< Security Level 2 > Sheet 1 of 2 ENGINEERING SPECIFICATION CATHODIC PROTECTION SYSTEM FOR HINDUSTAN PETROLEUM CORPORATION LTD. VISAKH REFINERY DHT PROJECT JOB NO.: 6261 DOCUMENT NO.: 6261-N-119 A 16/10/2008 | For Bid Enquiry x Oo Ww Rey. | Issue Date| __Description Prepared | Checked | Approved | @ TOYO ENGINEERING INDIA LIMITED ‘ooo MUMBAI INDIA< Security Level 2 > ENGINEERING SPECIFICATION ae f ge CATHODIC PROTECTION SYSTEM __HPCL, Visakh : TOYO ENGINEERING INDIA LTD. ISSUED ; 16/10/2008 A JOB NO. : 6261 DOC.No. 6261-N-119 ___ DHT PROJECT 7 Sheet 2 of 2 TABLE OF CONTENTS 'SI.No| Title Rev. No of _ Pages 4, Technical specification for Cathodic Protection System - A a Doc. No. 6261-N-119-TS | Specification for Natural Oil Air cooled Transformer A fa Rectifier Unit -Doc.no. 6261-N-119/TRU Data sheet for Transformer Rectifier Unit-Doc. no. 6261-N-| a 5 119/ TRU/ DS | 4, Specification for Anode & Cathode Junction Boxes ~ Doc. A 2 | 4: No. 6261-N-119/JB _ 5, Data Sheet for Deep Anode Ground bed -Doc: no. 6261-N- a 5 419 / ANODE / DS i: 6,_ [Specification for Cables for C.P. System — Doc. no. 6267- A . |S IN-119/; CABLE c 7,_ [Schedule of rates for supply of material - Doc. No. 6261-N-| . *_1119/ supp : _| , Schedule of rates for Installation of material Dos. No. in ; 6261-N-119/INST< Security Level2 > GO TECHNICAL SPECIFICATION FOR DOC.NO. 6261-N-19- ey _|___CATHODIC PROTECTION SYSTEM _ Toyo Engineering Tada Lid JOB NO.: 6261 a ISSUED: 16/10/2008 A DHT PROJECT PAGE 1 OF 19 INDEX 1 Introduction 2 2 Scope of work 2 3. Appiicable Codes and Standard 3 4 Type of Contract 4 5 Basic Corrosion Survey and Data Collection 4 6 Design Basis 4 7 Detailed Engineering 7 8 _List of Specifications 7 9 Desoription of Construction Work 8 40 Quality Plan 16 41 Material Inspection and Testing 17 12 Pre-Commissioning Test 17 13 Commissioning of C.P. System 18 14 Miscellaneous 19 15 Guarantee 19 16 Monitoring 19 6261-N-110.TS< Security Level 2 G TECHNICAL SPECIFICATION FOR poe Ne reaat Nie: irom CATHODIC PROTECTION SYSTEM | Toye Engineering india Ltd. = JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 2 OF 19 1.0 2.0 > [ INTRODUCTION This specification covers the technical requirements for the design, supply, detail engineering, transportation, construction, erection, testing, and commissioning of the Impressed Current Cathodic Protection System (ICCP) SCOPE OF WORK The LSTK Bidder's (hereinafter called Bidder) responsibility is to protect the External Surface of all buried metallic structures against corrosion within the Battery Limits of the plant .These buried metallic structures mainly consist of U/G Piping & Piles. The design life of this impressed Current Cathodic Protection System shall be 25 years. The work shall be carried out as per this enquiry document. The contractor should strictly supply material as per technical specifications and as per approved vendor list enclosed in tender document. CONTRACTOR'S SCOPE OF WORK: Carrying out basic surveys including soil resistivity measurements and other topographical data collection, Development of detailed engineering document on the basis of survey data and optimize the ICCP System. Calculation of anode quantity and size based upon maximum current requirement and design life. Sizing calculation for T/R unit, Anode loop resistance and potential profile on the protected structures. Submission of detailed engineering package including preparation of detailed material / equipment and construction drawings for Approval by Owner. Procurement of Material and equipment. Construction drawings for cabling system, fixing details, cable sizing, cable schedule, interconnection diagram, cable tray details for complete ICCP system. Installation details including location and fixing details of T/R unit, junction box, anodes and control equipment. Installation details of anode bed, reference cell, junction box etc. for complete impressed current cathodic protection system. Electrical Continuity shall be ensured for reinforcement stee! bars of all piles & slab only for storage tanks & all other piles in the onshore part. C.P. contractor would ensure electrical Continuity between piles of different units 6261.N-110-7S,< Security Level 2> 2> GH TECHNICAL SPECIFICATION FOR a toro ma CATHODIG PROTECTION SYSTEM | Toyo Engineering india Lid JOB NO.: 6261 = ISSUED: 16/10/2008 A DHT PROJECT PAGE 3 OF 19 > Preparation of detailed factory / laboratory testing procedures for critical equipment. Submission of test certificate for equipment installed. - Installation and Erection of ICCP System. > Development of system testing and commissioning procedures including interference testing. > Energizing, testing and commissioning of ICCP System. > Preparation and submission of As-built drawings, O&M manual. > Handing over and Training of Owners Personnel. > Maintenance and Monitoring of ICCP System for 01 year from date of commissioning. 2.1.2 PURCHASER’S SCOPE : TEIL shall provide AC Power Supply from their Distribution Panel in Substation for ICCP System. Further power distribution shall be in contractor's scope. The Contractor shall provide ICP load details to M/s TEIL. TEIL shall provide Detail Drawing of all Buried Structures for carrying out Detailed Engineering of ICCP System. 3.0 CODES AND STANDARDS: The Cathodic Protection system design shall be based on the guidelines of following listed codes, standards and specifications: 31 TEIL technical specification for CCP System Doc # 6179-N-119 3.2 NACE Standard RPO169, RP0S72. 3.3 IS 8062 — Part — | (1976): Code of Practice for C.P of Steel Structures. 3.4 1S 5571(1971): Guide for selection of electrical equipment for hazardous areas. 3.5 Indian Electricity act 3.6 Petroleum Act, 1976. 3.7 British Standard Institute B7361 Part-| 1991 Code of Practice for C.P of Steel ‘Structures. 3.8 VDE: 0150, Protection against corrosion due to stray current DC installation. 3.9 1S 3043: -Code for Practice for Earthing. e261.-119-TS< Security Level 2> “Toyo Engineering india Led JOB NO.: 6261 @ TECHNICAL SPECIFICATION FOR Boe NonGeet Nt roroKen CATHODIC PROTECTION SYSTEM ISSUED: 16/10/2008 A DHT PROJECT PAGE 4 OF 19 3.10 3.14 3.12 3.13 4.0 5.0 6.0 181554: - Part | & lI PVC Insulated Cable 1S 7098: - Part | for Cross-linked polyethylene insulated PVC sheathed cable. IS 2148 (1981): - Flame Proof enclosures for Electrical apparatus IS 2147:1962: - Degree of protection provided by enclosures for low voltage switchgear & controlgear TYPE OF CONTRACT The type of contract under the above scope of work shall be on Lump sum turnkey basis. Contractor shall prepare the actual Bill of Material required after conducting basic surveys and optimization of ICCP System. Quantities shall be filled in the Schedule of Rates based on the preliminary design. The work done by the contractor shall be measured and payments shall be made based on the unit rates as per Purchase Order. BASIC CORROSION SURVEYS AND DATA COLLECTION : The detailed corrosion survey including soil resistivity, soil chemical analysis and other topographical data required for design of ICCP system shall be carried out by Contractor. In addition verification and adequacy of data furnished shall be the entire responsibility of the contractor. Cathodic Protection contractor shall be required to perform all survey jobs in connection with this project. Contractors are advised to visit site and apprise themselves thoroughly of the site conditions before submitting the offer. Demand of any data after award of work or verification of data furnished herewith shall be at contractor's own cost. DESIGN BASIS : The Cathodic Protection System Design shall be essentially derived from the input data collected by vendor and information made available by TEIL. ‘The cathodic protection current requirement, therefore shall be governed by following factors: "Surface area and coating quality of all buried structure to be protected. + Relative position of Anode and the Buried structure to be cathodically protected The CP System for congested network in plant complex shall therefore be designed and installed in two stages by providing one preliminary design and another supplementary design as follows: 6261-N18TS< Security Level 2> 2> G TECHNICAL SPECIFICATION FOR DOG. NO. 6261.N-118- ___rerowwa _|___caTHopIC PROTECTION SYSTEM ‘Toye Engineering India Ltd, JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 5 OF 19 6.1 DETAILED DESIGN: The detailed design shal’ be made on based upon parameters such as current density for protection, Consumption rate of anode/ backfill materials, circuit resistance etc. The surface of all buried structures shall be estimated and Protective Current shall be calculated. The CP System shall then be energized and its performance shall be checked 6.1.1 DESIGN PARAMETERS: The below parameters shall be used for preliminary design and to finalize the bill of material. a) The Minimum Design Life of CCP System shall be 25 years b) Protective Current Density of 25mA / m2 shaii be considered for Calculation of Protective Currents of Bare Steel, 6-10mA /m2 for coated structure & 2mA /m2 for steel in concrete. c) _ For Coated Structures such as Pipelines coating defects / Holidays of 30% shall be considered at the End of calculation of current. d) Electrical continuity shall be ensured for reinforcement steel bars of all piles & slab only for storage tanks, and all other piles in the onshore part. ) Earthing System shall be considered for ICCP designing and 100% bare surface area should be considered for current calculations. f) Incidental structures to be considered as 30% of total known calculated surface area to be protected and shall be considered bare for current calculation purposes. 9) Average Soil Resistivity of 03 - 10 Ohms mtr shall be considered for Preliminary Designing. h) Deep Anode Ground beds shall be used for ICCP System with Inactive Depth of e261-N-119-7S 18M to avoid interference of RCC Piles, which extend up to 18M depth. Mixed Metal Oxide Anode should be used for Installation in Deep Anode Groundbeds with Anode Surface current density of 100 A / m* with Coke Backfill Consumption rate of 3-6 mg / A-yr. should be considered for calculating design life of Deep Anode Ground bed with Calcined Petroleum Coke Backfill and utilization factor of 75%.< Socurty Level 2> 2> GO TECHNICAL SPECIFICATION FOR DOC. NO. 6261-N-119- Tov NDN CATHODIC PROTECTION SYSTEM Tayo Engineering india Utd. JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 6 OF 19 k) Deep Ground beds and operating current density at Coke to Earth interface should not exceed 1.6 Amps / m? for satisfactory performance. 1) Distributed Anode Ground beds shall be used during supplementary design for hot spot protection. m) _ Resistance of Group of Distributed Anode Ground beds connected to single TR Unit and a Single Deep Anode Ground bed to T/R Unit shall not exceed 1 Ohms. n) All ICCP Equipment installed in Hazardous Areas shall be Explosion Proof suitable for Zone — 2 Gas Group ~ II A/B area classification. 0) TR Unit should not be loaded more than 75% of its rated output voltage and current capacity at the start of life. p) The maximum T/R Output Voltage should be limited to 75 Volts DC. While preparation of preliminary design contractor should make all the endeavor to ensure the adequacy of the design so that the requirement of supplementary design is bare minimum. 