Standard Specification.

e. Codes and Standards.

3.0DEFINITIONS

For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows: OWNER / COMPANY OWNER of the particular Project (Project Specific). CONSULTANT The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management.



4.0 MATERIALS

4.1 CPTR unit shall be housed in sheet steel enclosure. The front, rear walls and doors shall be made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.6 mm thick sheet steel.

4.2 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. 5.0 DESIGN 5.1 GENERAL REQUIREMENTS 5.1.1 The offered equipment shall be brand new with state of art technology and proven field track record. No prototype equipment shall be offered.


5.1.3 Vendor shall give a notice of at least one year to the end user of equipment and purchasers before phasing out the product/spares to enable the end user for placement of order for spares and services.

5.2 EQUIPMENT DESCRIPTION The CPTR unit shall be complete with following main sections:

a. Transformer and input controls. b. Rectifier and filter. c. Output protections.

d. System controls. e. Control, indication and metering.

5.2.1 TRANSFORMER AND INPUT CONTROLS a. The transformer shall be natural cooled dry type with separate primary and secondary windings. An intermediate earth screen shall be provided between primary and secondary windings. CPTR Units having multiple output circuits shall have separate secondary windings for each output circuit. Transformer shall be vacuum impregnated with epoxy varnish and baked. The safety factor for transformer rating shall be minimum 125%. b. Single phase transformers may be provided up to 50V, 50A DC output rating of the CPTR units. Beyond this rating, 3 phase transformers shall be provided. c. A moulded case circuit breaker with thermal over load and short circuit release shall be provided at the input of the transformer. Miniature circuit breaker with thermal overload and short circuit release in place of moulded case circuit breaker may be provided, where the miniature circuit breaker rated for the incoming AC supply short circuit current indicated in the Data Sheet is available.

5.2.2 RECTIFIER AND FILTERS a. The rectifier shall be made of thyristors and diodes as basic components. The CPTR unit shall be suitable for 415 V AC, 3-ph power supply. Rectifier shall be 3 phase full wave type and controlled type. For CPTR units rated 50V, 50A DC or less, the unit may be suitable for 240V AC, 1 ph power supply and the rectifier shall be full wave type and controlled type. Alternatively, for single phase AC CPTR units, diode rectifier of full wave type in the secondary of the transformer and triac or back to back connected thyristors in the transformer primary AC supply circuit may be provided. The current and voltage ratings of thyristors, diodes shall be at least two times the actual maximum device current and minimum two times the actual maximum voltage coming across the device respectively. The thyristors/ triad rectifier elements shall be protected against voltage surges coming from the incoming power supply and from output side from the pipeline. Required shunt zeners / MOV shall be provided across the rectifier elements for protection. b. The rectifier elements shall have humidity/Moisture resistant finish and mounted in sufficiently sized heat sink designed to provide adequate cooling under worst conditions of operation. The rectifier elements shall have- adequate protection against high dv/dt and di/ dt. c. The thyristors/ triacs shall be protected by semiconductor fuses. For units rated 50V, 50A DC or less, if the thyristors or triacs are adequately over rated and system has enough inductance so that in case of sudden output short circuit the over current limit feature comes into action before short circuit current rises beyond the rating of the thyristors/triacs, then the semiconductor fuses may not be provided. This feature shall be demonstrated during testing of the unit at works. d. Adequate filtering shall be provided on the DC output of the rectifier to limit the ripple content in the output to less than 5% at rated output. e. The rectifier system shall be of natural air cooled type. f. For CPTR units with multiple output circuits, each output circuit shall have independent rectifier and filter. 5.2.3 OUTPUT PROTECTIONS Two pole moulded case circuit breaker or miniature circuit breaker (if available) rated for the DC output current, short circuit current and having thermal overload, short circuit release shall be provided in the output. A lightning arrestor rated for minimum 1OKA impulse current discharge capacity and rated voltage & maximum spark over voltage rating suitable to protect the CPTR unit components against lightning and switching surges shall be provided at the output. For CPTR units with multiple output circuits, each output circuit shall be provided with circuit breaker and lightning arrestor.

5.2.4 SYSTEM CONTROLS The CPTR unit shall have two distinct modes of operation (independent for each output circuit) as below:

a. CONSTANT VOLTAGE AND CONSTANT CURRENT MODE (CVCC)

i. In this mode the output voltage of CPTR unit shall be' continuously adjustable from 0.5V DC to the rated output voltage specified on the Data Sheet. The set output voltage (Vos) shall remain constant irrespective of output current. Current limit feature shall be provided. The current limit (Ios) shall be continuously adjustable from zero to rated output current. ii. For constant voltage mode of operation the output current limit shall be set at maximum and output voltage setting shall be varied. Irrespective of output current demand the chosen value of the output voltage shall be maintained by the control system till the current limit is reached. After that, the output current limit shall be maintained and output voltage shall decrease to keep the current constant. iii. For constant current mode of operation the output voltage shall be set at maximum and output, current shall be varied through varying the setting of output current limit. Irrespective of output voltage requirement the control system shall maintain the output current to the set current limit value till the voltage limit is reached. After that the output voltage limit shall be maintained and output current shall decrease to keep the voltage constant. b. AUTO PSP MODE i. In this mode of operation the output of the CPTR unit shall operate in an external closed loop with pipe to soil potential (PSP), measured by reference cell, in feedback loop. The CPTR unit control shall adjust the output voltage such that the PSP as measured by reference cell always remains equal to the set potential on the unit. The set potential (Vps) shall have high long time stability and minimum temperature drift. The set potential shall be continuously adjustable over the range specified in Data Sheet. ii. The unit shall be designed to operate with number of reference cells connected to it (to be provided by others) as specified in Data Sheet. In case of more than one reference cell being specified, CPTR unit shall have feature to automatically select the reference cell having less negative potential than the others and use the same for auto control of the unit (e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be provided in selecting the less negative potential reference cell, to avoid hunting between the reference cells at change over conditions. iii. In case of open circuit or short circuit of reference cell or potential being less negative than a minimum set potential (Vrs), the unit shall sense these conditions as reference cell failure and shall automatically switch over to the other healthy reference cell for control. Should fault occur in all the reference cells, the output voltage or current of the CPTR unit shall adjust automatically to a preset value (Vas/Ias), which shall be adjustable. iv. In both CVCC and auto PSP modes of operation a fast acting electronic over current limit protection shall be provided. This protection shall be fast enough to protect the active devices of the unit and fast enough to act before tripping of MCCB/MCB or blowing of fuse. v. The unit shall continuously monitor the PSP and necessary annunciation shall be provided in case of PSP either exceeding the specified maximum limit (Vpm) or remaining lower than the specified minimum limit (Vpn). vi. The output voltage regulation for no load to full load variation with input voltage variation from maximum to minimum shall not be more than 2.5 % of rated voltage throughout the range of output voltage and over the specified ambient temperature variation as specified in Data Sheet, in

CVCC, Constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation for no load to full load variation with input voltage variation from maximum to minimum and PSP feedback varying over the specified range shall be within 20 mV. vii. In CVCC constant current mode of operation, the current regulation for minimum to maximum output voltage and minimum to maximum variation in input voltage shall not be more than 2.5% throughout the range of output current. viii. The DC output of the CPTR unit shall be floating (ungrounded) in the Unit. However the CPTR Unit shall allow grounding of positive output terminal through the anode ground bed. ix. For CPTR units with multiple output circuits, each output circuit shall have independent control system. c. CURRENT INTERRUPTER i. If specified on the data sheet a current interrupter for CPTR Unit output current interruption shall be provided. ii. The current interrupter shall have an output contactor with current rating minimum 125% of the output current rating of the CPTR unit and a digital timer to operate it. iii. The timer shall have 'ON' and 'OFF' timings. When the timer is turned on the 'ON' timing shall start and shall close the output contactor till the end of the 'ON' timing. At the end of the 'ON' timing the 'OFF' timing shall start and keep the contactor open till the end of the 'OFF' timing. At the end of the 'OFF' timing the 'ON' timing shall start again and close the output contactor. This process of ON and OFF timing shall continue. iv. The 'ON' and 'OFF' timings of the timer shall be settable by separate 2 digit thumbwheel switches, each settable from 1 to 99 seconds. The timing error of the timer shall be less than 5 parts per million. In case of microprocessor based system keypad with display may be provided in place of thumb wheel switches. v. Whenever the timer is switched on it shall always Start With ON `timing'. A timer reset push button shall be provided. On pressing this push button during operation of the timer, the timer shall get reset and upon release of the button the timer shall be start with `ON' timing. vi. The power required for operation of the timer and contactor shall be derived from the main power supply to the CPTR unit. vii. The following controls and indications shall be provided for current interrupter. The controls shall be housed in a lockable cover, so that normally they are not accessible. The indications shall be mounted on the door. CONTROL. Timer power 'ON' / ̀ OFF'. Timer reset. Thumb wheel switch for 'ON' timing. Thumb wheel switch for 'OFF' timing.

In case of microprocessor based system key pad with displays may be provided in place of thumbwheel switches.

INDICATIONS (LED) Timer power `ON' ON timing OFF timing viii. The output contact of the current interrupter contactor shall be wired in the positive DC output of the CPTR unit. A Link shall be provided for shorting these terminals whenever the current interrupter is not in use. ix. If specified in the Data Sheet the current interrupter shall be an independent unit of portable type. The interrupter unit shall have terminals for input power supply and terminals of the output contactor. The input power supply and the rating of the output contactor shall be specified on the Data Sheet. Terminals shall be provided in the CPTR unit for taking power supply to the current interrupter. x. Where the current interrupter is not specified with CPTR unit or is specified as portable type external to the CPTR unit, then the CPTR unit shall have provision / terminals for connection of input power supply and output contacts of external current interrupter, for current interruption test. A link shall be provided for shorting the output terminals provided in CPTR unit whenever the current interrupter is not connected. xi. For CPTR units with multiple output circuits, each output circuit shall have independent current interrupter. 5.2.5 CONTROLS, INDICATIONS AND METERING a. Following controls shall be provided on CPTR unit front door. i. ON/OFF control for input through MCCB/MCB. ii. ON /OFF control for output through MCCB/MCB. iii. Auto/CVCC mode selector switch. iv. Potentiometers for Vos, Vps and Ios settings. v. Selector switch for selecting indication of PSP set and PSP actual for all the reference cells. b. Following controls shall be provided inside the module at user accessible common location: i. Potentiometer for Vrs, Vpm, Vpn and Vas/las settings. ii. Controls for current interrupter: Timer power 'ON' / 'OFF'. Timer reset. Thumb wheel switch for 'ON' timing. Thumb wheel switch for 'OFF' timing. c. TR unit shall have following indicating lights (lamps or minimum 5 mm dia LEDs): i. CPTR unit ON/OFF ii. Unit in auto/CVCC (2 lamps)

iii. Reference cell controlling the closed loop control of the CPTR unit (number of lamps same as number of reference cells). iv. Reference cell faulty (number of lamps same as number of reference cells). v. Pipeline over protected. vi. Pipeline under protected vii. Indications for current interrupter: Timer power `ON' 'ON' timing 'OFF' timing d. It shall be possible to switch off all the indication lamps by a single switch. In case of LED indication lights this facility may not be provided. e. Following meters having min. accuracy shall be provided on the CPTR unit ±1%: i. Digital meter for output voltage ii. Digital meter for output current iii. Digital voltmeter to measure PSP set (Vps) and PSP actual for all the reference cells. The meter shall have range from -4 V to 0 V and shall have ±1% accuracy. iv. Digital meters for measuring Vrs, Vpm, Vpn and Vas/las settings. v. Meters for input voltage and current f. It shall be possible to switch-off all the digital meters preferably by a single switch. g. If specified in data sheet, CPTR unit shall incorporate provision for remote monitoring of the unit through SCADA system as below: i. Potential free contacts for the following: All the reference cells failed. (Contact open on alarm condition). Pipeline overprotected. (Contact open on alarm condition). Pipeline under protected. (Contact open on alarm condition). System in auto-mode. (Contact close in auto condition). System in CVCC mode. (Contact close in CVCC mode). ii. 4 to 20 mA electrically isolated signal for the following: PSP (-4V to OV). CPTR unit output voltage. CPTR unit output current. h. The transducers shall have electrical isolation between input and output. The isolation insulation shall withstand 2kV, 50Hz for minimum 1 minute. The accuracy class of the transducer shall be 0.5%. The transducers shall be protected against input and output voltage surges. The transducer shall be suitable for driving up to 600 ohms load impedance located up to 500 m away and wired with 0.5 mm² copper conductor cable.

i. For units having multiple outputs, each output circuit shall have independent controls, indication and metering.

6.0 FABRICATION 6.1 FABRICATION AND GENERAL DETAILS 6.1.1 CPTR unit shall be housed in sheet steel enclosure. The front, rear walls and doors shall be made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.6 mm thick sheet steel. Wherever required, suitable stiffeners shall be provided. The Unit shall be freestanding type. Hinged doors shall be provided at the front and back as required. The unit shall be natural cooled type. 6.1.2 Louvered-openings with wire mesh for natural ventilation may be provided. Degree of protection for the panel shall be minimum IP-42. The CPTR unit panel shall, preferably, not need rear access for operation, maintenance and shall be suitable for mounting flushed to the wall.

6.1.3 Suitable hooks shall be provided for lifting the panel. These hooks when removed shall not Leave any hole in the panel or imperfection in the paint finish.

6.1.4 All instruments shall be panel mounted type and back connected. All fuses shall be provided inside the panel and shall be of link type. 660V grade PVC insulated BIS approved wires with stranded copper conductor of size minimum 2.5 mm² shall be used for power and auxiliary wiring. Control wiring for electronic circuits shall be through flat ribbon cable or through copper wire of minimum 0.5 mm diameter. All wirings shall be ferruled with PVC ferrules at both ends for ease of identification. Clamp type terminals suitable for termination up to 10 mm²

conductor shall be provided for all control cable connection. Suitable power terminals shall be provided for power cables. Minimum 20% spare terminals shall be provided. The terminal blocks shall be mounted minimum 300 mm above the gland plate.

6.1.5 All live parts shall be properly shrouded. This shall ensure complete safety to personnel intending routine maintenance by opening the panel doors.

6.1.6 CPTR unit shall be suitable for bottom cable entry unless otherwise specified in the data sheet and shall be supplied complete with crimping type cable termination lugs and cable glands. Cable glands shall be of brass, nickel plated, single compression type for indoor installations and double compression type for outdoor installations. The space in the terminal chamber shall be adequate for termination of required number and sizes of cables as specified in the data sheet.

6.1.7 The input power factor of the unit at rated load shall be 0.8 lag or better. 6.1.8 The CPTR unit shall be field proven. The design, internal component layout and rating of component shall ensure high MTBF and low MTTR. Prototype equipment shall not be acceptable.

6.1.9 All the control equipment like switches, pushbuttons, potentiometers etc. shall be located

at a convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.

6.1.10 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB tracks shall be tinned and solder masked. The PCB shall be coated with suitable lacquer to make it immune to dust, moisture and fungal growth. Where plug in type of PCBs are used gold plated male-female connectors shall be used for the purpose. 6.1.11 If required the panel shall be provided with space heater to prevent moisture: condensation. The space heaters shall be located at the bottom of the panel and shall be provided with a manually operated switch, HRC fuse and link for phase and neutral respectively. The space heater shall have porcelain connectors. Where space heater is not provided the electronic PCBs/components and other control devices shall be made immune to moisture condensation.

6.1.12 Panel shall be provided with integral base frame channel. The integral base frame of panel shall be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack welding to purchaser's insert plate/flat/channel embedded in the floor. Amply dimensioned oblong holes shall be provided at the bottom of the panel for its bolting to the embedded insert plate/channel,

6.1.13 An earth bus-bar of minimum (25x3) mm² copper or equivalent aluminum shall be provided throughout the length of the panel. Provision shall be made For connecting this earth bus at two ends with the plant earth grid by means of (40x5) mm² GI flat. All non-current carrying metallic parts of the panel and mounted equipment shall be connected to the panel earth bus. All doors and movable parts shall be connected to the earth bus by flexible copper cables.

6.1.14 All panel mounted equipments (e.g. lamps, push buttons, switches, meters, PCBs, etc.) shall be provided with suitable nameplates. Nameplates shall be engraved out of 3 ply (black-white-black) lamicoid sheets or anodised aluminum. Back engraved Perspex sheet nameplates may also be acceptable. Engraving shall be done with groove cutters. Hard paper or self adhesive plastic tape nameplates shall not be acceptable Nameplates shall be fastened by screws and not by adhesive.

6.1.15 Labels shall the provided for every component on the cards connecting wires as well as for the terminals in the terminal strip inside the panel

6.1.16 Where specified in the data sheet the CPTR unit shall he housed in an outdoor kiosk. The kiosk shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and external surfaces. Hinged lockable doors shall be provided at the front and back. The kiosk shall be suitable for outdoor mounting and shall give proper protection to the CPTR unit against rain, other harsh weather conditions Necessary ventilation arrangement with louvers and wire mesh shall be provided for proper operation of the CPTR unit. The cable entry to the kiosk shall be from bottom through cable glands. Suitable canopy shall be provided on the top of the Kiosk.

6.2 PAINTING 6.2.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt.

6.2.2 Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The undersurface shall be made free from all imperfections before undertaking the finishing coat. 6.2.3 After preparation of the under surface, the panel shall be spray painted with two coats of final paint or shall be powder coated. Colour shade of final paint shall be approved by the Purchaser before final painting is started. The finished panels shall be dried in stowing ovens in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off paint, etc.

6.2.4 All unpainted steel parts shall be suitably treated to prevent corrosion. If these parts are moving elements, then they shall be greased.

7.0 INSPECTION AND TESTING 7.1 During manufacture, the equipment shall be subjected to inspection by Owner or his authorized representative to assess the progress of the work as well as to ascertain that only quality raw materials are used for the same. He shall be given all assistance to carry out the inspection.

7.2 Final acceptance test shall be carried out at manufacturer's works under his care and expense. Instruments and equipments required for testing shall be arranged by manufacturer. Owner's representative shall be given minimum 2 weeks prior-notice for witnessing the tests. Test certificates indicating test results shall be furnished by the manufacturer. Acceptance tests shall include but not be limited to the tests listed below.

7.3 VISUAL INSPECTION This shall include-

a. Completeness of the equipment in line with specification. Checking of all settings. b. All labels provided. c. Dimensional checking. d. Proper mounting of components and neatness of wiring etc. e. Model number.

7.4 INSULATION TESTS 7.4.1 The voltage specified in the table below shall be applied for one minute to the circuits indicated:

Withstand voltage Control electronics <60V

Power electronics Un1 Auxiliary circuits Un2

To earth 700VD.C. 2xUn1 + 1000V 2xUn2+ 1000V

To control electronics - 2xUn1 + 1000V 2xUn2+ 1000V

To power electronics 2xUn1+ 1000V - 2xUn,+ 1000V

To auxiliary circuits 2xUn2+ 1000V 2xUn1 + I000V -

(Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits respectively)

7.4.2 DC test voltages may be applied instead of AC The magnitude of DC test voltages to be applied shall be 2 times the above-mentioned AC (r.m.s) Values:

7.4.3 Insulation resistance test shall be conducted before and after heat run test. 7.5 HEAT RUN TEST 7.5.1 All CPTR units shall be subjected to a heat run test performed at rated voltage for period not less than 16 hours prior to execution of functional tests.

7.5.2 At least one CPTR unit of each rating shall be loaded to its rated output throughout 16 hour test period. All other CPTR units shall be energized under partial load or zero load current condition throughout the test period.

7.6 FUNCTIONAL TESTS 7.6.1 Functional tests as below shall be performed on each CPTR unit. If during execution of functional tests, any electronic component of the unit is required to be replaced e.g. due to malfunction or failure of the unit to fulfill the performance requirements of the Specification, then the load test shall be repeated at rated current following which functional tests shall be carried out. 7.7 CVCC MODE OPERATION TESTING 7.7.1 CONSTANT VOLTAGE OPERATION a. During the test, current limit shall be set to rated output current. Performance testing shall be carried out for various output voltage settings and load varying from zero to maximum. The verification of operation of the control functions, measurement of output voltage, current, input AC voltage, current, power factor, ripple in the output, evaluation of output voltage regulation and efficiency of the unit shall be carried out during the testing. 7.7.2 CONSTANT CURRENT OPERATION a. During the test, voltage limit shall be set to rated output voltage. Performance testing shall be carried out for various output current limit settings and load resistance varied to achieve output voltage from minimum to maximum. The verification of operation of the control functions,

measurement of output voltage, current, input AC voltage, current, power factor, ripple in the output, evaluation of output current regulation of the unit shall be carried out during the testing. 7.8 AUTO PSP MODE OPERATION 7.8.1 Suitable set up shall be arranged for output loading and reference cell feedback. The closed loop performance and regulation shall be checked with the PSP set voltage varied from 0.85V to 1.2V. 7.8.2 Disconnecting the reference cell feedback connection in the above set up shall simulate the reference cell failed condition. The output voltage/current of the unit shall go to the value set on the potentiometer Vas/las provided inside the CPTR UNIT. The settings on Vas/las shall be varied and the output voltage/current shall be observed.

7.8.3 Operation of sensors for pipeline over protection, under protection, reference cell failure and reference cell selection logic in auto PSP mode shall be verified by connecting variable external voltage sources to reference cell inputs of the CPTR unit. The number of external voltage sources shall be same as number of reference cell inputs specified for the CPTR unit.

7.8.4 The unit shall be checked for operation of the current limit by over loading the unit in both CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not provided for protection of the thyristors/triacs, the protection of same shall be tested as below:

7.8.5 A switch rated for making and carrying CPTR unit output short circuit current shall be connected to the output terminals of the unit. The output voltage and the output current limit settings of the unit shall be set to the maximum rated values. The switch connected in the output shall be shorted quickly.

7.8.6 The unit shall go to current limit mode and shall not damage any active component of the unit.

7.8.7 The current interrupter shall be tested for time interval settings and specified operation.

8.0 MARKING, PACKING AND SHIPMENT 8.1 The equipment shall be properly packed for selected mode of transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent damage to finish. Crates shall have skid bottom for handling. Special notations such as `Fragile', `This side up', `Center of gravity', `Weight' etc., shall be clearly marked on the package together with Tag nos., P.O. Nos. etc.

8.2 The equipment may be stored outdoors for long periods before erection. The packing shall be completely suitable for outdoor storage in areas with heavy rains/ high ambient temperature.

STANDARD SPECIFICATION FOR CATHODIC PROTECTION POWER SUPPLY MODULE (CPPSM)

ABBREVIATION



BSI: British Standards Institution

ANSI: American Standard Institution

CP: Cathodic Protection

CPPSM: Cathodic Protection Power supply Module

AC: Alternating Current

DCDB: Direct Current Distribution Board

PVC: Poly Vinyl Chloride

MTBF: Mean Time Between Failure

MTTR: Mean Time To Repair

HRC: High Rupturing Capacity

PCB: Printed Circuit Board

MOSFET: Metal Oxide Semiconductor Field Effect Transistor

MOV: Motor Operated Valve

CVCC: Constant Voltage Constant Current

PSP: Pipe to Soil Potential

LED: Light Emitting Diode SCADA: Supervision Control And Data Acquisition

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE

2.0REFERENCE DOCUMENTS ..............................................................................

3.0DEFINITION

4.0DESIGN………………………………………………………………...

5.0INSPECTION AND TESTING ................................................................................

6.0PACKING AND DESPATCH ...............................................................................

1.0 SCOPE

1.1 This Specification covers the requirements for the design, manufacture and testing of cathodic protection power supply module (CPPSM) working on controlled switch mode principle intended to supply power to cathodic protection system for underground pipelines/ structures.

2.0 REFERENCE DOCUMENTS 2.1 The system design, performance and materials to be supplied shall conform to the requirements of the latest revision of following standards:

IS: 1248 : IS: 3700 : IS: 3715 :

Direct acting indicating analogue electrical measuring (Parts - 1,2.8 & 9) instruments and accessories Essential rating and characteristics of semiconductor devices. (Parts – 1 to 11) Letter symbols for semiconductor devices (Parts-1 to 4)

IS: 441 : Code of designation of semiconductor devices.

IS: 5469 : Code of practice for the use of semiconductor junction devices (Parts-1 to 4) IS: 6619 : Safety code for semiconductor rectifier equipment. IS:7204 : Stabilised power supplies DC output (Parts-1 to 4) IS: 12021 : Control transformers for switchgear and control gear for voltages not exceeding 1000 V AC. (Parts-1 to 4) IS:13947 : Low voltage switchgear and control gear. (Parts-4, section-1) 2.2 In case of imported equipment, Standards of the country of origin shall be applicable if these Standards are equivalent or stringent than the applicable Indian Standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country.


a. Statutory regulations. b. Data Sheets c. Job Specification d. Standard Specification e. Codes and Standards.

3.0DEFINITION For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows: OWNER / COMPANY - OWNER of the particular Project (Project Specific). CONSULTANT - The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management. BIDDER / SUPPLIER / VENDOR The party(s) which manufactures and / or supplies material, equipment, technical documents / drawings and services to perform the duties specified by Contractor

4.0 GENERAL REQUIREMENT 4.0.1 The offered equipment shall be brand new with state of art technology and proven field track record. No prototype equipment shall be offered.


4.0.3 Vendor shall give a notice of at least one year to the end user of equipment and Consultant before phasing out the product/spares to enable the end user for placement of order for spares and services.

4.1 TECHNICAL REQUIREMENTS (FABRICATION AND GENERAL DETAILS) 4.1.1 CPPSM shall be housed in sheet steel enclosure. The front, rear walls and doors shall be made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.6 mm thick sheet steel. Whenever required, suitable stiffeners shall be provided. The unit shall be natural cooled type. Louvered openings with wire mesh for natural ventilations may be provided. Louvered openings with wire mesh for natural ventilations may be provided. Degree of protection for the panel shall be minimum for mounting flushed to the wall.

4.1.2 CPPSM shall be housed in sheet steel enclosure Suitable hooks shall be provided for lifting the panel. These hooks when removed shall not leave any hole in the panel or imperfection in the paint finish. 4.1.3 All instruments shall be panel mounted type and back connected. All fuses shall be provided inside the panel and shall be of link type. 660 V grade PVC insulated BIS approved wires with stranded copper conductor of size minimum 2.5 mm² shall be used for power and auxiliary wiring. Control wiring for electronic circuits shall be through flat ribbon cable or through copper wire of minimum 0.5 mm diameter. All wirings shall be ferruled with PVC ferrules at both ends for ease of identification. Clamp type terminals suitable for termination up to 10 mm² conductor shall be provided for all control cable connection. Suitable power terminals shall be

provided for power cables. Minimum 20% spare terminals shall be provided. The terminal blocks shall be mounted minimum 300 mm above the gland plate.

4.1.4 All live parts shall be properly shrouded. This shall ensure complete safety to personnel intending routine maintenance by opening the panel doors.

4.1.5 CPPSM shall be suitable for bottom cable entry unless otherwise specified in the Data Sheet and shall be supplied complete with crimping type tinned copper lugs and cable glands. Cable glands shall be of brass, nickel plated, single compression type for indoor installations and double compression type for outdoor installations. The space in the terminal chamber shall be adequate for termination of required number and sizes of cables as specified in the data sheet.

4.1.6 The CPPSM shall be field proven. The design, internal component layout and rating of component shall ensure high MTBF and low MTTR. Prototype equipment shall not be acceptable. Layout of panel components shall enable easy access to the components for maintenance.

4.1.7 All the control equipment like switches, push buttons, potentiometers etc. shall be located at a convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.

4.1.8 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB tracks shall be, tinned and. solder masked. The PCB shall be coated with suitable lacquer to make it immune to lust moisture and fungal growth. Where plug in type of PCBs are used gold plated male-female connectors shall be used for the purpose.

4.1.9 If required the panel shall be provided with space heater to prevent moisture condensation. The space heaters shall be located at the bottom of the panel and shall be provided with a manually operated switch and HRC fuse. The space heater shall have porcelain insulated connectors. Where space heater is not provided, the electronic PCBs/components and other control devices shall be made immune to moisture condensation:

4.1.10 Panel shall be provided with integral base frame channel. The integral base frame of panel shall be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack welding to Purchaser's insert plate/flat/channel embedded in the floor. Amply dimensioned oblong holes shall be provided at the bottom of the panel for its bolting to the embedded insert plate/channel. 4.1.11 An earth bus bar of minimum (25 x 3) mm² copper or equivalent aluminium shall be provided throughout the length of the panel. Provision shall be made for connecting this earth bus at two ends with the plant earth grid by means of (40x5) mm² GI flat. All non-current carrying metallic parts of the panel and mounted equipment shall be connected to the panel earth bus. All doors and movable parts shall be connected to the earth bus by flexible copper cables.

4.1.12 All panel mounted equipments (e.g. lamps, push buttons, switches, meters; PCBs, etc.)

shall be provided with suitable nameplates. Nameplates shall be engraved out of 3-ply (black-white black) lamicoid sheets or anodised aluminium. Back-engraved perspex sheet nameplates may also be acceptable. Engraving shall be done with groove cutters. Hard paper or self adhesive plastic tape nameplates shall not be acceptable. Nameplates shall be fastened by screws and not by adhesive.

4.1.13 Labels shall be provided for every component on the cards, connecting wires as well as for the terminals in the terminal strip inside the panel.

4.1.14 Where specified in the data sheet the CPPSM shall be housed in an outdoor kiosk. The kiosk shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and external surfaces. Hinged lockable doors shall be provided at the front and back. Acrylic transparent glass window shall be provided on the front door of the kiosk so that the meters, indications and positions of the control switches on the CPPSM can be seen without opening the door of the kiosk. The kiosk shall be suitable for outdoor mounting and shall give proper protection to the CPPSM against rain, other harsh weather conditions. Necessary ventilation arrangement with louvers and wire mesh shall be provided for proper operation of the CPPSM. The cable entry to the kiosk shall be from bottom through cable glands. Suitable canopy shall be provided on the top of the kiosk.

4.2 PAINTING 4.2.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt.

4.2.2 Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The undersurface shall be made free from all imperfections before undertaking the finishing coat.

4.2.3 After preparation of the under surface, the panel shall be spray painted with two coats of final paint or shall be powder coated. Colour shade of final paint shall be approved by the purchaser before final painting is started. The finished panels shall be dried in stowing ovens in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off paint, etc.

4.2.4 All unpainted steel parts shall be cadmium plated or suitably treated to prevent corrosion. If these parts are moving elements, then they shall be greased.

4.3 EQUIPMENT DESCRIPTION The CPPSM shall be complete with following main sections:INPUT CONTROLS. a. A moulded case circuit breaker with thermal over load and short circuit release (rated for the input power supply short circuit current) shall be provided at the input for power supply control. 4.3.2 POWER CONVERTER AND FILTERS. a. The CPPSM shall convert and control the input DC power supply voltage/current into

variable DC output voltage/current through 'switching power semiconductor devices (Thyristor/power, transistor/power, MOSFET, etc.). The variation in the output voltage/current shall be achieved through control of duty cycle of conduction of the switching power semiconductor devices The current and voltage ratings of the power semiconductor devices shall be at least two times the maximum device current and min. two times the maximum voltage coming across it respectively The voltage rating of the power semi-conductor devices shall be coordinated with the breakdown voltage of lightning arrestor provided at the output so that the power semiconductor devices are protected from any voltage surge coming from the pipeline. Shunt MOV shall be provided across power-semiconductor devices for protection the power semiconductor devices shall have humidity/moisture resistant finish and mounted in sufficiently sized heat sink designed to provide adequate cooling under worst conditions of operation. The power semiconductor devices shall have adequate protection against high dv/dt and di/dt. b. Where specified in the data sheet, the converter shall electrically isolate the input power to CPPSM from its output so that the grounding of the positive output of the CPPSM through anode ground bed shall not affect the grounding system of the input power supply. Alternatively, a separate DC to DC converter having electrical isolation between input and output power supply shall be provided at the input of the CPPSM. c. The power semiconductor devices shall be protected by semiconductor fuses or the system shall have instantaneous short circuit current limit feature to protect the devices against output short circuits. An adjustable output over current limit feature shall be provided. d. Filter shall be provided in the input power supply circuit to minimise the AC injected into the DC input power supply system. e. Adequate filtering shall be provided on the DC output of the converter to limit the ripple content in the output to less than 5% at rated output. f. The converter system shall be of natural air cooled type. g. For CPPSMs with multiple output circuits, each output circuit shall have independent output converter-and output filters. 4.3.3 OUTPUT PROTECTIONS a. Two pole moulded case circuit breaker or miniature circuit breaker .rated for the DC output current, short circuit current and having thermal over load, short circuit release shall be provided in the output. A lightning arrestor rated for minimum 10KA impulse current discharge capacity and rated voltage & max. spark over voltage rating suitable to protect the CPPSM components against lightning and switching surges shall be provided at the output. For CPPSMs with multiple output circuits, each output circuit shall have independent protections.

4.3.4 SYSTEM CONTROLS The CPPSM shall have two distinct modes of operation (independent for each output circuit) as below:

a. Constant Voltage - Constant Current Mode (CVCC) i. In this mode the output voltage (Vos) of CPPSM shall be continuously adjustable from

0.5V DC to the rated output voltage specified on the Data Sheet Current limit feature shall be provided in this mode of operation. The current limit (Ios) shall be continuously adjustable from zero to rated output current. ii. For constant voltage mode of operation the output current limit be set at maximum and output Voltage. Setting shall be varied irrespective of output current demand the chose value of the output voltage shall be maintained by the control system till the current limit reached. After that the output current shall be maintained and output voltage shat decrease to keep the current constant. iii. For constant current mode of operation the output voltage, shall be set at maximum and output current shall be varied through varying the setting of output current limit. Irrespective of output voltage requirement the control system shall maintain the output current to the set current limit value till the voltage limit is reached. After that the output voltage limit call be maintained and output current shall decrease to keep the voltage constant. b. Auto PSP Mode i. In this mode of operation the output of the CPPSM shall operate in an external closed loop with pipe to soil potential (PSP) in feedback loop. The CPPSM control shall adjust the output voltage such that the PSP as measured by reference cell always remains equal to the set potential on the unit. The set potential (fps) shall have high long time stability and minimum temperature drift. The set potential shall be continuously adjustable over the range specified in Data Sheet an adjustable over current limit shall be provided to limit the maximum output current. ii. The unit shall be designed to operate with the number of reference cells connected to it (to be provided by others) as specified in .Data Sheet In case of more than one reference cell being specified, CPPSM shall have feature to automatically select the reference cell having less negative potential than the others and use the same for auto, control of the unit (e.g. (-) 0.8 V is less negative than (-) 0.9 V. Adequate hysterisis shaIl be provided in selecting the less negative potential reference cell to avoid hunting between the references cells at change over conditions. iii. In case of open circuit or short circuit of the reference cell or potential being less negative than a minimum set potential (Vrs), for the controlling reference cell, the unit shall sense these conditions as reference cell failure and shall automatically switch over to the other healthy reference cell for control. Should fault occur in all the reference cells, the output voltage or current of the CPPSM shall adjust automatically to a preset value (Vas/las), which shall be adjustable. iv. In both CVCC and auto PSP modes of operation the electronic over current limit shall be fast enough to protect the active devices of the unit and fast enough to act before tripping of MCCB/MCB or blowing of fuse. 4.3.5 The unit shall continuously monitor the PSP and necessary annunciation shall be provided in case of PSP either exceeding the specified maximum limit (Vpm) or remaining lower than the specified minimum limit (Vpn).

4.3.6 The output voltage regulation for no load to full load variation with input voltage variation from maximum to minimum shall not be more than 2.5 % of rated voltage throughout the range of output voltage and over the specified ambient temperature variation as specified in Data Sheet in CVCC constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation for no load to full load variation with input voltage variation from maximum to

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minimum shall be within 20mV throughout the PSP setting range specified.

4.3.7 In CVCC constant current mode of operation, the current regulation for minimum to maximum output voltage and minimum to maximum variation in input voltage shall not be more than 2.5% throughout the range of output current.

4.3.8 The output of the unit shall be ungrounded and shall allow grounding of positive terminal of the output through the anode ground bed.

4.3.9 For CPPSMs with multiple output circuits, each output circuit shall have independent control system.

4.4 CURRENT INTERRUPTER

4.4.1 If specified on the Data Sheet a current interrupter for CPPSM output current interruption shall be provided.

4.4.2 The current interrupter shall have an output contactor with current rating minimum 125% of the output current rating of the CPPSM and a digital timer to operate it.

4.4.3 The timer shall have 'ON' and 'OFF' timings. When the timer is turned on the 'ON' timing shall start and shall close the output contactor till the end of the 'ON' timing. At the end of the 'ON' timing the 'OFF' timing shall start and keep the contactor open till the end of the `OFF' timing. At the end of the 'OFF' timing the 'ON' timing shall start again. This process of 'ON' and 'OFF' timing shall continue. 4.4.4 The 'ON' and 'OFF' timings of the timer shall be settable by separate 2 digit thumbwheel switches, each settable from 1 to 99 seconds. The timing error of the timer shall be less than 5 parts per million. In case of microprocessor based system keypad with display may be provided in place of thumbwheel switches.

4.4.5 Whenever the timer is switched on it shall always start with 'ON' timing. A timer reset push button shall be provided. On pressing this pushbutton during operation of the timer, the timer shall get reset and upon release of the button, the timer shall restart with 'ON' timing.

4.4.6 The power required for operation of the timer and contactor shall be derived from the main power supply to the CPPSM.

4.4.7 The following controls and indications shall be provided for current interrupter. The controls shall be housed in a lockable cover, so that normally they are not accessible. The indications shall be mounted on the door.

a. Controls i. Timer power `ON' / ̀ OFF' ii. Timer reset iii. Thumb wheel switch for 'ON' timing iv. Thumb wheel switch for 'OFF' timing 4.4.8 In case of microprocessor based system, keypad with display may be provided in place of

thumbwheel switches

b. Indications (LED) i. Timer power `ON' ii. ‘ON’ timing iii. `OFF’ timing 4.4.9 The output contact of the current interrupter contactor-shall be wired in the positive DC output of the CPPSM. A link shall be provided for shorting these terminals whenever the current interrupter is not in use.

4.4.10 If specified in the Data Sheet the current interrupter shall be an independent unit of portable type. The interrupter unit shall have terminals for input power supply and terminals of the contactor in the timer output. The input power supply and the rating of the timer output contactor shall be as specified on the data sheet.

4.4.11 Where the current interrupter is not specified with CPPSM or is specified as portable type external to the CPPSM, then the CPPSM shall have provision for connection of input power supply terminals and output contacts of external current interrupter for current interruption test. A link shall be provided for shorting the output terminals provided in CPPSM for current interruption, whenever the current interrupter is not connected. 4.4.12 For CPPSMs with multiple output circuits, each output circuit shall have independent current interrupter.

4.5 CONTROLS, INDICATION AND METERING 4.5.1 Following controls shall be provided on CPPSM front door. a. ON/OFF control for input through MCCB. b. ON /OFF control for output through MCCB/MCB. c. Auto/CVCC mode selector switch. d. Potentiometers for Vos, Vps and Ios settings. e. Selector switch for selecting indication of PSP set and PSP actual for all the Reference cells. 4.5.2 Following controls shall be provided inside the module at user accessible common location:

a. Potentiometer for Vrs, Vpm, Vpn and Vas/Las settings. b. Control for current interrupter: i. Timer power 'ON' / ̀ OFF'. ii. Timer reset. iii. Thumb wheel switch for 'ON' timing. iv. Thumb wheel switch for 'OFF' timing.

4.5.3 CPPSM shall have following indicating lights (lamps or minimum 5 mm dia LEDs): a. CPPSM ON/OFF. b. Unit in auto/CVCC (2 lamps). c. Reference cell controlling the closed loop control of the CPPSM (number of lamps same as number of reference cells). d. Reference cell faulty (number of lamps same as number of reference cells). e. Pipeline over protected. f. Pipeline under protected. g. Indications for current interrupter: i. Timer power 'ON'. ii. 'ON' timing. iii. 'OFF' timing. 4.5.4 It shall be possible to switch-off all the indication lamps by a single switch. In case of LED indication lights this facility may not be provided.

4.5.5 Following meters having min cl.1.5 accuracy shall be provided on the CPPSM: a. Digital meter for output voltage b. Digital meter for output current c. Digital voltmeter to measure PSP set (Vps) and PSP actual for all the reference cells. The meter shall have range from (-) 4 V to 0 V and shall have cl.0.5 accuracy. d. Digital Meters for measuring Vrs, Vpm, Vpn and Vas/Las settings. e. Meters for input voltage and current. 4.5.6 It shall be possible to switch-off all the digital meters preferably by a single switch. 4.5.7 If specified in Data Sheet, CPPSM shall incorporate provision for remote monitoring of the unit through SCADA system as below:

a. Potential free contacts for the following: i. All the reference cells failed. (Contact open on alarm condition). ii. Pipeline overprotected. (Contact open on alarm condition). iii. Pipeline under protected. (Contact open on alarm condition). iv. System in auto-mode. (Contact close in auto condition). v. System in CVCC mode. (Contact close in CVCC mode). b. 4 to 20 mA electrically isolated signal for the following: i. PSP (-4V to 0V). ii. CPPSM output voltage.

iii. CPPSM output current. 4.5.8 The transducers shall have electrical isolation between input and output. The isolation insulation shall withstand 2 kV, 50 Hz for minimum 1 minute. The accuracy class of the transducer shall be 0.5. The transducers shall be protected against input and output voltage surges. The transducer shall be suitable for driving upto 600 ohms load impedance located upto 500 in away and wired with 0.5 mm² copper conductor cable. The transducers shall be suitable for minimum 125% continuous over load in the input voltage/current parameter.

4.5.9 For units having multiple outputs, each output circuit shall have independent controls, indication and metering.

5.0 INSPECTION AND TESTING 5.1 During fabrication, the equipment shall be subjected to inspection by Owner or his authorised representative to assess the progress of the work as well as to ascertain that only quality raw materials are used for the same. He shall be given all assistance to carryout the inspection.

5.2 Final acceptance test shall be carried out at manufacturer's works under his care and expense. Instruments and equipments required for testing shall be arranged by manufacturer. Owner's representative shall be given minimum 2 weeks prior notice for witnessing the tests. Test certificates indicating test results shall be furnished by the manufacturer. Acceptance tests shall include but not be limited to the tests listed below.

5.2.1 VISUAL INSPECTION This shall include a. Completeness of the equipment in line with Specification. b. Checking of all settings. c. All labels provided and satisfactory. d. Dimensional checking. e. Proper mounting of components and neatness of wiring etc. f. Model number. 5.2.2 INSULATION TESTS a. The voltage specified in the table below shall be applied for one minute to-the circuits indicated:

Withstand voltage Control Electronics <60V

Power electronics Un1 Auxiliary circuits Un2

To earth 700V D.C. 2xUn1 + 1000V 2xUn2 + 1000V

To control electronics - 2xUn1 +1000V 2xUn2 + 1000V

To power electronics 2 x U n 1 + 1 0 0 0 V - 2xUn1 +'1000V

To auxiliary circuits 2 x U n 2 + I 0 0 0 V 2xUn1 + I000V -

(Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits respectively).

b. DC test voltages may be applied instead of AC, The magnitude of DC test voltages to be applied shall be 2 times the above mentioned AC (r.m.s)Values c. Insulation resistance test shall be conducted before and after heat run test. 5.2.3 HEAT RUN TEST a. All CPPSMs shall be subjected to a heat run test-performed at rated voltage for period not less than 16 hours prior to execution of functional tests. b. At least one CPPSM of each rating shall be loaded to its rated output throughout 16 hour test period. All other CPPSMs shall be energized under partial load or zero load current condition throughout three test period. 5.2.4 FUNCTIONAL TESTS a. Functional tests as below shall be performed on each CPPSM. If during execution of functional tests, any electronic component of the unit is required to be replaced e.g. due to malfunction or failure of the unit to fulfill the performance requirements of the Specification, then the load test shall be repeated at rated current following which functional tests shall be carried out. 5.3 CVCC MODE OPERATION TESTING 5.3.1 CONSTANT VOLTAGE OPERATION a. During the test, current limit shall be set to rated output current. Performance testing shall be carried out for various output voltage settings and load varying from zero to maximum. The verification of operation of the control functions, measurement of output voltage, current, input voltage, current, ripple in the output, input, and evaluation of output voltage regulation and efficiency of the unit shall be carried out during the testing.

5.3.2 CONSTANT CURRENT OPERATION a. During the test, voltage limit shall be set to rated output voltage. Performance testing shall be carried out for various output current limit settings and load resistance varied to achieve output voltage from minimum to maximum. The verification of operation of the control functions, measurement of output voltage, current, input voltage, current, ripple in the output, input, and evaluation of output current regulation of the unit shall be carried out during the testing.

5.3.3 AUTO PSP MODE OPERATION a. Suitable set up shall be arranged for output loading and reference cell feedback. The closed loop performance and regulation shall be checked with the PSP set voltage varied from 0.85V to 1.2V. b. Disconnecting. the reference cell feedback connection in. the above set up shall simulate the reference cell failed condition. The output voltage/current of the unit shall go to the value set on the potentiometer Vas/las provided inside the CPPSM. The settings on Vas/las shall be varied and the output voltage/current shall be observed.

5.3.4 Operation of sensors for pipeline over protection, under protection, reference cell failure and reference cell selection logic in auto PSP mode shall be verified by connecting variable external voltage sources to reference cell inputs of the CPPSM. The number of external voltage sources shall be same as number of reference cell inputs specified for the CPPSM.

5.3.5 The unit shall be checked for operation of the current limit by over loading the unit in both CVCC and auto PSP modes of operation. For units where semiconductor fuses are not provided for protection of the power semiconductor device, the protection of same shall be tested as below.

5.3.6 A switch rated for making and carrying CPPSM output short circuit current shall be connected to the output terminals of the unit. The output voltage and the output current limit settings of the unit shall be set to the maximum rated values. The switch connected in the output shall be shorted quickly. 5.3.7 The unit shall go to current limit mode and shall not damage any active component of the unit.

5.3.8 The current interrupter shall be tested for time interval settings and specified operation.

6.0 PACKING AND DESPATCH 6.1.1 The equipment shall be properly packed for selected mode of transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent damage to finish. Crates shall have skid bottom for handling. Special notations such as `Fragile', `This side up', `Center of gravity', `Weight' etc., shall be clearly marked on the package together with Tag nos. P.O. Nos. etc.

6.1.2 The equipment may be stored outdoors for long periods before erection. The packing shall be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature.

STANDARD SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION

ABBREVIATION

BIS/IS Bureau of Indian standards IEC International Electro-Technical Commission BS British Standards IEEE Institute of Electrical and Electronics Engineers NEMA National Electrical Manufacturers Association OISD Oil Industries Safety Directorate CCE Chief Controller of Explosive DGMS Director General Mines Safety IE Rules Indian Electricity Rules CPRI Central Power Research Institute AC Alternating Current DC Direct Current CP Cathodic Protection SCADA Supervisory Control And Data Acquisition HV High Voltage MV Medium Voltage LV Low Voltage ACDB Alternating Current Distribution Board DCDB Direct Current Distribution Board CT Current Transformer PT Potential Transformer IR Insulation Resistance CTC Carbon Tetra Chloride MMI Man Machine Interface

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE

2.0REFERENCE DOCUMENTS ..............................................................................

3.0INSTALLATION ..................................................................................................

4.0INSPECTION, TESTING AND COMMISSIONING ................................................

5.0SPARES AND ACCESSORIES ............................................................................

1.0 SCOPE

1.1 Specification defines the requirements for the installation, field inspection, testing and commissioning of electrical equipment, forming part of electrical power distribution and utilization system, including communication and fire alarm system.

2.0 REFERENCE DOCUMENTS 2.1 The work shall be carried out in the best workmanlike manner in conformity with this specification, Consultant Installation Standards, layout drawings and to the following specifications/ codes of practice of Bureau of Indian Standards and OISD standards.

SP-30(BIS) : National Electrical Code. IS-7816 : Guide for testing Insulation resistance of rotating machines. IS 10028(Part-2) : Code of practice for selection, Installation and maintenance of transformers; Part 2: Installation.

IS 10118(Part-3) : Code of practice for selection, installation and maintenance of switchgear and control gear Part 3 Installation.

OISD 137 : Inspection of Electrical Equipment. OISD 147 : Inspection and safe practices during electrical installations 2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable:

a. Indian Electricity Act and Rules. b. Regulations laid down by CEA/Electrical Inspectorate. c. Regulations laid down by CCE/DGMS (as applicable). d. The Petroleum Rules (Ministry of Industry, Government of India). e. Any other regulations laid down by central/state/local authorities and Insurance agencies.

3.0 INSTALLATION

3.1 Prior to start of installation of the electrical equipment contractor shall verify that equipment and complete materials have been received. Handling, shifting to required site location, installation, testing and commissioning of all electrical equipment shall be done by contractor with utmost care. Manufacturer's instructions and the requirements given in their technical manuals shall be strictly adhered. The substation/switchgear room wherein the equipment shall be installed shall be kept clean, dry and-free from all debris. Panel floor cutouts not in immediate use shall be suitably covered to avoid any mishap. When handling the switchboard panels, care shall be taken to observe the correct lifting arrangements and to make sure that slings are attached to the manufacturer's designated lifting points. No parts shall be subjected to undue strains or sudden stresses which could cause damage to the equipment.

3.2 The lifting position mark indicated on packing casing shall be adhered to strictly, for keeping it in required vertical position.

3.3 Contractor shall check and report to the Engineer-in-charge about any damaged item and / or missing component for getting the same replaced as per Specifications. During installation, all accessories and loose items shall also be inspected by the contractor before their assembly/mounting.

3.4 SWITCHBOARDS AND BUS DUCTS 3.4.1 The term switchboard here includes all HV / MV/ LV switchboard panels, motor control centers, power and lighting distribution boards, UPS panels, ACDB, charger panels, DCDB etc. The switchboard panels shall be handled with care, avoiding any impact to the equipment. Dragging of the panels directly on floor shall be avoided. Roller bars may be used for shifting of panels. Use of a crane and trailer shall be made for handling of equipment. The switchboard panels shall be properly supported on the truck or trailer by means of ropes to avoid any chance of tilting. The switchboards shall be lifted after ensuring that panel supports, nuts and bolts are all intact and tightened. While lifting the panels in packed conditions utmost care shall be taken to avoid any damage to insulators, bushings, metering and protective equipment. The panels shall be preferably kept inside the packing cases till foundations are ready.

