ELECTRICAL, CP & CMS SYSTEM - gailebank.gail.co.in · electrical, cp & cms system ... datasheet for...

VOLUME – III

ELECTRICAL, CP & CMS SYSTEM

SPUR LINES OF CHAINSA – JHAJJAR PIPE LINE

0 10.11.2008

DESIGN BASIS/JOB SPECIFICATION/ STANDARD

SPECIFICATION/STANDARDS/ DRAWINGS/DATASHEET

REV. DATE

DOCUMENT REV-0 GAIL (INDIA) LTD NEW DELHI

LIST OF ATTACHMENTS FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL &

CATHODIC PROTECTION) 0001-01-07-11-001 Page 1 of 6

© GAIL – All rights reserved

LIST OF ATTACHMENTS FOR

PIPELINE LAYING AND ASSOCIATED

WORKS (ELECTRICAL & CATHODIC

PROTECTION)





SL NO

SPECIFICATION NUMBER

NO OF SHEETS

REVISION DOCUMENT TITLE

SCOPE OF WORK

1 0001-01-04-06-003-SW2 SCOPE OF WORK FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL)

2 0001-01-04-06-003-SW5 SCOPE OF WORK FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING PIPE

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

DESIGN BASIS

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

SPECIFICATIONS

5 0001-01-07-02-001 10 0 JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL)

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

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

8 0001-01-07-02-006 4 0SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING PIPELINE

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

DATASHEETS

10 0001-01-07-04-BC-001 4 0 DATA SHEET FOR BATTERY BANKS 24V

11 0001-01-07-04-CBL-001 4 0 DATA SHEET FOR MV-HV CABLES

12 0001-01-07-04-CPS-001 7 0DATASHEET FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES

13 0001-01-07-04-CPS-002 6 0 DATASHEET FOR IMPRESSED CURRENT CP SYSTEM

14 0001-01-07-04-CPS-003 3 0 DATASHEET FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

15 0001-01-07-04-CPS-004 3 0 DATASHEET FOR CATHODIC PROTECTION POWER SUPPLY MODULE

16 0001-01-07-04-EGS-001 9 0 DATASHEET FOR EMERGENCY GENERATOR





SL NO


NO OF SHEETS


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

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

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

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

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

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

LOAD ANALYSIS

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

STANDARD SPECIFICATIONS

23 S-07-02-001 11 0 SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT

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

25 S-07-02-003 17 0 SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION

26 S-07-02-004 8 0SPECIFICATION FOR INSPECTION FIELD TESTING AND COMMISSIONING OF ELECTRICAL EQUIPMENT

27 S-07-02-005 8 0 SPECIFICATIONS FOR EARTHING INSTALLATION

28 S-07-02-006 13 0 SPECIFICATIONS FOR CABLE INSTALLATION

29 S-07-02-007 15 0 SPECIFICATIONS FOR LIGHTING INSTALLATION

30 S-07-02-008 9 0 SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL)

31 S-07-02-009 7 0 SPECIFICATION FOR CORROSION SURVEY

32 S-07-02-010 20 0SPECIFICATION FOR EQUIPMENT MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES

33 S-07-02-011 21 0SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES

34 S-07-02-012 26 0SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM





SL NO


NO OF SHEETS


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

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

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

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

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

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

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

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

43 S-07-02-022 8 0 INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS

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

INSPECTION TEST PLAN

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

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

47 S-07-06-003 4 0 INSPECTION AND TEST PLAN FOR FIRE ALARM SYSTEM

STANDARD DRAWINGS

48 S-07-01-004 1 0 TYPICAL EARTH ELECTRODE FOR EARTHING SYSTEM

49 S-07-01-005 1 0 TYPICAL EARTH ELECTRODE IN TEST PIT

50 S-07-01-006 1 0 TYPICAL EARTH PLATE FIXING DETAILS

51 S-07-01-007 1 0TYPICAL EARTH CONNECTION FOR STREET LIGHTING POLE

52 S-07-01-008 1 0 TYPICAL EARTHING ARRANGEMENT FOR PROCESS EQUIPMENT





SL NO


NO OF SHEETS


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

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

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

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

57 S-07-01-013 1 0 TYPICAL INSTALLATION OF LIGHTING FIXTURE AT GROUND LEVEL

58 S-07-01-014 1 0 TYPICAL OPEN AREA STREET LIGHT OR FLOOD LIGHT FIXTURE MOUNTED ON WALL/COLUMN

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

60 S-07-01-014B 2 0 TYPICAL OPEN AREA STREET LIGHT LIGHT FIXTURE MOUNTED ON POLE

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

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

63 S-07-01-016 1 0TYPICAL INSTALLATION OF FLUORESCENT FIXTURE MOUNTING IN EXPOSED WIRING SYSTEM

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

65 S-07-01-018 1 0TYPICAL INSTALLATION OF RECESSED MOUNTED OR BELOW FALSE CEILING MOUNTED FLUORESCENT FIXTURE

66 S-07-01-019 1 0TYPICAL INSTALLATION DETAILS OF LIGHTING FIXTURE MOUNTING IN CONCEALED CONDUIT SYSTEM

67 S-07-01-020 1 0 TYPICAL INSTALLATION OF LIGHTING/ POWER PANEL FLUSH MOUNTED

68 S-07-01-021 1 0 TYPICAL INSTALLATION OF MESTEC CHANNEL

69 S-07-01-022 2 0 SAFETY MEASURES FOR ELECTRICAL INSTALLATIONS DURING CONSTRUCTION

70 S-07-01-023 1 0 TYPICAL INSTALLATION DETAILS OF ELECTRICAL PANELS ON FALSE FLOORING

71 S-07-01-024 2 0 TYPICAL INSTALLATION DETAILS OF ELECTRICAL PANELS ON CABLE TRENCH

72 S-07-01-025 1 0 PREPACKED ZINC ANODE





SL NO


NO OF SHEETS


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

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

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

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

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

78 S-07-01-031 1 0 ZINC RIBBON ANODE FOR CASED CROSSINGS WITH COATED/ PAINTED CASING

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

80 S-07-01-033 1 0 TYPICAL CONSTRUCTION DETAILS OF HIGH SILICON CAST IRON ANODE

81 S-07-01-034 1 0 PERMANENT COPPER-COPPER SULPHATE REFERENCE CELL AND INSTALLATION DETAILS

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

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

84 S-07-01-037 14 0NOTES, LEGEND AND DETAILS FOR AREA CLASSIFICATION (ONSHORE OIL/ GAS INSTALLATIONS)

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

86 S-07-01-039 3 0DETAILS OF HOT DIP GALVANIZED LADDER TYPE CABLE TRAY

87 S-07-01-040 0INSTALLATION DETAILS FOR DOUBLE POLE TERMINATING STRUCTURE UPTO 33 KV

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

STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI

ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM 0001-01-07-03-001 Page 1 of 7


ELECTRICAL DESIGN BASIS FOR

CATHODIC PROTECTION SYSTEM

AND ELECTRICAL SYSTEM

SPUR LINES OF CHAINSA - JAHJJAR PIPELINE




CONTENTS

1. SITE CONDITIONS

2. POWER SOURCE DETAILS

3. SYSTEM VOLTAGES

4. CONTROL BUILDING DESIGN

5. EQUIPMENT DESIGN

6. MONITORING AND CONTROL SIGNAL THROUGH SCADA

7. CABLING SYSTEM

8. EARTHING SYSTEM

9. LIGHTING AND VENTILATION SYSTEM

10. ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

11. STATUTORY APPROVALS

12. CP SYSTEM




This electrical design data defines the design requirements applicable for this project in addition to the Specification for Sacrificial Anode Cathodic Protection System S-07-02-011, Specification For Impressed Current Cathodic Protection System S-07-02-012. (Data marked ‘* ’shall be furnished/ confirmed by client).Site ConditionsA Equipment design temperature 40oCB. Soil Resistivity As per Soil Analysis reportC. Min. temp. for battery sizing 5oCD. Altitude above mean sea level Less than 1000M

E. WeatherDry, dust storms in summer, humid / heavy rain fall during monsoon

Power Source Details: At Manned Terminals:-

All CGS

Power generation by 24V DC Solar Panels

1 nos.415V, 50Hz,TPN AC supply from local grid to be arranged by the contractor

Battery back-up of 72 hours3. Utilisation voltage & Operating philosophy3.1 TelecomSCADA

3.2 Instrumentation

For all stations one 24 V DC feeder to be provided. All DC-DC converters to meet the equipment requirements shall be in the scope of the equipment vendor

3.3 Electrical System For all stations 240 V AC from Grid Power Supply

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

3.5 Air Conditioning At CGS control room / telecom /

SCADA room 240V,1-Ph AC grid power supply.

3.6 Lighting/ventilation At all locations 240 V AC grid power

supply

3.7 Fire detection & fire protection system For all stations 24 V DC. Feeder to be provided

3.8Number/configuration of DC to DC converters for- Instrumentation power supply Not requiredCP power supply Single (shall be part of CPPSM)

Telecom power supply -48 V DCIn the scope of Telecom Equipment Vendor

SCADA Power Supply 24 V DC Not required4 Control Building Design4.1 Building floor Level raised by Internal trenches

No (use of porta-cabins is envisaged)




4.2 Specific Equipment LocationsA. Batteries Separate room B. Battery charger (for boost charging) Electrical Room(Note:- For EQUALISING CHARGE/BOOST CHARGE to batteries (whenever required) at stations, it is proposed that the same shall be done through the battery charger which is fed from grid supply.C. Solar Array Out door4.3 Air Conditioning

A. For Telecom /SCADA/Instrument /Control room Required

B. For electrical room Not required 4.4 Fire alarm and detection system Required at all locations

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

5 Equipment Design5.1 MV Switchboard/ Battery Charger/ DCDBMV Switchboard/DC Switchboard:-

-Incomer panel :

Load break Switch/MCCB/switch-fuse contactor Fixed, Single front without rear access, with only front access and maintenance only.

-Outgoing motor feeders Fixed, Single front(If applicable)-Outgoing Switch fuse feeders Fixed, Single front-Outgoing MCB feeders Fixed, Single front5.2 Lighting Panel Wall mounted5.3 Back-up battery5.3.1 Back up Battery

A. Battery type/back up timeBattery type shall be Nickel-cadmium with 72 hours backup time

B. Battery execution

Entire battery capacity shall be split into two banks of 50% capacity nos. at each Unmanned SV/IP station and manned station

5.4 DC to DC converters 5.4.1 Instrumentation power supply Not required- Type Not applicable- Out put voltage Not applicable- Number/configuration Not applicable5.4.2 CP power supply :- Type Galvanically isolated between input and

output. Shall be part of CPPSM- Out put voltage As required- Number/ configuration To be decided by CP system design




5.5 Inverter5.5.1 For Air conditioners Not required- Out put voltage Not applicable- Number/configuration Not applicable5.5.2 Lighting Not required- Out put voltage Not applicable- Number/configuration Not applicable5.6 Cables for Electrical System

5.6.1 TypePVC insulated armoured, PVC sheathed for MV cable and XLPE insulated, armored, PVC sheathed for HV cable

5.6.2 Conductor material Copper up to 16 sq mm and Aluminium for 35 sq mm and above.

5.6.3 Minimum size of cable for power and control cablesa) Medium voltage power cable 2.5 mm² (Copper)b) Control cables 2.5 mm² (Copper)c) Lighting 2.5 mm² (Copper)d) Number of cores for MOV cables NA6.0 Monitoring and control signal through SCADADigital and analogue monitoring and control signals as required for Solar Panel power source, CP system, fire detection and alarm system shall be provided7.0 Cabling System7.1 Cable laying philosophyA. Paved area Cable tray / RCC trenchB. Unpaved area RCC trench / Directly buriedC. Inside Buildings Cable trays / conduits

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

8.0 Earthing System

A. Number of earthing system

4 separate systems (one each for Electrical general & safety earth,, Instruments + Scada / Telecom systemsand lightening protection).

B. Earth electrode GI Pipe/plateC. Main earthloop material GI stripD. Control building earth loop GI9.0 Lighting and Ventilation System9.1 Lighting Control Philosophy ManualA. Outdoor (for stations with electric grid power only)

Manual

B. Building((for stations with electric grid power only: control building and Guard room)

Manual

C. Lighting cum Power Panel control MCCB/MCB




elementD. ELCB at Incomer of AC Lighting cum Power Panels

Yes for DC, Yes for AC

9.2 Wiring TypeA. Out door Armoured cable

B. Buildings Concealed / Surface conduits or cable trays

9.3 VentilationA. Battery room DC exhaust fan

B. SCADA/Telecom roomDC exhaust fan activated by thermostatwith powered louver for exhaust fan and air inlet.

C. Electrical room AC exhaust fan.10.0 Electrical Equipment for Hazardous AreasAll the electrical equipment for Gas Group IIA/ IIB hazardous areas shall be of Ex-d type suitable for temp classification T3.11.0 Statutory ApprovalStatutory Authority for Electrical : Central Electrical Inspectorate/State Installation electrical inspectorate.12.0 CP System12.1 Temporary cathodic protection Required A. Type Sacrificial magnesium anode

B. Design life 1 Year or till commissioning of PCP whichever is later

C. Pipeline coating Three Layer PolyethyleneD. Protective current density As per Cl. 5.1.(iii) of spec. S-07-02-011E. Anode material (for sacrificial CP System)

Zinc/ low potential (1.55 V ) Magnesium

F. Electrical resistance probesShall be provided as per Cl.7.4 of (ER Probes) spec. S-07-02-011

a. Quantity of E/R probes1 no., however location to be decided by CP Contractor based on Cl.7.4.1 of spec. S-07-02-011

b. No. of E/R probe reading instrument One

G. Polarisation couponsShall be provided as per Cl.7.5.2 of spec. S-07-02-011

a. Size of exposed area of coupon 100mm x 100mm

b. No. of coupons To be decided by CP contractor based on Cl.7.5.2 of spec. S-07-02-011

c. No. of magnet devices for operation of magnetic reed switch

By CP contractor

H. Polarisation cell Electrolytic typeI. Additional tests to evaluate the coating defects

Shall not be conducted

K. CPL survey Shall not be conducted during TCP




12.2 Permanent Cathodic Protection SystemA. Type Impressed current typeB. Design life of protection 35 YearsC. Pipeline coating Three Layer PolyethyleneD. Design protection current density As per Cl.5.1.(iii) of spec. S-07-02-012E. Current drainage survey Shall be carried out

F. Type of Anodes for anode ground bed High silicon iron / mixed metal oxide titanium/ Zinc/Magnesium

G. Electrical resistance probesShall be provided as per Cl.7.8 of spec. S-07-02-012 (Also refer Cl.12.1F above)

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

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

b. No. of computerised test station reader

One station readers/ portable data collection & storage instruments.

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

07-02-012 (Also Refer Cl.12.1.G above)J Polarisation cell Electrolytic typeK. Acquisition of land for anode ground bed, anode junction boxes and anode ground bed cable laying

By Contractor

L. Chain link fencing around the ground bed:

Shall be provided

M. Close interval potential logging survey:

Shall be carried out

N. Additional tests to be conducted for identifying pipe coating defects/holidays

:Pearson survey /DCVG survey

O. Proposed location of CP stations/ Anode Ground bed (For impressed Current Cathodic protection system)

As per Pipeline Schematic drg.

P. Proposed location of E/R probes Computerised test stations/ Polarisation Coupons

To be decided by CP contractor during detail engineering based on specifications and in consultation with the GAIL.


JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS

(ELECTRICAL) 0001-01-07-02-001 Page 1 of 10


JOB SPECIFICATION FOR PIPELINE

LAYING AND TERMINAL WORKS

(ELECTRICAL)






CONTENTS

1. GENERAL

2. AREA CLASSIFICATION

3. DESCRIPTION OF REQUIREMENTS FOR CATHODIC PROTECTION AND

ELECTRICAL WORKS

4. INSPECTION, TESTING AND COMMISSIONING

5. DRAWINGS AND DOCUMENTS

ANNEXURE-1: MAKE OF ELECTRICAL EQUIPMENT/COMPONENTS





1.0 GENERAL

1.1 Introduction

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

1.1.2 The electrical portion for pipeline laying work as covered in this specification includes design, supply, installation, testing and commissioning of the power system as per the single line diagrams (SLDs) and description given in this document and other associated documents enclosed with this tender, taking statutory approvals and energizing the system. The contractor shall also prepare electrical layout drawings for equipment layout, cabling layout, lighting layout, earthing and lightning protection layouts, Fire alarm system layout, cable schedule, interconnection diagrams, etc. for each station/Terminal along the route of the pipeline.

1.1.3 The Electrical works at each station/Terminal and all works related to temporary and permanent cathodic protection system for the pipeline shall be executed by contractor in line with scope document, job specification, design basis, data sheets, standard specifications, standard drawings and National/International codes & standards. In case of conflict between various documents, following shall be order of priority:-

- Scope document - Design Basis & Single Line Diagrams - Data sheets - standard specifications/standard drawings - Codes and standards

1.1.4 The work shall be carried out to the best workmanship like manner, in conformity with these specifications, approved drawings/ construction drawings and the instructions of the or Engineer-in-Charge from time to time.

1.1.5 The contract shall include clearing of temporary constructions, waste materials and loose earth, which might get collected in and nearby the work site during execution of work and after final completion.

1.2 Standards

1.2.1 The work shall be performed in conformity with these specifications and code of practices of the Bureau of Indian Standards. In case of any conflict, the stipulations under these specifications shall govern.





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

(a)The Indian Electricity Act and rules framed there under. (b)The fire insurance Regulations. (c) The regulations laid down by Electrical Inspectorate (CEA). (d)The regulations laid down by the Factory Inspector. (e)The regulations laid down by the Chief Controller of Explosives. (f) The regulations laid down by Oil Industries Safety Directorate (OISD).

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

1.3 Guarantee

The contractor shall guarantee the installation for satisfactory operation against any defects of workmanship and materials (supplied by the contractor) for a period as specified elsewhere. Any damage or defect connected with the erection of materials, equipments or fittings supplied by the contractor that may be discovered at the time of issue of the completion certificate, or arise or come to light thereafter, shall be rectified or replaced by the contractor at his own expense as deemed necessary and as per the instruction of owner or Engineer-in-Charge within the time limit specified by the owner or Engineer-in-Charge.

1.4 Site Condition

The equipment offered and the installation shall be suitable for continuous operation under the site conditions mentioned in design basis doc.no. 0001-01-07-03-001.

1.5 Utilisation Voltage

The utilization voltages shall be as per design basis doc.no. 0001-01-07-03-001.

2.0 AREA CLASSIFICATION

Electrical/Control room building at all stations shall be located in safe area. All the electrical equipment to be located in hazardous area Zone 1 or Zone 2, Gas Group IIA/IIB and Temp. class T3, based on area classification as per IS 5572, Indian Petroleum Rules and as shown in the respective equipment specification/ particular specification, shall be flameproof type.





3.0 REQUIREMENTS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL WORKS

3.1 CATHODIC PROTECTION SYSTEM:-The requirements of cathodic protection system have been specified in Design basis document no. 0001-01-07-03-001., data sheets and specifications attached elsewhere in this tender. Temporary cathodic protection(TCP) works to be done immediately upon lowering of pipeline.’

3.2 ELECTRICAL WORKS

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

The power supply shall be met from Solar system at 24V DC (Floating) output. The electrical power distribution to various electrical consumers at 24V DC shall be done from 24V DC switchboard. 24V DC power distribution as required for SCADA, FA panel, DC lighting (in Telecom room, electrical room). Necessary DC-DC converters required for feeding telecom equipment shall be provided as part of DC switchboard.

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

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

3.5 Safety Earth (Instrumentation cabinet earth): The same shall be common earth for Instrumentation/SCADA/Telecom, connected to electrical safety earth. Cables (e.g Instrumentation cables/ Optical cable, etc) coming from field shall also be terminated on this earth

3.6 Signal/system earth : For Instrumentation and SCADA one dedicated earth of 1 ohm to be provided by contractor.

3.7 Separate Earth pits for Lightning conductor/arrestor, Instrument IS and Non IS, Power Supply and Control supply is required to be provided as per OISD Guidelines.

3.8 For Telecom a separate dedicated earth of 1 ohm to be provided by contractor.

3.9 Pipeline contractor shall install earth strips and terminate the earth cables to the respective Instrumentation/SCADA/Telecom equipment cabinet (both





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

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

4.0 INSPECTION, TESTING AND COMMISSIONING

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

4.2 Any work not conforming to the execution drawings, specifications, or codes shall be rejected forthwith and the contractor shall carry out modifications at his own cost.

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

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

5.0 DRAWINGS AND DOCUMENTS

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

5.2 A complete set of reproducible drawings for contractor-supplied equipment shall be furnished to the owner/GAIL for records. As-built layouts, cable schedules and interconnections shall be submitted by the contractor on the hard copies as well as in soft copy usable on a WINDOWS .

5.3 Drawings and data of Solar system power source, Ni-Cd batteries, 24V DC Switchboards, cables, lighting fixtures, CP system shall be submitted for review by owner.

5.4 Vendor catalogues and literature shall be supplied for all equipment included in the scope of Contractor.

5.5 Storage and maintenance instructions along with necessary handling precautions shall be furnished by the contractor for equipment supplied in this tender.

5.6 Minimum 6 sets of drawings/ documents of the vendor-supplied equipment shall be submitted within 4 weeks of order placement. Final set shall be submitted in folders and shall be stamped as final drawing along with the copy of the





necessary test/ inspection certificates. Before submitting the drawings, vendor shall ensure that job number, title, drawing number, equipment number and revision number are marked on each drawing.

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





ANNEXURE-1

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

MV Switchboards (Fixed type) (Item Code- 13BB)

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

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

Associated Flexibles & Wires (P) Ltd./ CCI/ Finolex Cables Ltd./ Gemscab Ind. Ltd./Industrial Cables(I) Ltd./ KEI Ind. Ltd./ Nicco Corp. Ltd./ Polycab Wires Pvt. Ltd./ Radiant Cables Pvt. Ltd./ Ravin Corporation Ltd./ Torrent Cables Ltd./ Universal Cables Ltd./Havell’s India Pvt. Ltd/RPG Cables ltd

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

Associated Flexibles & Wires (P) Ltd./CMI Ltd./Brooks Cable Works, Bombay/ Cords Cable Ind.Ltd./ Delton Cables Ltd./ Evershine Electricals/ Elkay Telelinks (P) Ltd./ Finolex Cables Ltd./ Gemscab Ind.Ltd./ Goyolene Fibres (India) Pvt.Ltd./ Havell’s India Pvt.Ltd./ Industrial Cables(I) Ltd./ KEI Ind.Ltd./ Nicco Corp. Ltd./ North Eastern Cables Pvt. Ltd./ Paramount Communications Ltd./ Polycab Wires Pvt.Ltd./ Radiant Cables Pvt.Ltd./Ravin Cables Ltd./ Reliance Engineers Ltd./ Suyog Electricals Ltd./ Torrent Cables Ltd./ Universal Cables Ltd.

Cables-Fire alarm and comm. (Item Code-13OE).

CMI Ltd./ Delton Cables Ltd./ KEI/ Elkay Telelinks/ Reliance Engineers Ltd./Cords Cable

Anodes for CP system (Item Code-13EA)

Cathodic Control Co. Pvt. Ltd./ Electro Protection Services India (P) Ltd./ PSL Ltd./ Scientific Metal Engineers (P) Ltd

Fire Alarm system(Item code- 13TA)

New Fire Engineers/ Honeywell Inc./ Honeywell Automation India Ltd./ Mather & Platt Pumps Ltd./ Kidde India Ltd. (Formerly-Vijay Fire)/ Edward International

Cable termination & Jointing Kit (Item code-14CB)

Mahindra Engg. & Chemical Products Ltd./ Raychem RPG Limited/ Yamuna Gases & Chemical Ltd./ Heat Shrunk technologies.

Nickel-Cadmium batteries (Item code-13HD)

Amco Power Systems Ltd./HBL Nife Power systems Ltd.

Solar System Central Electronics





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

Lighting Fixtures for non Hazardous area (Item Code-14LB)

Bajaj/Crompton/Philips/Havell’s Ind Pvt. Ltd.

Cable glands for Hazardous area.

Baliga/ Comet Brass Products/ Comet Industries/ Flexpro/ Flameproof Equipment / FCG Power/ FCG Flameproof Control Gears Pvt Ltd./ Prompt Engg. Works/ Sudhir Swgrs. Pvt. Ltd/Standard Metal Industries.

Protection relays (Electromechanical type)

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

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

Control switches/Selector Switches

L&T/ Siemens/ Switron Devices/ Hot Line Swgrs.& Controls/ Kaycee/ Areva T&D India Ltd. / Reliable Electronic components Pvt. Ltd.

MCBs

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

MCCBs GE India Industrial Pvt. Ltd./ L&T/ Schneider Electric

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

Timers Bhartia Ind./ L&T/ Siemens/ Electronic Automation

Meters

Automatic Electric/ Meco Instruments/ Rishab Instruments/ Nippen Electricals Instruments Co./ Areva T&D India Ltd. (Type : Energy meters)

Push Buttons/Indicating lamps

L&T/ Siemens/ Tecknic Controls/ Bhartia Ind./Schneider Electric India Pvt. Ltd./ Shri Tulsi Switchgears/ Controls & Switchgears Contactors Ltd./ Hot Line Switchgears & Controls./ Precifine Product Pvt. Ltd. (For LED type Indicating lamp only)/Essen Deinki

Contactors L&T/ Siemens/ GE India Industrial Pvt. Ltd./ Schneider Electric/ Bhartia Ind./ Controls & Switchgears Contactors, Ltd./ ABB





(Bangalore) L&T/Siemens/ Bhartia Ind./Control & Swgrs. Contactors Ltd./ Schneider Electric/ ABB (Bangalore)/GE India Ind. Pvt. Ltd.

Fuse switch combination

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

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

Earth leakage circuit breaker (ELCB)

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

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

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

Zinc ribbon anode Platt Line/Corpro

Permanent reference cell Borin, USA

Polarisation Cell Kirk, USA

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

Notes:-

1.0 Make of other equipment/components not mentioned above shall be subject to prior approval of Owner.

2.0 Contractor may procure material from any of Owner approved vendor/sub-vendors.

3.0 Contractor can offer component of makes other than specified in the tender, during order execution. The alternate make of components will be evaluated post order, based on the satisfactory track record and test certificates to be furnished by the contractor. In case alternate makes are not found acceptable, components shall be strictly as per above vendor list.

4.0 In case of non-availability of equipment/material from above vendors, alternate makes, if required may be supplied after owner approval.


SCADA I/O LIST FOR ELECTRICAL PARAMETERS 0001-01-07-01-002 Page 1 of 4

Copyright GAIL – All rights reserved

SCADA I/O LIST FOR ELECTRICAL PARAMETERS





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

STATION USING SOLAR SYSTEM AS POWER SOURCEA. Signal List

S. No. DESCRIPTION MONITORING (M)

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

NO. OF SIGNAL

STAG NO.

1 SOLAR SYSTEM START

C D 1 SS-ST

2 SOLAR SYSTEM STOP C D 1 SS-STP

3 SOLAR SYSTEM RESET

As per vendor recommendation

C D 1 SS-RST

4 SOLAR ARRAY CURRENT mA* M A *

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

5 BATTERY CHARGING CURRENT

M A 1 BCC

6 BATTERY DISCONNECTED M D 1 BAT.-DIS7 BATTERY DEEP DISCHARGE M D 1 BDD-B18 BATTERY VOLTAGE M A 1 BTT-V9 LOAD CURRENT M A 1 SY-LC

10 SOLAR PANEL FAULT M D 1 SP-F11 SOLAR CONTROLLER FAULT M D 1 SC-F12 ARRAY FAULT M D 1 AF-F

13 SOLAR SYSTEM CONTROL CIRCUIT

M D 1 SCC-F1

14 BUS VOLTAGE OF MAIN DCDB M A 1 DCDB-V15 GRID POWER AVAILABLE M D 1 GRID-ON16 FIRE DETECTION ALARM M D 1 FA

17 FIRE DETECTION ELECTRICAL ROOM M D 1 FA-ELECT-RM

18 FIRE DETECTION TELECOM/SCADA

M D 1 FA-TEL-RM

19 FAULT IN FIRE DETECTION SYSTEM

M D 1 FA-F

20 CO2 GAS RELEASED M D 1 CO2-PRL

M D 1 CO2-PRL

21AIR CONDITIONING TELECOM/SCADA ROOM ON

M D 1 AC ON

22CO2 CYLINDER WEIGHT LOSS BY LEAKAGE

M D 1 CO2-LKG

2323 VENTILATION SYSTEM ON (TELECOM/SCADA) M D 1 VENT-ON

24 TELECOM/SCADA ROOM TEMP M A 1TEL-RM-TEMP

25

BATTERY ROOM/ELECTRICAL EQPT. ROOM/TELECOM-SCADA ROOM/CO2 ROOM DOOR OPEN

M D 1 RELRM-T




B. Contact configuration of digital inputs to SCADASTATE DESCRIPTIONTAG NO DESCRIPTION

CONTACT CLOSE CONTACT OPENBAT- DIS BATTERY DISCONNECTED NORMAL OPERATION BATTERY DISCONNECTED

BDD-B1 BATTERY DEEP DISCHARGE

NORMAL OPERATION BATTERY DEEP DISCHARGE

SP-F SOLAR PANEL FAULT NORMAL OPERATION SOLAR PANEL FAULT

SC-FSOLAR CONTROLLER FAULT

NORMAL OPERATIONSOLAR CONTROLLER FAULT

AF-F SCC-F1ARRAY FAULT SOLAR SYSTEM CONTROL CIRCUIT FAIL

NORMAL OPERATION NORMAL OPERATION

ARRAY FAULT SOLAR SYSTEM CONTROL CIRCUIT FAIL

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

FA-ELECT RMFIRE DETECTION ELECTRICAL ROOM NORMAL OPERATION

FIRE DETECTION ELECTRICAL ROOM

FA-TEL-RMFIRE DETECTION TELECOM/SCADA ROOM

NORMAL OPERATIONFIRE DETECTION TELECOM/SCADA ROOM

FA-F FAULT IN FIRE DETECTION SYSTEM

NORMAL OPERATION FAULT IN FIRE DETECTION SYSTEM

CO2-PRL CO2 GAS RELEASED NORMAL OPERATION CO2 GAS RELEASED

CO2-LKG CO2 CYLINDER WEIGHT LOSS BY LEAKAGE

NORMAL OPERATION CO2 CYLINDER WEIGHT LOSS BY LEAKAGE

AC-ONAIR CONDITIONING TELECOM/SCADA ROOM ON

NORMAL OPERATIONAIR CONDITIONING TELECOM/SCADA ROOM ON

VENT-ON VENTILATION SYSTEM ON (TELECOM/SCADA) NORMAL OPERATION VENTILATION SYSTEM ON

(TELECOM/SCADA)

RM-TEL-DO

BATTERY ROOM/ELECTRICAL EQPT.ROOM/TELECOM-SCADA ROOM/CO2 ROOM DOOR OPEN

BATTERY ROOM / ELECTRICAL EQPT. ROOM/TELECOM- SCADA ROOM DOOR CLOSED

TELECOM-SCADA ROOM DOOR OPEN

C. Details of Analog inputs to SCADA

TAG NO. DESCRIPTION ANALOG SIGNAL DETAILS

RANGE ALARM (HIGH)

ALARM (LOW)

SAC-A1

SAC-A2*(AS PER NO. OF ARRAYS)

SOLAR ARRAY CURRENT 0-100A

BCC BATTERY CHARGING CURRENT

BATT-V BATTERY VOLTAGE

SY-LC LOAD CURRE NT

DCDB-V BUS VOLTAGE OF MAIN DCDB 0-32V 27.5V 20.5V

TELRM-T TELECOM/SCADA ROOM TEMPERATURE

0-60°C 35°C




D. Contact configuration of digital outputs from SCADA

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

S. No. DESCRIPTION MONITORING (M) /CONTROL (C)

DIGITAL (D) / ANALOGUE (A)

NO. OF SIGNALS

TAG NO.

1 PSP Voltage M A 1 PSP

2 CPPSM OutputVoltage M A 1 CPPSM V

CPPSM Output Current

M A 1 CPPSM I

B. Details of Analog inputs to SCADA

NOTES :1. ALL DIGITAL OUTPUTS FROM SCADA SHALL BE POTENTIAL FREE

CONTACT, WHICH WILL MOMENTARILY CLOSE FOR 2 SECOND FOR ACTIVATION OF CORRESPONDING DIGITAL OUTPUT COMMAND.

2. ALL ANALOGUE SIGNALS TO SCADA SHALL BE THROUGH 4-20 mA TRANSDUCERS.

3. VALUES SPECIFIED UNDER ANALOG SIGNAL DETAILS ARE BASED ON AVAILABLE INFORMATION .EXACT VALUES BASED ON ORDERED EQUIPMENT SHALL BE INFORMED LATER.

STATE DESCRIPTIONTAG NO DESCRIPTION

CONTACT CLOSE CONTACT OPEN

SS-ST SOLAR SYSTEM START SOLAR SYSTEM START NA

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

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

ANALOG SIGNAL DETAILSTAG NO.

DESCRIPTIONRANGE ALARM (HIGH) ALARM (LOW)

PSP PIPE TO SOIL POTENTIAL

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


SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM 0001-01-07-02-005 Page 1 of 12


SPECIFICATION FOR SOLAR ELECTRIC

POWER SYSTEM (ELECTRICAL)





CONTENTS

SECTION TITLE

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 SITE CONDITIONS

4.0 SCOPE OF SUPPLY

5.0 TECHNICAL REQUIREMENTS

6.0 TESTING AND INSPECTION

7.0 VENDOR DATA REQUIREMENTS

8.0 CERTIFICATION

9.0 PACKING AND TRANSPORTATION




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

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

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

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

the relevant standards of :NEC National Electrical Code

NEMA National Electrical Manufacturers’ Association

NFPA National Fire Protection Association

API American Petroleum Institute

ANSI American National Standards Institute

ASTM American Society for Testing and Materials

BIS Bureau of Indian Standards

IEC International Electro-technical Commission

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

3.0 SITE CONDITIONSThe equipment offered and the installation shall be suitable for continuous operation under the site conditions mentioned in design basis doc.no.0001-01-07-03-001. Controller panel shall be designed to be located in closed, ventilated room. Battery Bank shall be designed to be located in closed, ventilated battery room.

4.0 SCOPE OF SUPPLY

4.1 The scope of supply through this specification includes, but not be limited to the following:

4.1.1 Photo voltaic solar panels with mounting accessories, solar power controller.4.1.2 Battery set with stand and its accessories etc.




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

4.1.4 Flame retardant low smoke (FRLS) type interconnecting cables between solar panels and main junction boxes, as required.


5.1 POWER SYSTEMPower system shall include the following equipment :

5.1.1 Photovoltaic solar cell array (Solar panels).5.1.2 Battery Bank5.1.3 Solar power controller

The solar power system shall be self sustained type.The photovoltaic solar cell array (solar panels) and the solar controller shall be sized to meet through battery back-up, the load cycle requirements of the connected loads with the solar energy availability at site under worst weather conditions.

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

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

Solar panels will be mounted on steel support structure of suitable height on the control room roof top. The solar panel array shall be designed based upon Isolation Data (to be gathered by contractor from metrological department) and following design conditions:

i) Output current to be considered at operating point based on following operatingconditions:

a) Cell temperature while delivering current corresponding to Pmax point on the I-Vcurve at specified ambient temperature.

b) Operating voltage considering: Charging voltage of the battery. Voltage drop in cables between solar array and solar controller and solar

controller and battery.




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

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

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

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

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

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

e) Losses in field wiring and array wiring.

f) Losses in solar controller.

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

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

i) De-rating factor of 2% or as applicable (whichever is higher) to account for panel orientation other than the specified one as per insolation data.

j) The solar panels shall be able to fully charge the battery bank after “3 NO SUN DAYS” cycle from the surplus power available from the solar panel in next 14 days with 70% Depth of Discharge of battery.

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

The solar panel shall have suitable supporting arrangement complete with adjustable mounts, solar module fixing accessories, inter-module connections, cable termination arrangement, double compression, nickel/chromium plated, brass cable glands and all other necessary equipment and hardware. The supporting arrangement shall be such as to utilize minimum space on the control room roof top. Unless specified otherwise width of the walkway is 1600mm. The panel dimension and its supporting structure shall be so sized as to leave a clear walkingspace of minimum 750mm. Materials used in the construction of panel frame to support the solar modules, supporting structure and all other accessories shall be suitable for location in extremely corrosive, dusty environment to be encountered. The solar module framing shall be copper free aluminium alloy. Arrangement, such as, vertical stainless steel rods or flexible rods shall be provided to prevent bird landing on the panels. Each panel shall be provided with a weatherproof Junction




box with minimum IP 55 enclosure with removable gasketed front cover for termination of external cables. The electrical terminals in the junction box shall be corrosion proof and anti-loosening type. Suitable bypass diodes shall be provided for partial shadowing of modules, if recommended by manufacturer.

5.3 BATTERY BANK5.3.1 Battery Cells

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

The battery shall incorporate the following features: High charging efficiency. Good cycle life even for deep discharge. Extended life expectancy. Long maintenance interval/Maintenance free for VRLA battery cell. Large electrolyte reservoir.

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

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

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

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

v) 70% Depth of Discharge.vi) Minimum 3 days back-up to independently feed the load plus losses, if any.vii) Design ambient temperature-minimum and maximum site temperatures as given in

Specification- “Site Conditions and Climate”.viii) Deterioration factor over the life span (Actual or 20% whichever is higher).ix) Weight of individual cell shall be of the order of 55 Kg.x) Self discharge during low insolation periods considering average ambient

temperature of 30°C.

The battery shall be able to fully charge after “3 NO SUN DAYS” cycle from surplus power available from the solar panel in next 14 days with 70% depth of discharge.




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

5.4 SOLAR POWER CONTROLLER

5.4.1 Technical requirements

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

The controller shall be provided with low loss type, high efficiency, tested and tropicalized components with overall loss of the solar controller not exceeding 10% of the rated load. MCCBs and MCBs shall be used for the circuit or device protection in place of fuses. However, semiconductor grade fuses shall be used for diodes, SCRs etc. Unless specified otherwise, the solar controller shall be wall mounted type with hinged and gasketed door in the front. The cable entry shall be from top or bottom (to be decided at the time of detailed engineering) through glands and access to all inside equipments shall be from the front only.

The supply system shall be suitable for both negative earthed and unearthed system as required. The provision of negative earthing shall be through an isolating link.

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

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

ii) The battery bank shall be automatically disconnected from the solar panels when the state of charge of the battery reaches 110% or maximum permissible charge level (as indicated by the battery manufacturer) and from the load when the depth of discharge reaches 70%. The battery bank shall be automatically reconnected to the Solar Panel when the state of charge of the battery drops to 100%.

iii) Ammeters to measure load current and solar array current. iv) An array fault indicator to indicate solar array failure. v) Voltmeter to indicate system output voltage and Battery voltage.vi) Charge-discharge Ammeter.vii) Battery deep discharge alarm and indication.viii) Control circuit fail alarm and indication.ix) Switches mounted on the front to disconnect all alarms and indications.x) Necessary transducers for providing two wire 4-20 mA signals for the following

parameters : Battery voltage Solar array current




Battery charging current Load current Solar panel fault indicators

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

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

5.4.2 General Requirements

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

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

Unless specified otherwise, all terminal blocks shall be rated for minimum 20A at 650 volts. The terminal block shall have a white plastic marking strip of the length of the terminal block. Each terminal block assembly shall have 20% spare terminals. All wiring shall be identified by permanent slip-on or clip-on marking sleeves on each terminating wire in addition to marking at the terminal block.

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

5.4.2.04 EarthingAn earth bus bar of minimum 2mm x 3mm size made of electrolytic copper shall be provided, running the complete length of the solar controller. All non current carrying parts shall be bonded with flexible copper wires with the earth bus. The earth bus shall have provisions at both ends for connecting it to earth grid conductor.




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

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

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

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

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

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

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

The company reserves the right to have a representative to witness the final testing and inspection. Prior intimation of at least 20 days shall be given to enable the Company depute its representative to witness the tests.

Testing and inspection shall include but not necessarily limited to the following:

6.1 GENERAL (FOR ALL ITEMS)

6.1.1 A quantitative check to ensure that all items in specified quantity are present.6.1.2 A visual inspection to check workmanship and compliance with submitted

drawings.6.1.3 Dimensional checks




6.2 SOLAR PANELS

6.2.1 Following environmental tests as per applicable IEC/IS shall be carried out on photovoltaic modules on sampling basis. Minimum 2% of ordered modules or 1 No. module, whichever is higher, shall be subjected to following tests and performance of module before and after each test shall be tabulated and furnished. The tests shall be carried out sequentially on each module selected for testing and the tested module shall be discarded after tests.

In case on account of testing:

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

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

The entire ordered lot of modules shall be rejected.S.No Test Test Details

1 Cold Temp (-) 40°C Duration : 16 Hrs

2 Rapid Change of Temp. Low Temp.: (-)40°C High Temp:+ 85°CNo. of cycles :10 Duration of Exposure:30 Min.

3Dry heat 85°C

Duration : 16 Hrs

4 Salt mist Temp. : + 35°C Duration : 48 hrs.

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

6 Rain Test as required in the mentioned standards7 Dust Test as required in the mentioned standards

8 Composite /Humidity Test

Test as required in the mentioned standards

9* Mould Growth 84 days10* Hail Storm test Test as required in the mentioned standard

11** Shock Test Peak Acceleration : 490m/sec 2 Duration : 11msec

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

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




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

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

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

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

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

7.0 VENDOR DATA REQUIREMENTS

7.1 GENERAL7.1.1 Make, type & catalogue no. of equipment.7.1.2 Dimension, weight & general arrangement drawings.7.1.3 Type test certificates.7.1.4 Routine test certificates.7.1.5 Applicable International Standards7.1.6 Installation, Operating & maintenance manual7.1.7 Hazards & safety precaution.7.1.8 Catalogues & Brochures.7.1.9 Interconnection diagram for various equipment along with cable size.7.1.10 Bill of material.7.1.11 Completed data sheet.

7.2 SOLAR PANELS7.2.1 I-V characteristics (plotted on graph) indicating values of Voc, Isc. Voltage & current

(at P max point & operating point) of modules and arrays at 16°C, 28°C, 40°C,60°C cell temperature, at 10 mW/cm2 and 100 mW/cm2 solar insolation.

7.2.2 Temperature co-efficient of voltage & current.7.2.3 Solar panel sizing calculations.7.2.4 Expected life span with 20% degradation in output power.7.2.5 Detailed calculations to verify suitability of structure to withstand wind velocities of

280 km/hr.7.3 BATTERY SET :

7.3.1 Various characteristics curves not limited to the following :i) Charging-discharging characteristics at various cell voltage & temperature.




ii) Self discharge at various ambient temperatures.iii) Cell voltage V/s. State of charge.iv) Capacity V/s. rate of discharge.v) State of charge V/s. Sp. Gravity of electrolyte.vi) Depth of discharge V/s. no. of cycles.

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

7.4 SOLAR CONTROLLER

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

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

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

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

8.0 CERTIFICATIONAll offered equipments or equipments of similar design manufactured by the same supplier : Shall have been type tested by an independent authority. Shall have been in continuous satisfactory service for a minimum period of two

years. Shall be having current certification/approval/listing by an approved agency or UL

or FM.

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


SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY

PIGGING OF PIPELINE 0001-01-07-02-006 Page 1 of 6


SPECIFICATION FOR MAGNETIC

CLEANING AND ELECTRONIC

GEOMETRY PIGGING OF PIPELINE






TECHNICAL SPECIFICATIONS

1.0 INTENT The intent of the specification is to set forth the requirements of the Electronic Geometry Survey of the pipelines to help bidder quote his unit rate price in the schedule of rates. This requirement is not intended to be all inclusive and use of guidelines set-forth does not relieve the contractor of his responsibility of successfully carry out all activities and to obtain reliable and valid data from the EGP tool about condition of the pipeline as defined under Scope of work.

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

3.0 3.0 MAGNET CLEANING PIG RUNS Prior to launching of Electronic Geometry pig, contractor shall complete all activities required to establish adequate cleanliness of pipeline to the satisfaction of the contractor and to verify the internal geometry of the pipeline with relation to ovality, dent etc. Contractor shall decide the number of Magnet cleaning pig runs and the choice of the Magnet cleaning pig for each cleaning run as suitable for the purpose to obtain internal condition adequately clean so as to obtain valid and interpretable inspection data from the Electronic Geometry pig and to safeguard Electronic Geometry pig against damage due to debris in the pipeline.

However, the ferrous debris permitted with magnetic cleaning pig shall not exceed 5 Kg/100KM. In case debris received is more than this amount, the contractor shall be required to make subsequent run(s) until at least the above limit is achieved.

The cleaning pigs for successive cleaning pig runs shall be selected by the contractor in such a manner that effective cleaning i.e. 5kg/100km ferrous debris is achieved.

4.0 ELECTRONIC GEOMETRY PIG RUNS The Electronic Geometry pig should be capable of recording the entire length of each segment i. e. from launcher to receiver in one single run and therefore its electronic recorder system should have requisite data storage capacity. Battery life therefore should be adequate to commensurate with the run time required to travel the pipe length of each segment and the drive cups should have requisite resistance to wear and tear to maintain effective sealing throughout the entire run time.





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

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

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

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

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

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

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

The tool should be capable of negotiating minimum 3D bend and 15%reduction in Pipe ID.

6.0 PIG TRACKING The movement of any type of pig put into the pipeline during Magnetic cleaning and Electronic Geometry Pigging shall be required to be monitored along the pipeline length from launcher to receiver trap. The BIDDER shall detail out the complete methodology of pig tracking proposed to be deployed by him including complete technical details of the equipment and device proposed to be used for this purpose.

It is proposed that pig tracking would be done in a discrete manner at least 5 to 10 KM intervals on each pipeline segment at pre-selected locations. The exact KM chainage of these locations shall be decided at site in consultation with the Contractor and Company.

7.0 DATA ANALYSIS Bidder shall carry out the data analysis for EGP at his data analysis center. The analysis shall consist minimum of following:

o Defect sizing (Depth & length) for all "significant defects" (Deformation > 2% of ID).

o Identification of all pipeline permanent features e.g. valves, tees etc.





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

o The Contractor will transfer all the processed data generated on a CD with user-friendly operation on a compatible PC.

Providing all the raw and processed data along with the software package for enabling company/consultant to study the data as required. The software should be user friendly.

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

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

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

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

defects. The location of each defect should be suitably listed with reference to permanent pipeline features, girth weld no., relative and absolute distance.

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

o Preliminary site report for each pipe segment for each running of Magnet cleaning, and Electronic Geometry pig runs stating comments/observations of each run, pig condition, operating parameters, and total time required.

o Velocity plot of the Electronic Geometry pig along the length of the segment.

The format and Performa of the above report shall be mutually agreed upon between the successful bidder and company. The above report to be submitted in four copies of bound volume.

Final processed inspection log shall also be compiled in a CD having user-friendly operation on a Compatible PC along with the operating software necessary for review/analysis of data. This is required to facilitate selection of significant defects, their chainage and sizing. Contractor will furnish this CD and viewer as part of report.

9.0 DEFECT VERIFICATION At the discretion of the company/consultant identify at least two verification dig sites (In case SIGNIFICANT defects are detected during Electronic Geometry Pigging) for each pipeline segment jointly with GAIL from the recorded data and provide GAIL defect sheet indicating distance from the nearest pipeline feature or reference marker to facilitate location of defect in the field. In case no physical verifiable defect is





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

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

9.1 EGP run shall be considered SUCCESSFUL provided at the end of the electronic geometry Pigging run, the Contractor is able to deliver valid, interpretable and physically verifiable data and which after dig site verification in the field is found in conformity with the Defect Significancementioned at Clause No 5.0 Part II, Technical specification of the bid document.

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

10.0 ABNORMAL SITUATIONS: The objective of this section is to write down foreseeable abnormal circumstances for taking appropriate measures, should such a condition arise during implementation of Project. The company has foreseen the following abnormal conditions. However, if the bidder foresees any other abnormal condition, he is free to make a mention of the same in his technical bid offer.

10.1 TOOL FAILURE Contractor is required to get valid interpretable and verifiable data for each segment of the pipeline. In case contractor's equipment fails to perform electronic geometry inspection to generate valid data for any of the pipeline segment, contractor will make extra runs to get valid and physically verifiable data without any additional cost and time implication to the company.

10.2 STUCK-UP TOOL The bidder shall detail out a contingency plan in his bid as proposed by him in case any of the pigs get stuck up. The plan shall identify procedure for exactly locating the stuck up pig, detail procedure for retrieval of pig, equipment, including support facilities required to retrieve the pig. If Pig does not move from stuck up location, by any of suggested measure, then the pipeline section shall have to be cut for retrieval of Pig. Contractor shall carry out necessary fabrication and modification of pipe with new pipe piece after retrieval of pig at no cost to the company in the event of pig stuck situation for reason attributable to contractor. The pipe shall be issued to contractor by company as free issue material. However locating the stuck up





pig and its retrieval shall always be responsibility of the contractor. After modification pigging Contractor shall run Gauge pig to check internal restriction, if any.

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

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

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

o Bidder should have full-fledged calibration and testing facility for Electronic Geometry Pig tool including test loop of similar size and data interpretation facilities.

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

o Bidder should own the proposed 18" tool.

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

and its related cleaning process) Dubai, UAE iii) M/s TDW India Limited, Baroda iv) M/s BJ Services Company Middle East Limited. v) M/s Graffin Technologies, Baroda vi) M/S Bhotika Pipeline Services Co.Ltd. (In Technical Support With

Analytic Gmbh) New Delhi-vii) M/s SPETSNEFTEGAZ, Moscow


SPECIFICATION FOR CORROSION MONITORING SYSTEM 0001-01-07-02-007 Page 1 of 9


SPECIFICATION FOR CORROSION MONITORING SYSTEM





CONTENTS

1.0 INTRODUCTION

2.0 GENERAL

3.0 SCOPE OF WORK

4.0 SPECIFICATION

5.0 INSPECTION & TESTING

6.0 PAINTING, MARKING & SHIPMENT

7.0 SPARE & ACCESSORIES

8.0 DOCUMENTATION TO BE PROVIDED BY VENDOR

9.0 SUGGESTED VENDOR LIST

10.0 GUARANTEE




1.0 IntroductionThis specification covers the minimum requirements for design, fabrication, supply, installation and testing of corrosion monitoring system to be located on Sultanpur – Neemrana Pipeline.

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

ER-Probes & coupons are located at Sultanpur on the 18” line to Neemrana and consists of : Corrosion probe Transmitter Corrosion Meter Corrosion Coupon ER Probe access fitting assembly

3.0 Scope of WorkDesign, engineering, supply of all materials, preservation at site, fabrication, assembly, erection/installation, testing, commissioning, guaranteeing, trial run, training the client’s personnel, preparation of operation manual, preparation of technical data sheet and engineering drawings and obtaining approval from GAIL for Corrosion Monitoring System as per system description, drawing, specification, standards etc enclosed with the tender document and as per direction of Engineer-in-charge.

4.0 Specification4.1 Technical RequirementsThe electrical resistance (ER) probes & CS corrosion coupons to be installed at the stations as mentioned above shall be retrievable from the line under pressure. The probes & coupons shall be flush mounted on the pipeline. All materials in contact with fluid shall be in accordance with NACE Standard MR-0175. Pipeline inlet pressure may vary according to pipeline pressure drop due to different flow rate, the corrosion monitoring system shall be suitable for operation under this fluctuating pressure conditions.

Each probe shall be connected to a transmitter (2 wire system) to give an o/p of 4~20 mA, proportional to corrosion rate. This o/p will be connected to a panel mounted corrosion meters for direct digital read out of corrosion rate in the control room at each station. The transmitters shall be intrinsically safe certified & suitable safety barriers between transmitters & corrosion meters shall be provided by the vendor. 4-20mA output from the transmitter - corrosion meter shall also be available for interfacing with DCS/ SCADA. The manufacturer shall provide operation manual for these instruments.




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

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

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

datasheet enclosed).Probes shall be high-pressure retrievable type, flush mounted, body in SS316 with element of carbon steel for installation with high-pressure hollow plug access fitting assembly. The probe shall be suitable for measurement of corrosion rate in the range of 0-5 mpy.

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

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

c) ACCESS FITTING ASSEMBLY for ER Probe 2” NB, 5.25” height, flare weld Access Fitting Assembly (non-tee), body carbon steel, acme thread outlet with hollow-plug assembly in AISI-316 alongwith heavy duty protective C.S. cover complete with essential spare. Rating 6000psi.

4.2.2a) COUPONS

Mild steel flush disc coupons l.25” dia x 1/8” thickness with one mounting hole of ID 0.312”. Coupon shall be supplied with hard thin film rust preventive oil, removable by solvent before installation.(Data sheet enclosed)

Total –5 NosRetrievable coupon holder of SS 316 – 1 Nos

b) ACCESS FITTING ASSEMBLY for Corrosion Coupon – 1 Nos2” NB, 5.25” height, flare weld Access fitting Assembly (non-tee), body carbon steel, acme thread outlet with solid plug assembly in AISI-316, alongwith heavy duty protective C.S. cover complete with essential spare. Rating 6000 psi.

4.2.3 RETRIEVER KIT complete with repair & seal kit for ER probes & coupon with holders– 1 Nos. (1 for Sultanpur – Neemrana Section)Rating 1500 psi.




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

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

4.2.4 CORROSION METER – 1 Nos. for ER probe; (Data sheet enclosed)o Resolution: ± 0.1mpy or 0.01 milo Measurement repeatability: + 1 dial divisiono Measurement range: 0-5 mpy.o Operating temp. : (-) 10 °C to 65°Co Complete with suitable safety barrier & two wire cable of required

length between transmitter & corrosion meter, operation and maintenance manual

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

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

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

5.0 INSPECTIONS AND TESTINGThe manufacturer and third party inspector shall carry out inspection and testing as per relevant codes and service requirements of this specification, for all items of his work prior to shipment. Manufacturer’s third party inspector’s test certificates in printed format must be sent with the despatch paper of all supply items.

6.0 PAINTING, MARKING AND SHIPMENTAll items shall be painted and marked as per manufacturer’s standard before shipment.All items shall be properly packed and protected to avoid damage during shipment.Insurance during shipment shall be ensured by the manufacturer.

7.0 SPARE AND ACCESSORIESThe manufacturer shall supply required spare and accessories for 2 yrs operation.

8.0 DOCUMENTATION TO BE PROVIDED BY VENDOR8.1 All component data sheet8.2 Engineering, Purchasing and construction schedule8.3 Spare part list for commissioning & start-up8.4 Spare part list for 2 years operation




8.5 Operating and maintenance manual8.6 Quality control plan8.7 Intrinsically safe certificates with catalogue wherever applicable.8.8 Preservation procedure for coupons, probes and other spare accessories.8.9 Manufacturer’s test certificate/ Third party Inspector Certificate.

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

i) Rohrback Cosasco System, USAii) Metal Samples, USAiii) Cormon, UKiv) Atel, Italyv) Corrocean, Norwayvi) Caproco-UK

All the components shall be purchased from a single manufacturer.

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




CORROSION MONITORING SYSTEM (ER PROBE) – DATA SHEET

Tag no. 30″-P-80-3205-

Line no.

Wall thickness

Pipe material API

Operating temperature (oC)

0-55

Design temperature (oC) 29-65

Operating pressure (kg/cm2g)

45-92

Design pressure (kg/cm2g )

92

Flow(m3/hr.) 11.87

General

Service Natural Gas

Type Retrievable ER probe

Material Body: SS316

Element: carbon steel

End connection 2” flare weld

Probe element type Flush mounted

Element thickness –. 5mil min

Probe

Probe length To be decided by vendor

Type 2” NB, 5.25” height flare weld (non-tee), ACME thread outlet with hollow plug assembly.

Material Body: carbon steelAccess fittings

Hollow plug assembly: SS316

Protective cover RequiredAccessories Retriever & service valve

kitRequired

TypeWith field transmitter and panel mounted corrosion meter installed in control room Monitoring

Nos. As given in 4.2




CORROSION MONITORING SYSTEM (TRANSMITTER) – DATA SHEET

Tag no. Later

Line no. Later

Type 2 wire type

Input ER probe

Output 4-20Ma

Cable lead5’ for ER probe connection and as required for connection to corrosion meter

Power supply 24 VDC from receiver unit

Mounting At site near probe by bracket/ yoke support

Whether intrinsically safe Yes (valid certificate required)

Safety barrier between transmitter & receiver

Yes

Nos. As given in 4.2

CORROSION MONITORING SYSTEM (CORROSION METER) – DATA SHEET

Tag no. Later

Line no. Later

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

between transmitter & corrosion meter, operation & maintenance manual.o Owner will provide 220V power supply for this unit. The unit shall be suitable

to provide 24VDC supply for powering the transmitter’s 4-20mA loop through the two wire cable.

o The unit shall receive 4-20mA signal proportional to corrosion rate from the transmitter through the same two wire cable & provide digital display of corrosion rate through the same two wire cable 4-20 mA signal shall also be available from the transmitter Corrosion meter for interfacing with DCS/ SCADA.

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




CORROSION MONITORING SYSTEM (COUPON) – DATA SHEET

Tag no. Later

Line no. Later

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

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

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

DATASHEET REV-0 GAIL (INDIA) LTD NEW DELHI

DATA SHEET BATTERY BANKS 24V0001-01-04-BC-002 Page 1 of 4


DATA SHEET FOR 24 Volts DC

BATTERY BANKS





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

A Site ConditionsMax.: 40oCDesign ambient tempMin.: 5oC (for battery sizing)

Humidity Highly humid

AtmosphereHighly corrosive and dusty as applicable for refineries

Altitude Less than 1000 m above MSL

B Battery1.0 Type Battery type shall be Nickel-cadmium2.0 Quick charging time 10 hours

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

Duty cycleItem No

Location

Nominal. DC

system voltage

First1 min

Next 28 min

Next.. 90 min

Last1 min

No. of cells Ni-

Cd

End cell voltage Ni-

Cd

1 24V Refer Load analysis doc.no.0001-01-07-08-001

By Contracto

r

1.16

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

Note: The end cell voltage shall conform to the values specified above.4.0 Battery stands formation: Double row double tier5 Accessories required with each battery set

a) Hydrometer (syringe type) suitable for specific gravity reading

2 Nos. for each location

b) Thermometer with specific gravity correction scale

2 Nos. for each location

c) Cell testing voltmeter (3V-0-3V) complete with leads

1 No. for each location

d) Rubber gloves : 2 Pairs for each location

e) Spanner 2 No. for each location

f) Acid-resistant jugs and funnels 2 Nos. each for each locationg) Wall-mounting type teak wood

holder for hydrometer1 No. for each location




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

BATTERY

1 Item no.

2 Tag no

3 Manufacturer's name

4 Type and catalogue no. of cell

5 Ampere hour capacity

6 No. of cells

7 Nominal cell voltage

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

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

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

11 Quantity of electrolyte per cell (litres)

12 Weight of each cell with electrolyte (kg)

13 Quick charging current

13.1 Max. safe quick charging rate (amperes)

13.2 Permissible ripple content

14 Suggested quick charging rate (amperes)

15 Quick charging voltage

15.1 Max. quick charging voltage per cell

15.2 Quick charging voltage per cell for constant voltage finishing charging

16 Float charging voltage per cell

17 Float charging current

17.1 Float charging current range (amperes)




17.2 Permissible ripple content

18 AH efficiency at 10 hours/ 5 hours rate

19 Short circuit current of the battery bank

20 Short circuit withstand time (sec.)

21Max. allowable temp. of electrolyte which the cells can withstand without injurious effects

21.1 Continuously

21.2 For short periods

22 Type of positive plate

23 Type of negative plate

No. of +ve plates per cell

No. of -ve plates per cell

Material and thickness of separators

27 Ampere-hour capacity at min. ambient ___ oC

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

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

27.3 2 hour rate to end cell voltage specified at S. no. 8 above :

27.4 1 hour rate to end cell voltage specified at S. no. 8 above :

27.5 30 minute rate to end cell voltage specified at S. no. 8 above :

28 Dimensions of each battery rack

28.1 Width (mm) :

28.2 Depth (mm) :

28.3 Height (mm)

29 Number of battery racks


DATASHEET FOR MV/HV CABLE 0001-01-07-04-CBL-001 Page 1 of 4


DATA SHEET FOR

H.V/M.V.CABLES





MV CABLE DATA SHEETPart 1

(Data by Purchaser)1. SITE CONDITIONS1.1 Ambient temperature : Max. : 40oC Min. : 10oC

2. SYSTEM PARAMETERS2.1 Voltage

Nominal System Voltage Highest System Voltage Voltage grade□ 415 V 500 V 650 V/ 1100 V□ 3.3 kV(E) 3.6 kV 1.9 kV/ 3.3 kV□ 3.3 kV(UE) 3.6 kV 3.3 kV/ 3.3 kV□ 6.6 kV(E) 7.2 kV 3.8 kV/ 6.6 kV□ 6.6 kV(UE) 7.2 kV 6.6 kV/ 6.6 kV or

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

E: Earthed UE Un-earthed System

2.2 Frequency 50 Hz ± 3 %

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

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

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

Copper (up to 16 mm²)

iii) Control Cables Copper

4 SPECIFIC REQUIREMENTS

4.1 Cable to be flame retardant □ Yes / □No4.2 Type of sheath and armour bonding □ Solidly bonded (earthed at both

ends)

system adopted for single core cables □ Single point bonded □N.A

4.3 Whether installation falls under the jurisdiction □ Yes □ Noof Directorate General of Mines Safety




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

specification (Electrical) document no. 0001-01-

07-02-001

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

Drum length required By Pipeline Contractor

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

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




HV/MV CABLE DATA SHEET

Part 2

(Data by Vendor/Contractor)

1 GENERAL1.1 Name of manufacturer :

1.2 Cable type / code :

2 TECHNICAL PARTICULARS (TO BE FURNISHED SEPARATELY FOR EACH SIZE)2.1 Conductor material :

2.2 Material/ thickness of semi-conductingconductor screen (for HV cables) :

2.3 Thickness of insulation :

2.4 Material/ thickness of semi-conductinginsulation screen (for HV cables) :

2.5 Thickness of inner sheath :

2.6 Calculated diameter of cableunder armour (as per IS:10462) :

2.7 Material/ Type and size of armour :

2.8 Nominal diameter of cable underouter sheath :

2.9 Calculated diameter of cable underouter sheath :

2.10 Thickness of outer sheath :

2.11 Nominal outer diameter of cable :

2.12 Tolerance on outer diameter :

2.13 Type of compound for conductorinsulation, inner sheath and outer sheath

2.14 Max. Drum length of cable :

DATASHEET Rev - 0Gail (India) Ltd. New Delhi

DATASHEET FOR SACRIFICIAL ANODE CATHODIC PROTECTION

SYSTEM FOR PIPELINES 0001-01-07-04-CPS-001 Page 1 of 7

Copyright GAIL – All rights reserve

DATASHEET FOR SACRIFICAL ANODE

CATHODIC PROTECTION SYSTEM FOR

PIPELINES






DATA SHEETSACRIFICIAL

ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES

PART I

(PURCHASER SPECIFIED DATA)

1.0 Type of coating for the pipelines : 3 Layer Polyethylene

2.0 Type of CP system : Permanent / Temporary using sacrificial anodes

3.0 Design life of protection : Temporary CP system : 1 Year or till commissioning of PCP, whichever is later

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

5.0 Corrosion survey data : Corrosion survey shall be conductedby contractor

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

7.0 Test stations To be provided as per requirement

8.0 CP at cased crossings To be provided at TCP stage for carrier pipe and casing pipe based on applicability as per Cl.7.8 of specification no.S-07-02-011.

9.0 Close interval ‘ON’/’OFF’ potential: Shall be carried out during TCP stage particularly atlogging survey interference prone areas such as

EHV/HV transmission lines (11KV & above) / foreign pipeline either crossing/running in parallel.Readings shall be taken after every 24 hours.





10.0 Additional tests to be conducted Pearson survey / DCVG survey / Not required for identifying pipe coating defects/holidays

11.0 Interference detection Required

12.0 Interference mitigation Shall be done using sacrificial anodes only as a part

Of temporary CP system

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

Chainage

S. NoFrom To Pipeline

Dia M

Pipeline Wall

thickness mm

Type of coating

Anode material Zinc /

Magnesium

Anode type

Solid / Ribbon

Anode ground

bed spacing

No. of anodes

per ground

bed Nos.

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

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

11.3. Type of anode installation : Horizontal / Vertical

11.4. Distance between individual anodes : _ _ _ M

11.5. Distance between centre line : 5000 mm min. for magnesium anodes /of pipeline and first anode 2000 mm min. for zinc anodes

11.6. Distance between edge of Pipeline and : 500 mm minmagnesium ribbon anode.

Notes:i. Where sacrificial anode system is specified as temporary cathodic protection

system, unless otherwise specified, monitoring of the sacrificial anode cathodic

protection system till the commissioning of permanent C.P. system shall be

carried out by C.P. contractor.



SYSTEM FOR PIPELINES


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

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

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

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

cases where temporary and permanent cathodic protection works are being

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

for further details.

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

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

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

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

operation and maintenance of complete cathodic protection system and

associated equipment.

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

contractor depending on the protection current requirement of the pipeline as

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

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

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

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

vii. List of acceptable vendors: (Refer Elsewhere)

The make of equipment, materials shall be from GAIL approved vendors.

0001-01-07-04-CPS-001 Page 4 of 7





DATA SHEET

SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES

PART-II

(TO BE FILLED IN BY THE VENDOR)

1.0 Cables

1.1Type : ____________

1.2Voltage grade ____________

1.3Make ____________

2.0 Cable to pipe connection

-For charged pipeline : ____________

- For non charged pipeline : ____________

2.1Make and model number of - ____________

- Cad weld Material : ____________

- Pin brazing equipment : ____________

3.0 Details of anodes

3.1Prepacked type

- Anode material : Zinc Magnesium

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

- Size :

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

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

- Make : _ _ _ _ _ _

3.2Ribbon type

- Anode material : Zinc Magnesium

-Net weight : _ _ _ Kg min per metre _ _ _ Kg min per metre

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

- Make : _ _ _ _ _ _

4.0 Makes

4.1Test stations :

4.2Special Backfill for sacrificial anodes :

4.3Special Backfill for sacrificial anodes :

TECHNICAL NOTES REV-0 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR STATIONARY VALVE REGULATED LEAD ACID BATTERIES Page 6 of 7


FORM-IA

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

Name of CP sub contractor:

EXPERIENCE DETAILS OF HYDROCARBON HANDLING CROSS COUNTRY PIPELINES

Sl No

Description (For Sacrificial

Anode CP System)

Length of Pipe Line

Dia Of

Pipe Line

Type of Coating

Type of Anodes

No of Anode Ground Beds

For The Pipeline

Name of Project & Owner

Work Order No**Date of

Commencement Of Work

Date of Completion

of Work

Name of Backup Agency

Considered

Experience of Backup Agency

1Design and Engineering experience

2Supply of CP equipment / material

3Installation of CP system

4 Testing and commissioning

* Strike out which ever is not applicable

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

0001-01-07-04-CPS-001

TECHNICAL NOTES REV-0 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR STATIONARY VALVE REGULATED LEAD ACID BATTERIES Page 7 of 7


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

Name of CP sub contractor FOR CP System:

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

Mitigation SurveySl No

Cause of Interference

Length of Pipe Line

Dia Of

Pipe Line

Type of Coating

No of CP

Stationsfor the Pipeline

Name of Project & Owner

Work Order No**Date of

Commencement Of Work

Date of Completion

of Work Name of Agency

Experience of Backup Agency

1

Cathodically protected foreign pipelines crossing/ parallel running

2

Cathodically unprotected foreign pipelines/ structures crossing/ parallel running

3

High voltage line AC/DC (66KV and above) crossing & parallel running

4AC/DCelectrified traction

* STRIKE OUT WHICH EVER IS NOT APPLICABLE** COPY OF WORK ORDER AND COMPLETION CERTIFICATE SHALL BE ATTACHED*** LIST OF INTEREFERENCE DETECTION, MITIGATION JOBS DONE ALONG WITH WORK ORDER AND COMPLETION CERTIFICATE SHALL BE ATTACHED

0001-01-07-04-CPS-001

FORM-IB


DATA SHEET IMPRESSED CURRENT CATHODIC PROTECTION



DATA SHEET FOR IMPRESSED CURRENT

CATHODIC PROTECTION SYSTEM FOR

PIPELINES






DATA SHEETIMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES

PART-I(PURCHASER SPECIFIED DATA)

1.0 Pipeline coating : 3 layer Polyethyelene coating

2.0 Type of CP system : Permanent / Temporary

3.0 Design life of protection : 35 Yrs

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

5.0 Current drainage survey : Shall be carried out / Need not be carried out, However current measurement survey for proper current distribution shall be carried out by CP contractor.

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

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

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

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

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

S.NO SPREAD NUMBER QUANTITY OF E/R PROBES REMARKS

A Section A 2 nos.

B Section B 2 nos.

Quantity indicated here in is tentative only. Contractor shall quote unit rates for E/R probes for addition/deletion purpose in future.

9.2 No. of E/R probe reading instrument 1 No. per Part10.0 Computerised test stations : Required

10.1 No. of computerisd test stations : Two Nos. (One per Part)

10.2 Data collection interval : Once every 24 hours interval

10.3 No. of computerised test station : Two Nos. (One per Part) readers/Data retrieval computer of portable type for data collection.

11.0 Polarisation coupons : Required / Not required11.1 Size of exposed area of coupon : 100mm x 100mm

11.2 No. of coupons : To be worked out by CP sub Contractor based on Cl.no.7.12 of spec. S-07-02-012.

11.3 No. of magnet devices for operation To be worked out by CP sub Contractor based on magnetic reed switch on criteria specified in spec. S-07-02-012

12.0 Surge diverter across insulation joints To be provided in line with requirement ofCl.7.9.2 of spec. S-07-02-012.





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

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

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

16 Close interval potential logging survey Shall be carried out

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

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

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

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

Sl. No Locations of ER probes Locations of Computerised test stations

Locations of polarisation coupons

Notes:i) Unless otherwise specified in project specifications/data sheet, integration of the permanent

impressed current CP system with the sacrificial anode temporary CP system (whether provided by a different contractor or included along with the impressed current CP system) shall be the responsibility of the impressed current CP contractor whose scope shall include disconnection of sacrificial anodes wherever required.

ii) The permanent CP system includes certain activities, which are common with the temporary and permanent cathodic protection facilities. In cases where temporary and permanent cathodic protection works are being executed by the same agency, the common activities shall be completed as part of temporary cathodic protection system. In cases where temporary and permanent cathodic protection works are being executed by different agencies, the contractual scope of work shall be referred for further details.

iii) Obtaining approval certificate from electrical inspectorate for electrical installation and carrying out any modifications as per the requirement of electrical inspectorate shall be included in contractor scope.

iv) All civil works associated with the complete cathodic protection system are included in scope ofContractor. This shall include providing cable trenches and foundations for all equipment, kiosks, anode lead junction boxes, all test stations, deep well ground beds, etc.





