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VOLUME – III

ELECTRICAL, CP & CMS SYSTEM

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LIST OF ATTACHMENTS FOR

PIPELINE LAYING AND ASSOCIATED

WORKS (ELECTRICAL & CATHODICPROTECTION)

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SL

NO

SPECIFICATION

NUMBER

NO OF

SHEETSREVISION DOCUMENT TITLE

SCOPE OF WORK

1 0001-01-04-06-003-SW2SCOPE OF WORK FOR PIPELINE LAYING AND

ASSOCIATED WORKS (ELECTRICAL)

2 0001-01-04-06-003-SW5SCOPE OF WORK FOR MAGNETIC CLEANING

AND ELECTRONIC GEOMETRY PIGGING PIPE

3 0001-01-04-06-003-SW6 SCOPE OF CORROSION MONITORING SYSTEM

DESIGN BASIS

4 0001-01-07-03-001 7 0ELECTRICAL DESIGN BASIS FOR CATHODIC

PROTECTION SYSTEM AND ELECTRICAL

SYSTEM

SPECIFICATIONS

5 0001-01-07-02-001 10 0

JOB SPECIFICATION FOR PIPELINE LAYING

AND TERMINAL WORKS (ELECTRICAL)

6 0001-01-07-02-002 4 0 SCADA I-O LIST

7 0001-01-07-02-005 12 0SPECIFICATION FOR SOLAR ELECTRIC POWER

SYSTEM

8 0001-01-07-02-006 4 0SPECIFICATION FOR MAGNETIC CLEANING

AND ELECTRONIC GEOMETRY PIGGING

PIPELINE

9 0001-01-07-02-007 5 0SPECIFICATION FOR CORROSION

MONITORING SYSTEM

DATASHEETS

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SL

NO

SPECIFICATION

NUMBER

NO OF


17 0001-01-07-04-FAS-001 6 0 DATASHEET FOR FIRE ALARM SYSTEM

18 0001-01-07-04-LF-001 8 0 DATASHEET FOR LIGHTING FIXTURES

19 0001-01-07-04-SB-001 8 0 DATA SHEET FOR AC- DC SWITCHBOARD

20 0001-01-07-04-SPS-001 5 0DATASHEET FOR SOLAR ELECTRIC POWER SYSTEM

21 0001-01-07-04-UPS-001 7 0 DATA SHEETFOR UPS SYSTEM

0001-01-07-01-001 1 0 SINGLE LINE DIAGRAM FOR CGS

LOAD ANALYSIS

22 0001-01-07-08-001 3 0 LOAD ANALYSIS

STANDARD SPECIFICATIONS

23 S-07-02-001 11 0SPECIFICATION FOR MV SWITCHBOARDS

FIXED TYPE FOR PACKAGE EQUIPMENT

24 S-07-02-002 8 0 SPECIFICATION FOR DC-DC CONVERTER

25 S-07-02-003 17 0SPECIFICATION FOR ELECTRICAL EQUIPMENTINSTALLATION

26 S-07-02-004 8 0 SPECIFICATION FOR INSPECTION FIELDTESTING AND COMMISSIONING OF

ELECTRICAL EQUIPMENT

27 S-07-02-005 8 0SPECIFICATIONS FOR EARTHINGINSTALLATION

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SL

NO

SPECIFICATION

NUMBER

NO OF


35 S-07-02-013 17 0 SPECIFICATIONS FOR CATHODIC PROTECTIONTRANSFORMER RECTIFIER UNIT

36 S-07-02-014 9 0SPECIFICATION FOR FLAMEPROOF LIGHTING

AND POWER PANELS

37 S-07-02-015 11 0SPECIFICATION FOR MEDIUM AND HIGH

VOLTAGE CABLES AND ACCESSORIES

38 S-07-02-016 7 0SPECIFICATION FOR STATIONARY NICKEL

CADMIUM BATTERIES

39 S-07-02-018 25 0SPECIFICATION FOR UNINTERRUPTED POWER

SUPPLY UNIT

40 S-07-02-019 19 0 SPECIFICATION FOR BATTERY CHARGER

41 S-07-02-020 16 0 SPECIFICATIONS FOR CPPSM

42 S-07-02-021 16 0SPECIFICATIONS FOR MEDIUM VOLTAGE

MOTORS

43 S-07-02-022 8 0INSTRUCTIONS TO TURNKEY CONTRACTORS

FOR ROUTING AND REVIEW OF DOCUMENTS

44 S-07-02-024 32 0SPECIFICATION FOR FIRE DETECTION AND

ALARM SYSTEM

INSPECTION TEST PLAN

45 S-07-06-001 3 0INSPECTION TEST PLAN FOR BATTERY

CHARGER

46 S-07-06-002 3 0INSPECTION AND TEST PLAN FOR MV-HV

CABLES

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SL

NO

SPECIFICATION

NUMBER

NO OF


53 S-07-01-009 2 0 EARTHING/ BONDING OF PIPES AND PIPERACKS

54 S-07-01-010 1 0FENCE AND GATE EARTHING (TRANSFORMER

YARD)

55 S-07-01-011 1 0 EQUIPMENT EARTHING SCHEDULE

56 S-07-01-012 1 0TYPICAL DETAILS OF DIRECTLY BURIED

EARTH ELECTRODE

57 S-07-01-013 1 0TYPICAL INSTALLATION OF LIGHTING

FIXTURE AT GROUND LEVEL

58 S-07-01-014 1 0TYPICAL OPEN AREA STREET LIGHT OR FLOOD

LIGHT FIXTURE MOUNTED ON WALL/COLUMN

59 S-07-01-014A 2 0TYPICAL OPEN AREA STREET LIGHT OR FLOODLIGHT MOUNTED ON POLE

60 S-07-01-014B 2 0TYPICAL OPEN AREA STREET LIGHT LIGHT

FIXTURE MOUNTED ON POLE

61 S-07-01-014C 1 0TYPICAL MARSHALLING BOX DETAILS FOR

LIGHTING POLE

62 S-07-01-015 1 0 POST TOP LANTERN INSTALLED ON GATE

63 S-07-01-016 1 0TYPICAL INSTALLATION OF FLUORESCENTFIXTURE MOUNTING IN EXPOSED WIRING

SYSTEM

64 S-07-01-017 1 0 TYPICAL INSTALLATION OF RECESSEDMOUNTED FLUORESCENT FIXTURE

65 S-07-01-018 1 0TYPICAL INSTALLATION OF RECESSED

MOUNTED OR BELOW FALSE CEILING

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SL

NO

SPECIFICATION

NUMBER

NO OF


73 S-07-01-026 1 0 PREPACKED MAGNESIUM ANODE

74 S-07-01-027 1 0 MAGNESIUM RIBBON ANODE

75 S-07-01-028 1 0 TEST STATION WITH FOUNDATION DETAILS

76 S-07-01-029 4 0 TEST STATION CONNECTION SCHEMES

77 S-07-01-030 1 0 GALVANIC ANODE INSTALLATION

78 S-07-01-031 1 0ZINC RIBBON ANODE FOR CASED CROSSINGS

WITH COATED/ PAINTED CASING

79 S-07-01-032 1 0PIPELINE GROUNDING THROUGHPOLARISATION CELL AND GALVANIC ANODE.

80 S-07-01-033 1 0TYPICAL CONSTRUCTION DETAILS OF HIGH

SILICON CAST IRON ANODE

81 S-07-01-034 1 0PERMANENT COPPER-COPPER SULPHATE

REFERENCE CELL AND INSTALLATION DETAILS

82 S-07-01-035 1 0 SHALLOW ANODE GROUND BED (PCP)

83 S-07-01-036 1 0 ANODE LEAD JUNCTION BOX

84 S-07-01-037 14 0

NOTES, LEGEND AND DETAILS FOR AREA

CLASSIFICATION (ONSHORE OIL/ GASINSTALLATIONS)

85 S-07-01-038 1 0MARKING OF TRENCHES FOR ELECTRIC

CABLES

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ELECTRICAL DESIGN BASIS FOR

CATHODIC PROTECTION SYSTEM

AND ELECTRICAL SYSTEM

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CONTENTS

1. SITE CONDITIONS

2. POWER SOURCE DETAILS

3. SYSTEM VOLTAGES

4. CONTROL BUILDING DESIGN

5. EQUIPMENT DESIGN

6. MONITORING AND CONTROL SIGNAL THROUGH SCADA

7. CABLING SYSTEM

8. EARTHING SYSTEM

9. LIGHTING AND VENTILATION SYSTEM

10. ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

11. STATUTORY APPROVALS

12. CP SYSTEM

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This electrical design data defines the design requirements applicable for this projectin addition to the Specification for Sacrificial Anode Cathodic Protection System S-07-

02-011, Specification For Impressed Current Cathodic Protection System S-07-02-012.(Data marked ‘* ’shall be furnished/ confirmed by client).

Site Conditions

A Equipment design temperature 40oC

B. Soil Resistivity As per Soil Analysis report

C. Min. temp. for battery sizing 5oC

D. Altitude above mean sea level Less than 1000M

E. WeatherDry, dust storms in summer, humid /

heavy rain fall during monsoonPower Source Details: At Manned Terminals:-

All CGS

Power generation by 24V DC SolarPanels

1 nos.415V, 50Hz,TPN AC supply fromlocal grid to be arranged by thecontractor

Battery back-up of 72 hours

3. Utilisation voltage & Operating philosophy3.1 Telecom

SCADA

3.2 Instrumentation

For all stations one 24 V DC feederto be provided. All DC-DCconverters to meet the equipmentrequirements shall be in the scopeof the equipment vendor

3.3 Electrical System For all stations 240 V AC from Grid

Power Supply

3.4 CP system For all stations one 24 V DC feeder to

be provided.

3 5 Ai C di i i At CGS control room / telecom /

SCADA 240V 1 Ph AC id

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4.2 Specific Equipment Locations

A. Batteries Separate room

B. Battery charger (for boost charging) Electrical Room(Note:- For EQUALISING CHARGE/BOOST CHARGE to batteries (whenever required)at stations, it is proposed that the same shall be done through the battery chargerwhich is fed from grid supply.

C. Solar Array Out door

4.3 Air Conditioning

A. For Telecom /SCADA /Instrument /Control room

Required

B. For electrical room Not required4.4 Fire alarm and detection system Required at all locations

4.5 CO2 Flooding SystemRequired for Electrical, Telecom, SCADA & Control & Battery Room

5 Equipment Design

5.1 MV Switchboard/ Battery Charger/ DCDB

MV Switchboard/DC Switchboard:-

-Incomer panel :

Load break Switch/MCCB/switch-fuse

contactor Fixed, Single front without rearaccess, with only front access andmaintenance only.

-Outgoing motor feeders Fixed, Single front(If applicable)

-Outgoing Switch fuse feeders Fixed, Single front

-Outgoing MCB feeders Fixed, Single front

5.2 Lighting Panel Wall mounted

5.3 Back-up battery5.3.1 Back up Battery

A. Battery type/back up timeBattery type shall be Nickel-cadmium with72 hours backup time

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5.5 Inverter

5.5.1 For Air conditioners Not required- Out put voltage Not applicable

- Number/configuration Not applicable

5.5.2 Lighting Not required

- Out put voltage Not applicable

- Number/configuration Not applicable

5.6 Cables for Electrical System

5.6.1 Type

PVC insulated armoured, PVC sheathed

for MV cable and XLPE insulated,armored, PVC sheathed for HV cable

5.6.2 Conductor materialCopper up to 16 sq mm and Aluminiumfor 35 sq mm and above.

5.6.3 Minimum size of cable for power and control cables

a) Medium voltage power cable 2.5 mm² (Copper)

b) Control cables 2.5 mm² (Copper)

c) Lighting 2.5 mm² (Copper)

d) Number of cores for MOV cables NA 6.0 Monitoring and control signal through SCADADigital and analogue monitoring and control signals as required for Solar Panel powersource, CP system, fire detection and alarm system shall be provided

7.0 Cabling System

7.1 Cable laying philosophy

A. Paved area Cable tray / RCC trench

B. Unpaved area RCC trench / Directly buried

C. Inside Buildings Cable trays / conduits

D. Type of cable traysGalvanized prefabricated / Site fabricated And painted

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element

D. ELCB at Incomer of AC Lighting cum

Power Panels

Yes for DC,

Yes for AC9.2 Wiring Type

A. Out door Armoured cable

B. BuildingsConcealed / Surface conduits or cabletrays

9.3 Ventilation

A. Battery room DC exhaust fan

B. SCADA/Telecom room

DC exhaust fan activated by thermostat

with powered louver for exhaust fan andair inlet.

C. Electrical room AC exhaust fan.

10.0 Electrical Equipment for Hazardous Areas All the electrical equipment for Gas Group IIA/ IIB hazardous areas shall be of Ex-dtype suitable for temp classification T3.

11.0 Statutory ApprovalStatutory Authority for Electrical : Central Electrical Inspectorate/State Installation

electrical inspectorate.12.0 CP System

12.1 Temporary cathodic protection Required

A. Type Sacrificial magnesium anode

B. Design life1 Year or till commissioning of PCPwhichever is later

C. Pipeline coating Three Layer Polyethylene

D. Protective current density As per Cl. 5.1.(iii) of spec. S-07-02-011

E. Anode material (for sacrificial CPSystem)

Zinc/ low potential (1.55 V ) Magnesium

F Electrical resistance probesShall be provided as per Cl.7.4 of (ER

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12.2 Permanent Cathodic Protection System

A. Type Impressed current type

B. Design life of protection 35 Years

C. Pipeline coating Three Layer Polyethylene

D. Design protection current density As per Cl.5.1.(iii) of spec. S-07-02-012

E. Current drainage survey Shall be carried out

F. Type of Anodes for anode ground bedHigh silicon iron / mixed metal oxidetitanium/ Zinc/Magnesium

G. Electrical resistance probesShall be provided as per Cl.7.8 of spec. S-

07-02-012 (Also refer Cl.12.1F above)

H. Computerised test stationsShall be provided as per Cl.7.13 of spec. S-07-02-012

a. No. of computerized test stations1 nos., however exact locations to bedecided by CP sub contractor based onCl.7.13 of spec. S-07-02-012

b. No. of computerised test stationreader

One station readers/ portable datacollection & storage instruments.

c. Interval for data acquisition/ storing Once every dayI Polarisation coupons Shall be provided as per Cl.7.12 of spec. S-

07-02-012 (Also Refer Cl.12.1.G above)

J Polarisation cell Electrolytic type

K. Acquisition of land for anode groundbed, anode junction boxes and anodeground bed cable laying

By Contractor

L. Chain link fencing around the groundbed:

Shall be provided

M. Close interval potential loggingsurvey:

Shall be carried out

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JOB SPECIFICATION FOR PIPELINE

LAYING AND TERMINAL WORKS

(ELECTRICAL)

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CONTENTS

1. GENERAL

2. AREA CLASSIFICATION

3. DESCRIPTION OF REQUIREMENTS FOR CATHODIC PROTECTION AND

ELECTRICAL WORKS

4. INSPECTION, TESTING AND COMMISSIONING

5. DRAWINGS AND DOCUMENTS

ANNEXURE-1: MAKE OF ELECTRICAL EQUIPMENT/COMPONENTS

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1.0 GENERAL

1.1 Introduction

1.1.1 The intent of this specification is to define the requirements for Design,engineering, supply, erection, testing and commissioning of the electrical works,viz. power supply system, lighting, cabling, earthing, lightning protectionsystem and fire alarm system, etc. at various locations along the SPUR LINESOF CHAINSA - JAHJJAR PIPELINE and associated installations.

1.1.2 The electrical portion for pipeline laying work as covered in this specificationincludes design, supply, installation, testing and commissioning of the powersystem as per the single line diagrams (SLDs) and description given in thisdocument and other associated documents enclosed with this tender, takingstatutory approvals and energizing the system. The contractor shall alsoprepare electrical layout drawings for equipment layout, cabling layout, lightinglayout, earthing and lightning protection layouts, Fire alarm system layout,cable schedule, interconnection diagrams, etc. for each station/Terminal along

the route of the pipeline.

1.1.3 The Electrical works at each station/Terminal and all works related to temporaryand permanent cathodic protection system for the pipeline shall be executed bycontractor in line with scope document, job specification, design basis, datasheets, standard specifications, standard drawings and National/Internationalcodes & standards. In case of conflict between various documents, followingshall be order of priority:-

- Scope document

- Design Basis & Single Line Diagrams

- Data sheets

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1.2.2 In addition, the work shall also conform to the requirements of the following:

(a)The Indian Electricity Act and rules framed there under.

(b)The fire insurance Regulations.

(c) The regulations laid down by Electrical Inspectorate (CEA).

(d)The regulations laid down by the Factory Inspector.

(e)The regulations laid down by the Chief Controller of Explosives.

(f) The regulations laid down by Oil Industries Safety Directorate (OISD).

Any other regulations laid down by the Central, State or Local Authorities fromtime to time during the execution of this contract.

1.3 Guarantee

The contractor shall guarantee the installation for satisfactory operation againstany defects of workmanship and materials (supplied by the contractor) for aperiod as specified elsewhere. Any damage or defect connected with theerection of materials, equipments or fittings supplied by the contractor thatmay be discovered at the time of issue of the completion certificate, or arise or

come to light thereafter, shall be rectified or replaced by the contractor at hisown expense as deemed necessary and as per the instruction of owner orEngineer-in-Charge within the time limit specified by the owner or Engineer-in-Charge.

1.4 Site Condition

The equipment offered and the installation shall be suitable for continuous

operation under the site conditions mentioned in design basis doc.no.0001-01-07-03-001.

1.5 Utilisation Voltage

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3.0 REQUIREMENTS FOR CATHODIC PROTECTION SYSTEM AND

ELECTRICAL WORKS

3.1 CATHODIC PROTECTION SYSTEM:-

The requirements of cathodic protection system have been specified in Designbasis document no. 0001-01-07-03-001., data sheets and specificationsattached elsewhere in this tender. Temporary cathodic protection(TCP) worksto be done immediately upon lowering of pipeline.’

3.2 ELECTRICAL WORKS

Electrical works including design, supply, installation, testing and commissioningof all electrical items shall be provided.

The power supply shall be met from Solar system at 24V DC (Floating) output.The electrical power distribution to various electrical consumers at 24V DC shallbe done from 24V DC switchboard. 24V DC power distribution as required forSCADA, FA panel, DC lighting (in Telecom room, electrical room). Necessary

DC-DC converters required for feeding telecom equipment shall be provided aspart of DC switchboard.

3.3 At all earth test pits, earth strip shall be bolted with electrode using minimumtwo bolts as per the requirements of OISD. Earthing of main gate, fence andsteel cage over MOV etc. at each station shall also be in the scope of contractor. All SVs installed on cathodically protected pipeline shall be earthedusing 2 number of zinc anodes (20KG net weight).

3.4 Rat repellant electrical system is to be provided in all stations to avoid damageto the cables and cabling into the marshalling units/electrical equipment.

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system & safety) & cables coming from field for instrumentation/Telecom.

3.10 A display board of suitable size to be provided adjacent to all earth pit so as todisplay earth pit number, date of testing, test value, next due date etc.

4.0 INSPECTION, TESTING AND COMMISSIONING

4.1 All the equipment shall be tested and commissioned as per contractrequirements.

4.2 Any work not conforming to the execution drawings, specifications, or codes

shall be rejected forthwith and the contractor shall carry out modifications at hisown cost.

4.3 All tests shall be conducted in the presence of the owner/ Engineer-in-charge orhis authorised representative unless he waives this requirement in writing. Thecontractor shall arrange all testing equipment necessary to carry out the tests.The tests shall be recorded on approved Performa and certified records of thetests shall be submitted to the owner/ Engineer-in-charge.

4.4 All test certificates and the contractor shall submit field test reports aftercompletion of work in bound volumes (6 sets).

5.0 DRAWINGS AND DOCUMENTS

5.1 Contractor shall submit all datasheets/ drawings and documents to theowner/ Engineer-in-charge.

5.2 A complete set of reproducible drawings for contractor-supplied equipment shallbe furnished to the owner/GAIL for records. As-built layouts, cable schedulesand interconnections shall be submitted by the contractor on the hard copies as

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necessary test/ inspection certificates. Before submitting the drawings, vendorshall ensure that job number, title, drawing number, equipment number andrevision number are marked on each drawing.

5.7 For list of acceptable makes of electrical equipment, see Annexure-I. For makesof items not covered therein, prior approval from owner shall be obtainedbefore placement of order.

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ANNEXURE-1

1.1 Following is the list of approved makes for electrical equipment:-

MV Switchboards (Fixed type) (ItemCode- 13BB)

Siemens/ L&T/ GE India Industrial Pvt.Ltd. /Schneider Electric/ Control & Swgr./ Control & Schematics/M.K.Engineers & Controls Pvt.Ltd./Bhartia Industries Ltd.

Cables-Medium Voltage-Power -PVC(Item Code-13OC)

Associated Flexibles & Wires (P) Ltd./ CCI/Finolex Cables Ltd./ Gemscab Ind.

Ltd./Industrial Cables(I) Ltd./ KEI Ind. Ltd./Nicco Corp. Ltd./ Polycab Wires Pvt. Ltd./Radiant Cables Pvt. Ltd./ Ravin CorporationLtd./ Torrent Cables Ltd./ Universal CablesLtd./Havell’s India Pvt. Ltd/RPG Cables ltd

Cables-Control-PVC (Item Code-13OD)

Associated Flexibles & Wires (P) Ltd./CMILtd./Brooks Cable Works, Bombay/ CordsCable Ind.Ltd./ Delton Cables Ltd./ Evershine

Electricals/ Elkay Telelinks (P) Ltd./ FinolexCables Ltd./ Gemscab Ind.Ltd./ GoyoleneFibres (India) Pvt.Ltd./ Havell’s India Pvt.Ltd./Industrial Cables(I) Ltd./ KEI Ind.Ltd./ NiccoCorp. Ltd./ North Eastern Cables Pvt. Ltd./Paramount Communications Ltd./ PolycabWires Pvt.Ltd./ Radiant Cables Pvt.Ltd./RavinCables Ltd./ Reliance Engineers Ltd./ Suyog

Electricals Ltd./ Torrent Cables Ltd./ UniversalCables Ltd.

Cables-Fire alarm and comm. (ItemCode-13OE)

CMI Ltd./ Delton Cables Ltd./ KEI/ ElkayTelelinks/ Reliance Engineers Ltd /Cords Cable

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1.2 Following is the list of approved makes for electrical components:-

Lighting Fixtures for nonHazardous area (Item Code-14LB) Bajaj/Crompton/Philips/Havell’s Ind Pvt.Ltd.

Cable glands for Hazardous area.

Baliga/ Comet Brass Products/ CometIndustries/ Flexpro/ Flameproof Equipment / FCG Power/ FCG Flameproof ControlGears Pvt Ltd./ Prompt Engg. Works/Sudhir Swgrs. Pvt. Ltd/Standard MetalIndustries.

Protection relays(Electromechanical type)

ABB (Baroda) /Easun Reyrolle/ Areva T&DIndia Ltd. (T&D Group)/Siemensltd./Schneider Elect. Pvt.ltd./L&T

Auxiliary Relays Areva T&D India Ltd. (T&D Group)/Jyotiltd./ABB (Bangalore)

Control switches/Selector

Switches

L&T/ Siemens/ Switron Devices/ Hot LineSwgrs.& Controls/ Kaycee/ Areva T&D India

Ltd. / Reliable Electronic components Pvt.Ltd.

MCBs

Datar Switchgear/ Havell’s India/ Indo Asian fuse gear/ Indiana Current Control/Standard Electricals/ Legrand India Pvt.Ltd./Schneider Electricals India Pvt. Ltd.

MCCBsGE India Industrial Pvt. Ltd./ L&T/Schneider Electric

FusesL&T/ Siemens/ GE India Industrial Pvt. Ltd /Indo Asian fuse gear/Cooper Bussman (I)Pvt. Ltd.

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(Bangalore) L&T/Siemens/ BhartiaInd./Control & Swgrs. Contactors Ltd./Schneider Electric/ ABB (Bangalore)/GEIndia Ind. Pvt. Ltd.

Fuse switch combination

ABB (Bangalore)/ Control & Switchgear/Indo Asian Fuse Gear/ L&T/ Siemens/Schneider Electric./ Havells India Pvt. Ltd./Standard Electrical Ltd. /GE India Pvt. Ltd.

Heavy duty switchesL&T/ Siemens/ Schneider Electric/ Control& Switchgear/ Indo Asian Fuse Gear

Earth leakage circuitbreaker (ELCB)

Datar Switchgear/ Indo Asian FuseGear/ Legrand India Pvt.Ltd./Havell’s India Pvt. Ltd./Schneider lectric

1.2 Following is the list of preferred makes equipment /material for CP system:-

Surge Diverters (Explosion Proof)Dehn+Sohne,Germany/OBOBettermann, Germany

Zinc ribbon anode Platt Line/Corpro

Permanent reference cell Borin, USA

Polarisation Cell Kirk, USA

E/R probes & reading meter Rose corrosion,USA/Caproco

Notes:-

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SCADA I/O LIST FOR ELECTRICALPARAMETERS

SPUR LINES OF CHAINSA - JAHJJAR

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1.0 Name of station: MANESAR, DHARUHERA,BHIWADI, KUSHKHERA,NEEMRANA (WITH SOLAR SYSTEM AS POWER SOURCE OPTION)

STATION USING SOLAR SYSTEM AS POWER SOURCE A. Signal List

S.No.

DESCRIPTIONMONITORING (M)

/CONTROL(C)DIGITAL (D) / ANALOGUE(A)

NO. OFSIGNAL

STAG NO.

1SOLAR SYSTEMSTART

C D 1 SS-ST

2SOLAR SYSTEMSTOP

C D 1 SS-STP

3SOLAR SYSTEMRESET

As pervendorrecommendation

C D 1 SS-RST

4 SOLAR ARRAY CURRENT mA* M A *

SAC-A1SAC-A2* (AS PER NO. OF

ARRAYS)

5BATTERY CHARGINGCURRENT

M A 1 BCC

6 BATTERY DISCONNECTED M D 1 BAT.-DIS7 BATTERY DEEP DISCHARGE M D 1 BDD-B1

8 BATTERY VOLTAGE M A 1 BTT-V

9 LOAD CURRENT M A 1 SY-LC

10 SOLAR PANEL FAULT M D 1 SP-F

11 SOLAR CONTROLLER FAULT M D 1 SC-F

12 ARRAY FAULT M D 1 AF-F

13SOLAR SYSTEM CONTROLCIRCUIT

M D 1 SCC-F1

14 BUS VOLTAGE OF MAIN DCDB M A 1 DCDB-V15 GRID POWER AVAILABLE M D 1 GRID-ON

16 FIRE DETECTION ALARM M D 1 FA

17FIRE DETECTION ELECTRICAL

M D 1 FA ELECT RM

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B. Contact configuration of digital inputs to SCADASTATE DESCRIPTION

TAG NO DESCRIPTIONCONTACT CLOSE CONTACT OPEN

BAT- DIS BATTERY DISCONNECTED NORMAL OPERATION BATTERY DISCONNECTED

BDD-B1BATTERY DEEPDISCHARGE

NORMAL OPERATIONBATTERY DEEPDISCHARGE

SP-F SOLAR PANEL FAULT NORMAL OPERATION SOLAR PANEL FAULT

SC-FSOLAR CONTROLLER

FAULTNORMAL OPERATION

SOLAR CONTROLLER

FAULT

AF-F SCC-F1 ARRAY FAULT SOLAR SYSTEM CONTROLCIRCUIT FAIL

NORMAL OPERATIONNORMAL OPERATION

ARRAY FAULT SOLAR SYSTEM CONTROLCIRCUIT FAIL

GRID-ON GRID POWER AVAILABLE NORMAL OPERATION GRID POWER AVAILABLEFA FIRE DETECTION ALARM NORMAL OPERATION FIRE DETECTION ALARM

FA-ELECT RMFIRE DETECTIONELECTRICAL ROOM

NORMAL OPERATIONFIRE DETECTIONELECTRICAL ROOM

FA-TEL-RMFIRE DETECTION

TELECOM/SCADA ROOMNORMAL OPERATION

FIRE DETECTION

TELECOM/SCADA ROOM

FA-FFAULT IN FIREDETECTION SYSTEM

NORMAL OPERATIONFAULT IN FIREDETECTION SYSTEM

CO2-PRL CO2 GAS RELEASED NORMAL OPERATION CO2 GAS RELEASED

CO2-LKG CO2 CYLINDER WEIGHTLOSS BY LEAKAGE NORMAL OPERATION CO2 CYLINDER WEIGHTLOSS BY LEAKAGE

AC-ON AIR CONDITIONING

TELECOM/SCADA ROOMON

NORMAL OPERATION AIR CONDITIONING

TELECOM/SCADA ROOMON

VENT-ON VENTILATION SYSTEM ON(TELECOM/SCADA)

NORMAL OPERATION VENTILATION SYSTEM ON(TELECOM/SCADA)

RM-TEL-DO

BATTERY

ROOM/ELECTRICALEQPT.ROOM/TELECOM-

SCADA ROOM/CO2 ROOMDOOR OPEN

BATTERY ROOM /ELECTRICAL EQPT.

ROOM/TELECOM- SCADA ROOM DOOR CLOSED

TELECOM-SCADA ROOM

DOOR OPEN

C D t il f A l i t t SCADA

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D. Contact configuration of digital outputs from SCADA

2.0 NAME OF STATION : ALL CP STATIONS A. Signal List

S. No. DESCRIPTIONMONITORING (M)

/CONTROL (C)DIGITAL (D) /

ANALOGUE (A)NO. OF

SIGNALSTAG NO.

1 PSP Voltage M A 1 PSP

2

CPPSM Output

Voltage M A 1 CPPSM VCPPSM Output

CurrentM A 1 CPPSM I

B. Details of Analog inputs to SCADA

NOTES :

STATE DESCRIPTION

TAG NO DESCRIPTION CONTACT CLOSE CONTACTOPEN

SS-ST SOLAR SYSTEM START SOLAR SYSTEM START NA

SS-STP SOLAR SYSTEM STOP SOLAR SYSTEM STOP N.A.

SS-RST SOLAR SYSTEM RESET SOLAR SYSTEM RESET N.A.

ANALOG SIGNAL DETAILSTAGNO.

DESCRIPTIONRANGE ALARM (HIGH) ALARM (LOW)

PSP PIPE TO SOILPOTENTIAL

0-(-4)V DC (-)1.3V (-)0.8

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SPECIFICATION FOR SOLAR ELECTRIC

POWER SYSTEM (ELECTRICAL)

SPUR LINES OF CHAINSA - JAHJJAR PIPELINE

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CONTENTS

SECTION TITLE

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 SITE CONDITIONS

4.0 SCOPE OF SUPPLY

5.0 TECHNICAL REQUIREMENTS

6.0 TESTING AND INSPECTION

7.0 VENDOR DATA REQUIREMENTS

8.0 CERTIFICATION

9.0 PACKING AND TRANSPORTATION

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1.0 SCOPEThis specification provides the minimum requirements for the design, manufacture,testing and supply of the Solar Electric Power System to be installed. The SolarElectric Power System shall independently meet the power requirement of continuous loads as defined in data sheet.

The exact number of solar electric power systems along with loads connected toeach system and the load rating of each system shall be as indicated in theequipment data sheet.

Each solar electric power system when installed in accordance with vendor’sinstructions shall form self-sufficient power system to meet the powerrequirements of continuous loads.

2.0 CODES AND STANDARDS2.1 The equipment supplied shall comply with the requirements of the latest revision of

the relevant standards of :NEC National Electrical Code

NEMA National Electrical Manufacturers’ Association

NFPA National Fire Protection Association

API American Petroleum Institute

ANSI American National Standards Institute

ASTM American Society for Testing and Materials

BIS Bureau of Indian StandardsIEC International Electro-technical Commission

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4.1.3 Junction boxes and Nickel/Chromium plated double compression type brass cableglands and tinned copper lugs, as required.

4.1.4 Flame retardant low smoke (FRLS) type interconnecting cables between solar

panels and main junction boxes, as required.


5.1 POWER SYSTEMPower system shall include the following equipment :

5.1.1 Photovoltaic solar cell array (Solar panels).5.1.2 Battery Bank 5.1.3 Solar power controller

The solar power system shall be self sustained type.The photovoltaic solar cell array (solar panels) and the solar controller shall besized to meet through battery back-up, the load cycle requirements of the

connected loads with the solar energy availability at site under worst weatherconditions.

The load requirement per day shall be determined on the basis of load dataspecified in the data sheet.

5.2 SOLAR PANELSThe photovoltaic solar panel array shall consist of required number of individual

solar panels. The individual photovoltaic elements shall be connected in suitableseries-parallel combinations to obtain the required voltage and current rating of asolar module. Individual solar modules shall be connected in suitable series–parallel combinations to obtain the required voltage and current rating of a solar

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Voltage losses in solar controller.

Negative tolerance, if any, on the output voltage at solar controller.

After working out the output current at operating point, the following de-ratingfactors shall be applied:

a) Deterioration factor over life span or 15% whichever is higher.

b) Losses due to dust deposit or 1% whichever is higher.

c) Losses due to module/branch mismatch or 2% whichever is higher.

d) Losses due to line resistance cables (panel to controller).

e) Losses in field wiring and array wiring.

f) Losses in solar controller.

g) Battery charge/discharge efficiency or 93% whichever is lower.

h) Any other de-rating factor considered essential for satisfactory and guaranteedperformance of Solar Power System (e.g. negative tolerance on nominal rating of

solar panels)i) De-rating factor of 2% or as applicable (whichever is higher) to account for panel

orientation other than the specified one as per insolation data. j) The solar panels shall be able to fully charge the battery bank after “3 NO SUN

DAYS” cycle from the surplus power available from the solar panel in next 14 dayswith 70% Depth of Discharge of battery.

5.2.1 Panel Construction

The Solar modules shall have suitable encapsulation and sealing arrangements toprotect the Silicon elements (Cells) from the environment. The arrangement andmaterial of encapsulation shall be compatible with the thermal expansion

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box with minimum IP 55 enclosure with removable gasketed front cover fortermination of external cables. The electrical terminals in the junction box shall becorrosion proof and anti-loosening type. Suitable bypass diodes shall be provided

for partial shadowing of modules, if recommended by manufacturer.

5.3 BATTERY BANK 5.3.1 Battery Cells

The battery bank shall be charged from the surplus power available from the solarpanel when the sunlight is available and will supply/supplement the solar electricpower from the solar panel when the sunlight is inadequate under cloudy conditionand during nights. The battery cells shall be low self discharge (up to 3% at 27°Cper month) Ni-Cd suitable for photo voltaic application. The battery cells shall beprovided with flame arresting type catalytic caps or ceramic plugs. The type of battery cells shall be as specified in equipment data sheet.

The battery shall incorporate the following features: High charging efficiency. Good cycle life even for deep discharge.

Extended life expectancy. Long maintenance interval/Maintenance free for VRLA battery cell. Large electrolyte reservoir.

The type, AH capacity and no. of cells in the battery bank shall be decided on thefollowing basis :

i) Geographical and climatic conditions prevalent at site.ii) Back-up during low insolation periods considering the de-rated solar panel output

and insolation data.iii) Unless specified otherwise, the system voltage shall be 24 V (Nominal).iv) Battery suitable for 4000 or more charge-discharge cycle for 10% depth of

discharge and for 1600 or more charge discharge cycle for 70% depth of

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5.3.2 General requirements and Performance for Ni-Cd Batteries shall be asper GAIL spec. S-07-02-016.

5.4 SOLAR POWER CONTROLLER

5.4.1 Technical requirements

The solar power controller shall regulate the charge of the battery and shallmonitor the charging current from the solar array. Power from the battery set & solar arrays shall be routed through the solar controller.

The controller shall be provided with low loss type, high efficiency, tested andtropicalized components with overall loss of the solar controller not exceeding 10%of the rated load. MCCBs and MCBs shall be used for the circuit or deviceprotection in place of fuses. However, semiconductor grade fuses shall be used fordiodes, SCRs etc. Unless specified otherwise, the solar controller shall be wallmounted type with hinged and gasketed door in the front. The cable entry shall befrom top or bottom (to be decided at the time of detailed engineering) through

glands and access to all inside equipments shall be from the front only.

The supply system shall be suitable for both negative earthed and unearthedsystem as required. The provision of negative earthing shall be through anisolating link.

Apart from required control elements, the following components/ features shall beprovided in the controller as a minimum requirements:

i) A 2-Pole MCCB with shunt trip to isolate the solar panel from the solarcontroller/battery on receipt of 60% LEL signal from the gas detection panel. (Thesignal will be in the form of a normally open potential-free contact).

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Battery charging current Load current Solar panel fault indicators

xi) Current limiting features with active elements.xii) Voltage regulator shall be switching mode type.xiii) Digital Ampere hour meter.

Protection features to take care of faults in DCDB bus, solar controller, solar panel,battery circuit etc.

5.4.2 General Requirements

5.4.2.01 Panel ConstructionThe panel shall be fabricated out of minimum 14 SWG sheet steel. The degree of protection of enclosure shall be IP-51 minimum. Panels shall be provided withnecessary lifting hooks and mounting brackets/base channels.

5.4.2.02 WiringThe wiring shall be done with minimum 2.5 mm2 PVC insulated copper wire of 650volts grade. Wiring to door mounted devices shall be with flexible wires. Wire lugsshall be of crimping type. Bundles of wires shall be routed neatly in vertical orhorizontal planes. Individual wires and bundles shall be secured with PVC wire ties,cable lacings or by enclosing in PVC wire trays.

Unless specified otherwise, all terminal blocks shall be rated for minimum 20A at

650 volts. The terminal block shall have a white plastic marking strip of the lengthof the terminal block. Each terminal block assembly shall have 20% spareterminals. All wiring shall be identified by permanent slip-on or clip-on markingsleeves on each terminating wire in addition to marking at the terminal block.

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5.4.2.05 Segregation All electrical devices and live parts in the solar controller panel shall be segregatedby means of metallic screens. All power connections in case of solar controller shall

be segregated from one another and from the electronic circuits

5.4.2.06 Cabling All interconnecting cables between various solar panels and main JBs, included inscope of supply, shall be Flame Retardant Low Smoke (FRLS) type. Cables of sizes,as specified, connecting JBs to solar controller, solar controller to battery shall besupplied by contractor.

Adequate space shall be provided for termination of external cables. All requiredNickel-Chromium plated brass double compression cable glands and tinned copperlugs shall be included in the scope of supply.

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

All electronic circuit boards shall be tropicalised to prevent corrosion and fungusgrowth.

5.6 IDENTIFICATION All solar panels, batteries, solar controller and related devices and materials shallhave permanent tags in contrasting colours affixed on them and lettering of atleast 12 mm size. The tag inscription shall be in line with the equipment numberlist.

6.0 TESTING AND INSPECTION All tests shall be carried out as per relevant standards at Vendor’s works.

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6.2 SOLAR PANELS

6.2.1 Following environmental tests as per applicable IEC/IS shall be carried out on

photovoltaic modules on sampling basis. Minimum 2% of ordered modules or 1 No.module, whichever is higher, shall be subjected to following tests and performanceof module before and after each test shall be tabulated and furnished. The testsshall be carried out sequentially on each module selected for testing and the testedmodule shall be discarded after tests.

In case on account of testing:

i) The overall deterioration in the performance of the tested modules after testexceed 5% of rated performance, or

ii) The tested module exhibits any open circuits and or ground faults, oriii) The tested module develops cracks or mechanical damage, oriv) the tested module fails to pass the electrical isolation tests

The entire ordered lot of modules shall be rejected.

S.No Test Test Details1

Cold Temp (-) 40°CDuration : 16 Hrs

2Rapid Change of Temp. Low Temp.: (-)40°C High Temp:+ 85°C

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

3Dry heat 85°C

Duration : 16 Hrs

4Salt mist Temp. : + 35°C

Duration : 48 hrs.5

Wind Pressure equivalent to an air velocity of 280km/hr.

6 Rain Test as required in the mentioned standards

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NOTE: Type test certificate can be accepted for the tests marked with asterisks(*).

6.3 BATTERY : Refer GAIL Specification S-07-02-016

6.4 SOLAR CONTROLLER Tests in the following order shall be conducted for the panel :

i) Generalii) Earth Continuity Testiii) Functional Testsiv) Insulation Resistance Measurementv) Heat Run Testvi) Insulation Resistance Measurementvii) Functional Test

6.5 Burn out tests for 120 hrs. on the complete system in one assembly.

7.0 VENDOR DATA REQUIREMENTS

7.1 GENERAL7.1.1 Make, type & catalogue no. of equipment.7.1.2 Dimension, weight & general arrangement drawings.7.1.3 Type test certificates.7.1.4 Routine test certificates.7.1.5 Applicable International Standards

7.1.6 Installation, Operating & maintenance manual7.1.7 Hazards & safety precaution.7.1.8 Catalogues & Brochures.7.1.9 Interconnection diagram for various equipment along with cable size.

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ii) Self discharge at various ambient temperatures.iii) Cell voltage V/s. State of charge.iv) Capacity V/s. rate of discharge.

v) State of charge V/s. Sp. Gravity of electrolyte.vi) Depth of discharge V/s. no. of cycles.

7.3.2 Selection criteria including sizing calculation.7.3.3 Recommended float charging voltage & current.7.3.4 Memory effect (if any).

7.4 SOLAR CONTROLLER

7.4.1 Operational write up.7.4.2 Schematic & wiring diagrams.7.4.3 Expected temperature at critical points for maximum load.

NOTE:1. Items marked with asterisks (*) must be furnished along with bids. All other items

including the above shall be submitted for Company’s approval/information duringdetailed engineering.

2. All calculations furnished during bid stage shall be for information only. They shallbe checked during detailed engineering stage. Any change in size of battery, solarpanel etc. shall be done without any price implication.

8.0 CERTIFICATION All offered equipments or equipments of similar design manufactured by the same

supplier : Shall have been type tested by an independent authority. Shall have been in continuous satisfactory service for a minimum period of two

years.

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SPECIFICATION FOR MAGNETIC

CLEANING AND ELECTRONIC

GEOMETRY PIGGING OF PIPELINE

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TECHNICAL SPECIFICATIONS

1.0 INTENT The intent of the specification is to set forth the requirements of the

Electronic Geometry Survey of the pipelines to help bidder quote his unit rateprice in the schedule of rates. This requirement is not intended to be allinclusive and use of guidelines set-forth does not relieve the contractor of hisresponsibility of successfully carry out all activities and to obtain reliable andvalid data from the EGP tool about condition of the pipeline as defined underScope of work.

2.0 PROPELLING MEDIUM Since pipeline is not commissioned, contractor shalluse air as propelling medium for which single compressor of 900 cfm capacityshall be used. The compressor should have the capacity to develop pressureupto 10KG/CM2. Contractor shall also keep one compressor of the samecapacity mentioned above as stand by. Contractor has to arrange all thefacilities required for pressurising air into the pipeline and running the pigs atrequired speed so that valid and interpretable data by running ElectronicGeometry pig is generated by using the above media

3.0 3.0 MAGNET CLEANING PIG RUNS Prior to launching of ElectronicGeometry pig, contractor shall complete all activities required to establishadequate cleanliness of pipeline to the satisfaction of the contractor and toverify the internal geometry of the pipeline with relation to ovality, dent etc.Contractor shall decide the number of Magnet cleaning pig runs and thechoice of the Magnet cleaning pig for each cleaning run as suitable for thepurpose to obtain internal condition adequately clean so as to obtain valid

and interpretable inspection data from the Electronic Geometry pig and tosafeguard Electronic Geometry pig against damage due to debris in thepipeline.

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The measurement shall cover the entire 360o of internal pipe wallcircumference using properly oriented and sufficient no of sensors. The toolshall be capable to identify and locate the following features as a minimum

o Individual Girth weldo Dent, ovality, buckles, or any other out of roundness, change in

pipeline I.D. and difference of thickness.o Valves or any partially closed valves.

4.1 Magnetic cleaning and Electronic geometry pigging shall be carried outsegment wise. Length of each segment shall be decided to suit siteconditions and spread in consultation with Engineer-in-charge. Whereverrequired temporary launcher/receiver to be deployed for each segment

5.0 DEFECT SIGNIFICANCE The following information/performance isexpected out of the Electronic Geometry pig inspection:

5.1 Accuracy of defects: The best accuracy offered and guaranteed by theBIDDER for each category of defect should be clearly spelt out. However, thetool should have minimum capabilities as under.

Minimum Detection level: 2% of IDSizing Accuracy: +0%, -25%of measured valueLocation Accuracy Axial: 0.1% from nearest Permanent Features.Within pipe ± 0.20 Meter

The tool should be capable of negotiating minimum 3D bend and15%reduction in Pipe ID.

6.0 PIG TRACKING The movement of any type of pig put into the pipeline

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o Identification of potentially hazardous defects likely to affect structuralintegrity of the pipeline.

o The Contractor will transfer all the processed data generated on a CD

with user-friendly operation on a compatible PC.Providing all the raw and processed data along with the software package forenabling company/consultant to study the data as required. The softwareshould be user friendly.

8.0 FINAL WORK REPORT The Bidder shall include in his offer the mostappropriate reporting procedure envisaged for the subject pipeline. This willhave to be mutually agreed between the successful bidder and company.

However, any reporting system shall include but not limited to the following:o A detailed report in respect of each pipe segment of running each of

the pre-inspection tools such as Magnet cleaning pig.o Detailed report about running of the Electronic Geometry pig including

but not limited to the operational and functional details.o Details describing the type, size and location of individual mechanical

defects. The location of each defect should be suitably listed withreference to permanent pipeline features, girth weld no., relative andabsolute distance.

o A detailed report in respect of each defect for which sizing has to bedone indicating its length, depth and axial location suitably referenced.

o Preliminary site report for each pipe segment for each running of Magnet cleaning, and Electronic Geometry pig runs statingcomments/observations of each run, pig condition, operating

parameters, and total time required.o Velocity plot of the Electronic Geometry pig along the length of the

segment.

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reported, then EGP tool performance will be verified by detection andlocational accuracy of permanent installations on the pipeline

The contractor shall depute his representative to observe the verification atverification sites for proving that field log detected anomalies conform tosizing, including linear positions.

9.1 EGP run shall be considered SUCCESSFUL provided at the end of theelectronic geometry Pigging run, the Contractor is able to deliver valid,interpretable and physically verifiable data and which after dig siteverification in the field is found in conformity with the Defect Significance

mentioned at Clause No 5.0 Part II, Technical specification of the biddocument.

EGP run shall be considered NOT SUCCESSFUL provided at the end of theelectronic geometry Pigging run, the Contractor is not able to deliver valid,interpretable and physically verifiable data and which after dig siteverification in the field is found in non conformity with the Defect Significancementioned at Clause No 5.0 Part II, Technical specification of the biddocument. Also refer clause No. 9.0 above in case no physical verifiable dataare reported.

10.0 ABNORMAL SITUATIONS: The objective of this section is to write downforeseeable abnormal circumstances for taking appropriate measures, shouldsuch a condition arise during implementation of Project. The company hasforeseen the following abnormal conditions. However, if the bidder foresees

any other abnormal condition, he is free to make a mention of the same inhis technical bid offer.

10.1 TOOL FAILURE Contractor is required to get valid interpretable and

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pig and its retrieval shall always be responsibility of the contractor. Aftermodification pigging Contractor shall run Gauge pig to check internalrestriction, if any.

11.0 MISMATCH OF INSPECTION RESULTS WITH ACTUAL DEFECTSDURING SITE VERIFICATION: In case of variance between the results of physical defect verification and the results reported by the contractor on thebasis of Electronic Geometry Survey (after considering the tolerance asprovided in the contract) segments, this shall be considered as a failed runand shall be dealt as per Cl.10.1 above.

12.0 BID EVALUATION CRITERIA (TECHNICAL) If the bidder is not amongthe list of suggested vendor at clause 13.0, bidder should satisfy the entirefollowing technical and past experience requirement. Bidder should submitdocumentary evidence to substantiate his claim for his past experience in theform of work order/ completion certificate.

o Bidder should have carried out satisfactory similar job of pipeline of diameter 24"or above for at least 50km length in single run and alsowith cumulative length of 140 km during last ten years.

o Bidder should have full-fledged calibration and testing facility forElectronic Geometry Pig tool including test loop of similar size and datainterpretation facilities.

o Bidder's proposed tool should be capable of inspecting minimum 2%of ID defects.

o Bidder should own the proposed 18" tool.

13.0SUGGESTED VENDOR LIST Following is the list of suggested vendors whohave done the similar type of jobs.i) M/s ROSEN Europe B.V. The Netherlands.ii) M/s Linscan Advanced Pipeline And Tank Services. (Exclusively for EGP

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SPECIFICATION FOR CORROSION

MONITORING SYSTEM


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CONTENTS

1.0 INTRODUCTION

2.0 GENERAL

3.0 SCOPE OF WORK

4.0 SPECIFICATION

5.0 INSPECTION & TESTING

6.0 PAINTING, MARKING & SHIPMENT7.0 SPARE & ACCESSORIES

8.0 DOCUMENTATION TO BE PROVIDED BY VENDOR

9.0 SUGGESTED VENDOR LIST

10.0 GUARANTEE

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1.0 IntroductionThis specification covers the minimum requirements for design, fabrication,supply, installation and testing of corrosion monitoring system to be located

on Sultanpur – Neemrana Pipeline.

2.0 GeneralThe corrosion monitoring system will be used to establish the internalcorrosion profile of the pipeline using electrical resistance (ER) corrosionprobes & corrosion coupons in conjunction with other inspection techniques.

ER-Probes & coupons are located at Sultanpur on the 18” line to Neemrana and

consists of : Corrosion probe Transmitter Corrosion Meter

Corrosion Coupon ER Probe access fitting assembly

3.0 Scope of Work Design, engineering, supply of all materials, preservation at site, fabrication,assembly, erection/installation, testing, commissioning, guaranteeing, trialrun, training the client’s personnel, preparation of operation manual,preparation of technical data sheet and engineering drawings and obtainingapproval from GAIL for Corrosion Monitoring System as per systemdescription, drawing, specification, standards etc enclosed with the tenderdocument and as per direction of Engineer-in-charge.

4.0 Specification4.1 Technical RequirementsThe electrical resistance (ER) probes & CS corrosion coupons to be installed at the

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Instrumentation department will have to keep provision of space for panelmounting. Electrical department shall arrange connection of mains UPS to receiverat each location. Drawing enclosed as Annexure-A for connection to DCS/ SCADA.

4.2 MaterialsThe scope of supply shall consist as minimum requirement of the followingcomponents:

4.2.1a) ER PROBE - (1+1) Nos.; Probe: (IW+IS) for each location as in 2.0. (

datasheet enclosed).

Probes shall be high-pressure retrievable type, flush mounted, body in SS316with element of carbon steel for installation with high-pressure hollow plugaccess fitting assembly. The probe shall be suitable for measurement of corrosion rate in the range of 0-5 mpy.

Probe life shall be at least 2 yrs. at 1-to 1.5 mpy corrosion rate.

b) Transmitter: Transmitter 1 for each location as in 2.0. (Datasheet enclosed)The transmitter shall have valid intrinsically safe certificate from authorizedcertifying agency.

c) ACCESS FITTING ASSEMBLY for ER Probe2” NB, 5.25” height, flare weld Access Fitting Assembly (non-tee), bodycarbon steel, acme thread outlet with hollow-plug assembly in AISI-316 alongwith heavy duty protective C.S. cover complete with essential spare. Rating6000psi.

4.2.2a) COUPONS

Mild steel flush disc coupons l.25” dia x 1/8” thickness with one mounting

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Service valve kit, complete with blanking plug, extension lever, brasshammer, spare face-to-access fitting O-ring, heavy duty field service box,essential repair and seal kit

Each retriever and service valve kits shall be designed for operationon all the locations both for probe & coupon.

4.2.4 CORROSION METER – 1 Nos. for ER probe; (Data sheet enclosed)

o Resolution: ± 0.1mpy or 0.01 milo Measurement repeatability: + 1 dial divisiono Measurement range: 0-5 mpy.o Operating temp. : (-) 10 °C to 65°Co Complete with suitable safety barrier & two wire cable of required

length between transmitter & corrosion meter, operation andmaintenance manual

o Owner will provide 220V power supply for this unit. The unit shall besuitable to provide 24VDC supply for powering the transmitter’s 4-20mA loop through the two wire cable.

o The unit shall receive 4-20 mA signal proportional to corrosion ratefrom the transmitter through the same two-wire cable and providedigital display of corrosion rate through the same two-wire cable. 4-20mA signal shall also be available from the transmitter-corrosion meterfor interfacing with DCS/ SCADA.

o The corrosion meter shall have valid intrinsically safe certificate fromauthorized certifying agency.

5.0 INSPECTIONS AND TESTINGThe manufacturer and third party inspector shall carry out inspection and testing asper relevant codes and service requirements of this specification, for all items of hiswork prior to shipment. Manufacturer’s third party inspector’s test certificates in

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8.5 Operating and maintenance manual8.6 Quality control plan8.7 Intrinsically safe certificates with catalogue wherever applicable.

8.8 Preservation procedure for coupons, probes and other spare accessories.8.9 Manufacturer’s test certificate/ Third party Inspector Certificate.

9.0 The corrosion monitoring items shall be procured from one of thefollowing vendors:

i) Rohrback Cosasco System, USA ii) Metal Samples, USA iii) Cormon, UK

iv) Atel, Italyv) Corrocean, Norwayvi) Caproco-UK

All the components shall be purchased from a single manufacturer.

10.0 GUARANTEEThe vendor shall guarantee for Quality, Integrity & standard of all monitoringinstruments & accessories.

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CORROSION MONITORING SYSTEM (ER PROBE) – DATA SHEET

Tag no. 30″-P-80-3205-

Line no.

Wall thickness

Pipe material API

Operating temperature(oC)

0-55

Design temperature (

o

C) 29-65Operating pressure(kg/cm2g)

45-92

Design pressure(kg/cm2g )

92

Flow(m3/hr.) 11.87

General

Service Natural Gas

Type Retrievable ER probe

Material Body: SS316

Element: carbon steel

End connection 2” flare weld

Probe element type Flush mounted

Element thickness –. 5mil min

Probe

Probe length To be decided by vendor

2” NB 5 25” h i h fl ld (

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CORROSION MONITORING SYSTEM (TRANSMITTER) – DATA SHEET

Tag no. Later

Line no. Later

Type 2 wire type

Input ER probe

Output 4-20Ma

Cable lead

5’ for ER probe connection and as

required for connection to corrosionmeter

Power supply 24 VDC from receiver unit

Mounting At site near probe by bracket/ yokesupport

Whether intrinsically safe Yes (valid certificate required)

Safety barrier between transmitter &

receiver Yes

Nos. As given in 4.2

CORROSION MONITORING SYSTEM (CORROSION METER) – DATA SHEET

Tag no. Later

Line no. Later

R l ti 0 1 0 01 il

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CORROSION MONITORING SYSTEM (COUPON) – DATA SHEET

Tag no. Later

Line no. Later

o Mild Steel flush disc coupons 1.25” dia x 1/8” thickness with one mountinghole of ID 0.312”.

o Retrievable coupon Holder of SS 316o Access Fitting Assembly for coupons:

2” NB, 5.25” height, flare weld Access Fitting Assembly (non-tee), body carbonsteel, acme thread outlet with solid plug assembly in AISI-316, along with heavyduty protective CS cover complete with essential spare. Rating 6000 psi.

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DATA SHEET FOR 24 Volts DC

BATTERY BANKS

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DATA SHEET - BATTERY BANKS(24V)Part-I (Data to be filled in by purchaser)

A Site Conditions

Max.: 40oCDesign ambient tempMin.: 5oC (for battery sizing)

Humidity Highly humid

AtmosphereHighly corrosive and dusty as applicable forrefineries

Altitude Less than 1000 m above MSL

B Battery

1.0 Type Battery type shall be Nickel-cadmium2.0 Quick charging time 10 hours

3.0 Discharge duty requirements :# Refer Load Analysis doc.no.000-01-07-08-001

Duty cycleItemNo

Location

Nominal. DC

systemvoltage

First1min

Next28min

Next..90 min

Last1min

No. of cells Ni-

Cd

End cellvoltage Ni-

Cd

1 24V Refer Load analysisdoc.no.0001-01-07-08-001 ByContractor

1.16

Minimum AH capacities of batteries have bee indicated in Scope doc.no.0001-01-04-06-003-SW2.In case higher AH capacities of batteries are required, same shall beprovided by vendor, without any time and cost implication. Design margin of 10%shall be considered in battery sizing. Detailed calculations shall be reviewed duringdetail engg.without any time and cost implication.

Note: The end cell voltage shall conform to the values specified above.

4.0 Battery stands formation: Double row double tier

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DATA SHEET - BATTERY BANKS (24V)Part - II (Guaranteed Technical Particulars - by Vendor)

BATTERY

1 Item no.

2 Tag no

3 Manufacturer's name

4 Type and catalogue no. of cell

5 Ampere hour capacity

6 No. of cells

7 Nominal cell voltage

8Cell voltage at the end of full discharge at 10hours/ 5 hours rate :

9 Specific gravity of electrolyte at the end of full charging at ___ oC :

10Specific gravity of electrolyte at the end of full discharge at 10 hours / 5 hours rate at ___ oC :

11 Quantity of electrolyte per cell (litres)

12 Weight of each cell with electrolyte (kg)

13 Quick charging current

13 1 Max safe quick charging rate (amperes)

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17.2 Permissible ripple content

18 AH efficiency at 10 hours/ 5 hours rate

19 Short circuit current of the battery bank

20 Short circuit withstand time (sec.)

21Max. allowable temp. of electrolyte which the cells can withstand withoutinjurious effects

21.1 Continuously

21.2 For short periods

22 Type of positive plate

23 Type of negative plate

No. of +ve plates per cell

No. of -ve plates per cell

Material and thickness of separators

27 Ampere-hour capacity at min. ambient ___ oC

27.110 hour rate to end cell voltage specified atS. no. 8 above :

27.25 hour rate to end cell voltage specified at S.no. 8 above :

27.32 hour rate to end cell voltage specified at S.no. 8 above :

27 41 hour rate to end cell voltage specified at S.