3.4.2 The switchboard panels shall be installed on prepared foundations or floor cutouts. Steel base channels shall be welded to inserts provided in floor slab. Cross members shall be provided at the junctions of each shipping section and other places as required. Alternatively when the floor is being laid, base channel frame of panels supplied by the Vendor shall be grouted and leveled in cement concrete. It shall be ensured that the base plate level of HV switchboard shall match with the finished floor level. The foundation pockets and the grouted bolts shall be cured for a minimum period of 48 hours.

3.4.3 The switchboard panels shall be taken out from the packed cases and shifted one by one to its proper place. All the panels shall be assembled, aligned and leveled. Alignment of panels shall be checked in both longitudinal and lateral directions. It shall be ensured that panel to panel coupling bolts, bus bar links etc. fit properly without any strain on any part. No new holes for jointing of the panels other than those recommended by the Vendor shall be drilled. No gaps shall be left between the panels. The lifting, racking in and out operation of the breaker and all other motions shall be free from any obstruction. 3.4.4 The panels shall be checked for correct vertical position using pendulum weight and spirit levels. The switchboard panels shall be tack welded at suitable intervals at base channel. 3.4.5 After erection of switchboard panels, all uncovered portions of floor cutouts shall be covered with 6 mm thick removable chequerred plates finished with floor level. The design of the chequerred plates shall be such that the maximum allowable deflection is L/200 (where L is the span of the chequerred plates in meters) for a live load of 500 kg/sq. meters. Suitable lifting arrangements shall be provided for chequerred plates. The chequerred plates shall be painted with a coat of red oxide zinc chromate primer after proper surface preparation as per specifications. Where specified, panel’s cutouts provided for future use shall be filled with lean

concrete.

3.4.6 After completion of erection of switchboards, all the cubicles, switchboard components such as switches, starters, C.T. and P.T. chambers, busbar chamber shall be cleaned and checked for tightness of all the components. Vacuum circuit breakers shall be checked for integrity of bottle seals. All loosely supplied items shall be fitted up. Bus bar sections or links shall be inserted and where specified, of high voltage equipment shall be insulated. Interconnection wiring between shipping sections shall be made by contractor. All the wiring connections shall also be checked. Phase sequence and polarity of PTs and CTs shall be checked. Contact resistance of all busbar joints and contactors shall be checked. Insulator shall be checked for any damage. All the starters, switches, contacts shall be cleaned with C.T.C. where required. All the moving parts shall be checked for easy and free movement. Hinges of panel doors shall be lubricated to give free and noise free movement. All -openings shall be kept completely closed to avoid ingress of any foreign particles inside the panel.

3.4.7 Functional scheme verification of individual feeder shall be carried out and minor wiring modifications in the panel wiring, if required shall be done as per the directions of Engineer-in-charge. Special attention shall be paid to CT circuits polarity, wiring continuity and correctness in the protection as well as measurement circuits. Auto transfer scheme shall be simulated and verified. During the course of scheme verification tests, defective components if any shall be taken out, after bringing to the notice of Engineer-in-charge. The same shall be replaced by component supplied by Owner.

3.4.8 Where switchboard is damp or having a low IR value due to damaged insulators/ bushings/any other insulated parts, or any other reason, the entire-switchboard shall be dried up according to the instruction of the Engineer-in-charge for the IR value-to improve to a safe level for commissioning. Care shall be taken to protect the surrounding insulation from direct local heating during the drying up process.

3.4.9 All the metering instruments, protective relays and other relays and contactors shall be tested as per manufacturer's recommendations and according to the instructions of the Engineer-in- charge. Protection relays shall be inserted and connected and settings adjusted as required by the Engineer- in- charge. 3.4.10 All moving parts, of closing / tripping mechanism racking in and racking out mechanism, spouts and shutter closing mechanism shall be checked for proper operation. All the auxiliary contacts of breaker shall be checked-up cleaned and contact pressure measured.

3.4.11 All the control wiring, PTs, bushings, bus bars other live parts of switchgear, incoming and outgoing cables shall be meggered.

3.4.12 Electrical simulation tests shall be named out for all the protective alarm and annunciation relays and external interfaces to ascertain proper functioning.

3.4.13 Safety insulation mats of approved make and of required voltage grade shall be provided in the sub-station.

3.4.14 Pre-Commissioning Checklist Before commissioning any switchboard, following points shall be checked and ensured for safe energising of the switchboard:

a. That the installation of equipment to be commissioned is complete in all respects with its auxiliaries and all other mounting including earthing. Openings in floor within and outside panels have been sealed off. All cover and door gaskets are intact to-make the enclosure vermin proof.

b. That all the metering instruments have been checked and found in working order. Indicating lamps are healthy and are in correct position. All power and control fuses are of proper rating.

c. That the polarity test and ratio test of all the PT s and CT s is complete and phase sequence of CTs conforms to the correct vector group connections. Wiring continuity and correctness are ensured in the protection and measurement circuits. Polarity of D.C. supply for all the circuits-is correct.

d. That the high voltage tests of incoming and outgoing cables have been conducted and results are satisfactory.

e. That all the protective relays including both conventional and microprocessor based numerical relays and thermal overload relays have been tested for secondary injection tests. (Primary injection tests shall be carried out for differential protection, Restricted Earth fault protection at full / reduced current to ensure correctness of complete wiring). Relay settings, status indications, fault annunciations, data logging, and display of switchboard SLDs shall be verified from MMI in case the same is provided.

f. That I.R. Value have been recorded for bus bars, circuit breaker, incoming and outgoing cables, control wiring and potential transformers. Where required joint resistance of bus bars have been recorded and found to be satisfactory. All the surroundings and panels have been cleaned and temporary earth leads have been removed. 3.4.15 Bus Ducts: The bus ducts as per issued drawings will be supplied in parts and all the parts shall be assembled and the bus bar connections shall be made at site. The insulators in bus ducts shall be inspected for any possible damage during transit and the defective ones shall be replaced. The insulators shall be cleaned. Contact surface of bus bars, bus bar bolts and nuts shall be thoroughly cleaned. Petroleum jelly shall then be applied and bolted connection made. The bus duct enclosure shall be checked for earth continuity and then earthed at two places. The bus duct shall be properly supported between switchgear and transformer. The opening in the wall where the bus duct enters the switchgear room .shall be completely sealed to avoid rain water entry. Expansion joints, flexible connections etc. supplied by the manufacturer of the bus duct shall be properly connected. The bus duct leveling shall be checked with spirit level and pendulum weight.

3.5 TRANSFORMERS 3.5.1 Transformers on receipt at site shall be unloaded by means of crane or lifting devices of

adequate capacity. All lifting lugs shall be used to avoid unbalanced lifting and undue stresses on lugs. Lifting lugs if any provided for partial lifting (e.g. for. active part, conservator) etc. shall not be used for lifting complete transformer. Parts other than those identified for lifting of the transformer shall not be used for lifting. While slinging, care shall be taken to avoid slings touching other parts.

3.5.2 Before lifting transformer, it shall be ensured that all cover bolts are tightened fully. In case when it is necessary to use jacks for lifting, projections provided for the purposes of jacking shall be used. Lifting jacks shall not be used under the valves or radiator tubes. For transporting transformers from stores to site, the transformers shall be loaded on a suitable capacity truck or trailer. The transformers shall be properly supported by steel ropes and stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and vibrations. At no instance the transformer shall be kept on bare ground. Where it is not possible to unload the transformer directly on a foundation, it shall be unloaded on a properly built wooden sleeper platform. A transformer shall never be left without putting stoppers to the wheels.

3.5.3 Transformers shall be examined, for any sign of damage in transit Particular attention shall be given to the following in this regard.

a. Dents on tank wall or cooling tubes. b. Damage to protruding parts like valves, sight glass etc. c. Loosening of bolts due to vibration in transit. d. Cracked or broken bushings. e. Oil leakage particularly along welds. Anything adverse is noted the same shall be brought to the notice of Engineer- in- charge. 3.5.4 Contractor shall examine the transformer base, oil pit, fire walls and foundations laid by the civil contractor. It shall be ensured that oil spills cannot propagate along cable trenches. Any discrepancy noted will be brought to the notice of Engineer- in- charge. Transformers shall be placed on channels or rails over concrete foundation. The transformers shall be leveled, aligned and checked for free movement on the channels or rails. Stoppers shall be provided to the transformer immediately to prevent any movement. Normally transformers up to 1000 kVA rating shall be received duly fitted-with radiator tubes, conservator tanks, valves, wheels and other accessories. While the transformers of above 1000 kVA rating may be supplied with loose accessories. All the accessories like radiators, cooling fans, valves, conservator tanks, explosion vent pipe, bushings and other devices which are supplied indifferent packages shall be checked for any transit damage and cleaned thoroughly before fixing on the transformer. All loosely supplied parts shall be assembled as per manufacturer's instruction manuals/ drawings and documents. All the connections for C.T.s bushings and other wiring shall be checked for tightness and correctness before replacing the lid or tightening all the bolts.

3.5.5 TOPPING OF TRANSFORMER WITH OIL Before topping up with oil, transformer shall fitted with all accessories such as valves, gauges,

thermometers etc. Oil samples shall be taken from each drum and tested for determination of dielectric strength. Any sign of leakage of the barrel or of its having been opened shall be recorded and reported. It is necessary to filter the oil before the transformers are filled. It shall be ensured in oil filling operation that no air pockets are left in the tank and that no dust or moisture enters the oil. All air vents shall be opened. Oil shall be filled through a Streamline oil filter using metal hose. To prevent aeration of the oil, the transformer tank shall be filled through the bottom drain valve. In a transformer with conservator tank, the rate of oil flow shall be reduced when the level is almost up to the bottom of the main cover to prevent internal pressure from rupturing the pressure relief-pipe diaphragm. Sufficient time shall be allowed for the oil to permeate the transformers and also for the locked -up air bubbles to escape. Any air accumulation in the buchholz relay shall be released.

3.5.6 TRANSFORMER OIL a. Sample of oil from the transformer shall be taken from the bottom of the tank. b. Testing of oil :- For dielectric test, the oil shall be tested as described in IS: 335. The oil shall also be tested for acidity in accordance with methods prescribed.

3.5.7 Drying out of the transformer's if required shall be carried out and record maintained in accordance with IS: 10028. Normally a streamline filter shall be used for drying-up. I.R. value versus time of both windings shall be recorded during the drying up process.

Precaution when drying: a. The maximum sustained temperature to which transformer oil may be subjected shall be limited to 80° C. b. The transformer shall be carefully monitored throughout the drying out process and all observations shall be carefully recorded c. Drying out shall be continued so that the insulation resistance as prescribed in the standard code of practice is attained and the value remains constant for more than 12 hours. However, a minimum number of cycles shall be done for each transformer as found necessary by the engineer-in-charge. Generally a megger reading of 2 mega ohms / KV at 60° C temp. with a 5 KV megger may be a rough indication for stopping the dehydration.

3.5.8 The following work on transformers shall be performed by the contractor if specifically called for:

Before finally commissioning the transformer it may sometimes be desired to run it for a few hours on short-circuit, applying a low voltage, approximately equal to the impedance voltage of the transformer. During this process, regular readings of the insulation resistance of the winding to earth and winding to winding and temperature against time shall be recorded.

Testing of radiator tubes for any leakage and rectifying these by welding / brazing. 3.5.9 PRE-COMMISSIONING CHECK LIST:

Before commissioning of any transformer, the following points shall be checked for safe energisation of the transformer:

a. That all the accessories have been fixed properly and transformer body and neutral are properly earthed. The transformer dehydration is over and results are satisfactory and approved by the Engineer-in-charge. In case transformers are idle for more than one month after dehydration, transformer oil has been given at least two circulations. b. That the oil level, in the transformer conservator tank and all the bushings is up to the marked point and the oil have been tested for dielectric strength and acidity. c. That the silica gel is in reactivated condition. The breather pipe is clear from any blocking and contains oil up to the proper level. d. The explosion vent diaphragm does not have any dents. Accumulation of any oil and air had been released. e. That the operation of off-load and .on-load tap changers on all the tap positions is satisfactory. The mechanical parts of the on-load tap changer are lubricated. Motor IR value has taken and found satisfactory. Tap position mechanical indicator on the transformer and tap position indication meter on the control panel are reading the same tap positions. Tap changer limit switches are operating satisfactorily on the maximum and minimum tap positions. On-load tap changer contact pressure and resistance is as per manufacturers recommendations. Oil level of tap changer tank is up to the required level and oil has been tested for dielectric strength. The tap setting on which the off load tap switch is locked shall be recorded. Generally the off-load tap switch shall be kept on nominal tap. f. That the buchholz relay has been tested and checked up for any friction in the movement, and floats are free. All the other protective relays, alarm and annunciation relays have been tested. g. That all the metering equipments have been tested and polarity test of PT's and transformer winding is satisfactory. Phase sequence and connections have been checked for proper vector group. h. That the ratio test and winding resistance on all the tap positions is satisfactory. i. That gaps of arcing horns for the bushings where provided are in order and earth connections for the surge diverters have been checked. j. That the winding and oil temperature thermometer -pockets contain oil and the winding and oil temperature settings on dial gauges are in order. k. That the transformers fitted with fans for forced air cooling have been checked up for automatic starting and stopping of the fans and air-displacement has been verified. l. That the simulation tests for all external interface connection alarm, annunciation and trip circuits have been checked and are order. m. That the insulation resistance of all the control circuits and IR value of the transformer windings and all the incoming and outgoing cables have been checked. n. That all the valves in the codling system and valve between the buchholz relay and the conservator tank is in open position. o. That the setting of all the protective relays is at the desired value and D.C. Trip supply is

healthy.

3.5.10 Observations after Commissioning: After switching on-the transformer the following points shall be observed and recorded. a. The inrush magnetizing current and no load current. b. Alarm if any, or if any relay flag has operated. c. Voltage and current on all the three phases d. Transformer hums or abnormal noise. e. Circulation of oil and leakages. f. Record current, voltage, cooling air temperature, winding temperature and oil temperature readings, hourly for 24 hours. g. Cable end boxes for any overheating. 3.6 H.V. AND M.V. MOTORS 3.6.1 All the motors generally would be erected by the mechanical contractor. 3.6.2 Electrical contractor shall keep the, motor space heater energized, as per the directions of Engineer-in-charge. Electrical contractor shall measure the insulation resistance of motor windings. Insulation resistance of thee motors shall be measured between the winding the machine and its frame by means of a 500/1000 V megger in case of 415 V motors. A minimum value of 1 mega ohm for 415 V motors shall be considered a safe value. In case of lower I.R. Value, the insulation value shall be improved by any of the following methods as directed by the Engineer-in-charge.

a. Blowing hot air from external source. b. Putting the motor in oven. c. Placing heaters or lamps around and inside after making suitable guarding and covering arrangements so as to conserve the heat.

3.6.3 In case the insulation is low, the following method of drying has to be adopted, after consultation with Engineer-in-charge. During drying the temperature rise of winding shall not exceed the permissible value for the class of insulation used.

a. By locking the motor so that it cannot rotate and then applying such a low voltage to the stator terminals so .as to pass full load current in the stator keeping the stator winding temperature below 90° C . In this case a close watch shall be kept for any possible overheating and I.R. Values vs. temperature shall be plotted and heating continued till I.R. value becomes steady. b. By blasting hot air from external source, Maximum temperature of winding while drying shall be 70° C to 80° C (thermometer) or 90° C to 95° C by resistance method. Heating shall be done slowly first till steady temperature of winding is reached after 4 to 5 hours, and for large machines after 10 hours. A record has to be kept for drying process, with half an hour readings and, till steady temperature is reached. In case it is essential, the drying process can be supplemented by blower.

3.6.4 It shall be ensured that the motor leads are correctly connected in the terminal box, as

indicated in the `Name Plate'. The covers of all terminal boxes shall be properly fixed, the gaskets intact. The control circuit shall be tested for proper functioning as per circuit diagram.

3.6.5 In case of synchronous machines, slip rings and brush gear shall be polished and brushes shall be fixed in their holders with clearance and pressure as recommended by the manufacturers.

3.6.6 Before commissioning, the ventilation and cooling system of the motor must be inspected. In case of motor with forced ventilation the air inlet shall be examined to ensure that it is free from moisture and any foreign material. It shall also be ensured that recommended flow and pressure of air is available to produce the required cooling effect. 3.6.7 The motor control gear shall also be carefully examined, the over-load settings may be reduced or time lags bypassed from protective gear to ensure rapid tripping of switchgear in event of faults. The direction of rotation of a new motor especially of large capacity, and phase sequence of supply shall be kept in view while joining and connecting to the motor terminals.

3.6.8 Finally the motor shall be started on no-load after decoupling, and shall be allowed to run for a minimum period of 4 hours, or for a time as instructed by Engineer-in- charge. Attention shall be given to the proper running of the bearings, vibration or unusual noises if any. Voltage, starting current, no-load current, stator winding and bearing temperature shall be recorded after every 1 hour during this test. Direction of rotation shall be checked and recorded. Normally the motors run in clockwise direction as viewed with reference to the phase sequence R, Y, B.

3.6.9 After switching off the motor, the insulation resistance of the motor shall be recorded under hot and cold conditions.

3.6.10 If the no load test run is found satisfactory, the motor shall be allowed to run for 8 hours and all readings shall be recorded.

3.6.11 The following work on motors may be performed by the contractor if specifically called for.

a. The proper level of bearing oil has to be checked. The condition of grease in bearings shall be checked and in case it is necessary, complete replacement of bearing with specified grade of grease after proper cleaning of the bearing shall have to be done. Wherever external greasing facility exists, the condition of grease may be checked by pumping some new grease of specified grade at start. If the grease coming out is deteriorated grease shall be replaced. b. All the motors,-motor exciter set and induction generators directly coupled or coupled through reduction gears shall be checked for abnormal vibration, if any Large rated HV motors with journal type bearings are liable to get damaged from shock, rough handling during transit. Any minor defect in a race or roller may give rise to considerable amount of vibration and noise. Contractor shall check and bring to the attention of Engineer-in-charge any defect noticed in this regard. c. Due care shall be taken to avoid any damage to bearing insulation wherever provided.

3.7 BATTERIES 3.7.1 Battery (Lead acid, Nickel Cadmium or VRLA type as specified) shall be erected on stands and insulators supplied by the manufacturer of the batteries. The installation shall be done as per the layout drawings and manufacturer's instructions. Electrolyte if required / as applicable shall be filled as per manufactures instructions. Inter row connections shall be made with the leads supplied by the manufacturer.

3.8 NEUTRAL EARTHING RESISTOR 3.8.1 The neutral earthing resistor shall be inspected for any damage to the resistor grid and other components. The resistor shall be leveled and installed. All covers etc. shall be checked for lightness to ensure that the enclosure of the resistor is dust, vermin acid weatherproof. Earthing conductors shall be taken from the out end terminal of the resistor for connection to earth electrodes and to the main grid.

3.9 WELDING RECEPTACLES 3.9.1 The welding receptacles shall be erected on steel/concrete structures as per the drawings, in isolated places a separate support shall be fabricated and installed.

3.10 PUSH BUTTON/CONTROL STATIONS 3.10.1 The push buttons / control stations shall be installed near to the motors to be controlled. Individual channel support shall be installed as per standard installation drawings. If control stations for hazardous areas are to be supplied by contractor. These shall be of Ex (d) type tested by CMRI and approved by CCE or other applicable certifying authorities. All outdoor push buttons / control stations shall preferably have integral canopies for additional weather protection. The canopy shall be made of 2 mm thick galvanized sheet steel or FRP where these are not integral with the equipment.

3.11 GANG OPERATED ISOLATORS/OUTDOOR DISCONNECTORS 3.11.1 The isolators shall be transported to site in the dismantled condition. All the insulators may be also supplied loose. The contractor shall inspect, clean assemble and install the isolator on the base structure previously fabricated erected and leveled by him. The operating mechanism shall be installed on the structure and connected to the isolator poles. The operating mechanism shall be tested by slowly bringing the isolator to the closed position and carrying out the necessary adjustment as per the manufacturer's instructions. The earthing switches, frames and operating handle etc. shall be earthed.

3.11.2 Contractor shall provide the following items in substation as per Indian Electricity Rules:

a. Fire buckets filled with clean dry sand and ready for immediate use for extinguishing fires and fire extinguisher (carbon dioxide, dry chemical extinguisher etc.) suitable for dealing with electric fires shall be conspicuously marked and kept. b. First aid boxes containing ointments and medicines for immediate treatment of injuries (As prescribed by Indian Red Cross Society or equivalent). c. Instructions of restoration of persons suffering from electric shock in English, Hindi and local

language of the district shall be affixed in a conspicuous place. d. Danger boards (H.V, M.V.) shall be provided on transformer gate, switchboards, entrance to switchgear room and at other places as required by Engineer-in- charge. e. The Communication system and Fire alarm system panels and equipment shall be installed complying to manufacturer's instructions. The location of field station (call back station unit, break glass unit, telephone set etc.) shown on, the drawing are indicative. The exact location shall be decided at site by contractor in consultation with Engineer-in-charge. Correct type of equipment with regard to hazardous protection as specified on drawing shall be adhered to by contractor, for installation.

4.0INSPECTION, TESTING AND COMMISSIONING

4.1.1 Field inspection, testing and commissioning of the complete electrical installation shall be carried out as per consultants Specification.

4.1.2 After the equipment is installed properly in accordance with drawings and Specifications, Contractor shall carry out all pre-commissioning checks and tests as per company format in the presence of Engineer-in-charge and test readings shall be recorded and furnished to Consultant/Owner in triplicate.

4.1.3 All equipment layout drawings shall be marked by the Contractor for "AS BUILT STATUS" and two sets of copies shall be submitted to Consultant/Owner.

5.0SPARES AND ACCESSORIES 5.1.1 The Contractor shall have all necessary construction equipment, tools and tackles and testing instruments to carry out the erection works and to commission the system as specified. These shall include but not be limited to the following, and these shall be brought to site by Contractor before the start of work.

Equipment: a. Portable grinder. b. Portable welding machine. c. Portable gas cutting / welding set. d. Pipe threading machine. e. Pipe bending machine (hydraulic). f. Portable drill machine suitable to take up drilling for different sizes as per requirement. g. Dewatering pump sets (diesel driven). h. Power Hacksaw. i. Conduit dye set. j. Hydraulic crimping machine. k. Hand crimping tool. l. Portable electric blowers, vacuum cleaners.

m. Miscellaneous items such as slings, pulleys, tarpaulins, wooden sleepers, ladders. etc. as required. n. Safety belts, safety goggles, and gloves. o. Separate tool kit for each Electrician.

p. Insulation tester 1000 V hand driven. q. Insulation tester 2500 V motor/hand driven. r. Insulation tester 5000 V motor/hand driven s. Phase sequence indicator. t. Earth Resistance tester. u. Single phase variac v. 3 phase variac of adequate capacity. w. Secondary injection testing kit. x. Multimeter both analogue and digital y. Portable Ammeters, Wattmeter, P.F. meters. z. Portable Voltmeters. aa. Clip on meters of different ranges.

bb. Tacho-meter. cc. Kelvin’s double bridge for measurement of very low resistance. dd. D.C. high pot test kit. ee. D.C. high pot test kit. ff. Oil filtration machine of adequate capacity. gg. Lux meter to measure illumination levels.

STANDARD SPECIFICATION FOR CABLE INSTALLATION

ABBREVIATION

BIS/IS Bureau of Indian standards OISD Oil Industries Safety Directorate CCE Chief Controller of Explosive CEA Central Electrical Authorities GI Galvanised Iron MS Mild Steel FLP Flam Proof RCC Reinforced Concrete Cement PV Poly Vinyl Chloride

TABLE OF CONTENTS

SL NO. DESCRIPTION 1.0 SCOPE.......................................................................................... 2.0 REFERENCE DOCUMENTS ........................................................ 3.0 DEFINITION .................................................................................. 4.0 DESIGN ........................................................................................ 5.0 INSTALLATION ............................................................................. 6.0 TESTING AND COMMISSIONING ................................................

1.0 SCOPE

1.1 This Specification defines the requirements for supply of materials, wherever applicable, installation, testing and commissioning of cable installation.


2.1 The work shall be carried out in the best workman like manner in conformity with this Specification, Installation standards, layout drawings, the latest edition of relevant Specifications, codes of practice of Bureau of Indian Standards and OISD Standards listed below:

SP: 30 (BIS) Special Publication - National Electrical Code. IS:1255 Code of practice for installation and maintenance-of power cables upto and including 33 KV rating.

IS:10810 Method of Test for cables; Part 43 Insulation resistance. (Part 43)

IS:10810 Method of Test for cables ; Part 45 High voltage test. (Part45)

OISD 147 Inspection and safe practice during electrical installation

OISD I 73 Fire prevention and protection system for electrical installation 2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable:

a. Indian Electricity Act and Rules. b. Regulations laid down by CEA/Electrical Inspectorate. c. Regulations laid down by CCE/DGMS/DGFASLI (as applicable). d. The Petroleum rules (Ministry of Industry Government of India). e. Any other regulations- laid down by central/state/local authorities and insurance agencies

3.0DEFINITION


OWNER / COMPANY OWNER of the particular Project (Project Specific). CONSULTANT The party which is doing engineering, procurement, construction, pre-commissioning and assistance for commissioning, monitors and controls the overall project management.



4.0 DESIGN 4.1 MATERIAL SPECIFICATIONS All materials and hardware to be supplied by the contractor shall be new, unused and of best quality and shall conform to the latest Specifications of Bureau of Indian Standards.

4.2 CABLE TRAYS These shall be ladder type trays either prefabricated hot dip galvanised sheet steel trays or site fabricated angle iron painted trays as specified in job Specification.

4.3 PRE-FABRICATED HOT DIPPED GALVANISED TRAYS The cable trays shall comply with the requirements specified in Installation std.XX-XX- XX.

4.4 SITE FABRICATED ANGLE IRON TRAYS 4.4.1 Angle iron cable trays shall be fabricated from standard rolled angle iron sections of size 75x75x8 for runners for supporting spans limited to 3000 mm. Cross support shall be 25 x 6 mm MS flat for tray width upto 500 mm and 32 x 6 mm flat for tray of more than 500 mm wide and spacing between two cross supports shall not exceed 250 mm.

4.4.2 Vertical supports for both the prefabricated and site fabricated type trays shall be fabricated out of ISMC 100 and horizontal supports shall be with 65 x 65 x 6 mm angle iron sections. Outer most tier of all vertical cable trays shall be covered with GI sheet for protection against physical damage to cables.

4.4.3 Cable racks and trays shall be covered by removable top covers on upper most tier allowing adequate ventilation in following cases where:

a. Mechanical damage of cables is likely to occur during maintenance in the plant. b. Oil or spillage of chemicals can be expected. c. Protection from exposure to sun is required. 4.4.4 GI cover sheet shall allow adequate ventilation to the cables and shall be in standard length of 3000 mm, flanged on both sides for fixing on cable tray. Covers shall be complete with required GI hardwares.

4.5 CABLE GLANDS 4.5.1 Cable glands shall be of nickel plated brass unless otherwise specified. The single compression type cable glands shall be used for _indoor.-panels/equipment, (e.g. substation, control room etc). The cable glands for outdoor terminations shall be weather protected, double compression type and shall have PVC shroud for additional weather protection. Cable glands forming a part of relevant FLP enclosure shall be FLP type, tested by CMRI or any other recognized independent testing laboratory and approved by CCE/DGMS or any other statutory

authority as applicable. Indigenous FLP glands shall have valid BIS license as per the requirements of statutory authorities. The size of the cable glands supplied shall be appropriate to the size of cable so that flame proofnes of glands is retained.

4.5.2 Entry thread of cable gland shall be compatible to the entry thread provided in the equipment (BS, ET, NPT, and PG as applicable). If required, suitable reducers/adopters shall be used.

4.6 CONNECTORS Power cable terminations shall be made with crimped type tinned copper solder less lugs which shall be suitable for the cable size mentioned in cable schedule.

4.7 FERRULES Ferrules shall be of approved type and of size to suit core size mentioned and shall be employed to designate the various cores of control cable by the terminal numbers to which the cores are connected, for ease of identification.

5.0 INSTALLATION 5.1 CABLE LAYING (GENERAL) 5.1.1 Cable installation shall include power, control, lighting, fire alarm, telephone and communication cables. These shall be laid in trenches/ cable trays as detailed in the cable layout drawings. Cable routing given on the cable layout drawings shall be checked in the field so as to avoid interference with structures, heat sources, drains, piping, air-conditioning duct etc. Any change in routing shall be -done to suit -the field conditions wherever deemed necessary, 'after obtaining approval of Engineerin- charge.

5.1.2 High voltage, medium voltage power and control cables shall be separated from each other by adequate spacing or by running through independent pipes, trenches or cables trays, as shown on layout drawings/installation standards, Details of-cable routes and , cable spacing not shown in detail on these drawing shall be determined by the Contractor and approved by the Engineer in charge.

5.1.3 When single core cables are laid in flat formation, the individual cable fixing clamps and spacers shall be of non-magnetic material. As a general practice, the sheath of single core cables shall be earthed at one point to keep sheath at earth potential unless otherwise stated. Single core cables, when laid in trefoil formation shall be braced by suitable clamps at a distance, not exceeding 3 meters along the cable routing.

5.1.4 If straight through joints are required to be provided on single core cables, armour shall be broken at joints as per manufacturer's recommendations. For single core cables armour shall be earthed at one end for the cable run length as per manufacturer's recommendation.

5.1.5 The Telephone, Communication and Fire alarm cables shall run on instrument trays/ducts/ trenches in the units. Wherever these are not available, cables shall be taken in, a separate

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trench/tray with a min spacing of 600mm from power, and control cables but in any case such separation shall not be less than 300mm.

5.1.6 Telephone, fire alarm and plant communication cables shall be directly buried in road berm area, (unless otherwise specified in cable layout drawings).These cables shall cross power cables preferably at right angles. Street lighting cables shall be laid on the other side of road berm area.

5.1.7 The lengths indicated in the cables schedule are only approximate. The contractor shall ascertain the exact length of cable for a particular feeder by measuring at site. All cable routes shall be carefully measured. Before the start of cable laying, the contractor shall prepare cable drum schedule and get that approved by Engineer-in- charge to minimize/avoid straight through joints and then the cables cut to the required lengths, leaving sufficient lengths for the terminations of the cable at both ends. The various cable lengths cut from the cable reels shall be carefully selected to prevent undue wastage of cables. Extra loop length shall be given for feeder cables where required as per the directions of Engineer-in-charge to meet contingencies.

5.1.8 Cables shall be laid in directly buried trench or in RCC trench (underground trench) or in cable tray along pipe sleepers or in over head trays as shown on cable layout drawings.

5.1.9 Overhead trays shall be installed 2700-mm (minimum) above grade level. At road crossings overhead trays shall be installed at 7000mm (minimum) above grade level or cables shall be routed cable tray culvert/ Electrical road crossings as per layout drawings. Sufficient care shall be taken while laying cables to avoid formation of twist, sharp bend etc. in order to avoid mechanical injuries to cables. Rollers shall be used for pulling of cables.

5.1.10 Cable installation shall provide minimum cable bending radii as recommended by cable manufacturer.

5.1.11 Cables shall be neatly arranged in the trenches / trays in such a manner that crisscrossing is avoided and final take off to the motor / switchgear is facilitated. Arrangement of cables within the trenches / trays shall be in line with cable layout drawings. Cable routing between cable trench and equipment/motors shall be taken through GI pipe sleeves of adequate size. Pipe sleeves shall be laid at an angle of maximum 45 to the trench wall. Bending radii of pipes shall not be less than 8D. It is to be ensured that both the ends of GI, pipe sleeves shall be sealed with approved weather proof sealing plastic compound after cabling. In places where it is not possible, cables shall be laid in smaller branch trenches.

5.1.12 All cables shall be identified close to their termination point by cable tag numbers as per cable schedule. Cable tag numbers shall be punched on aluminium straps (2mm thick, 20 mm wide and of enough length) securely fastened to the cable-and wrapped around it.

5.1.13 Each underground cable shall be provided with cable tags of lead securely fastened every 30 m of its underground length with at least one tag at each end before the cable enters/leaves the ground. In unpaved areas, cable trenches shall be identified by means of cable markers as per installation drawing. These cable markers shall be placed at location of changes in the direction of cables and at intervals of not more than 30 m and also at cable

straight through, joint locations.

5.1.14 All temporary ends of cables must be protected against dirt and moisture to prevent, damage to the insulation. For this purpose, ends of cables shall be taped with an approved PVC end cap or rubber insulating tape.

5.1.15 Each row of cables shall be laid in place and before covering with sand. All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water inside building/lined trench. Every cable shall be given an insulation test in presence of Engineer-in-charge/Owner before filling the cable trench with sand Any cable which is found defective shall be replaced:

5.1.16 Where cables pass through, foundation walls, the necessary openings shall be provided in advance for the same by another agency. However, should it become necessary to cut holes in existing structures for example floor slab etc., the electrical contractor shall determine their location and obtain approval of the Engineer-in- charge before carrying out the same.

5.1.17 Cables for road crossings shall be taken through ERC (Electrical Road Crossing) as shown in the cable layout drawings.

5.1.18 At road crossing and other places where cables enter pipe sleeves adequate bed of sand shall be given so that the cables do not slack and get damaged by pipe ends.

5.1.19 Wherever cable trench crosses storm water, waste water channel/drain, cables shall be taken through PVC/RCC pipes. Where cables are required to cross drains of depth more than 1200 mm, cables shall be taken over the drain on cable trays supported suitably using ISMC 150/200 sections.

5.1.20 Ends of cables leaving trench shall be coiled & capped and provided with protective cover till such time the final termination to the equipment is completed.

5.2 CABLES LAID DIRECT IN GROUND 5.2.1 Cables shall be laid underground in excavated cable trenches where specified in cable layout drawings. Trenches shall be of sufficient depth and width for accommodation of all cables. Cables shall be properly spaced and arranged with a view of heat dissipation and economy of design. Maximum number of cable layers in trench shall be preferably limited to 5 layers.

5.2.2 Minimum depth of cable trench shall be 750 mm for medium voltage and 900 mm for H.V. Cables. The depth and the width of the trench shall vary depending upon the number of layers of cables as per Installation Standard.

5.2.3 Cables shall be laid in buried trenches depth as shown in the cable layout drawings. It is to be insured by the contractor that the bottom of buried trenches shall be cleared of all rocks, stones and sharp objects before cables are placed. The trench bottom shall be filled with a layer of sand. This sand shall be leveled and cables laid over it. These cables shall be covered with

150 mm of sand on top of the largest diameter cable and sand shall be lightly compacted. A flat protective covering of 75 mm thick second class red bricks shall then be laid and the remainder of the trench shall then be back filled with soil, rammed and leveled.

5.3 CABLES LAID IN CONCRETE TRENCH 5.3.1 Cables shall be laid in 3 or 4 tiers in concrete trench as shown on layout drawings. Concrete cables trenches shall be filled with sand in hazardous area to avoid accumulation of hazardous gases and oil. RCC covers of trenches shall be effectively sealed to avoid ingress of chemical and oil in process area. Removal of concrete covers where required for the purpose of cable laying and reinstating them in their proper position after cables are laid shall be done by electrical contractor.

5.3.2 All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water.

5.4 ABOVE GROUND CABLES 5.4.1 Cables installed above grade shall run in cable trays, clamped on walls, ceiling or structures and shall be run parallel or at right angles to beams, walls or column. Cable routing shall be planned to be away from heat sources such as hot piping, gas, water, oil drainage piping, air conditioning duct etc. Each cable shall contain only one layer of cables as far as possible for power cables. However control may be laid in double layer in the cable trays.

5.4.2 Individual cable or small group of cables (upto 3 to 4 cables) which run along structures / walls etc. shall be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle bars. Alternatively small group of cables can be taken through 100/150 mm slotted channel tray / ISMC 100. Cables shall be supported so as to prevent sagging. In general, distance between supports shall be approximately 300 mm for cables upto 25 mm diameter and maximum 450 mm for cables larger than 25 mm dia. to prevent the sagging of cables.

5.4.3 Cable laid on supporting angle in cable trenches structures, columns and vertical run of cable trays shall be suitably clamped by means G.I. saddles / clamps, whereas cables in horizontal run of cable trays shall be tied by means of nylon cords. Distance between supporting angles shall not exceed 600 mm.

5.4.4 All cable trays (other than galvanized trays) and supporting steel structures .shall be painted before laying of cables. The under surfaces shall be properly degreased, derusted, descaled and cleaned. The painting shall be done with one coat of red oxide zinc chromate primer. Final painting shall be done with two coats of approved bituminous aluminium paint unless otherwise specified.

5.4.5 Where cables rise from trench to motor, lighting panel, control station, junction box etc., they shall be taken in GI pipe for mechanical protection upto a minimum of 300 mm above grade. Cable ends shall be carefully pulled through conduit to prevent damage to cable.

5.4.6 All G.I. Pipes shall be laid as per layout drawings and site conditions. Before fabrication of various profiles of pipes by hydraulically operated bending machine (which is to be arranged by

the contractor) all the burrs from the pipes shall be removed. GI Pipes having bends shall be buried in soil / concrete in such a way that the bend shall be totally concealed. For G.I. pipes buried in soil, bitumen coating shall be applied on the buried lengths, Installation of G.I. pipes shall be undertaken well before paving is completed and necessary co ordination with paving agency shall be the responsibility of Electrical Contractor.

5.4.7 Following guide shall be used for sizing of G.I. pipe. a) 1 cable in a pipe -53% of pipe cross-sectional area occupied by cables. b) 2 cables in a pipe -31% of pipe cross-sectional area occupied by cables. c) 3 cables in a pipe - 43% of pipe cross-sectional area occupied by cables d) And above cables in a pipe - 40% of pipe cross-sectional: area occupied by cables. 5.4.8 After the cables are installed and all testing is complete, conduit ends above grade shall be plugged with a suitable weatherproof plastic compound/bitumen/suitable sealing compound. Alternatively rubber bushes shall be employed for the purpose of sealing

5.5 TERMINATIONS 5.5.1 All PVC cables up to 1100V grade shall be terminated at the equipment by, means of compression type cables glands suitable for the cable size. They shall have a screwed nipple with conduit electrical threads and check nut. The cables shall be identified close to their termination points at both the ends of cable (cable numbers shall be punched on aluminium 2mm thick and securely fastened to the cable, Wrapped around it) and also along the, route at recommended intervals, by cable tag numbers.

5.5.2 All cable entries for outdoor termination shall be preferably through bottom. Outdoor cable termination through top of equipment shall not be permitted.

5.5.3 Power cables cores wherever colour coding is not available shall be identified with red, yellow and blue PVC tapes. Where copper to aluminium connections are made, necessary bimetallic washers shall be used.

5.5.4 In case of control cables, all cores shall be identified at both ends by their terminal numbers by means of PVC ferrules suitable for core size. Wire numbers shall be as per schematic/ wiring/inter-connection diagram. All unused spare cores of control cables shall be neatly bunched and ferruled with cable tag at both ends, for future use. For trip circuit identification additional red ferrules shall be used only in the particular cores of control cables at the termination points in the Switchgear/ Control panels and Control Switches

5.5.5 Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of nonmagnetic material/ aluminium sheet in case of single core cables. All unused cable entries

on equipment/panels shall be plugged / sealed.

5.5.6 The cable shall be terminated at electrical equipment /switchboards through glands of proper size. The individual cores shall then be dressed and taken along the cables ways or shall be fixed to the panels with polyethylene straps. The cable glanding shall be done as per manufacturer’s instructions. Cable armour shall not be exposed after termination is complete.

5.5.7 In case of termination of cables at the bottom of a panel over a cable trench having no access from the bottom close fit holes shall-be drilled in the gland plate for all the cables in one line, then gland plate shall be split in two parts along the centre line of holes. After fixing bottom plate, uncovered cable holes/gaps shall be sealed with cold settings compound.

5.5.8 Crimping of lugs to cable leads shall be done by hand crimping / hydraulically operated tool as per requirement Insulation of the leads shall be removed before crimping. Conductor surface shall be cleaned and shall not be left open. Suitable conducting jelly shall be applied on the conductor lead. Lugs shall enclose all strands of cable core. Cutting of strands shall not be allowed.

5.5.9 The contractor shall bring to the notice of Engineer-in-charge any mismatch in cable glands, lugs provided with the equipment vis-a-vis to the cable size indicated in cable schedule for taking corrective action.

5.5.10 The cable joints in-power and control tables shall be avoided as far as possible. In case a joint is unavoidable, the following shall be insured:

a. The number of joints shall be restricted to minimum as far as possible, b. The location of joints shall be identified with permanent markers. c. No joints shall be allowed in hazardous areas without the approval of Engineer-in charge

5.5.11 The jointing and termination of medium voltage power cables shall be carried out by trained personnel only. Jointing wand termination of high voltage cables shall be done by skilled and experienced jointer duly approved by Engineer-in-charge. Only type tested termination kits of approved make shall be used.

5.5.12 No unauthorized repairs modifications shall be carried-out on the hazardous area equipment terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall bring to the notice of Engineer-in-charge by Contractor. After termination is complete all the bolts, nuts, hardware of terminal box shall be properly placed in its position and tightened.

5.5.13 Where required, cable sealing boxes intended to be used with the apparatus shall be filled with solid setting type bituminous compound unless otherwise specified.

6.0 TESTING AND COMMISSIONING 6.1 Field testing and commissioning of electrical installation shall be carried out as per

Standard Specification XX-XX-XXX.

6.2 Before energising the insulation resistance of every-circuit-shall-be measured from phase to phase, phase to neutral and from phase/neutral to earth.

6.3 Where splices or terminations are required in circuits rated above 650 volts, insulation resistance of each length of cable shall be measured before splicing and or / terminating. After completion of splices and /or terminations measurements shall be repeated.

6.4 The insulation resistance of directly buried cables shall be measured before cable trenches are backfilled. Measurements shall be repeated after back filling.

6.5 For cables up to 1.1 kV grade 1000V Megger and for H.V. Cables 2.5 kV / 5 kV Megger shall be used.

6.6 D.C. High Voltage test shall be conducted on cables given below after installation. . 6.7 All 1100 volts grade cables in which straight through joints have been made. 6.8 All cables above 1100 V grade. 6.9 The D.C. High Voltage test shall be performed as detailed below in the presence of the Engineer in charge or his authorised representative only,

6.10 Cables shall be installed in final position with all the straight through joints complete. During the high voltage test, all other electrical equipment related to the cable installation, such as switches, instrument transformers, bus bars, etc., must be earthed and adequate clearance shall be maintained from the other equipment and framework to prevent flash over.

6.11 In each test, the metallic sheath/screen/armour shall be connected to earth. 6.12 All checks and tests shall be made as per Consultant standard test Performa available with site engineer.

6.13 All test readings shall be recorded and submitted to Consultant / Owner in triplicate sets.

6.14 Cable schedule, cable layout drawings, Interconnection drawings shall be marked by contractor for `AS BUILT STATUS' and two sets of copies shall be submitted to Consultant / Owner.

STANDARD SPECIFICATION FOR EARTHING INSTALLATION

ABBREVIATION

BIS/IS Bureau of Indian standards IEC International Electro-Technical Commission BS British Standards IEEE Institute of Electrical and Electronics Engineers NEMA National Electrical Manufacturers Association OISD Oil Industries Safety Directorate CCE Chief Controller of Explosive DGMS Director General Mines Safety IE Rules Indian Electricity Rules CPRI Central Power Research Institute GI Galvanized Iron MS Mild Steel

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE .........................................................................................


3.0 DEFINITIONS ...............................................................................

4.0 MATERIALS ................................................................................

5.0 DESIGN .......................................................................................

6.0 INSTALLATION ...........................................................................

7.0 INPSPECTION AND TESTING ....................................................

1.0 SCOPE

1.1 This specification defines the requirements for the supply of earthing and lightning protection materials and installation of the earthing and lightning protection systems.


2.1 The work shall be carried out in the best workman like manner in conformity with this specification, consultant installation standards, layout drawings, the latest edition of relevant specifications, codes of practice of Bureau of Indian standards and OISD standards listed below:

SP: 30 (BIS): Special Publication-National Electrical Code IS: 2309: Protection of buildings and allied structuresagainst lightning.

IS: 3043: Code of practice for earthing. IS: 7689: Guide for control of undesirable static electricity.

OISD 110: Recommended practices on static electricity

OISD 147: Inspection and safe practice during electrical installation. 2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable:

a. Indian Electricity Act and Rules. b. Regulations laid down by CEA/Electrical Inspectorate. c. Regulations laid down by CCE/DGMS (as applicable). d. The petroleum rules (Ministry of Industry Government of India). e. Any other regulations laid down by central/state/local authorities and Insurance agencies.

3.0DEFINITIONS






4.0 MATERIALS 4.1 MATERIAL SPECIFICATIONS 4.1.1 All materials and hardwares to be supplied by the contractor shall be new, unused and of best quality and shall conform to the specifications given here under and to latest Specifications of Bureau of Indian Standards. Contractor shall bring material samples to site and get it approved by engineer-in-charge before installation.

4.1.2 The main earth grid conductor shall be hot dip galvanised M.S. flat unless otherwise specified. Sizes for main conductors shall be as indicated on the earthing layout drawing. Amount of galvanising shall be 610gm per sqmetre. Earth electrodes and Earth plate shall be as per job specification.

5.0 DESIGN 5.1 EARTHING NETWORK 5.1.1 This consists of main earth conductor (grid conductor) forming a closed ring network with required number of earth electrodes connected to it to provide a common earth for electrical devices and metallic structures. From each earth electrode two distinct connections shall be made to the main earth conductor. The earth plates shall be used for taking multiple earth connections to two or more equipment.

5.1.2 The earth conductor shall be laid along cable trays/cable trench/pipe racks as indicated on the earthing layout drawing. Where lined cable trenches are available, the earth conductor shall be laid in the trenches and shall be firmly cleated to the sidewall of concrete trenches using GI clamps at interval of 400 mm to 500 mm and near to the termination end. The earthing conductor shall run along one of the cable trays along a cable route. The earthing conductor shall be suitably cleated and electrically bonded to all the other cable trays on the same cable route at a regular interval of 25 to 30 metre. The earthing for equipment shall be tapped from the main earth conductor and not from cable tray support structure. Earth conductor when laid underground shall be at a depth of 500mm below finished grade level.

5.1.3 Joints and tappings in the main earth loop shall be made in such a way that reliable and good electrical connections are permanently ensured. All joints below grade shall be welded and shall be suitably protected by giving two coats of bitumen and covering with hessian tape. Earth strip laid above ground shall be welded across straight through joints and joints shall be suitably protected by giving two coats of bitumen to avoid oxidation and insulation film formation of the strip surface. When two earth strips are to be joined by means of welding, lap welding with an overlapping of strip equivalent to double the width of the strip and all four sides shall be continuously welded. All joints at tappings above ground shall be by means of connector/lugs. A minimum of two bolts of adequate size shall be used for this purpose. Earthing strip joints at earth plate and equipment shall be through GI bolts, nut etc.

6.0 INSTALLATION 6.1 INSTALLATION OF EARTH ELECTRODE 6.1.1 Earth Electrode shall be installed as shown on installation standard and layout drawings. The location shown on the layout drawings are indicative.

6.1.2 The exact location of earth electrodes in the field shall be determined by contractor in consultation with the Engineer-in-charge, depending on the soil strata and resistivity. Earth electrodes shall be located avoiding interferences with road, building foundation, column, pipelines etc. The civil area drawings shall be referred for this. The distance between two electrodes shall not be less than twice the depth of electrode.

6.1.3 Electrodes shall preferably be located in a moist soil which has a fine texture, grain size and distribution. Wherever practicable the soil shall be dug up, all lumps broken and stones removed from the immediate vicinity of the electrodes and soil packed by watering and ramming as tight as possible.

6.1.4 The electrodes shall have a clean surface, not covered by paint, enamel, grease or other materials of poor conductivity.

6.1.5 All earth electrodes shall be tested for earth resistance by means of standard earth test meter. The tests shall take place in dry months, preferably after a protracted dry spell.

6.1.6 The disconnect facility shall be provided for the individual earth electrode to check its earth resistance periodically.

6.1.7 Location of earth electrodes shall be marked by permanent markers for easy identification. All earth Electrodes shall be serial numbered and also marked on `As Built' drawing for future reference.

6.1.8 Individual earth electrodes shall be provided for each lightning arrestor and flood light mast.

6.1.9 Earthing system provided for concrete paved area by other agency where applicable; shall be connected to the plant earthing system below ground by minimum two earth connections.

6.2 CONNECTION 6.2.1 The earth system connections shall generally cover the following: a. Equipment earthing for personnel safety b. System neutral earthing c. Static and lightning protection d. System neutral e. Current and potential transformer secondary neutral f. Metallic non-current carrying parts of all electrical apparatus such as transformers,

switchboards, bus ducts, motors, neutral earthing resistors, capacitors, UPS, battery charger panels, welding receptacles, power sockets, lighting/power panels, control stations, lighting fixtures etc. g. Steel structures/columns, rail loading platforms etc. h. Cable trays and racks, lighting mast and poles i. Storage tanks, spheres, vessels, columns and all other process equipment. j. Fence and Gate for electrical equipment (e.g. transformer, yard etc.) k. Cable shields and armour. l. Flexible earth provision for Wagon, Truck m. Shield wire 6.2.2 Conductor size for branch connection to various equipment shall be as per consultant Installation Standards unless otherwise stated on earthing layout drawings.

6.2.3 All process pipelines shall be bonded and earthed at the entry and exist points of battery limit of hazardous area. Earth continuity conductors across pipe line flanges shall not be provided as per OISD 110.

6.2.4 Steel pipe racks in the process units and offsite area shall be earthed at every 24 meters.

6.2.5 Equipment / street light pole etc. located remote from main earth network may be earthed by means of individual earth electrode and earth conductor unless otherwise stated in Job Specifications.

6.2.6 Lightning protection shall be provided for the equipment, structures and buildings as shown on layout drawing. Self conducting structures shall not require separate aerial rod and down conductors. These shall however be connected to the earthing system at two or more points as shown on layout drawing. An independent earthing network shall be provided for lightning protection and this shall be bonded at least at two points with the main earthing network below ground. Lightning down conductor shall be brought to earth electrode in shortest straight path as feasible to minimize surge impedance.

6.2.7 The main earthing network shall be used for earthing of equipment to protect against static electricity.

6.2.8 All medium and high voltage equipment (above 250V) shall be earthed by two separate and distinct connections with earth.

6.2.9 Plant instrument system clean earthing, UPS system clean/safety earth shall be separate from the electrical earthing system.

6.2.10 All paint, scale and enamel shall be removed from the contact surface before the earthing connections are made.

6.2.11 All earthing connections for equipment earthing shall be preferably from the earth plate

mounted above ground wherever provided.

