cp technical

FCCU & PRU REVAMP PROJECT, MATHURALOCATION: IOCL PANIPAT REFINERY

Tender No:TPKTI/0785/FCCU-PR/096 Page 5 of 6Rev. 0

PARTNO

SECTION DESCRIPTION DOCUMENT NO. Rev

5.0 ELECTRICAL DOCUMENTS 00785-000-LD-1490-01 1

5.1 Electrical Job Specification For Mounded Bullet00785-068-JSD-1675-01 A

5.2 Engineering Design Basis For Electrical00785-000-JSD-1650-01 0

5.3 Data Sheet For MV Switchgear00785-000-DS-1654-01 0

5.4Standard Specification For MV Cable And Accessories

00785-000-STD-1621-03 0

5.5Specification For Cable For Cathodic Protection System

00785-000-STD-1621-04 0

5.6Standard Specification For Medium Voltage Switchgear

00785-000-STD-1654-01 0

5.7 Standard Specification For Cathodic Protection00785-000-STD-1675-01 0

5.8 List Of Mandatory Spares (Electrical)00785-000-NM-1603-01 1

5.9 Vendor list -Electrical00785-000-NM-1602-01 0

5.10 Standard spec. for Electrical Heat Tracing00785-000-STD-1686-01 0

6.0 INSTRUMENTATION DOCUMENTS 00785-000-STD-1686-01 0

6.1Job Specification For Instrumentation Items For Mounded Bullets

00785-68-JSS-1514-15 C

6.2 Mandatory Spares For Instrumentation00785-000-NM-1587-01 2

6.3 Design Basis – Instrumentation 00785-000-JSD-

1501-01 0

6.4 Job specification for MOV00785-68-JSS-1543-12 C

6.5 Vendor list - Instrumentation00785-000-NM-1502-01 0

6.6 Electrical data sheet for MOV actuators00785-000-DS-1669-01 0

FCCU & PRU REVAMP PROJECT, MATHURALOCATION: IOCL PANIPAT REFINERY

Tender No:TPKTI/0785/FCCU-PR/096 Page 6 of 6Rev. 0

PARTNO

SECTION DESCRIPTION DOCUMENT NO. Rev

6.7 Technical specification for procurement of valves00785-000-JSS-1300-0004 3

6.8 Quality control plan for control valve00785-000-ITP-1541-01 0

7.0 HSE DOCUMENTS 00785-68-SOW-1900-01 0

7.1Design Basis For Fire Protection And F&G Detection System For Offsite Mounded Bullet Facility

00785-068-JSD-1900-01

1

7.2Scope Of Work For Fire Protection And F&G Detection System For Offsite Mounded Bullet Facility

00785-68-SOW-1900-01

0

7.3 Layouts for fire protection system00785-68-DW-1930-01 1

8.0 MISCELLANEOUS Refer Attached --

8.1Site Facilities & Requirements – Mounded Bullets

00785-071-PTC-(1)-01 0

8.2 Deviations list format Refer Attached --

8.3 Inspection and Test Plan for Mounded Bullets Package

00785-071-ITP-2543-01

0

8.4 General Quality Control Requirements 00785-19-PP-502 0

8.5 Planning, Scheduling, Monitoring and Scheduling 00785-019-PP-0308-01

0

8.6 Vendor list-Mech -- -

Project N° Unit Document Code Serial N° Rev. Page

00785 068 JSD 1675 01 A 1/20

ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET

A 19.03.2012 ISSUED FOR ENQUIRY ABS VV SM VJK

REV. DATE STATUS PREPARED BY REVIEWED BY APPROVED BY PM

DOCUMENT REVISIONS Sections changed in last revision are identified by a line in the right margin

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UNIT : 0068-PANIPAT NAPHTHA CRACKER

PROJECT : FCCU AND PRU REVAMP, MATHURA.

LOCATION : IOCL, PANIPAT NAPHTHA CRACKER

OWNER EPCM

INDIAN OIL CORPORATION LIMITED. TECHNIP KT INDIA LTD.

NOIDA, INDIA.

ELECTRICAL JOB SPECIFICATION

FOR

MOUNDED BULLET


00785 068 JSD 1675 01 A 2/20


CLIENT : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER.

UNIT : 0068- PANIPAT NAPHTHA CRACKER

PROJECT : FCCU AND PRU REVAMP.

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CONTENTS

1. GENERAL ............................................................................................................................................ 3

2. DEFINITION ......................................................................................................................................... 3

3. SITE CONDITIONS .............................................................................................................................. 3

4. AREA CLASSIFICATION .................................................................................................................... 4

5. SCOPE OF WORK SUPPLY ............................................................................................................... 5

6. MISCELLANEOUS WORKS.............................................................................................................. 13

7. JOB MATRIX...................................................................................................................................... 14


00785 068 JSD 1675 01 A 3/20





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1. GENERAL This document along with standard specifications, drawings attached with bid shall form the

basis of electrical works for mounded bullets at Panipat Refinery, IOCL.

For engineering design basis refer doc. no. 00785-000-JSD-1650-01, for applicable items/

clause.

The contract scope also includes clearing up of temporary constructions, waste materials

and loose earth which might get collected consequent to the execution of the work performed

under this contract.

In case of any discrepancy / conflict amongst various documents, following order of

precedence shall prevail:

� Statutory requirement

� IS Codes and standards

� This document

� Engineering design basis

� Data sheets

� Technical specifications

In case of ambiguity, bidder shall inform Owner/EPCM of their interpretation. In case bidder

fails to convey the same prior to award, the owner's decision on interpretation shall be

considered final if need arises during the execution. No additional cost or time on account of

conflicts/ambiguities shall be admissible if not notified prior to award of contract.

2. DEFINITION

In this document following are implied:

EPCM - TPKTI

Bidder - Package/system vendor

End user - IOCL

3. SITE CONDITIONS * Maximum temperature : 47ºC

* Design maximum temperature : 50ºC

* Minimum temperature : 2ºC

* Winterizing temperature : 2ºC


00785 068 JSD 1675 01 A 4/20





The

pres

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or d

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* Design minimum temperature : 2ºC

* Relative humidity

- Average : 36% @ 4º-50ºC

- Maximum : 95%

* Dry bulb temperature :

* Barometric pressure

- Minimum :

- Maximum :

- Average : 740 mm Hg

* Altitude above mean sea level : < 1000 mm

4. AREA CLASSIFICATION The area classification shall be done in accordance with IS: 5572, Petroleum Rules and

Project Design Basis.

The Mounded Storage bed shall be classified as Zone-1 hazardous area. All areas within the

pump station shall be classified as minimum Zone-2 hazardous area. In addition, all area

enclosed within 16 m distance around the storage bed and pump station shall be classified

as Zone-2 hazardous area.

The area within 1.5 m radius (extending in all directions) of safety vents, product sampling

locations, process water drains, oily sewer vents, inspection hatches, discharge orifice of

fixed liquid level gauges, rotary or dip gauges, filler openings, shall also be classified as

Zone-1. Further an area from 1.5 m to 3.0 m (extending in all directions) from vents shall be

classified as Zone-2. However, the vents or drains blanked during normal operation and used

only when the plant is depressurized or under shut down, should not be regarded as an

operational vent or drain or source of hazard.

Open trenches, pits or sump below grade level within Zone-2 area shall be classified as

Zone-1 area.

In case of pipeline handling flammable material, where well maintained valves, fittings and

meters are installed in well ventilated areas or pit, the extent of Zone-2 area above ground

shall be considered as 4.0 m in all directions from the possible source of hazard, although

the pit itself shall be classified as Zone-1 area.

Irrespective of the area classification (whether Zone-1 or 2), all electrical equipment such as

motors, local control stations, lighting/power panels, welding receptacles/sockets, junction


00785 068 JSD 1675 01 A 5/20





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boxes, lighting fixtures and accessories etc. shall be flameproof type Ex’d’ as per IS:2148

with IP-55 protection, suitable for Gas Group-IIA & IIB and Temperature Class-T3.

All hazardous area equipment shall be tested by CMRI and approved by CCE or equivalent

testing agencies and statutory authority of country of origin. All flameproof equipment shall

be BIS-approved. Bidder shall be required to submit the testing and approval certificates for

all hazardous area equipment for Owner’s/ EPCM’s approval.

5. SCOPE OF WORK SUPPLY

Electrical works are divided into two parts herein

i) Cathodic protection system

ii) Balance Electricals

5.1. Cathodic Protection5.1.1. Scope

5.1.1.1. Shifting of Existing CP System for Existing Bullets (6 nos.)

The existing CP system yard along with all equipments like TR-units, JBs, DBs, etc. for

existing bullets (6 nos.) is to be relocated and the proposed location has been indicated in

equipment layout, however, location shall be verified and finalized by bidder in accordance

with latest amendments in OISD regulations. The TR-Units as required for new bullets shall

also be installed in the same yard. Vendor shall design and submit drawings for EPCM

approval. Design and construction of yard, including foundations, if required, shall be in

bidder’s scope of work.

The scope of work to be carried out for shifting of CP system shall include but not limited to

the following:

� Design of CP system yard including all civil works, and submitting drawings to EPCM for

approval.

� Bidder shall visit site to get relevant information and get familiar with this shifting job.

� Shifting of two nos. earth pits to new CP system yard from existing yard for earthing of

equipments.

� Following cables are to be laid:

- Cable size 1CX95 sqmm to be laid from AJB 1B to Distribution box.

- Cable size 1CX95 sqmm to be laid from CRJB 1 to Distribution box.


00785 068 JSD 1675 01 A 6/20





The

pres

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ocum

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or d

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is p

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- Cable size 1CX95 sqmm to be laid from AJB 1A to Distribution box.

- Cable size 1CX95 sqmm to be laid from CRJB 6 to Distribution box.

- Cable of 20CX1.5 sqmm to be laid from each CRJB box to measurement junction

box. Total 6 nos. of 20CX1.5 sqmm cable to be laid.

- Cable of size 1CX35 sqmm to be laid from new earthing pits inside the yard to

earthing junction box in the same yard.

- Cable specification is given below:

1CX95 sqmm cable shall be aluminium conductor pvc insulated armoured cable

with double insulation.

20CX1.5 sqmm cable shall be single stranded copper with double insulation.

1CX35 sqmm cable shall be aluminium conductor unarmoured with pvc insulation

and pvc sheathing.

Detailed specification shall be obtained by bidder from site.

� Any other existing cable, if damaged shall be supplied and laid by bidder free of cost.

� All dismantling and re-installation works for existing CP system is in bidder’s scope. The

existing CP system TR-unit is of Raychem make, Serial no.- 101542-07K8, 4000 VA.

Bidder to co-ordinate with CP system vendor for dismantling and re-installation work and

this work shall be done under supervision of existing CP system vendor.

5.1.1.2. New CP system for New Bullet (1 no.)

The design, supply, installation and commissioning of a new CP system for 1 no. new bullet

is in bidder’s scope of work.

- Bidder shall design the new CP system to work along with the existing CP system and

design the CP system yard accordingly to accommodate existing as well as new

equipments.

- Bidder shall consider a new power distribution board, to be supplied and installed by

bidder in the CP system yard, with 2 no. Incomers and outgoing feeders to supply to both

existing as well as new CP system. The power distribution philosophy for existing CP

system henceforth shall be kept unchanged.

- The incoming power supply to this power distribution board shall be taken from MC-1341

in S/S-13, feeder nos. 5FC and 11FC. Bidder shall check the sufficiency of existing cable

incomer from MC-1341 for supplying to the new power distribution board, i.e. adequacy


00785 068 JSD 1675 01 A 7/20





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pres

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ocum

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or d

raw

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is p

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f TE

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of cable, length etc. and if necessary supply and laying of new cables shall be in bidder’s

scope of work.

The scope of work for new cathodic protection system shall include but not limited to the

following:

� Obtain, generate and evaluate necessary information to perform complete design,

supply, installation, testing, commissioning and documentation of the cathodic protection

systems including a design site survey for collection of data.

� Review and validate correctness of information furnished by the EPCM, on equipment to

be protected.

� Supply of all labor, supervision, installed and consumable materials, services, equipment,

tools, and each and every item of expense necessary for the design, procurement,

installation and commissioning of cathodic protection systems for mounded bullets in

contact with soil, in compliance with this specification and referenced standards.

� Supply and install permanent testing facilities and remote monitoring capabilities to

monitor the cathodic protection systems using latest proven technology available at the

time of system design.

� Test, evaluate and mitigate possible interference caused by cathodic protection system

on communication and low energy control systems.

� Test, evaluate and mitigate stray currents generated by newly installed cathodic

protection systems.

� Provide documentation for system design and installation.

� Furnish operation manual for system operation and maintenance.

� Submit to EPCM a detailed cathodic protection design and installation methods for review

and approval. The design data shall include basis, calculations and drawings.

� Preparation and submission of general cathodic protection system layout.

� Supply of mandatory spares and commissioning spares as required.

� Bidder shall indicate dimensions of such equipment to be placed in CP system yard (eg

T/R unit) and Electrical power consumption along with bid. This is essential part of bid.

� Bidder to provide redundant transformer / rectifier set, which shall be hot standby type.


00785 068 JSD 1675 01 A 8/20





The

pres

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or d

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is p

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� The bidder shall include in the material schedule a list of proposed monitoring equipment

(hardware and software) required to carry out regular surveys of the cathodic protection

system

Effort is made to define the scope of work as completely as possible, however, it is bidder’s

responsibility to carry out successful commissioning of CP system and include any

supply/work, not included herein, in his scope of work to ensure completeness of operation.

5.1.2. Power supply

Owner shall provide 415 V 3 Phase Power Supply at two points in Substation-13, MCC-1341

feeder nos. 5FC and 11FC for CP System. Further power distribution shall be in bidder’s

scope. Bidder shall consider a power distribution board in field to supply power to existing

and new CP system. The bidder shall provide load details for new CP system in his offer to

EPCM.

5.1.3. Design documents

The basic design documents shall be submitted for approval to the EPCM covering the

following requirements:

� Results of any site surveys and soil investigations that have been carried out.

� Calculations of current requirements, resistance and current output of ground beds.

� A schematic diagram of the proposed cathodic protection system.

� A list of the estimated number and types of cathodic protection monitoring facilities.

� The civil works required to install the cathodic protection system. Such works

include transformer/rectifier plinths, deep well head works, mounting details of

distribution boxes and test posts, cable trenches, security fencing, etc.

� Any sensitivity in the proposed cathodic protection system that requires special

attention.

The following detailed design documents shall be submitted by Bidder to the EPCM for

approval before construction starts:

� A schedule of materials including a complete set of material and equipment

specifications.

� A complete set of design drawings.

� Installation procedures.

� Commissioning procedures.


00785 068 JSD 1675 01 A 9/20





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or d

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is p

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5.1.4. Training

Bidder shall consider presence of Owner’s operating personnel during installation, pre-

commissioning, commissioning and close interval potential survey of the cathodic protection

system. The bidder shall include training of Owner’s personnel in the operation and

maintenance of the cathodic protection system with particular attention being paid to any

special features of the system and troubleshooting.

5.1.5. Safety

The Bidder shall address in his design all safety related topics regarding the cathodic

protection systems and indicate, in the installation and operating documentation, procedures

to ensure safe working practices. The bidder shall be familiar with local safety rules and

practices and implement these in his work.

5.2. Balance Electricals5.2.1. The main equipment for balance electrical works for the job broadly includes, but is not

limited to, supply of the following:

- Flameproof lighting fixtures lamps and accessories for all local lighting.

- Flameproof welding receptacles, sockets and junction boxes as required.

- Flameproof hand-lamps and 24 V sockets (with built-in transformers).

- All supporting structures for lighting fixtures including poles, brackets, clamps, etc.

- Supply, laying, termination of all power and control cabling from switchgear in

substation to equipment within battery limit shall be by bidder.

- All cable trays, tray supports, trenches, electrical road crossings etc. for installing

cables from substation to within the battery limit. Inside process units, cable tray

should be covered after laying of all cables.

- Wherever available, existing cable tray /trench shall be used by bidder. In case of

requirement of new cable trench, bidder shall provide the same after carrying out

site survey.

- In case of using existing trench, making good of existing trench after laying cable is

in bidder’s scope.

- Any other electrical loads defined elsewhere in tender, or equipment not specifically

mentioned but required for completion of job.


00785 068 JSD 1675 01 A 10/20





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or d

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- Flameproof double compression cable glands for all equipment, panels supplied.

- Tool kits for maintenance of all equipment and systems as recommended by

respective manufacturers.

- Commissioning spares & spares for 2 years’ normal operation for all electrical

equipment.

5.2.2. Owner’s scope

� Owner shall provide two nos. feeders for power supply to CP system in substation-13.

Bidder shall consider a power distribution box at field to feed both existing and new

CP system.

� 1 no. feeder for power supply to MOV shall be provided in Substation-13, AB-1351

feeder no. 17R-B (63 A SFU).

� 1 no. feeder for supply to Heat Tracing shall be provided in field heat tracing DB.

Further power distribution shall be by bidder.

5.2.3. Bidder’s scope of work

Bidder’s scope shall include detailed engineering, preparation of all layout drawings, sizing,

selection, procurement, supply of all electrical equipment and materials required for the

package, transportation to site, installation, supervision, testing and commissioning of

complete electrical system forming part of this tender, for the safe, efficient, trouble-free

operation of the complete system and equipment as covered in the tender. Bidder's scope of

work shall include the following:

5.2.3.1. Detailed Engineering

Sizing and selection of equipment, cables and materials including all devices for indication,

metering, annunciation, interlocks, control, operation and protection as required. This

includes but is not limited to the following:

a) Overall Single Line Diagram of the facilities provided.

b) Calculations for Lighting System, Earthing System, Voltage Drop.

c) Preparation of cable tray/trench, lighting and earthing layout drawings including

associated documents such as, installation details.

d) Preparation of control schematics and logic for control panels and other equipment

requiring sequential or other control systems.


00785 068 JSD 1675 01 A 11/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

e) Preparation of cable schedule, interconnection diagrams, terminal details for equipment

/ devices including Electrical-Instrumentation interface details.

f) Preparation of all Bills of Material for all electrical equipment including cable trays,

cable tray supports, steel supports, lighting, earthing and miscellaneous items and

procurement of all items in Bills of Material.

g) Preparation of "As Built" drawings.

5.2.4. Installation, testing and commissioning

Installation, testing and commissioning of all equipment and materials supplied by Bidder

including complete lighting, earthing, cabling, cable tray works etc. within the battery limit.

5.2.5. Job specifications

a) Switchboards housing switch fuse feeders required for the mounted Bullet package in

refinery will be supplied and installed by the owner. All Power and Control cable supply,

laying, termination from substation to equipment within the package battery limit will be

done by the Bidder.

b) Bidder shall ensure that equipment supplied by them shall be provided with suitably

sized terminal boxes having suitable cable entry. Wherever required, additional adapter

box/JB shall be provided by the bidder.

c) The complete electrical system shall conform to requisition attachments and data

sheets in this tender. Various electrical works covered under this contract like

equipment erection, cabling, lighting and earthing works etc. shall be performed in

accordance with the specifications attached with the tender. Installation standard

drawings shall be issued to the successful Bidder.

d) Makes of electrical equipment, materials and components shall be selected out of the

list attached elsewhere in the Tender. Any other makes shall be subject to

EPCM’s/Owner’s written approval. For makes of items not included in the list, prior

approval from Owner/EPCM shall be required. However, the sub-vendors’ current

validity and range of approval as per enlistment letter, workload, stability and solvency

needs to be verified by the vendor before placement of order.

e) Local lighting for the mounded storage, pump station, pumps, operating platforms,

panels, walkways, stairs etc. shall be provided by Bidder. Both normal and

emergency/critical lighting circuits shall be provided. Power supply required for local


00785 068 JSD 1675 01 A 12/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

lighting of new bullet shall be tapped from existing lighting panels for lighting of existing

bullets. Bidder to use 4.5M pole mounted lighting fixtures for local lighting of new bullet.

f) Heat tracing for new bullet in totality is in bidder’s scope. Bidder shall obtain and

evaluate necessary information to perform complete design, supply, installation, testing,

commissioning and documentation for heat tracing system. Heat tracing system shall

conform to standard specification for heat tracing attached with the tender.

g) Cables shall be laid on trays above ground on cable racks/sleepers. Where

unavoidable, a few cables may be laid in trenches subject to specific approval by

owner/EPCM.

h) Spares for two years’ normal operation of all electrical equipment and commissioning

spares shall be included in the scope of supply.

Lamps and control gear shall be included for lighting fixtures while control

switches/push buttons shall be provided for local control stations.

i) Mandatory spares shall be provided as per mandatory spares list.

5.2.6. Drawing/ documents required from Bidder

5.2.6.1. With bids

a) Load list.

b) Guaranteed power consumption for rated throughput of plant.

c) UPS and DC load requirements.

d) Cable tray requirement in substation/field.

e) Makes for various equipments offered.

f) - Specific confirmation to scope of tender.

- Specific confirmation to specifications and technical requirements of tender.

- Deviation, if any.

g) Recommended list and quantity of maintenance spares.

5.2.6.2. After contract award

Electrical document deliverables to be submitted by Bidder for review and records shall

broadly include the following:


00785 068 JSD 1675 01 A 13/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

After orderSr. No. DescriptionReview Ref./

Records

Remarks

1. Design calculations

a Load data, equipment sizing *

b Lighting/earthing calculations *

2. Basic designa SLD *3. Material requisitions *

4.

a

Purchase requisitions (before

order placement) for bulk items

such as cables, lighting fittings

etc and equipment.

*

5. Layoutsa Equipment layouts, Cable tray

layout

*

b Earthing/Lighting layouts *

6. MTO & schedules *

7. Vendor drawings

a GAD, Data Sheets *b Wiring schemes, technical data for

all electrical equipment

*

6. MISCELLANEOUS WORKS

6.1. Supply and installation of all other equipment/ accessories not specifically mentioned herein

but nevertheless necessary for completion of job.

6.2. Correction and submission of drawings for AS-built status.

6.3. Obtaining approvals and clearance for energizing the complete electrical facilities covered

under this tender including approval of drawings from Central Electricity Authority/other

statutory agencies. Any changes required by the CEA/statutory agency, shall be incorporated

by the Bidder without any time or cost implication to owner.


00785 068 JSD 1675 01 A 14/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

6.4. Submission of test certificates, catalogues, vendor drawings, installation, operation and

maintenance manuals for all equipment/materials in Bidder's scope of supply.

7. JOB MATRIX Scope & Miscellaneous work as defined in clause 5.0 & 6.0 shall be read in conjunction with

the following matrix:

S. No. Description Bidder EPCM/ Owner Remarks

7.1 Engineering

7.1.1Identification of shut down requirements and

planning for hook up activities �

7.1.2

Any item not specifically mentioned in the

package but required as per good

engineering practice and for smooth and

safe operation of the equipment/ system/

plant shall deem to have been specified and

shall be in the scope of Bidder with no

additional cost and schedule implication to

the Owner/EPCM

�

7.1.3

Collecting necessary information about the

existing system, co-ordination with

owner/EPCM, as per requirement for the

satisfactory completion of the electricals for

mounded bullets.