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DATA SHEET FOR

H.V/M.V.CABLES

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MV CABLE DATA SHEETPart 1

(Data by Purchaser)

1. SITE CONDITIONS1.1 Ambient temperature : Max. : 40oC Min. : 10oC

2. SYSTEM PARAMETERS2.1 Voltage

Nominal System Voltage Highest System Voltage Voltage grade□ 415 V 500 V 650 V/ 1100 V□ 3.3 kV(E) 3.6 kV 1.9 kV/ 3.3 kV

□ 3.3 kV(UE) 3.6 kV 3.3 kV/ 3.3 kV□ 6.6 kV(E) 7.2 kV 3.8 kV/ 6.6 kV□ 6.6 kV(UE) 7.2 kV 6.6 kV/ 6.6 kV or

6.35 kV / 11 kV

□ 11 kV(E) 12 kV 6.35 kV/ 11 kV□ 11 kV(UE) 12 kV 11 kV/ 11 kV□ 22 kV 24 kV 12.7 kV/ 22 kV□ 33 kV 36 kV 19 kV/ 33 kV

E: Earthed UE Un-earthed System

2.2 Frequency 50 Hz ± 3 %

2.3 Single line to ground fault current / duration Refer Single line diagram

3 CONDUCTOR MATERIALi) HV Power Cables Aluminium / Copper N.A

ii) MV Power Cables Aluminum (25 mm² & above) and

Copper (up to 16 mm²)

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4.4 Make of accessories (if applicable) Refer Annexure-I enclosed with Job

specification (Electrical) document no. 0001-01-

07-02-001

4.5 Type of cable accessories (if applicable) N.A.

Drum length required By Pipeline Contractor

(Indicate whether standard drum lengths as per specification or specific drumlengths are required)

Note : N.A. = Not Applicable Please tick mark (√) against box.

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DATASHEET FOR SACRIFICAL ANODE

CATHODIC PROTECTION SYSTEM FOR

PIPELINES

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DATA SHEETSACRIFICIAL

ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES

PART I

(PURCHASER SPECIFIED DATA)

1.0 Type of coating for the pipelines : 3 Layer Polyethylene

2.0 Type of CP system : Permanent / Temporary using sacrificialanodes

3.0 Design life of protection : Temporary CP system : 1 Year or tillcommissioning of PCP, whichever islater

4.0 Design protection current density : As per specification no. S-07-02-011

5.0 Corrosion survey data : Corrosion survey shall be conductedby contractor

6.0 Type of sacrificial anode : Magnesium low potential type (1.55V) /magnesium high potential type (1.75V)(To be selected by CP contractor based

on the requirements of specification)

7.0 Test stations To be provided as per requirement

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10.0 Additional tests to be conducted Pearson survey / DCVG survey / Notrequired for identifying pipe coatingdefects/holidays

11.0 Interference detection Required

12.0 Interference mitigation Shall be done using sacrificial anodesonly as a part

Of temporary CP system

11.0 Indicative Design data for sacrificial anodes ground bed (see note ‘v’ below)11.1 To be decided by CP contractor

Chainage

S. NoFrom To

PipelineDia M

PipelineWall

thickness mm

Type of coating

AnodematerialZinc /

Magnesium

Anodetype

Solid /Ribbon

Anodeground

bedspacing

No. of anodes

perground

bed Nos.

11.2. Details of anodes (By CP sub Contractor)- Type : Zinc Magnesium- Net weight : _ _ _ Kg _ _ _ Kg- Size :

- Bare : _ _ x _ _ x _ _ mm. min. _ _ x _ _ x _ _ mm. Min.- Prepacked : _ _ x _ _ x _ _ mm. min. _ _ x _ _ x _ _ mm. Min.

11.3. Type of anode installation : Horizontal / Vertical

11 4 Distance between individual anodes : M

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ii. In cases where sacrificial anode CP system is specified as temporary and where

both temporary, permanent cathodic protection works are being executed by the

same agency, activities of permanent CP system which are common to

temporary C.P. system shall be completed as part of temporary C.P. system. In

cases where temporary and permanent cathodic protection works are being

executed by different agencies, the contractual scope of work shall be referred

for further details.

iii. All civil works associated with the complete cathodic protection system are

included in the scope of Contractor. This shall include providing cable trenches

and foundations for all equipment, all test stations, etc.

iv. Contractor shall supply all instruments, tools and tackles necessary for proper

operation and maintenance of complete cathodic protection system and

associated equipment.

v. The design data for anode ground beds and anodes shall be decided by CP

contractor depending on the protection current requirement of the pipeline as

laid. Contractor shall quote for CP system on lump sum basis.

vi. Contractor shall fill up all the data asked for in the ‘Data sheet sacrificial anode

cathodic protection system for pipelines, part-II (to be filled in by the contractor)’

and submit the same for GAIL’S’s review.

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DATA SHEET

SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES

PART-II(TO BE FILLED IN BY THE VENDOR)

1.0 Cables

1.1Type : ____________

1.2Voltage grade ____________

1.3Make ____________

2.0 Cable to pipe connection

-For charged pipeline : ____________

- For non charged pipeline : ____________

2.1Make and model number of - ____________

- Cad weld Material : ____________

- Pin brazing equipment : ____________

3.0 Details of anodes

3.1Prepacked type

- Anode material : Zinc Magnesium

- Net weight : _ _ _ Kg min. _ _ _ Kg min.

- Size :- Bare : _ _ x _ _ x _ _ mm. min. _ _ x _ _ x _ _ mm. Min.

- Prepacked : x x mm min x x mm Min

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TECHNICAL NOTES REV-0GAIL (INDIA) LTDNEW DELHI

SPECIFICATION FOR STATIONARY VALVE REGULATEDLEAD ACID BATTERIES Page 6 of 7

Copyright GAIL – All rights reserved

FORM-IA

DETAILS OF SPECIFIC EXPERIENCE OF BIDDER * / HIS NOMINATED SUB-CONTRACTOR FOR SACRIFICIAL ANODE CP SYSTEM(SEPARATE SHEETS SHALL BE FILLED UP FOR EACH JOB/PROJECT HANDELED)

Name of CP sub contractor:

EXPERIENCE DETAILS OF HYDROCARBON HANDLING CROSS COUNTRY PIPELINES

SlNo

Description

(For Sacrificial Anode CP

System)

Length

of PipeLine

Dia

Of Pipe

Line

Type of Coating

Type of Anodes

No of Anode

Ground BedsFor The

Pipeline

Name of

Project & Owner

Work Order No**Date of

CommencementOf Work

Date of

Completionof Work

Name of

Backup Agency

Considered

Experience of

Backup Agency

1Design andEngineering

experience

2Supply of CPequipment /

material

3Installation of CP system

4Testing andcommissioning

* Strike out which ever is not applicable

** Copy of the work order and completion certificate shall be attached

0001-01-07-04-CPS-001

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TECHNICAL NOTES REV-0GAIL (INDIA) LTDNEW DELHI

SPECIFICATION FOR STATIONARY VALVE REGULATEDLEAD ACID BATTERIES Page 7 of 7


DETAILS OF SPECIFIC EXPERIENCE OF BIDDER * / HIS NOMINATED SUB-CONTRACTOR FOR CP SYSTEM / BACKUP AGENCY FOR INTERFERENCE DETECTION ANDMITIGATION (SEPARATE SHEETS SHALL BE FILLED UP FOR EACH JOB/PROJECT HANDELED)

Name of CP sub contractor FOR CP System:

Name of Backup Agency for Interference Detection And MitigationDetails of Backup Agency if Hired for CP Interference /

Mitigation SurveySl

No

Cause of

Interference

Lengthof PipeLine

Dia

Of PipeLine

Type of

Coating

No of

CPStationsfor thePipeline

Name of Project &

OwnerWork Order No**

Date of Commencement

Of Work

Date of Completion

of Work Name of

Agency

Experience of

Backup Agency

1

Cathodicallyprotectedforeignpipelinescrossing/

parallel running

2

Cathodicallyunprotectedforeignpipelines/structurescrossing/parallel running

3

High voltageline AC/DC(66KV andabove) crossing& parallelrunning

4 AC/DCelectrifiedtraction

* STRIKE OUT WHICH EVER IS NOT APPLICABLE

** COPY OF WORK ORDER AND COMPLETION CERTIFICATE SHALL BE ATTACHED*** LIST OF INTEREFERENCE DETECTION, MITIGATION JOBS DONE ALONG WITH WORK ORDER AND COMPLETION CERTIFICATE SHALL BE ATTACHED

0001-01-07-04-CPS-001

FORM-IB

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DATA SHEET FOR IMPRESSED CURRENT

CATHODIC PROTECTION SYSTEM FOR

PIPELINES

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DATA SHEETIMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES

PART-I(PURCHASER SPECIFIED DATA)

1.0 Pipeline coating : 3 layer Polyethyelene coating

2.0 Type of CP system : Permanent / Temporary

3.0 Design life of protection : 35 Yrs

4.0 Design protection current density : As per specification no. S-07-02-012

5.0 Current drainage survey : Shall be carried out / Need not be carried out,

However current measurement survey for propercurrent distribution shall be carried out by CPcontractor.

6.0 Corrosion survey data : Enclosed / Corrosion survey shall be conductedby contractor

7.0 Integration of permanent CP with : In the scope of the contractor / Not in the scopeTemporary CP of the contractor.

8.0 Type of Anodes for anode ground bed : High silicon iron / mixed metal oxide titanium

9.0 Electrical resistance probes : Shall be provided for marshy areas and water(E/R Probes) logged area

9.1 Quantity of E/R probes : Tentative quantity is given below, however exactrequirement to be decided by CP contractor in line withGAIL spec. S-07-02-012

S.NO SPREAD NUMBER QUANTITY OFE/R PROBES

REMARKS

A Section A 2 nos.

B Section B 2 nos.

Quantity indicated here in is tentative

only. Contractor shall quote unit ratesfor E/R probes for addition/deletion

purpose in future.

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13.0 Grounding through Polarisation cells To be provided in line with Cl.no.7.9.1 of inconjunction with galvanic anodes as perS-07-02-012. The galvanic anode shall be of weight/size for design life of PCP system.The polarization cell shall be of electrolytic typeof rating as per cl. No. 4.9 of spec.no. S-07-02-010,S-07-02-012

14 Acquisition of right of Use for : By Contractoranode ground bed, anode junctionboxes and anode ground bed cablelaying

15 Chain link fencing around the ground Shall be provided / Shall not be provided.

16 Close interval potential logging survey Shall be carried out

17 Additional tests to be conducted Shall be carried out (Also refer Note (xiv)for identifying pipe coating defects/holidays

18 Interference detection & mitigation Shall be done by Contractor as per Cl.no.10.0of spec.no. S-07-02-012.

19 Proposed location of CP stations/anode ground beds: By contractor

20 Proposed location of E/R probes / Computerised test stations / Polarisation coupons:Location/quantity of E/R probes, Computerised test stations, Polarization coupons shall bedecided by CP sub contractor as per specification requirement and same shall be subject toreview during detail engineering by Owner/)

Sl. No Locations of ER probes Locations of Computerisedtest stations

Locations of polarisationcoupons

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v) Contractor shall supply all instruments, tools and tackles necessary for proper operation andmaintenance of complete cathodic protection system and associated equipment.

vi) Contractor shall clearly bring out during bidding stage, the requirement of additional CPstations/higher rated ground bed, if any, over and above those specified in clause 19 above.

vii) Vendor shall fill up all the data asked for in the ‘Data sheet Impressed current cathodic protectionsystem for pipelines, part II (to be filled in by the vendor)’ and submit the same for GAIL’S’sreview.

viii) Necessary coordination with pipeline laying contractor shall also be in the scope of CP contractor.ix) Reference signal cables coming from permanent reference cells and pipeline shall be 1-pair X 2.5

MM2 and shall be laid in a separate cable trench. These cables shall not be laid in cable trench forpower/anode/cathode cables.

x) For make of equipment refer elsewhere. The make of equipment, materials shall be selected fromGAIL approved vendors.

xi) Anode Ground Bed shall preferably be horizontal type, however type of anode ground bed finallyselected shall be as per soil resistivity data by CP sub-contractor.

xii) CAT survey with ‘A’ frame shall be carried out at a regular interval of 250 meters along the routeof pipeline to identify coating defects/holidays. Where signal loss observed is higher, reading shallbe taken at close intervals as per the direction of Engineer-in-Charge. DCVG survey shall be carriedout to pin point the coating defect/holiday wherever signal loss is greater than 2db/unit distanceand complete report shall be submitted to Owner/GAIL for further action.

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DATA SHEETIMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES

PART-II(TO BE FILLED IN BY THE VENDOR)

1.0 E/R probes1.1 Make and model no. of E/R probe

1.2 Material of E/R probe :

1.3 Size of the exposed area of the probe

1.4 Make and mode no. of E/R probe :reading instrument

2.0 Permanent reference electrodes

2.1 Make & model no. :

2.2 Design life of electrode under burial _ _ _ Yearscondition.

3.0 Polarisation cells

3.1 Type :

3.2 Make & model no. :

3.3 Maximum DC leakage current at 400 C at

- 1V DC across the Polarisation cell : _ _ _ mA

- 1.5V DC across the Polarisation cell: _ _ _ mA

- 2.0V DC across the Polarisation cell: _ _ _ mA

3.4 50 Hz AC current rating at 400 C

- Contnuous : _ _ _ A

- Short time : _ _ _ KA for _ _ _ sec

3 5 Rated no of operations over life time

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5.2.1 Current, 8/20 micro second wave :

5.2.2 AC spark over voltage

-50 Hz AC :

-Impulse(1.2/50 micro second) :

5.3 Make :

6.0 Cables6.1 Type and voltage grade

-For anode tail cables : _ _ _ / _ _ _ V

-For other CP cables : _ _ _ / _ _ _ V

6.2 Make

-For anode tail cables :

-For other CP cables :

7.0 Cable to pipe connection- For charged pipeline :

- For non charged pipeline :

7.1 Make and model number of - Cad weld Material :

- Pin brazing equipment :

8.0 Anode type and make8.1 Impressed current anodes

- Type :

- Make :

8.2. Sacrificial anodes make

-Zinc anodes :

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DATA SHEET IMPRESSED CURRENT

TRANSFORMER RECTIFIER UNIT


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DATA SHEET

CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

PART - I (TO BE FURNISHED BY PURCHASER)

1 Input power supply 240 V ± 10 %, 50 Hz ± 3 %, 1 Phase

2 Input power supply fault level 25kA at power supply point

3 Number of output circuits One/two as required

4 Output voltage (+ve earthed) See note-2

5 Rated output current See note-2

6 Pipe to soil potential setting range (Vps) -0.85V - to -2.5V

7 Minimum set potential range (Vrs) -0.4V to -0.9V

8 Maximum pipeline potential range (Vpm) -1.1V to-2.5V

9 Minimum pipeline potential range (Vpm) -0.7V to -1.0V

10 Number of reference cells for control Two

11 Site conditions

- Design ambient temperature 40 oC

- Relative humidity Highly humid

- Altitude above mean sea level Less than 1000 m

12 Shade of final paint Vendor Standard

13 Commissioning at site By Contractor

14 Remote monitoring and control throughSCADA for SCADA I/O)

Required (Refer doc.no.0001-01-07-02-002

15 Type of Control

- Auto : Close loop control with PSP of reference cells in feedback loop (as per clause no. 6.4 of spec. no.S-07-02-013

- ManualConstant voltage and constant current Mode (CVCC)having regulated output voltage at set value of constantvoltage and constant current with current limit features(as per clause 6 4 of spec S-07-02-013

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PART - II (TO BE FILLED BY CONTRACTOR/VENDOR)

1 Rating of each CPTR unit along R.O.W.

S. No Location along ROWCPTR unit output

rating

Installation in sub station

building/ outdoor kiosk

Size of incomer

cable

Voltage Current

2 Guaranteed technical particulars of CPTR unit

2.1 Efficiency at 10 % load _______________

at 25 % load _______________

at 50 % load _______________

at 75 % load _______________

at 100 % load _______________

2.2

Voltage regulation (from zero to100 % load variation and

through out the output voltage range(Refer clause 6.4.3 of spec.

no. S-07-02-012)(Manual mode) * _______ %

2.3

Current regulation (from 0.5 V to100 % output voltage variation

and through out the output current range (Refer clause 6.4.3 of

spec. no. S-07-02-012)(Manual mode) * ________%

2.4Closed lop PSP regulation in auto mode (refer clause 6.4.3 of

spec. no. S-07-02-012) ± ________ mv

2.5 Output ripple at full load current and Auto mode Manual mode

- At 10% output voltage : * *



(refer clause 6.2.3 of spec. no. S-07-02-012)3 Technical particulars of Current interrupter

3 1 Type of interrupterMounted CPTR unit / Portable

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DATA SHEET FOR IMPRESSED

CURRENT CATHODIC PROTECTION

POWER SUPPLY MODULE

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DATA SHEET

CATHODIC PROTECTION POWER SUPPLY MODULEPART - I (TO BE FURNISHED BY PURCHASER)

1 Input power supply 24 VDC ±15%

2 Input power supply fault level 10 kA at power supply point

3 Number of output circuits One/two as required

4 Output voltage (+ve earthed) See note-2

5 Rated output current See note-2

6 Pipe to soil potential setting range (Vps) -0.85V - to -2.5V

7 Minimum set potential range (Vrs) -0.4V to -0.9V

8 Maximum pipeline potential range (Vpm) -1.1V to-2.5V

9 Minimum pipeline potential range (Vpm) -0.7V to -1.0V

10 Number of reference cells for control Two

11 Site conditions

- Design ambient temperature 40 oC

- Relative humidity Highly humid

- Altitude above mean sea level Less than 1000 m

12 Shade of final paint Vendor Standard

13 Commissioning at site By Contractor

14 Remote monitoring and control through SCADA

0001-01-07-02-002 for SCADA I/O LIST)Required (Refer doc.no. S-07-02-020

15 Type of Control

- Auto :Close loop control with P.S.P. of reference cells in

feedback loop (as per clause no. 6.4 of spec. 6-51-0024).

M l

Constant voltage and constant current mode (CVCC)

having regulated output voltage at set value of l d h

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PART - II (TO BE FILLED BY CONTRACTOR/VENDOR)

1 Rating of each CPSSM unit along R.O.W.

S. No Location along ROW CPSSM unit output

rating

Installation in sub station

building/ in an out door kiosk

Size of incomer

cable

Voltage Current

2 Guaranteed technical particulars of CPSSM unit

2.1 Efficiency at 10 % load _______________*

at 25 % load _______________*at 50 % load _______________*

at 75 % load _______________*

at 100 % load _______________*

2.2 Voltage regulation (from zero to100 % load variation and through

out the output voltage range(Refer clause 6.4.3 of spec. no. S-07-02-020)

(Manual mode) * _______ %

2.3

Current regulation (from 0.5 V to100 % output voltage variation

and through out the output current range (Refer clause 6.4.3 of

spec. no. S-07-02-020)

(Manual mode) * ________%

2.4 Closed lop PSP regulation in auto mode (refer clause 6.4.3 of spec.

no. S-07-02-020)± ________ mv

2.5 Output ripple at full load current and Auto mode Manual mode




(refer clause 6.2.3 of spec. no. 6-51-0025)

3 Technical particulars of Current interrupter

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DATA SHEET FOR EMERGENCY

GENERATOR PACKAGE

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Data Sheet for Emergency generator packagePart-1 Scope of work (Electrical)

A. Vendor's scope :

Sl.no Description Supply InstallationTesting &

Commissioning

1 Emergency generator completewith brushless excitation and AVR system, frame earthingconnections & lubrication system.

Yes/No Yes/No Yes/No

2 Generator control panel with AMFsystem and control / metering andauxiliary equipments.


2.1 Line Cubicle for CT /PT Yes/No Yes/No Yes/No

2.2 Neutral Cubicle for CTs Yes/No Yes/No Yes/No

2.3 Line side breaker in cubicle Yes/No Yes/No Yes/No

3 Synchronizing equipment Yes/No Yes/No Yes/No

4 Power and Control cabling inbetween the package equipment


5 Earthing within the battery limitsand connection to main earthinggrid


6 Battery & battery charger forcontrol power requirement of thecomplete DG set.


7 Fabricated steel cable trays andracks as required for cabling inthe battery limits


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Data Sheet-Part-2(Data furnished by purchaser)

1 Site Conditions

1.1 Design ambient temperature for electricalequipment design (IS:9676)

40oC

1.2 Altitude Less than 1000mm above mean sea level

1.3 Humidity Highly Humid

(For machines wish acoustic enclosure , this temperature is applicable for the ambience outside

acoustic enclosure )

2 Equipment location Outdoor/ Indoor /Shed with sides

open/Trolley mounted suitable for outdoorlocation.(Since DG is for temporary powersupply till the commissioning of permanentpower source i.e SPV ) suitable FRP sheetover the trolley mounted DG shall also beprovided.

Ventilation Adequate/Inadequate

3 Utilization voltage for auxiliaries to be supplied by vendor No auxiliary power shall beavailable. Any aux. power as required shall be derived by the vendor within the DG package.

4 Power supplies available from owner's system

4.1 D.C supply for controls (excluding engine startingbattery which is supplied by vendor)

Yes/ No

4.2 a) Mains supply for auxiliaries: 415V ± 10%,TPN, Fault level : 25kA (1 sec).(Including for battery charger while

Generator is at standstill)

Not Available

b) Mains supply for auxiliaries: 415V ±

10%, TPN,Fault level : 9kA (1 sec).(Including for battery charger while

G i d ill)

Not available

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along the pipeline route. Cyclic operation between DG setsas described in job specification doc.no.0001-01-07-02-001 shall be provided.

h. Rated Terminal voltage 415V

i. Rated P.F. 0.8 lag (min.)

j. Rated Frequency 50Hz ± 3%

k. System neutral earthing Solidly earthed

l. System fault level (KA) 9.0 kA (1 sec.) at for SV stations

m. Degree of protection : Minimum IP-23

n. Insulation class Class F (Alternatively Class-H insulation with temp. rise

limited to Cl-F is also acceptable)o. Temp Rise limited to Class B

p. Maximum TransientReactance (Xd‘)

As per IS:13364

7.2 Technical Particulars

a. Type of excitation system. Brushless

b. Excitation support by PMG Required / Not Required

c. Type of cooling. Air cooled / Water Cooled

d. Short time parallel operation (remark-1) Required / Not Requirede. Continuous parallel operation (remark-1) With state grid /with other Generators / both

f. Permissible voltage drop (remark-2) 2%

g. Black start facility. Required / Not Required

h. Generator start-up time <30 seconds

Remarks :-

In case of short time parallel operation for load transfer, AVR may not be provided with excitationcurrent limiter. However, in case of continuous parallel operation with load sharing, AVR shall beprovided with excitation current limiter. The relays for sensing grid disturbances and timely isolating thedistribution system from grid shall be provided by purchaser in this case.

7.3 Termination Details

a. Generator line side Bus-duct/cable

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7.5 C.T.s /P.T.s : Required (as per table given below) /Not required.

Current transformer for protection CT/PT for AVR

P- CT D- CT R- CT N- CT AVR CT AVR PT

Requirement Yes/No Yes/No Yes/No Yes/No Yes Yes

Ratio

Class 5P10 PS PS 5P10 Cl 1

Burden 15 VA 10 VA 10 VA 10VA

Function protection differential REF

earth

fault regulation regulation Vk/Rct 1 2 3 4

Location

Protection CTs shall be physically located inside the terminal box / cubicle as given below:-

1. P-CT : CT for Over Current and Short Circuit Protection , to be located just beforethe star point (neutral formation point).

2. D-CT: CT for Differential protection to be located just before the star point

(neutral formation point).3. R-CT: CT for restricted earth fault protection in Neutral, to be located betweenstar point and the neutral tee off point.

4. N-CT: CT for earth fault protection in Neutral , to be located between earthconnection and the neutral tee off point .

(Neutral tee off point is the tapping for earth connection provided in the neutral conductor / lead)

7.4 Protection Relays / Metering :

Type Required Type Required

Voltage restrained O/C relay Yes / No P.T fuse failure relay Yes / No

O/V relay with time delay Yes / NoSynchroscope & cut-off switch

Yes / No

Stand by earth fault relay Yes / No Ammeter with selector

Yes / No

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7 Auto/Manual selector switch for regulation Yes / No Yes / No

8 Local/remote switches Yes / No Yes / No

9 Annunciation windows Yes / No Yes / No

10 Annunciation accept/reset P.B Yes / No Yes / No

$$ Frequency increase/decrease from remote control panel shall be achievable bychangeover of contacts (push button type). Vendor to ensure governor suitability for thistype of control.

7.6 Indication & alarm :- As per vendor’s standard

S. No Function LCP RCP (*)

1 Load on mains/generator Yes / No No

2 Gen C.B (open/close/trip) Yes / No No

3 Control supply failure Yes / No No

4 Winding temp high Yes / No No

5 Bearing temp high Yes / No No6 Start Failure Yes / No No

7 P.T. fuse failure Yes / No No

8 DG ready to start (#) Yes / No No

(#) DG ready to start indication shall be active only after all auxiliaries of DG set (i.e. lubeoil pump, other auxiliary motors, etc.) are in ready/healthy condition.

Notes :1. Unless otherwise specified remote control panel shall be in purchaser’s scope of supply.

Emergency generator vendor shall provide necessary facility enabling the above

mentioned control/monitoring functions to be transferred to the remote control panels bycables.

8 TESTING AT WORKS

8.18.1 Witness of Generator Control Panel functionalrequirements by simulation

Yes/No

8.2Witness of routine test as per IS:4722, wave formtest , vibration test of alternator

Yes/No

8.3 Special tests

Transient voltage performance with Job AVR and Shop Drivera) By 100 % Load Rejection at 1 pf Yes / No

b) By 100 % Load Application at 0.2 pf Yes/ No

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Part-3 Technical Data from Alternator Manufacturers9.1 Rating & performance details:

a. Make :

b. Temp inside acoustic enclosure : _______ oC higher than designambient

c. Frame designation :

d. Rated output : KVA

e. Terminal voltage : KV

f. Enclosure :

g. Rated P.F. : Lag

h. Phase/connection/no. of terminals :

i. Full load current : Amps

j. Speed : RPM

k. Rated frequency : Hz

l. Cooling system :

m. Max permissible inductive loading :

n. Steady state 3-phase S.C. currents :o. 3-phase S.C. withstand time :

p. Type of voltage regulator :

q. Insulation class :

r. Max. permissible impact load :

s. Temperature rise at full load :

Efficiency % 25% Load 50% Load 75% Load 100% Load

Rated P.F.Unity P.F.

9.2 Reactances (Mfr. to indicate tolerances)

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9.4 Local control panel

a. Make :

b. Dimension : mm

c. Type :

d. Degree of protection IP.

e. Weight :

f. Colour shade : 631 as per IS

9.5 Remote control panel

a. Dimension :b. Weight :

c. Degree of protection : IP-

9.6 Miscellaneous data

a. Alternator dimension (LxWxH) :

b. Stator weight :

c. Rotor weight :

d. Total weight :

e. Coupling : Direct / Through gear Box

9.7 Auxillary Motors

a. Make :

b. Voltage/Freqency : 415 V,3 - phase , 50 Hz

c. Enclosure protection : IP- 55

d. Insulation class : 'B'

e. Starting : DOL

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9.8.2 Battery charger

a. Make :

b. Model :

c. Input voltage :

d. Float voltage range :

e. Boost voltage range :

f. Float charge current :

g. Boost charge current :

h. Overall dimension LxWxH :..

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DATA SHEET FIRE ALARM SYSTEM


PIPELINE

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FIRE ALARM SYSTEMDATA SHEET

Part 2

(To to be filled in by the vendor)

1 Make, type and model no. of following items

Make Type / Model No Dimensions

1.1 Heat detectors

1.1.1 (safe area) :

1.1.2 (hazardous area)

1.2 Ionisation type smoke detectors

1.2.1 (safe area)


1.3 Photoelectric type detectors

1.3.1 (safe area)


1.4 Linear beam smoke detectors

1.4.1 1 (safe area)

1.5 Manual break glass boxes

1.5.1 (safe area)


1.6 Ultra-violet flame detectors

1.7 I/R detectors

1.8 Heat sensing cables

1.8.1 Detector unit for heat sensingcables

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2 Conventional fire alarm system

2.1 Central fire alarm panel

a. Make & model no. ::

b. No. of zones

c. Operating voltage & power consumption :

d. Ingress protection IPe.

e. Dimensions (L x D x H) mm

f. Mimic GIntegral/Non-integral

g. LED size

h. LEDs arrangement : As graphic mimic of plant/unit

i. LEDs arrangement basis Zone Wise/ Unit wise/ orDetector/Manual call point wise

2.2 Siren

a. Siren :Required/ Not required

b. Output KW/ db at 1 meter

c. Voltage/ phase/ frequency (AC)

DC

V/ Phase/

Hz

V

d. Starter for siren(IP-55) : Required/ Not required

2.3 Mimic panel(if non-integral)

a. Make & model no. :

b. Operating voltage :

G l /G ll

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2.5 Repeat alarm panel


b. Operating voltage & power consumption:

c. Mounting : GWall mounting

d. Dimensions (L x D x H) mm :

e. LEDs arranged in a matrix :

f. LEDs arranged on graphic mimic :

3 Computer aided fire alarm system

3.1 Central fire alarm panel (CFAP)

a. Make & Model no. :

b. Memory capacity :

c. No of inputs :

d. No of programmable outputs :

e. Scanning speed :

f. Operating voltage & power consumption :

g. Software used :

h. Processor redundancy (Refer clause5.3.1.28 of spec. S-07-02-024:

100%

i Ingress protection : IP

j. Dimensions (L x D x H) mm

3.2 Video display unit (VDU)


b. Locations :

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3.4 Data gathering cum fire alarm panel (DGFAP)


b. Type of panel :

c. Max. and min. number of loops :

d. Max number of devices in each analogue loop :

e. Event history storage processing :

f. Number of programmable outputs :

g. Scan frequency for devices :

h. Operating voltage & power consumption :

i. Communication protocol :

j. Ingress protection : IPk.

k. Dimensions (L x D x H) mm

3.5 Repeat alarm panel


b. Operating voltage & power consumption :

c. Display :

d. Ingress protection : IPe.

e. Dimensions (L x D x H) mm

4 Battery bank & charger details

4.1 Battery DGFAP CFAP Zonal panel

a. Makeb. Type/model no.

c AH Rating :

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5 Power requirements

a. DGFAP (Watts)

b. Zonal fire alarm panel(Watts)

c. The total fire alarm system (Watts):

6 Cables

6.1 Recommended cable / wire size & type

a. Between DGFAP & detectors, manual callpoints :

b. Between Zonal panel & detectors, manual call

points :

6.2 Recommended cable size & type :

a. Between CFAP & DGFAP :

b. Between CFAP & Zonal panel :

c. Between CFAP & repeat alarm panel :

d. Between DGFAP & repeat alarm panel:

e. Between zonal panel & repeat alarm panel :

6.3 Cable resistance(Max. Per loop) : S/km

6.4 Cable capacitance(Max. Per loop) : nF/km

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DATA SHEET FOR LIGHTING FIXTURES


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FIXTURE

TYPEDESCRIPTION WATTAGE

MANUFACTURERE TYPE

DESIGNATION

ND1Mounting rail type fixture suitable for 1 x 36 Wfluorescent lamp made of stove enamel finish MS

sheet steel housing.

1x36 WPhilips-TMC 50 1/136Crompton-IGP13 14HSB

Bajaj-BJIR-136, 140

ND2Similar to IND1 but suitable for 2x36W fluorescentlamps.

2x36 WPhilips-TMC 50 1/236Crompton-IGP 1 3-24H5BBajaj-BJIR-236

ND3

Industrial type fixture suitable for 1x36Wfluorescent lamp made of stove enamel finish MSsheet steel housing and vitreous enamelled whitereflector.

1x36 W

Philips-TKC 203/136Crompton-IGE- 1314/RSE14Bajaj-BJIV-136

ND4

Similar to IND3 but suitable for 2x36W fluorescent

lamps. 2x36 W

Philips-TKC-203/236,

Crompton-IGE 1324/ R5E24Bajaj BJIV-236

ND5Similar to ND3 but with white epoxy powder coatedfrom inside and outside with reflector.

1x36 W

Philips-TKC-203/136Crompton-IGP- 1314

/RPC14Bajaj BJIE-136

ND6Similar to IND5 but suitable for 2x36W fluorescentlamps.

2x36 WPhilips-TKC-203/236Crompton-IGP 1324 /RPC24Bajaj BJIE-236

SFD3Pendent mounting decorative fixture suitable for1x36W fluorescent lamp with opal acrylic cover 1x36 W

Philips TCS-19/136Crompton-CPA 1114 HSB

SFD4

Ceiling/pendant mounting fixture suitable for 2x36W fluorescent lamps with opal acrylic translucentdiffuser and high import black polystyrene endplates.

2x36 WPhilips-TCS- 19/23 6Crompton-CPA 1124 HSBBajaj BJP-236

SFD5Ceiling/pendent mounting decorative fixture suitablefor 2x36W fluorescent lamps with serrated Al. cross

louvres.

2x36 WPhilips TCX-398 / 236Bajaj BJSM-02236

Crompton CMLM 24HITW

SFD6

Wide spread decorative ceiling/pendent mounting

fixture made of white stove enamelled sheet steelhousing and aluminum mirror optic system toachieve wide light distribution and having a serrated

2x36 WPhilips TCS-306/236Bajaj-BJPMS-236,Crompton CSBW 1124 HSB

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FIXTURE


MANUFACTURERE TYPE

DESIGNATION

SFD15

Widespread minor optics ceiling mounted luminaries

with high purity aluminum reflector and serrated Al.cross louvers suitable for 2x36 W compactfluorescent lamps.

2x36 W Bajaj BLSM 236 CFLP2Crompton CRDI 236

SFD16Widespread minor optics decorative ceiling/pendentluminaries suitable for 1x36 W fluorescent lamps.

1x36 WPhilips TCS 498/136Bajaj BJPMS 136

RSD1

Wide spread, mirror optics decorative recessmounting fixture for use in areas with strip falseceiling having a reflector made of high purityaluminum sheet and fined with serrated Al. cross

louvres, suitable for 1x36 W fluorescent lamp.

1x36 WPhilips TBS-185/136Bajaj BJMM-136Crompton CRFA- 1 4HSB

RSD2

Wide spread mirror optics decorative recessmounting fixture having a reflector made of highpurity aluminum sheet and fined with senated Al.cross louvres across the minor system for

minimizing glare, suitable for 2x36 W fluorescentlamp.

2x36 WPhilips TB S-90Bajaj BJLM-236Crompton CRFD-24H5B

RSD6

Recess mounting luminaries with minor system

housing and dispersive anodised aluminum reflector

for use in areas with strip false ceiling type suitablefor 2x36W fluorescent lamp.

2x36 W

Philips TBS 285/236(DL)

Darklite

Crompton CRFD 24H5BBajaj BJDL 236

RSD7 Same as above but with 4x18 W fluorescent lamp. 4X18WPhilips TBS 300/418M1Crompton CRFL 42H5BBajaj BJDL 418

RSD9Recess mounting decorative fixture suitable for 4x18 W fluorescent lamp with dished opal acrylic cover.

4x18 WPhilips TBC-305/418(0)Crompton CRP 42HITWBajaj BJMP 420

RSD10Recess mounting down-lighter fixture with 60/100W

incandescent lamp.

1x60 W/

1x100 W

Philips DN 622Crompton DDLV 10BC

Bajaj BJDR 100

RSD12 Same as RSD6 but for single 36 W fluorescent lamp. 1x36 WBajaj BJDL 136Philips TBS 185/136 (DL)

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FIXTURETYPE

DESCRIPTION WATTAGEMANUFACTURERE TYPE

DESIGNATION

HB2 Similar to HB1 but with 400 W HPMV lamp. 1x400 W

Philips HDK225HPL400

Crompton TMB 1 34OTHIPBajaj BJHBT-400

HB3 Similar to HB1 but with a gasketed front glass cover. 1x250 WPhilips HDK-103/250WCrompton THS-1225TH1PBajaj BJHBT-250MV

HB4 Similar to HB2 but with a gasketed front glass cover. 1x400 WPhilips HDK-103/400Bajaj BJHBT-400MV/TECrompton THS- 124OTHIP

HB5 Similar to HB1 but with 150W SON lamp. 1x150 W

Philips SDK-100

Bajaj BJMBT-150Crompton SHS-1215 TH

HB6 Similar to HB1 but with 250W SON lamp. 1x250 WPhilips SDK-100/250Bajaj BJHB-250Crompton SHS- 1225TH

HB7 Similar to HB1 but with 400 W SON lamp. 1x400 WPhilips SDK-100/400Bajaj BJHBT-400 SVCrompton SHS- 1240TH

CM2

Chemical resistance fixture suitable for 2x36 W

fluorescent lamp. 2x36 W

Philips TMX-95/236

Crompton IFV-24H/TWBajaj BJI-236 VP

CM3

Similar to CM2 but suitable for 2xlSW fluorescentlamps with reeded light stabilized clear acrylic cover(for use in indoor areas with high humidity andcorrosive vapours).

2x18 WPhilips TDC-10/218Bajaj BJI-218FG

CM4 Similar to CM3 but with 2x36W fluorescent lamps. 2x36 WPhilips TDC-10/236Crompton IFC-1124H SBBajaj BJI-236FG

CM5

Ceiling/pendent mounting drip proof and dust tightfixture suitable for 2x36 W fluorescent lamps withaluminum housing, stove enamelled grey outsideand white inside with gasketed clear acrylic cover.

2x36 WPhilips TPW-1 1/236Crompton IDJ-24HITWBajaj BJI-236

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FIXTURE


MANUFACTURERE TYPE

DESIGNATION

CFL 4(with DC

choke)

Similar to CFL4 but with built in D.C. choke 2x1 1 WContractor to select subjectto approval of GAIL

Engineer-in-Charge

CFL5Decorative wall/ceiling mounted luminaries with opalacrylic cover suitable for 2x9W CFL.

2x9 WCrompton TLK 29Bajaj BJDS 29

CFL6Similar to CFL5 but in horizontal version suitable for2x9W CFL.

2x9 W Crompton DDLH29

CFL7 Similar to CFL6 but in round shaped. 2x9 WCrompton TLJ29Bajaj BJDR29

OUTDOOR TYPE FIXTURES

ST1

Street lighting fixture suitable for 2x36W

fluorescent lamps made of stove enamelled greyaluminum canopy and acrylic transparent cover.

2x36 W

Philips TRC-34/236

Crompton SFE-24H/TWBajaj BJSLA-236/240

ST2Similar to ST1 but suitable for 2x18W fluorescentlamp.

2x18 WPhilips TRC-33/220Bajaj BJSLA 220

ST3

Street lighting fixture suitable for 125W HPMV lampwith cast aluminum housing stove enamelled greyoutside and white inside, a pair of anodised

aluminum reflectors and highly transparent clearacrylic sheet cover with hinge and toggle fastening,neoprene gaskets and integrated pre-wired ballastsetc.

1x125 WCrompton MSC-1 112 IH

Bajaj BJMSD-125MVPhilips HRP-48

ST4 Similar to 5T3 but suitable for 250W HPMV lamp. 1x250 WCrompton MSNR1 125THBajaj BJMIP-250MV

ST7Similar to 5T3 but suitable for 35 W SOX lowpressure sodium vapour lamp.

1x35 WPhilips XRP-5 1/35Bajaj BJLS-35

ST8 Similar to 5T3 but suitable for 70W HPSV lamp. 1x70 WPhilips SRP-48Crompton SSC-1 107 IHIWIBajaj BJMSC-705V

ST9

Similar to ST1O but suitable for 70W HPSV tubular

lamp. 1x70 W

Crompton SSG-1407 TH/WT

Bajaj BJMSC-705V

ST1OSingle piece die-cast aluminum body street lightfixture with bowl type Al. reflector and with clear lxlSO W

Philips SRP 51Bajaj BGEST 150

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FIXTURE


MANUFACTURERE TYPE

DESIGNATION

BK1

Bulk head fitting with cast aluminum alloy body

having stove enamelled finish (silver grey outside,white inside) and complete with prismatic frontglass, wire guard, tropicalised gasket and BC lamp

holder suitable for 100W GLS lamp.

1x100 WCrompton IBH-1110BCBajaj BJDB-100

BK2

Similar to BK1 but with pressed aluminum body,finished stove enamelled grey outside white inside

with frosted front glass fitted with tropicalisedgasket and without wire guard.

lx 100 WPhilips-NXC-1 1Crompton IBH-111OBC

BK3

Industrial well glass fixture with cast aluminum

alloy mounting piece and a sheet aluminum canopystove enamelled white inside and grey outside withheat resistant glass and wire guard suitable forupto 200W GLS/160 W MLL.

lx 100 WPhilips NDC-22Crompton 1WV- 1 12OBC/ESBajaj BJVW 200

BK4Similar to BK3 but suitable for 125 W HPMV lampwith necessary control gear and housingattachment.

1x125 W

Philips NDC-22Crompton 1WV-121OBC/ES/VEBajaj VWI 125 MV

BK5Similar to BK3 but with additional vitreous

enamelled reflector.lx 100 W

Philips NDC-22Crompton IWV 2OBL/Y Bajaj VWI 125/VE

FD1

Flood lighting fixture suitable for 250W HPMV lampcomprising of anodised aluminum housing andreflector with adjustable lamp holder, heat resistantfront glass cover fixed to reflector by aluminumring and rubber gasket. (IP-54 enclosure).

1x250 WBajaj BJEF-18(S)Philips HVF 12Crompton FMD 14

FD2 Similar to FD1 but suitable for 400W HPMV lamp. 1x400 WPhilips HVF 12Bajaj BJEF-18 (5)Crompton FBD14

FD4

Flood lighting fixture suitable for 2x400W HPMVlamps made of cast aluminum with cooling fins,anodised reflector gasketed heat resisting glass

2x400 WPhilips MNT-00 1Crompton FHD 1224

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FIXTURE


MANUFACTURERE TYPE

DESIGNATION

FD12 Similar to FD6 but suitable for ix400W SON tubularlamp. 1x400 W

Philips SNT-14

Bajaj BJEF-14CATCrompton FAD-i 114

FD13 Similar to FD6 but suitable for 2x250W HPMV lamp. 2x250 WPhilips SNT-00iBajaj BJEF-22CA/ BGENF 22Crompton FHD- 12/24

FD14

Integrated flood lighting fixture of die-castaluminum housing with ALGLAS reflector, heatresistant toughened clear glass cover suitable for150 W HPSV lamp.

1x150 W Bajaj BGEMF 1505 V

AV1Neon aviation obstruction lighting fixture completewith neon lamp, designed to give omni directionalsteady ‘ON’ red colour light.

1x100 W Bajaj BJAOL-i

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FLAMEPROOF/INCREASED SAFETY TYPELIGHTING FIXTURE (ZONE-i AND ii)

FLP-1

Flameproof and weatherproof well glass lighting fixture for use in zone-i

classified areas with 100/200W incandescent lamp.

1x 100 W

/ 1x200WFLP-2 Same as FLP-i but with 160W ML blended lamp. 1x 160 W

FLP-3 Same as FLP-i but with SOW HPMV lamp and separate control gear. 1x80 W

FLP-3a Same as FLP-3 but with integral control gear. 1x80 W

FLP-4 Same as FLP-i but with 125W HPMV lamp and separate control gear. 1x125 W

FLP-4a Same as FLP-4 but with integral control gear. 1x125 W

FLP-5 Same as FLP-i with 250W HPMV lamp and separate control gear 1x250 W

FLP-5a Same as FLP5 but with integral control gear. 1x250 W

FLP-6

Flameproof and weatherproof flood lighting fixture with 500W

incandescent lamp. 1x500 WFLP-7 Same as FLP-6 but with 250W HPMV lamp. 1x250 W

FLP-8 Flameproof bulk head lighting fixture with 100W incandescent lamp. lx 100 W

FLP-9 Same as FLP6 but with 400 W HPMV lamp. 1x400 W

FLP-10Flameproof and weatherproof fluorescent lamp fixture suitable 2x36/40Wfluorescent lamps with integrated choke box housing mounting clamps etc.

2x36/40W

FLP-11 Same as FLP-10 but for 2x20W fluorescent lamps. 2x20 W

Exe-1Weatherproof well glass increased safety lighting fixture for use in zone-2classified areas with 100/200W incandescent lamp.

Lx100 W

Exe-2 Same as Exe-1 but with 160W blended lamp. lx 160 WExe-3 Same as Exe-1 but with 80W HPMV lamp and separate control gear. 1x80 W

Exe-3a Same as Exe-3 but with integral control gear. 1x80 W

Exe-4 Same as Exe-1 but with 125 W HPMV lamp and separate control gear. 1x125 W


Exe-5 Same as Exe-1 but with 250 W HPMV lamp and separate control gear. 1x250 W


Exe-6Increased safety & WP Well glass lighting fixture for use in zone-2classified areas with 400 W HPMV lamp.

1x400 W

FLP IIC-i Flameproof & WP Well glass lighting fixture with 200 W incandescent lampfor use in TIC classified areas.

1x200 W

FLP IIC 2Flameproof & WP Well glass lighting fixture with 80 W HPMV lamp for use

1x80 W

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DATA SHEET FOR AC/DC SWITCHBOARD


PIPELINE

DATA SHEET FOR 24V DC SWITCHBOARD

PART I (TO BE FURNISHED BY PURCHASER)

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PART-I (TO BE FURNISHED BY PURCHASER)

1.0 SITE CONDITIONS:1.1 Design Temp 40°C

1.2 Relative humidity Highly humid

1.3 Altitude above MSL Less than 1000 m

1.4 Location Various

1.5 Atmosphere : Highly corrosive and dusty as applicable forrefineries

2.0 OPERATING CONDITIONS:2.1 Voltage 415 V AC / 24 V DC

2.2 Frequency 50 Hz ± 3% (applicable for AC switchboards)

2.3 No of phases 3 (applicable for AC switchboards)

2.4 System fault level : Min.25kA for 415 V AC & Min. 10 kA for DC switchboards(However DC Switchboards shall be suitable for

withstandingfault level/current as applicable for short circuit

contribution of

Ni-Cd batteries at a particular location)

2.5 System earthing Solidly earthed for AC & Floating for DC

2.6 Auxiliary supply -

2.7 Power supply forspring charging motor N.A.

3.0 ELECTRICAL DATA:3.1 Short circuit withstand3 2 capacity for 1 sec Min 25kA for 415 V AC & Min 10 kA for DC switchboards

3.7 Type of Circuit breaker Not applicable

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3.8 Duty cycle of breaker Not applicable

3.9 Incoming power entry Cable as per data sheets

3.10 Cable entry (I/C & O/G) Bottom

3.11 Bus duct entry Not applicable

3.12 Cable gland/lugs Included

3.13 Colour shade Exterior As per IS-5

3.14 Feeder arrangement Single front, fixed type suitable for flush mounting againstwall with front access, front maintenance only and withoutrear access. Contractor shall ensure that equipmentsupplied can be located in available space. For incomingand outgoing feeder details, refer SLDs

3.15 Minimum motor starter module size Vendor standard

3.16 Minimum switchfuse module size Vendor standard

3.17 Floor fixing Integral base frame and tack welding to thefloor channel

4.0 MAKE OF EQUIPMENTS/COMPONENTSRefer Annexure-I enclosed with Job specification (Electrical) document no. 0001-01-07-02-001 orelsewhere.

PART-II

(TO BE FILLED UP BY VENDOR ALONG WITH QUOTATION)

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(TO BE FILLED UP BY VENDOR ALONG WITH QUOTATION)

415 V AC / 24V DC Switchboard1.0 Make :

2.0 Type / designation :

3.0 Degree of protection :

4.0 Overall weight of CB panel

Incomer kg

Outgoing kg

5.1 Overall dimensions of CB panel

Length : mm

Depth : mm

Height : mm

NOTE: Vendor shall furnish the dimensions of various types/ratings of CB panels separately.

5.2 Overall dimensions of MCC/contactor controlled feeder panel:

Length : mm

Depth : mm

Height : mm

6.1 Overall dimensions of each switchboard:

PCC (Length*Depth*Height) : mm

PMCC (Length*Depth*Height) : mm

Front : mm

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Rear : mm

Above : mm

8.0 Shock loading on foundation :

9.0 Max size/no of PVC-insulated Al cond (AYFY)

cables that can be terminated inside the panel

with rear extension/ without rear extension :

10.0 Clearance in air

Phase to phase : mm

Phase to earth : mm

11.0 Main horizontal bus bar

11.1 Busbar current rating at design ambient (40 °C) : A

11.2 Main bus bar size :

11.3 Main bus bar material : Al/Cu

11.4 Main bus bar location : Top/Bottom

12.0 Vertical bus bars

12.1 Busbar current rating at design ambient (40 °C) : A

12.2 Bus bar size :

12.3 Bus bar material : Al/Cu

21.0 CIRCUIT BREAKER ( Following data for each rating of breaker)

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21.1 Make :

21.2 Type designation :

21.3 No of poles/phase :

21.4 Nominal current rating (in free air) : A at °C

21.5 In panel current rating at site conditions : A

21.6 Breaking capacity : kA

21.7 Short time rating (1 sec) : kA

21.8 Peak making current : kA (peak)

21.9 1 min dry withstand volt (power frequency) :

21.10 Duty cycle :

21.11 Total opening time : m sec

21.12 Total closing time : m sec

21.13 Power required for opening : W/VA

21.14 Power required for closing : W/VA

21.15 Power required for spring charging motor : W/VA

21.16 Breaker is trip free : Yes

21.17 Closing mechanism :

21.18 Provision of manual spring charging : Yes

22.0 CONTACTOR ( Following data for each rating of contactor)

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22.1 Make :

22.2 Type designation : __________

22.3 Rated voltage : __________

22.4 Rated current __________

AC-3 Duty : __________

AC-4 Duty : __________

22.5 Thermal rating : __________

22.6 Making capacity : __________

22.7 Breaking capacity : __________

22.8 Switching frequency : ops/hr __________

22.9 Life Electrical : _________ ops (at rated voltage)

Mechanical : ops

22.10 Coil consumption - Pick up : VA

22.11 Coil consumption - Hold on : VA

22.12 Closing time : secs

22.13 Opening time : secs

22.14 No of aux. contacts : NO + NC

22.15 Maximum permitted back up fuse rating :

24.0 THERMAL OVERLOAD RELAY ( Following data for each type of relay)

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24.1 Make : __________

24.2 Type : __________

24.3 Setting range : __________

24.4 Single phasing preventor : Intergral / Separate

24.5 Type of operation : Direct / CT operated

24.6 Maximum permitted back up fuse rating : __________

25.0 FUSES ( Following data for each rating of fuse)

25.1 Make : __________

25.2 Type : __________

25.3 Current rating __________

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DATASHEET FOR SOLAR ELECTRIC

POWER SYSTEM (ELECTRICAL)

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1 Solar System

1.1 Type Photovoltaic

1.2 Application Telecom; scada; lighting and other electrical loads

1.3 Load Voltage 24 V DC +4%, -0.0%; 2 Wire

1.4 Ripple Output 20 mV

1.5 Daily Load Demand As per Load Analysis Document No. 0001-01-07-08-001

1.6 System Earthing Floating

1.7 Battery Backup Required Yes

1.8 Type Of Alternative Energy Source Available Grid Power

1.9 Location (Solar Panels) Unclassified Area

1.10 Wind Velocity (Max.) Refer Elsewhere

1.11 Latitude Refer Elsewhere

1.12 Longitude Refer Elsewhere

1.13 Ambient Temp Refer Elsewhere

1.14 Insolation Data Refer Specification 0001-01-07-02-005

1.15 Expected Life Span 25 years for all components

2.0 Solar Panel

2.1 Module Output Watts Peak

2.2 No. Of “NO SUN DAYS” Battery Backup Required 03 Days

Load To Be Disconnected If Battery State Of

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1.14 No. Of Solar Cells Per Module

2.15 Solar Cell Manufacturer’s Type Ref. No.

2.16 Make Of Solar Modules

2.17 Country Of Origin

2.18 Weight Of Solar Module

2.19Max. Temperature Rise Of Solar Cells UnderSevere Working Condition Over Max. Ambient

Temperature

2.20 Nominal Voltage Of Solar Array

2.21 Annual Deficit Of Capacity (Ah) From Solar Array

2.22 Weight Of Solar Array

2.23 Dimension Of Solar Array

2.24 Material Of Solar Array Junction Box

2.25 Degree Of Protection Of Solar Array JB

2.26 No. Of Solar Panels

3.0 Solar Controller Panel

3.1 Type

3.2 Enclosure Degree Of Protection IP-51

3.3 Dimensions ______ mm( L) x _____ mm (W) x _____ mm (H)

3.4 Weight

3.5 Mounting Floor mounted

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4.0 4.0 Battery Bank

4.1 Application Solar power system application

4.2 Type Ni-Cd

4.3 Make

4.4 Country Of Origin

4.5 Model No.

4.6 Battery Self Discharge

4.7 Location/Installation Battery room

4.8 Site/Environment Conditions

4.9 Nominal Voltage 1.2 V/CELL

4.10 End Cell Voltage At 70% & 100% Dod

4.11 No. Of Cells

4.12 Rating In Ah (C10)

4.134.13 Recommended Value Of Float/Boost charge

Voltage

4.14Recommended Value Of Float/Boost Charge

Current

4.15

Recommended Mounting Arrangement With

Minimum/Statutory Clearances Required BetweenRacks/Stacks & All Round Clearances In TheBattery Room

4.16 Internal Resistance Of Each Cell

4 17 Short Circuit Current Of Battery Bank

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5.5 No. Of Rows/Stack

5.6 Dimensions _____ mm (L) x _____ mm (W) x _____ mm (H)

5.7 Weight (Rack/Stack)

5.8Total Weight Of The Battery (Including BatteryRack/Stack & Batteries)

5.9 Material Of Enclosure Of Battery Rack/Stack

5.10 Inter-Row/Inter-Cell Connectors

A Number

B Material

6.0 Miscellaneous Materials

6.1 Cable Size/ Type

A On Solar Module

B Solar Module To Array Jb/Main Jb

C Main Jb To Solar Controller Panel

D Battery To Solar Controller Panel

E Interconnecting Cable Conductor Material

F Make Of Interconnecting Solar Panel Cable

GWhether Interconnecting Cable Between Solar

Array/Module Panel & Main JB YES

6.2 Cable Gland TypeDouble compression

Nickel/chromium plated brass6.3 Cable Gland Quantity

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DATA SHEET FOR UPS SYSTEM



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PART -I

PURCHASER'S DATA

RATING AND JOB REQUIREMENTS

1 INPUT POWER SUPPLY

1.1 Voltage/freq./phases : 415 V± 10%, 50 Hz ± 3%, 3 Ph

1.2 System fault level : 25kA(1 sec.)

2 SITE CONDITIONS

2.1 Design ambient temperature 40oC

Min. ambient for battery sizing 10oC

2.2 Max. relative humidity Highly Humid

2.3 Altitude above MSL Less than 1000 m

3 SYSTEM REQUIREMENTS

3.1 Type of inverter Transistorised

3.2 Rating (KVA at 0.8 pf) 10kVA

3.3 No. of phases 1 Phase (Ph-N)

Output Voltage 230V±1%(Ungrounded)

Output frequency 50Hz ± 1%

3.4 Mode of operation `Parallel Redundant with bypass transformer

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4 ACDB

For incoming and outgoing feeder details of UPS ACDB, refer Single linediagram attached with the tender document.

Item No.Incomer Rating

No.Of OutgoingFeeders

KVARating Of Feeder

SwitchRating

FuseRating

5SPECIFIC REQUIREMENTS

5.1 All interconnecting cables (including associated cable glands and lugs) between allpanels of UPS system are included in vendor’s scope.

5.2 ACDB shall be suitable for flush mounting with front access, front maintenencetype only and without any rear access.

5.3 LED shall be provided instead of conventional indicating lamps.

5.4 Owner’s Interface

Normally closed (NC) potential-free contacts shall be wired upto terminal strip for

connection by purchaser, for the following conditions:a) UPS MOD-1 Trouble

b) UPS MOD 2 T bl

PART II

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PART - II

TECHNICAL DATA FROM MANUFACTURERS

1 UPS SYSTEM

1.1 Make

1.2 Type designation

1.3 Rating (KVA at 0.8 p.f.)

1.4 Mode of operation

1.5 Dynamic Response under following conditions

a) For 50% step load

b) For 100% step load and unload

c) Power supply interruption and restoration:

d) Load Transferred to bypass line

e) When one inverter gets faulty and load

transferred to healthy inverter 1.6

Maximum recovery time to reach steady state after abovedisturbance

1.7 Type of cooling/Redundancy in cooling system

1.8 Degree of ingress protection of panels

1.9 Noise level

1.10 Colour shade

1.11Efficiency of each rectifier and inverter module includinginput and output transformer

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1.13

Overall efficiency of UPS system( ratio of output load toinput power drawn from mains when all charger andinverters are on and Synchronized with bypass operating

at no load)a) At 100% load

b) At 75% load

c) At 50% load

d) At no load

1.14 Cable entry :

1.15Guaranteed dimensions (LXDXH) of UPS :system except ACDB and Battery

1.16 Heat loss for the total system (KW) :

2 INVERTER

2.1 Rating (at specified ambient)/No. of phases :

2.2Steady state output voltage (Nominal/Variation) : Steadystate output frequency (Nominal / Variation)

2.3 Output voltage adjustment range at rated load :2.4 Input voltage DC (Nominal/Range) :

2.5Frequency variation limit for inverter :phase locked withmain

2.6 Allowable unbalance between phases (for 3 phase only):

2.7 Harmonic distortion at inverter output at rated load

a) For linear load

b) For nonlinear load

2.8 Overloading capacity and duration

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3 STATIC SWITCHES

3.1 3.1 No. of static switches in each UPS system

3.23.2 Current rating at specified ambient (continuous / shorttime) :

3.3 Type of static switch :

3.4 Transfer time

a) Synchronised mode

b) Unsynchronised mode

4 BATTERY CHARGER

4.1 Current Rating

4.2 Type of Charger

4.3 Output voltage under float/rapid charging condition

4.4 Output Voltage accuracy under specified input

4.5Maximum ripple content on DC side with battery

:connected/disconnected4.6 Maximum harmonic content in input current

4.7 Input transformer rating

5 MANUAL TRANSFER DEVICES

5.1 Make/Type designation

5.2 Rating (continuous/short time)

6 BATTERY

6.1 Make :

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6.10 Rapid charging time

6.11Overall rack dimensions, no. of racks and tiers withclearances :

6.12 Container type

6.13 No. of recommended air changes/hour for battery room

7STEP DOWN BYPASS TRANSFORMER WITH SOLID

STATE VOLTAGE STABILIZER

7.1 Make/Type designation

7.2 Rating and voltage ratio

7.3 Accuracy of Stabilizer 7.4 Type of Control

7.5 Type of Cooling

7.6 Type of Stabilizer

8 AC DISTRIBUTION BOARD

8.1 Make /Type designation

8.2 Rating of board

8.3 No. of outgoing feeders/rating of each

8.4 Overall dimensions(LXDXH)

8.5 Maximum & minimum operating height

9 CELL BOOSTER

9.1 Make/ Type designation9.2 Voltage range

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SPECIFICATION REV-0GAIL (INDIA) LTD

NEW DELHISINGLE LINE DIAGRAM FOR CGS

0001-01-07-01-001 Page 1 of 1


NOTES:1. 24 V SPV POWER SOURCE + 415/220V AC POWER SOURCE HAS BEEN

CONSIDERED.

