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Filled-up, signed & stamped compliance sheet shall accompany each re-submission of
civil-structural document/ drawing by the contractor:
Review Code: ❑ 1 ❑2 ❑ 3 DR oV
4.
5.
6.
7.
8.
9.
Code 1 No comments.
V Void.
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Page 1 of 1
STRUCTURES
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wz 1 : 4 CEMENT MORTAR
CONCRETE STRUCTURES FOR FOLLOWING :
a) GRADE OF CONCRETE
FA CD
A♦
0150/0250 INLET OUTLET d) CLEAR COVER IN R.C.C. WORKS.
A
-S-11■
--- 3. BAR BENDING SHALL CONFORM TO IS:2502
IL:SSZSSf - 1:2:2:527 150 0
AS GIVEN ON 4. MANHOLE FRAME & COVER, RUNGS, VENT PIPE & OTHER EXPOSED STEEL
GEN. CIVIL PCC M20 PARTS SHALL BE PAINTED WITH TWO COATS OF APPROVED ANTICORROSIVE PAINT.
AREA DRGS.
CD 5. DESLUDGING SHALL BE DONE PERIODICALLY EVERY YEAR PREFERABLY
-7/ BY A PORTABLE NON CLOG. PUMP.
Naaa.go
v.'.7■
A AA
O
0150/0250 (RCC PIPE) 6. 075 C.I. VENT PIPE (AS PER IS:1729) SHALL BE 3.0M MINIMUM HEIGHT FOR SELF
1 STANDING VENT. INCASE SEPTIC TANK IS LOCATED WITHIN 20M RADIUS FROM
HABITABLE BUILDING VENT PIPE SHALL BE EXTENDED FROM SIDE OF
PLAN DETAIL-1 SEPTIC TANK & TO BE BROUGHT NEAR TO THE NEAREST COLUMN/ BUILDING
(VENT ON SIDE) AND SHALL BE TAKEN AT LEAST 2.0M ABOVE THE HIGHTEST POINT OF
10 @ 150 C/C BOTHWAYS AT BOTTOM THE BUILDING/STRUCTURE. HOWEVER, THERE SHALL BE ONLY ONE
075 C.I. VENT PIPE WITH COWEL (ALT-I) 075 C.I. VENT PIPE FROM THE SEPTIC TANK, NEAR INLET PIPE.
R.C.C. SLAB (REF. NOTE-6)
(SEE NOTE-2) MANHOLE COVER & FRAME MEDIUM DUTY AS PER IS: 1726 7. EXACT THICKNESS OF BRICK MASONRY WALL SHALL BE AS PER LOCALLY
/OF GRADE MD-10 CIRCULAR 0500 CLEAR OPENING AVAIBLE BRICKS. HERE WALL THICKNESS HAS BEEN GIVEN AS PER BRICK
I I II DETAIL-1 750 SIZE OF 250X125X75.
1:2 CEMENT MORTAR JOINT 8. PROPORTION FOR NOMINAL MIX CONCRETE SHALL BE AS PER
TABLE 9 OF IS:456.
CD F.G.L.
CD
075 C.I. VENT PIPE
0500 111
PIPE WITH COWEL (ALT-II)
(REF. NOTE -6) O FOR CLEAR COVER
CD
CO
13 THK. CEMENT PLASTER 1:3
0 SEE NOTE-2
GROUTING IN 1:2 CEM. MORTAR lir250 II WITH WATER PROOFING COMPOUND RECOMMENDED DIMENSIONS OF SEPTIC TANKS
SIZE OF OPENINGS OUTER DIA. OUTLET LEVEL
OF PIPE + 100 (SQUARE) NO. OF USERS TYPE LENGTH BREADTH DEPTH
r471 TO SOAK PIT L B D
CD
CD
CD
0150 C.I. PIPE
INLET PIPE 10 I 2000 900 1075
O
CD *A
l I
0150/0250 (RCC PIPE)
8 @ 150 CLC 20 II 2300 1100 1385
HWAYS
Px
r
INLET LEVEL
CD 16 THK. CEMENT PLASTER 30 III 4000 1400 1400
(AS GIVEN ON GEN. CIVIL CD
CD
CD
cr) 1:3 WITH WATER PROOFING COMPOUND
AREA DRG.) 50 IV 4650 2000 1440
/
V
13 THK. CEMENT PLASTER
E
CD
62 1:3 WITH WATER PROOFING COMPOUND
100 THK. BAFFLE CD
CD
CD
PCC 1:5:10
757
50 750 750 50
SECTION A-A
thg,n
—461. GROUTING I 1:2 FREE FLOW
/ Ze'e. N 7. BOTTOM OF THE SOAK PIT SHOULD NOT BE LESS THAN 600mm ABOVE THE SUB SOIL WATER LEVEL. SUB SOIL WATER LEVEL
ati
cD
') 75
P !).14,. / CEMENT MO TAR TYP
30MMTHICK 1:2CEMM
cNo,
A
° ,;,. / MEANS HIGHEST OBSERVED SUB SOIL WATER LEVEL.
/ 8. AS PER MANUAL ON SEWERAGE AND SEWAGE TREATMENT, MINISTRY OF URBAN DEVELOPMENT, NEW DELHI, 1987,
LOCATION OF SOAK PIT SHOULD BE MORE THAN 20M AWAY FROM ANY WATER SOURCES LIKE TUBE WELL ETC. AND MINIMUM
/ / 7.0M AWAY FROM NEAREST HABITABLE BUILDING.
9. SOAK PITS ARE NOT SUITABLE FOR IMPERVIOUS SOIL SUCH AS DENSE CLAY OR ROCK. IT IS ALSO NOT SUITABLE
/_ / IF THE PERCOLATION RATE OF SOIL EXCEEDS 30 MINUTES FOR 25mm ABSORPTION AS PER APPENDIX-A OF
IS : 2470 (PART-2).
/ /
Dab00 00°'
.
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(11()K10
,
417,07
,1( 4
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4Do
4
k.7§D
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'!/
pv
250 D 1250
TABLE FOR SOAK PIT
SECTION A-A DEPTH DIA AREA OF ABSORPTION
TYPE NO.OF USERS H(METRE) D(METRE) ADH+7V4 D2 (M2)
1 10 2.0 2.0 15
2 20 2.5 3.0 30
3 30 3.0 3.7 45
4 50 4.0 4.7 75
PLAN
Ifgar faaes
(Wen. eierPlelTSTJLICD+0
INDIA LIMITED
(A Govt. of India Undertaking)
Rev.
No.
4 20.05.09
Date Purpose
Prepared
by
Checked
by
Stds. Committee Stds. Bureau
Convenor Chairman
Approved by
DETAIL OF SOAK PIT 7-65-0217 Rev. 5
Page 1 of 1
Copyright EIL - All rights reserved
Format No. 8-00-0001-F5 Rev. 0
Page 1179 of 2065
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1 > 0 .7,Z ,_ z
0 co r-
FILTER MEDIA MEDIA
b b b is.) Co 'co Cr Z
CA 0 > C7 (i)
Si S4 .,4 = -r1 -0 >. > rn
PROVIDED
I---I v) 0
OF FILTER
3. ,n 1 6- (.,/
i- = r_ co -'1
1- r- 3
z - I =: 1- Mr1 -I 0 M 5 co
m c, xi xi
Pl
Ca 73 0 >
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m 0
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)). z
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0 73
MIN. VOLUME ACTUAL VOL. BREDTH
1.0
b b b b b > 77 0 3. 92 =4 n u) rn 0
IN METRE
Co 0 m .7Z < Z
M S 0 m > 1 „„ !:) ,
'S381311111111 NI 321V SNOISN3WI0
C) O C
IM
M 23-,-
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M
M m CD 0 z
SHALL CONFORM TO I.S. 3489.
O i..1 .1 iv b M
THE PERCOLATION RATE OF SOILIS MORE THAN
Z 0M -■ Z 2
cn m 1- M is.., M
IN METRE
O
83338 S13A31 183ANI
7q.
THE TABLE FOR UPFLOW ANAEROBIC FILTER IS "READY
- - .... - O
o o
iv s., is.) b
IN METRE
Cn
io coo
o o 0 Coo
LENGTH (L) DEPTH OF
TI
FILTER MEDIA (D)
GENERAL NOTES :-
1. ALL LUGS SHALL BE OF HIGH STRENGTH DEFORMED BARS OF
GRADE Fe500/Fe500D CONFORMING TO 15:1786 (WITH GUARANTEED WELDABILITY)
AND SHALL BE CONNECTED TO METAL INSERT PLATES BY 6 mm
FILLET WELDS AS SHOWN IN SKETCHES.
2. METAL INSERT PLATES SHALL BE CONFORMING TO IS:2062 (GR—A/B).
IP—(A) 0 (C)
IP = INSERT PLATE
A = TYPE OF INSERT PLATE
C = ELEVATION OF INSERT PLATE (TOP EDGE)
e.g IP—R9a 0 EL.110.300 MEANS INSERT PLATE TYPE R9a AT EL.110.300.
Nie( Q/-
6 23.10.12 REVISED AND ISSUED AS STANDARD VPS P.K.MITTAL s OHATURVEDI VINAY KUMAR D MALHOTRA
5 09.10.07 REVISED AND ISSUED AS STANDARD VP$ P.K.MITTAL VINAY KUMAR V.CHATURVE)I
Prepared Checked Stds. Committee CGM(E) Stds. Bureau
Rev
Date Purpose Chairman
hairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
a ENGINEERS
NDIA UMRH)
(A Gov! of Nick Uncla-taking)
METAL INSERT PLATES
(LUG BENDING DETAILS)
7-68-0056 Rev. 6
Page 2 of 7
M.I. PLATE
12 4 LUG (TYP)
M.I.
R.C.C. BEAM
80
200
121 LUG
w = THICKNESS
OF M.I.
PLATE
M.I.
z
I-
150(LW) 12 1 LUG
M.I. PLATE
5 09.10.07 REVISED AND REISSUED AS STANDARD VPS P.K.MITTAL VINAY KUWAR V.CMW WM
M.I. PLATE
LUG
0 = DIA OF LUG
LW = WELD LENGTH AVAILABLE
LUG
PLUG WELD
M.I. PLATE
5 09.10.07 REVISED AND REISSUED AS STANDARD VPS P.K.IMITAL VINAY KUMAR V.CHATURVEDI
TYPEOF INSERT ]
TYPEOFINSERT
THK. OFINSERT
DETAILS OF INSERT PLATE DETAILS OF INSERT PLATE
THK. OFINSERT
Le,
DIAOFLUGS
o
0
6 6 _.
Z PLAN CROSS SECTION Z "a- PLAN CROSS SECTION
vi vi 6
, . 195 195 .
11.1111=1.
S1a 12 12 57a 12 12
U
01 I . 1
% 7. 0
4—± -
j, 300
Sib b 16 16 1, 400 j,
SIZE 150x150 SIZE 450x450
ili,_tc*
i, ,R, n
S2a 12 12 R1a 12 12
.V. I I V-I
2. - 1 1 8. L
0 0'
1 ---t- % cl)
irrsp, . 90
r
Nat
S3a 12 12 R2a 12 12
1
0 V 0
3. 9.
t—t-
Sib 16 16 I 300 1 R2b 16 16 1 300
SIZE 250x250 SIZE 150x300
S5b 16 16
1---dr-t- R4b 16 16
350 I,
/ 350
SIZE 350x350 n SIZE 200x400
5 09.10 07 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL VIMAY KUMAR V.CHATURVEDI
THK. OFINSERT
TYPE OFINSERT
TYPE OF INSERT
DETAILS OF INSERT PLATE DETAILS OF INSERT PLATE
THK. OF INSERT
DIAOFLUGS
E
6 6
Z PLAN CROSS SECTION Z PLAN CROSS SECTION
N ..c
a
N
30{1451451130
R6a 12 12 R12a 12 12
o
0
5
13. 19. ,5
o
R8a 12 12
.4 240 ,
li mn u R14a 12 12
?frril
__ -
o 1 o ■
MN o
15. 5 21.
='11
Sig
° MI u.1
ft—
,...
R8b 16 16 I 350 R14b 16 16 1 400
SIZE 300x400 SIZE 400x500
y1 2o) 20fr0
I
R9a 12 12 gins.
o raj
16. ° Bann
o Ilarri
swi
.=== l
i, 5
R9b 16 16 400
SIZE 300x500
o 3942041204430
R10a 12 12 o .. 1
17. 1
R10b 16 16 5 400
SIZE 300x600
290
R11a 12 12
======
18. o
5
R11b 16 16 j, 350
SIZE 350x400
TA 43tzpar \0)`()% 2„.„.4___
6 23.10 12 REVISED AND ISSUED AS STANDARD P.K.MITTAL TU VI NAY KUMAR D MALHOTRA
5 09.10 07 REAFFIRMED AND ISSUED AS STANDARD VPS P.K ARTTAL VINAY KUMAR V.0 HAT URVED I
PS1 12 12 1011
1.
;250 (rY
—P)1 FOR 14 LUGS
PS2 16 16 SIZE 150x150 300 (TYP) FOR lel LUGS
aatri*-rr
PS3 12 12 1.
o_ Iil
2.
P54 16 16
SIZE '
225x225
3/11, 240 1
,430
PS5 12 12
Mal
3. all
am■
wasi
PS6 16 16
SIZE 300x300
3 200 1,1401
,30
PS7 12 12
°
_ -.-I"
4. o i 0
I 1 1 1 0
° t--4°■
4t 14- "
PS8 16 16 100, 200 1
SIZE 400x400
30 { 195 195 fro
PS9 12 12 Lo
— I I 1
5. Lo kitrk I
— _ 1
PS10 16 16
SIZE 450x450
30.11, 220 ir 220 1..30
PS11 12 12 II
PS12 16 16
SIZE 500x500
.uk,1‘ / n rpZ Pr \r,Arf)-
c.4,_.-f,
6 23.10.12 REVISED AND ISSUED AS STANDARD R. Al %CHAT KUMAR D IIALHOTRA
5 09.10.07 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.WITTAI. MAY KUMAR V.CHATURVEDI
a ENGINEERS
LAMM
(A Govt. of kidlo UndertokIng)
METAL INSERT PLATES
(T DESIGNATES)
7-68-0056 Rev. 6
Page 7 of 7
w
30 250 ,, 30
71(—- i
w
{ 30 30
w
\ L
30 30 7
i
±r. k 250 A,
II
t---
i
t 0
=
TYPE T1 TYPE T2, T3 & T4 TYPE T5 & 16 TYPE T7
50 mm (MIN.)
SLAB
25 mm w
(MIN.) B
SECTION 1 —1
ii
TYPICAL FIXING DETAIL
SeV cete
6 23.10.12 REVISED AND ISSUED AS STANDARD VPS P.K.M AL s vumvum MAY KUMAR D IIALHOTRA
5 09.10.07 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL vINAY KUMAR V.CHATURVEDI
L 250 300 450 450 550 600 650 750 850 950 1000 1100
I E 95 115 155 170 190 210 230 255 285 315 345 370
8c
III TYPE —I 280 336 498 504 610 666 722 831 940 1049 1108 1217
H
TYPE —III 430 486 648 654 910 966 1022 1281 1390 1499 1558 1667
M20
L 200 200 300 350 400 450 450 550 600 700 700 800
II E 150 180 240 270 300 330 380 405 450 495 540 585
8c
IV TYPE —II 230 236 348 404 460 516 522 631 690 799 808 917
H
TYPE—IV 380 386 498 554 760 816 822 1081 1140 1249 1258 1367
L 200 250 400 400 450 550 550 650 700 800 850 950
I E 95 115 155 170 190 210 230 255 285 315 345 370
&
111 TYPE —1 230 286 448 454 510 616 622 731 790 899 958 1067
H
TYPE —III 380 436 598 604 810 916 922 1181 1240 1349 1408 1517
M25
L 150 150 250 250 300 350 350 450 500 550 600 650
II E 150 180 240 270 300 330 360 405 450 495 540 585
&
IV TYPE —II 180 186 298 304 360 416 422 531 590 649 708 767
H
TYPE —IV 330 336 440 454 660 716 722 981 1040 1099 1158 1217
L 180 220 315 335 390 445 470 550 600 680 735 815
1 E 95 115 155 170 190 210 230 255 285 315 345 370
8c
III TYPE —I 210 260 365 390 450 515 545 635 690 780 845 935
H
TYPE —III 360 410 515 540 750 815 845 1085 1140 1230 1295 1385
M30
L 150 150 200 200 250 275 300 350 375 425 450 500
II E 150 180 240 270 300 330 360 405 450 495 540 585
8c
IV TYPE—II 180 190 250 255 310 345 375 435 465 525 560 620
H
TYPE—IV 330 340 400 405 610 645 675 885 915 975 1010 1070
+9-4;
7 26.11.13 REVISED AND ISSUED AS STANDARD A. . SHARMA AMARJEET P.K.MITTAL S.CHATURVEDI S.CHANDA
6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL VINAY KUMAR N. DUARI
L 160 190 275 295 340 390 410 480 525 595 640 710
I E 95 115 155 170 190 210 230 255 285 315 345 370
8c
III TYPE —I 190 230 325 350 400 460 485 565 615 695 750 830
H
TYPE—III 340 380 475 500 700 760 785 1015 1065 1145 1200 1280
M35
L 150 150 150 150 180 225 225 275 300 350 350 400
II E 150 180 240 270 300 330 360 405 450 495 540 585
8c
IV TYPE—II 180 190 200 205 240 290 300 360 390 450 460 520
H
TYPE—IV 330 340 350 355 540 590 600 810 840 900 910 970
L 150 170 240 255 300 340 360 425 460 525 565 625
I E 95 115 155 170 190 210 230 255 285 315 345 370
&
III TYPE —I 180 210 290 310 360 410 435 510 550 625 675 745
H
TYPE—III 330 360 440 460 660 710 735 960 1000 1075 1125 1195
M 40
L 150 150 150 150 175 200 200 225 250 275 300 325
II E 150 180 240 270 300 330 360 405 450 495 540 585
&
IV TYPE—II 180 190 200 205 235 270 275 310 340 375 410 445
H
TYPE—IV 330 340 350 355 535 570 575 760 790 825 860 895
elie 0_
■ Ile■ t'4,».■
tata
il
TYPE — I TYPE — II
o I—
K (NOMINAL BORE) a.
0
TACK WELD
(TYP)
DETAIL—A
TYPE — III TYPE — IV (TYP)
YX1_ A1:4--
7 26.11.13 REVISED AND ISSUED AS STANDARD A.K: SHARMA AMARJEET .ANTTAL S.CHATURVEDI S.CHANDA
6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL V1NAY KUMAR N. DUARI
000r0000000>(>000
N II,
in in (1) o o co tO tri 0 .4.
r, oro ro ro o csi 0 rO rO 00 00 N
.-
.- Cs1
0 .- 0 (0 O O O O U") O tO tr) O O
00 0 co rO ro O o tO 0 co ro in rs. in -rr
to 0 N l*, ..- CO N Cf> .- >L") (0 N N
I- ,- Csi .- ...
0 1- 0 LO O O O 0 in O to tn O O
'et O N. N in O in CO O N N 10 N O .1'
(1) 0> .-- >0) 0/ r. N 00 0 K> tf, N N
000000000001000
0 O tn a> tn in O U:> O 10 0> in 1-- in ->1.
cD a> -. N N r. N CO O N N) ti, N
1-«
0 ifl 0 10 0 0 0 O in O to tn O O
(c) O ■,) N. et O in sl• 11, co N. et N O O
tr) co O N tn tt, N r... 0) N N CD N
.- .- ..-
0 u, 0 >r) o o o 0 11, 0 tn 10 0 in
N >n r. <0 "zr in 0 ,4. Lf> N U:› •ct 1... 14, co
i.n N a, CsI 0,"> LO N LD 00 N O 11, 1.-
1- 1-
0 000000010000010
03 0 o ro •rt 0 rn er 0 o ro vi 0 O co
•ct N a, N N ll,
-
N (0 CO N O tn
O .- O (o O O O O in O Qa in O O
in tn ...a. N ro O O O tn ..d. N /") p. Lf> LID
'et CD CO LNI ..- 11, N tn N N cr> .1' .-
0 CDOCD000000t0 0 00
N O cla 1- I,) tn tn O O 0/ .- K> lo O u,
"Cr CD r. N O et N tn 10 N CO el• .-
..., 0 0 10 0 0 CO 0 N o 0 0 0 0 O N O O 10
Sli U) CO a) Pei tn O CO >..> ir, tt, cD 11, •-• LO c." O O N
Pf) et •- vi CD .- r.. s, .-- .4- CD .- CD >/) .-
0 0 CD 0 0 CO 0 CO 0 000030
BOLTDIA ( 0 ) INMM
o 0 LI, LI, 0 0 o tn 00 0 0 0 tn in
N. in co r■ o in co •rr c‘i C‘I N
N "." .- * tn .-- tn .* 1n .- ro
O o O in O N O tn t0 O If> O O tn
..:1-
Csl 0 cep r■ 0 0 C`l 0 0 .- 0 Cs1 N
W") >," et .- et re, et .- PO
0 0 ci, o o 0 o 0 o 0 0 0 o co
N O co to cn o .- rO N o o r- O N N
N r`) ro -er -- * 1.") * .-- Oc)
00 0000000 0000in
0 O tn iD CO O cn O t's1 in oO oN1--
N 0, 1,
1 1,
1 .-- I,> 1,>
.4- .- N
0 0 0 11, 0 .- 0 LO O O O LO
CO tn in (1) 1•••• 0 Ch 0 •-• 0 cn O •-
.- N N .- N N .-
0 0 If> 0 0 et ,-, u, 0 to o co
co it, tn if> P. tf> K> ..,,
`"" .- tn 1,) 0/ .-
.-- N •-• N
00L000NON 0 if> 0 N
C•1 tn tn et to u, N CO •-• tn CV 00 .--
1- .- .-- N ..- N
00000000 0000
C) lf> Lf> sl• tn II, .- CO .- II, .- CO
..- •- .- N .- N
DOUBLE NUT
SINGLE NUT
DIMENSIONS
CD
t3
THREADED (T)
LENGTH
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6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITTAL V1NAY KUMAR N. DUARI
Rev. Prepared Checked Stds. Committee GM Stds. Bureau
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6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.MITrAL VINAY KUMAR N. DUARI
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26.11.13 REVISED AND ISSUED AS STANDARD A. SHARMA AMARJEET P.K. AL S.CHATURVEDI S.CHANDA
6 26.03.09 REAFFIRMED AND ISSUED AS STANDARD VPS P.K.14ITTAL VINAY KUMAR N. DUARI
NUT NUT
WASHER WASHER
BASE PLATE BASE PLATE
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(FOR FORGED BOLT HEAD)
TYPE - XI
7 26.11.13 REVISED AND ISSUED AS STANDARD A.K. SHARMA AMARJE P.K.MITTAL S.CHATURVEDI S.CHANDA
6 26.03.09 REVISED AND ISSUED AS STANDARD VPS P.K.MITTAL VINAY KUMAR N. DUARI
NOTES:—
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7 16.12.2014 REVISED & ISSUED AS STANDARD V.P.SINGH V ,-GOEL PK MITTAL S CHANDA
6 29.01.2010 REVISED & ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
TYPE -
14 0 HOLES FOR
200 I112 MEDIUM DUIT RUST PROOF
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0
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V3 ho TUBULAR HANDRAIL
11 II POST
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LEVEL
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, II I
eiie Niim
12 LUG(2N0S)
32 NB(M) TUBE— o
o
R=100
STRUCTURAL F.F.L.
CONC. LEVEL
If
6 29.01.2010 REVISED & ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
TYPE - II
CONC. / STEEL FACE-DISCONTINUOUS END OF HANDRAIL
25 1500(MAX.) 1500(MAX.)
250
(MA X.) (TYP) (TY P)
Ip
[1=1oeu_.
32 NB(M) TUBE
o
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o
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v
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7 16.12.2014 REVISED dc ISSUED AS STANDARD V .P.SI GH V- GOEL PK MITTAL S CHANDA
6 29.01.2010 REVISED dc ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
TYPE - II
PIPE SHALL BE
GROUND TO SHAPE
PLATE
50x50x6 THK.
VIEW 7-7
6 29.01.2010 REVISED & ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
Page 5 of 8
TYPE - III
32 NB(M) TUBULAR
HAND RAILING
SEE DETAIL VIEW 9-9
OF WALL PLATE
1500(MAX.)
LANDING
100
1500(MAX.)
14 0 HOLES
WALL
8mm THK. 12 0
PLATE EXPANSION
3mm MIN. FASTNERS
CONTINUOUS
FILLET WELD
120 0-8 THK.
WALL PLATE
VIEW 8-8
DETAIL OF WALL PLATE
ELEVATION
6 29.01.2010 REVISED dc ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
Page 6 of 8
TYPE - IV
o
o
u)
TOE PLATE — 25 THK.
100x5 THK. GRATING
1 Oj
SEC. 10-10
NOTE : HANDRAIL TYPE-IV SHALL BE USED OVER PIPE CROSS OVER AND LOW LEVEL PLATFORMS
SUCH AS FOR VALVE OPERATION ETC. AS MENTIONED IN STD 7-68-0562 & 0563.
(FOR DETAILSA
O REFER PAGE 8 OF 8)
6 29.01.2010 REVISED & ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
TYPE - IV
32 0 NB M
TUBE
\;W\I•V G}K
7 16.12.2014 REVISED & ISSUED AS STANDARD V.P.SINGH GO L PK MITTAL S CHANDA
6 29.01.2010 REVISED & ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Förmat Nn fc-nn-rinni-F4 Revn nnnvrinht Fll - All rinhts rpsprvpri
IIIV
■J I
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32 NB(M)
TUBE
4V
tn
II
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TOE PLATE
0.•
100x5 THK.
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OF MEMBER
VIEW 12-12
VT2
50 SQ.
1—
6 THK. PL.
u)
DETAIL - (A)
CONNECTION DETAILS
(FOR TYPE II & IV)
NOTE : CHEQUERED PLATES / GRATINGS SHALL BE SUITABLY NOTCHED TO ACCOMMODATE THE TUBE
IN CASE OF BEAM MC100 OR MC125.
6 29.01.2010 REVISED & ISSUED AS STANDARD V.P.SINGH PK MITTAL S.CHATURVEDI VINAY KUMAR N DUARI
30, - r 75x75x8
NOSING
IOW 71O-1=1-4111111111-11MFill..=. ■
-■
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2 2
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5
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BASE
NOTES :-
1. FOR STAIRWAY/TREAD USE ELECTROFORGED GRATING TYPE—II AS PER EIL STD NO 7-68-0697.
2. FOR CONNECTION DETAILS REFER SHEETS 3, 4, 5 AND 6.
3. STRINGER SHALL BE SUITABLY DESIGNED FOR OFFICE BUILDING, WARE HOUSES AND WORKSHOP.
4. FOR DETAIL OF INSERT PLATE `R1a° REFER EIL STD. NO. 7-68-0056.
SHT. 2 of 6
300
II II
_7::
EL. 'A'
II Ii T.O.G/CH. PL
4i J1
EL. `B'
T.O.G/CH. Pl.
r75x75x8
EL. 'C'
T.O.G/CH. PL/T.O.C.
1500
MAX.
STRINGER MC 150
R
OR MC 200
0
0
z
EL. TOP OF GROUT\Ir
REFERENCE EL.
17
FOR STRINGER MC 150 REFER DET. <
FOR STRINGER MC 200 REFER DET. (g.)
ON SHEET 6 OF 6
MAXIMUM RISER IS 200 HOWEVER IT
SECTION 1 -1 MAY BE REDUCED AND ADJUSTED AS
REQUIRED.
SHT. 3 of 6
F
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CLEAT
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—75x75x8-150 LG.
0
La
6 THK. STIFFN. PL.
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6 THK. STIFFN. PL.
MC150 OR MC200
■ ■
■
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6 THK.
STIFFN. PL. CLEAT WELDED TO STRINGER
AND BOLTED TO MC
—TOE PLATE
SECTION 3-3
(CONNECTION WITH STEEL BEAM ISMC) VIEW 10-10
MC150 OR
MC200
—50x50x6 o ;i
SEC. 11-11
6 THK.
CHEQ. PL.
•
HANDRAILING
230
/
111111=11r
r'
BRACING STRINGER
L-50x50x6
(APPROX.)
T —50x50x6
L-50x50x6 STIFFENING
BRACING TO BE PROVIDED
FULL STRENGTH FOR STAIR WITH MORE
BUTT WELD FOR THAN 20 RISER
FLANGES
8 THK. PL.
230 229
7 135
L-75x75x8-120 LG.
_Ada
r4, W.P.
H
M20 BOLT
REFERENCE EL.
SLOTTED HOLE 22x50 LG. FOR FDN. DETS. REFER
IN ANGLE CLEAT EIL STD. 7-67-0008
150 160
DETAIL —
230 219
4o
L 75x75x8-120 LG.
o •3.
W.P.
M20 BOLT
REFERENCE EL.
SLOTTED HOLE 22x50 LG. FOR FDN. DETS. REFER
IN ANGLE CLEAT EIL STD. 7-67-0008
100 255
DETAIL —
/11
I:24:2 \ DtLIS
INNNN
EL. TOP
SUPPORT RUNG
X1
MENSION BETWEEN SUPPORTS
O
O
O
LJ
1—
0
z
0
0
O
o
o OF RUNGS
EL.
re)
SUPPORT
X2 x
z
NOS.
N=
o
0
1,4)
EL.
SU P o
SAFETY CAGE O
LADDER HEAD O
AT SIDE
EL. --L—
SUPPORT o
X2 o
o
eouom
RUNG
(REFER SHT. 3 OF 3)
O
o LOWER OR
INTERNED
HOOPS
*
VESSEL DIA (mm) DISTANCE `D' (mm) MC100 SHALL BE ADOPED FOR DISTANCE
MORE THAN 1350 UPTO 2000
UPTO 800 200 + e
> 800 < 3200 260 + e
> 3200 4 8000 275 + e
6 06.11.08 REAFFIRMED AND ISSUED AS STANDARD S.P.JOSH1 P.K.MITTAL VINAY KUMAR V. CHATURVEDI
800 800
FLAT
75x10
0
0 TOP OF
14, GRATING/
CHEQ. PL.
EL. ON
SUPPORT
SECTION
NOS. OFRUNGS
O
O
o o
O O
re) re,
EL. ON x II
SUPPORT ZZ
SECTION3_
400/
TOE ANGLE/EDGE OF
PLATF RM MEMBER
CD
CD REF. EL. REF. EL.
L()
TOP OF PEDESTAL/ " BOTTOM
CHEQ. PL /GRATING RUNG
AONL
TYPE OF ATTACHMENT DEPENDING
ON FLOORING TYPE. LADDER FOR FRONT ENTRY
(REF. SHT. 3 OF 3)
LADDER FOR SIDE ENTRY
NOTES :-
1. LADDER POSTS SHALL BE OF FLAT (75x10) UPTO 3.60m (MAX.) BETWEEN SUPPORTS AND ISMC 100 UPTO
7.0m (MAX.) BETWEEN SUPPORTS.
2. RUNGS SHALL BE 20 0.
3. SUPPORT TYPE X1' CORRESPONDS TO FIXED SUPPORT AND X2' CORRESPONDS TO SLIDING SUPPORT.
4. SUPPORT ELEVATION X1, X2 CORRESPOND TO CL OF BOLT HOLES.
5. SUPPORTS 'X1' IS CAPABLE TO SUSTAIN A LOAD FOR 9000 mm LONG LADDER ONLY.
6. LADDER SHALL BE GIVEN A SUITABLE SLOPE (MAX.6*),IF NECESSARY, TO AVIOD FOULING WITH ANCHOR CHAIRS.
REFERENCE
ELEVATION
(TYP)
M.S. GRATING
WITHOUT
NUT
— Ll 00x1 00x8
(TYP)
BOTTOM _ff
NTGO M REFERENCE
ELEVATION
WITHOUT (TYP)
/ NUT 8 WITHOUT
GRATING
1
EL. X1
OR X2
CHEQ.
PLATE
11111 ,;;r
PLATE (1 20x1 20x6)
TYPE - D1 TYPE - D2
O
TYPE - E
NOTE (FREE)
100 IN CASE OF TOWERS BOTTOM RUNG SHALL
280 I, 280 BE 300 mm FROM FGL /HPP.
560 24 0 HOLES FOR
M20 BOLTS TYPE OF ATTACHMENT AT BASE
LADDER BOTTOM DETAILS
GROOVE IN PLASTER
12 THICK CEMENT
MORTAR
TILE ADHESIVE (1 CEMENT : 3 SAND) z
0
......
• . ' •
• • .
. „
5 07.11.16 REAFFIRMED & ISSUED AS STANDARD Dow' JS/J RAJANJI SRIVASTAVA R. KAMA
RCC COLUMN
CEMENT PLASTER
TILE ADHESIVE
TILE SKIRTING 0
1-7
C•1
0
TILE SKIRTING
Id
RCC COLUMN TILE FLOOR FINISH
FLOOR BASE
Id
TILE ADHESIVE a.
= •
FINISHED
FLOOR LEVEL
•
• .
.•
• 4 ..• : . A • • .g
• A.
CHAMFER OF TILES • • •
AT 45' ANGLE
RCC COLUMN
CEMENT PLASTER
111 1/4.74.....:* 1 1
• . .
• •
12 THICK CEMENT
MORTAR
(1 CEMENT : 3 SAND) • 0
STONE SKIRTING
C)
STONE SKIRTING
0
RCC COLUMN
Id
STONE FLOOR FINISH
FLOOR BASE
I •
CEMENT MORTAR a.
(1 CEMENT: 4 SAND)
In
FINISHED
FLOOR LEVEL
•
CHAMFER OF STONE •• 4 . • :
AT 45' ANGLE
07.11.16
NOTE: ALL DIMENSIONS ARE IN MM
BRICK WALL/RCC
COLUMN
CEMENT PLASTER
12 THICK
CEMENT MORTAR
(1 CEMENT : 3 SAND)/
TILE ADHESIVE FOR TILES
STONE/TILE DADO
PERDRAWING
STONE/TILE
FLOORING
FLOOR BASE
CEMENT MORTAR -
(1 CEM : 4 SAND)/
TILE ADHESIVE FOR
TILES
FINISHED
FLO VE
SECTION A-A
CHAMFER OF TILES/STONE
AT 45* ANGLE
/1/
CHAMFER OF TILES/STONE
AT 45* ANGLE
RCC COLUMN
BRICK WALL
STONE/TILE DADO
or"
PLAN PLAN
(DADO ON BRICK WALL) (DADO ON RCC COLUMN)
WOODEN FRAME
OUT OF 65x125
CEMENT
PLASTER
WOODEN
DOOR FRAME WOODEN FRAME
TOWER BOLT OUT OF 65x125
-e—o-
0
--o-
rr HOLD FAST
TEAK WOOD LIPPING
BUTT HINGE
0 600 MAXIMUM
4 THICK PLAIN GLASS
VISION PANEL WITH 35 THK.FLUSH
TEAK WOOD BEADING DOOR SHUTTER
_CAS PER DOOR PROFILE
)--
DRAWING)
0
cm 0
0 0
)—
780 TO 11804
Page 1 of 1
R.C.C. LINTEL/
BEAM
CEMENT PLASTER
F F F FiO 101.60x44.45x2 5
ALUMINIUM DOOR FRAME
Nr (SECTION No.20102)
I -.
ALUMINIUM GLAZING CLIP
(SECTION NO.19377)
GLASS
F I F
OPENABLE SHUTTER
SECTION 4-4
k] c DOOR HANDLE
ALUMINIUM GLAZING CLIP
F oom II O F
(SECTION NO.19377)-
101.60x44.45x2.5
) L.., ALUMINIUM DOOR FRAME
. C) (SECTION No.20102)
3
PIVOT 50x44.50x2.5
6 GAP PIVOT ALUMINIUM SHUTTER FRAME
(SECTION No.19554)
ELEVATION
(F—FIXED GLAZING)
ALUMINIUM BOTTOM RAIL
(SECTION NO.19584) ALUMINIUM GLAZING CLIP
(SECTION NO.19377)
101.60x44.45x2.5
ALUMINIUM DOOR FRAME GLASS
(SECTION NO.20102)
50x44.50x2.5 ALUMINIUM
RUBBER/EPDM GASKET
SECTION 5-5
SHUTTER FRAME
(SECTION No.19554)
PIVOT 100x44.45x2
GLASS ALUMINIUM LOCK RAIL
47.62X44.45X2.8 ALUMINIUM
SHUTTER FRAME (SECTION No.19564)
(SECTION No.19502)
SECTION 2-2
BRICK WALL/R.C.C. COLUMN
CEMENT PLASTER ALUMINIUM GLAZING CLIP
(SECTION NO.19377)
101.50x44.50x2.5 ALUMINIUM DOOR
FRAME (SECTION No.20102) FIXED WITH
ALUMINIUM LUGS/ANCHOR FASTENER
ALUMINIUM GLAZING CLIP (SECTION NO.19377) SECTION 6-6
GLASS
GLASS
ALUMINIUM GLAZING CLIP
(SECTION NO.19377)
GLASS
150x44.45x3.10
ALUMINIUM BOTTOM RAIL
101.60X44.45X2.5 (SECTION No.19584)
ALUMINIUM FRAME
(SECTION NO.20057)
SECTION 1 —1 SECTION 3-3 FINISHED FLOOR LEVEL
NOTES:
1. ALL DIMENSIONS ARE IN MM.
THE SECTION DESIGNATION NOS. PERTAIN TO EXTRUDED ALUMINIUM SECTIONS OF
"JINDAL ALUMINIUM LTD." AND ARE INDICATED FOR REFERENCE. EQUIVALANT SECTIONS
S ECTION 7-7
OF OTHER APPROVED MANUFACTURERS CAN ALSO BE USED.
FOR FINISHING OF ALUMINIUM SECTION (ANODISED/POWDER COATING) REFER BID/TEND ER.
RUBBER/EPDM GASKET SHALL BE USED FOR FIXING OF GLASS.
HARDWARE SHALL BE AS PER BID/TENDER.
4 27.03.12 REVISED & ISSUED AS STANDARD JKAFV" MAY KUMAR D.MALHOTRA
SECTION 2-2
GLASS
SECTION 19428
SECTION 20916
Page 1 of 1
SECTION: BEST QUALITY HOT ROLLED MILD STEEL SECTION CONFORMING TO IS:7452 SHALL BE
USED.
CONSTRUCTION: SECTIONS SHALL BE CUT TO REQUIRED LENGTH. THE CORNERS OF THE WINDOW
SHALL BE ELECTRICALLY FLASH BUT WELDED AND MITRED TO FORM A SOLID
FUSED RIGHT ANGLE JOINT SO THAT ALL FRAME SHALL BE SQUARE AND FLAT.
SUB DIVIDING BARS OF THE UNIT SHALL BE TENDED AND RIVETED TO THE FRAMES.
FENESTRA JOINT: AT THE INTERSECTION OF TEE SECTIONS THE VERTICAL TEE SHALL BE BROACHED
AND THE HORIZONTAL TEE SHALL BE THREADED THROUGH IT. THE INTERSECTION
SHALL BE CLOSED BY HYDRAULIC PRESSURE.
HINGES: PRESSED STEEL (HEAVY DUTY) HINGES SHALL BE INSERTED IN THE SLOTS CUT IN
THE OUTER FRAME FROM INSIDE. SIDE HUNG WINDOWS SHALL BE FITTED WITH
PROJECTING HINGES WITH ELECTRO GALVANISED STEEL PINS AND WASHERS TO
FACILITATE CLEANING OF GLASS PANES. TOP HUNG VENTILATORS SHALL BE
PROVIDED WITH PRESSED STEEL BUTT HINGES RIVETED TO OPENING SHUTTER AND
WELDED TO THE OUTER FRAME CUTTING SLOT IN IT.
FITTINGS: SIDE HUNG WINDOWS SHALL BE PROVIDED WITH HANDLES AND PEG STAYS OF
STEEL.
HANDLES SHALL HAVE A TWO POINT NOSE WITH A MILD STEEL BEVELLED STRIKING
PLATE RIVETED TO THE FIXED FRAME.
PEG STAYS SHALL HAVE THREE / FOUR DIFFERENT HOLES TO KEEP THE WINDOW
OPEN IN DIFFERENT POSITIONS UP TO A MAXIMUM OF 90 DEGREE.
HANDLE PLATES STAY, PEG STAY RESTS AND LOCKING BRACKETS SHALL BE OF
PRESSED STEEL AND SHALL BE RIVETED TO THE FRAME.
TOP HUNG VENTILATORS SHALL BE PROVIDED WITH PEG STAYS OF BRASS OR STEEL.
Page 1 of 1
I I I I
49,_ I I
I Nir I I
J L J
ELEVATION
GLASS AS
SPECIFIED
F4B
2 THICK MS SHEET 2 THICK WEATHER BAR
FABRICATED BOX
PUTTY SHUTTER FRAME F7D
PUTTY
GLASS AS GLASS AS SPECIFIED
SPECIFIED
MS HINGE
a
r \‘‘‘N‘Sjr
A
PUTTY
SECTION 2-2 MS SCREW
MASTIC
100X15X6 MS GLASS AS
LUGS 0 750 C/C SPECIFIED
BRICK WALL CENTRAL
CEMENT PLASTER GLASS AS MULLION F4B
SPECIFIED
SHUTTER —PUTTY
FRAME F7D SHUTTER
MS HINGE FRAME F7D
WINDOW FRAME F7D
SECTION 1 -1
NOTE: ALL DIMENSIONS ARE IN MM
DESIGNATION OF SECTIONS ARE AS/ IS : 7452.
(v^›
5 12.09.16 REAFFIRMED & ISSUED AS STANDARD DK /141". RAJANJI SRIVASTAVA R. NANA
STEEL FRAME
T
3 THICK MS FLAT
CUT/BENT TO SHAPE
NYLON WASHER 0
DETAIL OF HANDLE
73 ; so TO WE
30
2 THICK MS
4) rp- -+- Ri
FABRICATED STAY 8 DIA PIN
1 B
75
I 65
300
65 75
40x5mm MS
FLAT NOSING
TREAD FINISH
CEMENT MORTAR
32 0 N.B. (MEDIUM)
MS PIPE 12mm THICK CEMENT
WELDED PLASTER
TO BALUSTERS
25x25mm MS SQUARE
BAR BALUSTERS OVER
EACH STEP
SECTION A-A
(FOR CAST IN—SITU CONCRETE TREAD)
NOSING
CEMENT MORTAR
— KOTA/GRANITE/MARBLE STONE
FINISH
TREAD FINISH
CEMENT MORTAR
50x50x100mm POCKET
FOR FIXING MS FLAT 10MM
SHOE FILLED WITH MINIMUM
CEMENT CONCRETE (1:3:6)
40x40x6mm THK. MS
FLAT SHOE WELDED AT
BOTTOM OF BALUSTER &
INSERTED IN RCC STEP
SECTION A-A
12mm THICK (FOR STONE FINISHED TREAD)
CEMENT PLASTER
DETAIL OF HANDRAIL
Rev. Date Purpose Prepared Checked Stds. Committee GM(CIVIL) Stds. Bureau
No. by by Convenor Chairman
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - AII rights reserved
RCC SLAB
25x25x3 THICK
MS ANGLE FIXED
TO ROOF WITH
ANCHOR FASTENERS
@ 1200 C/C MAX.
BRICK WALL
10 110
LEVELING NUT
3 THICK MS
FLAT CLAMP
/ 11111111 10111
ALUMINIUM MAIN TEE
25 x 35 x 2.5 THICK
ALUMINIUM ANGLES
CEILING TILES
AS SPECIFIED
SECTION AT 1-1
AI A V /
ALUMINIUM CROSS
RETURN AIR SLIT TEE 25x25
COVERED WITH
GRILL AS/SECTION 1-1
26 SWG GI
MAIN RUNNER ROOF SLAB
44
G I CEILING
,
HANGER (SLOTTED) FIXED TO
CEILING I WALL r /
A
H
CEMENT
) PLASTER / /
t
GI SUSPENSION
ANGLE
R ETURN / /
AIR GRILL
/ /
if SI
ALUMINIUM ALLOY
ALUMINIUM
CEILING PANEL ANGLES
ALUMINIUM
SECTION 1-1 HOLD ON HANGER
ALUMINIUM ALLOY
CEILING PANEL
MAIN RUNNER
SIZE : 254/305x1264
OR AS/DRAWING
RAWL PLUG
'J' HOOK
GI ROD HANGER
AT 1200 C/C
RETURN
—CLIP IN PROFILE AIR GRILL
AT 600mm C/C
I'll
ALUMINIUM ALLOY ALUMINIUM ANGLES
CEILING PANEL
SECTION 1-1
(HANGING/SUSPENSION ARRANGEMENT CAN VARY FROM VENDOR TO VENDOR)
— MAIN RUNNER
ALUMINIUM ALLOY RETURN AIR SLIT
CEILING PANEL 600 COVERED WITH
f 17C • LfMLnn
JILL
• (TTY.) (KILL AS/StC. I ,
1 ii II 11 1
1 - II 11 ii 1
1 11 ii ii 1
1 II II II 1
0
.., iii I -ti I
II II
,.. N/11
1 i/.1 II 0 1
II 1 II 1, 1, II
ii ii 11 11
11 1 ii ii ii II
II II iiII II ,,\ 1, 11 II II II
II II II II II I I, I, II II II 1
,
LIGHTING FIXTURE/DIFFUSER
41_
5 02.03.16 REVISED Et ISSUED AS STANDARD 4/4-CK )(CfSD/JK8 RAJANJI SRIVASTAVA S. CHANDA
4 31.08.10 REVISED 11 ISSUED AS STANDARD SANDHYA GB/JS JKB N. DUARI
50x50x8 GAUGE
R.C.0 COLUMN WELDED MESH
75X50,8 THK
M.S INSERT PLATE 25x25x3 M.S ANGLE
2 NOS. 6 THK. M.S.FLATS
WELDED TO INSERT PLATE
40x40x3.2 M.S. SQUARE
FABRICATED HINGE ASSEMBLY HOLLOW SECTION
AS/DETAIL DETAIL AT
2 NOS. 6 THK. M.S.FLATS
25x25x3 M.S ANGLE
WELDED TO FRAME
40x40x3.2 M.S. SQUARE 50x50x4.5 M.S SQUARE
HOLLOW SECTION HOLLOW SECTION FRAME
50x50x8 GAUGE —
WELDED MESH
75
12 DIA. HOLE
50x50x4.5 M.S SQUARE FOR LOCK
HOLLOW SECTION FRAME 40x40x6 M.S. ANGLE FOR
M.S HOLD FAST LOCKING ARRANGEMENT
25x6x200 LONG
(I)
I-
L11 D
.-I 12 SQUARE 0
L
M.S BARS 50x50x8 GAUGE
EARTHING LUG (TYP.) WELDED MESH
(FOR DETAILS REFER
40x40x3.2 M.S. SQUARE
ELECTRICAL STD. NO. 7-51-0115)
HOLLOW SECTION
ELEVATION 25 DIA. 100 LONG
HOLE IN FLOOR 25x25x3 M.S ANGLE
20 DIA. M.S. BAR
TOWER BOLT 250 LONG
EQUAL, / "EQUAL
I I
L_-- 3000 TO 6000 _J
PLAN
NOTE:
SECTION AT 0 -0
ALL STEEL MEMBERS SHALL CONFORM TO RELEVANT B.I.S. CODES AS4PPLICABLE. L
5 14.12.15 REVISED ft ISSUED AS STANDARD '1"4/'DK )1,4*[;/A&-- RAJANJI SdlatrAlq, S. CHANDA
75 1 75
R.C.C. COLUMN
2 NOS. 6 THK. 50x50x4.5 M.S SQUARE
M.S.FLATS WELDED TO HOLLOW SECTION FRAME
INSERT PLATE
40x40x3.2 M.S. SQUARE
75X50,8 THK. HOLLOW SECTION
M.S INSERT PLATE
M.S HOLD FAST 50x50x8 GAUGE
25x6x200 LONG
4 WELDED MESH
FABRICATED HOLLOW
M.S CYLINDER MADE OF 2 NOS. 6 THK. M.S.FLATS
5 THK. M.S PLATE WITH WELDED TO FRAME
20 INTERNAL DIA.
FIXED TO SHUTTER 25x25X3 M.S. ANGLE
FABRICATED
HINGE ASSEMBLY
DETAIL AT
NMI
■ 49 AM/
25X25X3 M.S. ANGLE
50x50x8 GAUGE
■ AMP WELDED MESH
► 12 SQUARE
4•\ \
M.S BARS
1111011
DETAIL AT
75
50x50x8 GAUGE
R.C.C. COLUMN WELDED MESH
111
NOTE: DETAIL AT
ALL STEEL MEMBERS SHALL CONFORM TO RELEVANT B.I.S. CODES ASPPLICABLE.
132X132X5.4 M.S.
SQUARE BOX SECTION
4-16
BOLT
300X300, 12 THK.
M.S. BASE PLATE
PLAN DETAIL AT 0
FIXING DETAIL AT OA 25X25X3 M.S. ANGLE
FABRICATED HINGE 50x50x4.5 M.S SQUARE CAP PLATE
ASSEMBLY AS/DETAIL HOLLOW SECTION FRAME 6 THK.
40x40x3.2 M.S. SQUARE (TYP.)
50x50x8 GAUGE
WELDED MESH HOLLOW SECTION
IAN
I
1 C i -11
1 •X M•
1
1•11 /ter, la%
EQ.
1000
If EQ.
/1,
DADO
DOOR CISTERN
BRACKET
(AS/ITEM DESCRIPTION)
BIB COCK
O FLUSH PIPE
O
FINISHED FLOOR
FLOOR FINISH ORISSA PAN WC LEVEL
SUNK BY
MINIMUM 10MM
FILLED UP MATERIAL
AS/ITEM DESCRIPTION
SLOPE TO MAIN HOLE
. • ' • . • . •
. v
„ •.
—.a a ' • ,* • .
CUT OUT IN WALL
r BIB COCK
150
4%
6' 0
C====
S 0
O
10fr ORISSA PAN W
O
A STOP COCK
1200 MINIMUM
1
PLAN
NOTE: REFER SHEET 2 OF 2.
114
5 07.11.16 REVISED & REISSUED AS STANDARD. Dict"Y‘,°' JI sop RAJANJI SRIVASTAVA R. NANDA
BRACKET
(AS/ITEM DESCRIPTION)
BIB COCK
FLUSH PIPE
FINISHED FLOOR
FLOOR FINISH — ORISSA PAN WC LEVEL
SUNK BY
MINIMUM 10MM VERTICAL PIPE
FILLED UP
MATERIAL AS PER
ITEM DESCRIPTION
CUT—OUT IN RCC
BEAM FOR PIPE
PENETRATION
SECTION A-A
(FOR UPPER FLOOR WITH SUNK SLAB)
(REFER SHEET 1 OF 2 FOR SECTION A—A APPUCABLE TO GROUND FLOOR)
NOTES:
1. ALL DIMENSIONS ARE IN MILLIMETRES.
2. ALL FLOOR FINISH LEVEL INSIDE THE W.C. CUBICLE SHALL
BE 10 TO 15MM LOWER THAN OUTSIDE.
3. PROVISION FOR NECCESSARY CUT—OUT IN THE R.C.C. STRUCTURAL
BEAM SHALL BE KEPT (FOR DISPOSAL PIPE PENETRATION). THE LOCATION
ANGLE, GRADIENT ETC. OF THE CUT—OUT SHALL BE AS PER SITE REQUIREMENTS.
4. REFER RELEVANT ARCHITECTURAL DRAWINGS FOR ACTUAL SIZE OF THE CUBICLE.
DADO
TOILET PAPER
HOLDER
CISTERN
EUROPEAN
TYPE WC
FLOOR FINISH
SUNK BY S OR P TRAP
MINIMUM 10MM.
SLOPE
BIB COCK
V0
4 0
e 200
(AS/ARCH. 'DRAWINGS)
10MM DROP
IN FLOOR EUROPEAN In
TYPE WC
CISTERN
STOP COCK
1300 MINIMUM
PLAN
NOTE: REFER SHEET 2 OF 2.
TOILET PAPER
HOLDER
CISTERN
I I VERTICAL PIPE
EUROPEAN I I
I I
TYPE WC I
DOOR I I
I I
FLOOR FINISH
SUNK BY S OR P TRAP
MINIMUM 10MM.
FLOOR TRAP
COVERED WITH
GRATING CUT OUT IN RCC
BEAM FOR PIPE
RCC BEAM PENETRATION
N
FILLED UP MATERIAL AS PER ITEM DESCRIPTION
SECTION A-A
(FOR UPPER FLOOR WITH SUNK SLAB)
(REFER SHEET 1 OF 2 FOR SECTION A—A APPLICABLE TO GROUND FLOOR)
NOTES:
1. ALL DIMENSIONS ARE IN MILLIMETRES.
2. ALL FLOOR FINISH LEVEL INSIDE THE W.C. CUBICLE SHALL
BE 10 TO 15MM LOWER THAN OUTSIDE.
3. PROVISION FOR NECCESSARY CUT—OUT IN THE R.C.C. STRUCTURAL
BEAM SHALL BE KEPT (FOR DISPOSAL PIPE PENETRATION). THE LOCATION
ANGLE, GRADIENT ETC. OF THE CUT—OUT SHALL BE AS PER SITE REQUIREMENTS.
4. REFER RELEVANT ARCHITECTURAL DRAWINGS FOR ACTUAL SIZE OF THE CUBICLE.
5 07.11.16 REVISED & REISSUED AS STANDARD DoO"'" JS/J RAJANJI SRIVASTAVA R. MAMBA
FLUSH PIPE
CONCEALED TYPE
(CONNECTED TO
CISTERN OR O.H.
TANK)
TILES/WALL
FNISH
SENSOR
(APPLICABLE IF
SPECIFIED IN
TENDER ITEM)
URINAL PARTITION
(ALL EDGES
ROUNDED OFF)
SPREADER
LAT BACK
RINAL
i
9 LIIM OTTLE
RAP 1144
ij BOTTLE
TRAP
ro
OP OF
LATFORM
GRATING
L=
LOOR LEVEL URINAL
CI CX/ A TInkl
II TRAP
9
0. 0,
11
0
0
co
EQ. EQ.
600 URINAL
(MINIMUM)
100 RAISED
PLATFORM
PLAN URINAL TRAP
NOTES:
1. ALL DIMENSIONS ARE IN MILLIMETRES.
2. THIS STANDARD IS INDICATIVE. TYPE AND NO. OF URINAL FIXTURES, FLUSHING ARRANGENT ETC.
SHALL BE AS PER ARCHITECTURAL DRAWINGS & TENDER ITEM.
3. SENSORS SHOWN SHALL BE PROVIDED ONLY IN CASE THE SAME E SPECIFIED IN T DER ITEM.
5 01.12.16 REVISED & REISSUED AS STANDARD RAJAHS A—
STAVA R. HANDS
550
M NIMUM
DADO AS PER TENDER
ITEM / ARCH. DRAWINGS
0
MIRROR
0
GLASS SHELF
600MMx120MMx6MM THK
0
In FIXED BY 'D' OR 'F'
BRACKETS
SOAP CONTAINER
TOWEL RAIL
0
0 MANUALLY OPERATED
a)
PILLAR COCK OR
BATTERY OPERATED
FAUCET WITH SENSOR
0
BOTTLE TRAP
co
WASTE PIPE
EMBEDED IN WALL
GRATING
ELEVATION FLOOR TRAP
MS BRACKETS
IT A PA TAM W/
FLOOR TRAP
BELOW
WASH BASIN
TOWEL RAIL
PLAN
(FOR WALL HUNG TYPE WASH BASIN)
NOTES:-
1. ALL DIMENSIONS IN MILLIMETRES.
2. THE SIZE OF MIRROR SHOWN IS INDICATIVE. ACTUAL SIZE
SHALL BE AS PER ARCHITECTURAL DRAWINGS/ ITEMS DESCRIPTION.
3. THE ARRANGEMENT AND DETAIL OF WASH BASIN SHOWN (HERE AND IN SHEET-2) IS
TYPICAL. FOR 2 OR MORE WASH BASIN, REFER RELEVANT ARCHITECTURAL DRAWING
(FOR LOCATION & CONFIGURATION) WHICH SHALL BE READ IN CONJUNCTION WITH
THIS STANDARD.
4. LOCATION & TOWEL RAIL IS INDICATIVE. REFER RELEVANT ARCHITECTURAL DRAWING OR
EXACT LOCATION.
5 21.11.16 REVISED & REISSUED AS STANDARD MLT JS/JKB RAJAMJI ASTAVA R. NANDA
1
550 DADO AS PER
TENDER ITEM /
ARCH DRAWINGS
•
0 MIRROR
0
o
co
SOAP CONTAINER
600
POLISHED STONE TO
COUNTER + FACIA
0 •
0 OVER R.C.C. SLAB
O
co
R.C.C. SLAB
0
o
co
BOTTLE TRA
•
MANUALLY OPERATED PILLAR
ELEVATION COCK OR BATTERY OPERATED
FAUCET WITH SENSOR
SECTION
AS PER ARCH. DRAWING
0
Ih
MIRRO
0
0 ROUND TYPE COUNTER TOP
WASH BASIN FITTED NEATLY IN
STONE COUNTER TOP AND RCC
SLAB UNDERNEATH.
(CUT NEATLY FOR EXACT SIZE
AND SHAPE OF WASIN BASIN).
TOWEL RAIL
PLAN
(FOR COUNTER TOP TYPE WASH BASIN)
NOTES:— REFER SHEET-1.
5 21.11.16 REVISED & REISSUED AS STANDARD MLT JS/JKi RAJANJI SRIVASTAVA R. BANDA
ROAD
BUILDING
0
0
0
ce BUILDING DRAIN
(TO BE CONNECTED TO MAIN STORM
WATER DRAINAGE SYSTEM AT
SUITABLE LOCATION AS PER STORM
I
WATER DRAINAGE SYSTEM DRAWING)
ROAD
1 1 i n
KEY PLAN
C/C OF COLUMNS
BUILDING DRAIN
(SLOPE 1:500)
COVERED WITH M.S.
GRATING
0
0
te) RWP EMBEDDED
IN CONCRETE
STRUCTURAL COLUMN
0 0
0 0
it)
EXTERNAL FACE
OF WALL
0 RWP EMBEDDED
0 IN CONCRETE
rn
RCC COLUMN
EXTERNAL FACE
OF WALL
O
O
BRICK WORK
M20 CONC.
RAMMED EARTH
SECTION A-A
600 MAX. (ONE PIECE)
BRICK WALL
10 DIA MS BAR LUG
0 500 C/C WELDED
TO ANGLE AND
DETAIL EMBEDDED IN PCC DETAIL 0
(1:3:6)
NOTES:
1. ALL DIMENSIONS ARE IN MM.
2. WIDTH OF THE PLINTH PROTECTION SHALL BE MINIMUM 900mm AND X+300 MAXIMUM UNLESS OTHERWISE
MENTIONED IN BUILDING DRAWING.
3. PLINTH PROTECTION ALONG ANY PARTICULAR SIDE OF THE BUILDING SHALL BE OF CONSTANT WIDTH FOLLOWING
THE EXTERNAL WALL AUGNEMENT IF NOT SPECIFICALLY MENTIONED/INDICATED IN BUILDING DRAWING.
4. M.S. DRAIN COVER GRATING SHALL BE PROVIDED OVER BUILDING DRAIN AT ALL APPROACHES UNLESS OTHERWISE
MENTIONED/INDICATED IN BUILDING DRAWING.
AL
5 09.11.16 REVISED AND REISSUED AS STANDARD AIS/JKI\15P-'" RAJANJI SRIVASTAVA LNANDA
RCC LINTEL
CEMENT PLASTER 10
A
L 750 TO 1000
f C
C
A
L
B
0
lN
— F0
P8
FINISHED
FLOOR LEVEL
M
(gt
ELEVATION SECTION 2-2
H
A
BRICK WORK
SECTIONAL PLAN 1 —1 CEMENT
LEGEND:
A: WOODEN FRAME OUT OF 125x65 H: TOILET DOOR LATCH
B: TEAK WOOD STYLE 100x35 J: TOWER BOLT
C: TEAK WOOD TOP RAIL 100x35 K: DOOR HANDLE
D: TEAK WOOD BOTTOM RAIL 200x35 L: COAT AND HAT HOOK
E: 12 THK. PARTICLE BOARD/MARINE PLY (INTERNAL SIDE OF THE DOOR)
INFILL PANEL WITH SPECIFIED FACING. M: ACRYLIC KICK PLATE 200X3 THICK.
F: 150 LONG BUTT HINGES N: TEAK WOOD LOCK RAIL 150x35
0 MAX. 600 C/C. P: TEAK WOOD BEADING
G: MS HOLD FAST
EMBEDDED IN CONCRETE
BLOCK 350x100x100
al
NOTE: ALL DIMENSIONS ARE IN MM
SHUTTER
3 THICK MS FLAT
)— CONTINUOUS ALONG
VISION PANEL
18 SWG GI 'Z'
SECTION FIXED
0 TO FRAME
EPDM GASKET
ALL AROUND THE
GLASS
0
0 GLASS
II I
II I
II
II
I
I IF
SECTION 3-3
II
II II
II II
III II FINISHED
FLOOR LEVEL
20X20X3 MS ANGLE
880 TO 1180 WELDED TO BOTH
I FACES OF FRAME
ELEVATION SECTION 1 —1
12X10 GROOVE IN
PLASTER FILLED WITH
POLYSULPHIDE SEALANT
L BRICK WORK
0
10 79
A
tisivil 014 I I I L5
,.W '(?'
CEMENT
PLASTER
414 M
0
SECTION 2-2
LEGEND:
A: OVER HEAD HYDRAULIC DOOR CLOSER (HEAVY DUTY). H: 3 THICK MS FLAT CONTINUOUS ALONG
B. MS HOLD FAST 200x25x6THICK 0 MAXIMUM 600 C/C PERIMETER OF SHUTTER.
WELDED TO FRAME SPACER (L) 18 SWG GI VERTICAL STIFFNER 0 200 C/C
40 THICK (OVER ALL) 18 SWG GALVANIZED PRESSED (SPACING TO BE ADJUSTED FOR VISION PANEL).
STEEL SHUTTER FILLED WITH MINERAL WOOL (48Kg/cum). SPRING LOADED HEAVY DUTY DOOR STOPPER.
3 THICK MS FLAT SPACER WELDED TO FRAME
16 SWG GALVANIZED PRESSED STEEL FRAME OUT OF AT 0 500 C/C.
125X60 PROFILE FILLLED WITH CONCRETE (REBATE 40x150x3 THICK MS PAD WELDED TO FRAME
DIMENSION TO BE SUITABLY ADJUSTED FOR AT ALL HINGE & LOCK LOCATIONS.
ACCOMODATING GASKET FOR AIR TIGHT DOOR). N: SS 304 GRADE 19 DIA, 200 LONG HANDLE
VISION PANEL (AS/PROJECT DRAWING). ON BOTH SIDES.
100 LONG SS 304 GRADE HEAVY DUTY BALL BEARING 0: 18 SWG GI MORTAR GUARD AT THE BACK OF
HINGE 0 600 C/C MAXIMUM. HINGES & LOCK.
G: SS 304 GRADE 16 DIA 250 LONG ALDROP ON BOTH P: 10 DIA SS 304 TOWER BOLT (250 LONG FOR
SIDES. 2100 HT. & 600 LONG FOR 2500 HT.).
'D' PROFILE EPDM GASKET ALONG FRAME REBATE
NOTE: 1. ALL DIMENSIONS ARE IN MM (FOR AIR TIGHT DOOR ONLY).
(mom
4 09.04.12 REVISED & REISSUED err& a .111(C 16... PIA UMAR D.SAUK) TRA
CYK
Page 1 of 1
R
QC
—< FINISHED
K F BiR EVEL
ELEVATION
12X10 GROOVE IN
PLASTER FILLED WITH
POLYSULPHIDE SEALANT
BRICK WORK
D
10
}moo
z
La
ce
4354 CEMENT
104 M
PLASTER
0
SECTION 1 -1
LEGEND:
OVER HEAD HYDRAULIC DOOR CLOSER (HEAVY DUTY). 18 SWG GI VERTICAL STIFFNER 0 200 C/C
MS HOLDFAST 200x25x6 THICK 0 MAXIMUM 600 C/C (SPACING TO BE ADJUSTED FOR VISION PANEL).
WELDED TO FRAME SPACER (L). SPRING LOADED HEAVY DUTY DOOR STOPPER.
C. 40 THICK (OVER ALL) 18 SWG GALVANIZED PRESSED 3 THICK MS FLAT SPACER WELDED TO FRAME
STEEL SHUTTER FILLED WITH MINERAL WOOL (48Kg/cum). AT 0 500 C/C.
16 SWG GALVANIZED PRESSED STEEL FRAME OUT OF 40x150x3 THICK MS PAD WELDED TO FRAME
125X60 PROFILE FILLLED WITH CONCRETE (REBATE AT ALL HINGE & LOCK LOCATIONS.
DIMENSION TO BE SUITABLY ADJUSTED FOR ACCOMODATING N: SS 304 GRADE 19 DIA, 200 LONG HANDLE
GASKET FOR AIR TIGHT DOOR). ON BOTH SIDES.
VISION PANEL (AS/PROJECT DRAWING). 0: 18 SWG GI MORTAR GUARD AT THE BACK OF
100 LONG SS 304 GRADE HEAVY DUTY BALL BEARING HINGES & LOCK.
HINGE 0 600 C/C MAXIMUM. 10 DIA SS 304 TOWER BOLT (250 LONG FOR
SS 304 GRADE 16 DIA 300 LONG ALDROP ON BOTH SIDES. 2100 HT. & 600 LONG FOR 2500 HT.).
H: 3 THICK MS FLAT CONTINUOUS ALONG PERIMETER OF 'D' PROFILE EPDM GASKET ALONG FRAME REBATE
OF SHUTTER. (FOR AIR TIGHT DOOR ONLY).
R: 2 THICK 25X25 GI ANGLE (VERTICAL) EACH
NOTE: 1. ALL DIMENSIONS ARE IN MM WELDED TO ONE SHUTTER.
2. FOR OTHER DETAILS REFER STANDARD NO. 7-75-0070. • \Ot C\ WLsk
4 09.04.12 REVISED & REISSUED II" DK ?fKD (Nail'.
JK N AY KUMAR DUALH OTRA
3 21.03.07 REVISED, ISSUED AS STANDARD AMARJIT JKB/SD ARVIND KUMAR V.CHATURVEDI
, nciLam'
itscom coma (it-flat-11/
vcotvc-i c61 tira4131-1)
1WtkEurr -titteTur
ei1.71 Outettft)
1A1-
2 19.02.2016 REVISED AND REISSUED
DJ AKM TKS SC
1 04.07.2011 REVISED AND REISSUED SM SM MKG DM
Abbreviations:
CONTENTS
GENERAL NOTE
The enclosed ITPs are indicative and shall be followed for developing the job specific ITP’s for the
works to be performed by the contractor. The provisions indicated for stage wise inspection by
EIL/Owner (For specific activities) are the minimum and the Engineer-In-Charge may decide to
increase Hold Points/ Witness Points while approving the job specific ITP’s. Activities for which
ITP’s are not provided in this specification contractor to develop and get the same approved by
EIL/Owner before start of the work. In general role of EIL has been specified in the document. The
role of owner to be specified during preparation of site specific ITPs
Contractor to submit job specific reporting formats with the aid of enclosed sample reporting
formats and job procedures for the jobs for which ITP’s are attached and submit to EIL/Owner for
approval, before commencement of the activity. If the contractor has to deviate from the given ITP
for a valid reason, he shall obtain prior written approval of EIL/Owner. Contractor to carry out
100% examination of all activities.
LEGEND
HP : Hold Point;
W : Witness Point ;
Responsibility for execution of the inspection/testing is with the Contractor; Owner/EIL only
verifies examination or testing done by the Contractor at important stages
SL.
ACTIVITY CONTRACTOR EIL
NO.
SOIL INVESTIGATION
SL.
ACTIVITY CONTRACTOR EIL
NO.
SITE GRADING
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
Clearing and stripping of soil including disposal of
1. WC S -
unsuitable material
a) Availability of valid calibration certificates of
2. WC HP HP
instruments/ testing equipments
EXCAVATION
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT A CAT B CAT C
a) Availability of valid calibration
1. certificates of instruments/ testing WC HP HP RW
equipments
b) Field calibration, if any WC W S -
2. Layout checking WC S - -
BACK FILLING
EIL
SL.
ACTIVITY CONTRACTOR
NO.
CAT A CAT B CAT C
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
8. Backfilling in layers WC Rw Rw
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
WBM ROADS
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
a) Availability of valid calibration certificates
1. WC HP RW
of instruments/ testing equipments
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
CAT B: Roads subjected to heavy loading, connected to main highway, main plant roads
CAT C: Balance Roads
SL.
ACTIVITY CONTRACTOR EIL
NO.
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
TANK PADS
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT A CAT B
1. Approval of source of materials WC NOTE 1 NOTE 1
2. Stripping the area WC - -
a) Availability of valid calibration certificates of
3. WC HP RW
instruments/ testing equipments
b) Field calibration, if any WC W S
4. Layout and marking of ground level WC S -
Excavation to required level, compaction of sub-
5. WC W S
base
6. Checking/ testing of materials WC W S
Filling selected materials in specified layers,
7. WC S -
rolling, watering
8. Compaction tests WC W Rw
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
CAT A: All Site fabricated steel storage tanks for process fluid/ Hydrocarbon, floating roof,
tanks having capacity 600cum or 10m dia. and 8 m height.
CAT B: Site fabricated steel storage tanks for Raw water, Fire water, waste water, DM water, etc.
and all tanks not covered under “CAT A”.
MICRO GRADING
SL.
ACTIVITY CONTRACTOR EIL
NO.
7. Final inspection WC W
SL. EIL
ACTIVITY CONTRACTOR
NO CAT B CAT C
A. PRIOR TO FABRICATION
3. WPS/PQR
ii) Testing WC Rw Rw
NOTE : 1) For incoming material inspection please refer ITP no: -6-82-1010.
CAT B : All pressure lines, Fire Water line, Cooling Water line, etc.
CAT C : Balance Works
SL. EIL
ACTIVITY CONTRACTOR
NO
CAT B CAT C
6. Baking of Electrodes WC S -
9. PT/MT WC S -
1. Procedure Review WC Rw Rw
CAT B : All pressure lines, Fire Water line, Cooling Water line, etc.
CAT C : Balance Works
SL. EIL
ACTIVITY CONTRACTOR
NO CAT B CAT C
D. LAYING
6. Application of primer WC S S
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
CAT B : All pressure lines, Fire Water line, Cooling Water line, etc.
CAT C : Balance Works
SL. EIL
ACTIVITY CONTRACTOR
NO CAT B CAT C
E. SYSTEM COMPLETION
Refer
1. Tie in joints WC Refer 2740A
2740A
Refer
2. Scrutiny of test packs for system testing WC Refer 2740B
2740B
3. System testing WC W Rw
CAT B : All pressure lines, Fire Water line, Cooling Water line, etc.
CAT C : Balance Works
SL.
ACTIVITY CONTRACTOR EIL
NO.
A. Fit up WC W
B. Root Run DP WC W
C. Final Run DP WC W
D. Radiograph Review WC HP
E. PWHT Hardness WC RW
F. RF Pad Testing WC HP
H. Coating, Wrapping WC W
I. Peel Test WC HP
J. Holiday Testing WC HP
Checking For Any Damage In Wrapping &
K. Coating After Lowering, Their Repair Holiday WC W
Testing, Etc.
L Back Filling WC S
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
1. Clearance for flushing & testing WC Rw Rw
Mechanical clearance
1a.
- Conformity with drawing HP Rw
WC
- PT/MT WC Rw Rw
- Radiography WC Rw Rw
- RF pad testing WC Rw Rw
- Surface preparation WC Rw -
- Primer application WC Rw Rw
- Holiday check WC Rw Rw
4. Laying
- Trench leveling WC Rw Rw
- Lowering & checking for damages in
wrapping & coating, their repair, WC Rw Rw
Holiday testing, etc.
- Backfilling WC Rw Rw
CAT B : All pressure lines, Fire Water line, Cooling Water line, etc.
CAT C : Balance works
ITP NO : 2741
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
a) Availability of valid calibration
1. certificates of instruments/ testing WC RW RW
equipments
b) Field calibration, if any WC S Rw
3. Mix proportion WC S -
7. Curing WC - -
ITP NO : 2742
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT A CAT B CAT C
1 Approval of source of materials WC HP HP Rw
a) Availability of valid calibration
2. certificates of instruments/ testing WC HP HP HP
equipments
b) Field calibration, if any WC Rw Rw Rw
Checking of layout & condition of PCC/
3. WC S S -
leveling course
4. Incoming material checking WC NOTE 1 NOTE 1 NOTE 1
Design of mix &establishment of strength at
5. WC HP HP HP
site by trial mix
Check for line & level of shuttering
6. WC S S -
including its condition, quality and rigidity.
Check for sub-soil water & dewatering
7. WC S S -
arrangement, if any
8. Reinforcement & covers to reinforcement WC S S S
Inserts, Anchor bolts and pipe sleeves,
9. WC S S S
pockets, dowels, etc.
10. Pour Card WC W W Rw
Check for obstacles encountered (Electrical
11. WC S S -
conduits, pipe lines, etc.)
12. Concreting, testing, compaction & finishing WC W S Rw
13. Casting of cubes WC S S S
14. Curing WC S S -
15. Testing of cubes WC W W W
16. Removal of shuttering WC S - -
17. Check for water tightness, rendering, if any WC S S S
18. Preparation of As-built drawings WC Rw Rw Rw
INSPECTION & TEST DOCUMENTS
Review Test and Inspection Documents WC Rw Rw Rw
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
ITP NO : 2743
SL. EIL
ACTIVITY CONTRACTOR
NO. CATA CATB CAT C
1 Approval of source of materials WC HP HP Rw
a) Availability of valid calibration certificates
2. WC HP HP HP
of instruments/ testing equipment
b) Field calibration, if any WC Rw Rw Rw
3. Checking of layout WC S S -
4. Incoming material inspection WC Note 1 Note 1 Note 1
Design of mix &establishment of strength at
5. WC HP HP HP
site by trial mix
Check for line & level of shuttering and
6. scaffolding/ vertical bracing including hoisting WC S S -
arrangements.
7. Reinforcement & covers to reinforcement WC S S S
Inserts, bolts, pipe sleeves, MS rungs, concealed
8. electrical conduits, fan hooks, dowels, etc. WC S S -
including welding if any
9. Pockets/ openings WC S S -
10. Expansion joints, if any WC S S -
11. Check for water stops, slopes, stoppers, if any WC S S -
12. Pour Card WC W W Rw
13. Concreting, testing, compaction & finishing WC W S S
14. Casting of cubes WC S S S
15. Curing WC S S -
16. Testing of cubes WC W W W
17. Removal of formwork/ staging WC S - -
Verification of dimensions viz AFC drawings
18. WC S S S
and tolerances
19. Check for water tightness, rendering, if any WC S S -
20. Preparation of As built drawings. WC Rw Rw Rw
INSPECTION & TEST DOCUMENTS
Review Test and Inspection Documents WC Rw Rw Rw
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
CAT A: Super structure of foundations for Critical equipments i.e. compressors, reactors,
columns, stacks, foundations subjected to dynamic loading and super structure of any
other foundation with RCC Quantity > 250 Cum. in single pour, Slabs of plant and non-
plant buildings, etc.
CAT B: Unit Pipe racks, plant buildings and super structure of other equipment not covered in
category A, etc
CAT C: Non critical pipe racks (branch pipe, offsite pipe rack, etc.) non-plant buildings, pipe
sleepers, manhole, catch pit and balance works.
ITP NO : 2745
RCC PAVEMENT/FLOORING
SL.
ACTIVITY CONTRACTOR EIL
NO.
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
ITP NO : 2746
BRICK MASONARY
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
a) Availability of valid calibration certificates
1. WC RW RW
of instruments/ testing equipments
b) Field calibration, if any WC Rw Rw
3. Cleaning of surface WC - -
4. Wetting/soaking of bricks WC S S
13. Curing WC - -
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
ITP NO : 2747
STRUCTURAL STEEL WORKS
S. CONTRA- EIL
ACTIVITY
NO CTOR CAT A CAT B CAT C
A PRE – FABRICATION ACTIVITIES
a) Availability of valid calibration certificates of
1. WC HP HP RW
instruments/ testing equipments
b) Field calibration, if any WC S S Rw
2. Incoming material inspection WC Note 1 Note 1 Note 1
3. Welding Filler material approval/ qualification
a) Manufacturing test certificates/ documents WC Rw Rw Rw
b) Testing, if any WC W W W
4. Approval of WPS/ PQR WC HP HP HP
5. Welders performance qualification WC W W Rw
6. Layout checking WC S - -
7. Welding equipment and accessories WC S - -
8. Preparation and approval of Fabrication drawings WC Rw Rw -
B FABRICATION ACTIVITIES
1. Materials as per design drawing WC Rw Rw Rw
2. Check straightness and non-warping of members WC S S -
Dimensional and fit-up checks including provision of
3. WC S S -
slopes for deflection wherever required
4. Visual check for welding WC S S -
Grinding including surface preparation for painting and
5. WC S S Rw
application of primer
6. Checking paint as per specs, shelf-life, etc. WC S S -
7. Application of specified paint, painting thickness, etc. WC S S -
C FIELD ERECTION ACTIVITIES
Lifting arrangements including test certificates of lifting
1. WC S S Rw
tackles
2. Correctness of location WC S - -
3. Orientation of bracing, lugs WC S - -
4. Alignment & levels WC S - -
5. Field welding (if any) WC S S -
6. Grouting WC S S -
7. Finishing coat of paint, thickness of paint etc. WC S S S
8. Preparation of As-built drawings WC Rw Rw Rw
INSPECTION & TEST DOCUMENTS
Review Test and Inspection Documents WC Rw Rw Rw
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
CAT A: Steel structures pertaining to equipments i.e. compressors, reactors, columns, stacks,
Technological structures.
CAT B: Steel structures pertaining to Unit Pipe racks, and other equipments not covered in
category A, etc.
CAT C: Steel structures of Non critical pipe racks (branch pipe, offsite pipe rack, etc) plant
buildings and non-plant buildings, pipe sleepers, manhole, catch pit, walkways, platforms
at grade levels, etc.
ITP NO : 2748
PILING WORKS
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT A CAT B CAT C
1. Approval of source of materials WC Rw Rw Rw
8. Concreting, testing WC W S S
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
CAT B: Unit Pipe racks, plant buildings and other equipment foundations not covered in category
A, etc.
CAT C: Non critical pipe racks(branch pipe, offsite pipe rack, etc.) non-plant buildings ,pipe
sleepers, manhole, catch pit, etc.
ITP NO : 2771
ANTI-TERMITE TREATMENT
SL.
ACTIVITY CONTRACTOR EIL
NO.
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
ITP NO : 2772
PLASTERING
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
Check for completeness of all hidden jobs like piping,
1. WC - -
conduiting, etc.
8. Curing WC S -
CAT B: Area requiring special finish (e.g. pebble dash finish etc.)
CAT C: Balance works.
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
EIL
SL.
ACTIVITY CONTRACTOR
NO.
CAT B CAT C
5. Curing, if any WC S -
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
SANITARY FITTINGS
SL. EIL
NO. ACTIVITY CONTRACTOR CAT B CAT C
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
SL.
ACTIVITY CONTRACTOR EIL
NO.
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
ITP NO : 2777
SL.
ACTIVITY CONTRACTOR EIL
NO.
FALSE FLOORING
FALSE CEILING
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
SL.
ACTIVITY CONTRACTOR EIL
NO.
6. Finishing WC S
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
ROOFING ACCESSORIES
SL. EIL
ACTIVITY CONTRACTOR
NO. CAT B CAT C
NOTE : 1) For incoming material inspection please refer ITP no: 6-82-1010.
CAT B: Important structures (e.g. Compressor House, Warehouse and Pump House etc.)
CAT C: Balance works.
SL.
ACTIVITY CONTRACTOR EIL
NO.
SCOPE OF WORK
FOR
ELECTRICAL WORKS
CLIENT: NALCO.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
The Contractor’s scope of work shall include the design and detail engineering
activities, including but not limited to the following:
1.2.1 Compilation of load data, its analysis and determination of sizes of various electrical
equipments.
1.2.2 Preparation of Overall Single Line Diagram.
1.2.3 Preparation of Protection cum metering single line diagram of each switchgear/power
distribution system in contractor’s scope.
1.2.4 Preparation of cabling, lighting, earthing, lightning protection layout drawings (earthing
for GTS s/s & cabling/earthing/lighting/lightning protection layout for new raw water
intake s/s) including associated documents like cable schedules, lighting/power panel
schedules etc.
1.2.5 Preparation of cable interconnection drawings.
1.2.6 Preparation of electrical equipment list and motor list.
1.2.7 Preparation of equipment layout of GTS s/s & new raw water intake s/s.
1.2.8 Preparation of sag-tension calculation chart at different locations of 11KV transmission
line showing that max. allowable sag at 70oC is with in 800mm. from lower phase
conductor.
1.2.9 Preparation of voltage drop calculation & motor starting study ensuring that minimum
voltage available at motor terminal located at new raw water intake substation is not
below 80% of rated value (6.6KV) during starting considering transmission line drop
over entire route length. Size of ACSR conductor, tap changer range along with
impedence voltage of isolation transformer (at GTS s/s) & 3-winding transformer (at
new intake s/s) shall be selected accordingly. System study in E-tap software shall be
carried out by contractor. All relevant data regarding 11KV existing system shall be
informed to contractor during detailed engineering stage.
1.2.10 11KV Transmission Line
Preparation of 11KV new line survey report & installation/erection plan of new
transmission line.
Detailed survey including route alignment, profiling, tower spotting, optimization of
tower location locations, soil resistivity measurement & geo technical investigations
(including special foundation locations/pile foundation locations)
Right of way and way leave clearance including the payment of compensations (rail,
road, forest, line crossing and any other approval/permission requirement for
completion of job) shall be in the scope of work of contractor.
Design/engineering, fabrication, factory testing, supply, installation of all type of
lattice structured poles as envisaged in MR.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Supply & installation of all types of pole accessories such as phase plate, circuit
plate, number plate, danger board, anti climbing device, bird guard, earthing
arrangement etc.
Supply & installation of various hardware fittings required for conductor.
Design & construction of pole foundations/substation foundations as per guidelines
described in structural part of MR.
Complete erection of poles, tack welding of bolts & nuts including supply and
application of zinc rich primer & two coats of enamel paint, pole earthing, fixing of
insulator string, stringing of conductors along with all line accessories.
Complete painting of transmission line poles by anti rusting, anti corrosive paint
along with erection of span markers, warning lights (if required as per norms) and
stay set arrangements to neutralize the tension.
Complete testing & commissioning of erected transmission line.
All the raw materials like steel, zinc for galvanizing, reinforcement steel, cement,
sand, coarse & fine aggregates for pole foundations, coke & salt for earthing
purpose etc are included in contractor’s scope of work.
Any other miscellaneous requirements/works required for successful commissioning
of entire transmission line which are not mentioned above.
1.2.11 Preparation of overall plot plan of entire 11KV transmission line (from refinery to new
raw water intake s/s & from 11KV tapping point to existing raw water intake s/s)
showing different type of poles as envisaged and its elevation/bending angles.
1.2.12 Preparation of GA drawing of different transmission line poles to be used for 11KV
transmission line along with its bill of quantity.
1.2.13 Preparation of detailed relay parameterization chart.
1.2.14 Preparation of testing and commissioning scheduled for various electrical equipments
in contractor’s scope.
1.2.15 Preparation of operation and maintenance manuals.
1.2.16 Preparation of bill of materials for cabling, lighting earthing and lightning protection
system.
1.2.17 Preparation of all final as built drawings.
1.3.1 8 Nos. Extensions to existing (HT-227A) Siemens make (model no. 8BK80)
11KV±10%, 1600A (single bus rating), 50±3%Hz, 3-phase, 40KA (1 sec.),
drawout type switchboard complete with horizontal and vertical busbars including all
interconnecting links, hardware, material and accessories as required for hooking-up of
extension panel with existing panel line-up, including VCB breaker, protection and
metering equipment/components/wiring as per attached hardwire data sheet (B001-
000-16-50-DS-9004/9007/9013). For detailed scope refer job specification.
1.3.2 11KV±10%, 630A (single bus rating), 50Hz±3%, 3 phase, 40KA (1 sec.), HV
switchboard as per attached data sheet (B001-000-16-50-DS-9007/9012/9013). Same
shall be located at new raw water intake s/s (refer key single line diagram) - 1 no.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
1.3.3 6.6KV±10%, 630A (single bus rating), 50Hz±3%, 3 phase, 20KA (1 sec.), HV
switchboard as per attached data sheet (B001-000-16-50-DS-9005/9007/9013). Same
shall be located at new raw water intake s/s (refer key single line diagram) - 1 no.
1.3.4 415V±10%, 1250A (single bus rating), 50Hz±3%, TPN, 50KA (1 sec.), MV switchboard
as per attached data sheet (B001-000-16-50-DS-9006/9007/9013). Same shall be
located at new raw water intake s/s (refer key single line diagram) - 1 no.
1.3.5 One no. Oil filled 2-winding isolation transformer as per data sheet. B001-000-16-50-
DS-9001
1.3.6 Two nos. cast resin dry type 2-winding 11/6.9KV distribution transformers & 2 nos. cast
resin dry type 11/0.433 KV transformers of required ratings.
1.3.7 2 nos. Neutral grounding resistor as per data sheet. B001-000-16-50-DS-9003. For
details, refer key single line diagram.
1.3.8 One (1) no. 3-way outdoor type Ring Main Unit (RMU) having following as minimum:-
Incomer shall have off-load isolator (Rating: 630A)
O/G-1 having vacuum circuit breaker (rating:-630A) along with CT, PT & relay
O/G-2 having vacuum circuit breaker (rating:-630A) along with CT, PT & relay
Complete structural foundation along with shed for rain protection
Earthing arrangement
1.3.9 11kV overhead line (ACSR conductor of suitable size preferably by PANTHER). Cross
section to be calculated by contractor as per cl. no. 1.2.8 above. Length of conductor
shall be calculated by contractor based on schematic arrangement drawing (B001-000-
11-42-3001) & line survey report. Per unit price of conductor shall also be furnished
along with lump sum price so that same can be applied at later date if addition quantity
is required.
1.3.10 4 Nos. 4 pole structures (at Kantabausuni temple for new water intake supply, 2 nos. at
old water intake substation, 1 no. at new water intake substation)
1.3.11 8m high, galvanized lattice structured poles (single pole with V-cross arm/double pole
with post insulator, gang operated isolator with earthing switch, conceal type box for
cable to conductor connection, lightning arrester/double pole with strain insulator/four
pole with strain insulator/single pole for 3-way 11KV connection) for carrying 11kV line
at a distance of approximately, every 50m, complete with insulators (pin/strain & post),
top/F- bracket, danger board & anti climbing device, cross arm for guard wire (required
at road crossings), guy wire with insulators (where required), necessary clamps, bolts
and fixing hardware/other structural items. Actual quantity to be calculated by
contractor after carrying out line survey report & sag-tension calculation. However, unit
price shall also be quoted so that if addition poles are required at later date, same can
be applied. (Refer typical pole GA drawing: B001-000-16-50-DS-4001A/B/C/D/E for
reference).
1.3.12 All HV motors and other field electrical devices.
1.3.13 110V DC system along with VRLA battery, dual redundant battery charger & DCDB.
Back up time shall be considered as 2 Hours.
1.3.14 Supply of following cables:-
1.3.13.1 11KV grade XLPE insulated armored Al cable (UE) of 3Cx300 sq.mm.size for following:
From HT-227A in Existing GTS s/s to Four Pole structure located at Refinery
boundary limit. Approx. length = 7000M.
From Four pole structure to HT-240 in new Intake well s/s. Approx. length = 100M.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
From Four pole structure to existing spare feeder of 11KV switchboard in existing
Intake well s/s. Approx. length = 100M.
3-way point for bifurcation of line envisaged for existing intake well s/s. Approx
length = 100 mtr.
Incoming Cable from HT 227 Pnl #34 (ABB make at GTS) to 7.5MVA Isolation
Transformer
Outgoing Cable from 7.5MVA Isolation Transformer to HT#227A (Siemens make at
GTS)
From HT-227A at GTS to CSS-07 (approx. length = 50M), From HT-227A at GTS
to CSS-08 (approx. length = 50M) including supply of 03 Nos of End Termination
Kits & 03 Nos of Straight Through jointing Kits. Cable size shall be 1 Run 3CX300
Sqmm.
From HT-227A at GTS to new 4 pole structure at kantabausuni temple
From new 4 pole structure to old 4 pole structure near old intake substation.
From new 4 pole structure at old water intake substation to bridge crossing
From 4 Pole structure at new Water Intake to 11 KV Switchboard (02 runs of cable
to be laid each from two different poles of the 4 pole structure.
From 11 KV Switchboard at New Water Intake Sub Station to 04 nos of
Transformers
From 4 pole Structure at Old Intake Sub Station (to be constructed) to existing
11KV Switchboard
From existing Double Pole to 4 Pole (near existing water Intake Sub Station)
From new 4 Pole (to be constructed) to existing 11KV Switchboard (Existing water
Intake)
Actual length is to be calculated by contractor based on requirement. Actual Run &
Length of cable to be calculated by the bidder based on requirement. Design
calculation of the cable to be submitted for review".
1.3.14.2 6.6KV grade XLPE insulated armored Al cable (UE) of 3Cx120 sq.mm. & 3Cx50
sq.mm. size. Length to be calculated by contractor based on actual requirement. Unit
price shall also be quoted.
1.3.14.3 1.1KV grade 415V PVC insulated armored Al/Cu cored power & control cables. Actual
length shall be calculated by contractor based on requirements. Unit price shall also be
quoted.
13.15 1 no. metering/alarm panel shall be considered in new raw water substation. Same
shall be located in operator room of new intake well substation. This panel shall have
Rittal make stainless steel enclosure having following indications/alarms:
Run Indication of each pump
Trip indication for each pump
Ready to start indication for each pump
Ammeter reaing for each pump
Emergency Push button for each pump
Hooter for pump tripped.
All necessary control cabling (supply, laying & termination) from starter panel to
control panel shall be in contractors scope.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
1.3.15 Lighting fixtures suitable for indoor building lighting (for new raw water intake s/s
building), outdoor area lighting, flood lighting and high bay lighting etc. all weatherproof
to IP-55 as required for installation and use in dusty corrosive areas. All lighting fixture
shall have stainless steel reflector with cast iron body.
1.3.16 LED Lamps for all the lighting fixtures. Lighting fixture data sheet indicates
flouroscent/HPSV/HPMV/SON/GLS which are indicative only. Equivalent lumen output
LED lamps shall be provided. Company approval shall be obtained prior to
procurement of type of LED lighting fixtures.
1.3.17 Indoor and outdoor Lighting / power panels having IP-55 degree of protection.
1.3.18 Junction boxes, plugs, sockets, hand lamps and welding receptacles.
1.3.19 Local start/stop/metering control stations as required.
1.3.20 Suitable nos. of 415V, 3-ph. Welding Receptacles and 240V, 1-ph convenience outlet
in New Intake Well s/s and Pump house. One no. welding receiptacle shall be provided
in new transformer bay (7.5MVA). Suitable rated SFU feeder for the same shall be
provided by Owner from US-13 substation. However supply and laying of cable (approx
length 450m) on exsting cable trays shall be in contractors scope
1.3.21 30mtr. high flood light mast having 12 nos. of lighting fixture each having 2 nos. LED
lamps equivalent to 400watt. HPSV lamp & 2 nos. LED type aviation lamp- 1 no.
1.3.22 GI pipes, structural steel, MS frames, supports, canopies, brackets, anchor fastners,
etc and all materials for foundations for 11kV poles etc.
1.3.23 Hot dip galvanized prefabricated cable trays, cable tray structures and accessories
including all materials, fittings and fixtures and GI cable tray covers.
1.3.24 Cable markers/identification tags, GI saddles, saddle bars and associated accessories.
1.3.25 End termination and straight through jointing kits for 11/6.6/1.1 KV grade power/,
control/lighting cables.
1.3.26 Single/Double compression Nickel plated brass cable glands, tinned copper lugs.
1.3.27 Complete materials for earthing such as GI earth electrodes, GI earthing strip (75x10
GI), lightning rods, earth plates and grounding conductor of various sizes, connectors
etc.
1.3.28 DC junction boxes.
1.3.29 Junction boxes/ Main distribution Frame (MDF) for telephone cables with varying
number of control terminals and telephone sockets.
1.3.30 Exhaust fans and air circulators in substation buildings and corrosion resistant exhaust
fan/tiles in battery room.
1.3.31 Site work involving cabling, lighting, earthing and lightning protection including supply
of materials as per cl. No. 2.20 of Job specification.
1.3.32 Fire emulsifying system for 11/11.5KV, 7.5MVA ISOL TRAFO#3 located in GTS s/s.
1.3.33 Safety equipment in sub-stations and wherever specified as per IE rules.
1.3.34 Portable emergency lighting units.
1.3.35 Civil structural works and foundations for installation of Contractor’s supplied electrical
equipments along with supply of all required material
1.3.36 Safety equipment, fire extinguishers in new raw water intake substation.
1.3.37 Fabrication, supply, erection and painting of steel structural supports required for
various electrical equipment such as switchgears, push button stations, transmission
line poles etc.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
1.3.38 Special tools and tackles for installation of electrical equipment are included in
contractor’s scope.
1.3.39 Mandatory spares for Electrical equipments as per the list enclosed elsewhere in the
bid package.
1.3.40 One year operation & maintenance spares for different electrical equipments supplied
by Contractor as per Annexure-1. Contractor shall give itemsied unit price for the listed
spares as a minimum. Apart from the listed items, Contractor shall also quote itemized
unit price for other suggested spares. Ordering of the spares shall be decided by client
separately.
1.3.41 Miscellaneous material for civil works like sand, bricks, cement, reinforcement steel
rods etc. and structural steel for cable trays, supports, canopies, pole foundation etc.
1.3.42 Any other material required for completion of the work as per specifications, drawings
and instruction of Engineer-in-charge
Note: Pole foundations/size of structural items for transmission line shall be calculated by
contractor based on soil investigation report carried out by contractor, forces, wind
velocity, sag-tension for 50mtr. span & other structural parameters.
Supply & installation of new dual core protection cum metering CT (Ratio:-
400/1/1A, 5P10 & CL 1.0)
Supply & installation of PS class CT (ratio:- 400/1A)
Supply & installation of numerical relay suitable for power transformer protection
(suitable for IEC-61850)
Existing breaker shall be retained
Protection realys shall be rovided., Differential relay (87T) shall be installed at
upstream (ABB) breaker & transformer trouble/ trip relay (63TX) shall be supplied
by Siemens & installed at downstream breaker. Inter Trip commands from both the
relays shall be routed accordingly. Accordingly, modification in control wiring shall
be carried out considering new relays i.e. main protection relay, differential relay &
transformer trouble relay & inter tripping of breakers.
Supply & installation of new terminal block
1.5.5 Cable laying and termination of 11kV & 6.6 unearthed grade cables.
1.5.6 Cable laying and termination of 1.1kV grade cables.
1.5.7 Complete installation, testing & commission of 11KV overhead transmission line
system which shall include poles, conductor, earthing & lightning protection system
(from refinery to new intake s/s & from tapping point to existing intake s/s).
1.5.8 Scope of work under this contract shall be inclusive of breaking of walls/floors and
chipping of concrete foundations necessary for the installation of equipment, materials
and making good of the same after completion of work.
1.5.9 Minor modifications wherever required to be done in the owner free supplied
equipment/ devices to enable cable entry/ termination, etc.
1.5.10 Sealing of openings made in the walls/ floors for the cables to be suitably closed using
fire retardant materials, acceptable practice and standards.
1.5.11 Supply and installation of all other accessories not specifically mentioned herein but
nevertheless necessary for completion of job.
1.5.12 Obtaining clearance for energising the complete electrical facilities covered under this
tender and approval of installation/drawings from Central Electricity Authority / any
other statutory authority (This includes equipment installed/ commissioned by others
within the battery limit. This is for the purpose of obtaining comprehensive approval in
one go).
1.5.13 Up-dation and submission of all owner's drawings to incorporate as-built status. Both
hard and editable soft print in AutoCAD format shall be submitted.
1.5.14 Test certificates, catalogues, vendor drawings, installation, operation and maintenance
manuals for all equipment/materials in contractor's scope of supply.
1.5.15 Engineering and preparation of specification and drawings for electrical equipment and
installation wherever applicable or required by the owner and submit to owner for
approval.
Note: All commissioning formats shall be handed over to the successful contractor at the time
of award of contract.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
ANNEXURE-1
2 11KV/6.6KV Switchboard
Spring Charging Motor
Indication lamps
Switch
Push button
4 415V LT Panels
Spring charging motor
CT One No. each Type
PT One No. each Type
Power contactors One No. each Type
Switches One No. each Type
2/3 position selector switch One No. each Type
2/3 position selector switch lockable One No. each Type
Ammeter selector switch
Voltmeter selector switch
TNC switch
DC Selector switch
Indicating lamps
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
7 HV Motor
Cooling fan (bi-directional)
Terminal box
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
JOB SPECIFICATION
FOR
ELECTRICAL WORKS
CLIENT: NALCO.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
1.0 GENERAL
1.1 Introduction
The intent of this specification is to define the requirement for the supply of
equipment and materials (wherever specified), installation, testing and
commissioning of complete electrical power distribution system, consisting of
equipment, lighting, earthing, lightning protection and cabling system for New Raw
Water Intake System.
The work shall be carried out in the best workmanship, in conformity with these
specifications, approved drawings and the instructions of the Owner or Engineer-in-
Charge from time to time.
The contract shall include clearing of temporary construction, waste materials and loose
earth, which might get collected in and nearby the work site consequent to the execution
of work under this contract.
1.2 The work shall be performed in conformity with these specifications and Codes of
Practice of the Bureau of Indian Standards. In case of any conflict, the stipulations under
these specifications shall govern.
In addition, the work shall also conform to the requirements of the following:
a) The Indian Electricity Act and the Rules framed there under
b) The Fire Insurance Regulations.
c) The regulations laid down by the Chief Electrical Inspector of the state government.
d) The regulations laid down by the Factory Inspector.
e) The regulations laid down by the Central Electricity Authority.
Any other regulations laid down by the Central, State or Local Authorities from time to
time during the execution of this contract.
1.3 Guarantee
1.3.1 The contractor shall guarantee the installation against any defect of workmanship
and materials (supplied by the contractor) for a period of 12 months from the date of
issue of the completion certificate. Any damage or defect that may be undiscovered at
the time of issue of the completion certificate, but may arise or come to light
thereafter, shall be rectified or replaced by the contractor at his own expense as
deemed necessary and as per the instructions of the Owner or Engineer-in-Charge
within the time limit specified by the Owner or Engineer-in-Charge.
1.3.2 The above guarantee shall be applicable for the quality of the work executed as well as
for the equipments/cables/fittings/other materials supplied by the contractor.
The equipment offered and the installation shall be suitable for continuous operation
under the following site conditions:
Ambient Temperature (Max./Min.) : 47º C / 3º C
Design Ambient : 47º C
Max relative humidity : 89%(max.)
Altitude above MSL : <1000m
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
The equipment and materials to be supplied by the contractor shall be designed for the
following power supply conditions.
HV : 11 KV± 10%
6.6 KV± 10%
MV : 415 V± 10%
Frequency : 50 Hz ± 3%
To execute this facility, approximately 17 kM long pipeline network has been envisaged
from the bank where proposed intake well shall be constructed to the water treatment
plant located with in alumina refinery. Two (2) nos. pumps (one working & another
one is stand by) of each capacity for 580m3/hr shall be installed with electrical motor
of BKW. For calculation of actual motor name plate rating, please follow the mechanical
part of Tender.
To run the electrical motor at new water intake well, a new electric substation has
been planned at near to location of new intake well. All civil/structural construction
works pertaining to this has been included in contractor’s scope of work. Location
of this substation has been shown in schematic arrangement drawing (B001-000-
11-42-3001) attached along with this Tender. Tentative size of this substation
(refer drawing no: B001-302-16-50-SS-9001) has been worked out based on
preliminary key single line diagram & same has been attached with this Tender for
contractor’s reference.
To meet the power requirement of this package, owner shall provide one (1) no.
suitable rated 11KV plant feeder from existing 11KV double busbar switchboard
(HT-227 located at GTS s/s) for contractor’s use. Contractor’s scope of work shall
intiate from outgoing terminal of 11KV breaker located in above mentioned trafo. feeder
panel. Extent of modification in existing feeder shall be as follows:-
This 11KV power supply from HT-227 shall be extended further to another Siemens
make 11KV single busbar switchboard (new to be supplied & installed by contractor)
which shall be extension of existing Siemens make 11KV switchboard (HT-227A). In
between this two board, one (1) no. 7.5MVA, 11/.11.5KV isolator transformer has
been envisaged for isolation purpose. This 11KV power supply shall be further
connected to 11KV overhead transmission line which shall start from plant’s
boundary. F o u r pole lattice structure shall be used for cable to conductor
connection & same shall be located just outside of plant’s boundary wall. Within
plant, 11KV power shall be transmitted through 11KV cable only & existing route
shall be followed/utilized through which power supply for existing raw water intake well
has been provided. No new infrastructure is required for this cable laying.
Existing 4-pole structure used for construction power & ‘Suraksha Vihar’ shall be
dismantled. In that place, new one no. 7.5MVA, 11/11.5KV transformer (ISOL#3) shall
be installed. Suitable sized transformer bay along with soak pit, water sprinkler system,
fire wall of 2 hour rating & fencing arrangement shall be constructed at this place. Due
to construction of new transformer bay, existing approach road to GTS coming from
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
west side shall be blocked. Hence, new maintenance/ approach road to be prepared
from north side direction for connectivity with GTS substation. Same shall be included
in bidder’s scope.
For new water Intake substation, power shall be transmitted through 11KV cable from
HT 227A switchboard at GTS to Four Pole Structure (to be constructed new) near
Kantabausuni temple. From the 4 pole structure, power shall be transmitted through
lattice poles to 4 Pole Structure (to be constructed near existing water intake
substation). From the 4 pole structure, power shall be transmitted through 11KV cable
for bridge/road crossing upto another 4 pole structure (to be constructed near new
water Intake substation). Power shall be transmitted through 11KV cable from the four
pole structure to new 11KV Switchboard at new water Intake sub station.
Supply & Installation of 02 nos of 4 pole structures near Existing Water Intake
Substation (01 of these shall feed power to the New Water Intake Sub Station & the
other shall replace the existing 02 pole structure presently transmitting power to the
existing Water Intake substation).
Inter Connection of the above 02 nos of newly constructed 4 pole structures through
11KV cable.
Laying of 01 nos of cable from new 4 pole structure to existing water intake substation
(Incomer 1)
Re Routing of existing cable (including supply of all associated materials like End
termination Kit, straight Through Jointing kit etc) from existing 02 pole structure to the
new 4 pole structure
Laying of Cable from new 4 Pole Structure to Existing 11KV Switchboard at Existing
Water Intake Substation (Incomer 2)
Dismantling of existing 2 pole structure.
2.1 General
11kV, 1600A, 40kA (1 sec.) single busbar extension panels both at incoming and
outgoing (RHS, LHS to existing Siemens make board, HT-227A).
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Existing right most panel of existing HT-227A has been used as incomer feeder to 4-
pole structure for construction power # 1, construction power # 2 & ‘Surakshya Vihar’.
This bifurcation has been made on 4-pole structure installed in between GTS s/s &
ISOL # 1 on north side. This 4-pole structure shall be dismantled. Hence, before this
dismantling work, existing feeder used for construction power # 1 & construction power
# 2 shall be disconnected from 4-pole structure & same shall be re-connected with
newly procured Siemens make extension panel installed HT-227A. Existing 11KV
incomer shall be re-connected with the 3rd outgoing feeder used for ‘Surakshya Vihar’
by using straight through joint. Dismantling of 4-pole structure along with
disconnection/reconnection of cable along with supply of straight through joint, End
termination Kit etc shall be considered in bidder’s scope. Feeder description of
extensions panels are as follows:-
Bus coupler
Incomer From Isolation Transformer #3 with Line PT
Bus PT
Outgoing Plant feeder for New Water Intake
Outgoing Plant feeder for CSS 7
Plant feeder for construction power
Outgoing Plant Feeder for CSS 8
Spare plant feeder
Further the the switchboard extensions shall be as per enclosed data sheet (B001-
302-16-50- DS-9004/9007/9013) and EIL standard specification. 6-51-0001
and shall meet the minimum following requirements:-
2.2.1 Selection, sizing and suitability of all components shall be the contractor’s
responsibility. The equipment as required for safe and satisfactory operation shall
be considered included in contractor’s scope even not specifically mentioned in
Tender.
2.2.2 The contractor shall solely responsible to co-ordinate the relay characteristics with
relay manufacturer for the proper selection of CT with special care to select PS class
CT.
2.2.3 Relay settings (calculations & incorporating the same in numerical relay) shall be
undertaken done by the contractor.
2.2.5 CT ratios shall be calculated by contractor considering full load current rating & 20%
design margin. The value shown in key single line diagram are tentative & same shall
change at later date without any cost & time implication to owner. The VA burden,
knee point voltage, CT resistance, magnetizing current shall be calculated by
contractor for owner’s/EIL review before proceeding for manufacturing/procurement.
2.2.6 No dummy panel is required as new extension panel is of same make as existing (M/s
Siemens).
2.2.7 VCB rating specified in several documents (SLD & data sheets) are tentative & may
change at later date with out any cost implication owner. Only in-panel rating shall be
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
furnished.
2.2.8 All 11kV (extension) panels shall have numerical type relay for specific application
having IEC-61850 protocol. Same shall be exactly in line with EIL standard spec. 6-
51-0055. Numerical relay shall have integral metering function & lock out element
shall be part of relay only. Each relay shall have 16 nos. DI/DO & all of them shall
be programmable at site. All numerical relays shall be procured considering IEC-
61850 protocol. All relays of 11KV extension panels (in GTS s/s) shall be internally
hooked up with each other. A laptop plug point to be made available inside the switch
board to access all relays for parameterization. Entire communication activity including
laying & termination is in bidder’s scope.
2.2.9 Following automation software shall be provided along with extension panels:
2.2.10 Following mentioned test certificates for identical rated panel shall be submitted for
review & approval:-
Heat run test
Short circuit withstand capacity
Power frequency & lightning impulse withstand capacity
Internal arc
Breaker duty cycle
2.3 11kV New Switchboard, HT-240 (at new raw water intake s/s)
11kV, 630A, 40kA (1 sec.) single busbar extension panels shall be as per
enclosed data sheet (B001-302-16-50-DS-9007/9012/9013) and EIL standard
specification. 6-51-0001 and shall meet the following requirements:-
2.3.1 Selection, sizing and suitability of all components shall be the contractor’s
responsibility. The equipment as required for safe and satisfactory operation
shall be considered included in contractor’s scope even not specifically mentioned
in Tender.
2.3.2 The contractor shall solely responsible to co-ordinate the relay characteristics with
relay manufacturer for the proper selection of CT.
2.3.3 Relay settings (calculations & incorporating the same in numerical relay) shall be
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
2.3.5 All necessary s/w & h/w for numerical relays corresponding to 11KV switchboards at
new Water Intake s/s to be supplied. One no. laptop of latest configuration having
suitable communication port for communication with Numerical Relay to be supplied.
Same shall be loaded with relay parameterization software (full version) through which
relay data can be altered at site.
2.3.6 Each panel shall be provided with communicable multi function meter.
2.3.9 CT ratios shall be calculated by contractor considering full load current rating &
20% design margin. The value shown in key single line diagram are tentative &
same shall change at later date with out any cost & time implication to owner.
2.3.10 VCB rating specified in several documents (SLD & data sheets) are tentative &
may change at later date without any cost implication owner. Only in-panel rating
shall be furnished.
2.3.11 All 11kV (new) panels shall have numerical type relay for specific application having
IEC-61850 protocol. Same shall be exactly in line with EIL standard spec. 6-51-
0055. Numerical relay shall have integral metering function & lock out element shall
be part of relay only. Each relay shall have 16 nos. DI/DO & all of them shall be
programmable at site.
2.3.12 Following mentioned test certificates for identical rated panel shall be submitted for
review & approval:-
Heat run test
Short circuit withstand capacity
Power frequency & lightning impulse withstand capacity
Internal arc
Breaker duty cycle
2.4 6.6kV New Switchboard, HT-265 (at new Water intake Substation)
6.6kV, 630A, 20kA (1 sec.) single busbar extension panels shall be as per
enclosed data sheet (B001-302-16-50-DS-9005/9007/9013) and EIL standard
specification. 6-51-0001 and shall meet the following requirements:-
2.4.1 Selection, sizing and suitability of all components shall be the contractor’s
responsibility. The equipment as required for safe and satisfactory operation shall be
considered included in contractor’s scope even not specifically mentioned in Tender.
2.4.2 The contractor shall solely responsible to co-ordinate the relay characteristics with
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
2.4.3 Relay settings (calculations & incorporating the same in numerical relay) shall be
undertaken done by the contractor.
2.4.5 CT ratios shall be calculated by contractor considering full load current rating &
20% design margin. The value shown in key single line diagram are tentative &
same shall change at later date with out any cost & time implication to owner.
2.4.7 VCB rating specified in several documents (SLD & data sheets) are tentative &
may change at later date without any cost implication owner. Only in-panel rating
shall be furnished.
2.4.8 All 6.6kV (new) panels shall have numerical type relay for specific application having
IEC-61850 protocol. Same shall be exactly in line with EIL standard spec. 6-51-
0055. Numerical relay shall have integral metering function & lock out element
shall be part of relay only. Each relay shall have 16 nos. DI/DO & all of them shall
be programmable at site. In addition to that, motor protection relay shall have min.