6.1.2 CATHODIC PROTECTION DESIGN CRITERIA : The C.P. SYSTEM will be designed to meet the following Design Criteria: The ON pipe-to-electrolyte potential measurements shall be between (-) 0.85V and (- ) 2.5V with respect to a Cu / CuSO4 reference electrode. The INSTANT OFF pipe-to-electrolyte potential measurements shall be between (-) 0.85V and (-) 1.2V with respect to a Cu / CuSO4 reference electrode. Alternatively, the pipeline will be considered protected when a minimum (-) 300 mV potential shift has been achieved from the initial native potentials to the ‘ON’ potentials. In certain circumstances a minimum polarization shift of (-) 100mV will indicate adequate levels of cathodie protection. 62 SUPPLEMENTARY DESIGN: After energizing C.P. System, if any unprotected / under protected and over protected areas are observed, a supplementary design is to be made to bring all buried metatiic structures within protection acceptable limits. Requirement of any additional anode bed locations or additional T/R Unit requirements or disconnection of some anodes / anode ground beds, if required, to update the CP System performance shall be decided based on the results obtained during commissioning. 626.N-119-75< Security Level 2> 2> G TECHNICAL SPECIFICATION FOR —_| DOC. NO. 6261-N-119- to CATHODIC PROTECTION SYSTEM [Toye Engineering nda id, JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 7 OF 19 7.0 DETAILED ENGINEERING : The following detailed engineering works are to be performed by contractor based on design basis: a) Preparation of Design Calculations based on input data available. b) Preparation of Bill of Quantities (BOQ) based on design calculations. c) Configuration of ICCP System. d) Selection of ICCP Equipment ) Preparation of Construction Drawings. f) Preparation of Quality Assurance System g) Over all CP system layout after Physical verification at location h) Prepare electrical connection scheme including cable schedules, i) Preparation of testing and commissioning procedure. i) Preparation of as built drawings with reproducible after completion of CP ‘System Work. Contractor should get the design and detailed engineering works reviewed and approved by the TEIL /Owner before execution of work. 8.0 _LIST OF SPECIFICATIONS : The following is the list of indigenous and imported materials to be procured for installation of a CP System along with approved vendor list. The Detailed Specifications and Data Sheets of Following material is enclosed with as below ‘Specified Document No. [sr ] Description of Specification ‘Approved No. | Material Document No. Manufacturers / Vendor | 4 | VR Unit | 6229-N-1197 TRU | Kriston, Canara Electric Controls _| REV-0 [2 | Cables = 8220-N-1197 Cable /NETCO | | REV -0 [3 [Deep Anode Ground} ~ 6229-N-1197 | CerAnode Technologies, Titanor, bed Anode/DS ELTECH 6251.N-1107S.< Security Level 2.7 2> GO TECHNICAL SPECIFICATION FOR BOC. NO. 6261-N-119- revono |__CATHODIC PROTECTION SYSTEM | Toyo Engineering india Ls. JOB NO.: 6261 CC ISSUED: 16/10/2008 A DHT PROJECT PAGE 8 OF 19 i 2 REV-0_ 4 _| Junction Boxes 6228-N-119/ JB | Flexpro, Ex-Protecta REV-0 6 | Calcined Petroleum — ‘Goa Carbon, India Carbon Coke Breeze 6 | Reference Electrodes == Borin USA / HARCO (USA) Permanent. 7 Thermit weid == Thermo Weld USA, ERICO Portable reference cell == M.C Miller (USA) All materials shall be inspected by TEIL / Owner at the approved vendors workshop before despatch to check whether these items are meeting the requirement of the specifications. All equipment shall be new and procured from approved reputed manufacturers, Equipment offered shall be field proven. Equipment requiring specialized maintenance or operation shall be avoided as far as possible. Prototype equipment shall not be accepted. Make and construction of all equipment / materials shall be ‘subjected to vendor list enclosed. All equipments shall be adequately protected against corrosive atmosphere for marine application, water and dust ingress, thermal and mechanical stress as per site conditions specified in tender document. 9.0 DESCRIPTION OF CONSTRUCTION WORK: 9.4 MOBILIATION: Contractor shall mobilize the site with engineers, supervisors, technicians skilled/unskilled labourers and materials/ equipment required for commencing construction work within 15 days from the date of issue of intent. 92 SITE PREPARATION: Contractor shall be solely responsible for thorough investigation as to all local conditions affecting the work, including but net limited to transportation and access to the job site, including the availability and condition of roads, disposals, handling and storage of materials; availability and quality of labour, water and electric power, climatic conditions, ground water level and soil strata equipment machinery and material required by contractor, prior to and during performance of the work. 6261.10.75,< Security Level 2°> 2> T GO TECHNICAL SPECIFICATION FOR BOC. NO. 6261-N-118- ey CATHODIC PROTECTION SYSTEM _| “Toye Engineering India US, ‘JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 9 OF 19 After completion of design & detail engineering works, the contractor should get the same reviewed by TE!L / Owner and proceed with construction once the design and detailed engineering works are approved and materials are procured. For commencing construction work, the contractor shall survey and mark the exact location of rectifiers, junction boxes, cable routes and anode ground beds for C. P. Systems as per layout drawing & CP Wiring diagram and get the focations approved by purchaser prior to commencing any installation work at each site. The Contractor shall also focate with the help of a locator all existing under ground piping as per layout drawings required to be protected in this project before ‘starting excavation for cable to pipe joints. When the plant construction is under progress, bidder may have to install C.P. ‘System at following three possible locations: (i) Where R.C.C. pavement is completed (ii) | Where R.C.C. pavement is proposed but not yet complete (ii) Where R.C.C pavement will not be done Provisions given in this document elsewhere for working in R.C.C paved areas, should also be considered by C.P. contractor 9.3 DEEP ANODE GROUND BEI 9.3.1 Drilling of bore hole: Before drilling is started, Contractor should use pipe iocator to check any piping is minimum 3M away from the locations of bore hole. At each boring site the Contractor shall excavate for approximately 1 Sq. meter area both in paved / unpaved areas to a depth of 2 meter. This excavation is required to ensure that no underground structure exist at the drilling site. If such structures are encountered, the Contractor shall advise the TEIL and accordingly the bore hole locations shall be shifted at no extra cost. The Contractor shall supply ali equipment and personnel required to drill bore holes. The bore holes will be approximately 36-54M deep and with suitable diameter for lowering 8" dia. casing pipe. In case the bore hole quantities and depth of deep well anode beds vary from those given in SOR the contractor shall be compensated based on the actual quantities and depth installed and as per unit rates available in SOR. 9.3.2 Casing of Bore Hole: After completion of drilling, contractor need to install 8° dia. M.S. casing pipe for 36- ‘54m deep anode ground bed as follows: a) Weld a round flat plate of 1/2” W.T for sealing the bottom opening of the first casing pipe. Also weld one pointed angle from piece to the sealing plate to 2201.N-119-TS< Security Level 27 2> 7 GO | TECHNICAL SPECIFICATION FOR BOC.NO, g261-NAt9- ‘eros CATHODIC PROTECTION SYSTEM [ Taxo engineering fia Lia, JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 10 OF 19 facilitate easy driving of the casing pipe, lower the first casing pipe inside the bore hole upto a depth 1 feet above grade level and hold it using a clamp. b) Weld second piece of M.S. casing pipe to first piece and lower it same way as it is done for item above. c) Weld consecutive piece of MS. casing pipes and lower them as in case of item (b). tn case lowering becomes difficult by weight of casing pipe alone then fill the casing pipe with fresh water lift it using lifting equipment of drill rig & drop it from required height. 9.3.3 Components of Deep Anode Ground bed The non-replaceable type of deep anode ground bed requires various equipment, which are given below. Ail down hole materials will be procured by Contractor. The following sections briefly describe the major components for the non-replaceable deep anode ground beds. a) 11/2" Hose Pipe 1 1/2" diameter rubber PE heavy wall flexible hose pipe will be used for pumping the fluidized coke breeze. This pipe will be required for installation of the Anode ground bed and will be taken back by contractor after the installation is complete. The hose pipe shall be of single length without any joint in between. b). Vent Pipe A perforated 1” diameter PVC vent pipe will be installed for 36-54m deep well anode bed at a distance of 25mm from anode string for the entire length of the casing. ©). Anode String MMO tubular string will be suspended within the 10” dia bore hole. Anode string should have a lead wire. The lead wire will be terminated in a junction box. The Contractor should ensure that all anodes are lowered centrally in bore holes. For this purpose, Contractor shall provide necessary plastic centralizer D-Clamp arrangement for keeping anodes in centre of bore holes. d). Coke breeze Backfill The calcined petroleum coke breeze should be used as backfill material for deep anode ground beds. The backfill will be mixed with water to form slurry and pumped down hole. Prior to commencing with installation of the down hole deep anode ground bed equipment, the contractor shall ensure that all Contractor's supplied materials are available on site. In addition the contractor shall have all necessary personnel and specialized equipment at the work site. 5251-N-119-TS< Security Level 2 > 2> G | TECHNICAL SPECIFICATION FOR DOC. NO. G261-N-119- } ona _CATHODIC PROTECTION SYSTEM _ Toyo Engineering india Lid JOB NO.: 626% ISSUED: 16/10/2008 A. DHT PROJECT PAGE 11 OF 19 9.3.4 Construction Equipment: The specialized contractor's construction equipment shall include but is not limited to the following: a) Lifting equipment of the drilling rig capable of supporting, lifting and lowering of 06m long section of 6 inch dia. M.S. casing pipe for 36-54m deep anode ground beds for the purpose of casing of bore holes. b) Mixing tanks for fluidizing the coke breeze back fill shall be of 2 cubic meter capacity. ) Mud pump for handling coke breeze in slurry form. 4) All necessary fittings, valves and hoses to fluidize and pump the coke breeze backfill ©) 1 1/2 “diameter rubber / PE heavy wall flexible hose pipe will be used for pumping the fluidized coke breeze. The detailed procedures can be altered to meet site condition and facilitate construction with approval from the TEIL. 9.3.5 Procedure: The following procedures are provided to give the CONTRACTOR general guidelines on installation of non replaceable Deep Anode Ground bed after installation of MS casing pipe. a). Lower the entire length of coke pumping pipe by hand and tie with help of nylon rope with the MS casing pipe. b) Lowering the 1” diameter perforated PVC vent pipe into Bore hole up to 36- 54M by hand after plugging the open end of the bottom piece with the help of a wooden plug, Each section of vent pipe shall be connected using PVC primer and PVC Solution The joint shall be covered using PVC adhesive pipe. c) Assemble the Anode string with centralizer clamps and lower the anode string. Clamp the anode leads with MS casing pipe and then terminate at the anode junction box d) Mix the appropriate quantity of coke breeze back fill with water in the mixing tanks to form a slurry. The coke breeze mixing may be accomplished in several stages but must be agitated through the entire mixing / pumping operation. Pump the coke into the bore hole and simuitaneously lift the pumping pipe. Continue pumping until the estimated quantity of coke breeze has been pumped into the bore hole. Allow the coke breeze to settle for 24 hours then measure the depth. If depth is found low then additional coke breeze shall be poured in the powder form from the top until required depth of coke breeze column is achieved. 