2. 24 V SPV AND BATTERY CHARGER

IN PARALLELL OPERATION HAVEBEEN CONSIDERED.

3. ANY DC-DC CONVERSION WILL BE

IN THE SCOPE OF THESCADA/TE;ECOM VENDOR

4. SCADA/TELECOM EQUIPMENT

WILL BE SUPPLIED AND INSTALLED

BY THE OWNER.

5. AC DISTRIBUTION FOR LIGHTING,

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LOAD ANALYSIS DOCUMENT


PIPELINE

NOTES & ASSUMPTIONS:-

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NOTES & ASSUMPTIONS:-

1.0 FOR STATIONS AT Manesar, Dharuhera, Bhiwadi, Kushkhera andNeemrana.

(a) 24V power source Solar Panel configuration along with battery back-up for 72hours has been considered for meeting the power requirements at the unmannedstations.

(b) Lighting / ventilation / Air conditioning load for CGS has been considered and willbe fed by grid power supply.

(c) 24V DC(Floating) 1 no. feeder for Telecom and 1 no. feeder for SCADA shall beprovided at each location. Any DC-DC conversion as required shall be in respectiveTelecom/SCADA equipment to be supplied & installed by other vendors separately.

(d) The efficiency of dual redundant DC to DC converters to be provided inSCADA/Telecom equipment is assumed as 0.7 in power source sizing calculations.

(e) Loads considered are following:-On Power source with Battery Backup:-

- SCADA - Telecom- Instrumentstion

- Cathodic Protection- Fire Alarm & Detection & CO2 Flooding SystemOn Grid Power Supply:-

- Ex Fan BR

- Ex. Fan Elect Room

- Contr Building Lighting

- Contr Room A/C

- Area Ltg

(f) Boost charging requirement of batteries has not been considered in sizing of SPV.The battery charger connected to the grid power supply shall be used for boostcharging of the batteries.

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LOCATIONS

LOAD SultanpurKh & Man

ToPManesar Dharuhera Bhiwadi Kushkhera Neemrana

Load On Power Source With Battery BackupTelecom 0 0 150 150 150 250 250

Scada 0 0 130 130 130 130 130

Instt /PLC 0 0 200 200 200 200 200

Ex Fan BR 0 0 50 50 50 50 50

Ex Fan TC/SCADA Room

0 0 50 50 50 50 50

F A System 0 0 100 200 200 200 200

CP Syatem 100 100 100 100 100 100 100

Batt. Chg - - By ContractorTotal CriticalLoad

100 100780

Say 800W780

Say 800W780

Say 800W880

Say 900W880

Say 900W

Power SourcePower by

CJPLPower by

CJPL

Solar+Grid +

Battery

Solar+ Grid+ Battery

Solar+Grid +

Battery

Solar+ Grid +Battery

Solar+ Grid +Battery

Battery BackupTime

- - 72 Hrs 72 Hrs 72 Hrs 72 Hrs 72 hrs

Load on Grid Power

Light Contr Bldg 0 0 1000 1000 1000 1000 1000Contr Room A/C 0 0 3000 3000 3000 3000 3000

Area Ltg 0 0 2500 2500 2500 2500 2500

Battery Charger By Contractor

Watts Watts Watts Watts Watts Watts Watts

1. The above loads are indicative. Contractor to verify the adequacy at the design stage.2. Battery Capacity Required (Ah) for 72 hours backup AND a DESIGN MARGIN OF 10%3. SPV system to be sized for Critical loads + battery charging current

4. Battery charger connected to grid supply to be sized for critical loads + battery boost chargingcurrent5. Sizing of SPV system, Battery Bank, Battery charger and Grid Power supply to be done

b h

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SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR

PACKAGE EQUIPMENT

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ABBREVIATIONS:

BIS Bureau of Indian Standard.

CRCA Cold rolled cold annealed

DOL Direct on line starting

LED Light emitting diode

NO Normally open contact

NC Normally open contact

PVC Polyvinyl chloride

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CONTENTS

1.0 SCOPE


3.0 GENERAL REQUIREMENTS

4.0 SITE CONDITIONS

5.0 DESIGN AND FABRICATION REQUIREMENTS

6.0 EQUIPMENT SPECIFICATION

7.0 INSPECTION, TESTING AND ACCEPTANCE

8.0 PACKING AND DESPATCH

1.0 SCOPE

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1.0 SCOPE

This specification covers the requirement of design, fabrication, testing,packing and supply of Medium voltage fixed type switchboard in single frontexecution required for receipt, control and distribution of power to various

medium voltage consumers of the package equipment such as Airconditioning plant, Pressurisation plant, Air dryer plant etc


2.1 The equipment shall comply with the requirements of latest revision of following standards issued by BIS unless other wise specified.o IS 772 AC Electricity Meterso IS 248 Direct acting electrical indicating instrurhentso IS 2705 Current transformerso IS 2824 Method for determining the comparative tracking index of solid

insulating materials under moist conditionso IS 3156 Voltage transformerso IS 323 1 Electrical relays for power systems protection..o IS 3618 Phosphate treatment of iron and steel for protection against

corrosion.o

IS 5082 Material data for aluminium bus bars.o IS 5578 Guide for marking of insulated conductor.o IS 6005 Code of practice of Phosphating of iron and steel.o IS 8623 Factory built assemblies of switchgear and control gear for

voltages upto and including 1000 V AC and 1200 V C.Part -IIparticular requirements for busbar trunking systems (bus ways).

o IS 11353 Guide for uniform system marking and identification of conductors

and apparatus terminals.o IS 13703 Low voltage fuses.o IS 13947 LV Switchgear and control gear.(Part-1 to Part-5)

o Statutory regulations

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o Statutory regulationso Data sheetso Job specificationo This specificationo Codes and standards

3.0 GENERAL REQUIREMENTS3.1 The offered equipment shall be brand new with state of art technology and

proven field track record. No prototype equipment shall be offered.

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

3.3 Vendor shall give a notice of at least one-year to the end user of equipmentand GAIL before phasing out the product/spares to enable the end user forplacement of order for spares and services.

4.0 SITE CONDITIONS

4.1 The switchboards shall be suitable for installation and satisfactory operationin a pressurised substation or in substation with restricted natural airventilation in a tropical, humid and corrosive atmospheres. l’he switchboardsshall be designed to operate under specified site conditions. If not specificallymentioned a design ambient temperature of 400 C and altitude notexceeding 1000 metres above mean sea level shall be considered.

4.2 All the equipment described in this specification is intended for continuous

duty at the Specified ratings under the specified ambient conditions unlessindicated otherwise.

5.3 The switchgear shall be assembled out of vertical panels of uniform height

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5.3 The switchgear shall be assembled out of vertical panels of uniform heightnot exceeding 2450 mm. The maximum height of the operatinghandle/switches shall not exceed 1900 nmi and the minimum height notbelow 300 mm.

5.4 The switchboard shall be designed to ensure maximum safety duringoperation, inspection, and connection of cables, relocation of outgoingcircuits and maintenance with the energised bus bar system and withouttaking any special precautions. The switchgear shall permit maximuminterchangeability and shall be extensible on either side.

5.5 The switchboard shall be sheet steel clad with the frame fabricated out of 2mm cold rolled sheet steel and doorsi’covers out of 1.6mm cold rolled sheetsteel, having integral base frame for each vertical panel.

5.6 All hardware shall be corrosion resistant. All joints and connections of thepanel members shall be made of galvanised, zinc passivated or cadmiumplated high quality steel bolts, nuts and washers, secured against loosening.

5.7 All openings, covers and doors shall be provided with neoprene gasketsaround the perimeter to make the switchboard dust and vermin proof.Suitable lifting hooks shall be provided and each shipping section for ease of lifting of switchboard.

5.8 All metal surfaces shall be thoroughly cleaned, degreased to remove millscale, rust, grease and dirt. Fabricated structure shall be pickled and thenrinsed to remove any trace of acid. The under coat shall be prepared by

applying a coat of phosphate paint and a coat of yellow zinc chromateprimer. The switchboard shall be spray painted with two coats of final paintor powder coated. The final paint shade shall be as per manufacturer

be housed in independent compartments separated from each other by

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p p p ymetallic barrier.

5.11 Main horizontal bus bars shall be provided at the top in separate

compartment. Vertical bus bars required for connection between main busbars and outgoing feeders shall be in separate vertical chamber. One set of vertical bus bars can be provided for feeding outgoing feeders in two panelson either side of the vertical bus bar.

5.12 All components including bus bars and cable termination shall be accessibleonly from the front side for repair and maintenance.

5.13 Each outgoing feeder shall be in multitier arrangement having minimumheight of individual module as defined in switchboard data sheet. All feedersshall be of modular design with height in multiple of standard unit size.

5.14 Number and rating of feeders shall be as per package vendor’s electrical loadlist/single line diagram. The components rating and type for various types of outgoing feeders such as motor feeders shall be selected based on packagerequirement and shown in data sheets.

5.15 All auxiliary devices for control, indication, measurement and protectionexcept the bimetallic relays shall be mounted on the front side of therespective compartment. Components requiring frequent inspection duringoperation shall be easily accessible.

5.16 Each vertical panel shall be provided with anti condensation heater rated for

240 V AC supply, provided with a switch fuse and thermostat having variablesetting range of 30-70 °C. Adequate space shall be provided for terminationof incoming and outgoing cables.

requirements. Necessary tee-off connections shall be used for distributing

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q y gauxiliary supply to each vertical panel.

5.21 All horizontal and vertical bus bars shall be insulated with heat shrink PVC

sleeves of 1100 V grade and removable shrouds shall be provided for joints. All bus bars shall be prominently marked with Red, Yellow and Blue colourrings for easy phase identification at regular interval and at every power tapoff point and designed to withstand specified short circuit currents for onesecond.

5.22 Copper earth bus of 30x6 mm2 size for fault level upto 31.5 KA and 50x6mm2 size for fault level above 31.5 KA shall be provided throughout thelength of the switchboard with provision for interconnection to earthing gridat two ends. All non-current carrying metallic parts of the mountedequipment shall be earthed. Doors and movable parts shall be earthed usingflexible copper connections.

5.23 The inside the switchboards, the wiring for power, control, signalingprotection and instrument circuits shall be done with PVC insulated copperconductors having 660/1100 V grade insulation.

5.24 For modules rated above 100 Amp. preferably copper strip connection shallbe used. Minimum size of control wire shall be 1.5 mm2 coppers for circuitshaving fuse rating 10 Amp. or less. For higher fuse rating control circuits,mm. 2.5 mni2 copper conductor shall be used. Each wire shall be identified atboth ends by self-sticking wire marker tapes or PVC ferrules. Transparentshrouds shall be used on outgoing power terminals.

5.25 Clamp type terminals shall be acceptable for wires upto 10 mm2 size, forconductors larger than lOmm2 bolt type terminals with crimping lugs shall be

All switches drives other than rotary switches shall be lockable in both on and

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yoff position.

6.2 All fuses shall be non-deteriorating HRC cartridge, pressure fitting link type

6.3 The contactors shall be air break type having AC-3 or AC-4 duty rating as perpackage requirement. All contactors shall be provided with 1 NO + 1 NCpotential free spare auxiliary contacts wired to the terminal block for owneruse.

6.4 Thermal overload relays shall be three elements, positive acting ambienttemperature compensated type with adjustable setting range and built inprotection feature against single phasing. Bimetal relays shall be manuallyreset type with the reset push button provided on the cubicle door.

6.5 Current transformers for metering shall have an accuracy class 1.0 andinstrument safety factor less than 5. However accuracy class of 3.0 isacceptable for ammeters only for outgoing feeders. Protective currenttransformers shall have an accuracy class 5P and an accuracy limit factorgreater than 10.

6.6 All measuring AC instruments shall be moving iron, flush mounting type andof 96 x 96 mm and 72 mm x 72 mm square pattern instruments for incomerand outgoing feeders respectively. Accuracy class shall be 2.5 for KW/KWHmeter and 1.5 for ammeter and voltmeter. Ammeters for motor feeders shallhave a non-linear compressed scale at the end to indicate motor startingcurrent and red mark for the normal current.

6.7 All selector switches shall be rotary back-connected types having a camoperated contact mechanism with knob type handle. Ammeter selector switch

“Stop” push buttons for motor control feeders shall have stayput feature.

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All motor starter feeders shall have Stop and Reset push buttons and On andTrip indication lamps.

6.9 A centrally located engraved nameplate shall be provided for theswitchboard. Each module shall have engraved nameplate-bearing data asper approved drawings. Name plate or polyester adhesive stickers shall beprovided for each equipment mounted on the switchboard. Identification tagsshall be provided inside the panels matching with those shown on circuitdiagram. Special warning labels shall be provided on removable covers ordoors giving access to cable terminals and bus bars.

6.10 At least 10% spare feeders of each rating of outgoing feeders subject to aminimum of one feeder of each rating shall be provided in the switchboard.


7.1 In addition to the expediting/inspection activities being undertaken by thpackage vendor, switchboard shall be subject to inspection by GAIL or by anagency authorised by the owner. All necessary information concerning thesupply shall be furnished to GAILs inspectors. Two weeks notice shall begiven to GAIL for witnessing the final testing of the complete assembly toensure satisfactory operation of all components.

7.2 Tests shall be carried out at the manufacturer works under his supervisionand at his cost.

7.3 All routine tests as specified by the applicable standards and codes shall beconducted. Type tests certificates of a recognised testing organisation shallbe furnished with the bids. The vendor shall also submit the guaranteed

7.5.3 Dry insulation test with power frequency voltage for all circuits in ‘On’

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position.

7.5.4 Insulation resistance of the main and auxiliary circuit shall be checked.

7.5.5 Operation check for every control function as per the schematic diagram bymanually simulating the actual operating conditions.

7.5.6 Primary injection test to check winding of current transformers, ammeter,ammeter selector switch and correctness of wiring connection between them.

7.5.7 Relays shall preferably be tested with secondary injection test equipment.

7.5.8 For equipment bought from other sub-suppliers certified test reports of testscarried out at the manufacturer’s works shall be submitted. Normally allroutine tests as specified in the relevant standards shall be conducted by thesub-supplier at his works. in addition type test if specified shall beadditionally carried out and witnessed by the owner at CPRI/approved testingauthority.


All the equipment shall be divided in to several shipping sections forprotection and ease of handling during transportation .The equipment shallbe properly packed for transportation by ship/rail or trailer. The panels shallbe wrapped in polyethylene sheets before being placed in wooden crates /eases to prevent damage to the finish. Crates /cases shall have skid bottomsfor handling. Special precaution notations such as Fragile, This side up,

center of gravity, weight,Owner’s particulars, Purchase number etc. shall be clearly marked on thepackage together with other details as per purchase order. The equipment

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SPECIFICATION FOR DC-DC

CONVERTER

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CONTENTS

1.0 SCOPE

2. CODES AND STANDARDS

3. GENERAL REQUIREMENTS

4. SITE CONDITIONS

5. DESIGN AND FABRICATION REQUIREMENTS

6. PERFORMANCE REQUIREMENTS

7. MONITORING, CONTROLS, INDICATIONS AND METERING

8. INTERFACE WITH SCADA

9. PAINTING

10. INSPECTION AND TESTING

11. PACKING AND DESPATCH

1 SCOPE

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1.1 This specification covers the requirements of design, manufacture, testing,packing, delivery to site. testing and commissioning of the DC to DC converters.

2 CODES AND STANDARDS:2.1 The equipment shall comply with the requirements of latest revision of following

standards, unless other wise specified:i) BIS specifications

ii) International Electrotechnical Commission (IEC)

iii) American standards institution (ANSI)

2.2 The equipment shall also conform to the provisions of Indian Electricity rules andother statutory regulations currently in force in the country.

2.3 In case Indian standards are not available for any equipment, standards issued byIEC/BS/ VDE/ IEEENEMA or equivalent agency shall be applicable.

2.4 In case of any contradiction between various referred standards / specifications /

data sheet and statutory regulations the following order of priority shall govern:o Statutory regulations

o Data sheets

o Job specification

o This specification

o Codes and standards

3 GENERAL REQUIREMENTS

other attention at unattended stations. The basic module of DC to DC convertersh ll b hi hl li bl h i f d

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shall be highly reliable, having proven performance record.

4 SITE CONDITIONS4.1 The DC to DC converters shall be suitable for installation and satisfactory operation

in a non air-conditioned room with restricted ventilation. The DC to DC convertershall be designed to operate under site conditions as specified in the data sheet. If not specifically mentioned a design ambient temperature of 40°C and altitude notexceeding 1000 meters above mean sea level shall be considered.

4.2 All the equipments described in this specification are intended for continuous dutyat the specified ratings under the specified ambient conditions unless indicatedotherwise.

5 DESIGN AND FABRICATION REQUIREMENTS5.1 The converter panel shall be fabricated with 1.6/2mm thick sheet steel. Frames

shall be enclosed by using 2mm thick sheet steel and doors and covers shall bemade of 1.6 mm sheet steel. Wherever required, suitable stiffeners shall beprovided. The converter panel shall be wall mounted type and shall not need rearaccess for maintenance. All components, connectors and terminals shall bearranged, so . that maintenance requirements can be attended from front only.Overall hinged door shall be provided at the front of the panel. Alternatively thecabinet may be designed in two vertical portions with plug in modules of DC to DCconverters in one portion, while other auxiliary devices, housed in another portion.In this type of construction, the front facia of DC to DC converter module shall beflushed with - the front of panel, so that LEDs and operating knobs/potentiometer

can be directly accessed. The bottom vertical portion with hinged door shallaccommodate MCCBs/MCBs, alarm, indication and other . auxiliary devices asrequired for the overall unit. Suitable louvers shall be fitted for ventilation. It shall

be provided in the panel for terminating the power cables, using suitable cablel

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lugs.

5.6 All components and devices shall be provided with screwed nameplates.

Nameplates shall be 3 ply (white/black/white) two colour laminated plastic.

6 PERFORMANCE REQUIREMENTS6.1 DC to DC converter shall be of solid state type and shall operate on switch mode

principle. The .. converters shall operate on a switching frequency above 20kHz.The voltage conversion/control from input to output shall be by control of dutycycle of conduction of the power semiconductor device.

6.2 The DC to DC converters shall either work in dual parallel redundant mode orsingle non redundant mode, as specified in the data sheet/MR/tender document.The parallel redundant DC-DC converters shall have two nos. DC-DC converterswhich shall work in parallel redundant mode, sharing the load in normal operation,but each capable of delivering full load. In case of failure of any one of converter,the other converter shall continue to feed the load.

6.3 DC-DC converters shall be suitable for the incoming supply voltage as specified inthe data sheet, with . variation in voltage up to +25% and -15%, unless specifiedotherwise in the data sheet. It shall be possible to operate the DC to DC converterswith its output polarities ungrounded or any of its polarity grounded, irrespective of grounding of input supply. The DC to DC converters shall have galvanic isolation(between input supply and output supply), requisite isolation transformer shall beprovided in E the converter. The electrical isolation between input and output shallbe rated for mm 500V DC.

6.4 The overall efficiency shall be minimum 75%. The output of the converter shall befiltered/smoothened to provide DC output with less than 2% ripple. The steady

6.7 Each converter module shall be protected against output short circuit and overt DC t DC t h ll b it bl t ith t d it hi

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current. DC to DC converters shall be suitable to withstand switching surges orotherwise protective devices shall be provided.

6.8 The converter shall preferably be of natural cooled type.

6.9 The noise level measured at 1 m. distance from the converter unit at any positionshall not exceed 70 . db (A) at any load from 0-100%.

6.10 The converter shall have input filters to minimise the AC feedback to the powersupply. Radio - interference noise emitted by the converter shall be minimised toallow proper operation of telecom and SCADA systems in the vicinity and powered

by the converter.

6.11 The converter shall be field proven and shall be suitable for unattended operationat remote locations. The converter design, internal component layout andcomponent rating shall ensure high MTBF and low MTTR

7 MONITORING, CONTROLS, INDICATIONS AND METERING

7.1 Each DC to DC converter module shall be provided with monitoring for thefollowing:i) Load voltage highii) Load voltage lowiii) Thermal overload protectioniv) Module- Fault/Fail(Module not feeding the load)v) Input fuse failvi) Input voltage - Too high/Too low

7.2 Following control devices, LED indications and meters for each DC to DC convertershall be provided on front of the panel:

8 3 Th t d h ll h l t i l i l ti t d f i i 2kV 50H

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8.3 The transducers shall have electrical isolation rated for minimum 2kV, 50Hzbetween input and output. The transducers shall be protected against input andoutput voltage surges. The accuracy class of the 4-20 mA current transducers shall

be 5% or better. The 4-20mA current transducers shall be suitable for driving loadresistance of 600 ohms located up to 100 m away and connected through 0.5 mm2copper cable.

9.0 PAINTINGThe sheet steel used for fabrication shall be thoroughly cleaned and degreased toremove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and

then rinsed to remove any trace of acid. The under surfaces shall be prepared byapplying a coat of phosphate and a coat of zinc oxide/phosphate primer. The undersurface shall be free from all imperfections before undertaking the finishing coat. Itshall then be spray painted with two coats of epoxy paint. Colour of final paint shallbe vendor standard.

The finished panel shall be dried in stoving ovens in dust free atmosphere. Panelfinish shall be free from imperfections like pin holes, orange peels etc. Allunpainted steel parts shall be cadmium plated or suitably treated to preventcorrosion. Alternatively, powder coating as per manufacturer’s standard is alsoacceptable.

10.0 INSPECTION AN]) TESTING10.1 The owner or his authorised representatives may visit the works during

manufacture of equipment to g 8 assess the progress of work as well as to

ascertain that only good quality raw materials are used for the same. He shall begiven all assistance to carry out the inspection.

c) Heat run test (full load test) shall be carried out for a minimum duration of 8hours on all units except that in case of identical ratings for more than one

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hours on all units except that in case of identical ratings for more than oneunit, heat run test may be conducted only on one of the identical units.During this test, measurements shall be carried out to prove that the

operating temperatures of various components do not exceed their designratings with sufficient margins as per good engineering practice/establishedguidelines.

d) Type test certificates shall be submitted for ensuring compliance to otherguaranteed performance parameters.


The equipment shall be properly packed for transportation by ship/rail or trailer.

The panels shall be wrapped in polyethylene sheets before being placed in woodencrates /cases to prevent damage to the finish. Crates /cases shall have skidbottoms for handling. Special precaution/parameters such as “Fragile”, “This sideup”, center of gravity, weight, Owner’s particulars, Purchase number etc. shall beclearly marked on the package together with other details as per purchase order.

The equipment may be stored outdoors for long periods before installation. Thepacking should be suitable for outdoor storage in areas with heavy rains and highambient temperature unless otherwise agreed.

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SPECIFICATION FOR ELECTRICAL

EQUIPMENT INSTALLATION

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Abbreviations:

ACDB AC Distribution Board

C.T.C Carbon Tetrachloride

C T Current Transformer

DCDB DC Distribution Board

HV High Voltage

MMI Man Machine Interface

MV Medium Voltage

OISD Oil Industry Safety Directorate

PF Power Factor

PT Potential Transformer

UPS Uninterrupted Power Supply

VRLA Valve Regulated Lead Acid

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CONTENTS

1. SCOPE


3. INSTALLATION OF EQUIPMENT

4. EQUIPMENT COMMISSIONING

5. LIST OF CONSTRUCTION EQUIPMENT

1 SCOPE

This specification defines the requirements for the installation field

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This specification defines the requirements for the installation, fieldinspection, testing and commissioning of electrical equipment, forming partof electrical power distribution and utilisation system, including

Communication and Fire alarm system.

2 CODES AND STANDARDS

2.1 The work shall be carried out in the best workmanlike manner in conformitywith this specification, GAIL Installation Standards, layout drawings and tothe following specifications/ codes of practice of Bureau of Indian Standardsand OISD standards.

o SP-30(BIS) National Electrical Code.

o IS-7816 Guide for testing Insulation resistance of rotating machines.

o IS 10028(Part-2) Code of practice for selection, Installation and

maintenance of transformers; Part 2 Installation.

o IS 1011 8(Part-3) Code of practice for selection, installation and

maintenance of switchgear and control gear ;Part 3: Installation.

o OISD 137 Inspection of Electrical Equipment.

o OISD 147 Inspection and safe practices during electrical installations

2.2 In addition to the above it shall be ensured that the installation conforms tothe requirements of the following as applicable:a) Indian Electricity Act and Rules.

b) Regulations laid down by CEA/Electrical Inspectorate.

avoid any mishap. When handling the switchboard panels, care shall be takento observe the correct lifting arrangements and to make sure that slings are

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to observe the correct lifting arrangements and to make sure that slings areattached to the manufacturer’s designated lifting points. No parts shall besubjected to undue strains or sudden stresses which could cause damage to

the equipment.

The lifting position mark indicated on packing casing shall be adhered tostrictly, for keeping it in required vertical position.

Contractor shall check and report to the Engineer-in-charge about anydamaged item and / or missing component for getting the same replaced asper specifications. During installation, all accessories and loose items shall

also be inspected by the contractor before their assembly/mounting.

3.1 Switchboards and Bus Ducts

3.1.1 The term switchboard here includes all HV / MV/ LV switchboard panels ,motor control centers, power and lighting distribution boards, UPS panels, ACDB, charger panels, DCDB etc. The switchboard panels shall be handledwith care, avoiding any impact to the equipment. Dragging of the panelsdirectly on floor shall be avoided. Roller bars may be used for shifting of panels. Use of a crane and trailer shall be made for handling of equipment.The switchboard panels shall be properly supported on the truck or trailer bymeans of ropes to avoid any chance of tilting. The switchboards shall belifted after ensuring that panel supports, nuts and bolts are all intact andtightened. While lifting the panels in packed conditions. utmost care shall betaken to avoid any damage to insulators, bushings, metering and protectiveequipment. The panels shall be preferably kept inside the packing cases tillfoundations are ready.

operation of the breaker and all other motions shall be free from anyobstruction

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obstruction.

The panels shall be checked for correct vertical position using pendulum

weight and spirit levels . The switchboard panels shall be tack welded atsuitable intervals at base channel. After erection of switchboard panels, all uncovered portions of floor cutoutsshall be covered with 6 mm thick removable checkered plates finished withfloor level. The design of the checkered plates shall be such that themaximum allowable deflection is 1) 200 (where L is the span of thecheckered plates in metres) for a live load of 500 kg./sq. meters. In thisregard, reference shall be made to GAIL structural standard No. S-11-01-010

(Cable Trench). Suitable lifting arrangements shall be provided for checkeredplates. The checkered plates shall be painted with a coat of red oxide zincchromate primer after proper surface preparation as per specifications.Where specified , panels cutouts provided for future use shall be filled withlean concrete.

3.1.4 After completion of erection of switchboards, all the cubicles, switchboardcomponents such as switches, starters, C.T. and PT. chambers, busbarchamber shall be cleaned and checked for tightness of all the components. Vacuum circuit breakers shall be checked for integrity o bottle seals. Allloosely supplied items shall be fitted up. Bus bar sections or links shall heinserted and where specified, of high voltage equipment, shall be insulated.Interconnection wiring between shipping sections shall be made bycontractor. All the wiring connections shall also be checked. Phase sequenceand polarity of PTs and CTs shall be checked. Contact resistance of all busbar joints and contactors shall be checked. Insulator shall be checked for anydamage. All the starters, switches, contacts shall be cleaned with C.T.C.where required. All the moving parts shall be checked for easy and free

Engineer-in-charge for the IR value to improve to a safe level forcommissioning Care shall be taken to protect the surrounding insulation from

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commissioning. Care shall be taken to protect the surrounding insulation fromdirect local heating during the drying up process.

3.1.6 All the metering instruments, protective relays and other relays andcontactors shall be tested as per manufacturers recommendations andaccording to the instructions of the Engineer-in- charge. Protection relaysshall be inserted and connected and settings adjusted as required by theEngineer- in- charge

3.1.7 All moving parts, of closing/tripping mechanism, racking in and racking outmechanism, spouts and shutter closing mechanism shall be checked for

proper operation. All the auxiliary contacts of breaker shall be checked-up,cleaned and contact pressure measured.

3.1.8 All the control wiring, PTs, bushings, bus bars, other live parts of switchgear,incoming and outgoing cables shall be meggered.

3.1.9 Electrical simulation tests shall be carried out for all the protective, alarm andannunciation relays and external interfaces to ascertain proper functioning.

3.1.10 Safety insulation mats of approved make and of required voltage grade shallbe provided in the sub-station.

3.1.11 Pre-Commissioning Check List:Before commissioning any switchboard, following points shall be checked andensured for safe energising of the switchboard:

i) That the installation of equipment to be commissioned is complete inall respects with its auxiliaries and all other mounting including

shall be carried out for differential protection, Restricted Earth faultprotection at full / reduced current to ensure correctness of complete

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protection at full / reduced current to ensure correctness of completewiring). Relay settings, status indications, fault annunciations, datalogging, display of switchboard SLDs shall be verified from MMI in case

the same is provided.vi) That I.R. Value have been recorded for bus bars, circuit breaker,

incoming and outgoing cables, control wiring and potentialtransformers. Where required joint resistance of bus bars have beenrecorded and found to be satisfactory. All the surroundings and panelshave been cleaned and temporary earth leads have been removed.

3.1.12 Bus Ducts:

The bus ducts as per issued drawings will be supplied in parts and all theparts shall be assembled and the bus bar connections shall be made at site.The insulators in bus ducts shall be inspected for any possible damage duringtransit and the defective ones shall be replaced. The insulators shall becleaned. Contact surface of bus bars, bus bar bolts and nuts shall bethoroughly cleaned. Petroleum jelly shall then be applied and boltedconnection made. The bus duct enclosure shall be checked for earthcontinuity and then earthed at two places. The bus duct shall be properlysupported between switchgear and transformer. The opening in the wallwhere the bus duct enters the switchgear room shall be completely sealed toavoid rain water entry. Expansion joints, flexible connections etc. supplied bythe manufacturer of the bus duct shall be properly connected. The bus ductlevelling shall be checked with spirit level and pendulum weight.

3.2 Transformers

Transformers on receipt at site shall be unloaded by means of crane or liftingdevices of adequate capacity. All lifting lugs shall be used to avoid

built wooden sleeper platform. A transformer shall never be left withoutputting stoppers to the wheels.

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putting stoppers to the wheels.

3.2.2 Transformers shall be examined, for any sign of damage in transit. Particular

attention shall be given to the following in this regard.i) Dents on tank wall or cooling tubes.ii) Damage to protruding parts like valves, sight glass etc.iii) Loosening of bolts due to vibration in transit.iv) Cracked or broken bushings.v) Oil leakage particularly along welds.

If any thing adverse is noted the same shall be brought to the noticeof Engineer- in- charge.

3.1.5 Contractor shall examine the transformer base, oil pit, fire walls andfoundations laid by the civil contractor. It shall be ensured that oil spills cannot propagate along cable trenches. Any discrepancy noted will be brought tothe notice of Engineer- in- charge. Transformers shall be placed on channelsor rails over concrete foundations. The transformers shall be levelled, alignedand checked for free movement on the channels or rails. Stoppers shall beprovided to the transformers immediately to prevent any movement.

Normally transformers upto 1000 kVA rating shall be received duly fitted withradiator tubes, conservator tanks, valves, wheels and other accessories.While the transformers of above 1000 kVA rating may be supplied with looseaccessories. All the accessories like radiators, cooling fans, valves,conservator tanks explosion vent pipe, bushings and other devices which aresupplied in different packages shall be checked for any transit damage andcleaned thoroughly before fixing on the transformer. All loosely supplied partsshall be assembled as per manufacturer’s instruction manuals/ drawings anddocuments. All the connections for CTs bushings and other wiring shall bechecked for tightness and correctness before replacing the lid or tightening

Sufficient time shall be allowed for the oil to permeate the transformers andalso for the locked -up air bubbles to escape. Any air accumulation in the

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a so o t e oc ed up a bubb es to escape y a accu u at o t eBuchholz relay shall be released.

3.2.5 Transformer Oili) Sample of oil from the transformer shall be taken from the bottom of

the tank.ii) Testing of Oil:

For dielectric test, the oil shall be tested as described in IS 335, The oilshall also be tested for acidity in accordance with the methodsprescribed.

3.2.6 Drying out of the transformers, if required , shall be carried out and recordmaintained in accordance with IS : 10028. Normally a streamline filter shallbe used for drying-up. JR. value versus time of both windings shall berecorded during the drying-up process.Precautions when dryingi) The maximum sustained temperature to which transformer oil may be

subjected shall be limited to 80 C.ii) The transformer shall be carefully monitored throughout the drying

out process and all observations shall be carefully recorded.iii) Drying out shall be continued so that the insulation resistance as

prescribed in the standard code of practice is attained and the valueremains constant for more than 12 hours. However, a minimumnumber of cycles shall be done for each transformer as foundnecessary by the Engineer-in-charge. Generally a megger reading of 2megohms / kV at 600 C temp. with a 5 kV Megger may be a roughindication for stopping the dehydration.

3.2.7 The following work on transformers, shall be performed by the contractor if

i) That all the accessories have been fixed properly and transformerbody and neutral are properly earthed. The transformer dehydration is

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y p p y yover and results are satisfactory and approved by the Engineer-in-charge. In case transformers are idle for more than one month after

dehydration, transformer oil has been given at least two circulations.ii) That the oil level, in the transformer conservator tank and all the

bushings is upto the marked point and the oil has been tested fordielectric strength and acidity.

iii) That the silica gel is in reactivated condition. The breather pipe is clearfrom any blocking and contains oil upto the proper level.

iv) The explosion vent diaphragm does not have any dents. Accumulationof any oil and air had been released.

v) That the operation of off-load and on-load tap changers on all the tappositions is satisfactory. The mechanical parts of the on-load tapchanger are lubricated. Motor IR value has taken and foundsatisfactory. Tap position mechanical indicator on the transformer andtap position indication meter on the control panel are reading thesame tap positions. Tap changer limit switches are operatingsatisfactorily on the maximum and minimum tap positions. On-load tapchanger contact pressure and resistance is as per manufacturers

recommendations. Oil level of tap changer tank is upto the requiredlevel and oil has been tested for dielectric strength. The tap setting onwhich the off load tap switch is locked shall be recorded. Generally theoff-load tap switch shall be kept on nominal tap.

vi) That the Buchholz relay has been tested and checked up for anyfriction in the movement, and floats are free. All the other protectiverelays, alarm and annunciation relays have been tested.

vii) That all the metering equipment have been tested and polarity test of PT’s and transformer winding is satisfactory. Phase sequence andconnections have been checked for proper vector group.

xiv) That all the valves in the cooling system and valve between theBuchholz relay and the conservator tank are in open position.

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y p pxv) That the setting of all the protective relays is at the desired value and

D.C. Trip supply is healthy.

3.2.9 Observations after Commissioning: After switching on the transformer the following points shall be observed andrecorded.i) The inrush magnetizing current and no-load current.ii) Alarm, if any, or if any relay flag has operated.iii) Voltage and current on all the three phases.iv) Transformer hum or abnormal noise.

v) Circulation of oil and leakages.vi) Record current , voltage, cooling air temperature, winding temperature

and oil temperature readings, hourly for 24 hours.vii) Cable end boxes for any over -heating.

3.3 H.V. and M.V. MOTORS

3.2.6 All the motors generally would be erected by the mechanical contractor.

3.2.7 Electrical contractor shall keep the motor space heater energised as per thedirections of Engineer-in-charge. Electrical contractor shall measure theinsulation resistance of motor windings. Insulation resistance of the motorsshall be measured between the winding of the machine and its frame bymeans of a 500 / 1000 V Meggar in case of 415 V motors . A minimum valueof 1 megohm for 415 V motors shall be considered a safe value. In case of lower l.R. Value, the insulation value shall be improved by any of thefollowing methods as directed by the Engineer-in-charge.i) Blowing hot air from external source.

ii) By blasting hot air from external source, Maximum temperature of winding while drying shall be 70° C to 80° C (thermometer) or 90° C

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g y g ( )to 95° C by resistance method. Heating shall be done slowly first tillsteady temperature of winding is reached after 4 to 5 hours, and for

large machines after 10 hours. A record has to be kept for dryingprocess, with half an hour readings and, till steady temperature isreached. In case it is essential, the drying process can besupplemented by blower.

3.2.8 It shall be ensured that the motor leads are correctly connected in theterminal box, as indicated in the Name Plate’. The covers of all terminalboxes shall be properly fixed, the gaskets intact. The control circuit shall be

tested for proper functioning as per circuit diagram.

3.2.9 In case of synchronous machines, slip rings and brush gear shall be polishedand brushes shall be fixed in their holders with clearance and pressure asrecommended by the manufacturers.

3.2.10 Before commissioning, the ventilation and cooling system of the motor mustbe inspected. In case of motor with forced ventilation the air inlet shall be

examined to ensure that it is free from moisture and any foreign material. Itshall also be ensured that recommended flow and pressure of air is availableto produce the required cooling effect.

3.2.11 The motor control gear shall also be carefully examined, the over-loadsettings may be reduced or time lags bypassed from protective gear toensure rapid tripping of switchgear in event of faults. The direction of rotation of a new motor specially of large capacity, and phase sequence of supply shall be kept in view while joining and connecting to the motorterminals.

3.2.15 The following work on motors, may be performed by the contractor if specifically called for.

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3.2.15.1.1 The proper level of bearing oil has to be checked . The condition of

grease in bearings shall be checked and in case it is necessary, completereplacement of bearing with specified grade of grease after propercleaning of the bearing shall have to be done ‘Wherever external greasingfacility exists, the condition of grease may be checked by pumping somenew grease of specified grade at start. If the grease coming out isdeteriorated grease shall be replaced.

3.2.15.1.2 All the motors, motor exciter set and induction generators directly

coupled or coupled through reduction gears shall be checked forabnormal vibration, if any Large rated HV motors with journal typebearings are liable to get damaged from shock, rough handling duringtransit. Any minor defect in a race or roller may give rise toconsiderable amount of vibration and noise. Contractor shall check andbring to the attention of Engineer-in-charge any defect noticed in thisregard.

3.2.15.1.3 Due care shall be taken to avoid any damage to bearing insulationwherever provided.

3.4 BatteriesBattery (Lead acid, Nickel Cadmium or VRLA type as specified) shall beerected on stands and insulators supplied by the manufacturer of thebatteries. The installation shall be done as per the layout drawings andmanufacturer’s instructions. Electrolyte if required / as applicable shall befilled as per manufacturer’s instructions. Inter row connections shall be madewith the leads supplied by the manufacturer.

3.7 Push Button/Control StationsThe push buttons / control stations shall be installed near to the motors to be

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controlled. Individual channel supports shall be installed as per GAILstandard. If control stations for hazardous areas are to be supplied by

contractor, these shall be of Ex(d) type, tested by CMRI and approved byCCE or other applicable certifying authorities. All outdoor push buttons /control stations shall preferably have integral canopies for additional weatherprotection. The canopy shall be made of 2 mm thick galvanized sheet steel orFRP where these are not integral with the equipment.

3.8 Gang operated Isolators/outdoor DisconnectorsThe isolators shall be transported to site in the dismantled condition. All the

insulators may be also supplied loose. The contractor shall inspect, clean ,assemble and install the isolator on the base structure previously fabricated,erected and levelled by him. The operating mechanism shall be installed on thestructure and connected to the isolator poles. The operating mechanism shallbe tested by slowly bringing the isolator to the closed position and carrying outthe necessary adjustment as per the manufacturer’s instructions. The earthingswitches, frames and operating handle etc. shall be earthed.

3.9 Contractor shall provide the following items in substation, as per IndianElectricity Rules:

3.9.1 Fire buckets filled with clean dry sand and ready for immediate use forextinguishing fires and fire extinguisher (carbon dioxide, dry chemicalextinguisher etc.) suitable for dealing with electric fires shall beconspicuously marked and kept.

3.9.2 First aid boxes containing ointments and medicines for immediate treatmentof injuries (As prescribed by Indian Red Cross Society or equivalent).

4 Equipment Commissioning

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4.1 Field inspection, testing and commissioning of the complete electricalinstallation shall be carried out as per GAIL specification no. S-07-02-004.

After the equipment is installed properly in accordance with drawings andspecifications, contractor shall carry out all pre-commissioning checks andtests as per GAIL format in the presence of Engineer-in-charge and testreadings shall be recorded and furnished to BIL in triplicate.

4.2 All equipment layout drawings shall be marked by the Contractor for “ASBUILT STATUS” and two sets of copies shall be submitted to GAIL.

5 LIST OF CONSTRUCTION EQUIPMENTThe contractor shall have all necessary construction equipment, tools andtackles and testing instruments to carry out the erection works and tocommission the system as specified. These shall include but not be limited tothe following, and these shall be brought to site by contractor before thestart of work.

5.1 Equipment:i) Portable grinder.

ii) Portable welding machine.

iii) Portable gas cutting / welding set.

iv) Pipe threading machine.

v) Pipe bending machine (hydraulic).

vi) Portable drill machine suitable to take up drilling for different sizes as

5.2 Test Instruments

i) Insulation tester 1000 V hand driven.

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ii) Insulation tester 2500 V motor/hand driven.

iii) Insulation tester 5000 V motor/hand driven

iv) Phase sequence indicator.

v) Earth Resistance tester.

vi) Single phase variac

vii) 3 phase variac of adequate capacity.

viii) Secondary injection testing kit.ix) Multi-meter, both analogue and digital

x) Portable Ammeters, Watt-meters, P.F. meters.

xi) Portable Voltmeters.

xii) Clip on meters of different ranges.

xiii) Tacho-meter.

xiv) Kelvin's double bridge for measurement of very low resistance.

xv) D.C. high -pot test kit.

xvi) D.C. high -pot test kit.

xvii) Oil filtration machine of adequate capacity.

xviii) LUX METER to measure illumination levels.

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SPECIFICATION FOR FIELD

INSPECTION, TESTING AND

COMMISSIONING OF ELECTRICAL

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ABBREVIATIONS:

AFC Approved for construction

CEA : Central Electricity Authority

CCE : Chief Controller of Explosives

DC Direct current

DGMS : Director General Mines and Safety

GI : Galvanized Iron

HV : High Voltage

IS : Indian Standard

MV : Medium voltage

OISD : Oil Industry Safety Directorate

CONTENTS

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1.0 SCOPE


3.0 FIELD INSPETION, TESTING AND COMMISSIONING

4.0 RECORDS

1.0 SCOPE

This specification covers the requirements for the field inspection, testing andi i i f El t i l E i t d I t ll ti f i t f

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commissioning of Electrical Equipment and Installation, forming part of electrical power distribution and utilisation system.


2.1 The field inspection, testing and commissioning of electrical equipment shallbe carried out in line with this specification and the latest edition of followingIndian Standards and OISD standards.

SP-30(BIS) National Electrical Code

IS-78 16Guide for testing Insulation resistance of rotating

machines.IS 1255 Code of practice for installation and maintenance of

power cables up to & including 33 kV rating.

IS 10810(Part 43) Method of Test for cables; Part 43 Insulation resistance

IS 108 10(Part 45) Method of Test for cables; Part 45 High voltage test

OISD 137 Inspection of Electrical Equipment

OISD 147 Inspection and safe practice during electrical installation

2.2 In addition to the above it shall be ensured that the installation conforms tothe requirements of the following as applicable:

i) Indian Electricity Act and Rules.ii) Regulations laid down by CEA / Electrical Inspectorate.iii) Regulations laid down by Tariff Advisory Committee/Loss

prevention council.iv) Regulations laid down by CCE/DGMS (as applicable).v) The petroleum rules (Ministry of Industry Government of India).

vi) Any other regulations laid down by central / state / local authorities / Insurance agencies

3.4 Visual inspection for soundness of bus bar connections of bus-ducts, terminalconnections of equipment/motor shall be carried out. It shall be ensured thatno fo eign mate ials a e p esent inside b sd ct and eq ipment te minal

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no foreign materials are present inside busduct and equipment terminalboxes. After the visual inspection, all the covers of terminal boxes, inspection

chambers shall be refitted with gaskets, bolts & nuts as per equipmentmanufacturer’s instructions.

3.5 Pre-commissioning tests shall include but not be limited to the following:

o Continuity test for each winding and power and control circuits.o Insulation test for each winding and power and control circuito High voltage test for cableso Dielectric strength test on transformer oil.o Checking the correctness of wiring schemes, control circuit interlocks

for intended functioning.o Verification of phase sequence.o Testing of all types of relays/releases for required operation.o Testing of measuring instruments for proper functioning.o Earth continuity test for all circuits.o Checking of safety features for correctness of operation etc.o Checking of all wired interface contacts (analog, digital input/output

contacts) for DCS and ECS interface, at panel and equipment terminalchambers as applicable.(Electrical contractor shall co-ordinate with other agencies involved forthe above and provide support services for checking interfaces of electrical equipment and the intended functioning)

o Earth resistance measurement for each earth electrode, and theearthing system as a whole.

o Lighting installation shall be tested for correct illumination levels, with

the fittings installed. Fittings shall be operated only with specified typeof a lamp or tube.

assistance to the equipment vendor to perform Site acceptance testing toenable the equipment vendor to perform the same.

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3.10 All pre-commissioning checks and tests shall be carried out as per the

directions of Engineer- in-charge. In addition to the equipmentmanufacturer’s instructions, pre-commissioning check requirements shall alsobe complied. All tests shall be carried out by contractor in the presence of GAIL/Owner’ s representatives

3.11 The contractor shall bring to site all required tools, tackles, and testinginstruments for carrying out field testing. Contractor shall use only calibratedmeasuring and test instruments and shall maintain calibration records.

3.12 The Insulation Resistance test values for various electrical equipment shall beas below:

3.12.1 Cables

The insulation resistance test values for cables shall be as per following table:

Rated voltage of theCable

DC Test Voltage in Volts

Minimum Insulationresistance in MΩ

Lighting and powercircuit wiring

250 1

650/1 100V grade cables 1,000 10

1,900/3,300V grade 1,000 200

3,800/6,600V grade 1,000 200

6,350/11,000V grade 5,000 200

8,700/15,000V grade 5,000 200

12,700/22,000V grade 5,000 200

19 000/33000V d 5 000 200

3.12.3 Generators and Motors3.12.4 The insulation resistance test values for the Generators and Motors shall be

as per following table:

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as per following table:

Rated voltage of the

Generators andMotors

DC Test

Voltage in Volts

Minimum Insulation resistance inMega ohms at 40°C

11,000V 5,000 120

6,600V 1,000 80

3,300V 1,000 50

415V 1,000 15

240V 500 12

3.12.5 Transformers3.12.6 The insulation resistance test values for the Transformers shall be as per

following table

Rated voltage of theDC Test Voltage in

VoltsMinimum Insulation

resistance in MΩ at 40°

Transformers C

Upto600V 1,000 100601 to 5000V 2,500 1,000

5001 to 15,000V 5,000 5,000

15001 to 35,000V 5,000 10,000

3.12.7 It shall be ensured that during insulation tests, electronic devices andcomponents that are liable to get damaged on applied test voltage shall be

disconnected from circuit. The instructions of equipment/panel manufacturershall be followed strictly in this regard.

Rated Voltageof Cable (kV)

TEST VOLTAGE (kV) BETWEEN

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of Cable (kV)( )

U0 I U*

Any Conductor and

Metallic Sheath!Screen/Armour

Conductor to

Conductor (ForUnscreened Cables)

Duration(Minutes)

6.6/6.6 18 18 5

6.35/11 18 30 5

11/11 30 30 5

12.7/22 37.5 - 5

19/33 60 - 5

U0: Phase Voltage U* Line Voltage

3.13.2 The cable cores must be discharged on completion of DC high voltage testand cable shall be kept earthed until it is put into service.

3.13.3 DC test voltage for old cables shall be 1.5 times rated voltage or less

depending on the age of cables, repair work or nature of jointing work carried out, etc. In any case, the test voltage shall not be less than the ratedvoltage.

3.13.4 All protective relays including thermal overload relays shall be tested bysecondary injection current. Primary injection tests shall be carried out fordifferential protection, restricted earth fault protection at full/reduced currentto ensure correctness of complete wiring.

3.13.5 Before energising any equipment, ‘COMMISSIONING CLEARANCE FORM’ as

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SPECIFICATION FOR EARTHING

INSTALLATION

ABBREVIATIONS:

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ABBREVIATIONS:

CEA Central Electricity Authority

DGMS Director General Mines and Safety

GI : Galvanized Iron

IS Indian Standard

MS Mild Steel


UPS : Uninterrupted Power Supply

CONTENTS

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CONTENTS

1.0 Scope

2.0 Codes and Standards

3.0 Material Specifications

4.0 Earthing Network

5.0 Installation Of Earth Electrode

6.0 Connection

7.0 Testing

1.0 SCOPE

This specification defines the requirements for the supply of earthing andlightning protection materials and installation of the earthing and lightning

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lightning protection materials and installation of the earthing and lightningprotection systems.


2.1.1 The work shall be carried out in the best workman like manner in conformitywith this specification, GAIL Installation Standards, layout drawings, thelatest edition of relevant specifications, codes of practice of Bureau of IndianStandards and OISD Standards listed below

SP:30 (BIS) Special Publication-National Electrical Code

IS:2309 Protection of buildings and allied structures against

lightning.

IS:3043 Code of practice for earthing

IS:7689 Guide for control of undesirable static electricity.

OISD 110 Recommended practices on static electricity

OISD 147 Inspection and safe practice during electrical installation.

2.2 In addition to the above it shall be ensured that the installation conforms tothe requirements of the following as applicable:i) Indian Electricity Act and Rules.

ii) Regulations laid down by CEA (Eiectrical Inspectorate).

iii) Regulations laid down by CCE/DGMS (as applicable).iv) The petroleum rules (Ministry of Industry Government of India).

metre. Earth electrodes shall be as per GAIL Standard S-07-01-004. Earthplate shall be as per GAIL Standard S-07-01-006.

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4.0 EARTHING NETWORK

4.1 This consists of main earth conductor (grid conductor) forming a closed ringnetwork with required number of earth electrodes connected to it to providea common earth for electrical devices and metallic structures. From eachearth electrode two distinct connections shall be made to the main earthconductor. The earth plates shall be used for taking multiple earthconnections to two or more equipment.

4.2 The earth conductor shall be laid along cable trays/cable trench/pipe racks asindicated on the earthing layout drawing. Where lined cable trenches areavailable, the earth conductor shall be laid in the trenches and shall be firmlycleated to the sidewall of concrete trenches using Gl clamps. at interval of 400 mm to 500 mm and near to the termination end. The earthing conductorshall run along one of the cable trays along a cable route. The earthingconductor shall be suitably cleated and electrically bonded to all the othercable trays on the same cable route at a regular interval of 25 to 30 metre.

The earthing for equipment shall be tapped from the main earth conductorand not from cable tray support structure. Earth conductor when laidunderground shall be at a depth of 500mm below finished grade level.

4.3 Joints and tappings in the main earth loop shall be made in such a way thatreliable and good electrical connections are permanently ensured. All jointsbelow grade shall be welded and shall be suitably protected by giving twocoats of bitumen and covering with hessian tape. Earth strip laid above

ground shall be welded across straight through joints and joints shall besuitably protected by giving two coats of bitumen to avoid oxidation and

the soil strata and resistivity. Earth electrodes shall be located avoidinginterferences with road, building foundation, column, pipelines etc The civilarea drawings shall be referred for this. The distance between two electrodes

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area drawings shall be referred for this. The distance between two electrodesshall not be less than twice the depth of electrode.

5.2 Electrodes shall preferably be located in a moist soil which has a fine texture, grain size and distribution. Wherever practicable the soil shall be dug up, alllumps broken and stones removed from the immediate vicinity of theelectrodes and soil packed by watering and ramming as tight as possible..

5.3 The electrodes shall have a clean surface, not covered by paint, enamel,grease or other materials of poor conductivity.

5.4 All earth electrodes shall be tested for earth resistance by means of standardearth test meter. The tests shall take place in dry months, preferably after aprotracted dry spell.

5.5 The disconnect facility shall be provided for the individual earth electrode tocheck its earth resistance periodically.

5.6 Location of earth electrodes shall be marked by permanent markers for easyidentification. All earth Electrodes shall be serial numbered and also markedon ‘As Built’ drawing for future reference.

5.7 Individual earth electrodes shall be provided for each lightning arrestor andflood light mast.

5.8 Earthing system provided for concrete paved area by other agency where

applicable; shall be connected to the plant earthing system below ground byminimum two earth connections.

- Cable trays and racks, lighting mast and poles- Storage tanks, spheres, vessels, columns and all other process

equipment.

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equipment.

- Fence and Gate for electrical equipment (e.g. transformer, yard

etc.)- Cable shields and armour- Flexible earth provision for Wagon, Truck - Shield wire

Conductor size for branch connection to various equipment shall be as perGAIL Installation Standards unless otherwise stated on earthing layoutdrawings.

6.2 All process pipelines shall be bonded and earthed at the entry and existpoints of battery limit of hazardous area. (Reference installation standard S-07-01-009). Earth continuity conductors across pipe line flanges shall not beprovided as per OISD 110.

6.3 Steel pipe racks in the process units and offsite area shall be earthed at every24 metres.

6.4 Equipment/street light pole etc. located remote from main earth network maybe earthed by means of individual earth electrode and earth conductor unlessotherwise stated in job specifications.

6.5 Lightning protection shall be provided for the equipment, structures andbuildings as shown on layout drawing. Self conducting structures shall notrequire separate aerial rod and down conductors. These shall however be

connected to the earthing system at two or more points as shown on layoutdrawing. An independent earthing network shall be provided for lightning

6.10 All earthing connections for equipment earthing shall be preferably from theearth plate mounted above ground wherever provided Equipment foundationbolts shall not be used for earthing connection.

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g

6.11 Earth connections shall be made through compression type cable lugs/bywelded lugs.

6.12 All hardware used for earthing installation shall be hot dip galvanised or zincpassivated. Spring washers shall be used for all earthing connections and allconnections adequately locked against loosening.

6.13 Lighting fixtures and receptacles shall be earthed through the extra core

provided in the lighting circuit/cable for this purpose.

6.14 The reinforcements of sub-station building and the sub-station floor shall beconnected to main earth grid.

7.0 TESTING AND COMMISSIONING

7.1 Field inspection, testing and commissioning of electrical installation shall bedone as per GAIL standard 6-5l-0087.Earthing systems/connections shall be

tested as follows

7.2 Resistance of individual earth electrodes shall be measured afterdisconnecting it from the grid by using standard earth test megger.

7.3 Earthing resistance of the grid shall be measured after connecting all theearth electrodes to the grid. The resistance value of an earth grid to thegeneral mass of earth shall be as follows:

o For the electrical system and equipment a value that ensures theoperation of the protection device in the electrical circuit but not in

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SPECIFICATION FOR CABLE

INSTALLATION

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Abbreviations:

BS British Standards


ET Electrical Thread

FLP Flame Proof

GI Galvanised Iron

MS Mild Steel


RCC Reinforced Concrete Cement

SWG Standard Wire Gauge

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CONTENTS

1. SCOPE


3. MATERIAL SPECIFICATIONS

4. CABLE LAYING

5. TERMINATIONS

6. TESTING

1 SCOPEThis specification defines the requirements for supply of materials, whereverapplicable, installation, testing and commissioning of cable installation.

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2.1 The work shall be carried out in the best workman like manner in conformitywith this specification, GAIL installation standards, layout drawings, the latestedition of relevant specifications, codes of practice of Bureau of IndianStandards and OISD standards listed below

SP:30 (BIS) Special Publication National Electrical Code.

IS: 1255 Code of practice for installation and maintenance of power cables upto and including 33 KV rating.

IS:108 10 Method of Test for cables; Part 43 Insulation resistance.(Part 43)

IS:10810 Method of Test for cables ; Part 45 High voltage test.(Part45)

OISD 147 Inspection and safe practice during electrical installationOISD 173 Fire prevention and protection system for electrical

installation

2.2 In addition to the above it shall be ensured that the installation conforms tothe requirements of the following as applicable:a. Indian Electricity Act and Rules.b. Regulations laid down by CEA/Electrical Inspectorate.c. Regulations laid down by CCE!DGMS/DGFASLI (as applicable).d. The petroleum rules (Ministry of Industry Government of India).

e. Any other regulations laid down by central/state/local authoritiesand insurance agencies

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3.4 Ferrules:Ferrules shall be of approved type and of size to suit core size mentioned andshall be employed to designate the various cores of control cable by the

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terminal numbers to which the cores are connected, for ease of identification.

4 Cable Laying4.1 General

Cable installation shall include power, control, lighting, fire alarm, telephoneand communication cables. These shall be laid in trenches! cable trays asdetailed in the cable layout drawings. Cable routing given on the cable layoutdrawings shall be checked in the field so as to avoid interference withstructures, heat sources, drains, piping , air-conditioning duct etc. Any

change in routing shall be done to suit the field conditions wherever deemednecessary, after obtaining approval of Engineer-in-charge.

4.1.1 High voltage, medium voltage power and control cables shall be separatedfrom each other by adequate spacing or by running through independentpipes, trenches or cables trays, as shown on layout drawings/installationstandards. Details of cable routes and cable spacing not shown in detail onthese drawing shall be determined by the contractor and approved by the

engineer in-charge.