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

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

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

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

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

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

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

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





DATA SHEETIMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES

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

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

1.2 Material of E/R probe :

1.3 Size of the exposed area of the probe

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

2.0 Permanent reference electrodes

2.1 Make & model no. :

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

3.0 Polarisation cells

3.1 Type :

3.2 Make & model no. :

3.3 Maximum DC leakage current at 400 C at

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

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

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

3.4 50 Hz AC current rating at 400 C

- Contnuous : _ _ _ A

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

3.5 Rated no. of operations over life timeunder maximum ratings _ _ _ Nos.

4.0 Polarisation Coupons

4.1 Exposed area of metal :

4.2 Metal type :

4.3 Make and model no. of reed switch :

4.4 Make and model no. of reed switch :operator magnet

4.5 Rating of reed switch :

-Continuous current rating : _ _ _ A DC, at _ _ _ V DC

-breaking current : _ _ _ A DC, at _ _ _ V DC

5.0 Surge Diverters

5.1 Type :

5.2 Ratings :





5.2.1 Current, 8/20 micro second wave :

5.2.2 AC spark over voltage

-50 Hz AC :

-Impulse(1.2/50 micro second) :

5.3 Make :

6.0 Cables6.1 Type and voltage grade

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

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

6.2 Make

-For anode tail cables :

-For other CP cables :

7.0 Cable to pipe connection- For charged pipeline :

- For non charged pipeline :

7.1 Make and model number of

- Cad weld Material :

- Pin brazing equipment :

8.0 Anode type and make8.1 Impressed current anodes

- Type :

- Make :

8.2. Sacrificial anodes make

-Zinc anodes :

-Zinc ribbon anodes :

9.0 Make of9.1 CPTR unit :

9.2 CPPSM :

9.3 Test stations :

9.4 Anode junction box :

9.5 Cathode junction box :

9.6 Calcined petroleum coke breeze :

9.7 Permanent reference electrodes

-CuCuSO4 type :

-Ag-AgCl type :

9.8 Special Backfill for sacrificial anodes:


DATA SHEET IMPRESSED CURRENT TRANSFORMER RECTIFIER UNIT 0001-01-07-04-CPS-003

Page 1 of 3


DATA SHEET IMPRESSED CURRENT

TRANSFORMER RECTIFIER UNIT




Page 2 of 3


DATA SHEETCATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT

PART - I (TO BE FURNISHED BY PURCHASER)1 Input power supply 240 V ± 10 %, 50 Hz ± 3 %, 1 Phase

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

3 Number of output circuits One/two as required

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

5 Rated output current See note-2

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

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

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

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

10 Number of reference cells for control Two

11 Site conditions

- Design ambient temperature 40 oC

- Relative humidity Highly humid

- Altitude above mean sea level Less than 1000 m

12 Shade of final paint Vendor Standard

13 Commissioning at site By Contractor

14 Remote monitoring and control through SCADA for SCADA I/O) Required (Refer doc.no.0001-01-07-02-002

15 Type of Control

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

- Manual

Constant voltage and constant current Mode (CVCC) having regulated output voltage at set value of constant voltage and constant current with current limit features (as per clause 6.4 of spec. S-07-02-013

16 Current Interrupter Required

16.1Type of current interrupter

Mounted in CPTR unit / Portable Type(GPS based timer interrupters for measuring OFF potentials shall be provided)

16.2 Interrupter controls Auto (operation through SCADA) and (for start, stop, reset) Manual / Manual only

17 Specific requirement (if any) Galvanic Isolation required between input & output circuits.

NOTES : 1. All Pipe to soil potentials (PSP) measured/set values specified are w.r.t. copper-copper-sulphate half

cell. .2. The output voltage, current ratings of CPTR units and their location along the ROW of the pipe line

shall be as per contractor/vendor data in S.No.1 of Part II of the data sheet. 3. CPTR unit shall be provided with a door having transparent glass cover for viewing various

parameters/indications with out opening the door. The type of indicating lamps shall be minimum 10mm dia. LED type.

4. *Separate data shall be furnished for each rating of CPTR unit.5. CPTR units for CP system shall be provided with micro processor based synchronisable ON/OFF

current interrupter timer with GPS interface.



Page 3 of 3


PART - II (TO BE FILLED BY CONTRACTOR/VENDOR)1 Rating of each CPTR unit along R.O.W.

S. No Location along ROWCPTR unit output

rating

Installation in sub station

building/ outdoor kiosk

Size of incomer

cable

Voltage Current

2 Guaranteed technical particulars of CPTR unit

2.1 Efficiency at 10 % load _______________

at 25 % load _______________

at 50 % load _______________

at 75 % load _______________

at 100 % load _______________

2.2Voltage regulation (from zero to100 % load variation and through out the output voltage range(Refer clause 6.4.3 of spec.

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

2.3Current regulation (from 0.5 V to100 % output voltage variation and through out the output current range (Refer clause 6.4.3 of

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

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

spec. no. S-07-02-012) ± ________ mv

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

- At 10% output voltage : * *



(refer clause 6.2.3 of spec. no. S-07-02-012)

3 Technical particulars of Current interrupter

3.1 Type of interrupter Mounted CPTR unit / Portable

type

3.2 Power supply voltage _______________

3.3 Detail of output Contractor

- Make _______________

- Current rating : * A, DC, suitable for the

interruption duty. _______________

- Voltage rating of coil : * V, AC/DC _______________

3.4 Timer Details

- Make _______________

- Timing range

- On 0.1 - 99.9 Sec

- Off 0.1 - 99.9 Sec

- Timing Accuracy _______________*

* Separate data shall be furnished for each rating of CPTR unit.


DATA SHEET IMPRESSED CURRENT CPPSM NUMBER

Page 1 of 3


DATA SHEET FOR IMPRESSED

CURRENT CATHODIC PROTECTION

POWER SUPPLY MODULE




Page 2 of 3


DATA SHEETCATHODIC PROTECTION POWER SUPPLY MODULE

PART - I (TO BE FURNISHED BY PURCHASER)

1 Input power supply 24VDC ±15%

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

3 Number of output circuits One/two as required

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

5 Rated output current See note-2

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

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

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

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

10 Number of reference cells for control Two

11 Site conditions

- Design ambient temperature 40 oC

- Relative humidity Highly humid

- Altitude above mean sea level Less than 1000 m

12 Shade of final paint Vendor Standard

13 Commissioning at site By Contractor

14 Remote monitoring and control through SCADA 0001-01-07-02-002 for SCADA I/O LIST)

Required (Refer doc.no. S-07-02-020

15 Type of Control

- Auto :Close loop control with P.S.P. of reference cells in feedback loop (as per clause no. 6.4 of spec. 6-51-0024).

- Manual

Constant voltage and constant current mode (CVCC) having regulated output voltage at set value of constant voltage and constant current,with current limit feature (as per clause 6.4 of spec. S-07-02-020)

16 Current Interrupter Required / Not Required

16.1Type of current interrupter

Mounted in CPSSM unit / Portable Type (GPS based timer interrupters for measuring OFF potentials shall be provided)

16.2 Interrupter controls Auto (operation through SCADA) (for start, stop, reset) and

17 Specific requirement (if any)

NOTES : 1. All Pipe to soil potentials (PSP) measured/set values specified are w.r.t. coppercopper sulphate half cell. .2. The output voltage, current ratings of CPTR units and their location along the ROWof the pipe line shall be as per

contractor/vendor data in S.No.1 of Part II of the data sheet. 3. DC-DC converter required for galvanic isolation shall be a part of CPPSM unit.4. CPTR unit shall be provided with a door having transparent glass cover for viewing various parameters/indications with out

opening the door. The type of indicating lamps shall be minimum 10mm dia. LED type. 5. *Separate data shall be furnished for each rating of CPTR unit.6. CPPSM units for CP system shall be provided with micro processor based synchronisable ON/OFF current interrupter timer

with GPS interface.’



Page 3 of 3


PART - II (TO BE FILLED BY CONTRACTOR/VENDOR)1 Rating of each CPSSM unit along R.O.W.

S. No Location along ROW CPSSM unit output rating

Installation in sub station building/ in an out door kiosk

Size of incomer cable

Voltage Current

2 Guaranteed technical particulars of CPSSM unit

2.1 Efficiency at 10 % load _______________*

at 25 % load _______________*

at 50 % load _______________*

at 75 % load _______________*

at 100 % load _______________*

2.2Voltage regulation (from zero to100 % load variation and through out the output voltage range(Refer clause 6.4.3 of spec. no. S-07-02-020)

(Manual mode) * _______ %

2.3Current regulation (from 0.5 V to100 % output voltage variation and through out the output current range (Refer clause 6.4.3 of spec. no. S-07-02-020)

(Manual mode) * ________%

2.4 Closed lop PSP regulation in auto mode (refer clause 6.4.3 of spec. no. S-07-02-020)

± ________ mv

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




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

3 Technical particulars of Current interrupter

3.1 Type of interrupter Mounted CPTR unit / Portable type

3.2 Power supply voltage _______________

3.3 Detail of output Contractor

- Make *_______________

- Current rating : * A, DC, suitable for the

interruption duty. _______________

- Voltage rating of coil : * V, AC/DC _______________

3.4 Timer Details

- Make _______________

- Timing range

- On 0.1 - 99.9 Sec

- Off 0.1 - 99.9 Sec

- Timing Accuracy _______________*

* Separate data shall be furnished for each rating of CPSSM unit.


DATA SHEET EMERGENCY GENERATORNUMBER Page 1 of 9


DATA SHEET FOR EMERGENCY

GENERATOR PACKAGE





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

A. Vendor's scope :

Sl.no Description Supply InstallationTesting &

Commissioning

1 Emergency generator complete with brushless excitation and AVR system, frame earthing connections & lubrication system.

Yes/No Yes/No Yes/No

2 Generator control panel with AMF system and control / metering and auxiliary equipments.


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

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

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

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

4 Power and Control cabling in between the package equipment


5 Earthing within the battery limits and connection to main earthing grid


6 Battery & battery charger for control power requirement of the complete DG set.


7 Fabricated steel cable trays and racks as required for cabling in the battery limits


8 Spares for commissioning Yes/No Yes/No Yes/No

9 Spares for two years trouble-freeoperation.


Notes:1. ‘Yes’ indicates activity in vendor’s/contractor’s scope.2. Items listed at sl. no. 2.1, 2.2 & 2.3 can also form part of Generator Control Panel listed

at sl. no. 2.0 above.




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

1 Site Conditions

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

40oC

1.2 Altitude Less than 1000mm above mean sea level

1.3 Humidity Highly Humid

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

acoustic enclosure )

2 Equipment location Outdoor/ Indoor /Shed with sides open/Trolley mounted suitable for outdoor location.(Since DG is for temporary power supply till the commissioning of permanent power source i.e SPV ) suitable FRP sheet over the trolley mounted DG shall also be provided.

Ventilation Adequate/Inadequate

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

4 Power supplies available from owner's system

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

Yes/ No

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

Generator is at standstill)

Not Available

b) Mains supply for auxiliaries: 415V ± 10%, TPN,

Fault level : 9kA (1 sec). (Including for battery charger while

Generator is at standstill)

Not available

5 Acceptable makes for equipment / material Refer Annexure-I of Job specification

6 ATTACHMENTS

6.1 Standard specifications for Emergency Generator Set

7 Rating & Job Requirements (furnished by Purchaser)

7.1 Alternator Data

a. Item No. By Pipeline Contactor

b. Duty Continuous

c. No. Of units 2 nos.(1W +1 S) for each SV/IP station.

d. Type of driver : Self excited internal combustion engine

e. Painting : Epoxy

f. Colour shade : 631 as per IS

g. Rated output : 2 nos.(1W+1S) 10kVA for each Intermediate SV/IP station




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

h. Rated Terminal voltage 415V

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

j. Rated Frequency 50Hz ± 3%

k. System neutral earthing Solidly earthed

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

m. Degree of protection : Minimum IP-23

n. Insulation class Class F (Alternatively Class-H insulation with temp. rise limited to Cl-F is also acceptable)

o. Temp Rise limited to Class B

p. Maximum Transient Reactance (Xd‘)

As per IS:13364

7.2 Technical Particulars

a. Type of excitation system. Brushlessb. Excitation support by PMG Required / Not Requiredc. Type of cooling. Air cooled / Water Cooledd. Short time parallel operation (remark-1) Required / Not Required

e. Continuous parallel operation (remark-1) With state grid /with other Generators / both

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

g. Black start facility. Required / Not Requiredh. Generator start-up time <30 seconds

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

7.3 Termination Detailsa. Generator line side Bus-duct/cable

b. Line side cable -Type/size Refer Single line diagrams(Exact cable size shall be decided during detail engineering.)

c. Neutral side cable-type/size During detail engineering.

7.4 Generator breaker : Required/ Not required

a. Generator breaker rating V Amp

b. Breaking capacity KA

c. Making capacity KA




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

Current transformer for protection CT/PT for AVR

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

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

Ratio

Class 5P10 PS PS 5P10 Cl 1

Burden 15 VA 10 VA 10 VA 10VA

Function protection differential REF earth fault regulation regulation

Vk/Rct 1 2 3 4

Location

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

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

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

3. R-CT: CT for restricted earth fault protection in Neutral, to be located between star point and the neutral tee off point.

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

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

7.4 Protection Relays / Metering :Type Required Type Required

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

O/V relay with time delay Yes / No Synchroscope & cut-off switch

Yes / No

Stand by earth fault relay Yes / No Ammeter with selector switch Yes / No

Lockout relay Yes / No Voltmeter with selector switch

Yes / No

Control supply failure relay Yes / No KWH meter Yes / NoCheck synchronizing relay Yes / No KW meter Yes / NoWinding R.T.D Yes / No P.F. meter Yes / NoBearing R.T.D Yes / No Frequency meter Yes / NoReverse power relay Yes / No Hour run counter Yes / NoThermal overload relay Yes / No Gen. differential relay Yes / NoUnder voltage relay Yes / No

7.5 Control requirements (Refer Clause no. 7.7 also)S. No. Control Function / Element LCP RCP (*)

1 Gen Start/stop P.B Yes / No Yes / No(refer clause no.7.7)

2 Freq increase/decrease P.B $$ Yes / No Yes / No3 Voltage increase/decrease Yes / No Yes / No4 Gen C.B. control switch Yes / No Yes / No5 Synchronizing equipment Yes / No Yes / No6 Auto/Manual selector switch for starting Yes / No Yes / No




7 Auto/Manual selector switch for regulation Yes / No Yes / No8 Local/remote switches Yes / No Yes / No9 Annunciation windows Yes / No Yes / No10 Annunciation accept/reset P.B Yes / No Yes / No$$ Frequency increase/decrease from remote control panel shall be achievable by changeover of contacts (push button type). Vendor to ensure governor suitability for this type of control.

7.6 Indication & alarm :- As per vendor’s standardS. No Function LCP RCP (*)1 Load on mains/generator Yes / No No2 Gen C.B (open/close/trip) Yes / No No3 Control supply failure Yes / No No4 Winding temp high Yes / No No5 Bearing temp high Yes / No No6 Start Failure Yes / No No7 P.T. fuse failure Yes / No No8 DG ready to start (#) Yes / No No(#) DG ready to start indication shall be active only after all auxiliaries of DG set (i.e. lube oil pump, other auxiliary motors, etc.) are in ready/healthy condition.

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

Emergency generator vendor shall provide necessary facility enabling the above mentioned control/monitoring functions to be transferred to the remote control panels by cables.

8 TESTING AT WORKS

8.1 8.1 Witness of Generator Control Panel functional requirements by simulation

Yes/No

8.2 Witness of routine test as per IS:4722, wave form test , vibration test of alternator Yes/No

8.3 Special testsTransient voltage performance with Job AVR and Shop Drivera) By 100 % Load Rejection at 1 pf Yes / Nob) By 100 % Load Application at 0.2 pf Yes/ No




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

a. Make :

b. Temp inside acoustic enclosure : _______ oC higher than design ambient

c. Frame designation :

d. Rated output : KVA

e. Terminal voltage : KV

f. Enclosure :

g. Rated P.F. : Lag

h. Phase/connection/no. of terminals :

i. Full load current : Amps

j. Speed : RPM

k. Rated frequency : Hz

l. Cooling system :

m. Max permissible inductive loading :

n. Steady state 3-phase S.C. currents :

o. 3-phase S.C. withstand time :

p. Type of voltage regulator :

q. Insulation class :

r. Max. permissible impact load :

s. Temperature rise at full load :

Efficiency % 25% Load 50% Load 75% Load 100% LoadRated P.F.Unity P.F.

9.2 Reactances (Mfr. to indicate tolerances)

Sl.no Parameter Abbr Tolerance % Value (pu)

a Direct axis transient reactance Xd’ ±

b Direct axis sub-transient reactance Xd” ±

c Synchronous reactance Xd ±

d Zero sequence reactance X0 ±

e Negative sequence reactance X2 ±

9.3 9.3 Resistances and time constants

a. Armature resistance (25_c) Ohm/phase

b. Armature resistance (100_c) Ohm/phase

c. Transient time constant Td’ Sec

d. Sub-transient time constant Td” Sec




9.4 Local control panel

a. Make :

b. Dimension : mm

c. Type :

d. Degree of protection IP.

e. Weight :

f. Colour shade : 631 as per IS

9.5 Remote control panel

a. Dimension :

b. Weight :

c. Degree of protection : IP-

9.6 Miscellaneous data

a. Alternator dimension (LxWxH) :

b. Stator weight :

c. Rotor weight :

d. Total weight :

e. Coupling : Direct / Through gear Box

9.7 Auxillary Motors

a. Make :

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

c. Enclosure protection : IP- 55

d. Insulation class : 'B'

e. Starting : DOL

9.8 D.C. power supply

9.8.1 Battery

a. Make :

b. Model :

c. Type :

d. No. of cells :

e. Nominal voltage :

f. Nominal capacity :

g. Dimension of rack :

h. Cell arrangement :




9.8.2 Battery charger

a. Make :

b. Model :

c. Input voltage :

d. Float voltage range :

e. Boost voltage range :

f. Float charge current :

g. Boost charge current :

h. Overall dimension LxWxH :

..


DATA SHEET FIRE ALARM SYSTEM0001-01-07-04-FAS-001 Page 1 of 6


DATA SHEET FIRE ALARM SYSTEM





FIRE ALARM SYSTEMDATA SHEET

Part 2(To to be filled in by the vendor)

1 Make, type and model no. of following items

Make Type / Model No Dimensions

1.1 Heat detectors

1.1.1 (safe area) :

1.1.2 (hazardous area)

1.2 Ionisation type smoke detectors

1.2.1 (safe area)


1.3 Photoelectric type detectors

1.3.1 (safe area)


1.4 Linear beam smoke detectors

1.4.1 1 (safe area)

1.5 Manual break glass boxes

1.5.1 (safe area)


1.6 Ultra-violet flame detectors

1.7 I/R detectors

1.8 Heat sensing cables

1.8.1 Detector unit for heat sensing cables

1.9 Wired telephone handset

1.10 Response indicators

1.11 Exit signs

1.12 Hooters

1.12.1 Hooter acknowledge boxes

1.13 Blinking lights

1.14 Halon /CO2 release /Inhibit switches

1.15 Siren

1.16 Detectors where radioactive materials are used

1.16.1 Strength of radioactive material Less than 1 microcurie




2 Conventional fire alarm system

2.1 Central fire alarm panel

a. Make & model no. ::

b. No. of zones

c. Operating voltage & power consumption :

d. Ingress protection IPe.

e. Dimensions (L x D x H) mm

f. Mimic GIntegral/Non-integral

g. LED size

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

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

2.2 Siren

a. Siren :Required/ Not required

b. Output KW/ db at 1 meter

c. Voltage/ phase/ frequency (AC)

DC

V/ Phase/

Hz

V

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

2.3 Mimic panel(if non-integral)

a. Make & model no. :

b. Operating voltage :

c. Mounting : GFloor mounting/GWall mounting

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

2.4 Zonal fire alarm panel


b. Operating voltage & power consumption:

c. Mounting : GFloor mounting/GWall mounting


e. Max. & Min. No. of zones :

f. No. of devices per loop(Max.) :




2.5 Repeat alarm panel


b. Operating voltage & power consumption:

c. Mounting : GWall mounting


e. LEDs arranged in a matrix :

f. LEDs arranged on graphic mimic :

3 Computer aided fire alarm system

3.1 Central fire alarm panel (CFAP)

a. Make & Model no. :

b. Memory capacity :

c. No of inputs :

d. No of programmable outputs :

e. Scanning speed :

f. Operating voltage & power consumption :

g. Software used :

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

100%

i Ingress protection : IP

j. Dimensions (L x D x H) mm

3.2 Video display unit (VDU)


b. Locations :

c. VDU screen size

d. VDU type/ Colour Graphic display/ Text only/ Multicolour


3.3 Printer


b. Quantity :

c. Location :

d. Speed & size :





3.4 Data gathering cum fire alarm panel (DGFAP)


b. Type of panel :

c. Max. and min. number of loops :

d. Max number of devices in each analogue loop :

e. Event history storage processing :

f. Number of programmable outputs :

g. Scan frequency for devices :

h. Operating voltage & power consumption :

i. Communication protocol :

j. Ingress protection : IPk.

k. Dimensions (L x D x H) mm

3.5 Repeat alarm panel


b. Operating voltage & power consumption :

c. Display :

d. Ingress protection : IPe.


4 Battery bank & charger details

4.1 Battery DGFAP CFAP Zonal panel

a. Make

b. Type/model no.

c. AH Rating :

d. No. of cells :

e. Voltage per cell :

f. End cell voltage :

g. Dimensions (L x D x H)mm

4.2 Charger / UPS Charger UPS

a. Make :

b. Type/Model No. :

c. Rating : Amp KVA





5 Power requirements

a. DGFAP (Watts)

b. Zonal fire alarm panel(Watts)

c. The total fire alarm system (Watts):

6 Cables

6.1 Recommended cable / wire size & type

a. Between DGFAP & detectors, manual call points :

b. Between Zonal panel & detectors, manual call

points :

6.2 Recommended cable size & type :

a. Between CFAP & DGFAP :

b. Between CFAP & Zonal panel :

c. Between CFAP & repeat alarm panel :

d. Between DGFAP & repeat alarm panel:

e. Between zonal panel & repeat alarm panel :

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

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


DATASHEET FOR LIGHTING FIXTURES 0001-01-07-04-LF-001 Page 1 of 8


DATA SHEET FOR LIGHTING FIXTURES





FIXTURE TYPE

DESCRIPTION WATTAGE MANUFACTURERE TYPE DESIGNATION

ND1Mounting rail type fixture suitable for 1 x 36 W fluorescent lamp made of stove enamel finish MS sheet steel housing.

1x36 WPhilips-TMC 50 1/136 Crompton-IGP13 14HSB Bajaj-BJIR-136, 140

ND2 Similar to IND1 but suitable for 2x36W fluorescent lamps.

2x36 WPhilips-TMC 50 1/236 Crompton-IGP 1 3-24H5B Bajaj-BJIR-236

ND3

Industrial type fixture suitable for 1x36W fluorescent lamp made of stove enamel finish MS sheet steel housing and vitreous enamelled white reflector.

1x36 W

Philips-TKC 203/136 Crompton-IGE- 1314/ RSE14 Bajaj-BJIV-136

ND4 Similar to IND3 but suitable for 2x36W fluorescent lamps.

2x36 WPhilips-TKC-203/236, Crompton-IGE 1324/ R5E24 Bajaj BJIV-236

ND5 Similar to ND3 but with white epoxy powder coated from inside and outside with reflector.

1x36 W

Philips-TKC-203/136 Crompton-IGP- 1314 /RPC14 Bajaj BJIE-136

ND6 Similar to IND5 but suitable for 2x36W fluorescent lamps. 2x36 W

Philips-TKC-203/236 Crompton-IGP 1324 /RPC24 Bajaj BJIE-236

SFD3 Pendent mounting decorative fixture suitable for 1x36W fluorescent lamp with opal acrylic cover 1x36 W Philips TCS-19/136

Crompton-CPA 1114 HSB

SFD4

Ceiling/pendant mounting fixture suitable for 2x36 W fluorescent lamps with opal acrylic translucent diffuser and high import black polystyrene end plates.

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

SFD5Ceiling/pendent mounting decorative fixture suitable for 2x36W fluorescent lamps with serrated Al. cross louvres.

2x36 WPhilips TCX-398 / 236 Bajaj BJSM-02236 Crompton CMLM 24HITW

SFD6

Wide spread decorative ceiling/pendent mounting fixture made of white stove enamelled sheet steel housing and aluminum mirror optic system to achieve wide light distribution and having a serrated Al. cross louvres suitable for 2x36 W fluorescent lamps.

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

SFD9 Ceiling mounting decorative fixture suitable for 4x18 W fluorescent lamps with dished opal acrylic cover.

4x1 8 W Crompton CSP 42HITW Bajaj BJMP-420

SFD1O Similar to SFD9 but with prismatic louvers. 4x18 W Crompton CRL 42HITW/P Bajaj BJML-420

SFD12 Ceiling/wall mounting fixture with prismatic glass cover.

1x60 W/ lxl00 W

Crompton IBH-1 1 1OBC PHILIPS FXC1O1 Bajaj BJDB-100

SFD13

Wide spread minor optics with decorative finish on ends. Ceiling/ pendant luminaries fined with aluminum reflector and having serrated cross louvers suitable for 2x36 W fluorescent lamps.

2x36 WPhilips TCS 3 1/236 White Bajaj BJSM 236 Crompton CSBW 11 24H5B

SFDI4

Widespread minor optics decorative recess/surface mounting luminaries fined with aluminum reflector and having serrated Al. cross louvers suitable for 2x36 W fluorescent lamps.

2x36 WPhilips TCS 306/236 Bajaj BJCM 236 Crompton CRFG 24H5B




FIXTURE TYPE DESCRIPTION WATTAGE MANUFACTURERE TYPE

DESIGNATION

SFD15

Widespread minor optics ceiling mounted luminaries with high purity aluminum reflector and serrated Al. cross louvers suitable for 2x36 W compact fluorescent lamps.

2x36 W Bajaj BLSM 236 CFLP2 Crompton CRDI 236

SFD16 Widespread minor optics decorative ceiling/pendent luminaries suitable for 1x36 W fluorescent lamps. 1x36 W Philips TCS 498/136

Bajaj BJPMS 136

RSD1

Wide spread, mirror optics decorative recess mounting fixture for use in areas with strip false ceiling having a reflector made of high purity aluminum sheet and fined with serrated Al. cross louvres, suitable for 1x36 W fluorescent lamp.

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

RSD2

Wide spread mirror optics decorative recess mounting fixture having a reflector made of high purity aluminum sheet and fined with senated Al. cross louvres across the minor system for minimizing glare, suitable for 2x36 W fluorescent lamp.

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

RSD6

Recess mounting luminaries with minor system housing and dispersive anodised aluminum reflector for use in areas with strip false ceiling type suitable for 2x36W fluorescent lamp.

2x36 W

Philips TBS 285/236(DL) Darklite Crompton CRFD 24H5B Bajaj BJDL 236

RSD7 Same as above but with 4x18 W fluorescent lamp. 4X18WPhilips TBS 300/418M1 Crompton CRFL 42H5B Bajaj BJDL 418

RSD9 Recess mounting decorative fixture suitable for 4x1 8 W fluorescent lamp with dished opal acrylic cover. 4x18 W

Philips TBC-305/418(0) Crompton CRP 42HITW Bajaj BJMP 420

RSD10 Recess mounting down-lighter fixture with 60/100W incandescent lamp.

1x60 W/1x100 W

Philips DN 622Crompton DDLV 10BCBajaj BJDR 100

RSD12 Same as RSD6 but for single 36 W fluorescent lamp. 1x36 WBajaj BJDL 136 Philips TBS 185/136 (DL) Crompton CRFD 14 HSB

RSD13 Similar to RSD1 but suitable for 4x18W fluorescent lamps. 4x18 W

Philips TBS-305/418 Crompton CRFD 42H5B Bajaj BJMM 420

LB 1 Low bay sheet steel fixture, with wide distribution mirror system, bracket mounting suitable for 70 W sodium vapour lamp.

lx7OWPhilips SGK-27 Bajaj BJRLB-7OSV Crompton LSA 7TH

LB2 Same as LB 1 but with wire guard. lx7OWPhilips SGK-27 Crompton LSA 7TH Bajaj BJRLB 7OSV/WG

LB3

Medium bay fixture made of sheet steel finished with stove enamel light grey. The housing is closed with clear toughened glass fitted with a robust MS frame with anodised aluminum reflector and complete with integral control gear, suitable for 125 W HPMV lamp.

lxl2SWBajaj BJRLB Crompton LMA 1112 1H/BC Philips HGK 27

HB1 Industrial high bay fixture with anodised aluminum reflector, suitable for 250 W HPMV lamp complete with integral ballast, capacitor etc.

1x250 WPhilips HDK225HPL250 Crompton TMB 1 325TH Bajaj BJHBT-250





DESIGNATION

HB2 Similar to HB1 but with 400 W HPMV lamp. 1x400 WPhilips HDK225HPL400 Crompton TMB 1 34OTHIP Bajaj BJHBT-400

HB3 Similar to HB1 but with a gasketed front glass cover. 1x250 WPhilips HDK-103/250W Crompton THS-1225TH1P Bajaj BJHBT-250MV

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

HB5 Similar to HB1 but with 150W SON lamp. 1x150 WPhilips SDK-100 Bajaj BJMBT-150 Crompton SHS-1215 TH

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

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

CM2 Chemical resistance fixture suitable for 2x36 W fluorescent lamp.

2x36 WPhilips TMX-95/236Crompton IFV-24H/TWBajaj BJI-236 VP

CM3

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

2x18 W Philips TDC-10/218 Bajaj BJI-218FG

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

CM5

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

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

CM6 Dust & Vapour proof fixture suitable for lx4OW fluorescent lamp with glass sheet cover.

lx4OW Crompton IFV 1 124H/TW Bajaj BJI-136FG

COMPACT FLUORESCENT LAMP (CFL)

CFL 1 Wall/ceiling mounting fixture suitable for 9W CFL with opal acrylic diffuser. 1x9 W

Crompton TLN 91 LPhilips FWN 012 (OPAL)Bajaj BJEXL 19

CFL2 Recess mounted luminaries, fitted with anodised aluminum reflector suitable for 9W CFL. 1x9 W

Philips FBS-03Crompton DDLV9Bajaj BJMR 19

CFL3 Ceiling mounted decorative luminaries, with minor louvers suitable for 2x11 W CFL. 2x1 1 W

Crompton TLE 211Philips FCS-31/211Bajaj BJMS 211

CFL3 (with DC choke)

Similar to CFL3 but with built in D.C. choke 2x1 1 WContractor to select subject to approval of GAIL Engineer-in-Charge

CFL4 Recess mounted decorative luminaries, with minor louvers suitable for 2xllW CFL. 2x1 1 W

Crompton TLD 211Philips FBS-285/211Bajaj BJMR 211




FIXTURE TYPE


CFL 4 (with DC choke)

Similar to CFL4 but with built in D.C. choke 2x1 1 WContractor to select subject to approval of GAIL Engineer-in-Charge

CFL5 Decorative wall/ceiling mounted luminaries with opal acrylic cover suitable for 2x9W CFL.

2x9 W Crompton TLK 29 Bajaj BJDS 29

CFL6 Similar to CFL5 but in horizontal version suitable for 2x9W CFL. 2x9 W Crompton DDLH29

CFL7 Similar to CFL6 but in round shaped. 2x9 W Crompton TLJ29 Bajaj BJDR29

OUTDOOR TYPE FIXTURES

ST1Street lighting fixture suitable for 2x36W fluorescent lamps made of stove enamelled grey aluminum canopy and acrylic transparent cover.

2x36 WPhilips TRC-34/236Crompton SFE-24H/TWBajaj BJSLA-236/240

ST2 Similar to ST1 but suitable for 2x18W fluorescent lamp. 2x18 W Philips TRC-33/220

Bajaj BJSLA 220

ST3

Street lighting fixture suitable for 125W HPMV lamp with cast aluminum housing stove enamelled grey outside and white inside, a pair of anodised aluminum reflectors and highly transparent clear acrylic sheet cover with hinge and toggle fastening, neoprene gaskets and integrated pre-wired ballasts etc.

1x125 WCrompton MSC-1 112 IH Bajaj BJMSD-125MV Philips HRP-48

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

ST7 Similar to 5T3 but suitable for 35 W SOX low pressure sodium vapour lamp. 1x35 W Philips XRP-5 1/35

Bajaj BJLS-35

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

ST9 Similar to ST1O but suitable for 70W HPSV tubular lamp.

1x70 W Crompton SSG-1407 TH/WT Bajaj BJMSC-705V

ST1O Single piece die-cast aluminum body street light fixture with bowl type Al. reflector and with clear acrylic cover suitable for 150 W SON tubular lamp.

lxlSO WPhilips SRP 51 Bajaj BGEST 150 Crompton SSG 1515 TH

PT1 Post top lantern suitable for 80W HPMV lamp with necessary control gear and housing attachment. (Tntegral type).

1x80 WCrompton MPT-1 18TL Bajaj BJPTT-8OMV Philips HRC-40/80

PT2 Similar to PT1 but suitable for 125W HPMV lamp. (Tntegral type). 1x125 W

Crompton MPT-1 12TL Bajaj BJPTT-125 Philips HRC 40/125W

PT3 Similar to PT1 but suitable for 70W HPSV lamp. (Integral type). 1x70 W

Crompton SPT-71 17TL Bajaj BJPTT-70 Philips HRC-40/70W

PT4

Decorative luminaries made of coloured FRP with clear acrylic cover suitable for aesthetic and decorative lighting of lawns and parks etc. with 1xGLS6OW lamp.

1x60 W Philips NGC 100 Bajaj BJB 100

PT5 Similar to PT4 but suitable for 9W CFL. 1x9 WPhilips FGC-100 Crompton CFBL-9 Bajaj BJBE 19




FIXTURE TYPE


BK1

Bulk head fitting with cast aluminum alloy body having stove enamelled finish (silver grey outside, white inside) and complete with prismatic front glass, wire guard, tropicalised gasket and BC lamp holder suitable for 100W GLS lamp.

1x100 WCrompton IBH-1110BCBajaj BJDB-100

BK2

Similar to BK1 but with pressed aluminum body, finished stove enamelled grey outside white inside with frosted front glass fitted with tropicalised gasket and without wire guard.

lx 100 W Philips-NXC-1 1 Crompton IBH-111OBC

BK3

Industrial well glass fixture with cast aluminum alloy mounting piece and a sheet aluminum canopy stove enamelled white inside and grey outside with heat resistant glass and wire guard suitable for upto 200W GLS/160 W MLL.

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

BK4 Similar to BK3 but suitable for 125 W HPMV lamp with necessary control gear and housing attachment.

1x125 W

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

BK5 Similar to BK3 but with additional vitreous enamelled reflector.

lx 100 WPhilips NDC-22 Crompton IWV 2OBL/Y Bajaj VWI 125/VE

FD1

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

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

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

FD4

Flood lighting fixture suitable for 2x400W HPMV lamps made of cast aluminum with cooling fins, anodised reflector gasketed heat resisting glass front cover, easy relamping facility (without disturbing the beam direction) protector scale for quick day light adjustment.

2x400 WPhilips MNT-00 1 Crompton FHD-1224 Bajaj BJEF-22CA/ BGENF 22

FD6

Flood light fixture of cast aluminum housing and spun aluminum reflector heat resistant glass cover and adjusting facility suitable for lx250W HPSV lamp. (IP-54 enclosure).

1x250 WPhilips SVF-12 Crompton-FBD 14 Bajaj BJEF 18 (5)

FD7 Similar to FD6 but with 2x250W HPSV lamp. 2x250 WPhilips SNT-00l Bajaj BJEF-22 CA/BGENF 22 Crompton FHD- 12/24

FD9 Similar to FD6 but with 2x400W SON tubular lamp. 2x400 WPhilips SNT-001 Bajaj BJEF-22CA/ BGENF 22 Crompton FHD- 12/24

FD10 Similar to FD6 but suitable for 1x250W SON tubular lamp. 1x250 W

Philips SNF-14 Bajaj BJEF-14CAT Crompton FAD-i 114

FD1 1 Similar to FD6 but suitable for 2x250W SON tubular lamp. 2x250 W

Philips SNT-00i Bajaj BJEF-22CA/ BGENF 22 Crompton FHD- 12/24





DESIGNATION

FD12 Similar to FD6 but suitable for ix400W SON tubular lamp.

1x400 W Philips SNT-14 Bajaj BJEF-14CAT Crompton FAD-i 114

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

FD14

Integrated flood lighting fixture of die-cast aluminum housing with ALGLAS reflector, heat resistant toughened clear glass cover suitable for 150 W HPSV lamp.

1x150 W Bajaj BGEMF 1505 V

AV1 Neon aviation obstruction lighting fixture complete with neon lamp, designed to give omni directional steady ‘ON’ red colour light.

1x100 W Bajaj BJAOL-i




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

FLP-1 Flameproof and weatherproof well glass lighting fixture for use in zone-i classified areas with 100/200W incandescent lamp.

1x 100 W / 1x200W

FLP-2 Same as FLP-i but with 160W ML blended lamp. 1x 160 W FLP-3 Same as FLP-i but with SOW HPMV lamp and separate control gear. 1x80 W FLP-3a Same as FLP-3 but with integral control gear. 1x80 W FLP-4 Same as FLP-i but with 125W HPMV lamp and separate control gear. 1x125 W FLP-4a Same as FLP-4 but with integral control gear. 1x125 W FLP-5 Same as FLP-i with 250W HPMV lamp and separate control gear 1x250 W FLP-5a Same as FLP5 but with integral control gear. 1x250 W

FLP-6 Flameproof and weatherproof flood lighting fixture with 500W incandescent lamp.

1x500 W

FLP-7 Same as FLP-6 but with 250W HPMV lamp. 1x250 W FLP-8 Flameproof bulk head lighting fixture with 100W incandescent lamp. lx 100 W FLP-9 Same as FLP6 but with 400 W HPMV lamp. 1x400 W

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

2x36/40 W

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

Exe-1 Weatherproof well glass increased safety lighting fixture for use in zone-2 classified areas with 100/200W incandescent lamp. Lx100 W

Exe-2 Same as Exe-1 but with 160W blended lamp. lx 160 W Exe-3 Same as Exe-1 but with 80W HPMV lamp and separate control gear. 1x80 W Exe-3a Same as Exe-3 but with integral control gear. 1x80 W Exe-4 Same as Exe-1 but with 125 W HPMV lamp and separate control gear. 1x125 W Exe-4a Same as Exe-4 but with integral control gear. 1x125 W Exe-5 Same as Exe-1 but with 250 W HPMV lamp and separate control gear. 1x250 W Exe-5a Same as Exe-5 but with integral control gear. 1x150 W

Exe-6 Increased safety & WP Well glass lighting fixture for use in zone-2 classified areas with 400 W HPMV lamp. 1x400 W

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

1x200 W

FLP IIC-2 Flameproof & WP Well glass lighting fixture with 80 W HPMV lamp for use in TIC classified areas 1x80 W

FLP IIC-3 Flameproof & WP Well glass lighting fixture with 125 W HPMV lamp for use in TIC classified areas.

lxl25W

FLP IIC-4 Flameproof & WP Well glass lighting fixture with 250 W HPMV lamp for use in TIC classified areas. 1x250 W

NOTES: 1. All fixtures shall be complete with lamps. 2. All fluorescent/Mercury vapour! Sodium Vapour fixtures shall be high power factor (Mm. 0.9) type.3. All fluorescent fixtures shall be fitted with low loss type (i.e. limited to 9W loss) ballast. 4. All 36 W fluorescent lamp can be replaced by 40W with the consultation of site engineer-in-charge. 5. All mirror optics luminaries should be epoxy powder coated. 6. Make of fixtures shall be embossed on the body.


DATA SHEET FOR AC/DC SWITCHBOARD 0001-01-07-04-SB-002 Page 1 of 8


DATA SHEET FOR AC/DC SWITCHBOARD





DATA SHEET FOR 24V DC SWITCHBOARDPART-I (TO BE FURNISHED BY PURCHASER)

1.0 SITE CONDITIONS:1.1 Design Temp 40°C

1.2 Relative humidity Highly humid

1.3 Altitude above MSL Less than 1000 m

1.4 Location Various

1.5 Atmosphere : Highly corrosive and dusty as applicable for refineries

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

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

2.3 No of phases 3 (applicable for AC switchboards)

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

withstanding fault level/current as applicable for short circuit

contribution of Ni-Cd batteries at a particular location)

2.5 System earthing Solidly earthed for AC & Floating for DC

2.6 Auxiliary supply -

2.7 Power supply forspring charging motor N.A.

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

(However DC Switchboards shall be suitable for withstanding

fault level/current as applicable for short circuit contribution of

Ni-Cd batteries at a particular location)

3.3 Busbar current rating insidepanel at specified ambient As per Single line diagrams

3.4 Busbars Insulation Heat shrunk PVC Sleeves

3.5 System breaking capacity Min.25kA for 415 V AC & Min. 10 kA for DC switchboards (However DC Switchboards shall be suitable for withstanding fault level/current as applicable for short circuit contribution of Ni-Cd batteries at a particular location)

3.6 System making capacity As per approved Test certificates




3.7 Type of Circuit breaker Not applicable

3.8 Duty cycle of breaker Not applicable

3.9 Incoming power entry Cable as per data sheets

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

3.11 Bus duct entry Not applicable

3.12 Cable gland/lugs Included

3.13 Colour shade Exterior As per IS-5

3.14 Feeder arrangement Single front, fixed type suitable for flush mounting against wall with front access, front maintenance only and without rear access. Contractor shall ensure that equipment supplied can be located in available space. For incoming and outgoing feeder details, refer SLDs

3.15 Minimum motor starter module size Vendor standard

3.16 Minimum switchfuse module size Vendor standard

3.17 Floor fixing Integral base frame and tack welding to the floor channel

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




PART-II(TO BE FILLED UP BY VENDOR ALONG WITH QUOTATION)

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

2.0 Type / designation :

3.0 Degree of protection :

4.0 Overall weight of CB panel

Incomer kg

Outgoing kg

5.1 Overall dimensions of CB panel

Length : mm

Depth : mm

Height : mm

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

5.2 Overall dimensions of MCC/contactor controlled feeder panel:

Length : mm

Depth : mm

Height : mm

6.1 Overall dimensions of each switchboard:

PCC (Length*Depth*Height) : mm

PMCC (Length*Depth*Height) : mm

MCC (Length*Depth*Height) : mm

ASB (Length*Depth*Height) : mm

LDB (Length*Depth*Height) : mm

6.2 Overall weight and dimensions of largest shipping section:

Weight : kg

Length : mm

Depth : mm

Height : mm

7.0 Recommended clearances for SWBD




Front : mm

Rear : mm

Above : mm

8.0 Shock loading on foundation :

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

cables that can be terminated inside the panel

with rear extension/ without rear extension :

10.0 Clearance in air

Phase to phase : mm

Phase to earth : mm

11.0 Main horizontal bus bar

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

11.2 Main bus bar size :

11.3 Main bus bar material : Al/Cu

11.4 Main bus bar location : Top/Bottom

12.0 Vertical bus bars

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

12.2 Bus bar size :

12.3 Bus bar material : Al/Cu

13.0 Insulating material :

14.0 Earth bus size/material : mm2/ Al / Cu

15.0 1 min power frequency voltage : kV

16.0 1 sec short circuit withstand capacity : kA

17.0 Peak dynamic withstand capacity : kA

18.0 Safety shutter provided for

test and drawout positions : Yes/No

19.0 Whether adaptor panel required

between PCC/MCC panel : Yes/No

19.1 If Yes, furnish dimensions :




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

21.1 Make :

21.2 Type designation :

21.3 No of poles/phase :

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

21.5 In panel current rating at site conditions : A

21.6 Breaking capacity : kA

21.7 Short time rating (1 sec) : kA

21.8 Peak making current : kA (peak)

21.9 1 min dry withstand volt (power frequency) :

21.10 Duty cycle :

21.11 Total opening time : m sec

21.12 Total closing time : m sec

21.13 Power required for opening : W/VA

21.14 Power required for closing : W/VA

21.15 Power required for spring charging motor : W/VA

21.16 Breaker is trip free : Yes

21.17 Closing mechanism :

21.18 Provision of manual spring charging : Yes

21.19 Tripping mechanism :

21.20 Mechanical trip PB provided : Yes

21.21 Mechanical ON/OFF indicator provided : Yes

21.22 Operation counter provided : Yes/No

21.23 Time taken for spring charging : sec

21.24 No. of auxiliary contacts : NO + NC

21.25 Derating required for capacitor switching : %




22.0 CONTACTOR ( Following data for each rating of contactor)

22.1 Make :

22.2 Type designation : __________

22.3 Rated voltage : __________

22.4 Rated current __________

AC-3 Duty : __________

AC-4 Duty : __________

22.5 Thermal rating : __________

22.6 Making capacity : __________

22.7 Breaking capacity : __________

22.8 Switching frequency : ops/hr __________

22.9 Life Electrical : _________ ops (at rated voltage)

Mechanical : ops

22.10 Coil consumption - Pick up : VA

22.11 Coil consumption - Hold on : VA

22.12 Closing time : secs

22.13 Opening time : secs

22.14 No of aux. contacts : NO + NC

22.15 Maximum permitted back up fuse rating :

23.0 SWITCH ( Following data for each rating of switch)

23.1 Rated voltage : __________

23.2 Rated current : __________

23.3 AC 23 rating : __________

23.4 Rated making capacity : __________

23.5 Rated breaking capacity : __________

23.6 Rated short circuit withstand current with

max. permissible rated fuses : __________

23.7 Mechanical life : __________

23.8 Maximum permitted back up fuse rating : __________




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

24.1 Make : __________

24.2 Type : __________

24.3 Setting range : __________

24.4 Single phasing preventor : Intergral / Separate

24.5 Type of operation : Direct / CT operated

24.6 Maximum permitted back up fuse rating : __________

25.0 FUSES ( Following data for each rating of fuse)

25.1 Make : __________

25.2 Type : __________

25.3 Current rating __________


DATASHEET FOR SOLAR ELECTRIC POWER SYSTEM 0001-01-07-04-SPS-01 Page 1 of 5


DATASHEET FOR SOLAR ELECTRIC

POWER SYSTEM (ELECTRICAL)





1 Solar System

1.1 Type Photovoltaic

1.2 Application Telecom; scada; lighting and other electrical loads

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

1.4 Ripple Output 20 mV

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

1.6 System Earthing Floating

1.7 Battery Backup Required Yes

1.8 Type Of Alternative Energy Source Available Grid Power

1.9 Location (Solar Panels) Unclassified Area

1.10 Wind Velocity (Max.) Refer Elsewhere

1.11 Latitude Refer Elsewhere

1.12 Longitude Refer Elsewhere

1.13 Ambient Temp Refer Elsewhere

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

1.15 Expected Life Span 25 years for all components

2.0 Solar Panel

2.1 Module Output Watts Peak

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

2.3 Load To Be Disconnected If Battery State Of Charge Is Low (Indicate SoC %)

Yes (30%)

2.4 Pv Array Mounting Considerations

2.5 Clear Space Required For Mounting The Solar Panel Array

2.6 System Downtime Considerations (To Determine System Safety Factors)

2.7 Solar Module Framing Material

2.8 Module Dimensions /Weight

2.9 Junction Box Material Of Solar Panel

2.10 Material Of Bird Spikes

2.11 No. Of Bird Spikes Per Module

2.12 No. Of By-Pass Diodes Per Module

2.13 Make And Type Of By-Pass Diodes




1.14 No. Of Solar Cells Per Module

2.15 Solar Cell Manufacturer’s Type Ref. No.

2.16 Make Of Solar Modules

2.17 Country Of Origin

2.18 Weight Of Solar Module

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

2.20 Nominal Voltage Of Solar Array

2.21 Annual Deficit Of Capacity (Ah) From Solar Array

2.22 Weight Of Solar Array

2.23 Dimension Of Solar Array

2.24 Material Of Solar Array Junction Box

2.25 Degree Of Protection Of Solar Array JB

2.26 No. Of Solar Panels

3.0 Solar Controller Panel

3.1 Type

3.2 Enclosure Degree Of Protection IP-51

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

3.4 Weight

3.5 Mounting Floor mounted

3.6 Cable Entry From bottom

3.7 Access From front only

3.8 Internal Wiring Minimum Size Control 2.5 sq. mm2 PVC insulated copper wire

3.9 Bus Bar Electrolytic copper, 1100 V grade, flame retardant PVC sleeved

3.10 Make


3.12 Voltage Regulator




4.0 4.0 Battery Bank

4.1 Application Solar power system application

4.2 Type Ni-Cd

4.3 Make


4.5 Model No.

4.6 Battery Self Discharge

4.7 Location/Installation Battery room

4.8 Site/Environment Conditions

4.9 Nominal Voltage 1.2 V/CELL

4.10 End Cell Voltage At 70% & 100% Dod

4.11 No. Of Cells

4.12 Rating In Ah (C10)

4.13 4.13 Recommended Value Of Float/Boost charge Voltage

4.14Recommended Value Of Float/Boost Charge Current

4.15

Recommended Mounting Arrangement With Minimum/Statutory Clearances Required Between Racks/Stacks & All Round Clearances In The Battery Room

4.16 Internal Resistance Of Each Cell

4.17 Short Circuit Current Of Battery Bank

4.18 Factor For Converting Discharge Over A Period Of 168 Hours To A Standard C10 Rating

4.19

Factors For Converting Discharged Ah Capacity During Deficit Month When Part Of The Load Are Fed From Solar Panel And The Rest By The Battery

4.20 Battery Bank Weight

4.21 Battery Accessories Provided As Per Spec. 0001-01-07-02-005

5.0 Battery Rack/Stack

5.1 Make

5.2 Construction

5.3 Coating And Colour Shade

5.4 No. Of Tiers/Stack




5.5 No. Of Rows/Stack

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

5.7 Weight (Rack/Stack)

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

5.9 Material Of Enclosure Of Battery Rack/Stack

5.10 Inter-Row/Inter-Cell Connectors

A Number

B Material

6.0 Miscellaneous Materials

6.1 Cable Size/ Type

A On Solar Module

B Solar Module To Array Jb/Main Jb

C Main Jb To Solar Controller Panel

D Battery To Solar Controller Panel

E Interconnecting Cable Conductor Material

F Make Of Interconnecting Solar Panel Cable

G Whether Interconnecting Cable Between Solar Array/Module Panel & Main JB YES

6.2 Cable Gland Type Double compressionNickel/chromium plated brass

6.3 Cable Gland Quantity

6.4 Whether Glands Supplied By Vendor

6.5 Lugs – Type Tinned Copper

NOTES:

1. The design load shall be finalized by the contractor based on actual load of selected equipment.

However, the daily load demand given under Item 1.5 are minimum required.

2. Vendor shall furnish duly filled-in datasheet along with the Bids.

3. AH capacity of battery shall be selected considering design ambient of 10°C.

4. The interconnecting cables between solar panel and Main junction boxes shall be Flame retardant

Low Smoke (FRLS) type. All cables shall be in continuous lengths without intermediate joints.

5. The loads shall be considered as a minimum. The loads as indicated are tentative. The contractor

shall decide the final load based on the final selected equipment.

6. ATTACHMENTS: Specification for Solar Electric Power System-.0001-01-07-02-005 and Load

Analysis Document No. 0001-01-07-08-001


DATA SHEET UPS SYSTEM0001-01-07-04-UPS-001 Page 1 of 7


DATA SHEET FOR UPS SYSTEM





DATA SHEET FOR UPS SYSTEMPART -I

PURCHASER'S DATARATING AND JOB REQUIREMENTS

1 INPUT POWER SUPPLY

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

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

2 SITE CONDITIONS

2.1 Design ambient temperature 40oC

Min. ambient for battery sizing 10oC

2.2 Max. relative humidity Highly Humid

2.3 Altitude above MSL Less than 1000 m

3 SYSTEM REQUIREMENTS

3.1 Type of inverter Transistorised

3.2 Rating (KVA at 0.8 pf) 10kVA

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

Output Voltage 230V±1%(Ungrounded)

Output frequency 50Hz ± 1%

3.4 Mode of operation `Parallel Redundant with bypass transformer

3.5 Load p.f. (rated and variation) 0.8, 0.6 to 1 (lag)

3.6 Type of battery Battery type shall be Nickel-cadmium

3.7 Battery Backup Time 30 minutes

3.8 Battery rack formation Double row double tier

3.9 Fault diagnostic unit Required/Not Required

3.10 Ingress protection of enclosure IP-31

3.11 Cable entry : From bottom/top

3.12 Painting : Epoxy paint shade 631 as per IS:5




4 ACDB

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

Item No.Incomer Rating

No.Of Outgoing Feeders

KVA Rating Of Feeder

Switch Rating

Fuse Rating

5 SPECIFIC REQUIREMENTS

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

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

5.3 LED shall be provided instead of conventional indicating lamps.

5.4 Owner’s Interface

Normally closed (NC) potential-free contacts shall be wired upto terminal strip for connection by purchaser, for the following conditions:

a) UPS MOD-1 Trouble

b) UPS MOD-2 Trouble

c) Charger Failure

d) Inverter Failure

e) Battery Discharged

f) Battery Isolated.




PART - IITECHNICAL DATA FROM MANUFACTURERS

1 UPS SYSTEM

1.1 Make

1.2 Type designation

1.3 Rating (KVA at 0.8 p.f.)

1.4 Mode of operation

1.5 Dynamic Response under following conditions

a) For 50% step load

b) For 100% step load and unload

c) Power supply interruption and restoration:

d) Load Transferred to bypass line

e) When one inverter gets faulty and load transferred to healthy inverter

1.6Maximum recovery time to reach steady state after above disturbance

1.7 Type of cooling/Redundancy in cooling system

1.8 Degree of ingress protection of panels

1.9 Noise level

1.10 Colour shade

1.11Efficiency of each rectifier and inverter module including input and output transformera) At 100% load

b) At 75% load

c) At 50% load

d) at no load

1.12 Efficiency of bypass stabilizer including input transformer

a) At 100% load

b) At75% load

c) At 50% load

d) At no load




1.13

Overall efficiency of UPS system( ratio of output load to input power drawn from mains when all charger and inverters are on and Synchronized with bypass operating at no load) a) At 100% load

b) At 75% load

c) At 50% load

d) At no load

1.14 Cable entry :

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

1.16 Heat loss for the total system (KW) :

2 INVERTER

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

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

2.3 Output voltage adjustment range at rated load :

2.4 Input voltage DC (Nominal/Range) :

2.5Frequency variation limit for inverter :phase locked with main

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

2.7 Harmonic distortion at inverter output at rated load

a) For linear load

b) For nonlinear load

2.8 Overloading capacity and duration

2.9 Short circuit capacity and duration

2.10 Output voltage and phase angles (for 3-Ph only)

a) For 30% unbalance load

b) For 40% unbalance load

c) For 50% unbalance load

d) For 100% unbalance load

2.11 Type of control circuit

2.12 Load crest factor (for which UPS is designed)

2.13Max. allowed rating of outgoing feeders for fault clearance of feeder fault by UPS with and without mains bypass supply back up (as percentage of UPS rating)a) With fast acting semiconductor fuses

b) With normal HRC fuses




3 STATIC SWITCHES

3.1 3.1 No. of static switches in each UPS system

3.23.2 Current rating at specified ambient (continuous / short time) :

3.3 Type of static switch :

3.4 Transfer time

a) Synchronised mode

b) Unsynchronised mode

4 BATTERY CHARGER

4.1 Current Rating

4.2 Type of Charger

4.3 Output voltage under float/rapid charging condition

4.4 Output Voltage accuracy under specified input

4.5Maximum ripple content on DC side with battery :connected/disconnected

4.6 Maximum harmonic content in input current

4.7 Input transformer rating

5 MANUAL TRANSFER DEVICES

5.1 Make/Type designation

5.2 Rating (continuous/short time)

6 BATTERY

6.1 Make :

6.2 Type designation

6.3 Type

6.4 AH rating

6.5 End cell voltage

6.6 Nominal voltage

6.7 No. of cells in each bank

6.8 No. of battery banks

6.9 Battery charging requirements

a) Nominal Volts/cell

b) Float Voltage/cell

c) Rapid charging Voltage/cell




6.10 Rapid charging time

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

6.12 Container type

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

7 STEP DOWN BYPASS TRANSFORMER WITH SOLID STATE VOLTAGE STABILIZER

7.1 Make/Type designation

7.2 Rating and voltage ratio

7.3 Accuracy of Stabilizer

7.4 Type of Control

7.5 Type of Cooling

7.6 Type of Stabilizer

8 AC DISTRIBUTION BOARD

8.1 Make /Type designation

8.2 Rating of board

8.3 No. of outgoing feeders/rating of each

8.4 Overall dimensions(LXDXH)

8.5 Maximum & minimum operating height

9 CELL BOOSTER

9.1 Make/ Type designation

9.2 Voltage range

9.3 Current range

10 RELIABILITY

10.1 Safety factor used for selecting the components

(a) Electronic devices

(b) Electrical devices

10.2 MTBF/MTTR

10.3 Availability factor

SPECIFICATION REV-0 GAIL (INDIA) LTD NEW DELHI

SINGLE LINE DIAGRAM FOR CGS 0001-01-07-01-001 Page 1 of 1


NOTES:1. 24 V SPV POWER SOURCE + 415/220 V AC POWER SOURCE HAS BEEN CONSIDERED.2. 24 V SPV AND BATTERY CHARGER IN PARALLELL OPERATION HAVE BEEN CONSIDERED.3. ANY DC-DC CONVERSION WILL BE IN THE SCOPE OF THE SCADA/TE;ECOM VENDOR4. SCADA/TELECOM EQUIPMENT WILL BE SUPPLIED AND INSTALLED BY THE OWNER.5. AC DISTRIBUTION FOR LIGHTING, VENTILATION AND


LOAD ANALYSIS DOCUMENT0001-01-07-08-001 Page 1 of 3


LOAD ANALYSIS DOCUMENT





NOTES & ASSUMPTIONS:-

1.0 FOR STATIONS AT Manesar, Dharuhera, Bhiwadi, Kushkhera and Neemrana.

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

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

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

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

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

- SCADA- Telecom- Instrumentstion- Cathodic Protection- Fire Alarm & Detection & CO2 Flooding System

On Grid Power Supply:-- Ex Fan BR- Ex. Fan Elect Room- Contr Building Lighting- Contr Room A/C- Area Ltg

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

2.0 FOR RECEIPT TERMINAL (CGS) AT Manesar, Dharuhera, Bhiwadi, Kushkhera and Neemrana.

(a) New building/porta-cabin has been considered at above locations. As such indoor/outdoor lighting, air conditioning loads, etc. have been considered. Power requirement is envisaged to be met through 415/240 V, feeders from existing grid power system of the vicinity/industrial areas.




LOCATIONS

LOAD Sultanpur Kh & Man ToP

Manesar Dharuhera Bhiwadi Kushkhera Neemrana

Load On Power Source With Battery BackupTelecom 0 0 150 150 150 250 250Scada 0 0 130 130 130 130 130Instt /PLC 0 0 200 200 200 200 200Ex Fan BR 0 0 50 50 50 50 50Ex Fan TC/SCADA Room 0 0 50 50 50 50 50

F A System 0 0 100 200 200 200 200CP Syatem 100 100 100 100 100 100 100Batt. Chg - - By ContractorTotal Critical Load

100 100 780Say 800W

780Say 800W

780Say 800W

880Say 900W

880Say 900W

Power Source Power by CJPL

Power by CJPL

Solar+Grid + Battery

Solar+ Grid + Battery




Battery Backup Time - - 72 Hrs 72 Hrs 72 Hrs 72 Hrs 72 hrs

Load on Grid PowerLight Contr Bldg 0 0 1000 1000 1000 1000 1000Contr Room A/C 0 0 3000 3000 3000 3000 3000Area Ltg 0 0 2500 2500 2500 2500 2500Battery Charger By Contractor

Watts Watts Watts Watts Watts Watts Watts

1. The above loads are indicative. Contractor to verify the adequacy at the design stage.2. Battery Capacity Required (Ah) for 72 hours backup AND a DESIGN MARGIN OF 10% 3. SPV system to be sized for Critical loads + battery charging current4. Battery charger connected to grid supply to be sized for critical loads + battery boost charging

current5. Sizing of SPV system, Battery Bank, Battery charger and Grid Power supply to be done

by the contractor** Loads not on Battery Backup


SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT S-07-02-001 Page 1 of 11


SPECIFICATION FOR MV

SWITCHBOARDS FIXED TYPE FOR

PACKAGE EQUIPMENT




ABBREVIATIONS:

BIS Bureau of Indian Standard.

CRCA Cold rolled cold annealed

DOL Direct on line starting

LED Light emitting diode

NO Normally open contact

NC Normally open contact

PVC Polyvinyl chloride




CONTENTS

1.0 SCOPE


3.0 GENERAL REQUIREMENTS

4.0 SITE CONDITIONS

5.0 DESIGN AND FABRICATION REQUIREMENTS

6.0 EQUIPMENT SPECIFICATION

7.0 INSPECTION, TESTING AND ACCEPTANCE

8.0 PACKING AND DESPATCH




1.0 SCOPEThis specification covers the requirement of design, fabrication, testing, packing and supply of Medium voltage fixed type switchboard in single front execution required for receipt, control and distribution of power to various medium voltage consumers of the package equipment such as Air conditioning plant, Pressurisation plant, Air dryer plant etc

2.0 CODES AND STANDARDS 2.1 The equipment shall comply with the requirements of latest revision of

following standards issued by BIS unless other wise specified. o IS 772 AC Electricity Meters o IS 248 Direct acting electrical indicating instrurhents o IS 2705 Current transformers o IS 2824 Method for determining the comparative tracking index of solid

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

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

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

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

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

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

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

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

2.5 In case of any contradiction between various referred standards / specifications / data sheet and statutory regulations the following order of priority shall govern:




o Statutory regulations o Data sheets o Job specification o This specification o Codes and standards

3.0 GENERAL REQUIREMENTS 3.1 The offered equipment shall be brand new with state of art technology and

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

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

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

4.0 SITE CONDITIONS 4.1 The switchboards shall be suitable for installation and satisfactory operation

in a pressurised substation or in substation with restricted natural air ventilation in a tropical, humid and corrosive atmospheres. l’he switchboards shall be designed to operate under specified site conditions. If not specifically mentioned a design ambient temperature of 400 C and altitude not exceeding 1000 metres above mean sea level shall be considered.

4.2 All the equipment described in this specification is intended for continuous duty at the Specified ratings under the specified ambient conditions unless indicated otherwise.

5.0 DESIGN AND FABRICATION REQUIREMENTS Medium voltage switchboard shall meet the requirements of medium voltage switchboard data sheet, and following requirements of this specification in addition to the general requirements as per latest editions of applicable Indian standards.

5.1 The switchboard shall be free standing, suitable for flushing mounting to wall, with complete front access for operation and maintenance. The switchboard shall be fixed type in single front execution, assembled in single line up, metal enclosed, fully compartmentalised, totally segregated compartments for feeders, cables and bus bar, dust and vermin proof suitable for indoor installation.

5.2 Switchboard enclosure shall provide a degree of protection not less than P-42 as per applicable IS.




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

5.4 The switchboard shall be designed to ensure maximum safety during operation, inspection, and connection of cables, relocation of outgoing circuits and maintenance with the energised bus bar system and without taking any special precautions. The switchgear shall permit maximum interchangeability and shall be extensible on either side.

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

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

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

5.8 All metal surfaces shall be thoroughly cleaned, degreased to remove mill scale, rust, grease and dirt. Fabricated structure shall be pickled and then rinsed to remove any trace of acid. The under coat shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The switchboard shall be spray painted with two coats of final paint or powder coated. The final paint shade shall be as per manufacturer standard unless specified otherwise.

5.9 The switchboard shall he suitable for bottom cable entry unless specified otherwise and shall be provided with removable gland plates unless otherwise specified. The switchboard shall have a separate cable alley for each vertical panel with cable tying arrangement. The width shall be sufficient to accommodate the required number of cables. However, in any case it shall not be less than 200mm width. The cable alley shall he provided with a suitable hinged door. Required number of single compression nickel plated brass cable glands and tinned copper compression type lugs for all power and control cables shall be included in the vendor’s scope of supply.

5.10 The switch board shall comprise of incoming load break switch panel or air circuit breaker panel, outgoing switch fuse, fuse switch contactors feeders, motor starter feeders, control supply transformers, both power and auxiliary/control bus bars, cable termination compartment etc. All these shall




be housed in independent compartments separated from each other by metallic barrier.

5.11 Main horizontal bus bars shall be provided at the top in separate compartment. Vertical bus bars required for connection between main bus bars and outgoing feeders shall be in separate vertical chamber. One set of vertical bus bars can be provided for feeding outgoing feeders in two panels on either side of the vertical bus bar.

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

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

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

5.15 All auxiliary devices for control, indication, measurement and protection except the bimetallic relays shall be mounted on the front side of the respective compartment. Components requiring frequent inspection during operation shall be easily accessible.

5.16 Each vertical panel shall be provided with anti condensation heater rated for 240 V AC supply, provided with a switch fuse and thermostat having variable setting range of 30-70 °C. Adequate space shall be provided for termination of incoming and outgoing cables.

5.17 Main bus bars shall be of high conductivity Electrical Grade aluminium having uniform current rating throughout their length. Horizontal and vertical bus bars shall be sized depending upon the maximum expected current and to limit the specified maximum operating temperature at specified design ambient temperature.

5.18 The maximum operating temperature of bus bars including joints at the maximum design temperature inside the panel shall not exceed 95°C under normal operating conditions.

5.19 Minimum clearance between line parts, between live parts/neutral to ground shall be 19 mm.

5.20 Adequately sized auxiliary copper bus bars running horizontally in a separate enclosure shall be provided for space heaters, control supply and metering




requirements. Necessary tee-off connections shall be used for distributing auxiliary supply to each vertical panel.

5.21 All horizontal and vertical bus bars shall be insulated with heat shrink PVC sleeves of 1100 V grade and removable shrouds shall be provided for joints. All bus bars shall be prominently marked with Red, Yellow and Blue colour rings for easy phase identification at regular interval and at every power tap off point and designed to withstand specified short circuit currents for one second.

5.22 Copper earth bus of 30x6 mm2 size for fault level upto 31.5 KA and 50x6 mm2 size for fault level above 31.5 KA shall be provided throughout the length of the switchboard with provision for interconnection to earthing grid at two ends. All non-current carrying metallic parts of the mounted equipment shall be earthed. Doors and movable parts shall be earthed using flexible copper connections.

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

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

5.25 Clamp type terminals shall be acceptable for wires upto 10 mm2 size, for conductors larger than lOmm2 bolt type terminals with crimping lugs shall be provided. Each wire shall be terminated at a separate terminal. A minimum of 10% spare terminal shall be provided on each terminal block. Shorting links shall be provided for all CT terminals.

5.26 All motor starting shall be DOL type unless otherwise specified. 240 V AC control supply for motor starters shall be derived from a common 415/240 V adequately sized transformer for each bus section.

5.27 Components of the similar modules of same sizes shall be identically located and wired. Control supply change over switch shall be provided in case the switchboard is with two bus-sections.

6.0 EQUIPMENT SPECIFICATION 6.1 All breaker shall be air break type All switches shall be load break, heavy

duty/mzaor duty, air break type with the operating handle mounted on the compartment door, complete with necessary interlock and defeat mechanism.




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

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

6.3 The contactors shall be air break type having AC-3 or AC-4 duty rating as per package requirement. All contactors shall be provided with 1 NO + 1 NC potential free spare auxiliary contacts wired to the terminal block for owner use.

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

6.5 Current transformers for metering shall have an accuracy class 1.0 and instrument safety factor less than 5. However accuracy class of 3.0 is acceptable for ammeters only for outgoing feeders. Protective current transformers shall have an accuracy class 5P and an accuracy limit factor greater than 10.

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

6.7 All selector switches shall be rotary back-connected types having a cam operated contact mechanism with knob type handle. Ammeter selector switch shall have make before break feature on its contacts.

6.8 Indicating lamps shall be suitable for 6.0 V AC, complete with built in 240/6V transformers. Lamps shall be provided with translucent covers to diffuse light. Alternately clustered LED type indicating light with minimum 8mm-diameter size shall be considered. The following indicating colours shall be used.

o Close/on Red o Open/off Green o Fault trip : Amber o Control supply on : White o Push button colours shall be as follows: o Stop/open/emergency : Red o Start/close : Green o Reset/test : Yellow/Black/White




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

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

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

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

7.0 INSPECTION, TESTING AND ACCEPTANCE 7.1 In addition to the expediting/inspection activities being undertaken by th

package vendor, switchboard shall be subject to inspection by GAIL or by an agency authorised by the owner. All necessary information concerning the supply shall be furnished to GAILs inspectors. Two weeks notice shall be given to GAIL for witnessing the final testing of the complete assembly to ensure satisfactory operation of all components.

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

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

7.4 In addition, specified tests shall be conducted to check mechanical and electrical operation and the control wiring to specification and schematic drawings.

7.5 Acceptance tests shall be as follows:

7.5.1 A general visual check shall be carried out. This shall cover measurement of overall dimensions, location, number, and type of devices and their ratings as per bill of materials, terminal blocks, location and connection of terminals.

7.5.2 Manual and electrical operation of switches, contactors, relays etc. under various conditions of supply voltage.




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

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

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

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

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

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

8.0 PACKING AND DESPATCH All the equipment shall be divided in to several shipping sections for protection and ease of handling during transportation .The equipment shall be properly packed for transportation by ship/rail or trailer. The panels shall be wrapped in polyethylene sheets before being placed in wooden crates /eases to prevent damage to the finish. Crates /cases shall have skid bottoms for handling. Special precaution notations such as Fragile, This side up, center of gravity, weight, Owner’s particulars, Purchase number etc. shall be clearly marked on the package together with other details as per purchase order. The equipment may be stored outdoors for long periods before installation. The packing should be suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed


SPECIFICATIONS FOR DC-DC CONVERTER S-07-02-002 Page 1 of 8


SPECIFICATION FOR DC-DC CONVERTER




CONTENTS

1.0 SCOPE

2. CODES AND STANDARDS

3. GENERAL REQUIREMENTS

4. SITE CONDITIONS

5. DESIGN AND FABRICATION REQUIREMENTS

6. PERFORMANCE REQUIREMENTS

7. MONITORING, CONTROLS, INDICATIONS AND METERING

8. INTERFACE WITH SCADA

9. PAINTING

10. INSPECTION AND TESTING

11. PACKING AND DESPATCH




1 SCOPE 1.1 This specification covers the requirements of design, manufacture, testing,

packing, delivery to site. testing and commissioning of the DC to DC converters.

