project name: epcc 03 package petrochemical fluidized

ALL RIGHTS RESERVED

THIS DOCUMENT AND ANY DATA AND INFORMATION CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF L&T HYDROCARBON ENGINEERING (LTHE) AND THE COPYRIGHT THEREIN IS VESTED IN LTHE NO PART OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY PURPOSE WHATSOEVER, EXCEPT WITH THE PRIOR WRITTEN PERMISSION OF LTHE.

PROJECT NAME: EPCC 03 Package – Petrochemical Fluidized Catalytic Cracking Unit and Propylene

Recovery Unit for Rajasthan Refinery Project (RRP) of M/s HRRL, BARMER, RAJASTHAN, INDIA

L&T- CHIYODA LIMITED

Title : PURCHASE SPECIFICATIONS FOR PNEUMATIC BLOWNDOWN VALVES Doc. No. : B224-FCC-LT-111-MS-SP-VD09-13550

Rev. No.: 00

Page No.: 1 of 314

OWNER : HPCL RAJASTHAN REFINERY LIMITED (HRRL) PMC : ENGINEERS INDIA LIMITED (EIL) UNIT : 111 PMC JOB NO. : B224 LTHE JOB NO. : 600457 EQUIPMENT TAG : 111-LZ-1102 EQUIPMENT DESCRIPTION : FLUE GAS COOLER VENDOR NAME : THERMAX BABCOCK & WILCOX ENERGY SOLUTIONS PRIVATE LIMITED. VENDOR P.R. NO. : B224‐FCC‐LT‐111‐MS‐PR‐0012 VENDOR DOCUMENT NO. : Z29-WH-CS-209259

DOCUMENT SUBMISSION STATUS – LTHE/VENDOR

REVIEW STATUS - EIL

LTHE EIL

DOC. CATEGORY: (USE TICK MARK)

R I

CODE 1 – NO COMMENTS. PROCEED WITH MANUFACTURE / FABRICATION / CONSTRUCTION AS PER THE DOCUMENT.

CODE 1 – NO COMMENTS. PROCEED WITH MANUFACTURE / FABRICATION / CONSTRUCTION AS PER THE DOCUMENT.

ISSUED FOR CODE 2 – PROCEED WITH MANUFACTURE / FABRICATION / CONSTRUCTION AS PER COMMENTED DOCUMENT. REVISED DOCUMENT REQUIRED.

CODE 2 – PROCEED WITH MANUFACTURE / FABRICATION / CONSTRUCTION AS PER COMMENTED DOCUMENT. REVISED DOCUMENT REQUIRED.

INFORMATION

REVIEW

CONSTRUCTION

AS BUILT

CODE 3 – DOCUMENT DOES NOT CONFORM TO BASIC REQUIREMENTS AS MARKED. RESUBMIT FOR REVIEW CODE R – DOCUMENT IS RETAINED FOR RECORDS. PROCEED WITH MANUFACTURE / FABRICATION

CODE V – VOID

CODE 3 – DOCUMENT DOES NOT CONFORM TO BASIC REQUIREMENTS AS MARKED. RESUBMIT FOR REVIEW CODE R – DOCUMENT IS RETAINED FOR RECORDS. PROCEED WITH MANUFACTURE / FABRICATION

CODE V – VOID

NAME DISCIPLINE SIGN. DATE

NAME DISCIPLINE SIGN. DATE

00 Issued for Approval PGB SA RS - - 14-10-2021

Revision No.

Description Prepared

by Reviewed

by Approved

by Approved

Date Approved

by Approved

Date

ALL RIGHTS RESERVED






Rev. No.: 00

Page No.: 2 of 314

REVISION HISTORY SHEET

REV. NO. REV. DATE REVISED PAGE REVISION DESCRIPTION

00 14-10-2021 - First Issue

ALL RIGHTS RESERVED






Rev. No.: 00

Page No.: 3 of 314

INDEX

1. PURCHASE SPECIFICATIONS FOR MOTORISED VALVES 4 - 5

PARTS CATALOG

Customer: : L&T A/C HRRL Date : 01-06-2021

Consultant : EIL Made by : PGB

OC No. : PL1961 App. By : SA/RS

Specification No : Z29-WH-CS-209259 Rev. no. : 02

S.No Description Rev

1.0 GENERAL

1.1 Part name Pnuematic operated Angular CBD valve

1.2 Brief Description of the system Pnuematic operated Angular CBD valve to be installed for FGC

1.3 Installation Unsheltered Outdoor installation

1.4 Ambient Temperature 48.2 / 28 / 3.4 °C (Max / Nor / Min)

1.5 Relative Humidity 100 / 45 / 3 % (Max / Nor / Min)

1.6 Site location Pachpadra /Barmer [Rajasthan/India]

1.7 Description of site Corrosive

1.8 Altitude above Mean Sea Level 104 - 106 m above mean sea level

1.9 Area Classification Zone-2, Gas Group-IIA/IIB, Temp Class T3

1.10 Electric motor design temperature 45 °C

2.0 DOCUMENTS REQUIRED FROM VENDOR

2.1 General arrangement drawings.

2.2 Manufacturer's catalogue giving full details of the valves and actuators.

2.3 Wiring and termination diagram if applicable

2.4 Actuator details

2.5 Material test certificates and Final inspection certifications.

2.6 Lubrication schedule

2.7 6 sets of catalogues & 6 sets of Installation / O & M Manuals.

2.8 IBR certificates in Form IIIC with attachments, if any.

2.9 Vendor to give valve calculation indicating selected CV & CV for min., normal, max. flow .

3.0 TESTS TO BE CARRIED OUT BY VENDOR AT WORKS AND TEST CERTIFICATES REQUIRED

3.1 Seat Leakage test

3.2 Sub-vendors conformity certificates

3.3 Material test certificates

3.4 Valves are to be certified for design pressure

3.5 Vendor to stand guarantee for Design, material & workmanship

3.6 Vendor to stand guarantee for Sealing efficiency required.

3.7 Vendor to stand guarantee for power consumption committed.

3.8 Tests will be witnessed by Thermax / Client

5.0 NOTES:

4.1 Vendor to specify the max. pressure drop across the valves.

4.2 Vendor to furnish motor technical data, indicating FLC, max. current rating, rpm etc. if applicable

4.3 Vendor to submit typical wiring diagram if applicable

4.4 Vendor to furnish Interfacing diagram between MCC feeder & actuator if applicable

4.5 Vendor to furnish typical cable schedule between MCC & Actuator for all valves if applicable

4.6 Vendor to show the tripping contact in the wiring diagram.(tripping of motor because of over heated) if applicable

4.7 * Marked items shall be furnished by vendor

4.8 Please refer attached specifications for Electrical motor operated valves & Actuators if applicable

4.9 The valve vendor has to select the trim for the pressure and temperature as mentioned in the datasheets.

4.10 Vendor to follow the Approved QAP & ITP

4.11 Vendor to comply to all the relevant tender specifications attached along with this specification

5.0 SCOPE OF SUPPLY:

5.1 Valves with pnuematic actuators with necessary accessories.

5.2 Proper packing as per attached specification

5.3 Painting as per attached specification

6.0 SPARES FOR TWO YEARS OPERATION & MAINTENANCE :

6.1 Commission Spare:- Vendor to recommend, Item wise price list and shall be included in base offer

6.1 Two years operation spare :-Vendor to recommend, Item wise price list & quote separately.

7.0 EXCLUSIONS:

7.1 Piping, Valve supports, insulation, electric cabling, instrument cabling.

7.2 Site erection & commissioning.

8.0 LIST OF ATTCHEMENT

8.1 Attachment-01 D86-WH-CS-208455 - Rev-0 - EMS1

8.2 Attachment-02 D8A-WH-CS-208454 - MOV Actuator Specifications - R0

8.3 Attachment-03 B224-000-79-41-PLS-01_Job spec_for Surface Preparation & Coating

8.4 Attachment-04 6-81-0001_Rev.3_Spec_PMI_At_Supplier_Works

8.5 Attachment-05 Annexure L_ Packing Marking

8.6 Attachment-06 6-51-0091_Specification for MOV

8.7 Attachment-07 PMS

8.8 Attachment-08 VMS

8.9 Attachment-09 B224-111-16-51-SP-7203-Job specification-Instrumentation

8.10 Attachment-10 6-44-052_Rev 7

8.11 Attachment-11 6-81-1091_Rev 2

8.12 Attachment-12 B224-FCC-LT-111-MS-PR-0012

THERMAX BABCOCK & WILCOX ENERGY SOLUTIONS PVT LIMITED

PL1961 Page 1 of 2 Z29-WH-CS-209259 R01

Customer: : L&T A/C HRRL Date : 01-06-2021

Consultant : EIL Made by : PGB

OC No. : PL1961 App. By : SA/RS

Specification No : Z29-WH-CS-209259 Rev. no. : 02

8.0 Rev

DESCRIPTION UNIT 1 Remark

8.1 Location Continuous Blow Down valve8.2 Tag no. of Main valves --- HV-186018.3 Tag no. of Integral bypass NA8.4 Quantity per boiler Nos. 18.5 No.of boilers Nos. 18.6 Total Quantity for 1 boilers Nos. 18.7 Part Number PL1961Z29209259018.8 Pipe size mm NB 258.9 Pipe schedule XS8.10 Pipe pressure class # 800

8.11 Pipe material of construction SA-106 Gr. B

8.12 End connection of valve SW

8.13 Valve certification IBR

8.14 Function of main valve Flow regulation

8.15 Integral bypass valve Not required

8.16 Function of bypass valve NA

8.17 Type of main valve Angular Blow Down valve

8.18 Type of bypass valve NA

8.19 Actuation of main valve Pneumatic operated

8.20 Actuation of bypass valve Not required

8.21 Required

8.22 Not required

8.23 NA

8.24 NA

8.25 Regulating duty

8.26 Paint finish

8.27 Fail Safe Position N.A

8.28 Total Weight Kg By vendor

8.29 Voltages available at site

Operating conditions

8.30 Medium BOILER WATER

8.31 Flow Normal kg/hr 1,361

8.32 Flow (Maximum) kg/hr 3,120

8.33 Operating temperature °C 261.0

8.34 °C 300

8.35 Kg/Cm2g 48.3

8.36 Kg/Cm2g 57.5

8.37 Inlet pressure (normal) Kg/Cm2g 48.3

8.38 Outlet pressure (normal) Kg/Cm2g 5.0

8.39 Service details Flow regulation

8.40 Period of service ContinuousMaterial of construction (* Vendor to mention / confirm)

8.41 PMS piping Class applicable D2A

8.42 Body AS PER PMS

8.43 Other parts AS PER PMS

Actuator details:

8.42 Type of actuation Pneumatic Actuator

8.43 Actuator enclosure type As per attached Specs

8.44 Torque switch (Open direction) Required

8.45 Torque switch (Close direction) Required

8.46 Limit switch ( Open direction) Required

8.47 Limit switch ( Close direction) Required

8.48 Remote operation ( Open) Required

8.49 Remote operation (Close) Required

8.50 Position feedback transmitter Required

8.51 Required

8.52 Overload protection of Electric motors Required

8.53 Travel adjustment Required

8.54 Make, Model No. & type * As per App. Vendor list

8.55 kW rating and Power factor *

8.56 Rated voltage

8.57 Starting current & torque *

8.58 Running current *

8.59 Seating current *

8.60 Valve operating speed *

8.61 Opening & closing time limit *

8.62 Limit switch & torque switch details *

8.63 No. of normally closed & normally *

Open contacts for each Limit switch

8.64 Make of actuator *

Note : 1. * - Vendor to confirm, $ - Client to confirm,

9.0 Revision Notes : 01 Valve actuiator changed to Pneumatic Actuator

02 Typo error updated

THERMAX BABCOCK & WILCOX ENERGY SOLUTIONS PVT LIMITED

Refer attached EMS-1

No. of start and stop per

hour

Modulating type Actuator for

main valveON-OFF type Actuator for

main valveModulating type Actuator for

bypass valve

ON-OFF type Actuator for

bypass valve

Manual override

Operating pressure

Design pressure

Design temperature

Refer EMS-1

PL1961 Page 2 of 2 Z29-WH-CS-209259 R01

PROJECT :HPCL RAJASTHAN REFINERY LTD PR CODE:PL1961 CONSULTANT: EIL

MADE BY CHKD.BY APPD. BY DATE DOC. NO.

REV

VPK PCR SJP 21.4.2021 D8A-WH-CS-208455 0

PROJECT NO : PL1961

PRODUCT : EPCC 03 Package – Petrochemical Fluidized Catalytic Cracking Unit and Propylene Recovery Unit for Rajasthan Refinery Project (RRP) of M/s HRRL, BARMER, RAJASTHAN, INDIA

CUSTOMER

HPCL RAJASTHAN REFINERY LIMITED (HRRL)

CONSULTANT

ENGINEERS INDIA LIMITED (EIL)

OEM M/s. TBWES BABCOCK & WILCOX ENERGY SOLUTIONS PVT. LTD. PUNE

DWG/ DOC. TITLE EMS1 Specifications

DWG/DOC. NO. D86-WH-CS-208455 REV. NO. 00

REVISION:

Project :HHRL RAJASTHAN REFINARIESConsultant : EILProject No:- PL1961 Electrical/System requirements for Motor Selection (EMS1) LV MOTOR

Date :21.4.21

Sr. No ParametersRequirement Remarks

Vendor Compliance

A SITE CONDITIONS1 Design Ambient in ° C 452 Altitude Above MSL in mtrs < 10003 Relative Humidity (Max) 100%4 Location OUTDOORB AREA CLASSIFICATION HAZARDOUS AREA

HAZARDOUSZONE-2, GAS GROUP IIA, IIB,

TEMP CLASS T3

C SUPPLY SYSTEM1 System Voltage, Frequency, Phases 415, 50Hz, Three2 Voltage Variation ± 103 Frequency Variation ± 34 Combined Variation 10%D Motor Details1 Type Squirrel cage IM2 Duty S13 Insulation Class,Temp rise F temp rise limited to class B4 Synchronous Speed at rated condition As per Vender Std5 Speed Variation NA

5.a Speed Variation by NA5.b Drive Control CONSTANT SPEED

6 Winding TreatmentTropicalised Winding – Vacuum

ImpregnatedRefer EIL Specs.

7 Type of Starting DOL Refer Notes8 Direction Of Rotation from DE Bi-directional9 Earth Terminals 2

10 Greasing Arrangement AS PER EIL SPECS11 Main Name Plate SS SERIES 30012 Aux Name Plate Required13 Type of Cooling TEFCE ENCLOSURE

1 Protection Class Ex-d / Ex-d'e

1. Motors for Soot blowers : Ex-d2. Motors for Seal air blowers and other pumps : Ex-deShall be confirmed during Detailed Engineering

2 Degree of Protection IP-55 with Canopy

F TERMINAL BOXAt right hand side as viewed

from Drive end of Motor

1 Terminal Nos6 Nos for 2.2 KW & above

3 Nos below 2,2 KW2 Size of Terminals AS PER EIL SPECS3 Separate TB for Space Heater if applicable Required4 Separate TB for Thermistor if applicable NA5 Separate TB for vibration probes if applicable NAG SPECIAL REQUIREMENT1 Space Heater (240 VAC) Required above 30 KW2 PTC Thermistor NA3 RTD / BTD NA

H PAINT - Type / Shade632 of IS 5 / RAL7035

Shall be confirmed during detailed engineering

I CABLE1 Type XLPE, FRLS2 Cable Lugs Tinned Copper3 Cable Glands DC- Ni plated Brass Double Compression typeJ DRAWINGS TO BE SUBMITTED BY VENDOR1 Data Sheet

2 GA drawings for Motor & all TB's

3 TS curve at 80 %,100 % & 110 % RV

ELECTRICAL / SYSTEM REQUIREMENTS FOR MOTOR SELECTION (EMS1)

PRED.BY CHKD.BY APPD.BYVPK PCR SJP Document No : D86-WH-CS-208455 Rev- 0

Project :HHRL RAJASTHAN REFINARIESConsultant : EILProject No:- PL1961 Electrical/System requirements for Motor Selection (EMS1) LV MOTOR

Date :21.4.21

4Starting Current V/s Time Curve at 80 %,100 % & 110 % RV

5Starting Current V/s Speed Curve at 80 %,100 % & 110 % RV

6Thermal Withstand Curve (Hot & Cold) at 80 %,100 % & 110 % RV

7 Efficiency,Power Factor,Current,Slip V/s Load CurvesK PERFORMANCE PARAMETER BY VENDOR1 Make

2 Enclosure TEFC3 Output at Design Amb. kW4 Full Load Current

5Acceleration time to Rated speed at 80 %,100 % & 110 % RV

6 Frame size & Weight7 Rated Speed at rated conditions8 Lock rotor current in % of Full Load Current9 Starting Power Factor

10 Temp rise over design ambient °C11 No Load Current12 Starting Torque13 Stalling Torque14 Efficiency @ 50 % of Load

75% of load100% of load

15 Power Factor @ 50 % of Load75% of load100% of load

16 Number of successive HOT & COLD Starts

17Safe stall time with Motor in HOT conditionat 80% & 100% voltage

18 Space Heater Rating & details19 Embedded detectors details20 Stator Winding Connections21 Type of bearing & Lubricant22 Test Certificate Details Vendor to submit

L SPARE1 LV Motor AS PER EIL SPECS

1

2

3

4

5

6

7

8

9

10

11

Vendor shall Comply to below listed documents: i) B224-111-80-43-DS-1004 - RevA - STD Specs for Centrifugal Pump.ii) Annexure-1 to B224-000-16-50-DS-1016 - Allowable limits of Vibration in Motorsiii) B224-FCC-LT-111-MS-PR-0012 - Document Schedule for LV motors.iv) 6-51-0031 Rev. 6 Motor Specifications v)6-81-1064 Rev. 0 - ITP MV INDUCTION MOTOR

Deviations to the specifications / design if any to be furnished clause wise by vendors along with quotation .for purchaser's approval with statement of compliance except deviations.

Safe stall time with Motor in HOT condition at 80% & 100% voltage

All LV motors shall be Energy Efficient type (IE2) as per relevant IEC, as per EIL Specs.

Motors shall be flameproof with certification as mentioned above in Point - E1

Testing will be done as per EIL approved QAP

Vendor to submit completely filled EIL & Vendor data sheet during submission.

Vendor To Submit Point Wise Compliance To Customer & TBWES Specs In Offer Stage

For any ambiguity in specification, customer specification will be governing.

Refer EMS-2 For Type Of Starting & Cable Size

Notes:-

Hot start 3, Cold start 4 per hour for LT motors (upto 160KW and below)

PRED.BY CHKD.BY APPD.BYVPK PCR SJP Document No : D86-WH-CS-208455 Rev- 0

SS/SHIRALI KJ BRB SC

SD BRB JMS ND

Prepared by Checked by

Standards Committee Convenor

Standards Bureau

Chairman

Approved by

REVISED & ISSUED AS STANDARD 1 12.08.14 SPECIFICATION

0 20.04.09 ISSUED AS STANDARD SPECIFICATION

Rev. No Date Purpose

SPECIFICATION , k31 ENGINEERS FOR

$iga fèiffl-eg INDIA LIMITED ENERGY EFFICIENT MEDIUM IA Govt of Ind,a Underlaking)

VOLTAGE INDUCTION MOTORS

STANDARD SPECIFICATION No.

6-51-0064 Rev. 1

Page 1 of 12 1.12M ~I, 4,1 JvA,N,

d»71E. -gurg

Wf"kil 11

fqw SPECIFICATION

FOR ENERGY EFFICIENT MEDIUM VOLTAGE

INDUCTION MOTORS

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL — All rights reserved

Page 11676 of 13291

SPECIFICATION ■31 ENGINEERS FOR fa;1W5 w INDIA LIMITED

1.177T s'1,,,q51.7~1) ENERGY EFFICIENT MEDIUM VOLTAGE INDUCTION MOTORS


6-51-0064 Rev. 1

Page 2 of 12

Abbreviations: AL Aluminium BASEEFA British Approvals Service for Electrical Equipment in Flammable Atmospheres

BIS Bureau of Indian Standards

BS British Standards

CEA Central Electricity Authority

CIMFR Central Institute of Mines and Fuel Research

CPRI Central power research institute

CT Current Transformer

CU Copper

DGMS Directorate General of Mines Safety

DOL Direct On Line

EIL Engineers India Limited ERTL Electronics Regional test laboratory FM Factory Mutual

FRP Fiber Reinforced Plastic

IEC International Electro-technical Commission

IEEE Institute of Electrical & Electronics Engineers

IP Ingress Protection

IS Indian Standard

JEC Japanese Electro-technical Committee

KLPL Karandikar laboratories Pvt. Ltd.

LCIE Laboratoire Central des Industries Electriques

NEMA National Electrical Manufacturers Association

PESO Petroleum and Explosive Safety Organisation

PO Purchase Order

PVC Poly Vinyl Chloride

RPM Revolutions per Minute

UL Underwriter's Laboratories

VFD Variable Frequency Drive

VDE Verband Deutscher Elektrotechniker

Electrical Standards Committee

Convenor: Mr. B.R. Bhogal

Members: Ms. S. Anand Mr. Parag Gupta Mr. M.K. Sahu Mr. A.K. Chaudhary (Inspection) Ms. N.P. Guha (Project)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved

Page 11677 of 13291

SPECIFICATION --1 ENGINEERS FOR

igzx Wes w INDIA LIMITED INWR 290O 2151JY4M,



6-51-0064 Rev. 1

Page 3 of 12 ENERGY EFFICIENT MEDIUM

CONTENTS

1.0 SCOPE 4

2.0 CODES AND STANDARDS

4

3.0 GENERAL REQUIREMENTS 5

4.0 OPERATING CONDITIONS 5

5.0 PERFORMANCE 6

6.0 CONSTRUCTION DETAILS 7

7.0 MISCELLANEOUS ACCESSORIES 10

8.0 CRITICAL SPEEDS

10

9.0 PAINTING 10

10.0 INSPECTION AND TESTING 11

11.0 CERTIFICATION 11

12.0 PACKING AND DESPATCH 11


678 of 13291

SPECIFICATION ‘31 ENGINEERS FOR 02-'eg INDIA LIMITED

2.1~,151~11



6-51-0064 Rev. 1


1.0 SCOPE This specification covers the design, manufacture, testing, packing and supply of energy efficient-High efficiency (IE2) 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 Indian Standards) 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 Electrical insulation- Thermal evaluation and designation. IS - 2223 Dimensions of flange mounted AC Induction motors. IS - 2253 Designation for types of construction and mounting arrangement of

rotating electrical machines. IS - 2254 Dimensions of vertical shaft motors for pumps. IS - 2968 Dimensions of slide rails electric motors. IS - 4029 Guide for testing three phase induction motors. IS - 4889 Method of determination of efficiency of rotating electrical machines. IS - 6362 Designation of methods of cooling of rotating electrical machines. IS - 7816 Guide for testing insulation resistance of rotating machines. IS - 8223 Dimensions and output series for rotating electrical machines. IS - 8789 Values of performance characteristics for three phase induction

motors. IS - 9283 Motors for submersible pump sets. IS - 12065 Permissible limits of noise level for rotating electrical machines. IS - 12075 Mechanical vibration of rotating Electrical Machines with shaft

heights 56 mm and higher - measurement, evaluation and limits of vibration severity.

IS — 12615 Energy Efficient induction motors - Three phase squirrel cage. IS - 12824 Type of duty and classes of rating assigned to rotating electrical

machines. IS - 13529 Guide on effects of unbalanced voltages on the performance of three

phase cage induction motors. IS - 13555 Guide for selection and application of three phase induction motors

for different types of driven equipment. IS - 14568 Dimensions and output series for rotating electrical machines, frame

numbers 355 to 1000 and flange numbers 1180 to 2360. IS / IEC60079-0: Electrical apparatus for explosive gas atmospheres (General

requirements) IS/IEC-60079-1: Explosive atmospheres-Equipment protection by flame proof

enclosures "d". IS/IEC60079-2 : Explosive protection by pressurized enclosure "p". IS/IEC60079-7 : Explosive atmospheres-Equipment protection by increased safety —

IS/IEC-60079-15: Construction, test & marking of type of protection "n" electrical apparatus.

IS/ IEC: 60529 : Degree of protection provided by enclosures (IP Code)

IS/IEC 60034-1 : Rotating electrical machines:-Rating & Performance

IS/IEC-60034-5: Degrees of protection provided by the internal design of rotating electrical machines.


Page 11679 of 13291

SPECIFICATION k31 --1 ENGINEERS FOR 5g-u f&IJeg INDIA LIMITED

1.7E,, c-1,cnr1,711.3~11



6-51-0064 Rev. 1


IS/IEC 60034-8: Rotating electrical machines-Terminal marking and direction of rotation

IS/IEC 61241: Electrical apparatus for use in the presence of combustible dust

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

2.3 The motors shall also conform to the provisions of CEA regulations and other statutory regulations currently in force in the country.

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

2.5 In case of any conflict between requirements specified in various applicable documents, the most stringent one shall prevail. However, owner's decision in this regard shall be final and binding.

3.0 GENERAL REQUIREMENTS

3.1 The offered equipment shall be brand new with state of the art technology and proven field track record. No prototype equipment shall be offered.

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

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

4.0 OPERATING CONDITIONS

4.1 Ambient Conditions

Motors shall be suitable for operating satisfactorily in humid and corrosive atmosphere found in refineries, petrochemical, fertilizer and metallurgical plants. Service conditions shall be as specified in the motor data sheet. If not specifically mentioned therein, a design ambient temperature of 40 ° C and an altitude not exceeding 1000 meters above mean sea Level shall be taken into consideration.

4.2 Frequency and Voltage Variations

Unless otherwise agreed, motors shall be designed for continuous operation at rated output under the following conditions:

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) Motors shall be designed for direct-on-line starting or other method of starting as specified in datasheet.

b) Motors shall be designed for re-acceleration under full load after a momentary loss of voltage with the residual voltage being 100% and is in phase opposition to the applied voltage.

c) Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds under cold conditions and 8 seconds under hot conditions. In addition, Locked Rotor


Page 11680 of 13291

ENGINEERS SPECIFICATION

INDIA LIMITED FOR IA Govt of Indo Undertaking) ENERGY EFFICIENT MEDIUM



6-51-0064 Rev. 1

Page 6 of 12

$'fg-ar fafaie5 two,/, ‘151,19M,

withstand time under hot conditions at 75% & 100% voltages, shall be minimum 1.4 times the starting time at the corresponding voltage.

d) Unless otherwise specified, all motors shall be suitable for starting under specified load conditions with 75 % of the rated voltage at the motor terminals.

e) Motors shall be designed to allow the minimum number of consecutive starts indicated in Table below:

Starts Min. no. of consecutive starts No. 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

4.4 Direction of Rotation

Motors shall be suitable for either direction of rotation. In case unidirectional fan is provided for motors, direction of rotation for which the motor is designed shall be permanently indicated by means of an arrow. Directional arrow should be manufactured from corrosion resistant material. When a motor is provided with bi-directional fans, a double-headed arrow should be provided.

Normally, clockwise rotation is desired as observed from the driving (coupling) end, when the terminals UVW are connected to a power supply giving a terminal phase sequence in the order UVW. Counter-clockwise rotation of the motor shall be obtained by connecting the power supply to terminals so that the phase sequence corresponds to the reversed alphabetical sequence of the terminal letters. Ample space shall be provided at the terminal box for interchanging any two external leads for obtaining the reverse phase sequence.

5.0 PERFORMANCE

5.1 Motors shall be rated for continuous duty (Si), unless otherwise specified.

5.2 Unless specified, the starting current (as % rated current) shall be limited to maximum 600- 700% (based on number of poles and KW rating) as per IS 12615:2011, subject to IS tolerance

5.3 In particular cases, when the starting current is to be limited, care shall be taken such that the design values of torque meets the load requirement while at the same time complying to clause 4.3 above of this specification. Unless otherwise specified the minimum pull-up torque of motors, at rated voltage & frequency shall be minimum 50% of the rated full load torque.

5.4 In particular cases, when the starting with reduced voltage is specified, care shall be taken such that the design values of torque meets the load requirement while at the same time complying to clause 4.3 above of this specification.

5.5 Starting torque and minimum torque of the motor shall be compatible with the speed torque curve of the driven equipment under specified starting and operating conditions.

In case where characteristics of driven equipment are not available while selecting the motor, minimum starting torque shall be 110% of rated value for motors up to 75 kW and shall be 90% of rated value for motors above 75 kW.

5.6 The breakdown torque at the rated voltage shall be not less than 175% of the rated load torque with no negative tolerance. Unless otherwise agreed, the breakdown torque shall not exceed 300% of the rated load torque.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL -All rights reserved

Page 11681 of 13291

725165

Text Box

4

725165

Text Box

3

ENGINEERS SPECIFICATION

FOR INDIA LIMITED IA GoN oi Unde■tak.91 ENERGY EFFICIENT MEDIUM



6-51-0064 Rev. 1

Page 7 of 12

In case of motors driving equipment with pulsating loads (e.g. reciprocating compressors, crushers, ball mills) the minimum value of pull out torque at 75% of the rated voltage shall be more than the peak value of pulsating torque and the current pulsation shall be limited to 40%.

5.7 Motors fed by variable frequency drive shall additionally meet the following requirements.

5.7.1 The motors shall be suitable for the current wave forms produced by the power supply including harmonics generated by the drive. The necessary coordination by motor manufacturers with drive manufacturers regarding harmonics generated by VFD shall be taken care and incorporated in motor design suitably.

5.7.2 The motors shall be designed to operate continuously at any speed over the range as per process requirement with minimum range as 10-100% of rated speed or as specified in data sheet. The characteristics shall be baked on the application — in terms of constant torque / variable torque as per the driven equipment. Additional cooling fan shall be provided if required to limit the temperature rise to specified limits, alternatively option of applying suitable de-rating may be considered.

5.7.3 The motors shall withstand torque pulsation resulting from harmonics generated by the solid state power supply.

5.7.4 The motors required to be transferred to DOL bypass mode shall be rated for specified variations in line voltage and frequency.

5.8 The minimum values for performance characteristics of these motors shall be as given in the tables 1, 2 & 3 of IS 12615-2011 for 1E2 motors, subjected to tolerance as per IS/IEC. Motor meant for application with VFD, the efficiency value can be one class lower as per IS.

6.0 CONSTRUCTIONAL DETAILS

6.1 Windings

6.1.1 Unless otherwise specified, motors shall be provided with class 'B' insulation as a minimum. In case of motors with class 'F' insulation, the permissible temperature rise above the specified ambient temperature shall be limited to those specified in the applicable Indian standards for class 'B' insulation.

6.1.2 The winding shall be tropicalised. The windings shall preferably be vacuum impregnated. Alternately the windings shall be suitably varnished, baked and treated with epoxy gel for operating satisfactorily in humid and corrosive atmospheres.

6.1.3 Windings shall be adequately braced to prevent any relative movement during operation. In this respect, particular care shall be taken for the stator windings for direct-on-line starting squirrel cage motors. Insulation shall be provided between coils of different phases that lie together. Core laminations must be capable of withstanding burnout for rewind at 350 °C without damage or loosening.

6.1.4 In case of motors driving equipment with pulsating loads, special care shall be taken for the joints of rotor bars and end rings to avoid premature failures due to induced fatigue stresses.

6.1.5 The windings shall be connected in delta. However, for motors rated 2.2 kW and below, star connection may be accepted. In case of motors with star-delta starting, the motor windings shall be fully insulated for delta connection.



Page 11682 of 13291

SPECIFICATION ENGINEERS FOR

5Igur fda--eg INDIA LIMITED

--,,,,,,aw,ansmsn. ENERGY EFFICIENT MEDIUM VOLTAGE INDUCTION MOTORS


6-51-0064 Rev. 1

Page 8 of 12

6.1.6 The ends of the windings shall be brought out into a terminal box. These shall be terminated by means of terminals mounted on an insulating base made of non-hygroscopic and non-flammable material.

6.1.7 All motors shall be provided with six terminals and suitable links to connect them in star or in delta except for motors rated up to and including 2.2 kW which may be accepted with three terminals.

6.2 Terminal Box and Cable Entries

6.2.1 Unless otherwise agreed, the terminal box shall be located on the right hand side as viewed from the driving (coupling) end. The terminal box shall have side cable entry from non-driving end. However, as a special case, terminal box located on top may also be accepted, particularly for hazardous area motors, in case manufacturer has only top mounted terminal box design which is duly tested/certified by CIMFR and approved by PESO for installation in hazardous area. The terminal box design shall allow rotation in steps of 90 ° C to facilitate cable entry from any direction at site.

6.2.2 Terminal box cover shall be provided with handles to facilitate easy removal. However, for terminal box covers weighing less than 5 kg., terminal box covers without handles can be accepted.

6.2.3 The terminal box shall be provided entries for suitable cable glands corresponding to the size of the specified cable. Crimp type tinned Copper lugs and nickel-plated brass (or aluminum if specifically required), double compression type cable glands shall be supplied along with the motors for the specified cable sizes for power and space heater cables.

6.2.4 For flameproof motors, terminal box can be provided in increased safety `Exe' execution.

6.2.5 The terminals, cable lugs, terminal box, cable entries and cable glands shall be suitable for the maximum cables sizes as specified below 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 2.5 cu

3.7 kW 6 cu 5.5 kW 10 cu 7.5 kW 16 cu 9.3 kW 16 cu 11.0 kW 16 cu 15.0 kW 50 Al. 18.5 kW 70 Al 22.0 kW 70 Al 30.0 kW 95 Al 37.0 kW 120 Al 45.0 kW 150 Al 55.0 kW 240 Al 75.0 kW 2x95 Al 90.0 kW 2x120 Al 110.0 kW 2x240 Al

125.0 kW/132 kW 2x240 Al 160.0 kW 2x240 Al

6.2.6 Cable sizes for motors having synchronous speeds 750 RPM and below shall be as agreed between the purchaser and manufacturer.



Page 11683 of 13291

rr fa2es 1.12,f elvostVO51,~11

ENGINEERS INDIA LIMITED IA Govt of Indo Undertalong)

SPECIFICATION FOR

ENERGY EFFICIENT MEDIUM VOLTAGE INDUCTION MOTORS


6-51-0064 Rev. 1

Page 9 of 12

6.3 Motor Casing and Type of Enclosure

6.3.1 The minimum degree of motor enclosures including terminal boxes and bearing housing shall be IP-55 as per IS.

6.3.2 Motors for outdoor use shall be suitable for installation and satisfactory operation without any protective shelter or canopy. Motor casing shall be provided with a suitable drain for removal of condensed moisture except in case of flameproof motors (Type Ex d/Exde).

6.3.3 A11 internal and external metallic parts, which may come into contact with cooling air, shall be of corrosion resistant material or appropriately treated to resist the corrosive agents, which may be present in the atmosphere. Screws and bolts shall be of rust proof material or protected against corrosion.

6.3.4 Unless otherwise agreed, motors shall have standard frame sizes (min.) for various output ratings as stipulated in IS.

6.4 Bearing and Lubrication

6.4.1 Motors shall have grease lubricated ball or roller bearings. In all cases, the bearings shall be chosen to provide a minimum L-10 rating life of 5 years, (40, 000 hours) at rated operating conditions (The L-10 rating life is the number 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 The bearings shall be adequate to absorb axial thrust produced by the motor itself or due to shaft expansion. Motors designed to handle external thrust from the driven equipment shall be supplied with a thrust bearing at the non-driving end.

6.4.3 In cases such as pumps for hot liquids where the driven equipment operates at high temperatures, bearings shall be cooled by a shaft-mounted fan. This shall ensure efficient ventilation of the bearing and disperse the heat transmitted from the driven equipment by conduction or convection.

6.4.4 Bearings shall be capable of grease injection from outside without removal of covers with motors in the running conditions. The bearing boxes shall be provided with necessary features to prevent Loss of grease or entry of dust / moisture e.g. labyrinth seal/ oil seal/ V seal. Where grease nipples are provided, these shall be associated, where necessary, with appropriately located relief devices, which ensure passage of grease through the bearings.

6.4.5 Pre-lubricated sealed bearings may be considered provided a full guarantee is given for 4 to 5 years of trouble-free service without the necessity of re-lubrication.

6.5 Cooling System

All motors shall be self ventilated, fan cooled. Fans shall be corrosion resistant or appropriately protected. They shall be suitable for motor rotation in either direction without affecting the performance of the motor. If this is not possible for large outputs, it shall be possible to reverse the fan without affecting the balancing of the motor.

For motors operating in hazardous area, the fans shall be of an anti-static non-sparking material.



Page 11684 of 13291

ENG1NEERS SPECIFICATION

FOR Ogzrr w INDIA LIMITED Mt c-lecnrc' 411 ENERGY EFFICIENT MEDIUM



6-51-0064 Rev. 1

Page 10 of 12

6.6 Rotor

The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration Level and long service life for the bearings. Die cast aluminum rotors for motors in hazardous areas may be accepted provided the same are type tested and approved by competent authorities.

6.7 Shaft Extension

Motors shall be provided with a single shaft extension with key-way and full key. Motor shaft shall be sized to withstand 10 times the rated design torque.

6.8 Lifting Hooks

A11 motors weighing more than 30 kg. shall be provided with lifting hooks of adequate capacity.

6.9 Earth Terminals

Two earth terminals located preferably on diametrically opposite sides shall be provided for each motor. Necessary nuts and spring washers shall be provided for earth connection.

7.0 MISCELLANEOUS ACCESSORIES

7.1 Anti-Condensation Heaters

All motors rated 30 kW and above shall be provided with 240 V anti-condensation heaters, sized and located so as to prevent condensation of moisture during shutdown periods.

For motors with heaters installed in hazardous atmospheres (Zone - 1 or Zone - 2), such heaters shall conform to the provisions of applicable Indian Standards and temperature classification specified in the motor data sheet.

The heater leads shall be brought out, preferably, to a separate terminal box which shall be of the same specification and grade of protection as the main terminal box.

A warning label with indelible red inscription shall be provided on the motor to indicate that the heater supply shall be isolated before carrying out any work on the motor.

7.2 Name Plates

In addition to the motor rating plate, a separate number plate for motor tag number shall be fixed in a readily visible position. This number shall be as per the motor data sheets.

8.0 CRITICAL SPEEDS

The first actual critical speed of stiff rotors shall not be lower than 120 % 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 above 120 % of the synchronous speed.

9.0 PAINTING

A11 metal surfaces shall undergo manufacturer's standard cleaning /painting cycle. After preparation of the under surface, the equipment shall be painted with two coats of epoxy based final paint. Color shade of final paint shall be 632 of IS: 5/ RAL-7035. All unpainted steel parts shall be suitably treated to prevent rust formation. If these parts are moving elements, then these shall be greased.



Page 11685 of 13291

Govt o7 Indo Undertaking) ENERGY EFFIC1ENT MEDIUM VOLTAGE INDUCTION MOTORS

SPECIFICATION ENGINEERS

f laZ5 la INDIA LIMITED FOR STANDARD SPECIFICATION No.

6-51-0064 Rev. 1

Page 11 of 12

10.0 INSPECTION AND TESTING

10.1 All tests shall be carried out at manufacturer's shop under his care and expense.

10.2 The manufacturer shall submit all internal test records of the tests carried out by him on the bought-out items, motor sub-assembly and complete motor assembly.

10.3 The manufacturer shall carry out the following routine and acceptance tests as per applicable Standards/ITP on all the motors.

a) Visual check (Nameplate, terminal box location, terminal type, clearance, size, entries, space adequacy & gland size, direction of rotation etc.)

b) Dimension check (shaft height etc.) c) Cable glands, cable lugs size and no. of entries in terminal box. d) Winding resistance e) No load test & measurement of voltage, speed, current, power input f) Measurement of starting torque, starting current, full load torque, breakdown torque

g) Reduced voltage starting & running h) Insulation resistance before and after high voltage test i) High voltage

i) Vibration

10.4 The manufacturer shall submit the following type test certificates (one sample from each type/rating): a) Full load test & measurement of voltage, current, power slip, power factor, bearing,

noise b) Efficiency & pf at 100%, 75% and 50% load c) Temperature rise test d) Momentary overload test e) Vibration f) Noise Level

g) Over speed h) Measurement of starting torque, starting current, full load torque.

10.5 For VFD fed motors, all tests as specified in the VFD specification shall be followed in addition to the above.

11.0 CERTIFICATION

The motors and associated equipment shall have test certificates issued by recognised independent test house (CIMFR/ CPRI/ ERTL/ BASEEFA/ LCIE/ UL/ FM/ KLPL or equivalent). All indigenous motors shall conform to Indian standards and shall be certified by recognised testing agencies. A11 motors (indigenous & imported) shall also have valid statutory approvals (e.g. PESO, DGMS etc). as applicable for the specified location. All indigenous fiameproof motors shall have valid BIS license and marking as required by statutory authorities.

12.0 PACKING AND DESPATCH

A11 the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases to prevent damage to the finish. Crates/cases shall have skid bottom for handling. Special notations such as `Fragile', `This nide up', `Center of gravity', Weighe, `Owner's particulars', `PO Nos.' etc. shall be clearly marked on the package together with other details as per purchase order.


Copyright EIL - All rights reserved

Page 11686 of 13291

SPECIFICATION ENGINEERS FOR

fg".2x w INDIA LIMITED elvOrt'4,13~1)


6-51-0064 Rev. 1

Page 12 of 12 (A Govt ot InOla Undertahmg) ENERGY EFFICIENT MEDIUM


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

Copyright EIL —All rights reserved Format No. 8-00-0001-F1 Rev. 0

Page 11687 of 13291

JOB SPECIFICATION

(ELECTRICAL) EPCC-3 PACKAGE

FOR RAJASTHAN REFINERY PROJECT

Part C / Section C-4 Sub-section C-4.5

B224-111-16-50-SP-7203 Rev. B

Page 1 of 24

Template No. 5-0000-0001-T1 Rev. 1 Copyrights EIL – All rights reserved

JOB SPECIFICATION (ELECTRICAL)

EPCC-03 PACKAGE FOR PETROCHEMICAL

FLUIDIZED CATALYTIC CRACKING UNIT &

PROPYLENE RECOVERY UNIT

TENDER NO. B224-111-86-41-PM-T-7203

PROJECT : RAJASTHAN REFINERY PROJECT

UNIT : 111

OWNER : HPCL RAJASTHAN REFINERY LIMITED

PMC : ENGINEERS INDIA LIMITED

JOB NO. : B224

B 25/09/2019 REVISED & ISSUED WITH TENDER SM MKS MKS

A 14/08/2019 ISSUED FOR TENDER SM MKS MKS Rev.

No Date Purpose

Prepared by

Checked by

Approved by

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JOB SPECIFICATION




B224-111-16-50-SP-7203 Rev. B

Page 2 of 24


1.0 PURPOSE

This specification shall be read in conjunction with Electrical system described in the Process Licensor documents. Intent of this job specification is to define the electrical system and the specific requirement applicable to the scope covered under this contract in addition to the equipment specifications, design philosophy, drawings etc. as enclosed with the bid document, licensor documents and shall be complied for engineering, supply, installation, testing and commissioning. The designed system shall also comply with the requirement of applicable Indian/ international standards and must comply with the Indian statutory regulations. Wherever EIL specification is not available, specification prepared by contractor subject to EIL approval shall be followed. Critical job specific requirement are also covered in this document as conflict avoidance. Codes and standards as prevailing in the country of origin may be followed for equipment purchased abroad provided that the equivalent standards are more stringent than Indian / International standards and meet the statutory regulations of the approving Indian statutory authorities. It is responsibility of the Contractor to highlight any contradiction amongst various documents at the bid stage itself. In case of conflict between OWNER / EIL specifications and Licensor specifications, the most stringent requirements will apply. The following order of priority shall be followed. In case of conflict between requirements specified in various documents, the more stringent one shall be followed. Owner’s concurrence shall, however, be obtained before taking a decision in such matters.

Statutory Regulations In particular, the latest version of the following statutory regulations shall be followed for design of electrical system: o Indian Electricity Act o Indian Electricity Rules o The Factory Act o The Petroleum Rules o OISD standards o Requirements of other statutory bodies as applicable, e.g. CEA, CCE, LPCB.

Engineering Design Basis (Electrical) Data sheets & drawings Job specifications for electrical facilities Design Philosophy Equipment Specifications Codes & standards

Contractor shall furnish list of conflicts, if any, along with their offer and also furnish the basis that is considered for submitting offer. Owner/EIL will resolve listed conflicts prior to award. In case of ambiguity, bidder shall inform owner/EIL of their interpretation. In case bidder fails to convey the same prior to award, the Owner's decision on interpretation shall be considered final if need arises during the execution. No additional cost or extra time on account of conflicts/ambiguities shall be admissible.

2.0 PROJECT DESCRIPTION/ DATA

CONTRACTOR shall refer the Key Single Line Diagram B224-111-16-50-0001 Rev-A SLD (attached with tender) for the Power system description envisaged for PFCC Unit Substation.

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B224-111-16-50-SP-7203 Rev. B

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2 nos. 66 kV feeders, each rated for 100% load, from 66KV Gas Insulated Switchgear located at sending end CPP substation will supply power to PFCC BLOCK substation SS-11 located within the battery limit of the contractor. 66KV GIS isolation breaker panels shall be provided for each of the 66kV feeders for primary isolation of the unit power transformers by contractor. These feeders, each rated for 100% unit power transformer rating will feed downstream unit substation SS-11. 220kV, 66 kV and 415 V system neutrals shall be solidly earthed, whereas, 6.6 kV system neutral shall be resistance earthed. At SS-11, power will be received at the 66KV GIS isolation breaker panels via 66 kV cables and will be stepped down to 6.6 kV utilization level through 2 nos.(min) 66/6.9 kV main Power transformers for feeding the 6.6 kV loads through 6.6 kV switchboards having two bus sections interconnected by means of a bus coupler. 6.6 kV power shall be stepped down to 415 V using 6.6/0.433 kV distribution transformers for feeding 415 V loads of unit through power control centers, motor control centers and auxiliary service boards. All these facilities shall be located in SS-11. Emergency power will be received at 6.6kV Level. Emergency loads i.e. 6.6 KV motors shall be fed through 6.6KV emergency switchboard. 6.6/0.433 KV distribution transformers shall be provided along with 415V switchboard to feed lighting, UPS system, DC system etc. Contractor shall follow Electrical Design basis attached for the power feeding of various HV/MV loads through HV switchboards and MV switchboards. Contractor shall develop detailed PFCC BLOCK SLD. For various MV loads of ISBL, normal PCCs fed from normal power supply and Emergency PMCC fed from emergency supply feeders has been envisaged. Adequate nos. of MCCs shall be considered for feeding loads as per design basis. Auxiliary service board and lighting distribution boards shall be provided to distribute miscellaneous load and lighting loads respectively. Lighting shall have blackout control from remote during emergency situations. UPS systems and DC systems shall be provided to supply respective loads. POWER SYSTEM DESCRIPTION:

In order to meet the power supply requirement of the project, three nos. Steam turbine generators STG-1 of 35MW and STG-2, and STG-3 of rating 26MW each (in other’s scope) is envisaged. The power will be generated at 11 kV and shall be stepped up to 66 kV through 11 /66 kV generator transformers (in other’s scope). All 3 STGs shall be connected to 66kV GIS (in other’s scope) and shall run in parallel along with 4 nos 220/ 66 kV grid transformers of rating 125/160MVA. The 66 kV GIS at the downstream of generator and generator transformers is a double bus GIS and shall be provided with Incomers for STGs, & bus Couplers. System design shall be suitable for the parallel operation of STG1/2/3/GRID. The equipment shall be suitable for the same. CONTRACTOR shall refer sheet-1 of Key Single Line Diagram of CPP B224-511-16-50-00001 SHT1 (attached with tender) for the Power system description envisaged for CPP Substation.

3.0 ADDITIONS / DELETIONS / MODIFICATIONS TO STANDARD SPECIFICATION

3.1 Engineering Design Basis Electrical (B068-999-16-50-EDB-1001, Rev.1)

a. Clause no. 5.6.12 : 230V AC UPS supply mentioned shall be read as 110V AC UPS supply. b. Clause no. 5.6.6 / Sl. No.6 : Description of this clause shall be read as ``MCCB (non-

microprocessor based with S/C protection and shunt trip coil), Electronic Motor protection relay and contactor’’ which is applicable for Motor starter feeder up to 55kW.

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c. Refer clause 5.7.2, 1/2/3 : Cable shall be laid overhead on pipe rack or dedicated overhead electrical rack to the extent possible. Overhead electrical rack shall be at a height decided during detailed engineering based on vehicular/crane movement, constructional requirement, obstruction etc. Wherever pipe rack or overhead electrical rack is not possible cable shall be laid in RCC cable trenches. Cables within Substation battery limit, SS to SRR/ CR and column dropping to the nearby loads in Unit area may be trough RCC trench. However, cable tray on pipe rack/dedicated overhead electrical rack and its height /RCC trench shall be finalized during detailed engineering based on the owner/EIL decision and same shall be executed by contactor without any time and cost implication.

3.2 Specification for Medium and High Voltage cables & accessories (6-51-0051 Rev.8)

1. Clause No. 5.1.6 (b) shall be read as below: “Temperature index as per ASTM-D-2863 i.e. to determine at what temperature normal oxygen content of 21% in air will support combustion of FRLS sheath will remain as 250ºC”.

2. Refer Cl. 6.3.1 and note that standard cable drum lengths for below mentioned cable sizes stands revised as mentioned below:

a. Multi core power cables up to 50 sq.mm. – 2000 m b. Control cable of size up to 7x2.5 sq.mm. – 2000 m 3. The following point shall stand added at the end of specification:

“For screen sizing calculations, final temperature to be considered shall be 200 ºC under adiabatic conditions”.

3.3 Specification for Extra High Voltage Cables and Accessories (6-51-0067 Rev.1)

Clause No. 5.1.7 (b) shall be read as below: “Temperature index as per ASTM-D-2863 i.e. to determine at what temperature normal oxygen content of 21% in air will support combustion of FRLS sheath will remain as 250ºC”.

3.4 Specification for Communication and Fire Alarm Cables (6-51-0052 Rev. 6)

The following clauses of 6-51-0052 stands modified as below: a) Cl. 4.3.2 – Type of core insulation mentioned in the Table under this clause shall be read

as Type-A as per IS-5831. b) Cl. 4.3.2 – For PVC insulated PA/FA/Telephone/Paired Control Cables, PVC insulation

thickness (minimum values) shall be as per table mentioned under this clause, however for XLPE insulated PA/FA/Telephone/Paired Control Cables, insulation thickness (nominal values) shall be as per IS-7098 (Part-1).

c) Cl. 4.8.1 – The material of inner sheath mentioned as ST2 in this clause stands revised to and shall be read as ST1.

d) Cl. 4.10.1 – The type of outer sheath material for outer sheath mentioned as ST2 under this clause shall be read as ST1.

e) Cl. No. 6.3 (d) - Temperature index as per ASTM-D-2863 i.e. to determine at what temperature normal oxygen content of 21% in air will support combustion of FRLS sheath will remain as 250ºC.

f) Cl. No. 7.3 – Standard cable drum lengths for below mentioned cable sizes stands revised as mentioned below: i) PA/FA/Signal cable having size up to 6 pair 1.5 & 2.5 sq.mm. – 2000 m ii) PA/FA/Signal cable having size up to 10 pair 0.9 mm dia. – 2000 m

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3.5 Specification for HV & MV Bus Duct (6-51-0054 Rev.4)

Clause no. 5.3 of standard specification 6-51-0054 Rev 4 shall be read as below: “The hot spot temperature of bus bars for HV bus duct including joints at design ambient temperature shall not exceed 90 deg. C for normal operating condition. However, for silver plated joints, the allowable maximum temperature shall be 115 Deg. C”.

3.6 Design Philosophy for Electrical facilities (6-51-0099 Rev.6)

“2.5 Metres clear height of substation cable cellar mentioned under clause no. 6.2 of standard specification no. 6-51-0099 Rev 6 titled design philosophy for Electrical facilities, stands revised and shall be read as 3.5 Metres.”. Cl. no. 7.4.10: Lux level shall be read as minimum rather than average. This shall also be as per OISD as a minimum.

3.7 Specification for MV variable frequency drive system (6-51-0038 Rev.2)

The following paragraph shall stand added at the end of cl. No. 5.3.5 of specification: “The type/material of construction for all name plates shall be preferably anodised aluminium or 3-ply (Black-White-Black) lamicoid sheets. However back engraved Perspex sheet nameplates may also be acceptable. Nameplates shall be fastened by screws and not by adhesives”. The following paragraph shall stand added at the end of cl. No. 5.3.6 of specification: “All components mounted on DIN RAIL shall be provided with end clamps except for components mounted firmly on base plate using screws”.

3.8 Specification for small MV variable frequency drive system (6-51-0049 Rev.1)

The following paragraph shall stand added at the end of cl. No. 5.3.5 of specification: “The type/material of construction for all name plates shall be preferably anodised aluminium or 3-ply (Black-White-Black) lamicoid sheets. However back engraved Perspex sheet nameplates may also be acceptable. Nameplates shall be fastened by screws and not by adhesives.” The following paragraph shall stand added at the end of cl. No. 5.3.6 of specification: “All components mounted on DIN RAIL shall be provided with end clamps except for components mounted firmly on base plate using screws”

3.9 Specification for Uninterrupted Power Supply System (6-51-0017 Rev. 7)

The following stands added at the end of Cl. No. 5.3.9 of specification: “The efficiency of DC-DC Converter / Buck Boost Amplifier shall be considered in battery sizing calculations as well as rectifier sizing calculations and capacity of battery and rectifier shal0l be accordingly sized”.

Refer clause 5.7.3.2 of 6-51-0017, 2 set of contacts to be provided for ECS and DCS Interface for the following:

a) Common remote alarm UPS fault b) Load on bypass supply c) UPS current & voltage indication

3.10 Specification for Electrical Works as Part of Paving Works (6-51-0088 Rev. 3)

Last sentence of Cl. No. 4.2.9 of standard specification 6-51-0088 shall be read as below: “Welding shall be done with an overlapping of strip equivalent to double the width of the strip and all the four sides (three on top and one on bottom) shall be continuously welded”.

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3.11 Specification for Battery Charger (6-51-0019 Rev. 5)

The following stands added at the end of Note-2 on Page 13 & 14 of specification: “Battery isolator (MCCB/Switch Fuse) shall be provided with three pole version to ensure positive isolation of all the three connections of battery”. Following is added, 2 set of potential free contacts to be provided for ECS and DCS Interface shall be provided for remote monitoring :

i) Charger-1 failure ii) Charger-2 failure iii) Battery set-1 discharged iv) Battery set-2 discharged v) Battery set-1 isolated vi) Battery set-2 isolated vii) Charger-1 boost charging viii) Charger-2 boost charging

3.12 Specification for Electrics for EOT Cranes (6-51-0094 Rev. 4)

The last sentence of clause 6.4.4 (c) shall be read as below: Rotor resistance controls and variable stator voltage converter inverter controls or variable frequency drives controls using AC motors shall not be used for cranes to be intended for installation in hazardous areas.

3.13 Electrical Installation Standards 7-51-0201 Rev. 5, 7-51-0202 Rev. 5, 7-51-0221 Rev. 5 & 7-51-0233 Rev. 0

50 Dia. GI Pipe and 100 Dia. GI Pipe mentioned wherever in the standards shall be read as 50 NB (Medium Grade) GI Pipe and 100 NB (Medium Grade) GI Pipe respectively.

4.0 SPECIFIC JOB REQUIREMENTS

4.1 GENERAL

Various equipment covered in the bid package to be supplied by the contractor shall in general be, in accordance with the requirements defined in design basis document, licensor’s documents, standard specifications, respective equipment datasheet and hardware datasheet. Besides these, the following requirements as detailed out in respective clauses for the equipment shall also be considered: (i) Contractor shall ensure that all electrical equipment comply to site and system

conditions, rating and other technical requirement as specified in the engineering design basis and licensor documents.

(ii) CONTRACTOR shall use this specification, datasheet, and design basis document, licensor specifications /requirements and OWNER / EIL’s standard specifications for various equipments. However for equipment where OWNER/ EIL’s standard specifications have not been attached, the CONTRACTOR shall use their own specification developed based on project specific requirement, licensor requirements and good engineering practices prevalent in petroleum industry so as to ensure satisfactory operational and maintenance requirements subject to approval by owner/EIL.

(iii) CONTRACTOR shall note that data sheets for some of the equipment are not enclosed separately. Equipment data sheets for all equipment shall be prepared by the CONTRACTOR based on relevant codes and specifications and data sheet shall contain all technical data and information which are essential for review and technical

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acceptability, detailed engineering, installation, testing, repair and maintenance, replacement etc.

(iv) All equipment shall be subjected to routine and acceptance tests as per applicable specifications. In addition, equipment shall be subjected to type tests if specified elsewhere.

(v) CONTRACTOR shall clearly specify in their purchase specifications, the requirement of conducting other special tests/ type tests, which are envisaged for various electrical equipment, which shall have no impact on cost and time.

(vi) Epoxy based insulating coating/paint for the required breakdown voltage as per IS on complete flooring of switchgear hall in substations floor/ MCC room instead of insulation mat shall be provided. Thickness of this coating shall be uniform and shall be for the maximum voltage in the substation/ MCC room.

(vii) Sealing of cut-outs (for switchboards) on switchgear hall floor in substation to be properly done after placement of chequered plate.

(viii) Sizing of earthing strips shall be suitable for maximum fault current & for 3 seconds. 4.2 ELECTRICAL ENGINEERING DESIGN BASIS

Standard design philosophy for electrical facilities 6-51-0099 along with Engineering design basis (Electrical), Amendment to Engineering design basis (Electrical) and single line diagram enclosed shall form the basis for basic design and developing detailed design and engineering for electrical facilities including electrical power system, electrical equipment, and electrical installation etc.

4.3 AREA CLASSIFICATION

CONTRACTOR shall finalize hazardous material source list based on information available in process package/Licensor documents and shall submit the same along with area classification drawings for review. Area classification drawings included in licensor documents shall also be considered for preparation of the final area classification drawings. Equipment selection shall be done based on the approved area classification drawing.

i. All electrical equipment shall be suitable as per the area classification, as applicable. All equipment related to turbine starting & ventilation system and those which are envisaged to start before the start-up of ventilation system shall be flameproof only. Lighting fixtures for turbine enclosure shall be flameproof only.

ii. All push button stations, junction boxes etc. located within the Zone-1/ Zone-2 classified area shall be flame proof Ex-d type suitable for Gas Group IIA/IIB. All cable glands in hazardous area shall be flameproof only.

iii. All electrical equipment for use in hazardous areas shall be certified by CIMFR, ATEX, Baseefa or equivalent independent testing agency for the service and the area in which it can be used and shall be approved by PESO/CCE.

iv. All indigenous flameproof equipment (Type Ex-d) shall be manufactured valid under BIS licence.

4.4 FAULT LEVEL SELECTION

Overall Key Single Line diagram indicates the fault levels at different voltage level. CONTRACTOR shall however verify and select parameter such that to limit the fault level as per the following. (i) 40 kA for 1 sec. on 66 kV bus (ii) 40 kA for 1 sec. on 6.6 kV bus

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(iii) 65 kA for 1 sec. on 415 V bus Equipment with higher short circuit rating shall be selected based on short circuit studies.

4.5 EQUIPMENT SIZING

a) Single line diagram attached for S/S-11 shows the Philosophy of distribution of electrical power and is indicative only. Quantity of transformers, HV & MV switchboards shown in SLD are minimum and shall have no bearing on the actual quantity and rating of equipment required during detail engineering. CONTRACTOR shall detail out the single line diagram based on loads finalized during engineering and licensor’s requirements and size all electrical equipment and shall furnish same for the review of Owner/EIL.

b) Sizing of various equipment in contractor’s scope of supply i.e. 66KV Isolation breaker panels, 66/6.9kV Power transformers, 6.6 kV switchboards, 6.6 kV Isolation breaker panel, 6.6kV bus ducts, 6.6 / 0.433kV distribution transformers, PCC, MCC, MV bus ducts, ASB, LDB, lighting transformers, Capacitor banks, DC systems, UPS systems, Soft Starters, VFD systems, 66 kV EHV power cables, HV power cables, MV power and control cabling etc. is included in Contractor’s scope of work. All equipment shall be sized subject to load analysis to be carried out by the Contractor. Besides these, feeders required for Owner’s use, as indicated elsewhere in the bid package, shall also be taken into account in equipment sizing.

c) Sizing factor for normal, standby and intermittent loads shall be considered as 1, 0.1 and 0.5 (min.) respectively. However, wherever process requirements calls for higher factors to be considered, the same shall be taken into account.

d) Starting current of large motors may be further reduced by the contractor from the limiting values mentioned in Electrical design basis based on the motor start up studies such that starting of motor shall not cause voltage drop more than 8% at 66KV bus considering all tolerances. Contractor must also ensure positive acceleration of motor at resulting voltage available at motor terminals during starting.

e) In case during large motor startup, the limit on voltage drop at 66kV bus mentioned above cannot be achieved based on motor kW rating & starting current, contractor shall provide separate V/F type soft starter for each motor for facilitating motor startup. The motor startup study shall be furnished during detail engineering for PMC/Owner’s review for deciding requirement of V/F soft-starter.

4.6 EQUIPMENT SPECIFICATIONS

4.6.1 POWER & DISTRIBUTION TRANSFORMER

(i) Minimum guaranteed Efficiency of 66/6.9 KV power transformers at 40% load & 0.8 power factor shall not be less than 99.5%.