When single core cables are laid in flat formation, the individual cable fixingclamps and spacers shall be of non-magnetic material. As a general practice,the sheath of single core cables shall be earthed at one point to keep sheathat earth potential unless otherwise stated. Single core cables, when laid intrefoil formation shall be braced by suitable clamps at a distance, notexceeding 3 meters along the cable routing.

If straight through joints are required to be provided on single core cables,

4.1.2 The lengths indicated in the cables schedule are only approximate. Thecontractor shall ascertain the exact length of cable for a particular feeder bymeasuring at site. All cable routes shall be carefully measured .Before the

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start of cable laying, the contractor shall prepare cable drum schedule and

get that approved by Engineer-in -charge to minimise/avoid straight through joints and then the cables cut to the required lengths, leaving sufficientlengths for the terminations of the cable at both ends. The various cablelengths cut from the cable reels shall be carefully selected to prevent unduewastage of cables. Extra loop length shall be given for feeder cables whererequired as per the directions of Engineer-in-charge to meet contingencies

Cables shall be laid in directly buried trench or in RCC trench (underground

trench) or in cable tray along pipe sleepers or in over head trays as shown oncable layout drawings.

Overhead trays shall be installed 2700 mm (minimum) above grade level. Atroad crossings overhead trays shall be installed at 7000 mm (minimum)above grade level or cables shall be routed cable tray culvert! Electrical roadcrossings as per layout drawings.

Sufficient care shall be taken while laying cables to avoid formation of twist,sharp bend etc. in order to avoid mechanical injuries to cables. Rollers shallbe used for pulling of cables.

Cable installation shall provide minimum cable bending radii as recommendedby cable manufacturer.

4.1.3 Cables shall be neatly arranged in the trenches / trays in such a manner that

cr155-crossing is avoided and final take off to the motor / switchgear isfacilitated, Arrangement of cables within the trenches / trays shall be in line

trenches shall be identified by means of cable markers as per installationdrawing. These cable markers shall be placed at location of changes in thedirection of cables and at intervals of not more than 30 m and also at cable

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straight through joint locations.

4.1.5 All temporary ends of cables must be protected against dirt and moisture toprevent damage to the insulation. For this purpose, ends of cables shall betaped with an approved PVC end cap or rubber insulating tape.

4.1.6 Each row of cables shall be laid in place and before covering with sand. Allwall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water inside building/lined trench. Every cable

shall be given an insulation test in presence of Engineer-in-charge/Ownerbefore filling the cable trench with sand Any cable which is found defectiveshall be replaced.

4.1.7 Where cables pass through foundation walls, the necessary openings shall beprovided in advance for the same by another agency. However, should itbecome necessary to cut holes in existing structures for example floor slabetc., the electrical contractor shall determine their location and obtain

approval of the Engineer-in-charge before carrying out the same.

4.1.8 Cables for road crossings shall be taken through ERC (Electrical RoadCrossing) as shown in the cable layout drawings.

At road crossing and other places where cables enter pipe sleeves adequatebed of sand shall be given so that the cables do not slack and get damagedby pipe ends.

4.1.9 Wherever cable trench crosses storm water, waste water channel/drain,

Minimum depth of cable trench shall be 750 mm for medium voltage and 900mm for H.V. Cables. The depth and the width of the trench shall varydepending upon the number of layers of cables as per GAIL installationS d d

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Standards

Cables shall be laid in buried trenches at depth as shown in the cable layoutdrawings. It is to be insured by the contractor that the bottom of buriedtrenches shall be cleared of all rocks, stones and sharp objects before cablesare placed. The trench bottom shall be filled with a layer of sand. This sandshall be leveled and cables laid over it. These cables shall be covered with150 mm of sand on top of the largest diameter cable and sand shall be lightlycompacted. A flat protective covering of 75 mm thick second class red bricks

shall then be laid and the remainder of the trench shall then be back -filledwith soil, rammed and leveled.

4.3 Cables laid in concrete trenchCables shall be laid in 3 or 4 tiers in concrete trench as shown on layoutdrawings. Concrete cables trenches shall be filled with sand in hazardousarea to avoid accumulation of hazardous gases and oil. RCC covers of trenches shall be effectively sealed to avoid ingress of chemical and oil in

process area. Removal of concrete covers where required for the purpose of cable laying and reinstating them in their proper position after cables are laidshall be done by electrical contractor.

All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water

4.4 Above ground cables

4.4.1 Cables installed above grade shall be run in cable trays, clamped on walls,ceiling or structures and shall be run parallel or at right angles to beams ,

4.4.3 Cable laid on supporting angle in cable trenches, structures, columns andvertical run of cable trays shall be suitably clamped by means of G.I. saddles / clamps, whereas cables in horizontal run of cable trays shall be tied by

f l d Di t b t ti l h ll t d

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means of nylon cords. Distance between supporting angles shall not exceed

600 mm.

4.4.4 All cable trays (other than galvanised trays) and supporting steel structuresshall be painted before laying of cables. The under surfaces shall be properlydegreased, de-rusted, de-scaled and cleaned. The painting shall be done withone coat of redoxide zinc chromate primer. Final painting shall be done withtwo coats of approved bituminous aluminium paint unless otherwisespecified.

4.4.5 Where cables rise from trench to motor, lighting panel, control station, junction box etc., they shall be taken in GI pipe for mechanical protectionupto a minimum of 300 mm above grade. Cable ends shall be carefully pulledthrough conduit to prevent damage to cable.

4.4.6 All GI Pipes shall be laid as per layout drawings and site conditions. Beforefabrication of various profiles of pipes by hydraulically operated bending

machine (which is to be arranged by the contractor) all the burrs from thepipes shall be removed. 01 Pipes having bends shall be buried in soil /concrete in such a way that the bend shall be totally concealed. For G.I.pipes buried in soil, bitumen coating shall be applied on the buried lengths,Installation of G.I. pipes shall be undertaken well before paving is completedand necessary co ordination with paving agency shall be the responsibility of Electrical Contractor.

Following guide shall be used for sizing of pipe.a. 1 cable in a pipe -53% of pipe cross-sectional area occupied by cables.

thick and securely fastened to the cable, wrapped around it) and also alongthe route at recommended intervals, by cable tag numbers.

All bl t i f td t i ti h ll b f bl th h b tt

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All cable entries for outdoor termination shall be preferably through bottom.

Outdoor cable termination through top of equipment shall not be permitted.

5.2 Power cables cores wherever colour coding is not available shall be identifiedwith red, yellow and blue PVC tapes. Where copper to aluminium connectionsare made, necessary bimetallic washers shall be used.

5.3 In case of control cables, all cores shall be identified at both ends by theirterminal numbers by means of PVC ferrules suitable for core size. Wire

numbers shall be as per schematic! wiring/inter-connection diagram. Allunused spare cores of control cables shall be neatly bunched and ferruledwith cable tag at both ends, for future use.

For trip circuit identification additional red ferrules shall be used only in theparticular cores of control cables at the termination points in the Switchgear/Control panels and Control Switches

5.4 Contractor shall drill holes for fixing glands wherever necessary. Gland plate

shall be of non- magnetic material! aluminium sheet in case of single corecables. All unused cable entries on equipment/panels shall beplugged/sealed.

5.5 The cable shall be terminated at electrical equipment /switchboards throughglands of proper size. The individual cores shall then be dressed and takenalong the cables ways or shall be fixed to the panels with polyethylene straps. The cable glanding shall be done as per manufacturers instructions. Cable

armour shall not be exposed after termination is complete. In case of termination of cables at the bottom of a panel over a cable trench having no

5.8 The cable joints in power and control cables shall be avoided as far aspossible. In case a joint is unavoidable, the following shall be insured:# The number of joints shall be restricted to minimum as far as possible.# The location of joints shall be identified ith pe manent ma ke s

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# The location of joints shall be identified with permanent markers.

# No joints shall be allowed in hazardous areas without the approval of Engineer-in- charge.The jointing and termination of medium voltage power cables shall be carriedout by trained personnel only. Jointing and termination of high voltage cablesshall be done by skilled and experienced jointer duly approved by Engineer-in-charge. Only type tested termination kits of approved make shall be used.

5.9 No unauthorised repairs, modifications shall be carried out on the hazardous

area equipment terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall be brought to the notice of Engineer-in-charge by contractor. After termination is complete, all the bolts, nuts, hardwares of terminal box shall be properly placed in its position and tightened.

5.10 Where required, cable sealing boxes intended to be used with the apparatusshall be filled with solid setting type bituminous compound unless otherwisespecified.

6 TESTING AND COMMISSIONING

6.1 Field testing and commissioning of electrical installation shall be carried outas per GAIL specification S-07-02-004.

6.2 Before energising, the insulation resistance of every circuit shall be measuredfrom phase to phase, phase to neutral and from phase/neutral to earth.

6.3 Where splices or terminations are required in circuits rated above 650 volts,

insulation resistance of each length of cable shall be measured beforesplicing and or / terminating. After completion of splices and for terminations

Cables shall be installed in final position with all the straight through jointscomplete. During the high voltage test, all other electrical equipment relatedto the cable installation, such as switches, instrument transformers, bus bars,etc must be earthed and adequate clearance shall be maintained from the

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etc., must be earthed and adequate clearance shall be maintained from the

other equipment and framework to prevent flash-overs.

In each test, the metallic sheath/screen/armour shall be connected to earth.

6.6 All checks and tests shall be made as per Owner’s standard test Performaavailable with site engineer. All test readings shall be recorded and submittedto GAIL in triplicate sets.

6.7 Cable schedule, cable layout drawings, Interconnection drawings shall bemarked by contractor for ‘AS BUILT STATUS’ and two sets of copies shall besubmitted to GAIL.

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SPECIFICATION FOR LIGHTING

INSTALLATION

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Abbreviations:

BIS : Bureau of Indian Standards


CMRI Central Mining Research Institute

DG Diesel Generator

DGMS Director General Mines and Safety

ELCB Earth Leakage Circuit Breaker

FFL Finished Floor Level

FRP Fibre Glass Reinforced Plastic

GI Galvanised Iron

HPMV High Pressure Mercury Vapour

HPSV High Pressure Sodium Vapour

MCB : Miniature Circuit Breaker

MDB M i Di ib i B d

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CONTENTS

1 SCOPE


1 EQUIPMENT SPECIFICATIONS

1 LIGHTING INSTALLATION


1 SCOPEThis specification defines the requirements for the supply of equipment,materials, installation, testing and commissioning of the lighting system(lighting fixtures lighting power distribution telephone wiring etc )

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(lighting fixtures, lighting power distribution, telephone wiring etc.).

2 CODES AND STANDARDS2.1 The work shall be carried out in the best workmanlike manner, in conformity

with this specification GAIL Installation Standards, and the relevantspecifications/codes of practice of the Bureau of Indian Standards.

2.2 In addition to the above it shall be ensured that the installation conforms tothe requirements of the following as applicable:

a) Indian Electricity Act and Rules.b) Regulations laid down by CEA/Electrical Inspectorate.c) Regulations laid down by CCE/DGMS (as applicable).d) The petroleum rules (Ministry of Industry Government of India).e) Any other regulations laid down by central/state/local authorities and

Insurance agencies.

3 EQUIPMENT SPECIFICATIONS

All materials, fittings and appliances to be supplied by the contractor shall benew, unused and of the best quality and shall conform to the specificationsgiven hereunder. These shall be manufactured in accordance with the latestrevision of the specifications of Bureau of Indian Standards/Internationalstandards. In the absence of any specifications for a particular item,contractor shall bring material samples along with proven track record to siteand get the same approved by Engineer-in-Charge/Owner before installation.

3.1 Lighting and Power Panels3.1.1 Lighting and Power panels (general purpose panels for safe area) shall be

current carrying capacity. The outgoing feeders shall be provided with singlepole miniature circuit breakers (MCBs) for safe areas and double pole MCBsfor hazardous areas. The incomer shall be with MCB and ELCB unit unlessotherwise specified Miniature circuit breakers shall be mounted in such a

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otherwise specified. Miniature circuit breakers shall be mounted in such a

way that the operating levers project outside the front bakelite cover platesfor ease of operation. A hinged door to cover the operating knobs shall beprovided. In addition, a circuit diagram indicating incomer details andoutgoing details viz. Circuit number, circuit rating, load connected and detailsof the load shall be pasted inside the panel. Also a laminated copy of thediagram shall be provided inside the panel in a suitably designed pocket. Twoexternal earthing studs for connection to the plant eathing grid shall beprovided on the panel. Further, the panel shall be provided with an earth bus

bar with terminal studs for connection to the third core of each outgoingcircuit. Each circuit phase and neutral shall be given ferrule numbers.Complete wiring inside the panel, shall be neatly bunched with PVC tape andbutton. Sufficient terminals shall be provided in the terminal block so as toensure that not more than one wire (core) is connected to a terminal. Thepanel shall have knock out holes or removable gland plate for the entry of incoming and outgoing conduits or cables. The panels shall be complete withrequisite number of cable glands as specified.

3.1.3 The Main distribution board (MDB) where used, shall be made of 2mm thick sheet steel panel, dust and vermin proof similar in construction to Lightingand Power panels but with TPN MC13 incoming and TPN outgoings (MCBwith ELCB units and MCB without ELCB unit as applicable) of requirednumbers as specified.

3.1.4 All MCBs shall be of M9 category as per IS 8828 and sensitivity of ELCBs shall

be 100 mA unless otherwise specified.

3.3 SwitchesSwitches, manufactured in accordance with IS:13947 shall be used for nonhazardous areas. Switches in areas where concealed wiring has beenadopted shall be flush mounting piano type unless otherwise specified For

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adopted, shall be flush mounting piano type unless otherwise specified. For

surface conduit wiring, piano type switches in surface mounted box shall beprovided. Industrial Type switches (Weather protected) shall be used foroutdoor areas.

3.4 ReceptaclesThree pin type 5A/15A receptacles manufactured in accordance with IS: 1293shall be used for non hazardous areas. The receptacles and the controllingON/OFF switch shall be mounted in the same enclosure box but these shall

be in separate units to facilitate replacement by parts. Flush mounting typereceptacles shall be used in areas where concealed wiring has been adoptedand surface type shall be used in other areas. For exhaust fans and wallmounted air circulators, socket and switch enclosures shall be separate. Inbuildings such as sub-station, D.G. shed, Workshop, maintenance shop etc.industrial type metal clad socket outlets and plugs shall be provided. Thesesockets shall be supplied complete with plugs.

3.5 Outlet BoxesThe outlet boxes used as point outlets shall be prefabricated type 65mmdeep junction boxes. Outlet boxes custom fabricated for sockets, switches,fixtures and fan regulators etc. shall be made of M.S. Sheet having minimumthickness of 1.6mm. Outlet boxes shall be galvanized after fabrication. Theseshall be complete with terminal block suitable for connection of wires up to 4sq. mm Front cover plate shall be of 3mm thick backelite / PB sheet. Thecolour shall suit the shade of the walls or shall be white if the shade of the

walls is not finalised. The sheet shall extend at least 2 cm on all sides of outlet box. Cover plate shall be fixed by cadmium plated brass screws and

together when hot and bevelled on outside edges. Poles shall be coated withbituminous preservative solution on the ground portion of the outsidesurface. Remainder of the outside surface shall be given one coat of redoxideprimer and finished with two coats of aluminium paint. The pole shall have, a

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primer and finished with two coats of aluminium paint. The pole shall have, a

marshalling box near the bottom to contain HRC fuses, a neutral link, anearth stud and terminal block.

3.8 Lighting Mast3.8.1 Lighting masts (Lattice tower) where used, shall be fabricated as per

VENDOR STANDARDS AND THE DESIGN MUST BE APPROVED BY GAIL. Theyshall be complete with 2 nos. MS flats provided at the base plate forconnection to the plant earthing grid. A ladder, platform, handrail, a weather

protected TPN switch (at 1500mm from ground level) and a weatherprotected distribution board fabricated out of sheet steel shall be provided atthe top of mast. The TPN Switch and the distribution board shall also have acanopy for additional weather protection. The TPN switch shall be suitable forlooping one more lighting mast from the same incoming power supply. Thedistribution board shall have TP&N busbars of 30 Amps. rating and 12 Nos.outgoing circuits each with a 6A single pole MCB. The distribution board shallhave cable entries from bottom. Necessary space provision and suitable

mounting arrangement shall be made on top of the tower for mounting of ballast (choke) and condensers for all the circuits and the lighting fixtures.The masts shall be given one coat of red oxide primer and two coats of aluminium paint. Distribution board shall be fabricated out of 2mm thick sheet steel and shall be painted with two coats of enamel over a base coat of red oxide.

3.8.2 Unless otherwise specified the flood lighting high masts shall be telescopic

type AND MUST BE APPROVED BY GAIL BEFORE PROCUREMENT.

3.11 Decorative switches and sockets

Decorative lighting switches and sockets where specified, shall be modular indesign. All these items shall fit into the same frame with overall standard

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design. All these items shall fit into the same frame with overall standard

dimensions. Frames shall be suitable for surface and flush mounting in brick!concrete wall. The frames shall be suitable for conduit entry from all thesides. Switches and sockets shall match colors of the frame and cover platesto obtain a combination which shall match decor of the interiors of ControlRoom, Administrative buildings, offices rooms etc.

4 LIGHTING INSTALLATION

4.1 General

4.1.1 The lighting fixtures in the plant shall be fed from lighting panel. All outdoorlighting shall be group controlled manually or through synchronous timer orphotocell. Lighting wiring between panel and lighting fixtures shall be donewith PVC insulated 3-core (phase, neutral and earth) copper conductorarmoured cable for hazardous areas. Wiring in the building shall be done bymeans of 3-core copper, conductor PVC insulated, un-armoured cables, orPVC insulated copper conductor wires in conduit Metsec channel as specified. All joints of conductors in Switch boards/JBs Fittings shall be made only by

means of approved mechanical connectors (nylon/PVC connectors). Baretwisted joints shall not be permitted any where in the wiring system.

4.1.2 The lighting layouts furnished by owner will indicate approximate locations of lighting fixtures. The electrical contractor shall determine, with approval of Engineer-in-Charge, the exact locations of each fixture in order to avoidinterference with piping or other mechanical equipment and also with a viewto obtain as much uniform illumination as practicable, and to avoid

objectionable shadows. Conduits shall be laid out by the contractor to suitfield conditions and as per directions of the Engineer-in-Charge.

4.1.6 Mounting height of equipment shall be as undero Top of Switch Box 1200 mm from FFL(Finished floor level)o Top of Lighting/Power Panel : 1800mm from FFLo 5/15 Amp. receptacle : 300mm from FFL unless otherwise specified (1200

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o 5/15 Amp. receptacle : 300mm from FFL unless otherwise specified (1200

mm for process areas and industrial sheds)o Lighting fixture As indicated in layout drawingo Exhaust fan : In the cutout provided / as indicated in Layout drawings.

4.1.7 Fixtures shall be firmly supported from the structures. Support clamps etc.may be bolted or welded to the existing steel work or metal inserts. In caseof concrete structures, where metal inserts are not available, fixtures shall besuspended from concrete surfaces with the help of anchor fasteners, In such

cases special care shall be taken to see that anchoring is firm. In placeswhere ceiling fans are provided, lighting fixtures shall be suspended belowthe level of fan to avoid shadow effect.

4.1.8 Circuit cables in a group shall be cleated to structure by using galvanisedstrip clamps or cable run in cable trays wherever trays are available. Spacersand cleats shall be of required size to accommodate the cables. All hardwareshall be galvanised or zinc passivated. Underground lighting cables (in paved

areas) shall be taken in suitable G.1. sleeves buried at a minimum depth of 300mm from FFL. GI pipe sleeves shall be extended to 300mm above FFL.Exact termination/layout of G.I. pipes (for protection of cables) shall bedecided at site as per site convenience in consultation with Engineer-in-charge.

4.1.9 Wiring for all outlet sockets shall be done with 3 cores of equal sizes forphase, neutral and earth. The terminals of switch sockets shall be suitable to

receive the size of wire specified.

4.1.14 Wiring for exhaust fans shall be terminated in receptacles as specified inlayout drawing and the connection from receptacle to the exhaust fan shallbe by means of a flexible cord equivalent in size to the main run of wires.Switch for exhaust fan shall be located in a separate switch board along with

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p g

other switches.

4.2 Conduit System4.2.1 Surface or concealed conduit system of wiring shall be adopted, as specified

in the drawings. Required number of pull boxes shall be used at intervals tofacilitate easy drawing of wires. Separate conduit shall be run for lighting andpower circuits. Further, conduits for Normal lighting/Emergency lighting/DCcritical lighting shall be separate. Conduit layout shall be decided at site as

per site conditions. Drop conduits for switch boards shall be decided bycontractor as per wall locations shown in Architectural drawings. All exposedrun of conduits on surface, shall be vertical or horizontal.

4.2.2 Only threaded type conduit fittings shall be used for metallic conduit system.Pin grip type or clamp type fittings are not acceptable. Conduit ends shall befree from sharp edges or burrs, The ends of all conduits shall be reamed andneatly bushed.

Conduit shall be of minimum 25mm dia. Maximum number of wirespermissible in a conduit shall be seven/nine for wire size of 2.5 sqmnill.5sq.mm. respectively.

4.2.3 The exposed outer surface of the conduit pipes, including all accessoriesforming part of the conduit system, shall be adequately protected againstrusting. In all cases, bare threaded portion of conduit pipe shall not be

exposed unless such bare threaded portion is treated with anti corrosivepreservative or covered with approved plastic compound.

other agencies involved in the civil works in such a way, that the work of theother agencies is not hampered or delayed. Vertical conduit runs shall bemade in wall before plastering is done so as to avoid chasing. Where chasesare made for conduit run contractor shall fill these chases or any other

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y

openings made by them after completing the work and patch the surface.During installation, care shall be taken to see that proper covers are providedto prevent rusting of conduits. Locations of all point outlets, junction boxesshall be marked with brick powder or sand so that these are easily identifiedafter shuttering removal. As built conduit layout drawing shall be submittedby contractor after completion of the work.

4.2.7 All junction boxes, bends and other accessories shall be of the same material

as that of conduit and shall have the same protective coatings.

4.2.8 After erection, the entire conduit system shall be tested, for mechanical andelectrical continuity and shall be permanently connected to earth by means of approved type of earthing clamps.

4.3 Hazardous Area Installation

4.3.1 Wiring in hazardous area shall be done by using minimum 2.5mm2 copper

conductor armoured cable. Circuit wiring feeding hazardous areas shall becontrolled by two pole switches/MCBs (for phase as well as neutral isolation).

4.3.2 Correct type of lighting equipment (fixtures and JBs) with regard tohazardous protection as specified in the drawing, shall be installed for theareas classified as Zone 1, Zone 2 etc.

4.3.3 The terminations in the junction boxes and the lighting fittings shall be done

avoiding possibility of loose connections due to vibrations. After theterminations are made the cover of the junction boxes and the lighting

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4.4.5 Building conduit lighting system of wiring where measurement is done onpoint wiring basis generally consists of two parts. The first part is the circuitwiring which includes the work necessary from lighting panel up to switchbox and from switch box to another switch box.. The second part is the point

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p p

wiring which shall include the work necessary from tapping point in theswitch box upto various fixtures or fan outlets/ceiling roses.

4.4.6 In no case, two different sources or two different phases of supply shall becombined in one switchboard.

4.4.7 Switches for light fixtures/exhaust fans in battery room shall be providedoutside the Battery room.

4.4.8 Lighting layouts for non-plant buildings (such as ware house, cementgodown, gate house, workshop, service building, rest room, etc.) shall beprepared by installation contractor.

The following basic data/document for preparation of layouts will be providedto the contractor.i) Architectural drawings

ii) Illumination level requirediii) Type of lighting fixtureiv) Type of wiring (concealed/surface conduit/cable wiring etc.)

Based on the above input, contractor shall prepare and submit lighting layoutdrawings, panel schedules, conduit layout drawings for concealed wiring,design calculations wherever required, for review by purchaser beforeerection work is started. The lighting layout drawing shall show the location,

type and mounting details of lighting fixtures, receptacles, junction boxes,layout of circuit indicating number of wires etc. The number of points in a

4.5.2 Each pole shall be earthed at two points by connecting to the plant earth gridas shown on Installation standards.

4.5.3 Street lighting fixture shall be mounted on steel tubular poles as per standard

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drawings. The foundation for the street lighting poles will be made byelectrical contractor. Street lighting poles shall be supplied with a base plate.

4.5.4 The poles shall be numbered as per the drawings! directions of Engineer in-Charge.

4.6 Mast Lighting4.6.1 The lattice structure masts shall be installed on concrete foundations with the

base plate bolted on to the anchor bolts. The lattice structure shall bepainted with a coat of primer and two coats of aluminium paint, the secondcoat to be given just before handing over to the owner. The masts shall benumbered as per drawings. The masts shall be connected to the plant earthgrid at two points

4.6.2 The main feeder upto the distribution board of lighting mast shall be throughPVC insulated armoured cable of size as specified in the respective drawing.

Wiring from Distribution Board to each flood-light fixture shall be by means of a 3-core 2.Ssqmm, copper conductor PVC insulated armoured cable. All thecables shall be neatly clamped to the structure at intervals not exceeding 25cm.

4.6.3 Alternatively the flood light high mast shall comply to specification no. S-07-01-014

4.6.4 Exact orientation of flood lighting fixtures shall be decided at site to achieveoptimum utility of these fixtures.


5.1 Lighting installation shall be tested and commissioned by installationcontractor as per GAIL specifications S-07-02-004. Pre-commissioning checksand tests, shall include but not be limited to the following:

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(i) The insulation resistance of each circuit without the lamps (load) being inplace shall be measured and it should not be less than 500,000 ohms.(Between phases, phases to neutral, phase/neutral to Earth).

(ii) Current and voltage of all the phases shall be measured at the lightingpanel busbars with all the circuits switched on with lamps. If required loadshall be balanced on the three phases.

(iii) The earth continuity for all socket outlets shall be checked. A fixedrelative position of the phase and neutral connections inside the socket

shall be established for all sockets.(iv) After inserting all the lamps and switching on all the circuits, minimumand maximum illumination level shall be measured in the area andrecorded.

(v) It shall be ensured that switch provided for ON/OFF control of point(light/fan/socket) is only on LIVE side.

(vi) Operation of ELCB’s shall be checked

Contractor shall duly fill in all the above test results and submit the test reportsto Engineer-in- Charge in triplicate.

5.2 All lighting layout drawings shall be marked by contractor for ‘AS BUILTSTATUS’ Wand two sets of copies shall be submitted to GAIL.

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SPECIFICATION FOR PIPELINE

LAYING AND TERMINAL WORKS

(ELECTRICAL)

CONTENTS

1 GENERAL

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1. GENERAL

2. AREA CLASSIFICATION

3. DESCRIPTION OF REQUIREMENTS FOR CATHODIC PROTECTION AND

ELECTRICAL WORKS

4. INSPECTION, TESTING AND COMMISSIONING

5. DRAWINGS AND DOCUMENTS

ANNEXURE-1: MAKE OF ELECTRICAL EQUIPMENT/COMPONENTS

1.0 GENERAL

1.1 Introduction

1.1.1 The intent of this specification is to define the requirements for Design,i i l ti t ti d i i i f th l t i l

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engineering, supply, erection, testing and commissioning of the electricalworks, viz. power supply system, lighting, cabling, earthing, lightningprotection system and fire alarm system, etc. at all stations associated withSultanpur-Neemrana pipeline

1.1.2 The electrical portion for pipeline laying work as covered in this specificationincludes design, supply, installation, testing and commissioning of the powersystem as per the single line diagrams (SLDs) and description given in thisdocument and other associated documents enclosed with this tender, takingstatutory approvals and energizing the system. The contractor shall alsoprepare electrical layout drawings for equipment layout, cabling layout,lighting layout, earthing and lightning protection layouts, Fire alarm systemlayout, cable schedule, interconnection diagrams, etc. for eachstation/Terminal along the route of the pipeline.

1.1.3 The Electrical works at each station/Terminal and all works related to

temporary and permanent cathodic protection system for the pipeline shall beexecuted by contractor in line with scope document, job specification, designbasis, data sheets, GAIL standard specifications, standard drawings andNational/International codes & standards. In case of conflict between variousdocuments, following shall be order of priority:-

- Scope document

- Design Basis & Single Line Diagrams

- Data sheets- GAIL standard specifications/standard drawings

1.2.2 In addition, the work shall also conform to the requirements of the following:

(a)The Indian Electricity Act and rules framed there under.

(b)The fire insurance Regulations.

( ) Th l ti l id d b El t i l I t t (CEA)

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(c) The regulations laid down by Electrical Inspectorate (CEA).

(d)The regulations laid down by the Factory Inspector.

(e)The regulations laid down by the Chief Controller of Explosives.

(f) The regulations laid down by Oil Industries Safety Directorate (OISD).

Any other regulations laid down by the Central, State or Local Authoritiesfrom time to time during the execution of this contract.

1.3 Guarantee

The contractor shall guarantee the installation for satisfactory operationagainst any defects of workmanship and materials (supplied by thecontractor) for a period as specified elsewhere. Any damage or defectconnected with the erection of materials, equipments or fittings supplied bythe contractor that may be discovered at the time of issue of the completioncertificate, or arise or come to light thereafter, shall be rectified or replacedby the contractor at his own expense as deemed necessary and as per the

instruction of owner or Engineer-in-Charge within the time limit specified bythe owner or Engineer-in-Charge.

1.4 Site Condition

The equipment offered and the installation shall be suitable forcontinuous operation under the site conditions mentioned in design basisdoc.no. 0001-01-07-03-001

1.5 Utilisation Voltage

Design basis document no. 0001-01-07-03-001, data sheets andspecifications attached elsewhere in this tender.

3.2 ELECTRICAL WORKS

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Electrical works including design, supply, installation, testing andcommissioning of all electrical items shall be provided.

The power supply shall be met from Solar system at 24V DC (Floating)output. The electrical power distribution to various electrical consumers at24V DC shall be done from 24V DC switchboard. 24V DC power distributionas required for SCADA, FA panel, DC lighting (in Telecom room, electricalroom). Necessary DC-DC converters required for feeding telecom equipment

shall be provided as part of DC switchboard.

3.3 At all earth test pits, earth strip shall be bolted with electrode using minimumtwo bolts as per the requirements of OISD. Earthing of main gate, fence andsteel cage over MOV etc. at each station shall also be in the scope of contractor. All SVs installed on cathodically protected pipeline shall be earthedusing 2 number of zinc anodes (20KG net weight).

3.4 Rat repellant electrical system is to be provided in all stations to avoiddamage to the cables and cabling into the marshalling units/electricalequipment.

3.5 Safety Earth (Instrumentation cabinet earth): The same shall be commonearth for Instrumentation/SCADA/Telecom, connected to electrical safetyearth. Cables (e.g Instrumentation cables/ Optical cable, etc) coming fromfield shall also be terminated on this earth

3 6 Signal/system earth : For Instrumentation and SCADA one dedicated earth of

4.2 Any work not conforming to the execution drawings, specifications, or codesshall be rejected forthwith and the contractor shall carry out modifications athis own cost.

4 3 All t t h ll b d t d i th f th / i i h

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4.3 All tests shall be conducted in the presence of the owner/engineer-in-chargeor his authorised representative unless he waives this requirement in writing.The contractor shall arrange all testing equipment necessary to carry out thetests. The tests shall be recorded on approved Performa and certified recordsof the tests shall be submitted to the owner/ engineer-in-charge.

4.4 All test certificates and the contractor shall submit field test reports aftercompletion of work in bound volumes (6 sets).

5.0 DRAWINGS AND DOCUMENTS

5.1 Contractor shall submit all datasheets/ drawings and documents to the

5.2 owner/ engineer-in-charge.

5.2 A complete set of reproducible drawings for contractor-supplied equipmentshall be furnished to the owner for records. As-built layouts, cable schedulesand interconnections shall be submitted by the contractor on the hard copiesas well as in soft copy usable on a WINDOWS 2000 PC.

5.3 Drawings and data of Solar system power source, Ni-Cd batteries, 24V DCSwitchboards, cables, lighting fixtures, CP system shall be submitted forreview by owner/ GAIL.

5.4 Vendor catalogues and literature shall be supplied for all equipment includedin the scope of Contractor.

ANNEXURE-1

1.1 Following is the list of approved makes for electrical equipment:-

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MV Switchboards (Fixed type)Siemens/ L&T/ GE India Industrial Pvt.Ltd. /Schneider Electric/ Control & Swgr./ Control & Schematics/M.K.Engineers & Controls Pvt.Ltd./Bhartia Industries Ltd.

Cables-Medium Voltage-Power -PVC

Associated Flexibles & Wires (P) Ltd./ CCI/Finolex Cables Ltd./ Gemscab Ind. Ltd./IndustrialCables(I) Ltd./ KEI Ind. Ltd./ Nicco Corp. Ltd./Polycab Wires Pvt. Ltd./ Radiant Cables Pvt. Ltd./Ravin Corporation Ltd./ Torrent Cables Ltd./Universal Cables Ltd./Havell’s India Pvt. Ltd/RPGCables ltd

Cables-Control-PVC

Associated Flexibles & Wires (P) Ltd./CMILtd./Brooks Cable Works, Bombay/ Cords CableInd.Ltd./ Delton Cables Ltd./ EvershineElectricals/ Elkay Telelinks (P) Ltd./ FinolexCables Ltd./ Gemscab Ind.Ltd./ Goyolene Fibres(India) Pvt.Ltd./ Havell’s India Pvt.Ltd./ Industrial

Cables(I) Ltd./ KEI Ind.Ltd./ Nicco Corp. Ltd./North Eastern Cables Pvt. Ltd./ ParamountCommunications Ltd./ Polycab Wires Pvt.Ltd./Radiant Cables Pvt.Ltd./Ravin Cables Ltd./Reliance Engineers Ltd./ Suyog Electricals Ltd./Torrent Cables Ltd./ Universal Cables Ltd.

Cables-Fire alarm and comm.CMI Ltd./ Delton Cables Ltd./ KEI/ ElkayTelelinks/ Reliance Engineers Ltd./Cords Cable

Cathodic Control Co. Pvt. Ltd./ Electro Protection

1.2 Following is the list of approved makes for electrical components:-

Lighting Fixtures for nonHazardous area

Bajaj/Crompton/Philips/Havell’s Ind Pvt. Ltd.

Baliga/ Comet Brass Products/ Comet Industries/ Flexpro/

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Cable glands for azardous area Flameproof Equipment / FCG Power/ FCG Flameproof Control GearsPvt Ltd./ Prompt Engg. Works/ Sudhir Swgrs. Pvt. Ltd/StandardMetal Industries.

Protection relays(Electromechanical type)

ABB (Baroda) /Easun Reyrolle/ Areva T&D India Ltd. (T&DGroup)/Siemens ltd./Schneider Elect. Pvt.ltd./L&T

Auxiliary Relays Areva T&D India Ltd. (T&D Group)/Jyoti ltd./ABB (Bangalore)

Control switches/SelectorSwitches

L&T/ Siemens/ Switron Devices/ Hot Line Swgrs.& Controls/Kaycee/ Areva T&D India Ltd. / Reliable Electronic components Pvt.Ltd.

MCBsDatar Switchgear/ Havell’s India/ Indo Asian fuse gear/ IndianaCurrent Control/ Standard Electricals/ Legrand India Pvt.Ltd./Schneider Electricals India Pvt. Ltd.

MCCBs GE India Industrial Pvt. Ltd./ L&T/ Schneider Electric

FusesL&T/ Siemens/ GE India Industrial Pvt. Ltd / Indo Asian fusegear/Cooper Bussman (I) Pvt. Ltd.

Timers Bhartia Ind./ L&T/ Siemens/ Electronic Automation

Meters

Automatic Electric/ Meco Instruments/ Rishab Instruments/ Nippen

Electricals Instruments Co./ Areva T&D India Ltd. (Type : Energymeters)

1.2 Following is the list of preferred makes equipment /material for CP system:-

Dehn+Sohne,

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Surge Diverters (Explosion Proof) Germany/OBOBettermann, Germany

Zinc ribbon anode :- Platt Line/Corpro

Permanent reference cell :- Borin, USA

Polarisation Cell:- Kirk, USA

E/R probes & reading meter:-Rose corrosion,USA/Caproco

Notes:-

1.0 Make of other equipment/components not mentioned above shall besubject to prior approval of GAIL.

2.0 Contractor may procure material from any of GAIL approved vendor/sub-vendors.

3.0 Contractor can offer component of makes other than specified in thetender, during order execution. The alternate make of components will beevaluated post order, based on the satisfactory track record and testcertificates to be furnished by the contractor. In case alternate makes arenot found acceptable, components shall be strictly as per above vendorlist.

4.0 In case of non-availability of equipment/material from above vendors,alternate makes if required may be supplied after GAIL approval

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SPECIFICATION FOR CORROSION

SURVEY

Abbreviations:

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ROU : Right of Use

EHV : Extra High Voltage

HV : High Voltage

CONTENTS

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1.0 SCOPE


3.0 GENERAL

4.0 SOIL RESISTIVITY SURVEY

5.0 TESTS ON SOIL SAMPLES

6.0 ADDITIONAL DATA COLLECTION

7.0 REPORT

1. SCOPE

The specification covers the requirements for corrosion survey includingmeasurement of soil resistivity, chemical analysis of soil/water and collectionof other cathodic protection related data along ROU of the pipelines.

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Equipment and measurement techniques shall unless otherwise specified,conform to the requirement of latest revisions of following applicablestandards:

BIS specificationsBS specifications and codes of practice

NACE publications

The work shall be carried out in compliance with all applicable local laws andregulations. In case of any contradiction between various referredstandards/specifications/data sheet and statutory regulations the followingorder of priority shall govern:

o Statutory regulations.o

Data sheets.o Job specification.o This specification.o Codes and standards.

3 GENERAL

This specification defines the basic guidelines for carrying out the corrosionsurvey. Contractor shall be responsible for providing necessary data

interpretation based on corrosion survey measurements, which is intended toform a basis for design of cathodic protection system for the pipeline.

be surrounding the pipe, shall be measured. Hence the depth of measurement / electrode spacing may vary depending on topography andstrata at the area.

4.3 At places where ROU has not yet been cleared, measurements shall be maderight over the centre line of pipeline route surveyed accounting for the

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right over the centre line of pipeline route surveyed accounting for thecuttings /fillings also.

4.4 Observations shall be made enclosing the soils adjoining the trench whereverpipeline trenching has already been done.

4.5 The observations shall be made enclosing the soil immediately surroundingthe pipeline route where ROU has been cleared but trenching has not been

done.

4.6 All measurements shall be taken at right angles to the ROU unless otherwiseasked by OWNER or his representative at site.

4.7 At places in ROU where other pipelines are already existing care shall betaken to precisely locate such pipes line and take such precautions thatobservations are not adversely affected by presence of such pipelines.

4.8 Care shall also be taken that the observations are not influenced by presenceof other earth currents in the area especially in the vicinity of EHV/HV linesand plants using earth return in their source of power etc.

4.9 Wherever possible / advised by OWNER or his representative, depth of watertable shall be determined by resistivity observations.

4.10 All measurements shall be made and recorded in metric units. Whilerecording the data reference to the nearest intersecting point shall be made.

The collected soil / water samples shall be analyzed to determine presenceand percentage of corrosive compounds including carbonates, bicarbonates,nitrates, chlorides, oxygen activity, moisture content and pH value.

6 ADDITIONAL DATA COLLECTION

The following data shall be collected with a view to generate design data for

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The following data shall be collected with a view to generate design data forevaluation of cathodic protection interaction possibilities due to presence of other services in ROU and its vicinity:

6.1 Following information regarding foreign service/pipeline in or around the ROU(for existing and those, which are likely to come up during contractexecution).

6.1.1 Types of service / pipeline and year of laying.

6.1.2 Diameter and pipeline coating in case of pipeline.

6.1.3 Parallel running / crossing.

6.1.4 Year of laying / commissioning.

6.1.5 Depth of laying.

6.1.6 Type of existing cathodic protection systems (impressed current /sacrificial).

6.1.7 Location and type (Deep well / surface) of anode ground bed.

6.1.8 Rating of impressed current type of anode ground bed.

6.1.9 Location of existing CP power supply units and their output voltage,

to verify possible interference with the CP system of the pipeline coveredunder this project.

6.2 Voltage rating, phases and sheathing details of cables running parallel orcrossing the ROU.

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crossing the ROU.

6.3 Existing and proposed DC/AC power sources and systems using earth returnpath such as HVDC substations/ earthing stations, fabrication yards withelectric welding etc. in the vicinity of the entire pipeline route.

6.4 Crossing and parallel running of electrified and non-electrified traction (alongwith information regarding, operating voltage, AC/DC type etc.) as well asabandoned tracks near ROU having electrical continuity with the tracks inuse.

6.5 Crossing or parallel running of any existing or proposed EHV/HV AC/DCoverhead power lines along with details of voltage, AC/DC type etc.

6.6 Voltage rating, phases, sheathing details of underground power cables alongROU or in its vicinity.

6.7 Any other relevant information that may be needed in designing andimplementing of proper cathodic protection scheme for the proposedpipeline.

7 REPORT

On completion of all the field and laboratory work an interim reportincorporating results generated from surveys, additional data collected,

results of test carried out, etc, shall be submitted for comments / approval.The report shall also highlight any adverse impact on performance of

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SPECIFICATION FOR EQUIPMENT /

MATERIAL FOR CATHODIC

PROTECTION SYSTEM FOR

PIPELINES

Abbreviations:

AC: Alternating Current

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BS: British Standards

BIS: Bureau of Indian Standards

CMRI: Central Mining Research Institute

CP: Cathodic Protection

CPPSM: Cathodic Protection Power Supply Module

CPTR: Cathodic Protection Transformer RectifierDC: Direct Current

HV: High Voltage

IS: Indian Standards

MMO: Mixed Metalic Oxide

MOV: Motor Operated Valves

NACE: National Association of Corrosion Engineers

PE: Polyethylene

PVC: Polyvinyl Chloride

ROW: Right of Way

CONTENTS

1. SCOPE

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3. SITE CONDITIONS

4. EQUIPMENT/MATERIAL SPECIFICATIONS

5. EQUIPMENT FOR CLASSIFIED AREAS

6. TESTS AND ACCEPTANCE


1.0 SCOPE

This specification covers the requirements for the design, manufacture,supply and testing of various equipment and materials for CathodicProtection system for underground pipelines/structures.These equipment and materials shall broadly include:

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q p y

- Sacrificial Anodes- Test Stations- Anodes for impressed current CP system- Anode junction boxes- Cathode junction boxes- Permanent reference cells- Electrical resistance probes- Polarisation cells and surge diverters/grounding cells- Polarisation coupons- Computerised test stations- Cables

Requirement of Cathodic protection TR units (CPTR unit) and cathodicprotection power supply modules (CPPSM) are covered in separate

specifications.


2.1 All equipment and material covered in this specification shall conform to therequirements of the latest revision of following standards:

IS 3043 Code of practice for earthing

NACE standardRP0169

Standard recommended practice Control of corrosionon underground or submerged metallic piping system

BS 7361, Part-I Cathodic protection, code of practice for land andmarine applications

2.4 In case of any contradiction between various referredstandards/specifications/data sheet and statutory regulations the followingorder of priority shall govern:- Statutory regulations.- Data sheets.

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- Job specification.- This specification.- Codes and standards.

3.0 SITE CONDITIONSThe equipment and materials shall be suitable for installation in locationshaving generally corrosive, warm and humid or dusty atmosphere. Serviceconditions shall be as specified in the project specification/data sheet. If notspecifically mentioned therein, a design ambient temperature 400C and analtitude not exceeding 1000 M above mean sea level shall be considered.

4.0 EQUIPMENT/MATERIAL SPECIFICATIONS All equipment/material shall be brand new with state of art technology andproven field track record. No prototype equipment shall be offered. Makeand construction of all equipment/materials shall be subject to approval byOwners representative.

4.1 Sacrificial Anodes4.1.1 Magnesium Anode

The anode shall conform to the requirements of ASTM-B 843 standard. Theanode shall be of high manganese, magnesium alloy packed with specialback fill. The metallurgical composition, potential and consumption rate of anode shall be as below:Composition

Element Weight Weight(High potential type) (Low potential type)

4.1.2 Zinc AnodeThe anode shall conform to the requirements of ASTM-B 418 standard. Themetallurgical composition of anode, potential and consumption rate of anodes shall be as below. Anodes of type I shall be used for seawater,brackish water or saline electrolyte application and anode of type II shall be

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used for fresh water, back fill and soil applications. The anode (other thanribbon anode) shall be packaged with special backfill. The type of ribbonanode inside the casing at cased crossing shall be suitable for the type of soil outside the casing..

Composition:

Element Weight Weight

(Type I) (Type II) Aluminium 0.1% to 0.5% 0.005% max.

Cadmium 0.025-0.07% 0.003% max.

Copper 0.005% max. 0.002% max.

Iron 0.005% max. 0.0014% max.

Lead 0.006% max. 0.003% max.

Others 0.01% max. -

Zinc Remainder Remainder

ii) Anode open circuitPotential

1.1 volts 1.1 volts

iii) Anode consumption rate 11.24Kg/(A.Yr) max 11.24Kg./(A.Yr.)max.

4.1.3 The anodes shall be provided with cable tail of sufficient length to reach teststation/ buried junction box, as applicable without any intermediate joint inthe cable and with minimum of 0.5m cable slack provided at each anodeand test station ends.

4 1 4 Th d h ll b k d ith i l b kfill d t l th t th

location of installation. For pipelines protected by sacrificial anodes, theanodes for directly grounding the pipeline shall be of the same type as theone provided for the protection of the pipeline.

4.1.8 Special Backfill

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The composition of special back fill for anodes shall be as below :

Gypsum 75%

Bentonite 20%

Sodium Sulphate 5%

4.2 Test StationsTest stations shall be provided along the pipeline ROW for monitoring theperformance of the cathodic protection system.

i) Test station enclosure shall be made of sheet steel of at least 3 mmthickness and shall be suitable for GI pipe post mounting. Teststations shall have weatherproof enclosure having degree of protection IP-55 and hinged lockable shutter. The inner and outersurfaces of test stations shall be epoxy painted.

ii) The resistors for control of current provided in the test stations,anode/cathode junction box, etc, shall be of variable, grid coil type.The resistors shall be suitable for operation over the design life forthe permanent CP system specified in the project specification/datasheet.

iii) Number of terminals and different schemes of wiring shall be as perthe applicable GAIL standard drawing. Minimum twenty percent

applicable GAIL standard drawings.4.3 Anodes for Impressed Current CP System

4.3.1 High Silicon Cast Iron Anodes.

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i) High silicon cast iron type anodes shall be center-connected hollowtype or end connected solid type. Cable to anode joint shall bereliable and long lasting for total design life of anode. Composition of anodes shall be as below and shall also conform to ASTM A518 M-86Gr. III.

Element WeightSilicon 14.2 - 14.75 %Manganese 1.5% max.Carbon 0.7% - 1.1 %Chromium 3.25 - 5.0 %Copper 0.5% max.Molybdenum 0.2% max.Iron Remainder

ii) Surface current density rating of the anode for continuous operationshall be 15 amperes/sq.m (max.) for shallow anode ground bed and10 amperes/sq.m (max.) for deep well anode ground beds.

iii) Anode consumption rate shall not be more than 0.2 kg./Amp. Yr.

iv) The design life of anode under burial condition, at the designoperating current shall be in minimum the design life of the CP

system specified in the project specifications/data sheet.

vi) For deep well ground beds, anodes shall be non canistered type.Calcined petroleum coke breeze slurry conforming to clause 4.3.1 v)above shall be supplied along with the anodes.

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4.3.2 Mixed Metal Oxide Coated Titanium Anode

i) Mixed metal oxide coated titanium anodes shall be of pure titaniumhaving substrate composition of titanium of ASTM B-338, GradeI/Grade II, over laid with mixed oxide of noble metals (MMO coated).These anodes shall be dimensionally stable. The anodes shall becentre connected sealed tubular type. The design life of anode underburial condition, at the design operating current in minimum be thedesign life of the CP system specified in the projectspecifications/data sheet.

The guaranteed design parameters of anode regarding currentdensity, consumption rate, design life, rated current output,dimensions, shape, noble metal oxide coating thickness (gm/squaremeter), their physical and mechanical properties shall besubstantiated by manufacturer’s published catalogues and backed up

by type test reports. Each anode shall be supplied with anode leadcable connected to it.

ii) The anodes shall be provided with sheet steel canisters and cokebreeze as per clause No. 4.3.1 (v) & (vi) above.

4.3.3 Each anode shall be supplied with anode tail cable connected to it, whichshall long enough for termination on their associated anode lead junction

box without intermediate joint. Anode cable tail shall be connected/jointedto the anode and the joint insulated at the anode manufacturer’s shop

of anode cable coming form main anode junction box (in case of sectionalised ground bed) or from CP station power source.

ii) Junction boxes shall have sheet steel enclosure of minimum 3 mmthickness and hinged lockable shutters. Junction boxes shall be

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weatherproof with degree of protection IP- 55. It shall be epoxypainted on inside and outside surface. Junction boxes shall haveanode bus of copper with nickel/ silver plated or tinned. Provisionshall be made for measurement and control of individual out goingcircuit/anode current by providing suitable shunt and resistors of gridcoil type. Disconnecting links shall be provided for each outgoing/anode circuit. 30% spare out going circuits shall be provided ineach anode junction box. Terminals shall be of anti loosening typeand provided with

identification labels. Each outgoing circuit shall be labelled clearly toindicate the circuit/sub anode junction box to which it is connected.

iii) The constructional features of junction boxes shall be as per theapplicable GAIL standard drawing enclosed with the data sheet for

impressed current cathodic protection system for pipelines.

iv) A nameplate of anodised aluminium with black back ground and whiteletters shall be fixed to the inner side of the junction box. Thenameplate shall carry the following minimum information:

- Ground bed current rating- Ground bed resistance

- Connection scheme.- Distance form pipeline in metres.

outgoing circuit shall be provided.

iii) Junction box shall have sheet steel enclosure of minimum 3 mmthickness and hinged lockable shutters. Junction box shall beweatherproof with degree of protection IP-55. The inside and outside

f f h b h ll b d h l

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surfaces of the junction box shall be epoxy painted. The terminalsshall be of anti loosening type. Proper identification labelling shall beprovided for each terminal. Each outgoing circuit label shall clearlyindicate the size and identification of the pipeline to which it isconnected.

iv) A nameplate of anodised aluminium with black back ground and whiteletters shall be fixed to the inner side of the junction box. Thenameplate shall carry the following minimum information:- Chainage in km.- Connection scheme- Distance form the nearest pipeline in metres.- Direction of product flow.

4.6 GI Earth Electrodes

For earthing of above ground cathodically unprotected pipelines atintermediate SV stations, pigging stations, etc. and at terminals GI earthelectrodes shall be supplied. Earth electrodes shall be 100 mm dia, 3000mm long, and 13 mm thick conformity to IS 3043.

4.7 Permanent Reference Cells

High purity copper/copper sulphate reference cells or Zinc reference cells asspecified in project specification/data sheets, with proven high reliability

shall be supplied for providing stable pipe to soil potential measurementreference at CP stations, at computerised test station locations and at

connection to test station without any joint in between.

4.8 Electrical Resistance ProbeElectrical resistance probes utilising the electrical resistance technique shallbe suitable for use along the pipeline at marshy areas and at interference

ff t d l ti / l bl l ti t it th t l i

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affected locations/vulnerable locations to monitor the external corrosionactivity on the pipeline.

The material of the E/R probe element shall be of the same alloy as that of the pipeline material. Probe shall be provided with cable leads forconnecting it to CP system and required for the probe resistancemeasurements.

Portable E/R probe reading instrument shall be supplied by contractor, asspecified in the project specification/data sheet. The probe readinginstrument shall be suitable for use in field and shall have IP 55,weatherproof enclosure. The probe reading instrument shall be of digitaltype with 3.5 digit display. The instrument shall run on rechargeablebatteries. The instrument shall be able to directly read out the resistance of probes.

4.9 Polarisation Cell and Surge Diverter4.9.1 Polarisation Cell

Polarisation cell shall be a electrolytic type or solid state device as specifiedin project specification/data sheets, designed to simultaneously provideisolation for DC current and low resistance path for AC current. The deviceshall require minimum maintenance. The solid state device shall haveweather proof enclosure and shall be suitable for mounting inside a test

station.

diverters shall be of explosion proof type.

4.9.3 The minimum ratings of polarisation cells and surge diverters shall be asbelow unless otherwise specified in the project specification/data sheet.

i) P l i ti C ll

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i) Polarisation Cell

a) Type:Solid state type/Electrolytictype

b) Description Rating

- Minimum rated 50 Hzsteady:

30Amin at 280C and min 2VDC

state current (RMS

symmetrical)- AC fault current: 5 kA min for 1 cycle

(RMS symmetrical)

- Ac voltage under maximum

rated AC fault current: Less than 10 V peak to peak

ii) Surge Diverter

a) Type:Spark gap, explosion proof type.

b) Current, 8/20 micro Secondwave:

100 Kilo Amp.

c) Spark - over AC voltage

-50 Hz: 1KV

-Impulse (1.2/50 microSecond):

2.2 KV

iii) The polarisation cells, surge diverters, anodes, connecting cables,

cable joints, etc, shall be adequately sized and suitable for the design

project specification/data sheet.

4.11 Computerised Test Station and Test Station Reader

4.11.1 Computerised Test Stations

Th t it f i t lli t t i d t t t ti h ll b bl

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The computer units for installing at computerised test stations shall be ableto measure and record the field CP system parameters automatically atregular programmed intervals. The computer shall have required numbersof input ports for measurement of pipe to soil DC potentials, induced ACpotentials, pipeline current, bond current, etc. In any case the number of input ports shall not be less than five. All the input measurement ports shallbe protected against high voltage surges due to lightning/HV switching thatmay come from the pipeline.

The computer shall have a real time clock and shall indicate the date andtime of the data collection along with the data. The accuracy of the internalclock shall be +/- 0.1% or better. The input data measurement accuracyshall be +/- 0.5% or better. The measurement range for the input ports forpipe to soil measurement shall be (+) 5 V to (–) 5 V DC. The measurementrange for the other input ports shall be decided based on the maximumvalue of the in put parameters measured.

Unless otherwise specified in the job specification/data sheet the computersshall be programmed to collect and store all the field parameters once daily.It shall be possible to reprogram the computer for the data collectioninterval/set/initialize the computers at field with the help of data retrievalcomputer.

It shall be possible to designate a unique identification number incorporatedin to the software of each computer for identification of the unit after down

4.11.2 The Data Retrieval ComputerThe data retrieval computer shall be of portable type suitable for use infield. The computer shall be suitable for retrieving/down loading the datacollected by the field computer, field programming/setting/initializing thefield computer and estimating the field computer battery capacity/life left

h t d t th fi ld t S it bl l t

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over, when connected to the field computer. Suitable plug arrangementshall be provided on the data-retrieval computer so that it can be plugged into the field computer for data transfer. The data-retrieval computer shallhave enough memory capacity for retrieving/down loading the datacollected and stored by minimum ten field computers, each having collectedthe field data for minimum six months continuously. The battery provided inthe data-retrieval computer shall be suitable for this operation without anyreplacement/recharging the same during the operation.

It shall be possible to down load the data collected by the data-retrievalcomputer to a station computer for further analysis of the data or directly toa printer.

The data-retrieval computer shall have IP 55, weatherproof enclosure. Theunit shall be provided with a carry bag suitable for carrying in field.

4.12 Miscellaneous Requirementsi) The sheet steel used for fabrication shall be thoroughly cleaned and

degreased to remove mill scale, rust, grease and dirt. Fabricatedstructures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The undersurface shall be free from all imperfections before undertaking the

finishing coat. After preparation of the under surface, final spraypainting with two coats of epoxy based paint shall be done. Panel

4.13 Cables

4.13.1 Cables shall be of annealed high conductivity stranded copper conductor,650/1100V grade PVC insulated, armoured, PVC sheathed conforming to IS-1554 part-I, except for reference cell, potential measurement andimpressed current CP anode tail cables. The size of the copper conductor of

the cables shall be as below:

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the cables shall be as below:

i) Minimum 4 mm2 for potential measurement, reference cells, 6 mm2 forcurrent measurement and 25 mm2 for bonding/grounding.

ii) For sacrificial anode CP system the cable size shall be minimum 6 mm2

copper for anode tail cable from anode to buried junction box and 10 mm2

copper from buried junction box to test station in case of temporary CPanodes. In case of sacrificial anodes for permanent CP system the size of anode tail cable from anode to test station shall be minimum 6 mm2 copper.

iii) For impressed current CP system the size of conductor of cables shall bebased on the current to be carried, ground bed loop resistance and shall beminimum 35mm2 copper for positive, negative drainage cables and 10 mm2

copper for anode tail cables. The size of CPTR unit AC incomer cables shallbe of minimum 4mm2 copper conductor.

4.13.2 Impressed current CP anode tail cables shall be of minimum 10 mm²,annealed high conductivity stranded copper conductor, single core, 650voltage grade PE insulated, unarmoured, PVC sheathed. Contractor maysuggest cables with alternative insulation/sheathing having proven track record for impressed current anode ground bed application, for Owner’sapproval.

4.13.3 The cables for reference cells and pipeline potential measurements shall be

applicable without any intermediate joint.

5.0 EQUIPMENT FOR CLASSIFIED AREASEquipment for hazardous area shall be flame proof type and shall meet therequirement of IS:2148 or equivalent international standard and shall be

suitable for gas group IIB temperature class T3 (2000C) Indigenous

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suitable for gas group IIB, temperature class T3 (2000C). Indigenousequipment shall be certified by CMRI or any other recognised testing bodyand shall be approved by the concerned statutory authority. All flameproof equipment shall carry the BIS license marking as per the requirement of statutory authorities.

All Imported equipment for hazardous area may be tested and certified byan independent certifying agency of country of equipment origin and shallbe approved by the concerned statutory authority in India.

6.0 TESTS AND ACCEPTANCE6.1 Unless other wise agreed by the Engineer-in-Charge, all the

equipment/material shall be subject to inspection by GAIL/Owner or by anagency authorised by the owner. All necessary information concerning thesupply shall be furnished to GAIL/Owner’s inspector. Two weeks notice shallbe given to GAIL/Owner for witnessing the final testing.