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

standards, unless other wise specified: i) BIS specifications

ii) International Electrotechnical Commission (IEC)

iii) American standards institution (ANSI)


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


o Statutory regulations

o Data sheets

o Job specification

o This specification

o Codes and standards

3 GENERAL REQUIREMENTS 3.1 The offered equipment shall be brand new with state of art technology and proven

field track record. No prototype equipment shall be offered.


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

3.4 DC to DC converters are required for installation at remote and unattended stations of pipelines for feeding power to station loads of telecommunication, SCADA, instrumentation and CP system requiring highly reliable power supply. These DC to DC converters shall be suitable for continuous and uninterrupted operation without failure and requiring minimum maintenance (maintenance interval not less than three months) and without requiring any operator or any




other attention at unattended stations. The basic module of DC to DC converters shall be highly reliable, having proven performance record.

4 SITE CONDITIONS 4.1 The DC to DC converters shall be suitable for installation and satisfactory operation

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

4.2 All the equipments described in this specification are intended for continuous duty at the specified ratings under the specified ambient conditions unless indicated otherwise.

5 DESIGN AND FABRICATION REQUIREMENTS 5.1 The converter panel shall be fabricated with 1.6/2mm thick sheet steel. Frames

shall be enclosed by using 2mm thick sheet steel and doors and covers shall be made of 1.6 mm sheet steel. Wherever required, suitable stiffeners shall be provided. The converter panel shall be wall mounted type and shall not need rear access for maintenance. All components, connectors and terminals shall be arranged, so . that maintenance requirements can be attended from front only. Overall hinged door shall be provided at the front of the panel. Alternatively the cabinet may be designed in two vertical portions with plug in modules of DC to DC converters in one portion, while other auxiliary devices, housed in another portion. In this type of construction, the front facia of DC to DC converter module shall be flushed with - the front of panel, so that LEDs and operating knobs/potentiometer can be directly accessed. The bottom vertical portion with hinged door shall accommodate MCCBs/MCBs, alarm, indication and other . auxiliary devices as required for the overall unit. Suitable louvers shall be fitted for ventilation. It shall be possible to operate the MCCBs/MCBs without opening the door of the converter panel.

5.2 All instruments shall be switchboard type and back connected. 660V PVC insulated wires with stranded copper conductor of size 2.5 mm2 shall be used for control wiring. All fuses shall be provided inside the panel and shall be of link type.

5.3 All live parts shall be properly shrouded. This shall ensure complete safety to personnel intending routine maintenance by opening the panel doors.

5.4 All non-current carrying metallic parts shall be earthed with copper wire. The main earth connection shall be brought out to two terminals for connection to station earthing system.

5.5 Removable cable gland plate shall be provided for glanding of all cables, using single compression nickel plated brass cable glands. The termination provision shall




be provided in the panel for terminating the power cables, using suitable cable lugs.

5.6 All components and devices shall be provided with screwed nameplates. Nameplates shall be 3 ply (white/black/white) two colour laminated plastic.

6 PERFORMANCE REQUIREMENTS 6.1 DC to DC converter shall be of solid state type and shall operate on switch mode

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

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

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

6.4 The overall efficiency shall be minimum 75%. The output of the converter shall be filtered/smoothened to provide DC output with less than 2% ripple. The steady state output regulation for no load to full load and with input voltage variation of +25% and -1 5%(unless specified otherwise) over nominal voltage, shall be better than ± 1% of the rated output. The output voltage shall be adjustable up to ± 5% of the nominal output voltage.

6.5 The DC to DC converter shall be suitable for feeding power to loads having switch mode power supply regulators at the input, drawing repetitive peak surge currents.

6.6 The output voltage dynamic response of the converter unit shall not be more than ± 10% of nominal output voltage for step loading and unloading of 50% of the rated output in case of dual redundant DC to DC converters and on 100% step loading and unloading in case of single non redundant DC to DC converters. The normal output shall be restored within 100msec.




6.7 Each converter module shall be protected against output short circuit and over current. DC to DC converters shall be suitable to withstand switching surges or otherwise protective devices shall be provided.

6.8 The converter shall preferably be of natural cooled type.

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

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

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

7 MONITORING, CONTROLS, INDICATIONS AND METERING 7.1 Each DC to DC converter module shall be provided with monitoring for the

following: i) Load voltage high ii) Load voltage low iii) Thermal overload protection iv) Module- Fault/Fail(Module not feeding the load) v) Input fuse fail vi) Input voltage - Too high/Too low

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

a) Potentiometer for adjustment of output voltage. b) LED indication for module fault/fail(Module not feeding the load) c) Other alarm indication & control devices as per manufacturer’s

requirement/standard.

8 INTERFACE WITH SCADA 8.1 Following digital/analog monitoring signals shall be provided in DC to DC

converters for remote . connection to SCADA system: cob. (a) DC to DC converter module feeding the load for each DC to DC converter

module. (Module - not faulty/not failed) (b) DC output voltage.

8.2 Potential free contacts for remote monitoring shall be provided for digital signals and 4-2OmA current signals corresponding to input parameter range(0- 110% of maximum rated value of the parameter) for analog signals. The potential free contact for digital monitoring shall be open to alarm state.




8.3 The transducers shall have electrical isolation rated for minimum 2kV, 50Hz between input and output. The transducers shall be protected against input and output voltage surges. The accuracy class of the 4-20 mA current transducers shall be 5% or better. The 4-20mA current transducers shall be suitable for driving load resistance of 600 ohms located up to 100 m away and connected through 0.5 mm2 copper cable.

9.0 PAINTING The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surfaces shall be prepared by applying a coat of phosphate and a coat of zinc oxide/phosphate primer. The under surface shall be free from all imperfections before undertaking the finishing coat. It shall then be spray painted with two coats of epoxy paint. Colour of final paint shall be vendor standard.

The finished panel shall be dried in stoving ovens in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels etc. All unpainted steel parts shall be cadmium plated or suitably treated to prevent corrosion. Alternatively, powder coating as per manufacturer’s standard is also acceptable.

10.0 INSPECTION AN]) TESTING 10.1 The owner or his authorised representatives may visit the works during

manufacture of equipment to g 8 assess the progress of work as well as to ascertain that only good quality raw materials are used for the same. He shall be given all assistance to carry out the inspection.

10.2 Detailed test procedures along with the facilities available at vendor’s works shall be submitted along with the bid. Owner’s representative shall be given minimum four weeks advance notice for witnessing the final testing. Test certificates including test records and performance data etc. shall be furnished by the vendor.

10.3 Final acceptance tests shall be carried out at manufacturer’s works under his care and expense. All the instruments and equipment required for testing shall be arranged by vendor. Acceptance tests shall include but not be limited to the following:

a) Visual Inspection - Completeness of the equipment in line with specs. - Dimensional checking - Proper mounting of components and neatness of wiring etc. - Model number

b) Functional testing:- All functions shall be checked up for proper operation.




c) Heat run test (full load test) shall be carried out for a minimum duration of 8 hours on all units except that in case of identical ratings for more than one unit, heat run test may be conducted only on one of the identical units. During this test, measurements shall be carried out to prove that the operating temperatures of various components do not exceed their design ratings with sufficient margins as per good engineering practice/established guidelines.

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

11.0 PACKING AND DESPATCH The equipment shall be properly packed for transportation by ship/rail or trailer. The panels shall be wrapped in polyethylene sheets before being placed in wooden crates /cases to prevent damage to the finish. Crates /cases shall have skid bottoms for handling. Special precaution/parameters such as “Fragile”, “This side up”, center of gravity, weight, Owner’s particulars, Purchase number etc. shall be clearly marked on the package together with other details as per purchase order.

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


SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION S-07-02-003 Page 1 of 17


SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION




Abbreviations:

ACDB AC Distribution Board

C.T.C Carbon Tetrachloride

C T Current Transformer

DCDB DC Distribution Board

HV High Voltage

MMI Man Machine Interface

MV Medium Voltage

OISD Oil Industry Safety Directorate

PF Power Factor

PT Potential Transformer

UPS Uninterrupted Power Supply

VRLA Valve Regulated Lead Acid




CONTENTS

1. SCOPE


3. INSTALLATION OF EQUIPMENT

4. EQUIPMENT COMMISSIONING

5. LIST OF CONSTRUCTION EQUIPMENT




1 SCOPE This specification defines the requirements for the installation, field inspection, testing and commissioning of electrical equipment, forming part of electrical power distribution and utilisation system, including Communication and Fire alarm system.

2 CODES AND STANDARDS

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

o SP-30(BIS) National Electrical Code.

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

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

maintenance of transformers; Part 2 Installation.

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

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

o OISD 137 Inspection of Electrical Equipment.

o OISD 147 Inspection and safe practices during electrical installations

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

b) Regulations laid down by CEA/Electrical Inspectorate.

c) Regulations laid down by CCE/DGMS (as applicable).

d) The petroleum rules (Ministry of Industry Government of India).

e) Any other regulations laid down by central/state/local authorities and

Insurance agencies.

3 INSTALLATION OF EQUIPMENT Prior to start of installation of the electrical equipment contractor shall verify that equipment and complete materials have been received. Handling, shifting to required site location, installation, testing and commissioning of all electrical equipment shall be done by contractor with utmost care. Manufacturer’s instructions and the requirements given in their technical manuals shall be strictly adhered. The substation/switchgear room wherein the equipment shall be installed shall be kept clean, dry and free from all debris. Panel floor cutouts not in immediate use shall be suitably covered to




avoid any mishap. When handling the switchboard panels, care shall be taken to observe the correct lifting arrangements and to make sure that slings are attached to the manufacturer’s designated lifting points. No parts shall be subjected to undue strains or sudden stresses which could cause damage to the equipment.

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

Contractor shall check and report to the Engineer-in-charge about any damaged item and / or missing component for getting the same replaced as per specifications. During installation, all accessories and loose items shall also be inspected by the contractor before their assembly/mounting.

3.1 Switchboards and Bus Ducts

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

3.1.2 The switchboard panels shall be installed on prepared foundations or floor cutouts. Steel base channels shall be welded to inserts provided in floor slab. Cross members shall be provided at the junctions of each shipping section and other places as required. Alternatively when the floor is being laid, base channel frame of panels supplied by the vendor shall be grouted and levelled in cement concrete. It shall be ensured that the base plate level of HV switchboard shall match with the finished floor level. The foundation pockets and the grouted bolts shall be cured for a minimum period of 48 hours.

3.1.3 The switchboard panels shall be taken out from the packed cases and shifted one by one to its proper place. All the panels shall be assembled, aligned and levelled. Alignment of panels shall be checked in both longitudinal and lateral directions. It shall be ensured that panel to panel coupling bolts, bus bar links etc. fit properly without any strain on any part. No new holes for jointing of the panels other than those recommended by the vendor shall be drilled. No gaps shall be left between the panels. The lifting, racking in and out




operation of the breaker and all other motions shall be free from any obstruction.

The panels shall be checked for correct vertical position using pendulum weight and spirit levels . The switchboard panels shall be tack welded at suitable intervals at base channel. After erection of switchboard panels, all uncovered portions of floor cutouts shall be covered with 6 mm thick removable checkered plates finished with floor level. The design of the checkered plates shall be such that the maximum allowable deflection is 1) 200 (where L is the span of the checkered plates in metres) for a live load of 500 kg./sq. meters. In this regard, reference shall be made to GAIL structural standard No. S-11-01-010(Cable Trench). Suitable lifting arrangements shall be provided for checkeredplates. The checkered plates shall be painted with a coat of red oxide zinc chromate primer after proper surface preparation as per specifications. Where specified , panels cutouts provided for future use shall be filled with lean concrete.

3.1.4 After completion of erection of switchboards, all the cubicles, switchboard components such as switches, starters, C.T. and PT. chambers, busbar chamber shall be cleaned and checked for tightness of all the components. Vacuum circuit breakers shall be checked for integrity o bottle seals. All loosely supplied items shall be fitted up. Bus bar sections or links shall he inserted and where specified, of high voltage equipment, shall be insulated.Interconnection wiring between shipping sections shall be made by contractor. All the wiring connections shall also be checked. Phase sequence and polarity of PTs and CTs shall be checked. Contact resistance of all busbar joints and contactors shall be checked. Insulator shall be checked for any damage. All the starters, switches, contacts shall be cleaned with C.T.C. where required. All the moving parts shall be checked for easy and free movement. Hinges of panel doors shall be lubricated to give free and noise free movement. All openings shall be kept completely closed to avoid ingress of any foreign particles inside the panel.

Functional scheme verification of individual feeder shall be carried out and minor wiring modifications in the panel wiring, if required shall be done as per the directions of Engineer- in-charge. Special attention shall be paid to CT circuits polarity, wiring continuity and correctness in the protection as well as measurement circuits. Auto transfer scheme shall be simulated and verified. During the course of scheme verification tests, defective components if any shall be taken out, after bringing to the notice of Engineer-in-charge. The same shall be replaced by component supplied by owner.

3.1.5 Where switchboard is damp or having a low IR value due to damaged insulators/ bushings/any other insulated parts, or any other reason, the entire switchboard shall be dried- up according to the instruction of the




Engineer-in-charge for the IR value to improve to a safe level for commissioning. Care shall be taken to protect the surrounding insulation from direct local heating during the drying up process.

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

3.1.7 All moving parts, of closing/tripping mechanism, racking in and racking out mechanism, spouts and shutter closing mechanism shall be checked for proper operation. All the auxiliary contacts of breaker shall be checked-up, cleaned and contact pressure measured.

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

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

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

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

i) That the installation of equipment to be commissioned is complete in all respects with its auxiliaries and all other mounting including earthing . Openings in floor within and outside panels have been sealed off. All cover and door gaskets are intact to make the enclosure vermin proof.

ii) That all the metering instruments have been checked and found in working order. Indicating lamps are healthy and are in correct position. All power and control fuses are of proper rating.

iii) That the polarity test and ratio test of all the PTs and CTs is complete and phase sequence of CTs conforms to the correct vector group connections. Wiring continuity and correctness are ensured in the protection and measurement circuits. Polarity of D.C. supply for all the circuits is correct.

iv) That the high voltage test of incoming and outgoing cables have been conducted and results are satisfactory.

v) That all the protective relays including both conventional and microprocessor based numerical relays and thermal overload relays have been tested for secondary injection tests. (Primary injection tests




shall be carried out for differential protection, Restricted Earth fault protection at full / reduced current to ensure correctness of complete wiring). Relay settings, status indications, fault annunciations, data logging, display of switchboard SLDs shall be verified from MMI in case the same is provided.

vi) That I.R. Value have been recorded for bus bars, circuit breaker, incoming and outgoing cables, control wiring and potential transformers. Where required joint resistance of bus bars have been recorded and found to be satisfactory. All the surroundings and panels have been cleaned and temporary earth leads have been removed.

3.1.12 Bus Ducts:

The bus ducts as per issued drawings will be supplied in parts and all the parts shall be assembled and the bus bar connections shall be made at site. The insulators in bus ducts shall be inspected for any possible damage during transit and the defective ones shall be replaced. The insulators shall be cleaned. Contact surface of bus bars, bus bar bolts and nuts shall be thoroughly cleaned. Petroleum jelly shall then be applied and bolted connection made. The bus duct enclosure shall be checked for earth continuity and then earthed at two places. The bus duct shall be properly supported between switchgear and transformer. The opening in the wall where the bus duct enters the switchgear room shall be completely sealed to avoid rain water entry. Expansion joints, flexible connections etc. supplied by the manufacturer of the bus duct shall be properly connected. The bus duct levelling shall be checked with spirit level and pendulum weight.

3.2 Transformers Transformers on receipt at site shall be unloaded by means of crane or lifting devices of adequate capacity. All lifting lugs shall be used to avoid unbalanced lifting and undue stresses on lugs. Lifting lugs if any provided for partial lifting (e.g. for active part, conservator) etc. shall not be used for lifting complete transformer. Parts other than those identified for lifting of the transformer shall not be used for lifting. While slinging, care shall be taken to avoid slings touching other parts.

3.2.1 Before lifting transformer, it shall be ensured that all cover bolts are tightened fully. In case when it is necessary to use jacks for lifting, projections provided for the purposes of jacking shall be used . Lifting jacks shall not be used under the valves or radiator tubes. For transporting transformers from stores to site, the transformers shall be loaded on a suitable capacity truck or trailer. The transformers shall be properly supported by steel ropes and stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and vibrations. At no instance the transformer shall be kept on bare ground. Where it is not possible to unload the transformer directly on a foundation, it shall be unloaded on a properly




built wooden sleeper platform. A transformer shall never be left without putting stoppers to the wheels.

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

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

3.1.5 Contractor shall examine the transformer base, oil pit, fire walls and foundations laid by the civil contractor. It shall be ensured that oil spills can not propagate along cable trenches. Any discrepancy noted will be brought to the notice of Engineer- in- charge. Transformers shall be placed on channels or rails over concrete foundations. The transformers shall be levelled, aligned and checked for free movement on the channels or rails. Stoppers shall be provided to the transformers immediately to prevent any movement. Normally transformers upto 1000 kVA rating shall be received duly fitted with radiator tubes, conservator tanks, valves, wheels and other accessories. While the transformers of above 1000 kVA rating may be supplied with loose accessories. All the accessories like radiators, cooling fans, valves, conservator tanks explosion vent pipe, bushings and other devices which are supplied in different packages shall be checked for any transit damage and cleaned thoroughly before fixing on the transformer. All loosely supplied parts shall be assembled as per manufacturer’s instruction manuals/ drawings and documents. All the connections for CTs bushings and other wiring shall be checked for tightness and correctness before replacing the lid or tightening all the bolts.

3.1.6 Topping of transformer with oil:

Before topping up with oil, transformer shall be fitted with all accessories such as valves, gauges, thermometers etc. Oil samples shall be taken from each drum and tested for determination of dielectric strength. Any sign of leakage of the barrel or of its having been opened shall be recorded and reported. It is necessary to filter the oil before the transformers are filled. It shall be ensured in oil filling operation that no air pockets are left in the tank and that no dust or moisture enters the oil. All air vents shall be opened. Oil shall be filled through a streamline oil filter using metal hose. To prevent aeration of the oil, the transformer tank shall be filled through the bottom drain valve. In a transformer with conservator tank, the rate of oil flow shall be reduced when the level is almost upto the bottom of the main cover to prevent internal pressure from rupturing the pressure relief-pipe diaphragm.




Sufficient time shall be allowed for the oil to permeate the transformers and also for the locked -up air bubbles to escape. Any air accumulation in the Buchholz relay shall be released.

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

the tank. ii) Testing of Oil:

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

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

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

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

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

3.2.7 The following work on transformers, shall be performed by the contractor if specifically called for:

3.2.7.1 Before finally commissioning the transformer it may sometimes be desired to run it for a few hours on short-circuit, applying a low voltage, approximately equal to the impedance voltage of the transformer. During this process, regular readings of the insulation resistance of the winding to earth and winding to winding and temperature against time shall be recorded.

3.2.7.2 Testing of radiator tubes for any leakage and rectifying these by welding / brazing.

3.2.8 Pre-commissioning Check List:

Before commissioning of any transformer, the following points shall be checked for safe energisation of the transformer:




i) That all the accessories have been fixed properly and transformer body and neutral are properly earthed. The transformer dehydration is over and results are satisfactory and approved by the Engineer-in-charge. In case transformers are idle for more than one month after dehydration, transformer oil has been given at least two circulations.

ii) That the oil level, in the transformer conservator tank and all the bushings is upto the marked point and the oil has been tested for dielectric strength and acidity.

iii) That the silica gel is in reactivated condition. The breather pipe is clear from any blocking and contains oil upto the proper level.

iv) The explosion vent diaphragm does not have any dents. Accumulation of any oil and air had been released.

v) That the operation of off-load and on-load tap changers on all the tap positions is satisfactory. The mechanical parts of the on-load tap changer are lubricated. Motor IR value has taken and found satisfactory. Tap position mechanical indicator on the transformer and tap position indication meter on the control panel are reading the same tap positions. Tap changer limit switches are operating satisfactorily on the maximum and minimum tap positions. On-load tap changer contact pressure and resistance is as per manufacturers recommendations. Oil level of tap changer tank is upto the required level and oil has been tested for dielectric strength. The tap setting on which the off load tap switch is locked shall be recorded. Generally the off-load tap switch shall be kept on nominal tap.

vi) That the Buchholz relay has been tested and checked up for any friction in the movement, and floats are free. All the other protective relays, alarm and annunciation relays have been tested.

vii) That all the metering equipment have been tested and polarity test of PT’s and transformer winding is satisfactory. Phase sequence and connections have been checked for proper vector group.

viii) That the ratio test and winding resistance on all the tap positions is satisfactory.

ix) That gaps of arcing horns for the bushings where provided are in order and earth connections for the surge diverters have been checked.

x) That the winding and oil temperature thermometer pockets contain oil and the winding and oil temperature settings on dial gauges are in order.

xi) That the transformers fitted with fans for forced air cooling have been checked up for automatic starting and stopping of the fans and air-displacement has been verified.

xii) That the simulation tests for all external interface connection alarm, annunciation and trip circuits have been checked and are in order.

xiii) That the insulation resistance of all the control circuits and IR value of the transformer windings and all the incoming and outgoing cables have been checked.




xiv) That all the valves in the cooling system and valve between the Buchholz relay and the conservator tank are in open position.

xv) That the setting of all the protective relays is at the desired value and D.C. Trip supply is healthy.

3.2.9 Observations after Commissioning: After switching on the transformer the following points shall be observed and recorded. i) The inrush magnetizing current and no-load current. ii) Alarm, if any, or if any relay flag has operated. iii) Voltage and current on all the three phases. iv) Transformer hum or abnormal noise. v) Circulation of oil and leakages. vi) Record current , voltage, cooling air temperature, winding temperature

and oil temperature readings, hourly for 24 hours. vii) Cable end boxes for any over -heating.

3.3 H.V. and M.V. MOTORS

3.2.6 All the motors generally would be erected by the mechanical contractor.

3.2.7 Electrical contractor shall keep the motor space heater energised as per the directions of Engineer-in-charge. Electrical contractor shall measure the insulation resistance of motor windings. Insulation resistance of the motors shall be measured between the winding of the machine and its frame by means of a 500 / 1000 V Meggar in case of 415 V motors . A minimum value of 1 megohm for 415 V motors shall be considered a safe value. In case of lower l.R. Value, the insulation value shall be improved by any of the following methods as directed by the Engineer-in-charge. i) Blowing hot air from external source.

ii) Putting the motor in oven.

iii) Placing heaters or lamps around and inside after making suitable guarding and covering arrangements so as to conserve the heat.

In case the insulation is low, the following method of drying has to be adopted, after consultation with Engineer-in-charge. During drying the temperature rise of winding shall not exceed the permissible value for the class of insulation used.

i) By locking the motor so that it can not rotate and then applying such a low voltage to the stator terminals so as to pass full load current in the stator keeping the stator winding temperature below 90° C . In this case a close watch shall be kept for any possible overheating and I.R. Values vs. temperature shall be plotted and heating continued till I.R. value becomes steady.




ii) By blasting hot air from external source, Maximum temperature of winding while drying shall be 70° C to 80° C (thermometer) or 90° C to 95° C by resistance method. Heating shall be done slowly first till steady temperature of winding is reached after 4 to 5 hours, and for large machines after 10 hours. A record has to be kept for drying process, with half an hour readings and, till steady temperature is reached. In case it is essential, the drying process can be supplemented by blower.

3.2.8 It shall be ensured that the motor leads are correctly connected in the terminal box, as indicated in the Name Plate’. The covers of all terminal boxes shall be properly fixed, the gaskets intact. The control circuit shall be tested for proper functioning as per circuit diagram.

3.2.9 In case of synchronous machines, slip rings and brush gear shall be polished and brushes shall be fixed in their holders with clearance and pressure as recommended by the manufacturers.

3.2.10 Before commissioning, the ventilation and cooling system of the motor must be inspected. In case of motor with forced ventilation the air inlet shall be examined to ensure that it is free from moisture and any foreign material. It shall also be ensured that recommended flow and pressure of air is available to produce the required cooling effect.

3.2.11 The motor control gear shall also be carefully examined, the over-load settings may be reduced or time lags bypassed from protective gear to ensure rapid tripping of switchgear in event of faults. The direction of rotation of a new motor specially of large capacity, and phase sequence of supply shall be kept in view while joining and connecting to the motor terminals.

3.2.12 Finally the motor shall be started on no-load after decoupling, and shall be allowed to run for a minimum period of 4 hours, or for a time as instructed by Engineer-in-charge. Attention shall be given to the proper running of the bearings, vibration or unusual noises if any. Voltage, starting current, no load current, stator winding and bearing temperature shall be recorded after every 1 hour during this test. Direction of rotation shall be checked and recorded. Normally the motors run in clockwise direction as viewed from the driving end with reference to the phase sequence R, Y, B.

3.2.13 After switching off the motor, the insulation resistance of the motor shall be recorded under hot and cold conditions.

3.2.14 If the no load test run is found satisfactory, the motor shall be allowed to runfor 8 hours and all readings shall be recorded.




3.2.15 The following work on motors, may be performed by the contractor if specifically called for.

3.2.15.1.1 The proper level of bearing oil has to be checked . The condition of grease in bearings shall be checked and in case it is necessary, complete replacement of bearing with specified grade of grease after proper cleaning of the bearing shall have to be done ‘Wherever external greasing facility exists, the condition of grease may be checked by pumping some new grease of specified grade at start. If the grease coming out is deteriorated grease shall be replaced.

3.2.15.1.2 All the motors, motor exciter set and induction generators directly coupled or coupled through reduction gears shall be checked for abnormal vibration, if any Large rated HV motors with journal type bearings are liable to get damaged from shock, rough handling during transit. Any minor defect in a race or roller may give rise to considerable amount of vibration and noise. Contractor shall check and bring to the attention of Engineer-in-charge any defect noticed in this regard.

3.2.15.1.3 Due care shall be taken to avoid any damage to bearing insulation wherever provided.

3.4 Batteries Battery (Lead acid, Nickel Cadmium or VRLA type as specified) shall be erected on stands and insulators supplied by the manufacturer of the batteries. The installation shall be done as per the layout drawings and manufacturer’s instructions. Electrolyte if required / as applicable shall be filled as per manufacturer’s instructions. Inter row connections shall be made with the leads supplied by the manufacturer.

3.5 Neutral Earthing Resistor The neutral earthing resistor shall be inspected for any damage to the resistor grid and other components. The resistor shall be levelled and installed. All covers etc. shall be checked for tightness to ensure that the enclosure of the resistor is dust, vermin and weatherproof. Earthing conductors shall be taken from the out end terminal of the resistor, for connection to earth electrodes and to the main grid.

3.6 Welding Receptacles The welding receptacles shall be erected on steel/concrete structures as per the drawings. In isolated places a separate support shall be fabricated and installed.




3.7 Push Button/Control Stations The push buttons / control stations shall be installed near to the motors to be controlled. Individual channel supports shall be installed as per GAILstandard. If control stations for hazardous areas are to be supplied by contractor, these shall be of Ex(d) type, tested by CMRI and approved by CCE or other applicable certifying authorities. All outdoor push buttons / control stations shall preferably have integral canopies for additional weather protection. The canopy shall be made of 2 mm thick galvanized sheet steel or FRP where these are not integral with the equipment.

3.8 Gang operated Isolators/outdoor Disconnectors The isolators shall be transported to site in the dismantled condition. All the insulators may be also supplied loose. The contractor shall inspect, clean , assemble and install the isolator on the base structure previously fabricated, erected and levelled by him. The operating mechanism shall be installed on the structure and connected to the isolator poles. The operating mechanism shall be tested by slowly bringing the isolator to the closed position and carrying out the necessary adjustment as per the manufacturer’s instructions. The earthing switches, frames and operating handle etc. shall be earthed.

3.9 Contractor shall provide the following items in substation, as per Indian Electricity Rules:

3.9.1 Fire buckets filled with clean dry sand and ready for immediate use for extinguishing fires and fire extinguisher (carbon dioxide, dry chemical extinguisher etc.) suitable for dealing with electric fires shall be conspicuously marked and kept.

3.9.2 First aid boxes containing ointments and medicines for immediate treatment of injuries (As prescribed by Indian Red Cross Society or equivalent).

3.9.3 Instructions of restoration of persons suffering from electric shock in English, Hindi and local language of the district shall be affixed in a conspicuous place.

3.9.4 Danger boards (H.V., M.V.) shall be provided on transformer gate, switchboards, entrance to switchgear room and at other places as required by Engineer-in-charge.

3.10 The Communication system and Fire alarm system panels and equipment shall be installed complying to manufacturer’s instructions. The location of field station (call back station unit, break glass unit, telephone set etc.) shown on the drawing are indicative. The exact location shall be decided at site by contractor in consultation with Engineer-in-charge. Correct type of equipment with regard to hazardous protection as specified on drawing shall be adhered to by contractor, for installation.




4 Equipment Commissioning

4.1 Field inspection, testing and commissioning of the complete electrical installation shall be carried out as per GAIL specification no. S-07-02-004.

After the equipment is installed properly in accordance with drawings and specifications, contractor shall carry out all pre-commissioning checks and tests as per GAIL format in the presence of Engineer-in-charge and test readings shall be recorded and furnished to BIL in triplicate.

4.2 All equipment layout drawings shall be marked by the Contractor for “AS BUILT STATUS” and two sets of copies shall be submitted to GAIL.

5 LIST OF CONSTRUCTION EQUIPMENT The contractor shall have all necessary construction equipment, tools and tackles and testing instruments to carry out the erection works and to commission the system as specified. These shall include but not be limited to the following, and these shall be brought to site by contractor before the start of work.

5.1 Equipment: i) Portable grinder.

ii) Portable welding machine.

iii) Portable gas cutting / welding set.

iv) Pipe threading machine.

v) Pipe bending machine (hydraulic).

vi) Portable drill machine suitable to take up drilling for different sizes as

per requirement.

vii) Dewatering pump sets (diesel driven).

viii) Power Hacksaw.

ix) Conduit dye set.

x) Hydraulic crimping machine.

xi) Hand crimping tool.

xii) Portable electric blowers , vacuum cleaners.

xiii) Miscellaneous items such as slings, pulleys, tarpaulins, wooden

sleepers, ladders. etc. as required.

xiv) Safety belts, safety goggles, and gloves.

xv) Separate tool kit for each Electrician.




5.2 Test Instruments i) Insulation tester 1000 V hand driven.

ii) Insulation tester 2500 V motor/hand driven.

iii) Insulation tester 5000 V motor/hand driven

iv) Phase sequence indicator.

v) Earth Resistance tester.

vi) Single phase variac

vii) 3 phase variac of adequate capacity.

viii) Secondary injection testing kit.

ix) Multi-meter, both analogue and digital

x) Portable Ammeters, Watt-meters, P.F. meters.

xi) Portable Voltmeters.

xii) Clip on meters of different ranges.

xiii) Tacho-meter.

xiv) Kelvin's double bridge for measurement of very low resistance.

xv) D.C. high -pot test kit.

xvi) D.C. high -pot test kit.

xvii) Oil filtration machine of adequate capacity.

xviii) LUX METER to measure illumination levels.


SPECIFICATION FOR INSPECTION, FILED TESTING & COMMISSIONING OF ELECTRICAL

EQUIPMENT S-07-06-004 Page 1 of 8


SPECIFICATION FOR FIELD

INSPECTION, TESTING AND

COMMISSIONING OF ELECTRICAL

INSTALLATIONS





ABBREVIATIONS:

AFC Approved for construction

CEA : Central Electricity Authority

CCE : Chief Controller of Explosives

DC Direct current

DGMS : Director General Mines and Safety

GI : Galvanized Iron

HV : High Voltage

IS : Indian Standard

MV : Medium voltage

OISD : Oil Industry Safety Directorate





CONTENTS

1.0 SCOPE


3.0 FIELD INSPETION, TESTING AND COMMISSIONING

4.0 RECORDS





1.0 SCOPE This specification covers the requirements for the field inspection, testing and commissioning of Electrical Equipment and Installation, forming part of electrical power distribution and utilisation system.

2.0 CODES AND STANDARDS 2.1 The field inspection, testing and commissioning of electrical equipment shall

be carried out in line with this specification and the latest edition of following Indian Standards and OISD standards. SP-30(BIS) National Electrical Code

IS-78 16 Guide for testing Insulation resistance of rotating machines.

IS 1255 Code of practice for installation and maintenance of power cables up to & including 33 kV rating.

IS 10810(Part 43) Method of Test for cables; Part 43 Insulation resistanceIS 108 10(Part 45) Method of Test for cables; Part 45 High voltage testOISD 137 Inspection of Electrical EquipmentOISD 147 Inspection and safe practice during electrical installation

2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable:

i) Indian Electricity Act and Rules. ii) Regulations laid down by CEA / Electrical Inspectorate. iii) Regulations laid down by Tariff Advisory Committee/Loss

prevention council. iv) Regulations laid down by CCE/DGMS (as applicable). v) The petroleum rules (Ministry of Industry Government of India). vi) Any other regulations laid down by central / state / local authorities

/ Insurance agencies

3.0 FIELD INSPECTION, TESTING AND COMMISSIONING3.1 Contractor shall carry out complete field inspection, testing and

commissioning of electrical equipment as per Inspection Test plans.

3.2 Before the completed installation or an addition to the existing installation is put into service, inspection / pre-commissioning checks and tests shall be carried out by contractor. In the event of defects being found out, the same shall be rectified and the installation retested as applicable.

3.3 The pre-commissioning inspection among other requirements shall include visual inspection, checking the workmanship of the installation, the rating of equipment, safety clearances, sizes of cables installed, conformance to the AFC document, soundness of switchgear bus connections, wiring properly dressed and labeled, sealing of unused cable entries, checking of all safety interlocks, control/interface functions as per requirement etc.





3.4 Visual inspection for soundness of bus bar connections of bus-ducts, terminal connections of equipment/motor shall be carried out. It shall be ensured that no foreign materials are present inside busduct and equipment terminal boxes. After the visual inspection, all the covers of terminal boxes, inspection chambers shall be refitted with gaskets, bolts & nuts as per equipment manufacturer’s instructions.

3.5 Pre-commissioning tests shall include but not be limited to the following: o Continuity test for each winding and power and control circuits. o Insulation test for each winding and power and control circuit o High voltage test for cables o Dielectric strength test on transformer oil. o Checking the correctness of wiring schemes, control circuit interlocks

for intended functioning. o Verification of phase sequence. o Testing of all types of relays/releases for required operation. o Testing of measuring instruments for proper functioning. o Earth continuity test for all circuits. o Checking of safety features for correctness of operation etc. o Checking of all wired interface contacts (analog, digital input/output

contacts) for DCS and ECS interface, at panel and equipment terminal chambers as applicable. (Electrical contractor shall co-ordinate with other agencies involved for the above and provide support services for checking interfaces of electrical equipment and the intended functioning)

o Earth resistance measurement for each earth electrode, and the earthing system as a whole.

o Lighting installation shall be tested for correct illumination levels, with the fittings installed. Fittings shall be operated only with specified type of a lamp or tube.

3.6 After the above tests and inspection are completed, control circuits shall be tested for correct operation under all operating combinations and proved correct before applying power to main circuits.

3.7 Plant Communication, Fire alarm, telephone and security system shall be checked for correct operation and intended function.

3.8 A close visual inspection of electrical equipment in hazardous areas shall be made to ensure that equipment is suitable for the classified zone and gas group and correctly installed, with all covers, bolts, nuts and hardwares intact and there is no physical damage mark seen on the enclosure

3.9 Site Acceptance Test procedure for specific equipment shall be furnished by the respective equipment vendor. The contractor shall provide necessary





assistance to the equipment vendor to perform Site acceptance testing to enable the equipment vendor to perform the same.

3.10 All pre-commissioning checks and tests shall be carried out as per the directions of Engineer- in-charge. In addition to the equipment manufacturer’s instructions, pre-commissioning check requirements shall also be complied. All tests shall be carried out by contractor in the presence of GAIL/Owner’ s representatives

3.11 The contractor shall bring to site all required tools, tackles, and testing instruments for carrying out field testing. Contractor shall use only calibrated measuring and test instruments and shall maintain calibration records.

3.12 The Insulation Resistance test values for various electrical equipment shall be as below:

3.12.1 Cables The insulation resistance test values for cables shall be as per following table:

Rated voltage of the Cable

DC Test Voltage in Volts

Minimum Insulation resistance in MΩ

Lighting and power circuit wiring

250 1

650/1 100V grade cables 1,000 101,900/3,300V grade 1,000 2003,800/6,600V grade 1,000 2006,350/11,000V grade 5,000 2008,700/15,000V grade 5,000 20012,700/22,000V grade 5,000 20019,000/33000V grade 5,000 200

3.12.2 HV, MV and Miscellaneous SwitchboardsThe insulation resistance test values for the switchboards shall be as per

following table:Rated voltage of the

SwitchboardDC Test Voltage in

VoltsMinimum Insulation

resistance in MΩ33,000V 5,000 20011,000V 5,000 2006,600V 1,000 2003,300V 1,000 200415V 1,000 100240V 500 10110V 500 10





3.12.3 Generators and Motors 3.12.4 The insulation resistance test values for the Generators and Motors shall be

as per following table:Rated voltage of the

Generators and Motors

DC Test Voltage in

Volts

Minimum Insulation resistance in Mega ohms at 40°C

11,000V 5,000 1206,600V 1,000 803,300V 1,000 50415V 1,000 15240V 500 12

3.12.5 Transformers3.12.6 The insulation resistance test values for the Transformers shall be as per

following table

Rated voltage of the DC Test Voltage in Volts

Minimum Insulation resistance in MΩ at 40°

Transformers C

Upto600V 1,000 100

601 to 5000V 2,500 1,000

5001 to 15,000V 5,000 5,000

15001 to 35,000V 5,000 10,000

3.12.7 It shall be ensured that during insulation tests, electronic devices and components that are liable to get damaged on applied test voltage shall be disconnected from circuit. The instructions of equipment/panel manufacturer shall be followed strictly in this regard.

3.13 High-voltage testing 3.13.1 D.C. high voltage test shall be conducted as per following table on all H. V.

feeder cables and also on 1100 V grade cables where straight through joints have been made.Rated Voltage of Cable (kV)

TEST VOLTAGE (kV) BETWEEN

U0 I U*Any Conductor and

Metallic Sheath! Screen/Armour

Conductor to Conductor (For

Unscreened Cables)

Duration (Minutes)

0.65/1.1 3 3 5

1.9/3.3 5 9 5

3.3/3.3 9 9 5

3.8/6.6 10.5 18 5





Rated Voltage of Cable (kV)

TEST VOLTAGE (kV) BETWEEN

U0 I U*Any Conductor and

Metallic Sheath! Screen/Armour

Conductor to Conductor (For

Unscreened Cables)

Duration (Minutes)

6.6/6.6 18 18 5

6.35/11 18 30 5

11/11 30 30 5

12.7/22 37.5 - 5

19/33 60 - 5

U0: Phase Voltage U* Line Voltage

3.13.2 The cable cores must be discharged on completion of DC high voltage test and cable shall be kept earthed until it is put into service.

3.13.3 DC test voltage for old cables shall be 1.5 times rated voltage or less depending on the age of cables, repair work or nature of jointing work carried out, etc. In any case, the test voltage shall not be less than the rated voltage.

3.13.4 All protective relays including thermal overload relays shall be tested by secondary injection current. Primary injection tests shall be carried out for differential protection, restricted earth fault protection at full/reduced current to ensure correctness of complete wiring.

3.13.5 Before energising any equipment, ‘COMMISSIONING CLEARANCE FORM’ as per standard format shall be duly filled in by contractor and submitted to GAIL.

3.13.6 It shall be ensured that the electrical inspectorate approval is available before energising the equipment

4.0 RECORDS Contractor shall keep up-to-date records of all activities carried out and test results. Field inspection / test reports shall be submitted to GAIL / Owner by the contractor in bound volumes (triplicate copies).


SPECIFICATIONS FOR EARTHING INSTALLATION

S-07-02-005 Page 1 of 8


SPECIFICATION FOR EARTHING INSTALLATION



S-07-02-005 Page 2 of 8


ABBREVIATIONS:

CEA Central Electricity Authority

DGMS Director General Mines and Safety

GI : Galvanized Iron

IS Indian Standard

MS Mild Steel


UPS : Uninterrupted Power Supply



S-07-02-005 Page 3 of 8


CONTENTS

1.0 Scope

2.0 Codes and Standards

3.0 Material Specifications

4.0 Earthing Network

5.0 Installation Of Earth Electrode

6.0 Connection

7.0 Testing



S-07-02-005 Page 4 of 8


1.0 SCOPE This specification defines the requirements for the supply of earthing and lightning protection materials and installation of the earthing and lightning protection systems.


2.1.1 The work shall be carried out in the best workman like manner in conformity with this specification, GAIL Installation Standards, layout drawings, the latest edition of relevant specifications, codes of practice of Bureau of Indian Standards and OISD Standards listed below SP:30 (BIS) Special Publication-National Electrical Code

IS:2309 Protection of buildings and allied structures against

lightning.

IS:3043 Code of practice for earthing

IS:7689 Guide for control of undesirable static electricity.

OISD 110 Recommended practices on static electricity

OISD 147 Inspection and safe practice during electrical installation.

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

ii) Regulations laid down by CEA (Eiectrical Inspectorate).

iii) Regulations laid down by CCE/DGMS (as applicable).

iv) The petroleum rules (Ministry of Industry Government of India).

v) Any other regulations laid down by central/state/local authorities and

Insurance agencies.

3.0 MATERIAL SPECIFICATIONS

3.1 All materials and hardware to be supplied by the contractor shall be new, unused and of best quality and shall conform to the specifications given here under and to latest specifications of Bureau of Indian Standards. Contractor shall bring material samples to site and get it approved by Engineer-in-charge before installation.

3.2 The main earth grid conductor shall be hot dip galvanised M.S. flat unless otherwise specified. Sizes for main conductors shall he as indicated on the earthing layout drawing .Amount of galvanizing shall be 610 gm per sq.



S-07-02-005 Page 5 of 8


metre. Earth electrodes shall be as per GAIL Standard S-07-01-004. Earth plate shall be as per GAIL Standard S-07-01-006.

4.0 EARTHING NETWORK

4.1 This consists of main earth conductor (grid conductor) forming a closed ring network with required number of earth electrodes connected to it to provide a common earth for electrical devices and metallic structures. From each earth electrode two distinct connections shall be made to the main earth conductor. The earth plates shall be used for taking multiple earth connections to two or more equipment.

4.2 The earth conductor shall be laid along cable trays/cable trench/pipe racks as indicated on the earthing layout drawing. Where lined cable trenches are available, the earth conductor shall be laid in the trenches and shall be firmly cleated to the sidewall of concrete trenches using Gl clamps. at interval of 400 mm to 500 mm and near to the termination end. The earthing conductor shall run along one of the cable trays along a cable route. The earthing conductor shall be suitably cleated and electrically bonded to all the other cable trays on the same cable route at a regular interval of 25 to 30 metre. The earthing for equipment shall be tapped from the main earth conductor and not from cable tray support structure. Earth conductor when laid underground shall be at a depth of 500mm below finished grade level.

4.3 Joints and tappings in the main earth loop shall be made in such a way that reliable and good electrical connections are permanently ensured. All joints below grade shall be welded and shall be suitably protected by giving two coats of bitumen and covering with hessian tape. Earth strip laid above ground shall be welded across straight through joints and joints shall be suitably protected by giving two coats of bitumen to avoid oxidation and insulation film formation of the strip surface. When two earth strips are to be jointed by means of welding, lap welding with an overlapping of strip equivalent to double the width of the strip and all four sides shall be continuously welded. All joints at tappings above ground shall be by means of connector/lugs. A minimum of two bolts of adequate size shall be used for this purpose. Earthing strip joints at earth plate and equipment shall be through GI bolts, nut etc.

5.0 INSTALLATION OF EARTH ELECTRODE 5. 1 Earth Electrode shall be installed as shown on installation standard and

layout drawings.

The location shown on the layout drawings are indicative.

The exact location of earth electrodes in the field shall be determined by contractor in consultation with the GAIL Engineer-in-charge, depending on



S-07-02-005 Page 6 of 8


the soil strata and resistivity. Earth electrodes shall be located avoiding interferences with road, building foundation, column, pipelines etc The civil area drawings shall be referred for this. The distance between two electrodes shall not be less than twice the depth of electrode.

5.2 Electrodes shall preferably be located in a moist soil which has a fine texture , grain size and distribution. Wherever practicable the soil shall be dug up, all lumps broken and stones removed from the immediate vicinity of the electrodes and soil packed by watering and ramming as tight as possible..

5.3 The electrodes shall have a clean surface, not covered by paint, enamel, grease or other materials of poor conductivity.

5.4 All earth electrodes shall be tested for earth resistance by means of standard earth test meter. The tests shall take place in dry months, preferably after a protracted dry spell.

5.5 The disconnect facility shall be provided for the individual earth electrode to check its earth resistance periodically.

5.6 Location of earth electrodes shall be marked by permanent markers for easy identification. All earth Electrodes shall be serial numbered and also marked on ‘As Built’ drawing for future reference.

5.7 Individual earth electrodes shall be provided for each lightning arrestor and flood light mast.

5.8 Earthing system provided for concrete paved area by other agency where applicable; shall be connected to the plant earthing system below ground by minimum two earth connections.

6.0 CONNECTION The earth system connections shall generally cover the following:

- Equipment earthing for personnel safety - - System neutral earthing - - Static and lightning protection

6.1 The following shall be earthed. - System neutral - Current and potential transformer secondary neutral - Metallic non-current carrying parts of all electrical apparatus such

as transformers, switchboards, bus ducts, motors, neutral earthing resistors, capacitors, UPS, battery charger panels, welding receptacles, power sockets, lighting/power panels, control stations, lighting fixtures etc.

- Steel structures/columns, rail loading platforms etc.



S-07-02-005 Page 7 of 8


- Cable trays and racks, lighting mast and poles - Storage tanks, spheres, vessels, columns and all other process

equipment. - Fence and Gate for electrical equipment (e.g. transformer, yard

etc.) - Cable shields and armour - Flexible earth provision for Wagon, Truck - Shield wire

Conductor size for branch connection to various equipment shall be as per GAIL Installation Standards unless otherwise stated on earthing layout drawings.

6.2 All process pipelines shall be bonded and earthed at the entry and exist points of battery limit of hazardous area. (Reference installation standard S-07-01-009). Earth continuity conductors across pipe line flanges shall not be provided as per OISD 110.

6.3 Steel pipe racks in the process units and offsite area shall be earthed at every 24 metres.

6.4 Equipment/street light pole etc. located remote from main earth network may be earthed by means of individual earth electrode and earth conductor unless otherwise stated in job specifications.

6.5 Lightning protection shall be provided for the equipment, structures and buildings as shown on layout drawing. Self conducting structures shall not require separate aerial rod and down conductors. These shall however be connected to the earthing system at two or more points as shown on layout drawing. An independent earthing network shall be provided for lightning protection and this shall be bonded at least at two points with the main earthing network below ground. Lightning down conductor shall be brought to earth electrode in shortest straight path as feasible to minimise surge impedance.

6.6 The main earthing network shall be used for earthing of equipment to protect against static electricity.

6.7 All medium and high voltage equipment (above 250V) shall be earthed by two separate and distinct connections with earth.

6.8 Plant instrument system clean earthing, UPS system clean/safety earth shall be separate from the electrical earthing system.

6.9 All paint, scale and enamel shall be removed from the contact surface before the earthing connections are made.



S-07-02-005 Page 8 of 8


6.10 All earthing connections for equipment earthing shall be preferably from the earth plate mounted above ground wherever provided Equipment foundation bolts shall not be used for earthing connection.

6.11 Earth connections shall be made through compression type cable lugs/by welded lugs.

6.12 All hardware used for earthing installation shall be hot dip galvanised or zinc passivated. Spring washers shall be used for all earthing connections and all connections adequately locked against loosening.

6.13 Lighting fixtures and receptacles shall be earthed through the extra core provided in the lighting circuit/cable for this purpose.

6.14 The reinforcements of sub-station building and the sub-station floor shall be connected to main earth grid.

7.0 TESTING AND COMMISSIONING 7.1 Field inspection, testing and commissioning of electrical installation shall be

done as per GAIL standard 6-5l-0087.Earthing systems/connections shall be tested as follows

7.2 Resistance of individual earth electrodes shall be measured after disconnecting it from the grid by using standard earth test megger.

7.3 Earthing resistance of the grid shall be measured after connecting all the earth electrodes to the grid. The resistance value of an earth grid to the general mass of earth shall be as follows:

o For the electrical system and equipment a value that ensures the operation of the protection device in the electrical circuit but not in excess of 4 ohm. However for generating stations and large sub-systems, the value shall not be more than 1 ohm.

o For lightning protection, the value of 5ohms as earth resistance shall be desirable, but in no case it shall be more than 10 ohms.

7.4 The resistance to earth shall be measured typically at the following points: a) At each electrical system earth or system neutral earth. b) At each earth provided for structure lightning protections. c) At one point on earthing system used to earth electrical equipment

enclosures. d) At one point on earthing system used to earth wiring system, enclosures,

such as metal conduits and cable sheaths or armour. e) At one point on fence enclosing electrical equipment.

7.5 All earthing layout drawings shall be marked by contractor for ‘AS BUILT STATUS’ and two sets of copies shall be submitted to GAIL.


SPECIFICATION FOR CABLE INSTALLATION S-07-02-006 Page 1 of 13


SPECIFICATION FOR CABLE

INSTALLATION




Abbreviations:

BS British Standards


ET Electrical Thread

FLP Flame Proof

GI Galvanised Iron

MS Mild Steel


RCC Reinforced Concrete Cement

SWG Standard Wire Gauge




CONTENTS

1. SCOPE


3. MATERIAL SPECIFICATIONS

4. CABLE LAYING

5. TERMINATIONS

6. TESTING




1 SCOPE This specification defines the requirements for supply of materials, wherever applicable, installation, testing and commissioning of cable installation.


2.1 The work shall be carried out in the best workman like manner in conformity with this specification, GAIL installation standards, layout drawings, the latest edition of relevant specifications, codes of practice of Bureau of Indian Standards and OISD standards listed below

SP:30 (BIS) Special Publication National Electrical Code. IS: 1255 Code of practice for installation and maintenance of

power cables upto and including 33 KV rating. IS:108 10 Method of Test for cables; Part 43 Insulation resistance.

(Part 43) IS:10810 Method of Test for cables ; Part 45 High voltage test.

(Part45) OISD 147 Inspection and safe practice during electrical installation OISD 173 Fire prevention and protection system for electrical

installation

2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable: a. Indian Electricity Act and Rules. b. Regulations laid down by CEA/Electrical Inspectorate. c. Regulations laid down by CCE!DGMS/DGFASLI (as applicable). d. The petroleum rules (Ministry of Industry Government of India). e. Any other regulations laid down by central/state/local authorities

and insurance agencies

3 MATERIAL SPECIFICATIONS All materials and hardware to be supplied by the contractor shall be new, unused and of best quality and shall conform to the latest specifications of Bureau of Indian Standards.

3.1 Cable Trays: These shall be ladder type trays either prefabricated hot dip galvanised sheet steel trays or site fabricated angle iron painted trays as specified in job specification.

3.1.1 Pre-fabricated hot dipped galvanised trays The cable trays shall comply to the requirements of relevant Indian Standards.

3.1.2 Site fabricated angle iron trays




Angle iron cable trays shall be fabricated from standard rolled angle iron sections of size 75x75x8 for runners for supporting spans limited to 3000 mm. Cross support shall be 25 x 6 mm MS flat for tray width upto 500 mm and 32 x 6 mm flat for tray of more than 500 mm wide and spacing between two cross supports shall not exceed 250 mm.

3.1.3 Vertical supports for both the prefabricated and site fabricated type trays shall be fabricated out of ISMC 100 and horizontal supports shall be with 65 x 65 x 6mm angle iron sections.

Outer most tier of all vertical cable trays shall be covered with GI sheet for protection against physical damage to cables.

Cable racks and trays shall be covered by removable top covers on upper most tier allowing adequate ventilation in following cases where

o Mechanical damage of cables is likely to occur during maintenance in the plant.

o Oil or spillage of chemicals can be expected. o Protection from exposure to sun is required.

GI cover sheet shall allow adequate ventilation to the cables and shall be in standard length of 3000 mm, flanged on both sides for fixing on cable tray. Covers shall be complete with required GI hardware.

3.2 Cable Glands: Cable glands shall be of nickel plated brass unless otherwise specified. The single compression type cable glands shall be used for indoor panels/equipment (e.g. substation, control room etc). The cable glands for outdoor terminations shall be weather protected, double compression type and shall have PVC shroud for additional weather protection. Cable glands forming a part of relevant FLP enclosure shall be FLP type, tested by CMRI or any other recognized independent testing laboratory and approved by CCE/DGMS or any other statutory authority as applicable. Indigenous FLP glands shall have valid BIS license as per the requirements of statutory authorities. The size of cable glands supplied shall be appropriate to the size of cable so that flame proofness of glands is retained.

Entry thread of cable gland shall be compatible to the entry thread provided in the equipment (BS, ET, NPT, PG as applicable). If required, suitable reducers/adopters shall be used.

3.3 Connectors: Power cable terminations shall be made with crimped type tinned copper solder less lugs which shall be suitable for the cable size mentioned in cable schedule.




3.4 Ferrules: Ferrules shall be of approved type and of size to suit core size mentioned and shall be employed to designate the various cores of control cable by the terminal numbers to which the cores are connected, for ease of identification.

4 Cable Laying4.1 General

Cable installation shall include power, control, lighting, fire alarm, telephone and communication cables. These shall be laid in trenches! cable trays as detailed in the cable layout drawings. Cable routing given on the cable layout drawings shall be checked in the field so as to avoid interference with structures, heat sources, drains, piping , air-conditioning duct etc. Any change in routing shall be done to suit the field conditions wherever deemed necessary, after obtaining approval of Engineer-in-charge.

4.1.1 High voltage, medium voltage power and control cables shall be separated from each other by adequate spacing or by running through independent pipes, trenches or cables trays, as shown on layout drawings/installation standards. Details of cable routes and cable spacing not shown in detail on these drawing shall be determined by the contractor and approved by the engineer in-charge.

When single core cables are laid in flat formation, the individual cable fixing clamps and spacers shall be of non-magnetic material. As a general practice, the sheath of single core cables shall be earthed at one point to keep sheath at earth potential unless otherwise stated. Single core cables, when laid in trefoil formation shall be braced by suitable clamps at a distance, not exceeding 3 meters along the cable routing.

If straight through joints are required to be provided on single core cables, armour shall be broken at joints as per manufacturer’s recommendations. For single core cables, armour shall be earthed at one end for the cable run length as per manufacturer’s recommendation.

The Telephone, Communication and Fire alarm cables shall run on instrument trays/ducts! trenches in the units. Wherever these are not available, cables shall be taken in a separate trench/tray with a mm. spacing of 600 mm from power and control cables but in any case such separation shall not be less than 300 mm.

Telephone, fire alarm and plant communication cables shall be directly buried in road berm area, (unless otherwise specified in cable layout drawings).. These cables shall cross power cables preferably at right angles. Street lighting cables shall be laid on the other side of road berm area




4.1.2 The lengths indicated in the cables schedule are only approximate. The contractor shall ascertain the exact length of cable for a particular feeder by measuring at site. All cable routes shall be carefully measured .Before the start of cable laying, the contractor shall prepare cable drum schedule and get that approved by Engineer-in -charge to minimise/avoid straight through joints and then the cables cut to the required lengths, leaving sufficient lengths for the terminations of the cable at both ends. The various cable lengths cut from the cable reels shall be carefully selected to prevent undue wastage of cables. Extra loop length shall be given for feeder cables where required as per the directions of Engineer-in-charge to meet contingencies

Cables shall be laid in directly buried trench or in RCC trench (underground trench) or in cable tray along pipe sleepers or in over head trays as shown on cable layout drawings.

Overhead trays shall be installed 2700 mm (minimum) above grade level. At road crossings overhead trays shall be installed at 7000 mm (minimum) above grade level or cables shall be routed cable tray culvert! Electrical road crossings as per layout drawings.

Sufficient care shall be taken while laying cables to avoid formation of twist, sharp bend etc. in order to avoid mechanical injuries to cables. Rollers shall be used for pulling of cables.

Cable installation shall provide minimum cable bending radii as recommended by cable manufacturer.

4.1.3 Cables shall be neatly arranged in the trenches / trays in such a manner that cr155-crossing is avoided and final take off to the motor / switchgear is facilitated, Arrangement of cables within the trenches / trays shall be in line with cable layout drawings. Cable routing between cable trench and equipment/motors shall be taken through GI pipe sleeves of adequate size. Pipe sleeves shall be laid at an angle of maximum 45 to the trench wall. Bending radii of pipes shall not be less than 8D. It is to be ensured that both the ends of GI pipe sleeves shall be sealed with approved weather proof sealing plastic compound after cabling. In places where it is not possible, cables shall be laid in smaller branch trenches.

4.1.4 All cables shall be identified close to their termination point by cable tag numbers as per cable schedule. Cable tag numbers shall be punched on aluminium straps (2mm thick, 20 mm wide and of enough length) securely fastened to the cable and wrapped around it.

Each underground cable shall be provided with cable tags of lead securely fastened every 30 m of its underground length with at least one tag at each end before the cable enters/leaves the ground. In unpaved areas, cable




trenches shall be identified by means of cable markers as per installation drawing. These cable markers shall be placed at location of changes in the direction of cables and at intervals of not more than 30 m and also at cable straight through joint locations.

4.1.5 All temporary ends of cables must be protected against dirt and moisture to prevent damage to the insulation. For this purpose, ends of cables shall be taped with an approved PVC end cap or rubber insulating tape.

4.1.6 Each row of cables shall be laid in place and before covering with sand. All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water inside building/lined trench. Every cable shall be given an insulation test in presence of Engineer-in-charge/Owner before filling the cable trench with sand Any cable which is found defective shall be replaced.

4.1.7 Where cables pass through foundation walls, the necessary openings shall be provided in advance for the same by another agency. However, should it become necessary to cut holes in existing structures for example floor slab etc., the electrical contractor shall determine their location and obtain approval of the Engineer-in-charge before carrying out the same.

4.1.8 Cables for road crossings shall be taken through ERC (Electrical Road Crossing) as shown in the cable layout drawings.

At road crossing and other places where cables enter pipe sleeves adequate bed of sand shall be given so that the cables do not slack and get damaged by pipe ends.

4.1.9 Wherever cable trench crosses storm water, waste water channel/drain, cables shall be taken through PVC/RCC pipes. Where cables are required to cross drains of depth more than 1200 mm, cables shall be taken over the drain on cable trays supported suitably using ISMC 150/200 sections.

4.1.10 Ends of cables leaving trench shall be coiled & capped and provided with protective cover till such time the final termination to the equipment is completed.

4.2 Cables laid direct in ground Cables shall be laid underground in excavated cable trenches where specified in cable layout drawings. Trenches shall be of sufficient depth and width for accommodation of all cables. Cables shall be properly spaced and arranged with a view of heat dissipation and economy of design. Maximum number of cable layers in trench shall be preferably limited to 5 layers.




Minimum depth of cable trench shall be 750 mm for medium voltage and 900 mm for H.V. Cables. The depth and the width of the trench shall vary depending upon the number of layers of cables as per GAIL installation Standards

Cables shall be laid in buried trenches at depth as shown in the cable layout drawings. It is to be insured by the contractor that the bottom of buried trenches shall be cleared of all rocks, stones and sharp objects before cables are placed. The trench bottom shall be filled with a layer of sand. This sand shall be leveled and cables laid over it. These cables shall be covered with 150 mm of sand on top of the largest diameter cable and sand shall be lightly compacted. A flat protective covering of 75 mm thick second class red bricks shall then be laid and the remainder of the trench shall then be back -filled with soil, rammed and leveled.

4.3 Cables laid in concrete trench Cables shall be laid in 3 or 4 tiers in concrete trench as shown on layout drawings. Concrete cables trenches shall be filled with sand in hazardous area to avoid accumulation of hazardous gases and oil. RCC covers of trenches shall be effectively sealed to avoid ingress of chemical and oil in process area. Removal of concrete covers where required for the purpose of cable laying and reinstating them in their proper position after cables are laid shall be done by electrical contractor.

All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water

4.4 Above ground cables 4.4.1 Cables installed above grade shall be run in cable trays, clamped on walls,

ceiling or structures and shall be run parallel or at right angles to beams , walls or columns. Cable routing shall be planned to be away from heat sources such as hot piping, gas, water, oil drainage piping, air-conditioning duct etc. Each cable tray shall contain only one layer of cables as far as possible for power cables. However control cables may be laid in double layer in the cable trays.

4.4.2 Individual cable or small group of cables (upto 3 to 4 cables) which run along structures / walls etc. shall be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle bars. Alternatively small group of cables can be taken through 100/150 mm slotted channel tray / ISMC 100. Cables shall be supported so as to prevent sagging. In general, distance between supports shall be approximately 300 mm for cables upto 25 mm diameter and maximum 450 mm for cables larger than 25 mm dia. to prevent the sagging of cables.




4.4.3 Cable laid on supporting angle in cable trenches, structures, columns and vertical run of cable trays shall be suitably clamped by means of G.I. saddles / clamps, whereas cables in horizontal run of cable trays shall be tied by means of nylon cords. Distance between supporting angles shall not exceed 600 mm.

4.4.4 All cable trays (other than galvanised trays) and supporting steel structures shall be painted before laying of cables. The under surfaces shall be properly degreased, de-rusted, de-scaled and cleaned. The painting shall be done with one coat of redoxide zinc chromate primer. Final painting shall be done with two coats of approved bituminous aluminium paint unless otherwise specified.

4.4.5 Where cables rise from trench to motor, lighting panel, control station, junction box etc., they shall be taken in GI pipe for mechanical protection upto a minimum of 300 mm above grade. Cable ends shall be carefully pulled through conduit to prevent damage to cable.

4.4.6 All GI Pipes shall be laid as per layout drawings and site conditions. Before fabrication of various profiles of pipes by hydraulically operated bending machine (which is to be arranged by the contractor) all the burrs from the pipes shall be removed. 01 Pipes having bends shall be buried in soil / concrete in such a way that the bend shall be totally concealed. For G.I. pipes buried in soil, bitumen coating shall be applied on the buried lengths, Installation of G.I. pipes shall be undertaken well before paving is completed and necessary co ordination with paving agency shall be the responsibility of Electrical Contractor.

Following guide shall be used for sizing of pipe. a. 1 cable in a pipe -53% of pipe cross-sectional area occupied by cables. b. 2 cables in a pipe -31% of pipe cross-sectional area occupied by cables. c. 3 cables in a pipe - 43% of pipe cross-sectional area occupied by cables. d. 4 and above cables in a pipe- 40% of pipe cross-sectional area occupied

by cables.

4.4.7 After the cables are installed and all testing is complete, conduit ends above grade shall be plugged with a suitable weatherproof plastic compound/bitumen/suitable sealing compound. Alternatively rubber bushes shall be employed for the purpose of sealing.

5 TERMINATIONS 5.1 All PVC cables up to 1 100V grade shall be terminated at the equipment by

means of compression type cables glands suitable for the cable size. They shall have a screwed nipple with conduit electrical threads and check nut. The cables shall be identified close to their termination points at both the ends of cable(cable numbers shall be punched on aluminium straps 2mm




thick and securely fastened to the cable, wrapped around it) and also along the route at recommended intervals, by cable tag numbers.

All cable entries for outdoor termination shall be preferably through bottom. Outdoor cable termination through top of equipment shall not be permitted.

5.2 Power cables cores wherever colour coding is not available shall be identified with red, yellow and blue PVC tapes. Where copper to aluminium connections are made, necessary bimetallic washers shall be used.

5.3 In case of control cables, all cores shall be identified at both ends by their terminal numbers by means of PVC ferrules suitable for core size. Wire numbers shall be as per schematic! wiring/inter-connection diagram. All unused spare cores of control cables shall be neatly bunched and ferruled with cable tag at both ends, for future use.

For trip circuit identification additional red ferrules shall be used only in the particular cores of control cables at the termination points in the Switchgear/ Control panels and Control Switches

5.4 Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of non- magnetic material! aluminium sheet in case of single core cables. All unused cable entries on equipment/panels shall be plugged/sealed.

5.5 The cable shall be terminated at electrical equipment /switchboards through glands of proper size. The individual cores shall then be dressed and taken along the cables ways or shall be fixed to the panels with polyethylene straps . The cable glanding shall be done as per manufacturers instructions. Cable armour shall not be exposed after termination is complete. In case of termination of cables at the bottom of a panel over a cable trench having no access from the bottom close fit holes shall be drilled in the gland plate for all the cables in one line, then gland plate shall be split in two parts along the centre line of holes. After fixing bottom plate, uncovered cable holes/gaps shall be sealed with cold setting compound.

5.6 Crimping of lugs to cable leads shall be done by hand crimping / hydraulically operated tool as per requirement. Insulation of the leads shall be removed before crimping. Conductor surface shall be cleaned and shall not be left open. Suitable conducting jelly shall be applied on the conductor lead. Lugs shall enclose all strands of cable core. Cutting of strands shall not be allowed.

5.7 The contractor shall bring to the notice of Engineer-in-charge any mismatch in cable glands, tugs provided with the equipment vis-à-vis to the cable size indicated in cable schedule for taking corrective action.




5.8 The cable joints in power and control cables shall be avoided as far as possible. In case a joint is unavoidable, the following shall be insured: # The number of joints shall be restricted to minimum as far as possible. # The location of joints shall be identified with permanent markers. # No joints shall be allowed in hazardous areas without the approval of

Engineer-in- charge. The jointing and termination of medium voltage power cables shall be carried out by trained personnel only. Jointing and termination of high voltage cables shall be done by skilled and experienced jointer duly approved by Engineer-in-charge. Only type tested termination kits of approved make shall be used.

5.9 No unauthorised repairs, modifications shall be carried out on the hazardous area equipment terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall be brought to the notice of Engineer-in-charge by contractor. After termination is complete, all the bolts, nuts, hard wares of terminal box shall be properly placed in its position and tightened.

5.10 Where required, cable sealing boxes intended to be used with the apparatus shall be filled with solid setting type bituminous compound unless otherwise specified.

6 TESTING AND COMMISSIONING 6.1 Field testing and commissioning of electrical installation shall be carried out

as per GAIL specification S-07-02-004. 6.2 Before energising, the insulation resistance of every circuit shall be measured

from phase to phase, phase to neutral and from phase/neutral to earth.

6.3 Where splices or terminations are required in circuits rated above 650 volts, insulation resistance of each length of cable shall be measured before splicing and or / terminating. After completion of splices and for terminations measurements shall be repeated.

6.4 The insulation resistance of directly buried cables shall be measured before cable trenches are backfilled. Measurements shall be repeated after back filling. For cables upto 1.1 kV grade 1000 V Megger and for H.V. Cables 2.5 kV / 5 kV Megger shall be used.

6.5 D.C. High Voltage test shall be conducted on cables given below after installation.

a) All 1100 volts grade cables in which straight through joints have been made. b) All cables above 1100 V grade.

The D.C. High Voltage test shall be performed as detailed below in the presence of the Engineer-in-charge or his authorised representative only,.




Cables shall be installed in final position with all the straight through joints complete. During the high voltage test, all other electrical equipment related to the cable installation, such as switches, instrument transformers, bus bars, etc., must be earthed and adequate clearance shall be maintained from the other equipment and framework to prevent flash-overs.

In each test, the metallic sheath/screen/armour shall be connected to earth.

6.6 All checks and tests shall be made as per Owner’s standard test Performaavailable with site engineer. All test readings shall be recorded and submitted to GAIL in triplicate sets.

6.7 Cable schedule, cable layout drawings, Interconnection drawings shall be marked by contractor for ‘AS BUILT STATUS’ and two sets of copies shall be submitted to GAIL.


SPECIFICATION FOR LIGHTING INSTALLATION S-07-02-007 Page 1 of 15


SPECIFICATION FOR LIGHTING INSTALLATION




Abbreviations:

BIS : Bureau of Indian Standards


CMRI Central Mining Research Institute

DG Diesel Generator

DGMS Director General Mines and Safety

ELCB Earth Leakage Circuit Breaker

FFL Finished Floor Level

FRP Fibre Glass Reinforced Plastic

GI Galvanised Iron

HPMV High Pressure Mercury Vapour

HPSV High Pressure Sodium Vapour

MCB : Miniature Circuit Breaker

MDB Main Distribution Board

MS Mild Steel

PVC Polyvinyl Chloride

TPN Three Phase and Neutral




CONTENTS

1 SCOPE


1 EQUIPMENT SPECIFICATIONS

1 LIGHTING INSTALLATION

1 TESTING AND COMMISSIONING




1 SCOPE This specification defines the requirements for the supply of equipment, materials, installation, testing and commissioning of the lighting system (lighting fixtures, lighting power distribution, telephone wiring etc.).

2 CODES AND STANDARDS 2.1 The work shall be carried out in the best workmanlike manner, in conformity

with this specification GAIL Installation Standards, and the relevant specifications/codes of practice of the Bureau of Indian Standards.

2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable: a) Indian Electricity Act and Rules. b) Regulations laid down by CEA/Electrical Inspectorate. c) Regulations laid down by CCE/DGMS (as applicable). d) The petroleum rules (Ministry of Industry Government of India). e) Any other regulations laid down by central/state/local authorities and

Insurance agencies.

3 EQUIPMENT SPECIFICATIONS All materials, fittings and appliances to be supplied by the contractor shall be new, unused and of the best quality and shall conform to the specifications given hereunder. These shall be manufactured in accordance with the latest revision of the specifications of Bureau of Indian Standards/International standards. In the absence of any specifications for a particular item, contractor shall bring material samples along with proven track record to site and get the same approved by Engineer-in-Charge/Owner before installation.

3.1 Lighting and Power Panels 3.1.1 Lighting and Power panels (general purpose panels for safe area) shall be

made of 1.6mm thick sheet steel and shall be dust and vermin proof. All metal surfaces shall be cleaned free of rust, given a coat of red-oxide primer and finished with two coats of epoxy based paint of shade 632 of IS 5. Panels shall be indoor/outdoor type as specified. Indoor type panels shall have 1P42 degree of protection and shall be suitable for surface or flush mounting on wall surface as specified. Lighting and power panels located outdoor shall be 1P55 weather protected and shall also preferably have integral canopy for additional weather protection. The canopy shall be made of 2mm thick galvanized sheet steel or FRP where these are separate from the equipment.