(ii) Distribution transformer shall comply to latest IS-1180 (Part-1): 2014 and Gazette of India Order dtd. 16-Dec-2016 & 17-Feb-2017. Accordingly, efficiency of transformer at 50% and 100% load shall be considered with total losses at 50% and 100% loading not exceeding maximum losses values specified in Table-6 of IS-1180 (Part-1) for Energy Efficiency Level-2/ Star-1 as per Gazette of India.

(iii) The Transformer shall bear Standard Mark of the Bureau of Indian Standards in line with Gazette of India Order dtd. 16-Dec-2016 & 17-Feb-2017. Copy of license obtained from Bureau of Indian Standards shall be furnished by vendor post order in compliance to IS-1180 (Part-1).

(iv) Sizing factor for standby and intermittent loads shall be considered as 0.1 and 0.5 (min.) respectively. However, wherever process requirements calls for higher factors to be considered, the same shall be taken into account.

(v) Maximum rating of outgoing 6.6/ 0.433 kV transformers shall be limited to 2.5 MVA.

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(vi) The transformers impedances shall be chosen to suit switchgear fault withstand capabilities and large motor start-up.

(vii) Power transformers provided with OLTC shall have RTCC. It should be possible to change taps manually from transformer, RTCC and ECS.

(viii) All transformers except lighting transformers shall have WTI/OTI transducer for interfacing with substation MMI and ECS. Oil temperature indicator (OTI) and winding temperature indicator (WTI) shall be Digital type with compensator.

(ix) Power transformer HV termination box shall be air insulated type. (x) Indicating Lamps shall be LED type

4.6.2 GIS ISOLATOIN BREAKER PANELS

Each 66kV isolation breaker panel shall be provided with feeder differential CTs and feeder differential relay (receiving end relay) and same shall be mounted on each of isolation breaker panel. Contractor shall provide the receiving end feeder differential relay of identical make & model no. that of the sending end relay. Details of the relay at sending end shall be furnished during detail engineering by owner/other contractor. EHV Over voltage indication to be considered. Line PT MCB off indication to be considered for incomers.

4.6.3 HV SWITCHBOARDS

(i) All requirements shall be considered while sizing the switchboards and feeders, as required, including feeder for free-issues material based on final approved single line diagram, shall be provided with no cost and time implication to owner.

(ii) Auto changeover between incomers and bus coupler for 6.6 kV system shall be provided. Additionally manual change over through synchro-check relay with momentary paralleling shall also be provided. All necessary hardware shall be included to achieve auto, independent and manual operation of incomers and bus coupler.

(iii) Only major relays, meters and controls are indicated in the hardware data sheets. Any auxiliary relays, timers, switches, etc, as required while developing the control schematic and felt necessary for safe operation, even if these are not specifically included, shall be supplied by the Contractor. All logic shall be implemented in the relay itself and not externally. Provision of adequate I/O count in the relays shall be ensured.

(iv) All relays, metering and control components shall be mounted on the panel front only. Dummy panel and rear extension, as required, for bus trunking/ cable terminations shall be provided.

(v) Line PT MCB off indication to be considered for incomers. (vi) Microprocessor based Fast bus transfer system shall be provided between Incomer-1,

bus coupler-1 and incomer-2. Changeover scheme for these two incomers (Incomer-1, incomer-2) and one bus-coupler-1 shall be as follows Auto/Manual Changeover with fast bus transfer scheme for switchboard with two incomers and one bus-coupler breakers shall comply with the logic described briefly as follows. Safety interlocks as deemed necessary shall however be considered during detailed engineering.

Auto/Manual Fast Bus Transfer

The auto/ manual fast bus transfer scheme is described in brief as follows:

Facility to be provided

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a) Auto fast bus changeover between the two incomers and one bus-coupler shall be in such a way that two incomer breakers are 'ON' at a time and bus-coupler breaker is normally open.

b) Bus-coupler breaker is made 'ON' automatically in case the incoming supply at incomer breaker no. 1 or 2 fails in following modes:

i. Fast Transfer ii. Delayed In phase transfer iii. Residual voltage transfer (slow changeovers)

c) Interlocks shall be continuously checked not limited to the following

i. Transfer system healthiness ii. Breaker in service iii. Breaker status & breaker contact integrity iv. Master trip relay lockout condition (86) v. Breaker coil healthiness and breaker configuration vi. PT in service and PT MCB condition vii. Other source voltage healthiness

d) Blocking of auto transfer (i.e., closing of bus-coupler) if any incomer breaker trips due

to a fault. e) Tripping of incomer on under voltage shall be blocked, if both the incomers

simultaneously experience an under voltage. f) The auto-change over shall be blocked during load shedding.

Normal operating condition

Incomer no. 1 and 2 breakers are 'ON'. Bus-coupler breaker is 'OFF'.

I. Fast Transfer

The bus voltage and incoming source voltage shall be monitored on a continuous basis for magnitude and phase angle and it shall be ensured that the same are within the specified limit values at the moment of initiation to ensure that transfer operation is carried out under conditions conducive to fast bus transfer as per high speed sync-check supervision. The open and close commands to the circuit breaker from the high speed transfer device shall be issued synchronously.

II. In-Phase Transfer

If the synchronized conditions are not present the fast transfer shall be blocked. The supply breaker feeding to the bus opened and the bus-coupler is closed in the first minimum of the difference of healthy and bus bar voltage. The transfer system is able to determine the course of the difference voltage and the point in time of the 1st phase coincidence (first slip cycle synchronization). In order to compensate for the installation specific processing time like system response time, circuit breaker opening time etc. the close command is issued accordingly before the actual first minimum difference voltage occurs.

III. Residual voltage transfer

When the criteria for a fast transfer operation are not met and in phase transfer is not feasible, the closing of breaker in fast transfer and in phase transfer is not possible, the residual voltage transfer shall be utilized. The closing of the bus coupler shall take place when the voltage of the bus bar has subsided to a preset, permissible safe value (20-30% of rated voltage).

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IV. Manual transfer a) It is possible to trip incomer no. 1 or 2 after closing the bus-coupler to facilitate

maintenance as required. b) When supply is again available at incomer breaker after auto changeover has already

taken place, it is possible to restore the system to normal operating condition by operating selector switch (meant for tripping incomer no. 1 or 2 or bus-coupler) and by setting auto/ manual switch in 'Manual' mode.

c) In manual transfer the closing circuit shall be checked through contacts of check synchronizing function during momentary paralleling.

d) In manual transfer after momentary paralleling if desired breaker does not trip after preset time delay, breaker last closed shall trip.

V. Independent mode

In addition to the transfer modes, all the incomer and bus-coupler breaker shall be desired to operate independently (ON-OFF operation) on independent mode for dead bus charging & other maintenance requirement of switchboard. Paralleling of sources shall not be permitted in this mode. Auto-Manual-independent (A-I-M) selector switch shall be provided in the switchboard for selection of different modes for operation.

Number of binary and analog inputs / outputs shall be adequate for the required system configuration.

FBT (Fast bus transfer) RELAY shall be physically located in Bus coupler panel or in any panel placed in the panel line-up only. All signal interchange between FBT relay & other panels shall be through inter-panel wiring only.

(vii) Separate CTs shall be provided for differential & REF protection meaning thereby that REF CT and differential protection CT can be combined in one CT as two different cores.

(viii) The different cores of metering (Class 1) and protection CTS (5P10) may be combined in one CT as different cores.

(ix) The CTs having different primary rating shall not be combined in same CT under different core.

(x) In view of (viii) above, bus bar differential protection CT for incomer/bus coupler/outgoing feeders shall necessarily be a separate CT and not as a part of some other CT having different cores.

(xi) Transformer differential, motor differential and feeder differential shall be with a separate CT not part of any CTs with different cores.

(xii) Marshalling panel at each bus section of switchboard shall be used for DCS interface. (xiii) ECS interface DI/AI shall be as per requirement defined in the job specification for ECS

system in the bid document. (xiv) CT and PT burden mentioned in data sheets are indicative. Contractor shall provide the same

as required including the burden for transducers provided at transducer panel. CONTRACTOR may consider 1.5 VA per phase per transducer for CT burden and 1.5 VA per phase per transducer for PT burden for analogue input for ECS interface.

(xv) DC and AC control supply scheme for HV switchboards shall be in line with hardware data sheet attached for HV switchboards.

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(xvi) All HV motor feeders schematics shall have provision for auto start and auto re-acceleration with feature to inhibit irrespective of process/licensor’s requirement.

(xvii) All HV switchboards shall have provision for positive LOTO implementation. Photographs of LOTO provision in each type of panels shall be submitted during drawing review for approval.

(xviii) All requirements as specified above including ECS interface, shall be applicable for switchboard. Line PT and protection & metering requirements shall be as per Design data sheets and 6.6 kV hardware data sheets as applicable.

(xix) Power factor meter shall be provided for synchronous motors in addition to the metering provided for induction motors.

(xx) The validity requirements for the type test reports for HV switchboards , breakers etc. shall be as below :-

S. No Type Test Equipment Validity

1 Short Circuit Withstand Capacity Switchboard Panel

Up to 5 years from the final bid opening date or design change which is earlier

2 Temperature Rise Switchboard Panel Up to 5 years from the final bid opening date or design change which is earlier

3 Impulse and power frequency withstand Switchboard Panel Till any design change

4 Internal Arc Fault Switchboard Panel Till any design change

5 Degree of protection for panels Switchboard Panel Up to 5 years from the final bid opening

date or design change which is earlier

6 Breaker short circuit duty cycle test Circuit Breaker Till any design change

In case the valid type tests on the offered design of Equipment is not available, all type tests shall be conducted by the successful vendor on the offered design after order finalisation without any extra cost and delivery impact.

4.6.4 Capacitors: Capacitor Banks of requisite rating will be placed as per system study report through ETAP.

4.6.5 MV SWITCHBOARDS

(i) Limiting maximum rating of PCC/PMCC shall be 4000A and fault level limited to 65kA for 1 sec (in case of 2.5MVA distribution transformer).

(ii) The maximum rating of all MCC’s shall be limited to 1250A. The minimum rating of MCCs shall be 800A except MCC/PDB for package systems irrespective of loading.

(iii) The maximum rating of ASB shall be limited to 1250A.The minimum rating of ASB shall be 800A irrespective of loading.

(iv) MCCs and ASB connected to PCC with 65kA fault level shall also be suitable for 65kA fault level.

(v) Equipment with higher short circuit rating shall be supplied based on short circuit studies. (vi) For MV Switchboards rated up to 4000A, forced cooling for any of the components e.g.

bus bars, air circuit breakers etc. is not acceptable. To achieve the continuous current

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rating under site conditions at design ambient temperature inside the panel / cubicle, the required derating as / if applicable shall be considered by switchboard vendor.

(vii) Line PT MCB off indication to be considered for incomers. (viii) No. of outgoing feeders shall be decided based on system requirement, spare feeders and

feeders for Owner’s use as defined elsewhere. However, feeders, as required, based on final approved single line diagram, shall be provided with no cost and time implication to owner.

(ix) Remote HV & MV switchboard shall have lockable trip switch and indicating lamp for sending end breaker for safety interlock during maintenance.

(x) Marshalling panel at each bus section of switchboard shall be provided for DCS interface. (xi) Only major relays, meters and controls are indicated in the data sheets. Any auxiliary

relays, timers, switches, etc., as required while developing the control schematic and felt necessary for safe operation, even if these are not specifically included, shall be supplied by the Contractor. All relays, metering and control components shall be mounted on the panel front only. All logic shall be implemented in the relay itself and not externally. Provision of adequate I/O count in the relays shall be ensured.

(xii) Dummy panel and rear extension, as required, for bus trunking / cable terminations shall be provided.

(xxi) Auto/Manual change over scheme for switchboard with two incomers and one bus-coupler breakers shall comply with the logic described briefly as follows. Safety interlocks as deemed necessary shall however be considered during detailed engineering. AUTO CHANGEOVER:

(a) Auto changeover between the two incomers and one bus-coupler shall be in such a way those two-incomer breakers are 'ON' at a time and bus-coupler breaker is normally open.

(b) Bus-coupler breaker is made 'ON' automatically in case the incoming supply at incomer breaker no. 1 or 2 fails and the respective breaker trips on under voltage.

(c) Blocking of auto transfer (i.e., closing of bus-coupler) if any incomer breaker trips due to a fault. Trip due to 64R shall allow the transfer.

(d) Tripping of incomer on under voltage shall be blocked, if both the incomers simultaneously experience an under voltage.

MANUAL CHANGEOVER: (a) Incomer no. 1 and 2 breakers are 'ON'. Bus-coupler breaker is 'OFF' Manual closing of

bus-coupler with momentary paralleling (interlocked with check synchronizing relay) of the incoming supplies to facilitate taking out any of the incomer breakers for maintenance.

(b) Trip incomer 1 or 2 (pre-selected) after closing of coupler to avoid continuous paralleling of incomers.

INITITIATION OF AUTO CHANGEOVER: (a) When the incoming supply to breaker no. 1 or 2 fails, the respective incomer is tripped

through under voltage relays and a timer. The time delay is in the range of 0.5 to 5 sec. Breaker trip on under voltage is blocked in case of power failure on both the incomers.

(b) The voltage on healthy bus section has been above the set value of normal voltage for a specified duration (settable through a timer 0.5-5 sec) and the incomer breaker of healthy bus is closed in service position.

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(c) Bus-coupler is open and in-service position. (d) Auto/ Manual switch is set for 'AUTO' operation.

CLOSING OF BUS COUPLER BREAKER UNDER AUTO OPERATION: (a) One of the incomer breaker has tripped on under voltage. (b) The residual voltage on the bus that has lost supply is less than 40% of normal

voltage. (c) Incoming voltage of healthy incomer has been above 80% of normal voltage for a

specific duration of 3 sec. (Through timer 0.5 sec - 5.0 sec) (d) Auto/ Manual switch is set for 'AUTO' operation.

SPECIFIC BLOCKING OF AUTO TRANSFER: (a) Bus-coupler should not close, if any of the two incomer’s trips due to faults. However

on operation of REF of transformer, it should not be blocked. MANUAL TRANSFER AFTER AUTOCHANGEOVER:

(a) When supply is again available at incomer breaker after auto changeover has already taken place, it is possible to restore the system to normal operating condition by operating selector switch (meant for tripping incomer no. 1 or 2 or bus-coupler) and by setting auto/ manual switch in 'Manual' mode.

In manual transfer the closing circuit shall be interlocked through check synchronizing relay.

(xiii) Philosophy and the requirement of ECS shall be same as described for HV switchboard above and ECS Job specification

(xiv) CT and PT burden shall be determined as described under clause for HV switchboard above.

(xv) All MV motor feeders schematics shall have provision for auto start. Breaker fed motors shall have auto re-acceleration irrespective of process/ licensor’s requirement with feature to inhibit. Contactor fed motors shall have auto re-acceleration feature if specified in process package.

(xvi) All MV switchboards shall have provision for positive LOTO implementation. Photographs of LOTO provision in each type of panels shall be submitted during drawing review for approval.

(xvii) All super critical application motors shall be provided with double contactors in DOL feeder. OWNER will identify and shall furnish the list of motors for super critical applications during detail engineering.

(xviii) R-C Circuit across power contactor and low-burden auxiliary contactor for receiving start/stop command from field shall be provided in all DOL starter feeders.

(xix) Incomers & bus couplers of all MV switchboards i.e. PCC, PMCC, EPMCC/EPCC, MCC, ASB shall be 4 pole ACB.

(xx) Common selector switch for selection of photo cell and timer shall be provided for one LDB/ELDB.

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(xxi) The validity requirements for the type test certificates for MV switchboards, breakers and busducts shall be as per the table given below:

S. No Type Test Equipment Validity

1. Short Circuit Withstand Capacity

MV Switchboards. Busducts

Upto 5 years from the final bid opening date or design change whichever is earlier

2. Heat Run MV Switchboards

and Bus-duct. Upto 5 years from the final bid opening date or design change whichever is earlier

3. Short circuit duty Air Circuit Breaker Till any design change In case the type tests on the offered design of switchboards, breaker & bus duct do not meet the above criteria, all required type tests shall be conducted by the successful vendor on the offered design of equipments after order finalization without any extra cost and delivery impact.

4.6.6 NUMERICAL RELAYS & INTEGRATION

a) The requirement of numerical relays and integration shall be in compliance with the requirement given in attached data sheet, design basis system architecture and specification. Even though data sheets define the requirement in terms of discreet relays (electromechanical type) but numerical relay comprising the all required functions shall be provided.

b) Scheme of switchboard shall be engineered to minimize the use of discreet auxiliary relays, timers etc. The control logic, as required shall be achieved through relay logic.

c) Output relays shall have 4 numbers spare NO contacts. d) Numerical motor protection relays shall be integrated to substation automation system on

open protocol such as Modbus TCP/IP protocol. e) Motor protection relays shall have alphanumeric display for configuration of relay and

metering. f) All relays shall be integrated to substation ECS RTU and HMI for monitoring and control.

The relays shall be integrated on the basis system architecture attached with the bid document.

g) Relays for HV switchboards shall be connected serially/ LAN topology to HV ECS RTU. Similarly relays for MV switchboards shall be connected in serial/ LAN topology to ECS RTU.

h) The redundancy in communication hardware substation automation system shall be provided as per the data sheet attached.

i) Input power supply as required shall be provided even though not listed under the scope of supply.

j) Separate laptops for HV and LV system, with required software, hardware, accessories and material shall be supplied. System configuration shall be latest proven model and upgradeable.

k) Laptop and HMI PC shall be of the latest configuration and processor as available at the time of purchase subject to approval by EIL/owner.

l) Laser printer shall be provided configured for line by line printing

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m) All the data as available in the relay including the status of DI should be considered to be communicated to HMI. The data required for final configuration shall be finalized during engineering. Similarly whether specified or not, serial interface shall have no limitation for data transfer to ECS. However data as required for ECS interface shall be decided during detail engineering.

n) Control supply supervision relay (80) where provided as a standalone conventional relay (i.e. in 415V MCC) shall also be hard-wired up to SAS (Substation Automation System) panels/HMI for monitoring purpose.

o) SAT shall be conducted to verify the actual simulation and shall be verified for required functionality and the scan time. The methodology shall be mutually agreed to verify the system simulation and intended specification of bid document. All graphics and navigation between different pages shall be configured to Owner’s satisfaction and successful commissioning. Any modification as required to meet the bid document requirement and customization modification due to Owner’s site engineer incharge shall be carried out with no commercial implication to owner.

p) Necessary hardware such as LIU, pigtail / patch cord etc. for termination of owner’s armoured FO cable shall be part of numerical relay system / switchboard and shall be in contractor’s scope

q) PCU of solar power plant, thyristor control panels of Electric heaters shall be integrated to substation automation system.

r) Interface between SAS panels and UPS shall be on MODBUS TCP/IP and through FO cable. FO cable and other termination accessories required for interface of SAS panels with UPS, DC system, VFDs, etc is included in Contractor’s scope.

4.6.7 HV AND MV MOTORS

HV and MV motors shall comply to the requirement of relevant data sheet, specifications and design basis attached with the bid document. In addition, motor supplied shall also meet the following requirement.

a) Cl. 7.1 & 7.2 of HV Motor Specification, 6-51-0031: Temperature detectors where provided as per specification for bearing and winding of HV motors shall be suitably interfaced with DCS for alarm

b) All MV motors shall be energy efficient IE2 (for hazardous area) and IE3 (for safe area) type as per IS 12615:2011.

c) RTD/BTD for packages if required for equipment safety shall be wired to trip as per operational scheme.

d) All HT motor bearings shall be provided with probes / detectors for measuring bearing vibration and temperature.

e) The cable entries of all Terminal Boxes of motors, before dispatch from motor manufacturer works, shall be fitted with suitably sized Metallic Sealing Plugs to prevent water entry/ingress in motor windings through openings meant for cable entry in terminal boxes at construction site till the time motors are erected and cable terminations are done.

4.6.8 PUSH BUTTON STATIONS

Local push button control station shall be provided for all motors. In addition to Local Control stations for motors, weatherproof emergency push button station (break glass type with hammer) near each power transformer and distribution transformer shall be considered to trip the transformer feeder in case of emergency. Outdoor area local control stations shall have canopies for additional weather protection.

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4.6.9 MOTOR OPERATED VALVES

a) MOV shall be conventional type or 2 wire control as defined in instrumentation scope of work and specification attached with the bid document. MOVs shall be compatible with foundation field bus.

b) Fire safe MOV shall be provided if specified in Process data sheet. Fire survival type cable shall be provided for fire proof MOV’s.

4.6.10 FIRE ALARM AND COMMUNICATION CABLES

Minimum size of communication cable shall be 3P * 0.9mm diameter, annealed copper conductor. Communication cables shall be provided with overall screen. Communication cables shall be as per enclosed data sheet and EIL standard specification no. 6-51-0052. Minimum size of fire alarm cable for manual call points/detectors loop & power supply loop shall be 2 pair, 1.5 mm2, and annealed copper conductor, with overall screen. Wiring for detectors/power supply loops shall be concealed wiring inside buildings and in surface conduit in cable cellar and above false ceiling/ below false flooring. Fire alarm cables shall be as per enclosed data sheet and EIL standard specification no. 6-51-0052. All fire alarm cables and plant communication cables as required within unit battery limits shall be supplied & installed by contractor. The final selected cable size type for fire alarm cables and plant communication cables shall be informed during detail engineering based on the final selected vendors for these systems. No additional cost or extra time will be admissible on account of the same.

4.6.11 FIRE DETECTION AND ALARM SYSTEM

(i) Fire alarm system shall be engineered as per the specifications attached with the bid document.

(ii) Fire alarm system shall be engineered and procured for the complex by Owner/others. The fire alarm system shall be addressable type consisting of central fire alarm panel (CFAP) work station, Data gathering and fire alarm panel (DGFAP), repeater panel, intelligent addressable multi sensor detector, manual call points, hooters, sirens and integrating hardware. Based on estimated quantity, the entire system shall be engineered and procured by Owner/others. Fire alarm system as required for unit/area including buildings with in battery limit shall be engineered by this CONTRACTOR. Installation and cabling including supply & laying of cables up to battery limit DGFAP for all field equipment in line with approved calculations shall be done by contractor. The fire alarm system shall be from one of manufacturer as per vendor list. The cables for the system are vendor specific and shall be informed during detailed engineering.

(iii) Fire alarm equipment installation and cabling shall be as per specification attached, MTO, approved sizing calculations and block diagram

(iv) The fire alarm system FIM (Free Issue Material) quantities are mentioned in the bid package. In case quantity required by CONTRACTOR is more than the estimated FIM, contractor shall supply the additional quantity without any time & cost implication. The make of these additional equipment/devices shall be of identical make, type & model no. as that of the free-issued equipment/devices.

(v) Interface cabling with air-conditioning system, clean agent system and other systems shall be provided by contractor as applicable.

(vi) Fire Alarm cables shall be as per the specification attached with the bid document and size shall be informed during engineering with no commercial and time implication to owner.

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4.6.12 PLANT COMMUNICATION SYSTEM

(i) Plant communication system shall be engineered in line with the specifications attached with the bid document for all areas within battery limit including buildings.

(ii) Plant communication system shall be engineered and procured for the complex by Owner/others. This system shall be consisting of Plant communication system central exchange, FCS racks, Field call stations (FCS), Loud speakers (LS), beacons, Power supply unit, distributed amplifier units etc. The entire system shall be engineered and procured by Owner/others. Based on the communication requirement, contractor shall be issued maximum no. field devices as FIM as defined in the bid document. The Field equipment shall be wired to Plant communication FCS rack by contractor including supply & laying of communication cables for wiring from FCS rack to FCS & loudspeakers. The communication system shall be from one of manufacturer as per vendor list. The cables for the system are vendor specific and shall be informed during detailed engineering

(iii) In case quantity required by CONTRACTOR is more than the estimated FIM, Contractor shall supply the additional quantity without any time & cost implication. The make of these additional equipment/devices shall be of identical make, type & model no. as that of the free-issued equipment/devices

(iv) Installation and cabling including supply of cabling as per approved layouts and block diagram for Plant communication system equipment including FIM shall be done by contractor.

(v) Communication cables shall be as the specification attached with the bid document and size & type shall be informed during engineering with no commercial and time implication.

4.6.13 FIBER OPTIC CABLES

i) Contractor shall supply the data-highway using mono mode armoured fiber-optic cable and associated HDPE ducts as per specifications of this package. Each data highway shall be on a separate fiber-optic cable with minimum 4 number of spare fibers as per EIL standard specification 6-51-0080.

ii) HDPE duct supplied shall be of black colour with red strip for main data highway and blue strip for redundant data highway.

iii) Solid pre–lubricated HDPE ducts for underground routing of cables shall be used in the entire project area. HDPE ducts shall be supplied complete with all applicable accessories such as push fit coupler, bends and elbows, plugs, sonic head etc. on as required basis.

iv) For all cables, supply of termination kits at both ends, jointing kits (as applicable) is also in contractor’s scope.

4.6.14 AIR CONDITIONING SYSTEM

Air conditioning system provided as a part of this bid document shall have necessary interface with fire alarm system. The interface cables shall be laid up to DGFAP by contractor.

4.6.15 CABLES AND WIRES

Cable sizing shall be based on the system fault level with duration as defined elsewhere in the tender in the engineering design basis. Heat shrinkable type HV cable end termination kits shall be used for 6.6KV cables. Either heat shrinkable type or cold shrinkable type end termination kits shall be provided for 66KV EHV cable termination. Make and model no. of shrinkable type termination kit shall be approved by owner/PMC during detailed engineering based on PTR (Past Track Record) and type test certificates furnished by contractor/manufacturer.

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B224-111-16-50-SP-7203 Rev. B

Page 19 of 24


Single point screen bonding shall be provided on 66KV EHV cable complete with Link box having SVL at one end and with link box without SVL at other end. All EHV cable, HV cable, MV/ LV cable, wires, control cable, Fire alarm and communication cables shall be XLPE insulated.

4.6.16 LIGHTING SYSTEM

Normal & emergency lighting shall be provided as per Electrical Design Basis. DC critical lighting shall also be provided to enable operation in the event of power failure. They shall be provided at exit, escape route inside the substation buildings, control room, TG building, DG room and other strategic locations/units.. All lighting fixtures shall be suitable for the area in which they are installed viz safe or hazardous area. Twin cluster LED type medium intensity flashing lamps, maintenance-free aviation lighting for all tall structures, stacks etc. as per aviation regulations and norms shall be provided. Aviation lighting fixtures shall be fed from the emergency lighting panel only. Aviation lighting fixtures at alternate elevation shall be fed from different circuit to ensure availability of aviation lighting in case of failure of one circuit. Lighting & Power panels shall be standardized to have 6, 12 or 18 single phase outgoing feeders with ELCB.

4.6.17 EARTHING & LIGHTNING PROTECTION SYSTEM

Earthing system of the entire package shall be designed to meet the statutory requirements and shall be included in contractor’s scope including interconnection with Owner’s earth grid and earthing of all equipment. Minimum size of the main earth grid around substation, from substation to unit area etc. shall be 75 X 10 mm GI. Contractor’s scope shall include connection of each transformer neutral including lighting transformer through two nos. independent earth electrodes with pits and interconnection to main earth strip, lightning protection of tall structures, substation, chimney, lighting mast etc. (no. of connections of the equipment to the earthing system for lightning protection shall be as per relevant standards. However, minimum two nos. independent earth electrodes shall be provided for tall structures for connection to earth and to the main earth grid) and providing earth electrodes with test pits for the substation and plant area. Adequate number of earth plates for taking branch connections shall be provided. Contractor shall provide earth grid up to battery limit of the package including provision of earth plate near the battery limit for interconnection of the unit earth grid with the Owner’s main plant grid.

4.6.18 SUBSTATION BUILDING

The substation for PFCC BLOCK i.e. SS-11 shall be adequately sized with proper equipment layout and this shall be subject to Owner/ EIL’s approval. Substations shall be located in the safe area only. Contractor shall increase the size of the building / number of floors, if required at any stage, to accommodate electrical equipment required for the unit and owner’s equipment. Contractor shall also provide cut outs, floor insert plates, etc. for all equipment to be supplied by Owner/other contractors and to be installed in substation building. Cable cellar with cable trays shall be provided for spreading cables below switchgear room for substation building. Cable cellar shall be adequately ventilated with fresh air entry from safe side (opposite to process unit) with exhaust fans. The substation building shall have

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switchgear room, battery room, HVAC rooms, maintenance room, store, operator room and Toilet as minimum. Outdoor type capacitor bays and transformer bays shall be provided. Capacitor and Transformer bays shall be covered with roof slab. Switchgear room, operator room on the first floor shall be Air conditioned. Battery room shall be adequately ventilated with exhaust fans. Lighting fixtures and exhaust fans in battery room shall be flameproof & suitable for gas group IIC. Proper sealing / baffles or frame shall be installed to separate busduct sections inside and outside building in order to prevent interchange of air between the sections. The minimum head clearance for personnel movement for cross cable trays in cable cellar shall be 1800mm for escape routes. The cable cellar clear height shall be decided accordingly. The air-conditioning ducts in substation shall be so mounted that they do not fall above the switchboard and do not obstruct illumination. Fire fighting system like emulsifying system for transformers, water sprinkler system for cable cellar, portable type CO2 extinguishers, sand buckets, Fire paint etc shall be provided for substation, transformer bay etc. as per statutory regulations and as defined elsewhere. Switchboards shall not be located on the building expansion joints. If unavoidable, dummy panel shall be provided on expansion joint. Mono rail with chain pulley block shall be provided above 66kV GIS isolator breaker panels for installation and maintenance. Any other civil work required for completion of work is included in contractor’s scope of work.

4.6.19 RCC LINED TRENCHES/CABLE TRAYS

(i) Overhead electrical cable Trays shall be provided for cable cellar in substations, plant/ unit area and upto SRR.

(ii) Cables for different voltage grades shall be laid in independent cable trays. Separate cable trays shall be provided for control cables.

(iii) Wherever trenches/trays within battery limit have interface with the trays and trenches outside battery limit, the details shall be finalized during detailed engineering.

(iv) It shall be contractor’s responsibility to co-ordinate the cable trench/ tray routing from other contractor and other agencies involved. Trenches and trays shall be provided up to the battery limits as per the final approved layouts.

(v) Cable trenches in unit shall be sand filled. (vi) Refer plot plan for exact location of substation, SRR and unit for further details and

estimation of cabling. (vii) All HV & MV power cables in racks/trays shall be laid in single layer only. (viii) Single core cables shall be laid in Trefoil configuration. (ix) 20% spare space shall be provided in cable trays/trenches. (x) Cable trays covers shall be provided for top most cable trays and vertical trays. Further

wherever trays crosses hydrocarbon lines, bottom covers shall be provided. (xi) Cable tags shall be made from Stainless steel and numbers shall be engraved. SS

wires to be used for binding Cable Tags. 4.6.20 ECS SYSTEM

Refer ECS system job specifications. Doc No. B224-111-16-50-SP-7204 attached.

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JOB SPECIFICATION




B224-111-16-50-SP-7203 Rev. B

Page 21 of 24


5.0 COMPREHENSIVE POST WARRANTY ANNUAL MAINTENANCE CONTRACT (CPWAMC)

Comprehensive post warranty annual maintenance contract for 5 years duration shall be provided for VFD / Soft Starters/ Substation Automation System (SAS) / UPS / DC System / Thyristor control panel system and to be executed after expiry of warranty. In the event of any malfunction of the system hardware / system software, experienced service engineer shall be made available at site within 48 hours on the receipt of such information from OWNER. Owner personnel will work on system day-to-day basis and wherever possible, owner shall inform the type of failure of hardware /software to Bidder/Contractor based on diagnostic available with the system. However Bidder/Contractor shall be fully responsible to attend and rectify the root cause and the failure at the shortest possible time. The contract shall include supply of maintenance spares, tools & tackles as required, travel, boarding & lodging of service engineer. The quote shall be made year wise up to 5 years. Contract shall include on-site stock and shall provide cost of each item after expiry of 5 years AMC with escalation formula. The service under Post Warranty Maintenance Contract including supply of spare parts and services shall broadly cover the Periodic maintenance, Emergency service, Software support, etc. as per the following: a) Periodic maintenance:

Four no. pre defined visits per annum for inspection of general healthiness of the VFD / Soft Starter/ Substation Automation System (SAS) /UPS/DC System/ Thyristor control panel system / ECS, study and advice on daily maintenance, inspection of hardware and software shall be provided. If any problem/ malfunction is reported, the running of test programs, on-line servicing and resolution to reported problems shall be done. Checks shall be conducted on the following running system:

i. On-line sub-systems ii. Power supply checks iii. Bought out items & peripherals

Pre-defined visits shall start immediately from the next month after commissioning. HRRL will have the right to reschedule the visits. Each Visit shall be of Min 2 days including to & fro charges, lodging and boarding and shall conclude only after the deliverables are achieved as per the approved check list. Checking of computer/printer hardware and software is also be covered in these visits, no other extra cost will be reimbursed for the same. b) Software/ Hardware maintenance: Maintain existing software/hardware, providing antivirus software to improve and utilize existing application and improve performance of the system. Minor modification of the software shall also be covered under this scope. During the CPWAMC period if bidder feels that the system require software release up gradation necessarily then same shall be provided without any additional cost implication to HRRL. c) Emergency Service:

Any failure shall be on system suppliers' account. The Engineer must report at site within 48 hrs of report of failure, with necessary spares. The system must be brought back within 48 hours after reporting at site. These visits shall not be counted as part of pre-defined visits. NOTE:

“Contractor to note that while carrying out the Post Warranty Maintenance Contract activities, Owner's (HRRL) engineers may associate with system engineers. On-job training of

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B224-111-16-50-SP-7203 Rev. B

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these associated engineers shall be covered under this scope. All financial aspects of the Comprehensive Post Warranty Maintenance Contract must be listed clearly by the Contractor.”

6.0 MISCELLANEOUS REQUIREMENTS

(i) Variable frequency drive panels/equipments for motor/equipments shall be provided as per licensor/ process package requirements.

(ii) VFD systems shall be sized taking care of input voltage variation as per Engineering Design Basis and voltage drop within the VFD system

(iii) All cable glands/adopter/blocking plug for hazardous area equipment shall comply with requirements of IS/IEC 60079-0.

(iv) Contractor shall furnish complete relay coordination and relay settings for the complete package including coordination with other EPCC contractor/owner, relay settings for the upstream feeders.

(v) Power system study shall be carried out in ETAP. Contractor shall furnish the native file of ETAP after carrying out the preliminary study and also along with the final report.

(vi) It is CONTRACTOR’s responsibility to identify and supply the safety equipment such as hand gloves, apron, eye shields, danger boards, first aid box, UPS panels etc., portable fire extinguishers in substation building and other equipment for safety of all electrical equipment and personnel as per statutory regulations.

(vii) All outdoor electrical equipment’s i.e. motors, LCS, switch sockets, LP/PP, FCS, MCP, etc. shall be provided with FRP canopy.

(viii) Safe and hazardous area lighting fixtures shall be provided with external reflectors. (ix) Wherever single core cables are to be terminated in switchboard, aluminium gland

plates shall be provided. (x) Tinned copper lugs having sector shaped/circular barrel shall be used for making

connections for cables having sector shaped/circular geometry of conductor respectively.

(xi) Contractor shall include painting and marking of all buses, individual incomers, all outgoing feeders etc. with detail such as Tag no., feeder rating, sending end source reference etc. for all switchboards.

(xii) Paint shade for indoor electrical equipment shall be RAL 7032 and for outdoor electrical equipment shall be RAL 7031.

(xiii) HV busducts shall be air insulated type only. MV busducts shall be Sandwich type. (xiv) For termination of aluminium cables to copper bus or copper cables to aluminium bus,

bimetal lugs shall be used. (xv) Sealing of cut-outs for switchboards on switchgear hall floor shall be properly done

after placement of chequered plates. (xvi) Proper stencilling showing reading & date with letters of radium stickers to be done on

each and every Earth Electrode. (xvii) Use of power junction boxes for cable terminations to be avoided to the extent

possible. Use of power junction box shall be under exception cases subject to Owner’s approval.

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7.0 INSPECTION AND TESTING AT MANUFACTURER’S WORKS

(i) All major electrical equipment and material shall be subject to inspection by owner/ PMC or authorized representative at manufacturers’ works. Contractor/Vendor/ Sub-Vendor shall furnish all necessary information concerning the supply to owner/PMC.

(ii) Contractor shall ensure that the electrical equipment procured have type test certificates. Type test certificates for HV and MV switchboards shall not be more than five years old. In those cases where type test certificates are more than five years old, contractor/manufacturer shall carry out the type tests at CPRI or any authorized testing lab prior to dispatch of equipment with no commercial implication.

(iii) During fabrication, all the equipment shall be subject to inspection by owner/PMC or by an agency authorized by the owner to assess the progress of work as well as to ascertain that only quality raw material is used.

(iv) Routine and acceptance tests as listed in relevant Indian standard and equipment specifications shall be conducted. Type test if listed in ITPs and in the relevant data sheet shall be conducted. Type test, if specified, shall be conducted only on one of equipment of each type and rating. These tests shall be carried out by the Contractor/vendor/sub-vendor and shall be witnessed by owner/PMC or an agency authorized by owner/PMC.

(v) Contractor shall ensure that the hazardous area equipments provided shall have the necessary test certificates and valid CCOE approval certificates.

8.0 FIELD TESTING & COMMISSIONING

(i) Contractor shall carry out the installation, field testing and commissioning of all items of electrical equipment including installation, assistance in field testing and commissioning of free issue items such as fire detection and alarm system equipment, plant communication system equipment, etc. Further appropriate test and commissioning reports and as-built documentation as necessary for all electrical equipment shall be provided.

(ii) Field testing and commissioning of HV switchboards, numerical relay and integrating equipment, VFD, UPS system, battery chargers electronic equipment and large rated motors shall be done by OEM (Original Equipment supplier). For other equipment, contractor shall ensure services of manufacturers’ representatives for supervision of installation, testing and commissioning.

(iii) Contractor shall coordinate with manufacturers of other equipment wherever required and shall freely and readily supply all technical information for this purpose as and when called for.

(iv) All electrical equipment shall be said to be installed and mechanically complete after circuit testing, primary and secondary injection testing and loop simulation is complete. Due care and consideration shall be given to the installation of all equipment, materials and facilities.

(v) Obtaining clearance for energizing the complete electrical facilities covered under this tender and approval of installation / drawings from central electrical inspector and any other concerned approving authority e.g. CEA, TAC, CCE, DGFASLI etc. is in contractor scope.

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9.0 TWO YEARS SPARES

Bidder shall furnish the required spares for two years of normal operation and maintenance for all electrical equipment with itemized quantity and unit rate. However owner will decide ordering as per their requirement.

10.0 MAKES OF EQUIPMENT/COMPONENTS

(i) Refer elsewhere in the bid document for acceptable makes of major electrical equipment and electrical components.

(ii) Contractor/ vendor while ordering shall ensure the availability of spare parts and maintenance support services for the offered equipment at least for 15 years from the date of supply. Contractor/ vendor shall give a notice of at least one year to the Owner and PMC before phasing out the products/spares to enable the owner for placement of order for spares and services.

(iii) Contractor/ Vendor may procure material from any of owner/ PMC-approved vendors. However current validity and range of approval as per PMC enlistment letter, workload, stability and solvency need to be verified by the vendor/contractor before placement of order.

(iv) Contractor/ Vendor can offer equipment/components of makes other than specified in the tender during order execution. The alternate make of equipment/components will be evaluated post order, based on the satisfactory track record and test certificates to be furnished by the Vendor/ Contractor. In case the alternate makes are not found acceptable, equipment/components shall be strictly as per vendor list enclosed with the tender.

(v) For equipment/components not listed in the Vendor list such as EHV GIS isolation breaker panel, EHV cable termination kits; Contractor shall submit the 1 year operation certificate, PTR (Past Track Record) and Valid Type test certificates for review by Owner/PMC. EHV GIS supplier shall submit 1 year operation certificate, PTR for offered models manufactured / assembled at proposed works with details of sourcing & sub-assemblies of various equipment / components (if sourcing of any equipment / component is from overseas principals). The type test reports shall be for the GIS manufactured / assembled & supplied from the proposed works with identical sourcing & sub-assemblies as being offered.

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Engineering Design Basis (Electrical)

Document No. B068-999-16-50-EDB-1001

Rev No. 1 Page 1 of 46


ENGINEERING DESIGN BASIS ELECTRICAL

JOB NO: B068

PROJECT: RRP

CLIENT: HRRL

EIL SIGNATURE:

CLIENT SIGNATURE:

1 05/Dec/2018 Revised & Issued for Engineering RATHAUR RASHMI

SINGH (MS)

SAHU MANJIT KUMAR

SAHU MANJIT KUMAR

0 23/Nov/2018 Issued For Engineering RATHAUR RASHMI

SINGH (MS)

SAHU MANJIT KUMAR

SAHU MANJIT KUMAR

Rev. No. Date Purpose Prepared by Reviewed by Approved by

Legend:Bold italic text denotes change with respect to previous revision.

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Document No. B068-999-16-50-EDB-1001



Table ofContents 1.0 SCOPE .................................................. 5

2.0 ABBREVIATIONS, CODES & STANDARDS / PUBLICATIONS ........... 5

2.1 ABBREVIATIONS ......................................... 5

2.2 CODES & STANDARDS / PUBLICATIONS ....................... 6

3.0 GENERAL / DESIGN CONSIDERATIONS ......................... 8

4.0 SPECIFIC DESIGN REQUIREMENTS ............................ 8

5.0 OWNER / CLIENT SPECIFIC REQUIREMENTS ..................... 9

5.1 SITE CONDITIONS ........................................ 9

5.2 POWER SOURCE DETAILS ................................ 10

5.3 POWER SUPPLY DISTRIBUTION SYSTEM ..................... 11

5.3.1 VOLTAGE AND FREQUENCY VARIATION ................. 11

5.3.2 UTILISATION VOLTAGE .............................. 12

5.3.3 UTILISATION VOLTAGE FOR CRITICAL SUPPLIES .......... 12

5.3.4 OPERATING PHILOSOPHY ............................ 13

5.4 CONTROL-PROTECTION - METERING ........................ 14

5.4.1 CONTROL PHILOSOPHY ............................. 14

5.4.2 POWER ISOLATION FOR TRANSFORMERS LOCATED REMOTELY AWAY FROM HV SUBSTATION ............................. 15

5.4.3 RELAY PROTECTION SYSTEM ......................... 17

5.4.3.1 PROTECTION DEVICES FOR POWER DISTRIBUTION SYSTEM................................................... 17

5.4.3.2 POWER GENERATION AND EXTERNAL POWER SUPPLY .. 18

5.4.3.3 RELAY PROTECTION PHILOSOPHY .................. 20

5.4.4 METERING ........................................ 22

5.4.4.1 METERING DEVICES IN EHV, HV AND MV SWITCHBOARDS 22

5.4.4.2 METERING FOR GENERATOR AND GENERATOR TRANSFORMER ...................................... 24

5.5 SUBSTATION DESIGN .................................... 24

5.5.1 SUBSTATION AUTOMATION SYSTEM .................... 24

5.5.2 EHV SWITCHYARD .................................. 25

5.5.3 SUBSTATION FEATURES ............................. 25

5.5.4 SPECIFIC EQUIPMENT LOCATIONS ..................... 26

5.6 EQUIPMENT DESIGN..................................... 27

5.6.1 EHV DESIGN ...................................... 27

5.6.1.1 EHV OUTDOOR SWITCHYARD ...................... 27

5.6.1.2 EHV SWITCHBOARD ............................. 27

5.6.2 HV SWITCHBOARD ................................. 27

5.6.3 CURRENT TRANSFORMER (CT)/POTENTIAL TRANSFORMER (PT)

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.................................................... 28

5.6.4 TRANSFORMERS (POWER/DISTRIBUTION) ............... 28

5.6.5 MV SWITCHBOARD ................................. 28

5.6.6 MEDIUM VOLTAGE MOTOR STARTER TYPE ............... 29

5.6.7 MEDIUM VOLTAGE OUTGOING FEEDER TYPE ............. 30

5.6.8 MOTOR CONTROLS (AS PER PROCESS PACKAGE & OPERATING PHILOSOPHY) ......................................... 30

5.6.9 CONTROL SUPPLY VOLTAGE.......................... 30

5.6.10 MOTORS ........................................ 31

5.6.11 UPS SYSTEM ..................................... 31

5.6.12 COMMUNICATION SYSTEM .......................... 32

5.6.13 FIRE DETECTION AND ALARM SYSTEM ................. 32

5.6.14 DC SYSTEM ...................................... 33

5.6.15 VARIABLE FREQUENCY DRIVE........................ 34

5.6.16 CABLE SIZES ..................................... 34

5.7 CABLING SYSTEM ....................................... 35

5.7.1 CABLE DETAILS .................................... 35

5.7.2 CABLE LAYING PHILOSOPHY .......................... 36

5.8 EARTHING SYSTEM ..................................... 37

5.9 LIGHTING SYSTEM ...................................... 37

5.9.1 SUPPLY SYSTEM ................................... 37

5.9.2 CONTROL PHILOSOPHY ............................. 37

5.9.3 AC EMERGENCY LIGHTING ........................... 38

5.9.4 DC CRITICAL LIGHTING FOR ESCAPE ................... 38

5.9.5 WIRING TYPE...................................... 39

5.9.6 SPECIFIC LIGHTING REQUIREMENTS ................... 39

5.10 ELECTRIC HEAT TRACING SYSTEM ........................ 39

5.11 ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS ............ 40

5.11.1 NOTES .......................................... 40

5.12 ELECTRICAL CONTROL SYSTEM-ECS ....................... 41

6.0 SPARE PARTS ........................................... 42

6.1 MANDATORY SPARES.................................... 42

6.2 COMMISSIONING SPARES ................................ 46

6.3 RECOMMENDED SPARE FOR NORMAL OPERATION & MAINTAINENCE 46

6.4 SPECIAL TOOLS AND TACKLES ............................ 46

7.0 VENDOR DATA REQUIREMENT .............................. 46

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1.0 SCOPE

This electrical design basis defines the design requirements agreed by owner/clients in addition to "EIL standard design philosophy for electrical facilities no. 6-51-0099 Rev. No. 6" In case of any conflict between statutory requirements, this design basis and standard design philosophy, the most stringent requirement shall govern. This electrical design basis is applicable for the Rajasthan Refinery Project in Pachpadra, Rajasthan.

2.0 ABBREVIATIONS, CODES & STANDARDS / PUBLICATIONS

2.1 ABBREVIATIONS

Code Description #/@ Data to be provided/ confirmed by Client NA Not Applicable $ To be decided during detail engineering AC Alternating Current ACB Air Circuit Breaker ASB Auxiliary Service Board CBCT Core Balance Current Transformer CEA Central Electricity Authority CT Current Transformer DC Direct Current DCP Data Concentrator Panel DG Diesel Generator DGMS Director General Mines Safety DOL Direct On Line EHV Extra High Voltage ELCB Earth Leakage Circuit Breaker EPC Emergency Power Control Center EPMCC Emergency Power cum Motor Control Center FRLS Flame Retardent Low Smoke GI Galvanised Iron GTG Gas Turbine Generator HMI Human Machine Interface HSR High Availability Seamless Redundancy HV High Voltage IEC International Electro-Technical Commission LDB Lighting Distribution Board LV Low Voltage MCC Motor Control Centre MCCB Moulded Case Circuit Breaker MOV Motor Operated Valve MV Medium Voltage NGR Neutral Grounding Resistor OLTC On Load Tap Changer PCC Power Control Centre PESO Petroleum & Explosive Safety Organisation PLC Programmable Logic Control PMCC Power Cum Motor Control Centre PRP Parallel Redundancy Protocol PT Potential Transformer

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Code Description PTB Physikalisch-Technische Bundesanstalt PVC Polyvinyl Chloride RCC Reinforce Cement Concrete RSTP Rapid Spanning Tree Protocol SFU Switch Fuse Unit SPN Single Phase & Neutral STG Steam Turbine Generator TP Three Phase TPN Three Phase & Neutral UPS Uninterrupted Power Supply VFD Variable Frequency Drive XLPE Cross Link Poly Ethylene NA Not Applicable VCB Vacuum Circuit Breaker

2.2 CODES & STANDARDS / PUBLICATIONS

The main codes and standards, considered as minimum requirements, as applicable, are as follows -

S.No. Description Standards / Codes Edition 1 Code of practice for the fire safety

of buildings - Electrical Installations.

IS-1646 Latest

2 Code of practice for selection: installation and maintenance of automatic fire detection and alarm system.

IS-2189 Latest

3 Code of practice for the protection against lightning.

IS/IEC-62305 Latest

4 Code of practice for fire safety of industrial buildings - Electrical generating and distributing stations.

IS-3034 Latest

5 Code of practice for Earthing. IS-3043 Latest 6 Code of practice for Interior

Illumination. IS-3646 Latest

7 Application guide for Insulation Coordination.

IS-3716 Latest

9 Guide for safety procedures and practices in electrical work

IS-5216 Latest

10 Guide for selection of electrical equipment for hazardous areas.

IS-5571 Latest

11 Classification of hazardous areas(other than mines) having flammable gases and vapours for electrical installations.

IS-5572 Latest

12 Code of practice for Industrial Lighting.

IS-6665 Latest

13 Guide for Control of undesirable static electricity.

IS-7689 Latest

14 Guide for improvement of power factor - consumer's installations.

IS-7752 Latest

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S.No. Description Standards / Codes Edition 15 Application guide for on load tap

changers. IS-8478 Latest

16 Reference ambient temperature for electrical equipment

IS-9676 Latest

17 Code of practice for selection, installation and maintenance of transformer.

IS-10028 Latest

18 Code of practice for selection, installation and maintenance for switchgear and control gear.

IS-10118 Latest

19 Voltage bands for electrical installations including preferred voltages and frequencies.

IS-12360 Latest

20 Guide for short circuit calculations in three phase AC systems.

IS-13234 Latest

21 Guide to the use of electrical apparatus for potentially explosive atmospheres in the presence of combustible dusts

IS- 15142 Latest

22 National Electrical Code (NEC) - BIS Publication.

SP-30 Latest

23 Recommended practices on static electricity

OISD-STD-110 Latest

24 Classification of Area for electrical installation at Hydrocarbon Processing and handling facilities

OISD STD-113 Latest

25 Inspection and safe practices during electrical installation

OISD-STD-147 Latest

26 Design aspects for safety in electrical systems

OISD STD-149 Latest

27 Fire Protection System for Electrical Installations

OISD STD 173 Latest

28 Lightning Protection OISD STD-180 Latest 29 Electrical apparatus for explosive

gas atmospheres - General requirements.

IS/IEC 60079-0 Latest

30 Equipment protection flameproof enclosures "d"


31 Electrical apparatus for explosive gas atmospheres - Intrinsic safety ''''I''''

IS/IEC 60079: Part-11 Latest

32 Electrical apparatus for explosive gas atmospheres Increased safety type "e"

IS/IEC 60079: Part 7 Latest

33 Classification of flammable gases or vapours with air with air according to their maximum experimental safe gaps and minimum igniting currents

IS 9570/IEC 60079-12 Latest

34 Electrical apparatus for explosive gas atmosphere -Part-15 Construction, test and marking of type of protection "n" electrical apparatus


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S.No. Description Standards / Codes Edition 35 Material characterstics for gas

and vapour classifications-section-1- Test methods and data

IS/IEC 60079-20-1 Latest

36 Energy efficient induction motors-Three phase squirrel cage

IS-12615 Latest

37 Outdoor type oil immersed distribution transformers rating upto and including 2500 KVA, 33KV- specification part 1 mineral oil immersed.

IS-1180 Latest

38 Electrical apparatus for explosive gas atmospheres - Oil immersion "o"

IS/IEC 60079 : Part-6 Latest

39 Electrical Apparatus for explosive gas atmospheres - Powder filling ''''q''''

IS/IEC 60079 : Part-5 Latest

40 Electrical apparatus for use in the presence of combustible dust: General requirements

IS/ IEC 61241-0 Latest

41 Electrical apparatus for use in the presence of combustible dust: classification of areas where combustible dusts are or may be present


42 Electrical apparatus for use in the presence of combustible dust: selection and installation


43 IEEE recommended practice and requirements for harmonic control in electric power systems

IEEE-519 Latest

3.0 GENERAL / DESIGN CONSIDERATIONS

S.No. Project Philosophy 1 LV - Low Voltage. The voltage which does not normally exceeds 250 V. 2 MV - Medium Voltage. The voltage which normally exceeds 250 V and does not

exceeds 650 V. 3 HV - High Voltage. The voltage which normally exceeds 650 V but does not exceed

33 kV. 4 EHV - Extra High Voltage. The voltage which exceeds 33 kV under normal condition. 5 Canopy shall be provided for all outdoor equipments except transformers &

Capacitor Banks. However, Roof slab for all transformers, Capacitor banks and removable type shed for Generator transformers & Tie transformers shall be provided.

4.0 SPECIFIC DESIGN REQUIREMENTS

S.No. Project Philosophy

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S.No. Project Philosophy 1 a) For spare philosophy of outgoing feeders in EHV/HV/MV switchboards, AC

distribution board (UPS system), DC distribution board (DC system), DBs etc., relevant clauses of EIL Standard design philosophy for electrical facilities Doc. No. 6-51-0099, Rev 6 shall be considered and 10% spare mentioned in 6-51-0099 shall be read as 20% spare (spare feeders are not applicable for isolating breaker panels) for all EHV, HV, MV switchboards,DCDB, DBs etc.; for ACDB-40% spare feeders shall be considered. Incomer rating of the all switchboards (EHV, HV, MV, ACDB, DCDB, DBs etc.) and complete UPS System, complete DC system shall be sized for having 20% future growth in place of 10% mentioned in 6-51-0099. b) Transformer rating shall be decided considering 20% spare margin in place of 10% spare margin as mentioned in 6-51-0099. c) Refer to clause no. 5.13.9 of 6-51-0099, all incoming cables to switchgear/UPS/DC System/DBs and other equipment shall be sized for maximum load including 20% future growth.

2 Incomer and bus coupler of MCC & ASB shall be electrically operated Air Circuit Breaker in place of load break switch.

3 All enclosed spaces like columns, vessels, furnaces, boilers etc. shall be provided with common fixed 240/24V transformer at the bottom of columns, vessels, furnaces, boiler etc. Only 24V sockets shall be provided at each platform/ man holes for shut down lighting purpose. 24V hand lamp unit shall be provided with 20m length of cable in place of 15m as indicated in clause 6.4.1 of 6-51-0021.

4 Wherever there are two process motors/ heaters/ loads with A & B for the same application/ service, the same shall be distributed in bus section A & the other in bus section B.

5 Current transformer shall be provided in each motor feeder in switchboard wherever 4-20mA motor current feedback is sought in DCS/ PLC as per Electrical & Instrumentation interface.

6 Conformal coating shall be as per grade 3C3 (harsh environment) of IEC 60721-3-3. Alternatively, it shall comply with ANSI/ ISA S71.04 class G3 or IEC 60068-2-60 for mixed gas flow test or ASTM B845

7 FA/ PA cable shall not be clamped with columns or structures or any wall support; it shall be through trays wherever cable duct is not available.

5.0 OWNER / CLIENT SPECIFIC REQUIREMENTS

5.1 SITE CONDITIONS

S.No. Description Selected Option Available Options 1 Equipment design

temperature (IS-9676) $ 45 DEG C a)40 DEG C

b)45 DEG C c)50 DEG C d)Any other

2 Relative humidity maximum 100% at 48.2 degree C

3 Soil Resistivity As per soil investigation report.

4 Minimum temperature. for battery sizing

10 DEG C a)10 DEG C b)20 DEG C c)Any other

5 Altitude above mean sea level

Less than 1000m above MSL

a)Less than 1000m above MSL b)Any Other

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S.No. Description Selected Option Available Options 6 Maximum temp 48.2 DEG C a)40 DEG C

b)45 DEG C c)50 DEG C d)Any other

7 Minimum temp 3.4 DEG C

8 Siesmic Zone As per IS-1893 (Also Refer Structural Design Basis)

Notes: 1. Pollution Level- Heavy 2. Minimum temperature for Heat tracing- $ (To be decided during detailed engineering)

5.2 POWER SOURCE DETAILS

S.No. Description Selected Option Available Options 1 Power System $Grid Supply with CPP a)Independent system

b)Existing system 2 Grid Supply $Grid and CPP in Parallel a)Yes

b)No (Below Clause is not applicable)

2.1 Name of sub station @

2.2 Number of feeders @2

2.3 Length of feeder @

2.4 Type /size of conductor/ cable size

@ __ sqmm

2.5 Voltage @ 220kv± 10% $

2.6 Frequency @50Hz ± 3%

2.7 Maximum fault level

2.7.1 3 Phase fault @ kA, sec.

2.7.2 1 Phase fault @ kA, sec.

2.7.3 X/R Ratio @

2.8 Minimum fault level @ kA, sec.

2.9 Design fault level @ kA

2.10 Basic Insulation Level @ kV

2.11 System neutral Earthing @

2.12 Minimum power factor @0.95 (Note-3) a)0.9 b)0.95 c)Any other

2.13 Parallel operation of incomers

$Yes a)YES b)NO

2.14 PLCC requirement @NA a)YES b)NO

3 CPP and its configuration # 3.1 Type of Generator $STG & GTG a)STG

b)GTG 3.1.1 Number of Generator $Refer CPP Design Basis

3.1.2 Rating of Generator/Voltage/P.f

$ MW/ 11KV/ 0.8 (Refer CPP Design Basis)

3.1.3 Requirement of Generator Circuit Breaker

NO a)YES b)NO

3.2 Parallel operation with grid $YES a)YES b)NO

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S.No. Description Selected Option Available Options 3.3 Type of Neutral Earthing for

Generators Neutral Grounding Transformer

3.4 Black Start DG Envisaged $ Yes a)YES b)NO

4 Emergency generator Centralised(REFER NOTE-1)

a)Centralised b)Distributed

4.1 Generator Voltage 6.6KV a)6.6KV b)415V c)Any Other

4.2 Parallel operation with other sources

Momentary Paralleling a)Momentary Paralleling b)Continuously Paralleling

4.3 Auto Starting Yes a)YES b)NO

4.4 Type of Emergency Generator

Diesel a)Diesel b)Gas

5 Solar Power System $ REQUIRED

5.1 Solar PV System Provided a)Provided b)Not provided

5.2 Buildings on which solar power system to be mounted

$

5.3 Technology Silicon Crystalline (Poly)

5.4 Battery NO

5.5 Connectivity Local Switchboard

5.6 Monitoring System $ Internet web based with HMI

a)Provided b)Not provided

5.7 Location of Inverter $ Outdoor a)Outdoor b)Indoor

Note: 1. The rating and number of emergency DG set shall be finalized during detailed engineering. The emergency DG set for the plant shall cater to emergency loads of various units, utility and offsite areas. 2. 1 no. Dedicated DG for the black start shall be considered. 3. Power Factor 0.95 (min.)- Grid Transformer Primary/ Point of coupling Power factor 0.98 (min.)- at 6.6KV Switchboard Power factor 0.9 (min.) - at CPP 66KV Bus

5.3 POWER SUPPLY DISTRIBUTION SYSTEM

5.3.1 VOLTAGE AND FREQUENCY VARIATION

S.No. Description Selected Option Available Options 1 AC System

1.1 Voltage 66KV/6.6KV/ 415V ± 10%

1.2 Frequency 50HZ ± 3%

2 DC System

2.1 Electrical protection and Control system

110V ± 10%

2.2 DC critical Lighting system 110V ± 10%

2.3 Instrumentation Power Supplies

Refer Instrumentation Design Basis

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Note: 1. Refer section 5.6.10 of this document for design voltage/frequency variation for motors.

5.3.2 UTILISATION VOLTAGE

S.No. Description Selected Option Available Options 1 Primary EHV/HV distribution

voltage 66kV a)33kV

b)66kV c)Any other

2 Secondary HV distribution voltage

6.6kV a)11kV b)6.6kV c)3.3kV d)Any Other

3 Primary EHV/HV distribution system neutral Earthing

Solidly Earthed (for 220kV, 66kV)

a)Solidly Earthed b)NGR c)Unearthed

4 Secondary HV distribution system Neutral Earthing

NGR

5 HV motor voltage for DOL 6.6kV (For motors rating > 160kW)

6 MV motor voltage 415 V AC (except VFD motor) (For motors rating 0.18<=kW<=160)

7 AC Motors 240V AC (except MOVs) (For motors rating < 0.18kW)

8 DC Motor As per equipment supplier std.

9 Motor operated valves 415V AC, TP

10 Battery chargers incoming power supply

415V AC,TPN

11 UPS System incoming power supply

415V AC,TPN

12 AC Lighting/Power Panels 415V AC,TPN

13 Auxiliary Boards incoming power supply

415V AC,TPN

14 Welding Receptacles 415V AC,TPN

15 Bulk loads like Process Heaters etc

415V AC,TP

16 Normal Lighting/Emergency Lighting

240V AC,SPN

17 LAN UPS 230V AC,SPN

NOTES: 1) Electrical heaters shall be designed with 415V elements connected in delta.