�

7.1.4

In general, all electricals required for the

areas under mounded bullets including all

sheds/ buildings within plant battery limit

area shall be included in Bidder’s scope.

�

7.1.5

Bidder shall draw power from designated

substation for all electrical consumers. Area

lighting in mounded battery limit area and

power supply to CP system shall be from

LDB/switchgear in designated substation. All

�


00785 068 JSD 1675 01 A 15/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.


other equipment necessary for smooth

operation of mounded bullets shall be

supplied, installed, tested and commissioned

by bidder. Bidder shall design the system

accordingly.

7.1.6

Preparation and submission of drawings and

documents after award of contract and

obtaining comments/ approval on the same

�

7.1.7Timely review of documents and conveying

comments and approval �

7.1.8

Preparation of enquiry specifications and

data sheets, bid evaluation and obtaining

approval from EPCM as necessary,

placement of order, procurement of all items

as involved to complete the package

�

7.1.9

Obtaining statutory approvals such as CCE,

Central Electricity Authority (CEA), Factory

Inspectorate, local statutory authorities,

government authorities and any other

agency as required for completion of work

and commissioning of the plant

�

7.1.10 Electrical load list/ consumer list �

7.1.11 Earthing design and calculations for plant �

7.1.12 Cable sizing calculations �

7.1.13 Cable tray sizing calculations �

7.1.14 Lighting calculations �

7.1.15 Selection of equipment for hazardous area �

7.1.16 CP system calculations �

7.1.17Any other calculation not specified above but

required as support of selected equipments �

7.1.18 Timely submission of calculations and �


00785 068 JSD 1675 01 A 16/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.


support documents

7.1.19

Timely review of calculations and support

documents and conveying comments and

approval

�

7.1.20 Drawings

7.1.20.1 SLD

a. Lighting scheme �

b. Any other SLD as required �

7.1.20.2 Schematic diagrams �

7.1.20.3 Interconnection & terminal wiring diagrams �

7.1.20.4Cable tray/ Trench/ conduit routing, Earthing

and Lighting layouts. �

7.1.20.5Overall earthing layout for the areas within

bidder’s scope of work �

7.1.20.6 Area lighting layouts as required �

7.1.21 Cable schedule, cable drum schedule �

7.1.22

MTO schedules for bulks like cables, trays.

Lighting fixtures, LP/PP, junction boxes,

cable accessories, earthing materials, LCS,

structural steel. Socket outlets etc.

�

7.1.23 As built drawings/ documents as required �

7.2 Design, Procurement, Supply and Installation of Electrical Equipment

Design, procurement, supply, installation,

testing, pre-commissioning, commissioning

of electrical equipment as a minimum but not

limited to the following:

EPCM review of

MR/PR/ Vendor

documents w.r.t.

semi-critical, non-

critical equipment

as per

Annexure-I

7.2.1LT Switchboards

� PDB for CP system �

CP system panel

shall be in safe


00785 068 JSD 1675 01 A 17/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.


area. Panel shall

be provided with

GI canopy, if

located outdoor.

7.2.2 UPS PDB �UPS system by

owner/EPCM

7.2.3 Motorised valve actuators (if any) �

7.2.4 LT power and control cables. �

7.2.5Lighting fittings FLP for outdoor areas as

required�

7.2.6 Local control stations (FLP) �

7.2.7

Bulk items (cable trays, glands lugs, welding

and convenience socket outlets with plugs,

earthing material, structural steel, all types of

junction boxes, conduits, hume pipes etc.

�

7.2.8All erection hardwares materials, tools,

gauges etc. as required �

7.2.9All consumables required during erection,

pre-commissioning and commissioning �

7.2.10

Design, supply, installation, testing and

commissioning of Cathodic protection

system

�

7.3 Interface with EPCM/OWNER

7.3.1

Interface with EPCM/ OWNER for scope as

defined in cl. 5 of job specification.

Interfacing shall include receiving all

necessary information from/to EPCM/Owner

for satisfactory completion of work under

Bidder’s scope.

�

7.3.2Forwarding all inputs related to sizing and

selection of equipment (under Bidder’s �


00785 068 JSD 1675 01 A 18/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.


scope) to EPCM/Owner with regard to

consumer list, cable sizes, lighting load

requirement, CP system load requirement

etc. Bidder shall also forward input details of

cable tray/space requirement in substation,

space and floor cut out requirement for

installation of TR units, feeder requirement

for mounded bullet consumers to

EPCM/Owner.

7.4 Enabling Works

7.4.1

Re-routing and relocation of existing cables/

trenches/ structures over/under ground,

which are fouling with new construction job.

�

7.4.2Installation, testing and commissioning of

rerouted/ relocated underground services. �

7.4.3

Proper laying of all cables (both new and old)

in the existing cable trenches, wherever

made available to Bidder, after taking out the

cables laid in those trenches and backfilling

with sand, putting RCC covers etc.

�

7.4.4Construction box culvert type road crossings

wherever cable trenches enter unit area �

7.4.5

Provision of required numbers and sizes of

hume pipes at the road crossings for power,

control and signal cables.

�

7.5 Inspection & Testing

7.5.1

Inspection, testing of the electrical equipment

and systems supplied as listed in the

respective specifications at supplier’s shop

and at site as per electrical job specification

and approved QC plan

� �

EPCM’s scope is

limited to critical

equipment as

enclosed in

Annexure-I


00785 068 JSD 1675 01 A 19/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.


7.5.2Any other tests as required/ identified for the

equipment during detail engineering � �

7.5.3

QA/QC documents compiled as per

specifications to be submitted for review/

approval of EPCM/Owner

�

7.6 Documentation

7.6.1

All documentation and drawings as listed

elsewhere with their soft copy on CD with

native file.

�

7.6.2

Detailed testing, pre-commissioning,

commissioning procedures for EPCM/

owners review/ approval

�

7.6.3All AS-BUILT engineering drawings &

documents�

7.6.4 All AS-BUILT vendor drawings & documents �

7.7 Erection and Commissioning

7.7.1 Site fabrication, machining etc. �

7.7.2Supply of all consumables up to handing

over. �

7.7.3

Construction of RCC built up cable trenches

from substation, to the battery limit of

mounded bullets.

�

7.7.4

Testing and inspection of materials on

receipt at site and to take remedial action for

replacement of damaged items

�

7.7.5

Transportation and handling of equipment/

material from storage site near the

equipment foundation

�

7.7.6

Erection, alignment, testing and

commissioning of equipment as per

approved installation/commissioning

�


00785 068 JSD 1675 01 A 20/20





The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.


procedures, drawings, etc.

7.7.7

Filled up Performa of field activities &

recording test results for EPCM/Owner

approval

�

7.7.8 Trial runs �

7.7.9 Commissioning �

Testing &

commissioning

shall be under

original

equipment

manufacturer’s

scope

7.7.10 Performance tests/ Reliability tests � Owner/EPCM

witness

7.7.11 Handing over �

7.7.12 Training of Owner’s personnel �

7.8 Miscellaneous

7.8.1

Any other works/ services/ materials/

interfacing/ enabling works not specifically

covered above but required for

completeness of the project

�


00785 000 JSD 1650 01 00 1/43

ENGINEERING DESIGN BASIS FOR ELECTRICAL

00 26.10.2010 REVISED AND RE-ISSUED ABS DYS DYS CSA



The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

ance

s, b

e to

tally

or

parti

ally

, dire

ctly

or

indi

rect

ly, t

rans

ferre

d, r

epro

duce

d, c

opie

d,di

sclo

sed

or u

sed,

with

out i

ts p

rior w

ritte

n co

nsen

t, fo

r any

pur

pose

and

in a

ny w

ay o

ther

than

that

for w

hich

it is

spe

cific

ally

furn

ishe

d or

out

side

the

exte

nt o

f the

agr

eed

upon

righ

t of u

se.

UNIT : FCC UNIT


LOCATION : IOCL, MATHURA REFINERY.

OWNER EPCM

INDIAN OIL CORPORATION LIMITED.

TECHNIP KT INDIA LTD.

NOIDA, INDIA.

ENGINEERING DESIGN BASIS

FOR

ELECTRICAL


00785 000 JSD 1650 01 00 2/43


CLIENT : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.

UNIT : FCC UNIT.


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.

CONTENTS 1. SCOPE ................................................................................................................................................. 3

2. UNITS ................................................................................................................................................... 3

3. SITE CONDITIONS .............................................................................................................................. 3

4. CODES AND STANDARDS ................................................................................................................ 4

5. SYSTEM DETAILS .............................................................................................................................. 6

6. PERMISSIBLE VOLTAGE DROP ....................................................................................................... 8

7. POWER DISTRIBUTION ..................................................................................................................... 9

8. SYSTEM CONFIGURATION ............................................................................................................. 11

9. CONSTRUCTION POWER : DETAIL TO BE INCORPORATED................................................... 11

10. AREA CLASSIFICATION AND EQUIPMENT SELECTION............................................................. 12

11. PROTECTION – METERING – CONTROL....................................................................................... 14

12. SUBSTATION DESIGN ..................................................................................................................... 18

13. EQIPMENT DESIGN .......................................................................................................................... 22

14. EARTHING SYSTEM ......................................................................................................................... 38

15. LIGHTING SYSTEM........................................................................................................................... 40

16. COMMISSIONING OF EQUIPMENT ................................................................................................. 43


00785 000 JSD 1650 01 00 3/43



UNIT : FCC UNIT.


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pres

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or d

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.

1. SCOPE This document along with related specifications, drawings shall form the basis of Electrical

design for developing detail engineering for revamp of FCCU for LPG yield and reliability

improvement at Mathura Refinery, IOCL.

In case of any discrepancy / conflict amongst various documents, following order of

precedence shall prevail:

• Statutory requirement

• Engineering design basis

• Technical specifications ,data sheets

• IS Codes and standards

2. UNITS

Following units shall be executed based on this document:

• FCCU Revamp

• Propylene Recovery Unit (PRU)

• LPG Treater

• Offsite & Utilities (O&U)

• Propylene service at Marketing terminal

3. SITE CONDITIONS * Maximum temperature : 47ºC

* Design maximum ambient temperature : 50ºC

* Minimum temperature : 2ºC

* Winterizing temperature : 2ºC

* Design minimum temperature : 2ºC

* Relative humidity

- Average : 36% @ 4º-50ºC

- Maximum : 95%

* Dry bulb temperature :

0


00785 000 JSD 1650 01 00 4/43



UNIT : FCC UNIT.


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pres

ent d

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or d

raw

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is p

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.

* Barometric pressure

- Minimum :

- Maximum :

- Average : 740 mm Hg

* Altitude above mean sea level : < 1000 mm

4. CODES AND STANDARDS

Codes and standards as per minimum requirement shall be as follows:

a) Statutory Regulations:

- Indian electricity act.

- Indian electricity rules. (1998)

- The factory act.

- The petroleum rules.

- The TAC rules.

b) Codes and Standards

- IS13234 (1992): Guide for short circuit calculations in three phase AC

system

- IS 5572 (2009): Classification of hazardous areas having flammable

gases and vapours for electrical installations

- IS 5571 (2000): Guide for selection of electrical equipment for

hazardous areas.

- IS 12360 (1988): Voltage bands for electrical installation including

preferred voltages and frequencies.

- IS 3961 (2001): Recommended current rating for cables.

- IS 4201 (1983): Application guide for CT.

- IS 3842 (2001): Application guide for electrical relays for AC systems.

- IS 4146 (1983): Application guide for VT.

- IS 10028 (2001): Code of practice for selection, installation and

maintenance of transformers.

- IS 1255 (1983): Code of practice for installation & maintenance of power

cables up to & including 33kV rating.


00785 000 JSD 1650 01 00 5/43



UNIT : FCC UNIT.


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pres

ent d

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or d

raw

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is p

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.

- IS 8478 (1977): Application guide for on load tap changers.

- IS 3043 (1987): Code of practice for earthing.

- IS 3716 (1978): Application guide for insulation co-ordination.

- IS 732 (1989): Code of practice fro electrical wiring installations.

- IS 6665 (1972): Code of practice for industrial lighting.

- IS 3646 (1992): Code of practice for interior illumination.

- IS 13346 (2004): General requirements for electrical apparatus for

explosive gas atmosphere.

- IS 13408 (1992): Code of practice for the selection, installation and

maintenance of electrical apparatus for use in

potentially explosive atmospheres.

- IS 7689 (1989): Guide for control of undesirable static electricity.

- IS 2309 (1989): Code of practice for the Protection of buildings and

allied structures against lightning.

- IS 1646 (1997): Code of practice for fire safety of buildings - electrical

installations.

- IS 3034 (1993): Code of practice fro fire safety of industrial buildings –

electrical generating and distributing stations.

- IS 10118 (1982): Code of practice for selection, installation and

maintenance of switchgear and control gear.

- IS 5216 (1982): Guide for safety procedures and practices in electrical

work.

- IS 9676 (1980): Reference ambient temperature for electrical

equipments.

- SP-30: National Electrical Code (NEC) – BIS Publication.

- OISD-STD-113 (2001): Classification of areas for electric installations of hydro-

carbon processing and handling facilities

- OISD-STD-173 (2003): Fire prevention and protection system for electrical

installations.

- OISD-RP-110 (1999): Recommended practices on static electricity.

- OISD-RP-147 (2002): Recommended practices – inspection & safe practices

during electrical installations.


00785 000 JSD 1650 01 00 6/43



UNIT : FCC UNIT.


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pres

ent d

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or d

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.

-OISD-RP-149 (2001): Recommended practices – design aspects for safety in

electrical system.

- OISD-GDN-180 (1999): Lightning protection

- IEC 79: Electrical apparatus for explosive gas atmospheres

- NFPA 70B (1994): Recommended practice for electrical equipment

maintenance

- NFPA 72 (2002): National fire alarm code

- NFPA 77 (2000): Static electricity

- NFPA 497 (2004): Recommended practice for classification of flammable

liquids, gases or vapours and of hazardous locations for

electrical installation on chemical process areas.

- IEEE 519 – 1992: Recommended practices and requirements for

harmonic control in electrical power systems

Any other standards may be followed provided it is equivalent or more stringent than the

available codes indicated above.

5. SYSTEM DETAILS

In this document HV implies : 11kV and 6.6 kV

MV implies : 415 V

• Utilization voltages : Main power supply : 11 kV, 50 Hz, 3 phase, 3 wire,

resistance earthed, 6.6 kV, 50 Hz, 3

phase, 3 wire, resistance earthed

For 415 V distribution : 415 V, 3 phase, 4 wire, 50 Hz, solidly

earthed

For motors above 160kW : 6.6 kV, 50 Hz, 3 phase, 3 wire

For motors from 0.37 kW to : 415 V, 3 phase, 3 wire, 50 Hz

up to and including 160 kW

For motors less than 0.37 kW : 240 V AC, 1phase, 50 HZ

MOVs, welding receptacles : 415 V AC

Normal lighting : 240 V AC, 1phase, 50 HZ


00785 000 JSD 1650 01 00 7/43



UNIT : FCC UNIT.


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or d

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.

Convenience receptacle : 240 V AC, 1phase, 50 HZ

Critical lighting : 220 V DC, 2 wire

Control supply 1. 240 V, 1 phase AC up to MCC level

shall be derived from individual

module

2. 220 V DC for 415 V PMCC , 6.6 kV

and 11 kV Switchgear

Instrumentation supply : 230 V AC UPS

(Refer Instrument : 24 V DC

Design basis) : 240 V AC non –UPS (For non-critical

load)

Power supply for : 230 V AC UPS

Fire Alarm system

Power supply for : 230 V AC UPS

Public address system

• Emergency Power

HOLD

• Voltage and frequency variations : : 11kV + 10%

: 6.6 kV + 10%

: 415 V+ 10%

: 240 V + 10%

: 50 Hz + 5% Combined voltage and frequency variation : + 10%.

• System fault level

HOLD

0


00785 000 JSD 1650 01 00 8/43



UNIT : FCC UNIT.


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pres

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or d

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.

6. PERMISSIBLE VOLTAGE DROP The maximum voltage drops under steady state conditions at full load shall be within the

limits stated in the following table:

S.No. System Element

Maximum

Permissible

Voltage Drop

a) Cable at HV switchboard incomer with sending end

board located remotely

2%

b) Cable between HV switchboard and transformer primary

(located near)

2%

c)

Bus duct or cable between transformer secondary and

HV Switchboard or PCC/PMCC

0.5%

d) Cable between PCC/PMCC and MCC or auxiliary

switchboard;

i) MCC / Auxiliary Switchboard near PCC/PMCC 0.5%

ii) MCC/Auxiliary Switchboard situated remote from

PCC/PMCC

2 to 2.5%

e) Cables between HV Switchboard and HV Motor Running-3%

Starting-10%

f) Cable between PCC/PMCC and motor Running-5.5%

Starting-10%

g) Cable between MCC (situated near PCC/PMCC) and

motors

Running-5%

Starting-10%

h) Cable between MCC (situated remote from PCC/PMCC)

and motors

3%


00785 000 JSD 1650 01 00 9/43



UNIT : FCC UNIT.


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.

S.No. System Element

Maximum

Permissible

Voltage Drop

i) Cable between Auxiliary Switchboard & Lighting Panel 1 to 1.5%

j) Circuit between lighting panels and lighting points

4%

k) DC Supply Circuit (Electrical Controls)

5%

l) DCDB to Control Room

2% (Note – 1)

m) UPS outgoing circuit

5% (Note-1)

Note:

1. Minimum voltage available across any instrument in the field shall be as per

instrumentation design basis. Distribution system for instrumentation supplies shall be

designed accordingly. In case of any conflict between electrical design basis and

instrumentation design basis, the latter shall govern regarding instrumentation power

supplies.

2. For 415 V motors starting voltage at motor terminal shall not be less than 80% of rated

value.

3. For 6.6kV motors starting voltage at motor terminal shall not be less than 90% of rated

value.

7. POWER DISTRIBUTION

A) FCCU, PRU & LPG Treater Two nos. 11 kV extension panels shall be installed and integrated with 11 kV

Switchgear, (BHEL make, typeVM12) located at TPS substation, one panel at each

side .11 kV power supply shall be brought to new substation (mentioned as S/S 51

hereafter) for Electrical loads of FCCU revamp unit, PRU and LPG Treater Unit. 11 KV

power Cable between TPS to proposed sub station 51 shall have one additional run of

0


00785 000 JSD 1650 01 00 10/43



UNIT : FCC UNIT.


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pres

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.

the cable in each of the two feeders. This run shall be in addition to the runs which are

calculated as per the load requirement.

These two extension panels shall feed one no 11 kV Switchgear in Substation 51. This

Switchgear shall feed two nos. 11/6.6 kV transformers and two nos. 11/0.433 kV

transformers. The transformers shall supply 6.6 kV Switchgear and 415 V switchgear

respectively. Refer Overall key single line diagram 00785-000-DW-1652-01, for Load

distribution of substation 51.

11 kV extension panels shall be in the scope of supply for the Erection contractor.

B) LPG Storage Facility Electrical loads for this facility shall be fed from New MCC 193 in LPG MCC room.

Existing MCC shall be replaced with new MCC and available feeder details shall be

furnished to TPKTI.

C) Cooling Tower Cooling tower fan motors (3 nos on 415 V) shall be fed from existing PMCC in NHGU

substation. PMCC shall be extended by one vertical panel each on both sides. Two

nos. new CT Fan motors shall be fed from extension panels, one on each bus section.

Third motor shall be supplied from existing motor feeder no. --- in switchgear no.--- in

substation 11. Existing motor fed from feeder no. --- of switchgear no. --- in substation

11 shall be disconnected from switchgear no. ---and reconnected to PMCC extension

panel in NHGU Substation to receive power supply.

Two nos. Cooling water pump motors shall be fed from existing 6.6 kV switchgear in

DHDS substation. Required CTs, protection relays etc shall be provided in existing

feeders, compatible to the system. One no. Cooling water pump motor shall be

supplied from feeder no ----of existing 6.6 kV switchgear ---- in substation 11. Existing

motor fed from feeder no. --- of 6.6 kV switchgear no,.-- in substation 11 , in turn , shall

be disconnected from switchgear no. --- and reconnected to 6.6 kV switchgear in

DHDS substation to receive power supply.

11 kV switchgear in NHGU substation shall be extended by one panel each on both

sides.


00785 000 JSD 1650 01 00 11/43



UNIT : FCC UNIT.


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pres

ent d

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ent

or d

raw

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.

D) Marketing terminal

HOLD

E) Unloading facilities and Panipat Refinery

HOLD

8. SYSTEM CONFIGURATION System configuration for 11 kV, 6.6 kV and 415 V switchgears shall be as follows:

• 11 kV, 6.6 kV switchgear and 415 V PMCCs shall have two bus sections with two

incomers and one bus coupler.

• In normal operation both incomers shall be ON and bus coupler OFF.

• On failure of any one incomer, due to loss of power supply, bus coupler shall be

closed through automatic changeover, and restore power to the affected section.

• Once affected incomer is restored, closing of incomer and opening of bus coupler

shall be through manual changeover with momentary paralleling between two

incomers through synchro check relay.

• Auto changeover shall be blocked if both incomers sense under voltage

simultaneously.

9. CONSTRUCTION POWER : DETAIL TO BE INCORPORATED


00785 000 JSD 1650 01 00 12/43



UNIT : FCC UNIT.


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.

10. AREA CLASSIFICATION AND EQUIPMENT SELECTION 10.1. The electrical equipment for hazardous areas shall be selected as per IS-5571 and

petroleum rules. The MINIMUM requirement is summarized below:

Zone – 1 Zone – 2 Equipment

Gas Group IIA, IIB

Gas Group

IIC

Gas Group IIA, IIB

Gas Group IIC

MV Motors

Ex-d Ex-d Ex-e/Ex-n

(refer note2)

Ex-e/Ex-n

(refer note2)

HV Motors

Ex-d/Ex-p Ex-d/Ex-p Ex-e/Ex-n

(refer note2)

Ex-e/Ex-n

(refer note2)

Push Button Station

Ex-d Ex-d Ex-d Ex-d

Motor Starter (for MOV etc) Ex-d Ex-d Ex-d Ex-d

Plug & Socket

Ex-d Ex-d Ex-d Ex-d

Welding Receptacle Ex-d Ex-d Ex-d Ex-d

Lighting Fixtures

i) Lighting Fitting and control

gear box

Ex-d Ex-d Ex-nR Ex-nR

ii) Control Gear Box

Ex-d Ex-d Ex-nR Ex-nR

Junction Boxes Ex-d Ex-d Ex-n Ex-n

Hand Lamps

i) Light fitting Ex-d Ex-d Ex-d Ex-d

ii) Transformer Unit Ex-d Ex-d Ex-d Ex-d

iii) Plug & Socket Ex-d Ex-d Ex-d Ex-d

Break glass unit

(Fire Alarm System)

Ex-d Ex-d Ex-d Ex-d

Lighting panel / power panel Ex-d Ex-d Ex-d Ex-d


00785 000 JSD 1650 01 00 13/43



UNIT : FCC UNIT.