3.1.2 Lighting and Power panels shall have TPN incoming feeder and single phase outgoing feeders. Lighting circuit feeders shall be rated for 10 amps and power circuit feeders shall have current rating of I 6Amps.In power panels for window Air conditioning units, power circuit feeder shall be rated for 20 amps. Panels shall be equipped with phase and neutral busbars of required




current carrying capacity. The outgoing feeders shall be provided with single pole miniature circuit breakers (MCBs) for safe areas and double pole MCBs for hazardous areas. The incomer shall be with MCB and ELCB unit unless otherwise specified. Miniature circuit breakers shall be mounted in such a way that the operating levers project outside the front bakelite cover plates for ease of operation. A hinged door to cover the operating knobs shall be provided. In addition, a circuit diagram indicating incomer details and outgoing details viz. Circuit number, circuit rating, load connected and details of the load shall be pasted inside the panel. Also a laminated copy of the diagram shall be provided inside the panel in a suitably designed pocket. Two external earthing studs for connection to the plant eathing grid shall be provided on the panel. Further, the panel shall be provided with an earth bus bar with terminal studs for connection to the third core of each outgoing circuit. Each circuit phase and neutral shall be given ferrule numbers. Complete wiring inside the panel, shall be neatly bunched with PVC tape and button. Sufficient terminals shall be provided in the terminal block so as to ensure that not more than one wire (core) is connected to a terminal. The panel shall have knock out holes or removable gland plate for the entry of incoming and outgoing conduits or cables. The panels shall be complete with requisite number of cable glands as specified.

3.1.3 The Main distribution board (MDB) where used, shall be made of 2mm thick sheet steel panel, dust and vermin proof similar in construction to Lighting and Power panels but with TPN MC13 incoming and TPN outgoings (MCB with ELCB units and MCB without ELCB unit as applicable) of required numbers as specified.

3.1.4 All MCBs shall be of M9 category as per IS 8828 and sensitivity of ELCBs shall be 100 mA unless otherwise specified.

3.1.5 Wherever the size of incoming cable to lighting, power panels/MDB is more than 35 sq. mm a suitable cable adapter box shall be provided and attached to the panel. The incoming cable leads shall be connected to terminal block (bolted type terminals) of required size. This terminal block shall be connected to TPN incomer unit through separate PVC insulated copper conductor wires/bus bars. Sufficient space shall be provided (200 to 250mm) between gland plate and the bottom of terminal block for easy termination.

3.2 Lighting fixtures The types, makes and catalogue numbers of various types of lighting fixtures shall be as given in Fixture schedule job data sheet. HPMV/HPSV lighting fixtures shall be complete with ballast, starters and capacitor, as required. Control gears shall be integral or non-integral as specified in lighting layout drawings. Unless otherwise specified, all fixtures shall be supplied complete with lamps. Ballast for fixture shall be copper wound or electronic type. The fixtures shall be of high power factor type i.e. at least 0.9 or more.




3.3 Switches Switches, manufactured in accordance with IS:13947 shall be used for non hazardous areas. Switches in areas where concealed wiring has been adopted, shall be flush mounting piano type unless otherwise specified. For surface conduit wiring, piano type switches in surface mounted box shall be provided. Industrial Type switches (Weather protected) shall be used for outdoor areas.

3.4 Receptacles Three pin type 5A/15A receptacles manufactured in accordance with IS: 1293 shall be used for non hazardous areas. The receptacles and the controlling ON/OFF switch shall be mounted in the same enclosure box but these shall be in separate units to facilitate replacement by parts. Flush mounting type receptacles shall be used in areas where concealed wiring has been adopted and surface type shall be used in other areas. For exhaust fans and wall mounted air circulators, socket and switch enclosures shall be separate. In buildings such as sub-station, D.G. shed, Workshop, maintenance shop etc. industrial type metal clad socket outlets and plugs shall be provided. These sockets shall be supplied complete with plugs.

3.5 Outlet Boxes The outlet boxes used as point outlets shall be prefabricated type 65mm deep junction boxes. Outlet boxes custom fabricated for sockets, switches, fixtures and fan regulators etc. shall be made of M.S. Sheet having minimum thickness of 1.6mm. Outlet boxes shall be galvanized after fabrication. These shall be complete with terminal block suitable for connection of wires up to 4 sq. mm Front cover plate shall be of 3mm thick backelite / PB sheet. The colour shall suit the shade of the walls or shall be white if the shade of the walls is not finalised. The sheet shall extend at least 2 cm on all sides of outlet box. Cover plate shall be fixed by cadmium plated brass screws and cup washers. Outlet boxes shall be provided with adequate number of knock outs on all the sides for ease of wiring either with conduits or without conduits.

3.6 Conduit and Accessories Conduits for Electrical installations shall conform to IS:9537. The type of conduit (steel/GI/PVC) shall be as specified on drawing. Black enameled steel or GI conduit shall be of 1.6mm thick and the minimum wall thickness of PVC conduit shall be 1.6mm. Generally PVC conduits shall be used in concealed wiring and for surface wiring GI conduit (in plant buildings) and black enameled steel conduit (in non plant buildings) shall be used.

3.7 Lighting Poles Lighting poles shall be fabricated (as per GAIL installation standards namely 7-51-0201, 7-510202, 7-51-0205, 7-51-0207, 7-51-0210 and 7-51-0228) from ERW steel tubular pipes of specified section, with joints, swaged




together when hot and bevelled on outside edges. Poles shall be coated with bituminous preservative solution on the ground portion of the outside surface. Remainder of the outside surface shall be given one coat of redoxide primer and finished with two coats of aluminium paint. The pole shall have, a marshalling box near the bottom to contain HRC fuses, a neutral link, an earth stud and terminal block.

3.8 Lighting Mast 3.8.1 Lighting masts (Lattice tower) where used, shall be fabricated as per

VENDOR STANDARDS AND THE DESIGN MUST BE APPROVED BY GAIL. They shall be complete with 2 nos. MS flats provided at the base plate for connection to the plant earthing grid. A ladder, platform, handrail, a weatherprotected TPN switch (at 1500mm from ground level) and a weather protected distribution board fabricated out of sheet steel shall be provided at the top of mast. The TPN Switch and the distribution board shall also have a canopy for additional weather protection. The TPN switch shall be suitable for looping one more lighting mast from the same incoming power supply. The distribution board shall have TP&N busbars of 30 Amps. rating and 12 Nos. outgoing circuits each with a 6A single pole MCB. The distribution board shall have cable entries from bottom. Necessary space provision and suitable mounting arrangement shall be made on top of the tower for mounting of ballast (choke) and condensers for all the circuits and the lighting fixtures. The masts shall be given one coat of red oxide primer and two coats of aluminium paint. Distribution board shall be fabricated out of 2mm thick sheet steel and shall be painted with two coats of enamel over a base coat of red oxide.

3.8.2 Unless otherwise specified the flood lighting high masts shall be telescopic type AND MUST BE APPROVED BY GAIL BEFORE PROCUREMENT.

3.9 WiresWires shall be PVC insulated and shall be of 660 Volts grade as per 1S694. Conductor shall be of stranded copper and size shall be minimum 1.5 Sq. mm for lighting, 2.5 Sq. mm for ISA power socket circuits and 4 sq. mm for split A/C power socket circuits. Red/Yellow/blue wires for phases. black wire for neutral and green wire for earth shall be used (size of earth wire shall be same as for phase and neutral size). Wire size for air conditioning circuit feeders shall be as indicated in the panel schedule.

3.10 Ceiling fan/Exhaust fan Ceiling fans shall be of 1200mm sweep unless otherwise specified with double ball bearing and regulator. The suspension down rod shall be sturdy mild steel rod of adequate diameter and of minimum length of 300mm with shackles suspension arrangement as per IS. For exhaust fans, the sweep dia. and air CFM shall be as specified in job specification. Exhaust fans for battery room shall be with anticorrosive blades suitable for use in acidic fumes.




3.11 Decorative switches and sockets Decorative lighting switches and sockets where specified, shall be modular in design. All these items shall fit into the same frame with overall standard dimensions. Frames shall be suitable for surface and flush mounting in brick! concrete wall. The frames shall be suitable for conduit entry from all the sides. Switches and sockets shall match colors of the frame and cover plates to obtain a combination which shall match decor of the interiors of Control Room, Administrative buildings, offices rooms etc.

4 LIGHTING INSTALLATION 4.1 General 4.1.1 The lighting fixtures in the plant shall be fed from lighting panel. All outdoor

lighting shall be group controlled manually or through synchronous timer or photocell. Lighting wiring between panel and lighting fixtures shall be done with PVC insulated 3-core (phase, neutral and earth) copper conductor armoured cable for hazardous areas. Wiring in the building shall be done by means of 3-core copper, conductor PVC insulated, un-armoured cables, or PVC insulated copper conductor wires in conduit Metsec channel as specified. All joints of conductors in Switch boards/JBs Fittings shall be made only by means of approved mechanical connectors (nylon/PVC connectors). Bare twisted joints shall not be permitted any where in the wiring system.

4.1.2 The lighting layouts furnished by owner will indicate approximate locations of lighting fixtures. The electrical contractor shall determine, with approval of Engineer-in-Charge, the exact locations of each fixture in order to avoid interference with piping or other mechanical equipment and also with a view to obtain as much uniform illumination as practicable, and to avoid objectionable shadows. Conduits shall be laid out by the contractor to suit field conditions and as per directions of the Engineer-in-Charge.

4.1.3 On walkways, platforms and other outdoor area, lighting fixtures shall be located nearer to landing of stairs or ladders, gauges, flow meters, panel boards and other equipment to provide proper illumination.

4.1.4 The minimum height of any lighting fixture shall be preferably not less than 2.5 meters above the floor level.

4.1.5 All outdoor cable terminations to outdoor junction boxes, panels, socket outlets etc. shall be through bottom or from side. Top entries for cables shall be avoided to avoid water entry. All cable glands for outdoor terminations shall be double compression type and the gland shall be covered with PVC or rubber boot shroud. All unused cable entries shall be plugged with suitable blanking plugs.




4.1.6 Mounting height of equipment shall be as under o Top of Switch Box 1200 mm from FFL(Finished floor level) o Top of Lighting/Power Panel : 1800mm from FFL o 5/15 Amp. receptacle : 300mm from FFL unless otherwise specified (1200

mm for process areas and industrial sheds) o Lighting fixture As indicated in layout drawing o Exhaust fan : In the cutout provided / as indicated in Layout drawings.

4.1.7 Fixtures shall be firmly supported from the structures. Support clamps etc. may be bolted or welded to the existing steel work or metal inserts. In case of concrete structures, where metal inserts are not available, fixtures shall be suspended from concrete surfaces with the help of anchor fasteners, In such cases special care shall be taken to see that anchoring is firm. In places where ceiling fans are provided, lighting fixtures shall be suspended below the level of fan to avoid shadow effect.

4.1.8 Circuit cables in a group shall be cleated to structure by using galvanised strip clamps or cable run in cable trays wherever trays are available. Spacers and cleats shall be of required size to accommodate the cables. All hardware shall be galvanised or zinc passivated. Underground lighting cables (in paved areas) shall be taken in suitable G.1. sleeves buried at a minimum depth of 300mm from FFL. GI pipe sleeves shall be extended to 300mm above FFL. Exact termination/layout of G.I. pipes (for protection of cables) shall be decided at site as per site convenience in consultation with Engineer-in-charge.

4.1.9 Wiring for all outlet sockets shall be done with 3 cores of equal sizes for phase, neutral and earth. The terminals of switch sockets shall be suitable to receive the size of wire specified.

4.1.10 All lighting fixtures shall be provided with terminal block with required terminals suitable for connection of wire up to 2.5 sq. mm copper conductor.

4.1.11 The cable shall be straightened after unwinding it from the drum. All cables be clamped/laid in straight run without any sag and kink.

4.1.12 For location where fan points are shown, fan hooks with junction box shall be provided during concreting. Where fan hooks and J.Bs. are provided separately JB shall be located within a distance of 3 00mm from hook for mounting of ceiling rose.

4.1.13 Industrial type plug sockets with 20A MCB or rating as per job specification shall be provided at a height of 5 00mm from FFL for window AC units. Socket outlets and plugs for installation in Sub-station building, DG shed, workshop, maintenance shop etc. shall be of industrial metal clad type.




4.1.14 Wiring for exhaust fans shall be terminated in receptacles as specified in layout drawing and the connection from receptacle to the exhaust fan shall be by means of a flexible cord equivalent in size to the main run of wires. Switch for exhaust fan shall be located in a separate switch board along with other switches.

4.2 Conduit System 4.2.1 Surface or concealed conduit system of wiring shall be adopted, as specified

in the drawings. Required number of pull boxes shall be used at intervals to facilitate easy drawing of wires. Separate conduit shall be run for lighting and power circuits. Further, conduits for Normal lighting/Emergency lighting/DC critical lighting shall be separate. Conduit layout shall be decided at site as per site conditions. Drop conduits for switch boards shall be decided by contractor as per wall locations shown in Architectural drawings. All exposed run of conduits on surface, shall be vertical or horizontal.

4.2.2 Only threaded type conduit fittings shall be used for metallic conduit system. Pin grip type or clamp type fittings are not acceptable. Conduit ends shall be free from sharp edges or burrs, The ends of all conduits shall be reamed and neatly bushed.

Conduit shall be of minimum 25mm dia. Maximum number of wires permissible in a conduit shall be seven/nine for wire size of 2.5 sqmnill.5 sq.mm. respectively.

4.2.3 The exposed outer surface of the conduit pipes, including all accessories forming part of the conduit system, shall be adequately protected against rusting. In all cases, bare threaded portion of conduit pipe shall not be exposed unless such bare threaded portion is treated with anti corrosive preservative or covered with approved plastic compound.

4.2.4 Conduit connection to outlet boxes shall be by means of screwed hubs or check nuts on either side. Where concealed wiring is done, junction boxes (65mm deep) shall be used so as to rest on shuttering properly. Conduits shall be laid above reinforcement. All conduit connections shall be properly screwed and Junction box covers shall be properly fitted so as to avoid entry of concrete slurry.

4.2.5 Conduit pipes shall be fixed by 1.6mm thick G.I. saddles on 3mm thick G.l. saddle bars of required width in an approved manner at intervals of not more than 5Ocms for straight run. At places near junction boxes, bends, or similar fittings, saddle and bars shall be provided on either side.

4.2.6 Where concealed wiring is to be adopted, conduits shall be laid in time before concreting of the slab. Pull wire (GI or steel) shall be provided inside conduit for the ease of wire pulling. The contractor shall coordinate his work with




other agencies involved in the civil works in such a way, that the work of the other agencies is not hampered or delayed. Vertical conduit runs shall be made in wall before plastering is done so as to avoid chasing. Where chases are made for conduit run contractor shall fill these chases or any other openings made by them after completing the work and patch the surface. During installation, care shall be taken to see that proper covers are provided to prevent rusting of conduits. Locations of all point outlets, junction boxes shall be marked with brick powder or sand so that these are easily identified after shuttering removal. As built conduit layout drawing shall be submitted by contractor after completion of the work.

4.2.7 All junction boxes, bends and other accessories shall be of the same material as that of conduit and shall have the same protective coatings.

4.2.8 After erection, the entire conduit system shall be tested, for mechanical and electrical continuity and shall be permanently connected to earth by means of approved type of earthing clamps.

4.3 Hazardous Area Installation 4.3.1 Wiring in hazardous area shall be done by using minimum 2.5mm2 copper

conductor armoured cable. Circuit wiring feeding hazardous areas shall be controlled by two pole switches/MCBs (for phase as well as neutral isolation).

4.3.2 Correct type of lighting equipment (fixtures and JBs) with regard to hazardous protection as specified in the drawing, shall be installed for the areas classified as Zone 1, Zone 2 etc.

4.3.3 The terminations in the junction boxes and the lighting fittings shall be done avoiding possibility of loose connections due to vibrations. After the terminations are made the cover of the junction boxes and the lighting fittings shall be closed properly with all bolts and hard wares in correct position, retaining its explosion and weather protections. In fixtures having double cable entries, both the entries shall be used for looping in and looping out connection, thus minimising the use of a separate junction box. Wherever separate control gear boxes (C.G. box) are provided looping in and looping out connections shall be through CG box, thus avoiding the use of a additional junction box. All unused cable entries shall be sealed with suitable plugs.

4.3.4 Circuit cables shall be firmly cleated in a group along columns! beam/ladders/side channels/platform using 1.6mm thick GI saddles on 25x3 mm GI saddle bar at intervals of 400mm to 500mm for straight run and on either side close to bending and at both termination ends as per the directions of Engineer-in-charge. Where required 3 or more of cables may be taken in slotted channel tray after getting the approval of Engineer-in-charge. Cables shall not be routed along hand rails.




Where fire proofing column/structures are encountered, all cabling shall be taken in GI pipes of required size and both ends shall be sealed, well before fire proofing is done. Similarly equipment such as lighting fixture, control gear box, lighting! power panels, field call stations, junction boxes etc. shall be installed on a suitable steel mounting frame/distance bracket, thereby avoiding direct contact with the concrete used for fire proofing.

4.3.5 Cable glands for terminating cable on flameproof equipment shall be of double compression FLP type. Any material/equipment specified to be supplied by contractor for installation in hazardous areas, shall be tested by CMRI and duly approved by C.C.E. Nagpur or DGMS Dhanbad or any other applicable statutory authority. All indigenous FLP equipment shall also have valid BIS license as required by statutory authorities.

4.4 Building Lighting 4.4.1 The type of wiring system shall comprise surface/concealed conduit system

or cable wiring as specified on layout drawings.

4.4.2 Mounting details of fixtures shall be indicated on the drawings. If specified on the drawings, a group of fluorescent lighting fixtures which are to be mounted end to end, shall be fixed to mild steel cold rolled sections of 50mm x 50mm and of 1.2mm thick (Metsec channel). The entire assembly shall be fixed to the ceiling with necessary number of supports which may be by means of steel conduit or chromium plated chain link as required. The Metsec’ Channel shall run continuous in suitable sections from one end to other end of wall. The complete channel shall be spray painted, with approved colour as per the directions of Engineer-in-Charge. All wires inside channel shall be neatly bunched by nylon tape & buttons.

4.4.3 Wiring in areas above false ceiling shall be done in Surface Conduit (25mm dia GI conduit) suitably clamped to the true ceiling. Vertical drops from true ceiling for panels, switches, receptacles etc. shall be taken in 25mm dia PVC conduit concealed in walls upto switchboards/panels. Lighting fixtures shall be supported from true ceiling. Exact location of fixtures shall be finalised in co-ordination with air-conditioning duct diffuser layout, panels layout and false ceiling grid layout. To facilitate easy maintenance ‘Looping back system’ of wiring shall be followed throughout. Accordingly supply tappings and other interconnections including for earthing are made only at fixture connector blocks or at switch boards. Required number of j unction boxes shall be used at intervals for wire pulling and inspection.

4.4.4 All wires in conduit shall be colour coded as specified. Each circuit shall have independent phase neutral and earth wire. However when group of circuits are run in a single conduit the earth wire can be common.




4.4.5 Building conduit lighting system of wiring where measurement is done on point wiring basis generally consists of two parts. The first part is the circuit wiring which includes the work necessary from lighting panel up to switch box and from switch box to another switch box.. The second part is the point wiring which shall include the work necessary from tapping point in the switch box upto various fixtures or fan outlets/ceiling roses.

4.4.6 In no case, two different sources or two different phases of supply shall be combined in one switchboard.

4.4.7 Switches for light fixtures/exhaust fans in battery room shall be provided outside the Battery room.

4.4.8 Lighting layouts for non-plant buildings (such as ware house, cement godown, gate house, workshop, service building, rest room, etc.) shall be prepared by installation contractor.

The following basic data/document for preparation of layouts will be provided to the contractor. i) Architectural drawings ii) Illumination level required iii) Type of lighting fixture iv) Type of wiring (concealed/surface conduit/cable wiring etc.)

Based on the above input, contractor shall prepare and submit lighting layout drawings, panel schedules, conduit layout drawings for concealed wiring, design calculations wherever required, for review by purchaser before erection work is started. The lighting layout drawing shall show the location, type and mounting details of lighting fixtures, receptacles, junction boxes, layout of circuit indicating number of wires etc. The number of points in a circuit shall not exceed ten and the load in each circuit shall be less than 1000 Watts.

The panel schedule shall include rating of incoming and outgoing feeders, number of outlets, load for each outgoing circuit, etc.

All drawings shall be prepared preferably in A0 and Al size. Panel schedules shall be in A4 size drawings. Final submission of drawings shall be in soft copies and in bound volumes together with one transparency of each document).

4.5 Street Lighting 4.5.1 Street lighting poles to be located on road side shall be installed at a

minimum distance of 300mm from the edge of the walkway of the road (road berm). Size of wires from marshalling box upto fixture shall be 1.5mm2/2.5mm2, copper conductor PVC insulated.




4.5.2 Each pole shall be earthed at two points by connecting to the plant earth grid as shown on Installation standards.

4.5.3 Street lighting fixture shall be mounted on steel tubular poles as per standard drawings. The foundation for the street lighting poles will be made by electrical contractor. Street lighting poles shall be supplied with a base plate.

4.5.4 The poles shall be numbered as per the drawings! directions of Engineer in-Charge.

4.6 Mast Lighting 4.6.1 The lattice structure masts shall be installed on concrete foundations with the

base plate bolted on to the anchor bolts. The lattice structure shall be painted with a coat of primer and two coats of aluminium paint, the second coat to be given just before handing over to the owner. The masts shall be numbered as per drawings. The masts shall be connected to the plant earth grid at two points

4.6.2 The main feeder upto the distribution board of lighting mast shall be through PVC insulated armoured cable of size as specified in the respective drawing. Wiring from Distribution Board to each flood-light fixture shall be by means of a 3-core 2.Ssqmm, copper conductor PVC insulated armoured cable. All the cables shall be neatly clamped to the structure at intervals not exceeding 25 cm.

4.6.3 Alternatively the flood light high mast shall comply to specification no. S-07-01-014

4.6.4 Exact orientation of flood lighting fixtures shall be decided at site to achieve optimum utility of these fixtures.

4.7 Telephone Wiring Conduits for telephone wiring in buildings shall be of 1.6mm thickness. 25mm dia black enamelled steel conduit/PVC as per IS 9537, installed on wall surface or concealed or as specified in job specification.

Conduit installation system shall comply to the requirements given in clause 4.2 conduit system’. Required number of pull boxes shall be provided at interval for easy drawing of wires. The telephone wiring shall be done with 0.63mm dia annealed copper conductor PVC insulated 660V grade, twin flat wire, unless otherwise specified in job specification. One telephone socket outlet shall be provided for connection to telephone instrument.




5 TESTING AND COMMISSIONING 5.1 Lighting installation shall be tested and commissioned by installation

contractor as per GAIL specifications S-07-02-004. Pre-commissioning checks and tests, shall include but not be limited to the following:

(i) The insulation resistance of each circuit without the lamps (load) being in place shall be measured and it should not be less than 500,000 ohms. (Between phases, phases to neutral, phase/neutral to Earth).

(ii) Current and voltage of all the phases shall be measured at the lighting panel busbars with all the circuits switched on with lamps. If required load shall be balanced on the three phases.

(iii) The earth continuity for all socket outlets shall be checked. A fixed relative position of the phase and neutral connections inside the socket shall be established for all sockets.

(iv) After inserting all the lamps and switching on all the circuits, minimum and maximum illumination level shall be measured in the area and recorded.

(v) It shall be ensured that switch provided for ON/OFF control of point (light/fan/socket) is only on LIVE side.

(vi) Operation of ELCB’s shall be checked

Contractor shall duly fill in all the above test results and submit the test reports to Engineer-in- Charge in triplicate.

5.2 All lighting layout drawings shall be marked by contractor for ‘AS BUILT STATUS’ Wand two sets of copies shall be submitted to GAIL.

SPECIFICATIONS REV-0 GAIL (INDIA) LTD NEW DELHI

SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) S-07-02-008 Page 1 of 9


SPECIFICATION FOR PIPELINE

LAYING AND TERMINAL WORKS

(ELECTRICAL)




CONTENTS

1. GENERAL

2. AREA CLASSIFICATION

3. DESCRIPTION OF REQUIREMENTS FOR CATHODIC PROTECTION AND ELECTRICAL WORKS

4. INSPECTION, TESTING AND COMMISSIONING

5. DRAWINGS AND DOCUMENTS

ANNEXURE-1: MAKE OF ELECTRICAL EQUIPMENT/COMPONENTS




1.0 GENERAL 1.1 Introduction

1.1.1 The intent of this specification is to define the requirements for Design, engineering, supply, erection, testing and commissioning of the electrical works, viz. power supply system, lighting, cabling, earthing, lightning protection system and fire alarm system, etc. at all stations associated with Sultanpur-Neemrana pipeline

1.1.2 The electrical portion for pipeline laying work as covered in this specification includes design, supply, installation, testing and commissioning of the power system as per the single line diagrams (SLDs) and description given in this document and other associated documents enclosed with this tender, taking statutory approvals and energizing the system. The contractor shall also prepare electrical layout drawings for equipment layout, cabling layout, lighting layout, earthing and lightning protection layouts, Fire alarm system layout, cable schedule, interconnection diagrams, etc. for each station/Terminal along the route of the pipeline.

1.1.3 The Electrical works at each station/Terminal and all works related to temporary and permanent cathodic protection system for the pipeline shall be executed by contractor in line with scope document, job specification, design basis, data sheets, GAIL standard specifications, standard drawings and National/International codes & standards. In case of conflict between various documents, following shall be order of priority:-

- Scope document - Design Basis & Single Line Diagrams - Data sheets - GAIL standard specifications/standard drawings - Codes and standards

1.1.4 The work shall be carried out to the best workmanship like manner, in conformity with these specifications, approved drawings/ construction drawings and the instructions of the owner or Engineer-in-Charge from time to time.

1.1.5 The contract shall include clearing of temporary constructions, waste materials and loose earth, which might get collected in and nearby the work site during execution of work and after final completion.

1.2 Standards

1.2.1 The work shall be performed in conformity with these specifications and code of practices of the Bureau of Indian Standards. In case of any conflict, the stipulations under these specifications shall govern.




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

(a)The Indian Electricity Act and rules framed there under. (b)The fire insurance Regulations. (c) The regulations laid down by Electrical Inspectorate (CEA). (d)The regulations laid down by the Factory Inspector. (e)The regulations laid down by the Chief Controller of Explosives. (f) The regulations laid down by Oil Industries Safety Directorate (OISD).

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

1.3 Guarantee

The contractor shall guarantee the installation for satisfactory operation against any defects of workmanship and materials (supplied by the contractor) for a period as specified elsewhere. Any damage or defect connected with the erection of materials, equipments or fittings supplied by the contractor that may be discovered at the time of issue of the completion certificate, or arise or come to light thereafter, shall be rectified or replaced by the contractor at his own expense as deemed necessary and as per the instruction of owner or Engineer-in-Charge within the time limit specified by the owner or Engineer-in-Charge.

1.4 Site Condition

The equipment offered and the installation shall be suitable for continuous operation under the site conditions mentioned in design basis doc.no. 0001-01-07-03-001

1.5 Utilisation Voltage

The utilization voltages shall be as per design basis doc.no. 0001-01-07-03-001

2.0 AREA CLASSIFICATION

Electrical/Control room building at all stations shall be located in safe area. All the electrical equipment to be located in hazardous area Zone 1 or Zone 2, Gas Group IIA/IIB and Temp. class T3, based on area classification as per IS 5572, Indian Petroleum Rules and as shown in the respective equipment specification/ particular specification, shall be flameproof type.

3.0 REQUIREMENTS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL WORKS

3.1 CATHODIC PROTECTION SYSTEM:-The requirements of cathodic protection system have been specified in




Design basis document no. 0001-01-07-03-001, data sheets and specifications attached elsewhere in this tender.

3.2 ELECTRICAL WORKS

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

The power supply shall be met from Solar system at 24V DC (Floating) output. The electrical power distribution to various electrical consumers at 24V DC shall be done from 24V DC switchboard. 24V DC power distribution as required for SCADA, FA panel, DC lighting (in Telecom room, electrical room). Necessary DC-DC converters required for feeding telecom equipment shall be provided as part of DC switchboard.

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

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

3.5 Safety Earth (Instrumentation cabinet earth): The same shall be common earth for Instrumentation/SCADA/Telecom, connected to electrical safety earth. Cables (e.g Instrumentation cables/ Optical cable, etc) coming from field shall also be terminated on this earth

3.6 Signal/system earth : For Instrumentation and SCADA one dedicated earth of 1 ohm to be provided by contractor.

3.7 For Telecom a separate dedicated earth of 1 ohm to be provided by contractor.

3.8 Pipeline contractor shall install earth strips and terminate the earth cables to the respective Instrumentation/SCADA/Telecom equipment cabinet (both system & safety) & cables coming from field for instrumentation/Telecom.

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

4.0 INSPECTION, TESTING AND COMMISSIONING

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




4.2 Any work not conforming to the execution drawings, specifications, or codes shall be rejected forthwith and the contractor shall carry out modifications at his own cost.

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

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

5.0 DRAWINGS AND DOCUMENTS

5.1 Contractor shall submit all datasheets/ drawings and documents to the

5.2 owner/ engineer-in-charge.

5.2 A complete set of reproducible drawings for contractor-supplied equipment shall be furnished to the owner for records. As-built layouts, cable schedules and interconnections shall be submitted by the contractor on the hard copies as well as in soft copy usable on a WINDOWS 2000 PC.

5.3 Drawings and data of Solar system power source, Ni-Cd batteries, 24V DC Switchboards, cables, lighting fixtures, CP system shall be submitted for review by owner/ GAIL.

5.4 Vendor catalogues and literature shall be supplied for all equipment included in the scope of Contractor.

5.5 Storage and maintenance instructions along with necessary handling precautions shall be furnished by the contractor for equipment supplied in this tender.

5.6 Minimum 6 sets of drawings/ documents of the vendor-supplied equipment shall be submitted within 4 weeks of order placement. Final set shall be submitted in folders and shall be stamped as final drawing along with the copy of the necessary test/ inspection certificates. Before submitting the drawings, vendor shall ensure that job number, title, drawing number, equipment number and revision number are marked on each drawing.

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




ANNEXURE-1

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

MV Switchboards (Fixed type)

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

Cables-Medium Voltage-Power -PVC

Associated Flexibles & Wires (P) Ltd./ CCI/ Finolex Cables Ltd./ Gemscab Ind. Ltd./Industrial Cables(I) Ltd./ KEI Ind. Ltd./ Nicco Corp. Ltd./ Polycab Wires Pvt. Ltd./ Radiant Cables Pvt. Ltd./ Ravin Corporation Ltd./ Torrent Cables Ltd./ Universal Cables Ltd./Havell’s India Pvt. Ltd/RPG Cables ltd

Cables-Control-PVC

Associated Flexibles & Wires (P) Ltd./CMI Ltd./Brooks Cable Works, Bombay/ Cords Cable Ind.Ltd./ Delton Cables Ltd./ Evershine Electricals/ Elkay Telelinks (P) Ltd./ Finolex Cables Ltd./ Gemscab Ind.Ltd./ Goyolene Fibres (India) Pvt.Ltd./ Havell’s India Pvt.Ltd./ Industrial Cables(I) Ltd./ KEI Ind.Ltd./ Nicco Corp. Ltd./ North Eastern Cables Pvt. Ltd./ Paramount Communications Ltd./ Polycab Wires Pvt.Ltd./ Radiant Cables Pvt.Ltd./Ravin Cables Ltd./ Reliance Engineers Ltd./ Suyog Electricals Ltd./ Torrent Cables Ltd./ Universal Cables Ltd.

Cables-Fire alarm and comm. CMI Ltd./ Delton Cables Ltd./ KEI/ Elkay Telelinks/ Reliance Engineers Ltd./Cords Cable

Anodes for CP system Cathodic Control Co. Pvt. Ltd./ Electro Protection Services India (P) Ltd./ PSL Ltd./ Scientific Metal Engineers (P) Ltd

Fire Alarm system

New Fire Engineers/ Honeywell Inc./ Honeywell Automation India Ltd./ Mather & Platt Pumps Ltd./ Kidde India Ltd. (Formerly-Vijay Fire)/ Edward International

Cable termination & Jointing Kit Mahindra Engg. & Chemical Products Ltd./ Raychem RPG Limited/ Yamuna Gases & Chemical Ltd./ Heat Shrunk technologies.

Nickel-Cadmium batteries Amco Power Systems Ltd./HBL Nife Power systems Ltd.

Solar System Central Electronics




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

Lighting Fixtures for non Hazardous area

Bajaj/Crompton/Philips/Havell’s Ind Pvt. Ltd.

Cable glands for azardous area

Baliga/ Comet Brass Products/ Comet Industries/ Flexpro/ Flameproof Equipment / FCG Power/ FCG Flameproof Control Gears Pvt Ltd./ Prompt Engg. Works/ Sudhir Swgrs. Pvt. Ltd/Standard Metal Industries.

Protection relays (Electromechanical type)

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

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

Control switches/Selector Switches

L&T/ Siemens/ Switron Devices/ Hot Line Swgrs.& Controls/ Kaycee/ Areva T&D India Ltd. / Reliable Electronic components Pvt. Ltd.

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

MCCBs GE India Industrial Pvt. Ltd./ L&T/ Schneider Electric

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

Timers Bhartia Ind./ L&T/ Siemens/ Electronic Automation

Meters Automatic Electric/ Meco Instruments/ Rishab Instruments/ Nippen Electricals Instruments Co./ Areva T&D India Ltd. (Type : Energy meters)

Push Buttons/Indicating lamps

L&T/ Siemens/ Tecknic Controls/ Bhartia Ind./Schneider Electric India Pvt. Ltd./ Shri Tulsi Switchgears/ Controls & Switchgears Contactors Ltd./ Hot Line Switchgears & Controls./ Precifine Product Pvt. Ltd. (For LED type Indicating lamp only)/Essen Deinki

Contactors

L&T/ Siemens/ GE India Industrial Pvt. Ltd./ Schneider Electric/ Bhartia Ind./ Controls & Switchgears Contactors Ltd./ ABB (Bangalore) L&T/Siemens/ Bhartia Ind./Control & Swgrs. Contactors Ltd./ Schneider Electric/ ABB (Bangalore)/GE India Ind. Pvt. Ltd

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

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

Earth leakage circuit breaker (ELCB)

Datar Switchgear/ Indo Asian Fuse Gear/ Legrand India Pvt. Ltd./Havell’s India Pvt. Ltd./ Schneider Electric




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

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

Zinc ribbon anode :- Platt Line/Corpro

Permanent reference cell :- Borin, USA

Polarisation Cell:- Kirk, USA

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

Notes:-

1.0 Make of other equipment/components not mentioned above shall be subject to prior approval of GAIL.

2.0 Contractor may procure material from any of GAIL approved vendor/sub-vendors.

3.0 Contractor can offer component of makes other than specified in the tender, during order execution. The alternate make of components will be evaluated post order, based on the satisfactory track record and test certificates to be furnished by the contractor. In case alternate makes are not found acceptable, components shall be strictly as per above vendor list.

4.0 In case of non-availability of equipment/material from above vendors, alternate makes, if required may be supplied after GAIL approval.


SPECIFICATION FOR CORROSION SURVEY S-07-02-009 Page 1 of 7


SPECIFICATION FOR CORROSION SURVEY




Abbreviations:

ROU : Right of Use

EHV : Extra High Voltage

HV : High Voltage




CONTENTS

1.0 SCOPE


3.0 GENERAL

4.0 SOIL RESISTIVITY SURVEY

5.0 TESTS ON SOIL SAMPLES

6.0 ADDITIONAL DATA COLLECTION

7.0 REPORT




1. SCOPE The specification covers the requirements for corrosion survey including measurement of soil resistivity, chemical analysis of soil/water and collection of other cathodic protection related data along ROU of the pipelines.

2. CODES AND STANDARDS Equipment and measurement techniques shall unless otherwise specified, conform to the requirement of latest revisions of following applicable standards:

BIS specifications BS specifications and codes of practice NACE publications

The work shall be carried out in compliance with all applicable local laws and regulations. In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern:

o Statutory regulations. o Data sheets. o Job specification. o This specification. o Codes and standards.

3 GENERAL This specification defines the basic guidelines for carrying out the corrosion survey. Contractor shall be responsible for providing necessary data interpretation based on corrosion survey measurements, which is intended to form a basis for design of cathodic protection system for the pipeline.

4 SOIL RESISTIVITY SURVEY 4.1 Unless otherwise specified the soil resistivity measurements shall be carried

out at intervals of approximately 500 m along the ROU. Where soil resistivity is less than 100 ohm. m and two successive readings differ by more than 2:1 then additional soil resistivity readings in between the two locations shall be taken.

4.2 To carryout the soil resistivity measurement Wenner’s 4 pin method or approved equal shall be used. The depth of resistivity measurement at each location shall be at around 1 m and at the burial depth of the pipeline accounting for the cuttings /fillings or 2 m approximately which ever is higher. At locations where multi layer soil with large variation in resistivity/ corrosiveness is expected and /or locations specifically advised by OWNER or his representative resistivity measurements at additional depth of up to 3 m (approx) or more shall be taken. In general the resistivity of soil, which shall




be surrounding the pipe, shall be measured. Hence the depth of measurement / electrode spacing may vary depending on topography and strata at the area.

4.3 At places where ROU has not yet been cleared, measurements shall be made right over the centre line of pipeline route surveyed accounting for the cuttings /fillings also.

4.4 Observations shall be made enclosing the soils adjoining the trench wherever pipeline trenching has already been done.

4.5 The observations shall be made enclosing the soil immediately surrounding the pipeline route where ROU has been cleared but trenching has not been done.

4.6 All measurements shall be taken at right angles to the ROU unless otherwise asked by OWNER or his representative at site.

4.7 At places in ROU where other pipelines are already existing care shall be taken to precisely locate such pipes line and take such precautions that observations are not adversely affected by presence of such pipelines.

4.8 Care shall also be taken that the observations are not influenced by presence of other earth currents in the area especially in the vicinity of EHV/HV lines and plants using earth return in their source of power etc.

4.9 Wherever possible / advised by OWNER or his representative, depth of water table shall be determined by resistivity observations.

4.10 All measurements shall be made and recorded in metric units. While recording the data reference to the nearest intersecting point shall be made. To provide visual representation of variations in the resistivity along ROU, values shall be plotted on semi log graph sheets. The resistivity graph shall also indicate the resistivity at additional depths measured at various locations and depth of water table.

5 TESTS ON SOIL SAMPLES Soil/water samples shall be collected along the ROU for analysis. Samples shall be collected on an average at one location for every 10 km along ROU with minimum at two locations. Exact locations shall be decided at site depending on the type of soil, soil resistivity and in consultation with OWNER or his representative. At each location the soil samples shall be collected at I m, 2 m depth and at expected depth of pipeline if it is more than 2 m at the location.




The collected soil / water samples shall be analyzed to determine presence and percentage of corrosive compounds including carbonates, bicarbonates, nitrates, chlorides, oxygen activity, moisture content and pH value.

6 ADDITIONAL DATA COLLECTION The following data shall be collected with a view to generate design data for evaluation of cathodic protection interaction possibilities due to presence of other services in ROU and its vicinity:

6.1 Following information regarding foreign service/pipeline in or around the ROU (for existing and those, which are likely to come up during contract execution).

6.1.1 Types of service / pipeline and year of laying.

6.1.2 Diameter and pipeline coating in case of pipeline.

6.1.3 Parallel running / crossing.

6.1.4 Year of laying / commissioning.

6.1.5 Depth of laying.

6.1.6 Type of existing cathodic protection systems (impressed current / sacrificial).

6.1.7 Location and type (Deep well / surface) of anode ground bed.

6.1.8 Rating of impressed current type of anode ground bed.

6.1.9 Location of existing CP power supply units and their output voltage, current, pipe to soil potential readings.

6.1.10 Location of existing test stations.

6.1.11 Remedial measures existing on foreign service/pipeline to prevent interactions.

6.1.12 Graphical representation of existing structure / pipe to soil potential records.

6.1.13 Possibility of integration/isolation of CP system of the foreign service/pipeline with that of the proposed pipeline, which may involve negotiations with owner’s of foreign services.

6.1.14 Where pipeline is likely to pass close to any existing ground bed (with in 100 m approx), anode- bed potential gradient survey shall be carried out




to verify possible interference with the CP system of the pipeline covered under this project.

6.2 Voltage rating, phases and sheathing details of cables running parallel or crossing the ROU.

6.3 Existing and proposed DC/AC power sources and systems using earth return path such as HVDC substations/ earthing stations, fabrication yards with electric welding etc. in the vicinity of the entire pipeline route.

6.4 Crossing and parallel running of electrified and non-electrified traction (along with information regarding, operating voltage, AC/DC type etc.) as well as abandoned tracks near ROU having electrical continuity with the tracks in use.

6.5 Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power lines along with details of voltage, AC/DC type etc.

6.6 Voltage rating, phases, sheathing details of underground power cables along ROU or in its vicinity.

6.7 Any other relevant information that may be needed in designing and implementing of proper cathodic protection scheme for the proposed pipeline.

7 REPORT On completion of all the field and laboratory work an interim report incorporating results generated from surveys, additional data collected, results of test carried out, etc, shall be submitted for comments / approval. The report shall also highlight any adverse impact on performance of sacrificial anodes due to the percentage of corrosive compounds including carbonates, bicarbonates, nitrates, chlorides present in the soil and pH value of the soil noticed during the survey. The final report incorporating comments / missing data shall be furnished for records. The report along with various drawings, graphs etc. prepared in connection with the work shall be submitted along with six prints by the contractor.


SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES S-07-02-010 Page 1 of 20


SPECIFICATION FOR EQUIPMENT /

MATERIAL FOR CATHODIC

PROTECTION SYSTEM FOR

PIPELINES




Abbreviations:AC: Alternating Current

BS: British Standards

BIS: Bureau of Indian Standards

CMRI: Central Mining Research Institute

CP: Cathodic Protection

CPPSM: Cathodic Protection Power Supply Module

CPTR: Cathodic Protection Transformer Rectifier

DC: Direct Current

HV: High Voltage

IS: Indian Standards

MMO: Mixed Metalic Oxide

MOV: Motor Operated Valves

NACE: National Association of Corrosion Engineers

PE: Polyethylene

PVC: Polyvinyl Chloride

ROW: Right of Way




CONTENTS

1. SCOPE


3. SITE CONDITIONS

4. EQUIPMENT/MATERIAL SPECIFICATIONS

5. EQUIPMENT FOR CLASSIFIED AREAS

6. TESTS AND ACCEPTANCE





1.0 SCOPE This specification covers the requirements for the design, manufacture, supply and testing of various equipment and materials for Cathodic Protection system for underground pipelines/structures. These equipment and materials shall broadly include:

- Sacrificial Anodes - Test Stations - Anodes for impressed current CP system - Anode junction boxes - Cathode junction boxes - Permanent reference cells - Electrical resistance probes - Polarisation cells and surge diverters/grounding cells - Polarisation coupons - Computerised test stations - Cables

Requirement of Cathodic protection TR units (CPTR unit) and cathodic protection power supply modules (CPPSM) are covered in separate specifications.

2.0 CODES AND STANDARDS 2.1 All equipment and material covered in this specification shall conform to the

requirements of the latest revision of following standards: IS 3043 Code of practice for earthingNACE standard RP0169

Standard recommended practice Control of corrosion on underground or submerged metallic piping system

BS 7361, Part-I Cathodic protection, code of practice for land and marine applications.

ASTM A518 MCorrosion Resistant High Silicon Iron Castings ASTM B418 Cast and wrought galvanic zinc anodes.

ASTM B338Specification for seamless and welded Titanium and Titanium alloy tubes for condensers and heat exchangers.

ASTM B843 Magnesium Alloy Anodes for Cathodic Protection.

IS 1554, Part-I PVC insulated (heavy duty) cables.

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

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




2.4 In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern: - Statutory regulations. - Data sheets. - Job specification. - This specification. - Codes and standards.

3.0 SITE CONDITIONS The equipment and materials shall be suitable for installation in locations having generally corrosive, warm and humid or dusty atmosphere. Service conditions shall be as specified in the project specification/data sheet. If not specifically mentioned therein, a design ambient temperature 400C and an altitude not exceeding 1000 M above mean sea level shall be considered.

4.0 EQUIPMENT/MATERIAL SPECIFICATIONS All equipment/material shall be brand new with state of art technology and proven field track record. No prototype equipment shall be offered. Make and construction of all equipment/materials shall be subject to approval by Owners representative.

4.1 Sacrificial Anodes 4.1.1 Magnesium Anode

The anode shall conform to the requirements of ASTM-B 843 standard. The anode shall be of high manganese, magnesium alloy packed with special back fill. The metallurgical composition, potential and consumption rate of anode shall be as below: Composition

Element Weight Weight(High potential type) (Low potential type)

Manganese 0.5 - 1.3 % 0.15 - 0.7%Copper 0.02% max. 0.02% max.Silicon 0.05% max. 0.1% max.Zinc - 2.5% - 3.5%Aluminium 0.01% max. 5.3% - 6.7%Iron 0.03% max. 0.003% max.Nickel 0.001% max. 0.002% max.Calcium - -Other metallic elements- Each 0.05% max.- Total 0.3% max. 0.3% max.Magnesium Balance BalanceAnode open circuit Potential

1.75 volts 1.55 volts

Anode consumption rate 7.9 Kg/(A.Yr) max. 7.9Kg./(A.Yr.) Max.




4.1.2 Zinc AnodeThe anode shall conform to the requirements of ASTM-B 418 standard. The metallurgical composition of anode, potential and consumption rate of anodes shall be as below. Anodes of type I shall be used for seawater, brackish water or saline electrolyte application and anode of type II shall be used for fresh water, back fill and soil applications. The anode (other than ribbon anode) shall be packaged with special backfill. The type of ribbon anode inside the casing at cased crossing shall be suitable for the type of soil outside the casing..

Composition:Element Weight Weight

(Type I) (Type II)Aluminium 0.1% to 0.5% 0.005% max.Cadmium 0.025-0.07% 0.003% max.Copper 0.005% max. 0.002% max.Iron 0.005% max. 0.0014% max.Lead 0.006% max. 0.003% max.Others 0.01% max. -Zinc Remainder Remainder

ii) Anode open circuit Potential

1.1 volts 1.1 volts

iii) Anode consumption rate 11.24Kg/(A.Yr) max 11.24Kg./(A.Yr.)max.

4.1.3 The anodes shall be provided with cable tail of sufficient length to reach test station/ buried junction box, as applicable without any intermediate joint in the cable and with minimum of 0.5m cable slack provided at each anode and test station ends.

4.1.4 The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.

4.1.5 The anodes shall be suitable for the composition/conditions of soil in which they will be installed.

4.1.6 The other details of anodes shall be as shown in the applicable GAILstandard drawings.

4.1.7 The anodes for grounding of cathodically protected above ground pipelines at intermediate SV stations, pigging stations, etc, grounding of motor operated valves on cathodically protected portion of the pipeline, grounding of pipeline through polarization cell at EHV/HV line crossings or running in parallel, etc, shall be of minimum 20 kg net weight each. The anode and cable terminations shall be suitable for the anticipated fault current at the




location of installation. For pipelines protected by sacrificial anodes, the anodes for directly grounding the pipeline shall be of the same type as the one provided for the protection of the pipeline.

4.1.8 Special Backfill The composition of special back fill for anodes shall be as below :

Gypsum 75%

Bentonite 20%

Sodium Sulphate 5%

4.2 Test StationsTest stations shall be provided along the pipeline ROW for monitoring the performance of the cathodic protection system.

i) Test station enclosure shall be made of sheet steel of at least 3 mm thickness and shall be suitable for GI pipe post mounting. Test stations shall have weatherproof enclosure having degree of protection IP-55 and hinged lockable shutter. The inner and outer surfaces of test stations shall be epoxy painted.

ii) The resistors for control of current provided in the test stations, anode/cathode junction box, etc, shall be of variable, grid coil type. The resistors shall be suitable for operation over the design life for the permanent CP system specified in the project specification/data sheet.

iii) Number of terminals and different schemes of wiring shall be as per the applicable GAIL standard drawing. Minimum twenty percent spare terminals shall be provided in each test station.

iv) At locations where solid state polarization cells are provided, the test station size shall be suitable for mounting the polarization cell inside the test station.

v) A nameplate of anodized aluminum with black back ground and white letters shall be fixed to the inner side of the test station. The nameplate shall carry the following minimum information:

- Chainage in km. - Test station connection scheme. - Distance form pipeline in meters. - Direction of product flow.

vi) The constructional features of test stations shall be as per the




applicable GAIL standard drawings. 4.3 Anodes for Impressed Current CP System

4.3.1 High Silicon Cast Iron Anodes.

i) High silicon cast iron type anodes shall be center-connected hollow type or end connected solid type. Cable to anode joint shall be reliable and long lasting for total design life of anode. Composition of anodes shall be as below and shall also conform to ASTM A518 M-86 Gr. III.

Element WeightSilicon 14.2 - 14.75 %Manganese 1.5% max.Carbon 0.7% - 1.1 %Chromium 3.25 - 5.0 %Copper 0.5% max.Molybdenum 0.2% max.Iron Remainder

ii) Surface current density rating of the anode for continuous operation shall be 15 amperes/sq.m (max.) for shallow anode ground bed and 10 amperes/sq.m (max.) for deep well anode ground beds.

iii) Anode consumption rate shall not be more than 0.2 kg./Amp. Yr.

iv) The design life of anode under burial condition, at the design operating current shall be in minimum the design life of the CP system specified in the project specifications/data sheet.

v) For shallow anode ground bed sheet steel anode canisters of adequate size shall be provided for each anode. Anode canisters shall be filled with petroleum coke breeze with following specification conforming to IS: 8502, Grade-A type.

a) Chemical CompositionFixed carbon content by mass: 99% min.Ash by mass: 0.5% max.Moisture by mass: 0.1% max.Volatile matters by mass: 0.5% max.

b) Bulk density 800 kg./M3 to 1200 kg./M3

c) Real density 2.03 kg/litre min.d) Particle size 1 mm max, dust freee) Resistivity 0.1 ohm cm max at 150 PSI




vi) For deep well ground beds, anodes shall be non canistered type. Calcined petroleum coke breeze slurry conforming to clause 4.3.1 v) above shall be supplied along with the anodes.

4.3.2 Mixed Metal Oxide Coated Titanium Anode i) Mixed metal oxide coated titanium anodes shall be of pure titanium

having substrate composition of titanium of ASTM B-338, Grade I/Grade II, over laid with mixed oxide of noble metals (MMO coated). These anodes shall be dimensionally stable. The anodes shall be centre connected sealed tubular type. The design life of anode under burial condition, at the design operating current in minimum be the design life of the CP system specified in the project specifications/data sheet.

The guaranteed design parameters of anode regarding current density, consumption rate, design life, rated current output, dimensions, shape, noble metal oxide coating thickness (gm/square meter), their physical and mechanical properties shall be substantiated by manufacturer’s published catalogues and backed up by type test reports. Each anode shall be supplied with anode lead cable connected to it.

ii) The anodes shall be provided with sheet steel canisters and coke breeze as per clause No. 4.3.1 (v) & (vi) above.

4.3.3 Each anode shall be supplied with anode tail cable connected to it, which shall long enough for termination on their associated anode lead junction box without intermediate joint. Anode cable tail shall be connected/jointed to the anode and the joint insulated at the anode manufacturer’s shop before despatch of anode.

4.3.4 For deep well ground beds steel pipe casing for active portion of the ground bed and non metallic pipe casing for the top inactive portion of the ground bed shall be provided. The top non metallic casing and the lower metallic pipe casing shall have threads for jointing each other. Anode supporting pipe, anode centralisers and gas venting pipes shall be provided for the ground bed.

4.4 Anode Junction Box Depending on the size and configuration of anode ground beds, requisite main and sub anode junction boxes (where required) shall be supplied for each ground bed.

i) Each junction box shall have provision of termination of cable tails from individual anodes of the ground bed and provision of connection




of anode cable coming form main anode junction box (in case of sectionalised ground bed) or from CP station power source.

ii) Junction boxes shall have sheet steel enclosure of minimum 3 mm thickness and hinged lockable shutters. Junction boxes shall be weatherproof with degree of protection IP- 55. It shall be epoxy painted on inside and outside surface. Junction boxes shall have anode bus of copper with nickel/ silver plated or tinned. Provision shall be made for measurement and control of individual out going circuit/anode current by providing suitable shunt and resistors of grid coil type. Disconnecting links shall be provided for each out going/anode circuit. 30% spare out going circuits shall be provided in each anode junction box. Terminals shall be of anti loosening type and provided with

identification labels. Each outgoing circuit shall be labelled clearly to indicate the circuit/sub anode junction box to which it is connected.

iii) The constructional features of junction boxes shall be as per the applicable GAIL standard drawing enclosed with the data sheet for impressed current cathodic protection system for pipelines.

iv) A nameplate of anodised aluminium with black back ground and white letters shall be fixed to the inner side of the junction box. The nameplate shall carry the following minimum information:

- Ground bed current rating - Ground bed resistance - Connection scheme. - Distance form pipeline in metres. - Distance form CP station in metres.

4.5 Cathode Junction Box

Where output of the CP power supply unit is connected to multiple pipelines a cathode junction box shall be supplied for providing near the pipelines at the location of connection of the negative drainage cable to the pipelines.

i) The junction box shall have a bus bar with an incoming circuit for connecting to negative of the CP power source and separate out going circuits for collection of negative drainage current from each of the pipelines.

ii) The incoming circuit shall have a current measurement shunt. Each out going circuits shall have isolation link, variable resistance of grid coil type and a current measurement shunt. One number spare




outgoing circuit shall be provided.

iii) Junction box shall have sheet steel enclosure of minimum 3 mm thickness and hinged lockable shutters. Junction box shall be weatherproof with degree of protection IP-55. The inside and outside surfaces of the junction box shall be epoxy painted. The terminals shall be of anti loosening type. Proper identification labelling shall be provided for each terminal. Each outgoing circuit label shall clearly indicate the size and identification of the pipeline to which it is connected.

iv) A nameplate of anodised aluminium with black back ground and white letters shall be fixed to the inner side of the junction box. The nameplate shall carry the following minimum information: - Chainage in km. - Connection scheme - Distance form the nearest pipeline in metres. - Direction of product flow.

4.6 GI Earth Electrodes For earthing of above ground cathodically unprotected pipelines at intermediate SV stations, pigging stations, etc. and at terminals GI earth electrodes shall be supplied. Earth electrodes shall be 100 mm dia, 3000 mm long, and 13 mm thick conformity to IS 3043.

4.7 Permanent Reference Cells High purity copper/copper sulphate reference cells or Zinc reference cells as specified in project specification/data sheets, with proven high reliability shall be supplied for providing stable pipe to soil potential measurement reference at CP stations, at computerised test station locations and at locations of polarisation coupons along ROW.

Silver/silver chloride type reference cells shall be supplied for marshy area locations where water table is high and chloride ion content is more than 300 ppm.

i) The reference cells shall have high accuracy and stability and maintain the same over its design life.

ii) The permanent reference cells shall have a minimum design life of 20 years under installed/buried condition.

iii) The reference cell for high resistivity areas shall be suitable for the prevailing dry soil conditions to give maximum service life.

iv) The reference cells shall be provided with cable tail long enough for




connection to test station without any joint in between.

4.8 Electrical Resistance Probe Electrical resistance probes utilising the electrical resistance technique shall be suitable for use along the pipeline at marshy areas and at interference affected locations/vulnerable locations to monitor the external corrosion activity on the pipeline.

The material of the E/R probe element shall be of the same alloy as that of the pipeline material. Probe shall be provided with cable leads for connecting it to CP system and required for the probe resistance measurements.

Portable E/R probe reading instrument shall be supplied by contractor, as specified in the project specification/data sheet. The probe reading instrument shall be suitable for use in field and shall have IP 55, weatherproof enclosure. The probe reading instrument shall be of digital type with 3.5 digit display. The instrument shall run on rechargeable batteries. The instrument shall be able to directly read out the resistance of probes.

4.9 Polarisation Cell and Surge Diverter 4.9.1 Polarisation Cell

Polarisation cell shall be a electrolytic type or solid state device as specified in project specification/data sheets, designed to simultaneously provide isolation for DC current and low resistance path for AC current. The device shall require minimum maintenance. The solid state device shall have weather proof enclosure and shall be suitable for mounting inside a test station.

Unless other wise specified in project specification/data sheet the DC blocking voltage shall not be less than 1.2 volts. The DC leakage current at 1.2 volt shall not be more than 0.5 mA.

The device shall be suitable for continuously conducting maximum AC steady state current and short time AC short circuit current expected to flow through the pipeline under the normal operating condition/any kind of fault on the EHV/HV line at respective sites, subject to minimum ratings as indicated in clause 4.9.3 below.

4.9.2 Surge Diverter The surge diverter when connected in parallel across the insulating joints shall protect the insulating joint against surges coming across it due to lightning strikes, electrical faults, etc, on the above ground portion of the pipeline. The surge diverter shall be of spark gap type. The device shall have weatherproof enclosure suitable for out door mounting. The surge




diverters shall be of explosion proof type.

4.9.3 The minimum ratings of polarisation cells and surge diverters shall be as below unless otherwise specified in the project specification/data sheet.

i) Polarisation Cell

a) Type:Solid state type/Electrolytic type

b) Description Rating- Minimum rated 50 Hz steady:

30Amin at 280C and min 2V DC

state current (RMS symmetrical)

- AC fault current: 5 kA min for 1 cycle(RMS symmetrical)

- Ac voltage under maximumrated AC fault current: Less than 10 V peak to peak

ii) Surge Diverter

a) Type:Spark gap, explosion proof type.

b) Current, 8/20 micro Second wave:

100 Kilo Amp.

c) Spark - over AC voltage-50 Hz: 1KV-Impulse (1.2/50 micro Second):

2.2 KV

iii) The polarisation cells, surge diverters, anodes, connecting cables, cable joints, etc, shall be adequately sized and suitable for the design life of permanent CP system. The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.

4.10 Polarisation Coupons The Polarisation Coupons shall be made from the material of the pipeline. The coupon shall have one side exposed area of 100 mm x 100 mm unless other wise specified in project specification/data sheet. Cable connection of 10 mm2 and 4 mm2 shall be provided to the coupon for connecting it to pipeline for cathodic protection and potential measurements respectively.

Connection of coupon to pipeline shall be through a vacuum sealed magnetic reed switch housed inside the test station. The magnetic reed switch shall be rated to carry and break minimum 50 mA at 50 V DC. Magnet for operation of reed switches shall be provided as specified in




project specification/data sheet.

4.11 Computerised Test Station and Test Station Reader

4.11.1 Computerised Test Stations The computer units for installing at computerised test stations shall be able to measure and record the field CP system parameters automatically at regular programmed intervals. The computer shall have required numbers of input ports for measurement of pipe to soil DC potentials, induced AC potentials, pipeline current, bond current, etc. In any case the number of input ports shall not be less than five. All the input measurement ports shall be protected against high voltage surges due to lightning/HV switching that may come from the pipeline.

The computer shall have a real time clock and shall indicate the date and time of the data collection along with the data. The accuracy of the internal clock shall be +/- 0.1% or better. The input data measurement accuracy shall be +/- 0.5% or better. The measurement range for the input ports for pipe to soil measurement shall be (+) 5 V to (–) 5 V DC. The measurement range for the other input ports shall be decided based on the maximum value of the in put parameters measured.

Unless otherwise specified in the job specification/data sheet the computers shall be programmed to collect and store all the field parameters once daily. It shall be possible to reprogram the computer for the data collection interval/set/initialize the computers at field with the help of data retrieval computer.

It shall be possible to designate a unique identification number incorporated in to the software of each computer for identification of the unit after down loading the field data from it.

The computer shall have memory capacity suitable for storing the data measured at programmed intervals continuously for six months without down loading the data.

The battery provided in the computer shall be suitable for its operation including storing the measured data at field, as programmed, for minimum 10 years without requiring the replacement/recharging of the battery

The computer shall have provision/plug in arrangement for retrieval of the stored data with a hand held data-retrieval computer.

The field computer shall have weatherproof enclosure. The test station housing the computer shall be of IP 55, weather proof with locking arrangement.




4.11.2 The Data Retrieval Computer The data retrieval computer shall be of portable type suitable for use in field. The computer shall be suitable for retrieving/down loading the data collected by the field computer, field programming/setting/initializing the field computer and estimating the field computer battery capacity/life left over, when connected to the field computer. Suitable plug arrangement shall be provided on the data-retrieval computer so that it can be plugged in to the field computer for data transfer. The data-retrieval computer shall have enough memory capacity for retrieving/down loading the data collected and stored by minimum ten field computers, each having collected the field data for minimum six months continuously. The battery provided in the data-retrieval computer shall be suitable for this operation without any replacement/recharging the same during the operation.

It shall be possible to down load the data collected by the data-retrieval computer to a station computer for further analysis of the data or directly to a printer.

The data-retrieval computer shall have IP 55, weatherproof enclosure. The unit shall be provided with a carry bag suitable for carrying in field.

4.12 Miscellaneous Requirements i) The sheet steel used for fabrication shall be thoroughly cleaned and

degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under surface shall be free from all imperfections before undertaking the finishing coat. After preparation of the under surface, final spray painting with two coats of epoxy based paint shall be done. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint etc.

ii) All unpainted steel parts shall suitably treated to prevent rust formation. Copper bus bars, interconnection copper link shall betinned or nickel/silver coated.

iii) Test station/junction box cabling

Adequate space shall be provided inside the test station/junction box for termination of cables. Termination shall be performed using crimped lugs. The lugs shall be of tinned copper. Requisite cable lugs shall be supplied.




4.13 Cables 4.13.1 Cables shall be of annealed high conductivity stranded copper conductor,

650/1100V grade PVC insulated, armoured, PVC sheathed conforming to IS-1554 part-I, except for reference cell, potential measurement and impressed current CP anode tail cables. The size of the copper conductor of the cables shall be as below:

i) Minimum 4 mm2 for potential measurement, reference cells, 6 mm2 for current measurement and 25 mm2 for bonding/grounding.

ii) For sacrificial anode CP system the cable size shall be minimum 6 mm2

copper for anode tail cable from anode to buried junction box and 10 mm2

copper from buried junction box to test station in case of temporary CP anodes. In case of sacrificial anodes for permanent CP system the size of anode tail cable from anode to test station shall be minimum 6 mm2 copper.

iii) For impressed current CP system the size of conductor of cables shall be based on the current to be carried, ground bed loop resistance and shall be minimum 35mm2 copper for positive, negative drainage cables and 10 mm2

copper for anode tail cables. The size of CPTR unit AC incomer cables shall be of minimum 4mm2 copper conductor.

4.13.2 Impressed current CP anode tail cables shall be of minimum 10 mm², annealed high conductivity stranded copper conductor, single core, 650 voltage grade PE insulated, unarmoured, PVC sheathed. Contractor may suggest cables with alternative insulation/sheathing having proven track record for impressed current anode ground bed application, for Owner’s approval.

4.13.3 The cables for reference cells and pipeline potential measurements shall be of 4 mm2 copper conductor, PVC insulated, Aluminium backed by mylar / polyster tape shielded, PVC sheathed, armoured, PVC over all sheathed type. The tape shield shall be helically applied with metallic side down, with either side 25% overlap and 100% coverage. The minimum shield thickness shall be 0.05 mm.

4.13.4 Cables for connecting various transducers from CPTR Unit/CPPSM to telemetry interface junction box shall be copper conductor, PVC insulated, twisted pair with individual pair shielded and overall shielded with Aluminium backed by mylar / polyster tape, PVC sheathed, armoured, PVC over all sheathed type. Cable conductor sizes indicated above are minimum only and where necessary for proper operation of the CP system higher sized cables shall be provided.

4.13.5 Length of anode tail cables shall be sufficient for routing and terminating the cable inside anode junction box/buried junction box/test station as




applicable without any intermediate joint.

5.0 EQUIPMENT FOR CLASSIFIED AREAS Equipment for hazardous area shall be flame proof type and shall meet the requirement of IS:2148 or equivalent international standard and shall be suitable for gas group IIB, temperature class T3 (2000C). Indigenous equipment shall be certified by CMRI or any other recognised testing body and shall be approved by the concerned statutory authority. All flameproof equipment shall carry the BIS license marking as per the requirement of statutory authorities.

All Imported equipment for hazardous area may be tested and certified by an independent certifying agency of country of equipment origin and shall be approved by the concerned statutory authority in India.

6.0 TESTS AND ACCEPTANCE 6.1 Unless other wise agreed by the Engineer-in-Charge, all the

equipment/material shall be subject to inspection by GAIL/Owner or by an agency authorised by the owner. All necessary information concerning the supply shall be furnished to GAIL/Owner’s inspector. Two weeks notice shall be given to GAIL/Owner for witnessing the final testing.

6.2 Routine tests and final acceptance tests shall be carried out at manufacturer’s works under his care and expense. Instruments and equipment required for testing shall be arranged by the manufacturer. Final acceptance shall be subject to successful testing. Type test certificates instead of conducting the tests may be accepted where specified in the project specifications.

6.3 Sacrificial Anodes

i) Inspection

a) Visual inspection shall be carried out on all the anodes regarding surface finish excessive shrinkage, cracks, cable joint to anode cone, etc.

b) Minimum 10% of number of anodes from each heat for conformity to dimensions and weight.

c) The anode surface shall be free from cracks, which may reduce the performance of the anode.

Any cracks which follow the longitudinal direction of elongated anodes shall not be acceptable.




Small cracks in the transverse direction of elongated anodes and in anodes of other shapes may be accepted provided the cracks would not cause any mechanical failure during service of the anode considering that the combination of cracks and lack of bond to the anode core is detrimental.

For transverse cracks the acceptable limits shall be furnished by the bidders along with the offer.

d) The anode shall be free from excessive shrinkage. The following limits shall be used.

Maximum 10% of the depth of anode or 50% of the depth of the anode core whichever is less. The depression may be measured for the edges of one side.

The surface of the anodes shall be free from coatings and slag/dross inclusions etc.

The maximum deviation from straightness shall not exceed 2%.

The weight tolerance of individual anode may be taken as +5%. The total weight of the anodes shall not have negative tolerance

Recommended dimensional tolerance shall be as follows:

- Length ±2.5%- Width/thickness ±5.0%

ii) One anode per heat shall be subjected to radiographic test completely to evaluate cracks, voids, slag inclusion, etc.

iii) Destructive Testing

At least one anode per heat shall be subject to close inspection by destructive testing for slag inclusions, bond between the anode material and steel inserts. If the anode fails the test, two more anodes shall be tested. If the second lot of anodes also fails the test, all the anodes of the heat shall be rejected.

iv) Chemical Analysis

One anode sample per heat shall be subject to chemical analysis by spectrography. Sample shall be taken in the beginning for first heat, at the end for the second heat, at the beginning for the 3rd heat and so on.




In case the chemical composition of the tested anode do not meet the requirements of this specification, all the anodes of the heat shall be rejected. Vendor shall indicate specific method of spectrography for each element (e.g. atomic absorption/emission/photometrics etc.).

v) Electrochemical Tests

One anode from the ordered lot shall be tested for

- Open circuit potential - Consumption rate by weight loss method - Visual examination of corrosion pattern (uneven consumption,

inter granular attack, etc.)

Where agreed by Owner type test certificate in lieu of actual conduction of electrochemical test may be accepted.The anode open circuit potential shall lie with in (+) 10 MV and (-) 50 MV of the guaranteed value. The anode consumption rate shall not be less than the specified value. In case of anode closed circuit potential and/or the anode consumption rate do not meet the acceptance criteria all the anodes of the heat shall be rejected.

vi) Manufacturer’s test reports regarding reference cell calibration shall be furnished. The report shall also indicate the month and year of manufacture of reference cell.

6.4 Impressed Current Anodes6.4.1 High silicon Cast Iron anode

i) Visual inspection Visual inspection regarding surface finish, surface cracks & craters, shrinkage, cable joint, measurements of dimension, weight, radiographic tests etc. shall be conducted as per clause 6.3 i) above. The anode acceptance criteria shall be as specified in the clause except that no crack in the anode shall be acceptable unless the cracks are only superficial.

ii) Destructive testing Destructive testing and acceptance criteria shall be as per clause 6.3 iii) above.

iii) Chemical analysis Chemical analysis test and acceptance criteria shall be as per clause 6.3 iv) above.




iv) Electrochemical tests Electrochemical tests for anode consumption, visual examination of corrosion pattern and the anode acceptance criteria shall be as per clause 6.3 v) above

v) Spectrographic analysis The anodes from each heat shall be tested for chemical composition by spectrographic analysis and for homogeneity, dross inclusion, voids etc. by radiography. Destructive tests shall be carried out where asked by owner based on the radiographic test results.

6.4.2 Mixed Metal Oxide Coated Titanium Anode Contractor shall furnish list/details of the tests that will be conducted by manufacturer of anode and their acceptance criteria.

6.4.3 Petroleum coke breeze and special back fill The petroleum coke breeze material shall be tested for chemical composition, bulk density, real density, particle size and resistivity and test certificate shall be furnished.

The special back fill material for the sacrificial anodes shall be tested for composition and test reports shall be submitted.

7.0 PACKING & DESPATCH All equipment/material for CP system along with one set of final drawings shall be dispatched to site packed in wooden crates.

All the equipment shall be divided in to several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets before being placed in crates/cases to prevent damages to finish. Crates/cases shall have skid bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Centre of gravity’, ‘Weight’, ‘Owners particulars’, ‘PO nos’, etc shall be clearly marked on the package together with other details as per purchase order.

The equipment may be stored out doors for long periods before installation. The package shall be completely suitable for out door storage in areas with heavy rain/high ambient temperature unless otherwise agreed.


SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES S-07-02-011 Page 1 of 21


SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION





Abbreviations:

AC Alternating current



CP Cathodic Protection


CPPSM Cathodic Protection Power Supply Module

CPTR Cathodic Protection Transformer Rectifier

CTE Coal tar enamel

DC Direct Current

EHV Extra High Voltage

FBE Fusion bonding epoxy

HDD Horizontal Directional Drilling

HV High Voltage

HVDC High Voltage Direct Current

IS Indian Standards

MOV Motor operated valve

Micro A/mm2 Micro-ampere per square millimeter

NACE National Association of Corrosion Engineers

PE Polyethylene


ROW Right of way

SV Sectionalizing Valve




CONTENTS

1.0 SCOPE


3.0 SYSTEM IMPLEMENTATION

4.0 CORROSION SURVEY

5.0 CATHODIC PROTECTION DESIGN PARAMETERS

6.0 CATHODIC PROTECTION DESIGN CRITERIA

7.0 SYSTEM DETAILS

8.0 INSTALLATION

9.0 FIELD TESTING AND COMMISSIONING

10.0 INTERFERENCE MITIGATION

11.0 SYSTEM MONITORING

12.0 CLOSE INTERVAL POTENTIAL LOGGING SURVEY




1. SCOPE 1.1 This specification defines the requirements of design, engineering,

installation, testing and commissioning of sacrificial anodes cathodic protection system for external surface of cross country onshore underground pipelines/structures including supplementing of corrosion survey, investigation for interference/interaction problems and mitigation of the same.