4 nos. programmable AI for analog signal interface. All necessary s/w & h/w for
numerical relays corresponding to 11KV switchboards at new Water Intake s/s to be
supplied.
2.4.10 Following mentioned test certificates for identical rated panel shall be submitted for
review & approval:-
Heat run test
Short circuit withstand capacity
Power frequency & lightning impulse withstand capacity
Internal arc
Breaker duty cycle
2.4.11 Laptop with following configuration shall be provided wherever mentioned bid package:
Make: HP / Dell / Lenovo / Sony.
Processor: Intel Core i5 2.26 GHz, 3MB L3 Cache, or higher
RAM Memory : 4GB DDR3 1060 MHz or higher
Chipset: Mobile Intel GS45 or higher
Hard Disk: 500 GB SATA Hard Disk or higher with impact protection.
Display: 13 to 15.4 inches LED with inbuilt web camera.
Graphics: 1 GB graphics video card memory.
Optical Drive: Internal DVD Writer.
Network Interface: Gigabit Ethernet (10/100/1000 Mbps) port.
Wireless: Wireless and Bluetooth.
Ports: 3 USB 4.0 Ports, External display (VGA) port.
External Mouse: External small optical Scroll mouse with mouse pad.
Audio: Two Built-in speakers with integrated microphone
Battery: Lithium-Ion 6 Cell battery.
Carry Bag: Deluxe Cushioned OEM Carry Bag
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
2.5.1 Lightning arrester shall be single pole, gapless type (having ZnO) suitable for
use in 11kV effectively earthed system. Same shall be strictly complying to IS:
3070. All ferrous part shall be hot dip galvanized to prevent corrosion. LA shall be
provided with event counter & mA leakage current meter.
2.5.2 The rated voltage rating of lightning arrester shall be 9kV (rms).
2.5.3 The nominal discharge current rating of the lightning arresters shall be 5kA.
2.6 Insulators
2.6.1 Pin/strain/post insulators shall be made from high grade porcelain and shall
be uniformly Pin/Strain insulators shall be made from high grade porcelain and
shall be uniformly brown glazed. The porcelain shall be homogeneous, free from
laminations, cavities and other flaws or imperfections that might affect the
mechanical or dielectric quality and shall be thoroughly vitrified, tough and
impervious to moisture. When operating at normal rated voltage, there shall be no
electric discharge which would cause erosion or injury to conductors, insulators or
supports by the formation of substance produced by chemical action. The
hardware shall be hot dip galvanized. The insulation design shall conform to
relevant IS. Strain insulators shall consist of standard 10 inch discs and shall be ball
and socket type.
Guard wire shall be provided where O/H line is crossing the roads.
All the structures shall be earthed with electrodes as per drawing No. 7-51-117.
Separate earth electrodes in test pit shall be provided for lightning arrestors. All
earth electrodes shall be driven to a sufficient depth to reach permanent moist
soil. All electrodes shall be tested for earth resistance by means of standard
earth meager. A continuous earth wire shall be run along the entire route of
overhead line and connected to earth at three points in every km as per rules.
2.11 Transformer
2.11.1 7.5MVA, 11/11.5KV isolation transformer shall be oil filled type where as 2.5MVA,
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
11/6.9KV and 0.63 MVA 11/0.433 transformers shall be dry type cast resin insulated.
2.11.2 7.5MVA transformer shall be located in place of dismantled existing 4 pole structure
used for constructon power and suraksha vihar by contractor.
2.11.2 11/6.9KV & 11/0.433KV dry type transformers shall be located inside the new water
intake substation.
2.11.3 All external hardware (like those of tank cover, terminal box, marshalling box, pipe
flanges etc.) and name plate/rating plate etc. shall be of stainless steel.
2.11.5 Following mentioned test certificate shall be submitted for identical rated transformer:-
- Heat run test
- Short circuit withstand capacity (primary/secondary/tertiary)
- Power frequency & Lightning impulse withstand voltage
- Ingress protection
- Partial discharge
If suitable test certificates are not available, then new test shall be carried out on
identical rated transformer without any cost and time implication.
2.11.6 The following tests shall be carried out in addition to routine tests as per cl. no. 13.3 of
EIL spec.6-51-0041 & 5-51-0044.
i) Oil leakage test- All tanks and oil filled compartments. ii. Vacuum test- One
transformer tank of each size.
ii) Pressure test- One transfer tank of each size.
Test certificates of above tests shall be furnished during detailed engineering for review
purpose.
2.12 DC system
Separate 110V DC system comprising VRLA battery, battery charger and
DCDB (as per datasheet no. B001-302-16-50-DS-9011)shall be provided to cater
switchgear control supply & DC critical lighting of the substation.
The battery charger shall be fed from MV SWBD and the same shall be
parallel redundant complying with the requirement of EIL Specification 6-51-0019.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
The battery for the DC system shall be sized considering backup time of 2 hours.
2.13 HV Motors
2.13.1 All offered HV motors shall be exactly in line with EIL standard spec. 6-51-0031 &
motor data sheet (B001-302-16-50-DS-9015). In addition to that, following shall also
fulfilled:
2.13.2 All the motors shall be designed for direct on line starting.
2.13.4 The motor starting current shall strictly limit to 6 times of the motor full load current
subject to tolerance.
2.13.5 All motors shall be totally enclosed type having degree of protection IP-55 suitable for
outdoor installation. The vendor shall furnish a copy of test certificates for IP-55 degree
of protection.
2.13.6 All Motors shall be with class ‘F’ insulation with temperature rise limited to Class ’B’.
2.13.7 RTD & BTD shall be provided in motor and same shall be wired to motor protection
relay for protection against temperature rise.
2.13.8 Motor body & its terminal boxes shall be made of cast iron only.
2.13.9 Motor body shall be painted by epoxy based shade 632 as per IS-5 suitable for
outdoor location.
2.13.10 Name plate material shall be of stainless steel with external bolts of stainless steel.
Following shall also be provided on the name plate in addition to requirements of EIL
standard specification:
-
i) Description & code no. of motor.
ii) Degree of protection of enclosure
iii) Driving end and non-driving end bearing type and no.
iv) Weight of the motor
v) Type of lubrication and recommended interval of lubrication.
2.15.1 The Local control stations shall be supplied as per EIL standard specification 6-51-
0014.
2.15.2 All push button cabinets & power socket cabinets shall be fabricated out of minimum
14SWG thick sheet steel.
b) Ammeter
2.16 MV Switchboard
2.16.3 It shall have two nos. of incomer with interlock facility with in them. Bus shall be suitable
for fault level of 50kA for 1 sec.
2.16.5 Type test certificates (i.e. IP protection, temperature rise & short circuit withstand
capacity) shall be submitted during detailed engineering stage. If test certificates are
more then five year old, fresh tests shall be carried out without any cost & time
implication.
2.16.6 At least 20% spare outgoing feeders, subject to a minimum of 1 of each type shall be
provided
2.16.7 All indicating lamps shall be LED type only and provided with low voltage glow
protection (LVGP) feature.
2.16.8 Separate control module/terminal box shall be provided on either side of the MCC for
interfacing control signals.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
All control cables shall be 2.5 sq. mm. and shall have solid conductor instead of
stranded conductor.
The size of cable trays (if required) shall be limited to 300 / 450 / 600 /750mm
(as required). Size of angle shall be min. 65x65x8 mm with flat runner 50x3 mm at a
distance of 300 mm.
Lighting system
Indoor lighting of new intake well s/s building as well as outdoor lighting around new
s/s shall be carried out by contractor. All hardware such as fixture, lamp, cable,
lighting panel, lighting poles etc. along with site work shall be carried out by
contractor.
For lighting circuit 3 core 2.5 sq. mm. copper conductor cable shall be used, third
core shall be used for earthing purposes.
LED lamps shall be used for high bay lighting and outdoor area lighting. All roads to be
constructed with in new intake well s/s area (if any) shall be provided with street
lighting.
Lighting system shall conform to enclosed EIL specifications 6-51-0083
Earthing system
Earthing system shall be designed, supplied and installed as per enclosed
EIL standard specifications 6-51-0084.
Earthing system envisages the earthing network with designed number of earth
electrodes attached to meet the required values of earth resistance
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Contractor shall carry out soil resistivity test at site and size the earthing grid
accordingly. Earthing (includes supply of all materials & site work) of all
equipments/system from 11/11.5KV, 7.5MVA isolation transformer onwards to new
intake well motor & double pole structure envisaged at existing intake well s/s is
included in contractor’s scope.
Type of lighting fixture shall be as per Lighting Fixture Datasheet Doc. No. B001-
302-16-50-DS-9019, enclosed herewith.
5.0 INSPECTION, TESTING & COMMISSIONING
5.1 Site inspection, testing and commissioning of electrical installation shall be carried
out as per enclosed Specification no. 6-51-0087 and Inspection and Test Plans
included or referred in this Tender.
5.2 All the equipment installed by the contractor shall be tested and commissioned as
required and no separate payments shall be made. Contractor shall carefully
inspect all equipment before receiving them from owner for installation
purposes. Any damage or defect noticed shall be brought to the notice of the
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
7.0 DRAWINGS
7.1 The drawings accompanying the tender document are indicative of the nature of
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
work and issued for tendering purposes only. Purpose of these drawings is to
enable the tenderer to make an offer in line with the requirements of the Owner.
However, no extra claim, whatsoever, shall be entertained for any variation
in the "Approved for Construction" and "Tender Drawings" regarding any
changes in units. Construction shall be as per drawings/specifications issued/
approved by the Engineer-in-Charge during the course of execution of
work. Detailed construction drawings on the basis of which actual execution
of work is to proceed will be furnished to the contractor progressively based on
the detailed construction programme evolved after the award of work and also
based on construction progress achieved by the contractor.
7.2 Prospective contractor shall be deemed to have studied the drawings enclosed
with tender or displayed for scrutiny and fully understood the nature and
magnitude of the work before submitting the bids.
7.3 Where the contractor has to prepare drawings e.g. for fabrication of lighting and
power panels etc. contractor should submit the drawings to Engineer-in-Charge
and the approval in writing of the Engineer-in-Charge shall be obtained before
commencing fabrication.
7.4 After the job completion, contractor shall prepare 'AS-BUILT' drawings, Final
certified "As Built" drawings in editable soft copy shall be submitted by the
contractor to owner in bound volume with one set of reproducible original sepia plus
ten sets of prints.
7.5 Contractor shall submit equipment manufacturer’s drawings for supply items for
review in five sets of prints, and the approval in writing of the Engineer-in-
Charge shall be obtained before commencing manufacture. However, it is to be
understood that the review of drawings shall not absolve the Contractor from his
basic responsibility to check total compliance to specifications included in tender
document. Final drawings in bound volumes with one set of reproducible
original sepia plus ten sets of prints shall be submitted by contractor along
with supply of materials at site.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
\IM4r1
00.4 3-
REVISED & ISSUED AS STANDARD
6. 15.10.2013 VB HK UAP/JMS SC
SPECIFICATION
REVISED & ISSUED AS STANDARD
5. 28.04.2010 HK SA NS/JMS ND
SPECIFICATION
REVISED & ISSUED AS STANDARD
4. 03.03.2005 RM AKT AAN SKG
SPECIFICATION
REVISED & ISSUED AS STANDARD
3. 31.12.2001 RM AAN VPS MMR
SPECIFICATION
REVISED & ISSUED AS STANDARD
2. 15.07.1996 AP VPS SG AS
SPECIFICATION
1. 22.05.1987 ISSUED AS STANDARD SPECIFICATION PVR KVS SG GNT/AK
Standards Standards
Rev. Prepared Checked Committee Bureau
Date Purpose Convenor Chairman
No by by
Approved by
Abbreviations:
A Ampere
AC Alternating Current
BIS Bureau of Indian Standards
BS British Standard
CNT Close-Neutral-Trip
CPRI Central Power Research Institute
CRCA Cold Rolled Cold Annealed
CT Current Transformer
DC Direct Current
EPDM Ethylene Propylene Diene Monomer
FRP Fiber Reinforced Polyester
HV High Voltage
Hz Hertz
IAC Internal Arc Classification
IEC International Electro-Technical Commission
IEEE Institute of Electrical & Electronics Engineer
IP Ingress Protection
kV Kilo Volt
kW Kilo Watt
kWH Kilo Watt Hour
LED Light Emitting Diode
LOTO Lock-Out Tag-Out
LSC Loss of Service Continuity
MCB Miniature Circuit Breaker
MCC Motor Control Center
MCCB Moulded Case Circuit Breaker
NEMA National Electrical Manufacturers Association
NO Normally Open Contact
NC Normally Close Contact
PO Purchase Order
PT Potential Transformer
PU Polyurethane
PVC Poly Vinyl Chloride
RAL Reichs-Ausschuss fur Lieferbedingungen
SF6 Sulphur Hexafluoride
SWG Standard Wire Gauge
VCB Vacuum Circuit Breaker
VDE Verband Deutscher Elektrotechniker
VFD Variable Frequency Drive
VT Voltage Transformer
XLPE Cross linked Poly Ethylene
CONTENTS
1.0 SCOPE. 4
2.0 CODES AND STANDARDS 4
3.0 GENERAL REQUIREMENTS 5
4.0 SITE CONDITIONS 5
5.0 DESIGN AND FABRICATION REQUIREMENTS .5
6.0 SWITCHBOARD COMPONENTS 11
7.0 INSPECTION, TESTING AND ACCEPTANCE 15
8.0 PACKING AND DESPATCH 16
1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of indoor,
drawout type High Voltage Switchboards up to and including 33 kV, incorporating Vacuum or
SF6 circuit breakers.
62271-200. Independent pressure relief devices shall be provided for all I-1V compartments,
i.e. bus bar, cable and breaker compartments and each compartment shall have type test
certificate for internal arc classification (IAC) as per IS/IEC 62271-200 for the short circuit
current and duration as specified. IAC test shall be conducted on the offered panel variants
such as smallest width panel, panel with louvers, panel with thermography window and any
other variants (as applicable) as per job requirements. The panel shall also be AFLR tested as
per IS/IEC 62271-200 requirements.
5.1.7 All identical equipment and corresponding parts shall be fully interchangeable.
5.1.8 Safety barriers / shutters shall be provided to permit personnel to work safely within an empty
compartment with the bus bars energised. Loss of Service Continuity (LSC) category of the
switchgear shall be LSC2B as per IS/IEC-62271-200.
5.1.9 It shall be possible to extend the switchgear in either direction at a later date. Ends of bus bars
shall be suitably drilled for this purpose. Panels at extreme ends shall have openings, which
shall be covered with plates screwed to the panel. Details of drilled holes in bus bar and
openings in the panels, provided for future extension shall be clearly shown in the vendor
drawings.
5.1.10 The drawout carriage on the switchboard shall have three positions: "Service", "Test" and
"Drawout" viz:
"Full in" or "Service" position - In this position both power and control circuits shall
be connected. This shall be the normal operating position of the circuit breaker.
"Test" position - The power contacts shall be disconnected in this position but the
control connections shall not be disturbed, it shall be possible to close and trip the
breakers in this position.
- "Draw out" Position - both power and control circuits shall be disconnected in this
position. Alternatively, "Test Position" with the secondary control circuit disconnected
may be provided in lieu of "Draw out Position"
Circuit breaker operation shall be possible only in "Service" and "Test" positions. The circuit
breaker shall be lockable in "Test" / "Draw-out" positions. Automatic safety shutters shall be
provided to ensure the inaccessibility of all live parts after the carriage is drawn out.
There shall be a distinct overall door for the breaker compartment, which can be closed with
the carriage in drawout position and it shall be lockable type.
5.1.11 All circuit breaker modules of the same rating shall be inter-changeable. Suitable interlocks
shall be provided to prevent the following operations:
"Plugging in" or "drawing out" of a closed breaker.
"Plugging in" a breaker with the earthing isolator closed.
"Closing" of the earthing isolator with the breaker "plugged in".
Pulling out the auxiliary circuit plug with the breaker in the service position. Pushing
in the breaker to the service position, with the auxiliary circuit plug not in position.
Additionally, the following shall also be provided:
All operations such as breaker rack-in, breaker rack-out, breaker On/Off, spring
charging, earth switch On/Off etc. shall be possible only with panel door closed.
Pad locking arrangement shall be provided for rack in operation of breaker as well as
for the panel door meeting LOTO requirements.
LOTO arrangement shall include provision for the following:
a) Provision for hooking lockout devices by multiple lock arrangement to prevent
opening of panel door and racking-in of circuit breaker.
b) Provision for attaching tag-out device for warning against energisation and to
provide information regarding date of isolation, agency working on the
equipment, etc.
c) Provision for Hasp such that the same shall be put-in and closed in the locking
arrangement of the breaker/switch and panel door.
5.1.12 All hardware shall be corrosion-resistant. All joints and connections of the panel members
shall be made by zinc-passivated high-quality Grade 8.8 or superior steel bolts, nuts and
washers, secured against loosening.
5.1.13 Suitable eyebolts/ lifting clamps shall be provided for the lifting of the panel/shipping section.
The bolts, when removed shall not leave any opening in the panels.
5.1.14 If specified in datasheet, light/ arc/ pressure based sensors with controller shall be provided to
quickly detect internal arc and immediately initiate tripping action.
5.1.15 Thermo-graphy window for infrared electrical inspection shall be provided if specified in the
datasheet. The switchgear with thermo-graphy window shall be type tested and certified for
internal arc faults as per IS/IEC 62271-200 requirements.
5.2 Accessibility
5.2.1 All relays, metering, and control components shall be mounted on the panel front only.
However, auxiliary contact multiplier relays with auto reset can be mounted inside the panel.
5.2.2 The switchgear shall be considered to be accessible to authorized personnel having access all
around and shall be tested for following type of accessibility as per IS/IEC 62271-200:
Type of accessibility AFLR
where
Accessibility type A Restricted to authorised personnel only
F for front side
L for lateral side
R for rear side
5.2.3 Checking and removal of components shall be possible without disturbing adjacent equipment.
All equipment shall be easily accessible. It shall be possible to set all measuring relays and
instruments in-situ without de-energising the switchboard. All mounted equipment shall have
identification tags of self-sticking PVC tapes at the rear also. In addition, permanent
identification details shall be provided on the panel. Mounting of relays for a particular
breaker feeder panel shall be limited to that particular feeder only.
5.2.4 All terminals shall be shrouded with plastic covers to prevent accidental contact.
5.3 Bus Bar
5.3.1 The switchboard shall comprise of 3-phase bus bars which shall extend through all units of the
switchgear line-up. The main bus bars shall have uniform cross-section throughout their length
and shall be sized to carry continuously the rated current specified in the data sheet.
5.3.2 Bus bars shall be of high conductivity electrolytic aluminium or copper supported on
insulators made of non-hygroscopic, non-inflammable material with tracking index equal to or
more than that defined in Indian standards. Self supporting busbars can also be accepted
provided the same is type tested design.
5.3.3 Bus bars shall be housed in a separate chamber and shall be accessible for inspection. Wire
guards /cover shall be provided inside the enclosure to avoid accidental contact when the cover
is removed.
5.3.4 Both bus bars and the supports shall be adequately sized and braced to withstand the specified
short-circuit current for 1 second. Dynamic stresses shall be calculated on the basis of the
specified peak short-circuit current. All bus supports shall be of non-carbonising material,
resistant to acids and alkalies.
5.3.5 Bus bars shall be insulated by using heat-shrinkable sleeves suitable for withstanding heat
under worst operating condition. The sleeves shall be rated to withstand the system line-to-line
voltage for 1 minute. This shall be verified by a type test in which the line voltage will be
applied between the sleeved main bus bar and an aluminium foil wrapped closely around the
insulation over a length of at least 500mm.
5.3.6 All bus bar joints and all tap-off connections from the main horizontal bus bars shall be
provided with removable FRP/PU/PVC shrouds. The material of the shrouds shall be flame
retardant (FR).
5.3.7 Bus bars shall be prominently marked with Red, Yellow and Blue colour rings/ stickers for
easy phase identification at regular interval and at every power tap off point.
5.3.8 The thermal design of the bus bars shall be based on installation of the switchgear in poorly
ventilated conditions. The cooling air volume shall take into account only the bus bar
enclosure.
5.3.9 The hot spot temperature of busbars, including joints, at design ambient temperature shall not
exceed 90°C under normal operating conditions while for silver plated joints, the allowable
maximum temperature shall be 115°C in line with IS/IEC-62271-1.
5.3.10 Only zinc passivated high tensile strength high-quality Grade 8.8 or superior steel bolts, nuts
and washers shall be used for all busbar joints and supports.
5.3.11 The current rating as defined for switchboard and components in data sheet/job specification
are for design ambient temperature at site conditions and for being inside the cubicle at fully
loaded condition. The vendor shall suitably derate the nominal rating to suit the above
condition.
5.4 HV Power Connections
5.4.1 The incoming power connection shall be through XLPE cables / busduct and outgoing power
connection shall be through XLPE cables, as indicated in the data sheet. Ample space for
connection of these cables shall be provided at the rear of the switchboards. In order to avoid
accidental contact in the cable compartment while carrying out inspection by opening the rear
cover, a removable expanded metal barrier/ wire mesh shall be provided in the cable
compartment. In order to facilitate infra-red electrical inspection through thermography
window, metal barrier/ wire mesh may not be provided. Unless otherwise specified, the power
cable shall enter the switchboard from the bottom. Non-magnetic cable gland plates shall be
provided for feeders wherever single core cables are used.
5.4.2 The switchboard shall be supplied complete with supports for clamping outgoing and
incoming cables. The head-room available between cable gland plate and terminal lugs shall
not be less than 600 mm for switchgear up to 11 kV, and 900 mm for 22 and 33 kV cables.
5.4.3 In case the standard panel depth cannot accommodate the specified number of cables, a rear
extension panel of full height shall be provided. An earth strip shall also be brought to this
extension panel.
5.4.4 Unless otherwise specified, all power cables shall enter the switchgear from the bottom.
5.5 Auxiliary Wiring and Terminals
5.5.1 Inside the cubicles, the wiring for control, signalling, protection and instrument circuits shall
be done with BIS approved, PVC insulated, flame retardant low smoke (FRLS) type, copper
conductor wire. The insulation grade shall be 660 V. The wiring shall preferably be enclosed
in plastic channels or neatly bunched together. Wiring between I-W breakers or cable
compartments to relay and metering compartments shall be routed through flexible conduits.
5.5.2 A minimum of 10% spare terminals shall be provided on each terminal block. Conductors
shall be terminated with adequately sized compression-type lugs for connection to equipment
terminals and strips. Stranded conductors shall be soldered at the ends/ crimped with suitable
lugs before connections are made to the terminals. Sufficient terminals shall be provided on
each terminal block to ensure that not more than one outgoing wire is connected per terminal.
Terminal strips shall preferably be separated from power circuits by metal barriers or
enclosures. All spare contacts of auxiliary relays, timers, etc shall be wired up to the terminals.
5.5.3 Each wire shall be identified at both ends by correctly sized PVC ferrules. Shorting links shall
be provided for all CT terminals.
5.5.4 PVC insulated copper conductor of cross section 1.5 mm2 may normally be used provided the
control fuse rating is 10A or less. For 16A control fuse circuit 2.5 mm2 copper conductors shall
be used. Each wire shall be terminated at a separate terminal. CT Circuit wiring shall be done
with 2.5 mm2 copper conductors. Shorting links / suitable shorting arrangement for shorting
CT secondary shall be provided.
5.5.5 Unless otherwise specified, all control cables shall enter the switchgear from the bottom.
5.5.6 Supporting facilities shall be provided for clamping the control cables.
5.5.7 All inter-panel control wiring within each shipping section shall be by switchgear vendor. The
inter-panel wiring shall be taken through PVC sleeves or suitable grommets. For inter-panel
wiring between the shipping sections, wires in rolls of the required length, connected at one
point, shall be supplied with the panel for connection at site.
5.6 Control and Indication
5.6.1 Breaker tripping, closing and spring charging devices shall be fed with DC control power
supply. The rated DC voltage shall be as specified in the data sheet. The power supply for
breaker opening, closing and indication devices shall be arranged as follows:
a. One DC feeder shall be provided for each bus section. The bus coupler panel may be
fed from any of the two supplies.
b. One separate, single-phase power supply shall be provided for each bus section for
feeding space heaters, etc. Supply voltage shall be 240 V AC, unless otherwise
specified.
Provision to receive DC and AC control supply shall preferably be provided in bus-coupler
panel / bus PT panel.
5.6.2 Breaker positions (CLOSE, OPEN, spring-charged, test position, service position) shall be
indicated mechanically. Electrical indications, with colours as given below, shall also be
provided:
Breaker 'CLOSED' Red lamp
Breaker 'OPEN' Green lamp
Breaker 'Auto-trip' Amber lamp
Trip circuit healthy White lamp
Spring charging Blue lamp
5.6.3 A common DC control supply fail indication shall be provided for each bus section with a blue
coloured lamp.
5.7 Earthing Connections
All cubicles shall be connected to an earth bus bar running throughout the length of the
switchboard. The minimum earth bus bar size shall be 30 x 6 mm2 copper, up to short-circuit
withstand capacity of 31.5 kA, and 50 x 6 mm2 copper, for a short-circuit withstand capacity
above 31.5 kA. All doors and movable parts shall be connected to the earth bus with flexible
copper connections. Provision shall be made to connect the earthing bus bar to the plant
earthing grid at two ends. All non current-carrying metallic parts of the equipment and
components shall be earthed. The earth bus shall be brought back to the cable compartment,
and earthing bolts shall be provided to ground cable armour. The mating surfaces of all bolted
parts shall be zinc passivated to ensure continuity between them.
5.8 Space Heaters
The panels shall be provided with space heaters to prevent moisture condensation, and
maintain cubicle temperature 5°C above the ambient. The space heaters shall be located at the
bottom of the panel, and shall be controlled through a double pole MCB and a thermostat with
an adjustable setting range of 30 to 70°C. The thermostat shall preferably be located in the
metering or relay chamber. Space heaters shall be supplied from 240V AC auxiliary bus for
space heater.
5.9 Panel Supporting Frame
The panels shall be suitable for installation on panel supporting frame, to be supplied by
others. The panels shall be suitable for tack welding, directly to this frame.
5.10 Nameplates
5.10.1 The switchgear shall be provided with durable and clearly legible nameplate in accordance
with Table-1 of IS/IEC 62271-200 requirements.
5.10.2 A nameplate with the switchboard designation shall be fixed at the top of the central panel.
A separate nameplate giving details for each feeder compartment of all panels shall be
provided. Danger plate (Red) shall be provided at the front and rear for each panel.
5.10.3 The nameplates for feeder compartments shall be in two parts. One part shall have necessary
details pertaining to the compartment's number of vertical panel of the switchboards. The
other parts shall be removable and shall contain all details regarding the feeder number for
drives/equipment controlled by the particular module as per approved single line diagram.
5.10.4 Blank nameplates shall be provided for all spare and vacant modules.
5.10.5 Nameplate or polyester adhesive stickers shall be provided for each equipment mounted inside
the switchboard. Special warning plates shall be provided on removable covers or doors giving
access to cable terminals and bus bars.
5.10.6 Special warning labels shall be provided inside the switchboards also, wherever considered
necessary. Identification tags shall be provided inside the panels matching with those shown
on the circuit diagram.
5.10.7 Engraved nameplates shall preferably be of 3- ply (Black-White-Black) lamicoid sheets or
anodised aluminium. However back engraved perspex sheet nameplates may also be
acceptable. Nameplates shall be fastened by screws and not by adhesives.
5.11 Painting
5.11.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease
and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The
under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. Alternately, supplier's standard paint procedure as per their ISO standard is
also acceptable. The under surface shall be made free from all imperfections before
undertaking the finishing coat.
5.11.2 After preparation of the under surface, the switchboard shall be spray painted with two coats
of epoxy based final paint or shall be powder coated.
5.11.3 Colour shade of final paint shall be as RAL 7032 unless specified otherwise.
5.11.4 The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall
be free from imperfections like pinholes, orange peels, runoff paint etc. Vendor shall supply
final paint (1 litre per switchboard) in non-returnable container for final touch up at site.
5.11.5 All unpainted steel parts shall be Zinc passivated or suitably treated to prevent rust formation.
If these parts are moving elements then they shall be greased. Aluzinc/ pre-galvanised sheet,
wherever provided, need not be painted.
iv) Closing operation shall be completed once the closing impulse is given and
the first device in the control scheme has responded even though the control
switch / Push Button is released, provided no counter trip impulse is present.
6.1.7 Circuit breaker trip and closing coils, in case of electrically operated breakers, and trip coil in
case of mechanically operated breakers and circuit breaker indication shall be suitable for
satisfactory operation on a control supply system indicated in data sheets/job specification.
Additional second shunt trip coil (operating on different control voltage supply) shall also be
provided if specified in the datasheet.
6.1.8 All circuit breakers shall be provided with mechanically operated emergency trip device. This
device shall be available on the front of the panel. Mechanically operated 'closing' device
shall be provided for all breakers. However mechanical closing shall be inhibited for all circuit
breakers in service position.
6.1.9 The breakers shall be provided with anti pumping & trip free feature. Each breaker shall be
also provided with an operation counter.
6.1.10 For all HV VFD feeders, breaker shall be provided with one no. shunt trip coil and with
undervoltage release. However, in case it is not possible to provide undervoltage release in the
standard design, as an alternative, two shunt trip coils shall be provided. One shunt trip coil
shall be suitable for switchgear DC control supply while second shunt trip coil shall be
suitable for external AC control supply. The control supply voltage level shall be as specified
in data sheet.
6.1.11 Metal Oxide surge suppressors shall be provided on all outgoing vacuum circuit breakers to
limit the over voltage to a maximum of 2.2 p.u. rated peak line to earth voltage. Sizing
calculations for surge suppressor shall be provided post order.
6.1.12 Line PT shall be mounted in a separate drawout carriage. In case of truck mounted breaker, line
PT shall be provided in a separate panel.
6.1.13 The complete breaker assembly should have inter-changeability with breakers of identical
ratings.
6.1.14 For switchgears specified with double tier circuit breaker arrangement, the outgoing feeder
breakers shall have double tier arrangement and incomer breakers with Line/bus PT shall be
housed in one vertical panel. In double tier arrangement, sheet steel partitions shall be
provided for each compartment. Compartmentalization shall be such that maintenance of one
breaker is possible without disturbing the adjacent breaker compartment. Suitable trolley(s)
shall be supplied for drawing out the breakers in upper tier. The maximum height of the
operating handle/switches/reset knobs/pushbuttons shall not exceed 1900 mm and minimum
height shall not be below 300 mm.
6.1.15 An integral earthing system, or a separate earthing carriage/truck, shall be provided. In case of
a separate earthing carriage, the necessary trolleys for bus-side and cable-side earthing shall be
supplied. After withdrawing the circuit breaker, this can be inserted to facilitate earthing of
cables and bus bars. Earthing truck shall be complete with the PT and voltmeter, giving audio-
visual indication and solenoid interlock to prevent closing of bus side earthing truck on live
busbars. Suitable interlock shall also be provided for Earthing switch. Earthing truck/ earthing
switch operation shall be only with door closed.
Integral earthing truck/earthing switch shall be suitable for short time withstand current and
peak withstand current rating equal to the corresponding breaker withstand rating.
Contactors shall comply with IS/IEC-60470 and shall be suitable for intermittent duty class
0.1 as well as for uninterrupted duties.
The minimum short circuit breaking capacity of the contactor shall be at least 6 kA at rated
voltage.
Overvoltage surge diverters shall be installed if required to keep high over-voltages during
operating conditions within acceptable values.
Contactors for motor starters and capacitor Bank feeders shall be of the latched type. The
tripping supply shall be obtained from the DC tripping and closing supply. Motor contactor
panels shall be provided with restarting facilities as specified in job specification/ datasheet.
Fuse links shall be in accordance with IEC 60282-1 and shall have high rupturing capacity.
They shall be short circuit current limiting type. Fuses shall be provided with striker pin
arrangement tripping the contactor.
Fuses for motor starters shall have a time-current characteristic suitable for the method of
starting.
Correct discrimination shall be established between fuse characteristics and contactor breaking
capacities. This shall ensure that overload and fault currents are safely interrupted by the
appropriate devices avoiding any risk of welding or other damage to the contactor.
i) Current transformers shall conform to IS: 2705. The short-time rating shall be equal to
that of the switchboard. They shall be mounted on the stationary part of the
switchboard. The CT ratings shall be as shown in the data sheet. Protective CTs shall
have an accuracy class of 5P and an accuracy limit factor greater than 10. CTs for
instruments shall have an accuracy class of 1.0 and an accuracy limit factor less than
5.0. For numerical relays having protection and metering functions, dual rated CT
shall be provided suitable for protection class and metering class. One leg of the CTs
shall be earthed. Separate CTs shall be provided for Differential and Restricted Earth
fault protection.
ii) All CTs shall be star connected. Interposing CT (ICT) shall be provided (if required)
for differential protection of transformers having star-delta connection.
iii) Proper access to each set of CTs shall be provided for repair / maintenance.
6.3.2 Potential transformer
i) The potential transformers shall conform to IS: 3156. The potential transformers shall
be of drawout-type, and shall be provided with 4 pole miniature circuit breakers with
auxiliary contacts on the secondary side.
ii) The drawout mechanism shall disconnect the PT from the busbars. The primary
connection shall be disconnected before the PT becomes accessible. Neutral point of
the star connected PTs both on the primary and secondary sides shall be earthed.
iii) The PTs shall have an over-voltage factor of 1.9 for 30 seconds, and an accuracy class
of 1.0 from 10% to 120% of normal voltage. PT selected shall be compatible with
system grounding.
iv) The primary rated voltage shall be equal to the rated voltage V of the system, or V/43,
if the PT is connected between phase and neutral.
v) If not otherwise specified, the secondary voltage shall be 110 V, or 110/43 V. The
burden and class of accuracy shall be as specified in data sheets. For directional relays,
either a 3-phase 5-limb PT, or 3 single-phase PTs with secondary windings connected
in open delta shall be provided.
6.5 Relays
6.5.1 Type of relay i.e. electromechanical, static or numerical shall be as defined in data sheet / job
specification.
6.5.2 All electromechanical protective relays shall be back-connected, of drawout type, suitable for
flush mounting, and fitted with dust-tight covers. Alternatively, "plug-in" type relays will also
be acceptable. Auxiliary relays are acceptable in fixed execution.
6.5.3 The protective relay cases shall have a provision for insertion of a test plug at the front for
testing and calibration using an external power supply without disconnecting the permanent
wiring. The insertions of the test plug shall automatically short circuit the CTs and permit
extension of external power supply to the relay.
6.5.4 All protective relays shall have hand reset facility and clear operating indication, e.g. flags for
electro-mechanical type relays or light emitting diodes for static/numerical type relays. It shall
be possible to reset the flag without opening the relay case.
6.5.5 All tripping relays (electrical fault trip) shall be of lockout type with hand-reset contacts, and
shall be suitable to operate on the specified voltage. These relays shall have self coil cut off
contacts, and shall be provided with hand-reset operation indicators. However, for process trip,
the lock out relay shall be self reset type Tripping relays will be acceptable in non-drawout
cases.
6.5.6 The tripping relay shall be suitable for satisfactory operation from 50% to 110% of the
specified control supply voltage.
SPECIFICATION
FOR
INDUSTRIAL TYPE CONTROL
STATIONS
Abbreviations:
AC Alternating Current
BIS Bureau of Indian standards
BS British Standards
CEA Central Electricity Authority
CT Current Transformer
DC Direct Current
FRP Fibre Reinforced Plastic
GI Galvanised Iron
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
IP Ingress Protection
IS Indian Standard s
LED Light Emitting Diode
LV Low Voltage
NC Normally Closed
NEMA National Electrical Manufacturers Association
NO Normally Open
PVC Poly Vinyl Chloride
SS Stainless Steel
SWG Standard Wire Gauge
VDE Verband Der Electrotechnik, Elecktronik and Information Stechnik
CONTENTS
1.0 SCOPE 4
1.0 SCOPE
This specification covers the requirements of design, manufacture, testing, packing and supply
of industrial type control stations and accessories suitable for installation in non-hazardous/
safe outdoor areas.
2.3 The equipment shall also conform to the provisions of CEA Regulations and other statutory
regulations with latest amendments currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent requirement shall govern. However, Owner's/EIL's decision in this
regard will be final and binding.
5.1.3 All control stations shall be suitable for 240V AC as well as for 110V/220V DC control
supply.
5.1.5 All metal surfaces shall undergo manufacturer's standard cleaning/ painting cycle. After
preparation of under surface, the equipment shall be painted with two coats of epoxy based
final paint with colour shade as dark admiralty grey, shade 632 of IS-5/ RAL 7031. All
unpainted steel parts shall be suitably treated to prevent rust formation. If these parts are
moving elements, then they shall be greased.
5.1.6 All accessories like nuts, bolts, washers etc and operating shaft of pushbuttons and switches
etc. shall be made of stainless steel SS-304.
5.1.7 The control stations shall be provided with two earthing studs with lugs on the external
surface of the enclosures suitable for termination of 8 SWG GI wire.
5.1.8 The control stations shall be provided with undrilled gland plate. However, double
compression nickel-plated brass cable gland shall be supplied loose to suit the specified cable
sizes.
5.1.9 The control stations shall have external fixing lugs for mounting on wall or column. The holes
provided on these lugs shall be of oblong type.
5.1.10 Engraved nameplate indicating Tag Number shall be permanently fixed on each control
station.
5.2.1 Push buttons for START and STOP shall be of GREEN and RED colour respectively. Each
push button shall have two NO and two NC contacts. The STOP push button shall be
mushroom type with stay put feature and lockable in pressed position.
5.2.2 All control switches shall be provided with a pistol grip handle. Circuit breaker control switch,
wherever specified, shall have three positions (START - NEUTRAL - STOP) with spring
return to neutral from START position and stay put in STOP position. All selector switches
shall have minimum two poles for each position. Each position of switch shall be indelibly
marked on the control station. Exact configuration of selector switch (LOCAL-OFF-
REMOTE or AUTO-OFF-MANUAL) shall be as per datasheet / MR requirement.
5.2.3 All ammeters shall be of moving iron type having an accuracy class of 3 and suitable for
lAmpere CT secondary. Unless otherwise specified, min. size of ammeter shall either be 72
mm x 72 mm or min. 65 mm dia., 80% of the scale length shall cover 100% of the CT primary
current uniformly and the balance 20% of the scale shall cover 100-800% of the CT primary.
A red mark corresponding to the full load current of the motor shall be provided on the
ammeter dial. The ammeter front glass shall be toughened.
5.2.4 Indicating lamp(s), wherever provided, shall be clustered LED type with minimum 3 numbers
LEDs, preferably connected in parallel, mounted inside an enclosure of minimum diameter of
15mm.
5.3.2 All internal wiring shall employ 1.5 mm 2 , 660V grade, FR type PVC insulated copper
conductor wires.
6.2 For testing requirements refer inspection and test plan no. 6-81-1014.
TruriT
fafT
SPECIFICATION
FOR
MEDIUM VOLTAGE SWITCHBOARD
Abbreviations:
CONTENTS
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 GENERAL REQUIREMENTS 4
4.0 SITE CONDITIONS 5
5.0 DESIGN AND FABRICATION REQUIREMENTS 5
6.0 SPECIFIC REQUIREMENTS OF AIR CIRCUIT BREAKER PANELS 8
7.0 SPECIFIC REQUIREMENTS OF FEEDERS OTHER THAN ACB FEEDERS 10
8.0 SWITCHGEAR MODULES 11
9.0 SWITCHBOARD COMPONENTS 11
10.0 INSPECTION, TESTING AND ACCEPTANCE 15
11.0 PACKING AND DESPATCH 16
1.0 SCOPE
1.1 This specification covers the requirements of design, manufacture, testing, packing and supply
of fixed and draw out type medium voltage switchboards.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the requirements of the latest revision of the following
standards issued by BIS unless otherwise specified.
IS : 5 Colours for ready mixed paints and enamels
IS : 1248 Direct Acting Indicating Analogue Electrical Measuring Instruments
and their Accessories
IS : 2705 Current transformers
IS : 2824 Method for determining the proof and the comparative tracking
indices of solid insulating materials.
IS : 3156 Voltage transformers
IS : 3231 Electrical relays for power systems protection.
IS : 3618 Phosphate treatment of iron and steel for protection against corrosion.
IS : 5082 Wrought aluminum and aluminum alloy bars, rods, tubes and sections
for electrical purposes.
IS : 5578 Guide for marking of insulated conductor.
IS: 8623(Part-2): Low voltage switchgear and control gear assemblies. Particular
requirement for bus bar trunking system.
IS : 11353 Guide for uniform system marking and identification of conductors
and apparatus terminals.
IS : 13703 Low voltage fuses for voltages not exceeding 1000V AC or 1500V
DC.
IS/ IEC: 60529 : Degree of protection provided by enclosures (IP Code).
IS/ IEC: 60947 : LV Switchgear and control gear.
2.2 In case of imported equipments, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other
statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/BS /
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standards / specifications / data sheet
and statutory regulations the following order of priority shall govern:
Statutory regulations
Data sheets
Job specifications
This specification
Codes and standards
3.0 GENERAL REQUIREMENTS
3.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment at least for 15 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to enable the end user for placement of order for spares and
services.
4.0 SITE CONDITIONS
4.1 The switchboards shall be suitable for installation and satisfactory operation in a pressurised
substation or in a substation with restricted natural air ventilation in a tropical, humid and
corrosive atmosphere.
4.2 The switchboards shall be designed to operate under specified site conditions. If not
specifically mentioned, a design ambient temperature of 40° C and altitude not exceeding
1000 metres above mean sea level shall be considered.
4.3 All the equipment described in this specification is intended for continuous duty at the
specified ratings under the specified ambient conditions, unless specified otherwise.
5.0 DESIGN AND FABRICATION REQUIREMENTS
5.1 Medium voltage switchboard shall be metal enclosed fully draw out or fixed, as specified in
datasheet/ job specification, free standing, floor mounting, compartmentalised, modular type
suitable for indoor installation.
5.2 The switchboard enclosure shall be dust and vermin proof and shall provide a degree of
protection not less than IP-41.
5.3 The switchboard shall be assembled out of vertical panels of uniform height, not exceeding
2450mm in a single line up.
5.4 It shall be possible to extend the switchboard, in either direction at a later date. End of bus
bars shall be suitably drilled for this purpose. Panels at extreme end shall have openings,
which shall be covered with plates screwed to the panel.
5.5 The switchboard shall be designed to ensure maximum safety during operation, inspection,
connection of cables, relocation of outgoing circuits and maintenance, with the bus bar system
energised and without taking any special precautions.
5.6 Adequate means shall be provided to prevent shorting of power and / or control terminals due
to accidental dropping of maintenance tools etc. inside the switchboard. Checking and
removal of components shall be possible without disturbing adjacent equipment.
5.7 All identical equipment and corresponding parts shall be fully interchangeable.
5.8 The frame, of individual vertical panels shall be fabricated using pressed and cold rolled sheet
steel. The sheet steel used for panel shall be of minimum 2mm (14SWG) CRCA except the
doors and covers that may be made of 1.6mm (16SWG) CRCA. Wherever required, stiffeners
shall be provided to increase stiffness of large size doors and covers.
5.9 The switchboard shall be provided with integral base frame for each vertical panel. The
switchboard integral base frame shall be suitable for tack welding.
5.10 All openings, covers and doors shall be provided with gaskets around the perimeter to make
the switchboard dust and vermin proof.
5.11 All hardware shall be corrosion resistant. All joints and connections of the panel members
shall be made of galvanized or zinc passivated or cadmium plated high quality steel bolts, nuts
and washers, secured against loosening.
5.12 Suitable removable type eyebolts/ lifting hooks shall be provided for lifting of the
panel/shipping section. These eyebolts/ lifting hooks, when removed shall not leave any
opening in the panels.
5.13 Non-magnetic cable gland plates shall be provided for termination of single core cables.
5.14 The switchboard shall be formed using distinct vertical panels each comprising of the
following compartments.
5.14.1 A metal enclosed horizontal bus bar compartment running at the top, unless otherwise
specified.
5.14.2 Individual feeder modules in multitier mode.
5.14.3 Vertical bus bars serving all feeder modules in the vertical panel.
5.14.4 Cable termination compartment.
5.14.5 Perforated sheet steel / insulating material enclosed, horizontal auxiliary bus bars for control,
interlock, indication and metering running horizontally.
5.15 Metal sheets shall be provided between two adjacent vertical panels running upto the full
useful height of the switchboard.
5.16 MCC shall be of single/double front execution as specified in data sheet/job specification.
However circuit breaker panels and fixed type switchboard shall be in single front execution
only.
5.17 Motor starter and switch fuse modules shall not be accommodated at front and rear of ACB
Incomer and bus coupler panel.
5.18 All metering and protection equipment associated with a particular circuit, as specified in data
sheet, shall be housed in separate and independent compartment earmarked for that particular
circuit and in the fixed portion of the vertical panel in case of breaker panels.
5.19 All auxiliary devices for control, reset, indication, measurement and protection such as push
buttons, control and selector switches, indicating lamps, measuring instruments and protective
relays shall be mounted on the front side of the respective compartment. The design shall be
such that all power ON/OFF or START / STOP and relay reset operations shall be performed
without opening the panel door.
5.20 Space Heaters
The switchboard panels shall be provided with space heaters to prevent moisture
condensation. The space heater shall be located in the bottom part of each panel and shall be
supplied from 240 V AC auxiliary buses for space heater. The space heater shall be provided
with a switch, fuse or double pole MCB and thermostat having adjustable setting range of 30-
70° C. Further, one number 240V AC, 5/ 15A, 5 Pin socket for owner's use shall be provided
inside panels.
5.21 Auxiliary Bus bars
5.21.1 Auxiliary bus bars, each of minimum size 18-mm2 copper, shall be provided for the following
applications.
Panel space heater supply and motor space heater supply.
AC Control supply.
DC Control supply.
AC PT supply for energy meters, voltage operated relays etc.
5.21.2 Tee-off connectors shall be used for distributing auxiliary supply to each vertical panel.
Rubber grommets shall be used for all wire entries to make the entries dust and vermin proof.
5.21.3 Provision for hook up of external AC space heater/ DC control supply to be provided either in
bus PT panel or bus coupler panel.
5.22 Bus Bar
5.22.1 Bus bars shall be of high conductivity electrolytic aluminium or copper supported on
insulators made of non-hygroscopic, non-inflammable material with tracking index equal to or
more than that defined in Indian standards.
5.22.2 The main bus bars shall have uniform current ratings throughout their length as specified in
data sheet/job specification. The current rating of the neutral shall be half that of the phase bus
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
bars. Removable neutral links shall be provided on feeders to permit isolation of the neutral
bus bar.
5.22.3 Both horizontal and vertical bus bars, bus joints and supports shall be capable of withstanding
dynamic and thermal stresses of the specified short circuit currents.
5.22.4 Only zinc passivated or cadmium plated high tensile strength steel bolts, nuts and washers
shall be used for all bus bar joints and supports.
5.22.5 The hot spot temperature of bus bars, including joints, at design ambient temperature shall not
exceed 95° C under normal operating conditions. However, for silver plated joints, the
allowable maximum temperature shall be 115°C.
5.22.6 The current rating as defined for switchboard and components in data sheet/job specification
are for design ambient temperature at site conditions and for being inside the cubicle at fully
loaded condition. The vendor shall suitably derate the nominal rating to suit the above
condition.
5.22.7 All bus bars shall be insulated with heat shrunk PVC sleeves of 1100 V grade. Red, yellow
and blue colour shall be used for phase bus bars and black colour shall be used for neutral bus
bars. Alternatively, colour bands at suitable intervals along PVC sleeved bus bars may be
provided. Removable type shrouds shall be provided for joints.
5.22.8 Minimum clearance between live parts, between live parts/neutral to earth shall be 19 mm.
However clearances between terminals at components shall be as per applicable individual
standards for components.
5.22.9 Vertical bus bars for circuit breaker panels shall be sized depending upon the rating and
number of breakers per vertical panel. However vertical bus bars of all other panels shall be of
uniform cross section.
5.23 Wiring and Terminals
5.23.1 Inside the cubicles, the wiring for control, signaling, protection and instrument circuits shall
be done with BIS approved, PVC insulated, flame retardant type, copper conductor wire. The
insulation grade shall be 1100 V. The wiring shall preferably be enclosed in flame retardant
plastic channels or neatly bunched together.
5.23.2 PVC insulated copper conductor of cross section 1.5 mm 2 may normally be used provided the
control fuse rating is 10 A or less. For 16 A control fuse circuit 2.5 mm 2 copper conductor
shall be used. Each wire shall be terminated at a separate terminal. CT circuit wiring shall be
done with 2.5mm2 copper conductor.
5.23.3 Shorting links/suitable-shorting arrangement for shorting CT secondary shall be provided.
5.23.4 Each wire shall be identified at both ends by PVC ferrules.
5.23.5 Inter panel wiring within each shipping section shall be switchboard vendor's responsibility.
For wiring between shipping sections, vendor shall provide terminal blocks on adjoining
shipping sections and supply suitable jumpering wires. Inter-panel wiring shall be taken
thorough PVC sleeves or rubber grommets.
5.23.6 A minimum of 10% spare terminals shall be provided on each terminal block.
5.23.7 Conductors shall be terminated with adequately sized compression-type lugs for connection
to equipment terminals and strips. Sufficient terminals shall be provided on each terminal
block to ensure that not more than one outgoing wire is connected per terminal.
5.23.8 Terminal strips shall preferably be separated from power circuits by metal barriers or
enclosures. All spare contacts of auxiliary relays, timers, etc shall be wired up to the
terminals.
5.24 Earthing
5.24.1 All panels shall be connected to a tinned copper earth bus bar running throughout the length of
the switchboard.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
5.24.2 The minimum earth bus size shall be 30x6 mm2 copper for fault level up to 31.5kA and 50x6
mm2 copper for fault level above 31.5kA.
5.24.3 All doors and movable parts shall be earthed, using flexible copper connections, to the fixed
frame of the switchboard. Provision shall be made to connect the earthing bus bar to the plant-
earthing grid at two ends.
5.24.4 All non-current carrying metallic parts of the mounted equipment shall be earthed. Minimum
4 nos, 10 mm diameter bolts with nuts shall be provided on the earth bus for termination of
fourth core of cable per vertical panel.
5.25 Name plate
5.25.1 A nameplate with the switchboard designation shall be fixed at the top of the central panel. A
separate nameplate giving details for each feeder compartment of all panels shall be provided.
Danger nameplate shall be provided at the front and rear of each panel.
5.25.2 The nameplates for feeder compartments shall be in two parts. One part shall have necessary
details pertaining to the compartments number of vertical panel of the switchboards. The other
parts shall be removable and shall contain all details regarding the feeder number for
drives/equipment controlled by the particular module as per approved single line diagram.
5.25.3 Blank nameplates shall be provided for all spare and vacant modules.
5.25.4 Nameplate or polyester adhesive stickers shall be provided for each equipment mounted inside
the switchboard. Special warning plates shall be provided on removable covers or doors
giving access to cable terminals and bus bars.
5.25.5 Special warning labels shall be provided inside the switchboards also, wherever considered
necessary. Identification tags shall be provided inside the panels matching with those shown
on the circuit diagram.
5.25.6 Engraved nameplates shall preferably be of 3- ply (Black-White- Black) lamicoid sheets or
anodised aluminium. However back engraved perspex sheet nameplates may also be
acceptable. Nameplates shall be fastened by screws and not by adhesives.
5.26 Painting
5.26.1 All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease
and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid.
The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow
zinc chromate primer. The under surface shall be made free from all imperfections before
undertaking the finishing coat.
5.26.2 After preparation of the under surface, the switchboard shall be spray painted with two coats
of epoxy based final paint or shall be powder coated.
5.26.3 Colour shade of final paint shall be 631 as per IS: 5 or RAL 7032, unless otherwise specified.
5.26.4 The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall
be free from imperfections like pinholes, orange peels, runoff paint etc.
5.26.5 All unpainted steel parts shall be zinc passivated or cadmium plated or suitably treated to
prevent rust formation. If these parts are moving elements then they shall be greased
6.0 SPECIFIC REQUIREMENTS OF AIR CIRCUIT BREAKER PANELS
6.1 The breaker panels shall have distinct bus bar, breaker and cable compartments.
6.2 The design of each compartment shall be such as to prevent movement of vermin from a
particular compartment to any other compartment of the panel when the breaker is withdrawn
and compartment door is closed.
6.3 In order to minimise accidental access and avoid accidents due to falling tools, all the
outgoing links shall be shrouded.
6.4 Outgoing air circuit breaker can be mounted in a maximum of two-tier execution while the
incoming/bus coupler air circuit breaker shall be in single tier execution only.
6.5 Cable Compartment
6.5.1 Separate compartment, totally enclosed from all sides, shall be provided for cable termination,
on the rear side. Access to cables shall be from the rear side after opening the cabling
compartment cover.
6.5.2 The incoming / outgoing cable termination shall be staggered for each circuit and barriers of
sheet steel or insulating material shall be provided between terminations of two circuits such
that maintenance on one circuit could be carried out while the other circuit is live. Suitable
clamping arrangements shall be provided for cables and cable termination. Terminal blocks
shall not be used for supporting the cables.
6.5.3 The incoming supply for PCC/ PMCC panels shall be through top entry bus ducts or through
bottom entry cables unless specified otherwise. The outgoing cables shall have bottom entry
unless specified otherwise.
6.5.4 The cable terminations shall be suitably sized for receiving specified number of cables per
termination and provision shall be made for terminating each outgoing cable with a separate
bolted connection. In case the total number of cables entering a particular panel cannot be
accommodated in the cabling compartment of the panel, an extension panel of full height shall
be added to the cabling compartment for accommodating extra cables. Alternatively, in view
of extra cables, provision for back to back connections of cables may be offered.
6.6 Circuit Breaker Compartment
6.7.1 The circuit breaker compartment shall be fully draw out. Suitable guides shall be provided to
facilitate easy withdrawal of the circuit breaker.
6.7.2 The current transformers for the ammeter/protection circuits shall be mounted on the
fixed portion of the compartment. However, current transformers associated with built-in
releases may be mounted on the breaker trolley.
6.7.3 All terminals except wiping/sliding type control terminals shall be shrouded with plastic
covers to prevent accidental contact. For direct termination, clip-on shrouded type terminals
shall be provided.
6.7.4 There shall be three positions for the draw out trolley viz:
"Service" position - In this position both power and control circuits shall be
connected. This shall be the normal operating position of the circuit breaker.
"Test" position - The power contacts shall be disconnected in this position but the
control connections shall not be disturbed, testing provision for the entire control
circuitry shall be available in test mode including close and trip of breakers.
"Drawout" Position - both power and control circuits shall be disconnected in this
position and breaker removed from the cubicle.
6.7.5 The circuit breaker shall be lockable in "service" and "test" positions. Safety shutters shall be
provided when the breaker is in withdrawn/drawout position.
6.7.6 The earth connection must remain connected in "Test" position; Earthing of the unit shall be
done with a "pin" or with scrapping earth connections.
6.7.7 The earth connection shall make before the main power / control contacts make and break
after the power /control contacts are disconnected. Earthing connection through a plug and
socket connection shall not be acceptable
6.7 Interlocks
Following interlocks shall be provided:
6.7.1 Compartment doors shall be interlocked against opening when breaker is in closed condition.
However, it shall be possible to defeat this interlock for inspection purposes.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
6.7.2 It shall not be possible to push "in " a drawn out circuit breaker in closed condition or
withdraw a circuit breaker in closed condition.
6.7.3 It shall be possible to operate a circuit breaker only in the defined "Full in" or "service" and
"test' position inside the panel. It shall not be possible to operate the breaker in intermediate
positions while inserting or withdrawing circuit breaker.
6.8 Any unused circuit breaker compartment shall be fully equipped and provided with
compartment door, vertical busbars and control terminals/ wiring etc. such that the same could
be used for housing outgoing breakers in future without any modifications to the panel.
7.0 SPECIFIC REQUIREMENTS OF FEEDERS OTHER THAN ACB FEEDERS
7.1 The design of drawout feeder modules shall not change for single front or double front
execution. Separate vertical bus bars shall be provided for each front side modules.
7.2 All identical feeder modules shall be interchangeable.
7.3 Each vertical panel shall have a separate cable alley. The width of this cable alley shall be
sufficient to accommodate all the cables and shall have free access for cable terminations and
in any case shall not be less than 200mm minimum. Cable alleys shall be provided with
suitable doors.
7.4 Sheet steel barrier shall be provided between individual compartments and cable alley. This
barrier shall be provided with opening for power and control connections and it shall be
possible to safely carryout maintenance work on cable connections to any one circuit in the
cable alley with the busbars and the adjacent circuits live.
7.5 Maintenance and connection of cables to any modules shall be possible without having to take
out the modules from its position from the panel.
7.6 The outgoing feeder trolleys for drawout type switchboard shall be fully drawout and shall
have the following features.
7.6.1 It shall be possible to withdraw the trolley without having to unbolt or unscrew any power and
control connections to the equipment mounted on the withdrawable trolley.
7.6.2 Both power and control connections shall be drawout type. All line and bus PTs shall be in
drawout execution only. However, outgoing modules having size more than half of the useful
vertical height of the panel may be in mixed combination of drawout /fixed type.
7.6.3 Control supply transformer modules with burden higher than 2.5kVA may be in fixed
execution.
7.6.4 The trolley withdrawal shall be by means of crank and screw arrangement. Alternatively
movement on guided rollers may also be acceptable. Plug in operation shall be independent of
manual force. An insulating handle for racking in/ out modules shall be provided, as required.
7.6.5 For drawout type feeders of size equal to or greater than half the useful vertical height of
panel, positive clamping arrangement shall be provided on the top portion of the trolley in
addition to clamping arrangement at the bottom, to ensure all round positive pressure on the
power drawout contacts once the trolley is plugged in.
7.6.6 Power drawout contacts shall preferably be located towards the bottom portion of each trolley.
The trolley shall be lockable in fully plugged in position and devices shall be provided to
ensure positive plugging in. In test position, power contacts shall be totally isolated and a
device shall be provided for indication of test position. In test position, testing provision for
the entire control circuitry shall be available.
7.7 The incomer and bus tie feeders with load break switches rated 800A and above may be in
fixed execution
7.8 Various compartment sizes in a vertical panel shall be multiples of a basic dimension.
However the minimum module size for switch fuse feeder and motor startor/contactor feeder
shall not be less than that defined in data sheet/job specification. Vertical bus bars shall be pre-
drilled at regular intervals for complete flexibility for changes in size of modules.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
7.9 All switch drives other than rotary control switches, shall be lockable in 'OFF' position.
7.10 The switches/Moulded case circuit breakers /MCB shall be interlocked with the compartment
door to prevent opening of the door when the switch/ moulded case circuit breaker is in 'ON'
position and to prevent switching on when the door is open. A defeat mechanism for this
interlock shall also be provided.
7.11 The maximum height of the operating handle and switches shall not exceed 1900 mm and the
minimum height shall not be below 300 mm.
7.12 Unused modules in the panel shall be fully equipped with hinged door and shall be suitable for
mounting power and control terminals for starter modules and cradle for future use.
8.0 SWITCHGEAR MODULES
8.1 Switchboard shall be completely lined up in one straight row with the type and quantities of
feeders as defined in switchboard data sheet. Generally the feeders of three main categories are
identified as circuit breaker, motor starters and switch fuse.
8.2 Starter modules required for motor control shall be of the following types and internal control
wiring of all starter modules of each type shall be identical for all ratings.
8.2.1 FVNR Full Voltage Non -Reversing starter with minimum 18 control terminals.
8.2.2 FVR Full Voltage Reversing starter with minimum 24 control terminals.
8.2.3 FVNR - HD Full Voltage Non -Reversing Heavy Duty starter with long starting time such
as for compressors and fans etc. with minimum 18 control terminals.
8.3 Switch fuse /contactor feeder modules shall be of following types and internal control wiring
of all modules of each type shall be identical for all ratings.
8.3.1 SFU Switch Fuse Unit modules with no control terminals.
8.3.2 SFC Switch Fuse Contactor modules with 18 control terminals.
8.4 Control transformer shall be provided for each bus section of the PMCC/MCC switchboard
having contactor control feeders and each transformer shall be sized for the entire switchboard.
Switchboard having two bus sections and coupled by bus tie shall have manual changeover
switch for the control transformers. The control transformer shall have at least 10% spare
capacity.
8.5 To facilitate site modification due to changes in motor KW ratings and to minimise spares
inventory, overload relays and power fuse links shall meet the following requirements.
8.5.1 All bimetal overload relays shall be separately mounted type with connecting links rated for
the maximum rating of the contactor in a starter module.
8.5.2 Bimetal overload relays of various current ranges required for motors likely to be connected to
a contactor must be identical in dimension for inter-changeability. In case offered relays are
with different dimension for any particular starter module, special mounting plate suitable for
mounting different relays shall be provided in all the modules of that size.
8.6 Heavy duty starters shall be provided with saturable type, current transformer operated;
overload relays only, which shall be suitable for motor starting time of 15-60 seconds.
8.7 All contactor controlled starter feeders shall meet the requirements of type-2 co-ordination as
per IS/IEC: 60947
9.0 SWITCHBOARD COMPONENTS
9.1 Circuit Breakers
9.1.1 Circuit breakers shall be air break, 3 pole and drawout type. However circuit breaker for
generator incomer shall be with four poles unless specified otherwise.
9.1.2 The circuit breakers shall be provided with mechanically operated emergency tripping device.
This device shall be available on the front of the panel. Mechanically operated 'closing' device
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
shall be provided for all breakers. However mechanical closing shall be inhibited for all
breakers in service position
9.1.3 The circuit breakers shall be provided with minimum 4 NO + 4 NC contacts, wired and
available for owner's use.
9.1.4 Circuit breaker's Open and closed positions; Service and test locations and spring charged
condition shall also be indicated mechanically in addition to electrical indications.
9.1.5 Unless otherwise specified, all circuit breakers in the switchboard shall be provided with
electrical power operating mechanism. Wherever circuit breakers are provided in place of
Isolators, Breaker can be manually operated type.
9.1.6 Operating Mechanism
Electric power operating mechanism shall be motor wound spring charged stored
energy type. However, manual-operating mechanism may be of the spring charging
stored energy type or spring assisted type. For circuit breakers with electrical power
operating mechanism, provision shall also be made for manual spring charging.
Closing time of circuit breakers with manual operating mechanism shall be
independent of the speed of the operating handle.
All stored energy operating mechanisms shall be equipped with the following features:
Failure of springs, vibrations or shocks shall not cause unintended operation of
breaker or prevent intended tripping operation.
Closing of circuit breakers shall be prevented unless the spring is fully charged.
c) All electrical power operating mechanisms shall be suitable for remote operation and
shall be equipped with the following features:
Provided with universal motor operable on AC or DC control supplies.
Provided with emergency manual charging facility. The motor shall be
automatically, decoupled (mechanically) once the manual-charging handle is
inserted.
Closing operation of circuit breaker shall automatically initiate charging of the
spring for the next closing operation without waiting for tripping of circuit
breaker.
Closing operation shall be completed once the closing impulse is given and the
first device in the control scheme has responded even though the control switch /
Push Button is released, provided no counter trip impulse is present.
9.1.7 Circuit breaker trip and closing coils, in case of electrically operated breakers and trip coil in
case of mechanically operated breakers and circuit breaker indication shall be suitable for
satisfactory operation on a control supply system indicated in data sheets/job specification.
9.1.8 Circuit breakers shall be provided with anti-pumping and trip free feature.
9.1.9 Circuit breakers shall be provided with operation counters.
9.1.10 Releases are not required to be provided with breakers where relays are used. However
breaker-having AC control supply voltage shall be provided with under voltage release unless
specified otherwise.
9.2 Switches
9.2.1 All switches or fuse switches shall be air break type provided with quick make/break manual
operating mechanism. The operating handle shall be mounted on the door of the compartment
having the switch.
9.2.2 Rating of switches for starter module shall meet the requirements of AC-23 duty as per IS/ IEC
60947 and minimum rating shall be as specified in job specification/data sheets.
9.3 Fuses
9.3.1 Fuses shall be non-deteriorating HRC cartridge link type.
9.3.2 Power fuses shall be pressure fitted type and shall preferably have ribs on the contact blades to
ensure good line contact.
9.3.3 It shall be possible to handle fuses during off load conditions with full voltage available on the
terminals. Wherever required fuse pullers shall be provided. The fuse base shall be so located
in the modules to permit insertion of fuse pullers and removal of fuse links without any
problem.
9.4 Contactors
9.4.1 The contactors shall be air break type, equipped with three main contacts and minimum
1NO+1NC auxiliary contacts. The main contacts of a particular contactor for motor starter
module shall have AC-3 or AC4 ratings, as specified in data sheet
9.4.2 Unless specified otherwise, the coil of the contactor shall be suitable for operation on 240 V, 1
Phase, AC supply.
9.5 Thermal Overload Relay
9.5.1 Bimetal relays shall be provided for protecting the motor from thermal overload.
9.5.2 Bimetal relays shall be manually reset type with the reset push button brought out on the front
of the panel. The reset push button shall be capable of being operated without opening the
compartment door.
9.5.3 Bimetal relays shall be positive acting ambient temperature compensated type with adjustable
setting range.
9.5.4 Bimetal relays shall have built-in single phasing prevention feature, which operates even with
50% rated current at the time of single phasing.
9.6 Moulded Case Circuit Breakers
9.6.1 MCCBs shall be provided with spring assisted quick make/ break manually operated trip free
mechanism. Wherever specified, MCCB shall be suitable for remote tripping operation and
the tripping device shall be suitable for the specified control supply voltage.
9.6.2 MCCBs shall be provided a tripping device with inverse time characteristic for over load
protection and instantaneous characteristics for short circuit protection and MCCB rated above
125A shall preferably have adjustable settings.
9.6.3 'ON' and 'OFF' position of the operating handle of MCCB shall be displayed and the
operating handle shall be mounted on the door of the compartment housing MCCB.
9.6.4 Each MCCB shall be provided with minimum 1 NO + 1 NC auxiliary contact and 1NO
contact for tripping indication/alarm for owner's use.
9.6.5 MCCBs shall be provided with solenoid/ motorised closing mechanism to make them suitable
for remote closing operation if specified. The closing solenoid/motor shall be suitable for
specified control supply voltage.
9.6.6 MCCB's as part of motor starter module shall be current limiting type and type tested for type-
2 co-ordination as per IS/ IEC 60947.
9.7 Relays
9.7.1 Type of relay shall be numerical, static or electro-mechanical type as specified in the data
sheet /job specification.
9.7.2 All electro-mechanical protective relays shall be back connected, of drawout type, suitable for
flush mounting, and fitted with dust-tight covers. Alternatively, "plug-in" type relays will also
be acceptable. Auxiliary relays and lock out relays are acceptable in fixed execution.
5i ar Ea&
g J INDIA LIMITED FOR 6-51-0018 Rev. 4
1.11,2n MUNE,. 3,ITIM) IA Govt. of India Undertaking) MEDIUM VOLTAGE SWITCHBOARD Page 14 of 16
9.7.3 The protective relay cases shall have a provision for insertion of a test plug at the front for
testing and calibration purpose using an external power supply. It shall be possible to test the
relays without disconnecting the wiring and without withdrawing the relays. The insertion of
the test plug shall automatically short circuit the CTs and permits extension of external power
supply to the relay.
9.7.4 Each protective relay shall be provided with minimum 2 numbers potential free contacts of
required configuration.
9.7.5 Each tripping relay shall be of lockout type with hand reset coil cut-off contact.
9.7.6 Protective relays shall be preferably mounted on the front side and upper part of the panel and
mounting of relays on the lower portion shall be avoided.
9.8 Instrument Transformers (CTs/PTs)
9.8.1 Current transformers shall generally conform to IS: 2705 and any special requirement with
respect to numerical relay shall be taken care by the vendor.
9.8.2 For general guidance the vendor shall note that the protective current transformers shall have
an accuracy class "5 P" and an accuracy limit factor greater than "10 ". However CTs for
restricted earth fault shall be of class "PS". Vendor shall co-ordinate the knee point voltage,
magnetising current for PS class CTs to avoid saturation and mismatching of CTs provided at
other end by other vendor.
9.8.3 Current transformers for instruments shall have an accuracy class 1.0 and accuracy limit factor
less than 5.0. However accuracy class of 3.0 is acceptable for CT meant for remote ammeters.
9.8.4 The current transformers in breaker feeders shall be capable of withstanding the applicable
peak momentary short circuit and the symmetrical short circuit current.
9.8.5 The voltage transformers shall be cast resin type transformers and PT shall generally conform
to IS: 3156. PT shall be provided with HRC fuses on primary side and Miniature circuit
breakers with auxiliary contact on the secondary side.
9.9 Measuring Instruments
9.9.1 All measuring instruments shall be of 96 x 96 mm and 72 x 72 mm square pattern, flush
mounting type for incomer and outgoing feeders respectively in the switchboard.
9.9.2 All auxiliary equipment such as shunts, transducers, CT, PT, etc. as required shall be included
in the supply of the switchboard.
9.9.3 All AC ammeters and voltmeters shall be of moving iron type with accuracy class of 1.5 or
better as per IS: 1248. Ammeters for motor feeders shall have a non-linear compressed scale at
the end to indicate motor starting current and red mark for the full load current.
9.9.3 The KW/KWH meters shall be suitable to measure unbalanced loads on 3 phases 4-wire
system. Test terminal block shall be provided for KWH meters. The accuracy class of KWH
meters shall be 2.5 or better.
9.9.4 Digital meters shall be provided, if specified in job specification/data sheets. All digital meters
shall be highly reliable, accurate, compact and self powered. Digital meter data shall be saved
in case of power failure. Field programming from front of the meter shall be possible and shall
have RS232/485 port in case specified in the job specification/data sheet.
9.10 Control Switches
9.10.1 All control switches shall be rotary type, having a cam operated contact mechanism. Switch
shall have pistol grip handle for circuit breaker control and knob type handle for other
applications.
9.10.2 Ammeter selector switches shall have make before break feature on its contacts. The selector
switch shall generally have 4 positions, three for reading 3 phase currents and the fourth
position for off. The voltmeter selector switch shall also have 4 positions. Three positions shall
be used to measure phase-to-phase voltage and fourth shall be OFF position.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
10.4 Type and shop tests shall be witnessed by an inspector of EIL / Owner or of an agency
authorised by the owner. Prior notice of minimum 4 weeks shall be given to the inspector for
witnessing the tests.
10.5 Acceptance Tests
Acceptance tests shall be as follows:
10.5.1 A general visual check and dimensional check shall be carried out. This shall cover
measurement of overall dimension, location, number and type of devices, location and
connection of terminals, etc,
10.5.2 Manual and electrical operation of Circuit Breakers. / Relays shall be checked under the worst
conditions of auxiliary supply voltage.
10.5.3 Verification of bus bar supports with respect to type tested panel drawings, provision for
external cable termination and bus duct flange dimensions.
10.5.4 Make of components.
10.5.5 Dry insulation test with power frequency voltage shall be conducted for the power, control and
auxiliary circuits.
10.5.6 Insulation resistance of the main and auxiliary circuits shall be checked before and after power
frequency voltage withstand test.
10.5.7 Operation check shall be carried out for every control function /interlocks as per the schematic
diagrams by manually simulating fault conditions and operation of control switches/relays etc.
10.5.8 Relay operation check through secondary injection.
10.5.9 Communication check between relays and data concentrator/ MMI.
10.5.10 MMI operation and functional check.
10.5.11 For equipment bought from other sub-suppliers, certified test reports of tests carried out at the
manufacturer's works shall be submitted. Normally all routine tests as specified in the relevant
standards shall be conducted by the sub-supplier at his works.
10.5.12 Interchange ability of similar modules shall be checked on a random basis for draw out
switchboards.
11.0 PACKING AND DESPATCH
All the equipment shall be divided into several shipping sections for protection and ease of
handling during transportation .The equipment shall be properly packed for selected mode of
transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polyethylene sheets
before being placed in wooden crates /cases to prevent damage to the finish. Crates /cases
shall have skid bottoms for handling. Special precaution notations such as 'Fragile', 'This side
up', 'Centre of gravity', 'weight', Owner's particulars, Purchase order number etc. shall be
clearly marked on the package together with other details as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
should be suitable for outdoor storage in areas with heavy rains and high ambient temperature
unless otherwise agreed.
*at bide
fuR feitu
SPECIFICATION
FOR
BATTERY CHARGER
Abbreviations:
AC Alternating Current
Ah Ampere-hour
BIS Bureau of Indian Standards
BS British Standard
CEA Central Electricity Authority
CFL Compact Fluorescent Camp
CRCA Cold Rolled Cold Annealed
DC Direct Current
DCDB Direct Current Distribution Board
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
IP Ingress Protection
IS Indian Standard
LED Light Emitting Diode
MCB Miniature Circuit Breaker
MCCB Moulded Case Circuit Breaker
MR Material Requisition
MSL Mean Sea Level
NEMA National Electrical Manufacturers Association
Ni-Cd Nickel Cadmium
PO Purchase Order
PVC Poly Vinyl Chloride
RFI Radio Frequency Interference
RMS Root Mean Square
UPS Uninterrupted Power Supply
V Volt
VDE Verband Der Elecktrotechniker, Elektronik and Information stechnik
VRLA Valve Regulated Lead Acid
CONTENTS
1.0 SCOPE 4
1.0 SCOPE
This specification covers the design, manufacture, testing at manufacturer's works, packing
and supply to site of Battery Chargers and Distribution Boards.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the requirements of latest revision of the following
standards issued by BIS (Bureau of Indian Standards) :
IS 5 Colours for ready mixed paints and enamels.
IS 1248 Direct acting indicating analogue electrical measuring instruments and
accessories.
IS 3700 Essential rating and characteristics of semi-conductor devices.
IS 3715 Letter symbols for semi-conductor devices.
IS 4411 Code of designation of semi-conductor devices.
IS 5001 Guide for preparation of drawings for semi-conductor devices and
integrated circuits.
IS 5469 Code of practice for the use of semi-conductor junction devices.
IS 6619 Safety code for semiconductor rectifier equipment.
IS 7204 Stabilised power supplies DC output.
IS 12021 Control transformers for switchgear and controlgear for voltages not
exceeding 1000VAC.
IS 13703 Low voltage fuses for voltages not exceeding 1000VAC or 1500VDC.
IS/ IEC 60947 Low voltage switchgear and control gear.
IEC 60146 Semiconductor converters.
2.2 In case of imported equipment, the standards of the country of origin shall be applicable, if
these standards are equivalent or more stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents for
the project, the most stringent one shall prevail. However, Owner's decision in this regard
will be final and binding.
3.0 GENERAL REQUIREMENTS
3.1 The offered equipment shall be brand new with state of the art technology and a proven field
track record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment for at least 10 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to enable the end user to place order for spares and services.
site conditions as specified in the data sheet. If not specifically mentioned therein, design
ambient temperature of 40°C and altitude not exceeding 1000 m above MSL shall be
considered for all equipment.
5.0 TECHNICAL REQUIREMENTS
5.1 Input Power Supply
5.1.1 The Battery Chargers shall be suitable for input power supply as defined in the data sheet. If
not specified therein, they shall be suitable for the following input power supply:
Voltage : 415V + 10%
Frequency : 50 Hz + 3%
In addition to the above variations, the input voltage may be subject to transient variations
comprising of voltage dips up to 20% of normal voltage during motor start-up, voltage
interruptions during short circuits as well as frequency variations due to large motor start-up.
The Battery Chargers shall operate satisfactorily with a total harmonic distortion of up to 5%
in the input power supply.
The Battery Chargers shall also be designed to operate satisfactorily while drawing input
power from an emergency diesel generator set.
5.1.2 The incoming power supply to the Battery Charger system shall be provided by 2
independent feeders. One feeder shall supply power to each rectifier.
5.2 Battery Charger
5.2.1 Design Basis
5.2.1.1 The Battery Charger system shall have two chargers (Charger-1 & Charger-2). Both chargers
shall be of identical design and rating. The battery to be connected to the chargers shall be of
Nickel Cadmium/ flooded electrolyte Lead Acid/ VRLA type as indicated in the data sheet.
Battery Chargers for flooded Lead Acid and Nickel Cadmium batteries shall be sized to
provide quick charging of the battery within a duration of 10 hours. Battery Chargers for
VRLA battery shall be sized to provide quick charging of the battery up to 90% of rated
Amperehours within a duration of 24 hours and to 100% within 4 days. Each charger shall be
sized for the most stringent of the following duty conditions, whichever is higher:
Offline quick charging of the battery assembly. The charger shall be sized as under:
Charger rating in Amps. = 0.14 Ah(C 10) of battery (for Lead Acid battery)
= 0.2 Ah(C io) of battery (for VRLA battery)
0.2 Ah(C5) of battery (for Nickel Cadmium battery).
Online float charging of the battery assembly while feeding the complete DC load.
The charger shall be sized as under:
5.2.1.4 Filter circuits consisting of smoothing choke and condenser, complete with protection to
limit the ripple content at the output, shall be provided.
5.2.1.5 Silicon blocking diodes shall be provided in the charger output circuit to prevent back-feed
from battery into the charger and filters.
5.2.1.6 Protection against reverse battery connection and DC earth fault relay for earth leakage
detection shall be provided.
5.2.1.7 Silicon blocking diodes (min. 4 nos.) connected to 80% tap of the battery bank shall be
provided to maintain continuity in the DC supply to the load.
5.2.1.8 Internal cooling of the charger unit shall preferably be by natural ventilation. If forced air
cooling is necessary, a redundant air cooling fan shall be provided. The charger components
shall be capable of delivering their rated output with one forced air cooling fan out of
service. Under this condition, maximum continuous temperature of components shall not
exceed the permissible limits. In case of chargers with forced cooling, loss of ventilation
alarm/ trip with override facilities shall be provided.
5.2.1.9 Selection, sizing and suitability of all components used for various applications shall be
vendor's responsibility and the rating of components shall be increased, if required, to suit
associated components during execution of the order without any claim for extra price or
time.
5.2.1.10 The DC system shall be unearthed. However, a high impedance earth fault relay shall be
provided for the protection of the battery.
5.2.1.11 Each charger shall be galvanically isolated from the input power supply by providing a
double wound transformer at its input. The transformer shall be natural air cooled, dry type
suitable for location inside a panel.
5.2.1.12 An RFI filter shall be provided to suppress the radio frequency interference to permissible
limits. The production of radio frequency interference voltages shall not exceed the value of
suppression grade N' as defined in VDE-0875.
5.2.1.13 Transient/ surge protection devices shall be provided in the input circuit of chargers to
protect them against surges & voltage spikes.
5.2.1.14 The Chargers shall be designed to draw power from mains supply at a minimum power factor
of 0.85 lag while sharing the rated load in normal operating configuration.
5.2.1.15 The chargers shall be designed to ensure that the harmonic component in the input currents
are limited so as not to cause undue harmful effects on other sensitive equipment operating
on the same supply bus. Suitable filters/ harmonic traps shall be provided, as required, for
this purpose.
5.2.1.16 All breakers shall be adequately rated for the required continuous rating and breaking
capacity as applicable. Paralleling of breaker/ switch/ contactor poles to achieve the required
current rating is not acceptable. All output isolating devices shall be double pole type. The
DC contactors shall be operated with a DC control supply using ON/ OFF selector switches
and not push buttons.
5.2.1.17 All the thyristors, diodes and other power electronic devices shall be protected with high
speed semiconductor fuses. Pt co-ordination between fuse and semi-conducting power
devices shall be ensured.
5.2.1.18 The Battery Chargers shall be specifically designed to limit float and quick charging voltages
to the battery to limits recommended by the battery manufacturer. Output voltage shall be
limited to maximum +10% of nominal system voltage when the battery is float charged
while feeding the load. Vendor shall specifically ensure that the charger output voltage does
not exceed the recommended limits of operation under any conditions of internal/ external
fault or operation, including:
- Filter capacitor fuse failure of either charger
Normal operation requires that the battery assembly shall be float charged
simultaneously by both Chargers-1 & 2 while feeding the DC load, the chargers thus
operating in parallel and equally sharing the total load.
However in case of failure of either of the chargers, the other charger shall float
charge the battery while feeding the complete DC load. Faulty charger shall
automatically get disconnected from the healthy system.
In case of AC mains failure, the battery shall continue to supply the load.
The process of changeover from float to quick charging and reverting from quick to
float charging shall be selectable in Automatic or Manual mode by means of an Auto/
Manual selector switch. In Automatic mode, the changeover from float to quick
charging shall be initiated through a current sensor, set at a preset value. Similarly, the
changeover from quick to float charging shall also be automatic based on current
sensing. In Manual mode, both change over from float to quick charging and from
quick to float charging shall be performed manually using push buttons. When quick
charging mode is selected, the battery charger shall initially charge the battery under
constant current mode followed by constant voltage (finishing charging) mode or as
per the battery manufacturer's recommendation. Changeover from constant current to
constant voltage (finishing charging) mode shall be fully automatic. A backup
synchronous or digital timer shall also be provided for initiating the changeover to
float mode by default after a preset time period. The timer range shall be 0 to 24 hours
or the nearest available as per manufacturer's standard range.
In the event of failure of the charger feeding the load, when battery is being quick
charged by the other charger, continuity in DC supply shall be maintained from the
battery to the load through 80% tap of the battery bank followed by full battery
supplying the load through contactor C-2 (refer block diagram Option — I).
Interlock shall be provided to ensure that when either of the chargers is selected in
quick charging mode, it will be disconnected from both the DC load and the other
charger operating under float charging mode.
The chargers shall have facility for manual mode of operation in the event of failure of
controller under closed loop control. The selection shall be done through Auto/
Manual selector switch.
Energisation of contactor for DC critical lighting shall be initiated by means of an AC
mains failure relay complete with Auto/ Manual selector switch, On/ Off push
buttons etc.
Selection of Float / quick mode shall be Automatic or Manual based on the position of
selector switch for Auto / Manual selection.
In case of failure of either of chargers, the other charger shall float charge both the
batteries while feeding the complete DC load. Faulty charger shall automatically get
disconnected from the healthy system.
e) In case of AC mains failure, both the batteries shall continue to supply the load.
0 After restoration of power supply, one of the Charger (say Charger-1) shall float
charge Battery-1 and also feed the complete DC load while the other Charger-2 shall
quick charge Battery-2. Upon completion of quick charge of Battery-2, Charger-2
shall switchover to float mode and shall float charge Battery-2 and also feed the
complete DC load while the other Charger-1 shall switchover to quick mode and shall
quick charge Battery-1.
The process of changeover from float to quick charging and reverting from quick to
float charging mode shall be selectable in Automatic or Manual mode by means of
Auto / Manual selector switch.
In automatic mode, the changeover from float to quick charging shall be initiated
through a current sensor set at a preset value. Similarly, the changeover from quick to
float charging shall also be automatic based upon current sensing and through timer.
i) In manual mode, both the changeovers i.e. from float to quick charging and from
quick to float charging shall be performed manually using push buttons. When quick
charging mode is selected, one of the battery charger (say Charger-1) shall initially
charge the battery under constant current mode followed by constant voltage
(finishing charging) mode or as per the battery manufacturer's recommendation.
Changeover from constant current to constant voltage (finishing charging) mode shall
be fully automatic. A back-up synchronous or digital timer shall also be provided for
initiating the changeover to float mode by default after a preset time period. The timer
range shall be 0 to 24 hours or the nearest available as per manufacturer's standard
range.
In the event of failure of charger feeding the load (say Charger-1), when Battery-2 is
being quick charged by the other Charger-2, Charger-2 shall changeover to float mode
and continuity of 100% DC supply to the load shall be maintained from the Charger-2
while float charging both Battery-1 as well as Battery-2 after providing suitable time
delay.
k) In an event of AC mains failure, when one of the Charger (say Charger-1) is float
charging the Battery-1 and supplying the 100% DC load while the other Charger-2
was quick charging Battery-2, continuity of 100% DC supply to the load shall be
maintained from Battery-1 (through 100% tap). Further, Battery-2 (which was being
quick charged) shall also be made available, after providing suitable time delay, to
feed the DC load by operating in parallel with Battery-1 and sharing the total load.
1) Interlock shall be provided to ensure that when either of the chargers (say Charger-1)
is selected in quick charging mode, it will be disconnected from both the DC load as
well as the other Charger-2 operating under float charging mode.
The chargers shall have facility for manual mode of operation in the event of failure of
controller under closed loop control. The selection shall be done through Auto/Manual
selector switch.
Energisation of contactor for DC critical lighting shall be initiated by means of an AC
mains failure relay complete with Auto/Manual selector switch, On/Off push buttons
etc.
5.2.2.3 Performance
Both chargers shall be of solid state design, constant voltage and current limit type.
The output voltage shall be stabilised to within +1% of set value in float charging
mode for mains steady state voltage and frequency variation of +10% and +3%
respectively, and load variation of 10 to 100% at any temperature up to the design
ambient temperature specified in the data sheet. However, the variation in output
voltage can be up to +2% for chargers with rated output voltage up to 24V.
Under constant current quick charging condition, the DC output current shall be
maintained within +2% of set value.
The output voltage dynamic response of the charger unit with battery disconnected
shall not vary more than +10% of nominal output voltage in the event of step load of
up to 50% of the rated output. The output voltage shall be restored to a value within
the steady state limits within 250 msec.
The maximum allowable RMS ripple voltage, with battery disconnected, shall be
equal to or less than 2% of the nominal output voltage.
The maximum noise level from the chargers measured at 1 metre distance in any
position, at any load between 0- 100% with all normal cooling fans running shall not
exceed 75 dB(A).
5.2.2.4 Controls
The minimum controls shall include but not be limited to those shown in the block diagrams
(OPTION-I or OPTION-II as applicable):
5.2.2.5 Panel Metering and Indication
These shall include but are not limited to those shown in the block diagrams (OPTION-I or
OPTION-II as applicable):
LEDs provided for indication shall be cluster type with adequate brightness and minimum 2
Nos. LEDs chips per light. LEDs shall be connected in parallel and each LED chip having
diameter not less than 3mm.
5.2.2.6 Annunciation
Static type audio-visual annunciator with annunciation windows, acknowledge, test and reset
push buttons and hooter shall be provided on each charger for the following annunciations.
Any additional relays/ components, including DC undervoltage relay and current sensors,
required for this purpose shall be provided in the chargers. Facility for bypassing the audio
alarm on each charger shall also be provided.
DC under voltage
DC overvoltage
DC earth leakage
AC incoming power supply failure
AC input fuse blown-off
Thyristor/ diode failure
DC output fuse blown-off
DC battery fuse blown-off
Filter Capacitor fuse blown-off
Load on Battery (using current direction sensing with time delay)
Battery undervoltage/ Disconnected during discharge (using zero current sensing)
Cubicle fan failure/ cubicle temperature high (for chargers with forced cooling).
One summary alarm potential-free contact each for Battery, Charger-1 and Charger-2 shall
be wired to terminal block for remote annunciation.
5.3.7 All fuses shall be link type and shall be located inside the panel. Diazed fuses shall not be
accepted.
5.3.8 All power and control wiring connections within the panels shall be carried out with 660V
grade, PVC insulated, BIS marked wires having stranded copper conductors. However,
copper strip connections shall preferably be used for currents exceeding 100A. Control
wiring for electronic circuits/ components shall be through flat ribbon cable or copper wire
of minimum 0.5mm diameter. Ferruling of wires shall be as per relevant IS.
5.3.9 For all cabling external to panels, power cables shall be with aluminium/ copper conductors
and control cables shall be with copper conductors. All cable connections shall be from the
bottom of the panel. Removable bolted undrilled gland plates shall be provided along with
single compression type nickel plated brass cable glands for all external cable connections.
Separate test terminals shall be provided for measuring and testing the equipment to check
performance. All panels shall be supplied complete with tinned copper cable termination
lugs.
5.3.10 A suitably sized earth bus shall be provided at the bottom of the panels running through the
panel line up with provision for earth connections at both ends to owner's main earth grid.
All potential free metallic parts of equipment shall be suitably earthed to ensure safety.
5.3.11 The maximum height of the operating handles/ switches shall not exceed 1800 mm and the
minimum height shall not be below 300 mm.
5.3.12 All components/ devices/ feeders shall be provided with screwed nameplates and lettering
shall be of minimum 6 mm height.
5.3.13 Panels shall undergo manufacturer's standard cleaning and painting cycle. After preparation
of the under surface, the panel shall be painted with two coats of epoxy based final paint.
Colour shade of final paint shall be 631 of IS 5/ RAL 7032. All unpainted steel parts shall be
suitably treated to prevent rust formation. If these parts are moving elements, then they shall
be greased.
5.4 Cell Booster
Cell booster shall be suitable for charging one to six cells within the time duration specified
at C1.5.2.1.1. It shall be suitable for charging not only new cells before being introduced to
the battery bank but also for any treatment to be given to individual weak cells. Cell booster
shall be suitable for 240 V + 10%, 50 Hz + 3% SPN input power supply. Cell booster output
voltage shall be in the range of 0-18V and 0-12V for Lead Acid and Nickel Cadmium
batteries respectively. Cell booster shall be sized as under:
5.5.1 There shall be no common device between the two units, the failure of which could cause
shutdown of more than one charger.
5.5.2 It shall be possible to attend to any individual power circuit for maintenance without
affecting the total DC supply.
5.5.3 Series-parallel combination of smaller devices to achieve specified rating shall not be
acceptable.
6.0 INSPECTION, TESTING AND ACCEPTANCE
6.1 During fabrication, the equipment shall be subjected to inspection by EIL / Owner or by an
agency authorised by the Owner. Manufacturer shall furnish all necessary information
concerning the supply to EIL's/ Owner's inspector. Tests shall be carried out at
manufacturer's works under his care and expense.
6.2 Each Battery Charger/ DCDB/ Cell Booster shall be tested in accordance with applicable
standards. The following acceptance tests shall be performed on each Battery Charger and
DCDB as a minimum. Detailed test schedule and procedures shall be formulated by the
vendor and submitted for EIL's/ Owner's approval. Vendor shall indicate the maximum
allowable tolerance against each test parameter in line with applicable standards. All tests
shall be witnessed by owner or his authorised representative and 4 weeks prior notice shall
be given before the date of commencement of tests. In case the equipment fails to meet any
requirements of the specifications, necessary modifications/ corrections shall be made by the
vendor to ensure compliance to the specifications, and the equipment shall be retested before
acceptance. Test certificates indicating the test results shall be submitted to owner.
6.2.1 Insulation Tests
Insulation tests shall be performed as per IEC 60146-1-1.
The insulation tests shall be carried out using an AC power frequency voltage or a DC
voltage at the choice of the manufacturer. In the case of AC power frequency voltage test,
the test voltage at the frequency available in the test facility or at the rated frequency, but not
exceeding 100 Hz, shall be increased to the full value shown in the following table in not
less than 10 seconds continuously or in maximum steps of 0.05 p.u. of the full value starting
at a maximum of 0.5 p.u. The unit on test shall withstand the specified voltage for 1 minute.
In case DC voltage is used for the test, the value of DC voltage shall be equal to the crest
value of the test voltage specified in the table.
V p / /2 (Vp is the highest crest voltage to be Test Voltage (AC RMS value)
expected between any pair of terminals)
# 60 V 500 V
# 125 V 1000 V
# 250 V 1500 V
# 500 V 2000 V
6.2.2 Printed Circuit Boards
PCBs and other electronic circuits shall undergo a burn-in test for 96 hours at 50°C at a
voltage varied between the maximum and minimum supply voltage. In case of failure of any
component during testing, the tests shall be repeated after replacement of the faulty
component. Supplier's test certificates are also acceptable for the test.
6.2.3 Heat Run Test
Prior to execution of functional tests, each of the two chargers of each Battery Charger set
shall be subjected to a Heat Run test performed at rated load and voltage for a period not less
than 8 hours. The other charger of the set shall be energized under zero load current
condition throughout the test period. The temperature of electronic power devices shall be
measured and the device junction temperature shall be calculated. The calculated value shall
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
be at least 10-20°C lesser than the maximum rated junction temperature of the device with
proper ambient temperature correction applied.
6.2.4 Functional Tests
Functional tests shall be performed on each charger. If during execution of functional tests,
an electronic component of the charger is required to be replaced, e.g. due to charger
malfunction or failure of the unit to fulfil the performance requirements of the specification,
then the heat run test shall be repeated at rated current following which functional tests shall
be carried out.
6.2.4.1 Charger Testing at Constant Output Voltage
Measurements shall be carried out in the float charging mode and in the quick charging
mode. In each mode, measurements shall be carried out at nominal AC input voltage and at
zero, 50% and 100% of rated output current. Measurements at 100% rated load current shall
be repeated at 90% and 110% of nominal AC supply voltage. Measurements shall include
input AC phase voltage, frequency, current and power and DC output voltage, current and
output voltage ripple.
6.2.4.2 Charger Testing at Constant Output Current Limit
Measurements shall be carried out both in the float charging and quick charging mode. In
each mode, measurements shall be carried out when the charger is operating under DC
current limiting conditions with DC output voltage between zero and set value
corresponding to constant voltage operation. Measurements shall include DC output voltage
and current.
6.2.4.3 Auxiliary Equipment and Control Circuit Tests
The correct functioning of all measuring instruments, alarms, indications, protections and
controls mentioned in the specification shall be verified.
6.2.4.4 Parallel Operation
Parallel operation of both chargers, sharing of the load and automatic isolation of faulty
charger shall be checked.
6.2.4.5 Charger Efficiency
This shall be determined by measurement of the active power input and output at 50%, 75%
and 100% load.
6.2.4.6 Audible Noise Test
Audible noise shall be measured around each charger at 1 meter distance in at least 4 to 5
positions.
6.3 Site Acceptance Test
The Battery Chargers, DCDB and Cell Boosters shall be tested at site along with the battery.
Vendor shall perform all tests at site as per the approved SAT procedure.
7.0 PACKING & DESPATCH
All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for transportation by ship/ rail
or trailer. It shall be wrapped in polythene sheets before being placed in crates/ cases to
prevent damage to finish. The rates/ cases shall have skid bottoms for handling. Special
notations such as 'Fragile', 'This side up', 'Center of gravity', 'Weight', 'Owner's
particulars', 'PO Nos.' Etc., shall be clearly and indelibly marked on the packages together
with other details as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage in areas with heavy rains and high ambient
temperature
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved
OPTION-1
FROM 415V,TPN BUS FROM 415V,TPN BUS
CHARGER -1 P CHARGER-
0
AC POWER 'ON'
AC POWER 'ON'
o■ 0
■ ON/OFF
SEL. SWITCH 0 ON/OFF
SEL. SWITCH
•
CONT. Cl • CONT. C •
(:2)
(1-1) CHARGER
FAULT O 11:11 CHARGER
MDDE P.B.
FLOAT QUICK FLOAT QUICK
FLOAT CH. QUICK CH. CH. 'ON' CH. 'ON' FLOAT CH. QUICK CH.
CH. 'ON' CH. 'ON'
CHARGER-1 MODE P.B.
FLOAT CHARGER _ 2 MODE P.B. MODE P.B.
FLOAT
CH. ADJ CH. ADJ
QUICK QUICK
CH. ADJ 0-24HR. A/M SEL. CH. ADJ 0 -24HR. A/M SELI
SWITCH SWITCH1
PB RESET PB RESET
TRIP
11
TRIP, L
• T
• CONT,2A \IL/ \Iv CDNT.2B
• 0 •
• • •k
• l< TRIP TRIP
0
CONT.1A CDNT.IB
) SEE NOTE:-2
-
EU Y
ci1D-1171-
II vs-0
L J
50% 80%
41:14:1 elle
CONT.
C2
O 000
"'
CONT. C3 LOAD D C. BUS
( .';AA/M SEL
SWITCH
•
1
ON OFF
PB PB
CRITICAL DC FEEDER
NOTES: —
1. a) THE DC CONTACTORS SHALL HAVE A TESTED/ PUBLISHED DC RATING EQUAL TO OR EXCEEDING THE MOST
STRINGENT CURRENT CARRYING AND BREAKING REQUIREMENTS CONSIDERING ADEQUATE DESIGN MARGINS.
PUSH BUTTONS ARE NOT ACCEPTABLE IN PLACE OF SELECTOR SWITCHES FOR THE ON/OFF SWITCHING
OPERATIONS OF THE CONTACTORS.
THE DC CONTACTORS SHALL BE OPERATED WITH A DC CONTROL SUPPLY.
2. SUITABLY RATED DC MCCB CAN BE ACCEPTED IN PLACE OF SWITCH FUSE UNIT AT BATTERY OUTPUT.
I ar tlf5ltu
g INDIA LIMITED FOR 6-51-0019 Rev. 4
(411ZPI MIR2,1,13cRRA) IA Govt of India Undertaking) BATTERY CHARGER Page 15 of 15
OPTION-II
FROM 415V,TPN BUS FROM 415V,TPN BUS
AC POWER 'ON'
0 n
CHARGER-T1
0
AC POWER 'ON'
CHARGER-
0 ON/OFF
SEL. SWITCH 0 ON/OFF
SEL. SWITCH
: .0
CONT. CI CONT. CI• I
(12)
CHARGER CHARGER
(2) ; FAULT (I) FAULT
FLOAT QUICK FLOAT QUICK FLOAT CH. QUICK CH.
CH. 'ON' FLOAT CH. QUICK CH. CH. 'ON'
HARGER,MODE P.B. MODE P.D.
o••
MODE P.B. FLOAT HARGER_,MODE
FLOAT
CH. ADJ CH, ADJ
QUICK IM • • • 49
11.
QUICK A/M SEL.,
CH. ADJ 0-24HR. A/M SEL. CH. ADJ 0-24HR.
SWITCH SWITCH
PB TESTIPBI ACK
PB RESET
PB TEST PB ACK
PB RESET
Oro
co CD
a4 TRIP
7
CD
E-3 (111 TRIPI . 11
r
CONT.2A W 1;/ CONT.213
0 0 0 -0
0 00
TRIP k TRIP
CONT.1A CDNT.IB
27 NOTE-2 SEE NOTE-2
BrIEB1-1.16-14=11 B LER Y..72.16-1411}
000 I
100 0 0
SWITCH
I
ON OFF
PB PB
1
CRITICAL DC FEEDER
LTG. (PIP) (PIP)
_J
THE DC CONTACTORS SHALL HAVE A TESTED/ PUBLISHED DC RATING EQUAL TO OR EXCEEDING THE MOST
STRINGENT CURRENT CARRYING AND BREAKING REQUIREMENTS CONSIDERING ADEQUATE DESIGN MARGINS.
PUSH BUTTONS ARE NOT ACCEPTABLE IN PLACE OF SELECTOR SWITCHES FOR THE ON/OFF SWITCHING
OPERATIONS OF THE CONTACTORS.
c) THE DC CONTACTORS SHALL BE OPERATED WITH A DC CONTROL SUPPLY.
2. SUITABLY RATED, DC MCCB CAN BE ACCEPTED IN PLACE OF SWITCH FUSE UNIT AT BATTERY OUTPUT.
f~r
SPECIFICATION
FOR
HIGH VOLTAGE
INDUCTION MOTORS
\k.
t .■, -
'4•1 CV/'' 7,Q
REVISED AND ISSUED AS STANDARD SA BRB UAP/JMS SC
5 20.11.13
SPECIFICATION
REVISED AND ISSUED AS STANDARD SD BRB JMS VC
4 26.09.07
SPECIFICATION
3 09.04.02 UG AAN VPS SKG
REVISED AND RE-ISSUED
REVISED AND ISSUED AS STANDARD AAN VPS SG AS
2 01.02.97
SPECIFICATION
1 30.01.89 ISSUED AS STANDARD SPECIFICATION VPS VPS SKG RCPC
Standards Standards
Comm ittee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by
Abbreviations:
CONTENTS
1.0 SCOPE .4
5.0 PERFORMANCE 7
12.0 PAINTING 16
14.0 CERTIFICATION . 17
1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of high
voltage squirrel cage induction motors.
2.1 The squirrel cage induction motors and their components shall comply with the latest
editions of following standards issued by BIS (Bureau of Indian Standards) unless
otherwise specified:
2.2 In case of imported motors, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian Standards.
2.3 The motors shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.
2.5 In case of any conflict between requirements specified in various applicable documents,
the most stringent one shall prevail. However, owner's decision in this regard shall be
final and binding.
3.1 The offered equipment shall be brand new with state of the art technology and proven
field track record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment at least for 10 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL
before phasing out the product/spares to enable the end user for placement of order for
spares and services.
Motors shall be suitable for operating satisfactorily in humid and corrosive atmospheres
found in refineries, fertilizer, petrochemical and metallurgical plants. Service conditions
shall be as specified in the motor data sheet. If not specifically mentioned therein, a
design ambient temperature of 40°C and an altitude not exceeding 1000 meters above
mean sea level shall be taken into consideration.
Unless otherwise agreed, motors shall be designed for continuous operation at rated
output under the following conditions:
a) The terminal voltage differing from its rated value by not more than ± 6 % or
b) The frequency differing from its rated value by not more than ± 3 %
c) Any combination of (a) and (b)
4.3 Starting
a) Motors shall be designed for direct on line starting or other method of starting as
specified in datasheet.
b) Motors shall be designed for re-acceleration with full load after a momentary loss
of voltage with the possibility of application of 100% of the rated voltage when the
residual voltage has dropped down to 50% and is in phase opposition to the applied
voltage.
c) Motors shall be designed to allow the minimum number of starts on full load
indicated in Table below:-
d) Unless otherwise specified, the locked rotor withstand time under hot condition at
100% voltage (time tE for increased safety i.e. Ex e motor) shall be minimum 5
seconds more than the starting time at 100 % voltage, under specified load
conditions.
4.4 Unless otherwise stated in the motor data sheet, motors shall be suitable for starting at
80% of the rated voltage against the torque speed characteristics of the driven equipment.
a) Starting torque and minimum torque of the motor shall be compatible with the
speed torque characteristics of the driven equipment under specified starting and
operating conditions.
b) For heavy duty drives such as blowers, crushers, compressors etc., high starting
torque motors shall be provided.
This shall be checked against the speed torque characteristics of the load and the
thermal withstand characteristics of the motors.
4.5 The pull out torque at rated voltage shall be not less than 175 percent of the rated load
torque with no negative tolerance. In case of motors driving equipments with pulsating
loads (e.g. reciprocating compressors), the minimum value of the pull out torque at 80%
of rated voltage shall be more than the peak value of the pulsating torque and the current
pulsation shall be limited to 40%.
Unless otherwise agreed, the pull out torque shall not exceed 300% of the rated load
torque.
Motors shall preferably be suitable for either direction of rotation. In case unidirectional
fan is provided for motors, direction of rotation for which the motor is designed shall be
permanently indicated by means of an arrow. Any alteration required for obtaining a
change in the direction of rotation such as reversal of the fan, must be clearly specified.
Motors which are suitable for only one direction of rotation shall have this direction of
rotation clearly indicated on the motor together with the phase sequence of the terminals
associated with this rotation in indelible marking. Motors suitable for bi-directional
rotation shall be provided with a double headed arrow. Directional arrow should be
manufactured from corrosion resistant material.
Normally, clockwise rotation is desired as observed from the driving (coupling) end,
when the terminals ABC are connected to a supply giving a terminal phase sequence in
the order ABC. Counter clockwise rotation of the motor shall be obtained by connecting
the supply to terminals so that the phase sequence corresponds to the reversed
alphabetical sequence of the terminal letters. Ample space shall be provided at the
terminal box for interchanging external leads C and A for this purpose.
5.0 PERFORMANCE
5.1 Motors shall be rated for continuous duty (S1 ), unless otherwise specified.
5.2 Motors shall have adequate torque to accelerate the load from zero to full speed under the
specified starting and operating conditions.
5.3 Starting current shall be 500% subject to IS/IEC tolerance for motors up to 1000 kW. For
motors above 1000 kW, it shall be agreed with purchaser for each case.
5.4 In particular cases, when the starting current is to be limited, care shall be taken such that
the design values of torque meets the load requirement while at the same time complying
with clause 4.3 above of this specification.
5.5 In particular cases, when the starting with reduced voltage is specified, care shall be taken
such that the design values of torque meets the load requirement while at the same time
complying with clause 4.4 and 4.5 above of this specification.
5.6 Motors fed by variable frequency drive shall additionally meet the following requirements:
5.6.1 The motors shall be suitable for the current wave forms produced by the power supply
including harmonics generated by the drive.
5.6.2 The motors shall be designed to operate continuously at any speed over the range (1—
100%) of rated speed or as specified in data sheet. The characteristics shall be based on the
application — in terms of constant torque / variable torque as per the driven equipment.
Additional cooling fan shall be provided if required to limit the temperature rise to
specified limits.
5.6.3 The motors shall withstand torque pulsation resulting from harmonics generated by the
solid state power supply.
5.6.4 The motors required to be transferred to DOL bypass mode shall be rated for specified
variations in line voltage and frequency.
6.1 Windings
6.1.1 Motors shall be provided with class-F insulation. The permissible temperature rise above
the specified ambient temperature shall be limited to those specified in the applicable
Indian Standards for class-B insulation.
6.1.2 The windings, along with the stator, shall be tropicalised and shall be vacuum
impregnated(resin poor type).
Winding shall be adequately braced to prevent any relative movement during operation. In
this respect, special care shall be taken for the stator windings of direct-on-line starting
squirrel cage motors. Insulation shall be provided between coils of different phases which
lie together.
6.1.3 Core laminations must be capable of withstanding burnout for rewind at 400°C without
damage or loosening.
In case of motors driving equipment with pulsating loads, special attention shall be paid
to the joints of rotor bars and end rings to avoid premature failures due to induced fatigue
stresses.
For Ex n and Ex e motors, the conductor insulation must be carried right up to the
terminal clamp.
6.1.4 Motors shall be designed to withstand impulse voltages specified in applicable Indian
Standards/relevant IEC. The wave shape shall be as per IS/relevant IEC.
6.1.5 Windings of motors shall be star connected. For VFD fed motors, the main winding
connected in `Delta' can also be considered acceptable subject to motor manufacturer
having adequate proven track record.
6.2.1 The ends of the winding shall be brought out into a terminal box. The terminations shall
be by means of clamp type bushing or bushings with adequately sized bolted terminals.
Line terminals shall be properly insulated from the frame with material resistant to
tracking.
6.2.2 The terminal box shall be located on the right hand side viewed from the driving
(coupling) end. Unless otherwise specified, the terminal box shall be suitable for side
cable entry. The size of the cable end boxes shall be large enough to provide a minimum
distance of 600 mm between cable gland plate and terminal lug.
6.2.3 The neutral point of the star windings shall also be brought out to a separate terminal box.
This shall house the current transformers for differential protection of motors wherever
required and shall be located on the opposite side of main terminal box.
6.2.4 The main and neutral terminal box shall be of fabricated sheet steel. The main terminal
box shall be phase segregated type, unless otherwise agreed.
Motors can have elastimold phase insulated terminals in a common box. Ex d type (flame
proof) motors can have phase insulated terminal box of Exd rating whereas Ex p type
(pressurized) motors can have phase insulated terminal box of Ex d/Ex p rating. Ex d
(Flameproof) motors with non phase segregated & non phase insulated flameproof
terminal box duly tested at independent test laboratory can be considered acceptable
subject to motor manufacturer having adequate proven track record.
6.2.5 The terminal box must be of robust construction, with necessary clearance, creepage
distances between live parts and between live parts to earth considering air insulation and
without any compound filling.
6.2.6 The terminal box shall be provided with pressure relief flaps/devices for increase safety
i.e. Ex e motors, non-sparking i.e. Ex n motors and safe area motors, as per
manufacturer's standard.
6.2.7 The terminal box shall be capable of withstanding the fault current for a period of 0.25
seconds specified in the motor data sheet.
6.2.8 Appropriate phase markings as per IS shall be provided inside the terminal box. The
markings shall be non-removable and indelible.
6.2.9 The terminal box shall be provided with entries for suitable cable glands corresponding to
the size of the specified cables.
Equipment and accessories provided shall conform to the hazardous area classification
and the environmental conditions as specified in the motor data sheet.
6.2.10 An adequately sized earth terminal shall be provided for cable armour termination. It is
essential that all metal parts (mounting rail and cable glands) are bonded and connected to
the earth system. Bonding straps are also required across joints on non-active parts.
6.2.11 Separate terminal boxes shall be provided for space heaters, resistance temperature
detectors and vibration probes.
6.2.12 Main and neutral terminal box covers must be provided with handles to facilitate easy
removal.
6.3.1 All Motors shall be suitable for installation directly outdoor and must have degree of
protection corresponding to IP-55 as per IS.
6.3.2 All internal and external metallic parts, which can come into contact with cooling air
(Piping, air supply and discharge conduits, protective grills air deflectors, filters and
supports etc.) shall be of corrosion resistant material or appropriately treated to resist
corrosive agents which may be present in the atmosphere. Screws and bolts shall be of
rust proof material or protected against corrosion.
6.3.3 Effective equipotential bonding straps to guard against the occurrence of sparks due to
presence of circulating currents shall be provided in type Ex n, Ex e and Ex p motors.
6.4.1 Motors shall have grease lubricated ball or roller type bearings or of the manufacturer's
standard type. However, 2 pole motors above 750 kW rating shall be provided with
sleeve bearings as a minimum. Sleeve bearings when provided shall be of proven design.
6.4.2 The bearings shall be chosen to give a minimum L- 10 rating life of 5 yrs. (40,000 hrs) at
rated operating conditions.
(The L -10 rating life is the number of hours at constant speed that 90 % of a group of
identical bearings will complete or exceed before the first evidence of the failure ).
6.4.3 Where bearing supports are attached to the motor casing adequate bracing shall be
provided on these supports to reduce vibrations and ensure long life of the bearings.
Bearings shall be adequate to absorb axial thrust in either direction produced by the motor
itself or due to shaft expansion.
6.4.4 Motor bearings exposed to high temperatures (e.g. motors for hot oil/boiler feed pumps)
shall have adequate provisions for cooling of bearings.
6.4.5 Vertical motors shall be provided with thrust bearings suitable for the load imposed by
the driven equipment.
Bearings shall be capable of grease injection from outside without removal of covers.