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cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

Note: 1. The electrical equipment for hazardous areas shall generally be suitable for gas

group IIA/IIB and temperature classification T3 as applicable to the selected type of

explosion protection. In case of hydrogen or hydrocarbon mixtures having more

than 30% volume hydrogen, the gas group to be considered shall be IIC.

2. In case of Ex-e/Ex-n motors, risk analysis shall be carried out as per IS-6381:2004

and IEC 60079-7(2001), considering operational and maintenance conditions. Else

EX-d or Ex-p motors shall be offered.

10.2. As additional safety features, the following requirements for electrical equipment shall be

followed:

a. All electric motors for agitators / mixers and metering pumps handling flammable

material shall be flameproof type irrespective of the area being classified as Zone-2

or Zone-1.

b. All electric motors for vertical oil sump pumps shall be flameproof type.

c. Irrespective of the area classification (whether Zone-1 or Zone-2), all lighting

fixtures within the storage areas shall be flameproof type.

d. Irrespective of the area classification (whether Zone-1 or Zone-2), all motors and

lighting fittings within the pump house (station) associated with storage area and

within the loading/unloading gantries shall be of flameproof type.

e. All emergency / critical lighting fixtures and associated junction boxes in hazardous

areas (whether Zone-1 and Zone-2) shall be flameproof type.

f. Even though fired heaters in process units are not considered for area

classification, all electrical equipments associated with fired heaters in process units

shall as a minimum be suitable for installation in Zone-2 area.

g. All electrical equipment installed in Analyzer shelter shall be flameproof type

suitable for Gas Group IIA, IIB, IIC irrespective of the area being classified as Zone-

1 or Zone-2.

h. Building such as compressor sheds inside the process area shall be designed to

allow adequate ventilation to allow area classification as Zone-2. Lighting

equipment, EOT crane etc. in the shed shall be flameproof type. All other electrical

equipment shall be suitable for Zone-1 or Zone-2 area depending on extent of


00785 000 JSD 1650 01 00 14/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

hazard. Ex-d motors shall be used in Zone-2 areas for HV motors for centrifugal

compressors.

i. All motors for hazardous area Zone-1 shall preferably be flameproof type.

Pressurized motors may be provided in case Ex-d motors are not available.

j. Ex-d motors shall be used in Zone-2 areas for motors having frequent start/ stop

requirements e.g. EOT cranes, Elevators, MOV actuators.

k. Ex-n motors with prestart ventilation provision or Ex-d or Ex-p motors shall be used

in Zone-2 areas for application having average starting frequency more than 1 per

week, where rating of motor is more than 100kW.

l. Ex-p motors shall be used for large rating motors where either Ex-n or Ex-d motors

are not available.

m. For Ex-n and Ex-e motors, the appropriate risk assessment factors shall be worked

out taking operational and maintenance conditions. Else, Ex-d motors shall be

provided.

11. PROTECTION – METERING – CONTROL

11.1. Protection devices for power distribution system shall be as indicated below:

Transformer Feeder

Motor Feeder

Outgoing Feeder Incomer

Relay Number Secondary winding voltage 6.6kV

L.V winding < 0.433 KV)

HV HV MV PCC/ PMCC

HV MV PCC/ PMCC

51 ID MTL Over-

current relay Yes Yes -- Yes

Yes

(4)

Yes

Yes

(4)

51N IDMTL earth-

fault-relay

Yes

(6)

Yes

-- Yes

Yes

(4)

Yes

Yes

(4)

51G backup earth-

fault-relay (secondary

neutral)

Yes Yes -- No No No No

Motor protection relay

No No Yes No

Yes

(7) No No

0


00785 000 JSD 1650 01 00 15/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

Transformer Feeder

Motor Feeder

Outgoing Feeder Incomer

Relay Number Secondary winding voltage 6.6kV

L.V winding < 0.433 KV)

HV HV MV PCC/ PMCC

HV MV PCC/ PMCC

with locked rotor

feature (50, 50N, 46,

49, 50L/R)

64R instantaneous

restricted earth-fault

relay (secondary side)

No Yes -- No No No Yes

50 instantaneous

over-current relay Yes Yes -- No No No No

50N instantaneous

earth-fault relay

Yes

(6) Yes -- No No No No

87 differential

protection relay

Yes

(1) No

Yes

(2)

Yes

(3) No Yes No

86 tripping relay Yes Yes Yes Yes Yes Yes Yes

95 trip circuit

supervision relay Yes Yes Yes Yes No Yes

Yes

(13)

63 auxiliary relay

(transformer) Yes Yes -- No No No No

PT Fuse monitoring

(Block U/V trip) Yes

27,2 under voltage

relay with timer -- --

No

(13) -- --

Yes

(5)

Yes

(5)

25 check

synchronization relay -- -- -- -- --

Yes

(8)

Yes

(8)

Cable differential

protection Yes Yes

Feeder management

relay Yes


00785 000 JSD 1650 01 00 16/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

Notes: (1) For transformers rated 5 MVA and above

(2) For motors rated 1500 KW and above

(3) For critical / long feeders and plant feeders connected to main power generation

and distribution bus.

(4) DC supply shall be extended to remote substation

(5) Wherever auto transfer feature is provided proper logics as discussed above to be

implemented.

(6) Instantaneous earth fault 50N shall be provided only for transformer with delta

primary.

(7) For motor feeders rated 75 kW and above.

(8) For switchgears having bus transfer scheme, where continuous or momentary

paralleling is envisaged, check synchronizing relay shall be integrated with overall

paralleling scheme.

(9) The bus tie feeders in HV switchboards shall be provided with 51, 51N, 86 and 95

relays. All HV switchboards will have bus differential protection with C.T circuit

supervision. There shall be overlapping of zones such that no blind spots are left in

the system. For this CT location must be checked before finalizing the vendor

drawings.

(10) HV and MV breaker controlled motor feeders or contactor feeders with DC control

supply, shall be provided with timers for delayed tripping on bus under voltage while

the under voltage relay shall be common for the bus. Under voltage relay will sense

all three phases and tripping shall be blocked in case of P.T fuse failure.

(11) All HV switchboards shall have two sources of DC supply for redundancy.

(12) One No. DC supply supervision relay (80) shall be provided for each incoming DC

supply to the switchboard.

(13) Trip circuit supervision shall be provided as part of numerical relay in switchgear.

(14) Numerical relays shall be comprehensive units with all protection, metering and

control and communicable with existing ECS system in the refinery.

(15) 2 nos. of Master Trip (86) relays shall be considered for all breaker controlled

motors. One self reset type (flag hand reset) for process trip, another manual reset

for electrical trip. Both relay actuation shall be recorded through numerical motor

protection relay.

0

0

0

0


00785 000 JSD 1650 01 00 17/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

(16) Motors below 30 kW shall be provided with ELCB .Motors above 30 kw shall be

provided with suitable earth leakage relay with CBCT.

(17) deleted

(18) Under frequency load shedding relays to be provided in each HV switchboard. At

least six stages of under frequency settings are to be provided. Manual load

shedding command from TPS should also operate the load shedding relays. For

tripping individual feeders self reset type VAJ relays to be envisaged.

11.2. The metering devices in HV and MV Switchboards shall be as below:

Feeder

Type

A(3

phase)

V(3

phase)

Hz PF KW KWH Hour

Run

KVAR KVAH KVA

HV Incomer X X X X - X - - - -

HV Bus Tie X - - - - - - - - -

HV

Transformer

X - - - - X - - - -

HV Bus P. T - X - - - - - - - -

HV Plant

Feeder

X X - - - X - - - -

HV Motor X - - - - X

X - - -

PCC/PMCC

Incomer

X X - X - X

- - - -

PCC /

PMCC

X - - - - - - - - -

0


00785 000 JSD 1650 01 00 18/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

Bus Tie

PCC Bus

P.T

- X - - - - - - - -

ACB

outgoing

X - - - - X

- - - -

MV Motor

(> 75kW)

X - - - - - - - - -

MCC/ASB

Incomer

X X - - - - - - - -

MCCB/SFU

Outgoing

(> 250A)

X - - - - X

- - - -

LDB

Incomer

X X - - - - - - - -

1) Ammeter shall be provided at field for motors rated 30 kW and above.

2) Comprehensive metering shall be part of numerical relay, wherever numerical relay is

provided. Separate microprocessor based energy meter connected to metering C.T

will be provided .Metering data shall be communicable to ECS system through

numerical relay/ intelligent energy meter.

12. SUBSTATION DESIGN

A) FCCU, PRU and LPG Treater

One new substation shall be designed for FCCU, PRU and LPG treater. This substation shall

be located adjacent to substation 39.

1) This substation shall house 11 kV switchgear, 6.6 kV switchgear, 415 V PMCC/MCC,

auxiliary switchboard, Main lighting distribution board, lighting transformer, DC battery

charger, VFDs, DCDB, RTU panels, NGR, 11/6.6 kV and 11/0.433 kV distribution transformers

as required.

2) Substation shall be maintained at a positive pressure through pressurization system in the

switchgear rooms. It is to be ensured that the inlet air of the pressurized system shall be free from

0


00785 000 JSD 1650 01 00 19/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

moisture and hazardous mixtures. Positive pressure of 2 mm of Hg shall be maintained inside

the substation. Pressurisation duct arrangement shall take into due consideration MV bus duct

layout.

3) Sub-station floor shall be raised above grade level and the space below the switchgear room

shall be utilized as cable cellar. The cable cellar floor shall be 500 mm above the approach

road level and shall be paved and cemented. The cable cellar shall have a minimum clear

height of 2.5 m and shall house all cable trays, supports etc. The roof shall be given adequate

water proofing treatment to ensure that rain water does not seep into the substation.

4) An entry of 3.0 m with rolling shutter shall be provided for entry of equipment. A separate entry

for operating personnel and also an emergency door opening outwards shall be provided

in the substation.

5) In the Substation Room, where Switchboards are installed suitably sloped ramp for transition

between the floor and the switchgear bottom plate shall be provided to allow easy installation and

removal of any draw out devices.

6) Substation wall adjacent to the transformer bays shall be either 355 mm thick brick wall or

230 mm thick RCC wall. Substation building shall be preferably without any columns

within the switchgear room to ensure optimum space utilization.

7) Battery bank shall be located in a separate adequately ventilated room in the substation

building, along with necessary flameproof exhaust fan and other electrical fittings and

switches and water connection with sink. Floor of the battery room and walls up to 1.0

m height shall have acid/alkaline resistant protective material coating/tiling. Light fittings

in this room shall be chemical resistant and flameproof type. The battery rooms shall be

provided with exhaust fans and louvered opening in opposite wall/door.

8) VFD’s , Chargers , UPS (if any), will be installed in air conditioned environment.

9) Substation lighting shall be controlled by push button stations located at the entrance.

10) Substation shall have fire fighting equipment, first aid boxes and other safety equipment

as per statutory requirements. Rubber mats of required voltage rating shall be provided

around all the switchboards and panels.

11) Switchgear room shall be provided with the following minimum equipment:

a. Framed laminated shock treatment chart, conforming to IE rules, in English and

local language. Name, address and telephone number of nearest doctor shall be

mentioned in it.

0


00785 000 JSD 1650 01 00 20/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

b. Easily accessible first aid box containing ointments and medicines for treatment of

electrical burns, conforming to IE rules.

c. Self contained portable hand lamp, complete with rechargeable battery.

d. Portable battery operated emergency light.

e. Adequate number and size of CO2 fire extinguishers and dry chemical powder

suitable for dealing with fire.

f. Round bottom fire buckets filled with clean dry sand.

g. Framed single line diagram (AC and DC).

h. One no. earthing rod.

i. Earthing truck (for both circuit and bus).

j. Caution notices shall be provided for all energized electrical equipment.

k. HT megger

l. LT megger (2 nos.)

m. Discharge rod (2 nos.)

n. Breaker handling trolley (2 nos.)

o. Tools for working on HT Panels and LT panels (if required)

p. Laser temperature measurement guns (2 nos.)

Supply of above equipment shall be in the scope of Erection contractor.

12) Oil filled distribution transformers shall be located in bays adjacent to the substation

building. Transformer bays shall have well drained floor, surfaced with gravel or other

suitable material. Each bay shall be provided with 2.5 m high removable chain link fence

with a lockable gate at the open side. Partition walls between transformer bays and the

end wall of the last bay shall be of fireproof type and shall extend at least 600 mm

above the height of the equipment. Height of the bay shall be decided so as to facilitate

maintenance and easy removal of equipment and requirements of natural ventilation.

Minimum 1000 mm clearance shall be provided all round the transformer. Fire

extinguishers and round bottom fire buckets filled with clean dry sand shall be provided

in each transformer yard.

13) In every transformer bay one no. 100 A outlet shall be provided for oil filtration and other

maintenance.

14) Oil immersed transformer with oil capacity exceeding 2000 litres shall be provided with

a soak pit of sufficient capacity to accommodate entire volume of oil. Where oil capacity

0


00785 000 JSD 1650 01 00 21/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

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e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

of transformers exceeds 9000 litres, provision shall be made to drain away the oil to a

separate waste oil tank/pit located away, through suitable drain pipes of 150 mm or 200

mm in diameter.

15) The substation building shall be sized to take care of present and future needs and to

maintain the adequate clearances between equipment for ease of maintenance. Space

for two adjacent panels for future extension on each side of switchboard shall be

maintained.

16) The sub station shall be designed such that all new HT panels, PMCC and MCCs

panels can be extended in either side for minimum 2 no panels on either side in future.

Following minimum clearances around various equipments shall be maintained:

Front clearance for HV switchboard 2500 mm Front clearance for all other switchboards / panels 2000 mm

Between front to front of different switchboard / panels Rear clearance for panels having maintenance access from front only

3000 mm Less than 200mm or more than 800mm

Rear clearance for panels requiring maintenance from rear

1500 mm

Side clearance between two boards or from nearest obstruction

1500 mm (but not less than twice the width of each panel)

All-round clearance 1000 mm

Battery rack to wall clearance for - Single row, single/double tier

100 mm ( increase to 300 -400 mm))

- Double row, single tier 100 mm( increase to 300 -400 )) - Double row, double tier 750 mm

Between battery racks Front clearance for wall mounted equipment

750 mm 1000 mm

Head room clearance below bus ducts or any other overhead equipment

2000 mm

Front clearance for operation station, annunciation / control panel.

2500 mm

Minimum vertical clearance above the top of highest equipment shall be minimum 1500 mm

measured from bottom of roof slab and minimum 500 mm measured from the bottom of the lowest

roof beam.

Substation, together with cable cellar and panels shall have provision for 20% future expansion.

0


00785 000 JSD 1650 01 00 22/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

17) Fire proofing of cables shall be done for 1 m length at indoor equipment entry point, and

similarly for outdoor equipment entry point. Fire barriers shall be installed at substation building

cable entry points. All cables shall have FRLS outer sheath.

18) Cable cellar shall be provided with exhaust fans for adequate ventilation.

19) Transformer bay shall have clear approach road for movement of crane / Hydra.

B) LPG Storage facility Electrical loads for this facility shall be fed from New MCC 193 in LPG MCC room. Existing

MCC shall be replaced with new MCC and existing feeder details shall be furnished to

TPKTI.

C) Cooling Tower

Cooling tower electrical loads shall be supplied from NHGU substation, DHDS and

Substation 11. For distribution details refer clause 7.c. No new substation is envisaged.

D) Marketing Terminal (HOLD) Existing substation shall be utilized for this facility. If space /supply feeders are not available,

EPCM contractor shall extend existing substation and provide new panel for Propylene

service. Incoming power shall be taken from existing substation only.

E) Unloading facilities at Panipat refinery

HOLD

13. EQIPMENT DESIGN

13.1. HV Switchboard/ HV Extension panel 1) HV extension panel on either side of 11 kV switchgear 7A/8A (BHEL make, type VM12)

shall be provided in TPS substation. 11 kV and 6.6 kV Switchgear shall be provided in

New substation 59. 11KV board to be extended on both sides by 1 feeder each in

NHGU substation.

2) HV extension panel breaker rating shall be suitably rated for total electrical load down

stream.

0

0


00785 000 JSD 1650 01 00 23/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

3) HT switchgear, fed from transformers shall be rated for at least equal to the continuous

rating of transformer considering site ambient conditions.

4) Short circuit rating for 11 kV Extension panel and switchgear shall be 40kA for 3 sec.

5) Short circuit rating for 6.6kV switchgear shall be ---- kA for 3 sec.

6) Each vertical section shall consist of 1 no. circuit breaker only.

7) All breakers shall be horizontal isolation draw out type VCB. Trolley shall have

SERVICE, TEST and ISOLATION positions, each having locking facility. These

positions shall have limit switches with auxiliary contacts for interlock. CB shall be

operable in SERVICE and TEST positions with the cubicle door closed. The TEST

position shall be within the cubicle. A flexible duty interlocked plug and socket

arrangement with scrapping earth terminals shall be used for auxiliary supply.

8) All protection and metering CTs, PTs shall be easily accessible for testing,

maintenance and replacement. All protection CTs except class PS shall be of minimum

5P10 class. All CTs shall have P.D values less than 20 pc and window type CTs are to

be used for high ratings.

9) Interlock of upstream breaker shall be taken in closing and tripping circuits of incomers.

10) Contact multiplication shall preferably be avoided. Direct contact of breakers, master

trip relays etc shall be used for interlocking, tripping, closing etc.

11) 11 kV and 6.6 kV Switchgears and Line PTs and bus PTs shall be in separate

compartments and shall not be part of incomer breaker or outgoing feeder breakers.

12) All panels shall have peeping infra-red window at the rear for thermo graphy.

13) All breaker contacts shall be silver plated.

14) Auto changeover circuit supervision and remote and local indication shall be provided

for the same.

15) For VCBs, over voltage due to motor switching shall be limited to 2.2 times rated peak

line to earth voltage. Surge arrestors shall be provided for this purpose. Surge arrestors

shall be of adequate rating and located near the cable termination after bus differential

C.T.

16) Rating of CBs / contactors used in motor feeders shall be 125% of maximum

continuous rated current of motor.

17) Normal and standby loads shall be evenly distributed on both bus sections. Normal and

standby loads shall be fed from different bus sections.

18) Earthing trolleys, rods, breaker lifting trolleys shall be provided.

0

0

0

0


00785 000 JSD 1650 01 00 24/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

19) Marshalling cabinet shall be provided for DCS / PLC interfacing in the switchgear itself.

Terminal block shall have provision for termination of armoured multicore copper

cables.

20) Spare outgoing feeders shall be provided in HV Switchgears (not extension panels). At

least one number of each rating and type or 20% whichever is more shall be provided as

spare on each bus section. All the three compartments, i.e. breaker / bus / cable

compartments shall also be provided with metal barrier sheets.

21) HT switchgear shall be metal clad only.

22) Failure of DC control supply shall not trip any breaker.

23) CT secondary shall be 1A for both metering and protection. PT secondary shall be

110VAC. For all other design requirement, refer Standard specification of HT Switchgear

doc no. 0785-000-1652-01.

24) Provision for 20% spare feeders to be kept, with minimum of 2 spare feeders( one on

each side of panel).

13.2. Transformers

Distribution transformers shall be with following turn ratio

a) 11/6.9 kV

b) 11/0.433 kV 1) Power connection for 11/6.9 kV transformer shall be:

Primary – through cables

Secondary – through cables

2) Power connection for 11/0.433 kV transformer shall be:

Primary – through cables

Secondary – through bus duct

3) Distribution transformers shall be three-phase, oil immersed, double wound type,

ONAN cooled, suitable for outdoor use, with off circuit tap changer having range of

plus ±5% in steps of 2.5%, boltless design.

4) Transformer rating shall suit 20% spare capacity with 100% load as basis. During

normal operation, each transformer shall be loaded to 40% of rated capacity. During

outage of one transformer, other healthy transformer shall be loaded to 80% of

rated capacity.


00785 000 JSD 1650 01 00 25/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

5) The maximum rating shall be 2 MVA. Number of such distribution transformers shall

be decided based upon the total load requirement. Due consideration shall be given

to the starting current of large motors. Transformer of rating up to 2.5 MVA

maximum can be considered as special case.

6) Transformer rating and impedance shall be selected in order to limit short circuit

current to values within the current rating and rupturing capacity of switchgear and

also to permit the DOL starting of the largest motor without exceeding the

permissible voltage drop limit. Transformer sizing shall take care of minimum 8

hours maximum demand.

7) Distribution transformers shall be of low loss type. Maximum efficiency shall occur

at about 40-50% of ONAN rating, and shall not be less than 99.5%.

8) Distribution Transformers shall be supplied with required accessories. For list of

accessories and other design requirement, refer Standard specification of

Distribution Transformer doc no. 0785-000-1641-02.

9) Lighting transformers shall be ANAN type. For design requirement, refer Standard

specification of Dry Transformer doc no. 0785-000-1641-03.

13.3. MV Switchboard

Switchboard Rating shall be at least equal to maximum demand under any circuit

configuration, with provision for 20% future requirement.

1) Starters for the motors in general shall be provided in PCC/MCC located in

substation. However in special cases like MOVs & EOT cranes etc. starters

(suitable for classified area) shall be provided by the package vendor in the field

near the motors .

2) Separate feeders shall be provided in the switchboard for each load/motor.

However, as an exception maximum two numbers welding receptacles may be

connected to one power feeder.

3) Motors rated 30 kW and above shall be provided with a CT in MCC for connection of

an ammeter in the local control station.

4) Motors rated upto and including 55 kW shall be fed from MCC and provided with

DOL starter.


00785 000 JSD 1650 01 00 26/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

5) Motors above 55 kW and upto and including 160 kW shall be fed from PMCC and

provided with ACB and motor protection relay.

6) However, in case number of motors is not many for one unit/switchgear, all motors

may be fed from same PMCC, subject to prior discussion and concurrence with

OWNER.

7) Minimum rating of ACB incomers for MCC shall be 800A

8) Motor feeders shall be provided with IEC type-2 co-ordination.

9) All PMCC feeders shall be with ACBs. No switch fuse feeders shall be used in

PMCC.

10) All breakers in PMCC shall be provided with suitable numerical relays

communicable with Existing ECS system in the refinery.

11) PMCCs shall have auto changeover facility. Under voltage tripping in PMCC shall

be inhibited if voltage dip is transient or if it occurs on both incomers

simultaneously.

12) MCCs shall have mechanical interlock and manual changeover facility between

incomers and bus coupler.

13) PMCCs shall be suitable for bus duct top entry. MCCs shall be suitable for bottom

cable entry.

14) MCCs shall preferably be single front. However, in case of space constraint, double

front MCCs may be provided after prior discussion with OWNER.