1.2 This specification defines the basic guidelines to develop a suitable sacrificial anode cathodic protection system for the pipelines/structures required to be protected. All data required in this regard shall be taken into consideration to develop an acceptable design and for proper engineering of the system.

1.3 Compliance with these specifications and/or approval of any of the contractor’s documents shall in no case relieve the contractor of his contractual obligations.

2. APPLICABLE CODES AND STANDARDS 2.1 The system design, performance and materials to be supplied shall conform

to the requirements of the latest revision of following standards as a minimum:

NACE Standard RP-0 169 : Standard Recommended Practice Control of External Corrosion on Underground or Submerged Metallic Piping Systems.

NACE Publication 1 OA 190: Measurement technique related to criteria for CP of Underground or Submerged Steel Piping System (as defined in NACE Standard RPO 169-83).

NACE Standard RP-0177 : Standard Recommended Practice Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems.

NACE Standard RP-0286 : Standard Recommended Practice The Electrical isolation of Cathodically Protected Pipelines.

NACE Publication No.54276: Cathodic Protection Monitoring for Buried Pipelines.

BS 7361 Part I : Code of Practice for Cathodic Protection for land and Marine applications.

VDE 0150 : Protection against Corrosion due to Stray Current from DC Installations.

IS:1554 Part I : PVC insulated (heavy duty) cables.






2.4 In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern:

o Statutory regulations.o Data sheets. o Job specification. o This specification. o Codes and standards.

3.0 SYSTEM IMPLEMENTATION All work to be performed and supplies to be effected as a part of contract shall require specific review by owner or his authorised representative. Major activities requiring review shall include but not be limited to the following:

a) Corrosion survey data interpretation report and design basis for C. P.

system.

b) C.P. system design package.

c) Detailed engineering package.

d) Field testing and commissioning procedure.

e) Procedures for interference testing and mitigation. F

f) Close interval potential logging survey and system monitoring procedures.

g) As built documentation.

4.0 CORROSION SURVEY 4.1 The details of corrosion survey including soil resistivity data along ROW and

other data required for C. P. design if available with the Owner shall be included as part of project specification/data sheet. However, verification of its veracity and adequacy shall be the entire responsibility of the contractor. In addition, contractor shall have to generate/collect additional data as per clause 4.2 below required for completeness of the job. Contractor shall also carry out soil resistivity survey at sacrificial anode ground bed locations for proper design of ground beds as specified in data sheet. Wenner’ s 4-pin method or approved equal shall be used for such measurements. Survey instruments shall have maximum AC and DC ground current rejection feature.

Care shall be taken to ensure that the resistivity observations are not influenced by the presence of foreign pipelines/structures, and earth currents in the vicinity of EHV/HV lines and installations using earth return in their power system etc.




Where specified in the project specification/data sheet, the contractor shall carry out corrosion survey along the ROW of the pipeline conforming to the specifications included in the tender document.

4.2 Additional Data to be Collected The following data shall be collected to generate design data for evaluation of interaction/interference possibilities due to presence of other services in ROW/in vicinity. OWNER shall provide assistance for liaison work to the extent possible:

(i) Route and types of foreign service/pipeline in and around or crossing the right of way (including those existing and those which are likely to come up during contract execution).

(ii) Diameter, wall thickness, pressure, soil cover, and coating scheme used, type of cathodic protection system provided, if any, and year of laying/commissioning in case of foreign pipelines.

(iii) Details of the existing cathodic protection systems protecting the services i.e. type of protection, location, type, rating of anode beds, test station locations and their connection schemes. Present output current and voltage readings of the CP power supply units.

(iv) Remedial measures existing on foreign pipelines/services to prevent interaction.

(v) Graphical representation of existing structure/ pipe-to-soil potential records.

(vi) Possibility of integration/isolation of CP systems, which may involve negotiations with owners of other services.

(vii) Information on existing and proposed DC/AC power sources and systems using earth return path such as HVDC substations/ earthing stations, fabrication yards with electric welding etc. in the vicinity of the entire pipeline route.

(viii) Crossing and parallel running of electrified and non-electrified traction (along with information regarding, operating voltage, AC/DC type etc.) as well as abandoned tracks near ROW having electrical continuity with the tracks in use.

(ix) Crossing or parallel running of any existing or proposed 11 KV and above AC/DC overhead power lines along with details of voltage, AC/DC type etc.

(x) Voltage rating, phases, sheathing details of underground power cables running along ROW or in its vicinity.

(xi) Any other relevant information that may be needed in designing and implementing proper protection scheme for the proposed pipeline.

Contractor shall conduct necessary potential gradient surveys for any existing anode ground beds that may interfere with the CP system of the pipelines covered under this project.




4.3 Report On completion of all fieldwork, a report incorporating all the results generated from surveys and details of additional data collected shall be prepared. The report shall also contain detailed interpretation of survey results and resistivity data enclosed, probable interference prone areas etc. to form design basis for the scheme of cathodic protection. This report shall also include various drawings prepared in connection with the above work. The soil resistivity values shall be plotted on semi-log graph sheets.

5.0 CATHODIC PROTECTION DESIGN PARA1’IETERSUnless otherwise specified in the data sheet, following parameters shall be used for design of cathodic protection system.

Where the cathodic protection system is specified for temporary protection, those parts of sacrificial anode cathodic protection system, which will be integrated, with the permanent CP system shall be designed based on permanent CP parameters.

5.1 Protection Current Density (i) Pipe lines having coal tar enamel (CTE) coating with two / three layers of reinforcement.

Pipeline SurroundingMinimum Protection Current Density

Soil resistivity more than 100 ohm. m

Temporary CP (μA/m2)

Permanent CP (μA/m2)

40 200Soil resistivity 10ohm to 100 ohm. m

75 300

Soil resistivity 10ohm to 100 ohm. m

500 2000

Sea water 1000 5000

(ii) Pipe lines having fusion bonded epoxy coating

Pipeline Surrounding Minimum Protection Current Density





25 90


35 125

Soil resistivity less than 10ohm 125 500




(iii) Pipe lines having polyethylene(PE) coating

Pipeline Surrounding Minimum Protection Current Density





10 35


15 50

Soil resistivity less than 10ohm 35 125

The above current density values for temporary CP system are applicable for CP system design life up to two years.

Actual current density to be adopted shall be decided based upon soil and other environmental conditions, current drainage survey data (where included in contractor’s scope), proximity of foreign pipe lines/structures and other interference areas affecting the installation. Where considered necessary for satisfactory protection of pipeline the current density shall be suitably increased by contractor.

5.2 The pipe protection Current Density indicated in the clause 5.1 above shall be applicable where the temperature of the fluid transported by the pipeline /the surface temperature of the buried portion of the pipeline does not exceed 300 C. Where this temperature exceeds 30° C, the protection Current Density shall be increased suitably in consultation with the GAIL.

5.3 At HDD (horizontal directional drilling) crossing, the pipe protection current density applicable for marshy area shall be considered.

5.4 Safety factor for current density : 1.3

5.5 Anode utilisation factor : 0.85 for solid anodes and 0.6 for ribbon anodes

5.6 Pipeline natural potential : (-) 0.45V.

5.7 Unless otherwise specified in data sheet the design life of temporary CP shall be one year and that of permanent CP shall be 30 years.

5.8 Along the ROW where soil resistivity is higher than 100 ohm. m temporary CP for the pipeline may not be provided after obtaining specific approval from the Owner.




6.0 CATHODIC PROTECTION DESIGN CRITERIA Cathodic protection system shall be designed to meet the following criteria:

The pipe to soil potential measurements shall be between (-) 0.95 V (ON) and (-) 1.5 V (ON) for polyethylene coated pipe lines, between (-) 0.95 V (ON) and (-) 1.7 V (ON) for fusion bonded epoxy/coal tar coated pipe lines with respect to a copper/copper sulphate reference electrode.

6.1 A positive potential swing of 100 milli-volts or more shall be considered sufficient to indicate the presence of an interaction/interference situation requiring investigation and incorporation of mitigation measures by the CONTRACTOR.

7.0 SYSTEM DETAILS The system shall include the following major equipment/sub-systems unless otherwise specified in project specifications.

o Sacrificial anodes and anode ground beds

o CP system at cased crossings

o Test stations

o Surge diverter and polarisation cell

o Permanent reference cells

o Electrical resistance probes

o Interconnecting cables

o Cables to pipe connections

All equipment shall be new and procured from approved manufacturers. Equipment offered shall be field proven. Equipment requiring specialised maintenance or operation shall be avoided as far as possible Prototype equipment shall not be accepted.

Equipment shall conform to the relevant specifications enclosed with the tender document. All equipment including test stations, anode lead junction boxes etc. shall be located in safe non-hazardous areas.

Where it is essential to install the equipment in hazardous area, such equipment shall be flame proof type and shall meet the requirement of IS: 2148 or equivalent international standard and shall be suitable for gas group IIB, temperature class T3 (200°C). Indigenous equipment shall be certified by CMRI or any other recognised testing body and shall be approved by the concerned statutory authority. All flameproof equipment shall carry the BIS license marking as per the requirement of statutory authorities.


SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES S-07-02-011

Page 10 of 21



7.1 Anode Ground Beds Along ROW where soil resistivity predominantly remains low, ranges from 0-10 ohm. m and pH value is within 9, zinc anodes may be provided.

Anodes of type I as per ASTM-B 418 standard shall be used for seawater, brackish water or saline electrolyte application and anode of type II as per ASTM-B 418 standard shall be used for fresh water, back fill and soil applications.

7.1.1 Along ROW where soil resistivity is predominantly in the range of 10 ohm. m to 30 ohm. m, low potential (1 .55V) magnesium anodes may be provided.

7.1.2 Along ROW where soil resistivity is predominantly in the range of 30 ohm-mto 50 ohm-m high potential (1 .75V) magnesium anodes may be provided.

7.1.3 At high resistivity area where resistivity is of the order of 50 ohm. m and above magnesium ribbon anodes may be provided.

7.1.4 Where magnesium anode is used for protection of polyethylene coated pipelines, the anodes shall preferably of low potential (1. 55V) type.

7.1.5 Anodes shall be installed along the pipeline at suitable intervals as per pipeline protection voltage attenuation calculations and ground bed resistance/current output of anode installations. At high resistivity area the magnesium ribbon anodes shall be installed all along the pipeline by the side of the pipeline in the pipeline trench.

7.1.6 Suitability of the selected sacrificial anodes for the soil conditions with particular attention to carbonates, bicarbonates, phosphates and nitrates, shall be checked for proper operation by the contractor. The anodes shall be laid in proper type of back fill, such that the effect of soil is minimum on the anode effectiveness and life. Suitable safe guards against anode passivation in prevailing soil shall be taken by the contractor.

7.1.7 Each electrically continuous section of pipeline shall be protected totally by single type of anode to avoid inter-anode circulation currents.

7.1.8 The anodes shall be installed at sufficient depth to reach moist soil and shall be separated from the pipeline by at least 5 m and 2 m for magnesium and zinc anodes respectively. The magnesium ribbon anode shall be separated from the pipeline by at least half a meter. The anode connections to pipe line shall be routed through test stations.



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7.1.9 At the temporary CP anode ground bed, the leads of all the anodes shall be joined together in a junction box filled with epoxy and buried. A single cable shall be routed from the junction box to test station.

7.1.10 For sacrificial anode ground bed which is intended for permanent CP system and/or which is to be integrated with permanent CP system, the leads of all the anodes shall be brought up to the test station and shall be terminated individually.

7.1.11 The number of anodes at each ground bed shall be sufficient for providing the specified pipe protection current density taking into consideration the ground bed resistance, cable resistance, etc. For permanent cathodic protection system, contractor shall prepare a table for number of anodes required at different soil resistivities to produce the specified protection current for the specified designed life. For temporary cathodic protection system, an indicative design data for sacrificial anodes ground bed in tabular form is given in data sheet. The number of anodes for ground bed, spacing of ground beds based on the applicable soil resistivity, size of pipeline, type of coating for the pipeline shall be chosen from the table after necessary verification by the CP contractor. Any deficiency in the protection system if noticed during commissioning or during monitoring shall be corrected by the CP contractor by suitably augmenting the system with additional anodes without any cost/schedule implications.

7.1.12 For the portion of the pipeline for which the CP system has been specified based on the permanent CP system parameters, the contractor shall ascertain the requirement of the cathodic protection current density indicated in clause 5.1 above. Where specified in the project specification/data sheet the requisite current density test/survey shall be conducted by the contractor to establish the adequacy of CP current requirement and number of anode ground beds.

7.2 Test Stations 7.2.1 Test stations shall be provided along the pipeline ROW for monitoring the

performance of the cathodic protection system at the following locations. Test stations shall be provided at additional locations, if required, so that distance between any two adjacent test stations does not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like forest/deserts:

a) At the locations of anode ground beds.

b) At both sides of metalled road crossings.

c) At all insulating joints.

d) At vulnerable locations with drastic changes in soil resistivity.



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e) At locations of surge diverters, pipeline grounding through polarisation

cells, zinc and magnesium anodes.

f) At EHV/HV AC/DC overhead line crossings and selected locations where

EHV/HV overhead line is in the vicinity of the pipeline.

g) At railway line crossings and at selected locations along lines running

parallel to the pipeline.

h) At both sides of major river crossings.

i) At EHV/HV cable crossings or along routes where EHV/HV cables are

running in parallel.

j) In the vicinity of DC networks or grounding systems and HVDC grounding

systems where interference problems are suspected.

k) At crossings of other pipelines/structures.

l) At the locations of reference cell and Electrical Resistance probe

installation.

m) At both sides of cased crossings.

n) Locations where interference is expected.

o) At locations of Sectionalizing Valve (SV) stations.

p) At any other locations considered necessary by OWNER or OWNER’ s representative.

7.2.2 Test stations used for sacrificial anodes shall have shunt for measurement of anode current, provision for resistance insertion to limit the anode current output and anode-disconnecting link.

7.2.3 Test stations for bonding shall be provided with shunt and resistor as a means to monitor and control current flow between the pipeline and foreign pipelines or structures that may exist in common ROW.

7.2.4 Test station with current measuring facility shall be provided at interference prone areas, on both sides of major river crossings, near marshy areas and minimum one for every 10 km max. along the pipeline.

7.2.5 The test stations shall be installed with the face of the test station facing the pipeline. The nameplate of test stations shall carry the following minimum information:

o Chainage in km.

o Test station connection scheme



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o Distance from pipeline in metres.

o Direction of product flow. 7.2.6 Terminals and different schemes of wiring shall be provided as per the test

station connection scheme. Minimum twenty percent spare terminals shall be provided in each test station.

7.2.7 Minimum two cables shall be provided from the pipeline at any test station.

7.2.8 The location of all the test stations shall be marked with their connection schemes and other relevant information on alignment sheets. A detailed test-station schedule shall be prepared.

7.3 Permanent Reference Cells 7.3.1 High purity copper-copper sulphate reference cells with proven high reliability

shall be provided for stable coupon to soil potential measurement at the locations of polarisation coupons.

7.3.2 The reference cells shall be of silver/silver chloride type in place of copper/copper sulphate cells, at marshy area locations, where water table is high and chloride ion concentration is more than 300 ppm. For marshy area in saline soils, high purity zinc may be considered as an alternative to silver/silver chloride.

7.3.3 The life of reference cells shall be minimum 10 years under burial conditions.

7.3.4 The test station connection scheme inside the test station shall clearly indicate the type of reference cell (Cu-CuSO4/Ag-AgCl).

7.4 Electrical Resistance Probe 7.4.1 Where specified in data sheet electrical resistance probes (E/R probes)

utilising the electrical resistance technique shall be provided along the pipeline at marshy areas and at vulnerable locations to monitor the external corrosion activity on the pipeline. The lead- wires of the probe shall be connected to pipeline through test station and terminated inside test station enabling periodic resistance measurement of the probe using a portable measuring instrument.

7.4.2 The E/R probes shall be provided preferably at the bottom portion of pipeline. The number of E/R probes, the locations of their installation and the number of portable E/R probe reading instruments shall be as specified in the project specification/data sheet.

7.5 Surge Diverter and Polarisation Cell 7.5.1 Surge Diverter :

Explosion proof type spark gap surge diverter shall be connected across each insulating joint to protect it from high voltage surges.



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7.5.2 Polarisation Cell i) Wherever the pipeline is either crossing or running in parallel with

overhead EHVIHV transmission lines of voltage grade 66kV and above, it is mandatory that the pipeline shall be grounded to discharge any accumulated potential/surge that may appear in case of transmission line faults, as per below:o The pipeline shall be grounded through polarization cell with zinc

galvanic anodes of minimum 20 kg net weight each at location where pipeline crosses EHV/HV transmission lines.

o The pipeline shall be grounded at regular intervals of maximum 1.0 km where EHV/HV transmission lines run parallel within 25 m of the pipeline.

ii) Locations along pipeline where continuous induced over-voltage due to other overhead transmission lines/underground cables of voltage grade below 66kV is expected or observed during commissioning, the pipeline shall be grounded through polarization cell to the earth system of the EHV/HV tower causing the voltage induction or to a separate earthing system of zinc anodes through polarisation cell.

iii) The polarization cell shall be installed inside test station of suitable size.

iv) Type of polarization cell shall be as specified in data sheet.

7.5.3 The total system including cable, cable termination, surge diverters/polarisation cells/anodes shall be suitable for the anticipated fault current at the location of its installation

7.5.4 The surge diverter, polarization cell and anode system shall be suitable for the design life of permanent CP system. The grounding system shall have minimum resistance to earth to restrict the pipeline voltage as per NACE/VDE criteria but shall not exceed 5 ohms. The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.

7.6 Motor operated valves where located on the cathodically protected portion of the pipeline shall be grounded by a zinc or magnesium anode of 20 kg net where the type of anode provided for the CP system of the pipeline is zinc or magnesium respectively. The MOV power supply cable armour shall be insulated (by cutting and taping with insulation tape) at MOV end to avoid armour carrying CP current.

7.7 The above ground cathodically unprotected pipeline at intermediate SV stations, pigging stations, etc. and terminals shall be earthed with GI earth



Page 15 of 21


electrodes. The resistance to earth of grounding shall be limited to 5 ohms max.

7.8 CP at cased crossing

7.8.1 At cased crossings where casing is coated, the casing shall be protected by sacrificial anode installations, provided at both ends of casing. The anode installation shall be sized based on the permanent C .P. design parameters and design life of permanent CP system. At cased crossings where casing is painted or uncoated, additional protection for casing pipes may not be provided.

7.8.2 The carrier pipe inside the painted or coated casing shall be protected by zinc ribbon anodes weld connected to the outer surface of bottom of carrier pipe extending up to hour hand positions of 4 and 8 O’clock. The anodes shall be placed at close intervals as per design calculations with minimum one number of anodes installed between every two supports provided between carrier and casing. The anodes shall be sized based on the permanent CP design parameters for marshy area and design life of permanent CP system.

7.8.3 Where casing is bare (i.e. uncoated or unpainted) additional protection for carrier pipe may not be provided.

7.9 Reference Cell Access Points Reference cell access points shall be provided near insulating joint locations and at SV stations, where the ground is paved, for measurement of pipe to soil potentials. A perforated PVC pipe filled with native soil and buried at the location shall be provided for the purpose. The length of the PVC pipe shall be adequate to reach the native soil below the paving.

7.10 Cables 7.10.1 Cables shall be with annealed high conductivity, stranded copper conductor,

PVC insulated, 650/1100V grade, armoured, PVC sheathed conforming to IS.1554 Part-I except for the cables for reference cells and pipeline for potential measurement. The size of the copper conductor shall be 6 sq. mm. for anode tail cable from anode to buried junction box or test station (in case of permanent CP anode ground bed), 10 sq.mm. from buried junction box to test station and 10 sq.mm. from test station to pipeline. The size of cable for bonding, polarisation cell, grounding anodes and surge diverter connections shall be suitable for the maximum fault current subject to minimum 25 sq mm. The length of anode tail cable shall be sufficient for routing from anode to buried junction box or test station for anodes for temporary CP or permanent CP respectively.

7.10.2 The cables for reference cells and pipeline potential measurements shall be of 4 sq. mm copper conductor, PVC insulated, Aluminium backed by



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mylar/polyster tape shielded, PVC sheathed, armoured, PVC over all sheathed type.

8.0 INSTALLATION 8.1 Cable Laying

8.1.1 Cables shall be laid in accordance with the layout drawings to be prepared by the contractor. No straight through joint shall be permitted. Cable route shall be carefully measured and cables cut to required length. Minimum half metre cable slack shall be provided near anodes, pipeline and test stations to account for any settling.

8.1.2 All cables inside station/plant area shall be laid at a depth of 0.75 M. Cables outside station/plant area shall be laid at a depth of minimum 1. 5 m. Cables shall be laid in sand under brick cover and back filled with normal soil. For cables laid outside the station/plant area, polyethylene warning mats shall placed at a depth of 0.9 m. from the finished grade, to mark the route.

8.1.3 In case of above ground cable, all unarmoured CP cables shall be laid in GI conduits of sufficiently large size, up to accessible height for protecting against the mechanical damage.

8.1.4 All underground unarmoured cables including anode tail cables shall run through PE sleeves. The cables routed along the pipeline shall be carried at the top of the carrier pipe by securely strapping it at intervals with adhesive tape or equivalent as required.

8.1.5 PVC pipes of proper size shall be provided for all underground cables for road crossings.

8.1.6 Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and final take-off to equipment is facilitated.

8.1.7 The cables for reference cells and pipeline potential measurement shall be routed in a separate trench other than the trench provided for the rest of the CP system cables, AC cables for CPTR units, etc.

8.1.8 The armour of all the cables from pipeline to test station (potential measurement, reference cell cables, cathode cables, etc) and test station to ground bed (anode cable) shall be earthed only at test station end of the cable to avoid armour carrying CP current. The cable armour shall be insulated by cutting and taping with insulation tape



Page 17 of 21


8.2 Permanent Reference Cells The permanent reference cells shall be installed in natural soil conditions as per the recommendations of the cell manufacturer. Installations in highly acidic/alkaline soil and soil contaminated by hydrocarbons shall be avoided.

8.3 Cable to pipe connections All cable connections to the new pipeline shall be made by an approved exothermic process or by pin brazing. However, cable connection to charged pipelines shall be made by pin brazing. Exothermic welding shall be adopted for water pipelines. The resistance of the cable to pipe at the connection point shall not exceed 0.1 ohm. Coating shall be repaired after connection of cable conductor to pipeline. The coating repair material shall be compatible with the original coating and shall prevent ingress of water along the cable surface and at the interface of coating repair with the original pipe coating.

8.4 Ground bed Fencing Where specified in project specifications/data sheet a chain link fencing shall be provided around the location of each ground bed, designed based on the permanent CP design parameters.

9.0 FIELD TESTING AND COMMISSIONING 9.1 System testing at site

9.1.1 Field tests as per the reviewed field testing and commissioning procedures prepared by the Contractor, shall be carried out on the equipment/systems before these are put into service. Acceptance of the complete installation shall be contingent upon inspection and test results.

9.1.2 Before the C.P. system facilities are put into operation, necessary tests shall be carried out to establish that all equipment, devices, wiring and connection have been correctly installed, connected and are in good working condition as required for the intended operation. Owner/Owner’s representative may witness all tests. Intimation shall be given at least one week before commencing the tests.

9.1.3 All tools, equipment and instruments required for testing shall be provided by Contractor.

9.1.4 Generally, the following minimum tests must be carried out and recorded. i) Cables

Cable No.

Voltage grade.

Conductor cross section.

Continuity check.

Voltage test.

Insulation resistance values between each core & earth,



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between cores.

All cables shall be tested by 500 V megger.

ii) Insulating joint Location.

Pipe to soil potential of both protected and non-protected sides of the insulating joint before and after energisation of CP system.

iii) Surge diverter Location/identification number.

Rating

Type

Explosion proof enclosure.

Check for healthiness.

Check for proper connection.

iv) Polarisation Cell Location/Identification number.

Type

Ratings

Check for wiring

Check standby current drain after CP system energisation. (Current drain with respect to voltage across the cell shall be recorded).

Details of grounding provided for the polarisation cell.

v) Anode Ground Bed Location/Station

Vertical/horizontal

Check for actual layout and compliance with drawings.

Current output of ground bed

Current out put of each anode (in case of permanent CP anode ground beds)



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vi) EIR Probe Location/Identification number

Checking of wiring as per schematics

Resistance reading of probe

Installed on top/bottom/side of the pipeline

vi) vii) Reference Cell

Location

Type of cell

Potential reading

Installed on top/bottom level of pipeline

9.2 Commissioning 9.2.1 Natural potential of pipe to soil for the complete pipeline and casing pipeline

at the locations of cased crossings shall be measured at all the test station locations, recorded prior to connecting anodes to pipe line and casing pipeline respectively.

9.2.2 The anode shall be connected to pipeline in the test station and the pipe to soil potential observation shall be made after allowing sufficient time for polarisation. The current output of each anode at permanent CP anode ground bed or the total current output of anode bed at temporary CP anode ground bed shall also be measured to ensure that it does not exceed the output current capacity of the anodes. In case the anode output current exceeds the rated capacity, it shall be controlled by insertion of resistance element in the anode circuit inside test station and the pipe to soil potential shall be rechecked for adequacy of protection. At locations of polarisation coupons the coupon ‘OFF’ potential shall be measured by switching off the reed switch. Additional anodes shall be provided where required to achieve desired level of protection and to keep the anode out put current with in the rated value. In case pipe to soil potential exceeds the specified value, suitable resistance shall be inserted in the anode circuit to limit the potential. Anode installation shall become individually operational as above.

9.2.3 At the locations of cased crossings where anode installations are provided for the protection of the casing pipe, these anode installations shall be commissioned as per the procedure detailed in clause 9.2.2. above.

9.2.4 After connecting all the anode ground beds to pipe line, measurement of pipe to soil potentials shall be taken at each test station to ensure conformity to protection criteria.



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9.2.5 In case of insufficient protection as per the CP design criteria, on any portion of the pipeline! casing pipeline (at cased crossings where casing is cathodically protected) Contractor shall carry out necessary additions/modifications to the provided protection in consultation with the Owner/Owner’s representative.

9.2.6 Resistance readings of the probe shall be taken at all the locations of electrical resistance probes.

10.0 INTERFERENCE MITIGATION 10.1 Investigations shall be made for stray current electrolysis of the pipeline,

mutual interference between the pipeline and foreign pipelines/structures, interference on foreign pipelines/structures due to the CP of the pipeline and ground bed, AC induction on pipeline due to 11 KV and above overhead HV/EHV line, interference due to high voltage DC line, HVDC groundings, electric traction etc.

10.2 Where transmission lines cross the pipeline or run in parallel within or more than 25m from the pipeline, AC voltage measurements shall also be made on the pipeline to find out continuous induction of voltage. In case of induced voltage being beyond safe limits, the pipeline shall be grounded in line with clause no.7.5 above.

10.3 Measurements including pipe/structure to soil potential and pipeline/structure current etc. on the pipeline/structure being CP protected and on foreign pipelines/structures shall be made to investigate the current discharge and pickup locations. In case of fluctuating stray current, investigations shall be made continuously over a period of time and if required simultaneously at different locations to find out the stray current source(s). For measurements over longer durations, recorders shall preferably be used.

10.4 Where foreign pipelines (unprotected or protected by independent CP system) run in parallel to the pipeline in same trench or very near to the pipeline, and are not bonded to the pipeline then investigation shall be made for current discharge points on both the pipelines.

10.5 Mitigation measures shall be provided depending on type of stray current electrolysis! interference. These shall include installation of bond with variable resistor, diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment/relocation (if possible) of offending interference source, provision of electrical shield etc. depending on the type of interference.

10.6 Bonding with foreign pipeline/structure, as a mitigation measure shall be provided where the owner of the foreign pipeline/structure has no objection, otherwise alternative mitigation measure shall be provided. Where bonding is



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provided for mitigation, the bonding resistor shall be adjusted for optimum value for minimum/no interference. Galvanic anodes installed as a mitigation measure shall be sized for the design life specified for permanent CP.

11.0 SYSTEM MONITORING

Where the CP system provided is temporary, the C .P. system shall be monitored at all test stations once in a month for healthiness/adequacy of protection till commissioning of permanent CP or for design life of temporary CP specified, which ever is less. During this period if any deficiency! interference in protection system is noticed, the same shall be rectified/augmented by providing additional anodes as required. The monitoring report shall be submitted regularly to owner for his review/information.

12.0 CLOSE INTERVAL POTENTIAL LOGGING SURVEY Where specified in project specification/data sheet, contractor shall carry out a close interval potential survey over the entire length of pipeline by computerised potential logging method and identify the under protected/over protected area, any major coating damage on the pipeline, after the back-filling has been consolidated sufficiently and CP system has stabilized. Contractor shall provide required mitigation measures and rectify the under/over-protected zones, identify if any, the major pipeline coating defects required to be repaired. During the survey the reference cell shall be calibrated minimum once in 24 hours.

Where specified in the project specification/data sheet, additional tests for detailed identification of coating defects shall be conducted by the contractor.


SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR

PIPELINES S-07-02-012 Page 1 of 26


SPECIFICATION FOR IMPRESSED

CURRENT CATHODIC PROTECTION






Abbreviations:




CP Cathodic Protection


CPPSM Cathodic Protection Power Supply Module

CPTR Cathodic Protection Transformer Rectifier

CTE Coal tar enamel

DC Direct Current

EHV Extra High Voltage

FBE Fusion bonding epoxy

HDD Horizontal Directional Drilling

HV High Voltage

HVDC High Voltage Direct Current

IS Indian Standards

MOV Motor operated valve

Micro A/mm2 Micro-ampere per square millimeter

NACE National Association of Corrosion Engineers

PE Polyethylene


ROW Right of way

SV Sectionalizing Valve





CONTENTS

1.0 SCOPE


3.0 SYSTEM IMPLEMENTATION

4.0 CORROSION SURVEY

5.0 CATHODIC PROTECTION DESIGN PARAMETERS

6.0 CATHODIC PROTECTION DESIGN CRITERIA

7.0 SYSTEM DETAILS

8.0 INSTALLATION



11.0 CLOSE INTERVAL POTENTIAL SURVEY





1.0 SCOPE 1.1 This specification defines the requirements of system design, engineering,

installation, testing and commissioning of an Impressed Current Cathodic Protection System for cross- country onshore underground pipelines/structures including supplementing of corrosion survey, close interval potential logging survey, investigations for interaction/interference problems and mitigation of the same.

1.2 This specification provides the basic parameters to develop a suitable impressed current cathodic protection system for the pipelines/structures requiring protection. All data required in this context shall be taken into consideration to develop an acceptable design and for proper engineering of the system.

1.3 Compliance with these specifications, and/or approval of any documents submitted by contractor shall in no case relieve the contractor of his contractual obligations.

2.0 APPLICABLE CODES AND STANDARDS

2.1 The system design, performance and materials to be supplied shall conform to the requirements of the latest revision of following standards as a minimum:

NACE Standard RP-0 169 : Standard Recommended Practice Control of External Corrosion on Underground or Submerged Metallic Piping Systems.

NACE Publication 1 OA 190: Measurement technique related to criteria for CP of Underground or Submerged Steel Piping System (as defined in NACE Standard RPO 169-83).

NACE Standard RP-0177 : Standard Recommended Practice Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems.

NACE Standard RP-0286 : Standard Recommended Practice The Electrical isolation of Cathodically Protected Pipelines.

NACE Publication No.54276: Cathodic Protection Monitoring for Buried Pipelines. BS 7361 Part I : Code of Practice for Cathodic Protection for land and Marine

applications. VDE 0150 : Protection against Corrosion due to Stray Current from DC

Installations. IS:1554 Part I : PVC insulated (heavy duty) cables.



2.4 In case of any contradiction between various referred standards! specifications! data sheet and statutory regulations the following order of priority shall govern:





Statutory regulations. Data sheets. Job specification. This specification. Codes and standards.

3.0 SYSTEM IMPLEMENTATION All work to be performed and supplies to be effected as a part of contract shall require specific review by Owner or his authorised representative. Major activities requiring review shall include but not be limited to the following:

i) Corrosion survey data interpretation report and plot plans for land acquisition.

ii) Conceptual system design. iii) Basic engineering package. iv) Detailed engineering package. v) Field testing and commissioning procedures. vi) Procedures for interference testing and mitigation. vii) Close interval potential logging survey procedure. viii) As built documentation.

4.0 CORROSION SURVEY 4.1 General 4.1.1 The details of corrosion survey including soil resistivity data along ROW and other

data required for C. P design if available with the Owner shall be included as part of project specification/data sheet. However, verification of its veracity and adequacy shall be the entire responsibility of the contractor. In addition, contractor shall have to generate/collect additional data as per clause 4.4 below required for completeness of the job.

Contractor shall carry out soil resistivity survey at anode ground bed locations for design of ground bed. Where specified in the data sheet, Contractor shall carry out corrosion survey along the ROW of the pipeline conforming to the specifications included in the tender document.

4.1.2 To carry out soil resistivity measurement Wenner’ s 4-pin method or an equivalent method approved by Owner shall be used. Survey instruments shall have maximum AC and DC ground current rejection feature.

Care shall be taken to ensure that the resistivity observations are not influenced by the presence of foreign pipelines/structures, and earth currents in the vicinity of EHV/HV lines and installations using earth return in their power system etc.

4.2 Soil Resistivity Survey At Impressed Current Anode Ground Bed Plot 4.2.1 Each selected anode bed plot shall be sub-divided into sub-plots. Sizes of sub-

plots shall depend upon the expected depth for soil resistivity investigations. Each of these sub-plots shall be investigated for resistivity data individually. Sufficient





observations shall be taken at each of these sub-plots as required and desired by Owner/Owner s representative to obtain sufficient information about sub-soil stratification and, wherever °possible, to establish the depth of water table. The number of subplots at each ground bed plot shall be decided at site in consultation with Owner/Owner’s representative.

4.2.2 Number, location, demarcation and size of sub-plots and number of sets of resistivity observations required for each sub-plot shall be individually decided for each ground bed plot location.

4.2.3 One or more ground bed plots may be required to be selected and surveyed at each CP station to form a suitable ground bed.

4.3 Topographic Surveys Cathodic protection stations consisting of anode ground bed, CP station, etc. as applicable, along with all associated cabling up to pipeline and any other related equipment and accessories for CP station shall be demarcated on the ground. Ground plots so demarcated shall be surveyed for all other topographical and cadastral features and topo-sheets shall be developed by the CONTRACTOR, which shall be suitable for use in land acquisition etc.

4.4 Additional Data to be Collected The following data shall be collected to generate design data for evaluation of interaction/ interference possibilities due to presence of other services in ROW or in its vicinity. OWNER shall provide assistance for liaison work to the extent possible.

i) Route and types of foreign service/pipeline in and around or crossing the right of way (including those existing and those which are likely to come up during contract execution).

ii) Diameter, wall thickness, pressure, soil cover, and coating scheme used, type of cathodic protection system provided, if any, year of laying/commissioning in case of foreign pipelines.

iii) Details of the existing cathodic protection systems protecting the services i.e. type of protection, location, type, rating of anode beds, test station locations and their connection schemes. Present output current and voltage readings of the CP power supply units.

iv) Remedial measures existing on foreign pipelines/services to prevent interaction.

v) Graphical representation of existing structure! pipe-to-soil potential records. vi) Possibility of integration/isolation of CP systems, which may involve

negotiations with owners of other services. vii) Existing and proposed DC/AC power sources and systems using earth return

path such as HVDC substations! earthing stations, fabrication yards with electric welding etc. in the vicinity of the entire pipeline route.





viii) Crossing and parallel running of electrified and non-electrified traction (along with information regarding, operating voltage, AC/DC type etc.) as well as abandoned tracks near ROW having electrical continuity with the tracks in use.

ix) Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power lines along with details of voltage, AC/DC type etc.

x) Voltage rating, phases, sheathing details of underground power cables along ROW or in its vicinity.

xi) Any other relevant information that may be needed in designing and implementing proper cathodic protection scheme for the proposed pipeline. Contractor shall conduct necessary potential gradient surveys for any existing anode ground beds that may interfere with the CP system of the pipelines covered under this project.

4.5 Report On completion of all field work, a report incorporating all the results generated from surveys and details of additional data collected shall be prepared. The report shall also contain detailed interpretation of survey results and resistivity data, probable interference prone areas, selected locations for anode ground beds, etc., to form a design basis for the scheme of cathodic protection. This report shall also include various drawings prepared in connection with the above work. Soil resistivity values shall be plotted on semi-log graph sheets.

5.0 CATHODIC PROTECTION DESIGN PARAMETERS A distinctly independent impressed current cathodic protection system shall be provided to protect the external surfaces of the complete pipeline/structure installation as specified.

Unless otherwise stated in the data sheets, the following parameters shall be used for design of permanent cathodic protection system

5.1 Protection Current Density Range i) Pipe lines having coal tar enamel (CTE) coating with two/three layers of

reinforcement. Minimum Protection Current

Density.Pipeline SurroundingTemporary CP

(μA/m2)Permanent CP (μA/m2)

Soil resistivity more than 100 ohm. m 40 200Soil resistivity 10ohm to 100 ohm. m 75 300Soil resistivity 10ohm to 100 ohm. m 500 2000Sea water 1000 5000





ii) Pipe lines having fusion bonded epoxy coating Minimum Protection Current

DensityPipeline Surrounding




25 90

Soil resistivity 10ohm to 100 ohm. m 35 125Soil resistivity less than 10ohm 125 500

iii) Pipe lines having polyethylene(PE) coatingMinimum Protection Current

DensityPipeline Surrounding



Soil resistivity more than 100 ohm. m 10 35Soil resistivity 10ohm to 100 ohm. m 15 50Soil resistivity less than 10ohm 35 125

The above current density values for temporary CP system are applicable for CP system design life up to two years.

Actual current density to be adopted shall be decided based upon soil and other environmental conditions, current drainage survey data, proximity of foreign pipe lines/structures and other interference areas affecting the installation. Where considered necessary for satisfactory protection of pipeline the current density shall be suitably increased by contractor. Also refer to clause 7.1 iv) below.

At HDD (horizontal directional drilling) crossing, the pipe protection current density applicable for marshy area shall be considered.

5.2 The pipe protection Current Density indicated in the clause 5.1 above shall be applicable where the temperature of the fluid transported by the pipeline! the surface temperature of the buried portion of the pipeline does not exceed 300 C. Where this temperature exceeds 30° C, the protection Current Density shall be increased suitably in consultation with the GAIL.

5.3 Safety factor for current density : 1.35.4 Anode utilisation factor (For high

silicon cast iron anode)0.85 for centre connected anode and 0.6 for end connected anode

5.5 Anode surface current density(For high silicon cast iron anode for continuous operation)

15 Amp./sq.m (max.) for shallow anode ground bed and 10 Amp./sq.m (max.) for deep well anode ground bed

5.6 Anode consumption rate 0.2 kg./Amp.yr. (For high silicon cast iron anode)





5.7 Pipeline natural potential (-) 0.45 V5.8 Design life of CP system 30 years, unless specified otherwise 5.9 Anode ground bed loop resistance

including anode to ground resistance, anode and cathode cable resistances

1 ohm (max.).

(The output voltage rating of the CPTR unit / CPPSM shall in minimum be adequate to drive the specified end of life cathodic protection current with safety factor, considering the total anode ground bed loop resistance as the sum of the resistance specified in this clause and pipe to earth resistance).

5.10 For mixed metal oxide coated titanium anodes the anode utilisation factor, anode surface current density and anode consumption rate etc. shall be as per the guaranteed values published by the manufacturer and supported by test certificates/field proven ness.

6.0 CATHODIC PROTECTION DESIGN CRITERIA Cathodic protection system shall be designed to meet the following criteria

i) The pipe to soil potential measurements shall be between (-) 0.9V (OFF) and (-) 1. 1 8V (OFF) with respect to a copper/copper sulphate reference electrode.

ii) In rare circumstances, a minimum polarisation shift of (-) 100 milli voltsmay be accepted as an adequate level of cathodic protection for the pipeline with the approval of Owner.

iii) A positive potential swing of 100 milli volts or more shall be considered sufficient to indicate the presence of an interaction/interference situation requiring investigation and incorporation of mitigation measures by the CONTRACTOR.

7.0 SYSTEM DETAILS

The system shall include the following major equipment/sub-systems unless otherwise specified in project specifications:

o CP stations o - CPTR units/cathodic protection power supply modules (CPPSM). o Anode ground beds and anodes o Anode junction box o Cathode junction box o Test stations o Permanent reference cells o Electrical resistance probes o Polarisation cell and surge diverter o Polarisation coupons



PIPELINES S-07-02-012Page 10 of

26© GAIL – All rights reserved

o Computerized Test Stations o CP system at cased crossing o Bond Stations o Cables

All equipment shall be new and procured from approved reputed manufacturers ..Equipment offered shall be field proven. Equipment requiring specialised maintenance or operation shall be avoided as far as possible. Prototype equipment shall not be accepted.

All equipment/materials shall conform to the relevant specifications included in the tender document.

All equipment including CPTR unit, CPPSM, test stations, anode lead junction boxes etc. shall be located in safe non-hazardous areas.

Where it is essential to install the equipment in hazardous area, such equipment shall be flameproof type and shall meet the requirement of IS: 2148 or equivalent international standard and shall be suitable for gas group IIB, temperature class T3 (200°C). Indigenous equipment shall be certified by CMRI or any other recognised testing body and shall be approved by the concerned statutory authority. All flameproof equipment shall carry the BIS license marking as per the requirement of statutory authorities.


7.1 Cathodic Protection Stations The number and exact locations of CP stations shall be worked out based on the corrosion survey data collected. In addition, the following guidelines shall be followed for selecting the locations:

I) Number of CP stations and their selected locations shall ensure that these remain valid and are adequate for the full design life of the system after considering all foreseeable factors.

II) As far as possible, the availability of nearby low resistivity areas for location of associated ground beds must be ensured while selecting the locations of CP stations.

III) As far as possible, locations of intermediate CP stations shall coincide with the locations of SV stations.

IV) The proposed locations of CP stations and anode ground bed current ratings are detailed in project specifications/data sheets. The same shall be verified for





adequacy by the contractor. The requisite current drainage tests/survey shall be conducted by the contractor to establish the adequacy of CP current requirement indicated in clause 5.0 above and adequacy of number, ratings of CP stations for permanent CP system indicated in the data sheet. The minimum end of life pipe protection current requirement shall be considered as the current requirement indicated in the clause 5.0 above or 3 times the current density value measured by the current drainage survey for polyethylene coated pipeline and 4 times the current density value measured by the current drainage survey for fusion bonded epoxy, coal tar enamel with reinforcement coated pipeline, whichever is maximum.

7.2 CP Transformer Rectifier Unit/CPPSM If specified in project specifications/data sheet, the supply, installation, testing and commissioning of cathodic protection power supply module (CPPSM) /indoor type Cathodic Protection Transformer Rectifier Unit (CPTR unit)! outdoor type CPTR unit installed in kiosk along with kiosk shall be included in contractor’s scope The CP TR units shall be provided at CP stations where reliable AC power supply is available. CPPSM shall be provided at other CP stations where reliable DC power supply instead of reliable AC power supply is available. The CPTR unit/CPPSM shall be installed in non-hazardous (safe) area as specified in data sheets.

7.3 Anode Ground Beds i) Each CP station shall have an independent anode ground bed, which may be of

shallow or deep well construction depending upon the data collected by the contractor. Deep well ground beds may also be used in the congested locations where availability of suitable land for spread out ground beds is restricted.

ii) Ground bed shall be located electrically remote from the pipeline and foreign pipeline! other buried metallic structures. Nearest part of the anode bed shall at least be 100 meters away from the pipeline and foreign pipeline! other buried metallic structures. The anodes installed in the ground shall be located in perennially moist strata, wherever possible. Horizontal ground beds shall be at right angles to the pipeline, as far as possible. The location of ground bed shall be checked and ensured for remoteness from the pipeline and other buried foreign pipelines/structures, building foundations, switchyards, electrical earthing systems, etc.

iii) Unless otherwise agreed, anodes shall be of high silicon cast iron type or mixed metal oxide coated titanium anodes.

iv) Sheet steel anode canisters of adequate size shall be provided for each anode. Anode canisters shall be filled with petroleum coke breeze. In case of deep well ground beds non-canistered anodes with petroleum coke breeze in the well surrounding the anodes shall be provided.





v) Each shallow anode-bed shall contain anodes with canisters positioned horizontally or vertically in the soil with suitable backfill. The depth of anodes (depth of top of anode in case of vertically laid anodes) shall not be less than 2 meter from grade level

vi) Layout of anode installation in anode bed shall be detailed out in drawings showing anode installation details, anode grouping, anode wiring, anode cable routing, etc. The deep well anode ground bed details shall include the details of anodes, deep well casing, anode positioning, anode cable supporting, deep well gas venting, active, passive portions of the ground bed, etc.

vii) Anodes shall be supplied complete with tail cables, which shall be long enough for termination on their associated anode lead junction boxes without intermediate joints. Exact lengths and termination details shall be indicated in construction drawings.

viii) Potential gradient around the anode bed shall be within safety requirements with regard to interference on foreign structures and its effective boundary shall be defined.

ix) In case of two parallel pipelines running in the same ROW, the anode ground beds of the respective pipelines shall be located on the respective sides of the pipelines.

7.4 Anode Junction Box Depending on the size and configuration of anode ground beds, one or more anode junction boxes shall be provided at each ground bed. All cable tails from individual anodes shall be terminated onto the respective anode junction boxes, which shall be further connected to the main anode junction box (where applicable). The main anode junction box shall be connected to the cable coming from CP power source. Each outgoing circuit in main junction box (where applicable) and each anode circuit in junction shall have provision for measurement and control of individual circuit/anode current.

7.5 Cathode Junction Box Where output of the CP power supply unit is connected to multiple pipelines a cathode junction box shall be provided near the pipelines at the location of connection of the negative drainage cable to the pipelines.

The negative of the CP power source shall be connected to the incoming circuit of the cathode junction box. The junction box shall have separate out gong circuit one for each pipeline to collect the negative drainage currents from each of the parallel pipelines.

The incoming circuit shall have a current measurement facility. Each out going circuits shall have provision for measurement and control of current.





7.6 Test Stations 7.6.1 Test stations shall be provided along the pipeline ROW for monitoring the

performance of the cathodic protection system at the following locations. Test stations shall be provided at additional locations, if required, so that distance between any two adjacent test stations does not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like forest/deserts:

i) At all insulating joints.

ii) At both sides of metalled road crossings.

iii) At vulnerable locations with drastic changes in soil resistivity.

iv) At locations of surge diverters, pipeline grounding through polarisation cells, zinc and magnesium anodes.

v)vi) At EHV/HV AC/DC overhead line crossings and selected locations where

EHV/HV overhead line is in the vicinity of the pipeline.

vii) At railway line crossings and at selected locations along lines running parallel to the pipeline.

viii) At both sides of major river crossings.

ix) At EHVIHV cable crossings or along routes where EHV/HV cables are running in parallel.

x) In the vicinity of DC networks or grounding systems and HVDC grounding systems where interference problems are suspected.

xi) At crossings of other pipelines/structures.

xii) At the locations of reference cell, electrical resistance probe and polarization coupon installation.

xiii) At the location of computerised test stations.

xiv) At both sides of cased crossings.

xv) Locations where interference is expected.

xvi) At locations of sectionalizing valve (SV) stations.

xvii) At any other locations considered necessary by Owner/Owner’s representative





7.6.2 Test stations for bonding shall be provided with shunt and resistor as a means to monitor and control current flow between the pipeline and foreign pipelines or structures that may exist in common ROW.

7.6.3 Test stations with current measuring facility shall be provided at each CP station drainage point (to measure pipeline current on any one side of pipeline from drainage point at intermediate CP station and towards protected side of the pipeline at starting, end point CP stations), at interference prone areas, on both sides of major river crossings, near marshy areas and minimum one for every 10 km max. along the pipeline.

7.6.4 Test stations shall be installed with the face of the test station facing the pipeline. The nameplate of test stations shall carry the following minimum information:

o Chainage in km.

o Test station connection scheme

o Distance from pipeline in meter.

o Direction of product flow.

7.6.5 Number of terminals and different schemes of wiring shall be as per the test station connection scheme. Minimum twenty percent spare terminals shall be provided in each test station.

7.6.6 Minimum two cables from the pipeline shall be provided at any test station.

7.6.7 The location of all the test stations shall be marked with their connection schemes and other relevant information on alignment sheets. A detailed test-station schedule shall be prepared.

7.7 Permanent Reference Cells

7.7.1 High purity copper/copper sulphate reference cells with proven high reliability shall be provided for stable pipe to soil potential measurement at CP stations, polarization coupons and computerized test station locations along ROW.

7.7.2 Silver/Silver Chloride reference cells in place of copper/copper sulphate cells shall be provided at marshy area locations, where water table is high and chloride concentration is more than 300 ppm. For marshy area in saline soil, high purity zinc may be considered as an alternative to silver/silver chloride. The test station connection scheme shall clearly indicate the type of the reference electrode (Cu CuSO4/Ag AgC1) at these locations.

7.7.3 The life of the reference cells shall be minimum 10 years under the installed conditions.





7.7.4 The cable from reference cells shall be provided up to CP power source at CP Stations and up to test stations at the locations of polarization coupons, computerised test stations. The cable up to CP power source shall be routed through test stations near pipeline.

7.8 Electrical Resistance Probe

7.8.1 Where specified in project specification/data sheet electrical resistance probes (E/R probes) utilising the electrical resistance technique shall be provided along the pipeline at marshy areas and at vulnerable locations to monitor the external corrosion activity on the pipeline. The lead-wires of the probe shall be connected to pipeline through test station and terminated inside test station enabling periodic resistance measurement of the probe using a portable probe measuring instrument.

7.8.2 The material of the E/R probe element shall be of the same alloy as of the pipeline material. The probes shall be provided preferably at the bottom portion of pipeline.

7.8.3 The number of E/R probes, the locations of their installation and the number of portable E/R probe reading instruments shall be as specified in the project specification/data sheet.

7.9 Polarisation Cell and Surge Diverter

7.9.1 Polarisation Cell

i) Wherever the pipeline is either crossing or running in parallel with overhead EHV/HV transmission lines of voltage grade 66 kV and above, it is mandatory that the pipeline shall be grounded to discharge any accumulated potential/surge that may appear in case of transmission line faults, as per below:

o The pipeline shall be grounded through polarization cell with zinc galvanic anodes of minimum 20kg net weight each at location where pipeline crosses EHV/HV transmission lines.

o The pipeline shall be grounded at regular intervals of maximum 1.0 km where EHV/HV transmission lines run parallel within 25m of the pipeline.

ii) Locations along pipeline where continuous induced over-voltage due to other overhead transmission lines/underground cables of voltage grade below 66kV is expected or observed during commissioning, the pipeline shall be grounded through polarisation cell to the earth system of the EHV/HV tower causing the voltage induction or to a separate earthing system of zinc anodes through polarisation cell.

iii) Polarisation cell shall be installed inside test station of suitable size. iv) Type of polarization cell shall be as specified in data sheet.





7.9.2 Surge Diverter Explosion proof spark gap surge diverter shall be provided across each insulating joint to protect it from high voltage surges. surge diverters shall be suitable for installation in classified areas.

7.9.3 The total system including cables, cable termination, anodes/surge diverters, polarisation cell shall be suitable for the anticipated fault current at the location of installation.

7.9.4 The surge diverter and polarisation cell system shall be suitable for the design life of permanent CP system. The grounding system shall have minimum resistance to earth to restrict the pipeline voltage as per NACE/VDE criteria but shall not exceed 5 ohms.

7.9.5 The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.

7.10 Motor operated valves where located on the cathodically protected portion of the pipeline shall be grounded by a zinc anode of 20 kg net. Magnesium anodes grounding, if any, provided during temporary CP system shall be disconnected. The MOV power supply cable armour shall be insulated (by cutting and taping with insulation tape) at MOV end to avoid armour carrying CP current.

7.11 The above ground cathodically unprotected pipeline at terminals, intermediate SV stations, pigging stations, etc. shall be earthed with GI earth electrodes. The resistance to earth of grounding shall be limited to 5 ohms max.

7.12 Polarisation Coupons Where specified in the project specification/data sheet steel coupons of pipeline material shall be provided along the pipeline to monitor the adequacy of the CP system to polarize/protect coating holidays. Coupon shall be installed at CP station drainage points, predicted cathodic protection mid points along the pipeline, at locations where the pipeline is bonded to foreign pipeline/structures, interference prone areas, marshy areas and at other locations such that minimum one coupon is installed maximum every 10 km approximate or the maximum interval specified in the project specification/data sheet, along the pipe line.

Coupons shall be installed at bottom 1/3 portion of the pipeline and 250 mm away from the pipe surface.

The coupons shall be constructed from the pipeline material and shall have uncoated surface of 100 mm x 100 mm exposed to soil. Two cables one for connection to pipeline for protection and other for potential measurement shall be provided for each coupon. The protection cable hail be connected through a





magnetic reed switch inside the test station to enable measurement of coupon ‘OFF’ potential.

A permanent reference electrode shall be installed adjacent to the coupon in a manner so as to measure the representative potential of the coupon. Magnets for operation of reed switch shall be provided as specified in the project specification/data sheet.

7.13 Computerized Test Stations Where specified in the project specification/data sheet computerized test stations shall be provided along the ROW of the pipeline for automatically monitoring and recording the pipe to soil potential, pipe current, etc. of the pipeline, casing pipeline and foreign pipelines, etc, as required. The computer with in the test station shall measure and record these parameters regularly at programmed intervals. The computers shall have required number of input ports for measurement of potentials and current as applicable at the location of its installation. Computers shall have real time clock and record the time of data measurement. Each computer shall an identification number incorporated in its software, which shall be clearly indicated along with the data display/print out.

The computers shall be programmed to collect and store all the field parameters at intervals as specified in the project specification/data sheet.

Data-retrieval computer of portable type suitable for use in field shall be provided as specified in the project specification/data sheet for programming the field computers and retrieving the data stored by the field computers.

7.14 CP at Cased Crossing

7.14.1 At cased crossings where casing is coated, the casing shall be protected by sacrificial anode installations provided at both ends of casing. The anode installation shall be sized based on the permanent C .P. design parameters and design life of permanent CP system. At cased crossings where casing is uncoated or painted, additional protection for casing pipes may not be provided.

7.14.2 The carrier pipe inside the painted or coated casing shall be protected by zinc ribbon anodes weld connected to the outer surface of bottom of carrier pipe extending up to hour hand positions of 4 and 8 O’clock. The anodes shall be placed at close intervals as per design calculations with minimum one number of anode installed between every two supports provided between carrier and casing. The anodes shall be sized based on the permanent CP design parameters for marshy area and design life of permanent CP system.

7.14.3 Where casing is uncoated or unpainted additional protection for carrier pipe may not be provided.





7.15 Reference Cell Access Points Reference cell access points shall be provided near insulating joint locations and at SV stations, where the ground is paved, for measurement of pipe to soil potentials. A perforated PVC pipe filled with native soil and buried at the location shall be provided for the purpose. The length of the PVC pipe shall be adequate to reach the native soil below the paving.

7.16 Cables

7.16.1 Cables shall be with annealed high conductivity stranded copper conductor, PVC insulated, 650/1100 V grade, armoured, PVC sheathed conforming to IS 1554 part-I, except for the cables for anode tail, reference cells and pipeline for potential measurements. The size of the copper conductor shall be minimum 35 sq. mm. for anode and cathode cables, 6 sq. mm. for current measurement, 10 sq. mm. for anode tail cables and polarization coupon protection cables. The size of cable for bonding, polarisation cell, grounding anodes and surge diverter connections shall be suitable for the maximum fault current subject to minimum 25 sq mm.

7.16.2 The anode tail cables shall be PE insulated, 650V grade, unarmoured, PVC sheathed and length shall be sufficient for termination on anode lead junction box without any joint in between.

7.16.3 The cables for reference cells, coupon and pipeline potential measurements shall be of 4 sq. mm copper conductor, PVC insulated, Aluminium backed by mylar/polyster tape shielded, PVC sheathed, armoured, PVC over all sheathed type.

7.16.4 The CPTR unit incomer cable shall be minimum 4 sq.mm. Copper conductor, 650/1100 V grade, PVC insulated, armoured, PVC sheathed. The cable shall be of 3 core type for single phase CPTR units and of 4 core type for 3 phase CPTR units.

7.16.5 The cables for connecting various transducers from CPTR unit/CPPSM to telemetry interface junction box shall be twisted pair with individual pair shielded and overall shielded with aluminium backed by mylar/polyster tape, PVC sheathed, armoured, PVC over all sheathed type.

8.0 INSTALLATION

8.1 Cable Laying i) Cables shall be laid in accordance with layout drawings to be prepared by the

contractor. No straight through joint shall be permitted. Cable route shall be carefully measured and cables cut to required length. Minimum half metre cable





slack shall be provided near anodes, anode junction box, pipeline and test stations to account for any settling.

ii) All cables inside station/plant area shall be laid at a depth of 0.75 metre. Cables outside station/plant area shall be laid at a depth of minimum 1.5 metres. Cables shall be laid in sand under brick cover and back filled with normal soil. For cables laid outside the station/plant area, polyethylene warning mats shall be placed at a depth of 0.9 metre from the finished grade, to mark the route.

iii) In case of above ground cables, all unarmoured CP cables shall be laid in GI conduits of sufficiently large size, up to accessible height for protecting against the mechanical damage.

iv) All underground unarmoured cables including anode tail cables shall run through PE sleeves. Distant measurement cables and permanent reference cell cables routed along the pipeline shall be carried at the top of the carrier pipe by securely strapping it at intervals with adhesive tape or equivalent as required.

v) PVC pipes of proper size shall be provided for all underground cables for road crossings.

vi) Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and final take-off to equipment is facilitated.

vii) The cables for reference cells and pipeline potential measurement shall be routed in a separate trench other than the trench provided for the rest of the CP system cables, AC cables for CPTR Units etc.

viii) The armour of the cables from CP station to test station (potential measurement, reference cell & drainage cables etc.), CP station to ground bed (anode cable) and test station to pipeline shall be earthed only at CP station end and test station end respectively of the cables. The cable armour shall be insulated (by taping with insulation tape) to avoid armour carrying CP current.

8.2 Permanent Reference Cells The permanent reference cells shall be installed in natural soil conditions as per the recommendations of the cell manufacturer. Installations in highly acidic/alkaline soil and soil contaminated by hydrocarbons shall be avoided.

8.3 Cable to Pipe Connections

All cable connections of other than cathode drainage cables to the new pipeline shall be made by an approved exothermic process or by pin brazing. However, cable connection to charged pipelines shall be made by pin brazing. Exothermic welding shall be adopted for water pipelines. The resistance of the cable to pipe at the pin brazing connection point shall not exceed 0.1 ohm.





The cathode drainage cable shall be connected to a bolt welded to a metal plate, which is weld connected to the pipeline. The material of the plate shall be same as that of the material of the pipeline.

Pipe coating shall be repaired after connection of cable to pipeline. At cathode drainage point the cable joint including the bolt, metal plate and the exposed portion of the pipeline shall be covered by the coating repair material against ingress of water/moisture. The coating repair material shall be compatible with the original coating and shall prevent ingress of water along the cable surface and at the interface of coating repair with the original pipe coating.

8.4 Ground Bed Fencing Where specified in project specifications/data sheet chain link fencing shall be provided around the location of each ground bed/anode lead junction box.


9.1 System testing at site Field tests as per the reviewed field testing and commissioning procedures prepared by the Contractor, shall be carried out on the equipment/systems before these are put into service. Acceptance of the complete installation shall be contingent upon inspection and test results. Field testing shall include but not be limited to the following:

i) Contractor shall carry out pre-commissioning operations after completion of installation of the system including all pre-commissioning checks, setting of all equipment, control and protective devices. All site tests, reliability and performance tests shall be carried out by Contractor.

ii) Before the electrical facilities are put into operation, necessary tests shall be carried out to establish that all equipment and devices have been correctly installed, connected and are in good working condition as required for the intended operation. Owner/Owners representative may witness all tests. At least one week’s intimation notice shall be given before commencing the tests.

iii) All tools, equipment and instruments required for testing shall be provided by Contractor.

iv) Generally, the following minimum tests must be carried out and results shall be recorded: Visual Inspection : Comparison with drawings, specifications, detailed

physical inspection and, if necessary, by taking apart the component parts.

Testing : Simulation tests of equipment to determine its operational fitness.

a) Cables Cable No.





Voltage grade. Conductor cross section Continuity check Voltage test. Insulation resistance values between each core & earth, between cores (between core and earth for single core cable). All cables shall be tested by 500 V megger.

b) E/R Probe Location/Identification number Checking of wiring as per schematics Resistance reading of probe Installed on top/bottom/side of the pipeline

c) Reference Cell Location Type of cell Potential reading Installed on top/bottom level of pipeline

d) Insulating joint Location Pipe to soil potential of both protected and non-protected sides of the insulating joint before and after energisation of CP system.

e) Surge diverter Location/identification number. Rating Type Check for healthiness.

f) Polarisation CellLocation/Identification number RatingCheck for wiring Check standby current drain after CP system energisation. (Current drain with respect to voltage across the cell shall be recorded). Details of grounding provided for the polarisation cell.

g) Anode Ground Bed Location/Station Check for actual layout and compliance with drawings. Resistance of each individual anode. Current dissipation by each individual anode. Total resistance of complete anode bed. Mutual interference.

h) Computerised test station Location/Identification number Checking of wiring as per schematics Checking programmed interval for collection of the field data by the computer





Type of reference cell

i) Polarisation CouponsLocation Exposed area/size of couponCoupon to soil ‘ON’ and ‘OFF’ potentialsType of reference cellMagnetic reed switch rating. Operation of magnetic reed switch with magnet

9.2 CP Commissioning Procedure A model commissioning procedure for a three stations CP system of a pipeline is given below for general guidance. Contractor shall develop detailed commissioning procedure as per this guideline.

i) In completion of installation of anode beds and other systems as envisaged in this specification, they shall be individually checked, tested and compared against the agreed specifications and procedure.

ii) Electrical continuity of the entire pipeline shall be verified in conformity with design.

iii) Input resistance of the pipeline at all the drainage points shall be checked and recorded.

iv) All current measuring test stations shall be calibrated and recorded using portable battery, variable resistances, voltmeters, ammeters, etc. as required.

v) Temporary protection facilities provided (if any) which do not form part of permanent CP shall be disconnected from the system & removed unless agreed otherwise.

vi) Anodes provided for grounding at the MOVs on cathodically protected portion of the pipeline shall be disconnected. Sacrificial anode where provided for the protection of the casing pipe at cased crossings shall be disconnected.

vii) The pipeline shall be allowed to depolarize for at least 72 hours after switching ‘OFF’ the protection (if any) of all other pipelines in the common ROW.

viii) Before the pipelines are put on charge by switching ‘ON’ any of the CP stations, natural pipeline to soil, casing pipe to soil and coupon to soil potential values at all the test stations of the system (coupon to soil potential at the locations of the coupon installations) shall be measured with respect to Copper/Copper Sulphate half cell.

ix) CP station no.1 shall be energised with out put potential adjusted to achieve a maximum pipe to soil potential (PSP) as specified, at the test station nearest to the drainage point. Observations on either spread of protected portion of pipeline and coupons under this CP station shall be taken for PSP ‘ON’ and PSP ‘OFF’ values at each of the installed test stations (coupon to soil potential at the locations of the coupon installations). The typical switching cycle of current interrupter shall be 12 seconds ‘ON’ and 3 seconds ‘OFF’ .The pipeline current values across the cross section of the pipeline shall also be determined at all the intended test stations influenced by this station.





x) CP station no.1 shall now be switched ‘OFF’, CP station no. 3 shall be switched ‘ON’ and measurement procedure as detailed in clause ix) above shall be repeated.

xi) Similarly CP station no. 1 and 3 shall now be switched ‘OFF’, CP station no.2 shall be switched ‘ON’ and measurement procedure as detailed in clause ix) above shall be repeated.

xii) All the CP stations of the system shall be switched ‘OFF’ and the pipelines shall be allowed to depolarize. All the three CP stations in the system shall then be simultaneously switched ‘ON’ and PSP values at the drainage points of pipeline shall be brought to a value of maximum PSP as specified and a complete set of observations shall be taken.

Another complete set of pipe to soil and coupon to soil observations shall be taken after lines have stayed on charge for 48 hours. If there are appreciable differences in these observations as compared to those of earlier set, a third set of observations shall be taken after 72 hours. Maximum drainage point protective potentials shall not be allowed to go beyond the maximum PSP values as specified, in any case.

Coupon to soil ‘OFF’ potential shall be measured at all locations of coupon installations by operation of magnetic reed switch in the test station. The PSP of the coupons shall be within the PSP range specified in clause 6 of this document.

The output of all CP stations shall then be so adjusted that the sites of occurrence of least negative protective potentials are not less negative than (-) O.95V (OFF) and sites of occurrence of the most negative protective potential are not more negative than (-) 1. 18V (OFF). A full set of pipe to soil, coupon to soil observations shall again be taken 72 hours after the adjustment of potentials and the protection system shall be left in this state of operation.

xiii) Care shall be exercised to ensure that power supply remains uninterrupted during the period of commissioning. In case of an interruption, the test in progress shall be repeated after allowing time for polarisation. More sets of observations shall be taken in any of the steps specified above, if advised by the Owner/Owner’s representative.

xiv) The zinc anodes for grounding of MOVs at the locations of MOVs on cathodically protected portion of the pipeline shall be reconnected to the MOVs.

xv) At cased crossings where casing is protected, sacrificial anodes provided for the casing shall be connected to the casing pipe. The casing to soil potential and anode out put current shall be measured and recorded. Where casing pipe protection is inadequate or the out put current of the anode is more than the designed current, then additional anodes shall be provided as required.

xvi) PSP values at each of the test stations of the existing pipelines shall be measured, plotted, where existing pipelines run in parallel to the new pipeline, mutual





interference situations between the pipelines shall be identified and necessary mitigation measures shall be provided. Interference situations shall also be identified and mitigated by comparing different sets of readings taken at same test stations at -different intervals of time under identical conditions where positive potential swing is 100 mV or more.

xvii) Current readings at all the current measuring test stations shall be measured and recorded.

xviii) Where computerized test stations are provided the computer shall be initialized/started to collect and store the field data of potentials, current readings, etc as programmed.

xix) After one month of starting the computers to collect the field data, the data stored by the computers at all the computerized test stations shall be retrieved/down loaded using the field data-retrieving computer. The data shall be analyzed with the help of a station main computer.

xx) At the locations of the Electrical resistance probe installations the resistance readings of the probes shall be measured using probe reader.

xxi) Final records of testing and commissioning including graphical representation of final pipe to soil potential readings shall be compiled with interpretation in consultation with Owner/Owner’s representative and submitted.

xxii) If any deficiencies are found in the system, the same shall be rectified by the contractor, at no extra cost or time schedule impact, to the complete satisfaction of Owner/Owner’s representative. Such deficiencies shall include mitigation of stray current electrolysis and interference problems that may be found existing in the course of testing and commissioning. A set of PSP observations shall also be taken during the peak of the first dry season after commissioning the system into regular operation. Any deficiency found in the protection of the pipeline shall be rectified by the contractor at his own cost.

xxiii) If it is found during commissioning that the sites of occurrence of least negative or most negative protective potentials are less negative than (-) 0. 95V (OFF) or more negative than (-) 1.1 8V (OFF) respectively even after 72 hours of operation, then the drainage point potentials shall be adjusted depending upon anode ground bed currents in consultation with Owner/Owner’s representative. In any case, the protective ‘OFF’ potential values of pipeline and polarization coupons shall not exceed the PSP value range specified in Cl. 6 of this document, at any location on the pipeline.

xxiv) The reference cell shall be calibrated minimum once in 24 hours during the commissioning.





xxv) The current dissipated by individual anodes shall be measured from the anode lead junction box and corrected for equal dissipation to the extent possible keeping the total ground bed current same.


10.1 Investigations shall be made for stray current electrolysis of the pipeline, mutual interference between the pipeline and foreign pipelines/structures, interference on foreign pipelines/structures due to the CP of the pipeline and ground bed, interference on metallic structures which lie in between pipeline and ground bed or near to ground bed, AC induction on pipeline due to overhead EHV/HV lines, interference due to high voltage DC lines, HVDC earthing system, electric traction, etc.

10.2 Measurements including pipe/structure to soil potentials and pipe/structure currents etc. on the pipeline/structure being CP protected and on foreign pipelines/structures, and ground potential gradient etc. shall be made to investigate the current discharge and pickup locations. In case of fluctuating stray currents, investigations shall be made continuously over a period of time and if required simultaneously at different locations to find out the stray current source(s). Recorders shall preferably be used for long time measurements.

10.3 Wherever foreign pipelines which may or may not be protected by an independent CP system run in parallel to the protected pipeline, either in the same trench or very near to the protected pipeline and are not bonded to it, investigations shall be performed for current discharge points on both the pipelines.

10.4 Mitigation measures shall be provided depending upon the type of stray current electrolysis/interference. These shall include installation of bond with variable resistor, diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment/ relocation (if possible) of offending interference source, provision of electrical shield etc. depending on the type of interference.

10.5 Bonding with foreign pipelines/structures as a mitigation measure shall be provided where the owners of the foreign pipelines/structures have no objection. Otherwise alternative mitigation measures shall be provided. Wherever bonding is provided for mitigation, the bonding resistor shall be adjusted for optimum value for minimum/no interference. Galvanic anodes installed as a mitigation measure shall be adequately sized for the life specified for permanent CP system.

10.6 Where overhead EHV/HV transmission lines/underground electric cables cross the pipeline or run in parallel with in or more than 25m from the pipeline, A. C. Voltage measurements shall also be made on the pipeline to find out continuous induction of voltage. In case of the induced voltage being beyond the safe limits, the pipeline shall be grounded in line with clause no.7.9 above.





11.0 CLOSE INTERVAL POTENTIAL SURVEY Where specified, contractor shall carry out a close interval ‘ON’/’OFF’ potential survey over the entire length of pipeline by computerised potential logging method and identify the under protected/over protected area, any major coating damage on the pipeline, after the backfilling has been consolidated sufficiently and CP system has stabilized. Contractor shall provide required mitigation measures and rectify the under/over protected zones, identify if any, the major pipeline coating defects, required to be repaired. During the survey the reference cell shall be calibrated minimum once in 24 hours. Detailed procedures for running this survey shall be submitted for review.