The bearing boxes shall be provided with labyrinth seals, to prevent loss of grease or
entry of dust or moisture. When grease nipples are provided, these shall be associated,
where necessary, with appropriately located relief devices, which ensure passage of
grease through the bearings.
Sleeve type bearings shall be fitted with oil rings for continuous lubrication. The oil
reservoirs shall have a form suitable for allowing settling of any solids or residual
particles contained in the oil.
The covers shall be provided with suitable openings for adding and draining oil, together
with an overflow plug and level indication. The shaft shall have perfect seals so as to
prevent entry of dust or moisture.
The oil lubrication system shall be independent of the driven machine. Common
lubrication system for the driven equipment and the motor can be accepted provided it is
separate from the seal oil system. The common lubrication system shall be provided with
suitable degassing equipments to extract gas reducing the probability of gas entering the
motor.
In the independent lubrication system, oil supply shall be guaranteed by one of the
following methods:
With a mechanical pump co-axial with the motor and supplemented by a separate
electric motor driven pump for initial lubrication during start up and stopping
operations.
With a separate electric motor driven pump. In this case the lubricating system
shall consist of two identical motor driven pumps, one running and one acting as
standby.
In addition to the pumps, the lubrication system shall be supplied complete with the
following as a minimum:
a) An oil cooler of shell and tube type with tubes of inhibited admiralty brass.
Internal coolers shall not be accepted. To prevent the oil from being
contaminated, if the cooler fails, the oil side operating pressure shall be higher
than the water side operating pressure.
The capacity to avoid frequent filling, to provide adequate allowance for system
rundown and to provide a retention time of at least 3 minutes to settle
Provision to eliminate air and minimize flotation of foreign matter to the pump
suction
Fill connections, reflex type level indicators and breathers suitable for outdoor
use
Sloped bottoms and connections for complete drainage
Clean out openings as large as is practicable
A bypass line that returns below the oil level to eliminate aeration and static
electricity
A thermostat with two electrical contacts for alarm & tripping in case of high oil
temperature
e) The motor driven auxiliary pumps shall be provided with suction stainer and an
automatic/manual control system arranged to start automatically on low oil
pressure and with manual shutdown only
g) Temperature gauges (with thermowells) in the reservoir, after the oil cooler and
each bearing drain line
i) A pressure gauge (valved for removal) for each pressure level and a pressure
differential indicator to measure filter pressure drop
k) The oil pumps shall have steel casings unless they are enclosed in a reservoir. All
other oil containing pressure components shall be steel.
A control panel shall be provided for operation & control of the lubrication system. The
control panel shall include fuses, electrical contactors and thermal relays for the
protection and operation of the motor driven pumps, push-buttons, auxiliary relays and
timer relays for the automatic and manual starting up and shutting down of the oil pump.
Equipment and accessories provided shall conform to the hazardous area and the
environmental conditions specified in the motor data Sheet.
Armoured cables suitable for high temperature duty shall be used for extemal electrical
connections between the control panel and the lubrication system.
Induced voltage at the shaft end of the motor at no load shall not exceed 250 mV r.m.s.
for roller and ball bearings and 400 mV r.m.s. for sleeve bearings. The non driving end
bearing shall be insulated from the motor frame to avoid circulating current.
The insulated bearing end shield or pedestal shall bear a prominent warning and
manufacturer shall provide detailed drawings showing insulation arrangement.
All motors shall preferably be self-ventilated. Motors with higher outputs having
manufacturer's standard designs using forced ventilation cooling or closed circuit cooling
employing external coolants may also be considered.
A11 motors shall be fan cooled. The fans shall be of corrosion resistant material and
appropriately protected. For fertilizer plants, brass or bronze are not permitted materials.
The material of fan for motors to be used in hazardous areas shall be anti-static and non-
sparking type.
Motors for installation in dusty atmospheres or in the presence of sand, fuels or other
suspended solid particles in the air shall be fitted with filters for the cooling air. The
filters shall be easily accessible for inspection and removable for cleaning and re-use. The
material of the filters and supports trays shall be rust proof or protected against oxidation
or corrosion.
Motors with forced ventilation shall be equipped with two motor driven fans each capable
of supplying the full quantity of cooling air required by the motor at full load.
Where air cooler design permits provision of one fan only; the second fan shall be
supplied loose. Cooler design shall allow easy replacement of fan in such case.
The ventilating system shall include the flanges for the air intake and the mating flanges
for the discharge ducts. An airflow indicator as described in paragraph 7.3 (a) shall also
be provided.
Motors and fans used for forced ventilation shall conform to the hazardous area
classification and environmental conditions specified in the motor data sheet.
6.5.3 Motors with closed circuit cooling with water to air heat exchangers
The material of the heat exchangers shall be corrosion resistant (e.g. cupro-nickel alloy,
muntz metal, admiralty brass) and suitable for the type of water used. The heat
exchangers shall be designed for minimum water pressure of 5 kg / cm 2 and with head
losses not greater than 0.5 kg / cm 2 , unless otherwise agreed.
The heat exchangers shall be arranged by the side(s) of the motor, if possible. Screens
shall be provided to protect the motor windings from water leaks or leakage in the tubes.
Suitable drains shall be fitted for draining water in case of leakage. The cooling system
shall include the trip and alarm devices mentioned in paragraph 7.3 (b). Heat exchangers
for identical motors shall be interchangeable.
6.5.4 Motors with closed circuit cooling with air to air heat exchangers
The heat exchanger tubes shall be of steel or extruded aluminium. All exposed surfaces of
the heat exchanger and of the motors shall be safeguarded against corrosion by
immersion in varnish followed by baking.
Joints between the heat exchanger and the main body of the motor shall be sealed by
weather-proof gaskets.
6.6 Rotor
The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration
level and a long service Life to the bearings. The accepted values of vibrations for a motor
at rated voltage and speed shall not exceed those given in the IS. The shaft ends shall be
provided with suitably threaded hole or holes to facilitate the assembly or removal of
couplings and bearing races.
Motors shall be provided with a single, bare shaft extension with key way and key.
Motor shaft shall be sized to withstand 10 times the rated design torque.
All motors shall be provided with lifting facility (i.e. hooks etc.) of adequate capacity.
For motors provided with heat exchangers, lifting facility shall also be provided for the
heat exchanger.
6.9 Earth terminals
Two earth terminals shall be provided on the frame of each motor at diametrically
opposite points. Minimum size of the stud shall be 12 mm. Necessary nuts and spring
washers shall be provided for earth connection. These earth terminals shall be in addition
to the earth terminals provided in the terminal box for earthing of the armour.
All electrical contacts for the devices described below (e.g. at sections 7.3 & 7.4) shall
have a current carrying capacity not lower than 5 A and a minimum interrupting capacity
of 1 A at 220 V DC or 5 A at 240 V AC.
The contacts shall be located in explosion proof or totally sealed housing according to the
type of motor enclosure. The cable ends shall be brought together to the terminal box.
Any external connections between the housing containing the relay contacts and the
terminal box shall be carried out by insulated copper wires in steel conduits or by PVC
insulated, armoured, copper conductor cables with cable entries through double
compression type cable glands.
Motors with outputs greater than 750 KW or those provided with filters for cooling air
irrespective of output shall be provided with platinum resistance temperature measuring
devices of 100 ohms resistance at 0°C and a temperature co-efficient of 3.85 x 10 -3
located in suitable positions to measure the winding temperature. A minimum of three
(one per phase) detectors shall be provided between the coil sides to measure the winding
temperature and three (one per phase ), preferably at the base of the slots, to measure core
temperature, each placed 120° apart. TETV motors may not be provided with core
temperature detectors.
A separate terminal box shall be provided for the temperature detectors for hook up with
a remote located control / monitoring unit.
a) Two mercury bulb type, indicating dial thermometers for checking of bearing
temperatures.
b) For motors with output greater than 750 KW, a resistance type of temperature
measuring device shall be provided for bearings with connections terminating in
the common terminal box for winding temperature detectors.
Motors with forced ventilation and those with air water heat exchangers shall be provided
with:
a) An airflow circulation indicator with electrical trip contacts that operate if the
flow of cooling air is interrupted or is inadequate.
b) A cooling water flow circulation indicator with electrical trip contacts, which
close if the flow of cooling water is interrupted or is inadequate. The indicator
shall be located on the discharge piping of the heat exchanger.
All pressurized motors (Type Ex p) shall be provided with a control panel for controlling
the initial purging and pressurization of the motor. The pressurization control panel shall
be mounted on the motor itself and shall be suitable for the hazardous area classification
specified in the motor data sheet.
The panel shall be complete with but not limited to the following items :
Timers
Push buttons for purging/pressurization
Solenoid valves/dampers
Indicating lamps for purging ON, purging OVER etc.
Pressure switches and flow switches with alarm and trip contacts.
Unless otherwise specified, motors rated 1500 KW and above shall have differential
protection and shall be equipped with current transformers suitably designed for
installation in the neutral terminal box.
Unless otherwise specified, the CTs shall be supplied along with the motor and mounted
in the terminal box, which shall be suitable for housing the CTs and providing the
necessary connections. CT terminals shall be brought out to a separate auxiliary terminal
box.
These transformers shall have a secondary current of 1 A, and the characteristics of the
CTs (Vk, RcT and Im) shall be finalized at detailed engineering stage in consultation with
the purchaser. CT ratio shall be as indicated in the motor data sheet.
All motors shall be provided with 240 V anti-condensation heaters, sized and located so
as to prevent condensation of moisture during shut down periods. The heaters shall
remain 'ON' when the motor is not in service and shall not cause damage to the windings.
The heater leads shall be brought out to a separate terminal box of the same specification
and grade of protection as the main power terminal box.
A warning label with indelible red inscription shall be provided on the motor to indicate
that the heater supply shall be isolated before carrying out any work on the motor.
Motors with special features (e.g. motors with single bearing, explosion proof and
increased safety motors) shall be provided with a set of spanners and special tools,
required for dismantling and maintenance of the motor.
8.4 Motors shall be supplied complete with double compression Nickel plated brass (or
Aluminum, if specifically required) cable glands, crimp type tinned Cu cable lugs for all
power, space heater and auxiliary cables (for the specified cable sizes) and first filling of
lube oil for forced lubricated bearings.
8.5 Auxiliary motors, if any, shall be as per relevant Indian / International standards and shall
be suitable for the hazardous classification as specified in the motor data sheet.
A stainless steel name plate manufactured from series 300 stainless steel and having
information as per IS shall be provided on each motor. In addition to the motor rating
plate, a separate number plate for motor tag number shall be fixed in a readily visible
position. This number shall be as per the motor data sheets.
The permissible noise level shall not exceed the stipulations laid down in IS.
Motor vibrations at bearing housing shall be within the limits of IS, unless otherwise
specified for the driven equipment. Limits of shaft vibration for motors with sleeve
bearings shall be as per IEC-60034-14.
Two and four pole motors having sleeve bearings with forced oil lubrication shall be
provided with proximity probes to measure the shaft vibration adjacent and relative to the
bearings.
The first actual critical speed of stiff rotors shall not be lower than 125% of the
synchronous speed. For flexible rotors, this shall be between 60% and 80% of the
synchronous speed. The second actual synchronous speed shall be above 125% of the
synchronous speed.
12.0 PAINTING
All metal surfaces shall undergo manufacturer's standard cleaning /painting cycle. After
preparation of the under surface, the equipment shall be painted with two coats of epoxy
based final paint. Color shade of final paint shall be 632 of IS: 5/ RAL-7035. All
unpainted steel parts shall be suitably treated to prevent rust formation. If these parts are
moving elements, then these shall be greased.
13.1 All tests shall be carried out at manufacturer's shop under his care and expense.
13.2 The manufacturer shall submit all internal test records of the tests carried out by him on
the bought-out items, motor sub-assembly and complete motor assembly.
13.3 All the type, routine and other acceptance tests shall be witnessed by EIL Inspector/TPIA
(appointed by OEM supplier.)
13.4 Tests certificates duly signed by the EIL Inspector/TPIA (appointed by OEM supplier.)
shall be a part of final documentation.
The following type tests (on one motor of each rating and frame size) shall be carried out
as per applicable Indian Standards and shall form part of acceptance testing :
a) Full load test and measurement of voltage, current, power & slip
b) Measurement of starting torque, starting current, full load torque and pull out
torque
c) Measurement of efficiency and p.f. at 100%, 75% and 50% load
d) Temperature rise test
e) Momentary overload test
f) Tan delta test
g) Measurement of noise level
i) Over speed test
i) Measurement of radial & axial clearance between fan & stationary parts &
measurement of radial air gap (if provision for measurement is not available in
fully assembled motor stage records/calculations to be reviewed by Inspection)
13.6 The manufacturer shall submit the following certificates for verification by the
EIL/Owner's Inspector:
a) Test certificate from recognised testing laboratory for area classification.
b) BIS certificate for indigenous FLP motors and accessories as applicable.
c) CCOE/PESO approved certificates for motors and accessories as applicable
d) Fault level of terminal box
e) Degree of protection of enclosure
f) Impulse test certificate for coils
g) Hydraulic test certificate for coolers
13.7 For VFD fed motors, all tests as specified in the VFD specification shall be followed in
addition to the above.
13.8 In case any of the Type & Routine tests mentioned above can not be carried out due to
manufacturer's test bed limitations etc., altematively calculations to establish the required
parameters as per International codes eg IEC, JEC etc. may be accepted which shall be
furnished to attending inspector. However, acceptance of calculations in place of actual
test shall be with prior approval (agreement between motor manufacturer & purchaser).
13.9 Though the motors shall be accepted on the basis of the satisfactory result of the testing at
the shop, it shall not absolve the Vendor from liability regarding the proper functioning of
the motors coupled to the driven equipment at site.
14.0 CERTIFICATION
The motors and associated equipment shall have test certificates issued by recognised
independent test house (CIMFR/ CPRI/ ERTL/ Baseefal LCIE/ UL/ FM or equivalent).
All indigenous motors shall conform to Indian standards and shall be certified by Indian
testing agencies. All motors (indigenous & imported) shall also have valid statutory
approvals (e.g. PESO, DGMS etc. as applicable for the specified location. All indigenous
flameproof motors shall have valid BIS license and marking as required by statutory
authorities.
All the equipment shall be divided into several sections for protection and ease of
handling during transportation. The equipment shall be properly packed for
transportation by ship/rail or trailer. The equipment shall be wrapped in polythene sheets
before being placed in crates/cases to prevent damage to finish. Crates/cases shall have
skid bottom for handling. Special notations such as Tragile', `This side up', `Centre of
gravity', `Weight', `Owner's particulars', `PO Nos.' etc. shall be clearly marked on the
package together with other details as per purchaser order.
The equipment may be stored outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage in areas with heavy rains/high ambient
temperature, unless otherwise agreed.
f-~
SPECIFICATION
FOR
MEDIUM VOLTAGE
INDUCTION MOTORS
Abbreviations:
CONTENTS
1.0 SCOPE 4
5.0 PERFORMANCE 6
9.0 PAINTING 14
11.0 CERTIFICATION 15
1.0 SCOPE
This specification covers the design, manufacture, testing, packing and supply of three phase
medium voltage squirrel cage induction motors for line voltages upto 1000V AC.
2.1 The squirrel cage induction motors and their components shall comply with the latest editions
of following standards issued by BIS.
2.2 In case of imported motors, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian Standards.
2.3 The motors shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.
2.4 In case Indian Standards are not available, standards issued by IEC/ BS/ VDE/ IEEE/
JEC/NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents, the
most stringent one shall prevail. However, owner's decision in this regard shall be final and
binding.
3.1 The offered equipment shall be brand new with state of the art technology and proven field
track record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment at least for 10 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to ensure the end user for placement of order for spares and
services.
Motors shall be suitable for operating satisfactorily in humid and corrosive atmosphere found
in refineries, petrochemical, fertilizer and metallurgical plants. Service conditions shall be as
specified in the motor data sheet. If not specifically mentioned therein, a design ambient
temperature of 40°C and an altitude not exceeding 1000 meters above mean sea Level shall be
taken into consideration.
Unless otherwise agreed, motors shall be designed for continuous operation at rated output
under the following conditions:
a) The terminal voltage differing from its rated value by not more than V 6 % or
b) The frequency differing from its rated value by not more the V 3 % or
c) Any combination of (a) and (b)
4.3 Starting
d) Al1 motors shall be suitable for starting under specified load conditions with 75 % of
the rated voltage at the motor terminals.
Motors shall be suitable for either direction of rotation. In case unidirectional fan is provided
for motors, direction of rotation for which the motor is designed shall be permanently
indicated by means of an arrow. When a motor is provided with bi-directional fan, a double-
headed arrow should be provided.
Normally, clockwise rotation is desired as observed from the driving (coupling) end, when the
terminals ABC are connected to a power supply giving a terminal phase sequence in the order
ABC. Counter-clockwise rotation of the motor shall be obtained by connecting the power
supply to terminals so that the phase sequence corresponds to the reversed alphabetical
sequence of the terminal letters. Ample space shall be provided at the terminal box for
interchanging any two external leads for obtaining the reverse phase sequence.
5.0 PERFORMANCE
5.1 Unless otherwise specified, Motors shall be rated for continuous duty (S1).
5.2 Unless otherwise specified, the starting current (as % rated current) shall not exceed 600%
(subject to IS tolerance). However, motors upto 22KW motors having starting current upto
700% of rated current (subject to IS tolerance) shall also be acceptable.
5.3 In particular cases, when the starting current is to be limited, care shall be taken such that the
design values of torque meets the load requirement while at the same time complying to
clause 4.3 above of this specification.
5.4 In particular cases, when the starting with reduced voltage is specified, care shall be taken
such that the design values of torque meets the load requirement while at the same time
complying to clause 4.3 above of this specification.
5.5 Starting torque and minimum torque of the motor shall be compatible with the speed torque
curve of the driven equipment under specified starting and operating conditions.
In case where characteristics of driven equipment are not available while selecting the motor,
minimum starting torque shall be 110% of rated value for motors up to 75 kW and shall be
90% of rated value for motors above 75 kW.
5.6 The breakdown torque at the rated voltage shall not be less than 175 percent of the rated load
torque with no negative tolerance. the breakdown torque shall not exceed 300 percent of the
rated load torque.
In case of motors driving equipment with pulsating loads (e.g. reciprocating compressors), the
minimum value of breakdown torque at 75 percent of the rated voltage shall be more than the
peak value of pulsating torque and the current pulsation shall be limited to 40%.
5.7 Motors fed by variable frequency drive shall additionally meet the following requirements:-
5.7.1 The motors shall be suitable for the current wave forms produced by the power supply
including harmonics generated by the drive. The necessary coordination by motor
manufacturers with drive manufacturers regarding harmonics generated by VFD shall be taken
care and incorporated in motor design suitably.
5.7.2 The motors shall be designed to operate continuously at any speed over the range as per
process requirement with minimum range as 10-100% of rated speed or as specified in data
sheet. The characteristics shall be based on the application - in terms of constant torque /
variable torque as per the driven equipment. Additional cooling fan shall be provided if
required to limit the temperature rise to specified limits.
5.7.3 The motors shall withstand torque pulsation resulting from harmonics generated by the solid
state power supply.
5.7.4 The motors required to be transferred to DOL bypass mode shall be rated for specified
variations in line voltage and frequency.
5.8 The minimum values for performance characteristics of motors shall be as per Table 1-4 below
TABLE 1
Values of Performance Characteristic of 2 Pole Induction Motors
Rated Frame Full Full Breakaway Breakaway Nominal
output Designation Load Load Torque in Current in Terms Efficiency
speed Current terms of Full of full Current,
load Torque Equal or Below
(Refer cl. 5.2)
Min Max
kW Rev/min Amp Min (Percent) (Percent) (Percent)
TABLE 2
Values of Performance Characteristic of 4 Pole Induction Motors.
NOTE: - Output to frame size relation is maintained in accordance with IS 1231 for all
motors, except those marked as 11 , where in frame size indicated is `preferred frame size'.
TABLE 3
Values of Performance Characteristic of 6 Pole Induction Motors.
NOTE: - Output to frame size relation is maintained in accordance with IS 1231 for all
motors, except those marked as 11 , where in frame size indicated is `preferred frame size'.
TABLE 4
Values of Performance Characteristic of 8 Pole Induction Motors.
NOTE: - Output to frame size relation is maintained in accordance with IS 1231 for all
motors, except those marked as 11 , where in frame size indicated is `preferred frame size'.
6.1 Windings
6.1.1 Unless otherwise specified, Motors shall be provided with class 'B' insulation as a minimum.
In case of motors with class 'F' insulation, the permissible temperature rise above the
specified ambient temperature shall be limited to those specified in the applicable Indian
standards for class 'B' insulation.
6.1.2 The winding shall be tropicalised. The windings shall preferably be vacuum impregnated.
Alternately the windings shall be suitably varnished, baked and treated with epoxy gel for
operating satisfactorily in humid and corrosive atmospheres.
6.1.3 Windings shall be adequately braced to prevent any relative movement during operation. In
this respect, particular care shall be taken for the stator windings for direct-on-line starting
squirrel cage motors. Insulation shall be provided between coils of different phases that lie
together. Core laminations must be capable of withstanding burnout for rewind at 400EC
without damage or loosening.
6.1.4 In case of motors driving equipment with pulsating loads, special care shall be taken for the
joints of rotor bars and end rings to avoid premature failures due to induced fatigue stresses
6.1.5 The windings shall be connected in delta. However, for motors rated 2.2 kW and below, star
connection may be accepted. In case of motors with star-delta starting, the motor windings
shall be fully insulated for delta connection.
6.1.7 The ends of the windings shall be brought out into a terminal box. These shall be terminated
by means of terminals mounted on an insulating base made of non-hygroscopic and non-
flammable material.
6.1.6 All motors shall be with six terminals and suitable links to connect them in star or in delta
except for motors rated up to and including 2.2 kW which may be accepted with three
terminals.
6.2.1 The terminal box shall be located on the right hand side as viewed from the driving (coupling)
end. The terminal box shall have side cable entry from non-driving end. However, as a special
case, terminal box located on top may also be accepted, particularly for hazardous area
motors, in case manufacturer has only TOP mounted terminal box design which is duly
tested/certified by CIMFR and approved by PESO/CCOE for installation in hazardous area.
The terminal box design shall allow rotation in steps of 90° to facilitate cable entry from any
direction.
6.2.2 Terminal box cover shall be provided with handles to facilitate easy removal. However, for
terminal box covers weighing less than 5 kg., terminal box covers without handles can be
accepted.
6.2.3 The terminal box shall be provided with entries for suitable cable glands corresponding to the
size of the specified cable. Crimp type tinned Cu lugs and nickel-plated brass (or aluminum if
specifically required), double compression type cable glands shall be supplied along with the
motors for the specified cable sizes for power and space heater cables.
6.2.4 For flameproof motors, terminal box can be provided in increased safety `Exe' execution.
6.2.5 The terminals, cable lugs, terminal box, cable entries and cable glands shall be suitable for the
maximum cables sizes as specified below for 2 pole, 4 pole or 6 pole motors:
6.2.6 Cable sizes for motors having synchronous speeds 750 RPM and below shall be as agreed
between the purchaser and the manufacturer.
6.2.7 Cables used are of 650/1100 V grade aluminum conductor, PVC /XLPE insulated, PVC
extruded inner sheath, armoured with overall PVC sheath. However for cables up to &
including 16 mm2 cross-section, cables used may be with copper or aluminum conductor as
indicated in the motor data sheet.
6.3.1 The minimum degree of motor enclosures including terminal boxes and bearing housing shall
be IP-55 as per IS.
6.3.2 Motors for outdoor use shall be suitable for installation and satisfactory operation without any
protective shelter or canopy. Motor casing shall be provided with a suitable drain for removal
of condensed moisture except in case of flameproof motors (Type Ex d/Exde).
6.3.3 A11 internal and external metallic parts, which may come into contact with cooling air, shall be
of corrosion resistant material or appropriately treated to resist the corrosive agents, which
may be present in the atmosphere. Screws and bolts shall be of rust proof material or protected
against corrosion.
6.3.4 Unless otherwise agreed, motors shall have standard frame sizes for various output ratings as
stipulated in IS.
6.4.1 Motors shall have grease lubricated ball or roller bearings. In all cases, the bearings shall be
chosen to provide a minimum L-10 rating Life of 5 years, (40, 000 hours) at rated operating
conditions.
(The L-10 rating life is the number of hours at constant speed that 90% of a group of identical
bearings will complete or exceed before the first evidence of failure).
6.4.2 The bearings shall be adequate to absorb axial thrust produced by the motor itself or due to
shaft expansion. Motors designed to handle external thrust from the driven equipment shall be
supplied with a thrust bearing at the non-driving end.
6.4.3 In cases such as pumps for hot liquids where the driven equipment operates at high
temperatures, bearings shall be cooled by a shaft-mounted fan. This shall ensure efficient
ventilation of the bearing and disperse the heat transmitted from the driven equipment by
conduction or convection.
6.4.4 Bearings shall be capable of grease injection from outside without removal of covers with
motors in the running conditions. The bearing boxes shall be provided with necessary features
to prevent loss of grease or entry of dust / moisture e.g. labyrinth seal. Where grease nipples
are provided, there shall be associated, where necessary, with appropriately located relief
devices, which ensure passage of grease through the bearings.
6.4.5 Pre-lubricated sealed bearings may be considered provided a full guarantee is given for 4 to 5
years of trouble-free service without the necessity of re-lubrication.
A11 motors shall be self-ventilated, fan cooled. Fans shall be corrosion resistant or
appropriately protected. They shall be suitable for motor rotation in either direction without
affecting the performance of the motor. If this is not possible for large outputs, it shall be
possible to reverse the fan without affecting the balancing of the motor.
For motors operating in hazardous area, the fans shall be of an anti-static non-sparking
material.
6.6 Rotor
The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration level
and long service life for the bearings. Die cast aluminum rotors for motors in hazardous areas
may be accepted provided the same are type tested and approved by competent authorities.
Motors shall be provided with a single shaft extension with key-way and full key. Motor shaft
shall be sized to withstand 10 times the rated design torque.
Two earth terminals located preferably on diametrically opposite sides shall be provided for
each motor. Necessary nuts and spring washers shall be provided for earth connection.
A11 motors rated 30 kW and above shall be provided with 240 V anti-condensation heaters,
sized and located so as to prevent condensation of moisture during shutdown periods.
Motors with heaters installed in hazardous atmospheres (Zone-1 or Zone-2), shall conform to
the provisions of applicable Indian standards and temperature classification specified in the
motor data sheet
The heater leads shall be brought out, preferably, to a separate terminal box which shall be of
the same specification and grade of protection as the main terminal box.
A warning label with indelible red inscription shall be provided on the motor to indicate that
the heater supply shall be isolated before carrying out any work on the motor.
In addition to the motor rating plate, a separate number plate for motor tag number shall be
fixed in a readily visible position. This tag number shall be as per the motor data sheets.
The first actual critical speed of stiff rotors shall not be lower than 120 % of the synchronous
speed. For flexible rotors this shall be between 60 % and 80 % of the synchronous speed; the
second actual critical speed shall be above 120 % of the synchronous speed.
9.0 PAINTING
All metal surfaces shall undergo manufacturer's standard cleaning /painting cycle. After
preparation of the under surface, the equipment shall be painted with two coats of epoxy based
final paint. Color shade of final paint shall be 632 of IS: 5/ RAL-7035. All unpainted steel
parts shall be suitably treated to prevent rust formation. If these parts are moving elements,
then these shall be greased.
10.1 A11 tests shall be carried out at manufacturer's shop under his care and expense.
10.2 The manufacturer shall submit all internal test records of the tests carried out by him on the
bought-out items, motor sub-assembly and complete motor assembly.
10.3 The manufacturer shall carry out the following routine and acceptance tests as per applicable
Standards/ITP on all the motors.
10.4 The manufacturer shall submit the following type test certificates (one sample from each
type/rating):
a) Full load test & measurement of voltage, current, power slip, power factor, bearing,
noise
b) Efficiency & pf at 100%, 75% and 50% load
c) Temperature rise test
d) Momentary overload test
e) Vibration
f) Noise Level
g) Over speed
h) Measurement of starting torque, starting current, full load torque.
10.5 For VFD fed motors, all tests as specified in the VFD specification shall be followed in
addition to the above.
11.0 CERTIFICATION
The motors and associated equipment shall have test certificates issued by recognised
independent test house (CIMFR/ CPRI/ ERTL/ Baseefa/ LCIE/ UL/ FM or equivalent).
A11 indigenous motors shall conform to Indian standards and shall be certified by
recognised testing agencies. All motors (indigenous & imported) shall also have valid
statutory approvals (e.g. PESO, DGMS etc). as applicable for the specified location. All
indigenous flameproof motors shall have valid BIS license and marking as required by
statutory authorities.
A11 the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for selected mode of
transportation i.e. ship/rail or trailer. The equipment shall be wrapped in polythene sheets
before being placed in crates/cases to prevent damage to the finish. Crates/cases shall have
skid bottom for handling. Special notations such as `Fragile', `This nide up', `Center of
gravity', `Weight', `Owner's particulars', `PO Nos.' etc. shall be clearly marked on the
package together with other details as per purchaser for scrutiny.
The equipment may be stored outdoors for long periods before installation. The packing shall
be completely suitable for outdoor storage, in areas with heavy rains/ high ambient
temperature.
SPECIFICATION
FOR
HIGH MAST LIGHTING SYSTEM
Abbreviations:
A : Ampere
BIS : Bureau of Indian Standards
BS : British Standard
CEA : Central Electricity Authority
CRCA : Cold Rolled Cold Annealed
EIL : Engineers India Limited
ELCB : Earth Leakage Circuit Breaker
EPR : Ethylene Propylene Rubber
FGL : Finished Grade Level
GI : Galvanized Iron
HPP : Highest Pavement Point
HRC : High Rupture Capacity
ICAO : International Civil Aviation Organisation
IEC : International Electrotechnical Commission
IEEE : Institute of Electrical and Electronics Engineers
IP : Ingress Protection
IS : Indian Standard
LED : Light Emitting Diode
LM-6 : Light Metal Alloy
MCB : Miniature Circuit Breaker
NEMA : National Electrical Manufactures Association
PO : Purchase Order
PVC : Poly Vinyl Chloride
QAP : Quality Assurance Plan
TMT : Thermo Mechanically Treated
TPN : Three Phase and Neutral
V : Volt
VDE Verband Deutscher Elecktrotechniker
CONTENTS
1.0 SCOPE 4
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
t.71 (
rr ENGINEERS SPECIFICATION STANDARD SPECIFICATION No.
1.0 SCOPE
This specification defines the requirements for design, fabrication, testing at manufacturer's
works, supply, installation at site, testing and commissioning of high mast lighting system,
including supply and installation of associated cables and materials, design and supply of civil
and structural foundation and supply of all related materials.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the requirements of latest revision of the following standards
issued by BIS, unless otherwise specified.
2.2 In case of imported equipment, standards of the country of origin shall be applicable, if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of CEA Regulations and other statutory
regulations currently in force in the country.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
2.4 hi case Indian standards are not available for any equipment, standards issued by
IEC/BSNDE/ IEEE /NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between various referred standard/specification/datasheet and statutory
regulations, the most stringent requirement shall govern and decision of owner in this regard
shall be final & binding.
3.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment at least for 10 years from the date of supply.
3.3 Vendor shall give a notice for at least one year to the end user of equipment and E1L before
phasing out the product/spares to enable the end user for placement of order for spares and
services.
3.4 The high mast lighting system shall have a minimum design life of 25 years unless otherwise
specified.
The equipment and materials to be supplied & installed by the vendor shall be suitable for
continuous and trouble free operation at 40° C unless specified otherwise in the data sheet.
The high mast and other equipment and materials shall be of the best quality and shall conform
to the specifications given hereunder.
5.1 Mast
5.1.1 The high mast shall be of continuously tapered, polygonal cross section construction.
Minimum height of mast shall be 30 meters unless otherwise specified. The mast shall be
fabricated from steel plates in suitable number of sections, telescopically jointed, giving a
continuous tapered profile and presenting good visual appearance. The base flange shall be
provided with gaskets and high/medium tensile anchor bolts. The bottom section shall have
adequate sized opening with a hinged door to accommodate electric drive for winch, cable,
plug socket, etc. The opening shall be such as to permit clear access to the above components
inside the mast. The opening shall be complete with a close fitting, dust and vermin proof
door, weather protected with gaskets of durable material and provided with a heavy-duty
double locking arrangement.
5.1.2 The means for natural ventilation of the mast shall be provided.
5.1.3 Both the inner and the outer surfaces of the entire fabricated mast along with the attached
accessories shall be hot dip galvanized. The amount of galvanizing shall be 610gm per sq.
metre (85 micron uniform thickness) in accordance to IS: 2629 unless otherwise specified.
5.1.4 The whole head frame assembly shall be covered and protected by an aluminum/ galvanised
sheet steel canopy secured to the frame by stainless steel bolts and nuts. The canopy shall have
suitable prevention arrangement against entry of birds etc.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
11?-zir evaw
E1151ft INDIA LIMITED FOR 6-51-0039 Rev. 3
/mayors')
1.41L7f IA Gov[. of
in" U"dena" ) HIGH MAST LIGHTING SYSTEM Page 6 of 11
5.1.5 The mast shall have integral power tool for winch drive unless otherwise specified in the
datasheet.
5.1.6 The mast shall have stainless steel/galvanized earthing terminals at convenient location in the
base compartment and these shall be suitable for connection with 40x5mm GI strip to the
plant-earthing network unless otherwise specified.
5.1.7 Lightning rod at the top of the mast for the lightning protection of the lighting mast system as
per standard: IS-2309 shall be provided.
5.1.8 Horizontal deflection shall be limited to 1/40 of mast height at 2/3 of design wind speed as per
technical report no. 7 of Institution of Lighting Engineers.
5.1.9 The complete design of the mast and associated foundation shall be such that mast is
structurally and mechanically safe.
5.2.1 The Lantern carriage shall be of steel tubular ring type construction designed to accommodate
the specified number of lighting fixtures and balance counter weights shall be provided
wherever required. The carriage shall be fabricated in two halves jointed by bolted flanges to
enable easy removal from the erected mast for replacement and maintenance purpose.
5.2.2 The complete lantern carriage assembly shall be hot dip galvanized after fabrication. It shall
have perfect self-balance arrangement so as to avoid swing and to prevent damage to mast
surface or other installed parts, during lowering/raising operation of carriage.
5.2.3 All hardware used shall have necessary corrosion protection. The carriage shall have weather
protected IP-55 cast aluminum junction box with required number of terminals (phase, neutral
and earth) for connection to the designed number of flood light fittings and associated control
gear boxes fixed on the carriage.
5.2.4 Unless otherwise specified, Lantern carriage shall be suitable for accommodating a minimum
of 12 numbers of flood light fixtures. The number, wattage and type of lighting fixture of the
high mast shall be supplied as specified in job specification/data sheet.
5.2.5 The flood light fixtures shall have die cast aluminum body with facility for lamp centering and
focusing and shall be provided with angle indicator for aiming, and also with anodized and
polished aluminum reflector with control gearbox.
5.2.6 Each high mast shall have minimum two numbers aviation obstruction lighting fixtures. The
lighting fixtures shall have cluster LED lamps of medium intensity (as per ICAO regulations)
and of red color.
5.2.7 Provision shall also be available to test the luminaries while lantern carriage is in lower
position by connecting the plug to the receptacle provided on the lantern carriage.
5.3.1 For lowering and raising of lantern carriage assembly, a winch arrangement shall be fixed in
the bottom of the mast. This shall have provision to operate both manually and electrically.
5.3.2 The winch shall be suitable to handle the weight of the lantern carriage assembly with lighting
fixtures and all other accessories, with factor of safety not less than two unless otherwise
specified.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
5.3.3 Minimum two number of winch drums shall be provided for the winch assembly. The winch
shall be of self-sustaining type with positive locking arrangement without the need for brake
shoe, springs or clutches.
5.3.5 The mast shall be fitted with flexible stranded high tensile strength stainless steel wire ropes,
which shall have a factor of safety not less than five times the safe working load of winch.
5.3.6 Particular care shall be exercised in all aspects of design, manufacture, testing and installation
arrangements of the system to ensure safety under all operation conditions.
5.3.7 The material of construction for top pulley block shall be non-corrosive and preferably made
up of die cast LM-6 aluminum alloy, with self-lubricating bearing. The design shall ensure
that the operation of pulleys is maintenance-free.
The rating and capacity of the electric motor used in power tool shall be compatible to lift the
design load of lantern carriage with design margin of minimum 20%. The winch drive shall
incorporate torque limiter. Manual handle shall also be provided for hand operation of
winches. Power tool shall have self-alignment arrangement.
5.5.1 Each high mast shall be supplied with one power supply feeder pillar distribution box, which
shall be located near it.
5.5.2 The feeder pillar distribution box shall be metal enclosed, freestanding type made out of 2mm
thick mild sheet steel/CRCA, epoxy painted and IP-55 weather protected. Additional canopy
for rain protection shall be provided as an integral part of feeder pillar distribution box.
5.5.3 The feeder pillar distribution box shall be complete with incomer Switch, HRC fuse/MCB,
ELCB, motor starters for winch drive, MCB for lighting control and a 3 pin 5/15A socket
alongwith 15A MCB. MCB and ELCB shall be separate unit.
5.5.4 Motor starter shall be complete with switch, HRC fuse, contactor, and bimetal relay with
single phasing prevention feature.
5.5.5 LEDs for indication of incoming power supply healthy for feeder pillar distribution box
incomer shall be provided. Feeder pillar shall also have provision to receive emergency power
supply for aviation fixtures in case specified in the data sheet.
5.5.6 Adequately rated space heater with MCB, thermostat shall be provided for the feeder pillar
distribution box.
5.5.7 Feeder pillar distribution box shall have adequate space to receive incoming and outgoing
cable terminations for 415V, TPN supply loop in and loop out arrangement.The feeder pillar
distribution box shall be complete with double compression nickel-plated brass cable glands
and tinned copper lugs.
5.5.8 The feeder pillar distribution box shall have two numbers external earthing terminals.
5.5.9 The feeder pillar distribution box shall have required wiring interface for taking signals from
hand held external control push button station for raising and lowering of lantern carriage.
5.5.10 The feeder pillar distribution box shall be installed on a raised concrete foundation block and
foundation shall be up to the level of minimum 300mm above ground level.
5.6.1 Local control station shall be hand held type. This control station shall have necessary
raise/lower pushbuttons, emergency stop push button etc.
5.6.2 The hand held control Pushbutton station shall be supplied with minimum of 5 meters length
of 5Cx2.5 sq mm flexible cable and cable shall be with copper conductor, PVC insulation,
metal braiding and overall PVC sheath.
5.6.3 The hand held control station and associated cable shall be kept inside feeder pillar
distribution box when not in use and suitable arrangement shall be provided for the same.
5.7.1 All power and control cables including flexible trailing cables shall be supplied laid and
terminated by the high mast vendor.
5.7.2 The electrical connections from base compartment to the junction box on the lantern carriage
shall be made through special multicore trailing cable of minimum size 4 sq.mm copper
conductor, EPR insulated, metal braided and sheathed in heavy duty Polychloroprene.
5.7.3 Minimum 5 cores shall be provided unless otherwise specified. Separate cores shall be used
for lighting fixtures, aviation fixtures and one dedicated core shall be kept for earthing.
Suitable chemicals shall be added to outer sheath of cable to protect the cable against birds,
rodent and termite attack.
5.7.4 All power and control cables shall be 1100V grade and shall conform to IS-1554 and all
flexible-trailing cables shall also comply with requirement of IS-9968.
5.7.5 The trailing cable shall be terminated by means of metal cased plug and socket, which shall be
provided at the base compartment to enable easy disconnection.
5.7.6 The cable for connection to flood lighting fixtures /aviation lighting fixtures from junction box
provided on lantern carriage shall be through 3C x 2.5 sq.mm copper conductor, PVC
insulated, armoured and overall PVC sheathed cable. The trailing cable at the lantern carriage
shall be taken in flexible metal conduit.
5.7.7 Connection to the power tool motor inside mast at the bottom shall be through metal cased
plug and socket arrangement to enable easy disconnection.
5.7.8 All cabling from feeder pillar distribution box to high mast shall be laid in directly buried
trenches.
The scope of work under this also includes design, detailing, supply and construction of
foundations for high mast lighting system works. The work shall in general be executed as per
IS-456 and all referred codes therein.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
6.2 Materials
6.2.1 Cement
The cement used shall be any one of the following types unless otherwise specified in project
data sheet:
6.2.2 Aggregates
6.2.3 Water
Water used for manufacture and curing of concrete shall be clean and free from injurious
amounts of oils, acids, alkalies, salts, sugar, organic materials or other substances that may be
deleterious to concrete or steel as specified in IS-456. Potable water shall be considered
satisfactory.
Only high strength deformed steel bars of grade Fe 500 (TMT)/ Fe 500 D conforming to
IS: 1786 shall be used.
Minimum diameter of main reinforcing bars in foundation and pedestal shall be 12mm.
Links shall be of minimum 8mm diameter.
High/Medium tensile steel bars for turning anchor bolts shall conform to IS-2062 Grade
A/BR/BO. Nuts shall conform to IS-1363 & IS 6623. Washers shall conform to IS: 6649.
6.3 Concrete
The concrete shall be design mix of minimum grade of M25 as per Geotechnical Document
(whichever is higher) and other requirements as mentioned in project data sheet. 75mm thick
lean concrete shall be provided under the structural foundation of proportion 1:5:10 using
40mm down aggregates. The mud mat of lean concrete shall project 50mm beyond all sides of
the structural foundation slab. Minimum cover to reinforcement shall be 50 mm.
Height of pedestal shall be minimum 300mm above FGL/HPP. Sleeves for cable entry and
exit shall be placed in the pedestal. Minimum thickness for foundation slab shall be 500mm.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
The foundation shall be placed minimum 1.5 meters below Finished Grade Level (FGL)
or as per Geotechnical Document No. XXXX-16-60-GD-0001.
Factor of safety against overturning and sliding shall be considered as 2.0 and 1.5,
respectively. Only 50% of the overburden weight of backfilled soil over base slab of the
foundation shall be accounted for checking of over-turning and sliding. All design
parameters for foundation shall be as per IS-456 and referred BIS codes. Limit state
method shall be used.
c. Information of Soil bearing capacity/ filled up soil/ ground improvement etc. shall be as
per Geotechnical Document No. XXXX-16-60-GD-0001.
6.5 Loadings
Loading in general shall be as per IS-875. The basic wind speed shall be as per the Project/site
location and as called for in IS-875 (Part-3). The value of K 1 , K2 and K3 shall be as follows:
Design and drawing shall be prepared on standard size sheets and submitted for
review/approval prior to execution of works. Construction shall not be taken up prior to
documents/drawings reviewed in code 1 or 2.
Construction shall be done following all safe practices required in IS-456 and other referred
codes.
7.1 During fabrication, the High mast lighting system equipment and materials shall be subject to
inspection by EIL / Owner, or by an agency authorized by the Owner, to assess the progress of
work, as well as to ascertain that only proven raw material is used. The manufacturer shall
furnish all necessary information /data concerning the supply to Elf, / Owner's inspectors. The
vendor shall give at least 15 days notice to the purchaser regarding the date of testing to enable
him or his representative to witness the tests.
7.2 Tests shall be carried out at the manufacturer's works under his care and expense. All routine
tests as specified by the applicable standard codes shall be conducted. Type test certificates for
the high mast lighting system equipments used shall be furnished from a recognized testing
organization.
7.3 Inspection and testing requirements for high mast system shall be as per Inspection and test
plan, specification no. 6-81-1039 and owner-approved vendor's QAP to check mechanical and
electrical operation.
The equipment shall be divided into several shipping sections for protection and ease of
handling during transportation. The equipment shall be properly packed for transportation by
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL—All rights reserved
ship/rail or trailer. The equipment shall be wrapped in polyethylene sheets before being placed
in wooden crates/cases to prevent damage to the finish. Crates/cases shall have skid bottoms
for handling. Special notations such as 'Fragile', 'This side up', 'Weight', 'Owner's
particulars', 'PO nos.' etc., shall be clearly marked on the package together with other details
as per purchase order.
The equipment may be stored outdoors for long periods before installation. The packing
should also be suitable for outdoor storage areas with heavy rains/ high ambient temperature
unless otherwise agreed.
9.1 Supervision during installation, testing and commissioning shall be carried out by vendor's
experienced and trained engineer/supervisor. Any defect pointed out by EIL/Owner shall be
rectified by vendor at no extra cost to the owner.
9.2 Before any part of the High mast lighting system is energised, the pre-commissioning tests
shall be carried out. This shall include but not be limited to the following:
All pre-commissioning checks and tests both for power distribution and lighting system shall
be carried out by vendor in the presence of Engineer-in-charge of EIL/Owner.
9.3 After completion of job, vendor shall carry out the measurement of achieved illumination
level in different areas and shall furnish test reports. The focusing angle of fixture shall be
changed/ adjusted where required.
9.4 After inspection and pre-commissioning tests are carried out, vendor shall obtain necessary
statutory approval of the system from Central Electricity Authority or any other statutory body
as specified in the specification. All test results shall be recorded and submitted to ELL/owner.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
SPECIFICATION
FOR
OIL FILLED TRANSFORMERS
Abbreviations:
BS British Standards
BIS Bureau of Indian Standards
CBIP : Central Board of Irrigation & Power
CEA Central Electricity Authority
CT Current Transformer
GI Galvanised Iron
HV High Voltage
IEC International Electro Technical Commission
IEEE : Institute of Electrical and Electronics Engineers
IP Ingress Protection
IS Indian Standards
LV Low Voltage
MV Medium Voltage
KV Kilo Volt
KVA : Kilo Volt Ampere
NGR Neutral Grounding Resistor
OLTC : On Load Tap Changer
ONAF : Oil Natural Air Forced
ONAN : Oil Natural Air Natural
OTI Oil Temperature Indicator
PO Purchase Order
PVC Poly Vinyl Chloride
PRV Pressure Release Valve
RTCC : Remote Tap Changer Control
TPN Three Phases and Neutral
VDE Verband Der Electrotechnik, Elecktronik and Information Stechnik
WTI Winding Temperature Indicator
XLPE : Cross Linked Polyethylene
CONTENTS
1.0 SCOPE 4
5.0 CONSTRUCTION 5
7.0 COOLING 6
9.0 ACCESSORIES 8
1.0 SCOPE
The intent of this specification is to define the requirements for design, manufacture, testing,
packing and supply of oil filled power/distribution transformers.
2.1 The equipment shall comply with the requirements of the latest revision of the following standards
issued by BIS.
2.2 In case of imported equipment, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of CEA Regulations and any other statutory
regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by
IEC/BSNDE/IEEE/NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent one shall prevail. However owner's decision in this regard will be final
and binding.
3.1 The offered equipment shall be brand new with state of art technology and proven field track record.
No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered
equipment for at least 10 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before phasing
out the product/spares to enable the end user for placement of order for spares and services.
Transformer shall be suitable for installation and satisfactory operation in tropical, humid and
corrosive atmospheres. The transformer shall be designed to operate under site conditions as
specified in data sheet. If not specifically mentioned therein, design ambient temperature of 40°C
and altitude not exceeding 1000m above MSL shall be considered.
5.0 CONSTRUCTION
5.1 Transformer tank shall be of welded sheet steel construction and provided with gasketed steel cover
plates. Base shall be suitably reinforced to prevent any distortion during lifting. Base channels shall
be provided with skids and pulling eyes to facilitate handling.
5.2 Transformer shall be double wound, core type with high grade cold rolled non-aging grain
oriented low loss, high permeability silicon steel laminations (M-4 or better grade) perfectly
insulated and clamped to minimise vibration and noise. Care shall be taken to insulate core-fastening
bolts to reduce losses and avoid hot spots. All parts of magnetic circuit shall be bonded to earth
system.
5.3 Transformers shall have conventional type of windings. Foil type windings are not acceptable.
Windings shall be of copper and shall be designed to withstand the applicable thermal and dynamic
short circuit stresses.
5.4 All covers and seals shall be oil and airtight and shall not be affected by mineral or synthetic oil
action. Detachable radiators (tank mounted) equipped with air vent, drain plug and lifting lugs shall
be provided with shut-off valves for transformer rated more than or equal to 500kVA to permit
removal of any radiator unit without emptying the tank. Radiators shall be securely braced to prevent
undue vibration.
5.5 All fasteners and bolts etc. shall be galvanised. All surfaces to be painted shall be thoroughly
cleaned, de-scaled, made free from rust and transformer shall be epoxy painted.
5.6 Different non-current carrying parts of transformers shall be connected by copper flexibles for earth
continuity purpose.
5.7 Transformer shall be supplied with first filling of oil and 10% extra oil in non-returnable drums Oil
shall conform to IS-335.
6.1 Windings shall be brought out and terminated on outdoor bushings, cable boxes or bus-duct
chamber, which will be located as specified on the data sheet.
6.2 When outdoor bushings are specified they shall be supplied complete with terminal connectors
suitable for the specified conductor size.
6.3 Cable boxes shall be supplied with cable lugs and glands.
6.3.1 For HV XLPE Cables and MV PVC Power/control cables double compression cable glands and
crimped type tinned copper cable lugs shall be supplied. Gland plate shall be removable type. For
single core cables, gland plate shall be of non-magnetic material. HV cable box shall be suitable for
termination of specified size of XLPE insulated cable .The head-room available between cable gland
plate and terminals shall not be less than 600mm for cable upto 11 kV, and 900 mm for 22 kV and
33 kV cables. Cable box and disconnecting chamber shall be air insulated.
6.3.2 Cable box shall be weatherproof to IP-55. For fixed portion of cable box, inspection cover with
lifting handle shall be provided.
6.3.3 Primary cable box (where applicable) shall be able to withstand specified primary system fault level
for 0.20 secs.
6.4 Terminal chamber for bus-duct termination shall have a gasketed cover plate bolted to it and shall be
weatherproof to IP-55. A separate inspection cover with lifting handle shall be provided to facilitate
connection and inspection. Phase sequence of the bus bars shall be as specified in the data sheets.
6.5 Marshalling box shall be mounted on transformer and shall be weatherproof to IP-55. All protective
devices and neutral CTs shall be wired by means of PVC insulated copper conductor armoured
cables upto the marshalling box. Terminals shall be clamp type. Removable gland plate with double
compression type glands shall be provided. Lamp with switch & socket shall be provided in the
marshalling box. Preferably, marshalling box shall be located on the front side of transformer.
6.6 For transformers having provisions for terminating TPN bus duct on the 433V side, neutral of the
star connected secondary winding shall be brought out to a secondary terminal chamber. A CT shall
be mounted (if specified) on the neutral terminal with CT secondary wired up to the marshalling
box.
6.7 A separate neutral bushing shall be provided for neutral earthing of transformers. The neutral CT
shall be mounted as below:-.
CT for 51 G shall be located in the earth path after bifurcation of neutral.
CT for 64 R can be located before bifurcation of neutral.
Supporting arrangement for GI strip/cable as applicable shall be provided for connection of neutral
bushing to earth/NGR.
7.0 COOLING
7.2 Forced air-cooling system shall have a weather proof IP-55 control panel to be installed on the body
of the transformer, complete with cooler controls and cable glands necessary for Purchaser's
external cable connections. Contacts shall be provided for remote indication/alarm for following
operating conditions:
Auto/manual selection
Winding over temp.
(iii) Fans ON (for each fan separately) & Fans tripped (for each fan separately).
Cooling fans shall be complete with mounting/supporting structure. These shall be suitably sized to
limit the temperature rise of the transformer to specified values with continuous maximum loading
of ONAF rating and at maximum specified ambient temperatures. One standby fan per 50% cooler
bank shall be provided.
In Auto mode all fans including redundant fans shall be running. In manual mode, provision shall
be made for starting each fan independently.
8.1 These shall be provided on high voltage side and connected to off circuit or on-load tap changing
gear as specified on data sheet. Under conditions of external short circuit, the tap changing
equipment shall be capable of carrying the same current as the windings.
Off circuit tap changing gear shall have an external operating handle mounted on the transformer
side and shall meet the following requirements:
Positive snap-action contact changing
The mechanism shall be such that it is impossible for the contacts to be set in a position
whereby the windings remain open-circuited or partly short-circuited.
Mechanical stops at the ends shall be provided to prevent overrun.
The driving rod through cover or tank wall shall be properly sealed against oil leakage under
all service conditions.
The handle shall be metallic and the adequately sized in order to allow operation without the need of
tools and be located in a directly accessible position.
The handle shall be provided with padlock facilities to lock the tap changer in the desired position.
Tap positions shall be clearly marked in line with the data given on the rating plate.
8.3.1 High speed on load tap changing gear with number of steps as specified on the data sheet shall be
provided and mounted on the transformer. The OLTC gear shall have diverter resistance and the
current diverting contacts shall be housed in a separate oil chamber segregated from the main tank of
the transformer. The contacts shall be accessible for inspection and their tips shall be replaceable.
OLTC oil chamber shall have oil filling, drain and sampling facility. It shall be provided with oil
level indicator, connection orifices, valves and silica gel breather shall be provided.
Manual-Mechanical Control
The cranking device for operation of the OLTC gear shall be removable and located at a height not
exceeding 1500mm above ground level for easy operation. The mechanism shall be complete with
normal accessories including at least the following:-
A mechanical tap position indicator (Rated tap voltages shall be marked on the diagram
plate).
A mechanical operation counter.
Mechanical stops to prevent over cranking of the mechanism beyond extreme tap positions.
Electrical Control
v) All auxiliaries and devices for electrical control of OLTC gear should be housed in a
weather-proof cabinet mounted on the transformer and shall include:
RTCC panel shall be dust & vermin proof, floor mounting, and freestanding type. The
enclosure shall be cold rolled sheet of 2.0 mm thick. All doors and opening shall be provided
with neoprene gaskets.
8.3.4 OLTC wherever called for shall be suitable for bi-directional power flow.
9.0 ACCESSORIES
Rating Plate
Terminal marking Plate
Two earthing terminals
De-hydrating breather(For transformer rated 25 kVA and above for rated voltage 11 kV and
below, and all ratings above 11 kV)
Conservator (For transformer rated 50 kVA and above for rated voltage 11 kV and below,
and all ratings above 11 kV)
Air release Device (for transformers with conservator)
Oil filling hole with cover
Oil Level indicator with alarm contact
Thermometer pocket
Oil temperature indicator with alarm & trip contacts
Winding temperature indicator with alarm & trip contacts (for transformers of rating 500
KVA and above)
4-20mA transducers for OTI & WTI (For Transformers rated above 1000kVA)
Pressure relief valve shall be provided (with alarm contact).
Sampling valve
6-51-0041 Rev. 5
Ogeir f&Pleu
1.1,MORMENEIJMINF) (A Gout. of India undertaiong)
OIL FILLED TRANSFORMERS Page 9 of 11
9.2 Conservator shall be complete with oil filling plug and cap, oil drain valve, oil level gauge in
addition to magnetic oil level gauge. A flexible oil resistance air bag shall be provided for
conservator for transformer rated above 2500kVA. Air bag shall be designed to withstand repeated
expansion and contraction due to changes in oil level.
9.5 Separate buchholz relay shall be provided for main tank and OLTC chamber. This shall be double
float type for the main tank with separate normally open trip and alarm contacts. For the OLTC
chamber the relay shall be of single float type or oil surge relay with one trip contact. Isolating valve
shall be provided on either side of the relay and distance piece shall be supplied.
9.9 Size of valves for drain, filter and sampling shall be as per table below.
Transformer rating Size of drain Size of filter valve Size of sampling valve
(kVA) valve (mm) mm Mm
Upto 1600 25 25 15
>1600 to 10000 50 25 15
>10000 to 25000 80 50 15
9.10 ECS Interface signals as listed below shall be provided if specified in the data sheet / projects
specifications.
Audible Noise level shall not exceed the limits indicated in CBIP manual.
11.1 Owner's representative shall be given free access in the works from time to time for stage wise
inspection and progress reporting. Four weeks advance notice shall be given to witness the final
routine test as per IS: 2026 and other tests as agreed upon. These tests shall be performed on the
complete assembly at manufacturer's works. Test certificates duly signed by owner's representative
shall be issued as part of final document.
11.2 Routine tests and special tests as listed below shall be carried out on all transformers:
11.2.1 GA along with verification of all accessories
11.2.2 Dimensional & electrical clearance
11.2.3 Rating plate details
11.2.4 Terminal/ tapping markings
11.2.5 Earthing arrangement
11.2.6 Measurement of winding resistance
11.2.7 Measurement of voltage ratio and check of voltage vector relationship
11.2.8 Measurement of impedance voltage and load loss
11.2.9 Measurement of no- load loss and current
11.2.10 Induced over voltage withstand test
11.2.11 Separate-source voltage withstand test (HV Test)
11.2.12 Measurement of insulation resistance before and after HV test
11.2.13 Noise level check
11.2.14 Magnetic Balance test
11.2.15 Dielectric test
11.2.16 BDV on transformer oil
11.2.17 Tests on OLTC/ control panel (if applicable)
11.2.18 Measurement of power taken by fans & oil pumps (on sample basis on one transformer)
11.3.1 Oil leakage Test - All tanks and oil filled compartments shall be tested for oil tightness by being
completely filled with air/oil of a viscosity not greater than that of insulating oil to IS: 335 at an
ambient temperature and subjected to a pressure equal to the normal pressure plus 35 kN/m2
measured at the base of the tank. This pressure shall be maintained for a period of not less than 12
hours for oil and 1 hour for air, during which time no leakage shall occur.
11.3.2 Vacuum Test - One transformer tank of each size shall be subjected to the specified vacuum as in
table-1. The tanks designed for vacuum of 760mm of mercury shall be tested at a maximum internal
pressure of 3.33 kN/m2 (25mm of Hg) for one hour. The permanent deflection of flat plates after the
vacuum has been released shall not exceed the value specified in Table-2 without affecting the
performance of the transformer.
Table —1
Highest System Vacuum Gauge
MVA Rating mm of Hg
Voltage pressure kN/m2
Upto 1.6 34.7 250
Upto 72kv above 1.6 & upto 20 68.0 500
Above 20
100.64 760
Above 72kv For all MVA ratings
Table — 2
Horizontal length of flat plate (in mm) Permanent deflection (in mm)
Upto and including 750 5
751 to 1250 6.5
1251 to 1750 8
1751 to 2000 9.5
2001 to 2250 11
11.3.3 Pressure Test - One transformer tank of each size shall be subjected to a pressure corresponding to
twice the normal head of oil or to the normal pressure plus 35 kN/m2 whichever is lower measured
at the base of the tank and will be maintained for one hour. The permanent deflection of flat plates
after the excess pressure has been released shall not exceed the figure specified in Table-2.
11.3.4 One transformer of each rating shall be subjected to heat run test, if specified in data sheet.
11.3.5 Impulse test, if specified in the data sheet, shall be carried out on all three limbs of the transformer.
11.3.6 Transformer shall be subjected to short circuit test, if specified in the data sheet.
All the equipment shall be divided into several sections for protection and ease of handling during
transportation. The equipment shall be properly packed for the selected mode of transportation i.e.
by ship/ rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in
the crates/ cases to prevent damage to the finish. Crates / cases shall have skid bottom for handling.
Special notations such as 'Fragile', 'This side up', 'Centre of gravity', 'Weight', 'Owner's
particulars', 'P.O. numbers' etc., shall be clearly marked on the package together with other tag
numbers, P.O. number etc.
The equipment may be stored outdoors for long periods before erection. The packing shall be
suitable for outdoor storage in areas with heavy rains/ high ambient temperature.
7FF ich*4-1
f~F T
SPECIFICATION
FOR
DRY TYPE DISTRIBUTION
TRANSFORMERS
Abbreviations:
CONTENTS
1.0 SCOPE 4
5.0 CONSTRUCTION 4
7.0 COOLING 6
9.0 ACCESSORIES 6
1.0 SCOPE
The intent of this specification is to define the requirements for design, manufacture, testing,
packing and supply of cast resin / resin impregnated dry type distribution transformers.
2.1 The equipment shall comply with the requirements of the latest revision of the following
standards issued by BIS (Bureau of Indian Standards) unless otherwise specified.
2.2 In case of imported equipment, standards of the country of origin shall be applicable, if these
standards are equivalent to or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of the CEA Regulations with latest
amendments and other statutory regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
2.5 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent one shall prevail. However Owner's / EIL's decision in this regard
will be final and binding.
3.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment for at least 10 years from the date of supply.
3.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to enable the end user for placement of order for spares and
services.
Transformer shall be suitable for installation and satisfactory operation in tropical, humid and
corrosive atmospheres found in refineries, Petrochemical and Fertiliser Plants or as specified
in the Material Requisition / Tender . The transformer shall be designed to operate under site
conditions as specified in data sheet. If not specifically mentioned therein, design ambient
temperature of 40°C and altitude not exceeding 1000m above MSL shall be considered.
5.0 CONSTRUCTION
5.1 The transformers shall have core type construction. The core shall be assembled out of
low-loss, nonageing, high permeability cold rolled grain oriented steel laminations.
5.2 The windings shall be of high-grade electrolytic copper. The insulation system for cast resin
transformers shall comprise of windings cast under vacuum, free of voids in a homogenous
uniform laminate of epoxy resin/ polyester resin. The totally assembled core and coil
assembly, for resin impregnated transformers, shall be vacuum pressure impregnated to
effectively make it impermeable to moisture, dirt, salt, air and other industrial contaminants.
5.3 The entire core assembly shall be covered with a resin-based lacquer for corrosion protection.
5.4 Lifting lugs shall be provided for core and winding assemblies.
5.5 The HV and MV windings shall have class 'F' or better insulation. The temperature rise of
windings under continuous full load shall not exceed the maximum allowable temperature for
the appropriate class of insulation as per IS 11171, above the design temperature specified in
the data sheet.
5.6 The insulation material used shall be non-hygroscopic, non- inflammable and self-
extinguishing if ignited by direct flame or arc. No toxic or harmful gases shall form during
heating and for burning. The insulation materials shall be sufficiently resistant to ageing.
5.7 The transformers shall be capable of withstanding the thermal and mechanical effects of a
dead short circuit on any or all winding terminals with full voltage maintained on other
windings as per IS. The transformers shall sustain a symmetrical short circuit on secondary
terminals for 2 seconds without damage or impairment.
5.8 Each limb shall have two solid state winding temperature monitoring elements to initiate an
alarm and trip for winding over temperature.
5.9 The transformers for Indoor & outdoor location shall have minimum degree of protection as
IP 23 & IP 43 respectively. However the marshalling box, cable termination box, bus-duct
termination chamber etc. shall have a degree of protection not less than IP-55.
5.11 The transformers shall be spray-painted or powder coated with epoxy paint. Colour shade of
final paint shall be as specified in the data sheet.
6.1 Windings shall be brought out on suitable nickel-plated copper terminals for cable
termination. HV side termination shall be from the bottom. Suitable disconnection chambers
shall be provided to permit the transformer to be removed without disconnecting the cable
termination. The MV side termination shall be by bus-duct or cable as defined in datasheet /
job specification.
6.2 The high voltage and medium voltage cable termination arrangement shall be complete with
cable box and bolted type undrilled cable gland plates. Non-magnetic gland plate shall be
provided for single core cables.
6.3 Primary cable box shall be able to withstand specified primary system fault level for 0.2 secs.
6.4 Terminal chamber for busduct termination shall have a gasketed cover plate, bolted to it.
Separate inspection covers shall be provided to facilitate connection and inspection.
6.5 All protection, alarm and indication devices and neutral CTs shall be wired by means of PVC
insulated cables upto the marshalling box. There shall be two gland plates, one for internal
wiring to the marshalling box from various devices which shall be glanded and pre-wired,
while the second gland plate shall be removable and undrilled for glanding outgoing cables.
6.6 One neutral terminal inside the cable box/ MV bus-duct connection chamber and a separate
neutral terminal outside shall be provided for earthing of transformer winding neutral on the
secondary side. The neutral terminal shall be complete with connector block assembly for
easy termination of GI earth strip/cable.
6.8 Two earthing terminals shall be provided on the transformer frame for transformer body
earthing. Suitable lifting arrangement shall be provided in the transformer frame. The
transformer shall be supported on flat rollers.
7.0 COOLING
Primary off-circuit rotary type tap changer shall be provided and shall have a range as
specified in the data sheet. Tap changing arrangement through links is not acceptable. Under
conditions of external short circuit, the tap changing device shall be capable of carrying the
same current as the windings.
9.0 ACCESSORIES
9.1 Accessories as specified on data sheet shall be included in the scope of supply. All protective,
alarm and indicating devices shall have minimum I no. potential free contact each for alarm
and trip. All transformers must be provided with at least the following:
9.2 Temperature monitoring system shall be supplied with temperature sensors fitted in each limb.
Temperature monitoring system shall initiate alarm and trip for winding over temperature.
Alarm and trip temperatures shall be site settable. The monitoring system shall also have an
indicating device.
The average audible sound level for the transformers at a distance of 30 cm shall be as below:
EIL / owner's representatives shall be given free access to enter the plant and inspect the
equipment at any time during fabrication. However, 4 weeks advance notice shall be given by
vendor to witness the final tests.
For testing requirements, refer Inspection & Test Plan doc. no. 6-81-1044. All testing shalt be
carried out at manufacturer's works under his care and expense.
All the equipment shall be divided into several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for the selected mode of
transportation i.e. by ship/ rail or trailer. The equipment shall be wrapped in polythene sheets
before being placed in the crates/ cases to prevent damage to the finish. Crates / cases shall
have skid bottom for handling. Special notations such as 'Fragile', 'This side up', 'Centre of
gravity', 'Weight', 'Owner's particulars', 'P.O. numbers' etc., shall be clearly marked on the
package together with other tag numbers etc.
The equipment may be stored outdoors for long periods before erection. The packing shalt be
suitable for outdoor storage in areas with heavy rains/ high ambient temperature.
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SPECIFICATION
FOR
MEDIUM AND HIGH VOLTAGE
CABLES & ACCESSORIES
Abbreviations:
CONTENTS
1.0 SCOPE 4
1.0 SCOPE
This specification along with data sheets covers requirements for design, manufacture, testing
at works and supply of Fire survival Medium voltage cables and Flame Retardant Low Smoke
Medium & High Voltage cables and cable jointing / terminating accessories for medium and
high voltage systems.
2.1 The cables and cables jointing & terminating accessories shall comply with the latest edition
of the following standards as applicable:
2.2 The cables and accessories shall also conform to the provisions of CEA Regulations and other
statutory regulations, as applicable.
2.3 In case of any conflict between requirements specified in various applicable documents for the
project, the most stringent one shall prevail. However, Owner's decision in this regard will be
final and binding.
3.1 The cables shall be suitable for laying in trays, trenches, ducts, and conduits and for
underground-buried installation with uncontrolled backfill and possibility of flooding by water
and chemicals.
3.2 Outer sheath of all cables shall be black in colour and the minimum value of oxygen index
shall be 29% at 27 ± 2 ° C. In addition suitable chemicals shall be added into the PVC
compound of the outer sheath to protect the cable against rodent and termite attack. However,
for earthing cables; colour of outer sheath shall be green.
3.3 All cables covered in this specification shall be Flame Retardant Low Smoke (FRLS) or Fire
Survival (FS). The outer sheath of FRLS cables shall possess flame propagation properties
meeting requirements as per IS-10810 (Part-62) category AF. FRLS cable shall be identified
by indenting, embossing or printing the appropriate legend i.e. 'FRLS, Category — C2'
throughout the cable length. FRLS properties shall be as per IS:10810 Part 61 & 62, IEC-
60332 Part 1 & Part 3, IEEE-383, IEC-61034, IEC-60754 Part 1, ASTM-D-2863.
3.4 Sequential marking of the length of the cable in metres shall be provided on the outer sheath at
every one metre. The embossing/engraving shall be legible and indelible.
3.5 The overall diameter of the cables shall be strictly as per the values declared by the
manufacturer in the technical information subject to a maximum tolerance of ±2 mm up to
overall diameter of 60mm and ±3mm for beyond 60mm.
3.6 PVC/ Rubber end caps shall be supplied free of cost for each drum with a minimum of eight
per thousand metre length. In addition, ends of the cables shall be properly sealed with caps to
avoid ingress of water during transportation and storage.
3.7 The joints in armour wire/strips shall be made by brazing or welding and any surface
irregularities shall be removed. A joint in any wire/strip shall be at least 300mm. from the
nearest joint in any wire/strip in the complete cable.
3.8 The cables meant to be used in mining area under the jurisdiction of DGMS shall satisfy the
following
3.9.1 All power/control cables for use on medium voltage systems shall be heavy-duty type,
650/1100V grade with aluminium/ copper conductor, PVC/XLPE (as mentioned in datasheet /
Material requisition) insulated, inner-sheathed, armoured/ unarmoured and overall PVC
sheathed. XLPE insulated cables shall meet the requirement specified in IS-7098 (Part-1).
3.9.2 The conductors shall be solid for conductor of nominal area up to and including 6mm2 and
stranded beyond 6mm2 . Conductors of nominal area less than 16 mm 2 shall be circular only.
Conductors of nominal area 16 mm 2 and above may be circular or shaped as per IS 8130.
Cables with reduced neutral conductor shall have sizes as per Table 1 of IS 1554 (Part-1).
3.9.3 The core insulation shall be with PVC/XLPE compound applied over the conductor by
extrusion. PVC compound shall conform to the requirements of type 'C' compound as per IS:
5831. The thickness of insulation and the tolerance on thickness of insulation shall be as per
Table 2 of IS: 1554 (Part-1). Control cables having 6 cores and above shall be identified with
prominent and indelible Arabic numerals on the outer surface of the insulation. Colour of the
numbers shall contrast with the colour of insulation with a spacing of maximum 50 mm
between two consecutive numbers. Colour coding for cables up to 5 cores shall be as per
Indian standard.
3.9.4 The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC
conforming to the requirements of Type ST-2 PVC compound as per IS: 5831. The minimum
thickness of inner sheath shall be as per Table-4 of IS: 1554 (Part-1). Single core cables shall
have no inner sheath.
3.9.5 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-magnetic
material. For multicore cables, the armour shall be by single round galvanised steel wires
where the calculated diameter below armouring does not exceed 13 mm and by galvanised
steel strips where this dimension is greater than 13 mm. Requirement and methods of tests for
armour material and uniformity of galvanisation shall be considered as per IS 3975 and IS -
-
10810 (Part 41). The dimensions of armour shall be considered as per method (b) of IS - 1554
(Part -1).
3.9.6 The outer sheath for the cables shall be applied by extrusion and shall be formulated for lower
smoke and shall be of PVC compound conforming to the requirements of type ST-2
compound as per IS: 5831. The minimum and average thickness of outer sheath for
unarmoured cables and minimum thickness of outer sheath for armoured cables shall be as per
Table-7 of IS: 1554 (Part -I).
3.9.7 If heat resisting PVC cables are specified in the data sheet„ it shall be possible to continuously
operate the cable at a maximum conductor temperature of 85°C under full load condition and
160°C under short-circuit condition.
3.9.8 For XLPE insulated cables, it shall be possible to continuously operate the cable at a
maximum conductor temperature of 90°C under full load condition and 250°C under short-
circuit condition.
3.9.9 The fire survival cables shall meet the following additional requirements :
i) The insulation shall be of EPR or equivalent material with glass mica tape below or
above insulation.
ii) The cables shall meet requirement of circuit integrity test for a minimum period of 3
hours at maximum temperature of 950° C.
iii) Vendor shall have the test certificate for circuit integrity test as per IEC: 60331-21.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved
3.10.1 Power cables from 3.3kV and up to and including 33kV systems shall be Aluminium/ Copper
conductor, XLPE insulated, sheathed, armoured/ unarmoured and overall PVC sheathed.
3.10.2 The conductors shall be stranded and compacted circular for all cables.
3.10.3 All cables rated 3.8/ 6.6kV and above shall be provided with both conductor screening and
insulation screening. The conductors shall be provided with non-metallic extruded semi
conducting screen.
3.10.4 The core insulation shall be with cross linked polyethylene insulating compound dry cured,
applied by extrusion. It shall be free from voids and shall withstand all mechanical and
thermal stresses under steady state and transient operating conditions. It shall conform to the
properties given in Table-I of IS: 7098 (Part -2).
3.10.5 The insulation screen shall consist of non-metallic extruded semi-conducting compound in
combination with a non-magnetic metallic copper screen. The copper screen for all the three
cores together shall be capable of carrying the single line to ground fault current value and the
duration specified in the data sheet. For single core cable, non-magentic armour shall
constitute the copper screen which shall be capable of carrying the single line to ground fault
current value and the duration specified in the data sheet.
3.10.6 The conductor screen, XLPE insulation and insulation screen shall all be extruded in one
operation by 'Triple Extrusion' process to ensure perfect bonding between the layers. The core
identification shall be by coloured strips or by printed numerals.
3.10.7 The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the
requirements of type ST 2 compound of IS: 5831. The extruded inner sheath shall be of
uniform thickness. In case of single core cables, there shall be extruded inner sheath between
insulation metallic screen and armouring.
3.10.8 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables intended for use on AC system, the armouring shall be of non-magnetic
material. For multicore cables, the armour shall be by galvanised steel strips. Requirement and
methods of tests for armour material and uniformity of galvanisation shall be as per IS - 3975
and IS -10810 (Part 41). The dimensions of armour shall be as per method (b) of IS - 7098
(Part -2).
3.10.9 The outer sheath of the cables shall be applied by extrusion over the armouring and shall be of
PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831. The
minimum and average thickness of outer sheath for unarmoured cables and minimum
thickness of outer sheath for armoured cables shall be as per IS: 7098 (Part-2).
3.10.10 The thickness of the insulation, inner sheath shall be governed by values given in Table-4 and
Table-5 of IS: 7098 (Part -2).
4.1 The termination and straight through jointing kits for use on the systems shall be suitable for
the type of cables offered as per this specification and shall meet requirements of IS 13573.
4.2 The accessories shall be supplied in kit form. Each component of the kit shall carry the
manufacturer's mark of origin.
4.3 The kit shall include all stress grading, insulating and sealing materials apart from conductor
fittings and consumable items. An installation instruction sheet shall also be included in each
kit.
4.4 The contents of the accessories kit including all consumable shall be suitable for storage
without deterioration at a temperature of 45° C, with shelf life extending to more than 5 years.
The terminating kits shall be suitable for termination of the cables to an indoor switchgear or
to a weatherproof cable box of an outdoor mounted transformer/ motor. For outdoor
terminations, weather shields/ sealing ends and any other accessories required shall also form
part of the kit. The terminating kits shall be from one of the makes/ types mentioned in the
data sheet.
The straight through jointing kits shall be suitable for installation on overhead trays, concrete
lined trenches, and ducts and for underground burial with uncontrolled backfill and possibility
of flooding by water and chemicals. These shall have protection against any mechanical
damage and suitably designed to be protected against rodent and termite attack. The inner
sheath similar to that provided for cables shall be provided as part of straight through joint.
The jointing kits shall be from one of the makes/ types mentioned in the data sheet.
The cables shall be tested and inspected at the manufacturer's works. Manufacturer shall
furnish all necessary information concerning the raw material supply to EIL/ Owner's
inspectors. The inspector shall have free access to the manufacturer's works for the purpose of
inspecting the process of manufacture in all its stages and will have the power to reject any
material, which appears to be of unsuitable description or of unsatisfactory quality. For HV
cables, the vendor shall give at least 2 weeks advance notice to the purchaser, regarding the
date of testing to enable purchaser's representative to witness the tests.
5.1 Cables
5.1.1 After completion of manufacture of cables and prior to despatch, the cables shall be subjected
to type, routine, acceptance and special tests as detailed below. The test reports for all cables
shall be got approved from the Engineer before despatch of the cables.
5.1.2 All routine tests, acceptance tests, type tests and additional type tests for improved fire
performance shall be carried out as listed in IS: 1554 (Part-1) and IS: 7098 (Part-2) on PVC
and XLPE insulated cables respectively.
5.1.3 The test requirements for PVC insulation and sheath of cables shall be as per latest revision of
IS: 5831.
5.1.4 Test for Resistance to Ultra Violet Radiation: This test shall be carried out as per ASTM-G-53
or ASTM-G-I54 on outer sheath. The retention value of tensile strength and ultimate
elongation after the test shall be minimum 60 % of tensile strength and ultimate elongation
before the test. Test certificates with respect to this test (not older than one year) from
recognised testing laboratory to be furnished for review by EIL before despatch clearance of
cables. In case test certificates are not available, test is to be conducted by vendor at his own
cost in any recognised test laboratory or in house testing laboratory, before despatch clearance
of cables. Sampling for this test is to be done randomly once for each order, provided outer
sheath remains same.
5.1.5 Acceptance tests as per IS-1554 (Part-1) and IS-7098 (Part-2) and the following special tests
to be performed on the cables as per sampling plan for all cables. However these tests are
required to be witnessed by EIL/ Owner for HV cables.
a. Accelerated water absorption test for insulation as per NEMA-WC-70. (For PVC
insulated cables) and as per NEMA-WC-53 (for XLPE/ EPR insulated cables). Test
certificates with respect to this test (not older than one year) from recognised testing
laboratory to be furnished for review by EIL before despatch clearance of cables. In case
test certificates are not available, test is to be conducted by vendor at his own cost in any
recognized test laboratory or in house testing laboratory, before despatch clearance of
cables. Sampling for this test is to be done randomly once for each order, provided type of
insulation remains same.
b. Dielectric Retention Test: The dielectric strength of the cable insulation tested in
accordance with NEMA-WC-70 at 75 ± 1° C shall not be less than 50 % of the original
dielectric strength. (For PVC insulated cables). Test certificates with respect to this test
(not older than one year) from recognised testing laboratory to be furnished for review by
EIL before despatch clearance of cables. In case test certificates are not available, test is
to be conducted by vendor at his own cost in any recognized test laboratory or in house
testing laboratory, before despatch clearance of cables. Sampling for this test is to be done
randomly and once for each order.
c. Oxygen Index Test: The test shall be carried out as per IS-10810 (Part 58). Sampling to
be done for every offered lot/size as per sampling plan.
d. Flammability Test: The test shall be carried out on finished cable as per IS-10810 (Part 61
& 62). Sampling for these tests is to be done randomly once for each order, provided
outer sheath remains same. The acceptance criteria for tests conducted shall be as under:
Part-61-The cable meets the requirement if there is no visible damage on the test
specimen within 300 mm from its upper end
Part-62-The maximum extent of the charred portion measured on the test sample should
not have reached a height exceeding 2.5 m above the bottom edge of the burner at the
front of the ladder.
e. Test for rodent and termite repulsion property shall be done by analysing the property by
chemical method.
5.1.6 Following tests shall be carried out to prove FRLS property of the cable.
c. Halogen acid gas emission as per IEC-60754 Part 1 i.e. To determine the % of release of
hydrochloric acid gas from the FRLS sheath under fire which shall be 20% (max.)
d. Smoke Density Test shall be as per ASTM D - 2843 and Smoke Density Rating of FRLS
Sheath shall be 60% (max.).
5.1.7 The test for circuit integrity for fire survival cables shall be carried out as per IEC-60331
(Part-21).
Type tests should have been carried out to prove the general qualities and design of a given
type of termination/ jointing system as per IS-13573. The type test certificates from
independent testing laboratory shall be submitted before despatch.
6.1 Cables shall be despatched in non-returnable steel drums of suitable barrel diameter, securely
packed, with the take-off end fully protected against mechanical damage. Ferrous parts used
shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit
or storage.
6.2 On the flange of the drum, necessary information such as project title, manufacturer's name,
type, size, voltage grade of cable, length of cable in metres, drum no., cable code, BIS
certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum
with suitable instructions to show the direction of rotation of the drum.
6.3.1 MV Cables
Multicore Power cables upto 6 mm2 1000 m
Multicore Power cables from 10 mm 2 up to 500 mm2 500 m
Single Core Power cables upto 630 mm 2 1000 m
Control cables upto 61 cores 1000 m
6.3.3 HV Power Cables Above 11kV Grade and upto 33kV Grade
However exact drum lengths shall be finalised during order execution. A tolerance of ± 3 %
shall be permissible for each drum. However overall tolerance on each size of cable shall be
limited to ±2%.
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SPECIFICATION
FOR
NUMERICAL RELAYS &
SUBSTATION AUTOMATION SYSTEM
/
REVISED AND ISSUED AS STANDARD SC
2 12-06-14 SV
SPECIFICATION
REVISED AND ISSUED AS STANDARD
1 24-03-09
SPECIFICATION SKM AK JMS ND
0 12-08-02 ISSUED AS STANDARD SPECIFICATION RCS AAN VPS GRR
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by
Abbreviations:
CONTENTS
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 SITE CONDITIONS 4
4.0 GENERAL REQUIREMENTS 4
5.0 TECHNICAL REQUIREMENTS 5
6.0 SUBSTATION AUTOMATION SYSTEM 9
7.0 INSPECTION, TESTING AND ACCEPTANCE 11
8.0 PACKING AND DESPATCH 12
1.0 SCOPE
The intent of this specification is to define the minimum requirement of design, manufacture,
testing, packing and dispatch of numerical relays. The specification also defines the requirement
of communication and integration for Substation Automation System.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the requirements of latest revision of following IEC standards /
equivalent Indian Standards, unless otherwise specified:
IEC 60068 : Environmental Testing
IEC 60073 : Basic safety principles for man machine interface, marking & identification —
Coding principles for indicators and actuators
IS/IEC 60529 : Degree of protection provided by enclosure (IP Code)
IEC 60255 : Electrical relays
IEC 61000 : Electromagnetic compatibility (EMC)
IEC 61850 : Communication networks & systems in substations
2.2 In case of imported equipment, standards of the country of origin shall be applicable, if there
standards are equivalent or more stringent than the applicable IEC / Indian standards.
2.3 The equipment shall also conform to the provisions of CEA regulations and other statutory
regulations currently in force in the country.
2.4 In case Indian standards are not available for any equipment, standards issued by IEC / BS /
VDE / IEEE / NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standard/ specification/ data sheet and
statutory regulation, most stringent requirements shall prevail. However, Owner's decision in
this regard will be final and binding.
3.0 SITE CONDITIONS
3.1 The relay shall be tropicalised, for satisfactory operation when installed in a panel located in a
pressurised substation with restricted natural air ventilation, in tropical humid and corrosive
atmosphere. Relay shall be designed to perform all its functions and operate under site conditions
specified in numerical relay data sheet. If not specifically mentioned there in, a design ambient
temperature of 40°C and an altitude not exceeding 1000M above the mean sea Level shall be
cons idered.
4.0 GENERAL REQUIREMENTS
4.1 The equipment offered shall be brand new with state of the art technology with proven field
track record of similar type and model or model in same series with additional features. No
prototype equipment shall be offered.
4.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered
equipment at least for 15 years from the date of supply.
4.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to enable the end user for placement of order for spares and
services.
4.4 In case of relays manufactured outside India, the relay manufacturer through his Indian
establishment or associate in India shall provide application, testing, commissioning, after sales
service and other necessary support for minimum of 15 years to customer. Their Indian
establishment or associate company in India shall also maintain adequate inventory of each type
of relay or spares to meet the requirement arising during project execution and plant operation.
Relay manufacturer shall possess a signed Memorandum of Understanding with their Indian
associate for providing customer support
50N). Over current protection function provided should have IDMTL characteristic for low
set and high set stages and definite time delay for high set instantaneous stage.
ii) Over current relay shall be three phase type with 4 elements; 3 elements for inverse and
definite time delay over current and one element for inverse and definite time delay earth
fault current. Selection of inverse or definite time feature shall be user selectable.
iii) The IDMTL characteristic (for 51 and 51N) shall be as per IEC. The inverse characteristics
shall include normal inverse, very inverse, extremely inverse, long inverse and shall be soft
ware selectable. Inverse element shall have two or more stages (low and high set) for
selection of required inverse characteristic to achieve close protection as required.
Definite time characteristic shall have minimum 2 stages with adjustable current and time
setting.
iv) Relay shall also have separate current input from CBCT for measured earth fault current
element. It shall be possible to connect earth fault element either through CBCT or to be
connected residually. Minimum setting current for sensitive earth fault element shall be 1%.
v) Directional overcurrent & earth fault element shall be provided, wherever required.
vi) Voltage biased overcurrent / earth fault element shall be provided wherever required.
5.5.2 Motor Protection
i) Motor protection relay shall have all protection function such as over current, thermal (over
load), locked rotor current, zero sequence, negative sequence, maximum number of start,
motor overload pre-alarm, motor re-acceleration, lock out, inhibit of over current protection
during motor starting through contactor feeders, hour run count, inhibit start after elapse of
maximum number of starts etc.
ii) The relay shall be provided with 6 Nos. RTD and 2 Nos. BTD analog inputs, if specified in
the data sheet / job specification. Alternatively, external RTD/BTD module having interface
with numerical relay can be provided. The numerical relay with RTD / BTD inputs shall be
suitable for shielded triad cable of conductor size 1.5sqmm copper, unless otherwise
specified.
iii) Separate motor differential protection shall be provided, wherever specified.
5.5.3 Transformer Protection
i) In addition to overcurrent & earth fault function, wherever required, the main numerical
relay shall also include standby earth fault protection function (51G) for the transformer.
The standby earth fault shall operate from a separate neutral CT input and shall have
definite time / IDMTL characteristics as per IEC.
ii) Wherever the transformer requires restricted earth fault protection (64R), separate
numerical relay shall be provided. 64R function can be included as a part of main
differential protection relay (87T), unless otherwise specified. For details of transformer
differential protection relay refer Cl. 5.5.6.
iii) Transformer auxiliary protection (OTI/WTI/Buchholz/MOG etc) shall be included as a part
of numerical relay.
iv) Transformer differential protection shall be provided, wherever specified.
5.5.4 Generator Protection
i) Medium Voltage Generators (415V) shall have all protection functions such as voltage
restrained overcurrent (51V), standby earth fault (51G), negative sequence (46), Reverse
power (32), under voltage (27), overvoltage (59), thermal overload (49), PT fuse failure
monitoring function (60), generator differential (87G) as a minimum.
ii) In addition to the above, HV generators (turbine / diesel engine driven) shall have additional
protection functions such as rotor back up earth fault (64R)-1st and 2nd stage, low forward
power flow (37), loss of excitation (40), under frequency (81U), rate of change of frequency
(df/dt) unless otherwise specified.
iii) If specified in the datasheet, additional protection functions such as field overcurrent, over
frequency (810), back up impedance (21), over fluxing (99), out of step shall be provided
as a part of generator protection numerical relay.
iv) The generator protection functions can be included as a part of one numerical relay or a
separate numerical relays can be provided.
5.5.5 Voltage Operated Protection Functions
i) These functions include under voltage (27), over voltage (59), ON delay and OFF delay
timers, phase sequence voltage, neutral displacement and Synchro-check functions etc.
ii) The under voltage and overvoltage protective function shall have different stages with
IDMTL and definite time characteristics.
iii) If specified in datasheet, the relay shall have under and over frequency function along with
frequency supervised Rate of change or average rate of change of frequency function.
5.5.6 Differential Protection
Suitable differential protection shall be provided as required as per data sheet / job specification
for the specific application such as for generator, transformer, overall generator & transformer,
motor, feeder, bus section etc. The following requirements, as applicable, shall be complied:
i) Differential protection shall be either high impedance or low impedance type. In case of
high impedance type, suitable non linear resistor shall be provided to limit the peak
overvoltage.
ii) Transformer differential protection shall have suitable harmonic restraint feature to avoid
maltripping during switching.
iii) For transformer differential protection, necessary correction for ratio error and for
transformer primary and secondary vector grouping shall be taken care in the relay itself
without additional ICTs. The required relay setting for this shall be programmable.
iv) Bus differential relay shall have feature for CT supervision and check differential.
v) In case separate hard-wired relay is used for check differential, the status/ event of same
shall be communicated through the numerical relay provided for main differential
application.
vi) Unless otherwise specified, the differential relays such as generator differential, transformer
differential, overall generator transformer differential, motor differential, feeder differential
etc. shall be suitable for cable connection between CTs and relay using 2.5 sq.mm., Cu
conductor, PVC insulated, armoured cable. However for differential protections provided
for feeders having long lengths, armoured FO cable may be considered. In cases where FO
cable is not suitable, shielded twisted pair cable of conductor size 1.5sqmm copper shall be
specifically mentioned by the bidder in the offer for EIL/Owner's acceptance on case to
case basis.
5.6 Metering Functions
The metering function shall be provided as required and same shall be built inside the numerical
relays.
5.7 Control Functions
5.7.1 The control function shall be built inside the numerical relays. For this purpose relays shall have
all graphical PLC/Boolean logic functions such that complete control logic of the feeder along
with all necessary interlocks as required can be developed inside the relay.
5.7.2 Relays for motor feeder shall be equipped with all control functions and interlocks related to
motor feeder. If reacceleration is a part of motor feeder, the control function shall also cover
reacceleration logic.
5.7.3 Relays shall have sufficient integral I/Os to take care of complete feeder logic. External I/O
module for implementation of logics is not acceptable.
5.8 Lock Out (86), Trip Circuit Supervision (95), Auxiliary Relays and Timer Functions
5.8.1 Unless otherwise specified the numerical relays shall have built in lock out function. For motor
feeders additional built-in lockout element shall be provided to receive process trip signals. Lock
out elements shall be self reset or hand reset and shall be software selectable.
5.8.2 The numerical relays shall have built in trip circuit supervision function, unless otherwise
specified.
5.8.3 Auxiliary relays/ Timers function etc as required for control schematics shall be programmable
as a part of numerical relay. The number of such elements as required for schematic shall be
considered.
5.8.4 Timer function shall be programmable for both ON/OFF delays.
5.9 Disturbance/ Event Recording and Data Storage
5.9.1 Breaker trip/ close status, relay faults, trip values, event data and disturbance record data shall be
stored in the relay in non-erasable memory or memory backed up by lithium battery. Under no
circumstances such as withdrawal of power to the relays shall the status, data and events in the
memory get erased. Unless otherwise specified, it should be possible to store total 10 seconds of
disturbance recording and 200 sequence of event records. Subsequent events shall be overwritten
following principle of FIFO.
5.9.2 All disturbances/ events shall be time stamped within the relay.
5.10 Input/ Output Interface, Filters and Galvanic Isolation
5.10.1 Voltage (through PT) input to relay, shall be 110V +/- 10%, unless otherwise specified.
5.10.2 Out put relays shall have 4 numbers spare NO contacts; each shall separately be programmable
for either hand reset or self- reset.
5.10.3 Contacts of pushbuttons from field, interlocks from DCS/ other switchboards shall be wired to
the relay as binary input using 1.5/2.5sqmm, multi core, copper conductor cables. The distance
between push buttons/ interlock to switchboard may be considered as 1000m, unless otherwise
specified. The pick-up voltage for BIs/BOs shall be site selectable. The additional components as
required to overcome the cable capacitance effect shall be considered as a part of supply of relay.
The binary input to relay from field contacts and interlocks shall be momentary type. Logic to
latch the momentary contact, as required shall be built as a part of protection relay.
5.10.4 All I/Os shall have galvanic isolation. Analog inputs shall be protected against switching surges,
harmonics etc.
5.11 Relay Communication
5.11.1 All numerical relay shall have RS232/RJ45/USB port on the front for hooking laptop.
5.11.2 At the rear numerical relays shall have suitable communication port for communication with data
concentrator/ HMI/ Station bus. The type of port shall be selected based on method of
communication (Serial or Ethernet) and type of physical transmission medium (twisted pair
copper or fiber optic). For serial communication, the relay port shall be RS485 or FO (fiber
optic) and for Ethernet (IEC 61850 based) communication same shall be RJ45or FO.
5.11.3 The communication protocol shall be selected to transfer all information including time stamp
data from relay to data concentrator/ substation HMI. The relays shall communicate on industry
open protocol such as IEC 60870-5-103/IEC 61850/ Modbus-RTU / Modbus TCP-IP or any
other open protocol.
5.11.4 For IEC 61850 based communication, each relay shall be suitable for communicating with
minimum three numbers client devices.
6.0 SUBSTATION AUTOMATION SYSTEM
Substation automation system broadly comprises of numerical relays, data concentrator panels
(as required), HMI, laptop, printers and their associated software for monitoring of the electrical
system.
6.1 Communication
Communication is the backbone of any substation automation system. It is through this medium,
the monitoring of various parameters takes place effectively.
6.1.1 Serial Communication
i) Data concentrator shall have two serial ports (1 no. in each CPU module) for simultaneous
remote communication on relay LAN. The relays shall be multi-dropped on RS485 through
single drop from LAN to each relay. In the event of either failure of any relay or break in
LAN cable or failure of port at data concentrator, the redundant hardware shall ensure
healthy communication between relay and data concentrator (refer Figure-1).
ii) Alternatively, relays shall communicate in star topology using star coupler. Communication
from relays to star coupler shall be through single communication port. Communication
from star coupler to data concentrator shall be through redundant communication link (each
link part of separate star coupler unit). RS485 to FO converters wherever required shall be
part of offered relay/ other hardware. Star coupler shall be provided with dual power supply
module
iii) The maximum number of relays in one loop shall be decided so as to achieve maximum
scan time as 500 ms for status input and maximum 6 sec for analog and historical data
considering total number of serial loop and star coupler as a total integration. The above
scan time does not include screen refresh rate at HMI.
iv) For sequence of event recording, time discrimination between two events shall be
maintained to 1 m sec or better.
6.1.2 IEC-61850 based Communication
i) Ethernet switches shall provide error free communication in harsh substation environment
and shall be immune to EMI. The Ethernet switches shall comply to IEC 61850-3 and shall
be KEMA approved or equivalent.
ii) For real time deterministic performance, managed Ethernet switch shall be considered in the
Ethernet network. The switch shall support following features:
- Full duplex operation
- Priority Queuing
- Virtual LAN (VLAN)
- Rapid Spanning tree
- Multicast filtering
iii) Dedicated Ethernet switches shall be provided for each switchboard. 20% spare ports shall
be provided in each Ethernet switch.
iv) Ethernet switch shall have dual DC power supply facility.
v) Communication between relay and HMI shall be provided as follows:
Redundant Ethernet communication architecture shall have RSTP topology. Numerical
relays shall be hooked up to Ethernet switch in star topology and the switches (within the
switchboard) shall be further connected in ring (refer Figure 2).
Alternatively, from each switch (within the switchboard) redundant communication link
shall be extended to two number backbone switches to be located within the switchboard
(refer Figure 3).
For hooking up to HMI/gateway for upper level connectivity, redundant communication
link either from any two switches within the ring or from back bone switches shall be
further extended and hooked up to two numbers master Ethernet switches dedicated for
hooking HMI/gateway/printers/GPS etc. From HMI redundant communication link shall be
extended to the master Ethernet switches.
6.2 Data Concentrator
6.2.1 Data concentrator shall be supplied to facilitate communication with relays on open protocol.
6.2.2 As a minimum data concentrator shall have separate power supply module, CPU module and I/0
module. To achieve redundant architecture, either separate data concentrator shall be considered
or data concentrator shall have redundant power supply module and redundant CPU module. The
CPU module shall have sufficient communication ports depending on relay LAN requirement.
6.2.3 Data concentrator shall provide gateway to upper level control system on Ethernet/ 1EC61850
protocol/Modbus-RTU protocol or protocol as specified in the data sheet. The communication to
upper level control system shall be redundant as per data sheet/ system architecture.
6.2.4 Data concentrator shall have binary and analog (4 to 20mA) I/0 cards suitable for interface
requirement specified in data sheet. Unless otherwise specified, 20% 1/0s shall be considered as
spare. Alternatively, a separate Data Acquisition Unit may be supplied for binary and analog
interface.
6.2.5 Data concentrator shall have required number of ports for relay LAN/ star couplers. Number of
relay LAN/ star couplers shall be as per project requirement. 20% or minimum 2 Nos. spare
ports whichever is maximum shall be provided for future extensions.
6.2.6 Data concentrator shall have required number of RS232/ RS422/RJ45 ports for connection to
Laptop PC and substation HMI having operator's work station and engineering station PC.
6.2.7 Data concentrator shall have redundant RS485/ FO/ Ethernet port for communication to
substation HMI and upper level ECS-RTU. Hook up to upper level system shall be carried out
by extending serial connectivity from each communication ports in two CPU modules.
6.3 Gateway
6.3.1 Gateway for upper level connectivity if separately provided shall have redundancy in power
supply module, CPU module. Alternatively, redundant gateways can be provided.
6.3.2 In case of IEC-61850 based communication, if gateway is envisaged, gateway shall have binary
and analog (4 to 20mA) I/0 cards suitable for interface requirement specified in datasheet.
Unless otherwise specified, 20% 1/0s shall be considered as spare. Alternatively, a separate Data
Acquisition Unit may be supplied for binary and analog interface with communicates to ethernet
switch on IEC-61850 protocol.
6.4 Human Machine Interface (HMI)
6.4.1 Following functions as a minimum shall be a part of HMI:
Display of Single Line Diagram
- Feeder status monitoring
- Data logging
Relay parameterization
- Event recording
- Historical data & trending
- Annunciation
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
6.4.2 Human machine interface shall include engineering and operator function. Engineering and
operator workstations shall be separate.
6.4.3 HMI shall be of industrial grade suitable for continuous operation at design ambient temperature
with restricted natural ventilation.
6.4.4 HMI shall be of latest version of industrial grade PC and the same shall be provided with 21"
color monitor (TFT flat screen) with non glare glass filters to minimize glare from external
lighting.
6.4.5 Operator workstation shall have user friendly software for interactive display of substation data
in multiwindow feature. Software shall have capability to display substation single line
diagrams, display of electrical system parameters, reports, alarm annunciation, daily and monthly
data logging, continuous polling, relay monitoring, relay supervision, fault disturbance record of
each relay, graphic representation and trending of data etc. The offered system shall comply with
requirements of IEC for basic and safety requirements for Human-machine interface.
6.4.6 Engineering workstation shall have software for engineering, detailed self diagnostic for
maintenance, trouble shooting and changing parameters. Further, it shall also have facility to
program and configure numerical relays, data concentrator and other intelligent devices. In
addition engineering work station shall have all the facilities as provided for operator
workstation.
6.4.7 The HMI system shall be provided with color laser jet A3 printer for generating hardcopy of
alarm, event and logging report. The printing shall be on demand, unless otherwise agreed.
6.4.8 If specified, separate laptop shall be provided. The laptop shall include all functionalities as
specified for HMI system and the same shall be provided with required licensed software,
hardware, accessories and material. System configuration shall be latest proven model and
upgradable.
6.4.9 HMI system shall be provided with all associated furniture for PC, printer etc.
6.5 Time Synchronization
6.5.1 All internal clocks of numerical relay, data concentrator, SOE modules, HMI etc. shall always
work in synchronism such that there is one and only one system-wide time. GPS shall be
considered to synchronize with an external satellite clock. The time synchronization accuracy
shall be ± 1.0 msec or better.
6.5.2 The GPS system shall consist of GPS antenna, lightning arrestor, GPS receiver/server and
associated cables.
6.5.3 The time synchronization shall be carried out either through communication over substation
relay LAN or by considering dedicated time synchronization channel. In case of synchronization
through relay LAN, the communication protocol shall support to carry time synchronization
message to the relays/data concentrator/HMI and maintain the desired accuracy. In case of time
synchronization through dedicated time synchronization channel, relays, data concentrator and
HMI shall be provided with IRIG- B port and the same shall be directly hooked up to GPS
receiver.
6.5.4 In Ethernet based communication network, GPS receiver shall be directly hooked up to Ethernet
LAN and all internal clocks of HMI and numerical relays shall be updated using SNTP protocol.
7.0 INSPECTION, TESTING AND ACCEPTANCE
7.1 During assembly, EIL / Owner or his authorized representative shall be permitted to assess the
progress of work as well as to ascertain that quality raw material is used for the same. All
assistance as required during inspection shall be given to inspector.
7.2 For testing requirements refer Inspection & Test Plan No. 6-81-1055.
0WS EW S
LAPTOP PRINTER
LAPTOP
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ETHERNET SWITCH-1 ETHERNET SWITCH-2
12 I 11 . I. I. I In
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REDUNDANT DATA CONCENTRATOR
I I I II I I 1
li I I I
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Lit
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MASTER MASTER
ETHERNET SWITCH-1 ETHERNET SWITCH-2
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ECS RTU
to ECS or ti—
r- GATEWAY (IEC-61 850)
II
to DCS =JJ
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HV SWITCHBOARD MV SWITCHBOARD
— —i
12J 12J 11J L2J
Note: connectivity to DCS is envisaged from ECS RTU. Where ECS RTU is not envisaged, gateway shall be
considered as part of Substation Automation System
EWS
PRINTER
LAPTOP
LAPTOP
/,\
r JJ
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GPS Clock
With Annetna L1J L2] L3J LsJ LSJ LiJ L2J L3J L9.J
MASTER MASTER
ETHERNET SWITCH-1 ETHERNET SWITCH-2
I 1 1,1 I- I- In I I t 1> I I. In I
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to ECS 27.= or -) ti
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II
to DCS
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HV SWITC1f1BOARD MV SWITCHBOARD
lZ UJ UJ uJ tZ 1.1.1
BACKBONE BACKBONE BACKBONE BACKBONE
ETHERNET SWITCH-1 ETHERNET SWITCH-2 ETHERNET SWITCH-1 ETHERNET SWITCH-2
1 I
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1NR-n — — — IN R -n — — —
Note: connectivity to DCS is envisaged from ECS RTU. Where ECS RTU is not envisaged, gateway shall be
considered as part of Substation Automation System
SPECIFICATION FOR
ELECTRICAL EQUIPMENT
INSTALLATION
Abbreviations:
AC Alternating Current
ACDB AC Distribution Board
AL Aluminium
BIS Bureau of Indian Standards
CCoE Chief Controller of Explosives
CD Compact Disc
CEA Central Electricity Authority
CIMFR Central Institute of Mining and Fuel Research
CT Current Transformer
CTC Carbon Tetrachloride
CU Copper
DC Direct Current
DCDB DC Distribution Board
DGMS Directorate General of Mines and Safety
Ex(d) Flameproof
FRP Fibre Reinforced Plastic
HV High Voltage
IR Insulation Resistance
IS India Standard
LV Low Voltage
HMI Human Machine Interface
MV Medium Voltage
OISD Oil Industry Safety Directorate
OSR Oil Surge Relay
OTI Oil Temperature Indicator
PF Power Factor
PI Polarisation index
PRV Pressure relief Valve
PT Potential Transformer
SLD Single Line Diagram
UPS Uninterrupted Power Supply
VRLA Valve Regulated Lead Acid
WTI Winding Temperature Indicator
CONTENTS
1.0 SCOPE 4
1.0 SCOPE
This specification defines the requirements for the installation, field inspection, testing and
commissioning of electrical equipment, forming part of electrical power distribution and
utilisation system, including Communication and Fire alarm system.
2.1 The work shall be carried out in the best workmanlike manner in conformity with this
specification, EIL Installation Standards, layout drawings and to the following specifications/
codes of practice of Bureau of Indian Standards and OISD standards.
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:
a. CEA Regulations.
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by CCoE/DGMS (as applicable).
d. The petroleum rules (Ministry of Industry Government of India).
e. Any other regulations laid down by central/state/local authorities and Insurance
agencies.
Prior to start of installation of the electrical equipment, Contractor shall verify that equipment
and complete materials have been received. Handling, shifting to required site location,
installation, testing and commissioning of all electrical equipment shall be done by contractor
with utmost care. Manufacturer's instructions and the requirements given in their technical
manuals shall be strictly adhered. The substation/switchgear room wherein the equipment
shall be installed shall be kept clean, dry and free from all debris. Panel floor cutouts not in
immediate use shall be suitably covered to avoid any mishap. When handling the switchboard
panels, care shall be taken to observe the correct lifting arrangements and to make sure that
slings are attached to the manufacturer's designated lifting points,where applicable. No parts
shall be subjected to undue strains or sudden stresses which could cause damage to the
equipment.
The lifting position mark indicated on packing casing shall be adhered to strictly, for keeping
it in required vertical position.
Contractor shall check and report to the Engineer-in-charge about any damaged item and / or
missing component for getting the same replaced as per specifications. During installation, all
accessories and loose items shall also be inspected by the contractor before their
assembly/mounting.
3.1.1 The term switchboard here includes all HV / MV/ LV switchboard panels, motor control
centers, power and lighting distribution boards, UPS panels, ACDB, Battery charger panels,
DCDB etc.
The switchboard panels shall be handled with care, avoiding any impact to the equipment.
Dragging of the panels directly on floor shall be avoided. Roller bars may be used for shifting
of panels. Use of a crane and trailer shall be made for handling of equipment. The
switchboard panels shall be properly supported on the truck or trailer by means of ropes to
avoid any chance of tilting. The switchboards shall be lifted after ensuring that panel supports,
nuts and bolts are all intact and tightened. While lifting the panels in packed conditions,
utmost care shall be taken to avoid any damage to insulators, bushings, metering and
protective equipment and if specified in the tender document tyre mounted hydraulic trolley
shall be used.
The panels shall be preferably kept inside the packing cases till foundations are ready. Proper
rain/sun/dust protection shall be ensured till switchboards are installed.
3.1.2 The switchboard panels shall be installed on prepared foundations or floor cutouts. Steel base
channels shall be welded to inserts provided in floor slab. Cross members shall be provided at
the junctions of each shipping section and other places as required.. It shall be ensured that the
base plate level of HV switchboard shall match with the finished floor level.
The foundation pockets and the grouted bolts shall be cured for a minimum period of 48
hours. Proper level of base frames shall be maintained throughout and shall be checked with
water level/spirit level. Steel Shims shall be provided below base frame wherever required.
3.1.3 The switchboard panels shall be taken out from the packed cases and shifted one by one to
their proper place. Al1 the panels shall be assembled, aligned and leveled. Alignment of
panels shall be checked in both longitudinal and lateral directions. It shall be ensured that
panel to panel coupling bolts, bus bar links etc. fit properly without any strain on any part. No
new holes for jointing of the panels other than those recommended by the vendor shall be
drilled. No gaps shall be left between the panels. Gap if any found between panels shall be
suitably sealed using sealing compound or T-profile. The lifting, racking in and out operation
of the breaker and all other motions shall be free from any obstruction.
The panels shall be checked for correct vertical position using Plumb line and spirit levels.
The switchboard panels shall be tack welded at suitable intervals to base channel.
After erection of switchboard panels, all uncovered portions of floor cutouts shall be covered
with 6 mm thick removable chequered plates finished with floor level. The design of the
chequered plates shall be such that the maximum allowable deflection is L/200 (where L is the
span of the chequered plates in meters) for a live load of 500 kg./sq. meters.
Additional stiffer shall be provided at the bottom if required. Suitable lifting arrangements
shall be provided for chequered plates. The chequered plates shall be painted with a coat of
red oxide zinc chromate primer after proper surface preparation as per specifications. Where
specified, panels' cutouts provided for future use shall be filled with lean concrete.
3.1.4 After completion of Installation of switchboards, all the cubicles, switchboard components
such as switches, starters, CT and PT chambers, bus bar chamber shall be cleaned and
checked for tightness of all the components.
Vacuum circuit breakers shall be checked for integrity of bottle seals. A11 loosely supplied
items shall be fitted up. Bus bar sections or links shall be inserted and where specified, of high
voltage equipment shall be insulated. Interconnection wiring between shipping sections shall
be done by contractor.
All the wiring connections shall also be checked. Contact resistance of all bus bar joints and
contactors shall be checked. Insulator shall be checked for any damage. All the starters,
switches, contacts shall be cleaned with CTC where required.
A11 the moving parts shall be checked for easy and free movement. Hinges of panel doors
shall be lubricated to give free and noise less movement. A11 openings shall be kept
completely closed to avoid ingress of any foreign particles inside the panel.
Functional scheme verification of individual feeder shall be carried out and minor wiring
modifications in the panel wiring, if required shall be done as per the directions of Engineer-
in-charge. Special attention shall be paid to CT circuits' polarity, wiring continuity and
correctness in the protection as well as measurement circuits. Auto transfer scheme shall be
simulated and verified. During the course of scheme verification tests, defective components
if any shall be taken out, after bringing to the notice of Engineer-in-charge. The same shall be
replaced by component supplied by owner.
3.1.5 Where switchboard is damp or having a low IR value due to damaged insulators/
bushings/any other insulated parts, or any other reason, the entire switchboard shall be dried-
up according to the instruction of the Engineer-in-charge for the IR value to improve to a safe
level for commissioning. Care shall be taken to protect the surrounding insulation from direct
local heating during the drying up process.
3.1.6 All the metering instruments, protective relays and other relays and contactors shall be tested
as per manufacturer's recommendations and according to the instructions of the Engineer-in-
charge. Protection relays shall be inserted and connected and settings adjusted as required by
the Engineer- in- charge
3.1.7 All moving parts, of closing/tripping mechanism, racking in and racking out mechanism,
spouts and shutter closing mechanism shall be checked for proper operation. A11 the auxiliary
contacts of breaker shall be checked-up, cleaned and contact pressure measured.
3.1.8 All the control wiring, PTs, bushings, bus bars, other live parts of switchgear, incoming and
outgoing cables shall be meggered.
3.1.9 Electrical simulation tests shall be carried out for all the protective, alarm and annunciation
relays and external interfaces to ascertain proper functioning.