5.3.3 UTILISATION VOLTAGE FOR CRITICAL SUPPLIES

S.No. Description Selected Option Available Options 1 Switchgear protection

control power supply 110 V DC a)220V DC

b)110V DC

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S.No. Description Selected Option Available Options 2 Critical lighting power

supply 110 V DC a)220V DC

b)110V DC 3 Input power supply for Plant

communication system 110V AC UPS a)240V AC SPN (With

Dedicated battery back up) b)110V AC UPS

4 Input power supply Fire alarm system power supply

240V AC SPN (With Dedicated battery backup)

5 Power supply for electrical annunciation panel

Not Applicable a)220V DC b)110V DC

6 Normal Instrumentation power supply

Refer Instrumentation design basis

7 Critical instrumentation power supply


8 Instrumentation Shut-down system power supply


NOTES: 1) Auxiliary supply of all critical systems such as VFD control supply and DAVR control supply shall be provided from Battery chargers/DC system. 2) Sr. No. 9 shall be added in the above table which is as per the following: ECS system- 110V DC in Substation & 110V AC UPS in CPP Control Room.

5.3.4 OPERATING PHILOSOPHY

S.No. Description Selected Option Available Options 1 Auto/Manual transfer at

primary distribution voltage bus with momentary paralleling

$ No a)YES b)NO

2 Auto/Manual transfer at secondary distribution voltage bus with momentary paralleling

(Note-1) a)YES b)NO

3 Auto /Manual transfer at MV with momentary paralleling

3.1 At PCC/EPC/EPMCC Level Yes

3.2 At MCC/ASB/LDB Level Yes (for MCC/ ASB having ACBs as Incomer & Bus-coupler) No for LDB

a)YES b)NO

4 Continuous Parallel operation of Incomers

4.1 Primary EHV/HV voltage YES a)YES b)NO

4.2 Secondary HV voltage No a)YES b)NO

4.3 PCC/PMCC No a)YES b)NO

5 Power Factor Correction Required

5.1 Power factor improvement capacitors- location

6.6kV bus with APFC a)6.6kV bus b)415V c)Both 6.6kV & 415V d)Any other

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S.No. Description Selected Option Available Options 5.2 Minimum P.F. to be

maintained at Transformer Primary

0.95 at Grid transformer primary

5.3 Monitoring at Transformer Primary

Yes a)YES b)NO

6 Load shedding Yes a)YES b)NO

6.1 Voltage level for Load Shedding

6.6KV & 0.415KV - All incomers, bus-coupler, outgoing breaker feeders, all process motors and breaker fed heaters.

a)33kV b)11kv c)6.6kV d)0.415kV e)Any Other

1) Fast bus transfer shall be considered for 6.6KV Switchboard.

5.4 CONTROL-PROTECTION - METERING

5.4.1 CONTROL PHILOSOPHY

S.No. Description Selected Option Available Options 1 Location of Relays for

Generator Separate relay & control panel

2 Location of Relays for Outdoor Switchyard

Separate relay & control panel

3 Location of Protection relays for EHV/HV switchgear

3.1 Primary voltage EHV/HV switch gear

Separate relay & Control panel for 66kV, 220kV

a)On switchgear b)Separate relay and control panel

3.2 Secondary Voltage HV switchgear

On switchgear a)On switchgear b)Separate relay and control panel

4 EHV/HV Switchgear control

4.1 Generator Separate relay and control panel , SCAP

4.2 Outdoor Switchyard Separate relay and control panel

4.3 Primary voltage EHV/HV switch gear

Separate relay & control panel

a)On switchgear b)Separate relay and control panel

4.4 Secondary Voltage HV switchgear

On switchgear/ ECS a)On switchgear b)Separate relay and control panel c)ECS

5 Numerical Protection/Monitoring system for

5.1 EHV system YES a)YES b)NO

5.2 HV Switchboard YES a)YES b)NO

5.3 PMCC/PCC YES for I/C, B/C, ACB outgoing feeders

a)YES b)NO

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S.No. Description Selected Option Available Options 5.4 MCC YES (Incomer & Bus-

coupler)-Refer Note-4 a)YES b)NO

6 Control and logic through numerical relays

YES a)YES b)NO

7 Hardwired synchronization control panel-SCAP

YES a)YES b)NO

7.1 Synchronizing trolley required YES a)YES b)NO

7.2 Type of Panel Mosaic a)Mosaic b)Simplex

7.3 Extent of Coverage on SCAP $ Incomers, bus-coupler, bus PT, line PT, bus-tie

8 Type of annunciation panel Part of SCAP a)HMI b)Part of SCAP

9 Load shedding panel Part of ECS a)Part of ECS b)Separate PLC c)Hardwired

10 Method of motor starting

10.1 HV Motors DOL/ Soft Starter upto 2 MW (Note-2)

10.2 HV Motors Note-2 (Above 2 MW) a)Auto transformer b)Soft starter c)VFD d)Dedicated transformer 2 MW and above

10.3 MV Motors DOL up to motor 160 kW rating

11 Starting MVA limitation conditions for Motors

11.1 HV Motors Up to 1 MW : 550% inclusive of + tolerance rating >1MW - to be decided during detailed engineering (Note-3)

11.2 MV Motors During detailed engg.

Notes: 1. Provision of laptop connectivity to the ECS shall be provided for sub-station. 2. V/F controlled soft starter shall be considered for starting large HV motors if essential/unavoidable as per system design requirement/equipment design limitation. 3. Starting current for motors shall be further reduced from 550% (inclusive of positive tolerance) as per motor start up study. 4. Numerical protection/ Monitoring system (clause 5.4 above) shall also be applicable for ASB (incomer & bus-coupler). 5. Clause 5.5 is to be added "5.5 Generators - Yes" for generator numerical protection/ Monitoring system

5.4.2 POWER ISOLATION FOR TRANSFORMERS LOCATED REMOTELY AWAY FROM HV SUBSTATION

S.No. Description Selected Option Available Options

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S.No. Description Selected Option Available Options 1 Push button in transformer

bay for tripping remote breaker

Yes (Push Button shall trip the local isolator breaker)

a)YES b)NO

2 Local power isolating device Yes a)YES b)NO

3 Type Breaker in panel

4 Protection relay required Yes

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5.4.3 RELAY PROTECTION SYSTEM

5.4.3.1 PROTECTION DEVICES FOR POWER DISTRIBUTION SYSTEM

Protection devices for power distribution system shall be as indicated below - (Figure inside bracket refers to note below) (YES - Applicable)

S.No. Relay Description

Relay No.

HV Transformer Feeder - Sec. Winding Volt=>3.3kv

HV Transformer Feeder - Sec. Winding Volt<=0.433kv

HV Motor Feeder

Outgoing Breaker Feeder - HV Plant Feeder

Outgoing Breaker Feeder - MV PCC/PMCC

Incomer - EHV/HV

Incomer - MV PCC/PMCC

1 IDMTL over-current relay

51 YES YES - YES YES YES (1) YES

2 IDMTL earth-fault relay

51N YES(4) YES - YES YES YES (1) YES

3 51G backup earth-fault relay (Earthed neutral)

51G(11) YES(23) YES(23) - - - - -

4 Motor protection relay with (50, 50N,46, 49, 50L/R,86,95 )

99 - - YES - YES(3) - -

5 Instantaneous restricted earth-fault relay (Earthed side)

64R(11) - - - YES(24) YES (24)

6 Instantaneous over-current relay

50 YES YES - - - - -

7 Instantaneous earth-fault relay

50N YES(2) YES - - - - -

8 Differential protection relay

87 YES(5) - YES(6) YES(7) - - -

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S.No. Relay Description

Relay No.

HV Transformer Feeder - Sec. Winding Volt=>3.3kv

HV Transformer Feeder - Sec. Winding Volt<=0.433kv

HV Motor Feeder

Outgoing Breaker Feeder - HV Plant Feeder

Outgoing Breaker Feeder - MV PCC/PMCC

Incomer - EHV/HV

Incomer - MV PCC/PMCC

9 High speed tripping relay

86(20) YES YES YES(21) YES YES(21) YES YES

10 Trip circuit supervision relay

95(20) YES YES YES YES YES YES YES

11 Transformer auxiliary relay

63 YES YES - - - - -

12 Under-voltage relay with timer

27/2 - - YES(14) - - YES(9) YES(9)

13 Check synchronisation relay

25 - - - - - YES(10) YES(10)

14 RTD & BTD YES (31)

5.4.3.2 POWER GENERATION AND EXTERNAL POWER SUPPLY

Minimum protection relays for Synchronous generator (GTG/STG), generator transformer Grid power supply incomer and Synchronous motors shall be as follows: (YES - Applicable) Thermal overload relay (49G) and Local breaker backup protection relay (50LBB) shall be provided for Generator.

S.No. Relay Description NEMA Code Generator Generator Transformer

EHV Incomer EHV Transformer Syn. Motor

1 Distance protection 21 YES YES

2 Synchronous check 25 YES (27) YES YES

3 Under voltage with timer

27 YES YES YES

4 Reverse power 32 YES YES 5 Low power flow 37 YES

6 Loss of excitation 40 YES YES 7 Negative sequence 46 YES YES

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8 Over current 50 YES YES 9 Earth fault relay 50N YES YES 10 Over current 51 YES YES

11 Voltage restrained 51V YES YES Yes

12 Earth Fault back up 51G YES YES YES

13 Over current E/F 51N YES YES YES

14 Over voltage with timer

59 YES YES YES

15 VT failure 60 YES YES 16 Auxiliary relay for

transformer 63TX YES YES

17 Transformer Restricted Earth Fault

64R YES(26) YES YES

18 Stator back up earth fault

64G YES

19 Generator Rotor Earth fault

64R YES YES

20 Directional O/C 67 YES

21 Directional E/F 67N YES

22 Under frequency/df/dt

81 YES YES YES

23 Tripping relay 86 YES YES YES YES YES 24 Gen differential 87G YES

25 Gen and Transformer differential

87GT YES

26 Transformer differential

87T YES YES

27 Feeder differential 87F YES

28 Bus bar differential and check

87B/ 87CH

YES

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29 Trip circuit supervision

95 YES YES YES YES

30 Dead bus charging relay

98 YES(31) YES YES

31 Over fluxing 99 YES YES(32)

32 Out of step 78 YES

5.4.3.3 RELAY PROTECTION PHILOSOPHY

S.No. Project Philosophy 1 In case of HV switchboards with continuous parallel operation of incomers, following additional relays shall be provided:

a. One set of 87B (Bus differential) and 95 B (Bus wire supervision) for each bus section.The Bus wire supervision relay (95B) shall be provided for alarm and shall not lead to trip.

b. 67 and 67N (Directional IDMTL over current and earth fault) relays for the incomers. 2 Instantaneous earth fault (50N) shall be provided only for transformer with delta primary. 3 MPR shall be provided for breaker fed motor feeders. 4 Directional IDMTL earth fault (67N) shall be provided for transformer with star primary. 5 For transformers rated 5 MVA and above. 6 For motors rated 1500 kW and above, excluding VFD fed motors without bypass feature. 7 For critical/long feeders and plant feeders connected to main power generation and distribution bus. A plant feeder implies outgoing

feeders from one switchboard to another switchboard of same voltage level. Pilot wire communication for feeder differential relay shall be throuch OFC.

8 Trip circuit supervision relay 95 shall be provided as part of the numerical relay for HV/ MV feeders wherever numerical relays are provided.

9 Wherever auto-transfer feature is provided 10 For switchgears where continuous or momentary paralleling of Incomers is envisaged, check synchronising relay shall be provided. 11 51G and 64R relays for input transformer of VFD system shall be decided by VFD Manufacturer. CT’s for REF (64R) and SEF (51G)

shall be located at either side of the neutral tap point of transformers to prevent spurious tripping of transformers on 51G due to unbalanced current.

12 The bus tie feeders in HV switchboards shall be provided with 51, 51N, 86 and 95 relays. 13 HV capacitor bank feeders shall be provided with 51, 51N, 59 (over voltage), 60 (Neutral displacement), 86 and 95 relays.

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S.No. Project Philosophy 14 The following feeders shall be provided with timers for delayed tripping on bus under voltage while the under voltage relay shall be

common for the bus a. HV and MV capacitor feeders b. HV and MV breaker controlled motor feeders c. Contactor controlled motor feeders with DC control supply. Numerical relays where ever provided for motor and capacitor feeders shall use in built under voltage relay and timer for delayed tripping on bus under voltage.

15 One no. DC supply supervision relay (80) shall be provided for each incoming DC supply to the switchboard. 16 One set of bus differential relays (87B) and bus wire supervision relay (95 B) for each bus section shall be provided for HV

switchboards connected directly to generation buses. 17 In case of numerical relays, all relays shall be comprehensive units including all protection, metering and control. 18 Under voltage and over voltage function along with associated timer shall be part of the numerical relays. 19 Auto changeover logic between Incomers and bus coupler shall be built in the numerical relay. 20 Tripping relays (86) & Trip Circuit supervision relay (95) shall be part of numerical relay. 21 2 Nos. of 86 relays shall be considered for HV and MV breaker fed motors for ease of differentiation between process & electric trip in

the numerical relay. Built-in logic to be provided in relay for process/electrical trip with LED latched condition. Process trip in the numerical relay should be auto reset but LED should be latched. Electrical trip shall be hand reset type.

22 Breaker control switch shall be hardwired type. 23 Stand by earth fault relay 51G shall be provided for all transformers. 24 Restricted earth fault relay 64R shall be provided in the incomer of switchboard fed from transformer of rating >= 2.5 MVA and

secondary winding is star connected. 25 Relay 51V voltage controlled over current relay shall be provided on specific requirement considering the rating of the outgoing feeders

with respect to the Incomer rating. Generally this relay shall be provided wherever CT primary current of outgoing feeders is exceeding 40% of the CT primary current of the Incomer.

26 415V DG set shall be provided with protection but not limited to 51V,51G,40,46,86,95,80,64R etc for generator rated above 500KVA and Generator rated less than 500KVA shall have 51V,51G,40,46,86,95,80 unless otherwise agreed with the owner.

27 All master trip relay (86) shall be part of numerical relay. No electromechanical type relay shall be provided. 29 Relay 87 and 64R shall be seperate numerical relay. Hence shall not be part of main comprehensive numerical relay.CT for 87 and

64R can be clubbed, as two core of single CT. 30 Stabilizing resistors shall be provided in residual earth fault connections for all motors & transformers even in case of Numerical relays

to prevent any spurious tripping during starting. 31 For directly connected generator. 32 For large transformer as per manufacturer''s standard.

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S.No. Project Philosophy 33 Following LED indication shall be provided for the following:

-EHV Incomer over voltage -Line PT MCB off for incomers

34 Bus-bar differential protection shall also be provided for 6.6KV switchboard

5.4.4 METERING

5.4.4.1 METERING DEVICES IN EHV, HV AND MV SWITCHBOARDS

The metering devices in EHV, HV and MV switchboards shall be as below: Type of metering : Multifunction digital meter / As part of the Numerical relay

(Figure inside bracket refers to note below) (YES - Applicable)

S.No. Feeder Type A V Hz PF MW MWH HM MVAR MVAH MVA 1 Grid Incomers YES YES YES YES YES(2) YES YES(2) YES(2) YES(1,2) 2 Grid Bus Tie YES

3 Grid Transformer

YES YES YES

4 Grid Bus P.T. YES

5 EHV/HV Incomer

YES YES YES YES YES YES - YES YES YES

6 EHV/HV Bus Tie

YES - - - - - - - - -

7 EHV/HV Transformer

YES - - - YES YES - - - -

8 EHV/HV Bus P.T.

- YES - - - - - - - -

9 EHV/HV Plant Feeder

YES - - - - YES - - - -

10 EHV/HV Motor YES - - YES (NOTE-7)

- YES(kWh) YES - - -

11 EHV/HV Capacitor

YES YES - - - - - YES - -

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S.No. Feeder Type A V Hz PF MW MWH HM MVAR MVAH MVA 12 PCC/PMCC

Incomer YES YES - YES - YES(kWH) - - - -

13 PCC/PMCC Bus Tie

YES - - - - - - - - -

14 PCC Bus P.T. - YES - - - - - - - - 15 ACB Outgoing

( Non motor) YES - - - - YES(kWh) - - - -

16 MV Motor (>55kW)

YES - - - - - YES - - -

17 MCC/ASB Incomer

YES YES - - - - - - - -

18 MCCB/SFU O/G(250A)

YES - - - - YES(kWh) - - - -

19 LDB Incomer YES YES - - - YES(kWh) - - - - 20 DG Set-MV YES YES YES YES YES(kW) YES(kWh) YES YES YES YES

Notes: 1. MVA meter in EHV external power supply Incomers shall include maximum demand indication also. 2. Separate MW, MVAR, MVA and MVAH meters shall be provided for EHV external power supply Incomers only. 3. Seperate 3 nos. voltmeter and 3 nos. ammeter shall be provided for EHV external power supply incomers. 4. All metering shall be provided through numerical relay in case switchboard are having numerical relay 5. One no CT with 1 secondary core shall be provided in Y phase of motor feeder in switchgear for remote metering on local control station. 6. Field Ammeters are to be provided for motors >=5.5 KW. 7. PF meter shall be provided for HV Synchronous Motors. 8. Separate Analog meter shall be provided shall be provided in the following feeders: -Ammeter : Incomer, Bus-coupler, Plant feeder, Motor feeder, Capacitor -Voltmeter : Incomer, Capacitor, Bus PT

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5.4.4.2 METERING FOR GENERATOR AND GENERATOR TRANSFORMER

S.No. Meter HV Generator Generator transformer 1 Ammeter (3 nos.) YES YES 2 Voltmeter (3 nos.) YES YES 3 MW meter YES YES 4 MVAR meter YES

5 MVA meter YES

6 MWH meter YES YES 7 MVARH meter YES

8 Power factor YES YES 9 Frequency meter YES

Notes: 1. Metering shall be part of numerical relays 2. The HV Generator metering shall be applicable for HV Generator and DG.

5.5 SUBSTATION DESIGN

5.5.1 SUBSTATION AUTOMATION SYSTEM

S.No. Description Selected Option Available Options 1 Substation Automation

System (SAS) Required

2 Communication protocol for relay network

IEC 61850 a)IEC 61850 b)open protocol

3 System architecture IEC 61850 RSTP a)IEC 61850 RSTP b)IEC 61850 PRP c)IEC 61850 HSR d)Redundant architecture for other open protocols

4 Data concentrator for SAS Not required a)not required b)common for HV & MV c)seperate for HV & MV

5 Communication with other devices

5.1 Communication with ECS YES

5.1.1 Protocol for communication with ECS

IEC 61850 a)IEC 61850 b)Modbus

5.2 Communication with DCS Part of ECS RTU a)part of data concentrator b)part of ECS RTU

5.2.1 Protocol for communication with DCS

MODBUS TCP/ IP protocol

5.3 Communication with VFD & UPS

Part of ECS RTU a)part of data concentrator b)part of ECS RTU

5.3.1 Protocol for communication with VFD & UPS

MODBUS TCP/ IP protocol

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S.No. Description Selected Option Available Options 6 HMI for SAS 1 operator & 1

engineering workstation a)not required b)operator cum engineering workstation c)1 operator & 1 engineering workstation

7 Laptop Separate for HV & MV for each substation

a)not required b)common for HV & MV for each substation c)seperate for HV & MV for each substation

8 Local storage of data $ Not Required (Part of ECS)

a)not required (part of ECS) b)part of HMI c)part of data concentrator

9 Relay parameterization Laptop for SAS a)SAS HMI b)ECS HMI

Note:

5.5.2 EHV SWITCHYARD

S.No. Description Selected Option Available Options 1 Type Conventional Open bus

2 Type of bus $ Tubular Bus a)String bus b)Tubular bus

3 Structure for outdoor Galvanised a)Galvanised b)Painted c)Not applicable

4 Bus material Aluminium a)Aluminium

b)Copper

Note: 1) 66KV circuit breaker except 220KV Switchyard shall be through indoor GIS.

5.5.3 SUBSTATION FEATURES

S.No. Description EHV HV MV MCC/Elec. Room

1 Elevated with trays in cable cellar

YES YES YES YES

2 Raised with internal trenches

NO NO NO NO

3 All top cable entry with trays below ceiling

NO NO NO NO

4 Pressurisation against ingress of dust

NO NO NO NO

5 Air-conditioned room for operator

YES YES YES NA

6 Roof slab for

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S.No. Description EHV HV MV MCC/Elec. Room

6.1 Power transformer NO (NOTE-2)

YES (NOTE-2)

YES (NOTE-2)

NA

6.2 Distribution transformer

NA YES (NOTE-2)

YES (NOTE-2)

NA

7 Air conditioning of switchgear hall

YES YES YES YES

8 EOT crane in sub-station

YES NO NO NA

Column HV is defined below :- 1. Substation having full fledged HV Switchboard having incomer, bus coupler & outgoing feeder. 2. Roof slab for all transformers shall be provided except for Generator transformers & Tie transformers. However, removable type shed shall be provided for Generator transformers & Tie transformers. 3. Each substation shall be provided with a toilet, maintenance room, store room for workmen to keep their tools, spare breakers etc., operator room for keeping HMI & 5 persons sitting arrangement etc. 4. Lift to be provided with adequate capacity for substations having higher than 2 floors. 5. Sealing of cut-outs (for switchboard) on switchgear hall floor in substation to be properly done after placement of chequered plate. 6. Insulation paint (epoxy coating) shall be suitable for required voltage level. Provide epoxy coating in complete flooring of switchgear hall in substations floor/ MCC room instead of insulation mat. Thickness of this coating shall be uniform and shall be for the maximum voltage in the substation/ MCC room. 7. Exhaust fans for ventilation to be provided in cable cellar in Substation & MCC room.

5.5.4 SPECIFIC EQUIPMENT LOCATIONS

S.No. Description Selected Option Available Options 1 Batteries in substation and

control Rooms Separate room

2 Battery charger in substation

Air conditioned room a)Air conditioned room

b)Non air conditioned room

3 Battery charger in control room

Air conditioned room a)Air conditioned room

b)Non air conditioned room

4 Variable speed drive panels

Air-conditioned room in substation

a)Air-conditioned room in substation b)SRR

5 Thyristor controlled panels Air-conditioned room in substation

a)Air-conditioned room in substation b)SRR

6 UPS System Air conditioned room in control room

7 Lead-Acid and Nickel- Cadmium

Separate room a)Separate room

b)Common room 8 Location of VRLA battery Air conditioned room

9 Annunciation panel Part of HMI

10 Energy saver panel with Lighting transformers

NA

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S.No. Description Selected Option Available Options 11 GIS Hall Air conditioned a)Air Conditioned

b)Pressurised

1. Battery room shall be preferably located in corner side at cable switchgear floor level of the substation building. 2. Battery charger for Instrumentation if applicable, shall be placed in air-conditioned UPS room in control room. 3. Electrical equipment installed in battery room such as exhaust fan, lighting fixtures, receptacles, battery isolator shall be of flameproof and certified for gas group II-C classified locations. Heat detectors installed in battery room shall be of intrinsically safe type. 4. Lighting transformers are to be located in switchgear room.

5.6 EQUIPMENT DESIGN

5.6.1 EHV DESIGN

5.6.1.1 EHV OUTDOOR SWITCHYARD

S.No. Description Selected Option Available Options 1 Bus bar system Double a)Single

b)Double 2 Circuit breaker type SF6

3 Isolator type Centre rotating/ Centre Break

a)Pantograph b)Semi Pantograph c)Centre rotating d)Centre break

5.6.1.2 EHV SWITCHBOARD

S.No. Description Selected Option Available Options 1 Execution Fixed Type

2 Type of Switchgear Gas Insulated

3 Busbar Double (single for 66KV GIS Isolating Breaker panel)

a)Double b)Single

4 Circuit Breaker Type SF6

5.6.2 HV SWITCHBOARD

S.No. Description Selected Option Available Options 1 Execution Drawout for AIS a)Drawout

b)Fixed 2 Type of switchgear Air Insulated for 6.6kV a)Air insulated

b)Gas insulated 3 Bus bar Single bus for AIS a)Single bus

b)Double bus 4 Circuit breaker type VCB a)SF6

b)VCB 5 Motor Control Breaker a)Breaker

b)Vacuum contactor

NOTES:

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1) All HV Switchboard shall be LOTO compliant. 2) In HT Switchboards, the thermo-graphic window shall be provided to check cable termination. 3) HV switchboards (6.6kV) shall be provided with earthing trucks for cable side and/or busbar side earthing. 4) Number of bus-coupler shall be one.

5.6.3 CURRENT TRANSFORMER (CT)/POTENTIAL TRANSFORMER (PT)

S.No. Description Selected Option Available Options 1 CT Secondary

1.1 General Protection 1A

1.2 Special protection(87,64R ,51G etc)

1A

1.3 Metering 1A for conventional and remote metering

2 PT Secondary 110V AC

Note :- 1.) CT for metering shall be separate from the protection CT and no interposing CT shall be provided in the protection CT secondary circuit for metering purpose.

5.6.4 TRANSFORMERS (POWER/DISTRIBUTION)

S.No. Transformer Voltage Ratio Vector Group

Tap Changer

Cooling

1 Grid power transformer

220/66KV YNyn0 OLTC ONAN/ONAF

2 Generator unit transformer

11/66KV YNd11 Off-circuit ONAN

3 Power transformer

66/6.9KV Dyn1 OLTC ONAN/ONAF

4 Distribution transformer (<= 2500 KVA)

6.6/0.433KV Dyn 11 Off-circuit ONAN

5 Dedicated (e.g. for VFD)

As Reqd. As Reqd. Off-circuit AN

Note: 1) Provision of Oil Soak Pit & Oil Collection Pit for transformers shall be as follows: a) Oil quantity <= 2000L: Not Required b) 2000L < Oil Quantity <= 9000L: Soak Pit c) Oil Quantity > 9000L: Soak Pit + Collection Pit 2) Fire fighting system (Nitrogen injection fire protection system) shall be provided for transformers having oil greater than 2000 Liters. 3) 1 no. 100A weatherproof wall mounted TPN MCCB outlet fed from ASB shall be provided in alternate transformer bay (minimum 1 no. for two transformer bays).

5.6.5 MV SWITCHBOARD

S.No. Description Selected Option Available Options 1 PCC / PMCC

1.1 Breaker panels Drawout Single front

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S.No. Description Selected Option Available Options 1.2 Contactor feeders Drawout Single front a)Drawout Single Front

b)Drawout Double front c)Fixed Single front

2 MCC Drawout Single front a)Drawout Single Front b)Drawout Double front c)Fixed Single front

3 ASB Drawout Single front a)Drawout Single Front b)Drawout Double front c)Fixed Single front

4 LDB Drawout Single front a)Drawout Single Front b)Drawout Double front c)Fixed Single front

5 Motors

5.1 PMCC Above 55 kW Up to 160 kW

5.2 MCC Up to 55 kW

6 Type of switchboard for small package (AC system, Pressurisation system ,Bagging plant etc)

Draw-out single front a)Compartmentalised Fixed type b)Non Compartmentalised Fixed type

Notes: 1) 4-pole ACBs for PCC/PMCC/ EPCC/EPMC/ MCC/ASB incomer & bus coupler. 2) All MV Switchboard shall be LOTO compliant. 3) In MV switchboards, wherever, non-linears loads are fed, switchboard neutral bus-bar shall be suitable rated.

5.6.6 MEDIUM VOLTAGE MOTOR STARTER TYPE

S.No. Description Selected Option Available Options 1 Contactor and switch fuse

with overload relay NA

2 Contactor, switch fuse and overload relay with CBCT for earth fault protection

NA

3 Contactor and switch fuse with motor protection relay

NA

4 Air circuit breaker with motor protection relay

Above 55kW up to 160KW

(Note-1)

5 Contactor and MCCB with overload relay

NA

6 Contactor, MCCB and overload relay with CBCT for earth fault protection

Upto 55kW

NOTES: 1) Motor protection relay (numerical type) shall be provided with communication facility as per IEC 61850. 2) MCCBs shall be conventional type (non-microprocess based) provided with S/C protection and shunt trip coil. 3) All motor feeders upto 55KW shall be provided with communicable type Electronic Motor protection relay.

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5.6.7 MEDIUM VOLTAGE OUTGOING FEEDER TYPE

S.No. Description Selected Option Available Options 1 Switch fuse NA

2 Switch fuse with Contactor and CBCT for earth fault protection

NA

3 MCCB with Contactor and CBCT for earth fault protection

250A and up to 400A (with O/C & S/C protection)(Note-1)

a)___A and up to ___A b)Not Applicable

4 MCCB below 250A (with O/C, S/C & E/F protection)

a)___A and up to ___A b)Not Applicable

NOTES: 1) CBCT+ ELR shall be provided for all MCCB feeder for E/F protection for 250A and above rated feeders. 2) All MCCBs shall be provided with shunt trip coil and shall be microprocessor based. 3) R-C Circuit across power contactor and low-burden auxiliary contactor for receiving start/ stop command from field shall be provided in all DOL starter feeders. 4) ELCB with 30mA rating shall be provided for all outgoing single phase feeders/ circuits in lighting panels (normal & emergency), power panels, power points, receptacles, plant lighting system, heat tracing system etc. for human safety.

5.6.8 MOTOR CONTROLS (AS PER PROCESS PACKAGE & OPERATING PHILOSOPHY)

S.No. Description Selected Option Available Options 1 Auto/OFF/Manual switch Control room a)Near motor

b)Switchgear c)Control room

2 Local/OFF/Remote switch Near Motor a)Near motor b)Switchgear c)Control room

3 Process interlock PLC/DCS/Switchgear (Note-1)

a)PLC b)Switchgear

4 Reacceleration equipment Switchgear a)PLC b)Switchgear

Note :- 1) To be made available at Switchgear as per instrumentation philosophy.

5.6.9 CONTROL SUPPLY VOLTAGE

S.No. Description Selected Option Available Options 1 Breaker control 110V DC a)220V DC

b)110V DC 2 Breaker spring charging 110V DC a)240V AC

b)220V DC c)110V DC

3 Contactor feeder 110V DC/240V AC (for remotely located MCCs)

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S.No. Description Selected Option Available Options 4 Control supply for earth

fault relay in contactor feeder(Note 1)

110V DC/ 240V AC a)24V DC b)220V DC c)110V DC d)240V AC

5 Control supply for contactor motor starter

Control Transformer (one for each bus section)

a)Control Transformer b)Tapping P-N of Respective Feeder c)Control Transformer in individual DOL Starter

6 Control transformer for each feeder

NO a)YES b)NO c)Not Applicable

Notes: 1. MCCB shunt trip coil voltage suitability - 240V AC/110V DC

5.6.10 MOTORS

S.No. Motors High voltage 415 volts 1 Enclosure

1.1 Indoor IP55 IP55 1.2 Outdoor IP55 IP55 2 Insulation class F (Temp. Rise limited to

B) F (Temp. Rise limited to B)

3 Anti-condensation heater Yes 30 kW and Above 4 Additional canopy

(outdoor motors) Yes Yes

5 Design voltage variation ±10% ±10%

6 Design frequency variation ±3% ±3% 7 Combined voltage /

frequency variation (Design)

±10 %

Any combination of above ±10 %

Any combination of above

8 Energy Efficient IE-2 Motors

NA Yes (for Hazardous area motors)

9 Energy Efficient IE-3 Motors

NA Yes (for safe area motors)

1. Motors for MOV actuator shall have F class of insulation with temperature rise limited to class-B.

5.6.11 UPS SYSTEM

S.No. Description Selected Option Available Options 1 Redundancy 100% a)50%

b)100%

2 Type of redundancy Dual redundant a)Parallel redundant b)Hot standby

3 Back-up time 30 minutes (refer Instrumentation Design Basis)

a)30 minutes b)60 minutes c)120 minutes

4 Bypass transfer control Auto a)Auto b)Manual

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S.No. Description Selected Option Available Options 5 Separate fault diagnostic

unit (Note 1) No a)YES

b)NO 6 Battery type Ni-Cd (1x100%

configuration) a)Lead acid b)Ni-Cd c)VRLA(in 2x50% configuration)

7 Type of UPS Transistorised (IGBT) a)IGBT b)Transistorised

8 UPS Output Supply Single Phase a)Single Phase b)Triple Phase

9 UPS Output Voltage 110V AC (Final voltage shall be as per Instrumentation Design Basis)

NOTES: 1. Seperate Fault Diagnostic Unit(FDU) is not required in case UPS system is serial connected to HMI and fault diagnostic can be done from HMI/ ECS. 2. ACDB outgoing feeders type shall be switch-fuse uni. 3. UPS for data communication system/ LAN and sub-station HMI and small package units shall be non redundant with bypass type with VRLA battery. 4. UPS shall be with dual redundant and battery shall be 1x100% with each UPS.

5.6.12 COMMUNICATION SYSTEM

S.No. Description Selected Option Available Options 1 Plant Communication

System Yes (Note-1)

a)YES b)NO

2 Telephone System Yes (Note-2)-Refer Instrumentation Design Basis

a)YES b)NO c)Separate

3 Telephone system and plant Communication system

Separate a)Separate b)Integrated

4 Interface of Communication system

4.1 With fire alarm system Yes a)YES b)NO

4.2 With telephone system Yes- Refer Instrumentation Design Basis

a)YES b)NO

Notes:- 1) Dedicated battery is not envisaged for plant communication system. 230V AC UPS supply shall be given to Plant communication exchange.

5.6.13 FIRE DETECTION AND ALARM SYSTEM

S.No. Description Selected Option Available Options 1 Type Analogue addressable a)Conventional

b)Analogue addressable

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S.No. Description Selected Option Available Options 2 Name of buildings to be

provided with Detectors Control room, sub-station, SRR,admin/ office building, other buildings as required.

3 Detection System Break Glass, Multi sensor detectors, heat detectors, linear heat sensing cables, linear beam detectors

4 Type of manual call point

Without call back facility a)With call back facility b)Without call back facility

5 Qty of Siren and location

To be decided during detail engineering.

6 Power supply for Siren 415V AC a)415V AC b)110V AC UPS c)48V DC

7 Siren range 5 Km(Diametrically)

8 Response indicator for rooms and concealed area for Addressable Fire alarm system

Not Applicable a)YES b)NO c)Not Applicable

NOTES: 1) Fire siren hooter & flashlight to be provided inside control room and major buildings.

5.6.14 DC SYSTEM

S.No. Description Selected Option Available Options 1 Battery type

1.1 Switchgear Protection Control and critical lighting

Ni-Cd

a)Lead acid b)Ni-Cd c)VRLA

1.2 Instrumentation System As per Instrumentation Design Basis


1.3 Diesel Engine Starting Lead Acid

1.4 DC Motors As per equipment supplier recommendations


1.5 Fire alarm system VRLA

1.6 Telephone system VRLA

1.7 End Cell Voltage

1.7.1 Lead Acid Battery 1.85 VOLT

1.7.2 VRLA Battery 1.75 VOLT

1.7.3 Ni-Cd Battery 1.16 VOLT

2 Battery backup time

2.1 Switchgear Protection and Control

120 minutes a)30 minutes b)60 minutes c)120 minutes

2.2 DC Critical lighting 120 minutes a)30 minutes b)60 minutes c)120 minutes

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S.No. Description Selected Option Available Options 2.3 Instrumentation 30 minutes (As per Inst.

Design basis) a)30 minutes b)60 minutes c)120 minutes

2.4 Diesel Engine Starting 10 starts (FW pumps) & 6 starts (others)

2.5 DC Motors As per equipment manufacturer's recommendation

3 Battery Configuration 2X50% a)2X50%

b)1X100%

Notes: 1. DCDB outgoing feeder type shall be switch-fuse unit

5.6.15 VARIABLE FREQUENCY DRIVE

S.No. Description Selected Option Available Options 1 By pass feature required Yes(Note-1) a)YES

b)NO 2 VFD rated output voltage

2.1 MV Inverter i) Motor kW rating less than 315kW at 415V without bypass , ii) More than 315kW & up to 700kW at voltage upto 690V without bypass (refer Note-2)

2.2 HV Inverter Motor rating more than 700kW

Notes: 1. Bypass for VFD shall be provided as a standard practice unless not recommended from Process or driven equipment operation point of view. 2. Sr. No. 2.1 above is applicable for the case where Bypass is not envisaged.

5.6.16 CABLE SIZES

The power and control cables shall have the following minimum cross sectional areas:

S.No. Description Selected Option Available Options 1 Medium voltage power

cable Upto 16 Sq.mm.-Copper. Greater than and equal to 25 Sq.mm.- Aluminium

a)Above 16 sqmm (Aluminium) b)2.5 sqmm to 16 sqmm (Copper)

2 Control cables 2.5 sqmm (Copper) Overall shielded (Note-4)

3 Lighting Cabling for plant lighting shall be with 2.5 / 4 sq. mm. copper conductor cables only

4 Communication system 0.9 mm dia. (Copper)

5 Telephone System 0.63 mm dia.(Copper)

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S.No. Description Selected Option Available Options 6 Fire alarm system 1.5 sqmm (Copper)-

twisted pair (Note-4)

Notes: 1. For lighting inside the building, minimum 1.5 sqmm copper conductor, PVC Insulated FRLS wires shall be used in conduit system (for circuit and point wiring), with proper colour coding. 2. Cable sizes are indicative only and these shall be finalised as per the recommendations of the equipment manufacturer. 3. Special cable type and size shall be decided on specific requirement. 4. Control cable& FA cables shall be twisted pair overall shielded type. 5. Control cable (except for PA/ FA/ Telephone cable) shall be stranded type. 6. Refer to clause no. 3.9 of 6-51-0083, 2.5 sq mm wire shall be used for upto 15A power socket circuits.

5.7 CABLING SYSTEM

5.7.1 CABLE DETAILS

S.No. Design Criteria EHV HV 415 volts 1 Loads located

beyond 1 km

1C cable 1C / 3C cable 1C / 3.5C cable

2 Loads located 200-1000 m

1C cable 1C / 3C cable 1C / 3.5C cable

3 Loads located upto 200 m

1C cable 1C / 3C Cable 1C / 3.5C Cable

4 Loads beyond 1250A rating & located near the transformer

NA Busduct/ 1C cable Busduct / 1C cable

5 Recommended limiting size of multi-core cable (sqmm)

630 (1C Cable) 300 (3C Cable) & 630 (1C Cable)

300 (3C Cable) & 630 (1C Cable)

6 Short circuit withstand time (sec)

1.Incomer from

transformer:1.0 2.Plant feeder/ Incomer from other switchboard:0.6 3.Transformer/ Motor feeder:0.2

1.Incomer from

transformer:1.0 2.Plant feeder/ Incomer from other switchboard:0.6 3.Transformer/ Motor feeder:0.2

NA

7 Insulation voltage grade

220kV(Earthed), 66kV (Earthed)

6.6kV(Unearthed) Earthed

8 Type of cable insulation

XLPE XLPE XLPE

9 Fire survival (Resistant) cable for Fire proof MOV

NA NA Yes

10 Power Cable for Motors/MOV

NA 3 core 3 core

11 Cable Conductor Copper Copper / Aluminium Refer Sr no. 1 of Cl. 5.6.16

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S.No. Design Criteria EHV HV 415 volts 12 Power & Earthing

cable Armoured Armoured;

Earthing-NA Armoured; Earthing-NA

NOTES: 1) All power cables for Electrical heat tracing shall be 4-Core of suitable size.

5.7.2 CABLE LAYING PHILOSOPHY

S.No. Description Selected Option Available Options 1 Process area -Cable tray (where pipe

rack/ sleeper is available) -RCC trench (pipe-rack/ sleeper is not available) -Above ground cable tray (overhead rack) as per site requirement.

a)Overhead cable tray b)RCC trench

2 Offsite paved area -Cable tray (where pipe rack/ sleeper is available) -RCC trench (pipe-rack/ sleeper is not available) -Above ground cable tray (overhead rack) as per site requirement.

a)Above Ground cable tray on sleeper b)Overhead rack c)RCC trench

3 Offsite unpaved area -Cable tray (where pipe rack/ sleeper is available) -RCC trench (pipe-rack/ sleeper is not available) -Above ground cable tray (overhead rack) as per site requirement.

a)Above Ground cable tray b)Directly buried

4 Type of cable trays Galvanized prefabricated a)Galvanized prefabricated. b)Site fabricated and painted c)FRP type

5 Road Crossings for underground cables

PVC Pipes embedded in concrete(ERC)/ Cable culvert

a)PVC Pipes b)Cable culvert

6 Road Crossings for Above ground cables

Overhead cable bridge / pipe rack

a)Overhead cable bridge b)Culvert

1.) Plant communication, fire alarm and telephone cables shall be laid in instrumentation overhead cable duct / instrumentation trenches as far possible. In case these are not available. Cable shall be laid in buried cable trenches along berm of the roads. 2.) Walkways and handrail shall be provided on either side of cable tray (with ladders at regular intervals) to facilitate movement of people while pulling cable. 3.) No cable Trays/ racks will be provided in RCC lined trenches. 4.) RCC cable trenches shall be filled with river sand/manufactured sand. 5.) Street lighting cables shall not be laid along with fire alarm, communication and telephone cables. These cables shall be laid in separate buried cable trench in road berm. 6.) The single core cables shall be laid in trefoil formation except for short run of cables within substations. Single core cables pertaining to 3-phase circuits shall be laid together & separated from multi-core cables as per requirements specified in IS-1255. 7.) Underground Road crossings shall be provided using Cable culverts where ever large

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number of cables cross the roads. At road crossings where few cables cross the roads, Electrical road crossings(ERC) using 160mm PVC/RCC pipes may be provided. The ERC shall have minimum 40% spare pipes. The pipes shall be embedded in concrete. Minimum 2 nos. 160mm pipes shall be provided at any road crossing. 8) In case of vehicular traffic over the RCC cable trench, the same shall be of heavy duty construction suitable for vehicular movement.

5.8 EARTHING SYSTEM

S.No. Description Selected Option Available Options 1 Earth electrode GI pipe

2 Main earth loop material GI strip

3 Substation earth loop GI strip

4 EHV switchyard earth grid MS Rod

Notes: 1) Sizing of earthing strips shall be suitable for maximum fault current and for a duration of 3 seconds.

5.9 LIGHTING SYSTEM

5.9.1 SUPPLY SYSTEM

S.No. Description Selected Option Available Options 1 Centralised with Lighting

distribution board-LDB Yes a)YES

b)NO 2 LDB at each substation Yes a)YES

b)NO 3 Lighting transformer

required Yes a)YES

b)NO 4 100% Standby transformer

for normal lighting system Yes a)YES

b)NO 5 100% Standby transformer

for emergency lighting system

YES a)YES b)NO

6 Lighting transformer voltage ratio

415V/415V a)415V/415V

5.9.2 CONTROL PHILOSOPHY

S.No. Description Selected Option Available Options 1 Outdoor yard Auto/ Manual/ Local a)Auto

b)Manual c)Centralised d)Local

2 Street lighting Auto/ Manual/ Local a)Auto b)Manual c)Centralised d)Local

3 Outdoor process area Auto/ Manual/ Local a)Auto b)Manual c)Centralised d)Local

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S.No. Description Selected Option Available Options 4 Process building Manual/Local a)Auto

b)Manual c)Centralised d)Local

5 Auto control Synchronous timer & Photocell timer

a)Synchronous timer b)Photocell c)ECS

6 Lamp type for outdoor general lighting

(1). Process Area:LED (2). Offsite Hazardous Area: LED (3). Offsite Safe Area: LED (4). Street Lighting: LED (5). High Mast: LED

7 Lamp wattage for outdoor lighting (Normal)

$

8 Lamp type for emergency AC lighting

LED a)CFL b)LED

9 ELCB at Incomer of Lighting / Power Panels

NO (ELCB shall be provided in Outgoing of PP/LP/ELP)

a)YES b)NO

10 Switch ON/OFF push button at substation entry

Yes a)YES b)NO

Note: 1) In LDB/ ELDB, both timers - synchronous timer & photo cell timers shall be provided and 1 no. common selector switch for selection of photo cell and timer shall be provided for each LDB/ELDB.

5.9.3 AC EMERGENCY LIGHTING

S.No. Description Selected Option Available Options 1 Name of process

plants All process areas (as per operation requirement)

2 Name of buildings Substation, Control room, Fire Water Pump House, Admin Building, Lab., R&D Building, Workshop, DG Shed, Canteen, Warehouse (Office Area) and other locations/ buildings as per OISD

3 Power supply source Diesel generator

5.9.4 DC CRITICAL LIGHTING FOR ESCAPE

S.No. Description Selected Option Available Options 1 Name of process units All (at escape routes)

2 Name of building Substation, control room, SRR, Administration building/office, FWPH, Fire Station, DG Shed, Compressor House and other locations as per OISD

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S.No. Description Selected Option Available Options 3 Power supply 110V DC a)220V DC

b)110V DC 4 DC lighting for remote

buildings Lighting fixture with built in battery & charger

5.9.5 WIRING TYPE

S.No. Description Selected Option Available Options 1 Process plant / Building /

Shed Armoured cable

2 Large service building Black enamelled surface conduit/ PVC concealed conduit

3 Buildings with false ceiling

Black enamelled Surface conduit above false ceiling/ PVC concealed conduit below false ceiling

a)Surface conduit above false ceiling b)Cables

4 Substation (Switchgear Room)

METSEC channel/Black enamelled Surface conduit above false ceiling/ PVC concealed conduit below false ceiling

a)METSEC channel b)Concealed conduit

5 Substation (Cable Cellar) Armoured cable a)Surface Conduit b)Armoured cable

6 Other buildings in safe area

Black enamelled Surface conduit above false ceiling/ PVC concealed conduit below false ceiling

5.9.6 SPECIFIC LIGHTING REQUIREMENTS

S.No. Description Selected Option Available Options 1 Aviation lighting Yes (Clustered LED

lamps, flashing) Refer Note-1

a)YES b)NO

2 Security lighting for peripheral road boundary wall

Yes

3 Type of control gear for HPMV/HPSV lamps

NA a)Separate b)Integral

4 Control gear box location NA

5 Type of high mast flood light

30 meters Telescopic tubular

a)30 meters Telescopic tubular b)Lattice structural mast

Notes: 1) 3 numbers of light fixtures to be used at 120 degrees apart on tall structures as per statutory requirement with separate circuit for each lamp.

5.10 ELECTRIC HEAT TRACING SYSTEM

S.No. Description Selected Option Available Options

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S.No. Description Selected Option Available Options 1 System Design Basis

approach Product classification/ as per process recommendation

a)Product Classification b)System approach

5.11 ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

The electrical equipment for hazardous areas shall be selected as per IS-5571 and petroleum rules & Gas group shall be selected based on the hazardous area classification. The minimum requirement is summarised below:

S.No. Equipment Zone-1 Zone-2 1 MV Motors Ex-de Ex-n/Ex-de(Note-2.9, 2.10

& 2.11) 2 HV Motors Ex-de / Ex-p (Refer note-

2.8) Ex-n/Ex-de/Ex-p (Note-2.9, 2.10 & 2.11)

3 Push Button Station Ex-de Ex-de 4 Motor Starters Ex-de Ex-de 5 Plug & Socket Ex-de Ex-de 6 Welding Receptacle Ex-de Ex-de 7 Lighting fitting Ex-de Ex-nR/ Ex-de 8 Control Gear Box NA NA 9 Junction Boxes Ex-de Ex-n (Power JB shall be

Ex-de) 10 Transformer Unit Ex-de Ex-de 11 Plug & Socket Ex-de Ex-de 12 Break Glass Unit

(Fire Alarm System) Ex-de Ex-de

13 Lighting Panel/Power Panel

Ex-de Ex-de

14 Transformers Hermetically sealed with surface temperature not exceeding 200 DEG C

Hermetically sealed with surface temperature not exceeding 200 DEG C

For additional Hazardous Area requirements, refer notes below -

5.11.1 NOTES

S.No. Notes 1 The electrical equipment for hazardous areas shall generally be suitable for gas

group IIB and temp classification T3 as applicable to the selected type of explosion protection. In case of hydrogen or hydrocarbon mixtures having more than 30% hydrogen, the gas group to be considered shall be IIC.

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

2.1 All electric motors for agitators/mixers and metering pumps/ dosing package pumps handling flammable material shall be flameproof type irrespective of the area being classified as zone 2 or zone 1.

2.2 All electric motors for vertical sump pumps handling flammable material shall be flameproof type. (Ex-de)

2.3 Irrespective of the area classification (whether zone 1 or zone 2), all lighting fixtures within the storage areas shall be flameproof type. (Ex-de)

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S.No. Notes 2.4 Irrespective of the area classification (whether zone 1 or zone 2), all motors and

lighting fittings within the pump house/pump station/compressed house associated with offsite tank farm and within the loading/unloading gantries shall be of flameproof type. (Ex-de)

2.5 All emergency/critical lighting fixtures and associated junction boxes in hazardous areas (whether zone-1 and zone-2) shall be flameproof type. (Ex-de)

2.6 Even though fired heaters in process units are not considered for area classification, all electrical equipments associated with fired heaters in process units shall as a minimum be suitable for installation in Zone-2 area. In furnace area , the Gas Group shall be considered as IIC apart from IIA/IIB and temperature class shall be T3 (min.).

2.7 Building such as Compressor sheds inside the process area shall be designed to allow adequate ventilation to allow area classification as Zone-2. Lighting equipment, EOT crane etc. in the shed shall be flameproof type. All other electrical equipment shall be suitable for Zone-1 or Zone-2 area depending on extent of hazard.

2.8 All motors for hazardous area Zone-1 shall preferably be Ex-de type. Pressurised motors may be provided in exceptional cases, when Ex-de motors are not available. Pressurised motors shall be provided with facility to trip motor in case of failure of pressurisation.

2.9 Ex-n motors shall be used unless any other type is specified by process licensor, except for following cases: (i) HV motors in Zone-2 area for centrifugal compressors shall be Ex-de type. (ii)Ex-de motors shall be used in zone-2 areas having frequent start-stop requirements such as EOT cranes, elevators, MOV actuators, etc.

2.10 For zone-2 areas, motors with rating above 100kW having average starting frequency of more than 1 per week, Ex-de or Ex-p motors shall be used.

2.11 Ex-p motors shall be used for higher rated motors where Ex-de / Ex-n motors are not available.

2.12 All motors and light fittings in Zone-1 and Zone-2 areas for ETP shall be flameproof type.

2.13 Ex-ec type motors are also acceptable in place Ex-n motor as per new designation of IEC-60079.

3 Statutory Approval 1. Statutory Authority for Electrical Installation: CEA 2. Statutory authority for hazardous area: PESO:For area other than mines

5.12 ELECTRICAL CONTROL SYSTEM-ECS

S.No. Description Selected Option Available Options 1 Extent of coverage Upto PCC/PMCC level

1.1 No of substations All

1.2 Monitoring

1.2.1 EHV/HV switchboard YES a)YES b)NO

1.2.2 415V switchboard (I/C, B/C & outgoing breaker feeders)

YES (Refer Note-1) a)YES b)NO

1.2.3 Emergency DG set YES a)YES b)NO

1.3 Control

1.3.1 EHV/HV switchboard YES a)YES b)NO

1.3.2 415V switchboard (I/C, B/C & outgoing breaker feeders)

$ YES a)YES b)NO

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S.No. Description Selected Option Available Options 1.3.3 Emergency DG set NO a)YES

b)NO 2 Base ECS functionalities

2.1 Breaker control in CPP & Switchyard

$ OFF control for motor feeders, ON/OFF for all other breakers

2.2 Breaker control in other substations

$ ON/OFF control for capacitor feeder and OFF control for all other feeders

2.3 Area lighting YES

2.4 Electrical plant data acquisition and display

YES a)YES b)NO

2.5 Routine log report generation and energy balance report

YES a)YES b)NO

2.6 Detection and reporting of alarms

YES a)YES b)NO

2.7 Sequence of event recording

YES a)YES b)NO

3 Advanced ECS functionalities

3.1 Load shedding including maximum demand limit control

YES a)YES b)NO

3.2 Synchronization Yes a)YES b)NO

3.3 Capacitor feeder control for power factor improvement

YES a)YES b)NO

3.4 Active & Reactive power control

YES a)YES b)NO

3.5 Frequency & load control of all generators except DG

YES a)YES b)NO

3.6 Excitation control of synchronous motors

NO a)YES b)NO

3.7 Grid transformer OLTC control

Yes a)YES b)NO

4 Communication with other systems

Refer communication requirement in SAS

Note: 1) All incomer, bus-coupler and outgoing breaker and all process motors shall be considered

6.0 SPARE PARTS

6.1 MANDATORY SPARES

Mandatory spares shall be procured along with the main equipment. Such spares for each equipment shall be as per the below table. These spares include only those spares, which are critical for equipment.

S.No. Part Description Description

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S.No. Part Description Description 1 Generator (one set of spare for each

Generator)

1.1 Generator relay one set (each type & make) 1.2 DVR -all control card One each type 1.3 Exciter diodes and fuses 1 set 1.4 Control fuses/ MCB 10 nos. of each rating & type 1.5 Control & Selector switches 1 no of each type and make 1.6 Aux. contactors 20% of each type and make or 1 no.

(min.) of each type and make, whichever is more

2 Power Transformer (one set of spare for each power transformer)

Quantity is per transformer

2.1 Complete set of Gaskets one set 2.3 Sealing/ Gauge glass of convervator 2 Nos of each rating & type. 2.2 Control fuses/ MCB for MB cubicles 20% for each rating or 1 no. (min.) of

each rating, whichever is more 3 66KV Gas Insulated Switchgear (GIS) One set of sparfe for each switchboard

(Refer note-7) 3.1 Portable gas filling equipment/SF6 gas

cart 1 No.

3.2 Handle for disconnector switch drive 4 Nos. 3.3 Handle for earthing switch drive 4 Nos. 3.4 Pre selection key for three position switch 1 No. 3.5 Power cable termination kit 2 Nos. 3.6 Tripping coil 1 No 3.7 Closing coil 1 No. 3.8 Capacitive type voltage detectors 1 set 3.9 Control fuses/ MCB 10 Nos. each rating and type 3.12 Pressure Gauge 2 Nos. of each type 3.13 Indicating lamp covers 5 Nos. of each colour 3.10 Density monitoring device 2 Nos. of each type 3.11 Indicating lamps 20% or 3 nos. (min.), whichever is more 4 11 kV Switchgear (one set of spare for

each switchgear) Quantity is per switchboard

4.1 Closing coil 1 No. of each Rating & Type 4.2 Shunt trip coil 1 No. of each Rating & Type 4.3 control fuses(all type & rating ) 10 Nos. each rating & type 4.6 Breaker Finger 1 set for rating and type 4.5 Indicating lamp covers 20% or 3 nos. (min.), whichever is more 4.4 Indicating lamp covers 5 nos. of each colour 5 6.6KV Switchgear (one set of spare for

each switchgear) Quantity is as per switchboard

5.1 Closing coil 1 No. of each Rating & Type 5.2 Shunt trip coil 1 No. of each Rating & Type 5.6 Breaker finger jaws 1 set for each rating and type 5.4 Indicating lamp covers 5 nos. of each colour 5.3 Control fuses/ MCB 10 nos. of each rating & type 5.5 Indicating lamps 20% or 3 nos. (min.) whichever is more 6 415 V PCC/PMCC/EPCC or MV

Switchboard (one set of spare for each Switchboard)

Quantity is per switchboard

6.1 Closing coil 1 No. of each Rating & Type 6.2 Shunt trip coil 1 No. of each Rating & Type 6.3 control fuses/ MCB 10 Nos. each rating & type

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S.No. Part Description Description 6.4 Indicating lamps covers 5 nos. of each colour 6.5 Indicating lamps 20% or 3 nos. (min.) whichever is more 6.6 Breaker finger jaws 1 set for each rating and type 6.7 Contactor contacts 1 set for each rating and type 7 Variable Frequency Drive (one set of

spare for each VFD)/ Soft Starter Quantity is per VFD/ Soft Starter

7.1 Transistors/IGBT/ IGCT One No of each rating & type 7.2 Control cards One No of each type 7.3 Power supply cards One No of each rating & type 7.4 Power fuses 20% for each rating or one no. (min.) of

each rating, whichever is more 7.5 Control fuses/ MCB 10 Nos. of each rating & type 7.6 Contactors 10% of each type or 1 no. (min.) of each

type, whichever is more 7.7 Indicating lamps 20% or 1 no. (min.), whichever is more 7.8 Indicating lamps covers 2 nos. of each colour 7.9 Blocker Diode 2 nos. of each rating and type 7.10 Water cooled exchanged (for water

cooler VFD) 1 no. for each model and type

7.11 Raisin Bed(for water cooler VFD) 1 no. for each model and type 7.12 Bellows(for water cooler VFD) 1 no. for each model and type 8 Substation Automation System/HMI (one

set of spare for each SAS/ HMI)

8.1 All cards such as input & output cards, power supply cards, processor cards etc.

One No of each type

8.2 Control fuse/ MCB 10 Nos of each rating & type 8.3 Ethernet switches 1 No of each type 9 UPS (one set of spare for each UPS

system)

9.1 Power transistors/IGBT/ IGCT/ transistors One No of each rating & type 9.2 Power supply cards One No of each rating & type 9.3 Control Cards One No of each type 9.4 Power Fuses 20% for each rating OR 1 no. (min.) of

each rating, whichever is more 9.5 Control Fuses/ MCB 10 nos. of each rating & type 9.6 Indicating Lamps 10% OR 3 nos. (min.) whichever is

more 9.7 Indicating Lamp covers 2 nos. of each colour 9.8 Blocker Diode 2 nos. of each rating and type 10 DC System(one set of spare for each DC

System)

10.1 Power Thyristors/ Transistors/ IGBT/ IGCT

1 no. of each rating & type

10.2 Control Cards 1 no. of each type 10.3 Power supply cards 1 no. of each rating & type 10.4 Power Fuses 20% of each rating OR 1 no. (min.) of

each rating, whichever is more 10.5 Control fuses/ MCB 10 nos. of each rating & type 10.6 Indicating lamps 10% OR 3 nos. (min.) whichever is

more 10.7 Indicating lamps Covers 2 nos. of each colour 10.8 Blocker Diode 2 nos. of each rating & type 11 Synchronous motors (one set of spare for

each rating & type)

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S.No. Part Description Description 11.1 Power Fuses 20% of each rating OR 1 no. (min.) of

each rating, whichever is more 11.2 Control Fuses/ MCB 10 nos. of each rating and type 11.3 Bearing ( DE & NDE ) (as applicable) one set 11.4 Control Cards 1 no. of each type 12 HV induction motors (one set of spare for

each rating & type)

12.1 Bearing ( DE & NDE ) one set 12.2 Terminal studs/bushing assembly one set each 13 MV induction motors 37 kW & above (one

set of spare for each rating & type)

13.1 Bearing set (DE & NDE) one set 13.2 Terminal studs/ bushing assembly one set each 15 Fire alarm system

15.1 All cards one no. of each type 15.2 Control Fuses/ MCB 10 nos. of each rating & type 15.3 Terminal blocks 20 nos 15.4 Fire detectors 1% of total installed capacity of each

type OR 1 no. (min.) of each type, whichever is more

15.5 Glass for Break Glass Boxes/ Manual call point

5% of each type OR 1 no. (min.) of each type, whichever is more

15.6 Power Fuses 20% of each rating OR 1 no. (min.) of each rating, whichever is more

16 Paging system / Plant Communication System

16.1 All cards one no of each type 16.2 Power fuses 20% of each rating OR 1 no. (min.) of

each rating, whichever is more 16.3 Control fuses/ MCB 10 nos. of each rating & type 17 Thyristor control panel for heaters

17.1 Rectifier control module(Control card fully assembled)

one no. of each type

17.2 Power supply card one no. of each type 17.3 Control Cards one no. of each type 17.4 Power Fuses 2 nos. min. of each rating & type 17.5 Control fuses/ MCB 10 nos. each rating & type 17.6 Contactor 10% of each type OR one no. (min.) of

each type, whichever is more 17.7 Indicating lamps 20% or 1 no. (min.), whichever is more 17.8 Indicating lamps Covers 2 no. of each colour 17.9 Blocker diode 2 no. of each rating & type 18 ECS

18.1 Interposing relays (As applicable) 5 Nos. of each type 18.2 Power supply & control cards 1 nos. of each type 18.3 Transducer 20% of the estimated quantity of each

type and make OR 1 no. (min.) of each type and make, whichever is more

18.4 Function generator cum counter 1 no. 18.5 4-20mA signal injection set 1 no. 18.6 Isolation transformer 1 no. 19 Numerical relays 1 no. of each type 20 Distribution Transformer (One set of

spare for each transformer)

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S.No. Part Description Description 20.1 Complete set of gaskets 1 set 20.2 Sealing/ gauge glass of convervator 2 no. of each rating & type 20.3 Control fuses. MCB for MB cubicles 20% for each rating or 1 no. (min.) of

each rating, whichever is more

1. The word ''TYPE'' means the Make, Model no., Type, Range, Size/ Length, Rating, Material as applicable. 2. Wherever % age is identified, Contractor shall supply next rounded figure. 3. The terminology used under ''Part Description'' is the commonly used name of the part and may vary from manufacturer to manufacturer. 4. Mandatory spares as indicated above do not cover commissioning spares. 5. Mandatory spares as indicated above do not cover two year O&M spares. 6. Mandatory spares shall be applicable for electrical items of motors / sub-packages as per mandatory spares philosophy specified elsewhere in the bid document. 7. For Isolation breaker panel (GIS or AIS) one set of “Tripping Coil (1 No.), Closing coil (1 No.) and Control fuse/MCB (10 Nos. of each rating and type) “shall be considered as mandatory spares for each Isolation breaker panel (GIS or AIS). 8. For Isolation breaker panel (GIS or AIS) one set of “Auxiliary relays (1 no. of each type)” shall be considered as mandatory spares for Relays for Isolation breaker panel (GIS or AIS).

6.2 COMMISSIONING SPARES

Commissioning Spare Parts shall be procured along with the main equipment as per equipment manufacturer's recommendations. The list of such recommended spares shall be obtained along with the offer and supplied.