Additional tests for detailed identification of coating defects shall be conducted by the contractor, if specified in the project specification/ data sheets.


SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT S-07-02-013 Page 1 of 17


SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER

RECTIFIER UNIT




Abbreviations:

CPTR units: Cathodic protection transformer rectifier units

MTBF : Mean time between failure

MTTR : Mean time to repair

PCB : Printed circuit board

MOV : Metal oxide varistor

PSP : Pipe to soil potential

CVCC : Constant Voltage and Constant Current Mode




CONTENTS

1. SCOPE


3. SITE CONDITIONS


5. TECHNICAL REQUIREMENTS

6. EQUIPMENT DESCRIPTION

7. INSPECTION, TESTING AND ACCEPTANCE





1 SCOPE This specification covers the requirements for the design, manufacture and testing of Cathodic Protection Transformer Rectifier units (CPTR units) working on controlled rectification principle intended to supply power to cathodic protection system for underground pipelines! structures.

2 CODES AND STANDARDS 2.1 The system design, performance and materials to be supplied shall conform

to the requirements of the latest revision of following standards: o IS: 1248 : Direct acting indicating analogue electrical measuring

instruments and (Parts-i, 2, 8 & 9) accessories. o IS: 3700 : Essential rating and characteristics of semiconductor

devices (Parts-i to 11) o IS: 3715 : Letter symbols for semiconductor devices (Parts-i to 4) o IS: 4411 : Code of designation of semiconductor devices. o IS: 5469 : Code of practice for the use of semiconductor junction

devices. (Parts-i to 4) o IS: 6619 : Safety code for semiconductor rectifier equipment. o IS:7204 : Stabilised power supplies DC output. (Parts-i to 4) o IS: 12021 : Control transformers for switchgear and control gear for

voltages not exceeding 1000 V AC (Parts-i to 4). o IS: 13703 : Low voltage fuses for voltages not exceeding 1000 V AC or

1500 V DC. (Parts-i to 4) o IS: 13947 : Low voltage switchgear and control gear. (Parts-4,

section-i)

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


2.4 In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern:

o Statutory regulations. o Data sheets. o Job specification. o This specification. o Codes and standards

3 SITE CONDITIONS The CPTR unit shall be suitable for installation in non air-conditioned room with restricted ventilation or in outdoor kiosk (as specified in data sheet), in locations having generally corrosive, warm, humid and dusty atmosphere.




Service conditions shall be as specified in the data sheet. If not specifically mentioned therein, a design ambient temperature of 40°C and an altitude not exceeding 1000 m above mean sea level shall be considered

4 GENERAL REQUIREMENTS

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

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


5 TECHNICAL REQUIREMENTS

5.1 Fabrication and General Details

5.1.1 CPTR unit shall be housed in sheet steel enclosure. The front, rear walls and doors shall be made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.6 mm thick sheet steel. Wherever required, suitable stiffeners shall be provided. The Unit shall be freestanding type. Hinged doors shall be provided at the front and back as required. The unit shall be natural cooled type. Louvered openings with wire mesh for natural ventilation may be provided. Degree of protection for the panel shall be minimum IP-4 1. The CPTR unit panel shall, preferably, not need rear access for operation, maintenance and shall be suitable for mounting flushed to the wall.

5.1.2 Suitable hooks shall be provided for lifting the panel. These hooks when removed shall not leave any hole in the panel or imperfection in the paint finish.

5.1.3 All instruments shall be panel mounted type and back connected. All fuses shall be provided inside the panel and shall be of link type. 660 V grade PVC insulated BIS approved wires with stranded copper conductor of size minimum 2.5 mm2 shall be used for power and auxiliary wiring. Control wiring for electronic circuits shall be through flat ribbon cable or through copper wire of minimum 0.5 mm diameter. All wirings shall be ferruled with PVC ferrules at both ends for ease of identification. Clamp type terminals suitable for termination up to 10 mm2 conductor shall be provided for all control cable connection. Suitable power terminals shall be provided for




power cables. Minimum 20% spare terminals shall be provided. The terminal blocks shall be mounted minimum 300 mm above the gland plate.

5.1.4 All live parts shall be properly shrouded. This shall ensure complete safety to personnel intending routine maintenance by opening the panel doors.

5.1.5 CPTR unit shall be suitable for bottom cable entry unless otherwise specified in the data sheet and shall be supplied complete with crimping type cable termination lugs and cable glands. Cable glands shall be of brass, nickel plated, single compression type for indoor installations and double compression type for outdoor installations. The space in the terminal chamber shall be adequate for termination of required number and sizes of cables as specified in the data sheet.

5.1.6 The input power factor of the unit at rated load shall be 0.8 lag or better.

5.1.7 The CPTR unit shall be field proven. The design, internal component layout and rating of component shall ensure high MTBF and low MTTR. Prototype equipment shall not be acceptable.

5.1.8 All the control equipment like switches, pushbuttons, potentiometers etc. shall be located at a convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.

5.1.9 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB tracks shall be tinned and solder masked. The PCB shall be coated with suitable lacquer to make it immune to dust, moisture and fungal growth. Where plug in type of PCBs are used gold plated male-female connectors shall be used for the purpose.

5.1.10 If required the panel shall be provided with space heater to prevent moisture condensation. The space heaters shall be located at the bottom of the panel and shall be provided with a manually operated switch, HRC fuse and link for phase and neutral respectively. The space heater shall have porcelain connectors. Where space heater is not provided the electronic PCBs/components and other control devices shall be made immune to moisture condensation.

5.1.11 Panel shall be provided with integral base frame channel. The integral base frame of panel shall be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack welding to purchaser’s insert plate/flat/channel embedded in the floor. Amply dimensioned oblong holes shall be provided at the bottom of the panel for its bolting to the embedded insert plate/channel.




5.1.12 An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminium shall be provided throughout the length of the panel. Provision shall be made for connecting this earth bus at two ends with the plant earth grid by means of (40x5) mm2 GI flat. All non-current carrying metallic parts of the panel and mounted equipment shall be connected to the panel earth bus. All doors and movable parts shall be connected to the earth bus by flexible copper cables.

5.1.13 All panel mounted equipments (e.g. lamps, pushbuttons, switches, meters, PCBs, etc.) shall be provided with suitable nameplates. Nameplates shall be engraved out of 3-ply (black-white- black) lamicoid sheets or anodised aluminium. Back-engraved Perspex sheet nameplates may also be acceptable. Engraving shall be done with groove cutters. Hard paper or self-adhesive plastic tape nameplates shall not be acceptable. Nameplates shall be fastened by screws and not by adhesive.

Labels shall be provided for every component on the cards, connecting wires as well as for the terminals in the terminal strip inside the panel.

5.1.14 Where specified in the data sheet the CPTR unit shall be housed in an outdoor kiosk. The kiosk shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and external surfaces. Hinged lockable doors shall be provided at the front and back. The kiosk shall be suitable for outdoor mounting and shall give proper protection to the CPTR unit against rain, other harsh weather conditions. Necessary ventilation arrangement with louvers and wire mesh shall be provided for proper operation of the CPTR unit. The cable entry to the kiosk shall be from bottom through cable glands. Suitable canopy shall be provided on the top of the Kiosk.

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

After preparation of the under surface, the panel shall be spray painted with two coats of final paint or shall be powder coated. Colour shade of final paint shall be approved by the purchaser before final painting is started. The finished panels shall be dried in stowing ovens in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off paint, etc.




All unpainted steel parts shall be suitably treated to prevent corrosion. If these parts are moving elements, then they shall be greased.

6 EQUIPMENT DESCRIPTION The CPTR unit shall be complete with following main sections:

o - Transformer and input controls. o Rectifier and filter o Output protections o System controls o Control, indication and metering

6.1 Transformer and Input Controls

6.1.1 The transformer shall be natural cooled dry type with separate primary and secondary windings. An intermediate earth screen shall be provided between primary and secondary windings. CPTR Units having multiple output circuits shall have separate secondary windings for each output circuit. Transformer shall be vacuum impregnated with epoxy varnish and baked. The safety factor for transformer rating shall be minimum 125%.

6.1.2 Single-phase transformers may be provided up to 50V, 50A DC output rating of the CPTR units. Beyond this rating, 3 phase transformers shall be provided.

A moulded case circuit breaker with thermal over load and short circuit release shall be provided at the input of the transformer. Miniature circuit breaker with thermal overload and short circuit release in place of moulded case circuit breaker may be provided, where the miniature circuit breaker rated for the incoming AC supply short circuit current indicated in the data sheet is available.

6.2 Rectifier and Filters

6.2.1 The rectifier shall be made of thyristors and diodes as basic components. The CPTR unit shall be suitable for 415 V AC, 3-ph power supply. Rectifier shall be 3 phase full wave type and controlled type. For CPTR units rated 50V, 50A DC or less, the unit may be suitable for 240V AC, 1 ph power supply and the rectifier shall be full wave type and controlled type. Alternatively, for single phase AC CPTR units, diode rectifier of full wave type in the secondary of the transformer and triac or back to back connected thyristors in the transformer primary AC supply circuit may be provided. The current and voltage ratings of thyristors, diodes shall be at least two times the actual maximum device current and minimum two times the actual maximum voltage coming across the device respectively. The thyristors! triad rectifier elements shall be protected against voltage surges coming from the incoming power supply




and from output side from the pipeline. Required shunt zeners / MOV shall be provided across the rectifier elements for protection.

The rectifier elements shall have humidity/moisture resistant finish and mounted in sufficiently sized heat sink designed to provide adequate cooling under worst conditions of operation. The rectifier elements shall have adequate protection against high dv/dt and di/dt.

6.2.2 The thyristors/triacs shall be protected by semiconductor fuses. For units rated 50V, 50A DC or less, if the thyristors or triacs are adequately over rated and system has enough inductance so that in case of sudden output short circuit the over current limit feature comes into action before short circuit current rises beyond the rating of the thyristors/triacs, then the semiconductor fuses may not be provided. This feature shall be demonstrated during testing of the unit at works.

6.2.3 Adequate filtering shall be provided on the DC output of the rectifier to limit the ripple content in the output to less than 5% at rated output.

6.2.4 The rectifier system shall be of natural air cooled type.

6.2.5 For CPTR units with multiple output circuits, each output circuit shall have independent rectifier and filter.

6.3 Output Protections Two pole moulded case circuit breaker or miniature circuit breaker (if available) rated for the DC output current, short circuit current and having thermal over load, short circuit release shall be provided in the output. A lightning arrestor rated for minimum 1OKA impulse current discharge capacity and rated voltage & maximum spark over voltage rating suitable to protect the CPTR unit components against lightning and switching surges shall be provided at the output. For CPTR units with multiple output circuits, each output circuit shall be provided with circuit breaker and lightning arrestor.

6.4 System Controls

6.4.1 The CPTR unit shall have two distinct modes of operation (independent for each output circuit) as below:

A) Constant Voltage and Constant Current Mode (CVCC) In this mode the output voltage of CPTR unit shall be continuously adjustable from O.5V DC to the rated output voltage specified on the data sheet. The set output voltage (Vos) shall remain constant irrespective of output current. Current limit feature shall be provided. The current limit (los) shall be continuously adjustable from zero to rated output current.




For constant voltage mode of operation the output current limit shall be set at maximum and output voltage setting shall be varied. Irrespective of output current demand the chosen value of the output voltage shall be maintained by the control system till the current limit is reached. After that the output current limit shall be maintained and output voltage shall decrease to keep the current constant.

For constant current mode of operation the output voltage shall be set at maximum and output current shall be varied through varying the setting of output current limit. Irrespective of output voltage requirement the control system shall maintain the output current to the set current limit value till the voltage limit is reached. After that the output voltage limit shall be maintained and output current shall decrease to keep the voltage constant.

B) Auto PSP mode In this mode of operation the output of the CPTR unit shall operate in an external closed loop with pipe to soil potential (PSP), measured by reference cell, in feed back loop. The CPTR unit control shall adjust the output voltage such that the PSP as measured by reference cell always remains equal to the set potential on the unit. The set potential (Vps) shall have high long time stability and minimum temperature drift. The set potential shall be continuously adjustable over the range specified in data sheet.

The unit shall be designed to operate with number of reference cells connected to it (to be provided by others) as specified in data sheet. In case of more than one reference cell being specified, CPTR unit shall have feature to automatically select the reference cell having less negative potential thanthe others and use the same for auto control of the unit (e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be provided in selecting the less negative potential reference cell, to avoid hunting between the reference cells at change over conditions.

In case of open circuit or short circuit of reference cell or potential being less negative than a minimum set potential (Vrs), the unit shall sense these conditions as reference cell failure and shall automatically switch over to the other healthy reference cell for control. Should fault occur in all the reference cells, the output voltage or current of the CPTR unit shall adjust automatically to a preset value (Vas/las), which shall be adjustable.

In both CVCC and auto PSP modes of operation a fast acting electronic over current limit protection shall be provided. This protection shall be fast enough to protect the active devices of the unit and fast enough to act before tripping of MCCB/MCB or blowing of fuse.




6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shall be provided in case of PSP either exceeding the specified maximum limit (Vpm) or remaining lower than the specified minimum limit (Vpn).

6.4.3 The output voltage regulation for no load to full load variation with input voltage variation from maximum to minimum shall not be more than 2.5 % of rated voltage through out the range of output voltage and over the specified ambient temperature variation as specified in data sheet, in CVCC.-constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation for no load to full load variation with input voltage variation from maximum to minimum and PSP feedback varying over the specified range shall be within 20 mV.

In CVCC- constant current mode of operation, the current regulation for minimum to maximum output voltage and minimum to maximum variation in input voltage shall not be more than 2.5% through out the range of output current.

6.4.4 The DC output of the CPTR unit shall be floating (ungrounded) in the Unit. However the CPTR Unit shall allow grounding of positive output terminal through the anode ground bed.

6.4.5 For CPTR units with multiple output circuits, each output circuit shall have independent control system.

6.5 Current Interrupter

6.5.1 If specified on the data sheet a current interrupter for CPTR Unit output current interruption shall be provided.

6.5.2 The current interrupter shall have an output contactor with current rating minimum 125% of the output current rating of the CPTR unit and a digitaltimer to operate it.

6.5.3 The timer shall have ‘ON’ and ‘OFF’ timings. When the timer is turned on the ‘ON’ timing shall start and shall close the output contactor till the end of the ‘ON’ timing. At the end of the ‘ON’ timing the ‘OFF’ timing shall start and keep the contactor open till the end of the ‘OFF’ timing. At the end of the ‘OFF’ timing the ‘ON’ timing shall start again and close the output contactor. This process of ‘ON’ and ‘OFF’ timing shall continue.

6.5.4 The ‘ON’ and ‘OFF’ timings of the timer shall be settable by separate 2 digit thumbwheel switches, each settable from 1 to 99 seconds. The timing error of the timer shall be less than 5 parts per million. In case of microprocessor based system keypad with display may be provided in place of thumbwheel switches.




6.5.5 Whenever the timer is switched on it shall always start with ON ‘timing’. A timer-reset push button shall be provided. On pressing this pushbutton during operation of the timer, the timer shall get reset and upon release of the button the timer shall restart with ‘ON’ timing.

6.5.6 The power required for operation of the timer and contactor shall be derived from the main power supply to the CPTR unit.

6.5.7 The following controls and indications shall be provided for current interrupter. The controls shall be housed in a lockable cover, so that normally they are not accessible. The indications shall be mounted on the door.

a) Controls - Timer power’ ON’ /‘OFF’ - Timer reset - Thumb wheel switch for ‘ON’ timing - Thumb wheel switch for ‘OFF’ timing

In case of microprocessor based system keypad with display may be provided in place of thumbwheel switches.

b) Indications(LED) - Timer power ‘ON’ - ‘ON’ timing - ‘OFF’ timing

6.5.8 The output contact of the current interrupter contactor shall be wired in the positive DC output of the CPTR unit. A link shall be provided for shorting these terminals whenever the current interrupter is not in use.

6.5.9 If specified in the data sheet the current interrupter shall be an independent unit of portable type. The interrupter unit shall have terminals for input power supply and terminals of the output contactor. The input power supply and the rating of the output contactor shall be as specified on the data sheet. Terminals shall be provided in the CPTR unit for taking power supply to the current interrupter.

6.5.10 Where the current interrupter is not specified with CPTR unit or is specified as portable type external to the CPTR unit, then the CPTR unit shall have provision! terminals for connection of input power supply and output contacts of external current interrupter, for current interruption test. A link shall be provided for shorting the output terminals provided in CPTR unit whenever the current interrupter is not connected.

6.5.11 For CPTR units with multiple output circuits, each output circuit shall have independent current interrupter.




6.6 Controls, Indication and Metering

6.1.1 Following controls shall be provided on CPTR unit front door. a) ON/OFF control for input through MCCB/MCB. b) ON /OFF control for output through MCCB/MCB. c) Auto/C VCC mode selector switch. d) Potentiometers for Vos, Vps and los settings. e) Selector switch for selecting indication of PSP set and PSP actual for all

the reference cells.

6.6.2 Following controls shall be provided inside the module at user accessible common location: a) Potentiometer for Vrs, Vpm, Vpn and Vas/las settings. b) Controls for current interrupter:

- Timer power ‘ON’ / ‘OFF’ - Timer reset - Thumb wheel switch for ‘ON’ timing - Thumb wheel switch for ‘OFF’ timing

6.6.3 TR unit shall have following indicating lights (lamps or min. 5 mm dia LEDs): a) CPTR unit ON/OFF b) Unit in auto/CVCC (2 lamps) c) Reference cell controlling the closed loop control of the CPTR unit

(number of lamps same as number of reference cells). d) Reference cell faulty (number of lamps same as number of reference

cells). e) Pipeline over protected. f) Pipeline under protected g) Indications for current interrupter:

- Timer power ‘ON’ - ‘ON’ timing - ‘OFF’ timing

It shall be possible to switch-off all the indication lamps by a single switch. In case of LED indication lights this facility may not be provided.

6.6.4 Following meters having minimum Cl. 1.5 accuracy shall be provided on the CPTR unit: a) Digital meter for output voltage b) Digital meter for output current c) Digital voltmeter to measure PSP set (Vps) and PSP actual for all the

reference cells. The meter shall have range from -4 V to 0 V and shall have cl.O.5 accuracy.

d) Digital meters for measuring Vrs, Vpm, Vpn and Vas/las settings. e) Meters for input voltage and current




It shall be possible to switch-off all the digital meters preferably by a single switch.

6.6.5 If specified in data sheet, CPTR unit shall incorporate provision for remote monitoring of the unit through SCADA system as below: a) Potential free contacts for the following: o All the reference cells failed. (Contact open on alarm condition) o Pipeline overprotected. (Contact open on alarm condition) o Pipeline under protected. (Contact open on alarm condition) o System in auto-mode. (Contact close in auto condition) o System in CVCC mode. (Contact close in CVCC mode)

b) 4 to 20 mA electrically isolated signal for the following: - - PSP (-4V to OV) - - CPTR unit output voltage - - CPTR unit output current

The transducers shall have electrical isolation between input and output. The isolation insulation shall withstand 2kv, 50Hz for minimum 1 minute. The accuracy class of the transducer shall be 0.5. The transducers shall be protected against input and output voltage surges. The transducer shall be suitable for driving up to 600 ohms load impedance located up to 500 m away and wired with 0.5 mm2 copper conductor cable.

6.6.6 For units having multiple outputs, each output circuit shall have independent controls, indication and metering.

7. TESTS AND ACCEPTANCE

7.1 During manufacture, the equipment shall be subjected to inspection by owner or his authorised representative to assess the progress of the work as well as to ascertain that only quality raw materials are used for the same. He shall be given all assistance to carryout the inspection.

7.2 Final acceptance test shall be carried out at manufacturer’s works under his care and expense. Instruments and equipments required for testing shall be arranged by manufacturer. Owner’s representative shall be given minimum 2 weeks prior notice for witnessing the tests. Test certificates indicating test results shall be furnished by the manufacturer. Acceptance tests shall include but not be limited to the tests listed below.

7.2.1 Visual Inspection This shall include-

o Completeness of the equipment in line with specification. o Checking of all settings. o All labels provided.




o Dimensional checking. o Proper mounting of components and neatness of wiring etc. o Model number.

7.2.2 Insulation tests The voltage specified in the table below shall be applied for one minute to the circuits indicated:

Withstand voltage Control electronics <60V

Power electronics Un1

Auxiliary circuits Un2

To earth 700V D.C. 2xUn1 + 1000V 2xUn2 + 1000VTo control electronics - 2xUn1 + 1000V 2xUn2 + 1000V To power electronics 2xUn1 + 1000V - 2xUn1 + 1000VTo auxiliary circuits 2xUn2 + 1000V 2xUn1 + 1000V -

(Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits respectively).

D.C. test voltages may be applied instead of A.C. The magnitude of D.C. test voltages to be applied shall be 2 times the above-mentioned A.C. (r.m.s) values.

Insulation resistance test shall be conducted before and after heat run test.

7.2.3 Heat run test All CPTR units shall be subjected to a heat run test performed at rated voltage for period not less than 16 hours prior to execution of functional tests.

At least one CPTR unit of each rating shall be loaded to its rated output through out 16 hour test period. All other CPTR units shall be energized under partial load or zero load current condition through out the test period.

7.2.4 Functional tests Functional tests as below shall be performed on each CPTR unit. If during execution of functional tests, any electronic component of the unit is required to be replaced e.g. due to malfunction or failure of the unit to fulfill the performance requirements of the specification, then the load test shall be repeated at rated current following which functional tests shall be carried out.

7.2.4.1 CVCC mode operation testing a. Constant voltage operation

During the test, current limit shall be set to rated output current. Performance testing shall be carried out for various output voltage settings and load varying from zero to maximum. The verification of operation of the control functions, measurement of output voltage, current, input AC voltage, current, power factor, ripple in the output,




evaluation of output voltage regulation and efficiency of the unit shall be carried out during the testing.

b. Constant current operation During the test, voltage limit shall be set to rated output voltage. Performance testing shall be carried out for various output current limit settings and load resistance varied to achieve output voltage from minimum to maximum. The verification of operation of the control functions, measurement of output voltage, current, input AC voltage, current, power factor, ripple in the output, evaluation of output current regulation of the unit shall be carried out during the testing.

7.2.4.2 Auto PSP mode operation Suitable set up shall be arranged for output loading and reference cell feed back. The closed loop performance and regulation shall be checked with the PSP set voltage varied from O.85V to 1.2V.

Disconnecting the reference cell feed back connection in the above set up shall simulate the reference cell failed condition. The output voltage/current of the unit shall go to the value set on the potentiometer Vas/las provided inside the CPTR UNIT. The settings on Vas/Jas shall be varied and the output voltage/current shall be observed.

Operation of sensors for pipeline over protection, under protection, reference cell failure and reference cell selection logic in auto PSP mode shall be verified by connecting variable external voltage sources to reference cell inputs of the CPTR unit. The number of external voltage sources shall be same as number of reference cell inputs specified for the CPTR unit.

7.2.4.3 The unit shall be checked for operation of the current limit by over loading the unit in both CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not provided for protection of the thyristors/triacs, the protection of same shall be tested as below:

A switch rated for making and carrying CPTR unit output short circuit current shall be connected to the output terminals of the unit. The output voltage and the output current limit settings of the unit shall be set to the maximum rated values. The switch connected in the output shall be shorted quickly.

The unit shall go to current limit mode and shall not damage any active component of the unit.




7.2.4.4 The current interrupter shall be tested for time interval settings and specified operation.

8 PACKING AND DESPATCHThe equipment shall be properly packed for selected mode of transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent damage to finish. Crates shall have skid bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’ etc., shall be clearly marked on the package together with Tag nos., P.O. Nos. etc.

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


SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS S-07-02-014 Page 1 of 9


SPECIFICATION FOR FLAMEPROOF LIGHTING AND POWER PANELS




ABBREVIATIONS:

GI Galvanised Iron

MCB Miniature Circuit Breaker

ELCB Earth Leakage Circuit Breaker

PVC Poly Vinyl Chloride

FRP Fibre Reinforced Plastic

CIMFR Central Institute of Mines and Fuel Research (formerly CMRI)

CCE Chief Controller of Explosives

FM Factory Mutual Research Corporation

IEC International Electrotechnical Commission

LCIE Laboratoire Central des Industries Electriques

PESO Petroleum and Explosives Safety Organization

UL Underwriters Laboratory




CONTENTS

1.0 SCOPE



4.0 SITE CONDITIONS

5.0 POWER SUPPLY

6.0 CERTIFICATION







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

2.0 CODES AND STANDARDS 2.1 The equipment shall comply with the requirements of latest revision of the

following standards issued by BIS (Bureau of Indian Standards), unless otherwise specified: IS-5 Colours for ready mixed paints and enamels. IS-1248 (Parts 1 & 2) Direct acting indicating analogue measuring

instruments and their accessories. IS-2 148 : Flameproof enclosures for electrical apparatus. IS-5571 : Guide for selection of electrical equipment for hazardous

areas. IS-8828 : Specifications for Circuit breakers for Over current

protection for household and similar installations IS-12640 : Residual current operated circuit breakers. IS-13346 : General requirements for electrical apparatus for

explosive gas atmosphere. IS- 13408 (Part-1) : Code of practice for the selection, installation and

maintenance of electrical apparatus for use in potentially explosive atmospheres (other than mining applications or explosives processing and manufacture).

IS-13947 (Parts 1 & 5) L.V. Switchgear and Controlgear.

2.2 Imported equipment shall conform to the international standards such as IEC / BS / VDE / NEMA or equivalent.

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

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

2.5 In case of any contradiction between various referred standards! specifications! data sheet and statutory regulations, the following order of decreasing priority shall govern: Statutory regulations

Data sheets

Job specification

This specification

Codes and standards.






4.0 SITE CONDITIONS The equipment shall be suitable for installation and satisfactory operation in classified hazardous locations in tropical, humid and corrosive atmosphere as prevalent in refineries, petrochemical and fertilizer plants. The lighting and power panels shall be designed to operate under site conditions as specified in the data sheet. If not specifically mentioned therein, a design ambient temperature of 400 C and an altitude not exceeding 1 000m above mean sea level shall be considered.

5.0 POWER SUPPLY 5.1 Unless otherwise specified, lighting and power panels shall be suitable for

415V, 50Hz, three phase and neutral (TPN) incoming supply and outgoing circuits for 240V, single phase and neutral (SPN).

5.2 For projects falling under the jurisdiction of DGMS, the following additional requirements shall apply:

5.2.1 The phase-to-phase voltage shall not exceed 125 volts (where electric lighting is used in underground mine)! 250 volts (where electric lighting is used in open cast mine or surface of a mine), with the neutral or the mid-point of the lighting system connected with earth.

5.2.2 The panels shall have three phase, 3-wire system, without neutral.

5.2.3 Outgoing circuits shall be controlled by 2-pole MCBs. Earth leakage protection shall be provided for all outgoing circuits, which shall isolate both poles.

6.0 CERTIFICATION The equipment shall have test certificates issued by recognised independent test house (CIMFR / CPRI / ERTL / BASEEFA / LCIE / UL / FM or equivalent). All indigenous equipment shall conform to Indian standards and shall be certified by Indian testing agencies. All equipment (indigenous & imported) shall also have valid statutory approvals as applicable for the specified location. All indigenous flameproof equipment shall have valid BIS license and marking as required by statutory authorities.


7.1 Construction

7.1.1 The enclosures of the lighting and power panels shall be made of cast light metal alloy and shall be free from frictional sparking hazard. The magnesium




content in the alloy shall be as per IS-13 346. The temperature of external surfaces shall be limited to 200°C, unless otherwise specified. The enclosures shall be sized to facilitate easy maintenance and heat dissipation.

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

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

7.1.4 The enclosures shall be treated and prepared for painting with two coats of epoxy paint with final colour shade (both internal and external) as below: Flame proof (Gas group IIA/IIB) Dark admiralty grey shade 632 of IS-S Flame proof (Gas group IIC) Light yellow shade 355 of IS-S

7.1.5 A warning inscription “Isolate power supply elsewhere before opening” shall be provided on each enclosure. The warning inscription shall be embossed on the enclosure or a separate warning plate with above inscription shall be fixed to the enclosure with screws. The warning plate shall be of nickel plated brass or stainless steel.

7.1.6 All accessories like nuts, bolts, washers etc. shall be made of stainless steel SS-304.

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

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

Conductor Size

Up to 2.5

mm2

Above 2.5 mm2 & Up to

10 mm2

Above 10mm2

Upto35 mm2

Above 35 mm2 & Upto70

mm2

Gland to terminal distance

40 mm 60 mm 100 mm 150 mm




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

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

7.1.11 A nameplate indicating TAG NO. shall be provided on each panel. Nameplates shall also be provided for each incoming and outgoing feeder. Separate nameplate shall also be provided to indicate the details of testing agency (CIMFR or equivalent), test certificate no. with date, statutory approval no. with date and agency (PESO / CCE / DGFASLI / DGMS), BIS license number and date, applicable gas group etc. The nameplates shall be engraved on 3 ply black white black lamicold sheets using square cutters. Black engraved perspex sheet nameplate shall also be acceptable. Nameplates shall be fixed by screws and shall not be pasted. In case the standard details given above are embossed on the enclosures, the same need not be repeated on the name plate.

7.2 Component Specification

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

7.2.2 Unless otherwise specified, the incomer shall have one no. 4 pole 40A MCB isolator (without overload and short-circuit release) and one no. 4 pole ELCB. ELCBs shall have a maximum sensitivity of 3OmA.

7.2.3 Unless otherwise specified, the outgoing feeders shall be provided with double pole 1OA MCBs having overload and short-circuit releases.

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

7.2.5 The ELCB shall be hand reset type. One no. door mounted reset push button shall be provided.

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




7.3 Terminals & Wiring

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

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

Incomer : 16 mm2 Outgoing : 2.5 mm2


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

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

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

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

8.4.1 General visual inspection 8.4.2 Dimensional inspection 8.4.3 Verification of mechanical and electrical operations 8.4.4 Dielectric tests 8.4.5 Routine pressure test as per IS-2 148 8.4.6 Any other routine and acceptance test as per applicable standards.

8.5 Type tests shall be carried out if specified in data sheet! job specification.




9.0 PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for the selected mode of transportation, i.e. by ship! rail or trailer and shall be wrapped in polythene sheets before being placed in crates! cases to prevent damage to finish. The crates! cases shall have skid bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’, ‘Owner’s particulars’, ‘P0 no.’ etc., shall be clearly marked on the packages together with other details as per purchase order.

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

SPECIFICATION REV-0 GAIL (INDIA) LTD

NEW DELHI

SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES S-07-02-015 Page 1 of 11


SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES &

ACCESSORIES


NEW DELHI



Abbreviations:

ASTM: American Society for Testing and Materials

BIS: Bureau of Indian Standards

IEC: International Electrotechnical Commission

IS: Indian Standards

NEMA National Electrical Manufacturers Association


XLPE Crosslinked Polyethylene

HR PVC Heat Resistant Polyvinyl Chloride

FR Flame Retardant


NEW DELHI



CONTENTS

1. SCOPE

2. STANDARDS

3. GENERAL CONSTRUCTION

4. CABLES ACCESSORIES




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1. SCOPE This specification along with data sheets covers requirements for design, manufacture, testing at works and supply of Flame Retardant PVC/XLPE cables and cable jointing I terminating accessories for medium and high voltage systems.

2. STANDARDS 2.1 The cables and cables jointing & terminating accessories shall comply with

the latest edition of the following standards as applicable:

IS: 1554 PVC insulated (heavy duty) electric cables

IS: 7098 Cross-linked polyethylene insulated PVC sheathed

IS: 8130 Conductors for insulated electric cables and flexible cords

IS: 5831 PVC insulation and sheath of electric cables

IS: 3975 Mild steel wires, strips and tapes for armouring of cables

IS 108 10(Part 41) Methods of test for cables: Mass of zinc coating on steel armour.

IS: 209 Specification for zinc

IS: 3961(Part 2) Recommended current ratings for cables: Part - 2 PVC Insulated and PVC sheathed heavy-duty cables.

IS: 10418 Drums for electric cables

IS: 10462 (Pt-I)Fictitious calculation method for determination of Dimensions of protective coverings of cables: Part - I Electrometric and thermoplastic insulated cables.

IS: 10810 (Pt -58) Oxygen Index test

IS: 10810 (Pt 61) Flame Retardant test

IS: 10810 (Pt 62) Fire resistance test for bunched cables

IS: 13573Joints and terminations for polymeric cables for working Voltages from 6.6 KV up to and including 33 KV.

IEC: 60332-3 Tests on electric cables under fire conditions

IEC: 60502Extruded solid dielectric insulated power cables for rated Voltages from 1 kV.upto30kV.

IEC 60540 & 60540A

Test methods for insulation and sheaths of electric Cables

ASTM: D2863Standard method of test for flammability of plastics using oxygen index method.

ICEA S-61-402NEMA-WC5

Thermoplastic insulated wire and cable for transmission and distribution of electrical energy

ICEA S-66-524 NEMA-WC7

Cross-linked thermosetting polyethylene insulated wire and cable for transmission and distribution of electrical energy


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2.2 The cables and accessories shall also conform to the provisions of Indian Electricity Rules and other statutory regulations, as applicable.

2.3 In case of any contradiction between various referred standard/ specification/data sheet and statutory regulations, the following order of priority shall govern:

o Statutory Regulations o Data Sheets o Job Specifications o This Specification o Codes and Standards

3 GENERAL CONSTRUCTION

3.1 The cables shall be suitable for laying in trays, trenches, ducts, and conduits and for underground-buried installation with uncontrolled backfill and possibility of flooding by water and chemicals.

3.2 Outer sheath of all PVC and XLPE cables shall be black in colour and the minimum value of oxygen index shall be 29 at 27 ± 2 C. In addition suitable chemicals shall be added into the PVC compound of the outer sheath to protect the cable against rodent and termite attack.

3.3 All cables covered in this specification shall be flame retardant (FR) unless specified otherwise in the data sheet. The outer sheath of PVC and XLPE cables shall possess flame propagation properties meeting requirements as per IS-l0810 (Part-62) category AF.

3.4 Sequential marking of the length of the cable in metres shall be provided on the outer sheath at every one metre. The embossing /engraving shall be legible and indelible.

3.5 The overall diameter of the cables shall be strictly as per the values declared by the manufacturer in the technical information subject to a maximum tolerance of ±2 mm up to overall diameter of 60mm and ±3mm for beyond 60mm.

3.6 PVC / Rubber end caps shall be supplied free of cost for each drum with a minimum of eight per thousand metre length. In addition, ends of the cables shall be properly sealed with caps to avoid ingress of water during transportation and storage.

3.7 The cables used in installations under the jurisdiction of Director General of Mines and Safety (DGMS) shall be of copper conductor only, and shall have valid DGMS approvals for the specified locations. The word” Mining Cable”


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shall be embossed /engraved on the cable outer sheath as per the applicable Indian Standards

3.8 PVC cables

3.8.1 All power/control cables for use on medium voltage systems shall be heavy-duty type, 650/1100 V grade with aluminium / copper conductor, PVC insulated, inner-sheathed, armoured and overall PVC sheathed unless specified otherwise in data sheet

3.8.2 The conductors shall be solid for conductor of nominal area up to and including 6mm2 and stranded beyond 6mm2. Conductors of nominal area less than 16 mm2 shall be circular only. Conductors of nominal area 16 mm2 and above may be circular or shaped as per IS 8130. Cables with reduced neutral conductor shall have sizes as per Table I of IS 1554 (Part-I).

3.8.3 The core insulation shall be with PVC compound applied over the conductor by extrusion and shall conform to the requirements of type ‘A’ compound as per IS: 5831. The thickness of insulation and the tolerance on thickness of insulation shall be as per Table 2 of IS: 1554 (Part-l). Control cables having 6 cores and above shall be identified with prominent and indelible Arabic numerals on the outer surface of the insulation. Colour of the numbers shall contrast with the colour of insulation with a spacing of maximum 50 mm between two consecutive numbers. Colour coding for cables up to 5 cores shall be as per Indian standard.

3.8.4 The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC conforming to the requirements of Type ST-I PVC compound as per IS: 5831. The minimum thickness of inner sheath shall be as per IS: 1554 (Part-I). Single core cables shall have no inner sheath.

3.8.5 If armouring is specified for multicore cables in the data sheet, the same shall be by single round galvanised steel wires where the calculated diameter below armouring does not exceed 13 mm and by galvanised steel strips where this dimension is greater than 13 mm. Requirement and methods of tests for armour material and uniformity of galvanisation shall be as per IS -3975 and IS -10810 (Part 41). The dimensions of Armour shall be as per method (b) of IS - 1554 (Part -1). If armouring is specified for single core cables in the data sheet, the same shall be with 114 grade hard drawn aluminium round wire of 2.5 mm diameter. For mining cables, the size and type of armour shall be such that the combined conductance of armour shall be equivalent to 75 percent of the conductance of the largest conductor of the cable.

3.8.6 The outer sheath for the cables shall be applied by extrusion and shall be of PVC compound conforming to the requirements of type ST-I compound as per IS: 5831. The minimum and average thickness of outer sheath for


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unarmoured cables and minimum thickness of outer sheath for armoured cables shall be as per IS: 1554 (Part -1).

3.8.7 If heat resisting PVC cables are specified in the data sheet, the following shall be the requirements: It shall be possible to continuously operate the cable at a maximum conductor temperature of 85oC. PVC compounds used for HR PVC cables shall be as follows:

a. Conductor insulation -Type C b. Inner sheath -Type ST 2 c. Outer sheath -Type ST 2

3.9 XLPE Cables

3.9.1 Power cables for 3.3 KV up to and including 33 KV systems shall be Aluminium! copper conductor, XLPE insulated, sheathed, armoured and overall PVC sheathed.

3.9.2 The conductors shall be stranded and compacted circular for all cables.

3.9.3 All cables rated 3.8 ! 6.6 kV and above shall be provided with both conductor screening and insulation screening. The conductors shall be provided with non-metallic extruded semi conducting screen.

3.9.4 The core insulation shall be with cross linked polyethylene insulating compound dry cured, applied by extrusion. It shall be free from voids and shall withstand all mechanical and thermal stresses under steady state and transient operating conditions. It shall conform to the properties given in Table-I of IS: 7098 (Part -2).

3.9.5 The insulation screen shall consist of non-metallic extruded semi-conducting compound in combination with a non-magnetic metallic copper screen. Unless specified otherwise, the copper screen for all the three cores together shall be capable of carrying the single line to ground fault current value and the duration specified in the data sheet.

3.9.6 The conductor screen, XLPE insulation and insulation screen shall all be extruded in one operation by ‘Triple Extrusion’ process to ensure perfect bonding between the layers. The core identification shall be by coloured strips or by printed numerals.

3.9.7 The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the requirements of type ST 2 compound of IS: 5831. The extruded inner sheath shall be of uniform thickness. In case of single core cables, there shall be extruded inner sheath between insulation metallic screen and armouring.


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3.9.8 For multicore cables, the armouring shall be by galvanized steel strips as per method (b) of IS- 7098 (Part-2). If armouring is specified for single core cables in the data sheet, the same shall be with H4 grade hard drawn aluminium round wire of 2.5 mm diameter.

3.9.9 The outer sheath of the cables shall be applied by extrusion over the armouring and shall be of PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831. The minimum and average thickness of outer sheath for unarmoured cables and minimum thickness of outer sheath for armoured cables shall be as per 15: 7098 (Part-2)

3.9.10 The thickness of the insulation, inner sheath shall be governed by values given in IS: 7098 Part -2

3.9.11 Where specified, 1100 V grade power cables shall also be XLPE insulated and shall meet the requirement specified in IS-7098 (Part-1).

4 CABLE ACCESSORIES

4.1 The termination and straight through jointing kits for use on the systems shall be suitable for the type of cables offered as per this specification.

4.2 The accessories shall be supplied in kit form. Each component of the kit shall carry the manufacturer’s mark of origin.

4.3 The kit shall include all stress grading, insulating and sealing materials apart from conductor fittings and consumable items .An installation instruction sheet shall also be included in each kit.

4.4 The contents of the accessories kit including all consumable shall be suitable for storage without deterioration at a temperature of 45°C, with shelf life extending to more than 5 years.

4.5 Terminating Kits The terminating kits shall be suitable for termination of the cables to an indoor switchgear or to a weatherproof cable box of an outdoor mounted transformer I motor. For outdoor terminations, weather shields / sealing ends and any other accessories required shall also form part of the kit. The terminating kits shall be from one of the makes / types mentioned in the data sheet.

4.6 Jointing Kits The straight through jointing kits shall be suitable for installation on overhead trays, concrete lined trenches, and ducts and for underground burial with uncontrolled backfill and possibility of flooding by water and chemicals. These


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shall have protection against any mechanical damage and suitably designed to be protected against rodent and termite attack. The inner sheath similar to that provided for cables shall be provided as part of straight through joint. The jointing kits shall be from one of the makes / types mentioned in the data sheet.

The cables shall be tested and inspected at the manufacturer’s works. All the materials employed in the manufacture of the cable shall be subjected, both before and after manufacture, to examination, testing and approval by GAIL I owner. Manufacturer shall furnish all necessary information concerning the supply to GAIL I owner’s inspectors. The inspector shall have free access to the manufacturer’s works for the purpose of inspecting the process of manufacture in all its stages and he will have the power to reject any material, which appears to him to be of unsuitable description or of unsatisfactory quality. The vendor shall give at least 2 weeks advance notice to the purchaser, regarding the date of testing to enable him or his representative to witness the tests.

5.1 Cables

5.1.1 After completion of manufacture of cables and prior to despatch, the cables shall be subjected to type, routine, acceptance and special tests as detailed below. GAIL/ Owner reserves the right to witness all tests with sufficient advance notice from vendor. The test reports for all cables shall be got approved from the Engineer before despatch of the cables.

5.1.2 All routine tests, acceptance tests, type tests and additional type tests for improved fire performance shall be carried out as listed in IS: 1554 (Part-I), and IS: 7098 (Part-2) on PVC and XLPE insulated cables respectively.

5.1.3 The test requirements for PVC insulation and sheath of cables shall be as per latest revision of IS: 5831.

5.1.4 Test for Resistance to Ultra Violet Radiation: This test shall be carried out as per DIN 53387 or ASTM-G-53 on outer sheath. The retention value of tensile strength and ultimate elongation after the test shall be minimum 60 % of tensile strength and ultimate elongation before the test. Test certificates with respect to this test (not older than one year) from recognised testing laboratory to be furnished for review by GAIL before despatch clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognised test laboratory or in house testing laboratory, before despatch clearance of cables. Sampling for this test is to be done randomly once for each order, provided outer• sheath remains same.


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5.1.5 Acceptance tests as per IS-1554 (Part-I) and IS-7098 (Part-2) and the following special tests to be performed on the cables as per sampling plan. These tests are required to be witnessed by GAIL before despatch of cables.

a. Accelerated water absorption test for insulation as per NEMA - WC - 5. (For PVC insulated cables) and as per NEMA WC - 7 (for XLPE insulated cables). Test certificates with respect to. this test (not older than one year) from recognised testing laboratory to be furnished for review by GAIL before despatch clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in house testing laboratory, before despatch clearance of cables. Sampling for this test is to be done randomly once for each order, provided type of insulation remains same.

b. Dielectric Retention Test: The dielectric strength of the cable insulation tested in accordance with NEMA WC - 5 at 75 ± 10 C shall not be less than 50 % of the original dielectric strength. (For PVC insulated cables). Test certificates with respect to this test (not older than one year) from recognised testing laboratory to be furnished for review by GAIL before despatch clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in house testing laboratory, before despatch clearance of cables. Sampling for this test is to be done randomly and once for each order.

c. Oxygen Index Test: The test shall be carried out as per ASTM D2863 or applicable Indian Standard specifications. Sampling to be done for every offered lot/size as per sampling plan.

d. Flammability Test: The test shall be carried out on finished cable as per IS - 10810 (part 61 & 62). Sampling for these tests is to be done randomly once for each order, provided outer sheath remains same. The acceptance criteria for tests conducted shall be as under: Part-61-The cable meets the requirement if there is no visible damage on the test specimen within 300 mm from its upper end Part-62-The maximum extent of the charred portion measured on the test sample should not have reached a height exceeding 2.5 m above the bottom edge of the burner at the front of the ladder.

e. Test for rodent and termite repulsion property: The vendors shall furnish the test details to analyse the property by chemical method. Sampling to be done for every offered lot / size as per sampling plan.

5.2 Cable Accessories Type tests should have been carried out to prove the general qualities and design of a given type of termination / jointing system as per IS-13573. The type test certificates from independent testing laboratory shall be submitted before despatch.


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6 PACKING AND DESPATCH

6.1 Cables shall be despatched in non-returnable wooden or steel drums of suitable barrel diameter, securely battened, with the take-off end fully protected against mechanical damage. The wood used for construction of the drum shall be properly seasoned, sound and free from defects. Wood preservatives shall be applied to the entire drum. Ferrous parts used shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit or storage.

6.2 On the flange of the drum, necessary information such as project title, manufacturer’s name, type size, voltage grade of cable, length of cable in metres, drum no., cable code, BIS certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum with suitable instructions to show the direction of rotation of the drum.

6.3 Unless otherwise specified, Cables shall be supplied in drum lengths as follows:

MV Cables Multicore Power cables up to 6 mm2 : 1000 m Multicore Power cables from 10mm2 up to 300 mm2 : 500 m Single Core Power cables up to 630 mm2 1000 m Control cables up to 61 cores : 1000 m

HV power cables - Up to 11 kV(E) Grade Three Core cables up to 400 mm2 : 500 m Single Core cables up to 400 mm2 : 1000 m Single Core cables above 400 mm2 and up to 630 mm2 : 750 m

HV power cables - Above 11 kV(E) Grade and up to 33kV(E) Grade Three Core cables up to 300 mm2 grade : 350 m Single Core cables up to 400 mm2 : 1000 m Single Core cables above 400 mm2 and up to 1000 mm2 : 500 m

A tolerance of plus or minus 3 % shall be permissible for each drum. However overall tolerance on each size of cable shall be limited to ± 2%. Offers with short / non-standard lengths are liable for rejection. If non-standard drum lengths are specified in the data sheet, the same shall be supplied.


SPECIFICATION FOR NICKEL CADMIUM BATTERIES S-07-02-016 Page 1 of 7


SPECIFICATION FOR STATIONARY NICKEL CADMIUM BATTERIES




Abbreviations:


Ah Ampere-hour

BS British Standard

DC Direct current

IEC International Electrotechnical Commission

IEEE Institute of Electrical & Electronics Engineers

IS Indian Standard

MSL Mean Sea Level


P0 Purchase Order


UPS Uninterrupted Power Supply

VDE Verband der Elektrotechnik, Elektronik und Information technique

V Volt




CONTENTS

1.0 SCOPE



4.0 SITE CONDITIONS


6.0 PERFORMANCE






1. SCOPEThe intent of this specification is to define the design, Manufacture and testing requirements of stationary Nickel Cadmium batteries for DC power system /AC UPS application.


2.1 The equipment shall comply with the requirements of the latest revision of the following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified. IS-10918 Specification for Vented type Nickel Cadmium batteries

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


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

2.5 In case of any contradiction between various referred standards/specifications/data sheets and statutory regulations, the following order of priority shall govern: Statutory regulations. Data sheets. Job specification. This specification. Codes and standards.


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.


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




4 SITE CONDITIONS Stationary Nickel Cadmium battery shall be suitable for operating satisfactorily in humid and corrosive atmosphere found in refineries, petrochemical and gas processing plants, metallurgical plants and other industrial plants. Service conditions shall be as specified in the data sheets/job specification. If not specifically mentioned therein, a design ambient temperature of 40°C and an altitude not exceeding l000m above MSL shall be considered, with a minimum temperature of 10°C for battery sizing.


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

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

5.3 Ampere hour of the battery shall be selected based on the following: a. Minimum site ambient temperature of 10°C or as defined in the

data sheet b. Discharge duty cycle c. End cell voltage d. Ageing factor of 0.8 e. Design margin of 10%, if not defined in the data sheet f. Capacity rating factor

5.4 Number of cells and end cell voltage shall be decided by the vendor on the basis of maximum permissible voltage to the load when batteries are float charged while feeding the load and minimum DC system voltage. However the number of cells and end cell voltage shall be as per the data sheet, unless other wise specified.

5.5 The battery shall be suitable for being boost charged to fully charged condition from fully discharged condition within 10 hours, unless other wise specified.

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




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

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

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

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

5.11 The following information shall be permanently marked on the cell. Nominal voltage Name of manufacturer/model reference Rated capacity in ampere hours (Ah) with End Cell Voltage Voltage for float operation at 27°C with tolerance of ±1 % Month and year of manufacture Polarity Marking

5.12 Each set of battery shall be supplied with all the accessories, including, but not limited to the following: a. Battery stand in formation as per data sheet. Mild steel stand

pretreated and epoxy painted /PVC coated. b. Inter cell, inter row and inter bank connectors and end take offs.

These shall be of tin plated copper/flexible insulated copper cable. c. Stand insulator. d. Cell number plates, Lugs for cable termination, as required. e. Other accessories and their quantity as per data sheet.

6 PERFORMANCE Nickel Cadmium batteries shall have been type tested to meet the performance requirements for each design and Ah rating of cells as per Indian Standard IS-10918.

7 INSPECTION, TESTING AND ACCEPTANCE Batteries shall be subject to inspection by GAIL/owner or by an agency authorised by the owner, to assess the progress of work. The manufacturer shall furnish all the necessary information concerning the supply to GAIL/owner’ s representative. GAIL/owner’ s representative shall be given free access in the works from time to time for stage wise inspection and progress reporting. Four




weeks advance notice shall be given to witness the final routine tests and other tests as agreed upon.

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

A) Routine test i) Physical examination test. ii) Polarity and absence of short circuit. iii) Dimension, mass and layout. iv) Marking and packing.

B) Acceptance test i) Marking and packing. ii) Verification of dimensions. iii) Test for Ah capacity. iv) Test for voltage during discharge. v) Internal resistance test.

C) Type test i) Verification of constructional requirement. ii) Test for voltage during discharge. iii) Test for Ah capacity. iv) Test for charge retention/loss of capacity if

specified in the data sheet. v) Air pressure test. vi) Ampere hour and Watt-hour efficiency test.

Battery duty cycle test to meet the load cycle requirement shall also be performed at site after installation as part of commissioning unless otherwise defined in the data sheet.

8 PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases to prevent damage to finish. Crates/cases shall have skid bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Centre of gravity’, ‘Weight’, ‘Owner’s particulars’, ‘P0 nos.’ etc., shall be clearly marked on the package together with other details as per purchase order.

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


SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY S-07-02-018 Page 1 of 25


SPECIFICATION FOR

UNINTERRUPTED POWER SUPPLY

UNIT




CONTENTS

1 SCOPE


3 GENERAL REQUIREMENIS

4 SITE CONDITIONS


6 INSPECTION. TESTING AND ACCEPTANCE

7 SITE ACCEPTANCE TESTS

8 PACK[NG AND DESPATCH




1 SCOPE The scope of this specification is to define the requirements of design, manufacture, testing, packing and despatch of static Uninterrupted Power Supply (UPS) system.


2.1 The equipment shall comply with the requirements of latest revision of thefollowing standards issued by BIS (Bureau of Indian standards I unless other wise specified: IS. 5 IS: 1248 15:2147IS 3700 (Part I to 11)IS: 3715 (Part I to 4 IS:4411IS: 5001 (Part I & 2)IS:54b9 (Part 1 to 3)IS 7204 (Part I to 4) IS: 12021 IS: 133 14 IS. 13703 (Part Ito 4)IS: 13947 (Part-4/ Sec-I)


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

2.4 In case Indian standards are not aailab1e for any equipment. standards issued by IEC./ BS / VDE/IFEE/NEMA or equivalent agency shall he applicable.

2.5 In case of any contradiction between various referredstandards/specifications’ data sheet and statutory regulations. the following order of priority shall govern:

o Statutory regulations o Data sheets o Job specification o This specification o Codes and standards





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

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

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

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

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

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

3.7 The design of the UPS shall he such as to minimise the risk of short circuits and shall ensure human and operational safety

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

3.9 The UPS shall he single phase or three phase system as indicated in the data sheets.




3.10 The batteries shall meet the requirement of battery Data Sheet! battery specifications attached with the hid document

4 SITE CONDITIONSThe U PS system shall be suitable for installation and satisfactory operation in a closed substation with restricted natural air ventilation in tropical. humid and corrosive atmosphere. The UPS system shall he designed to operate under site conditions as specified in the data sheet. If not specifically mentioned therein, design ambient temperature of 40C and altitude not exceeding 100CM above MSL shall he considered for the UPS


5.1 Input power supply 5.1.1 The UPS shall he suitable for input power supply as defined in the data sheet.

If not specified therein the UPS shall he suitable for the following input power supply.

Voltage 230/415V ± 10% Frequency : 50 Hz ± 5%

In addition to above variations, the input voltage may be subject to transient variations comprising voltage dip to 20% of normal voltage during motor start-up and voltage interruption during short circuit as well as frequency variations due to large motor start up. UPS system shall be designed to operate satisfactorily while deriving the input power from an emergency diesel generator set

UPS system shall also operate satisfactorily on input power supply having. o the ratio of negative to the positive sequence components not

exceeding 5% and o total harmonic distortion of not more than 5%.

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

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

5.2 UPS Configuration and Operational requirements The UPS system shall have one of the following basic configurations as specified in data sheet and drawings:

5.2.1 Single UPS with Bypass (Refer Sketch 1) In UPS system having this configuration a single rectifier and inverter shall be provided. Under normal conditions when AC mains power is available, the




rectifier shall simultaneously feed power to inverter as well as for float/rapid charging of the battery The AC supply to loads shall he fed from inverter output. in case of any fault in the inverter, the load shall he automatically transferred to stabilized bypass supply and retransfer of load from stabilized bypass supply to the inverter shall be possible in auto as well as in manual mode.

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

5.2.2 Parallel Redundant UPS with bypass (Refer Sketch 2) In UPS system having this configuration two sets of rectifiers and inverters shall he provided. Under normal conditions, when AC mains power is available, both the rectifiers shall operate in parallel and supply DC power for float/rapid charging the battery and simultaneously to inverters. In case of failure in one rectifier, the other rectifier shall feed the complete load and the battery without any interruption. In case of incoming supply failure or failure of both rectifiers the battery shall feed the inverters without any interruption. Each rectifier shall he designed for simultaneously feeding complete inverter load and float/rapid charging of the battery to its rated capacity. Each rectifier shall be equipped with On Line automatic as well as manual charging facility.

Normally both inverters will he synchronised with each other and with stabilized bypass supply. Both inverters shall operate in parallel and share the load equally When a disturbance/fault occurs in any one of the inverters, the faulty unit shall automatically get disconnected and the entire load shall be fed from the other inverter. In case both the inverters develop a fault, the complete load shall he transferred to stabilized bypass supply through the static switches and retransfer of load from stabilized bypass supply to the Inverter shall be possible in auto as well as in manual mode.

5.2.3 Hot stand-by Redundant UPS with bypass In UPS s stem having this configuration, the arrangement of rectifiers/inverters and the operating philosophy is same as described in Cl.5.2.2 above, except that only one inverter shall be operating at one time The other inverter shall not be sharing the load but shall be synchronised with the running inverter and stabilized bypass supply and remain ready to accept the load in case of fault in the running inverter. Retransfer of load from stabilized bypass supply to the inverter shall he possible in auto as well as in manual mode.




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

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

5.3 UPS Design and Performance Requirements

5.3.1 Incoming AC supply shall he converted to DC through three phase full wave controlled rectifiers 1 he rectifiers shall operate according to the constant voltage current limiting principle and shall incorporate a “Soft Start” feature to gradually accept load on initial energising.

5.3.2 The rectifier section of the UPS system shall be capable of precise regulation to prevent damage to the battery. The output voltage of rectifier’s DC bus without the battery shall be stabilised to within ± 1% of set value during load variation between 0 to l00 of the rectifiers and specified mains input supply voltage variation.

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

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

5.3.5 An RFI filter shall be provided. The production of radio frequency interference voltage shall not exceed the value of suppression grade N as defined in VDE-0875. The performance of UPS system shall not get affected or in any way be degraded by the use of portable radio transmitter receiver in the vicinity of the UPS system and or UPS room.

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

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




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

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

5.3.10 For battery sizing, the following factors shall he considered unless specified otherwise in the data sheet;

a. Load Power Factor of 0.8 b. Minimum ambient temperature as specified in Data

sheet.

c.cellsofNovoltagecellendRatedefficiencyInverter

fploadRatedkVAratedInverterrentBatteryCur

.**

.*

d. Aging factor of 0.8 e. Back up time of 30 minutes in case of mains power

failure unless specified otherwise in data sheet f. Minimum end cell voltage for lead acid/VRLA battery 1

.85 V per cell and 1.0 V per cell for Ni-Cd battery g. Battery state of charge factor of 0.95

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

5.3.12 The rectifiers shall be sized based on the maximum inverter input load when inverter is delivering its rated output at 0.8 p.f. lagging and recharge the battery to nominal rated capacity of the battery. The DC load imposed by the inverters shall be considered under the most severe operating conditions where only one rectifier is operating but the UPS load is equally shared by’ all the inverters. The rating of each rectifier shall he not less than the value calculated as follows:

- For Lead Acid Batteries = inverter input current + 0.14 Ah (10 hr. Rating of the battery)




- For Nickel- Cadmium Batteries = Inverter input current +0.20 Ah (5 hr. Rating of the battery)

- For VRLA Batteries = Inverter input current + 0.2Ah ( 10 hr. Rating of the battery) Where

efficiencyInvertervoltageingchBattery

fpLoadUPSofcapacitykVARatedntInputCurreInverter

*arg

.*

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

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

5.3.15 Battery D.C. link shall be provided with a sensitive earth leakage protection.

5.3.16 The inverter shall be of the current limiting type (short circuit proof) and have nominal output voltage and frequency as specified in the data sheet. The inverter output voltage and frequency shall not exceed the operational tolerances, as measured at the output terminals of the unit during the following conditions of UPS loading:

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

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

3rd harmonic - 34% of fundamental 5th harmonic 33% of fundamental 7th harmonic 1 8% of fundamental 9th harmonic 7% of fundamental 11th harmonic 10% of fundamental

The Relative harmonic content is the ratio of the r.m.s. value of the harmonic content to the r.m.s value of the total non-sinusoidal periodic waveform i.e. relative harmonic content

2

1voltageorcurrentofwaveformtotalofvaluerms

voltageorcurrentofcomponentlfundamentaofvaluerms




DC input voltages over the range corresponding to battery rapid charge and battery discharge operation during the specified discharge times.

The UPS output voltage waveform shall be sinusoidal with a relative harmonic content not exceeding 5% under linear load conditions, and not exceeding 15% under the rion4inear load conditions . specified above.

5.3.17 The inverter shall control the output voltage of the UPS such as to maintain synchronism with the mains bypass voltage during variations in mains frequency up to the limits specified. During variations in mains frequency exceeding these limits, the inverter shall revert to internal frequency control.

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

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

5.3.20 The UPS system shall he able to operate satisfactorily on rated loads (in kVA) with power factors in the range of 0.7 lag to 1 0. The overall efficiency of the UPS system shall not be less than 80% at rated load and 0.8 p.f.

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

5.3.22 The inverters shall he ‘phase locked’ to the stabilized bypass power supply as long as stabilized bypass supply frequency remain within ± 4% of nominal. When bypass supply frequency variation exceeds the above limits, the inverters shall be de-linked from mains. Free running frequency tolerance limit shall not exceed ± 1 % . Facility shall also be provided for adjustment of range of synchronising frequency.

5.3.23 Unless otherwise specified. the UPS system output voltage variation shall not exceed ± 10% and complete recovery to normal steady state shall be within 0. 1 Sec. The phase angle disturbance shall he less than 120 ± 3% in case of 3 phase inverter. The above requirement shall be complied for following transient disturbances :

o 100% step load and unload (For single UPS and hot stand by UPS o 50% step load (for parallel redundant UPS o Momentary interruption in power supply




o Load transfer to stabilized bypass supply o Complete load transfer to other healthy inverter when one of the to

parallel inverters develop a fault.

5.3.24 For 3 phase UPS system, the maximum output voltage and angle variation between the phases should nor exceed 6% and S degrees respectively even under the condition of 100% unbalanced loading of the S phase output.

5.3.25 UPS system shall he suitable both for floating output or earthing of one leg star point in case of single phase! three phase system respectively.

5.3.26 The stabilized bypass supply shall he designed to regulate the output voltage within 2% of the rated voltage over complete range of load from no load to full load and fir specified input supply voltage variation. The type of Voltage stabilizer in stabilized bypass supply shall he as indicated in data sheet .

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

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

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

5.3.30 The criteria for load transfer: A) Load transfer from inverter to the stabilized bypass supply shall he as

follows: a) The load transfer shall only he possible when o the stabilised bypass output voltage is within ± 5 % of rated UPS

output voltage ando the mains bypass frequency is within ± 4%.




b) Auto-transfer of the load from inverter to stabilized bypass supply shall be initiated when:

o the inverter output voltage drops below 95 % of nominal output voltage under steady state condition and/or if the inverter output voltage falls below 90% of the nominal value tinder transient conditions.

ORo The inverter output voltage exceeds 105% of the nominal output

voltage under steady state condition and/or if the inverter output voltage reaches 110% of the nominal value under transient conditions.

ORo the inverter output current exceeds its tolerable limits.

B) Retransfer of load from stablised bypass supply to the inverter shall he as follows: a) The load transfer shall he possible when o The inverter output voltage is within ± 5% of nominal output

voltage a. for more than 5 sec. and inverter output and o stablised bypass supply are synchronised Retransfer of load from stabilised by pass to the inverter shall be done manually only unless otherwise specified in the data sheet

If automatic retransfer of load to the inverter is specified in the data sheet, then the retransfer of load to the invertors shall he inhibited following four automatic transfers of load to stablised by pass within a period of 5 minutes.

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

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

5.3.33 All the thyristors, power transistors, diodes and other electronic devices of UPS shall be protected with high speed semiconductor fuses 12t co-ordination between fuse and semi-conducting power devices shall be ensured.




5.3.34 The outgoing circuits of ACDB shall be protected by semiconductor fuses. Each inverter shall he designed to clear a fault in any of the branch circuitsupto a maximum rating of 25% of the system capacity without the assistance of the stabilized bypass supply. In case of any fault in branch circuits, the load connected to the healthy circuits shall not get affected The fault clearing time shall be less 2 than 4 msec.

5.3.35 All PCBs shall be provided with a transparent epoxy coating for environmental protection and trivialization. They shall he suitably located away from heat sources,

5.3.36 All electronic control and monitoring printed circuit cards shall be installed in standardized electronic equipment frames and shall he fitted with suitable means for easy removal. The frames shall incorporate guides for PCB’s to facilitate correct insertion of PCB’s and shall allow access to the wiring side of the connectors All PCBs shall be placed in a manner to avoid replacement of a PCB by a wrong spare PCB. Monitoring points shall be provided on each of the PCB’s and the PCB shall be firmly clamped in position so that vibration or long usage do not result in loose contacts. Failure 7 of each PCB shall he indicated by visual alarms. Visual fault diagnostics shall preferably identify faults upto various sections in the card.

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

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

5.4 Construction 5.4.1 Rectifier/charger and inverter. stabilized bypass supply and static switch

sections shall he suitably housed in sheet steel panels complete with all interconnections.

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

The panels shall he free standing, fitted with suitable louvers for ventilation and cooling fans as required. Hinged doors shall he provided at the front and




back with dust tight gaskets. Inter panel sheet steel barriers shall he provided. The enclosure shall provide minimum lP-31 degree of protection, if not specified otherwise in the data sheer. The maximum and minimum operating height of the switches shall be 1800 mm and 300 mm respectively.

5.4.2 Power cables shall be with aluminum / copper conductors and control cables shall he with copper conductors All the cable connections shall be from bottom and front of the panel, if nor specified otherwise in the data sheet. A removable bolted gland plate shall be provided along with single compression type nickel plated brass cable glands for external cable connections. Clamp type terminals shall be used for connection of all wires upto 10 mm2. Bolted type terminals suitable for cable lugs shall be provided for wire size above this. Tinned copper lugs for all external connections shall be provided with the panels

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

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

5.4.5 A suitably sized earth bus shall he provided at the bottom of the panels including ACDB running through the panels line up with provision for earth connection at both ends to purchasers main earth grid. The minimum size of earth bus shall be 25 x 3 mm2 copper (or equivalent aluminium). All potential free metallic parts of various equipment shall he earthed suitably to ensure safety.

5.4.6 All panels shall be of same height so as to form a panel lineup which shall have good aesthetic appearance .

5.4.7 Inside the panels, the controls connections shall be done with 660V grade PVC insulated wires having stranded copper conductors. 1.5 mm2 size wire




shall normally he used for circuits with control fuse rating of 10 Amp. or less. For control circuit having fuse of 16 Amps., 2.5 mm2 size wire shall he used. Control wiring for electronic circuits shall he through flat ribbon cable or through copper wire minimum of 0.5 mm dia.

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

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

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

5.5 Cell Booster 5.5.1 Cell booster shall he suitable for charging one to six cells within a time

duration as specified at Cl.5.3. 12. It shall be suitable for charging not only the new cells before being introduced to the battery hank hut also any treatment to he given to the individual weak cells. Quantity of such boosters shall he as defined in the MR. Cell booster shall be suitable for 240 V ± 10% 50 Hz ± 3% SPN input power supply. Cell booster output voltage shall be in the range of 0 -18 V and 0 - 12V for Lead Acid and Nickel Cadmium batteries respectively. Cell booster shall be sized as under:

o For Lead Acid battery 0.14 x Ah of cell (10 hr. Rating of the cell) o For VRLA battery = 0.2 x Ah of cell (10 hr. Rating of the cell) o For Ni-Cd battery 0.2 x Ah of cell ( 5 hr. Rating of the cell)

Cell booster shall have heavy duty switch fuse or MCCB on AC incomer and DC output. AC voltmeter. DC ammeter and voltmeter, indicating lamp for .AC/ DC power ON. The output voltage and current of cell booster shall have manual control using a suitably rated variac or a full wave controlled rectifier bridge. Suitable interlock shall be provided so as to ensure that the variac’ controlled rectifier is at its minimum position while switching on the cell booster. Cell booster shall be portable type with wheels. Each cell booster shall be supplied with 5 m long flexible copper conductor. PVC insulated and braided cable for AC incomer power supply and DC output connection to the battery.




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

5.7 Alarm, Control, Indication and Metering Requirements If not specified otherwise in the data sheets, following schedule shall be followed for alarm, control, indication and annunciation. Any additional devices/features considered necessary for reliable operation and maintenance shall also be included in various panels and same shall he highlighted separately . An illuminated one line diagram indicating operational status shall he provided on the front of the panel. Metering, indications, audio-visual alarm shall he provided Parameters! information indicated shall he available in LCD panel or by other means directly or indirectly,

5.7.1 Metering

5.7.1.1 Rectifier a) Incoming line voltages (For all the three phases). b) Input line currents.(For all the three phases) c) D.C. voltage at each rectifier output. d) Battery current.

5.7.1.2 Inverters a) AC voltage at each inverter output (AC voltages for 3 phase inverter) b) AC current at each inverter output (AC currents for 3 phase inverter)c) Frequency meter at each inverter output

5.7.1.3 Stabilized bypass supply a) Frequency meter for incoming supply. b) Voltmeter with selector switch for incoming supply. c) Ammeter with selector switch for incoming supply.

5.7.1.4 ACDB Following shall be provided for each of the ACDB incomers




a) Voltmeter (voltmeter selector switch shall also he provided for 3 phase inverter).

b) Ammeter (ammeter selector switch shall also he provided for 3 phase inverter).

c) Power factor meter

5.7.2 Indications (All indication lamps shall he provided with series resistors. Clustered/Jumbo LED’s of minimum 10mm dia. ma be provided in place of lamps subject to their having at least equal illurninance).

5.7.2.1 Mains/Bypassa) AC mains ‘ON - Rectifier b) AC mains ON Bypass.

5.7.2.2 Rectifiers (for each rectifier) a) Rectifier output ‘ON b) Battery on float charge c) Battery on rapid charge

5.7.2.3 Inverters (for each inverter) a) DC input ‘ON b) Load on inverterc) Inverter synchronised with mains.

5.7.2.4 Load on bypass.

5.7.3 Audio-Visual Alarm ( separately for each circuit) a) Mains failure b) Battery charger failure c) Battery fault d) Inverter temperature high e) Low voltage from inverter f) Load on bypass g) Inverter overloaded h) All power Fuse Failures

5.7.3.1 Two nos changeover contacts shall be wired to the terminal strip, 1 no for common remote alarm of UPS fault in owners panel and 1 no for load on bypass supply annunciation.

5.7.4 Controls a) All the switches for starting. shut down and testing sequence. b) Primary input circuit breakers for feeding chargers, bypass line and dc bus

from battery including backup protection. c) Inverter ON/OFF switch (to initiate inverter operation)




d) Static switch transfer test Push Button.

5.8 Reliability All necessary care shall he taken in selection, design, manufacture, testing and commissioning of 2 the equipment for ensuring high system reliability. Following design consideration shall be taken into account to ensure maximum availability of the system.

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

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

5.8.3 Series-parallel combination of smaller devices to achieve required rating shall not he acceptable.

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

5.9 Fault Diagnostic Unit If specified in the data sheet, each UPS set shall have provision for adding microprocessor based ON line fault diagnostic unit. This shall supervise the UPS operation continuously. It shall identify and locate faults immediately so that corrective action can he taken. Fault Diagnostic unit shall he compatible to hook up with owners PC through RS232/RS385 interface. The software shall be provided on a CD ROM.

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

o UPS power source changeover from mains to battery. o UPS power source changeover from battery to mains. o Changeover from inverter to stabilized bypass supply and vice versa o Changeover from one inverter to other inverter. o Changeover time in case of inverter to stabilized bypass supply and

from one inverter to other inverter. o UPS failure. o Type of failure incident along with diagnostic report.

In addition to the above, any other feature which vendor feels may he useful shall he provided and highlighted separately.




If any additional equipment (e.g. bin connector, adaptor cards etc.) are required for connecting this unit with UPS system as well as with owners PC. the same are also to he included in the vendors scope.