9.4 DISTRIBUTED ANODE BED VERTICAL. e261.N-119.78,< Security Level 2 > 2> G TECHNICAL SPECIFICATION FOR a | ronma CATHODIG PROTECTION SYSTEM | Faye Engineering aio Li JOB NO,: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 12 OF 19 Distributed vertical anode bed system shall be used for hot spot protection during supplementary design. Necessary bore holes for vertical anode bed, anode installation, back filling with coke breeze and making of RCC pit for anode beds need to be done by contractor. MS Casing pipe to 08" Dia MS casing pipe should be used for casing of distributed shallow ground bed. The depth of distributed Ground bed should be 3-6m. The procedure for installation of casing pipe, anode, coke breeze is same as for deep anode Ground bed. 9.4.1 Anode installation: One or Two Nos. MMO tubular anode complete with anode lead cable shall be lowered centrally in each bore hole of 6m respectively. To ensure that anodes are located centrally in each bore hole. To ensure that anodes are located centrally, each anode shall be fitted with a non metallic centralizer. Anodes shall be lowered in such fashion that bottom of anode is 300mm above the bottom of bore hate. Annular space between casing pipe anodes as well as between casing pipe & bore hole shall be filled with Petroleum grade coke breeze. One M.S. cap shall be installed over the anode. The anode bed No. should be engraved and stenciled using paint on RCC pit cover/M.S. cap. All Anode lead cables shall be terminated inside the respective Anode lead junction box. 9.5.0 CABLE LAYING AND TERMINATIO! Various methods of installing the cables are: a) Direct buried in soil b) In R.C.C./Paved area through available cable trench otherwise in G.| Conduit. c) Through existing overhead cable trays / cable ducts by clamping cable. d) Above grade by welding or fixing spacer saddles for laying cable on wall/structure without conduit pipe as required. e) Through road / nullah crossing using G.I. conduit. f) Along existing cable tray, R.C.C. cable trench inside / outside Substation buildings. ‘The majority of the plant areas are paved with reinforced concrete cement (RCC) cover. In order to minimize damage and restoration of the RCC; cable installation through: existing trenches is preferable. Prior to installation of any cables the contractor shall measure the exact length of the cable for each size as per cable layout drawing to be prepared by contractor and approved by TEIL and present a detailed schedule to the TEIL. This schedule shall include the routing, length, conduit size, trench dimensions and method of installation for each cable run No splices will be allowed in anode lead cables or any of the positive C.P. cables. Splices in the negative cables and AC power supply cable shall be avoided. If necessary, any splices require TEIL/Owner approval. s2614-11972> < Security Level 2> OH | TECHNICAL SPECIFICATION FOR DOG. NO. 6261-Nt9- ror0 No. |__CATHODIC PROTECTION SYSTEM _ Toy Engineering india Ud ~ JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 13 OF 19 9.5.4 9.5.2 9.5.3 Contractor shall supply necessary Gl conduit, conduit fittings, cables/conduit clamps, cable markers, cable tags, sand, backfill and bricks. However, the contractor will be responsible to supply any additional materials required for installation of the C.P. cable including installation of owner supplied cable trays wherever trays are not available or space is not available in the existing trays. In unpaved areas the cable shall be installed by excavation of cable trench, laying cables encompassing cables with a cushion of sand backfill and protecting cables with overlying brick cover. CP cables at all road / nullah crossings shall be installed within propery sized GI conduits. Any damage resulting to road / nullah crossing during installation of the C.P cable shall be repaired to its original condition The cable routes shall be identified with permanent cable markers. R.C.C. AREAS EXISTING OR PROPOSED: Cable laying in RCC covered areas should be {aid in 2" Dia. Class B Gl Pipe. The GI pipes should be faid during construction. Whereas in existing RCC covered areas a narrow trench will be cut in the existing concrete. The cables will be installed in a properly sized G.|. conduit. After the conduit and cable has been installed with, trench shall be properly paved to restore the R.C.C. to its original condition, The cable routes shall be identified with permanent cable markers. Existing Overhead Cable Trays / Cable Trenches: Where ever possible the C.P. cables shall be routed through existing overhead cable trays or cable trenches. The cables may be installed by clamping with M.S. cleats welded with column without conduit along the column of the overhead cable trays or trenches in some areas where they would not be subject to damage. Cable Markers and Terminations: Cable markers with cable service and cable serial number shall be provided along the cable routes where the cables are laid underground at 20m intervals and at all turning points for each cable route. One cable marker shall be installed over each direct drainage cable to pipe connection point. The pipe service and pipe diameter at drainage point should be written in the marker using 1” stencil ‘An aluminum tag with the cable number and cable service engraved on it shall be attached to each cable at T/R unit, cathode junction box and anode lead junction box. Cables shall be properly glanded at T/R unit, junction boxes, C.P. system PDB and owners Panel. No cables shat be terminated directly to the cable terminals. All cable termination shall be made by crimping of cables to proper sized solder-less aluminum / copper, crimping lugs of DOWELL’S or equivalent make suitable for both copper and 6251.N-1197S2> < Security Level 2 H TECHNICAL SPECIFICATION FOR Doc. NO. 6261-N-119- TOKOA CATHODIC PROTECTION SYSTEM | Toyo Engineering india Ud, JOB NO.; 6264 ISSUED: 16/10/2008 A DHT PROJECT PAGE 14 OF 19 96 a7 aluminum cables. Before crimping each strand of cable conductor and the inner surface of the lug is to be cleaned by fine sand paper to remove existing oxide film. After cleaning Dawell’s corrosion inhibiting compound GTZ - 8785 shai! be applied on the contact surface of both conductor and lug. Then the conductors shall be inserted inside the lug and it skal! be crimped by approved crimping tool. The same corrosion inhibiting compound shall be applied at the interface of the bus bar and the lug before tightening lug at terminal. Contractor should get the crimping procedure approved by TEIL at site by terminating one sample cable before starting actual work. INSTALLATION OF TRANSFORMER RECTIFIER UNITS: All T/R units will be installed in substation. A few typical C.P. schematic wiring diagram showing connection scheme for T/R unit - anode - cathode circuit shall be prepared by contractor and submitted to TEIL for approval. The owner will provide a 415 VAC three phase 4-wire power supply at C.P.system distribution board fuse or breaker) at substation. Contractor needs to arrange cable laying from owner's distribution board to T/R unit along with necessary cable termination arrangement at Owner's switch distribution board and T/R unit. Wiring diagram for power supply arrangement to T/R unit to be prepared by contractor and submitted to TEIL for approval. The TIR units shall be installed outdoor on a RCC Plinth of 2M x 2M raised above normal ground level by 300mm. The RCC Plinth mounted should be suitable for convenient access to entry / exit cables. All cables shall be mounted at the bottom of the T/R unit using suitable size double compression cable glands as per data sheet of TIR unit. T/R unit installation drawings should be approved by TEIL before construction. Two grounding lug terminals of the T/R unit shall be connected to the local earthing bus of the Plant. Wherever earthing bus is not available near 7/R unit installed site, earth pit is to be constructed with 3M G.l. Pipe electrode and a MS. cover. INSTALLATION OF JUNCTION BOXES: Different types of junction boxes will be installed in electrical classified areas. The contractor shall carry out all electrical work in the classified areas in accordance with Zone 2 / Group I! A/B application as per !S:5871, 5572, 2148, 8289. Wherever columns / pillars or any supporting structures are existing in the plant area contractor need to make necessary arrangements to mount the junction boxes, on suitable supporting structure to be constructed by contractor, A schedule of the junction boxes required for this project to be prepared by contractor. The schedule of junction box must contain Sr. No., location details, area classification details, also the details of the piping or anode beds connected to junction box such as number of pipes or anode beds, dia of pipes and service of pipes. e25tw19.Ts,< Security Level 2 GO TECHNICAL SPECIFICATION FOR DOC. NO. e261-Na18- oro CATHODIC PROTECTION SYSTEM | Toya Engineering tna U JOB NO. 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 15 OF 19 98 99 9.10 9.14 9.12 All junction boxes in the classified areas shall be earthed by connecting them to existing earthing grid or earth pit of the plant. The exact location of each junction box shall be selected at site during detailed engineering by contractor & as per instruction of TEIL. CATHODE CABLE CONNECTION: All Cathode Cable Connections to the Structures to be protected are to be done by Thermit welding using either horizontal or vertical mould. After making cathode cable connection the exposed metallic areas shall be insulated using epoxy. Also one 2” Dia GI conduit shall be provided from 0.5m below grade level to pipeline for mechanicai protections of the cable. In case joint is done underground in vertical riser then joint shall be made 300mm below the paved level. Contractor should get Thermit welding procedure approved by TEIL at site by jointing cable to sample pipe before starting actual work. Precise location of drainage connection shall be selected & decided at site by contractor after consultation with TEIL. Colour of the fina! shade of paint application shall be yellow. Identification number on the body of all junction boxes shall be written by using yellow paint and 2” stencil and as advised by TEIL at site. MARKER POSTS The marker post for cable routes, direct drainage points, & Distributed Anode location shall be painted. The write-up on the marker post shall be stenciled using black paint. GROUNDBED PIT COVERS / TEST STATION NAME PLATES: Pit covers of Anode ground bed & name plates for Test station shall be painted with two coats of synthetic Enamel paint of Asian PainU/Berger Paint or equivalent make. Surface preparation primer and paint application shall be as per paint manufacturer's, instruction. Colour of the paint shall be yellow. Anode bed number and Test station nos. as advised by TEIL at site shall be engraved as well as painted using black paint. 