6.3 RECOMMENDED SPARE FOR NORMAL OPERATION & MAINTAINENCE

Quotation for two-years spares for normal operation and maintenance (over and above mandatory spares) along with unit price shall be obtained with the proposal for Client to order the same separately.

6.4 SPECIAL TOOLS AND TACKLES

Required Special Tools and Tackles shall be procured along with the main equipment as per equipment manufacturer's recommendations. The list of such recommended special tools/tackles shall be obtained along with the offer and supplied.

7.0 VENDOR DATA REQUIREMENT

Vendor Data Requirement as indicated in the respective equipment Material Requisitions shall be followed.

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DATA SHEET

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REV

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ENGINEERS INDIA LIMITED

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NEW DELHI

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copied, exhibited or used except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1650-Mv ic_mcc_asb_ldb.dwg Rev.0. A4-210x297.

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The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced,

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DATE

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PURPOSE

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BY

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CHKD

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APPRV

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M.V. SW. BD. DATA SHEET

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PCC/PMCC/MCC

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A

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REV

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Sheet 1

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B224-000-16-50-DS-1026

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bZ vkbZ ,y

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(WITH AUTOTRANSFER)

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3

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1

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DESCRIPTION

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QTY.

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NO.

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NEMA

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NO.

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ITEM

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415V, 50Hz TPN BUS

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A

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51

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86

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2

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V

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--/1A

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--/1A

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D.C POWER SUPPLY BUS (110V)

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27

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R

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27

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27

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M

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RX

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27

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MX

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KWH

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240V, 1PH AC AUX. SUPPLY BUS

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EQUIPMENT DATA

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11

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12

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28

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22

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21

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19

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BY SWGR

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VENDOR

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BY OTHERS

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24

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19

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15

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5

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27U

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PF

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25

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80

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1521AIR CIRCUIT BREAKER (4 POLE) 521AIR CIRCUIT BREAKER (4 POLE) 1AIR CIRCUIT BREAKER (4 POLE) AIR CIRCUIT BREAKER (4 POLE) 2-3PROTECTION CT, CL-5P10 -3PROTECTION CT, CL-5P10 3PROTECTION CT, CL-5P10 PROTECTION CT, CL-5P10 3-3METERING CT CL-1.0 -3METERING CT CL-1.0 3METERING CT CL-1.0 METERING CT CL-1.0 4-1ANALOG AMMETER WITH 4 WAY SELECTOR -1ANALOG AMMETER WITH 4 WAY SELECTOR 1ANALOG AMMETER WITH 4 WAY SELECTOR ANALOG AMMETER WITH 4 WAY SELECTOR SWITCH 5-ASINDICATING LAMP (LED TYPE) AND CUBICLE -ASINDICATING LAMP (LED TYPE) AND CUBICLE ASINDICATING LAMP (LED TYPE) AND CUBICLE INDICATING LAMP (LED TYPE) AND CUBICLE LAMP (LED TYPE) AND CUBICLE LAMP (LED TYPE) AND CUBICLE (LED TYPE) AND CUBICLE (LED TYPE) AND CUBICLE TYPE) AND CUBICLE TYPE) AND CUBICLE AND CUBICLE AND CUBICLE CUBICLE CUBICLE REQLAMPS LAMPS 6-3HT BREAKER ON/OFF AND TRANSFORMER -3HT BREAKER ON/OFF AND TRANSFORMER 3HT BREAKER ON/OFF AND TRANSFORMER HT BREAKER ON/OFF AND TRANSFORMER TROUBLE INDICATING LAMPS (LED TYPE) 7-1TRIP CKT. HEALTHY CHECK INDICATION LAMP -1TRIP CKT. HEALTHY CHECK INDICATION LAMP 1TRIP CKT. HEALTHY CHECK INDICATION LAMP TRIP CKT. HEALTHY CHECK INDICATION LAMP CKT. HEALTHY CHECK INDICATION LAMP CKT. HEALTHY CHECK INDICATION LAMP HEALTHY CHECK INDICATION LAMP HEALTHY CHECK INDICATION LAMP CHECK INDICATION LAMP CHECK INDICATION LAMP INDICATION LAMP INDICATION LAMP LAMP LAMP (LED TYPE) 8--DELETED --DELETED -DELETED DELETED 952C/S1BREAKER CONTROL SWITCH CLOSE-NEUTRAL 52C/S1BREAKER CONTROL SWITCH CLOSE-NEUTRAL 1BREAKER CONTROL SWITCH CLOSE-NEUTRAL BREAKER CONTROL SWITCH CLOSE-NEUTRAL CONTROL SWITCH CLOSE-NEUTRAL CONTROL SWITCH CLOSE-NEUTRAL SWITCH CLOSE-NEUTRAL SWITCH CLOSE-NEUTRAL CLOSE-NEUTRAL CLOSE-NEUTRAL -TRIP(LOCKABLE WITH SPRING RETURN TO WITH SPRING RETURN TO WITH SPRING RETURN TO SPRING RETURN TO SPRING RETURN TO RETURN TO RETURN TO TO TO NEUTRAL) 10-1CONTROL SWITCH (LOCKABLE) TO TRIP H.T -1CONTROL SWITCH (LOCKABLE) TO TRIP H.T 1CONTROL SWITCH (LOCKABLE) TO TRIP H.T CONTROL SWITCH (LOCKABLE) TO TRIP H.T SWITCH (LOCKABLE) TO TRIP H.T SWITCH (LOCKABLE) TO TRIP H.T (LOCKABLE) TO TRIP H.T (LOCKABLE) TO TRIP H.T TO TRIP H.T TO TRIP H.T TRIP H.T TRIP H.T H.T H.T BREAKER 11-1 SETPT 415V/110V, CL-1.0 CONNECTED WITH -1 SETPT 415V/110V, CL-1.0 CONNECTED WITH 1 SETPT 415V/110V, CL-1.0 CONNECTED WITH PT 415V/110V, CL-1.0 CONNECTED WITH WITH FUSE ON PRIMARY & 4 POLE MCB ON SECONDARY 12-1 SETPT 415V/110V, CL-1.0 CONNECTED WITH -1 SETPT 415V/110V, CL-1.0 CONNECTED WITH 1 SETPT 415V/110V, CL-1.0 CONNECTED WITH PT 415V/110V, CL-1.0 CONNECTED WITH WITH FUSE ON PRIMARY & 4 POLE MCB ON SECONDARY 13-1DP SWITCH FUSE 10A FOR DC SUPPLY -1DP SWITCH FUSE 10A FOR DC SUPPLY 1DP SWITCH FUSE 10A FOR DC SUPPLY DP SWITCH FUSE 10A FOR DC SUPPLY 14-1PANEL SPACE HEATER WITH MCB & -1PANEL SPACE HEATER WITH MCB & 1PANEL SPACE HEATER WITH MCB & PANEL SPACE HEATER WITH MCB & THERMOSTAT 15-2VOLTMETER 0-500V WITH 4 WAY SELECTOR -2VOLTMETER 0-500V WITH 4 WAY SELECTOR 2VOLTMETER 0-500V WITH 4 WAY SELECTOR VOLTMETER 0-500V WITH 4 WAY SELECTOR 0-500V WITH 4 WAY SELECTOR 0-500V WITH 4 WAY SELECTOR WITH 4 WAY SELECTOR WITH 4 WAY SELECTOR 4 WAY SELECTOR 4 WAY SELECTOR WAY SELECTOR WAY SELECTOR SELECTOR SELECTOR SWITCH 1627R1RESIDUAL VOLTAGE CHECK RELAY WITH 40% 27R1RESIDUAL VOLTAGE CHECK RELAY WITH 40% 1RESIDUAL VOLTAGE CHECK RELAY WITH 40% RESIDUAL VOLTAGE CHECK RELAY WITH 40% VOLTAGE CHECK RELAY WITH 40% VOLTAGE CHECK RELAY WITH 40% CHECK RELAY WITH 40% CHECK RELAY WITH 40% RELAY WITH 40% RELAY WITH 40% WITH 40% WITH 40% 40% 40% SETTING (27R) ÀLSTOM' TYPE VAG-21 1727C1HEALTH CHECK RELAY WITH TIMER 27C1HEALTH CHECK RELAY WITH TIMER 1HEALTH CHECK RELAY WITH TIMER HEALTH CHECK RELAY WITH TIMER 1827M1U/V RELAY FOR TRIPPING MOTOR ÀLSTOM' 27M1U/V RELAY FOR TRIPPING MOTOR ÀLSTOM' 1U/V RELAY FOR TRIPPING MOTOR ÀLSTOM' U/V RELAY FOR TRIPPING MOTOR ÀLSTOM' RELAY FOR TRIPPING MOTOR ÀLSTOM' RELAY FOR TRIPPING MOTOR ÀLSTOM' FOR TRIPPING MOTOR ÀLSTOM' FOR TRIPPING MOTOR ÀLSTOM' TRIPPING MOTOR ÀLSTOM' TRIPPING MOTOR ÀLSTOM' MOTOR ÀLSTOM' MOTOR ÀLSTOM' ÀLSTOM' ÀLSTOM' TYPE VAGM-22 SETTING RANGE 40-80% 19-ASAUX. RELAYS FOR 27M & 27R ÀLSTOM' & -ASAUX. RELAYS FOR 27M & 27R ÀLSTOM' & ASAUX. RELAYS FOR 27M & 27R ÀLSTOM' & AUX. RELAYS FOR 27M & 27R ÀLSTOM' & & REQTYPE VAA-11 TYPE VAA-11 20-1VOLTMETER. -1VOLTMETER. 1VOLTMETER. VOLTMETER. 21861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 1TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 22511IDMTL O/C RELAY ÀLSTOM' TYPE CDG-33 2 511IDMTL O/C RELAY ÀLSTOM' TYPE CDG-33 2 1IDMTL O/C RELAY ÀLSTOM' TYPE CDG-33 2 IDMTL O/C RELAY ÀLSTOM' TYPE CDG-33 2 O/C RELAY ÀLSTOM' TYPE CDG-33 2 O/C RELAY ÀLSTOM' TYPE CDG-33 2 RELAY ÀLSTOM' TYPE CDG-33 2 RELAY ÀLSTOM' TYPE CDG-33 2 ÀLSTOM' TYPE CDG-33 2 ÀLSTOM' TYPE CDG-33 2 TYPE CDG-33 2 TYPE CDG-33 2 CDG-33 2 CDG-33 2 2 2 & 51NNOS O/C (50-200%) & 1NO E/F (10-40%) NOS O/C (50-200%) & 1NO E/F (10-40%) 23951TRIP CIRCUIT SUPERVISION RELAY 951TRIP CIRCUIT SUPERVISION RELAY 1TRIP CIRCUIT SUPERVISION RELAY TRIP CIRCUIT SUPERVISION RELAY 24-1KWH METER -1KWH METER 1KWH METER KWH METER 25-1POWER FACTOR METER -1POWER FACTOR METER 1POWER FACTOR METER POWER FACTOR METER 26-1AMMETER. -1AMMETER. 1AMMETER. AMMETER. 27-1VOLTMETER. -1VOLTMETER. 1VOLTMETER. VOLTMETER. 2827U2U/V RELAY ÀLSTOM' TYPE VAGM-23 SETTING 27U2U/V RELAY ÀLSTOM' TYPE VAGM-23 SETTING 2U/V RELAY ÀLSTOM' TYPE VAGM-23 SETTING U/V RELAY ÀLSTOM' TYPE VAGM-23 SETTING RELAY ÀLSTOM' TYPE VAGM-23 SETTING RELAY ÀLSTOM' TYPE VAGM-23 SETTING ÀLSTOM' TYPE VAGM-23 SETTING ÀLSTOM' TYPE VAGM-23 SETTING TYPE VAGM-23 SETTING TYPE VAGM-23 SETTING VAGM-23 SETTING VAGM-23 SETTING SETTING SETTING RANGE 40-80% 2921TIME DELAY ON PICK-UP TIMER 0.5-5.0SEC. 21TIME DELAY ON PICK-UP TIMER 0.5-5.0SEC. 1TIME DELAY ON PICK-UP TIMER 0.5-5.0SEC. TIME DELAY ON PICK-UP TIMER 0.5-5.0SEC. DELAY ON PICK-UP TIMER 0.5-5.0SEC. DELAY ON PICK-UP TIMER 0.5-5.0SEC. ON PICK-UP TIMER 0.5-5.0SEC. ON PICK-UP TIMER 0.5-5.0SEC. PICK-UP TIMER 0.5-5.0SEC. PICK-UP TIMER 0.5-5.0SEC. TIMER 0.5-5.0SEC. TIMER 0.5-5.0SEC. 0.5-5.0SEC. 0.5-5.0SEC. ÀLSTOM'TYPE VTT-11 3021TIME DELAY ON DROP-OFF TIMER 21TIME DELAY ON DROP-OFF TIMER 1TIME DELAY ON DROP-OFF TIMER TIME DELAY ON DROP-OFF TIMER 0.5-5.0SEC. ÀLSTOM 'TYPE VTT-12 31801CONTROL SUPPLY FAILURE CHECK RELAY 801CONTROL SUPPLY FAILURE CHECK RELAY 1CONTROL SUPPLY FAILURE CHECK RELAY CONTROL SUPPLY FAILURE CHECK RELAY ÀLSTOM' TYPE VAG-11 WITH 60% SETTING. 3251G1IDMTL O/C RELAY 'AREVA' TYPE CDG-11 51G1IDMTL O/C RELAY 'AREVA' TYPE CDG-11 1IDMTL O/C RELAY 'AREVA' TYPE CDG-11 IDMTL O/C RELAY 'AREVA' TYPE CDG-11 (20-80%) 3364R1INST. E/F RELAY 'AREVA' TYPE CAG 14 (WITH 64R1INST. E/F RELAY 'AREVA' TYPE CAG 14 (WITH 1INST. E/F RELAY 'AREVA' TYPE CAG 14 (WITH INST. E/F RELAY 'AREVA' TYPE CAG 14 (WITH E/F RELAY 'AREVA' TYPE CAG 14 (WITH E/F RELAY 'AREVA' TYPE CAG 14 (WITH RELAY 'AREVA' TYPE CAG 14 (WITH RELAY 'AREVA' TYPE CAG 14 (WITH 'AREVA' TYPE CAG 14 (WITH 'AREVA' TYPE CAG 14 (WITH TYPE CAG 14 (WITH TYPE CAG 14 (WITH CAG 14 (WITH CAG 14 (WITH 14 (WITH 14 (WITH (WITH (WITH STABILISING RESISTOR) (10-40%)

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7

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V

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15

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23

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95

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27

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C

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A

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A

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4

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V

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2

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17

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R1 -PART OF NUMERICAL RELAY-1 R2 -PART OF NUMERICAL RELAY-2 NOTES: 1.ANTIPUMPING RELAY USED, IF ANY, SHALL BE ANTIPUMPING RELAY USED, IF ANY, SHALL BE RELAY USED, IF ANY, SHALL BE RELAY USED, IF ANY, SHALL BE USED, IF ANY, SHALL BE USED, IF ANY, SHALL BE IF ANY, SHALL BE IF ANY, SHALL BE ANY, SHALL BE ANY, SHALL BE SHALL BE SHALL BE BE BE CONSIDERED AS PART OF BREAKER MECHANISM. AS PART OF BREAKER MECHANISM. 2.THE ONE LINE DIAGRAM SHOWN ABOVE IS ONLY THE ONE LINE DIAGRAM SHOWN ABOVE IS ONLY ONE LINE DIAGRAM SHOWN ABOVE IS ONLY ONE LINE DIAGRAM SHOWN ABOVE IS ONLY LINE DIAGRAM SHOWN ABOVE IS ONLY LINE DIAGRAM SHOWN ABOVE IS ONLY DIAGRAM SHOWN ABOVE IS ONLY DIAGRAM SHOWN ABOVE IS ONLY SHOWN ABOVE IS ONLY SHOWN ABOVE IS ONLY ABOVE IS ONLY ABOVE IS ONLY IS ONLY IS ONLY ONLY ONLY INDICATIVE ALL THE ITEMS SPECIFIED UNDER ALL THE ITEMS SPECIFIED UNDER ALL THE ITEMS SPECIFIED UNDER THE ITEMS SPECIFIED UNDER THE ITEMS SPECIFIED UNDER ITEMS SPECIFIED UNDER ITEMS SPECIFIED UNDER SPECIFIED UNDER SPECIFIED UNDER UNDER UNDER "EQUIPMENT DATA" AND IN SPECIFICATION DATA" AND IN SPECIFICATION DATA" AND IN SPECIFICATION AND IN SPECIFICATION AND IN SPECIFICATION IN SPECIFICATION IN SPECIFICATION SPECIFICATION SPECIFICATION 6-51-18 SHALL BE IN VENDOR'S SCOPE. 3.AREVA RELAYS ARE INDICATED FOR TYPE AREVA RELAYS ARE INDICATED FOR TYPE RELAYS ARE INDICATED FOR TYPE RELAYS ARE INDICATED FOR TYPE ARE INDICATED FOR TYPE ARE INDICATED FOR TYPE INDICATED FOR TYPE INDICATED FOR TYPE FOR TYPE FOR TYPE TYPE TYPE REFERENCE ONLY. 4.FOR THE OTHER REQUIREMENTS OF RELAYS AND FOR THE OTHER REQUIREMENTS OF RELAYS AND THE OTHER REQUIREMENTS OF RELAYS AND THE OTHER REQUIREMENTS OF RELAYS AND OTHER REQUIREMENTS OF RELAYS AND OTHER REQUIREMENTS OF RELAYS AND REQUIREMENTS OF RELAYS AND REQUIREMENTS OF RELAYS AND OF RELAYS AND OF RELAYS AND RELAYS AND RELAYS AND AND AND METERS, REFER JOB SPECIFICATION 5.FOR THE REQUIREMENTS OF ECS INTERFACE, FOR THE REQUIREMENTS OF ECS INTERFACE, THE REQUIREMENTS OF ECS INTERFACE, THE REQUIREMENTS OF ECS INTERFACE, REQUIREMENTS OF ECS INTERFACE, REQUIREMENTS OF ECS INTERFACE, OF ECS INTERFACE, OF ECS INTERFACE, ECS INTERFACE, ECS INTERFACE, INTERFACE, INTERFACE, REFER I/O LIST ENCLOSED SEPARATELY IN M.R. 6.ALL PROTECTIVE RELAYS SHALL BE NUMERICAL ALL PROTECTIVE RELAYS SHALL BE NUMERICAL PROTECTIVE RELAYS SHALL BE NUMERICAL PROTECTIVE RELAYS SHALL BE NUMERICAL RELAYS SHALL BE NUMERICAL RELAYS SHALL BE NUMERICAL SHALL BE NUMERICAL SHALL BE NUMERICAL BE NUMERICAL BE NUMERICAL NUMERICAL NUMERICAL TYPE OF APPROVED MAKES. METERING SHALL BE OF APPROVED MAKES. METERING SHALL BE OF APPROVED MAKES. METERING SHALL BE APPROVED MAKES. METERING SHALL BE APPROVED MAKES. METERING SHALL BE MAKES. METERING SHALL BE MAKES. METERING SHALL BE METERING SHALL BE METERING SHALL BE SHALL BE SHALL BE BE BE A PART OF NUMERICAL RELAY. NUMERICAL RELAY. 7.VA BURDEN OF CT & PT SHALL BE DECIDED BY VA BURDEN OF CT & PT SHALL BE DECIDED BY BURDEN OF CT & PT SHALL BE DECIDED BY BURDEN OF CT & PT SHALL BE DECIDED BY OF CT & PT SHALL BE DECIDED BY OF CT & PT SHALL BE DECIDED BY CT & PT SHALL BE DECIDED BY CT & PT SHALL BE DECIDED BY & PT SHALL BE DECIDED BY & PT SHALL BE DECIDED BY PT SHALL BE DECIDED BY PT SHALL BE DECIDED BY SHALL BE DECIDED BY SHALL BE DECIDED BY BE DECIDED BY BE DECIDED BY DECIDED BY DECIDED BY BY BY THE SWITCHBOARD VENDOR.

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INCOMER

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R1

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R1

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27

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V

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20

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CABLE OR BUSDUCT

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A

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ISSUED WITH TENDER

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AP

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RKR

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MKS

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PROJECT: RRP

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CLIENT: M/s HRRL

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3

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--/1A

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64R

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FROM TRAFO

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NEUTRAL

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51G

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R1

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R2

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REV

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NEW DELHI

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DATE

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PURPOSE

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BY

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CHKD

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APPRV

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PCC/PMMC/MCC

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A

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REV

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Sheet 2

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B224-000-16-50-DS-1026

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bZ vkbZ ,y

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BUS-COUPLER

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DESCRIPTION

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QTY.

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NO.

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NEMA

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NO.

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ITEM

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415V, 50Hz TPN BUS-1

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EQUIPMENT DATA

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11

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10

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1521AIR CIRCUIT BREAKER (4 POLE) 521AIR CIRCUIT BREAKER (4 POLE) 1AIR CIRCUIT BREAKER (4 POLE) AIR CIRCUIT BREAKER (4 POLE) 2-3PROTECTION CT CL-5P10 -3PROTECTION CT CL-5P10 3PROTECTION CT CL-5P10 PROTECTION CT CL-5P10 3-1METERING CT CL-1.0 -1METERING CT CL-1.0 1METERING CT CL-1.0 METERING CT CL-1.0 4-ASINDICATING LAMP AND CUBICLE LAMPS, (LED -ASINDICATING LAMP AND CUBICLE LAMPS, (LED ASINDICATING LAMP AND CUBICLE LAMPS, (LED INDICATING LAMP AND CUBICLE LAMPS, (LED LAMP AND CUBICLE LAMPS, (LED LAMP AND CUBICLE LAMPS, (LED AND CUBICLE LAMPS, (LED AND CUBICLE LAMPS, (LED CUBICLE LAMPS, (LED CUBICLE LAMPS, (LED LAMPS, (LED LAMPS, (LED (LED (LED REQTYPE) TYPE) 5-1TRIP CKT. HEALTHY CHECK INDICATION LAMP-1TRIP CKT. HEALTHY CHECK INDICATION LAMP1TRIP CKT. HEALTHY CHECK INDICATION LAMPTRIP CKT. HEALTHY CHECK INDICATION LAMP CKT. HEALTHY CHECK INDICATION LAMPCKT. HEALTHY CHECK INDICATION LAMP HEALTHY CHECK INDICATION LAMPHEALTHY CHECK INDICATION LAMP CHECK INDICATION LAMPCHECK INDICATION LAMP INDICATION LAMPINDICATION LAMP LAMPLAMPLAMP(LED TYPE) 6--DELETED --DELETED -DELETED DELETED 752C/S1BREAKER CONTROL SWITCH CLOSE-NEUTRAL 52C/S1BREAKER CONTROL SWITCH CLOSE-NEUTRAL 1BREAKER CONTROL SWITCH CLOSE-NEUTRAL BREAKER CONTROL SWITCH CLOSE-NEUTRAL CONTROL SWITCH CLOSE-NEUTRAL CONTROL SWITCH CLOSE-NEUTRAL SWITCH CLOSE-NEUTRAL SWITCH CLOSE-NEUTRAL CLOSE-NEUTRAL CLOSE-NEUTRAL -TRIP(LOCKABLE WITH SPRING RETURN TO WITH SPRING RETURN TO WITH SPRING RETURN TO SPRING RETURN TO SPRING RETURN TO RETURN TO RETURN TO TO TO NEUTRAL) 8-1AUTO-OFF-MAN SELECTROR SWITCH -1AUTO-OFF-MAN SELECTROR SWITCH 1AUTO-OFF-MAN SELECTROR SWITCH AUTO-OFF-MAN SELECTROR SWITCH (LOCKABLE) 9-13 POSITION SEL. SWITCH FOR TRIP BKR-A/ -13 POSITION SEL. SWITCH FOR TRIP BKR-A/ 13 POSITION SEL. SWITCH FOR TRIP BKR-A/ 3 POSITION SEL. SWITCH FOR TRIP BKR-A/ TRIP TIE/TRIP BKR-B (STAYPUT & LOCKABLE) 10-1DP SWITCH FUSE 10A FOR DC SUPPLY -1DP SWITCH FUSE 10A FOR DC SUPPLY 1DP SWITCH FUSE 10A FOR DC SUPPLY DP SWITCH FUSE 10A FOR DC SUPPLY 11-1PANEL SPACE HEATER WITH MCB & -1PANEL SPACE HEATER WITH MCB & 1PANEL SPACE HEATER WITH MCB & PANEL SPACE HEATER WITH MCB & THERMOSTAT 12951TRIP CIRCUIT SUPERVISION RELAY 951TRIP CIRCUIT SUPERVISION RELAY 1TRIP CIRCUIT SUPERVISION RELAY TRIP CIRCUIT SUPERVISION RELAY 13251CHECK SYNCRONISING ALSTOM TYPE SKE-11 251CHECK SYNCRONISING ALSTOM TYPE SKE-11 1CHECK SYNCRONISING ALSTOM TYPE SKE-11 CHECK SYNCRONISING ALSTOM TYPE SKE-11 14511IDMTL O/C RELAY ÀLSTOM' TYPE CDG-31 2 511IDMTL O/C RELAY ÀLSTOM' TYPE CDG-31 2 1IDMTL O/C RELAY ÀLSTOM' TYPE CDG-31 2 IDMTL O/C RELAY ÀLSTOM' TYPE CDG-31 2 O/C RELAY ÀLSTOM' TYPE CDG-31 2 O/C RELAY ÀLSTOM' TYPE CDG-31 2 RELAY ÀLSTOM' TYPE CDG-31 2 RELAY ÀLSTOM' TYPE CDG-31 2 ÀLSTOM' TYPE CDG-31 2 ÀLSTOM' TYPE CDG-31 2 TYPE CDG-31 2 TYPE CDG-31 2 CDG-31 2 CDG-31 2 2 2 & 51NNOS O/C (50-200%) & 1NO E/F (10-40%) NOS O/C (50-200%) & 1NO E/F (10-40%) 15861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 1TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 16-1AMMETER WITH 4-WAY SELECTOR SWITCH-1AMMETER WITH 4-WAY SELECTOR SWITCH1AMMETER WITH 4-WAY SELECTOR SWITCHAMMETER WITH 4-WAY SELECTOR SWITCH

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3

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1

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A

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--/1A

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7

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8

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9

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16

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BUS-2

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4

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5

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--/1A

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14

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2

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51

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51N

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14

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86

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15

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12

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25

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13

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95

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R1 -PART OF NUMERICAL RELAY-1 NOTES: 1.ANTIPUMPING RELAY USED, IF ANY, SHALL BE CONSIDERED AS PART OF BREAKER MECHANISM. ANTIPUMPING RELAY USED, IF ANY, SHALL BE CONSIDERED AS PART OF BREAKER MECHANISM. AS PART OF BREAKER MECHANISM. 2.THE ONE LINE DIAGRAM SHOWN ABOVE IS ONLY INDICATIVE ALL THE ITEMS SPECIFIED UNDER "EQUIPMENT DATA" THE ONE LINE DIAGRAM SHOWN ABOVE IS ONLY INDICATIVE ALL THE ITEMS SPECIFIED UNDER "EQUIPMENT DATA" AND IN SPECIFICATION 6-51-0018 SHALL BE IN VENDOR'S SCOPE. 3.AREVA RELAYS ARE INDICATED FOR TYPE REFERENCE ONLY. AREVA RELAYS ARE INDICATED FOR TYPE REFERENCE ONLY. 4.FOR THE OTHER REQUIREMENTS OF RELAYS AND METERS, REFER JOB SPECIFICATION FOR THE OTHER REQUIREMENTS OF RELAYS AND METERS, REFER JOB SPECIFICATION 5.FOR THE REQUIREMENTS OF ECS INTERFACE, REFER I/O LIST ENCLOSED SEPARATELY. FOR THE REQUIREMENTS OF ECS INTERFACE, REFER I/O LIST ENCLOSED SEPARATELY. 6.ALL PROTECTIVE RELAYS SHALL BE NUMERICAL TYPE OF APPROVED MAKES. METERING SHALL BE A PART OF ALL PROTECTIVE RELAYS SHALL BE NUMERICAL TYPE OF APPROVED MAKES. METERING SHALL BE A PART OF NUMERICAL RELAY. 7.VA BURDEN OF CTs SHALL BE DECIDED BY THE SWITCHBOARD VENDOR.VA BURDEN OF CTs SHALL BE DECIDED BY THE SWITCHBOARD VENDOR.

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R1

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A

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ISSUED WITH TENDER

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AP

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RKR

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MKS

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PROJECT: RRP

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CLIENT: M/s HRRL

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REV

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NEW DELHI

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DATE

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PURPOSE

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BY

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CHKD

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APPRV

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OUTGOING BREAKER

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A

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REV

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Sheet 3

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PROJECT: RRP

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CLIENT: M/s HRRL

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A

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ISSUED WITH TENDER

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AP

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RKR

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MKS

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B224-000-16-50-DS-1026

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bZ vkbZ ,y

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FEEDER

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DESCRIPTION

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QTY.

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NO.

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NEMA

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NO.

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ITEM

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415V, 50Hz TPN BUS

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EQUIPMENT DATA

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9

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8

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PT BUS

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1521AIR CIRCUIT BREAKER 521AIR CIRCUIT BREAKER 1AIR CIRCUIT BREAKER AIR CIRCUIT BREAKER 2-3PROTECTION CT CL-5P10 -3PROTECTION CT CL-5P10 3PROTECTION CT CL-5P10 PROTECTION CT CL-5P10 3-1METERING CT CL-1.0 -1METERING CT CL-1.0 1METERING CT CL-1.0 METERING CT CL-1.0 4-ASINDICATING LAMP AND CUBICLE LAMPS, (LED -ASINDICATING LAMP AND CUBICLE LAMPS, (LED ASINDICATING LAMP AND CUBICLE LAMPS, (LED INDICATING LAMP AND CUBICLE LAMPS, (LED LAMP AND CUBICLE LAMPS, (LED LAMP AND CUBICLE LAMPS, (LED AND CUBICLE LAMPS, (LED AND CUBICLE LAMPS, (LED CUBICLE LAMPS, (LED CUBICLE LAMPS, (LED LAMPS, (LED LAMPS, (LED (LED (LED REQTYPE) TYPE) 5-1TRIP CKT. HEALTHY CHECK INDICATION LAMP-1TRIP CKT. HEALTHY CHECK INDICATION LAMP1TRIP CKT. HEALTHY CHECK INDICATION LAMPTRIP CKT. HEALTHY CHECK INDICATION LAMP CKT. HEALTHY CHECK INDICATION LAMPCKT. HEALTHY CHECK INDICATION LAMP HEALTHY CHECK INDICATION LAMPHEALTHY CHECK INDICATION LAMP CHECK INDICATION LAMPCHECK INDICATION LAMP INDICATION LAMPINDICATION LAMP LAMPLAMPLAMP(LED TYPE) 6--DELETED --DELETED -DELETED DELETED 752C/S1BREAKER CONTROL SWITCH CLOSE-NEUTRAL 52C/S1BREAKER CONTROL SWITCH CLOSE-NEUTRAL 1BREAKER CONTROL SWITCH CLOSE-NEUTRAL BREAKER CONTROL SWITCH CLOSE-NEUTRAL CONTROL SWITCH CLOSE-NEUTRAL CONTROL SWITCH CLOSE-NEUTRAL SWITCH CLOSE-NEUTRAL SWITCH CLOSE-NEUTRAL CLOSE-NEUTRAL CLOSE-NEUTRAL -TRIP(LOCKABLE WITH SPRING RETURN TO WITH SPRING RETURN TO WITH SPRING RETURN TO SPRING RETURN TO SPRING RETURN TO RETURN TO RETURN TO TO TO NEUTRAL) 8-1DP SWITCH FUSE 10A FOR DC SUPPLY -1DP SWITCH FUSE 10A FOR DC SUPPLY 1DP SWITCH FUSE 10A FOR DC SUPPLY DP SWITCH FUSE 10A FOR DC SUPPLY 9-1PANEL SPACE HEATER WITH MCB & -1PANEL SPACE HEATER WITH MCB & 1PANEL SPACE HEATER WITH MCB & PANEL SPACE HEATER WITH MCB & THERMOSTAT 10951TRIP CIRCUIT SUPERVISION RELAY 951TRIP CIRCUIT SUPERVISION RELAY 1TRIP CIRCUIT SUPERVISION RELAY TRIP CIRCUIT SUPERVISION RELAY 11861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 1TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 12511IDMTL O/C RELAY ÀLSTOM' TYPE CDG-31 2 511IDMTL O/C RELAY ÀLSTOM' TYPE CDG-31 2 1IDMTL O/C RELAY ÀLSTOM' TYPE CDG-31 2 IDMTL O/C RELAY ÀLSTOM' TYPE CDG-31 2 O/C RELAY ÀLSTOM' TYPE CDG-31 2 O/C RELAY ÀLSTOM' TYPE CDG-31 2 RELAY ÀLSTOM' TYPE CDG-31 2 RELAY ÀLSTOM' TYPE CDG-31 2 ÀLSTOM' TYPE CDG-31 2 ÀLSTOM' TYPE CDG-31 2 TYPE CDG-31 2 TYPE CDG-31 2 CDG-31 2 CDG-31 2 2 2 & 51NNOS O/C (50-200%) & 1NO E/F (10-40%) NOS O/C (50-200%) & 1NO E/F (10-40%) 13-1AMMETER -1AMMETER 1AMMETER AMMETER 14-1VOLTMETER -1VOLTMETER 1VOLTMETER VOLTMETER 15-1KWH METER -1KWH METER 1KWH METER KWH METER 16-1AMMETER WITH 4-WAY SELECTOR SWITCH -1AMMETER WITH 4-WAY SELECTOR SWITCH 1AMMETER WITH 4-WAY SELECTOR SWITCH AMMETER WITH 4-WAY SELECTOR SWITCH 17-ASAUXILLIARY RELAYS -ASAUXILLIARY RELAYS ASAUXILLIARY RELAYS AUXILLIARY RELAYS REQD.

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3

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1

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A

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--/1A

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7

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16

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4

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5

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--/1A

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12

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2

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51

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51N

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12

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86

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11

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13

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R1 -PART OF NUMERICAL RELAY-1 NOTES: 1.ANTIPUMPING RELAY USED, IF ANY, SHALL BE CONSIDERED AS PART OF BREAKER MECHANISM. ANTIPUMPING RELAY USED, IF ANY, SHALL BE CONSIDERED AS PART OF BREAKER MECHANISM. AS PART OF BREAKER MECHANISM. 2.THE ONE LINE DIAGRAM SHOWN ABOVE IS ONLY INDICATIVE ALL THE ITEMS SPECIFIED UNDER "EQUIPMENT DATA" THE ONE LINE DIAGRAM SHOWN ABOVE IS ONLY INDICATIVE ALL THE ITEMS SPECIFIED UNDER "EQUIPMENT DATA" AND IN SPECIFICATION 6-51-0018 SHALL BE IN VENDOR'S SCOPE. 3.ALSTOM RELAYS ARE INDICATED FOR TYPE REFERENCE ONLY. ALSTOM RELAYS ARE INDICATED FOR TYPE REFERENCE ONLY. 4.FOR THE OTHER REQUIREMENTS OF RELAYS AND METERS, REFER JOB SPECIFICATION FOR THE OTHER REQUIREMENTS OF RELAYS AND METERS, REFER JOB SPECIFICATION 5.FOR THE REQUIREMENTS OF ECS INTERFACE, REFER I/O LIST ENCLOSED SEPARATELY. FOR THE REQUIREMENTS OF ECS INTERFACE, REFER I/O LIST ENCLOSED SEPARATELY. 6.ALL PROTECTIVE RELAYS SHALL BE NUMERICAL TYPE OF APPROVED MAKES. METERING SHALL BE A PART OF ALL PROTECTIVE RELAYS SHALL BE NUMERICAL TYPE OF APPROVED MAKES. METERING SHALL BE A PART OF NUMERICAL RELAY. 7.VA BURDEN OF CTs SHALL BE DECIDED BY THE SWITCHBOARD VENDOR.VA BURDEN OF CTs SHALL BE DECIDED BY THE SWITCHBOARD VENDOR.

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R1

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KWH

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A

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14

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V

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15

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10

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95

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TO D/S 415V SWBD.

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INTERTRIP

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REV

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NEW DELHI

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DATE

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BREAKER CONTROLLED

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A

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REV

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Sheet 4

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B224-000-16-50-DS-1026

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bZ vkbZ ,y

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(FOR MOTOR RATED >55kW AND <=160kW)

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DESCRIPTION

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QTY.

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NO.

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NEMA

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NO.

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415V, 50Hz TPN BUS

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EQUIPMENT DATA

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8

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PT BUS

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1521AIR CIRCUIT BREAKER 521AIR CIRCUIT BREAKER 1AIR CIRCUIT BREAKER AIR CIRCUIT BREAKER 2-3PROTECTION CT CL-5P10 -3PROTECTION CT CL-5P10 3PROTECTION CT CL-5P10 PROTECTION CT CL-5P10 3-1METERING CT CL-1.0 -1METERING CT CL-1.0 1METERING CT CL-1.0 METERING CT CL-1.0 4-ASINDICATING LAMPS (LED TYPE) AND CUBICLE -ASINDICATING LAMPS (LED TYPE) AND CUBICLE ASINDICATING LAMPS (LED TYPE) AND CUBICLE INDICATING LAMPS (LED TYPE) AND CUBICLE LAMPS (LED TYPE) AND CUBICLE LAMPS (LED TYPE) AND CUBICLE (LED TYPE) AND CUBICLE (LED TYPE) AND CUBICLE TYPE) AND CUBICLE TYPE) AND CUBICLE AND CUBICLE AND CUBICLE CUBICLE CUBICLE REQLAMP LAMP 5-1TRIP CKT. HEALTHY CHECK INDICATION LAMP-1TRIP CKT. HEALTHY CHECK INDICATION LAMP1TRIP CKT. HEALTHY CHECK INDICATION LAMPTRIP CKT. HEALTHY CHECK INDICATION LAMP CKT. HEALTHY CHECK INDICATION LAMPCKT. HEALTHY CHECK INDICATION LAMP HEALTHY CHECK INDICATION LAMPHEALTHY CHECK INDICATION LAMP CHECK INDICATION LAMPCHECK INDICATION LAMP INDICATION LAMPINDICATION LAMP LAMPLAMPLAMP(LED TYPE) 6-1TRIP CIRCUIT HEALTHY CHECK PUSHBUTTON -1TRIP CIRCUIT HEALTHY CHECK PUSHBUTTON 1TRIP CIRCUIT HEALTHY CHECK PUSHBUTTON TRIP CIRCUIT HEALTHY CHECK PUSHBUTTON 752C/S1BREAKER CONTROL SWITCH CLOSE-NEUTRAL 52C/S1BREAKER CONTROL SWITCH CLOSE-NEUTRAL 1BREAKER CONTROL SWITCH CLOSE-NEUTRAL BREAKER CONTROL SWITCH CLOSE-NEUTRAL CONTROL SWITCH CLOSE-NEUTRAL CONTROL SWITCH CLOSE-NEUTRAL SWITCH CLOSE-NEUTRAL SWITCH CLOSE-NEUTRAL CLOSE-NEUTRAL CLOSE-NEUTRAL -TRIP (LOCKABLE WITH SPRING RETURN TO (LOCKABLE WITH SPRING RETURN TO (LOCKABLE WITH SPRING RETURN TO WITH SPRING RETURN TO WITH SPRING RETURN TO SPRING RETURN TO SPRING RETURN TO RETURN TO RETURN TO TO TO NEUTRAL) 8-1DP SWITCH FUSE 10A FOR DC SUPPLY -1DP SWITCH FUSE 10A FOR DC SUPPLY 1DP SWITCH FUSE 10A FOR DC SUPPLY DP SWITCH FUSE 10A FOR DC SUPPLY 9-1DP SWITCH & FUSE FOR MOTR SPACE HEATER -1DP SWITCH & FUSE FOR MOTR SPACE HEATER 1DP SWITCH & FUSE FOR MOTR SPACE HEATER DP SWITCH & FUSE FOR MOTR SPACE HEATER SWITCH & FUSE FOR MOTR SPACE HEATER SWITCH & FUSE FOR MOTR SPACE HEATER & FUSE FOR MOTR SPACE HEATER & FUSE FOR MOTR SPACE HEATER FUSE FOR MOTR SPACE HEATER FUSE FOR MOTR SPACE HEATER FOR MOTR SPACE HEATER FOR MOTR SPACE HEATER MOTR SPACE HEATER MOTR SPACE HEATER SPACE HEATER SPACE HEATER HEATER HEATER SUPPLY THROUGH BREAKER AUXILLARY CONTACT 10-1PANEL SPACE HEATER WITH MCB & -1PANEL SPACE HEATER WITH MCB & 1PANEL SPACE HEATER WITH MCB & PANEL SPACE HEATER WITH MCB & THERMOSTAT 11861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 1TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. TRIPPING RELAY ÀLSTOM' TYPE VAJH-23. 12861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23 FOR 861TRIPPING RELAY ÀLSTOM' TYPE VAJH-23 FOR 1TRIPPING RELAY ÀLSTOM' TYPE VAJH-23 FOR TRIPPING RELAY ÀLSTOM' TYPE VAJH-23 FOR RELAY ÀLSTOM' TYPE VAJH-23 FOR RELAY ÀLSTOM' TYPE VAJH-23 FOR ÀLSTOM' TYPE VAJH-23 FOR ÀLSTOM' TYPE VAJH-23 FOR TYPE VAJH-23 FOR TYPE VAJH-23 FOR VAJH-23 FOR VAJH-23 FOR FOR FOR TRIP THROUGH PROCESS SIGNAL. 13951TRIP CIRCUIT SUPERVISION RELAY 951TRIP CIRCUIT SUPERVISION RELAY 1TRIP CIRCUIT SUPERVISION RELAY TRIP CIRCUIT SUPERVISION RELAY 14MPR1MOTOR PROTECTION RELAY ' ALSTOM' TYPE MPR1MOTOR PROTECTION RELAY ' ALSTOM' TYPE 1MOTOR PROTECTION RELAY ' ALSTOM' TYPE MOTOR PROTECTION RELAY ' ALSTOM' TYPE PROTECTION RELAY ' ALSTOM' TYPE PROTECTION RELAY ' ALSTOM' TYPE RELAY ' ALSTOM' TYPE RELAY ' ALSTOM' TYPE ' ALSTOM' TYPE ' ALSTOM' TYPE ALSTOM' TYPE ALSTOM' TYPE TYPE TYPE CTMM (501-510). . 1522ON DELAY AND OFF DELAY TIMERS FOR AUTO 22ON DELAY AND OFF DELAY TIMERS FOR AUTO 2ON DELAY AND OFF DELAY TIMERS FOR AUTO ON DELAY AND OFF DELAY TIMERS FOR AUTO DELAY AND OFF DELAY TIMERS FOR AUTO DELAY AND OFF DELAY TIMERS FOR AUTO AND OFF DELAY TIMERS FOR AUTO AND OFF DELAY TIMERS FOR AUTO OFF DELAY TIMERS FOR AUTO OFF DELAY TIMERS FOR AUTO DELAY TIMERS FOR AUTO DELAY TIMERS FOR AUTO TIMERS FOR AUTO TIMERS FOR AUTO FOR AUTO FOR AUTO AUTO AUTO REACCELERATION 16-1AMMETER -1AMMETER 1AMMETER AMMETER 17-1VOLTMETER -1VOLTMETER 1VOLTMETER VOLTMETER 18-1KWH METER -1KWH METER 1KWH METER KWH METER 19-1HOUR RUN METER -1HOUR RUN METER 1HOUR RUN METER HOUR RUN METER 20-ASAUXILLIARY RELAYS -ASAUXILLIARY RELAYS ASAUXILLIARY RELAYS AUXILLIARY RELAYS REQD.

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3

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1

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A

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--/1A

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7

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4

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5

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6

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--/1A

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14

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2

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MPR

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(46,49,50,50N,

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86

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11

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16

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R1 -PART OF NUMERICAL RELAY-1 NOTES: 1.ANTIPUMPING RELAY USED, IF ANY, SHALL BE CONSIDERED AS PART OF BREAKER MECHANISM. ANTIPUMPING RELAY USED, IF ANY, SHALL BE CONSIDERED AS PART OF BREAKER MECHANISM. AS PART OF BREAKER MECHANISM. 2.THE ONE LINE DIAGRAM SHOWN ABOVE IS ONLY INDICATIVE ALL THE ITEMS SPECIFIED UNDER "EQUIPMENT DATA" THE ONE LINE DIAGRAM SHOWN ABOVE IS ONLY INDICATIVE ALL THE ITEMS SPECIFIED UNDER "EQUIPMENT DATA" AND IN SPECIFICATION 6-51-18 SHALL BE IN VENDOR'S SCOPE. 3.ALSTOM RELAYS ARE INDICATED FOR TYPE REFERENCE ONLY. ALSTOM RELAYS ARE INDICATED FOR TYPE REFERENCE ONLY. 4.FOR THE OTHER REQUIREMENTS OF RELAYS AND METERS, REFER JOB SPECIFICATION FOR THE OTHER REQUIREMENTS OF RELAYS AND METERS, REFER JOB SPECIFICATION 5.ALL PROTECTIVE RELAYS SHALL BE NUMERICAL TYPE OF APPROVED MAKES. METERING SHALL BE A PART OF ALL PROTECTIVE RELAYS SHALL BE NUMERICAL TYPE OF APPROVED MAKES. METERING SHALL BE A PART OF NUMERICAL RELAY. 6.AUTO REACCELERATION FEATURE WITH INHIBIT TO BE PROVIDED AS STANDARD. AUTO REACCELERATION FEATURE WITH INHIBIT TO BE PROVIDED AS STANDARD. 7.VA BURDEN OF CTs SHALL BE DECIDED BY THE SWITCHBOARD VENDOR.VA BURDEN OF CTs SHALL BE DECIDED BY THE SWITCHBOARD VENDOR.

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R1

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A

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17

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V

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13

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95

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MOTOR FEEDER

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M

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15

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2

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12

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86

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10

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9

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27,50L/R)

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PROJECT: RRP

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CLIENT: M/s HRRL

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A

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ISSUED WITH TENDER

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AP

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RKR

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MKS

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18

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KWH

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19

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HR

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13.08.19

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DATA SHEET

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REV

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NEW DELHI

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copied, exhibited or used except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1650-Mvsb_conmotfdr_reacc.dwg Rev.0. A4-210x297.

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CONTACTOR CONTROLLED MOTOR FEEDER

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ITEM

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NO.

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NEMA

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NO.

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QTY.

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DESCRIPTION

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EQUIPMENT DATA

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A

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(FOR MOTORS <=55kW)

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Sheet 5

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bZ vkbZ ,y

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DATE

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PURPOSE

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BY

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CHKD

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APPRV

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REV

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B224-000-16-50-DS-1026

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%%UNOTES:

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- AS AUX.CONTACTORS WITH MIN.2NO+2NC CONTACTS

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REQD

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20

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TRIP THROUGH PROCESS SIGNAL

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TRIPPING RELAY ALSTOM TYPE VAJH-23 FOR

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11

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ELECTRONIC MOTOR PROTECTION RELAY 'ALSTOM'

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10

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86

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1

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MPR

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1

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1

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DP SWITCH & FUSE FOR MOTOR SPACE HEATER

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REQD

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AS

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1

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-

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9

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AND THERMOSTAT

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PANEL SPACE HEATER WITH MCB

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-

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8

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INDICATING LAMPS - LED TYPE

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-

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7

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METERING CT CL-1.0

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1

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-

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6

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STOP PUSH BUTTON

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1

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-

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5

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4

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PROTECTION CT CL-5P10

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3

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-

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3

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WITH 2NO+2NC AUXILIARY CONTACTS.

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AIR BREAK CONTACTOR, DUTY-AC3

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1

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-

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2

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MCCB (NON-MICROPROCESSOR BASED) WITH

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1

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-

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1

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7. VA BURDEN OF CTs SHALL BE DECIDED BY THE SWITCHBOARD VENDOR

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2.

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COMPONENT RATING SHALL BE AS PER DATA SHEET

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3.

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NO. OF CONTROL TERMINALS PROVIDED SHALL INCLUDE 20% SPARE TERMINALS

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SHALL BE IN VENDOR'S SCOPE.

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SPECIFIED UNDER "EQUIPMENT DATA" AND IN SPECIFICATION 6-51-0018

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1. THE ONE LINE DIAGRAM SHOWN ABOVE IS ONLY INDICATIVE. ALL THE ITEMS

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4.

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MOTOR SPACE HEATER CKT. TO BE PROVIDED FOR MOTORS RATED 30kW AND ABOVE.

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SUBJECT TO A MINIMUM 24 TERMINALS.

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6. ALL PROTECTIVE RELAYS SHALL BE NUMERICAL TYPE OF APPROVED MAKES. METERING SHALL BE

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( NOTE-4)

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7

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HEATER

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MOTOR SPACE

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M

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3

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2

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4

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DC POWER SUPPLY BUS (110 V)

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8

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415V,50HZ TPN BUS

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240V,1PH AC AUX SUPPLY BUS

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1

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86

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1

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A

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ISSUED WITH TENDER

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AP

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RKR

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MKS

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PROJECT: RRP

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CLIENT: M/S HRRL

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--/1A

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9

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EMPR

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(46,49,50,50N,

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27,50L/R)

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86

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86

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--/1A

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11

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10

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5

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TYPE CTMM (501-510)

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TRIPPING RELAY ALSTOM TYPE VAJH-23

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6. ALSTOM RELAYS ARE INDICATED FOR TYPE REFERENCE ONLY.

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NUMERICAL RELAY

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R1

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R1

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NUMERICAL RELAY

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PT BUS

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8. CONTROL SUPPLY FOR CONTACTORS AND MCCB SHUT TRIP SHALL BE 110V DC.

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15

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V

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16

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KWH

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17

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HR

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14

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A

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18

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6

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19

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12

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95

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12

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95

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-

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TRIP CIRCUIT SUPERVISION RELAY

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13

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2

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-

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ON DELAY AND OFF DELAY TIMERS FOR AUTO

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REACCELERATION

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14

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-

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-

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AMMETER

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15

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-

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-

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VOLTMETER

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16

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-

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-

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KWH METER

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17

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-

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-

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HOUR RUN METER

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18

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-

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1

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DP SWITCH & FUSE 10A FOR DC SUPPLY

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19

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-

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1

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TRIP CIRCUIT HEALTHY CHECK INDICATION LAMP

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(LED TYPE)

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SHUNT TRIP COIL & S/C PROTECTION

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9. CT FOR AMMETER TO BE PROVIDED FOR MOTORS RATED 5.5KW & ABOVE.

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10. RC CIRCUIT SHALL BE PROVIDED ACROSS POWER CONTACTOR AND LOW BURDEN AUXILIARY

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CONTACTOR SHALL BE PROVIDED FOR RECEIVING START/STOP COMMAND FROM FIELD.

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DATA SHEET

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REV

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NEW DELHI

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POWER FEEDER

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ITEM

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NO.

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NEMA

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NO.

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QTY.

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DESCRIPTION

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EQUIPMENT DATA

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A

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SHEET 6

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bZ vkbZ ,y

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DATE

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PURPOSE

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BY

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CHKD

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APPRV

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REV

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B224-000-16-50-DS-1026

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%%UNOTES:

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1

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REQD

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AS

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AND THERMOSTAT

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-

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-

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5

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4

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MCCB (MICROPROCESSOR BASED) WITH SHUNT

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1

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-

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1

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2.

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COMPONENT RATING SHALL BE AS PER DATA SHEET.

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3.

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4

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5

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415V,50HZ TPN BUS

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1

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A

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ISSUED WITH TENDER

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AP

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RKR

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MKS

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PROJECT: RRP

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CLIENT: M/s HRRL

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4. CONTROL SUPPLY FOR CONTACTORS AND SHUNT TRIP VOLTAGE FOR MCCB SHALL BE

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110V DC.

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POWER FEEDER

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(UPTO 160A)

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TRIP, S/C, O/C

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DATA SHEET

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REV

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NEW DELHI

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CONTACTOR CONTROLLED POWER FEEDER

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ITEM

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NO.

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NEMA

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NO.

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QTY.

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DESCRIPTION

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EQUIPMENT DATA

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A

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SHEET 7

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bZ vkbZ ,y

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DATE

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PURPOSE

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BY

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CHKD

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APPRV

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REV

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B224-000-16-50-DS-1026

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%%UNOTES:

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1

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REQD

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AS

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1

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50N

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AND THERMOSTAT

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AutoCAD SHX Text

-

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7

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-

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5

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4

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METERING CT

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3

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-

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3

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WITH 2NO+2NC AUXILIARY CONTACTS.

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AIR BREAK CONTACTOR, DUTY-AC3

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1

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-

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2

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1

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-

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1

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6. VA BURDEN OF CTs SHALL BE DECIDED BY THE SWITCHBOARD VENDOR.

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2.

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COMPONENT RATING SHALL BE AS PER DATA SHEET.

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3.

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4. EARTH LEAKAGE RELAY SHALL BE SUITABLE FOR 110V DC.

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4

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5

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3

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2

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415V,50HZ TPN BUS

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1

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A

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13.08.19

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ISSUED WITH TENDER

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AP

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RKR

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MKS

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PROJECT: RRP

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CLIENT: M/s HRRL

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--/1A

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5. CONTROL SUPPLY FOR CONTACTORS AND SHUNT TRIP VOLTAGE FOR MCCB SHALL BE

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110V DC.

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50N

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6

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7

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POWER FEEDER

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CORE BALANCE CURRENT TRANSFORMER

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EARTH LEAKAGE RELAY 'AREVA' TYPE CTUM-15

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SETTING RANGE (1-16%) WITH BUILTIN TIMER

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1

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-

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6

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(ABOVE 160A & UPTO 400A)

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A

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9

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KWH

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8

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9

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ANALOGOUS AMMETER WITH 4WAY SELECTOR

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1

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-

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SWITCH

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8

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-

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1

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ANALOGOUS KWH METER WITH ACCURACY CL.1.0

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MCCB (MICROPROCESSOR BASED) WITH SHUNT

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TRIP, S/C, O/C

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DATA SHEET

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REV

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NEW DELHI

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copied, exhibited or used except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1650-MVCTRF Rev.0. A4-210x297.

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DATE

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PURPOSE

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BY

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CHKD

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APPRV

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PROJECT: RRP

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CLIENT: M/s HRRL

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SCHEME FOR AC CONTROL SUPPLY

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CONTROL TRANSFORMER

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ITEM

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NO

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NEMA

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NO.

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QTY

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DESCRIPTION

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1

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-

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1

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DP SWITCH 25A

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2

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-

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2

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HRC FUSE

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3

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-

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1

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415/240V, 2KVA(MIN) WITH TAP+5%

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IN STEP OF +2.5% CONTROL TRANSFORMER

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4

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-

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1

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2P,MCB, 30A

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5

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-

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6

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-

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1

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7

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-

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INDICATING LAMPS

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EQUIPMENT DATA

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BUS A

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BUS B

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1

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2

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CT-A

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4

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5

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6

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240V, 1PH, AC

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CONTROL SUPPLY

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BUS-B

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BUS-A

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CONTROL SUPPLY

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240V, 1PH, AC

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4 POSITION CHANGEOVER SWITCH

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240V, 50HZ, CONTROL SUPPLY

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BUS BARS

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AS

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REQD

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1

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NOTES:

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1

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2

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3

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4

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6

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5

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4

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CT-B

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2

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( MIN )

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( MIN )

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1

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2. THE COMPONENT RATING ARE INDICATIVE ONLY AND SAME SHALL BE SELECTED

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AS PER CONTROL TRANSFORMER RATING.

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B224-000-16-50-DS-1026

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A

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7

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7

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SELECTOR SWITCH POSITION

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POSITION

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DESCRIPTION

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POSITION-1

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POSITION-2

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POSITION-3

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POSITION-4

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CONTROL SUPPLY FROM

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IND.CONTROL TRANSFORMER

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CONTROL SUPPLY FROM

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CONTROL TRANSFORMER-A

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OFF

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CONTROL TRANSFORMER-B

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CONTROL SUPPLY FROM

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5

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5

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3

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3

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REV

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SHEET 8

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ISSUED WITH TENDER

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AP

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RKR

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MKS

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A

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bZ vkbZ ,y

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13.08.19

Pag

e 10

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5

Page 3422 of 6022

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DATA SHEET

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REV

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NEW DELHI

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copied, exhibited or used except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1650-MVDCF Rev.0. A4-210x297.

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DATE

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PURPOSE

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BY

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CHKD

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APPRV

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PROJECT: RRP

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CLIENT: M/s HRRL

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2.

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THE COMPONENT RATING ARE INDICATIVE AND SAME SHALL BE SIZED BASED ON

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SCHEME FOR DC POWER SUPPLY

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ITEM

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NO

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NEMA

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NO.

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QTY

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DESCRIPTION

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1

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-

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1

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DP SWITCH 25A

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2

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-

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2

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HRC FUSE

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3

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80

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2

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4

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-

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5

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-

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6

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-

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1

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EQUIPMENT DATA

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1

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2

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5

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6

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BUS-B

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BUS-A

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CONTROL SUPPLY

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DC

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4 POSITION CHANGEOVER SWITCH

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DC CONTROL SUPPLY

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BUS BARS

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1

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NOTES:

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1

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2

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3

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4

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6

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( MIN )

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2

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1

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EXTERNAL DC FDR-A

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EXTERNAL DC FDR-B

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80

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80

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3

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3

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4

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4

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CONTROL SUPPLY

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DC

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DC SUPPLY FAILURE RELAY

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'ALSTOM' TYPE VAG-11 (30-60%)

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2 INDICATING LAMPS

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DC POWER REQUIREMENT OF THE SWITCHBOARD.

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B224-000-16-50-DS-1026

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A

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CONTROL SUPPLY FROM

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DC FEEDER -B

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DC FEEDER -A

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CONTROL SUPPLY FROM

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INDIVIDUAL FEEDER

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CONTROL SUPPLY FROM

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DESCRIPTION

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SELECTOR SWITCH POSITION

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POSITION-4

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POSITION-3

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OFF

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POSITION-1

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POSITION-2

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POSITION

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5

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5

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5

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REV

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ISSUED WITH TENDER

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AP

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RKR

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MKS

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A

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SHEET 9

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13.08.19

of 14785

Page 3423 of 6022

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DATA SHEET

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REV

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NEW DELHI

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copied, exhibited or used except in the limited way permitted by a written consent given by the lender to the borrower for the intended use. EIL-1650-Mv sfu_fdr.dwg Rev.0. A4-210x297.

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MCCB CONTACTOR FEEDER

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415V, 50Hz TPN BUS

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ITEM

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NO.

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NEMA

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NO.

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QTY.

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DESCRIPTION

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1

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1

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2

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1

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EQUIPMENT DATA

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2

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-

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-

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%%UNOTES:

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3

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0

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5

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3

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CONTACTOR

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WITH PHOTOCELL AND TIMER

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PHOTO CELL TO TAKE CARE OF WEATHER CONDITION

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4

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1

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P

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ELCB

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FOR THE OTHER REQUIREMENTS OF RELAYS AND METERS INCLUDING SEPARATE METERS

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, REFER JOB SPECIFICATION.

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2.

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(FOR OUTDOOR LIGHTING PANEL/

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4

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MCCB WITH OVERLOAD & SHORT CIRCUIT PROTECTION

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SCHEME INDICATED IS FOR CENTRALIZED CONTROL OF OUTDOOR LIGHTING FEEDERS I.E.

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3.

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SWITCHING "ON" AND "OFF" THROUGH MAIN CONTACTOR WHICH SHALL BE ACTIVATED BY

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A PHOTOCELL AND SYNCHRONOUS TIMER (IN AUTO MODE OF SELECTOR SWITCH).

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5

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6

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6

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ON & OFF PUSH BUTTON FOR CONTACTOR

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1 NO. COMMON PHOTOCELL AND TIMER SHALL BE PROVIDED FOR EACH LDB/ ELDB HAVING

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4.

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OUTDOOR LIGHTING FEEDERS. ALL CONTACTORS SHALL BE WIRED AND BROUGHT UPTO A

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LIGHTING DISTRIBUTION BOARD

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NOTE-6

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ELCB SHALL BE PROVIDED IN OUTGOING FEEDER TO LIGHTING PANELS ONLY. OUTGOING

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6.

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FEEDERS FEEDING POWER TO FLOOD LIGHT MAST SHALL NOT BE PROVIDED WITH ELCB.

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FLOOD LIGHT MAST)

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7

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-

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2

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AUTO-MANUAL SELECTOR SWITCH (3 POSITION)

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AUX. CONTACTOR FOR INTERLOCK

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8

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-

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AS

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REQD

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7

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COMMON TERMINAL BLOCK INSIDE EACH LDB/ ELDB WHERE THE PHOTOCELL SHALL BE

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CONNECTED.

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CLIENT: M/s HRRL

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B224-000-16-50-DS-1026

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SHEET 10

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COMMON SELECTOR SWITCH FOR SELECTION OF PHOTOCELL AND TIMER SHALL BE

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5.

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PROVIDED FOR ONE SWITCHBOARD

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T

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9

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SYNCHRONOUS TIMER

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9

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-

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STANDARD SPECIFICATION NO.

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This Inspection and Test Plan covers the minimum testing & inspection requirements of three phase medium voltage energy efficient squirrel cage induction motors.

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CHARACTERISTICS

Chemical, Physical Properties, Finish as per Relevant Standard

STAGE/ ACTIVITY

Procedures

Material Inspection

Raw Material: Body (casting or

fabrication), Rotor Shaft, Core

Laminations, Copper, Insulation Material,

Bearings, Cable Boxes, Cable Glands, etc.