6 INSPECTION ,TESTING AND ACCEPTANCE 6.1 During fabrication. the equipment shall he subjected to inspection by Owner

or by an agency authorised by the Owner. Manufacturer shall furnish all necessary information concerning the supply to Owners inspector. Tests shall be carried out at manufacturers works under his care and expense

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

Following system acceptance tests shall be conducted on each UPS system:

6.2.1 Insulation tests Insulation tests shall be performed as per IEC 60146-1.-I

The insulation tests shall be carried out using an AC power frequency voltage or by using DC Voltage at the choice of the vendor. In the case of AC power frequency voltage test, the test voltage at the frequency available in the test facility or at the rated frequency, but not exceeding 100Hz of the full value starting at a maximum of 0.5 p.u. The unit on test shall withstand the specified voltage for 1 minute.

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

2pV

Vp is the highest crest voltage to be expected between any pair of terminals

Test Voltage (AC r.m.s Value)

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

6.2.2 Interconnection cable check The interconnection cable are to he checked for correct wiring, insulation and quality of the terminations

6.2.3 A.C. input failure test




The test is performed with the test battery and carried out by tripping ac. incoming circuit breakers or by switching off rectifiers and bypass supply at the same time. Output voltage and frequency ‘variations are to he checked for specified limits.

6.2.4 A.C. input return test The test is performed by closing ac. incoming circuit breakers or is simulated by energising rectifiers and bypass supply. Proper operation of rectifiers starting and voltage and frequency variations of output are to be checked.

6.2.5 Simulation of parallel redundant UPS fault The test is applicable for UPS with parallel redundant configuration Fault of rectifier or inverter are to be simulated and output transients are to he recorded.

6.2.6 Transfer test Transients shall he measured during load transfer from inverter to bypass supply caused by simulated fault and load retransfer after clearing the fault.

6.2.7 Regulation test This test shall be carried out by measuring input voltage, input current, output voltage, output current, DC link voltage, output distortion, input active power. output active power and frequency at no load, 50% load and 100% load at 0,7 and 0.8 p.f.

Following parameters of rectifiers and inverters are to measured

Measurement shall be carried out in the rectifier float charge mode and in rapid charge mode. Measurement shall he at nominal ac. voltage and at no load. 50% load and 100% of rectifier full load. Rectifier measurement shall comprise of

o Input voltage, frequency, phase current and input power. o D.C. output voltage and current. o Ripple current at the DC link bus shall he recorded after isolating the

test battery.

Inverter measurement shall also be at no load, 50% load and 100% load of inverter rated output current and shall he repeated for inverter D.C input voltages corresponding to battery float charge operation as well as rated inverter maximum and minimum input D.C. voltage. Measurement shall comprise of

o Input voltage, input current. o Output voltage, frequency and waveform distortion, output power and

current.




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

6.2.9 Current division in parallel UPS Load sharing between UPS units shall he measured with a dummy load under parallel redundant UPS configuration

6.2.10 Light load test The test is to verify that all functions of the UPS system operate properly. The load applied is limited to some percentage of rated load The followingpoints are to he checked. a) Output voltage and frequency and correct operation of meters. b) Operation of all control switches and other means to put UPS system into

operation. c) Functioning of protective and warning devices

6.2.11 Burn-in test for Printed circuit boards PCBs and other electronic components sub assemblies shall undergo a burn-in test for 96 hours at 50o C at a voltage varied between the maximum and minimum supply voltage. In case of failure of any component during testing, the tests shall be repeated after replacement of the faulty component.

6.2.12 Continuous full load test at 0.8 power factor with temperature rise measurement The test is required to he performed by connecting resistive load or resistive and inductive load to the UPS system output. The load shall be placed outside the test room to avoid influences of its heat upon UPS ventilation,

UPS system in this test shall undergo a complete fill load test for 32 hours at 0.8 power factor. Out of these 32 hours, each inverter section shall he subjected to full load test for 8 hours both invertors sections operating in parallel shall be subjected to full load test for 8 hours and the for remaining 8 hours; the by pass section shall he subjected to full load test. Steady state temperature of rectifier transformer, rectifier set, DC choke, inverter set, static switch etc. shall he recorded during the lest. The temperature of all UPS panels are also to be recorded.

6.2.13 Auxiliary equipment and control circuit tests The correct functioning of all measuring instruments, alarms, indications, protection devices and controls are to he verified, The functioning of auxiliary devices such as lighting, cooling fans. annunciation etc. should he checked.




6.2.14 Synchronisation test Frequency variation limits of inverter is to he tested by feeding bypass supply incoming line by variable frequency generator and inverter synchronisation limit is to he checked as specified.

6.2.15 Unbalanced load test (For 3 phase UPS only) Unbalance load at specified limits is applied to the UPS system. The specified voltage and phase angle variation may he checked for compliance with specified values.

6.2.16 Output voltage unbalance (For 3 phase UPS only) Output voltage unbalance shall he checked under symmetrical load conditions and unbalance load conditions. Phase to phase and phase to neutral output voltage are to be observed. The voltage unbalance is the ratio of highest phase voltage minus lowest phase voltage to the average value. Phase angle variation may he measured for phase to phase and phase to neutral voltages

6.2.17 Overload capability test Specified values of short time overload are to he applied for specified time interval. Values of output voltage and output current are to he recorded.

6.2.18 Short circuit current capability test Specified short circuit current capability is to be tested by application of a short circuit to UPS output if necessary via a suitable fuse, Short circuit current is to be recorded.

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

6.2.20 Restart Manual restart to he tested after complete shut down of UPS system.

6.2.21 Output over Voltage Operation of output over voltage protection is to he checked.

6.2.22 Dynamic Response test Output recording at different loads and operating condition to he done.

6.2.23 Harmonic components Harmonic components of output voltage are to be recorded at no load, 50% load and 100% load conditions. Harmonic voltages caused by UPS system components in the AC. incomer side shall he recorded at site




6.2.24 Earth fault test An earth fault is to he applied to the output terminal of UPS system. UPS output transients are to he measured. An earth fault is also to be applied to the battery terminal and UPS system output transient shall he measured.

6.2.25 Audible noise test The audible noise is required to be measured at 1 meter distance from UPS system in at least 4 to 5 locations and its value shall be within permissible limit.

The detailed test schedule and test procedure shall be formulated in line with above. Before giving call for the witness of the tests, vendor shall get approval on the test procedures. Vendor shall also indicate the max. allowable tolerance for each test result, along with the test procedures.

If tests show that certain requirements of the specifications are not met, vendor shall make necessary corrections to the equipment so that it satisfies all the requirements before acceptance is made.

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

8 PACKING AND DESPATCH All the equipment shall he divided in to several shipping sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets before being placed in wooden crates ‘cases to prevent damage to the finish. Crates /cases shall have skid bottoms for handling. Special notations such as “Fragile”, “This side up”, “center of gravity” , “weight”, “Owner’s particulars”, “PO nos.” etc. shall be clearly marked on the package together with other details as per purchase order. The equipment may he stored outdoors for long periods before installation. The packing shall be suitable for outdoor storage iii areas with heavy rains and high ambient temperature unless otherwise agreed.


SPECIFICATION FOR BATTERY CHARGER S-07-02-019 Page 1 of 19


SPECIFICATION FOR BATTERY CHARGER




CONTENTS

1.0 SCOPE



4.0 SITE CONDITIONS







1 SCOPE This specification covers the design, manufacture, testing at manufacturer’s works, packing and supply to site of Battery Chargers and Distribution Boards.


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

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

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


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

2.5 In case of any contradiction between various referred standards/ specifications/ data sheets and statutory regulations, the following order of decreasing priority shall govern: o Statutory regulations o data sheets o Job specifications o This specification




o Codes and standards.

3 GENERAL REQUIREMENTS 3.1 The offered equipment shall be brand new with state of the art technology and

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


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

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

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

3.6 The vendor shall be responsible for design, engineering and manufacturing of the complete system to fully meet the intent and requirements of this specification and attached data sheets.

3.7 The Battery shall meet the requirements of data sheets and specifications attached with the Material Requisition) Bid document.

4 SITE CONDITIONS The Battery Chargers shall be suitable for installation and satisfactory operation in a pressurised or non-pressurised substation with restricted natural air ventilation in a tropical, humid and corrosive atmosphere. The Battery Chargers shall be designed to operate under site conditions as specified in the data sheet. If not specifically mentioned therein, design ambient temperature of




40°C and altitude not exceeding 1000 m above MSL shall be considered for all equipment.

5 TECHNICAL REQUIREMENTS 5.1 Input Power Supply 5.1.1 The Battery Chargers shall be suitable for input power supply as defined in the

data sheet. If not specified therein, they shall be suitable for the following input power supply: Voltage : 415V ± 10% Frequency : 50Hz ± 5% In addition to the above variations, the input voltage may be subject to transient variations comprising of voltage dips up to 20% of normal voltage during motor start-up, voltage interruptions during short circuits as well as frequency variations due to large motor start-up. The Battery Chargers shall operate satisfactorily with a total harmonic distortion of up to 5% in the input power supply.

The Battery Chargers shall also be designed to operate satisfactorily while drawing input power from an emergency diesel generator set.

5.1.2 The incoming power supply to the Battery Charger system shall be provided by 2 independent feeders. One feeder shall supply power to each rectifier.

5.2 Battery Charger 5.2.1 Design Basis 5.2.1.1 The Battery Charger system shall have two chargers (Charger-1 & Charger-2).

Both chargers shall be of identical design and rating. The battery to be connected to the chargers shall be of Nickel Cadmium! flooded electrolyte Lead Acid VRLA type as indicated in the data sheet. Battery Chargers for flooded Lead Acid and Nickel Cadmium batteries shall be sized to provide quick charging of the battery within a duration of 10 hours, unless specified otherwise. Battery Chargers for VRLA battery shall be sized to provide quick charging of the battery up to 90% of rated Ampere-hours within a duration of 24 hours and to 100% within 4 days. Each charger shall be sized for the most stringent of the following duty conditions, whichever is higher:

a. Offline quick charging of the battery assembly. The charger shall be sized as under:

o Charger rating in Amps. = 0.14 Ah(C10) of battery (for Lead Acid battery)

o = 0,2 Ah(C10) of battery (for VRLA battery) o = 0.2 Ah(C5) of battery (for Ni-Cd battery).

b. Online float charging of the battery assembly while feeding the complete DC load. The charger shall be sized as under:

Charger rating in Amps. = 1.15 x Average DC load + float charging current




(Average DC load Area under the battery duty cycle! battery duty cycle duration).

c. Initial charging of the uncharged battery assembly to fully charged condition.

5.2.1.2 Each charger shall have a 3 phase full wave, controlled rectifier bridge with protective devices.

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

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

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

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

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

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

5.2.1.9 Selection, sizing and suitability of all components used for various applications shall be vendor’s responsibility and the rating of components shall be increased, if required, to suit associated - components during execution of the order without any claim for extra price or time. All electronic power devices including thyristors, transistors, diodes etc. shall be rated under operating conditions for at least 150% of the maximum current carried by the device. All




electrical components such as transformers, reactors, contactors, switches, busbars etc. shall be rated for at least 125% of the maximum required rating. No electronic device shall experience a Ply greater than 50% of its rated value.

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

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

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

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

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

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

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

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




5.2.1.18 All the thyristors, diodes and other power electronic devices shall be protected with high speed semiconductor fuses. 121 co-ordination between fuse and semi-conducting power devices shall be ensured.

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

o Filter capacitor fuse failure of either charger o DC output switch OFF of either charger o DC output fuse blown of either charger.

Other specific current! voltage limits during normal charging! operation of the chargers shall also he incorporated in the design of the chargers.

5.2.2 Operation and Performance 5.2.2.1 Operation (refer block schematic diagram on last page)

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

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

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

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




a preset time period. The timer range shall be 0 to 24 hours or the nearest available as per manufacturer’s standard range.

e. In the event of failure of the charger feeding the load, when battery is being quick charged by the other charger, continuity in DC supply shall be maintained from the battery to the load through 80% tap of the battery bank followed by full battery supplying the load through contactor C-2 (refer block diagram on last page).

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

g. The chargers shall have facility for manual mode of operation in the event of failure of controller under closed loop control. The selection shall be done through Auto! Manual selector switch.

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

i. Facility for Initial charging of the uncharged battery shall also be provided.

5.2.2.2 Performance a) Both chargers shall be of solid state design, constant voltage and current

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

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

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

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




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

5.2.2.3 Controls Controls shall include but not be limited to the following: a. ON! OFF control switch for AC supply to charger (push buttons are not

acceptable) b. Push buttons for float! quick charging mode selection c. Potentiometers under float mode for voltage and current adjustment d. Potentiometers under quick mode for voltage and current adjustment e. Auto! Manual selector switch to select mode of operation f. Others as required.

5.2.2.4 Panel Metering and Indication These shall include but are not limited to the following:

a. Meters (1) Charger-1

o AC input Voltmeter with selector switch o AC input Ammeter with selector switch o DC output Voltmetero DC output Ammeter o DC Voltmeter with selector switch (battery voltage) o DC Ammeter (battery) o DC Earth Leakage Ammeter (mA).

(2) Charger-2 o AC input Voltmeter with selector switch o AC input Ammeter with selector switch o DC output Voltmeter o DC output Ammeter.

(3) DC Distribution Board o DC Voltmeter o DC Ammeter.

b. Lamps (1) Chargers-1 & 2

o AC power ON (1 lamp for each phase) o Float charger ON o Quick charger ON o Charger fault.

(2) DC Distribution Board




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

5.2.2.5 Annunciation Static type audio-visual annunciator with annunciation windows, acknowledge, test and reset push buttons and hooter shall be provided on each charger for the following annunciations. Any additional relays! components, including DC under voltage relay and current sensors, required for this purpose shall be provided in the chargers. Facility for bypassing the audio alarm on each charger shall also be provided.

o DC under voltageo DC over voltageo DC earth leakage o AC incoming power supply failure o AC input fuse blown-off o Thyristor/ diode failure o DC output fuse blown-off o DC battery fuse blown-off o Filter Capacitor fuse blown-off o Load on Battery (using current direction sensing with time delay) o Battery under-voltage / Disconnected during discharge (using zero

current sensing) o cubicle fan failure! cubicle temperature high (for chargers with forced

cooling). One summary alarm potential-free contact each for Battery, Charger-1 and Charger-2 shall be wired to terminal block for remote annunciation.

5.2.2.6 Printed Circuit Boards (PCBs) PCBs used in the chargers shall be made of glass epoxy material. Components shall be properly mounted without undue stress, torsion, bends, twists etc. All PCBs shall be provided with a transparent epoxy coating on both sides for environmental! anti-fungus protection and tropicalisation. Industrial grade components shall be used in the PCBs and electronic circuits. PCBs shall preferably be wave soldered. Copper strips! prints on PCBs shall have smooth edges free from hair line cuts and shall be provided with tin coating. Plug-in PCBs shall preferably be mounted in a standard rack and shall be suitable for easy replacement. They shall be located away from heat sources. The rack shall have PCB guides which shall allow the insertion of PCBs smoothly without requiring undue force. The rack shall be mounted on hinged pivots to enable it to be turned for access to the back side terminals. The PCBs shall be firmly clamped in position so that vibration or continued usage do not result in loose contacts. All PCBs shall be fitted in a manner to avoid replacement of a PCB by




a wrong spare card. The PCBs shall be provided with visual light emitting diode (LED) status indications, monitoring points! test connections and setting potentiometers in a readily accessible location which is visible without removing the PCBs. Visual fault diagnostics shall preferably identify faults up to various sections in the card.

5.2.2.7 Vendor shall provide adequate protection to the system, even if not specifically mentioned.

5.2.2.8 For other equipment! component details, refer to block schematic diagram on last page.

5.3 Construction of Chargers! Distribution Board

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

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

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

5.3.3 The charger panels and DC distribution board shall be provided with minimum IP-31 degree of ingress protection as per IS-13947 (Part-1).

5.3.4 Bus bars shall be colour coded and live parts shall be shrouded to ensure complete safety to personnel intending routine inspection by opening the panel doors. All the equipment inside the panel and on the doors shall have suitable nameplates and device tag numbers as per the schematic diagram. All wires shall be ferruled and terminals shall be numbered.




5.3.5 The DCDB incomer and main busbars shall be rated based on the maximum load current considering an additional 10% design margin for contingencies. The rating shall be selected from standard available ratings and shall be adequate for the expected short circuit current. The busbar voltage shall 2 be higher than the recommended boost voltage for the system. The insulation for all equipment where provided shall be heat resistant, moisture proof and tropicalised.

5.3.6 All power and control switches shall be rotary! cam operated type. All power switches shall be air insulated load break type, Vendor shall ensure that all equipment! components such as incomer switches, outgoing DC switches, MCCBs, push buttons, indicating lamps, charger mode selector switches, voltage control switches, annunciator windows etc. are suitably located on the charger and distribution board door such that they can be operated without opening the front door. Power switches shall be provided with a door interlock. In case of difficulty in installation on the charger front panel door, the AC incoming power switches, DC outgoing switches and MCCBs may be installed within the panel provided that they are operable after opening the front panel door. However, all other selector! control switches, push buttons, indicating lamps, annunciators, meters etc. shall necessarily be installed on the front panel door as specified above.

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

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

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

5.3.10 For all cabling external to panels, power cables shall be with aluminum! copper conductors and control cables shall be with copper conductors. All cable connections shall be from the bottom of the panel, unless specified otherwise in




the data sheet. Removable bolted undrilled gland plates shall be provided along with single compression type nickel plated brass cable glands for all external cable connections. Clamp type terminals shall be used for connection of wires up to 10 mm2. Bolted type terminals suitable for cable lugs shall be provided for wire sizes above this. Separate test terminals shall he provided for measuring and testing the equipment to check performance. All panels shall be supplied complete with tinned copper cable termination lugs.

5.3.11 All potential free metallic parts shall be earthed using soft drawn copper conductor wire, A suitably sized earth bus shall be provided at the bottom of the panels running through the panel lineup with provision for earth connections at both ends to owner’s main earth grid. The minimum size of earth bus shall be 25 x 6 mm2 copper (or equivalent aluminium). All potential free metallic parts of equipment shall be suitably earthed to ensure safety.

5.3.12 The maximum height of the operating handles! switches shall not exceed 1800 mm and the minimum height shall not be below 300 mm.

5.3.13 All components! devices! feeders shall be provided with screwed nameplates. Nameplates shall be 3 ply white-black-white 2 colour laminated plastic type. Lettering shall be of minimum 6 mm height and edges shall be bevelled at 450

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

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

5.4 Cell Booster Cell booster shall be suitable for charging one to six cells within the time duration specified at Cl. 5.2.1.1. It shall be suitable for charging not only new cells before being introduced to the battery bank but also for any treatment to be given to individual weak cells. Cell booster shall be suitable for 240 V ± 10%, 50 Hz ± 5% SPN input power supply. Cell booster output voltage shall be in the range of 0- 18V and 042V for Lead Acid and Nickel Cadmium batteries respectively. Cell booster shall he sized as under:

For Lead Acid battery = 0.14 x AH(CI0 of cell




For VRLA battery 0.2 x AH(C10) of cell For Ni-Cd battery = 0.2 x AH(C5) of cell.

Cell booster shall have a heavy duty switch fuse or MCCB on both AC incomer and DC output sides, along with AC voltmeter, DC ammeter, DC voltmeter and indicating lamps for AC! DC power ON. The output voltage and current of cell booster shall be manually controlled using a suitably rated variac or a full wave controlled rectifier bridge. Suitable interlock shall be provided so as to ensure . that the variac! controlled rectifier is at its minimum position while switching on the cell booster. Cell booster shall be portable type with wheels. Each cell booster shall be supplied with 5 m long flexible copper conductor, PVC insulated braided cables for both AC incoming power supply and DC output connection to the battery. An industrial type 3 pin ISA plug shall be provided on AC incoming cable end and lugs shall be provided on DC outgoing cable end.

5.5 Reliability All necessary care shall be taken in selection, design, manufacture, testing and commissioning of the equipment for ensuring high system reliability. The following design considerations shall be taken into account to ensure maximum availability of the system:

5.5.1 There shall be no common device between the two units, the failure of which could cause shutdown of more than one charger.

5.5.2 It shall be possible to attend to any individual power circuit for maintenance without affecting the total DC supply.

5.5.3 Series-parallel combination of smaller devices to achieve specified rating shall not be acceptable.

5.5.4 A lithe components used shall be time tested and standardised. Vendor shall state the safety factors used in selecting such items as semi-conductors, electrolytic capacitors, transformers etc.

6 INSPECTION, TESTING AND ACCEPTANCE

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

6.2 Each Battery Charger/ DCDB/ Cell Booster shall be tested in accordance withapplicable standards. The following acceptance tests shall be performed on each Battery Charger and DCDB as a minimum. Detailed test schedule and procedures shall be formulated by the vendor and submitted for Owner’s approval. Vendor shall indicate the maximum allowable tolerance against each




test parameter in line with applicable standards. All tests shall be witnessed by owner or his authorised representative and 4 weeks prior notice shall be given before the date of commencement of tests. In case the equipment fails to meet any requirements of the specifications, necessary modifications! corrections shall be made by the vendor to ensure compliance to the specifications, and the equipment shall be retested before acceptance. Test certificates indicating the test results shall he submitted to owner.

6.2.1 Insulation Tests Insulation tests shall be performed as per IEC 60146-1-1.

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

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

2pV

Vp is the highest crest voltage to be expected between any pair of terminals

Test Voltage (AC r.m.s

Value)

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

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

6.2.3 Heat Run Test Prior to execution of functional tests, each of the two chargers of each Battery Charger set shall be subjected to a Heat Run test performed at rated load and voltage for a period not less than 8 hours. The other charger of the set shall be energized under zero load current condition throughout the test period. The temperature of electronic power devices shall be measured and the device junction temperature shall be calculated. The calculated value shall be at least




10-20°C lesser than the maximum rated junction temperature of the device with proper ambient temperature correction applied.

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

6.2.4.1 Charger Testing at Constant Output Voltage Measurements shall be carried out in the float charging mode and in the quick charging mode. In each mode, measurements shall be carried out at nominal AC input voltage and at zero, 50% and 100% of rated output current. Measurements at 100% rated load current shall be repeated at 90% and 1 10% of nominal AC supply voltage. Measurements shall include input AC phase voltage, frequency, current and power and DC output voltage, current and output voltage ripple.

6.2.4.2 Charger Testing at Constant Output Current Limit Measurements shall be carried out both in the float charging and quick charging mode. In each mode, measurements shall be carried out when the charger is operating under DC current limiting conditions with DC output voltage between zero and set value corresponding to constant voltage operation. Measurements shall include DC output voltage and current.

6.2.4.3 Auxiliary Equipment and Control Circuit Tests The correct functioning of all measuring instruments, alarms, indications, protections and controls mentioned in the specification shall be verified.

6.2.4.4 Parallel Operation Parallel operation of both chargers, sharing of the load and automatic isolation of faulty charger . shall be checked.

6.2.4.5 Charger Efficiency This shall be determined by measurement of the active power input and output at 50%, 75% and 100% load.

6.2.4.6 Audible Noise Test Audible noise shall be measured around each charger at 1 meter distance in at least 4 to 5 positions and its value shall be within the permissible limits.

6.3 Site Acceptance Test The Battery Chargers, DCDB and Cell Boosters shall be tested at site along with the battery. Vendor shall furnish a Site Acceptance Test (SAT) procedure for




owner’s approval and all tests shall be performed as per the approved SAT procedure.

7 PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship! rail or trailer. It shall be wrapped in polythene sheets before being placed in crates! cases to prevent damage to finish.

The crates! cases shall have skid bottoms for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’, ‘Owner’s particulars’, ‘P0 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.


SPECIFICATION FOR CPPSMS-07-02-020 Page 1 of 16


SPECIFICATION FOR CATHODIC

PROTECTION POWER SUPPLY

MODULE (CPPSM)




ABBREVIATIONS:

CPPSM Cathodic protection power supply module

MTBF Mean time between failure

MTTR Mean time to repair

PCB : Printed circuit board

MOV Metal oxide varistor

PSP Pipe to soil potential

CVCC : Constant Voltage and Constant Current Mode




CONTENTS

1.0 SCOPE

2.0 CODESAND STANDARDS

3.0 SITE CONDITIONS



6.0 EQUIPMENT DESCRIPTION






1.0 SCOPE This specification covers the requirements for the design, manufacture and testing of Cathodic Protection Power Supply Module (CPPSM) working on controlled switch mode principle intended to supply power to cathodic protection system for underground pipelines! structures.

2.0 CODES AND STANDARDS 2.1 The system design, performance and materials to be supplied shall conform

to the requirements of the latest revision of following standards: IS: 1248 Direct acting indicating analogue electrical measuring

instruments and (Parts-i, 2, 8 & 9) accessories. IS 3700 Essential rating and characteristics of semiconductor devices

(Parts-i to ii) IS 3715 Letter symbols for semiconductor devices (Parts-i to 4) IS 4411 Code of designation of semiconductor devices. IS 5469 Code of practice for the use of semiconductor junction

devices.(Parts I to IV) IS 6619 Safety code for semiconductor rectifier equipment. IS 7204 Stabilised power supplies DC output. (Parts-i to 4) IS 12021 Control transformers for switchgear and control gear for

voltages not exceeding 1000 V AC. (Parts-i to 4)IS 13703 Low voltage fuses for voltages not exceeding 1000 V AC or

1500 V DC. (Parts-i to 4) IS 13947 Low voltage switchgear and control gear. (Parts-4, section-i)

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



o Statutory regulations. o Data sheetso Job specificationo This specification. o Codes and standards.

3.0 SITE CONDITIONS The CPPSM shall be suitable for installation in non air-conditioned room with restricted ventilation or in outdoor kiosk (as specified in data sheet), in locations having generally corrosive, warm, humid and dusty atmosphere. Service conditions shall be as specified in the data sheet. If not specifically




mentioned therein, a design ambient temperature of 40°C and an altitude not exceeding 1000 m above mean sea level shall be considered.






5.1 Fabrication and General Details

5.1.1 CPPSM shall be housed in sheet steel enclosure. The front, rear walls and doors shall be made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.6 mm thick sheet steel. Wherever required, suitable stiffeners shall be provided. The Unit shall be freestanding type. Hinged doors shall be provided at the front and back as required. The unit shall be natural cooled type. Louvered openings with wire mesh for natural ventilation may be provided. Degree of protection for the panel shall be minimum TP-4 1. The CPPSM panel shall, preferably, not need rear access for operation, maintenance and shall be suitable for mounting flushed to the wall.

5.1.2 Suitable hooks shall be provided for lifting the panel. These hooks when removed shall not leave any hole in the panel or imperfection in the paint finish.

5.1.3 All instruments shall be panel mounted type and back connected. All fuses shall be provided inside the panel and shall be of link type. 660 V grade PVC insulated BIS approved wires with stranded copper conductor of size minimum 2.5 mm2 shall be used for power and auxiliary wiring. Control wiring for electronic circuits shall be through flat ribbon cable or through copper wire of minimum 0.5 mm diameter. All wirings shall be ferruled with PVC ferrules at both ends for ease of identification. Clamp type terminals suitable for termination up to 10 mm2 conductor shall be provided for all control cable connection. Suitable power terminals shall be provided for power cables. Minimum 20% spare terminals shall be provided. The terminal blocks shall be mounted minimum 300 mm above the gland plate.




5.1.4 All live parts shall be properly shrouded. This shall ensure complete safety to personnel intending routine maintenance by opening the panel doors.

5.1.5 CPPSM shall be suitable for bottom cable entry unless otherwise specified in the data sheet and shall be supplied complete with crimping type tinned copper lugs and cable glands. Cable glands shall be of brass, nickel plated, single compression type for indoor installations and double compression type for outdoor installations. The space in the terminal chamber shall be adequate for termination of required number and sizes of cables as specified in the data sheet.

5.1.6 The CPPSM shall be field proven. The design, internal component layout and rating of component shall ensure high MTBF and low MTTR. Prototype equipment shall not be acceptable. Layout of panel components shall enable easy access to the components for maintenance.

5.1.7 All the control equipment like switches, push buttons, potentiometers etc. shall be located at a convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.

5.1.8 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB tracks shall be tinned and solder masked. The PCB shall be coated with suitable lacquer to make it immune to dust, moisture and fungal growth. Where plug in type of PCBs are used gold plated male-female connectors shall be used for the purpose.

5.1.9 If required the panel shall be provided with space heater to prevent moisture condensation. The space heaters shall be located at the bottom of the panel and shall be provided with a manually operated switch and HRC fuse. The space heater shall have porcelain-insulated connectors. Where space heater is not provided, the electronic PCB5/components and other control devices shall be made immune to moisture condensation.

5.1.10 Panel shall be provided with integral base frame channel. The integral base frame of panel shall be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack welding to purchaser’s insert plate/flat/channel embedded in the floor. Amply dimensioned oblong holes shall be provided at the bottom of the panel for its bolting to the embedded insert plate/channel.

5.1.11 An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminium shall be provided throughout the length of the panel. Provision shall be made for connecting this earth bus at two ends with the plant earth grid by means of (40x5) mm2 GI flat. All non-current carrying metallic parts of the panel and mounted equipment shall be connected to the panel earth bus. All doors




and movable parts shall be connected to the earth bus by flexible copper cables.

5.1.12 All panel mounted equipments (e.g. lamps, push-buttons, switches, meters, PCBs, etc.) shall be provided with suitable nameplates. Nameplates shall be engraved out of 3-ply (black-white- black) lamicoid sheets or anodised aluminium. Back-engraved perspex sheet nameplates may also be acceptable. Engraving shall be done with groove cutters. Hard paper or self-adhesive plastic tape nameplates shall not be acceptable. Nameplates shall be fastened by screws and not by adhesive.

Labels shall be provided for every component on the cards, connecting wires as well as for the terminals in the terminal strip inside the panel.

5.1.13 Where specified in the data sheet the CPPSM shall be housed in an outdoor kiosk. The kiosk shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and external surfaces. Hinged lockable doors shall be provided at the front and back. Acrylic transparent glass window shall be provided on the front door of the kiosk so that the meters, indications and positions of the control switches on the CPPSM can be seen without opening the door of the kiosk. The kiosk shall be suitable for outdoor mounting and shall give proper protection to the CPPSM against rain, other harsh weather conditions. Necessary ventilation arrangement with louvers and wire mesh shall be provided for proper operation of the CPPSM. The cable entry to the kiosk shall be from bottom through cable glands. Suitable canopy shall be provided on the top of the kiosk.

5.1.14 Painting All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt.

Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The undersurface shall be made free from all imperfections before undertaking the finishing coat.

After preparation of the under surface, the panel shall be spray painted with two coats of final paint or shall be powder coated. Colour shade of final paint shall be approved by the purchaser before final painting is started. The finished panels shall be dried in stowing ovens in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off paint, etc.

All unpainted steel parts shall be cadmium plated or suitably treated to prevent corrosion. If these parts are moving elements, then they shall be greased.




6.0 EQUIPMENT DESCRIPTION The CPPSM shall be complete with following main sections:

o Input controls. o Power converter and filters. o Output protections o System controls o Current interrupter o Control, indication and metering

6.1 Input Controls

6.1.1 A moulded case circuit breaker with thermal over load and short circuit release (rated for the input power supply short circuit current) shall be provided at the input for power supply control.

6.2 Power Converter and Filters

6.2.1 The CPPSM shall convert and control the input DC power supply voltage/current into variable DC output voltage/current through switching power semiconductor devices (Thyristor/power transistor/power MOSFET, etc.). The variation in the output voltage/current shall be achieved through control of duty cycle of conduction of the switching power semiconductor devices. The current and voltage ratings of the power semiconductor devices shall be at least two times the maximum device current and mm. two times the maximum voltage coming across it respectively. The voltage rating of the power semi-conductor devices shall be co-coordinated with the breakdown voltage of lightning arrestor provided at the output so that the power semiconductor devices are protected from any voltage surge coming from the pipeline. Shunt zeners / MOV shall be provided across the power semiconductor devices for protection. The power semiconductor devices shall have humidity/moisture resistant finish and mounted in sufficiently sized heat sink designed to provide adequate cooling under worst conditions of operation. The power semiconductor devices shall have adequate protection against high dv/dt and di/dt.

6.2.2 Where specified in the data sheet, the converter shall electrically isolate the input power to CPPSM from its output so that the grounding of the positive output of the CPPSM through anode ground bed shall not affect the grounding system of the input power supply. Alternatively, a separate DC to DC converter having electrical isolation between input and output power supply shall be provided at the input of the CPPSM.

6.2.3 The power semiconductor devices shall be protected by semiconductor fuses or the system shall have instantaneous short circuit-current limit feature to protect the devices against output short circuits. An adjustable output over current limit feature shall be provided.




6.2.4 Filter shall be provided in the input power supply circuit to minimise the AC injected into the DC input power supply system.

6.2.5 Adequate filtering shall be provided on the DC output of the converter to limit the ripple content in the output to less than 5% at rated output.

6.2.6 The converter system shall be of natural air cooled type.

6.2.7 For CPPSMs with multiple output circuits, each output circuit shall have independent output converter and output filters.

6.3 Output Protections Two pole moulded case circuit breaker or miniature circuit breaker rated for the DC output current, short circuit current and having thermal over load, short circuit release shall be provided in the output. A lightning arrestor rated for minimum 1 OKA impulse current discharge capacity and rated voltage & max. spark over voltage rating suitable to protect the CPPSM components against lightning and switching surges shall be provided at the output. For CPPSMs with multiple output circuits, each output circuit shall have independent protections.

6.4 System Controls

6.4.1 The CPPSM shall have two distinct modes of operation (independent for each output circuit) as below:

a) Constant Voltage - Constant Current Mode (CVCC) In this mode the output voltage (Vos) of CPPSM shall be continuously adjustable from O.5V DC to the rated output voltage specified on the data sheet. Current limit feature shall be provided in this mode of operation. The current limit (los) shall be continuously adjustable from zero to rated output current.

For constant voltage mode of operation the output current limit shall be set at maximum and output voltage setting shall be varied. Irrespective of output current demand the chosen value of the output voltage shall be maintained by the control system till the current limit is reached. After that the output current limit shall be maintained and output voltage shall decrease to keep the current constant.

For constant current mode of operation the output voltage shall be set at maximum and output current shall be varied through varying the setting of output current limit. Irrespective of output voltage requirement the control system shall maintain the output current to the set current limit value till the voltage limit is reached. After that the output voltage limit shall be maintained and output current shall decrease to keep the voltage constant.




b) Auto PSP Mode In this mode of operation the output of the CPPSM shall operate in an external closed loop with pipe-to -soil potential (PSP) in feed back loop. The CPPSM control shall adjust the output voltage such that the PSP as measured by reference cell always remains equal to the set potential on the unit. The set potential (Vps) shall have high long time stability and minimum temperature drift. The set potential shall be continuously adjustable over the range specified in data sheet. An adjustable over current limit shall be provided to limit the maximum output current.

The unit shall be designed to operate with the number of reference cells connected to it (to be provided by others) as specified in data sheet. In case of more than one reference cell being specified, CPPSM shall have feature to automatically select the reference cell having less negative potential than the others and use the same for auto control of the unit (e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be provided in selecting the less negative potential reference cell, to avoid hunting between the reference cells at change over conditions.

In case of open circuit or short circuit of the reference cell or potential being less negative than a minimum set potential (Vrs), for the controlling reference cell, the unit shall sense these conditions as reference cell failure and shall automatically switch over to the other healthy reference cell for control. Should fault occur in all the reference cells, the output voltage or current of the CPPSM shall adjust automatically to a preset value (Vas/las), which shall be adjustable.

In both CVCC and auto PSP modes of operation the electronic over current limit shall be fast enough to protect the active devices of the unit and fast enough to act before tripping of MCCB/MCB or blowing of fuse.

6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shall be provided in case of PSP either exceeding the specified maximum limit (Vpm ) or remaining lower than the specified minimum limit (Vpn).

6.4.3 The output voltage regulation for no load to full load variation with input voltage variation from maximum to minimum shall not be more than 2.5 % of rated voltage through out the range of output voltage and over the specified ambient temperature variation as specified in data sheet, in CVCC-constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation for no load to full load variation with input voltage variation from maximum to minimum shall be within 20 mV through out the PSP setting range specified.

In CVCC- constant current mode of operation, the current regulation for minimum to maximum output voltage and minimum to maximum variation in




input voltage, shall not be more than 2.5% through out the range of output current.

6.4.4 The output of the unit shall be ungrounded and shall allow grounding of positive terminal of the output through the anode ground bed.

6.4.5 For CPPSMs with multiple output circuits, each output circuit shall have independent control system.

6.5 Current Interrupter 6.5.1 If specified on the data sheet a current interrupter for CPPSM output current

interruption shall be provided.

6.5.2 The current interrupter shall have an output contactor with current rating minimum 125% of the output current rating of the CPPSM and a digital timer to operate it.

6.5.3 The timer shall have ‘ON’ and ‘OFF’ timings. When the timer is turned on the ‘ON’ timing shall start and shall close the output contactor till the end of the ‘ON’ timing. At the end of the ‘ON’ timing the ‘OFF’ timing shall start and keep the contactor open till the end of the ‘OFF’ timing. At the end of the ‘OFF’ timing the ‘ON’ timing shall start again. This process of ‘ON’ and ‘OFF’ timing shall continue.

6.5.4 The ‘ON’ and ‘OFF’ timings of the timer shall be settable by separate 2 digit thumbwheel switches, each settable from 1 to 99 seconds. The timing error of the timer’ shall be less than 5 parts per million. In case of microprocessor based system keypad with display may be provided in place of thumbwheel switches.

6.5.5 Whenever the timer is switched on it shall always start with ON ‘timing’. A timer-reset push button shall be provided. On pressing this push-buttonduring operation of the timer, the timer shall get reset and upon release of the button, the timer shall restart with ‘ON’ timing.

6.5.6 The power required for operation of the timer and contactor shall be derived from the main power supply to the CPPSM.

6.5.7 The following controls and indications shall be provided for current interrupter. The controls shall be housed in a lockable cover, so that normally they are not accessible. The indications shall be mounted on the door.

a) Controls - Timer power ‘ON’ / ‘OFF’ - - Timer reset - - Thumb wheel switch for ‘ON’ timing - - Thumb wheel switch for ‘OFF’ timing




- In case of microprocessor based system, keypad with display may be provided in place of thumbwheel switches.

b) Indications (LED) - Timer power ‘ON’ - ‘ON’ timing - ‘OFF’ timing

6.5.8 The output contact of the current interrupter contactor shall be wired in the positive DC output of the CPPSM. A link shall be provided for shorting these terminals whenever the current interrupter is not in use.

6.5.9 If specified in the data sheet the current interrupter shall be an independent unit of portable type. The interrupter unit shall have terminals for input power supply and terminals of the contactor in the timer output. The input power supply and the rating of the timer output contactor shall be as specified on the data sheet.

6.5.10 Where the current interrupter is not specified with CPPSM or is specified as portable type external to the CPPSM, then the CPPSM shall have provision for connection of input power supply terminals and output contacts of external current interrupter for current interruption test. A link shall be provided for shorting the output terminals provided in CPPSM for current interruption, whenever the current interrupter is not connected.

6.5.11 For CPPSMs with multiple output circuits, each output circuit shall have independent current interrupter.

6.6 Controls, Indication and Metering 6.6.1 Following controls shall be provided on CPPSM front door.

a) ON/OFF control for input through MCCB. b) ON 10FF control for output through MCCB/MCB. c) Auto/CVCC mode selector switch. d) Potentiometers for Vos, Vps and los settings. e) Selector switch for selecting indication of PSP set and PSP actual

for all the reference cells.

6.6.2 Following controls shall be provided inside the module at user accessible common location:

a) Potentiometer for Vrs, Vpm, Vpn and Vas/las settings. b) Controls for current interrupter:

o Timer power ’ON’/’OFF’ o Timer reset o Thumb wheel switch for ‘ON’ timing o Thumb wheel switch for ‘OFF’ timing




6.6.3 CPPSM shall have following indicating lights (lamps or minimum 5 mm dia LEDs): a) CPPSM ON/OFF b) Unit in auto/CVCC (2 lamps) c) Reference cell controlling the closed ioop control of the CPPSM (number

of lamps same as number of reference cells). d) Reference cell faulty (number of lamps same as number of reference

cells). e) Pipeline over protected. f) Pipeline under protected g) Indications for current interrupter:

o Timer power ‘ON’ o ‘ON’ timing o ‘OFF’ timing

It shall be possible to switch-off all the indication lamps by a single switch. In case of LED indication lights this facility may not be provided.

6.6.4 Following meters having mm ci. 1.5 accuracy shall be provided on the CPPSM: a) Digital meter for output voltage b) Digital meter for output current c) Digital voltmeter to measure PSP set (Vps) and PSP actual for all the

reference cells. The meter shall have range from (-) 4 V to 0 V and shall have cl. 0.5 accuracy.

d) Digital meters for measuring Vrs, Vpm, Vpn and Vas/las settings. e) Meters for input voltage and current It shall be possible to switch-off all the digital meters preferably by a single switch.

6.6.5 If specified in data sheet, CPPSM shall incorporate provision for remote monitoring of the unit through SCADA system as below: a) Potential free contacts for the following:

- All the reference cells failed. (Contact open on alarm condition) - - Pipeline overprotected. (Contact open on alarm condition) - - Pipeline under protected. (Contact open on alarm condition) - - System in auto-mode. (Contact close in auto condition) - - System in CVCC mode. (Contact close in CVCC mode)

b) 4 to 20 mA electrically isolated signal for the following: - PSP (-4V to OV) - CPPSM output voltage - - CPPSM output current

The transducers shall have electrical isolation between input and output. The isolation insulation shall withstand 2 kV, 50 Hz for minimum 1 minute. The




accuracy class of the transducer shall be 0.5. The transducers shall be protected against input and output voltage surges. The transducer shall be suitable for driving upto 600 ohms load impedance located upto 500 m away and wired with 0.5 mm2 copper conductor cable. The transducers shall be suitable for minimum 125% continuous over load in the input voltage/current parameter.

6.6.6 For units having multiple outputs, each output circuit shall have independent controls, indication and metering

.7.0 TESTS AND ACCEPTANCE

7.1 During fabrication, the equipment shall be subjected to inspection by owner or his authorised representative to assess the progress of the work as well as to ascertain that only quality raw materials are used for the same. He shall be given all assistance to carryout the inspection.

7.2 Final acceptance test shall be carried out at manufacturer’s works under his care and expense. Instruments and equipments required for testing shall be arranged by manufacturer. Owner’s representative shall be given minimum 2 weeks prior notice for witnessing the tests. Test certificates indicating test results shall be furnished by the manufacturer. Acceptance tests shall include but not be limited to the tests listed below.

7.2.1 Visual Inspection This shall include-o Completeness of the equipment in line with specification. o Checking of all settings. o All labels provided and satisfactory. o Dimensional checking. o Proper mounting of components and neatness of wiring etc. o Model number.

7.2.2 Insulation Tests The voltage specified in the table below shall be applied for one minute to the circuits indicated: Withstand Voltage Control

electronics voltage <60V

Power electronics Un1

Auxiliarycircuits Un2

To Earth 700V D.C. 2xUn1 + 1000V 2xUn2 + 1000V

To Control Devices- 2xUn1 + 1000V

2xUn2 + 1000V

To power electronics

2xUn1 + 1000V - 2xUn1 + 1000V

To auxiliary circuits 2xUn1 + 1000V 2xUn1 + 1000V -




(Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits respectively).

D.C. test voltages may be applied instead of A.C. The magnitude of D.C. test voltages to be applied shall be 2 times the above-mentioned A.C. (r.m.s) Values. Insulation resistance test shall be conducted before and after heat run test.

7.2.3 Heat run Test All CPPSMs shall be subjected to a heat run test performed at rated voltage for period not less than 16 hours prior to execution of functional tests.

At least one CPPSM of each rating shall be loaded to its rated output through out 16 hour test period. All other CPPSMs shall be energized under partial load or zero load current condition through out the test period.

7.2.4 Functional testsFunctional tests as below shall be performed on each CPPSM. If during execution of functional tests, any electronic component of the unit is required to be replaced e.g. due to malfunction or failure of the unit to fulfill the performance requirements of the specification, then the load test shall be repeated at rated current following which functional tests shall be carried out.

7.2.4.1 CVCC mode operation testing a) Constant voltage operation

During the test, current limit shall be set to rated output current. Performance testing shall be carried out for various output voltage settings and load varying from zero to maximum. The verification of operation of the control functions, measurement of output voltage, current, input voltage, current, ripple in the output, input, evaluation of output voltage regulation and efficiency of the unit shall be carried out during the testing.

b) Constant current operationDuring the test, voltage limit shall be set to rated output voltage. Performance testing shall be carried out for various output current limit settings and load resistance varied to achieve output voltage from minimum to maximum. The verification of operation of the control functions, measurement of output voltage, current, input voltage, current, ripple in the output, input, evaluation of output current regulation of the unit shall be carried out during the testing.

7.2.4.2 Auto PSP mode operation Suitable set-up shall be arranged for output loading and reference cell feed back. The closed loop performance and regulation shall be checked with the PSP set voltage varied from O.85V to 1.2V.




Disconnecting the reference cell feed back connection in the above set up shall simulate the reference cell failed condition. The output voltage/current of the unit shall go to the value set on the potentiometer Vas/las provided inside the CPPSM. The settings on Vas/las shall be varied and the output voltage/current shall be observed.

7.2.4.3 Operation of sensors for pipeline over protection, under protection, reference cell failure and reference cell selection logic in auto PSP mode shall be verified by connecting variable external voltage sources to reference cell inputs of the CPPSM. The number of external voltage sources shall be same as number of reference cell inputs specified for the CPPSM.

7.2.4.4 The unit shall be checked for operation of the current limit by over loading the unit in both CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not provided for protection of the power semiconductor device, the protection of same shall be tested as below:

A switch rated for making and carrying CPPSM output short circuit current shall be connected to the output terminals of the unit. The output voltage and the output current limit settings of the unit shall be set to the maximum rated values. The switch connected in the output shall be shorted quickly.

The unit shall go to current limit mode and shall not damage any active component of the unit.

7.2.4.5 The current interrupter shall be tested for time interval settings and specified operation.

8.0 PACKING ANB DESPATCH The equipment shall be properly packed for selected mode of transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent damage to finish. Crates shall have skid bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’ etc., shall be clearly marked on the package together with Tag nos., P.O. Nos. etc.

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


SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS S-07-02-021 Page 1 of 16


SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS




Abbreviations:

BIS Bureau of Indian Standard


CIMFR Central Institute of Mines and Fuel Research

CT Current Transformer

FM Factory Mutual

FRP Fiber Reinforced Polyester

IEEE Institute of Electrical & Electronics Engineers

IS Indian Standard

LCIE Laboratoire Central des Industries Electriques


P0 Purchase Order

PVC Poly Vinyl Chloride

RPM Revolutions per Minute

UL Underwriter’s Laboratories

VDE Verband Deutscher Elektrotechniker




CONTENTS

1.0 SCOPE .0 CODES AND STANDARDS

3.0 GENEAL REQUIREMENTS

4.0 OPERATING CONDITIONS

5.0 PERFORMANCE

6.0 CONSTRUCTION DETAILS

7.0 MISCELLANEOUS ACCESSORIES

8.0 NOISE LEVEL

9.0 MOTOR VIBRATION

10.0 CRITICAL SPEEDS

11.0 PAINTING

12.0 INSPECTION AND TESTING

13.0 CERTIFICATION





1.0 SCOPE This specification covers the design, manufacture, testing, packing and supply of three phase medium voltage squirrel cage induction motors.

2.0 CODES AND STANDARDS 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 Thermal evaluation and classification of electrical insulation. IS 2148 Flame proof enclosures of electrical apparatus. IS 2223 Dimensions of flange mounted AC Induction motors. IS 2253 Designation for type of construction and mounting

arrangement of rotating electrical machines. IS 2254 Dimensions of vertical shaft motors for pumps. IS 2968 Dimensions of slide rails for electric motors. IS 4029 Guide for testing three phase induction motors. IS 4691 Degrees of protection provided by enclosure for rotating

electrical machinery. IS 4722 Rotating electrical machines. IS 4728 Terminal marking and direction of rotation for rotating

electrical machinery. IS 4889 Method of determination of efficiency of rotating electrical

machines. IS 6362 Designation of methods of cooling of rotating electrical

machines. IS 6381 Construction and testing of electric apparatus with type of

protection ‘e’. IS 7389 Pressurized enclosure of electrical equipment for use in

hazardous area. IS 7816 Guide for testing insulation resistance of rotating machines. IS 8223 Dimensions and output series for rotating electrical machines. IS 8289 Electrical equipment with type of protection ‘n’. IS 8789 Values of performance characteristics for three phase

induction motors. IS 9283 Motors for submersible pump sets. IS 9628 Three phase induction motors with type of protection ‘n’. 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 12802 Temperature rise measurement of rotating electrical machines.

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.

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 Indian Electricity rules 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/ NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred standards! specifications! data sheets and statutory regulations, the following order of priority shall govern:

o Statutory regulations o Data sheets o Job specifications o This specification o Codes and standards


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.


3.3 Vendor shall give a notice of at least one year to the end user of equipment and GAIL 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) Unless otherwise specified, motors shall be designed for direct-on-line starting.

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. The starting time of the motor shall be less than the hot thermal withstand time (time tE in case of increased safety i.e. Ex-e motors) to permit application of conventional bimetal relays or thermal release against locked rotor and overload conditions.

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:

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 ABC are connected to a power supply giving a terminal phase sequence in the order ABC. 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.

StartsMinimum no. of

consecutive startsNo. of consecutive start-ups with initial temp. of the motor at ambient level (cold)

3

No. of consecutive start-ups with initial temp. of the motor at full load operating level (hot).

2

5.0 PERFORMANCE

5.1 Motors shall be rated for continuous duty (S1), unless otherwise specified.

5.2 Unless otherwise specified, the starting current (as % rated current) shall not exceed 600% subject to 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.

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.

For heavy duty drives such as blowers, crushers etc. high starting torque motors shall be provided. 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 pull out torque at the rated voltage shall be not less than 175 percent of the rated load torque with no negative tolerance. Unless otherwise agreed, the pull out torque shall not exceed 300 percent of the rated load torque in case of motors driving equipment with pulsating loads (e.g. reciprocating compressors) the minimum value of pull out torque at 75 percent 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 The minimum values for performance characteristics of motors rated up to and including 37 kW shall be as per IS-8789 TABLE-ito1 TABLE-8

The minimum value for product of efficiency and power factors of 2 pole, 4-pole, and 6-pole motors rated above 37 kW shall be as given in Table below.

Rated output Product of efficiency & power factor at rated load (minimum)

2-Pole 4- Pole 6-Pole45 kW 0.82 0.80 0.79 55 kW 0.82 0.80 0.7975 kW 0.82 0.80 0.80 90 kW 0.82 0.80 0.80 110kW 0.86 0.80 0.80 125 kW 0.86 0.80 0.80 160kW 0.86 0.81 0.80 180kW 0.86 0.83 0.80 200 kW 0.86 0.83 0.80

Efficiency and power-factor figures for motors having synchronous speeds of 750 RPM and below, shall be as agreed between the purchaser and the manufacturer.

6.0 CONSTRUCTIONAL DETAILS

6.1 Windings

6.1.1 Unless otherwise specified in the motor data sheet, 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 400°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.

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 nonflammable material.

6.1.7 All motors shall be 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.

6.1.8 All terminals shall be thoroughly insulated from the frame with material resistant to tracking.

6.1.9 Anti-loosening, anti-vibration type of terminals shall be provided in case of increased safety (Type Ex e) and non-sparking (Type Ex n) motors.

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. 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/CCE for installation in hazardous area.. The terminal box design shall allow rotation in steps of 900 to facilitate cable entry from any direction.

6.2.2 The terminal box shall be of robust construction and large enough to facilitate easy connection of the cables. The terminal box shall be with necessary clearances, creepage distances between live parts and between live parts to earth considering air insulation and without any compound filling. 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 An adequately sized earth terminal shall be provided in the motor terminal box for termination of the fourth core of specified cables.

6.2.4 The terminal box shall be provided entries for suitable cable glands corresponding to the size of the specified cable. Crimp type tinned Cu 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.

6.2.5 Equipment and accessories provided shall conform to the hazardous area classification and the environmental conditions as specified in the motor data sheet.

6.2.6 Unless otherwise specified, the terminals, cable lugs, terminal box, cable entries and cable glands shall be suitable for the cables sizes as specified below in Table for 2 pole, 4 pole or 6 pole motors:

Motor rating up to and including Size of phase conductor (mm2) 2.2 kW and below 4 Al.! 2.5 Cu 3.7kw 6A1./ 4Cu 5.5kw 10Al/ 6Cu 7.5kw 16Al/6Cu 9.3kW 25 Al/ 10Cu 11.0kW 25 Al./ 16Cu 15.0kW 35Al18.5kW 50A1 22.0kw 50A1 30.0kW 70A1 37.0kw 95A1 45.0kw 95A1 55.0kw 120A1 75.0kw 185 Al 90.0kw 2x95Al 110.0kW 2x120Al 125.0 kW/132 kW 2x150 Al 150.0kW 2xl85Al 160.0kW 2x185Al 180.0kw 2x240Al 200.0kw 2x300Al

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




6.2.8 Cables used are of 650/1100 V grade aluminum conductor, PVC insulated, PVC extruded inner sheath, armoured with overall PVC sheath. However for cables up to & including 16 mm2 cross-section, cables used may be with copper or aluminum conductor as indicated in the motor data sheet.

6.2.9 The terminal box shall be capable of withstanding internal short circuit conditions without danger to personnel or plant from the emission of hot gases or flame or due to excessive distortion or damage to the terminal enclosure.

6.2.10 Appropriate phase markings as per IS shall be provided inside the terminal box. The marking shall be non-removable and indelible.

6.3 Motor Casing and Type of Enclosure

6.3.1 Motors for use in safe areas shall be industrial type meeting the specified ambient conditions, starting and operating requirements.

6.3.2 Motors for use in hazardous areas (Zone-I or Zone-2) shall have type of protection Ex d or Ex e or Ex n as specified in the motor data sheet and shall meet the requirements of applicable Indian standards.

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

6.3.4 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).

6.3.5 Vertical motors with downward shaft shall be provided with suitable canopies covering the motor fully. Vertical motors with upward shaft e.g. on fin-fan coolers, shall be adequately protected, (such as cowls/canopies) against ingress of water into the enclosure or the bearing housing even when standing still for long periods of time. Motors designed to handle external thrust from the driven equipment shall be supplied with a thrust bearing at the non-driving end.

6.3.6 All 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.

Unless otherwise agreed, motors shall have standard frame sizes 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-l 0 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 Unless otherwise specified, the bearings shall be adequate to absorb axial thrust produced by the motor itself or due to shaft expansion.

6.4.3 Vertical motors shall be provided with thrust bearings suitable for the load imposed by the driven equipment.

6.4.4 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.

6.4.5 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. Where grease nipples are provided, these shall be associated, where necessary, with appropriately located relief devices, which ensure passage of grease through the bearings.

6.4.6 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.

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. The accepted values of peak to peak vibration amplitudes for a motor at rated voltage and speed on a machined surface bedplate with the motor leveled and with a half-key or coupling fitted shall not exceed those given in IS. 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 All 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. The size of each earth stud shall be as given below in Table:

Motor Rating Stud size Up to and including 7.5 kW 6 mm Upto 30 kW 10mm Above37kW 12mm

Necessary nuts and spring washers shall be provided for earth connection. An additional earth terminal shall be provided inside the terminal box as stated in 6.2.3.

7.0 MISCELLANEOUS ACCESSORIES

7.1 Anti-Condensation Heaters Unless otherwise stated, all motors rated above 22 kW shall be provided with 240 V anti-condensation heaters, sized and located so as to prevent condensation of moisture during shutdown periods. The heaters shall permanently remain ‘ON’ when the motor is not in service and as such shall not cause damage to the windings. For motors 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 A stainless steel name plate manufactured from series 300 stainless steel and having information as per IS shall be provided on each motor.




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.

Additional information as stipulated in applicable standards shall be included in the nameplate for motors meant for use in hazardous atmospheres.

8.0 NOISE LEVEL The permissible noise level shall not exceed the stipulations laid down in IS, unless otherwise specified in the motor data sheet.

9.0 MOTOR VIBRATIONS Motor vibrations shall be with-in the limits of IS, unless otherwise specified for the driven equipment.

10.0 CRITICAL SPEEDS The first actual critical speed of stiff rotors shall not be lower than 125 % of the synchronous speed. For flexible rotors this shall be between 60 % and 80 % of the synchronous speed; the second actual critical speed shall be above 125 % of the synchronous speed.

11.0 PAINTING Internal and external parts of the casing and all metal parts including the canopy likely to come in contact with the surrounding air shall be protected with anti-acid paint that will resist the specified environment conditions.

All external surfaces of the motor and its canopy shall be given a coat of epoxy-based paint. Paint shade shall be 632 as per Indian Standard-IS-S.

12.0 INSPECTION AND TESTING 12.1 During manufacturing of motors, the motors shall be subject to inspection by

GAIL/ Owner’s Inspector or by an agency authorised by the Owner. The manufacturer shall provide all necessary information concerning the supply to GAIL/Owner’s Inspector.

12.2 Type tests, if specified, all the routine tests and other acceptance tests shall be witnessed by the GAIL I Owner’s Inspector. The manufacturer shall give prior notice of minimum 4 weeks to the Inspector for witnessing the tests. Witness of acceptance test shall be applicable for motors rated above 11 kW. In case of motors rated up to 11 kW, routine test records shall be provided as part of final documentation.

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




12.4 Tests certificates duly signed by the GAIL I Owner’s Inspector shall be a part of final documentation.

12.5 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 to the Inspector before offering the motors for final inspection and testing.

12.6 The manufacturer shall periodically carry out the following type tests as per applicable Indian Standards for all the frame sizes and ratings of motors:

a) Full load test and measurement of voltage, current, power & slip b) Measurement of starting torque, starting current, full load torque and pull out

torque c) Measurement of efficiency and p.f. at 100%, 75% and 50% load d) Temperature rise test e) Momentary overload test f) Measurement of vibration g) Measurement of noise level h) Over speed test

The above tests must be witnessed and approved by reputed inspection agencies. The manufacturer shall maintain test records and submit to the Owner's Inspector at the time of final inspection & testing. In no case, the test records shall be more than 5 year old.

In special cases where the type tests are asked to be carried out, GAIL/Owner’s Inspector shall witness these.

12.7 The manufacturer shall carry out routine tests as per applicable Indian Standards on all the motors. Routine tests not limited to the following shall form part of acceptance testing:

a) General visual checks, nameplate details, mounting, terminal box location and cable gland sizes

b) Measurement of shaft center height dimensions c) Measurement of clearances in the terminal box d) Verification of type of terminals (for Ex-e & Ex-n motors) e) Verification of direction of rotation f) Measurement of winding resistance g) Insulation resistance test (before & after high voltage test) h) High voltage test i) No load test and measurement of voltage, speed, current & power input j) Locked rotor test at reduced voltage and measurement of voltage, current &

power input k) Reduced voltage starting & running l) Tests on the Ex d enclosures as per IS




12.8 The manufacturer shall submit the following certificates for verification by the GAIL/Owner’s Inspector:

a) Test certificate for degree of protection of enclosure b) Test certificates issued by the recognised independent test house for

hazardous area motors c) Approval certificates issued by Statutory Authorities for hazardous area

motors d) BIS license and marking as required by Statutory Authorities for Ex d

motors

12.9 Though the motors shall be accepted on the basis of the satisfactory result of the testing at the shop, it shall not absolve the Vendor from liability regarding the proper functioning of the motors coupled to the driven equipment at site.

13.0 CERTIFICATION The hazardous area motors and associated equipment shall have test certificates issued by recognised independent test house (CIMFR/Basefa/LCIE/UL/FM or equivalent). All indigenous motors shall conform to Indian Standards and shall be certified by Indian testing agencies. All motors (indigenous & imported) shall also have valid statutory approvals as applicable for the specified location. All indigenous flameproof motors shall have valid BIS license & marking as required by statutory authorities. Ex n motors shall be supplied with manufacturer’s certificate of conformity to IS 9628 or equivalent international standard and Indian statutory approval.

14.0 PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases to prevent damage to the finish. Crates/cases shall have skid bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’, ‘Owner’s particulars’, ‘PO Nos.’ etc. shall be clearly marked on the package together with other details as per purchaser 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/high ambient temperature, unless otherwise agreed.


INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS S-07-02-022 Page 1 of 8


INSTRUCTIONS TO TURNKEY

CONTRACTORS FOR ROUTING AND

REVIEW OF DOCUMENTS




CONTENTS

1. PURPOSE

2. SCOPE

3. DETAILS

4. ATTACHMENTS




1. PURPOSE This document describes the procedures to he followed lbr routing and review of turnkey contractor’s documents to ensure quality during design and engineering phase.

2. SCOPEThis procedure is applicable to contractor’s engineering documents and to the documents generated by his sub-contractors, packagers, and finally selected equipment manufacturers.

3. DETAILS 1.1 Documents to be submitted to GAIL by contractor during the design and

engineering phase shall include

a) Engineering designs, drawings and documents generated by the Contractor or his sub-contractor for engineering.

b) Vendor drawings and documents generated by Contractor’s sub-vendors/subcontractors/packagers and/or finally selected equipment manufacturers.

2.2 Extent of Engineering Review Broad discipline-wise requirement of contractor’s documents for GAIL’S’s . review/records is included in hid package.

3.3 Engineering drawings and documents

3.3.1 Contractor shall prepare and submit to owner/GAIL a detailed discipline-wise drawing schedule fir the drawings/documents to be generated by contractor or his sub contractor for Engineering indicating submission schedule for each drawing/document. The schedule shall be based on project schedule as per contract and shall be updated and resubmitted to GAIL Project Manager every month. The Review and Record categories shall be marked on the schedule by the contractor based on guidelines given in the bid package.

Suggested format for such a schedule is given in S-07-02-022-F1.

The updated drawing schedule shall also include schedule of resubmission of drawings/documents after review. While resubmitting the drawings/documents, the contractor shall specifically confirm whether all the comments are incorporated or otherwise with necessary justification.

3.3.2 Contractor shall submit six copies of engineering drawings/documents to GAIL Project Manager.

3.3.2.1 Documents under Review Category




Following review codes shall he used for engineering drawings/documents. (a) No comments. Work may proceed. (b) Proceed with engineering/construction as per comments marked.

Submit revised drawing.

(c) Document does not conform to contract specifications as marked. Resubmit for review after incorporating comments.

3.3.3.2 Documents under Records Category Documents under this category are meant for GAIL records. However, comments, if any, shall he communicated to contractor.

3.3.3 Review by GAIL shall not absolve the contractor of his contractual obligations. Any error/deficiency noticed during execution/installation shall be promptly corrected by the contractor, irrespective of whether comments from GAIL were received or not during the drawing submission stage.

3.3.4 Contractor shall also provide a copy of updated drawing schedule to GAILsite-in- charge every month.

All necessary engineering drawings and documents as required by GAILsite-in-charge to ensure quality during execution/installation shall be provided by the contractor.

Contractor shall maintain at site one set of drawings/documents (under review category) bearing signatures of GAIL along with the review code for reference by owner’s site-in-charge.

4.4 Vendor drawings and documents 3.4.1 While preparing the purchase requisition, contractor shall include a list of

all drawings and documents to he submitted by his sub-contractor/packager/equipment manufacturer. All such drawings/documents shall he categorized as below

S. No Document DetailsFor Owner’s

Review Yes/NoFor Contractor’s

Review

Identification of vendor drawings for owner’s review shall be completed by the contractor in consultation with the owner.

3.4.2 All vendor drawings shall he first received and reviewed by contractor. Contractor may communicate his comments to vendor with a provision,




that any further comments by owner shall he communicated subsequently for incorporation.

3.4.3 Contractor shall submit vendor drawings/documents to GAIL only after ensuring that the documents meet the contract requirements. All such documents shall include contractor’s comments and his approval signature/stamp.

3.4.4 Contractor shall submit six copies of vendor drawings/documents to GAILProject Manager.

3.4.5 Following review codes shall he used fir vendor drawings/documents. a) No comments. Work may proceed

b) Proceed with fabrication/manufacture as per comments marked. Submit revised drawing.

c) Document does not conform to contract specifications as marked. Resubmit for review after incorporating comments.

3.4.6 Contractor shall provide copies of Purchase Requisition bearing owner’s signature as well as the copies of vendor drawings. reviewed by GAIL to the inspector for shop testing/inspection of various equipment/materials..

3.4.7 Documents under Record Category shall be retained by Owner for records. However, comments, if any, shall he communicated.

3.5 Waiver and Deviation All waiver/deviations after contract award shall be routed as below

a) For design and engineering through Owner’s Project Manager.

b) For equipment manufacture and supply through Owner’s Procurement In-charge.

c) For construction activities through Owner’s site-in-charge.

Enclosed Format No. S-07-02-022-F2 shall be used for the purpose.

3.6 As Built Documentation As built documents/vendor drawings shall he provided by the contractor to owner as per contract. Additionally one set of all as-built documents/vendor drawings in bound volumes and/or in the form of electronic files on specified media shall be . submitted to GAIL Project Manager along with the certified and updated drawing schedule.

4 ATITACHMENTS Format No. S-07-02-022-F1 Typical Drawing Document Schedule. S-07-02-022-F2 Waiver and deviation Permit.




Typical Drawing Document Schedule S-07-02-022-F1

Discipline ______________________

Rev 0 Rev I Rev 2Sch Date

Review Code

Sch Date

Review Code

Sch Date

Review CodeS

No Drg. /Doc. No Title

CategoryReview / Record Actual

Issue Date

Review Date

Actual Issue Date

Review Date

Actual Issue Date

Review Date




WAIVER/DEVIATION PERMIT S-07-02-022-F2(Strike out whichever is not applicable)

Project: ________________________________ Originator Ref: _______________________

Job No: ________________________________ Order/Contract No ____________________

Originator: Vendor/Consultant/Contractor: ____________________________________

Requirement as per specification Description of Waiver / deviation Sought

Why is the waiver required?

Contractual implication if waiver/deviation is granted

o Time taken shall be More Less No Change

o Cost of Item shall be More Less No Change

o Performance requirement shall be Satisfactory Unsatisfactory

TO

BE

FIL

LE

D B

Y T

HE

OR

IGIN

AT

OR

Under the present constraints requested waiver/deviation is most optimum for the project and does not involve any security and safety hazard.

Date: ___________________ Signature & SealVendor/Consultant/Contractor

Decision on waiver/deviation with remarks, if any, on time/cost implications(To be filled by the department responsible for conveying to the originator)

Date: ___________________ Signature _________________________Name:____________________________




S-07-02-022-F2Opinion from Consultant’s Supervisor/Inspector(Specific if post facto approval is required)

Date :___________________ Signature: _______________________Name: __________________________Department: ______________________

Forwarded to _________________________ by Head of Consultant Establishment(Project Manager)

Date:__________________ Signature: _______________________Name: __________________________

Forwarded to _________________________ (Target Resolution Div/Deptt/Group)

Date:__________________ Signature: _______________________(Project Manager)

Name: __________________________

Disposition by Target Resolution Div/Deptt/Group


FINAL DECISION OF PROJECT MANAGER ALONGWITH OVERALL REVIEW


DECISION OF ACCEPTING AUTHORITY (IF REQUIRED)



SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM S-07-02-024 Page 1 of 32


SPECIFICATION FOR FIRE DETECTIONAND ALARM SYSTEM




Abbreviations:

BIS Bureau of Indian Standards BASEEFA British Approvals Service for Electrical Equipment in Flammable

Atmosphere CCE Chief Controller of Explosives CFAP Central Fire Alarm Panel CMRI Central Mining Research Institute CPU Central Processing Unit DGFAP Data Gathering cum Fire Alarm Panel ERTL Electronic Regional Test Laboratory FAT Factory Acceptance Tests FDD Floppy Disk Drive FM Factory Mutual FRP Fibre Reinforced Plastic FO Fibre Optic GUI Graphic User Interface HAB Hooter acknowledgement box (to mute hooters) HDD Hard Disk Drive ISDN Integrated Service Digital Network ITU- T International Telecommunication Union- (Telecom) LED Light Emitting Diode LPC Loss Prevention Council LIFO Last in First Out MCP Manual call point (break glass unit; BGU) MMI Man Machine interface MR Material Requisition Ni-Cd Nickel Cadmium (battery) PO Purchase Order RF Radio Frequency SAT Site Acceptance Tests SOE Sequence Of Event TAC Tariff Advisory Committee UL Under Writers Laboratory UPS Uninterrupted Power Supply VRLA Valve Regulated Lead Acid (battery) WP Weather Proof ZFAP Zonal Fire Alarm Panel




CONTENTS

1. SCOPE



4. DEFINITIONS

5. SYSTEM AND SITE CONDITIONS

6. FIRE ALARM SYSTEM DESCRIPTION

7. CONVENTIONAL FIRE ALARM SYSTEM

8. MICROPROCESSOR BASED FIRE ALARM SYSTEM

9. INTEGRATION WITH VARIOUS PLANT SYSTEMS

10. PANEL CONSTRUCTION (CFAP, DGFAP, ZFAP, REPEATER)

11. CABLE AND CABLE ACCESSORIES

12. AUTOMATIC FIRE DETECTORS AND ACCESSORIES

13. FIELD DEVICES FOR HAZARDOUS AREA

14. ENGINEERING REQUIREMENTS



17. INSTALLATION AND COMMISSIONING

18. TRAINING




1. SCOPE 1.1 The intent of this specification is to define the functional and design

requirements for an Integrated Fire Alarm System for industrial plants and buildings. This specification covers the requirements for selection, design, and engineering, manufacture, testing at vendor’s works, supply, installation, testing at site and commissioning of the system.

1.2 The Integrated Fire Alarm System shall be conventional or micro processor based analog addressable system comprising of MCP, detectors; conventional or microprocessor based Fire Alarm panels, CFAP and associated equipments detailed hereunder and in Project data sheets! drawings.


2.1 The system and equipment shall comply with relevant BIS (Bureau of Indian Standards) and other Indian/ International standards, as applicable. In case Indian standards are not available for any equipment, standards issued by IEC! BS/ VDE! IEEE! NEMA/NFPA or equivalent agency shall be applicable. 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.

2.2 The equipment shall also conform to the special requirement! provisions of applicable statutory regulations currently in force in the country.