3.1.10 Safety insulation mats of approved make and of required voltage grade shall be provided in
the sub-station.
iii. That the polarity test and ratio test of all the PTs and CTs is complete and phase
sequence of CTs conforms to the correct vector group connections. Wiring continuity
and correctness are ensured in the protection and measurement circuits. Polarity of
D.C. supply for all the circuits is correct.
iv. That the high voltage tests of incoming and outgoing cables have been conducted and
results are satisfactory.
v. That all the protective relays including both conventional and microprocessor based
numerical relays and thermal overload relays/electronic motor protection relays have
been tested for secondary injection tests. (Primary injection tests shall be carried out
for differential protection, Restricted Earth fault protection at full / reduced current to
ensure correctness of complete wiring). Relay settings, status indications, fault
annunciations, data logging, display of switchboard SLDs shall be verified from HMI
in case the same is provided.
vi. That IR Value has been recorded for bus bars, circuit breaker, incoming and outgoing
cables, control wiring and potential transformers. Where required joint resistance of
bus bars have been recorded and found to be satisfactory. All the surroundings and
panels have been cleaned and temporary earth leads have been removed.
vii. Following tests shall be ensured for all CTs
- Insulation resistance test
Ratio test through primary injection
Polarity test
Knee point voltage for class PS CTs
viii. Following tests shall be ensured for all PTs
Insulation resistance test
Ratio test through primary injection
- Polarity test
ix. Following tests shall be ensured for all breakers
- Insulation resistance test
- Breaker closing, opening sequence using 3 pole timers
- High voltage test both in open and close condition for HV breaker
Contact resistance of all three poles using 100A DC Kit
x. Following tests shall be ensured for all meters
- Calibration of meters
Functional verification and settings
xi. Following tests shall be ensured for all relays
Secondary injection test
- Relay settings
Timing check with timers
- Any other test recommend by the supplier
xii. Following tests shall be ensured for all bus bars
- Tightness of all nuts/bolts using Torque wrench
IR value
- Contact resistance using 100A DC Kit
- Cleaning of bus bar chamber using vacuum cleaner
- Conducting jelly shall be applied on AL/CU joints as per manufacturer's
recommendations
- HV test in case of HV switchboard
The bus ducts as per issued drawings will be supplied in parts and all the parts shall be
assembled and the bus bar connections shall be made at site. The insulators in bus ducts shall
be inspected for any possible damage during transit and the defective ones shall be replaced.
The insulators shall be cleaned. Contact surface of bus bars, bus bar bolts and nuts shall be
thoroughly cleaned. Petroleum jelly shall then be applied and bolted connection made. The
bus duct enclosure shall be checked for earth continuity and then earthed at two places. The
bus duct shall be properly supported between switchgear and transformer. The opening in the
wall where the bus duct enters the switchgear room shall be completely sealed to avoid rain
water entry. Expansion joints, flexible connections etc. supplied by the manufacturer of the
bus duct shall be properly connected. The bus duct levelling shall be checked with spirit level
and pendulum weight.
Before commissioning any bus duct, following points shall be checked and ensured for safe
energising of the bus ducts
3.2 Transformers
3.2.1 Before lifting transformer, it shall be ensured that all cover bolts are tightened fully. In case
when it is necessary to use jacks for lifting, projections provided for the purposes of jacking
shall be used . Lifting jacks shall not be used under the valves or radiator tubes. For
transporting transformers from stores to site, the transformers shall be loaded on a suitable
capacity truck or trailer. The transformers shall be properly supported by steel ropes and
stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and vibrations.
At no instance, the transformer shall be kept on bare ground. Where it is not possible to
Copyright EIL — All rights reserved
Format No. 8-00-0001-F1 Rev. 0
3.2.2 Transformers shall be examined, for any sign of damage in transit. Particular attention shall
be given to the following in this regard.
If any thing adverse is noted, the same shall be brought to the notice of Engineer- in- charge.
3.2.3 Contractor shall examine the transformer base, oil pit, fire walls and foundations made by the
civil contractor. It shall be ensured that oil spills can not propagate along cable trenches. Any
discrepancy noted will be brought to the notice of Engineer- in- charge. Transformers shall be
placed on channels or rails over concrete foundations. The transformers shall be levelled,
aligned and checked for free movement on the channels or rails. Stoppers shall be provided to
the transformers immediately to prevent any movement. Normally transformers upto 1000
kVA rating shall be received duly fitted with radiator tubes, conservator tanks, valves, wheels
and other accessories. While the transformers of above 1000 kVA rating may be supplied with
loose accessories. All the accessories like radiators, cooling fans, valves, conservator tanks,
explosion vent pipe, bushings and other devices which are supplied in different packages
shall be checked for any transit damage and cleaned thoroughly before fixing on the
transformer. All loosely supplied parts shall be assembled as per manufacturer's instruction
manuals/ drawings and documents. All the connections for CTs bushings and other wiring
shall be checked for tightness and correctness before replacing the lid or tightening all the
bolts. Gravels shall be filled in the transformer bay, soak pit as per requirement.
Before topping up with oil, transformer shall be fitted with all accessories such as valves,
gauges, thermometers etc. Oil samples shall be taken from each drum and tested for
determination of dielectric strength. Any sign of leakage of the barrel or of its having been
opened shall be recorded and reported. It is necessary to filter the oil before the transformers
are filled. It shall be ensured in oil filling operation that no air pockets are left in the tank and
that no dust or moisture enters the oil. All air vents shall be opened. Oil shall be filled
through a streamline oil filter using metal hose. To prevent aeration of the oil, the transformer
tank shall be filled through the bottom drain valve. In a transformer with conservator tank, the
rate of oil flow shall be reduced when the level is almost upto the bottom of the main cover to
prevent internal pressure from rupturing the pressure relief-pipe diaphragm. Sufficient time
shall be allowed for the oil to permeate the transformers and also for the locked -up air
bubbles to escape. Any air accumulation in the buchholz relay shall be released.
i. Sample of oil from the transformer shall be taken from the bottom of the tank.
3.2.6 Drying out of the transformers, if required, shall be carried out and record maintained in
accordance with IS: 10028. Normally a streamline filter shall be used for drying-up. IR value
versus time of both windings along with OTI/WTI and filtrations machine temperature curve
for IR value Vs time shall also be plotted and recorded during the drying-up process.
i. The maximum sustained temperature to which transformer oil may be subjected shall
be limited to 80° C.
ü. The transformer shall be carefully monitored throughout the drying out process and
all observations shall be carefully recorded.
Drying out shall be continued so that the insulation resistance as prescribed in the
standard code of practice is attained and the value remains constant for more than 12
hours. However, a minimum number of cycles shall be done for each transformer as
found necessary by the Engineer-in-charge. Generally a Megger reading of 2
megohms / kV at 60° C temperature. with a 5 kV Megger may be a rough indication
for stopping the dehydration.
3.2.7 The following work on transformers shall be performed by the contractor if specifically called
for:
ü. Testing of radiator tubes for any leakage and rectifying these by welding / brazing.
Before commissioning of any transformer, the following points shall be checked for safe
energisation of the transformer:
i. All the accessories have been fixed properly and transformer body and neutral are
properly earthed. The transformer dehydration is over and results are satisfactory and
approved by the Engineer-in-charge. In case transformers are idle for more than one
month after dehydration, transformer oil has been given at least two circulations.
ü. Oil level, in the transformer conservator tank and all the bushings is upto the marked
point and the oil has been tested for dielectric strength and acidity.
Silicagel is in reactivated condition. The breather pipe is clear from any blocking and
contains oil upto the proper level.
iv. The explosion vent diaphragm does not have any dents. Accumulation of any oil and
air had been released.
v. Operation of off-load and on-load tap changers on all the tap positions is satisfactory.
The mechanical parts of the on-load tap changer are lubricated. Motor IR value has
been taken and found satisfactory. Tap position mechanical indicator on the
transformer and tap position indication meter on the control panel are reading the
same tap positions. Tap changer limit switches are operating satisfactorily on the
maximum and minimum tap positions. On-load tap changer contact pressure and
resistance is as per manufacturers recommendations. Oil level of tap changer tank is
upto the required level and oil has been tested for dielectric strength. The tap setting
on which the off load tap switch is locked shall be recorded. Generally the off-load
tap switch shall be kept on nominal tap.
vi. Buchholz relay has been tested and checked up for any friction in the movement, and
floats are free. All the other protective relays, alarm and annunciation relays have
been tested.
vii. Metering equipment has been tested and polarity test of PT's and transformer winding
is satisfactory. Phase sequence and connections have been checked for proper vector
group.
viii. Ratio test and winding resistance on all the tap positions is satisfactory.
ix. Gaps of arcing horns for the bushings where provided are in order and earth
connections for the surge diverters have been checked.
x. Winding and oil temperature thermometer pockets contain oil and the winding and oil
temperature settings on dial gauges are in order.
xi. Transformers fitted with fans for forced air cooling have been checked up for starting
and stopping of the fans both in manual and auto mode and air-displacement has been
verified.
xii. Simulation tests for all external interface connection alarm, annunciation and trip
circuits have been checked and are in order.
xiii. Insulation resistance of all the control circuits and IR value of the transformer
windings and all the incoming and outgoing cables have been checked.
xiv. Valves in the cooling system and valve between the buchholz relay and the
conservator tank are in open position.
xv. Setting of all the protective relays is at the desired value and DC Trip supply is
healthy.
xvi. Magnetic, current and magnetic balance test have been conducted
xvii Simulation test for WTI,OTI,PRV,OSR
xviii Settings of WTI/OTI as per the instruction of the manufacturer
xix Earth resistance value for the neutral earthing
After switching on the transformer the following points shall be observed and recorded.
3.3.1 All the motors generally would be erected by the mechanical contractor.
3.3.2 Electrical contractor shall keep the motor space heater energised as per the directions of
Engineer-in-charge. Electrical contractor shall measure the insulation resistance of motor
windings and PI in case of HV motors. Insulation resistance of the motors shall be measured
between the winding of the machine and its frame by means of a 500 / 1000 V Meggar in case
of 415 V motors. A minimum value of 1 megohm for 415 V motors shall be considered a safe
value. In case of lower I.R. Value, the insulation value shall be improved by any of the
following methods as directed by the Engineer-in-charge.
In case the insulation is low, the following method of drying has to be adopted, after
consultation with Engineer-in-charge. During drying the temperature rise of winding shall not
exceed the permissible value for the class of insulation used.
i. By locking the motor so that it can not rotate and then applying such a low voltage to
the stator terminals so as to pass full load current in the stator keeping the stator
winding temperature below 90° C . In this case a close watch shall be kept for any
possible overheating and I.R. Values vs. temperature shall be plotted and heating
continued till I.R. value becomes steady.
ü. By blasting hot air from external source, Maximum temperature of winding while
drying shall be 70° C to 80° C (thermometer) or 90° C to 95° C by resistance
method. Heating shall be done slowly first till steady temperature of winding is
reached after 4 to 5 hours, and for large machines after 10 hours. A record has to be
kept for drying process, with half an hour readings and, till steady temperature is
reached. In case it is essential, the drying process can be supplemented by blower.
3.3.3 It shall be ensured that the motor leads are correctly connected in the terminal box, as
indicated in the `Name Plate'. The covers of all terminal boxes shall be properly fixed, the
gaskets intact. The control circuit shall be tested for proper functioning as per circuit diagram.
3.3.4 In case of synchronous machines, slip rings and brush gear shall be polished and brushes shall
be fixed in their holders with clearance and pressure as recommended by the manufacturers.
3.3.5 Before commissioning, the ventilation and cooling system of the motor must be inspected. In
case of motor with forced ventilation the air inlet shall be examined to ensure that it is free
from moisture and any foreign material. It shall also be ensured that recommended flow and
pressure of air is available to produce the required cooling effect.
3.3.6 The motor control gear shall also be carefully examined, the over-load settings may be
reduced or time lags bypassed from protective gear to ensure rapid tripping of switchgear in
event of faults. The direction of rotation of a new motor specially of large capacity , and phase
sequence of supply shall be kept in view while joining and connecting to the motor terminals
3.3.7 Finally the motor shall be started on no-load after decoupling, and shall be allowed to run for
a minimum period of 4 hours, or for a time as instructed by Engineer-in-charge. Attention
shall be given to the proper running of the bearings, vibration or unusual noises if any.
Voltage, starting current, no load current, stator winding and bearing temperature shall be
recorded after every 1 hour during this test. Direction of rotation shall be checked and
recorded. Normally the motors run in clockwise direction as viewed from the driving end
with reference to the phase sequence R, Y, B.
3.3.8 After switching off the motor, the insulation resistance of the motor shall be recorded under
hot and cold conditions.
3.3.9 If the no load test run is found satisfactory, the motor shall be allowed to run for 8 hours and
all readings shall be recorded.
3.3.10 The following work on motors, may be performed by the contractor if specifically called for.
i. The proper level of bearing oil has to be checked. The condition of grease in bearings
shall be checked and in case it is necessary, complete replacement of bearing with
specified grade of grease after proper cleaning of the bearing shall have to be done.
Wherever external greasing facility exists, the condition of grease may be checked by
pumping some new grease of specified grade at start. If the grease coming out is
deteriorated grease shall be replaced.
ü. All the motors, motor exciter set and induction generators directly coupled or coupled
through reduction gears shall be checked for abnormal vibration, if any Large rated
HV motors with journal type bearings are liable to get damaged from shock, rough
handling during transit. Any minor defect in a race or roller may give rise to
considerable amount of vibration and noise. Contractor shall check and bring to the
attention of Engineer-in-charge any defect noticed in this regard.
Due care shall be taken to avoid any damage to bearing insulation wherever provided.
Battery (Lead acid, Nickel Cadmium or VRLA type as specified) shall be erected on stands
and insulators supplied by the manufacturer of the batteries. The installation shall be done as
per the layout drawings and manufacturer's instructions. Electrolyte if required / as applicable
shall be filled as per manufacturer's instructions. Interrow connections shall be made with the
leads supplied by the manufacturer. Functional check shall be done on the battery charger
including battery charging and discharging, recharging as per the recommendation of the
manufacturer.
The neutral earthing resistor shall be inspected for any damage to the resistor grid and other
components. The resistor shall be levelled and installed. All covers etc. shall be checked for
tightness to ensure that the enclosure of the resistor is dust, vermin and weatherproof.
Earthing conductors shall be taken from the out end terminal of the resistor, for connection to
earth electrodes and to the main grid. Check such as IR, operation of space heater, earth
resistance shall be done before the commissioning.
The welding receptacles shall be erected on steel/concrete structures as per the drawings. In
isolated places a separate support shall be fabricated and installed.
The push buttons / control stations shall be installed near to the motors to be controlled.
Individual channel supports shall be installed as per EIL standard. If control stations for
hazardous areas are to be supplied by contractor, these shall be of Ex (d) type, tested by
CIMFR and approved by CCoE or other applicable certifying authorities. All outdoor push
buttons / control stations shall preferably have integral canopies for additional weather
protection. The canopy shall be made of 2 mm thick galvanized sheet steel or FRP where
these are not integral with the equipment.
The isolators shall be transported to site in the dismantled condition. All the insulators may be
also supplied loose. The contractor shall inspect, clean, assemble and install the isolator on the
base structure previously fabricated, erected and levelled by him. The operating mechanism
shall be installed on the structure and connected to the isolator poles. The operating
mechanism shall be tested by slowly bringing the isolator to the closed position and carrying
out the necessary adjustment as per the manufacturer's instructions. The earthing switches,
frames and operating handle etc. shall be earthed.
3.9 Contractor shall provide the following items in substation, as per CEA Regulations.
3.9.1 Fire buckets filled with clean dry sand and ready for immediate use for extinguishing fires and
fere extinguisher (carbon dioxide, dry chemical extinguisher etc.) suitable for dealing with
electric fires shall be conspicuously marked and kept.
3.9.2 First aid boxes containing ointments and medicines for immediate treatment of injuries (As
prescribed by Indian Red Cross Society or equivalent).
3.9.3 Instructions of restoration of persons suffering from electric shock in English, Hindi and Local
language of the district shall be affixed in a conspicuous place.
3.9.4 Danger boards (HV., MV.) shall be provided on transformer bay gate, switchboards, entrance
to switchgear room and at other places as required by Engineer-in-charge.
3.10 The Communication system and Fire alarm system panels and equipment shall be installed
complying to manufacturer's instructions. The location of field station (call back station unit,
break glass unit, telephone set etc.) shown on the drawing are indicative. The exact location
shall be decided at site by contractor in consultation with Engineer-in-charge. Correct type of
equipment with regard to hazardous protection as specified on drawing shall be adhered to by
contractor, for installation.
4.1 Field inspection, testing and commissioning of the complete electrical installation shall be
carried out as per EIL specification no. 6-51-0087.
After the equipment is installed properly in accordance with drawings and specifications,
contractor shall carry out all pre-commissioning checks and tests as per EIL format in the
presence of Engineer-in-charge and test readings shall be recorded and furnished to EIL in
triplicate.
4.2 All equipment layout drawings shall be marked by the Contractor for "AS BUILT STATUS"
and two sets of hard copies shall be submitted to EIL.
The contractor shall have all necessary construction equipment, tools and tackles and testing
instruments to carry out the erection works and to commission the system as specified. These
shall include but not be limited to the following, and these shall be brought to site by
contractor before the start of work.
5.1 Equipment
i. Portable grinder.
ü. Portable welding machine.
üi Portable gas cutting / welding set.
iv. Pipe threading machine.
v. Pipe bending machine (hydraulic).
vi. Portable drill machine suitable to take up drilling for different sizes as per
requirement.
vii Dewatering pump sets (diesel driven).
viii. Power Hacksaw.
ix. Conduit dye set.
x. Hydraulic crimping machine with round/hexagonal dye set.
xi. Hand crimping tool.
xii. Portable electric blowers, vacuum cleaners.
xiii. Miscellaneous items such as slings, pulleys, tarpaulins, wooden sleepers, ladders. etc.
as required.
xiv. Safety belts, safety goggles, and gloves.
xv. Separate tool kit for each Electrician.
xvi. Hydraulic/Hand held grease gun
SPECIFICATION
FOR
CABLE INSTALLATION
Abbreviations:
CONTENTS
1.0 SCOPE 4
5.0 TERMINATIONS 9
1.0 SCOPE
This specification defines the requirements for supply of materials, wherever applicable,
installation, testing and commissioning of cable installation.
2.1 The work shall be carried out in the best workman like manner in conformity with this
specification, EIL installation standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD standards listed
below :
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:
a. CEA Regulations
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by CCOE/DGMS/DGFASLI (as applicable).
d. The petroleum rules (Ministry of Industry, Government of India)(As applicable)
e. Any other regulations laid down by central/state/local authorities and insurance
agencies
All materials and hard wares to be supplied by the contractor shall be new, unused and of best
quality and shall conform to the latest specifications of Bureau of Indian Standards.
These shall be ladder type trays either prefabricated hot dip galvanised sheet steel trays or site
fabricated angle iron painted trays or FRP trays as specified in job specification.
The cable trays shall comply with the requirements specified in EIL installation standard
enclosed with the specification/Tender.
Angle iron cable trays shall be fabricated from standard rolled angle iron sections of size
75x75x8 for runners for supporting spans limited to 3000 mm. Cross support shall be 25 x 6
mm MS flat for tray width upto 500 mm and 32 x 6 mm flat for tray of more than 500 mm
wide and spacing between two cross supports shall not exceed 250 mm.
3.1.3 Vertical supports for both the prefabricated and site fabricated type trays shall be fabricated
out of ISMC 100 and horizontal supports shall be with 65 x 65 x 6 mm angle iron sections.
Outer most tier of all vertical cable trays shall be covered with GI sheet for protection against
physical damage to cables.Bottom most cable tray shall also be provided with GI sheet from
the bottom side for the protection of the cables from the hydrocarbon pipes located below. GI
Covers also shall be provided for the top most cable trays located outdoors.
Cable racks and trays shall be covered by removable top covers on upper most tiers allowing
adequate ventilation in following cases where:
GI cover sheet shall allow adequate ventilation to the cables and shall be in standard length of
3000 mm, flanged on both sides for fixing on cable tray.
The cable trays shall comply with the requirements specified in EIL standard specification
and installation standard enclosed with the specification/Tender
Cable glands shall be of nickel plated brass unless otherwise specified. The single
compression type cable glands shall be used for indoor panels/equipment (e.g. substation,
control room etc). The cable glands for outdoor terminations shall be weather protected,
double compression type. Cable glands forming a part of relevant FLP enclosure shall be FLP
type, tested by CIMFR or any other recognized independent testing laboratory and approved
by CCoE/DGMS or any other statutory authority as applicable. Indigenous FLP glands shall
have valid BIS license as per the requirements of statutory authorities. All cable glands shall
comply with the requirements given in IS/IEC-60079 Part 0.
Entry thread of cable gland shall be compatible to the entry thread provided in the equipment
(BS, ET, NPT, PG as applicable). If required, suitable reducers/adopters shall be used.
3.3 Connectors
Terminations of cables with stranded conductor shall be made with crimped type tinned
copper solder less lugs which shall be suitable for the cable size mentioned in cable schedule.
3.4 Ferrules
Ferrules shall be of approved type and of size to suit core size mentioned and shall be
employed to designate the various cores of control/signal cable by the terminal numbers to
which the cores are connected, for ease of identification.Furrule shall be printed type.
4.1 General
Cable installation shall include power, control, lighting, fire alarm, telephone and
communication cables. These shall be laid in trenches/ cable trays /Duct as detailed in the
cable layout drawings. Cable routing given on the cable layout drawings shall be checked in
the field so as to avoid interference with structures, heat sources, drains, piping, air-
conditioning duct etc. Any change in routing shall be done to suit the field conditions
wherever deemed necessary, after obtaining approval of Engineer-in-charge.
4.1.1 High voltage, medium voltage power and control cables shall be separated from each other by
adequate spacing or by running through independent pipes, trenches or cables trays, as shown
on layout drawings/installation standards. Details of cable routes and cable spacing not shown
in detail on these drawing shall be determined by the contractor and approved by the
engineer- In-charge.
The individual cable fixing clamps and spacers for laying of single core cables shall be of
non-magnetic material. As a general practice, the metallic sheath, screen and armour of
single core cables shall be earthed at one point to keep the same at earth potential unless
otherwise stated. The continuity of armour and semiconductor screen shall be broken at each
joint. Single core cables, when laid in trefoil formation shall be braced by suitable clamps at a
distance, not exceeding 3 meters along the cable routing.For laying of long length of single
core cables recommendations from vendor shall be followed.
If straight through joints are required to be provided on single core cables, armour shall be
broken at joints as per manufacturer's recommendations. For single core cables, armour shall
be earthed at one end for the cable run length as per manufacturer's recommendation.
The Telephone, Communication and Fire alarm cables shall run on instrument trays/ducts/
trenches in the units. Wherever these are not available, cables shall be taken in a separate
trench/tray with a minimum spacing of 300 mm from power and control cables
Telephone, fire alarm and plant communication cables shall be directly buried in road berm
area, (unless otherwise specified in cable layout drawings). These cables shall cross power
cables preferably at right angles. Street lighting cables shall be laid on the other nide of road
berm area
4.1.2 The lengths indicated in the cables schedule are only approximate. The contractor shall
ascertain the exact length of cable for a particular feeder by measuring at site. All cable routes
shall be carefully measured .Before the start of cable laying, the contractor shall prepare cable
drum schedule and get that approved by Engineer-in-charge to minimize/avoid straight
through joints and then the cables cut to the required lengths, leaving sufficient lengths for the
terminations of the cable at both ends. The various cable lengths cut from the cable reels shall
be carefully selected to prevent undue wastage of cables. Extra loop length shall be given for
feeder cables where required as per the directions of Engineer-in-charge to meet
contingencies
Cables shall be laid in directly buried trench or in RCC trench (underground trench) or in
cable tray along pipe sleepers or in over head trays as shown on cable layout drawings.RCC
covers of trenches shall be effectively sealed to avoid ingress of chemicals and oils.
Overhead trays shall be installed 2700 mm (minimum) above grade level and 300mm above
FGL in case cable trays are installed along with pipe sleepers. At road crossings overhead
trays shall be installed at 7000 mm (minimum) above grade level or cables shall be routed
cable tray culvert/ Electrical road crossings as per layout drawings.
Sufficient care shall be taken while laying cables to avoid formation of twist, sharp bend etc.
in order to avoid mechanical injuries to cables. Rollers shall be used for pulling of cables.
Cable installation shall provide minimum cable bending radii as recommended by cable
manufacturer.
4.1.3 Cables shall be neatly arranged in the trenches / trays in such a manner that criss-crossing is
avoided and final take off to the motor / switchgear is facilitated. Arrangement of cables
within the trenches / trays shall be in line with cable layout drawings. Cable routing between
cable trench and equipment/motors shall be taken through GI pipe sleeves of adequate size.
Pipe sleeves shall be laid at an angle of maximum 45 to the trench wall. Bending radii of
pipes shall not be less than 12D. It is to be ensured that both the ends of GI pipe sleeves shall
be sealed with approved weather proof sealing plastic compound after cabling. In places
where it is not possible, cables shall be laid in smaller branch trenches. Different rows of
cable trays in cable cellar below the cutout shall be fixed so that the trays don't obstruct cable
entry to the panels.
4.1.4 All cables shall be identified close to their termination point by cable tag numbers as per cable
schedule. Cable tag numbers shall be punched on aluminium /Lead straps (2mm thick, 20 mm
wide and of enough length) securely fastened to the cable and wrapped around it.
Each underground cable shall be provided with cable tags of lead /Aluminium securely
fastened every 30 m of its underground length with at least one tag at each end before the
cable enters/leaves the ground. In unpaved areas, cable trenches shall be identified by means
of cable markers as per installation drawing. These cable markers shall be placed at location
of changes in the direction of cables and at intervals of not more than 30 m and also at cable
straight through joint locations. Cable route markers shall extend 600mm above ground.
4.1.5 All temporary ends of cables must be protected against dirt and moisture to prevent damage to
the insulation. For this purpose, ends of cables shall be covered with an approved PVC end
cap or rubber insulating tape.
4.1.6 Each row of cables shall be laid in place and before covering with sand. All wall
openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage
of water inside building/lined trench. Every cable shall be given an insulation test in presence
of Engineer-in-charge/Owner before filling the cable trench with sand Any cable which is
found defective shall be replaced.
4.1.7 Where cables pass through foundation walls, the necessary openings shall be provided in
advance for the same by another agency. However, should it become necessary to cut holes
in existing structures for example floor slab etc., the electrical contractor shall determine
their location and obtain approval of the Engineer-in-charge before carrying out the same.
4.1.8 Cables for road crossings shall be taken through ERC (Electrical Road Crossing) as shown in
the cable layout drawings and sleeves/ducts shall be effectively sealed thereafter.
At road crossing and other places where cables enter pipe sleeves adequate bed of sand shall
be given so that the cables do not slack and get damaged by pipe ends.
4.1.9 Wherever cable trench crosses storm water, waste water channel/drain, cables shall be taken
through PVC/RCC pipes. Where cables are required to cross drains of depth more than 1200
mm, cables shall be taken over the drain on cable trays supported suitably using ISMC
150/200 sections.
4.1.10 Ends of cables leaving trench shall be coiled and capped and provided with protective cover
till such time the final termination to the equipment is completed.
Cables shall be laid underground in excavated cable trenches where specified in cable layout
drawings. Trenches shall be of sufficient depth and width for accommodation of all cables.
Cables shall be properly spaced as per installation standards. Maximum number of cable
layers in trench shall be preferably limited to 6 layers.
Minimum depth of directly cable trench shall be 750 mm, for medium voltage and 900 mm
for HV. Cables. The depth and the width of the trench shall vary depending upon the number
of layers of cables as per EIL installation Standards.
Cables shall be laid in buried trenches at depth as shown in the cable layout drawings. It is to
be ensured by the contractor that the bottom of buried trenches shall be cleared of all rocks,
stones and sharp objects before cables are placed. The trench bottom shall be filled with a
layer of sand or stone dust. This sand /stone dust shall be leveled and cables laid over it.
These cables shall be covered with 150 mm of sand on top of the largest diameter cable and
sand shall be lightly compacted. A flat protective covering of 75 mm thick second class red
bricks or concrete tiles as per specification shall then be laid and the remainder of the trench
shall then be back -filled with natural soil, rammed and leveled.
Cables shall be laid in 5 or 6 tiers in concrete trench as shown on layout drawings. Concrete
cables trenches shall be filled with sand /stone dust in hazardous area to avoid accumulation
of hazardous gases and oil. RCC covers of trenches shall be effectively sealed to avoid
ingress of chemical and oil in process area. Removal of concrete covers where required for
the purpose of cable laying and reinstating them in their proper position after cables are laid
shall be done by electrical contractor.
Minimum depth of RCC cable trench shall be 500mm for all voltage grades with 300mm
clearance between the bottoms of the trench cover and top of the cable. The depth and the
width of the trench shall vary depending upon the number of layers of cables and bending
radius required for cables as per EIL installation Standards
A11 wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid
seepage of water
4.4.1 Cables installed above grade shall be run in cable trays, clamped on walls, ceiling or
structures and shall be run parallel or at right angles to beams, walls or columns. Cable
routing shall be planned to be away from heat sources such as hot piping, gas, water, oil
drainage piping, air-conditioning duct etc. Each cable tray shall contain only one layer of
cables as far as possible for power cables. However control cables may be laid in multiple
layers in the cable trays.
4.4.2 Individual cable or small group of cables (upto 3 cables) which run along structures / walls
etc. shall be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle bars.
Alternatively small group of cables can be taken through 60/100/150 mm slotted channel tray
4.4.3 Cable laid on supporting angle in cable trenches, structures, columns and vertical run of cable
trays shall be suitably clamped by means of GI saddles / clamps, whereas cables in horizontal
run of cable trays shall be tied by means of nylon cords. Distance between supporting angles
shall not exceed 600 mm.
4.4.4 All cable trays (other than galvanized/FRP trays) and supporting steel structures shall be
painted before laying of cables. The under surfaces shall be properly degreased, derusted,
descaled and cleaned. The painting shall be done with one coat of redoxide zinc chromate
primer. Final painting shall be done with two coats of approved bituminous aluminium paint
unless otherwise specified.
4.4.5 Where cables rise from trench to motor, lighting panel, control station, junction box etc., they
shall be taken in GI pipe for mechanical protection upto a minimum of 300 mm above grade
for outdoor area. Cable ends shall be carefully pulled through conduit to prevent damage to
cable.
4.4.6 All GI Pipes shall be laid as per layout drawings and site conditions. Before fabrication of
various profiles of pipes by hydraulically operated bending machine (which is to be arranged
by the contractor) all the burrs from the pipes shall be removed. GI Pipes having bends shall
be buried in soil / concrete in such a way that the bend shall be totally concealed. For G.I.
pipes buried in soil, bitumen coating shall be applied on the buried lengths, Installation of G.I.
pipes shall be undertaken well before paving is completed and necessary co ordination with
paving agency shall be the responsibility of Electrical Contractor.
d) 4 and above cables in a pipe - 40% of pipe cross-sectional area occupied by cables.
4.4.7 After the cables are installed and all testing is complete, conduit ends above grade shall be
plugged with a suitable weatherproof plastic compound/bitumen/suitable sealing compound.
Alternatively rubber bushes shall be employed for the purpose of sealing.
4.4.8 Fire proofing of end of power cables at least 1 meter at each end as per OISD norms for the
refinery and Petroleum industry, shall be carried out as per the recommendation of the paint
supplier .Rates for the fire proofing of cables shall be included in the cable installation and no
separate payment shall be made for the painting.
5.0 TERMINATIONS
5.1 All cables up to 1100V grade and higher levels shall be terminated at the equipment by means
of compression type cable glands suitable for the cable size. They shall have a screwed nipple
with electrical threads and check nut. The cables shall be identified close to their termination
points at both the ends of cable(cable numbers shall be punched on aluminium/Lead straps
2mm thick and securely fastened to the cable, wrapped around it) and also along the route at
regular intervals, by cable tag numbers.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
All cable entries for outdoor termination shall be through bottom/side. Outdoor cable
termination through top of equipment shall not be permitted.
5.2 Power cables cores wherever colour coding is not available shall be identified with red,
yellow and blue PVC tapes. Where copper to aluminium connections are made, necessary
bimetallic washers shall be used.
5.3 In case of control cables, all cores shall be identified at both ends by their terminal numbers
by means of PVC ferrules suitable for core size. Wire numbers shall be as per schematic/
wiring/inter-connection diagram. All unused spare cores of control cables shall be neatly
bunched and ferruled with cable tag at both ends, for future use.
5.4 Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of non-
magnetic material/ aluminium sheet in case of single core cables. All unused cable entries on
equipment/panels shall be plugged/sealed.
5.5 The cable shall be terminated at electrical equipment/switchboards through glands of proper
size. The individual cores shall then be dressed and taken along the cables ways or shall be
fixed to the panels with polyethylene straps. The cable glanding shall be done as per
manufacturer's instructions. Cable armour shall not be exposed after termination is complete.
In case of termination of cables at the bottom of a panel over a cable trench having no access
from the bottom close fit holes shall be drilled in the gland plate for all the cables in one line,
then gland plate shall be split in two parts along the centre line of holes. After fixing bottom
plate, uncovered cable holes/gaps shall be sealed with cold setting compound.
5.6 Crimping of lugs to cable leads shall be done by hand crimping / hydraulically operated tool
as per requirement. Insulation of the leads shall be removed before crimping. Conductor
surface shall be cleaned and shall not be left open. Suitable conducting jelly shall be applied
on the conductor lead. Lugs shall enclose all strands of cable core. Cutting of strands shall
not be allowed.
5.7 The contractor shall bring to the notice of Engineer-in-charge any mismatch in cable glands,
lugs provided with the equipment vis-à-vis to the cable size indicated in cable schedule for
taking corrective action.
5.8 The cable joints shall be avoided as far as possible . In case a joint is unavoidable, the
following shall be insured:
The jointing and termination of medium voltage power cables shall be carried out by trained
personnel only. Jointing and termination of high voltage and EHV cables shall be done by
skilled and experienced jointer duly approved by Engineer-in-charge. Only type tested
jointing and termination kits of approved make shall be used.
5.9 No unauthorized repairs, modifications shall be carried out on the hazardous area equipment
terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall be
brought to the notice of Engineer-in-charge by contractor. After termination is complete, all
the bolts, nuts, hard wares of terminal box shall be properly placed in its position and
tightened.
5.10 Where required, cable sealing boxes intended to be used with the apparatus shall be filled with
solid setting type bituminous compound unless otherwise specified.
5.11 All cables glands installed outdoor shall be provided with suitable sized shrouds and rates for
the same shall be included in the scope of the termination of the cable glands. No separate
payment is envisaged for the same.
6.1 Field testing and commissioning of electrical installation shall be carried out as per EIL
specification.
6.2 Before energising, the insulation resistance of every circuit shall be measured from phase to
phase, phase to neutral and from phase/neutral to earth.
6.3 Where splices or terminations are required in circuits rated above 650 volts, insulation
resistance of each length of cable shall be measured before splicing and or / terminating. After
completion of splices and /or terminations measurements shall be repeated.
6.4 The insulation resistance of directly buried cables shall be measured before cable trenches are
backfilled. Measurements shall be repeated after back filling.
For cables upto 1.1 KV grade 1000 V Megger and for H.V. Cables 2.5 KV / 5 KV Megger
shall be used.
6.5 D.C. High Voltage test shall be conducted on cables given below after installation.
a) A11 1100 volts grade power cables in which straight through joints have been made.
The DC High Voltage test shall be performed as detailed below in the presence of the
Engineer-in-charge or his authorized representative only.
Cables shall be installed in final position with the entire straight through joints complete.
During the high voltage test, all other electrical equipment related to the cable installation,
such as switches, instrument transformers, bus bars, etc., must be earthed and adequate
clearance shall be maintained from the other equipment and framework to prevent flash over.
6.6 All checks and tests shall be made as per EIL standard test Performa available with site
engineer.
All test readings shall be recorded and submitted to EIL in triplicate sets.
6.7 Cable schedule, cable layout drawings, Interconnection drawings shall be revised and marked
by contractor for `AS BUILT STATUS' and two sets of copies along with CD shall be
submitted to EIL.
WIRT FzraTlIT 3-
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SPECIFICATION
FOR
LIGHTING INSTALLATION
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5 10.03.15 REVISED AND ISSUED AS SPECIFICATION AKG SA BR /' SC
Abbreviations:
AC Alternating Current
BIS Bureau of Indian Standards
CCoE Chief Controller of Explosives
CD Compact Disc
CEA Central Electricity Authority
CFL Compact Fluorescent Lamps
CIMFR Central Institute of Mining and Fuel Research
DC Direct Current
DG Diesel Generator
DGMS Director General Mines and Safety
ELCB Earth Leakage Circuit Breaker
FFL Finished Floor Level
FRP Fibre Reinforced Plastic
GI Galvanised Iron
HPMV High Pressure Mercury Vapour
HPSV High Pressure Sodium Vapour
HRC High Rupturing Capacity
IP Ingress Protection
IS Indian Standards
JB Junction Box
LED Light Emitting Diode
MCB Miniature Circuit Breaker
MCCB Moulded Case Circuit Breaker
MDB Main Distribution Board
MS Mild Steel
PE Polyethelene
PVC Polyvinyl Chloride
TPN Three Phase and Neutral
CONTENTS
1.0 SCOPE 4
1.0 SCOPE
This specification defines the requirements for the supply of equipment, materials,
installation, testing and commissioning of the lighting system (lighting fixtures, lighting
power distribution, telephone wiring etc.).
2.1 The work shall be carried out in the best workman like manner in conformity with this
specification, EIL installation standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD standards listed
below :
SP:30 (BIS) Special Publication - National Electrical Code.
IS:5 Colours for ready mixed paints and enamels.
IS:3854 Switch for domestic & similar purpose
IS/IEC 60947 L.V. Switch gear and control gear
IS: 1293 Plugs & socket outlets of rated voltage upto and including 250V &
rated current upto 16A.
IS:9537 Conduits for electrical installations
IS 694 Polyvinyl Chloride insulated unsheathed & sheathed cables/cords
upto & including 450/750V
OISD RP- 147 Inspection and safe practice during electrical installation
OISD 173 Fire prevention and protection system for electrical installation
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:
a. CEA Regulations
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by CCoE/DGMS (as applicable).
d. The petroleum rules (Ministry of Industry Government of India).
e. Any other regulations laid down by central/state/local authorities and Insurance
agencies.
All materials, fittings and appliances to be supplied by the contractor shall be new, unused and
of the best quality and shall conform to the specifications given hereunder. These shall be
manufactured in accordance with the latest revision of the specifications of Bureau of Indian
Standards/International standards. In the absence of any specifications for a particular item,
contractor shall bring material samples along with proven track record to site and get the same
approved by Engineer-in-Charge/Owner before installation.
3.1.1 Lighting and Power panels (general purpose panels for safe area) shall be made of 1.6mm
thick sheet steel or polycarbonate material as specified and shall be dust and vermin proof.
All metal surfaces shall be cleaned free of rust, given a coat of red-oxide primer and finished
with two coats of epoxy based paint of shade 632 of IS 5. Panels shall be indoor/outdoor type
as specified. Indoor type panels shall have IP42 degree of protection and shall be suitable for
surface or flush mounting on wall surface as specified. Lighting and power panels located
outdoor shall be IP55 weather protected and shall also preferably have integral canopy for
additional weather protection. The canopy shall be made of 2mm thick galvanized sheet steel
or FRP where these are separate from the equipment.
3.1.2 Lighting and Power panels shall have TPN incoming feeder and single phase outgoing
feeders. Lighting circuit feeders shall be rated for 10 amps and power circuit feeders shall
have current rating of 16Amps.In power panels for window Air conditioning units, power
circuit feeder shall be rated for 20 amps. Panels shall be equipped with phase and neutral bus
bars of required current carrying capacity. The outgoing feeders shall be provided with single
pole miniature circuit breakers (MCBs) for safe areas and double pole MCBs for hazardous
areas. The incomer shall be with MCB and ELCB unit unless otherwise specified. In case of
panel for Green Buildings incomer shall also be provided with Energy Meter as per GRIHA
requirements. Accordingly, CTs shall be provided in all the three phases for current
measurement and voltage shall be tapped directly from phases through control fuses.
Miniature circuit breakers shall be mounted in such a way that the operating levers project
outside the front Bakelite cover plates for ease of operation. A hinged door to cover the
operating knobs shall be provided. In addition, a circuit diagram indicating incomer details
and outgoing details viz. Circuit number, circuit rating, and load connected and details of the
load shall be pasted inside the panel. Also a laminated copy of the diagram shall be provided
inside the panel in a suitably designed pocket. Two external earthing studs for connection to
the plant earthing grid shall be provided on the panel. Further, the panel shall be provided
with an earth bus bar with terminal studs for connection to the third core of each outgoing
circuit. Each circuit phase and neutral shall be given ferrule numbers. Complete wiring inside
the panel, shall be neatly bunched with PVC tape and button. Sufficient terminals shall be
provided in the terminal block so as to ensure that not more than one wire (core) is connected
to a terminal. The panel shall have knock out holes or removable gland plate for the entry of
incoming and outgoing conduits or cables. The panels shall be complete with requisite
number of cable glands as specified.
3.1.3 The Main distribution board (MDB) where used, shall be made of 2mm thick sheet steel
panel, dust and vermin proof similar in construction to Lighting and Power panels but with
TPN MCCB or switch fuse incoming and TPN outgoings ( MCB with ELCB units and MCB
without ELCB unit as applicable) of required numbers as specified.
3.1.4 All MCBs shall be of M9 category as per IS 8828 and sensitivity of ELCBs shall be 100 mA-
300 mA unless otherwise specified.
3.1.5 Wherever the size of incoming cable to lighting, power panels/MDB is more than 35 sq.mm a
suitable cable adapter box shall be provided and attached to the panel. The incoming cable
leads shall be connected to terminal block (bolted type terminals) of required size. This
terminal block shall be connected to TPN incomer unit through separate PVC insulated copper
conductor wires/bus bars. Sufficient space shall be provided (minimum 300mm) between
gland plate and the bottom of terminal block for easy termination.
The types, makes and catalogue numbers of various types of lighting fixtures shall be as given
in Fixture schedule job data sheet. HPMV/HPSV/fluoroscent lighting fixtures shall be
complete with ballast, starters and capacitor, as required. Control gears for these fixtures shall
be integral or non-integral as specified in lighting layout drawings. Unless otherwise
specified, all fixtures shall be supplied complete with lamps. Ballast for fixture shall be
copper wound or electronic type. The fixtures shall be of high power factor type i.e. at least
0.9 or more.
3.3 Switches
Switches, manufactured in accordance with IS:3854 shall be used for non hazardous areas.
Switches in areas where concealed wiring has been adopted, shall be flush mounting piano
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type unless otherwise specified. For surface conduit wiring, piano type switches in surface
mounted box shall be provided. Industrial Type switches (Weather protected) shall be used
for outdoor areas. Modular switches along with required boxes shall be provided for indoor
application in case shown in the layout.
3.4 Receptacles
Three pin type 5A/15A receptacles manufactured in accordance with IS: 1293 shall be used
for non hazardous areas. The receptacles and the controlling ON/OFF switch shall be mounted
in the same enclosure box but these shall be in separate units to facilitate replacement by
parts. Flush mounting type receptacles shall be used in areas where concealed wiring has been
adopted and surface type shall be used in other areas. For exhaust fans and wall mounted air
circulators, socket and switch enclosures shall be separate. In buildings such as sub-station,
DG. Shed, Workshop, maintenance shop etc. industrial type metal clad socket outlets and
plugs shall be provided. These sockets shall be supplied complete with plugs. Modular type
receptacles along with required boxes shall be provided for indoor application in case shown
in the layout
The outlet boxes used as point outlets shall be prefabricated type 65mm deep junction boxes.
Outlet boxes custom fabricated for sockets, switches, fixtures and fan regulators etc. shall be
made of MS sheet having minimum thickness of 1.6mm.Outlet boxes shall be galvanized/
nickel plated after fabrication. These shall be complete with terminal block suitable for
connection of wires up to 4 sq. mm Front cover plate shall be of 3mm thick Bakelite / PE
sheet. The colour shall suit the shade of the walls or shall be white if the shade of the walls is
not finalised. The sheet shall extend at least 2 cm on all sides of outlet box. Cover plate shall
be fixed by cadmium plated brass screws and cup washers. Outlet boxes shall be provided
with adequate number of knock outs on all the sides for ease of wiring either with conduits or
without conduits.
Conduits for Electrical installations shall conform to IS: 9537. The type of conduit (steel / GI/
PVC) shall be as specified on drawing. Black enameled steel or GI conduit shall be of 1.6mm
thick and the minimum wall thickness of PVC conduit shall be 1.6mm. Generally PVC
conduits shall be used in concealed wiring and for surface wiring GI conduit (in plant
buildings) and black enameled steel conduit (in non plant buildings) shall be used.
Lighting poles shall be fabricated as per EIL installation standards enclosed with the
specification from ERW steel tubular pipes of specified section, with joints, swaged together
when hot and beveled on outside edges or hexagonal shape. Poles shall be coated with
bituminous preservative solution on the ground portion of the outside surface. Remainder of
the outside surface shall be given one coat of redoxide primer and finished with two coats of
aluminium paint. The pole shall have a marshalling box near the bottom to contain HRC
fuses, a neutral link, an earth stud and terminal block. FRP type lighting poles shall be
provided in case shown in the layout.
3.8.1 Lighting masts (Lattice tower) where used, shall be fabricated as per EIL Standard Drawing
enclosed with the tender/specification. They shall be complete with 2 nos. MS flats provided
at the base plate for connection to the plant earthing grid. A ladder, platform, handrail, a
weather protected TPN switch (at 1500mm from ground level) and a weather protected
distribution board fabricated out of sheet steel shall be provided at the top of mast. The TPN
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Switch and the distribution board shall also have a canopy for additional weather protection.
The TPN switch shall be suitable for looping one more lighting mast from the same incoming
power supply. The distribution board shall have TPN bus bars of 30 Amps. rating and 12 Nos.
outgoing circuits each with a 6A single pole MCB. The distribution board shall have cable
entries from bottom. Necessary space provision and suitable mounting arrangement shall be
made on top of the tower for mounting of ballast (choke) and condensers for all the circuits
and the lighting fixtures. The masts shall be given one coat of red oxide primer and two coats
of aluminium paint. Distribution board shall be fabricated out of 2mm thick sheet steel and
shall be painted with two coats of enamel over a base coat of red oxide.
3.8.2 Unless otherwise specified the flood lighting high masts shall be telescopic type conforming
to EIL specification and data sheet.
3.9 Wires
Wires shall be PVC insulated and shall be of 660 Volts grade as per IS694. Conductor shall be
of stranded copper and size shall be minimum 1.5 Sq. mm for lighting, 2.5 Sq. mm for 15A
power socket circuits and 4 sq. mm for split A/C power socket circuits. Red/Yellow/blue
wires for phases, black wire for neutral and green wire for earth shall be used (size of earth
wire shall be same as for phase and neutral size). Wire size for air conditioning circuit feeders
shall be as indicated in the panel schedule.
Ceiling fans shall be of 1200mm sweep with BEE (Bureau of energy efficiency) rating of
minimum 3 star, unless otherwise specified with double ball bearing and regulator. The
suspension down rod shall be sturdy mild steel rod of adequate diameter and of minimum
length of 300mm with shackles suspension arrangement as per IS. For exhaust fans, the sweep
dia. and air CFM shall be as specified in job specification. Exhaust fans for battery room shall
be with anticorrosive blades suitable for use in acidic fumes. Exhaust fans shall be with BEE
rating of minimum 3 star.
Decorative lighting switches and sockets where specified, shall be modular in design. All
these items shall fit into the same frame with overall standard dimensions. Frames shall be
suitable for surface and flush mounting in brick / concrete wall. The frames shall be suitable
for conduit entry from all the sides. Switches and sockets shall match colors of the frame and
cover plates to obtain a combination which shall match decor of the interiors of Control
Room, Administrative buildings, offices rooms etc.
4.1 General
4.1.1 The lighting fixtures in the plant shall be fed from lighting panel. All outdoor lighting shall be
group controlled manually or through synchronous timer or photocell. Lighting wiring
between panel and lighting fixtures shall be done with PVC insulated 3-core (phase, neutral
and earth) copper conductor armoured cable for hazardous areas. Wiring in the building shall
be done by means of 3-core copper, conductor PVC insulated, un-armoured cables, or PVC
insulated copper conductor wires in conduit/Metsec channel as specified. All joints of
conductors in Switch boards/JBs Fittings shall be made only by means of approved
mechanical connectors (nylon/PVC connectors). Bare twisted joints shall not be permitted any
where in the wiring system.
4.1.2 The lighting layouts furnished by owner will indicate approximate locations of lighting
fixtures. The electrical contractor shall determine, with approval of Engineer-in-Charge, the
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exact locations of each fixture in order to avoid interference with piping or other mechanical
equipment and also with a view to obtain as much uniform illumination as practicable, and to
avoid objectionable shadows. Conduits shall be laid out by the contractor to suit field
conditions and as per directions of the Engineer-in-Charge.
4.1.3 On walkways, platforms and other outdoor area, lighting fixtures shall be located nearer to
landing of stairs or ladders, gauges, flow meters, panel boards and other equipment to provide
proper illumination.
4.1.4 The minimum height of any lighting fixture shall be preferably not less than 2.5 meters above
the floor level.
4.1.5 All outdoor cable terminations to outdoor junction boxes, panels, socket outlets etc. shall be
through bottom or from side. Top entries for cables shall be avoided to avoid water entry. All
cable glands for outdoor terminations shall be double compression type and the gland shall be
covered with PVC or rubber boot shroud. All unused cable entries shall be plugged with
suitable blanking plugs.
4.1.8 The lighting fixtures on various circuits shall be suitably interlaced so that failure of any one
circuit does not result in complete darkness.
4.1.9 Circuit cables in a group shall be cleated to structure by using galvanised strip clamps or cable
run in cable trays wherever trays are available. Spacers and cleats shall be of required size to
accommodate the cables. All hardware shall be galvanised or zinc passivated. Underground
lighting cables (in paved areas) shall be taken in suitable GI sleeves buried at a minimum
depth of 300mm from FFL. GI pipe sleeves shall be extended to 300mm above FFL. Exact
termination/layout of GI pipes (for protection of cables) shall be decided at site as per site
convenience in consultation with Engineer-in-charge.
4.1.10 Wiring for all outlet sockets shall be done with 3 cores of equal sizes for phase, neutral and
earth. The terminals of switch sockets shall be suitable to receive the size of wire specified.
4.1.11 All lighting fixtures shall be provided with terminal block with required terminals suitable for
connection of wire up to 2.5 sq. mm copper conductor.
4.1.12 The cable shall be straightened after unwinding it from the drum. All cables are clamped/laid
in straight run without any sag and kink.
4.1.13 For location where fan points are shown, fan hooks with junction box shall be provided during
concreting.
Where fan hooks and JBs. are provided separately JB shall be located within a distance of
300mm from hook for mounting of ceiling rose.
4.1.14 Industrial type plug sockets with 20A MCB or rating as per job specification shall be provided
at a height of 500mm from FFL for window AC units.
Socket outlets and plugs for installation in Sub-station building, DG shed, workshop, and
maintenance shop etc. shall be of industrial metal clad type.
4.1.15 Wiring for exhaust fans shall be terminated in receptacles as specified in layout drawing and
the connection from receptacle to the exhaust fan shall be by means of a flexible cord
equivalent in size to the main run of wires. Switch for exhaust fan shall be located in a
separate switch board along with other switches.
4.2.1 Surface or concealed conduit system of wiring shall be adopted, as specified in the drawings.
Required number of pull boxes shall be used at intervals to facilitate easy drawing of wires.
Separate conduit shall be run for lighting and power circuits. Further, conduits for Normal
lighting/Emergency lighting/DC critical lighting shall be separate. Conduit layout shall be
decided at site as per site conditions. Drop conduits for switch boards shall be decided by
contractor as per wall locations shown in Architectural drawings. All exposed run of conduits
on surface, shall be vertical or horizontal.
4.2.2 Only threaded type conduit fittings shall be used for metallic conduit system. Pin grip type or
clamp type fittings are not acceptable. Conduit ends shall be free from sharp edges or burrs.
The ends of all conduits shall be reamed and neatly bushed.
Conduit shall be of minimum 25mm dia. Maximum number of wires permissible in a conduit
shall be seven/nine for wire size of 2.5 sqmm/1.5 sq.mm. respectively.
4.2.3 The exposed outer surface of the conduit pipes, including all accessories forming part of the
conduit system, shall be adequately protected against rusting. In all cases, bare threaded
portion of conduit pipe shall not be exposed unless such bare threaded portion is treated with
anti corrosive preservative or covered with approved plastic compound.
4.2.4 Conduit connection to outlet boxes shall be by means of screwed hubs or check nuts on either
side. Where concealed wiring is done, junction boxes (65mm deep) shall be used so as to rest
on shuttering properly. Conduits shall be laid above reinforcement. All conduit connections
shall be properly screwed and Junction box covers shall be properly fitted so as to avoid entry
of concrete slurry.
4.2.5 Conduit pipes shall be fixed by 1.6mm thick GI saddles on 3mm thick Gl. saddle bars of
required width in an approved manner at intervals of not more than 50cms for straight run. At
places near junction boxes, bends, or similar fittings, saddle and bars shall be provided on
either side.
4.2.6 Where concealed wiring is to be adopted, conduits shall be laid in time before concreting of
the slab. Pull wire (GI or steel) shall be provided inside conduit for the ease of wire pulling.
The contractor shall coordinate his work with other agencies involved in the civil works in
such a way, that the work of the other agencies is not hampered or delayed. Vertical conduit
runs shall be made in wall before plastering is done so as to avoid chasing. Where chases are
made for conduit run contractor shall fill these chases or any other openings made by them
after completing the work and patch the surface. During installation, care shall be taken to see
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved
that proper covers are provided to prevent rusting of conduits. Locations of all point outlets,
junction boxes shall be marked with brick powder or sand so that these are easily identified
after shuttering removal. As built conduit layout drawing shall be submitted by contractor
after completion of the work.
4.2.7 All junction boxes, bends and other accessories shall be of the same material as that of conduit
and shall have the same protective coatings.
4.2.8 After erection, the entire conduit system shall be tested, for mechanical and electrical
continuity and shall be permanently connected to earth by means of approved type of earthing
clamps.
4.3.1 Wiring in hazardous area shall be done by using minimum 2.5mm2 copper conductor
armoured cable.3' core of the cable shall be used as earth conductor for earthing of lighting
fixture. Circuit wiring feeding hazardous areas shall be controlled by two pole
switches/MCBs (for phase as well as neutral isolation).Switches for lighting panels installed
in hazardous area shall have a pole to break the neutral in addition to poles for phases.
4.3.2 Correct type of lighting equipment (fixtures and JBs) with regard to hazardous protection as
specified in the drawing shall be installed for the areas classified as Zone 1, Zone 2 etc.
4.3.3 The terminations in the junction boxes and the lighting fittings shall be done avoiding
possibility of loose connections due to vibrations. After the terminations are made the cover of
the junction boxes and the lighting fittings shall be closed properly with all bolts and hard
wares in correct position, retaining its explosion and weather protections. In fixtures having
double cable entries, both the entries shall be used for looping in and looping out connection,
thus minimising the use of a separate junction box. Wherever separate control gear boxes (CG
box) are provided looping in and looping out connections shall be through CG box, thus
avoiding the use of an additional junction box. All unused cable entries shall be sealed with
suitable plugs.
4.3.4 Circuit cables shall be firmly cleated in a group along columns/ beam/ladders/side
channels/platform using 1.6mm thick GI saddles on 25x3 mm GI saddle bar at intervals of
400mm to 500mm for straight run and on either side close to bending and at both termination
ends as per the directions of Engineer-in-charge. Where required 3 or more of cables shall be
taken in perforated150mm wide slotted channel cable tray after getting the approval of
Engineer-in-charge. Minimum straight run shall be 3000mm.Cables shall not be routed along
hand rails.
Where fire proofing column/structures are encountered, all cabling shall be taken in GI pipes
of required size and both ends shall be sealed, well before fire proofing is done. Similarly
equipment such as lighting fixture, control gear box, lighting/ power panels, field call stations,
junction boxes etc. shall be installed on suitable steel mounting frame/distance bracket,
thereby avoiding direct contact with the concrete used for fire proofing.
4.3.5 Cable glands for terminating cable on flameproof equipment shall be of double compression
FLP type. Any material/equipment specified to be supplied by contractor for installation in
hazardous areas, shall be tested by CIMFR and duly approved by CCoE or DGMS or any
other applicable statutory authority. All indigenous FLP equipment shall also have valid BIS
license as required by statutory authorities.
4.4.1 The type of wiring system shall comprise surface/concealed conduit system or cable wiring as
specified on layout drawings.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
4.4.2 Mounting details of fixtures shall be indicated on the drawings. If specified on the drawings, a
group of fluorescent lighting fixtures which are to be mounted end to end shall be fixed to
mild steel cold rolled sections of 50mm x 50mm and of I .2mm thick (Metsec channel). The
entire assembly shall be fixed to the ceiling with necessary number of supports which may be
by means of steel conduit or chromium plated chain link as required. The 'Metsec' Channel
shall run continuous in suitable sections from one end to other end of wall. The complete
channel shall be spray painted, with approved colour as per the directions of Engineer-in-
Charge. All wires inside channel shall be neatly bunched by nylon tape and buttons.
4.4.3 Wiring in areas above false ceiling shall be done in Surface Conduit (25mm dia GI conduit)
suitably clamped to the true ceiling. Vertical drops from true ceiling for panels, switches,
receptacles etc. shall be taken in 25mm dia PVC conduit concealed in walls upto
switchboards/panels. Lighting fixtures shall be supported from true ceiling. Exact location of
fixtures shall be finalised in co-ordination with air-conditioning duct diffuser layout, panel's
layout and false ceiling grid layout. To facilitate easy maintenance 'Looping back system' of
wiring shall be followed throughout. Accordingly supply tapping's and other interconnections
including for earthing are made only at fixture connector blocks or at switch boards. Required
number of junction boxes shall be used at intervals for wire pulling and inspection.
4.4.4 All wires in conduit shall be colour coded as specified. Each circuit shall have independent
phase neutral and earth wire. However when group of circuits are run in a single conduit the
earth wire can be common.
4.4.5 Building conduit lighting system of wiring where measurement is done on point wiring basis
generally consists of two parts. The first part is the circuit wiring which includes the work
necessary from lighting panel up to switch box and from switch box to another switch box.
The second part is the point wiring which shall include the work necessary from tapping point
in the switch box upto various fixtures or fan outlets/ceiling roses.
4.4.6 Switches for light fixtures/exhaust fans in battery room shall be provided outside the Battery
room.
4.4.7 Lighting layouts for non-plant buildings (such as ware house, cement godown, gate house,
workshop, service building, rest room, etc.) shall be prepared by installation contractor as
defined in the scope of work.
The following basic data/document for preparation of layouts will be provided to the
contractor.
i) Architectural drawings
ii) Illumination level required
iii) Type of lighting fixture
iv) Type of wiring (concealed/surface conduit/cable wiring etc.)
Based on the above input, contractor shall prepare and submit lighting layout drawings, panel
schedules, conduit layout drawings for concealed wiring, design calculations wherever
required, for review by purchaser before erection work is started. The lighting layout drawing
shall show the location, type and mounting details of lighting fixtures, receptacles, junction
boxes, layout of circuit indicating number of wires etc. The number of points in a circuit shall
not exceed ten and the load in each circuit shall be less than 1000 Watts.
The panel schedule shall include rating of incoming and outgoing feeders, number of outlets,
load for each outgoing circuit, etc.
All drawings shall be prepared preferably in AO and Al size. Panel schedules shall be in A4
size drawings. Final submission of drawings shall be in soft copies (CD form) and in bound
volumes.
4.5 Street Lighting
4.5.1 Street lighting poles to be located on road side shall be installed at a minimum distance of
300mm from the edge of the walkway of the road (road berm). Size of wires from marshalling
box upto fixture shall be 1.5mm2/2.5mm2, copper conductor PVC insulated.
4.5.2 Each pole shall be earthed at two points by connecting to the plant earth grid as shown on
Installation standards.
4.5.3 Street lighting fixture shall be mounted on steel tubular poles as per standard drawings. The
foundation for the street lighting poles will be made by electrical contractor. Street lighting
poles shall be supplied with a base plate.
4.5.4 The poles shall be numbered as per the drawings/ directions of Engineer Incharge.
4.6.1 The lattice structure masts shall be installed on concrete foundations with the base plate bolted
on to the anchor bolts. The lattice structure shall be painted with a coat of primer and two
coats of aluminium paint, the second coat to be given just before handing over to the owner.
The masts shall be numbered as per drawings. The masts shall be connected to the plant earth
grid at two points
4.6.2 The main feeder upto the distribution board of lighting mast shall be through PVC insulated
armoured cable of size as specified in the respective drawing. Wiring from Distribution Board
to each flood-light fixture shall be by means of a 3-core 2.5sqmm, copper conductor PVC
insulated armoured cable. All the cables shall be neatly clamped to the structure at intervals
not exceeding 25 cms.
4.6.3 Exact orientation of flood lighting fixtures shall be decided at site to achieve optimum utility
of these fixtures.
Conduits for telephone wiring in buildings shall be of 1.6mm thickness. 25mm dia black
enameled steel conduit/PVC as per IS 9537, installed on wall surface or concealed or as
specified in job specification.
Conduit installation system shall comply with the requirements given in clause 4.2 'conduit
system'. Required number of pull boxes shall be provided at interval for easy drawing of
wires. The telephone wiring shall be done with 0.63mm dia annealed copper conductor PVC
insulated 660V grade, twin flat wire, unless otherwise specified in job specification. One
telephone socket outlet shall be provided for connection to telephone instrument.
5.1 Lighting installation shall be tested and commissioned by installation contractor as per EIL
specifications. Precommissioning checks and tests shall include but not be limited to the
following:
(i) The insulation resistance of each circuit without the lamps (load) being in place shall
be measured and it should not be less than 500,000 ohms. (Between phases, phases to
neutral, phase/neutral to Earth).
(ii) Current and voltage of all the phases shall be measured at the lighting panel bus bars
with all the circuits switched on with lamps. If required load shall be balanced on the
three phases.
(iii) The earth continuity for all socket outlets shall be checked. A fixed relative position
of the phase and neutral connections inside the socket shall be established for all
sockets.
(iv) After inserting all the lamps and switching on all the circuits, minimum and
maximum illumination level shall be measured in the area and recorded.
(v) It shall be ensured that switch provided for ON/OFF control of point (light/fan/socket)
is only on LIVE side.
(vi) Operation of ELCB's shall be checked.
Contractor shall duly fill in all the above test results and submit the test reports to Engineer-
in-Charge in triplicate.
5.2 All lighting layout drawings shall be marked by contractor for 'AS BUILT STATUS' and two
sets of hard copies plus 1 set of soft copy in CD, shall be submitted to EIL.
3Trztrr f«R-r
SPECIFICATION
FOR
EARTHING INSTALLATION
Abbreviations:
CONTENTS
1.0 SCOPE 4
6.0 CONNECTION 6
1.0 SCOPE
This specification defines the requirements for the supply of earthing and lightning protection
materials and installation of the earthing and lightning protection systems.
2.1 The work shall be carried out in the best workman like manner in conformity with this
specification, EIL Installation Standards, layout drawings, the latest edition of relevant
specifications, codes of practice of Bureau of Indian Standards and OISD Standards listed
below :
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements
of the following as applicable:
a. CEA Regulations
b. Regulations laid down by CEA/Electrical Inspectorate.
c. Regulations laid down by PESO/DGMS (as applicable).
d. The petroleum rules (Ministry of Industry Government of India).
e. Any other regulations laid down by central/state/local authorities and Insurance
agencies.
3.0 MATERIAL SPECIFICATIONS
3.1 All materials and hardware to be supplied by the contractor shall be new, unused and of best
quality and shall conform to the specifications given here under and to latest specifications of
Bureau of Indian Standards. Contractor shall bring material samples to site and get it approved
by Engineer-in-charge before installation.
3.2 The main earth grid conductor shall be hot dip galvanised M.S. flat unless otherwise specified.
Sizes for main conductors shall be as indicated on the earthing layout drawing .Amount of
galvanizing shall be 610gm per sq.metre. Earth electrodes and Earth plate shall be as per EIL
Installation Standards.
4.1 This consists of main earth conductor (grid conductor) forming a closed ring network with
required number of earth electrodes connected to it to provide a common earth for electrical
devices and metallic structures. From each earth electrode two distinct connections shall be
made to the main earth conductor. The earth plates shall be used for taking multiple earth
connections to two or more equipment.
4.2 The earth conductor shall be laid along cable trays/cable trench/pipe racks/ buried in
pavement/ below finished grade level as indicated on the earthing layout drawing. Where
lined cable trenches are available, the earth conductor shall be preferably laid in the trenches
and shall be firmly cleated to the sidewall of concrete trenches using GI clamps at interval of
400 mm to 500 mm and near to the termination end. The earthing conductor shall run along
one of the cable trays along the overhead cable route. The earthing conductor shall be suitably
cleated and electrically bonded to all the other cable trays on the same cable route at a regular
interval of 25 to 30 meter. The earthing for equipment shall be tapped from the main earth
conductor and not from cable tray support structure. Earth conductor when laid underground
shall be at a depth of 500mm below finished grade level.
4.3 Joints and tapping's in the main earth loop shall be made in such a way that reliable and good
electrical connections are permanently ensured. All joints below grade shall be welded and
shall be suitably protected by giving two coats of bitumen and covering with Hessian tape.
Earth strip laid above ground shall be welded across straight through joints and joints shall be
suitably protected by giving two coats of bitumen to avoid oxidation and insulation film
formation of the strip surface. When two earth strips are to be jointed by means of welding,
lap welding with an overlapping of strip equivalent to double the width of the strip and all
four sides shall be continuously welded. All joints at tappings above ground shall be by
means of connector/lugs. A minimum of two bolts of adequate size shall be used for this
purpose. Earthing strip joints at earth plate and equipment shall be through GI bolts, nut etc.
5.1 Earth Electrode shall be installed as shown on installation standard and layout drawings.
The location shown on the layout drawings are indicative.
The exact location of earth electrodes in the field shall be determined by contractor in
consultation with the Engineer-in-charge, depending on the soil strata and resistivity. Earth
electrodes shall be located avoiding interferences with road, building foundation, column,
pipelines etc. The civil area drawings shall be referred for this. The distance between two
electrodes shall not be less than twice the depth of electrode.
5.2 Electrodes shall preferably be located in a moist soil which has a fine texture, grain size and
distribution. Wherever practicable the soil shall be dug up, all lumps broken and stones
removed from the immediate vicinity of the electrodes and soil packed by watering and
ramming as tight as possible.
5.3 The electrodes shall have a clean surface, not covered by paint, enamel, grease or other
materials of poor conductivity.
5.4 All earth electrodes shall be tested for earth resistance by means of standard earth test meter.
The tests shall take place in dry months, preferably after a protracted dry spell.
5.5 The disconnect facility shall be provided for the individual earth electrode to check its earth
resistance periodically.
5.6 Location of earth electrodes shall be marked by permanent markers for easy identification. All
earth Electrodes shall be serial numbered and also marked on `As Built' drawing for future
reference.
5.7 Individual earth electrodes shall be provided for each lightning arrestor and flood light mast.
5.8 Earthing system provided for concrete paved area by other agency where applicable; shall be
connected to the plant earthing system below ground by minimum two earth connections.
6.0 CONNECTION
Conductor size for branch connection to various equipment shall be as per EIL Installation
Standards unless otherwise stated on earthing layout drawings.
6.2 A11 process pipelines shall be bonded and earthed at the entry and exist points of battery limit
of hazardous area.
6.3 Steel pipe racks in the process units and offsite area shall be earthed at every 24 meters.
6.4 Equipment/street light pole etc. located remote from main earth network may be earthed by
means of individual earth electrode and earth conductor unless otherwise stated in job
specifications/earthing layout drawing.
6.5 Lightning protection shall be provided for the equipment, structures and buildings as shown
on layout drawing. Self conducting structures shall not require separate aerial rod and down
conductors. These shall however be connected to the earthing system at two or more points as
shown on layout drawing. Each down conductor shall be provided with an earth electrode and
all earth electrodes shall be interconnected through underground strip. Lightning protection
earthing system may be bonded to electrical safety earthing system, inside ground. Lightning
down conductor shall be brought to earth electrode in shortest straight path as feasible to
minimise surge impedance.
6.6 The main earthing network shall be used for earthing of equipment to protect against static
electricity.
6.7 All medium and high voltage equipment (above 250V) shall be earthed by two separate and
distinct connections with earth.
6.8 Plant instrument system clean earthing, UPS system clean/safety earth, Data concentrator
panel, HMI etc shall be separate from the electrical earthing system, if mentioned in job
specification/ layout drawings.
6.9 All paint, scale and enamel shall be removed from the contact surface before the earthing
connections are made.
6.10 All earthing connections for equipment earthing shall be preferably from the earth plate
mounted above ground wherever provided
6.11 Earth connections shall be made through compression type cable lugs/by welded lugs.
6.12 All hardware used for earthing installation shall be hot dip galvanised or zinc passivated.
Spring washers shall be used for all earthing connections and all connections adequately
locked against loosening.
6.13 Lighting fixtures and receptacles shall be earthed through the extra core provided in the
lighting circuit/cable for this purpose.
6.14 The reinforcements of sub-station building and the sub-station floor shall be connected to
main earth grid.
7.1 Field inspection, testing and commissioning of electrical installation shall be done as per EIL
standard specification.Earthing systems/connections shall be tested as follows:
7.2 Resistance of individual earth electrodes shall be measured after disconnecting it from the grid
by using standard earth test meggar.
7.3 Earthing resistance of the grid shall be measured after connecting all the earth electrodes to
the grid. The resistance value of an earth grid to the general mass of earth shall be as follows:
- For the electrical system and equipment a value that ensures the operation of the
protection device in the electrical circuit but not in excess of 4 ohm. However for
generating stations and large sub-systems, the value shall not be more than 1 ohm.
- For lightning protection, the value of 5ohms as earth resistance shall be desirable, but
in no case it shall be more than 10 ohms
7.4 The resistance to earth shall be measured typically at the following points:
a) At each electrical system earth or system neutral earth.
b) At each earth provided for structure lightning protections.
c) At one point on earthing system used to earth electrical equipment enclosures.
d) At one point on earthing system used to earth wiring system, enclosures, such as
metal conduits and cable sheaths or armour.
e) At one point on fence enclosing electrical equipment.
7.5 All earthing layout drawings shall be marked by contractor for `AS BUILT STATUS' and
two sets of hard copies plus 1 set of soft copy, shall be submitted to EIL. For projects, where
layout drawings have been prepared based on 3D modeling, contractor shall carryout
necessary changes for `AS BUILT STATUS' in the 3D model.
-ftw #f-~
PiRkurr, -crftwr
SPECIFICATION
FOR
FIELD INSPECTION, TESTING
AND
COMMISSIONING OF ELECTRICAL
INSTALLATIONS
Abbreviations:
AC Alternating Current
AFC Approved for Construction
BIS Bureau of Indian Standards
CCOE Chief Controller of Explosives
CEA Central Electricity Authority
DC Direct Current
DCS Distributed Control System
DGMS Director General for Mines and Safety
ECS Electrical Control Station
GI Galvanized Iron
HV High Voltage
IS Indian Standard
MV Medium Voltage
OISD Oil Industry Safety Directorate
CONTENTS
1.0 SCOPE 4
4.0 RECORDS 8
1.0 SCOPE
This specification covers the requirements for the field inspection, testing and commissioning
of Electrical Equipment and Installation, forming part of electrical power distribution and
utilisation system.
2.1 The field inspection, testing and commissioning of electrical equipment shall be carried out in
line with this specification and the latest edition of following Indian Standards and OISD
standards.
2.2 In addition to the above it shall be ensured that the installation conforms to the requirements of
the following as applicable:
a. CEA Regulations
b. Regulations laid down by CEA / Electrical Inspectorate.
c. Regulations laid down by Tariff Advisory Committee/Loss prevention council.
d. Regulations laid down by CCoE/DGMS (as applicable).
e. The petroleum rules (Ministry of Industry, Government of India).
f. Any other regulations laid down by central / state / local authorities / insurance
agencies
3.1 Contractor shall carry out complete field inspection, testing and commissioning of electrical
equipment as per Inspection & Test plans.
3.2 Before the completed installation or an addition to the existing installation is put into service,
inspection / pre-commissioning checks and tests shall be carried out by contractor. In the
event of defects being found out, the same shall be rectified and the installation retested as
applicable.
3.3 The pre-commissioning inspection among other requirements shall include visual inspection,
checking the workmanship of the installation, the rating of equipment, safety clearances, sizes
of cables installed, conformance to the AFC document, soundness of switchgear bus
connections, wiring properly dressed and labeled, sealing of unused cable entries, checking of
all safety interlocks, control/interface functions as per requirement etc.
3.4 Visual inspection for soundness of bus bar connections of busducts, terminal connections of
equipment/motor shall be carried out. It shall be ensured that no foreign materials are present
inside busduct and equipment terminal boxes. After the visual inspection, all the covers of
terminal boxes, inspection chambers shall be refitted with gaskets, bolts & nuts as per
equipment manufacturer's instructions.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
3.5 Pre-commissioning tests shall include but not be limited to the following:
Continuity test for each winding and power and control circuits.
Insulation test for each winding and power and control circuit
High voltage test for cables
- Dielectric strength test on transformer oil.
- Checking the correctness of wiring schemes, control circuit interlocks for intended
functioning.
(Electrical contractor shall co-ordinate with other agencies involved for the above and
provide support services for checking interfaces of electrical equipment and the intended
functioning)
Earth resistance measurement for each earth electrode, and the earthing system as a whole.
Lighting installation shall be tested for correct illumination levels, with fittings installed.
Fittings shall be operated only with specified type of a lamp or tube.
3.6 After the above tests and inspection are completed, control circuits shall be tested for correct
operation under all operating combinations and proved correct before applying power to
main circuit.
3.7 Plant Communication, Fire alarm detection and telephone system shall be checked for correct
operation and intended function.
3.8 A close visual inspection of electrical equipment in hazardous areas shall be made to ensure
that equipment is suitable for the classified zone and gas group and correctly installed, with all
covers, bolts, nuts and hardwares intact and there is no physical damage mark seen on the
enclo sure
3.9 Site Acceptance Test procedure for specific equipment shall be furnished by the respective
equipment vendor. The contractor shall provide necessary assistance to the equipment vendor
to perform Site acceptance testing to enable the equipment vendor to perform the same.
3.10 All pre-commissioning checks and tests shall be carried out as per the directions of Engineer-
in-charge. In addition to the equipment manufacturer's instructions, pre-commissioning check
requirements shall also be complied. All tests shall be carried out by contractor in the presence
of EIL/Owner' s representatives
3.11 The contractor shall bring to site all required tools, tackles, and testing instruments for
carrying out field testing. Contractor shall use only calibrated measuring and test instruments
and shall maintain valid calibration records.
3.12 The Insulation Resistance test values for various electrical equipment shall be as below:
3.12.1 Cables
The insulation resistance test values for cables shall be as per following table:
The insulation resistance test values for the switchboards shall be as per following table:
3.12.4 The insulation resistance test values for the Generators and Motors shall be as per following
table:
3.12.5 Transformers
3.12.6 The insulation resistance test values for the Transformers shall be as per following table:
3.12.7 It shall be ensured that during insulation tests, electronic devices and components that are
liable to get damaged on applied test voltage shall be disconnected from circuit. The
instructions of equipment/panel manufacturer shall be followed strictly in this regard.
3.13.1 DC high voltage test shall be conducted as per following table on all HV feeder cables and
also on 1100 V grade cables where straight through joints have been made.
The cable cores must be discharged on completion of DC high voltage test and cable shall be
kept earthed until it is put into service.
DC test voltage for old cables shall be 1.5 times rated voltage or less depending on the age of
cables, repair work or nature of jointing work carried out, etc. In any case, the test voltage
shall not be less than the rated voltage.
3.13.2 AC high voltage test shall be conducted as per following table on all HV Switchboards.
The withstand voltage values across the isolating distances are valid only for switching
devices, where the clearance between open contacts is designed to meet the safety
requirements specified for disconnectors.
3.14 All protective relays including thermal overload relays shall be tested by secondary injection
current. Primary injection tests shall be carried out for differential protection, restricted earth
fault protection at full/reduced current to ensure correctness of complete wiring.
3.16 It shall be ensured that the electrical inspectorate approval is available before energizing the
equipment
4.0 RECORDS
Contractor shall keep up-to-date records of all activities carried out and test results. Field
inspection / test reports shall be submitted to EIL / Owner by the contractor in bound volumes
(triplicate copies).
40 11-51
1 130 n ,40
12 DIA HOLES
DETAIL-1
NOTE:-
1. THE PIPE ASSEMBLY SHALL BE HOT DIP GALVANISED AFTER FABRICATION.
6 THICK CHEQUERED
PLATE COVER REMOVABLE CAP SEE
REFER DETAIL-1 NOTE-3 AND DETAIL-3
(SEE NOTE-4)
1060 SQ
BRICK WORK
0
(SEE NOTE- 5 ) (SEE NOTE-2)
FINISHED GRADE LEVEL
PAINTED SYMBOL
G.I. EARTH STRIP IN RED ON
(SEE NOTE-6) WHITE BASE
CHARCOAL LAYER
'RESISTANCE VALUE
ALTERNATE LAYER OF DATE-XX.XX.XXXX
0
CHARCOAL OR COKE HANDLE f 0
N
AND COMMON SALT
NUMBER PLATE
FIXED TO EARTH ELECTRODE
3000 LONG, 65 DIA. N.B. TOP COVER
PIPE (MEDIUM), WITH CAP PIT NO.-XX
(FOR DETAILS REFER
STD. 7-51-0101) 700
0
0
CV
DETAIL-1
1000 PVC PIPE
BRICK
WORK
II
li
NOTES:- DETAIL-2
FUNNEL WITH
1. ALL DIMENSIONS ARE IN MM. STEELWIRE
2. BRICK WORK SHALL BE DONE AFTER COMPACTING THE SOIL. MESH
3. AFTER REMOVAL OF CAP, OWNER SHALL BE ABLE TO POUR (REMOVABLE)
WATER THROUGH HIS OWN FUNNEL WITH STEEL WIRE MESH.
4. COLOUR CODING & PAINTING OF COVERS SHALL BE AS PER 65 DIA N.B.
OISD NORMS. PIPE
(MEDIUM)
5. IN CASE OF PAVED AREAS, TOP OF PIT SHALL BE FLUSHED
WITH FFL, WHEREAS IN UNPAVED AREAS, TOP OF PIT SHALL
BE PROJECTED 100MM ABOVE FGL.
6. CONNECTIONS OF G.I. EARTH STRIP TO THE PLATE SHALL BE
IN LINE WITH STD. 7-51-0103. D E TA I L- 3
.- .1\ 1 1101.1e11b91
,1 11
6 08.11.16 UPDATED & ISSUED AS STANDARD BP FA/HK BR RN
5 27.06.11 REAFFIRMED & ISSUED BP RKS/RSC UAP DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001JF4 Rev.O Copyright EIL - All rights reserved
II
U)
II
MIL
12 DIA G.I. SPACER SEE
PIPE (TYP.) NOTE-2
ini
% 11 %/
/ 11 %/
/ 4! 11 %
// 11 %/
/ /,11 %/
/ %4111! 7411v Alv 4117 Air A1117 41Iv zIlv All'4
nW 1111 IUI
G.I. EARTH
PLATE
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
SEE NOTE-1
is
. .
.
• .
t:1 •
DETAIL-1
CONNECTION WITH BURIED EARTH GRID
— SEE NOTE-1
G.I. EARTH STRIP
CABLE TRENCH •
•
•
G.I. EARTH STRIP
DETAIL-2
CONNECTION WITH EARTH GRID IN RCC TRENCH
NOTE:-
1. MOTOR FOUNDATION BOLT SHALL NOT BE USED FOR EARTHING.
2. EARTHING OF P.B. STN. INSTALLED NEAR MOTOR FOUNDATION SHALL BE DONE BY
TAPPING 8 SWG G.I. WIRE FROM EARTH PLATE.
7-51-0105 Rev. 6
Page 1 of 1
NEUTRAL BUSHING
TRANSFORMER
4? 4.
F.F.L./F.G.L.
I 1.1
I I L - -x-
X
--Z TO EARTH ELECTRODE IN TEST PIT
5-- ->4F- _ _ _x_
EARTH PLATE AS PER LMAIN EARTH GRID
STD. 7-51-0103
1
1(
_- -44- --$- -4( I 1
I )11r L34__ __ _1 Y
2--*
14
--44 --*- -- -- -4,4- -4-- -X-- 4 ---t ...x__
1, __ __x_44._ __,Ar__ __ ...x..1 _,
L__ __J L_ _J
- -
NOTES:-
1. EARTH ELECTRODE IN TEST PITS SHALL BE SO LOCATED THAT DISTANCE BETWEEN TWO PITS
SHALL BE MINIMUM 6 METER.
PUSH BUTTON
STATION
• •
0 0
TINNED COPPER LUG
0
CONCRETE COLUMN
STEEL SUPPORT
0
0
C•1
4- F. F. L./F.G.L.
:
4, • • • •• .
1.
•
• • • .4 a. • .
/ i
WELD —/ WELD—/
NOTES:-
1. ALTERNATIVELY, CONNECTION SHALL BE TAKEN FROM THE NEAREST AVAILABLE EARTH PLATE.
_ IL\
50 MM WIDE x 60 MM x 6 MM THICK
M.S. FLAT WELDED TO POLE FOR EARTH
TERMINATION (SEE DETAIL-1)
O • TERMINAL CONNECTOR
rn
F.F.L./F.G.L.
10 MM DIA HOLE
WELDED TO POLE
DETAIL-1
NOTES:-
1. USE TWO WIRES ROPES IF VOLTAGE IN THE POLE JUNCTION BOX IS 415 VOLTS.
DETAIL-1 (TANK)
NIL
6 08.11.16 REVISED & ISSUED AS STANDARD —'B P FA/HK BR 2 RN
5 27.06.11 REAFFIRMED & ISSUED BP RKS/RSC UAP DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
OMO FiNGNEERS
INDIA UNITED
(A Govt. of Mick Undertaking)
TYPICAL EARTHING OF
TANKS, VESSEL AND SPHERES
7-51-0108 Rev. 6
Page 2 of 2
G.I. STRIP
40x5 MM
DETAIL-2 (SPHERE)
16 DIA G.I. WIRE
ROPE TO EARTH LUG
ON VESSEL SADDLE
10 MM DIA 25 LONG BOLT, NUT G.I. BOLT
AND TWO SPRING WASHERS VESSEL
PAD AND NUT
(SEE NOTE-3) •
L (M) . •
F.F.L./F.G.L.
DETAIL-4
VESSEL SADDLE F.F.L./F.G.L.
SADDLE
NOTES:-
1. FOR VESSELS TWO NOS. OF DIAMETRICALLY OPPSITE EARTHING LUGS WILL BE AVAILABLE ON LEG
SUPPORTS OF EQUIPMENT FOR PROVIDING EARTH CONNECTION.
2. ALL VESSELS SHALL HAVE TWO EARTH CONNECTIONS IN GENERAL.
No
Date Purpose
by by
Convenor Chairman
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
CEILING
• •
WALL / COLUMN
EQUIPMENT
• CLAMP (NP)
TO EARTH GRID
F.F.L./F.G.L.
CABLE TRAY
NOTE:-
1. ALL PROCESSING EQUIPMENT SUCH AS MIXTURES, CHURNS, AUTOCLAVES, COLUMNS,
CENTRIFUGES, FILTERS, PRESS PUMPS ETC. SHALL BE EARTHED, IF THESE ARE NOT
IN DIRECT CONTACT WITH PROPERLY EARTHED STEEL MEMBERS.
2. ALL TEMPORARY EARTH CONNECTIONS SHALL BE MADE BEFORE OPENING THE VESSEL.
ileMZE9r.RSPMw
■
RN
lit
5 08.11.16 REAFFIRMED & ISSUED BP FA/HK BB
4 27.06.11 REAFFIRMED & ISSUED BP RKS/RSC UAP DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8 - 00 - 0001 - F4 Rev.O Copyright EIL - All rights reserved
FIrLEXIB
(IN HAZARDOUS AREA) Page 1 of 2
SEE DETAIL-2
465
1P
CONNECTION
o r SEE DETAIL-1
FOR LUG
40X5 G.I.
EARTH STRIP
r F.F.L./F.G.L.1
a- - - — 4t — -- —X -- -- X— -- q— —K — --t -- X—
FRONT VIEW LMAIN EARTH GRID SIDE VIEW
PIPE TO BONDED
30
CRIMPED -J
CABLE LUG SEE DETAIL-3
6
25 SQ. MM
FLEXIBLE
8 DIA G.I. - COPPER CABLE (L=INSULATION THICKNESS+50)
BULI, NUT
DETAIL-1 & WASHERS DETAIL-3
DETAIL-2 (SEE NOTE-3)
NOTES:-
1. UNLESS MENTIONED OTHERWISE ON PLANS OR JOB SPECIFICATIONS, THE PIPE LINES SHALL BE
BONDED AND EARTHED ONLY AT THE ENTRY AND EXIT POINTS OF BATTERY LIMIT OF PROCESS UNIT
HANDLING FLAMMABLE SUBSTANCES.
2. STEEL PIPE RACKS IN THE PROCESS UNIT AND OFFSITE AREA SHALL BE EARTHED AT MAXIMUM
SPACING OF 25 METRES.
3. BEFORE HYDROTESTING OF PIPELINES, PIPING CONTRACTOR SHALL WELD A PLATE (AS SHOWN IN
DETAIL-3) OF SUITABLE MATERIAL TO SUIT PIPELINE MATERIAL.
4. SUPPLY OF FLEXIBLE COOPER CABLE, LUGS, BOLTS, NUTS AND WASHERS ETC. AND MAKING
CONNECTIONS SHALL BE DONE BY ELECTRICAL CONTRACTOR.
SEE NOTE-4
(SHT. 1 OF 2)
25 SQ. MM FLEXIBLE
COPPER CABLE ARRANGEMENT-1
PIPE FLANGE
PIPE
ARRANGEMENT-2
(APPLICABLE WHERE WELDED FLAT ARE
NOT AVAILABLE AS PER ARRANGEMENT-1)
PIPE
PIPE
EARTH CONNECTION
PIPE SUPPORT
M.S. FLAT
SEE DETAIL-1 (SHT. 1 OF 2)
_L -->f-
ARRANGEMENT-3
(APPLICABLE WHEREVER PIPE SUPPORTS ARE WELDED
ON BOTH SIDES OF FLANGES / VALVES ETC.)
ORM -0 ENCINEERS
INDIA
A UNITED
(A Govt. of India Undertaking)
FENCE AND GATE EARTHING
(TRANSFORMER YARD)
7-51-0115 Rev. 5
Page 1 of 1
EARTHING CLAMP
SEE DETAIL-1
FENCE POST
FENCE GATE
FENCE
EARTHING CONNECTIONS
TO G.I. BOLT AND NUT
G.I. EARTHING LUG
F.F.L./F.G.L.
FENCE POST
TO FENCE POST
FENCE POST
G.I. NUT
AND BOLT
TO MAIN
EARTH GRID
DETAIL-2
WELD
G.I. EARTHING LUG
(SEE DETAIL-2)
FENCE
•
1#■••■••■■••■•■■•■•■ ■•■•■■•■
7-51-0117 Rev. 5
Page 1 of 1
F.F.L./F.G.L.
0 z
M.S. FLAT
50x6x85 LONG
(SEE DETAIL-1)
I
w WELD
0
z
Lu 40 DIA, 2500 MM LONG
PIPE (MEDUIM)
(SEE NOTE-1)
20 45 20
0
0
of
40 DIA. 2500 MM
LONG PIPE (MEDUIM)
(SEE NOTE-1)
10 DIA HOLE
6 THICK M.S.
FLAT
WELD
DETAIL-1
NOTES:-
1. PIPE ASSEMBLY SHALL BE HOT DIP GALVANISED AFTER FABRICATION.
2. THE ELECTRODE SHALL BE DRIVEN TO A DEPTH TO REACH PERMANENT MOIST SOIL.
AitA)
a Imo' -----
'
450
0
0
Li)
LIGHTING
FIXTURE
G.I REDUCER 100/50
50 DIA G.I. PIPE
DETAIL-2
MARSHALLING BOX
AS PER STD. 7-51-0208
OR FLP/DIV 2 JUNCTON BOX/
o CONTROL GEAR BOX
0 (SEE NOTE-2)
0 500
SEALING COMPOUND/BUSHING
FLUORESCENT
CABLE GLAND FIXTURE
4e (FOR SAFE AREA)
EARTHING LUG —s.
50x60x6 MM M.S. 0
0
FLAT WELDED TO
POLE
0
0 50 DIA G.I. PIPE
G.I. PIPES FOR 0
INCOMING AND
OUTGOING CABLES
G.I. REDUCER 100/50
(DIA. AND LENGTH
AS REQUIRED) 100 DIA G.I. PIPE
0 F.F.L. /F.G.L
A.K\
DETAIL-3
O
In
0
0 200x200x8 MM M.S. PLATE
WELDED TO POLE
DETAIL-1
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. MARSHALLING BOX, JUNCTION BOX AND G.I. PIPES FOR CABLES SHALL BE LOCATED
FACING CABLE TRENCH SIDE.
3. ALL G.I. PIPES SHALL BE MEDIUM GRADE.
ADAPTOR OR REDUCER
TO SUIT FIXTURE
0
0
LIGHTING FIXTURE
VIP
ARMOURED CABLE
500
BUSHING
ADAPTOR
M.S. ANGLE
75x75x6-125 LONG
50 DIA. G.I. PIPE
WELDED TO HANDRAIL
ADAPTOR
GLAVANISED U BOLT
50 DIA. G.I. PIPE
FIXED TO ANGLE IRON
PIECE WELDED TO
HAND RAIL FOR
PLATFORM HANDRAIL
DETAIL-2
POLE SUPPORT
M.S. ANGLE
100X75X6-100 MM LONG
WELDED TO PLATFORM 0
MEMBER FOR VERTICAL
0
Li)
SUPPORT OF THE POLE
PLATFORM
REDUCER 50/25 RESTING
IN DRILLED HOLE OF
ANGLE IRON PIECE
DETAIL-1
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. TYPE OF FIXTURE USED SHALL BE INDICATED ON THE LAYOUT DRAWING BY DESIGNATION
AND IDENTIFIED FROM DATA SHEET FOR LIGHTING FIXTURE SCHEDULE.
BP FA/SA UAP/JM DM
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD
RKS/NS JMS VC
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP
3 Stds. Committee Stds. Bureau
Prepared Checked
Rev. Convenor Chairman
Date Purpose by by Approved by
No.
Copyright EIL - All rights reserved
Format No. 8-00-0001-F4 Rev.O
Page 1521 of 2065
STANDARD No.
TYPICAL INSTALLATION OF
k31 ENGINEERS 7-51-0203 Rev. 4
INDIA LIMITED OPEN AREA FLOOD LIGHT FIXTURE
$Nuffe1fRerg (A Govt. of India Undertaking)
MOUNTED ON WALL OR COLUMN Page 1 of 1
CABLE
OPEN AREA
FLOOD LIGHT FIXTURE
0
0
ELBOW
NOTES:—
1. ALL DIMENSIONS ARE IN MM.
la
Ye.,,f,1
FA/SA UAP/JMS DM
17.07.13 REAFFIRMED & ISSUED AS STANDARD BP
4
RKS/NS JMS VC
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP
3 Stds. Committee Stds. Bureau
Prepared Checked
Rev. Convenor Chairman
Date Purpose by by Approved by
No.
Copyright EIL - All rights reserved
Format No. 8-00-0001-F4 Rev.O
Page 1522 of 2065
250 250
♦
FLOOD LIGHT
`tee gig FIXTURE
/14.3x3 6 0011
THICK
VP %VP
MARSHALLING
BOX/CONTROL GEAR
BOXES(2 NOS.)
CABLE GLAND
0
0
N
SEE
DETAIL-2 50 DIA. G.I.
PIPE(MEDIUM)
11'
ARMOURED CABLE
0
0 SEALING COMPOUND/ %ENTINE.
0 BUSHING
ELBOW
450 TEE REDUCER
ROUND o F.F. L./F.G. L.
S /la /he 114.3 O.D.
0 50 DIA. G.I. PIPES
0
(SEE NOTE-2)
0
139.7x ,
0 5 0 0 DETAIL-1
co THICK 0 0
0
N
BOLTS,NUTS
1654)(5 0 AND WASHERS 6 MMBASE
THICK PLATE WELDED
WITH POLE
HOLE FOR TAKING
TUBULAR THE WIRES IN
POLE 410SP-54 FLEXIBLE CONDUIT
AS PER IS:2713
50x60x6 MM M.S.
FLAT WITH 10 DIA.
U) 0 `SLOT FOR CABLE
HOLE WELDED TO PO U)
o.) ENTRY INTO POLE
N N
POLE FOR EARTH (SEE NOTE-3)
CONNECTION
139.7x4.5
THICK
165.1x5.4
THICK
350x350x10 MM M.S.
0
Lo PLATE WELDED TO POLE
LIGHTING FIXTURE
1000
MARSHALLING BOX
0 R 800
O CABLE GLAND
U)
50x60X6 MM M.S.
FLAT WELDED TO
50 DIA G.I. PIPE
POLE FOR EARTHING AS
PER STD. 7-51-0107
ARMOURED CABLE
88.9 x 3.25 THICK
SEALING COMPOUND/
0 BUSHING
0
U) 0 O o 450 ROUND
0 to
to o
F.F. F.
LT
40 DIA. G.I. PIPES
114.3 x 3.65 THICK
0 600 MM SQ. PLAIN
0 CONCRETE (M15)
to STEEL TUBULAR POLE
410 SP-8 AS PER IS:2713
350x350x10 MM M.S.
PLATE WELDED TO POLE
139.7 x 4.85 THICK
0
O VIEW-AA
U)
MARSHALLING BOX
AS PER STD 7-51-0208
EARTHING LUG 1000 I 1000
VIEW-AA
O 100
O O
O
O O
OT—.s I LI)
o F.F.L./F.G.L. R-800
r),
0 A/
0
0 O
O to
U)
ARRANGEMENT FOR
O TWO FIXTURES
U)
NOTES:-
1. ALL G.I. PIPE SHALL BE MEDIUM GRADE.
BP FA/SA UAP/J MS DM
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD
RKS/NS JMS VC
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP
3 Stds. Committee Stds. Bureau
Prepared Checked Chairman
Rev. Convenor
Date Purpose by by Approved by
No
Copyright EIL - All rights reserved
Format No. 8-00-0001-F4 Rev.0
Page 1525 of 2065
STANDARD No.
TYPICAL INSTALLATION
2.1 ENGINEERS 7-51-0207 Rev. 4
g"ra INDIA LIMITED OF STREET LIGHTING FIXTURE
(A Govt. of Indio Undertaking)
Page 2 of 2
LIGHTING FIXTURE
700
MARSHALLING BOX
CABLE GLAND
50x60X6 MM M.S.
FLAT WELDED TO
POLE FOR EARTHING AS
0 PER STD. 7-51-0107
0
ARMOURED CABLE
SEALING COMPOUND/
50 DIA. G.I. PIPE
0 0
BUSHING
450 ROUND
o
F.F. .
~A%
W/4 /71 o
114.3 x 3.65 THICK ccip)
0
40 DIA. G.I. PIPES
N
N
700 MM SQ. PLAIN
CONCRETE (M15)
350x350x10 MM M.S.
PLATE WELDED TO POLE
VIEW—AA
139.7 x 4.50 THICK
0
N
N
STEEL TUBULAR POLE
410 SP-38 AS PER IS:2713
EL\
165.1 x 4.85 THICK
700 700
16
MARSHALLING BOX
VIEW—AA AS PER STD. 7-51-0208
R-800
EARTHING LUG
0
n
°
o 8
0 Lci),
n
F.F.L./F.G.L.
^VA\
0
0
D
_L
0 0
0 Lc)
c0
ARRANGEMENT FOR
TWO FIXTURES
u)
(9.2M HIGH ABOVE ROAD LEVEL) NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. ALL G.I. PIPES SHALL BE MEDIUM GRADE.
FA/SA UAP/JMS DM
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD
BP RKS/NS JMS VC
3 15.12.08 REAFFIRMED & ISSUED AS STANDARD
Stds. Committee Stds. Bureau
Prepared Checked
Rev. Convenor Chairman
Date Purpose by by
No. Approved by
Copyright EIL - All rights reserved
Format No. 8-00-0001-F4 Rev.O
Page 1526 of 2065
STANDARD No.
ENGINEERS TYPICAL MARSHALLING BOX DETAILS
7-51-0208 Rev. 5
INDIA LIMITED FOR LIGHTING POLES
(A Govt. of Indio Undertaking)
Page 1 of 1
25 MM DIA.,
25 MM LONG NEOPRENE GASKET 3 MM THICK
ALL AROUND FOR WEATHER
HALF COUPLING 75
PROTECTION
HINGE (TYP.)
-SEE DETAIL-1 FRONT
A COVER
COVER SHEET(12 SWG/
GASKET
2.64 MM THICK)
WELD 50x20x5 MM M.S.
PLATES WELDED
DETAIL-1
TO BOX
BAKELITE SHEET/ INSULATOR BASE
POLE
FOR MOUNTING OF TERMINAL
BLOCK WITH BRASS BOLT,
NUT AND WASHERS TO EARTHING
STUD ON
2.5 SQ. MM, COPPER MARSHALLING
BOX
CONDUCTOR, PVC
INSULATED WIRES
(PHASE, NEUTRAL
SCREW KNOB
AND EARTH) TO
WITH ANTI—
LIGHTING FIXTURES
FALLING
ARRANGEMENT
(CIRCLIP) j HINGES
'D'
BOX COVER
TO
EARTHING
STUD
G.I. NUT AND BAKELITE HINGE WELDED TO CABLE
'C' SHEET MARSHALLING BOX
BOLT HARDWARE GLAND
ENCLOSURE AND COVER
PVC BUSH ARMOURED
(TYP.) CABLE
BP FA/SA UAP/J MS DM
5 17.07.13 REAFFIRMED & ISSUED AS STANDARD
BP RKS/NS JMS VC
4 15.12.08 REVISED & ISSUED AS STANDARD
Stds. Committee Stds. Bureau
Prepared Checked
Rev. Convenor Chairman
Date Purpose by by
No. Approved by
Copyright EIL - All rights reserved
Format No. 8-00-0001-F4 Rev.O
Page 1527 of 2065
STANDARD No.
RYBN
FLOODLIGHT FIXTURE
PLATFORN
FLOODLIGHT
CABLE GLAND
INCOMING AND
CABLE CLEATED OUTGOING CABLES
TO LADDER SIDE
RUNNER
P N ISOLATOR
6A HRC FUSE
EARTH BAR WITH
0 CONNECTING LINK
0
0
co EARTHING STUD (S)
LADDER
2(40x5 MM) G.I.
STRIPS TO THE
BOTTOM OF MASTS
TERMINALS
MAST AS PER
STRUCTURAL DETAILS WIRING DIAGRAM OF
TPN ISOLATOR DISTRIBUTION BOARD
IN WEATHER
PROTECTED (IP55) AND ISOLATOR
ENCLOSURE
MAST NUMBER PLATE
SIZE 150x225 MM
50x60x6 MM M.S. FLATS WELDED
TO STRUCTURE FOR EARTHING
0
0
F.G.L.
0
0
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
ALL CABLES FROM DISTRIBUTION BOARD TO CONTROL GEAR BOX / LIGHTING FIXTURE
2.
SHALL BE NEATLY CLAMPED TO THE HANDRAIL STRUCTURE.
I FA/SA UAP/JMS DM
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD
RKS/NS JMS VC
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP
3 Stds. Committee Stds. Bureau
Prepared Checked Chairman
Rev. Convenor
Date Purpose by by Approved by
No.
Copyright EIL - All rights reserved
Format No. 8-00-0001-F4 Rev.O
Page 1528 of 2065
TYPICAL INSTALLATION OF STANDARD No.
ENGINEERS
11?„-Eraiwilten3 INDIA LIMITED FLUORESCENT FIXTURE MOUNTING 7-51-0212 Rev.4
(A Govt. of India Undertaking)
IN EXPOSED WIRING SYSTEM Page 1 of 1
FIXED TO CEILING
CEILING
SPACER
CLAMP
CABLE OR CONDUIT SEE NOTE-2
SUPPORT BOX WITH SPRING
LOADED BALL & SOCKET
ARRANGEMENT
(CHROMIUM PLATED)
19 DIA. G.I. PIPE (MEDIUM)
CHECK NUT
(PAINTED WHITE OR
AS SPECIFIED) NON—METALLIC BUSHING
MOUNTING HEIGHT
•
FLUORESCENT FIXTURE
DETAIL-1
SUSPENSION MOUNTING
FIXED TO CEILING
CABLE OR CONDUIT—
CEILING
CLAMP SEE NOTE-2
SPACER
CHECK NUT AND
NON METALLIC CABLE GLAND IN CASE
BUSHING OF CABLE WIRING
FLUORESCENT FIXTURE
DETAIL-2
CEILING MOUNTING
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. SUSPENSION/FIXING CENTRES SHALL BE AS PER FIXTURE MANUFACTURER'S DETAILS.
3. IN CASE OF CABLE WIRING ONE NO. JUNCTION BOX COMPLETE WITH CABLE GLANDS
SHALL BE PROVIDED NEAR EACH FIXTURE.
INSPECTION BOX
(NO WIRE JOINT INSIDE
THE INSPECTION BOX)
FIXED TO CEILING
- CEILING
FIXED TO CEILING
SPACER
32x6-110 MM LONG
CONDUIT M.S. FLAT BEND TO
SHAPE (PAINTED)
CLAMP
FALSE CEILING
WIRES IN 19 DIA.
FLEXIBLE PVC CONDUIT
FLUORESCENT FIXTURE
RUBBER GROMMET
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
4 14^-4A
17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS
3 DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD
BP RKS/NS JMS VC
Rev.
Date Prepared Checked Stds. Committee Stds. Bureau
No. Purpose
by by Convenor Chairman
Format No. 8-00-0001-F4 Rev.O Approved by
Copyright EIL - All rights reserved
Page 1530 of 2065
TYPICAL INSTALLATION OF RECESSED STANDAR D No.
ENG14316 MOUNTED OR BELOW FALSE CEILING
digaTMONDIA LRCM 7-51-0214 Rev. 5
Nomiwnewsixo (A Go.t. a p.m Undertaking) MOUNTED LIGHTING FIXTURE
Page 1 of 1
INSPECTION BOX
FIXED TO CEILING
(NO WIRE JOINT INSIDE — CEILING
THE INSPECTION BOX)
CONDUIT
SPACER WIRES IN 19 DIA.
FLEXIBLE METALLIC CONDUIT
CLAMP
RUBBER GROMMET
M.S. FLAT AT BOTH
ENDS OF FIXTURE
BOLT WITH FLY NUT
LOOPING BACK SYSTEM OF
WIRING AT LIGHT POINT
FALSE CEILING
LIGHTING FIXTURE
DETAIL-1
RECESS MOUNTED FIXTURE
SUPPORTED ON WOODEN FRAME
• • • •
CONDUIT
JUNCTION BOX
SPACER FIXED TO CEILING
CLAMP
SEE NOTE-2
OPENING IN
19 DIA. G.I. PIPE (MEDIUM) FALSE CEILING
(TYP.)
FALSE CEILING
CHECK NUT
LIGHTING FIXTURE
NON METALLIC BUSHING
DETAIL-2
FIXTURE MOUNTING BELOW FALSE CEILING
NOTES: -
1. ALL DIMENSIONS ARE IN MM.
2. SUSPENSION/FIXING CENTRES SHALL BE AS PER FIXTURE MANUFACTURER'S DE "
Nrip,
e•
Y
5 21.10.16 REVISED & ISSUED AS STANDARD BP FA/HK BRB RN
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8 - 00 - 0001 - F4 Rev.O Copyright EIL - All rights reservec
BVGINIEERS
1MOICIA LIMITED
045 MOUNTED LIGHTING FIXTURE 7-51-0215 Rev. 5
01111,11111111101a1M) (A Govt. of India Undertaking)
BLOCK OF FOUR
Page 1 of 1
— FALSE CEILING
LIGHTING FIXTURES
WIRES IN 19 MM DIA.
FLEXIBLE METALLIC CONDUIT
4- 141
4.h
LIGHTING FIXTURES
(BLOCK OF FOUR)
4- ther
4 4
44 \4
WIRING CONNECTIONS
BETWEEN THE
FITTINGS
4-
It
NOTES:—
1 ALL DIMENSIONS ARE IN MM.
2. SUSPENSION/FIXING CENTRES SHALL BE AS PER FIXTURE MANUFACTURER'S DETAILS.
)4.–
5 21.10.16 REVISED & ISSUED AS STANDARD P FA/HK BRB RN
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS DM
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No . by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reservec
Page 1532 of 2065
STANDARD No.
011 ENGINEERS TYPICAL INSTALLATION OF
I xren
rae INDIA LIMITED 7-51-0216 Rev. 4
05,3,
4N N) (A Govt. of India Undertaking) HIGH BAY LIGHTING FIXTURE
Page 1 of 1
41111111101111.11
__,10
. 0 VI=I
.w
/Q1
SEE DETAIL 1
.1-.1 CABLE OR CONDUIT
CLAMP
ADAPTOR
JUNCTION BOX
INTEGRAL BALLAST
I WIRES IN 19 MM
FLEXIBLE PVC CONDUIT
HIGH BAY
LIGHTING FIXTURE
25x3 MM M.S. ST
BENT TO SHAPE BOLT,NUT AND WASHER 8 DIA. OR
TO SUIT FIXTURE
LIGHTING FIXTURE
DETAIL-1
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
4 7
17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS
3 DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD
Rev. , __BP _ RKS/NS JMS VC
No. Date Purpose Checked Stds. Bureau
by by Convenor Chairman
Format No. 8-00-0001-F4 Rev.0
Approved by
Page 1533 of 2065 Copyright EIL - All rights reserved
TYPICAL INSTALLATION OF STANDARD No.
401 elt4 ENGINEERS
ad
laiTFR ,Veffre 0/13,;71.7
INDIA LIMITED
(A Govt. of Indio Undertaking)
WELL GLASS 7-51-0217 Rev.4
LIGHTING FIXTURE (SAFE AREA) Page 1 of 1
AMOUNTING HEIGHT
VAS PER PLAN
THROUGH CONDUIT
OR CABLE 30
600
WALL
WALL-MOUNTED
SPACER CEILING
CLAMP
AMOUNTING HEIGHT
\LAS PER PLAN
REDUCER 25/19 AND
19 MM DIA. NIPPLE
CEILING-MOUNTED
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. APPLICABLE FOR SAFE AREAS.
0:1k.'
- / / I 2P1 A - •.1
). -
4 17.07.13 REAFFIRMED & ISSUED AS STANDARD
BP FA/SA
3 UAP/JMS DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS VC
Rev.
Date Purpose Prepared Checked Stds. Committee Stds. Bureau
No.
by by Convenor Chairman
Format No. 8-00-0001-F4 Rev.O Approved by
Page 1534 of 2065 Copyright EIL - All rights reserved
STANDARD No.
ENGINEERS TYPICAL INSTALLATION OF
• eieme 41)
INDIA LIMITED BULKHEAD LIGHTING FIXTURE 7-51-0218 Rev.4
(A Govt. of India Undertaking)
Page 1 of 1
SPACER
CABLE OR CONDUIT
CLAMP
WALL
JUNCTION BOX
DETAIL-2
NOTES:- WALL MOUNTED
1. ALL DIMENSIONS ARE IN MM.
2.
FOR INSTALLATION IN OUT DOOR FIXTURES, JUNCTION BOX SHALL BE IP-55
(WEATHER PROTECTED).
3.
PROPER SEALING SHALL BE ENSURED WHEREVER REQUIRED TO PREVENT INGRESS OF WATER.
4 432111W
17.07.13 REAFFIRMED & ISSUED AS STANDARD
FA/SA UAP JMS DM
3 15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS
Rev. VC
Date Checked Stds. Committee Stds. Bureau
No. Purpose
by by Convenor Chairman
Format No. 8-00-0001-F4 Rev.0 Approved by
Page 1535 of 2065 Copyright EIL - All rights reserved
TYPICAL INSTALLATION OF STANDARD No.
ENGINEERS
Iggbael g
01
07 ete=2 M-5,
0,
..)
INDIA LIMITED
(A Govt. of India Undertaking)
DISPERSIVE REFLECTOR 7-51-0219 Rev. 4
FIXTURE
Page 1 of 1
CABLE/CONDUIT
CEILING
CLAMP
REDUCER CABLE GLAND IN CASE
OF CABLE WIRING
(IF REQUIRED)
WIRES IN 19 DIA.
G.I. CONDUIT
CHECK NUT
LIGHTING FIXTURE
AAQl4N7Iw
.-1 HT
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
REDUCER
M.S. ANGLE
75x75x6-125 MM LONG
50 DIA. G.I. PIPE (MEDIUM)
SUPPORT FOR POLE
GLAVANISED U BOLT
FIXED TO ANGLE IRON
PIECE WELDED TO PLATFORM HANDRAIL
HAND RAIL 0
0
N
N
CABLE JUNCTION BOX
(IF REQUIRED)
M.S. ANGLE
100X75X6-100 MM LONG
0
WELDED TO PLATFORM MEMBER 0
FOR VERTICAL SUPPORT OF LO
THE POLE
PLATFORM
REDUCER 50/25 RESTING IN
DRILLED HOLE OF ANGLE IRON
PIECE
REDUCER
0
0
N
N
/REDUCER 50/25 AND
25 NIPPLE
0
0 ROOF TOP
r)
4 I.\-r.--01
17.07.13 REAFFIRMED & ISSUED AS STANDARD
3 _ BP FA/. A UAP/JMS DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD
BP RKS/NS JMS
Rev. VC
Date Purpose Checked Stds. Bureau
No.
by Convenor Chairman
by
Format No. 8-00-0001-F4 Rev.0 Approved by
Copyright EIL - AU rights reserved
Page 1537 of 2065
STANDARD No.
k74 ENGINEERS TYPICAL INSTALLATION OF
11 1r Braes
1.11FR Fet,re 2613,
PA1Ji)
INDIA LIMITED WEATHER PROOF LIGHT FIXTURE 7-51-0224 Rev.4
(A Govt. of India Undertaking)
Page 1 of 1
LIGHTING FIXTURE
MOUNTING HEIGHT
REDUCER
50 DIA. G.I. PIPE
(MEDIUM)
0
0 (30° IF MOUNTING HEIGHT
IS MORE THAN 5 METRES)
0
M.S. CLAMPS o
to
WALL OR COLUMN
WEATHER PROOF
JUNCTION BOX
(SEE DETAIL-1)
i
(SEE NOTE-2)
WIRES IN G.I. PIPE
CONDUIT OR CABLE
JUNCTION BOX
(WEATHER PROTECTED)
DETAIL-1
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2.