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Vacuum Impregnation and Bracing of Winding, Core Assembly, Rotor Bars and End Rings Assembly, Rotor Balancing, Terminal Box

Mounting and Clearances in between, Bearing Setting, etc. as per Supplier's Internal Standards

•

Visual Check (Nameplate, Terminal Box Location, Terminal Type, Clearances, Size, Entries, Space Adequacy & Gland Size, Direction of Rotation etc.)

•

Dimensions Check (Including Shaft Height etc., Foundation Hole Dia and Distance, Shaft Dia.)

•

Cable Glands, Cable Lugs Size and No. of Entries in Terminal Box

•

Winding Resistance

•

No Load Test and Measurement of Voltage, Speed, Current, Power Input

•

Reduced Voltage Starting and Running

•

Insulation Resistance before & after High Voltage Test

•

High Voltage (Per Phase )

•

Vibration at No Load

•

Noise Level

STAGE/ ACTIVITY

In-process Inspection

Motor Assembly

Final Inspection

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Full Load Test and Measurement of Voltage, Current, Power, Slip, Power Factor, Bearing Noise.

• Efficiency and Pf at 100%, 75% and 50% Load

• Temp Rise Test •

Momentary Overload Test

•

Vibration

•

Over Speed

•

Measurement of Starting Torque, Starting Current, Full Load Torque, Pull Out Torque by JEC/IEC (By Logarithmic Proportion Current Method II

•

Visual

•

Suitable protection to prevent entry of foreign material.

•

Proper packing with suitable plugs to prevent Ingress of Moisture and any damage during Transportation and Storage.

•

Review of Internal Test Reports

•

Test Certificate from Recognized Testing Laboratory for Area Classification.

•

BIS Certificate for FLP Motors and Accessories as applicable.

STAGE/ ACTIVITY

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PESO approved Certificates for Motors and Accessories as applicable.

•

Degree of Protection of Terminal Box and Body

• IC Issuance

Compilation of Inspection Reports, Drawings, etc. as per VDR / PR

STAGE/ ACTIVITY

Final Document submission

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Page 3435 of 6022

MANDATORY SPARES LIST



Part A / Section A-4 Subsection A-4.4

B224-111-16-50-SL-7203 Rev. A

Page 1 of 5


MANDATORY SPARES LIST (ELECTRICAL)

EPCC-03 PACKAGE FOR PETROCHEMICAL

FLUIDIZED CATALYTIC CRACKING UNIT &

PROPYLENE RECOVERY UNIT

TENDER NO. B224-111-86-41-PM-T-7203

PROJECT : RAJASTHAN REFINERY PROJECT

UNIT : 111

OWNER : HPCL RAJASTHAN REFINERY LIMITED

PMC : ENGINEERS INDIA LIMITED

JOB NO. : B224

A 14/08/19 ISSUED FOR TENDER SM MKS MKS Rev. No

Date Purpose Prepared

by Checked

by Approved

by

Page 1285 of 14785

Page 3532 of 6022





B224-111-16-50-SL-7203 Rev. A

Page 2 of 5


LIST OF MANDATORY SPARES: ELECTRICAL

Mandatory spares shall be procured along with the main equipment. Such spares for each equipment shall be as per the below table. These spares include only those spares, which are critical for equipment.

S.No. Part Description Description 1 Generator (one set of spare for each

Generator)

1.1 Generator relay one set (each type & make) 1.2 DVR -all control card One each type 1.3 Exciter diodes and fuses 1 set 1.4 Control fuses/ MCB 10 nos. of each rating & type 1.5 Control & Selector switches 1 no of each type and make 1.6 Aux. Contactors 20% of each type and make or 1 no.

(min.) of each type and make, whichever is more

2 Power Transformer (one set of spare for

each power transformer) Quantity is per transformer

2.1 Complete set of Gaskets one set 2.2 Control fuses/ MCB for MB cubicles 20% for each rating or 1 no. (min.) of

each rating, whichever is more 2.3 Sealing/ Gauge glass of conservator 2 Nos of each rating & type. 3 66KV Gas Insulated Switchgear (GIS)

One set of spare for each switchboard (Refer note-8)

3.1 Portable gas filling equipment/SF6 gas Cart

1 No.

3.2 Handle for disconnector switch drive 4 Nos. 3.3 Handle for earthing switch drive 4 Nos. 3.4 Pre selection key for three position switch 1 No. 3.5 Power cable termination kit 2 Nos. 3.6 Tripping coil 1 No 3.7 Closing coil 1 No. 3.8 Capacitive type voltage detectors 1 set 3.9 Control fuses/ MCB 10 Nos. each rating and type 3.10 Density monitoring device 2 Nos. of each type 3.11 Indicating lamps 20% or 3 nos. (min.), whichever is more 3.12 Pressure Gauge 2 Nos. of each type 3.13 Indicating lamp covers 5 Nos. of each colour 4 6.6KV Switchgear (one set of spare for

each switchgear)

Quantity is as per switchboard

4.1 Closing coil 1 No. of each Rating & Type 4.2 Shunt trip coil 1 No. of each Rating & Type 4.3 Control fuses/ MCB 10 nos. of each rating & type 4.4 Indicating lamp covers 5 nos. of each colour 4.5 Indicating lamps 20% or 3 nos. (min.) whichever is more 4.6 Breaker finger jaws 1 set for each rating and type

Page 1286 of 14785

Page 3533 of 6022





B224-111-16-50-SL-7203 Rev. A

Page 3 of 5


S.No. Part Description Description 5 415 V PCC/PMCC/EPCC or MV

Switchboard (one set of spare for each Switchboard)

Quantity is per switchboard

5.1 Closing coil 1 No. of each Rating & Type 5.2 Shunt trip coil 1 No. of each Rating & Type 5.3 control fuses/ MCB 10 Nos. each rating & type 5.4 Indicating lamps covers 5 nos. of each colour 5.5 Indicating lamps 20% or 3 nos. (min.) whichever is more 5.6 Breaker finger jaws 1 set for each rating and type 5.7 Contactor contacts 1 set for each rating and type 6 Variable Frequency Drive (one set of

spare for each VFD)/ Soft Starter Quantity is per VFD/ Soft Starter

6.1 Transistors/IGBT/ IGCT One No of each rating & type 6.2 Control cards One No of each type 6.3 Power supply cards One No of each rating & type 6.4 Power fuses 20% for each rating or one no. (min.) of

each rating, whichever is more 6.5 Control fuses/ MCB 10 Nos. of each rating & type 6.6 Contactors 10% of each type or 1 no. (min.) of each

type, whichever is more 6.7 Indicating lamps 20% or 1 no. (min.), whichever is more 6.8 Indicating lamps covers 2 nos. of each colour 6.9 Blocker Diode 2 nos. of each rating and type 6.10 Water cooled exchanged (for water

cooler VFD) 1 no. for each model and type

6.11 Raisin Bed(for water cooler VFD) 1 no. for each model and type 6.12 Bellows(for water cooler VFD) 1 no. for each model and type 7 Substation Automation System/HMI (one

set of spare for each SAS/ HMI)

7.1 All cards such as input & output cards, power supply cards, processor cards etc.

One No of each type 7.2 Control fuse/ MCB 10 Nos of each rating & type 8.3 Ethernet switches 1 No of each type 8 UPS (one set of spare for each UPS

system)

8.1 Power transistors/IGBT/ IGCT/ transistors One No of each rating & type 8.2 Power supply cards One No of each rating & type 8.3 Control Cards One No of each type 8.4 Power Fuses 20% for each rating OR 1 no. (min.) of

each rating, whichever is more 8.5 Control Fuses/ MCB 10 nos. of each rating & type 8.6 Indicating Lamps 10% OR 3 nos. (min.) whichever is

more 8.7 Indicating Lamp covers 2 nos. of each colour 8.8 Blocker Diode 2 nos. of each rating and type 9 DC System(one set of spare for each DC

System)

9.1 Power Thyristors/ Transistors/ IGBT/ IGCT

1 no. of each rating & type 9.2 Control Cards 1 no. of each type 9.3 Power supply cards 1 no. of each rating & type 9.4 Power Fuses 20% of each rating OR 1 no. (min.) of

each rating, whichever is more 9.5 Control fuses/ MCB 10 nos. of each rating & type

Page 1287 of 14785

Page 3534 of 6022





B224-111-16-50-SL-7203 Rev. A

Page 4 of 5


S.No. Part Description Description 9.6 Indicating lamps 10% OR 3 nos. (min.) whichever is

more 9.7 Indicating lamps Covers 2 nos. of each colour 9.8 Blocker Diode 2 nos. of each rating & type 10 Synchronous motors (one set of spare for

each rating & type)

10.1 Power Fuses 20% of each rating OR 1 no. (min.) of each rating, whichever is more 10.2 Control Fuses/ MCB 10 nos. of each rating and type

10.3 Bearing ( DE & NDE ) (as applicable) one set 10.4 Control Cards 1 no. of each type 11 HV induction motors (one set of spare for

each rating & type)

11.1 Bearing ( DE & NDE ) one set 11.2 Terminal studs/bushing assembly one set each 12 MV induction motors 37 kW & above (one

set of spare for each rating & type)

12.1 Bearing set (DE & NDE) one set 12.2 Terminal studs/ bushing assembly one set each 13 Fire alarm system 13.1 All cards one no. of each type 13.2 Control Fuses/ MCB 10 nos. of each rating & type 13.3 Terminal blocks 20 nos 13.4 Fire detectors 1% of total installed capacity of each

type OR 1 no. (min.) of each type, whichever is more

13.5 Glass for Break Glass Boxes/ Manual call point

5% of each type OR 1 no. (min.) of each type, whichever is more 13.6 Power Fuses 20% of each rating OR 1 no. (min.) of each rating, whichever is more

14 Paging system / Plant Communication System

14.1 All cards one no of each type 14.2 Power fuses 20% of each rating OR 1 no. (min.) of

each rating, whichever is more 14.3 Control fuses/ MCB 10 nos. of each rating & type 15 Thyristor control panel for heaters 15.1 Rectifier control module(Control card fully

assembled) one no. of each type

15.2 Power supply card one no. of each type 15.3 Control Cards one no. of each type 15.4 Power Fuses 2 nos. min. of each rating & type 15.5 Control fuses/ MCB 10 nos. each rating & type 15.6 Contactor 10% of each type OR one no. (min.) of

each type, whichever is more 15.7 Indicating lamps 20% or 1 no. (min.), whichever is more 15.8 Indicating lamps Covers 2 no. of each colour 15.9 Blocker diode 2 no. of each rating & type 16 ECS 16.1 Interposing relays (As applicable) 5 Nos. of each type

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B224-111-16-50-SL-7203 Rev. A

Page 5 of 5


S.No. Part Description Description 16.2 Power supply & control cards 1 nos. of each type 16.3 Transducer 20% of the estimated quantity of each

type and make OR 1 no. (min.) of each type and make, whichever is more

16.4 Function generator cum counter 1 no. 16.5 4-20mA signal injection set 1 no. 16.6 Isolation transformer 1 no. 17 Numerical relays 1 no. of each type 18 Distribution Transformer (One set of

spare for each transformer)

18.1 Complete set of gaskets 1 set 18.2 Sealing/ gauge glass of conservator 2 no. of each rating & type 18.3 Control fuses. MCB for MB cubicles 20% for each rating or 1 no. (min.) of

each rating, whichever is more

Notes:-

1. Mandatory spares list is applicable only for the items supplied by the Contractor.

2. The word ‘TYPE’ means the Make, Model no., Type, Range, Size/ Length, Rating, Material as applicable.

3. Wherever % age is identified, Contractor shall supply next rounded figure. 4. The terminology used under ‘Part Description’ is the commonly used name of the part and

may vary from manufacturer to manufacturer. 5. Mandatory spares as indicated above do not cover commissioning spares. 6. Mandatory spares as indicated above do not cover two year O&M spares. 7. Mandatory spares shall be applicable for electrical items of motors / sub-packages as per

mandatory spares philosophy specified elsewhere in the bid document. 8. For Isolation breaker panel (GIS or AIS) one set of “Tripping Coil (1 No.of each rating), Closing

coil (1 No. of each rating) and Control fuse/MCB (10 Nos. of each rating and type) “shall be considered as mandatory spares for each Isolation breaker panel (GIS or AIS).

9. For Isolation breaker panel (GIS or AIS) one set of “Auxiliary relays (1 no. of each type)” shall be considered as mandatory spares for Relays for Isolation breaker panel (GIS or AIS).

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■31 eit§ e..41 fdialeg

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ENONEERS INDIA LIMITED IA Govt of India undenaxing)

SPECIFICATION FOR

CABLE INSTALLATION


6-51-0082 Rev. 5 Page 1 of 11

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SPECIFICATION FOR

CABLE INSTALLATION

5 26.02.18 REVISED AND ISSUED AS STANDARD

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3 25.04.08 REVISED AND ISSUED AS SPECIFICATION RKS SSM JMS

2 28.02.03 REVISED and ISSUED AS SPECIFICATION HKM RSG VPS

1 04.08.97 REVISED and ISSUED AS STANDARD SPECIFICATION

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Rev. No

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Copyright EIL — All rights reserved Format No. 8-00-0001-F1 Rev. 0

Page 13062 of 14785

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MADE BY CHKD.BY APPD. BY DATE DOC. NO. PAGE

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REV


PROJECT NO : PL1961

PRODUCT : EPCC 03 Package – Petrochemical Fluidized Catalytic Cracking Unit and Propylene Recovery Unit for Rajasthan Refinery Project (RRP) of M/s HRRL, BARMER, RAJASTHAN, INDIA

CUSTOMER

HPCL RAJASTHAN REFINERY LIMITED (HRRL)

CONSULTANT

ENGINEERS INDIA LIMITED (EIL)

OEM M/s. TBWES BABCOCK & WILCOX ENERGY SOLUTIONS PVT. LTD. PUNE

DWG/ DOC. TITLE MOV – ACTUATOR SPECIFICATIONS

DWG/DOC. NO. D8A-WH-CS-208454 REV. NO. 00

REVISION:



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SPECIFICATION FOR MOTORISED ACTUATORS

RECORD OF REVISION

SRNO DESCRIPTION OF REV. REV.

NO. DATE MADE BY

CHKD. BY

APPR BY.

01 INITIAL SUBMISSION 0 22.4.21 VPK PCR SJP



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Specification for Electrical Actuators Voltage: 415 VAC +/- 10%, 3 Phase Frequency: 50 Hz +/-3%

Electrical Design Temperature: 45 Deg C Ambient Temperature: Minimum = 3.4 Deg C & Maximum = 48.2 Deg C Type of Actuator: Integral MOV Signal Type: Non FF or FF Compatible(For all MOV’s – Shall be confirmed DDE) Area Classification: Hazardous Area Zone-2, Gas Group-IIA/IIB, Temp. Class. T3 Type of Position Transmitter: 4-20 mA Remote Position Transmitter Space Heater Voltage: 240 VAC Reference Document for Motorized Actuator: a) Data sheet MOV actuator – Doc no 6-51-0091 – R5 b) EMS1, Doc no: D86-WH-CS-208455 c) Spares list for electrical / MOVs d) ITP for Electrical Motor Operated Valve Actuators: ITP 6-81-1091 – R2 e) Gland entry shall be Metric type (Size will be confirmed during detailed Engg.). f) ITP to be as per EIL approved document.



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Standard Specification For Motorized Actuator with Integral Starter 1. This Motorized Actuator specification shall be applicable for VALVES / DAMPERS as

applicable. 2. Motorized Actuator equipment’s and components shall be suitable for the duty specified valve

schedule / specification. (ON/OFF (OR) INCHING (OR) REGULATING) 3. Motorized Actuator equipment’s and components shall conform to relevant IS / DIN standards. 4. Motor : a) Make : Approved Vendor b) Rating : As required c) Voltage : 3 phase, 3 wire. Refer covering note for specific Voltage d) Frequency : Refer covering note e) Enclosure : Ex-de, IP65 or better f) Design Ambient : 45˚C g) Class of insulation : F with temperature rise limited to B h) System Fault level : 50 kA for 1 Sec i) Relative Humidity : 100 % Applicable terminal plan (wiring diagram no.) to be mentioned in the offer for approval and records. 5. Actuator: Actuator shall consist of following:

a) Travel limit switch 1 No. each in both open and close condition with 2 NO & 2 NC independent contacts.

b) Torque limit switches 1 No. each in both open and close conditions with 2 NO & 2 NC independent contacts.

c) Auxiliary limit switches 1 No. each in both open and close direction 2 NO & 2 NC independent contacts.

d) All the contacts of limit switches, Torque limit switches shall be wired up to the terminal box as potential free contacts.



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e) The Enclosure of complete MOV actuator including Motor, integral starter, control Transformer unit and all control devices shall have minimum IP-65 degree of ingress.

f) All switches shall be double break snap action type and rated for 240 VAC, 5 Amp. g) Setting of limit torque switches should be possible easily. Trip values of Torque should

be readable on a scale of the torque switch mechanism.

6. A Hand-wheel with hand / auto lockable lever shall be provided for emergency operation of the MOV. The energization of the motor shall automatically re-engage power operation.

7. Motor shall be provided with thermostat(s)/ thermistor(s) embedded in hot spot of motor

windings. Motors for MOV actuator shall have F class of insulation with temperature rise limited to class-B

8. The Motor shall be suitable for starting under required torque with 75% of rated voltage

at motor terminals. 9. Actuator shall be capable of 60 Starts per hour for On-Off operation, 150 starts per

hour for inching operation & 1200 starts per hour for modulating operation unless otherwise mentioned.

10. Actuator shall be with in-built starter. As a bare minimum, following components, features/ protections shall be available in the actuator

11. The integral starter shall be supplied with the following devices:

a. Electrically and mechanically interlocked reversing contactors for opening and

closing operations. b. Control transformer with necessary tappings and protected with suitable easily

Replaceable fuses. c. Terminal block for external cable connection fully prewired for internal devices

of Valve actuator.

d. MOV Actuators operating with AC power supply shall be provided with Instantaneous Phase reversal protection.

e. OPEN, STOP & CLOSE push buttons f. Local – Off – Remote selector switch with Pad lockable in each Position. g. Control transformer.

12. Control Facilities:

Common status contact indicating the availability of the MOV actuator for remote Control shall be provided by monitoring the following: -

a. Loss of one or more phases of power supply



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b. Loss of control circuit supply c. Selector switch in local mode d. Local stop push button set to ‘Off’ e. Motor thermostat tripped f. Any other local fault/ abnormal condition. g. Overload relay protection for motor. h. Actuator healthy monitor relay.

13. Potential free contacts for indication shall be available Provided in actuator assembly

for hardwire interface with PLC/DCS and or Remote Push Button:

From Boiler PLC/ DCS (DO Signal):

Local / remote Selection from DCS Open command Close command

For these commands, necessary voltage shall be derived from MOV. No external potential required

To Boiler PLC/DCS (DI Signal): Run Indication Ready to start Thermostat Status Valve closing Valve opening, Valve opened, Valve closed, Open torque switch operated Closed torque switch operated Local/ remote Selected Monitor relay for collective fault signal / Trip

Potential free contacts made available for interface with other system (DI to other system)

14. All types of actuators shall have digital position indicator, with display of valve position. 15. All devices required for safe operation and control of actuator shall be integral part of

the actuator.

16. Electrical actuator shall be filled with high quality grease (not oil filled) to facilitate mounting at any angle / position.

17. Motorized actuators for Inching duty shall have contact type position transmitter for

remote position indication through 4 -20mA. The indication accuracy should be within



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0.5% service duty. These shall be of two wire type working on 24 V DC from customer. The position transmitter shall not be of bare PCB type.

18. Actuator shall be of S2 - 15 Minute rating for inching and ON-OFF duty and S4-25% for

regulating duty and shall confirm to IEC-60034 or equivalent International Standard.

19. Actuator shall be provided with minimum five adequately sized cable entries viz., one for power cable and four for control Cable. Suitable double compression Glands shall be provided for all cable entries and sealing plugs for all control cables. M20 X 1.5 – 1 no. for Power M20 X 1.5 – 1 no. for Position transmitter (wherever applicable) or as a spare M25 X 1.5 – 1 no. for Open close commands (whichever as applicable) M32 X 1.5 – 1 no. for Control cable M25 X 1.5 – 1 no. SPARE with End Plug.

Cable gland and Plugs shall be made of Nickel – Plated Brass (Flame Proof type)

with O-ring, Minimum 10% spare terminals shall be provided for future interlocks.

20. Actuator terminal connection shall be plug in type. .

21. The wiring & terminal blocks used for the wiring of the transducer shall be of different

color to discriminate the Power / Control / Signal wiring.

22. Actuator painting shall be RAL-7035 / 632 of IS: 5 ( Shall be confirmed during detailed engineering )

23. NAME PLATE

Each MOV actuator shall be provided with a stainless-steel name plate attached firmly to it at a place convenient for reading, furnishing the following details. a. Actuators tag number. b. Motor kW, motor time rating, motor supply voltage, nominal motor phase current,

Aux switch rating. c. Maximum Torque setting. d. Actuator enclosure type, lubrication type e. Actuator type, Wiring Diagram No/Catalogue number, Actuator serial Number. f. Duty Type. g. Type / Catalogue Number. h. A Separate Name plate shall be provided on each actuator to indicate details

of testing agency, test certificate number with date, statutory approval number with date, approval agency, applicable Gas Group and Temperature Class.

24. Standards and Tests

Standards for Motor and Actuators as Mentioned in IS: 9334-1986.and IS-325. Operational Test as Mentioned in IS: 9334-1986.



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Earth Continuity Test with Low Voltage Tester (6Volts) All Routine Test as per IS standards of AC motors.

25. Supplier to furnish following information:

a) General Arrangement drawing showing mounting & necessary dimensional details b) Wiring Diagram for various electrical connections c) Inspection & Test procedure d) Motor data sheets e) Terminal arrangement and connection diagram f) Assembly & Sectional drawings g) Construction spare parts list h) Exploded view of actuator i) Special tool list j) Lubricant list & period of change k) Inspection & test reports l) Installation, Operation and Maintenance manual including trouble shooting

guidelines. m) Vendor to furnish valid CMRI/CCOE certificate.

26. SPARES: (Price to submitted separately)

a) Mandatory spares – As per the following : S.No Item Spares 1 Position transmitter 10% ( 1 No. Min) 2 Power Supply unit 10% ( 1 No. Min) 3 Logic Board 10% ( 1 No. Min) 4 Local Control Board Assembly 10% ( 1 No. Min) 5 Switchgear Assembly 10% ( 1 No. Min)

NOTE:

1. Vendor to submit the offer with EIL and vendor data sheet completely filled. 2. In offer vendor to highlight deviation separately. Clarifications are not considered

as deviations. 3. Vender to comply TBWES & Customer specification without any deviation (

Attached along with ) 4. No deviations against EIL specs are acceptable. Any generic deviations

mentioned in the form of notes/comments will not be reviewed. 5. Factory setting of open and close switch to be done 100% and 0% off valve open

conditions respectively. 6. Manufacturer to submit actuator data sheet at individual as per the tag No. 7. For any ambiguity in specification customer specification will be governing. 8. In case of intrusive type actuator, anti-condensation heater shall be provided

irrespective of IP-65 enclosure. However, in case of non-intrusive type actuator, space heater is not required.

SPECIFICATION FOR STANDARD SPECIFICATION NO. ENGINEERS ELECTRICAL MOTOR OPERATED INDIA LIMITED 6-51-0091 Rev. 5 (A Govt of Incha Undettang) VALVE ACTUATORS Page 1 of 10

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SPECIFICATION FOR

ELECTRICAL MOTOR OPERATED VALVE ACTUATORS

5 30-03-19

4 25-03-14

3 27-08-07

2 16-09-02

1 03-04-97

REVISED AND ISSUED SPECIFICATION REVISED AND ISSUED SPECIFICATION REVISED AND ISSUED SPECIFICATION REVISED AND ISSUED SPECIFICATION REVISED AND ISSUED SPECIFICATION

AS STANDARD

AS STANDARD

AS STANDARD

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AS STANDARD

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Prepared by

Checked by

Standards Standards Committee Bureau Convenor Chairman

Approved by


Page 13102 of 14785

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ENGINEERS SPECIFICATION FOR INDIA LIMITED ELECTRICAL MOTOR OPERATED

VALVE ACTUATORS Ogeir fai5leg

laaVIMeetedn.FKM


6-51-0091 Rev. 5 Page 2 of 10

(A GoN of Incka Undertaking)

Abbreviations:

CEA CIMFR DGMS FM IEC LCIE MOV PESO PVC UL

Central Electricity Authority Central Institute of Mines & Fuel Research Director General of Mines & Safety Factory Mutual Research Corporation International Electro technical Commission Laboratoire Central des Industries Electriques Motor operated valve Petroleum and Explosives Safety Organisation Poly Vinyl Chloride Underwriters Laboratory


Convener: Members:

Mr. B.R. Bhogal Ms. S. Anand

Mr. Parag Gupta

Mr. M. K. Sahu

Ms. N S Bhattacharya Mr. Saeed Akhtar (Inspection) Ms. N.P. Guha (Projects)



Page 13103 of 14785

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ENGINEERS SPECIFICATION FOR INDIA LIMITED ELECTRICAL MOTOR OPERATED IA Govt Nmdta Undertak.9) VALVE ACTUATORS


it5leg (NWT 2922111P =JANA)

6-51-0091 Rev. 5 Page 3 of 10

CONTENTS

1.0 SCOPE 4

2.0 CODES AND STANDARDS 4


4.0 SITE CONDITIONS 4

5.0 POWER SUPPLY 5

6.0 TECHNICAL SPECIFICATIONS 5

7.0 EQUIPMENT FOR CLASSIFIED HAZARDOUS AREAS 8

8.0 FIREPROOFING 9

9.0 INSPECTION, TESTING AND ACCEPTANCE 9




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ENGINEERS SPECIFICATION FOR INDIA LIMITED ELECTRICAL MOTOR OPERATED (A Govl of InOla Undeltalfong) VALVE ACTUATORS


lfgari815ieg (4.312ri ei20,42 ,01.1.R.1)

6-51-0091 Rev. 5 Page 4 of 10

1.0 SCOPE

The scope of this specification covers design, manufacture, assembly, shop testing and supply of electrical motor operated valve actuators intended for fully/ partially opening and closing valve duty with inching facility.


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

IS 5

IS 12615

IS/IEC 60034-1

IS/IEC 60529

IS/IEC 60079

Colours for ready mixed paints and enamels

`Line Operated Three Phase a.c. Motors (IE CODE)- Efficiency Classes and Performance Specification

Rotating electrical machines- Rating & Performance

Degrees of protection provided by enclosure for rotating electrical Machinery

Electrical apparatus for explosive gas atmospheres

EN 15714-2/IS 9334 Electric Motor Operated Actuators for Industrial valves

IS/IEC 60947 Low Voltage Switchgear and Controlgear (Parts-1, 3, 4 & 5)

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

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

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

2.5 In case of any contradiction between various referred standards/ specifications/ data sheets and statutory regulations, the most stringent requirement shall govern and decision of Owner in this regard shall be final and binding.


3.1 The offered equipment shall be brand new with state of the art technology having a proven field track record. No prototype equipment shall be offered.

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

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

3.4 The vendor shall be responsible for design, engineering and manufacturing of the complete actuator to fully meet the intent and requirements of this specification and attached data sheets.

4.0 SITE CONDITIONS

The electrical motor operated valve actuators shall be suitable for operating under site conditions as specified in the requisition and data sheet. If not specifically mentioned therein,


Page 13105 of 14785

Page 3809 of 6022

011 Ogg

(1WM 29R131F 4151.1,10.1)

ENGINEERS INDIA LIMITED (A Govt d indo Undertaking)

SPECIFICATION FOR ELECTRICAL MOTOR OPERATED

VALVE ACTUATORS


6-51-0091 Rev. 5 Page 5 of 10

a design ambient temperature of 40°C and an altitude not exceeding 1000m above mean sea level shall be considered.

5.0 POWER SUPPLY

The electrical motor operated valve actuators shall be suitable for power supply at 415V ± 10%, 50 Hz ± 3%, 3 phase, unless specified otherwise in the data sheet.

6.0 TECHNICAL SPECIFICATIONS

Each MOV actuator shall include the motor, actuator unit, gears, position indicators, limit switches, handwheel, electrical starter and controls, terminal box etc. as a self-contained unit. The actuator shall be sized to provide adequate torque and/ or thrust to ensure the complete intended travel of the valve under the worst operating and electrical power supply conditions.

6.1 Motor

6.1.1 The motor shall be 3-phase squirrel cage induction type unless specified otherwise in the data sheet. It shall have totally enclosed non-ventilated and surface cooled construction.

6.1.2 The motor shall be designed for valve actuator service with high starting torque and shall be suitable for Direct on line starting. It shall be rated for S2-15 minute duty and shall conform to IS 60034-1 or equivalent international standards.

6.1.3 The actuator assembly shall be provided with Thermostat(s)/thermistor(s) embedded in it to achieve protection of motor against over-temperature.

6.1.4 The motor shall be suitable for starting under required torque with 75% of rated voltage at motor terminals.

6.1.5 The motor shall have class 'F' insulation with temperature rise limited to class 'B' limits. Motor winding shall be treated to resist corrosive agents and moisture.

6.1.6 Motor rotor shall preferably be of die-cast aluminium and, if brazed, shall be free from phosphorous.

6.1.7 Motor installed in actuator shall be rated for minimum of 60 starts/stop per hour. This is minimum requirement of actuator envisaged for ON-OFF duty only.

6.1.8 Anti-condensation heater shall be provided for all the MOV actuators. Power supply for the Anti-condensation heater shall be derived by vendor from incoming supply mentioned at cl. No. 5.0.

6.2 Integral Starter and Control Transformer

The reversing starter, control transformer and local controls shall be integral with the valve actuator, unless specified otherwise in the data sheet. Solid state control of valve actuator and electrically isolated interface for remote control requirement shall be provided, wherever these features exist in manufacturer's design.

The integral starter shall be supplied with the following devices:

a) Electrically and mechanically interlocked reversing contactors for opening and closing operations

b) Control transformer with necessary tapping and protected with suitable easily replaceable fuses


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,31ta ENGINEERS SPECIFICATION FOR ELECTRICAL MOTOR OPERATED

VALVE ACTUATORS


6-51-0091 Rev. 5 Page 6 of 10

Ogur 251eg 1.2A eiieWAAJATAA)

INDIA LIMITED IA Govt of Abu UndertakM

c) Terminal block for external cable connection fully prewired for internal devices of valve actuator.

d) MOV Actuators operating with AC power supply shall be provided with automatic phase correction feature.

6.3 Integral Push Button, Selector switches, Indications and Control devices

The following local control devices shall be provided integral with the MOV actuator:

a) Push buttons for 'Opening/ Closing/ Stop' or alternatively 'Open/ Close' selector switch

b) 'Local/ Off/ Remote' selector switch, pad-lockable in each position c) Local continuous position indication from 'Valve fully open' to 'Valve fully closed'

position, which may be of analogue or digital type using mechanical indication/ Indicating lamps/ LEDs.

6.4 Torque and Travel Limit Switches

Torque limit switches shall be provided to protect the motor from over-loading by cutting-off the power supply to motor during opening and closing operations. The limit switches shall be preset. However, it shall be possible to set the value of maximum torque during closing from 50% to 100% of rated torque of actuators. Travel limit switch shall be provided to cut-off the power supply to the motor at the end of preset limit of valve travel. The switches shall be provided with requisite number of potential-free contacts for valve actuator operation and for indication on remote panels as specified in data sheet. Instead of mechanical torque limit switches, magnetic pulse counter/encoders to measure and control the stroke of actuator may be provided, wherever this feature exists in manufacturer's design.

6.5 Control Facilities

The internal controls and monitoring circuits shall be incorporated within the integral starter along with transformer and control unit of valve actuator.

Remote control facility shall be provided as a standard feature. The remote control circuits shall be powered from internally derived control supply voltage. Common status contact indicating the availability of the MOV actuator for remote control shall be provided by monitoring the following:

Loss of one or more phases of power supply Loss of control circuit supply Selector switch in local mode Local stop push button set to 'Off Motor thermostat tripped Any other local fault/ abnormal condition.

Where applicable, one number hand-held infrared/blue tooth remote programming device required for site commissioning and reconfiguring (without the need of removal of the MOV cover) shall be supplied for each group of 10 valve actuators (subject to minimum one infrared/ Bluetooth remote setting device, even if number of valve actuators are less than ten).

6.6 Interface with Owner's PLC/DCS / REMOTE PUSH BUTTON STATION

Potential free contacts for the following shall be provided in actuator assembly for hardwire interface with Owner's DCS/PLC and/or Remote Push Button station:-

a) Run indication



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ENGINEERS SPECIFICATION FOR *12 ezr INDIA LIMITED ELECTRICAL MOTOR OPERATED

(A Govt Inda Um/A/taking) VALVE ACTUATORS


6-51-0091 Rev. 5 Page 7 of 10

0.11F71 2120312 ‘61 .FP:Fil

b) Trip indication — 2 Nos. c) Open status — 2 Nos. d) Close status — 2 Nos. e) Ready to start indication f) Torque high indication g) Thermostat status h) Open command — 2 Nos. i) Close command — 2 Nos. j) Local/Remote

In the event of voltage dips/ power outage, status of MOVs (OPEN/ CLOSE indication) for remote annunciation shall not undergo any change. The wiring for all MOVs feedback controls shall be fail safe type. Any backup for power supply & hardware required for achieving the same shall be provided by vendor within the actuator. Owner shall not provide any power supply other than 415V±10%, three phase, 50Hz±3% incoming supply to each of MOV Actuator".

6.7 Hand Operation

A hand wheel with hand/ auto lockable lever shall be provided for emergency operation of the MOV. The energisation of the motor shall automatically re-engage power operation.

6.8 Two-Wire Control system

Where specified in the data sheet, the MOV actuators shall be suitable for 2-wire control system working on protocol as specified in the MR. These actuators shall have individual field units connectable to a master station through a single 2-core cable on line topology for control and monitoring of the MOVs. The vendor shall indicate the maximum number of field units that can be connected to a master station / PLC /DCS and the maximum distance from the field unit to the master station /PLC /DCS. The vendor shall also indicate maximum number of control inputs and control/ status outputs from each field unit that can be handled through the 2-wire control system.

Each field unit/ MOV actuator shall be addressable from the master station through a unique address code. All the field settable/ adjustable parameters of the MOV actuator shall be settable from the master station. Similarly all the indications available on the MOV actuator shall be available at the master station. Full diagnostic features for the MOV actuators shall be available on the actuator as well as on the Master station through a LCD / screen display.

Suitable redundancy feature shall be provided, such that in case of a single fault at any location in the cable, the field unit continues to communicate with the master station. The master station shall be suitable for hook-up with the plant DCS system.

6.9 Digital Control System

If specified in data sheet, electric actuator shall be provided with an integrally mounted device providing digital connectivity with Owner's PLC/DCS for actuator control, status indication & monitoring. In this case, master station is not required any more. The control device shall meet the appropriate recognized protocol or BUS standards. Selection of protocol shall be as per data sheet only. Typical protocol/buses include:-

- Modbus RTU - Profibus DP - Device Net - Foundation FieldBus



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(= ENGINEERS INDIA LIMI I ED


VALVE ACTUATORS


6-51-0091 Rev. 5 Page 8 of 10

,/lfZk_JeY Of5ieg

(awinT ?Vase all,Artano (A &AA a Incka Undertaking)

Terminal for hardwired communication shall also be provided in addition to digital communication facility.

6.10 Remote Position Indicator

If requirement of remote position indication is specified in the data sheet, a 4-20 mA remote position transmitter shall be provided in the valve actuator which can be connected to user's PLC / DCS. The remote position indicator shall continuously indicate the position of travel of the valve.

6.11 Nameplate

Each motorized valve actuator shall be provided with a stainless steel nameplate furnishing the following details, at a place convenient for reading: The nameplates shall be riveted/ fixed with screws and not pasted.

a) Actuator tag number as per data sheet b) Motor kW rating, motor short time rating, motor supply voltage, nominal motor phase

current, auxiliary switch rating c) Maximum torque setting d) Actuator enclosure type, lubricant type e) Actuator type, wiring diagram number/ catalogue number, actuator serial number. f) Wherever applicable, Hazardous area certification details which shall include details

of the testing agency (CIMFR or equivalent), test certificate number with date, statutory approval number with date, approval agency (PESO / DGMS), BIS license number with date, applicable Gas group and Temperature class etc.

6.12 The enclosure of complete MOV actuator including motor, integral starter, control transformer unit and all control devices shall have minimum IP-67 degree of protection which shall include the '0' ring for complete environmental protection.

6.13 Wiring and Terminals

All devices provided in the actuator shall be wired up to the terminal block. The contacts for remote operation and indication shall also be wired up to the terminal block. Minimum 10% spare terminals shall be provided for future interlocks. Internal wiring for power and control circuits shall be appropriately sized for MOV actuator rating. Each wire shall be identified at both ends using PVC ferrules. The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal so that the actuator electrical components are protected from the ingress of moisture and foreign materials when the terminal cover is removed during installation and maintenance.

6.14 The actuator shall be provided with minimum five adequately sized cable entries viz., one for power cable and two for control cables. However, the actual number of control cable entries in actuators with 2-wire control system shall be provided based on job requirements as specified in data sheets/specification for control systems for MOVs. Suitable double compression cable glands shall be provided with each actuator for all cable entries and sealing plugs for all control cable entries. The cable glands and plugs shall be made of Nickel-plated brass. Plastic plugs shall not be acceptable. Cable sizes shall be informed during detailed engg and actuator shall be provided with suitable arrangement for termination these sizes.

7.0 EQUIPMENT FOR CLASSIFIED HAZARDOUS AREAS

7.1 Actuators meant for hazardous areas shall meet the requirements of IS/IEC 60079 or equivalent international standards and shall be suitable for Gas groups and Temperature class as specified in the data sheet. Gas group IIB and Temperature class T3 (200°C) shall be



Page 13109 of 14785

Page 3813 of 6022

ENGINEERS SPECIFICATION FOR

INDIA LIMITED ELECTRICAL MOTOR OPERATED IA Govt of Mu Undertaking, VALVE ACTUATORS


6-51-0091 Rev. 5 Page 9 of 10

/gal f&ti5teg 1.1e1 e922612 03,3,71:643)

considered if not indicated in data sheet. The manufacturer shall possess valid test certificates issued by a recognized independent test house (CIMFR/ Baseefa/ LCIE/ UL/ FM or equivalent) for the offered actuators. All indigenous equipment shall conform to Indian standards and shall have been tested and certified by Indian testing agencies. All equipment (indigenous and imported) shall also have valid statutory approvals as applicable for the specified hazardous locations from Petroleum and Explosives Safety Organisation (PESO / DGMS) or any other applicable statutory authority. All indigenous flameproof equipment shall have valid BIS license and corresponding marking as required by statutory authorities.

8.0 FIREPROOFING

8.1 Electric actuators shall be provided with fire proofing if specified in data sheet. The fire proofing shall be rated for 30 minutes. Unless otherwise specified in the datasheet, fire proofing shall be provided by Intumescent paint only (K- Mass/ERS/equivalent). The required certificates for the fireproof rating shall be furnished from an independent test laboratory.

8.2 MOV Actuators with fireproofing shall be suitable for termination of mica insulated fire survival type power and control cables.

9.0 INSPECTION, TESTING AND ACCEPTANCE

9.1 The equipment shall be subject to inspection by EIL/ Owner or by an agency authorized by the owner. Manufacturer shall furnish all necessary information concerning the supply to EIL/ Owner's inspector. During the course of manufacturing, the purchaser or his authorized representative shall be free to visit the works and assess the progress of work and the manufacturer shall render him all possible assistance to do so.

9.2 Following routine tests shall be carried out at the manufacturers' works under his supervision and at his own cost for all the actuators:-

9.2.1 Functional and calibration test for torque and limit switches

9.2.2 Response time test

9.2.3 Variation of supply voltage

9.2.4 Variation of frequency

9.2.5 Test on output shaft at 100% torque

9.2.6 Tests for motor(As per relevant IS/IEC)

9.3 Following type test certificates of offered model of actuator shall be submitted for review & approval:-

9.3.1 Life test

9.3.2 Test on motor terminal box

9.3.3 Damp heat recycling test

Two weeks' notice shall be given to Owner / EIL for witnessing the final testing of the complete assembly to ensure satisfactory operation of the MOV actuators. Type test certificates shall be furnished during detailed engineering. Final acceptance of MOVs at site shall be subject to successful testing of the MOV actuators with the valves.



Page 13110 of 14785

Page 3814 of 6022

ENGINEERS SPECIFICATION FOR INDIA LIMITED ELECTRICAL MOTOR OPERATED (A Govt 04 !Wu Unclettaktngi VALVE ACTUATORS


fge.st es eTPERZ c131.14040

i=j 6-51-0091 Rev. 5 Page 10 of 10

9.4 Type test certificates, original drawings referred in certificates and statutory approval certificates and BIS license, where applicable, shall be shown to the inspection agency on demand. The certificates and BIS license must be valid at the time of dispatch.

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


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

The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed. In order to prevent movement of equipment/ components within the crates, proper packing supports shall be provided. A set of instruction manuals for erection, testing and commissioning, a set of operation and maintenance manuals and a set of final drawings shall be enclosed in a waterproof cover and supplied along with the shipment.


Page 13111 of 14785

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SPECIFICATION

FOR SURFACE PREPARATION

AND PROTECTIVE COATING

HRRL

Specification No. B224-000-79-41-PLS-01

Rev. 5 PAGE 1 OF 47

5 10-05-2019 ISSUED AS A JOB SPECIFICATION SM SS SG






Rev. No

Date Purpose Prepared by Checked by Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

JOB SPECIFICATION

FOR

SURFACE PREPARATION


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SPECIFICATION



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Rev. 5 PAGE 2 OF 47


Abbreviations: AS : Alloy Steel ASTM : American Society for Testing and Materials AWWA : American Water Works Association CS : Carbon Steel DFT : Dry Film Thickness GI : Galvanized Iron ID : Internal Diameter ISO : International Organization for Standardization LTCS : Low temperature Carbon Steel MS : Mild Steel MR : material requisition NB : Nominal Bore NA : Not applicable OD : Outside Diameter OSHA : Occupational Safety and Health Act RCC : Reinforced Cement Concrete RH : Relative humidity SS : Stainless Steel SOR : Schedule of Rate SSPC : Steel Structure Painting Council WFT : Wet Film Thickness

Page 7745 of 14785

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Rev. 5 PAGE 3 OF 47


Sl. No.

CONTENT

PAGE NO.

1.0 General 4

2.0 Scope 4

3.0 Reference codes & standards 5

4.0 Equipment 6

5.0 Surface preparation, shop primer, coating application, repair and documentation

7

6.0 Paint materials 15

7.0 Coating systems 22

8.0 Storage 36

9.0 Colour code 36

10.0 Identification of vessels, piping 42

11.0 Painting for civil defense requirements 42

12.0 Quality control, inspection and testing 43

13.0 Guarantee 45

14.0 Qualification criteria of painting CONTRACTOR/sub CONTRACTOR

45

15.0 Qualification/acceptance criteria of paint coating system 45

16.0 Method of sampling & dispatch for laboratory testing 48

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1.0 GENERAL 1.1 This technical specification shall be applicable for the work covered by the contract

and without prejudice to the provisions of various international codes of practice, standard specifications etc. It is understood that the CONTRACTOR shall carry out the work in all respects with the best quality of materials and workmanship and in accordance with the best engineering practice and instructions of Engineer-In-Charge.

1.2 Wherever it is stated in the specification that a specific material is to be supplied or

a specific work is to be done, it shall be deemed that the same shall be supplied or carried out by the CONTRACTOR.

Any deviation from this standard without written deviation permit from appropriate authority will result in rejection of the job.

1.3 This specification covers the requirement for protective coating for new

construction. 2.0 SCOPE 2.1 Scope of work covered in the specification shall include, without being limited to,

the following: This specification defines the requirements for surface preparation, selection and

application of primers and paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures, external & internal protection of storage tanks for all services and chimneys, if any. The items listed in the heading of tables of paint systems are indicative only. However, the CONTRACTOR is fully responsible for carrying out all the necessary painting, coating and lining job on external and internal surfaces as per the tender requirement.

2.2 Extent of work 2.2.1 The following surfaces and materials shall require shop, pre-erection and field

painting:

- All un-insulated carbon steel & alloy steel equipment like vessels, columns, storage tanks, exchangers, parts of boilers etc.

- All un-insulated carbon steel and low alloy plant and related piping, fittings and

valves (including painting of identification marks), furnace ducts and stacks.

- All insulated parts of vessels, boilers, chimneys, stacks, piping and steam piping and other insulated items present, if any.

- All items contained in a package unit.

- All structural steel work, pipes, structural steel supports, walkways, handrails,

ladders, platforms etc.

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- Flare lines, external surfaces of MS chimney with or without refractory lining and internal surfaces of MS chimney without refractory lining.

- Identification of colour bands on all piping, as required, including insulated

aluminium clad, galvanized, SS and nonferrous piping.

- Identification lettering/ numbering on all painted surfaces of equipment/piping insulated aluminium clad, galvanized, SS and non-ferrous piping.

- Marking / identification signs on painted surfaces of equipment and piping

including hazardous service.

- Supply of all primers, paints and all other materials required for painting (other than OWNER supplied materials)

- Application of pre-erection/fabrication and shop primer.

- Repair work of damaged pre-erection/ fabrication and shop primer and weld

joints in the field/site before and after erection.

- All CS piping, equipment, storage tanks and internal surfaces of RCC tanks in ETP plant.

- Quality control, testing and inspection during all stages of work (surface

preparation, application of coating and testing of furnished coating). 2.2.2 The following surfaces and materials shall not require painting in general. However,

if there is any specific requirement by the OWNER, the same shall be painted as per the relevant specifications:

a. Un-insulated austenitic stainless steel. b. Plastic and/or plastic coated materials. c. Non-ferrous materials like aluminum, Cu-Ni alloys, galvanized steel. In general Galvanized steel doesn’t require painting. However if painting is required due to OWNERs instructions, contractual or for colour coding requirement then coating system in Table 4.0 shall be followed.

2.3 Unless otherwise instructed, final paint coating (i.e. application of field primer,

intermediate and top coats) on pre-erection/ shop primed equipment shall be applied at site, only after all welding, testing on systems are completed as well as after completion of steam purging.

3.0 REFERENCE CODES & STANDARDS 3.1 Without prejudice to the provision of clause 1.1 above and the detailed

specifications of the contract, latest editions of the following codes and standards are applicable for the work covered by this contract:

ISO-12944 : Corrosion protection of steel structures by protective paint system.

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ASTM-Vol. 6.01&6.03 : American standard test methods for paints and coatings.

IS-101 : Methods of sampling and test for paints, varnishes and related products.

IS-5 : Colours for ready mixed paints and enamels. RAL DUTCH : International standard for colour shade (Dutch standard).

IS-2379 : Indian standard for pipe line identification-colour code

3.2 Surface preparation standards The latest editions of any of the following standards shall be followed for surface

preparation: 3.2.1 ISO 8501-1 / SIS-05 59 00: ISO standard for preparation of steel substrates before

application of paints and related products. This standard contains photographs of the various standards on four different degrees of rusted steel and as such is preferable for inspection purpose by the Engineer-In-Charge.

3.2.2 Steel Structures Painting Council, U.S.A. (surface preparation specifications

SSPC-SP). 3.2.3 National Association of Corrosion Engineers (NACE), U.S.A. 3.2.4 Various international standards equivalent to Swedish standard for surface

preparations are given in Table-1. 3.3 The CONTRACTOR shall arrange, at his own cost, to keep a set of latest edition of

above mentioned standards and codes at site. 3.4 The paint manufacturers’ instructions shall be followed as far as practicable at all

times for the best results. Particular attention shall be paid to the following:

a. Instructions for storage to avoid exposure as well as extremes of temperature. b. Surface preparation prior to painting shall be followed as per Table-4 to 13 of

this standard. c. Mixing and thinning.

d. Application, recommended limit on time intervals in between coats & DFT.

4.0 EQUIPMENT 4.1 All tools, brushes, rollers, spray guns, blast material, hand power tools for cleaning,

all equipment, scaffolding materials, shot & grit blasting equipment , air compressors etc. required shall be suitable for the work and shall be arranged by the CONTRACTOR in sufficient quantity at the site. The manufacturers test certificates / data sheets for all the above mentioned items shall be reviewed by Engineer-In-Charge at site before start of the work.

4.2 Mechanical mixer shall be used for paint mixing operations in case of two pack

systems except in case of specific requirement; the Engineer-In-Charge may allow the hand mixing of small quantities at his discretion for touch up work only.

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5.0 SURFACE PREPARATION, SHOP PRIMER / COATING APPLICATION, REPAIR AND DOCUMENTATION

5.1 General 5.1.1 Adhesion of the paint film to the surface depends largely on the degree of

cleanliness of the metal surface. Proper surface preparation contributes more to the success of the paint protective system. In order to achieve the maximum durability, one or more of the following methods of surface preparation shall be followed, depending on condition of surface to be painted and as instructed by the Engineer-In-Charge.

a. Abrasive blast cleaning

b. Mechanical or power tool cleaning

5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a

clean and dry surface is obtained. Unless otherwise specified, surface preparation shall be done as per provisions of relevant tables given elsewhere in this specification. The minimum acceptable standard, in case of thermally sprayed metal coatings, in case of mechanical or power tool cleaning shall be St. 3 or equivalent. In case of blast cleaning, it shall be Sa 2-1/2 as per Swedish standard SIS-055900 (latest edition) or SSPC-SP or ISO 8501-01.Blast cleaning shall be Sa 3 as per Swedish standard in case of thermally sprayed metal coatings.

Before surface preparation by blast cleaning, the surface shall be degreased by aromatic solvent to remove all grease, oil etc as per SSPC-SP-1.

5.1.3 Irrespective of whether external or internal surface to be coated, blast cleaning

shall not be performed where dust can contaminate surfaces undergoing such cleaning or during humid weather conditions having humidity >85%. In case of internal coating of storage tanks, dehumidifier shall be used to control humidity level below 60%. Dehumidifier should depress the dew point of air in the enclosed space, sufficient enough so as to maintain it 3⁰C below the metal substrate

temperature during entire period of blasting and coating application. During the interval time between application of primer coat and subsequent intermediate and top coats or between blast cleaning completion and start of application of primer coat, dehumidifier unit should be in continuous operation to ensure that no condensation occurs on the substrate. Dehumidifier should be able to maintain grain drop (moisture removal) at the rate of 25 grains per pound of air per hour. Dehumidifier should have capacity of at least 2 air changes per hour of the enclosed space. All necessary psychometric data should be collected by the CONTRACTOR for the given site conditions, before starting operation of dehumidifier, to ensure that desired values of dew point and moisture content in enclosed space is achieved. Dehumidification to be maintained round the clock for surface preparation and painting till the total coating application is over.

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Rev. 5 PAGE 8 OF 47


Dehumidifier shall not be stopped under any condition till the entire blasted surface is primed to the satisfaction of the technical representative of the paint manufacturer. In case the dehumidifier breaks down in middle of the job, the same shall be replaced at the risk and cost of the CONTRACTOR.

5.1.4 The Engineer in-Charge shall have the right to disallow usage of dehumidifier if the performance is not meeting the specified requirements. Under such circumstances, the CONTRACTOR shall remove the equipment and replace the same with another equipment to provide satisfactory results without any additional cost to the OWNER.

5.1.5 Irrespective of the method of surface preparation, the first coat of primer must be

applied by airless spray/ air assisted conventional spray, if recommended by the paint manufacturer, on dry surface. This should be done immediately and in any case within 4 hours of cleaning of the surface. However, at times of unfavorable weather conditions, the Engineer-In-Charge shall have the liberty to control the time period, at his sole discretion and/or to insist on re-cleaning before primer application is taken up. In general, during unfavorable weather conditions, blasting and painting shall be avoided as far as practicable.

5.1.6 The external surface of R.C.C. chimney to be painted shall be dry and clean. Any

loose particle of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush. Acid etching with 10-15% HCl solution for about 15 minutes shall be carried out. The surface must be thoroughly washed with water to remove acid and loose particles and then dried completely before application of paint.

5.2 Procedure for surface preparation 5.2.1 Air blast cleaning with abrasives

The surfaces shall be blast cleaned using one of the abrasives such as Al2O3 particles, chilled cast iron or steel grit, copper slag or nickel slag at a pressure of 7.0 kg/cm2 and at an appropriate distance & angle depending on nozzle size maintaining constant velocity and pressure. Chilled cast iron or steel shall be in the form of shot or grit of size in the range of G16 – G42 conforming to SSPC AB1 and S250 grade size of steel shots (maximum) to obtain a desired surface profile of 35-50 microns trough to peak. For all other abrasives, size shall be in the range of G16 – G24. The combination of steel grits and shots shall be normally in the ratio of 3:1. The quality of abrasives shall be free from contaminants and impurities and shall meet the requirements of SSPC AB1. The compressed air shall be free from moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron carbide as the material for liners. Nozzle orifice may vary from 3/16” to 3/4”. On completion of blasting operation, the blasted surface shall be clean and free from any scale or rust and must show a grey-white metallic luster. Primer or first coat of paint shall be applied within 4 hours of surface preparation. Blast cleaning shall not be done outdoors in bad weather without adequate protection. If there is dew on the metal surface, it shall be cleaned. The surface profile shall be uniform to provide good adhesion (i.e. 35 to 50 microns) to the paint. If possible, a vacuum collector shall be installed to collect and recycle the abrasives.

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Rev. 5 PAGE 9 OF 47


5.2.2 Mechanical or power tool cleaning Power tool cleaning shall be done by mechanical striking tools, chipping hammers,

grinding wheels or rotating steel wire- brushes. Excessive burnish of the surface shall be avoided as it can reduce paint adhesion. On completion of cleaning, the detached rust, mill scale etc. shall be removed by clean rags and /or washed by water/steam and thoroughly dried with compressed air jet before application of paint.

5.3 Non-compatible shop coat primer

For equipment on which application of total protective coating (primer + intermediate + top coat) is carried out at shop, compatibility of finish coat with primer should be checked with the paint manufacturer. If the shop coat is in satisfactory condition showing no major defect upon arrival at site, the shop coat shall not be removed.

5.4 Shop coated equipment (coated with primer & finishing coat) should not be

repainted unless paint is damaged. Repair shall be carried out as per Table-3 of paint systems depending upon the compatibility of paint.

5.5 Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas

by means of power tool brush cleaning or hand tool cleaning and then spot primed before applying one coat of field primer, unless otherwise specified. If shop primer is not compatible with field primer, then shop coated primer should be completely removed before application of selected paint system for a particular environment.

5.6 For package units/equipment, shop primer should be as per the paint system given

in this specification. However, manufacturers’ standard can be followed after review.

5.7 Coating procedure and application All coatings shall be applied by airless spray except for the following special cases,

where application can be carried out by brush subject to suitability of the application of the paint product by brush.

- Spot repair - Stripe coating on edges - Small bore parts not suitable for spray application Irregular surfaces such as sharp edges, welds, small brackets, and interstices may stripe coated to ensure specified DFT is achieved. Paint manufacturer recommendation should be followed before deciding for brush application.

5.7.1 Surface shall not be coated in rain, wind or in an environment where injurious

airborne elements exist, when the steel surface temperature is less than 5 0F above dew point, when the relative humidity is greater than 85%, when the temperature is below 40oF and when the ambient/substrate temperature is below the paint manufacturers recommended temperature of application and curing. De-

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Rev. 5 PAGE 10 OF 47


humidifier equipment shall be used to control RH and Dew point. The paint application shall not be done when the wind speed exceeds 20 km per hour.

5.7.2 Blast cleaned surface shall be coated with complete application of primer as soon

as practicable but in no case later than 4 hours the same day. 5.7.3 To the maximum extent practicable, each coat of paint shall be applied as a

continuous film with uniform thickness and free of probes. Any spots or areas missed in application shall be re-coated and permitted to dry before the next coat is applied. Applied paint should have the desired wet film thickness.

5.7.4 Each coat shall be in proper state of cure or dryness before the application of

succeeding coat. Material shall be considered dry for re-coating when an additional coat can be applied without the development of any detrimental film irregularities such as lifting or loss of adhesion of the under coat. Manufacturer’s instructions shall be followed for inter coat interval.

5.7.5 When the successive coat of the same colour have been specified, alternate coat

shall be tinted, when practical, sufficiently to produce enough contrast to indicate the complete coverage of the surface. The tinting material shall be compatible with the material underneath and shall not be detrimental to its service life and shall be recommended by the original paint manufacturer.

5.7.6 Airless spray application shall be in accordance with the following procedure:

As per steel structure paint manual Vol.1 & Vol.2 by SSPC, USA. Airless spray relies on hydraulic pressure rather than air atomization to produce the desired spray. An air compressor or electric motor, issued to operate a pump to produce pressures of 1000 to 6000 psi paint, is delivered to the spray gun at this pressure through a single hose within the gun. A single paint stream is divided into separate streams, which are forced through a small orifice resulting in atomization of paint without the use of air. This results in more rapid coverage with less over spray. Airless spray usually is faster, cleaner, more economical and easier to use than conventional air spray.

Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint from any container, including drums. The unit shall have in-built agitator that keeps the paint uniformly mixed during the spraying. The unit shall consist of in-built strainer. Usually, a very small quantity of thinning is required before spray. In case of high build epoxy coating (two packs), 45:1 pump ratio and 0.020-0.023” tip size will provide a good spray pattern. Ideally, fluid hoses should not have ID less than 3/8” and not longer than 50 ft. to obtain optimum results.

In case of gun choking, de-choking steps shall be followed immediately.

5.7.7 Brush application of paint shall be in accordance with the following:

a. Brushes shall be of a style and quality that will enable proper application of paint.

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b. Round or oval brushes are most suitable for rivets, bolts, irregular surfaces, and rough/ pitted steel. Wide flat brushes are suitable for large flat areas but they shall not have width over 5 inches.

c. Paint shall be applied into all corners. d. Any runs or sags shall be brushed out. e. There shall be a minimum of brush marks left in the applied paint. f. Surfaces not accessible to brushes shall be painted by spray, daubers, or

sheepskin. 5.7.8 For each coat, the painter should know the WFT corresponding to the specified

DFT and standardize the paint application technique to achieve the desired WFT. This has to be ensured in the qualification trial.

5.8 Drying of coated surfaces 5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be

considered dry for re-coating when another coat can be applied without the development of any film irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat should not exceed maximum specified for it as a first coat. If this exceeds, the paint material has possibly deteriorated or mixing is faulty.

5.8.2 No paint shall be force dried under conditions which will cause chalking, wrinkling, blistering formation of pores, or detrimentally affect the conditions of the paint.

5.8.3 No drier shall be added to paint on the job unless specifically called for in the manufacturers’ specification for the paint.

5.8.4 Paint shall be protected from rain, condensation, contamination, snow and freezing until dried to the fullest extent practicable.

5.9 Spot repair of damaged primer 5.9.1 Where pre-erection/shop primer has been damaged at isolated localized spots

during handling and transportation or after erection / welding, its repair shall be done as given below and as per the Table-3 of this specification.

5.9.2 Surface preparation: Quickly remove the primer from damaged area by mechanical

scraping and emery paper conforming to SSPC-SP-3 to expose the white metal. Blast clean the surface, if possible. Feather the primed surface, over the intact adjacent surface surrounding the damaged area, by emery paper.

Primer coating: One coat of F-9 shall be applied wherever damage was observed on pre-erection / pre fabrication or shop primer of inorganic zinc silicate coating (F-9). Similarly one coat of F-12 shall be applied wherever damage observed on pre-erection / pre-fabrication/shop primer of silicone aluminium (F-12).

5.9.3 If damaged areas are found to be extensive and spread over large areas, then entire pre-erection/pre-fabrication/shop primer shall be removed by blasting to

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achieve SSPC-SP-10 and entire blasted surface shall be primed again with F-9 or F-12, as applicable, for the intended design temperature. (See note of Table-3).

5.10 Assessment of painting requirement The paint system to be applied for a specific job shall be arrived at sequentially as

given below:

- Identify the environment from area classification details and choose the appropriate table.

- Identify the design temperature from the technical documents. - Identify the specific field paint system and surface preparation requirement from

the above identified table and temperature range. - Identify the shop priming requirement from based on compatibility of the above

paint system. - Identify the need of repair of shop primer and execute as per Table-3.

5.11 Documentation / records 5.11.1 A written quality plan with procedure for qualification trials and for the actual work

including test and inspection plan & procedure for approval before start of work. 5.11.2 Daily progress report with details of weather conditions, particular of applications,

no. of coats and type of materials applied, anomalies, progress of work versus program.

5.11.3 Results of measurement of temperatures, relative humidity, surface profile, film

thickness, holiday detection, adhesion tests with signature of appropriate authority. 5.11.4 Particulars of surface preparation and paint application during trials and during the

work. 5.11.5 Details of non-compliance, rejects and repairs. 5.11.6 Type of testing equipment and calibration. 5.11.7 Code and batch numbers of paint materials used.

The coating applicator must maintain a job record consisting of all the information as per 5.11.2 -5.11.7 above as well as the approved procedure of work (5.11.1 above). The job record consisting of information in accordance to 5.11.2 – 5.11.7 shall be entered on daily basis and should be daily signed by Engineer-in-charge.

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TABLE-1: SURFACE PREPARATION STANDARDS

Sl. No.