3” stencil shall be used on each pit cover of the deep well anode bed / distributed vertical anode bed and test station name plates for writing numbers. MATERIAL REMOVAL AND SITE CLEANUP: Work and field storage areas shall be cleaned up in a manner acceptable to TEIL representatives. Loose dirt from ditch must be raked into ditch line and compacted. Roads, paved areas, ditches, drains and fences shall be restored to original conditions. DENTIFICATION NUMBER: 6261.N-119TS< Security Level 2.9 2> T GO | TECHNICAL SPECIFICATION FOR BOC. NO. e261. 18. rovosa CATHODIC PROTECTION SYSTEM Taye Engineering india La, JOB NO.: 6261 7 ISSUED: 16/10/2008 A DHT PROJECT PAGE 16 OF 19 The identification number given to CPS, Deep well, JB, AJB, Type-A Test station and distributed anodes shall be approved by TEIL. After completion of construction TEIL shall provide identification numbers in sequential manner. Contractor needs to incorporate them in the equipment the way it is specified elsewhere in this document and the enclosed drawings. The contractor is also required to incorporate them in the as-built drawings. 10.0 QUALITY PLAN : The following documents are to be submitted to fulfill requirement of quality plan for Impressed Current Cathodic Protection System. = Site Quality Plan - Bought Out iter Quafity Pian - Indicative Inspection and Test Plan with Check List - Site Organization Chart - Manufacturers QA Plan for major items 14.0 MATERIAL INSPECTION AND TESTING : TEIL or his representative will visit the works during manufacture of various equipment to assess the progress of work as well as to ascertain that quality raw materials are used. All necessary assistance shall be provided by contractor and vendor during such inspection. ‘The minimum testing and inspection requirements for all components/equipment shall confirm to requirements as defined in the relevant codes and standards. Detailed inspection and testing procedure along with acceptance criteria shall be prepared by contractor for Owner's approval. Test certificates including test records, performance curves etc., shall be furnished All test certificates shall be endorsed with sufficient information to identify the equipment to which certificate refer and shail carry project titles. Owner reserves the right to ask for inspection of all or any item under the contract and witness all tests and carryout inspection or authorize his representative to witness tests and carryout inspection. Contractor shall notify the Owner/Owner's representative at least 20 days in advance giving exact details of tests dates and address of locations where the tests would be carried out. Generally, the following minimum tests must be carried out and recorded for all equipment. Checking Visual inspection comparison with drawings and specifications. Inspection — :Detailed physical inspection. Testing Heat run tests of equipment to determine its operational fitness. 6261.0-119-7S< Security Level2> T G TECHNICAL SPECIFICATION FOR Dl Tevones CATHODIC PROTECTION SYSTEM Toyo Engineering nila Ud ‘JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT _ [Pace 17 oF 19 12.0 12.4 12.2 PRE- COMMISSIONING: The contractor shall furnish the detailed field testing and pre-commissioning procedures for approval. Field tests as per these approved procedures 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. Contractor shall carry out pre-commissicning operations after completion of stallation 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. Before the electrical 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 intended for the required operation. TEIL representative may witness all tests. At least one week's notice shall be given before commencing the tests. All tools, equipment and instrument required for testing shall be provided by contractor. Contractor shall furnish detailed CP commissioning procedure for approval. The CP. commissioning shai! be carried out as per approved procedure. The measurement carried out during CP commissioning shall be recorded. interference situation shall be identified and necessary mitigation measures shall be carried out. Interference situation shall also be identified and mitigated by comparing different sets of readings taken a same test station at different intervals of time under identical conditions. Anode Bed Resistance Logging: Resistance Logging of anode beds shall be done after completion of installation of Anode bed and during Commissioning of C.P. System. The procedure for same shall be given by TEIL as a part of Commissioning procedure during Commissioning of C.P. System. Holiday Detection of Anode Leads: To ensure the integrity of the insulation, the contractor shall detect holiday of all anode lead cables. This test shall be conducted at the time of lowering anodes in the Deep Anode Groundbeds or trench. In case anode bed is located in hazardous area then the holiday detection test shall be conducted in the safe area before installation, after conducting test in the safe area anodes with iead wires to be shifted in anode bed location. The contractor shai! provide an approved holiday detection instrument complete with al! accessories for testing the following cables at the specified voltage. The actual procedures for the holiday detection testing shall be in accordance with the recommendation of the manufacturer of the holiday detection instrument. No repair will be allowed on the down hole anode lead wires. Should holiday be detected, the entire cable and anode assembly shall be replaced. e2siN-t10-1S,< Security Level 2> O TECHNICAL SPECIFICATION FOR poe No Tere Ne von CATHODIC PROTECTION SYSTEM Toyo Engineering india Lid, JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 18 OF 19 12.3 13.0 14.0 15.0 Energization of T/R Unit: After installation of each C.P. Station is complete, the Contractor shall energise the TIR unit in the presence of the TEIL to check the functioning of the C.P. System. COMMISSIONING OF C.P, SYSTEM: Once construction of the entire C.P. System is complete, contractor shall commission the system under the supervision of TEIL, the procedure for commissioning and the formats for recording commissioning results shall be submitted by contractor for TEIL approval at least 2 months before commissioning. Key persons from Contractor's side who were involved in the construction work shall take part in commissioning Interference test as per instructions of TEIL shall also be conducted during commissioning using mostly the existing test points. However if some additional test points simiiar fo existing test points are required for the interference test the same is to be arranged by contractor. Measurement of pipe to soil potentials during commissioning on such lines which do not have risers or test points over long sections shall have to be done by trailing wire method. PVC insulated copper cable shall be connected to the available riser / valve or to the temporary test leads (potential measurement cable) Thermit welded to the pipe under test. The other end of the trailing wire shall be connected to +ve of voltmeter. Measurement shall be made by moving the portable Cu/CuSO4 reference electrode (connected to -ve voltmeter) over the line at 10m interval while drawing out the trailing wire. A max. length of 100m of 10mm2 Cu cable reel shall be carried during such continuous measurement. For lines running parallel to each other in same trench corridor, measurement shall be done independently for each pipeline, with trailing wire connected to the subject pipeline. MISCELLANEOUS ‘Supply of commissioning spares shall be part of the system. In addition contractor has to quote recommended spares for 2 years maintenance and monitoring with unit price for each equipment. Supply and installation of miscellaneous items like safety equipment, caution boards is included in contractor's scope. Supply of portable reference cells with Multimeter and supporting accessories for carrying out potential measurement of structures. All fastening devices like bolts, screws etc. Shall be made of materials suitable for marine applications. All supporting structures and support hardware shall be hot dipped galvanized to 80micron min. GUARANTEE : e261. 1187S2> < Security Level 2) O Tovonan TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION SYSTEM DOC. NO. 6261-N-119- 1S Toyo Engineering India Lid, JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 19 OF 19 Contractor shall guarantee the proper performance of the complete cathodic protection system and equipment provided by him for a period of 12 months from the date of commissioning of the CP system, 16.0 MONITORING: Contractor shall monitor the performance of the complete cathodic protection system and equipment provided by him for a period of 12 months from the date of ‘commissioning of the CP system. 6261-N-110.7SG ] ‘SPECIFICATIONS FOR NATURAL OIL / AIR COOLED TRANSFORMER RECTIFIER UNIT < Security Level 2> DOC. NO. 6261-N-119- TRU "Toyo Engineering india Ud, JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 1 OF 12 INDEX 1. Scope 2 2. Codes and Standards 2 3. Transformer 4 4. Reetifying Elements 4 5. AC. Input 5 6. D.C. Output 5 7. D.C. Output Adjustments 5 8. Current interruption 6 9. DC Output Ripple 6 10. Input Overload Protection 6 11, Output Overload Protection 6 12. Voltage Surge Protection 7 13. Cooling 7 14. Input and Output Terminals 7 15. Meters 7 46. Annunciation 8 17. Enclosure 8 18. Name Plate 10 19. Testing of T/R Unit 10 6251.N-118-TRU< Security Level 2 > ~ ' ‘SPECIFICATIONS FOR NATURAL OIL / AIR COOLED Ud) Troma TRANSFORMER RECTIFIER UNIT = Engineering India Lid, JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 2 OF 12 | 1.0 20 ‘SCOPE This specification covers the minimum technical requirements for Supply_of Transformer Rectifier Unit for Impressed Current Cathodic Protection System The transformer rectifier units shall be a standard product of a manufacturer regularly engaged in production of cathodic protection power supplies. The units shall be supplied in accordance with the following specifications and data sheets. CODES AND STANDARDS The design, manufacturing, testing of OiV/Air Cooled Transformer Rectifier Unit and their components shall be in accordance with the latest revisions of the following Indian standards, wherever applicable. Where appropriate Indian standards are not available, the relevant IEC standards shall apply. * Indian Standards institution (IS!) * International Electro technical commission (IEC) * American Standards institution (ANSI) * British Standards Institution (BS) Is: 2026 - Power Transformer IS: 2026 (Part |) 1977 - General (first revision) with amend No. 1 to 3 1S: 2026 (Part II) 1977 - Temperature rise (First revision with Amend 1 & 2) 1S: 2026 (Part Ill) 1981 - __ Insulation levels and dielectric tests (second Revision with Amendment No. 1) 1S: 2026 (Part 1V)- 1977 - Terminal markings, tapping, and connections (First revision with Amendment No. 1) Is: 3700 - Essential rating and characteristics of semi Conductors devices. IS: 3700 (Part!) 1972 - General (first revision) & (Reaffirmed 1988) IS: 3700 (Part Il)- 1972 - __ Low Power signal diodes (first & revision) (Reaffirmed 1988) 1S: 3700 (Part III) 1973 - Rectifier Diodes (First revision) & IS: 4400 (Part Ill) 1968 (Reaffimed 1992) 1S: 3700 (Part lv) - 1968 Low power small signal transistors (Reaffirmed 1988) 1S: 3700 (Part V)- 1968 - Power transistor (Reaffirmed 1992) IS: 3700 (Part VI) 1968 - Switching transistors (Reaffirmed 1992) 700 (Part Vil) 1970 - _ Reverse blocking triode thyristors (Reaffirmed 1988) IS: 3700 (Part Vill) 1970- _Voltage regulator & voltage reference diodes (Reaffirmed 1988) 1S: 3700 (Part XI) 1984 - Light emitting diodes (Reaffirmed 1991) 1S: 4400 (Part '}— 1967 - Methods of measurements on semi-conductor devices-General 18: 4400 (Part Il) ~ 1967 - Methods of measurement on semi-conductor device-Low 6261.N-119-7RU< Security Level 2 > GO NATURAL OIL / AIR COOLED —_ rovonon TRANSFORMER RECTIFIER UNIT ‘SPECIFICATIONS FOR DOC. NO. 6261-N- Taye Engineering india LG, JOB NO.: 6261 | ISSUED: 16/10/2008 A DHT PROJECT PAGE 3 OF 12 | IS: 9224 (Part |) - 1979 IS; 9224 (Part Il) - 1979 IS: 13703 part 2/ sec 1)~ 064 (Part |) — 1978 IS: 3070 1$:3070 (Part !) — 1985 IS: 3070 (Part Il) - 1966 IS: 11548: 1985 IS: 694-1990 961 961 (Part Il) -1967 IS: 3961 (Part IV) ~ 1968 IS: 3964 (Part V) - 1968 IS: 4800 IS: 4800 (Part 1) - 1968 1S: 4800 (Part Il) ~ 1968 1S: 4800 (Part V) - 1968 ¥S: 4800 (Part Vil) 1970 IS: 4800 (Part XII) - 1986 IS: 1122-1974 IS: 1248 (Part 1) -1983. 