PROPER SEALING SHALL BE ENSURED TO PREVENT INGRESS OF WATER.
3.
WHERE FIRE PROOFING COLUMNS / STRUCTURES ARE ENCOUNTERED RECEPTACLE,
JUNCTION BOX AND CABLE SHALL BE INSTALLED ON A SUITABLE DEEP LEGGED
ANGLE IRON FRAME / DISTANCE BRACKET.
JUNCTION BOX
(WHEREVER REQUIRED) CEILING SLAB
OR STEEL MEMBER
MS SPACER
0
0 EARTH TERMINAL ON PANEL
oo
CLAMP
SEALING COMPOUND/BUSHING
F.F.L.
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
4
17.07.13 REAFFIRMED & ISSUED AS STANDARD BP
2154^ 'K
3 FA/SA UAP/JMS DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS
Rev. VC
Date Purpose Prepared Checked Stds. Bureau
No.
by by Convenor Chairman
Format No. 8-00-0001-F4 Rev.O Approved by
Page 1539 of 2065 Copyright EIL - All rights 11,4SPrVPri
TYPICAL INSTALLATION DETAILS STANDARD No.
ENGINEERS OF
INDIA LIMITED 7-51-0229 Rev. 4
(A Govt. of India Undertaking) LIGHTING FIXTURE MOUNTING
IN CONCEALED CONDUIT SYSTEM Page 1 of 1
PULL/INSPECTION BOX
R.C.C. SLAB
``.-1 120(MIN)
CONCEALED CONDUIT
19 DIA. G.I. PIPE (MEDIUM)
(PAINTED WHITE OR SPRING LOADED BALL AND SOCKET
AS SPECIFIED) SEE NOTE-2 ARRANGEMENT (CHROMIUM PLATED)
LOCK NUT (TYP.)
MOUNTING HEIGHT
FLUORESCENT FIXTURE
DETAIL-1
SUSPENSION MOUNTING
PULL/JUNCTION BOX
FIXING SCREW
R.C.C. SLAB
I. 1
1 20(MIN.)
FLUORESCENT FIXTURE
DETAIL-2
CEILING MOUNTING
NOTES:-
1 ALL DIMENSIONS ARE IN MM.
4
17.07.13 REAFFIRMED & ISSUED AS STANDARD ti
BP FA/SA
3 UAP/JMS DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD
BP RKS/NS
Rev JMS VC
No. Date Prepared
Purpose Checked Stds. CommitteeStds. Bureau
Format No. 8-00-0001-F4 Rev.O by by Convenor Chairman
Ap roved b
Page 1540 of 2065
TYPICAL INSTALLATION OF STANDARD No.
ENGINEERS
dab.
R.C.C. SLAB
!— •
20(MIN.)
TOP OF PANEL
CHECK NUT
LIGHTING/POWER PANEL
CABLE GLAND
CABLE
G.I. BOX
(SEE NOTE-2)
CHECK NUT AND
SEALING COMPOUND/BUSHING
WALL OR COLUMN
F.F.L.
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2.
G.I. ADAPTOR BOX OF SUITABLE SIZE WITH REMOVABLE COVER SHALL BE PROVIDED
BELOW THE PANEL TO FACILITATE CABLE TERMINATION.
4 T9,1111 —
17.07.13 REAFFIRMED & ISSUED AS STANDARD
BP FA/SA
3 UAP/JMS DM
15.12.08 REAFFIRMED & ISSUED AS STANDARD
BP RKS/NS
Rev. JMS VC
No. Date Purpose Prepared Checked Stds. Committee Stds. Bureau
by by Convenor Chairman
Format No. 8-00-0001-F4 Rev.0
Approved by
Page 1541 of 2065 Copyright EIL - All rights reserved
STANDARD No.
ENGINEERS TYPICAL INSTALLATION OF
INDIA LIMITED METSEC CHANNEL 7-51-0232 Rev. 3
(A Govt. of Indio Undertaking)
Page 1 of 1
0 PRESS FIT
REMOVABLE COVER
50
DETAIL-1
METSEC CHANNEL
RCC SLAB/BEAM
41
LIGHTING FIXTURE
NUT AND BOLT ARRANGEMENT
FOR SUPPORTING OF
LIGHTING FIXTURE
MOUNTING HEIGHT —1
DETAIL-2
INSTALLATION OF LIGHTING FIXTURE BELOW METSEC CHANNEL
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. LENGTH OF SUSPENSION CONDUITS SHALL BE ADJUSTED AS PER MOUNTING HEIGHT OF
LIGHTING FIXTURES.
3. IN CASE, METSEC CHANNEL IS NOT TO BE SUSPENDED, IT SHALL BE DIRECTLY FIXED
TO THE CEILING BY 3/16" DIA. ANCHOR FASTENERS @ 2 M INTERVALS.
4. METSEC CHANNEL AND SUSPENSION CONDUITS SHALL BE SPRAY PAINTED AFTER INSTALLATION.
5. WIRES FOR EACH TYPE OF CIRCUIT (t k;HTING/POWER/DC LIGHTING) SHALL BE NEATLY
BUNCHED IN METSEC CHANNEL.
irk
3 17.07.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS
2 15.12.08 REAFFIRMED & ISSUED AS SIANUARD . BP RKS/NS JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.0
Copyright Ell. - AN rights reserved
Page 1542 of 2065
MARKING OF TRENCHES STANDARD No.
‘31 ENGINEERS
lffETT EIRWiffl"2.1)
INDIA umrrED
(A Govt. of Indla UnOortakIng)
FOR 7-51-0301 Rev. 4
ELECTRIC CABLES
Page 1 of 1
MARKER POST
65x65x6 MM ANGLE
PAINTED WHITE
< >
0
to 0 0
60 60
4. j
47 ,c
r)
SIGN -'A'
—200 MM SQ.
Lr) PLAIN CONCRETE
(M15)
BURIED ELECTRIC
CABLES
200
II II
__ _
fr-- BURIED CABLE TRENCH r-
. . . .
ANGLE 65x65x6 ANGLE 65x65x6 ANGLE 65x65x6 ANGLE 65x65x6
1100 MM LONG 1100 MM LONG 1100 MM LONG 1100 MM LONG
NOTES: -
1. ALL DIMENSIONS ARE IN MM.
2. TRENCHES SHALL BE MARKED AT ALL DIRECTION CHANGES, INTERSECTIONS AND STRAIGHT RUNS.
3. SIGN BOARDS SHALL BE MADE OF 14 GAUGE ENAMELED STEEL PLATE WHITE LETTERING SHALL
BE ON JADE GREEN BACKGROUND.
•?.
4 21.11.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS SC
3 15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
Page 1543 of 2065
TYPICAL SECTION OF CABLE TRENCH STANDARD No.
ENGNEERS
f212e.5
(.41Miffl,WM.3.1~)
IND1A LIMI I ED
Govt. of lncfio Undertoking}
IN 7-51-0302 Rev. 4
UNPAVED AREAS Page 1 of 1
F.G.L.
EARTH STRIP
SPECIFIED)
BRICKS
M.V. CABLES
SAND/STONE DUST
u")
0
0 CONTROL CABLES
tf, 0
tr)
O
O
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. LEAVE SPACE FOR LATER ADDITION OF AT LEAST 2 CABLES OR 15% AVERAGE SPARE SPACE
FOR FUTURE EXPANSION.
3. IF FIRE ALARM AND COMMUNICATION CABLES ARE LAID IN THE SAME TRENCH A CLEARANCE
OF 300 MM (MIN.) FROM ELECTRIC POWER CABLES SHALL BE PROVIDED.
?5\4rt
4 21.11.13 REVISED & REISSUED AS STANDARD BP FA/SA UAP/JMS SC
3 15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
M.S. CLEAT
(SEE DETAIL 3 & 4)
CABLE OR CONDUIT
(TYP.)
WALL
ONE HOLE 'C' CLAMP
OR GROUP CLAMP
ON G.I. SPACER
WELD
DETAIL-1
SUPPORT ON WALL
SLAB / BEAM —
M.S. CLEAT
(SEE
ELD DETAIL 3 & 4)
W
40x40x6 MM M.S. SLOTTED ANGLE
CABLE OR CONDUIT
(LENGTH AS REQUIRED)
ONE HOLE 'C' CLAMP
DETAIL-2
SUPPORT ON SLAB / BEAM
1, 40
o
WALL / SLAB / BEAM
CONTROL STATION
z
O
cn
0
CABLE GLAND
0
0
o_ G.I. CLAMP 300
0
o CABLE
0
ISMC— 1 00 CHANNEL
R=12D OF PIPE
G.I. PIPE
SEE NOTE-2
G.I. PIPE
SECTION-AA
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DRAWINGS.
N CONTROL STATION
CABLE GLAND
CABLE
COLUMN
• 4
STEEL COLUMN
2NOS. 75X1OMM
R=12D OF PIPE
M.S. FLAT
G.I. PIPE WELDED TO
SEE NOTE-2 STEEL COLUMN
CONTROL
VIEW A-A BOLTED TOSTATION
CONCRETE (FOR STEEL COLUMN M.S. FLAT
COLUMN WITHOUT FIRE PROOFING)
FIRE PROOFING
75X10 MM M.S. STEEL COLUMN
FLAT BENT TO
CONTROL STATION SHAPE & FIXED 2NOS. 75X1OMM
BOLTED TO
TO COLUMN WITH M.S. FLAT
M.S. FLAT
10MM DIA. WELDED TO
VIEW A-A ANCHOR FASTNER STEEL COLUMN
(FOR CONCRETE COLUMN)
L
25x25x6 MM ANGLE
WELDED TO ISMC 100
150 MM (MIN) FOR INDOOR LOCATION
A= CHANNEL
{300 MM (MIN) FOR OUTDOOR LOCATION
v cA,V
4 21.11.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS SC
3 15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
CONTROL STATION
Z-
-
0 < -er-t1-
F- -11 +L
FQ
- L-k,1/451 .
O
CABLE GLAND
c.)
O
G.I. CLAMP C9 300
J
CABLE
ISMC-100 CHANNEL
R-12D OF PIPE
tr)
• di• I. 4
O • •II •
•
G.I. PIPE
44 • . A• SEE NOTE-2
400 MM SQ. PLAIN CONCRETE (M15)
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DRAWINGS.
■ •■V
,g'221j-j" /
4 21.11.13 REAFFIRMED & ISSUED AS STANDARD BP FA/SA UAP/JMS SC
3 15.12.08 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
ISMC— 1 00
SUPPORT FOR
CONTROL STATION
CONTROL STATION
CABLE GLAND
O
O
0
CABLE
G.I. CLAMP
A
SEALING COMPOUND/BUSHING
F.F.L.
. • • ,
• . ,• :
R=12D OF PIPE
G.I. PIPES
y =
SEE NOTE-2
1,}
CONTROL STATION
1Cl
i>
A 150 MM (MIN.) FOR INDOOR LOCATIONS
300 MM (MIN.) FOR OUTDOOR LOCATIONS
SECTION-AA = 1
NJ OTE.S : --
1 ALL DIMENSIONS ARE IN MM.
2. QUANTITY AND SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DRAWINGS.
.....,_ CONTROL
IU
STATION
CABLE GLAND
CABLE GLAND
CABLE
0
0
SEALING
COMPOUND/
BUSHING
I I F.F.L.
I.• . ' •
ISMC-100 CHANNEL
G CLAMP 0 300
CA°1;°1
g
A - 150 MM(MIN.) FOR INDOOR LOCATIONS
300 MM (MIN.) FOR OUTDOOR LOCATIONS
G.I. PIPES
SEE NOTE-2
11111 1141 elli
CABLE GLAND
MOTOR
SEALING COMPOUND/
i BUSHING
F.F.L.
. e.
G.I. PIPES
SEE NOTE-2
DETAIL-1 R= 12D OF PIPE
(SIDE ENTRY)
• •
SEALING COMPOUND/
BUSHING
a
•
G.I. PIPES
SEE NOTE-2
R= 12D OF PIPE
A 150 MM (MIN.) FOR INDOOR LOCATIONS
= 300
[ MM (MIN.) FOR OUTDOOR LOCATIONS
DETAIL-2
(BOTTOM ENTRY)
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. QUANTITY AND SIZE OF PIPE SLEEVE SHALL BE AS PER LAYOUT DRAWINGS.
3. UNDER NORMAL CONDITION DETAIL-1 SHALL BE FOLLOWED. ONLY IN EXCEPTIONAL
CASES DETAIL-2 SHALL BE FOLLOWED.
A
n.
WELD
M.S. ANGLE
(SIZE TO SUIT) CABLE TRAY
CABLE SUPPORT
1I
11
CABLE GLAND
CL I
O OBLONG HOLE WITH
PVC / RUBBER BUSHING
O
ISMC-100 CHANNEL
HEIGHT 3500MM (MAX.)
c
c
EQUIPMENT
F.F.L.
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. WHERE FEASIBLE MAIN CABLE TRAY CAN BE ROUTED IN SUCH A WAY THAT
ISMC CHANNEL CAN BE DIRECTLY WELDED TO TRAY / SUPPORT.
>d)'"'
4 21.11.13 REAFFIRMED & ISSUED AS STANDARD G BP FA/SA UAP/JMS SC
3 13.02.09 REAFFIRMED & ISSUED AS STANDARD BP RKS/NS JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
Page 1552 of 2065
INSTALLATION DETAILS FOR STANDARD No.
ENGINEERS SOCKET/RECEPTACLE
INDIA LIMITED MOUNTED ON COLUMN 7-51-0316 Rev. 4
(A Govt. of Indla Undertaking)
(CABLE IN TRAY) Page 1 of 1
COLUMN
SOCKET / RECEPTACLE
PLUG
FIXED TO COLUMN
WITH ANCHOR, BOLTS
AND NUTS
(SEE NOTE-2)
0
G.I. CLAMP 0
C■1
SEALING
COMPOUND/
BUSHING INSERT PLATE
=12D OF CABLE
CABLE ENTRY
TO BE SEALED
1040
G.I. CLAMP
NOTES:--
1. ALL DIMENSIONS ARE IN MM.
2. WHERE STEEL STRUCTURES ARE ENCOUNTERED, SOCKET RECEPTACLE SHALL BE
MOUNTED ON SUITABLE ANGLE IRON FRAME WELDED TO STEEL STRUCTURE.
3. WHERE FIRE PROOFING COLUMNS / STRUCTURES ARE ENCOUNTERED
SOCKET / RECEPTACLE AND CABLE SHALL BE INSTALLED ON A
SUITABLE DEEP LEGGED ANGLE IRON FRAME / DISTANCE BRACKET.
PLUG
CABLE CABLE
11 4—
Wr
i
G.I. CLAMP
11 1
CABLE
PLATFORM
G.I. CLAMP
1111
CABLE
PLATFORM
HOLE TO BE DRILLED ON
50x6 M.S. FLATS TO MATCH
HAND RAIL
WITH THOSE ON SOCKET /
SUPPORT
RECEPTACLE / CONTROL STATION
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
2. CABLE SHALL NOT BE ROUTED ALONG HAND RAIL.
11!
==
RCC DUCT WITH
RACK/TRAYS
== =
X
t-- heee.~K
IN M M ffill
= = = =
CABLE RACKS/TRAYS = = = =
= = = = DIRECTLY BURIED/
= = = =
RCC CABLE TRENCH
(SIZE AS PER LAYOUT)
PLAN
TOP OF ROAD
CABLE RACKS/TRAYS —
FGL
DIRECTLY BURIED/
SECTION X—X RCC CABLE TRENCH
r
(SIZE AS PER LAYOUT)
N
• 0
z
I
a_ w
1.- 4
0
INSERT PLATE z
(TYP.) •
4L o
o
.. •
• 4 ANGLE WELDED
I ie I 600 soo TO INSERT PLATE
AS REQUIRED 0500 MM (TYP.)
MIN. MIN
CABLE RACK
SECTION A—A SECTION
. A—A WELDED TO ANGLE
0500 MM (TYP.)
(ONE SIDE RACK/ (BOTH SIDES RACK/
TRAY ARRANGEMENT) TRAY ARRANGEMENT)
NOTES:—
1. ALL DIMENSIONS ARE IN MM.
2. CABLE SUPPORT ARRANGEMENT SHALL MATCH WITH THE ARRANGEMENT
OF OUTSIDE TRAY / TRENCH ON THE SIDES.
ROAD WIDTH
STORM WATER DRAIN
(IF THERE)
PLAN
— DIRECTLY BURIED
TOP OF ROAD CABLE TRENCH
(SIZE AS PER LAYOUT)
\IFGL
flk
0 0 41»
BOTTOM OF DUCT
\I(AS PER LAYOUT)
NOTES:-
1. ALL DIMENSIONS ARE IN MM.
7-51-0323 Rev. 4
wirimminaw. (A Govt. of Indio Undortaldng)
OVERHEAD TRAYS )
Page 1 of 1
TRAY ARRANGEMENT
AS PER JOB
REQUIREMENT
CABLE TRAY
WALKWAYS
AS PER JOB
REQUIREMENT
CABLES LAID IN
CABLE TRAY/CLAMPED
ON STRUCTURE
FFL
VIEW A-A
OF COLUMN
PLAN
••
UNPAVED AREA
(SEE NOTES-1 & 2)
•♦
bb UNDERGROUND G.I. PIPES
(SIZE, LOCATION AND NOS.
•• AS PER ELECT. DRAWING)
(SEE NOTE-3)
A
r •
A
PLAN
0
0 COLUMN
FFL
SECTION A A —
NOTES:-
1. AREA SHOWN AS HATCHED NEAR PUMP MOTOR EACH FOUNDATION SHALL BE LEFT UNPAVED
BY PAVEMENT CONTRACTOR.
2. CABLE LAYING & SAND / LEAN CONCRETE FILLING IN THIS UNPAVED AREA SHALL BE
DONE BY ELECTRICAL CONTRACTOR.
3. CIVIL CONTRACTOR SHALL PROVIDE G.I PIPES AND SEAL AT BOTH ENDS OF THE PIPES
WITH PVC BUSHINGS.
ELECTRICAL POWER IS THE MAINSTAY OF ANY CONSTRUCTION ACTIVITY. AT THE SAME TIME IT REQUIRES
UTMOST CARE IN IT'S UTILISATION TO AVOID ACCIDENTS DUE TO ELECTRICAL SHOCK, FIRE INCIDENTS OR
ELECTRIC SHORT CIRCUITS. EXPOSURE OF ELECTRICAL INSTALLATION TO ADVERSE ENVIRONMENTAL
CONDITIONS INCREASE THE RISK OF SUCH ACCIDENTS. HENCE IT IS NECESSARY TO TAKE EXTRA
PRECAUTIONS FOR SUCH INSTALLATIONS TO ENSURE SAFETY OF PERSONNEL AND EQUIPMENT. THIS
STANDARD ADDRESSES THE SAFETY MEASURES REQUIRED TO BE ADOPTED FOR THE ELECTRICAL
INSTALLATIONS BY ALL CONTRACTORS DURING CONSTRUCTION PHASE.
1. ALL ELECTRICAL CONNECTIONS/WORK FOR ELECTRICAL INSTALLATIONS SHALL BE CARRIED OUT AS PER
PROVISIONS OF THE LATEST REVISION OF THE FOLLOWING CODES AND STANDARDS IN ADDITION TO THE
REQUIREMENTS OF STATUTORY AUTHORITIES AND CEA REGULATIONS-2010.
OISD—STD-173 : FIRE PREVENTION AND PROTECTION SYSTEM FOR ELECTRICAL INSTALLATIONS.
OISD—STD-192 : SAFETY PRACTICE DURING CONSTRUCTION.
SP-30 (BIS) : NATIONAL ELECTRIC CODE.
THE INSTALLATION SHALL HAVE APPROVAL FROM CONCERNED STATUTORY AUTHORITIES.
2. ALL ELECTRICAL CONNECTIONS SHALL BE DONE BY AN ELECTRICIAN WITH VALID LICENCE AND TO THE
SATISFACTION OF ENGINEER—IN—CHARGE.
3. ONE COMPETENT UCENCED ELECTRICIAN SHALL BE MADE AVAILABLE BY CONTRACTOR AT SITE ROUND
THE CLOCK TO ATTEND TO THE NORMAL/EMERGENCY JOBS.
4. ALL SWITCH BOARDS/WELDING MACHINES SHALL BE KEPT IN WELL VENTILATED & COVERED SHED.
THE SHED SHALL BE ELEVATED TO AVOID WATER LOGGING. NO FLAMMABLE MATERIALS SHALL BE
USED FOR CONSTRUCTING THE SHED. ALSO FLAMMABLE MATERIALS SHALL NOT BE STORED IN AND
AROUND ELECTRICAL EQUIPMENT/SWITCHBOARD. ADEQUATE CLEARANCES AND OPERATIONAL SPACE
SHALL BE PROVIDED AROUND THE EQUIPMENT.
5. FIRE EXTINGUISHERS AND INSULATING MATS SHALL BE PROVIDED IN ALL POWER DISTRIBUTION CENTERS.
6. TEMPORARY ELECTRICAL EQUIPMENT SHALL NOT BE EMPLOYED IN HAZARDOUS AREAS WITHOUT OBTAINING
SAFETY PERMIT.
10. MULTIUNGUAL (ENGLISH, HINDI AND LOCAL LANGUAGE) CAUTION BOARDS, SHOCK TREATMENT CHARTS
AND INSTRUCTION PLATE CONTAINING LUCATION OF ISOLATION POINT FOR INCOMING SUPPLY, NAME
& TELEPHONE NO. OF CONTACT PERSON IN EMERGENCY SHALL BE PROVIDED IN SUBSTATIONS AND
NEAR ALL DISTRIBUTION BOARDS/LOCAL PANELS.
11. OPERATION OF EARTH LEAKAGE DEVICE SHALL BE CHECKED REGULARLY BY TEMPORARILY CONNECTING
SERIES TEST LAMP (2 BULBS OF EQUAL RATING CONNECTED IN SERIES) BETWEEN PHASE AND EARTH.
12. THE FOLLOWING DESIGN FEATURES SHALL BE ENSURED FOR ALL ELECTRICAL INSTALLATIONS DURING
CONSTRUCTION PHASE.
12.1 EACH INSTALLATION SHALL HAVE A MAIN SWITCH WITH A PROTECTIVE DEVICE, INSTALLED IN AN
ENCLOSURE ADJACENT TO THE METERING POINT. THE OPERATING HEIGHT OF THE MAIN SWITCH
SHALL NOT EXCEED 1.5 M. THE MAIN SWITCH SHALL BE CONNECTED TO THE POINT OF SUPPLY
BY MEANS OF ARMOURED CABLE.
12.2 THE OUTGOING FEEDERS SHALL BE DOUBLE OR TRIPLE POLE SWITCHES WITH FUSES/MCBs. LOADS
IN A THREE PHASE CIRCUIT SHALL BE BALANCED AS FAR AS POSSIBLE AND LOAD ON NEUTRAL
SHOULD NOT EXCEED 20% OF LOAD IN THE PHASE.
12.3 THE INSTALLATION SHALL BE ADEQUATELY PROTECTED AGAINST OVERLOAD, SHORT CIRCUIT AND EARTH
LEAKAGE BY THE USE OF SUITABLE PROTECTIVE DEVICES. FUSES WHEREVER USED SHALL BE HRC TYPE.
USE OF REWIRABLE FUSES SHALL BE STRICTLY PROHIBITED. THE EARTH LEAKAGE DEVICE SHALL HAVE
AN OPERATING CURRENT NOT EXCEEDING 30 mA.
12.4 ALL CONNECTIONS TO THE HANDTOOLS/WELDING RECEPTACLES SHALL BE TAKEN THROUGH PROPER
SWITCHES, SOCKETS AND PLUGS.
12.5 ALL SINGLE PHASE SOCKETS SHALL BE MINIMUM 3 PIN TYPE ONLY. ALL UNUSED SOCKETS SHALL BE
PROVIDED WITH SOCKET CAPS.
12.6 ONLY 3 CORE (P+N+E) OVERALL SHEATHED FLEXIBLE CABLES WITH MINIMUM CONDUCTOR SIZE OF
2
1.5 MM COPPER SHALL BE USED FOR ALL HAND TOOLS.
12.7 ONLY METALLIC DISTRIBUTION BOXES WITH DOUBLE EARTHING SHALL BE USED AT SITE. NO WOODEN
BOXES SHALL BE USED.
12.8 ALL POWER CABLES SHALL BE TERMINATED WITH COMPRESSION TYPE CABLE GLANDS. LUGS SHALL BE
USED FOR MULTISTRAND WIRES/CABLES HAVING MUTISTRAND/SOUD CONDUCTOR.
12.10 CABLES SHALL BE LAID IN UNDERGROUND AT A MINIMUM DEPTH OF 750 MM, FOR LV & CONTROLS
AND 900MM FOR HV CABLES COVERED WITH SAND, BRICK AND SOIL FOR ENSURING MECHANICAL
PROTECTION. CABLES SHALL NOT BE LAID IN WATER LOGGED AREA AS FAR AS PRACTICABLE.
CABLE ROUTE MARKERS SHALL BE PROVIDED AT EVERY 25 M OF BURIED TRENCH ROUTE. WHEN
LAID ABOVE GROUND, CABLES SHALL BE PROPERLY CLEATED OR SUPPORTED ON RIGID POLES OF
ATLEAST 2.1 M HIGH. MINIMUM HEAD CLEARANCE OF 6 METERS SHALL BE PROVIDED AT ROAD CROSSING.
12.11 UNDER GROUND CABLES SHALL NOT BE ALLOWED TO CROSS THE ROADS WITHOUT PIPE SLEEVE.
12.12 ALL CABLE JOINTS SHALL BE DONE WITH PROPER JOINTING KIT. NO TAPED/TEMPORARY JOINTS SHALL
BE USED.
12.13 AN INDEPENDENT EARTHING FACILITY SHOULD PREFERABLY BE ESTABLISHED WITHIN THE TEMPORARY
INSTALLATION PREMISES. ALL APPLIANCES AND EQUIPMENT SHALL BE ADEQUATELY EARTHED. IN CASE
ARMOURED CABLES ARE USED, THE ARMOUR SHALL BE BONDED TO THE EARTHING SYSTEM.
12.14 ALL CABLES AND WIRE ROPE USED FOR EARTH CONNECTIONS SHALL BE TERMINATED THROUGH TINNED
COPPER LUGS.
12.15 IN CASE OF LOCAL EARTHING, EARTH ELECTRODES SHALL BE BURIED NEAR THE SUPPLY POINT AND
EARTH CONTINUITY WIRE SHALL BE CONNECTED TO LOCAL EARTH PLATE FOR FURTHER DISTRIBUTION
TO VARIOUS APPLIANCES. ALL INSULATED WIRES FOR EARTH CONNECTION SHALL HAVE INSULATION OF
GREEN COLOUR.
12.16 SEPARATE CORE SHALL BE PROVIDED FOR NEUTRAL. EARTH/STRUCTURES SHALL NOT BE USED AS A
NEUTRAL IN ANY CASE.
12.17 ON/OFF POSITION OF ALL SWITCHES SHALL BE CLEARLY DESIGNATED/PAINTED FOR EASY ISOLATION
IN EMERGENCY.
3000 /11
250 125 125 250 250 250 I 1500 250 250 125
40x15 HORIZONTAL
A -4-1 RUNG (TYP.)
W
[45 45
40
SLOTTED RUNG
MEIMIMUrAMPIELIMINIMPLIMIR
1451
451
100x45 SIDE RUNNER (TYP.)
14 0 HOLE FOR SECTION-AA
12 0 BOLT (TYP.)
of
D-07 lc
0 0
0 a) 0 II
1=1MM
11111111111111111
IMAM_
mm411111111
ROUND HEAD BOLT
12 MM DIA
PL.215x90x2 THK.
1301401 75 i 40 P SPLICE PLATES
VIEW C-C
0
N
L--50
BARRIER PLATE
100 HOLE FOR
80 BOLT
(100 MM LONG)
NOTES:-
7A10> ;14'"A
C)4
2 23.04.13 REVISED AND REISSUED BP FA/RSC UAP/J MS DM
1 11.01.08 REVISED AND REISSUED BP RKS/SSM JMS VC
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
125
140 HOLES FOR FIXING
SPLICE PLATE (TYR)
H (Pi')
40x15 MM
RUNG @ 250 C/C
HORIZONTAL BEND
125 _1
(TYP)
0
U-)
N
[ W2 J
W W1
`T' JOINT
/f"4 ;,e4211
2 23.04.13 REVISED AND REISSUED BP FA/RSC UAP/JMS DM
GENERAL NOTES:-
1 THE CABLE TRAYS AND ACCESSORIES SHALL COMPLY WITH LATEST EDITION OF INDIAN STANDARDS
IS: 1363, IS: 1367(PART-13), IS:2629, IS:5986.
2. THE CABLE TRAYS SHALL BE LADDER TYPE PREFABRICATED, HOT DIP GALVANIZED. THE LADDER
TYPE TRAYS SHALL CONSIST OF SIDE RUNNERS & HORIZONTAL RUNGS AS PER DETAILS SHOWN
IN SH. 1 & 2.
3. THE LADDER TYPE TRAYS AND ACCESSORIES SHALL HAVE RIGID WELDED CONSTRUCTION AND
SHALL BE FABRICATED OUT OF 2 mm THICK HOT ROLLED SHEET STEEL. THE RUNGS SHALL
BE WELDED TO THE SIDE RUNNERS.
4. SIDE RUNNERS SHALL BE 100 x 45 mm CHANNEL WITH THE FLANGES FACING INSIDE. RUNGS
SHALL BE 40 x 15 mm SLOTTED CHANNEL TYPE.
5. CABLE TRAYS SHALL BE SUITABLE FOR A CABLE WEIGHT OF 75 kg PER METRE OF RUNNING
LENGTH OF TRAY AND SHALL BE SUPPORTED AT 3 m INTERVALS. IN ADDITION, TRAYS SHALL
BE SUITABLE FOR A POINT LOAD OF 70 kg (EQUIVALENT WEIGHT OF A MAN WORKING ON THE
CABLE TRAY).
6. SIDE RUNNER CHANNELS SHALL BE CONNECTED AT ENDS USING 2 SPLICE PLATES ONE EACH SIDE
AS SHOWN IN SHEET-1.
7. THE SIDE RUNNER WILL ALSO HAVE SUITABLE HOLES AT EVERY METRE FOR CLEATING EARTHING
STRIP. SUITABLE THREADED HOLES SHALL BE PROVIDED ON THE RUNNER TOP AND BOTTOM
FOR SUPPORTING AND FIXING TRAY COVERS WITH SCREWS AT EVERY METRE.
8. HOT DIP GALVANIZING SHALL BE DONE AFTER FABRICATION AS PER THE RELEVANT INDIAN
STANDARD SPECIFICATIONS. THE AMOUNT OF GALVANIZING SHALL BE MINIMUM 610 g/m 2
9. THE TYPE OF CONSTRUCTION SHALL BE SUCH AS TO FACILITATE EASY HANDLING, ASSEMBLY
AND INSTALLATION AT SITE. FOR THE CONSTRUCTION OF CABLE TRAYS THE STANDARD STRAIGHT
LENGTH OF CABLE TRAY SHALL BE 3 METERS UNLESS OTHERWISE SPECIFIED.
10. SPLICE PLATE OF CABLE TRAYS SHALL BE PLACED NOT MORE THAN 750 MM FROM
SUPPORT ANGLE.
11. THE WORKMANSHIP SHALL BE SUCH AS TO ENSURE EASY LAYING OF CABLES WITHOUT CAUSING
DAMAGE TO CABLES. ALL SURFACES SHALL BE FREE FROM DEFECTS SUCH AS BURRS, SHARP
EDGES ETC.
12. THE HARDWARE SHALL CONFORM TO THE RELEVANT INDIAN STANDARD SPECIFICATIONS AND SHALL
BE ABLE TO WITHSTAND THE MAXIMUM LOADING CONDITIONS AS REQUIRED. ALL HARDWARE AND
FITTINGS SHALL BE HARD CHROME OR CADMIUM PLATED. HARDWARE SHALL INCLUDE BOLTS,
NUTS, WASHERS ETC.
13. THE BENDS, TEES, REDUCERS AND DROPPERS SHALL HAVE A BENDING RADIUS AS DESCRIBED
IN THE SCHEDULE OF RATES.
14. THE FOLLOWING TESTS FOR THE AMOUNT OF ZINC COATING SHALL BE CARRIED OUT:
AN. ^
DEPTH
(SENOT-1)
MC-100
(TYP.)
0
0
to
z
RCC FLOOR
ELEVATION
(VIEW-A)
rn
NOTES:-
1. FOR PANELS DEPTH UPTO 800 MM SUPPORTING ARRANGEMENT AS SHOWN SHALL BE FOLLWED.
FOR PANELS DEPTH MORE THAN 800 MM ADDITIONAL SUPPORTS AS PER VENDOR'S FDN. PLAN
SHALL BE PROVIDED.
2. ALL PANELS SHALL BE TACK WELDED WITH BASE FRAME OF SWITCHBOARD.
3. SUPPORTING ARRANGEMENT FOR FALSE FLOORING SHALL BE AS PER ARCHITECTURAL DRAWINGS.
1
FL (SEE NOTE-1)
1
0
0
U)
750 L110x110x8
0 THROUGHOUT THE
0 (MIN.)
LENGTH OF CABLE
0 MC-100 0 EACH TRENCH (TYP.)
0
M
PANEL JOINT
0
0 CABLE SUPPORTS RCC CABLE TRENCH
(TYP.)
L45X45X6
MC-100 6 MM THK. REMOVABLE —
WELDED WITH
CHEQUERED PLATE
CHQD. PLATE FFL
L110x110x8
120x120x8THK. PLATE L45X45X6 THROUGHOUT THE LENGTH
WELDED TO MC-100 WELDED WITH OF CABLE TRENCH (TYP.)
TO SUPPORT MC-100 MC-100 MC-100
CLEAT L75x75x6
DETAIL-A 70 MM LONG
7-51-0336 Rev. 3
Page 2 of 2
ti
PANEL FRONT INTEGRAL BASE FRAME/
MV SWITCH BOARDS/ KICK PLATE
MC-100 0 EACH
PANEL JOINT MISC. PANELS
6 MM THK. REMOVABLE
CHEQUERED PLATE
50/75
MC-100 WELDED
TO INSERT ANGLE
BETWEEN CROSS
DETAIL-A 50mm THK.
FINISH FLOOR
MEMBERS (TYP.)
FFL (SEE NOTE-1)
o
0 Z
750
I
(MIN.5 L110x110x8
0 THROUGHOUT THE
0 MC-100
M, LENGTH OF CABLE
Io_ 0 EACH
TRENCH (TYP.)
0 PANEL JOINT
0
0
0
RCC CABLE TRENCH
IL CABLE SUPPORTS
(TYP.)
0
0
WIDTH
L45X45X6
MC-100 6 MM THK. REMOVABLE — WELDED WITH
CHEQUERED PLATE CHQD. PLATE FFL
\=[
0
L110x110x8
MC-100 - L45X45X6 THROUGHOUT THE LENGTH
WELDED WITH OF CABLE TRENCH (TYP.)
120x120x8THK. PLATE MC-100
WELDED TO MC-100 75
TO SUPPORT MC-100
CLEAT L75x75x6
DETAIL-A 70 MM LONG
NOTES:-
1. 50 THICK FINISH FLOORING SHALL BE DONE ONLY AFTER INSTALLATION OF BASE FRAME
2. ALL PANELS SHALL BE TACK WELDED WITH BASE FRAME OF SWITCHBOARD.
3. UNUSED PORTION OF CUTOUTS SHALL BE COVERED WITH 6 MM THICK CHEQUERED PLATES.
4. WIDTH OF TRENCH TO SUIT THE DIMENSIONS OF SWITCHBOARD SHALL BE AS PER AFC
DRAWING OF THE PROJECT.
Note
1 Performance data shall be furnished for ONAN rating & principal tap.
2 Losses shall be inclusive of positive tolerance and shall be at nominal tap.
3 Minimum guranteed effciency at 0.8 p.f. at 40% of ONAN rating shall be 99.5% (inclusive of all tolerance).
4 Makes of components shall be as per vendor list enclosed.
5 Transducers for providing 4-20mA signal for OTI & WTI for owner's interface shall be provided.
PURCHASER'S DATA
A Site conditions
1 Maximum ambient temperature: 47 °C 4 Relative humidity: 85 %
2 Minimum ambient temperature: 10 °C 5 Altitude above MSL: < 1000 m
3 Design ambient temperature: 47 °C 6 Environment: Humid & corrosive
B Technical particulars
1 Tag no.: TR-2500/2501, TR-2502/2502
27 Explosion protection PRV
2 Duty: Continuous 28 Terminal location:
3 No. of windings: 2 HV side Larger side
4 Type of cooling: ONAN LV w.r.t HV 90°
5 Rated MVA 29 Terminal connection
6 Rated voltage HV side Cable box
HV winding 11 kV LV side Cable box
LV-1/LV-2 winding 6.9kV, 0.433 kV 30 Cable size
7 System earthing: HV side
HV side Unearthed LV-1 side
LV-1/LV-2 side LV-2 side
Resistance earthed/solidely earthed 31 Neutral CT specification:
8 Rated frequency: 50 Hz ± 3%
9 No. of phases: Three 51G 200/1A, 5P10, 15VA
10 Fault level on HV side: 40 kA 64R Not Applicable
fault level on LV-1/LV-2 20kA/20kA Vk
11 Connection Im at Vk/2
HV side Delta RCT
LV-1/LV-2 side Star 32 Installation Outdoor
12 Vector group: DyN11 33 Painting & colour Epoxy & shade 632
13 Impedance at max. MVA: 0.0625 34 AC Auxiliary voltage 415 V ± 10% TPN
14 Insulation class: A 35 DC Auxiliary voltage 110 V ± 10% DC
15 Insulation level: 36 Bidirectional roller type Flat
P. f withstand 37 ¢ distance of flat rollers 1000 mm
HV winding 28 kV 38 Applicable specifications EIL std. 6-51-41
LV-1/LV-2 winding 28kV/3kV 39 Loss Capitalization Applicable
16 Impulse withstand a Rate for copper loss Rs./kW:
HV winding 75 kVp b Rate for iron loss Rs./kW:
LV-1/LV-2 winding 60kV/N.A
17 Oil type Mineral (as per IS 335) 40 Accessories requirement
18 Winding insulation type: Uniform Sampling valve Yes
19 Clearance: Conservator drain valve Yes
Ph to Ph As per IS Top oil filter valve Yes
Ph to N As per IS Explosion vent/PRV Yes
20 Tap changer Air bag for conservator Yes
Location HV winding Dial type thermometer Yes
Type Offcircuit & contacts for OTI, WTI
Range ± 7.5% Drain valve Yes
No. of steps 7 Marshalling box Yes
21 Normal load: 60% Double float Buchholz Yes
22 Temp. rise at extreme tap Channels, towing lugs : Yes
having max. losses: Rollers Yes
oil 55°C Neutral bushing Yes
winding 50°C outside terminal box
23 Minimum Guaranteed efficiency 99.3 with connector assembly
at 0.8 p.f at 80% of ONAN rating: Inspection cover Yes
24 Load at which max eff. occurs: 1.2 MVA Disconnecting chamber Yes
25 Power flow: Unidirectional WTI & OTI Yes
26 HV/LV phase sequence UVW/To suit switchgear Busduct flange on LV Yes
Lugs and cable glands Yes
Format No: EIL 1650-689 P2 Rev.2 Copyrights EIL - All rights reserved
MANUFACTURER'S DATA
A Make:
B Performance: C Constructional Features
1 No load loss at 1 Location of terminals
100% Voltage; kW Primary
110% Voltage: kW Secondary
2 Full load copper loss at 75°C: kW 2 Location of Neutral CT
3 No load current at 3 Explosion protection Explosion vent/PRV
100% Voltage: A
110% Voltage: A D Mechanical data
4 Efficiency at full load at 75°C 1 Core & winding weight: Kgs.
at 0.8 p.f: % 2 Tank & fitting weight: Kgs.
at 1.0 p.f: % 3 Radiator without oil weight: Kgs.
5 Eff. at 50% load at 75°C 4 Total weight: Kgs.
at 0.8 p.f; % 5 Total quantity of oil: ltrs.
at 1.0 p.f: % 6 Quantity of oil in radiators: ltrs.
6 Maximum efficiency: % 7 Overall dimensions: ltrs.
7 Load at which max eff. Occurs: MVA Length mm
8 Regulation at 75°C Breadth mm
at 0.8 p.f: % Height mm
at 1.0 p.f: %
9 X1/R1 Ratio
X0/R0 Ratio
10 Zero sequence impedence, Z0
Note
1 Losses shall be inclusive of positive tolerance and shall be at nominal tap.
2 Minimum Guaranteed efficiency for transformers at 0.8 p.f & at 40% of ONAN rating shall be as below:
Format No: EIL 1650-689 P2 Rev.2 Copyrights EIL - All rights reserved
B Technical particulars
1 Rated voltage 3.81 Volts 6 Installation Indoor
2 Rated current By contractor 7 Cable connections
3 Short time rating By contractor 7.1 Cable entry Side
4 Continuous rating Required 7.2 Separate bolted removable Required
(10% of short time rating) gland plate for cable entry
4 Resistance of NGR By contractor 7.3 Cable glands & lugs Required
5 Terminal Connections 8 Current transformer Required
5.1 Transformer nuetral to NGR Al Conductor Voltage grade By contractor
Cable size mm2
1Rx3Cx300 sq.mm. Ratio By contractor
Voltage grade 12 kV (UE) Burden By contractor
5.2 NGR to Earth GI earth strip Accuracy class By contractor
Size mm2
1Rx3Cx300 sq.mm. 9 Painting/Painting shade Epoxy & shade 632
Voltage grade 12 kV (UE) 10 Degree of protection Min. IP31
MANUFACTURER'S DATA
1 Make 4 Min. creepage distance
2 Resistor element Total mm
Material code Protected mm
Specific resistance ohm cm 5 P.f. withstand voltage kV (rms)
Temp. co-efficient 6 Overall dimensions
Resistance of banks ohms Width mm
No. of resistor banks Depth mm
Series nos. Height mm
Parallel (Min. two) nos. 7 Overall weight of panel kg
3 Separate canopy provided Required 8 Copies of type test certificates
furnished
Note:-
1. Actual value of earth fault current to be limited at 6.6kV level shall be calculated by contractor. Accordingly CT ratio shall be
selected.
2. NGR sizing calculation shall be submitted for review & approval.
3. Time to be considerd as 10 sec.
4.maximum system volatge to be considerd as 6.6kV
5. Resistor material to be considerd as metallic.
6. Temperature co-efficient to be considerd as 3.5% per 100 degree C temp. rise.
7. Nos. of terminal to be considered as three (3) nos.
8. Neutral terminal bushing rated voltage to be considerd as 6.6kV.
9. Earth bushing rated voltage to be considerd as 1.2kV.
10. Enclosure shall be made of 304 stainless mild steel.
Note:
1) Marked particulars may be referred in respective switchboard feeder detail data sheet.
MANUFACTURER'S DATA
A Switchboards
1 Make 9 Recommended clearances
2 Type designation Front mm
3 Degree of protection Rear mm
4 Max. overall weight of C.B. panel Kg Above mm
5 Overall dimensions of C.B. panel 10 Shock loading on foundation
a Width mm 11 Max. size/no. of cables that can be
b Depth mm terminated inside the panel
c Height mm a. without rear extension panel
6 Overall dimensions of dummy / b. with rear extension panel
adaptor panel of each type c. size of rear extension panel
a Width mm 12 Clearance in air
b Depth mm a. Phase to Phase (min.) mm
c Height mm b. Phase to Earth (min.) mm
7 Overall weight and dimensions of 13 Busbar current rating at design
largest shipping section ambient temperature A
a Weight Kg 14 Busbar (separately for each swbd)
b Width mm a. Horizontal main busbar size
c Depth mm (No. of flats x size of each flat)
d Height mm b. Horizontal main busbar size as
8 Overall dimensions of each swbd. tested at CPRI for full short ckt.
including all dummy/adaptor/rear withstand as per specification
extension panels requirement (No. of flats x size
Width of each flat)
Depth c. Vertical dropper size
Height (No. of flats x size of each flat)
Note: Contractor shall note that siemens manke panels has been envisaged. Hence dummy panel is not
required as existing HT-227A is of siemens make.
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
B Circuit Breaker
1 Type VCB 16 Power required for closing W/VA
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
27 Supressor
a Type designation
b Make
28 Derating reqd. for Cap. Switching %
29 Earthing System Integral earthing/
Separate earthing
carriage
30 Copies of following test cerificates
enclosed : Yes (*)
30.1 For each type of offered circuit
breaker panel with breaker
a. Short Circuit tests (Peak and 1 sec.
withstand)
b Heat run test
c Internal arc test
d Impulse and power freq. withstand
30.2 For each type of offered circuit
breaker (in panel)
a. Short Circuit test duties
* Switchboard offered shall be of proven design and shll havbe been successfully type tested. Type test
certificates for an exactly identical design of offered switchboard shall be furnished by bidders. These
test reports shall not be more than 5 years old, as on the final bid opening date. In case these type tests
have not been conducted during the last 5 years, bidder shall conduct these type tests on the offered
design of switchboard before despatch without any cost and delievery impact.
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
Note:
1) Marked particulars may be referred in respective switchboard feeder detail data sheet.
MANUFACTURER'S DATA
A Switchboards
1 Make 9 Recommended clearances
2 Type designation Front mm
3 Degree of protection Rear mm
4 Max. overall weight of C.B. panel Kg Above mm
5 Overall dimensions of C.B. panel 10 Shock loading on foundation
a Width mm 11 Max. size/no. of cables that can be
b Depth mm terminated inside the panel
c Height mm a. without rear extension panel
6 Overall dimensions of dummy / b. with rear extension panel
adaptor panel of each type c. size of rear extension panel
a Width mm 12 Clearance in air
b Depth mm a. Phase to Phase (min.) mm
c Height mm b. Phase to Earth (min.) mm
7 Overall weight and dimensions of 13 Busbar current rating at design
largest shipping section ambient temperature A
a Weight Kg 14 Busbar (separately for each swbd)
b Width mm a. Horizontal main busbar size
c Depth mm (No. of flats x size of each flat)
d Height mm b. Horizontal main busbar size as
8 Overall dimensions of each swbd. tested at CPRI for full short ckt.
including all dummy/adaptor/rear withstand as per specification
extension panels requirement (No. of flats x size
Width of each flat)
Depth c. Vertical dropper size
Height (No. of flats x size of each flat)
Note: Vendor shall furnish the dimensins of various types/ratings of swbds., CB panels
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
B Circuit Breaker
1 Type VCB 16 Power required for closing W/VA
2nd shunt trip coil for VFD feeders Yes
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
27 Supressor
a Type designation
b Make
28 Derating reqd. for Cap. Switching %
29 Earthing System Integral earthing/
Separate earthing
carriage
30 Copies of following test cerificates
enclosed : Yes *
30.1 For each type of offered circuit
breaker panel with breaker
a. Short Circuit tests (Peak and 1 sec.
withstand)
b Heat run test
c Internal arc test
d Impulse and power freq. withstand
30.2 For each type of offered circuit
breaker (in panel)
a. Short Circuit test duties
* Switchboard offered shall be of proven design and shll havbe been successfully type tested. Type test
certificates for an exactly identical design of offered switchboard shall be furnished by bidders. These
test reports shall not be more than 5 years old, as on the final bid opening date. In case these type tests
have not been conducted during the last 5 years, bidder shall conduct these type tests on the offered
design of switchboard before despatch without any cost and delievery impact.
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
Format No: EIL 1650-3054 Rev.2 Copyrights EIL - All rights reserved
Format No: EIL 1650-3054 Rev.1 Copyrights EIL - All rights reserved
PURCHASER'S DATA
A PROJECT DATA TICK FOR SELECTION
1 Project details 2 SITE CONDITIONS
a Project : 2nd Raw water intake project a Ambient tempeature
b Client : NALCO b Min 10 °C Max 47 °C Design 47 °C
c Location : Damanjodi c Relative Humidity : 85%
d Unit : New intake Well s/s d Altitude : Less than 1000M
e Atmospheric condtion : Highly corrosive
f Installation : Indoor inside pnl
B RELAY SELECTION TICK FOR SELECTION
1 RELAY FUNCTIONS 4 INPUT POWER SUPPLY
a Only Protection a Site selectable feature
b Protection and metering b Input supply : 110V DC/ 240V AC
c Protection and metering and control :
d Ethernet based commuication :
e Password protection
a. For write
b. For both read and write
2 CONSTRUCTION FEATURE 5 CT/ PT INPUT TO RELAY
a Enclosure type : IP5X a Current operated relays
b Terminal size- sqmm : 2.5 for control a1 Main CT input :
for external wires : 4 for CT/ PT a2 CT for sensitive EF :
c Mounting : Flush or back up EF
d Drawout feature : As per 6-51-0055 b Voltage operated relays
e Display type : AlphaNumeric LCD b1 PT input : 3phase, 4wire
+ LED Indication
3 SPECIAL REQUIREMENT IF ANY c Comprehensive relay
a Applicable standards: IEC c1 Main CT input : 3 CTs, 4wire
b Distance for cable capacitance up to 1200 m c2 PT input : 3phase, 4wire
for application where field contacts are c3 CT for sensitive EF : 1 CT, 2 wire input
directly wired to relay e.g. Motor start/ stop or back up EF (Yes for IC& TR FDR)
c4 CBCT input for motor
d CT Secondary current : Refer swbd data sht
MANUFACTURER'S DATA
1 NUMERICAL RELAYS TYPES
Feeder type INCOMER BUS PT BUS TIE MOTOR TRANSFORMER
Main relay
*Indicate equivalent
NEMA no. of element
offered inMainRelay
* lockout feature 86
* trip ckt sup 95
Relay selection
RS485
RS422
Port
FO
RTD -PT100
BTD- PT100
Analog input
WTI input
OTI input
* DI used by MFR
Nos of DI
* DI avaialble for
customer interlock
* DI for auto C/O logic
* Main relay
* Special relays
Protocol
SITE CONDITIONS
AMB TEMP MIN MAX DESIGN ATMOSPHERIC CONDTION
5 °C 45 °C 40 °C
10 °C 50 °C 45 °C
15 °C 47.6 °C 50 °C
47.6 °C
PROTECTION FUNCTIONS
FREQUENCY RELAY SELECTION DIGITAL INPUTS FOR INTERLOCKS/ SCHEMATICS
UNDER FREQUENCY 2
df/dt 4
5
6
SELECT
Highly corrosive
SELECT
indoor inside pnl
Indoor- in airconditioned room
Indoor- in pressurised room
Indoor
SELECT
110V DC
220V DC
110V AC
240V AC
110V DC/ 240V AC
DOUT
Drawout
Fixed
as per 6-51-0055
SELECT SELECT
2 NOS 2 NOS
4 NOS 4NOS
6 NOS 6 NOS
8 NOS 8 NOS
10 NOS 10 NOS
Not REQD Hand reset
Self reset
2A, 220V DC
5A, 240V AC
PORTS
RS 232
RS422
RS485
FO
Dual RS485
Dual FO
FO Rx/ Tx
IEC870-5-103
Vendor to decide
B Technical particulars
1 System voltage 3 Conductor material
Nominal Highest Voltage grade HV Power cable Aluminium
415 V 500 V 650/1100V MV Power cable Aluminium
3.3kV(E) 3.6 kV 1.9/3.3kV MV control cable Copper
3.3kV(UE) 3.6 kV 3.3/3.3kV
6.6kV(E) 7.2 kV 3.8/6.6kV 4 Installation under DGMS jurisdiction No
6.6kV(UE) 7.2 kV 6.6/6.6kV (See note-3)
11kV(E) 12 kV 6.35/11kV 5 Applicable spec. 6-51-0051 Rev 7
11kV(UE) 12 kV 11/11kV
22kV(E) 24 kV 12.7/22kV
33kV(E) 36 kV 19/33kV
2 Frequency 50 Hz ± 3%
MANUFACTURER'S DATA
1 Name of manufacturer 9 Inner sheath
2 MR/PR item no. Type of compound
3 Cable type/ code Thickness mm
4 Conductor material 10 Nominal dia under armour mm
5 Conductor semiconducting screen (HV cables) 11 Calculated dia under armour mm
Material 12 Armour
Thickness mm Material
6 Insulation Type
Type of compound Size
Thickness mm 13 Nominal dia under outersheath mm
7 Insulation semiconducting screen (HV cables) 14 Calculated dia under outersheath mm
Material 15 Outersheath
Thickness mm Type of compound
8 Copper tape Thickness mm
Thickness mm 16 Nominal outer dia of cable mm
17 Tolerance on outer dia %
18 Weight of cable per km kg
19 Maximum drum length mtr.
Notes
1 Single line to ground fault current (applicable for HV cables) for sizing of insulation screening shall be as under :
2 E- Earthed system
UE-Un Earthed system
3 Where the installation falls under the jurisdiction of Directorate General of Mines Safety, cables shall comply
Format No: EIL 1650-3002 Rev.2 Copyrights EIL - All rights reserved
PURCHASER'S DATA
Project 2nd Raw water intake project Location Damanjodi
Client NALCO Unit New Intake Well s/s
A Site conditions
1 Maximum ambient temperature: 47 °C 4 Relative humidity: 85 %
2 Min. amb temp for battery sizing 10 °C 5 Altitude above MSL: < 1000 m
3 Design ambient temperature: 47 °C 6 Environment: Humid & corrosive
B Technical particulars
1 Battery
a Type VRLA d Boost charging time 10 hours
b Plate construction Plante positive
c Discharge duty requirements e Electrolyte liquid in containers Required
Nominal Duty cycle No. of cells End cell voltage
Item no. DC First 1 Next 28 Next 90 Last 1 Lead Lead
VRLA Ni-cd VRLA Ni-Cd
voltage min. min. min. min. acid acid
1.85 V 1.85 V 1.16 V
By contractor
Format No: EIL 1650-3005 Rev.3 Copyrights EIL - All rights reserved
4 ECS Interface
a Indication-Charger failure Not required c Indication-Battery discharged Not required
b Indication-Inverter failure Not required d Indication-Battery isolated Not required
Notes
1 NO (Normally Open) potential free contacts shall be wired upto terminal strip for connection to ECS interface by
owner, for the following conditions.
2 End cell voltage shall confirm to the values specified.
3 * Asterisk marked items are not applicable for Ni-Cd and VRLA batteries.
4 Cable details shall be furnished during post order document review.
MANUFACTURER'S DATA
A Battery B Battery charger
1 Item no. 1 Item no.
2 Tag. No. 2 Tag. No.
3 Manufacturer's name 3 Manufacturer's name
4 Type & Catalogue no. of cell 4 Rating
5 Ampere hour capacity Charger rating
6 No. of cells Output voltage
7 Nominal cell voltage Output current
8 Cell voltage at the end of full 5 Nominal voltage
discharge at 10 hrs/ 5 hrs rate Float charging
9 Specific gravity of electrolyte at the Quck charging
end of full charging at °C 6 Float chrging voltage range
10 Specific gravity of electrolyte at the 7 Quick charging voltage range
end of full discharge at 10 hrs/ 8 Min. efficiency of charger
5 hrs rate at °C at light load (40%)
11 Quantity of electrolyte per cell at rated load
12 Weight of cell with electrolyte 9 Power factor at rated voltage
13 Quick charging current & load
Max. safe quick charging rate 10 Max. RMS ripple voltage at
Permissible ripple content rated load
14 Suggested quick charging rate with battery connected
15 Quick charging voltage without battery
Max. quick charging voltage/cell 11 Method of volatege control
Quick charging voltage/cell for Float charging mode
constant voltage finish charging QuIck charging mode
16 Float charging voltage/cell 12 Method of current control
17 Float charging current Float charging mode
Float charging current range QuIck charging mode
Permissible ripple content 13 Safety factor for component
18 AH efficiency at 10 hrs/5 hrs rate selection
19 Short ckt current of battery bank 14 Charger dimensions
20 Short circuit withstand time Width
21 Max. allowable termp.of electrolyte Depth
the cells can withstand without Height
injurious effects 15 Max. heat loss in watts
Continuously 16 Degree of protection
Short period
Format No: EIL 1650-3005 Rev.3 Copyrights EIL - All rights reserved
Format No: EIL 1650-3005 Rev.3 Copyrights EIL - All rights reserved
Format No: EIL 1650-3005 Rev.3 Copyrights EIL - All rights reserved
Note:
1) Marked particulars may be referred in respective switchboard feeder detail data sheet.
MANUFACTURER'S DATA
A Switchboards
1 Make 9 Recommended clearances
2 Type designation Front mm
3 Degree of protection Rear mm
4 Max. overall weight of C.B. panel Kg Above mm
5 Overall dimensions of C.B. panel 10 Shock loading on foundation
a Width mm 11 Max. size/no. of cables that can be
b Depth mm terminated inside the panel
c Height mm a. without rear extension panel
6 Overall dimensions of dummy / b. with rear extension panel
adaptor panel of each type c. size of rear extension panel
a Width mm 12 Clearance in air
b Depth mm a. Phase to Phase (min.) mm
c Height mm b. Phase to Earth (min.) mm
7 Overall weight and dimensions of 13 Busbar current rating at design
largest shipping section ambient temperature A
a Weight Kg 14 Busbar (separately for each swbd)
b Width mm a. Horizontal main busbar size
c Depth mm (No. of flats x size of each flat)
d Height mm b. Horizontal main busbar size as
8 Overall dimensions of each swbd. tested at CPRI for full short ckt.
including all dummy/adaptor/rear withstand as per specification
extension panels requirement (No. of flats x size
Width of each flat)
Depth c. Vertical dropper size
Height (No. of flats x size of each flat)
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
B Circuit Breaker
1 Type VCB 16 Power required for closing W/VA
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
27 Supressor
a Type designation
b Make
28 Derating reqd. for Cap. Switching %
29 Earthing System Integral earthing/
Separate earthing
carriage
30 Copies of following test cerificates
enclosed : Yes *
30.1 For each type of offered circuit
breaker panel with breaker
a. Short Circuit tests (Peak and 1 sec.
withstand)
b Heat run test
c Internal arc test
d Impulse and power freq. withstand
30.2 For each type of offered circuit
breaker (in panel)
a. Short Circuit test duties
* Switchboard offered shall be of proven design and shll havbe been successfully type tested. Type test
certificates for an exactly identical design of offered switchboard shall be furnished by bidders. These
test reports shall not be more than 5 years old, as on the final bid opening date. In case these type tests
have not been conducted during the last 5 years, bidder shall conduct these type tests on the offered
design of switchboard before despatch without any cost and delievery impact.
Format No: EIL 1650-3001A Rev.2 Copyrights EIL - All rights reserved
Type of relays
Electromechanical
Static
Numerical
Format No: EIL 1650-3001 Rev.2 Copyrights EIL - All rights reserved
Extension Panel No : HT-227A/ LHS Voltage rating : 11kV Auto-transfer: Not applicable
Location : GTS s/s Execution : Single front, Drawout New Switchboard/Extension to existing Swbd.
S Feeder Nameplate Inscription Bus Section Breaker Rating / CT Primary current rating Max Cable Size Reference Remarks
No Feeder (A) ** (mm²) Data Sheet
Panel Feeder Description Rating Scheme Left Right Designation Metering & # (6970-302-
No No (kW/A) No side side Protection 16-50-DS-
9007)
Incomer from
1 upstream isolation 800A 1 800A VCB feeder 800/5 2Rx3Cx300 Sht.1
XMFR (ISOL#3)
Outgoing plant feeder
2 for new water intake 800A 1 800A VCB feeder 800/5 2Rx3Cx300 Sht.3
S/S
3. Line PT - 1 - - - Sht.1
Note: ** CT primary current ratings indicated are tentative and shall be finalized during drawing approval stage. There shall not be implication due to the
same.
# All cables mentioned shall be XLPE insulated, AL cond cable. However, cable sizes mentioned are tentative and the final cable size shall be provided to
the vendor during detailed engineering stage.
REV DATE PURPOSE BY CHKD APPD DATA SHEET Rev
ENGINEERS INDIA LIMITED B 18.04.17 Issued with Bid Package CS MKS MKS SWITCHBOARD B001-302-16-50-DS-
(FEEDER DETAILS ) B
NEW DELHI A 20.12.16 Issued with Bid Package JM MKS MKS 9013
Sheet 1 of 5
Location : New Intake Well s/s Execution : Single front, Drawout New Switchboard/Extension to existing Swbd.
S Feeder Nameplate Inscription Bus Section Breaker CT Primary current rating Max Cable Size Reference Remarks
No Rating / (A) ** (mm²) Data Sheet
Feeder # (6970-302-
Designation 16-50-DS-
Panel Feeder Description Rating Scheme Left Right Metering & 9007)
No No (kW) No side side Protection
1. Incomer 1 630A VCB 600/5 2Rx3Cx300 Sht.1
11/6.9KV
2. 2.5MVA 1 630A VCB 200/5 1Rx3Cx300 Sht.4
Transformer feeder
11/6.9KV
3. 2.5MVA 1 630A VCB 200/5 1Rx3Cx300 Sht.4
Transformer feeder
2.5MVA,
4. Spare 2 630A VCB 200/5 1Rx3Cx300 Sht.4
0.63MVA
5. Line PT - 1 - - Sht.1
6. Bus PT - 1 - - Sht.5
11/0.433KV
7 0.63MVA 1 630A VCB 200/5 2Rx3Cx50
Transformer feeder
11/0.433KV
8 0.63MVA 1 630A VCB 200/5 2Rx3Cx50
Transformer feeder
Note: ** CT primary current ratings indicated are tentative and shall be finalised during drawing approval stage. No price implication on account of change of
CT ration in later date.
# All cables mentioned shall be XLPE insulated, AL cond cable. However, cable size mentioned are tentative and the final cable size shall be provided to
the vendor during detailed engineering stage.
Location : New Intake Well s/s Execution : Single front, Drawout New Switchboard/Extension to existing Swbd.
S Feeder Nameplate Inscription Bus Section Breaker Rating / CT Primary current rating Max Cable Size Reference Remarks
No Feeder (A) ** (mm²) Data Sheet
Designation # (6970-302-
16-50-DS-
9007)
6. Bus PT # 1 - - 1 - - - Sht.10
7. Bus PT # 2 - - 1 - - - Sht.10
Location : New Intake Well s/s Execution : Single front, Drawout New Switchboard/Extension to existing Swbd.
S Feeder Nameplate Inscription Bus Section Breaker Rating / CT Primary current rating Max Cable Size Reference Remarks
No Feeder (A) ** (mm²) Data Sheet
Designation # (6970-302-
16-50-DS-
9007)
Note: ** CT primary current ratings indicated are tentative and shall be finalised during drawing approval stage. No price implication due to change in CT ratio at later date.
Location : New Intake Well s/s Execution : Single front, Drawout New Switchboard/Extension to existing Swbd.
S Feeder Nameplate Inscription Bus Section Breaker CT Primary current rating Max Cable Size Reference Remarks
No Rating / (A) ** (mm²) Data Sheet
Feeder # (1202-00-
Designation XB-DS-
0012)
Note: ** CT primary current ratings indicated are tentative and shall be finalized during drawing approval stage. No price implication due to change in CT ratio
at later date.
# All cables mentioned shall be XLPE insulated, AL cond cable. However, cable sizes mentioned are tentative and the final cable size shall be provided to
the vendor during detailed engineering stage.
Note:-
8 metre height lattice type pole shall be
considered.(See the pole drawings)
Datasheet No.
DATA SHEET
B001-302-16-50-DS-9015
HIGH VOLTAGE SQUIRREL CAGE
Rev.No. A
INDUCTION MOTOR
Page 1 of 1
PURCHASER's DATA
A. Site conditions
1 Ambient temperature, minimum: 47 °C 3 Atmospheric condition: Humid & highly corrosive
maximum: 10 °C 4 Altitude: < 1000 m
design: 47 °C 5 Location: Outdoor
2 Relative humidity: 85 % 6
B. Technical particulars
1 Motor tag no.: By contractor 17 Hazardous area classification: Safe Area
2 Driven equipment name: Intake well pump 18 Gas group:
3 Voltage: 6.6. kV ±10% 19 Type of explosion protection:
4 Phase: Three 20 Type of ingress protection: IP 55
5 Frequency: 50 Hz ±3% 21 Reacceleration:
6 Fault level: 20 kA 22 Diff. protection CTs:
7 Fault duration: 1 sec. CT specs.:
8 System earthing: Resistance 24 Color shade: 632 as per IS 5
9 Duty: Continuous 25 Thermisters:
10 Method of starting: D.O.L. 26 RTD:
11 Cable size: 3Cx50 mm² 27 BTD:
12 Cable type: Al. cond. XLPE insulated 28 RTD/BTD monitoring device:
13 Temperature rise: 73 °C
14 Cooling: IC611
15 Insulation class: F 29 Applicable specification: EIL spec. 6-51-0031
16 Temperature rise limit B
DRIVEN EQUIPMENT MANUFACTURER's DATA
1 Suggested motor rating: kW 9 Coupling type:
2 Manufacturer: 10 Torque required, starting: mkg
3 Type of driver mounting: 11 maximum: mkg
4 Driven equipment: 12 GD2 of eqpt., including flywheel: kgm2
5 Shaft kW: kW excluding flywheel: kgm2
6 kW at maximum load: kW 13 Maximum thrust: kg
7 Speed: RPM 14 Pulsation rate:
8 Rotation of eqpt. from coupling end: 15 Starting condition:
MOTOR MANUFACTURER's DATA
1 Rating: kW
2 Manufacturer: 19 Space heater - voltage & power:
3 Frame designation: 20 Moment of inertia, GD2: kgm2
4 No. of poles: 21 DE/NDE bearing type & no.:
5 Full load speed: RPM 22 Type of lubrication:
6 Mounting: 23 Type of main terminal box:
7 Full load torque (FLT): mkg 24 Type of neutral terminal box:
8 Starting torque: % of FLT 25 No. of Terminals
9 Break down or pull out torque: % of FLT 26 Weight of motor: kg
10 Full load current (FLC): A 27 Thermisters, quantity: no.
11 Starting current at 100% voltage: % of FLC make: type:
12 Rotation viewed from coupling end: 28 RTD, quantity: no.
13 Starting time at 80%/100% voltage: sec. make: type:
14 Locked rotor withstand time (cold/hot) at, 29 BTD, quantity: no.
80% voltage: sec. make: type:
100% voltage: sec. 30 Shaft voltage: V
15 Time (Te) for Increased Safety Motor sec. 31 Critical speed, 1st/2nd stage: RPM
at 100% Voltage 32 Pressurization panel:
16 Efficiency at 75%/100% Load: % make: type:
17 Power factor at 75%/100% load: 33 Canopy:
18 Heating/Cooling Time Const. (min.) min 34 Fan rotation Design Universal/Fixed/Can be changed
1. Recommended list of maintenance spares for two years operation shall include the follwing as minimum:
a) Bearing DE/NDE one set b) Terminal box cover with screws c) Fan d) Terminal block
2. Starting time calculations shall be based on operating conditions specified in Material Requisition eg. open valve condition/closed
Voltage Voltage Duty Fault level Starting method Earthing No.of terminals
3.3 kV ±6% Continuous 20 kA D.O.L. Direct 3
6.6. kV ±10% 25 kA V.S.D. Resistance 4
11 kV 40 kA Star-delta 6
N.A. Auto transformer
DATASHEET
LIGHTING FIXTURE SCHEDULE
Rev. Prepared
Date Purpose Checked by Approved by
No by
Notes:
1.0 General
The fixtures shall be suitable for use in Alumina refinery. Certain fixtures in Alumina
plant shall be suitable for use in atmosphere, which has corrosive gases like sodium
hydoxide and acid vapours in different degree of saturation in the plant.
Since the corrosion of Aluminium metal is very rapid in the presence of Sodium
Hydroxide, it is of utmost importance not to use aluminium components and if not
absolutely possible the to provide special protection to all aluminium components used
in lighting fixtures such as starters, lamp caps of fluorescent and incandescent lamps.
3.1 All lighting fixtures shall be supplied with lamps, chokes, starters, capacitors (wherever
required) with complete inside wiring and hardwares. Fixtures with sodium vapour
lamps shall be supplied with suitable external electronic ignitors.
3.3 Clear/Opal Acrylic sheet covers wherever used shall be of very high quality. Thickness
for plain sheet shall be 2.5mm and that of moulded version be 3.0mm Cast Acrylic
sheet shall not be used.
3.4 Lamp holders for lamps other than fluorescent shall be screw type and shall be of
internationally acceptable standards and so constructed as to cause no ill effect to the
electrical contact due to vibration impact etc.
3.5 All terminals shall be clamping type suitable for terminating 1.5 mm 2 PVC insulated
copper wire of 2.5mm2 PVC insulated copper armoured cable. The terminals shall be
such that they do not produce arc or spark under normal condition of operation.
3.6 Control gearboxes for all high bay (HB type), flood ligh fixtures (FD type) and bulk head
fixtures (BK type) shall be non integral. Each control gear box shall be complete with
three nos. of 3/4'” ET threaded cable entries and shall also be provided with double
compression nickel plated brass cable glands.
3.7 All lighting fixtures suitable for discharge lamps shall be provided with one ¾” ET
threaded entry and supplied with double compression nickel plated brass cable glands.
3.8 All lighting fixtures suitable for incandescent lamps shall be provided with two ¾” ET
threaded entries and supplied with double compression nickel plated brass cable
glands.
3.9 The top of all well glass lighting fixtures shall be identically drilled/threaded to facilitate
the installation on pole/column or ceiling.
3.11 The temperature rise of the parts of the fixtures shall be limited to the maximum
allowable temperature as per Indian standards.
3.12 Fixtures shall be provided with antivibration/padding at suspension. fixing point. These
paddings shall be made of corrosion resistant high density synthetic rubber (Applicable
for high bay fixtures and totally enclosed anticorrosive type fixtures).
3.13 The stove enamel/epoxy/vitreous enamel colour shade shall be light grey as per IS 5
4.0 Fluorescent fixtures for indoor area (IND1X, IND2X, IND3X, IND4X)
4.1 The channel body of fluorescent fixtures shall be made of heavy gauge sheet steel
(22SWG) and it shall be provided with epoxy paint (on both inside and outside).
4.2 The choke boxes and other auxiliaries of the fluorescent lamps shall be housed on the
channel itself.
4.3 The pin holders of the fluorescent lamps shall be of die cast porcelain with synthetic
rubber gasket to cover the lamp caps so as to prevent ingress of dust in the holders.
4.4 The reflectors of the fluorescent fixtures shall be of high quality vitreous enameled
sheet steel of heavy guage (20SWG), white inside and grey outside.
5.0 Weather proof Well glass Fixtures for corrosive atmospheres (BK4X/BK3X)
Construction of weatherproof well glass fixture shall comprise of cast iron body with
high finish epoxy paint with vitreous enamel reflector made of heavy gauge steel (20
SWG). The fixture shall be provided with aminimum 3 mm dia. duly painted with anti
corrosive paint steel wire cage meshing.
Glass used shall be slear and suitable for use under the conditions involving
exceptional risk of mechanical strength. Perfect gasketing shall be done with neoprene
ti ensure weather proofness.
10.0 Accessories
10.1 Ballast for all discharge lamps shall be of copper wound and filled with polyester.
Ballasts for HPMV/HPSV lamps shall have atleast two voltage tappings capable of
connection to 20/240V single-phase 50Hz supply.
Format No. 8-00-0001-F3 Rev. 0 Copyright EIL – All rights reserved
10.2 The capacitors of appropriate value shall be used for fluorescent HPMV and HPSV
lamps and shall be of high power factor type (0.9). These shall be provided with
discharge resistors for electrical safety.
A. Site Conditions
1. Ambient temp. : 47 OC
2. Design ambient temp. : 47 OC
3. Humidity : 100 %
4. Atmosphere : Dusty, tropical & corrosive
5. Altitude above MSL : Less than 1000 m
6. Location : Damanjodi, Odisha
B. System conditions
The equipment and materials to be supplied by the contractor shall be designed for the following power
supply conditions
C. General requirements
Format No. EIL 1650-2065 Rev.0 Copyright EIL – All rights reserved
NOTE:
1. For make of equipments/components refer vendor list attached with the MR.
2. Contractor to note that scope of work also includes providing one no. dedicated earth electrode for
each of the high mast lighting system as per enclosed EIL standard no. 7-51-0102 Rev. 4.
3. Synchronous timer with contactor shall be provided in marshalling box of High Mast Lighting System.
4. Contractor to note that in some of the areas hard rocks may be encountered. Contractor shall
accordingly take this into account for carrying out all related civil/structural works.
5. Provision shall be made to enable owner to feed emergency power to the aviation lighting fixtures in
the future. For this purpose the mast shall be complete with cable with min. 2 cores dedicated to the
emergency lighting.
6. One set of recommended tools, tackles and special equipment required for the maintenance of the high
mast lighting system shall be supplied with the equipment.
7. FD-8 type fixture description: Flood light fixture of cast iron housing and spun aluminum reflector
heat resistant glass cover and adjusting facility suitable for 1x400W HPSV lamp. (IP-55 enclosure).
8. Reference model nos. of FD-8 type fixture : Philips MNF-14/400, Crompton FBD-14 & Bajaj BJEF
215.
Format No. EIL 1650-2065 Rev.0 Copyright EIL – All rights reserved
3.0 WINCH
a) Make of winch :
b) Number of drums per winch :
c) Gear ratio/materials :
d) Capacity :
e) Operating speed :
f) Time to raise/lower :
g) Method of operation :
h) Type of Lubrication arrangement :
i) Type of lubricants :
j) Tested load per drum (kg.) :
k) Factor of safety :
l) Positive locking
g) Factor of safety :
9.0 Proven track record for the offered mast : Furnished / Not Furnished
Format No. EIL 1650-2065 Rev.0 Copyright EIL – All rights reserved
OWNER : NALCO
TECHNICAL COMPLIANCE
DISCIPLINE : ELECTRICAL
NALCO
OWNER : NALCO
Notes: -
1. The Bidder shall indicate his reply in the space provided in the
Technical Questionnaire. In case space provided is not adequate,
the reply may be furnished separately under suitably numbered
annexure / attachments duly referred against the comment /
query.
2. The Compliance Statements / Queries are required to be
categorically confirmed / answered by the bidder and the
completely filled in Tech questionnaire shall be submitted together
with the Bid.
Bidder must furnish answers/clarifications/ confirmations of all the following queries and submit
along with offer.
Confirm compliance.
Confirm compliance.
Bidder must furnish answers/clarifications/ confirmations of all the following queries and submit
along with offer.
Confirm Compliance.
Confirm compliance.
Bidder must furnish answers/clarifications/ confirmations of all the following queries and submit
along with offer.
Page 1 of 16
SCOPE OF WORK
(CP SYSTEM)
PIPELINE
Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 2 of 16
INDEX OF CONTENTS
1.0 INTRODUCTION
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 3 of 16
ABBREVIATION
AC : Alternating Current
A/G : Above Ground
ACDB : Alternating Current Distribution Board
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 4 of 16
1.0 INTRODUCTION
M/s National Aluminium Company Ltd. (NALCO) proposes to lay 17 km* (approx.) long
raw water pipeline from proposed new 2nd water intake at Kerandi river to existing
storage reservoir at treatment plant, as an additional water of approx. 580 m3/hr or
3MGD is required to meet the water supply demands for various purposes of the refinery
& its township at Damanjodi in the state of Odisha. This required quantity is proposed to
be tapped from Kerandi River by constructing second Intake System (Intake Well) there
at.
* The pipeline length shall be decided upon route survey to be executed by Pipeline
Laying Contractor. Approximate margin of ±10% of asserted length of 17km shall be
considered as part of this present tender. Any deviation of pipeline length beyond the
prescribed limit shall be executed on a pro-rata basis.
1.1 Cathodic protection system shall be provided for the above mentioned pipeline.
1.2 This document covers details of work tendered, Scope of Work, and Scope of Supply
pertaining to Cathodic Protection System for the pipeline. All works and clauses of this
document shall be applicable to all spreads, unless specifically mentioned otherwise.
1.3 This document shall be read in conjunction with Schedule of Rates, List of Attachments,
Specifications, Standards, Drawings and other Documents/ Drawings forming part of
Tender Document.
i. The CP System contractor shall be Owner/ Consultant approved contractor who shall
carryout the complete Temporary and Permanent Cathodic Protection strictly as per the
scope of work defined in this document and Quality Assurance Plans/ Procedure as per
ANNEXURE –II of this document while the pipeline laying works are going on.
The CP System contractor shall carryout the design, engineering, procurement, supply,
installation, testing, commissioning and survey of TCP and PCP system for pipeline.
The CP System contractor shall also include the services of Owner/ Consultant
approved agency for carrying out interference survey and implementing mitigation
measures against DC, AC interference on pipeline due to proximity of foreign DC
source, AC source/ HV line, etc. Contractor shall follow the standard “BS EN
15280:2013 - Evaluation of A.C. corrosion likelihood of buried pipelines applicable to
cathodically protected pipelines”.
ii. The make of the equipment / materials shall be strictly as per the EIL approved vendor
list.
The works related to TCP/ PCP such as connection of cables to the pipeline,
installation of sacrificial anodes, laying of polarization coupons, reference cells,
CTSU etc. and laying of HDPE sheets between the pipeline under the scope of
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 5 of 16
work and other foreign pipelines at the crossing locations for providing electrical
isolation for minimizing the pickup and discharge of the CP System current
between the pipelines shall be completed before backfilling of the trench.
The CP contractor shall carryout the CIPL survey, CAT with ‘A’ frame & DCVG
survey and identify the chainage locations of coating defects / holidays. The
physically verification of the coating defects and repairing of the same shall be
done by the pipeline contractor at no extra cost to the Company.
CP contractor shall submit the TCP design document immediately after award of
contract and shift the required material as per reviewed/ approved design
document as per project schedule.
The work shall be performed in conformity with the scope and specifications for CP
System mentioned in this tender document. In case of any conflict, the following
shall be the priority:-
a) Scope of work
b) Design basis
c) Data sheets
d) Job specification/ codes/ standards
Protection current densities for both TCP & PCP for pipeline shall be considered as
follows:
The above current density values for temporary CP system are applicable for
CP system design life up to two years.
2.1.1 a) Corrosion survey, Design, detailed engineering, Supply, installation, testing and
commissioning of the temporary cathodic protection system using galvanic anodes to
protect the external surface of the pipelines mentioned in item (1) above against
corrosion for minimum 24 months or till commissioning of permanent CP system
whichever is later.
c) Where soil resistivity is 150 ohm-m or more, achievement of -850mV potential level shall
not be mandatory. However, minimum acceptable shift of potential level over and above
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 6 of 16
natural potential at such locations (where soil resistivity is 150 ohm-m or more) shall be
decided by Consultant/ Owner on the case to case basis. For the soil resistivity profile
for the Trunk line & Spur line attached elsewhere in the tender, at locations where soil
resistivity is more than 100 ohm-m, those locations shall be treated as high soil resistivity
areas.
(d) Laying of HDPE sheets between the OWNER’s pipeline and the other foreign pipelines
at the crossing locations for providing electrical isolation for minimizing the pickup and
discharge of the CP System current between the pipelines.
(e) Measurement of soil resistivity along the ROU at TCP anode bed locations, collection of
cathodic protection related data along ROU as per specifications.
(f) AC & DC interference detection using data logger and mitigation of the same due to
proximity of foreign AC & DC source, CP protected foreign pipelines, etc.
(h) Providing test stations along the pipeline route as per the specifications.
(i) Maintaining and safe keeping of test stations and monthly monitoring of the temporary
cathodic protection system including monitoring of AC and DC voltages till
commissioning of the permanent cathodic protection system.
(j) All work shall be carried out conforming to the Scope of work, Design Basis, Data
Sheets, specifications, standards, drawings, etc., as per the list of attachments for the
CP System documents provided elsewhere in the tender document and provisions of
GCC, SCC.
i) At saline soil Ag/ AgCl reference electrode shall be used and not Zinc electrode.
ii) Zinc ribbon anodes to be installed for protection of carrier pipe inside the casing
pipe along with Bentonite filling at the annular space between casing and carrier.
Discrete Mg anode (quantity as required to achieve -850mV potential level), shall
be connected to casing pipe at the cased crossings in case casing and carrier
pipe is shorted (i.e become in mechanical contact with each other) and the short
is not cleared after filling of Bentonite.
iii) Wherever discrete Magnesium anode shall be considered for the temporary
cathodic protection, average separation distance between each consecutive
anode location along the pipeline route shall be 1Km.
iv) Sacrificial Zinc Ribbon anode of approx size 15mm X 22mm laid in backfill of
Gypsum, Bentonite & Sodium sulphate minimum 100mm on all the sides of
anodes, shall be provided for grounding at HV line crossings/ parallel run at the
high soil resistivity areas, where as for grounding at HV line crossings/ parallel run
at the low resistivity areas discrete 20 Kg Sacrifical Zinc anode with backfill of
Gypsum, Bentonite & Sodium sulphate shall be considered.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 7 of 16
Number of anodes and length of each type of anode shall be decided as per soil
resistivity values to limit the grounding resistance to 5 ohms max. at each
installation.
v) Test station shall be installed at one side of the road crossing where casing pipe is
not considered for the crossing. In case more than one such road crossing occurs
within 1Km, then only one such road crossing shall be provided with test station.
vii) All TCP cables shall be HMWPE insulated and HMWPE sheathed in place of PVC.
viii) Cable from AJB to TR unit shall be laid in HDPE duct only and for acquisition of
ROU for cable route shall be made as per M/S NALCO sale deed agreement.
b) The scope shall include complete permanent cathodic protection system, including
cathodic protection related data collection along the ROU, carrying out the soil
resistivity measurement for anode ground beds.
c) Design of anode ground beds considering size / rating of anode bed not less than
the minimum requirements specified.
d) Providing new CP stations for the pipeline at locations as indicated in data sheet for
impressed current CP system No. B001-000-16-50-CDS-02, and bonding provision
with the existing foreign pipeline,
e) Detection using data logger and mitigation of DC, AC interference due to proximity
of foreign DC source, HV transmission lines, cables, AC ground current, etc. Both
AC & DC interference survey including mitigation to be done for proposed new
pipeline and existing old pipeline along the ROU (if any)
f) Close interval potential logging survey for entire lines and additional survey of CAT
with ‘A’ frame survey at selected locations decided from the abnormally and under
protected areas noticed during close interval potential logging survey, DCVG survey
shall be conducted to identify coating defects/ holiday at the probable defective
areas indicated by CAT survey.
The interference surveys and mitigation shall be carried out for both the pipelines i.e.
proposed and existing. Other CP related surveys for existing pipeline is not
applicable. For proposed new pipeline all CP related survey to be carried out.
h) Preparation of commissioning report and as built drawings etc. All work shall be
carried out conforming to the Scope of work, Design Basis, Data Sheets,
specifications, standards, drawings, etc., as per the list of attachments for the CP
System documents provided elsewhere in the tender document and provisions of
GCC, SCC. Also the entire work shall be executed through approved Contractors
only.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 8 of 16
i) The scope shall include acquisition of land in the name of M/S NALCO by CP
System contractor for anode ground bed & anode junction box, acquisition for right to
use of land in the name of M/S NALCO for 45 years for laying of cables from anode
ground bed to CP station and transfer the title of the same to M/S NALCO by the CP
System contractor. The relocation of others / foreign anode bed causing interference
to M/S NALCO Pipeline (if required) with the approval of foreign pipeline Owner shall
be done by CP System contractor
Disconnection of all the sacrificial anodes before PCP commissioning. After PCP
commissioning TCP may be reconnected, if required at some locations in the
event of detection of localized areas of inadequate protection (hot spot).This will
be only as a temporary measure, till the permanent measures are implemented
by the Contractor to increase the CP potential level at hot spot areas.
Supply, laying , termination of all the cables of CP System, including all incoming
and outgoing cables from CPTR units, permanent reference cables,
measurement cables, computerized test stations cables, etc as require.
k) Provisions for direct/ resistance bonding between the pipelines in the common ROU,
where applicable, shall be provided in the test stations along the pipeline route at an
average interval 1Km and at additional locations wherever required for interference
mitigation.
At all possible locations, the test stations for new pipeline need to be installed
matching with the test station of existing pipeline, for bonding purpose.
l) CPTR units to be installed shall be provided with facilities for sending and receiving
digital and analogue input/ output signals for remote SCADA/ RTU monitoring/
controlling system. Supply, installation and termination of copper conductor PVC
insulated screened cable for sending analogue signals and copper conductor YFY
cable for sending digital signals between CPTR & SCADA system I/O rack shall be
in the contractor’s scope.
m) The CP System contractor shall include the services of Owner/ Consultant approved
agency for carrying out interference survey and implementing mitigation measures
against DC, AC interference on pipeline due to proximity of foreign DC source, AC
source/ HV line, etc.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 9 of 16
Proposed
CP Rating of CPPSM/
location of CP Proposed location of CP
station CPTR unit
station Chainage station
No. V/A DC
(km)
Near proposed Intake
1 0.00
0
Facilities 50V/50A
Storage Reservoir
2 15.00
,NALCO 50V/50A
o) Where soil resistivity is lower at higher depth, deep well type anode ground beds
shall be provided. The soil resistivity values taken both by soil box method and using
Wenner's 4-pin method at 2M interval up to the proposed deep well depth shall be
furnished for deep well type anode ground beds. For each deep well anode bed
minimum 10 Nos. MMO tubular anode (each of 25mm dia. X 1000mm long) shall be
provided. Minimum depth of deep well anode bed shall be 50M & diameter of deep
well shall be 250/ 150mm. Adequate length of top portion of the anode bed shall be
made inactive to achieve remoteness of ground bed to pipeline. In case design
calculations based on soil resistivity at the anode bed or the life of anode bed or
ground bed current output works out to be of higher depth or higher No. of anodes
than the minimum requirement specified, the higher requirements shall be provided.
The unarmored anode tail cables shall be laid in PE conduits.
p) Where soil resistivity is lower at shallow depth, there horizontal type anode ground
bed shall be preferred. Irrespective of the life of anode bed or anode bed resistance
worked out by the design calculations, each anode bed shall contain minimum 10
Nos. MMO tubular anode (each of 25mm dia. X 1000mm long). In case the design
calculations based on soil resistivity at the anode bed or the life of anode bed or
anode bed current rating works out to be of higher no. of anodes than the minimum
requirement specified, the higher requirements shall be provided. Continuous coke
breeze backfill shall be provided for the entire length of anode bed trench of cross-
section 300mm x 300mm. Chain link fencing shall be provided around the ground
bed for all types of anode bed. For deep well anode bed minimum cross section 5mx
5m x 2m chain link fencing to be provided.
q) Three plots shall be identified for each anode bed and investigated individually and
best one of these shall be selected based on the observations/ data. Ground water
depth data shall be collected from Geographic survey of India to ensure that the
anode bed location is appropriate and is in perennially moist environment. The
anode ground bed loop resistance shall be restricted to 1 ohm (max) as specified in
spec.6-45-0028. However, in case of very high soil resistivity at anode ground bed
location, the upper acceptance limit of anode bed resistance may be increased at the
sole discretion of Consultant/ Owner. Any combination of the following alternative
measures may be adopted to limit anode bed loop resistance within 1 ohm limit.
r) The anode tail cable up to AJB shall be Halar/ KYNER type with HMWPE sheathed
and PVDF 1100 volt grade insulated, 7 strands, 10mm2 copper conductor, single
core, unarmored type. This shall be in place of 1x 10 sq.mm PVC insulated and
sheathed cable mentioned in spec.6-45-0029. The unarmored anode tail cables shall
be laid in PE conduits.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 10 of 16
Anode ground bed length may be increased for horizontal type ground beds
and depth of the deep well may be increased in case of deep well type
ground bed.
t) In case anode ground bed for foreign pipeline is existing within 100M of the
proposed pipeline ROU and cause interference to proposed pipeline, the ground bed
shall be relocated by the contractor with the consent of the OWNER of the foreign
pipeline.
u) Each CPTR units shall have GPS synchronized current interrupter with 0-99.9
second programmable timer and antenna for synchronized current interruption.
x) Minimum distance between the anode ground bed and the pipeline shall be
considered as 100m. In case design calculations based on soil resistivity of the
anode bed and anode bed current indicates that remoteness of the anode bed shall
be achieved at a distance more than 100M, the same shall be provided within
maximum limit up to 500M. Where land availability for horizontal ground bed with
clear distance of min 100M from pipeline is restricted, deep well type ground bed
with suitable active and inactive lengths may be provided.
y) Supply and installation of the AC / DC power supply cable from the outgoing
terminals of the feeder in the MCC / ACDB/ DCDB of the Electrical substation/
Electrical room/ control room to CPTR at each CP stations shall be included in CP
System contractor’s scope.
z) Computerized test station unit (CTSU) shall have the following feature:
aa) At saline soil Ag/ AgCl reference electrode should be used and not Zinc electrode.
bb) All CP System cables for PCP except anode lead cables & SCADA signal cables
shall be HMWPE insulated and HMWPE sheathed.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 11 of 16
cc) The reference cell and measurement cables between test station and reference
cell, pipeline shall be PVC insulated, aluminium backed by mylar/ polyster tape
shielded, PVC sheathed, armored.
dd) The layout of switchgear/ control room indicating CPTR units/ CPPSMs and
layout of cables inside the switchgear/ control room and inside the SV station/
terminal station areas shall be furnished as part of detailed engineering
document.
ff) For local monitoring of PSP at the CPTR units, Permanent Ref. cell &
measurement cables HMWPE insulated,, aluminium backed by mylar/ polyster
tape shielded, HMWPE sheathed, armoured need to be supplied and installed
from CJB to CPTR units.
hh) CP System contractor shall provide current measurement provision along with
PSP measurement at all SV station (where CP station is not available). Also
required Converter for PSP and current output for SCADA connectivity along
with cable to be provided by contractor.
The scope of design and engineering shall include preparation and submission for
review of CP system design & detailed engineering package, specification for
procurement of CP System equipment/ materials, equipment drawing/ document,
preparation of site engineering drawings and details for installation work wherever
applicable or required by the Owner/ Consultant, and submit to the Owner/ Consultant
for approval.
3. SCOPE OF SUPPLY
All the equipment and materials required for both the temporary and permanent CP
system shall be in the CP System contractor’s scope of supply. All equipment and
materials including cables as required for both Temporary & Permanent cathodic
protection of the pipeline shall be in line with the specifications (specification no. 6-45-
0026, 6-45-0027, 6-45-0029, standard specification, design basis and data sheets.) of
the tender.
Nil
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 12 of 16
6. LIST OF ATTACHMENTS
For List of attachment, refer technical section: Attachments/ CP System in this tender
document.
Sl.
Data Sheet No. Rev. Title
No.
B001-000-16-50-CDS-01 Data sheet Sacrificial anode cathodic
1. A
protection system for pipelines
B001-000-16-50-CDS-02 Data sheet Impressed current cathodic
2. A
protection system for pipelines
B001-000-16-50-CDS-03 A Data sheet cathodic protection transformer
3.
rectifier unit (CPTRU)
B001-000-16-50-CDS-04 A Data Sheet for Cathodic Protection Power
4.
Supply Module
B001-000-16-50-CDS-05 A Data sheet computerized Test Station unit
5.
(CTSU)
Sl.
Standard Spec. no. Rev. Title
No.
6-45-0025 Specification for cathodic protection
1.
0 transformer rectifier unit.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 13 of 16
NOTES:
1. CP System contractor shall note that the exact cable routing shall be decided at site
based on actual site conditions. Exact cable sizes/ quantities shall be based on electrical
load and actual measured route lengths at site which shall be finalized by CP System
contractor in coordination with Engineer-in-Charge/ OWNER. CP System contractor
shall ensure that there is no shortage of cables at site and procure cables accordingly
and avoid cable straight through joints.
2. CP System contractor shall furnish total bill of materials for both TCP and PCP system
during detail engineering stage for our review and record.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 14 of 16
ANNEXURE-I
Alphabetic & numeric PVC ferrules and following colour cable sleeve need to be
considered at termination for identification of different cables terminated inside Test
Station, AJB, CJB, TR/ CPPSM unit:
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 15 of 16
ANNEXURE-II
1.1 The CP System contractor shall establish document and maintain an effective Quality
Assurance system as outlined in recognized codes etc. and Quality Assurance Plans
included in Specifications etc. to ensure that the work is performed in a planned,
systematic manner to the best quality standards and properly documented to provide
confidence that materials supplied and/ or work executed and services performed by him
conform to the applicable specifications and all the requirements of contract document
and work executed by him shall perform satisfactorily over the entire period of its life.
The Quality Assurance Systems Plans/ Procedures of the CP System contractor shall
generally cover the following aspects/ details, which shall be furnished by CP System
contractor along with, his detail-engineering package.
iv) Quality Control of processes such as Pin brazing, anode to cable jointing etc.
1.2 Quality Assurance System Plans/ Procedures of the CP System contractor shall be
furnished in the form of a QA manual. CP System contractor shall be required to provide
explanation pertaining to the details furnished by him in accordance with provisions
contained in this clause and any further details, as sought for by OWNER/
CONSULTANT. In addition, all the Quality Assurance Programs/ Plans as per
specifications enclosed with the Contract shall be fully complied with by the contractor.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Page 16 of 16
ANNEXURE-III
For evaluation of the electrical strength of the coating, after one month of commissioning
of the CP system, Coating Conductance Surveys shall be conducted, to serve as
reference for future comparison. Although the same coating specifications are used
throughout the length of the pipeline, effective electrical strength thereby its ability to
resist flow of current would reasonably vary on account of terrain, construction defects,
soil resistivity along the pipeline length.
For conducting Coating Conductance Surveys, potential (∆V) & current (∆I) shall be
measured at two consecutive current measurement type test stations w.r.t remote earth,
both with current interrupter ‘on ‘ & ‘off” at each measurement point.
The difference of the two (∆I) will be the CP current being collected by this section of the
pipeline. The difference of two (∆V) will be the average change in pipeline potential within
the test section owing the current received from CP system.
The above procedure shall be repeated for all current measurement type test stations for
evaluating coating conductance value for different sections along the pipeline. All the
data obtained shall be handed over to the CONSULTANT/ OWNER & will form part of
technical documentation for commissioning report.
ANNEXURE-IV
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
PIPELINE
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
CONTENTS
SLNO. DESCRIPTION
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
1.1 Temporary cathodic protection (TCP) : Within 60 days of lowering of each continuous
segment of pipe, it should be protected at
minimum -850mV potential level by Mg anode as
part of TCP. Where soil resistivity is 150 ohm-m or
more, achievement of -850mV potential level shall
not be mandatory. However, minimum acceptable
shift of potential level over and above natural
potential at such locations (where soil resistivity is
150 ohm-m or more) shall be decided by EIL/
OWNER on the case to case basis. For the soil
resistivity profile for the Trunk line & Spur line
attached elsewhere in the tender, at locations
where soil resistivity is more than 100 ohm-m,
those locations shall be treated as high soil
resistivity areas.
The above current density values for temporary CP system are applicable for CP
system design life up to two years.
Where operating temperatures of U/G pipeline is above 30 deg. C, such as CP Stations located
near Compressor stations, protection Current Density shall be increased in minimum by 25% for
every 10 °C rise in temperature over 30 °C up to a temperature of 60 deg.C.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
b) At both sides of metalled road crossings where cased crossing is considered for
the crossing. At one side of the road crossing where casing pipe is not considered
for the crossing. In case more than one such uncased road crossing occurs within
1Km, then only one such uncased road crossing shall be provided with test station
within 1Km.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
The test station locations mentioned above shall override the same mentioned vide
cathodic protection system standard 6-45-0027.
F. Type of Anodes for anode ground : Tubular Mixed Metal Oxide (MMO) Titanium
bed
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
K. Chain link fencing around the ground: Shall be provided as per anode ground bed size.
bed
ii) For each IP,SV,DT/RT stations, insulating joint (IJ) shall be provided by EPC contractor
for isolating the incoming Trunk line / Spurline, outgoing Trunk line / Spurline, including
Compressor stations, existing consumer tapping (whichever is applicable) from the
station piping, earthing grids/ pits etc.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
iii) For protection of the carrier pipe inside casing pipe, any one of the following two
alternative options shall be considered by the pipeline CP system contractor. The
selection of any of the alternative options shall be as per sole discretion of EIL/
OWNER:
Zinc ribbon anodes to be installed for protection of carrier pipe inside the casing pipe
along with Bentonite filling at the annular space between casing and carrier. Discrete
Mg anode (quantity as required to achieve -850mV potential level), shall be connected
to casing pipe at the cased crossings in case casing and carrier pipe is shorted (i.e
become in mechanical contact with each other) and the short is not cleared after filling
of Bentonite.
Petroleum jelly (as per ANNEXURE-I or equivalent) filling at the annular space between
casing and carrier without installation of zinc ribbon & discrete Mg anode.
v) The pipeline shall be grounded through polarization cell with Zinc galvanic anode,
wherever the pipeline is either crossing or running in parallel with overhead EHV/ HV
transmission lines of voltage grade 33 KV and above.
vi) Further additional requirements (if any) shall be included during detailed
engineering stage, if required.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Notes:
1 For any control signal the signal shall be available from SCADA for
less than 2 seconds only.
2 The rating of the potential free contact for digital input and output
signals from Equipment/ PLC/ RTU shall be 24 V DC, 1.5 A DC.
Analogue signals shall be 4-20 mA, galvanically isolated.
3 Provision for minimum two nos analogue and two nos of digital input
signal to SCADA System shall be available for future use.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
ANNEXURE-I
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Specifications:
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
DATASHEET FOR
SACRIFICIAL ANODE CATHODIC PROTECTION
SYSTEM FOR PIPELINES
(CP SYSTEM)
PIPELINE
Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. EIL 1641-1924 Rev. 1 B001-000-16-50-CDS-01 RA Copyright EIL – All rights reserved
DATA SHEET
1. Type of coating for the pipelines : 3 Layer Polyethylene/ Coal tar enamel with 3 coat,
2 wrap / Fibre bonded epoxy /
2. Type of CP system : Permanent / Temporary using sacrificial anodes
3. Design life of protection :
- Temporary CP system : 2 years or till commissioning of PCP, whichever
is later
4. Design protection current density : As per cathodic protection system standards
6-45-0027 & 6-45-0028.
5. Corrosion survey data : Enclosed / Corrosion survey shall be conducted by
contractor
6. Type of sacrificial anode : Zinc / Magnesium low potential type (-1.55V) /
magnesium high potential type (1.75V)
7. Electrical Resistance Probes : Shall be provided for marshy areas and water
logged areas / Not required.
7.1 Quantity of E/R Probes : Please refer to Design Basis for CP system No.
B001-000-16-50-CDB-01(see note No. vi. below)
7.2 No. of E/R probe reading : Please refer to Design Basis for CP system No.
instrument B001-000-16-50-CDB-01
8. Polarisation coupons : Shall be provided
8.1 Size of exposed area of coupon : Please refer to Design Basis for CP system No.
B001-000-16-50-CDB-01 (also see note No. vi.
below)
8.2 No. of coupons : -Do-
8.3 No. of magnets for operation : -Do-
9.0 Close interval ‘ON’/‘OFF’ potential : Shall not be carried out / not be carried
Survey out during TCP
At DC interference prone areas and high induced voltage areas at EHV/HV transmission
lines (33KV & above) crossing/running in parallel / foreign pipeline either crossing
readings shall be taken using data logger for 24 hours at 1 minute interval or as required.
10.0 Additional tests to be conducted : Pearson survey / CAT with ‘A’ frame or
for identifying pipe coating DCVG survey / Not required
defects /holidays during TCP
11.0 Indicative Design data for sacrificial anodes ground bed (see note ‘v’ below)
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
- Net weight : _ _ _ Kg _ _ _ Kg
- Size :
- Bare : _ _ x _ _ x _ _ mm. __ x __ x __ mm.
min. Min.
- Prepacked : _ _ x _ _ x _ _ mm. __ x __ x __ mm.
min. Min.
11.3 Type of anode installation : Horizontal / Vertical
11.5 Clear distance between edge of : 5000 mm min for magnesium anodes / 2000
Pipeline and prepacked anode mm min. for zinc anodes
Notes:
i. Where sacrificial anode system is specified as temporary cathodic protection system,
unless otherwise specified, monitoring of the sacrificial anode cathodic protection
system till the commissioning of permanent CP system shall be carried out by TCP
contractor.
ii. In cases where sacrificial anode CP system is specified as temporary and where both
temporary, permanent cathodic protection works are being executed by the same
agency, activities of permanent CP system which are common to temporary CP system
shall be completed as part of temporary CP system. In cases where temporary and
permanent cathodic protection works are being executed by different agencies, the
contractual scope of work shall be referred for further details.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
iii. All civil works associated with the complete cathodic protection system are included in
the scope of Contractor. This shall include providing cable trenches and foundations for
all equipment, all test stations, etc.
iv. The design data for anode ground beds and anodes shall be decided by TCP contractor
depending on the protection current requirement of the pipeline as laid.
v. Contractor shall fill up all the data asked for in the ‘Data sheet sacrificial anode cathodic
protection system for pipelines, part-II (to be filled in by the contractor)’ and submit the
same for EIL’s review.
vi. Location of E/R probes and Polarization coupons shall be decided by CP sub contractor
as per specification requirement and in consultation with Owner/EIL during detailed
engineering)
vii. Contractor shall supply necessary instruments, tools and tackles necessary for proper
operation and maintenance of complete cathodic protection system and associated
equipment.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
DATA SHEET
SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES
PART-II
(TO BE FILLED IN BY THE VENDOR)
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
5.1 Type :
5.2 Ratings :
-50 Hz AC :
-Impulse (1.2/50 micro second) :
5.3 Make :
6.0 Cables
6.1 Type :
6.3 Make :
9.0 Makes
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
2 Supply of CP
DATA SHEET FOR
equipment/mat
erial
PROTECTION SYSTEM FOR
SACRIFICIAL ANODE CATHODIC
3 Installation of
CP system
4 Testing and
commissioning
Rev A
Page 7 of 8
DOCUMENT No.
SL. CAUSE OF LENG- DIAM- TYPE NO. OF CP NAME OF WORK DATE DATE OF DETAILS OF BACK-UP AGENCY, IF
NO. INTERFERENCE TH OF ETER OF STATIONS PROJECT ORDER OF COMPL- HIRED FOR CP INTERFERENCE/
PIPE OF PIPELI- FOR THE AND NO. (**) COMM- ETION MITIGATON
NE OWNER OF
LINE PIPE PIPELINE ENCEM-
COATI- WORK NAME OF EXPERIENCE OF
LINE NG ENT OF BACK UP
(**) AGENCY
WORK AGENCY(***)
1 Cathodically protected
foreign pipelines
crossing/ parallel
running
2 Cathodically
PIPELINES
unprotected foreign
DATA SHEET FOR
pipelines/ structures
crossing/ parallel
PROTECTION SYSTEM FOR
running
SACRIFICIAL ANODE CATHODIC
5
Page 8 of 8
DOCUMENT No.
*** LIST OF INTEREFERENCE DETECTION, MITIGATION JOBS DONE ALONG WITH WORK ORDER AND COMPLETION CERTIFICATE SHALL BE ATTACHED
DATA SHEET FOR DOCUMENT No.
IMPRESSED CURRENT CATHODIC B001-000-16-50-CDS-02
PROTECTION SYSTEM Rev A
Page 1 of 8
DATASHEET FOR
IMPRESSED CURRENT CATHODIC PROTECTION
SYSTEM FOR PIPELINES
(CP SYSTEM)
Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. EIL 1641-1924 Rev. 1 B001-000-16-50-CDS-02 RA Copyright EIL – All rights reserved
DATA SHEET
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
pipeline
19. Proposed location of new CP stations/ : As per. B001-000-16-50-CPS-01, R0
NB: The proposed location of CP stations shall be confirmed by CP system contractor during
bidding stage.
Notes:
i) Unless otherwise specified in project specifications/data sheet, integration of the
permanent impressed current CP system with the sacrificial anode temporary CP
system (whether provided by a different contractor or included along with the
impressed current CP system) shall be the responsibility of the impressed current CP
system contractor whose scope shall include disconnection of sacrificial anodes
wherever required.
ii) The permanent CP system includes certain activities, which are common with the
temporary protection facilities. In cases where temporary and permanent cathodic
protection works are being executed by the same agency, the common activities of
temporary and permanent cathodic protection system shall be completed as part of
temporary cathodic protection system. In cases where temporary and permanent
cathodic protection works are being executed by different agencies, the contractual
scope of work shall be referred for further details.
iii) Obtaining approval certificate from electrical inspectorate for electrical installation
and carrying out any modifications as per the requirement of electrical inspectorate
shall be included in CP system contractor scope.
iv) All civil works associated with the complete cathodic protection system are included
in scope of CP system contractor. This shall include providing cable trenches and
foundations for all equipment, kiosks, anode lead junction boxes, all test stations,
deep well ground beds, etc.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
DATA SHEET
IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES
PART-II
(TO BE FILLED IN BY THE VENDOR)
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
operator magnet
5.2 Ratings :
5.3 Make :
6.0 Cables
6.1 Type and voltage grade
-For anode tail cables : ___ /___V
-For other CP cables : ___ /___V
6.2 Make
-For anode tail cables :
-For other CP cables :
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
9.0 Make of
9.1 CPTR unit :
9.2 CPPSM :
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
DATASHEET FOR
CATHODIC PROTECTION TRANSFORMER RECTIFIER
UNIT (CP SYSTEM)
PIPELINE
Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. EIL 1641-1924 Rev. 1 B001-000-16-50-CDS-03 RA Copyright EIL – All rights reserved
DATA SHEET
CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT
PART - I (TO BE FURNISHED BY PURCHASER)
* CP system contractor shall take confirmation from EIL/Owner regarding the exact voltage of power
supply after placement of order.
NOTE:
1. All Pipe to soil potentials (PSP) measured/set values specified are w.r.t. copper-copper
sulphate half cell.
2. CPTR unit shall be provided with a door having transparent glass cover for viewing various
parameters/indications without opening the door. The type of indicating lamps shall be
minimum 10mm dia. LED type.
3. Separate data shall be furnished for each rating of CPTR unit.
4. The incomer power supply cable shall be sized to limit the max voltage drop in the cable to
5% max subject to min size of 3 X 4 sq.mm copper.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
DATASHEET FOR
CATHODIC PROTECTION POWER SUPPLY MODULE
(CP SYSTEM)
PIPELINE
Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. EIL 1641-1924 Rev. 1 B001-000-16-50-CDS-04 RA Copyright EIL – All rights reserved
DATA SHEET
CATHODIC PROTECTION POWER SUPPLY MODULE
PART - I
(TO BE FURNISHED BY PURCHASER)
15 Type of Control
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
NOTE:
1. All Pipe to soil potentials (PSP) measured/set values specified are w.r.t. copper-copper
sulphate half cell.
2. The output voltage, current ratings of CPPSM units and their location along the ROU of
the pipe line shall be as per CP system contractor/vendor data in S.No.1 of Part II of the
data sheet.
3. CPPSM unit shall be provided with a door having transparent glass cover for viewing
various parameters/indications without opening the door. The type of indicating lamps
shall be minimum 10mm dia. LED type.
4. *Separate data shall be furnished for each rating of CPPSM unit.
5. The CPPSM unit will have Built-in Galvanic Isolator to provide complete Electrical
Isolation between Input & Output of the CPPSM unit to enable use of common
Battery Bank for CPPSM and other utilities in the CP station. The CPPSM unit will
also have facility for step-up of voltage output from the CPPSM unit using suitable
DC – DC converter inbuilt in the CPPSM unit, so that it shall be possible to have 0
to 40V DC output from the CPPSM even when operating from a 24 Battery supply.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
2.5 Output ripple at full load current: Auto mode Manual mode
At 10% output voltage * *
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
DATASHEET FOR
COMPUTERIZED TEST STATION UNIT
(CP SYSTEM)
Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. EIL 1641-1924 Rev. 1 B001-000-16-50-CDS-05, RA Copyright EIL – All rights reserved
Analog Inputs : Logger will have 4 Nos. High accuracy, High Input Impedance,
16- bit resolution Analog channels with high common mode
rejection
ratio (CMRR), as under:
CH-1 : -4V to +4V DC (for DC PSP)
CH-2 : 0V to 25 V AC (for AC PSP Interference Monitoring)
CH-3 : 0A to 100A DC (for Pipeline Current Monitoring)
CH-4 : Battery Level ( For Internal Battery Monitoring)
The typical accuracy of each channel should be ± 1.0% of
F.S.±1 digit.
The PSP Input channels should have Input Impedance of 10
Meg Ohm minimum.
Isolation : All the four channels of the Data Logger should be fully Isolated
from each other.
Local Display : The CTSU Data Logger will have a 2 Line 16 x 2 LCD display for
entering local settings and viewing Test Station parameters
locally.
The LCD Display will display the following Parameters
DC Reference Potential (PSP)
AC Reference Potential (AC PSP)
Pipeline Current
Battery Level
Following Local settings should be done using the Laptop:
Setting Date/ Time
Setting Start Time for logging .
Setting Periodic logging Interval
Setting field ID of the Data Logger
Data Storage : The CTSU Data Logger should have built-in Non volatile memory
for local storage of Data. It should be possible to store about
250,000 Data readings for each channel i.e. a Total One Million
readings for all four channels in the Local memory of the Data
Logger. Locally stored data should be retained up to 10 years
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Time Stamping : The Data Logger unit should have a precise and accurate Real
Time Clock (RTC) for exact time stamping of data.