6.2.12 Equipment foundation bolts shall not be used for earthing connection. 6.2.13 Earth connections shall be made through compression type cable lugs/by welded lugs.

6.2.14 All hardware used for earthing installation shall be hot dip galvanised or zinc passivated. Spring washers shall be used for all earthing connections and all connections adequately locked against loosening.

6.2.15 Lighting fixtures and receptacles shall be earthed through the extra core provided in the lighting circuit/cable for this purpose.

6.2.16 The reinforcements of sub-station building and the sub-station floor shall be connected to main earth grid.

7.0INPSPECTION AND TESTING

7.1.1 Field inspection, testing and commissioning of electrical installation shall be done as per specification no.00004-PL-EL-SP-21-R0. Earthing systems/connections shall be tested as follows:

7.1.2 Resistance of individual earth electrodes shall be measured after disconnecting it from the grid by using standard earth test meggar.

7.1.3 Earthing resistance of the grid shall be measured after connecting all the earth electrodes to the grid. The resistance value of an earth grid to the general mass of earth shall be as follows:

a. For the electrical system and equipment a value that ensures the operation of the protection device in the electrical circuit but not in excess of 4 ohm. However for generating stations and large sub-systems the value shall not be more than 1 ohm. b. For lightning protection, the value of 5ohms as earth resistance shall be desirable, but in no case it shall be more than 10 ohms.

7.1.4 The resistance to earth shall be measured typically at the following points. a. At each electrical system earth or system neutral earth.

b. At each earth provided for structure lightning protections. c. At each point on earthing system used to earth electrical equipment enclosures. d. At one point on earthing system used to earth wiring system, enclosures, such as metal conduits and cable sheaths or armour. e. At one point on fence enclosing electrical equipment. 7.1.5 All earthing layout drawing shall be marked by contractor for ‘AS BUILT STATUS’ and two sets of copies shall be submitted to consultant.

STANDARD SPECIFICATION FOR LIGHTING INSTALLATION

ABBREVIATION

BIS/IS Bureau of Indian standards IEC International Electro-Technical Commission BS British Standards IEEE Institute of Electrical and Electronics Engineers NEMA National Electrical Manufacturers Association OISD Oil Industries Safety Directorate CCE Chief Controller of Explosive DGMS Director General Mines Safety IE Rules Indian Electricity Rules CPRI Central Power Research Institute AC Alternating Current DC Direct Current CP Cathodic Protection SCADA Supervisory Control And Data Acquisition FRP Fiber Reinforced Plastic TPN Triple Pole Neutral MCB Miniature Circuit Breaker ELCB Earth Leakage Circuit Breaker MDB Main Distribution Board HPMV High Pressure Mercury Vapor HPSV High Pressure Sodium Vapor PVC Poly Vinyl Chloride GI Galvanized Iron HRC High Rupturing Capacity MS Mild Steel CFM Cubic Flow Meter

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE..........................................................................................

2.0 REFERENCE DOCUMENTS ........................................................

3.0 DEFINITION ..................................................................................

4.0 FABRICATION (EQUIPMENT SPECIFICATION) ..........................

5.0 INSTALLATION .............................................................................

6.0 INSPECTION & TESTING .............................................................

1.0 SCOPE

1.1 This specification defines the requirements for the supply of equipment; materials, installation, testing and commissioning of the lighting system (lighting fixtures, lighting power distribution, telephone wiring etc.).

2.0 REFERENCE DOCUMENTS 2.1 The work shall be carried out in the best workmanlike manner, in conformity with this specification, and the relevant specifications/codes of practice of the bureau of Indian standards.

2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable:

a. Indian Electricity Act and Rules. b. Regulations laid down by CEA/Electrical Inspectorate. c. Regulations laid down by CCE/DGMS (as applicable). d. The petroleum rules (Ministry of Industry Government of India). e. Any other regulations laid down by central/state/local authorities and Insurance agencies.

1.0 DEFINITION


OWNER / COMPANY - OWNER of the particular Project (Project Specific).

CONSULTANT – The party which is doing engineering, procurement, construction, pre commissioning and assistance for commissioning, monitors and controls the overall project management.



4.0 FABRICATION (EQUIPMENT SPECIFICATION)

All materials, fittings and appliances to be supplied by the contractor shall be new, unused and of the best quality and shall conform to the specifications given hereunder. These shall be manufactured in accordance with the latest revision of the specifications of Bureau of Indian 'Standards/International Standards. In the absence of any specifications for a particular item contractor shall bring material samples along with proven track record to site and get the same, approved by Engineer-in-Charge/Owner before installation.

4.1 LIGHTING AND POWER PANELS 4.1.1 Lighting and power panels (general purpose panels for safe area) shall be made of 1.6mm thick sheet steel and shall be dust and vermin proof. All metal surfaces shall be cleaned free of rust, given a coat of red-oxide primer and finished with two coats of epoxy based paint of shade 632 of IS 5. Panels shall be indoor/outdoor type as specified. Indoor type panels shall have IP42 degree of protection and shall be suitable for surface or flush mounting on wall surface as specified. Lighting and power panels located outdoor shall be IP55 weather protected and shall also preferably have integral canopy for additional weather protection. The canopy shall be made of 2mm thick galvanized sheet steel or FRP where these are separate from the equipment.

4.1.2 Lighting and Power panels shall have TPN incoming feeder and single phase outgoing feeders. Lighting circuit feeders shall be rated for 10 amps and power circuit feeders shall have current rating of 16Amps. In power panels for window Air conditioning units, power circuit feeder shall be rated for 20 amps. Panels shall be equipped with phase and neutral bus bars of required current carrying capacity. The outgoing feeders shall be provided with single pole miniature circuit breakers (MCBs) for safe areas and double pole MCBs for hazardous areas. The incomer shall be with MCB and ELCB unit unless otherwise specified. Miniature circuit breakers shall be mounted in such a way that the operating levers project outside the front bakelite covers plates for ease of operation. A hinged door to cover the operating knobs shall be provided. In addition, a circuit diagrams indicating incomer details and outgoing details viz. Circuit number, circuit rating, and load connected and details of the load shall be pasted inside the panel. Also a laminated copy of the diagram shall be provided inside the panel in a suitably designed pocket. Two external earthing studs for connection to the plant earthing grid shall be provided on the panel. Further, the panel shall be provided with an earth bus bar with terminal studs for connection to the third core of each outgoing circuit. Each circuit phase and neutral shall be given ferrule numbers. Complete wiring inside the panel, shall be neatly bunched with PVC tape and button. Sufficient terminals shall be provided in the terminal block so as to ensure that not more than one wire (core) is connected to a terminal. The panel shall have knock out holes or removable gland plate for the entry of incoming and outgoing conduits or cables. The panels shall be complete with requisite number of cable glands as specified.

4.1.3 The Main distribution board (MDB) where used, shall be made of 2mm thick sheet steel panel, dust and vermin proof similar-in construction to Lighting and Power panels but with TPN MCB incoming and TPN outgoings (MCB with ELCB units and MCB without ELCB unit as applicable) of required numbers as specified.

4.1.4 All MCBs shall be of M9 category as per IS 8828 and sensitivity of ELCBs shall be 100 mA unless otherwise specified.

4.1.5 Wherever the size of incoming cable to lighting, power panels/MDB is more than 35 sqmm a suitable cable adapter box shall be provided and attached .to the panel. The incoming cable leads shall be connected to terminal block (bolted type terminals) of required size. This terminal block shall be connected to TPN incomer unit through separate PVC insulated copper

conductor wires/bus bars. Sufficient space shall be provided (200 to 250mm) between gland plate and the bottom of terminal block for easy termination.

4.2 LIGHTING FIXTURES The types, Makes and catalogue numbers of various types of lighting fixtures shall be as given in Fixture schedule job Data Sheet. HPMV/HPSV lighting fixtures shall be complete with ballast, starters and capacitor, as required. Control gears shall be integral or non- integral as specified in lighting layout drawings. Unless-otherwise specified all fixtures shall be supplied complete with lamps. Ballast for fixture shall be copper wound or electronic type. The fixtures shall be of high power factor type i.e. at least 0.9 or more.

4.3 SWITCHES Switches, manufactured in accordance with IS: 13947 shall be used for non hazardous areas. Switches in areas where concealed wiring has been adopted, shall he flush mounting piano type unless otherwise specified. For surface conduit wiring, piano type switches in surface mounted box shall be provided. Industrial Type switches (Weather protected) shall be used for outdoor areas.

4.4 RECEPTACLES Three pin type 5A/15A receptacles manufactured in accordance with IS: 1293 shall be used for non hazardous areas. The receptacles and the controlling ON/OFF switch shall be mounted in the same enclosure box but these shall be in separate units to facilitate replacement by parts. Flush mounting type receptacles shall be used in areas where concealed wiring has been adopted and surface type shall be used in other areas. For exhaust fans and wall mounted air circulators, socket and switch enclosures shall be separate. In buildings such as sub-station, D.G. shed, Workshop, maintenance shop etc. industrial type metal clad socket outlets and plugs shall be provided. These sockets shall be supplied complete with plugs.

4.5 OUTLET BOXES The outlet boxes used as point outlets shall be prefabricated type 65mm deep junction boxes. Outlet boxes custom fabricated for sockets, switches, fixtures and fan regulators etc. shall be made of M.S. Sheet having minimum thickness of 1.6mm. Outlet boxes shall be galvanized after fabrication. These shall be complete with terminal block suitable for connection of wires up to 4 sq. mm Front cover plate shall be of 3mm thick backelite/PE sheet. The colour shall suit the shade of the walls or shall be white if the shade of the walls is not finalized. The sheet shall extend at least 2 cm on all sides of outlet box. Cover plate shall be fixed by cadmium plated brass screws and cup washers. Outlet boxes shall be provided with adequate number of knock outs on all the sides for ease of wiring either with conduits or without conduits.

4.6 CONDUIT AND ACCESSORIES Conduits for Electrical installations shall conform to IS: 9537. The type of conduit (steel/GI/PVC) shall be as specified on drawing. Black enameled-steel or GI conduit shall be of 1.6mm thick and

http://areas.s--itchey.in/

http://areas.s--itchey.in/

the minimum wall thickness of PVC conduit shall be 1.6mm. Generally PVC conduits shall be used in concealed wiring and for surface wiring GI conduit (in plant buildings) and black enameled steel conduit (in-non plant buildings) shall be used.

4.7 LIGHTING POLES Lighting poles shall be fabricated from ERW steel tubular pipes of specified section, with joints, swaged together when hot and beveled on outside edges. Poles shall be coated with bituminous preservative solution on the ground portion of the outside surface. Remainder of the outside surface shall be given one coat of red oxide primer and finished with two coats of alluminium paint. The pole shall have, a marshalling, box near the bottom to contain HRC fuses, a neutral link earth stud and terminal block.

4.8 LIGHTING MAST Lighting masts (Lattice tower) where used. They shall be complete with 2 nos. MS flats provided at the base plate for connection to the plant earthing grid. A ladder, platform, handrail, a weather protected TPN switch (at 1500mm from ground-level) and ;a weather protected distribution board fabricated out of sheet steel shall be provided at the top of mast. The TPN Switch and the distribution board shall also have a canopy for additional weather protection. The TPN switch shall be suitable for looping one more lighting mast from the same incoming, power supply. The distribution board shall have TP&N bus bars of 30 Amps. rating and 12 Nos. outgoing circuits each with a 6A single pole MCB. The distribution board shall have cable entries from bottom. Necessary space provision and suitable mounting arrangement shall be made on top of the tower for mounting of ballast (choke) and condensers for all the circuits and the lighting fixtures. The masts shall be given one coat of red oxide primer and two coats of aluminium paint. Distribution board shall he fabricated out of 2mm thick sheet steel and shall be painted with two coats of enamel over a base coat of red oxide.

Unless otherwise specified the flood lighting high masts shall be telescopic type. 4.9 WIRES Wires shall be PVC insulated and shall be of 660 Volts grade as per IS694. Conductor shall be of stranded copper and size shall be minimum 1.5 Sq. mm for lighting, 2.5 Sq. mm for 15A power socket circuits and 4 sq. mm for split A/C power socket circuits. Red/Yellow/blue wires for phases, black wire for neutral and green wire for earth shall be used (size of earth wire shall be same as for phase and neutral size). Wire size for air conditioning circuit feeders shall be as indicated in the panel schedule.

4.10 CEILING FAN/EXHAUST FAN Ceiling fans shall be of 1200mm sweep unless otherwise specified with double ball bearing and regulator. The suspension down rod shall be sturdy mild steel rod of adequate diameter and of minimum length of 300mm with shakles suspension arrangement as per IS. For exhaust fans, the sweep dia. and air CFM shall be as specified in job specification. Exhaust fans for battery room shall be with anticorrosive blades suitable for use in acidic fumes.

4.11 DECORATIVE SWITCHES AND SOCKETS Decorative lighting switches and sockets where specified, shall be modular in design. All these items shall fit into the same frame with overall standard dimensions. Frames shall be suitable for surface and flush mounting in brick / concrete wall. The frames shall be suitable for conduit entry from all the sides. Switches and sockets shall match colors of the frame and cover plates to obtain a combination which shall match decor of the interiors of Control Room, Administrative buildings, offices rooms etc.

5.0 INSTALLATION

Lighting system installation shall be as per follows.

5.1 GENERAL 5.1.1 The lighting fixtures in the plant shall be fed from lighting panel. All outdoor lighting shall be group controlled manually or through synchronous timer or photocell. Lighting wiring between panel and lighting fixtures shall be done with PVC insulated 3 core (phase, neutral and earth) copper conductor armoured cable for hazardous areas. Wiring in the building shall be done by means of 3 core copper, conductor. PVC insulated, unarmoured cables, or PVC insulated copper conductor wires in conduit/Metsec channel as specified. All joints of conductors in Switch boards/JBs Fittings shall be made only by means of approved mechanical connectors (nylon/PVC connectors). Bare twisted joints shall not be permitted anywhere in the wiring system.

5.1.2 The lighting layouts furnished by Owner will indicate approximate locations of lighting fixtures. The electrical contractor shall determine, with approval of Engineer-in-Charge, The exact location of each fixture in order to avoid interference with the piping or other mechanical equipment and also with a view to obtain as much uniform illumination as practicable, and to avoid objectionable shadows. Conduits shall be laid out by the contractor to suit field conditions and as per directions of the Engineer-in-Charge.

5.1.3 On walkways, platforms and other outdoor area, lighting fixtures shall be located nearer to landing of stairs or ladders, gauges, flow meters, panel boards and other equipment to provide proper illumination.

5.1.4 The minimum height of any lighting fixture shall be preferably not less than 2.5 meters above the floor level.

5.1.5 All outdoor cable terminations to outdoor junction boxes, panels, socket outlets etc. shall be through bottom or from side. Top entries for cables shall be avoided to avoid water entry. All cable glands for outdoor terminations shall be double compression type and the gland shall be covered with PVC or rubber boot shroud. All unused cable entries shall be plugged with suitable blanking plugs.

5.1.6 Mounting height of equipment shall be as under: - a. Top of Switch Box 1200 mm from FFL(Finished floor level) b. Top of Lighting/Power Panel 1800mm from FFL

c. 5/15 Amp. Receptacle 300mm from FFL unless otherwise specified (1200 mm for process areas and industrial sheds) d. Lighting fixture As indicated in layout drawing e. Exhaust fan In the cutout provided / as indicated in Layout drawings. 5.1.7 Fixtures shall be firmly supported from the structures. Support (clamps etc. may be bolted or welded to the existing steel work or metal inserts. In case of concrete, structures, where metal inserts are not available, fixtures shall be suspended from concrete surfaces with the help of anchor fasteners. In such cases special care shall be taken to see that anchoring is firm. In places where ceiling fans are provided, lighting fixtures shall be suspended below the level of fan to avoid shadow effect.

5.1.8 Circuit cables in a group shall be cleated to structure by using galvanized strip clamps or cable run in cable trays wherever trays are available. Spacers and cleats shall be of required size to accommodate the cables. All hardware shall be galvanized or zinc passivated. Underground lighting cables (in paved areas), shall be taken in suitable G I sleeves buried at a minimum depth of 300 mm from FFL. GI pipe sleeves shall be extended to 300mm above. FFL Exact termination/layout of pipes (for protection of cables) shall be decided at site as per site convenience in consultation with Engineer-in charge.

5.1.9 Wiring for all outlet sockets shall be done with 3 cores of equal sizes for, phase, neutral and earth. The terminals of switch sockets shall be suitable to receive the size of wire specified.

5.1.10 All lighting fixtures shall be provided with terminal block with required terminals suitable for connection of wire up to 2.5 sq mm copper conductor.

5.1.11 The cable shall be straightened after unwinding it from the drum. All cables be clamped/laid in straight run without any sag and link.

5.1.12 For location where fan points are shown, fan hooks with junction box during concreting. 5.1.13 Where fan hooks and JB’s are provided separately JB shall be located within a distance of 300mm from hook for mounting of ceiling rose.

5.1.14 Industrial type plug sockets with 20A MCB or rating as per job specification shall be provided at a height of 500mm from FFL for window AC units.

5.1.15 Socket outlets and plugs for installation in Substation building, DG shed, workshop, and maintenance shop etc. shall be of industrial metal clad type.

5.1.16 Wiring for exhaust fans shall be terminated in receptacles as specified in layout drawing and the connection from receptacle to the exhaust fan shall be by means of a flexible cord equivalent in size to the main run of wires. Switch for exhaust fan shall be located in a separate switch board along with other switches.

5.2 CONDUIT SYSTEM 5.2.1 Surface or concealed conduit system of wiring shall be adopted, as specified in the

drawings. Required number of pull boxes shall be used at intervals to facilitate easy drawing of wires. Separate conduit shall be run for lighting and power circuits. Further, conduits for Normal lighting/Emergency lighting/DC critical lighting shall be separate. Conduit layout shall be decided at site as per site conditions. Drop conduits for switch boards shall be decided by contractor as per wall locations shown in Architectural drawings. All exposed run of conduits on surface, shall be vertical or horizontal.

5.2.2 Only threaded type conduit fittings shall be used for metallic conduit system. Pin grip type or clamp type fittings are not acceptable. Conduit ends shall be free from sharp edges or burrs. The ends of all conduits shall be reamed and neatly bushed.

5.2.3 Conduit shall be of minimum 25mm dia. Maximum number of wires permissible in a conduit shall be seven/nine for wire size of 2.5 sq mm/1.5 sq mm. respectively.

5.2.4 The exposed outer surface of the conduit pipes, including all accessories forming part of the conduit system, shall be adequately protected against rusting. In all cases, bare threaded portion of conduit pipe shall not be exposed unless such bare threaded portion is treated with anti corrosive preservative or covered with approved plastic compound.

5.2.5 Conduit connection to outlet boxes shall be by means of screwed hubs or check nuts on either side. Where concealed wiring is done, junction boxes (65mm deep) shall be used so as to rest on shuttering properly. Conduits shall be laid above reinforcement. All conduit connections shall be properly screwed and Junction box covers shall be properly fitted so as to avoid entry of concrete slurry.

5.2.6 Conduit pipes shall be fixed by I.6mm thick G.I. saddles on 3mm thick G.I. saddle bars of required width in an approved manner at intervals of not more than 50cms for straight run. At places near junction boxes, bends, or similar fittings, saddle and bars shall be provided on either side.

5.2.7 Where concealed wiring is to be adopted, conduits shall be laid in time before concreting of the slab. Pull wire (GI or steel) shall be provided inside conduit .for the ease of wire pulling. The contractor shall coordinate his work with other agencies involved in the civil works in, such a way, that the work of the other agencies is not hampered or delayed. Vertical conduit runs shall be made in wall before platering is done so as to avoid chasing. Where chases are made for conduit run contractor shall fill these chases or any other openings made by them after completing the work and patch the surface. During installation, care shall be taken to see that proper covers are provided to prevent rusting of conduits. Locations of all point outlets, junction boxes shall be marked with brick powder or sand so that these are easily identified after shuttering removal. As built conduit layout drawing shall be submitted by contractor after completion of the work.

5.2.8 All junction boxes, bends and other accessories shall be of the same material as that of conduit and shall have the same protective coatings.

5.2.9 After erection, the entire conduit system shall be tested, for mechanical and electrical continuity and shall be permanently connected to earth by means of approved type of earthing

clamps.

5.3 HAZARDOUS AREA INSTALLATION 5.3.1 Wiring in hazardous area shall be done by using minimum 2.5mm copper conductor armoured cable. Circuit wiring feeding hazardous areas shall be controlled by two pole switches/MCBs (for phase as well as neutral isolation).

5.3.2 Correct type of lighting equipment (fixtures and JBs) with regard to hazardous protection as specified in the drawing shall be installed for the areas classified as Zone 1, Zone 2 etc.

5.3.3 The terminations in the junction boxes and the lighting fittings shall be done avoiding possibility of loose connections due to vibrations. After the terminations are made the cover of the junction boxes and the lighting fittings shall be closed properly with all bolts and hard wares in correct position, retaining its explosion and weather protections. In fixtures having double cable entries, both the entries shall be used for looping in and looping out connection, thus minimising the use of separate junction box wherever separate control gear boxes (C.G. box) are provided looping in and looping out, connections shall be through CG-box, thus avoiding the use of a additional junction box. All unused cable entries shall be sealed with suitable plugs.

5.3.4 Circuit cables shall be firmly cleated in a group along, columns/ beam/ladders/side channels/platform using 1.6 mm thick GI saddles on, 25x3 mm GI saddle bar at intervals of 400mm to 500mm for straight run and on either side close to bending and at both termination ends as per the direction of Engineer-in-charge. Where required 3 or more of cables may be taken in slotted channel tray after getting the approval of Engineer-in-charge. Cables shall not be routed along hand rails.

5.3.5 Where fire proofing column/structures are encountered, all cabling shall be taken in GI pipes of required size and both ends shall be sealed, well before fire proofing is done. Similarly equipment such as lighting fixture, control gear box, lighting/ power panels, field call stations, junction-boxes etc. shall be installed on suitable steel mounting frame/distance bracket, thereby direct contact with the concrete used for fire proofing.

5.3.6 Cable glands for terminating cable on flameproof equipment shall be of double compression FLP type. Any material/equipment specified to be supplied by contractor for installation in hazardous areas, shall be tested by CMRI and duly approved by C.C.E. Nagpur or DGMS Dhanbad or any other applicable statutory authority. All indigenous FLP equipment shall also have valid BIS license as required by statutory authorities.

5.4 BUILDING LIGHTING 5.4.1 The type of wiring system shall comprise surface/concealed conduit system or cable wiring as specified on layout drawings.

5.4.2 Mounting details of fixtures shall be indicated on the drawings. If specified on the drawings, a group of fluorescent lighting fixtures which are to be mounted end to end shall be fixed to mild steel cold Tolled sections of 50mm x 50mm and of 1.2mm thick (Metsec channel). The entire assembly shall be fixed to the ceiling with necessary number of supports which may

be by means of steel conduit or chromium plated chain link as required. The 'Metsec' Channel shall run continuous in suitable sections from one end to other end of wall. The complete channel shall be spray painted, with approved colour as per the directions of Engineer-in-Charge. All wires inside channel shall be neatly bunched by nylon tape & buttons.

5.4.3 Wiring in areas above false ceiling shall be done in Surface Conduit (25mm dia GI conduit) suitably clamped to the true ceiling. Vertical drops from true ceiling for panels, switches, receptacles etc. shall be taken in 25mm dia PVC conduit concealed in walls up to switchboards/panels. Lighting fixtures shall be supported from true ceiling. Exact location of fixtures shall be finalized in co-ordination with air-conditioning duct-diffuser layout, panels layout and false ceiling grid layout. To facilitate easy maintenance Looping back system' of wiring shall be followed throughout. Accordingly supply tappings and other interconnections including for earthing are made only at fixture connector blocks or at switch boards. Required number of junction boxes shall be used at intervals for wire pulling and inspection.

5.4.4 All wires in conduit shall be colour coded as specified. Each circuit shall have independent phase neutral and earth wire. However when group of circuits are run in a single conduit the earth wire can be common.

5.4.5 Building conduit lighting system of wiring where measurement is done on point wiring basis generally consists of two parts. The first part is the circuit wiring which includes the work necessary from lighting panel up to switch box and from switch box to another switch box. The second part is the point wiring which shall include the work necessary from tapping point in the switch box up to various fixtures or fan outlets/ceiling roses.

5.4.6 In no case, two different sources or two different phases of supply shall be combined in one switchboard.

5.4.7 Switches for light fixtures/exhaust fans in battery room shall be provided outside the Battery room.

5.4.8 Lighting layouts for non-plant buildings (such house, cement godown, gate house, workshop, service building, rest room, etc.) shall be prepared by installation contractor.

5.4.9 The following basic data/document for layouts will be provided to the contractor.

f. Architectural drawings g. Illumination level required h. Type of lighting fixture i. Type of wiring (concealed/surface conduit/cable wiring etc.) 5.4.10 Based on the above input, contractor shall prepare and submit lighting layout drawings, panel schedules, conduit layout drawings for concealed wiring, design calculations wherever required, for review by purchaser before erection work is started. The lighting layout drawing shall show the location, type and mounting details of lighting fixtures, receptacles, junction boxes, layout of circuit indicating number of wires etc. The number of points in a circuit shall not exceed ten and the load in each circuit shall be less than 1000 Watts.

5.4.11 The panel schedule shall include rating of incoming and outgoing feeders, number of outlets, load for each outgoing circuit, etc.

5.4.12 All drawings shall be prepared preferably in AO and Al size. Panel schedules shall be in A4 size drawings (Final submission of drawings shall be in soft copies and in bound volumes together with one transparency of each document).

5.5 STREET LIGHTING 5.5.1 Street lighting poles to be located on road side shall be installed at a minimum distance of 300mm from the edge of the walkway of the road (road berm). Size of wires from marshalling box up to fixture shall be 1.5mm2/2.5mm2, copper conductor PVC insulated.

5.5.2 Each pole shall be earthed at two points by connecting to the plant earth grid as shown on Installation standards.

5.5.3 Street lighting fixture shall be mounted on steel tubular poles as per standard drawings. The foundation for the street lighting poles will be made by electrical contractor Street lighting poles shall be supplied with a base plate.

5.5.4 The poles shall be numbered as per the drawings/ directions of Engineer-in-charge. 5.6 MAST LIGHTING 5.6.1 The lattice structure masts shall be installed on concrete foundations with the base plate bolted on to the anchor bolts. The lattice structure shall be painted with a coat of primer and two coats of aluminium paint, the second coat to be given just before handing over to the owner. The masts shall be numbered as per drawings. The masts shall be connected to the plant earth grid at two points.

5.6.2 The main feeder up to the distribution board of lighting Mast shall be through PVC insulated armoured cable of size as specified in the respective drawing. Wiring from Distribution Board to each flood-light fixture shall be by means of a 3 core 2.5sqmm, copper conductor PVC insulated armoured cable. All the cables shall be neatly clamped to the structure at intervals not exceeding 25 cms.

5.6.3 Exact orientation of flood lighting fixtures shall be decided at site to achieve optimum utility of these fixtures.

5.7 TELEPHONE WIRING 5.7.1 Conduits for telephone wiring in buildings shall be of 1.6mm thickness. 25mm dia black enameled steel conduit/PVC as per IS 9537, installed on wall surface or concealed or as specified in job specification.

5.7.2 Conduit installation system shall comply to the requirements given in conduit system. Required number of pull boxes shall be provided at interval for easy drawing of wires. The

telephone wiring shall be done with 0.63mm dia annealed copper conductor PVC insulated 660V grade, twin flat wire, unless otherwise specified in Job Specification. One telephone socket outlet shall be provided for connection to telephone instrument.

6.0 INSPECTION & TESTING

6.1 Lighting installation shall be tested and commissioned by installation contractor as per Specifications. Pre commissioning checks and tests shall include but not be limited to the following:

6.1.1 The insulation resistance of each circuit without the lamps (load) being in place shall be measured and it should not be less than 500,000 ohms. (Between phases, phases to neutral, phase/neutral to earth).

6.1.2 Current and voltage of all the phases shall be measured at the lighting panel bus bars with all the circuits switched on with lamps. If require load shall be balanced on the three phases.

6.1.3 The earth continuity for all socket outlets shall be checked. A fixed relative position of the phase and neutral connections inside the socket shall be established for all sockets.

6.1.4 After inserting all the lamps and switching on all the circuits, minimum and maximum illumination level shall be measured in the area and recorded.

6.1.5 It shall be ensured that switch provided for ON/OFF control of point (light/fan/socket) is only on LIVE side.

6.1.6 Operation of ELCB's shall be checked

6.2 Contractor shall duly fill in all the above test results and submit the test reports to Engineer-in-Charge in triplicate.

6.3 All lighting layout drawings shall be marked by contractor for `AS BUILT STATUS' and two sets of copies shall be submitted to the consultant.

SPECIFICATION FOR FIELD INSPECTION, TESTING AND

COMMISSIONING OF ELECTRICAL INSTALLATION

ABBREVIATION

CEA Central Electricity Authority CCE Chief Controller of Explosive DC Direct Current DGMS Director General Mines & Safe GI Galvanised Iron OISD Oil Industries Safety Directorate AFC Approved For Construction DCS Distributed Control System ECS Emergency Control System HV High Voltage MV Medium Voltage

TABLE OF CONTENTS

SL NO. DESCRIPTION

1.0 SCOPE .........................................................................................................


3.0 DEFINITIONS ...............................................................................................

4.0 FIELD INSPECTION, TESTING AND COMMISSIONING .............................

5.0 RECORDS ....................................................................................................

1.0 SCOPE

1.1 This Specification covers the requirements for the field inspection, testing and commissioning of electrical equipment and installation, forming part of electrical power distribution and utilisation system.

2.0 REFERENCE DOCUMENTS 2.1 The field inspection, testing and commissioning of electrical equipment shall be carried out in line with this Specification and the latest edition of following Indian Standards and OISD standards.

SP-30(BIS) National Electrical Code IS-7816 Guide for testing Insulation resistance of rotating machines. IS 1255 Code of practice for installation and maintenance of power cables up to & including 33 kV rating. IS 10810(Part 43) Method of Test for cables; Part 43 Insulation resistance. IS 10810(Part 45) Method of Test for cables; Part 45 High voltage test. OISD 137 Inspection of Electrical Equipment. OISD 147 Inspection and safe practice during electrical installation. 2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable: a. Indian Electricity Act and Rules. b. Regulations laid down by CEA / Electrical Inspectorate. c. Regulations laid down by Tariff Advisory Committee/Loss prevention council. d. Regulations laid down by CCE/DGMS (as applicable). e. The petroleum rules (Ministry of Industry Government of India). f. Any other regulations laid down by central / state / local authorities / insurance agencies.

3.0 DEFINITIONS For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows:



BIDDER / SUPPLIER / VENDOR The party(s) which manufactures and / or supplies material, equipment, technical documents / drawings and services to perform the duties specified by Contractor.

4.0 FIELD INSPECTION, TESTING AND COMMISSIONING

4.1 Contractor shall carry out complete field inspection, testing and commissioning of electrical equipment as per Inspection Test plans.

4.2 Before the completed installation or an addition to the existing installation is put into service, inspection / pre-commissioning checks and tests shall be carried out by contractor. In the event of defects being found out, the same shall be rectified and the installation retested as applicable.

4.3 The pre-commissioning inspection among other requirements shall include visual inspection, checking the workmanship of the installation, the rating of equipment, safety clearances, sizes of cables installed, conformance to the AFC document, soundness of switchgear bus connections, wiring properly dressed and labeled, sealing of unused cable entries, checking of all safety interlocks, control/interface functions as per requirement etc.

4.4 Visual inspection for soundness of bus bar connections of bus ducts, terminal connections of equipment/motor shall be carried out. It shall be ensured that no foreign materials are present inside bus duct and equipment terminal boxes. After the visual inspection, all the covers of terminal boxes, inspection chambers shall be refitted with gaskets, bolts & nuts as per equipment manufacturer's instructions.

4.5 Pre-commissioning tests shall include but not be limited to the following: a. Continuity test for each winding and power and control circuits. b. Insulation test for each winding and power and control circuit c. High voltage test for cables d. Dielectric strength test on transformer oil. e. Checking the correctness of wiring schemes, control circuit interlocks for intended functioning. f. Verification of phase sequence. g. Testing of all types of relays/releases for required operation. Testing of measuring instruments for proper functioning Earth continuity test for all circuits. h. Checking of safety features for correctness of operation etc. i. Checking of all wired interface contacts (analog, digital input/output contacts) for, DCS and ECS interface, at panel and equipment terminal chambers as applicable. j. (Electrical contractor shall co-ordinate with other agencies involved for the above and, provide support services for checking interfaces of electrical equipment and the intended functioning) k. Earth resistance measurement for each earth electrode, and the earthing system as a whole. l. Lighting installation shall be tested for correct illumination levels, with the fittings installed. Fittings shall be operated only with specified type of a lamp or tube.

4.6 After the above tests and inspection are completed, control circuits shall be tested for correct operation under all operating combinations and proved correct before applying power to main circuits.

4.7 Plant Communication, Fire alarm, telephone and security system shall be checked for correct operation and intended function.

4.8 A close visual inspection of electrical equipment in hazardous areas shall be made to ensure that equipment is suitable for the classified zone and gas group and correctly installed, with all covers, bolts, nuts and hardwares intact and there is no physical damage mark seen on the enclosure.

4.9 Site Acceptance Test procedure for specific equipment shall be furnished by the respective equipment Vendor. The contractor shall provide necessary assistance to the equipment Vendor to perform site acceptance testing to enable the equipment Vendor to perform the same.

4.10 All pre-commissioning checks and tests shall be carried-out as per the directions of Engineer in-charge. In addition to the equipment manufacturer's instructions, pre- commissioning check requirements shall also be complied. All tests shall be carried out by contractor in the presence of Consultant / Owner's representatives

4.11 The contractor shall bring to site all required tools, tackles, and testing instruments for carrying out field testing. Contractor shall use only calibrated measuring and test instruments and shall maintain calibration records.

4.12 The Insulation Resistance test values for various electrical equipment shall be as below.

4.12.1 CABLES

The insulation resistance test values for cables shall be as per following table: Rated voltage of the Cable

DC Test Voltage in Volts

Minimum Insulation resistance in Mega ohms

Lighting and power circuit Wiring 250 1

650/1100 V grade cables 1000 1

1,900/3,300V grade cables 1000 200

3,800/6,600V grade cables 1000 200

6,350/11,000V grade cables 5000 200

8,700/115,000V grade cables 5000 200

12,700/22 000V grade cables 5000 200

19,000/33000V grade cables 5000 200

4.12.2 HV, MV AND MISCELLANEOUS SWITCHBOARDS The insulation resistance test values for the switchboards shall be as per following table:

Rated voltage of the Switchboard


M inimum Insulation resistance in Mega ohms

33,000V 5,000 200 11,000V 5,000 200

6,600V 1,000 200

3,300 1,000 200 415V 1,000 100

240V 500 10

110V 500 10

4.12.3 GENERATORS AND MOTORS

The insulation resistance test values for the Generators and Motors shall be as per following table:

Generators and Motors


Minimum Insulation resistance in Mega ohms at 40 °C

11,000V 5,000 120

6,600V 1,000 80

3,300V 1,000 50

415V 1,000 15 240V 500 12

4.12.4 TRANSFORMERS The insulation resistance test values for the Transformers shall be as per following table:

Rated Voltage of the

Transformer

DC Test Volt in volts Minimum Insulation

resistance in Mega ohms at 40°C

Up to 600V 1,000 100

601 to 5000V 2,500 1,000

5001 to 15,000V 5,000 5,000

15001 to 35,000V 5,000 10,000

It shall be ensured that during insulation tests; electronic devices and components that are liable to get damaged on applied test voltage shall be disconnected from circuit. The instructions of equipment/panel manufacturer shall be followed strictly in this regard.

4.12.5 HIGH-VOLTAGE TESTING D.C. high voltage test shall be conducted as per following table on all H. V. feeder cables and

also on 1100 V grade cables where straight through joints have been made.

Rated Voltage of Cable (kV)

TEST VOLTAGE (kV) BETWEEN

Duration (Minutes)

Uo / U* Any Conductor and Metallic Sheath/ Screen/Armour

Conductor to Conductor (For Unscreened Cables)

0.65/1.1 3 3 5

1.9/3.3 5 9 5

3.3/3.3 9 9 5

3.8/6.6 10.5 18 5

6.6/6.6 18 18 5

6.35/11 18 30 5

11/11 30 30 5

12.7/22 37.5 - 5

19 / 33 60 - 5

* Uo:Phase Voltage U:Line Voltage The cable cores must be discharged on completion of DC high voltage test and cable shall be kept earthed until it is put into service.

DC test voltage for old cables shall be 1.5 times rated voltage or less depending on the age of cables, repair work or nature of jointing work carried out, etc. In any case, the test voltage shall not be less than the rated voltage.

All protective relays including thermal overload relays shall be tested by secondary injection current. Primary injection tests shall-be carried out for differential protection, restricted earth fault protection at full/reduced current to ensure correctness of complete wiring.

Before energizing any equipment, ‘COMMISSIONING CLEARANCE FORM’ as per standard format shall be, duly filed in by contractor and submitted to Consultant / Owner.

It shall be ensured that the electrical inspectorate approval is available before energizing the equipment.

5.0 RECORDS

Contractor shall keep up-to-date records of all activities carried out and test results. Field inspection / test reports shall be submitted to Consultant / Owner by the contract in bound volume (triplicate copies).

LIST OF APPROVED PARTIES FOR BOUGHT OUT ITEMS

A. (ELECTRICAL) i) Air Conditioner 1. O General 2. Daikin 3. Hitachi ii) Batteries (Lead Acid) 1. Amco Batteries Ltd. 2. Exide Industries Ltd. 3. HBLNIFE Power System Ltd. 4. Amara Raja Batteries Ltd. iii) Batteries (Nickel Cadmium) 1. Amco Batteries Ltd. 2. HBLNIFE Power Systems Ltd. iv) Batteries Charger/DC-DC Converter 1. Amara Raja Power System(P)Ltd. 2. BCH. 3. Chhabi Electricals Pvt. Ltd. 4. Caldyne Automatics Limited 5. Dubas 6. HBL Nife Power Systems Ltd. 7. Universal Industries Products 8. Universal Instrument Mfg Co Pvt Ltd v) Cable – Fire Alarm & Communication Cables 1. Cords Cable Industries Ltd. 2. CMI 3. Delton cables Ltd. 4. ELKAY Telelinks 5. KEI Industries Ltd. 6. Reliance Engineers Ltd. vi) Cable – HT(XLPE) 1. Universal Cable Ltd. 2. KEI Industries Ltd. 3. Industrial Cables 4. NICCO Corporation Ltd. 5. Uniflex 6. Polycab. 7. Torrent cables Ltd. vii) Cable – LT Power and Control 1. Cords Cable Industries Ltd. 2. Universal Cable Ltd. 3. KEI Industries Ltd. 4. Havells. 5. Delton 6. Elkay Telelinks 7. Evershine Electricals 8. Ecko

9. Ravin 10. Rallison. 11. Suyog 12. Netco 13. Uniflex 14. Paramount 15. Gloster 16. Associated cables Pvt Ltd. 17. CMI 18. Gemscab 19. Industrial cables 20. NICCO 21. Polycab 22. Torrent viii) Cable – Gland

1. .Baliga 2. .Comet 3. Flexpro 4. Flameproof 5. FCG 6. Electro Werke 7. Dowels 8. CCI ix) Cable – Lugs 1. Dowels 2. Jainson 3. Ismal x) Cable – Tray 1. Ercon Composites 2. Yamuna Power & Infrastructure Ltd. xi) Cable Termination and Jointing Kit 1. CCI 2. Raychem 3. M-Seal xii) Ceiling/Exhaust/Pedestal Fans & Circulators 1. Bajaj Electricals Ltd. 2. Crompton Greaves Ltd. 3. Khaitan Electricals Ltd. 4. Havell’s xiii) Contractors – AC Power 1. Andrew Yule 2. ABB 3. BHEL 4. C&S 5. Havell’s 6. L&T 7. Schneider 8. Siemens Ltd. 9. Telemechanique

xiv) Control Transformer 1. AE 2. Indushree 3. Intra Vidyut 4. Kalpa Electrikals 5. Transpower Industries Ltd. 6. Siemens xv) DG Set 1. Sterling and Wilson. 2. GD ankalesaria. 3. Deev Genset. 4. Jackson 5. Sudheer Gensets. 6. Power Engineering(India) Pvt Ltd. xvi) Earthing Materials 1. Rukmani Electrical & Components Pvt Ltd. 2. Indiana Grating Pvt Ltd. 3. Jef Techno Solutions Pvt Ltd 4. Flame proof LDB’s/ JB,s/Control Station/ switches 7. FCG 8. Sudhir 9. Prompt Engineering Works 10. Flame Proof equipments pvt. Ltd. 11. Baliga Lighting Equipments Pvt. Ltd. 12. Flexpro Electricals Pvt. Ltd. xvii) High Mast 1. Bajaj Electricals Limited 2. Crompton Greaves Limited. 3. Philips India Limited 4. Surya Roshani xviii) High Voltage PCC/ MCC panels 1. BHEL 2. Control and Switchgear 3. Siemens 4. Tricolite Electrical Industries 5. Schneider 6. CGL 7. L&T xix) Indicating Lamps 1. Alstom Ltd. 2. BCH 3. L&T Ltd. 4. Siemens Ltd. 5. Vaishno Electricals xx) Indicating Meters 1. ABB 2. AMCO 3. AE

4. Alstom Ltd. (EE) 5. Conzerv/Schneider 6. Elecon Measurement Pvt. Ltd. 7. HPL Electric & Power Pvt. Ltd. 8. MECO Instruments Ltd. 9. Minilec

10. Rishabh Instruments Pvt. Ltd. 11. Trinity energy system 12. kaycee 13. Salzer xxi) Lighting Fixtures 1. GE Lighting Pvt. Ltd. 2. Bajaj Electricals Ltd. 3. Crompton Greaves Ltd. 4. Philips India Ltd. xxii) Lighting Fixtures – Flameproof

1. Bajaj Electricals Ltd. 2. Baliga Lighting Equipment Pvt. Ltd. 3. Crompton Greaves Ltd. 4. CEAG Flameproof Controlgear Pvt. Ltd. 5. Flexpro Electricals Pvt. Ltd. 6. Philips India Ltd. 7. Sudhir Switchgears Pvt. Ltd. 8. FCG. xxiii) Miniature Circuit Breakers (MCBs) and Lighting DB 1. ABB 2. Hagger 3. Havell’s India Ltd. 4. Indo Asian Fusegear Ltd. 5. Legrand 6. MDS Switchgear Ltd. 7. Schneider 8. Siemens Ltd. 9. HPL xxiv) Moulded Case Circuit Breaker (MCCBs) 1. ABB 2. Andrew yule 3. Larsen & Toubro 4. Schneider 5. Siemens 6. Control and Switchgear xxv) Protection Relays – Thermal 1. BCH 2. L&T Ltd. 3. Siemens Ltd. 4. Telemenchanique & Controls (India) Ltd. xxvi) Low Voltage Power Control Center (PCC)/ MCC/ PDB/ MLDB/ LDB 1. ABB 2. BCH

3. C & S 4. Elecmech Switchgear & Instrumentation 5. KMG ATOZ 6. L&T 7. Pyrotech Electronics Pvt. Ltd. 8. Risha control Engineers Pvt. Ltd. 9. Siemens 10. Tricolite Electrical Industries 11. Unilec Engineers ltd. 12. Vidyut Control India Pvt. Ltd. 13. Control and Schematic 14. Zenith Engineering xxvii) Push Buttons 1. BCH 2. Alstom Ltd. 3. L&T 4. Siemens Ltd. 5. Telemenchanique & Controls (India) Ltd. 6. Vaishno Electricals xxviii) Switches-Control

1. BCH 2. Easum Reyrolle Relays & Devices Ltd. 3. Alstom 4. Kaycee Industries Ltd. 5. L&T 6. Siemens Ltd. xxix) Switches – 5/15A Piano/ Plate, Switch Socket 1. Anchor Electronics & Electricals Pvt. Ltd. 2. Kingal Electricals Pvt. Ltd. 3. North-West Switchgear Ltd. xxx) Switch Socket Outlets (Industrial)

1. Alstom Ltd. 2. Best & Cromption Engineering Ltd. 3. BCH 4. Crompton Greaves Ltd. 5. Essen Engineering Company Pvt. Ltd. xxxi) Solar Modules 1. Tata BP Solar (I) Ltd. 2. REIL, Jaipur. 3. CEIL, Sahibabad. 4. HBL Power xxxii) Solar Street Lighting 1. Tata BP Solar (I) Ltd. 2. REIL, Jaipur. 3. CEIL, Sahibabad. 4. HBL. xxxiii) Terminals Blocks

1. Connect well

2. Controls & Switchgear Co. Ltd. 3. Elmex Controls Pvt. Ltd. 4. Essen Engineering Co. Pvt. Ltd. xxxiv) Transformers 1. ABB 2. Andrew Yule 3. Areva 4. BHEL 5. Bharat Bijlee 6. Crompton Greaves 7. EMCO Ltd. 8. Intra Vidyut 9. Indushree 10. Indcoil 11. Kirloskar 12. Skippers Electricals 13. Transformers & Rectifiers (I) Ltd. 14. Voltamp xxxv) UPS System and Inverter 1. DB Power 2. Aplab 3. Keltron 4. Hi-Rel 5. Dubas 6. Toshiba Corporation 7. Fuzi Electric Co Ltd xxxvi) GI-Octogonal Pole 1. Bajaj 2. Transrail 3. Wipro xxxvii) List Of Recommended Manufacturers for Heater 1. Escorts Limited, Faridabad, Haryana 2. Spherehot / Kanti Lal Chuni Lal & Sons Appliances Pvt Ltd.Surat 3. Kerone, Bhayander(E), Thane - 401105 4. Excel Heaters, Andheri (West), Mumbai - 400 053, India 5. Nirmal Industrial Controls Pvt. Ltd. , Mulund(W), Mumbai - 400 080 NOTE: - Item/Vendor, which are not listed above, shall be subject to prior approval from Client/Consultant.

Notes: 1. Bidder can select equipment of two different makes, selected from this VENDOR LIST and

mention the same in the checklist for technical evaluation attached with the tender. The offered bid must include filled datasheet indicating make, model, size, rating of offered instrument/ equipment duly supported by sizing calculation of offered equipment (wherever applicable).

2. Vendors who have already supplied above equipment in other terminals of GAIL (I) Ltd,

shall also be considered qualified for this tender provided the supplied equipment are commissioned and running successfully and they have not been put on holiday in list of Client/Other PSU etc.

3. Equipment / Instruments of any make which is offered by one bidder and acceptable to

GAIL (India) Ltd shall be accepted for other bidder also. After placement of order, on request of the successful bidder list of other qualified makes for a particular item (for which successful bidder wants to change the vendor) shall be provided.

4. Bidder shall take prior approval of the make / model no of the offered item and it shall be

from the list given above. However additional vendors will be considered in exceptional cases, provided they have supplied for similar application to reputed gas transmission/distribution companies, in quantities at least half the numbers being supplied for this tender, and working satisfactorily for minimum 6 months. Documentary evidence substantiating above shall be submitted for taking approval.

5. For procuring bought out items from vendors other than those listed above, the same may be acceptable subject to the following: - a) The vendor/ supplier of bought out item(s) is a manufacturer/ supplier of said item(s)

for intended services and the sizes being offered is in their regular manufacturing supply range.

b) Should have supplied at least one single random length (i.e. 5.5 meters to 6.5 meters) for item assorted pipes / tubes and for other items, which are to be supplied in quantity on number-basis (other than assorted pipes / tubes) minimum 01 (One) number of same or higher in terms of size and rating as required for intended services. The bidder should enclose documentary evidences i.e. PO copies, Inspection Certificate etc. for the above, along with their bids.

4 For any other item(s) for which the vendor list is not provided, bidders can supply those item(s) from vendors/ suppliers who have earlier supplied same item(s) for the intended services in earlier projects and the item(s) offered is in their regular manufacturing/ supply range. The bidder is not required to enclose documentary evidences (PO copies, Inspection Certificate etc.) along with their offer, however in case of successful bidder; these documents shall require to be submitted by them within 30 days from date of Placement of Order for approval to CLIENT.

5 The details of vendors indicated in this list are based on the information available with

GAIL, Contractor shall verify capabilities of each vendor for producing the required quantity with. GAIL does not guarantee any responsibility on the performance of the vendor. It is the contractor’s responsibility to verify the correct status of vendor and quality control of each party and also to expedite the material in time.

DATA SHEET FOR SOLAR ELECTRIC POWER SYSTEM

GENERAL INFORMATION Applicable To: Proposal Purchase As Built Vendor shall complete Data Sheet with

information not otherwise provided by Buyer. Client:

Facility: Tag Number:

Location: Manufacturer/Model No.:

Service:

[ITEM SPECIFICATIONS] 1.0 Site / Environment conditions

2.0 No. of systems / service

3.0 Application

4.0 Type/model no. & country of origin * 5.0 Load / Output voltage

6.0 Total output required

7.0 Ripple output

8.0 Daily load demand

9.0 Earthing

10.0 Battery backup required for

11.0 Battery type

12.0 Battery rating

13.0 Make/model no. Country of origin of battery * 14.0 Type of alternative energy source available locations

a. Solar panels

b. Power controller

c. Battery

15.0 Location of power controller Indoor Outdoor 16.0 Expected life span * 17.0 Area classification

18.0 Insulation data

19.0 Degree of protection of power controller enclosure & temp. Class

20.0 Power controller unit painting type * 21.0 Colour shade of finish coat

22.0 No. Of panels / modules required * 23.0 Battery charging and power control scheme

24.0 Type & material of hardwares to be used

25.0 Whether erection, testing & commissioning in vendor's scope Yes No

26.0 Additional information / requirements

27.0 Reference codes

NOTES: * Data to be filled by supplier with its bid in the supplier data column, those data shall be in accordance with

standard specification # Data to be defined during detailed engineering # # Data to be verified by supplier

DATA SHEET FOR BATTERY CHARGER

GENERAL INFORMATION

Applicable To: Proposal Purchase Built

Client:

Facility:

Location:

Service:

As Vendor shall complete Data Sheet with information not otherwise provided by Buyer.