6261-N-110-7RU. power signal diodes. Electrical accessories — circuit breakers for over current protection for household and similar installation (Second revision) Low voltage fuses. Low voltage fuses. General requirements Low voltage fuses-Supplementary requirements for fuses for industrial application. Superseeding Air-break switch, air-break disconnector, and air Break switches disconnectors and fuse-combination units for voltages not exceeding 1000V AC or 1200 V De. General requirements (first revision){with ‘Amend. No. 1) (Superseding IS: 2607 & IS: 4047) Lightning arrestors for alternating current systems. Non-linear resistor type lightning arrestors (Second revision) Expulsion type lightning arrestors (with Amendment No.1) (Reaffirmed 1977) Capacitor for surge protection above 650V and upto 33kv. : PVC insulated cables for working voltages upto and including 1100 volts (Third revision) with ‘Amendments No. 1 Recommended current rating for cables. PVC insulated and PVC-Sheathed heavy duty cables cables (with Amendment No. 2) Polyethylene insulated cables. PVC- insulated light duty cables. Enameled round winding wires. Conductor data (with Amendments No.3) Maximum overall diameter (Amendments No.3 ) Wires for elevated temperatures (Amendment No. 7) Wires with good dielectric properties under humid conditions (with Amendments no. 1 to 3) (Reaffirmed 1978) Self bonding wires, heat or solvent bonding enameled round copper wire with temperature index 155. Method of test for determination of true specific gravity of natural building stone. Direct acting indicating analogue electrical< Security Level 2 > - ‘SPECIFICATIONS FOR @ DOG. NO. 6261-N-119- NATURAL OIL / AIR COOLED ae Toro ROA TRANSFORMER RECTIFIER UNIT [Toye Engineoring india Lid, | JOB NO.: 6261 _ [ ISSUED: 16/10/2008 A DHT PROJECT PAGE 4 OF 12 3.0 4.0 measuring instruments and their accessories : Part | Ammeter and voltmeter (Third revision) Direct acting indicating analogue electrical measuring instruments and their accessories : Part II General requirements (Second revision) IS: 1248 (Part Il) - 1983 1S: 6236 - 1971 - Direct recording electrical measuring instrument Is: 2419 - 1979 - Dimensions for panel mounted indicating and recording electrical instruments. (First evision-Amendment 1) IS: 8573 - 1977 - Digital electronic DC volimeters and DC electronic analogue to digital convertors (Reaffirmed 1991) Wherever the requirements in this specification are in conflict with any of the above standards, the requirements under this specification shall be binding TRANSFORMER The main transformer will be the isolation type having separate primary and secondary windings. An electrostatic shield, composed of heavy copper foil, shall be placed between the two windings and grounded to the rectifier cabinet, for this purpose a visible lead should be brought out from the copper foil which shall be connected to any of the mounting stud of the transformer core. Transformer winding wire insulation, winding interlayer insulation, core to winding insulation shall be class F type. The transformer core and winding dipped in thermo-setting vamish and baked. Transformer varnish will meet the standards for 155 °C operation. The transformer winding shall withstand 2000voit (RMS at 50Hz) applied for one minute between the windings and between each winding and the transformer core. In case of oil cooled unit, the maximum temperature of oil will not exceed 85 °C at 100% full load current at ambient temperature of up to 45° C. In case of air cooled unit the maximum transformer winding temperature will not exceed 105 Deg. C at ambient temperature up to 45 Deg. C. Transformer full load efficiency will not be less than 95 %. The auto transformer shall be similar to main transformer except it will have single winding and tapping for manual, mode of control. RECTIFYING ELEMENTS The power rectification shall be done by silicon diodes mounted on heat sinks of sufficient size to prevent the diode case temperature from exceeding 100°C at ambient temperature of 45 °C. The peak inverse voltage rating and current rating of the diodes shall be as per data sheet. The diodes shall be connected in bridge circuitry for full wave rectification. Each diode in the bridge circuit shall be protected by a HRC fuse. o261.N-170-TRU< Security Level 2 > SPECIFICATIONS FOR G DOC. NO. 6264-N-119- a NATURAL OIL / AIR COOLED a Ton TRANSFORMER RECTIFIER UNIT Toye Engineering india Lid, | JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 5 OF 12 5.0 A.C. INPUT The transformer rectifier units shall be designed to operate on 240 volts (+ 10%) AC single phase, 50 Hz power supply. If required, Inrush current limiting reactor of suitable rating to be provided at input line of the main transformer to avoid possibility of nuisance tripping of MCB while closing circuit using MCB. 6.0 D.C. OUTPUT The transformer rectifier shall be designed to operate continuously at 100 % rated output current and 100 % rated output voltage at input supply voltage 240V (+ 10%) without damaging any components. 7.0 D.C. OUTPUT ADJUSTMENTS The D.C output control shall be available in any of the following modes, with the help of a selector switch, 7.4 MANUAL MODE Output voltage at 24 equal steps upto 100% rated voltage shall be available by means of coarse and fine tap changing switches for rated input supply voltage and 100% rated output current. Tapping for output voltage control shall be taken from a separate auto- transformer. The controlled output voltage of the auto-transformer shall be fed to main transformer input. The output of the main transformer shall be rectified for D.C. load supply. 7.2 AUTO MODE: Constant current control and constant pipe to soil potential control mode shall be provided in Auto mode. 7.2.4 CONSTANT CURRENT CONTROL Constant current control feature shall be achieved by automatically adjusting T/R unit output voltage between 0 to 100 % rated voltage through close loop control using T/R ‘output current as a feedback taken from the shunt side of the T/R unit, so that T/R unit output current does not vary more than + 1.0 A of set value when there is a change input supply voltage of + 10 % or change in load resistance over a specified range decided by the ratio of output voltage & current rating of the T/R unit. . Continuously adjustable potentiometer to be used for setting T/R unit output current. In addition to constant current control, constant voltage control can also be provided if its a standard additional feature of the current control PCB 7.22 CONSTANT PIPE TO SOIL POTENTIAL CONTROL Facility for controlling output by constant pipe to soil potential method should be provided in the T/R unit. Constant Pipe to soil potential (PSP) control feature shall be 6264-N-119-TRU< Security Level 2 > ; SPECIFICATIONS FOR GO DOC. NO. 6261-N-119- NATURAL OIL / AIR COOLED _ Toro OA TRANSFORMER RECTIFIER UNIT Toyo Engiieering india Ltd, _ JOB NO.: 6261 ISSUED: 76/10/2008 A DHT PROJECT PAGE 6 OF 12 ] 8.0 9.0 10.0 11.0 achieved by automatically adjusting T/R unit output voltage between 0 to 100 % rated voltage through close loop control using PSP as feed back taken from extemal reference cell, to cause change in output current of T/R unit so that PSP as measured by external reference cell always remains constant and does not vary more than + 15m\ of the set potential. For feed back PSP reference, 2 nos. Cu/CuSO4 Reference cell shall be used, one operating & one stand-by to be selected manually with the help of selector switch. Continuously adjustable potentiometer to be used for setting T/R unit PSP. Silicon controlled Rectifiers (SCR) shall be used in the Primary Circuit of main transformer for close loop control of the output voltage in auto mode. The SCR of the transformer rectifiers will be controlled by commands from electronic circuit cards. These cards shall be the plug-in type Printed Circuit Board (PCB) mounted on the front panel of the rectifier for easy field replacement. The printed circuit board contact pads will be gold plated to provide easy conduction and to eliminate contact corrosion. Completed printed circuit boards wil! be sealed with a circuit card sealant to prevent atmospheric corrosion and fungus contamination. Circuit elements in the control cards shall be de-rated properly and proper heat dissipation arrangements shall be made in the PCB so that they function properly for full load operation of T/R unit at ambient temperature as per data sheet. CURRENT iNTERRUPTION THR unit shall be provided with microprocessor based inbuilt current interrupter. It shall have ON and OFF time settable between 0 to 999 seconds in increment of 1.0 sec by using membrane keyboard & LCD display. The T/R unit shall be provided with feature of AC interruption. This facility shall be used for simultaneous measurement of OFF potential. DC OUTPUT RIPPLE The filter circuit shall be designed in such 2 manner that RMS ripple factor does not exceed 5% at rated load both in Auto and manual mode. INPUT OVERLOAD PROTECTION Protection from overloads on the input will be provided by miniature circuit breaker of suitable rating on the input side. The trip point will be unaffected by ambient temperature. The trip handles of individual poles of circuit breaker will be mechanically linked so that all lines are opened when an overload occurs. In addition to above MCB, HRC fuse of suitable rating should be connected before MCB. OUTPUT OVERLOAD PROTECTION Protection from overload on the output in auto made for T/R unit having either constant current or constant pipe to soil potential control will be provided by another close loop SCR control circuitry giving automatic constant current same as mentioned vide 7.2.1 6261-4-118-TRU< Security Level 2 > "SPECIFICATIONS FOR D ee NATURAL OIL / AIR COOLED us ToroWo TRANSFORMER