6.2 Routine tests and final acceptance tests shall be carried out atmanufacturer’s works under his care and expense. Instruments andequipment required for testing shall be arranged by the manufacturer. Finalacceptance shall be subject to successful testing. Type test certificatesinstead of conducting the tests may be accepted where specified in theproject specifications.

6.3 Sacrificial Anodes

Small cracks in the transverse direction of elongated anodes andin anodes of other shapes may be accepted provided the crackswould not cause any mechanical failure during service of theanode considering that the combination of cracks and lack of bond to the anode core is detrimental.

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For transverse cracks the acceptable limits shall be furnished bythe bidders along with the offer.

d) The anode shall be free from excessive shrinkage. The followinglimits shall be used.

Maximum 10% of the depth of anode or 50% of the depth of the anode core whichever is less. The depression may bemeasured for the edges of one side.

The surface of the anodes shall be free from coatings andslag/dross inclusions etc.

The maximum deviation from straightness shall not exceed 2%.

The weight tolerance of individual anode may be taken as +5%. The total weight of the anodes shall not have negativetolerance

Recommended dimensional tolerance shall be as follows:

- Length ±2.5%

- Width/thickness ±5.0%

ii) One anode per heat shall be subjected to radiographic test

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iv) Electrochemical testsElectrochemical tests for anode consumption, visual examination of corrosion pattern and the anode acceptance criteria shall be as perclause 6.3 v) above

v) Spectrographic analysis

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v) Spectrographic analysisThe anodes from each heat shall be tested for chemical compositionby spectrographic analysis and for homogeneity, dross inclusion,voids etc. by radiography. Destructive tests shall be carried outwhere asked by owner based on the radiographic test results.

6.4.2 Mixed Metal Oxide Coated Titanium AnodeContractor shall furnish list/details of the tests that will be conducted bymanufacturer of anode and their acceptance criteria.

6.4.3 Petroleum coke breeze and special back fillThe petroleum coke breeze material shall be tested for chemicalcomposition, bulk density, real density, particle size and resistivity and testcertificate shall be furnished.

The special back fill material for the sacrificial anodes shall be tested forcomposition and test reports shall be submitted.

7.0 PACKING & DESPATCH All equipment/material for CP system along with one set of final drawingsshall be dispatched to site packed in wooden crates.

All the equipment shall be divided in to several sections for protection andease of handling during transportation. The equipment shall be properly

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SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION

SYSTEM FOR PIPELINES

Abbreviations:

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AC Alternating current


BIS Bureau of Indian Standards

CP Cathodic Protection


CPPSM Cathodic Protection Power Supply Module

CPTR Cathodic Protection Transformer Rectifier

CTE Coal tar enamel

DC Direct Current

EHV Extra High Voltage

FBE Fusion bonding epoxy

HDD Horizontal Directional Drilling

HV High Voltage

HVDC High Voltage Direct Current

IS Indian Standards

MOV Motor operated valve

CONTENTS

1.0 SCOPE

2 0 CODES AND STANDARDS

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3.0 SYSTEM IMPLEMENTATION

4.0 CORROSION SURVEY

5.0 CATHODIC PROTECTION DESIGN PARAMETERS

6.0 CATHODIC PROTECTION DESIGN CRITERIA

7.0 SYSTEM DETAILS

8.0 INSTALLATION

9.0 FIELD TESTING AND COMMISSIONING

10.0 INTERFERENCE MITIGATION

11.0 SYSTEM MONITORING

12.0 CLOSE INTERVAL POTENTIAL LOGGING SURVEY

1. SCOPE1.1 This specification defines the requirements of design, engineering,

installation, testing and commissioning of sacrificial anodes cathodicprotection system for external surface of cross country onshore undergroundpipelines/structures including supplementing of corrosion survey,

investigation for interference/interaction problems and mitigation of the

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investigation for interference/interaction problems and mitigation of thesame.

1.2 This specification defines the basic guidelines to develop a suitable sacrificialanode cathodic protection system for the pipelines/structures required to beprotected. All data required in this regard shall be taken into consideration todevelop an acceptable design and for proper engineering of the system.

1.3 Compliance with these specifications and/or approval of any of thecontractor’s documents shall in no case relieve the contractor of hiscontractual obligations.

2. APPLICABLE CODES AND STANDARDS2.1 The system design, performance and materials to be supplied shall conform

to the requirements of the latest revision of following standards as aminimum:

NACE Standard RP-0 169 : Standard Recommended Practice Control of External Corrosion on Underground or Submerged Metallic Piping Systems.

NACE Publication 1 OA 190: Measurement technique related to criteria for CPof Underground or Submerged Steel Piping System (as defined in NACEStandard RPO 169-83).

NACE Standard RP-0177 : Standard Recommended Practice Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion

Control Systems. NACE Standard RP-0286 : Standard Recommended Practice The Electrical

2.4 In case of any contradiction between various referredstandards/specifications/data sheet and statutory regulations the followingorder of priority shall govern:

o Statutory regulations.

o Data sheets

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o Data sheets.

o Job specification.

o This specification.

o Codes and standards.

3.0 SYSTEM IMPLEMENTATION All work to be performed and supplies to be effected as a part of contractshall require specific review by owner or his authorised representative. Majoractivities requiring review shall include but not be limited to the following:

a) Corrosion survey data interpretation report and design basis for C. P.

system.

b) C.P. system design package.

c) Detailed engineering package.

d) Field testing and commissioning procedure.

e) Procedures for interference testing and mitigation. F

f) Close interval potential logging survey and system monitoring procedures.

g) As built documentation.

4 0 CORROSION SURVEY

Where specified in the project specification/data sheet, the contractor shallcarry out corrosion survey along the ROW of the pipeline conforming to thespecifications included in the tender document.

4.2 Additional Data to be Collected

The following data shall be collected to generate design data for evaluation

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The following data shall be collected to generate design data for evaluationof interaction/interference possibilities due to presence of other services inROW/in vicinity. OWNER shall provide assistance for liaison work to theextent possible:

(i) Route and types of foreign service/pipeline in and around or crossing theright of way (including those existing and those which are likely to comeup during contract execution).

(ii) Diameter, wall thickness, pressure, soil cover, and coating scheme used,

type of cathodic protection system provided, if any, and year of laying/commissioning in case of foreign pipelines.

(iii) Details of the existing cathodic protection systems protecting the servicesi.e. type of protection, location, type, rating of anode beds, test stationlocations and their connection schemes. Present output current andvoltage readings of the CP power supply units.

(iv) Remedial measures existing on foreign pipelines/services to preventinteraction.

(v) Graphical representation of existing structure/ pipe-to-soil potentialrecords.

(vi) Possibility of integration/isolation of CP systems, which may involvenegotiations with owners of other services.

(vii) Information on existing and proposed DC/AC power sources and systemsusing earth return path such as HVDC substations/ earthing stations,fabrication yards with electric welding etc. in the vicinity of the entirepipeline route.

(viii) Crossing and parallel running of electrified and non-electrified traction

4.3 ReportOn completion of all fieldwork, a report incorporating all the resultsgenerated from surveys and details of additional data collected shall beprepared. The report shall also contain detailed interpretation of surveyresults and resistivity data enclosed, probable interference prone areas etc.

to form design basis for the scheme of cathodic protection. This report shall

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to form design basis for the scheme of cathodic protection. This report shallalso include various drawings prepared in connection with the above work.The soil resistivity values shall be plotted on semi-log graph sheets.

5.0 CATHODIC PROTECTION DESIGN PARA1’IETERSUnless otherwise specified in the data sheet, following parameters shall beused for design of cathodic protection system.

Where the cathodic protection system is specified for temporary protection,those parts of sacrificial anode cathodic protection system, which will beintegrated, with the permanent CP system shall be designed based onpermanent CP parameters.

5.1 Protection Current Density(i) Pipe lines having coal tar enamel (CTE) coating with two / three layers of reinforcement.

Pipeline SurroundingMinimum ProtectionCurrent Density

Soil resistivity more than 100 ohm.m

TemporaryCP (μA/m2)

PermanentCP (μA/m2)

40 200

Soil resistivity 10ohm to 100 ohm.m

75 300

Soil resistivity 10ohm to 100 ohm.m 500 2000

(iii) Pipe lines having polyethylene(PE) coating

Pipeline SurroundingMinimum ProtectionCurrent Density

Soil resistivity more than 100 ohm.

m

TemporaryCP (μA/m2)

PermanentCP

(μA/m2)

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m (μA/m2)Soil resistivity more than 100 ohm.m

10 35

Soil resistivity 10ohm to 100 ohm.m

15 50

Soil resistivity less than 10ohm 35 125

The above current density values for temporary CP system are applicable forCP system design life up to two years.

Actual current density to be adopted shall be decided based upon soil andother environmental conditions, current drainage survey data (whereincluded in contractor’s scope), proximity of foreign pipe lines/structures andother interference areas affecting the installation. Where considerednecessary for satisfactory protection of pipeline the current density shall be

suitably increased by contractor.

5.2 The pipe protection Current Density indicated in the clause 5.1 above shall beapplicable where the temperature of the fluid transported by the pipeline /the surface temperature of the buried portion of the pipeline does not exceed300 C. Where this temperature exceeds 30° C, the protection Current Densityshall be increased suitably in consultation with the GAIL.

5.3 At HDD (horizontal directional drilling) crossing, the pipe protection currentdensity applicable for marshy area shall be considered

6.0 CATHODIC PROTECTION DESIGN CRITERIACathodic protection system shall be designed to meet the following criteria:

The pipe to soil potential measurements shall be between (-) 0.95 V (ON)and (-) 1.5 V (ON) for polyethylene coated pipe lines, between (-) 0.95 V

(ON) and (-) 1.7 V (ON) for fusion bonded epoxy/coal tar coated pipe lines

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(O ) a d ( ) (O ) o us o bo ded epo y/coa ta coated p pe eswith respect to a copper/copper sulphate reference electrode.

6.1 A positive potential swing of 100 milli-volts or more shall be consideredsufficient to indicate the presence of an interaction/interference situationrequiring investigation and incorporation of mitigation measures by theCONTRACTOR.

7.0 SYSTEM DETAILSThe system shall include the following major equipment/sub-systems unlessotherwise specified in project specifications.

o Sacrificial anodes and anode ground beds

o CP system at cased crossings

o Test stations

o Surge diverter and polarisation cell

o Permanent reference cells

o Electrical resistance probes

o Interconnecting cables

o Cables to pipe connections

All equipment shall be new and procured from approved manufacturers.Equipment offered shall be field proven. Equipment requiring specialised

All Imported equipment for hazardous area may be tested and certified by anindependent certifying agency of country of equipment origin and shall beapproved by the concerned statutory authority in India.

7.1 Anode Ground Beds

Along ROW where soil resistivity predominantly remains low, ranges from 0-

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g y p y , g10 ohm. m and pH value is within 9, zinc anodes may be provided.

Anodes of type I as per ASTM-B 418 standard shall be used for seawater,brackish water or saline electrolyte application and anode of type II as per ASTM-B 418 standard shall be used for fresh water, back fill and soilapplications.

7.1.1 Along ROW where soil resistivity is predominantly in the range of 10 ohm. mto 30 ohm. m, low potential (1 .55V) magnesium anodes may be provided.

7.1.2 Along ROW where soil resistivity is predominantly in the range of 30 ohm-mto 50 ohm-m high potential (1 .75V) magnesium anodes may be provided.

7.1.3 At high resistivity area where resistivity is of the order of 50 ohm. m andabove magnesium ribbon anodes may be provided.

7.1.4 Where magnesium anode is used for protection of polyethylene coatedpipelines, the anodes shall preferably of low potential (1. 55V) type.

7.1.5 Anodes shall be installed along the pipeline at suitable intervals as perpipeline protection voltage attenuation calculations and ground bedresistance/current output of anode installations. At high resistivity area themagnesium ribbon anodes shall be installed all along the pipeline by the sideof the pipeline in the pipeline trench.

7.1.9 At the temporary CP anode ground bed, the leads of all the anodes shall be joined together in a junction box filled with epoxy and buried. A single cableshall be routed from the junction box to test station.

7.1.10 For sacrificial anode ground bed which is intended for permanent CP system

and/or which is to be integrated with permanent CP system, the leads of all

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/ g p y ,the anodes shall be brought up to the test station and shall be terminatedindividually.

7.1.11 The number of anodes at each ground bed shall be sufficient for providingthe specified pipe protection current density taking into consideration theground bed resistance, cable resistance, etc. For permanent cathodicprotection system, contractor shall prepare a table for number of anodes

required at different soil resistivities to produce the specified protectioncurrent for the specified designed life. For temporary cathodic protectionsystem, an indicative design data for sacrificial anodes ground bed in tabularform is given in data sheet. The number of anodes for ground bed, spacingof ground beds based on the applicable soil resistivity, size of pipeline, typeof coating for the pipeline shall be chosen from the table after necessaryverification by the CP contractor. Any deficiency in the protection system if noticed during commissioning or during monitoring shall be corrected by theCP contractor by suitably augmenting the system with additional anodeswithout any cost/schedule implications.

7.1.12 For the portion of the pipeline for which the CP system has been specifiedbased on the permanent CP system parameters, the contractor shallascertain the requirement of the cathodic protection current density indicatedin clause 5.1 above. Where specified in the project specification/data sheetthe requisite current density test/survey shall be conducted by the contractorto establish the adequacy of CP current requirement and number of anode

e) At locations of surge diverters, pipeline grounding through polarisation

cells, zinc and magnesium anodes.

f) At EHV/HV AC/DC overhead line crossings and selected locations where

EHV/HV overhead line is in the vicinity of the pipeline.

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/ y p pg) At railway line crossings and at selected locations along lines running

parallel to the pipeline.

h) At both sides of major river crossings.

i) At EHV/HV cable crossings or along routes where EHV/HV cables are

running in parallel.

j) In the vicinity of DC networks or grounding systems and HVDC grounding

systems where interference problems are suspected.

k) At crossings of other pipelines/structures.

l) At the locations of reference cell and Electrical Resistance probe

installation.

m) At both sides of cased crossings.

n) Locations where interference is expected.

o) At locations of Sectionalizing Valve (SV) stations.

p) At any other locations considered necessary by OWNER or OWNER’ srepresentative.

7.2.2 Test stations used for sacrificial anodes shall have shunt for measurement of d i i f i i i li i h d

o Distance from pipeline in metres.

o Direction of product flow.7.2.6 Terminals and different schemes of wiring shall be provided as per the test

station connection scheme. Minimum twenty percent spare terminals shall be

provided in each test station.

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p

7.2.7 Minimum two cables shall be provided from the pipeline at any test station.

7.2.8 The location of all the test stations shall be marked with their connectionschemes and other relevant information on alignment sheets. A detailed test-station schedule shall be prepared.

7.3 Permanent Reference Cells7.3.1 High purity copper-copper sulphate reference cells with proven high reliabilityshall be provided for stable coupon to soil potential measurement at thelocations of polarisation coupons.

7.3.2 The reference cells shall be of silver/silver chloride type in place of copper/copper sulphate cells, at marshy area locations, where water table ishigh and chloride ion concentration is more than 300 ppm. For marshy area

in saline soils, high purity zinc may be considered as an alternative tosilver/silver chloride.

7.3.3 The life of reference cells shall be minimum 10 years under burial conditions.

7.3.4 The test station connection scheme inside the test station shall clearlyindicate the type of reference cell (Cu-CuSO4/Ag-AgCl).

7.4 Electrical Resistance Probe7 4 1 Wh ifi d i d h l i l i b (E/R b )

7.5.2 Polarisation Celli) Wherever the pipeline is either crossing or running in parallel with

overhead EHVIHV transmission lines of voltage grade 66kV and above, itis mandatory that the pipeline shall be grounded to discharge anyaccumulated potential/surge that may appear in case of transmission line

faults, as per below:Th i li h ll b d d th h l i ti ll ith i

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o The pipeline shall be grounded through polarization cell with zincgalvanic anodes of minimum 20 kg net weight each at location wherepipeline crosses EHV/HV transmission lines.

o The pipeline shall be grounded at regular intervals of maximum 1.0 kmwhere EHV/HV transmission lines run parallel within 25 m of thepipeline.

ii) Locations along pipeline where continuous induced over-voltage due toother overhead transmission lines/underground cables of voltage gradebelow 66kV is expected or observed during commissioning, the pipelineshall be grounded through polarization cell to the earth system of theEHV/HV tower causing the voltage induction or to a separate earthingsystem of zinc anodes through polarisation cell.

iii) The polarization cell shall be installed inside test station of suitable size.

iv) Type of polarization cell shall be as specified in data sheet.

7.5.3 The total system including cable, cable termination, surgediverters/polarisation cells/anodes shall be suitable for the anticipated faultcurrent at the location of its installation

7.5.4 The surge diverter, polarization cell and anode system shall be suitable forthe design life of permanent CP system. The grounding system shall have

electrodes. The resistance to earth of grounding shall be limited to 5 ohmsmax.

7.8 CP at cased crossing

7.8.1 At cased crossings where casing is coated, the casing shall be protected byifi i l d i t ll ti id d t b th d f i Th d

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sacrificial anode installations, provided at both ends of casing. The anodeinstallation shall be sized based on the permanent C .P. design parametersand design life of permanent CP system. At cased crossings where casing ispainted or uncoated, additional protection for casing pipes may not beprovided.

7.8.2 The carrier pipe inside the painted or coated casing shall be protected by zinc

ribbon anodes weld connected to the outer surface of bottom of carrier pipeextending up to hour hand positions of 4 and 8 O’clock. The anodes shall beplaced at close intervals as per design calculations with minimum onenumber of anodes installed between every two supports provided betweencarrier and casing. The anodes shall be sized based on the permanent CPdesign parameters for marshy area and design life of permanent CP system.

7.8.3 Where casing is bare (i.e. uncoated or unpainted) additional protection for

carrier pipe may not be provided.

7.9 Reference Cell Access PointsReference cell access points shall be provided near insulating joint locationsand at SV stations, where the ground is paved, for measurement of pipe tosoil potentials. A perforated PVC pipe filled with native soil and buried at thelocation shall be provided for the purpose. The length of the PVC pipe shallbe adequate to reach the native soil below the paving.

mylar/polyster tape shielded, PVC sheathed, armoured, PVC over all sheathedtype.

8.0 INSTALLATION8.1 Cable Laying

8 1 1 C bl h ll b l id i d ith th l t d i t b d b

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8.1.1 Cables shall be laid in accordance with the layout drawings to be prepared bythe contractor. No straight through joint shall be permitted. Cable route shallbe carefully measured and cables cut to required length. Minimum half metrecable slack shall be provided near anodes, pipeline and test stations toaccount for any settling.

8.1.2 All cables inside station/plant area shall be laid at a depth of 0.75 M. Cables

outside station/plant area shall be laid at a depth of minimum 1. 5 m. Cablesshall be laid in sand under brick cover and back filled with normal soil. Forcables laid outside the station/plant area, polyethylene warning mats shallplaced at a depth of 0.9 m. from the finished grade, to mark the route.

8.1.3 In case of above ground cable, all unarmoured CP cables shall be laid in GIconduits of sufficiently large size, up to accessible height for protectingagainst the mechanical damage.

8.1.4 All underground unarmoured cables including anode tail cables shall runthrough PE sleeves. The cables routed along the pipeline shall be carried atthe top of the carrier pipe by securely strapping it at intervals with adhesivetape or equivalent as required.

8.1.5 PVC pipes of proper size shall be provided for all underground cables for roadcrossings.

8.2 Permanent Reference CellsThe permanent reference cells shall be installed in natural soil conditions asper the recommendations of the cell manufacturer. Installations in highlyacidic/alkaline soil and soil contaminated by hydrocarbons shall be avoided.

8.3 Cable to pipe connectionsAll cable connections to the new pipeline shall be made by an approved

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All cable connections to the new pipeline shall be made by an approvedexothermic process or by pin brazing. However, cable connection to chargedpipelines shall be made by pin brazing. Exothermic welding shall be adoptedfor water pipelines. The resistance of the cable to pipe at the connectionpoint shall not exceed 0.1 ohm. Coating shall be repaired after connection of cable conductor to pipeline. The coating repair material shall be compatiblewith the original coating and shall prevent ingress of water along the cable

surface and at the interface of coating repair with the original pipe coating.

8.4 Ground bed FencingWhere specified in project specifications/data sheet a chain link fencing shallbe provided around the location of each ground bed, designed based on thepermanent CP design parameters.


9.1 System testing at site9.1.1 Field tests as per the reviewed field testing and commissioning procedures

prepared by the Contractor, shall be carried out on the equipment/systemsbefore these are put into service. Acceptance of the complete installationshall be contingent upon inspection and test results.

9.1.2 Before the C.P. system facilities are put into operation, necessary tests shallbe carried out to establish that all equipment, devices, wiring and connectionhave been correctly installed, connected and are in good working condition

between cores.

All cables shall be tested by 500 V megger.

ii) Insulating jointLocation.

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Pipe to soil potential of both protected and non-protected sides of the insulating joint before andafter energisation of CP system.

iii) Surge diverterLocation/identification number.

Rating

Type

Explosion proof enclosure.

Check for healthiness.

Check for proper connection.

iv) Polarisation Cell

Location/Identification number.

Type

Ratings

Ch k f i i

vi) EIR ProbeLocation/Identification number

Checking of wiring as per schematics

Resistance reading of probe

Installed on top/bottom/side of the pipeline

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p p p

vi) vii) Reference Cell

Location

Type of cell

Potential reading

Installed on top/bottom level of pipeline

9.2 Commissioning9.2.1 Natural potential of pipe to soil for the complete pipeline and casing pipeline

at the locations of cased crossings shall be measured at all the test stationlocations, recorded prior to connecting anodes to pipe line and casingpipeline respectively.

9.2.2 The anode shall be connected to pipeline in the test station and the pipe tosoil potential observation shall be made after allowing sufficient time forpolarisation. The current output of each anode at permanent CP anodeground bed or the total current output of anode bed at temporary CP anodeground bed shall also be measured to ensure that it does not exceed theoutput current capacity of the anodes. In case the anode output currentexceeds the rated capacity, it shall be controlled by insertion of resistance

element in the anode circuit inside test station and the pipe to soil potentialh ll b h k d f d f i A l i f l i i

9.2.5 In case of insufficient protection as per the CP design criteria, on any portionof the pipeline! casing pipeline (at cased crossings where casing iscathodically protected) Contractor shall carry out necessaryadditions/modifications to the provided protection in consultation with theOwner/Owner’s representative.

9 2 6 Resistance readings of the probe shall be taken at all the locations of

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9.2.6 Resistance readings of the probe shall be taken at all the locations of electrical resistance probes.

10.0 INTERFERENCE MITIGATION10.1 Investigations shall be made for stray current electrolysis of the pipeline,

mutual interference between the pipeline and foreign pipelines/structures,interference on foreign pipelines/structures due to the CP of the pipeline and

ground bed, AC induction on pipeline due to 11 KV and above overheadHV/EHV line, interference due to high voltage DC line, HVDC groundings,electric traction etc.

10.2 Where transmission lines cross the pipeline or run in parallel within or morethan 25m from the pipeline, AC voltage measurements shall also be made onthe pipeline to find out continuous induction of voltage. In case of inducedvoltage being beyond safe limits, the pipeline shall be grounded in line with

clause no.7.5 above.

10.3 Measurements including pipe/structure to soil potential and pipeline/structurecurrent etc. on the pipeline/structure being CP protected and on foreignpipelines/structures shall be made to investigate the current discharge andpickup locations. In case of fluctuating stray current, investigations shall bemade continuously over a period of time and if required simultaneously atdifferent locations to find out the stray current source(s). For measurementsover longer durations, recorders shall preferably be used.

provided for mitigation, the bonding resistor shall be adjusted for optimumvalue for minimum/no interference. Galvanic anodes installed as a mitigationmeasure shall be sized for the design life specified for permanent CP.

11.0 SYSTEM MONITORING

Where the CP system provided is temporary the C P system shall be

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Where the CP system provided is temporary, the C .P. system shall bemonitored at all test stations once in a month for healthiness/adequacy of protection till commissioning of permanent CP or for design life of temporaryCP specified, which ever is less. During this period if any deficiency!interference in protection system is noticed, the same shall berectified/augmented by providing additional anodes as required. Themonitoring report shall be submitted regularly to owner for his

review/information.

12.0 CLOSE INTERVAL POTENTIAL LOGGING SURVEY Where specified in project specification/data sheet, contractor shall carry outa close interval potential survey over the entire length of pipeline bycomputerised potential logging method and identify the under protected/overprotected area, any major coating damage on the pipeline, after the back-

filling has been consolidated sufficiently and CP system has stabilized.Contractor shall provide required mitigation measures and rectify theunder/over-protected zones, identify if any, the major pipeline coatingdefects required to be repaired. During the survey the reference cell shall becalibrated minimum once in 24 hours.

Where specified in the project specification/data sheet, additional tests fordetailed identification of coating defects shall be conducted by the contractor.

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SPECIFICATION FOR IMPRESSED

CURRENT CATHODIC PROTECTION

SYSTEM FOR PIPELINES

Abbreviations:



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CP Cathodic Protection


CPPSM Cathodic Protection Power Supply Module

CPTR Cathodic Protection Transformer Rectifier

CTE Coal tar enamel

DC Direct Current

EHV Extra High Voltage

FBE Fusion bonding epoxy

HDD Horizontal Directional DrillingHV High Voltage

HVDC High Voltage Direct Current

IS Indian Standards

MOV Motor operated valve

Micro A/mm2 Micro-ampere per square millimeter

NACE N i l A i i f C i E i

CONTENTS

1.0 SCOPE


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5.0 CATHODIC PROTECTION DESIGN PARAMETERS

6.0 CATHODIC PROTECTION DESIGN CRITERIA

7.0 SYSTEM DETAILS

8.0 INSTALLATION



11.0 CLOSE INTERVAL POTENTIAL SURVEY

1.0 SCOPE1.1 This specification defines the requirements of system design, engineering,

installation, testing and commissioning of an Impressed Current CathodicProtection System for cross- country onshore underground pipelines/structuresincluding supplementing of corrosion survey, close interval potential logging

survey, investigations for interaction/interference problems and mitigation of thesame.

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same.

1.2 This specification provides the basic parameters to develop a suitable impressedcurrent cathodic protection system for the pipelines/structures requiringprotection. All data required in this context shall be taken into consideration todevelop an acceptable design and for proper engineering of the system.

1.3 Compliance with these specifications, and/or approval of any documentssubmitted by contractor shall in no case relieve the contractor of his contractualobligations.

2.0 APPLICABLE CODES AND STANDARDS

2.1 The system design, performance and materials to be supplied shall conform tothe requirements of the latest revision of following standards as a minimum:

NACE Standard RP-0 169 : Standard Recommended Practice Control of ExternalCorrosion on Underground or Submerged Metallic Piping Systems.

NACE Publication 1 OA 190: Measurement technique related to criteria for CP of Underground or Submerged Steel Piping System (as defined in NACE StandardRPO 169-83).

NACE Standard RP-0177 : Standard Recommended Practice Mitigation of Alternating Current and Lightning Effects on Metallic Structures and CorrosionControl Systems.

NACE Standard RP-0286 : Standard Recommended Practice The Electrical

Statutory regulations.

Data sheets. Job specification.

This specification. Codes and standards.


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3.0 SYSTEM IMPLEMENTATION All work to be performed and supplies to be effected as a part of contract shallrequire specific review by Owner or his authorised representative. Major activitiesrequiring review shall include but not be limited to the following:

i) Corrosion survey data interpretation report and plot plans for landacquisition.

ii) Conceptual system design.

iii) Basic engineering package.iv) Detailed engineering package.v) Field testing and commissioning procedures.vi) Procedures for interference testing and mitigation.vii) Close interval potential logging survey procedure.viii) As built documentation.


4.1 General4.1.1 The details of corrosion survey including soil resistivity data along ROW and other

data required for C. P design if available with the Owner shall be included as partof project specification/data sheet. However, verification of its veracity andadequacy shall be the entire responsibility of the contractor. In addition,contractor shall have to generate/collect additional data as per clause 4.4 belowrequired for completeness of the job.

Contractor shall carry out soil resistivity survey at anode ground bed locations for

observations shall be taken at each of these sub-plots as required and desired byOwner/Owner s representative to obtain sufficient information about sub-soilstratification and, wherever °possible, to establish the depth of water table. Thenumber of subplots at each ground bed plot shall be decided at site inconsultation with Owner/Owner’s representative.

4.2.2 Number, location, demarcation and size of sub-plots and number of sets of

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u be , ocat o , de a cat o a d s e o sub p ots a d u be o sets oresistivity observations required for each sub-plot shall be individually decided foreach ground bed plot location.

4.2.3 One or more ground bed plots may be required to be selected and surveyed ateach CP station to form a suitable ground bed.

4.3 Topographic SurveysCathodic protection stations consisting of anode ground bed, CP station, etc. asapplicable, along with all associated cabling up to pipeline and any other relatedequipment and accessories for CP station shall be demarcated on the ground.Ground plots so demarcated shall be surveyed for all other topographical andcadastral features and topo-sheets shall be developed by the CONTRACTOR,which shall be suitable for use in land acquisition etc.

4.4 Additional Data to be CollectedThe following data shall be collected to generate design data for evaluation of interaction/ interference possibilities due to presence of other services in ROW orin its vicinity. OWNER shall provide assistance for liaison work to the extentpossible.

i) Route and types of foreign service/pipeline in and around or crossing the rightof way (including those existing and those which are likely to come up duringcontract execution).

ii) Diameter wall thickness pressure soil cover and coating scheme used type

viii) Crossing and parallel running of electrified and non-electrified traction (alongwith information regarding, operating voltage, AC/DC type etc.) as well asabandoned tracks near ROW having electrical continuity with the tracks in use.

ix) Crossing or parallel running of any existing or proposed EHV/HV AC/DCoverhead power lines along with details of voltage, AC/DC type etc.

x) Voltage rating, phases, sheathing details of underground power cables alongROW or in its vicinity.

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yxi) Any other relevant information that may be needed in designing and

implementing proper cathodic protection scheme for the proposed pipeline.Contractor shall conduct necessary potential gradient surveys for any existinganode ground beds that may interfere with the CP system of the pipelinescovered under this project.

4.5 ReportOn completion of all field work, a report incorporating all the results generatedfrom surveys and details of additional data collected shall be prepared. The reportshall also contain detailed interpretation of survey results and resistivity data,probable interference prone areas, selected locations for anode ground beds,etc., to form a design basis for the scheme of cathodic protection. This reportshall also include various drawings prepared in connection with the above work.Soil resistivity values shall be plotted on semi-log graph sheets.

5.0 CATHODIC PROTECTION DESIGN PARAMETERS A distinctly independent impressed current cathodic protection system shall beprovided to protect the external surfaces of the complete pipeline/structureinstallation as specified.

Unless otherwise stated in the data sheets, the following parameters shall beused for design of permanent cathodic protection system

ii) Pipe lines having fusion bonded epoxy coating

Minimum Protection CurrentDensity

Pipeline SurroundingTemporary CP

(μA/m2)PermanentCP (μA/m2)

Soil resistivity more than 100 ohm.m

25 90

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m

Soil resistivity 10ohm to 100 ohm. m 35 125


iii) Pipe lines having polyethylene(PE) coating

Minimum Protection CurrentDensity

Pipeline Surrounding Temporary CP(μA/m2)

PermanentCP (μA/m2)

Soil resistivity more than 100 ohm. m 10 35

Soil resistivity 10ohm to 100 ohm. m 15 50


The above current density values for temporary CP system are applicable for CP

system design life up to two years.

Actual current density to be adopted shall be decided based upon soil and otherenvironmental conditions, current drainage survey data, proximity of foreign pipelines/structures and other interference areas affecting the installation. Whereconsidered necessary for satisfactory protection of pipeline the current densityshall be suitably increased by contractor. Also refer to clause 7.1 iv) below.

At HDD (horizontal directional drilling) crossing the pipe protection currentd it li bl f h h ll b id d

5.7 Pipeline natural potential (-) 0.45 V5.8 Design life of CP system 30 years, unless specified otherwise5.9 Anode ground bed loop resistance

including anode to groundresistance, anode and cathode

cable resistances

1 ohm (max.).

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(The output voltage rating of the CPTR unit / CPPSM shall in minimum beadequate to drive the specified end of life cathodic protection current with safetyfactor, considering the total anode ground bed loop resistance as the sum of theresistance specified in this clause and pipe to earth resistance).

5.10 For mixed metal oxide coated titanium anodes the anode utilisation factor, anode

surface current density and anode consumption rate etc. shall be as per theguaranteed values published by the manufacturer and supported by testcertificates/field proven ness.

6.0 CATHODIC PROTECTION DESIGN CRITERIACathodic protection system shall be designed to meet the following criteria

i) The pipe to soil potential measurements shall be between (-) 0.9V (OFF) and

(-) 1. 1 8V (OFF) with respect to a copper/copper sulphate referenceelectrode.

ii) In rare circumstances, a minimum polarisation shift of (-) 100 milli voltsmay be accepted as an adequate level of cathodic protection for the pipelinewith the approval of Owner.

iii) A positive potential swing of 100 milli volts or more shall be consideredsufficient to indicate the presence of an interaction/interference situationrequiring investigation and incorporation of mitigation measures by the

CONTRACTOR

o Computerized Test Stationso CP system at cased crossingo Bond Stationso Cables

All equipment shall be new and procured from approved reputed manufacturers..Equipment offered shall be field proven. Equipment requiring specialised

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maintenance or operation shall be avoided as far as possible. Prototypeequipment shall not be accepted.

All equipment/materials shall conform to the relevant specifications included inthe tender document.

All equipment including CPTR unit, CPPSM, test stations, anode lead junctionboxes etc. shall be located in safe non-hazardous areas.

Where it is essential to install the equipment in hazardous area, such equipmentshall be flameproof type and shall meet the requirement of IS: 2148 or equivalentinternational standard and shall be suitable for gas group IIB, temperature classT3 (200°C). Indigenous equipment shall be certified by CMRI or any otherrecognised testing body and shall be approved by the concerned statutory

authority. All flameproof equipment shall carry the BIS license marking as per therequirement of statutory authorities.

All Imported equipment for hazardous area may be tested and certified by anindependent certifying agency of country of equipment origin and shall beapproved by the concerned statutory authority in India.

7.1 Cathodic Protection Stations

The number and exact locations of CP stations shall be worked out based on the

adequacy by the contractor. The requisite current drainage tests/survey shall beconducted by the contractor to establish the adequacy of CP current requirementindicated in clause 5.0 above and adequacy of number, ratings of CP stations forpermanent CP system indicated in the data sheet. The minimum end of life pipeprotection current requirement shall be considered as the current requirement

indicated in the clause 5.0 above or 3 times the current density value measuredby the current drainage survey for polyethylene coated pipeline and 4 times the

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current density value measured by the current drainage survey for fusion bondedepoxy, coal tar enamel with reinforcement coated pipeline, whichever ismaximum.

7.2 CP Transformer Rectifier Unit/CPPSMIf specified in project specifications/data sheet, the supply, installation, testing

and commissioning of cathodic protection power supply module (CPPSM) /indoortype Cathodic Protection Transformer Rectifier Unit (CPTR unit)! outdoor typeCPTR unit installed in kiosk along with kiosk shall be included in contractor’sscope The CP TR units shall be provided at CP stations where reliable AC powersupply is available. CPPSM shall be provided at other CP stations where reliableDC power supply instead of reliable AC power supply is available. The CPTR unit/CPPSM shall be installed in non-hazardous (safe) area as specified in datasheets.

7.3 Anode Ground Bedsi) Each CP station shall have an independent anode ground bed, which may be of

shallow or deep well construction depending upon the data collected by thecontractor. Deep well ground beds may also be used in the congested locationswhere availability of suitable land for spread out ground beds is restricted.

ii) Ground bed shall be located electrically remote from the pipeline and foreign

pipeline! other buried metallic structures Nearest part of the anode bed shall at

v) Each shallow anode-bed shall contain anodes with canisters positionedhorizontally or vertically in the soil with suitable backfill. The depth of anodes(depth of top of anode in case of vertically laid anodes) shall not be less than 2meter from grade level

vi) Layout of anode installation in anode bed shall be detailed out in drawingsshowing anode installation details, anode grouping, anode wiring, anode cable

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routing, etc. The deep well anode ground bed details shall include the details of anodes, deep well casing, anode positioning, anode cable supporting, deep wellgas venting, active, passive portions of the ground bed, etc.

vii) Anodes shall be supplied complete with tail cables, which shall be long enough fortermination on their associated anode lead junction boxes without intermediate

joints. Exact lengths and termination details shall be indicated in constructiondrawings.

viii) Potential gradient around the anode bed shall be within safety requirements withregard to interference on foreign structures and its effective boundary shall bedefined.

ix) In case of two parallel pipelines running in the same ROW, the anode groundbeds of the respective pipelines shall be located on the respective sides of the

pipelines.

7.4 Anode Junction BoxDepending on the size and configuration of anode ground beds, one or moreanode junction boxes shall be provided at each ground bed. All cable tails fromindividual anodes shall be terminated onto the respective anode junction boxes,which shall be further connected to the main anode junction box (whereapplicable). The main anode junction box shall be connected to the cable coming

from CP power source Each outgoing circuit in main junction box (where

7.6 Test Stations7.6.1 Test stations shall be provided along the pipeline ROW for monitoring the

performance of the cathodic protection system at the following locations. Teststations shall be provided at additional locations, if required, so that distancebetween any two adjacent test stations does not exceed 1000 meters in inhabited

areas and 2000 meters in uninhabited areas like forest/deserts:i) At all insulating joints.

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ii) At both sides of metalled road crossings.

iii) At vulnerable locations with drastic changes in soil resistivity.

iv) At locations of surge diverters, pipeline grounding through polarisation

cells, zinc and magnesium anodes.v)vi) At EHV/HV AC/DC overhead line crossings and selected locations where

EHV/HV overhead line is in the vicinity of the pipeline.

vii) At railway line crossings and at selected locations along lines runningparallel to the pipeline.

viii) At both sides of major river crossings.

ix) At EHVIHV cable crossings or along routes where EHV/HV cables arerunning in parallel.

x) In the vicinity of DC networks or grounding systems and HVDCgrounding systems where interference problems are suspected.

xi) At crossings of other pipelines/structures

7.6.2 Test stations for bonding shall be provided with shunt and resistor as a means tomonitor and control current flow between the pipeline and foreign pipelines orstructures that may exist in common ROW.

7.6.3 Test stations with current measuring facility shall be provided at each CP station

drainage point (to measure pipeline current on any one side of pipeline fromdrainage point at intermediate CP station and towards protected side of the

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pipeline at starting, end point CP stations), at interference prone areas, on bothsides of major river crossings, near marshy areas and minimum one for every 10km max. along the pipeline.

7.6.4 Test stations shall be installed with the face of the test station facing the pipeline.The nameplate of test stations shall carry the following minimum information:

o Chainage in km.

o Test station connection scheme

o Distance from pipeline in meter.

o Direction of product flow.

7.6.5 Number of terminals and different schemes of wiring shall be as per the test

station connection scheme. Minimum twenty percent spare terminals shall beprovided in each test station.

7.6.6 Minimum two cables from the pipeline shall be provided at any test station.

7.6.7 The location of all the test stations shall be marked with their connection schemesand other relevant information on alignment sheets. A detailed test-stationschedule shall be prepared.

7 7 P t R f C ll

7.7.4 The cable from reference cells shall be provided up to CP power source at CPStations and up to test stations at the locations of polarization coupons,computerised test stations. The cable up to CP power source shall be routedthrough test stations near pipeline.

7.8 Electrical Resistance Probe

8 1 Wh ifi d i j ifi i /d h l i l i b

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7.8.1 Where specified in project specification/data sheet electrical resistance probes(E/R probes) utilising the electrical resistance technique shall be provided alongthe pipeline at marshy areas and at vulnerable locations to monitor the externalcorrosion activity on the pipeline. The lead-wires of the probe shall be connectedto pipeline through test station and terminated inside test station enablingperiodic resistance measurement of the probe using a portable probe measuring

instrument.

7.8.2 The material of the E/R probe element shall be of the same alloy as of thepipeline material. The probes shall be provided preferably at the bottom portionof pipeline.

7.8.3 The number of E/R probes, the locations of their installation and the number of portable E/R probe reading instruments shall be as specified in the project

specification/data sheet.

7.9 Polarisation Cell and Surge Diverter

7.9.1 Polarisation Cell

i) Wherever the pipeline is either crossing or running in parallel withoverhead EHV/HV transmission lines of voltage grade 66 kV and above, it

is mandatory that the pipeline shall be grounded to discharge any

7.9.2 Surge DiverterExplosion proof spark gap surge diverter shall be provided across each insulating joint to protect it from high voltage surges. surge diverters shall be suitable forinstallation in classified areas.

7.9.3 The total system including cables, cable termination, anodes/surge diverters,polarisation cell shall be suitable for the anticipated fault current at the location of i t ll ti

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installation.

7.9.4 The surge diverter and polarisation cell system shall be suitable for the design lifeof permanent CP system. The grounding system shall have minimum resistanceto earth to restrict the pipeline voltage as per NACE/VDE criteria but shall notexceed 5 ohms.

7.9.5 The anodes shall be pre packed with special backfill adequately so that theperformance of the anode is not affected by the carbonates, bicarbonates,nitrates, etc, present in the soil. In any case, the thickness of back fill shall not beless than 50mm on all the sides of the anode.

7.10 Motor operated valves where located on the cathodically protected portion of thepipeline shall be grounded by a zinc anode of 20 kg net. Magnesium anodesgrounding, if any, provided during temporary CP system shall be disconnected.

The MOV power supply cable armour shall be insulated (by cutting and tapingwith insulation tape) at MOV end to avoid armour carrying CP current.

7.11 The above ground cathodically unprotected pipeline at terminals, intermediate SVstations, pigging stations, etc. shall be earthed with GI earth electrodes. Theresistance to earth of grounding shall be limited to 5 ohms max.

7.12 Polarisation Coupons

Where specified in the project specification/data sheet steel coupons of pipeline

magnetic reed switch inside the test station to enable measurement of coupon ‘OFF’ potential.

A permanent reference electrode shall be installed adjacent to the coupon in amanner so as to measure the representative potential of the coupon. Magnets for

operation of reed switch shall be provided as specified in the projectspecification/data sheet.

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7.13 Computerized Test StationsWhere specified in the project specification/data sheet computerized test stationsshall be provided along the ROW of the pipeline for automatically monitoring andrecording the pipe to soil potential, pipe current, etc. of the pipeline, casingpipeline and foreign pipelines, etc, as required. The computer with in the test

station shall measure and record these parameters regularly at programmedintervals. The computers shall have required number of input ports formeasurement of potentials and current as applicable at the location of itsinstallation. Computers shall have real time clock and record the time of datameasurement. Each computer shall an identification number incorporated in itssoftware, which shall be clearly indicated along with the data display/print out.

The computers shall be programmed to collect and store all the field parameters

at intervals as specified in the project specification/data sheet.

Data-retrieval computer of portable type suitable for use in field shall be providedas specified in the project specification/data sheet for programming the fieldcomputers and retrieving the data stored by the field computers.

7.14 CP at Cased Crossing

7 14 1 At cased crossings where casing is coated the casing shall be protected by

7.15 Reference Cell Access PointsReference cell access points shall be provided near insulating joint locations andat SV stations, where the ground is paved, for measurement of pipe to soilpotentials. A perforated PVC pipe filled with native soil and buried at the location

shall be provided for the purpose. The length of the PVC pipe shall be adequateto reach the native soil below the paving.

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7.16 Cables

7.16.1 Cables shall be with annealed high conductivity stranded copper conductor, PVCinsulated, 650/1100 V grade, armoured, PVC sheathed conforming to IS 1554part-I, except for the cables for anode tail, reference cells and pipeline for

potential measurements. The size of the copper conductor shall be minimum 35sq. mm. for anode and cathode cables, 6 sq. mm. for current measurement, 10sq. mm. for anode tail cables and polarization coupon protection cables. The sizeof cable for bonding, polarisation cell, grounding anodes and surge diverterconnections shall be suitable for the maximum fault current subject to minimum25 sq mm.

7.16.2 The anode tail cables shall be PE insulated, 650V grade, unarmoured, PVC

sheathed and length shall be sufficient for termination on anode lead junction boxwithout any joint in between.

7.16.3 The cables for reference cells, coupon and pipeline potential measurements shallbe of 4 sq. mm copper conductor, PVC insulated, Aluminium backed bymylar/polyster tape shielded, PVC sheathed, armoured, PVC over all sheathedtype.

7 16 4 The CPTR unit incomer cable shall be minimum 4 sq mm Copper conductor

slack shall be provided near anodes, anode junction box, pipeline and teststations to account for any settling.

ii) All cables inside station/plant area shall be laid at a depth of 0.75 metre. Cablesoutside station/plant area shall be laid at a depth of minimum 1.5 metres. Cables

shall be laid in sand under brick cover and back filled with normal soil. For cableslaid outside the station/plant area, polyethylene warning mats shall be placed at adepth of 0 9 metre from the finished grade to mark the route

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depth of 0.9 metre from the finished grade, to mark the route.

iii) In case of above ground cables, all unarmoured CP cables shall be laid in GIconduits of sufficiently large size, up to accessible height for protecting againstthe mechanical damage.

iv) All underground unarmoured cables including anode tail cables shall run throughPE sleeves. Distant measurement cables and permanent reference cell cablesrouted along the pipeline shall be carried at the top of the carrier pipe by securelystrapping it at intervals with adhesive tape or equivalent as required.

v) PVC pipes of proper size shall be provided for all underground cables for roadcrossings.

vi) Cables shall be neatly arranged in trenches in such a manner that crisscrossing isavoided and final take-off to equipment is facilitated.

vii) The cables for reference cells and pipeline potential measurement shall be routedin a separate trench other than the trench provided for the rest of the CP systemcables, AC cables for CPTR Units etc.

viii) The armour of the cables from CP station to test station (potential measurement,

reference cell & drainage cables etc ) CP station to ground bed (anode cable)

The cathode drainage cable shall be connected to a bolt welded to a metal plate,which is weld connected to the pipeline. The material of the plate shall be sameas that of the material of the pipeline.

Pipe coating shall be repaired after connection of cable to pipeline. At cathodedrainage point the cable joint including the bolt, metal plate and the exposedportion of the pipeline shall be covered by the coating repair material against

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portion of the pipeline shall be covered by the coating repair material againstingress of water/moisture. The coating repair material shall be compatible withthe original coating and shall prevent ingress of water along the cable surfaceand at the interface of coating repair with the original pipe coating.

8.4 Ground Bed Fencing

Where specified in project specifications/data sheet chain link fencing shall beprovided around the location of each ground bed/anode lead junction box.


9.1 System testing at siteField tests as per the reviewed field testing and commissioning proceduresprepared by the Contractor, shall be carried out on the equipment/systems before

these are put into service. Acceptance of the complete installation shall becontingent upon inspection and test results. Field testing shall include but not belimited to the following:

i) Contractor shall carry out pre-commissioning operations after completion of installation of the system including all pre-commissioning checks, setting of all equipment, control and protective devices. All site tests, reliability andperformance tests shall be carried out by Contractor.

ii) Before the electrical facilities are put into operation necessary tests shall be

Voltage grade.Conductor cross sectionContinuity check Voltage test.Insulation resistance values between each core & earth, between

cores (between core and earth for single core cable). All cables shallbe tested by 500 V megger.

b) E/R Probe

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b) E/R ProbeLocation/Identification numberChecking of wiring as per schematicsResistance reading of probeInstalled on top/bottom/side of the pipeline

c) Reference Cell

LocationType of cellPotential readingInstalled on top/bottom level of pipeline

d) Insulating jointLocationPipe to soil potential of both protected and non-protected sides of the insulating joint before and after energisation of CP system.

e) Surge diverterLocation/identification number.RatingTypeCheck for healthiness.

f) Polarisation CellLocation/Identification numberRating

Check for wiring

Type of reference cell

i) Polarisation CouponsLocationExposed area/size of coupon

Coupon to soil ‘ON’ and ‘OFF’ potentialsType of reference cellMagnetic reed switch rating

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Magnetic reed switch rating.Operation of magnetic reed switch with magnet

9.2 CP Commissioning Procedure A model commissioning procedure for a three stations CP system of a pipeline isgiven below for general guidance. Contractor shall develop detailed

commissioning procedure as per this guideline.i) In completion of installation of anode beds and other systems as envisaged in this

specification, they shall be individually checked, tested and compared against theagreed specifications and procedure.

ii) Electrical continuity of the entire pipeline shall be verified in conformity withdesign.

iii) Input resistance of the pipeline at all the drainage points shall be checked andrecorded.

iv) All current measuring test stations shall be calibrated and recorded using portablebattery, variable resistances, voltmeters, ammeters, etc. as required.

v) Temporary protection facilities provided (if any) which do not form part of permanent CP shall be disconnected from the system & removed unless agreedotherwise.

vi) Anodes provided for grounding at the MOVs on cathodically protected portion of the pipeline shall be disconnected. Sacrificial anode where provided for theprotection of the casing pipe at cased crossings shall be disconnected.

vii) The pipeline shall be allowed to depolarize for at least 72 hours after switching

x) CP station no.1 shall now be switched ‘OFF’, CP station no. 3 shall be switched ‘ON’ and measurement procedure as detailed in clause ix) above shall berepeated.

xi) Similarly CP station no. 1 and 3 shall now be switched ‘OFF’, CP station no.2 shallbe switched ‘ON’ and measurement procedure as detailed in clause ix) above

shall be repeated.xii) All the CP stations of the system shall be switched ‘OFF’ and the pipelines shall be

allowed to depolarize All the three CP stations in the system shall then be

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allowed to depolarize. All the three CP stations in the system shall then besimultaneously switched ‘ON’ and PSP values at the drainage points of pipelineshall be brought to a value of maximum PSP as specified and a complete set of observations shall be taken.

Another complete set of pipe to soil and coupon to soil observations shall be

taken after lines have stayed on charge for 48 hours. If there are appreciabledifferences in these observations as compared to those of earlier set, a third setof observations shall be taken after 72 hours. Maximum drainage point protectivepotentials shall not be allowed to go beyond the maximum PSP values asspecified, in any case.

Coupon to soil ‘OFF’ potential shall be measured at all locations of couponinstallations by operation of magnetic reed switch in the test station. The PSP of

the coupons shall be within the PSP range specified in clause 6 of this document.

The output of all CP stations shall then be so adjusted that the sites of occurrenceof least negative protective potentials are not less negative than (-) O.95V (OFF)and sites of occurrence of the most negative protective potential are not morenegative than (-) 1. 18V (OFF). A full set of pipe to soil, coupon to soilobservations shall again be taken 72 hours after the adjustment of potentials andthe protection system shall be left in this state of operation.

interference situations between the pipelines shall be identified and necessarymitigation measures shall be provided. Interference situations shall also beidentified and mitigated by comparing different sets of readings taken at sametest stations at -different intervals of time under identical conditions wherepositive potential swing is 100 mV or more.

xvii) Current readings at all the current measuring test stations shall be measured andrecorded

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recorded.

xviii) Where computerized test stations are provided the computer shall beinitialized/started to collect and store the field data of potentials, currentreadings, etc as programmed.

xix) After one month of starting the computers to collect the field data, the datastored by the computers at all the computerized test stations shall beretrieved/down loaded using the field data-retrieving computer. The data shall beanalyzed with the help of a station main computer.

xx) At the locations of the Electrical resistance probe installations the resistancereadings of the probes shall be measured using probe reader.

xxi) Final records of testing and commissioning including graphical representation of final pipe to soil potential readings shall be compiled with interpretation inconsultation with Owner/Owner’s representative and submitted.

xxii) If any deficiencies are found in the system, the same shall be rectified by thecontractor, at no extra cost or time schedule impact, to the complete satisfactionof Owner/Owner’s representative. Such deficiencies shall include mitigation of stray current electrolysis and interference problems that may be found existing in

the course of testing and commissioning A set of PSP observations shall also be

xxv) The current dissipated by individual anodes shall be measured from the anodelead junction box and corrected for equal dissipation to the extent possiblekeeping the total ground bed current same.


10.1 Investigations shall be made for stray current electrolysis of the pipeline, mutualinterference between the pipeline and foreign pipelines/structures interference

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interference between the pipeline and foreign pipelines/structures, interferenceon foreign pipelines/structures due to the CP of the pipeline and ground bed,interference on metallic structures which lie in between pipeline and ground bedor near to ground bed, AC induction on pipeline due to overhead EHV/HV lines,interference due to high voltage DC lines, HVDC earthing system, electric traction,etc.

10.2 Measurements including pipe/structure to soil potentials and pipe/structurecurrents etc. on the pipeline/structure being CP protected and on foreignpipelines/structures, and ground potential gradient etc. shall be made toinvestigate the current discharge and pickup locations. In case of fluctuating straycurrents, investigations shall be made continuously over a period of time and if required simultaneously at different locations to find out the stray currentsource(s). Recorders shall preferably be used for long time measurements.

10.3 Wherever foreign pipelines which may or may not be protected by anindependent CP system run in parallel to the protected pipeline, either in thesame trench or very near to the protected pipeline and are not bonded to it,investigations shall be performed for current discharge points on both thepipelines.

10.4 Mitigation measures shall be provided depending upon the type of stray current

electrolysis/interference These shall include installation of bond with variable

11.0 CLOSE INTERVAL POTENTIAL SURVEY Where specified, contractor shall carry out a close interval ‘ON’/’OFF’ potentialsurvey over the entire length of pipeline by computerised potential logging methodand identify the under protected/over protected area, any major coating damageon the pipeline, after the backfilling has been consolidated sufficiently and CP

system has stabilized. Contractor shall provide required mitigation measures andrectify the under/over protected zones, identify if any, the major pipeline coatingdefects, required to be repaired. During the survey the reference cell shall be

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defects, required to be repaired. During the survey the reference cell shall becalibrated minimum once in 24 hours. Detailed procedures for running this surveyshall be submitted for review.

Additional tests for detailed identification of coating defects shall be conducted bythe contractor, if specified in the project specification/ data sheets.

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SPECIFICATIONS FOR CATHODIC

PROTECTION TRANSFORMER RECTIFIER UNIT

Abbreviations:

CPTR units: Cathodic protection transformer rectifier units

MTBF : Mean time between failure

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MTTR : Mean time to repair

PCB : Printed circuit board

MOV : Metal oxide varistor

PSP : Pipe to soil potential

CVCC : Constant Voltage and Constant Current Mode

CONTENTS

1. SCOPE


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3. SITE CONDITIONS


5. TECHNICAL REQUIREMENTS

6. EQUIPMENT DESCRIPTION

7. INSPECTION, TESTING AND ACCEPTANCE


1 SCOPE

This specification covers the requirements for the design, manufacture andtesting of Cathodic Protection Transformer Rectifier units (CPTR units)working on controlled rectification principle intended to supply power tocathodic protection system for underground pipelines! structures.


2.1 The system design, performance and materials to be supplied shall conform

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y g , p ppto the requirements of the latest revision of following standards:

o IS: 1248 : Direct acting indicating analogue electrical measuringinstruments and (Parts-i, 2, 8 & 9) accessories.

o IS: 3700 : Essential rating and characteristics of semiconductordevices (Parts-i to 11)

o IS: 3715 : Letter symbols for semiconductor devices (Parts-i to 4)o IS: 4411 : Code of designation of semiconductor devices.o IS: 5469 : Code of practice for the use of semiconductor junction

devices. (Parts-i to 4)o IS: 6619 : Safety code for semiconductor rectifier equipment.o IS:7204 : Stabilised power supplies DC output. (Parts-i to 4)o IS: 12021 : Control transformers for switchgear and control gear for

voltages not exceeding 1000 V AC (Parts-i to 4).

o IS: 13703 : Low voltage fuses for voltages not exceeding 1000 V AC or1500 V DC. (Parts-i to 4)

o IS: 13947 : Low voltage switchgear and control gear. (Parts-4,section-i)

2.2 In case of imported equipment, standards of the country of origin shall beapplicable if these standards are equivalent or stringent than the applicableIndian standards.

Service conditions shall be as specified in the data sheet. If not specificallymentioned therein, a design ambient temperature of 40°C and an altitude notexceeding 1000 m above mean sea level shall be considered


4.1 The offered equipment shall be brand new with state of art technology andproven field track record. No prototype equipment shall be offered.

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p p yp q p

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

4.3 Vendor shall give a notice of at least one year to the end user of equipmentand GAIL before phasing out the product/spares to enable the end user forplacement of order for spares and services.

5 TECHNICAL REQUIREMENTS

5.1 Fabrication and General Details

5.1.1 CPTR unit shall be housed in sheet steel enclosure. The front, rear walls anddoors shall be made by using minimum 2 mm thick sheet steel and side wallsshall be made of minimum 1.6 mm thick sheet steel. Wherever required,suitable stiffeners shall be provided. The Unit shall be freestanding type.Hinged doors shall be provided at the front and back as required. The unitshall be natural cooled type. Louvered openings with wire mesh for naturalventilation may be provided. Degree of protection for the panel shall beminimum IP-4 1. The CPTR unit panel shall, preferably, not need rear access

for operation maintenance and shall be suitable for mounting flushed to the

power cables. Minimum 20% spare terminals shall be provided. The terminalblocks shall be mounted minimum 300 mm above the gland plate.

5.1.4 All live parts shall be properly shrouded. This shall ensure complete safety topersonnel intending routine maintenance by opening the panel doors.

5.1.5 CPTR unit shall be suitable for bottom cable entry unless otherwise specifiedin the data sheet and shall be supplied complete with crimping type cable

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pp p p g yptermination lugs and cable glands. Cable glands shall be of brass, nickelplated, single compression type for indoor installations and doublecompression type for outdoor installations. The space in the terminalchamber shall be adequate for termination of required number and sizes of cables as specified in the data sheet.

5.1.6 The input power factor of the unit at rated load shall be 0.8 lag or better.

5.1.7 The CPTR unit shall be field proven. The design, internal component layoutand rating of component shall ensure high MTBF and low MTTR. Prototypeequipment shall not be acceptable.

5.1.8 All the control equipment like switches, pushbuttons, potentiometers etc.

shall be located at a convenient height of minimum 300 mm and maximum1800 mm from the bottom of the panel.