Protection : The Input channels of Data Logger should have full protection
against high voltage surges and continuous over voltages of up
to 500V AC & DC.
Power Supply : The CTSU Data Logger will be a battery operated device and
will
have built-in Internal rechargeable Lithium Battery.
Battery Life : The CTSU Data Logger will be capable of functioning for
inimum
One Year at the logging rate of one log per day on the Internal
Battery, without any need of changing/ re-charging the battery.
Enclosure : The CTSU Data Logger unit should be housed in a compact &
study
non corroding enclosure.
Overall dimensions : 130mm x 130mm x 75mm (Maximum)
Mounting : Wall mounting inside C.P. Test Station
Cable Entry : From Bottom
The above indicated Enclosure Size is including the Internal
Battery.
It should be possible to install the Data Logger inside the
existing Test Station at site.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
PIPELINE
Format No. EIL 1641-1924 Rev. 1 B001-000-16-50-CVN-01 RA PIPELINE Copyright EIL – All rights reserved
a) SUGGESTED LIST OF CONTRACTORS FOR ON-SHORE CATHODIC PROTECTION SYSTEM SURVEY, DESIGN,
ENGINEERING, SUPPLY AND INSTALLATION, TESTING & COMMISSIONING WORKS:
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
b) SUGGESTED LIST OF SPECIALIST AGENCIES FOR DOING THE INTERFERENCE SURVEY AND
IMPLEMENTING MITIGATION MEASURES AGAINST INTERFERENCE FOR CP SYSTEM OF HIGH
INDUCED VOLTAGE IN PIPELINE DUE TO PROXIMITY OF HT LINES NEAR PIPELINE.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
e) CABLES
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
n) PIN BRAZING
SL. NO. VENDOR NAME
1 M/s. SAFETRACK , SWEDEN
2 M/s BAC, UK
o) THERMITWELD
SL. NO. VENDOR NAME
1 M/S. ERICO, USA
2 M/S THERMOWELD, USA
3 M/S. ERICO, EUROPE
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
SPECIFICATION
FOR
CATHODIC PROTECTION POWER
SUPPLY MODULE (CPPSM)
Abbreviations:
CONTENTS
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 SITE CONDITIONS 5
4.0 GENERAL REQUIREMENTS 5
5.0 TECHNICAL REQUIREMENTS 5
6.0 EQUIPMENT DESCRIPTION 7
7.0 TESTS AND ACCEPTANCE 13
8.0 PACKING AND DESPATCH 15
1.0 SCOPE
This specification covers the requirements for the design, manufacture and testing of Cathodic
Protection Power Supply Module (CPPSM) working on controlled switch mode principle
intended to supply power to cathodic protection system for underground pipelines/ structures.
2.1 The system design, performance and materials to be supplied shall conform to the requirements
of the latest revision of following standards:
IS: 1248 Direct acting indicating analogue electrical measuring instruments and
(Parts-1, 2, 8 & 9) accessories
IS: 5469 Code of practice for the use of semiconductor junction devices
(Parts-1 to 4)
IS: 12021 Control transformers for switchgear and control gear for voltages not
(Parts-1 to 4) exceeding 1000 V AC
IS: 13703 Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC
(Parts-1 to 4)
IS/ IEC: 60947 : Specification for low voltage switchgear and control gear
2.2 In case of imported equipment, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory
regulations currently in force in the country.
2.4 In case of any contradiction between various referred standards/ specifications/data sheet and
statutory regulations the following order of priority shall govern:
- Statutory Regulations
- Data Sheets
- Job Specification
- This Specification
- Codes and Standards
The CPPSM shall be suitable for installation in non air-conditioned room with restricted
ventilation or in outdoor kiosk (as specified in data sheet), in locations having generally
corrosive, warm, humid and dusty atmosphere. Service conditions shall be as specified in the data
sheet. If not specifically mentioned therein, a design ambient temperature of 40°C and an altitude
not exceeding 1000 m above mean sea level shall be considered.
4.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
4.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered
equipment for at least for 15 years from the date of supply.
4.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to enable the end user for placement of order for spares and
services.
5.1.1 CPPSM shall be housed in sheet steel enclosure. The front, rear walls and doors shall be made by
using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.6 mm thick
sheet steel. Wherever required, suitable stiffeners shall be provided. The Unit shall be
freestanding type. Hinged doors shall be provided at the front and back as required. The unit shall
be natural cooled type. Louvered openings with wire mesh for natural ventilation may be
provided. Degree of protection for the panel shall be minimum IP-41. The CPPSM panel shall,
preferably, not need rear access for operation, maintenance and shall be suitable for mounting
flushed to the wall.
5.1.2 Suitable hooks shall be provided for lifting the panel. These hooks when removed shall not leave
any hole in the panel or imperfection in the paint finish.
5.1.3 All instruments shall be panel mounted type and back connected. All fuses shall be provided
inside the panel and shall be of link type. 660 V grade PVC insulated BIS approved wires with
stranded copper conductor of size minimum 2.5 mm z shall be used for power and auxiliary
wiring. Control wiring for electronic circuits shall be through flat ribbon cable or through copper
wire of minimum 0.5 mm diameter. All wirings shall be ferruled with PVC ferrules at both ends
for ease of identification. Clamp type terminals suitable for termination up to 10 mm2 conductor
shall be provided for all control cable connection. Suitable power terminals shall be provided for
power cables. Minimum 20% spare terminals shall be provided. The terminal blocks shall be
mounted minimum 300 mm above the gland plate.
5.1.4 A11 live parts shall be properly shrouded. This shall ensure complete safety to personnel intending
routine maintenance by opening the panel doors.
5.1.5 CPPSM shall be suitable for bottom cable entry unless otherwise specified in the data sheet and
shall be supplied complete with crimping type tinned copper lugs and cable glands. Cable glands
shall be of brass, nickel plated, single compression type for indoor installations and double
compression type for outdoor installations. The space in the terminal chamber shall be adequate
for termination of required number and sizes of cables as specified in the data sheet.
5.1.6 The CPPSM shall be field proven. The design, internal component layout and rating of
component shall ensure high MTBF and low MTTR. Prototype equipment shall not be
acceptable. Layout of panel components shall enable easy access to the components for
maintenance.
5.1.7 All the control equipment like switches, push buttons, potentiometers etc. shall be located at a
convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.
5.1.8 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB tracks shall
be tinned and solder masked. The PCB shall be coated with suitable lacquer to make it immune to
dust, moisture and fungal growth. Where plug in type of PCBs are used gold plated male-female
connectors shall be used for the purpose.
5.1.9 If required the panel shall be provided with space heater to prevent moisture condensation. The
space heaters shall be located at the bottom of the panel and shall be provided with a manually
operated switch and HRC fuse. The space heater shall have porcelain-insulated connectors.
Where space heater is not provided the electronic PCBs/components and other control devices
shall be made immune to moisture condensation.
5.1.10 Panel shall be provided with integral base frame channel. The integral base frame of panel shall
be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack
welding to purchaser's insert plate/flat/channel embedded in the floor. Amply dimensioned
oblong holes shall be provided at the bottom of the panel for its bolting to the embedded insert
plate/channel.
5.1.11 An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminium shall be provided
throughout the length of the panel. Provision shall be made for connecting this earth bus at two
ends with the plant earth grid by means of (40x5) mm2 GI flat. All non-current carrying metallic
parts of the panel and mounted equipment shall be connected to the panel earth bus. All doors
and movable parts shall be connected to the earth bus by flexible copper cables.
5.1.12 A11 panel mounted equipments (e.g. lamps, push buttons, switches, meters, PCBs, etc.) shall be
provided with suitable nameplates. Nameplates shall be engraved out of 3-ply (black-white-
black) lamicoid sheets or anodised aluminium. Back-engraved perspex sheet nameplates may
also be acceptable. Engraving shall be done with groove cutters. Hard paper or self-adhesive
plastic tape nameplates shall not be acceptable. Nameplates shall be fastened by screws and not
by adhesive.
Labels shall be provided for every component on the cards, connecting wires as well as for the
terminals in the terminal strip inside the panel.
5.1.13 Where specified in the data sheet the CPPSM shall be housed in an outdoor kiosk. The kiosk
shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and
external surfaces. Hinged lockable doors shall be provided at the front and back. Acrylic
transparent glass window shall be provided on the front door of the kiosk so that the meters,
indications and positions of the control switches on the CPPSM can be seen without opening the
door of the kiosk. The kiosk shall be suitable for outdoor mounting and shall give proper
protection to the CPPSM against rain, other harsh weather conditions. Necessary ventilation
arrangement with louvers and wire mesh shall be provided for proper operation of the CPPSM.
The cable entry to the kiosk shall be from bottom through cable glands. Suitable canopy shall be
provided on the top of the kiosk.
5.1.14 Painting
All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease
and dirt.
Fabricated structures shall be pickled and then rinsed to remove any trate of acid. The under
surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. The undersurface shall be made free from all imperfections before undertaking
the finishing coat.
After preparation of the under surface, the panel shall be spray painted with two coats of final
paint or shall be powder coated. Colour shade of final paint shall be approved by the purchaser
before final painting is started. The finished panels shall be dried in stowing ovens in dust free
atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off
paint, etc.
All unpainted steel parts shall be cadmium plated or suitably treated to prevent corrosion. If these
parts are moving elements, then they shall be greased.
Input controls.
Power converter and filters.
Out put protections
System controls
Current interrupter
Control, indication and metering
6.1.1 A moulded case circuit breaker with thermal over load and short circuit release (rated for the
input power supply short circuit current) shall be provided at the input for power supply control.
6.2.1 The CPPSM shall convert and control the input DC power supply voltage/current into variable
DC output voltage/current through switching power semiconductor devices (Thyristor/power
transistor/power MOSFET, etc.). The variation in the output voltage/current shall be achieved
through control of duty cycle of conduction of the switching power semiconductor devices. The
current and voltage ratings of the power semiconductor devices shall be at least two times the
maximum device current and min. two times the maximum voltage coming across it respectively.
The voltage rating of the power semi-conductor devices shall be co-coordinated with the break
down voltage of lightning arrestor provided at the output so that the power semiconductor
devices are protected from any voltage surge coming from the pipeline. Shunt zeners / MOV
shall be provided across the power semiconductor devices for protection. The power
semiconductor devices shall have humidity/moisture resistant finish and mounted in sufficiently
sized heat sink designed to provide adequate cooling under worst conditions of operation. The
power semiconductor devices shall have adequate protection against high dv/dt and di/dt.
6.2.2 Where specified in the data sheet, the converter shall electrically isolate the input power to
CPPSM from its out put so that the grounding of the positive out put of the CPPSM through
anode ground bed shall not affect the grounding system of the input power supply. Alternatively,
a separate DC to DC converter having electrical isolation between input and out put power supply
shall be provided at the input of the CPPSM.
6.2.3 The power semiconductor devices shall be protected by semiconductor fuses or the system shall
have instantaneous short circuit-current limit feature to protect the devices against output short
circuits. An adjustable output over current limit feature shall be provided.
6.2.4 Filter shall be provided in the input power supply circuit to minimise the AC injected into the DC
input power supply system.
6.2.5 Adequate filtering shall be provided on the DC output of the converter to limit the ripple content
in the output to less than 5% at rated output.
6.2.7 For CPPSMs with multiple output circuits, each output circuit shall have independent output
converter and output filters.
Two pole moulded case circuit breaker or miniature circuit breaker rated for the DC output
current, short circuit current and having thermal over load, short circuit release shall be provided
in the output. A lightning arrestor rated for minimum 10KA impulse current discharge capacity
and rated voltage & max. spark over voltage rating suitable to protect the CPPSM components
against lightning and switching surges shall be provided at the output. For CPPSMs with multiple
output circuits, each output circuit shall have independent protections.
6.4.1 The CPPSM shall have two distinct modes of operation (independent for each output circuit) as
below:
In this mode the output voltage (Vos) of CPPSM shall be continuously adjustable from
0.5V DC to the rated output voltage specified on the data sheet. Current limit feature
shall be provided in this mode of operation. The current limit (Ios) shall be continuously
adjustable from zero to rated output current.
For constant voltage mode of operation the output current limit shall be set at maximum
and output voltage setting shall be varied. Irrespective of output current demand the
chosen value of the output voltage shall be maintained by the control system till the
current limit is reached. After that the output current limit shall be maintained and output
voltage shall decrease to keep the current constant.
For constant current mode of operation the output voltage shall be set at maximum and
output current shall be varied through varying the setting of output current limit.
Irrespective of output voltage requirement the control system shall maintain the output
current to the set current limit value till the voltage limit is reached. After that the output
voltage limit shall be maintained and output current shall decrease to keep the voltage
constant.
In this mode of operation the output of the CPPSM shall operate in an external closed
loop with pipe-to -soil potential (PSP) in feed back loop. The CPPSM control shall adjust
the output voltage such that the PSP as measured by reference cell always remains equal
to the set potential on the unit. The set potential (Vps) shall have high long time stability
and minimum temperature drift. The set potential shall be continuously adjustable over
the range specified in data sheet. An adjustable over current limit shall be provided to
limit the maximum output current.
The unit shall be designed to operate with the number of reference cells connected to it
(to be provided by others) as specified in data sheet. In case of more than one reference
cell being specified, CPPSM shall have feature to automatically select the reference cell
having less negative potential than the others and use the same for auto control of the unit
(e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be provided in
selecting the less negative potential reference cell, to avoid hunting between the reference
cells at change over conditions.
In case of open circuit or short circuit of the reference cell or potential being less
negative than a minimum set potential (Vrs), for the controlling reference cell, the unit
shall sense these conditions as reference cell failure and shall automatically switch over
to the other healthy reference cell for control. Should fault occur in all the reference cells,
the output voltage or current of the CPPSM shall adjust automatically to a preset value
(Vas/Ias), which shall be adjustable.
In both CVCC and auto PSP modes of operation the electronic over current limit shall be
fast enough to protect the active devices of the unit and fast enough to act before tripping
of MCCB/MCB or blowing of fuse.
6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shall be provided in case
of PSP either exceeding the specified maximum limit (Vpm ) or remaining lower than the
specified minimum limit (Vpn).
6.4.3 The output voltage regulation for no load to full load variation with input voltage variation from
maximum to minimum shall not be more than 2.5 % of rated voltage through out the range of
output voltage and over the specified ambient temperature variation as specified in data sheet, in
CVCC- constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation for
no load to full load variation with input voltage variation from maximum to minimum shall be
within 20mV through out the PSP setting range specified.
In CVCC- constant current mode of operation, the current regulation for minimum to maximum
output voltage and minimum to maximum variation in input voltage, shall not be more than 2.5%
through out the range of output current.
6.4.4 The output of the unit shall be ungrounded and shall allow grounding of positive terminal of the
output through the anode ground bed.
6.4.5 For CPPSMs with multiple output circuits, each output circuit shall have independent control
system.
6.5.1 If specified on the data sheet a current interrupter for CPPSM output current interruption shall be
provided.
6.5.2 The current interrupter shall have an output contactor with current rating minimum 125% of the
output current rating of the CPPSM and a digital timer to operate it.
6.5.3 The timer shall have `ON' and `OFF' timings. When the timer is turned on the `ON' timing shall
start and shall close the output contactor till the end of the `ON' timing. At the end of the `ON'
timing the `OFF' timing shall start and keep the contactor open till the end of the `OFF' timing.
At the end of the `OFF' timing the `ON' timing shall start again. This process of `ON' and `OFF'
timing shall continue.
6.5.4 The `ON' and `OFF' timings of the timer shall be settable by separate 2 digit thumbwheel
switches, each settable from 1 to 99 seconds. The timing error of the timer shall be less than 5
parts per million. In case of microprocessor based system keypad with display may be provided
in place of thumbwheel switches.
6.5.5 Whenever the timer is switched on it shall always start with ON `timing'. A timer-reset push
button shall be provided. On pressing this push button during operation of the timer, the timer
shall get reset and upon release of the button the timer shall restart with `ON' timing.
6.5.6 The power required for operation of the timer and contactor shall be derived from the main power
supply to the CPPSM.
6.5.7 The following controls and indications shall be provided for current interrupter. The controls
shall be housed in a lockable cover, so that normally they are not accessible. The indications shall
be mounted on the door.
a) Controls
In case of microprocessor based system keypad with display may be provided in place of
thumbwheel switches.
b) Indications (LED)
6.5.8 The output contact of the current interrupter contactor shall be wired in the positive DC output of
the CPPSM. A link shall be provided for shorting these terminals whenever the current
interrupter is not in use.
6.5.9 If specified in the data sheet the current interrupter shall be an independent unit of portable type.
The interrupter unit shall have terminals for input power supply and terminals of the contactor in
the timer output. The input power supply and the rating of the timer output contactor shall be as
specified on the data sheet.
6.5.10 Where the current interrupter is not specified with CPPSM or is specified as portable type
external to the CPPSM, then the CPPSM shall have provision for connection of input power
supply terminals and out put contacts of external current interrupter for current interruption test.
A link shall be provided for shorting the out put terminals provided in CPPSM for current
interruption, whenever the current interrupter is not connected.
6.5.11 For CPPSMs with multiple output circuits, each output circuit shall have independent current
interrupter.
6.6.2 Following controls shall be provided inside the module at user accessible common location:
6.6.3 CPPSM shall have following indicating lights (lamps or minimum 5 mm dia LEDs):
a) CPPSM ON/OFF
b) Unit in auto/CVCC (2 lamps)
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
c) Reference cell controlling the closed loop control of the CPPSM (number of lamps same
as number of reference cells).
d) Reference cell faulty (number of lamps same as number of reference cells).
e) Pipeline over protected.
f) Pipeline under protected
g) Indications for current interrupter:
It shall be possible to switch-off all the indication lamps by a single switch. In case of LED
indication lights this facility may not be provided.
6.6.4 Following meters having min cl. 1.5 accuracy shall be provided on the CPPSM:
It shall be possible to switch-off all the digital meters preferably by a single switch.
6.6.5 If specified in data sheet, CPPSM shall incorporate provision for remote monitoring of the unit
through SCADA system as below:
The transducers shall have electrical isolation between input and output. The isolation insulation
shall withstand 2 kV, 50 Hz for minimum 1 minute. The accuracy class of the transducer shall be
0.5. The transducers shall be protected against input and output voltage surges. The transducer
shall be suitable for driving up to 600 ohms load impedance located up to 500 m away and wired
with 0.5 mm2 copper conductor cable. The transducers shall be suitable for minimum 125%
continuous over load in the input voltage/current parameter.
6.6.6 For units having multiple outputs, each output circuit shall have independent controls, indication
and metering.
7.1 During fabrication, the equipment shall be subjected to inspection by owner or his authorised
representative to assess the progress of the work as well as to ascertain that only quality raw
materials are used for the same. He shall be given all assistance to carryout the inspection.
7.2 Final acceptance test shall be carried out at manufacturer's works under his care and expense.
Instruments and equipments required for testing shall be arranged by manufacturer. Owner's
representative shall be given minimum 2 weeks prior notice for witnessing the tests. Test
certificates indicating test results shall be furnished by the manufacturer. Acceptance tests shall
include but not be limited to the tests listed below.
The voltage specified in the table below shall be applied for one minute to the circuits indicated:
(Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits respectively).
D.C. test voltages may be applied instead of A.C. The magnitude of D.C. test voltages to be
applied shall be 2 times the above-mentioned A.C. (r.m.$) Values.
Insulation resistance test shall be conducted before and after heat run test.
All CPPSMs shall be subjected to a heat run test performed at rated voltage for period not less
than 16 hours prior to execution of functional tests.
At least one CPPSM of each rating shall be loaded to its rated output through out 16 hour test
period. A11 other CPPSMs shall be energized under partial load or zero load current condition
through out the test period.
Functional tests as below shall be performed on each CPPSM. If during execution of functional
tests, any electronic component of the unit is required to be replaced e.g. due to malfunction or
failure of the unit to fulfill the performance requirements of the specification, then the load test
shall be repeated at rated current following which functional tests shall be carried out.
During the test current limit shall be set to rated output current. Performance testing shall
be carried out for various out put voltage settings and load varying from zero to
maximum. The verification of operation of the control functions, measurement of output
voltage, current, input voltage, current, ripple in the output, input, evaluation of output
voltage regulation and efficiency of the unit shall be carried out during the testing.
During the test voltage limit shall be set to rated output voltage. Performance testing shall
be carried out for various out put current limit settings and load resistance varied to
achieve output voltage from minimum to maximum. The verification of operation of the
control functions, measurement of output voltage, current, input voltage, current, ripple
in the output, input, evaluation of output current regulation of the unit shall be carried out
during the testing.
Suitable set up shall be arranged for out put loading and reference cell feed back. The closed loop
performance and regulation shall be checked with the PSP set voltage varied from 0.85V to 1.2V.
Disconnecting the reference cell feed back connection in the above set up shall simulate the
reference cell failed condition. The output voltage/current of the unit shall go to the value set on
the potentiometer Vas/Ias provided inside the CPPSM. The settings on Vas/Ias shall be varied
and the output voltage/current shall be observed.
7.2.4.3 Operation of sensors for pipeline over protection, under protection, reference cell failure and
reference cell selection logic in auto PSP mode shall be verified by connecting variable external
voltage sources to reference cell inputs of the CPPSM. The number of external voltage sources
shall be same as number of reference cell inputs specified for the CPPSM.
7.2.4.4 The unit shall be checked for operation of the current limit by over loading the unit in both
CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not provided
for protection of the power semiconductor device, the protection of same shall be tested as below:
A switch rated for making and carrying CPPSM output short circuit current shall be connected to
the output terminals of the unit. The output voltage and the output current limit settings of the
unit shall be set to the maximum rated values. The switch connected in the output shall be shorted
quickly.
The unit shall go to current limit mode and shall not damage any active component of the unit.
7.2.4.5 The current interrupter shall be tested for time interval settings and specified operation.
The equipment shall be properly packed for selected mode of transportation i.e. by ship/ rail or
trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent
damage to finish. Crates shall have skid bottom for handling. Special notations such as `Fragile',
`This side up', `Center of gravity', ` Weighe etc., shall be clearly marked on the package together
with Tag nos., P.O. Nos. etc.
The equipment may be stored outdoors for long periods before erection. The packing shall be
completely suitable for outdoor storage in areas with heavy rains/ high ambient temperature.
:1<kIIT "cifUNT
tlii fffg "r~
SPECIFICATION
FOR
CATHODIC PROTECTION
TRANSFORMER RECTIFIER UNIT
Abbreviations:
CONTENTS
1.0 SCOPE 4
1.0 SCOPE
This specification covers the requirements for the design, manufacture and testing of Cathodic
Protection Transformer Rectifier units (CPTR units) working on controlled rectification
principle intended to supply power to cathodic protection system for underground pipelines/
structures.
2.1 The system design, performance and materials to be supplied shall conform to the requirements
of the latest revision of following standards:
IS: 1248 : Direct acting indicating analogue electrical measuring instruments and
(Parts-1, 2, 8 & 9) accessories
IS: 5469 : Code of practice for the use of semiconductor junction devices
(Parts-1 to 4)
IS: 12021 : Control transformers for switchgear and control gear for voltages not
(Parts-1 to 4) exceeding1000 V AC
IS: 13703 : Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC
(Parts-1 to 4)
IS/ IEC: 60947 : Specification for low voltage switchgear and control gear
2.2 In case of imported equipment, standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other
statutory regulations currently in force in the country.
2.4 In case of any contradiction between various referred standards/ specifications/data sheet and
statutory regulations the following order of priority shall govern:
- Statutory Regulations
- Data Sheets
- Job Specification
- This Specification
Codes and Standards
The CPTR unit shall be suitable for installation in non air-conditioned room with restricted
ventilation or in outdoor kiosk (as specified in data sheet), in locations having generally
corrosive, warm, humid and dusty atmosphere. Service conditions shall be as specified in the
data sheet. If not specifically mentioned therein, a design ambient temperature of 40°C and an
altitude not exceeding 1000 m above mean sea Level shall be considered
4.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
4.2 Vendor shall ensure availability of spare parts and maintenance support services for the offered
equipment for at least for 15 years from the date of supply.
4.3 Vendor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/spares to enable the end user for placement of order for spares and
services.
5.1.1 CPTR unit shall be housed in sheet steel enclosure. The front, rear walls and doors shall be
made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.6
mm thick sheet steel. Wherever required, suitable stiffeners shall be provided. The Unit shall be
freestanding type. Hinged doors shall be provided at the front and back as required. The unit
shall be natural cooled type. Louvered openings with wire mesh for natural ventilation may be
provided. Degree of protection for the panel shall be minimum IP-41. The CPTR unit panel
shall, preferably, not need rear access for operation, maintenance and shall be suitable for
mounting flushed to the wall.
5.1.2 Suitable hooks shall be provided for lifting the panel. These hooks when removed shall not
leave any hole in the panel or imperfection in the paint finish.
5.1.3 All instruments shall be panel mounted type and back connected. All fuses shall be provided
inside the panel and shall be of link type. 660 V grade PVC insulated BIS approved wires with
stranded copper conductor of size minimum 2.5 mm 2 shall be used for power and auxiliary
wiring. Control wiring for electronic circuits shall be through flat ribbon cable or through
copper wire of minimum 0.5 mm diameter. All wirings shall be ferruled with PVC ferrules at
both ends for ease of identification. Clamp type terminals suitable for termination up to 10 mm2
conductor shall be provided for all control cable connection. Suitable power terminals shall be
provided for power cables. Minimum 20% spare terminals shall be provided. The terminal
blocks shall be mounted minimum 300 mm above the gland plata.
5.1.4 All live parts shall be properly shrouded. This shall ensure complete safety to personnel
intending routine maintenance by opening the panel doors.
5.1.5 CPTR unit shall be suitable for bottom cable entry unless otherwise specified in the data sheet
and shall be supplied complete with crimping type cable termination lugs and cable glands.
Cable glands shall be of brass, nickel plated, single compression type for indoor installations
and double compression type for outdoor installations. The space in the terminal chamber shall
be adequate for termination of required number and sizes of cables as specified in the data
sheet.
5.1.6 The input power factor of the unit at rated load shall be 0.8 lag or better.
5.1.7 The CPTR unit shall be field proven. The design, internal component layout and rating of
component shall ensure high MTBF and low MTTR. Prototype equipment shall not be
acceptable.
5.1.8 All the control equipment like switches, push buttons, potentiometers etc. shall be located at a
convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.
5.1.9 The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. PCB tracks
shall be tinned and solder masked. The PCB shall be coated with suitable lacquer to make it
immune to dust, moisture and fungal growth. Where plug in type of PCBs are used gold plated
male-female connectors shall be used for the purpose.
5.1.10 If required the panel shall be provided with space heater to prevent moisture condensation. The
space heaters shall be located at the bottom of the panel and shall be provided with a manually
operated switch, HRC fuse and link for phase and neutral respectively. The space heater shall
have porcelain connectors. Where space heater is not provided the electronic PCBs/components
and other control devices shall be made immune to moisture condensation.
5.1.11 Panel shall be provided with integral base frame channel. The integral base frame of panel shall
be suitable for directly bolting with the help of foundation bolts and shall also be suitable for
tack welding to purchaser's insert plate/flat/channel embedded in the floor. Amply
dimensioned oblong holes shall be provided at the bottom of the panel for its bolting to the
embedded insert plate/channel.
5.1.12 An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminium shall be provided
throughout the length of the panel. Provision shall be made for connecting this earth bus at two
ends with the plant earth grid by means of (40x5) mm2 GI flat. All non-current carrying
metallic parts of the panel and mounted equipment shall be connected to the panel earth bus.
All doors and movable parts shall be connected to the earth bus by flexible copper cables.
5.1.13 All panel mounted equipments (e.g. lamps, push buttons, switches, meters, PCBs, etc.) shall be
provided with suitable nameplates. Nameplates shall be engraved out of 3-ply (black-white-
black) lamicoid sheets or anodised aluminium. Back-engraved Perspex sheet nameplates may
also be acceptable. Engraving shall be done with groove cutters. Hard paper or self-adhesive
plastic tape nameplates shall not be acceptable. Nameplates shall be fastened by screws and not
by adhesive.
Labels shall be provided for every component on the cards, connecting wires as well as for the
terminals in the terminal strip inside the panel.
5.1.14 Where specified in the data sheet the CPTR unit shall be housed in an outdoor kiosk. The kiosk
shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and
external surfaces. Hinged lockable doors shall be provided at the front and back. The kiosk
shall be suitable for outdoor mounting and shall give proper protection to the CPTR unit against
rain, other harsh weather conditions. Necessary ventilation arrangement with louvers and wire
mesh shall be provided for proper operation of the CPTR unit. The cable entry to the kiosk
shall be from bottom through cable glands. Suitable canopy shall be provided on the top of the
Kiosk.
5.1.15 Painting
All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease
and dirt.
Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under
surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. The undersurface shall be made free from all imperfections before
undertaking the finishing coat.
After preparation of the under surface, the panel shall be spray painted with two coats of final
paint or shall be powder coated. Colour shade of final paint shall be approved by the purchaser
before final painting is started. The finished panels shall be dried in stowing ovens in dust free
atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off
paint, etc.
All unpainted steel parts shall be suitably treated to prevent corrosion. If these parts are moving
elements, then they shall be greased.
6.1.1 The transformer shall be natural cooled dry type with separate primary and secondary windings.
An intermediate earth screen shall be provided between primary and secondary windings. CPTR
Units having multiple output circuits shall have separate secondary windings for each output
circuit. Transformer shall be vacuum impregnated with epoxy varnish and baked. The safety
factor for transformer rating shall be minimum 125%.
6.1.2 Single-phase transformers may be provided up to 50V, 50A DC output rating of the CPTR
units. Beyond this rating 3 phase transformers shall be provided.
A moulded case circuit breaker with thermal over load and short circuit release shall be
provided at the input of the transformer. Miniature circuit breaker with thermal overload and
short circuit release in place of moulded case circuit breaker inay be provided, where the
miniature circuit breaker rated for the incoming AC supply short circuit current indicated in the
data sheet is available.
6.2.1 The rectifier shall be made of thyristors and diodes as basic components. The CPTR unit shall
be suitable for 415 V AC, 3-ph power supply. Rectifier shall be 3 phase full wave type and
controlled type. For CPTR units rated 50V, 50A DC or less, the unit may be suitable for 240V
AC, 1 ph power supply and the rectifier shall be full wave type and controlled type.
Alternatively, for single phase AC CPTR units, diode rectifier of full wave type in the
secondary of the transformer and triac or back to back connected thyristors in the transformer
primary AC supply circuit may be provided. The current and voltage ratings of thyristors,
diodes shall be at least two times the actual maximum device current and minimum two times
the actual maximum voltage coming across the device respectively. The thyristors/ triac/
rectifier elements shall be protected against voltage surges coming from the incoming power
supply and from out put side from the pipeline. Required shunt zeners / MOV shall be provided
across the rectifier elements for protection.
The rectifier elements shall have humidity/moisture resistant finish and mounted in sufficiently
sized heat sink designed to provide adequate cooling under worst conditions of operation. The
rectifier elements shall have adequate protection against high dv/dt and di/ dt.
6.2.2 The thyristors/triacs shall be protected by semiconductor fuses. For units rated 50V, 50A DC or
less, if the thyristors or triacs are adequately over rated and system has enough inductance so
that in case of sudden output short circuit the over current limit feature comes into action before
short circuit current rises beyond the rating of the thyristors/triacs, then the semiconductor fuses
may not be provided. This feature shall be demonstrated during testing of the unit at works.
6.2.3 Adequate filtering shall be provided on the DC output of the rectifier to limit the ripple content
in the output to less than 5% at rated output.
6.2.5 For CPTR units with multiple output circuits, each output circuit shall have independent
rectifier and filter.
Two pole moulded case circuit breaker or miniature circuit breaker (if available) rated for the
DC output current, short circuit current and having thermal over load, short circuit release shall
be provided in the output. A lightning arrestor rated for minimum 10KA impulse current
discharge capacity and rated voltage & maximum spark over voltage rating suitable to protect
the CPTR unit components against lightning and switching surges shall be provided at the
output. For CPTR units with multiple output circuits, each output circuit shall be provided with
circuit breaker and lightning arrestor.
6.4.1 The CPTR unit shall have two distinct modes of operation (independent for each output circuit)
as below:
In this mode the output voltage of CPTR unit shall be continuously adjustable from 0.5V
DC to the rated output voltage specified on the data sheet. The set output voltage (Vos)
shall remain constant irrespective of output current. Current limit feature shall be
provided. The current limit (Ios) shall be continuously adjustable from zero to rated
output current.
For constant voltage mode of operation the output current limit shall be set at maximum
and output voltage setting shall be varied. Irrespective of output current demand the
chosen value of the output voltage shall be maintained by the control system till the
current limit is reached. After that the output current limit shall be maintained and output
voltage shall decrease to keep the current constant.
For constant current mode of operation the output voltage shall be set at maximum and
output current shall be varied through varying the setting of output current limit.
Irrespective of output voltage requirement the control system shall maintain the output
current to the set current limit value till the voltage limit is reached. After that the output
voltage limit shall be maintained and output current shall decrease to keep the voltage
constant.
In this mode of operation the output of the CPTR unit shall operate in an extemal closed
loop with pipe to soil potential (PSP), measured by reference cell, in feed back loop. The
CPTR unit control shall adjust the output voltage such that the PSP as measured by
reference cell always remains equal to the set potential on the unit. The set potential
(Vps) shall have high long time stability and minimum temperature drift. The set
potential shall be continuously adjustable over the range specified in data sheet.
The unit shall be designed to operate with number of reference cells connected to it (to be
provided by others) as specified in data sheet. In case of more than one reference cell
being specified, CPTR unit shall have feature to automatically select the reference cell
having less negative potential than the others and use the same for auto control of the unit
(e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be provided in
selecting the less negative potential reference cell, to avoid hunting between the reference
cells at change over conditions.
In case of open circuit or short circuit of reference cell or potential being less negative
than a minimum set potential (Vrs), the unit shall sense these conditions as reference cell
failure and shall automatically switch over to the other healthy reference cell for control.
Should fault occur in all the reference cells, the output voltage or current of the CPTR
unit shall adjust automatically to a preset value (Vas/Ias), which shall be adjustable.
In both CVCC and auto PSP modes of operation a fast acting electronic over current limit
protection shall be provided. This protection shall be fast enough to protect the active
devices of the unit and fast enough to act before tripping of MCCB/MCB or blowing of
fuse.
6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shall be provided in
case of PSP either exceeding the specified maximum limit (Vpm) or remaining lower than the
specified minimum limit (Vpn).
Copyright EIL — All rights reserved
Format No. 8-00-0001-F1 Rev. 0
6.4.3 The output voltage regulation for no load to full load variation with input voltage variation from
maximum to minimum shall not be more than 2.5 % of rated voltage through out the range of
output voltage and over the specified ambient temperature variation as specified in data sheet, in
CVCC- constant voltage mode of operation. In auto PSP mode the closed loop PSP regulation
for no load to full load variation with input voltage variation from maximum to minimum and
PSP feedback varying over the specified range shall be within 20 mV.
In CVCC- constant current mode of operation, the current regulation for minimum to maximum
output voltage and minimum to maximum variation in input voltage shall not be more than
2.5% through out the range of output current.
6.4.4 The DC output of the CPTR unit shall be floating (ungrounded) in the Unit. However the
CPTR Unit shall allow grounding of positive output terminal through the anode ground bed.
6.4.5 For CPTR units with multiple output circuits, each output circuit shall have independent control
system.
6.5.1 If specified on the data sheet a current interrupter for CPTR Unit output current interruption
shall be provided.
6.5.2 The current interrupter shall have an output contactor with current rating minimum 125% of the
output current rating of the CPTR unit and a digital timer to operate it.
6.5.3 The timer shall have `ON' and `OFF' timings. When the timer is turned on the `ON' timing
shall start and shall close the output contactor till the end of the `ON' timing. At the end of the
`ON' timing the `OFF' timing shall start and keep the contactor open till the end of the `OFF'
timing. At the end of the `OFF' timing the `ON' timing shall start again and close the output
contactor. This process of `ON' and `OFF' timing shall continue.
6.5.4 The `ON' and `OFF' timings of the timer shall be settable by separate 2 digit thumbwheel
switches, each settable from 1 to 99 seconds. The timing error of the timer shall be less than 5
parts per million. In case of microprocessor based system keypad with display may be provided
in place of thumbwheel switches.
6.5.5 Whenever the timer is switched on it shall always start with ON `timing'. A timer-reset push
button shall be provided. On pressing this push button during operation of the timer, the timer
shall get reset and upon release of the button the timer shall restart with `ON' timing.
6.5.6 The power required for operation of the timer and contactor shall be derived from the main
power supply to the CPTR unit.
6.5.7 The following controls and indications shall be provided for current interrupter. The controls
shall be housed in a lockable cover, so that normally they are not accessible. The indications
shall be mounted on the door.
a) Controls
In case of microprocessor based system keypad with display may be provided in place of
thumbwheel switches.
b) Indications (LED)
6.5.8 The output contact of the current interrupter contactor shall be wired in the positive DC output
of the CPTR unit. A link shall be provided for shorting these terminals whenever the current
interrupter is not in use.
6.5.9 If specified in the data sheet the current interrupter shall be an independent unit of portable type.
The interrupter unit shall have terminals for input power supply and terminals of the output
contactor. The input power supply and the rating of the output contactor shall be as specified on
the data sheet. Terminals shall be provided in the CPTR unit for taking power supply to the
current interrupter.
6.5.10 Where the current interrupter is not specified with CPTR unit or is specified as portable type
external to the CPTR unit, then the CPTR unit shall have provision/ terminals for connection of
input power supply and out put contacts of external current interrupter, for current interruption
test. A link shall be provided for shorting the out put terminals provided in CPTR unit whenever
the current interrupter is not connected.
6.5.11 For CPTR units with multiple output circuits, each output circuit shall have independent current
interrupter.
6.6.2 Following controls shall be provided inside the module at user accessible common location:
6.6.3 TR unit shall have following indicating lights (lamps or minimum 5 mm dia LEDs):
It shall be possible to switch-off all the indication lamps by a single switch. In case of LED
indication lights this facility may not be provided.
6.6.4 Following meters having min c1.1.5 accuracy shall be provided on the CPTR unit:
It shall be possible to switch-off all the digital meters preferably by a single switch.
6.6.5 If specified in data sheet, CPTR unit shall incorporate provision for remote monitoring of the
unit through SCADA system as below:
The transducers shall have electrical isolation between input and output. The isolation insulation
shall withstand 2kV, 50Hz for minimum 1 minute. The accuracy class of the transducer shall be
0.5. The transducers shall be protected against input and output voltage surges. The transducer
shall be suitable for driving up to 600 ohms load impedance located up to 500 m away and
wired with 0.5 mm2 copper conductor cable.
6.6.6 For units having multiple outputs, each output circuit shall have independent controls,
indication and metering.
7.1 During manufacture, the equipment shall be subjected to inspection by owner or his authorised
representative to assess the progress of the work as well as to ascertain that only quality raw
materials are used for the same. He shall be given all assistance to carryout the inspection.
7.2 Final acceptance test shall be carried out at manufacturer's works under his care and expense.
Instruments and equipments required for testing shall be arranged by manufacturer. Owner's
representative shall be given minimum 2 weeks prior notice for witnessing the tests. Test
certificates indicating test results shall be furnished by the manufacturer. Acceptance tests shall
include but not be limited to the tests listed below.
The voltage specified in the table below shall be applied for one minute to the circuits indicated:
(Uni and Un2 are nominal voltage rating of power electronics and auxiliary circuits
respectively).
D.C. test voltages may be applied instead of A.C. The magnitude of D.C. test voltages to be
applied shall be 2 times the above-mentioned A.C. (r.m.$) Values.
Insulation resistance test shall be conducted before and after heat run test.
A11 CPTR units shall be subjected to a heat run test performed at rated voltage for period not
less than 16 hours prior to execution of functional tests.
At least one CPTR unit of each rating shall be loaded to its rated output through out 16 hour test
period. All other CPTR units shall be energized under partial load or zero load current condition
through out the test period.
Functional tests as below shall be performed on each CPTR unit. If during execution of
functional tests, any electronic component of the unit is required to be replaced e.g. due to
malfunction or failure of the unit to fulfil the performance requirements of the specification,
then the load test shall be repeated at rated current following which functional tests shall be
carried out.
During the test current limit shall be set to rated output current. Performance testing shall
be carried out for various out put voltage settings and load varying from zero to
maximum. The verification of operation of the control functions, measurement of output
voltage, current, input AC voltage, current, power factor, ripple in the output, evaluation
of output voltage regulation and efficiency of the unit shall be carried out during the
testing.
During the test voltage limit shall be set to rated output voltage. Performance testing shall
be carried out for various out put current limit settings and load resistance varied to
achieve output voltage from minimum to maximum. The verification of operation of the
control functions, measurement of output voltage, current, input AC voltage, current,
power factor, ripple in the output, evaluation of output current regulation of the unit shall
be carried out during the testing.
Suitable set up shall be arranged for out put loading and reference cell feed back. The closed
loop performance and regulation shall be checked with the PSP set voltage varied from 0.85V to
1.2V.
Disconnecting the reference cell feed back connection in the above set up shall simulate the
reference cell failed condition. The output voltage/current of the unit shall go to the value set on
the potentiometer Vas/Ias provided inside the CPTR UNIT. The settings on Vas/Ias shall be
varied and the output voltage/current shall be observed.
7.2.4.3 Operation of sensors for pipeline over protection, under protection, reference cell failure and
reference cell selection logic in auto PSP mode shall be verified by connecting variable external
voltage sources to reference cell inputs of the CPTR unit. The number of external voltage
sources shall be same as number of reference cell inputs specified for the CPTR unit.
7.2.4.4 The unit shall be checked for operation of the current limit by over loading the unit in both
CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not provided
for protection of the thyristors/triacs, the protection of same shall be tested as below:
A switch rated for making and carrying CPTR unit output short circuit current shall be
connected to the output terminals of the unit. The output voltage and the output current limit
settings of the unit shall be set to the maximum rated values. The switch connected in the output
shall be shorted quickly.
The unit shall go to current limit mode and shall not damage any active component of the unit.
7.2.4.5 The current interrupter shall be tested for time interval settings and specified operation.
The equipment shall be properly packed for selected mode of transportation i.e. by ship/ rail or
trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent
damage to finish. Crates shall have skid bottom for handling. Special notations such as
`Fragile', `This side up', `Center of gravity', `Weight' etc., shall be clearly marked on the
package together with Tag nos., P.O. Nos. etc.
The equipment may be stored outdoors for long periods before erection. The packing shall be
completely suitable for outdoor storage in areas with heavy rains/ high ambient temperature.
SPECIFICATION
FOR
CORROSION SURVEY
tfk Nt".
ISSUED AS STANDARD SPECIFICATION
0 17.07.14 NSB RC PPL g SC
(OLD DOC. NO.: 6-51-0026, REV. 3)
Standards Standards
Rev. Prepared Checked Committee Bureau
Date Purpose by Convenor Chairman
No by
Approved by
Abbreviations:
AC Alternating Current
BIS Bureau of Indian Standards
BS British Standards
CP Cathodic Protection
DC Direct Current
EHV Extra High Voltage
HV High Voltage
HVDC High Voltage Direct current
NACE National Association for Corrosion Engineers
ROU Right of Use
CONTENTS
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 GENERAL 4
4.0 SOIL RESISTIVITY SURVEY 4
5.0 TESTS ON SOIL SAMPLES 5
6.0 ADDITIONAL DATA COLLECTION 5
7.0 REPORT 7
1.0 SCOPE
The specification covers the requirements for corrosion survey including measurement of soil
resistivity, chemical analysis of soil/ water and collection of other cathodic protection related
data along ROU of the pipelines.
Equipment and measurement techniques shall unless otherwise specified, conform to the
requirement of latest revisions of following applicable standards:
BIS specifications
NACE publications
The work shall be carried out in compliance with all applicable local laws and regulations.
In case of any contradiction between various referred standards/ specifications/ data sheet and
statutory regulations the following order of priority shall govern:
Statutory Regulations
Data Sheets
Job Specification
This Specification
Codes and Standards
3.0 GENERAL
This specification defines the basic guidelines for carrying out the corrosion survey. Contractor
shall be responsible for providing necessary data interpretation based on corrosion survey
measurements, which is intended to form a basis for design of cathodic protection system for
the pipeline.
4.1 Unless otherwise specified the soil resistivity measurements shall be carried out at intervals of
approximately 1000 m along the ROU. Where soil resistivity is less than 100 ohm-m and two
successive readings differ by more than 2:1 then additional soil resistivity readings in between
the two locations shall be taken.
4.2 To carryout the soil resistivity measurement, Wenner's 4 pin method or approved equal shall be
used. The depth of resistivity measurement at each location shall be at around 1 m and at the
burial depth of the pipeline accounting for the cuttings/ fillings or 2 m approximately which
ever is higher. At locations where multi layer soil with large variation in resistivity/
corrosiveness is expected and/or locations specifically advised by OWNER or his
representative, resistivity measurements at additional depth of up to 3 m (approx.) or more shall
be taken. In general the resistivity of soil, which shall be surrounding the pipe, shall be
measured. Hence the depth of measurement/ electrode spacing may vary depending on
topography and strata at the area.
4.3 At places where ROU has not yet been cleared, measurements shall be made right over the
centre line of pipeline route surveyed accounting for the cuttings/ fillings also.
4.4 Observations shall be made enclosing the soils adjoining the trench wherever pipeline trenching
has already been done.
4.5 The observations shall be made enclosing the soil immediately surrounding the pipeline route
where ROU has been cleared but trenching has not been done.
4.6 All measurements shall be taken at right angles to the ROU unless otherwise asked by OWNER
or his representative at site.
4.7 At places in ROU where other pipelines are already existing care shall be taken to precisely
locate such pipes line and take such precautions that observations are not adversely affected by
presence of such pipelines.
4.8 Care shall also be taken that the observations are not influenced by presence of other earth
currents in the area especially in the vicinity of EHV/HV lines and plants using earth return in
their source of power etc.
4.9 Wherever possible/ advised by OWNER or his representative, depth of water table shall be
determined by resistivity observations.
4.10 All measurements shall be made and recorded in metric units. While recording the data
reference to the nearest intersecting point shall be made. To provide visual representation of
variations in the resistivity along ROU, values shall be plotted on semi log graph sheets. The
resistivity graph shall also indicate the resistivity at additional depths measured at various
locations and depth of water table.
Soil/ water samples shall be collected along the ROU for analysis. Samples shall be collected on
an average at one location for every 10 km along ROU with minimum at approximate two
equidistant locations. Exact locations shall be decided at site depending on the type of soil, soil
resistivity and in consultation with OWNER or his representative. At each location the soil
samples shall be collected at 1 m, 2 m depth and at scheduled/ designed depth of pipeline if it is
more than 2 m at the location.
The collected soil/ water samples shall be analysed to determine presence and percentage of
corrosive compounds including carbonates, bicarbonates, nitrates, chlorides, oxygen activity,
moisture content and pH value.
The following data shall be collected with a view to generate design data for evaluation of
cathodic protection interaction possibilities due to presence of other services in ROU and its
vicinity:
6.1 Following information regarding foreign service/ pipeline in or around the ROU (for existing
and those, which are likely to come up during contract execution):
6.1.7 Location and type (Deep well / surface) of anode ground bed
6.1.9 Location of existing CP power supply units and their output voltage, current, pipe to soil
potential readings
6.1.13 Possibility of integration/isolation of CP system of the foreign service/ pipeline with that of the
proposed pipeline, which may involve negotiations with owner's of foreign services
6.1.14 Where pipeline is likely to pass close to any existing ground bed (with in 100 m approx), anode-
bed potential gradient survey shall be carried out to verify possible interference with the CP
system of the pipeline covered under this project.
6.2 Voltage rating, phases and sheathing details of cables running parallel or crossing the ROU.
6.3 Existing and proposed DC/AC power sources and systems using earth return path such as
HVDC substations/ earthing stations, fabrication yards with electric welding etc. in the vicinity
of the entire pipeline route.
6.4 Crossing and parallel running of electrified and non-electrified traction (along with information
regarding, operating voltage, AC/DC type etc.) as well as abandoned tracks near ROU having
electrical continuity with the tracks in use.
6.5 Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power lines
along with details of voltage, AC/DC type etc.
6.6 Voltage rating, phases, sheathing details of underground power cables along ROU or in its
vicinity.
6.7 Any other relevant information that may be needed in designing and implementing of proper
cathodic protection scheme for the proposed pipeline.
7.0 REPORT
On completion of all the field and laboratory work an interim report incorporating results
generated from surveys, additional data collected, results of test carried out etc. shall be
submitted for comments/ approval. The report shall also highlight any adverse impact on
performance of sacrificial anodes due to the percentage of corrosive compounds including
carbonates, bicarbonates, nitrates, chlorides present in the soil and pH value of the soil noticed
during the survey. The final report incorporating comments/ missing data shall be furnished for
records. The report along with various drawings, graphs etc. prepared in connection with the
work shall be submitted along with six prints by the contractor.
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SPECIFICATION
FOR
SACRIFICIAL ANODE CATHODIC
PROTECTION SYSTEM
FOR PIPELINES
Abbreviations:-
AC : Alternating Current
ASTM : American Society for Testing and Materials
BS : British Standards
BIS : Bureau of Indian Standards
CP : Cathodic Protection
CMRI : Central Mining Research Institute
CPPSM : Cathodic Protection Power Supply Module
CPTR : Cathodic Protection Transformer Rectifier
CTE : Coal Tar Enamel
DC : Direct Current
EHV : Extra High Voltage
FBE : Fusion bonding Epoxy
HDD : Horizontal Directional Drilling
HV : High Voltage
HVDC : High Voltage Direct Current
IS : Indian Standards
MOV : Motor Operated Valve
j, A/mm2 : Micro-Ampere per square millimeter
NACE : National Association of Corrosion Engineers
PE : Polyethylene
PVC : Polyvinyl Chloride
ROU : Right of Use
SV : Sectionalizing Valve
CONTENTS
1. SCOPE 4
2. APPLICABLE CODES AND STANDARDS 4
3. SYSTEM IMPLEMENTATION 5
4. CORROSION SURVEY 5
5. CATHODIC PROTECTION DESIGN PARAMETERS 6
6. CATHODIC PROTECTION DESIGN CRITERIA 8
7. SYSTEM DETAILS 8
8. INSTALLATION 14
9. FIELD TESTING AND COMMISSIONING 15
10. INTERFERENCE MITIGATION 17
11. SYSTEM MONITORING 17
12. CLOSE INTERVAL POTENTIAL LOGGING SURVEY 18
1. SCOPE
1.1 This specification defines the requirements of design, engineering, installation, testing and
commissioning of sacrificial anodes cathodic protection system for external surface of cross
country onshore underground pipelines/ structures including supplementing of corrosion
survey, investigation for interference/ interaction problems and mitigation of the same.
1.2 This specification defines the basic guidelines to develop a suitable sacrificial anode cathodic
protection system for the pipelines/ structures required to be protected. All data required in
this regard shall be taken into consideration to develop an acceptable design and for proper
engineering of the system.
1.3 Compliance with these specifications and/or approval of any of the contractor's documents
shall in no case relieve the contractor of his contractual obligations.
2.1 The system design, performance and materials to be supplied shall conform to the
requirements of the latest revision of following standards as a minimum:
2.2 In case of imported equipments standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable lndian Standards.
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other
statutory regulations currently in force in the country.
2.4 In case of any contradiction between various referred standards/ specifications/ data sheet
and statutory regulations the following order of priority shall govern:
Statutory Regulations
- Data Sheets
Job Specification
- This Specification
- Codes and Standards
3. SYSTEM IMPLEMENTATION
All work to be performed and supplies to be effected as a part of contract shall require
specific review by Owner or his authorised representative. Major activities requiring review
shall include but not be limited to the following:
a) Corrosion survey data interpretation report and design basis for CP system
b) CP system design package
c) Detailed engineering package
d) Field testing and commissioning procedure
e) Procedures for interference testing and mitigation
f) Close interval potential logging survey procedure and report
g) CAT/ DCVG survey procedure and report
h) System monitoring procedures
i) As built documentation
4. CORROSION SURVEY
4.1 The details of corrosion survey including soil resistivity data along ROU and other data
required for CP design if available with the Owner shall be included as part of project
specification/ data sheet. However, verification of its veracity and adequacy shall be the
entire responsibility of the contractor. In addition, contractor shall collect additional data as
per clause 4.2 below required for proper implementation of the protection system. Contractor
shall also carry out soil resistivity survey at sacrificial anode ground bed locations for proper
design of ground beds. Wenner's 4-pin method or approved equal shall be used for such
measurements. Survey instruments shall have maximum AC and DC ground current rejection
feature.
Care shall be taken to ensure that the resistivity observations are not influenced by the
presence of foreign pipelines/ structures, and earth currents in the vicinity of EHV/HV lines
and installations using earth return in their power system etc.
Where specified in the project specification/ data sheet, the contractor shall carry out
corrosion survey along the ROU of the pipeline conforming to the specifications included in
the tender document.
The following data shall be collected to generate design data for evaluation of interaction/
interference possibilities due to presence of other services in ROU/ vicinity. Owner shall
provide assistance for liaison work to the extent possible:
i) Route and types of foreign service/ pipeline in and around or crossing the right of use
(including those existing and those which are likely to come up during contract
execution).
ii) Diameter, wall thickness, pressure, soil cover, and coating scheme used, type of
cathodic protection system provided, if any, and year of laying/ commissioning in case
of foreign pipelines.
Details of the existing cathodic protection systems protecting the services i.e. type of
protection system, location (distance from the proposed pipeline), type, rating of anode
beds, test station locations and their connection schemes. Present output current and
voltage readings of the CP power supply units.
vi) Crossing and parallel running of electrified and non-electrified traction (along with
information regarding, operating voltage, AC/DC type etc.) as well as abandoned
tracks near ROU having electrical continuity with the tracks in use.
vii) Information on existing and proposed DC/AC power sources and systems using earth
return path such as HVDC substations/ earthing stations, fabrication yards with electric
welding etc. in the vicinity of the entire pipeline route.
viii) Crossing or parallel running of any existing or proposed 11 KV and above AC/DC
overhead power lines along with details of voltage, AC/ DC type etc.
ix) Voltage rating, phases, sheathing details of underground power cables running along
ROU or in its vicinity.
x) Any other relevant information that may be needed in designing and implementing
proper protection scheme for the proposed pipeline.
Contractor shall conduct necessary potential gradient surveys for any existing anode ground
beds that may interfere with the CP system of the pipelines covered under this project.
4.3 Report
On completion of all fieldwork, a report incorporating all the results generated from surveys
and details of additional data collected shall be prepared. The report shall also contain soil
resistivity data and detailed interpretation of survey results, probable interference prone areas
etc. to form design basis for the cathodic protection system. This report shall also include
various drawings prepared in connection with the above work. The soil resistivity values
shall be plotted on semi-log graph sheets.
Unless otherwise specified in the data sheet, following parameters shall be used for design of
cathodic protection system.
Where the cathodic protection system is specified for temporary protection, those parts of
sacrificial anode cathodic protection system which will be integrated with the permanent CP
system shall be designed based on permanent CP parameters.
i) Pipe lines having Coal Tar Enamel (CTE) coating with two/ three layers of
reinforcement:
ii) Pipe lines having Dual Layer Fusion Bonded Epoxy (DLFBE) coating or 3-Layer
Polyethylene (3LPE) coating:
25 250
The above current density values for temporary CP system are applicable for CP system
design life up to two years.
*Actual current density to be adopted shall be decided based upon soil and other
environmental conditions, current drainage survey data (where included in contractor's
scope), proximity of foreign pipe lines/ structures and other interference areas affecting the
installation. Where considered necessary for satisfactory protection of pipeline the current
density shall be suitably increased by contractor.
5.2 The pipe protection Current Density indicated in the clause 5.1 above shall be applicable
where the temperature of the fluid transported by the pipeline/ the surface temperature of the
buried portion of the pipeline does not exceed 30 °C. Where this temperature exceeds 30 °C,
the protection Current Density shall be increased in minimum by 25% for every 10 °C rise in
temperature over 30 °C.
5.3 For all pipeline sections which are having intermediate HDD (Horizontal Directional
Drilling) crossings, the nearby T/R units should have adequate provision of D.C. output
current to cater to the extra protection current demand at the HDD crossings.
5.7 Unless otherwise specified in data sheet the design life for temporary CP system shall be one
year and that for permanent CP system shall be 30 years.
5.8 Unless otherwise specified in the project specification/ data sheet, temporary CP for the
pipeline may not be provided along the ROU where soil resistivity is higher than 150 Ohm-m.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
6.1 The pipe to soil potential measurements shall be between (-) 0.95 V (ON) and (-) 1.5 V (ON)
for polyethylene coated pipe lines, between (-) 0.95 V (ON) and (-) 1.7 V (ON) for fusion
bonded epoxy/coal tar coated pipe lines with respect to a copper/copper sulphate reference
electrode.
Where polarisation coupons are provided along the pipeline the coupon to soil potential
measurements shall be between (-) 0.9V (OFF) and (-) 1.18V (OFF) with respect to a
copper/copper sulphate reference electrode.
6.2 A positive potential swing of 100 milli volts or more shall be considered sufficient to indicate
the presence of an interaction/ interference situation requiring investigation and incorporation
of mitigation measures by the Contractor.
7. SYSTEM DETAILS
The system shall include the following major equipment/ sub-systems unless otherwise
specified in project specifications.
All equipment shall be new and procured from approved manufacturers. Equipment offered
shall be field proven. Equipment requiring specialised maintenance or operation shall be
avoided as far as possible. Prototype equipment shall not be accepted.
Equipments shall conform to the relevant specifications enclosed with the tender document.
All equipment including test stations, etc. shall be located in safe non-hazardous areas.
Where it is essential to install electrical and electronic instrument enclosures and its
accessories in hazardous area, such equipment shall be flame proof type and shall meet the
requirements as per IS/ IEC: 60079 and shall be weather proof to IP-65 also as per
IS/IEC:60529.
A copy of approval from local statutory authority, as applicable such as Petroleum &
Explosives Safety Organization (PESO)/ Chief Controller of Explosives (CCE), Nagpur or
Director General of Mines Safety (DGMS) in India, for the electronic instruments installed in
electrically hazardous area along with:
i) Test certificate from recognized test house like Central Institute of Mining and Fuel
Research (CIMFR)/ Electronics Regional Testing Laboratory (ERTL) etc. for
flameproof enclosure/ intrinsic safety, as specified in the data sheet, as per relevant
standard for all Indian manufactured equipments or for items requiring Director General
of Mines Safety (DGMS) approval.
Along ROU, where soil resistivity is within 10 Ohm-m and pH value is within 9, either Zinc
anodes or Magnesium anodes shall be provided.
In case of Zinc anodes, anode of type I as per ASTM B418 standard shall be used for
seawater, brackish water having resistivity not exceeding 10 Ohm-m and for grounding/
earthing of pipelines. Anode of type II as per ASTM B418 standard shall be used for ribbon
anodes for protection of carrier pipes inside casing or for application in saline soil having
resistivity less than 10 Ohm-m.
7.1.1 Along ROU, where soil resistivity exceeds 10 Ohm-m, Magnesium anodes shall be provided.
7.1.2 Anodes shall be installed along the pipeline at suitable intervals as per pipeline protection
voltage attenuation calculations and ground bed resistance/ current output of anode
installations. At high resistivity area the Magnesium ribbon anodes shall be installed all along
the pipeline by the side of the pipeline in the pipeline trench.
7.1.3 Suitability for proper operation of the selected type of sacrificial anodes for the soil
conditions with particular attention to carbonates, bicarbonates, phosphates and nitrates shall
be checked by the contractor. The anodes shall be laid in proper type of back fill, such that
the effect of soil is minimum on the anode performance and life. Suitable safe guards against
anode passivation in prevailing soil shall be taken by the contractor.
7.1.4 Each electrically continuous section of pipeline shall be protected totally by single type of
anode to avoid inter-anode circulation currents.
7.1.5 The anodes shall be installed at sufficient depth to reach moist soil and shall be separated
from the pipeline by at least 5 m and 2 m for Magnesium and Zinc anodes respectively. The
Magnesium ribbon anode shall be separated from the pipeline by at least half a meter. The
anode connections to pipe line shall be routed through test stations.
7.1.6 At the temporary CP anode ground bed, the leads of all the anodes shall be joined together in
a junction box filled with epoxy and buried. A single cable shall be routed from the junction
box to test station.
7.1.7 For sacrificial anode ground bed which is intended for permanent CP system and/or which is
to be integrated with permanent CP system, the leads of all the anodes shall be brought up to
the test station and shall be terminated individually.
7.1.8 The number of anodes at each ground bed shall be sufficient for providing the specified pipe
protection current density taking into consideration the ground bed resistance, cable
resistance etc. For permanent cathodic protection system, contractor shall prepare a table for
number of anodes required at different soil resistivity to produce the specified protection
current for the specified designed life. For temporary cathodic protection system, an
indicative design data for sacrificial anodes ground bed in tabular form is given in data sheet.
The number of anodes at each anode ground bed, spacing of anode ground beds based on the
applicable soil resistivity, size of pipeline, type of coating for the pipeline shall be chosen
from the table after necessary verification by the CP contractor.
7.1.9 For the portion of the pipeline for which the CP system has been specified based on the
permanent CP system parameters, the contractor shall ascertain the requirement of the
cathodic protection current density indicated in clause 5.1 above. Where specified in the
project specification/ data sheet the requisite current requirement/ drainage survey shall be
conducted by the contractor to establish the adequacy of CP current requirement and number
of anode ground beds.
7.2.1 Test stations shall be provided along the pipeline ROU for monitoring the performance of the
cathodic protection system at the following locations. Test stations shall be provided at
additional locations, if required, so that distance between any two adjacent test stations does
not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like
forest/deserts:
b) At both sides of metalled road crossings where cased crossing is considered for the
crossing. At one side of the road crossing where casing pipe is not considered for the
crossing. In case more than one such uncased road crossing occurs within lKm, then
only one such uncased road crossing shall be provided with test station within 1Km.
f) At railway line crossings and at selected locations along railway lines running parallel to
the pipeline.
h) At EHV/HV cable crossings or along routes where EHV/HV cables are running in
parallel.
i) At EHV/HV AC/DC overhead line crossings and along routes where EHV/HV
overhead line are running in parallel.
7.2.2 Test stations used for sacrificial anodes shall have shunt for measurement of anode current,
provision for resistance insertion to limit the anode current output and anode-disconnecting
link.
7.2.3 Test stations for bonding shall be provided with a link and shunt, resistor as a means to
monitor and control current flow between the pipeline and foreign pipelines or structures that
may exist in common ROU.
7.2.4 Unless otherwise specified in the project specification/data sheet, Test station with current
measuring facility shall be provided at interference prone areas, on both sides of major river
crossings, and minimum one for every 10 km max. along the pipeline and at SV, IP, RT, DT
locations where CP Stations shall be considered.
7.2.5 The test stations shall be installed with the face of the test station facing the pipeline. The
nameplate of test stations shall carry the following minimum information:
Chainage in km.
Test station connection scheme
Distance from pipeline in metres.
Direction of product flow.
7.2.6 Terminals and different schemes of wiring shall be provided as per the test station connection
scheme. Minimum twenty percent spare terminals shall be provided in each test station.
7.2.7 Minimum two cables shall be provided from the pipeline at any test station.
7.2.8 The location of all the test stations shall be marked with their connection schemes and other
relevant information on alignment sheets. A detailed test-station schedule shall be prepared.
7.3.1 Unless otherwise specified in the project specification/data sheet steel coupons of pipeline
material shall be provided along the pipeline to monitor the adequacy of the CP system to
polarize/protect coating holidays. Coupon shall be installed at permanent CP station drainage
points, predicted cathodic protection mid points along the pipeline, at locations where the
pipeline is bonded to foreign pipeline/structures, interference prone areas, marshy areas, At
every 10 km approximate along the pipe line etc.
7.3.2 Coupons shall be installed at bottom 1/3rd portion of the pipeline and 200 mm approx away
from the pipe surface.
7.3.3 The coupons shall be constructed from the pipeline material and shall have one side uncoated
surface area of 100 mm x 100 mm exposed to soil. Two cables one for connection to pipeline
for coupon protection and other for coupon potential measurement shall be provided for each
coupon. The coupon protection cable shall be connected through a vacuum sealed magnetic
reed switch inside the test station to enable measurement of coupon `OFF' potential.
7.3.4 A permanent reference electrode shall be installed adjacent to the coupon in a manner so as
to measure the representative potential of the coupon.
7.3.5 Magnets for operation of reed switch shall be provided as specified in the project
specification/data sheet.
7.4.1 High purity copper-copper sulphate permanent reference cells with proven high reliability
shall be provided for stable coupon to soil potential measurement at the locations of
polarisation coupons.
7.4.2 The reference cells shall be of silver/silver chloride type in place of copper/copper sulphate
cells, at locations where chloride ion concentration is more than 300 ppm.
7.4.3 The life of reference cells shall be minimum 8 years under burial conditions.
7.4.4 The test station connection scheme inside the test station shall clearly indicate the type of
reference cell (Cu CuSO4/ Ag AgC1).
7.5.1 Explosion proof solid state surge diverter shall be connected across each insulating joint to
protect it from high voltage surges.
7.5.2 The total system including surge diverters, cables, cable termination, etc shall be suitable for
the anticipated fault current at the location of installation.
7.5.3 The surge diverter shall be suitable for the design life of permanent CP system.
7.6.1 Wherever the pipeline is either crossing or running in parallel with overhead EHV/HV
transmission lines of voltage grade 66kV and above, it is mandatory that the pipeline shall be
grounded to discharge any accumulated potential/ surge that may appear in case of
transmission line faults, as per below:
The pipeline shall be grounded through polarization cell with Zinc galvanic anodes of
either block anode or ribbon type. Sizing and quantity of anode shall be decided so as to
achieve maximum total earth resistance of 5 Ohm for each location where pipeline
crosses EHV/HV transmission lines.
The pipeline shall be grounded at regular intervals of maximum lkm where EHV/HV
transmission lines run parallel within 25m of the pipeline. Also, where EHV/HV
transmission lines run parallel beyond 25 m of the pipeline and it is expected from
calculations/ software simulations that surge would appear in case of transmission line
faults or any abnormal operating conditions.
7.6.2 Locations along pipeline where continuous induced over-voltage due to overhead
transmission lines/ underground cables is expected or observed by calculation/ software
simulations or observed during commissioning, the pipeline shall be grounded through
polarisation cell to the earth system of the transmission tower causing the voltage induction
or to a separate earthing system of Zinc anodes through polarisation cell.
7.6.3 The solid state type polarization cell shall be installed inside test station.
7.6.4 Areas where soil resistivity is higher than 50 Ohm-m Zinc ribbon anodes installed in
carbonaceous backfill instead of 20kg net prepacked Zinc solid anodes may be provided for
grounding.
7.6.5 The total system including cable, cable termination, polarisation cells and anodes shall be
suitable for the anticipated fault current at the location of its installation.
7.6.6 The polarisation cell and anode system shall be suitable for the design life of permanent CP
system. The grounding system shall have minimum resistance to earth to restrict the pipeline
voltage as per NACE/ VDE criteria but shall not exceed 5 Ohms.
7.6.7 The anodes shall be pre packed with special backfill adequately so that the performance of
the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In
any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.
7.7 Motor operated valves where located on the cathodically protected portion of the pipeline
shall be grounded by a Zinc or Magnesium anode of 20 kg net where the type of anode
provided for the CP system of the pipeline is Zinc or Magnesium respectively. The MOV
power supply cable armour shall be insulated (by cutting and taping with insulation tape) at
MOV end to avoid armour carrying CP current.
7.8 The above ground cathodically unprotected pipeline at intermediate SV stations, pigging
stations, etc. and terminals shall be earthed with GI earth electrodes. The resistance to earth
of grounding shall be limited to 5 Ohms max.
7.9.1 At cased crossings where casing will have coating on its external surface, it shall be protected
by sacrificial anode installations provided at both ends of casing. The anode installation shall
be sized based on the permanent CP design parameters and design life of permanent CP
system.
7.9.2 The carrier pipe inside the externally coated casing shall be protected by Zinc ribbon anodes
piggy backed longitudinally on the carrier pipe between 4 and 8 O'clock position. Anode
shall be tied with carrier pipe using Nylon rope at close intervals and weld connected at the
ends. The quantity/ no. of ribbon anodes shall be based on the permanent CP design
parameters for marshy area and design life of permanent CP system.
Reference cell access points shall be provided over the pipe near insulating joint locations
and at SV stations, where the ground is paved, for measurement of pipe to soil potentials. A
perforated PVC pipe filled with native soil and buried at the location shall be provided for the
purpose. The length of the PVC pipe shall be adequate to reach the native soil below the
paving.
7.11 Cables
7.11.1 Cables shall be with annealed high conductivity, stranded copper conductor, HMWPE
insulated, 650/1100V grade, armoured, HMWPE sheathed. The size of the copper conductor
shall be 6 sq.mm. for anode tail cable from anode to buried junction box, 10 sq.mm. from
buried junction box to test station and 10 sq.mm. from test station to pipeline. The size of
cable for bonding, polarisation cell, grounding anodes and surge diverter connections shall be
suitable for the maximum fault current subject to minimum 25 sq.mm. The length of anode
tail cable shall be sufficient for routing from anode to buried junction box or test station for
anodes for temporary CP or permanent CP respectively.
7.11.2 The cables for reference cells, pipeline potential measurements and polarisation coupon
potential measurements shall be of 4 sq.mm copper conductor, HMWPE insulated,
Aluminium backed by mylar/ polyester tape shielded, HMWPE sheathed, armoured,
HMWPE over all sheathed type.
8. INSTALLATION
8.1.1 Cables shall be laid in accordance with the layout drawings to be prepared by the contractor.
No straight through joint shall be permitted. Cable route shall be carefully measured and
cables cut to required length. Minimum half metre cable slack shall be provided near anodes,
pipeline and test stations to account for any settling.
8.1.2 All cables inside station/ plant area shall be laid at a depth of 0.75 M. Cables outside
station/plant area shall be laid at a depth of minimum 1.5 m. Cables shall be laid in sand
under brick cover and back filled with normal soil. For cables laid outside the station/plant
area, polyethylene warning mats shall placed at a depth of 0.9 m from the finished grade, to
mark the route. Inside plant area cable routes shall be marked by means of cable markers
located at maximum intervals of 30 M and at locations of changes in direction of cable route.
8.1.3 In case of above ground cable, all unarmoured cables shall be laid in GI conduits of
sufficiently large size, up to accessible height for protecting against the mechanical damage.
8.1.4 All underground unarmoured cables including anode tail cables shall run through PE sleeves.
The cables routed along the pipeline shall be carried at the top of the carrier pipe by securely
strapping it at intervals with adhesive tape or equivalent as required.
8.1.5 PVC pipes of proper size shall be provided for all underground cables for road crossings.
8.1.6 Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and
final take-off to equipment is facilitated.
8.1.7 The cables for reference cells and pipeline potential measurement shall be routed in a
separate trench other than the trench provided for the rest of the CP system cables, AC/DC
power supply cables for CPTR units/ CPPSM etc.
8.1.8 The armour of all the cables from pipeline to test station (potential measurement, current
measurement, reference cell cables, cathode cables, bonding cables, grounding cables, etc)
and test station to ground bed (anode cable) shall be earthed only at test station end of the
cable to avoid armour carrying CP current. The armour of the bonding cables between test
stations shall be earthed at any one end of the cable only. The cable armour shall be insulated
by cutting and taping with insulation tape.
The permanent reference cells shall be installed with special backfill material and as per the
recommendations of the cell manufacturer. Installations in highly acidic/ alkaline soil and
soil contaminated by hydrocarbons shall be avoided.
All cable connections of other than cathode drainage cables to the new pipeline shall be made
by an approved exothermic process or by pin brazing. However, cable connection to charged
pipelines shall be made by pin brazing. Approved exothermic welding may be adopted for
pipelines carrying water. Coating shall be repaired after connection of cable conductor to
pipeline. The coating repair material shall be compatible with the original coating and shall
prevent ingress of water along the cable surface and at the interface of coating repair with the
original pipe coating.
Where specified in project specifications/ data sheet chain link fencing shall be provided
around the location of each ground bed designed based on the permanent CP design
parameters.
9.1.1 Field tests as per the reviewed field testing and commissioning procedures prepared by the
Contractor shall be carried out on the equipment/systems before these are put into service.
Acceptance of the complete installation shall be contingent upon inspection and test results.
9.1.2 Before the CP system facilities are put into operation, necessary tests shall be carried out to
establish that all equipment, devices, wiring and connection have been correctly installed,
connected and are in good working condition as required for the intended operation.
Owner/Owner's representative may witness all tests. Intimation shall be given at least one
week before commencing the tests.
9.1.3 A11 tools, equipment and instruments required for testing shall be provided by Contractor.
9.1.4 Generally, the following minimum tests shall be carried out and recorded.
i) Cables
- Cable No.
- Voltage grade.
- Conductor cross section.
Continuity check.
- Voltage test.
- Insulation resistance values between each core & earth, between cores.
A11 cables shall be tested by 500 V megger.
Location.
- Pipe to soil potential of both protected and non-protected sides of the insulating
joint before and after energisation of CP system.
- Location/identification number.
Rating
- Type
- Explosion proof enclosure.
Check for healthiness.
- Check for proper connection.
- Location/Identification number.
v) Polarisation Coupon
- Location/Identification number.
- Exposed area/size of coupon.
- Depth and distance from pipeline of coupon
- Type of reference cell
- Distance of reference cell from coupon
- Magnetic reed switch rating
- Operation of magnetic reed switch with magnet
- Check for wiring.
- Coupon On and OFF potentials.
Location
- Type of cell
- Depth and distance from pipeline of reference cell
- Potential reading
- Location/ Station
- Horizontal/ Vertical
Check for actual layout and compliance with drawings.
- Current output of ground bed.
- Current output of each anode (in case of permanent CP anode ground beds)
9.2 Commissioning
9.2.1 Natural pipe to soil potential for the complete pipeline and casing pipelines at the locations of
cased crossings shall be measured at all the test station locations and recorded prior to
connecting anodes to pipe line and casing pipelines.
9.2.2 The anodes shall be connected to pipeline in the test station and the pipe to soil potential
observation shall be made after allowing sufficient time for polarisation. The current output
of each anode at permanent CP anode ground bed or the total current output of anode bed at
temporary CP anode ground bed shall also be measured to ensure that it does not exceed the
output current capacity of the anodes. In case the anode output current exceeds the rated
capacity, it shall be controlled by insertion of resistance element in the anode circuit inside
test station and the pipe to soil potential shall be rechecked for adequacy of protection. At
locations of polarisation coupons the coupon `OFF' potential shall be measured by switching
off the reed switch. Additional anodes shall be provided where required to achieve desired
Level of protection and to keep the anode output current within the rated value. In case pipe to
soil potential exceeds the specified value, suitable resistance shall be inserted in the anode
circuit to limit the potential.
9.2.4 At the locations of cased crossings where anode installations are provided for the protection
of the casing pipe, these anode installations shall be commissioned as per the procedure
detailed in ciause 9.2.2 above.
9.2.5 After connecting all the anode ground beds to the pipe line, measurement of pipe to soil
potentials shall be taken at each of the test stations to ensure conformity to protection criteria.
9.2.6 In case of insufficient protection as per the CP design criteria, on any portion of the pipeline/
casing pipeline (at cased crossings where casing is cathodically protected) Contractor shall
carry out necessary additions/modifications to the provided protection in consultation with
the Owner/ Owner's representative.
9.2.7 Healthiness of the insulating joints provided on the pipeline shall be checked by measuring
the pipe to soil potentials on both protected and non protected sides of the IJs.
10.1 Investigations shall be made for stray current electrolysis of the pipeline, mutual interference
between the pipeline and foreign pipelines/ structures, interference on foreign
pipelines/structures due to the CP of the pipeline and ground bed, AC induction on pipeline
due to 11 KV and above overhead HV/EHV line, interference due to high voltage DC line,
HVDC groundings, electric traction, DC mining, DC welding operations, impressed current
anode ground beds on other pipelines, etc.
10.2 Where transmission lines cross the pipeline or run in parallel within 25m from the pipeline,
AC voltage measurements shall also be made on the pipeline to find out continuous induction
of voltage. In case of induced voltage being beyond safe limits, the pipeline shall be
grounded in line with clause no.7.6 above. Where transmission lines run in parallel more than
25m from the pipeline, however, continuous induced AC of voltage beyond safe limits are
noticed on the pipeline the same shall be mitigated by grounding the pipeline in line with
clause no.7.6 above.
10.3 Measurements including pipe/ structure to soil potential and pipeline/ structure current etc. on
the pipeline/ structure being CP protected and on foreign pipelines/ structures shall be made
to investigate the current discharge and pickup locations. In case of fluctuating stray current,
investigations shall be made continuously over a period of time and if required
simultaneously at different locations to find out the stray current source(s). For measurements
over longer durations, recorders shall be used.
10.4 Where foreign pipelines (unprotected or protected by independent CP system) run in parallel
to the pipeline in same trench or very near to the pipeline, and are not bonded to the pipeline
then investigation shall be made for current discharge points on both the pipelines.
10.5 Mitigation measures shall be provided depending on type of stray current electrolysis/
interference. These shall include installation of bond with variable resistor, diodes,
installation of galvanic anodes for auxiliary drainage of current, adjustment/ relocation (if
possible) of offending interference source, provision of electrical shield etc. depending on the
type of interference.
10.6 Bonding with foreign pipeline/ structure, as a mitigation measure shall be provided where the
owner of the foreign pipeline/structure have no objection, otherwise alternative mitigation
measure shall be provided. Where bonding is provided for mitigation, the bonding resistor
shall be adjusted for optimum value for minimum/no interference. Galvanic anodes installed
as a mitigation measure shall be sized for the design life specified for permanent CP system.
Where the CP system provided is temporary, the CP system shall be monitored at all test
stations once in a month for healthiness/ adequacy of protection till commissioning of
permanent CP system or for design life of temporary CP system specified, whichever is less.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
During this period if any deficiency/ interference in protection system is noticed, the same
shall be rectified/ augmented by providing additional anodes as required. The monitoring
report shall be submitted regularly to owner for his review/ information.
Where specified in project specification/data sheet, contractor shall carry out a close interval
potential survey over the entire length of pipeline by computerised potential logging method
and identify the under protected/ over protected area, any major coating damage on the
pipeline, after the back-filling has been consolidated sufficiently and CP system has
stabilized. Contractor shall provide required mitigation measures and rectify the
under/overprotected zones, identify if any, the major pipeline coating defects required to be
repaired. During the survey the reference cell shall be calibrated minimum once in 24 hours.
Where specified in the project specification/ data sheet, additional tests for detailed
identification of coating defects shall be conducted by the contractor.
41q9(1144 et;k1-
#-(vErr wiji(41 fffq fqr-4-4-r
SPECIFICATION
FOR
IMPRESSED CURRENT
CATHODIC PROTECTION SYSTEM
FOR PIPELINES
Abbreviations:
AC Alternating Current
BS British Standards
BIS Bureau of Indian Standards
CP Cathodic Protection
CMRI Central Mining Research Institute
CPPSM Cathodic Protection Power Supply Module
CPTR Cathodic Protection Transformer Rectifier
CTE Coal tar enamel
DC Direct Current
EHV Extra High Voltage
FBE Fusion Bonding Epoxy
HDD Horizontal Directional Drilling
HV High Voltage
HVDC High Voltage Direct Current
IS Indian Standards
A/mm2 Micro-ampere per square millimeter
MMO Mixed Metal Oxide
MOV Motor Operated Valve
NACE National Association of Corrosion Engineers
PE Polyethylene
PVC Polyvinyl Chloride
ROU Right of Use
SV Sectionalizing Valve
CONTENTS
1.0 SCOPE 4
2.0 APPLICABLE CODES AND STANDARDS . 4
3.0 SYSTEM IMPLEMENTATION 5
4.0 CORROSION SURVEY 5
5.0 CATHODIC PROTECTION DESIGN PARAMETERS .7
6.0 CATHODIC PROTECTION DESIGN CRITERIA 9
7.0 SYSTEM DETAILS 9
8.0 INSTALLATION 16
9.0 FIELD TESTING AND COMMISSIONING 17
10.0 INTERFERENCE MITIGATION 21
11.0 CLOSE INTERVAL POTENTIAL SURVEY 22
1.0 SCOPE
1.1 This specification defines the requirements of system design, engineering, installation, testing
and commissioning of an Impressed Current Cathodic Protection System for cross-country
onshore underground pipelines/ structures including supplementing of corrosion survey, close
interval potential logging survey, investigations for interaction/interference problems and
mitigation of the same.
1.2 This specification provides the basic parameters to develop a suitable impressed current
cathodic protection system for the pipelines/ structures requiring protection. All data required
in this context shall be taken into consideration to develop an acceptable design and for
proper engineering of the system.
1.3 Compliance with these specifications, and/or approval of any documents submitted by
contractor shall in no case relieve the contractor of his contractual obligations.
2.1 The system design, performance and materials to be supplied shall conform to the
requirements of the latest revision of following standards as a minimum:
xi) IS/ IEC: 60079 Electrical Apparatus for Explosive Gas Atmosphere
2.2 In case of imported equipments standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other
statutory regulations currently in force in the country.
2.4 In case of any contradiction between various referred standards/ specifications/ data sheet and
statutory regulations the following order of priority shall govern:
Statutory Regulations
Data Sheets
- Job Specification
- This Specification
Codes and Standards
All work to be performed and supplies to be effected as a part of contract shall require
specific review by Owner or his authorised representative. Major activities requiring review
shall include but not be limited to the following:
i) Corrosion survey data interpretation report and plot plans for land acquisition
ii) Conceptual system design
iii) Basic engineering package
iv) Detailed engineering package
v) Field testing and commissioning procedures
vi) Procedures for interference testing and mitigation
vii) Close interval potential logging survey procedure
viii) As built documentation
4.1 General
4.1.1 The details of corrosion survey including soil resistivity data along ROU and other data
required for C.P design if available with the Owner shall be included as part of project
specification/ data sheet. However, verification of its veracity and adequacy shall be the entire
responsibility of the contractor. In addition, contractor shall have to generate/ collect
additional data as per clause 4.4 below required for completeness of the job.
Contractor shall carry out soil resistivity survey at anode ground bed locations for design of
ground bed. Where specified in the data sheet, Contractor shall carry out corrosion survey
along the ROU of the pipeline conforming to the specifications included in the tender
document.
4.1.2 To carry out soil resistivity measurement Wenner's 4-pin method or an equivalent method
approved by Owner/ Owner's representative shall be used. Survey instruments shall have
maximum AC and DC ground current rejection feature.
Care shall be taken to ensure that the resistivity observations are not influenced by the
presence of foreign pipelines/ structures, and earth currents in the vicinity of EHV/ HV lines
and installations using earth return in their power system etc.
4.2 Soil Resistivity Survey at Impressed Current Anode Ground Bed Plot
4.2.1 Each selected anode bed plot shall be sub-divided into sub-plots. Sizes of sub-plots shall
depend upon the expected depth for soil resistivity investigations. Each of these sub-plots
shall be investigated for resistivity data individually. Sufficient observations shall be taken at
each of these sub-plots as required and desired by Owner/ Owner's representative to obtain
sufficient information about sub-soil stratification and, wherever possible, to establish the
depth of water table. The number of subplots at each ground bed plot shall be decided at site
in consultation with Owner/ Owner's representative.
4.2.2 Number, location, demarcation and size of sub-plots and number of sets of resistivity
observations required for each sub-plot shall be individually decided for each ground bed plot
location.
4.2.3 One or more ground bed plots may be required to be selected and surveyed at each CP station
to form a suitable ground bed.
Cathodic protection stations consisting of anode ground bed, CP station etc. as applicable,
along with all associated cabling up to pipeline and any other related equipment and
accessories for CP station shall be demarcated on the ground. Ground plots so demarcated
shall be surveyed for all other topographical and cadastral features and topo-sheets shall be
developed by the CONTRACTOR, which shall be suitable for use in land acquisition etc.
The following data shall be collected to generate design data for evaluation of
interaction/interference possibilities due to presence of other services in ROU or in its
vicinity. OWNER shall provide assistance for liaison work to the extent possible.
i) Route and types of foreign service/ pipeline in and around or crossing the right of use
(including those existing and those which are likely to come up during contract execution).
ii) Diameter, wall thickness, pressure, soil cover, and coating scheme used, type of cathodic
protection system provided, if any, year of laying/ commissioning in case of foreign pipelines.
iii) Details of the existing cathodic protection systems protecting the services i.e. type of
protection, location, type, rating of anode beds, test station locations and their connection
schemes. Present output current and voltage readings of the CP power supply units.
vi) Possibility of integration/ isolation of CP systems, which may involve negotiations with
owners of other services.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reserved
vii) Existing and proposed DC/AC power sources and systems using earth return path such as
HVDC substations/ earthing stations, fabrication yards with electric welding etc. in the
vicinity of the entire pipeline route.
viii) Crossing and parallel running of electrified and non-electrified traction (alongwith
information regarding, operating voltage, AC/DC type etc.) as well as abandoned tracks near
ROU having electrical continuity with the tracks in use.
ix) Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power
lines along with details of voltage, AC/DC type etc.
x) Voltage rating, phases, sheathing details of underground power cables along ROU or in its
vicinity.
xi) Any other relevant information that may be needed in designing and implementing proper
cathodic protection scheme for the proposed pipeline.
Contractor shall conduct necessary potential gradient surveys for any existing anode ground
beds that may interfere with the CP system of the pipelines covered under this project.
4.5 Report
On completion of all field work, a report incorporating all the results generated from surveys
and details of additional data collected shall be prepared. The report shall also contain
detailed interpretation of survey results and resistivity data, probable interference prone areas,
selected locations for anode ground beds etc., to form a design basis for the scheme of
cathodic protection. This report shall also include various drawings prepared in connection
with the above work. Soil resistivity values shall be plotted on semi-log graph sheets.
Unless otherwise stated in the data sheets, the following parameters shall be used for design
of permanent cathodic protection system:
i) Pipe lines having Coal Tar Enamel (CTE) coating with two/ three layers of
reinforcement.
40 500
ii) Pipe lines having Dual Layer Fusion Bonded Epoxy (DLFBE) coating or 3-Layer
Polyethylene (3LPE) coating:
25 250
The above current density values for temporary CP system are applicable for CP system
design life up to two years.
*Actual current density to be adopted shall be decided based upon soil and other
environmental conditions, current drainage survey data, proximity of foreign
pipelines/structures and other interference areas affecting the installation. Where considered
necessary for satisfactory protection of pipeline the current density shall be suitably increased
by contractor. Also refer to clause 7.1 (iv) below.
For all pipeline sections which are having intermediate HDD (Horizontal Directional Drilling)
crossings, the nearby T/R units should have adequate provision of D.C. output current to cater
to the extra protection current demand at the HDD crossings.
5.2 The pipe protection Current Density indicated in the clause 5.1 above shall be applicable
where the temperature of the fluid transported by the pipeline/ the surface temperature of the
buried portion of the pipeline does not exceed 30 °C. Where this temperature exceeds 30 °C,
the protection Current Density shall be increased in minimum by 25% for every 10 °C rise in
temperature over 30 °C.
(The output voltage rating of the CPTR unit/ CPPSM shall in minimum be adequate to drive
the specified end of life cathodic protection current with safety factor, considering the total
anode ground bed loop resistance as the sum of the resistance specified in this clause and pipe
to earth resistance).
i) The pipe to soil potential measurements shall be between (-) 0.9V (OFF) and (-) 1.18V
(OFF) with respect to a copper/copper sulphate reference electrode.
ii) In rare circumstances, a minimum polarization Shift of (-) 100 millivolts may be accepted as
an adequate level of cathodic protection for the pipeline with the approval of Owner.
iii) A positive potential swing of 100 millivolts or more shall be considered sufficient to indicate
the presence of an interaction/ interference situation requiring investigation and incorporation
of mitigation measures by the Contractor.
The system shall include the following major equipment/ sub-systems unless otherwise
specified in project specifications:
- CP stations
- CPTR units/ cathodic protection power supply modules (CPPSM).
Anode ground beds and anodes
Anode junction box
Cathode junction box
Test stations
Permanent reference cells
Polarisation cell and surge diverter
- Polarisation coupons
CP system at cased crossing
- Bond Stations
Cables
A11 equipment shall be new and procured from EIL approved 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.
A11 equipment/ materials shall conform to the relevant specifications included in the tender
document.
All equipment including CPTR unit, CPPSM, test stations, anode lead junction boxes etc.
shall be located in safe non-hazardous areas.
Where it is essential to install electrical and electronic instrument enclosures and its
accessories in hazardous area, such equipment shall be flame proof type and shall meet the
requirements as per IS/ IEC: 60079 and shall be weather proof to IP-65 also as per
IS/IEC:60529.
A copy of approval from local statutory authority, as applicable such as Petroleum &
Explosives Safety Organization (PESO)/ Chief Controller of Explosives (CCE), Nagpur or
Director General of Mines Safety (DGMS) in India, for the electronic instruments installed
in electrically hazardous area along with:
i) Test certificate from recognized test house like Central Institute of Mining and Fuel
Research (CIMFR)/ Electronics Regional Testing Laboratory (ERTL) etc. for
flameproof enclosure/ intrinsic safety, as specified in the data sheet, as per relevant
standard for all Indian manufactured equipments or for items requiring Director General
of Mines Safety (DGMS) approval.
ii) Certificate of conformity from agencies like Laboratorie Central Des Industries
Electriques (LCIE), British Approval Service for Electrical Equipment in Flammable
Atmospheres (BASEEFA), Factory Mutual (FM), Physikalisch-Technische
Bundesanstalt (PTB), Canadian Standards Association (CSA), Underwriters
Laboratories (UL) etc. for compliance to ATEX directives or other equivalent standards
for all equipments manufactured outside India.
The number and exact locations of CP stations shall be worked out based on the corrosion
survey data collected. In addition, the following guidelines shall be followed for selecting the
locations:
i) Number of CP stations and their selected locations shall ensure that these remain valid and are
adequate for the full design life of the system after considering all foreseeable factors.
ii) As far as possible, the availability of nearby low resistivity areas for location of associated
ground beds must be ensured while selecting the locations of CP stations.
iii) As far as possible, locations of intermediate CP stations shall coincide with the locations of
SV stations.
iv) The proposed locations of CP stations and anode ground bed current ratings are detailed in
project specifications/ data sheets. The same shall be verified for adequacy by the contractor.
The requisite current drainage tests/ survey shall be conducted by the contractor to establish
the adequacy of CP current requirement indicated in clause 5.0 above and adequacy of
number, ratings of CP stations for permanent CP system indicated in the data sheet. The
minimum end of life pipe protection current requirement shall be considered as the current
requirement indicated in the clause 5.0 above or 3 times the current density value measured
by the current drainage survey for polyethylene coated pipeline and 4 times the current
density value measured by the current drainage survey for fusion bonded epoxy, coal tar
enamel with reinforcement coated pipeline, whichever is maximum.
If specified in project specifications/ data sheet, the supply, installation, testing and
commissioning of cathodic protection power supply module (CPPSM)/ indoor type Cathodic
Protection Transformer Rectifier Unit (CPTR unit)/ outdoor type CPTR unit installed in kiosk
along with kiosk shall be included in contractor's scope. The CP TR units shall be provided at
CP stations where reliable AC power supply is available. CPPSM shall be provided at other
CP stations where reliable DC power supply instead of reliable AC power supply is available.
The CPTR unit/ CPPSM shall be installed in non-hazardous (safe) area as specified in data
sheets.
i) Each CP station shall have an independent anode ground bed, which may be of shallow or
deep well construction depending upon the data collected by the contractor. Deep well ground
beds may also be used in the congested locations where availability of suitable land for spread
out ground beds is restricted.
ii) Ground bed shall be located electrically remote from the pipeline and foreign pipeline/ other
buried metallic structures. Nearest part of the anode bed shall at least be 100 meters away
from the pipeline and foreign pipeline/ other buried metallic structures. The anodes installed
in the ground shall be located in perennially moist strata, wherever possible. Horizontal
ground beds shall be at right angles to the pipeline, as far as possible.
The location of ground bed shall be checked and ensured for remoteness from the pipeline
and other buried foreign pipelines/ structures, building foundations, switchyards, electrical
earthing systems, etc.
iii) Unless otherwise agreed, anodes shall be of high silicon cast iron type or mixed metal oxide
coated titanium anodes.
iv) Sheet steel anode canisters of adequate size shall be provided for each anode. Anode canisters
shall be filled with petroleum coke breeze. In case of deep well ground beds non-canistered
anodes with petroleum coke breeze in the well surrounding the anodes shall be provided.
v) Each shallow anode-bed shall contain anodes with canisters positioned horizontally or
vertically in the soil with suitable backfill. The depth of anodes (depth of top of anode in case
of vertically laid anodes) shall not be less than 2 meter from grade level.
vi) Layout of anode installation in anode bed shall be detailed out in drawings showing anode
installation details, anode grouping, anode wiring, anode cable routing, etc. The deep well
anode ground bed details shall include the details of anodes, deep well casing, anode
positioning, anode cable supporting, deep well gas venting, active, passive portions of the
ground bed etc.
vii) Anodes shall be supplied complete with tail cables, which shall be long enough for
termination on their associated anode lead junction boxes without intermediate joints. Exact
lengths and termination details shall be indicated in construction drawings.
viii) Potential gradient around the anode bed shall be within safety requirements with regard to
interference on foreign structures and its effective boundary shall be defined.
ix) In case of two parallel pipelines running in the same ROU, the anode ground beds of the
respective pipelines shall be located on the respective sides of the pipelines.
Depending on the size and configuration of anode ground beds, one or more anode junction
boxes shall be provided at each ground bed. All cable tails from individual anodes shall be
terminated onto the respective anode junction boxes, which shall be further connected to the
main anode junction box (where applicable). The main anode junction box shall be connected
to the cable coming from CP power source. Each outgoing circuit in main junction box
(where applicable) and each anode circuit in junction shall have provision for measurement
and control of individual circuit/anode current.
Where output of the CP power supply unit is connected to multiple pipelines a cathode
junction box shall be provided near the pipelines at the location of connection of the negative
drainage cable to the pipelines.
The negative of the CP power source shall be connected to the incoming circuit of the cathode
junction box. The junction box shall have separate out gong circuit one for each pipeline to
collect the negative drainage currents from each of the parallel pipelines.
The incoming circuit shall have a current measurement facility. Each out going circuits shall
have provision for measurement and control of current.
7.6.1 Test stations shall be provided along the pipeline ROU for monitoring the performance of the
cathodic protection system at the following locations. Test stations shall be provided at
additional locations, if required, so that distance between any two adjacent test stations does
not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like
forest/deserts:
iv) At locations of surge diverters, pipeline grounding through polarisation cells, Zinc
and Magnesium anodes
v) At EHV/HV AC/DC overhead line crossings and selected locations where EHV/HV
overhead line is in the vicinity of the pipeline
vi) At railway line crossings and at selected locations along lines running parallel to the
pipeline
viii) At EHV/HV cable crossings or along routes where EHV/HV cables are running in
parallel
ix) In the vicinity of DC networks or grounding systems and HVDC grounding systems
where interference problems are suspected
7.6.2 Test stations for bonding shall be provided with shunt and resistor as a means to monitor and
control current flow between the pipeline and foreign pipelines or structures that may exist in
common ROU.
7.6.3 Test stations with current measuring facility shall be provided at each CP station drainage
point (to measure pipeline current on any one side of pipeline from drainage point at
intermediate CP station and towards protected side of the pipeline at starting, end point CP
stations), at interference prone areas, on both sides of major river crossings, near marshy areas
and minimum one for every 10 km max. along the pipeline.
7.6.4 Test stations shall be installed with the face of the test station facing the pipeline. The
nameplate of test stations shall carry the following minimum information:
Chainage in km.
Test station connection scheme
Distance from pipeline in meter.
Direction of product flow.
7.6.5 Number of terminals and different schemes of wiring shall be as per the test station
connection scheme. Minimum twenty percent spare terminals shall be provided in each test
station.
7.6.6 Minimum two cables from the pipeline shall be provided at any test station.
7.6.7 The location of all the test stations shall be marked with their connection schemes and other
relevant information on alignment sheets. A detailed test-station schedule shall be prepared.
7.7.1 High purity copper/copper sulphate reference cells with proven high reliability shall be
provided for stable pipe to soil potential measurement at CP stations and polarization coupons
along ROU.
7.7.2 Silver/Silver Chloride reference cells in place of copper/copper sulphate cells shall be
provided at marshy area locations, where water table is high and chloride concentration is
more than 300 ppm. For marshy area in saline soil, high purity Zinc may be considered as an
alternative to silver/silver chloride. The test station connection scheme shall clearly indicate
the type of the reference electrode (Cu CuSO4/Ag AgC1) at these locations.
7.7.3 The life of the reference cells shall be minimum 8 years under the installed conditions.
7.7.4 The cable from reference cells shall be provided up to CP power source at CP stations and up
to test stations at the locations of polarization coupons. The cable up to CP power source shall
be routed through test stations near pipeline.
i) Wherever the pipeline is either crossing or running in parallel with overhead EHV/HV
transmission lines of voltage grade 66kV and above, it is mandatory that the pipeline shall be
grounded to discharge any accumulated potential/ surge that may appear in case of
transmission line faults, as per below:
The pipeline shall be grounded through polarization cell with Zinc galvanic anodes of
either block anode or ribbon type. Sizing and quantity of anode shall be decided so as to
achieve maximum total earth resistance of 5 Ohm for each location where pipeline
crosses EHV/HV transmission lines.
ii) Locations along pipeline where continuous induced over-voltage due to other overhead
transmission lines/ underground cables of voltage grade below 66kV is expected or observed
during commissioning, the pipeline shall be grounded through polarisation cell to the earth
system of the EHV/HV tower causing the voltage induction or to a separate earthing system
of Zinc anodes through polarisation cell.
iii) Polarisation cell shall be installed inside test station of suitable size.
Explosion proof spark gap surge diverter shall be provided across each insulating joint to
protect it from high voltage surges. Surge diverters shall be suitable for installation in
classified areas.
7.8.2 The total system including cables, cable termination, anodes/ surge diverters, polarisation cell
shall be suitable for the anticipated fault current at the location of installation.
7.8.3 The surge diverter and polarisation cell system shall be suitable for the design life of
permanent CP system. The grounding system shall have minimum resistance to earth to
restrict the pipeline voltage as per NACE/VDE criteria but shall not exceed 5 Ohms.
7.8.4 The anodes shall be pre packed with special backfill adequately so that the performance of the
anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the soil. In any
case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.
7.9 Motor operated valves where located on the cathodically protected portion of the pipeline shall
be grounded by a Zinc anode of 20 kg. net Magnesium anodes grounding, if any, provided
during temporary CP system shall be disconnected. The MOV power supply cable armour shall
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
be insulated (by cutting and taping with insulation tape) at MOV end to avoid armour carrying
CP current.
7.10 The above ground cathodically unprotected pipeline at terminals, intermediate SV stations,
pigging stations etc. shall be earthed with GI earth electrodes. The resistance to earth of
grounding shall be limited to 5 Ohms (Max.).
Where specified in the project specification/data sheet steel coupons of pipeline material shall
be provided along the pipeline to monitor the adequacy of the CP system to polarize/ protect
coating holidays. Coupon shall be installed at CP station drainage points, predicted cathodic
protection mid points along the pipeline, at locations where the pipeline is bonded to foreign
pipeline/ structures, interference prone areas, marshy areas and at other locations as specified in
the project specification/ data sheet, along the pipe line.
Coupons shall be installed at bottom 1/3rd portion of the pipeline and 250 mm away from the
pipe surface.
The coupons shall be constructed from the pipeline material and shall have one side uncoated
surface of 100 mm x 100 mm exposed to soil. Two cables one for connection to pipeline for
protection and other for potential measurement shall be provided for each coupon. The
protection cable shall be connected through a magnetic reed switch inside the test station to
enable measurement of coupon `OFF' potential.
Magnets for operation of reed switch shall be provided as specified in the project
specification/data sheet.
7.12.1 At cased crossings where casing will have coating on its external surface, it shall be protected
by sacrificial anode installations provided at both ends of casing. The anode installation shall be
sized based on the permanent CP design parameters and design life of permanent CP system.
7.12.2 The carrier pipe inside the externally coated casing shall be protected by Zinc ribbon anodes
piggy backed longitudinally on the carrier pipe between 4 and 8 O'clock position. Anode shall
be tied with carrier pipe using Nylon rope at close intervals and weld connected at the ends. The
quantity/ no. of ribbon anodes shall be based on the permanent CP design parameters for
marshy area and design life of permanent CP system.
Reference cell access points shall be provided near insulating joint locations and at SV stations,
where the ground is paved, for measurement of pipe to soil potentials. A perforated PVC pipe
filled with native soil and buried at the location shall be provided for the purpose. The length of
the PVC pipe shall be adequate to reach the native soil below the paving.
7.14 Cables
7.14.1 Cables shall be with annealed high conductivity stranded copper conductor, PVC insulated,
650/1100 V grade, armoured, PVC sheathed conforming to IS 1554 part-I, except for the cables
for anode tail, reference cells and pipeline for potential measurements. The size of the copper
conductor shall be minimum 35 sq. mm. for anode and cathode cables, 6 sq.mm. for current
measurement, 10 sq.mm. for anode tail cables and polarization coupon protection cables. The
size of cable for bonding, polarization cell, grounding anodes and surge diverter connections
shall be suitable for the maximum fault current subject to minimum 25 sq mm.
7.14.2 The anode tail cables shall be PE insulated, 650V grade, unarmoured, PVC sheathed and length
shall be sufficient for termination on anode lead junction box without any joint in between.
7.14.3 The cables for reference cells, coupon and pipeline potential measurements shall be of 4 sq.mm
copper conductor, PVC insulated, Aluminium backed by mylar/ polyster tape shielded, PVC
sheathed, armoured, PVC over all sheathed type.
7.14.4 The CPTR unit incomer cable shall be minimum 4 sq.mm. Copper conductor, 650/1100 V
grade, PVC insulated, armoured, PVC sheathed. The cable shall be of 3 core type for single
phase CPTR units and of 4 core type for 3 phase CPTR units.
7.14.5 The cables for connecting various transducers from CPTR unit/CPPSM to telemetry interface
junction box shall be twisted pair with individual pair shielded and overall shielded with
aluminium backed by mylar/ polyster tape, PVC sheathed, armoured, PVC over all sheathed
type.
8.0 INSTALLATION
i) Cables shall be laid in accordance with layout drawings to be prepared by the contractor. No
straight through joint shall be permitted. Cable route shall be carefully measured and cables
cut to required length. Minimum half metre cable slack shall be provided near anodes, anode
junction box, pipeline and test stations to account for any settling.
ii) All cables inside station/plant area shall be laid at a depth of 0.75 metre. Cables outside
station/ plant area shall be laid at a depth of minimum 1.5 metres. Cables shall be laid in sand
under brick cover and back filled with normal soil. For cables laid outside the station/plant
area, polyethylene warning mats shall be placed at a depth of 0.9 metre from the finished
grade, to mark the route.
iii) In case of above ground cables, all unarmoured CP cables shall be laid in GI conduits of
sufficiently large size, up to accessible height for protecting against the mechanical damage.
iv) All underground unarmoured cables including anode tail cables shall run through PE sleeves.
Distant measurement cables and permanent reference cell cables routed along the pipeline
shall be carried at the top of the carrier pipe by securely strapping it at intervals with adhesive
tape or equivalent as required.
v) PVC pipes of proper size shall be provided for all underground cables for road crossings.
vi) Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and
final take-off to equipment is facilitated.
vii) The cables for reference cells and pipeline potential measurement shall be routed in a separate
trench other than the trench provided for the rest of the CP system cables, AC cables for
CPTR Units etc.
viii) The armour of the cables from CP station to test station (potential measurement, reference cell
& drainage cables etc.), CP station to ground bed (anode cable) and test station to pipeline
shall be earthed only at CP station end and test station end respectively of the cables. The
cable armour shall be insulated (by taping with insulation tape) to avoid armour carrying CP
current.
The permanent reference cells shall be installed in natural soil conditions as per the
recommendations of the cell manufacturer. Installations in highly acidic/ alkaline soil and soil
contaminated by hydrocarbons shall be avoided.
All cable connections of other than cathode drainage cables to the new pipeline shall be made
by an approved exothermic process or by pin brazing. However, cable connection to charged
pipelines shall be made by pin brazing. Exothermic welding shall be adopted for water
pipelines. The resistance of the cable to pipe at the pin brazing connection point shall not
exceed 0.1 Ohm.
The cathode drainage cable shall be connected to a bolt welded to a metal plate, which is weld
connected to the pipeline. The material of the plate shall be same as that of the material of the
pipeline.
Pipe coating shall be repaired after connection of cable to pipeline. At cathode drainage point
the cable joint including the bolt, metal plate and the exposed portion of the pipeline shall be
covered by the coating repair material against ingress of water/moisture. The coating repair
material shall be compatible with the original coating and shall prevent ingress of water along
the cable surface and at the interface of coating repair with the original pipe coating.
Where specified in project specifications/data sheet chain link fencing shall be provided
around the location of each ground bed/anode lead junction box.
Field tests as per the reviewed field testing and commissioning procedures prepared by the
Contractor shall be carried out on the equipment/ systems before these are put into service.
Acceptance of the complete installation shall be contingent upon inspection and test results.
Field testing shall include but not be limited to the following:
ii) Before the electrical facilities are put into operation, necessary tests shall be carried out to
establish that all equipment and devices have been correctly installed, connected and are in
good working condition as required for the intended operation. Owner/Owners representative
may witness all tests. At least one week's intimation notice shall be given before commencing
the tests.
iii) All tools, equipment and instruments required for testing shall be provided by Contractor.
iv) Generally, the following minimum tests must be carried out and results shall be recorded:
a) Cables
Cable No.
- Voltage grade.
- Conductor cross section
Continuity check
Voltage test.
Insulation resistance values between each core & earth, between cores (between
core and earth for single core cable). All cables shall be tested by 500 V megger.
b) Reference Cell
- Location
Type of cell
Potential reading
- Installed on top/ bottom level of pipeline
c) Insulating Joint
- Location
Pipe to soil potential of both protected and non-protected sides of the insulating
joint before and after energisation of CP system
d) Surge Diverter
e) Polarisation Cell
Location/ Station
- Check for actual layout and compliance with drawings
- Resistance of each individual anode
- Current dissipation by each individual anode
Total resistance of complete anode bed
- Mutual interference
g) Polarisation Coupons
- Location
- Exposed area/ size of coupon
- Coupon to soil `ON' and `OFF' potentials
- Type of reference cell
- Magnetic reed switch rating
- Operation of magnetic reed switch with magnet
A model commissioning procedure for a three stations CP system of a pipeline is given below
for general guidance. Contractor shall develop detailed commissioning procedure as per this
guideline.
ii) Electrical continuity of the entire pipeline shall be verified in conformity with design.
iii) Input resistance of the pipeline at all the drainage points shall be checked and recorded.
iv) All current measuring test stations shall be calibrated and recorded using portable battery,
variable resistances, voltmeters, ammeters, etc. as required.
v) Temporary protection facilities provided (if any) which do not form part of permanent CP
shall be disconnected from the system & removed unless agreed otherwise.
vi) Anodes provided for grounding at the MOVs on cathodically protected portion of the pipeline
shall be disconnected. Sacrificial anode where provided for the protection of the casing pipe
at cased crossings shall be disconnected.
vii) The pipeline shall be allowed to depolarize for at least 72 hours after switching `OFF' the
protection (if any) of all other pipelines in the common ROU.
viii) Before the pipelines are put on charge by switching `ON' any of the CP stations, natural
pipeline to soil, casing pipe to soil and coupon to soil potential values at all the test stations of
the system (coupon to soil potential at the locations of the coupon installations) shall be
measured with respect to Copper/Copper Sulphate half cell.
ix) CP station no.1 shall be energised with out put potential adjusted to achieve a maximum pipe
to soil potential (PSP) as specified, at the test station nearest to the drainage point.
Observations on either spread of protected portion of pipeline and coupons under this CP
station shall be taken for PSP 'ON' and PSP 'OFF' values at each of the installed test stations
(coupon to soil potential at the locations of the coupon installations). The typical switching
cycle of current interrupter shall be 12 seconds 'ON' and 3 seconds 'OFF'. The pipeline
current values across the cross section of the pipeline shall also be determined at all the
intended test stations influenced by this station.
x) CP station no.1 shall now be switched `OFF', CP station no. 3 shall be switched 'ON' and
measurement procedure as detailed in clause ix) above shall be repeated.
xi) Similarly CP station no. 1 and 3 shall now be switched `OFF', CP station no.2 shall be
switched `ON' and measurement procedure as detailed in clause ix) above shall be repeated.
xii) All the CP stations of the system shall be switched 'OFF' and the pipelines shall be allowed to
depolarize. All the three CP stations in the system shall then be simultaneously switched 'ON'
and PSP values at the drainage points of pipeline shall be brought to a value of maximum PSP
as specified and a complete set of observations shall be taken.
Another complete set of pipe to soil and coupon to soil observations shall be taken after lines
have stayed on charge for 48 hours. If there are appreciable differences in these observations
as compared to those of earlier set, a third set of observations shall be taken after 72 hours.
Maximum drainage point protective potentials shall not be allowed to go beyond the
maximum PSP values as specified, in any case.
Coupon to soil `OFF' potential shall be measured at all locations of coupon installations by
operation of magnetic reed switch in the test station. The PSP of the coupons shall be within
the PSP range specified in clause 6 of this document.