RECTIFIER UNIT | Toyo Engineering Indie UG, JOB NO.: 6261 | [1sSuED: 16/10/2008 DHT PROJECT PAGE 7 OF 12 | 12.0 13.0 14.0 15.0 except that it will act as back up control to main auto mode control. Separate PCB shall be used for main auto mode control and the back control. The current limit for backup control is to be set by two limit switches marked “Coarse” and “ Fine”. The limits of the two switches shall be algebraically additive and shall give equal steps of 3A each upto 110 % rated current. One scale calibrated in Ampere shall be provided with each limit switches so that current limit can be set by operator at any desired value in 3A step. In any circumstances even in case of short circuit the T/R unit output current should not exceed the current limit set by the backup control. In addition to above electronic current limiting feature HRC fuses of suitable rating to be used at positive and negative terminals to disconnect T/R unit quickly in case of failure of current limit during over loads in the output circuit VOLTAGE SURGE PROTECTION Each silicon controlled rectifier (SCR) and Diodes shall be protected from voltage surges by means of R-C circuitry/MOV. This R-C circuitry/MOV will be rated as recommended by the manufacturer of the SCR /Diodes so that they will conduct heavily before the peak inverse voltage ratings of the SCR / Diodes are reached. In addition, lightning arrestors or MOV type surge Diverters shall be provided in the A.C. input and D.C output circuit of the transformer rectifier. COOLING The transformer / rectifier will be Natural Oil Cooled or Natural Air Cooled, completely enclosed IPS55 construction. In case of oil cooled unit the temperature of oil measured at the top level shall not be more than 85 °C at ambient temperature of 45 °C. In case of air cooled unit the temperature of transformer winding shall not be more than 105 °C at ambient temperature of 45 °C. INPUT AND OUTPUT TERMINALS DC terminals made of tinned plated copper/Nickel plated brass shall be located convenient to the cable entrance. The terminals shall be suitable for specified cable sizes . Two negative and hwo positive output terminals shall be provided. AC terminals shait be insulated to withstand 2000 volts 50 Hz to the enclosure, shall be shielded fo prevent accidental contact and shall be sized to take cable sizes as per data sheet. METERS The transformer rectifier units shall be equipped with separate continuous reading voltmeter and ammeter for the D.C output and the A.C input voltage, current and PSP. measurement. All meters shall be electronic digital type with LED display arrangement and should be able to indicate the current and voltage ranges as per data sheet upto a resolution of one decimal place for DC Ammeter & Voltmeter and 2 decimal places for PSP meter. Digital size should be 12.5 mm (minimum). All meters shall be square in 6261-N-119-TRU< Security Level 2> ‘SPECIFICATIONS FOR @ DOC. NO. 6261-N-119- NATURAL OIL / AIR COOLED wa Toro TRANSFORMER RECTIFIER UNIT "Tayo Engineering india Lid, JOB NO.: 626% ISSUED: 16/10/2008 A DHT PROJECT PAGE 8 OF 12 16.0 17.0 shape and accurate to within 2 % at full load at ambient temp.They shall be temperature compensated to vary no more than 1% per 10% temperature changes. All AC & DC voltmeters shall be provided with separate fuse and toggle switch where as all Ammeters shall be provided with only toggle switch. ANNUNCIATION Each transformer rectifier shall be supplied with a continuous signal light, which will go out at loss of A.C. input. In addition to this each T/R unit should give annunciation for auto and manual mode of operation by continuous signal light. T/R unit should also indicate the failure of each fuse in bridge rectifier and two DC output fuses by an independent LED for each. ENCLOSURE The enclosure of T/R unit shall be plinth mounted type. The oil-cooled type of unit will have two compartments. Lower compartment shall contain main transformer, Auto- transformer, DC choke and This compartment should be filled with transformer oil to IEC 296. The upper compartment shall contain the SCRs, Diodes, indicating meters, Protective devices, Electronic control circuits/control cords etc. and shall be provided with a plexiglass viewing window. Both the compartments shall be completely enclosed type having IP55 construction. The Air cooled unit will have single compartment. The enclosure shall have a frame work made of minimum 50mm x 50mm x 3mm angle iron, the upper cabinet body shall be made of minimum 12SWG (2.50 mm) sheet steel, lower cabinet shall be 10 SWG (3.25 mm) sheet steel and bottom plate of lower and upper compartment shall be 8mm(min.) thick steel plate. Necessary fins for the cooling purpose shall be provided at lower compartment. An integrated sun/rain shade to be provided of suitable size. In case of Natural Air-cooled type of construction the complete unit will be fabricated 12 SWG sheet steel with integrated Sun/Rain shade. The transformer rectifier shall be provided with the following accessories as applicable * Steel channel under the base for plinth mounting. © Lifting lugs of size suitable for lifting complete transformer rectifier unit when full of oil shall be provided. © Sunshade / rain shade. il filing hole with screw cap and drain plug. * An oil sight gauge comprising a flat toughened glass window through which the oil is viewed. The viewing window shall have a white background. * Silica gel breather suitable for 10KVA transformer to be located inside the upper cabinet of T/R unit. * A removable dial type thermometer graduate on the scale at the maximum oil temperature. + Thermometer pocket. * Lockable control cabinet with viewing windows to IP55 as a minimum. degrees Celsius with a red mark 6261.N-119-TRU__= Security Level 2 > ‘SPECIFICATIONS FOR @ DOC. No. 6261-N-119- NATURAL OIL / AIR COOLED oeu roren0n TRANSFORMER RECTIFIER UNIT Taye Engineering nda LG, JOB NO.: 6261 = ISSUED: 16/10/2008 A DHT PROJECT PAGE 9 OF 12 47.4 17.2 Accessibility shall be provided by hinged and removable front and back shutters. A plexiglass viewing windows shall be provided at the front shutter to allow the meters to be read without opening the front shutter. One drawing pocket shall be made at inner side of the front shutter. One holder for 60 watt filament lamp connection shall be provided at a strategic point inside the cabinet to facilitate proper illumination during operation and maintenance. The enclosure shall be supplied with an engraved warning level with the word “ DANGER’ In case of oil cooled unit. Two junction boxes shall be provided at both sides of the upper compartment, one of them A.C. cable entries and other for D.C cable entries. Gland plate should be provided against each junction box for fixing double compression cable glands for A.C & DC control cables. For Air cooled unit the cable entry will be from the gland plate at the bottom of the unit. One 240V, 5A Socket shall be provided at a strategic point inside the cabinet to facilitate connection of soldering iron during maintenance. After fabrication the entire enclosure shall be painted as per vendor's standard procedure. The finish coat shall be as per shade 631 of |S 5. ENCLOSURE EARTHING All normally dead metallic parts shall be electrically continuous Earthing terminals shall be suitable for 35mm square cable connection. One earthing terminal shall be made for earthing connection to power supply earthing and two earthing terminals shall be made for earthing connection to the local earthing pits. The earth connection points shall be protected against corrosion. It shall not be necessary to scrape the paint away in order to make an effective earth connection. Provision shall also be made adjacent to each gland plate for cable gland earthing connection. CABLE TERMINATIONS i) Cable glanding and terminating facilities and terminals shall be suitable for the specified cable type and conductor size. Consideration and provision shall be taken by the SELLER on the equipment design for the use of cables with aluminum conductors. Cable glands & cable lugs shall be in the scope of supply for CP system installation contractor. ii) Terminal blocks shall be arranged and positioned to afford easy access for carrying out external cable termination, testing, inspection and maintenance. There shall be ample clear space allowed between the terminal block and gland plate for the spreading and termination of external conductors. iii) All terminal blocks shall be shrouded or provided with transparent covers. Pinch screw type terminals are not acceptable. iv) Two positives and two negative post types D.C. output terminals should be provided for rectifier transformers. Each post shall be fitted with double nuts and washers. v) Terminals for different voltages shall be separated by partitions 6261.N-119-TRU< Security Level 2 > 5 ‘SPECIFICATIONS FOR GO DOC. NO. 6261-N-119- NATURAL OIL / AIR COOLED wo ovo TRANSFORMER RECTIFIER UNIT [Toyo Engineering india Utd. | JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 10 OF 12 18.0 19.0 19.1 19.2 fine vi) A Terminal box or chamber with undrilled gland plate or entry panel of sufficient dimensions to terminate the specified incoming and outgoing cables shall be provided. Direction of cable entry shall be from below. vil) Termination of single core cables shall be through a non-magnetic metal panel or gland plate and provision made for bonding and earthing any armour and/or concentric ground conductors. viii) Cable terminal arrangements for power and control cables may be integrated provided that a barrier separates the two. ix) Auxiliary wiring shall have copper conductors of the manufacturer's standards sizing (subject to buyer's approval). x) Suitable terminals for two nos. ref. Cell cables, one no. measurement cables and a selector switch for permanent ref. Cell to be provided for T/R unit panel for connection to PSP meter.Wiring shall be crimped using self-insulated compression type terminal blocks which shall be suitably identified. Conductors shall be fitted with sleeve ferrules identified. Conductors shall be fitted with sleeve ferrules. bearing the same identification as the terminal to which they are connected. Minimum conductor size shail be 1.5 Sq.mm for control and indication wiring, Electronic wiring will be done with minimum conductor size of 0.5 Sq. mm (current density for power wiring shall not be more than 4A/mm2 for copper conductor ). NAME PLATE A permanently stamped stainless steel metal plate shall be attached to outside of the case with the following information. a. Manufacturer's name b. AC input voltage & current rating c. AC frequency / Phase d. Output DC volts and Amps. Rating e. Weight in Kg of T/R unit f. Model number / Serial number g. Year of Manufacture TESTING OF T/R UNIT All T/R units shall be tested by contractor and inspected by Purchaser before Testing shall be conducted in accordance with codes and standards enclosed in this document Following tests shall be done. Efficiency test of transformer rectifier assembly at 25 %, 50 %, 75 %, and 100 % rated ‘output current both in auto and manual mode of operation, Efficiency test of Transformer alone after isolating rectifier at 100 % rated output current No load output voltage test in manual mode for each voltage setting using coarse and tap switches at rated input voltage of 240 V AC. 6201-N-119-TRU< Security Level 2> ‘SPECIFICATIONS