15) ACBs shall be provided with minimum 4 NO +4 NC spare auxiliary contacts wired

up to terminal box.

16) Contactors shall be air break type with 3 main contacts and 3 NO+3 NC contacts.

17) Local/remote selector switch shall be mounted at field.

18) Reacceleration facility, if required by process, shall be provided in switchgear.

19) Separate Marshalling cabinet shall be provided in the new Substation for switchgear

and DCS/PLC interface requirements.

20) Wherever motors are fed from existing switchgears, cables for interface with

DCS/PLC shall be taken to control room from individual feeders directly.

21) For all other design requirement, refer Standard specification for MV

switchgear/distribution board doc no. 00785-000-STD-1654-01and single line

diagrams of individual switchgear.


00785 000 JSD 1650 01 00 27/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

13.4. MV Bus Duct 1) MV bus duct shall be non phase segregated type.

2) The bus bar material shall be electrolytic aluminium / copper.

3) Bus insulators shall be non-hygroscopic, non-inflammable and flame retarding type.

4) Outdoor bus duct shall be weather proof IP55 and shall be provided with suitable

seal and canopy.

5) Material shall be same as that used for switchgear bus bars.

6) Space heater with auto cut-off shall be provided at suitable location.

7) Continuous earthing strips of proper sizes shall be provided on the two sides of the

bus duct, for connection with the earthing grid.

8) For all other design requirement, refer Standard specification for MV Bus duct doc

no. 00785-000-STD-1653-09.

13.5. NGR Neutral Grounding Resistor (NGR) shall be housed in a sheet metal enclosure and

shall be naturally ventilated. The resistor shall be of unbreakable, corrosion proof joint

less stainless steel grids. The grids shall be in punched form. The NGRs shall be

rated to withstand the fault current for 10 seconds.

13.6. Motors

1) All motors shall be IP 55, insulation class F with temp rise limited to class B.

2) Motors rated 1500 kW and above shall be provided with soft start facility.

3) Only standard output (kW) ratings of motors shall be used. Motors shall be

continuous, maximum rated with possible exception of crane and hoist motors.

4) Sleeve or anti friction type bearings shall be used. Vertical motors shall have thrust

bearings.

5) HT motors shall have 6 nos duplex RTDs for winding temperature detection, 2 nos

bearing temperature detectors with suitable scanners (with provision of alarm and

trip output). Dual dial type temperature indicator without contacts for bearings shall

also be provided.

6) Terminal box of HT motors shall be Phase insulated / Phase separated / Phase

segregated / Pressurized with elastimold connector and shall withstand specified

0


00785 000 JSD 1650 01 00 28/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

short circuit current for 0.25 sec. A separate neutral terminal box shall be provided

for making star connection, and shall accommodate CTs for differential protection.

7) Motors shall be capable of 20% over speed.

8) Starting current shall be limited to 600% on DOL. Reduced voltage starting by soft

starter may be used if starting voltage drop limits cannot be maintained by DOL

starting method.

9) Reacceleration of motors, if so required by process, shall be provided for

interruption in normal power supply up to 5 seconds. Insulation for these motors

shall be designed for 140% of rated insulation level.

10) Motors rated 75 kW and above shall have space heaters. Ammeter shall be

provided for space heater circuit on switchgear.

11) Difference between starting time of motors at 80% voltage and hot thermal

withstand time at 100% voltage shall be minimum 3 sec.

12) Winding and bearing temperature alarm and trip shall be provided for HT motors.

Minimum 10% additional RTD points shall be provided.

13) EEx-d gr IIC motors with top terminal box shall be provided with extended shaft.

14) All motor terminal boxes shall be on the right hand side of the motor viewed from

driving end.

15) Terminal box of the motor shall be suitable for rotation by 90o.

16) All outdoor motors shall be provided with canopy.

17) Surge suppressor shall be provided in VCB operated motor feeders.

18) Instantaneous earth fault tripping shall be provided in motor feeders with residual

connection and variable stabilising resistor.

19) Auto start schemes shall be designed in instrument PLC.

20) Voting logic shall be provided in auto start schemes of motors.

21) Numerical relays for motors shall have RTD and BTD support feature and the RTDs

and BTDs of the motors may be hooked up to the respective numerical relay for

alarm / trip provision.

22) U/V protection provided for motor as well as transfer scheme shall be

comprehensive and sense all three-phase voltages. The under voltage protection

shall operate only on under voltage of all three phases and shall be blocked on

tripping of PT MCB. The under voltage input to the relay for motors shall be derived

from bus PT.


00785 000 JSD 1650 01 00 29/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

23) Under voltage relay contact multiplication shall be provided through self reset relay.

24) All breaker operated motors shall be provided with TNC switch at the local control

station.

25) For Excitation Panel of Synchronous Motors Single Phase Bridge to be considered.

The same is required for Reliability Improvement ( So That Single Phase UPS

SUPPLY CAN BE GIVEN TO BRIDGE).

26) All motors to have canopies.

13.7. UPS System

A) FCCU, PRU and LPG treater UPS power for instrument load, Fire alarm system, Public address system and for any

other requirement shall be obtained from existing UPS system located in Main control

room of refinery. New UPS Power distribution board shall be provided, if required.

There shall be no UPS power DB in field.

B) LPG Storage Facility

HOLD

C) Cooling Tower

HOLD

D) Marketing Terminal

HOLD

E) Unloading facilities at Panipat refinery

HOLD

13.8. Battery charger and DCDB

A) FCCU, PRU and LPG treater

1) Two nos. separate 220 V DC system with battery bank, charger and DC distribution

board shall be provided in new Substation. One DC system shall be utilized for

switchgear control supply and Owner’s future requirement. Another DC system shall be

0

0


00785 000 JSD 1650 01 00 30/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

utilized for critical lighting. Both chargers shall have configuration of 2 Float cum-boost

chargers with common battery bank.

2) Batteries shall be vented Ni-Cd type.

3) Each battery bank, charger & DCDB shall have at least 25% spare capacity to meet

future requirements.

4) Each DCDB shall be provided with at least 20% spare feeders.

5) Minimum battery backup shall be as follows:

a) 2 hours for switchgear

b) 30 minutes for DC critical lighting

6) Isolator shall be provided near battery.

7) All electrical equipment inside battery room shall be flameproof.

8) Charger shall have dual parallel redundant modules of float and boost charging units.

9) Rating of charger shall be suitable for trickle / boost charging of batteries and to feed

the DC loads, with 25% spare capacity.

10) One summary fault contact shall be provided for remote alarm.

11) DCDB shall have three incomers and one bus coupler.

12) DCDB incoming and outgoing cables shall be copper cables.

13) Battery charger shall be provided with ripple overshoot annunciation.

14) DCDBs shall be provided with semiconductor fuses for fast isolation.

15) Incoming supply to battery chargers shall be through either circuit breakers or switch

fuse units, and not through contactors.

16) DC ground fault scheme shall be provided in the DC systems.

17) Boost charging alarm and critical battery charger alarms shall be provided at manned

location / control room.

18) Autostart facility for chargers to be provided to avoid manual start of chargers during

system under-voltage conditions.

For all other requirement, refer standard specification of DC battery and charger.00785-

000-STD-1672-01.

B) LPG Storage facility

DC supply, if required, shall be obtained from LPG MCC room -----, DCDB no. ---

0

0


00785 000 JSD 1650 01 00 31/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

C) Cooling Tower DC supply, if required, shall be obtained from NHGU substation -----, DCDB no. ---

D) Marketing Terminal DC supply, if required, shall be obtained from existing substation -----, DCDB no. ---

E) Unloading facilities at Panipat Refinery DC supply, if required, shall be obtained from existing substation -----, DCDB no. ---

13.9. Corrosion Protection 1) Sacrificial anode cathodic protection system shall be provided for mounded bullets for

corrosion protection.

2) Suitable surface treatment (blast cleaned to SA 2 ½ surface finish) with Polyurethane /

Poly-Urea coating shall be provided over mounded bullet.

3) Thorough electrical isolation of CP system shall be ensured.

4) This job shall be executed as supply and apply basis with necessary guarantees. The

vendor shall submit the completion/ performance certificate for the job done in past 5

years.

5) The vendor shall have the necessary application equipment like plural component

airless spray equipment and blast cleaning equipment and all suitable inspection

instruments.

13.10. Communication System

1) Stand alone Plant communication system shall be provided for FCCU revamp, PRU

and LPG Treater unit. Required number of Field call stations shall be provided in plant

unit. One no. call station shall be provided in new substation ---. Master call station and

exchange shall be located at Main control room.

2) Integration with existing communication system shall not be provided.

3) Speakers shall produce a sound level at least 10 dB above ambient noise level.

4) Where it is not possible to achieve required dB above surrounding noise level, rotating

beacon shall be provided.


00785 000 JSD 1650 01 00 32/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

r writ

ten

cons

ent,

for a

ny p

urpo

se a

nd in

any

way

oth

er th

an th

at fo

r whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

5) It shall be possible to communicate between two field stations without the interference

of MCS / operator, and also to have direct communication with MCS.

6) System shall have battery backup of 8 hours in case of power failure.

7) The central exchange shall have redundant CPU.

8) The system shall have features like status monitoring, fault diagnostics and report

generation.

9) The system shall have facility for manual / auto recording of conversation, and shall be

able to broadcast pre-recorded messages.

10) The system shall have at least 30% spare capacity after meeting all requirements of the

process units.

11) Plant communication system shall have Interlock with Fire alarm system. For other

requirements, refer Standard specification for Public Address system 00756-000-STD-

1630-02.

13.11. Telephone System Adequate number of flameproof telephones shall be provided in FCCU Revamp, PRU

and LPG treater units. Telephone arrangement shall be as per telephone block diagram

no. 00785-000-DW-1665-04. Required no. of Flameproof telephone terminal boxes with

crone type connector shall be provided at field for hooking up with existing EPABX

located at -------.

For other requirements, refer Standard specification for Telephone system 00756-000-

STD-1630-03.

13.12. Walkie Talkie system 15 nos. of handheld walkie talkie sets and 5 nos. desk mounted sets shall be provided

in FCCU Revamp, PRU and LPG treater units.

13.13. Fire detection and Alarm system 1) Stand-alone Fire alarm system shall be provided for the following areas:

• Substations ( substation nos -----------------)

• Existing Control room

• New control room

0

0


00785 000 JSD 1650 01 00 33/43



UNIT : FCC UNIT.


The

pres

ent d

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or d

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disc

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nd in

any

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an th

at fo

r whi

ch it

is s

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.

• FCCU revamp, PRU, LPG Treater plant units

• LPG storage

2) FA system loops from above areas shall be hooked to Central Fire Alarm Panel in fire

control building. Integration with existing system shall not be required. Fibre optic cable

shall be used for long distance.

3) Fire alarm system shall be analogue addressable type.

4) Repeater panel , if required, shall be considered.

5) Fire resistant armoured pink colour cables shall be used for the system.

6) Detectors and manual call points shall be connected in separate loops. MCPs shall be

mounted at entry, exit and generally at a travel distance of 30 m.

7) Detectors shall be provided inside substation, control room and cable cellar. Linear

heat sensing cables shall be used in cable trays in cable cellar.

8) The system shall have 30% spare loop capacity for future expansion.

9) Interlock shall be provided between new substation fire alarm system and

pressurization system (Pressurisation blowers to trip sensing fire or gas release in Substation),

also between new control room AC system and fire alarm system.

10) Response indicators shall be provided for detectors located in hidden locations such as

control room / substation.

For other requirements, refer Standard specification for Fire Alarm system 00756-000-

STD-1630-01.

13.14. ECS system Existing BHEL Max-DNA ECS system shall be utilised for extension panels of 11 kV

Switchgear 7A/8A in TPS substation. If existing system is not adequate for

accommodating the additional I/ Os, additional card may be installed in the system.

Switchgears in new substation 59 shall hook up to existing Honeywell ECS system.

Required RTU shall be provided in the substation for this purpose.

13.15. Cables 1) In general, all HV cables shall be with stranded aluminium conductor, dry cured XLPE

insulated, insulation screened, FRLS PVC inner sheathed armoured & FRLS PVC outer

sheathed. The screen for the HV cables shall withstand earth fault current for one

0

0


00785 000 JSD 1650 01 00 34/43



UNIT : FCC UNIT.


The

pres

ent d

ocum

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or d

raw

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is p

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of t

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.

second. All HV cables shall be designed for fault levels as mentioned elsewhere in the

document.

2) Fault level with stand time for HV cables shall be as follows:

• 0.25 sec for outgoing feeder

• 0.5 sec for Plant feeder

• 1 sec for Incoming feeder

3) Generally all LV power cables shall be 1.1 kV grade with stranded aluminium / copper

conductor, PVC insulated, FRLS PVC inner sheathed, armoured & FRLS PVC outer

sheathed. Copper conductor shall be used for sizes up to and including 10 sq. mm, and

for higher sizes aluminium conductor shall be used.

4) The control cables shall be 1.1 kV grade with 2.5 sq. mm stranded copper conductor,

PVC insulated, FRLS PVC inner sheathed, armoured & FRLS PVC outer sheathed.

Control cables shall be twisted pair or shielded wherever electromagnetic / electrostatic

interference is anticipated.

5) Lighting cable shall be 1.1 kV grade , minimum 2.5 mm2 stranded copper conductor,

PVC insulated, FRLS PVC inner sheathed, armoured & FRLS PVC outer sheathed. For

lighting inside the building minimum 1.5mm2 copper conductor, PVC insulated wire

shall be used in conduit system (for circuit and point wiring), with proper colour coding.

6) All power and control cables shall be in single continuous lengths (except for long

feeder where the length of such feeder is above the manufacturing range of approved

cable manufacturers). In no case any joint shall be located in hazardous area.

7) All multicore / muItipair control cables shall have minimum 20% spare cores.

8) The telephone cable shall be single / multipair, PVC insulated, screened, armoured and

overall PVC sheathed FRLS type with 0.8 mm dia copper conductor. 20% spare cores

shall be provided in each communication cable.

9) For Plant communication and fire alarm system PVC insulated, armoured and overall

PVC sheathed FRLS cable with 1.5 mm2 copper conductors shall be used. 20% spare

cores shall be provided in each communication cable.

10) HT cables shall be unearthed grade.

11) Size of aluminium conductor shall be limited to 300 sq. mm for each core.

12) For HT cables, size of copper conductor shall be limited to 630 sq. mm.


00785 000 JSD 1650 01 00 35/43



UNIT : FCC UNIT.


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pres

ent d

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or d

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is p

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.

13) Tinned copper lugs and double compression type nickel plated brass cable glands shall

be used for cable termination. Cable glands shall be flameproof double compression

type nickel plated brass at process unit end.

14) Wherever inside unit cable trenches or trays are crossed by existing or new

process/utility lines , the process/utility lines is to be separately covered in that portion to

avoid future spillage into/onto cable trenches or trays in the event of leakage.

13.16. Local control station

1) Each motor shall be provided with a local control station (LCS) in the field.

2) The LCS enclosure shall have suitable protection for site conditions (such as flameproof,

weather proof, dust proof, corrosion resistant, etc.). Canopy shall be provided for all

control stations.

3) The LCS shall include the following equipment as per individual process requirement:

(a) Start/stop push button or breaker control switch (spring return to normal).

(b) Ammeter (for motors rated 30 kW and above).

(c) Stop push button shall generally have stay put feature except in the case of critical

drives such as lube oil pump etc.

4) One number control switch station with start / stop push button shall be provided at

ground level in addition to the push button on operating platform for air fin fan coolers.

13.17. Convenience and welding receptacle 1) The enclosure shall have suitable protection for site conditions specified (explosion

proof, weatherproof, dust proof, corrosion resistant etc.).

2) Adequate number of 3 phase welding receptacles shall be provided at suitable

locations to ensure accessibility with a 50 meters length of trailing cable to any point in

the process area. These shall be rated for 63A suitable for 415V, 3 phase system with a

scraping earth connection.

3) Adequate number of three-pin, 1 phase sockets for lamps and portable tools, as

required, shall be provided at suitable locations to ensure accessibility with a 15 meters

length of cable to all manholes of process equipments. These shall be rated for 16A,

240V single phase with earth connection. 24 V Hand lamps and portable tools shall be

earthed through flexible cords.


00785 000 JSD 1650 01 00 36/43



UNIT : FCC UNIT.


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pres

ent d

ocum

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or d

raw

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is p

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ght o

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.

4) 240/24V transformers shall be provided in a separate flameproof socket outlet.

5) Required number of industrial type socket outlets (20A) shall be provided in substations.

6) All power receptacles like 240 V, 24 V, 415 V shall be preferably supplied from power

DB/pane.

7) Source cubicle tag no. shall be marked on the cover of all field receptacles for easy

isolation.

13.18. Lighting 1) Lighting shall be provided for the following:

• new substation ---,

• FCCU revamp, PRU, LPG Treater

• LPG storage area, additional lighting, if required

• Modified area of main control room, as required

2) Energy efficient lighting fixture shall be used. Following types of fixtures shall be used for

the specified areas.

All Fixtures shall be suitable for classified area (safe or hazardous).

Emergency lighting – HOLD

3) Critical lights shall be provided for entry points & escapes routes as required. Location

of critical lights shall be determined in consultation with Process group. Critical lighting

shall be fed from 220 V DC supply.

New Control room Fitting suitable for 2 X 36 W ( 5 star) ,

energy efficient fluorescent mirror optic

fNew Substation 2 X 36 W ( 5 star) fluorescent compressor room etc with mounting

height more than 6 m

1 X 250 W HPMV medium bay or high bay

Process areas 1 X 80 W HPMV or 1 X 125 W HPMV well

glass fittings for all areas

Transformer bay HPMV / fluorescent lighting fittings

0

0


00785 000 JSD 1650 01 00 37/43



UNIT : FCC UNIT.


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ent d

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or d

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.

13.19. Cable laying philosophy 1) Wherever, existing substation is used, cables shall be laid in existing cable tray/trench.

However, in case of inadequate space in existing cable trays, new cable trays shall be

provided for FCCU revamp project. This shall be decided as per site requirement and

shall be reflected in cable tray /cable routing layout.

2) Inside new substation---, HV cables shall be laid in trench. MV power cables, control

cables, signal cables shall be laid in separate GI cable trays inside the cable cellar.

RCC trenches shall be used for routing the cables from the substation to the process

units. The RCC trenches shall be designed keeping provision of future requirement and

without affecting the cable capacity rating.

3) Outside substation, existing cable routing/cable tray/trench shall be utilised to the

extent possible for cable laying. For cable routing details, refer Overall cable

tray/trench/route layout drg no. 00785-000-DW-1624-01.

4) Cable trays shall be of GI type. Main cable trays shall be of ladder type. Small branch

trays (of sizes 150 mm and below) shall be of perforated type. Minimum 30% spare

space shall be kept for future use while designing.

5) Power Cables in cable trays shall be laid in single layer. However, control cables may

be laid in three layers. Separate trays shall be provided for AC and DC signal / control

circuits.

6) Wherever pipe rack is not available, cable tray support shall be sized to ensure lowest

tray level to be minimum 2.7 m above grade (Except Road /unit Entrances /crane

crossings).

7) Cables inside process units, shall in general be run through sand filled RCC trenches

with removable covers / overhead cable trays wherever provision on pipe rack for cable

tray supports is available.

8) Cables in offsite and utilities or interconnecting cables in unpaved area shall be directly

buried or laid in overhead cable tray.

9) Underground road crossing shall be through cable culvert and above ground road

crossing shall be overhead cable bridge, wherever available.

10) GI conduits shall be used between trenches and field equipment like motors, control

stations etc. Necessary supports shall be provided for the same. Care shall be taken to

give sufficient space in the trench to give required bending radius for the cable and

spare loop.


00785 000 JSD 1650 01 00 38/43



UNIT : FCC UNIT.


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ent d

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or d

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.

11) Concrete lined trenches shall have suitable drainage arrangement to avoid water

collection, or these trenches shall be connected to nearest storm water drain. These

trenches shall be sealed against ingress of liquids and gases.

12) The top of cable trenches before entering the substation shall be maximum 1 m above

the ground level. All cut-outs shall be properly sealed by a sealing compound. Pipes

laid for mechanical protection shall be sealed at both ends.

13) All entry and exit openings for cables crossing in substation, control room etc shall be

provided with fire barrier and it shall have minimum three hours rating.

14) Fire proofing / painting for all power cables on 3 m length of cable at motor end and

load end in the field and panel end in the substation shall be provided. Fire barriers

shall also be provided below the opening of all HT and LT switchboards in substations.

15) Fire protection for cables shall be provided as per IS12459.

16) Parallel / duplicate feeder cables shall be laid separately as far as possible.

17) All cable trays and accessories shall preferably be prefabricated, hot dip galvanized.

For tray system design, in addition to self-load and wind forces, following guidelines for

design shall be considered.

a) Support span : 3000mm

b) Cable load : 75kg/linear meter

In addition to this, 75 kg concentrated load at center span shall be considered. All

structural steel design shall be as per Indian Standards.

18) Tinned copper cable lugs and double compression nickel brass type cable gland shall

be used for cable termination. In hazardous area, glands shall be flameproof.

14. EARTHING SYSTEM 1) Earthing system shall in general cover the following

- Equipment earthing for personal safety

- System neutral earthing

- Static and lightning protection

2) The minimum size of main earthing loop (MEL) around the substation shall

be 75 x 10 mm GI. For connection up to individual equipment, refer table

below:


00785 000 JSD 1650 01 00 39/43



UNIT : FCC UNIT.


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pres

ent d

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or d

raw

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is p

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.

Type of equipment Bare G.I. strip / G.I. wire rope / G.I. wire

Motors upto 3.7 KW 8 SWG solid wire Motors 5.5 KW to 30 KW &

welding receptacles 10 mm (3/8”) wire rope

Motors above 37 kW including HT motors 16 mm (5/8”) wire rope Building columns 40 X 5 strip Pipe racks, vessels & heat exchangers 10 mm (3/8”) wire rope Small equipments & instruments 8 SWG solid wire Lighting, power & instruments panels 10 mm (3/8”) wire rope Main earth bus/LT & HT SW

gear interconnections/ transformer GI strip, As calculated

Sub-stations GI strip,As calculated Push button station 8 SWG solid wire Street light poles 10 mm (3/8”) wire rope Lighting transformers 16 mm (5/8”) wire rope

3) All earth electrodes shall be GI pipe electrodes, provided with earth pits. Earth pits shall be

constructed up to 300 mm above ground level and shall be covered by removable slabs.

4) MEL for FCC revamp, PRU and LPG treater unit shall be connected to existing refinery

earth grid at minimum two points:

- New Substation---shall have separate earthing grid.

- All other areas, existing earth grid shall be used. Wherever, extension panels are

provided panel earthing conductor shall be connected to existing earth grid.

5) DCS, PLC, and other electronic instruments, including electronic relays, shall be

provided with clean earth. This shall be kept galvanically isolated from the system and

safety earthing.