Tag Number:

Manufacturer/Model No.:

[ITEM SPECIFICATIONS] 1.0 Service

2.0 Application

3.0 Tag no.

4.0 Make / model no. & country of origin * 5.0 Location / installation Indoor Outdoor

6.0 Site / environment conditions

7.0 Area classification

8.0 Type

9.0 a). Charger rating

b). Connected load

c). Charging time

10.0 Battery details * a). Float/trickle charging current * b). Boost charging current A * c). Boost charging voltage V * d). Boost charging time hr * e). Type of battery

f). Battery capacity & number of cell

11.0 Input details

a). Voltage V

b). Frequency Hz

c). Fault level KA

d). Supply variation

e). Ac input current during boost charging

12.0 Output details

12.1 Rated voltage V * 12.2 Float charger *

a). Voltage range V * b). Current range A

c). Method of voltage control * 12.3 Boost charger *

a). Voltage range V * b). Current range A * c). Method of voltage control *

13.0 Voltage regulation from full load to no load

14.0 Harmonic content at rated load

15.0 Efficiency 20% load 100% load a). Float charger % * * b). Boost charger % * *

16.0 Power factor 20% load 100% load a). Float charger % * * b). Boost charger % * *

17.0 Type and make of components *

a). Rectifier * b). MCCB / MCB * c). Indicating instruments * d). Annunciators * e). Push buttons * f). Indicating lamps Required Not required

18.0 Annunciators requirement * 19.0 No. Of annunciator points

20.0 Construction details

a). Mounting type Floor Wall frame b). Type of cooling Top Bottom Side c). Cable entry Front Rear d). Access

e). Enclosure degree of protection and temperature class

f). Bus – bar material * g). Continuous current rating of busbar A * h). Short circuit withstand capacity KA Yes No

21.0 Provision provided for remote annunciator

22.0 Glands * a). Type * b). Number

c). Cable size sq.mm *

d). Supply required Yes No 23.0 OVERALL DIMENSION (LxWxH) MM * 24.0 Weight kg * 25.0 Earth bus terminal and size * 26.0 Heat output from panel W * 27.0 Space heater Required Not required

a). Voltage, rating & qty. Details of space heater * 28.0 Panel illumination Required Not required

a). Voltage, rating & qty. Details of lamp * 29.0 Painting * 30.0 Colour shade of finish coat *

31.0 Whether erection, testing and commissioning in vendor’s scope Yes No



NOTES: * Data to be filled by supplier with its bid in the supplier data column, those data shall be in accordance

with standard specification # Data to be defined during detailed engineering # # Data to be verified by supplier

DATA SHEET FOR HV & LV CABLES

GENERAL INFORMATION Applicable To: Proposal Purchase

Client:

Facility:

As Built Vendor shall complete Data Sheet with information not otherwise provided by Buyer.

Tag Number:

Location:

Service:

Manufacturer/Model No.:

[ITEM SPECIFICATIONS] 1.00 Service / Application

2.00 Make / Country of Origin *

3.00 Site / Environment Conditions

4.00 Power system details

4.01 System Voltage

4.02 System frequency

4.03 No. of phases & wires.

4.04 Earthing

4.05 Voltage Rating of Cables Earthed unearthed a) With earthed neutral

b) With unearthed neutral

4.06 Maximum system voltage

5.00 Type of cables

5.01 High Voltage low voltage

5.02 XLPE Insulated PVC Insulated

5.03 Fire Safe (FS) Heat Resistance (HR)

5.04 Flame Retardant , Low Smoke (FRLS)

5.05 Non flame retardant , Low smoke (NONFRLS)

6.00 Cable quantity – furnish details for each type

6.01 Quantity of H.V Cable with type & other details

6.02 Quantity of L.V. power cable with type & other details



7.00 Minimum bending radius

8.00 Derating factors

9.00 Single phase to ground fault current Applicable AMP

For 1 second Not applicable

10.00 Conductor

10.01 Material

10.02 No. of cores & cross section area

10.03 Current carrying capacity A * - Short circuit current carrying

KA capacity *

10.04 Wheather colour coded Yes No

10.05 Wheather numbered Yes No

10.06 Core identification details *

10.07 Wheather stranded conductor Yes No - Flexibility class *

10.08 Wheather shaped conductor Yes No

10.09 Wheather plated conductor Yes No

10.10 Plating details *

10.11 Conductor resistance at 20°C (DC) OHM/KM * - Conductor resistance at 20°C (DC)

OHM/KM *

- Conductor resistance at 50 Hz OHM/KM *

10.12 Conductor screening requirement Yes No - Type, material & thickness of screening *

10.13 Annealing test for copper *

10.14 Tensile & strength of aluminium N/mm² *

10.15 Wrapping test for aluminium *

11.00 Conductor insulation *

11.01 Insulation material & grade *

11.02 Insulation thickness MM *

11.03 Screening requirement Yes No

11.04 Type, material & thickness of screening *

11.05 Tensile strength of aluminium *

11.06 Wrapping test for aluminium *

12.00 Inner sheath Required Not

required

12.01 Material & colour *

12.02 Type of inner sheath extruded wrapped/tapped

FRLS NON FRLS

12.03 Inner sheath thickness - MM *

12.04 Wheather filler/dummy cores provided Yes No

12.05 Materials of dummy cores *

13.00 Armouring Required Required

Not

13.01 Type of armouring Wire Flat

13.02 Material & coating Steel Aluminium other (specify) Galvanised

Galvanised Non

13.03 Thickness / diameter / gauge of armour *

13.04 Wheather PVC tape provided below armour Yes No

14.00 Outer sheath *

14.01 Material *

14.02 Type Heat resistance (HR) (FS)

Fire safe

Flame retardant, low smoke (FRLS) Non flame retardant low smoke

(NONFRLS)

14.03 Thickness -MM *

14.04 Colour *

14.05 Temperature grade *

14.06 Oxygen index *

14.07 Anti-termite & Anti-Rodent characters required Yes No

14.08 Tensile strength -MM *

14.09 Elongation -% *

15.00 Outer diameter of complete cable *

16.00 Diameter of cable with cores & inner sheath only *

17.00 Diameter with cores, inner sheath & armouring *

18.00 Voltage drop of cable per KM length *

18.01 When laid in air. V *

18.02 When laid in ground V *

18.03 When laid in tray/duct V *

19.00 Wheather length marking on the cable is required Yes No

20.00 Wheather drum length as per cusomer Yes No Requirement can be supplied

21.00 Cable lengths supplied in each drum. *

22.00 Per meter weight of complete cable *

23.00 Total weight of cable with drum KG *

24.00 Quantity variation *

25.00 Tests

25.01 a) Wheather special test to be carried out on samples Yes No

b) Cables to undergo special test

25.02 a) Wheather type test to be carried out on samples Yes No

b) Cables to be type tested.

25.03 Wheather customer / client is going to witness tests Yes No



NOTES: * Data to be filled by supplier with its bid in the supplier data column, those data shall be in accordance with

standard specification Indicates applicable choice / requirement. Vendor shall follow reference codes as specified and / or otherwise shall list out codes followed by them

DATA SHEET FOR LV DISTRIBUTION BOARD





Service:

[ITEM SPECIFICATIONS] 1.00 GENERAL 1.01 Service

1.02 Application

1.03 Manufacturer

1.04 Standards / Codes

1.05 Place of installation Indoor Outdoor

2.00 ENVIRONMENTAL CONDITIONS 2.01 Maximum ambient temperature

2.02 Area Classification

2.03 Special conditions

2.04 Indoor ambient temperature

2.05 Temperature Class

3.00 SUPPLY SYSTEM 3.01 Voltage V

3.02 Frequency Hz

3.03 Phases & Wires

3.04 Fault Level kA

4.00 LV DB GENERAL CHARACTERISTICS

4.01 Mounting Floor Mounted Wall Mounted

4.02

Type

Drawout Non Drawout

Compartmental Non Compartmental

Single Front Double Front

4.03 System Neutral Earthing

4.04 Continuous Current rating of Busabar A *

4.05 Maximum temperature Busbar, Droppers and Contacts *

4.06 Short circuit and withstand for Busbars and Droppers *

4.07 a. Short time (1 Sec.) at 415V kA *

4.08 b. Dynamic Rating (Peak) kA *

4.09 Enclosure Material *

4.10 a. Sheet type Cold rolled Hot rolled

4.11 Thickness of Sheet still

4.12 a. Frame mm *

4.13 b. Doors mm *

4.14 c. Covers mm *

4.15 Degree of protection of Enclosure

4.16 Painting

4.17 Colour shade of finish coat

4.19 a. Interior

4.20 b. Exterior

5.00 BUSBAR

5.01 Busbar Material *

5.02 Busbar Size * a. Main Busbar mm * b. Vertical Busbar / Dropper mm *

5.03 c. Neutral Busbar mm *

5.04 Busbar clearance in air

5.05 Phase to Phase mm *

5.06 Phase to Earth mm *

5.07 Overall Dimensions (L x D x H) mm *

5.08 Overall weight in Kg (Panel Section wise) *

6.00 CABLE

6.01 Cable entry

6.02 a. Incoming Top Bottom Side

6.03 - Nos. & size of cable with details

6.04 b. Outgoing Top Bottom Side

6.05 - Nos. & size of cable with details

7.00 ELECTRICAL COMPONENTS 7.01 AIR CIRCUIT BREAKER

7.02 a. Type / Make *

7.03 b. Rated operating current A *

7.04 c. Rated Breaking capacity MVA *

7.05 d. Rated making current KA *

7.06 e. Short ckt with stand current for 1 Sec. KA *

7.07 f. Type of Operating mechanism

7.08 Manual, Spring assisted

7.09 Manual, Spring charged

7.10 Motor wound spring charged

7.11 g. Key interlocking required Yes No

7.12 h. Shunt trip required Yes No

7.13 i. Minimum no. of auxiliary contacts *

7.14 j. Control voltage *

7.15 k. Annunciators provided Yes No

7.16 MOULDED CIRCUIT BREAKER


7.19 b. Voltage, frequency & no. of phase *

7.20 c. Rated operating current A *

7.21 d. Rated Breaking capacity MVA *

7.22 e. Rated making current KA *

7.23 f. On / Off operation

7.24 - Manual Yes No

7.25 - Remote power operated Yes No

7.26 g. Releases required

7.27 - Overload inverse time Yes No

7.28 - Under voltage Yes No

7.29 - Shunt trip Yes No

7.30 h. Control Voltage V *

7.31 MINIATURE CIRCUIT BREAKER




7.35 d. Rated Breaking capacity MVA *

7.36 AIR BREAK SWITCH




7.40 d. No. of poles *

7.41 e. Short ckt current KA *

7.42 FUSES

7.43 a. Type / Make

7.44 b. Voltage V

7.45 c. Visible indication of Operation provided Yes No

7.46 d. Rating A

7.47 e. No. of auxiliary contacts

7.48 CONTACTORS


7.50 b. Duty *

7.51 c. Rating A *

7.52 d. No. of auxiliary contacts *

7.53 RELAYS


7.55 b. Setting Range *

7.56 c. No. of auxiliary contacts *

7.57 CURRENT TRANSFORMER


7.59 b. Burden & Class *

7.60 c. Winding ratio *

7.61 POTENTIAL TRANSFORMER


7.63 b. Rating & Class *

7.64 c. Primary voltage V *

7.65 d. Secondary voltage V *

7.66 INDICATING INSTRUMENTS


7.68 b. Size *

7.69 c. Range *

7.70 d. Scale deflection range Deg. *

7.71 e. Accuracy class *

7.72 INDICATING LAMPS


7.74 b. Operating Voltage *

7.75 PUSH BUTTONS


7.77 b. No. of contacts

7.78 CONTROL SWITCHES

7.79 a. Type / Make

7.80 b. Rating A *

7.81 c. Voltage V *

7.82 ANNUNCIATORS


7.84 b. Operating voltage *

7.85 c. No. of annunciator *

8.00 PANEL ACCESSORIES 8.01 SPACE HEATER

8.02 a. Panel space hater requirement Yes No

8.03 b. Power supply for space heater

8.04 c. No. of space heater provided *

8.05 PANEL ILLUMINATION

8.06 a. Panel illumination required Yes No

8.07 b. Power supply for illumination *

8.08 c. No. of lamps required with rating *

8.09 EARTHING CONDUCTOR

8.10 a. Material & Size *

8.11 b. Purchaser’s Earthing conductor & Size

8.12 CABLE GLANDS

8.13 a. Whether to be Supplied *

8.14 b. Type & Size of the glands Yes No

9.00 AC CONTROL SUPPLY DETAILS 9.01 Voltage V *

9.02 Source Individual transformer Common transformer Directly from main busbar

9.03 Transformer rating, Make & Type *

9.04 Busbar size & Material *

10.00 DC CONTROL SUPPLY DETAILS 10.01 Voltage

10.02 Source

10.03 Busbar Size & Material *

11.00 OTHER DETAILS 11.01 Terminal Block

11.02 a. Make / Type *

11.03 b. Rating *

11.04 c. Space block provided Yes No

11.05 Whether Erection, Testing & Commissioning in Vendor’s scope Yes No

11.06 Feeder details

11.07 Control circuit details

11.08 Additional Information / Requirements



DATA SHEET FOR STORAGE BATTERY





Service:

[ITEM SPECIFICATIONS] 1.00 GENERAL 1.01 Name of the manufacture

1.02 Type of Battery

1.03 Designation

1.04 Ambient temperature

1.05 a. Minimum

1.06 b. Maximum

2.00 GENERAL 2.01 Site conditions

2.02 Maximum Temperature

2.03 Design Maximum Ambient Temperature

2.04 Design Minimum Ambient Temperature

2.05 Relative Humidity

2.06 a. Minimum

2.07 b. Maximum

2.08 Site Elevation Above MSL

2.09 Plant Atmosphere

2.10 Maximum Rainfall

3.00 CONSTRUCTION DETAILS 3.01 Type of positive plate * 3.02 Type of negative plate * 3.03 Type of container * 3.04 Type of Seperator * 3.05 No. of vent plugs * 3.06 Spray Arrestors provided Yes No 3.07 Type of Battery racks provided * 3.08 Method of connection between cells *

4.00 TECHNICAL DETAILS 4.01 Battery capacity for 10 hr rate

4.02 a. At 27° C * 4.03 b. At maximum ambient temperature * 4.04 c. At minimum ambient temperature * 4.05 Nominal voltage

4.06 a. Cell V * 4.07 a. Battery V * 4.08 No. of cells * 4.09 Open circuit voltage / cell V * 4.10 End cell voltage / cell V * 4.11 Expected life of battery Yrs. * 4.12 Internal resistance of cell Ohms *

4.13 Ampere-hour efficiency % * 4.14 Watt-hour efficiency % * 4.15 Expected fault level at bus due to battery kVA * 4.16 Intermediate tapping

4.17 Terminal connections

4.18 Max. allowable voltage variation

4.19 Total resistance of Battery Ohms *

5.00 CHARGING 5.01 Mode of charging Float Boost Trickle 5.02 Recommended starting & finishing charging rates *

5.03 Charging Voltage & Current

5.04 a. Float charging V / Amps * 5.05 b. Boost charging V / Amps * 5.06 c. Trickle charging V / Amps *

5.07 Charging period (Hrs.)

5.08 a. Initial charging * 5.09 b. Boost charging * 5.10 c. Normal charging *

5.11 Volume & Specific gravity of electrolyte per cell (at 27 Deg. C)

5.12 a. For first filling * 5.13 b. At the end of full charge *

5.14 c. At the end of discharge at hrs rate *

5.15

5.16 Voltage of cell at the end of charge at the finishing rate *

5.17 Hydrogen Emission cm³ / hr / Cell at Deg. C * 5.18 Amount of air to be introduced cm³ / hr / Cell *

5.19 Equalizing charge

5.20 a. Voltage & Current V / Amps * 5.21 b. Duration min. * 5.22 c. Interval between successive * Hrs Equalizing charge

6.00 MISCELLANEOUS 6.01 Cell dimension (LxWxH) mm * 6.02 Battery Bank dimensions (LxWxH) mm * 6.03 Weight / Cell kg

6.04 a. Dry * 6.05 b. Filled * 6.06 Weight of battery with stand kg * 6.07 Battery stand suitable for single tier / double tier Single tier Double tier 6.08 Level indicator provide * Yes No 6.09 Battery bank layout furnished with offer Single tier Double tier 6.10 Recommended exhaust fans rating * kW X nos X Qty 6.11 Size of battery room required (L x W) mm * 6.12 Ageing factor

6.13 Charger to battery bank cable size sq.mm *

6.14 Design margin

6.15 Factor for rise of battery capacity after charge discharge

6.16 List of spares / accessories enclosed Yes No

6.17 Discharge characteristics at various rates (at 27 Deg. C ambient ) enclosed Yes No

6.18 Typical voltage curves enclosed Yes No 6.19 Ageing characteristic enclosed Yes No 6.20 Copies of test report enclosed Yes No

6.21 Copies of Installation, Commissioning, Operation and maintenance manual Yes No

6.22 Type test certificate enclosed `

6.23 Calculation for Battery sizing, cable sizing for battery enclosed Yes No

7.00 LIST OF MANDATORY SPARES 7.01 Cell container with cover per set (5 Nos.) Yes No 7.02 Vent plugs per cell (5 Nos.) Yes No 7.03 Level indication (if applicable) (5 Nos.) Yes No 7.04 Inter cell connector per set (5 Nos.) Yes No 7.05 Nut, bolts and washer per set Yes No


with standard specification # Data to be defined during detailed engineering

# # Data to be verified by supplier

DATA SHEET FOR LIGHTING FIXTURES & ACCESSORIES

GENERAL INFORMATION

Applicable To: Proposal Purchase As Built Vendor shall complete Data Sheet with information not otherwise provided by Buyer.

Client:



Service:

[ITEM SPECIFICATIONS] 1.00 GENERAL

1.01 Service / application

1.03 Make & country of origin *

1.04 Degree of protection of enclosure & temp. Class

1.05 Temperature class

2.00 SITE CONDITION

2.01 Location / installation



3.00 POWER SYSTEM DETAILS

3.01 Power system A.C. D.C.

3.02 Voltage & frequency

3.03 System in case of A.C. Power

3.04 a. No. of phases & wire

3.05 b. Neutral system With Neutral Without Neutral

3.06 c. Phase to Phase voltage

3.07 d. Phase to earth voltage

3.08 e. Whether neutral is earthed Yes No

3.09 System in case of D.C. Power Earthed Unearthed

4.00 LUMINAIRES TERMINAL DETAILS

4.01 Indoor & unclassified area

4.02 a. Type & Size of terminal

4.03 b. Conductor size & material

4.04 c. Termination method

4.05 Outdoor & hazardous area

4.06 a. Type & size of terminal


4.08 c. Termination method

4.09 Earthing terminals

4.10 a. Type & size of terminal


3.00 FIXTURES / LUMINAIRES

4.12 Type of fixtures/luminaires

4.13 Fluorescent

4.14 Sodium Vapour

4.15 Mercury Vapour

4.16 Incandescent

4.17 Halogen

4.18 FLUORESCENT LAMP FIXTURES

4.19 Type of fixtures Fluorescent Compact fluorescent

4.20 Location / installation Indoor Outdoor

4.21 Mounting in case of indoor type Ceiling Recess Bracket

4.22 a. Other details about fixture

4.23 b. Details

4.24 Mounting in case of outdoor type Ceiling Recess Bracket Pole

4.25 Other details about fixture type

4.26 Power supply details

4.27 Ballast & starter details *

4.28 No. Of indoor type fixtures (with type & rating details)

4.29 No. Of outdoor type fixtures (with type & rating details)

4.30 Lamp details *

4.31 a. Rating, type & average life

4.32 b. Luminous output after 100 hrs burning

4.33 c. Luminous output after 1000 hrs burning

4.34 d. Lamp cap type

4.35 SODIUM VAPOUR LAMP FIXTURES

4.36 Type of fixtures Low pressure High pressure

4.37 Location & application

4.38 Indoor Outdoor

4.39 Street Lighting Flood Lighting

4.40 Bay Lighting Area Lighting

4.41 Mounting in case of indoor type Ceiling Bracket

4.42 a. Whether control gear required separately Yes No

4.43 b. Other details about fixture

4.44 Mounting in case of outdoor type Ceiling Mast/Tower Bracket Pole

4.45 a. whether control gear required separately Yes No

4.46 b. Other details about fixture


4.48 Control gear details



4.51 Lamp details




4.55 d. Lamp cap type Pin Edison Screw

4.56 MERCURY VAPOUR LAMP FIXTURES

4.57 Type of fixtures Low Pressure High Pressure

4.58 Location & application

4.59 Indoor Outdoor

4.60 Street Lighting Flood Lighting

4.61 Bay Lighting Area Lighting

4.62

4.63 Mounting in case of indoor type Ceiling Bracket

4.64 c. Whether control gear required separately Yes No

4.65 d. Other details about fixture

4.66 Mounting in case of outdoor type Ceiling Bracket

Mast/Tower Pole

4.67 c. whether control gear required separately Yes No

4.68 d. Other details about fixture


4.70 Control gear details



4.73 Lamp details




4.77 d. Lamp cap type Pin Edision screw

4.78 INCANDESCENT LAMP FIXTURES

4.79 Location / installation Indoor Outdoor

4.80 Application

4.81 Mounting in case of indoor type Ceiling Recess

Bracket

4.82 Mounting in case of outdoor type Ceiling Bracket

Mast/Tower Pole




4.86 Lamp details





4.91 HALOGEN LAMP FIXTURES

4.92 Mounting type Ceiling Mast/Tower Pole / Post Recess

4.93 Mounting type


4.95 No. Of fixtures with type & rating details

4.96 Lamp details





4.101 Manufacturer's catalogues for fixture & Lamps enclosed Yes No

4.102 Power factor of capacitors *

4.103 Conductor material of ballasts *

4.104 Insulation class of ballast *

4.105 Luminaires & accessories for each type

4.106 Internal wiring size *

4.107 Wire guard size & material *

4.108 Material & thickness of housing & Reflectors *

4.109 Protective coatings Painted Coated

4.110 Material of coating *

4.111 - coating film thickness


4.113 a. Fixture

4.114 b. Control gear box

4.115 Weight of luminaires *

4.116 Packing details *



NOTES:

* Data to be filled by supplier with its bid in the supplier data column, those data shall be in accordance with standard specification

# Data to be defined during detailed engineering # # Data to be verified by supplier

DATA SHEET FOR LIGHTING DISTRIBUTION BOARD &

LIGHTING PANEL





Service:

[ITEM SPECIFICATIONS] 1.00 GENERAL 1.01 Service / application

1.02 Panel name

1.03 Make/type/model no. & country of origin

1.04 Degree of protection of enclosure & temp. Class

1.05 Installation Indoor Outdoor 1.06 Mounting type Floor Wall Frame / Structure

2.00 SITE CONDITION 2.01 Location



3.00 DISTRIBUTION BOARD DETAILS

3.01 ENCLOSURE CONSTRUCTION MATERIAL & type

Metallic Non - Metallic Sheet steel Casting Cold rolled Hot rolled

3.02 Thickness of enclosure * 3.03 Access Front Rear

4.00 INCOMER DETAILS 4.01 Voltage and frequency

4.02 No. Of phases and wires

4.03 Cable size and type

4.04 Cable entry Top Bottom Side

4.05 a. Incomer switch type MCCB MCB RCCB / ELCB Switch – Fuse unit

4.06 b. Rating and no. Of poles * 4.07 c. Sensitivity of RCCB / ELCB *

5.00 OUTGOING CIRCUIT DETAILS 5.01 Voltage and frequency

5.02 No. Of outgoing circuits with ratings

5.03 Cable entry Top Bottom Side 5.04 a. With switch fuse units

5.05 b. With MCB/ MCCB

5.06 c. With ELCB / RCCB

5.07 d. With contactor - timer interlocks

5.08 e. With contactor - photocell interlocks

5.09 f. With other interlocks

5.10 Sensitivity of ELCB / RCCB *

5.11 No. of poles in switching component * 5.12 No. of outgoing cables with cable size & type

5.13 Cable entry Top Bottom Side

6.00 BUSBAR 6.01 Whether Busbars required Yes No 6.02 Busbar material & size * 6.03 Nominal rating * 6.04 Short circuit rating

6.05 Busbar clearances

6.06 a. Phase to phase

6.07 b. Phase to earth

6.08 c. Phase to neutral

6.09 Minimum area of conductors used for internal wiring *

6.10 Cable glands

6.11 Whether busbars required Yes No 6.12 a. Cable gland supply

6.13 b. Cable gland type / details

6.14 Overall dimensions of panel (LxBxH)

6.15 Weight kg




DATA SHEET FOR CATHODIC PROTECTION TRANSFORMER

RECTIFIER UNIT





Service:

[ITEM SPECIFICATIONS] 1.00 GENERAL SYSTEM REQUIREMENTS 1.01 Number of output circuits * 1.02 Output voltage *

1.03 Rated output current A *

1.04 Pipe to soil potential setting range V *

1.05 Minimum set potential range * 1.06 Maximum pipeline potential * 1.07 Minimum pipeline potential * 1.08 Number of reference cells for control

1.09 Overall efficiency Min. 80% 1.10 SCADA interface Required Not Required 1.11 Remote monitoring through SCADA Required Not Required

2.00 SITE CONDITIONS 2.01 Ambient temperature Min. Max. 2.02 Design ambient

2.03 Relative humidity % Min. Max. 3.00 ENCLOSURE

3.01 Structural members mm *

3.02 Doors and covers mm *

3.03 Degree of protection IP-55 3.04 Cable entry Top Bottom 3.05 Painting *

4.00 TRANSFORMER 4.01 Type * 4.02 Tag no. * 4.03 Make / model no. / country of origin * 4.04 Duty * 4.05 Type of cooling * 4.06 Location *

5.00 TECHNICAL PARTICULARS OF TRANSFORMER 5.01 Rated power * 5.02 Voltage ratio * 5.03 Rated primary voltage * 5.04 Rated secondary voltage * 5.05 Rated primary current * 5.06 Percentage impedance *

5.07 Regulated power from (0 to 100% output) * 5.08 Efficiency V (Min.) V(Max.) 5.09 a. @ 10% Load

5.10 b. @ 25% Load

5.11 c. @ 50% Load

5.12 d. @ 75% Load

5.13 e. @ 100% Load

6.00 POWER SUPPLY SYSTEM 6.01 Voltage * 6.02 Frequency * 6.03 Fault level *

7.00 INPUT CONTROL

8.00 RECTIFIERS & FILTERS

8.01 Type

8.02 Current rating

8.03 Protection

8.04 Heat sink

8.05 Ripple content

8.06 Number of output circuits

8.07 System control Manual Automatic 8.08 Output protection

8.09 Over voltage protection



DATA SHEET FOR DATA SHEET OF IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM (PERMANENT) FOR

PIPELINE





Service:

[ITEM SPECIFICATIONS] 1.00 GENERAL 1.01 Service / Application

1.02 Make / Country of origin * 1.03 Location & Area classification

2.00 SITE/ENVIRONMENT CONDITIONS 2.01 System type / model no.

2.02 Degree of protection & temp. Class of enclosures

2.03 Type of soil

2.04 Sub soil water level

3.00 DESIGN BASIS 3.01 Design life of c.p. system

3.02 Equipment/structure to be protected

3.03 Details of equipment/structure to be protected

3.04 Quantity

3.05 Type of installation

3.06 Pipe details

3.07 Material of pipeline

3.08 Anti corrosion treatment on external

3.09 Surface of pipeline provided Yes No 3.10 Details of anti-corrosion treatment &

3.11 Coating provided

4.00 CATHODIC PROTECTION SYSTEM DESIGN CRITERIA 4.01 Type of cp system to be provided * 4.02 Make and type reference * 4.03 Anode material and composition * 4.04 Anode type, dimension and weight * 4.05 Anode potential * 4.06 Total number of anodes required * 4.07 No. Of cp stations provided * 4.08 No. Of test stations provided * 4.09 Permanent reference cells *

a. Material * b. Number of reference electrodes * c. Purity * d. Reference electrode potential * e. Reference electrode type, dimension and *

i) Polarisation cell required not required ii) Surge diverter required not required iii) Grounding cell required not required

4.10 Type of electrical resistance probe provided

4.11 Transformer/rectifier unit

a. input power supply voltage

b. Output power supply voltage * c. Rated output current * d. Transformer type & make * e. T/r unit location & area classification

f. Degree of protection of t/r unit * g. Dc output voltage * h. Dc output current * i. Efficiency of t/r unit * j. Voltage regulation

a. Auto mode * b. Manual mode * k) Output ripple at full load current *

4.12 Anode junction box

a. Make and type * b. Material of construction & thickness * c. Location & area classification * d. Degree of enclosure protection * e. Overall dimension * f. No. Of junction boxes provided * g. No.of terminals in junction boxes * h. Painting & colour shade of finish coat *

4.13 Cables

a. Make and type * b. Voltage grade

c. Conductor material

d. Conductor size * e. Type of insulation on conductor, inner

Sheath & outer sheath.

f. Cable armouring Required Not required

5.00 CURRENT DENSITY RANGE REQUIRED FOR PROTECTION 5.01 Pipeline with co altar coating with two

5.02 Or three layers of reinforcement:

5.03 Pipeline laid

a. In normal soil * b. Under sea - water / in marshy area * c. In sea - water * d. In high-resistivity area * (More than 100 w - m. Resistivity)

e. Pipe to soil `0n' potential not to exceed * 5.04 Pipeline with polyethylene coating :

Pipeline laid

a. in normal soil * b. under sea water / in marshy area * c. in sea water

d. IN HIGH RESISTIVITY AREA * (More than 100 w - m. Resistivity)

e. Pipe to soil 'on' potential not to exceed

(** Actual current density shall be

Decided based on soil, environment

And interference areas surrounding

Installation of pipeline / structure)

5.05 Safety factor for current density * 5.06 Anode surface current density

( Max. In amps / sq. Metre) * 5.07 Anode utilisation factor

5.08 For centre connected anode

5.09 For end connected anode * 5.10 Anode consumption rate

5.11 Pipeline natural potential *

6.00 WHEATHER INTERFERENCE MITIGATION INCLUDED 6.01 Whether interference mitigation included Yes No

In vendor's scope

6.02 Whether erection, testing and Yes No 6.03 Commissioning in vendor's scope

6.04 Additional information/ requirements


TECHNICAL DATA SHEET FOR MAIN ELECTRICAL DISTRIBUTION BOARD

TABLE OF CONTENTS

1.0 GENERAL

2.0 BUS BAR

3.0 CURRENT TRANSFORMER

4.0 POTENTIAL TRANSFORMER

5.0 SWITCHES

6.0 FUSES

7.0 RELAYS

8.0 INSTRUMENT METERS

9.0 MOULDED CASE CIRCUIT BREAKER

10.0 CIRCUIT BREAKERS

11.0 CONTACTOR

(TECHANICAL DATA SHEET) TECHINICAL DATA SHEET (To be furnished by Vendor)

1.0 GENERAL 1.1 Make 1.2 IP Class of enclosure 1.3 Panel Type 1.4 Thickness of sheet steel 1.5 Treatment 1.6 Painting 1.7 Overall dimension

L B H

1.8 Space heater rating of each panel : 1.9 Weight of the MEDB :

2.0 BUS BAR 2.1 Material 2.2 Size a) Horizontal bus bar : b) Vertical bus bar : c) Ground : 2.3 Minimum Clearance a) Between phases : b) Between phase and earth : 2.4 Minimum creep age distances :

2.5 Current rating : a) Continuous : b) Short time for 1 second : 2.6 Temp. rise over ambient : a) Supports : b) Material : c) Make : d) BIL :

2.7 a) Supports : b) Materials : c) Make : d) Voltage : e) BIL : 2.8 Bus bar insulation : 2.9 Bus bar phase identification mark :

3. CURRENT TRANSFORMER (CT)

3.1 Make :

3.2 Type of primary winding :

3.3 Ratio :

3.4 Rated Burden :

3.5 Accuracy class :

4.0 POTENTIAL TRANSFORMER (PT)

4.1 Make

4.2 Type of primary winding

4.3 Ratio

4.4 Rated burden

4.5 Accuracy class

5.0 SWITCHES

5.1 Rated voltage

5.2 Rated thermal current

5.3 Duty

6.0 FUSES

6.1 Make 6.2 Type of HRC fuse

6.3 Rated voltage

7.0 RELAYS

7.1 Application

7.2 Make

8.0 INSTRUMENT AND METERS

8.1 Application

8.2 Make

8.3 Maker’s type

8.4 Ref. Standard

8.5 Operating principle

8.6 Rated voltage/current

8.7 Burden at rated voltage/current

8.8 Operating range

8.9 Scale range

9.0 MOULDED CASE CIRCUIT BREAKER (MCCB)

9.1 Make

9.2 Rated Voltage

9.3 Rated current

9.4 Short Circuit Capacity

10.0 CIRCUIT BREAKERS

10.1 Make

10.2 Short circuit capacity

10.3 Short circuit category

10.4 Type of medium

10.5 Rated voltage

10.6 Maximum operating voltage

10.7 Frequency

10.8 No. of poles

10.9 Rated operating duty

10.10 Current rating

a) Continuous b) Short circuit Rating

10.11 Type of closing mechanism

10.12 Type of tripping mechanism

10.13 Anti pumping features

10.14 Details of spring charged motor a) Motor b) Rating c) Insulation d) Duty

10.15 Control Voltage with range

a) Closing b) Tripping c) Alarm and Indication

10.16 Power I Current required for

a) Closing b) Tripping

11.0 CONTACTOR

11.1 Make

11.2 Rated Voltage

11.3 Rated current

11.4 Short circuit capacity

TECHNICAL DATA SHEET FOR UPS SYSTEM

TABLE OF CONTENTS

1.0 STATIC INVERTER

2.0 STATIC TRANSFER SWITCH ASSEMBLY

3.0 AVERAGE SENSE VOLTAGE

4.0 RECTIFIER / BA TTERY CHARGER

5.0 ACDB

6.0 BATTE RY

7.0 SCHEMATIC DIAGRAM OF UPS SYSTEM FURNISHED

(TECHANICAL DATA SHEET) TECHINICAL DATA SHEET (To be furnished by Vendor)

1.0 STATIC INVERTER :

1.1 APPLICATION : 1.2 TYPE : 1.3 DUTY : 1.4 ENCLOSURE : 1.5 COOLING : 1.6 DESIGN AMBIENT TEMPERATURE : 1.7 INVERTER CAPACITY : 1.8 OVER LOAD CAPACITY : 1.9 POWER WORK ING : 1.10 VOLTAGE : A. INVERTER INPUT (BATTERY OUTPUT) B. NOMINAL OUTPUT 1.11 VOLTAGE REGULATION

: A. REGULATION FOR 0-100% LOAD AND FOR MIN. :

TO MAX. DC BATTERY VOLTS AND FOR BOTH THE CONDITIONS EXISTING SIMULTANEOUSLY.

B. DYNAMIC RESPONSE OR TRANS. VOLTAGE : REGULATION AT 100% STEP LOAD CHANGE (APPLICATION OR REMOVAL).

C. DYNAMIC RESPONSE OR TRANSIENT VOLTAGE : REGULATION DURING TRANSFER OF LOAD TO ALTERNATE SOURCE.

D. DYNAMIC RESPONSE OR TRANSIENT VOLTAGE : REGULATION DURING TRANSFER OF LOAD TO SYSTEM OUTPUT.

E. DYNAMIC RESPONSE OR TRANSIENT VOLTAGE : REGULATION AT ABRUPT + 10% CHANGE OF INPUT VOLTAGE.

F. DYNAMIC RESPONSE OR TRANSIENT VOLTAGE : REGULATION AT FAILURE/ RECOVERY OF COMMERCIAL POWER

G. TRANSIENT RECOVERY OR RESPONSE TIME. :

H. STEADY STATE : (0-100% LOAD AT ALL INPUT VOLTAGES AND ALL POWER FACTORS)

I. TRANSIENT VOLTAGE : (ON APPLICATION OR REMOVAL OF 100% LOAD)

J. TIME TO RECOVER FROM TRANSIENT TONORMAL VOLTAGE :

1.12 WAVE FORM

: A. NOMINAL FREQUENCY :

B. FREQUENCY RANGE FOR ALLCONDITIONS OF INPUT :

SUPPLIES,LOADS AND TEMP. OCCURING SIMULTION. OR IN ANY COMBINATION (AUTO CONTROLLED)

C. SYNCHRONISTION LIMITS (FOR MAINTENANCE OF : SYNCHRONISM BETWEEN INVERTER AND STANDBY A.C. SOURCE)

D. FIELD ADJUSTMENT RANGE FOR (C) ABOVE. :

E. TOTAL HARMONIC CONTENT AT 100% LINEAR LOAD. :

F. HARMONIC CONTEMT FOR ANY SINGLE HARMONIC

I) AT 100% LINEAR LOAD : II) AT 100% NON LINEAR LOAD :

G. FREQUENCY ACCURACY FOR INTERNAL : OSCILLATION.

H. SLEVE RATE :

I. OUTPUT VOLTAGE ADJUSTMENT RANGE: AT RATED LOAD

1.13 RATED OUTPUT CURRENT AT RATED OUTPUT VOLTAGE WITH CURRENT LIMIT NOT OPERATING A. CURRENT : B. DURATION :

1.14 EFFICIENCY AT FULL LOAD (WATT OUTPUT/WATT INPUT):

2.0 STATIC TRANSFER SWITCH ASSEMBLY

2.1 TYPE : 2.2 DUTY : 2.3 ENCLOSURE : 2.4 COOLING : 2.5 AMBIENT TEMPERATURE : 2.6 CAPACITY

A. CONTINUOUS : B. OVERLOAD : C. PEAK :

2.7 NORMAL VOLTAGE : 2.8 TRANSIENT VOLTAGE TOLERANCE : 2.9 TRANSFER TIME MILLI SECONDS :

3.0 AVERAGE SENSE VOLTAGE

3.1 INSTANTANEOUS SENSE VOLTAGE : 3.2 ANTI CYCLING CIRCUIT : 3.3 SYNCHRONOUS DISCONNENT RANGE : 3.4 MANUAL BY-PASS SWITCH : 3.5 TYPE : 3.6 VOLTAGE : 3.7 RATED CURRENT :

4.0 RECTIFIER/BATTERY CHARGER

4.1 CHARGER : 4.2 TYPE : 4.3 DUTY : 4.4 ENCLOSURE : 4.5 COOLING : 4.6 AMBIENT TEMPERATURE : 4.7 A.C. INPUT

A. SUPPLY : B. VOLTAGE VARIATION : C. FREQUENCY VARIATION : D. COMBINED VOLT FREQUENCY VARIATION : E. SHORT-CIRCUIT LEVEL : F. SYSTEM EARTHING :

4.8 D.C. OUTPUT : FEATURES PROVIDED

A. AUTOMATIC VOLTAGE REGULATION : B. CURRENT LIMITING CIRCUITRY : C. SMOOTHING FILTER CIRCUIT : D. SOFT START FEATURE : E. AUTOMATIC LOAD SHARING DURING PARALLEL OPERATION : F. SCR SURGE PROTECTION AND FAST ACTING HRC FUSES : G. DC EARTH FAULT ALARM :

5.0 ACDB INCOMER MCCB (0NE NO.) : CURRENT RATTING : MAKE : VOLTAGE FAULT LEVEL : OUTGOING FEEDERS (MCB) : QUANTITY : CURRENT RATING : VOLTAGE :

6.0 BATTERY

6.1 TYPE : 6.2 NO. OF BATTERY SET : 6.3 DC VOLTAGE OF BATTERY SET : 6.4 NOMINAL DISCHARGE VOLTAGE : 6.5 CELL END VOLTAGE AT THE END DUTY : CYCLE 6.6 DUTY CYCLE : 6.7 NUMVER OF CELLS PER BATTERY : 6.8 BATTERY CIRCUIT BREAKER IN SEPARATE WALL CUBICLES :

7.0 SCHEMATIC DIAGRAM OF UPS SYSTEM FURNISHED

TECHNICAL DATA SHEET FOR POWER & CONTROL CABLES

TECHNICAL DATA SHEET

TECHNICAL DATA SHEET (To be furnished by Vendor)

1. Name of the manufacturer 2. Voltage Grade 3. Type of cable 4. Standard Referred 5. Conductor

a. Normal cross sectional area b. Shape of the conductor c. Max. D.C. resistance at 20 Deg. C. d. Number of stands

6. Insulation

a. Type and material of Insulation b. Thickness of insulation c. Colour Scheme/Core Identification d. Extruded

7. Inner-Sheath

a. Material b. Minimum Thickness c. Extruded d. Approximate dia over inner sheath

8. Armour

a. Type b. Material c. Nominal Thickness

9. Outer Sheath

a. Material b. Minimum Thickness

c. Extruded

10. Approximate overall diameter.

11. Normal drum length 12. AC resistance of the conductor at

maximum operating Temperature

13. Approximate reactance per phase at 50Hz.

14. Current Rating

a. In ground b. In air c. Maximum conductor

temperature during continuous Operation

d. Maximum conductor temperature during short Circuit

e. Short circuit rating f. Maximum permissible bending radius

TECHNICAL DATA SHEET FOR NICKEL CADMIUM BATTERY

(TECHNICAL DATA SHEET)

(TECHNICAL DATA SHEET TO BE FURNISHED BY VENDOR)

1. Item No. as per MR/PO

2. Manufacturer’s name

3. Type of Construction

4. Type and catalogue no of cell

5. Ampere hour capacity

6. No. of Cells

7. Nominal cell voltage

8. End Cell voltage at the full discharge

9. Specific gravity of electrolyte at the end of full charging at 27ºC

10. Specific gravity of electrolytes at the end of full discharge at 27ºC

11. Quantity of electrolyte per cell (liters)

12. Weight of each cell with electrolyte (kg)

13a. Max boost charging voltage per cell

13b. Permissible ripple content

14. Manufacturer Suggested boost charging rate (amperes)

15. Max boost charging voltage per cell

16a. Recommended Float charging voltage per cell

16b. Maximum float charging voltage range per cell.

17a. Float charging current range (amperes)

17b. Permissible ripple content

18. AH Efficiency at 10 hours / 5 hour rate

19. Short circuit current of the battery bank

20. Short circuit withstand time (sec.)

21. Max. allowable temp. of electrolyte which the cells can withstand without injurious effects.

i. Continuously

ii. For short periods

22. Type of positive plate

23. Type of negative plate

24. No. of +ve and –ve plates per cell

25. Material and thickness of separators

26. Amper hour capacity at min. ambient 27ºC

26.1 10 hour rate to end cell voltage at Sl. No 8 above

26.2 5 hour rate to end cell voltage at Sl. No 8 above

26.3 2 hour rate to end cell voltage at Sl. No 8 above.

26.4 1 hour rate to end cell voltage at Sl. No 8 above.

26.5 30 minutes rate to end cell voltage at Sl. No. 8 above.

27. Dimensions of battery rack (WXDXH) in mm

',-------,----,------'

L

STANDARD NO. FRONT PAGE SD-EL-DOl

SHEET NO. I 1 OF 1

~ seE LA N E 0 U S DETA S

l'=== GHT N'G

r,-______________________________ ,-____________________________________ ,-__________________________ ,,

SR. DRAWiNG NO. NO.

1 SO-EL-OCl

2 SD-EL -002

3 SD-EL-OC3

4 SO-El-OC4

5 SD-El-005

6 SO-EL-006

7 SO-E"1-0C7

8 SD-EL-CC8

9 SD-EL-009

10 SD---EL---Ol0

11 SD-EL-Ol1

12 SD-El-012

13 SD-El-013

14 SO-EL-014

15 SO-1:1-015

16 SD-EL-016

17 SD-EL-017

18 SD-El-018

19 SD-[l-019

20 SD-EL-020

21 SD-El-021

22 SO-EL-022

23 SO-EL-023

24 SD-EL-024

25 SD-El-025

26 SD-EL-026

27 SO-[[_-027

28 SD-[1-028

29 SD EL029

30 SO-EL-030

31 SD-EL-031

32 SO-EL-032

3.3 SD-El-033

L

STANDARD NO, DRAWING INDEX SS-EL -002

SHEET NO, I 1 OF 1

DESCRIPTION

FRONT PAGE

lJRAWIf\lG INDEX

GENERAL NOiES - UGHTING

TYPICAL SUSPENS:ON MOUNTING DETAILS OF INDUSTRIAL FLUORESCENT UGHTING FITTING

TYPICAL SUSPENS:ON MOUNTING DETAILS OF INDUSTRIAL FLUORcSCENT liGHTING FITTING W:TH SUSPEr-.;$IQ:-.l MORE THAN 2 Mtrs.

TYPICAL DETAILS OF DECORATIVE L;GHTING F"lXTURE V.OUNTING RECESSED O~ BELOW FALSE CEIUf>.JG

TYPICAL DETAIL OF CONCEALED CONDUiT WIRING

TYPICAL CEILING ,\AOUNTING DETAILS OF INDUSTRIAL TYPE FISER GLASS REINFORCED FLUORESCENT UGHTING F:TTING

TYPICAL MOUNTING DETAILS :NO:)STRIAL/RECESS MOUNTING F-LUORESCENT UGHT!NG FITTING BELDW PERFORATED LIGHTING CABLE T!~AY

TYPICAL HANDRAIL PIPE MOUNTING DETAILS OF F~UORESCENT HPMV/HPSV LlGHTINC FITTING Of\J PLATFORM

TYPICAL MOUNTING DETAI~S OF FLUOR ESC Em LIGHTING FliTlNG (WALL/COLUMN MCUNTED)

TYPICAL MOUNTING DETAI~S OF STREET LIGHTING FITTING (WALL/COLUMN MOUNED)

TYPICAL MOUNTING DETAIi... OF STREET LIGHTING FITTING

TYPICAL PLATFORM MOUf>..iTED PIP~ DETAILS 0,- If'.JDUST~IAL TYPE/WITH BUILT -IN CONTROL GEAR OR WITHOUT CONTROL GEAR TYPE WEI_lGLASS LIGHTING FIT'lNG

TYPICAL MOUNTING DETAI~S OF SINGLE PHASE SOCKET O~TLET ON HANDRAIL

TYPICAL MOUNTING DETAI~S OF iNDUSTRIAL WE~lGLASS LIGHTING FITTING WITH BUILT IN CONTROL GEAR BOX

TYPICAL DETAIL OF CE:LlNG/SUSP[NSION MOUNTED HIGHBAY LIGHTING FTrTING

TYPICAL MOUNTING ARRANGEMENT OF FLOOD UGHT MOUNTED ON PLATFORM/WALKWAY

TYPICAL MOUNTING ARRANGEMENT OF FLOOD UGHT MOUNTED ON STEEL/CONCRETE COLUMN

TYPICAL MOUNTING DETAIi... OF 1 No. FLOOD LIGHTING FlTIIf>..iG

TYPICAL MOUNTING DETAIi... OF 2Nos. INDUSTRIAL WPE FlOCD UGHTING FITTING

TYPICAL MOUNTING DETAI~ OF 8Nos. FLOOD liGHTING FITT:NG ON LETTICE TYPE TOWER

TYPICAL MOUNTING DETAIL. OF SNos. FLOOD UG~TlNG ;:-ITI:NG ON LmlCE TYPe: TOWER

TYPICAL MOUNTING DETAI,--S OF r--LArv1EPROOF FLUORESCENr LIGHTING FiniNG

TYPICAL SIJSPENS:ON/CEIUNG/PIPE/BRACKET MOUNTING DETAILS OF FLAMEPROOF We:L.LGLASS lJGHTING F,TTING

TYPICAL HANDRAIL MOUNTED PIPE DETAILS OF FLAMEPROOF WELLGLASS UG~T:NG FITTING

TYPICAL CEILING/SUSPl::NSION MOUNT:NG DE7AILS OF FLA~EPROOr BULK HEAD LIGHTING FITTING

TYPICAL DETAILS OF BULK HEAD LIGHTING FliTlNG MOUNTED ON HANDRAIL

TYPICAL MOUNTING DETAI~S OF VESSEL LIGHT GLASS LIGHTiNG FITTING

TYPICAL MOUNTING DETAI~_.s OF DOLlBLE OBSTRUCTION L:GHT FOR AV:ATION LIGHTING r:ITTING

WPICAL DETAilS OF LOOPING BOX FOR STREET LIGHTING FITTING

TYPICAL DETAilS OF DUST/WEATHERPROOF ROUND JUNCTIOf\J BOX

TYPICAL MOUNTING OETAI~S OF SIt..)GLE PHASE SOCKET O'JrLE' ON HANDRAIi...

STANDARD NO. GENERAL NOTES-LIGHTING SS-EL-003

SHEET NO. OF 1

GENERAL NOTES:

[i',rnRE EU~:CTRiCj\l_ INST;\Uj\T:Or~ SHAlJ. BE CARRiED OUT STRICfl._'-( IN !\CCORD/\I\jCE \,\":TH THE DTCTRIC!\U __ Y RUl_IS, GiSD REGU CODES, Fmr~SURMjCE A~m (JTHEY .~.PPICABIE CODES M~D ~'ECU

/ EXCEP-: AS SPECIFiC,All __ Y ,APPROVED B'/ ClIENT/CCI\jSUl_JAI\F AT Si:E II\jSTA1l_j'lTiO~J OF UGf-iT:~JG FiTTING SHAl_J BE lAYEJ,j l __ Y ,AFTER ~'AAlJOR SERI/'iCE SUCH ,6,5 EOU:P~IENT ERECTiON, PIPING ETC. iN THAT PAPTICUl __ ,6,R AREA HAVE BEEN CO~IPU:JED.

C;\BES FROM IIGHTI PI\NEI TC UGHTI FTIING SHNI BE IDEI~TlFIED S:AINIESS STEEl STRP TN~S CIRCUIT REFEREIICE :\jUrv!B~:R.

4. WIRI TO L1GHTI FFING DE PUINT BUleDI AREA SHALL BE OAPRIED OUT BY I~EANS OF 3: x 2.5 SQ. 1,11,1 CAReES. FOR EARTHNG OF L!G!!T!:'~G FITIIljG D J BOX IRD CORE SHALL BE USED.

UGHTING DSTRIBUTiQr,1 BOA.RD. HOWEVER, LOOAL CDrHROL SWITCHES SHALL BE PROVIDED WHEREVER NECESSARY..e. FOR CO,IFROcW,IG UGHTiNG FITTlr~GS ;r~ TOilET BLOCf</OFTiCE/'STORE ROCr'/1/SUB -- STATlcr~,/CABL[ CEL~p.R ENTR,6,NCE ETC

EQIJIP~/IE1"H FROM F!:\JISHED FLOOR LEVEL SHALL BE AS FOLLOWS:

SUB···· 1200mm

B) L1C1ITING CONTROL SWITCHES

RECEfJTACLE WITH S\NiTCH 800:T1rn

7. EXCEFT AS SPECIFiED. CABlES FOR SIHIT ICHTI BE DRECI1Y BURIED 1:,1 c~,(JUr~D OR ROUTED 1:,1 CABIEIRH:Ccc/DUCTS AS E C~.SE BE.