FOR @ cag NATURAL OIL / AIR COOLED uu) TOYO mou TRANSFORMER RECTIFIER UNIT “Toxo Engineering India Lid, JOB NO.: 6261 cE _ iSSUED: 16/10/2008 A DHT PROJECT PAGE 11 OF 12 19.3 19.4 19.5 19.6 19.7 19.8 19.9 Output voltage and current test in manual mode for each voltage setting using coarse and fine tap switches for the following conditions. i) Input voltage 216V AC (~ 10%) ii) Input voltage 240 VAG ili) Input voltage 264 VAG (+ 10%) Output voltage test at rated output current setting in Auto mode for the following conditions. i) Input voltage 240VAC ii) Input voltage 264 VAC (+ 10%) iii) Input voltage 264 VAC (+ 10%), load resistance 0 ohm (short circuit across + ve & - ve terminal of T/R unit) iv) Input voltage 216 VAG (- 10 %) Output current and voltage shall be recorded for each of above conditions (i) to (iv). Heat run test for max. temp. rise to be conducted for main transformer, Auto transformer, filter choke, Diodes and SCR’s, at for 16 to 24 hours continuous operation. Number of T/R units to be considered for Heat run tests and actual duration for which test to be conducted upto 24 hours (max.) shall be decided by Purchaser. Thermocouple instrument shall be clamped at different locations inside the closed T/R. unit cubical and the cable of the sensors shall be connected to temperature indicator through a selector switch outside the T/R unit cubical during heat run test. Insulation resistance tests using 500V megger for auto transformer and Main transformer between primary and secondary, primary and earth, secondary and earth. Dielectric strength test using 2KV for 1 min. duration for Auto transformer, main transformer between Primary and Secondary, primary and earth, secondary and earth. Polarity test in Auto and manual mode of operation of T/R unit. Auto mode over load protection test: Set back up control at 50% of rate current and increase current from zero to max. possible using main Auto control for T/R unit having constant current control In case of Auto PSP control T/R unit ref. Feed back signal to be varied from min. to max. set potential of T/R unit using battery & rheostat in place of ref. Half cei signal, current during the test should not exceed more than 50% of rated current in both cases. 49.10 Constant voltage test for control circuitry. 6261-N-119-TRU< Security Level 2 > ‘SPECIFICATIONS FOR ) | Doc. No. 6261.N-119- ] NATURAL OIL / AIR COOLED Wd ona TRANSFORMER RECTIFIER UNIT = Engineering india ia, | JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 12 OF 12 19.11 19.12 19.13 Supply voltage of T/R unit to be applied 240V, 184V, and 276V For each input supply voltage the reference voltage +ve DC and — ve DC Voltage of Auto mode control circuit to be checked whether they are constant. Ripple factor test TIR unit shall be operated at full load both in Auto and Manual mode. In each case ripple voltage to be checked on a cathode ray oscilloscope (CRO). Annunciation check: Annunciation checks to be done for power on, manual mode operation and auto mode operation. Auto mode constant PSP operation test Connect one battery with variable rheostat in place of reference cell feed back signal and conduct the following test: i) Make both T/R unit set potential & feed back signal from battery 1.0V, switch ‘on T/R unit & note T/R out put current. Increase feed back signal from 1.0 V to 1.5V and again bring back to 1.0V. Note change in the T/R output current. ii) Conduct similar test as item (i) above with decrease of feed back signed from 1.0V to 0.5 V and again back to 1.0V. Note change in the T/R output current. 19.14 The test certificate shall contain results for all tests in addition the following observations: - SI. No. of T/R unit - D.C output rating of T/R unit - External dimensions of T/R unit = Weight of T/R unit - Thickness of M.S. Sheet steel used for T/R unit enclosure. . Painting details of enclosure. - Visual inspection details of T/R unit stating a) All components of T/R unit are as per specification b) All items are labeled property for identification purpose. Number used in ferrules of cable leads are matching wi TIR unit furnished. schematic/wiring diagram of 5261-N-418-7RU,< Security Level 2 > oO | DATA SHEET FOR DOC. NO. 6264-N-119- TR TRANSFORMER RECTIFIER UNIT ial | Toye Engineering india Lid JOB NO 6267 ISSUED: 16/10/2008 A DHT PROJECT PAGE 1 OF 2 DATA SHEET FOR AUTOMATIC C.P. T/R UNIT AC Input Voltage 240 + 10% Volt, 5OHz + 3Hz AG.Input Current As Required D.C, Power Output : As Required D.C, Output Voltage ; As Required D.C. Output Current As Required Reference Cell As Required Number of reference cell for control: As Required Reference EMF Setting As Required Regulation of Reference : As Required Derating Factor for Transformer : As Required Derating Factor for Diodes/SCRs As Required Full Load Efficiency transformer : As Required alone Full Load efficiency of T/R unit Power Factor : As Required Insulation Level : As Required Peak Inverse Voltage Diodes & : AS Required SCRs Peak Transient Reverse Voltage - : AS Required Diodes and SCRs Filtering Circuit : As Required Ripple and Hum : As Required Surge Diverters for Diodes / SCRs : As Required Lightening arrestors : As Required Protection As Required Meters / Instruments : As Required. 6261-N-119-TRU-DS. doe< Security Level 2> | DATA SHEET FOR DOC. NO. 6261-N-119- \ TRU-DS 7 TRANSFORMER RECTIFIER UNIT | Toyo Engineering India Ltd, JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 2 OF 2 Visual Indications : As Required Other Accessories As Required Design ambient temperature 42 deg. C Input and Output Terminals. : As Required Enclosure 2 As Required Approx. Dimension of TR Unit : Vendor to Furnish. Weight of TR unit + Vendor to Furnish. Cooling : The unit is natural air cooled. Measurement and control terminals : As Required Cable entries For anode, cathode, power, control and Painting Name plates and Labels 6261-N-118-TRUDS doc. measurement cables through cable gland plate at the bottom of the unit. : Shade 6321S 5 : As per Specification< Security Level2> GH SPECIFICATION FOR DOC. NO. 6261-H-119- toto ANODE & CATHODE JUNCTION | 7 BOXES & TEST STATIONS ‘Toyo Engineering india Ltd JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 1 OF 3 1.0 Anode and Cathode Junction Boxes for Classified Areas ‘An anode lead junction box will be provided for each T/R unit. These junction boxes will have provision for independent current measurement of each anode output. This will be accomplished by means of individual shunts for each anode circuit. Cathode junction boxes will be required for bonding the negative terminal of the transformer rectifier units with multiple pipelines/structures at drain point. The enclosure shall be back plate/Wall mounted type. Shutter should be provided with closed cell neoprene sealing gaskets. The terminal board shall be of 1mm WT Phenolic laminated sheet on which all terminals and shunts are to be mounted. The terminals shall be made of cadmium plated steel or stainless stee! stud nut and washers of M-10 size. All cable entries shall be through Aluminium double compression glands. The external bolt, nuts and clamps to be used for mounting the junction box with back plate/structures shall be MS electro- galvanised or Cadmium plated. Junction box enclosure shall be of type “Exd" protection Zone2/Group IIA/IIB application, Temp, Class: T-3, as per IS 5571, 5572, 2148 & 8289. The cable glands shall be FLP double compression type made of Aluminium Both the enclosure as well as the cable glands need to be certified by CMRS. The shutter of the junction box shall be screwed to the body of junction box by using MS electro galvanized / Cadmium plated nut, bolt and washers. The enclosure of the junction box shall be made of cast aluminium. One earthing terminal shall be provided for earthing the junction box. 1.1. Junction Boxes for non Classified Areas: An anode led junction box will be provided for each ground bed installation or a group of group bed installations. These junction boxes will have provision for independent current measurement of each anode output. This will be accomplished by means of individual shunts for each anode circuit. Cathode junction boxes will be required for bonding the negative terminal of the transformer rectifier units with multiple pipe/structure at drain point. The enclosure for the junction boxes shall be of IP-55 construction made of 12SWG(2.67) sheet steel. 6251-1198< Security Level 2 > O SPECIFICATION FOR BOC. NO. 6261-N-118- rovoHo ANODE & CATHODE JUNCTION iL BOXES & TEST STATIONS Toyo Engineering india Ltd, JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT PAGE 2 OF 3 The enclosure shall be back plate/wall mounted type having removable hinged front shutter with one handle and flush type locking arrangement. Shutter should be provided with closed cell neoprene sealing gaskets. The terminal board shall be of 8mm thick Phenolic laminated sheet on which all terminals shall be made of stainless steel stud, nut and double spring washers of M-8 & M-10 size. All cable entries shall be through Aluminium double compression glands. The external bolt, nuts and clamps to be used for mounting the junction box with back plate/structures shail be MS. electro galvanised or Cadmium, plated. Shutter should be provided with closed cell neoprene sealing gaskets. 1.2 Test Stations / intermediate Measurement boxes These shall be separate units or a combined unit as per Contractor's design. Cables from the permanent reference electrodes and the cathode shall be terminated at the test stations / measurement boxes which shail be located close to protected structures. This shall enable measurement of PSP at site. Further the test station / measurement box shall be connected to TRU via multicore cable for giving feedback of PSP in TRU fo achieve auto control. The test stations / measurerment box shall be of flameproof construction “Exd” protection suitable for Zone2/Group IIA/IIB application, Temp, Class: T-3, as per 1S 5571, 5572, 2148 & 8289. 1.3. Proper fitting of cables at cable glands it is essential that all cables should fit tight at cable glands. For this purpose vendor need to make openings for glands at junction box/test stations or cast/procure cable glands as per cable samples to be provided by OWNER. 1.4 Painting Enclosures of all anode and Cathode junction boxes / test stations shall be painted. Colour of the final shade of Paint application shall be yellow. 1.5 Inspection & testing Fabrication drawing of each type of junction box / test station shall be submitted by vendor to TEIVOWNER to obtain approval for a Prototype construction. After inspection and approval of prototype the mass production shall be started Calibration test for shunts for each junction box to be inspected by TEIL/OWNER before despatch. 6261-N-1108,O SPECIFICATION FOR ANODE & CATHODE JUNCTION < Security Level 2 > DOC. NO. 6261-N-119- JB L ___BOXES & TEST STATIONS Toyo Engineering india Ltd., JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT [PAGE 3 OF 3 NOTE: Required number of cable gland and studs (sealing plugs) shall be provided by vendor. Quantity of these items will be finalized during detailed engineering. 