5.1.9 The printed circuit boards (PCBs) shall be of copper clad glass epoxylaminate. PCB tracks shall be tinned and solder masked. The PCB shall becoated with suitable lacquer to make it immune to dust, moisture and fungalgrowth. Where plug in type of PCBs are used gold plated male-femaleconnectors shall be used for the purpose.

5.1.12 An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminiumshall be provided throughout the length of the panel. Provision shall be madefor connecting this earth bus at two ends with the plant earth grid by meansof (40x5) mm2 GI flat. All non-current carrying metallic parts of the paneland mounted equipment shall be connected to the panel earth bus. All doors

and movable parts shall be connected to the earth bus by flexible coppercables.

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5.1.13 All panel mounted equipments (e.g. lamps, pushbuttons, switches, meters,PCBs, etc.) shall be provided with suitable nameplates. Nameplates shall beengraved out of 3-ply (black-white- black) lamicoid sheets or anodisedaluminium. Back-engraved Perspex sheet nameplates may also beacceptable. Engraving shall be done with groove cutters. Hard paper or self-

adhesive plastic tape nameplates shall not be acceptable. Nameplates shallbe fastened by screws and not by adhesive.

Labels shall be provided for every component on the cards, connecting wiresas well as for the terminals in the terminal strip inside the panel.

5.1.14 Where specified in the data sheet the CPTR unit shall be housed in anoutdoor kiosk. The kiosk shall be made of sheet steel of minimum 3 mm thick

and epoxy painted on both internal and external surfaces. Hinged lockabledoors shall be provided at the front and back. The kiosk shall be suitable foroutdoor mounting and shall give proper protection to the CPTR unit againstrain, other harsh weather conditions. Necessary ventilation arrangement withlouvers and wire mesh shall be provided for proper operation of the CPTR unit. The cable entry to the kiosk shall be from bottom through cable glands.Suitable canopy shall be provided on the top of the Kiosk.

5 1 15 Painting

All unpainted steel parts shall be suitably treated to prevent corrosion. If these parts are movingelements, then they shall be greased.

6 EQUIPMENT DESCRIPTION

The CPTR unit shall be complete with following main sections:o - Transformer and input controls.o Rectifier and filter

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o Output protectionso System controlso Control, indication and metering

6.1 Transformer and Input Controls

6.1.1 The transformer shall be natural cooled dry type with separate primary andsecondary windings. An intermediate earth screen shall be provided betweenprimary and secondary windings. CPTR Units having multiple output circuitsshall have separate secondary windings for each output circuit. Transformershall be vacuum impregnated with epoxy varnish and baked. The safetyfactor for transformer rating shall be minimum 125%.

6.1.2 Single-phase transformers may be provided up to 50V, 50A DC output ratingof the CPTR units. Beyond this rating, 3 phase transformers shall beprovided.

A moulded case circuit breaker with thermal over load and short circuitrelease shall be provided at the input of the transformer. Miniature circuitbreaker with thermal overload and short circuit release in place of mouldedcase circuit breaker may be provided, where the miniature circuit breaker

rated for the incoming AC supply short circuit current indicated in the data

and from output side from the pipeline. Required shunt zeners / MOV shall beprovided across the rectifier elements for protection.

The rectifier elements shall have humidity/moisture resistant finish andmounted in sufficiently sized heat sink designed to provide adequate cooling

under worst conditions of operation. The rectifier elements shall haveadequate protection against high dv/dt and di/dt.

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6.2.2 The thyristors/triacs shall be protected by semiconductor fuses. For unitsrated 50V, 50A DC or less, if the thyristors or triacs are adequately over ratedand system has enough inductance so that in case of sudden output shortcircuit the over current limit feature comes into action before short circuitcurrent rises beyond the rating of the thyristors/triacs, then the

semiconductor fuses may not be provided. This feature shall bedemonstrated during testing of the unit at works.

6.2.3 Adequate filtering shall be provided on the DC output of the rectifier to limitthe ripple content in the output to less than 5% at rated output.

6.2.4 The rectifier system shall be of natural air cooled type.

6.2.5 For CPTR units with multiple output circuits, each output circuit shall haveindependent rectifier and filter.

6.3 Output ProtectionsTwo pole moulded case circuit breaker or miniature circuit breaker (if available) rated for the DC output current, short circuit current and havingthermal over load, short circuit release shall be provided in the output. A lightning arrestor rated for minimum 1OKA impulse current discharge

capacity and rated voltage & maximum spark over voltage rating suitable to

For constant voltage mode of operation the output current limit shall be setat maximum and output voltage setting shall be varied. Irrespective of outputcurrent demand the chosen value of the output voltage shall be maintainedby the control system till the current limit is reached. After that the output

current limit shall be maintained and output voltage shall decrease to keepthe current constant.

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For constant current mode of operation the output voltage shall be set atmaximum and output current shall be varied through varying the setting of output current limit. Irrespective of output voltage requirement the controlsystem shall maintain the output current to the set current limit value till thevoltage limit is reached. After that the output voltage limit shall be

maintained and output current shall decrease to keep the voltage constant.

B) Auto PSP mode

In this mode of operation the output of the CPTR unit shall operate in anexternal closed loop with pipe to soil potential (PSP), measured by referencecell, in feed back loop. The CPTR unit control shall adjust the output voltagesuch that the PSP as measured by reference cell always remains equal to theset potential on the unit. The set potential (Vps) shall have high long time

stability and minimum temperature drift. The set potential shall becontinuously adjustable over the range specified in data sheet.

The unit shall be designed to operate with number of reference cellsconnected to it (to be provided by others) as specified in data sheet. In caseof more than one reference cell being specified, CPTR unit shall have featureto automatically select the reference cell having less negative potential thanthe others and use the same for auto control of the unit (e.g. (-) 0.8 V is less

negative than ( ) 0 9 V) Adequate hysterisis shall be provided in selecting

6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shallbe provided in case of PSP either exceeding the specified maximum limit(Vpm) or remaining lower than the specified minimum limit (Vpn).

6.4.3 The output voltage regulation for no load to full load variation with input

voltage variation from maximum to minimum shall not be more than2.5

%of rated voltage through out the range of output voltage and over thespecified ambient temperature variation as specified in data sheet, in CVCC.-

f

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constant voltage mode of operation. In auto PSP mode the closed loop PSPregulation for no load to full load variation with input voltage variation frommaximum to minimum and PSP feedback varying over the specified rangeshall be within 20 mV.

In CVCC- constant current mode of operation, the current regulation forminimum to maximum output voltage and minimum to maximum variation ininput voltage shall not be more than 2.5% through out the range of outputcurrent.

6.4.4 The DC output of the CPTR unit shall be floating (ungrounded) in the Unit.However the CPTR Unit shall allow grounding of positive output terminalthrough the anode ground bed.

6.4.5 For CPTR units with multiple output circuits, each output circuit shall haveindependent control system.

6.5 Current Interrupter

6.5.1 If specified on the data sheet a current interrupter for CPTR Unit outputcurrent interruption shall be provided.

6.5.5 Whenever the timer is switched on it shall always start with ON ‘timing’. A timer-reset push button shall be provided. On pressing this pushbuttonduring operation of the timer, the timer shall get reset and upon release of the button the timer shall restart with ‘ON’ timing.

6.5.6 The power required for operation of the timer and contactor shall be derivedfrom the main power supply to the CPTR unit.

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6.5.7 The following controls and indications shall be provided for currentinterrupter. The controls shall be housed in a lockable cover, so that normallythey are not accessible. The indications shall be mounted on the door.

a) Controls

-Timer power’ ON’ /‘OFF’

- Timer reset

- Thumb wheel switch for ‘ON’ timing- Thumb wheel switch for ‘OFF’ timing

In case of microprocessor based system keypad with display may be providedin place of thumbwheel switches.

b) Indications(LED)

-Timer power ‘ON’

- ‘ON’ timing

- ‘OFF’ timing

6.5.8 The output contact of the current interrupter contactor shall be wired in thepositive DC output of the CPTR unit. A link shall be provided for shortingthese terminals whenever the current interrupter is not in use.

6 5 9 If specified in the data sheet the current interrupter shall be an independent

6.6 Controls, Indication and Metering

6.1.1 Following controls shall be provided on CPTR unit front door.a) ON/OFF control for input through MCCB/MCB.

b) ON /OFF control for output through MCCB/MCB.c) Auto/C VCC mode selector switch.d) Potentiometers for Vos, Vps and los settings.) S l t it h f l ti i di ti f PSP t d PSP t l f ll

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e) Selector switch for selecting indication of PSP set and PSP actual for allthe reference cells.

6.6.2 Following controls shall be provided inside the module at user accessiblecommon location:

a) Potentiometer for Vrs, Vpm, Vpn and Vas/las settings.b) Controls for current interrupter:

- Timer power ‘ON’ / ‘OFF’ - Timer reset- Thumb wheel switch for ‘ON’ timing- Thumb wheel switch for ‘OFF’ timing

6.6.3 TR unit shall have following indicating lights (lamps or min. 5 mm dia LEDs):

a) CPTR unit ON/OFFb) Unit in auto/CVCC (2 lamps)c) Reference cell controlling the closed loop control of the CPTR unit

(number of lamps same as number of reference cells).d) Reference cell faulty (number of lamps same as number of reference

cells).e) Pipeline over protected.f) Pipeline under protected

g) Indications for current interrupter:

It shall be possible to switch-off all the digital meters preferably by a singleswitch.

6.6.5 If specified in data sheet, CPTR unit shall incorporate provision for remotemonitoring of the unit through SCADA system as below:

a) Potential free contacts for the following:o All the reference cells failed. (Contact open on alarm condition)o Pipeline overprotected. (Contact open on alarm condition)

Pi li d t t d (C t t l diti )

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o Pipeline under protected. (Contact open on alarm condition)o System in auto-mode. (Contact close in auto condition)o System in CVCC mode. (Contact close in CVCC mode)

b) 4 to 20 mA electrically isolated signal for the following:

-- PSP (-4V to OV)

- - CPTR unit output voltage

- - CPTR unit output current

The transducers shall have electrical isolation between input and output. Theisolation insulation shall withstand 2kv, 50Hz for minimum 1 minute. Theaccuracy class of the transducer shall be 0.5. The transducers shall beprotected against input and output voltage surges. The transducer shall be

suitable for driving up to 600 ohms load impedance located up to 500 maway and wired with 0.5 mm2 copper conductor cable.

6.6.6 For units having multiple outputs, each output circuit shall have independentcontrols, indication and metering.

7. TESTS AND ACCEPTANCE

7 1 D ing man fact e the eq ipment shall be s bjected to inspection b

o Dimensional checking.o Proper mounting of components and neatness of wiring etc.o Model number.

7.2.2 Insulation tests

The voltage specified in the table below shall be applied for one minute tothe circuits indicated:

Withstand voltageControl electronics

60VPower electronicsU 1

Auxiliary circuitsU 2

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t sta d o tage<60V Un1 Un2

To earth 700V D.C. 2xUn1 + 1000V 2xUn2 + 1000V

To control electronics - 2xUn1 + 1000V 2xUn2 + 1000V

To power electronics 2xUn1 + 1000V - 2xUn1 + 1000V

To auxiliary circuits 2xUn2 + 1000V 2xUn1 + 1000V -

(Un1 and Un2 are nominal voltage rating of power electronics and auxiliarycircuits respectively).

D.C. test voltages may be applied instead of A.C. The magnitude of D.C. testvoltages to be applied shall be 2 times the above-mentioned A.C. (r.m.s)values.

Insulation resistance test shall be conducted before and after heat run test.

7.2.3 Heat run test All CPTR units shall be subjected to a heat run test performed at ratedvoltage for period not less than 16 hours prior to execution of functionaltests.

At least one CPTR unit of each rating shall be loaded to its rated output

th o gh o t 16 ho te t pe iod All othe CPTR nit h ll be ene gi ed

evaluation of output voltage regulation and efficiency of the unit shallbe carried out during the testing.

b. Constant current operationDuring the test, voltage limit shall be set to rated output voltage.

Performance testing shall be carried out for various output currentlimit settings and load resistance varied to achieve output voltage fromminimum to maximum. The verification of operation of the controlfunctions measurement of output voltage current input AC voltage

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functions, measurement of output voltage, current, input AC voltage,current, power factor, ripple in the output, evaluation of outputcurrent regulation of the unit shall be carried out during the testing.

7.2.4.2 Auto PSP mode operation

Suitable set up shall be arranged for output loading and reference cellfeed back. The closed loop performance and regulation shall bechecked with the PSP set voltage varied from O.85V to 1.2V.

Disconnecting the reference cell feed back connection in the above setup shall simulate the reference cell failed condition. The outputvoltage/current of the unit shall go to the value set on thepotentiometer Vas/las provided inside the CPTR UNIT. The settings on

Vas/Jas shall be varied and the output voltage/current shall beobserved.

Operation of sensors for pipeline over protection, under protection,reference cell failure and reference cell selection logic in auto PSPmode shall be verified by connecting variable external voltage sourcesto reference cell inputs of the CPTR unit. The number of externalvoltage sources shall be same as number of reference cell inputs

ifi d f th CPTR it

7.2.4.4 The current interrupter shall be tested for time interval settings and specifiedoperation.

8 PACKING AND DESPATCH

The equipment shall be properly packed for selected mode of transportation

i.e. by ship/rail or trailer. The panels shall be wrapped in polythene sheetsbefore being placed in crates to prevent damage to finish. Crates shall haveskid bottom for handling. Special notations such as ‘Fragile’, ‘This side up’,‘Center of gravity’ ‘Weight’ etc shall be clearly marked on the package

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Center of gravity , Weight etc., shall be clearly marked on the packagetogether with Tag nos., P.O. Nos. etc.

The equipment may be stored outdoors for long periods before erection. Thepacking shall be completely suitable for outdoor storage in areas with heavy

rains/high ambient temperature.

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SPECIFICATION FOR FLAMEPROOF

LIGHTING AND POWER PANELS

ABBREVIATIONS:

GI Galvanised Iron

MCB Miniature Circuit Breaker

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MCB Miniature Circuit Breaker

ELCB Earth Leakage Circuit Breaker

PVC Poly Vinyl Chloride

FRP Fibre Reinforced Plastic

CIMFR Central Institute of Mines and Fuel Research (formerly CMRI)

CCE Chief Controller of Explosives

FM Factory Mutual Research Corporation

IEC International Electrotechnical Commission

LCIE Laboratoire Central des Industries Electriques

PESO Petroleum and Explosives Safety Organization

UL Underwriters Laboratory

CONTENTS

1.0 SCOPE

2 0 CODES AND STANDARDS

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4.0 SITE CONDITIONS

5.0 POWER SUPPLY

6.0 CERTIFICATION




1.0 SCOPE

This specification covers the requirements of design, manufacture, testing,packing and supply of flameproof Lighting and Power panels! accessoriessuitable for installation in locations handling flammable liquids and gases.


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

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otherwise specified:IS-5 Colours for ready mixed paints and enamels.IS-1248 (Parts 1 & 2) Direct acting indicating analogue measuring

instruments and their accessories.IS-2 148 : Flameproof enclosures for electrical apparatus.

IS-5571 : Guide for selection of electrical equipment for hazardousareas.IS-8828 : Specifications for Circuit breakers for Over current

protection for household and similar installationsIS-12640 : Residual current operated circuit breakers.IS-13346 : General requirements for electrical apparatus for

explosive gas atmosphere.IS- 13408 (Part-1) : Code of practice for the selection, installation and

maintenance of electrical apparatus for use in potentiallyexplosive atmospheres (other than mining applications orexplosives processing and manufacture).

IS-13947 (Parts 1 & 5) L.V. Switchgear and Controlgear.

2.2 Imported equipment shall conform to the international standards such as IEC / BS / VDE / NEMA or equivalent.

2 3 Th i t h ll l f t th i i f I di El t i it R l



4.0 SITE CONDITIONSThe equipment shall be suitable for installation and satisfactory operation inclassified hazardous locations in tropical, humid and corrosive atmosphere asprevalent in refineries, petrochemical and fertilizer plants. The lighting andpower panels shall be designed to operate under site conditions as specified

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power panels shall be designed to operate under site conditions as specifiedin the data sheet. If not specifically mentioned therein, a design ambienttemperature of 400 C and an altitude not exceeding 1 000m above mean sealevel shall be considered.

5.0 POWER SUPPLY 5.1 Unless otherwise specified, lighting and power panels shall be suitable for415V, 50Hz, three phase and neutral (TPN) incoming supply and outgoingcircuits for 240V, single phase and neutral (SPN).

5.2 For projects falling under the jurisdiction of DGMS, the following additionalrequirements shall apply:

5.2.1 The phase-to-phase voltage shall not exceed 125 volts (where electriclighting is used in underground mine)! 250 volts (where electric lighting isused in open cast mine or surface of a mine), with the neutral or the mid-point of the lighting system connected with earth.

5.2.2 The panels shall have three phase, 3-wire system, without neutral.

5.2.3 Outgoing circuits shall be controlled by 2-pole MCBs. Earth leakage protection

h ll b id d f ll t i i it hi h h ll i l t b th l

content in the alloy shall be as per IS-13 346. The temperature of externalsurfaces shall be limited to 200°C, unless otherwise specified. The enclosuresshall be sized to facilitate easy maintenance and heat dissipation.

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

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shall be suitable for providing protection against rain from top and two sides.

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

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

Flame proof (Gas group IIA/IIB) Dark admiralty grey shade 632 of IS-S Flame proof (Gas group IIC) Light yellow shade 355 of IS-S

7.1.5 A warning inscription “Isolate power supply elsewhere before opening” shallbe provided on each enclosure. The warning inscription shall be embossed onthe enclosure or a separate warning plate with above inscription shall be

fixed to the enclosure with screws. The warning plate shall be of nickel platedbrass or stainless steel.

7.1.6 All accessories like nuts, bolts, washers etc. shall be made of stainless steelSS-304.

7.1.7 All the non-current carrying metallic parts of the panel shall be inherentlybonded together. Each lighting and power panel shall be provided with two

thi t d ith l th t i f th l l it bl f

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

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

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The holes provided on these lugs shall be of oblong type.

7.1.11 A nameplate indicating TAG NO. shall be provided on each panel. Nameplatesshall also be provided for each incoming and outgoing feeder. Separatenameplate shall also be provided to indicate the details of testing agency

(CIMFR or equivalent), test certificate no. with date, statutory approval no.with date and agency (PESO / CCE / DGFASLI / DGMS), BIS license numberand date, applicable gas group etc. The nameplates shall be engraved on 3ply black white black lamicold sheets using square cutters. Black engravedperspex sheet nameplate shall also be acceptable. Nameplates shall be fixedby screws and shall not be pasted. In case the standard details given aboveare embossed on the enclosures, the same need not be repeated on thename plate.

7.2 Component Specification

7.2.1 Busbars in the lighting and power panels shall be made of high conductivitycopper, and shall be supported by non-hygroscopic insulators. Busbars shallbe colour coded for identification of phases and neutral.

7.2.2 Unless otherwise specified, the incomer shall have one no. 4 pole 40A MCB

i l t ( ith t l d d h t i it l ) d 4 l ELCB

7.3 Terminals & Wiring

7.3.1 The panels shall be provided with sufficient number of terminals. More than 2

wires per terminal shall not be permitted. If required, additional terminal withshorting link may be used. Unless otherwise specified, the terminals fortermination of incoming and outgoing external cables shall be suitable fortermination of upto 70 mm2 and 6 mm2 copper conductor respectively.Terminals shall be suitable for termination of solid conductors upto 6 mm2 andstranded conductors above 6 mm2. Wherever lugs are required for cable

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g qtermination, tinned copper type lugs shall be provided.

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

Incomer : 16 mm2Outgoing : 2.5 mm2


8.1 During fabrication, the equipment shall be subjected to inspection by GAIL or byan agency authorised by the owner, if specified! agreed in Inspection Test Plan.Manufacturer shall furnish all necessary information concerning the supply to

GAIL’s inspector. All routine! acceptance tests shall be carried out atmanufacturer’s works under his care and expense.

8.2 Type test certificates from CIMFR or equivalent test house, applicable PESO/ CCE / DGFASLI / DGMS approval certificates, BIS license and original drawingsreferred in type test certificates shall be shown to the inspection agency ondemand during inspection. The certificates and BIS license must be valid at thetime of despatch.


All the equipment shall be divided into several sections for protection and easeof handling during transportation. The equipment shall be properly packed forthe selected mode of transportation, i.e. by ship! rail or trailer and shall bewrapped in polythene sheets before being placed in crates! cases to preventdamage to finish. The crates! cases shall have skid bottom for handling. Special

notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’, ‘Owner’sparticulars’, ‘P0 no.’ etc., shall be clearly marked on the packages together withother details as per purchase order.

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

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SPECIFICATION FOR MEDIUM &

HIGH VOLTAGE CABLES &

ACCESSORIES

Abbreviations:

ASTM: American Society for Testing and Materials

BIS: Bureau of Indian Standards

IEC: International Electrotechnical Commission

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IS: Indian Standards

NEMA National Electrical Manufacturers Association

PVC Polyvinyl Chloride

XLPE Crosslinked Polyethylene

HR PVC Heat Resistant Polyvinyl Chloride

FR Flame Retardant

CONTENTS

1. SCOPE

2. STANDARDS

3. GENERAL CONSTRUCTION

4 CABLES ACCESSORIES

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4. CABLES ACCESSORIES

5. INSPECTION, TESTING AND ACCEPTANCE


1. SCOPE

This specification along with data sheets covers requirements for design,manufacture, testing at works and supply of Flame Retardant PVC/XLPEcables and cable jointing I terminating accessories for medium and highvoltage systems.

2. STANDARDS

2.1 The cables and cables jointing & terminating accessories shall comply withthe latest edition of the following standards as applicable:

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IS: 1554 PVC insulated (heavy duty) electric cables

IS: 7098 Cross-linked polyethylene insulated PVC sheathed

IS: 8130 Conductors for insulated electric cables and flexible cords

IS: 5831 PVC insulation and sheath of electric cables

IS: 3975 Mild steel wires, strips and tapes for armouring of cables

IS 108 10(Part 41)Methods of test for cables: Mass of zinc coating on steelarmour.

IS: 209 Specification for zinc

IS: 3961(Part 2)Recommended current ratings for cables: Part - 2 PVC

Insulated and PVC sheathed heavy-duty cables.IS: 10418 Drums for electric cables

IS: 10462 (Pt-I)Fictitious calculation method for determination of Dimensions of protective coverings of cables: Part - IElectrometric and thermoplastic insulated cables.

IS: 10810 (Pt -58) Oxygen Index test

IS: 10810 (Pt 61) Flame Retardant test

2.2 The cables and accessories shall also conform to the provisions of IndianElectricity Rules and other statutory regulations, as applicable.

2.3 In case of any contradiction between various referred standard/specification/data sheet and statutory regulations, the following order of priority shall govern:

o Statutory Regulationso Data Sheets

o Job Specifications

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o This Specificationo Codes and Standards

3 GENERAL CONSTRUCTION

3.1 The cables shall be suitable for laying in trays, trenches, ducts, and conduitsand for underground-buried installation with uncontrolled backfill andpossibility of flooding by water and chemicals.

3.2 Outer sheath of all PVC and XLPE cables shall be black in colour and theminimum value of oxygen index shall be 29 at 27 ± 2 C. In addition suitablechemicals shall be added into the PVC compound of the outer sheath to

protect the cable against rodent and termite attack.

3.3 All cables covered in this specification shall be flame retardant (FR) unlessspecified otherwise in the data sheet. The outer sheath of PVC and XLPEcables shall possess flame propagation properties meeting requirements asper IS-l0810 (Part-62) category AF.

3.4 Sequential marking of the length of the cable in metres shall be provided on

h h h h b / h ll b

shall be embossed /engraved on the cable outer sheath as per the applicableIndian Standards

3.8 PVC cables

3.8.1 All power/control cables for use on medium voltage systems shall be heavy-duty type, 650/1100 V grade with aluminium / copper conductor, PVCinsulated, inner-sheathed, armoured and overall PVC sheathed unlessspecified otherwise in data sheet

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3.8.2 The conductors shall be solid for conductor of nominal area up to andincluding 6mm2 and stranded beyond 6mm2. Conductors of nominal arealess than 16 mm2 shall be circular only. Conductors of nominal area 16 mm2

and above may be circular or shaped as per IS 8130. Cables with reducedneutral conductor shall have sizes as per Table I of IS 1554 (Part-I).

3.8.3 The core insulation shall be with PVC compound applied over the conductorby extrusion and shall conform to the requirements of type ‘A’ compound asper IS: 5831. The thickness of insulation and the tolerance on thickness of insulation shall be as per Table 2 of IS: 1554 (Part-l). Control cables having 6cores and above shall be identified with prominent and indelible Arabic

numerals on the outer surface of the insulation. Colour of the numbers shallcontrast with the colour of insulation with a spacing of maximum 50 mmbetween two consecutive numbers. Colour coding for cables up to 5 coresshall be as per Indian standard.

3.8.4 The inner sheath shall be applied over the laid-up cores by extrusion andshall be of PVC conforming to the requirements of Type ST-I PVC compoundas per IS: 5831. The minimum thickness of inner sheath shall be as per IS:1554 (Part-I). Single core cables shall have no inner sheath.

unarmoured cables and minimum thickness of outer sheath for armouredcables shall be as per IS: 1554 (Part -1).

3.8.7 If heat resisting PVC cables are specified in the data sheet, the following shallbe the requirements:It shall be possible to continuously operate the cable at a maximumconductor temperature of 85oC. PVC compounds used for HR PVC cables shallbe as follows:

a. Conductor insulation -Type C

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b. Inner sheath -Type ST 2c. Outer sheath -Type ST 2

3.9 XLPE Cables

3.9.1 Power cables for 3.3 KV up to and including 33 KV systems shall be Aluminium! copper conductor, XLPE insulated, sheathed, armoured andoverall PVC sheathed.

3.9.2 The conductors shall be stranded and compacted circular for all cables.

3.9.3 All cables rated 3.8 ! 6.6 kV and above shall be provided with both conductor

screening and insulation screening. The conductors shall be provided withnon-metallic extruded semi conducting screen.

3.9.4 The core insulation shall be with cross linked polyethylene insulatingcompound dry cured, applied by extrusion. It shall be free from voids andshall withstand all mechanical and thermal stresses under steady state andtransient operating conditions. It shall conform to the properties given inTable-I of IS: 7098 (Part -2).

3.9.8 For multicore cables, the armouring shall be by galvanized steel strips as permethod (b) of IS- 7098 (Part-2). If armouring is specified for single corecables in the data sheet, the same shall be with H4 grade hard drawnaluminium round wire of 2.5 mm diameter.

3.9.9 The outer sheath of the cables shall be applied by extrusion over thearmouring and shall be of PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831. The minimum and average thickness of

h h f d bl d h k f h h

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outer sheath for unarmoured cables and minimum thickness of outer sheathfor armoured cables shall be as per 15: 7098 (Part-2)

3.9.10 The thickness of the insulation, inner sheath shall be governed by valuesgiven in IS: 7098 Part -2

3.9.11 Where specified, 1100 V grade power cables shall also be XLPE insulated andshall meet the requirement specified in IS-7098 (Part-1).

4 CABLE ACCESSORIES

4.1 The termination and straight through jointing kits for use on the systems

shall be suitable for the type of cables offered as per this specification.

4.2 The accessories shall be supplied in kit form. Each component of the kit shallcarry the manufacturer’s mark of origin.

4.3 The kit shall include all stress grading, insulating and sealing materials apartfrom conductor fittings and consumable items .An installation instructionsheet shall also be included in each kit.

shall have protection against any mechanical damage and suitably designedto be protected against rodent and termite attack. The inner sheath similar tothat provided for cables shall be provided as part of straight through joint.The jointing kits shall be from one of the makes / types mentioned in thedata sheet.

The cables shall be tested and inspected at the manufacturer’s works. All thematerials employed in the manufacture of the cable shall be subjected, bothbefore and after manufacture, to examination, testing and approval by GAIL I

M f t h ll f i h ll i f ti i th

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owner. Manufacturer shall furnish all necessary information concerning thesupply to GAIL I owner’s inspectors. The inspector shall have free access tothe manufacturer’s works for the purpose of inspecting the process of manufacture in all its stages and he will have the power to reject anymaterial, which appears to him to be of unsuitable description or of unsatisfactory quality. The vendor shall give at least 2 weeks advance noticeto the purchaser, regarding the date of testing to enable him or hisrepresentative to witness the tests.

5.1 Cables

5.1.1 After completion of manufacture of cables and prior to despatch, the cables

shall be subjected to type, routine, acceptance and special tests as detailedbelow. GAIL/ Owner reserves the right to witness all tests with sufficientadvance notice from vendor. The test reports for all cables shall be gotapproved from the Engineer before despatch of the cables.

5.1.2 All routine tests, acceptance tests, type tests and additional type tests forimproved fire performance shall be carried out as listed in IS: 1554 (Part-I),and IS: 7098 (Part-2) on PVC and XLPE insulated cables respectively.

5.1.5 Acceptance tests as per IS-1554 (Part-I) and IS-7098 (Part-2) and thefollowing special tests to be performed on the cables as per sampling plan.These tests are required to be witnessed by GAIL before despatch 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 insulatedcables). Test certificates with respect to. this test (not older than oneyear) from recognised testing laboratory to be furnished for review byGAIL before despatch clearance of cables. In case test certificates are notavailable, test is to be conducted by vendor at his own cost in any

i d t t l b t i h t ti l b t b f d t h

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recognized test laboratory or in house testing laboratory, before despatchclearance of cables. Sampling for this test is to be done randomly once foreach order, provided type of insulation remains same.

b. Dielectric Retention Test: The dielectric strength of the cable insulationtested in accordance with NEMA WC - 5 at 75 ± 10 C shall not be lessthan 50 % of the original dielectric strength. (For PVC insulated cables).Test certificates with respect to this test (not older than one year) fromrecognised testing laboratory to be furnished for review by GAIL beforedespatch clearance of cables. In case test certificates are not available,test is to be conducted by vendor at his own cost in any recognized testlaboratory or in house testing laboratory, before despatch clearance of cables. Sampling for this test is to be done randomly and once for each

order.c. Oxygen Index Test: The test shall be carried out as per ASTM D2863 orapplicable Indian Standard specifications. Sampling to be done for everyoffered lot/size as per sampling plan.

d. Flammability Test: The test shall be carried out on finished cable as per IS- 10810 (part 61 & 62). Sampling for these tests is to be done randomlyonce for each order, provided outer sheath remains same. Theacceptance criteria for tests conducted shall be as under:


6.1 Cables shall be despatched in non-returnable wooden or steel drums of suitable barrel diameter, securely battened, with the take-off end fullyprotected against mechanical damage. The wood used for construction of thedrum shall be properly seasoned, sound and free from defects. Woodpreservatives shall be applied to the entire drum. Ferrous parts used shall betreated with a suitable rust preventive finish or coating to avoid rustingduring transit or storage.

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6.2 On the flange of the drum, necessary information such as project title,manufacturer’s name, type size, voltage grade of cable, length of cable inmetres, drum no., cable code, BIS certification mark, gross weight etc. shallbe printed. An arrow shall be printed on the drum with suitable instructionsto show the direction of rotation of the drum.

6.3 Unless otherwise specified, Cables shall be supplied in drum lengths asfollows:

MV CablesMulticore Power cables up to 6 mm2 : 1000 mMulticore Power cables from 10mm2 up to 300 mm2 : 500 m

Single Core Power cables up to 630 mm

2

1000 mControl cables up to 61 cores : 1000 m

HV power cables - Up to 11 kV(E) GradeThree Core cables up to 400 mm2 : 500 mSingle Core cables up to 400 mm2 : 1000 mSingle Core cables above 400 mm2 and up to 630 mm2 :750 m

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SPECIFICATION FOR STATIONARY NICKEL CADMIUM BATTERIES

Abbreviations:


Ah Ampere-hour

BS British Standard

DC Direct current

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DC Direct current

IEC International Electrotechnical Commission

IEEE Institute of Electrical & Electronics Engineers

IS Indian Standard

MSL Mean Sea Level


P0 Purchase Order

PVC Polyvinyl ChlorideUPS Uninterrupted Power Supply

VDE Verband der Elektrotechnik, Elektronik und Information technique

V Volt

CONTENTS

1.0 SCOPE



4 0 SITE CONDITIONS

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4.0 SITE CONDITIONS


6.0 PERFORMANCE



1. SCOPE

The intent of this specification is to define the design, Manufacture andtesting requirements of stationary Nickel Cadmium batteries for DC powersystem /AC UPS application.


2.1 The equipment shall comply with the requirements of the latest revision of the following standards issued by BIS (Bureau of Indian Standards) unlessotherwise specified IS 10918 Specification for Vented type Nickel Cadmium

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otherwise specified. IS-10918 Specification for Vented type Nickel Cadmiumbatteries

2.2 In case of imported equipment, standards of the country of origin shall beapplicable if these standards are equivalent or more stringent than theapplicable Indian standards.

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

2.4 In case Indian standards are not available for any equipment, standardsissued by IEC/ BS/ VDE/ IEEE! NEMA or equivalent agency shall be

applicable.

2.5 In case of any contradiction between various referredstandards/specifications/data sheets and statutory regulations, the followingorder of priority shall govern: Statutory regulations. Data sheets.

Job specification.

4 SITE CONDITIONS

Stationary Nickel Cadmium battery shall be suitable for operatingsatisfactorily in humid and corrosive atmosphere found in refineries,petrochemical and gas processing plants, metallurgical plants and otherindustrial plants. Service conditions shall be as specified in the datasheets/job specification. If not specifically mentioned therein, a designambient temperature of 40°C and an altitude not exceeding l000m aboveMSL shall be considered, with a minimum temperature of 10°C for batterysizing.

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5.1 The Nickel Cadmium cell/battery shall be suitable for float duty operationwith a constant voltage permanently applied to its terminals which issufficient to maintain it in a state close to full charge and shall be designed tosupply load in the event of normal power supply failure. Type of plateconstruction for batteries shall be as per the data sheet.

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

5.3 Ampere hour of the battery shall be selected based on the following:a. Minimum site ambient temperature of 10°C or as defined in the

data sheetb. Discharge duty cyclec. End cell voltaged. Ageing factor of 0.8e. Design margin of 10%, if not defined in the data sheet

5.7 Each cell shall have a separate container. The cell container shall be of highstrength alkali resistant material and designed to withstand mechanicalstresses, shocks and vibrations. The cell container shall betranslucent/transparent.

5.8 The terminal posts shall be of nickel plated steel. The terminals shall be

suitable for short circuit current and specified discharge current withoutdamage to the cell as a result of terminal heating.

5 9 Stationary Nickel Cadmium cells shall be designed to withstand the

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5.9 Stationary Nickel Cadmium cells shall be designed to withstand themechanical stresses encountered during normal transportation and handling.

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

5.11 The following information shall be permanently marked on the cell.

Nominal voltage Name of manufacturer/model reference Rated capacity in ampere hours (Ah) with End Cell Voltage

Voltage for float operation at 27°C with tolerance of ±1 % Month and year of manufacture

Polarity Marking

5.12 Each set of battery shall be supplied with all the accessories, including, butnot limited to the following:a. Battery stand in formation as per data sheet. Mild steel stand

pretreated and epoxy painted /PVC coated.

weeks advance notice shall be given to witness the final routine tests and othertests as agreed upon.

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

A) Routine testi) Physical examination test.ii) Polarity and absence of short circuit.iii) Dimension mass and layout

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iii) Dimension, mass and layout.iv) Marking and packing.

B) Acceptance testi) Marking and packing.ii) Verification of dimensions.iii) Test for Ah capacity.iv) Test for voltage during discharge.v) Internal resistance test.

C) Type testi) Verification of constructional requirement.

ii) Test for voltage during discharge.iii) Test for Ah capacity.iv) Test for charge retention/loss of capacity if

specified in the data sheet.v) Air pressure test.vi) Ampere hour and Watt-hour efficiency test.

Battery duty cycle test to meet the load cycle requirement shall also be

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SPECIFICATION FOR

UNINTERRUPTED POWER SUPPLY

UNIT

CONTENTS

1 SCOPE

2 CODES AND STANDARDS3 GENERAL REQUIREMENIS

4 SITE CONDITIONS

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6 INSPECTION. TESTING AND ACCEPTANCE

7 SITE ACCEPTANCE TESTS

8 PACK[NG AND DESPATCH

1 SCOPE

The scope of this specification is to define the requirements of design,manufacture, testing, packing and despatch of static Uninterrupted PowerSupply (UPS) system.


2.1 The equipment shall comply with the requirements of latest revision of thefollowing standards issued by BIS (Bureau of Indian standards I unless otherwise specified:

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wise specified:IS. 5IS: 124815:2147IS 3700 (Part I to 11)IS: 3715 (Part I to 4IS:4411IS: 5001 (Part I & 2)IS:54b9 (Part 1 to 3)IS 7204 (Part I to 4)IS: 12021IS: 133 14IS. 13703 (Part Ito 4)IS: 13947 (Part-4/ Sec-I)

2.2 In case of imported equipments standards of the country of origin shall beapplicable if these standards are equivalent or stringent than the applicableIndian standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity rules


3.1 The offered equipment shall he brand new with state of art technology andproven field track record. No prototype equipment shall he offered.

3.2 Vendor shall ensure availability of spare parts and maintenance support

services for the offered equipment at least for 15 ‘years from the date of supply.

3.3 Vendor shall give a notice of at least one year to the end user of equipment

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3.3 Vendor shall give a notice of at least one year to the end user of equipmentand GAIL before phasing out the product/spares to enable the end user forplacement of order for spares and services

3.4 The UPS system shall he an integrated system comprising static rectifiers,battery, static inverters. static switches, manual by pass switch, ACdistribution hoard, voltage stabilizer in bypass, isolating and protectiondevices and all other equipment! accessories required for completeness of the system whether specifically mentioned herein or not, but necessary forcompleteness and satisfactory performance of the system.

3.5 The UPS system shall be suitable to feed all loads connected to the outputwhich are primarily instruments. DIDC (DCS). computers. disc drives andother SMPS equipment leading to high crest factor of the load.

3.6 The inverter shall he transistorized (IGBT) type or with the latest proventechnology. All components shall he of a high quality and reliability thatsatisfy with the requirements of a secure AC power to ital equipment withrespect to performance. controlling, monitoring and safeguarding function incontinuously operating petrochemical process units, petroleum refineries, gas

3.10 The batteries shall meet the requirement of battery Data Sheet! batteryspecifications attached with the hid document

4 SITE CONDITIONSThe U PS system shall be suitable for installation and satisfactory operation ina closed substation with restricted natural air ventilation in tropical. humid

and corrosive atmosphere. The UPS system shall he designed to operateunder site conditions as specified in the data sheet. If not specificallymentioned therein, design ambient temperature of 40C and altitude notexceeding 100CM above MSL shall he considered for the UPS

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g


5.1 Input power supply5.1.1 The UPS shall he suitable for input power supply as defined in the data sheet.

If not specified therein the UPS shall he suitable for the following input powersupply.

Voltage 230/415V ± 10%Frequency : 50 Hz ± 5%

In addition to above variations, the input voltage may be subject to transientvariations comprising voltage dip to 20% of normal voltage during motorstart-up and voltage interruption during short circuit as well as frequencyvariations due to large motor start up. UPS system shall be designed tooperate satisfactorily while deriving the input power from an emergencydiesel generator set

UPS system shall also operate satisfactorily on input power supply having.o the ratio of negative to the positive sequence components not

exceeding 5% ando 5%.

rectifier shall simultaneously feed power to inverter as well as for float/rapidcharging of the battery The AC supply to loads shall he fed from inverteroutput. in case of any fault in the inverter, the load shall he automaticallytransferred to stabilized bypass supply and retransfer of load from stabilizedbypass supply to the inverter shall be possible in auto as well as in manualmode.

In case of AC input power failure or battery charger failure, the battery shallsupply power to . ‘‘ inserter without any interruption. The charger shall bedesigned for simultaneously feeding complete inverter load and for

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g y g pfloat/rapid charging the battery to its rated capacity. Charger shall beequipped with on-line automatic as well as manual charging facility.

5.2.2 Parallel Redundant UPS with bypass (Refer Sketch 2)In UPS system having this configuration two sets of rectifiers and invertersshall he provided. Under normal conditions, when AC mains power isavailable, both the rectifiers shall operate in parallel and supply DC power forfloat/rapid charging the battery and simultaneously to inverters. In case of failure in one rectifier, the other rectifier shall feed the complete load and thebattery without any interruption. In case of incoming supply failure or failureof both rectifiers the battery shall feed the inverters without any interruption.Each rectifier shall he designed for simultaneously feeding complete inverterload and float/rapid charging of the battery to its rated capacity. Eachrectifier shall be equipped with On Line automatic as well as manual chargingfacility.

Normally both inverters will he synchronised with each other and withstabilized bypass supply. Both inverters shall operate in parallel and share theload equally When a disturbance/fault occurs in any one of the inverters, the

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

5.2.5 For ease of maintenance, it shall he possible to isolate inverters and staticswitches from load through manually operated make before break switches.In case of larger rating UPS, where it is not possible to provide one power

switch with make before break feature, combination of breakers with thecontrol scheme having make before break logic may be provided whichensures momentary parallelling before tripping of selected breaker.

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5.3 UPS Design and Performance Requirements

5.3.1 Incoming AC supply shall he converted to DC through three phase full wavecontrolled rectifiers 1 he rectifiers shall operate according to the constantvoltage current limiting principle and shall incorporate a “Soft Start” featureto gradually accept load on initial energising.

5.3.2 The rectifier section of the UPS system shall be capable of precise regulationto prevent damage to the battery. The output voltage of rectifier’s DC buswithout the battery shall be stabilised to within ± 1% of set value during loadvariation between 0 to l00 of the rectifiers and specified mains input supplyvoltage variation.

5.3.3 Suitable protection shall be provided in the control circuits to guard againstinstability of phase controlled rectifiers due to electrical oscillations whichmay be present in the input supply as caused by emergency DG set.

5.3.4 The UPS system including the stabilised by-pass shall he galvanically isolatedfrom input power I . supply system by providing double wound transformers.

5.3.8 The UPS shall be provided with automatic sequence and power walk incircuit(s) with time delay of upto 15 sec. such that the rectifiers and inverterscan start operating automatically when incoming AC power is restoredallowing the UPS to he loaded automatically.

5.3.9 Facility for initial charging of batteries shall also be provided. The inverters

may be disconnected during initial charging of the battery.

5.3.10 For battery sizing, the following factors shall he considered unless specifiedotherwise in the data sheet;

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a. Load Power Factor of 0.8

b. Minimum ambient temperature as specified in Datasheet.

c.cellsof Novoltagecell end Rated efficiency Inverter

f pload Rated kVArated Inverter rent BatteryCur

.**

.*

d. Aging factor of 0.8e. Back up time of 30 minutes in case of mains power

failure unless specified otherwise in data sheetf. Minimum end cell voltage for lead acid/VRLA battery 1

.85 V per cell and 1.0 V per cell for Ni-Cd batteryg. Battery state of charge factor of 0.95

5.3.11 The rectifiers/chargers shall he designed to completely charge the Lead acidand Nickel cadmium batteries in a maximum time of 10 hours after completedischarge. Facilities shall be provided to initiate battery rapid chargeoperation by manual & automatic means. An auto charging sequence shouldbe provided for the rapid and float charging based on current sensing.

- For Nickel- Cadmium Batteries = Inverter input current +0.20 Ah (5 hr.Rating of the battery)

- For VRLA Batteries = Inverter input current + 0.2Ah ( 10 hr. Rating of thebattery) Where

efficienc Inverter voltageing ch Battery f p Load UPS of capacitykVA Rated nt InputCurre Inverter

*arg.*

5.3.13 The DC rectifiers shall sense the battery charging current and adjust the DCbus voltage to maintain the charging current to preset level A separate

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bus voltage to maintain the charging current to preset level. A separatecurrent limit circuit shall also he provided for adjustment of battery current.The rectifiers shall be protected against reverse battery connection at DC link voltage bus. Subsequent to a discharge cycle when battery is connected to

rectifier, the battery current shall he monitored, controlled and limited to setvalue automatically irrespective of the inverter input current.

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

5.3.15 Battery D.C. link shall be provided with a sensitive earth leakage protection.

5.3.16 The inverter shall be of the current limiting type (short circuit proof) andhave nominal output voltage and frequency as specified in the data sheet.The inverter output voltage and frequency shall not exceed the operationaltolerances, as measured at the output terminals of the unit during thefollowing conditions of UPS loading:

o Load variations between 0-100% of’ the rated output of UPS

DC input voltages over the range corresponding to battery rapidcharge and battery discharge operation during the specified dischargetimes.

The UPS output voltage waveform shall be sinusoidal with a relative harmoniccontent not exceeding 5% under linear load conditions, and not exceeding

15% under the rion4inear load conditions . specified above.

5.3.17 The inverter shall control the output voltage of the UPS such as to maintainsynchronism with the mains bypass voltage during variations in mains

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

5.3.18 It shall be possible to vary the inverter output voltage steplessly within ± 5%of the specified output voltage. This adjustment shall he possible to be madewhen the inverter is in operation.

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

5.3.20 The UPS system shall he able to operate satisfactorily on rated loads (in kVA)with power factors in the range of 0.7 lag to 1 0. The overall efficiency of theUPS system shall not be less than 80% at rated load and 0.8 p.f.

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

o Load transfer to stabilized bypass supplyo Complete load transfer to other healthy inverter when one of the to

parallel inverters develop a fault.

5.3.24 For 3 phase UPS system, the maximum output voltage and angle variationbetween the phases should nor exceed 6% and S degrees respectively even

under the condition of 100% unbalanced loading of the S phase output.

5.3.25 UPS system shall he suitable both for floating output or earthing of one legstar point in case of single phase! three phase system respectively.

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5.3.26 The stabilized bypass supply shall he designed to regulate the output voltagewithin 2% of the rated voltage over complete range of load from no load tofull load and fir specified input supply voltage variation. The type of Voltage

stabilizer in stabilized bypass supply shall he as indicated in data sheet .

5.3.27 The stabilized bypass supply shall have a continuous current rating equivalentto the rated output of the UPS unit and be capable of conducting a currentten times the rated output for the duration more than the fault clearing timeof the type of fuse provided. The load transfer devices shall comprise of continuously’ rated static elements in both inverter and stabilized bypasssupply.

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

b) Auto-transfer of the load from inverter to stabilized bypass supplyshall be initiated when:

o the inverter output voltage drops below 95 % of nominal outputvoltage under steady state condition and/or if the inverter outputvoltage falls below 90% of the nominal value tinder transientconditions.

OR o The inverter output voltage exceeds 105% of the nominal output

voltage under steady state condition and/or if the inverter outputvoltage reaches 110% of the nominal value under transient

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conditions.OR

o the inverter output current exceeds its tolerable limits.

B) Retransfer of load from stablised bypass supply to the inverter shall heas follows:a) The load transfer shall he possible wheno The inverter output voltage is within ± 5% of nominal output

voltage a. for more than 5 sec. and inverter output ando stablised bypass supply are synchronisedRetransfer of load from stabilised by pass to the inverter shall bedone manually only unless otherwise specified in the data sheet

If automatic retransfer of load to the inverter is specified in the datasheet, then the retransfer of load to the invertors shall he inhibitedfollowing four automatic transfers of load to stablised by pass withina period of 5 minutes.

5.3.31 All breakers shall he adequately rated for continuous rating as well as

5.3.34 The outgoing circuits of ACDB shall be protected by semiconductor fuses.Each inverter shall he designed to clear a fault in any of the branch circuitsupto a maximum rating of 25% of the system capacity without the assistanceof the stabilized bypass supply. In case of any fault in branch circuits, theload connected to the healthy circuits shall not get affected The fault clearingtime shall be less 2 than 4 msec.

5.3.35 All PCBs shall be provided with a transparent epoxy coating for environmentalprotection and trivialization. They shall he suitably located away from heatsources,ll l l d d d h ll b ll d

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5.3.36 All electronic control and monitoring printed circuit cards shall be installed instandardized electronic equipment frames and shall he fitted with suitablemeans for easy removal. The frames shall incorporate guides for PCB’s tofacilitate correct insertion of PCB’s and shall allow access to the wiring side of

the connectors All PCBs shall be placed in a manner to avoid replacement of a PCB by a wrong spare PCB. Monitoring points shall be provided on each of the PCB’s and the PCB shall be firmly clamped in position so that vibration orlong usage do not result in loose contacts. Failure 7 of each PCB shall heindicated by visual alarms. Visual fault diagnostics shall preferably identifyfaults upto various sections in the card.

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

back with dust tight gaskets. Inter panel sheet steel barriers shall heprovided. The enclosure shall provide minimum lP-31 degree of protection, if not specified otherwise in the data sheer. The maximum and minimumoperating height of the switches shall be 1800 mm and 300 mm respectively.

5.4.2 Power cables shall be with aluminum / copper conductors and control cables

shall he with copper conductors All the cable connections shall be frombottom and front of the panel, if nor specified otherwise in the data sheet. A removable bolted gland plate shall be provided along with single compressiontype nickel plated brass cable glands for external cable connections. Clampt t i l h ll b d f ti f ll i t 10 2 B lt d

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type terminals shall be used for connection of all wires upto 10 mm 2. Boltedtype terminals suitable for cable lugs shall be provided for wire size abovethis. Tinned copper lugs for all external connections shall be provided withthe panels

5.4.3 Bus bars shall be used in all power circuits which are rated above 100 Amp.Copper conductor PVC insulated cables or wires of 660V grade shall he usedfor power circuits rated less than 100 Amp. Bus bars shall be colour codedand live parts shall be shrouded to ensure complete safety to personnelintending routine inspection by opening the panel doors. All the equipmentinside the panel and on the doors shall have suitable name plate and devicetag numbers as per the schematic diagram. All wires shall he ferruled andterminals shall be numbered.

5.4.4 MCCBs and load break power switches shall be mounted inside the panel.The control switches shall he rotary type, mounted on the door and shall beexternally operable. An 11W CFL lamp controlled through a door switch shallbe provided for illumination in each panel. All instruments shall heanalogue/digital, switchboard type. hack connected. 72 x 72 mm. square(Analogue type) of reputed make. Analogue instruments’ scale shall have red

shall normally he used for circuits with control fuse rating of 10 Amp. or less.For control circuit having fuse of 16 Amps., 2.5 mm2 size wire shall he used.Control wiring for electronic circuits shall he through flat ribbon cable orthrough copper wire minimum of 0.5 mm dia.

5.4.8 All control wiring shall preferably be enclosed in plastic channels or otherwiseneatly hunched together. Each wire shall be identified at both ends by PVC

ferrules. Ferruling of wires shall be as per relevant IS.

5.4.9 All metal surfaces shall he thoroughly cleaned and dc-greased to remove millscale. rust, grease and dirt Fabricated structures shall be pickled and theni d t t f id Th d f h ll b d b

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rinsed to remove any trace of acid. The under surface shall be prepared byapplying a coat of phosphate paint and a coat of yellow zinc chromateprimer. The under-surface shall he made tree from all imperfections beforeundertaking the finished coat.

5.4.10 After preparation of the under-surface, the panels shall be spray painted withtwo coats of epoxy based final paint or shall he powder-coated. Spraypainted finished panels shall be dried in stoving ovens in a dust-freeatmosphere. Panel finish shall be free from imperfections like pinholes,orange peels, runoff paint, etc. The vendor shall furnish the paintingprocedure along with the bids.

5.5 Cell Booster

5.5.1 Cell booster shall he suitable for charging one to six cells within a timeduration as specified at Cl.5.3. 12. It shall be suitable for charging not onlythe new cells before being introduced to the battery hank hut also anytreatment to he given to the individual weak cells. Quantity of such boostersshall he as defined in the MR. Cell booster shall be suitable for 240 V ± 10%50 Hz ± 3% SPN input power supply. Cell booster output voltage shall be inthe range of 0 -18 V and 0 - 12V for Lead Acid and Nickel Cadmium batteries

5.6 A.C. Distribution BoardSheet steel enclosed AC distribution hoard shall he provided as part of thecomplete UPS package It shall accommodate AC feeders as indicated in thedata sheet. The distribution board shall he floor mounted, fixed type withcompartmentalised construction unless otherwise indicated in the data sheet,It shall he possible to operate the switches without opening the doors.

Switches shall be provided with door interlock. Vertical cable alley of minimum 200mm width with suitable supports shall be provided for thetermination of outgoing cables. Suitable supports shall he provided forsupporting incoming and outgoing cables. All outgoing switches shall he airi l t d l d b k t F t i f d h ll h f t ti

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insulated load break type. Fuses on outgoing feeders shall he fast actingsemiconductor type and cable entry shall he from bottom. The gland plate of the distribution board shall be non-magnetic type where single core cablesare used as specified in the data sheet. Cable glands shall he of brass and

single compression type and cable lugs shall be of tinned copper.

5.7 Alarm, Control, Indication and Metering RequirementsIf not specified otherwise in the data sheets, following schedule shall befollowed for alarm, control, indication and annunciation. Any additionaldevices/features considered necessary for reliable operation and maintenanceshall also be included in various panels and same shall he highlightedseparately . An illuminated one line diagram indicating operational statusshall he provided on the front of the panel. Metering, indications, audio-visualalarm shall he provided Parameters! information indicated shall he availablein LCD panel or by other means directly or indirectly,

5.7.1 Metering

5.7.1.1 Rectifiera) Incoming line voltages (For all the three phases).

a) Voltmeter (voltmeter selector switch shall also he provided for 3 phaseinverter).

b) Ammeter (ammeter selector switch shall also he provided for 3 phaseinverter).

c) Power factor meter

5.7.2 Indications(All indication lamps shall he provided with series resistors. Clustered/JumboLED’s of minimum 10mm dia. ma be provided in place of lamps subject totheir having at least equal illurninance).

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5.7.2.1 Mains/Bypassa) AC mains ‘ON - Rectifierb) AC mains ON Bypass.

5.7.2.2 Rectifiers (for each rectifier)a) Rectifier output ‘ONb) Battery on float charge

c) Battery on rapid charge

5.7.2.3 Inverters (for each inverter)a) DC input ‘ONb) Load on inverter

c) Inverter synchronised with mains.

5.7.2.4 Load on bypass.

5.7.3 Audio-Visual Alarm ( separately for each circuit)a) Mains failureb) Battery charger failure

d) Static switch transfer test Push Button.

5.8 Reliability All necessary care shall he taken in selection, design, manufacture, testingand commissioning of 2 the equipment for ensuring high system reliability.Following design consideration shall be taken into account to ensure

maximum availability of the system.

5.8.1 There shall he no common device, between main and redundant units (e.g.master oscillators etc.) in order to ensure that the failure of the same doesnot cause shutdown of more than one unit

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not cause shutdown of more than one unit.

5.8.2 It shall be possible to take out any individual power circuit for maintenancewithout affecting the total UPS supply.

5.8.3 Series-parallel combination of smaller devices to achieve required rating shallnot he acceptable.

5.8.4 Vendors shall offer their nearest higher standard size that will meet therequirement of the specified UPS rating.

5.9 Fault Diagnostic UnitIf specified in the data sheet, each UPS set shall have provision for addingmicroprocessor based ON line fault diagnostic unit. This shall supervise theUPS operation continuously. It shall identify and locate faults immediately sothat corrective action can he taken. Fault Diagnostic unit shall he compatibleto hook up with owners PC through RS232/RS385 interface. The softwareshall be provided on a CD ROM.

The fault diagnostic unit shall have provision for automatic print out facilities

If any additional equipment (e.g. bin connector, adaptor cards etc.) arerequired for connecting this unit with UPS system as well as with owners PC.the same are also to he included in the vendors scope.

6 INSPECTION ,TESTING AND ACCEPTANCE6.1 During fabrication. the equipment shall he subjected to inspection by Owner

or by an agency authorised by the Owner. Manufacturer shall furnish allnecessary information concerning the supply to Owners inspector. Tests shallbe carried out at manufacturers works under his care and expense

6 2 UPS system shall be tested in accordance with applicable standards The

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6.2 UPS system shall be tested in accordance with applicable standards. Thefollowing acceptance tests shall he performed on each UPS system as aminimum. All tests shall be witnessed by owner or its authorisedrepresentative and 4 weeks prior notice shall he given before the date of

commencement of tests. The tests certificates indicating test results shall hefurnished.

Following system acceptance tests shall be conducted on each UPS system:

6.2.1 Insulation testsInsulation tests shall be performed as per IEC 60146-1.-I

The insulation tests shall be carried out using an AC power frequency voltageor by using DC Voltage at the choice of the vendor. In the case of AC powerfrequency voltage test, the test voltage at the frequency available in the testfacility or at the rated frequency, but not exceeding 100Hz of the full valuestarting at a maximum of 0.5 p.u. The unit on test shall withstand thespecified voltage for 1 minute.

In case the DC voltage is used for the test, the value of DC voltage shall he

The test is performed with the test battery and carried out by tripping ac.incoming circuit breakers or by switching off rectifiers and bypass supply atthe same time. Output voltage and frequency ‘variations are to he checkedfor specified limits.

6.2.4 A.C. input return test

The test is performed by closing ac. incoming circuit breakers or is simulatedby energising rectifiers and bypass supply. Proper operation of rectifiersstarting and voltage and frequency variations of output are to be checked.

6 2 5 Simulation of parallel redundant UPS fault

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6.2.5 Simulation of parallel redundant UPS faultThe test is applicable for UPS with parallel redundant configuration Fault of rectifier or inverter are to be simulated and output transients are to herecorded.

6.2.6 Transfer testTransients shall he measured during load transfer from inverter to bypasssupply caused by simulated fault and load retransfer after clearing the fault.

6.2.7 Regulation testThis test shall be carried out by measuring input voltage, input current,output voltage, output current, DC link voltage, output distortion, inputactive power. output active power and frequency at no load, 50% load and100% load at 0,7 and 0.8 p.f.

Following parameters of rectifiers and inverters are to measured

Measurement shall be carried out in the rectifier float charge mode and inrapid charge mode. Measurement shall he at nominal ac. voltage and at noload. 50% load and 100% of rectifier full load. Rectifier measurement shall

6.2.8 UPS efficiencyThis shall he determined by the measurement of the active power input andoutput at rated p.f. for 50%, 75% and 100% load.