2.3 In case of any contradiction between various referred standards! specifications! data sheets and statutory regulations, the following order of decreasing priority shall govern:

o Statutory regulations o Data sheets o Job specifications o This specification o Codes and standards

2.4. The fire alarm system and the components used shall conform to the latest edition of the following and also the other Indian and International Standards as applicable. o IS-5 Colours for ready Mixed Paint & Enamels.

o IS —513 Specification for cold rolled low carbon steel sheets and strips

o lS2 148 Flameproof enclosures for electrical apparatus

o IS 1646 Code of practice for fire safety of buildings (general): Electrical

Installations




o IS 2175 Specification for heat sensitive fire detectors for use in automatic

fire alarm system

o IS 2189 Code of practice for selection; installation and maintenance of

automatic fire detection and alarm system.

o IS 3034 Code of practice for fire safety of Industrial buildings: Electrical

generating and distributing stations

o IS 3700 Essential ratings and characteristics of semi conducting devices

(Applicable parts)

o IS 3826 Connectors for frequencies below 3 kHz General requirements

Part-I and tests IS 5469 Code of practice for the use of semi-conductor

junction devices (Applicable parts)

o IS 5780 Specification for Intrinsically safe electrical apparatus and circuits

o IS 11360 Specification for smoke detectors for use in automatic electrical

fire alarm system.

o IS 12459 Code of practice for fire safety in cable runs

o IS 13346 General requirements for electrical apparatus for explosive gas

atmosphere

o IS-14154 Electrical apparatus with protection of enclosure for use in the

presence of Part 2 combustible dust NFPA 72 National Fire Alarm code Vol

4

o LPC Loss prevention council recommendations.

o BS 5839 Specifications for manual call points. Part 2

o BS-EN EMC 5008 1-1 (Electromagnetic compatibility test)

o BS-EN EMC 50082-i (Electromagnetic compatibility test)


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

3.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least 15 years from the date of supply. The spares shall be available ex-stock with the vendor.




3.3 Vendor shall give a notice of at least one year to the end user of equipment and E1L 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 system and equipment to fully meet the intent and requirements of this specification and attached data sheets.

3.5 All equipment and accessories required for completeness of the system, whether specifically mentioned or not but considered essential for satisfactory performance, shall be included as a part of the offered system.

3.6 The system integrator shall coordinate with the manufacturers of various bought-out items associated with the system, as required, and shall freely and readily supply all technical information as and when called for.

3.7 Equipments to be located in hazardous areas shall have test certificates issued by recognized independent test house such as CMRI, ERTL, BASEEFA, UL, FM or equivalent. All indigenous equipment shall conform to Indian standards and shall be certified by Indian testing agencies. All equipment (indigenous & imported) shall also have valid statutory approvals as applicable for the specified location. All indigenous flameproof equipment shall have valid ISI license and marking as required by statutory authority.

4 DEFINITIONS

4.1 CFAP:It is a fire alarm panel located in fire station or in disaster management control rooms. It is electronic for conventional and microprocessor based for addressable system. CFAP is designed to gather information from distributed fire alarm panels provided in the plant! buildings and have features such as provision to activate plant-wide sirens, have interface with telephone exchange, plant’s public address system etc. It has mimic for geographical display of alarms either on panel or as graphic displays on MMI.

4.2 DGFAP: It is a Microprocessor based fire alarm panel, designed for use with addressable fire alarm system. It has alphanumeric LCD displays along with LED displays for fire! fault conditions. It also includes loop cards (for field devices), I/O cards for interface with other Purchaser’s equipment, exit sign and hooters. It functions as fire alarm panel located centrally to population of fire detectors distributed over an area for optimizing and limiting the loop lengths.




4.3 ZFAP: It is a fire alarm panel for conventional fire alarm system. This has functionality similar to what is provided for DGFAP. This has LEDs for fire! fault annunciations.

4.4 REPEATER PANEL: It is similar to distributed fire alarm panels (DGFAP/ ZFAP) but will not have Zone card! Loop card for field devices. These are provided at manned locations and are configured to acquire information about the fire! fault of selected zones from DGFAP! ZFAP and annunciate.

4.5 INTEGRATED FIRE ALARM SYSTEM: It signifies a comprehensive fire alarm system comprising all the distributed fire alarm panels (DGFAP, ZFAP, repeater panels etc) having integration with CFAP for fire monitoring of total plant! building. It provides audio! visual alarm building/plant-wide having provisions for connectivity with telephone exchange, pager system and public address system. It shall provide interfaces with fire protection system and other systems like pressurization systems, air conditioning etc.

4.6 SYSTEM ARCHITECTURE System architecture is line diagram defining the connectivity of DGFAPs, repeater and CFAP. This also specifies various system requirements such as redundancy, communication protocol, communication hardware, cable requirement, workstation and programming tools.

4.7 DATA HIGH WAY This term is meant to define the communication path between DGFAPs, CFAP and other network components in microprocessor based fire alarm system. Physical media for Data highway can be fibre optic (FO) cable or twisted pair copper conductor, screened cable.

4.8 FIELD DEVICES Devices such as detectors, MCP, exit signs, hooters, siren etc. are termed as field devices.

4.9 HAB This term is defined as Hooter Acknowledgement Box. I-lAB for individual buildings shall be provided at its exit.

4.10 HAZARDOUS AREA An area in which an explosive gas! dust atmosphere is present, or likely to be present in quantities such as to require special protection for the construction, installation and use of electrical apparatus.




5 SYSTEM AND SITE CONDITIONS

All equipment shall be designed to operate with power supply and site conditions as specified below:

5.1 INPUT POWER SUPPLY

5.1.1. Unless stated otherwise, purchaser shall provide one point power supply to each fire alarm panel (ZFAP/DGFAP/CFAP! repeater panel), details of which are indicated in data sheet. A suitable power distribution to various equipment and sub system shall be included in vendor’s scope.

5.1.2. Power supply for fire alarm panels shall have battery back up as per IS-2189. Battery AR rating shall be determined on the basis of maintaining the system in normal operation for a period of not less than 48 hours (quiescent condition) and successive full load alarm condition of period not less than 30 mm after the failure of normal mains supply.

The switch over from mains to back up, in the event of mains failure, shall be automatic. Batteries shall be Ni-Cd / VRLA type as specified in data sheets. Suitable and adequately rated battery charger shall be supplied as a part of back up battery system.

(The full load alarm condition is defined as operation of all panel/field audio and visual alarm and the alarm load of 25 percent of total zones besides other normal operation loads.)

5.2. SITE CONDITIONS

The offered equipment shall be capable of operating continuously and maintaining its guaranteed performance at the site ambient conditions indicated in data sheet.

Unless specified otherwise, fire alarm panels along with associated hardware shall be suitable for installation and operation in a closed building! room with restricted ventilation. Any specific requirements for air conditioned! dust free environment, etc. for the panels, if absolutely necessary, shall be clearly highlighted by the vendor in the offer.

6. FIRE ALARM SYSTEM DESCRIPTION

6.1 GENERAL Fire alarm system under this specification is envisaged to provide fire monitoring in industrial plants! chemical plants! plant and non- plant buildings. The system shall be designed to detect incipient fires and generate audio! visual alarm in case of fire.




The system shall consist of automatic fire detectors and manual call point or break glass unit. Automatic fire detectors shall work on the principle of sensing of smoke, heat or infrared rays. Depending on type of smoke, optica’ or ionization type detectors shall be used. Detectors shall generally be provided in plant! non-plant buildings. Manual Call Point shall be provided at exit doors of the buildings and at exit route of industrial plants. Number of detectors and break glass unit shall be decided as per guidelines given in applicable codes and standards.

The plant! building shall be divided into fire monitoring zones. Detectors and MCP at these buildings and plants shall be connected to DGFAP! ZFAP. These panels shall continuously monitor the state of these devices. On sensing fire condition, an audio! visual alarm shall be initiated identifying the zone where fire is detected. Panels shall continuously monitor the health of the cabling and in case of short circuit or open circuit fault alarm shall be actuated. Fire alarm panels shall also have powered outputs for switching on exit signs and hooters as specified in data sheet. Further, panels shall provide required output for interfacing with the Purchaser’s systems such as air conditioning system or pressurization system or fire protection systems.

Alarms, if specified, shall be relayed to repeater panel provided in buildings like control rooms! administrative buildings to provide zone wise annunciation. In addition facility shall be provided to actuate siren! hooter.

For integrated fire alarm system where plant-wide large numbers of fire alarm panels are envisaged, these panels shall be integrated to CFAP, which shall be located in fire station or in administrative control room of the building as per the job requirements. The connectivity shall be achieved using data high way or dedicated cable connection from each fire alarm panel to CFAP. Mimic at CFAP shall be provided for fire! fault annunciation on geographical location in addition to the text! LED. If defined, CFAP shall have provision for automatic and manual actuation of plant-wide siren as per operator’s choice. Interface with other systems such as telephone exchange! plant’s public address system! Pager system shall be provided for communication required for disaster management.

6.2 CONVENTIONAL / ADDRESSABLE FIRE ALARM SYSTEMS Fire alarm system shall be conventional fire alarm system or microprocessor based fire alarm system as specified in data sheet. Conventional fire alarm system shall have conventional field equipment and Microprocessor based system shall have addressable type field devices.

6.2.1 Conventional fire alarm system shall generally comprise but not be limited to the following equipment used in conjunction with conventional automatic fire alarm detectors and manual call points as a minimum.i. CFAP with! without mimic (as per data sheet)




ii. ZFAPs iii. Repeater Fire Alarm Panel iv. Plant-wide Sirens and starters v. Hooters, exit sign and flAB in buildings vi. Interface with Purchaser’s systems vii. Any other hardware as required to render system complete

6.2.2. Microprocessor based fire alarm system shall generally comprise but not be limited to the following equipments used in conjunction with addressable automatic detectors and addressable MCP as a minimum.

i. CFAP consisting of computer based graphic workstation and engineering station.

ii. Multi loop DGFAPs iii. Plant-wide sirens and starters iv. Hooters, exit sign and flAB in buildings v. Interface with Purchaser’s systems vi. Dual redundant copper! FO cable data highway complete with dual

redundant architecture for communication hardware including communication port, switches, processor and power supply

vii. Any other hardware! Software required for rendering system complete

6.2.3 As specified in data sheet, the system shall be provided with siren!s to be located at a suitable Iocation!s in the plant and it shall be actuated manually and automatically as selected by operator from CFAP! DGFAP located at fire station! other buildings.

7. CONVENTIONAL FIRE ALARM SYSTEM

7.1 DESIGN FEATURES

7.1.1 The system shall be modular and shall facilitate future extension ! modification. Panel design and component selections shall be done for future extension up to 10% of specified zones or one zone whichever is maximum in each panel. The design of common facility and hardware shall be provided for required future extension of zones.

7.1.2 PCBs shall have watchdog feature for self-diagnostic. Each PCB shall have LED for annunciating card failure. Following self-diagnostic features may be considered as minimum.

i. Open loop detection ii. Short circuit detection iii. Earth faults iv. Power supply failure e.g. low battery voltage, main incoming

supply fail v. System faults (PCB failure)




7.1.3 Logic of operation shall be built on ‘Fail safe” feature i.e. NC contact of field devices shall be considered as healthy condition and NO as fire condition. 1 NO+ I NC contact of output relays shall be wired to terminal block for interface with Purchaser’s other equipment.

7.1.4 It shall be possible to test lamps, hooters, flasher circuit, and functional tests etc through common “Test” push button.

7.1.5 The circuit shall be so designed that silencing of the current alarm by ACCEPT push button shall not prevent annunciation of subsequent fire alarm received from any other location

7.1.6 Signal-to noise ratio shall be high to avoid spurious actuation due to noise induced in the field wiring because of proximity with power cables. Cables for field devices shall be multicore copper conductor, unscreened, armoured, copper conductor cable. If required noise filters shall be provided at fire alarm panel.

7.1.7 Detectors and MCPs in a ioop shall be wired through I .5 mm2 multi-core, Copper conductors, PVC insulated, armoured cable. Limiting distance from fire alarm panel to last detector/MCP shall not be less than 2 km or as specified in data sheet whichever is maximum.

7.1.8 LEDs shall be provided for fire! fault visual annunciation on the panel front. LED shall also be provided for Power supply healthy, Battery backup ON, Battery/ Charger status.

7.1.9 If zone is protected with clean agent! CO2 system, the detectors and MCPs of the zone shall be wired in cross-zones by providing minimum two loops in a zone. The last device in each loop shall be provided with end of line resistor of suitable value as per circuit design to facilitate cable open circuit and short circuit detection.

7.1.10 Scheme for FIRE/FAULT annunciation shall be as per the following. System condition AUDIO VISUAL

NORMAL OFF OFF

FIRE ON (tone 1) Flasher ON, Fire LED Steady ON

Accept OFF Flasher steady, Fire LED steady ON

Reset OFF Flasher OFF, Fault LED OFF

FAULT ON (tone 2) Flasher OFF, Fault LED Steady ON

Accept OFF Flasher OFF, Fault LED Steady ON





7.1.11 Fire alarm panels including repeater panels and CFAP shall be certified! approved by applicable approving agency of country of origin as required.

7.2 ZONAL FIRE ALARM PANEL

7.2.1 ZFAP shall consist number of zones as specified in data sheet. Detectors! MCP! heat sensing cables etc shall he connected zone wise in a loop. It shall monitor fire! fault condition of the zone. ZFAP shall be located indoor in safe area..

7.2.2 ZFAP shall be freestanding, floor mounting vertical panel consisting of audio/visual annunciation with Alarm Accept, Test and Reset Push Buttons, Auto/Manual control of hooters provided in buildings. Provision to actuate siren shall be provided if specified in data sheet. Circuit shall be designed to provide annunciation if any detector in a zone senses fire. Annunciation scheme shall be as per clause 7.1.10

7.2.3 Audio! Visual indication and annunciation shall be as per clause 7.1.8.

7.2.4 ZFAP shall have required interface hardware where integration with CFAP/ repeater panel is envisaged as per data sheet.

7.2.5 Output contacts (1NO+1NC) shall be provided for interface with Purchaser’s systems as per clause 9 of this specification. The rating of output contact shall be 0.5A, 220V DC or 2A, 240V AC.

7.2.6 Input power supply and battery backup for ZFAP shall be as per data sheet and as per clause 5.1 of this specification.

7.3 REPEAT ALARM PANEL-CONVENTIONAL

7.3.1 Repeat fire alarm panel shall be similar to ZFAP except providing zones for detector loops. Fire! fault annunciation of ZFAP shall be repeated to repeater panel. Annunciation scheme shall be as per 7.1.10 Depending on the size Repeat Fire Alarm panel may be floor mounting type or wall mounting type.

7.3.2 Where required, input power supply from purchaser shall either be 240V or 110 V, 1 phase, 50Hz. It shall be possible to select supply either 240V or 110 V at site without modifying or adding additional equipment in the panel.

7.4 CENTRAL FIRE ALARM PANEL

7.4.1 CFAP shall be located in fire station in plants or in building control room. Fire and fault annunciation for each Zone or group of zones at ZFAP shall be repeated at CFAP. Annunciation scheme at CFAP shall be provided as per the clause 7.1.10.




7.4.2 CFAP shall be in vertical panel construction or desk type construction having controls such as Accept, Test and Reset Push Buttons, Auto/Manual control of siren etc.

7.4.3 Unless otherwise specified in the data sheet, CFAP shall have mimic to display geographical location of fire. Mimic shall form an integral part of the CFAP and shall be located at the top of the panel. When separate mimic panel is specified, it shall either be wall mounting or freestanding floor mounted type. Two LEDs shall be provided for each zone on mimic panel for display of fire alarm. Mimic panel shall be powered by CFAP. Mimic made out of plastic stickers shall not be acceptable.

7.4.4 Input supply and battery backup for CFAP and MIMIC shall be as per data sheet and as per clause 5.1 of this specification.

8 MICROPROCESSOR BASED FIRE ALARM SYSTEM

8.1 DESIGN FEATURE

8.1.1 Unless otherwise specified Microprocessor based system shall be analog addressable type. The system shall be integrated as per ‘system architecture’ indicated in data sheets.

8.1.2 Microprocessor based fire alarm system shall be designed to use state of the art technology. All fire alarm panels including repeater panel shall be networked through data high way. The system supplied shall not pose any limitation for future expansion by way of networking of fire alarm panels, data transfer, parameterization of addressable field devices, graphic displays etc.

8.1.3 The system shall be modular and shall facilitate future extension! modification. Panel design and component selections shall be done for future extension up to 10% of specified zones or one zone whichever is maximum in each panel. The design of common facility and hardware shall be provided for required future extension of zones.

8.1.4 PCBs shall have watchdog feature for self-diagnostic. Each PCB shall have LED for annunciating card failure. Following self-diagnostic features may be considered as minimum.

i. Open loop detection ii. Short circuit detection iii. Earth faults iv. Power supply failure e.g. low battery voltage, main incoming

supply fail v. System faults (PCB failure)




8.1.5 Unless specified otherwise in data sheet, system architecture shall have minimum redundancy indicated below however not limited to the same.

i) Dual redundant at processor level (communication processor and I/O card processor)

ii) Dual redundant communication port iii) Dual redundant data highway cable iv) Dual redundant microprocessor at CFAP v) Dual redundant work station/MMI (engineering station operator’s station) vi) Dual redundant power supply card at all fire alarm panels (but with single

source of battery backup) 8.1.6 Data highway shall be Fibre optic or twisted pair shielded copper cable as

specified in data sheets. Whether specified or not, data highway shall include all necessary hardware such as modem, repeaters, network switches! hubs etc including power supply system as required to suit the length of data highway.

8.1.7 The communication shall be peer to peer between various DGFAPs, repeater Panels, CFAP and other system components connected on fire alarm system data highway.

8.1.8 Any fault in Analog detector addressable loop and data highway shall not impair communication i.e. Communication! flow of analog signal shall be possible from either end of the loop.

8.1.9 The loop cabling for wiring detectors and MCPs shall be class A, fault tolerant type as per NFPA 72.

8.1.10 Fire alarm logic shall be programmable type. The logic for zone protected with clean agent system! CO2, shall be programmed to provide output for actuation after ensuring that there is no false alarm. Similarly logic to switch ON the exit sign and sound the hooters shall be programmable type.

8.1.11 The logic shall be so programmed that silencing of the current alarm by ACCEPT push button shall not prevent annunciation of subsequent fire alarm received from any other location.

8.1.12 Signal-to noise ratio shall be high to avoid spurious actuation due to noise induced in the field wiring because of proximity with power cables. Unless other wise specified, fire alarm cables laid in buildings shall be twisted pair, screened and unarmoured and shall be laid in conduits while cable laid outdoor in plant shall be twisted pair, screened and armoured. If required noise filters shall be provided at fire alarm panel.

8.1.13 Unless otherwise specified in data sheet, the minimum number of detectors! MCP/ addressable devices in a signal loop shall be 60.




8.1.14 Unless otherwise specified in data sheet, conductor size of loop cable shall be 1 .Ssqmrn copper. The allowable signal loop length shall not be less than 2 km. To optimize length, circuit design for loop shall allow the use of spur connection.

8.1.15 DGFAP and repeater panel shall have backlit alphanumeric LCD display to provide addresses, status of each field device. In addition LEDs shall be provided for fire/ fault visual annunciation. LED shall also be provided for Power supply healthy, Battery backup ON, Battery! Charger status.

8.1.16 Fire station shall be provided with dual redundant PC with monitor for operator’s workstation and for engineering station. Any of the two should be possible to configure as engineering station for programming off line. After Programming, the engineering station will be connected to network as online operator’s workstation. . Programming shall also allow activating Siren from the keyboard in manual mode as per operator’s choice.

8.1.17 Scheme for FIRE / FAULT annunciation shall be as per the following.

System condition AUDIO VISUAL

NORMAL OFF OFF

FIRE ON (tone 1) Flasher ON, Fire LED Steady ON

Accept OFF Flasher steady, Fire LED steady ON


FAULT ON (tone 2) Flasher OFF, Fault LED Steady ON

Accept OFF Flasher OFF, Fault LED Steady ON


8.1.18 All field devices such as detectors and MCPs shall be addressable type. If available in vendor’s design, hooters and exit sign may also be connected in addressable loop. Fault isolators shall be provided to minimize outage of number of detectors) MCPs in case of loop cable fault. For hazardous area flame proof equipment shall be used. As far as possible, the use of intrinsically safe field devices in hazardous area should be avoided. If unavoidable, due care shall be taken care in design to avoid signal distortion and thus the mal-operation due to cable capacitance and inductance.

8.1.19 System shall provide adequate EEPROM size to store minimum of 10 events fire! fault. The event shall be stored in LIFO structure. All events shall be time stamped. DGFAP shall have real time clock for event time stamping.

8.1.20 Software access for either Zone programming or access to plant! building graphic on monitor shall be password protected. For viewing status of




various field devices e.g. fire and fault status password protection shall not be given.

8.1.21 Fire alarm panels including repeater panels and CFAP shall be certified! approved by an international approving agency! approving agency of country of origin as applicable.

8.2 DATA GATHERING CUM FIRE ALARM PANEL (DGFAP)

8.2.1 DGFAP shall have basic design features as per clause 8.1 above, Number of signal loops in each DGFAP shall be as defined in the data sheet. Number of loops shall be basic part of main PCB and should not be extended by providing external electronic devices. LCD display and annunciation scheme shall be as per clause 8.1 .1 7.

8.2.2 It shall be possible to change the reference value of detector sensitivity either manually or automatically as required during the operation to avoid false alarms prior to detector maintenance.

8.2.3 DGFAP shall have serial port for communication to data highway. It should be possible to communicate all the information to CFAPI FA system workstation located with fire marshal. The protocol of communication shall preferably be open protocol.

8.2.4 In the event of non-availability of data highway, DGFAP shall work as stand alone intelligent panel monitoring fire in the zones connected to it.

8.2.5 It shall be possible to configure DGFAP to access data of any other DGFAP and display as per the operation requirement to be finalized during engineering! commissioning.

8.2.6 It shall be possible to interface with existing fire alarm system consisting of conventional zone detectors and MCPs with end of line resistor as a part of retrofitting.

8.2.7 DGFAPs shall have output relays to provide interface with Purchaser’s system defined in clause 9 as minimum.

8.3 REPEAT ALARM PANEL

8.3.1 These panels shall be required for repeat of alarm in building! plant control rooms. These panels shall be similar to DGFAP and shall be connected to data highway through serial communication. Panels shall have programming facility to inhibit the display of information that is not required in a particular repeater panel.




8.4 CFAP/ PC BASED MONITORING STATION OR WORK STATION

8.4.1 Based on vendor’s system design CFAP shall include network PC based monitoring station directly connected to data highway with other peripherals such as network switches! controller (HUB). Alternatively, vendor may supply CFAP similar to DGFAP along with PC based monitoring station. Application software shall be installed in PC as GUI. The graphic shall include geographical location of various plant areas including location of addressable detectors and MCPs. The navigation between various graphic pages shall be user friendly. The screen shall have defined area to display the latest fire or fault alarm and shall also have facility to pop up the graphic displaying the location of fire event.

8.4.2 Unless stated otherwise, CFAP shall have all the features and facilities of the DGFAPs. It shall monitor the status of each addressable field device indirectly from the DGFAPs connected on data highway.

8.4.3 Engineering workstation shall be used for programming off-line. After programming, the changed parameters shall be down loaded to other PC to work in synchronism as normal operation. This station shall also have two printers connected to PCs working as SOE printer and engineering printer. SOE printer shall be high-speed dot matrix printer and engineering printer shall be laser printer.

8.4.4 Unless specified otherwise, adequately rated UPS with bypass shall be provided for PC based monitoring station. Battery backup shall be sized as per criteria given under 5.1. Only normal supply shall be made available at one point by Purchaser at the location of central fire alarm panel.

8.4.5 It shall be possible to actuate plant-wide siren in auto! manual mode. Unless other wise specified, manual actuation shall be done from keyboard of workstation. Auto actuation shall be through software logic, which shall be finalized with end user during implementation. Auto!Manual selection shall be provided at operator’s workstation. The actuation signal under manual mode selection shall be communicated serially to DGFAP to which siren starter is connected. Siren starters shall be hardwired to DGFAP.

8.4.6 The minimum requirements for the PC and other peripherals shall be as stated below:

o Industrial type Latest generation PC o 1 .44 MB Floppy drive o CD-ROM o Mouse and keyboard o 21 Inch coloured monitor with flat screen o SOE dot matrix printer o Engineering laser jet coloured printer with 8 PPM




Application software supporting graphics with no limitation on number of graphics, events, alarms, number of field devices as required for any large plant like refinery, petrochemical complex or the large multistory building.

8.4.7 It shall be possible to provide multilevel access of fire alarm system. Read only access shall not require password protection. Access for programming and access for controls from keyboard shall be password protected. The levels of password protection shall be agreed with plant operators at the time of commissioning of system.

8.4.8 Printer i. Printer options shall include both graphic laser printer and dot-matrix

event text printer. ii. Printer used in the system shall provide real time records of the system

events and provide system reports on demand, and shall be microprocessor controlled, high speed, read only (RO) letter quality dot-matrix type 132 characters wide and 96 character set.

9 INTEGRATION WITH VARIOUS PLANT SYSTEMS

9.1 Fire Alarm System shall have required hardware to have interface with following plant systems as specified in data sheet.

i. Public Alarm Announcement system ii. Paging and plant intercom systems. iii. Plant data network iv. ISDN telephone exchange and pager system v. Fire suppression system

9.2 ZFAP as a minimum shall be provided with the following interface with fire suppression system unless specified otherwise.

i. Automatic signal for release of clean agent/CO2 release for protected area and RELEASE audio! Visual alarm for evacuation.

ii. Selector switches for primary or secondary clean agent/CO2 supply for each protected area.

iii. Manual push button for discharge of clean agent/CO2 in each protected area. The actual release of clean agent! C02 shall however be delayed by 30sec after the alarm.

iv. Clean agent/CO 2 Discharge inhibit push button for each protected area. v. Deluge valve activation push buttons, deluge valve test push buttons

and deluge valve activated status lamps. vi. Shutdown signals to various air-handling units relative to the zone of

fire. vii. Firewater pumps start push buttons. viii. Firewater pumps running indications.




10 PANEL CONSTRUCTION (CFAP, DGFAP, ZFAP, REPEATER)

10.1.1 All fire alarm Panels shall be free standing, floor mounting type unless specified otherwise and shall be fabricated out of minimum 2mm thick CRCA sheets and doors shall be fabricated out of minimum 1.6mm CRCA sheets. The panel shall be naturally ventilated in IP-41 enclosure protection as minimum.

10.2 EQUIPMENT MOUNTING

10.2.1 All apparatus, display screen, instruments and indicating lamps mounted on the panel front shall be flush mounting type. The external cabling shall not be terminated directly on the base connector of PCBs but shall be terminated on separate terminal block. Further connection to PCBs shall be as per manufacturer’s standard. Routine calibration, adjustments, programming and operation shall be accessible from the front of the panel without opening the door. External cabling shall preferably be done from the rear.

10.2.2 Power supply system including battery bank shall be mounted inside the panel.

10.2.3 Doors shall be provided with pistol grip handle with lock. Lamps shall be provided inside the panel to provide adequate light for maintenance of equipments.

10.2.4 Cable entry shall be from bottom unless otherwise specified in the data sheet. Terminal strip shall be provided for incoming I outgoing cables.

10.3 WIRING AND TERMINALS

10.3.1 Wiring within the panel shall be laid in slotted plastic raceways enclosed with cover. Control connections shall be done with 660V grade PVC insulated wires having stranded copper conductors. 1.5mm2 size of wire shall normally be used for circuits with control fuse rating of I OA or less. Control wiring for electronic circuits shall be through ribbon cable or through copper wire minimum of 0.5mm dia. Panels shall be supplied completely pre-wired, such that only field termination shall be required at site before it is energized.

10.3.2 PCBs for identical functions shall be interchangeable. PCBs shall be plug in type having pin/edge connectors. PCBs shall be suitable for use in tropical, humid and dusty environment. These shall be protected with anti fungus treatment.




10.3.3 Cables shall be terminated on terminal blocks. Clamp type terminals shall be of spring-loaded, stacking type, mounted on rails. Terminals shall be sized to accept, as a minimum 2.5mm2 cross section conductors. Not more than one conductor shall be terminated on the outgoing side of each terminal. At least 20 % spare terminals shall be provided in each panel for termination of spare cores of cables.

10.4 EARTHING

10.4.1 A common earth bar of minimum 25 x 3 mm. copper or equivalent aluminum shall be provided throughout the length of the panel. All non-current carrying metallic parts of the panel- mounted equipment shall be earthed. Flexible jumpers shall connect all doors and movable parts to the earth bus. Two numbers earth lugs shall be provided outside the panel.

10.5 NAME PLATES / WARNING PLATES

10.5.1 All nameplates for panel shall be engraved out of 3 ply (black-white- black) lam icoid sheets or anodized aluminum. Back-engraved Perspex sheet nameplates will also be acceptable. Engraving shall be done with square groove cutters. Hard paper or self-adhesive plastic tape nameplates shall not be acceptable.

10.5.2 Labels shall be provided for every component on the cards, connecting wires as well as for the terminals in the terminal strip inside the panel. Wiring diagram shall be pasted inside the panel door as required for termination and maintenance.

10.5.3 Special warning plates shall be provided on all removable covers or doors giving access to energized metallic parts above 24 volts.

10.6 PAINTING

10.6.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The undersurface shall be made free from all imperfections before undertaking the finishing coat.

10.6.2 After preparation of the undersurface, the panel shall be powder coated. The colour shade of final paint shall be as approved by the purchaser. The finished panels shall be dried in dust free atmosphere. Panel finish shall be free from imperfections Like pinholes, orange peels, run-off paint etc.

10.6.3 All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust-corrosion. Moving elements shall be greased.




11 CABLE AND CABLE ACCESSORIES

11.1.1 Unless otherwise specified, purchaser shall supply and lay only the following cables.

i. Signal Loop! Zone Cables from outdoor field devices to the fire alarm panel except for buildings.

ii. Loop! Zone cables from FA panel to JB (Vendor shall provide JBs in each building for signal loop cabling. Cables from JB to fire alarm panel is included in purchaser’s scope while cable from JB to detectors and all other field devices shall be included in vendor’s scope.)

iii. Exit sign and hooter cables from FA panel to JB (Vendor shall provide separate JB for exit sign and hooter. Cables from JB to fire alarm panel is included in Purchaser’s scope while JB to exit sign and hooter is included in vendor’s scope.)

iv. Cable from purchaser’s switchgear to siren starter and siren starter to siren.

v. All interface cables from fire alarm panels to purchaser’s system. vi. Incoming power supply cables from purchaser’s switchgear to Fire

Alarm Panels All other cables as required for fire alarm system including the supply, laying and termination of cables and accessories within buildings from JBs to detectors! MCPs. exist signs, hooters and also supply, laying, termination of data high way cables, high way accessories etc as required for successful commissioning shall be in vendor’s scope.

11.2 Though the supply and installation of field cabling is excluded from vendor’s scope but terminations of all cables (supplied by both vendor! purchaser) at both ends shall be in vendor’s scope.

11.3 Bidder, as a part of integration and selection of fire alarm equipment, shall furnish detailed specifications for loop/zone cables, data highway cables, cables for hooter/exit signs etc giving details such as type of cables, number of pairs, size of cable, inductance and capacitance data, number of fibres! connectors etc.

11.4 DATA HIGHWAY CABLES

11.4.1 Unless specified otherwise, vendor shall supply Copper cable? FO type data highway cable to suit system design and equipment specification. Copper cables, if supplied, shall be of adequate size, twisted pair, PVC insulated, overall screened, PVC inner sheathed, armoured, FR type PVC outer sheathed as the minimum requirement. Fibre Optic cables, if supplied, shall be armoured, overall FR PVC outer sheathed and shall be as per ITU-T recommendation as a minimum.




11.4.2 Vendor shall supply and install all hardware and cabling accessories as per data high way design including modems, repeaters etc as part of the FA system. Modems! repeaters shall be powered by the supply provided for DGFAPs ! CFAP.

11.5 CABLE GLANDS I ACCESSORIES

11.5.1 All cable glands/ lugs/ connectors as required for the equipment shall be included in vendor’s scope and shall be supplied along with the system, irrespective of whether installation is to be performed by vendor or not.

11.5.2 All the cable glands for outdoor application shall be weatherproof, nickel-plated brass and double compression type, whereas those for indoor application shall be single compression type.

11.5.3 Cable glands for hazardous area equipments shall be flameproof, weatherproof and nickelplated brass double compression type.

12 AUTOMATIC FIRE DETECTORS AND ACCESSORIES

12.1 GENERAL SPECIFICATIONS

12.1.1 Detectors for conventional fire alarm system shall be conventional type. End of line resistor shall be provided at the last detector in the zone. Detectors for microprocessor shall be addressable type. Detectors shall be plug-in type and shall have twist lock action fitting. Multicolour LEDs provided on the detectors shall indicate Normal and Alarm state. Essential features of detectors are indicated as below.

12.1.2 Detectors shall be supplied with mounting bases. Mounting base shall be identical for all type of detectors except special application detectors such as linear beam detectors etc. for installation as well as cable connection. Detector housing (body and cover) shall be made up of damage resistant, fire resistant polycarbonate and shall be suitable for either surface or recess mounting. Detector base shall be mounted on Junction boxes having terminals for cable termination. Where installation is included in vendor’s scope, equipment such as GI conduits, Gl junction box! conduit box etc. shall also be included in vendor’s scope.

12.1.3 Detectors shall be suitable for storage at ambient condition specified in data sheet,

12.1.4 Detectors, which employ Radio Active source, shall be such that the strength of the Radio Active material shall not exceed 1 micro curie or as per latest standard whichever is less.




12.1.5 All detectors shall be on the approved list of LPC, UL! FM! equivalent international approving agency as applicable.

12.1.6 All detectors shall be suitable for operation at DC power supply extended from fire alarm panel.

12.1.7 The addressable detectors shall be continuously monitored to measure changes in their sensitivity due to the environment (dirt, dust, temperature, humidity etc.). These detectors shall give an advance indication to the panel regarding the need for maintenance. The analogue reading sent by the detectors shall be sensed and if there is a rapid increase, an alarm shall be generated. However, if there is a gradual increase in the analogue reading, a maintenance alert shall be generated by the fire alarm panel. It shall be possible to generate maintenance reports from the fire alarm panel. For the addressable detectors two-wire operation shall be possible.

12.1.8 All addressable detectors shall have selectable settings for pre-alarm and alarm and preferably have the facility to set the sensitivity and address from the fire alarm panel.

12.1.9 Manual call points / break glass boxes for microprocessor based fire alarm system shall be addressable type. Each device shall have its own address module.

12.1.10 All addressable detectors shall be suitable for installation using fault tolerant wiring (class-A, style - 6 wiring as per NFPA72). T- Tapping shall not be permitted in the case of such wiring.

12.1.11 All detectors must have insect screen to prevent entry and cause false alarm.

12.1.12 All field devices shall be from the latest generation in the manufacturer’s range of products. Commonly used field devices are listed below. The specification given shall be considered as the minimum requirements.

12.2 HEAT DETECTORS

12.2.1 Heat detectors shall use negative temperature coefficient thermisters for sensing and for reference. The detector shall be designed to give a response that depends on both absolute temperature and rate of rise in temperature.

12.2.2 The rate of rise element shall be carefully calibrated to ignore any normal fluctuation in temperature, but to respond quickly when the temperature rise is 9°C or more per minute.




12.2.3 The fixed temperature feature should be entirely independent of the rate of rise element. The operating temperature of fixed temperature element should be factory set at 57° C ± 5° C.

12.2.4 The detector shall be self-restoring type ensuring repeated use and easy maintenance.

12.3 IONIZATION SMOKE DETECTOR

12.3.1 Ionization smoke detector shall be solid-state type, working on ionization principle and shall preferably be of dual chamber and dual source type.

12.3.2 The detector shall be able to sense incipient fire by detecting the presence of visible and invisible products of combustion like wood, paper, ammonia processing paper, cloth, PVC, bakelite, nylon, foam, acrylic, thermocol, Photo film, nylon, polyester, painted sheets, Teflon, leather etc.

12.3.3 The sensitivity of the detector shall not vary with change in ambient temperature, humidity, pressure or permissible voltage variation. Its performance shall not be affected by an air current of 5 rn/sec. It shall have an inbuilt arrangement such that puffs of smoke or hot air pockets do not inadvertently trigger the alarm. The detector shall be protected against dust accumulation! ingress. It shall have insect resistant screen to prevent nuisance alarms.

12.3.4 Where air velocity is expected to be higher, smoke guard! baffle shall be used.

12.3.5 Where specified, smoke detectors operating on laser diode principle shall be offered.

12.4 PHOTO ELECTRIC / OPTICAL SMOKE DETECTOR Photo electric optical smoke detectors shall work on the principle of light scattering utilizing a light emitting diode.

12.5 UV FLAME DETECTOR

12.5.1 UV flame detectors shall work on the principle of a vacuum photodiode tube to detect the UV radiation that is produced by a flame.

12.5.2 UV flame detectors shall respond to ultraviolet rays of a flame. The detector shall not be actuated by artificial lights, sunlight incident through a windowpane or welding arc. False alarm check circuit shall be incorporated to prevent false alarm due to intermittent flash or lightning.




12.6 IR DETECTORS

12.6.1 1k detectors shall work on the principle of a single wavelength infrared flame detector using one of several different photocell types to detect the infrared emissions in a single wave length band that are produced by a flame.

12.6.2 1k detectors shall react to the infrared rays of aflame. It should be sensitive enough to detect smoky fires in which flame is hardly recognizable. The detector should not react to extremely glaring artificial light or direct sunlight. The detector shall be completely solid-state type.

12.6.3 Where specified combination UV-IR detector shall be used.

12.7 LINEAR BEAM DETECTOR

12.7.1 Linear beam detector shall work on the principle of obscuration of infrared light beam by particles of smoke. The sensitivity shall be such as to enable operation at 30% to 50% obscuration.

12.7.2 Linear beam detector shall consist of separate transmitter and receiver. Linear beam detector shall be suitable for application in high roofed locations such as warehouses etc. The detector shall, preferably, be powered from the loop signal itself. However, if external power supply is required the same shall be explicitly stated by the vendor, which shall be covered under common power supply for the fire alarm panel and devices connected with it.

12.8 HEAT SENSING CABLES

12.8.1 Heat sensing cable shall be analogue type. It shall consist of four copper conductors, each covered with a colour coded, negative temperature co-efficient material. The cores shall be twisted together and protected by an outer sheath of high temperature, flame retardant PVC insulation. External mechanical protection shall be provided over the sensor cables. Vendor shall provide control unit for each 100 m length of the sensor cable.

12.9 MANUAL CALL POINT (MCP)/ BREAK GLASS UNIT (BGU)

12.9.1 Manual break glass unit shall be fabricated out of 14-gauge cold rolled sheet steel. Alternately the break glass unit may be made of die cast aluminum alloy such as LM6. It shall have IP-55 enclosure and weatherproof construction suitable for outdoor installation. The break glass unit shall have a minimum dimension of lOOxlOOx8Omm.

12.9.2 The box shall be fabricated in such a way it can be mounted flush to the wall or on the surface without any modification. Two nos. 19 mm knockouts




shall be provided at the bottom of the box to facilitate cable / conduit entry. The glass shall cover at least 30cm2 area and shall have a thickness not exceeding 2mm.

12.9.3 The box shall have a push button element kept in pressed condition by a glass sheet fitted in the front of the box.

12.9.4 The enclosure shall be painted with fire red colour (shade 536 of TS-5) epoxy painting and an inscription Break Glass in case of Fire”, shall be painted in white letters or riveted on the enclosure by a steel nameplate. A suitable nickel-plated brass hammer, duly chained to the box with stainless steel chain shall be provided with each box for breaking the glass. Each box shall have a distinct identification number boldly painted on it.

12.9.5 If specified in the data sheet, the BGU shall have a suitably wired telephone hand set to facilitate communication between the BGU and the central annunciation panel. Telephone hand set mounted on hook switch shall be housed in a separate lockable weatherproof break glass window enclosure. The glass will be broken in case of fire with the hammer provided with the BGU.

12.9.6 Hazardous area Break Glass Units shall meet the requirement of clause 13 of this specification.

12.10 RESPONSE INDICATOR

12.10.1 If specified in the data sheet, response indicators shall be provided suitable for wall! ceiling mounting. Response indicator shall be provided where the detector is located either above false ceiling or below false floor or where detectors are not directly visible. The response indicators shall be connected to the detectors directly and shall be complete with terminal blocks suitable to accept cables with up to 1.5mm2 copper conductor. In the normal state of detector, the LED shall flicker, but in the event the detector goes into alarm condition, the LED shall glow steadily. LEDs shall be red in colour with 5mm dia. as a minimum.

12.10.2 Use of Response indicators in addressable system is not envisaged unlessotherwise specified in data sheet.

12.11 EXIT SIGNS

12.11.1 Exit signs shall be fabricated out of 1.6mm thick cold rolled sheet steel. This shall be suitable for wall mounting or suspension from ceiling. Exit signs suspended from the ceiling shall have text! direction printed on both the side of exit sign.




12.11.2 Fire exit shall be displayed by means of 5mm dia LEDs or backlit text. It shall be powered from the fire alarm panel. Exit sign shall operate on DC power supply

12.11.3 The exit sign shall be either in red letters on white background or white letters on green background.

12.11.4 Where specified in data sheet, self-luminous exit sign shall be provided.

12.12 HOOTERS

12.12.1 The unit shall consist of solid-state circuitry on a printed circuit board, a loudspeaker and a flashing lamp housed in a weatherproof dust tight, wall mounting type enclosure. The hooter shall, at least, have 102 db (A) output measured at 1-meter distance. The unit shall be powered from the fire alarm panel and operate on DC power. In the event of fire, the hooter shall raise pulsating audio alarm and the lamp shall start flashing.

12.12.2 HAB shall be provided at exit doors of buildings to mute the hooters after evacuation.

12.12.3 Flashing Lights (Beacon)

12.13.1 .The unit shall consist of solid-state circuitry on a printed circuit board and a red-capped incandescent lamp and audio unit housed in a dust tight, wall! ceiling mounting type enclosure. It shall derive power from the DGFAP! ZFAP and shall operate on DC supply.

12.13.2 Flashing lights shall be installed in the enclosed areas where clean agent! CO2 is to be released. In the event a signal for clean agent!C02 release is given, the lamp shall start blinking with a warning sound enabling operating personnel to evacuate the area. The audio unit (hooter) shall have 102 db (A) output measured at 1-meter distance.

12.14 CLEAN AGENT / CO2 RELEASE AND INHIBIT SWITCHES

12.14.1 This unit is required to be provided at the exit of the protected buildings! rooms. If specified, this unit is integrated with DGFAP/ ZFAP. This shall consist of pull type release and inhibit switches clean agent! CO2. The unit shall be fabricated out of 2mm thick cold rolled sheet steel suitable for wall mounting. Switches shall be pulled to release or inhibit clean agent! CO2.

Release switches shall have inscription: ”PULL TO RELEASE CLEAN AGENT CO2” And inhibit switches shall have inscription: “PULL TO INHIBIT CLEAN AGENT / CO2”.




12.15 ZENER BARRIER

12.15.1 Preferably flameproof(Ex ‘d’) equipment that does not require the use of Zener barrier shall be used. When necessary, intrinsically safe (Ex ‘i’) detectors and MCPs, Zener barriers shall be provided. These shall be located in unclassified! non-hazardous areas.

12.15.2 Normally not more than 10 detectors shall be connected to one zener barrier. However vendor shall indicate maximum number of detectors! MCPs that can be connected to one Zener barrier without compromising on working of loop! zone. Vendor shall also indicate the maximum loop length from zener barrier considering 1.5 mm2 copper conductor, screened cable.

12.15.3 In case loop length permits, zener barrier shall be located at DGFAP itself else it shall be located in safe area nearest to the detector! MCP.

12.15.4 Wherever zener barriers are provided in safe area outside the Zonal panel or DGFAP, these shall be housed in their own enclosure with IP-55 degree of protection as a minimum.

12.16 FAULT ISOLATOR

12.16.1 Fault isolator shall be installed, if specified in the data sheet.

12.16.2 Fault isolator shall be designed to provide short circuit protection to an addressable detector loop. It shall be possible to wire the fault isolator at any point in the detector loop.

12.16.3 On occurrence of a fault (short circuit), the isolator shall cut power to all devices installed between the two isolators minimizing the outage of all the detectors in a loop.

12.16.4 The fault isolator shall have the capability to continuously check the faulted side of the loop to determine if the fault still exists. On rectification of the fault, the isolator shall automatically reset itself.

12.16.5 Fault isolator modules shall be housed in a enclosure having lP-55 degree of protection as a minimum. If located in hazardous area, it shall also be tested and approved for use in area classification defined in the data sheet.

12.17 SIRENS

12.17.1 Sirens shall be industrial type with minimum 2.5 km unidirectional range (i.e. 5km diametrical range) against the wind direction.




12.17.2 The decibel level of the siren shall, at least be 132db(A) at 1 meter, to meet the audibility requirement for the above range. Unless otherwise specified, Sirens shall operate at 415 V, 3 ph. AC supply. Sirens shall be housed in weatherproof enclosure. Starter shall be DOL and shall be housed in a separate 1P55 enclosure suitable for installation indoor! outdoor.

12.17.3 For three-phase siren, wall-mounting type three-phase DOL starter shall be supplied. Starter shall be mounted indoor in a building where siren is located. The supply to the siren starter shall be provided by purchaser from Normal or Emergency power source as defined in the data sheet.

13 FIELD DEVICES FOR HAZARDOUS AREA

13.1 Hazardous area is classified as Zone 1/Zone 2, gas group hA! IIB or lIC, temperature class T3 (200 °C) as specified in data sheet. The field devices shall be suitable for installation in hazardous area as per specified area classification.

13.2 Field devices such as detectors, MCPs, fault isolators, Beacons, hooters etc for use in hazardous area, if specified in the data sheet shall have flame proof enclosure conforming to IS 2148. All equipment for hazardous area installation shall be complete with flame proof, weather proof cable glands as specified in clause 11.5.

13.3 Equipment, which cannot have flameproof construction, shall be intrinsically safe in design and shall be used with Zener barriers located in safe area.

13.4 Equipment that are tested / certified by a recognized test laboratory of country of origin shall only be offered. The vendor shall possess valid test certificate issued by a recognized independent test house such as CMRI! BASEEFA! UL/ FM or Equivalent for the offered equipment.

13.5 All equipment (indigenous or imported) shall have valid statutory approval as applicable for the specified hazardous location from CCE or any other applicable statutory authority. All indigenous flameproof equipment shall also have valid BIS license and corresponding marking as required by statutory authority.

13.6 A separate name plate shall also be provided on each equipment to indicate details of testing agency, test certificate number with date, statutory approval number with date, approval agency, BIS license number with date, applicable gas group, temperature class etc. The nameplate shall be riveted! fixed with screws and not pasted. In case above information are embossed on the enclosure, the same need not be repeated.




14 Engineering Requirements Unless specified other wise, vendor shall design entire fire alarm system including design of system architecture with details of integration, cabling requirement and protocol selection etc. Vendor’s scope shall also include basic design and preparation of layouts for fire alarm system for plant! buildings as specified in the data sheet! purchase documents.

14.1.1 CONVENTIONAL FIRE ALARM SYSTEM i. For conventional fire alarm system, purchaser shall provide typical block

diagram. On this basis, vendor shall prepare detailed drawing giving various system component details. The design and engineering shall include sizing and selection of various equipment such as fire alarm panels, batteries, battery chargers, field equipments, siren, siren starter etc. including preparation of G.A. drawings of various equipment.

ii. The layout engineering for buildings shall include the drawings showing location of MCP/ Detector and other field devices, cable schedules, interconnection diagram, equipment installation drawings etc as minimum.

14.1.2 Addressable Fire Alarm System i) Vendor shall develop a system architecture based on purchaser’s

requirement showing details of various network elements such as DGFAP, CFAP, Work station, networking hardware, redundancy, protocols, data highway etc. including the maximum permissible loop length and length of data highway.

ii) The design and engineering shall include sizing and selection of various equipment such as fire alarm panels, batteries, battery chargers, field equipments, siren! siren starter etc. including preparation of G.A. drawings of various equipment.

iii) The layout engineering for buildings shall include the drawings showing location of MCP/ Detector and other field devices, cable schedules, interconnection diagram, equipment installation drawings etc. as minimum.

iv) The parameterization facilities of various field devices along with the geographic mimic, annunciation, text messages etc shall be available on the fire alarm panel.

15 INSPECTION, TESTING AND ACCEPTANCE

15.1 All the equipment shall be tested to the defined specifications as per mutually agreed test plan! FAT procedure, which shall be submitted and got




approved from Purchaser at least one month before inspection. GAIL/ Purchaser’s inspectors shall witness all the tests.

15.2 During manufacture, the equipment shall be subject to inspection as per attached inspection plan to assess the progress of work and to ascertain that the quality controls are being maintained. Vendor shall provide all necessary assistance and information concerning the supply to GAIL/Purchaser’ s inspectors.

15.3 Tests shall be carried out at the vendor’s works under his care and expense and Purchaser shall be informed at least 4 weeks in advance regarding this.

15.4 FAT shall include simulation of operational field conditions and test for functional adequacy. Besides all routine, and acceptance tests specified by applicable codes and standards, shall be performed on the complete system.

15.5 For bought out items, the routine and acceptance tests shall be conducted at the respective equipment manufacturer’s works.

15.6 At the time of inspection, vendor shall produce original of all the type test certificates, test and approval certificates for hazardous area equipment from testing and approving authority and any other certificates as required from statutory authority for the review of inspectors.

15.7 Vendor shall submit a SAT procedure for GAIL/ Purchaser’s approval. All equipment and systems shall be tested at site as per the approved SAT procedure

15.8 SAT shall be conducted by vendor after the entire fire alarm system is installed and inter connected by cables. These tests shall establish the operational correctness of the system. Vendor shall rectify deficiencies noticed during SAT with no commercial implication to Purchaser including replacement of system components and supply of new component for making system successfully operational.

16 PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for selected mode of transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent damage to finish. Crates shall have skid bottom for handling.

Special notations such as ‘Fragile &, ‘This side up’, ‘Center of gravity’, ‘Weight’ etc., shall be clearly marked on the package together with Tag nos., Purchase order Nos. etc.




The equipment may be stored outdoors for long periods before erection. The packing shall be completely suitable for outdoor storage in areas with heavy rains! high ambient temperature.

17 INSTALLATION AND COMMISSIONING Where installation of the system is included in the scope of the vendor, vendor shall arrange all necessary manpower and equipment required for the same. Commissioning of the complete system is to be carried out by vendor in all cases irrespective of whether the installation was performed by vendor or not. All tools, test equipment etc. for the successful commissioning of the system shall be arranged by the vendor. Only the cabling specifically excluded from vendor’s scope shall be installed by others. However, termination at panels for purchaser’s cables shall be done by the vendor.

18 TRAINING The vendor shall provide, free of cost, comprehensive training to Purchaser’s personnel on various operation and maintenance aspects of the Fire Alarm system as agreed during ordering


INSPECTION TEST PLAN FOR BATTERY CHARGERS-07-06-001 Page 1 of 3


INSPECTION TEST PLAN FOR BATTERY CHARGERS




1. SCOPE: This Inspection Test Plan covers the minimum testing requirements of Battery Chargers ,Distribution Boards and Cell boosters.

2 REFERENCE DOCUMENTS: 1) Standard specification S-07-02-019 and standards referred there in. 2) 2) Job specifications I approved documents.

1.0 INSPECTION AND TEST REQUIREMENTS: SCOPE OF INSPECTION

STAGE CHARACTERISTICSQUANTUM OF CHECK RECORD

Sub Vendor VENDOR GAIL

1 Incoming Material like Fabricated items, Electronic components, PCBs, Relays, Indicating Instruments, Switches, MCCBs, Contactors, etc

Visual, Dimensional, operational checks etc as applicable

100%

Supplier’s TC I Vendor’s Test Records

- W W

2 PCBs & Electronic components sub assemblies

Burn-in Test for 96 hours at 50o C 100%Vendor’s Test Records

- W W

3 Battery Charger Assembly

ACCEPTANCE TESTS: • Visual check including layout, Tag plates, Paint shade, Bus marking, Identification and location of components etc. a Dimension check including operational height, Bus size, Clearances etc. a Bill of material! Make of Components. • Full Load test for 16 hours with minimum 8hrs for each Charger. Temperature rise for critical components would be recorded during this test. • Charger testing at constant output voltage in float and boost charge mode, including measurement of AC phase voltage, frequency, current, power, DC output voltage, current and output voltage ripple at nominal AC input voftage at zero, 50% and 100% of rated output current. Measurement shall be

100%

Vendor’s Test RecordsInspection Witness Record

- W W




repeated at 100% full load current at 90% and 110% of nominal AC supply voltage.• Charger testing under constant output current limiting condition in float and boost mode, including measurement of DC output voltage and current with DC output voltage varying between zero and set value corresponding to constant voltage operation. Vendor’s Test • Proper functioning of all measuring Records I instruments, alarms, indications, protection 100% Inspection W W and controls as per requirement. Witness • Parallel operation of both chargers Record including load sharing and automatic isolation of faulty charger. • Charger Efficiency and Voltage regulation test. • Dynamic Response test for step load up to 50% of rated output. • Audible noise test. • Insulation resistance before and after HV test for power, control and auxiliary circuits. • High voltage withstand test for power, control and main circuits.


- W W

4D.C Distribution Board

Visual, Dimensions, Feeder Tag plates, Vendor’s Test Functional checks, IR and HV test

100%


- W W

5 Cell BoosterVisual, Dimensions, Feeder Tag Plates, Functional Test, IR & HV Test

100%


- W W

6 Battery Charger, Distribution Board, Cell Booster

Internal Test Reports 100% Vendor’s Test Records - - R

Notes:1. W – Witness R – Review 2. Vendor to submit these reports before offering items for inspection


INSPECTION AND TEST PLAN FOR MV/HV CABLES AND ACCESSORIES S-07-06-002 Page 1 of 3


INSPECTION AND TEST PLAN FOR MEDIUM AND HIGH VOLTAGE CABLES & ACCESSORIES




1.0 SCOPE: This Inspection and Test Plan covers the minimum testing requirements of PVC, XLPE insulated cables and cable jointing/terminating accessories for high and medium voltage systems.

2.0 REFERENCE DOCUMENTS:P0/PR / Standards referred there in /Job specifications / Approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS: SCOPE OF INSPECTION

Sl No

STAGE/ACTIVITY CHARACTERISTICS QUANTUM OF CHECK

RECORD SUB SUPPLIER

SUPPLIER GAIL/TPIA

1.

Incoming raw material like Copper, Aluminum, PVC, XLPE, Galvanized Armour.

Purity, Dimensions, Physical and Chemical Properties. 100%

Material Test Certificates/ supplier’s Test Records/ Third Party Lab

P P/R R

2. Finished Cable Visual, Drum details, Size, Ends Capping, Marking on outer sheath (such as Incremental Length, Voltage grade. manufacturer’s name), Colour coding, etc.

100% for Drum details and Sample drums for balance details

Supplier’s Test Records

P W

3. Finished Cable

Routine Checks: Conductor Resistance. High Voltage Partial Discharge (for XLPE only)

100% Supplier’s Test Records

P W/R

4. Finished Cable (Acceptance tests)

Dimension checks — overall dia, over/under armour, thickness of insulation, sheath, copper screen dimension, etc.

Conductor Resistance Insulation resistance / Volume resistivity High Voltage tests Partial Discharge(for XLPE)Hot_Set_(for_XLPE_insulation) Tests on Conductor as applicableTests on PVC/XLPE Insulation & Sheath*Armour Galvanization - dip test

As per sampling plan

Inspection Test Records

- P W




Volume resistivity, Insulation resistance Tensile and elongation (without ageing)

5. Finished Cable (Special tests)

Flammability test as per IS 10810 part 61 Flammability test as per IS 10810 part 62 Accelerated water absorption test as per NEMA(Electrical

method) # Test for resistance to Ultra Violet Radiation # Oxygen Index Rodent & Termite repulsion check Drum length !surface finish check by re-winding

1 sample/size/lot 1 sample /order 1 sample/order 1 sample/ order 1 sample/size lot 1 sample! lot 1 or 2 drums per lot

Inspection test records

6. Finished Cable (Type tests **)

Dielectric Retention. Type tests on PVC insulation and Sheath High Voltage test (Water Immersion) Dielectric power factor tests as function of voltage, temperature.

(XLPE cables) Heating cycle test (XLPE Cables) Impulse withstand test (XLPE cables)

Sample Supplier’s Test Records

R

7. Cable accessories Visual Dimensions Type tests** as per IS 13573

Sample Supplier’s Test Records

P R

# In case TC (not older than one year) from independent test lab is available & type of compound used is same then the same may be accepted. * Hot deformation, Heat shock and Shrinkage tests on insulation & sheath (One sample/Lot) shall be witnessed by GAIL, all other tests as per IS-583l, 7098 shall be carried out by supplier and test reports

shall be reviewed by GAIL. ** Supplier to submit Routine, Acceptance and Type test reports before offering items for inspection to GAIL.Legends: CCE or CCOE-Chief Controller of Explosives, DT- Destructive Testing, HT- Heat treatment, H- Hold (Do not proceed without approval), IBR-Indian Boiler Regulations, ITP Inspection and Test Plan, ,NDT-Not Destructive Testing,, P — Perform, PESO-Petroleum and Explosives safety Organisation, P0- Purchase Order, PR-Purchase Requisition, PQR Procedure Qualification Record, QAP-Quality Assurance Plan, Random -10% (min.l no.) of each size and type of Bulk item, R-Review, RT- Radiography Testing, RW-Random witness, TC-Test Certificate TPI or TPIA- Third Party Inspection Agency, VDR- Vendor Data Requirements, WPS- Welding Procedure Specification, WPQ- Welders Performance Qualification, WWitness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable): Wherever W/R or HJW is indicated, Inspection Engineer shall decide the option to be exercised for the particular stage and supplier 1 Supplier’s in house procedures may be accepted in case TPt/GAIL is satisfied with adequacy of procedures to comply with Purchase Order/Specifications requirements. In case of non availability of suitable

procedures, fresh procedures may be qualified under TPI/GAIL witness. In ease of conflict between purchase specification, contract documents and ITP, more stringent conditions shall be applicable. This document describes generally the requirements pertaining to all types of the item. Requirements specific to P0 and the item are only applicable. Acceptance Norms for all the activities shall be as per P0/PR/ Standards referred there in] Job specifications/Approved documents


INSPECTION AND TEST PLAN FOR FIRE ALARM SYSTEMS-07-06-003 Page 1 of 4


INSPECTION AND TEST PLAN FOR FIRE DETECTION AND ALARM SYSTEM




1.0 SCOPE: This Inspection and Test Plan covers the minimum testing requirements of automatic and manual Fire Alarm System incorporating detectors, Data Gathering Fire Alarm Panels(DGFAP) and central fire alarm panels(conventional or computer based).

1.0 REFERENCE DOCUMENTS:P0/PR / Standards referred there in /Job specifications / Approved documents.

1.0 INSPECTION AND TEST REQUIREMENTS:SCOPE OF INSPECTION

Sl No

STAGE/ACTIVITY CHARACTERISTICSQUANTUM OF

CHECKRECORD SUB

SUPPLIERSUPPLIER

GAIL/TPIA

1.

Incoming Material like Fabricated items, PCBs, Lamps, Push Buttons, Fire detectors,, Temp detectors, UV, IR, Ionization type, linear beam type and optical type detectors, Manual call points, Sirens, Annunciators, Relays, Switches, Battery, battery charger, Exit Signs, Flashing Lights, Release and Inhibit switches, Zener Barriers, Short Circuit/fault Isolator, etc.

Visual, Dimensional, Operational checks as applicable, Matching of detectors with given specifications, Statutory body certification, Make of Items, etc.

100%

Sub supplier’s TC / Supplier’s Test Records

P W/R R

2. PCBs Burn-In Test of PCBs for 96 hrs at 50 deg C 100% Supplier’s Test Records

R

3Conventional Fire Alarm System consisting Central, Zonal and Repeater Fire Alarm Panels (Final Inspection)

ACCEPTANCE TESTS: o Visual check including GA, layout, Tag plates,

Paint shade, Panel gasketing, Identification and location of components ,Mimic layout, Check of specifications of all types of detectors w.r.t data sheets, etc

o Bill of material/Make of components check o Quality of lacquering and Inter changeability of

PCBs o Verification of cable termination arrangement.o Operation check of scheme, Mimic lamps by

simulating fire, cable fault conditions w.r.t different type of detectors.

100%Inspection Witness Record

- P H/W




o Check of detector operation w.r.t loop impedance ( L, R, C parameters given in data sheet for the cable)

o Operation checks of scheme, mimic lamps w.r.t different type of release and inhibit switch thro’ output relays.

o Simulation of all Alarms o Auto & Manual release operation o Fail safe operation o Verification of Battery type and Capacity o Operation check for Break glass assembly o Operation check on applicable accessories like

Exit Signs, Beacon Lamps, Siren, Release and inhibit switches, Short circuit/fault isolator

o Provision of cable glands and earthing

4

Computer aided Fire Alarm System consisting of Central Fire Alarm Panel, Data gathering Fire alarm Panel (DGFAP) and Repeat Fire Alarm Panel. (Final Inspection)

ACCEPTANCE TESTS: o Visual check including GA, layout, Tag plates,

Paint shade, Panel gasketing, Identification and location of components , Check of specifications of all types of detectors w.r.t data sheets, Check of specifications for Zener barriers ,VDU, Keyboards, Printers etc

o Bill of material/make of Component check o Verification of cable termination arrangement

in DGFAP panels o Operation check of scheme by simulating fire,

cable fault conditions w.r.t different type of detectors.

o Check of detector operation w.r.t loop impedance ( L, R, C parameters given in data sheet for the cable)

o Operation checks of scheme w.r.t different type of release and inhibit switch, interfacing with suppression/clean agent systems.

o Simulation of all Alarms o Auto & Manual release operation

100%Inspection Witness Record

- P H/W




o Fail safe operation o Redundancy checks o Check of functions, commands ,reports,

operator level access, Supervisor level access on monitor, Graphics

o CFAP communication with all devices o Changing Address of detectors o Verification of Battery type and Capacity o Operation check on applicable accessories like

Exit Signs, Beacon Lamps, Siren, Release and inhibit switches, Short circuit/fault isolator

Fire Alarm system & Accessories

Submission of Certificates* o Certificate of Statutory testing authority like

FM, UL, BASEEFA, UL, CMRI etc. for DGFAP, Detectors and other accessories

o Certificate of Statutory approval authority like CCOE/PESO, DGFASLI, etc. (for Flameproof type items only)

o Valid BIS license( for indigenous flameproof equipment)

Samples

Certificates from Statutory bodies

R R

* - Supplier to submit these certificates before offering items for inspection to GAIL

Legends: CCE or CCOE-Chief Controller of Explosives, DT- Destructive Testing, HT- Heat treatment, H- Hold (Do not proceed without approval), IBR-Indian Boiler Regulations, ITP-Inspection and Test Plan, ,NDT- Not Destructive Testing, , P — Perform, PESO-Petroleum and Explosives safety Organisation, P0- Purchase Order, PR-Purchase Requisition, PQR- Procedure Qualification Record, QAP-Quality Assurance Plan, Random -10% (mm. 1 no.) of each size and type of Bulk item, R-Review, RT-Radiography Testing, RW-Random witness, TC-Test Certificate TPI or TPIA- Third Party Inspection Agency, VDR- Vendor Data Requirements, WPS- Welding Procedure Specification, WPQ- Welders Performance Qualification, W- Witness (Give due notice, work may proceed after scheduled date). NOTES (As applicable):

1. Wherever W/R or HJW is indicated, TPIJGAIL Inspection Engineer shall decide the option to be exercised for the particular stage and supplier. 2. Supplier’s in house procedures may be accepted in case TPI I GAIL is satisfied with adequacy of procedures to comply with Purchase Order/Specifications

requirements. In case of non Availability of suitable procedures, fresh procedures may be qualified under TPI / GAIL witness. 2. In case of conflict between purchase specification, contract documents and ITP, more stringent conditions shall be applicable. 2. This document describes generally the requirements pertaining to all types of the item. Requirements specific to P0 and the item are only applicable. 3. Acceptance Norms for all the activities shall be as per P0/PR/STANDARDS referred there in /Job Specification /Approved Documents.


Typical Electrode for Earthing System

S-07-01-004 Page

STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Typical Earth Electrode in Test Pit

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Typical Earth Plate Fixing Details

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Typical Earth Connection for Lighting Pole

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Typical Earthing Arrangement for Process Equipment S-07-01-008 Page 1 OF 1

STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Earthing/Bonding of Pipes & Pipe Racks

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Earthing/Bonding of Pipes & Pipe Racks

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Fence & Gate Earthing (Transformer Yard)

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Equipment Earthing Schedule

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Typical Details of Direct Buried Earth Electrode

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Typical Installation of Lighting Fixture at Ground level S-07-01-013 Page 1 OF 1


Typical Installation Of Open Area Flood Light Fixture Mounted On Wall/Column S-07-01-014 Page 1 OF 1


Typical Installation Of Open Area Flood Light Fixture Mounted On Pole S-07-01-014A Page 1 OF 2


Typical Installation Of Open Area Flood Light Fixture Mounted On Pole S-07-01-014A Page 2 OF 2

STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Typical Installation of Street Lighting Fixture

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Typical Installation of Street Lighting Fixture

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Typical Marshalling Box Detail for Lighting Pole

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Post Top Lantern Installed on Gate

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Typical Installation of Fluorescent Fixture Mounting in Exposed Wiring System S-07-01-016 Page 1 OF 1


Typical Installation of Recessed Mounted Fluorescent Fixture S-07-01-017 Page 1 OF 1


Typical Installation Of Recessed Mounted Or Below False Ceiling Mounted Fluorescent Fixture S-07-01-018 Page 1 OF 1


Typical Installation Of Lighting Fixture Mounting In Concealed Conduit System S-07-01-019 Page 1 OF 1


Typical Installation Of Lighting Panel Flush Mounted S-07-01-020 Page 1 OF 1

STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Typical Installation of METSEC Channel

S-07-01-021 Page 1 OF 1


Safety Measures for Electrical Installations During Construction S-07-01-022 Page 1 OF 2


Safety Measures for Electrical Installations During Construction S-07-01-022 Page 2 OF 2


Typical Installation Details of Electrical Panels on False Flooring S-07-01-023 Page 1 OF 3


Typical Installation Details of Electrical Panels on Cable Trench S-07-01-024 Page 1 OF 2


Typical Installation Details of Electrical Panels on Cable Trench S-07-01-024 Page 2 OF 2

STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Prepacked Zinc Anode

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Prepacked Magnesium Anode

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Magnesium Ribbon Anode

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GAIL (INDIA) LTD NEW DELHI Test Station With Foundation Details

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9.0 AN ADDITIONAL 100 MM OF M15 GRADE CONCRETE SHALL BE PLACED OVER THE BASE PLATEFIXING THE FOUNDATION BOLTS.

STANDARD REV-0

STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Test Station Connection Schemes

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Galvanic Anode Installation

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Zinc Ribbon Anode for Cased Crossing With Coated/Painted Casing S-07-01-031 Page 1 OF 1


Pipeline Grounding Through Polarization Cell and Galvanic Anode S-07-01-032 Page 1 OF 1


Typical Construction Details of High Silicon Cast Iron Anode S-07-01-033 Page 1 OF 1


Permanent Copper-Copper Sulphate Reference Cell and Installation Details S-07-01-034 Page 1 OF 1

STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Shallow Anode Ground Bed (PCP)

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Anode Lead Junction Box

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NOTES:1. ALL DIMENSIONS ARE IN METERS UNLESS OTHERWISE MENTIONED.2. THE AREA CLASSIFICATION CONFORMS TO THE LATEST ISSUE OF IS 5572, INDIAN PETROLEUM

RULES, OISD STD 113, OIL MINES REGULATIONS/DGMS GUIDELINES (FOR PROJECTS UNDER GGMS JURISDICTION) AND RECOMMENDATIONS OF PROCESS LISENCOR.

3. AREA WITHIN 1.50M (EXTENDING IN ALL DIRECTIONS) OF SAFETY VENTS, PRODUCT SAMPLING LOCATIONS, PROXESS WATER DRAINS, OILY SEWER VENTS, INSPECTION HATCHES, DISCHARGE ORIFICE OF FIXED LIQUID LEVEL GAUGES, ROTARY OR DIP GAUGES, FILLER OPENINGS, SHALL BE CLASSIFIED AS ZONE 1. FURTHER AN AREA FROM 1.5M TO 3.0 M (EXTENDING IN ALL DIRECTIONS) FROM VENTS SHALL BE CLASSIFIED AS ZONE 2. HOWEVER THE VENTS OR DRAINS BLANKED DURING NORMAL OPERATION AND USED ONLY WHEN THE PLANT IS DEPRESSURISED OR UNDER SHUTDOWN, SHOULD NOT BE REGARDED AS AN OPERATIONAL VENT OR DRAIN OR SOURCE OF HAZARD.

4. OPEN TRENCHES, PITS OR SUMP BELOW GRADE WITHIN ZONE 2 AREA SHALL BE CLASSIFIED AS ZONE 1 AREA.

5. IN CASE OF PIPELINE HANDLING FLAMMABLE MATERIAL, WHERE WELL MAINTAINED VALVES, FITTINGS AND METERS ARE INSTALLED IN VENTILATED AREAS OR PIT, THE EXTENT OF ZONE 2 AREA ABOVE GROUND SHALL BE CONSIDERED AS 4.0M IN ALL DIRECTIONSFROM THE POSSIBLE SOURCE OF HAZARD, ALTHOUGH THE PIT ITSELF SHALL BE CLASSIFIED AS ZONE 1 AREA.

6. GAS GROUPS ARE AS PER IS 9570.7. ROADS FULLY/PARTIALLY COVERED UNDER HAZARDOUS AREA SHALL BE BARRICADED FOR

VEHICULAR MOVEMENT.


Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation S-07-01-036 Page 1 OF 13


Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation S-07-01-036 Page 13 OF

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STANDARD REV-0 GAIL (INDIA) LTD NEW DELHI Marking of Trenches for Electric Cables

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Details of Hot Dip Galvanized Ladder Type Cable Tray S-07-01-039 Page 1 OF 3


Installation Details for Double Pole Terminating Structure upto 33 kV S-07-01-040 Page 1 OF 1


SINGLE LINE DIAGRAM FOR CGS 0001-01-07-01-001 Page 1 of 1


NOTES:1. 24 V SPV POWER SOURCE + 415/220 V AC POWER SOURCE HAS BEEN CONSIDERED.2. 24 V SPV AND BATTERY CHARGER IN PARALLELL OPERATION HAVE BEEN CONSIDERED.3. ANY DC-DC CONVERSION WILL BE IN THE SCOPE OF THE SCADA/TE;ECOM VENDOR4. SCADA/TELECOM EQUIPMENT WILL BE SUPPLIED AND INSTALLED BY THE OWNER.5. AC DISTRIBUTION FOR LIGHTING, VENTILATION AND

ELECTRICAL, CP & CMS SYSTEM - gailebank.gail.co.in · electrical, cp & cms system ... datasheet for...

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Transcript of ELECTRICAL, CP & CMS SYSTEM - gailebank.gail.co.in · electrical, cp & cms system ... datasheet for...