6251-1198,= _< Security Level 2 > DATA SHEET FOR DEEP DOC. NO. 6261.N-119- ANODE-DS me ANODE GROUND BED _ {CATHODIC PROTECTION SYSTEM) [Toyo Engineering inaia Lid, | JOB NO.: 6261 [ISSUED: 16/10/2008 4 DHT PROJECT [PAGE 1 OF 2 Codes and Standards a) Indian Standards institution (IS!) b) International Electro technical commission (IEC) ©) American Standards Institution (ANSI) 4) British Standards Institution (BS) ‘Anode Base Material : As Required Anode Diameter : As Required ‘Anode Length : As Required ‘Anode Weight As Required Anode Current Output As Required Anode Design Life at Maximum Output : As Required Number of Anodes in Single String: As Required Anode String Maximum Current Output : As Required Anode bed Operating Current Output: As Required Anode bed Life at Operating Current: As Required ‘Anode Consumption Rate : As Required Anode Coating : As Required Anode Coating Method : As Required Anode Coating Mean Thickness : As Required Anode Tail Cable Conductor : As Required Anode Tail Cable Cross Section : As Required Anode Tail Cable Primary Insulation: As Required Anode to Cable Connection : As Required Anode to Cable connection Resistance : As Required Anode to Anode Inter Distance (ctr-ctr) : As Required Anode Tail Cable Length As Required Total Anode String Cable Length : As Required 6261.N-119-anode.08< Security Level 2> i DATA SHEET FOR DEEP DOC. NO. 6261-N-119- | | ANODE-DS foreo | ANODE GROUND BED __(CATHODIC PROTECTION SYSTEM) 7 Toyo Enginasring India Ud, | JOB NO.: 6261 _ 7 ISSUED: 16/10/2008 A DHT PROJECT PAGE 2 OF 2 Inactive Depth of Deep Anode bed : As Required Active Depth of Deep Anode bed 2 As Required Total Depth of Deep Anode bed As Required Deep Anode bed Casing Pipe Material : As Required Deep Anode bed Casing Pipe Diameter : As Required Deep Anode bed Casing Pipe: As Required Thickness Resistance of group of anode bed: As Required connected to a single T/R unit Anode groundbed backfil ‘As Required Consumption rate of coke breeze : As Required Testing of EMMO anode testing : All Anode Strings shall be tested by contractor and inspected by TElL/Contractor before dispatch, testing shall be conducted by the manufacturer to satisfy this document. * Testing of Anode to cable joint shall be done using helium leak detection tester. Vendor to confirm the pressure of this test. 6261-N-119-anode-0s:< Security Level 2 > ‘SPECIFICATION ar _— FOR ‘CABLE CABLES FOR C.P. SYSTEM oro [Toyo Engineering india Ltd., | JOBNO.: 6261 ti L ISSUED: 16/10/2008 A J DHT PROJECT PAGE 1 OF 2 14.0 SCOPE Cables mentioned here shall be a standard product of a manufacture regularly engaged in production of power cables. This specification covers requirements for type, rating, manufacture and testing of the cables for impressed current type cathodic protection system. 1.1. CODES AND STANDARDS In general the cable covered by this specification shall unless otherwise specified be in the line with the requirements of any of the latest applicable standard of : a) 1S: 7098 (Part |) — 1988 b) 18:3961 (Part IV) — 1968 ©) IS: 3964 (Part-lll) - 1967 Where ever the requirements in this specification are in conflict with any of the above standard, the requirements under this specification shall be binding. 1.2 ANODE LEAD CABLE Anode lead cables shall be 10mm* stranded copper conductor, single core, unarmoured, with a double insulation system. The primary insulation shall be 1100 volt grade cross linked Polythylene (XLPE). The secondary insulation shall be PVC sheathing jacket over the primary insulation. Approx. over all dia of cable shall be 9.6mm. 1.3. +VE and -VE HEADER CABLE ++ve header and -ve header cable shall be 95mm’, stranded Aluminium conductor, single core, Aluminium wire armoured, PVC insulated and PVC sheathed 1100V grade cable. 1.4 DRAINAGE CABLE Drainage cables shall be 50mm’, stranded Copper conductor, single core, Aluminium wire armoured, PVC insulated and sheathed 1100V grade cable 1.5 POWER SUPPLY CABLE (Between PCC & T/R Unit) 6261.Ne119.cabes< Security Level 2 > Toyo Engineering India Lid, ~ JOB NO: 6261_ @ ToFoKeM ‘SPECIFICATION — He DOC. NO. 6261-N-119- CABLE CABLES FOR C.P. SYSTEM [issueo: 16/10/2008 A DHT PROJECT PAGE 2 OF 2 | 1.6 17 18 19 1.40 Power supply cable between Power source and T/R unit shall be stranded Aluminium conductor, 3-core, Aluminium wire armoured, PVC insulated and sheated 1100 grade cable. EARTHING CABLE Earthing cable shall be 35 mm* stranded Copper conductor, 1-core, unarmoured, PVC insulated 1 490V grade cable. MEASUREMENT CABLE AND PERMANENT REFERENCE CELL CABLE BETWEEN CJB CUM TEST STATION AND MJB The measurement cable & reference cell cable shall he 6mm2, stranded copper conductor, single core, armoured, PVC insulated and sheathed, 1100V grade. CABLE DRUMS All cables to be supplied in wooden drums. Cable ‘engths in each cable drum shall be 600m (min), where ever cable lengths are more than 600m. INSPECTION All cables alongwith manufacturer's test certificate as per IS standards shall be inspected by TEIL at the vendor's shop before dispatch. Minimum 15 days notice to be furnished by vendor for this purpose CABLE IDENTIFICATION For easy identification of cable, the oversheath of the cable should have yellow colour and “C.P.SYSTEM CABLES” should be printed using black colour at one meter interval throughout the fength of the cable. 6261. NI.cabes< Security Level 2 > ‘SCHEDULE OF RATES FOR SUPPLY OF MATERIALS DOC. NO. 6261-N-119- O ‘SUPPLY on (CATHODIC PROTECTION SYSTEM) | “Toyo Engineering India Ltd, JOB NO.: 6264 ISSUED: 16/10/2008. DHT PROJECT PAGE 1 OF 2 Sr. Description Units | Quantity [~ Unit [~ Amount No. Rate In Rs. InRs. 1.0 [Supply of Transformer Rectifier Unit with its accessories and auxilaries| Nos. |As Required including earthing arrangement, as per TEI specification, 2.0 [Supply of Cathodic protection cables including, clamps, cable markers ete. as| |___|per Specification 2.4 |16mm®, 1 Core, stranded Copper conductor, XLPE insulated, PVC sheathed, lunarmoured anode lead cable with PVC sheathing jacket. [As Required | As Required) 2.2 95mm, 1 Core, stranded Aluminium conductor, PVC insulated , PVC| IAs Required sheathed, Al. wire armoured +ve and -ve Header Cable. |Al. wire armoured drainage cable. 24 (35mm®, 1 Core, stranded Copper conductor, PVC unarmoured Earthing Cable sulated PVC sheathed, As Required M M. 2.3 |50mm®, 1 Core, stranded copper conductor, PVC insulated , PVC sheathed | M. [As Required Mi, M. 2.5 |6mm?, 1 Core, stranded copper conductor, PVC insulated , PVC sheathed , |AI. wire armoured Measurement cable & references cel! cable from pipeline to} CIB | | [As Required [26 |25mm, 1 Core, stranded Aluminium conductor, PVC insulated , PVC] M. As Required sheathed , Al. wire armoured Bonding cable 6261-N119-aupply<< Security Level 2 > a; SCHEDULE OF RATES FOR SUPPLY OF MATERIALS « j DOC. NO. 6261-N-119- ‘SUPPLY sono, (CATHODIC PROTECTION SYSTEM) | Toya Engineering India Ltd, ‘JOB NO.: 6261 ISSUED: 16/10/2008 A DHT PROJECT [Pace 2 oF 2 | Sr Description Units [Quantity [Unit [~ Amount No. Rate In Rs. In Rs. 3.0 [Supply of Junction Boxes as per TEIL Technical Specification. |= [As Required, 3.1 {Anode Junction Box for Deep Anode bed in hazardous area. Nos. {As Required 3.2 |Cathode Junction Box in hazardous area. Nos. [As Required 4.0 |Supply of Thermit weld cartridges long with accessories and auviliaries for, - [As Required, | | cable to pipe Thermit welding as per TEIL Technical specification 4.1 |Thermit Weld for 50mm2 Cable Size Nos. [As Required 4.2 |Thermit Weld for 25mm2 Cable Size Nos. |As Required 4.3 |Thermit Weld for 06 mm2 Cable Size Nos. [As Required 5.0 [Supply of Permanent Cu/CuSO4 Reference Electrode. Nos. |As Required 6.0 [Supply of Material for 36-54M Deep well Anode groundbed including supply] Nos. [As Required lof deep anode string with dual feed tail cable as per TEIL Technical specification, 7.0 [Supply of Instruments for operation and maintenance = _ As Required 7.1 {Supply of Portable Cu-CuSO4 reference Electrode Nos. [As Required 7.2 [Unit rate for 2 year spares . Lot 7.3 [Test Station Nos. [As Required 8.0 ional tem as per vender design. =< Security Level 2 > ‘SCHEDULE OF RATES FOR INSTALLATION & COMMISSIONING 1 [ @ (CATHODIC PROTECTION SYSTEM) CsA Rt aed on | Toyo Engineering India Lc, JOB NO: 6264 ISSUED: 16/10/2008 A DHT PROJECT PAGE 1 OF 2 Sr. Description Unit | Quantity | Unit Rate | _ Amount No. | s in Rupees | _in Rupees 1.0 {Basic surves \cluding soil Resistivity & other topographical data collection. As Reqd. | [2.0 [Design and detalled engineering for CP System including preparation of [As Reqd, construction drawings / documents and marking necessary locations at site for construction purpose as per TEIL Technical specification. 3.0 Installation of transformer rectifier unit of air cooled type complete with its Nos. |As Reqd. laccessories and auxiliaries including earthing arrangement. Related ci {foundation and making input / output cable connection, Glanding of cables inside T/R unit, including aff labour and materials as per TEIL Technical specification, 40 [Laying of cables including excavation of soil / concrete payment including ~ |As Read restoration of any damage of nallah / road, clamping of cables as per TEIL [Technical specification 6229-N-119 sev.0 and instruction of Engineer-in-charge. 4.1 (Cable laying in cable trays. M._|As Regd. | 42 |Cable laying in RCG cable trenches M._[As Read. | 4.3 [Cable laying in existing RCC cable trenches M._|As Reqd. 4.4 [Cable laying in RCC paved area in 2” Class B GI conduit. [_M. |As Reqd. 45 |Cable laying in unpaved area (directly buried). M. |As Reqd. 5.0 [Making cable to pipe joint by thermit welding method including excavation of - [As Read. Jconcrete payment / soil which ever existing for thermit welding, back filing and restoration of concrete pavement wherever existing after completion of works etc, complete including all labours, materials as per TEIL Technical specification. 5.1 |Thermit weld for 50mm2 cable size Nos. |As Reqd. [52 [Thermit weld for 25mm2 cable size Nos. |As Reqd. 5.3 |Thermit weld for 06 mm2 cable size Nos. [As Reqd. 6261-N-1194NST< Security Level 2> SCHEDULE OF RATES FOR INSTALLATION & COMMISSIONING ‘s O (CATHODIC PROTECTION SYSTEM) ert LS itn) | roe | Toyo Engineering India Ltd,, JOB NO.: 6261 | Vissue: 16012009 & DHT PROJECT PAGE 2 OF 2 Sr | Description Unit [Quantity [Unit Rate] Amount No. s in Rupees|_in Rupees 6.0 Installation of junction boxes including connection, termination and glanding of | - {As Reqd \cables at junction box end for + ve /- ve header, drainage, anode lead cable, measurement and reference electrode cables including support structures and mounting arrangement for junction box. Related civil works, excavation of labours, materials as per TEIL Technical specification. 6.1_ [Anode junction box for deep anode bed in hazardous area. Nos, |As Reqd 6.2 |Cathode / bonding junction box in hazardous area. Nos. |As Reqd 7.0 /Installation of reference electrode including excavation of concrete pavement /—_[Nos. [As Reqd soil, back filing and restoration of concrete pavement as per TEIL Technical specification. 8.0 |installation of deep well anode as per TEIL Technical specification, drawings and [Nos. |As Reqd instruction of Engineer-in-charge. 9.0 [Testing and commissioning of complete CP System including interference As Reqd testing, supply of tools and tackles, labour etc, as per TEIL Technical specification and instru 70.0 |Preparation and submission of approved as built drawings for complete CP |As Regd system as per enquiry requisition 77.0 [Any additional item as per vendor design. = As Read | l L 6261. N-1BINST