DESCRIPTION

VARIOUS INTERNATIONAL STANDARDS (EQUIVALENT)

REMARKS ISO 8501-1/ SIS-05 59 00

SSPC-SP, USA

NACE, USA

1

Manual or hand tool cleaning Removal of loose rust, loose mill scale and loose paint, chipping, scrapping, standing and wire brushing. Surface should have a faint metallic sheen.

St 2

SSPC-SP-2

-

This method is applied when the surface is exposed to normal atmospheric conditions when other methods cannot be adopted and also for spot cleaning during maintenance painting.

2

Mechanical or power tool cleaning Removal of loose rust loose mill scale and loose paint to degree specified by power tool chipping, de-scaling, sanding, wire brushing and grinding, after removal of dust, surface should have a pronounced metallic sheen.

St 3

SSPC-SP-3

-

3 Dry abrasive Blast cleaning There are four common grades of blast cleaning:

3.1

White metal Blast cleaning to white metal cleanliness. Removal of all visible rust. Mill scale, paint & foreign matter 100% cleanliness with desired surface profile.

Sa 3 SSPC-SP-5 NACE No.1

Extremely clean surface can be expected to have prolonged life of paint system.

3.2

Near white metal Blast cleaning to near white metal cleanliness, until at least 95% of each element of surface area is free of all visible residues with desired surface profile.

Sa 2½ SSPC-SP-

10 NACE No.2

The minimum requirement for chemically resistant paint systems such as epoxy, vinyl, polyurethane based and inorganic zinc

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Sl. No.

DESCRIPTION

VARIOUS INTERNATIONAL STANDARDS (EQUIVALENT)

REMARKS ISO 8501-1/ SIS-05 59 00

SSPC-SP, USA

NACE, USA

silicate paints. Also for conventional paint systems used under fairly corrosive conditions to obtain desired life of paint system.

3.3

Commercial Blast Blast cleaning until at least two-third of each element of surface area is free of all visible residues with desired surface profile.


For steel required to be painted with conventional paints, for exposure to mildly corrosive atmosphere and for longer life of the paint systems.

3.4

Brush-off Blast Blast cleaning to white metal cleanliness, removal of all visible rust, mill scale, paint & foreign matter. Surface profile is not so important.


-

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6.0 PAINT MATERIALS Typical characteristics and codes of various paint materials used in this specification

are as follows.

TABLE-2: PAINT MATERIALS (Refer to general notes at the end of this table)

DESCRIPTION P-6 P-7 P-4 Technical name

Epoxy Zinc Phosphate Primer

Cold Galvanizing product

Etch Primer/Wash Primer

Type and composition

Two component polyamine cured epoxy resin medium, pigmented with zinc phosphate.

One pack synthetic resin based zinc galvanizing containing min 92% of electrolytic zinc dust of 99.95% purity.

Two pack polyvinyl butyral resin medium cured with phosphoric acid solution pigmented with zinc tetroxy chromate.

Volume solids % Minimum

49 37 9

DFT per coat, μ

40-50

40-50

8-10

Theoretical covering capacity

in m2/coat/ litre

8-10

4m²/kg

8-10

Weight per litre in Kg/litre

1.4±0.05 2.67 kg at 15oC

1.2±0.05

Touch dry at 30oC (max.)

30 min.

10 min.

2 hrs.

Hard dry at 30oC (max.),

hrs

8

24

24

Over-coating interval, hrs

Min. 8

Min. 4

Min. 4-6

Pot life at

30⁰C for two component paints, hrs

6 - 8

NA

NA

Adhesion (ASTM D 4541) >7 NA NA

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Temperature resistance (min) ⁰ C (ASTM D 2485) *Note 8

80 (Method A)

50 (Method A)

NA

TABLE- 2: PAINT MATERIALS (Contd.)

DESCRIPTION F-2 F-3 F-6A/B F-6C

Technical name

Acrylic Polyurethane finish paint

Chlorinated rubber based finish paint

Epoxy-High Build coating

Solvent less epoxy coating

Type and composition

Two-pack aliphatic isocynate cured acrylic finish paint (free of alkyd/polyester resins).

Single pack plasticized chlorinated rubber based medium with chemical and weather resistant pigments.

F-6A Two- Pack Aromatic polyamine cured epoxy resin medium suitably pigmented. F-6B: polyamide cured epoxy

resin medium suitably

pigmented with MIO.

Two pack, cured with Amine Adduct; catalyzed epoxy resin suitably pigmented

Volume Solids % Minimum.

40 36 57 98

DFT per coat, μ 30-40

30-40

100-125

250-500

Theoretical covering capacity in m2/coat/litre

10-15

11-15

5-6

2-3

Weight per liter in Kg/litre

1.15±0.03

1.15±0.03

1.42±0.03

1.40±0.03

Touch dry at 30⁰C (max)

30 min.

30 min.

3 hrs

3 hrs

Hard dry at 30⁰C (max.), hrs

8

8

16

16

Full cure at 30⁰C (for immersion/ high temperature service)

NA

NA

5 days

5 days

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Over-coating Interval, hrs

Min.12.

Min. Overnight

Min. Overnight Max. 5 days

Min. 8. Max. 48

Pot life (approx.) at

30⁰C for two component paints, hrs

5-8

NA

3-6

0.5

Adhesion (ASTM D 4541) >5 >4 >7 >8

Abrasion Resistance (ASTM D4060) For 1000 g load

<300 mg /1000 cycles/CS17

or <100 mg /1000 cycles/CS10

NA NA NA

Temperature resistance (min.) ⁰ C (ASTM D 2485) *Note 8

80 (Method A)

60 (Method A)

80 (Method A)

120

(Method A)

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DESCRIPTION F-7 F-8 F-9 (primer) F-11 F-12

Technical name High build coal tar epoxy coating.

Self priming type surface tolerant high build epoxy coating (complete rust control Coating)

Inorganic zinc silicate Coating

Heat resistant synthetic medium based two pack Aluminium Paint suitable up to 250°C dry temp.

Heat resistant silicone Aluminium Paint suitable up to 540°C dry temp.

Type & composition

Two pack polyamide cured epoxy resin blended with coal tar medium, suitably pigmented

Two pack epoxy resin based suitable pigmented and capable of adhering to manually prepared surface and old coating.

A two pack air drying self curing solvent based inorganic zinc silicate coating with minimum 80% zinc content on dry film. The final cure of the dry film shall pass the MEK rub test as per ASTM D4752.

Heat resistant synthetic medium based two pack Aluminium paint suitable up to 250°C.

Single pack silicone resin based medium with Aluminium flakes.


62 75 57 35 18

DFT per coat in μ

100-125

100-125

65-75

15-20

15-20

Theoretical covering capacity in M2/coat/ litre

5.2-6.5

6.0-7.2

8-9

10-12

8-10

Weight per liter in Kg/litre

1.40±0.03

1.41±0.03

2.3±0.03

0.95±0.03

1.00±0.03

Touch dry at 30oC (maximum), hrs 4 3 0.5 3 0.5

Hard dry at 30oC (maximum), hrs

48

24

12

12

24

Full cure 30oC (for immersion /high temperature service)

5 days

5 days

NA

NA

NA

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Over-coating interval, hrs

Min. 24 hrs max.5days

Min. 10

Min. 12 hrs

at 20oC & 50% RH

Min. 24

Min. 24

Pot life at 30oC for two component Paints, hrs

4-6

1.5

4-6

NA

NA

Adhesion MPa (ASTM D 4541) >5 >5 >5 NA NA

Temperature resistance⁰ C (min) (ASTM D 2485 method B)

80 Dry service

80 Dry service

400 Dry service

250 Dry service

540

Dry service

Temperature resistance (min.) ⁰ C (ASTM D 2485) *Note 8

80 (Method A)

80 (Method A)

400 (Method B)

250

(Method A)

540 (Method B)

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DESCRIPTION F-14 F-15 F-16 F-17 F-20

Technical name Polyamine cured coal tar epoxy

Two- component Epoxy phenolic coating cured with Polyamine adduct hardener

Inert polymeric matrix coating suitable for under insulation for CS and SS.

Novolac epoxy phenolic coating cured with Polyamine adduct hardener

Glass flake reinforced vinyl ester coating.

Type & composition

Specially formulated polyamine cured coal tar epoxy suitable for application under insulation

Two pack ambient temperature curing epoxy phenolic coating system suitable for application under insulation oCS/SS piping

Suitable for high temperature service and under insulation coating for CS, alloy steel and SS

Novolac epoxy phenolic coating cured with Polyamine adduct hardener

Two component glass flake filled vinyl ester lining for under immersion services up to 90 deg. C.


67

67

50

98

98

DFT per coat in microns

100-125

75-100

100-125

300-450 500-600

Theoretical covering capacity in M2/coat/ litre

5-8

4-5

3 minimum

6.5 – 8

1.6 minimum

Weight per liter in Kg/litre (mix paint)

1.45±0.03

1.65±0.03

>1.3

1.7 >1.2

Touch dry at 30oC (max) , hrs

4

3

1

2 2

Hard dry at 30oC (max), hrs

24

24

16

24 4

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Full cure 30oC (for immersion / high temp service)

168 hrs (7 days)

168 hrs (7 days)

NA

168 hrs (7 days) 96 hrs

(4 days )

Over-coating interval

Min. 6 hrs Max.5 days


Min.6 hrs Max. Not applicable



Pot life at 30⁰C,

hrs (for two component paints)

4

4-6

1

1

50 min-1 hr

Adhesion, MPa (ASTM D 4541) >6 >7 NA >8

>7,

Tensile strength

>20N/mm2 (ASTM D 638)

Temperature resistance (min.) ⁰ C (ASTM D 2485) *Note 8 & 9

125 (Method A)

150 (Method A)

650 (Method B)

150

(Method A)

90 (Method A)

General notes for TABLE-2: 1. Covering capacity and DFT achieved per coat depends on method of application. Covering

capacity specified above is theoretical. For estimation of actual quantity of paints required, include the losses during application. Minimum specified DFT should be maintained in any case.

2. All primers and finish coats should be ambient temperature curing and air drying unless otherwise specified.

3. All paints shall be applied in accordance with manufacturer's instructions for surface preparation, intervals, curing and application. The surface preparation, quality and workmanship should be ensured. Wherever a deviation is noticed from the specification in manufacturer data sheet, more stringent one between the data sheet and the specification shall prevail e.g. if this specification recommends Sa 2 ½ and the manufacturer data sheet requires Sa3, the surface preparation shall be done as per Sa 3. However in another case if this specification requires the surface preparation of Sa 2 ½ and the manufacturer data sheet recommends only Sa 2 as minimum, the surface preparation shall be done as per Sa 2 ½.

4. Technical data sheets for all paints shall be supplied at the time of submission of quotations.

5. Higher specific gravity of F-9 is also acceptable.

6. Internationally recognized & acceptable testing method shall be used for lab testing wherever testing standards are not mentioned.

7. Touch dry, hard dry, pot life, full cure period, & over coating interval shall be as per manufacturer’s data sheets and no testing is required. Slight variation in the values of these parameters along with weight per liter may be permissible with the discretion of engineer-in-charge only.

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8. Temperature resistance tests (ASTM D2485) shall be carried out for minimum required temperature resistance indicated.

9. Wherever ASTM D 2485 method B is applicable, test results of the panels subjected to salt spray (ASTM B 117) after muffle furnace exposure shall be submitted for pre-qualification purpose.

10. F-6A shall be suitable for immersion services in line with recommendations in tables-7 to 9.

11. F-6C shall be suitable for immersion services of hydrocarbons and DM water ( in line with recommendations in table-9)

12. F-7 shall be suitable for immersion service of hydrocarbons & underground service up to 80 Deg C minimum.

13. F-14 shall be suitable for under insulation service up to 125 deg C.

14. F-15 shall be suitable for high temperature immersion & under insulation services in line with recommendations from table-8 to 13.

15. F-17 shall be suitable for high temperature immersion service and underground services as recommended in table-9 to 10.

7.0 COATING SYSTEMS The coating system should be selected based on the plant location as given below: Classification based on plant location:

a) Plant located in inland area (more than 50 km from coast). Environment classification – Industrial - For offsite areas: Table-5 to be followed. - For all process unit areas including DM, CPP and Cooling tower: Table-6

to be followed.

b) Plant located on sea coast or within 50 km from sea coast.

Environment classification- Industrial marine

- For offsite areas, process unit areas including DM, CPP, Cooling tower etc.: Table-6 to be followed.

c) For external surface of above ground tanks, Table-8 to be followed for all

locations (inland or coastal)

General notes for clause 7.0: 1. Coating systems (primers, finish paints etc.) based on area

classification/environments/applications are tabulated in Table-4 to Table-13

2. Repair of pre-erection/pre-fabrication & shop priming after erection/ welding shall be done as per Table-3.

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TABLE-3: REPAIR OF PRE-ERECTION/PRE-FABRICATION OR SHOP PRIMER AFTER ERECTION/WELDING

(For all un-insulated CS, LTCS & low allow steel items in all environments)

Sl. No.

Design Temp. in oC

Surface Preparation

Coating System

Total DFT in Microns

(min.) Remarks

3.1 -45 to 400 SSPC-SP-3 1 coat of F-9 65-75 See Note-1 below and

clause 5.9.3

3.2 401 to 550 SSPC-SP-3 1 coat of F-12 20

Notes for Table-3: Note-1: The application and repair of pre-erection/pre-fabrication or shop primer given in

above tables shall be done for all the items to be painted. In case the damages of primer are severe and spread over large area, entire primer shall be removed by blasting to achieve SSPC-SP-10 and surfaces to be primed again with F-9 or F-12 as applicable.

TABLE-4: COATING SYSTEM FOR GI HAND RAILS & GI ITEMS (Refer clause 2.2.2)

Sl. No.

Design Temp. in oC

Coating System Total DFT

in Microns (min.) Remarks

4.1 Up to

60

Hot Dip Galvanizing to 80-85 microns (600-610 gm/m2)as per

IS 4759, 2629, 4736, 2633 + 1 coat of P-6 @ 40µ DFT/coat + 1

coat of F-2 @ 40 microns DFT/coat

80 of finish coat (excluding the thickness

of galvanizing ) -

General notes for Table-4: 1. No galvanized specimen shall have thickness less than 80 microns. 2. Repair of the damaged areas of galvanized coatings due to welding during erection

shall be carried out as per recommended practice IS: 11759, using cold galvanizing spray process. Organic paint systems are not acceptable for the repair.

3. After repair of damaged galvanized coating by cold galvanization (P-7), the repaired area shall be top coated with paint system as given in table-4 above (i.e. 1 coat of P-6 @ 40µ DFT/coat + 1 coat of F-2 @ 40µ DFT/coat).

4. Suggested cold galvanizing manufacturers are ZINGA, LOCTITE or Z.R.C. 5. Galvanized gratings don’t require painting in general until otherwise specified

elsewhere or as per the requirement of the OWNER. Ladders, stairways & hand rails require painting to meet the colour coding requirement of the OWNER. Contractor has to ensure the applicable colour coding prior to application of coating as per this clause.

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TABLE-5: COATING SYSTEM FOR NORMAL CORROSIVE AREAS (OFFSITES) (For all un-insulated above ground CS, LTCS & low allow steel piping, equipment, structures, valves, vessels & columns etc.)

Sl. No.

Design Temp. in

oC

Surface Preparation &

Pre-erection/Shop

Primer

Coating System Total Final DFT

in Microns (min.)

Remarks Primer Finish Coat

5.1 -45 to -15

SSPC-SP-10; 1coat of F-9 @

65-75µ DFT/coat

- None 65-75 No over-coating shall be done on F-9 F-12 shall be ambient temperature curing type

5.2 -16 to 80


65-75µ DFT/coat

1 coat of P-6 @ 40

µ DFT/coat

1coat of F-6B @ 100 µ

DFT/coat+ 1 coat of F-2 @ 40µ DFT/coat

245-255

5.3 81 to 250


65-75µ DFT/coat

-

2 coats of F-11 @ 20µ DFT/coat (2x20=40)

105-115

5.4 251 to 400


65-75µ DFT/coat

-

2 coats of F-12 @ 20µ DFT/coat (2x20=40)

105-115

5.5 >400 SSPC-SP-10;

1coat of F-12 @ 20µ DFT/coat

-

2 coats of F-12 @20µ DFT/coat (2x20=40)

60

This system is suitable

up to 5400 C

General notes for Table-5: 1. The list of items given in the heading of the above table is not exhaustive. There may be more

items for a particular contract where these specifications are used. The CONTRACTOR is fully responsible for completing painting including prefabrication primer for all the items supplied and fabricated through his scope of work as per tender document.

2. Flare line within unit or offsite areas shall be coated as per clause 6.3 of Table-6. 3. If the application of pre-erection/pre-fabrication/shop primer has already been completed, the

same shall not be repeated in the field. In case the damages to the primer coat are severe and are spread over large areas, the Engineer-In-Charge may decide & advise re-blasting and re-application of the primer coat. Repair of pre-fabrication/pre-erection primer, if required, shall be done as per Table-3.

4. In case of paint systems as per sl. nos. 5.4 and 5.5, the colour bands shall be applied over the aluminum paint as per the colour coding requirement for specific service of the piping.

5. All coating system including surface preparation, primer, intermediate and finish coat for piping is recommended to be done at field only until otherwise specified.

6. For equipment, vessels, columns & valves etc scope of surface preparation, application of primers to finish coat including repair shall be as per applicable contractual documents like SOR, MR and PR etc.

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TABLE-6: COATING SYSTEM FOR CORROSIVE AREAS (PROCESS UNITS, COOLING TOWER, DM AND CPP) (For all un-insulated above ground CS, LTCS & low allow steel piping, equipment, structures, valves, vessels & columns etc.)

Sl. No.

Design Temp. oC

Surface Preparation

& Pre- erection/Sho

p Primer

Coating System

Total DFT

in Microns (min.)

Remarks

Primer

Finish Coat

6.1

-45 to -15

SSPC-SP-10; 1coat of F-9 @ 65-75µ

DFT/ coat

-

-

65-75

a) No over

coating on F-9 is allowed

b) F-12 shall

be ambient temperature curing type

6.2

-16 to 80


DFT/ coat

1 coat of P-6 @

40 µ DFT/

coat

2 coats of F- 6B @ 100 µ

DFT/coat + 1 coat of F-2

@ 40µ DFT/coat (2x100 +

40= 240)

345-355

6.3

81 to 400


DFT/ coat

-

2 coats of F- 12 @ 20µ DFT/coat 2x20=40

105-115

6.4

>400

SSPC-SP-10; 1coat of F-12

@ 20-25µ DFT/coat

-

2 coats of F- 12 @ 20-

25µ DFT/coat

(2x20=40)

60

This system

is suitable up to 540O C

Coating system for furnace stacks

6.5

Up to 200

SSPC-SP-10 1coat of F-9 @ 65-75µ DFT/ coat

---

3 coats of

Silicone acrylic (black) @40 µ DFT/coat

185-195

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General notes for TABLE-6: 1. The list of items given in the heading of the above table is not exhaustive. There may be more

items for a particular contract where these specifications are used. The CONTRACTOR is fully responsible for completing painting including prefabrication primer for all the items supplied and fabricated as per tender document and scope of work.

2. If the application of pre-erection/pre-fabrication/shop primer has already been completed, the same shall not be repeated in the field. In case the damages to the primer coat are severe and spread over large areas, the Engineer-In-Charge may decide & advise re-blasting and re-application of the primer coat. Repair of pre-fabrication/pre-erection primer, if required, shall be done as per Table-3.

3. For external surface of RCC Chimney, 2 coats of F-6 B@ 100µ DFT/coat to obtain a total DFT of 200 µ shall be applied after proper surface preparation as per guidelines in 5.1.6.

4. In case of paint systems as per sl. Nos. 6.3 and 6.4, the colour bands shall be applied over the aluminum paint as per the colour coding requirement for specific service of piping given in clause 9.0.

5. For piping, equipment, vessels, columns & valves etc, scope of surface preparation, application of primers to finish coat including repair shall be as per applicable contractual documents like SOR, MR, and PR etc.

TABLE-7: COATING SYSTEMS FOR EFFLUENT TREATMENT PLANT (ETP)

Sl. No.

Design Temp. in oC

Surface Preparation

Coating system Total DFT in Microns (min.)

Remarks Primer

Finish Coat

7.1 For external surfaces of C.S./M.S. items: screens, walk way bridges, baffles, dual media filters, vertical pumps, piping in treated effluent sump, bio sludge pump, screw pump and pump house, CS tanks, sumps and vessels.

-14 to 80 SSPS-SP-10

1 coat of F-9 @ 65-

75µ DFT/coat

2 coats of F-6A

@100µ DFT/coat +

1 coat of F-2 @ 40µ DFT/coat

(2x100+40=240)

305-315 -

7.2 For internal surfaces of CS/MS Items: bio-sludge sump, filter feed sump, process sump, sanitary sump, transfer sump, sludge, slop oil tank, scrapping mechanism in clarifier.

-14 to 80 SSPS-SP-10

1 coat of F-6A @ 65-

100µ DFT/coat.

2 coats of F-6A

@100µ DFT/coat

(2x100=300)

300 Note-1

7.3 All R.C.C./concrete surfaces exposed to effluent water / liquid such as tanks, structures, drains etc. in process sump, TPI separator (process and oil), aeration tank and transfer sump etc.

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-14 to 80

Blast cleaning to SSPC-SP guide lines and acid etching with 10-15% HCl acid followed by thorough water washing.

Epoxy screed lining 3000

Epoxy screed lining shall be applied as per manufacturer and Engineer-In-Charge instructions

7.4 CS dual media filters, chemical dosing tanks – internal surface

Up to 60 SSPC-SP-10

1 coat of clear two component solvent free vinyl ester primer @ 100µ DFT/ Coat + 2 coats of F-20 @ 500µ DFT/ Coat

1100 -

TABLE-8: EXTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW ALLOY STEEL STORAGE TANKS

Sl. No.

Design Temp. in

oC

Surface

Preparation

Coating system (Note-1)

Total DFT in

Microns (min.)

Remarks

Primer Finish Coat

8.1 All external surfaces of shell, wind girders, appurtenances, roof tops of all above ground tank including top side of external and internal floating roof and associated external structural works.

8.1.1 -14 to 80

SSPC-SP-

10

1coat of F-9 @ 65-75µ DFT/coat + 1coat of P-6 @ 40µ DFT/ coat

2 coats of F-6B @ 100µ DFT /coat + 1 coat of F-2 @ 40µ DFT/ coat

345-355

F-6 should be suitable

for occasional

water immersion

8.1.2 81 to 150

SSPC-SP-

10

1 coat of F-15 primer @ 80µ DFT/ coat + 1 coat of F-15 intermediate coat @ 80µ DFT/coat

1 coat of F-15 finish coat @80µ DFT/ coat + 1coat of F-2 @ 40µ DFT/ coat

280 -

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8.1.3 151 to 400

SSPC-SP-

10

1coat of F-9 @ 65-75µ DFT/coat

2 coats of F-12

@20 µ DFT/ coat or

1 coat of F-16 @ 125 µ DFT / coat

105-115

or

190-200

For higher design

temperatures, system

as per 8.2.3 of

this table is

applicable

8.2 External surfaces of bottom plate (in contact with soil) for all storage tanks.

8.2.1 -14 to 80

SSPC-SP-

10

1 coat of F-9 @ 65-75µ DFT/ coat

3 coats of F-7@ 100µ DFT/coat (3x100=300)

365-375

F-7 should be suitable

for immersion

service

8.2.2 81 to 150

SSPC-SP-

10

1 coat of F-17 primer @ 400µ DFT/ coat

1 coat of F-17 finish coat @ 400µ DFT/ coat

800-825 -

8.3 For underside of the bottom plate (not in contact with soil ) (in case tank is not lifted during PWHT) (Note- 2)

8.3.1 -29 to 400

(CS)

SSPC SP-

10

1 coat of inert polymeric matrix coating @ 125 µ

1 coat of inert polymeric matrix coating @ 125 µ

250-300 -

Notes for TABLE-8: 1. All paint coating application including primer for tanks shall be carried out at field after erection

and completion of entire welding. 2. For underside of bottom plate :

a) Painting shall be carried out before laying the bottom plate for tanks with non-Post Weld Heat Treatment (PWHT).

b) For tanks with PWHT, painting shall be carried out after PWHT. c) In case tank is not lifted during PWHT then painting shall be applied before laying the

bottom plate, clause no.8.3.1 shall be followed.

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TABLE-9: INTERNAL COATING SYSTEMS FOR CARBON STEEL AND LOW ALLOY STORAGE TANKS

Sl. No.

Design Temp. in

oC

Surface Preparation

Coating system

Total DFT in

Microns (min.)

Remarks

Primer Finish Coat

9.1

Crude oil, ATF, turpentine oil, lubricating oil: Underside of floating roofs, internal surface of cone roof, inside of bottom plate, internal surfaces of bare shell for full height, underside of floating roof, oil side surfaces of deck plates, oil side surfaces of pontoons, support structures and ladders etc.

9.1.1 -14 to 90 SSPC-SP-10 1 coat of F-15 primer @ 80µ

DFT/ coat

1 coat of F-15 intermediate coat @ 80µ DFT/coat + 1 coat of F-15 finish coat @ 80µ

DFT/ coat

240 -

9.2

Petroleum products & intermediates like LDO, HSD, gas oil, feeds of FCC-PC, FCC-LCO, VGO-HDT, ISOM, DHDT, reformate, DCU, NHT & gasoline, naphtha, isomerate and kerosene: Underside of floating roofs, internal surface of cone roof, inside of bottom plate, internal surfaces of bare shell for full height, underside of floating roof, oil side surfaces of deck plates, oil side surfaces of pontoons, support structures and ladders etc.

9.2.1 -14 to 45 SSPC-SP-10

1 coat of F-9 @

65-75 µ DFT/coat

- 65-75 -

9.2.2 46 to 90 SSPC-SP-10 1 coat of F-15 primer @ 80µ

DFT/ coat


DFT/ coat

240 -

9.3 Potable, Raw & Fire water All internal surfaces, accessories and roof structures of cone and dome roof tanks

9.3.1 -14 to 60 SSPC-SP-10 1 Coat of F-6A

@ 100 µ DFT/coat

2 Coats of F-6A @ 100µ DFT/

Coat (2x100=200)

300 Note-1

9.4 De-mineralized (DM) water & Condensates etc.: All internal surfaces, accessories and roof structures of cone and dome roof tanks.

9.4.1 -14 to 60 SSPC-SP-10 1 Coat of F-6A

@ 100µ DFT/coat

2 coats of F-6C @ 200µ DFT/ coat (2x200=400)

500

Single coat of F-6C @ 400 µ is

also acceptable

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9.4.2 61 to150 SSPC-SP-10 1 coat of F-15 primer @ 80µ

DFT/ coat


DFT/ coat (80+80=160)

240 -

9.5 Hydrochloric acid (HCl) 10 %: All internal surfaces, accessories and roof structures of cone and dome roof tanks

9.5.1 -14 to 60 SSPC-SP-10

1 Coat of clear two component

solvent free vinyl ester

primer @ 100µ DFT/ Coat

2 Coats of F-20 @ 500µ DFT/ Coat

1100 -

9.6 Aggressive solvents like hexane, exane, benzene, xylene and toluene: All internal surfaces, accessories and roof structures of cone and dome roof tanks

9.6.1 -14 to 65 SSPC-SP-10 1 coat of F-9

@ 65-75µ DFT/ coat

- 65-75 -

9.7 Ethylene glycol tanks: Internal shell-full height, bottom plate, underside of roof and all accessories

9.7.1 All SSPC-SP-10 -

3 coats of vinyl chloride co-polymer @ 75µ /Coat; (3x75=225)

225 -

9.8 Inside pontoon and inside of double deck of all floating roofs

9.8.1 -14 to 80 SSPC-SP-3 1 coat of F-8 @ 100µ DFT/coat


200 -

9.8.2 81 to150 SSPC-SP-10 1 coat of F-15 primer @ 80µ

DFT/ coat


DFT/ coat (80+80=160)

240 -

9.9 Wet slops, amine solutions, sour water , water draw off: All internal surfaces, accessories and roof structures of cone and dome roof tanks

9.9.1 -14 to 90 SSPC-SP-10 1 coat of F-15 primer @ 80µ

DFT/ coat


DFT/ coat (80+80=160)

240 -

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9.10

Vacuum residue, fuel oil , dry slop, bitumen and other high temperature hydrocarbon liquids: Underside of floating roof, internal surface of cone roof, bottom plate, inside of bare shell- including wetted and non wetted surfaces, oil side surfaces of deck plates, oil side surfaces of pontoons, roof structures, structural steel and ladders

9.10.1 Up to 150oC

SSPC-SP-10 1 coat of F-17 @ 375µ DFT/coat

375-425 -

9.11 Alkalis up to 50 % concentration: All internal surfaces, accessories and roof structures of cone and dome roof tanks

9.11.1 Up to 60oC

SSPC-SP-10 1 coat of F-15 primer @ 80µ

DFT/ coat

2 Coats of F-6 A @ 100µ DFT/coat

(2x100=200) 280 -

Notes for TABLE-9:

1. F-6 A shall be suitable for drinking water service and should have competent authority certification.

TABLE-10: COATING SYSTEMS FOR EXTERNAL SIDE OF UNDERGROUND CARBON

STEEL PLANT PIPING AND VESSELS

Sl. No.

Design Temp. in

oC

Surface Preparation

& Shop

Primer

Coating system Total DFT in

Microns (min.)

Remarks Surface Preparation &

Primer Finish Coat

10.1 Underground carbon steel plant piping

10.1.1 25 to 80 -

As per document

B224-000-79-41-PLS-04

3layer polyethylene (3LPE) coating as per document

B224-000-79-41-PLS-04

3.5mm Min.

--

10.1.2 81 to 150 -

SSPC-SP-10; 1 coat of F-17 primer @400 µ

DFT/ coat

1 coat of F-17 @ 400 DFT/coat

800 Min.

Note-2

10.2 External side of underground storage vessels

10.2.1 -45 to 80

SSPC-SP -10;

1 coat of F-9 @

65-75µ DFT/ coat

- 3 coats of F-7 @ 100µ DFT/coat

365-375 -

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10.2.2 81 to 150

SSPC-SP

-10

1 coat of F-17 primer @400 µ

DFT/ coat

1 coat of F-17 @400µ DFT/ coat

800 Min.

Note-2

Notes for TABLE-10:

1 For underground vessels, scope of surface preparation, application of primers to finish coat including repair shall be as per applicable contractual documents like SOR, MR, PR etc.

2 This coating system can be used for the lines/equipment/vessels which have operating temperature between ambient and 150 oC (normal operating temperature) with occasional rise in the temperature up to 200 oC (design temperature). TABLE-11: COATING SYSTEMS FOR UNDER INSULATION (ALL UNIT AREAS &

OFFSITES) (For insulated piping, equipment, storage vessels, tanks, columns etc. of CS, LTCS, Low alloy steel & stainless steels in all environments.)

Sl. No.

Design Temp. o C


Pre-erection/Shop Primer

Coating system Total DFT Microns (min.)

Remarks

Primer Finish paint

11.1 Carbon steel, LTCS and Low alloy steel Piping, Storage tanks, Vessels, Equipments etc

11.1.1 -45 to 125 SSPC-SP-10; 1coat of F-15 @ 75µ DFT/coat

None

2 coats of

F-15 @75µ DFT/coat

225

11.1.2 126 to 450

(CS)

SSPC-SP-10; 1 coat of F-16 @ 125µ DFT/coat

None

1 coat F-16 @ 125µ DFT/coat

250

11.2 Stainless Steel, Alloy Steel, Alloy-20 Piping, Tanks, Vessels & Equipments

11.2.1 -45 to 125

SSPC-SP-7; (15-25µ surface profile) 1 coat of F-15 @75 µ DFT/coat

None 2 coats of

F-15 @75µ DFT/coat

225

11.2.2 126 to 550

SSPC-SP-7; (15-25µ surface profile) 1 coat of F-16 @125μ DFT/coat

None 1 coat of

F-16 @125μ DFT/coat

250

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11.3 Cyclic service of CS, LTCS, SS, & Alloy Steels (Note-1)

11.3.1 -45 to 150 (Note-1)

SSPC-SP-10 For CS, LTCS & low

Alloy steel. SSPC-SP-7 for SS;

(15-25µ surface profile)

1 coat of F-15 @75 µ DFT/coat

None

2 coats of F-15 @75µ DFT/coat

225

Note-2

11.3.2

-29 to 400 (CS)

-180 to 400

(SS)

-29 to 650 (LAS)

SSPC-SP-10 for CS, LTCS & Alloy

steel. SSPC-SP-7 for SS

(15-25µ surface profile)


None

1 coat of F-16

@ 125µ DFT/coat

250

Note-3

Notes 1. In case of overlapping of cyclic temperature ranges as mentioned in 11.3.1 and 11.3.2 then

clause 11.3.1 shall be followed.

2. Alternatively, for this temperature range, 1 coat of F-17 @ 400 μ is also acceptable.

3. The coating system applicable for any other temperature range shall be reviewed if it is

encountered.

General notes for TABLE-11: 1. “Cyclic Service” is characterized by rapid or periodical temperature fluctuation or temperature

cycles.

2. The blasting abrasives for SS and alloy steels shall be aluminum oxide or garnet only.

3. For insulated vessels & equipment scope of surface preparation, application of primers to finish

coat including repair shall be as per applicable contractual documents like SOR , MR, PR etc.

TABLE-12: COATING SYSTEMS (INTERNAL PROTECTION) FOR CARBON STEEL

COMPONENTS OF COOLERS/CONDENSERS WITH FRESH COOLING

WATER SERVICE

Sl. No.

Design Temp. in

oC


Pre-erection/Shop Primer

Coating System Total Final DFT in

Microns (min.)

Rema-rks Primer Finish paint

12.1 Up to 80 SSPC-SP-10 1 coat of F-15 @ 80 µ DFT/coat

2 coats of F-15 @ 80 80 µ DFT/coat

240 -

12.2 81 to 150 SSPC-SP-10 --- 2 coats of F-

17@ 500μ/coat 1000 -

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TABLE-13: COATING SYSTEM (INTERNAL PROTECTION) FOR GALVANIZED OR NON

FERROUS OR STAINLESS STEEL/ DUPLEX STAINLESS STEEL COMPONENTS OF COOLERS/ CONDENSERS WITH FRESH COOLING WATER SERVICE

Sl. No.

Design Temp. in

oC


Pre-erection/Shop

Primer

Coating System Total Final DFT in

Microns (min.)

Rema-rks Primer Finish paint

13.1 Up to 80 Sweep Blasting 1 coat of F-15

@ 80µ DFT/coat;

2 coats of F-15 @ 80µ

DFT/coat; 240 -

13.2 81 to 150 Sweep Blasting - 2 coat of F-17@

500μ/coat 1000 -

Note: Coating systems in Table – 12 & 13 are applicable only as per the requirement specified in the data sheets of the respective exchangers/equipment. 8.0 STORAGE 8.1 All paints and painting materials shall be stored in rooms only which are to be

arranged by CONTRACTOR and approved by Engineer-In-Charge for the purpose. All necessary precautions shall be taken to prevent fire. The storage building shall preferably be separate from adjacent building. A signboard bearing the word “PAINT STORAGE- NO NAKED LIGHT-HIGHLY INFLAMMABLE” shall be clearly displayed outside. Manufacturers’ recommendation shall be followed for storage of paint materials.

9.0 COLOUR CODE

The colour coding system as per Table-14 shall be followed.

TABLE-14: COLOUR CODING

SR. No.

SERVICE

RECOMMENDED COLOUR

FOR PAINT SYSTEM

RAL COLOUR CODE

BASE COLOUR

BAND COLOUR

HYDROCARBON LINES (UNINSULATED)

‘

1 CRUDE SOUR Dark Admiralty grey with 1 orange band

7012 2011

2 CRUDE SWEET Dark Admiralty grey with 1 red 7012 3001

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band

3 LUBE OILS Dark Admiralty grey with 1 green band

7012 6010

4 FLARE LINES Heat Resistant Aluminium 9006

5 LPG Orange with 1 oxide red band 2011 3009

6 PROPYLENE Orange with 2 blue bands 2011 5013

7 NAPTHA Orange with 1 green band 2011 6010

8 M.S. Orange with 1 dark admiralty grey band

2011 7012

9 AV.GASOLINE (96 RON)

Orange with 1 band each of green, white and red bands

2011 6010 9010 3001

10 GASOLINE (regular, leaded)

Orange with 1 black band 2011 9005

11 GASOLINE (premium, leaded)

Orange with 1 blue band 2011 5013

12 GASOLINE (white) Orange with 1 white band 2011 9010

13 GASOLINE (Aviation 100/130)

Orange with 1 red band 2011 3001

14 GASOLINE (Aviation 115/145)

Orange with 1 purple band 2011 4006

15 N-PENTANE Orange with 2 blue bands 2011 5013

16 DIESEL OIL (White) Oxide red with 1 white band 3009 9010

17 DIESEL OIL (Black) Oxide red with 1 yellow band 3009 1023

18 KEROSENE Oxide red with 1 green band 3009 6010

19 HY.KEROSENE Oxide red with 2 green bands 3009 6010

20 DISUFIDE OIL (EX-MEROX)

Oxide red with 1 black band 3009 9005

21 M.T.O Oxide red with 3 green bands 3009 6010

22 DHPPA Oxide red with 2 white bands 3009 9010

23 FLUSHING OIL Oxide red with 2 black bands 3009 9005

24 LAB FS Oxide red with 2 dark admiralty grey bands

3009 7012

25 LAB RS Oxide red with 3 dark admiralty grey bands

3009 7012

26 LAB (Off. Spec) Oxide red with 1 light grey band 3009 7035

27 N-PARAFFIN Oxide red with 1-blue band 3009 5013

28 HEAVY ALKYLATE Oxide red with red band 3009 3001

29 BLOW DOWN, VAPOR LINE

Off white / Aluminum with 1-Brown band

9006 8004

30 BLOWDOWN Off white / Aluminum with 2 brown bands

9006 8004

31 A.T.F. Leaf brown with 1 white band 8003 9010

32 TOULENE Leaf brown with 1 yellow band 8003 1023

33 BENZENE Leaf brown with 1 green band 8003 6010

34 LAB PRODUCT Leaf brown with 1 blue band 8003 5013

35 FUEL OIL Black with 1 yellow band 9005 1023

36 FULE OIL (Aromatic rich)

Black with 2 yellow bands 9005 1023

37 ASPHALT Black with 1 white band 9005 9010

38 SLOP AND WASTE Black with 1 orange band 9005 2011

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OILS

39 SLOP AROMATICS Black with 2 orange bands 9005 2011

CHEMICAL LINES

40 TRI-SODIUM PHOSPHATE

Canary yellow with 1 violet band 1012 5000

41 CAUSTIC SODA Canary yellow with 1 black band 1012 9005

42 SODIUM CHLORIDE Canary yellow with 1 white band 1012 9010

43 AMMONIA Canary yellow with 1 blue band 1012 5013

44 CORROSION INHIBITOR

Canary yellow with 1 Aluminum band

1012 9006

45 HEXAMETA PHOSPHATE

Canary yellow with 2 black bands

1012 9005

46 ACID LINES Golden Yellow with 1 red band 1004 3001

47 RICH AMINE Canary yellow with 2 blue bands 1012 5013

48 LEAN AMINE Canary yellow with 3 blue bands 1012 5013

49 SOLVENT Canary yellow with 1 green band 1012 6010

50 LCS Canary yellow with 1 smoke grey 1012 7031

WATER LINES

51 RAW WATER Sky blue with 1 black band 5015 9005

52 INDUSTRIAL WATER Sky blue with 2 signal red band 5015 3001

53 TREATED WATER Sky blue with 1 oxide red band 5015 3009

54 DRINKING WATER Sky blue with 1 green band 5015 6010

55 COOLING WATER Sky blue with 1 light brown band 5015 1011

56 SERVICE WATER Sky blue with 1 signal red brown 5015 3001

57 TEMPERED WATER Sky blue with 2 green bands 5015 6010

58 DM WATER Sky blue with 1 aluminum band 5015 9006

59 DM WATER ABOVE

150F

Sky blue with 2 black bands 5015 9005

60 SOUR WATER Sky blue with 2 yellow bands 5015 1013

61 STRIPPED WATER Sky blue with 2 blue bands 5015 5013

62 ETP TREATED WATER Sky blue with 2 oxide red bands 5015 3009

FIRE PROTECTION SYSTEM (ABOVE GROUND)

63 FIRE WATER FOAM & EXTINGUISHERS

Post office red 3002

AIR & OTHER GAS LINES (UNINSULATED)

64 SERVICE AIR Yellow green with 1 signal red band

6018 3001

65 INSTRUMENT AIR Yellow green with 1 black band 6018 9005

66 NITROGEN Yellow green with 1 orange band 6018 2011

67 FREON Yellow green with 1 yellow band 6018 1023

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68 CHLORINE Canary yellow with 1 oxide band 1012 3009

69 SO2 Canary yellow with 2 white bands

1012 9010

70 H2S Orange with 2 red oxide bands 2011 3009

71 GAS (Fuel) Orange with 1 aluminum band 2011 9006

72 GAS (Sour) Orange with 2 aluminum bands 2011 9006

73 GAS (Sweet) Orange with 2 signal red band 2011 3001

74 HYDROGEN Orange with 1 light green band 2011 6021

STEAM AND CONDENSATE LINES (UNINSULATED)

75 HP STEAM Off white / Aluminum with 1 yellow band

9006 1023

76 MP STEAM Off white / Aluminum with 1 red band

9006 3001

77 MLP STEAM Off white / Aluminum with 1 orange band

9006 2011

78 LP STEAM Off white / Aluminum with 1 light green band

9006 6021

79 CONDENSATE Sky blue with 1 white band 5015 9010

80 CONDENSATE ABOVE

150F

Sky blue with 3 oxide red band 5015 3009

81 BFW Sky blue with 2 red bands 5015 3001

Note: For all insulated steam lines, the colour coding shall be followed as given for un-insulated lines with the specified length of colour bands.

INSULATED HYDROCARBON PIPING

82 IFO SUPPLY 1Black ground colour with 1 yellow band in centre

9005 1023

83 IFO RETURN Black ground colour with 1 green band in centre

9005 6010

84 HPS Black ground colour with 1 red band in centre

9005 3001

85 BITUMEN Black ground colour with 2 red bands in centre

9005 3001

86 CLO Black ground colour with 1 brown band in centre

9005 8004

87 VB TAR Black ground colour with 2 brown bands in centre

9005 8004

88 VR AM (BITUMEN / VBU FEED)

1 Black ground colour with 1 blue band in centre

9005 5013

89 VR BH 1 Black ground colour with 2 blue bands in centre

9005 5013

90 VAC. SLOP 1 Black ground colour with 1 white band in centre

9005 9010

91 SLOP 1 Black ground colour with 1 orange band in centre

9005 2011

92 CRUDE SWEET 1 Dark admiralty grey ground colour with 1 red band in centre

7012 3001

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93 CRUDE OUR 1 Dark admiralty grey ground colour with 1 orange band in centre

7012 2011

94 VGO / HCU 1 Oxide red ground colour with 2 steel grey bands in centre

3009 7011

95 OHCU BOTOM / FCCU FEED

1 Oxide red ground colour with 2 steel grey bands in centre

3009 7011

UNINSULATED EQUIPMENT, TANKS AND STRUCTURES

96 HEATER STRUCTURE Steel grey 7011

97 HEATER CASING Heat resistant aluminium 9006

98 VESSELS & COLUMNS Aluminium 9006

99 HYDROGEN BULLETS Pink 3014

100 LPG VESSELS Oxide red 3009

101 SO2 VESSEL Canary yellow 1012

102 HEAT EXCHANGER Heat resistant aluminium 9006

103 FO TANK AND HOT TANKS

Black 9005

104 ALL OTHER TANKS Aluminum / Off white 9006

105 CAUSTIC / AMINE / ACID TANKS

Golden yellow 1004

106 SOUR WATER Sky Blue 5015

107 OUTER SURFACE IN BOILER HOUSE

Heat resistant aluminum 9006

108 COMPRESSORS AND BLOWERS

Dark admiralty grey 7012

109 PUMPS Navy blue 5014

110 MOTORS & SWITCH GEAR

Bluish green 5024

111 HAND RAILING Signal red 3001

112 STAIRCASE, LADDER AND WALKWAYS

Black 9005

113 LOAD LIFTING EQUIPMENT AND MONORAILS ETC

Leaf brown 8003

114 GENERAL STRUCTURE

Black 9005

115 FLUE GAS STACK Black 9005

PIPES AND FITTINGS OF ALLOY STEEL AND SS MATERIAL IN STORE

115 IBR Signal red 3001

116 9Cr-1Mo Verdigris green 6021

117 5Cr-0.5Mo Satin blue 5012

118 21/4Cr-1 Mo Aircraft yellow 1026

119 11/4Cr- ½ Mo Traffic Yellow 1023

120 SS-304 Dark blue grey 5008

121 SS-316 Dark violet 4005

122 SS-321 Navy blue 5014

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SAFETY COLOUR SCHEMES

123 DANGEROUS OBSTRUCTION

Black and alert orange band 9005 2008

124 DANGEROUS OR EXPOSED PARTS OF MACHINERY

Alert orange 2008

General notes for table-14:

1. All LPG service PSVs shall be painted deep blue. 2. All drains & vents shall be painted in main line colour. 3. The colour code scheme is for identification of piping service group. It consists of a

ground colour and 1 / 2 colour bands. .

9.1 Identification The system of colour coding consists of a ground colour and secondary colour bands superimposed over the ground colour. The ground colour identifies the basic nature of the service and secondary colour band over the ground colour distinguishes the particular service. The ground colour shall be applied over the entire length of the un-insulated pipes. For insulated lines, ground colour shall be provided as per specified length and interval to identify the basic nature of service and secondary colour bands to be painted on these specified length to identify the particular service. Above colour code is applicable for both unit and offsite pipelines.

9.2 Ground colour

On un-insulated pipes, the entire pipe has to be painted in ground colour. On metal cladded insulated lines, minimum 2 m long portion should be painted.

9.3 Colour bands 9.3.1 Location of colour bands:

a. At battery limits. b. Intersection points & change of direction points in piping. c. Midway of piping section, near valves, across culverts. d. At 50 m interval on long stretch pipes. e. At starting and termination points.

9.3.2 Minimum width: NB Width 3” and below 75 mm Above 3” to 6” NB X 25 mm Above 6” to 12” NB X 18 mm Above 12” NB X 15 mm For insulated pipes, NB indicates OD of the insulation.

Sequence: Colour bands shall be arranged in sequence as shown above and the sequence follows the direction of flow. The width of the 1st Band to 2nd band is 4:1.

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Wherever deemed required by process department or safety, pipes handling hazardous substances will be given hazard marking of 30 mm wide diagonal stripes of black and golden yellow as per IS : 2379.

9.4 Special camouflage painting for un-insulated crude and product storage tanks Coating system shall be as per this standard.

Camouflage painting scheme for defense requirement in irregular patches will be applied with 3 colours.

Dark green : Light green : Medium brown 5 : 3 : 2

a. The patches shall be irregular and asymmetrical and inclined at 30 to 60 degrees.

b. Patches should be continuous at surface meeting lines / points. c. Slits / holes shall be painted in dark green shade. d. Width of patches shall be 1 to 2 m.

9.5 Identification markings on equipment/piping

Equipment tag numbers shall be stenciled/neatly painted using normal ‘Arial’ lettering style on all equipment and piping (both insulated & un-insulated) after completion of all paint works. Lettering colour shall be either black or white, depending upon the background, so as to obtain good contrast.

Operations group shall specify the location of the marking. Size of the making shall be as follows: Columns, vessels, heaters : 150 mm Pumps and other M/c machinery : 50 mm Piping : OD / 2 with maximum 100 mm Storage tanks : (as per drawings) 9.6 Colour coding for control valve

a) Carbon steel body : Light grey Alloy steel body : Canary yellow Stainless steel body : Natural

b) The actuator of the control valve shall be painted as: Direct action (open on air failure) valves : Green Reverse acting (close on air failure) valves : Red

The painting status shall be comprehensively updated every 6 months for compliance.

10.0 IDENTIFICATION OF VESSELS, PIPING ETC. 10.1 Equipment number shall be stenciled in black or white on each vessel, column,

equipment & machinery (insulated or un-insulated) after painting. Line number in black or white shall be stenciled on all the piping of more than one location as directed by Engineer-In-Charge. Size of letter printed shall be as below:

Column & vessels : 150 mm (high)

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Pump, compressor & other machinery : 50 mm (high) Piping : 40-150 mm 10.2 Identification of storage tanks

The storage tanks shall be marked as detailed in the drawing. 11.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS 11.1 The following items shall be painted for camouflaging, if required by the client: a. All columns

b. All tanks in offsite c. Large vessels d. Spheres

11.2 Two coats of selected finishing paint as per defence requirement shall be applied in

a particular pattern as per clause 11.3 and as per the instructions of Engineer-In-Charge.

11.3 Method of camouflaging 11.3.1 Disruptive painting for camouflaging shall be done in three colours in the ratio of

5:3:2 (all matte finish). Dark Green Light Green Dark Medium Brown 5 : 3 : 2 11.3.2 The patches should be asymmetrical and irregular. 11.3.3 The patches should be inclined at 30º to 60º to the horizontal. 11.3.4 The patches should be continuous where two surfaces meet at an angle. 11.3.5 The patches should not coincide with the corners. 11.3.6 Slits and holes shall be painted in dark shades. 11.3.7 Width of patches should be 1 to 2 m. 12.0 QUALITY CONTROL, INSPECTION AND TESTING 12.1 All painting materials including primers and thinners brought to site by CONTRACTOR

for application shall be procured directly from manufactures as per specifications and shall be accompanied by manufacturers’ test certificates. Paint formulations without certificates are not acceptable (see section 14.0 & 15.0).

12.2 The CONTRACTOR must produce test certificate from pre qualified paint

manufacturer for various tests as detailed out in section 15.0 of this document. The Engineer-In-Charge shall have the right to test wet samples of paint at random for verifying quality of paint supplied. CONTRACTOR shall arrange to have such tests, when required by Engineer-in-Charge, performed at his cost at any one of the NABL accredited laboratories.

Samples for the test will be drawn at random in presence Engineer-In-Charge or his

representations. Following tests to be carried out if called for by Engineer-in-Charge:

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- Specific Gravity - % solids by weight (% zinc content in case of inorganic or organic zinc primer) - Drying time (touch dry & full curing) - Adhesion - Storage stability (pot life)

Test methods for above tests shall be as per relevant ASTM or ISO Standard.

12.3 The painting work shall be subject to inspection by Engineer-In-Charge at all times. In

particular, following stage-wise inspection will be performed and CONTRACTOR shall offer the work for inspection and approval of every stage before proceeding with the next stage. The record of inspection shall be maintained in the registers. Stages of inspection are as follows:

a) Surface preparation b) Primer application c) Each coat of paint

Following tests are to be carried out during surface preparation:

- Test for presence of oil/grease and contamination

The steel substrate after degreasing as per SSPC-SP-1 shall be tested as per following procedure to validate absence of oil and grease contamination:

a) Visual inspection - continue degreasing until all visible signs of contamination are removed.

b) Conduct a solvent evaporation test by applying several drops or a small splash of residue-free tri-chloromethane on the suspect area especially pitting, crevice corrosion areas or depressed areas. An evaporation ring formation is indicative of oil and grease contamination. Continue degreasing and inspection till test is passed. - Tests for surface finish of blasted surface shall be done by visual inspection

using SSPC-VIS1. Clear cellophane tape test as per ISO 8502-3 shall be used to confirm absence of dust on blasted surface. Checks shall be done on each component at least once per 200 m2 of blasted surface and a minimum of 3 checks per shift.

- Test for presence of soluble salt as per method ISO 8502-9. Maximum allowable salt content shall be considered 20 mg/m2.Checks shall be done on each component at least once per 200 m2 of blasted surface and minimum of 3 checks per shift. In case salt exceeds specified limit, the contaminated surface shall be cleaned by method as per Annexure-C of IS 12944-4 (water cleaning). After cleaning, surface shall be retested for salt after drying.

Blast Profile Measurement: (In-Process testing during actual production before application coating)

The angular profile depth measurement shall be done by profile tape as per method NACE Standard RP 0287 or ASTM D 4417 method B (Profile depth gauge micrometer). Spot measurement shall be carried out every 15m2 of blasted surface.

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At each spot three measurements shall be taken over an area of 10 cm2 and average of measurements to be recorded and reported. If profile is <65 microns blasting shall continue till grater than 65 microns depth profile is achieved.

- Tests for blasting media, blasting air

Blasting Media (For every fresh batch of media and one random test during blasting)

Blasting Media shall be visually inspected for absence of contamination and debris using 10 X magnification. a) Inspection for the absence of oil contamination shall be conducted using

following procedure : - Fill a small clean 200 ml bottle half full of abrasive. - Fill the bottle with potable water, cap and shake the bottle. - Inspect water for oil film/slick. If present, the blasting media is not to be

used.

b) Soluble salt contamination if suspected shall be verified by method ASTM D 4940. If present, media to be replaced.

c) Clean blasting equipment, especially pot and hoses, and then replace

blasting media and retest.

Test for Blasting Air (Once Daily before start of blasting and once at random during blasting) The air for blasting shall be free from moisture and oil. The compressor air shall be checked for oil and water contamination per ASTM D 4285.

In addition to above, record should include type of shop primer already applied on equipment e.g. zinc silicate or zinc rich epoxy or zinc phosphate. Any defect noticed during the various stages of inspection shall be rectified by the CONTRACTOR to the entire satisfaction of Engineer-In-Charge before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, CONTRACTOR shall be responsible for rectifying any defects found during final inspection/guarantee period/defect liability period as defined in general conditions of the contract. Dry film thickness (DFT) shall be checked and recorded after application of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra cost to OWNER, the extra coat should have prior approval of Engineer-in-charge.

12.4 Final inspection of finished coating shall consist of the following:

1) Coating dry film thickness check: DFT measurement shall be as per ISO 2808. Type II electromagnetic gauges should be used for ferrous substrates. DFT gauge calibration, number of measurement shall be as per SSPC-DA-2. Measured DFT shall be within + 10% of the dry film thickness, specified in the specifications.

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2) Adhesion testing: Adhesion of the primer to the steel substrate and inter-coat adhesion of the subsequent coat(s) after curing for at least a week after application of the topcoat shall be examined by a knife test in accordance with ASTM D6677. For the knife test, if the rating is better than 8, the adhesion is considered acceptable. The adhesion is destructive and tested areas shall be repaired afterward using the spot repair procedure. Alternatively, the applicator may perform the adhesion test on a steel panel coated using the same surface preparation and coating application procedure as the work piece. Adhesion testing shall be carried out for each component at least once per 200 m2 of coated surface.

3) Holiday detection check: Holiday testing shall be conducted in accordance with

NACE SP0188. For immersion services, 100% of coated area shall be inspected for holidays. For atmospheric exposure, 10% of coated area which must include weld seams, corners and edges to be holiday tested. Voltage at which test is to be carried out will depend upon DFT of coating being tested and shall be as per NACE SP0188. Any holiday is unacceptable and should be marked and repaired immediately.

The CONTRACTOR shall arrange for spot checking of paint materials for specific

gravity, glow time (ford cup) and spreading rate. 13.0 GUARANTEE The CONTRACTOR shall guarantee that the chemical and physical properties of

paint materials used are in accordance with the specifications contained herein/to be provided during execution of work.

14.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR/SUB-CONTRACTOR Painting CONTRACTOR who is awarded any job for EIL, Projects under this

standard must have necessary equipment, machinery, tools and tackles for surface preparation, paint application and inspection. The CONTRACTOR must have qualified, trained and experienced surface preparator, paint applicator, inspector and supervisors. The CONTRACTOR supervisor, inspector, surface preparator and paint applicator must be conversant with the standards referred in this specification.

15.0 QUALIFICATION/ACCEPTANCE CRITERIA FOR PAINT COATING SYSTEM 15.1 Pre-qualification of paint coating manufacturer and his products

Paint manufacturer meeting the following requirements shall be considered by the CONTRACTOR for supply of the paint products.

- Manufacturer should have been in continuous business of paint coating formulation

and manufacturer for at least past 5 years. - Manufacturer should posses past experience of supplying his products to

hydrocarbon, petrochemical, fertilizer. Chemical processing industry or offshore platforms in the past 5 years.

- Coating manufacturer should have supplied at least 10000 litre of an individual product to hydrocarbon, petrochemical, fertilizer. Chemical processing industry or offshore platforms.

- The manufacturer’s manufacturing procedure & QA/QC system shall meet ISO 9001 requirements and preferably should posses ISO 14000 certificate.

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- The Quality control set up should be manned by qualified paint technologists whose bio data should be sent along with quality control organization chart.

CONTRACTOR shall procure the paint materials from the qualified manufacturer meeting above requirements and after obtaining prequalification testing approval as per requirements mentioned in clause 15.2 below.

15.2 Pre-Qualification Testing procedure:

The paint manufacturer engaged by the mechanical contractor shall carry out the tests in NABL accredited government laboratories like national test house (NTH), as a part of qualification. Paint manufacturer shall provide the paint samples to laboratory for testing of the parameters mentioned in Table-2 (typical characteristics) and Table-15 (tests on coating systems) of this specification. The testing laboratory will confirm the compliance of the paint material with respect to the acceptance criteria mentioned in the respective tables. Contractor shall furnish these test certificates along with all necessary supporting documents/information to EIL site for approval/ acceptance. The paint manufacturer will be qualified and approved by EIL site for supply of paints after review/assessment of the submissions made by the contractor. Test certificates which are more than 3 years old will not be considered. Paint manufacturers are advised to carryout pre-qualification testing accordingly for paints supply to EIL projects.

TABLE-15: PRE-QUALIFICATION TESTING

SYSTEM No.

COATING SYSTEM REFERENCE CLAUSE

(from table-3 to 12) TOTAL DFT μ

(min)

1. F-9+P6+F6B+F2 6.2 345

2. F12+F12+F12 6.4 60

3. F15+F15+F15 9.1.1 240

4. F16+F16 8.3.1 250

5. F17 9.10.1 375

6. F8+F8 9.8.1 200

7. F20+F20 9.5.1 1100

8. F6A+F6C+F6C 9.4.1 500

9. F6A+F6A+F6A 9.3.1 300

S. No. TEST FOR

SYSTEM NUMBER

DURATION ACCEPTANCE

CRITERIA

1.

Cyclic Test Salt Spray : 72 hrs. Drying in air: 16 hrs. UV-A340 nm weather meter: 80 hrs. One cycle: 168 hrs. (25 cycles at 168 hrs. each cycle) (ASTM D5894)

1 4200 hrs

Shall pass. No chalking, cracking, flaking, blistering or peeling shall be observed.

Page 7788 of 14785

SPECIFICATION



HRRL




2. Chemical Resistance Test (ASTM D543)

2a. 10% & 40% NaOH

3,5,7 & 9* *H2SO4 solution pH = 5.0 to 5.5 for system 10

1000 hrs

Shall pass. No cracking, discoloration, blistering, peeling or softening of film shall be observed.

2b. 5% H2SO4 168 hrs

2c. Xylene 4 weeks

2d.

Acetone 4 weeks

2e. Ethanol 4 weeks

2f. Kerosene 4 weeks

2g. Sea water 2000 hrs

3. Immersion in DM/DI water @900 (ASTM C868)

3,5 & 7

30 days

No softening, blistering or film damage.

4. Resistance to DM water using water immersion. (ASTM D870)

8 2000 hrs

Shall pass. No chalking, cracking, flaking, blistering or peeling.

5. 100% Humidity Test (ASTM D2247)

1 to 9

(except system-2 )

1440 hrs Shall pass

6.

Thermal Shock Resistance Test; 5 cycles @ 30 minutes in furnace at 120 ⁰ C and 15 minutes in water after quenching in water for each cycle. (ASTM D2485 method A)

2,3 & 4 (For system-2, testing to be done after heating the panels at 175°C for 2 hrs.)

- Shall pass

7. Cathodic Disbondment Test (ASTM G8 @60°C)

3&5 - Shall pass

Each coating product to be qualified shall be identified by the following:

1) Specific gravity of Base and curing agent (Ref. ISO 2811) 2) Ash content (ASTM D1650), volatile and non-volatile matters (ISO 3251) of each

component The identification shall be carried out on the batch, which is used for the Pre-qualification testing.

Page 7789 of 14785

SPECIFICATION



HRRL




15.3 Information to be furnished during delivery of paint materials:

CONTRACTOR along with delivery of paint material has to furnish following information from paint manufacturer to EIL for acceptance/approval of products: a) Batch test certificates:

Along with paint products delivery to site from the pre-qualified coating manufacturer, CONTRACTOR has to produce test certificate (from paint manufacturer) for each category of product for the following test items. All test results must mention clearly the batch no. and category of product tested. Tests to be conducted for following properties: - Specific Gravity - % solids by weight (% zinc content in case of inorganic or organic zinc primer)

b) Product information sheet/ technical data sheet for each category of product.

The contractor shall be fully responsible for the quality of the paints products as per prequalification testing. After the paint materials are supplied to site, the supplier shall organize random sampling and testing in a NABL laboratory as per discretion of the Engineer-in-charge. Failing to meet the specified quality requirements may cause rejection of the paint products.

16.0 METHOD OF SAMPLING & DISPATCH FOR LABORATORY TESTING (Pre-Qualification tests (sec. 15.2), Batch testing (sec. 15.3) and Inspection testing

(sec. 12.0)) 16.1 Samples of coating materials should be submitted to the laboratory in sealed

containers with batch no. and test certificate on regular format of manufacturer’s testing laboratory.