The output of CP stations shall then be so adjusted that the sites of occurrence of least
negative protective potentials are not less negative than (-) 0.95V (OFF) and sites of
occurrence of the most negative protective potential are not more negative than (-) 1.18V
(OFF). A full set of pipe to soil, coupon to soil observations shall again be taken 72 hours
after the adjustment of potentials and the protection system shall be left in this state of
operation.
xiii) Care shall be exercised to ensure that power supply remains uninterrupted during the period
of commissioning. In case of an interruption, the test in progress shall be repeated after
allowing time for polarisation. More sets of observations shall be taken in any of the steps
specified above, if advised by the Owner/Owner's representative.
xiv) The Zinc anodes for grounding of MOVs at the locations of MOVs on cathodically protected
portion of the pipeline shall be reconnected to the MOVs.
xv) At cased crossings where casing is protected, sacrificial anodes provided for the casing shall
be connected to the casing pipe. The casing to soil potential and anode out put current shall be
measured and recorded. Where casing pipe protection is inadequate or the out put current of
the anode is more than the designed current, then additional anodes shall be provided as
required.
xvi) PSP values at each of the test stations of the existing pipelines shall be measured, plotted,
where existing pipelines run in parallel to the new pipeline, mutual interference situations
between the pipelines shall be identified and necessary mitigation measures shall be provided.
Interference situations shall also be identified and mitigated by comparing different sets of
readings taken at same test stations at different intervals of time under identical conditions
where positive potential swing is 100 mV or more.
xvii) Current readings at all the current measuring test stations shall be measured and recorded.
xviii) Final records of testing and commissioning including graphical representation of final pipe to
soil potential readings shall be compiled with interpretation in consultation with
Owner/Owner's representative and submitted.
xix) If any deficiencies are found in the system, the same shall be rectified by the contractor, at no
extra cost or time schedule impact, to the complete satisfaction of Owner/ Owner's
representative. Such deficiencies shall include mitigation of stray current electrolysis and
interference problems that may be found existing in the course of testing and commissioning.
A set of PSP observations shall also be taken during the peak of the first dry season after
commissioning the system into regular operation. Any deficiency found in the protection of
the pipeline shall be rectified by the contractor at his own cost.
xx) If it is found during commissioning that the sites of occurrence of least negative or most
negative protective potentials are less negative than (-) 0.95V (OFF) or more negative than (-)
1.18V (OFF) respectively even after 72 hours of operation, then the drainage point potentials
shall be adjusted depending upon anode ground bed currents in consultation with
Owner/Owner's representative. In any case, the protective 'OFF' potential values of pipeline
and polarization coupons shall not exceed the PSP value range specified in clause 6 of this
document, at any location on the pipeline.
xxi) The reference cell shall be calibrated minimum once in 24 hours during the commissioning.
xxii) The current dissipated by individual anodes shall be measured from the anode lead junction
box and corrected for equal dissipation to the extent possible keeping the total ground bed
current same.
10.1 Investigations shall be made for stray current electrolysis of the pipeline, mutual interference
between the pipeline and foreign pipelines/ structures, interference on foreign
pipelines/structures due to the CP of the pipeline and ground bed, interference on metallic
structures which lie in between pipeline and ground bed or near to ground bed, AC induction
on pipeline due to overhead EHV/HV lines, interference due to high voltage DC lines, HVDC
earthing system, electric traction etc.
10.2 Measurements including pipe/ structure to soil potentials and pipe/ structure currents etc. on
the pipeline/ structure being CP protected and on foreign pipelines/ structures, and ground
potential gradient etc. shall be made to investigate the current discharge and pickup locations.
In case of fluctuating stray currents, investigations shall be made continuously over a period
of time and if required simultaneously at different locations to find out the stray current
source(s). Recorders shall preferably be used for long time measurements.
10.3 Wherever foreign pipelines which may or may not be protected by an independent CP system
run in parallel to the protected pipeline, either in the same trench or very near to the protected
pipeline and are not bonded to it, investigations shall be performed for current discharge
points on both the pipelines.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
10.4 Mitigative measures shall be provided depending upon the type of stray current
electrolysis/interference. These shall include installation of bond with variable resistor,
diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment/
relocation (if possible) of offending interference source, provision of electrical shield etc.
depending on the type of interference.
10.5 Bonding with foreign pipelines/ structures as a mitigation measure shall be provided where
the owners of the foreign pipelines/ structures have no objection. Otherwise alternative
mitigation measures shall be provided. Wherever bonding is provided for mitigation, the
bonding resistor shall be adjusted for optimum value for minimum/ no interference. Galvanic
anodes installed as a mitigation measure shall be adequately sized for the life specified for
permanent CP system.
10.6 Where overhead EHV/HV transmission lines/underground electric cables cross the pipeline or
run in parallel with in or more than 25m from the pipeline, A.C. Voltage measurements shall
also be made on the pipeline to find out continuous induction of voltage. In case of the
induced voltage being beyond the safe limits, the pipeline shall be grounded in line with
clause no.7.8 above.
Where specified, contractor shall carry out a close interval `01\17`OFF' potential survey over
the entire length of pipeline by computerised potential logging method and identify the under
protected/ over protected area, any major coating damage on the pipeline, after the backfilling
has been consolidated sufficiently and CP system has stabilized. Contractor shall provide
required mitigation measures and rectify the under/ over protected zones, identify if any, the
major pipeline coating defects, required to be repaired. During the survey the reference cell
shall be calibrated minimum once in 24 hours. Detailed procedures for running this survey
shall be submitted for review.
Additional tests for detailed identification of coating defects shall be conducted by the
contractor, if specified in the project specification/ data sheets.
.4frXW 'WkciT ul
4R4Kvi fffqfq?"4-47
SPECIFICATION
FOR
EQUIPMENT / MATERIAL FOR
CATHODIC PROTECTION SYSTEM
FOR PIPELINES
r-4
AI
ISSUED AS STANDARD SPECIFICATION
0 17.07.14 NSB RC PPLATCtii SC
(OLD DOC. NO.: 6-51-0029, REV. 1)
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by
Abbreviations:
AC Alternating Current
BS British Standards
BIS : Bureau of Indian Standards
CMRI : Central Mining Research Institute
CP : Cathodic Protection
CPPSM: Cathodic Protection Power Supply Module
CPTR : Cathodic Protection Transformer Rectifier
DC : Direct Current
HV High Voltage
IS : Indian Standards
MMO : Mixed Metallic Oxide
MOV : Motor Operated Valves
NACE : National Association of Corrosion Engineers
PE : Polyethylene
PVC : Polyvinyl Chloride
ROU : Right of Use
CONTENTS
1. SCOPE 4
2. CODES AND STANDARDS 4
3. SITE CONDITIONS 5
4. EQUIPMENT/ MATERIAL SPECIFICATIONS 5
5. EQUIPMENT FOR CLASSIFIED AREAS 14
6. TESTS AND ACCEPTANCE 14
7. PACKING AND DESPATCH 17
1.0 SCOPE
This specification covers the requirements for the design, manufacture, supply and testing of
various equipment and materials for Cathodic Protection System for underground
pipelines/structures.
Requirement of cathodic protection TR units (CPTR unit) and cathodic protection power
supply modules (CPPSM) are covered in separate specifications.
2.1 All equipment and material covered in this specification shall conform to the requirements of
the latest revision of following standards:
BS 7361, Part-I Cathodic Protection- Code of Practice for Land and Marine
Applications
ASTM A518 M Corrosion Resistant High Silicon Iron Castings ASTM B418
Cast and Wrought Galvanic Zinc Anodes
2.2 In case of imported equipments standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
2.3 The equipment shall also conform to the provisions of Indian Electricity rules and other
statutory regulations currently in force in the country.
2.4 In case of any contradiction between various referred standards/ specifications/ data sheet and
statutory regulations the following order of priority shall govern:
Statutory Regulations
Data Sheets
- Job Specification
This Specification
- Codes and Standards
The equipment and materials shall be suitable for installation in locations having generally
corrosive, warm and humid or dusty atmosphere. Service conditions shall be as specified in
the project specification/ data sheet. If not specifically mentioned therein, a design ambient
temperature 40°C and an altitude not exceeding 1000 M above mean sea level shall be
considered.
All equipments/ materials shall be brand new with state of art technology and proven field
track record. No prototype equipment shall be offered.
The anode shall conform to the requirements of ASTM B843 standard. The anode shall be of
high manganese, Magnesium alloy packed with special back fill. The metallurgical
composition, potential and capacity of anode shall be as below:
i) Composition
Element Weight
Manganese 0.15 - 0.7%
Copper 0.02% max.
Silicon 0.1% max.
Zinc 2.5% - 3.5%
Aluminium 5.3% - 6.7%
Iron 0.003% max.
Nickel 0.002% max.
Calcium
Other metallic elements (Total) 0.3% max
Magnesium Balance
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
The anode shall conform to the requirements of ASTM B418 standard. The metallurgical
composition of anode, potential and capacity of anodes shall be as below. Anode of type I shall
be used for seawater, brackish water having resistivity not exceeding 10 Ohm-m and for
grounding/ earthing of pipelines. Anode of type II shall be used for ribbon anodes for
protection of carrier pipes inside casing or for application in saline soil having resistivity less
than 10 Ohm-m. The anode (other than ribbon anode) shall be packaged with special backfill.
i) Composition:
4.1.3 The anodes shall be provided with cable tail of sufficient length to reach test station/ buried
junction box, as applicable without any intermediate joint in the cable and with minimum of
0.5m cable slack provided at each anode and test station ends.
4.1.4 The anodes for grounding/ earthing or for saline soil application shall be pre packed with
special backfill adequately so that the performance of the anode is not affected by the
carbonates, bicarbonates, nitrates, etc, present in the soil. In any case, the thickness of back fill
shall not be less than 50mm on all the sides of the anode or minimum 20 Kg. net, whichever is
higher.
4.1.5 The other details of anodes shall be as shown in the applicable EIL standard drawings.
4.1.6 The anodes for grounding of cathodically protected above ground pipelines at intermediate SV
stations, pigging stations etc., grounding of motor operated valves on cathodically protected
portion of the pipeline, grounding of pipeline through polarisation cell at EHV/HV line
crossings or running in parallel etc., shall be either of block anode or ribbon type. Sizing and
quantity of anode shall be decided so as to achieve maximum total earth resistance of 5 Ohm
for each location. The anode and cable terminations shall be suitable for the anticipated fault
current at the location of installation.
Test stations shall be provided along the pipeline ROU for monitoring the performance of the
cathodic protection system.
i) Test station enclosure shall be made of sheet steel of at least 3 mm thickness and shall
be suitable for GI pipe post mounting. Test stations shall have weather proof enclosure
having degree of protection IP-55 and hinged lockable shutter. The inner and outer
surfaces of test stations shall be Epoxy painted.
ii) The resistors for control of current provided in the test stations, anode/ cathode
junction box etc. shall be of variable, grid coil type. The resistors shall be suitable for
operation over the design life for the permanent CP system specified in the project
specification/ data sheet.
iii) Number of terminals and different schemes of wiring shall be as per the applicable
EIL standard drawing. Minimum twenty percent spare terminals shall be provided in
each test station.
iv) At locations where solid state polarisation cells are provided, the test station size shall
be suitable for mounting the polarisation cell inside the test station.
v) A nameplate of Anodised Aluminium with black back ground and white letters shall
be fixed to the inner side of the test station. The nameplate shall carry the following
minimum information:
- Chainage in km
- Test station connection scheme
Distance form pipeline in metres
Direction of product flow
vi) The constructional features of test stations shall be as per the applicable EIL standard
drawings.
i) High silicon cast iron type anodes shall be center-connected hollow type or end
connected solid type. Cable to anode joint shall be reliable and long lasting for total
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL - All rights reserved
design life of anode. Composition of anodes shall be as below and shall also conform
to ASTM A518 M-86 Gr. III.
Element Weight
Silicon 14.2 - 14.75 %
Manganese 1.5% max.
Carbon 0.7% - 1.1 %
Chromium 3.25 - 5.0 %
Copper 0.5% max.
Molybdenum 0.2% max.
Iron Remainder
ii) Surface current density rating of the anode for continuous operation shall be
15 Amp./sq.m for shallow anode ground bed and 10 Amp./sq.m for deep well anode
ground beds.
iii) Anode consumption rate shall not be more than 0.2 kg./Amp-Yr
iv) The design life of anode under burial condition, at the design operating current shall
be in minimum the design life of the CP system specified in the project
specifications/data sheet.
v) For shallow anode ground bed sheet steel anode canisters of adequate size shall be
provided for each anode. Anode canisters shall be filled with petroleum coke breeze
with following specification conforming to IS: 8502, Grade-A type.
a) Chemical Composition
vi) For deep well ground beds, anodes shall be non canistered type. Calcined petroleum
coke breeze slurry conforming to clause 4.3.1 v) above shall be supplied along with
the anodes.
i) Mixed metal oxide coated titanium anodes shall be of pure titanium having substrate
composition of titanium of ASTM B-338, Grade I/ Grade II, over laid with mixed
oxide of noble metals (MMO coated). These anodes shall be dimensionally stable. The
anodes shall be centre connected sealed tubular type. The design life of anode under
burial condition, at the design operating current in minimum be the design life of the
CP system specified in the project specifications/ data sheet.
ii) The anodes shall be provided with sheet steel canisters and coke breeze as per clause
No. 4.3.1 (v) & (vi) above.
4.3.3 Each anode shall be supplied with anode tail cable connected to it, which shall be long enough
for termination on their associated anode lead junction box without intermediate joint. Anode
cable tail shall be connected/ jointed to the anode and the joint insulated at the anode
manufacturer's shop before despatch of anode.
4.3.4 For deep well ground beds steel pipe casing for active portion of the ground bed and non
metallic pipe casing for the top inactive portion of the ground bed shall be provided. The top
non metallic casing and the lower metallic pipe casing shall have threads for jointing each
other. Anode supporting pipe, anode centralisers and gas venting pipes shall be provided for
the ground bed.
Depending on the size and configuration of anode ground beds, requisite main and sub anode
junction boxes (where required) shall be supplied for each ground bed.
i) Each junction box shall have provision of termination of cable tails from individual
anodes of the ground bed and provision of connection of anode cable coming form
main anode junction box (in case of sectionalised ground bed) or from CP station
power source.
ii) Junction boxes shall have sheet steel enclosure of minimum 3 mm thickness and hinged
lockable shutters. Junction boxes shall be weather proof with degree of protection IP-
55. It shall be epoxy painted on inside and outside surface. Junction boxes shall have
anode bus of copper with nickel/ silver plated or tinned. Provision shall be made for
measurement and control of individual out going circuit/ anode current by providing
suitable shunt and resistors of grid coil type. Disconnecting links shall be provided for
each out going/ anode circuit. 30% spare out going circuits shall be provided in each
anode junction box. Terminals shall be of anti loosening type and provided with
identification labels. Each outgoing circuit shall be labelled clearly to indicate the
circuit/ sub anode junction box to which it is connected.
iii) The constructional features of junction boxes shall be as per the applicable EIL
standard drawing enclosed with the data sheet for impressed current cathodic protection
system for pipelines.
iv) A nameplate of anodised aluminium with black back ground and white letters shall be
fixed to the inner side of the junction box. The nameplate shall carry the following
minimum information:
Where output of the CP power supply unit is connected to multiple pipelines a cathode
junction box shall be supplied for providing near the pipelines at the location of connection of
the negative drainage cable to the pipelines.
i) The junction box shall have a bus bar with an incoming circuit for connecting to
negative of the CP power source and separate out going circuits for collection of
negative drainage current from each of the pipelines.
ii) The incoming circuit shall have a current measurement shunt. Each out going circuits
shall have isolation link, variable resistance of grid coil type and a current measurement
shunt. One number spare outgoing circuit shall be provided.
iii) Junction box shall have sheet steel enclosure of minimum 3 mm thickness and hinged
lockable shutters. Junction box shall be weatherproof with degree of protection IP-55.
The inside and outside surfaces of the junction box shall be epoxy painted. The
terminals shall be of anti loosening type. Proper identification labelling shall be
provided for each terminal. Each outgoing circuit label shall clearly indicate the size
and identification of the pipeline to which it is connected.
iv) A nameplate of anodised aluminium with black back ground and white letters shall be
fixed to the inner side of the junction box. The nameplate shall carry the following
minimum information:
- Chainage in km
Connection scheme
Distance form the nearest pipeline in metres
- Direction of product flow
Silver/Silver Chloride/Saturated Potassium Chloride type reference cells shall be supplied for
marshy area/ brackish water/ saline soil locations where water table is high and chloride ion
content is more than 300 ppm.
i) The reference cells shall have high accuracy and stability and maintain the same over
its design life.
ii) The permanent reference cells shall have a minimum design life of 8 years under
installed/ buried condition.
iii) The reference cell for high resistivity areas shall be suitable for the prevailing dry soil
conditions to give maximum service life.
iv) The reference cells shall be provided with cable tail long enough for connection to test
station without any joint in between.
Polarisation cell shall be a electrolytic type or solid state device as specified in project
specification/ data sheets, designed to simultaneously provide isolation for DC current and low
resistance path for AC current. The device shall require minimum maintenance. The solid state
device shall have weather proof enclosure and shall be suitable for mounting inside a test
station.
Unless other wise specified in project specification/ data sheet the DC blocking voltage shall
not be less than 1.2 volts. The DC leakage current at 1.2 volt shall not be more than 0.5 mA.
The device shall be suitable for continuously conducting maximum AC steady state current
and short time AC short circuit current expected to flow through the pipeline under the normal
operating condition/ any kind of fault on the EHV/HV line at respective sites, subject to
minimum ratings as indicated in clause 4.9.3 below.
The surge diverter when connected in parallel across the insulating joints shall protect the
insulating joint against surges coming across it due to lightening strikes, electrical faults, etc,
on the above ground portion of the pipeline. The surge diverter shall be of spark gap type. The
device shall have weatherproof enclosure suitable for out door mounting. The surge diverters
shall be of explosion proof type.
4.8.3 The minimum ratings of polarisation cells and surge diverters shall be as below unless
otherwise specified in the project specification/ data sheet.
i) Polarisation Cell
iii) The polarisation cells, surge diverters, anodes, connecting cables, cable joints, etc,
shall be adequately sized and suitable for the design life of permanent CP system. The
anodes shall be pre packed with special backfill adequately so that the performance of
the anode is not affected by the carbonates, bicarbonates, nitrates, etc, present in the
soil. In any case, the thickness of back fill shall not be less than 50mm on all the sides
of the anode.
The Polarisation Coupons shall be made from the material of the pipeline. The coupon shall
have one side exposed area of 100 mm x 100 mm unless other wise specified in project
specification/ data sheet. Cable connection of 10 mm2 and 4 mm2 shall be provided to the
coupon for connecting it to pipeline for cathodic protection and potential measurements
respectively.
Connection of coupon to pipeline shall be through a vacuum sealed magnetic reed switch
housed inside the test station. The magnetic reed switch shall be rated to carry and break
minimum 50 mA at 50 V DC.
i) The sheet steel used for fabrication shall be thoroughly cleaned and degreased to
remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then
rinsed to remove any trace of acid. The under surface shall be prepared by applying a
coat of phosphate paint and a coat of yellow zinc chromate primer. The under surface
shall be free from all imperfections before undertaking the finishing coat. After
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — AII rights reserved
preparation of the under surface, final spray painting with two coats of epoxy based
paint shall be done. Panel finish shall be free from imperfections like pinholes, orange
peels, runoff paint etc.
ii) All unpainted steel parts shall suitably treated to prevent rust formation. Copper bus
bars, interconnection copper link shall be tinned or nickel/silver coated.
4.11 Cables
4.11.1 Cables shall be of annealed high conductivity stranded copper conductor, 650/1100V grade
PVC insulated, armoured, PVC sheathed conforming to IS-1554 part-I, except for reference
cell, potential measurement and impressed current CP anode tail cables. The size of the copper
conductor of the cables shall be as below:
i) Minimum 4 mm2 for potential measurement, reference cells, 6 mm2 for current
measurement and 25 mm2 for bonding/grounding.
ii) For sacrificial anode CP system the cable size shall be minimum 6 mm2 copper for
anode tail cable from anode to buried junction box and 10 mm2 copper from buried
junction box to test station in case of temporary CP anodes. In case of sacrificial anodes
for permanent CP system the size of anode tail cable from anode to test station shall be
minimum 6 mm2 copper.
iii) For impressed current CP system the size of conductor of cables shall be based on the
current to be carried, ground bed loop resistance and shall be minimum 35mm2 copper
for positive, negative drainage cables and 10 mm2 copper for anode tail cables. The size
of CPTR unit AC incomer cables shall be of minimum 4mm2 copper conductor.
4.11.2 Impressed current CP anode tail cables shall be of minimum 10 mm2, annealed high
conductivity stranded copper conductor, single core, 650 voltage grade PE insulated,
unarmoured, PVC sheathed. Contractor may suggest cables with alternative
insulation/sheathing having proven track record for impressed current anode ground bed
application, for Owner's approval.
4.11.3 The cables for reference cells and pipeline potential measurements shall be of 4 mm2 copper
conductor, PVC insulated, Aluminium backed by mylar/ polyster tape shielded, PVC sheathed,
armoured, PVC over all sheathed type. The tape shield shall be helically applied with metallic
side down, with either side 25% overlap and 100% coverage. The minimum shield thickness
shall be 0.05 mm.
4.11.4 Cables for connecting various transducers from CPTR Unit/CPPSM to telemetry interface
junction box shall be copper conductor, PVC insulated, twisted pair with individual pair
shielded and overall shielded with Aluminium backed by mylar/ polyster tape, PVC sheathed,
armoured, PVC over all sheathed type.
4.11.5 Cable conductor sizes indicated above are minimum only and where necessary for proper
operation of the CP system higher sized cables shall be provided.
4.11.6 Length of anode tail cables shall be sufficient for routing and terminating the cable inside
anode junction box/buried junction box/test station as applicable without any intermediate
joint.
All electrical and electronic instrument enclosures and its accessories for hazardous area shall
be flame proof type.
The flame proof equipment shall meet the requirements as per IS/ IEC: 60079 and shall be
weather proof to IP-65 also as per IS/IEC:60529.
A copy of approval from local statutory authority, as applicable such as Petroleum &
Explosives Safety Organization (PESO)/ Chief Controller of Explosives (CCE), Nagpur or
Director General of Mines Safety (DGMS) in India, for the electronic instruments installed in
electrically hazardous area along with:
i) Test certificate from recognized test house like Central Institute of Mining and Fuel
Research (CIMFR)/ Electronics Regional Testing Laboratory (ERTL) etc. for flameproof
enclosure/ intrinsic safety, as specified in the data sheet, as per relevant standard for all
Indian manufactured equipments or for items requiring Director General of Mines Safety
(DGMS) approval.
ii) Certificate of conformity from agencies like Laboratorie Central Des Industries
Electriques (LCIE), British Approval Service for Electrical Equipment in Flammable
Atmospheres (BASEEFA), Factory Mutual (FM), Physikalisch-Technische Bundesanstalt
(PTB), Canadian Standards Association (CSA), Underwriters Laboratories (UL) etc. for
compliance to ATEX directives or other equivalent standards for all equipments
manufactured outside India.
6.1 Unless other wise agreed by the Engineer-in-Charge, all the equipment/ material shall be
subject to inspection by Owner/ EIL or by an agency authorised by the Owner/ EIL. A11
necessary information concerning the supply shall be furnished to EIL/ Owner's inspector.
Two weeks notice shall be given to Owner/ EIL for witnessing the final testing.
6.2 Routine tests and final acceptance tests shall be carried out at manufacturer's works under his
care and expense. Instruments and equipment required for testing shall be arranged by the
manufacturer. Final acceptance shall be subject to successful testing. Type test certificates
instead of conducting the tests may be accepted where specified in the project specifications.
i) Inspection
a) Visual inspection shall be carried out on all the anodes regarding surface finish
excessive shrinkage, cracks, cable joint to anode cone, etc.
c) The anode surface shall be free from cracks, which may reduce the performance
of the anode.
Any cracks which follow the longitudinal direction of elongated anodes shall
not be acceptable.
For transverse cracks the acceptable limits shall be furnished by the bidders
along with the offer.
d) The anode shall be free from excessive shrinkage. The following limits shall be
used:
Maximum 10% of the depth of anode or 50% of the depth of the anode core
whichever is less. The depression may be measured for the edges of one side.
The surface of the anodes shall be free from coatings and slag/ dross inclusions
etc.
The maximum deviation from straightness shall not exceed 2%.
The weight tolerance of individual anode may be taken as + 5%. The total
weight of the anodes shall not have negative tolerance.
Length + 2.5%
Width/thickness + 5%
ii) One anode per heat shall be subjected to radiographic test completely to evaluate
cracks, voids, slag inclusion etc.
At least one anode per heat shall be subject to close inspection by destructive testing
for slag inclusions, bond between the anode material and steel inserts. If the anode
fails the test, two more anodes shall be tested. If the second lot of anodes also fails the
test, all the anodes of the heat shall be rejected.
One anode sample per heat shall be subject to chemical analysis by spectrography.
Sample shall be taken in the beginning for first heat, at the end for the second heat, at
the beginning for the 3rd heat and so on.
In case the chemical compositions of the tested anode do not meet the requirements of
this specification, all the anodes of the heat shall be rejected. Vendor shall indicate
specific method of spectrography for each element (e.g. atomic absorption/ emission/
photometrics etc.).
v) Electrochemical Tests
- Open circuit potential, closed circuit potential and anode capacity test shall be
carried out for one anode per heat for a duration of 96 hours as per DNV-RP-
B401 in the synthetic sea water conforming to ASTM D1144
- Consumption rate by weight loss method
Visual examination of corrosion pattern (uneven consumption, inter granular
attack etc.)
The anode open circuit potential shall lie within (+) 10 MV and (-) 50 MV of the
guaranteed value. The anode consumption rate shall not be less than the specified
value. In case of anode closed circuit potential and/or the anode consumption rate do
not meet the acceptance criteria, all the anodes of the heat shall be rejected.
vi) Manufacturer's test reports regarding reference cell calibration shall be furnished. The
report shall also indicate the month and year of manufacture of reference cell.
i) Visual inspection
Visual inspection regarding surface finish, surface cracks & craters, shrinkage, cable
joint, measurements of dimension, weight, radiographic tests etc. shall be conducted
as Yer clause 6.3 i) above. The anode acceptance criteria shall be as specified in the
clause except that no crack in the anode shall be acceptable unless the cracks are only
superficial.
v) Spectrographic analysis
The anodes from each heat shall be tested for chemical composition by spectrographic
analysis and for homogeneity, dross inclusion, voids etc. by radiography. Destructive
tests shall be carried out where asked by owner based on the radiographic test results.
Contractor shall furnish list/ details of the tests that will be conducted by manufacturer of
anode and their acceptance criteria.
The petroleum coke breeze material shall be tested for chemical composition, bulk density,
real density, particle size and resistivity and test certificate shall be furnished.
The special back fill material for the sacrificial anodes shall be tested for composition and test
reports shall be submitted.
All equipment/ material for CP system along with one set of final drawings shall be
dispatched to site packed in wooden crates.
All the equipment shall be divided in to several sections for protection and ease of handling
during transportation. The equipment shall be properly packed for transportation by ship/ rail
or trailer. The equipment shall be wrapped in polyethylene sheets before being placed in
crates/ cases to prevent damages to finish. Crates/ cases shall have skid bottom for handling.
Special notations such as `Fragile', `This side up', `Centre of gravity', Weighe, `Owners
particulars', `PO nos.' etc. shall be clearly marked on the package together with other details
as per purchase order.
The equipment may be stored out doors for long periods before installation. The package
shall be completely suitable for out door storage in areas with heavy rain/ high ambient
temperature unless otherwise agreed.
c D(0)
ZINC
ANODE
ANODE TAIL
CABLE SILVER SOLDER CONNECTION
PVC INSULATION
DETAIL-X
NOTES: —
1. ANODE COMPOSITION, NET WEIGHT, GROSS WEIGHT, PREPACKED ANODE WEIGHT AND DIMENSIONS
(A,B,C,D,E & F) SHALL BE FURNISHED BY CONTRACTOR.
2. ANODE TAIL CABLE SHALL BE HIGH CONDUCTIVITY, STRANDED, COPPER CONDUCTOR, 650V GRADE, PVC
INSULATED, PVC SHEATHED & ARMOURED.
C D(0)
ELEMENT %WEIGHT
MS CORE
C Al 5.3-6.7(max)
Mn 0.15-0.7
Cu 0.02(max)
Fe 0.003(max)
F
Ni 0.002(max)
SECTION-AA Zn 2.5-3.5
Si 0.1(max)
ARMOUR (SHALL NOT HAVE
Ca
ELECTRICAL CONNECTION
EPDXY
COMPOUND TO ANODE) OTHER METALLIC ELEMENTS
—TOTAL 0.3(max)
MS CORE Mg BALANCE
NOTES:-
1. ANODE COMPOSITION, NET WEIGHT, GROSS WEIGHT, PREPACKED ANODE WEIGHT AND DIMENSIONS
(A,B,C,D,E & F) SHALL BE FURNISHED BY CONTRACTOR.
2. ANODE TAIL CABLE SHALL BE HIGH CONDUCTIVITY, STRANDED, COPPER CONDUCTOR, 650V GRADE, PVC
INSULATED, PVC SHEATHED & ARMOURED.
3. THICKNESS OF BACK FILL SHALL BE ADEQUATE TO SAFEGUARD THE ANODES AGAINST EFFECT OF
CARBONATES, BICARBONATES, NITRATES etc. IN SOIL. ANODES SHALL BE PROVIDED WITH MIN. 50mm.
THICK BACK FILL ON ALL THE SIDES OF THE ANODE OR MIN. 20k NET, WHICHEVER IS HIGHER.
L
M.S WIRE CORE
T
i
CABLE
AJ
SEE DETAIL -'A' SECTION-`A A'
\\ MAGNESIUM RIBBON ANODE
tkktsi...
1 17.07.14 REVISED AND REISSUED NSB RC PPL ‘9A.114 sc
ISSUED AS STANDARD
0 06.03.13 NSB RC PPL DM
(OLD DOC. NO. 7-51-0603 Rev. 3)
Rev. Prepared Checked Stds. Committee Stds. Bureau
Date Purpose Convenor Chairman
No. by by
Approved by
Format No. 8-00-0001-F4 Rev.O Copyright EIL - All rights reserved
25 25 50
CANOPY WITH
15* (APPRX.)
SLOPE ANGLE
TERMINAL
SHUTER WITH
z PLATE
H NEOPRENE GASKET
CONCEALED
LOCK
FRONT
FOUNDATION
FOUNDATION PLATE BOLT (TYP.)
WITH STIFFNER
(6 THICK)
0
4 0 0
CV GRADE LVL.
PCC (M-15) //A\
FOUNDATION ••
•
600 .%
•.•••• • i% •• --THE ENTYRY
50—r- • • SHALL BE SEALED
T25 WITH BITUMEN
(Typ.)"
1 COMPOUND AFTER
LAYING CABLE TO
5
50T PREVENT WATER
CONCRETE 600
600 ENTRY.
NOTES :-
1. THE SHUTTER SHALL BE HINGED TYPE WITH CONCEALED LOCK & SHALL HAVE DOOR GASKET TO
MAKE THE TEST STATION WEATHER PROOF (IP:55)
2. THE INNER & OUTER SURFACE OF THE TEST STATION SHALL BE EPDXY PAINTED.
3. THE NAME PLATE SHALL BE OF ANODISED ALUMINIUM WITH BLACK BACKGROUND & WHITE LETTERS
& SHALL BE FIXED TO THE INNER SIDE OF SHUTTER.
4. TEST STATION SHALL BE ERECTED WITH THEIR SHUTTERS PARALLEL TO THE LINE OF AXIS & FACING
THE PIPE LINE.
5. THE CHAINAGE OF TEST STATION SHALL BE WRITTEN WITH BLACK PAINT ON THE OUTER SIDE OF
THE FRONT SHUTTER.
6. HEIGHT OF THE TEST STATION SHOWN ABOVE GROUND LEVEL IS MINIMUM ONLY. THE
ACTUAL HEIGHT SHALL BE DECIDED BASED ON LOCAL FLOOD LEVELS TO BE ASCERTAINED.
7. CONTRACTOR SHALL FURNISH ALL THE DIMENSIONS OF THE TEST STATION.
8. ALL THE DIMENSIONS ARE IN MM.
TEST STATION
(TYP.)
TERMINALS
(TYP.)
2
6MM CABLE
4MM 2 CABLE
PIN BRAZING
IIII1
(Typ 6
4MM2 CABLE CASING
(TYP.) 6011
1
1 =
CARRIER
POTENTIAL MEASUREMENT CURRENT MEASUREMENT CASED CROSSING WITH
(CONNECTION SCHEME-A) (CONNECTION SCHEME-B) UNCOATED/UNPAINTED CASING
(CONNECTION SCHEME-C)
VARIABLE LINK
RESISTOR
VARIABLE
RESISTOR
SHUNT
2
25MM
4MM2 CABLE CABLE
ZINC GALVANIC
ANODE 25MM2 SURGE
CARRIER CASING CABLE DIVERTOR
FOREIGN PIPELINE
CASED CROSSING WITH
CROSSING INSULATING JOINT
COATED CASING
(CONNECTION SCHEME-E) (CONNECTION SCHEME-F)
(CONNECTION SCHEME-D)
2
35MM (MIN.) CABLE
TO CPTR UNIT/CPPSM
TO CPTR UNIT/CPPSM
02 03 04 05 Q3 r 05
25MM2
6011
('fYP.) CABLE
4MM2CABLE
6MM2CABLE INSULATING
JOINT
35104 2(41N.) CABLE
{ TO CPTR UNIT/CPPSM
TO CPTR UNIT/CPPSM
LINK VARIABLE
VARIABLE SHUNT 35MM1 (MIN.) CABLE
RESISTOR RESISTOR
LINK
0 1 15 1 8 1 _12 _13 _14 SHUNT
0 4ioomito
13 14 35MM2(MIN.) CABLE TO STN.
TO STATION EARTHING
02 03
2 03 4 05/6 77 8 EARTHING SYSTEM
25MM2CABLE t 05 06 07
SYSTEM
UNPROTECTED SIDE 2C
25MM ABLE
25MM2CABLE
4MM2CABLE
SURGE DIVERTOR
6MM2CABLE
INSULATING JOINT
2
35 MM (MIN.)
25MM2 CABLE CABLE
I
O
lD
TO CPPSM/CPTR UNIT
..L
BOLT CONNECTION TO PLATE 60M (TIP.)
WELDED TO PIPE UNE (TIP.) ilk AN. al. /Ilk ilk
TEST STATION
2 TO CPPSM/CPTR UNIT
2 6mm CABLE
35mm (MIN.)
CABLE 4mm2 CABLE
CATHODE JUNCTION BOX
VARIABLE SHUNT LINK
RESISTOR (TYP.) (TYP.) (Tip.)
2 ;322 02 c)2 02
016 0 ---0—
X7 18 19 020
0 0 Qi 5
011 ,12 13 14
06 ,7 08
09 _/°10
2
01 03— 05 25mm
2 CABLE
SURGE 2
DIVERTOR(TYP.) 25mm
CABLE(TYP.)
INSULATING
JOINT(TYP.) UNPROTECTED TERMINAL SIDE
REFERENCE CELL (TYP.)
FOR AUTO PSP CONTROL
LINK SHUNT
5 6 7 8
0 0 0
VARIABLE
1 2_3r1=04 RESISTOR
1 OMM2 CABLE
GALVANIC ANODES
4MM2CABLE
BURIED JUNCTION BOX (SEE NOTE-3)
-
TCP GALVANIC ANODE INSTALLATION
(CONNECTION SCHEME-L)
LINK
(TYP.) 1
8
5 SOUD STATE
POLARISATION CELL
PIPE LINE
1. NUMBER OF TERMINALS FOR TEST STATION OF DIFFERENT CONNECTION SCHEME SHALL BE AS SHOWN ON
THE RESPECTIVE SCHEME DRAWING. TEST STATION FOR ANY OTHER SCHEME SHALL PREFERABLY BE
SIMILAR TO ANY OF THE ABOVE TYPES.
2. ELECTRICAL CONNECTIONS SHALL BE CLEANED TO BRIGHT SURFACE & TIGHTENED WITH NON—OXIDE GREASE
APPLIED ON MECHANICALLY MATED SURFACE.
3. FOR SECRIFICIAL ANODE GROUND BED WHICH IS INTENDED FOR PERMANENT CP SYSTEM AND/OR TO BE
INTEGRATED WITH PERMANENT CP SYSTEM, THE LEADS OF ALL ANODES SHALL BE BROUGHT UP TO THE
TEST STATION AND SHALL BE TERMINATED INDIVIDUALLY. ACCORDINGLY, THE NUMBER OF TERMINALS FOR
TEST STATION SHALL BE DECIDED BASED ON NUMBER OF ANODES.
4. WHERE INSULATING JOINT (IJ) ON THE PIPELINE IS BURIED, THE SURGE DIVERTER MOUNTED ACROSS THE
IJ SHALL BE HOUSED SUITABLY SO THAT OPERATION OF THE SAME IS NOT AFFECTED.
5. THE DISTANCE BETWEEN TWO SUCCESSIVE PIN BRAZING POINTS SHALL BE MIN. 300MM.
PIPE LINE
BURIED JUNCTION BOX
FOR CABLE JOINT
(EPDXY FILLED)
(SEE NOTE-5)
I )
ELEVATION
PREPACKED GALVANIC
ANODE (SEE NOTE-2) 10MM2CABLE PVC INSULATED
TEST STATION ARMOURED
(SEE NOTE-5)
PIPELINE
1—ANODE TAIL CABLE
BURIED JUNCTION BOX 6MM2 PVC INSULATED
(SEE NOTE-5) ARMOURED
TO TEST
STATION
)
4MM2 PVC INSULATED
PLAN ARMOURED
BOTTOM VIEW
5. CASING PIPE, WHERE COATED AGAINST CORROSION OF EXTERNAL SURFACE, SHALL BE PROTECTED BY
GALVANIC ANODES INSTALLED AT BOTH THE ENDS OF THE CASING PIPE.
6. ANODE TYPE—I SHALL BE USED FOR SEA WATER, BRACKISH WATER OR SALINE ELECTROLYTE APPLICATION
AND ANODE TYPE—II SHALL BE USED FOR WATER, SOIL APPLICATION.
ZO
ellOWSIONIWO
MINERS
NDIA UMTE)
(A Govt. of Indio Undertaking)
DETAILS OF HIGH SILICON
CAST IRON ANODE
7-45-0610 Rev. 0
10MM2ANODE-
TAIL CABLE IN
PE CONDUIT
GAS VENT
BRAZED SPACE RING
L
PREPACKED CANISTERED ANODE
TINNED COPPER LUG
EXPOSY RESIN FILLING
MS INSERT
BRASS WASHER
WITH TREADING
ANODE TAIL
CABLE
SOLDER
FILLING
HEAT SHRINK POLYETHYLENE HIGH SILICON
SLEEVE & ANODE CAP WASHERS I IRON ANODE
4
ANODE DETAILS
CHEMICAL COMPOSITION OF ANODE (% WEIGHT): —
CARBON 317%-1.1%
MANGANESE .5%max.
SILICON .14.2%-14.75%
CHROMIUM :3.25%-5%.
MOLYBDENUM ---:0.2%max.
COPPER- :0.5% max.
IRON :REMAINDER
NOTES:-
1. ANODE FOR SURFACE AND DEEP GROUND BED APPLICATION SHALL BE IDENTICAL EXCEPT FOR
BACK FILL PREPACKING.
2. SHEET STEEL ANODE CANISTERS SHALL BE FILLED WITH PETROLEUM COKE BREEZE CONFORMING TO
IS:8502 GRADE-A TYPE. ANODES SHALL BE PROVIDED WITH MIN. 50mm. THICK BACK FILL ON ALL THE
SIDES OF THE ANODE OR MIN. 20kg NET, WHICHEVER IS HIGHER.
3. PETROLEUM COKE BREEZE SLURRY BACKFILL SHALL BE PROVIDED IN THE WELL, SURROUNDING ANODES
IN DEEP WELL GROUND BEDS.
4. ANODE TAIL CABLE SHALL BE 10 SQ. MM. HIGH CONDUCTIVITY, STRANDED COPPER CONDUCTOR,
650V GRADE, PE INSULATED, PVC SHEATED & UNARMOURED.
5. ALL THE DIMENSIONS, NET WEIGHT, GROSS WEIGHT OF THE ANODE AND ALL THE DIMENTIONS, WEIGHT
OF PREPACKED CANISTERED ANODE SHALL BE FURNISHED BY THE CONTRACTOR.
6. THE ACTIVE LENGTH `la' OF ANODE SHALL BE CONSIDERED FOR CALCULATING THE SIZE/ WEIGHT
OF ANODE.
1■
.1
0 06.03.13 ISSUED AS STANDARD NSB RC DM
(OLD DOC. NO. 7-51-0610 Rev. 3)
ANODE
LEAD ALL OPENINGS SHALL BE SEALED
JUNCTION WITH BITU MIN COMPOUND AFTER
BOX LAYING OF CABLE
GRADE LEVEL A
///\\\
ANODE TAIL CABLE 0 0-
>- O ›-
o_ O
O POLYETHYLENE CABLE
0 0
>- rn
0
co
WARNING MAT
0
O T
0
Cs( 200(TY P.) / BRICK COVER
PIPELINE
1S)1
. oz
........:I •
:•:•:- : : : : : : : . : . ... • • •
f
_ 3000 L(MIN.) MIN
(SEE NOTE-1)
CABLEWARNING MAT
BRICK COVER
100(TYP.)
CABLE LAID
IN SAND BED
NATIVE 500
BACKFILL CANISTERED ANODE
SOIL (MIN.)
500
SECTION-AA ANODE BED MARKER POST
NOTES:-
1. THE ANODE GROUND BED SHALL BE LOCATED ELECTRICALLY REMOTE FROM THE PIPE LINE WITH
MINIMUM 100 MTR. AWAY FROM THE NEAREST POINT ON THE PIPE LINE.
2. NO SPLICING SHALL BE ALLOWED FOR THE CABLES.
3. CONTRACTOR SHALL FURNISH THE DIMENSIONED DRAWING SHOWING ACTUAL QUANTITY OF ANODES FOR
EACH GROUND BED.
4. ALL UNARMOURED CABLES SHALL BE RUN THROUGH PE SLEEVES.
5. ANODE BED MARKER SHALL BE FIXED ON BOTH SIDES OF GROUND BEDS.
ETC.
6. NATIVE BACKFILL SOIL SHALL BE MOIST, FREE OF ROCKS, GARBAGE, PAPERS, PLASTICS
7. ANODES MAY BE LAID VERTICALLY IN CASE OF VERTICAL SHALLOW ANODE GROUND BED DESIGN.
8. ALL THE DIMENSIONS ARE IN MM.
0 0 c:,
REMOVABLE LINK (TYP.)
ANODE LEAD JUNCTION BOX
g1-10 0
L (SHEET STEEL OF MIN. 3MM THICK)
. _
--
mr7=D_YTh_0= o-_/Th-oct_ro
COPPER BUS BAR
BAKELITE BOARD
7 FROM POSITIVE OF RECTIFIER
+ +
F
0
0
0 G.I STEEL CONDUIT FOR
CABLE ROUTING
200
PCC FOUNDATION (M15 GRADE)
GRADE LEVEL 600(W)(MIN.)X600(L)(MIN.)
/A% X800(H)(MIN.)
125
0 600
NOTES:-
1. SHUTTER SHALL BE HINGED TYPE WITH CONCEALED LOCK. THE DOOR SHALL BE PROVIDED
WITH GASKET TO MAKE THE BOX WEATHER PROOF (IP:55)
2. INSIDE & OUTSIDE OF THE BOX SHALL BE 125 tI GALVANIZED AND 300 'u EPDXY TOP COATED.
3. THE HEIGHT OF THE JUNCTION BOX ABOVE GROUND LEVEL, INDICATED IN THIS STANDARD IS
MINIMUM. THE ACTUAL HEIGHT SHALL BE DECIDED BASED ON LOCAL FLOOD LEVELS.
4. NUMBER OF ANODE CIRCUITS SHOWN IN THIS STANDARD ARE INDICATIVE ONLY. CONTRACTOR
SHALL FURNISH DRAWING WITH ACTUAL DIMENSIONS & NUMBER OF ANODE CIRCUITS.
5. THE SIZE OF THE CONCRETE FOOTING SHOWN IS MINIMUM ONLY. CONTRACTOR SHALL PROVIDE
ADEQUATELY SIZED FOUNDATION BASED ON SOIL CONDITION AND DIMENSIONS OF ANODE LEAD
JUNCTION BOX.
6. ALL THE DIMENSIONS ARE IN MM.
OWNER : NALCO
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
415 V Switchboard
3.0 Quantity is per switchboard.
(one set of spare for each Switchboard)
3.1 Closing coil 1
3.2 Shunt trip coil 1
3.3 control fuses(all type & rating ) 10 Nos. each rating & type.
4.0 DC System(one set of spare for each DC System)
4.1 All fuse 10 nos. of each rating & type.
All cards such as input & output cards, power supply
4.2 1 no. of each rating & type.
cards, processor cards etc.
4.3 Thyristors 1 no. of each rating & type.
4.4 fuse link 10 nos. of each rating & type.
4.5 BLOCKER DIODE Two nos.
HV induction motors (one set of spare for each rating
5.0
& type)
5.1 Bearing ( DE & NDE ) one each
5.2 Terminal studs/bushing assembly one no.
MV induction motors 37 kW & above (one set of spare
6.0
for each rating & type)
6.1 Bearing set (DE & NDE) one no of each type
6.2 Terminal/ bushing one set each
NOTES:
1. The word ‘TYPE’ means the Make, Model no., Type, Range, Size/ Length, Rating, Material
as applicable.
2. Wherever % age is identified, Contractor shall supply next rounded figure.
3. The terminology used under ‘Part Description’ is the commonly used name of the part and
may vary from manufacturer to manufacturer.
4. Mandatory spares as indicated above do not cover commissioning spares.
5. Mandatory spares as indicated above do not cover two year O&M spares.
6. Mandatory spares shall be applicable for electrical items of motors / sub-packages as per
mandatory spares philosophy specified elsewhere in the bid document.
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
Post order
With Final
Sr.No. Description For For
Bids Documents
Review Records
1. Schedule of Vendor Documents *
2. List of deviations to MR requirements *
Motor start up study & voltage drop
3. calculation for finalization of XMFR * *
impedence & ACSR conductor size
4. Single line diagram (Overall) * * *
5. Single line diagram (switchboard wise) * *
6. Electrical load data * * *
7. Equipment layout * *
Cable/lighting/earthing/lightning protection
8. * *
layout
Technical details/Data sheets/GA for each
9. electrical equipments as envisaged in * *
project
Transmission line layout/route survey/pole
10. * *
drawings
GA and internal arrangement drg. for
11. * *
panels
12. Schematic/Logic diagrams * *
Interconnection/Wiring diagrams/cable
13. * *
schedules
14. Bill of material * *
15. List of recommended maintenance spares * *
16. Type Test certificates * *
17. Test certificates * *
18. Catalogues and brochures * *
19. Installation manual *
20. Operation/maintenance manual *
Format No. 1650-EIL 1650-5193 Rev. 1 Copyright EIL – All rights reserved
Post order
With Final
Sr.No. Description For For
Bids Documents
Review Records
21. QA Plan of Vendor * *
22. Inspection Plan & Testing Procedure * *
23. Equipment storage procedure at site *
24. Sag tension calculation * *
DATA REQUIRED
Notes :
1. Unless otherwise agreed, the number of copies of various drawings and documents
shall be as follows:
Vendor shall furnish soft copy of all drawings in AutoCad and all documents in MS
Office as part of final documentation
2. Vendor shall furnish Schedule of Vendor Drawings and Documents (Format EIL 1641-
1923) within 15 days after placement of FOI/TOI.
3. All technical details and documents furnished with bids shall be treated as data for
engineering. These shall however be subject to Purchaser’s review after order
placement and bidder shall comply to MR/Tender requirements without any cost &
time implication to EIL/Owner.
Format No. 1650-EIL 1650-5193 Rev. 1 Copyright EIL – All rights reserved
CONTENTS
1.0 SCOPE 3
2.0 APPLICABLE CODE AND STANDARDS 3
3.0 BASE MATERIAL 4
4.0 WELDING CONSUMABLES 4
5.0 EQUIPMENT AND ACCESSORIES 5
6.0 WELDING PROCESSES 5
7.0 BEVEL CLEANING/BEVEL INSPECTION 5
8.0 ALIGNMENT AND SPACING 6
9.0 WEATHER CONDITIONS 7
10.0 WELDING 7
11.0 HEAT TREATMENT 8
12.0 INSPECTION AND TESTING 10
13.0 REPAIRS OF WELDS 13
ANNEXURE – 1: Destructive Testing of Welded joint (Butt welds) 14
ANNEXURE-3: RADIOGRAPHY INSPECTION 21
EXHIBIT – A: ELECTRODE QUALIFICATION TEST RECORD 26
EXHIBIT-B: STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION 29
EXHIBIT – C: RECORD FORM FOR WELDING PROCEDURE QUALIFICATION TEST 30
EXHIBIT – D: RECORD FORM FOR WELDER QUALIFICATION TEST 33
EXHIBIT – E: WELDER’S IDENTIFICATION CARD 34
EXHIBIT – F: RADIOGRAPHIC PROCEDURE FOR PIPE WELDING 35
1.0 SCOPE
The requirements stated herein shall be followed for the fabrication of all types of welded
joints of carbon steel piping systems connected with the pipeline and related facilities.
The welded pipe joints shall include the following:
a) All line pipe joints of the circumferential butt welded and socket welded types.
b) Attachments of castings, forgings, flanges and other supports to pipes.
c) Welded manifold headers and other sub-assemblies.
d) Welded branch connections.
e) Joints in welded/fabricated piping components.
f) The attachments of smaller connections for vents, drain drips and other instrument
tappings.
Any approval granted by the OWNER shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
The Welding Specification Charts specified in this document shall refer to B001-000-02-42-
WSC-0001.
2.1 Abbreviations:
ANSI: American National Standards Institute
API: American Petroleum Institute
ASME: American Society of Mechanical Engineers
BS: British Standard
CRT: Cathode Ray Tube
CTOD: Crack Tip Opening Displacement
GMAW: Gas Metal Arc Welding
GTAW: Gas Tungsten Arc Welding
HAZ: Heat Affected Zone
HV: Vickers Hardness
IIW: International Institute of Welding
IQI: Image Quality Indicator
ISO: International Organization for Standardisation
MPI: Magnetic Particle Inspection
PQR: Procedure Qualification Record
SMAW: Shielded Metal Arc Welding
UT: Ultrasonic Testing
UTS: Ultimate Tensile Strength
WPS: Welding Procedure Specification
c) The electrode shall be suitable for the welding process recommended and base metal
used. Physical properties of the welds produced by an electrode recommended for the
welding of a particular base metal shall not be lower than the minimum values
specified for the base metal unless otherwise specified in Welding Specification Chart
and shall correspond to the physical properties of the class of electrode adopted. The
choice of electrode shall be made after conducting the required tests on the electrodes
as per relevant standards, and shall be the sole prerogative of the OWNER.
d) The CONTRACTOR shall submit batch tests certificates from the electrode
manufacturers giving details of physical and chemical tests carried out by them for
each batch of electrodes to be used.
e) Electrode Qualification test records shall be submitted as per the Exhibit-A (attached)
in respect of the electrodes tested by the CONTRACTOR for obtaining the approval of
the OWNER.
f) All electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration. The electrodes removed from the containers (except cellulosic
electrodes) shall be kept in holding ovens, at the temperature recommended by the
electrode manufacturer. Ovens shall be used for low hydrogen electrodes only. Out-
of-the oven time of electrodes before they are consumed shall not exceed the limits
recommended by the electrode manufacturer. The electrodes shall be handled with
care to avoid any damage to the flux covering.
g) The electrodes used shall be free from rust, oil, grease, earth and other foreign matter
which affect the quality of welding.
5.1 The CONTRACTOR shall have sufficient number of welding and cutting equipment,
auxiliaries and accessories of sufficient capacities to meet the target schedules.
5.2 All the equipment for performing the heat treatment, including transformers, thermocouples,
pyro-metres, automatic temperature recorders with suitable calibration arrangements, etc. shall
be provided by the CONTRACTOR, at his own expense and these shall bear the approval of
the OWNER. Adequate means of measuring current and voltage shall be available.
5.3 Redoing of any work necessitated by faulty equipment or operation used by the
CONTRACTOR, will be done at his own expense.
6.1 The welding processes to be employed are given in the welding specification chart attached
along with other project data sheets. Any deviation desired by the CONTRACTOR shall be
obtained through the express consent of the OWNER.
successfully done, the damaged ends shall be cut and bevelled to the satisfaction of the
OWNER, with an approved bevelling machine. Manual cutting and weld repairs of bevels is
not allowed. Should laminations, split ends or inherent manufacturing defects in the pipe be
discovered, the lengths of pipe containing such defects shall be removed from the line to the
satisfaction of OWNER. On pipes which have been cut back, a zone extending 25 mm back
from the new field bevel, shall be ultrasonically tested to the requirement of the line pipe
specification to ensure freedom from laminations. The new bevel shall be 100% visual and
100% dye penetrant/MPI tested . A report shall be written for all testing and records kept.
Seam orientation of welded pipe shall be selected to ensure that at the circumferential welds, the
longitudinal welds shall be staggered in the top 90" of the pipeline, or 250 mm whichever is the
lesser. A longitudinal joint shall pass an appurtenance of a structural element at a minimum
distance of 50 mm. Should a section of the line containing uncompleted welds fall from the
skids, the CONTRACTOR shall immediately inform OWNER.
Every effort shall be made to reduce misalignment by the use of the clamp and rotation of the
pipes to the best fit. For pipe of same nominal wall thickness the off-set shall not exceed 1.6
mm. The off set may be checked from outside using dial gauges. Any branch connection
sleeve, etc. shall be at least 150 mm from any other weld. The welds for fittings shall be so
located that the toe of the weld shall not come within 50 mm of any other weld. Cold dressing is
permissible only in cases of slight misalignment and may only be carried out with a bronze
headed hammer. Hot dressing shall not be permitted. When welding pipes of different wall
thickness (as directed by OWNER) a special transition piece shall be used. This shall have a
minimum of 1:4 taper. The welds shall be subject to both ultrasonic and radiographic
inspections.
The root gap shall be accurately checked and shall conform to the qualified welding procedure.
The use of internal line-up clamps is mandatory for pipe diameters 10" and above. However, in
some case (tie-in welds, flanges, fittings, diameter of pipe 10" and below etc.) Where it is
impossible to use internal clamps, an external line-up clamp may be used.
The internal line-up clamp shall not be released before the entire first pass has been completed.
When an external line-up clamp is used, all spaces between bars or at least 60% of the first pass
shall be welded before the clamp is released and the pipe remaining adequately supported on
each side of the joint. segments thus welded shall be equally spaced around the circumference of
the pipe. Slag, etc. shall be cleaned off and the ends of the segments shall be prepared by
grinding, so as to ensure continuity of the weld bead.
10.0 WELDING
10.1 Root Pass for Line Pipe Welding
a) Root pass shall be made with electrodes/filler wires recommended in the welding
specification chart attached along with other project data sheets. The size of the
electrodes used shall be as per the approved welding procedure.
b) Position or roll welding may be permitted. Separate procedures shall be submitted and
qualified for up hill, down hill, vertical down and roll welding. The vertical up method of
welding shall be used for the root pass of the tie-ins, special crossings, fittings and special
parts, fillet welds, repairs and when an external line up clamp is used. The down hill
welding may be used for root run welding of tie-ins and special crossings when (a) the
edges are machined or have equivalent preparation (b) internal line up clamps are used
and the fit up is geometrically and mechanically similar to one of the ordinary line
welding without misalignment or unevenness.
c) The root pass of butt joints shall be executed properly so as to achieve full penetration
with complete fusion of the root edges. Weld projection inside the pipe shall not exceed 3
mm wherever not specified by the applicable code.
d) Any deviations desired from the recommended welding technique and electrodes indicated
in the welding specification chart shall be adopted only after obtaining express approval
of the OWNER.
f) On completion of each run, craters, welding irregularities, slag etc., shall be removed by
grinding and chiselling.
g) While the welding is in progress care shall be taken to avoid any kind of movement of the
components, shocks, vibration and stresses to prevent occurrence of weld cracks.
h) Fillet welds shall be made by shielded metal arc welding process using low hydrogen
electrodes only irrespective of the thickness and class of piping. Electrode size shall not
exceed 3.25 mm diameter for socket joints. At least two passes shall be made on socket
weld joints.
b) The number of welders and the allowable welding sequences shall be as those laid down
in the qualified welding procedure specification. Once the deposit of the first pass has
been started, it must be completed as rapidly as possible, reducing interruptions to the
minimum. The welding and wire speed shall be approximately same as that established in
the qualified weeding procedure specification.
c) The pipe shall always be adequately supported and must not be bumped or shaken during
welding. The clamp shall be removed, as indicated in clause 8.0 above. Before starting
the second pass, the first pass shall be cleaned and flattened with rotating grinders.
d) The interruption between completion of the first pass and starting the second pass shall be
as stated in the procedure specification, normally not exceeding four minutes.
e) For crack prevention a top and bottom reinforcement of at least one electrode shall be
applied before lowering the pipe on the skid.
f) The welding speed selected shall enable production of a bead which is sufficiently thick
and which shows no undercutting.
g) The time lapse between second and third pass shall be as stated in the procedure
specification, normally not exceeding five minutes. After completion of the third or
following passes, welding operations may be suspended, so allowing the joint to cool
down, provided that the thickness of the weld metal deposited is equal to at least 50% of
the pipe thickness. Upon restarting, depending on the materials, wall thickness and
welding process, a preheating to atleast 100˚ C shall be carried out. Subsequent passes up
to weld completion shall be protected to avoid rapid cooling, if meteorological conditions
to dictate. Cleaning between passes shall be done carefully so as to reduce the possibility
of inclusions.
h) Electrode starting and finishing points shall be staggered form pass to pass. Arc-strikes
outside the bevel on the pipe surface are not permitted. Arc-strike or arc-burn on the pipe
surface outside the weld, which are caused accidently by electrical arcs between the
electrode, electrode holder, welding cable or welding cable round and the pipe shall be
removed by grinding in accordance with a procedure approved by OWNER and the repair
checked by ultrasonic, radiographic, magnetic particle or dye penetrant tests which the
OWNER feels necessary. The pipe wall thickness after grinding shall not be less than the
minimum thickness limit permitted for the pipe. Repair of arc strikes by welding is
prohibited.
i) The completed weld shall be carefully brushed and cleaned and shall appear free from
spatters, scales, etc. These requirements apply not only to completed welds but also to the
bare strip at least so wide as to allow full skid examination at both ends of the pipe to
allow a good ultrasonic inspection when it is required.
d) Preheating temperature shall be maintained over the whole length of the joint during
welding. Temperature indicating crayons or other temperature indicating devices shall
be provided by the CONTRACTOR to check the temperature.
a) Post weld heat treatment, wherever required for joints between pipes and fittings, pipe
body and supports shall be carried out by the CONTRACTOR at his expense as per
the relevant specifications, applicable standards and the instructions of the OWNER.
b) The heat treatment of welded joints shall be carried out as per the requirements laid
down in ANSI B31.4 and other special requirements mentioned in welding
specification charts.
c) The CONTRACTOR shall submit for the approval of the OWNER, well before
carrying out actual heat treatments the details of the post weld heat treatment
procedure as per Exhibit-B attached, that he proposes to adopt for each of the
materials/assembly/part involved.
d) Post weld heat treatment shall be done in a furnace or by using an electric resistance or
induction heating equipment, as decided by the OWNER.
e) While carrying out local post weld heat treatment, technique of application of heat
must ensure uniform temperature attainment at all points of the portion being heat
treated. Care shall be taken to ensure that width of heated band over which specified
post weld heat treatment temperature is attained is atleast as that specified in the
relevant applicable standards/codes.
The width of the heated band centered on weld shall at least be equal to the width of
weld plus 2" (50mm). The temperature gradient shall be such that the length of the
material on each side of the weld, at a temperature exceeding half the heat treatment
temperature, is atleast 2.5 rt where ‘r’ is the bore radius and ‘t’ is the pipe thickness at
the weld.
f) Throughout the cycle of heat treatment, the portion outside the heat band shall be
suitably wrapped under insulation so as to avoid any harmful temperature gradient at
the exposed surface of pipe. For this purpose temperature at the exposed surface of
the pipe shall not be allowed to exceed 400˚C.
g) The temperature attained by the portion under heat treatment shall be recorded by
means of thermocouple pyrometer. Adequate number of thermocouples shall be
attached to the pipe directly at equally spaced locations along the periphery of the pipe
joint. The minimum number of thermocouples attached per joint shall be 2 upto 10"
dia and 3 for 12" dia and above. However, the OWNER can increase the required
minimum number of thermocouples to be attached if found necessary.
i) Immediately on completion of the heat treatment, the post weld heat treatment
charts/records along with the hardness test results on the weld joints (whenever
required as per the welding specification chart) shall be submitted to OWNER for its
approval.
j) Each joint shall bear an identification number which shall be maintained in the piping
sketch to be prepared by the CONTRACTOR. The joint identification number shall
appear on the corresponding post weld heat treatment charts. The same identification
numbers shall also be followed for identification of corresponding radiographic films.
The chart containing the identification number and piping sketch shall be submitted to
the OWNER in suitable folders.
k) Vickers hardness/Brinell hardness of the heat affected zone as well as of the weld
metal, after heat treatment shall be measured using a suitable hardness tester and shall
not exceed the maximum hardness specified in the welding specification chart. The
weld joint shall be subjected to reheat treatment, when hardness measured exceeds the
specified limit, at the CONTRACTOR's expense.
l) The CONTRACTOR shall arrange for the hardness testing and shall maintain the
records of all the joints tested. These records shall be checked by the plant owner's
inspector.
b) The OWNER is entitled to depute its own inspector to the shop or field where
prefabrication and erection of pipelines are being done, with (but not limited to) the
following objectives:
a) Welding procedure qualification shall be carried out in accordance with the relevant
requirements of ASME Section IX and other job requirements by the CONTRACTOR
at his expense. The CONTRACTOR shall submit the welding procedure
specifications in format as per Exhibit-C (attached) immediately after the receipt of
the order.
b) OWNER's inspector will review, check and approve the welding procedure submitted
and shall release the procedure for procedure qualification tests. The procedure
qualification test shall be carried out by the CONTRACTOR under field conditions at
his own expense. A complete set of test results in format as per Exhibit-C (attached)
shall be submitted to the OWNER”s Inspector for approval immediately after
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
completing the procedure qualification test and atleast 2 weeks before the
commencement of actual work. Standard tests as specified in the code shall be carried
out in all cases. In addition to these tests, other tests like radiography, macro/micro
examination, hardness tests, dye penetrant examination, charpy V-notch etc. shall be
carried out on specimens. It shall be the responsibility of the CONTRACTOR to
carryout all the tests required to the satisfaction of the OWNER's Inspector. The
destructive testing of welded joints shall be as per Annexure-1.
b) The welders shall always have in their possession the identification card as shown in
Exhibit-E and shall produce it on demand by the OWNER's Inspector. It shall be the
responsibility of the CONTRACTOR to issue the identity cards after it has been duly
certified by the OWNER.
The OWNER will review all the radiographs of welds and inform the CONTRACTOR
regarding unacceptable welds. The decision of the OWNER shall be final and binding in this
regard.
All requirements mentioned in the specification shall be arranged and executed by the
CONTRACTOR through his own resources. In addition, for pipes, ultrasonic inspection is
required in the following cases as per Annexure 2 of this Specification.
a) When 25 mm or more are cut from the pipe end as supplied, the ends shall be
ultrasonically inspected for an additional length of 25mm to assure no lamination
exist.
Line Pipe - Tie-in weld Joints, welding of valves, flanges, Golden joints etc.
Radiographic examination shall be required for certain critical welding of the pipeline (i.e. tie-
ins, welding of valves, flanges etc.) which have not undergone pressure testing (this is to
ensure soundness of the total pipeline). All fillet and groove welds other than those
radiographed shall be subjected to dye penetrant/MP inspection. The non-destructive test
system used for inspecting welds must be approved by the OWNER.
Weld quality as judged on the basis of the acceptability criteria mentioned below:
ii) In addition to the API 1104 requirements, the welds containing cracks including crater
cracks regardless of size or location are unacceptable.
Lack of fusion and lack of root penetration may be permitted only up to a maximum individual
length of t, where t is nominal pipe wall thickness. Cumulative length of the defect shall not
exceed 25 mm in any 300 mm length of weld. For welds less than 300 mm length, the
aggregate length shall not exceed 8 percent of the weld length. Defects situated in line and
separated by less than the length of the shortest defect shall be considered as one defect.
However, no Lack of fusion or lack of root penetration is permitted at any intersections of
welds.
Suitable records shall be maintained by the CONTRACTOR as desired by the OWNER on the
day to day work done on welding radiography, ultrasonic testing. The CONTRACTOR shall
present the records to the OWNER on day-to-day basis and whenever demanded, for approval.
If the results are unsatisfactory, welding operations shall be suspended and may not be
restarted until the causes have been identified and the CONTRACTOR has adopted measures
which guarantee acceptable results. If it is necessary in the OWNER's opinion the procedure
shall be re-qualified. The weld joint represented by unsatisfactory welds shall stand rejected
unless investigation prove otherwise.
13.1 With the prior permission of OWNER welds which do not comply with the standards of
acceptability shall be repaired or the joint cut out and re-welded.
Root sealing or single pass repair deposit shall not be allowed. Internal root defects shall be
ground thoroughly and welded with a minimum of two passes. However, while grinding for
repairs, care shall be taken to ensure that no grinding marks are made on the pipe surface
anywhere.
The repair shall be subjected, as a minimum requirement, to the same testing and inspection
requirements as the original weld. After the repair of the circumferential weld, re-radiography
of the full joint shall be carried out. A 100% ultrasonic test shall be done at the repaired area
externally. Any repaired area that is wide, irregular or rough shall be rejected and a full cut
out shall be done.
Repairs are limited to a maximum 30% of the weld length. Welds containing cracks shall be
cut out and rebevelled to make a joint. OWNER shall authorise all repairs.
After satisfactory completion of all visual and non-destructive testing the procedure test weld
shall be set aside for a period not less than 24 hours. No further work on the test weld and no
cutting of test specimens from the weld shall be performed until a period of at least 24 hours
has expired.
Weld specimens shall be taken from the positions indicated in Figure 1 of this specification
from areas as free from defects as possible; for this reason it is necessary to take the previous
non-destructive tests into account. The minimum number of tests to be carried out is given in
Table - 1 of this specification.
The test shall be carried out at laboratories approved by the OWNER. The specimens shall be
prepared in accordance with the figures given in the paragraphs which refer to the individual
test.
1.2.1 Method
The test shall be carried out in accordance with BS EN ISO 6892-1:2009.
TABLE 1
Type and Number of Test Specimens for Procedure Qualification Test and Production Welds
PIPE SIZE, OUT
SIDE DIAMETER NUMBER OF SPECIMENS
INCHES TENSILE TENSILE NICK ROOT FACE SIDE MACRO HARDNESS IMPACT TOTAL
API ISO BREAK BEND BEND BEND
UNDER 2 0 0 2 2 0 0 0 0 0 4
2 TO 4½ 0 0 2 2 0 0 0 0 0 4
INCLUDING
OVER 4½ LESS 2 0 2 2 2 0 2 2 12 24
THAN 12¾
12¾ AND OVER 2 2 4 4 4 0 2 2 24 44
4½ AND 0 2 0 0 0 2 0 0 0 4
SMALLER
OVER 4½ LESS 2 0 2 2 2 0 2 2 12 24
THAN 12¾
12¾ AND OVER 2 2 4 0 0 8 2 2 24 44
Test pieces shall be immersed in a thermostatic bath and maintained at the test temperature for
at least 15 minutes. They shall then be placed in the testing machine and broken within 5
seconds of their removal from the batch. The test temperature shall be as per Welding
Specification Chart.
1.6.3 Requirements (Note 1)
The impact energy shall be as per the values given in the Welding Specification Charts, for full-
size test pieces. If subsize test pieces are used, the required minimum average (set of three test
pieces) absorbed energy values shall be the required values for full-size test pieces times the
ratio of the specified width of the subsize test piece to the specified width of the full-size test
piece, with such derived values rounded to the nearest joule.
Note :
(1) These values are specified for resistance to brittle fracture only. Where additional
requirements are specified in project data sheet (Ex. pipeline materials with arrest
properties i.e. a higher upper shelf charpy V energy for resistance against propagating
ductile fractures) the same shall be followed.
(2) Only one value is permitted to be lower than average value upto the value specified.
1.7 Bend Test Requirements
The Bend test Specimens shall be made and tested as per the requirements of API 1104. The
acceptance criteria shall however be as per para 5.6.4.3 and 5.6.5.3 of API 1104.However, the
dimensions of the Jig for guided bend test in Figure 8 (of API 1104) shall be modified as
specified below:
Radius of the Plunger `A' = 2t
Radius of the die. `B' = 3t + 1.6 mm
Width of the die. `C' = 50.8
Where t = thickness of the specimen
to check whether any manufacturing defects are present which could have interfered with the
ultrasonic beam.
By way of an example, the equipment shall include but not be limited to the following:
a) Ultrasonic equipment and coupling medium
b) Sample sections for calibration of instruments
c) Equipment for cleaning of surface to be examined
d) Rules calibrated in centimeters for exact location of the position of defects.
The characteristics of the above listed instruments and equipment shall guarantee:
a) That the required standards of the inspection procedure, as previously established an
approved by the OWNER, are satisfied.
b) Continuous operation
All the instruments and equipment shall be approved by the OWNER before being used. The
OWNER has the authority to reject any item that is considered unsuitable. The decision of the
OWNER is final. The CONTRACTOR appointed to carry out ultrasonic inspections shall also
ensure the operational efficiency and maintenance of the instruments and equipment, and shall
immediately substitute any item rejected by the OWNER.
All the instruments and equipment necessary for carrying out ultrasonic inspection on site shall
satisfy the requirements laid down by the public boards of institutions that regulate `safety at
work`.
1.5 Ultrasonic Instruments
The ultrasonic instrument:
a) shall be pulse echo type, able to generate, receive and display, on the screen a
Cathode Ray Tube (CRT), pulse at frequencies between 1 and 6 MHz. The useful part
of the CRT screen shall be at least 70mm wide and at least 50mm high.
shall have variable amplification, with steps of 1 or 2 dB over a range of a least 60 dB.
b) the regulation control shall be accurate to within ±1 dB and this accuracy shall be
certified by the instrument manufacturer.
c) may be powered by a battery or an electric generator. In the first case, the autonomy
of operation (endurance) of the instrument shall be sufficient to carry on working
without frequent interruptions, and the instrument shall be equipped with an automatic
switch which switches if off when the battery runs down; in the second case, there
must be a voltage stabilising device with a tolerance of ±2 Volts.
1.6 Probes
The probes used shall have dimensions, frequencies, and a refraction angle suited to the type
of steel, the diameter, and the thickness of the pipeline and to the joint design.
1.7 Reference Sample Pieces
The efficiency of the equipment used, the effective refraction angle of the probe, and the beam
output point, shall be checked using a V1 and V2 sample block, IIW type or the calibration
block ASTM E-428-08.
For manual ultrasonic testing and automated ultrasonic testing the reference sample pieces
shall be as described in API 1104.
1.8 Calibration
The calibration, qualification of the testing procedure shall be done as provided in API 1104.
1.9 Regulation of Amplification during Production Testing
Scanning sensitivity shall be as provided in API 1104.
1.10 Qualification of Ultrasonic Testing Operators
Before the inspection begins or during the same inspection, the OWNER may require a
qualification test for the ultrasonic equipment operators.
The operators shall be fully qualified as per a recognized standard (ASME Sec V or
equivalent) and they shall have as minimum level II as described in para 11.4.3, API 1104.
The operators shall be able to:
a) calibrate the equipment;
b) perform an operational test under production conditions;
c) interpret the screen picture;
d) evaluate the size and location of reflectors;
e) interpret the type of defects detected;
The OWNER has the option of checking the ability of personnel employed for ultrasonic
testing by means of qualification tests.
1.11 Evaluation of indications given by Ultrasonic Tests
Each time that echoes from the weld bead appear during production testing, the instrument
amplification shall be altered to coincide with the reference amplifications and the probe shall
be moved until maximum response is obtained, paying attention all the time to the probe-tube
coupling.
If, under these conditions, the height of the defect echo is equal to or greater than that of the
reference echo, the defect shall be evaluated according to clause 12.5 of this specification. If
the defect has also been detected by the radiographic and/or visual examination, the
dimensions shall be judged according to the type of examination which detects the greater
defect. Returns that are less than 50% of the reference echo will not be considered. If returns
are above 50% but lower than 100% of the reference echo, and if the operator has good
reasons to suspect that the returns are caused by unfavorably oriented cracks, he shall inform
the OWNER. Moreover, when there is a defect to be repaired, such defect shall be removed
for a length corresponding to the one where no more return echo is given.
1.12 Other Equipment
The use of rules calibrated in centimetres, attached if possible to the probe, for the precise
location of the position of welding defects, is recommended. Defect location is effected by
measuring the projection distance between the probe output and the reflecting surface.
The operators carrying out the tests shall have, besides the probing instrument, tools for
cleaning the pipe surface (files, brushes, etc.) as well as the coupling liquid or paste appropriate
for the temperature of the section to be examined.
3.6 All the girth welds of mainline shall be subjected to 100% radiographic examination. The
CONTRACTOR shall furnish all the radiographs to the OWNER, immediately after
processing them, together with the corresponding interpretation reports on approved format.
The details of the radiographs along with the joint identification number shall be duly entered
in a register and signed by the CONTRACTOR and submitted to the OWNER for approval.
3.7 When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each exposure
shall not exceed the values given of API 1104. The minimum film overlap, in such cases,
shall be 40mm. The ellipse exposure technique may be used on nominal pipe sizes of 2 inch
and smaller provided that the source to film distance used is a minimum of 12 inch.
3.8 Three copies of each acceptable radiographic procedure (as per Exhibit-F) and three copies of
radiographic qualification records, shall be supplied to OWNER. One set of the qualifying
radiographs on the job shall be kept by the CONTRACTOR's authorized representative to be
used as a standard for the quality of production radiographic during the job. The other two
sets shall be retained by OWNER for its permanent record.
3.9 Three copies of the exposure charts relating to material thickness, kilo voltage, source of film
distance and exposure time shall also be made available to OWNER by the CONTRACTOR.
3.10 The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiograph's
number, (2) approximate chainage of weld location, (3) whether or not the welds meet the
specified acceptance standards and (4) the nature and approximate location of unacceptable
defects observed. It must be possible to relate back to a particular butt weld and welder on
piping drawing and pipe line alignment drawing.
3.11 Each day's production of processed radiographs shall be properly packaged separately,
identified by at least the (1) date, (2) radiographic unit, (3) job locations, (4) starting and
ending progress survey stations and (5) shall include original and three copies of the daily
radiographic record. The package shall be submitted to the OWNER daily when possible, but
in no event later than noon of the following day.
3.12 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room with
controlled temperature, film viewer etc. to enable the OWNER to examine the radiographs.
3.13 The CONTRACTOR, if found necessary, may modify the procedure of radiographic
examination suiting to the local conditions prevailing. This shall, however, be subject to the
approval of the OWNER.
3.14 OWNER shall have free access to all the CONTRACTOR's work facilities in the field.
3.15 Any approval granted by the OWNER shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
4.0 RADIATION SOURCE
4.1 Radiography examination shall be carried out using X-radiations. Radiography examination by
Gamma rays using slow speed films may be allowed, at the discretion of the
CONSULTANT/OWNER in case of inaccessible joints. Radiography by Gamma ray for tie-
in-joints shall be acceptable provided Type I of ASTM E1815-08 film or equivalent is used
and the required sensitivity obtained.
4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source inside the
pipe, on the pipeline axis, with a radiation of 6.28 red. (360 ).
If it is impossible to place the radiation source inside the pipe, the weld will be inspected with
the source on the outside. An overlap of at least 40 mm at the ends of each film shall be
required to ensure that the first and last location increment numbers are common to successive
films and to establish that no part of a weld has been omitted.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
10.1 Pipeline radiographers shall be qualified in accordance with the requirement of API 1104 and
to the full satisfaction of OWNER.
10.2 Certification of all the radiographers, qualified as per 10.1 above, shall be furnished by the
CONTRACTOR to the OWNER before a radiographer will be permitted to perform
production radiography. The certificate record shall include:
i) Background and Experience Record
ii) Training Course Record
iii) Technical Examination Record
iv) Doctor's report on radiographer's Oaecuer 0-1 acquity eye test
v) Date of qualification
10.3 The radiographers shall be required to qualify with each radiographic procedure they use, prior
to performing the work assigned to him in accordance with the specification.
11.0 PRESERVATION OF RADIOGRAPHS
11.1 The radiographs shall be processed to allow storage of films without any discoloration for at
least three years. All the radiographs shall be presented in suitable folders for preservation
along with necessary documentation.
11.2 All radiographs shall become property of the OWNER.
12.0 EQUIPMENT AND ACCESSORIES
12.1 CONTRACTOR shall make necessary arrangements at his own expense, for providing the
radiographic equipment, radiographic films and all the accessories for carrying out the
radiographic examination for satisfactory and timely completion of the job.
12.2 For carrying out the mainline radiographic examination the CONTRACTOR shall be equipped
with suitable mobile/stationary type dark rooms.
These shall have all the required facilities for film processing. Film viewer used shall be
equipped with the film illuminator that has a light source of sufficient intensity and suitably
controlled to allow viewing film densities upto 4.0 without damaging the film.
13.0 RADIATION PROTECTION
13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of every
man with or near radiation sources.
13.2 The protection and monitoring shall comply with local regulations.
13.3 In view of visual hazards in the handling of Radioactive source of material, CONTRACTOR
shall be solely responsible for complying with all rules and regulations set forth by Atomic
Energy Commission or any other Government agencies of India in this regard and OWNER
shall not be responsible and shall be kept indemnified by the CONTRACTOR for default (s) of
whatever nature by the CONTRACTOR. Safety equipment as considered adequate by the
OWNER for all necessary personnel shall be made available for use and maintained for
immediate and proper use by the CONTRACTOR.
14.0 DISPLAY OF SAFETY INSTRUCTIONS
14.1 The safety provisions shall be brought to the notice of all concerned by display on a notice
board at prominent place at the work spot. The person responsible for the “Safety” shall be
named by the CONTRACTOR.
15.0 ENFORCEMENT OF SAFETY REGULATIONS
15.1 To ensure effective enforcement of the rules and regulations relating to safety precautions, the
arrangement made by the CONTRACTOR shall be open to inspection by OWNER or its
representatives.
16.0 FIRST AID AND INDUSTRIAL INJURIES
16.1 CONTRACTOR shall maintain first aid facilities for its employees and those of sub-
contractors.
16.2 CONTRACTOR shall make outside arrangements for ambulance service and for treatment of
industrial injuries. Names of those providing these services shall be furnished to OWNER
prior to start of work and their telephone no. shall be posted prominently in CONTRACTOR'S
field office.
16.3 All critical industrial injuries shall be reported promptly to the OWNER and a copy of
CONTRACTOR's report covering each personal injury requiring the attention of physician
shall be furnished to the OWNER.
17.0 NO EXEMPTION
17.1 Notwithstanding the above there is nothing in these to exempt the CONTRACTOR from the
operation of any other act or rules in force.
EXHIBIT - A
Sheet 2 of 3
Batch No. :
%C %S %P % Si % Mn % Cr % Ni % Mo Other
Welding Positions :
Base Materials :
2)
3)
Macro Test Results :
Remarks :
In combination with :
Position of welding :
Preheat temperature :
Radiography :
EXHIBIT - A
Sheet 3 of 3
Conclusions :
Sheet 1 of 1
Name of the Heat-treater:
Name of the Project : Specification Reference No.
1. General Details : 2. Furnace Details
Name of the : Type of Heating : Gas/Oil/Elec.
Equipment Res./Induction
Name of the : Type of Heating : (Tick mark)
Assembly/Part
Assembly/Part : Capacity (Size) :
Drawing No.
Material : Maximum Temp.( C) :
Method of temp. :
Measurement
Atmosphere Control :
3. Heat Treatment Cycle Details :
Changing Temp. C
Rate of heating, C/Hr
Soaking Temp. C
Soaking Time, hrs.
Rate of Cooling, C/Hr.
Mode of Cooling
4. Other Details, if any :
Notes:
The following documents shall be furnished along with the specifications :
i) Material test certificates
ii) Assembly/Part Drawing.
EXHIBIT - C
Sheet 2 of 3
EXHIBIT – C
Sheet 3 of 3
Destructive tests 1 2 3 4
Transverse tensile
Fracture location
Test temperature
Macro-examination
Hardness survey :
Hardness range :
Parent metal
weld
Notch location
Test temperature
Additional test(s) and results. e.g. chemical analysis, micro-examination, CTOD tests, Bend tests,
Nick Break test.
The statements in this record are correct. The test joints were prepared, welded and tested in
accordance with the requirements of specification.
Contractor Inspector
Position Witnessed by
Date Date
Sheet 1 of 1
Welder test certificate Test no.
Project/Contract Date
Contractor Inspector
Welder’s name
Address
Pipe material
Pipe thickness
Electrode/wire
Vertical down
Visual
Non-destructive testing
Butt joint
Fillet weld
Number of attempts
Comments
* Delete as necessary
Name :
Identification : Photograph
Date of Testing :
Valid till :
Approval of Welding :
Welding Position :
Material :
Diameter :
Wall thickness :
Sheet 1 of 1
1. Location
2. Date of Testing
4. Material
10. Filter type and placement mask, Diaphragm Lead screen etc. adjacent to radiation source
or specimen.
11. Geometric relationship (Source local spot size, max and min source strength, object to film
distance, radiation angle with respect to weld and film).
15. Processing (time temperature for development stop bath or rinse, fixation, washing, drying
etc.)
16. Density
17. Sensitivity
Figure 5
NALCO
Rev. No.
Date Purpose Prepared by Checked by Approved by
Page 1857 of 2065 Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
WELDING SPECIFICATION JOB SPECIFICATION No.
CHART FOR RAW WATER B001-000-02-42-WSC-0001
INTAKE PUMP HOUSE AND Rev.0
PIPELINE, NALCO Page 2 of 2
MATERIAL FITTINGS -
SPECIFICATIONS FLANGES -
OTHERS -
GROOVE JOINTS
BUTT OTHER THAN BUTT
ROOT PASS:AWS SFA 5.1
FILLER PASS: AWS SFA 5.5
WELDING MATERIALS E6010 (NOTE-2) ROOT PASS: FILLER PASS:
E7010-P1 (NOTE-2)
MECHANICAL PROPERTY CHARPY `V’ NOTCH VALUE: (NOTE-3) MIN: --- AVERAGE: ---
REQUIREMENTS
AT TEMPERATURE: ---
TECHNICAL NOTES:
1. FILLET JOINTS/SOCKET JOINTS SHALL BE MADE BY SMAW PROCESS USING LHE ONLY.
2. THIS WELDING SPECIFCATION CHART SHALL BE REFERRED ALONG WITH DOCUMENT NO. B001-000-02-
42-WSP-0001.
DATA SHEET
FOR
HOT CRANE
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
1.0 GENERAL
2.01 Shop/Building : *
2.02 Quantity : *
2.03 Main hoist capacity (tonnes) : *
2.04 Auxiliary hoist capacity (tonnes) : *
2.05 Span (Centre-centre runway rails)M : *
2.07 Highest position of main hook from ground floor ( M ): *
2.08 Type of crane (Single/Double girder) : *
2.09 Class of Duty (As per IS 807 & 3177) : *
2.10 Max.lift of main hook (M) : *
2.12 Hoisting CP block type/rope drum type : CP Block
2.13 Maximum lifting pull at full load : *
2.14 Maximum LT & CT pull at full load : *
2.15 Bay length (M) : *
2.16 Location (Indoor/outdoor) : *
2.17 Area classification : *
2.18 Gantry (Runway) rails size mm : *
2.19 Special Requirements (if any) : None
MANUFACTURER'S SPECIFICATIONS
(Bidder to fill up completely and submit after order)
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
3.20 HOOK
a) Name of manufacturer : *
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
3.21 PAINTING
a) Primer : *
i) Type of primer : *
ii) Number of coats of primer : *
b) Finish Painting
i) Type of finish paint : *
ii) Colour of finish paint : *
iii) Number of coats of finish paint: : *
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
ITEM :
ITEM NUMBER. :
VENDOR :
INSTRUCTIONS TO BIDDERS:
1. This proforma duly filled in shall be submitted for each item separately, alongwith the bid.
2. Since the information requested in this proforma will be utilised to assess provenness of offered model, it is in the interest of the
equipment manufacturer to pick up those cases out of total list of references which most closely match with the offered model. The
equipment manufacturer shall also ensure that each & every information asked for is furnished and the same is correct and complete in
all respects. Incorrect information furnished in this proforma shall render the bid liable for rejection.
3. While furnishing the materials, where asked for, the equipment manufacturer shall furnish ASTM equivalents also.
4. For the referred installations, the equipment manufacturer shall indicate the name of the person (alongwith his address, telephone no.,
fax no./email-id etc.) who may be contacted by the Purchaser / his representative, if felt necessary.
5. The equipment manufacturer shall also furnish along with the bid his standard reference list for the offered equipment model
manufactured and supplied by him.
6. The equipment manufacturer shall clarify the meaning of each letter / digit used in the model designation below:
1.2 Make
3 CONSTRUCTION
4 MATERIAL OF CONSTRUCTION
4.2 Impellers
email-id
JOB SPECIFICATION
(STATIC & MACHINERY EQUIPMENT)
RAW WATER INTAKE &
ASSOCIATED PIPELINE FACILITIES
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
1.0 GENERAL
1.1 Scope
This Specification covers the design criteria for the purpose of carrying out
Engineering for Procurement of rotating equipment and maintenance equipment required and
their requirements with regard to spare parts & special tools. This Job Specification shall be
applied for RAW WATER INTAKE & ASSOCIATED PIPELINE FACILITIES and any other
rotating equipment defined in contractor’s scope vide process package.
The Contractor shall use data sheets / proformas as enclosed in this section of the bid
package, for carrying out engineering for procurement at his end.
For the equipment, for which no such data sheets / proformas are furnished by PMC/Owner,
the Contractor may use his standard data sheets / proformas or of Equipment Manufacturer’s
standard data sheets/ proformas.
1.5 UNITISATION
All rotating equipment shall be unitized with respective drivers at the manufacturer’s shop
before dispatch to check fit up of equipment, alignment, location of bolt holes, interface
locations / dimensions etc.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
1.7.1 All rotating equipment, drivers, auxiliary systems, instrumentation and control
systems, shall be provided with all necessary electrical and safety devices as applicable or
required for safe and reliable operation of the unit
The Contractor in his scope of supply and work shall also include the hardware required over
and above what is specified, for safe and satisfactory operation of the equipment package.
1.9.2 Removable coupling guard shall be provided which shall be fabricated from non-
sparking material, and shall be open at the bottom to permit manual shaft rotation. The
guard shall be sufficiently rigid to withstand deflections as a result of bodily contact of
nominally 100 kgs.
1.10.1 Equipment noise level (Driver + Driven equipment train + auxiliaries) shall not exceed 88
dBA when measured at One-meter distance from the equipment skid in any direction.
1.13.1 Pumps
All pumps shall be suitable for outdoor installation. No equipment shelter is envisaged.
1.13.2 General
1.13.2.1 All other rotating equipment shall be suitable for outdoor installation and shall be
installed on ground floor (i.e. on finished floor level). No equipment shelter is envisaged.
1.13.2.2 All rotating equipment base plates shall have jacking provision for leveling and screws
for alignment.
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1.13.2.3 Only Stainless Steel shims shall be used for equipment alignment. Shim thickness shall
be minimum 3mm.
1.14.1 Equipment layout shall incorporate adequate maintenance platforms, support structures,
hand rails, material handling facilities for operational access, inspection and maintenance
of equipment, which shall be provided by Contractor. (All platform gratings, handrails, steps
etc. shall be of galvanized steel).
1.14.2 Where the equipment are installed in open area, no permanently installed maintenance
facility shall be provided.
1.14.3 For all equipment located on grade level, the height of foundation shall be minimized for
easy accessibility, when it is not possible to do so suitable working platform shall be
provided around the equipment for ease of operability and maintenance.
1.15 MATERIALS
The material of construction of the wetted parts of rotating equipment shall be as
specified in the process package.
1.16 SAFETY
1.16.1 Equipment design and engineering shall incorporate adequate safety features (as per
applicable specifications of respective equipment as well as Health, Safety and Environment
Codes & Standards applicable for the subject project) to provide protection to operating
personnel, equipment and environment.
1.16.2 Thermal relief valves shall be provided for components that may be blocked in by
isolation valves (including any cooling water return circuit piping of a cooler or a jacket).
1.16.3 All electrical components & installations, instruments shall be suitable for the electrical area
classification and grouping in which the equipment is installed.
1.17.1 Inspection and test specified in the bid package shall be carried out by the Equipment Vendor
at his works. The Contractor shall conduct inspection and witness tests of all equipment at
vendor’s works and furnish inspection and test reports to the owner.
1.17.2 Owner and/or his Consultant may participate along with the Contractor’s inspectors in any
inspection and tests. The Contractor shall notify to owner of all inspection and tests at-
least four weeks before the scheduled date of inspection and test and reconfirm the
same at least one week before the date of inspection and testing.
1.20 Maximum allowable working pressure and temperature of the equipment shall not be less
than the design pressure and temperature specified in the data sheet nor less than those
specified in specifications, codes and standards.
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1.21 Driven equipment & drivers (including gear units and couplings if any) shall be
designed to perform satisfactorily under specified start up conditions, part load operation,
maximum differential pressure operation and relief valve set pressure and up to full speed.
2.1 Pump shall be as per Standard Specification for Centrifugal Pumps (Water Service) (6-41-
0003 Rev.4) attached elsewhere in the bid package.
3.1.1 These cranes are to be installed in intake well for handling pump machinery for
maintenance or replacement. Other applications involving use of cranes during other
operation may also exist.
3.1.2 The bridge structure of overhead traveling cranes may be of box section/(double web)
fabricated plate or fabricated from rolled sections. The structure can be single girder or
double girder type. The single girder bridge is typically limited to lifting capacities upto 5T and
span lengths upto 10 meters. In case either of these values is exceeded, the double girder
bridge should be used.
3.1.3 For cranes which are to operate in areas classified as hazardous, besides ensuring that all
electrical components are certified for use in the specified hazardous areas as envisaged in
the electrical design basis/ electrical specification, materials of construction for rubbing non
lubricated metallic parts should be specified in such a way that the possibility of sparking
during operation is eliminated. This is normally done by having one part in every such pair
made from a suitable non-ferrous material such as phosphor/aluminum bronze or gun
metal. The parts thus specified are the wheels (or wheel rims) for the cross and long travel
motions and chain wheels in case of manual drives as per Standard Specifications.
3.1.4 Maintenance walkways shall be provided on both sides along the bridge girders.
3.1.5 The minimum capacity of the crane shall be the weight of the largest component to be lifted
plus design margin of ten percent as a minimum.
3.1.6 Painting shall be as per applicable painting specification enclosed with bid package
3.1.7 HOT Cranes shall be as per EIL Standard Specification for HOT Cranes (6-48-0003 Rev.4)
attached elsewhere in the bid package.
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and tackles required shall be procured along with the main equipment. The list of such
special tools & tackles shall be obtained along with the offer.
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Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
Contractor shall refer the bid package and note the following:
1. Contractor scope of supply / work shall include but not limited to the following rotating and
maintenance equipment coming in the Raw water intake & associated pipeline:
All rotating equipment & maintenance equipment shall meet the requirements specified in the
process data sheets, job specifications, etc. as enclosed elsewhere in the bid package.
Contractor shall procure the complete rotating equipment package from the respective driven
equipment vendors. The package as defined herein means as a minimum of the driven
equipment, its driver, couplings, coupling guards, common base plate, foundation bolts, local
instruments, local gauge board (as required), local control panel (as required) and other
associated auxiliaries / accessories, as specified in the bid package and as required to make
the package ready for safe & smooth operation.
2. Contractor shall procure all the equipment from the list of approved vendors as attached with
the bid package elsewhere.
3. Contractor shall carry out the following activities for procurement of Rotating
Equipment & Maintenance equipment:
3.1 Contractor shall prepare the enquiry specifications/documents for each Rotating Equipment,
maintenance equipment and materials to be purchased including spare parts for erection &
commissioning, as applicable, spare parts for one-year normal operation and special tools
and tackles.
3.2 Contractor shall fill all the required data/information in the partially filled in Equipment data
sheets formats forming part of the bid package for preparation of enquiry specifications/
documents.
3.3 Contractor shall prepare the detailed Purchase Requisition / specification for each equipment
package. Purchase Requisition / specification shall contain the following:
- Filled in Equipment Data Sheet along with performance curves (as applicable) along
with a copy of approved process data sheet (for reference)
- List of deviations (if any) to the MR specifications, specific to the equipment
- Filled in Experience Record Proforma & General reference List (to justify meeting
vendor’s & equipment’s past experience in line with inquiry requirements)
- Equipment Manufacturer’s Latest Catalogue, General Arrangement Drawing, Cross
Sectional Drawing & Schematic drawing / P&ID for the proposed model shall also be
submitted along with the above documents.
3.4 Contractor shall prepare the detailed Purchase Requisition / specification for each equipment
package.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
4. Contractor shall carry out the detailed review and approval of data sheets,
engineering & fabrication drawings and other technical data furnished by the
respective Equipment Vendors to ensure a safe, smooth and reliable operation at site.
5. Contractor shall submit to the Owner/PMC, all engineering drawings/ documents/ data as
specified in “Documents/drawings for Owner/PMC review”.
6. Contractor shall ensure that, all inspection and tests are conducted for all equipment at
Vendor’s shops/site as specified in bid package. Contractor shall also submit the schedule of
witnessed tests of all rotating equipment well in advance.
7. Contractor shall furnish a list of spares recommended by the equipment vendor for one-year
normal operation along with firm unit prices and ensure that the Spare parts for one-year
normal operation, if ordered by the Owner, are procured from equipment vendor and
supplied to the Owner.
8. Contractor shall include all the Commissioning spares as required in the equipment vendor’s
scope. Contractor shall procure the same from the equipment vendors and make it available
well before commissioning of Plant/Equipment. In case, any additional spares are consumed
during commissioning the same to be provided by the contractor at no additional cost to the
Owner.
9. A list of special tools and tackles required for all rotating equipment are to be included in
vendor’s scope of supply. Such tools/tackles shall be supplied by the vendor and shall form
part of supply by Contractor to Owner.
10. Contractor’s scope shall include complete supply, transportation of equipment package from
vendor’s shop to site, Receipt of material at site, Handling at site and arrangement for
storage at site shall be as per the requirements indicated in the Bid Document.
11. Equipment, which is transported by sea, shall have sea-worthy packing. The Contractor shall
strictly follow the recommended preservation procedures during the period of storage for all
equipment.
12. Contractor shall carry out the erection of rotating & maintenance equipment at the specified
location on the properly designed & cast foundation as per bid document.
13. Contractor shall carry out the inter-connections at all interface points such as main process
and all utility connections.
14. Contractor shall note that consumables, lubricants etc. required during erection,
commissioning & running of Rotating Equipment & Maintenance equipment, as specified
elsewhere in the bid document, shall be in Contractor’s scope. A consolidated list for
all equipment shall be provided indicating type of lubricant, grease, oil etc. giving
specifications, quantities, brand name and their Indian equivalent.
15. Contractor shall supply & install all maintenance facilities sized for handling the
heaviest single piece of equipment for maintenance. The contractor shall provide
maintenance facilities like cranes, chain pulley blocks and monorails (as deemed necessary)
for Rotating equipment. Contractor shall provide sufficient space for maintenance,
dismantling and platforms for maintenance.
16. Contractor shall carry out the pre-commissioning and commissioning activity at site for all
Rotating Equipment & Maintenance equipment.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
17. Contractor shall ensure the presence of equipment manufacturer (Vendor) at site for
checking of equipment erection and hook-up & supervision of commissioning of all Rotating
Equipment & Maintenance equipment.
Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
TECHNICAL COMPLIANCE
(Static & Machinery Equipment)
1. This Technical Compliance is a general compliance and is required to be furnished ,duly completed,
by the bidders along with the proposal. The Bidder shall indicate his reply in the space provided in
this Technical Compliance. In case space provided is not adequate, the reply may be furnished
separately under suitably numbered annexes / attachments duly referred against the comment /
query.
2. The Compliance Statements / Queries are required to be categorically confirmed / answered by
the bidder and the completely filled in Tech Compliance shall be submitted together with the Bid.
Note:
1. In case no deviations are furnished, it shall be construed that
bidder’s proposal is in total compliance to bid package
requirements.
2. Bidder shall note that vendor specific deviations to specified
design codes (API/ISO/IS/BS etc.) and related Process
Specifications shall not be considered at this stage and shall
be subject to review and approval of Owner/PMC during
detail engineering. However bidder shall note that only those
deviations to specified standards & codes (if any), shall be
permitted which are technically infeasible to meet, provided
suitable justification for the same is furnished. Deviations,
which can be complied with extra cost and or time
implication, shall not be permitted.
3. Any deviations/deletions/corrections made elsewhere in the
body of the Bidder’s proposal will not be taken cognizance of
and all such deviations shall be deemed to have been
withdrawn by the bidder.
Confirm compliance.
3 Bidder’s Categorical Confirmation
3.1 Equipment Supplier
Confirm that all rotating equipment shall be procured from
the approved vendors listed in the bid package.
3.2 Requirements to be met prior to placement of
Purchase order
Confirm that Contractor shall ensure the following
requirements while placing the orders of rotating equipment
& maintenance equipment:
(a) Ensuring that equipment meets the specified
operating conditions and meets the stipulated
technical specifications, enclosed with the bid
package.
(b) Ensuring equipment meeting the equipment
qualification criteria (EQC) as specified in the
bid package and obtaining approval of the same.
Note:
1. Bidder shall note that vendor specific deviations to specified
design codes (API/ISO/IS/BS etc.) and related Process
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved
Confirm Compliance.
3.3 Scope of supply and Work
Confirm that the Scope of supply and work considered
in the Bidder’s proposal is in total compliance to the Bid
Package-requirement including Scope of Work/Supply, Job
specification, Process Package etc. with respect to all
Rotating Equipment.
3.4 Inspection & Tests
Confirm that all Inspection & Tests as required for each
equipment, as per the Job specifications and other
documents forming part of the bid package, have been
included by the bidder, in his proposal.
3.6 Spares required for One Year Normal Operation Confirm
that the list of Operation and Maintenance spares
required for One Year Normal Operation (indicatingthe
price against each spare) as
recommended by the respective Equipment
Manufacturers have been included in the Bidder’s
proposal.
3.7 Commissioning Spares
Confirm that Commissioning Spares as required for each
equipment have been included by the bidder in his proposal.
Further in case any spare is consumed over and above the
quoted commissioning spares during start-
up/commissioning, the same shall be supplied free of cost.
3.8 Special Tools & Tackles
Confirm that Special Tools & Tackles, as required for each
Rotating Equipment, have been included by the Bidder in his
proposal.
3.9 Consumables
Confirm that first fill of all consumables, chemicals,
lubricants etc. required during erection, commissioning and
performance guarantee run of Rotating Equipment have
been included in the Bidder’s proposal.
3.10 Documents/Data required during Detailed
Engineering
Confirm that all Drawings / Data requirements as specified in
VDR attached elsewhere in the bid package shall be
furnished for review/approval/records of Owner / PMC
during detailed engineering.
NOTES:
1) Section-wise Document Control Index (DCI) is to be submitted in the prescribed format, before the kick-off meeting
(Post Order stage) for finalization of the same during kick off meeting.
DCI shall be periodically updated w.r.t. submission of drawings, review of drawings & drawings remaining for
submission etc. and shall be submitted by contractor.
Requirements indicated in respective department’s (i.e. Electrical, Instrumentation, Piping, Structural, Architecture,
General Civil, Process, Inspection etc.) vendor data forms (as enclosed with the requisition) shall be governing &
shall be the basis of formation of section-wise DCI.
2) Each vendor Drawing/Data (listed under Review & Record) shall have been reviewed by the Contractor for ensuring
strict compliance to the Bid Specification requirements and shall carry the Reviewer’s signature/seal of the
Contractor, prior to submission for PMC’s Review/Records and as Final Documentation. Drawings submitted
without Contractor’s review shall be returned.
3) Documentation pertaining to auxiliary equipment of main rotating equipment shall not be reviewed & shall form part
of the Final Documentation.
6) Contractor shall furnish hard/ soft copies to Owner directly, however only soft copy shall be submitted to EIL.
7) Ensuring compliance to the requirements of bid package specifications is the responsibility of the Contractor.
Contractor to follow the requirements stipulated in 6-78-0001 & 0002.
8) For balance requirements of documentation / data, VDR’s of respective disciplines shall be referred to & shall be
governing.
Qs/
REVISED & ISSUED AS STANDARD
4 18/10/13 M TK DB SC
SPECIFICATION
REVISED & ISSUED AS STANDARD
3 20/03/08
SPECIFICATION NK AKN VKM VC
REVISED & ISSUED AS STANDARD
2 04/09/02 NK KDS VJN GRR
SPECIFICATION
REVISED & ISSUED AS STANDARD
1 18/02/98 NK KDS SKG AS
SPECIFICATION
0 26/08/86 ISSUED AS STANDARD SPECIFICATION VK MR SNG
Standards Standards
Committee Bureau
Rev. Prepared Checked
Date Purpose Convenor Chairman
No by by
Approved by
Abbreviations:
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
BIS Bureau of Indian Standards
CG Centre of Gravity
EQC Equipment Qualification Criteria
GA General Arrangement
IC Internal Combustion
ISA Instruments Society of America
MAWP Maximum Allowable Working Pressure
MCF Minimum Continuous Flow
MCR Maximum Continuous Rating
MCS Maximum Continuous Speed
NPSH Net Positive Suction Head
NPSHA Net Positive Suction Head Available
NPSHR Net Positive Suction Head Required
OD Outside Diameter
P&ID Piping and Instrumentation Diagram
PTR Proven Track Record
VDR Vendor Data Requirements
CONTENTS
Page No.
SECTION 1 - GENERAL 4
1.1 SCOPE 4
1.2 CONFLICTING REQUIREMENTS 4
1.3 DEFINITION OF TERMS 4
1.4 EQUIPMENT QUALIFICATION CRITERIA 5
SECTION 3 - ACCESSORIES 10
3.1 DRIVERS 10
3.2 GEARS 10
3.3 COUPLING 11
3.4 BASEPLATE 11
3.5 STRAINERS 12
SECTION 1 - GENERAL
1.1 SCOPE
This specification together with the attendant Data Sheets and other specifications/attachments
to inquiry/order defines the minimum requirements for vertical and horizontal centrifugal
pumps and their accessories/auxiliaries for use in Water service. DM water, Water injection
pump, boiler feed water pumps and pumps for sea water services are not covered by this
specification.
ii. Vendor shall make all possible efforts to comply strictly with the requirements of this
specification and other specifications/attachments to inquiry/order.
In case deviations are considered essential by the vendor (after exhausting all possible efforts)
these shall be separately listed in the vendor's proposal under separate section titled as "List of
deviations/exceptions to the inquiry document". Deviation shall be listed separately for each
document with cross reference to Page No./Section/Clause No./Para etc. of the respective
document supported with proper reasons for the deviation for purchaser's consideration. Any
deviation not listed under the above section, even if reflected in any other portion of the
proposal shall not be considered applicable.
No deviation or exception shall be permitted without the written approval of the purchaser.
iii Compliance with this specification shall not relieve the vendor of the responsibility of
furnishing equipment and accessories/auxiliaries of proper design, materials and workmanship
to meet the specified start up and operating conditions.
1.3.1 The Normal operating point is the point at which usual operation is expected.
1.3.2 The Rated operating point is the point at which the vendor certifies that performance is
within the tolerances stated in this specification.
1.3.3 Maximum allowable working pressure (MAWP) is the maximum continuous pressure for
which the manufacturer has designed the equipment (or any part to which the term is referred)
when the equipment is operating at the maximum allowable temperature.
1.3.4 Maximum allowable temperature is the maximum continuous temperature for which the
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manufacturer has designed the equipment (or any part to which the term is referred) when
handling the specified liquid at the specified pressure.
1.3.5 Minimum continuous stable flow is the lowest flow at which the pump can operate
continuously without exceeding the noise and vibration limits imposed by this specification.
1.3.6 The Pressure casing is the composite of all stationary pressure containing parts of the unit,
including all nozzles, glands and other attached parts.
1.3.8 Net positive suction head (NPSH) is the total absolute suction head, in meters of liquid,
determined at the suction nozzle and referred to the datum elevation minus the vapour pressure
of the liquid in meters absolute. The datum elevation is the shaft centerline for horizontal
pumps, the suction nozzle centerline for vertical in-line pumps and the top of foundation for
other vertical pumps.
1.3.9 Net positive suction head available (NPSHA) is the NPSH in meters of liquid, determined by
purchaser for pumping system with the liquid at the rated flow and normal pumping
temperature.
1 .3 . 1 0 Net positive suction head required (NPSHR) is the NPSH in meters, determined by vendor
testing with water. NPSHR is measured at the suction flange and corrected to the datum
elevation. NPSHR at rated and other capacities is equal to the NPSH that produces a 3 percent
head drop (first stage head in multistage pumps) due to cavitation within the pump.
1 .3 . 1 1 Minimum Submergence required is the liquid level with respect to pump suction flange
face, in millimeters, determined by the vendor when testing with water for vertical pumps.
This is the level required to prevent vortex formation/ingress of air/vapour into the pump
suction resulting in loss of flow/head.
1.4.1 Unless otherwise specified elsewhere, the Equipment Qualification Criteria (EQC) specified
vide para 1.4.2 to 1.4.3 of this specification shall be applied for acceptance of the offered
pump model.
1.4.2 a) The vendor shall be an established manufacturer of centrifugal pumps having adequate
design, engineering, manufacturing and testing facility for pumps and shall be the single point
responsibility vendor for the complete centrifugal pump package.
b) The vendor shall have designed, engineered, packaged, tested and supplied in the last TEN
(10) years from the proposed manufacturing plant, at least ONE (1) centrifugal pump package
with same type of driver having similar drive power.
As minimum, this package shall have completed ONE (1) year of satisfactory operation at site
as on bid due date.
1.4.3 a) The centrifugal pump model offered shall be from the existing pump model series and shall
be from the regular manufacturing range of the vendor. The mechanical as well as the
hydraulic performance (including NPSHR) for the complete range of operation of the offered
model shall have been established in the shop test. The offered pump model shall meet the
minimum service and manufacturing experience requirements specified in clause 1.5.3 b)
below.
b) Pumps shall be identical in terms of Hydraulics and similar in terms of Power rating, Inlet
flow, Differential Head, Operating Pressure & Temperature, Speed, Number & Type of
Impellers, Mechanical Design, Materials, Bearing Span(applicable for between bearing
pumps), Column Length (applicable for vertically suspended pumps) etc. as compared to at
least ONE(l) unit of the proposed model designed, engineered, manufactured, tested and
supplied from the proposed manufacturing plant in the last TEN(10) years and the reference
unit shall have completed ONE(1) year of satisfactory operation at site as on bid due date.
In case all the above parameters are not available from single past reference, more than one
reference can be cited/considered to satisfy the above qualification requirement.
Pump Vendor shall complete the Experience Record Proforma's enclosed with the inquiry
document to amply prove that the offered equipment meet the EQC for technical acceptance.
Vendor may furnish additional information to justify that the EQC is being met. In addition,
manufacturer's catalogue and general reference list for Centrifugal Pumps shall also be
furnished alongwith the proposal.
2.1 GENERAL
2.1.1 The vendor shall assume the Unit Responsibility for equipment and auxiliary system(s)
included in his scope.
2.1.2 Pumps with constant speed drivers shall be capable of atleast 5 percent head increase at rated
condition and pump rated speed by replacing with a new impeller or impellers. Offered
impeller shall in no case be less than the minimum diameter impeller.
2.1.3 Horizontal pumps of the close-coupled, the two stage overhung, or the single stage double
suction overhung, type shall not be furnished.
2.1.4 Pumps where difference between NPSHA and NPSHR from quoted minimum flow to rated
flow is less than 1 meter (for pumps with driver rating <55KW) & 0.6 meter(for pumps with
driver rating >55KW) are not acceptable. The said NPSHR value shall correspond to the
maximum value of NPSHR from rated flow down to the recommended minimum stable flow
specified by the vendor.
2.1.5 Pumps that have stable head/capacity curves (continuous head rise to shut-off) are preferred
for all applications and are required when parallel operation is specified.
2.1.6 The pumps for parallel operation shall have characteristics suitable for capacity sharing. The
shut off head in such cases shall not be less than 110 percent of the rated head and no more
than 120 percent of the rated head in horizontal pumps and 140 percent in the case of vertical
turbine pumps.
2.1.7 The best efficiency point for the furnished impeller is preferred between the rated point and
the normal point. However in no case the rated point shall be beyond 110 percent of the best
efficiency point of the rated impeller.
2.1.8 The maximum permissible sound pressure level of the pump driver train shall not exceed 88
dBA measured at 1 meter from pump surface for the recommended range of operation.
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2.1.9 For vertical pumps, not provided with non-reverse ratchet, vendor shall describe the
precaution taken, to prevent damage due to reverse rotation.
2.1.10 Pump-Driver train shall be designed to be suitable for outdoor installation without a roof.
2.1.11 Lifting lugs/eye hooks shall be provided for ease of lifting of complete pump as well as the
heavy maintenance components of the pump (e.g. Top half casing cover of axially split pump).
2.1.12 The guaranteed parameters shall be demonstrated during shop test without any coating on
impellers or casings.
2.1.13 Pumps with variable speed drivers shall be capable of operating continuously upto 105 percent
of rated speed as well as operating briefly upto driver trip speed.