6.2.9 Current division in parallel UPSLoad sharing between UPS units shall he measured with a dummy load under

parallel redundant UPS configuration

6.2.10 Light load testThe test is to verify that all functions of the UPS system operate properly.The load applied is limited to some percentage of rated load The following

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The load applied is limited to some percentage of rated load The followingpoints are to he checked.a) Output voltage and frequency and correct operation of meters.b) Operation of all control switches and other means to put UPS system into

operation.c) Functioning of protective and warning devices

6.2.11 Burn-in test for Printed circuit boardsPCBs and other electronic components sub assemblies shall undergo a burn-in test for 96 hours at 50o C at a voltage varied between the maximum andminimum supply voltage. In case of failure of any component during testing,the tests shall be repeated after replacement of the faulty component.

6.2.12 Continuous full load test at 0.8 power factor with temperature risemeasurementThe test is required to he performed by connecting resistive load or resistiveand inductive load to the UPS system output. The load shall be placedoutside the test room to avoid influences of its heat upon UPS ventilation,

6.2.14 Synchronisation testFrequency variation limits of inverter is to he tested by feeding bypass supplyincoming line by variable frequency generator and inverter synchronisationlimit is to he checked as specified.

6.2.15 Unbalanced load test (For 3 phase UPS only)

Unbalance load at specified limits is applied to the UPS system. The specifiedvoltage and phase angle variation may he checked for compliance withspecified values.

6 2 16 Output voltage unbalance (For 3 phase UPS only)

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6.2.16 Output voltage unbalance (For 3 phase UPS only)Output voltage unbalance shall he checked under symmetrical load conditionsand unbalance load conditions. Phase to phase and phase to neutral outputvoltage are to be observed. The voltage unbalance is the ratio of highest

phase voltage minus lowest phase voltage to the average value. Phase anglevariation may he measured for phase to phase and phase to neutral voltages

6.2.17 Overload capability testSpecified values of short time overload are to he applied for specified timeinterval. Values of output voltage and output current are to he recorded.

6.2.18 Short circuit current capability testSpecified short circuit current capability is to be tested by application of ashort circuit to UPS output if necessary via a suitable fuse, Short circuitcurrent is to be recorded.

6.2.19 Short circuit fuse testFuse tripping capability of the UPS system is to be tested by short circuitingthe UPS system output via a specified rating of fuse. The test is carried out atan appropriate UPS load under normal operation.

6.2.24 Earth fault test

An earth fault is to he applied to the output terminal of UPS system. UPSoutput transients are to he measured. An earth fault is also to be applied tothe battery terminal and UPS system output transient shall he measured.

6.2.25 Audible noise test

The audible noise is required to be measured at 1 meter distance from UPSsystem in at least 4 to 5 locations and its value shall be within permissiblelimit.

The detailed test schedule and test procedure shall be formulated in line with

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The detailed test schedule and test procedure shall be formulated in line withabove. Before giving call for the witness of the tests, vendor shall getapproval on the test procedures. Vendor shall also indicate the max.allowable tolerance for each test result, along with the test procedures.

If tests show that certain requirements of the specifications are not met,vendor shall make necessary corrections to the equipment so that it satisfiesall the requirements before acceptance is made.

7 SITE ACCEPTANCE TESTS

Vendor shall furnish Site Acceptance Tests procedure to be followed. Finalacceptance testing along with the batteries shall be done at site. It shall he

Vendor’s responsibility to arrange necessary instruments and tools asrequired by their commissioning engineer for these tests.


All the equipment shall he divided in to several shipping sections forprotection and ease of handling during transportation. The equipment shallbe properly packed for transportation by ship/rail or trailer. The equipmentshall be wrapped in polyethylene sheets before being placed in wooden

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SPECIFICATION FOR BATTERY CHARGER

CONTENTS

1.0 SCOPE



4.0 SITE CONDITIONS

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0 S CO O S




1 SCOPE

This specification covers the design, manufacture, testing at manufacturer’sworks, packing and supply to site of Battery Chargers and Distribution Boards.


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

IS 5 Colours for ready mixed paints and enamels.IS 1248 Direct acting indicating analogue electrical measuring

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g g g ginstruments and accessories. (Parts-i,2,8,9)IS 3700 Essential rating and characteristics of semi-conductor devices.(Parts-1 to 11)

IS 3715 Letter symbols for semi-conductor devices. (Parts-1 to 4)IS 4411 Code of designation of semi-conductor devices.IS 5001 Guide for preparation of drawings for semi-conductor devicesand integrated circuits. (Parts-1, 2)IS 5469 Code of practice for the use of semi-conductor junction devices.(Parts-I to 3)IS 6619 Safety code for semiconductor rectifier equipment.IS 7204 Stabilised power supplies dc output. (Parts-1 to 4)

IS 12021 Control transformers for switchgear and control-gear forvoltages not exceeding 1000VAC.IS 13703 Low voltage fuses for voltages not exceeding 1000VAC or1500VDC. (Parts-1 to 4)IS 13947 Low voltage switchgear and control gear. (Parts-i,3,4,5)IEC 60146 Semiconductor converters.

2.2 In case of imported equipment, the standards of the country of origin shall be

o Codes and standards.


3.1 The offered equipment shall be brand new with state of the art technology anda proven field track record. No prototype equipment shall be offered.


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3.3 Vendor shall give a notice of at least one year to the end user of equipmentbefore phasing out the product! spares to enable the end user to place orderfor spares and services.

3.4 The Battery Charger system shall be an integrated system comprising of staticrectifiers, DC Distribution Board, isolating and protection devices and all otherequipment! accessories required for completeness of the system whetherspecifically mentioned herein or not, but necessary for completeness andsatisfactory performance of the system. The Battery Charger equipment shallbe properly coordinated with the selected Battery to ensure completecompatibility.

3.5 All equipment and components shall be of excellent quality and reliability forproviding secure DC power required for vital equipment performance,controlling, monitoring and safeguarding functions in continuously operatingprocess units and utility installations of petroleum refineries, petrochemical andgas processing facilities and other industrial plants. Components shall becapable of withstanding the thermal and dynamic stresses resulting frominternal and external short circuits and circuit switching operations etc. The

40°C and altitude not exceeding 1000 m above MSL shall be considered for allequipment.


5.1 Input Power Supply5.1.1 The Battery Chargers shall be suitable for input power supply as defined in the

data sheet. If not specified therein, they shall be suitable for the following inputpower supply: Voltage : 415V ± 10%Frequency : 50Hz ± 5%

In addition to the above variations, the input voltage may be subject to

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, p g y jtransient variations comprising of voltage dips up to 20% of normal voltageduring motor start-up, voltage interruptions during short circuits as well asfrequency variations due to large motor start-up. The Battery Chargers shall

operate satisfactorily with a total harmonic distortion of up to 5% in the inputpower supply.

The Battery Chargers shall also be designed to operate satisfactorily whiledrawing input power from an emergency diesel generator set.

5.1.2 The incoming power supply to the Battery Charger system shall be provided by2 independent feeders. One feeder shall supply power to each rectifier.

5.2 Battery Charger5.2.1 Design Basis5.2.1.1 The Battery Charger system shall have two chargers (Charger-1 & Charger-2).

Both chargers shall be of identical design and rating. The battery to beconnected to the chargers shall be of Nickel Cadmium! flooded electrolyte Lead Acid VRLA type as indicated in the data sheet. Battery Chargers for floodedLead Acid and Nickel Cadmium batteries shall be sized to provide quick

(Average DC load Area under the battery duty cycle! battery duty cycleduration).

c. Initial charging of the uncharged battery assembly to fully chargedcondition.

5.2.1.2 Each charger shall have a 3 phase full wave, controlled rectifier bridge withprotective devices.

5.2.1.3 Independent current limits shall be provided for charger load current andbattery charging current. Subsequent to a discharge cycle and completion of

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quick charging, when battery is connected to charger under float mode, thebattery current shall be monitored, controlled and limited to set valueautomatically irrespective of the value of load current. Fast acting semi-

conductor fuses shall be provided for protection against internal short circuits.In case of external short circuits, the chargers shall be protected by rapidshutdown of the semi-conducting power devices. The high speed semi-conductor fuses used for rectifier protection shall be complete with tripindication.

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

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

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

5.2.1.7 Silicon blocking diodes (mm. 4 nos.) connected to 80% tap of the battery bank

electrical components such as transformers, reactors, contactors, switches,busbars etc. shall be rated for at least 125% of the maximum required rating.No electronic device shall experience a Ply greater than 50% of its rated value.

5.2.1.10 The DC system shall be unearthed, unless mentioned otherwise in the datasheet. However, a high impedance earth fault relay shall be provided for the

protection of the battery.

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

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5.2.1.12 Suitable protection shall be provided in the control circuits to guard againstthe instability of the controlled rectifiers due to electrical oscillations which

may be present in the input supply as caused by an emergency DG set.

5.2.1.13 An R . F. I. filter shall be provided to suppress the radio frequencyinterference to permissible limits. The production of radio frequencyinterference voltages shall not exceed the value of suppression grade N’ asdefined in VDE-0875. The performance of the Battery Charger system shallnot get affected or in any way be degraded by the use of portable radiotransmitter receivers in the vicinity of the chargers.

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

5.2.1.15 The Chargers shall be designed to draw power from mains supply at aminimum power factor of 0.85 lag while sharing the rated load in normaloperating configuration.

5.2.1.18 All the thyristors, diodes and other power electronic devices shall beprotected with high speed semiconductor fuses. 121 co-ordination betweenfuse and semi-conducting power devices shall be ensured.

5.2.1.19 The Battery Chargers shall be specifically designed to limit float and quick charging voltages to the battery to limits recommended by the battery

manufacturer. Output voltage shall be limited to maximum +10% of nominal system voltage when the battery is float charged while feeding theload. Vendor shall specifically ensure that the charger output voltage doesnot exceed the recommended limits of operation under any conditions of internal! external fault or operation, including:

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o Filter capacitor fuse failure of either chargero DC output switch OFF of either chargero DC output fuse blown of either charger.

Other specific current! voltage limits during normal charging! operation of thechargers shall also he incorporated in the design of the chargers.

5.2.2 Operation and Performance5.2.2.1 Operation (refer block schematic diagram on last page)

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

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

a preset time period. The timer range shall be 0 to 24 hours or the nearestavailable as per manufacturer’s standard range.

e. In the event of failure of the charger feeding the load, when battery isbeing quick charged by the other charger, continuity in DC supply shall bemaintained from the battery to the load through 80% tap of the battery

bank followed by full battery supplying the load through contactor C-2 (referblock diagram on last page).

f. Interlock shall be provided to ensure that when either of the chargers isselected in quick charging mode, it will be disconnected from both the DC

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load and the other charger operating under float charging mode.

g. The chargers shall have facility for manual mode of operation in the event

of failure of controller under closed loop control. The selection shall be donethrough Auto! Manual selector switch.

h. Energisation of contactor for DC critical lighting shall be initiated by meansof an AC mains failure relay complete with Auto/ Manual selector switch,On/ Off push buttons etc.

i. Facility for Initial charging of the uncharged battery shall also be provided.

5.2.2.2 Performancea) Both chargers shall be of solid state design, constant voltage and current

limit type. The output voltage shall be stabilised to within ±1 % of setvalue in float charging mode for mains steady state voltage andfrequency variation of ± 10% and ± 5% respectively, and load variationof 10 to 100% at any temperature up to the design ambienttemperature specified in the data sheet. However, the variation in

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

5.2.2.3 Controls

Controls shall include but not be limited to the following:a. ON! OFF control switch for AC supply to charger (push buttons are not

acceptable)b. Push buttons for float! quick charging mode selectionc. Potentiometers under float mode for voltage and current adjustment

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d. Potentiometers under quick mode for voltage and current adjustmente. Auto! Manual selector switch to select mode of operationf. Others as required.

5.2.2.4 Panel Metering and IndicationThese shall include but are not limited to the following:

a. Meters(1) Charger-1

o AC input Voltmeter with selector switcho AC input Ammeter with selector switcho DC output Voltmetero DC output Ammetero DC Voltmeter with selector switch (battery voltage)o DC Ammeter (battery)o DC Earth Leakage Ammeter (mA).

(2) Charger-2o AC input Voltmeter with selector switch

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

5.2.2.5 AnnunciationStatic type audio-visual annunciator with annunciation windows, acknowledge,test and reset push buttons and hooter shall be provided on each charger forthe following annunciations. Any additional relays! components, including DC

d l l d d f h h ll b

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under voltage relay and current sensors, required for this purpose shall beprovided in the chargers. Facility for bypassing the audio alarm on each chargershall also be provided.

o DC under voltageo DC over voltageo DC earth leakageo AC incoming power supply failureo AC input fuse blown-off o Thyristor/ diode failureo DC output fuse blown-off o DC battery fuse blown-off o Filter Capacitor fuse blown-off o Load on Battery (using current direction sensing with time delay)o Battery under-voltage / Disconnected during discharge (using zero

current sensing)o cubicle fan failure! cubicle temperature high (for chargers with forced

cooling).One summary alarm potential-free contact each for Battery, Charger-1 andCharger-2 shall be wired to terminal block for remote annunciation.

a wrong spare card. The PCBs shall be provided with visual light emitting diode(LED) status indications, monitoring points! test connections and settingpotentiometers in a readily accessible location which is visible without removingthe PCBs. Visual fault diagnostics shall preferably identify faults up to varioussections in the card.

5.2.2.7 Vendor shall provide adequate protection to the system, even if not specificallymentioned.

5.2.2.8 For other equipment! component details, refer to block schematic diagram onlast page.

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5.3 Construction of Chargers! Distribution Board

5.3.1 Each Battery Charger and DC distribution board shall be housed in a separatefree standing cubicle. All panels shall be of the same height so as to form apanel lineup which shall have good aesthetic appearance. Chargers-1 & 2 shallbe installed side by side whereas DCDB may be located separately andinterconnected to the charger through cables. The DCDB shall accommodateoutgoing feeders as specified in the data sheet. Each panel shall be providedwith an 11W CFL light with a door operated switch and a thermostaticallycontrolled MCB protected space heater.

Unless specified otherwise in the data sheet, the DCDB shall becompartmentalised with each outgoing feeder housed in a separatecompartment. Cable alley of minimum 200mm width with suitable supportsshall be provided for the termination of cables for each vertical arrangement of outgoing feeders in DCDB.

5.3.2 The Chargers, DCDB and Cell Booster enclosures shall be fabricated from

5.3.5 The DCDB incomer and main busbars shall be rated based on the maximumload current considering an additional 10% design margin for contingencies.The rating shall be selected from standard available ratings and shall beadequate for the expected short circuit current. The busbar voltage shall 2 behigher than the recommended boost voltage for the system. The insulation for

all equipment where provided shall be heat resistant, moisture proof andtropicalised.

5.3.6 All power and control switches shall be rotary! cam operated type. All powerswitches shall be air insulated load break type, Vendor shall ensure that all

i t! t h i it h t i DC it h

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equipment! components such as incomer switches, outgoing DC switches,MCCBs, push buttons, indicating lamps, charger mode selector switches,voltage control switches, annunciator windows etc. are suitably located on the

charger and distribution board door such that they can be operated withoutopening the front door. Power switches shall be provided with a door interlock.In case of difficulty in installation on the charger front panel door, the ACincoming power switches, DC outgoing switches and MCCBs may be installedwithin the panel provided that they are operable after opening the front paneldoor. However, all other selector! control switches, push buttons, indicatinglamps, annunciators, meters etc. shall necessarily be installed on the frontpanel door as specified above.

5.3.7 All instruments shall be switchboard type, back connected and 72 x 72 mmsquare size. Accuracy class of all meters shall be 1 %. Digital meters capable of displaying different parameters can be considered subject to Owner’s approval. Analogue instrument scales shall have a red mark indicating maximumpermissible operating rating.

5.3.8 All fuses shall be link type and shall be located inside the panel. Diazed fuses

the data sheet. Removable bolted undrilled gland plates shall be provided alongwith single compression type nickel plated brass cable glands for all externalcable connections. Clamp type terminals shall be used for connection of wiresup to 10 mm2. Bolted type terminals suitable for cable lugs shall be providedfor wire sizes above this. Separate test terminals shall he provided formeasuring and testing the equipment to check performance. All panels shall be

supplied complete with tinned copper cable termination lugs.

5.3.11 All potential free metallic parts shall be earthed using soft drawn copperconductor wire, A suitably sized earth bus shall be provided at the bottom of the panels running through the panel lineup with provision for earth

ti t b th d t ’ i th id Th i i i f

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connections at both ends to owner’s main earth grid. The minimum size of earth bus shall be 25 x 6 mm2 copper (or equivalent aluminium). All potentialfree metallic parts of equipment shall be suitably earthed to ensure safety.

5.3.12 The maximum height of the operating handles! switches shall not exceed 1800mm and the minimum height shall not be below 300 mm.

5.3.13 All components! devices! feeders shall be provided with screwed nameplates.Nameplates shall be 3 ply white-black-white 2 colour laminated plastic type.Lettering shall be of minimum 6 mm height and edges shall be bevelled at 450

5.3.14 The sheet steel used for fabrication shall be thoroughly cleaned and degreasedto remove mill scale, rust, grease and dirt. Fabricated structures shall bepickled and then rinsed to remove any trace of acid. The under-surface shall beprepared by applying a coat of phosphate paint and a coat of zinc oxide!phosphate primer. The under-surface shall be free from all imperfections beforeundertaking the finishing coat. After preparation of the under-surface, thepanels shall be either spray painted with two coats of epoxy paint or epoxypowder coated to a uniform thickness suitable for rugged industrial use.

For VRLA battery 0.2 x AH(C10) of cellFor Ni-Cd battery = 0.2 x AH(C5) of cell.

Cell booster shall have a heavy duty switch fuse or MCCB on both AC incomerand DC output sides, along with AC voltmeter, DC ammeter, DC voltmeter andindicating lamps for AC! DC power ON. The output voltage and current of cell

booster shall be manually controlled using a suitably rated variac or a full wavecontrolled rectifier bridge. Suitable interlock shall be provided so as to ensure .that the variac! controlled rectifier is at its minimum position while switching onthe cell booster. Cell booster shall be portable type with wheels. Each cellbooster shall be supplied with 5 m long flexible copper conductor, PVCinsulated braided cables for both AC incoming power supply and DC output

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insulated braided cables for both AC incoming power supply and DC outputconnection to the battery. An industrial type 3 pin ISA plug shall be provided on AC incoming cable end and lugs shall be provided on DC outgoing cable end.

5.5 Reliability All necessary care shall be taken in selection, design, manufacture, testing andcommissioning of the equipment for ensuring high system reliability. Thefollowing design considerations shall be taken into account to ensure maximumavailability of the system:

5.5.1 There shall be no common device between the two units, the failure of which

could cause shutdown of more than one charger.

5.5.2 It shall be possible to attend to any individual power circuit for maintenancewithout affecting the total DC supply.

5.5.3 Series-parallel combination of smaller devices to achieve specified rating shallnot be acceptable.

test parameter in line with applicable standards. All tests shall be witnessed byowner or his authorised representative and 4 weeks prior notice shall be givenbefore the date of commencement of tests. In case the equipment fails to meetany requirements of the specifications, necessary modifications! correctionsshall be made by the vendor to ensure compliance to the specifications, andthe equipment shall be retested before acceptance. Test certificates indicating

the test results shall he submitted to owner.

6.2.1 Insulation TestsInsulation tests shall be performed as per IEC 60146-1-1.

The insulation tests shall be carried out using an AC power frequency voltage

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The insulation tests shall be carried out using an AC power frequency voltageor a DC voltage at the choice of the manufacturer. In the case of AC powerfrequency voltage test, the test voltage at the frequency available in the test

facility or at the rated frequency, but not exceeding 100 Hz, shall be increasedto the full value shown in the following table in not less than 10 secondscontinuously or in maximum steps of 0.05 p.u. of the full value starting at amaximum of 0.5 p.u. The unit on test shall withstand the specified voltage for 1minute.

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

2 pV

Vp is the highest crest voltage to beexpected between any pair of terminals

Test Voltage(AC r.m.s Value)

≤60 V 500 V

≤125 V 1000 V

10-20°C lesser than the maximum rated junction temperature of the devicewith proper ambient temperature correction applied.

6.2.4 Functional TestsFunctional tests shall be performed on each charger. if during execution of functional tests, an electronic component of the charger is required to be

replaced, e.g. due to charger malfunction or failure of the unit to fulfill theperformance requirements of the specification, then the heat run test shall berepeated at rated current following which functional tests shall be carried out.

6.2.4.1 Charger Testing at Constant Output VoltageMeasurements shall be carried out in the float charging mode and in the quick

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Measurements shall be carried out in the float charging mode and in the quick charging mode. In each mode, measurements shall be carried out at nominal AC input voltage and at zero, 50% and 100% of rated output current.

Measurements at 100% rated load current shall be repeated at 90% and 110% of nominal AC supply voltage. Measurements shall include input AC phasevoltage, frequency, current and power and DC output voltage, current andoutput voltage ripple.

6.2.4.2 Charger Testing at Constant Output Current LimitMeasurements shall be carried out both in the float charging and quick charging mode. In each mode, measurements shall be carried out when thecharger is operating under DC current limiting conditions with DC output

voltage between zero and set value corresponding to constant voltageoperation. Measurements shall include DC output voltage and current.

6.2.4.3 Auxiliary Equipment and Control Circuit TestsThe correct functioning of all measuring instruments, alarms, indications,protections and controls mentioned in the specification shall be verified.

6.2.4.4 Parallel Operation

owner’s approval and all tests shall be performed as per the approved SATprocedure.


All the equipment shall be divided into several sections for protection and easeof handling during transportation. The equipment shall be properly packed for

transportation by ship! rail or trailer. It shall be wrapped in polythene sheetsbefore being placed in crates! cases to prevent damage to finish.

The crates! cases shall have skid bottoms for handling. Special notations suchas ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’, ‘Owner’s particulars’, ‘P0no ’ etc shall be clearly and indelibly marked on the packages together with

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no. etc., shall be clearly and indelibly marked on the packages together withother details as per purchase order.

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

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SPECIFICATION FOR CATHODIC

PROTECTION POWER SUPPLY

MODULE (CPPSM)

ABBREVIATIONS:

CPPSM Cathodic protection power supply module

MTBF Mean time between failure

MTTR Mean time to repair

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PCB : Printed circuit board

MOV Metal oxide varistor

PSP Pipe to soil potential

CVCC : Constant Voltage and Constant Current Mode

CONTENTS

1.0 SCOPE

2.0 CODESAND STANDARDS

3.0 SITE CONDITIONS

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6.0 EQUIPMENT DESCRIPTION



1.0 SCOPE

This specification covers the requirements for the design, manufacture andtesting of Cathodic Protection Power Supply Module (CPPSM) working oncontrolled switch mode principle intended to supply power to cathodicprotection system for underground pipelines! structures.

2.0 CODES AND STANDARDS2.1 The system design, performance and materials to be supplied shall conform

to the requirements of the latest revision of following standards:IS: 1248 Direct acting indicating analogue electrical measuring

instruments and (Parts-i, 2, 8 & 9) accessories.IS 3700 Essential rating and characteristics of semiconductor devices

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IS 3700 Essential rating and characteristics of semiconductor devices(Parts-i to ii)

IS 3715 Letter symbols for semiconductor devices (Parts-i to 4)

IS 4411 Code of designation of semiconductor devices.IS 5469 Code of practice for the use of semiconductor junction

devices.(Parts I to IV)IS 6619 Safety code for semiconductor rectifier equipment.IS 7204 Stabilised power supplies DC output. (Parts-i to 4)IS 12021 Control transformers for switchgear and control gear for

voltages not exceeding 1000 V AC. (Parts-i to 4)IS 13703 Low voltage fuses for voltages not exceeding 1000 V AC or

1500 V DC. (Parts-i to 4)IS 13947 Low voltage switchgear and control gear. (Parts-4, section-i)

2.2 In case of imported equipment, standards of the country of origin shall beapplicable if these standards are equivalent or stringent than the applicableIndian standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity rules

mentioned therein, a design ambient temperature of 40°C and an altitude notexceeding 1000 m above mean sea level shall be considered.




4.3 Vendor shall give a notice of at least one year to the end user of equipment

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4.3 Vendor shall give a notice of at least one year to the end user of equipmentand GAIL before phasing out the product/spares to enable the end user forplacement of order for spares and services.


5.1 Fabrication and General Details

5.1.1 CPPSM shall be housed in sheet steel enclosure. The front, rear walls anddoors shall be made by using minimum 2 mm thick sheet steel and side wallsshall be made of minimum 1.6 mm thick sheet steel. Wherever required,

suitable stiffeners shall be provided. The Unit shall be freestanding type.Hinged doors shall be provided at the front and back as required. The unitshall be natural cooled type. Louvered openings with wire mesh for naturalventilation may be provided. Degree of protection for the panel shall beminimum TP-4 1. The CPPSM panel shall, preferably, not need rear access foroperation, maintenance and shall be suitable for mounting flushed to thewall.

5.1.4 All live parts shall be properly shrouded. This shall ensure complete safety topersonnel intending routine maintenance by opening the panel doors.

5.1.5 CPPSM shall be suitable for bottom cable entry unless otherwise specified inthe data sheet and shall be supplied complete with crimping type tinnedcopper lugs and cable glands. Cable glands shall be of brass, nickel plated,

single compression type for indoor installations and double compression typefor outdoor installations. The space in the terminal chamber shall beadequate for termination of required number and sizes of cables as specifiedin the data sheet.

5.1.6 The CPPSM shall be field proven. The design, internal component layout and

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5 6 e C S s a be e d p o e e des g , te a co po e t ayout a drating of component shall ensure high MTBF and low MTTR. Prototypeequipment shall not be acceptable. Layout of panel components shall enable

easy access to the components for maintenance.

5.1.7 All the control equipment like switches, push buttons, potentiometers etc.shall be located at a convenient height of minimum 300 mm and maximum1800 mm from the bottom of the panel.

5.1.8 The printed circuit boards (PCBs) shall be of copper clad glass epoxylaminate. PCB tracks shall be tinned and solder masked. The PCB shall be

coated with suitable lacquer to make it immune to dust, moisture and fungalgrowth. Where plug in type of PCBs are used gold plated male-femaleconnectors shall be used for the purpose.

5.1.9 If required the panel shall be provided with space heater to prevent moisturecondensation. The space heaters shall be located at the bottom of the paneland shall be provided with a manually operated switch and HRC fuse. Thespace heater shall have porcelain-insulated connectors. Where space heater

and movable parts shall be connected to the earth bus by flexible coppercables.

5.1.12 All panel mounted equipments (e.g. lamps, push-buttons, switches, meters,PCBs, etc.) shall be provided with suitable nameplates. Nameplates shall beengraved out of 3-ply (black-white- black) lamicoid sheets or anodised

aluminium. Back-engraved perspex sheet nameplates may also beacceptable. Engraving shall be done with groove cutters. Hard paper or self-adhesive plastic tape nameplates shall not be acceptable. Nameplates shallbe fastened by screws and not by adhesive.

Labels shall be provided for every component on the cards, connecting wires

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p y p , gas well as for the terminals in the terminal strip inside the panel.

5.1.13 Where specified in the data sheet the CPPSM shall be housed in an outdoorkiosk. The kiosk shall be made of sheet steel of minimum 3 mm thick andepoxy painted on both internal and external surfaces. Hinged lockable doorsshall be provided at the front and back. Acrylic transparent glass windowshall be provided on the front door of the kiosk so that the meters,indications and positions of the control switches on the CPPSM can be seenwithout opening the door of the kiosk. The kiosk shall be suitable for outdoormounting and shall give proper protection to the CPPSM against rain, other

harsh weather conditions. Necessary ventilation arrangement with louversand wire mesh shall be provided for proper operation of the CPPSM. Thecable entry to the kiosk shall be from bottom through cable glands. Suitablecanopy shall be provided on the top of the kiosk.

5.1.14 Painting All metal surfaces shall be thoroughly cleaned and degreased to remove millscale, rust, grease and dirt.

6.0 EQUIPMENT DESCRIPTIONThe CPPSM shall be complete with following main sections:

o Input controls.o Power converter and filters.o Output protectionso System controls

o Current interruptero Control, indication and metering

6.1 Input Controls

6.1.1 A moulded case circuit breaker with thermal over load and short circuit

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release (rated for the input power supply short circuit current) shall beprovided at the input for power supply control.

6.2 Power Converter and Filters

6.2.1 The CPPSM shall convert and control the input DC power supplyvoltage/current into variable DC output voltage/current through switchingpower semiconductor devices (Thyristor/power transistor/power MOSFET,etc.). The variation in the output voltage/current shall be achieved throughcontrol of duty cycle of conduction of the switching power semiconductor

devices. The current and voltage ratings of the power semiconductor devicesshall be at least two times the maximum device current and mm. two timesthe maximum voltage coming across it respectively. The voltage rating of thepower semi-conductor devices shall be co-coordinated with the breakdownvoltage of lightning arrestor provided at the output so that the powersemiconductor devices are protected from any voltage surge coming from thepipeline. Shunt zeners / MOV shall be provided across the powersemiconductor devices for protection. The power semiconductor devices shall

6.2.4 Filter shall be provided in the input power supply circuit to minimise the ACinjected into the DC input power supply system.

6.2.5 Adequate filtering shall be provided on the DC output of the converter to limitthe ripple content in the output to less than 5% at rated output.

6.2.6 The converter system shall be of natural air cooled type.

6.2.7 For CPPSMs with multiple output circuits, each output circuit shall haveindependent output converter and output filters.

6.3 Output ProtectionsTwo pole moulded case circuit breaker or miniature circuit breaker rated for

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pthe DC output current, short circuit current and having thermal over load,short circuit release shall be provided in the output. A lightning arrestor rated

for minimum 1 OKA impulse current discharge capacity and rated voltage & max. spark over voltage rating suitable to protect the CPPSM componentsagainst lightning and switching surges shall be provided at the output. ForCPPSMs with multiple output circuits, each output circuit shall haveindependent protections.

6.4 System Controls

6.4.1 The CPPSM shall have two distinct modes of operation (independent for eachoutput circuit) as below:

a) Constant Voltage - Constant Current Mode (CVCC)In this mode the output voltage (Vos) of CPPSM shall be continuouslyadjustable from O.5V DC to the rated output voltage specified on the datasheet. Current limit feature shall be provided in this mode of operation.The current limit (los) shall be continuously adjustable from zero to rated

b) Auto PSP Mode

In this mode of operation the output of the CPPSM shall operate in anexternal closed loop with pipe-to -soil potential (PSP) in feed back loop.The CPPSM control shall adjust the output voltage such that the PSP asmeasured by reference cell always remains equal to the set potential onthe unit. The set potential (Vps) shall have high long time stability and

minimum temperature drift. The set potential shall be continuouslyadjustable over the range specified in data sheet. An adjustable overcurrent limit shall be provided to limit the maximum output current.

The unit shall be designed to operate with the number of reference cellsconnected to it (to be provided by others) as specified in data sheet. In

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case of more than one reference cell being specified, CPPSM shall havefeature to automatically select the reference cell having less negative

potential than the others and use the same for auto control of the unit(e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall beprovided in selecting the less negative potential reference cell, to avoidhunting between the reference cells at change over conditions.

In case of open circuit or short circuit of the reference cell or potentialbeing less negative than a minimum set potential (Vrs), for the controllingreference cell, the unit shall sense these conditions as reference cell

failure and shall automatically switch over to the other healthy referencecell for control. Should fault occur in all the reference cells, the outputvoltage or current of the CPPSM shall adjust automatically to a presetvalue (Vas/las), which shall be adjustable.

In both CVCC and auto PSP modes of operation the electronic overcurrent limit shall be fast enough to protect the active devices of the unitand fast enough to act before tripping of MCCB/MCB or blowing of fuse.

input voltage, shall not be more than 2.5% through out the range of outputcurrent.

6.4.4 The output of the unit shall be ungrounded and shall allow grounding of positive terminal of the output through the anode ground bed.

6.4.5 For CPPSMs with multiple output circuits, each output circuit shall haveindependent control system.

6.5 Current Interrupter6.5.1 If specified on the data sheet a current interrupter for CPPSM output current

interruption shall be provided.

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6.5.2 The current interrupter shall have an output contactor with current rating

minimum 125% of the output current rating of the CPPSM and a digital timerto operate it.

6.5.3 The timer shall have ‘ON’ and ‘OFF’ timings. When the timer is turned on the ‘ON’ timing shall start and shall close the output contactor till the end of the ‘ON’ timing. At the end of the ‘ON’ timing the ‘OFF’ timing shall start andkeep the contactor open till the end of the ‘OFF’ timing. At the end of the ‘OFF’ timing the ‘ON’ timing shall start again. This process of ‘ON’ and ‘OFF’

timing shall continue.

6.5.4 The ‘ON’ and ‘OFF’ timings of the timer shall be settable by separate 2 digitthumbwheel switches, each settable from 1 to 99 seconds. The timing errorof the timer’ shall be less than 5 parts per million. In case of microprocessorbased system keypad with display may be provided in place of thumbwheelswitches.

- In case of microprocessor based system, keypad withdisplay may be provided in place of thumbwheel switches.

b) Indications (LED)- Timer power ‘ON’ - ‘ON’ timing

- ‘OFF’ timing

6.5.8 The output contact of the current interrupter contactor shall be wired in thepositive DC output of the CPPSM. A link shall be provided for shorting theseterminals whenever the current interrupter is not in use.

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6.5.9 If specified in the data sheet the current interrupter shall be an independentunit of portable type. The interrupter unit shall have terminals for input

power supply and terminals of the contactor in the timer output. The inputpower supply and the rating of the timer output contactor shall be asspecified on the data sheet.

6.5.10 Where the current interrupter is not specified with CPPSM or is specified asportable type external to the CPPSM, then the CPPSM shall have provision forconnection of input power supply terminals and output contacts of externalcurrent interrupter for current interruption test. A link shall be provided for

shorting the output terminals provided in CPPSM for current interruption,whenever the current interrupter is not connected.

6.5.11 For CPPSMs with multiple output circuits, each output circuit shall haveindependent current interrupter.

6.6 Controls, Indication and Metering6.6.1 Following controls shall be provided on CPPSM front door.

a) ON/OFF control for input through MCCB.

6.6.3 CPPSM shall have following indicating lights (lamps or minimum 5 mm diaLEDs):a) CPPSM ON/OFFb) Unit in auto/CVCC (2 lamps)c) Reference cell controlling the closed ioop control of the CPPSM (number

of lamps same as number of reference cells).

d) Reference cell faulty (number of lamps same as number of referencecells).e) Pipeline over protected.f) Pipeline under protectedg) Indications for current interrupter:

o Timer power ‘ON’

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o ‘ON’ timingo ‘OFF’ timing

It shall be possible to switch-off all the indication lamps by a single switch. Incase of LED indication lights this facility may not be provided.

6.6.4 Following meters having mm ci. 1.5 accuracy shall be provided on theCPPSM:a) Digital meter for output voltageb) Digital meter for output current

c) Digital voltmeter to measure PSP set (Vps) and PSP actual for all thereference cells. The meter shall have range from (-) 4 V to 0 V and shallhave cl. 0.5 accuracy.

d) Digital meters for measuring Vrs, Vpm, Vpn and Vas /las settings.e) Meters for input voltage and currentIt shall be possible to switch-off all the digital meters preferably by a singleswitch.

accuracy class of the transducer shall be 0.5. The transducers shall beprotected against input and output voltage surges. The transducer shall besuitable for driving upto 600 ohms load impedance located upto 500 m awayand wired with 0.5 mm2 copper conductor cable. The transducers shall besuitable for minimum 125% continuous over load in the input voltage/currentparameter.

6.6.6 For units having multiple outputs, each output circuit shall have independentcontrols, indication and metering

.7.0 TESTS AND ACCEPTANCE

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7.1 During fabrication, the equipment shall be subjected to inspection by owneror his authorised representative to assess the progress of the work as well as

to ascertain that only quality raw materials are used for the same. He shallbe given all assistance to carryout the inspection.

7.2 Final acceptance test shall be carried out at manufacturer’s works under hiscare and expense. Instruments and equipments required for testing shall bearranged by manufacturer. Owner’s representative shall be given minimum 2weeks prior notice for witnessing the tests. Test certificates indicating testresults shall be furnished by the manufacturer. Acceptance tests shall include

but not be limited to the tests listed below.

7.2.1 Visual InspectionThis shall include-o Completeness of the equipment in line with specification.o Checking of all settings.o All labels provided and satisfactory.o Dimensional checking.

(Un1 and Un2 are nominal voltage rating of power electronics and auxiliarycircuits respectively).

D.C. test voltages may be applied instead of A.C. The magnitude of D.C. testvoltages to be applied shall be 2 times the above-mentioned A.C. (r.m.s) Values.

Insulation resistance test shall be conducted before and after heat run test.

7.2.3 Heat run Test All CPPSMs shall be subjected to a heat run test performed at rated voltagefor period not less than 16 hours prior to execution of functional tests.

A l CPPSM f h i h ll b l d d i d h h

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At least one CPPSM of each rating shall be loaded to its rated output throughout 16 hour test period. All other CPPSMs shall be energized under partial

load or zero load current condition through out the test period.

7.2.4 Functional testsFunctional tests as below shall be performed on each CPPSM. If duringexecution of functional tests, any electronic component of the unit is requiredto be replaced e.g. due to malfunction or failure of the unit to fulfill theperformance requirements of the specification, then the load test shall berepeated at rated current following which functional tests shall be carried out.

7.2.4.1 CVCC mode operation testinga) Constant voltage operation

During the test, current limit shall be set to rated output current.Performance testing shall be carried out for various output voltage settingsand load varying from zero to maximum. The verification of operation of thecontrol functions, measurement of output voltage, current, input voltage,current, ripple in the output, input, evaluation of output voltage regulation

Disconnecting the reference cell feed back connection in the above set upshall simulate the reference cell failed condition. The output voltage/currentof the unit shall go to the value set on the potentiometer Vas/las providedinside the CPPSM. The settings on Vas/las shall be varied and the outputvoltage/current shall be observed.

7.2.4.3 Operation of sensors for pipeline over protection, under protection, referencecell failure and reference cell selection logic in auto PSP mode shall beverified by connecting variable external voltage sources to reference cellinputs of the CPPSM. The number of external voltage sources shall be sameas number of reference cell inputs specified for the CPPSM.

7 2 4 4 Th it h ll b h k d f ti f th t li it b l di

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7.2.4.4 The unit shall be checked for operation of the current limit by over loadingthe unit in both CVCC and auto PSP modes of operation. For Units where

semiconductor fuses are not provided for protection of the powersemiconductor device, the protection of same shall be tested as below:

A switch rated for making and carrying CPPSM output short circuit currentshall be connected to the output terminals of the unit. The output voltageand the output current limit settings of the unit shall be set to the maximumrated values. The switch connected in the output shall be shorted quickly.

The unit shall go to current limit mode and shall not damage any activecomponent of the unit.

7.2.4.5 The current interrupter shall be tested for time interval settings and specifiedoperation.

8.0 PACKING ANB DESPATCH

The equipment shall be properly packed for selected mode of transportation

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SPECIFICATION FOR MEDIUM

VOLTAGE INDUCTION MOTORS

Abbreviations:

BIS Bureau of Indian StandardBS British Standards

CIMFR Central Institute of Mines and Fuel Research

CT Current Transformer

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FM Factory Mutual

FRP Fiber Reinforced Polyester

IEEE Institute of Electrical & Electronics Engineers

IS Indian Standard

LCIE Laboratoire Central des Industries Electriques


P0 Purchase Order

PVC Poly Vinyl Chloride

RPM Revolutions per Minute

UL Underwriter’s Laboratories

VDE Verband Deutscher Elektrotechniker

CONTENTS

1.0 SCOPE .0 CODES AND STANDARDS3.0 GENEAL REQUIREMENTS

4.0 OPERATING CONDITIONS

5.0 PERFORMANCE

6 0 CONSTRUCTION DETAILS

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6.0 CONSTRUCTION DETAILS

7.0 MISCELLANEOUS ACCESSORIES

8.0 NOISE LEVEL

9.0 MOTOR VIBRATION

10.0 CRITICAL SPEEDS

11.0 PAINTING

12.0 INSPECTION AND TESTING

13.0 CERTIFICATION


1.0 SCOPE

This specification covers the design, manufacture, testing, packing andsupply of three phase medium voltage squirrel cage induction motors.


2.1 The squirrel cage induction motors and their components shall comply with

the latest editions of following standards issued by BIS (Bureau of IndianStandards) unless otherwise specified:

IS - 5 Colours for ready mixed paints and enamels. IS 325 Three phase induction motors. IS 1076 Preferred numbers. IS 1231 Dimensions of three phase foot mounted induction motors. IS 1271 Thermal evaluation and classification of electrical insulation

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IS 1271 Thermal evaluation and classification of electrical insulation. IS 2148 Flame proof enclosures of electrical apparatus.

IS 2223 Dimensions of flange mounted AC Induction motors. IS 2253 Designation for type of construction and mounting

arrangement of rotating electrical machines.

IS 2254 Dimensions of vertical shaft motors for pumps.

IS 2968 Dimensions of slide rails for electric motors. IS 4029 Guide for testing three phase induction motors. IS 4691 Degrees of protection provided by enclosure for rotating

electrical machinery.

IS 4722 Rotating electrical machines. IS 4728 Terminal marking and direction of rotation for rotating

electrical machinery. IS 4889 Method of determination of efficiency of rotating electrical

machines. IS 6362 Designation of methods of cooling of rotating electrical

machines. IS 6381 Construction and testing of electric apparatus with type of

IS 12802 Temperature rise measurement of rotating electricalmachines.

IS 12824 Type of duty and classes of rating assigned to rotatingelectrical machines.

IS 13529 Guide on effects of unbalanced voltages on the performanceof three phase cage induction motors.

IS 13555 Guide for selection and application of three phase inductionmotors for different types of driven equipment.

IS 14568 Dimensions and output series for rotating electricalmachines, frame numbers 355 to 1000 and flange numbers 1180 to2360.

2 2 In case of imported motors standards of the country of origin shall be

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2.2 In case of imported motors, standards of the country of origin shall beapplicable if these standards are equivalent or stringent than the applicable

Indian Standards.

2.3 The motors shall also conform to the provisions of Indian Electricity rules andother statutory regulations currently in force in the country.

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

2.5 In case of any contradiction between various referred standards!

specifications! data sheets and statutory regulations, the following order of priority shall govern:

o Statutory regulationso Data sheetso Job specificationso This specificationo Codes and standards

4.0 OPERATING CONDITIONS

4.1 Ambient Conditions: Motors shall be suitable for operating satisfactorily inhumid and corrosive atmosphere found in refineries, petrochemical, fertilizerand metallurgical plants. Service conditions shall be as specified in the motordata sheet. If not specifically mentioned therein, a design ambient

temperature of 40°C and an altitude not exceeding 1000 meters above meansea level shall be taken into consideration.

4.2 Frequency and Voltage Variations : Unless otherwise agreed, motors shall bedesigned for continuous operation at rated output under the followingconditions:

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a) The terminal voltage differing from its rated value by not more than ± 6 %

or

b) The frequency differing from its rated value by not more the ± 3 % or

c) Any combination of (a) and (b)

4.3 Starting

a) Unless otherwise specified, motors shall be designed for direct-on-linestarting.

b) Motors shall be designed for re-acceleration under full load after amomentary loss of voltage with the residual voltage being 100% and is inphase opposition to the applied voltage.

c) Minimum locked rotor thermal withstand time at rated voltage shall be 10

arrow. Directional arrow should be manufactured from corrosion resistantmaterial. When a motor is provided with bi-directional fans, a double-headedarrow should be provided.

Normally, clockwise rotation is desired as observed from the driving(coupling) end, when the terminals ABC are connected to a power supply

giving a terminal phase sequence in the order ABC. Counter-clockwiserotation of the motor shall be obtained by connecting the power supply toterminals so that the phase sequence corresponds to the reversedalphabetical sequence of the terminal letters. Ample space shall be providedat the terminal box for interchanging any two external leads for obtaining thereverse phase sequence.

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StartsMinimum no. of

consecutive startsNo. of consecutive start-ups with initial temp.of the motor at ambient level (cold)

3

No. of consecutive start-ups with initial temp.of the motor at full load operating level (hot).

2

5.0 PERFORMANCE

5.1 Motors shall be rated for continuous duty (S1), unless otherwise specified.

5.2 Unless otherwise specified, the starting current (as % rated current) shall notexceed 600% subject to tolerance.

5.3 In particular cases, when the starting current is to be limited, care shall betaken such that the design values of torque meets the load requirement whileat the same time complying to clause 4 3 above of this specification

5.6 The pull out torque at the rated voltage shall be not less than 175 percent of the rated load torque with no negative tolerance. Unless otherwise agreed,the pull out torque shall not exceed 300 percent of the rated load torque incase of motors driving equipment with pulsating loads (e.g. reciprocatingcompressors) the minimum value of pull out torque at 75 percent of therated voltage shall be more than the peak value of pulsating torque and the

current pulsation shall be limited to 40%.

5.7 The minimum values for performance characteristics of motors rated up toand including 37 kW shall be as per IS-8789 TABLE-ito1 TABLE-8

The minimum value for product of efficiency and power factors of 2 pole, 4-pole and 6-pole motors rated above 37 kW shall be as given in Table below

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pole, and 6 pole motors rated above 37 kW shall be as given in Table below.

Rated output Product of efficiency & power factor at rated load(minimum)

2-Pole 4- Pole 6-Pole45 kW 0.82 0.80 0.7955 kW 0.82 0.80 0.79

75 kW 0.82 0.80 0.8090 kW 0.82 0.80 0.80

110kW 0.86 0.80 0.80125 kW 0.86 0.80 0.80160kW 0.86 0.81 0.80180kW 0.86 0.83 0.80200 kW 0.86 0.83 0.80

Efficiency and power-factor figures for motors having synchronous speeds of 750 RPM and below, shall be as agreed between the purchaser and the

6.1.3 Windings shall be adequately braced to prevent any relative movementduring operation. In this respect, particular care shall be taken for the statorwindings for direct-on-line starting squirrel cage motors. Insulation shall beprovided between coils of different phases that lie together. Core laminationsmust be capable of withstanding burnout for rewind at 400°C without

damage or loosening.6.1.4 In case of motors driving equipment with pulsating loads, special care shallbe taken for the joints of rotor bars and end rings to avoid premature failuresdue to induced fatigue stresses.

6.1.5 The windings shall be connected in delta. However, for motors rated 2.2 kWand below star connection may be accepted In case of motors with star-

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and below, star connection may be accepted. In case of motors with stardelta starting, the motor windings shall be fully insulated for delta

connection.

6.1.6 The ends of the windings shall be brought out into a terminal box. Theseshall be terminated by means of terminals mounted on an insulating basemade of non-hygroscopic and nonflammable material.

6.1.7 All motors shall be with six terminals and suitable links to connect them instar or in delta except for motors rated up to and including 2.2 kW which

may be accepted with three terminals.

6.1.8 All terminals shall be thoroughly insulated from the frame with materialresistant to tracking.

6.1.9 Anti-loosening, anti-vibration type of terminals shall be provided in case of increased safety (Type Ex e) and non-sparking (Type Ex n) motors.

removal. However, for terminal box covers weighing less than 5 kg., terminalbox covers without handles can be accepted.

6.2.3 An adequately sized earth terminal shall be provided in the motor terminalbox for termination of the fourth core of specified cables.

6.2.4 The terminal box shall be provided entries for suitable cable glandscorresponding to the size of the specified cable. Crimp type tinned Cu lugsand nickel-plated brass (or aluminum if specifically required), doublecompression type cable glands shall be supplied along with the motors forthe specified cable sizes for power and space heater cables.

6.2.5 Equipment and accessories provided shall conform to the hazardous area

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6.2.5 Equipment and accessories provided shall conform to the hazardous areaclassification and the environmental conditions as specified in the motor data

sheet.6.2.6 Unless otherwise specified, the terminals, cable lugs, terminal box, cableentries and cable glands shall be suitable for the cables sizes as specifiedbelow in Table for 2 pole, 4 pole or 6 pole motors:

Motor rating up to and including Size of phase conductor (mm2)2.2 kW and below 4 Al.! 2.5 Cu3.7kw 6A1./ 4Cu

5.5kw 10Al/ 6Cu7.5kw 16Al/6Cu9.3kW 25 Al/ 10Cu11.0kW 25 Al./ 16Cu15.0kW 35Al18.5kW 50A122.0kw 50A130.0kW 70A1

6.2.8 Cables used are of 650/1100 V grade aluminum conductor, PVC insulated,PVC extruded inner sheath, armoured with overall PVC sheath. However forcables up to & including 16 mm2 cross-section, cables used may be withcopper or aluminum conductor as indicated in the motor data sheet.

6.2.9 The terminal box shall be capable of withstanding internal short circuit

conditions without danger to personnel or plant from the emission of hotgases or flame or due to excessive distortion or damage to the terminalenclosure.

6.2.10 Appropriate phase markings as per IS shall be provided inside the terminalbox. The marking shall be non-removable and indelible.

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6.3 Motor Casing and Type of Enclosure

6.3.1 Motors for use in safe areas shall be industrial type meeting the specifiedambient conditions, starting and operating requirements.

6.3.2 Motors for use in hazardous areas (Zone-I or Zone-2) shall have type of protection Ex d or Ex e or Ex n as specified in the motor data sheet and shallmeet the requirements of applicable Indian standards.

6.3.3 The minimum degree of motor enclosures including terminal boxes andbearing housing shall be P-55 as per IS.

6.3.4 Motors for outdoor use shall be suitable for installation and satisfactoryoperation without any protective shelter or canopy. Motor casing shall beprovided with a suitable drain for removal of condensed moisture except incase of flameproof motors (Type Ex d).

6.3.5 Vertical motors with downward shaft shall be provided with suitable canopies

6.4 Bearing and Lubrication

6.4.1 Motors shall have grease lubricated ball or roller bearings. In all cases, thebearings shall be chosen to provide a minimum L- 10 rating life of 5 years,(40, 000 hours) at rated operating conditions (The L-l 0 rating life is thenumber of hours at constant speed that 90% of a group of identical bearings

will complete or exceed before the first evidence of failure).

6.4.2 Unless otherwise specified, the bearings shall be adequate to absorb axialthrust produced by the motor itself or due to shaft expansion.

6.4.3 Vertical motors shall be provided with thrust bearings suitable for the loadimposed by the driven equipment.

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imposed by the driven equipment.

6.4.4 In cases such as pumps for hot liquids where the driven equipment operatesat high temperatures, bearings shall be cooled by a shaft-mounted fan. Thisshall ensure efficient ventilation of the bearing and disperse the heattransmitted from the driven equipment by conduction or convection.

6.4.5 Bearings shall be capable of grease injection from outside without removal of covers with motors in the running conditions. The bearing boxes shall beprovided with necessary features to prevent loss of grease or entry of dust /

moisture e.g. labyrinth seal. Where grease nipples are provided, these shallbe associated, where necessary, with appropriately located relief devices,which ensure passage of grease through the bearings.

6.4.6 Pre-lubricated sealed bearings may be considered provided a full guarantee isgiven for 4 to 5 years of trouble-free service without the necessity of re-lubrication.

6.7 Shaft ExtensionMotors shall be provided with a single shaft extension with key-way and fullkey. Motor shaft shall be sized to withstand 10 times the rated design torque.

6.8 Lifting Hooks All motors weighing more than 30 kg. shall be provided with lifting hooks of

adequate capacity.

6.9 Earth TerminalsTwo earth terminals located preferably on diametrically opposite sides shallbe provided for each motor. The size of each earth stud shall be as givenbelow in Table:

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Motor Rating Stud size

Up to and including 7.5 kW 6 mmUpto 30 kW 10mm Above37kW 12mm

Necessary nuts and spring washers shall be provided for earth connection. An additional earth terminal shall be provided inside the terminal box asstated in 6.2.3.

7.0 MISCELLANEOUS ACCESSORIES

7.1 Anti-Condensation HeatersUnless otherwise stated, all motors rated above 22 kW shall be provided with240 V anti-condensation heaters, sized and located so as to preventcondensation of moisture during shutdown periods. The heaters shallpermanently remain ‘ON’ when the motor is not in service and as such shallnot cause damage to the windings.

In addition to the motor rating plate, a separate number plate for motor tagnumber shall be fixed in a readily visible position. This number shall be as perthe motor data sheets.

Additional information as stipulated in applicable standards shall be includedin the nameplate for motors meant for use in hazardous atmospheres.

8.0 NOISE LEVEL

The permissible noise level shall not exceed the stipulations laid down in IS,unless otherwise specified in the motor data sheet.

9.0 MOTOR VIBRATIONS

Motor vibrations shall be with-in the limits of IS, unless otherwise specified

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, pfor the driven equipment.

10.0 CRITICAL SPEEDS

The first actual critical speed of stiff rotors shall not be lower than 125 % of the synchronous speed. For flexible rotors this shall be between 60 % and 80% of the synchronous speed; the second actual critical speed shall be above125 % of the synchronous speed.

11.0 PAINTING

Internal and external parts of the casing and all metal parts including thecanopy likely to come in contact with the surrounding air shall be protectedwith anti-acid paint that will resist the specified environment conditions.

All external surfaces of the motor and its canopy shall be given a coat of epoxy-based paint. Paint shade shall be 632 as per Indian Standard-IS-S.

12.0 INSPECTION AND TESTING

12.4 Tests certificates duly signed by the GAIL I Owner’s Inspector shall be a partof final documentation.

12.5 The manufacturer shall submit all internal test records of the tests carried outby him on the bought-out items, motor sub-assembly and complete motorassembly to the Inspector before offering the motors for final inspection andtesting.

12.6 The manufacturer shall periodically carry out the following type tests as perapplicable Indian Standards for all the frame sizes and ratings of motors:

a) Full load test and measurement of voltage, current, power & slipb) Measurement of starting torque, starting current, full load torque and pull out

torquec) Measurement of efficiency and p.f. at 100%, 75% and 50% load

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) y p ,d) Temperature rise test

e) Momentary overload testf) Measurement of vibrationg) Measurement of noise levelh) Over speed test

The above tests must be witnessed and approved by reputed inspectionagencies. The manufacturer shall maintain test records and submit to theOwner's Inspector at the time of final inspection & testing. In no case, the

test records shall be more than 5 year old.

In special cases where the type tests are asked to be carried out,GAIL/Owner’s Inspector shall witness these.

12.7 The manufacturer shall carry out routine tests as per applicable IndianStandards on all the motors. Routine tests not limited to the following shallform part of acceptance testing:

12.8 The manufacturer shall submit the following certificates for verification by theGAIL/Owner’s Inspector:

a) Test certificate for degree of protection of enclosureb) Test certificates issued by the recognised independent test house for

hazardous area motorsc) Approval certificates issued by Statutory Authorities for hazardous area

motorsd) BIS license and marking as required by Statutory Authorities for Ex dmotors

12.9 Though the motors shall be accepted on the basis of the satisfactory result of the testing at the shop, it shall not absolve the Vendor from liability regardingthe proper functioning of the motors coupled to the driven equipment at site.

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p p g p q p

13.0 CERTIFICATION

The hazardous area motors and associated equipment shall have testcertificates issued by recognised independent test house(CIMFR/Basefa/LCIE/UL/FM or equivalent). All indigenous motors shallconform to Indian Standards and shall be certified by Indian testing agencies. All motors (indigenous & imported) shall also have valid statutory approvalsas applicable for the specified location. All indigenous flameproof motors shallhave valid BIS license & marking as required by statutory authorities.

Ex n motors shall be supplied with manufacturer’s certificate of conformity toIS 9628 or equivalent international standard and Indian statutory approval.


All the equipment shall be divided into several sections for protection andease of handling during transportation. The equipment shall be properlypacked for transportation by ship/rail or trailer. The equipment shall bewrapped in polythene sheets before being placed in crates/cases to prevent

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INSTRUCTIONS TO TURNKEY

CONTRACTORS FOR ROUTING AND

REVIEW OF DOCUMENTS

CONTENTS

1. PURPOSE

2. SCOPE

3. DETAILS

4. ATTACHMENTS

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1. PURPOSEThis document describes the procedures to he followed lbr routing andreview of turnkey contractor’s documents to ensure quality during designand engineering phase.

2. SCOPEThis procedure is applicable to contractor’s engineering documents and to

the documents generated by his sub-contractors, packagers, and finallyselected equipment manufacturers.

3. DETAILS1.1 Documents to be submitted to GAIL by contractor during the design and

engineering phase shall include

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a) Engineering designs, drawings and documents generated by the

Contractor or his sub-contractor for engineering.

b) Vendor drawings and documents generated by Contractor’s sub-vendors/subcontractors/packagers and/or finally selected equipmentmanufacturers.

2.2 Extent of Engineering ReviewBroad discipline-wise requirement of contractor’s documents for GAIL’S’s

. review/records is included in hid package.

3.3 Engineering drawings and documents

3.3.1 Contractor shall prepare and submit to owner/GAIL a detailed discipline-wise drawing schedule fir the drawings/documents to be generated bycontractor or his sub contractor for Engineering indicating submissionschedule for each drawing/document. The schedule shall be based on

j t h d l t t d h ll b d t d d b itt d t

Following review codes shall he used for engineeringdrawings/documents.(a) No comments. Work may proceed.(b) Proceed with engineering/construction as per comments marked.

Submit revised drawing.

(c) Document does not conform to contract specifications as marked.

Resubmit for review after incorporating comments.

3.3.3.2 Documents under Records CategoryDocuments under this category are meant for GAIL records. However,comments, if any, shall he communicated to contractor.

3.3.3 Review by GAIL shall not absolve the contractor of his contractual

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3.3.3 Review by GAIL shall not absolve the contractor of his contractualobligations. Any error/deficiency noticed during execution/installation shall

be promptly corrected by the contractor, irrespective of whether comments from GAIL were received or not during the drawing submissionstage.

3.3.4 Contractor shall also provide a copy of updated drawing schedule to GAILsite-in- charge every month.

All necessary engineering drawings and documents as required by GAIL

site-in-charge to ensure quality during execution/installation shall beprovided by the contractor.

Contractor shall maintain at site one set of drawings/documents (under review category) bearing signatures of GAIL along with the review codefor reference by owner’s site-in-charge.

4.4 Vendor drawings and documents3 4 1 Whil i th h i iti t t h ll i l d li t f

that any further comments by owner shall he communicated subsequentlyfor incorporation.