8. UGHTI CN31ES SHNI [j[ TH!mUGH HI~[ PIP! mmlED I~j C;W)U~m I\T SU

9, Sir~GLE PHASE SWiTCHED SOCf<ET OUTLETS I Dil\~G: cs: !\BOVE SHj\LL BE FED AND CONTROLLED FROI\~

10. r,IC WRI~G II~ COI~OIJIT Srl.~.LL BE CA.RRIED OUT BY USr,IC 19n~rl 011\. HE.AVY C,AUCE STEEL ~:GD Cm,iDUT fOR ICH TYPE OF Cm)I'ER CONDUCTOR PVC: FLE/iBLE \ViRE SHALL BE USED

UGHTI & ~i6 AMPS. COMMERCIAl TYPE SWITCHED 2.5 SO.HH

8) ~,AETj\L CU\D S\ViTCH SOCKET OUTLETS 6.0 SO.~I~1

C(JU)UR WiRE SHAll BE USED

f:-Ol:\ 1,_, ,

~'HASE 1\ RED COLOUR COPPER CONDUCTOR PVC BLE WII~E

2. FOR 'y' PH/\SE YELLO\;\/ CO~OUR COPPER CONDUCTOR P\/C FLE/:iB~E \NiRE

,0. fOR '8' PHAS~: BlUE C()U)UR COPPER c(J~mUCT(W PVC HEll WI

LJ. f:-Ol:\ ' r,j' P~-jftSE B~ALK COLDUf\ COPPEi~ CONDUCTOf\ PVC 1::1EXIBLE wlf\E

5. FOR EARTH GREE~,j COLOIJR 1.5 SQ. ~il~il COPPER CONDUCTOR PVC FLE;\IB~E VVIRE

SITE FABRIC~ITD C(]~TS DF ANTI-CDRRlJSIV[

:.3. t\LL HARDVV!\RE SHALL BE O~ STAiNLESS STEE~<

L ~

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

r

TYPICAL SUSPENSION MOUNTING DETAILS OF INDUSTRIAL FLUORESCENT LIGHTING

FITTING

AS REQUI~ED

sr::EL STRuCTURE

500 • I

I /r-0 STEFL STRUCh!RE-

STANDARD NO.

SS-EL -004 SHEET NO.

~~

--@) ....... ~

I /

CRCUIT CABLE ~ \ CABL€: GLAND (TO

, SUIT CIRCU,T CABLE) \

FARTHiNG TERMINAL

FLEXI6LE WIRES

ReG SLAB

0-/\ -0 0 f3\ ________ : \ EXtERNAL EARTHING \:.:.f TERMINAL

). NDs. - 2.5 SO. MM FLEXIBLE WiRES

INCUSTRIAl TYPE fLUORESCENT

LI1G!WNG FITTING

MOuNTING HEIGHT

TYPICAL MQUNTING ARRANGEMENT DE ELUQRESCENT LIGHTING FITTING ON STRUCTURE STEEL & WIRING

WITH PVC INSULATED CABLE MOUNTING TYPE : SMl

STEEL S1RUCTURE -...~" .~ (6)- -0

TYPICAL MOUNTING ARRANGEMENT OF FLUORESCENT

LIGHTING FITTING ON R.C.C. SLAB & CONDUIT WIRING '-0

")----1' I

• • • •

SlUL STRUCTURE

NIPPLE

OF 1

50x50x6 At><GLE" ~~ TO Bf PROVIDED WHFN

TYPICAL MOUNTING DETAILS OF

J.B. ON STRUCTURAL STEEL MQUNTING TYPE eMl

~{/ h / LENGTH c.XGEECl 1200m,.,.,

'~ TO SWT FLEXISl E CONDUIT! ~ > .. ~ "'-_, -I 50x5Cx6 ANGLE CONDUIT -...,., ,~ /- I FNGTH TO SUIT

~~ ~- , /" GROuTED IN WALL

~l

NOTES:

• •

~ "- CIRWI CABLE

aRA~KUMQUNILNgQ~

WALL/COLUMN MTG, TYPE: BMl

• • MATERIAL TAKE-OFF

DESCRIPTION QUA.NTITY REMA.RKS

1 NO.

2 & SOCKU 1 NO.

2 NOS.

4 AS REOUI~ED

5 2 NOS.

6 4 NOS.

7 AS REQUIRED

r,-______________________________ ,-____________________________________ ,-__________________________ ,,

0)-

6

NOTES:

L

TYPICAL SUSPENSION MOUNTING DETAILS OF INDUSTRIAL FLUORESCENT LIGHTING FITTING

WITH SUSPENSION MORE THAN 2 Mtrs.

STANDARD NO.

SS-EL -005 SHEET NO. I 1 OF I

ANGLE CLEATS FIXED TO CONCRETE SLAB WITH R,C.:::. SLA8 O.'~

STEEL STRIJCTURE .I ANCHOR BOLTS OR WELOED TO STR.UCTURAl STEEL

/

. 0-\ '-', \

, .

ANGLE CLEAT

HOLE

TYPICAL MOUNTING DETAILS

WELDED (T:'P.) ,--y, //~ -CIRCUIT CA8L[

m~2T~3 (

~ __ SELF TAPP!"lG SCREW

-

'-' --'-' '---@

'A'

ITEM NO.

MOUNTING HEIGHT

@- ,

0- --@ \

= I

I • • • •

25 x S fAS SUSPENSICN Fl.AT --- (PROVIDED MS ANGLE FOR SUSPENSION

,r SUSPENSION EXCEEDS 15 METERS)

- r_,, __ /_JiFlDEO (TiP.)

-0 /~/-/ _ 2 Nos. 10mmll HOLES ON R./I.IUNG -,...- ...------ AT 13Smm FROM BeTH [NOS SH}ll~

@---;J====,J!~ilI",,-----;;:.~__I.8E CRILLED BY SITE. j

~.--~ DETAIL 'A'

MATERIAL TAKE OFF

DESCRIPTlm~

2 x 40W fL:.JORESCENT LIGHTING FrmNG

QUANT!W RE MARKS 4WAY--l00mm DtA ROUND JUNCTION BOX WITH TERMINAL BLOCK.

1 NO,

SECT10N 'A-A' 2 M8-40(f'm LO~G BOll Wffl-< NUT AND PLAIN WASHER 2 NOS.

3

4

, 6

, 8

9

C.L SADDLE/CLEAT ALONG WITH SUITA8LE SIZE OF F'XiNC SCREW & ~UT TO SUIT FOR CiRCUiT CASU,.

Ml0-68mm LONG ANCHOR STUD WITH SOli & Pl.A:N WASHER

SADDLE/CLEAT WITH fiXING SCREW' 0" M6 68mm LONG STUD, NUTS & LOCK WASHERS FOR CIRCUIT CABLE

25 x 6mm THK. M.S. FlAT (LENG,H TO SUIT)

ISA 50 ~ 50 x 6 THK.---75mm LONG ANGLE CLEAT WITH lC Il HOLES

10r:1m ¢ 35 LONG COUNTER SUNK SCREWS WITH RAWAL PLUG

ISA 50 x 50 x 6 TH":.-150mm lONG .IINGLE CLfAT WITH 2 NOS_ 12 </I HOLES

AS ~EQUIRED

4 NOS.

AS REQUIRED

2 NOS.

4 NOS.

2 NOS.

2 NOS_

NOTES:

L

STANDARD NO. TYPICAL DETAIL OF CONCEALED CONDUIT 1------------1

WIRING SS-EL -007 Pa e OF 1

• _". '- _·d, .• '."" _. _~-'./ .• _' .:', ':~ 1- ,;-; .'> ... :: '. .. oj " .. ~ _ :; ';-"'.;, -~.:~.:,.. .", j~.' ;,', .: ",'., ~- .-" •• " :;" .... _-.

'-, ,-. < _ ~ • '":. '::: ""'-,j~': ~-~'~'='~'~~~='~'~'~'=![:":':')'='='='~' ='~' ~'"~'~'~l~.~' ..• ~'~'.=,~ ... ~.~.~'~' ',', .. -, , .. ". . _, ; ~ ~ " •• , _:' • ___ . ;4.,,;,-- , ' • • ~-

"~':...':.....-,,-'-'~-,~ . " r :,' .. C- •• ,·'

. -. '- '.

,

. '." . ". ~. ; ,' .. -, ),', ." '" ,

-~,' ~ . ,., .

:- '- . , • _. • -- ,a, ~ WORK TO BE CARRIED OUT

BEFORE CONCRETING

F.F.L

TYPICAL INSTALLATION DETAIL Qr CONDUIT ENTERY

FROM R.C.C SLAB INTO THE BRICK WALL

MATERIAL TAKE-OFF

ITEM DESCR:PTION NO. 1 PVC/G." CONDUIT SIZt AS REQU:RED

2 WIRE PULL BOX WITH FLA.T CaVER

3 PVC/G." 9C' BEND SiZE AS r-<EQUIRED

4 PVC/G." COUPLING SIZE AS REQ~IRED

5 SWITCH BOARD, SOCKET OUTLET ETC.

QUAN!IIY

AS REQUIRED

AS REQUIRED

AS REQUIRED

AS REQUIRED

AS REQUIRED

REMARKS

L

TYPICAL MOUNTING DETAilS OF STREET LIGHTING FITTING

(WALL/COLUMN MOUNTED)

HEIGHT

TEAK WOOD '""'c/, AT CENTE>';

STANDARD NO.

SS-EL -012 SHEET NO. OF 1

I. SACCLE/CLEAT SU:TAB,-E FOR 40 NB G.:. PIPE

WIRE NUT AND WASHERS

SECTION 'A-A'

3 Nos. 2.5 SQ. mm COPPER FLEXIBLE WIRES WITH FLEXiBLE

CONDUIT PIECE

(i)

'~ CABLE GLAND (TO SUIT CIRCUIT CABLE)

@-

3 N:)s. 2.5 SO. mr:1 COPPER //f.LtXj-EfLE---WIRE-S----V,iI'fH----~LEXI B LE

CONDUIT PIECE

19mm DIA. HEAVY GAUGE CONti:..:;;

JUNCTION BOX

FL:..::)R£:s,~:::;tv; STREET

L1G""Y;:;,v;:: r:TIJNG

~ ~ '~"-_, CIRCUIT CABLE (4C ): 6SQ.mrr) {/ ()

MATERIAL TAKE OFF

~Ii -"--LLJy;.,--,-~"",. WAL:"/STRUCTURE

-C "

ITEM DESCR:PTION QUAN :ITY REMA,RKS NO. , .. WAY JIJNCTION BOX 1 NO.

2 I.Ornm ClIA C.L PIPE (CCASS HEAVf) 1 NO. MOUNTING TYPE - PM4

3 G.L SADOLE/CLEAT TO SU:TAS:"E FOR 4{Jmm 0 & G.I. WffH SCRE.WS, PLAI:-.J WASHERS AND SPRING W.A.sHEHS

PIPE. 2 NOS.

4 l5mm THK. TEAK WOOD SHOE WITH BITUM,NOLIS PAINT 1 BLOCK

5 G.!. PIPE COUPLING (TO SUIT 40mm '" G.!. PIPE) 1 NO.

S RURDER GROMMET (TO S~IT 40mm ¢ C.:. PIPE) 1 NO.

7 ,)Omm DlA G.L PiPE SLEAVE 1 NO.

8 19mm i)lA G.L HEAVY GAUGE CONDUIT AS REQUIRED

9 lOA. 250V D.P WEATHER ;>ROOF UGHTING SWITCH WITH 80TTOM [r,;TRY 1 NO.

NOTES: 10 SCREW WITH PLAIN WASHER AND RAWAL PLUG FOR FIXING JB & lIGH1"!NC SWITCH 8 NOS.

',-------------------------------,-------------------------------------,---------------------------,'

L

TYPICAL MOUNTING DETAILS OF STREET LIGHTING FITTING

STANDARD NO.

SS-EL -013 SHEEr NO. I 1 OF 1

1-

DETAIL OF PIPE CAP

~ / -8 i l -@

t~ . .J ~~. -@ .., --@

DETAIL-C

LENGTH W s:.m SIZE OF LOOPING BOX

'f'*I"-"1 9mm DiA HOLE , . , ' / (TYP,)

PLATE WELDED ! -:0 POLE

~ .-@ DETAIL-B

'£[ ITEM NO,

LIGHT FIniNG TYPE

POLE POLE DASIG~ATIO(\ LENGTH

(MTRS.) (H)

PLANTING HEIGHT ABOVEk..,.LENGTH OF 0.0. & THK.

(~~~~~) GRO~~g(~pS.)r;-~~~-I~-~---~~~~-~;+, __ -'r(_fA_M,,-) -,-----1 (H4) (HS) ,H1) (H2) (HJ) (Hl) (H2) (H3)

, lOW HPSV 125w HPSv

410 SP-!2 8,0 1.50

2 150W HPSV 25CW HPSV

410 SP-42 10.0 1.80 ,

DETAIL 8 I r- 3 250W HPSV 400W HPSV

410 SP-S8 12.0 2.00

@

0 ; Tv.J I 'INL~' ': 01 \':

01 ' SI

100 THK. x 300 HIGH pee All AROUND

------& TO BE CCATED VI'T~I BITUMINASTIC WITH //" B:TUMINASTIC PAINT 'UP TO 300mm ABOVE

650 4.50 US 1 7511 ~ 4 3x5.40 88.9x4.85 7S.1x3.25

8.20 5.20 2.40 2.4°1139.7X5.40 114.3x4.S0 88.9x3,25

10.00 5.80 3.10 3·10116S.~X4.50 139.7>:4.50 114.3x3.65

Ffi'1I#l,/ MATERIAL TAKE OFF h! '

FO ' I , I ~~+~-!~ - .'. I 1:1 .: -~

'4 ' I <'~ 60Cx600 PCC

'. . I IrTBASE pee U6 gi .' I' '.: ,------@ "': ,

t j r': : 5SLm (:.) \, ~Imm,-® '[ .3'00.".3;0..... -@

NOTES: 1. /tLL DIMENSIO~S 'IRE IN M!WMmRS.

2. AFTER INSTALLATION THE "SSEM8~Y IS TO BE PREPARED, PRiMED ANCl Pt~r;TED IN

ACCOROA'ICE WITH THE PROJECT PAINHjG SPECflr-ATlOI'<.

3. UGHT FI11lNG mlNG O~AIcS TO BE FURNiSHED BY SITE.

4. EARTH~NG TERM~NN.. ARE LOCATED ~L\M[ffiICKLY OPPOSITE.

5. ALL NUTS, BOLTS AXO WASHERS SHAll. SE GALVANISECl AND Z:N::: PASSIVATED.

6. MOU~'TIr,G Cl[TAICS OF COf<1R<JL GEAR BOX AND LOOPING BOX REFER INSTALLAnON DETAILS,

7. ALL SHARP EDGES AND BURRS SfW.l 8E R[MOYEi).

8. POLE SHAL~ 8E f.!ADE fRO", TUBULAR STEEL PIPES SWAGED AND WELDECl CONFORl-.!ING TO

JESIGNArION AS MENTIONED IN ABOVE fABLE- ftS 15-2713 (PART III) - 1980.

ITEM NO.

2

3

5

6

7

DESCRIPTION

PIPE CAP FOR STREET ~ICHTING POLE

40'11m DIA PIPf WE".lDEO TO C~.P

STIFFER PlP.TE

SiREET L~GH:ING POLE (REFER SElECTION TABLE B~LOW)

2.5 Sq.mm. pvc FLEXIBLE W'RE

STREET L:GH-:1NG LOOPING BOX

CABLE GlAND

8 80 N8 G.1. PIPE "OR CABLES

9 250 x 250 x 6mm THK. M.S. BASE PLATE

10 BRICK SOLlt>-:C (SIZE 23:)xl15y.75mm)

11 Ml0 x 30mI':) LONG FULL THREADED SOLT

12 50x8mm THICK G.1. STlW WELDED TO PQLE

13 Me x .}Ornm LONG THREADED SOLT, NUT & WASHER

14 M10, NUl WELDED TO L~GH;ING PO:...E

15 PLAIN AND SPRING w/tS>-lER SUITABLE FOR '<110 BOLT

1$ WiD fULL nmEAC>(o SOL, 40mm LONG

9. DOIJ8~E ARM SHALL BE ErrdER AT 180' OR 30' AS PER THE LOCATION Of THE UGHT.NG FITTING & SITE REOLlIRD.lENT.

QUANTIW REMARKS

1 NO.

1 NO.

1 NO.

AS REQUIRED

1 NO.

2 N8S.

AS REQUIRED

1 NO.

15 NOS.

eNOS.

2 NOS.

4 NOS. E"ACH

2 N8S.

2 NOS. EACH

2 NOS.

..J

L

STANDARD NO. TYPICAL MOUNTING DETAILS OF SINGLE PHASE SOCKET OUTLET ON HANDRAIL SS-EL -015

NOTES:

SIDE VIEW

WELDED

AlI.::::J ALT.-2

ALTERNATE ARRANGEMENT FOR FIXING OF BRACKET TO MID RAIL POST

DETAIL-'1'

1. ALL DIMENSION ARE IN MM.

3

2. DRILLING OF fTEM :> A~D 7 TO BE DtTERM'NEO BY FA8RICA10~ 1"0 rHE SOCKE.T OUrLET AND JUNCTION BOX.

3. JUNCTION BOX, RECEPToICLES ANS ACCESSORIES SHAUl BE CALLED UP ON THE RELEVANT L.\,YOUT DRAWING

MATERlAl LIST AS REquiRED.

'" ALL CAlllE AND GLANDS SHALL CALL£D liP ON DISTR!BUTION BOARD SCHEDULE.

5. AffiR FASRICJI.TION THE ASSEMBLY IS TO BE PAINTED WlTH iWO COATS or ANTI-CORROSIVE PAINT ANO TWO

COATS OF EPOXY PAINT.

6. ALL NUTS, BOLTS, WASHERS SHALL BE GALVANiSm 0'1 ZINC PASSIVA1ED-

7. RECEPTACLES AND JUNCTlCN BOX SHALL BE CERTlflEO fOR T~E HAliIRCO'JS AREA IN WHICH THEY ARE TO

BE LOCATEll.

ITEM NO.

I.

2.

3.

•• 5.

6.

7.

SHEEr NO.

FRONT VIEW

FLEXIBLE WIRES

JUNCTION BOX ---, ,--,-'-, . r!:::r::-r!:::r::-r+:c;-, I

E '

~;e:rl FROM PREVIOUS JU~~CnON BOX

TO NEXT JUNCTION BOX

WIRING DIAGRAM FOR JUNCTION BOX TO RECEPTACLE

MATERIAL TAKE-OFF DESCRIPTION QUANTITY

SMALL POWER SOCKET OIJTLH AS REQUIRCD

JliNCTION BOX WITH TERMINAl Bl.OCK AS REQUIRED

50 ~ 6mm THK. (LENGTH AS ~EOUiRED) MS FlAT ~OR .3 1.{j""S. FIXING rOil POWER SOCKO OUTLET

M6 " 40mm LONG ~S BOLT WITH NUT & WASHER FOR 8 NOS . FIXING OF "U:-JCTION 80X ON 8RACKEi

PLUG TO surr SMALL PowtR SOCKET OUTLET AS REQUIRED

Ml0 '1/ BOLT OF SUITABLE TO MD HANDRAIL POST WITH 2 ~OS. fl-oREftDED BOTH THE SIDE W'TH NUl. LOCK NUT & WASHE"!

50 x 6mm TclK. (l.ENGTH AS qEQUiRtD) MS flAT ~OR 2 NOS. FlXING JUNCTION BOX

OF 1

REMARKS

',------------------------------r----------------------------------,-------------------------,,

L

TYPICAL DETAIL OF ARRANGEMENT OF FLOOD LIGHT MOUNTED ON

PLATFORM/WALKWAY

z------------------------------------------------------------------

TO SUIT CONTROL GEAB.~QX F[fING /'ElQEO

I /

)---------------------------------------! I

1------1 - ---------T

li't ® I I , , , , , , .. ,

8- i

z

- ------)

, , , , , , , , , _~ CONTROL GEAR

BOX

STANDARD NO.

SS-EL -018 SHEET NO. I I OF I

150 r-- '--

"'1 I I , , , , I WELDE9

~

! / I / , ' ,

iIIII 50 mm MINIMUM

VIEW 'X'

...lQQ.., i 100

Fl()OD_"2HI ' , ~I 8\ \ J!(i --FiniNG -~ I

=' I, \\=='=j"h--.--' = --,-1-

_I\:-l-~

..... ~

_ I '" ,mflf'T-v-'

;~ i =

dl'

ec'

DETAIL 'A'

NOTES: 1. All illMENSIONS ARE 1"1 Mllll~ETFRS.

®--

, '-'--' I -,

\. , , / ,--_' _+1 -II----po:<---,I

\ 0/ ", \ INCOMING CIRCUIT CABLE ~ ~ 'NCOMII\!G CIRCUIT CABLE

FROM CONTROL GEAR BOX ,~ 300 _ 'rRQM CONTROL GEAR BOX , ,

FLEXIBLE C~Rcun CABLE , , -- 650 \ ---'

FLEXIBLE CIRCUIT CABLE VIEW 'X'

MOUNTING TYPE-BMI Q

MATERIAL TAKE-OFF

ITEM DESCRIPTION QUANTITY REMARKS ~JO.

1 CABLE GLAND (SIZE TO SUIT CIRC:JIT CABLE) AS REQUIRED

2 50 x 50 x 6mm THK. 650mm LONG M.S. ANGLE 2 NOS.

3 300 x .300 x 6rnm THK. MILO ST~EL FLAT AS REQUIRED

4 50 x 6mm THK. MILD STEEL F~T (LE.i\GTH 10 SUI1) AS REQUIRED

5 M',O x 50 LONG M.s. BOLT WITH NUT & WASHER AS REQUIRED

6 3 mm THK. KICK PLATE (SIZE TO SUIT AT SrrE) AS REQUIRED

2. AFTER INSTALLATION THE ASSfM8~Y is TO BE PREP,oRED, PRIMED AND "IIINTEO.

L

STANDARD NO.

SS-EL -019

TYPICAL MOUNTING ARRANGEMENT OF FLOOD LIGHT MOUNTED ON STEEL/CONCRETE COLUMN

SHEET NO. OF 1

(/)1 :

/

FLEXIBLE C:RCUIT CABLE ,-------

/ j FLOOD UGHi

FITTING

,;'lOOD LIGHT FIXING 8RACK~

DETAIL 'X'

-~"-~~,_ BRACKET ANGLE

WELDED

.~.

'-.", ____ BRACKET F:XED WITH ANCHOR

MlO---80LT WHE~ FIXTL:RE IS MOU~TED ON CONCRETE COLUMN

"~~ b+D~. [7"" A",ILL _'YL'

!-______ --'CONTROl GEAR BOX (FOR FLOOD LIGHT)

",\4, ---di-'F ,

o , 25 300.. 25 ~-t---""=--."TT"-- I r 1---- ,

l

--0 6Nos.-12¥!i HOLES SLJITABlE/

FOR /VilQ ANCHOR BOLT (TiP.)'"

BRACING ANGLE / ~~~~~~~~.- 1,'_' WELDED TO BRACKET

INCOMING CIRCUIT CABLE

STt"LL COLUMN OR --CONCR£Yt COi::UMN

I

o o U)

1--

-0 -_.-YI!J 250 300 400

, fIT ... + ... +

': \:"'. ,

c........'.TC+/ill--'

SIDE VIEW

HOLES FOR MTG.

GC::AR BOX (HOLE

NOTES:

I+il+

--150: ...

'15 :?SI -+r-+H'i;

I

TO SUT~~

1· j J' I \ - ,- ",:. Ifi -, r, ,_', 0, ''j~c ''F==*~ . '"S. ~i ,'! .

CCNTROl/ \_} 2rnm ¢ HOLES FOR MTG_

¢ TO SUIT) DETAIL 'y' BRACKET --:0 WAlL/COLU;'1~

1. All O:MENS:ONS ARE IN MIl..LMETERS.

2. ArT[R INSTALlAmt-; THE ASSEMBLY IS TO BE PAINTED Wml ,'110 COATS or ANTl-CORROSf1[ PAINT

AND HlO COATS or EPOXY PAINTS.

ITEM "0,

2

3

4

5

6

MATERIAL TAKE-OFF

DESCR:PTION

50 • 50 x 6r'lm TI-<K. M.S. ANGLE (AS PER OETAll-'X'

300 x 300 x 5mm THK. MILD STEEL PlJITE FO" FIXING FLOOD UGHT FITT~NG

50 ~ 6mm THK. MIL~ srn:t F;,A[ (AS PC? O(TAIl-Y'

M10--50mm LONG BOU WITH ~OCK NlH &: WASHER FOR FIXING FlOOO LlGH:- FiniNG MlO-68mm LONG STUD wnH NUl & LOC"; WA...'-il-<ER FOR FIXING BRACK~r SAClDLE CLfAT (TO SUIT CA8LE SIZE) WITH SUITA8LE SIZE FIXING ANCbOR SOL T$ LOCK WASHER 7 MJTS.

0: o

"" ,

-! 0: if>' "'- :

j

WE,-DED

FLEXIBLE CIRCUIT C/',8LE

CONTROL GEAR BOX (FOR Fc..OOD LlG~T)

~--,--g~§~-~---~~!~~Q_--~!Q_--SUIT CIRCUIT CABLE)

~,~__ STEEL COLUMN OR "------- ---------------------_.

CONCRETE COll)MN

INCOMING CIRCUIT CABLE

QUANTITY REMARKS

A-.S !'lEQUIRED

1 NO.

2 r~cs.

10 "os.

AS r!EQUIREO

r,-__________________________ -, ________________________________ ,-______________________ -,'

L

STANDARD NO. TYPICAL MOUNTING DETAIL OF 1 NO,

FLOOD LIGHT FITTING SS-EL-020

01--' "',

!Tt

0 01 -<0

0: co 0 co - !

0 0 0 N

@ .. (2) 0

0 I '" <:) ro

'" In

~t I

NOTES:

c ,t: -T I I

I-

t I-I

I I

I-I

1 I-

TO 8E FIXED WITH NeTS

AND BOLTS (DETAIL BY SITE)

3Nos-:-2.5 Sq.MIl"' FlEXIBLE

WIRES TO fLOOD LIG~TiNG FTC,

1 t 4.3mrr> DIA PIPE

(.3.65mn) 1+-11<.;

r d8uLAR PO,--E

139.7mm OIA PIPE (450tnm THK)

1M.100m D1P,\....PjtE (450rnm THK.)

3Nos-2.5 S!l.mrn FLExiBLE

WIRES TO FLOOD UO...;11NG FTG.

, .4 DETAil'S' ~W .\ II

.. \;j I I

, r~~ .. -~ i' '-<- .

, ,

J DnA!L 'c'

,

CONTROL GEAR BOX FQi:( FLCOD UGHHNG fiTTING CABLE GLAND (TO SUIT

C:RCuIT CABLE)

10 aE" COATEO WITH ~ 8iTUM1NAsnc PAiNT UPTO

300 ABOVE FGl

£OOxoO'L ~rn BASE pee

1~90MfNGlQ~T90~N(; C:RCUIT CABLE

300:.::300x6rnm THK, - ---M,S. BASE PLATE

SRJCK SOUNG

1. UGHI:NC flTflNC F1X:NC DElAILS TO BE flIRNISH[!) !':JY SITE.

2, FARTH!NG TERMINAlS ARE LOCAT!Il OIAMETRI~i' OPPOSITE,

3. ALL Nl}TS, BOLTS AND WASt-IER SHAll BE GALVANiSm OR ZINC P,ISSIVATED,

-4. MOUNTING DErAilS Of CONTROL GEAR 80X &: LOOPING BO~ REFER INSTAlLATIo'J DETAILS.

5, All. SHARP EDGES AND B!JRRS SHALL BE REMovm

6, POLE SHAll BE MAOE flIOM TU8'JLAR SIlEL PIPES SWAGED IWD WELDED GONfORM:NG 10

DESIGNATION 410T?-60 AS PER 15-2713 (PART II) - 1980,

ITEM NO.

I I I I I

2

I 3 I I

I I 4 I I

5

G

7

a , '0

SHEET NO. I 1 OF 1

0)

,0

DETAIL 'A'

@

ev o @ o 0·····

F , ,

'll: __ .:J;..-t I

, I

~ I

CON'!'ROL GfI'R eox FOR ---" - , FLOOD LIGhTING FiTTtNG

H1E:J mm 1)JA PIPE -

(4.50mm THfC) 3N::JS-2.;S Sq>~nr1"1 FLEXt9~..E

WIRES TO FLOOD LlGrlTING FTG,

LOOPING 80X

,,;::<cun CABLi:

DETAil'S'

sf-- TLiBULAR POLE -+-I- NU~ WE~DEC TO POLE

, k. or tARTHJNG : ",' 4' TERMINAL-

-L@ '"'i-

DETAIL C

MATERIAL TAKE-OFF

DESCRIPTION QUANTITY

STREET l;GI--G1NG lOOPING BOX , '0

Mil x 40mm LONG 80LT wm, NUTS &: PI.AIf; W,\SH[R FOR AS REQUIRED Fl~I~,G fLOOD LIGHT EARTHI~G TERMINAL M1G-40mm LONG BOLT WITH NUTS. 2:.1QS, SPRING WASHERS &. 2Nos, PLAIN WASHERS

, NO.

75rnrn NB C.I. PIPE SI.EAV[ 2 NOS,

M,$ PIPE CAP 10 SUIT 1114,JOmm OIA PIPE 1 NO.

300 ~ 300 " 10rrm THICK M.s. PLArE , NO.

MlO-40Mm LONG BOLT TO Bt, usm AS SlOWER 3 NOS,

fAl 0 ~ 40mm LONG BOLT W,TIj LOCK NUT TO BE USED AS :, 1'<05. HOLDER M8 40mm LONG SOlT WITH NUTS' &: PLA:N WASHER FOR 8 NOS. FIXING OF CO.vrROL GEAR BOX & lOOPING BOX

BP.AC"E1~CLAMP MADE OUT fROM 25x6MIT' THK, M.S. flAT FOR ,,-,XI 'G OF CONTROL GEAR BOX & lOOPING BOX 4 NOS.

REMARKS

-'

r,-______________________________ ,-____________________________________ ,-__________________________ ,,

L

STANDARD NO. TYPICAL MOUNTING DETAIL OF 2 NOS.

SS-EL -021 INDUSTRIAL TYPE FLOOD LIGHTING FITTING ~--~S~HE~IT~N~O.---,----~OF~I----1

t

~LOOD LlG'"n FITTING

DETAIL 'At

114.3mm DIA PIPE (3.65mm THK.)

TUBULAR POLE

139.7mm DIA PIPE

(4.S0mm THK.)

o o o o

165. ) mm DIA PIPE

(4.50mm THK.)

Fel

LOOPING OOx

CONT~Ol GEAR BOX FOR FLOOD UGHTING FITTING

CABLE __ ~~!':!Q ___ ~!g ____ ?_~}_~ CIRCUIT CABLE)

tCIRCeIT I

0"" CA8LE ~: "1=i==A TO 8£ COATED WITH ~ -r-- ~i: ........_.---------SITUMINASTIC PAINT UPTO

o 00

, '" 0' gl@-

LL 01 01 NI

8! ',i -/ 300 ABOV~-_ FGL.

"" '

· · , '

· .

· ,

60Q_~600 Q:l.f}J __ BAst ;:;cc

INCOMING/OUTGOING Cl~CUIT CABLE

300x300x6mm THK. M.S. BASE PLATE

BRICK SOLING

NOTES: FIXING DETAILS TO BE FURNISHED BY SITE,

2. EARfHING TERMINALS AHE lCCAfW DIAMETR!CAllY OPPCSffE.

3. :{ Nos. 20mm ;l HOLtS lOCATFD lllAMfTRirAllY OPPOSrTf.

4. MOUNlII>lG DElI1JLS OF GONrROl GfAR BOX & lOOPING BOX TO BE FIXED BY SilL

5. fOR INCANDESCE~T LAMP. FLEXIB~ CABLE TO GO DIRECTlY TO fIlTING.

6. ALL SHARP EDGES AriO 8URRS SHAU BE REMOVEO.

7. ALL NUTS. BOll'S i\N~ WASHER SH./ILL 8£ GALVANiSm OR ZINC PASSIVAiE~.

8. POLE SHALL 8E MADE FROM TIJ8UlAR STEEL PIPES SWAGED AND WELDED CONrORMIt-;G TO

DESIG"lATlON 410TP-60 AS FE"! IS-2713 (PART II) - 1980.

ITEM NO.

1

2

.>

, 5

, 7

• 9

TO SUIT

3Nos. 13mm ¢

"MOUN-riNG HOlES'"

WE,-OED

.-- ""'"

~2~O~m~m~.~H~O~l~E~S~~~~ FOR CABLE E~TRY

TU8ULAR POLE

DETAil 'A'

MATERIAL TAKE-OFF

DESCRIPTION

STREET L'GH'ING LOOPING SOX

75mm NB G.1. PIPE SLEAV[

M.S PIPE CAP (TO SUIT ~ 114.30.-nm DIA PIPE)

100 x 50 x 6r'lm THK. M.S. CHANNEL (LENGTH TO suIT)

30G x 300 x 6mm THICK M.S. PLATE

50 x Smrn ,HICK M.S. FLAT (LENGTH TO suIT)

Ml0 30mm LONG BOLT WITH NUl, WASHER fOR fiXING FLOOD UGH"f

Ml0 BOLT (10 BE USED AS STOPPER)

Ml0 BOL' WITH LOCK NUT (TO BE lJSED AS HOLDER)

8

QUANTITY REMARKS

-

2 ~OS.

1 "'0.

AS REQUiRED

2 NOS.

AS REQU!RED

AS REQUiRED

3 NOS.

5 r-<os.

',----------------------------,--------------------------------,------------------------,'

L

®

'I'

AS PER ACn1A~ DISTANCE

TYPICAL MOUNTING DETAILS OF FLAMEPROOF FLUORESCENT

LIGHTING FITTING

t A

MOUNTII'G HEIGHT

STANDARD NO,

SS-EL-024 SHEET NO, OF 1

-0-. , , , , ,

®-'eh~c=', ~~,,",¥="'-®

_J25_ TO SUIT _~L_

SECTION 'A-A'

KNOCKOIJT (TiP.)

~EPROOF FLUORESCENT i.iGHTlhG FITTING

.--@

,

------G9LAMEPROOF FLUORESCENT

DETAil FOR SUSPENSION MQUNTING MOUNTING TYPE : SOl9

600 ; . AS PER ACTUAL --j DISTANCE $

® ri"'B /' ~.

'. , i { :m

'I '18 -(1)-"-..L.>-/- 1 F~£)ifqJor V:"UORESCENT , / ----- -- .---

I 0 ':::""f :JGh""IIG FITTING ~ B ' I I -.FU.MEPROOF CABLE

i GLAND (TO SUIT

CIRCUIT CABLE , I , 1 , I

MOUNTlNS. HEIGHT

DETAil FOR ROOF ITERRACE MOUNTING MOUNT!NG TYPE : BM9

--0' / ' /

/-0

___ /- UGI-ITIr\G FITTING

MOUNTING HEIGHT

SECTION '8-8'

-0 /--®---~B

-@ As PER ACTUA0. I 7 DISTANCE

FLAME?ROOF FLUORESCENT: UGHTING FrfllNG

- _ __.. FLAMEPRCOF CABLE GLAND iTO SUITCIRCUli CABLE

DETAIL FOR BRACKET MOUNTING MOUNTING TYPE = 8M9

MQUt>;TING. I-IEIGHT

. .", '" ." ·',;.'C' ~"'~'~'cl' ;;'::'·7';;·¥·~~'·';':~~;~Z~~~;":-~1-~;rl·ELQED i>'OUNTING CLAMP Of

MATERIAL TAKE OFF -

QUANT!TY .___------ LIGHTING FITTING ""'-c,.:::lTI:- FLAMEPROOf- F~JJOR~SCENT __ .- UGHTING FI'i"ING

1,,10UNTI'lG HEIGb~

DETAil FOR CEILING MOUNTING MOUNTING TYPE : CM9

NOTES:

ITEM NO.

1

2

3

4

S

e

7

8

DESCRIPTION

FLAM(PROGF ~UNCTICN BOX W!m T[RMIN,\L BLOCK.

ISA 50 x 50 x 5mm Tl1":. (LENGTH TO SUIT)

BRACKET ~ADE )I~~"T FROM )SA 75 x 75 x 5mrn THK. ILENGiH TO SUII _

SAw OLE/CLEAT ALONG WITH SUITA8~E SIZE OF FIXING SCREWS. TO 51)IT FOR CIRCUIT CABLE. 1.18 68mm LONG STUD ANCH8R wnH G~~T & LOCK WASHER FOR JU~Cf!CN BOX FIXI~C -:-0 CEIUNG WALl.

MlOx40mm ~ONG BOLT NUT & PLAIN WASHER.

M10 68mm LONG STUD ANC~~I!WlTH NUT & LOC": WAShER FOR FIXING OF ISA TO CEIUNG IA~L

ISMC --150 (LENGTH TO SUIT)

REtv1ARKS eM SM 8M

1 NO, 1 NO, 1 NO.

AS REOD AS REOD -

- - AS REOD

AS REQD AS REQD AS REOD

2 NOS. ::: NOS. 2 NOS.

2 NOS. 4 NOS. 4 NOS.

2 NOS. 4 NOS. 4 NOS.

- - AS REOD

ELEVATION (WITHOUT COVER)

,

~ ,

PLAN

NOTES:

L

STANDARD NO. TYPICAL DETAilS OF LOOPING BOX FOR

STREET LIGHTING FITTING SS-EL -031

HINGE"

J. 2MM <P MOUNTING - HOLES TyPICAL,

(fr"

(i)--

CD 0-

® @-\

SHEEr NO.

- l.UL -. ,

, \

CABLE GL,NDS TO SelT CABLE SIZES INCOMING jOUTGOING CABLE ~--....

SIDE VIEW

MATERIAL TAKE -OFF ITEM NO. D;::SCRIPTION

I. 2 MM TH!CK SHEET STEEL ENCLOS'JRE WITH COVER

2 6 NQ, 30A TERMINAL CONt<ECTOR SUITABLE FOR TE~MINATiNG Of 4C~j6 SQ, MM CABLE (CHANNEL MFG.)

J. 4A, HRC FUSE

4. M4x20 MM LONG ROUND IlEAC [ARmiNG SCREW WITH 2 No. P~N WASHE.R & 1 No. SPRING WASHER.

; 25x3 I.'Mx70 MM LONG MS FLAT W,TH 12 !AM ¢i HOLE WELDED TO ErnOSUR[ lOGS ,OK MOUNTlOlG

6. 3Cx2.5 SQ. MM pvC flEXIBLE WIRES.

. 7. :20 MM " -- 25 MM LONG G.I. PIPE WELDED "fO lNCLCSURE .

8. M1Dx40 MM LONG BOLTS WITH NUT LOCK NIJT & PIJ\IN WASHERS FOR ENCLOSURE FIXING,

h'OUN'ING C~ANMEl SUITABLE FOR 6 No. JOA, TERMINAL CONNEcrOR LEN(;TI< f.S REQUIRED)

QUANTITY

1 ~;o.

1 No.

1 Ne.

2 f;o.

4 No,

AS REOUIR[C

1 ~o.

4 No.

1 t-;o.

OF 1

REMARKS

NOTES:

L

STANDARD NO. TYPICAL DETAILS OF DUST !WEATHERPROOF

ROUND JUNCTION BOX SS-EL -032

SUITABLE FOR 19¢ /CONDUIT / CA8~E G!.ANO

"

/ /

, I

VIEW WITH COVER ROMOVED

/ /

JUNCTION WITH PLANE COVER SECTION 'A-A'

,-{D

,-nXING LUG.

I A

nEM NO

I.

2.

3.

4.

5.

SHEEr NO. 1 OF 1

, , - -...I

JUNCTION WITH DOME COVER SECTION 'A-A'

MATERIAL TAKE-OFF DESCRIPTION Ql.:AN1HY R~MARKS

JUNCTION 80X (CAST AlUMINIUl.1) AS REQiJlREO

30A, 4 WAY, T~RMINAl BLOCK 1 No.

B MM ~ONG BRASS SCREW WITH 2 No. PI..AI~ AND SP~iNG WASHER fOR INTERNAL .lIND EXTERNAL EARTHING TERM,NAL 2 No.

D;SC lYf'E NWPRENE GP,SKU. 1 No.

COVS'! nX:NG G_'_ SCREWS WITH WASHER 4 No.

r

STANDARD NO. TYPICAL MOUNTING DETAILS OF SINGLE PHASE SOCKET OUTLET ON HANDRAIL SS-EL-033

SHEET NO. I 1 OF 1

c- -"'- :'" , 'r"_32 ,

'" NAME PLATE '" ~, [§E $., -CD _ .. --":

" ~.:,~~.-.- 'J.! , -(j) .-" .~ :tlJ m '~CD--'-'-

§ --+ +- -- --' ,0 )-- , ,--~,- -0 ,

1C!:lbltl TO BE '--~ ® i-Ixm W THE

ENCLOSURE WI1H II> I SCREW.

L... 10lll.$Q ---..- -----Q) .-. /...--®-O~ON

~----'-. ... / '.

f='-. ""([)

[§E 'd' l!i FIXING LUGS FOR V L:_6.~LSg-------.!

6--ivH;;Oi[(--eO[J<S.

'" <1> -

-® L.. ~65_ --L.." ' --FRONT VIEW SIDE VIEW

MATERIAL TAKE -OFF ~TEM NO. DESCRI~TION QUANTITY REMARKS

1 5 MM DlA M/C SCREWS. 4 No.

2. 5 MM DlA. EARTHING SCREW W:TH 2 "0. Pu\.IN 1 No. t No. SPRING WASHER.

J. 16A, 2 POLE, ON-OFF ROTARY SWITCH. ~ No.

4. lOA, 1¢ AND EART>-i METAL CLAD SOCKET OUTLET 1 No.

5. 3 MM ,DIA Mle SCREWS I) No.

6. 14- SWG MS BOX WIl:-i COVER FOR MOUNnNG OF swnCH

~ No. AN:l SOCKET OUTLET

) 14 SWC M.S. SHEET nxEO TO COV[R PLATE rOOM INSIDE

j No. FO~ MOiJNTING OF SOCKET

NOTES: 8. 19 MM DIA KNOCKOUT fj No.

1. SIMilEq ARRANGEMENT ('AN BE EMPLOYfD FO.'I 20A, SP & f, 30A, TP & E, SO WITH 3011, DP & 63A, TP SWITCH RESPECTIVELY.

2. EPOXY BASED PAINT OF SPECIFIED SHADE SHAll BE APPLIED. 3. R[AR E:'lGRAVlO PERSPEX OF LAMlrjATEO PlASTIC NAME PAUE WITli APPROPRIATE

INSC"WllON SHAlL BE fIXED ON COVER WITH OR SUITABLE AOHESNE.

L

STANDARD NO. FRONT SHEET SD-EL-l0l

SHEET NO. I 1 OF 1

M SCELLANEOUS DETA~LS

~ARTH ~~G

STANDARD NO. DRAWING INDEX SD-EL-102

SHEET NO, I I OF 1

SR. DRAWING NO. DESCRIPTION NO.

1 SC-El-101 FRONT PAGE

2 SC-El-102 DRAWING INDEX

3 SD-EL-103 GENERAL NO'ES - EARTHING

4 SO----EL ---103 GENERAL NO'7ES - EARTHING

5 SC-El-104 ELECTRODE FOR EARTH:NG SYSTEM

6 SO---El---105 EARTH ELECTRODE iN TEST PIT

7 SO-EL-106 ;;:ARTH PLATES FlXIi\jG DETAilS

8 SD-EL-107 TYPICAL EARTHING r-OR MOTOR

9 SO-El-l0B TYPICAL ARRANGEMENT FOR TRANSFORMER EARTHING (NEUTRAL SOLIDLY EARTHED)

10 SO-EL-109 TYPICAL EARTH CONNECT~ON FOR PUSH BUTTON STAT:ON

11 SD-EL-l10 TYPICAL EARTH CONNECT;ON FOR STREET LIGHT POLE

12 SD-El-l1 i (SI-!. i Or2) EARTHING OF TANKS, VESSELS AND SPHERES

13 SD-EL -1" (SH,20F2) EARTHING OF TAf'..!KS, VESSELS AND SPHERES

I" SO-El-12 t:ARTHING or TANKS, VESSELS AND SPHERES

15 SC-EL-112 TYPICAL EARTHING OF CABLE iRAY AND ELECTRIC MOTOR

16 SD-EL-113 TYPICAL EARTHlt-.)C ARRAt"CEMENT FOR PROCESS EQUIPMENT

17 SO-EL-114 ~ARTHINC/80NDiNG OF PIPES AND ~IPE RACKS

18 SO-EL-114 eARTHING/BONDING OF PIPES AND ~IPE RACKS

19 SD-EL -115 (SH.l0F2) TYPICAl. EARTHING ARRANGEMENT ···WAGON

20 SDEL 115(SH.' OF2) TYPICAL E.A'!~THING .ARRANGEMENT -WAGON

21 SD-EL-116 ~ARTHING- iRUCK LOADING PLATFORM

22 SC-EL-117 FE['.;CE GATE EARTHING (TRANSFORMER YARC)

23 SD-EL-118 EQUIPMENT EARTHING SCHEDULE

24 SD-El.-119 TYPICAL DETAILS OF DIRECTLY BURIED EARTH ELECTRODE

25 SO ··EL ··120 TYPICAl. DETAIl.S OF Pl.ATE E"ARTC-I ELECTRODE

26 SO ··EL ·121 TYPICAL TRANSFORMER NEUTRAL & 80DY EARTHING CETAllS FOR RESISTANCE GROUNDED SYSTEM

27 SD-E.L-122 TYPICAL TRANSFORMER NEUTRAL & 80DY EARTHI~C DETAILS FOR RESISTANCE GROUNDED SYS1"EM

28 SD-EL-123 TYPICAL EARTHING DETAILS OF H'J/LV SWITC'-IBOARD PANEL

L

~,----------------------------.---------------------------------,-----------------------.'

L

STANDARD NO. GENERAL NOTES-EARTHING SD-EL-l03

SHEET NO. I 1 OF 2

1 ENTIRE EARTHING INSTALLATION SHALL COMPLY WITH THE REQUIREMENT OF IS-3043:1987 INDIAN ELECTRICITY RULES OISD REGULATION AND OTHER APPLICABLE STATUTORY REGULATIONS AND SAFETY CODES IN THE LOCALITY OF THE INSTALLATION.

2. MAIN EARTH LOOPS SHALL BE OF 75x10mm G.1. STRIP ALUMINUM CONDUCTOR CABLES SHALL BE USED FOR EARTHING OF MOTORS, LOCAL CONTROL STATION ETC.

3. PIPE ELECTRODE SHALL BE USED FOR EARTH ELECTRODES, THE EARTH ELECTRODES SHALL BE KEPT SUFFICIENTLY AWAY FROM STRUCTURE TO CLEAR FOUNDATIONS, FOOTING ETC. SPACING OF MINIMUM 6 METERS SHALL BE KEPT BETWEEN ADJACENT EARTH ELECTRODES.

4. RESISTANCE OF EARTHING STATION SHALL BE MEASURED AT EACH EARTH ELECTRODE AFTER ITS INSTALLATION BY MEANS OF AN EARTH MEGGER. RESISTANCE OF EARTHING GRID SHALL BE MAINTAINED WITHIN 1 OHM (BY ADDITION OF EARTH ELECTRODE IN PARALLEL, IF NECESSARY).

5. THE MAIN EARTH LOOP (MEL) IN PLANT AREAS SHALL BE GENERALLY ROUTED UNDERGROUND EARTH CO~IDUCTORS TO INDIVIDUAL EQUIPMENT SHALL BE RUN ALONG WITH POWER AND CONTROLI LIGHTING CABLES. WHEN EQUIPMENT ARE LOCATED AWAY FROM M.E.L. , SUITABLE SUB LOOPS MAY BE RUN UP TO THEM FOR DERIVING CONNECTIONS FOR INDIVIDUAL EQUIPMENT.

6. ALL ELECTRICAL EQUIPMENT SHALL BE EARTHED AT TWO DISTINCT POINTS WITH EARTH CONDUCTOR.

7. PROCESSI UTILITY PIPE RACK COLUMN SHALL BE EARTHED AT EVERY 25 mtr. AT NEAREST AVAILABLE EARTHING NETWORK AS PER IS : 3043-1987.

8. ENTIRE EARTHING SHALL BE TESTED FOR CONTINUITY BY ELV TESTER AFTER INSTALLATION.

9. THE PLANT EARTHING SYSTEM SHALL ALSO BE USED FOR STATIC EARTHING OF PROCESS EQUIPMENT, PIPELINE EARTHING ETC. WHICH SHALL BE DONE BY USING 75X10mm THICK G.1. STRIPI SIZE AS REQUIRED.

10. 75x10mm THICK G.1. STRIP SHALL BE USED FOR ENTIRE EARTHING NETWORK. ALL JOINTS SHALL BE WELDED EXCEPT AT EQUIPMENT ENDS, WHICH SHALL BE BOLTED.

11. ALL STRUCTURE STEEL WORK TO BE CONNECTED TO EARTHING SYSTEM,

12. FOR CONDUIT WIRING OF LIGHTING CIRCUITS. FOR EARTHING OF LIGHTING FITIINGS, JUNCTION BOXES 14 SWG

13. THE LIGHTNING PROTECTION SYSTEM SHALL BE DESIGNED IN ACCORDANCE WITH IS :2309-1989 'CODE or PRACTICE FOR PROTECTION OF BUILDING AND ALLIED STRUCTURES AGAINST LIGHTNING'.

14. EARTH SYSTEM AND LIGHTNING PROTECTION SHALL BE BONDED TO EACH OTHER TO PREVENT SIDE FLASH OVER, IF ADEQUATE CLEARANCE BETWEEN THE TWO SYSTEM CAN NOT BE MAINTAINED.