16.2 All test panels should be prepared by testing laboratory. Surface preparation for a system shall be done in accordance with this specification. For individual products testing, minimum shall be Sa 2.5. Colour photographs of test panels should be taken before and after the test and should be enclosed along with test report. Sample batch no. and manufacturer’s test certificate should be enclosed along with the report. Test report must contain details of observation and rusting if any, as per the testing code.

16.3 Manufacturers should intimate EIL, details of sample submitted for testing, name of testing agency, date, and contact personnel of the testing agency.

Page 7790 of 14785

■311 ENGINEERS

Ogeg fai5ieg LJMITED I MKT, Mn1512 011 A Govt of Indict Undertaking)

STANDARD SPECIFICATION FOR POSITIVE MATERIAL IDENTIFICATION (PMI) AT

SUPPLIER'S WORKS


6-81-0001 Rev. 3

Page 1 of 8

fir ~i~fYnc~i 110111010 111+1 4.11 116t111

fe4hr

STANDARD SPECIFICATION

FOR POSITIVE MATERIAL

IDENTIFICATION (PMI)

AT SUPPLIER'S WORKS

3 19.09.16. REVISED AND RE-ISSUED TKK RKS RN

2 20.10.11 REVISED AND RE-ISSUED RKS SCG AKC DM

1 15.07.08 REVISED AND RE-ISSUED NKR SSL SKP VC

0 07.12.00 ISSUED AS STANDARD SPECIFICATION AKC AKB AKB MI

Rev. No


by Checked

by


Standards Bureau

Chairman

Approved by


Page 16356 of 17890

401 ei sigez

INFer eRmiletel39RIMI

ENGINEERS INDIA LIMITED (A Govt d tie Undertaking)


SUPPLIER'S WORKS


6-81-0001 Rev. 3

Page 2 of 8

Abbreviations:

API American Petroleum Institute AS Alloy Steel HIC Hydrogen Induced Cracking LSTK Lump Sum Turn Key NACE National Association of Corrosion Engineers PMI Positive Material Identification RTJ Ring Type Joint Sch Schedule SS Stainless Steel TPI or TPIA Third Party Inspection Agency


Convenor: Mr.R K Singh

Members: Mr. Rajeev Kumar Mr. Himangshu Pal Mr. Neeraj Mathur Mr. T Kamalakannan Mr. Mahendra Mittal Mr. Deepak Gupta (Project)



Page 16357 of 17890

,311ae, O1 ii id1151-eg

(KU( t.larolZeimanO.1)

ENGINEERS INDIA LIMITED (A Govt of Info Undertaking)


SUPPLIER'S WORKS


6-81-0001 Rev. 3

Page 3 of 8

CONTENTS

1.0 SCOPE 4

2.0 REFERENCE DOCUMENTS 4

3.0 DEFINITIONS 4

4.0 PMI EXAMINATION 5

5.0 ACCEPTABLE METHODS FOR PMI 5

6.0 EXTENT OF PMI EXAMINATION 6

7.0 ACCEPTANCE CRITERIA .6

8.0 REJECTION CRITERIA ... ...... .... ..... ............ ...... ... ...... ............... ..... . ......... ..8

9.0 RECORDING AND DOCUMENTATION 7

10.0 MARKING 7



Page 16358 of 17890


SUPPLIER'S WORKS

15inazieT ENGINEERS O1 ii INDIA LIMITED

MKT, oxemeenoqwwo IA Govt A Inds Undertaking)


6-81-0001 Rev. 3

Page 4 of 8

1.0 SCOPE

1.1

This specification applies to the requirements for Positive Material Identification (PMI) to be performed at the Supplier's works on Metallic Materials procured either directly by the Owner/EIL/ LSTK contractor or indirectly through the sub-Suppliers.

1.2 This specification covers the procedures and methodology to be adopted to assure that the chemical composition of the material is consistent with the material specifications as specified in purchase documents using 'Alloy Analyzer' at the time of fmal inspection before dispatch.

13

The scope of this specification shall include but shall not be limited to Positive Material Identification (PMI) to be performed on Materials listed below:

1.3.1 For alloy Steel materials as below: Alloy Steel Pipes including Clad Pipes

- Alloy Steel Flanges & Forgings - Alloy Steel Fittings including Clad Fittings

Alloy Steel Fasteners - Alloy Cast & Forged steel valves

Alloy Steel Instrumentation Items (Control Valves, Safety Valves etc.) - Longitudinal Pipe & Fittings Welds. - Gaskets (for Ring Type Joints)

1.3.2 For Carbon Steel materials as below: - All Carbon Steel Piping items under NACE or MC or 112 or Wet Hydrogen Sulfide

(1-12S), Hydrofluoric acid (HF), Sulfuric acid (H2 SO4) services etc. - Carbon Steel flanges and valves (Rating 900# and above)

Following items shall be excluded from scope of PMI examination.

Gaskets other than for Ring Type Joints - Internal Components of Valves

1.4 All grades of material supplies including Stainless Steels shall be liable for PMI test at site. In case of any defective materials being found at site, the Supplier shall be responsible to effect replacement of such defective materials at project site without any delays to the satisfaction of E1L site RCM (Resident Construction Manager).

2.0 REFERENCE DOCUMENTS

2.1 API Recommended Practice 578 (First Edition, May 1999) - Material Verification Program for New and Existing Alloy Piping Systems.

3.0 DEFINITIONS

3.1 Supplier: Any Supplier or Manufacturer on whom an order is placed for the supply of referred items. This definition shall also include any sub-Supplier or manufacturer on whom a sub-order is placed by the Supplier.

3.2 Inspection Lot: A group of items offered for inspection covered under same size, Heat and Heat treatment lot.

33 Alloy Material: Any metallic material (including welding filler materials) that contains alloying elements such as Chromium, Nickel, Molybdenum or Vanadium, which are intentionally added to enhance mechanical or physical properties and/or corrosion resistance.


Page 16359 of 17890

lagtael *Igelf ti5teg

1.12n 2 IETIWQRJ■10.11 (A Govt Of India undenaong)



SUPPLIER'S WORKS


6-81-0001 Rev. 3

Page 5 of 8

4.0 PMI EXAMINATION

4.1 The Supplier shall submit a procedure of PMI to comply with the requirements of this Specification. Approval of PMI Procedure shall be obtained from Owner / EIL / TPIA prior to commencing manufacture / inspection of product.

4.2 PMI examination of materials is independent of any certification, markings or colour coding that may exist and is aimed at verifying that the alloy used are as per specified grades.

4.3 The Supplier shall identify all incoming alloy materials and maintain full traceability of all alloy materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to cutting to ensure maintenance of identification on off-cuts.

4.4 The Supplier shall ensure that all alloy materials are segregated and stored in separately identified locations to prevent the mix up of materials of different alloy specifications or alloy material with carbon steel. Non ferro-magnetic materials shall be segregated at all times from ferro-magnetic materials.

4.5 PMI examination is subject to surveillance inspection by Owner / EIL / TPIA.

5.0 ACCEPTABLE METHODS FOR PMI

5.1 The method used for PMI examination shall provide a quantitative determination of the alloying elements like Chromium, Nickel, Molybdenum or Vanadium in Alloy Steel items.

5.2 Instruments or methods used for PMI examination shall be able to provide quantitative, recordable, elemental composition results for positive identification of alloying elements present.

5.3 The acceptable instruments for alloy analyzer shall be either "Portable X-Ray fluorescence" or "Optical Emission" type each capable of verifying the percentage of alloy elements within specified range.

5.4 Chemical spot testing, magnets, alloy sorters and other methods using eddy current or triboelectric testing methods are not acceptable for PMI examination.

5.5 The PMI instrument used shall have the sensitivity to detect the alloying elements in the specified range.

5.6 All PMI instruments shall have been serviced within a 6 month period of the time of use to verify the suitability of batteries, sources etc., and the data of the last service shall be stated on the PMI Report Form (Sample enclosed).

5.7 Each analyzer must be calibrated according to the manufacturer's specification at the beginning and end of each shift. Instrument must be checked against known standard for each alloy type to be inspected during the shift.

5.8 Certified samples, with full traceability, of a known alloy materials shall be available for use as a random spot check on the instrument calibration.

5.9 The surfaces to be examined shall be prepared by light grinding or abrasive paper and solvent cleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding or abrasive paper. No permanent marks, which are injurious to the usage of product in service, are acceptable.


Copyright EIL—All rights reserved

Page 16360 of 17890


SUPPLIER'S WORKS

t11 t—ft- ENGINEERS **gel' fililegW INDIA LIMITED

IvilVA PROW =Jowl/ (A Govt d b16H Undertakmg)


6-81-0001 Rev. 3

Page 6 of 8

5.10 Alloy Steel ring type joint Gaskets shall be inspected by using portable X-Ray fluorescence instrument.

5.11 Testing shall be done as per the procedures outlined by the manufactures of alloy analyzer being used. Modification of these procedures if any must be approved by Owner/EIL.

5.12 The persons performing PMI shall demonstrate their capabilities to the satisfaction of Owner/EIL/TPIA visiting engineer. If the Supplier has qualified operator on their rolls, he may perform the examination. Otherwise PMI examination shall be sub-contracted to an independent testing agency approved by EIL.

5.13 Whenever material is identified as not meeting requirements by the visiting engineer a rejection note shall be issued.

6.0 EXTENT OF PMI EXAMINATION

Following sampling plans shall be applicable for PMI examination of various items.

A. Flanges, Fittings 100% Valves, RTJ Gaskets

B. Pipes 100% (for pipes procured from traders).

2 random samples drawn from each Size/Heat/Lot (for pipes procured directly from mills)

C. Fasteners

Lot Size

Upto 100 101 to 500 501 and above

Note:

Sample Size

2% (Min 2) 1% (Min 3) 0.5% (Min 5)

a. For Welded Pipes and Fittings, PMI shall be performed on Base Metal as well as weldments.

7.0 ACCEPTANCE CRITERIA

7.1 Base Metal

PMI test results showing presence of characteristic elements upto 10% less than the minimum specified value in the material specification and upto 10% more than the maximum specified value in the material specification shall be acceptable.

7.2 Deposited Weld Metal

For deposited weld metal using welding consumables matching with base metals, the recorded presence of characteristic elements upto 12.5% less than the minimum specified value in the welding consumable specification and upto 12.5% more than the maximum specified value in the welding consumable specification shall be acceptable.


Page 16361 of 17890

5.1geal laZg (wed ereenZeld3O0en) In Govt or India UndertakIng)

7-77 ENGINEERS INDIA LIMITED


SUPPLIER'S WORKS


6-81-0001 Rev. 3

Page 7 of 8

8.0 REJECTION CRITERIA

8.1 If PMI test results fall outside the acceptable range as specified in 7.0 above, the supplier shall obtain a quantitative check analysis performed by a laboratory acceptable to Owner / EIL / TPIA for a complete chemical analysis. Alternatively, the item can be tested with a spark analyser for verification. Results of this analysis shall be submitted to Owner / EIL / TPIA for final decision.

Decision of Owner / EIL / TPIA shall be final in this regard.

8.2 If any sample drawn to PMI test on the basis of percentage selection as per 6.0 above, fails to meet specification requirements, 100% of items of lot shall be tested for PMI by supplier. Any failure thereafter during sample check shall mean rejection of whole lot.

9.0 RECORDING AND DOCUMENTATION

The results of PMI examination shall be recorded in a Report Format as enclosed with this specification.

10.0 MARKING

10.1 All alloy materials tested by PMI shall be identified using either of the following methods by indicating "PMI OK"

a) Bar Code/Hologram Sticker b) A low stress stamp marking


Page 16362 of 17890


SUPPLIER'S WORKS

lafitzArtft ENGINEERS ogeil ElfiThegW7 INDIA LIMITED

1.1■2i1 MOW 4,13,R1.0 (A Govt d India Undertaking)


6-81-0001 Rev. 3

Page 8 of 8

POSITIVE MATERIAL IDENTIFICATION REPORT BULK MATERIALS

Page of

Project: Client Job No.

PMI Report No. Supplier/Sub-Supplier

Purchase Order No. Testing Agency

Purchase Requisition No:

PMI Location

Bulk Item Type (as per Requisition)

Material Specification/Grade

Number of items in Lot

Requisition Item No./ Description Major content, Weight Percent Remarks Accept/Reject

Element Cr

Cb Ni Mo V Ti*

/

Nb **

Specified Range

Actual observations

1.

2.

3.

4.

5.

6.

7.

8.

Instrument Type / ID

Last Service Date Inspection Agency Witnessed By

To be reported in case of SS321 Material * * To be reported in case of SS347 Material


Page 16363 of 17890

of 25

Annexure L: Packing, Marking & Shipping Instructions

L&T HYDROCARBON ENGINEERING

LIMITED

HRRL PFCCU PRU PROJECT

of 25

INDEX

SECTION NO. DESCRIPTION PAGE NO.

1 Scope 3

2 General Application 3

3 References Codes & Standards 3

4 Environmental conditions 3

5 Packaging 3

6 Marking 10

7 Handling and Stowage 11

8 Hazardous Certificates 12

9 Containerization 12

10 Documentation 14

11 Responsibilities and Warranties 15

12 Shipping 15

13 Dispatch Dossier 18

APPENDIX – A : General preservation requirement 18

APPENDIX – B : Equipment storage code 23

L&T HYDROCARBON ENGINEERING

LIMITED

HRRL PFCCU PRU PROJECT

of 25

1.0 SCOPE This procedure describes the Packing, Marking, and Shipping and documentation requirements for the shipment of all materials and equipment for “HRRL PFCCU PRU PROJECT.

2.0 GENERAL/ APPLICATION

This procedure describes the minimum requirements, and adherence to the procedure in no way absolves or relieves the Contractor, Vendor or Supplier of any responsibility or obligation to correctly pack, mark all equipment and materials including shipping arrangement & provide all necessary documentation for import into India and deliver them to the HURL facilities.

Documentation, packing and marking requirements shall fully comply with all relevant contractual requirements specified in the Scope of Work and Technical Specification of the Contract or Purchase Agreement.

3.0 REFERENCE CODES & STANDARDS

Where conflicts exist between this Standard and other Drawings, standards, codes and specifications, the most stringent shall be applied. Reference Documents: ISO 780 - Packaging, Pictorial Marking for handling of goods.

4.0 ENVIRONMENTAL CONDITIONS

Packing, marking and protection of the documentation which accompanies materials and equipment shall in all respects be suitable for shipment from the point of origin to the Project site/s in India and storage till further use.

The environment of India is severe and must be considered carefully before design and procurement of plant and equipment. It must be assumed that, unless otherwise specified, equipment may be subjected to sand and fine particle dust storms, sand laden winds, thunderstorms, heavy rain, chemical contaminants, and extreme temperatures.

Temperature, Max. 55 deg c, Min. 12 deg c Humidity, max, low Relative humidity. 80% to 60% Rainfall, Maximum in one hour 10mm Snowfall, per year not to be considered Sea Breeze to be considered Sandstorm to be considered.

5.0 PACKAGING

5.1 General

5.1.1 The following guidelines are designed to facilitate preservation, safe arrival, and expeditious movement of material being purchased, from the point of origin to the Facility. Any charges incurred due to the failure of the Contractor or Supplier to comply with these instructions shall be to his account. The method of packing and the packaging materials shall be suitable to protect purchased items against the hazards associated with multiple handling by manual and mechanical means,

of 25

trucks, air and ocean transport and storage conditions encountered in transit and the environmental conditions at the HURL Sites.

5.1.2 A "Shipping Unit" is defined as one of the following:

Carton, crate, cradle, box, barrel, cage, drum, tower, tank, pipe, bar, steel, pallet, bundle, container or skid.

5.1.3 As equipment may be stored outdoors for an extended time, all packaging shall be designed and constructed such that their contents are protected in external, non-covered storage at site for a minimum period of 12 months. Where additional preservation measures as VPI’s or desiccants are required for protection, they shall be capable of renewal after 12 months without harm to the contents.

5.1.4 All packing materials, cases, crates, drums, saddles and supports etc. shall become a part of the Purchase Order / Project and are not returnable.

5.1.5 Alloy, stainless steel and carbon steel material shall be segregated and packed in separate boxes for shipping to facilitate the positive material program at the site.

5.1.6 Materials and equipment from different Purchase Order Numbers shall not be consolidated and packaged together unless authorized by the CONTRACTOR. Nevertheless, individual Purchase Order Line items shall be segregated, marked and packed separately.

5.2 Preservation and Packaging

5.2.1 All materials and equipment shall be strongly packed for shipment. Special blocking, bolting, shims and dummy bearings shall be provided as required for rotating parts of large pumps, motors, compressors and other similar equipment.

5.2.2 Machinery, parts or tools with a highly finished surface shall be treated in accordance with recognized industry standards, as a protection from dirt and moisture. Application of tape is not acceptable on finished surfaces.

5.2.3 All shafts fitted with anti-friction bearings shall be suitably strapped to prevent damage of the bearings during transport.

5.2.4 Particular care shall be taken to protect and preserve sensitive items such as instruments, control panels, hydrodynamic bearings, mechanical seals, etc.

5.2.5 Supplier should submit item specific detail procedures for preservation of items supplied.

5.2.6 In all instances (with the exception of various size pipe), items shall be nested or packed to reduce volume as much as possible. Waste space within a shipping unit is a source of weakness. Fragile items shall be wrapped in crepe-cellulose wadding or some equally efficient cushioning material and floated in excelsior.

5.2.7 Vendor to provide MSDS & Storage procedure for first fill lubricants, to be used for Rotary equipments.

of 25

5.2.8 Prior to packing, all PROJECT CARGO shall be checked internally and externally to insure that they are free from all weld spatter, scale, rust, cuttings, filings etc. as well as any other foreign matter.

5.2.9 If there are any preservatives used to protect equipment there should be a permanent label (not paper) securely attached to advise of this and where to reference how it is removed etc. prior to putting the equipment into operation.

5.2.10 Commissioning Spare Parts supplied by the SUPPLIER/CONTRACTOR shall be packaged separately with packages clearly identified with the words “COMMISSIONING SPARES”. Packing lists in all instances shall clearly identify by quantity and description all Commissioning Spare parts supplied.

5.2.10 Mandatory Spare Parts supplied by the SUPPLIER/CONTRACTOR shall be packaged separately with packages clearly identified with the words “MANDATORY SPARES”. Packing lists in all instances shall clearly identify by quantity and description all Mandatory Spare parts supplied.

5.2.11 Both general hand tools and any special tools including keys etc. to be provided by the Supplier for the installation of supplied materials and equipment shall be packaged separately with packages being clearly identified with the words “TOOLS”. Packing lists in all instances shall be clearly identified by quantity and description all tools supplied.

5.2.12 Packing/stuffing has to be seaworthy and in compliance with the applicable laws of land, IMO, IMDG, ILO compliance

5.3 Packing Specification

The manner in which a commodity is packed governs to a great extent its condition on arrival at a destination. This procedure covers the minimum packing requirements. Where this Standard does not specify, the best packing practice shall be followed. Materials and supplies used for wrapping packaging, taping, sealers, moisture barriers and retardants and corrosion prevention shall be of recognised brands and acceptable grade. Supplier to ensure that internal movement must be arrested with proper chocking & lashing inside wooden box. Packing material shall be capable of performing their functions without damage and/or contamination to the Purchase Order items packed.

Supplier to share the photographs before and after packing for LTHE Approval prior to dispatch from supplier works.

Supplier shall emphasis upon sustainable/environment friendly use of packing material.

5.3.1 Air Shipments These shall be packed to acceptable airline industry standards and in such a way as to afford items maximum mechanical protection, ease of handling and the minimization of total weight of shipping units. The International Air Transport Association (IATA) sets the regulations for packaging airfreight shipments and these must be respected.

of 25

5.3.2 Timber Boxes and Crates

a. All Timber materials used shall be sound and well seasoned without evidence of rot, grazes or splits. Knots shall be sound and not in excess of one fourth of the width of the board.

b. All shipping units shall be either weatherproof lined and/or purchased items weatherproof wrapped prior to packing. For maximum strength, nails shall be driven into side grain of Timber.

c. Timber boxes and crates shall be sized to contain all parts of the equipment. Protrusion of valve stems, etc. beyond the top or sides of the box or crate shall not be permitted.

d Spreaders shall be used for items which are extremely heavy but small in volume.

e. Timber boxes and crates shall be steel strapped. Straps shall be secured with crimped steel seals. Seller shall perform fumigation of units, as applicable, at his own cost and fumigation certificate shall be submitted to LTHE (Fumigated timber to be used, in case of oversea consignment & vendor to provide fumigation certificate)

f. Non-metallic strapping may only be used on cartons and packages within shipping units.

g. All boxes and crates weighing more than 50 kg or physically large in size shall be fitted with skid platform or pallet bases for handling by a forklift. Minimum size of bearers shall be 70-mm height by 80-mm width, the total number and size dependent on shipping unit length and weight. The Contractor or Supplier shall brand all shipping units with the marks as detailed herein.

Note: Packing lists itemizing contents on each box or crate shall be placed inside each shipping unit. A second copy, together with any special instructions regarding preservation of contents, shall be sealed in a waterproof envelope and securely fastened to the outside of each shipping unit.

h. Only the contents of the unit to which the packing list is attached may appear on the packing list. Individual cartons or packages within a shipping unit shall be branded with the purchase order item number and content detail.

The Contractor or Supplier shall not pack goods from different purchase order numbers into a common shipping unit.

5.3.3 Saddles, Supports, Spiders, Lifting Equipment and Shipping Drawings

a. All vessels, Columns, tanks and similar equipment which cannot be shipped without independent support shall be supplied with shipping saddles

of 25

suitable for deep-sea transit and road transportation. All internal fittings shall be properly supported.

b. Shipping drawings shall be submitted by the Supplier to Purchaser/Freight Forwarding agent 90 days in advance, for all individual items with a weight in excess of 20 tonnes and/or a length in excess 12 m and/or a width or height in excess of 3 m or where shipping/transportation saddles are being provided. Such drawings must show clearly full dimensions, weights, centre of gravity, lifting/securing points and saddle locations..

c. Transportation/Shipping Saddles shall be affixed to vessels with straps to

prevent damage to painted surface.

d. Width should by uniform for all saddles used for the equipment for easy loading and off-loading on stools.

e. Unless equipment is of a nature which allows for unprotected lifting and / or

slinging, SELLER should ensure that if necessary, trunnions, lugs or eyes are fitted to enable a safe lifting operation to take place without the risk of damage to equipment.

f. Suitable securing points and/or lashing areas shall be provided and suitably

identified on all equipment. Where needed, protection (wood battens, rubber or similar) to painted areas that might be impacted by transport-securing lashings or lifting wires shall be incorporated.

5.3.4 Moisture Control

a. Weatherproof case liners (in bag form or an overwrap, constructed of asphalt-laminated craft paper and sealed in waterproof adhesive) shall be used,if the materials and equipment are susceptible to damage from moisture.

b. All Instrument panels, instruments, electrical equipment, precision machinery and control valves shall be packed in suitable wooden cases. They shall also be vacuum heat sealed in a polythene barrier c/w sufficient silica gel to afford protection for 12 months.

c. Openings in vessels, shop-built tanks, etc. shall be properly sealed after

placement of silica gel or comparable desiccant, to absorb moisture within the vessel, tank, etc.

d. Openings in electric motors, generators and other electrical equipment shall

be sealed with waterproof tape or in some equally efficient manner. A protective paper (Grade A - greaseproof or equivalent) shall be inserted between the brushes and armature of motors and generators.

e. 60 days before start of packaging of items for first shipment, the Supplier shall conform to acceptance to this document and also Purchasers approval to their proposal for packing, marking, shipping & storage, preservation procedures for long-term storage or for the period between manufacture and installation of the various types of equipment, tanks, etc. at the HURL facilities.

of 25

5.3.4 Open Crates a. Crates shall be constructed of nominal lumber sizes indicated for boxes

(see paragraph 5.3.12). They shall be diagonally braced on all faces, and 3-way corner joints shall be constructed.

b. A common point of weakness in a crate containing over 100 kg is its top edge, upon which a severe strain is placed by slings each time it is handled. A fully sheathed box is required for equipment weighing over 300 kg.

5.3.6 Palletizing

a. Items impervious to damage from moisture, etc., and which can be conveniently secured to a pallet to facilitate handling shall be packed in this manner For example, roofing paper shall be placed upright on pallets in groups of 25 or 36 rolls and strapped together, covered with a cap constructed of 20-mm lumber, and shall be secured to the pallet with a minimum of two 30-mm straps.

b. Attached to the steel strapping of the pallet shall be a timber placard of sufficient size to clearly show shipping mark. A waterproof envelope shall be attached to the placard containing packing lists.

c. Individual contents of a pallet shall be clearly marked by affixing the packing list outside package.

d Individual packaged loads (cargo consolidated onto crates/pallets/skids) shall not exceed 210 centimeters in any dimension or 2,000 kilograms maximum gross weight. Deviation from these limits must be approved by the owner/Purchaser.

5.3.7 Sacks

If sacks are to be used in packaging the product, the Supplier shall be guided by the counsel of the Approved Manufacturer of such containers. In general, a 6-ply waterproof sack with one external Onsaburg cloth sack is suitable. A supply of empty refill sacks equal to 5% of the number of filled packages in the shipment to replace those damaged in transit shall be provided and shall accompany the shipment to the destination. All individual sacks shall be tagged or branded with the purchase order number, purchase order item numbers and contents details.

5.3.8 Steel Drums

Watertight steel drums may be used and consolidated onto pallets for ease of handling. Shipping marks and packing lists are required for all individual steel drums, and each drum shall be tagged or branded with the purchase order number, purchase order item numbers and content details.

5.3.9 Bundling

a. Each bundle shall be treated as an individual package and marked accordingly.

of 25

b. All items shall be segregated to length and size and bundles into units generally not to exceed 1000 kg, using minimum 3-cm steel strap that may be spaced up to 120 cm apart (where practical, ends shall be cross braced).

5.3.10 Spare Parts

All spare parts (such as commissioning spares or mandatory spares) when available at time of shipment of main equipment shall either be packed or clearly marked and included in main packing case attached to base board, or if size and dimensions deem separate shipment then shall be properly protected for short-term storage.

5.3.11 Hazardous Cargoes

All outside containers and packing of hazardous cargoes shall be in accordance with rules and regulations of applicable governmental agencies and the International Air Travel Association for all hazardous cargo such as chemicals, poisons, poisonous gas, inflammable liquids, compressed gases, inflammable solids, oxidizing materials, non-inflammable compressed gases, explosives and radioactive material. Hazardous materials shall be packed separately from all other materials and shall not be encased inside other packages. All GOODS and packages containing hazardous substances or systems of reservation or stored energy shall be clearly labelled externally with the required hazard classification labels and marks. The instructions for the maintenance, replenishing and safe removal and disposal of preservations, protective films, gases, coatings and desiccants shall be included and placed within easy access.

5.3.12 Types of Boxes and Crates for Shipment.

Gross Weight Style

Lumber Dimension Nominal all Cleats & Bands min 60 mm

wide with spacing 1 m maximum

Steel Strapping Space no greater

than 600 mm apart

Up to 50 kgs. 4 *25 - mm ends 20- mm sides, top and bottom. 2 straps - 20 mm

51- 150 kgs. 4 *25- mm throughout 2 straps - 30 mm

151 - 300 kgs. 2 (banded) *25 - mm throughout Commensurate with weight 125 mm framing, 30 mm sheathing

2 straps - 30 mm Corner straps - 30 mm

300-5000 kgs. Open or sheath crates

Commensurate with weight and type load *Finished Size Lumber as required

5.3.13 Certification Of Wooden Material Used In Packing

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All wood packaging material (including dunnage) used shall be in accordance with ISPM 15 (International Standards for Phytosanitary Measures Publication No. 15, March 2002). These requirements include certifying that either heat treatment or chemical (methyl bromide) treatment has been performed and thus labeling the wood with the IPPC accepted symbol. Markings shall be in conformance with the IPPC (International Plant Protection Convention) standards. The suppliers shall submit the Phytosanitary Certificate for packages where ever the wood is used.

5.3.14 Supplier can use the following packing type:

STATIC Pressure Vessels, Boilers, Stacks, Cyclones, Hoppers, Ejectors, Static Filters, Reactors, Heat Exchangers, Tanks, Silos,

Saddles, Crates/skid

ROTARY Agitators, Centrifuges, Air Or Steam Generators, Pumps, Mixers, Screens, Fans, Soundproof Booths, Turbine, Compressors, Alternators, Extruders, Refrigeration Units, Conditioning Systems.

Case

E&I Laboratory Equipment, Analyzers, Battery And Battery Charger, Electric Boxes and Terminal Boards, Converters, Switchboards, Electrical And Instrument Components, Thermometers, Orifices Plates And Rupture Disks, Level Indicators, Electric Isolators, Electrical fittings, Control Valves, E&I-Transformers, Switchboards, Capacitor banks, UPS with batteries, Lighting Systems, CP & Heat Tracing, DG Sets, Analysers, valves (Control/ On Off/MOV, PSV), DCS & ESD System with cabinets, RTU with Solar panels, Field Instruments, Trays, Fittings, Testing Equipment, Miscellaneous E&I items. E&I Cables

Case Drum

PIPING, STEEL STRUCTURES & PLATES Fittings, Fasteners, Flanges, Steel Structures With Thk upto 5mm, Stairs And Platforms, Supports, Tubing and SS Pipes upto 6", Lined Metal Pipes, Plastic Pipes. Expansion Joints, Gaskets, Valves, Manifolds. Steel Structures with Thk > 5mm, Plates, Bars, CS Pipes. REMARK: Carbon steel pipe of 8" or over shall be shipped individually. Special materials (i.e.: stainless steel, copper, Titanium etc) will be packed in cases. (SS should not be packed with CS/LAS to avoid contamination). Supplier shall provide wooden sleepers/dunnage wherever required as a part of safe loading.

Crate Case Bundles

NON-HAZARDOUS PRODUCTS Chemical Products, Paints & Solvents, Mineral Wool And Glass Fibber, Refractory Materials, Compressed Or Liquefied Gasses, Epoxy Resin, Oils And Greases Lubricants, Electrolyte For Batteries, REMARK: The use of pallets will be applicable for above products already packed in metal drums or waterproof bags as original standard packing.

Crate/cases

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HAZARDOUS PRODUCTS

Product specific as international standards

NOTE: Loose material & Gunny Bag is not acceptable.

6.0 MARKING

6.1 As a minimum the Supplier shall mark each box/pallet with the following:

CONSIGNEE : L&T HYDROCARBON ENGINEERING LIMITED SHIPPER : ________________________ PROJECT NAME : “HRRL PFCCU PRU PROJECT, [ ** ] (**: indicate Sindri or Barauni as applicable) PO NO. : ITEM DESCRIPTION : TAG NO : PACKING LIST NUMBER : : PACKAGE NO. : __OF __ DIMENSION (IN CM) : XXX x XXX x XXX WEIGHT (IN KGS) : NET WT. _____, GROSS WT. ______ ORIGIN : MADE IN _______ PORT OF DISCHARGE : ________, INDIA DESTINATION : WARNING MARKS : FRAGILE, ATTENTION, TOP, KEEP DRY ETC.) STORAGE CODE : As per APPENDIX – B LTHE DISPATCH CLEARANCE NO: PART SHIPMENT/FULL SHIPMENT/FINAL SHIPMENT:

6.2 Mark each shipping unit as shown below under section 6.3, Shipping Marks, in at least three places. Marking shall be of waterproof ink or exterior grade paint in a color which produces high contrast with the background, is fade resistant and able to withstand possible extended periods of storage in bright sunlight and other atmospheric conditions prevalent at the Site. Lettering shall be 50 mm in size, or larger.

6.3 Shipping units which cannot be marked directly as described above shall be marked as follows (in order of preference):

6.3.1 Labels

Labels shall be type face printed on durable, weather-resistant material using waterproof ink. Labels shall be affixed to the shipping unit by waterproof glue.

6.3.2 Placards

Placards shall be constructed of exterior grade timber of minimum thickness of 6 mm or galvanized sheet metal; of a minimum thickness of 0.5 mm. Placards shall be securely attached with stainless steel or other non-corrosive fasteners. If wire is used for affixing, a minimum of two (2) wires shall be used.

6.3.3 Tags

Tags shall be stainless steel, non-rusting ferric alloy, brass, copper or durable plastic, of a minimum thickness of 0.5 mm. Tags shall be legibly embossed or metal stamped in characters no smaller than 5 mm in height. Tags shall be attached in the same manner and with the same material as placards.

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6.4 Colour marking shall be as follows: 6.4.1 Each shipping unit shall have a color band a minimum of 50 mm wide,

painted around smallest girth.

6.4.2 On boxes and crates, three sides of each corner shall be painted so that color marking is visible on all four sides and on top.

6.4.3 On barrels, kegs, drums, tanks, bundles of pipe and rebar, and structural steel, a color daub shall be painted on or near both ends of each shipping unit.

6.4.4 In no case shall paint be applied to any machined surface or to any surface prepared for field welding.

6.4.5 Exterior grade blue paint shall be used for all color marking, unless otherwise advised in writing by the Purchaser.

6.4.6 Packages/equipment of five tons or more must be marked with slinging points and also clearly show on all sides the center of gravity.

6.4.7 Each package and its contents must clearly show the “country of origin” of supplies.

6.4.8 All items packed in the package must have “Made in XXXX” marking Labels on an un-removable print, 3m stickers or embedded on the goods.

6.4.9 Green Color marking shall be applied to Units/Packages/Cargos/Items supplied to

HURL Sindri Site.

Yellow Color marking shall be applied to Units/Packages/Cargos/Items supplied to HURL Barauni Site.

7.0 HANDLING AND STOWAGE INSTRUCTIONS

7.1 Marking International symbols on packages

Symbols for special handling are to be based on the International Standard ISO 780 Packaging, Pictorial Marking for Handling of Goods or an acceptable alternative. Symbols shall be applied legibly by stencil with exterior grade paint or waterproof ink in a color that produces a high contrast with the surrounding background. Easily damaged material shall be marked "FRAGILE" and also when required, "HANDLE WITH CARE," "PROTECT FROM HEAT," and/or "USE NO HOOKS." Material that must be kept upright to prevent damage, such as machinery, motors, engines, etc., shall be marked "THIS WAY UP" and if appropriate "TOP HEAVY," with arrows on all sides of box pointing to top. When required, due to length or unbalanced weight, crates or boxes shall have a centre of gravity indicated by the relevant symbol, and the words "CENTRE OF GRAVITY" shall appear in letters at least 24 mm high, below the symbol.

7.2 PRECAUTION FOR STOWAGE & HANDLING OF CARGO SUPPLIER shall submit precaution for stowage and handling of such cargo as requiring special attention in handling in terms of natural conditions such as temperature, humidity and the like.

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a) SUPPLIER shall stencil appropriate instructions for the handling, transport and

storage of the equipment and material on outside of the package.

b) Care marks (Centre of gravity, sling, top, keep dry, fragile, dangerous etc) on thecrates are to be stencilled with waterproof ink.

c) Supplier shall be responsible for recommendations for handling and storage of the

supplies at Project site, using the following conventional letters for each package, unless approved in advance by Owner/LTHE, The storage conditions should be mentioned on the packing list against each package separately.

X Packages to be stored outside (Open Air) XX Packages to be stored under cover (Open Shed) XXX Packages to be stored in covered or closed premises (Closed Warehouse) XXXX Packages which must be stored in Air Conditioned Warehouse

The indicative guidelines for Equipment storage code is attached at Appendix – B. The SELLER/SUPPLIER of equipment, such as pressure vessel, heat exchangers etc., shall attach to each equipment the warning tag with the following descriptions by stencilling in red color. “Any welding to item is prohibited during transportation.” Nitrogen filled equipment shall have a warning sign in English and the local language: “CAUTION NITROGEN FILLED. DO NOT ENTER.” Pressure Gauge of equipment filled with Nitrogen or any other gas should be not be mounted on extreme portion of equipment as it may be unsafe while transportation. PWHT item shall have sign: “POSTWELD HEAT TREATED - DO NOT FLAME CUT OR WELD ON THIS VESSEL.” Internally coated item shall have sign: “INTERNALLY COATED – DO NOT FLAME CUT OR WELD ON THIS VESSEL.” On vessels shipped with internally pressured item shall have: “DE-PRESSURIZE BEFORE OPENING”.

8.0 Hazardous Certificates

8.3.1 Hazardous materials shall be identified on a separate invoice and packing list from non-hazardous materials. All hazardous materials shall be identified by the appropriate hazard class technical or proper shipping name. All invoices and packing lists for hazardous materials shall contain the following statement:

"This is to certify that the above named materials are properly classified, described, packaged, marked and labeled and are in proper condition for transportation according to the appropriate Government or International transportation regulations"

________________ _________________________________________ (Hazardous Class) (Technical or Proper Shipping Name) (U.N. number) __________ _______________ (Name) (Vendor's Name)

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8.3.2 The Contractor/Supplier shall provide any necessary hazardous cargo certificates,

in accordance with the appropriate government and international transportation regulations for all shipments.

9.0 CONTAINERISATION The cargo shall be stuffed in 20 ft or 40 ft containers (dry, open top, flat racks).This definition of containerization is valid for sea containers. All categories of cargo can be shipped in containers. Since the container is not leak tight, where pre-packing is not leak tight, packing in contact with the bottom shall be raised in order to prevent it from being damaged by accumulations of water (on pallets, for example). Since mechanical stress differs, the case for the equipment may have a lighter structure. However, it is necessary that, after the discharging of equipment out of containers, their packaging and packing be appropriate so as to protect equipment at the job site during the storage period.

Packing Prior to Placing Into the Containers Supplier shall take into account the stresses and strains acting on the container and its contents during transport. The most important resulting from the following:

1) Road Transport:

Acceleration & slowing-down causing longitudinal motion in both directions, Centrifugal forces while moving the loads on road turns, Vibrations settling the packages on the floor.

2) Railway Transport:

Shock, due to brakes and buffers during marshalling.

3) Sea Transport: Rolling and pitching

Consequently the Supplier shall comply with following requirements:

Perfect load balance. Appropriate stowage of load. Adequate wedging and fitting suitable to the transport facilities used.

Instrument and sophisticated electrical Panels shall be packed in Dry Container in order to protect from damage. (Applicable for import shipment). Based on the container load plan SELLER should ascertain the number and type of container what will be required, CONTRACTOR’S logistics team / FREIGHT FORWARDER will review, book and provide the containers release / booking confirmation to the SELLER appropriately. When the SELLER considers containerization as the most appropriate mode of shipment, pro-forma packing list should be handed over and approved by CONTRACTOR.

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Inspection of the Container:

The container must be inspected before it is stuffed. From the inside, the container is to be checked for cleanliness and air tightness. If a container appears to be badly damaged or unclean, a replacement is to be requested. In general, the container must be in compliance with the requirements for protection of cargo and structural integrity established by the International Institute of Container Lessors. If there is any reasonable doubt regarding the container's condition, it must be resolved. Prior to stuffing: Stowage of a container must be planned before stuffing begins. Packages of an appropriate strength and type must be placed adjacent (as practical) to each other to gain the desired tightness of stow and compatibility between items. Shipments must be stuffed in containers to the maximum practical extent in accordance with volume and weight limit factors for the container. Articles that do not completely fill the selected container must be cushioned, braced, fastened, or blocked to prevent damage to the article itself or to the container. Wooden bracings when necessary should be applied to loaded container to ensure the cargo will not fall out when the doors are opened. The Packages weight exceeding 2 MT, should not be loaded in GP containers. In event of supplier unable to maintain this limitation, the same should be communicated to owner/L&T in advance during shipment planning stage. The planned load of the container must not exceed the container's weight capacity marked on it. The relevant limitations on the highway (road axle weights) in the country of loading or transit must not be exceeded. The gross weight of container should NOT exceed 24 MT which is maximum permissible weight per trailer for road transportation. In event of supplier unable to keep the containers gross weight below 24 tones, due to volume and weights of packages, the same should be communicated to owner/Purchaser in advance during shipment planning stage. Supplier to take the approval on photographs from LTHE before and after packing for LTHE Approval prior to container stuffing. Supplier to ensure that internal movement must be arrested with proper chocking & lashing inside container Supplier to share us the stuffing photographs for LTHE Approval prior to sealing of container and release from Supplier works. For CFR Shipment supplier need to take care on following points

21 Days Free Period at Destination Port No Security deposit to be asked by shipping line to LTHE while release of

Delivery order to LTHE / CHA nominated by LTHE.

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10.0 DOCUMENTATION

10.1.1 Documents

All correspondence, drawings, instructions, data sheets, design calculations or any other written information shall be in the English Language. All dimensions, units of measurements, physical constants, etc. shall be in the SI units, unless otherwise specified.

10.1.2 The following documents shall accompany materials and equipment for all deliveries/consignments and shipments originating outside India: a. Copy of commercial invoice. b. Copy of certificate of Origin. c. Copy of packing list. d. Copy of assembly instructions as applicable. e. Copy of the Approved Manufacturer’s instructions as applicable,

including the use and removal of rust preventatives as defined in Appendix A, General Preservation Requirement.

f. Formal Dispatch Clearance from Buyer. g. Final Inspection Release Note.

10.1.3 The Contractor shall provide material safety data sheets for any hazardous material shipments.

10.1.4 Other Documents

Supplier should comply with any other request for documentation from either the Buyer/Logistics Engineer/Freight Forwarder or project Logistics Team. Other documents called for may include but are not limited to:

Phytosanitary/ Fumigation Certificate Product Catalogues. Certificate of origin endorsed by local Chamber of Commerce at origin. Invoice attested by local Chamber of Commerce at origin. Instruction for handling, transport and storage.

In addition, when requested to do so sellers are required to assist the customs clearance activity by providing additional information to support HS classification. This assistance may include additional functional descriptions, provision of literature to support the items application/usage, brochures, etc. The Buyer/ Logistics Coordinator will communicate any special requirement in this regard and seller's compliance with the request will be required within 2 working days.

Supplier is also requested to maintain a record of digital photographs of cargo before and after final packaging and to provide these photographs upon request.

10.2 Packing Lists

Tentative/Advance Packing list should be submitted by vendor before 3-4 week prior actual shipment in provided project format, Packing lists shall show all the following information and details:

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a. Purchase order number, item number, quantity.

b. Commercial description of the material (no abbreviations, brand or trade names) matching the purchase order.

c. Total number of items/materials in each package/case.

d. Total number of packages/cases, sizes, cubic metre, gross and net weights (in kilos) of each package.

e. Grand total of packages/cases, gross weight (kilos) and cubic meters.

f. additional details as per the Billing instructions.

11.0 RESPONSIBILITIES AND WARRANTIES

Supplier shall be responsible for compliance with these instructions and the choice of category for packing, according to the nature of the supplies and transport facilities used.

Supplier shall be responsible for the accuracy of the weights and dimensions declared, and marking of packages. The packing list shall be in strict conformity with the packing contents.

Supplier shall be responsible for recommendations for storage and handling of

the supplies.

12.0 SHIPPING

If specific packing & shipping details are not specified in the Purchase Order/Engineering specifications, Cargo will be packed according to the following order of preference:

In Containers In Export crates, cases

12.1.1 Cargo Classification

Based on package Dimensions & weight, cargo can be classified in three categories: General Cargo/ Containerized In- Gauge Cargo:

Dimensions & Weight up to -

Length: 11.8m, Width: 2.1m, Height: 2.1m, Weight: 16 MT

Break Bulk Cargo/ Containerized Out-Gauge Cargo Dimensions & Weight up to - Length: 11.8m, Width: 3.6m, Height: 4.0m, Weight: 28 MT

ODC/ OWC Cargo Dimensions & Weight exceeding - Length: 12 m, Width: 3.5 m, Height: 3.5 m, Weight: 28 MT 12.1.2 Partial shipments

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Partial shipments are not allowed unless specifically authorized by Purchaser in writing. Partial Shipments must be accompanied by identifying documents and shall not be construed as fulfillment of Seller's obligations. No extra charge will be allowed for packing, shipment or handling of partial shipments unless stated in the Purchase Order. Itemized packing lists must accompany each shipment.

12.1.3 Equipment for Ocean Carriage

The Supplier shall warrant that his equipments are ready for shipment, suitable for handing by Mechanical means, i.e. ports and/or vessel's lifting gear. All equipment pieces shall be skidded, pre-slung, or fitted with lifting lugs, or with other adequate means of lifting, and shall be accurately and clearly marked with the centre of gravity, lifting points to ensure safe handling, during loading, off-loading, and truck transport operations. All Seller-supplied lifting devices shipped with major equipments, such as lifting beams, spreader bars, slings and lugs, as supplied, shall be certified by an officially recognized authority and acceptable to the authorities in loading and discharge ports including Project Site. Shipping cradles and supports for equipments shall be suitable for ocean transportation in design, strength, and capable to safely support.

Equipment shall be fitted with sufficient tie-down lugs for lashing /securing the pieces during shipment.

Supplier shall specify if the cargo is stackable and showable on vessel deck or under-deck

12.1.4 Overweight and Over dimensional items:

The suppliers shall provide Shipping drawing to the Buyer minimum of 3 months in advance of expected cargo release for all oversized cargo. It is understood this will be a preliminary document and not final.

The Shipping drawing must illustrate the cargo as it will be supplied for transportation, and include as a minimum: a. Weight, outer dimensions (L x W x H) & Dia of the equipment b. Center of gravity c. Lifting Lugs, sling blanket, lashing and/or jacking locations d. Size of Lugs e. Saddle material used (wood or steel) f. Saddle location g. Number of saddles used h. Methodology for saddle attachment i. Saddle width, height and weight (per saddle) j. Any specific transportation and lifting requirements and precautions.

12.1.5 Equipment Preparation for Overland Transportation:

Transportation saddles constructed for equipment are designed to provide support for the item until its final placement and installation. Therefore, it is necessary for these saddles to be designed and constructed of sufficient strength and attached securely to the equipment to withstand the stresses to be encountered during shipment from the Seller's plant to Project Construction Site. Supplier shall adhere to following:

Saddle specification subject to LTHE logistics approval. Number of saddles subject to LTHE logistics approval

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Supplier shall tie tarpaulin in a such a way that lifting/lashing point shall remain visible

CG Marking/location to be done above tarpaulin wherever applicable Supplier shall provide actual weight of the ODC cargo on packing list (

measured on load cell or on weighbridge or by crane indicator) 12.1.6 Palletization / Unitization:

Unitize, palletize, or assemble cargo to the largest practical unit consistent with handling, weight and dimension limitations at transshipment points and destination. Palletized materials should be capped and strapped, or shrink-wrapped to 4-way entry pallets. Material must fit the pallet without large voids and must be capable of withstanding stacking without damage to the materials. Any single piece which weighs in excess of 35 kilograms should be unitized for fork lift handling of loading and unloading. Clearance for fork lift tines should be no less than 8.9 centimeters. The Gross weight on pallets should not exceed 2 MT.

12.1.7 Vessel Selection criteria:

Shipper shall only use vessels that have been in service for less than 15 years, unless certified as seaworthy to satisfaction of the Marine Warranty Surveyor, and in no event should use vessels over 20 years in service. Shipper shall only use vessels that have been fully accredited in accordance with standards established by the International Conference Freight Forwarders (ICFF)/International Association of classification Societies (IACS).

All carrying vessels to be not less than 2000 DWT (dead weight tonnage) and should be in class Lloyds 100 A1 or equivalent.

12.1.8 Air Shipment

The supplier shall use internationally reputed Airlines for Contractor for airfreight of materials.

12.1.9 Shipping plan and Documents:

The supplier shall submit the estimated cargo readiness dates, mode of shipment, shipping plan 30 days in advance.

A full copy set of all required documents is to be sent to the Buyer/Logistics Engineer and the nominated Freight Forwarder a minimum of 7 days in advance of expected cargo release date. The shipping documents will be scrutinized and commented by Buyer/Logistics Coordinator for its suitability for Custom clearance in country of importation. Supplier should send back the commented documents incorporating the correction.

Supplier should also forward Digital Photographs indicating Shipping marks on packages and Labeling marks on items supplied showing Made in (insert country name). Suppliers must note that labeling marks on each item is compulsory for importation in to India. Scanned/Electronic copies of all final documents are to be provided by email to Buyer, Logistics Coordinator and Freight Forwarder prior to cargo collection.

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Separate instructions indicating the guidelines for preparation of shipping documents will be issued by Buyer/Logistics Coordinator.

13 DISPATCH DOSSIER:

Supplier are also requested to compile a dispatch dossier for ODC/OWC packages containing namely Statics, Rotary & package items.

A Dispatch Dossier will contain the following documents:

a) Transportation drawing; b) Shipping & Handling Instructions; c) Preservation Instructions; d) Weight Lifting Certificates; e) Final Inspection Report & Release Note.

Supplier shall courier one set of Dispatch Dossier to Project Site and it must be received at Site prior to arrival of materials at Project site. The scan copies of Dispatch Dossier documents are sent to Buyer/ Logistics Coordinator.

APPENDIX A

1.0 GENERAL PRESERVATION REQUIREMENTS

1.1 References to rust preventatives, indicator type desiccants and solvents are as defined in the attached Table 1, Recommended Rust Preventatives.

1.2 In general, application of rust preventatives to alloy and non-corrodible equipment and materials is not required; stainless steel items shall require special treatment to prevent stress corrosion, especially when exposed to a salty atmosphere.

1.3 Equipment subject to shop hydrostatic test shall be cleaned and dried (no water pockets) prior to application of rust preventatives and to closing openings.

1.4 All internal surfaces and internal components of mechanical equipment including cases, bearings, gears, mechanical seals and threaded connections, not adversely affected by rust preventatives, shall be type A coated.

1.5 All external machine-finish surfaces, such as flange facings, valve stems, shafts, shaft couplings, shall be type-C coated.

1.6 External machine-finish surfaces, for which a hard durable coating is required, shall be type-B coated.

1.7 All flanged openings of mechanical equipment, vessels, 6 in. and larger valves 8 in. and larger control and relief valves shall have heat and water-tight closures; these shall take the form of gasket metal closures. Wooden closures shall be metal cross-braced and securely bolted or clamped on. The cover and gasket size shall match the flange outside diameter (OD). Gaskets shall be 1/8-in.- minimum, thick red rubber or neoprene. The cover thickness and bolt ing size and number of bolts used shall be such that the cover

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effectively seals the flanged opening. The use of plastic snap-on covers is acceptable on 4-in. and smaller openings except for equipment which will be air or nitrogen pressurized during shipment and storage.

1.8 All threaded connections such as vents, drains, conduit and piping connections shall be capped or plugged with metal or plastic materials after application of type A rust preventative.

1.9 Penetrations of rotating or reciprocating parts through equipment case shall be sealed with oil/waterproof tape. Exposed finished surfaces such as shafts, which are to mate with other equipment during job site assembly, shall be additionally protected with wood, plastic or soft metal.

1.10 All engaged and exposed threads, especially those used for flange protection, shall be coated with a grease-based rust preventative, type C. The rust preventative shall be replaced after each loosening bolt-up to ensure adequate protection.

1.11 A list of the specific rust preventatives used to protect the equipment shall be securely attached to or enclosed in the shipping unit. This list, additional to the Equipment designation tag, shall include internal as well as external rust preventatives, giving the approved manufacturer and type number and the locations where each has been applied.

1.12 Included in the above list shall be any special instructions deemed necessary by the Approved Manufacturer for the removal or replacement of any rust preventatives, together with any special precautions to be taken in the care of its equipment during the period of storage

1.13 A copy of this total instruction package shall be provided to the purchaser Company under separate cover for Site records and scan copy to Buyer.

2.0 SPECIFIC PROTECTION REQUIREMENTS

2.1 Mechanical Equipment 2.1.1 Centrifugal pumps, reciprocating pumps, gears, auxiliary oilers, rotary

compressors, blowers and similar equipment: coat internal parts and surfaces including case bearings and packing or mechanical seal housing, by spraying or circulating type A fluid through the enclosures; rotate equipment to ensure coating of all parts and drain. Cover shaft-mounted coupling with plastic film sealed to shaft with oil/waterproof tape.

2.1.2 Internal combustion Engines

a. Final shop running of engines shall be with preservative oil in the crank- case and corrosion inhibitor in the cooling circuit; drain oil, water and fuel prior to shipment, labels shall be fitted indicating the fluid status of the engine i.e. without oil, water, fuel.

b. Injectors and electrical accessories such as magnetos which are subject to moisture damage shall be removed from the engine and hermetically packaged separately with desiccant or VPI.

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c. A small amount of type A fluid shall be injected into each cylinder; seal openings with type-A-coated threaded metal plugs or spark plugs.

d. Engine intake, injector ports and exhaust openings shall be sealed with plastic plugs and waterproof tape. Alternator/generator and electric starter shall be enclosed and sealed in polythene bags.

2.1.3 Air-Cooled Heat Exchanger

a. Requirements for motor bearings, shafts, sheaves, hubs, gear, electrical and flanged or threaded openings are covered elsewhere in this Standard and shall be adhered to especially to ensure that moisture does not creep into the motor via the drive shaft.

b. Tube bundles, plain and finned, shall be crated with special care taken to provide protection to fins from physical damage. Fan blades shall be crated with suitable blocking and bracing and with type C coating on finished parts. Fan drive belts shall be sealed in a closed container. Hardware (nuts, bolts, lock washers) shall be protected with rust preventative type C and shall be shipped in waterproof containers.

c. Brushes if installed, shall be lifted of slip rings and commutator.

2.1.4 Interior surface protection for pressure vessels and heat exchangers is not required unless otherwise noted in the material requisition.

Flange facing of tanks shall be type C coated and protected. Bottom drain connection shall be left open so water does not accumulate in the tank.

2.1.5 Piping and Fittings

a. Bracing, blocking, separators and wood, soft metal or plastic caps shall be provided to protect valves and fittings, external pipe threads, flange facings, ends prepared for welding and other external machine finished surfaces.

b. Valves with operators, bypass piping, limit switches and similar fittings shall be carefully packed and braced to eliminate damage during shipment.

c. Valves shall be shipped with wedge, etc., lightly seated to prevent entry of dirt into the bonnet and to reduce exposed length of stem.

d. All ring grooves shall be thoroughly cleaned and rust preventative type B or C applied before attaching flange cover.

e. Straight-run and fabricated piping shipping bundles or crates shall be limited preferably to 4 tonnes.

f. Straight-run pipe shall be bundled and secured to minimum height supports spaced at 5-m maximum intervals. The end of the bundle shall be boxed to provide bundle bracing and to protect pipe ends. Shop- primed galvanized or other coated straight-run pipe bundles shall be wood

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stripped both ways to provide about 6-mm clearance between pipes to prevent abrasion of the pipe coating. The bundle shall be stripped at a section near each end of the bundle at 5-m maximum intervals.

g. All openings in pipe spools shall be securely closed and flange faces and threaded connections protected with suitable plugs, flange covers and thread protectors. Small branches and flimsy parts shall be adequately braced or otherwise protected to prevent damage in handling, shipping and storage.

h. Ring joint flanges shall have the gasket groove cleaned of all scale, rust and dirt, then coated with rust preventative prior to attaching the flange cover.

i. Finished pipe ends such as bevel-f or-weld and grooved-for-couplings shall be finished with wood, plastic or soft-metal cover if method of bundling or crating does not provide natural protection. Threaded pipe shall be coated with rust preventative and shipped with couplings.

2.1.6 Electrical Equipment

a. Ventilation openings of waterproof and drip-proof motor enclosures shall be sealed with a plastic film cover and waterproof tape.

b. Motors shall be enclosed in a sealed plastic bag containing a desiccant charge with at least a 6 months' rechargeable life. The enclosed motors shall then be individually cased. The requirements for the protection and packing of transformers, switchgear, starters, control equipment, cabling, and other electrical materials are covered by the individual equipment specifications.

2.1.7 Instrumentation Equipment

Equipment shall be packed in shipping crates or cartons that shall be dust tight, moisture resistant and substantial enough to withstand the selected means of transport, warehouse and site handling and to prevent damage to the equipment. The instrument internals shall be further protected by a container of silica gel inside the instrument case.

Table 1 : Recommended Rust Preventatives

Type A (Oil) (Lube Oil Base)

B (Hard Film) (Asphalt Base)

C (Soft Film) (Grease Base)

Typical Use Interior surface of mechanical equipment, e.g., bearings, cylinders etc.

Exposed machined surfaces, e.g., flange face, etc.

Where removal is difficult or a lubrication on services is required.

Enjay (Humble)

Rust-Ban 339 Rust-Ban 373 Rust-Ban 394

Shell Ensis Engine Oil 30 Ensis 264 Ensis 210

of 25

Mobil Mobilarma 524 Mobilarma 633 Mobilarma 247

Texaco Preservative Oil 30 Texacoat Rustproof Compound H

Valvoline Tectyl 876 Tectyl 890 Tectyl 858

BP Energol Protective Oil 30 Energol CPD 33 or CPF 11

Energrease PR2 or CPC 41

Desiccants Desiccants for moisture absorption shall be regenerable, non-corrosive and colour indicator type to show loss of activity.

Solvents Only aliphatic petroleum naphtha or pure turpentine shall be used for cleaning surfaces.

If the rust preventatives in the above table are no longer available, vendors shall propose their

standard rust preventative coating. The specification of such coatings shall be issued for

approval 6 weeks prior to shipment.

APPENDIX – B

EQUIPMENT STORAGE CODE

xxxx Air-

Conditioned Warehouse

xxx Closed

Warehouse

xx Open Shed

x Open Air

STRUCTURAL STEEL - Panels, Beams, Columns, Grating X - Bolting X EQUIPMENT - Towers, Vessels, Heat Exchanger, Air Coolers, Boilers X

- Pumps, Compressors, Blowers, Fans, Mixers X - Tower and Vessel Internals. X - Bolting and special small items X - Packing Units. X PIPING - Flanges, Fittings 6" and smaller than 6" X - Valves 4" and smaller than 4" X - Pipe and remaining valves, Fittings and Flanges X - Gasket and Bolting X - Welding Rods X INSTRUMENTATION - Cable Tray and supports X - Control Room Panels, Racks, Cabinets & associated instrument X

- All other items X ELECTRICAL - Cable Reels, Conduits and Cables X - Electrical Motors designed for outside service X

of 25

- Electrical Motors designed for inside service X - Supporting Steel, Stanchion, Saddles, etc. X X - All other Materials - Lightning Equipment X

- All Other Materials X - U.P.S. Batteries X - Transformers X - Panel Boards, Racks, Cabinets and Associated Electrical Material X

REFRACTORY LINING - Refractory Liquid, Mortar, Castables Mixers, Ceramic Fibers, Expanded Polystyrene, Paper Adhesive Coating Paints.

X

- Dense Fire Bricks, Steel Parts, Insulating Fire Bricks and Blocks. X

INSULATION - Ceramic Fiber & Calcium Silicate Materials, Metal Sheeting X

- Mineral Wool Blankets, Supporting Rings, Fasteners, Banking X

PAINTING, THINNERS, etc. - All Material X FURNACE / REFORMERS

- Steel Panels, Beams, Columns, Stack X - Catalyst Tubes and Radiant Coils, Convection Coils, Peep Holes, Access Doors.

X

- Springs, Bolting and other Miscellaneous small items

X

- Sealing Mastics (as per VENDOR’s Recommendations) X

CIVIL - Anchor Bolts X - Reinforcing Steel X - Cement (in Bags), Bricks X CHEMICALS & CATALYST - Catalysts, Alumina Ball, Molecular Sieves X

SPECIFICATION FOR STANDARD SPECIFICATION NO. ENGINEERS ELECTRICAL MOTOR OPERATED INDIA LIMITED 6-51-0091 Rev. 5 (A Govt of Incha Undettang) VALVE ACTUATORS Page 1 of 10

t311 Igar

fa 5011(14) qltrcl ict•Wct

fffR fgribT

SPECIFICATION FOR

ELECTRICAL MOTOR OPERATED VALVE ACTUATORS

5 30-03-19

4 25-03-14

3 27-08-07

2 16-09-02

1 03-04-97

REVISED AND ISSUED SPECIFICATION REVISED AND ISSUED SPECIFICATION REVISED AND ISSUED SPECIFICATION REVISED AND ISSUED SPECIFICATION REVISED AND ISSUED SPECIFICATION

AS STANDARD

AS STANDARD

AS STANDARD

AS STANDARD

AS STANDARD

KS KS BRB RKT

RG MKS BRB SC

AM SKG JMS VC

VCB JMS VPS SKG

RKM VPS SG A.SONI


Prepared by

Checked by

Standards Standards Committee Bureau Convenor Chairman

Approved by


Page 13102 of 14785

ENGINEERS SPECIFICATION FOR INDIA LIMITED ELECTRICAL MOTOR OPERATED

VALVE ACTUATORS Ogeir fai5leg

laaVIMeetedn.FKM


6-51-0091 Rev. 5 Page 2 of 10

(A GoN of Incka Undertaking)

Abbreviations:

CEA CIMFR DGMS FM IEC LCIE MOV PESO PVC UL

Central Electricity Authority Central Institute of Mines & Fuel Research Director General of Mines & Safety Factory Mutual Research Corporation International Electro technical Commission Laboratoire Central des Industries Electriques Motor operated valve Petroleum and Explosives Safety Organisation Poly Vinyl Chloride Underwriters Laboratory


Convener: Members:

Mr. B.R. Bhogal Ms. S. Anand

Mr. Parag Gupta

Mr. M. K. Sahu

Ms. N S Bhattacharya Mr. Saeed Akhtar (Inspection) Ms. N.P. Guha (Projects)



Page 13103 of 14785

ENGINEERS SPECIFICATION FOR INDIA LIMITED ELECTRICAL MOTOR OPERATED IA Govt Nmdta Undertak.9) VALVE ACTUATORS


it5leg (NWT 2922111P =JANA)

6-51-0091 Rev. 5 Page 3 of 10

CONTENTS

1.0 SCOPE 4

2.0 CODES AND STANDARDS 4


4.0 SITE CONDITIONS 4

5.0 POWER SUPPLY 5

6.0 TECHNICAL SPECIFICATIONS 5

7.0 EQUIPMENT FOR CLASSIFIED HAZARDOUS AREAS 8

8.0 FIREPROOFING 9

9.0 INSPECTION, TESTING AND ACCEPTANCE 9




Page 13104 of 14785

ENGINEERS SPECIFICATION FOR INDIA LIMITED ELECTRICAL MOTOR OPERATED (A Govl of InOla Undeltalfong) VALVE ACTUATORS


lfgari815ieg (4.312ri ei20,42 ,01.1.R.1)

6-51-0091 Rev. 5 Page 4 of 10

1.0 SCOPE

The scope of this specification covers design, manufacture, assembly, shop testing and supply of electrical motor operated valve actuators intended for fully/ partially opening and closing valve duty with inching facility.