3.4.3 Contractor shall submit vendor drawings/documents to GAIL only after ensuring that the documents meet the contract requirements. All suchdocuments shall include contractor’s comments and his approvalsignature/stamp.

3.4.4 Contractor shall submit six copies of vendor drawings/documents to GAILProject Manager.

3.4.5 Following review codes shall he used fir vendor drawings/documents.a) No comments. Work may proceed

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b) Proceed with fabrication/manufacture as per comments

marked. Submit revised drawing.

c) Document does not conform to contract specifications asmarked. Resubmit for review after incorporating comments.

3.4.6 Contractor shall provide copies of Purchase Requisition bearing owner’ssignature as well as the copies of vendor drawings. reviewed by GAIL tothe inspector for shop testing/inspection of various equipment/materials..

3.4.7 Documents under Record Category shall be retained by Owner for records. However, comments, if any, shall he communicated.

3.5 Waiver and Deviation

All waiver/deviations after contract award shall be routed as belowa) For design and engineering through Owner’s Project

Manager.

Typical Drawing Document Schedule S-07-02-022-F1

Discipline ______________________

Rev 0 Rev I Rev 2

SchDate

ReviewCode

SchDate

ReviewCode

SchDate

ReviewCodeS

NoDrg. /Doc. No Title

CategoryReview /Record Actual

IssueDate

ReviewDate

ActualIssueDate

ReviewDate

ActualIssueDate

ReviewDate

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WAIVER/DEVIATION PERMIT S-07-02-022-F2(Strike out whichever is not applicable)

Project: ________________________________ Originator Ref : _______________________

Job No: ________________________________ Order/Contract No ____________________

Originator: Vendor/Consultant/Contractor: ____________________________________

Requirement as per specification Description of Waiver / deviation Sought

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Why is the waiver required?

Contractual implication if waiver/deviation is granted

o Time taken shall be More Less No Change

o Cost of Item shall be More Less No Change

o Performance requirement shall be Satisfactory Unsatisfactory

T O B

E

F I L L E D

B Y

T H E

O R I G I N A T O R

Under the present constraints requested waiver/deviation is most optimum for the project and does not involveany security and safety hazard.

S-07-02-022-F2Opinion from Consultant’s Supervisor/Inspector (Specific if post facto approval is required)

Date :___________________ Signature: _______________________ Name: __________________________ Department: ______________________

Forwarded to _________________________ by Head of Consultant Establishment(Project Manager)

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Date:__________________ Signature: _______________________ Name: __________________________

Forwarded to _________________________ (Target Resolution Div/Deptt/Group)

Date:__________________ Signature: _______________________

(Project Manager)Name: __________________________

Disposition by Target Resolution Div/Deptt/Group

Date Signat re

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SPECIFICATION FOR FIRE DETECTION

AND ALARM SYSTEM

Abbreviations:


BASEEFA British Approvals Service for Electrical Equipment in Flammable

AtmosphereCCE Chief Controller of Explosives

CFAP Central Fire Alarm Panel


CPU Central Processing Unit

DGFAP Data Gathering cum Fire Alarm Panel

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ERTL Electronic Regional Test Laboratory

FAT Factory Acceptance TestsFDD Floppy Disk Drive

FM Factory Mutual

FRP Fibre Reinforced Plastic

FO Fibre Optic

GUI Graphic User Interface

HAB Hooter acknowledgement box (to mute hooters)

HDD Hard Disk DriveISDN Integrated Service Digital Network

ITU- T International Telecommunication Union- (Telecom)

LED Light Emitting Diode

LPC Loss Prevention Council

LIFO Last in First Out

MCP Manual call point (break glass unit; BGU)

CONTENTS

1. SCOPE



4. DEFINITIONS

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5. SYSTEM AND SITE CONDITIONS

6. FIRE ALARM SYSTEM DESCRIPTION

7. CONVENTIONAL FIRE ALARM SYSTEM

8. MICROPROCESSOR BASED FIRE ALARM SYSTEM

9. INTEGRATION WITH VARIOUS PLANT SYSTEMS

10. PANEL CONSTRUCTION (CFAP, DGFAP, ZFAP, REPEATER)

11. CABLE AND CABLE ACCESSORIES

12. AUTOMATIC FIRE DETECTORS AND ACCESSORIES

1. SCOPE

1.1 The intent of this specification is to define the functional and designrequirements for an Integrated Fire Alarm System for industrial plants andbuildings. This specification covers the requirements for selection, design,and engineering, manufacture, testing at vendor’s works, supply, installation,testing at site and commissioning of the system.

1.2 The Integrated Fire Alarm System shall be conventional or micro processorbased analog addressable system comprising of MCP, detectors; conventionalor microprocessor based Fire Alarm panels, CFAP and associated equipmentsdetailed hereunder and in Project data sheets! drawings.


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2.1 The system and equipment shall comply with relevant BIS (Bureau of IndianStandards) and other Indian/ International standards, as applicable. In caseIndian standards are not available for any equipment, standards issued byIEC! BS/ VDE! IEEE! NEMA/NFPA or equivalent agency shall be applicable. Incase of imported equipment, the standards of the country of origin shall beapplicable if these standards are equivalent or more stringent than theapplicable Indian standards.

2.2 The equipment shall also conform to the special requirement! provisions of applicable statutory regulations currently in force in the country.

2.3 In case of any contradiction between various referred standards!specifications! data sheets and statutory regulations, the following order of decreasing priority shall govern:

o Statutory regulations

o IS 2175 Specification for heat sensitive fire detectors for use in automatic

fire alarm system

o IS 2189 Code of practice for selection; installation and maintenance of

automatic fire detection and alarm system.

o IS 3034 Code of practice for fire safety of Industrial buildings: Electrical

generating and distributing stations

o IS 3700 Essential ratings and characteristics of semi conducting devices

(Applicable parts)

o IS 3826 Connectors for frequencies below 3 kHz General requirements

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Part-I and tests IS 5469 Code of practice for the use of semi-conductor

junction devices (Applicable parts)

o IS 5780 Specification for Intrinsically safe electrical apparatus and circuits

o IS 11360 Specification for smoke detectors for use in automatic electrical

fire alarm system.

o IS 12459 Code of practice for fire safety in cable runs

o IS 13346 General requirements for electrical apparatus for explosive gas

atmosphere

o IS-14154 Electrical apparatus with protection of enclosure for use in the

presence of Part 2 combustible dust NFPA 72 National Fire Alarm code Vol

4

3.3 Vendor shall give a notice of at least one year to the end user of equipmentand E1L before phasing out the product! spares to enable the end user toplace order for spares and services.

3.4 The vendor shall be responsible for design, engineering and manufacturingof the complete system and equipment to fully meet the intent andrequirements of this specification and attached data sheets.

3.5 All equipment and accessories required for completeness of the system,whether specifically mentioned or not but considered essential forsatisfactory performance, shall be included as a part of the offered system.

3.6 The system integrator shall coordinate with the manufacturers of variousbought-out items associated with the system as required and shall freely

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bought-out items associated with the system, as required, and shall freelyand readily supply all technical information as and when called for.

3.7 Equipments to be located in hazardous areas shall have test certificatesissued by recognized independent test house such as CMRI, ERTL, BASEEFA,UL, FM or equivalent. All indigenous equipment shall conform to Indianstandards and shall be certified by Indian testing agencies. All equipment(indigenous & imported) shall also have valid statutory approvals asapplicable for the specified location. All indigenous flameproof equipment

shall have valid ISI license and marking as required by statutory authority.

4 DEFINITIONS

4.1 CFAP:

It is a fire alarm panel located in fire station or in disaster managementcontrol rooms. It is electronic for conventional and microprocessor based foraddressable system. CFAP is designed to gather information from distributed

4.3 ZFAP:

It is a fire alarm panel for conventional fire alarm system. This hasfunctionality similar to what is provided for DGFAP. This has LEDs for fire!fault annunciations.

4.4 REPEATER PANEL:

It is similar to distributed fire alarm panels (DGFAP/ ZFAP) but will not haveZone card! Loop card for field devices. These are provided at mannedlocations and are configured to acquire information about the fire! fault of selected zones from DGFAP! ZFAP and annunciate.

4.5 INTEGRATED FIRE ALARM SYSTEM:

It signifies a comprehensive fire alarm system comprising all the distributedfire alarm panels (DGFAP ZFAP repeater panels etc) having integration with

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fire alarm panels (DGFAP, ZFAP, repeater panels etc) having integration withCFAP for fire monitoring of total plant! building. It provides audio! visualalarm building/plant-wide having provisions for connectivity with telephoneexchange, pager system and public address system. It shall provideinterfaces with fire protection system and other systems like pressurizationsystems, air conditioning etc.

4.6 SYSTEM ARCHITECTURE

System architecture is line diagram defining the connectivity of DGFAPs,

repeater and CFAP. This also specifies various system requirements such asredundancy, communication protocol, communication hardware, cablerequirement, workstation and programming tools.

4.7 DATA HIGH WAY

This term is meant to define the communication path between DGFAPs, CFAPand other network components in microprocessor based fire alarm system.Physical media for Data highway can be fibre optic (FO) cable or twisted pair

5 SYSTEM AND SITE CONDITIONS

All equipment shall be designed to operate with power supply and siteconditions as specified below:

5.1 INPUT POWER SUPPLY

5.1.1. Unless stated otherwise, purchaser shall provide one point power supply toeach fire alarm panel (ZFAP/DGFAP/CFAP! repeater panel), details of whichare indicated in data sheet. A suitable power distribution to variousequipment and sub system shall be included in vendor’s scope.

5.1.2. Power supply for fire alarm panels shall have battery back up as per IS-2189.Battery AR rating shall be determined on the basis of maintaining the system

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Battery AR rating shall be determined on the basis of maintaining the systemin normal operation for a period of not less than 48 hours (quiescentcondition) and successive full load alarm condition of period not less than 30mm after the failure of normal mains supply.

The switch over from mains to back up, in the event of mains failure, shall beautomatic. Batteries shall be Ni-Cd / VRLA type as specified in data sheets.Suitable and adequately rated battery charger shall be supplied as a part of back up battery system.

(The full load alarm condition is defined as operation of all panel/field audioand visual alarm and the alarm load of 25 percent of total zones besidesother normal operation loads.)

5.2. SITE CONDITIONS

The offered equipment shall be capable of operating continuously and

The system shall consist of automatic fire detectors and manual call point orbreak glass unit. Automatic fire detectors shall work on the principle of sensing of smoke, heat or infrared rays. Depending on type of smoke, optica’ or ionization type detectors shall be used. Detectors shall generally beprovided in plant! non-plant buildings. Manual Call Point shall be provided atexit doors of the buildings and at exit route of industrial plants. Number of detectors and break glass unit shall be decided as per guidelines given inapplicable codes and standards.

The plant! building shall be divided into fire monitoring zones. Detectors andMCP at these buildings and plants shall be connected to DGFAP! ZFAP. Thesepanels shall continuously monitor the state of these devices. On sensing firecondition, an audio! visual alarm shall be initiated identifying the zone wherefire is detected. Panels shall continuously monitor the health of the cabling

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fire is detected. Panels shall continuously monitor the health of the cablingand in case of short circuit or open circuit fault alarm shall be actuated. Firealarm panels shall also have powered outputs for switching on exit signs andhooters as specified in data sheet. Further, panels shall provide requiredoutput for interfacing with the Purchaser’s systems such as air conditioningsystem or pressurization system or fire protection systems.

Alarms, if specified, shall be relayed to repeater panel provided in buildingslike control rooms! administrative buildings to provide zone wise

annunciation. In addition facility shall be provided to actuate siren! hooter.

For integrated fire alarm system where plant-wide large numbers of firealarm panels are envisaged, these panels shall be integrated to CFAP, whichshall be located in fire station or in administrative control room of thebuilding as per the job requirements. The connectivity shall be achievedusing data high way or dedicated cable connection from each fire alarmpanel to CFAP. Mimic at CFAP shall be provided for fire! fault annunciation on

ii. ZFAPsiii. Repeater Fire Alarm Paneliv. Plant-wide Sirens and startersv. Hooters, exit sign and flAB in buildingsvi. Interface with Purchaser’s systemsvii. Any other hardware as required to render system complete

6.2.2. Microprocessor based fire alarm system shall generally comprise but not belimited to the following equipments used in conjunction with addressableautomatic detectors and addressable MCP as a minimum.

i. CFAP consisting of computer based graphic workstation and engineeringstation.

ii. Multi loop DGFAPsiii. Plant-wide sirens and starters

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i ii. Plant wide sirens and startersiv. Hooters, exit sign and flAB in buildingsv. Interface with Purchaser’s systemsvi. Dual redundant copper! FO cable data highway complete with dual

redundant architecture for communication hardware includingcommunication port, switches, processor and power supply

vii. Any other hardware! Software required for rendering system complete

6.2.3 As specified in data sheet, the system shall be provided with siren!s to be

located at a suitable Iocation!s in the plant and it shall be actuated manuallyand automatically as selected by operator from CFAP! DGFAP located at firestation! other buildings.

7. CONVENTIONAL FIRE ALARM SYSTEM

7.1 DESIGN FEATURES

7.1.3 Logic of operation shall be built on ‘Fail safe” feature i.e. NC contact of fielddevices shall be considered as healthy condition and NO as fire condition. 1NO+ I NC contact of output relays shall be wired to terminal block forinterface with Purchaser’s other equipment.

7.1.4 It shall be possible to test lamps, hooters, flasher circuit, and functional testsetc through common “Test” push button.

7.1.5 The circuit shall be so designed that silencing of the current alarm by ACCEPT push button shall not prevent annunciation of subsequent fire alarmreceived from any other location

7.1.6 Signal-to noise ratio shall be high to avoid spurious actuation due to noiseinduced in the field wiring because of proximity with power cables. Cables for

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induced in the field wiring because of proximity with power cables. Cables forfield devices shall be multicore copper conductor, unscreened, armoured,copper conductor cable. If required noise filters shall be provided at firealarm panel.

7.1.7 Detectors and MCPs in a ioop shall be wired through I .5 mm2 multi-core,Copper conductors, PVC insulated, armoured cable. Limiting distance fromfire alarm panel to last detector/MCP shall not be less than 2 km or asspecified in data sheet whichever is maximum.

7.1.8 LEDs shall be provided for fire! fault visual annunciation on the panel front.LED shall also be provided for Power supply healthy, Battery backup ON,Battery/ Charger status.

7.1.9 If zone is protected with clean agent! CO2 system, the detectors and MCPs of the zone shall be wired in cross-zones by providing minimum two loops in azone. The last device in each loop shall be provided with end of line resistor

7.1.11 Fire alarm panels including repeater panels and CFAP shall be certified!approved by applicable approving agency of country of origin as required.

7.2 ZONAL FIRE ALARM PANEL

7.2.1 ZFAP shall consist number of zones as specified in data sheet. Detectors!MCP! heat sensing cables etc shall he connected zone wise in a loop. It shallmonitor fire! fault condition of the zone. ZFAP shall be located indoor in safearea..

7.2.2 ZFAP shall be freestanding, floor mounting vertical panel consisting of audio/visual annunciation with Alarm Accept, Test and Reset Push Buttons, Auto/Manual control of hooters provided in buildings. Provision to actuatesiren shall be provided if specified in data sheet. Circuit shall be designed to

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p p gprovide annunciation if any detector in a zone senses fire. Annunciationscheme shall be as per clause 7.1.10

7.2.3 Audio! Visual indication and annunciation shall be as per clause 7.1.8.

7.2.4 ZFAP shall have required interface hardware where integration with CFAP/repeater panel is envisaged as per data sheet.

7.2.5 Output contacts (1NO+1NC) shall be provided for interface with Purchaser’ssystems as per clause 9 of this specification. The rating of output contactshall be 0.5A, 220V DC or 2A, 240V AC.

7.2.6 Input power supply and battery backup for ZFAP shall be as per data sheetand as per clause 5.1 of this specification.

7.3 REPEAT ALARM PANEL-CONVENTIONAL

7.4.2 CFAP shall be in vertical panel construction or desk type construction havingcontrols such as Accept, Test and Reset Push Buttons, Auto/Manual controlof siren etc.

7.4.3 Unless otherwise specified in the data sheet, CFAP shall have mimic todisplay geographical location of fire. Mimic shall form an integral part of theCFAP and shall be located at the top of the panel. When separate mimicpanel is specified, it shall either be wall mounting or freestanding floormounted type. Two LEDs shall be provided for each zone on mimic panel fordisplay of fire alarm. Mimic panel shall be powered by CFAP. Mimic made outof plastic stickers shall not be acceptable.

7.4.4 Input supply and battery backup for CFAP and MIMIC shall be as per datasheet and as per clause 5.1 of this specification.

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p p

8 MICROPROCESSOR BASED FIRE ALARM SYSTEM

8.1 DESIGN FEATURE

8.1.1 Unless otherwise specified Microprocessor based system shall be analogaddressable type. The system shall be integrated as per ‘system architecture’ indicated in data sheets.

8.1.2 Microprocessor based fire alarm system shall be designed to use state of theart technology. All fire alarm panels including repeater panel shall benetworked through data high way. The system supplied shall not pose anylimitation for future expansion by way of networking of fire alarm panels,data transfer, parameterization of addressable field devices, graphic displaysetc.

8.1.5 Unless specified otherwise in data sheet, system architecture shall haveminimum redundancy indicated below however not limited to the same.

i) Dual redundant at processor level (communication processor and I/O cardprocessor)

ii) Dual redundant communication portiii) Dual redundant data highway cableiv) Dual redundant microprocessor at CFAPv) Dual redundant work station/MMI (engineering station operator’s station)vi) Dual redundant power supply card at all fire alarm panels (but with single

source of battery backup)8.1.6 Data highway shall be Fibre optic or twisted pair shielded copper cable as

specified in data sheets. Whether specified or not, data highway shall includeall necessary hardware such as modem, repeaters, network switches! hubsetc including power supply system as required to suit the length of data

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g p pp y y q ghighway.

8.1.7 The communication shall be peer to peer between various DGFAPs, repeaterPanels, CFAP and other system components connected on fire alarm systemdata highway.

8.1.8 Any fault in Analog detector addressable loop and data highway shall notimpair communication i.e. Communication! flow of analog signal shall be

possible from either end of the loop.

8.1.9 The loop cabling for wiring detectors and MCPs shall be class A, fault toleranttype as per NFPA 72.

8.1.10 Fire alarm logic shall be programmable type. The logic for zone protectedwith clean agent system! CO2, shall be programmed to provide output foractuation after ensuring that there is no false alarm. Similarly logic to switch

8.1.14 Unless otherwise specified in data sheet, conductor size of loop cable shall be1 .Ssqmrn copper. The allowable signal loop length shall not be less than 2km. To optimize length, circuit design for loop shall allow the use of spurconnection.

8.1.15 DGFAP and repeater panel shall have backlit alphanumeric LCD display toprovide addresses, status of each field device. In addition LEDs shall be

provided for fire/ fault visual annunciation. LED shall also be provided forPower supply healthy, Battery backup ON, Battery! Charger status.

8.1.16 Fire station shall be provided with dual redundant PC with monitor foroperator’s workstation and for engineering station. Any of the two should bepossible to configure as engineering station for programming off line. AfterProgramming, the engineering station will be connected to network as online

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g g g goperator’s workstation. . Programming shall also allow activating Siren fromthe keyboard in manual mode as per operator’s choice.

8.1.17 Scheme for FIRE / FAULT annunciation shall be as per the following.

System condition AUDIO VISUAL

NORMAL OFF OFF

FIRE ON (tone 1) Flasher ON, Fire LED Steady ON Accept OFF Flasher steady, Fire LED steady ON

Reset OFF Flasher OFF, Fault LED OFF

FAULT ON (tone 2) Flasher OFF, Fault LED Steady ON

Accept OFF Flasher OFF, Fault LED Steady ON

R OFF Fl h OFF F l LED OFF

various field devices e.g. fire and fault status password protection shall notbe given.

8.1.21 Fire alarm panels including repeater panels and CFAP shall be certified!approved by an international approving agency! approving agency of countryof origin as applicable.

8.2 DATA GATHERING CUM FIRE ALARM PANEL (DGFAP)

8.2.1 DGFAP shall have basic design features as per clause 8.1 above, Number of signal loops in each DGFAP shall be as defined in the data sheet. Number of loops shall be basic part of main PCB and should not be extended byproviding external electronic devices. LCD display and annunciation schemeshall be as per clause 8.1 .1 7.

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8.2.2 It shall be possible to change the reference value of detector sensitivityeither manually or automatically as required during the operation to avoidfalse alarms prior to detector maintenance.

8.2.3 DGFAP shall have serial port for communication to data highway. It shouldbe possible to communicate all the information to CFAPI FA systemworkstation located with fire marshal. The protocol of communication shall

preferably be open protocol.

8.2.4 In the event of non-availability of data highway, DGFAP shall work as standalone intelligent panel monitoring fire in the zones connected to it.

8.2.5 It shall be possible to configure DGFAP to access data of any other DGFAPand display as per the operation requirement to be finalized duringengineering! commissioning.

8.4 CFAP/ PC BASED MONITORING STATION OR WORK STATION

8.4.1 Based on vendor’s system design CFAP shall include network PC basedmonitoring station directly connected to data highway with other peripheralssuch as network switches! controller (HUB). Alternatively, vendor may supplyCFAP similar to DGFAP along with PC based monitoring station. Applicationsoftware shall be installed in PC as GUI. The graphic shall include

geographical location of various plant areas including location of addressabledetectors and MCPs. The navigation between various graphic pages shall beuser friendly. The screen shall have defined area to display the latest fire orfault alarm and shall also have facility to pop up the graphic displaying thelocation of fire event.

8.4.2 Unless stated otherwise, CFAP shall have all the features and facilities of the

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DGFAPs. It shall monitor the status of each addressable field device indirectlyfrom the DGFAPs connected on data highway.

8.4.3 Engineering workstation shall be used for programming off-line. Afterprogramming, the changed parameters shall be down loaded to other PC towork in synchronism as normal operation. This station shall also have twoprinters connected to PCs working as SOE printer and engineering printer.SOE printer shall be high-speed dot matrix printer and engineering printershall be laser printer.

8.4.4 Unless specified otherwise, adequately rated UPS with bypass shall beprovided for PC based monitoring station. Battery backup shall be sized asper criteria given under 5.1. Only normal supply shall be made available atone point by Purchaser at the location of central fire alarm panel.

8.4.5 It shall be possible to actuate plant-wide siren in auto! manual mode. Unless

Application software supporting graphics with no limitation on number of graphics, events, alarms, number of field devices as required for any largeplant like refinery, petrochemical complex or the large multistory building.

8.4.7 It shall be possible to provide multilevel access of fire alarm system. Readonly access shall not require password protection. Access for programmingand access for controls from keyboard shall be password protected. The

levels of password protection shall be agreed with plant operators at the timeof commissioning of system.

8.4.8 Printer

i. Printer options shall include both graphic laser printer and dot-matrixevent text printer.

ii. Printer used in the system shall provide real time records of the system

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events and provide system reports on demand, and shall bemicroprocessor controlled, high speed, read only (RO) letter quality dot-matrix type 132 characters wide and 96 character set.

9 INTEGRATION WITH VARIOUS PLANT SYSTEMS

9.1 Fire Alarm System shall have required hardware to have interface withfollowing plant systems as specified in data sheet.

i. Public Alarm Announcement systemii. Paging and plant intercom systems.iii. Plant data network iv. ISDN telephone exchange and pager systemv. Fire suppression system

9.2 ZFAP as a minimum shall be provided with the following interface with firesuppression system unless specified otherwise.

10 PANEL CONSTRUCTION (CFAP, DGFAP, ZFAP, REPEATER)

10.1.1 All fire alarm Panels shall be free standing, floor mounting type unlessspecified otherwise and shall be fabricated out of minimum 2mm thick CRCA sheets and doors shall be fabricated out of minimum 1.6mm CRCA sheets.The panel shall be naturally ventilated in IP-41 enclosure protection asminimum.

10.2 EQUIPMENT MOUNTING

10.2.1 All apparatus, display screen, instruments and indicating lamps mounted onthe panel front shall be flush mounting type. The external cabling shall notbe terminated directly on the base connector of PCBs but shall beterminated on separate terminal block. Further connection to PCBs shall be

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as per manufacturer’s standard. Routine calibration, adjustments,programming and operation shall be accessible from the front of the panelwithout opening the door. External cabling shall preferably be done fromthe rear.

10.2.2 Power supply system including battery bank shall be mounted inside thepanel.

10.2.3 Doors shall be provided with pistol grip handle with lock. Lamps shall beprovided inside the panel to provide adequate light for maintenance of equipments.

10.2.4 Cable entry shall be from bottom unless otherwise specified in the datasheet. Terminal strip shall be provided for incoming I outgoing cables.

10.3 WIRING AND TERMINALS

10.3.3 Cables shall be terminated on terminal blocks. Clamp type terminals shall beof spring-loaded, stacking type, mounted on rails. Terminals shall be sizedto accept, as a minimum 2.5mm2 cross section conductors. Not more thanone conductor shall be terminated on the outgoing side of each terminal. Atleast 20 % spare terminals shall be provided in each panel for terminationof spare cores of cables.

10.4 EARTHING

10.4.1 A common earth bar of minimum 25 x 3 mm. copper or equivalentaluminum shall be provided throughout the length of the panel. All non-current carrying metallic parts of the panel- mounted equipment shall beearthed. Flexible jumpers shall connect all doors and movable parts to theearth bus. Two numbers earth lugs shall be provided outside the panel.

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10.5 NAME PLATES / WARNING PLATES

10.5.1 All nameplates for panel shall be engraved out of 3 ply (black-white- black)lam icoid sheets or anodized aluminum. Back-engraved Perspex sheetnameplates will also be acceptable. Engraving shall be done with squaregroove cutters. Hard paper or self-adhesive plastic tape nameplates shallnot be acceptable.

10.5.2 Labels shall be provided for every component on the cards, connectingwires as well as for the terminals in the terminal strip inside the panel.Wiring diagram shall be pasted inside the panel door as required fortermination and maintenance.

10.5.3 Special warning plates shall be provided on all removable covers or doorsgiving access to energized metallic parts above 24 volts.

11 CABLE AND CABLE ACCESSORIES

11.1.1 Unless otherwise specified, purchaser shall supply and lay only the followingcables.

i. Signal Loop! Zone Cables from outdoor field devices to the firealarm panel except for buildings.

ii. Loop! Zone cables from FA panel to JB (Vendor shall provide JBs in

each building for signal loop cabling. Cables from JB to fire alarmpanel is included in purchaser’s scope while cable from JB todetectors and all other field devices shall be included in vendor’sscope.)

iii. Exit sign and hooter cables from FA panel to JB (Vendor shallprovide separate JB for exit sign and hooter. Cables from JB to firealarm panel is included in Purchaser’s scope while JB to exit sign

d h t i i l d d i d ’ )

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and hooter is included in vendor’s scope.)iv. Cable from purchaser’s switchgear to siren starter and siren starter

to siren.v. All interface cables from fire alarm panels to purchaser’s system.vi. Incoming power supply cables from purchaser’s switchgear to Fire

Alarm Panels All other cables as required for fire alarm system including thesupply, laying and termination of cables and accessories withinbuildings from JBs to detectors! MCPs. exist signs, hooters and alsosupply, laying, termination of data high way cables, high wayaccessories etc as required for successful commissioning shall be invendor’s scope.

11.2 Though the supply and installation of field cabling is excluded from vendor’sscope but terminations of all cables (supplied by both vendor! purchaser) atboth ends shall be in vendor’s scope.

11.4.2 Vendor shall supply and install all hardware and cabling accessories as perdata high way design including modems, repeaters etc as part of the FA system. Modems! repeaters shall be powered by the supply provided forDGFAPs ! CFAP.

11.5 CABLE GLANDS I ACCESSORIES

11.5.1 All cable glands/ lugs/ connectors as required for the equipment shall beincluded in vendor’s scope and shall be supplied along with the system,irrespective of whether installation is to be performed by vendor or not.

11.5.2 All the cable glands for outdoor application shall be weatherproof, nickel-plated brass and double compression type, whereas those for indoor

li ti h ll b i l i t

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application shall be single compression type.

11.5.3 Cable glands for hazardous area equipments shall be flameproof,weatherproof and nickelplated brass double compression type.

12 AUTOMATIC FIRE DETECTORS AND ACCESSORIES

12.1 GENERAL SPECIFICATIONS

12.1.1 Detectors for conventional fire alarm system shall be conventional type. Endof line resistor shall be provided at the last detector in the zone. Detectorsfor microprocessor shall be addressable type. Detectors shall be plug-in typeand shall have twist lock action fitting. Multicolour LEDs provided on thedetectors shall indicate Normal and Alarm state. Essential features of detectors are indicated as below.

12.1.5 All detectors shall be on the approved list of LPC, UL! FM! equivalentinternational approving agency as applicable.

12.1.6 All detectors shall be suitable for operation at DC power supply extendedfrom fire alarm panel.

12.1.7 The addressable detectors shall be continuously monitored to measurechanges in their sensitivity due to the environment (dirt, dust, temperature,

humidity etc.). These detectors shall give an advance indication to the panelregarding the need for maintenance. The analogue reading sent by thedetectors shall be sensed and if there is a rapid increase, an alarm shall begenerated. However, if there is a gradual increase in the analogue reading,a maintenance alert shall be generated by the fire alarm panel. It shall bepossible to generate maintenance reports from the fire alarm panel. For theaddressable detectors two-wire operation shall be possible.

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12.1.8 All addressable detectors shall have selectable settings for pre-alarm andalarm and preferably have the facility to set the sensitivity and address fromthe fire alarm panel.

12.1.9 Manual call points / break glass boxes for microprocessor based fire alarmsystem shall be addressable type. Each device shall have its own addressmodule.

12.1.10 All addressable detectors shall be suitable for installation using fault tolerantwiring (class-A, style - 6 wiring as per NFPA72). T- Tapping shall not bepermitted in the case of such wiring.

12.1.11 All detectors must have insect screen to prevent entry and cause falsealarm.

12.2.3 The fixed temperature feature should be entirely independent of the rate of rise element. The operating temperature of fixed temperature elementshould be factory set at 57° C ± 5° C.

12.2.4 The detector shall be self-restoring type ensuring repeated use and easymaintenance.

12.3 IONIZATION SMOKE DETECTOR

12.3.1 Ionization smoke detector shall be solid-state type, working on ionizationprinciple and shall preferably be of dual chamber and dual source type.

12.3.2 The detector shall be able to sense incipient fire by detecting the presenceof visible and invisible products of combustion like wood, paper, ammoniaprocessing paper cloth PVC bakelite nylon foam acrylic thermocol

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processing paper, cloth, PVC, bakelite, nylon, foam, acrylic, thermocol,Photo film, nylon, polyester, painted sheets, Teflon, leather etc.

12.3.3 The sensitivity of the detector shall not vary with change in ambienttemperature, humidity, pressure or permissible voltage variation. Itsperformance shall not be affected by an air current of 5 rn/sec. It shall havean inbuilt arrangement such that puffs of smoke or hot air pockets do notinadvertently trigger the alarm. The detector shall be protected against dustaccumulation! ingress. It shall have insect resistant screen to preventnuisance alarms.

12.3.4 Where air velocity is expected to be higher, smoke guard! baffle shall beused.

12.3.5 Where specified, smoke detectors operating on laser diode principle shall beoffered.

12.6 IR DETECTORS

12.6.1 1k detectors shall work on the principle of a single wavelength infraredflame detector using one of several different photocell types to detect theinfrared emissions in a single wave length band that are produced by aflame.

12.6.2 1k detectors shall react to the infrared rays of aflame. It should be sensitiveenough to detect smoky fires in which flame is hardly recognizable. Thedetector should not react to extremely glaring artificial light or directsunlight. The detector shall be completely solid-state type.

12.6.3 Where specified combination UV-IR detector shall be used.

12 7 LINEAR BEAM DETECTOR

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12.7 LINEAR BEAM DETECTOR

12.7.1 Linear beam detector shall work on the principle of obscuration of infraredlight beam by particles of smoke. The sensitivity shall be such as to enableoperation at 30% to 50% obscuration.

12.7.2 Linear beam detector shall consist of separate transmitter and receiver.Linear beam detector shall be suitable for application in high roofedlocations such as warehouses etc. The detector shall, preferably, bepowered from the loop signal itself. However, if external power supply isrequired the same shall be explicitly stated by the vendor, which shall becovered under common power supply for the fire alarm panel and devicesconnected with it.

12.8 HEAT SENSING CABLES

12.8.1 Heat sensing cable shall be analogue type. It shall consist of four copper

shall be provided at the bottom of the box to facilitate cable / conduit entry.The glass shall cover at least 30cm2 area and shall have a thickness notexceeding 2mm.

12.9.3 The box shall have a push button element kept in pressed condition by aglass sheet fitted in the front of the box.

12.9.4 The enclosure shall be painted with fire red colour (shade 536 of TS-5)epoxy painting and an inscription Break Glass in case of Fire”, shall bepainted in white letters or riveted on the enclosure by a steel nameplate. A suitable nickel-plated brass hammer, duly chained to the box with stainlesssteel chain shall be provided with each box for breaking the glass. Each boxshall have a distinct identification number boldly painted on it.

12 9 5 If specified in the data sheet the BGU shall have a suitably wired telephone

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12.9.5 If specified in the data sheet, the BGU shall have a suitably wired telephonehand set to facilitate communication between the BGU and the centralannunciation panel. Telephone hand set mounted on hook switch shall behoused in a separate lockable weatherproof break glass window enclosure.The glass will be broken in case of fire with the hammer provided with theBGU.

12.9.6 Hazardous area Break Glass Units shall meet the requirement of clause 13of this specification.

12.10 RESPONSE INDICATOR

12.10.1 If specified in the data sheet, response indicators shall be provided suitablefor wall! ceiling mounting. Response indicator shall be provided where thedetector is located either above false ceiling or below false floor or wheredetectors are not directly visible. The response indicators shall be connectedto the detectors directly and shall be complete with terminal blocks suitable

12.11.2 Fire exit shall be displayed by means of 5mm dia LEDs or backlit text. Itshall be powered from the fire alarm panel. Exit sign shall operate on DCpower supply

12.11.3 The exit sign shall be either in red letters on white background or whiteletters on green background.

12.11.4 Where specified in data sheet, self-luminous exit sign shall be provided.

12.12 HOOTERS

12.12.1 The unit shall consist of solid-state circuitry on a printed circuit board, aloudspeaker and a flashing lamp housed in a weatherproof dust tight, wallmounting type enclosure. The hooter shall, at least, have 102 db (A) outputmeasured at 1 meter distance The unit shall be powered from the fire

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measured at 1-meter distance. The unit shall be powered from the fire

alarm panel and operate on DC power. In the event of fire, the hooter shallraise pulsating audio alarm and the lamp shall start flashing.

12.12.2 HAB shall be provided at exit doors of buildings to mute the hooters afterevacuation.

12.12.3 Flashing Lights (Beacon)

12.13.1 .The unit shall consist of solid-state circuitry on a printed circuit board and ared-capped incandescent lamp and audio unit housed in a dust tight, wall!ceiling mounting type enclosure. It shall derive power from the DGFAP!ZFAP and shall operate on DC supply.

12.13.2 Flashing lights shall be installed in the enclosed areas where clean agent!CO2 is to be released. In the event a signal for clean agent!C02 release is

12.15 ZENER BARRIER

12.15.1 Preferably flameproof(Ex ‘d’) equipment that does not require the use of Zener barrier shall be used. When necessary, intrinsically safe (Ex ‘i’)detectors and MCPs, Zener barriers shall be provided. These shall be locatedin unclassified! non-hazardous areas.

12.15.2 Normally not more than 10 detectors shall be connected to one zenerbarrier. However vendor shall indicate maximum number of detectors! MCPsthat can be connected to one Zener barrier without compromising onworking of loop! zone. Vendor shall also indicate the maximum loop lengthfrom zener barrier considering 1.5 mm2 copper conductor, screened cable.

12.15.3 In case loop length permits, zener barrier shall be located at DGFAP itself else it shall be located in safe area nearest to the detector! MCP

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else it shall be located in safe area nearest to the detector! MCP.

12.15.4 Wherever zener barriers are provided in safe area outside the Zonal panelor DGFAP, these shall be housed in their own enclosure with IP-55 degreeof protection as a minimum.

12.16 FAULT ISOLATOR

12.16.1 Fault isolator shall be installed, if specified in the data sheet.

12.16.2 Fault isolator shall be designed to provide short circuit protection to anaddressable detector loop. It shall be possible to wire the fault isolator atany point in the detector loop.

12.16.3 On occurrence of a fault (short circuit), the isolator shall cut power to alldevices installed between the two isolators minimizing the outage of all the

12.17.2 The decibel level of the siren shall, at least be 132db(A) at 1 meter, tomeet the audibility requirement for the above range. Unless otherwisespecified, Sirens shall operate at 415 V, 3 ph. AC supply. Sirens shall behoused in weatherproof enclosure. Starter shall be DOL and shall be housedin a separate 1P55 enclosure suitable for installation indoor! outdoor.

12.17.3 For three-phase siren, wall-mounting type three-phase DOL starter shall be

supplied. Starter shall be mounted indoor in a building where siren islocated. The supply to the siren starter shall be provided by purchaser fromNormal or Emergency power source as defined in the data sheet.

13 FIELD DEVICES FOR HAZARDOUS AREA

13.1 Hazardous area is classified as Zone 1/Zone 2, gas group hA! IIB or lIC,temperature class T3 (200 °C) as specified in data sheet The field devices

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temperature class T3 (200 C) as specified in data sheet. The field devices

shall be suitable for installation in hazardous area as per specified areaclassification.

13.2 Field devices such as detectors, MCPs, fault isolators, Beacons, hooters etcfor use in hazardous area, if specified in the data sheet shall have flameproof enclosure conforming to IS 2148. All equipment for hazardous areainstallation shall be complete with flame proof, weather proof cable glandsas specified in clause 11.5.

13.3 Equipment, which cannot have flameproof construction, shall be intrinsicallysafe in design and shall be used with Zener barriers located in safe area.

13.4 Equipment that are tested / certified by a recognized test laboratory of country of origin shall only be offered. The vendor shall possess valid testcertificate issued by a recognized independent test house such as CMRI!

14 Engineering RequirementsUnless specified other wise, vendor shall design entire fire alarm systemincluding design of system architecture with details of integration, cablingrequirement and protocol selection etc. Vendor’s scope shall also includebasic design and preparation of layouts for fire alarm system for plant!buildings as specified in the data sheet! purchase documents.

14.1.1 CONVENTIONAL FIRE ALARM SYSTEMi. For conventional fire alarm system, purchaser shall provide typical block

diagram. On this basis, vendor shall prepare detailed drawing givingvarious system component details. The design and engineering shallinclude sizing and selection of various equipment such as fire alarmpanels, batteries, battery chargers, field equipments, siren, siren starteretc. including preparation of G.A. drawings of various equipment.

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ii. The layout engineering for buildings shall include the drawings showinglocation of MCP/ Detector and other field devices, cable schedules,interconnection diagram, equipment installation drawings etc asminimum.

14.1.2 Addressable Fire Alarm Systemi) Vendor shall develop a system architecture based on purchaser’s

requirement showing details of various network elements such asDGFAP, CFAP, Work station, networking hardware, redundancy,protocols, data highway etc. including the maximum permissibleloop length and length of data highway.

ii) The design and engineering shall include sizing and selection of various equipment such as fire alarm panels, batteries, batterychargers, field equipments, siren! siren starter etc. including

approved from Purchaser at least one month before inspection. GAIL/Purchaser’s inspectors shall witness all the tests.

15.2 During manufacture, the equipment shall be subject to inspection as perattached inspection plan to assess the progress of work and to ascertainthat the quality controls are being maintained. Vendor shall provide allnecessary assistance and information concerning the supply to

GAIL/Purchaser’ s inspectors.

15.3 Tests shall be carried out at the vendor’s works under his care and expenseand Purchaser shall be informed at least 4 weeks in advance regarding this.

15.4 FAT shall include simulation of operational field conditions and test forfunctional adequacy. Besides all routine, and acceptance tests specified byapplicable codes and standards shall be performed on the complete

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applicable codes and standards, shall be performed on the complete

system.

15.5 For bought out items, the routine and acceptance tests shall be conductedat the respective equipment manufacturer’s works.

15.6 At the time of inspection, vendor shall produce original of all the type testcertificates, test and approval certificates for hazardous area equipmentfrom testing and approving authority and any other certificates as requiredfrom statutory authority for the review of inspectors.

15.7 Vendor shall submit a SAT procedure for GAIL/ Purchaser’s approval. Allequipment and systems shall be tested at site as per the approved SATprocedure

15.8 SAT shall be conducted by vendor after the entire fire alarm system is

The equipment may be stored outdoors for long periods before erection.The packing shall be completely suitable for outdoor storage in areas withheavy rains! high ambient temperature.

17 INSTALLATION AND COMMISSIONING

Where installation of the system is included in the scope of the vendor,

vendor shall arrange all necessary manpower and equipment required forthe same. Commissioning of the complete system is to be carried out byvendor in all cases irrespective of whether the installation was performed byvendor or not. All tools, test equipment etc. for the successfulcommissioning of the system shall be arranged by the vendor. Only thecabling specifically excluded from vendor’s scope shall be installed byothers. However, termination at panels for purchaser’s cables shall be doneby the vendor.

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by the vendor.

18 TRAINING

The vendor shall provide, free of cost, comprehensive training toPurchaser’s personnel on various operation and maintenance aspects of theFire Alarm system as agreed during ordering

INSPECTION TEST PLAN FOR BATTERY CHARGERS

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NEW DELHIINSPECTION TEST PLAN FOR BATTERY CHARGER

S-07-06-001 Page 1 of 3


1. SCOPE:This Inspection Test Plan covers the minimum testing requirements of Battery Chargers ,Distribution Boards and Cell boosters.

2 REFERENCE DOCUMENTS:1) Standard specification S-07-02-019 and standards referred there in.2) 2) Job specifications I approved documents.

1.0 INSPECTION AND TEST REQUIREMENTS:

SCOPE OF INSPECTIONSTAGE CHARACTERISTICS

QUANTUMOF CHECK RECORD

Sub Vendor VENDOR GAIL

1 Incoming Material

like Fabricateditems, Electroniccomponents,PCBs, Relays,IndicatingInstruments,Switches, MCCBs,Contactors, etc

Visual, Dimensional, operational checks etc asapplicable

100%

Supplier’s TCI Vendor’sTestRecords

- W W

2 PCBs & Electroniccomponents subassemblies

Burn-in Test for 96 hours at 50o

C 100%Vendor’sTest Records

- W W

3 Battery Charger Assembly

ACCEPTANCE TESTS:• Visual check including layout, Tag plates, Paint

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S-07-06-001 Page 2 of 3


Assembly Visual check including layout, Tag plates, Paint

shade, Bus marking, Identification and location of components etc.a Dimension check including operational height,Bus size, Clearances etc.a Bill of material! Make of Components.• Full Load test for 16 hours with minimum 8hrs for each Charger. Temperature rise for criticalcomponents would be recorded during this test.• Charger testing at constant output voltage in floatand boost charge mode, including measurement of AC phase voltage, frequency, current, power, DCoutput voltage, current and output voltage ripple atnominal AC input voftage at zero, 50% and 100%

of rated output current. Measurement shall be

100%

Vendor’sTest RecordsInspectionWitnessRecord

- W W

repeated at 100% full load current at 90% and110% of nominal AC supply voltage.• Charger testing under constant output currentlimiting condition in float and boost mode, includingmeasurement of DC output voltage and current withDC output voltage varying between zero and setvalue corresponding to constant voltage operation.Vendor’s Test• Proper functioning of all measuring Records I

instruments, alarms, indications, protection 100%Inspection W W and controls as per requirement.Witness

• Parallel operation of both chargers Recordincluding load sharing and automatic isolation of faulty charger.• Charger Efficiency and Voltage regulation test.• Dynamic Response test for step load up to50% of rated output.• Audible noise test.• Insulation resistance before and after HV test for power, control and auxiliary circuits.• High voltage withstand test for power, control andmain circuits.

Vendor’sTest RecordsInspection

WitnessRecord

- W W

Vendor’sTest Records

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S-07-06-001 Page 3 of 3


4 D.C DistributionBoard

Visual, Dimensions, Feeder Tag plates, Vendor’sTest Functional checks, IR and HV test

100%Test RecordsInspectionWitnessRecord

- W W

5 Cell Booster Visual, Dimensions, Feeder Tag Plates, FunctionalTest, IR & HV Test

100%

Vendor’sTest RecordsInspectionWitnessRecord

- W W

6 Battery Charger,Distribution Board,Cell Booster

Internal Test Reports 100% Vendor’sTest Records - - R

Notes:

1. W – Witness R – Review 2. Vendor to submit these reports before offering items for inspection

INSPECTION AND TEST PLAN FOR MEDIUM AND HIGH

VOLTAGE CABLES & ACCESSORIES

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NEW DELHI

INSPECTION AND TEST PLAN FOR MV/HV CABLES AND

ACCESSORIES S-07-06-002 Page 1 of 3


1.0 SCOPE:

This Inspection and Test Plan covers the minimum testing requirements of PVC, XLPE insulated cables and cable jointing/terminating

accessories for high and medium voltage systems.

2.0 REFERENCE DOCUMENTS:

P0/PR / Standards referred there in /Job specifications / Approved documents.


SCOPE OF INSPECTIONSl

NoSTAGE/ACTIVITY CHARACTERISTICS

QUANTUM OF

CHECK RECORD SUB

SUPPLIER SUPPLIER GAIL/TPIA

1.

Incoming raw material

like Copper,

Aluminum, PVC,XLPE, Galvanized

Armour.

Purity, Dimensions, Physical and Chemical Properties. 100%

Material Test

Certificates/

supplier’s TestRecords/ Third

Party Lab

P P/R R

2. Finished Cable

Visual, Drum details, Size, Ends Capping, Marking on outer

sheath (such as Incremental Length, Voltage grade.

manufacturer’s name), Colour coding, etc.

100% for Drum

details and

Sample drums for balance details

Supplier’s Test

RecordsP W

Routine Checks:

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3. Finished Cable

Routine Checks:

Conductor Resistance.High Voltage

Partial Discharge (for XLPE only)

100%Supplier’s TestRecords

P W/R

4.Finished Cable

(Acceptance tests)

Dimension checks — overall dia, over/under armour, thickness

of insulation, sheath, copper screen dimension, etc.

Conductor Resistance

Insulation resistance / Volume resistivity

High Voltage testsPartial Discharge(for XLPE)

Hot_Set_(for_XLPE_insulation)Tests on Conductor as applicable

Tests on PVC/XLPE Insulation & Sheath*

Armour Galvanization - dip test

As per sampling

plan

Inspection Test

Records- P W

Volume resistivity, Insulation resistance

Tensile and elongation (without ageing)

5.Finished Cable (Special

tests)

Flammability test as per IS 10810 part 61

Flammability test as per IS 10810 part 62Accelerated water absorption test as per NEMA(Electrical

method) #

Test for resistance to Ultra Violet Radiation #Oxygen Index

Rodent & Termite repulsion check

Drum length !surface finish check by re-winding

1 sample/size/lot

1 sample /order 1 sample/order

1 sample/ order

1 sample/size lot1 sample! lot

1 or 2 drums per

lot

Inspection test

records

6.Finished Cable (Type

tests **)

Dielectric Retention.Type tests on PVC insulation and Sheath

High Voltage test (Water Immersion)Dielectric power factor tests as function of voltage, temperature.

(XLPE cables)

Heating cycle test (XLPE Cables)

Impulse withstand test (XLPE cables)

SampleSupplier’s Test

RecordsR

7. Cable accessoriesVisualDimensions

Type tests** as per IS 13573

SampleSupplier’s TestRecords

P R

# In case TC (not older than one year) from independent test lab is available & type of compound used is same then the same may be accepted.

* Hot deformation Heat shock and Shrinkage tests on insulation & sheath (One sample/Lot) shall be witnessed by GAIL all other tests as per IS-583l 7098 shall be carried out by supplier and test reports

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Hot deformation, Heat shock and Shrinkage tests on insulation & sheath (One sample/Lot) shall be witnessed by GAIL, all other tests as per IS 583l, 7098 shall be carried out by supplier and test reports

shall be reviewed by GAIL.** Supplier to submit Routine, Acceptance and Type test reports before offering items for inspection to GAIL.

Legends: CCE or CCOE-Chief Controller of Explosives, DT- Destructive Testing, HT- Heat treatment, H- Hold (Do not proceed without approval), IBR-Indian Boiler Regulations, ITP Inspection and Test Plan, ,NDT- Not Destructive Testing,, P — Perform, PESO-Petroleum and Explosives safety Organisation, P0- Purchase Order, PR-Purchase Requisition, PQR Procedure Qualification Record, QAP-Quality Assurance Plan,

Random -10% (min.l no.) of each size and type of Bulk item, R-Review, RT- Radiography Testing, RW-Random witness, TC-Test Certificate TPI or TPIA- Third Party Inspection Agency, VDR- Vendor DataRequirements, WPS- Welding Procedure Specification, WPQ- Welders Performance Qualification, WWitness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable):Wherever W/R or HJW is indicated, Inspection Engineer shall decide the option to be exercised for the particular stage and supplier 1 Supplier’s in house procedures may be accepted in case TPt/GAIL is satisfied with adequacy of procedures to comply with Purchase Order/Specifications requirements. In case of non availability of suitable

procedures, fresh procedures may be qualified under TPI/GAIL witness.In ease of conflict between purchase specification, contract documents and ITP, more stringent conditions shall be applicable.This document describes generally the requirements pertaining to all types of the item. Requirements specific to P0 and the item are only applicable.Acceptance Norms for all the activities shall be as per P0/PR/ Standards referred there in] Job specifications/Approved documents

INSPECTION AND TEST PLAN FOR FIRE DETECTION AND

ALARM SYSTEM

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NEW DELHIINSPECTION AND TEST PLAN FOR FIRE ALARM SYSTEM

S-07-06-003 Page 1 of 4


1.0 SCOPE:

This Inspection and Test Plan covers the minimum testing requirements of automatic and manual Fire Alarm System incorporating detectors, Data Gathering Fire

Alarm Panels(DGFAP) and central fire ala rm panels(conventional or computer based).

1.0 REFERENCE DOCUMENTS:

P0/PR / Standards referred there in /Job specifications / Approved documents.


SCOPE OF INSPECTIONSl

No

STAGE/ACTIVITY CHARACTERISTICSQUANTUM OF

CHECK

RECORD SUB

SUPPLIER SUPPLIER

GAIL/TPI

A

1.

Incoming Material like Fabricated items,PCBs, Lamps, Push Buttons, Fire detectors,,

Temp detectors, UV, IR, Ionization type,linear beam type and optical type detectors,

Manual call points, Sirens, Annunciators,

Relays, Switches, Battery, battery charger,

Exit Signs, Flashing Lights, Release andInhibit switches, Zener Barriers, ShortCircuit/fault Isolator, etc.

Visual, Dimensional, Operational checks as

applicable, Matching of detectors with givenspecifications, Statutory body certification, Make

of Items, etc.

100%

Sub

supplier’s TC/ Supplier’s

Test Records

P W/R R

2. PCBs Burn-In Test of PCBs for 96 hrs at 50 deg C 100%Supplier’s

Test RecordsR

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S-07-06-003 Page 2 of 4


3Conventional Fire Alarm System consistingCentral, Zonal and Repeater Fire Alarm

Panels (Final Inspection)

ACCEPTANCE TESTS:o Visual check including GA, layout, Tag plates,

Paint shade, Panel gasketing, Identification and

location of components ,Mimic layout, Check of specifications of all types of detectors w.r.t

data sheets, etc

o Bill of material/Make of components check

o Quality of lacquering and Inter changeability of PCBs

o Verification of cable termination arrangement.

o Operation check of scheme, Mimic lamps by

simulating fire, cable fault conditions w.r.t

different type of detectors.

100%InspectionWitness

Record

- P H/W

o Check of detector operation w.r.t loop

impedance ( L, R, C parameters given in data

sheet for the cable)

o Operation checks of scheme, mimic lamps w.r.t

different type of release and inhibit switch thro’output relays.

o Simulation of all Alarms

o Auto & Manual release operation

o Fail safe operationo Verification of Battery type and Capacity

o Operation check for Break glass assemblyo Operation check on applicable accessories like

Exit Signs, Beacon Lamps, Siren, Release and

inhibit switches, Short circuit/fault isolator

o Provision of cable glands and earthing

ACCEPTANCE TESTS:

o Visual check including GA, layout, Tag plates,Paint shade, Panel gasketing, Identification and

location of components , Check of

specifications of all types of detectors w.r.t datasheets, Check of specifications for Zener

barriers ,VDU, Keyboards, Printers etco Bill of material/make of Component check

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S-07-06-003 Page 3 of 4


4

Computer aided Fire Alarm Systemconsisting of Central Fire Alarm Panel, Datagathering Fire alarm Panel (DGFAP) and

Repeat Fire Alarm Panel. (Final Inspection)

o Bill of material/make of Component check

o Verification of cable termination arrangement

in DGFAP panels

o Operation check of scheme by simulating fire,

cable fault conditions w.r.t different type of detectors.

o Check of detector operation w.r.t loopimpedance ( L, R, C parameters given in data

sheet for the cable)

o Operation checks of scheme w.r.t different typeof release and inhibit switch, interfacing with

suppression/clean agent systems.

o Simulation of all Alarms

o

Auto & Manual release operation

100%InspectionWitness

Record

- P H/W

o Fail safe operation

o Redundancy checks

o Check of functions, commands ,reports,operator level access, Supervisor level access

on monitor, Graphics

o CFAP communication with all devices

o Changing Address of detectors

o Verification of Battery type and Capacity

o Operation check on applicable accessories likeExit Signs, Beacon Lamps, Siren, Release and

inhibit switches, Short circuit/fault isolator

Fire Alarm system & Accessories

Submission of Certificates*

o Certificate of Statutory testing authority like

FM, UL, BASEEFA, UL, CMRI etc. for

DGFAP, Detectors and other accessories

o Certificate of Statutory approval authority

like CCOE/PESO, DGFASLI, etc. (for Flameproof type items only)

o Valid BIS license( for indigenous flameproof

equipment)

Samples

Certificatesfrom

Statutory

bodies

R R

* - Supplier to submit these certificates before offering items for inspection to GAIL

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S-07-06-003 Page 4 of 4


Legends: CCE or CCOE-Chief Controller of Explosives, DT- Destructive Testing, HT- Heat treatment, H- Hold (Do not proceed without approval), IBR-Indian Boiler Regulations, ITP-Inspection and Test Plan, ,NDT- Not Destructive Testing, , P — Perform, PESO-Petroleum and Explosives safety Organisation, P0- Purchase Order, PR-

Purchase Requisition, PQR- Procedure Qualification Record, QAP-Quality Assurance Plan, Random -10% (mm. 1 no.) of each size and type of Bulk item, R-Review, RT-

Radiography Testing, RW-Random witness, TC-Test Certificate TPI or TPIA- Third Party Inspection Agency, VDR- Vendor Data Requirements, WPS- Welding Procedure

Specification, WPQ- Welders Performance Qualification, W- Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable):

1. Wherever W/R or HJW is indicated, TPIJGAIL Inspection Engineer shall decide the option to be exercised for the particular stage and supplier.

2. Supplier’s in house procedures may be accepted in case TPI I GAIL is satisfied with adequacy of procedures to comply with Purchase Order/Specificationsrequirements. In case of non Availability of suitable procedures, fresh procedures may be qualified under TPI / GAIL witness.

2. In case of conflict between purchase specification, contract documents and ITP, more stringent conditions shall be applicable.2. This document describes generally the requirements pertaining to all types of the item. Requirements specific to P0 and the item are only applicable.

3. Acceptance Norms for all the activities shall be as per P0/PR/STANDARDS referred there in /Job Specification /Approved Documents.

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NOTES:

1. ALL DIMENSIONS ARE IN METERS UNLESS OTHERWISE MENTIONED.2. THE AREA CLASSIFICATION CONFORMS TO THE LATEST ISSUE OF IS 5572, INDIAN PETROLEUM

RULES, OISD STD 113, OIL MINES REGULATIONS/DGMS GUIDELINES (FOR PROJECTS UNDER GGMS JURISDICTION) AND RECOMMENDATIONS OF PROCESS LISENCOR.

3. AREA WITHIN 1.50M (EXTENDING IN ALL DIRECTIONS) OF SAFETY VENTS, PRODUCT SAMPLING

LOCATIONS, PROXESS WATER DRAINS, OILY SEWER VENTS, INSPECTION HATCHES, DISCHARGEORIFICE OF FIXED LIQUID LEVEL GAUGES, ROTARY OR DIP GAUGES, FILLER OPENINGS, SHALL BE

CLASSIFIED AS ZONE 1. FURTHER AN AREA FROM 1.5M TO 3.0 M (EXTENDING IN ALLDIRECTIONS) FROM VENTS SHALL BE CLASSIFIED AS ZONE 2. HOWEVER THE VENTS OR DRAINS

BLANKED DURING NORMAL OPERATION AND USED ONLY WHEN THE PLANT IS DEPRESSURISED OR

UNDER SHUTDOWN, SHOULD NOT BE REGARDED AS AN OPERATIONAL VENT OR DRAIN OR

SOURCE OF HAZARD.

4. OPEN TRENCHES, PITS OR SUMP BELOW GRADE WITHIN ZONE 2 AREA SHALL BE CLASSIFIED AS

ZONE 1 AREA.

5. IN CASE OF PIPELINE HANDLING FLAMMABLE MATERIAL, WHERE WELL MAINTAINED VALVES,

FITTINGS AND METERS ARE INSTALLED IN VENTILATED AREAS OR PIT, THE EXTENT OF ZONE 2

AREA ABOVE GROUND SHALL BE CONSIDERED AS 4.0M IN ALL DIRECTIONSFROM THE POSSIBLESOURCE OF HAZARD, ALTHOUGH THE PIT ITSELF SHALL BE CLASSIFIED AS ZONE 1 AREA.

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6. GAS GROUPS ARE AS PER IS 9570.

7. ROADS FULLY/PARTIALLY COVERED UNDER HAZARDOUS AREA SHALL BE BARRICADED FOR VEHICULAR MOVEMENT.

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