15. ALL HARDWARE SHALL BE OF STAINLESS STEEL.

16. WHEN EQUIPMENT DO NOT HAVE EXTERNAL EARTHING TERMINAL ELECTRICAL CONTRACTOR SHALL PROVIDE THE SAME ON EQUIPMENT. SIZES OF EARTH CONDUCTORS SHALL GENERALLY BE AS FOLLOWS:

STANDARD NO. GENERAL NOTES-EARTHING SD-El-103

SHEET NO. I 2 OF 2

FO -"I-k'N' C' A ; ("" ;>"10 SC'i~VL~ "; ":" i4 . E./I,RTHING SiZE

TYPE OF EQUIPMENT G.1. Al COPPER

MOTORS UPTO & INCLUDING 3.7 kW 8 SWG SOUD lCx6 SQ.mm -

MOTORS 7.5 KW TO 9.3 kW & WELDING RECi::PTACLES Wm('J;¢ WIR5: ROPE ICxl0 SQ,r;)m -

MOTeRS II kW TO 22kW ~ Ornm¢ WIRE: ROPE 1C~16 SQ.mm

MOTORS 30kW 10mrr¢ WIRe: ROPE 1Cx25 SQ.MiYl -

MOTORS 3/kW ~ 6mm¢ WIR5: ROPE IC;.:35 SQ.mm -

MorCRS ~5kW ~ 6mm¢ WIRE ROPE 1::::,,50 SQ.mm -

MOTORS 75kW 1 6mm¢ WIR~ ROPE lCx120 SQ.m'l1 -

MOTORS 132kW ~ 6mm¢ WIRE ROPE l(;x150 SQ.m:n -

MOTeRS 160kW i 6mm¢ WIRE ROPE 1::::;.:185 SQ.mm -

MOTORS ABOVE 160kW ,6mrr¢ WIRt:: ROPE - -

BUILDING COLUMN 50)(6 STRIP -

STORAGE TANK & HEAT EXCHANGERS 50)(5 STRIP --

lOADIf.lG RACKS 50x6 STRIP - -

PIPE RACKS, VESSEL & INSrRUMENTS ~ Omm¢ WIRE ROPE - -

LIGHTING, POWER & INSTRUMENT PANEL ~ Omn;¢ WIRE ROPE -

MAIN EARTH GRID/ LT & HT SWITCH GEAR 75)(10 STRIP -INTERCONNECTiONS/ POWER TRANSFORMER -

EHV & HV SUBSTATION 75)(10 STRIP -

rUSH BUTTO~; STAi!ON 8 SWG SOLID - -

STREET LIGHTING POLES j Ornn;'i\ WIR~ ROPE - -

UGHTING TRANSFORMER : 5mm¢ WIRE ROPE - -

, 'r"",: >,ii" r "'~O'" r< 1(' ~ I , 1"t /;;,o1',,1,'\ '- \)':::i"\/

ROOF CONDUCTOR 32x6 STR:P NA 25x6 STRiP

ROOF CONDUCTCR (ABOVE GROUND) 32)(6 STR:P NA 25x6 STRiP

ROOF CONDUCTGR (BELOW GROUND) 50x6 sm;p NA 50x6 STRIP

TEST UN~ 50x1Q STRIP NA 50x6 STRiP

PIPE ELECTRODES 65V!1 NB PIPE NA -

L

r.-____________________________ -. __________________________________ -. ________________________ -.'

L

NOTES:

STANDARD NO. ELECTRODE FOR EARTHING SYSTEM SD-EL -104

65 OIA N.8. G.I. PIPE MEDIUM

SHEET NO. I 1 OF 1

, ,

¢ l-:;j ,~~ '~ \\10 DIA HOLES TAPPED

. ',,75x'iO M.S. EA.RTHi~JG

PLATE WELDED TO PIPE

}.. -.~ 12 DIA HOLES ------

l

~~ cd "~

, ,

I /WELD

:yp~ -1

REMOVABLE CAP MADE Of M.5. PLATE WEI.DED TO 75 DIA N.S. G.I. PIPE

75 OIA N.8. 0.1. PIPE

d a d ,~

EARTH ELATE BEND \\' 10 SHAPE 0 WFtD

~/

~: I """ ~,,,,/ I : f / , , s: '-, _____ ~:'iOJl'__ _____ ,.J

,.-"

.J

IJ~i ~ " ~ '...~

-

G.I. PIPE

DETAI: 1

I. TI'E PIPE ASSEMBLY SHALL BE HOT DIP GALVANISED AFTER FABRICATION.

2. UN cESS STATED OTHERWISE ON PLAN DRAWINGS, ONLY TYPE -2 SHALL BE USED.

L

STANDARD NO. EARTH ELECTRODE IN TEST PIT SD-El-l05

SHEET NO.

500)(500x75 THICK REMOVABLE R.C.C. COVER SEE DETAIL I !

REMOVA8lE CAP SEE DE:NL3

860212. / _

GRO~ND LEVEL i= 4005Q <! ---r 210 -- GROUND LEVEL

~{~ ~~~~'~"~'/"~"'~:~{ 'TT77777'TT"??,~'~'

10 DIA TAPPED HOLES

CHARcm lAYER

BRICK WORK

NOTES:

l

=..:.-..=---",-"",,--= ~

""

BRICK iN LIME OR CEME~T

100x75 GROOVES ON FOUR '" /SiOESFOREARTHSI.RIPTNTRY

SEE DETAIL-2

C.i. £ARTH STR:P

'"GI. EARTHI~G PlATE 75,10 BENT TO SHAPE OF PIPE & WELD (SEE DETAIL -4)

_f--__ --''-L...L_~_+_' '---------.-~'.~ T[RNA:-E LJWEB.. OF CHARCOL OR COKE OUST AND COMMON SALT

~ , , , , , ,

d

1.,

r<==eeI

PAINTED SYMBOL IN REDON WHITEBASE'I,

HANDLE! + 1------... r -t ~ ~

65 DIA N.e. G.1. PIPE MEDIUM (ClASS 8) 30eO LONG--

JI

REMOVABc[ CAP MADE IOF MS PlATE WELDED' 10 75 DIA N.R G,i. PIPE 10:

, , ! _l

mmmmmmmmm mf1~!

U~ I ""'£AmR"', Hr. ITEL"EC"'TR"'O"'DcE" /

NUMBER PlATE FIX[~;~~L _ 1 ,.J I ~IA NJL TO TOP COVER G.I. PIPE

\\ 55 OIA ''-8 \ G I. PIPE

OCTAIL-~

,. THE PIPE ASSEMBLY SHALL BE HOT DIP GALVANiSm AFTER FABRICATION.

2. BRICK WORK SHALL BE DONE AFTER CO~PACTING THE SOIL.

OF I

L

NOTES:

EARTH PLATES FIXING DETAILS

~-

r f I ~ f-ffl-

,J Hl=t+

tt ~=-=-_[;;;~ ~~". ~. CONNECTION WITH GJ STRIP , DRILL TO TAP HOLES gF . 50,S AND BELOW (TYP.)

SIZE AS REQUIRED

i GJ EARTH PLATE

....... .,;' ...

-+---

L . ..'

L\'r----'-

.... "1

, d d "i , ' d d n,

TY PICAL : NST ALLAT! O~ 0: L'\ Q ,'I ~

STANDARD NO.

SD-EL-l06 SHEET NO.

METAL

iTO SUIT G.I. STRIP I PIPE

, /~;.I~ ;,i;"" '"

OF 1

1. WHERE FIRE P,QO'ING OF STEEL STRUCTURES AR, ENCOUNTERED lENGTH OF CARoON STEEL BOLT SHALl BE INCREAS'D FOR FIXING OF EARTH PLATE

2. ALI CONNECTIONS WITH EARTH PlATE SHAll BE MADE WITH GJ BOLT. NUT, SPRING AND PLAIN WASHERS.

L

NOTES:

. . . ,'. . . .. .

· . .' · ' . . · . ' .. '. . .' · '. ., . ' '. .. .' · ". '. .

· . · . · · . .. ' .' .". ." .. .

· '" . . · . .

",'.' . .~ . .. , . . .. · . '., .. .

.' . . . . . . · . . . · .... , . .... ." . .

· .. , . '. ,

· '. . .' . . .' . . , . . . · . .. .' - .., ,

· ..' : · . . · . . ' • .1 • • • • .' .~'. '.

· ." . · . · . . . . .

, . ~ '. .. · . .. . . · '. .' .. . · . . . · . .. . · . . .. :. . ; .. ' . .' . '. . · . "." · . " . · . " . .

'. '. 0 •

, . .' .. · .. -" . . · .' . · . · . . .. · '. . .. ". .. - . ". . ~"

· ."' . '. . . . . . . .- • 0 . :', .... : ...

· .' . . · .' · . ..." . · · . . . . ... .. :.": ' . .'. . . . .

" . . · , ,'. . · . . .. . " . . '

· - .' . . · , , , '.' . . ' .. .' . . ~. . .

o ' ". '.

· . '" . , .

· .. · . . . , '.. ' .' :. o. .. .

· . . . . " . .

STANDARD NO, TYPICAL EARTH CONNECTION FOR I---------------l

STREET LIGHT POLE SD EL 110

\

STREET LIGHT OR FLOOD LIGHT POLE

50MM WIDE x60X6MM THICK M.S. --------------------------------

T WELDED TO POLE FOR EARTH TERMINAT ON SEE DETAIL-1

10MM D A GALVINISED M.S. BOLT UT & SPRING WASHER.

TERMINAL CO~I~IECTOR

· '.-.... ~ '. . . . '. · "'.

. . . - . ... """"., ..

" . . · '. · . .... .

· . . . · . . . .....: : ," , · ~ .' · . .' .'

" . " · . . "',, .... ..' . . . . . · ..

o 0 0 , 0

. ' 0 0 • 0 0 · :. . . . . . . . · '. '. . .'

o , ', _.

.' .'" • • " •• '" 0 · . . . .. . . , ,0' •

· ..'" . . .,: .. . .

'. . . : ..' . , . . .

.. . · . .. . ••• • 'M_, ••• ,'

· . . '. · " ... · .' .' . . . . . '. ' · .. . · . ' .' . - .' . · . . .,'

· " ,. . , .. .' ' . .' '

· . .' . . · . . '. '. .'. . . , .., . · . · . · . · . . .' . '. · . . .' .. . · . ", .. . . .

. ,... .' . . . .

. ' .. . . '.:: ".' :,' , .' . " ,

.. . : . . ' · . . . • .. - " .. . . .' ',.

. . · " ' , . . · . . .. , · . . .

., o. •• • · . · " . . o '. "

•..... .. " ,.

LOi NI

: I

i lO!

10MM DIA GJ WIRE ROPE FROM \EAREST MAIN EARTH GR D OR FROM LOCAL EARTHII~G STAT ON SEE DETA L-2

\ !

N!

\ I 10 MM DIA HOLE , \

\ WELDED TO POLE

SHEET NO. 1 OF 1

. "'. '. . . · .

" . . . . .'. . . . . . .. . .. · . . . . · . .'. .

· . · . .... ~ ,., · ". ." " . ," . .. · . . . .

.. . . · . . o • • • • 0 • "

.: . · ." . . • i ....

.' " ··.0 . . .. · . . ." .. '. '. . · .' · .

" "0 o::~.,.· , .' o. ".

, ,.' : . ;.... . ....

• - 0 • · ... '. • • 0

. .,' · '.. : " . .'. . .

· '. · '. ." · . '.' .

· . ... ." . .' '''. ': '

.' . .

..: ... :','.:.

10MM DIA GALVINISED M.S. BOLT NUT AND SPRING WASHER

, . .' . . . . . '.

· . '. . · . ..' .. . .. · '. ' . · .' . .

· '. . "" , . · . . , '" ..

" ' . · .. · . .'. .. . ' .

• '.. '0 • • • .. • .'" ' · . .'

- . ' 0 · · ' '. · . . . · . .' . ., . - '. o • . ' •

• • • 0 · .' · . . '. 0 '.

, ! · . .,' . . .. '. .. · ".' · . · '. . · . · . . /

· . '. · . . . '" 0 .. • • .' . · " . · · .

, . . .' . .: :.: ...... :"

· . · ."' . . . · . .. · ' .. ' . '.. , .. : . ., .

· .

,

! !

i

, , i i , ,

· '. . ~ -+--.. : ..... .' '. I. ..., . .. .. ~'.'.-'. ~----+---~.-.. -'~'-+~

• •. .. L __ · '. . .. . . .,,'" .. · ; . .... .... . . . .

. . .' .' '. · . . · . .- ..- .. · . '. " .. ". . · '.' . .

. " . .' . .' ' . · .

: ... "0 ' .... :: · . . '.

• · .' · . . "

-. :. ' .. -.. .' · . . '. · · .

, '" . . . . '.. .' ,'. . ," .'

, .' 0 '. . .' . · '. . . ..

.' . ~ .. , ." : '.. .' ,0. " · ' ..'

, . . . . . .

" o. '. . . · , . " . ,. • • • • 0 ' · . . .

, . . , '. · .' . · . • ' • , ."', 0 , ~ · .. . .

· '. . " • • 0 '.' i

.' • !" .. "

.' , ' . . . ,,' ,. . . . . . _. . ,,' ..

• • ' 1 , " " ' . . .' .

.. 0 ' ", . " . .

. , · '. '." · .

• >'. • • · . ., " .... .'

! ! ! I

50x6x85 LONG; M.S. FLAT

DET/\IL~2

LOc'4L EARTHlt~G STAT ON

I ,

•

z 2:

". ". "~

"

38 MM G.I. AI~D "'" 2500 MM LONG G.I. PIPE (MEDIUM)

1. USE TWO EARTH W RES IF VOLTAGE II~ THE POLE JUI~CTIOI~ BOX IS 415 VOLTS.

L

STANDARD NO. TYPICAL EARTHING ARRANGEMENT 1------------1

FOR PROCESS EQUIPMENT SD-EL -113

, ~ , , ,

\ G.I. BOLT NUT j-<ARDWARE~ CO:<NECTION AS PER STD. OR CONNECT TO NOZZLE USING EARTH CLAMP

SHARP JAW TONG STR'P

I , I -r

HEAVY DUTY SPRII~G CLAMP-l0GA

PORCA8!I MIXING TAUK

~ ,

J

I .

25 MM SO COPPER i\CONDLlCTOR ;:lEXIB~E j I,CABLE

.... '

.'" •. ' / I

SHEET NO.

40x~GLI:ARTH .STRIP ,

EARTH STRIP FIXED ON STRLCTURE FOR LtJG CCNNECTIONS.

"""::J / , Itt············································)

//\ ! ~ATI~A~C~H~T~ER~M~IN~A~L~LI~JG~,~TO~EX~IS~C~IN~G~S~U~pp~O~RT~ __ ~.. I LUG ON VESSEL AND CAR.qy LEAD TO EARTH " ,-----! U -----m-----~~~~~ ~

,

I STATIONARY MIXING TANK

NOTES:

1. Acl PROCESSNG EQUloMENT SUCH AS MIXTURES, CHURNS, AUTOCLAVES, COLUMNS, CENTRI'UGES, FILTER PRESS PUMPS ETC. SHALL BE EARTHED IF NOT INDIRECT CONTACT WITH PROPERLY EARTHED STEEL MEMBERS

2. ALL TEMPOPARY EARTH CONNECTIONS SHALL BE MADE BEFORE OPENING THE VESSEl.

OF 1

L

EARTHING/BONDING OF PIPES AND PIPE RACKS

,

I

NOTES:

SEE DETAlL-C / ~-~----

" .! ,

L 7' I[ ,

7- -4 , ,

~ SEE DETAIL -A --+--

\ MAIN EARTH STRIP

FRONT VlfW

11 DIA f I ,"

N

t 1 L

l' OIA ,

\ \1',

"-v

~_25_ r_

25 __

OUAIL -f,

1. UNLESS MENTIO,ED OTHERWISE ON FcJ\.NS OR JOB SPECIFICATIONS. THE PI',L'NES SHAlL BE BONDED AND EARTHED AT THE EN'RY AND EXITS POINTS OF BATTERY L'MIT

, , -, , , , , , , , , , , , , , , ,

I L " &

2 STEEL PIPE RACKS IN THE PROCESS U,JIT AND OFFSITE AREA SHALe BE EARTHED AT EVERY 24 METRES.

\'FLEXIBLE CONNECTION

SiDE VIEW

STANDARD NO,

SD-El-114 SHEET NO.

T'

PiPE TO BONDED

CRIMPED CABLE LUG

COPPER CABLE

DET ;\[! 8

OF 2

,------------------------------,----------------------------------,--------------------------"

L

NOTES:

EARTHING/BONDING OF PIPES AND PIPE RACKS

10 MM D'A G.I. BOLT PIPE FLANGE NUT A.ND WASHERS -..............

"'E[ , , , ,

P1P[

/~ r--------,-. ,

, ____________________________________________________________________ J'-....~

~"M SQ. FlEXIBLE _,,-' COPPER CABLe

, •

, , , ,

25MM SQ fiEXIBLE COPPER CABLE

~ 2

~ , , ,

"

./-__ --.,.;:__--J

PIPE i SUP-PORT I M.S. FLAT AS

I~PER DETAIL A EAR"f:-l CONN~CTIONS I I TOFIPCSUPFORT .... n ' , i I,'GLIIIRI!:l5IRIE(Z5x6)

,

, ,MIN G.L EARTH ST~:P

ARRANG I'iNr-5

,. HOT DIP GALVANISHED M.5. FLAT (SOx lOx (x+50) WHERE x IS THE INSULATION THICKNESS) SHALL 3E PROVIDED 31' THE PIPiNG CONTACTOR.

2. SUPPLY OF FLEXIBLE COPPER CABLE, LUGS, BOLTS, NUTS, WASHERS HARDWARE AND MAKING CONNECTIONS, SHALL BE DONE BY ELECTRICAL CONTACTOR.

STANDARD NO.

SD-EL-114 SHEET NO. 2 OF 2

STANDARD NO. EQUIPMENT EARTHING SCHEDULE SD-EL -118

SHEET NO. I 1 OF 1

TYPE OF EQUIPI~ENT BARE G.I. STRIP / GJ WIRE ROPE OR G.I. WiRE

MOTOR UP TO 3.7KW NO. 8 SWG SOLID

MOTOR 5.5KW TO 30KW & WE~DING RECEPTACLES 10 MM 13/8") , , DIA WIRE ROPE

16 MI~ (5 '8") DIA WIRE ROPE/40x5 M~~ MOTOR ABOVE 37KW INCLUDING HV MOTORS ' /

GJ STRIP

BUILDING COLUfmS 40x5 STRIP

STOR.AGE TANKS (VERTICAL & HORIZONTAL) 40x5 STRIP

LOADNG RA,CKS 40x5 STRIP

VESSELS & HEAT EXCH!,NGERS 40x5 STRIP

SI#:I EQUIP.1ENTS & II~STRUMENTS NO. 8 SWG SOLID

LlGHT~IG, POWER & INSTRU~IENT PANELS 10 MM (3/8") DIA WIRE ROPE

MAIN EARTH BUS/MV & HV SWITCH GEAR INTERCOI~NECTIONS/ AS CALCULATED POIVER TRANSFORMER

[HV & HV SUB STATIONS AS CALCULATED

PUSH BUr:OI~ STATIONS NO. 8 SWG SOLID

STREET LIGHT POcES 10 MM (3/8") DIA WIRE ROPE

LIGHTING TRANSFORMER 16 MM (e 18") ,:)/ DIA WIRE ROPE/40x5 MM

PIPE RACKS 21:. l"'fI J ;:)\.>1. I~~A

NOTES:

1. E!\RTH CONNECTIOI,S TO II,DIVIDUAL EQUIPMENT ,ROM NE/,REST EARTH PLATE/LUe MAY ALSO B, DONE ALTERNATIVELY US,NG ALUMINIUM/COPPER CONDUCTOR PVC INSULATED mRF OF SI7F NOT I FSS THAN HAl F THF CROSS-SFCTION OF RFSPFCTIVF POWFR CARl F TO EQUIPME:,T (MCTOR,PANEL ETC,). CONNECTIONS SHALL BE MADE USING CRIMP lYPE CABLE LUGS. GREEN COLOR SIEVING (ABOUT 50 MM lH1GTH) SHALL BE 0ROVIDE" AT 80TH ENDS TO DENOTE EARTHING.

I I

L

'r--------------------------------,-------------------------------------,--------------------------,,

L

I

!

TYPICAL DETAILS OF DIRECTLY BURIED EARTH ELECTRODE

MS. FLAT - -

50x6x85 lONG

USE 10 MM DiA GA: .. Vl\NfSD M.S .. SOlT, NUTS AND W.L6r:ERS' FO:=\ CONNECTING EARTH CONOUCTORS·

~r-2Q"t--"5.... ... UO-

i •

STANDARD NO.

SD-EL-119 SHEET NO. I 1 OF 1

j

,,6 iH1CK MS FlAT

G,f, P~?~

NOTES:

1 ~SSEMBLY SHALL 3E HOT OiP GALV.A~ISED AFTER FABRICATION. 2 To, ELECTRODE SHALL BE DRIVEN TO A DEPTH TO RfACo PERMANENT MOIST SOIl.

~ '"

d iil ,

d cri -j

,

L

'B'~

r --I

. AI""

I

TYPICAL DETAILS OF PLATE EARTH ELECTRODE

@

@ 2 No. 10011' GJ. PiPE SLEEVE SEALED AFTER INSTALLATION

I I

gd C,,") h",

l

,-'

I"

STANDARD NO.

SD-EL-120 SHEET NO.

LOD_ -, lCill "

,-- ® .,- :f

"'~'-1-.- IY".,--,-.77

'" ~ 0 ()

'" <{ I ()

I.e 0

'" W

~ @-

± Q}

VI~W'A'

-. . . ITEM No. DESCRIPTION QUAI~TlTY REMARKS

I. 1~~~I~~'}:sG~PF~WW~ ~O}~~m A~~Ph~~:~lJ~~ 1C pvC INSULATED A E 'p:n IN NTRA T D 'M N _ AS REQUIRED

2 75Xl0rnm G.1. STRiP/ 50x6rnm COPP~R STRIPS 2 No.

3. 25¢ G.1. PERfORATED PIPE FOR WATERING. 1 No.

4. 350x75x12 mm THICK G.1. TEST LINK 1 No.

5. MB STAINLESS STEEL ANCHOR STUD Wl'H BOLT AND WASWR '" No. 6. 600x600x12 mm THICK G.I./COpnR [{!,~nl ElECTRODE, 1 No.

7. WIRE MESH 1 No.

B. 50x6 mm THIC'< 350 LONG G.1. SAvDLL 2 No.

9. Ml0 STAINLESS STEEL BOLT WITH 2 No. PLA:N & 1 No, SPRING 5 No. WASHERS.

10. 100$ GJ PIPE SLE~E SEALED AFTER INSTAlL4.TION, 6 No.

II. B~ICK WATERiNG CHAMBER WITH PLASTER r:NISH INSIDE & OIJTSIDE 1 N,.

12. C.I. REMOVABLE COVER HINGED Te CAST IRON FRAME. , No.

OF 1

~r--------------------------------r-------------------------------------r--------------------------,'

L

TYPICAL EARTHING DETAilS OF HV /lV SWITCHBOARD PANEL

STANDARD NO.

SD-EL-123

PANEL PANEL

EART1~ BUS

'" -------"

IN SW8.

. '...

GLAND .... pL~fC' '-. , T - .:>. - -

r-oI-SEE DETAIL' I ' - • ----U

,

, ,

® I I ~1-,------~------d-------~,~

BASE CHANNEL

" "

I.

2.

0) .......... I

/ " (2} 1/

\ j !

I I

J

[A~TH BUS IN Mee

fvlATER!AL TAKE --OFF -----------------------.

ITEM No.1 DESCRIPTION

1, i COPPER/ALUMINUM ADAPTER PLATE.

2. iM10 STAINLESS STEEL BOLT WITH 2No. PLAIN &INo. SPRING WASHERS.

3. iCABLE LUG AND SOLDER

4. 11e ALUMINUM PVC INS~lJl..TE.O CABLE, CABLE. SIZE AS SPECIFIED It~ 'CABLE SCHEDULE

5, ICAB~ . .E G~NO SUITABLE FOR ITEM NO.4

6, IMlO BOlTS WITH 2No_ PLAIN & lNo. SPRING WASHERS. ,

7. iG.I. STRIP.

PETROLEUM co~mUCTING .jELLY SHALe. BE APPLIED TO ALL SU,\FACES TO BE ~'OINED.

ALL srEEL srRUCTURE USED FOR ELEC'RICAL INS1ALLA'nON SHALe BE APPLIED rwo COATS OF ANi! CORROSIVE: PRIMER AND EPOXY PAINT or APPROVEC SHADE.

3. ALL HARDWARE SHALL BE OF STAINLESS STEEL.

PA~EL

SHEET NO. I 1 OF 1

/

/---® /

r---N.~L SEE DETAIL' 2'

F=4"====t=I=~1 i'>~ EARTH BUS IN

PANEL BOTH SIDE

~. '" ,--~"" ~'-0

ilvj' Y SW!TC"HOA'i') fANc(~.BASt CHANNEL

;-® f--- i EARTH BUS IN }___:::E: PANEe. BOTH SIDE

r·-GJ

TAL '2' ; ;;';'"1(; G.'. Si;~;;

Al -~r -2

QUANTIlY REMARKS

2 No. ALT.-l

6 No. ALl --1

2 No. ALl-l

AS REQUIRED ALT.-l

2 No. ALT.-1

2 No. ALT.-2

AS REQUIRED ALT,-2

...J

r,---_-,--__ --,--_ ___,

L

STANDARD NO. FRONT SHEET SD-EL-201

SHEET NO. I 1 OF 1

M SCELLA \ EOUS DETA~LS

CABL~ TRAY


SHEIT NO. I 1 OF 1

SR. DRAWING NO. DESCRIPTION NO.

1 SD-EL-201 FRONT PAGE

2 SD-EL-202 DRAWING INO:::X

3 SD-EL-203 STANDARD DRAWI~G LADDER TYPE CABLE TRAY

4 SD-EL-204 STANDARD DRAWING PERFORATED TYPE CABLE -;"RAY

5 SD-EL-205 STANDARD DRAWING CABLE TRAY

6 SD---EL---206 (Sh.--- 10f7) STANDARD DRAWII~G CABLE TRAY ACCESSORIES

7 SD-EL-206 (Sh.-20f7) STANDARD DRAWI~G CABLE TRAY ACCESSORIES

8 SD-EL-206 (Sh.-30fl) STANDARD DRAWING CABLE TRAY ACCESSORIES

9 SD-EL-206 (Sh.-4017) STANDARD DRAWING CABLE TRAY ACCESSORIES

10 SD-EL-206 (Sh.-'.)Of7) STANDARD DRAWING CABLE TRAY ACCESSORIES

11 SD-EL-206 (Sh.-60f7) STANDARD DRAWING CA3LE TRAY ACCESSORIES

12 SD-EL-206 (Sh.-7017) STANDARD DRAWING CABLE TRAY ACCESSORIES

13 SD-EL-207 STANDARD DRAWING CABLE TRAY ACCESSORIES (FRP)

14 SD-EL-208 STANDARD DRAWING CABLE TRAY COUPLER ~LATE

15 SD-EL-209 STANDARD DRAWING CABLE TRAY MOUNTING PLATE

L

L

1 0

, [I" I

!~ -RUNG

:~ (TYP.)

I • .L- L ...u

~-

STANDARD DRAWING LADDER TYPE CABLE TRAY

2500 "

;[ I' 'I 1: ;[ I' 'I 1: I I I I I I I I I I I I I I I I I I I I I I I I I I I I , I

I I I I , I

I I I I , I

I I I I , I

I I' I I I I' I I I I' I I I I' I I J.L I IL -II I lL-1 t JlI IL ....II IlL

I I I

10mm¢ HOLES (4Nos.)

---$--------~t- RUNG (TYP.)

~-WELD (TYP.)

[I" I I I I I I I I I I , I

I I' I I L'...u

?sn (TYP.)

1 0

STANDARD NO.

SD-EL-203 SHEET NO.

2.5 _, T

S"CTION 't /\'

-{--+---

cJ

NOTES:

50 50

75 I 375 I -,--------- -----r e~~-_=_~_ _ _- ~: J

INSIDE TRAY WIDTH (W) - 150,300,450,600,800MM (AS PER MTO) MATERIAL - 12 GAUGE (2.5MM) M.S.SHEET/G.S/AL/FRP (AS PER MTO)

1. ALL DIMENSIONS ARE IN MM.

2. M.S. SHEET SHALL CONFORM TO 152062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP GALVANIZING SHALL BE DONE AS PER IS4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. CABLE TRAY SUPPLIED WITH OTHER MATERIALS SHALL CONFIRMED TO RELEVANT IS/INTERNATIONAL STANDARDS.

3. THE MATERIAL DIMENSIONAL DETAILS SHOWN ARE TYPICAL FOR GS STRESS.

4. EACH CABLE TRAY SHALL BE SUPPLIED COMPLETE WITH MATCHING COUPLER PLATES WITH REQUIRE HARDWARE AS PER DRG. No. SO-75-6706.

5. CABLE TRAYS SHALL DESIGN FOR 3000mm SUPPORT SPAN UNLESS NOTED OTHERWISE FOR SPECIFIED TRAY LOADING.

OF 1

1,-' ----------,----------,-----------, I

L

STANDARD DRAWING PERFORATED TYPE CABLE

TRAY

STANDARD NO.

SD-EL -204 SHEET NO. 1 OF 1

1~51 40 I I I I

2500

-I---tt---------- -------I 0-0

PERFORATIONS (TYP.)

20

------1----t--j I

U ,

'll

I

-r-l 15

~----~-------------~ _______ -I ____ ~-J

I I

AL

NOTES:

I I

/\~

I

-t---t --$-----$--, , I

-t---t --$----, I ,

---------, ,

50 IOmm¢ HOLES (4Nos.)

5:C-,ON 'A.·A'

INSIDE WIDTH (W) - 100,150,300,450,600,800MM (AS PER MTO) MATERIAL - 12 GAUGE (2.5MM) M.S.SHEET/G.S./AL/FRP (AS PER MTO)

I. ALL DIMENSIONS ARE IN MM.

I

3:

1nn

2. M.S. SHEET SHALL CONFORM TO 152062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP GALVANIZING SHALL BE DONE AS PER IS4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. CABLE TRAY SUPPLIED WITH OTHER MATERIALS SHALL CONFIRMED TO RELEVANT IS/INTERNATIONAL STANDARDS.

3. THE MATERIAL DIMENSIONAL DETAILS SHOWN ARE TYPICAL FOR GS STRESS. 4. EACH CABLE TRAYS SHALL BE SUPPLIED COMPLETE WITH MATCHING COUPLER PLATES WITH REQUIRED

HARDWARE AS PER DRG. No. SD-75-6706.

5. CABLE TRAYS SHALL BE DESIGNED FOR 3000mm SUPPORT SPAN UNLESS NOTED OTHERWISE FOR SPECIFIED TRAY LOADING.

2.5

r,-·· --------,---------------------,-1

L

NOTES:

~ \t

TRAY COVER

OVERUIP 7I

A

L

~

T 25

CABLE TRAY

(TYP.)

'"' , ; ~ 0' ;, '

I I I I I I I

STANDARD DRAWING CABLE TRAY COVER

, """ " ;"" 1,; ;" . /""r" "" " \" f\ HY<; ., . , .,d :;; '" ,

A A A I V V V I

I I I I I I I I I I I I I I

STANDARD NO.