6) Self-conducting structures may not be provided with aerial rod and down conductors,

they shall however be connected to the earthing system at minimum two points at the

base. An independent earthing network shall be provided for lightning protection and

this shall be bonded with the main earthing network only at the buried electrode.

7) Value of earth resistance for system earthing shall not exceed 1 Ohm.

8) For lightning protection, the value of 5 ohms as earth resistance shall be desirable but

in no case it shall be more than 10 ohms.


00785 000 JSD 1650 01 00 40/43



UNIT : FCC UNIT.


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pres

ent d

ocum

ent

or d

raw

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is p

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.

9) All utility / process pipelines shall be bonded to a common conductor by means of earth

bars or pipe clamps. Steel pipe racks shall be earthed at every 25 m. Earth continuity

shall be ensured across all flanges.

10) Underground earthing strips to be provided with 50% corrosion allowance.

11) Above ground local earth grid of minimum 50 X 6 mm size shall be provided for all

indoor areas. This shall be connected to the main earth grid at minimum two points.

12) Dedicated single earthing strip shall be laid along cable trays, welded to the main cable

tray support, and shall be connected to the earthing grid at every 20 m interval.

13) Metallic sheaths, screens and armour of all multicore cables shall be earthed at both

equipment and switchgear ends.

14) At least two nos. of earth strips of adequate size shall be tapped from the main earth

grid and taken to the top of all tall structures, platforms, and a ring shall be made at the

highest point.

15) Cadmium coated nuts and bolts shall be used at tapping points where welding is not

envisaged.

16) In plant area all stair cases, railings, monkey ladders shall be earthed at least at two

points.

17) Lightning Protection shall be provided for all buildings including Compressor house as

per IS - 2309. The horizontal air terminations and down conductors shall be of 20 x 3

mm2 GI Strip.

18) Proper wrapping and coating shall be given to the underground welded earthing joints

to avoid any corrosion.

19) Earth electrodes shall be galvanized after fabrication. No welding and drilled holes are to

be left without galvanization.

20) All earth pits shall be marked with earth pit number for easy identification. In addition,

metallic tag is also to be fastened with the earth electrode inside the pit as a permanent

identification.

21) Separate earthing shall be provided for transformer neutral.

15. LIGHTING SYSTEM

Emergency Lighting – HOLD

1) Areas requiring DC critical lighting shall be as following:


00785 000 JSD 1650 01 00 41/43



UNIT : FCC UNIT.


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pres

ent d

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or d

raw

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is p

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.

- New control room

- New sub station

- Process units under EPCM contractors scope

2) Critical (DC) lighting shall be normally “OFF” and during failure of normal power supply;

battery bank shall feed the critical lighting system.

3) HPMV lamps shall generally be used for plant lighting. Keeping in view the restrike

time lag and ‘to avoid complete darkness in case of a voltage dip/black out condition

necessary incandescent lamps may be judiciously distributed throughout the plant area.

Fluorescent lamps with electronic ballast shall be used for indoor lighting for substation

and control room. Safe area street and area lighting may employ sodium vapour lamps.

All chemical-handling facilities shall be provided with chemical resistant fixtures.

4) Non–integral type lighting fixtures shall be used. Mounting height of control gear box

shall not be more than 2 m in height from operating level.

5) DC critical lighting shall employ incandescent lamps. All ballasts shall be with copper

winding and capacitor for power factor improvement (to 0.95) shall be provided with

fixtures as applicable.

6) Tall structures shall have aviation obstruction lighting as per statutory requirements.

7) Lighting system for FCCU revamp, PRU , LPG treater units, new substation and new

control room, shall consist of lighting transformers for reduction of fault level, lighting

distribution boards (LDBs), lighting and power panels, fixtures, junction boxes etc.

8) Lighting and power panels shall be fed from LDB through 433/433 V, Dynll, dry type

lighting transformer having taps up to + 7.5%. These panels shall be provided with

MCB + ELCB as incomer and MCBs for outgoing feeders. MCBs shall not be loaded

beyond 80% of rated capacity. Minimum of 25% of feeders in each lighting panel shall

be left as spares. Normally about 8-10 fixtures or maximum 1000 W shall be wired in

each circuit.

9) For other areas (excluding areas mentioned vide cl.15.6), local lighting panels may be

fed from existing system. Also, for small lighting loads, lighting transformer need not be

provided.

10) All outdoor lighting shall be automatically controlled by means of photoelectric cell /

synchronous timers with manual overriding control.


00785 000 JSD 1650 01 00 42/43



UNIT : FCC UNIT.


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pres

ent d

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or d

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11) Telescopic tubular high masts shall be provided for illumination of offsite&utility /

general area. The masts shall be provided with motorized racking mechanism for

lowering and hoisting lantern carriage.

12) Lighting and power panels shall be fed from LDB through 433/433 V, Dynll, dry type

lighting transformer having taps upto + 7.5%. In case of oil mine installations,

secondary side voltage shall be 240 V between phases. These panels shall be

provided with MCB + ELCB as incomer and Miniature Circuits Breakers (MCBs) for

outgoing feeders control and protection of lighting cirucitrs. 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. Normally about 8-10 fixtures shall be wired in each

circuit. In areas having less lighting load, lighting transformer can be avoided.

13) Lighting Lux Levels

Lighting system design shall be based on average illumination levels as specified below:

Area Lux

- Roads 10

- Pump house, Sheds 100

- Main operation platforms and access stairs 60

- Ordinary platforms 20

- Process area, pipe racks, heat exchanger heater, 60

cooling tower, separators etc.

- Switchgear room 200

- Cable cellar 70

- Battery room 150

- Control Room 500

- Compressor Area 150

14) 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 shall be 0.7.

15) 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


00785 000 JSD 1650 01 00 43/43



UNIT : FCC UNIT.


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cable shall enter lighting fixture / JB through double compression gland for safe area,

Ex(e) or Ex(n) equipment and through flameproof glands for Ex(d) equipment.

16) Two pole isolation devices shall be used for controlling fixtures in hazardous areas to

isolate phase as well as neutral.

17) Substation ---cable cellar lighting shall be by armoured cables. Substation lighting shall

be done by surface conduit wiring.

18) For new control room with false ceiling, concealed conduit wiring shall be used below

the false ceiling and surface conduit wiring above the false ceiling.

19) Battery room shall have fixtures mounted on wall in order to facilitate easy replacement

of fused lamps. Switches controlling the lighting fixtures and exhaust fan shall be

installed outside the battery room.

20) Locally mounted lighting fixtures on platforms, walkways, stairs shall be installed in

such a way that re-lamping can be done without the use of ladders.

16. COMMISSIONING OF EQUIPMENT OEM shall provide commission assistance at site as per requirement for following Equipment.

1 BATTERY BANK AND BATTERY CHARGER

2. HT SWITCHGEAR

3. HT SWITCHGEAR, PCC&MCC FOR RELAY COMMUNICATION & CONFIGURATION

4. HIGH MAST

5. VFD

6. EOT

7. HT MOTORS(SYNCHRONOUS)& ITS EXCITATION PANEL

8. FIRE ALARM SYSTEM

9. ECS

10. PLANT PAGING SYSTEM

11 WALKIE TALKIE

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OWNER EPCM



NOIDA, INDIA.

DATA SHEET

FOR

MV SWITCHGEAR

02 18.08.2011 ISSUED FOR DESIGN ABS VV DYS VJK

01 01.08.2011 REISSUED FOR REVIEW VV DYS DYS VJK

00 11.11.2010 ISSUED FOR REVIEW ABS DYS DYS CSA




00785 000 DS 1654 01 02 1/5

DATA SHEET FOR MV SWITCHGEAR

UNIT : FCC UNIT



2 OF 5

CLIENT :PROJECT :LOCATION : 0 7 8 5 0 0 D S 1 6 5 4 0 1 2

1234

56789

1011121314151617181920

2122232425

27282930313233

34

35363738

3940414243

95%

240V AC SPN for _______ / 220VDC for _______240V AC SPN

less than 1000MHighly corrosive & Humid

Solidly earthed

IOCL, MATHURA REFINERY

GENERAL

Number of Phases

MV Switch Board Tag no.QuantityRef. Std.

Rated voltage with variationOPERATING CONDITIONS

SITE CONDITIONSTemp. Max./ Min./ Design °C

TECHNIP KT IndiaDATA SHEET FOR MV SWITCHGEAR

INDIAN OIL CORPORATION LIMITED, MATHURA REVFCCU AND PRU REVAMP, MATHURA PROJECT No. UNIT DOC. CODE SERIAL No.

IS:2147, 3231, 3427, 8623

Three phase + Neutral

415V AC ±10%50 Hz ± 5%

47 °C / 2 °C / 50 °C

50 KA for 1 sec.

240V AC SPN for _______ / 220VDC for _______

______KA (peak)

Control circuit power supplySystem Earthing

Cable for ______switch boards / Busduct for ______switch boardsTop / bottomTop / bottomTop

Relative Humidity Altitude Above MSL

Rated Frequency

System fault level

Environment

Aux. Power supply for spring charge motorAux. Power supply for Panel space heater

Main & vertical busbar InsulationMain busbar locationEarth busbar material

Safety shutters for test & drawout positionsHeat run test

DATA BY PURCHASER (Shall be separately furnished for each board)Switch Board

Metal EnclosedType of Switch BoardIP-54

YesYes / NoRequired / Not required

Glossy white631 as per IS:5Integral base frame suitable for tack welding or boltingSingle front for breaker feeders & other feeders except for LPG PMCC,whichmay be double front.Fixed / drawout type

Yes / No

Top / BottomHeat shrunk PVC sleeved

Copper / Aluminium

Aluminium

Exterior final colour shade

Bus barsMain & Vertical busbar material

Floor fixing

Feeder arrangement

Feeder typeSpace heater with thermostat & switch fuse in each panel

Incoming cable entryOutgoing cable entryBusduct entryInterior final colour shade

Degree of protectionAdaptor panel between switch board

Incoming power connection

26 Dummy panel to maintain 6000mm centre line distance between the two incomers for busduct entry Yes / No

System breaking capacitySystem making capacity

50 KA

3 OF 5

CLIENT :PROJECT :LOCATION : 0 7 8 5 0 0 D S 1 6 5 4 0 1 2IOCL, MATHURA REFINERY



44454647

4849505152535455565758

59606162

636465

6667686970717273747576777879808182 Daisy Chain / Star topology

Yes / No

Digital type / Analogue type64x64 / 72x72 / 96x96 mm1 / 1.5Copper, 1.5 / 2.5 sq mm

1 Star + 1 Open Delta

SwitchesRating & spare aux. contacts in switches 10A / 1 NO + 1 NC

Yes5P20 / 10VACL 1.0 / 10VACL 1.0 / 10VA

As per single line diagram of respective switch board

10A / 1 NO + 1 NC

Double / Single compression nickel plated brass cable glands

Contactor duty10A / 2 NO + 2 NCAC3

Air Circuit BreakerO-0.3min-CO-3min-CO10A / 8 NO + 8 NCYesYes

Type of circuit breakerDuty cycle of breakerRating & spare aux. contacts in ACB control feederAnti pumping feature in ACBBreaker trip free

Cables and cable glandsCable glands & Lugs for incoming & outgoing cables

1 Main + 1 Redundant RS485 serial link outputModbus RTU

Microprocessor based communicable type / Electro-mechanical

Circuit breaker

Switches duty

DATA BY PURCHASER (Contd.)

AC23

Included

YesRequired / not requiredRequired / not requiredYes / NoYes / No

IncludedYes / No

Suitable for capacitor switching

ContactorsRating & spare aux. contacts in contactor controlled feeder

Provision for manual spring charging of breakerTrip PB for mechanical trip

PT accuracy class / burdenType of secondary winding of potential transformer

Rating & spare aux. contacts in over load relaySingle phase prevention feature in thermal O/L relayProtection CT accuracy class / burdenMetering CT accuracy class / burden

Mechanical on / off indicatoroperation counter

Protections & metering requiredProtection relay type (except thermal overload relay)

Protection, Metering & relays

Suitable for capacitor switching

Type of cable glands

Connectivity with remote system (SCADA / ECS)Type of connections with SCADA / ECS / DCSCommunication protocolRelay connection type

Measuring instrument typeMinimum size of metersAccuracy class of measuring instrumentsControl wiring Material & size

4 OF 5




8384858687888990919293949596979899

100101102103

104105106107108109110

112113114115116117

118119120121122123

125

Circuit breakersDATA BY SWBD MANUFACTURER (Vendor to furnish data for each rating of ACB's, Contactors, Switches)

Circuit breaker make

124

Nominal current rating (In free air)Current rating at site cond. (Inside panel)

Circuit breaker TypeNo. poles / phase

Breaking capacity% DC componentPeak making currentShort circuit withstand capacity for 1 sec.

Derating reqd. for capacitor switching in %

Total closing time in sec.

Time taken for spring charging in sec.

Power required for opening in VA

Total opening time in sec.

Breaker closing mechanismBreaker tripping mechanism

400A63A 125A 250A 630A32A

Making capacityBreaking capacity

Thermal rating

Contactors

Contactor makeContactor rating in Amps

opening time in sec.Derating reqd. for capacitor switching in %

Mechanical life in no. of operations

Coil consumption in VA - Hold on

Rated breaking capacityRated making capacity

Mechanical life in no. of operations

Rated S.C. withstand current with max. permissible rated fuses

Switches

Contactor type

4000A1250A800A 2500A 3200A1600A

Power required for closing in VA____VA

Circuit breaker rating (Amps)

Electrical life in no. of operations at rated voltage

Switch type

____VA

111

Switch rating in AmpsSwitch make

Coil consumption in VA - Pick up

Closing time in sec.

Power required for spring charging motor ____VA ____VA ____VA ____VA

5 OF 5




126127128129130131132133134135136

137138139140141142143144145146147

2 18.08.20111 1.08.20110 11.11.2010

Rev. Date

DATA BY SWBD MANUFACTURER (Contd.) PCC EPMCC MCC ASB MLDB ELDBBus barsMain busbar current rating inside panel

Main busbar clearance in airMain busbar size

Phase to phase in mmPhase to neutral in mmPhase to earth in mm

Vertical busbar rating

Earth bus sizeVertical busbar size

Switch Board detailsSwitch board manufacturer

Overall dimensions of switch board (LxDxH) mm mm mm mm mm mmManufacturer's type / designation

Heat loss of switch boardTotal weight of switch board

Recommended clearances for switch board

Rear in mmFront in mm

Above in mmShock loading on foundation _____Kg_____Kg _____Kg _____Kg _____Kg _____Kg

ISSUED FOR DESIGN ABS VV DYSREISSUED FOR REVIEW VV DYS DYS

ISSUED FOR REVIEW ABS DYS DYSStatus Prepared By Checked By Approved By


00785 000 STD 1621 03 0 1/8

STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES

0 18.10.2010 ISSUED FOR DESIGN VV DYS DYS CSA



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UNIT : FCC UNIT



OWNER EPCM



NOIDA, INDIA.

STANDARD SPECIFICATION

FOR

MV CABLE AND ACCESSORIES


00785 0 STD 1621 03 0 2/8



UNIT : FCC UNIT.


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CONTENTS

Sr.No Page

1.0 Scope .............................................................. …………… 3 2.0 Codes and standard ......................................... …………… 3 3.0 General construction and material of construction.…………. 4 3.1 PVC insulated FRLS cables ............................. ………….. 4 3.2 Conductor .......................................................... …………. 4 3.3 Insulation ................................. …… ........................……. 4 3.4 Filler and inner sheath .................. …… ...................……. 4 3.5 Armouring ........................................... …… .............……. 5 3.6 Outer sheath ............................................ …… .......…….. 5 3.7 Dimension / thickness of materials ................. ……............ 5

4.0 Core identification ........................................... ……............ 5

5.0 Identification of cables ...................................... ………….. 6

6.0 Information required with the bid ......................... ………… 6

7.0 Cables drums ................................................... ………….. 6

8.0 Cable quantity ................................................. …….......... 7

9.0 Inspection and tests ............................................ ………… 7


00785 0 STD 1621 03 0 3/8



UNIT : FCC UNIT.


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1.0 SCOPE

This specification covers the basic requirements for design, manufacture, inspection and testing at vendor’s works, of PVC insulated cables up to 1.1KV for power, control, lighting, purpose to be used in FCCU and PRU Revamp project of M/s Indian Oil Corporation Ltd. (IOCL), Mathura Refinery, Mathura.

2.0 CODES AND STANDARDS

The design, manufacture and performance of PVC insulated cables shall conform to the applicable Indian, IEC Standards.

The relevant standards are: -

IS: 613 (1984) Copper rods and bars for electrical purposes. IS:1885 (Part 32)1993 Electro Technical Vocabulary-Electric Cables. IS:2633 (1986) Method of testing uniformity of coating on Zinc coated

articles. IS:3961 (Part 4) Recommended current ratings for Polyethylene 1968 insulated cables. IS:3975 (1988) Mild steel wire, formed wires and tapes for armouring of

cables. IS:5831 (1984) Specification for PVC insulation and sheath of electric

cables. IS:6474 (1984) Specification for Polyethylene insulation and sheath of

electric cables. IS:10418 (1982) Drums for Electric cables. IS:10462(Part1)1983 Fictitious calculation method for determination of dimensions

of protective coverings of cables. IS:10810(Pt 58) Methods of test for cables: Part 58 Oxygen Index test IS:10810(Pt 61) Methods of test for cables: Part 61 Flame retardant test IS:10810(Pt 62) Methods of test for cables: Part 62 Flame retardant test for

bunched cables IEC:60540 & 60540A Test methods for insulation & sheaths of electric cables. IEC:230 (1966) Impulse tests on cables and their accessories. IEC:60332 (3 parts) Test on electric cables under fire conditions. IEC:811 (5 parts) Test methods for insulating and sheathing materials of electric

cables.

2.1 The cables & accessories shall also confirm to the provisions of the Indian Electricity Rules and other statutory regulations in force in the country.

2.2 In case of any contradiction between various referred standards/


00785 0 STD 1621 03 0 4/8



UNIT : FCC UNIT.


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specifications/ data sheets and statutory regulations, the following order of priority shall be given:

- Statutory regulations - Data sheets - Unit Specifications - This Specification - Codes & Standards

3.0 General construction and material of construction The cables shall be suitable for laying trays, trenches, ducts and conduits and for underground buried installation with possibility of flooding by water & chemicals. Sequential marking of the length of the cable in the meters shall be provided at every one meter. The embossing or engraving shall be legible or indelible. The overall diameter of the cables shall be as per manufacturer’s data sheet subject to a maximum tolerance of +/- 2mm up to overall diameter up to 60mm and +/- 3mm for above 60mm.

3.1 PVC insulated FRLS cables

All power and control cables shall be heavy-duty type, 650/1100V grade, with Copper/Aluminium Conductor, PVC insulated, inner sheathed, armoured and overall FRLS PVC sheathed. All cables covered in this specification shall be FRLS unless otherwise specified in the data sheet. The outer sheath of PVC cables shall possess flame propagation properties meeting requirements as per IS-10810 (Part-62) category AF.

3.2 Conductor

The conductor shall be of plain aluminium or high conductivity annealed copper wires complying with relevant Indian standards. The conductors of size above 6mm2 shall be stranded.

3.3 Insulation

The insulation shall be of polyvinyl chloride (PVC) compound applied over the conductor by extrusion and shall conform to the requirements of Type “A” insulation as per IS: 5831.

3.4 Filler and inner sheath

(1) The filler and inner sheath shall be of the following: (a) Unvulcanized rubber, or


00785 0 STD 1621 03 0 5/8



UNIT : FCC UNIT.


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(b) Thermoplastic materials

(2) Unvulcanized rubber or thermoplastic material used shall not be harder than PVC used for insulation and outer sheath.

(3) The inner sheath shall be applied by extrusion method such that it fits closely on the laid-up cores and shall be possible to remove without damaging the insulation.

(4) Single core cables shall have no inner sheath.

3.5 Armouring

(1) Armouring shall be one of the following: - (a) Galvanized round steel wire (b) Galvanized steel strip

(2) Where the cable diameter below armour does not exceed 13mm, the armour shall consist of galvanized round steel wires. Where the diameter below armouring is greater than 13mm, the armour shall consist of either galvanized round steel wires or galvanized steel strips.

(3) The joints in armour wires or strips shall be made by brazing or welding and any surface irregularities shall be removed.

3.6 Outer sheath (1) The outer sheath shall be poly-vinyl chloride (PVC) compound conforming to

the requirements of Type ST1/ST2 compound as per IS: 5831 and shall be of FRLS type only.

(2) Outer sheath of all PVC cables shall be black in colour and the minimum value of oxygen index shall be 29 at 27 ± 2 deg. C. In addition suitable chemicals shall be added to the PVC compound of the outer sheath to protect the cable against rodent and termite attack.

(3) The outer sheath shall be applied by extrusion over the armouring.

3.7 Dimension / thickness of materials

The thickness of insulation, inner sheath, outer sheath and dimension of wire/strips used for armouring shall be as per relevant standards.

4.0 Core identification

Cores of cable shall be identified by colour coding of PVC insulation as per IS:1554 (Part 1)


00785 0 STD 1621 03 0 6/8



UNIT : FCC UNIT.


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5.0 Identification of Cables The cables shall be clearly and permanently marked with following information throughout the length. (1) Voltage grade. (2) Manufacturer’s name or trade mark. (3) Year of manufacture. (4) Cross sectional area of conductor and no of cores.

6.0 Information required with the bid

Vendor shall furnish technical particulars / description and performance details of all cables, current carrying capacities and de-rating factors, for all conditions of cable laying.

7.0 Cable Drums (1) Cables shall be supplied in non-returnable wooden drums of heavy

construction. The wood used for construction of the drum shall be properly seasoned, free from defects and wooden preservatives shall be applied to the entire drum. All ferrous parts shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit or storage.

(2) The vendor shall indicate in the offer, the maximum length of cable, which can be accommodated on one drum. The actual length supplied on each drum shall be within tolerance limit of +5%. The drum length shall be as per cable drum schedule.

(3) The cables shall be wound on drums of suitable barrel diameter,

securely battened, with the take-off and fully protected against mechanical damage. The cut ends of cable shall be sealed by means of non-hygroscopic sealing material to avoid ingress of water during transit or storage. Also, PVC /Rubber end caps shall be supplied free of cost for each drum with a minimum of eight per thousand metre length.

(4) The following information shall be stencilled on each drum.

(a) Name of manufacturer, brand name or trademark. (b) Nominal cross sectional area of conductor (c) Number of cores. (d) Type of cable and voltage grade. (e) Cable code (f) Length of cable on the drum.


00785 0 STD 1621 03 0 7/8



UNIT : FCC UNIT.


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prod

uced

, co

pied

,di

sclo

sed

or u

sed,

with

out i

ts p

rior

writ

ten

cons

ent,

for

any

purp

ose

and

in a

ny w

ay o

ther

than

that

for

whi

ch it

is s

peci

fical

ly fu

rnis

hed

or o

utsi

de th

e ex

tent

of t

he a

gree

d up

on ri

ght o

f use

.