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

IS 5

IS 12615

IS/IEC 60034-1

IS/IEC 60529

IS/IEC 60079

Colours for ready mixed paints and enamels

`Line Operated Three Phase a.c. Motors (IE CODE)- Efficiency Classes and Performance Specification

Rotating electrical machines- Rating & Performance

Degrees of protection provided by enclosure for rotating electrical Machinery

Electrical apparatus for explosive gas atmospheres

EN 15714-2/IS 9334 Electric Motor Operated Actuators for Industrial valves

IS/IEC 60947 Low Voltage Switchgear and Controlgear (Parts-1, 3, 4 & 5)

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

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

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

2.5 In case of any contradiction between various referred standards/ specifications/ data sheets and statutory regulations, the most stringent requirement shall govern and decision of Owner in this regard shall be final and binding.


3.1 The offered equipment shall be brand new with state of the art technology having a proven field track record. No prototype equipment shall be offered.

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

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

3.4 The vendor shall be responsible for design, engineering and manufacturing of the complete actuator to fully meet the intent and requirements of this specification and attached data sheets.

4.0 SITE CONDITIONS

The electrical motor operated valve actuators shall be suitable for operating under site conditions as specified in the requisition and data sheet. If not specifically mentioned therein,


Page 13105 of 14785

011 Ogg

(1WM 29R131F 4151.1,10.1)

ENGINEERS INDIA LIMITED (A Govt d indo Undertaking)


VALVE ACTUATORS


6-51-0091 Rev. 5 Page 5 of 10

a design ambient temperature of 40°C and an altitude not exceeding 1000m above mean sea level shall be considered.

5.0 POWER SUPPLY

The electrical motor operated valve actuators shall be suitable for power supply at 415V ± 10%, 50 Hz ± 3%, 3 phase, unless specified otherwise in the data sheet.

6.0 TECHNICAL SPECIFICATIONS

Each MOV actuator shall include the motor, actuator unit, gears, position indicators, limit switches, handwheel, electrical starter and controls, terminal box etc. as a self-contained unit. The actuator shall be sized to provide adequate torque and/ or thrust to ensure the complete intended travel of the valve under the worst operating and electrical power supply conditions.

6.1 Motor

6.1.1 The motor shall be 3-phase squirrel cage induction type unless specified otherwise in the data sheet. It shall have totally enclosed non-ventilated and surface cooled construction.

6.1.2 The motor shall be designed for valve actuator service with high starting torque and shall be suitable for Direct on line starting. It shall be rated for S2-15 minute duty and shall conform to IS 60034-1 or equivalent international standards.

6.1.3 The actuator assembly shall be provided with Thermostat(s)/thermistor(s) embedded in it to achieve protection of motor against over-temperature.

6.1.4 The motor shall be suitable for starting under required torque with 75% of rated voltage at motor terminals.

6.1.5 The motor shall have class 'F' insulation with temperature rise limited to class 'B' limits. Motor winding shall be treated to resist corrosive agents and moisture.

6.1.6 Motor rotor shall preferably be of die-cast aluminium and, if brazed, shall be free from phosphorous.

6.1.7 Motor installed in actuator shall be rated for minimum of 60 starts/stop per hour. This is minimum requirement of actuator envisaged for ON-OFF duty only.

6.1.8 Anti-condensation heater shall be provided for all the MOV actuators. Power supply for the Anti-condensation heater shall be derived by vendor from incoming supply mentioned at cl. No. 5.0.

6.2 Integral Starter and Control Transformer

The reversing starter, control transformer and local controls shall be integral with the valve actuator, unless specified otherwise in the data sheet. Solid state control of valve actuator and electrically isolated interface for remote control requirement shall be provided, wherever these features exist in manufacturer's design.

The integral starter shall be supplied with the following devices:

a) Electrically and mechanically interlocked reversing contactors for opening and closing operations

b) Control transformer with necessary tapping and protected with suitable easily replaceable fuses


Page 13106 of 14785

,31ta ENGINEERS SPECIFICATION FOR ELECTRICAL MOTOR OPERATED

VALVE ACTUATORS


6-51-0091 Rev. 5 Page 6 of 10

Ogur 251eg 1.2A eiieWAAJATAA)

INDIA LIMITED IA Govt of Abu UndertakM

c) Terminal block for external cable connection fully prewired for internal devices of valve actuator.

d) MOV Actuators operating with AC power supply shall be provided with automatic phase correction feature.

6.3 Integral Push Button, Selector switches, Indications and Control devices

The following local control devices shall be provided integral with the MOV actuator:

a) Push buttons for 'Opening/ Closing/ Stop' or alternatively 'Open/ Close' selector switch

b) 'Local/ Off/ Remote' selector switch, pad-lockable in each position c) Local continuous position indication from 'Valve fully open' to 'Valve fully closed'

position, which may be of analogue or digital type using mechanical indication/ Indicating lamps/ LEDs.

6.4 Torque and Travel Limit Switches

Torque limit switches shall be provided to protect the motor from over-loading by cutting-off the power supply to motor during opening and closing operations. The limit switches shall be preset. However, it shall be possible to set the value of maximum torque during closing from 50% to 100% of rated torque of actuators. Travel limit switch shall be provided to cut-off the power supply to the motor at the end of preset limit of valve travel. The switches shall be provided with requisite number of potential-free contacts for valve actuator operation and for indication on remote panels as specified in data sheet. Instead of mechanical torque limit switches, magnetic pulse counter/encoders to measure and control the stroke of actuator may be provided, wherever this feature exists in manufacturer's design.

6.5 Control Facilities

The internal controls and monitoring circuits shall be incorporated within the integral starter along with transformer and control unit of valve actuator.

Remote control facility shall be provided as a standard feature. The remote control circuits shall be powered from internally derived control supply voltage. Common status contact indicating the availability of the MOV actuator for remote control shall be provided by monitoring the following:

Loss of one or more phases of power supply Loss of control circuit supply Selector switch in local mode Local stop push button set to 'Off Motor thermostat tripped Any other local fault/ abnormal condition.

Where applicable, one number hand-held infrared/blue tooth remote programming device required for site commissioning and reconfiguring (without the need of removal of the MOV cover) shall be supplied for each group of 10 valve actuators (subject to minimum one infrared/ Bluetooth remote setting device, even if number of valve actuators are less than ten).

6.6 Interface with Owner's PLC/DCS / REMOTE PUSH BUTTON STATION

Potential free contacts for the following shall be provided in actuator assembly for hardwire interface with Owner's DCS/PLC and/or Remote Push Button station:-

a) Run indication



Page 13107 of 14785

ENGINEERS SPECIFICATION FOR *12 ezr INDIA LIMITED ELECTRICAL MOTOR OPERATED

(A Govt Inda Um/A/taking) VALVE ACTUATORS


6-51-0091 Rev. 5 Page 7 of 10

0.11F71 2120312 ‘61 .FP:Fil

b) Trip indication — 2 Nos. c) Open status — 2 Nos. d) Close status — 2 Nos. e) Ready to start indication f) Torque high indication g) Thermostat status h) Open command — 2 Nos. i) Close command — 2 Nos. j) Local/Remote

In the event of voltage dips/ power outage, status of MOVs (OPEN/ CLOSE indication) for remote annunciation shall not undergo any change. The wiring for all MOVs feedback controls shall be fail safe type. Any backup for power supply & hardware required for achieving the same shall be provided by vendor within the actuator. Owner shall not provide any power supply other than 415V±10%, three phase, 50Hz±3% incoming supply to each of MOV Actuator".

6.7 Hand Operation

A hand wheel with hand/ auto lockable lever shall be provided for emergency operation of the MOV. The energisation of the motor shall automatically re-engage power operation.

6.8 Two-Wire Control system

Where specified in the data sheet, the MOV actuators shall be suitable for 2-wire control system working on protocol as specified in the MR. These actuators shall have individual field units connectable to a master station through a single 2-core cable on line topology for control and monitoring of the MOVs. The vendor shall indicate the maximum number of field units that can be connected to a master station / PLC /DCS and the maximum distance from the field unit to the master station /PLC /DCS. The vendor shall also indicate maximum number of control inputs and control/ status outputs from each field unit that can be handled through the 2-wire control system.

Each field unit/ MOV actuator shall be addressable from the master station through a unique address code. All the field settable/ adjustable parameters of the MOV actuator shall be settable from the master station. Similarly all the indications available on the MOV actuator shall be available at the master station. Full diagnostic features for the MOV actuators shall be available on the actuator as well as on the Master station through a LCD / screen display.

Suitable redundancy feature shall be provided, such that in case of a single fault at any location in the cable, the field unit continues to communicate with the master station. The master station shall be suitable for hook-up with the plant DCS system.

6.9 Digital Control System

If specified in data sheet, electric actuator shall be provided with an integrally mounted device providing digital connectivity with Owner's PLC/DCS for actuator control, status indication & monitoring. In this case, master station is not required any more. The control device shall meet the appropriate recognized protocol or BUS standards. Selection of protocol shall be as per data sheet only. Typical protocol/buses include:-

- Modbus RTU - Profibus DP - Device Net - Foundation FieldBus



Page 13108 of 14785

(= ENGINEERS INDIA LIMI I ED


VALVE ACTUATORS


6-51-0091 Rev. 5 Page 8 of 10

,/lfZk_JeY Of5ieg

(awinT ?Vase all,Artano (A &AA a Incka Undertaking)

Terminal for hardwired communication shall also be provided in addition to digital communication facility.

6.10 Remote Position Indicator

If requirement of remote position indication is specified in the data sheet, a 4-20 mA remote position transmitter shall be provided in the valve actuator which can be connected to user's PLC / DCS. The remote position indicator shall continuously indicate the position of travel of the valve.

6.11 Nameplate

Each motorized valve actuator shall be provided with a stainless steel nameplate furnishing the following details, at a place convenient for reading: The nameplates shall be riveted/ fixed with screws and not pasted.

a) Actuator tag number as per data sheet b) Motor kW rating, motor short time rating, motor supply voltage, nominal motor phase

current, auxiliary switch rating c) Maximum torque setting d) Actuator enclosure type, lubricant type e) Actuator type, wiring diagram number/ catalogue number, actuator serial number. f) Wherever applicable, Hazardous area certification details which shall include details

of the testing agency (CIMFR or equivalent), test certificate number with date, statutory approval number with date, approval agency (PESO / DGMS), BIS license number with date, applicable Gas group and Temperature class etc.

6.12 The enclosure of complete MOV actuator including motor, integral starter, control transformer unit and all control devices shall have minimum IP-67 degree of protection which shall include the '0' ring for complete environmental protection.

6.13 Wiring and Terminals

All devices provided in the actuator shall be wired up to the terminal block. The contacts for remote operation and indication shall also be wired up to the terminal block. Minimum 10% spare terminals shall be provided for future interlocks. Internal wiring for power and control circuits shall be appropriately sized for MOV actuator rating. Each wire shall be identified at both ends using PVC ferrules. The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal so that the actuator electrical components are protected from the ingress of moisture and foreign materials when the terminal cover is removed during installation and maintenance.

6.14 The actuator shall be provided with minimum five adequately sized cable entries viz., one for power cable and two for control cables. However, the actual number of control cable entries in actuators with 2-wire control system shall be provided based on job requirements as specified in data sheets/specification for control systems for MOVs. Suitable double compression cable glands shall be provided with each actuator for all cable entries and sealing plugs for all control cable entries. The cable glands and plugs shall be made of Nickel-plated brass. Plastic plugs shall not be acceptable. Cable sizes shall be informed during detailed engg and actuator shall be provided with suitable arrangement for termination these sizes.

7.0 EQUIPMENT FOR CLASSIFIED HAZARDOUS AREAS

7.1 Actuators meant for hazardous areas shall meet the requirements of IS/IEC 60079 or equivalent international standards and shall be suitable for Gas groups and Temperature class as specified in the data sheet. Gas group IIB and Temperature class T3 (200°C) shall be



Page 13109 of 14785

ENGINEERS SPECIFICATION FOR

INDIA LIMITED ELECTRICAL MOTOR OPERATED IA Govt of Mu Undertaking, VALVE ACTUATORS


6-51-0091 Rev. 5 Page 9 of 10

/gal f&ti5teg 1.1e1 e922612 03,3,71:643)

considered if not indicated in data sheet. The manufacturer shall possess valid test certificates issued by a recognized independent test house (CIMFR/ Baseefa/ LCIE/ UL/ FM or equivalent) for the offered actuators. All indigenous equipment shall conform to Indian standards and shall have been tested and certified by Indian testing agencies. All equipment (indigenous and imported) shall also have valid statutory approvals as applicable for the specified hazardous locations from Petroleum and Explosives Safety Organisation (PESO / DGMS) or any other applicable statutory authority. All indigenous flameproof equipment shall have valid BIS license and corresponding marking as required by statutory authorities.

8.0 FIREPROOFING

8.1 Electric actuators shall be provided with fire proofing if specified in data sheet. The fire proofing shall be rated for 30 minutes. Unless otherwise specified in the datasheet, fire proofing shall be provided by Intumescent paint only (K- Mass/ERS/equivalent). The required certificates for the fireproof rating shall be furnished from an independent test laboratory.

8.2 MOV Actuators with fireproofing shall be suitable for termination of mica insulated fire survival type power and control cables.

9.0 INSPECTION, TESTING AND ACCEPTANCE

9.1 The equipment shall be subject to inspection by EIL/ Owner or by an agency authorized by the owner. Manufacturer shall furnish all necessary information concerning the supply to EIL/ Owner's inspector. During the course of manufacturing, the purchaser or his authorized representative shall be free to visit the works and assess the progress of work and the manufacturer shall render him all possible assistance to do so.

9.2 Following routine tests shall be carried out at the manufacturers' works under his supervision and at his own cost for all the actuators:-

9.2.1 Functional and calibration test for torque and limit switches

9.2.2 Response time test

9.2.3 Variation of supply voltage

9.2.4 Variation of frequency

9.2.5 Test on output shaft at 100% torque

9.2.6 Tests for motor(As per relevant IS/IEC)

9.3 Following type test certificates of offered model of actuator shall be submitted for review & approval:-

9.3.1 Life test

9.3.2 Test on motor terminal box

9.3.3 Damp heat recycling test

Two weeks' notice shall be given to Owner / EIL for witnessing the final testing of the complete assembly to ensure satisfactory operation of the MOV actuators. Type test certificates shall be furnished during detailed engineering. Final acceptance of MOVs at site shall be subject to successful testing of the MOV actuators with the valves.



Page 13110 of 14785

ENGINEERS SPECIFICATION FOR INDIA LIMITED ELECTRICAL MOTOR OPERATED (A Govt 04 !Wu Unclettaktngi VALVE ACTUATORS


fge.st es eTPERZ c131.14040

i=j 6-51-0091 Rev. 5 Page 10 of 10

9.4 Type test certificates, original drawings referred in certificates and statutory approval certificates and BIS license, where applicable, shall be shown to the inspection agency on demand. The certificates and BIS license must be valid at the time of dispatch.

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


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

The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed. In order to prevent movement of equipment/ components within the crates, proper packing supports shall be provided. A set of instruction manuals for erection, testing and commissioning, a set of operation and maintenance manuals and a set of final drawings shall be enclosed in a waterproof cover and supplied along with the shipment.


Page 13111 of 14785

–

JOB SPECIFICATIONS (INSTRUMENTATION)

FOR

HPCL RAJASTHAN REFINERY LIMITED

RAJASTHAN REFINERY PROJECT AT

PACHPADRA, RAJASTHAN, INDIA

BIDDING DOCUMENT FOR

EPCC – 03 PACKAGE

(TENDER NO. – B224-111-86-41-PM-T-7203)

–

’s process

–

link to Purchaser’s DCS.

in Owner’s DCS / PLC. Contractor shall review DCS / PLC vendor’s drawings & documents pertaining to

this tender which are prepared based on contractor’s engineering

–

–

Owner’s instructions) ##

–

MCC and Purchaser’s

–

from Machine Monitoring System to purchaser’s

interface to purchaser’s DCS vendor for

/ owner’s prior approval.

–

intrinsically safe type for 24V DC ( 700 M cable

.

–

–

–

Pressure relief valve type shall be contractor’s

90% of Set pressure

–

–

” TFT with backlit LED

–

purchaser’s DCS

purchaser’s

package PLC to purchaser’s DCS

serial link at site with purchaser’s DCS is contractor’s responsibility. Sein contractor’s scope.

shutdown & normal operation for purchaser’s

–

e control systems to purchaser’s

this interface to purchaser’s DCS

(22” –

protection to purchaser’s DCS through Modbus RTU

–

interface to purchaser’s DCS vendor for configuring

IS PC (minimum 15” size) can be used for local

–

vided by contractor as per contractor’s requirement

All these feeders for owner’s equipments shall be provided from UPS ACDB.

–

Generally ½” NPTF for signal, ¾” NPTF for power, 1” NPTF for 6 pair

cable, 1.5” NPTF for 12 pair.

explosion proof (EEx‘d’). Number of fieldbus

–

FFJB shall have a label mentioning “No switching off

permission”.

–

minimum size of ¾”

–

for owner’s review.

–

.

–

–

Purchaser’s

–

–

along with PTR for owner’s approval.

manufacturer’s specialists. Contractor to make specialist’s services available.

–

submission for PMC’s approval for each item. The

–

Contractor’s authorized representatives, Third Party

Contractor’s participation in Owner’s DCS/ PLC

Contractor’s full participation required (for proper

’s

Contractor’s full participation is required in process

vendor’s workshop.

–

At manufacturer’s w

manufacturer’s/ supplier’s

–

–

CONTRACTOR shall propose 3 year’s post warranty

scope of work, and Vendor’s responsibility with year

–

(To be signed by Principal’s corporate level signatory on company’s letterhead)

(To be signed by Vendor’s corporate level signatory on company’s letterhead)

ENGINEER INDIA LIMI

STED FOR VALVES

(A Govt of India Undertaking)


6-44-0052 Rev. 7 Page 1 of 12

TECHNICAL NOTES fg0j1 fetWeg


01/4 ‘)t.144<-1 MI RN

RN ATD SC DM ND

RN SC DM VC

RN BRB NS MI

AKG NS GRR AS

Prepared by

Checked by


Standards Bureau

Chairman

7 13.07.17

6 04.08.10

5 04.07.08

4 15.11.00

3 04.04.94

REVISED AND ISSUED AS STANDARD SPECIFICATION REVISED AND ISSUED AS STANDARD SPECIFICATION REVISED AND ISSUED AS STANDARD SPECIFICATION REVISED AND ISSUED AS STANDARD SPECIFICATION

ISSUED IN LINE WITH GENERAL REVISION

Rev. No

Date Purpose

Approved by

vilcni rduAluiii*

TECHNICAL NOTES FOR VALVES

Page 10765 of 14785


6-44-0052 Rev.7 Page 2 of 12


ENGINEERS taleg INDIA LIMITED

ailErf t-recnr11513‘grai (A Govt of India Undertaking)

Abbreviations:

AARH : Arithmetic Average Roughness Height ANSI American National Standards Institute API American Petroleum Institute ASME : American Society of Mechanical Engineers ASTM : American Society for Testing & Materials BGO Bevel Gear Operator BHN Brinnel Hardness Number BIS Bureau of Indian Standards BS • British Standard BVIS ▪ Bureau Veritas Industrial Services BW • Butt Weld CAT • Category CEIL • Certification Engineers International Limited CS Carbon Steel DFT Dry Film Thickness DNV Det Norske Veritas DP Dye-Penetrant eDMS : Electronic Document Management System IBR Indian Boiler Regulations IGC Inter Granular Corrosion IS Indian Standard LT • Low Temperature LTCS • Low Temperature Carbon Steel MOV • Motor Operated Valve MP • Magnetic Particle MR • Material Requisition NDT • Non Destructive Testing PMI • Positive Material Identification PO Purchase Order PR Purchase Requisition RFQ Request for Quotation SCRD : Screwed SS Stainless Steel SW Socket Weld

Piping Standards Committee

Convenor : Mr M. Ismaeel

Members : Mr. Amrendra Kumar Mr. G. Balaji Mr. Udayan Chakravarty Mr. K.J. Harinarayanan (S&ME) Mr. S. Ghoshal (Process-2) Mr. G.K. Iyer (Projects) Mr. Pankaj Kumar Rai (Construction)

Copyright EIL - All rights reserved Format No. 8-00-0001-F1 Rev. 0

Page 10766 of 14785

1f lots ENGINEERS TECHNICAL NOTES Igar 0151-e-G INDIA LIMITED FOR VALVES

tole,r rievore tri.ltrovn)


6-44-0052 Rev.7 Page 3 of 12

(A Govt of India Undertaking)

CONTENTS

1.0 GENERAL 4

2.0 DOCUMENTATION 4

3.0 DESIGN AND CONSTRUCTION 5

4.0 OPERATION 9

5.0 INSPECTION AND TESTING 9

6.0 RADIOGRAPHY OF CAST VALVES 10

7.0 IBR CERTIFICATION 11

8.0 MARKING 11

9.0 DESPATCH 11

10.0 ATTACHMENTS 12

11.0 REFERENCES 12



Page 10767 of 14785

LIIdel ENGINEERS TECHNICAL NOTES $1gziT tif4leg INDIA LIMITED FOR VALVES

IA Govt of India Undertaking)


6-44-0052 Rev.7 Page 4 of 12

MIRFC eleax, 45134115-41)

1.0 GENERAL

1.1

Vendor shall supply valves in accordance with the valve specification sheets along with auxiliaries, if any, such as gear operator, bypasses, drains, locking arrangements etc. wherever specified in the specification sheets, subject notes and other enclosures to the material requisition (MR).

1.2 Vendor shall quote in strict accordance with the valve data / specification sheets, subject technical notes and all other enclosures to the MR. For 'Cat-I valves', no deviations whatsoever shall be accepted. Post Order Waiver/ Deviation format 5-0000-0180-F1 as mentioned in Cl. 5.17 of specification for Quality Management System Requirements from Bidder (6-78-0001) is not applicable for Cat-I valves. For Cat-II Valves, if exceptions/ deviations become absolutely must, the same shall be requested as explained in clause 2.3.6 giving reasons for seeking such exceptions/ deviations.

1.3 All codes and standards for manufacture, testing, inspection etc. shall be of latest editions as on issue date of RFQ.

2.0 DOCUMENTATION

2.1 All document submissions to EIL shall be through EIL eDMS.

2.2 For 'Cat-I' valves, no documents shall be submitted with the offer.

2.3 For 'Cat-IF valves, vendor shall submit the following documents with the offer:

2.3.1 Manufacturer's complete descriptive and illustrative catalogue / literature.

2.3.2 Detailed dimensioned cross section drawing with parts / material lists, weight etc.

2.3.3 Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator, motor, extension bonnet, extended stems with stands, bypass etc. giving major salient dimensions.

2.3.4 One copy of the valve specification sheets signed as "Accepted" by the manufacturer. Deviations, if any shall be marked as applicable on the valve specification sheet.

2.3.5 If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve specification sheets as "Regret" or "No Deviation".

2.3.6 For 'CAT-II' valves, if there is any deviation, the same shall be listed clausewise.

2.3.7 On failure to submit documents as specified in clauses 2.1.1 to 2.1.6 above, the offer is likely to be rejected.

2.4 The following documents shall be submitted through eDMS of EIL after placement of the order:

2.4.1 For Cat-I valves to manufacturers' standard specified in MR/valve specification sheet, detailed dimensioned cross section drawing with parts, materials, weight, etc. shall be submitted for records/information.


Page 10768 of 14785

laffaad ENGINEERS TECHNICAL NOTES $/fg-ar

kites INDIA LIMITED FOR VALVES (A Govt of India undertaking)


6-44-0052 Rev.7 Page 5 of 12

(Merl e4tax,...13,63.0

2.4.2 For 'Cat-II' valves, Vendor shall submit for review drawings mentioned in clauses 2.1.2 & 2.1.3 before start of manufacture. No other drawings shall be submitted for review.

2.4.3 Test report shall be supplied for all mandatory tests as per the applicable code. Test reports shall also be furnished for any supplementary tests as specified in clauses 3.13, 3.14 & 3.15.

2.4.4 Material test certificates (physical properties, chemical composition & heat treatment report) of the pressure containing parts shall be furnished for the valves supplied. Material test certificates for the other parts shall also be furnished for verification during inspection.

2.5 In addition to submissions through EIL eDMS, Catalogues/Drawings shall be in submitted in hard copies (6 sets) and soft copies (2 CDs/DVDs) along with delivery for Purchaser's record for all categories/types of valves.

3.0 DESIGN AND CONSTRUCTION

3.1 Valve shall be designed, manufactured, tested, inspected and marked as per the manufacturing standards, design codes and standards indicated in the respective valve specification sheets. Any conflict between the requisition, enclosures, specification sheets and referred standards/ codes shall be brought to the notice of the purchaser for clarifications and resolution, before proceeding with the manufacture. The purchaser's decision shall be final and binding to the vendor. The drawings submitted for review shall not include any deviations except as communicated in writing in Deviation permits. The Drawings shall be reviewed only for design and construction features.

3.2 All flanged valves shall have flanges integral (except forged valves) with the valve body. Flange face finish shall be normally specified in the valve specification sheet as 125 AARH etc. The interpretation for range of face finish shall be as follows:

Stock Finish

: 1000 p. in AARH max. 125 AARH

: Serrations with 125 to 250 p in AARH 63 AARH

: 32 to 63 p. in AARH

33 For all weld end valves with bevel end as per ASME B 16.25, the contour of bevel shall be as follows:

Material Wall Thickness Weld Contour

Carbon Steel (Except Low Temp. Carbon Steel)

Upto 22 mm Figure 2 Type A

> 22 mm Figure 3 Type A

Alloy Steel, Stainless Steel & Low Temp. Carbon Steel

Upto 10 mm Figure 4

> 10 mm & Upto 25 mm Figure 5 Type A

> 25 mm Figure 6 Type A

Valve ends shall match thickness of the connecting pipe. Sloping of inside contour of valves shall be done wherever necessary to achieve this.



Page 10769 of 14785

ENGINEERS r..11 feitReg INDIA LIMITED

411M eiecnte J ,,RfrA IA Govt or India Undertaking)



6-44-0052 Rev.7 Page 6 of 12

3.4 For flanged valves with ring joint flanges the hardness shall be as follows:

Flange Material Min. Hardness of Groove (BHN)

Carbon Steel 140

1% Cr to 5% Cr, 9% Cr 150

Type 304, 316, 321, 347 160

Type 304L, 316L 140

3.5 Following requirements for check valves shall be met over and above the valve specification sheet requirements:

3.5.1 Unless specified otherwise in the data sheet all check valves 3" & above (except in 900#, 1500# & 2500# rating) shall have a drain boss at location "G" (Refer Fig.No.1 of ASME B16.34) where pocket is formed in valve body. A tapped drain hole with plug shall be provided as per ASME B 16.34. Threads shall be as per ASME B 1.20.1 (Taper) NPT.

3.5.2 For heavy check valves, provisions shall be available for lifting by way of lugs, eye bolts and other such standard devices.

3.6 If an overlay weld-deposit is used for the body seat ring seating surface, the corrosion resistance of the seat ring base material shall be at least equal to the corrosion resistance of the material of the shell.

3.7 Following valve bypass requirements shall be met:

3.7.1 By-pass requirement for Gate valves shall be as follows unless otherwise mentioned.

ASME 150 Class ASME 300 Class ASME 600 Class ASME 900 Class ASME 1500 Class ASME 2500 Class

On sizes 26" and above On sizes 16" and above On sizes 6" and above On sizes 4" and above On sizes 4" and above On sizes 3" and above

3.7.2 The by-pass piping arrangement shall be such that clearance between main valve body and by-pass assembly shall be the minimum possible for layout reasons. Vendor shall follow the sketch enclosed in Specification No. 6-44-0052-Al.

3.7.3 By-pass valve shall be a globe valve. The sizes shall be as under:

On main valve 4" 1/2" On main valve 6" to 8" 3/4" On main valve 10" & above 1"

By-pass piping shall be of same metallurgy as main valve. The by-pass piping, fittings and valve tag numbers shall be as specified in Specification No. 6-44-0052-A2. In case details of by-pass arrangement for any Valve tag number is missing, Vendor shall bring the same to notice of EIL and provide by-pass as per details specified.

3.7.4 Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves with by-pass shall have the direction of flow marked on the main valve. By-pass attachment to the


Page 10770 of 14785

,31 Ogell ttfaeg

IA Govt of India Undertaking)



6-44-0052 Rev.7 Page 7 of 12


main valve body shall not be screwed. All fillet welds for by-pass installation shall be 100% examined by DP/MP test and Butt-weld joints shall be 100% examined by radiography.

3.8 Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of casting but not vice-versa.

3.9 Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However, integral stem of cast material is acceptable for Plug valves.

3.10 Stelliting / hardfacing by deposition, shall be minimum 1.6 mm.

3.11 Renewable seat rings shall be seal welded for valves of size 3" and above to prevent loosening in service.

3.12 For Low Temperature & Cryogenic valve requirements, refer Specification.No.6-44-0052-A3 unless otherwise specified.

3.13 For Hydrogen service valve requirements, refer Specification.No.6-44-0052-A4 unless otherwise specified.

3.14 Valves under `NACE' category shall meet the requirements specified in MR-0103 unless otherwise specified.

3.15 For all austenitic stainless steel valves Inter Granular Corrosion (IGC) test shall be conducted as per the following:

3.15.1 ASTM A262 Practice 'B' with acceptance criteria of '60 mils/year (max.)' for all materials -forged, rolled, wrought and casting.

Or ASTM A262 Practice `E' with acceptance criteria of 'No cracks as observed from 20X magnification' for all materials other than castings. 'Microscopic structure to be observed from 250X magnification' in addition.

3.15.2 When specifically asked for in MR for high temperature application of some grades of austenitic stainless steel (eg. SS309, 310, 316, 316H etc.) ASTM A262 Practice 'C' with acceptance criteria of ' 15 mils/year (max.)' shall be conducted.

3.15.3 For the IGC test as described in Clauses 3.15.1 & 3.15.2, two sets of samples shall be drawn from each solution annealing lot. One set shall correspond to the highest Carbon content and the other to the highest pressure rating. When testing is conducted as per practice `E', photograph of the microscopic structure shall be submitted for record.

3.16 All types of 321 or 347 stainless steel valves shall be in a stabilised heat treated condition. Stabilising heat treatment shall be carried out subsequent to the normal solution annealing. Soaking temperature and holding time for stabilising heat treatment shall be 900°C and 4 hours respectively.

3.17 Spiral wound bonnet gaskets are to be provided with inner/outer ring except when encapsulated gaskets type body-bonnet joints are employed. Outer ring may be avoided in case of non-circular spiral wound gasket used in 150# valve provided the outermost layer of spiral touches the bolts ascertaining the centering.

3.18 All Stainless Steel Castings shall be solution heat treated.


Copyright EIL —All rights reserved

Page 10771 of 14785

IrkRer eteakeott3tratTO (A Govt of India Undertaking)

101 tGI J ENGINEERS Ogen EtOleg INDIA LIMITED S TECHNICAL NOTES

FOR VALVES


6-44-0052 Rev.7 Page 8 of 12

3.19 Only normalized and tempered material shall be used in the following specifications :

Castings A217 Gr.WC1, A217 Gr.WC4, A217 Gr.WC5, A217 Gr.WC6, A217 Gr.WC9, A217 Gr.C5, A217 Gr.C12

Forgings : A182 Gr.F11 C1.2, A182 Gr.F12 C1.2

3.20 Ball / Plug / Butterfly Valves

3.20.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS EN ISO 10497 (Supersedes BS 6755 Part II) shall be carried out on soft seated ball, plug & butterfly valves and also on lubricated plug valves The test shall be witnessed and certified by a third party inspection agency like Lloyds, BVIS, DNV or EIL/ CEIL unless otherwise specified. The vendor has to submit test certificate for the particular design of the valve offered, if fire safe design is required as per the Valve Material Specification sheet..

3.20.2 Each valve shall be supplied with a lever / wrench except for gear operated / motor operated valves.

3.20.3 Soft-seated ball, plug & butterfly valves shall be supplied with antistatic devices.

3.20.4 BW / SW end ball valves shall have a 100 mm long seamless pipe nipple welded to each end of the valve. Nipples are to be welded prior to assembling Teflon seats / seals. Specifications of the nipples shall be as indicated in the MR.

3.20.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of the corresponding ANSI class (except 10" onwards in Class 150 where the face-to-face dimensions shall be as per API 6D long pattern).

3.20.6 The ball of ball valve shall not protrude outside the end flanges of valve.

3.20.7 Ball valves shall be of floating ball/trunnion mounted type as per following:

150#

8" & below

Floating ball 10" & above

Trunnion mounted

300#

4" & below

Floating ball 6" & above

Trunnion mounted

600# 1.5" & below Floating ball & above 2" & above Trunnion mounted

3.20.8 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall be limited to one size lower than the nominal bore.

3.21 The MOVs are to be installed in an open area and the actuators shall be suitable for all weather conditions. The testing of complete assemblies of MOVs along with the actuators shall be done by the supplier at his works.

3.22 Ends of flanged valves of 22" size shall match corresponding flanges to MSS-SP44 unless otherwise specified.

3.23 Yoke material shall be same as bonnet material where maximum temperature specified is more than 427°C.


Page 10772 of 14785

ENGINEERS TECHNICAL NOTES /gar Ea& INDIA LIMITED FOR VALVES (A Govt. of India undertaking,


6-44-0052 Rev.7 Page 9 of 12

(ORR MEW MI 3‘17.3)

4.0 OPERATION

4.1 Gear operation shall be provided as under:

Valve Type Class Size Requiring Gear-Operator

Gate Valve, Globe Valve & Diaphragm Valve

150 Class 12" and larger






Ball Valve / Plug Valve (Other than pressure balance plug valves)






Butterfly Valve 150, 300 Class 6" and larger

For sizes lower than these ranges, hand wheel / lever / wrench shall be provided. For pressure balance plug valves manufacturer's recommendation shall be acceptable provided the requirements specified in clause 4.6 are met.

4.2 Gear operator shall be provided, with position indicators for open / close positions and with limit stops. (Limit stops are not applicable for gate and globe valves).

4.3 Where gear operator is not called for as per Clause 4.1 but vendor recommends a gear operator, the same shall be highlighted.

4.4 Gear operator shall be so designed as to operate effectively with the differential pressure across the closed valve equal to the cold non-shock pressure rating.

4.5 Ball, plug and butterfly valves, shall have "Open" position indicators with limit stops.

4.6 Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on either side. Effort to operate shall not exceed 35 Kg at handwheel periphery. However, failing to meet the above requirements, vendor shall offer gear operated valve and quote as per clause 4.3.

5.0 INSPECTION AND TESTING

5.1 Every valve shall be subjected to all the mandatory tests and checks called in the respective codes / data sheet by EIL inspection or any third party as approved by the purchaser. For IBR valves refer clause 7.0.

5.2 Every valve, its components and auxiliaries must be subjected to all the mandatory tests and checks called for in the respective codes, data sheets etc. by the manufacturer.

5.3 Though the extent of inspection shall be as under, exact extent with hold points shall be decided by EIL regional inspection office and recorded in the form of inspection plan. In case of third party inspection, the inspection plan shall be approved by the purchaser.


Page 10773 of 14785

Reie? ENGINEERS Ogelf idaeg INDIA LIMITED

eIreel ,tooe MI OW.) IA Govt of India Undertaking)

(7-A TECHNICAL NOTES FOR VALVES


6-44-0052 Rev.7 Page 10 of 12

Forged Valves:

1. Visual and dimensional inspection.

2. Review of material test certificates.

3. Any mandatory or supplementary test.

4. Hydrostatic test on 10% valves selected on random basis.

5. Strip check is required for 1% of total ordered quantity of Gate & Globe valves (min. 1 No.) for each Valve sheet no., however, strip check is not required for CS/ Brass/ Bronze material valves with 13% Cr/ Brass/ Bronze trims.

Cast Steel Valves:

1. Visual and dimensional inspection.

2. Review of material test certificates.

3. Review of radiographs/radiographic reports or any other NDT tests wherever applicable as per data sheet.

4. Any mandatory or supplementary test.

5. Hydrostatic test 100% for body, 10% other test.

6. Strip check is required for 1% of total ordered quantity of Gate & Globe valves (min. 1 No.) for each Valve sheet no., however, strip check is not required for CS/ Brass/ Bronze material valves with 13% Cr/ Brass/ Bronze trims.

Samples for strip check shall be selected at random and shall generally be in the highest size in the lot.

5.4 In case of motor operated or actuator operated valves, functional / operational checks as per the requirements of the specifications shall be made on each valve.

6.0 RADIOGRAPHY OF CAST VALVES

6.1 Valve castings shall undergo radiographic examination as specified below.

Material Rating Size Range Radiography

All 150# 24" and below NIL**

26" and above* 100%

300# 16" and below NIL**

18" and above 100%

600# & above All sizes 100%

* No radiography is required for valves of size 26" and above in cooling water service.

**For sizes 24" & below in 150# and 16" & below in 300#, radiography percentage if specifically mentioned in individual valve material spec sheet shall govern.

Radiography specified as random 10% or 20% etc. in the respective valve data sheet implies 10% or 20% etc. of number of valves ordered against each item number with a minimum of one valve against each item.



Page 10774 of 14785

rn~rel fEff5teg

ENGINEERS TECHNICAL NOTES INDIA LIMITED (A Govt of India Unclertalcing)


6-44-0052 Rev.7 Page 11 of 12

FOR VALVES

6.2 Radiography procedure, areas of casting to be radiographed shall be as per ASME B 16.34 and acceptance criteria shall be as per ASME B 16.34 Annexure-B. However for areas of casting to be radiographed for types of valves not covered in ASME B 16.34, vendor shall radiograph castings in line with ASME B 16.34.

6.3 For random radiography wherever specified in individual data sheets, the sampling shall be per size of the quantity ordered for each foundry.

6.4 Radiography wherever specified in the data sheets or as per clause 6.1 shall be done by X-ray / 'y-ray to get the required sensitivity.

7.0 IBR CERTIFICATION

7.1 For valves described "IBR", valves shall be in accordance with the latest IBR (Indian Boiler Regulation) including the requirements specified in the specification.

7.2 For SW / BW end carbon steel valves under IBR, the chemical composition shall conform to the following:

Carbon (Max) Others (S, P, Mn)

0.25% As per IBR

7.3 Valves coming under the purview of "IBR"(Indian Boiler Regulations) shall each be individually accompanied by IBR certificate original in Form III-C duly approved by IBR authority / local authority empowered by the Central Boiler Board of India. Photocopy of original certificate duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance.

7.4 All "IBR" valves shall be painted red in body-bonnet / body-cover joint.

8.0 MARKING

8.1 Valve markings, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the standard referred in specification sheet as applicable. Vendor's name, valve rating, material designation, nominal size, direction of flow (if any) etc. shall be integral on the body.

8.2 Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely attached to the valve body.

8.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead or copper which cause corrosive attack on heating.

8.4 Carbon Steel / Alloy Steel valves shall be painted with one coat of inorganic zinc silicate (minimum DFT 65 to 75 microns).

9.0 DESPATCH

9.1 Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of any kind.

9.2 Valves shall be protected from rust, corrosion and any mechanical damage during transportation, shipment and storage.


Page 10775 of 14785

,511faeie`i Q41 k1Rs

ENGINEERS TECHNICAL NOTES INDIA LIMITED (A Govt of India Undertaking)


6-44-0052 Rev.7 Page 12 of 12

Lfth FOR VALVES

9.3 Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent or shall not be harmful to welding.

9.4 Each end of valve shall be protected with the following materials:

Flange Face

Wood or Plastic Cover Bevelled End

Wood or Plastic Cover SW & SCRD. End

Plastic Cap

9.5 End protectors of wood / plastic to be used on flange faces shall be attached by at least three bolts and shall not be smaller than the outside diameter of the flange. However, plastic caps for SW & SCRD end valves shall be press fit type.

9.6 End protectors to be used on bevelled end shall be securely and tightly attached.

9.7 For special service valves additional requirement for despatch shall be as prescribed in data sheet.

10.0 ATTACHMENTS

6-44-0052-A 1 Bypass Piping Arrangement

6-44-0052-A2 Specifications for Bypass Piping, Fittings and Valves

6-44-0052-A3 Special Requirements for Low Temperature and Cryogenic Valves

6-44-0052-A4

11.0 REFERENCES

6-78-0001

6-78-0003

6-81-0001

6-81-0004

Special Requirements for Hydrogen Service Valves

Specification for Quality management system requirements from bidders

Specification for documentation requirements from suppliers

Specification for Positive Material Identification (PMI) at Supplier's Works

Inspection and Test plan for Valves


Page 10776 of 14785

INSPECTION AND TEST PLAN FOR

VALVES

REVISED AND RE-ISSUED

TKK RKS SCG DM

TKK SCG AKC DM

RKB VKJ SKP ND

CS SS MVKK VC

Prepared by

Checked by


Standards Bureau Chairman

Approved by

6 14 11 2018

5 17 06 2013

4 15 07 2011

3 30 06 2010

2 31 01 2008

Rev No Date





Purpose

ratSejege riv,I,tUMITED (A GoN al kIdu UnOxiakmg)


VALVES

STANDARD SPECIFICATION NO

6-81-0004 Rev. 6 Page 1 of 7

curl * Ml‘crar A trukTur 4 111

Format No 8-00-0001-F7 Rev 0 Copyright EIL — All rights reserved

Page 10858 of 14785

MRT NDT NPSH PO PESO PQR PR PM1 RT SSCC TC TPI or TPIA UT VDR WPS WPQ

Mechanical Run Test Non Destructive Testing Net Positive Suction Head Purchase Order Petroleum Explosive Safety Organization Procedure Qualification Record Purchase Requisition Positive Material Identification Radiography Testing Sulphide Stress Corrosion Cracking Test Certificate Third Party Inspection Agency Ultrasonic Testing Vendor Data Requirement Welding Procedure Specification Welders Performance Qualification

?ENGINEERS sLAfafaieg®INDIA LIMITED

Govt of ;ma Undertaking)


VALVES


6-81-0004 Rev. 6

Page 2 of 7

Abbreviations:

CELL CIMFR CE DFT DPT DHT ERTL FCRI HT HIC ITP IP IHT IC IGC MPT/MT MTC

Certification Engineers International Limited Central Institute of Mining & Fuel Research Carbon Equivalent Dry Film Thickness Dye Penetrant Testing De-hydrogen Heat Treatment Electronics Regional Test Laboratory Fluid Control Research Institute

: Heat Treatment : Hydrogen Induced Cracking : Inspection and Test Plan : Ingress Protection

Intermediate Heat Treatment Inspection Certificate Inter Granular Corrosion

: Magnetic Particle Testing : Material Test Certificate


Convenor : Mr. R K. Singh

Members: Mr. Rajeev Kumar Mr. T Kamalakannan

Mr. Neeraj Mathur Mr. Himangshu Pal Mr. Mahendra Mittal Mr Deepak Gupta (Projects)

Mr R Muthu Ramalingam (RPO Rep.)


Page 10859 of 14785

,-*ENGINEERS fittlWregW; INDIA LIMITED

Cori of IMW Undertitrngi


VALVES


6-81-0004 Rev. 6

Page 3 of 7

1.0 SCOPE

This Inspection and Test Plan covers the minimum testing requirements of Valves.

2.0 REFERENCE DOCUMENTS

PO/PR/Standards referred therein/ Job specifications /Approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS

SL NO / ACTIVITY CHARACTERISTICS

QUANTUM CHECK

RECORD RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA OF CECK

1.0 Procedure

1.1

Hydrostatic Test, Heat Treatment, NDT,

Helium Leak Test

Other Procedures and

Documented Procedures 100% Procedure

Documents H R

1.2 WPS, PQR & WPQ Welding Parameters & Qualification Record

100% WPS, PQR &WPQ - H W- New

R- Existing

1.3 Pre-Qualification Tests Fire safe,

Cryogenic & Other Test as applicable

As per PR / Purchase

Specification Acceptance Report - H

H (If new)

Format No 8-00-0001-F7 Rev 0


Page 10860 of 14785

p,"-M; ENGINEERS IgtlitailegW, INDIA LIMITED


VALVES


6-81-0004 Rev. 6

Page 4 of 7

SL NO

STAGE / ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

2.0 Material Inspection

2.1 Castings & Forgings (Body, Bonnet, Disc, Stem, Body ring)

Chemical, Mechanical, Heat Treatment, NDT,

IGC & Other Properties as applicable

100% Test Certificates H R R

2.2 Castings & Forgings

(Body, Bonnet, Disc, Stem, Body ring) Visual & Dimension 100% Inspection Report H H -

2.3 Body and Bonnet Castings Radiography Examination


Specification Films and report H R R

2.4 Bars for Trim material Chemical Analysis Each Heat Test Certificates &

Lab Report H R -

2.5 Gaskets, Gear units, Fasteners, Gland,

Packings, etc. Physical / Chemical

Properties 100%

Test Certificates & Lab Report H R

2.6 Actuators as applicable Performance,

Statutory Certificates as applicable

100% Test Certificates, Inspection report

H H R



Page 10861 of 14785

aaLlt4ft- ENGINEERS ar Ig WagW. INDIA LIMITED

eVaile


VALVES


6-81-0004 Rev. 6

Page 5 of 7

SL NO STAGE / ACTIVITY QUANTUM


CHARACTERISTICS SUB SUPPLIER SUPPLIER EIL/TPIA OF CHECK

3.0 In Process Inspection

3.1 Welding Welding Parameters as

per WPS / PQR 100% Inspection Reports - H -

3.2 Machining of components Visual / Dimension 100% Inspection Reports - H -

4.0 Final Inspection

4.1 Hydrostatic / Pneumatic Test and

Helium Leak test as applicable Leak Check As per PR /

Purchase Specification

Test Report - H RW

(Note 1)

4.2 Visual / Dimension Surface & Dim ension

Check 100% Test Report - H

RW (Note 1)

4.3 Functional Test for Actuator Operated

Valves Satisfactory Performance

100% Test Report - H RW



Page 10862 of 14785

liSiiftega, ENGINEERS W: INDIA LIMITED

(A GOA of Into Undenalmol


VALVES


6-81-0004 Rev. 6

Page 6 of 7

SL NO STAGE / ACTIVITY CHARACTERISTICS QUANTUM


OF CHECK SUB SUPPLIER SUPPLIER EIL/TPIA

4.4 PMI Check Chemical As per EIL

Spec. 6-81-0001

Inspection Report - H RW

4.5 Strip Check (As applicable) Verify Components & Differential hardness if

applicable


Specification Inspection Report -

(Note-1) H RW

4.6 Final Stamping Stamping of Accepted Valves

Stamping of Valves which

are witnessed by EIL/TPIA.

Inspection Report - H H (Note-1)

5.0 Painting

5.1 Painting and Color coding as applicable Visual / DFT Check 100% Inspection Report FI

6.0 Documentation & IC

6.1 Documentation & Inspection Certificate (IC)

Review of Stage Inspection Reports /

Test Reports & Issue of IC

100% Supplier TC & IC - H H


Page 10863 of 14785

ISM ENGINEERS SI-II M

5 ®INDIA INDIA LIMITEDJA,AA IA CAN of Endo Underlatingi


VALVES


6-81-0004 Rev. 6

Page 7 of 7

Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% ( min.1 no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable):

1. Non NACE & Non Hydrogen service Carbon Steel Cast Valves up to size 12"-300ANSI Class and Carbon Steel Forged Valves up to size 1.5"- 800 ANSI Class will be accepted on review of Supplier Test Certificates. Supplier Test Certificate along with back up reports to be reviewed by EIL/TPIA

2. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also be applicable. (Unless otherwise agreed upon)

3. Acceptance Norms for all the activities shall be as per PO/PR/STANDARDS referred therein /Job Specification /Approved Documents.



Page 10864 of 14785

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ELECTRICAL & INSTRUMENTATION INTERFACE PHILOSOPHY

RAJASTHAN REFINERY

B224-000-16-51-EI-01 Page 1 of 6

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved

ELECTRICAL & INSTRUMENTATION

INTERFACE PHILOSOPHY

(All UNITS)

2 24.01.2020 REVISED & REISSUED FOR ENGINEERING NA RK SB

1 19.03.19 ISSUED FOR ENGINEERING NA RK SB

0 13.11.18 ISSUED for Comments NA RK SB

Rev. No


by Checked

by Approved

by

Page 1578 of 1660

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RAJASTHAN REFINERY

B224-000-16-51-EI-01 Page 2 of 6


1.0 Unit wise allocation of Substations(S/s) and Control Room (CR)

UNIT No. Control Room S/s No.

CDU,VDU,SAT.LPG TREATING UNIT Including LPG DEPROPANIZER,SAT.FG TREATING UNIT (EPCC-1)

SRR#1

S/S-4

MS-BLOCK i.e. NHT, ISOM,SEMI REGENERATIVE REFORMING(SRR),PFCC GASOLINE HDT (EPCC-2)

SRR#10

S/S-7

DHDT , HYDROGEN GEN.UNIT (HGU) (EPCC-5)

SRR#11 S/S-6 for DHDT

S/S-9 for HGU

PFCC + PRU (EPCC-3) SRR#12 S/S-11

DCU, UNSATURATED LPG TREATING UNIT (EPCC-4)

SRR#3 S/S-8

PPU-TRAIN 1&2 (EPCC-9)

SRR#4

S/S-20 For Train-1

S/S-21 For Train-2

and Extruder

BUTENE-1, LLDPE/HDPE Swing (EPCC-8)

SRR#13 S/S-17 For Butene1

S/S-18 For Swing-1

S/S-19 For swing-2

VGO HDT, REF OFF GAS PSA (EPCC-10) SRR#2 S/S-5

DFCU,Ethylene Recovery Unit, BdEU, C4 Hydrogenation,Py.Gas HDT,BTX (EPCC-7)

SRR#9A SRR#9B

S/S-15(For DFCU)

S/S-16 (For Other

Units of EPCC 07)

SWS-I,SWS-II,ARU,SRU,TGTU (EPCC-6) SRR#5 S/S-24

RWTP, Flare, Fire Water SRR#14 S/S-23

Cooling Water System CT-1RMCR CT-2 SRR#9B

CT-3 PMCR CT-5 SRR#5 CT-6 /PMCR

S/S-10 CT-1 S/S-12 CT-2 S/S-32 CT-3 S/S-24 CT-5 S/S-12 CT-6

Compressed Air system and Nitrogen-Pkg PLC for LP Air compressor, Air dryer in local panel

PMCR S/S-13

Steam and Power System, CT-4 CPP CR CPP S/S33

ETP, RODM,CPU Water System SRR#6 ETP S/S-27

RODMCPU S/S-25

Crude Pipeline Receipt Terminal POMS S/S-2

PPU, LLDPE Product warehouse S/S-22

Admin Block S/S-1

BOG Compr, TF-22A/B SRR#9A S/S-31

Page 1579 of 1660

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RAJASTHAN REFINERY

B224-000-16-51-EI-01 Page 3 of 6


a)TF-1 to 3

b)TF- 4 TO 11,Crupe PS, IPS-1, VRU (LZ-1003)

c)TF-12

e)TF-13 TO 16, IPS-2,

f) TF-17,18,20,21, Bullets, H2 compressor House, PS-

5,

g)Butene/propylene/LPG Unloading compressor

h) TF-23 TO 26, PS-1, PS near MS Blending, MS

Blending , Spheres

i) Butadiene chilling pkg

j) TF-27 TO 30, IPS-4, Product PS-2,

k) Unloading PS

l) IPS-3, VRU(LZ-104)

m) TF-19

a) POMS

b) SRR#8

c) SRR#8

e) SRR#8

f) RMCR

g) Pkg PLC –LCP

h)SRR#7

i) Pkg-PLC -SRR#7

j) SRR#7

k)PkgPLC-

Unloading CR

l) SRR#8

m) SRR#8

a)S/S-2

b)S/S-3,

c)S/S-30/34

e) S/S-30

f) S/S-30

g) S/S-30

h) S/S-29

i) S/S-29

j) S/S 14

k)S/S-14

l) S/S-34

m) S/S-30/34

2.0 CABLING AND TERMINATION PHILOSOPHY

All signals shall be hardwired or serial as identified in E&I interface document.

Separate cable shall be used for each analog signal, Digital inputs and Digital outputs connected to

DCS

Separate cable shall be used for each analog signal, Digital inputs and Digital outputs connected to

PLC

Separate cable shall be used for Packages vendors supplied control system (as identified in E&I

interface document). In general, for package PLC, interface signals shall be hardwired between

substation and SRR. RIO Concept is generally not applicable for packages.

Separate cable shall be used for motor commands for motors (upto 55KW) and motors (>55 KW).

Clubbing of cable for signals related to DCS, PLC and Packages shall not be done.

3.0 MOTOR INTERLOCKS

3.1 Instrumentation Contact ratings for outputs for Electrical Interface:

LT (contactor feeder) : 110VDC, 0.5A (less than or equal to 55 KW)

LT (breaker driven) : 110VDC, 0.5A (greater than55 KW and less than or equal to160 KW)

HT : 110 VDC, 0.5A (drives greater than 160 KW)

a. Signal interface between MCC and Purchaser’s DCS/ PLC shall be hardwired in marshalling cabinets (RIO cabinet) kept in substation. All hardwired signal between MCC and PLC/DCS shall be through remote I/O of PLC/DCS and shall be located in sub-station.

b. Start/ Stop/ trip commands for MCC shall be hardwired in DCS, PLC Marshalling cabinets (DCS, PLC

RIO cabinet) kept in substation.

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RAJASTHAN REFINERY

B224-000-16-51-EI-01 Page 4 of 6


c. All running/ status indication from MCC to DCS shall be hardwired to DCS RIO (except which are used in interlocks shall be hardwired to PLC RIOs).

d. Current indications from MCC to DCS (4-20mA) and speed control signals for VFD from DCS to MCC (4-20mA) etc. shall be hard-wired to/ from DCS RIO (as per E&I Interface document). For all motors above 55 KW, current indications shall be provided. For other motors, current indications shall be as per P&ID.

Supply and laying of serial interface cables from RIO cabinets installed in substation (S/S) to

respective CR/SRRs shall be by Instrumentation in Electrical cable trays/ducts.

e) Potential free contacts, of rating 24V DC, 2A shall be provided by Electrical for hardwired digital

inputs to instrumentation wherever identified in E&I interface documents. All hardwired digital inputs

to instrumentation shall be interrogated by 24VDC.

3.2 Potential free contact shall be provided for all instrumentation outputs (suitable for rating given in 3.1

above) to Electrical.

3.3 110 V AC UPS redundant feeder cable shall be provided by Instrumentation from Instrumentation

PDB in rack room & laid in Electrical duct / tray for RIO cabinet in Substation.

Electrical shall provide 240 V AC non UPS feeder for the cabinet lighting for these Remote I/O

cabinets in the respective substations.

Space for cabinet housing Remote I/Os shall be provided in the substation. Space of Minimum 8

cabinets for RIO shall be provided.

3.4 All 4~20mA two wire isolated signal suitable for 600ohms load shall be provided for Current, Voltage,

Power, speed (for VFD Powered motors), etc. Instrumentation will identify all such motors in E&I

Interface document

3.5 Interlocks for all drives (as applicable based on P&ID, logic requirements). Location shall be as per

respective control room.

Type of Signal Type of contact Remarks

Start command NO (All drives) close to start, pulse of 2 sec duration

Stop command NO (All drives) Close to stop, Stay put type

Status Indication NO close to indicate Running status, stay put

type

Start permissive NO close to permit start (if required

additionally),

VFDs Shall be as per vendor’s

requirement which shall be

intimated by Electrical

3.6 Wherever there are both control room manual stop and logic trip, Control room manual Stop shall be

clubbed with logic trip at the DCS/PLC end and one net contact shall be given to Electrical. Field

manual stop shall be directly wired to MCC.

3.7 Separate contacts for start and stop command of same motor.

Separate contacts set for start and stop of A, B, C etc of same motor.

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RAJASTHAN REFINERY

B224-000-16-51-EI-01 Page 5 of 6


3.8 Unless otherwise indicated in E&I interface, Instrumentation shall provided stay put contact for

‘STOP’ of the motors/ drives. Electrical circuit shall be provided to inhibit motor/ drive ‘START’ as

long as ‘STOP’ contact from DCS/ PLC is maintained.

3.9 LOCAL/REMOTE (L/R) selector switch:

a. L/R shall be provided locally by Electrical along with local start/stop and directly wired to

MCC/PCC/ HT Switch Board by Electrical.

b. The start from DCS/PLC shall be possible when L/R switch provided on LCS is in

‘REMOTE’ position. Instrumentation shall give only one contact for start in any case.

c. Remote stop/trip command from DCS/PLC shall be possible irrespective of whether the L/R

switch is in ‘REMOTE’ position or ‘LOCAL’ position.

d. Local /remote switch status indication shall be provided by electrical

All motor: L/R remote switch status shall be available in ECS RTU. This status data can be

taken from port available on ECS RTU via serial link (Modbus TCP/IP). Electrical to provide

Modbus mapping list to Instrumentation.

e. Instrumentation will identify all such motors in E&I Interface document.

3.10 AUTO/MANUAL selector switch:

a. Wherever AUTO/ MANUAL selector is required, the location of AUTO/ MANUAL switch

shall be at the control system end and no separate contact shall be given to Electrical for the

same.

b. For VFD controlled motors, AUTO/ MANUAL selector switch shall be provided in VFD. In

case of AUTO mode the speed control shall be through 4~20mA signal provided from DCS. In

case of manual mode the speed control shall be from VFD panel/LCS. The VFD/LCS selector

switch shall be located in LCS.

4.0 VARIABLE SPEED DRIVE:

a. Refer 3.1.

b. Serial interface shall be provided for signals from VFD to DCS, wherever required.

Instrumentation will identify all such drives in E&I Interface document.

c. Electrical to provide modbus mapping list for VFDs to instrumentation.

5.0 MOTOR OPERATED VALVES:

a. MOV Status : Hardwired signal from field for valve open and close

b. MOV Command : Hardwired signal to field for valve open, close and jog

c. Contact Rating : 24V DC 2A

d. Contact type: Contacts shall close for open and close indications as well as for open/ close

commands. Contacts shall be stay put type for status indications from MOV and momentary

type (pulse of 2 sec duration) for commands to MOV.

e. All MOV actuators shall have provision for accepting hardwired trip command from

DCS/PLC.

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RAJASTHAN REFINERY

B224-000-16-51-EI-01 Page 6 of 6


f. Supply and lying of cables up to respective Control room /SRR for all status and commands

shall be by Electrical through Instrumentation duct and MCTs.

g. For offsite units MOVs (Detail-A of P&ID, as identified in E&I Interface), Electrical to

provide:

i. MOV Open & Closed status indications in DCS/ PLC (as per P&IDs, E&I Interface),

ii. MOV Open & Close Commands from DCS/ PLC (as per P&IDs, E&I Interface),

Cables for sr. nos. i & ii will be by Electrical,

h. For offsite units MOVs in tank body (Detail-A1 of P&ID, as identified in E&I Interface),

Electrical to provide:

i. LCS with Open & Close push buttons and Open & Closed indication lamps in field

outside the dyke which shall be directly wired to MOV,

ii. MOV Open & Closed status indications wired to DCS/ PLC (as per P&IDs, E&I

Interface),

iii. MOV Close Command from PLC (which shall be wired in MOV trip contact),

iv. Emergency Close Button Station for MOV outside the Dyke wired to PLC system.

Cables for sr. nos. i, ii and iii will be by Electrical, cable for sr. no. iv will be by

Instrumentation

6.0 RTD/BTD WIRING PHILOSOPHY:

a. RTDs/BTDs for stator and motor windings/ gear box from field shall be wired to the

DCS/PLC.

b. Electrical to provide the list and number of signals motor wise for the RTDs/ BTDs for

including in DCS/PLC MR.

7.0 VIBRATION SWITCHES FOR FANS:

Vibration transmitter signal of the fans (for tripping of fans) shall be directly taken to PLC in SRRs by

Instrumentation. Vibration trip, wherever applicable, shall be provided from PLC to MCC.

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TQ reply Lot-9, Sr. No.21; For packages like pumps, compressors etc. with MMS (where MMS is applicable as per API specified elsewhere), all vibration, key phasor and temperature signals etc. pertaining to equipment shall be connected to MMS. Only for other LT/HT motors, RTD/BTD/vibration shall be connected directly to DCS (RTD/BTD through temperature transmitters).

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