SD-EL-205 SHill NO. I 1 OF 1

r - AV

I I I I I I I

I I I I 1-1------------1-1 I I I I

, , I I I I I I I I I I I I I I I I I I I I A I I I I

J I I I I I I I I I I I I I I I I

I I

.. / \J '" .,

TRAY COVER

/

2500MM LONG TRAY COVER SNAP FITIED ON TO CABLE TRAY WITHOUT

~~~~=:=~:~rlQz:Z2zZ2z~~~A;NY HARDWARE ~ 40 d 771

, I -

MATERIAL-16 GAUGE( 1.7MM) M.S. SHEET/G.S./AL/FRP (AS PER MTO) TRAY COVER MATERIAL SAME AS OF TRAY & TRAY WIDTH AS PER MTO

1. AU DIMENSIONS ARE IN MM.

2. M.S. SHEET SHALL CONFORM TO 152062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP GALVANIZING SHALL BE DONE AS PER IS4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. CABLE TRAY SUPPLIED WITH OTHER MATERIALS SHALL CONFORMED TO RELEVANT IS/INTERNATIONAL STANDAROS.

.J

r,-' ---------,-------------,---------

L

ANGLE HORIZONTAL COUPLER PLATES (1YP.)

NOTES:

W

1, ALL DIMENSIONS ARE IN MM.

STANDARD NO. STANDARD DRAWING CABLE

TRAY ACCESSORIES SD-EL -206 SHEET NO. 1 OF 7

R

DETAIL-'X'

50 25 ,

H I-

• • 1- • . . :'.

I

1--++ 0 0 3: - --if-+

--/-------

10 ¢ HOLES/ (+ Nos.)

,

RUNG(1YP.)

ANGLE HORIZONTAL COUPLER PLATES (1YP.)

, , . ,

I

_I

(W) INSIDE WIDTH OF TRAY - 150,300,450,600,800MM (AS PER MTO)

(A) DEPTH OF TRAY - 100MM UNLESS NOTED

(R) BENDING RADIUS (AS PER MTO)

30

40

30

2. MATERIAL - 12 GAUGE(2.5MM) M.S, SHEET/G.S/AL/FRP (AS PER MTO),

3. M,S. SHEET SHALL CONFORM TO IS 2062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP GALVANIZING SHALL BE DONE AS PER IS 4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. TRAY FITTINGS SUPPLIED WITH OTHER MATERIAL SHALL CONFORM TO RELEVANT IS/INTERNATIONAL STANDARDS.

4. EACH CABLE TRAY SHALL BE SUPPLIED COMPLETE WITH MATCHING COUPLER PLATES WITH REQUIRE HARDWARE AS PER DRG. No. SO-75-6706,

5. ALL TRAY FITTINGS SHALL BE SUPPLIED COMPLETE WITH MATCHING ANGLE HORIZONTAL COUPLER PLATES & HARDWARE. ALTERNATIVELY WELDED ASSEMBLY MAY BE SUPPLIED FOR G,S, CABLE TRAY FITTINGS.

1,-· ----------,----------,-----------, I

L

ANGLE VERTICAL COUPLER PLATES (1YP.)

'N"··)' " --" !

STANDARD DRAWING CABLE TRAY ACCESSORIES

ow

STANDARD NO.


50 25

____ -+ +-1---1-30

40 ---- +-1--+--'--t~-~-=;t""-==.=O _L

30

10 ¢ HOLES

(4Nos.)

/ R

RUNG(1YP.)

(W) INSIDE WIDTH OF TRAY - 150,30Q,450,600,800MM (AS PER MTO). (A) DEPTH OF TRAY - 100MM UNLESS NOTED. (R) BENDING RADIUS (AS PER MTO).

NOTES: 1. ALL DIMENSIONS ARE IN MM. 2. MATERIAL - 12 GAUGE(2.5MM) M.S. SHEET/G.S/AL/FRP (AS PER MTO). 3. M.S. SHEET SHALL CONFORM TO IS 2062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP

GALVANIZING SHALL BE DONE AS PER IS 4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. TRAY FIDINGS SUPPLIED WITH OTHER MATERIAL SHALL CONFORM TO RELEVANT IS/INTERNATIONAL STANDARDS.

4. EACH CABLE TRAY SHALL BE SUPPLIED COMPLETE WITH MATCHING COUPLER PLATES WITH REQUIRE HARDWARE AS PER ORG. No. 50-75-6706.

5. ALL TRAY FIDINGS SHALL BE SUPPLIED COMPLETE WITH MATCHING ANGLE HORIZONTAL COUPLER PLATES AND HARDWARE. ALTERNATIVELY WELDED ASSEMBLY MAY BE SUPPLIED FOR G.S. CABLE TRAY FIDINGS.

1,-' ----------,----------,-----------, I

L


TRAY ACCESSORIES SD-EL -206 SHEET NO. 3 OF 7

/ /J'~I DETAIL-'X'

. . . RUNG(TYP.) 45¢ ANGLE VERTICAL

COUPLER PLATES (TYP)

O:j-rs:o::::

: 502~ : c.L -_--=-+-+ 30

40 --- ++--'-30

10 \11 HOlES 4Nos. I DETAIL X

45· VERTICAL RADIUS ELBOW

/ R

, F=::::::::::;~ A i '---,--=::z;

/ R

(W) INSIDE WIDTH OF TRAY - 150,300,450,600,800MM


(AS PER MTO)


NOTES:


2. MATERIAL - 12 GAUGE(2.5MM) M.S. SHEET/G.S/AL/FRP (AS PER MTO). 3. M.S. SHEET SHALL CONFORM TO IS 2062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP

GALVANIZING SHALL BE DONE AS PER IS 4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. TRAY FITTINGS SUPPLIED WITH OTHER MATERIAL SHALL CONFORM TO RELEVANT IS/INTERNATIONAL STANDARDS.

w

4. EACH CABLE TRAY SHALL BE SUPPLIED COMPLETE WITH MATCHING COUPLER PLATES WITH REQUIRE HARDWARE AS PER DRG. No. SD-75-6706.

5. ALL TRAY FITIINGS SHALL BE SUPPLIED COMPLETE WITH MATCHING ANGLE HORIZONTAL COUPLER PLATES & HARDWARE. ALTERNATIVELY WELDED ASSEMBLY MAY BE SUPPLIED FOR G.S. CABLE TRAY FITIINGS.

r,-' ---------,-------------,---------

L


STANDARD NO.


RUNG(TYP.)

NOTES:


~W ~;us 't,

IA

>

50 25 1---j , , , ,

-" f--+-+ 0 3: 0

,,-h ~ -+ _.

~ (

10 ¢ HOLES/ ( 4Nos.)


CA) DEPTH OF TRAY - 100MM UNLESS NOTED


2. MATERIAL - 12 GAUGE(2.5MM) M.S. SHEET/G.S/AL/FRP (AS PER MTO). 3. M.S. SHEET SHALL CONFORM TO IS 2062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP

GALVANIZING SHALL BE DONE AS PER IS 4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. TRAY FITIINGS SUPPLIED WITH OTHER MATERIAL SHALL CONFORM TO RELEVANT IS/INTERNATIONAL STANDARDS.


5. ALL TRAY FITIINGS SHALL BE SUPPLIED COMPLETE WITH MATCHING ANGLE HORIZONTAL COUPLER PLATES AND HARDWARE. ALTERNATIVELY WELDED ASSEMBLY MAY BE SUPPLIED FOR G.S. CABLE TRAY FITI!NGS.

30

40

30

r,-· ---------,-------------,---------

L


RUNG (TYP.) W

10 0 HOLES ( 4Nos.)

STANDARD NO.


50 25

f=~+-++--+30 40 --- ++--+ 30

--'-

:J' -:-A': -'X'

NOTES:

< W

·0 " . .,

W

~, ·~I/


CA) DEPTH OF TRAY - 100MM UNLESS NOTED


2. MATERIAL - 12 GAUGE(2.5MM) MS. SHEET/G.S/AL/FRP (AS PER MTO). 3. M.S. SHEET SHALL CONFORM TO IS 2062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP

GALVANIZING SHALL BE DONE AS PER IS 4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. TRAY FITIINGS SUPPLIED WITH OTHER MATERIAL SHALL CONFORM TO RELEVANT IS/INTERNATIONAL STANDARDS.

4. EACH CABLE TRAY SHALL BE SUPPLIED COMPLETE WITH MATCHING COUPLER PLATES WITH REQUIRE HARDWARE AS PER DRG. No. 5D-75-6706.

5. ALL TRAY FITIINGS SHALL BE SUPPLIED COMPLETE WITH MATCHING ANGLE HORIZONTAL COUPLER PLATES AND HARDWARE. ALTERNATIVELY WELDED ASSEMBLY MAY BE SUPPLIED FOR G.S. CABLE TRAY FITIINGS.

r,-· ---------,-------------,---------

L


·5· \ [·'T'CA· 4, .; "" '\ , ,

RUNG(lYP.)

.---R

25 50

30 ! +-1 --t 4- 4- ---

40

30 +---+4- ----

1 0 ¢ HOLES

j~-A . 'X' (4Nos,)

DETAIL-'x'-"-,-;.




NOTES: 1. ALL DIMENSIONS ARE IN MM.

R""

2. MATERIAL - 12 GAUGE(2.5MM) M.s. SHEET/G.s/AL/FRP (AS PER MiO).

STANDARD NO.


\ \

W

---

"" R

RUNG(lYP.)

RAG:US CROSS

3. M.s, SHEET SHALL CONFORM TO IS 2062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP GALVANIZING SHALL BE DONE AS PER IS 4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. TRAY FITIINGS SUPPLIED WITH OTHER MATERIAL SHALL CONFORM TO RELEVANT IS/INTERNATIONAL STANDARDS,


5. ALL TRAY FITIINGS SHALL BE SUPPLIED COMPLETE WITH MATCHING ANGLE HORIZONTAL COUPLER PLATES AND HARDWARE. ALTERNATIVELY WELDED ASSEMBLY MAY BE SUPPLIED FOR G.s. CABLE TRAY FITIINGS.

1,-· ----------,----------,-----------, I

L

DETAIL-'X ,

,

RUNG(TYP.) I

, I , ,

~


, , , , , I I I I I , , , , , I I I I v

~' , ,

'~

~ J~

I ~ I

II

/R , \ / R~

25 50

301 40 ++ )

+--++ 30

10 ¢ HOLES

>.·!\".···'X· (4Nos.)

I. w

HORIZON A~ ;~ADiUS

(W) - INSIDE WIDTH OF TRAY-150.300.450.600,800MM (AS PER MTO)

(A) - DEPTH OF TRAY-100MM UNLESS NOTED

(R) - BENDING RADIUS (AS PER MTO)

,; -"

w

STANDARD NO.


RUNG (TYP.)

90" VFRTiC.A.L RAJ;l..S


2. MATERIAL - 12 GAUGE(2.5MM) M.S. SHEET/G.S/AL/FRP (AS PER MTO). 3. M.S. SHEET SHALL CONFORM TO IS 2062: 1992 OR EOUIVALENT INTERNATIONAL STANDARDS AND HOT DIP

GALVANIZING SHALL BE DONE AS PER IS 4759: 1996 OR mUIVALENT INTERNATIONAL STANDARDS. TRAY FITTINGS SUPPLIED WITH OTHER MATERIAL SHALL CONFORM TO RELEVANT IS/INTERNATIONAL STANDARDS.

4. EACH CABLE TRAY SHALL BE SUPPLIED COMPLETE WITH MATCHING COUPLER PLATES WITH REQUIRE HARDWARE AS PER DRG. No. SO-75-6706.

5. ALL TRAY FITIINGS SHALL BE SUPPLIED COMPLETE WITH MATCHING ANGLE HORIZONTAL COUPLER PLATES AND HARDWARE. ALTERNATIVELY WELDED ASSEMBLY MAY BE SUPPLIED FOR G.S. CABLE TRAY FITTINGS.

1,-' ---------,-------------,---------

L

DETAIL--t.<,C:'./ I

W

25 50 1-

STANDARD DRAWING CABLE TRAY ACCESSORIES (FRP)

~~ RUNG(TYP.)

'/ , I 0:

I

, :

R

, ,

---

W

STANDARD NO.

SD-EL -207 SHEET NO. OF 1

301 ++--l +--++

40

(W) INSIDE WIDTH OF TRAY - 150,300,450,600,BOOMM (AS PER MTO)


30 L "===<===-=' (R) BENDING RADIUS (AS PER MTO)

10 ¢ HOLES ") . A 'X' (4Nos.)

NOTES:


IN

f--, , , , , , , , , , , , , "-,

2. MATERIAL - 12 GAUGE(2.5MM) M.S. SHEET/G.S/AL/FRP (AS PER MTO).

RUNG(TYP.)

/ R

1- A -I

3. M.S. SHEET SHALL CONFORM TO IS 2062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP GALVANIZING SHALL BE DONE AS PER IS 4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. TRAY FIITINGS SUPPLIED WITH OTHER MATERIAL SHALL CONFORM TO RELEVANT IS/INTERNATIONAL STANDARDS.


5. ALL TRAY FIITINGS SHALL BE SUPPLIED COMPLETE WITH MATCHING ANGLE HORIZONTAL COUPLER PLATES AND HARDWARE. ALTERNATIVELY WELDED ASSEMBLY MAY BE SUPPLIED FOR G.S. CABLE TRAY FIITINGS.

1,-' ----------,----------,-----------, I

L

STANDARD DRAWING CABLE TRAY COUPLER PLATE

STANDARD NO.

SD-EL -208 SHEET NO. I 1 OF I

10x30 LONG HOLES (4Nos.) SUITABLE FOR

M8x16 FLAT HEAD WITH\SHORT Sq. 2~:CK 80LTS

A

I ;CABLE TRAY

!-----'r\---"'-"--------lI (TYP.)

r 251 50-\, 25 10 25, 50 .1 25' -"

~~t=~\~I~~=r~~~--( -$--{~--T i i +---~

I !: I I I

I I I: I I \ en -f--i 3-{-i-3- i II -qt----+t ) - - '--_____ --t.-t-_____ --';'-t1---' __

)

o o -

~---------------- 1----------- -----j_L

EXPANSION COUPLER PLATES

8FLAT ROUND HEADED 5S BOLTS WITH WASHERS & NUTS (TYP.)

DETAIL-X

)

I CABLE TRAY (TYP)

~TW~O~C¥O~UP~L~E~R_--I)~ ~ PLATES &=== f


2. MATERIAL - 3MM M.S. SHEET/G.S/AL/FRP (AS PER MTO).

A.--J I O~q HOLES (4Nos.) SUITABLE FOR M8xl6 FLAT HEAD WITH 2mm Sq. NECK SS BOLTS

3. M.s. SHEET SHALL CONFORM TO IS 2062: 1992 OR EQUIVALENT INTERNATIONAL STANDARDS AND HOT DIP GALVANIZING SHALL BE DONE AS PER IS 4759: 1996 OR EQUIVALENT INTERNATIONAL STANDARDS. TRAY FITTINGS OF OTHER MATERIALS SHALL CONFORM TO RELEVANT IS/INTERNATIONAL STANDARDS.

4. NUTS/BOLTS/LOCKNUTS SHALL BE AS PER IS 1363(PART -1,2,3) : 1992/15 1367(PART -5) : 1980 OR EQUIVALENT INTERNATIONAL STANDARDS,

5. WASHERS SHALL BE AS PER IS 2016 : 1967 OR EQUIVALENT INTERNATIONAL STANDARDS.

~----------------~--------------------~-------------~

L


TRAY MOUNTING PLATE SD-EL -209 SHEET NO. I 1 OF 1

PLATE & CHANNEL

PLATE AND CHANNEL I

: +' ! . /t<1YP~

o ·t I ffV . N ",,:,,'JI u;i

+

'\: . ,-------"'-- --- . _:1 -'---7 ----

\ j I

l~~0=l=~1 :..-_·-_3-0+1! __ -f+~ __ ---t ___ 200x200xl0 THK M.s. PLATE FinED ON lbcl i --jl3c c- THE SLAB BY ANCHOR

200: FASTENERS

I I I

WELD", i 1,\1

.J-: I

PLA"

4 NOS. ANCHOR FASTENERS (SEE NOTE #2)

r FLOOR SLAB

, 1YPICAL DETAIL OF FIXING M.S. PLATE TO FLOOR BY ANCHOR FASTENER

NOTES:

FOR WELDING TRAY SUPPORT. (WHEREVER EMBEDDED PLATES OR STRUCTURAL

BEAMS ARE NOT AVAILABLE).


2. THE ANCHOR FASTENER SHALL BE OF HEAVY DU1Y 1YPE. THE AXIAL HOLDING STRENGTH SHALL BE AS FOLLOWS BOLT DIAMETER. 16mm -- 5000Kg FOR ADEQUATE SAFE1Y FACTOR 25% OF THE ABOVE VALUE SHALL BE USED .

.3. SAME DETAILS HOLD GOOD IF THE PLATE ARE FASTENED TO THE UNDERSIDE OF THE FLOOR SLAB.

4. STRUCTURAL STEEL SHALL BE AS PER IS 2062:1992.

5. WELDING SHALL BE DONE AS PER IS 816: 1969.

fC,---_-,--__ --,--_ ___,

L

STANDARD NO. FRONT SHEET SD-EL -301

SHErr NO. I 1 OF 1

M SCELLANEOUS DETA~=S

CABLE TRENCH

~'--------------------------------r-------------------------------------r--------------------------,'

L

SR. NO.

2

3

DRAWING NO.

SO-t:L-302

SO-EL-303

4 SO-EL-304

5 SD-EL-305

6 SO-i::L-306

7 SO-EL-307

8 SO-EL-308

9 SD-EL-309 (Sh. 10F2)

10 SO-EL-309 (Sh. 10F2)

11 SO-EL-10

12 SD-EL-311

13

14 SO-EL-313

15 SO-EL-314

16 SD-:=:L-315

17 SD-EL-316

18 SO-EL-317

19 SD-EL-318

20 SD-EL-319

21

22 SD-EL-321

23 SD-EL-322

24 SD-,L-323

25

26 SD-EL-325

27 SD-EL-326

28

29 SD-,L-328


SHEET NO. I 1 OF 1

DESCRIPTION

~RONT PAG~

~RAWli-JG INDEX

Rec DUCT ABOVE FCL

ERe BELew GRADE LEVEL

ARRP.,NGEMENT FOR TERMINATION OF CABLES ~!D IN TRAYS (FOR MV MOTORS)

ARRANGEMENT FOR 'ERMINA7 10N OF CABLES ~ID IN TRAYS (FOR HV I"'V MOTORS)

ARRANGDAENT FOR TERMINATION OF CABLES !...AID IN TRENCH (FOR MV MOTORS)

ARRANGEMENT FOR TERMINAilON OF CABLES :...AID IN TRENCH (FOR HV IMV MOTORS)

TYPICAL ARRANGEMENT FOR LAYING OF CABLES I~ CABLE TRAYS

TYPIc'';L ARRANGEMENT FOR LAYING OF CABLES IN CABLE TRAYS

MARKING OF TRENCHES FOR ELECTRIC CABLES

TYPICAL SECTION OF CABLE TRENCH IN UNPAVED AREAS

TYPICAL SECTION OF CABl_E TRENCH IN PAVED AREAS

CONDUIT OR CABLE SUPPORT ON CONCRETE BEAM OR COLUf.1N

TYPICAL INSTALLATION OF CABLE FOR MOTOR (CABLE IN TRE:-.lCH)

TYPICAL INSTALLATION OF CABLE FOR MOTOR (CABLE IN TRAY)

STANDARD DRAWING CABLE TRENCH TYPE - 0504








STANDARD DRAWI~G CABLE TRENCH TYPE - 1415


STANDARD DRAWING CABLE TRENCH TYPE 2/2015

STANDARD DRAWING CABLE IDENTIFICATION TAG

STANDARD DRAWING CABLE INSTA~LATION PRACTICE FOR BonOM ENTRY TO SWITCH BOAROS/CO~TROL PANELS

L

STANDARD NO. RCC DUCT ABOVE FGL SD-EL-303

SHEIT NO. OF 1

STORM '" '''''' ___ ~-DRA.IN -- .... ",t, , t::::::;~~::W.::'DT::H;;::t...,-.-_,.,. __ (IF THERE) ....

RCC OUCT ~~'I, n ___ _

RACK/ TRAYS

l x

CABLE RACKS/ TRA'(S·...J . DWGS.)

REMOVABLE I FIXED , RCC COVER

If . - ,

~ I " • ' " . " ,

- -- - , -, , ,

0 0

_~ e')

0 0 .

----------- --------------------, (Y) , - - >

0 - 0 /. (Y)

, -, - / ~ , , i , , 1 , •

800 , 600 , MIN. ,

SEC ~ON A --A

LH.S. --+-- R.;.s. (S[E NOE-4)

PLA.N

TOP OF rHo ROAD (AS PER GEN. CIVIL j , nf ,

, . -(~ , - w

, -, 5

",,,,

w , w !:2.

~ •

-EGL ,

• \I , .

, -/-

I/ , " / ,

: .

, • -,

- . , , - ,

800

- cEP7H AS PER ELECTRICAL DRAWING

RE~OVAB' E/ FIXED -RCC -

COVER

- , , , , . -.-.,

[ :j ~ - ,

/ ~ , --{ -,

.1. 600 .1. 800 (MIN.)

100X6 lAM MS :NSERT S,CT:ON A-A

TOP 0' THE ROAD , (AS PER GEN. CIVIL)

V

T , . -, -,

" ~

~ / i , ~

r 0

qz \ ,

~ w , '" ~ -

-, IFGL \i-, , - , . -

·1

(ONE SIDE RACK/TRAY ARRANGEMENT) PLATE AS PER JOB REQUiRED --

(B07H SIDE RACK/TRAY ARRANGEMENT)

NOTES: 1. WIDTH OF DUCT & NO. OF RACKS AND TRAY IN EACH ROAD CROSSING SHALL BE OECIDED BY ELECTRICAL AS PER THE REQUIREMENT

OF ELECT. CABLES AND MAXiMUM AVAILABLE DEPTe OF DUCT w.r.l. F.G.L. AND ROAD L[vEL.

2. IN CASE. SUFFICIENT DEPTH OF DUCT IS AVAILABLE (> 1500MM). THE DUCT CAN BE COVERED WITe FiXED SLA.8. 3, CO-ORDINATES OF TRENCHES & ReC DUCT ETC. SHALL BE DECIDED BY CIW ... & SHOWN IN RESP::CTIVE AREA. DRAWING. 4. :N CASE OF COMPem CABLE TRAY SYSTEM ON BOTH SIDES OF ROAD. ARRANGEMENT SHALL BE AS PER LHS ON BOTH SIDES AND

IN CASE OF TRENCe SYSTEM IT SHALe BE AS PER ReS ON BOTH SIDES.

L

NOTES:

STANDARD NO. ERe BELOW GRADE LEVEL SD-EL-304

SHEIT NO.

STORM WATER DRAIN ROAD WIDTH (IF THERE) ----c

FCl

~! I

-- - '-T.~·l'----

TOP OF ROAD

X _____ J J --::={

DIRECTLY BURIED CABLE TRENCH (SIZE AS PER ELECT)

lI....., 7_, r-r " . I " , / - ,/'

~ ___ ~_~~-L~ __ ~,--L ___ J

L ERG (NO. OF LAYERS/ PiPES AS PER ELECT.)

"eTION X-X

I

1500 RCC/PVC PIPE

r-. - , [[) r-. (\J

7. 275 I 275 275 7s

\2- BOTTOM OF DUCT (AS PER GtN. CIVIL)

,

S[C:ION A.A ([Re)

1. CO-ORDINATES OF TRENCH, ~ENGTH & LEVEL 0;:- EACH ERe SHA~L BE DECIDED BY GEN, CIVIL & SHOWN It~ RESPECTIVE AREA DRAWING, 2 NO. OF PiPES e.g. LAYERS & PIPES IN EACH LAYER SHALL BE AS PER !HE REQUIREMENT OF ELECIRICL.

OF I

L

STANDARD NO, TYPICAL ARRANGEMENT FOR LAYING OF f-----------j

CABLES IN CABLE TRAYS SD-EL -309 SHEET NO, I OF 2

,r--~,1V POWEr, CABLES CABLE TRAY (TYP,)

( 'I )'1"\.

CONTROL CABLES

I

(SEE NOTE - 1)

'----RU~JGE @ 250 (TYP.)

HV POWER C!,8LES __ ~_ ,------ BARR:ER PLATE

50

50

- COflTROL CABLE ~-MV POWer< CABLE

I( ~~v )OWI: ,; &,.. :W' C

(SEE NOTE-I & 2)

/\ MV POWER CABlES

~1Crn~xxx):xxxxxxX)J v~v .1{YNC;:;; :SJ

(SEE NOTH)

~ ~ m ~ ~ III ~~~~~~~~""=""""'=""""=""""'=""""=" ....... = ........ ~md

m • A I : "'

," • I

~HV POWER CABLES ~

(5 ~/ C) oJ :HV ~1JVvu{ \ is) D= DIA OF H.V. POWEI, CABLE

(SEE NOTE-2)

L

TYPICAL ARRANGEMENT FOR LAYING OF CABLES IN CABLE TRAYS

STANDARD NO,

SD-EL -309 SHEET NO, 2 OF 2

(TYP,) / .................. BARRIER PLATE @ 2000

/ / .... CO,ITROL CA.8LE

1n ~~I--m --"'20""--0 ....... ---o,1_---J HV POWER CABLES

Til;! " '" , t;?

X POWFR & CONTROL ES) (SEE NOTE-2 & 3)

............ CABLE FIXING CLAMPS

I" 100

2D

50 , I ....

POWER CABLES

® ] D= DIA OF H.V. POWER CABLE

iSING;; CORE MY CABL, S IN FLAT CONFIGURA.fON)

NOTES: 1. IN CASE OF SINGLE TRAY ARRANGEMENT, DETAILS-1 OR DETAIL -2 SHALL BE FOL~OWED WHEREAS IN CASE OF LOCATIONS

WHERE TWO OR MORE TRAYS ARE INSTALLEO, DETAIL 3 & 4 SHALL BE USED.

2. UNLESS OTHERWISE SPECIFIED, H.Y. POWER CABLES FOR H,V. MOTORS SHALL BE KEPT TOUCHING.

3. WHEREVER A FEW H,V. POWER CABLES ARc TO BE lAic ALONG WITH CONTROL CABLES IN THE SAME TRAY, H.Y. CABLES SHALL BE SEPERATED BY PROVIDING BARRIER PLATE AT AN INTERVAl OF 2M.

',. CABLE ~ID IN TRAYS SHALL BE SUITABLY C~MPED BY MEANS OF G1 SACDLES/CLAMPS FOR HORIZONTAL RUN AND VERTICAL RUN OF CABlES FOR SINGLE CORE CABLES LAID IN flAT CONFiGURATlmj, NON-MAGNETIC, NON-CORROSIVE CLAMPS AT AN iNTERV" OF O.SM TO O.8,~ S"ALL BE USED.

5. ALL COMMUNICAT:ON CABLES (TELEPHONE, PAGING / FA SYSTEM) & RTO S:GNAL CABLES SHAH RUN IN INSTRUMENT DUCT/ TRAY/TRENCHES IN ,HE UNITS WHEREVER THESE ARE NOT AVAiLABLE. CA8LE SHALL BE DIRECTLY CLEATED ON A SEPERATE ROUlE WAY FROM POWER CABLES OR TAKEN IN A SEPERATE TRAY IN LINE WITH DETAIL 4.

6. ALL DIMENSIONS .ARE IN MM.

~'--------------------------------r-------------------------------------r--------------------------,'

L

STANDARD NO.

NOTES:

,-,--- .............. y:

MARKING OF TRENCHES FOR ELECTRIC CABLES SD-EL-310

SHEET NO.

'0 ANGLE ;RON 65x6Sx6 PAINiEC WHITE SiGN--- '8'

a 0 --

a a: ""

~ 7

......... /-, ,

A _: • ~.;. , ,

~. -!. 4' .~: . ~ ..

-. , .

MAR'<~R POST

,0 .............. -.., ,0"

~I==~

"-- __________________ 9 ____ _

60

o

~ ~---

SIGN--- 'A'

BURIED E~ECTRIC CABLES

QjJ

60

o o '"

a o m

:: :#' -' ...

.: • .0\ : -/8Qrgf,IBLIQt<"f;fE ,

• . " ~. ~ -'" : , .' .,

,4.. "

, '. '11/' • , .. -i- . ','. ID 4- .4iJ~'''''/ [", ..... .,'

'- .".~

dll

r r

L 65x65x6-1.10M LONG

ASSEMBLY SIGN.-A-l NO, CONSISTING SIGN.-C-2 NO. OF

200

TYPICAl. ARRAN 'At NT OF MAKK: R

mCTRIC CABLE TRENCH

I

L 65x65x6-1. 1 OM LONG

SIGN.-A-l NO. SIGN.-3-1 NO.

(SEE NOTE -1)

l 65x65x6-1.10M LONG l 65x65x6-1.1 OM LONG

SIGN,-A-l NO. SIGN.-8-1 NO. S!GN. -C-l NO.

SIGN.-A-l NO. SIGN.-8-2 NO.

1. TRENCHES SHALL BE MARKED AT ALL DiRECTION CHANGES, :NTERSECTION$ AND STRAIGHT RUNS. 2. SIGN BOARuS SHAL, BE M,ADE OF 14G ENAMEL,ED STeEL PLATE WHITE LETTeRING S:~ALL BE ON JADE GREEN BACKGROUND

I I

1 OF 1

..J

L

NOTES:

STANDARD NO. TYPICAL SECTION OF CABLE TRENCH IN 1------------1

UNPAVED AREAS SD-EL-311

TYPICAL SECTION WITH HV AND ~1.V. CABLES

/ / / / / / /. / I // I /// .f // I j {/I/P/j// ./;; 1';,; ;i//f

l;;

; J f 'I ; f J .-' JJ j .Jf,J/f //;- .I. f; ;' f / ; ; ; f I / f;, ; f; fff;

f,"1'mml IIml immIi Immmm] Immmmj c" ;

CI)·Cp·cp·cp·CP·$·

o

200 MINIMUM CR TWICE 'HE 0.0. OF CABLE

200 300 100 100

·yP:c SLC~:ON WiTCI I~. V. CAB cs ONLY

cp.cp.cp.cp.cp......., •.......... °0"." ...

, '

SHEET NO. 1 OF 1

I·

1. LEAVE SPACE FOR LATER AOD;TION OF AT LEAST 2 CABLES OR 15% AVERAGE SPARE SPAC~ R~GARDLESS OF FUTljRE EXPANSiON. 2. IF F:RE ALARM ANO COMMl)NICATION CA8LES ARE LAIO IN THE SAME TRENCH A CLEARANCE OF 300mm (MINIMUM) AWAY FRO.V.

L

NOTES:

~EMOVABl.E CONCRETE COV~R

FI:~ISHED FLOOR LEVEL

HV POWE~ CABLES

Q, .

In: -o o -

SAND

TYPICAL SECTION OF CABLE TRENCH IN PAVED AREAS

LIFTING HA~~DLE

. ".~

~o 300 PxlO L.lQQJ

STANDARD NO.

SD-EL -312 SHEET NO.

G.L PIPE FOR CABLE WHERE REQuiRED

8RICK

p- NUMBER OF POWER CABLE

C_QlliBQL_C.~B.LE.s..

\ MY PDWER CABLE

REMOVABL.E COt~CRETE COVER LIFTING HANDLE

~

x 0 o

X M

o o -

I ,.~ t. ,_ i

, , , ,

F========= ' .. ,

m (PAVED A,EA'

j

E::::.=====::j./ ~ 100 WIDE INSERT PLAiT @ 750 BY STRUC". (lYC)

L 50x50x6 WELDED TO INSERT _ >' PLATE BY ELECT. (ryp.)

.....-:=-- ,',

c'F,= ;====~~ __ ~.~E===~~1: "~ '~, 'F -" ",' . I ,- , -, ,

I q 500 p ! 50C soa

ALT. -2

1. LEAVE SPACE FOR LATER ADDITiON OF i 5% AVERAGE SPARE SPACE FOR FUTURE EXPANSION. 2. REQUIREMENT OF RACKS 01>1 ONE SIDE OR oOTH SIDES SHALI_ BE DECIDED AS PER JOB REQUIREMENT AND AVA:LABILITY OF

SPACE FOR TRENC~. J. TRENCHE.S iN HAZARDOUS AREAS SHALL BE COMPLETELY F1:..LED WITH SAND. 4. THE C:XACT HC:IGHT OF OPENING IN TRENCH WAll FOR G,I. PIPE FOR TAKING CABLE SHAll BE SUITABLY DECIDED AT SITE.

OF 1

r~ ______________________ -, ____________________________ .-__________________ -,

CONDUIT OR CABLE SUPPORT ON CONCRETE BEAM OR COLUMN

M.S. CLEAT ISEE DETAIL ,j & 4

/ 40,40 M.S. SLOTTED ANGLE 1-/ (LENGTH AS REQUIRED)

'W· , : , : , L , ,

~ I 'f' , '

ONE HO~.E 'c' CLAMP OR GROUP CLAMP ON G.L SPACER

STANDARD NO,


ft" " " ------------r--- -~ MS CLEAT I : ~

50 WELD

.-~ /, -1

SEE DETAIL 3 & 4

/ 40,40 MS SLOTTED ANGLE! (LENGTH AS REQU:RED)

SU:lpOr;: -OR V ~- "CAt ~ c~ 0\ W/\LL

SUPPORTING ASSEMBLY FIXED TO COL. ELECT. WITH ANCHOR BOLi : DMM DIA.

~-~ CONCRETE BEAM! COLUMN OR BRICK WALL

f __ 5_~DI!IfLM5,_ I ANGlE

,-..:..--.----J

..... ~ ..

, ~ 40

D,TAII-4

. ,

ONE HOI ' 'C' CLAMP

i 1 DIA HOLE

(M,S, C FAT]

CABLE OR CONDUIT

L~-------L------~~--------------------------------L-----~------~------~

1,-' ----------,----------,-----------, I

L


STANDARD NO.


SEE DETAIL A OR B -_-I

ANCHOR

80x80x6

PLATE(TYP)

I I

1/

5001

EARTH COND~

I

o o

"' o o ...

I

_50

IT I :Z'!..-'

-r;-'--:;:s ;I;;:;T I £::.L

6 ¢ ANCHOR BAR

WELDED TO PLATE

IL-__ 50 THK P C C 1 :4:8

6 SO, BAR WELDED TO'\ 5 COVER TYPE'SO/43

DET. '0' FOR

1_ 300 _ '12. LIFTING HOOK ANGLE '

FLOOR LEVELl '\I [c;Ap i \'

CHOD. PL. TYPE DET 'E' FOR

CH7

I t-_~.(G~A~P~i'~;;~ :::: ~I II -.l d .----- JI(IIf"" //.? \, ' '.A,' f CO!',ER

L40x40xS- j fls4 ,y... t c- 12 THK. I

PREMOULDEJLj JT. FILLER

T I i LIFTING HOOK t

( "

NOTES:

)0'<',"I,,· .. 8¢ 150 LONG ANCHOR BAR , WELDED TO ANGLE @300 1".

"~,

7 --rl-.-=--. =--;q-' ...L-r- - 8[ t""1 -T tir '1-.-.-"-1'1- or

1 ~

WIDTH ~..:. f-100

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I

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~ 'X gl

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I

! 8

! o~ , w

I '. IO~ '-i50x50x6

GAP C-

"CH7 ~ 7 THK. CHOD. PL

• ReCOVER THICKNESS As3 As4

TYPE mm.

50/72 50 7-6. 7-60

50/36 50 7-6. 4-6¢

50/36 MEANS 50mm. THK.x36 Kg. COVER WEIGH: OF 600mm COVER WIDTH. PROVIDE TWO COVERS OF 300mm WIDTH FOR EVERY 10m LENGTH OF TRENCH,

DST. E

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SEE DETAIL A OR 8

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~- --- -~"

(

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PL. WITH STI FFN ER

R C COVER THICKNESS As3 As4 TYPE mm.

50/58 50 7-60 7-6.

WIDTH 100

50/58 MEANS SOmm. THK.x58 Kg. COVER WEIGHT OF 600mm COVER WIDTH. PROVIDE TWO COVERS OF 300mm WIDTH FOR EVERY 10m LENGTH OF TRENCH.

100 HOOK TIED TO REINF.

80 ¢ D AIN HOLE

~2- 2

NOTES: 1. ALL DIMENSIONS ARE IN MM

2. STRUCTURAL STEEL SHALL BE AS PER IS 2062: 1992

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OF 1

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----- ------ .. c CH7S~7THK. CHQD. PL CHOD. PL.

WITH STIFFENERS

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50/58 50 7-6" 6~6"

50x58 MEANS 50mm. THK.x58 Kg. COVER WEIGHT OF 600men COVER WIDTH. PROVIDE TWO COVERS OF 3DOmm WIDTH FOR EVERY 10m LENGTH OF TRENCH.

10¢ HOOK

~----------------,-----------------~------------~ STANDARD NO.

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@240

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··CH7S~7THK. CHOD. Pl. WfTH STIFFENERS

THICKNESS i As3 As4 mm. · · · 50 7-6¢ 6-6.

· 60 · 7-8. 6-8. ·

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·

60x95 MEANS 60mm. THK.x95 Kg. COVER WEIGHT OF 600mm COVER WIDTH. PROVIDE TWO COVERS OF 300ml11 WIDTH FOR EVERY 10m LENGTH OF TRENCH.

100 WIDTH J 00 \

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llEO TO REINF.

~, 1S¢ HOLE

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NOTES: 1. ALL DIMENSIONS ARE IN MM. 2. STRUCTURft.L STEEL SHALL BE AS PER IS 2062:1992

LL-----------------------------------------~~

1,-' ----------,----------.---------::::l

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TRENCH TYPE - 1210 SD-EL -320

SEE DEL 1200

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0 0

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j ENDS WELDED TO PLATE

a '" ,§1 "'t~ 765x75x6 THK.

PL. EMBEDDED IN CONe.


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12THK/ '<II I ", @240 FOR CH7 S ONLY, PREMOULDED 1 0 G~ I-- "'--150)(50)(6

JT. FILLER - I

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• R C COVER THICKNESS As3 As4

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: 8 50/B6 50 7-6¢ 9-5¢

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70/181 70 5-8¢ 7-8¢

, o

1 Wo

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60/104 MEANS 60mm. THK.x86 Kg. COVER WEIGHT OF 600mm COVER WIDTH. PROVIDE TWO COVERS OF 300mm WIDTH FOR EVERY 10m LENGTH OF TRENCH.

WIDTH

i'L.illi -

I 80

I 80 I / 1091 DRAIN HOLE -

100

10<;!l HOOK I //jIEO TO REINF.

Xg I 80 I

SECT. [-I DET. D

NOTES: 1. ALL DIMENSIONS ARE IN MM


WIDTH 100

PLAN

109l HOOK

SECT. 2 2 DET. E

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1200

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STANDARD NO.

SD-EL -321 SHEET NO. I 1 OF 1

SEE DEL 'A' OR'~ r-:,,--'-\------'-----'-":-.-.-.-.

,

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1

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1-

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300 5 DET. 0 FOR -70/121 I I I LIFTING HOOK .",

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WIDTH 100 WIDTH

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X---g'--I ----1

I 80

'I' 80 /

100 DRAIN HOLE~ 80

NOTES: 1. ALL DIMENSIONS ARE IN MM, 2. STRUCTURAL STEEL SHALL BE AS PER IS 2062:1992

"--'~

- ,- .,- -' --.-. "CH7S=7 THK. CHQD, PL

WITH STIFFENERS

* R C COVER THICKNESS As3 As4

TYPE mm,

50/86 50 7 60 9 6¢

60/104 60 6-80 7-B¢

70/121 70 5-8¢ 7-8¢

60xl04 MEANS 60mm. THK,x104 Kg, COVER WEIGHT OF 600mm COVER WIDTH. PROVIDE TWO COVERS OF 300mm WIDTH FOR EVERY 10m LENGTH OF TRENCH,

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TRENCH TYPE - 1410 SD-EL -322

SEE DET.

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L50x50x6-715 LONG - 1

SEE OET. 'c' 1'\

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SHEET NO. I I OF I

75;.;6 THK. PL.---" ~TYP. " /

--F a ~ H=

" N N

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-

-,

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• • 765x75x6 THK. 'I V

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300 DET, 0 FOR -80/173 I I I -1riiAP I LlF11NG HOOK, -''''

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75

I I

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FLOOR LEVEL i '\ljGAP, LIFTING HOOK

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12THK / ...J i~" @240

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STIFFENER

**CH7S~7 THK. CHQD. PL 'JB':',\:L Q WITH STIFFENERS

* R C COVER THICKNESS As3 As4

TYPE mm.

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60/130 60 6-8. 7-8.

.,<I.,<TRENCH-i I-....... ;;>

80/173 80 5-8. 7-8.

WIDTH 100

I 80 10~ HOOK

I /-I'ED TO RE'NF.

Xg 80

'" 80 ~ 1 O~ DRAIN HOLE

NOTES: 1. ALL DIMENSIONS ARE IN MM. 2. STRUCTURAL STEEL SHALL BE AS PER IS 2062: 1992

60x130 MEANS 60mm. THK.xI30 Kg. COVER WEIGHT OF 600mm COVER WIDTH. PROVIDE TWO COVERS OF 300mm WIDTH FOR EVERY 10m LENGTH OF TRENCH.

80 1- -I

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STANDARD DRAWING CABLE STANDARD NO.

TRENCH TYPE - 1412 SD-EL-323 SHEET NO. I 1 OF 1

1400 I 75x6 THK. PL -, ~.

SEEOET4 750 650 , ""-,

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,

I 0 F 'A' OR'S rJ " 0 ,

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N

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,... 1- 0

N ~

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950 LON~ N 0 N SEE OET. C' I" 1- L§~X9_!:l~6 , , - · "' I~~ ~ "' ,...

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60x130 MEANS 60mm. THK.x130 Kg. COVER WIDTH "- WIDTH;;:> 1 OD WEIGHT OF 600mm COVER WIDTH. PROVIDE 100 TWO COVERS OF 300mm WIDTH FOR EVERY

" \ \ .'; '\ \, 10m LENGTH OF TRENCH.

'~J 80

1 100 HOOK 80 1 ~IIED TO REiNF.

, 1- , , ,

'~ .

)< Xg HOLE :;50 I 50

80 '",-, 80 I . " .',' 1011> DRAIN HOLE '" , , , ,. .. .. , H, ' j.


2. STRUCTURAL STEEL SHALL BE AS PER IS 2062,1 992

L

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SEE DET. 'A' OR 's'

\

300

II

.

J 1\

,

V

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I I Ib " EARTH CONDUCTOR N

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1 (TYP.)

I >/ L50x50x6

1 1250 LONG I" SEE DET. 'C'

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I / TIED TO REINF.

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TYPE mm.

50/108 50 7 60 10-60

60/130 60 6-8" 8-8¢

80/173 80 5-8¢ 8-8"

60x130 MEANS 60mm. THK,x130 Kg, COVER WEIGHT OF 600mm COVER WIDTH. PROVIDE TWO COVERS OF 300mm WIDTH FOR EVERY 10m LENGTH OF TRENCH.

I 80

I

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TRENCH TYPE

SEED~ 2000 'A' OR '8' ! 650 700

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-4i l I

5 Nos. ,

:1 I --.l 150)(50)(6 THK L65x65x6 )1 (TYP.) M.S. FLATS

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SEE OET. 'C' , l I ,

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NOTES: 1, ALL DIMENSIONS ARE IN MM. 2 STRUCTURAL STEEL SHALL BE AS PER IS 2062,1992

-

0 0

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2015 SD-EL -325 SHEET NO. I 1 OF 1

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n t f---1, J'-!~ LSOx6 THK. STIFFENER

12THK / I "~ @240 PREMOULDE 1 0 GA· ,-- 150x50x6

JL FILLER

* R C COVER

TYPE

70/212

80/242

100/302

, ,

"CH7S~ 7 THK. CHQD. PL WITH STIFFENERS

, THICKNESS

, As3 As4

, , , mm. , , ,

70 5-80 11-8¢1

80 5-8. 11-8<6:

100 6-8" 11-8.1 ,

70x130 MEANS 70mm, THK.x212 Kg. COVER WEIGHT OF 600mm COVER WIDTH. PROVIDE TWO COVERS OF 300mm WIDTH FOR EVERY 1O.0m LENGTH OF TRENCH.

:,: c:. /' /.

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1,-' ----------,----------.---------::::l

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STANDARD DRAWING CABLE TRENCH TYPE 2/2015

STANDARD NO.

SD-EL -326

SEE DET. 'A' OR ',~

a

,-i 650

2000 700

SHEET NO. I 1 OF 1

75)(6 THK. PL--" 6 /lTYP. '. .. /.

p EARTH

5 ~os. 71"=1~~", CONDUCTOR

,j EARTH CONDUCTOR

l I l I 150)(50;.:6 THK

M S FLATS WITH LL65x65x~--,

(TYP.) I I LI65x65',6-, (TYP.)

I - M

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IN CONe.

,

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l , ,

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2. STRUCTURAL STEEL SHALL BE AS PER IS 2062,1992

I

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6 SQ. BAR """,-_ .. WELDED TO ANGLE \ 5 CHOD. PL TYPE CH7S . I~ DET. 'E' FOR FLOOR LEVEL -) \" I GAP r ~'FT'NG HOOK

f==!~~:::-r-I---....,

JnI~1 f----~ 1~ LSOx6 THK. STIFFENER

/ ·1· ... ·,@240 12THK "

PREMOULDED--J 10 G.&. . '--- L50x50x6 JT. FlLLER b

-- ------------- ---

• R C COVER

TYPE

70/212

80/242

100/302

"CH7S~ 7 THK. CHOD. PL WITH STIFFENERS

THICKNESS As3 As4 mm.

70 5-8" 11-8"

80 5-8. 11-80

100 6-8" 11-80

70x212 MEANS 70mm. THK.x212 Kg. COVER WEIGHT OF 600mm COVER WIDTH. PROVIDE TWO COVERS OF 300mm WIDTH FOR EVERY 10m LENGTH OF TRENCH.

r,-" --------,---------------------,-1

L

xj

STANDARD DRAWING CABLE IDENTIFICATION TAG

r----------- 1--------1 , -. - , , , , : I I

-----"'~--- r--=>i".-k~ 5

i

3 ..................)

i ------->----------"-............. __ ._-_.-I

3C-120mm' ~

3 I

STANDARD NO.

SD-EL -327 SHm NO. 1 OF 1

SPACE FOR CABLE NUMBER REFER NOTE-5

L0c- 120

@

2 mm /

CABLE NO. SEE NOTE-5

CABLE NO. SEE NOTE-5

t--.-{4

'{1'~ X v~ '"'" <- \ - /\ J

t--.-{4

TYPICAL METHOD OF TYING THE TAG FOR CABLES WITH OVERALL DIA. <25 (ONLY FOR MULTICORE CABLES)

TYPICAL METHOD OF TYING THE TAG FOR CABLES WITH OVERALL DIA.>25

NQIES: 1. ALL DIMENSIONS ARE IN MM. 2. THE CABLE IDENTIFICATION NUMBER, NUMBER OF CORES AND

SIZE SHALL BE EMBOSSED ON THE TAG. 3. THE TAG SHALL BE SUITABLY nED APPROXIM.ATELY 150lnfTl

AWAY FROM THE CABLE GLAND AT BOTH ENDS OF THE CABLE. 4. THE TAG SHALL BE FREE FROM SHARP EDGES.

5. CABLE NUMBER SHALL BE EMBOSSED AS PER CABLE SCHEDULE.

<D CABLE IDENTIfiCATION TAG FABRICATED FROM 12 GAUGE ALUMINIUM SHEET

G;l 16 GAUGE G.1. BINDING WIRE Q) 3¢ HOLE @ ARMOURED CABLE ® CABLE GLAND

L

CD

STANDARD DRAWING CABLE INSTALLATION PRACTICE FOR BOTTOM ENTRY TO SWITCH BOARDS/CONTROL PANELS

FRONT

FINISHED FLOOR LEVEL

STANDARD NO.


CD

DETAIL-A

, .. " . ,<! .. : '. > • - ": .. ' " '.. ,. ~ . ",. ,-.

~ I , I

-i' ,

, , ,

i :----= ~

~ 0 , , ,

't "; '-7 I , I

7

CD TO @ REFER SH. 1 OF 2

@ CABLE TRENCH

@ CABLE SUPPORTING ARM

,

:1C:-,J'

NOTES:

4

L . A

, , ,

il.J

1. FOR NOTES REFER SHEET 1 OF 2.

OETAIL-B REFER NOTE-3

,..-- ---- - ---

! E9 I 11

!

5

2. CONTROL AND POWER CABLES IN TRENCH SHALL BE TiED TO THE

SUPPORTING ARM WITH 3¢ NYLON CORD, IF CABLE TRAY IS NOT USED.

4

3. 1'50,50,6 FOR CLAMPING l/C CABLES TO BE SUITABLY GROUTED AT SITE.

L

STANDARD NO. FRONT SHEET SO-EL -401

SHEET NO. I 1 OF 1

M SC E LLAN EO U S DETA S

HAZARDOUS AREA

..J

r,-________________________________ -, ______________________________________ -,,-__________________________ -,


SHEET NO. I OF 1

SR. DESCRlf'TION ~JO.

SD-EL -401

2 SD-EL -402

SD-EL-40J i)

4 SD-EL-404 DETI\I~S ~-OR .~RE,A CU\SS:F-:CAi-:(jj\j (0: S~ORE Ol~/CJ-\S I NS-:-;:\LL,i\Tlor-~)

5 SD-EL-405 ClETAlcS ,OR .I\.R~.I\ C L,A,SS: F! CA:I 0 N (0;:; S~ORE O!~/GAS I r\jS:ALLATIOr-~)

6 SD-EL-406 DETI\I~S ::-OF~ ~I?E,A CU\SS: r:-:CAi-:(jj\j (0: SHOF~E Ol~/CJ-\S I NS-:-;:\LL,i\Tlor-~)

-:;- SD-EL-407 DETI\I~S ::-OF~ ~I?E,A CU\SS: r:-:CAi-:(jj\j (0' :', 51'01,[ Ol~/GI\S 1 N 5:/,LLilll 0 ,,)

8 SO-EL-40B ClETI\I CS ,OR A.R~,A CU\SS:FiC/,:!ON (0:\: SHORE O!~/G!\S I r\jS:;:\LL,i\TIOr-~)

9 SO-EL-409 DETA_I~S ::-OF~ AI?EA CLASS:f:-IU",-: 10",j (O:\J 51'01,[ Ol~/GAS IN5:ALLMIO,,)

Ii] SD-EL-410 DETA_I~S ::-OF~ AI?EA CLASS:f:-IU",-: 10",j (O:\J 51'01,[ OI~--1 GAS IN S-;-,ALL,6, ,J

i 1 SD-EL-411 DEIAlcS ~-OR ~RE,A CU\SS: F-:CAi-I(Jj\j (0: SHORE Ol~/CJ-\S 1 N S:/,LLilll 0 ,,)

12 SD-EL-412 DETA.lcS ::-OF~ AI?EA C LAS S: r:-: e"c",-;-: 0 j\j ( ( SHOF~E IN S-;-,ALL,6, ,J

1.3 SD-EL-413 DETI\I~S ::-OF~ ~"E,A CU\SS; r:-:CAi-I(Jj\j (O'i SHOI:~E Ol~/CJ-\S 1 N S:/,LLilll 0 ,,)

14 50-El __ -414 D[l~.lcS ::-0 F\ AR[A CLASS: FICi",iICJ~~ ( ( SHOF\[ IN SiP\LL,G, TI C, hi)

15 50-El __ -415 DETI\I~S ::-OF~ AFE,A CL,A,SS: r:-:CAi-:Oj\j (O'i SHOF~E Ol~/G!\S I NS-:-;:\LL,i\Tlor-~)

16 50-El __ -416 D[l~.lcS ::-0 F\ AR[A CLASS: FICi,,_iICJ~~ SHOF\[ IN SiP\LL,G, TI C' hi)

17 50-El __ -417 DETA.lcS ::-OF~ AI?EA CLASS; r:-:C,A,';':Oj\j (O:\J SHOF~E OI~/GA.s IW" LL;IIO,,) I :::.>:/-c", ,,-,\

18 50-El __ -418 DET.~,I ~ __ S ~OR AReA c: l_ASS: FI C:,A,iJ Cl ~~ SHORE IN Si,All._,6, TI C) hi)

-

-

I I I

L

,,--------------------------------.-------------------------------------.--------------------------,,

L

GENERAL NOTES & LEGENDS STANDARD NO, FOR AREA CLASSIFICATION

(ONSHORE OIL/GAS INSTALLATION)I---=c=-cS=D_EL.--40_3~~__I SHEET NO, I I OF 1

NOTES:-

I, ALL DIMENSIONS ARE IN METERS UNlESS OTHERWISE MENTIONED.

2. THE AREA CLASSIRCAlION CONFORM TO THE LAlEST ISSUE OF IS : 5572. INDIAN PETROLEUM RULES OISD-STD-113. OIL MINES REGULATIONS/OGMS GUIDEIJN[S (FOR PROJECTS UNDER OGMS JURISDICTION) & RECOMMENDATIONS OF PROCESS UCENSOR AND PROJECl DESIGN BASIS.

3. lHE AREA WITHIN 15M (EXITNDING IN ALL DIRECTIONS) or WIT! VENTS, PRODUCT SAMPUNG LOCATlONS,PROCESS WATER DRAINS, ONLY SEWERS VENTS, INSPECTION HATCHES, DISCHARGE ORIFICE or nxEO UQUID LEVEL GAUGES, ROTARY OR DIP GAUGES, FILLER OPENINGS SHALL BE ClASSIRED AS ZONE-I. FURTHER AN AREA FROM 1.5M TO 3.0M (EXTENDING IN ALL DIRECTIONS) FROM VENTS SHALL BE ClASSIFIED AS lONE-2, HOWEVER THE VENTS OR DRAINS BlANKED DURING NORMAL OPERATION AND USED ONLY WHEN THE PLANTIS DEPRESSURISED OR UNDER SHumDWN, SHOULD NOT BE REGARDED AS AN OPERATIONAL VENT OR DRAIN OR SOURCE OF HAZARD,

•. OPEN TRENCHES, PITS OR SUMP BELOW GRADE WITHIN ZONE-2 AREA SHAll BE CLASSI~EO IS ZONE-1 AREA.

5. IN CASE OF PIPEUNE HANDUNG FLAMMABLE MATERIAL, WHERE WELL MNNTAlNED VALVES, f1TTINGS AND METERS ARE INSTALLED IN WEll VENTILATED AREAS OR PIT, THE EXITNT OF ZONE-2 AREA ABOVE THE GROUND SHALL BE CONSIDERED AS '.OM IN ALL DIRECTIONS FROM TIlE POSSIBLE SOURCE OF HAZARD, ALTHOUGH THE PIT ITSELF SHAll BE CLASSIRED AS ZONE-I AREA,

S. GIS GROUPS ARE AS PER IS: 9570.

7. ROADS FUllY/PARTlY COVERED UNDER HAZARDOUS AREA CLASSIFICATION SHALL BE BARRICADED FOR VEHICULAR MOVEMENT.

LEGENDS:-

• []

- ZONE -1, GAS GROUP lIA/liB HAZAROUS AREA

- ZONE - 2, GAS GROUP IIA/IiB HAZAROUS MEA

- ADDITIONAL lONE-2, GAS GROUP IIA/IiB MEA (MEA SUGGESTED WHERE LARGE RELEASE OF VOLTAGE PRODUCTS MAY OCCUR)

- ZONE -I, GAS GROUP lie HAZAROUS AREA

- ZONE-2, GAS GROUP IIC HAZAROUS AREA

- SAFE AREA (NON HAZMDOUS)

~l I.

I >""

~"I a _

NOTES:

L

16M

- . c-, .'-

DETAILS FOR AREA CLASSIFICATION (ONSHORE

OIL/GAS INSTALLATION)

SOURCE OF HAZARD -ts</

\\1\1\1 ..

J SUMP/PIT /TRENCH

_I_ 16M _I_ 16M

DETAIL-1 FREELY VENILATED PROCESS AREA

(HEAVIER THAN i'JR GASES OR VAPOURS) (SOURCE OF HAZARD LOCATED ABOVE GROUND LEVEL)

I_ 8M .. I ... 8M _I

SOURCE OF HAZARD -1'7'"

- .• s",

\I \I \/. SUMP/PIT /TRENCH

.. " -- ..

16M .I- 16M -1- 16M .I-DETAIL-2

FREELY VENILATED PROCESS AREA (HEAVIER THAN AIR GASES OR VAPOURS)

(SOURCE OF HAZARD LOCATED NEAR GROUND LEVEL)

STANDARD NO.

SD-El-404 SHEET NO. 1 OF 1

FGL

16M .1

FGL

..

16M -I

NOTES:

L



SOURCE OF HAZARD

,-,>,,,,,,~, '--'--' ~".~, .

STANDARD NO.


FGl

~ ~1~~ ___ 1~6~M _____ .+I ___ ·V __ \I_V~16~~~--__ S_U~M:_~I_~~fi_R_EN_C~Hl~6~M __ ·_1_3_:+I~ ____ ~16~M~ _____ I

SOURCE OF HAZARD

DETAIL-3 PROCESS AREA WITH RESTRICTED VENTILATION

(HEAVIER THAN AIR GASES OR VAPOURS)

I

SlJ"P/prr/fRENC~/.13M I.

DETAIL-4 PROCESS AREA WITH RESTRICTED VENTlLATION

(HEAVIER THAN AJR GASES OR VAPOURS)

FGl

NOTES:

L



SOURCE OF HAZARD ----.

,. FGL 00

SUMP/PIT/TRENCH _/

SOURCE OF HAZARD-,

FGL -

4.5M

\\

-I 16M 16M

DETAIL-5 WElL VENTILATED INDOOR AREA

(HEAVIER THAN AIR GASES OR VAPOURS)

SOURCE OF HAZARD

FGL -

STANDARD NO.

SD-EL-406 SHEET NO. 1 OF I

4.5M I ---.

h<4.5M

ELEVATION ELEVATION

SOURCE OF HAZARD ~.~ ~

PLAN DETAIL-6

(FREELY VENTILATED PROCESS AREA) (FOR UGHTER THAN AIR GASES OR VAPOURS)

NOTES:

L

3M



STANDARD NO.

SD-EL-407 SHErr NO. 1 OF 1

AREA OF INADEQUATE /....-' VENnLATION

4.5M MAXIMUM OR TO GRADE

F.G.L

SOURCE OF HAZARD \ BODOM OF ENCLOSED AREA

SUMP PIT TRENCH

DETAIL-7 INADEQUAnELY VENTILAnEO COMPRESSOR SHELTER

(LIGHTER THAN PJR GASES OR VAPOURS)

LOUVERS

BODaM aF /

4.5M MAXIMUM F.G.l. OR TO GRADE

ENCLOSED AREA SOURCE OF HAZARD

SUMP /PITjTRENCH

DETAIL -8 ADEQUATELY VENliLATED COMPRESSOR SHELTER

(LIGHTER THAN AIR GASES OR VAPOURS)

NOTES:

L

3M



STANDARD NO.


AREA OF INADEQUATE /....-' VENnLATION

4.5M MAXIMUM OR TO GRADE

F.G.L

SOURCE OF HAZARD \ BODOM OF ENCLOSED AREA

SUMP PIT TRENCH

DETAIL-7 INADEQUAnELY VENTILAnEO COMPRESSOR SHELTER

(LIGHTER THAN PJR GASES OR VAPOURS)

LOUVERS

BODaM aF /

4.5M MAXIMUM F.G.l. OR TO GRADE

ENCLOSED AREA SOURCE OF HAZARD

SUMP /PITjTRENCH

DETAIL -8 ADEQUATELY VENliLATED COMPRESSOR SHELTER

(LIGHTER THAN AIR GASES OR VAPOURS)

NOTES:

L

16M

~ <D



~ 1_ 8M ~ I _ 8M ~ i I. 8M • I. 8M • I "

DETAIL -12 (SPHERE) (HEAVIER THAN AIR GASES OR VAPOUR)

STANDARD NO.


F.G.l. -,'- .. ,,'.

16M ·1

~~o=~~~~~~~~ F.G.L , - ,_', .,-'_- n_ _,<_'_. h' ,'., "_" <-

16M 8M 8M 8M 8M

DETAIL-13 (BULLET) (HEAVIER THAN AIR GASES OR VAPOUR)

NOTES:

L

1- x

1_45M_1

AREA WITH IN I.SM OF RELIEF VPLVE

"'s. "",

" ,

I. X .1

AREA WITH IN 15M OF RELIEF



AREA WITH IN LSM OF RELIEF

VPLVE

STANDARD NO.


DYKE WALL CONTAINER

·····················~G.L

DETAIL-14A DYKE HEIGHT LESS THAN DISTANCE FROM

CONTAINER TO DYKE (H LESS THAN X)

CONTAINER

DETAIL-14A DYKE HEIGHT LESS THAN DISTANCE FROM CONTAJNER TO DYKE(H GREATER THAN X)

1_45M_1

~~~ o.! DYKE WPLL ,

• mmmmmmmmmmmmmmJ:·L

SUMP PIT RENCH

VALVE F G L

~~/~~'~r~~----~~

DYKE WALL CONTAINER \'UMP /PIT /TRENCH

DETAIL -14C (STORAGE BELOW GRADE) STORAGE TANKS FOR CRYOGENIC LIQUIDS

J

r·~ ________________________ .-____________________________ ~ ____________________ -,

NOTES:

L

j ,

" : "':

,VMrPII 3M ---------------



RETURN HEADER HYDROCARBON VENT LINE

DETAIL-15 (HANDLING HYDROCARBON PReCESS COOUNG WATER)

DETAIL-16 FLARE

STANDARD NO.

SD-EL -411 SHEEr NO. 1 OF 1

r,-__________________________ -. ________________________________ -. ______________________ -,

NOTES:

L



SURFACE OF CONTENTS

DETAIL-17

3M -H--=

UNIT SEPARATORS, PRE-SEPARATORS AIID SEPERATORS

(APPLICABLE fOR OPEN TAIIKS OR BASINS)

DETAIL-18 DISSOLVED AIR FLOATATION (DPf) UNITS

(APPUCABLE fOR OPEN TANKS OR BASINS)

1611

iF.Gl,

t .lM SURFACE OF CONTENTS

DETAIL -19 BIOlOGlCAL OXIDATION (BIOX) UNITS

ZONE-1 (1.5M AROUNO VEtil)

ZONE-2 (1.5M TO 3M AROUND VENT)

VEI!II

F,OL

SURFACE OF CONTENTS~T-----=;:.1.! +1_.-.ll.c:5I5M\i

DETAIL-20 UNDERGROOND COVERED SUMP OR OilY WATER SEPARATOR

STANDARD NO.

SD-EL-412 SHEEr NO. 1 OF 1

r,-__________________________ -, ________________________________ -, ______________________ -,

NOTES:

L

I, · · ·

; \



j \

DETAIL-21

(MATERVlL: lIQUIFIED GAS/ COMPRESSED GAS/ CRYOGENIC lIOUID)

WAGON/TANK mUCK LOADING AND UNLOADING 1M CLOSED SYSTEM. PRODUCT TRANSFER THROUGH DOME ONLY

VAPOUR RETURN LINE LIQUID TRANSFER PIPE

( I \

DETAIL-22

(MATERIAL: FLAMW£LE LIQUID) WAGON/ TANK TRUCK LOADING AND UNLOADING VIA CLOSED SYSTEM.

PRODUCT ffiANSFER THROUGH DOME ONLY

. \ / ,

STANDARD NO.


u

NOTES:

L

(



/

~ VAPOUR OF RETURN LINE

STANDARD NO.


/~1""'~~~"""""""""""""""""""""" ........................... ~

r--"~--~~:;::----~.L.-L---, • / \ ) \ 0

SUMP!PIT/!RENCH 3M

............................. ~ ........... .

"" LIQUID TRANSFER LINE

DETAIL-23 (MATERIAl; FLAMMABLE LIQUID)

WAGON/TANK TRUCK LOADING AND UNLOADING ~A CLOSED SYSTEM.

/ \

BOTTOM PRODUCT TRANSFER ONLY

DETAIL-24 (MATERIAl; FlAMMABLE LIQUID)

WAGON/TANK TRUCK LOADING AND UNLOADING VIA OPEN SYSTEM.

TOP OR BOTTOM PRODUCT TRANSFER ONLY

, , , ,

------- --------------- -------------------I1;.G.L

.............. ~ ....... .

NOTES:

L

/ \



/ \

DETAIL -25 (MATERL'lL: UQUIRED GftS/ COMPRESSED GPS/ CRYOGANIC GAS)

WAGONfTANK TRUCK LOAD~NG ANO UNLOADING '.1A CLOSED SYSTEM.

PRODUCT TRANSFER THRUGH BOTIOM ONLY

STANDARD NO.


SELF CLOSING ._ DOOR (lYP.)

3M

NOTES:

L



EXHAUST FAN (lYP.) /

><, \ :

DETAIL-26A T '-- DOOR (TYP.)

FlAMMABLE SUBSTANCE RELEASED DURING NORMAL OPERATION WrTH INADEQUATE VENTILATION

777777»

V' IV I\,

DETAIL-268 FlAMMABLE SUBSTANCE RELEASED DURING ABNORMAL SITUAnoN

OR INFREQUENT OPERATIONS WITH INADEQUATE VENTILATION

DETAIL -26C

FlAMMABLE SUBSTANCE RELEASED DURING ABNORMAL SITUATION OR INFREQUENT OPERATIONS WITH ADEQUATE VENTILATION

I~

STANDARD NO.

r,-________________________ ,-____________________________ ,-____________________ -,

NOTES:

L



DETAIL-27 BALL OR PIG LAUNCHING OR RECEMNG INSTAllATION IN A NON-ENCLOSED. ADEQUAffiY VENTll.AlED AREA

STANDARD NO.

SD-EL -417 SHEIT NO. 1 OF 1

:F.G.l. . .

r,-________________________ -,,-____________________________ -,,-____________________ -,,

L

VESSEL



HIGHEST VENT POINT

/ vi'

SECTION 1-1

STANDARD NO.

SD-EL-418 SHEET NO. I 1 OF I

SHIP 1, VESSEL

........................................ / vlVvl' 'VVV, ,

NOTES:

vlV

,

1.-J

PLAN DETAIL-28

JETTIES OR MARINE FACILITIES

• SHALL BE REDUCED TO 10M IN CASE OF VESSELS WITH LOADING OR DISCHARGES RATES<;10M3jMIN.

H SHALL BE REDUCED TO SM FOR LOADING RATES~lOM3jMIN.

'"

J

I:::---,--------,---:::;l

L

STANDARD NO. FRONT PAGE SD-El-501

SHEET NO. I 1 OF 1

M SCE LA~ EOUS DETA~LS

CATHOD C PROTECT ION

-'

STANDARD NO. DRAWING INDEX SD-EL -502

SHEET NO. I 1 OF 1

SR. DRAWING NO. DESCRIPT:ON NO.

1 SO-EL-501 FRONT PAGE

2 SO-EL-582 DRAWING INDEX

SD-El-503 CATHODIC PROTECTION SCHEMATIC DIAGRAM

4 SD-El-S04 (5H 1) TEST STATION CONNECTION SCHD/ES

• 5 SD-EL-504 (SH2) TEST STATiON CONN[CTIO~~ SCHEwES

6 SD-El-504 (5H3) TEST Cot..JNt:CTION SC'·1EMES

7 SD-EL-50S TEST STATiON WITH FOUNDATION DETAilS

8 SO-El-506 GALVANIC ANODE INSTALLATION

9 SD-EL-507 DEEP WELL GROUNDED INSTALLATION DETA.lLS

10 SD---EL--·S08 SHALLOW M,JODE GROUND BED (PCP)

11 SO-EL-509 THERMITE WELD CONNECTION DETAILS

12 SO-EL-510 IYPICAl CONSTRUCTION CETAILS CF HIGH SILICON CAST IRON ANODE

1-"3 SO-El-511 ZINC R,BBON ANODE CASED CROSSING WITH COA;-ED/PAINTED CASING

14 SO-EL-S12 PIPELINE GROUNDING THROUGH PO: ... AHISP-.TION CELL AND GALVAN!C ANODE

15 SO-EL-S13 ZI!'-JC GROUNDING CEll TWO PLATE TYPE

',6 SO-EL-514 PERMANANT COPPER-COPPER SULPHATE REFERENCE CELL AND :NSTAlLATION DETAILS

17 SD-EL-515 PREPACK ED MAGNESIUM ANODE

18 SD-El-516 PREPACKED ZINC NlODE

19 SO---EL---S17 CATHODIC PROTECTION SYSTEM AI\ODE JUNCT:ON BOX (AJB) DETAILS

20 SO-EL-S18 NEGATIVE DISTRIBUTION 80ND BOX (NDBB) DETAILS

21 SD-EL-519 CATHODIC PROTECTION SYSTEM EQUIPOTENTIAL BOND BOX (EBB) DETAILS FOR RMETP

22 SD-El-520 CATHODIC PROTECTION SYSTEM FOREIGN BOND BOX (FBB) DETAilS (2 CIRCUITS)

23 SD-El-521 CATHODIC PROTECTION SYSTEM TEST POST INSTALLATION AT ROAD CROSSING (RX) ,

CATHODIC PROTECTION SYSTEM H:GH -rENSIO!'-J LINE CROSSING JUNcrlON BOX (HTB) , ,

24 SO-EL-S22 , INS7ALLAT;ON DETAILS

, , , , , , ,

L

L

ANODE JUNCTION BOX

rnSIIIV8

VARIABLE RESISTANCE

SHUNT

CATHODIC PROTECTION SCHEMATIC DIAGRAM

35 sq.mm XLPE/PVC/

SWA/PVC/POSITIVE ~~~==~~~~~=il HEADER CABLE TO T/R Ir

RECTIFIER UNIT

- -~ i 'L DRAIN POINT TEST POST L: ---

,---'>--,-l

STANDARD NO.


pvc NICKEL PLATED BRASS NUT AND SCREW FOR TERMINAL LEAD CONNECTION

NEGATIVE BONDING CABLES

5

4

3

~C~tjp~%S'l;O'f" MONitORING CABLE 2 No. 10 S .mm HMWPE RE. CABLES

(SEE NOTE-2

PRE-PACKED CuSo4 REFERENCE ELECTRICAL (PERMACELL PLUS)

5 No. 1 x16 S . mm KYNAR,IHMWPE ANODE

CABLES

,

I , I ,

-----~ p

POST

.. CONDUIT

.. • •

CABLE TO NDBB PRE PACKED REFERENCE

2 AT PIPE INVERTER LEVEL

A1

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS O"'HERWISE SPECIFIED. 2. ALL CA8LES-TO-PIPE CONNECTIONS (EXCEPT DRAIN CONNECTION ON RMETP) FOR UNDERGROUND PIPELINE

SHALL BE MADE VIA THERMITE WELDING AS PER DWG. STD.