(g) Number of lengths on drum (if more than one). (h) Drum number. (i) Direction of rotation of drum (by means of an arrow). (j) Reference standard (k) Approx. gross weight. (l) Job number. (m) Country of manufacture (n) Year of manufacture. A tolerance of +/- 3% shall be permissible for

each drum. However, overall tolerance for each size of cable shall be limited to +/ - 2%. Offer with short / non-standard lengths are liable for rejection. If non- standard drum lengths are specified in the data sheet, then same shall be supplied.

8.0 Cable quantity The bidder shall quote unit rates for all types of cables as indicated in the requisition. The unit rate quoted by bidder shall be valid in the event of addition / deletion of cable quantity.

9.0 Inspection and tests

(1) Inspection and testing shall be carried out in accordance with relevant

standards. Routine tests shall be witnessed by a representative of Owner / EPCM Contractor. Test certificates for type test shall be furnished with quotation. Vendor shall quote unit rate for witnessing such type test.

(2) Vendor shall submit blank formats where in the test results/readings are to be entered. This format shall give minimum acceptable value as per relevant standards.

(3) The inspector shall have free access to the manufacturer’s works for stage inspection and he will have the power to reject any material which appears to him to be of unsuitable description or of unsatisfactory quality. The vendor shall give at least 2 weeks prior notice to the purchaser, regarding the date of inspection to enable him or his representative to witness the tests.

(4) All routine tests, acceptance tests, type tests & additional type tests for improved fire performance shall be carried out as listed in IS-7098 (Part-2).

(5) The test requirement for PVC insulation & sheath of cables shall be as per latest revision of IS: 5831.

(6) The test for resistance to Ultraviolet radiation: This test shall be carried out as per DIN 53387 or ASTM-G-53 on outer sheath. The retention value of tensile strength & ultimate elongation value after the test shall be minimum 60% of the tensile strength and elongation value before the test. The test certificates with respect to this test (not older than 1 year)


00785 0 STD 1621 03 0 8/8



UNIT : FCC UNIT.


The

pre

sent

doc

umen

t or

dra

win

g is

pro

pert

y of

TE

CH

NIP

KT

IN

DIA

LT

D.

and

sha

ll no

t, un

der

any

circ

umst

ance

s, b

e to

tally

or

part

ially

, di

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prod

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, co

pied

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sclo

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or u

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with

out i

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rior

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ten

cons

ent,

for

any

purp

ose

and

in a

ny w

ay o

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than

that

for

whi

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is s

peci

fical

ly fu

rnis

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or o

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of t

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.

from recognized testing laboratory to be furnished for review by PMC before dispatch clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order, provided the outer sheath remains the same.

(7) Acceptance tests as per IS-1554 Part-1 and IS-7098 Part-2 and the following special tests to be performed on the cables as per the sampling plan. This tests are to be witnessed by PMC/ Owner before the dispatch of cables: a) Accelerated Water absorption test for insulation as per NEMA –WC-5 (For PVC insulated cables) and as per NEMA WC-7 (For XLPE insulated cables). Test certificates with respect to this test (not older than one year) from recognized testing laboratory to be furnished for review by PMC before dispatch, clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order

(8) Dielectric Retention test: The dielectric strength of the cable insulation tested in accordance with NEMA WC-5 at 75 ± 1o C shall not be less than 50% original dielectric strength. Test certificates with respect to this test (not older than one year) from recognized testing laboratory to be furnished for review by PMC before dispatch, clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order

(9) Oxygen Index Test: The test shall be carried out as per ASTM D2863 or applicable Indian Standard specifications. Sampling to be done for every offered lot / size as per sampling plan

(10) Flammability Test: The test shall be carried out on finished cable as per IS-10810 (part 61 & 62). Sampling for this test is to carried out one for each order, provided the outer sheath remains the same. The acceptance criteria for tests conducted shall be as under: Part-61: The cable meets the specifications if there is no visible damage on the test specimen within 300 mm from its upper end. Part-62: The maximum extent of charred portion measured on the test sample should not have reached a height exceeding 2.5m above the bottom edge of the burner at the front of the ladder.

(11) Test for rodent & termite repulsion property: The vendor shall furnish details to analyze the property by chemical method. Sampling to be done for every offered lot/ size as per the sampling plan.


00785 000 STD 1621 04 00 1/4

SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM

00 03.11.2010 ISSUED FOR DESIGN ABS DYS DYS CSA



The

pres

ent d

ocum

ent o

r dr

awin

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pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

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any

circ

umst

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s, b

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or

parti

ally

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UNIT : FCC UNIT



OWNER EPCM



NOIDA, INDIA.

SPECIFICATION FOR

CABLE FOR CATHODIC PROTECTION SYSTEM


00785 000 STD 1621 04 00 2/4



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

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f TE

CH

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KT

IND

IA L

TD.

and

shal

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, und

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ircum

stan

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be

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rtial

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dire

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nsfe

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rep

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disc

lose

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cons

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ny p

urpo

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any

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.

CONTENTS 1. SCOPE ................................................................................................................................................. 2


3. ANODE LEAD CABLE ........................................................................................................................ 3

4. +VE AND –VE HEADER CABLE ........................................................................................................ 3

5. DRAINAGE CABLE............................................................................................................................. 3

6. POWER SUPPLY CABLE ( BETWEEN PCC & T/R UNIT) ................................................................ 3

7. EARTHING CABLE ............................................................................................................................. 4

8. MEASUREMENT CABLE AND PERMANENT REFERENCE CELL ................................................. 4

9. CABLE DRUMS ................................................................................................................................... 4

10. INSPECTION........................................................................................................................................ 4

11. CABLE IDENTIFICATION ................................................................................................................... 4 1. SCOPE


00785 000 STD 1621 04 00 3/4



UNIT : FCC UNIT.


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pres

ent d

ocum

ent

or d

raw

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is p

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CH

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IND

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stan

ces,

be

tota

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rtial

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dire

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nsfe

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rep

rodu

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cop

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disc

lose

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use

d, w

ithou

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prio

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ten

cons

ent,

for a

ny p

urpo

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nd in

any

way

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er th

an th

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.

Cables mentioned here shall be a standard product of a manufacture regularly engaged in

production of power cables. This specification covers requirements for type, rating,

manufacture and testing of the cables for cathodic protection system.

2. CODES AND STANDARDS

In general the cable covered by this specification shall unless otherwise specified be in the line

with the requirements of any of the latest applicable standard of:

a) IS: 7098 (Part I)-1988

b) IS.3961 (Part IV)-1968

c) IS: 3961 (Part-Ill)-1967

Where ever the requirements in this specification are in conflict with any of the above standard,

the requirements under this specification shall be binding.

3. ANODE LEAD CABLE Anode lead cables shall be 10mm2 stranded copper conductor, single core, unarmoured, with a

double insulation system. The primary insulation shall be 1100 volt grade cross linked

Polythylene (XLPE). The secondary insulation shall be PVC sheathing jacket over the primary

insulation. Approx. over all dia. of cable shall be 9.6mm

4. +VE and –VE HEADER CABLE +ve header and -ve header cable shall be 95mm2, stranded Aluminium conductor, single core,

Aluminium wire armoured, PVC insulated and PVC sheathed 1100V grade cable.

5. DRAINAGE CABLE Drainage cables shall be 50mm2, stranded Copper conductor, single core, Aluminium wire

armoured, PVC insulated and sheathed 1100V grade cable.

6. POWER SUPPLY CABLE ( Between PCC & T/R Unit) Power supply cable between Power source and T/R unit shall be stranded Aluminium

conductor, 3-core, Aluminium wire armoured, PVC insulated and sheathed 1100 grade cable.


00785 000 STD 1621 04 00 4/4



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent

or d

raw

ing

is p

rope

rty o

f TE

CH

NIP

KT

IND

IA L

TD.

and

shal

l not

, und

er a

ny c

ircum

stan

ces,

be

tota

lly o

r pa

rtial

ly, d

irect

ly o

r in

dire

ctly

, tra

nsfe

rred,

rep

rodu

ced,

cop

ied,

disc

lose

d or

use

d, w

ithou

t its

prio

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ten

cons

ent,

for a

ny p

urpo

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nd in

any

way

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er th

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.

7. EARTHING CABLE Earthing cable shall be 35 mm2 stranded Copper conductor, 1-core, unarmoured, PVC

insulated 1100V grade cable.

8. MEASUREMENT CABLE AND PERMANENT REFERENCE CELL CABLE BETWEEN CJB CUM TEST STATION AND MJB

The measurement cable & reference cell cable shall be 6mm2, stranded copper conductor,

single core, armoured, PVC insulated and sheathed, 1100V grade.

9. CABLE DRUMS All cables to be supplied in wooden drums. Cable lengths in each cable drum shall be 600m

(min), where ever cable lengths are more than 600m.

10. INSPECTION All cables along with manufacturer's test certificate as per IS standards shall be inspected by

OWNER at the vendor's shop before dispatch. Minimum 15 days notice to be furnished by

vendor for this purpose.

11. CABLE IDENTIFICATION For easy identification of cable, the over sheath of the cable should have yellow colour and

"C.P.SYSTEM CABLES" should be printed using black colour at one meter interval throughout

the length of the cable.


00785 000 STD 1675 01 00 1/37

STANDARD SPECIFICATION FOR CATHODIC PROTECTION

00 11.11.2010 ISSUED FOR DESIGN ABS DYS DYS CSA



The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

ance

s, b

e to

tally

or

parti

ally

, dire

ctly

or

indi

rect

ly, t

rans

ferre

d, r

epro

duce

d, c

opie

d,di

sclo

sed

or u

sed,

with

out i

ts p

rior w

ritte

n co

nsen

t, fo

r any

pur

pose

and

in a

ny w

ay o

ther

than

that

for w

hich

it is

spe

cific

ally

furn

ishe

d or

out

side

the

exte

nt o

f the

agr

eed

upon

righ

t of u

se.

UNIT : FCC UNIT



OWNER EPCM



NOIDA, INDIA.

STANDARD SPECIFICATION

FOR

CATHODIC PROTECTION


00785 000 STD 1675 01 00 2/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

ance

s, b

e to

tally

or

parti

ally

, dire

ctly

or

indi

rect

ly, t

rans

ferre

d, r

epro

duce

d, c

opie

d,di

sclo

sed

or u

sed,

with

out i

ts p

rior w

ritte

n co

nsen

t, fo

r any

pur

pose

and

in a

ny w

ay o

ther

than

that

for w

hich

it is

spe

cific

ally

furn

ishe

d or

out

side

the

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agr

eed

upon

righ

t of u

se.

CONTENTS

1. INTRODUCTION .................................................................................................................................. 3

2. DEFINITION ......................................................................................................................................... 3


4. DOCUMENT REVIEW.......................................................................................................................... 5

5. DESIGN BASIS.................................................................................................................................... 5

6. SITE SURVEY...................................................................................................................................... 8

7. EQUIPMET AND MATERIALS.......................................................................................................... 10

8. SYSTEMS ENGINEERING AND INSTALLATION............................................................................ 15

9. SPECIAL FACILITIES ....................................................................................................................... 32

10. MATERIAL SCHEDULES.................................................................................................................. 34

11. HANDLING......................................................................................................................................... 36


00785 000 STD 1675 01 00 3/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

ance

s, b

e to

tally

or

parti

ally

, dire

ctly

or

indi

rect

ly, t

rans

ferre

d, r

epro

duce

d, c

opie

d,di

sclo

sed

or u

sed,

with

out i

ts p

rior w

ritte

n co

nsen

t, fo

r any

pur

pose

and

in a

ny w

ay o

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than

that

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hich

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1. INTRODUCTION

This specification covers the minimum requirements for cathodic protection of the

following steel items:

• Buried steel piping

• Buried tanks

• Bottom surfaces of on-grade storage tanks in contact with soil.

• Interior surfaces of water boxes and tanks which are in contact with water.

Cathodic protection system is utilized for corrosion control of ferrous metals in contact

with soil, buried concrete and water.

2. DEFINITION Deep Well/ Deep Ground Bed - One or more anodes installed vertically at a depth of

15 meters or more below the earth’s surface in a drilled hole.

(Bidder shall ensure there is no interference with RCC piles.)

Electrolyte - Moist soil and water in contact with the structure.

Parallel Bed - When used in the matters related to pipe, wire or cable type anode

placed parallel to the pipe run. When used in the matters related to tank bottoms, wire

or cable type anode in a coil or grid form in a plane parallel to the tank bottom at a

specified depth under the tank bottom.

Shallow Bed - One or more anodes installed vertically at a depth of 5 to 15 meters

below the earth’s surface.

Structure - The surface to which cathodic protection is being applied. A foreign structure

means a surface to which cathodic protection is being provided unintentionally.

Structure-To-Electrolyte Potential - The voltage difference between a buried (or

immersed) metallic surface and the electrolyte which is measured with reference to an

electrode (such as copper/copper sulfate and silver/silver chloride electrodes) in

contact with the electrolyte.

Surface Bed - One or more anodes installed horizontally or vertically at a depth of

5 meters or less, below grade.


00785 000 STD 1675 01 00 4/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

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d sh

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nder

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indi

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rans

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d, r

epro

duce

d, c

opie

d,di

sclo

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or u

sed,

with

out i

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ritte

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nsen

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r any

pur

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and

in a

ny w

ay o

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than

that

for w

hich

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spe

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3. CODES AND STANDARDS Unless otherwise specified, cathodic protection system shall conform to the following standards as a minimum.

IS 8062 - Part - I (1976): Code of Practice for C.P of Steel Structures

IS 5571(1971): Guide for selection of electrical equipment for hazardous areas

Indian Electricity act

Petroleum Act, 1976

British Standard Institute B7361 Part-I 1991 Code of Practice for C.P of

Steel Structures

VDE: 0150, Protection against corrosion due to stray current DC installation

IS 3043: -Code for Practice for Earthing

IS1554: - Part I & II PVC Insulated Cable

IS 7098: - Part I for Cross-linked polyethylene insulated PVC sheathed cable

IS 2148 (1981): - Flame Proof enclosures for Electrical apparatus

IS 2147:1962: - Degree of protection provided by enclosures for low voltage

switchgear & control gear

National Association of Corrosion Engineers (NACE) NACE RP0169 Control of External Corrosion on Underground or

Submerged Metallic Piping Systems.

NACE RP0177 Mitigation of Alternating Current and Lightning Effects on

Metallic Structures and Corrosion Control Systems

NACE RP0193 External Cathodic Protection of On-Grade Metallic

Storage Tank Bottoms

NACE RP0286 The Electrical Isolation of Cathodically Protected

Pipelines.

NACE RP0572 Design, Installation, Operation, and Maintenance of

Impressed Current Deep Ground Beds.

National Electrical Code

NEC NFPA-70

(ANSI-C1)

National Electrical Code


00785 000 STD 1675 01 00 5/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

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IP K

T IN

DIA

LTD

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d sh

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circ

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s, b

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d, r

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d, c

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d,di

sclo

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or u

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ritte

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and

in a

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than

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for w

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it is

spe

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4. DOCUMENT REVIEW Comments made by Contractor /Owner on drawing submittal shall not relieve bidder of

any responsibility in meeting the requirements of the specifications. Such comments

shall not be construed as permission to deviate from requirements of the Purchase

Order unless specific and mutual agreement is reached and confirmed in writing.

5. DESIGN BASIS

5.1. General Basis

The design of cathodic protection systems shall be based on the following and other

factors which are identified in the bidder’s pre-design survey:

• System designs and installations shall comply with applicable sections of the

industry standards referenced in Section 3.0 of this Specification, such as NACE

RP0169, RP0177, RP0193, RP0286 and RP0572.

• Equipment, materials, design, installation, testing and commissioning practices shall

conform to the codes and standards listed in this document, other requirements

stated in this document and all relevant project drawings.

• All design, installation, equipment and materials shall be suitable for continuous

operation under site conditions during the stated design life of the cathodic

protection system and shall be compatible with the environmental conditions of the

project.

The design life of the cathodic protection system shall correspond to the following.

Piping: 20 years

On-grade tank bottoms: 30 years

Buried tanks: 30 years

Tank internals: 20 years

Reference electrodes: 20 years

• For soil applications, the primary type of cathodic protection system shall be

impressed current using mixed metal oxide (MMO) anodes consisting of oxides of

iridium, tantalum and titanium on titanium base. The MMO anodes shall be canister,

wire, mesh, rod, tubular, ribbon type or a combination thereof. Sacrificial anode

systems shall be considered secondary or supplementary to the primary impressed

current systems.


00785 000 STD 1675 01 00 6/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

ance

s, b

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or

parti

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indi

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rans

ferre

d, r

epro

duce

d, c

opie

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sclo

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or u

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out i

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ritte

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nsen

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r any

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and

in a

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than

that

for w

hich

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spe

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furn

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agr

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se.

5.2. Schedule of cathodic protection systems The cathodic protection systems shall comply with Table 1. The anode shape,

construction, type and method of connection shall be approved by the purchaser/EPC

contractor.

TABLE 1

SCHEDULE OF CATHODIC PROTECTION SYSTEMS

MMO - mixed metal oxide (iridium/tantalum/titanium oxide) on titanium base

ITEM TO BE

PROTECTED

ANODE

MATERIAL

ANODE BED

TYPE

BACKFILL

SURFACES IN CONTACT WITH SOIL

Buried tanks MMO wire Surface Vertical Coke

breeze

Carbon steel piping within

plant boundaries

MMO wire

Surface horizontal

Surface vertical

Parallel to pipe

Coke

breeze

Carbon steel piping at

isolated road crossings

within plant boundaries

Zinc ribbon On the pipe None

Pipe casings at road

crossings within plant

boundaries (with or

without casing)

Magnesium

cast,

prepackage

d

Surface horizontal

Surface vertical

Bentonite

New on-grade storage

tank bottoms (coated and

uncoated) with HDPE

membranes

MMO wire Horizontal loops

(Parallel bed)

None

SURFACES IN CONTACT WITH WATER

Water tank internals

Water box internals

Platinized

niobium

None None


00785 000 STD 1675 01 00 7/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

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IP K

T IN

DIA

LTD

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5.3. Current requirements Total current requirements shall be calculated using the following formula:

I = DS*i + S*i*CF

Where, I = Total requirement current requirement, mA

DS = Surface area considered to have defective coating (i.e. bare surfaces)

CF = Current density adjustment factor for coated area

i = Current density, mA/m2

S = Total surface area of the Structure in contact with the electrolyte, m2

Current Density (i)

The following minimum current densities (based on bare surfaces) shall be used as

basis for current requirement calculations and shall be increased by 25% per 10°C rise

in temperature of the electrolyte above 30°C.

Surfaces in contact with soil 22 mA/ m2

Surfaces in contact with concrete 20 mA/ m2

Surfaces in fresh water 30 mA/ m2

Surfaces in saline water 65 mA/m2

Defective Surface Area (DS, % of the Surface Considered To Be Defective)

Buried pipe and tank surfaces: 1% of the total exterior surface.

On-grade storage tank bottoms: 5% of the bottom surface plus 100% of the

weld zone area (= total weld joint length, meters x 0.15 meters of zone width).

Tank internals (water tanks): 1% of the total floor and shell area

Tank internals: hydrocarbon services (in cases where water accumulates on the

floor): 1% of the floor area plus 1% of the first course of the shell area.

Water box interiors: 1% of the total boxed area.

Current Density Adjustment Factor For Coated Areas (CF)

Surfaces coated with fusion bonded epoxy, liquid epoxy and coal tar epoxy, coal

tar urethanes = 0.20

Surfaces coated with polyethylene and polypropylene = 0.05

Surfaces coated with 3-layer system (pipe surfaces) = 0.05

Surfaces coated with other coatings = 1.00

In case of any change in calculation procedure, vendor shall take prior approval from

contractor/ owner.


00785 000 STD 1675 01 00 8/37



UNIT : FCC UNIT.


The

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5.4. PERFORMANCE CRITERIA The installed system shall provide the levels of cathodic protection specified in Table 2.

TABLE 2

Cathodic Protection Potentials

INSTANT “OFF” POTENTIALS, mV

REFERENCE ELECTRODE

Cu/CuSO4(1) Ag/AgCl(2)

Steel in soil(3) -950 to -

1150

-900 to -

1100

Steel in water -950 to -

1100

-900 to -

1050

NOTES:

1. Cu/CuSO4 reference may be used for buried piping when

testing with portable reference electrodes.

2. Ag/AgCl reference electrodes shall be used for permanent

installations in soil and seawater.

6. SITE SURVEY

After locations of new buried refinery structures are determined, a predesign site survey

shall be carried out. The field survey shall evaluate the following:

• General terrain.

• Soil electrical resistivity and chemistry testing of the site.

• Possible interference sources such as high voltage transmission lines, man-

made stray currents or adjacent buried metallic structures or piping.

• Effects of existing cathodic protection system on new systems or vice versa.

If the area to be surveyed is affected by seasonal changes, the survey results shall be

adjusted to obtain a realistic design basis.


00785 000 STD 1675 01 00 9/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

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of T

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IP K

T IN

DIA

LTD

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6.1. General Terrain The survey shall include general information of the terrain including:

• Type of terrain and vegetation,

• Visible relevant features and crossings (main roads, overhead power lines,

other pipelines),

• Water drainage and channels,

• All other information that is considered relevant to the design of a cathodic

protection system.

6.2. Soil Resistivity Measurements

6.2.1. Surface and Shallow Beds

The number of measurements shall be determined locally using the following minimum

spacing, and readings shall be taken whenever there are visual changes in soil

characteristics. The site shall be marked off in a rectangular grid and readings shall be

taken at each grid intersection. If two successive readings differ by a ratio greater than

2:1, an additional reading shall be obtained at the midpoint between the previous two

readings. This shall be repeated until the readings meet the 2:1 ratio criteria.

For each type of soil, readings should be taken in at least two different locations. At

each location a minimum of two measurements shall be carried out.

6.2.2. Deep Well Ground Beds

Holes (or wells) drilled during geotechnical survey shall be used first, if possible, to test

the ground bed resistance for deep wells. Otherwise, pilot holes shall be drilled to

estimated depths indicated to be favorable from tests done for shallow beds. If water is

encountered, the hole may be allowed to fill with ground water. If hole is dry, it may be

filled with local water. A single anode may be lowered down the hole with a long lead

which is connected to a buried structure in series with a battery and an ammeter. By

measuring the current output at known power source voltage at intervals as the test

anode is lowered, a profile of current output and anode resistance with depth can be

developed. Soil resistivity shall be estimated by inputting the anode dimensions and

anode resistance in the Dwight formula for single vertical anode.


00785 000 STD 1675 01 00 10/37



UNIT : FCC UNIT.


The

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ocum

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IP K

T IN

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LTD

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6.3. Chemical Properties of Soil Tests shall include pH, chlorides, sulfides, sulfates, sulfate reducing bacteria and redox

potentials. The number of tests should be determined locally but measurements should

at least be carried out when there are visual changes in soil characteristics.