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

TEST STATION ,TYP.) ""-

03 04

02

TEST STATION CONNECTION SCHEMES

1 2 3

STANDARD NO,


04 05 06

1 02 03

4 MM' CABLE :--THERMIT WELD (TYP,) 30~M

~f==t==-tf-:t-"~MM' C~ ___ 1==t

V ,/_ r 4MM 2 CABLE

OMM<TYP.i : 300MM

bPIPE LINE (TYP.)

RESISTOR

\ Q5\~~~~ ! 1? i 2f±:'=::r?

~ L---------1 OM MI······ =+-+-1----'"

(I !

J ~F~" ~

, ......... ::fro / 08 , , , ,

~ , , , , ,

1 2 3 0' , , , , ~

CABLE I i -

300 MM

!-~FORFIGN 300MM 25Mrl CABLE I PIPEi INE

,\ y-(II U\ ( 11/ (J U' 'I \* (O----,/Z""'/f---1'-(

CA··R···R···I·E\R l,=' =~,,====i' ~ZINC GALVANIC (II

. 8 \ "-CASINC; ANODE 7'"

CASING , :) \ - ___ J

CW::SS: L;;- .-\ "L c-l

II

CARRIER:

04 05 06

0 1

4MM'CABLE k··:::····=J=··===±~~~_ 1- INSULATING

// JOINT

( ()

25W/ CABLE

o !

URGE DIVERTER

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

9 6 3 7 9 8 09 ,

,---- ,

1 r2 9 3 74 ,

, , , , , , , , , , , , , , , , , ,

3"" . rw) , ,-, , , , , , ,

··Tb· r 'L

()

, 0101 , , , , , , , ,

5 , , , , , ~

TEST STATION CONNECTION SCHEMES

4 MMz

CABLE

60 MM 'Tj'P j ~M CABLE 6

35 W/ CABLE ......... ....... ~ CATHODICALLY

PROTECTED SIDE ()

~""""''''''!.-'_-I----I},EFER[NCE CELL (lYo.)

~ REFERENCE CELL (lY'.)

'\ ~-;- ::;;-\1 ;;:-: '\-:--: S' A;- :Jl\ ~ C::-. ,):~: ___ \:_ £,' THE ~:6;:ON)

25 Mf/ CABLE

0 4

!\ Ii '\ S"-H",U,,,NT-+t-"f __ ~

LINK !,~~ 3

10 MM' CABLE

~ .............. " ANODES

4 M",'CABLE --, ~ '" BURiED JUNCTION BOX "-!"'"'-"'''''''---,j-' '300MM j.' Il.mmmmm mmmmmmmmmmmy

STANDARD NO.

SD-EL-504 SHEET NO. I

08

EARTHiNG 03 ,4 ?5 SYSTEM

., 0 M INSULATING JOINT /' -

u

2 OF 3

r,-____________________________ -, __________________________________ ,-________________________ ,

L

STANDARD NOc TEST CONNECTION SCHEMES SD-EL-504

SHEET NO. I 3 OF 3

\ ---+0' \ r ' \ 010 011 012

I 2

NOTES: 1. NUMBER OF TERIJINALS FOR TEST STATION OF OIFFEREW OC,,(C110N SCHEME $HA"L BE ,;; SHeWN ON THE RESPECllve SCHEME DRAW1NG, TEST STATON

FOR ANY OTHER SCHEME DR'WINC. TEST STATION FOR ANY OTHfR SCHeME Sf'"Ll PRcEER<BLY BE Sl\lllAR TO NW OE THE ABOVE PPES, 2. ElEClRlCAL CONNECIIONS ScALL BE CLEANED ro 3RIGHT SURfACE &IIGHlEND WlrH NON-OXIDE GREASE APPLlEO ON MECHANIC!lLLY MATED SURFACE 3 NUMBER or TERliiNALS roR TEST STATION FOR GALVANIC ANODES FOR PERMANENT EP SYSEM SHAle BE DECIDED BASED ON NUMBER or ANODES,

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

CONCEALED .lOCK----

TEST STATION WITH FOUNDATION DETAILS

W 1-1 -----'"----_~5

I D ~ -! I-

««««««««««««««<~-

TERM:NAL PLATE. ._-T =

z

STANDARD ND<

SD-El-505 SHEET NO. I 1 OF 1

50,

-"!lUTER WITH - t~EOPRENE GASKET

o o o

100 MM!Z> ,4.5MM THICK CI PIPE

NOTES:

FOUNDATION PLATE-, WITH STiFFNER ______ y!

/ / W / '0 i " ' _1 4 , , /1

pce IM-151 /1 , FOUNDATION , , , , , , ,

-, , ,-/ '/

, 1/ ,

/ , ,

,I , 1 , , , , ,.

- , , , / , , , -, ,

I I / 0

'" I

r-OUNOATION \ BOl"(lYP)

'i ~/ " o

o

'" p / , ,

GRADE LEVEL r-----T-;

/ ,

,

-~,

/ ,

/

i ,

-

;() , N

o o '"

/ ,

/ ,~

/ ( I

/ ,

- ,

i \ '" q-.

! , -,

/ ,

I~J \ /',

! '

Il III ,~~~HlJ

/ ,

!-

~

600 .............................. ~:::r-____ -'6'-'O'-'O'-____ -1

kll -I

THE ENTRY SHALL BE SEc\LED WITH BITUMEN COMPOUND AfTER LAYING CABLE TO PREVENT WATER ENTRY,

1. THE SHUTTER SHALL BE HINGED lYPE W:TH CONCeALED LOCK & SHALL HAVE ODOR GASKET TO MAKE THE TEST smlON WEATHER PROOF (IP:S5). 2. THE INNER & OUTER SURFACE OF THE TEST STATION SHALL BE EPOXY PAINTED. 3. THE NAME PLATE SHALL BE OF ANODISED ALUMINIUM V!I7H BLACK BACKC,OUND & WIH LEmRS & SHALL BE FIXED TO THE INNER SIDE OF SHumR. 4. TEST STAT:ON SHALL BE ERECTED WITH THEIR SHUTTERS PARALLEL TO THE L:NE OF AX:S & FACING THE PIPELINE, 5. THE CHAINAGE OF TEST STATION SHALL BE WRIHE' WITH BLACK PAINT ON THE OUTER SiDE OF THE FRONT SHUHER. 6. HEIGHT OF THE TEST STATION SHOWN ABOVE GROUND LEVEL IS MINIMUM ONLY. THE ACruAL HEIGH I SHALL BE DECiDED BASED ON LOCAL IcOOD

LEVELS ro BE ASCERTAINED .

7. CONTACTORS SHA~L FuRNISH ALL THE DIMENSIONS OF THE TEST STATION. S. ALL DIMENSIO~S ARE IN MM.

.J

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

STANDARD NO, GALVANIC ANODE INSTALLATION SD-El-506

SHEET NO. I 1 OF 1

PREPACKEO GALVANIC ANODE

NOTES:

TEST STATION

( ,

f f""""""""": [ t : ,~ r

/ / / " ""PIPE UNE '" 'C' f--- 0..

I-BURIED JUNCTION BOX

FOR CABLE JOINT '-,/1 -" :' to.. (I. \

I (EPOXY FIELD)

/ ANODE TAIL CABLE

10MM' PVC INSULATED , ,

// ARMOURED CABLE ~ PIPE LINE . '-,

c' ~

~

5000 MM MIN. FOR MAGNESIUM ANODE 2000 MM MIN. FOR ZINC ANODE

1. THE PREPACKEO GALVANIC ANODE SHALL BE INSTALLED AT A MINIMUM DEPTH, EQUAL TO BonOM LEV:::l OF THE ;:lIPEUNE.

2 THE ANODES ARE SHOWN HORIZONTALLY LAID. ALTERNATIVELY THE ANODES MAY BE VERTICALLY INSTALI,ED WITH 3. NUMBER Of TERMINALS FOR TEST STATION FOR GAcVANIC ANODES fOR PERMANENT CP SYSTEM SHAcL BE DECIDED BASED ON NUMBER OF ANODES.

L

I

STANDARD NO. DEEP WELL GROUNDED INSTALLATION DETAILS SD-EL -507

o ~ :Lr

NAME PLATE

IIOW.lI I 2~ -.., Z W

0 ~

0 ~ 0

N ;= - '" z a z

....... ,... CAt:lLt. "' ..... /

5-1xl0 SQ.mm -------------

~

.. -@-

CJ}-

, KYNAR;HMWPE CABLE

Ir-@SEENOTE-3

l o o

"' CABLE T[E g 'ilt NOlt-.

a

o a o N

~ ts o o o

_ N

TI ts o ,. g

~ N

~ ts o o o N

I~ 0 o

MMO ANODES SEE DETAil 2

u "l'''~O~~~!:@\ll ~f' (PER EACH ANODE) 1 ~~ SEE DETAll-1

L - N

~~ !l

~Y-o ~ODE CENTRALIZER

(PER EACH ANODE) (SEE DETAIL-1)

SECTiON A-/l,

...l....-__ :-cL....~.J.. 1-203-1

'SOLDERING' HALF OF CONNECTOR

·jAlL=-~

ANODf C~NTRA::lr~

ITEM NO. 1.

2"

3 .

4.

5.

6.

7.

8.

9.

1 D.

11.

12"

13.

ADJUSTMENT SCREW

~[,9I

SLOT FOR WIRE ATIACHMENT

CONNECTOR

SHEET NO.

MIXED METAL

fXIDE ANOPE

i)t$sll LEAD) , WIRE

OF 1

ANODE CABLE

J)F""/d:~7

.\fJPO TUBv~AR ANOD:- DrTAI~S

~~~f',AY (BY OTHER)

DESCRIPTION

CABLE ROPE HANGER oc,,'" ,~"C '"" ""U

PVC CASING, 203 MM '"

STEEL THREADED COLLAR

STEEL CASING 203mm DIA WITH END SEALED (BY OTHER)

~I?'ED~/~ET~!:. OXIDE TUBuLAR ANODES WIT 16 SQ. mm KYNAR HMWPE CABLE

CALCULATED PETROLEUM COKE BREEZE

PERFORATED PVC VENT PIPE (25mm ¢)

UNPERFORATED PVC VENT PIPE (25mm 0)

CLEAN SHINGLE 12mm 11 (BY OTHER)

M30 M.s. SUSPENSION BAR

ANODE JUNCTION BOX (450x450x260)

CRASH GUARD (BY OTHER)

ANODE CENTRALIZER

OTY.

1M

6M

2 No.

IBM

5 No.

800kG

16M

16M

AS REO.

1 No.

1 No.

AS REO.

5 No.

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.

2. ACTIVE LENGTH (16mm) SHAll BE FIELD WITH CALCINED PETROLEUM COKE BREEZE.

3, ONCE THE COKE BREEZE COLUMN BECOMES HARD, INACTIVE LENGTH TO BE FIELD WITH CLEAN SHINGLE 12rnrn DIA (BY OTHER)

4. CABLES TO BE TIED TO THE VENT PIPE USING PVC CABLE TIE. 5, CABLES TO BE TIED TO THE SUSPENSION ROC USING PVC CABLE TIES.

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

SHALLOW ANODE GROUND BED (PCP)

STANDARD NO.

SD-El-508 SHEET NO.

"-t:-o o o N

GRAOE LEVEL

150 :- TYP.l

, , ,

I

,

I , ,

,/ I

ANODE LEAD

JUCTION BOX

I

~-' '-1 I , , , , Ui -1--1\------" L'_-'

\

\CANISTERED ANODE LAID HORI70NTA,LY

- NATIVE SOIL --. ~ CL

, , , , , , ,

I , , , ,

NATIVE BACKFILL SO;L

F,-:::VA-:Q\i

, , , ,

I I

:::" 'I:: ~o' - - -I: ~ I- \ "-'" WARNiNG MAT I:oi'l---O

NATIVE SAC

-' 0J~~~~;::-~~~~~~~~::B~RI:CK~CO~V~ER o 00 o - -~ T - - I

00 1 50(TYP)

FILL

ALL OPENINGS SHALL BE SEALED WITH 8ITUM") COMPOUND A" ER LAYING OF CABLE

I

/// '"

ANODE TAIL CABLE

POLYETHYLENE CABLE I/NARNING MAT

BRICK COVER

I ,----- ', .......................... [ .. . I I _ I

:''\ I '

~l--1

PIPE LINE

~

"-I: ~

0 0

'" 0 -

L , , , , ,

~

CL

I: ~

0 0

"' -,

100 MTR.(MIN.)

z

" ~ o o

"'

-

L

PIPELINE

'S"A'"N D"'B"'ED

CAIJISTERED ANODE CONCRETE

NOTES: 1. THE ANODE GROUND 8ED SHALL BE LOCATED ELECTRICALLY REMOTE FROM THE PIPELINE WITH

MINIMUM 100 MTR, AWAY FROM THE NEAREST POINT ON THE PIPELINE. 2. NO. SPUCING SHALL BE ALLOWED FOR THE CABLES.

('I{I' ~ 7-,,>0,

, ~

,~

_,f.,NODE D 'tARK>:;? PQST

3. CONTACTQR SHALe FURNISH 7HE DIMENS;ONED DRAWING SHOWING ACTUAL QUANTITY OF ANODES FOR EACH GROUND BED 4. ALL UNARMO~RED CABLES SHALL BE RUN THROUGH P[ SLEEVES. 5. ANODE BED MARKER SHALL BE RUN THROUGH PE SLEEvES. 6. NATIVE BACKFILL SOIL SHALL BE FREE OF ROCKS, GARBAGE, PAPERS, PLASTICS ETC 7. ANODES MAY BE LAID VERTICALLY IN CASE OF VERTICALLY SHALLOW ANODE GROUND BED DESIGN. 8. ALL THE DIMEI<S!ONS ARE IN MM.

OF 1

L

STANDARD NO. THERMITE WELD CONNECTION

DETAILS SD-EL-509

REMOVABLE PIPE COATING. FILE TO BRIGHT METAL AND DRY ANY MOISTURE WITH A CLOTH

75x45 mm

-e----~----It

MOULD

EPOXY ENCAPSULATION

NOTES: GENERAL TH ERMITE WELD! NG PROCEDURE

SHEET NO. 1 OF 1

STRIP INSULATION FROM WIRE EQUAL TO LENGTH

OF MOULD

REMOVE SLAG WITH HAMMER/ WIRE BRUSH

J .) ~c=

-f'------------r-

1. REMOVABLE PIPE COATING FILE TO BRIGHT METAL AND DRY ANY MOISTURE WITH A CLOTH.

2. STRIP INSULATION FROM WIRE EQUAL TO LENGTH OF MOULD.

3. INSERT THE CONDUCTOR INTO MOULD.

4. INSERT STEEL DISC IN BonOM OF MOULD CAVI1Y INSIDE MOULD DUMP THE METAL INTO MOULD BEING

CAREFUL NOT TO UPSET THE STEEL DISC. TAP THE BonOM OF THE TUBE TO LOOSEN ALL THE IGNITION

POWDER AND SPREAD IT EVENLY OVER THE WELD METAL. PLACE A SMALL MOUNT OF STARTING POWDER ON

THE TOP EDGE OF THE MOULD UNDER COVER OPENING FOR EASY IGNITION.

5. CLOSE COVER AND IGNITE WITH THE FLINT GUN MOVE GUN AWAY QUICKLY TO PREVENT FOULING . IF FLINT

GUN SHOULD BECOME FOULED , SOAK IT IN HOUSEHOLD AMMONIA.

6. AFTER IGNITION, HOLD THE MOULD IN PLACE FOR 5 SECONDS TO ALLOW THE WELD TO SOLIDIFY, AFTER THE

WELD HAS COOLED, REMOVE THE SLAG WITH A CHIPPING HAMMER OR WIRE BRUSH.

7. ENCAPSULATE THE CONNECTION AND ENTIRE PREPARED SURFACE WITH TWO PART EPOXY COMPOUND.

8. REMOVE ALL SLAG'S FROM THE WELDER BEFORE MAKING THE NEXT WELD CLEAN THE COVER EVERY 6 TO 10 WELDS.

9. WET OR DAMP MOULDS WILL PRODUCE POROUS WELDS. MOULDS MUST BE DRIED OUT BEFORE

ATTEMPTING TO WELD

10. CONNECTIONS ARE TO BE PLACED A MINIMUM OF 100men APART, UNSUCCESSFUL WELDS ARE ABANDONED AND

MOVED TO ANOTHER PREPARED SURFACE NOT LESS THAN 100mrr. AWAY.

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

TYPICAL CONSTRUCTION DETAILS OF HIGH SILICON CAST

IRON ANODE

STANDARD NO.

SD-El-5l0 SHEET NO.

CANISTER END CAP

I 20 SWG SHEET STEEL CANISTER

GAS VENT , . B"AZED

BACK Fill

\ ANODE

\

SPACE RING

BRAZED JOINT ~

~-------------------L--------------------~

TINNED COPPER LUG

S~EEVE & ANODE CAP

CARBON --------' 0.7%-1.1 %

MANGANESE -----: '1.5% max,

S:UCON --------, 14,2%-14. 7~%

CHROMIUM ------ 3_25%-5%

MOlYBDYNUM ---- O.2%mox. COP:::ER --------. 0.5% mox

IRON -----------. REMAINDER

NOTES:

Ii I

1. AI~ODE FOR SURFACE AND DEEP GROUND BED AePLICATION SHALL BE IDENT:CAL EXCEPT FOR BACK FILL eREPACKING.

2. SHEET STEEL MiOD, CANISERS SHALL BE FI,LED WITH MeTALLuRGICAL GRADE COKE BREEZE.

3. FLuiD PeTROLeUM COKE BREEZE BACKFILL SHALL BE PROVIDED IN THE WELL, SuRROUNDING ANOD,S IN DEEP WELL GROUND BEDS,

4. ANODE TAlC CABLE SHALL BE 10 Sq.mm HIGH CONDUC7IVllY, STRANDED COPPER CONDUCTOR, 650V GRADE, PE INSULATED,

PVC SHI"THED & UNARMOURED.

5. ALe THE DIMENSIONS, NET WEIGH: & GROSS WEIGHT OF THE N10DE SHALL BE FURNISHED BY CONTACTOR. 6. THE ACTIVE LENGTH ',0' OF ANODE SHALL BE CONSIDERED FOR CALCULATING THE SiZE / WEiGHT.

o

OF 1

r,-------------------------------,-------------------------------------'I---------------------------,

L

ZINC RIBBON ANODE FOR CASED i STANDARD NO, CROSSINGS WITH COATED/PAINTED!-i ---S-D---EL---S-ll-------1

CAS I N G !-I -~~,---,---;-:,;c-;---I SHEET NO. OF 1

I 10" i ,CASING PIPE (COATED/PAINTED)

~~;:::-+------:::::,,'\ " / f ' II .! \\ I II \\ \\

I, 'H-r \ \ ' I II _1",HE",R""MI,-T ",Wl""lD,-, 1--1-

"'-" _---:::-- A

8 0' CLOCK POSITION /

(240')

:==~..-/--\

T " ' '---::~

\ 4 0' CLOCK POSITIDN

(, 20')

I

\ ZINC RIBBON ANODE

/ / ii ------~~' ~'---------------~>~~

n,i : L( \ , ,

, I I l -----;: 1-' ------I--ci----')

\mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmi

A1 -----------' 0.005% max.

Cd -----------, 0.003% mox. Cu ----------- 0.002% mox. Fe ----------- 00014% mox.

Pb ----------- O.OO3%mox. Ze -----------" REMAINDER

1. STEEL CORE TO BE THERMIT WELDED DIRECTLY TO CARRIER PIPE WITHIN CASINGS AT 4 & 8 '0' CLOCK POSITIONS FOR CA,RIER PIPE OF LESS THAN 4 INCH DIA ANODES MAY BE PROVIDED ALONG THE LENGTH OF THE CARRIER PIPE UNE AT THE BOTTOM [EVEL

2 SIZE OF ANODE & SPAC'NG BETWEEN ANODES SHALL BE DECIDED BASED ON DESIGN CRITER'A. HOWEVER MINIMUM ONE NUMBER ANODE SHALL BE PROVIDED BETWE" TWO PIPE SPACERS/CENTRAl!SERS PROVIDED BEW/lEN CARRIER AND CASING PIPES.

3. PIPE SPACERS/CENTRALISERS ARE NOT SHOWN.

4, ANODE CQMPOSIrION, DIMENSION, NET & Gf~OSS WEIGHT PER UNrr lENG1H SHA~L BE FURNISHED BY THE CONTACTOR.

5. CASING PIPE WHERE COATED AGAINST CORROSION OF EXTERNAL SURFACE SHALL BE PROTECTED BY GALVANIC ANODES INSTALLED AT 80TH THE ENOS OF THE CASING PIP[

',-----------------------------,-----------------------------------,-------------------------,

L

PIPELINE GROUNDING THROUGH POLARIZATION CELL AND

GALVANIC ANODE

STANDARD NO.

ZINC GALVANIC '\ ANODES (iW)

(EAC~ 20KG NET)

'. __ J' '----T'-~_..I , ...... , /

/ , pv/ 1 25/1P,i'

INSULMED pvc SHEATHED ARMOURED CABLE

'-----------,

,J..iNK

/ 1\ , , , ,

TEST STAIION , , ,

---------,

~ , , ,

SD-EL -512 SHEET NO.

POLARISATION cm

POLARISAT!ON CELl_

'i:~~=:~t=='-sHu~r , ..............................JJ /4MM' PVC INSULATED PVC SHEATHED ARMOURED

! __ ~/ 25M~f~ PVC !NSUlMED pYy_~J:!f;!.J.-_I:!~Q __ AR_MO_U __ RED

L OOM~ ,-----------~a--·~p~IP~E~L~IN~E-------------"{

u

NOTES: 1. THE "OLARISATION CELL, ANODES AND ASSOCIATED CABLES, CABLE JOINT ETC. SHALL BE i"NIMUM BE RATED

FOR THE EXPECTED FAULT CURRENT AT THE LOCATION OF THE INSTALLATION & 'SIZED FOR DESIGN UFE OF PER~IANENT CP SYSTEM.

2. THE POLARISATIO, cm SHALL BE HOUSED IN A Vp,NDIIllISM PROOF HOUSING.

3. WI SHALL HAVE GOOD VENTIlATION TO AT\lOSPHERE & SHALL BE PROTECTED AGANIST DIRECT SUN LIGHT & RAIN / WATER.

4. ANODE TAil CABLES OF [ACH ANODE SHALL BE TERMINATED INDIVIDUALLY IN TESTS1AlION. 5. CONTACTOR SHALL FURNISH DRAWlt~G WITH ACTuAL DIMENSIONS & RATINGS.

6 EASY ACCESS TO POLARISATION em SHA,L BE AS PER srANDARO 7-51-0601 (PREPACKED ZINC ANODE).

I OF 1

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

NOTES:

" , HERMIT WELD )

\. PIPELINE!

TEST STATION

GRADE /; "', /7""

1\ fY (

, l .~ ...... 750 ,; (MiN)

1500(TYP,)

ANODE TAIL CABLE

./

ZINC GROUNDING CELL TWO PLATE TYPE

'" '"

ZINC GROlJND:NG ~EC[(SEE DETAIL- '1\')

ARMOUR (SHALL NOT HAVE ELECTRICAL CONNECTION TO ANODE

SILVER SOLDER CONNECTION,

1, CONTACTOR SHALL FURNISH ANODE COMPOSITION, NET WE:GHT, GROSS WEIGHT AND ALL THE DIMENSIONS OF THE GROUNDING CELL,

2, ZINC GROUNDING CELLS SHALL B, INSTALLED VERTICALLY SUCH THAT THE TOP OF THE CELL IS APPROXIMAELY

AT TH, SAME ELEVATION AS PIPE CENTRE LINE

3, NET WEIGHT OF ZINC FOR EACH PLATE OF THE GROUfTDING CElc SHALL BE MINIMU" 20KG. 4. ALL CABLE LEADS FOR ZIf\;C GROUNDING CELL SHKL BE KEPT AS SHORT & DIRECT AS POSSIBLE.

5. GROUNDING C[Ll CABLE LEAD SHAll BE 25 Sqmm HIGH CONDUCTIVITY, STRANDED, COPPER CONDUCTOR

650V GRADE, EVC iNSULTED, ARMOURED & PVC SHEATHED.

6, CABLE JO:NT TO ANODE CO,[ SHALL BE SUITABLE TO DISCHARGE MINIMUM 10 KA FAULT CURRENT. 7. ALL DIMENSIONS ARE IN MM.

STANDARD NO,

SD-El-513 SHEET NO. OF 1

CABLE LEADS

I SEE DEiAIL-B

------BAKEUiE

INSULATiflG SPACER

45x45x 1500( min.)

CLOTH ENCASEMENT

TAPE STRAP

BACK FILL

ZINC ANODE

MS CORE

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

PERMANENT COPPER-COPPER SULPHATE REFERENCE CELL AND

INSTALLATION DETAILS

A"=--=UCC (PVC INSULATED ARMOURED PVC SEATHED)

!lEI~'f!.I{;iliI!UWL~I'Nt' "ED COPPER LuG

~POXY SEALING ,! , I ' PVC PIPE

NEOPRENE W',ASHER--------1

GRADE LEVEL

PIP, =LlN-"E+-__ --\

NOTES: 1. REFERENCE CELL SHALL BE BACK fiLLED WITH CARBONACEOUS BAC~ fiLL MATER'AL SPECIFIED. 2, FOR NEW PIPEliNES REFERENCE ELECTRODE SHALL BE INSTALLED APPROXIMATELY AT THE BOTTOM

LEVEL OF THE PIPE LINE, 200MM AWAY FROM SURFACE OF THE PIPEIIIIE.

3. REfERENCE ELECTRODES MAY BE INSTALLED AT THE TOP OF THE PIPEliNE. APPROXIMATELY 100MM ABOVE THE PIP,LlNE W",RE THE PIPELINE HAS ALREADY BEEi~ lAID.

4. REFERENCE Ct:li... CABLE SHALL BE ROUTED ALONG TI-;[ BODOM LEVEL or THE PIPELINE. AND 250MM APPROX. AWAY FROM THE SURFACE OF THE PIPE.

5. BACKFILLED REfE,ENCE ELECTRODES SHALL BE SOAKED IN 20 LTRS. OF CLEAN fRESH WATER fOR 24 HOURS IMMEDIATELY PRIOR TO INSTALL'TION.

6. CONTACTOR SHALL FURNISH REFERENCE CELL ORAWING WITH ALL OIMENSIONS.

STANDARD NO.

SD-EL-514 SHEET NO.

ELECIROLYIIC GRADE COPPER ROD

I '

'" '" o o

OF 1

• J

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

<.)

NOTES:

STANDARD ND. PREPACKED MAGNESIUM ANODE SD-El-515

SHEET NO. I 1 OF 1

A

B

l-------------____ ---__ ~-

y}~ ~ "\ I Ii _:-c: __ ~ += _ _ _ _ _ _ = J--~~'-'=7f-/---==-~-=-~-~----t--------,~_--__ ___.J

A.,..! ~-

i:~~ .... _ .... __ ---l-l ___ +--------J----' I ,lllVER SOLDER CONNECTiON lAS CORE

BACK FILL ZINC ANODE

iCOTTON BAS

ANODE TAIL CABLE SE, DETAIL-X

'" LEVAriOi'!

ARMOUR

I E I (SHAlL NOT HAVE ELECTRICAL CONNECTION

I \ TO ANODE) / \ /

/ \

/ \ 8W~

/ \ EPOXY / \ /

I \ MS CORE COMPOUND \,

/ \ , I f MS CORE

\ , , ,

/ .--- -~

~;~g~p'UM ---- ANODE TAIL ! CABLE

i , \SILVER SOeDER CONNECTION , , PVC INSULATION , , ,

--i !- -F-

SECT:ON-AA )f:Ak-X

I. ANODE COMPOSTION, NET WeiGHT, GROSS WEIGHT AND DIMENSIONS SHALL B, FURNISHED BY CONTA,CTOR.

2 ANODE TAIL CABL, SHALL BE HIGH CONDUCTIVEY, STRANDED, COPPER CONDUCTOR. 650V GRADE, PVC

INSUU,TED, PVC SHEATHED & ARMOURED.

r,-____________________________ ,-__________________________________ ,-________________________ ,

L

PREPACKED ZINC ANODE

A

B

~----.. --- --------------------~-----------...--

~;~/ A ""I --~ \,,' '\ ~,--

j--- -

\ i/ ~. A..,.J '--t ~-_L-_

---i-.... , ,

--,---I - ____ , ------------

~,lVER SO: OER CONNECTIOij , , , , ,

MS CORE :ZINC ANODE , , COr;-ON BAG

, :B.l\CK FILL

ANODE TAil CABLE SEE OE,All-X

E

I /

/ /

/ u /

/ / /

\ \ \ \ \ MS

\ \ \

CORE

,----ARMOUR

EPOXY---, COMPOUND

(SHAll NOT HAVE ELECTRICAL CONNECTION TO ANODE)

----- - - --.-- -,---=--ANOOE TAil ,--

CABLE 1

STANDARD NO.

SD-El-516 SHEET NO.

pvc INSULATlON~ Sil VER SOl DrR CONNt"CTION

r

,. -' '0"-1-1\6 " DErAII)(

NOTES:

1. Af/ODE COMPOSTiON, NET WEIGHT, GReSS WEIGHT AND DIMENSiONS (A,B,C,D,E & F) SHAll BE FURNISHED BY CONTAC'lOR. 2. ANODE TAIL CABLE SHALL BE HIGH CONDUCTIVITY, STRANDED, COPPER CONDUCTOR, 6S0V GRADE, pvc INSULATED, pvc SHEATHED & ARMOURED.

3. Af/ODE TYPE I SHALL BE IJSED FOR SEA WATER, BRACKiSH WATER OR SALINE ELECTROLYTE AND ANODE II SHALL BE USED FOR WATER, BACK

F,llS & SOil APPLICATION.

OF 1

r-,-···· ----------,----------_--------::-1

L

o o '" -

BOLTS

('II

BUS BAR

JC BOARD ~

1.29 60 ___ 'c~UUK

lOA ~HIINT

A~'"

55 .JUI BOX

5 10 sq.mm IN' '~j

440 4UL

CABLE

260 440 50x50x5mm MS ANGLE '--J

+ 0 AJB

. . 1 BOX FllTING CENTRE --~ -~- 0 G.1. FRAME @--=";"'''''' 0

-- cO ~ -~ 50x5mm MS PLATE

CATHODIC PROTECTION SYSTEM ANODE JUNCTION

BOX(AJ8) DETAILS

STANDARD NO.

SD-EL-S17 SHEET NO. I 1 OF 1

• , ,

260

~ NAME PLATE (SEE DETAIL-I)

HINGED

'-L-L~ __ -, 10sg. mm GLANDS

ITEM DESCRIPTION NO. PflNTED STEEL ENCLOSURE LOCKABLE TYPE

A. FOR IP 55 PROTECTION MIN. 3mm THICK.

B. PHENOLIC BOARD-6mm THICK

C. TINNED CUPPER BUS BAR 25x5mm PLATE

AJB RMETP

RATED

. .. T /,

OrY.

1 No.

1 No.

1 No.

_~_ _ D. SHUNT lOA. 100mV 5 No.

:~: CABLE TRAY-_-.Hi-i E. VARIABLE RESISTOR 1.29 OHM 60 WADS. -;:- g FILLED WITH FOAM

5 No.

-~- '\' ~ F. BRASS TERMINAL cjW WASHER, LOCK WASHER & NUTS

[\

~ ...--i- SUPPORT PLATE, ~ I G. BRASS CABLE GLAND (35 sq. mm) 1 No.

AS RED.

~ ;:'c4kt~~" MID BOLT ":~.:,/pwI-H-.-I-B-R-AS-S-CA-B-L-E-G-LA-N-D-'('-1-0-S-'q-. _m_m...:l _______ -+_5_N_O.-j

.. 2" DIA PVC' I. COPPER CABLE LINK 5 No.

\~Yt-,l%1~lRfflJN[)AII8~NDUITS ITEM NO. DESCRIPTION UNIT OTY.

1. MS FLAT SIZE 50x5mm, LENGTH TO SUIT NO 3

2

4 ,

4. 2" DIA PVC CONDUIT LENGTH TO SUIT. : NO 2 ,

5. CABLE TRAY LENGTH TO SUIT (APPROX. 800mm) I NO 1


~----------------~--------------------~-------------~

JUNCTION BOX

FIXING BOLT

lOA, IOOmA SHUNT

PHENOUC BOARD

, , :1

430

400

r- •

CRIMPED CABLE """" ~

NEGATIVE DISTRIBUTION BOND BOX (NDBB) DETAILS

I·

•

o 0

260

NAMF PlATE SEE DETAIL-I

-iTii"", lJ"-=----===t-tt-++-~---- LABEL ~~--,

1.6 OHM 20 A

o 0 "' <D

VARIABLE RESISTOR

3 No, 25sq.mm XLPE/PVC : ISWA;PVC NEGATIVE :. BONDING CABLE

35sq. mm XLPE/PVC/ NEGA/TIVE MAIN CABLE TO T R

0

""""

• ~. T 11 (lj)- 2

r('· '''",\, '" i\' \j \J" ',' "

: HINGE

Ji.! •

GI CONDUIT HUB -= 19,,;~QL

JS" Ri.ISGF'

STANDARD NO.

SD-EL -518 SHEET NO. I 1 OF I

FBB RMETP

SHIINT 12" NFL

35sq.mm XLPE/PVC/SWA/PVC /NEGATIVE BONDING CABLES

/ / THERMITE WELD (1YP.)

1x10sq.mm XLPE/PVC CABLE

~ NO. 25sQ.mm XLPE/PVC

50x5mm 50x50x5mm MS ANGLE

M';r-' "-330, '-;:;=.=2",OO.:..:.....j:::; 'I o I 1 I:'" FBB I

o o "'

i'l I (1) I '" BOX FIXING I I ---"2') ~ CENTERS I 1* :~\6J I I. 3 I I

I I

42;''' -lJ!D 'l6,A ;;-;-~'iJjr II CONDUIT HUB

G.1. FRAME

2"DIA CONDUIT

FILLED WITH FOAM

I SUPPORT PLATE

in I V ""'" T ! i! J! I.±!-, ' rii-t-""""''''''''-....,

~ ,. j I ~ • 4' G.L. G.L. : !: <I

ITEM NO. DESCRIPTION

PAINTED STEEL ENCLOSURE LOCKABLE 1YPE RATED A. FOR IP 55 PROTECTION MIN. 1.6mm THICK.

8. PHENOLIC BOARD-6mm THICK


D. SHUNT 1 GA, IOOmV

E. VARIABLE RESISTOR 1.29 OHM 60 WATTS.

F. BRASS TERMINAL C/W WASHER, LOCK WASHER & NUTS

G. CRIMPED CABLE LUG

H. 2" DIA G.1. CONDUIT HUB

Q1Y,

I No,

1 No,

1 No,

4 No,

4 No.

AS REO.

AS REO.

1 No.

,. is)

ITEM NO, DESCRIPTION UNIT Q1Y, . . ',!~ i ! ,':\. ~ ~~!) '" g 4'~' <l ~ &., I\M10 HILT t::= .... <> ... ~ ...

"""" .' '. ~. .' ~9L~'A PV<C --.."..- •• ' ,'. 1, MS FLAT SIZE 50x5mm, LENGTH TO SUIT NO 3

• CONDUIT " • ',,' " ,'" MS ANGLES SIZE 50x50x5mm, OVERALL ~~~~~~--~~~ 1~_2_. ~LE~N~'G~T~H.l~5~O~O~m*-m~~~~~~~=-m7W=rrTI-,,~ __ -+ ____ 41

3 FRAME AND BOX FIXING HOLES, I 1 mm DIAMETER AND I 700 I I 500 NO 2

NO 4 . STAINLESS STEEL SET SCREWS, NUTS AND WASHERS " ' ~, vi ,

~ ,,~ '''1\') ~~OX ' , , ) od • ;, "

- - - NO I 4. 3" PVC CONDUIT LENGTH TO SUIT. ~i 0 c~ "\j

, " r A _S ( ,~y' 0'; ;~S~ , \J ,j, , NO I 5. 2" G.1. CONDUIT LENGTH TO SUIT.


-

-

L

~----------------~------------------~--------------~

L

CATHODIC PROTECTION SYSTEM EQUIPOTENTIAL BOND BOX (EBB)

DETAILS FOR RMETP

330 JUNCTION BOX

"'- 300 FIXING BOLT :::.::itl ~~~~~~~~~~II--'-

lOA IOOmA SHUNT •• •

TINNED COPPER BUS BAR

PHENOLIC BOARD ~,-------, CRIMPED CABLE I - ..... '>II!l ~, 1J(;==t1t-++-~ o 0 -- - LABEL

1.29 OHM 60 WATT _ VARIABLE RESISTOR 3 No. 25sq.mm XLPE/PVC

o 0 N n

/SWA/PVC BONDING CABLEQ~~I~ =~~~~i~~~~l • glM:rPJ III • 'U' 2 GI CONDUIT US

, .. A' ., ;0\) ,OX

12" NFL

VARIABLE

, ,

200

NAME PLATE SEE DETAiL-I

: HINGE

STANDARD NO.

SD-EL-519 SHEET NO. I I OF I

EBB RMETP

SliUNT 25sq.mm XLPE/PVC/SWA/PVC

50x5mm MS ~LATE "330

0 i I""

""'" ,. I

I NEGATIVE BONDING CABLES

THERMITE WELD (TYP.) 110Xl~05s~a~.m~m~@[r====t~======~t-__ ~ __ J; XLPE/PVC CABLEEME[E~ V /

0(1 V; 2"NFL

50x50x5mm MS ANGLE

1-200~ nr=---=irr-

I I

36"RMSGP: I 34"NFG

I 0 I N Ii" BOX FIXING ITEM NO. DESCRIPTION orr.

0 0

"' ~

~ I

I I I I I

I I

1--<~:£i2 ~ CENTERS

=~I I .§2~" .gDI~A=-:-;;:'UJr I CONDUIT HUB I

G.1. FRAME , ,

2"DIA CONDUIT:

FILLED WITH FOAM

A.

B.

PAINTED STEEL ENCLOSURE LOCKABLE TYPE RATED FOR IP 55 PROTECTION MIN. 1.6mm THICK.

PHENOLIC BOARD-6mm THICK


D. SHUNT IDA, 100mV



G. CRIMPED CABLE LUG


1 No.

1 No.

1 No.

3 No.

3 No.

AS REQ.

i'S REO.

1 No.

ITEM NO.

DESCRIPTION UNIT QTY.

1.

2.

I 3.

4.

5.

NOTES:

MS FLAT SIZE 50x5mm, LENGTH TO SUIT

MS ANGLES SIZE 50x50x5mm, OVERALL LENGTH 1500mm

NO

NO

FRAME AND BOX FIXING HOLES, 11 mm DIAMETER AND NO STAINLESS STEEL SET SCREWS, NUTS AND WASHERS

3: PVC CONDUIT LENGTH TO SUIT. NO

2" G.1. CONDUIT LENGTH TO SUIT. NO

1. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.

I

3

2

4

1

1

~----------------~--------------------~-------------~

L

STANDARD NO.

SD-EL -520

CATHODIC PROTECTION SYSTEM FOREIGN BOND BOX (FBB)

DETAILS (2CIRCUITS) SHEET NO. I 1 OF 1

, , , :1

FIXING BOLT •

330

300

~1~'2~9~OHWM~6~0~W~A~D~~~·~~ VARIABLE RESISTOR ~ 1 GA, 1 GOmV SHUNT ,. r--- I"""""", ;m-----

CAB' C LUG LABEL ~-oror--TINNED CUPPER BUS BAR

10sq.mm XLPE/PVC POT. 1 ~ MUNII

•

10sQ.mm HMWPE REFERENCE ELECTRODE

i,J~~ IRIii!EJB II rr= '" '1111 •

CABLES

2" G,1. CONDUIT IT

HUB

o 0 o 0 N ...,

I· 200

NAMF PlATE SEE DETA:L-l

: HINGE

S"D::: vIew

FBB RMETP

. ELECl KUUt."

k!:!'PF POT

m~ XI PF fpve: fSWA ./ OA' I CABLES

50x5mm MS PII'TE""330 ,d-

PRE-I ""S04 ELECTRODES ,rF

50x50x5mm MS ANGLE

1-20°--< rir---'; rr-

o I 1 ;"", FBB I :0;: I (j) Ii'" BOX FIXING I

o o

"' ~

- :. Lw f't\/~ CENTERS :

I -0 I .§2~" ,gDI!to,A=-c~:'UJr I CONDUIT HUB I

G.1. FRAME , ,

2"DIA CONDUIT:

PLUS) ~

ITEM NO.

T~WELOING

I P! 1) d : ;0 N I:'';' AJS

DESCRIPTION

PAINTED STEEL ENCLOSURE LOCKABLE TYPE RATED A. FOR IP 55 PROTECTION MIN. 1.6mm THICK .



D, SHUNT lOA, 100mV

E. VARIABLE RESISTOR 1.29 OHM 60 WADS.

OTY.

1 No.

1 No.

1 No.

2 No.

2 No.

F. BRASS TERMINAL C/W WASHER, LOCK WASHER & NUTS AS REO.

I I

FI LLED WITH FOAM

I SUPPORT PLATE ,

G. CRIMPED CABLE LUG AS REO.

H. 2" DIA G,1. CONDUIT HUB 1 No,

3S) rnll '4'T iii I®-'-:Jrl-l,ft-___ ... f-,="_AO,' v_' N_' _\_c_:_'s_A_'vt_, ;~ __ ;_R __ i ,_,s., ;_s_c_'_;_~ _~ __ (_t1_. v_,--. __ -II

.' :Ir"\ C,L:!:' ITEM DESCRIPTION UNIT OTY,

NO 3

NO 2

10 1 i I : .. ~ .. ) ) : 4 • . 4".: NO g '0' .'tV~'.,I\Ml0HILT -:~)'" . <0. • .• ~.~ .. ~ BOLT --k..-" ",.. 1. MS FLAT SIZE 50x5mm, LENGTH TO SUIT

'. ". " ' , " 3" -DIA pvc " . .'. 2 MS ANGLES SIZE 50x50x5mm, OVERALL .. . • . I CONDUIT -, • . . '. . LENGTH 1500mm

NO 4 700 I I 500 I f-_3,-+~,"~",fl",~E",LE~~",~_D S",fc:t""El"-"~",tr"-IN~~",CH",R~""L",~",~'-,IN,-,IUm,-,T",g'-,A",~",lt_Mw,,,~,,,~"-RH",t,-,RNS,,,D+---I __ -I1

J ::J, ' '":'\ jC\'; "">")X ~ :;;,:1 h/;;;}',<: :7\jC

~ -'AII.S (;y 0-· r,{s)

NOTES:

4, CONDUIT LENGTH TO SUIT,

5, 2" DIA PVC CONDUIT LENGTH TO SUI:,

1. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.

NO 1

NO 1

..J

L

STANDARD NO.

SD-El-521

CATHODIC PROTECTION SYSTEM TEST POST INSTALLATION AT

ROAD CROSSING (RX) SHEET NO. 1 OF 1

,- ,- BIG FINK TEST POST (SEE DETAILS C FOR-TERMINATION DETAILS)

3" DIA GALVANIZED STEEL rX CONDUIT \ 1.5M LONG)

r

CULVERT LENGTH (VARIES)

t-~ CONCRETE FOUNDATION 300x400x300mm (BY 0

. ::::" "'I 'I' 1 'I' '1'1177777711 r:: 'I]" . ~. F1

. , 'U .. '," . . ~.~ ".' • • . .. . . .

THER)

"-.

/'..-- /' .

"" • ./\ •

,

) '/ , .~ 1050. MM HMWPE CABLE . I ~ -:-.... .' , ';'

.. .. ".:

Lx . j , V;\ j ;/::/>.,1

~ ZINC RIBBON ANODE

Cu/CuSo4 REFERENCE ELECTRODE

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS 07HERWISE SPECIFIED.

NICKEL PLATED BRASS NUT AND SCREW FOR TERMINAL LEAD CONNECTION

CABLE LINK

10sq.mm MONITORING CABL

IDs .mm CABLES FROM: ZINC RIBBON ANODE

2. ANODE RIBBONS SHALL BE INSTALLED AT ROAD CROSSING WHERE THE PIPE IS CASED IN CONCRETE CULVERT.

3. EACH TEST POST SHALL BE HAVE ONE MONITORING AND ONE DRAIN CABLE CONNECTED TO THE PIPE PIPE STRUCTURE.

m

CABLE

L

CATHODIC PROTECTION SYSTEM HIGH TENSION LINE

CROSSING JUNCTION BOX

STANDARD NO.

SD-EL -522 HTB INSTALLATION DETAILS SHEET NO. I OF I

HTR ROX f 400 I BOLT ,

• TERMINAl <CARl" LUG L'

PAINTED MS ENCLOSURE 0

PHENOLW BOARD , KRIK CELL (SEE DETAI-C

,

L© , ,

255q. mm XLPE/PVC SWA/ PVC CABLE t~ 'I

4 No. 16sq.mm XLPE/PVC o I ANODE HEADER CABLE Ii ~

IIII • •

f\l

--@

-®§ iBUS BA R

];I

50x5mm MS ~l{fE "-,330

I:;; I

o 1'1 o I i N ,

I f---<V ~, 3 I i

I

I o I o "' I

:" I

~ :1 , ,

I I I I

50x50x5mm MS ANGLE

,-260--1

HTB

~BOX FIXING CENTERS

3" DIA CONDUIT HUB

G.1. FRAME , , ,

3"DIA CONDUITI

3

CONNECTION~)~ G.1. CONDUIT HUB

I I I

THERMITE WELD

25sq. mm XLPE 'PVC P // ANODE TAIL CABLE I ./ /

INC GROUNDING I ANODE 5m 5m 35x35xl500

Z

PACLAGED IN GY SUM BENTONITE BACKFILL (VERTICAL INSTALLATION 2m FROM PIPE SURFACE AND AT 3m DEPTH FROM GI)

ZINC GROUNDING

""'\ " "" f"' "~ ! t' -, ',..

'<R'< :;E~L {.5/A HA \GJ

\"--"-

~ FI LLED WITH FOAM

I I

" I SUPPORT PLATE

I II T I 4

,

5m ,

Ol\

MA' 0.,,, : (/' r ' '-'" ".",-"-' S" -;"' r:-~~,' ~-~~'-

ITEM DESCRIPTION NO.

A. PAINTED STEEL ENCLOSURE LOCKABLE TYPE RATED FOR IP 55 PROTECTION MIN. 1.6mm THICK.



D. SHUNT lOA, IOOmV



G. CRIMPEO CABLE LUG


OTY.

I No.

I No.

, No. ,

2 No.

2 No.

AS REO.

AS REO.

I No.

MOUNT:"G FRAME MATER:AL Sr'HEil' ' c (8Y CT-',RS) 'JI '-..'''.1

ITEM DESCRIPTION NO.

1. MS FLAT SIZE 50x5mm, LENGTH TO SU!T

2. MS ANGLES SIZE 50x50x5mm, OVERALL LENGTH 1500mm

3. FRAME AND BOX FIXING HOLES II mm DIAMETER AND STAINLESS STEEL SET SCREWS,' NUTS AND WASHERS

4. CONDUIT LENGTH TO SUIT.

5. 2" DIA PVC CONDUIT LENGTH TO SUIT.

NOTES: 1. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. 2. THE ZINC GROUNDING ANODE INSTALLAT:ON CAN BE DONE ON

ANY ONE SIDE OF THE OVERHEAD POWER LINE CROSSING TO SUIT THE ACCESSIBILITY AT SITE.

DRILLING AUGERING MACHINE

UNIT QTY.

NO 3

NO 2

NO 4

NO 1

NO 1

STANDARD I\JO. SOLAR POWER SYSTEM SO-EL-601

SOLAR PANEL MODULAR (1 X 50%)

JB

CHARGE CONTROLLER \ 1 X 50%

I

T

DC DISTRIBUTION BOARD /\,

SHEET NO.

SOLAR PANEL MODULAR (1 X 50%)

JB

CHARGE CONTROLLER 1 X 50%

T

I LOCATION ELECTRICAL ROOM H •• G)O-50V f--.:. ··.--G)O-50V I 2 AMPS 63A 2P 2 AMPS

106K),A'Mt~B ~S~ - - - - - - - - - - - - T _________ 10K,tLMCCBjUSE

100A, 24V, 10KA, FOR lSEC, A O-BOA 2PH,2W. CU. BUS.

1 2 3

0.. 0.. o 0

...-::::.:E ...-:::.:E

~ : -=- : ,

--,-' -

NOTES:

4 5

I I

1~

1. ALL ELECTRICAL EQUIPMENT BE TROPICALISED IN COMPLIANCE WITH LOCAL SITE CONDITION.

2. THE SIZE OF ALL INSTRUMENTS SHALL BE 95mm x 95mm FOR FULL & HALF SIZE MODULES AND 72mm x 72mm FOR LOWER SIZE MODULES

3. ALL AMMETER & VOLTMETERS SHALL BE DIGITAL TYPE AND OF CLASS 1.5 ACCURACY. 4. POWER & CONTROL CABLES SHALL BE 1.1 W GRADE, STRANDED COPPER CONDUCTOR,

PVC INNER SHEATH & PVC OUTER SHEATH WITH FRLS CHARACTERISTICS CABLES SHALL CONFIRM TO IS:7000.

5. THE CABLE SIZE ARE CALCULATED ACCORDING TO CABLE SIZING CALCULATION SHEET.

6. ALL INDOOR DB'S SHALL BE PROVIDED WITH IP53 PROTECTION AND FOR OUTDOOR IP55. 7. TWO (2) NOS OF BATTERY BANKS WITH 3 DAYS BACK UP SHALL BE PROVIDED. 8, MCCB'S AND MCB'S SHALL BE DP, 10kA

A 0-80A

6 7 8 9 10

1 OF 1

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