7. EQUIPMENT AND MATERIALS All equipment and materials for permanent installation shall be compatible with the

environmental conditions of project.

All equipment (transformer rectifiers, junction boxes, test stations, permanent reference

electrodes etc.) shall have identification plates with information identifying their

purpose. The plates shall also have tag numbers, with numbering system in

accordance with project equipment tag numbering system. The tag numbers shall be

marked on as-built drawings and referred to in all cathodic protection documentation.

7.1. Impressed current anodes Impressed current anodes for services other than water tanks and boxes shall be mixed

metal oxides (iridium, tantalum and titanium oxides) on titanium base.

For water tank and water box services, the impressed current anodes shall be

platinized niobium anode with copper core capable of delivering 1,000 amps per square

meter at consumption rates not exceeding 80 milligrams/amp-yr.

Bidder shall submit the following information for product approval:

• Composition of anode coating (mixed metal oxides, platinum etc.)

• Anode core data including dimensional data.

• Anode shape and dimensional data.

• Electrical properties of the anode including internal resistance, attenuation

rating of the anode, current rating and consumption data.

• Cable data.

• Cable to anode connection including sealing materials and methods.

• Any other information that will effect Owner’s approval.


00785 000 STD 1675 01 00 11/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

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of T

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T IN

DIA

LTD

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7.2. Sacrificial anode Zinc anodes shall be ASTM B-418, Type II with the following composition:

Al 0.005% max

Cd 0.003% max

Cu 0.002% max

Fe 0.0014% max

Pb 0.003% max

Zn remainder

Magnesium anodes shall be of the following composition:

Al 0.01%

Cu 0.02% max

Fe 0.03% max

Mn 0.50-1.3%

Ni 0.001% max

Others 0.30% max

Mg Balance

Cast anodes shall be factory prepackaged with backfill. Each anode shall be clearly

marked with the type of material (trade name), batch or charge number and anode

weight (without backfill). Full documentation (type, weight, dimensions, chemical

analysis and performance data of the anodes) shall be submitted by the bidder for

review.

7.3. Backfill materials for pre-packaged sacrificial anodes

Backfill for sacrificial anodes, other than ribbon type, shall consist of a mixture of

Gypsum (75%), Bentonite clay (20%) and sodium sulfate (5%). Backfill is not required

for ribbon type anode installed directly on the structure.

7.4. Backfill materials for impressed current beds in soil Carbonaceous backfill, when specified, shall be metallurgical coke breeze with the

following properties:

Maximum resistivity: 0.10 ohm-cm

Fixed carbon: 99.77%

Ash: 0.1%


00785 000 STD 1675 01 00 12/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

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awin

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perty

of T

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IP K

T IN

DIA

LTD

. an

d sh

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Moisture: 0%

Volatiles: 0%

Bulk density: 1 185 kgs/m3

Particle size: 1.0 mm maximum, dust free.

7.5. Cables For cables refer standard specification no. 00785-000-STD-1621-04.

7.6. Transformers/ Rectifiers

Transformers/rectifier stations shall be equipped with an alarm system which

automatically signals when there is current interruption, and with a remote monitoring

system. Rectifier stations and other associated equipment shall be installed in non-

hazardous areas wherever practical.

Transformers/rectifiers shall comply with relevant IS/IEC standards. Rectifiers shall be

of a special design for cathodic protection service and should be 3 phase units,

415±10% V-AC, 50±5% Hz if available or single phase. Transformer/rectifiers shall be

mounted on concrete plinths and all units supplied for specific functions shall be by the

same Bidders and shall be interchangeable on their plinth mountings. All necessary

hardware shall be furnished.

All terminals, connectors, bolts and contact hardware shall be of copper, brass or

bronze. Locking devices shall be used at all bolts and screw connections.

The maximum T/R output voltage shall be 75 volts.

The output voltage shall be adjustable from zero to the maximum rated output when on

load. A step less (continuous) adjustment shall be used. Automatic potential control

shall be provided.

Transformer/rectifiers shall not be installed in series or in parallel in the same cathodic

protection circuit.

The rectifier shall be constructed silicon diodes so arranged as to provide full wave

rectification. The current rating of the diodes shall be more than 1.25 times the

maximum current rating of the rectifier and have a minimum peak inverse voltage of

1200V.

The output rms. ripple current shall not exceed 5% of the DC output current between

5% and 100% of the rated current output.


00785 000 STD 1675 01 00 13/37



UNIT : FCC UNIT.


The

pres

ent d

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of T

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The transformer/rectifier shall be provided with an isolator or Molded Case Circuit

Breaker (MCCB) on its incoming circuit and, where applicable, on its AC subcircuits.

Additionally, suitably sized fuses shall be installed on the transformer/rectifier’s phase

AC sub-circuits and negative DC output circuits.

The transformer/rectifier shall be capable of withstanding a short circuit of up to

15 seconds duration at the output terminals without damage to any of its devices.

The transformer/rectifier shall be provided with approximately 76 mm diameter meters

or similarly sized square pattern meters to read the output voltage, current and

permanent reference electrode potential. The measuring accuracy shall be better than

2% of full scale.

The polarity of the DC terminals and AC supply terminals shall be clearly marked. AC

and DC cables shall be physically separated by an insulating panel.

A built-in current interrupter unit is required. The current interrupter unit shall be

electronic and shall be capable of switching the full output current on ON/OFF

sequence infinitely variable and adjustable from 0 to 99 seconds independently for

ON/OFF periods. If a pipeline, piping, tank or plant area system is cathodically

protected by more than one transformer/rectifier, all transformer/rectifier interrupter

units shall be provided with a facility for synchronous switching. The cathodic protection

system in the plant shall be designed so that a synchronous switching can be achieved

from a central monitoring switching board. During normal operation, the built-in current

interrupter shall be bypassed and synchronous switching, switched off.

Incoming cables of oil cooled transformer/rectifiers shall be terminated in separate non

oil filled cable boxes and penetration into the tank shall be via bushings above oil level.

A sight glass and thermometer shall be provided.

Transformer/rectifiers shall be installed in a non-hazardous area wherever practical. If

this is not possible, the construction of the rectifier units shall fulfill the requirements of

the hazardous area classification applicable for the site. The bidder shall obtain the

required information on area classification from the Owner.

The enclosure shall have a minimum degree of protection IP 54. Transformer/rectifiers

shall be suitable to operate under the prevailing service conditions. The rectifier

cabinet shall be of not less than 2.6 mm steel. All weight bearing components shall be

constructed from coated angle steel. The cabinet and its component parts shall be of

sufficient strength and rigidity, so that no damage occurs under normal handling.


00785 000 STD 1675 01 00 14/37



UNIT : FCC UNIT.


The

pres

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Each transformer/rectifier shall have:

• Lifting lugs of suitable size and location to facilitate lifting of the unit when full of oil.

• An oil filling hole with screw cap.

• An oil drain with a valve.

• An oil tank breather provided with silica get cartridge and breather seal, complete

with spare desiccant cartridge.

• An earthing terminal.

• Surge arrestors across the output terminals of DC voltage sources

A rating plate indicating Manufacturer’s name, model number, manufacturing date, AC

rating, DC rating, rectifier material, maximum operating temperature of the unit, weight

of the oil and weight of the unit plus oil, project purchase order number, equipment

identification number, date of purchase shall be provided.

7.7. Anode terminal boxes Anode terminal boxes shall be of stainless steel type 316L and with minimum degree

of protection IP 54 .

They shall be provided with a 6 mm thick phenolic panel with appropriate shunts, grid

coil resistors, terminals, meters and hardware as indicated by the bidders’s detailed

design. The junction box shall be provided with one or more 75 mm diameter conduit

hub and conduit for cables.

Anode terminal boxes shall provide sufficient room for control and test equipment and

dissipation of heat, e.g. from resistors. The boxes shall be provided with hinged doors

giving access to all internal components.

7.8. Test stations Test posts shall provide sufficient room for the termination of test cables and for the

installation of bonding cables and/or resistors. Test post head shall be orange color. Big

Fink test station with upright post shall be used in all areas except areas directly in the

traffic path. In such areas, Flush Fink test station shall be used.

If test stations are required to be installed underground, they shall have adequate water

drainage facilities and they shall be provided with a closure to avoid ingress of dirt. If

installed in traffic areas, the station shall be flush (with grade) type such as FlushFink.


00785 000 STD 1675 01 00 15/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

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awin

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of T

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LTD

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Test stations shall be provided with lockable access doors or caps, or have external

insulated contacts fitted to allow easy connection of test clips for regular monitoring.

Cable entry shall be at the bottom through protective tubes.

Terminal board shall be easily removable for adding or deleting cables. The station shall

be dimensionally stable up to 70°C and resistant to ultraviolet light. Terminals shall be

completely accessible with leads located under the cover. The station shall be designed

to reduce shock hazard. Maximum height shall be 2 meters with no component

requiring adjustment or monitoring higher than 1.7 meters. Test station shall be Ex’d’

type, zone 2, gas group IIA/ IIB/ IIC, class T3.

8. SYSTEMS ENGINEERING AND INSTALLATION

8.1. Qualifications for design personnel All work consisting of site survey, stray current analysis, system selection, system

design, installation and commissioning shall be under direct supervision of vendor’s.

Education and experience data (known as CV or resume) of vendor’s Corrosion

Engineer/Specialist shall be forwarded to the PMC/Owner for approval before work

commences.

8.2. Tank bottoms The design and installation of cathodic protection system shall comply with the

requirements of NACE RP0193.

Corrosion protection for tank bottoms shall consist of the following (descriptions of

items under the tank plates starting from the tank plate) :

• Coating on the soil side (underside) of the tank floor plate in compliance to

specifications.

• A layer of 300 to 350 mm thick dry, clean, chloride free foundation fill material

• A cathodic protection system consisting of anodes and reference electrodes.

• A layer of 150 to 200 mm thick, dry, clean, chloride free foundation fill material.

• A HDPE or other plastic liner shall be installed approximately 450 to 550 mm

below the tank plates. The liner shall have chemical resistance to any fluid leak

from the tank floor plate.

• Foundation fill material.


00785 000 STD 1675 01 00 16/37



UNIT : FCC UNIT.


The

pres

ent d

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of T

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T IN

DIA

LTD

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Anodes shall be titanium wire with mixed metal oxide coating installed in the form of

horizontal circular loops with cables from both ends exiting through the foundation wall.

The spacing between the anode loops shall be calculated to provide uniform current

density to the tank plates.

All design calculations for the anode assembly with its power feed points and header

cable connections locations shall be performed by the anode assembly manufacturer.

Anode resistance, header cable resistance and anode geometry shall be optimized to

maintain variation of current distribution below 10% at any point on the linear cathodic

protection system.

Anode loop length and loop diameter calculations shall be performed by the Vendor

and verified by the contractor.

Tanks shall have grounding protectors installed at each electrically isolated joint.

Each tank shall have one anode terminal box. Cables from each anode loop shall be

brought outside the tank foundation ring and connected to the terminals in the anode

terminal box. Each cable shall be clearly tagged with anode loop number starting with

#1 for the loop in the center. A copy of the drawing showing anode loops, reduced to

reasonable size, shall be laminated and securely attached to the inside of the anode

terminal box. The drawing shall also show the installation date and maximum current

rating of the anode materials.

All anodes shall be powered with a dedicated transformer rectifier to each tank or a

rectifier dedicated to a group of adjacent tanks.

Reference electrodes shall be installed along the circumference of an imaginary circle

whose radius is 86% of the tank radius from the center point of the tank bottom. The

distance between the reference electrodes shall not exceed 15 meters subject to a

minimum of one reference electrode in each quadrant. Also, a minimum of three

permanent reference electrodes shall be installed in the middle of the tank bottom area

in a triangular pattern whose center is the center of the tank bottom. Reference

electrodes shall be placed close to the bottom and away from the anode loops.

Leads from all reference cells and two test cables from the tank plate shall be routed to

one test station. Reference cells shall be numbered starting with #1 for the center

reference electrode followed by the reference electrodes located clockwise from the

location of the test station. A copy of the drawing showing reference electrodes,


00785 000 STD 1675 01 00 17/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

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of T

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reduced to a reasonable size, shall be laminated and securely placed within the test

station for reference.

The cathodic protection system shall be energized using temporary power and checked

for performance after tank floor plate placement and before starting the shell

fabrication. The system shall be free of shorts and perform at the electrical potentials

specified in the cathodic protection criteria.

Before starting the cathodic protection installation, appropriate quality checks of the

following items shall be performed and documentation shall be maintained by the

vendor.

• Liner and lining fabrication.

• Quality of the sand.

• Quality of the coating on the soil side of the tank plates.

• Anode materials, cable connections, corrosion protection of anode to cable

connections, and overall anode assembly.

• Reference electrodes.

• Sufficient slack in the cables.

• Zero electrical resistance at the anode to cable connections.

During installation of the cathodic protection system, the following items shall be

checked:

• Thickness of the sand layers.

• Diameter of the anode loops

• Placement of the reference electrodes.

• Depths of the anode loops and reference electrodes.

• After the tank plates are welded, the system shall be checked for electrical

shorts and performance.

• Placement of grounding cells and appropriated checks recommended by the

manufacturer of grounding cells.

8.3. Buried tanks The design and installation of cathodic protection system shall comply with the



00785 000 STD 1675 01 00 18/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

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nder

any

circ

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s, b

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or u

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with

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and

in a

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Buried tanks shall be protected with impressed current cathodic protection system

using vertical anodes.

Tanks containing flammable fluids shall have grounding cells installed at each isolation

joint.

Levels of cathodic protection shall be similar to those described for buried piping.

8.4. Tank internals All welding and cutting of tank surfaces necessary for installation of internal cathodic

protection equipment shall be completed before application of internal and external

coatings when practical. All damages to the internal coating caused by cutting and

welding operations shall be repaired .

Anodes shall be metallurgically bonded platinum coating on niobium substrate 1.6 mm

diameter wire.

The permanent reference electrode shall be IR-free silver/silver chloride reference

electrode.

All cables inside the tank shall be resistant to the tank interior atmosphere.

All wiring on the outside of the tank shall be installed in rigid steel conduit.

Underwater splices of cables are not permitted. Connections between the positive lead

wire and the conductors from the anodes shall be mechanically secure, electrically

conductive and shall be sealed to prevent moisture penetration.

Hand holes and mounting devices shall be provided in the roof adjacent to each anode

suspension so that the anodes can be removed, replaced or inspected without entering

the tank. All hand holes shall have removable, gasketed covers.

Cables on the tank roof shall be run in galvanized and painted conduit. Junction boxes

shall be provided on tank roof for each anode to anode header cable connection.

Junction boxes shall also house shunts to permit current measurements. Each anode

circuit shall also have grid coil resistor to permit balancing of current output from the

anodes.

Positive header cable shall enter the tank interior from the roof from which individual

cable to the anodes shall be routed inside the ceiling space of the tank to the hand

holes. The feeder cable to the anode shall be properly and permanently secured at the

hand holes and shall be designed to easily disconnect the anode for repair or

replacement.


00785 000 STD 1675 01 00 19/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

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s, b

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or u

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with

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Anodes shall be supported by a metallic stranded rope of 3 mm minimum diameter with

PVC sheathing. Anodes shall not be self-supporting.

The anodes shall be supported from the roof in a vertical position for optimum current

distribution. Installation shall not require emptying, wall penetrations below the high

water line or the use of pressure fittings.

The anode assembly shall consist of full length anodes on the outer ring to protect the

shell surface. Horizontally suspended anodes shall be used to protect the floor surface.

Appropriate ballast weights shall be installed to keep the anodes stationary while the

fluid is moving inside the tank.

Unless otherwise approved by the Owner, the distance between the anode surface and

the tank surface shall not be less than one meter. The anode system shall be designed

to prevent electrical shorting to the tank.

The anode system shall provide and maintain an uniform distribution of current without

exceeding the potential limits stated in the cathodic protection criteria. The anode

system shall have lowest possible circuit resistance.

Voltage attenuation shall be less than 10% at the anode end opposite from the anode

to positive cable connection.

Reference electrodes shall be located approximately at equal distance from the anodes

and close to the intersection of floor and shell. A magnet secured to a reference

electrode cell shall be used to maintain the 10 mm distance from tank surface. The

straight line spacing between reference electrodes shall not exceed 10 meters and the

minimum number of reference electrodes per tank shall be two.

Automatic controls shall be installed to adjust the output of the rectifiers based on

potential readings of the permanent reference electrodes. The system shall be also

automatically adjustable for all variables except IR drop error.

8.5. Buried piping system

The design and installation of cathodic protection system shall comply with the


8.5.1. Piping without casing buried under roads:

Piping which is geographically remote or isolated from impressed current cathodic

protection systems shall be protected with zinc ribbons.


00785 000 STD 1675 01 00 20/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

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any

circ

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A test station shall be installed to monitor the potential of the piping.

Buried piping shall be electrically isolated on both sides of road by using dielectric joints

(couplings, flanges or unions). The electrical isolation shall be between the road

location and the first above ground pipe support or connection to aboveground

equipment.

8.5.2. Piping inside casings:

Piping inside casing shall be electrically isolated from the casing using insulators such

as LinkSeals which shall be installed at not more than 150 mm from each end

regardless of the size of the casing or the carrier pipe. In addition to the electrical

insulators at the casing ends, each pipe support inside the casing shall be electrically

nonconductive. If the pipe support is conductive, electrical isolation shall be approved in

writing by the Contractor and Company. The number of supports shall be as

recommended by the Manufacturer of the insulator and approved by the Contractor and

Owner.

Cathodic protection shall be provided to the carrier pipe inside the casing, by installing

zinc ribbon anodes together with a reference electrode. Zinc ribbons shall be attached

to the carrier pipe via a cable in a test post.

Link-Seals shall be supplied with high strength, noncreep glass reinforced nylon

pressure plates to improve insulation between the casing and the carrier piping.

The seal between the casing and carrier piping shall be moisture tight.

8.5.3. Pipe casings:

The use of pipe casings is not recommended. However, if their use is mandatory, the

design of the casing should be such as to cause minimal interference with or shielding

of cathodic protection to the carrier pipe.

Casings shall be dried, sealed using nonmetallic end seals and provided with vent

pipes at both ends.

Cathodic protection system for casing shall be completely separate from the cathodic

protection system of the piping. The surfaces on the soil side shall be protected with

magnesium anodes with anode to structure connections located abovegrade in a test

station.


00785 000 STD 1675 01 00 21/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

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any

circ

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8.5.4. Plant piping:

Plant piping, other than at road crossing either remote or isolated, shall be protected

with impressed current cathodic protection system.

Current drain point connection to the pipe shall be on the buried section of the piping.

The plant area shall be divided into geographical areas for cathodic protection circuits.

These geographical areas shall be of reasonable size to troubleshoot any system

related problems. Each geographical area shall be serviced by one dedicated cathodic

protection system.

Where possible, a cathodic protection area shall be an area separated from other

cathodic protection areas by roads.

8.6. Sacrificial anode beds Where the impressed current system is not economically feasible, such as at road

crossings or isolated areas, zinc anodes may be used provided the soil resistivity is

less than 1,500 ohm-cm and magnesium anodes if the soil resistivity is less than 3,000

ohm-cm. If the resistivity is more than 3,000 ohm-cm, the vendor shall submit a

description of technical options to the contractor. The use of a sacrificial anode system

may be considered, if the following conditions are met:

• If the pipeline (section) runs in low resistivity soil, water, swamps or marshes.

• On short pipeline sections, for economic reasons

• For temporary protection on newly laid pipelines.

• For temporary protection of existing pipelines, if pipeline isolation cannot be

immediately installed.

• For localized (hot-spot) protection to supplement impressed current systems.

If cathodic protection by sacrificial anodes is selected, the vendor shall show by

measurement and calculation that:

• The resistivity of the soil is sufficiently low to allow successful application of

sacrificial anodes.

• The selected type of anode is capable of continuously supplying the maximum

current demand.


00785 000 STD 1675 01 00 22/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

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any

circ

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with

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• The total mass of anode material is sufficient to supply the required current

during the design life of the system.

The anodes shall be buried in low resistivity chemical backfill to obtain the required

output.

Sacrificial anode cables shall be connected to the pipeline via a bondbox and shunts to

allow anode current monitoring.

For magnesium anodes, it is allowed to install a resistor in the anode circuit to limit the

protection levels to within the protection criteria.

8.7. Impressed current anode beds

8.7.1. Deep Well Beds

The design and installation of deepwell beds systems shall comply with the


Impressed current cathodic protection systems shall be powered by transformer /

rectifier units fed by an AC power supply.

The ground bed of an impressed current cathodic protection system shall be designed

such that:

• Its mass and quality are sufficient to last for the design life of the system.

• Its resistance to earth allows the maximum predicted current demand to be met

at 80% or less of the voltage capacity of the DC source during the design life of

the system.

• The risk of causing harmful interference on other buried structures is minimized.

The selection of the location and the type of groundbed shall be based on and take full

account of local conditions such as:

• Soil conditions and resistivity at various depths.

• Groundwater levels and resistivity.

• Strong seasonal changes in surface soil conditions.

• Available terrain (for surface groundbeds).

• Risk of shielding (especially for parallel pipelines).

• Risk of damage by excavation (surface groundbeds).


00785 000 STD 1675 01 00 23/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

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any

circ

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s, b

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with

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than

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Deepwell ground beds should be used:

• If the soil conditions at the required depth are suitable to meet the project

requirements.

• If there is a risk of shielding by other pipelines or buried structures.

• If the available space is limited.

• If there is a risk of stray currents on adjacent installations.

The vendor shall include in his basic design a calculation of the ground bed resistance

based on the most accurate soil resistivity data available, using established methods

and formulae. The vendor shall specify in his detailed design the method of drilling the

deepwell, establishing the resistivity of the soil at depth, completion of the borehole and

the method of installation of the anodes and backfill.

8.7.2. Casings for deepwells

The borehole design and construction shall be such that undesirable transfer between

water bearing formations and pollution of underlying strata from the surface (e.g., tank

farms) is prevented.

Metal casings may be used at the surface for stabilizing the borehole and in the active

section of the groundbed. Casing at depth shall be electrically isolated from metal

casing and structures at the surface. To achieve such isolation, plastic casing shall be

used.

8.7.3. Venting of deep well beds

Deepwell ground beds shall be provided with adequate venting pipes to prevent gas

blocking of the well. Vent pipe material shall be chlorine resistant. Geotextile shall be

used to avoid blockage of the vent pipe by coke backfill.

8.7.4. Shallow Ground bed and Surface Beds

The anodes or the highest point of the carbonaceous backfill shall be not less than one

meter below ground level.

Ground bed markers shall be installed at each end of each ground bed.

Where more than one ground bed is installed per a transformer rectifier, cables shall be

routed from each ground bed to a anode junction box.


00785 000 STD 1675 01 00 24/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

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The junction box shall contain grid coil resistors, shunts in each circuit and an ammeter

with selector switch to measure current flow in each circuit.

Each vertical anode shall have gravel vent and anode marker.

8.8. Connection of cables

8.8.1. General

Cable routes shall be clearly marked using cable markers. These shall be installed at

approximately 25 meter intervals and at every change of direction of the cable route.

Markers to indicate CP cable and include arrow to indicate the direction of cable run.

Cable markers at the sacrificial anode locations shall also include markings to indicate

the location of the sacrificial anodes. All cables shall be laid without coils or kinks,

buried in sand at a depth of at least 0.75 m, provided with cable protection tiles and

warning tape installed 250 mm above the cable.

All buried cables shall be of one continuous length without splices. Cable to cable

connections should be made aboveground inside test stations to reduce the risk of

damage and to allow monitoring.

Impressed current anode cable connections shall be insulated using epoxy resin and/or

heat shrinkable insulation sleeves. The cables shall be connected to the positive

feeder cable inside an aboveground junction box to enable current monitoring. The

cables of sacrificial anodes shall be connected to the pipe via an aboveground

distribution box to allow current monitoring and disconnection.

8.8.2. Connection Methods

The vendor shall include in the design detailed procedures of processes to be used for

cable connections. Welders shall be fully qualified for the applicable welding process.

Cable connections shall be designed to ensure adequate mechanical strength and

electrical continuity and to prevent damage to the structure. Connections shall be

made to surfaces which are thoroughly cleaned to the bare metal. Cleaning shall be

accomplished by grinders without reducing wall thickness lower than the project

requirements. Superficial wire brushing is not acceptable.

Welding of cable connections shall not be carried out on bends or within 200 mm from

welds.


00785 000 STD 1675 01 00 25/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

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All below and above ground electrical connections shall be fully encapsulated with a

coating Belzona 1121 before backfilling. Coating repair at cable connections shall

comply with Project coating specification requirements as applicable.

The following guideline for the selection of cable connections shall be followed:

• All underground connections to carbon steel surfaces (STRUCTURES and other

surfaces) shall be done by using Cad-welding process only.

• All aboveground connections to carbon steel STRUCTURES shall be done by

using Cad-welding process only.

• All other connections shall be done by bolted connections.

Bolted Connections:

Bolted connection consists of a stud welded to the surface requiring connection, a

cable terminal with brazed or crimped lug, washer and double nuts.

Stud material shall be similar to the structure material. Where a stud can not be welded

directly to the structure, a metal plate, 50x50 mm minimum, provided with a welded

M10 threaded stud bolt, shall be welded to the structure. The plate shall be made of

material similar to the structure.

The cables shall be connected to the threaded stud bolt using crimped or brazed cable

lugs, double nuts and serrated washers.

Stud welding may be done using an electrical (resistance welding) or mechanical

(friction welding) process which shall be approved by the contractor and owner.

The stud material and consumable shall be compatible with the structure material. The

process shall not influence the structure material properties to fall outside the original

specifications.

The size of threaded studs shall be 8 mm or more to suit the cable size. The cables

shall be connected to the stud using crimped or brazed cable lugs, nuts and serrated

washers.

The pin-brazing process shall use specially designed cable lugs and brazing pins to

braze the cables to the structure and shall be approved by the contractor and owner.

The brazing materials shall be compatible with the structure material. Penetration of

copper and/or other brazing metals into the structure shall not be deeper than 1 mm

and the hardness shall remain inside the original structure requirements.


00785 000 STD 1675 01 00 26/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

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IP K

T IN

DIA

LTD

. an

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all n

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than

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Cad welding:

Cad welding materials and charges shall be approved by the contractor and owner. The

vendor is solely responsible to verify the compatibility of the Cad-weld materials and

charges with the structure and submit the supporting data to contractor and owner.

Cad-welding process shall be such that copper penetration into the pipeline material

shall not be deeper than 1 mm and that the hardness shall meet the original structure

requirements. Cad-weld charges shall not be greater than CA15 for steel pipe and

cable cores shall not be heavier than 16 mm2. If heavier cables need to be attached,

the core shall be separated into smaller strands of less than 16 mm2 each and welded

separately.

Cad-welds shall be visually inspected and gently impact tested with a hammer. The

welds shall also be tested for electrical resistance using an electrical multimeter, and

shall have zero resistance. Any weld which does not meet these requirements shall be

discarded and the cable shall be rewelded.

Where Cadwelding is not possible, e.g. for safety reasons and only in exceptional

cases, the VENDOR may design glued electrical connections using metal plates

bonded with electrically conductive epoxy resin. This method shall not be used for

current carrying cables (drain cables or bond cables). The materials to be used and the

installation procedure shall be approved by the contractor and owner.

8.9. Electrical earthing Electrical safety earthing of the plant structures and equipment shall be made

compatible with the cathodic protection system.

Subject to owner’s approval, grounding protectors such as Cathodic Isolator shall be

installed between the protected structure and the plant earthing at locations where plant

earthing has adverse impact on the cathodic protection system. The grounding

protector must be of solid state construction, non-electrolytic and maintenance free. It

shall protect the structure, cathodic protection systems and personnel against AC fault

currents, lightning, AC induction and power switching surge currents.


00785 000 STD 1675 01 00 27/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

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8.10. Electrical continuity Bonding cables shall be installed to maintain electrical continuity at locations such as

nonwelded joints, mechanical joints, flanges, couplings, and locations where there is no

electrical continuity within the piping system to be cathodically protected.

8.11. Electrical isolation

8.11.1. General

Cathodically protected surfaces shall be electrically isolated from other plant, foreign

structures and earthing systems in accordance with NACE RP0169 and RP0286 using

isolating joints.

All isolation materials shall be resistant to the product/service inside the pipe.

Isolating joints/flanges shall never be buried. They shall be installed above ground.

Common, metal pipe supports shall be avoided or electrically isolated from the

pipelines.

Safety or instrument earthing shall be compatible with the cathodic protection system.

Isolating joints and flanges should be painted or striped in a contrasting color for easy

identification. The color should be consistent in one area. The paint shall be

compatible with the pipeline/tank coating. Paints containing metallic pigments (such as

zinc or aluminum) shall not be used for top coating on isolating joints/flanges.

8.11.2. Isolating Joints

The design, materials, dimensions and construction of the isolating joints shall meet the

design requirements of the pipeline.

Isolating joints shall be internally coated by the manufacturer over their full length using

an amine cured epoxy coating, applied on a blast cleaned surface (Sa 2 1/2, ISO 8501-

1). A length of 50 mm at each end shall be left uncoated to allow welding.

All sealing and isolation materials shall be resistant to the product transported.

The isolating joints shall withstand a voltage of 1500 volt AC, 50 Hz, across the joint for

5 minutes without bridging or reduction in electrical resistance.

The electrical resistance across the joint shall be more than 1 mega ohm (106 Ohm)

measured at 1000 V DC in dry air.


00785 000 STD 1675 01 00 28/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

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of T

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IP K

T IN

DIA

LTD

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d sh

all n

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any

circ

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in a

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If the product transported by the pipeline is dry gas, dry crude oil, or oil products, the

overall length of the isolating joint shall be at least one meter.

If the product transported by the pipeline is an electrolyte, or it may be anticipated that it

may contain an electrolyte at any time during the life of the pipeline, the following rule

applies:

• If the resistivity of the electrolyte is higher than 100 ohm-cm, or the volume

occupied by the electrolyte is less than 5% of the pipeline volume, the overall

length of the isolating joint shall be four times the pipe diameter (with a

minimum of one meter).

• If the resistivity of the electrolyte is below 100 ohm-cm, and the volume of

electrolyte is more than 5% of the pipeline volume, isolating spools shall be

used.

Isolating spools shall be used if required by the rules above.

The length of an isolating spool shall be determined by the following formula:

L = (400/ρ) x D

Where:

l = length of spool (cm)

ρ = electrolyte resistivity (Ohm-cm)

d = nominal pipe diameter (cm)

Isolating spools may be manufactured out of nonconductive composite pipe material

(GRE) or as an internally coated or lined steel spool with isolating joints or flanges at

both ends, depending on pipeline service, pressure and temperature.

The resistance across isolating joints shall be measured immediately before welding

into the pipeline. The minimum resistance shall be 1 mega ohm (106 ohm).

8.11.3. Insulating Flanges

If the use of isolating joints is not possible, electrical isolation should be provided using

insulated flanges.

Flanges and insulation kits shall meet the design requirements of the pipeline.

Insulating gaskets for raised face or full face flanges should be the neoprene coated

phenolic resin type. Bolts shall be insulated using full length phenolic or composite

sleeves and phenolic resin insulating washers and steel washers at both sides.


00785 000 STD 1675 01 00 29/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

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s, b

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or

parti

ally

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ferre

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epro

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d, c

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or u

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with

out i

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and

in a

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than

that

for w

hich

it is

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furn

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upon

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Insulating flanges should be assembled and tested before being welded into the

pipeline. A voltage of 1500 volt DC shall be applied across the flange assemble for one

minute without causing breakdown of the insulation or flash over. Subsequently the

resistance across the assembled flange shall be measured and shall be more than 1

mega ohm (106 ohm).

On existing flanges, the bolt-to-pipe resistance shall be measured and the overall

effectiveness of the isolated flange determined after cathodic protection has been

applied, This can effectively been done by measuring the current through the attached

pipe using a “Swain-type” current clamp/meter.

Insulated flanges shall be protected against ingress of dirt and moisture by the

application of flange protectors except when used in sour service conditions.

8.12. Stray currents The vendor shall carry out a survey for stray currents generated by the newly installed

cathodic protection systems.

Stray currents generated by the newly installed cathodic protection systems shall be

eliminated at the source by suitable insulation or other means. If this is not

economically feasible other measures such as installation of a current drainage system

shall be designed and installed.

8.13. Installation of junction boxes and test stations The contractor shall clearly indicate the type of test post, bond box and distribution box

for each application in the detailed design:

− Distribution boxes shall be of stainless steel type 316L painted and

weatherproofed.

− Bond boxes, e.g. for cased crossings, shall be of GRP/polyester material with the

minimum degree of protection IP65. Boxes shall be of lockable type, UV resistant,

high impact resistant and complete with neoprene gasket and stainless steel type

316 captive screws.

Sufficient number of test stations shall be installed to locally or remotely monitor the

system performance:


00785 000 STD 1675 01 00 30/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

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s, b

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or

parti

ally

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d, c

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or u

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with

out i

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and

in a

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than

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for w

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• Anode output - Individual anode circuits shall be provided with shunts and grid coil

resistors to measure and adjust anode current outputs. Sacrificial anode cables

shall be connected to the pipeline via a bondbox and shunts to allow anode current

monitoring. For magnesium anodes, a resistor shall be installed in the anode circuit

to limit the protection levels to within the protection criteria.

At the drain points, each negative connection to the pipe/tank shall be provided with

current measurement facilities. For single pipes, the ammeter built into the current

source may suffice. Where multiple negative connections are installed, separate

shunts and blocking diodes shall be provided complete with ammeter and selector

switch installed in a distribution box.

At the drain point, a potential monitoring station shall be installed using a separate

test cable connected to the pipe/tank for measurement of the drain point potential.

• Structure to electrolyte potentials

− Tank bottoms: Reference electrodes shall be installed along the circumference

of an imaginary circle whose radius is 86% of the tank radius from the center

point of the tank bottom. The distance between the reference electrodes shall

not exceed 15 meters subject to a minimum of four reference electrodes in each

quadrant. Also, a minimum of three permanent reference electrodes shall be

installed in the middle of the tank bottom area in a triangular pattern whose

center is the center of the tank bottom. Reference electrodes shall be placed

above the HDPE membrane, close to the bottom and away from the anode

loops.

− Plant piping: Reference electrodes shall be placed along piping systems at

distances not exceeding 100 meters but not less than 2 reference electrodes for

each service (fuel gas, fire water, oily water etc.). The total quantity and

placement of the reference electrodes shall be such that the potentials give a

reasonably accurate picture of the cathodic protection. Reference electrodes

near the anode beds shall not be considered in the number of reference

electrodes dedicated to the measurement of piping structure to electrolyte

potentials.


00785 000 STD 1675 01 00 31/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

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ly, t

rans

ferre

d, r

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d, c

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sclo

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with

out i

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than

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for w

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furn

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• Current drain/pickup - Test stations shall be installed at locations such as road

crossings to monitor the casing and carrier piping. If casings at road crossings, etc.

are longer than 10 meters, a test facility shall be installed at both ends of the

casing. Shorter casings shall be provided with a test facility at one end only. In

each test facility, two test cable shall be connected to the protected pipe and, if a

steel casing is used, two test cable shall be connected to the casing. Both cables

shall be terminated in one test post and shall be identified by color coding or

stainless steel tags.

• Cathodic interference - Test stations shall be installed at the crossings of

protected and foreign structures. At crossings with foreign structures, a bonding

facility shall be provided, consisting of two separate cables attached to each

individual pipeline, terminating in a test post with suitable facilities to install direct or

resistive bonds. The cables to each structure shall be identified by stainless steel

tags.

• Electrical continuity - Anode terminal boxes and test stations shall be installed for

bonding current carrying cables (including bonds between pipelines/ structures or

across isolation joints). These test stations shall be located outside hazardous

areas. If this is not possible, a box approved for the relevant area classification

shall be used

• Electrical isolation- Each isolating joint and isolating flange shall be provided with

test facilities. At all isolating joints/flanges, two cables shall be connected to each

side of the joint or flange. All cables shall be separately terminated in one test post

with suitable facilities to install direct or resistive bonds. The cables to each side of

the isolating joint shall be identified by stainless steel tags.

The contractor shall clearly indicate the type of test station and its purpose in the

detailed design.


00785 000 STD 1675 01 00 32/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

ance

s, b

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tally

or

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ctly

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indi

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ly, t

rans

ferre

d, r

epro

duce

d, c

opie

d,di

sclo

sed

or u

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with

out i

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ritte

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and

in a

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ay o

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than

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for w

hich

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8.14. Remote monitoring and system control Vendor shall submit for contractor’s and owner’s approval, details of a fully operational

computerized remote monitoring and system control facility which shall be supplied and

installed by the vendor.

Remote monitoring equipment shall be installed at all transformer/rectifiers and include

output voltage, output current, drain point potential and low voltage/high current alarms.

Remote monitoring at each transformer/rectifier shall include a minimum of four

reference electrodes distributed around the area of influence of each transformer

rectifier.

If specified the system shall be suitable to perform the following tasks from control

room:

• Measurement and adjustment of rectifiers’ inputs and outputs.

• Measurement and adjustment of impressed current anode outputs

• Measurement of structure-to-electrolyte potentials.

In addition to the above tasks, the following reports shall be automatically generated at

user selected frequency:

• Current status of rectifiers and anodes.

• Structure to electrolyte potentials of all or selected items.

Vendor shall supply and install all the hardware and software for the Remote monitoring

and System control.

9. SPECIAL FACILITIES

9.1. Temporary CP systems In the case that the installation of the permanent cathodic protection system cannot be

finalized before the pipe/tank is buried, or if specified by the contractor, a temporary

cathodic protection system shall be installed. Such a system shall be designed in the

same way as a permanent cathodic protection system with the exception that material

quantities and quality shall be adequate to cover a lifetime equal to the time of the

pipeline, tank, concrete structure construction until the expected commissioning of the


00785 000 STD 1675 01 00 33/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

ance

s, b

e to

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or

parti

ally

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or

indi

rect

ly, t

rans

ferre

d, r

epro

duce

d, c

opie

d,di

sclo

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or u

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with

out i

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than

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for w

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permanent cathodic protection system. Anode connections shall be constructed such

that they can easily be connected/ disconnected and coating repaired during and/or

after commissioning of the permanent system. The temporary system shall have a

minimum design life of at least 12 months.

For temporary cathodic protection system to be used for protection during construction

before AC power is available, other DC sources may be used such as batteries.

The permanent monitoring facilities connected to the pipeline/tank shall be constructed

simultaneously with the pipeline/tank to allow monitoring of the performance of the

temporary system.

9.2. Designs near high voltage power lines If the pipeline runs in the vicinity of high voltage power lines, the vendor shall

investigate whether high AC voltages can be present on the pipeline by induction or

otherwise and whether devices need to be installed for protection of the pipeline and

personnel.

The vendor shall show (by calculation or otherwise) that no harmful voltages can be

present or design additional facilities to prevent excessive voltages. Such facilities may

consist of dedicated pipeline earthing and/or the installation of polarization cells.

9.3. Designs in areas of lightning activity

The vendor shall install suitable lightning protection to protect the pipeline/tank isolation

and cathodic protection equipment. This shall consist of suitably rated surge arrestors.

Surge arrestors shall be mounted across isolating joints/flanges.

Surge arrestors required to prevent elevated voltages due to faults in adjacent electrical

power systems or lightning shall be of the spark gap type and shall be designed such

that:

• The impulse breakdown voltage of the arrestor is lower than that of the isolating

joint across which they are mounted.

• The spark gap is capable of discharging the expected lightning currents without

sustaining damage.

• The spark gaps are fully encapsulated to prevent sparks in open atmosphere

and to protect the spark gaps from moisture.


00785 000 STD 1675 01 00 34/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

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or

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ly, t

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epro

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d, c

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with

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and

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than

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furn

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10. MATERIAL SCHEDULES This schedule shall include the descriptions and quantities of all materials to install the

cathodic protection system.

The vendor shall also include in the material schedule a list of proposed monitoring

equipment (hardware and software) required to carry out regular surveys of the

cathodic protection system.

The vendor shall also include a list of proposed tools and spare parts required for

maintenance of the system during the first 5 years of operation.

10.1. Installation procedures Full construction details and installation procedures of the cathodic protection system

shall be submitted to the contractor and owner for review and approval.

These shall include:

• Written procedures for the installation of DC voltage sources, ground beds,

cables, test facilities and all civil works, procedures for cable connections to the

structures.

• A time schedule for the installation of the system, where required in relation to

the construction schedule of the structures.

• Written procedures of all tests required to demonstrate the specified quality of

installation.

• All relevant construction drawings including but not limited to plot plans,

locations of cathodic protection stations and test facilities, cable routing, single

line schematics, wiring diagrams, groundbed construction and civil works.

• Written procedures to ensure safe working practices during the installation and

operation of the cathodic protection system.

The installation of the cathodic protection system shall start only after approval of the

installation procedures by the contractor and owner.

10.2. Pre-commissioning, Testing and Inspection

The vendor shall perform all pre-commissioning tests in the presence of the owner to

confirm satisfactory installation and operation of all equipment. Such tests shall include

trial operation of power sources to their maximum capacity and measurement and


00785 000 STD 1675 01 00 35/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

ance

s, b

e to

tally

or

parti

ally

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ly, t

rans

ferre

d, r

epro

duce

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opie

d,di

sclo

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or u

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with

out i

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than

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furn

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checking of all cathodic protection circuits to confirm satisfactory connection and

identification. Test shall include resistance to earth tests of ground bed anodes and zinc

earthing electrodes, calibration checks of permanent reference electrodes, testing of

isolation joints and insulated flanges.

Vendor shall document the results of all tests for inclusion in the commissioning

manual.

Commissioning Procedures

Commissioning procedures are required to prove that the installed cathodic protection

system is in accordance with the design. The system shall be considered satisfactory

when the cathodic protection criteria is met at test stations and any other accessible

points of the structure to be protected where owner requires tests to conform

effectiveness of CP system.

The commissioning procedures document shall include as a minimum:

• Procedures for the testing of pipeline/tank isolation

• Procedures for natural potential surveys

• Procedures for energizing and de-energizing cathodic protection hardware.

• Procedures for full ON - instant OFF potential surveys

• Procedures for interference testing and interference mitigation.

• Requirements for polarization of pipeline.

• Procedures for interference testing if applicable.

• A time schedule for the commissioning of the system, where applicable in

conjunction with the construction or commissioning schedule of pipeline.

• Procedures for isolating structures.

• Procedures for testing and adjustment of structure to electrolyte potential.

10.3. Cathodic protection manual A cathodic protection manual is required to ensure that the as-built cathodic protection

system is fully documented and that operating and maintenance procedures are

available for the future operator.

This document shall contain:

• A description of the system and system components and their purpose.


00785 000 STD 1675 01 00 36/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

ance

s, b

e to

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or

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ctly

or

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rect

ly, t

rans

ferre

d, r

epro

duce

d, c

opie

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sed

or u

sed,

with

out i

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ritte

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in a

ny w

ay o

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than

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for w

hich

it is

spe

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furn

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• Pre-commissioning results

• The commissioning report which shall include copies of the relevant as-built

drawings marked up to show the location (with reference number) of all test

locations used during commissioning.

• As-built drawings.

• Vendor’s documentation for equipment and materials installed.

• A schedule of all monitoring facilities.

• Potential criteria for the systems.

• Monitoring schedules and requirements for monitoring equipment.

• Monitoring procedures for each of the types of monitoring facilities installed on

the pipeline, tank and steel in concrete.

• Guidelines for the safe operation of the cathodic protection system.

• Method statements, test procedures and test plans

• General guidelines for trouble shooting before cathodic protection specialists

are called for assistance.

11. HANDLING

11.1. Packaging and Shipping

Preparation for shipment shall be in accordance with the vendor’s standards and as

noted herein. Vendor shall be solely responsible for the adequacy of the preparation for

shipment provisions with respect to materials and application, and to provide equipment

at the destination in ex-works condition when handled by commercial carriers.

Adequate protection shall be provided to prevent mechanical damage and atmospheric

corrosion in transit and at the job site.

Preparation for shipment and packing will be subject to inspection and rejection by

Owner’s/ Contractor’s inspectors. All costs occasioned by such rejection shall be to the

account of the vendor.

Equipment shall be packed, securely anchored, and skid mounted when required.

Bracing, supports, and rigging connections shall be provided to prevent damage during

transit, lifting, or unloading. All temporary bracing/supports shall be marked "REMOVE

BEFORE EQUIPMENT COMMISSIONING AND START-UP."


00785 000 STD 1675 01 00 37/37



UNIT : FCC UNIT.


The

pres

ent d

ocum

ent o

r dr

awin

g is

pro

perty

of T

EC

HN

IP K

T IN

DIA

LTD

. an

d sh

all n

ot, u

nder

any

circ

umst

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s, b

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than

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Separate, loose, and spare parts shall be completely boxed. Pieces of equipment and

spare parts shall be identified by item number and service and marked with

Contractor's order number, tag number, and weight, both inside and outside of each

individual package or container. A bill of material shall be enclosed in each package or

container of parts.

One complete set of the installation, operation, and maintenance instructions shall be

packed in the boxes or crates with equipment. This is in addition to the number called

for in the Purchase Order.

11.2. Preservation and storage Equipment and materials shall be protected to withstand ocean transit and extended

period of storage at the jobsite for a minimum period of 18 months. Equipment shall be

protected to safeguard against all adverse environments, such as: humidity, moisture,

rain, dust, dirt, sand, mud, salt air, salt spray, and seawater.

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