2.1.14 Casing vents alongwith vent valves, as per manufacturer standards, for all pumps shall be
provided. For all horizontal pumps, casing drain with isolation valve and flanged piping
terminated at the skid edge shall be provided. Baseplate shall also be provided with flanged
drain connection.
2.1.15 Horizontal between bearing pumps, pumps with rated flow above 500m3/h(horizontal) and
pumps with rated flow above 100m3/h(vertical) shall be considered as Large Capacity in
LCWS.
2.2.1 Maximum allowable working pressure (MAWP) for all pressure containing parts e.g. casing,
bowl, discharge head, discharge pipe, column pipe, stuffing box etc. shall in no case be less
than the maximum discharge pressure produced by the pump at shut-off (including tolerances),
at the maximum suction pressure, for the maximum impeller diameter and the maximum
continuous speed.
MAWP shall also not be less than the specified downstream design pressure.
These pressure containing parts shall be suitable for hydrostatic test pressure of 11/2 times the
MAWP.
Note: MAWP shall not be less than 10 kg/cm2G for pumps with 125# flanges (i.e. with Cast Iron
casing) & 16 kg/cm2G for pumps with 150# flanges (i.e. with Carbon Steel or Alloy Steel casing).
2.2.2 Pumps shall have suction and discharge flanges designed for same rating. Unless otherwise
stated, flanges shall be machined and drilled conforming to ANSI B16.5 standard.
2.2.4 Unless otherwise specified, all pumps shall be supplied with companion flanges with rating
conforming to applicable specification of ANSI, drilled and faced in accordance with pump
suction and discharge flanges alongwith gaskets and fasteners.
For pumps with casing material as cast iron (CI), the companion flanges shall be of slip-on
(SO) type [for flange sizes 50 mm (2 inches) & above] or socket welded (SW) type [for
flanges of size 15 mm (0.5 inches) to 40 mm (1.5 inches)] with flat face (FF) & of carbon steel
material. The gasket shall be of full face type.
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For pumps with casing material other than cast iron, the companion flanges shall be of weld
neck (WN) type with raised face (RF) & of the material compatible with piping material.
2.3.2 Shaft shall be provided with sleeves under the packing/seal and shall be locked to the shaft.
The material of sleeve shall be 12 percent chrome steel (hardened).Where the size of pump
makes the use of shaft sleeve impracticable, the shaft shall be constructed of 12 percent
chrome steel (hardened). For vertical pumps, shaft material shall be 12 percent chrome steel.
Unless otherwise specified, renewable wear ring shall be furnished at least on the casings.
Mating wear surfaces of hardenable materials shall have a difference in Brinell hardness
number of at least 50. Integral impeller wear surfaces shall have higher hardness than that of
the casing wear rings, when only casing wear rings are provided.
2.5 DYNAMICS
The following vibration limits shall be applied at rated speed and at flow of ±10 percent of
rated flow.
2.5.1 Horizontal pumps
Unfiltered vibration velocity for horizontal pumps upto 3000 rpm with antifriction bearing or
sleeve bearings when measured at the bearing housing in horizontal or vertical direction shall
not exceed 4.0 mm/sec (0.16 inch/sec).
Unfiltered vibration velocity for vertical pumps with antifriction and or sleeve bearings when
measured at the top bearing housing of pump or top bearing housing of motor or mounting
flange for measuring points upto 3 meters above the mounting base shall not exceed the
following limit:
Pumps greater than 1500 rpm = 7.0 mm/sec (0.28 inch/sec)
Pumps upto & including 1500 rpm = 5.1 mm/sec (0.20 inch/sec)
2.5.3 The vibration limits specified vide clause. 2.5.1 and 2.5.2 above shall be applied for pumps
only. The vibration limits for the drivers shall be as per their respective applicable standards.
Where respective applicable standards do not specify such limits for the associated drivers, the
driver manufacturer's recommendation shall be applied for acceptance of the driver. Such
acceptable limits shall be indicated by the vendor in their proposal.
2.6.1 Unless otherwise specified, the pump shall be supplied with packings. Stuffing box shall have
minimum five packing rings plus lantern ring. Packing ring size shall be 3/8" or larger.
2.6.2 The mechanical seal shall be of a make, duly approved by the purchaser.
2.6.3 Seal manufacturers specific recommendation shall be obtained and submitted alongwith the
proposal.
2.6.4 All auxiliaries for flushing of mechanical seal shall be in vendor's scope of supply.
2.7 BEARINGS
2.7.1 Antifriction bearings shall be of standard type and shall meet minimum L-10 rating life of
either 25000 hours with continuous operation at rated conditions or 16000 hours at maximum
axial and radial loads and rated speed.
2.7.2 The rise in bearing grease/oil temperature with continuous running of the pump shall be within
the allowable limits which shall not exceed 30°C for grease and 39°C for oil lubricated
bearings above ambient. Cooling arrangements shall be provided if required. Bearings shall be
equipped with constant level oilers, vent breather & drain point for oil lubricated
arrangements.
2.7.3 Unless otherwise specified, for vertical pumps with open shaft, the intermediate bearings /
bushings shall be suitable for operation without any lubrication during start / shut-down or
during normal operation (i.e. bearing bush material shall be of self lubricating type). Details of
line shaft bearings shall be furnished with the proposal.
2.7.4 Unless otherwise specified, for vertical pumps, thrust from the pump shall not be transferred to
the electric motor.
2.8 MATERIALS
2.8.1 The material of construction of parts shall be as specified. Vendor shall furnish the equivalent
material as per ASTM.
For impellers in cast iron or bronze construction, the tip speed shall be limited to 40
meters/sec. Unless otherwise specified, for tip speeds exceeding 40 meters/sec, the material of
impellers shall be stainless steel.
As an alternate, vendor may suggest suitable material proven for higher impeller tip speeds.
2.8.2 Unless otherwise specified in the data sheet, material test certificates (chemical and
mechanical properties) shall be supplied for impeller, shaft, shaft sleeve, wearing rings and
casings.
2.8.3 The repair of pressure castings by peening, plugging, impregnating or by the use of plastic or
cement compound is prohibited. The Inspector's prior approval shall be obtained for the repair
of castings. When authorised, repair shall be carried out in accordance with applicable ASTM
Specification. Weld repair of pressure containing parts of Cast Iron construction is not
permitted.
Pumps for Fire Water Application shall also meet the following additional requirements:
2.9.1 Pumps shall meet the requirements of TAC (Tariff Advisory Committee), NFPA (National
Fire Protection Association) etc. as specified in the data sheet. The vendor shall also be
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
2.9.2 Pumps shall be direct-coupled except in the case of engine-driven vertical turbine pumps
wherein gear drives shall be used. Belt driven pumps are not acceptable.
2.9.3 Parts of pumps like impeller, shaft sleeve, wearing ring etc. shall be of non-corrosive metal
preferably brass or bronze unless the quality of water dictates the use of special metals/alloys
which shall be insisted upon.
2.9.4 Pumps shall be capable of furnishing not less than 150 percent of rated capacity at a head not
less than 65 percent of the rated head.
2.9.5 Difference between NPSHA and NPSHR at 150 percent of the duty point shall not be less than
0.6 meters.
2.9.6 The electrical motor shall be of continuous rating type and the rating shall be 110 percent of
the power at rated point or equal to maximum BKW rated impeller whichever is higher.
2.9.7 For Diesel engine drivers, the net continuous site power available after considering the
deration due to site condition and power losses, due to other parasitic loads and engine driven
auxiliaries shall be higher of the following two values:
(a) 20 percent in excess of the maximum BKW required to drive the pump at rated condition.
(b) Maximum BKW rated impeller as indicated by the manufacturer in the pump data sheets.
SECTION 3 - ACCESSORIES
3.1 DRIVERS
3.1.1 Electric motor drivers shall have a maximum continuous rating (MCR) (i.e. service factor
equal to 1) not lower than the following unless higher rating is dictated by the Note 1.
Motor Name plate Rating Motor MCR (% of Pump Rated BKW)
Less than 22 kW To suit maximum BKW indicated on pump data
sheet or 125% of rated pump BKW, whichever is
higher.
22 kW - 55 kW 115% of rated pump BKW.
Higher than 55 kW 110% of rated pump BKW.
Note :
1. The motor namelpate rating for pumps under parallel operation shall not be less than the
max. BKW indicated on pump data sheet (the power at End of the curve for the rated
impeller) or shall have the specified margin as per this clause whichever is greater. The
pump motors shall also be suitable for start-up under open discharge valve condition.
3.1.2 Steam Turbine rating shall be at-least 110% of rated pump BKW (unless higher rating is
dictated by Note 1 above) at the rated speed with coincident minimum inlet & maximum
exhaust steam conditions. As a minimum, steam turbine rating shall be equal to motor rating
(IS).
3.2 GEARS
Wherever right angle gear box are required the same shall be supplied non-reversible ratchet
and shall allow for vertical adjustment of the impeller. Further the gearbox shall be suitable
for absorbing the maximum thrust under any case of operation.
3.3 COUPLING
3.3.1 Unless otherwise specified, connection between pump and driver shall be made by a flexible
metallic coupling.
A spacer (127 mm minimum normal length), shall be used to permit the removal of coupling,
bearings, seal and/or rotor as applicable without disturbing the driver, the suction and
discharge piping, or the casing top cover, for all horizontal pumps.
It shall be the responsibility of the pump vendor to obtain purchaser's approval for the selected
coupling, its make and rating.
However, unless otherwise specified, the coupling shall be rated using a service factor of not
less than 1.25 for flexible element coupling.
3.3.2 Whether or not pump vendor is required to supply the driver, he shall still deliver the fully
machined coupling assembly alongwith the pump. The driver shaft dimensions and tolerances
shall be furnished by the Purchaser to the pump vendor.
3.3.3 Removable coupling guard shall be provided which shall be fabricated from non-sparking
material, and shall be open at the bottom to permit manual shaft rotation. The guard shall be
sufficiently rigid to withstand deflections as a result of bodily contact of nominally 100 kgs.
3.4 BASEPLATE
3.4.1.1 Baseplate shall extend under the pump, gear box and motor/turbine driver and shall be fully
machined for mounting the above equipment. Baseplate shall be steel fabricated and shall have
sufficient rigidity to avoid vibration and distortion. Baseplate shall be so designed as to
facilitate proper grouting (Vent holes where required shall be provided). Baseplate shall be
cleaned (sand blasted) inside and outside and coated with suitable anticorrosion paint.
3.4.1.2 The baseplate shall be provided with lifting lugs for at-least a four point lift. Lifting the
baseplate complete with all equipment mounted shall not permanently distort or otherwise
damage the baseplate or machinery mounted on it.
3.4.1.3 For driver trains over 75 kW, alignment positioning screws shall be provided for each drive
element to facilitate longitudinal and transverse horizontal adjustments. The lugs holding these
positioning screws shall be attached to the baseplate so that they do not interfere with the
installation or removal of the drive element.
3.4.1.4 Vertical leveling screws, spaced for stability shall be provided on the outside perimeter of the
baseplate. These shall be numerous enough to carry the weight of the baseplate, pump, gear-
box (if any) and driver without excessive deflection.
3.4.2.1 Vertical pumps shall have the manufacturer's standard mounting arrangement.
3.4.2.2 Alignment positioning screws shall be provided for 18.5 kW and above and as per
manufacturer's standard practice for lower ratings.
3.4.2.3 Unless otherwise specified, mounting plate for vertical pumps shall be made from
IS:2062/IS:2002 plate material with a thickness of 48 mm. Mounting plate shall be supplied
with gaskets & fasteners.
3.5 STRAINERS
Unless otherwise specified, all vertical pumps shall be provided with suction strainers of SS-
316 material.
4.1 GENERAL
4.1.1 Unless otherwise specified, all pumps shall be inspected and all tests shall be witnessed by the
Purchaser or by the Purchaser's authorised representative.
4.1.2 Purchaser's or their authorised representative shall have access to the plant including sub
vendors plants where work on or testing of equipment is being performed.
4.1.3 No surfaces of parts of pumps are to be painted until the inspection is completed.
4.1.4 Vendor shall give to the purchaser atleast 15 days notice prior to commencement of testing.
Vendor shall carry out all running tests and mechanical checks and satisfy himself prior to
purchaser's arrival for inspection and shall maintain desired log of tests.
4.1.5 Acceptance of shop test shall not constitute a waiver of requirement to supply equipment as
per specification and/or to meet field test under operating condition, nor does inspection
relieve the manufacturer of his responsibility in any way whatsoever.
4.2 TESTS
As a minimum following tests shall be performed. The basic reference standard shall be the
latest edition of Hydraulic Institute Standard or IS:5120.
4.2.1.1 Pressure casings including column pipe and discharge head shall be hydrostatically tested with
water at ambient temperature at 11/2 times the maximum allowable working pressure specified
in the data sheet.
4.2.1.2 Jackets for bearing, stuffing box, coolers, etc, shall be tested at 8 Kg/cm2g or 11/2 times the
maximum allowable jacket working pressure whichever is higher.
4.2.1.4 Hydrostatic test is under non-witness category & only review of manufacturer's shop test
reports is required.
4.2.2.1 Unless otherwise specified, performance test for Horizontal pumps for General Water
Services GWS shall be carried out as per following:-
Pumps with drivers upto 55KW Non witnessed. Only review of
manufacturer's shop test reports are
required
Pumps with drivers from 55KW to One pump per tag/item no. to be witnessed
160KW
Pumps with drivers above 160 KW All pump units in an item to be witnessed
However, in case of vertical pumps & for pumps for Large Capacity Water Services(LCWS) ,
all pumps in a tag needs to undergo witnessed performance test.
4.2.2.2 Unless specifically agreed upon, pump shall be tested at the rated speed specified in the data
sheet with calibrated motors, at least for four hours. During the four hour run test, complete
data including pressure, capacity, power, vibration levels, bearing temperatures and noise
levels shall be recorded and guaranteed parameters verified.
Prior to start of test, manufacturer shall furnish the certificate of latest calibration / re-
calibration of driver and measuring instruments. Unless electrical or mechanical failure occurs,
driver used for shop testing need not be recalibrated and original calibration certificate shall
remain valid. Duration of recalibration for all measuring instruments shall be as per the
recommendations of HI Standards and/or relevant standards of the country of origin of the
pump manufacturer.
4.2.2.3 The pump shall be tested with water at ambient temperature. Suitable rust inhibitor shall be
added in the water used during any internal testing / performance testing of the pumps, to
prevent rusting of pump internals.
4.2.2.4 The performance test for the pumps shall be in accordance with Indian Standard IS:5120
latest edition and the tolerance of the guaranteed parameters shall be as follows:
4.2.2.5 For fire water application all engine driven horizontal and vertical pumps shall be subjected to
a 4 hour complete unit string test at the pump vendor's works during which mechanical
performance of the train shall be verified, in terms of vibration, bearing/oil temperature,
engine parameters and controls.
In case multiple units are ordered, only one number of diesel engine and gear box unit (if
used) may be brought to the pump vendor shop for complete unit (string) test for the fire water
pump unit. For the remaining pumps, complete unit (string) need not be done. However, any
modification required to be done on the first unit shall be uniformly done on the remaining
units also for proper unitization of the same at site.
4.3 If it is necessary to dismantle a pump after the performance test for the sole purpose of
machining impellers to meet the tolerances for differential head, no re-test will be required
unless the reduction in diameter exceeds 5 percent of the original diameter. The diameter of
the impeller at the time of shop test, as well as the final diameter of the impeller, shall be
recorded on a certified shop test curve that shows the operating characteristics after the
diameter of the impeller has been reduced.
4.4 If it is necessary to dismantle a pump for some other correction, such as improvement of
power, NPSH, or mechanical operation, the initial test will not be acceptable, and the final
performance test shall be run after the correction is made.
4.5.1 After all tests are completed and after inspection is made, all exposed mechanical surfaces and
all internal parts shall be thoroughly coated with a rust preventive. All exterior parts of the unit
except machined surfaces shall receive one prime coat and one coat of vendor's standard
enamel.
4.5.2 All flanges, nozzles shall be blanked off. All untapped openings shall be provided with
substantial wood or metal closure. The ends of small piping may be sealed with tape.
4.5.3 The pump shall be supplied with a nameplate containing the following information:
-Purchaser's Item No.
-Manufacturer's Name
-Type and Serial No
-Speed.
The nameplate shall be of stainless steel and relevant information shall be punched into the
same.
4.5.4 All auxiliary, dismantled and packed separately shall be properly marked with the Item No. for
which it is intended by means of metal tag.
4.5.5 Pump with auxiliary shall be suitably packed, fastened to avoid damage during transit and
crated for shipment and storage for a period of 12 months. Lifting, unpacking and handling
instructions shall be securely attached to the exterior of the largest packing in a well marked
weather proof container. The upright position of lifting points, gross weights and dimensions
be clearly marked on each package. Each package shall clearly identify the equipment
contained therein. If any extra precaution is to be taken by the Purchaser for storage beyond 12
months the same shall be explicitly indicated in the operation and maintenance manuals.
i) A specific statement that the scope of supply, the offered equipment/systems and all its
components are in strict accordance with the data sheets, job specifications, this
specifications and all other attachments, except for specific deviations as listed in the
proposal.
5.2.1 General
5.2.1.1 Drawings and data as required after purchase order has been specified in Vendor Data
Requirement. Vendor to note that the drawing/document descriptions/titles as given in the
Vendor Data Requirement are generic in nature. It is possible that against one
drawing/document specified there are several drawings to be furnished by the vendor or vice
versa.
Vendor shall complete & forward a document "DOCUMENT CONTROL INDEX" to the
purchaser (Destination & contact person as per order).
This document shall list out in consolidated form all drawings and documents required by
purchaser (As specified in Data Sheets, Specifications and Vendor Data Requirement forms
enclosed with the order).
Against each drawing/document vendor shall indicate the vendor's drawing numbers, titles,
Rev. No., category (whether for information or approval) and schedule of submission.
This shall be the first document to be submitted by vendor within two weeks of order.
No drawing shall be taken up for review till DCI for the inquiry/order is finalized by
vendor.
5.2.1.2 All transmittal letters (covers), drawings and data shall have a title block (in addition to
vendor's standard title block) which shall as a minimum contain the following contract
information:
i) Purchaser's and Consultant's Corporate Name
ii) Project Name.
iii) Equipment Name and Item No.
iv) Purchase Order No.
v) Purchase Requisition No.
Title Block on drawings shall be placed on the lower right hand corner.
5.2.1.3 All vendor data/drawings/documents shall be in English Language and in Metric Systems.
5.2.1.4 Data specified in the VDR is the minimum requirements of Purchaser. Any additional
document/data required or requested by Purchaser for engineering or construction shall also be
made available by the vendor.
5.2.1.5 Whether or not specified the vendor shall furnish the following, before shipment:
As built running clearances and when applicable; thrust bearing, radial bearing and
seal running clearances.
A supplementary list of spare parts other than those included in his original proposal.
The supplementary list shall include recommended spare parts, cross-sectional or
assembly type drawings, parts numbers, materials, prices and delivery period. The
vendor shall forward this supplementary list to the purchaser promptly after receipt of
the reviewed drawings and in time to permit order and delivery of parts before field
start-up.
- A parts list for all equipment supplied. The list shall include pattern, stock, or
production drawing numbers and materials of construction. The list shall completely
identify each part so that the purchaser may determine the interchangeability of the
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
parts with other equipment furnished by the same manufacturer. Standard purchased
items shall be identified by the original manufacturer's name and part number.
At least 8 weeks before shipment, the vendor shall submit his preservation, packaging
and shipping procedures to the purchaser's for his review.
5.2.4 Drawings
5.2.4.1 The number of prints and/or reproducible required and the times within which these are to be
submitted by vendor are specified in Purchaser's inquiry/order.
If specified, drawing review may be through EDMSNDOCS in soft as per the details provided
elsewhere in the inquiry document.
5.2.4.2 The purchaser's review of the vendor's drawings shall not constitute permission to deviate
from any requirements in the purchase order/specifications unless specifically agreed upon in
writing. After the drawings have been reviewed, the vendor shall furnish certified copies in
the quantity specified. All drawings must be clearly legible and shall be folded to 216 mm x
279 mm (8'/2" x 11") size. All transparencies shall be rolled.
5.2.4.3 Drawings/documents with following titles shall contain as a minimum the following
information:
a) General Arrangement Drawing
A general arrangement drawing shall indicate:
i) Outline dimensions (minimum three views) (All principal dimensions).
ii) Allowable forces and moments on suction and discharge nozzles.
iii) Location (in all three planes), size, type, rating and identification of all purchaser's
interface connections including those of vents, drains lubricating oil, sealing fluid,
cooling water, steam & Electrical/Instrumentation.
Direction of rotation viewing from the driving end.
Weight of each assembly/component.
The weight & location of center of gravity of the heaviest assembly/components
that must be handled for erection.
Identification and weight, dimensions of the heaviest assembly / subassembly /
component required to be handled for maintenance.
Maintenance clearances and dismantling clearances.
Speeds of Driven Equipment and driver and driver rating. Location of driver
terminal box (in case of Electric Driver)
Layout of auxiliary equipment and operating platform.
Make, Type and Size of couplings and the location of guards and their coverage.
A list of reference drawings if any.
A list of any special weather-protection and climatic features.
b) Foundation Drawings
A foundation drawing shall indicate complete information required for foundation design
by purchase including the following:
i) Foundation bolt sizes, pipe sleeve details, pocket sizes and locations and also
distance between the first/ nearest anchor bolt and pump suction and discharge
nozzle centrelines.
ii) Grouting thickness and other necessary technical details.
iii) Static weight of each skid/independently grouted item and location of center of
gravity of each of such skid/items in all three planes.
iv) Weight distribution for each bolt/subsole plate location and total static weight.
v) Dynamic loading caused due to various items grouted independently.
vi) The direction and magnitude of unbalance forces and moments generated by each
such item at the worst operating condition and short circuit moments of motor
drivers at the C.G. of the pump-motor baseplate.
vii) GD2 value of each item resolved to driver speed.
viii) Maximum permissible amplitude of vibration on the foundation at base level.
ix) Total mass of rotating parts.
x) Total mass of reciprocating parts.
xi) Suggested dynamic factor and ratio of foundation weight to weight of
skid/equipment as per vendor experience.
5.2.5.1 The vendor shall provide complete performance curves to encompass the map of operations,
with any limitations indicated thereon.
5.2.5.2 All curves submitted prior to final performance testing shall be marked "PREDICTED". Any
set of curves resulting from a test shall be marked "TESTED".
5.2.5.3 Certified test curves and data shall be submitted within 15 days after testing and shall include
head, power recalculated to the proper specific gravity and efficiency plotted against capacity.
If applicable, viscosity corrections shall be indicated. If NPSHR test is specified, the water
NPSHR curve (drawn upto minimum continuous flow) shall also be included. The curve sheet
shall include the maximum and minimum diameters of the impeller design supplied, the eye
area of the first stage impeller, the identification number of the impeller or impellers and the
pump serial number.
5.2.6.1 The Vendor shall provide completely filled in data sheets, first for "as purchased" and then for
"as built". This shall be done by the vendor correcting and filling out the data sheets and
submitting copies to the purchaser.
5.2.7.1 Technical Data Manual/Mechanical Catalogue is a compilation of "as built" drawings and
data, manufacturing and test records, installation, operating and maintenance instructions.
5.2.7.2 Not later than two weeks after successful completion of all specified tests, the vendor shall
furnish the required number of Technical Data Manual/Mechanical Catalogues for the
equipment, any auxiliaries and instruments that the vendor is providing. The Technical Data
Manual/Mechanical Catalogue shall include the following documents as a minimum:
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL —All rights reserved
i) All drawings and data as listed in the vendor data index & schedule. (For drawings, where
purchaser's approval is required, the final certified drawings shall be attached.)
Sections shall be organised in a manner that data & drawings related to one subject is
grouped together such as Mechanical, Electrical, Instrumentation etc.
ii) All manufacturing, inspection and test data and records.
iii) Installation and Instruction Manual
The vendor shall provide sufficient written instructions, including a cross-reference list of
all drawings, to enable the purchaser to correctly install the equipment and prepare the
equipment for start-up. It shall include any special information required for proper
installation that is not on the drawings, special alignment or grouting procedures, utility
specifications (including quantity) and all installation data. It shall also contain the
following information:
(a) Instructions for erecting, piping, aligning (including the expected thermally
induced shaft centerline shift between normal site ambient temperature position
and that at normal equipment operating temperature).
(b) A description of rigging procedures, including the lifting of the assembled
equipment, and methods of disassembly, repair, adjustment, inspection and
reassembly of the equipment and auxiliaries.
(c) Pre-commissioning/commissioning/functional test procedures and acceptance
criterion.
iv) Operation and Maintenance Manual
This manual shall provide sufficient written instructions and data to enable purchaser to
correctly operate and maintain the equipment ordered. It shall include a section to cover
special instructions for operation at extreme environmental and/or extreme operating
conditions. The following shall be included in this manual:
(a) Instructions covering start-up, normal shutdown, emergency shutdown, operating
limits and routine operational procedures.
(b) A description of equipment construction features and the functioning of
component parts or systems (such as control, lubrication, sealing systems etc.).
(c) Outline and sectional drawings, schematics and illustrative sketches in sufficient
details to identify all parts and clearly show the operation of all equipment and
components and the methods of inspection and repair. Standardised sectional
drawings are acceptable only if they represent the actual construction of the
equipment.
(d) The following maintenance information:
i. Maximum and minimum bearing, labyrinth and seal clearances including
any other clearance between moving and stationary parts of the
equipment affecting proper running and maintenance of the equipment.
ii. Instructions for measuring and adjusting cold clearances, shaft runout,
concentricity etc.
iii. Rotor float allowance.
iv. Interference fits on parts that are required to be removed or replaced for
maintenance of normally consumable spares.
v. Balancing data with permissible tolerances.
vi. Lubricating schedules indicating recommended grades of oil, their
properties, replacement period etc.
vii. Normal maintenance procedure.
viii. Preventive maintenance schedules and criterion for replacement of parts.
ix. Trouble - shooting procedures.
(e) The following reassembly information:
1. Bolting sequence and torque values for all bolts affecting equipment
performance/integrity/safety.
2. Reassembly sequences together with required inspection checks.
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL — All rights reserved
5.2.7.3 Technical Data Manual/Mechanical Catalogue shall be in Hard board folder(s) of size 265 mm
x 315 mm (10Y2" x 12'/2") and shall not be more than 90 mm thickness; it may be of several
volumes and each volume shall have a volume number, index of volumes & index of contents
of that particular volume.
5.2.7.4 Title sheet (Top sheet) of each volume of Technical Data Manual/Mechanical Catalogue shall
contain the contract informations as defined under 5.2.1.2 besides the volume number.
5.2.7.5 In case order contains more than one item, separate dedicated mechanical catalogues shall be
submitted for each item.
5.2.7.6 Two (2) sets of Final / "As Built" drawings & documents shall also be submitted as electronic
files on secondary storage media (i.e. CD-ROM / DVD-ROM disk).
Abbreviations:
CI Cast Iron
CS Cast Steel
CT •. Cross Travel
HTB •. High Tensile Brass
IS •. Indian Standard
LT Long Travel
QA •. Quality Assurance
SWL •. Safe Working Load
Members Mr P.Bhattacharjee
Mr Sanjay Mazumdar
Mr P.P Pandey
Mr Nalin Kumar
Mr Tarun Kumar
Mr Anukul Mandal
Mr Shishupal Choudhary
Mr R R Srivastava
Mr J S Duggal
Mr KC Paikar
Mr A Natarajan
Mr K V K Naidu (Projects)
CONTENTS
1.0 GENERAL 4
2.0 CODES AND STANDARDS 4
3.0 TECHNICAL REQUIREMENT 4
4.0 INSPECTION AND TESTING 8
5.0 PROTECTION AND PAINTING 8
6.0 PACKAGING AND IDENTIFICATION 9
7.0 SPARE PARTS 9
1.0 GENERAL
This specification outlines the minimum requirements under which the manufacturer shall
design, manufacture, test and supply the Hand Operated Overhead Travelling (H.O.T.)
Crane, complete with all accessories.
2.1 This standard is based on the following Indian Standard, and the standards referred therein,
which shall be deemed to be part of this standard:
IS: 15560 : Specification for Point hooks with shank up to 160 Tonne.
Technical requirements of H.O.T Crane shall be as per Indian Standards referred in clause2.1
above, subject to the following additions, deletions and modifications:
3.1 Addition / Deletion / Modifications to IS-3177: 1999 (Reaffirmed 2006)
i) Clause no..4.2.b (Deletion): Clause deleted.
ii) Clause no..4.2.f (Deletion): The part "such as motors" from sentence deleted.
iii) Clause no. 7.4.8 (Deletion): Clause deleted.
iv) Clause no. 8.1.2 (Modification): Hook latch shall be provided on all hooks.
v) Clause no. 8.3 (Deletion): Clause deleted.
3.3 Addition / Deletion / Modification to IS 3832: 2005 (along with Amendment no. 1,
December 2005)
i) Clause no. 4.2.1 (Modification): Mechanism class 2 shall be considered for design of
chain pulley Block unless otherwise specified in the data sheet.
ii) Clause no. 11.2 (Modification): The chain pulley block shall carry ISI (BIS) stamp.
iii) Clause no.5.1 (Addition): The frame shall be built from steel plates with
bolted/welded construction.
iv) Clause no. 5.2 (Addition): All gears shall be machine cut.
v) Clause no. 5.5 (Addition): Only anti friction bearing shall be used.
vi) Clause no. 5.6 (Modification): The block shall be provided with adequate facilities for
lubrication and same shall be clearly indicated in the maintenance manual.
vii) Clause no. 5.7.1 (Addition): Hooks (both top and bottom) shall be provided with
safety latches to prevent accidental unhooking unless otherwise stated.
viii) Clause no. 5.7.1.2 (Modification): First line to be modified as "Bottom hook shall be
provided with thrust bearing to enable it to rotate freely under load so as to prevent
twisting of the load chain.
ix) Clause no. 5.10.3 (Modification): The length of hand chain shall be such that the
lowest point of the suspended loop shall be 400 mm above operating level.
x) Clause no. 5.11 (Addition): The trolley for the chain pulley block shall be geared type,
fabricated construction, 4 wheeled, driven by hand chain and shall have provision for
mounting the chain pulley block. Trolley shall be designed to suit the suitable joist
size and the hoisting capacity.
3.4 Addition requirements
i) The Crane may be under slung type if specifically asked in data sheet. For under slung
cranes, geared type four wheeled trolley shall be provided. The wheels/runner shall be
suitable for the flange of the I sections used for the girders.
ii) The bridge drive assembly shall consist of reduction gear assemblies with shaft
extensions and couplings to connect the bridge cross shaft extensions to truck wheels.
The travelling motion shall be communicated by endless hand chain wheel to a steel
cross shaft, positively driving one travelling wheel in each end carriage. The cross
shaft shall be suitably supported. The wheels and cross shaft shall have roller/ball
bearings.
iii) Cross traversing motion shall be transmitted through suitable gearing by an endless
hand chain and chain wheel.
3.5 The following material shall be used for construction of various parts of the crane.
SL
Name of Part Material
No.
1. Girder CS weldable quality as per IS 2062 (100% Radiography to
be taken on all Butt welded joints)
2. End carriage CS weldable quality as per IS 2062
SL
Name of Part Material
No.
3. Hand chain wheel for CI grade 25 of IS 210, or fabricated steel or pressed steel
trolley metal.
4. Hand chain for LT Grade L3 as per IS 2429
and Trolley
5. CT trolley CS weldable quality as per IS:2062
6. Rails for LT Crane rails as per IS: 3443 or Square Bar as per IS: 2062,
as applicable.
7. Wheels for LT 55C8 (Old designation:C55Mn75) as per IS:1570 (part
2/sec 1)
8. Gears 45C8 (Old designation :C45) as per IS:1570 (part 2/sec 1)
10. Shafts 3008 (Old designation :C30) as per IS:1570 (part 2/sec 1)
11. Axles 45C8 (Old designation :C45) as per IS:1570 (part 2/sec 1)
13. Suspension pin in the 50C4 (Old designation:C50 ) as per IS:1570 (part 2/sec 1)
trolley
All materials shall be of tested quality and shall conform to the standards as mentioned
above.
3.6 Special Requirements for Hazardous Area Cranes
3.6.1 For H.O.T. Crane to be located in hazardous area, non sparking type design features shall be
incorporated. Basic approach for such application calls for use of non-ferrous material for
one out of two mating parts for a non lubricated mating/striking pair.
3.6.2 The suggested materials for such components are as follows
Part/Component Material of Construction
A Lifting Mechanism
Ratchet wheel, chain guides Solid construction in Aluminium Bronze/ High
Tensile Brass
Hand chain wheel Solid construction of Aluminium Bronze/
Phosphor Bronze/ High Tensile Brass
Load chain wheel Solid construction in Aluminium Bronze/ High
Tensile Brass
Hook (Top & bottom) Bronze coated forged alloy steel/Forged
Stainless Steel
B Trolley Mechanism
Hand chain wheel guides Solid construction in Aluminium Bronze/
Phosphor Bronze/ High Tensile Brass
Hand chain wheel Solid construction of Aluminium Bronze/
Phosphor Bronze/ High Tensile Brass
Ungeared and geared wheels Solid construction in Aluminium Bronze/ High
or tyres, as appilcable Tensile Brass
C LT Mechanism
Tyres of LT wheels Solid construction in Aluminium Bronze/ High
Tensile Brass
3.6.3 Phosphor Bronze, High Tensile Brass and Aluminium Bronze shall conform to IS 28, IS 304
and IS 305 respectively.
4.1 Equipment shall be subjected to stagewise expediting, inspection and testing at vendor's/sub-
vendor's works by purchaser/its authorised inspection agency. Approved Quality Assurance
(QA) plan shall form the basis for equipment inspection.
4.2 Testing at Works
4.2.1 Vendor shall perform tests and inspection necessary to ensure that the material and
workmanship confirm to the requirement of this specification.
4.2.2 Testing at vendors works shall be carried out in accordance with IS:3177 and 3832 and shall
include following tests as minimum:
Full load and 125% overload test for hoist & cross travel motions at works (chain
pulley block shall be separately tested for operational proof as per cl. No. 9.2 of IS
3832).
Deflection Test at Works.
4.2.3 Any or all the tests, at purchaser's option, shall be witnessed by purchaser/its authorised
inspection agency. However, such inspection shall be regarded as check-up and in no way
absolve the vendor of his responsibility.
4.3 Performance Testing and Guarantees
4.3.1 A field performance test shall be conducted by the vendor to demonstrate the performance
of the equipment after commissioning in accordance with test procedure prepared as per EIL
Standard 7-76-0103.
4.3.2 Testing at site shall be carried out in accordance with IS: 3177. Following parameters shall
be guaranteed and demonstrated during the performance testing.
i) SWL of Hoist
ii) Deflection of bridge girder
4.3.3 All parts of the crane shall operate satisfactorily with no undue friction, noise or display of
any other unfavourable characteristics during the performance test.
4.3.4 All equipment and component parts shall be guaranteed by the vendor against defective
material and design for a period as specified in Purchaser's general purchase conditions.
4.3.5 If any defect occurs during the guaranteed period the Vendor shall make all necessary
alterations, repairs and replacement at their own cost.
4.3.6 Necessary instruments for the performance testing shall be arranged by the vendor, and shall
be tested and calibrated before undertaking the performance test. Only test load shall be
provided by purchaser near test site.
5.1 Surface preparation and painting shall be done as defined in Job Specification.
5.1 Stainless steel surfaces, both inside and outside, shall be pickled and passivated.
5.2 Machined and bearing surfaces shall be protected with varnish or thick coat of grease.
6.1 All packaging shall be done in such a manner as to reduce the volume. The equipment shall
be dismantled into major components, suitable for shipment and shall be properly packed to
provide adequate protection during shipment. All assemblies shall be properly match marked
for site erection.
6.2 Attachments, spare parts of the equipment and small items shall be packed separately in
wooden-cases. Each item shall be appropriately tagged with identification of main
equipment, item denomination and reference number of the respective assembly drawing.
6.3 Detailed packing list in water-proof envelope shall be inserted in the package together with
equipment.
6.4 Each equipment shall have an identification plate giving salient equipment data, make, year
of manufacture, equipment number, name of manufacturer etc.
6.5 Vendor shall furnish procedure for prolonged storage of supplied equipment/ material at site.
7.1 Vendor shall submit list of spare parts with recommended quantities and itemised prices for
first two years of operation of the equipment. Proper coding and referencing of spare parts
shall be done so that later identification with appropriate equipment is facilitated.
7.2 Recommended spares and their quantities should take into account related factors of
equipment reliability, effect of equipment downtime upon production or safety, cost of parts
and availability of vendor's service facilities around the proposed location of equipment.
7.3 Vendor shall also submit a list of commissioning spares with quantities. The commissioning
spares shall be sufficient for trouble free commissioning of the system at site. Any
commissioning spares required during commissioning, over and above, the commissioning
spares supplied, shall be made available by the vendor without any cost and time implication
to purchaser. If for any reason, during commissioning, vendor needs to utilise spares from 2
years' operation spares, the same shall be replenished by vendor within a reasonable time
without any cost implication to purchaser. Any unused commissioning spares shall be handed
over to owner.
TABLE OF CONTENTS
____________________________________________________________________
CLAUSE NO. TITLE PAGE NO.
_____________________________________________________________________
1.0 General 3
2.0 Execution on works 5
3.0 Execution Plans 7
4.0 Temporary Facilities 8
5.0 Construction Planning, Scheduling, Monitoring 9
& Reporting
6.0 Quality assurance and Quality Control (QA/QC) 9
7.0 Warehouse Management & Material Control 9
8.0 Field Engineering 10
9.0 Field Tendering 10
10.0 Field Purchase 10
11.0 Health, Safety and Environment (HSE) Management 11
12.0 House Keeping 11
13.0 Industrial Labour Relations 11
14.0 Construction Equipments 12
15.0 Construction Manpower 13
16.0 Interface with other CONTRACTORS 14
17.0 Colour Coding of Piping Material 14
List of Attachments:
Attachment-I Inspection & Test Plans (ITPs) for Cross country 6-82-1900 Rev.2
pipeline works
Attachment-II Standard Specification for Colour Coding of Piping 6-82-0003, Rev.2
Materials
Attachment-III Observation on Quality Aspect B001-00-000-19-41-0001 F1
Attachment-IV Observation on Safety Aspect B001-00-000-19-41-0001 F2
1.0 GENERAL
1.1 The Contractor shall construct Pipeline Facilities in accordance with the requirements of the
Technical Standards/ Specifications, with proven/good engineering practices and
procedures. Such Facilities shall be safe, reliable and suitable for their intended purpose.
1.2 The Contractor shall provide all supervision, labour, construction equipments, tools &
tackles, materials and consumables, temporary facilities, etc. and render all support
services necessary for the construction. Provision of construction power and water shall be
as per Special Conditions of Contract (SCC)/ General Conditions of Contract (GCC).
1.3 The Contractor shall plan, execute, manage and control all the construction activities for the
Facilities forming a part of this contract.
1.4 The Contractor shall arrange insurance coverage for all the personnel engaged by him for
the work as per statutory rules, regulations and local laws.
1.5 The Contractor shall insure all the materials and equipments against fire, flood, earthquake,
theft, etc. as per SCC/ GCC brought for the job till the Plant/Facilities are commissioned
and handed over to the OWNER.
1.6 The Contractor to ensure mechanizing the construction activities to the maximum.
1.7 The Contractor is deemed to have full knowledge of the applicable laws and regulations,
conditions of labour, local conditions, the SITE conditions, environmental aspects and shall
comply with the requirements thereof.
1.8 The Contractor is required to organize and mobilize Construction Management Services in
a systematic and sequential manner to ensure that the Plant installation is carried out in
accordance with the approved engineering drawings, specifications, standards, QA/QC
procedures etc. and its mechanical completion is achieved within targeted time schedule.
Construction Management and Supervision is to be carried out by the Contractor himself by
deploying persons on his rolls and this activity is not to be sub-contracted in any case.
For this purpose, the Contractor shall deploy a Construction Management Team headed by
a qualified & experienced person at site. The Construction Management team shall include
engineers/ specialists in QA/QC, Project Control (Planning, scheduling, monitoring),
contracts, construction supervision, welding & NDT, progress measurement/billing, safety,
warehousing, purchasing etc. Key personnel including the Head should have sufficient
experience and should not be changed without concurrence from Owner/PMC.
Curriculum vitae of all key Construction Personnel shall be submitted to Owner/PMC for
approval before deployment. Owner/PMC reserve the right to interview these personnel
before their mobilization.
1.9 The Contractor shall ensure delegation of adequate and sufficient powers (including
financial) to the Head of his Construction Team for effective and smooth functioning of the
construction management. HO support shall be provided to the Head of Construction Team
at site during construction on all matters of project execution including the following:
- Field engineering.
- Vendor specialists required during construction.
- Rectification/replacement of defective supplies, if any, noticed during construction.
- Expediting replacement of imported items found short/damaged.
1.10 The construction supervision, co-ordination and management activities shall be carried out
by the Contractor in accordance with the construction procedures developed and submitted
by the Contractor and approved by Owner/PMC. Contractor shall prepare construction
schedules within the framework of overall contract schedule and submit to Owner/PMC for
approval. Contractor shall plan, execute, monitor and control construction activities as per
the approved construction schedule.
Contractor shall depute a project team at site during construction phase under a project
coordinator for providing above-mentioned support to the Head of Construction Team.
1.11 Most of the civil construction materials like cement, reinforcement bars, aggregates, bricks,
and structural steel are available locally. Cement/rebars/structural materials shall be
procured from approved suppliers only. The Contractor shall establish and maintain a
material testing laboratory for carrying on field tests during execution of contracts under
different disciplines by sub-contractor’s, at no extra cost to OWNER. The entire test
equipments deployed shall have valid test/calibration certificates traceable to relevant
national/ international standards. Such material tests, for which testing facility at site is not
established, shall be carried out by Contractor at testing laboratories approved by Owner/
PMC at no extra cost. Contractor shall maintain the test records and the same shall be
made available for review/ inspection of Owner/ PMC. Further, Owner/PMC reserves the
right to witness/ inspect testing at the laboratory at no extra cost to Owner/PMC.
1.12 All electrodes/filler wires and other consumables like argon/oxygen cylinders etc shall be
arranged by main contractor from the approved suppliers/manufacturers in order to
exercise proper control on the fabrication of works.
1.13 Construction supervision and management functions to be performed by the Contractor shall
include the following as key functions for effective execution, monitoring and control:
1.14 Whenever the hookup is being taken with the facilities of operating Fire water network,
efforts shall be made by the Contractor to complete the work and restore the system
expeditiously. If required the work shall be continued round the clock.
1.15 Any modification, dismantling, re-routing etc. of the permanent / temporary facilities
belonging to Owner, private parties, public / government facilities including provision of
ramps at bridges to enable the ODC movement are in Contractor’s scope.
1.16 Restoration of the all the modified, dismantled facilities to original condition is in the scope
of the Contractor. Contractor shall obtain no claim certificates from such parties.
The Contractor’s work during construction shall include but not be limited to the following:
i) Prepare and submit all the Plans, Procedures and documents to Owner/PMC as
specified in the contract.
ii) Establish requisite site organization staffed by competent and experienced
specialists, supervisors and inspectors.
iii) Supervise, Coordinate and manage the activities performed at site by him and by
his sub-contractors for execution of work and render all technical/specialist services.
v) Plan and schedule the construction work monitor and take timely corrective action
when required to adhere to approved execution schedule.
vi) Plan, allocate and mobilize required resources, manpower, and construction
equipment/materials, commensurate with construction plan/schedule.
vii) Provide all temporary facilities required for Construction including Power,DG sets,
Construction water, drinking water, lighting, office space, dump sites, camp facilities,
electronic transmission of drawings & documents, printing facilities, rest rooms,
crèches, first-aid, fire protection system, toilets, canteen facilities, labour hutments
and transport facilities for the workers and staff.
viii) Prepare & implement approved Quality Control and Quality Assurance plan.
ix) Prepare & implement approved Health, Safety & Environment (HSE) plan.
x) Report beforehand and take approval from Owner/PMC regarding use of any
equipment and/or material not conforming to the contract, drawings and
specifications.
xi) Execute and supervise all additional works and modification works as required or
suggested by Owner/PMC as a part of approved change orders.
xii) Erect and install the equipments and materials according to the approved
specifications and procedures.
xiii) Establish required Field Inspection and Testing Laboratories at site to carryout tests
as specified in the standards/specifications of the contract.
xiv) Organize and obtain all applicable clearances/approvals from statutory
bodies/authorities, as required by the laws of land for the work executed at site by
the Contractor under the contract.
xv) Obtain approval of Owner/ PMC for Welding Procedure Specifications (WPS)/
Procedure Qualification Records (PQR) as required. Carry out inspection, non-
destructive tests and analyze and certify acceptability of all welds and materials in
accordance with specified Technical Standards. Carry out inspection and testing of
incoming materials as per agreed procedures.
xvi) Organize and conduct Weekly Project Review meeting related to site construction
activities.
xviii) Provide daily work progress reports and detailed weekly and monthly progress
reports summarizing percentage completion of the work including status of
drawings, materials and effects on approved schedule, areas of concern and
corrective actions required thereof. Contractor shall also identify any foreseeable
delays in any aspect of the work and take corrective actions to eliminate/minimize
the effect on Overall Completion Schedule. All progress shall be quantified.
xix) Take photographs and video recording of Project Construction Progress on regular
basis and submit the same to Owner/PMC on monthly basis along with the Monthly
Progress Report.
xx) Prepare and submit records of all site meetings and any other related documents to
all parties concerned within two (2) days of the meeting.
xxi) Prepare and submit safety and labour relation procedures in line with all applicable
codes, regulations and Owner’s requirements.
xxii) Supervise and monitor all safety and labour relation functions as per agreed
procedures and applicable laws of the land and report to Owner immediately for any
violations and injuries.
xxiii) If any part of the facilities is completed and is under operation, while other parts of
the facilities are under construction, or work is to be carried in existing running
Plant, it is essential that rigid safety rules be prepared and maintained for all works
in accordance with the requirements of Owner/PMC.
xxiv) Maintaining all the records generated during project execution up-to-date and made
available to Owner/PMC whenever requested. These records shall be handed over
to Owner on completion of the work at no extra cost to Owner.
xxv) Carryout warehouse management and material control in accordance with approved
procedure.
xxvii) Take all necessary precautions and required actions to protect construction work
and materials from damage by local weather conditions and ongoing construction
activities in the vicinity, theft and pilferage etc. till handing over of the plant to
Owner.
xxviii) Take insurance policies for materials in transit and storage-cum-erection risk and
other insurance covers required for men and materials at site as per SCC/ GCC in
consultation with Owner.
xxviii) Undertake housekeeping including sweeping, clean up to maintain cleanliness,
sanitation, removing excess materials, temporary facilities, scaffolding, etc. on
regular basis till hand over to Owner.
xxix) Prepare and submit to Owner/PMC the following daily reports for construction
activities covering the following:
a. Weather
b. Manpower deployment category wise
c. Construction Equipments
d. Work Progress
xxx) Ensure the control of all works with regard to its impact on the surrounding
environment.
xxxi) Ensure all hot works are performed outside hazardous areas and in compliance
with Owner’s Safety Permit System requirements wherever applicable.
xxxii) Arrange and coordinate the visits of supplier’s representatives/specialists at site.
xxxiii) All material handling equipment, tools, tackles, hoisting and lifting equipments/
machineries should be subjected to required load test initially and then periodically,
to ensure safe/stable operation.
xxxiv) Organize field engineering work, wherever required and ensure timely resolution of
interface problems / site constraints in consultation with Owner/PMC.
xxxv) Prepare and certify material reconciliation statement on completion of work to
enable Owner to take over the surplus materials, as applicable.
xxxvi) Organize the codification and handing over of surplus materials (as applicable) and
spares/ tools and tackles to the Owner on completion of work.
xxxvii) Provide weekly/daily activity plan for site inspection.
xxxviii) Develop a phased mechanical completion program to facilitate sequential Pre-
commissioning/Commissioning activities in a logical manner to meet the Overall
Project Schedule.
xxxix) Remove / demolish all temporary structures/ establishments/ facilities created by the
Contractor / his sub-contractors during the execution of the work and restore the site
to its original condition.
xl) Estimate monthly consumption of following utilities (if provided by Owner):
a. Industrial water
b. Drinking water
c. Electricity
xli) Carry out tightening of flange joints by using hydraulic tensioner/ torque wrench as
per specifications. Contractor shall ensure that stud bolts are ordered extra long to
facilitate tensioning.
xlii) Develop colour coding scheme (to avoid mix up during fabrication and erection) for
piping material and get it approved from Owner/PMC.
xliii) Organize safety induction programme for their manpower before deployment on
work and at regular intervals thereafter.
xliv) Carryout survey of pipeline in ROU, scour levels at sea bed areas etc, in order to
maintain minimum depth requirements for anti-buoyancy measures.
After award of the works, the contractor shall submit Construction Execution Plan to
Owner/PMC for review/approval during kick-off meeting. The Plan shall detail the
execution methodology of the Contractor during construction phase of the Project covering
following aspects as minimum –
Contractor shall submit Construction Management Plan to Owner/PMC for approval during
kick-off meeting. The Plan shall detail the management methodology to be applied during
the construction phase of the Project, along with a list of procedures to be utilized in
undertaking the work.
All reference procedures and detail work plans referred to in this document must be
submitted for review and approval by Owner/PMC at least (4) four weeks in advance of
actual commencement of the activity concerned.
It shall include
3.2.1 Contractor’s manpower and man-hour histogram by major section and discipline and their
manpower deployment schedule on monthly basis.
3.2.2 Major equipment mobilization plan on monthly basis with short description. Contractor to
develop this plan with due consideration to maximize the mechanization of construction
activities.
Other plans of Contractor and procedures to be submitted at least four (4) weeks prior to
start of respective activity at site include the following as a minimum:
b. Execution Methodology /Plan for Laying of pipeline, crossings & hookup with HDD as
applicable.
c. Schedule for opening of ROU
d. WPS/PQR submission schedule
e. Temporary facilities, etc
f. Piling plan (if applicable)
g. Barricading Plan
h. Scaffolding plan
i. Excavation and underground work plan
j. Pre-fabrication plan
k. Other activity plans e.g. piping, equipment and structural steel erection plan
l. Monsoon counter measures and preparation
m. Emergency Evacuation Procedure
n. Storm Management Plan
o. Schemes to carry out works in inclement weather
Contractor shall ensure that lay down area given to him shall be utilized optimally.
i) Sub-contracting philosophy
ii) List and scope of work of each subcontract
iii) Subcontract administration plan
iv) Organization chart of each sub-contractor.
The list and major scope of each subcontract shall not be changed from those of the
Contractor’s plan unless specially approved by Owner.
The Contractor shall arrange the following temporary facilities at the minimum (including for
his sub-contractors also):
1) Exact location of temporary work area, access and general layout inside the
operational area.
2) Planning and description of the temporary facilities such as:
Contractor shall develop the temporary facilities layout for approval of Owner/PMC.
The Contractor shall be responsible for construction Planning, Scheduling, Monitoring and
Reporting activities at site in line with the overall master schedule and details stipulated
elsewhere in the bid document.
The Contractor shall be responsible for ensuring quality of construction (including materials)
carried out by him/his approved sub-contractors in accordance with the requirements given
in Appendix-A for Quality Assurance / Quality Control (QA/QC) during construction
including all documents referred therein.
The Contractor shall construct/ build warehousing facilities (both covered and open)
appropriate for storing materials required for the job. The facilities shall include proper
lighting, fire protection system, office/rest rooms/toilets for warehouse personnel.
The Contractor shall obtain all statutory approvals from concerned authorities for all
warehouse equipment, instruments etc. The Contractor shall comply with statutory
regulations for storage of any material covered under Explosives rules.
The Contractor shall be responsible for carrying out the Warehouse Management and
Material Control in accordance with the approved warehousing procedure and material
control procedure, which is to be submitted by the Contractor during kick-off meeting. The
activities shall include but not limited to:
Contractor shall be responsible for controlling and issue of technical drawings and
documents, Alignment sheets, crossing drawings, preparation of field sketches, field
modifications, checking/preparation of as built drawings, etc. Contractor should have
adequate facilities for incorporating field changes, preparation of As-built drawings, Printing
machines and Drawing & Document Control System.
Contractor shall be responsible for carrying out field tendering activities, as required from
the site itself.
Contractor shall be responsible for carrying out field purchase activities, as required.
Field Purchase items are restricted to those required for running and maintenance of the
field offices, items required to expedite construction work and items found short, missing or
damaged against the main order when received at the site. Any material purchased from
field for usage in the plant should have proper inspection certificate and should be
purchased from Owner/PMC approved suppliers. If required by Owner/ PMC, check testing
of the material samples selected by Owner/PMC shall be carried out by Contractor without
any extra commercial implication.
The Contractor shall be responsible for Health, Safety and Environment (HSE)
Management at construction site for the construction activities to be carried out by the
him/his approved sub-contractors in accordance with the requirements mentioned in
Appendix-B for Health, Safety and Environment Management during construction.
Wastage and serviceable/ unserviceable scrap generated during dismantling and regular
works shall be segregated and dumped in designated locations in consultation with
Owner/PMC. Earth and landfill materials shall be dumped at locations identified by
Owner/PMC, otherwise outside the Project Site and the required fees charged by the local
authorities shall be borne by the Contractor without any extra cost to Owner.
Contractor shall be responsible for industrial relation functions and implementation of labour
laws at site. Contractor’s staff shall be suitably trained and experienced in Labour Relation
functions so as to ensure a good relationship with labour and to prevent the occurrence of
industrial disputes resulting in subsequent delays or work stoppages. In particular,
Contractor shall maintain close liaison with Owner/PMC.
Contractor shall maintain proper liaison with Statutory Authorities and local bodies and shall
be responsible to implement and observe all statutory laws at site. Contractor must have in
his staff; a well experienced Labour Relation Officer.
Contractor shall maintain the records of wages paid in a wage register, PF, Gratuity,
contribution towards building of construction works act etc. as per statutory regulations.
Contractor shall report immediately to Owner/PMC any problems including labour disputes,
fight, and work stoppages. A written report shall be submitted to Owner/PMC within 24
hours of the incident.
Contractor must submit a Labour Relation Plan including their sub-contractor(s) prior to the
start of the work/within one month of award of the contract, whichever is earlier, mentioning
as a minimum:
a. A detailed estimate of the number of labour, indirect and direct, sorted by craft.
b. Outline recruiting plans for all manpower requirements.
c. Identify personnel involved with labour relations and outline procedures to mitigate
labour disputes & problems.
d. Labour welfare plan.
Contractor shall hold labour relations meeting twice a month with their work force as well as
a separate meeting with the Owner.
The Contractor is required to organize and mobilize the construction equipments and other
tools/tackles in a sequential manner and ensure that plant/ Pipeline installation is carried
out in a mechanized manner to the extent possible and its mechanical completion is
achieved within targeted time schedule. Contractor shall ensure deployment of the key
construction equipments as per Annexure to SCC.
Contractor shall confirm that the above equipments in requisite no are available with him in
good working condition and shall be timely mobilized on this project site. Contractor has the
option to hire some of these equipment from hiring agencies also. Owner/EIL reserve the
right to physically check & verify the availability of these equipments prior to award of the
work. Contractor shall replace any defective/damaged equipments promptly to complete the
work without time & cost implication to the Owner/EIL.
For the purpose of Pipeline laying, the Contractor shall deploy a Pipeline team comprising
of civil/mechanical and electrical engineers and foreman’s for ROW clearing and Grading,
Stringing, welding, trenching, lowering, tie-in and backfilling etc., reporting to Spread in-
charge. Spread in charge should be well conversant with methods and techniques of
pipeline laying works.
Contractor shall prepare erection schedule in line with the overall project schedule in
phased manner with erection schemes of various equipments, vessels and submit to
Owner/PMC for approval, Monitoring and control of erection schedule and erection
activities shall be carried out by the Contractor as per the approved construction
procedures.
For efficient working and maintenance of construction aids, Contractor shall establish and
maintain crane yard / workshop equipped with regular maintenance facilities for various
construction aids for carrying out routine field maintenance during performance of the
contract. Temporary approach road and hard stands, wherever required for the movement
of the Cranes and other vehicles for equipment erection and transportation of material shall
be properly planned and made by the Contractor. Weekly/fortnightly maintenance shall be
planned in such a way that the same does not hamper the erection schedule.
During performances of the work, Contractor must ensure that structures, materials and
equipments are adequately braced with Guys, Struts or any other means as deemed fit &
approved by Owner/PMC. Such means shall be supplied and installed by the Contractors
as required till the erection works is satisfactorily completed. Such guys, shoring, bracing,
strutting, planking supports etc. shall not interfere with the work of other agencies and shall
not damage or cause distortion to works executed by other agencies. All lifting tools,
tackles and cranes shall be tested periodically by statutory/ competent authorities for their
load carrying capacity. Such relevant valid/test certificates shall be submitted to
Owner/PMC for review before actual use of the tools, tackles and cranes.
Contractor shall submit the construction equipment deployment schedule in the Performa
attached elsewhere in the bid. Daily construction equipment deployment report will also be
submitted by the Contractor to Owner/PMC along with DPR.
Contractor shall ensure the timely augmentation of the men, equipments and machinery
depending upon the exigencies of the work to meet the overall project schedule and as per
instructions of Owner/PMC.
For this purpose, the Contractor shall clearly indicate in his construction methodology
whether work shall be done departmentally or by engaging sub-contractor or the combina-
tion of both. Contractor shall prepare detailed methodology for the work to be carried out
departmentally as well as through sub-contractors clearly, defining the scope and re-
sponsibility of Contractor and his sub-contractors.
The works of all sub-contractors shall be managed by the construction staff of the main
Contractor who shall perform the duties of construction management and shall administer,
coordinate, and inspect the works of the sub-contractor(s) and be responsible for the
Quality and timely completion of respective works. The Contractor shall establish the
pre-requisites for successful completion of sub-contractor (s) work. However, by deploying
the sub-contractor (s), as approved by Owner/PMC for any discipline, does not absolve the
Contractor of his total responsibility under the subject contract.
The Contractor must note that in case of any sub-contractors' failure to execute the works
as per standards/specifications/drawings and/or negligence & disobedience in carrying out
any order or instruction of Owner/PMC, the same shall be viewed very seriously and any
action as deemed fit in accordance with provision(s) of the contract shall be taken by
Owner/PMC.
All construction supervision, coordination and management activities shall be carried out by
the Contractor in accordance with the construction procedures approved by Owner/PMC.
Contractor shall prepare construction schedules based on the Overall Project Schedule of
the PLANT and submit the same to Owner/PMC for approval. Monitoring and control of the
construction activities shall be carried out as per the approved construction schedule &
procedures.
During the execution of works at site, if the Contractor engages sub-contractor (s) for
execution of works at site as per approval obtained from Owner/PMC in line with contract
provision(s) and in the event sub-contractor complains in writing to the OWNER with regard
to the non-payment of their dues from the Contractor for the works executed by them
(excluding final payments and payments due after termination of sub-contractors' services
by the main Contractor), Owner/PMC reserves the right to make such payment to the sub-
contractors directly based on approved measurements with due notice to the Contractor.
Owner/PMC shall release such payments to sub-contractor at the cost and risk of the
Contractor in order to ensure smooth execution of work at site. All such payments made by
Owner/PMC to the sub-contractor(s) shall be deducted from the running account bills or
any other payments due to the Contractor.
The above provisions shall also be applicable in case of construction materials procured at
site by the Contractor from the suppliers.
Contractor shall ensure that his interface with other Contractors is smooth and cordial. In
case of any dispute, Owner/PMC decision shall be binding.
Owner/PMC may arrange weekly/fortnightly/monthly interface meetings. The Contractor
shall depute concerned personnel to attend these meetings.
Specification for colour coding of Stored Piping Material No. 6-82-0003 shall be uniformly
followed for the entire facilities.
APPENDIX - A
QUALITY ASSURANCE
AND
QUALITY CONTROL
TABLE OF CONTENTS
_____________________________________________________________________
CLAUSE NO. TITLE PAGE NO.
____________________________________________________________________________
1.0 PURPOSE 17
2.0 SCOPE 17
3.0 RESPONSIBILITY 17
4.0 METHODOLOGY 17
4.3 DOCUMENTATION 19
1.0 PURPOSE
The purpose of this document is for uniform understanding and implementation of quality
management and quality control by contractor during construction to produce the product
by combination of various activities and role of Owner/EIL in verification. The management
of quality shall also cover co-ordination, review, approval audit and proper documentation
of the works performed. Indicative Inspection and Test Plans (ITPs) are forming part of this
document as attachments.
2.0 SCOPE
3.0 RESPONSIBILITY
The Contractor shall comply with all statutory rules & regulations in force during execution
of work and interface with such authorities as required.
4.0 METHODOLOGY
The management of construction quality control is divided into the following categories:-
The Contractor shall develop list(s) defining the items to be procured along with proposed
Vendors for approval of the Owner/PMC. The list shall comprise of all items except
vessels, equipments, pumps, electrical/ instrumentation panels etc. which may be available
directly ready for installation or requiring small fabrication as per requirement. The vendor
list shall be in line with the contract document. In case, no vendor list exists in the contract
for a particular item, the Contractor shall propose a list of Vendors to Owner/PMC.
Contractor has to satisfy himself with the capability of the vendor to deliver the product in
time with quality before proposing him as a prospective vendor. Contractor shall submit
the QA/QC plans for all major items and carry out their procurement in line with the
approved plans. The categorization plan shall be submitted by contractor in line with the
contract requirement. The Contractor can either provide his own adequate qualified staff for
inspection or employ a separate third- party inspection agency with prior approval to carry
out these functions. Involvement of Owner/PMC in the quality control plan, if required, shall
be defined during approval of the same.
(i) The QA plans for execution shall be developed by the Contractor. Owner/ PMC’s
approval for the same shall be taken well before start of the work. The final
Inspection & Test Plans (ITPs), based on the indicative ITPs enclosed in document
Nos. 6-82-1900 shall be developed by the Contractor as per contract specifications
for approval by Owner/ PMC. For the activities which are identified as Witness or
Hold Point, specific inspection call shall be raised by the Contractor with Owner/
PMC in the requisite format well in advance.
The indicative ITPs and Formats enclosed in the feed package are for guidance to
the Contractor and may not cover some of the activities to be performed during
execution of works under the scope of this contract. The Contractor shall develop
Inspection & Test Plans and Formats for all such activities also and submit the
same to Owner/ PMC for approval, before actually undertaking such activities.
(iii) Storage
All the materials procured shall be stored/stacked as per the standard norms and as
recommended in various clauses of relevant codes and contract document. The
storage of material shall be such as to avoid damage to life/properties (physical and
chemical) of the materials. The storage shall not cause deterioration, rusting, mix-
up etc. and hamper the other related works in any way. Contractor shall submit his
detailed warehouse plan for Owner/ PMC approval to manage the above in
open/covered areas.
The materials susceptible to fire shall be kept away in a separate protected place.
In general, the materials shall be kept systematically in order of their class, batch
number and identification number, so that they are accessible for the inspection by
Owner/ PMC whenever required and to avoid the mix up in those materials.
(iv) Use
The materials shall be stacked in such a way that the lot, which is procured first, will
be consumed first. For materials which are having specific expiry date/ shelf life
shall not be used beyond that date and shall be removed from site. Wherever there
is any doubt about the change in properties of the materials, such materials shall be
sent to reputed approved laboratory for testing and acceptance.
(v) Inspection
The Contractor shall be responsible for carrying out inspection of the materials
brought at site and conducting tests/ checks (at site or in approved laboratories) at
predefined frequencies as per contract. It is the responsibility of the Contractor to
ensure that the materials used at site shall conform to relevant codes/ standards
and Manufacturer Test Certificates are available for correlation as and when
required. The Contractor shall maintain the records of all materials brought at site
and tests conducted on them.
The Contractor shall arrange verification of ingredients used and validation of the
software used at the batching plant(s). Owner/ PMC reserve the right to inspect the
working of batching plant including validation of the software used and calibration of
measuring & monitoring devices any time. The Contractor shall ensure the quality
of the concrete delivered by the transit mixers, as applicable and maintain verifiable
records.
vii) Any Observation on quality aspects , Owner/PMC shall raise observation in attached
OQA format which has to be acknowledged & compliance to be done by the
contractor within the agreed time period.
viii) The contractor shall follow the requirements given for control of monitoring and
measuring devices (Refer Document no. 7-82-0002).
4.3 DOCUMENTATION
All the necessary documentation & records shall be maintained by Contractor till completion
of project and handed over to Owner/ PMC in requisite copies as a part of completion
documents. Wherever Owner/ PMC personnel were directly involved particularly in witness
and hold point, the copies of the records shall also be provided to personnel on completing
inspection of those activities. The documentation & records shall include the following as a
minimum but not limited to:
e) Final verification report including any test checks done for compliance
During the execution of the works, Contractor shall carry out periodical Quality Audits at
least quarterly in all areas of work. These audits will be conducted by a team of specialists
in the respective areas. The auditors shall not be directly involved in the jobs being
audited.
The Contractor shall prepare an Audit Plan and Procedure and submit the same to Owner/
PMC for approval.
A copy of the Audit Report containing the findings of the Audit team will be submitted to
Owner/ PMC. After completion of rectification/modifications/corrective actions on the issues
indicated in Audit Report, Compliance Report shall be submitted by the Contractor to
Owner/ PMC for review.
Over and above the Contractor’s Internal QA/QC Audits outlined above, Owner/ PMC shall
also reserve the right to conduct QA/QC audits at the frequency decided by them.
Contractor shall participate and provide full support to the Audit Team and furnish all
documents / reports / records as desired by the Audit Team. The Contractor shall take all
actions required to comply with the findings of the Audit Report and issue regular
Compliance Reports for the same to Owner/ PMC till all the findings of the Audit Report are
fully complied.
In case major Non conformities are observed during execution of the works Owner/ PMC
reserve the right to appoint an independent person/Third Party Agency to conduct QA/QC
Systems Audit for full/part of the facilities being executed by the Contractor. This audit
will be in addition to the audits described above and may be carried out
intermittently/continuously for all or part of the facilities being executed by the Contractor.
Contractor shall bear the total cost of such audits and shall participate & provide full support
to the Audit Team and ensure compliance of the audit observations.
APPENDIX-B
DURING CONSTRUCTION
GENERAL REQUIREMENTS
1.0 Specification for Health, Safety and Environment (HSE) Management (Spec. No. 6-82-
0001) is required to be followed by Contractor during Construction Phase at site.
2.0 Contractor shall have a documented HSE policy to cover commitment of the organization to
ensure Health, Safety and Environment aspects in the line of operation.
3.0 It is the responsibility of the Contractor to ensure that safe construction procedures are
complied with. Contractor will also ensure that adequate First Aid medical facilities are
available and effectively operative for emergency purpose and that safety practices as per
the approved safety procedure are followed by his sub-contractors also.
Contractor to ensure all necessary & relevant safety measures at the minimum like:
a) The use of safety gadgets, viz. safety goggles, helmets, safety shoes, full body
harness, provision of safety net for construction at higher elevations and provision of
toe boards in scaffolding platforms, etc.
b) All hot works must be performed by ensuring compliance to the requirements as
specified by the Owner from time to time.
c) Barricading of crane movement areas / Radiography areas
d) Proper earthing of equipments.
e) Proper shoring / strutting of Excavated Areas, as applicable.
f) Cylinders of inflammable gases to be stacked upright.
In addition to above Contractor shall study the working conditions of the specific site and
assess hazards / risks corresponding to various activities in order of sequence and shall
carry out detailed “ Risk Analysis vis a vis Method Statement ” to deal with anticipated risks
and dangers during the course of work operations. The aforesaid exercise shall be
reviewed by Owner/PMC and after incorporating suggestions if any physical work shall be
carried out implementing requisite measures on work spots. The documents thus generated
(Hazard Identification and Risk Assessment) shall be utilized to develop corresponding
accident prevention curriculum.
The responsibilities of the Contractor shall include but not limited to:
4.0 Any Observation on Safety aspects , Owner/PMC shall raise observation in attached OSA
format, which has to be acknowledged & compliance to be done by the contractor within
the agreed time period.
A2(
IN 1
p
2 09/11/2015 Revised And Reissued DJ MKG TKS SC
Abbreviations:
CONTENTS
S. DOCUMENT PAGE
DESCRIPTION
NO NO. NO.
ITPs FOR Cross Country Pipeline works
1. Dump yard maintenance by coating contractor and 1901 8
Handing Over/Taking over of line pipes at dump yard
2. Incoming material Checking for Contractor’s Supplied 1902 9-11
Materials
3. ROU Survey, Clearing & Grading 1903 12
4. Trenching 1904 13
FORMATS
23. Inspection report for handing over taking over of line P-01 38
pipes at dump yard.
24. Material issue voucher P-02 39
S. DOCUMENT PAGE
DESCRIPTION
NO NO. NO.
28. Inspection report for trenching P-06 43
S. DOCUMENT PAGE
DESCRIPTION
NO NO. NO.
57. Clearance certificate of pipeline section for hydro P-33 72
testing
58. Safety checklist for pipeline section hydro testing P-34 73
84. Inspection report for horizontal anode bed installation P-60 100
S. DOCUMENT PAGE
DESCRIPTION
NO NO. NO.
85. Inspection report for commissioning of anode bed P-61 101
86. Inspection report for vertical anode bed installation P-62 102
GENERAL NOTE
1. The enclosed ITPs are indicative and shall be followed for developing the job specific ITPs for
the works to be performed by the contractor. The provisions indicated for stage wise
inspection by EIL and Owner (For specific activities) are the minimum and the Engineer-In-
Charge may decide to increase Hold Points/ Witness Points, while approving the job specific
ITPs. Activities for which ITPs are not provided in this specification, contractor to develop
and get the same approved by EIL/Owner before start of the work. In general role of EIL has
been specified in the document. The role of owner to be specified during preparation of site
specific ITPs.
2. Contractor to submit job specific reporting formats with the aid of enclosed sample reporting
formats and job procedures for the jobs for which ITPs are attached and submit to EIL/Owner
for approval, before commencement of the activity. If the contractor has to deviate from the
given ITP for a valid reason, he shall obtain prior written approval of EIL/Owner. Contractor
to carry out 100% examination of all activities.
LEGEND
HP : Hold Point;
The Contractor shall not process the activity/item beyond a Hold Point without written
approval by Owner/EIL except where prior written permission for further processing is
available.
W : Witness Point;
After proper notification has been provided (notification modalities and period shall be
finalized before hand), the Contractor is not obliged to hold further processing if
Owner/EIL is not available to witness the activity or does not provide comments before
the date notified. In such cases, basis of acceptance shall be review of Contractor
generated report/document as per relevant technical specification.
Responsibility for execution of the inspection/testing is with the Contractor; Owner/EIL only
verifies examination or testing done by the Contractor at relevant important stages
ITP No : 1901
DUMP YARD MAINTENANCE BY COATING CONTRACTOR
AND HANDING OVER/TAKING OVER OF LINE PIPES AT
DUMP YARD
Contractor Records to be
Sl.
Activity EIL Submitted/
No. Coating Laying
Format No.
Submission & approval of work
Approved
1 procedure including proposed WC - Rw
procedure
dumpsite layout.
Grading, leveling, and stripping, of
dumpsites with arrangement of Approved
2 WC - S
stacking as per relevant Records.
specification
Preparation of sand rows for
stacking of coated pipes and
Approved dump
fencing with gate barrier, lighting
3 WC - S site acceptance
arrangements, drainage systems etc.
report
as per approved layout of
dumpsites.
Holiday checking of line pipes,
Internal gauge plate run, pipe dia.
and thickness, internal cleaning,
Pipe identification nos like pipe no,
4 WC WC - P-01
coat no, heat nos, bevel edges. &
other markings correlating with
Inspection Release Note by laying
contractor
Note:
The above activities will be under EIL if warehousing is in EIL scope of work
*S for coating repair works / holiday repairs. W for pipe damage repair, if any.
ITP NO : 1902
INCOMING MATERIAL CHECKING FOR CONTRACTOR’S
SUPPLIED MATERIALS (Sheet 1 of 2)
EIL /Owner ($) Records to be
Sl.
Activity Contractor Submitted/
No. CAT 1 CAT 2 CAT 3
Format No.
A. Document Checking
B. Physical Verification
Checking for Inspection stamp/Identification
1. WC W* S S P-04
mark, if applicable
Correlation of MTC w.r.t. Heat nos/ Batch no /lot
2. WC HP W* W* P-04
no, as applicable
3. Physical assessment of Qty WC S S - P-04
NOTE:
($)A generic categorization plan could be firmed based on following guideline and as per Table A:-
(* )Sampling plan for checking of bulk items shall be as per discretion of EIL
General :
1) EIL/OWNER and contractor shall jointly finalize the list of incoming materials and categorize in line
with inspection categorization plan for bought out items. The items not covered in Table A shall be
finalized by Engineer In charge /Owner.
2) In general Sl no of the ITP: A(1,3,4 &5) B, E and F shall be applicable to both (#)and (@) i.e. Items
with and without TPI/EIL inspection
3) In general Sl no of the ITP: A (2), shall be applicable to (@) ie. Items with TPI/EIL inspection
4) In general Sl no. of ITP : C and D shall be applicable to (#) ie. Items without TPI/EIL inspection.
5) All items to be procured from approved vendors / source as per list enclosed in the contract / approved
vendor list. Prior approval for the source / vendor to be taken for items not listed in the contract /
approved vendor list.
6) Anodisation / galvanization shall be ensured in shops having proven track record and samples are to
be tested to check galvanizing / anodizing prior to dispatch to sites.
ITP NO : 1902
INCOMING MATERIAL CHECKING FOR CONTRACTOR’S
SUPPLIED MATERIALS (Sheet 2 of 2)
CAT 1 CRITICAL: The materials requiring long time impact to meet the stipulation of end user. Completely
engineered and inspected as per the contract.
CAT 2 MAJOR: The materials requiring lesser impact on end user. Specified to Industry standards, lower
design category (not fully reviewed of detailed Engg but all interfaces checked) and with complete
compliance with code but requiring limited inspection.
CAT 3 MINOR: Standard items, fit for the purpose with minimal Engg review.
TABLE: A
Sl CAT 1 CAT 2 CAT 3
No (Critical) (Major) (Minor)
Items without TPIA/EIL inspection (#)
1 Cement Coarse aggregate Anti-Corrosion coating
Reinforcement steel Fine aggregate materials
Structural steel Stone aggregate for road work Water
Filling soil AC sheets/CGI sheets
Murrum sand, etc Particle board
Brick and tile brick Stone for stone masonry
Asphalt(bitumen), Paint Glazing glass
Sanitary wares, sanitary fittings (pipes All galvanized /
& fittings) anodized items like GI
Chemicals for ATT, pipes
Acid resistant tiles and mortar, marble Door/window frames
and marble chips Pre-coated sheets
Mechanical hardener for flooring Steel doors
Grouting compound Aluminum doors
Wood for doors and windows Rolling shutters
Ventilator Cable ducts/trays
Flush door Lightning arrestors
Paneled door Street light poles
Roof treatment materials Earthing items.
False ceiling & flooring materials
RCC Hume pipes
Refractory
Anchor Fasteners
Items with TPIA/EIL inspection (@)
1 All process All types of compressors and pumps Hoists
Compressor except under category1 Pipes and piping
Process Pumps EOT crane materials (other than
Gas and Liquid Filters category 2)
Pipes Gauges Glass
Piping material including Valves Meter-flow-annubar
(AS, SS, LT) Solenoid valve
HT switch gear Pressure gauges and
Neutral Grounding resistor Receiver gauges
Fire alarm system Draft Gauges
CO2 Flooding system Pressure switches
HT / LT Motors Flow switches
DC System Level switches
Batteries & battery Charges (explosion Proof)
Plant communication system Annunciators
UPS Temperature sensing
Element-RTD’s
Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved
Note: For any material not covered above, the inspection requirement shall be decided
by EIC based on the criticality
ITP NO : 1903
ROU SURVEY, CLEARING & GRADING
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
ITP NO : 1904
TRENCHING
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission and approval of work procedure WC Rw
Procedure
Center line/dimensions of trench w.r.t established
2 markers & stacks or existing U/G line (in case of WC S P-06
existing ROU)
3 Measurement of trench depth WC S P-06
ITP NO : 1905
ROCK BLASTING FOR TRENCHING / FOUNDATION
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Submission & approval of work procedure by geologist Approved
1 WC Rw
engaged by contractor / by competent authority procedure
Availability and submission of valid license for
possessing as well as use of explosive materials from License for
2 WC HP
concerned statutory authority and notice to all blasting
concerned authorities
Availability of licensed blaster / other competent
3 personnel as per requirement of statutory authority and WC Rw Valid license
examining blasting material before use
Trial blasting
4 Trial blast & vibration recording WC S
records
ITP NO : 1906
LINE PIPE HANDLING, HAULING & STRINGING
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
ITP NO : 1907
COLD FIELD BENDING OF PIPES
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
Alignment sheet
3 Survey check WC S and field survey
report
ITP NO : 1908
CONCRETE WEIGHT COATING
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
Approved Mix
2 Approval of concrete mix design WC Rw
design report
Approved PQR
3 Concrete weight Coating procedure qualification WC HP for concrete
coating
4 Raw material inspection & testing wherever required WC Rw P-04, P-12, P-13
ITP NO : 1909
WELDING (INCLUDING TIE IN AND SV
INSTALLATION)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedures WC Rw
Procedure
Electrode / Filler wire P-04
a) Review of batch test certificates/documents from
WC Rw
manufacturer
2
b) Electrode / Filler wire Testing, as required
WC W
c) All weld tensile test and bend tests for each batch of Approved lab test
WC Rw
electrodes (as required ) reports
WPS/PQR
a) Review of proposed WPS WC Rw
3 Approved
b) Procedure Qualification Test WC HP
WPS/PQR
c) Approval of final WPS & PQR WC HP
Welders
a) Performance qualification test WC W Approved welder
4
b) Review of radiographs of qualification test piece WC HP ID card and
c) Final approval of welders WC HP Certificates.
NDT Procedure Qualification
5 a) Review of proposed procedure WC Rw Approved NDT
b) Procedure Qualification Test WC W PQR
Bevel inspection / Pipe facing / Bevel cutting) & inside
6 WC S P-16, P-17
cleaning of pipes
ITP NO : 1910
FIELD JOINT COATING AND REPAIR
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
Approved PQR
2 Coating Procedure Qualification WC HP
for coating
Approved
Qualification of applicators/application in presence of
4 WC HP applicator ID
Manufactures representative of coating material
card
ITP NO : 1911
LOWERING OF PIPE LINE SECTION & OFC
CABLES
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission and approval of work procedure WC Rw
procedure
ITP NO : 1912
BACK FILLING
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
ITP NO : 1913
CASED CROSSINGS (Sheet 1 of 2)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of Work Procedure WC Rw
procedure
Approval from competent authority before start the
2 work (in case of obtaining approval from the concerned WC Rw
authority is in the scope of the contractor)
Approved
Approval of construction drg. from concerned
Construction
authority having jurisdiction, for length & depth of
4 WC Rw drawing for
casing pipe (in case of approval of boring is in
cased crossing
contractor’s scope)
from CA
ITP NO : 1913
CASED CROSSINGS (Sheet 2 of 2)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
ITP NO : 1914
MAJOR WATER CROSSINGS BY OPEN CUT (Sheet 1 of 2)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
Approval of concerned authority having jurisdiction to Copy of written
2 WC Rw
start the work approval letter
7 Trenching WC S P-06
d) Pressurization WC S P-29
ITP NO : 1914
MAJOR WATER CROSSINGS BY OPEN CUT (Sheet 2 of 2)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
10 Holiday testing of the entire string WC W P-23, P28
P-23, P-24,
11 Lowering & Level Checking WC W
P-28, P-27
P-31, P-28,
15 Gauging & Post - hydro test ( in –Situ ) WC HP
P-36
ITP NO : 1914 A
CROSSINGS BY HORIZONTAL DIRECTIONAL DRILLING
(HDD) (Sheet 1 of 2)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
d) Pressurization WC S P-29
ITP NO : 1914 A
CROSSINGS BY HORIZONTAL DIRECTIONAL DRILLING
(HDD) (Sheet 2 of 2)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
10 Holiday testing of the entire string WC W P-23A, P28A
P-23A,
15 Pulling of Pipe String WC W
P-28A
P-31, P-28A,
18 Gauging & Post - hydro test ( in –Situ ) WC W
P-36
21 Disposal pf Bentonite WC S
ITP NO : 1915
INSTALLATION OF PIPELINE MARKERS
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
Approval letter
2 Approval of " Sample " markers including painting WC HP
for sample.
ITP NO : 1916
HYDROSTATIC TESTING & DEWATERING (Sheet 1 of 2)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
1 Submission & approval of work procedure WC Rw Approved procedure
ITP NO : 1916
HYDROSTATIC TESTING & DEWATERING (Sheet 2 of 2)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
18 Pressurization
*Temperature and Pressure reading at the beginning and end of the test shall be HP
ITP NO : 1917
FINAL CLEAN UP & RESTORATION
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
ITP NO : 1918
CALIBRATION OF INSTRUMENT
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
ITP NO : 1919
LAYING OFC INCLUDING LAYING IN SEPERATE TRENCH
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
1 Submission & approval of work procedure WC Rw
procedure
Approved
Review and approval of OFC alignment sheets/drum
2 WC Rw alignment sheet
schedule.
for OFC laying
Review of manufacturer test certificate of HDPE
3 WC Rw P-04
conduit & cable and clearance through IMIR
As built
12 As-Built drawings WC Rw
drawing.
ITP NO : 1920
OFC JOINTING AND TESTING
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Approved
- Submission & approval of work procedure WC Rw
procedure
1 Drum Testing
2 Jointing
3 Link Testing
Measurement of link loss from either side OFC
3.1 WC W P-52
between two stations after jointing
ITP NO : 1921
CATHODIC PROTECTION (Sheet 1 of 3)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Check for availability of approved Design document for
1 WC HP
Cathodic protection
2 Incoming Material check WC HP P-04
Availability of Approved procedure for execution of Approved
3 WC Rw
Cathodic protection Procedure
Demonstration of application of Thermit weld, Pin
Record of
4 brazing, etc. and conformity by pull / hammer test and PT WC HP
demonstration
etc.)
5 Pipe to cable Connection
Check location for Lead connection and expose pipe
a) WC S P-54
surface
Connection of cable to pipe as per demonstrated procedure
b) WC S P-54
(pin brazing, thermit welding etc.)
c) Bonding tightness test of cable WC S P-54
d) Continuity test WC Rw P-54
e) Epoxy filling after thermit welding/pin brazing WC S P-54
f) Holiday testing WC W P-54
g) Backfilling WC S P-54
6 Anode connection and sealing
a) Anode surface preparation WC S P-55
b) Continuity Test WC Rw P-55
c) Encapsulation WC S P-55
7 Anode installation
a) Check for Depth of anode, dimension, air/water tightness WC S P-56
b) Open circuit potential measurement WC S P-56
c) Natural PSP measurement WC W P-54
d) PSP measurement WC W P-54
8. Test Station or Test Lead Point Installation
a) Location of TS in ROW WC S P-54
Check for Concrete foundation: size, Concrete Mix and
b) WC S P-54
curing
c) Installation of Test Station above Foundation WC S P-54
d) Termination of Cables in the Test Station WC S P-54
e) Check proper sealing of Cable entry at Foundation WC S P-54
Ensure Galvanic earthing through polarization cells in
f) WC W P-54
Test stations at HV transmission line crossings as required
g) Name plate on Teat Station WC S P-54
ITP NO : 1921
CATHODIC PRTECTION (Sheet 2 of 3)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
9. Anode Junction box Installation
ITP NO : 1921
CATHODIC PROTECTION (Sheet 3 of 3)
Records to be
Sl.
Activity Contractor EIL Submitted/
No.
Format No.
Permanent Reference cell installation/ Polarisation
15
coupon installation
a) Interference Survey WC S*
b) CIPL Survey WC S*
c) CAT Survey (As required) WC S*
d) DCVG Survey (As required) WC S*
*Note: The interpretation of survey data and recommendations for mitigation measures shall
be vetted by Engineering
Format no : P-01
INSPECTION REPORT FOR HANDING OVER TAKING OVER
OF LINE PIPES AT DUMP YARD
The pipes mentioned above are coated (externally cleaned, primed and coated), tested and inspected in
accordance with the contract.
Visual Check includes mechanical damages, pipe bevels and proper securing with bevel protectors etc
Certified damage free handing over and receipt of above Line pipes.
Sign.:
Name:
Date:
Format no : P-02
MATERIAL ISSUE VOUCHER
CLIENT :
JOB DESCRIPTION :
REQUISITION NO : INDENT NO : MIV NO :
REQUISITION DATE : MIV DATE :
CONTR.NAME : CONTR. CODE : FREE/LOAN/CHARGEABLE
DRG NO:/LINE NO :
COST CENTRE : MATL.CARD NO:
ALLOCATION DATE : ALLOCATION RUN NO: VALID DATE
NOTE : For line pipes (coated / bare), the copy of IRN of the pipes, indented quantity shall be attached with MIV for identification & certification of
pipe No, Coating No& pipe length issued and received by contractor.
Format No : P-03
MATERIAL RETURN VOUCHER
Sl. Material Materials Description with Return Type Quantity For Account Deptt.
Unit Location
No. Code No. Tag No as applicable / category Returned Accepted Rate Value
Remarks Category
A – Unused & Serviceable
B – Used & Serviceable
C - Repairable
D – To be returned to Vendor
E - Scrap
Returned By Authorised By Accepted & Data Entered Approved
Format No : P-04
INCOMING MATERIAL INSPECTION REPORT
Report No. :
Date :
MTC No./
SOR Material IRN No. Heat/
Sl. Date of Qty. Qty. Manufacturer/ Ref. Invoice/ Observation/Remarks/
Item description/Tag with Batch
No. Receipt Received Accepted Vendor Challan No. Storage Instruction
No. Date/Sampling No.
no for field test, etc
Notes :
Format No : P-05
INSPECTION REPORT FOR HANDING OVER OF ROU/
CLEARING, GRADING OF ROU
Manpower
Machineries
CONTRACTOR EIL / OWNER
Sign Sign
Name Name
Date Date
Format No : P-06
INSPECTION REPORT FOR TRENCHING
Client: Consultant:
Contractor: Date:
Weather:
PROGRESS
CONTRACTOR EIL
sign Sign
Name Name
Date: date
Format No : P-07
INSPECTION REPORT FOR ROCK BLASTING
Contractor: Date:
Suitability for bend profile (Horizontal / Sag & Over bends) : YES / NA
Chainage Section Type of
S. No. Depth Width Remarks
From To Length Ground
Format No : P-08
INSPECTION REPORT FOR STRINGING
Contractor: Date:
Stringing Progress
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-09
INSPECTION REPORT FOR COLD FIELD BENDING.
SPREAD : Date :
FROM : TO : Report No. :
WEATHER :
Type
Sl. Coating Visual Wall Length Pull Through Holiday Disbondment
Chainage / TP No Pipe No. Heat No. Degree of
No. No. Inspection Thickness (m) Check Check Check
Bend
Machineries
Contractor EIL
Sign Sign
Name Name
Date Date
Format no : P-10
INSPECTION REPORT FOR CONCRETE WEIGHT COATING
OF PIPES
Owner: Consultant:
Contractor: Date:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-11
CRUSHING STRENGTH TESTING RESULTS OF CONCRETE CUBES
Project : Job No :
Client : Contractor :
Name of Work :
Project : Job No :
Client : Contractor :
Name of Work :
1. Reference :
2. Material :
3. Location of Source :
5. Physical Properties
a) Colour :
b) Shape : Rounded/Irregular
c) Texture : Glossy/Smooth/Granular
6. Tests conducted at :
COMMITTEE MEMBERS :
APPROVED : i) EIL :
ii) Client :
Date :
Place :
Contractor : Client :
Name of work :
1. Reference document :
2. Type of structure : Location :
3. Levels From : To :
4. Grade of concrete/ Approved Design Mix
5. Brand name, Grade and Consignment no. of cement
6. Estimated volume of concrete :
7. Quantity of cement required :
8. Reinforcement checking details :
No. Dia. Length
a) Laps
b) Separators
c) Chairs
d) Any other
Remarks
Remarks
11. The above structure is finally inspected on at AM/PM and found/ not found
satisfactory for concreting.
Remarks, if any
(Contractor) (EIL)
Sign Sign
Name Name
Date Date
Contractor : Client :
Name of work :
1. a) Quality of coarse aggregates
Satisfactory Not satisfactory
2. Quality of water
Satisfactory Not satisfactory
Details of abnormality :
(Precautions taken for <50C and >400C, rainy season)
10. Number of cubes taken :
11. Quantity of concrete poured :
12. Pour completion time : AM/PM ; Date :
13. Curing method :
(Contractor) (EIL)
Signature Signature
Name Name
Date Date
Format No : P-16
LINE UP AND WELDING VISUAL INSPECTION REPORT
Progress
Manpower: Joint No. Lining up Welding Completed
Remarks
From To Previous Today Cum Previous Today Cum
Machineries:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-17
INSPECTION REPORT FOR TIE-IN WELDING
Visual
Field
S Pipe Heat Fit Up Welder Inspection
Thickness Length Joint Remarks
No No. No. Inspection No. (including
No.
Arc Strike*)
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-18
INSPECTION REPORT FOR RADIOGRAPHY
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE:
FORMAT NO : P-19
INSPECTION REPORT FOR WELDING REPAIR
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE:
Format No : P-20
INSPECTION REPORT FOR LIQUID PENETRANT
EXAMINATION REPORT
PENETRANT :
REMOVER :
DEVELOPER :
PENETRANT DWELL DEVELOPER DWELL
SURFACE TEMP.:
TIME:______ Minutes TIME :____Minutes
DESCRIPTION
LINE JOINT OBSERVATIONS
SL.NO. OF TYPE SIZE REMARKS
NO. NO. / RESULTS
PART/SKETCH
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE:
Format No : P-21
INSPECTION REPORT FOR ULTRASONIC TESTING
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-22
INSPECTION REPORT FOR FIELD JOINT COATING
SURFACE PREPARATION
CHECK THICKNESS MEASUREMENT
SL. JOINT WFT OF HOLIDAY ON BODY
DUST VISUAL ON WELD SEAM
NO. NO. ROUGH PRIMER TEST
CONTAMINAN- VISUAL D/S U/S
NESS
TION TEST 3 6 9 12 3 6 9 12 AVG. 3 6 9 12 AVG.
PEEL TEST : Joints Marked for Peel Test: Value: On Joint On Overlap: Accepted / Rejected
FIXING OF END CLOSURE PATCH (IN CASE OF HIGH TENSILE SLEEVES IN HDD): YES / NO Repair of Peel Test Location: OK / Not OK
MANPOWER: MACHINERIES:
CONTRACTOR EIL / OWNER:
SIGNATURE : SIGNATURE :
NAME : NAME :
DATE : DATE :
Format No : P-23
INSPECTION REPORT FOR HOLIDAY TESTING AND
LOWERING
Note: 1) Pipe top Level record after lowering as per format P24 is to be attached.
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-23A
INSPECTION REPORT FOR HOLIDAY TESTING AND
PULLING OF HDD STRING
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-24
INSPECTION RECORD OR LEVEL RECORD AFTER
LOWERING
Certified that 500mm backfilling/post padding (if applicable) to cover pipeline & OFC cable is done immediately
after lowering of P/L and recording of levels as above.
REMARKS:
CONTRACTOR EIL/ OWNER
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-25
INSPECTION REPORT FOR BACKFILLING
Progress
Today Previous Cumulative Remarks
Padding (Post)
MANPOWER
MACHINERIES
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-26
INSPECTION REPORT FOR CASED CROSSING
PROJECT NAME: JOB NO:
OWNER: CONSULTANT:
CONTRACTOR: DATE:
FROM: TO: REPORT NO.:
SECTION: ALIGNMENT SHEET NO.:
WEATHER: CHAINAGE:
CARRIER PIPE DIA / GRADE / THICKNESS CROSSING DETAIL
Type of Crossing :- Road / Rail / Canal Chainage :-
A) CASING PIPE DETAIL
Material specification:- Total length : _____________ Visual Check (Out of roundness / dents etc.) OK / Not
OK
Painting
Weld visual
Dia. Thick Length Joint No. Casing pipe internal Casing pipe Remarks
after welding
DFT external DFT
Checked By
OTHER DETAILS:- Contractor Owner/EIL Boring Operation:-
Bottom Level of Casing Pipe Start-Date/Time:-
Installation of Zinc Ribbon Anode, if applicable Completed-Date/Time:-
Installation of Insulators, Nos, and Spacing. Carrier Pipe Insertion:-
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-27
INSPECTION REPORT FOR OPEN CUT ASPHALT ROAD
/ LISTED MINOR WATER CROSSING
GENERAL
DATE OF
CHAINAGE
COMMENCEMENT
ALIGNMENT SHEET NO. DATE OF COMPLETION
TYPE OF XING (ROAD/CANAL) ACTUAL NO. OF DAYS
CARRIER PIPE DETAILS
OPERATION STARTED
GRADE X WALL THK
ON
OPERATION FINISHED
PIPE INSTALLED ON
ON
CARRIER WELD REF REPORT NO.
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-28
INSPECTION REPORT FOR MAJOR RIVER CROSSING BY
OPEN CUT
S
ACTIVITY REPORT NO. DATE: REMARKS
NO
1 TRENCHING
2 STRINGING
3 WELDING
4 NDT
JOINT COATING / CONCRETE
5
WEIGHT COATING
6 PREHYDRO TESTING
7 LOWERING
8 BACKFILLING WITH PADDING
9 GAUGING
10 POST HYDRO TESTING
11 RESTORATION AND CLEANUP
12 TIE-IN
GENERAL TRENCHING
CHAINAGE DATE OF COMMENCEMENT
ALIGNMENT SHEET NO. DATE OF COMPLETION
RIVER XING ACTUAL NO. OF DAYS
OPEN CUT
LOWERING BACKFILLING
OPERATION STARTED ON OPERATION STARTED ON
OPERATION FINISHED ON OPERATION FINISHED ON
PIPE LINE BOTTOM CONTOUR
INSPECTION AFTER LOWERING :
Diver Report attached
AS BUILT SKETCH : __________________ Attached as Annexure
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-28 A
INSPECTION REPORT FOR MAJOR RIVER CROSSING /
OTHER CROSSINGS BY HDD
S
ACTIVITY REPORT NO. DATE: REMARKS
NO
1 TRENCHING
2 STRINGING
3 WELDING
4 NDT
5 PREHYDRO TESTING
6 JOINT COATING
7 HOLIDAY AND PULLING
8 GAUGING
9 POST HYDRO TESTING
10 TIE IN
11 RESTORATION AND CLEANUP
GENERAL DRILLING DETAILS
CHAINAGE DATE OF COMMENCEMENT
ALIGNMENT SHEET NO. DATE OF READINESS FOR PULLING
RIVER XING ACTUAL NO. OF DAYS
PULLING
OPERATION STARTED ON COATING INTEGRITY CHECK OK / NOT OK
OPERATION FINISHED ON
BENTONITE DISPOSAL
RESTORATION ON: CROSSING COMPLETED ON:
MARKER INSTALLATION ON:
AS BUILT DRAWING : __________________ Attached as Annexure
REMARKS:
CONTRACTOR EIL / OWNER
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-29
HYDROSTATIC PRE - TEST CUM EVALUATION REPORT
PROJECT NAME: JOB NO:
OWNER: CONSULTANT:
CONTRACTOR: DATE:
FROM: TO: REPORT NO.:
SECTION: ALIGN.SHEET NO.:
WEATHER:
Testing Duration
Start Date Finish Date
Start Time Finish Time
No of pipes in String : Length of pre-tested String :
Details of Tested Pipes and Weld Joints ( if any)
Pipe No./Section From- Weld joint NDT
Wall thickness Length of pipe Remarks
To no. Clearance
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-30
TEMPERATURE AND PRESSURE RECORDING LOG FOR
PRE HYDROTESTING
PROJECT NAME: JOB NO:
OWNER: CONSULTANT:
CONTRACTOR: DATE:
FROM: TO: REPORT NO.:
SECTION: ALIGN.SHEET NO.:
WEATHER:
3
4
5
6
7
8
9
10
11
12
13
14
15
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-31
HYDROSTATIC POST - TEST CUM EVALUATION REPORT
Testing Duration
Start Date: Finish Date
Start Time: Finish Time
Length of String : Test Pressure :
Variation in temperature, °C
Mano thermograph
Inference and acceptance.
Hydro test Accepted & Section released for depressurization / Hydro test not Accepted.
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-32
INSTALLATION OF MARKERS
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-33
CLEARANCE CERTIFICATE OF
PIPELINE SECTION FOR HYDROTESTING
O D (mm) Wall Thk. (mm) I.D.(mm) Grade Length (km) Volume (m3)
Max. : Max. :
Wall Thickness
Length (Mtr) Number of Welds :
(mm)
Length of not back filled section :
CONSTRUCTION PERIOD :
Start Date :
Format No : P-34
SAFETY CHECKLIST FOR PIPELINE SECTION
HYDROSTESTING
SL
CHECK POINTS YES NO
NO.
1 The test section has been isolated from all other pipeline sections.
2 Is a copy of the hydro test pack available in the area ?
3 Is adequate water disposal arrangement made?
Check Housekeeping standards are acceptable at the filling end and receiving
4
end.
5 Check the conditions of the tools and tackles to be used.
Check that the lighting arrangements are adequate and the condition of the
6
electrical wiring circuit boards, conduit etc. is acceptable and safe.
Check that test areas at each end of the test section have been cordoned off
7
with stakes and bunting tape.
Check that emergency equipment are adequate and are working condition-
8 standby vehicle, communication system, first aid boxes, medical facilities,
stretcher etc.
9 Check the condition of tools to be used.
All temporary piping test heads and other equipment connected to the test
10
section have been pre tested to a pressure of at least 1.1 times the test pressure.
Ensure; complete bolting on cleaning /Batching Pigs are properly tightened
11
before insertion in the test Headers.
12 The test section has been completely filled with water and the air vented off.
13 All instruments and gauges which are used have valid calibration certificates.
All warning notices, marker tapes, protective barriers and other safety
14
equipment have been positioned and all the concerned informed.
15 All persons who may be affected by the operations are informed of the activity.
Note : Hydro test engineer/ HSE officer to add any other safety points to this list as per the site
circumstances if deemed necessary.
Sign : Sign :
Name : Name :
Date : Date :
Format No : P-35
INSPECTION REPRT FOR AIR PIGGING OF PIPELINE
SECTION DURING HYDROTESTING
Remarks (Abnormal
Start End
quantity of water /
Run No Pig Type
debris or any
DATE TIME DATE TIME interruption)
REMARKS :
Format No : P-36
INSPECTION REPORT FOR GAUGING OF PIPELINE
SECTION DURING HYDROTESTING
Enclosure : - The Photograph of Gauge Plate After Run (Front, back and side views – 3 snaps)
Detail of Gauge Plate Damage ( if any ) :
REMARKS :
Format No : P-37
INSPECTION REPORT FOR WATER FILLING OF
PIPELINE SECTION DURING HYDROTESTING
Filled water temperature to be recorded continuously on Temperature Recorder & readings to be recorded hourly
REMARKS :
Format No : P-38
INSPECTION REPORT FOR THERMAL STABILISATION OF PIPELINE SECTION DURING HYDROTESTING
PROJECT NAME: JOB NO:
OWNER: CONSULTANT:
CONTRACTOR: DATE:
FROM: TO: REPORT NO.:
SECTION: ALIGN.SHEET NO.:
WEATHER:
No of welded joints:
Time Location No. ----> 1 2 3 4 5 6 7 8 9 10 11 12
( Hrs) Difference between Average Pipe Temperature
Date in 24 Average and Average Soil Temperature (0 C)
hour Chainage ( Km) ---->
format
TEMPERATURES ( o C )
Pipe
Soil
Pipe
Soil
Pipe
Soil
Pipe
Soil
READINGS TO BE TAKEN EVERY TWO HOURS
THERMAL STABILIZATION BE CONSIDERED TO HAVE BEEN ACHIEVED, WHEN THE DIFFERENCE BETWEEN THE AVG. PIPE TEMP. AND AVG. SOIL TEMP.IS NOT HIGHER
THAN 1˚C. FOR 2 CONSECUTIVE READINGS.
Remarks:
Format No : P-39
INSPECTION REPORT FOR AIR VOLUME CALCULATIONS DURING PRESURE TEST OF PIPELINE SECTION
PROJECT NAME: JOB NO: CONSULTANT:
OWNER: CONTRACTOR: DATE:
FROM: TO: REPORT NO.: SECTION:
WEATHER: ALIGN.SHEET NO.: No of welded joints:
Format No : P-40
INSPECTION REPORT FOR PRESSURIZATION OF PIPELINE SECTION DURING HYDROTESTING
Pressurization Cycle: 50% / 75 % / 100% Target Pressure at Test Station (Bar / kg/cm2):
Section Length: Theoretical volume: Material: Wall thickness: Source of water:
Elevation /Pressure at: Highest point: Pressurizing Point:
Lowest point: Pressurizing Point:
STROKE COUNTER/Flow mtr
TIME ( in Pressure/Dead Wt AMBIENT
DATE 24 hour READING VOLUME M3 CUM. VOL. M3 REMARKS
format)
Bar/Kg TEMPERATURE
STROKE COUNTER FLOW METRE
Dead Weight Tester : Make ____________ Model ___________ Calibration Certificate No: & Date _________
Flow Meter : Make ____________ Model ___________ Calibration Certificate No: & Date _________
Format No : P-41
INSPECTION REPORT FOR DEAD WT. PR.PIPE TEMP & SOIL TEMP. DURING 24 HR PRESSURE TEST OF PIPELINE
SECTION
Time Press P- S-
P-1 P-2 P-3 P-4 P-5 P-6 P-7 P-8 P-9 S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8 S-9
(Hrs) ure 10 10
Ambient
(Bar Average Pipe Average Soil
Date (in 24 /
Temp REMARK
Temperature Temperature
hour Kg/c KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM KM ˚C S
format) m2)
DEAD WEIGHT TESTER READINGS TO BE RECORED AT EVERY HOUR, PIPE & SOIL TEMPERATURE READINGS TO BE RECORDED EVERY 2 HOUR.
Format No : P-42
INSPECTION REPORT FOR CALCULATION AND EVALUATION OF HYDROSTATIC TEST FOR PIPELINE SECTION
PROJECT NAME: JOB NO: CONSULTANT:
OWNER: CONTRACTOR: DATE:
FROM: TO: REPORT NO.: SECTION:
WEATHER: ALIGN.SHEET NO.: No of welded joints:
Format No : P-43
INSPECTION REPORT FOR DEWATERING AFTER HYDROSTATIC TEST FOR PIPELINE SECTION
Format No : P-44
INSPECTION REPORT FOR SWABBING OF PIPELINE SECTION
REMARKS:
Format No : P-45
INSPECTION REPORT FOR SV INSTALLATION
MANPOWER
MACHINERIES
CONTRACTOR EIL CLIENT
Sign : Sign : Sign :
Name: Name : Name :
Date : Date : Date :
Format No : P-46
INSPECTION REPORT FOR RESTORATION
Format No : P-47
INSPECTION REPORT FOR CALIBRATION OF
INSTRUMENTS
Instrument Instrument
Master
S. Readings Readings while Difference in
Instrument Difference Remarks
No. while going coming down %
Reading
up the scale the scale
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-48
RECORDING OF SITE DATA FOR PREPARATION OF AS
BUILT OF OFC
11 OFC Loop length ( m ) with start & end marking readings ( if any )
NOTE: Permanent land mark may be used in defining physical location of OFC joint / joint pits.
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-49
INSPECTION REPORT FOR OFC LAID IN CROSSINGS
PROJECT NAME: JOB NO:
OWNER: CONSULTANT:
CONTRACTOR: DATE:
FROM: TO: REPORT NO.:
SECTION: CABLE ALIGN.SHEET NO.:
TYPE OF CROSSING
A) Laying in CS conduit
S.No.
Cable
Chainage
Drum
No. Installation of duct with pulling wire inside CS conduit Remarks
From To Previous Today Cumulative
C) Material Used:
Heat
OFC
S. No. Chainage HDPE CS Pipe shrinkable Joint Pit Electronic Marker Remarks
Marker
cap
From To
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-50
INSPECTION REPORT FOR OFC DRUM TESTING
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-51
INSPECTION REPORT FOR OFC JOINTING & SPLICING
OTDR Details: (Make, Sl No, Calibration Details) Cable No. (+Ve direction) :
Cable No. (-Ve direction) :
Testing Wave Length
Fibre Splice
Positive Direction Negative Direction Remarks
Fibre Identification Loss
No. Fibre Loss Fibre Loss
Bundle Color
Length dB/Km Length dB/Km
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-52
INSPECTION REPORT FOR OFC LINK TESTING
Fibre
Splice Loss, Joint No. Splice Loss ,Joint No. Splice Loss, Joint No. Remarks
Identification
Fibre
NO. Fibre A' B' Average A' B' Average A' B' Average
Bundle
Color Direction Direction (A+B)/2 Direction Direction (A+B)/2 Direction Direction (A+B)/2
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
RESTORATI
ON DATE
DATE OF PCP
STANDARD SPECIFICATION No.
EIL
BANK MINOR
C
PROTECTIO
N MAJOR
FINAL TIE-
IN DATE
DATE OF IP
CONTRACTOR
CONTRACTOR
DATE OF SV
OFC PART TESTING
HYDROTES
P/L FINAL T DT
CONC.
OWNER
FOR CROSS COUNTRY PIPELINE
COAT
ANTI-
INSPECTION & TEST PLAN
BUOYANCY SADDLE
CONTROL WT.
BACKFILL DATE
WORKS
EIL
OFC
SPLICING & JOINTING
B
TCP DATE
CONSULTANT
LENGTH
CONTRACTOR
OFC
LOWERING DATE
TIE-IN DATE
LOWERING DATE
JT CTNG. DATE
UT DATE
OWNER
PIPE BOOK FORMAT
X-RAY DATE
WPS No
WELDING DATE
JOINT NO.
__________ mtrs
__________ mtrs
A
To:
BENDING DATE
EIL
P-53
STRINGING DATE
CONTRACTOR
From:
PIPE LENGTH ON
THIS PAGE
CLIENT
HEAT No
KM
PIPE NO
Page 2032 of 2065
INSPECTION & TEST PLAN STANDARD SPECIFICATION No.
FOR CROSS COUNTRY PIPELINE 6-82-1900 Rev. 2
WORKS Page 93 of 106
(Sheet 1 of 2)
Format No : P-54
INSPECTION REPORT FOR CATHODIC PROTECTION
SYSTEM
PROJECT NAME: REPORT NO.:
OWNER: DATE:
CONTRACTOR: CONSULTANT:
(Sheet 2 of 2)
Format No : P-54
INSPECTION REPORT FOR CATHODIC PROTECTION
SYSTEM
LETTER WRITING ON TLP (Ch.No. DISTANCE FROM PIPELINE, DIR OF FLOW):- OK/NOT OK
Fixing of Schematic Diagram plate ON TLP :- OK/NOT OK
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-55
INSPECTION REPORT FOR ANODE CONNECTION & SEALING
SR
ANODE NO CABLE LENGTH CONTINUITY TEST ENCAPSULATION
NO
REMARKS
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-56
INSPECTION REPORT FOR ZINC RIBBON ANODE
INSTALLATION
CHAINAGE IN KM
LOCATION
TYPE OF CROSSING
ZINC ANODE AS PER SPECT. OK / NOT OK
LENGTH OF ANODES mm
NO. OF ANODE Nos.
SPACING BETWEEN ANODES Mtrs.
ANODE CORE EXPOSED EITHER SIDE mm
ANODE CORE CONNECTION TO PIPE AS PER OK / NOT OK
APPROVED DESIGN / DRAWING
CORE ENCAPSULATION OK / NOT OK
REMARKS
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-57
INSPECTION REPORT FOR ANODE JUNCTION BOX
INSTALLATION
CONTRACTOR: CONSULTANT:
PIPELINE CHAINAGE IN KM :
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-58
INSPECTION REPORT FOR CPTR AND CPPSM INSTALLATION
PROJECT NAME: REPORT NO.:
OWNER: DATE:
CONTRACTOR: CONSULTANT:
PIPELINE CHAINAGE: JOB NO:
STATION LOCATION: REF DOC NO.:
INSTALLATION OF TRU / CPPSM
1 Installation (Indoor / outdoor) OK / NOT OK
2 Cable connection, termination & tagging OK / NOT OK
3 Earthing of the unit
COMMISSIONIG OF TRU / CPPSM
1 Sr. No. Of the TRU / CPPSM
2 Total anode bed resistance OHMS
3 Test in manual / auto mode
3.1 Operation of switch / breaker Accepted /rejected
3.2 Operation of TRU / CPPSM Accepted /rejected
A) Auto mode Accepted /rejected
B) Manual mode Accepted /rejected
3.3 Meter calibration Accepted /rejected
Format No : P-59
INSPECTION REPORT FOR ER PROBE INSTALLATION
1 CHAINAGE IN KM : KM
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-60
INSPECTION REPORT FOR HORIZONTAL ANODE BED
INSTALLATION
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-61
INSPECTION REPORT FOR COMMISSIONING OF ANODE BED
A2
A3
A4
A5
A6
A7
A8
A9
A 10
TOTAL CIRCUIT RESISTANCE :- OHMS
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-62
INSPECTION REPORT FOR VERTICAL ANODE BED
INSTALLATION
PROJECT NAME: REPORT NO.:
OWNER: DATE:
CONTRACTOR: CONSULTANT:
PIPELINE CHAINAGE: JOB NO:
CP STATION NO: REF DOC NO.:
Remarks:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-63
INSPECTION REPORT FOR POLARIZATION CELL
INSTALLATION
LOCATION DESCRIPTION
RATING TYPE
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-64
INSPECTION REPORT FOR SURGE DIVERTER
INSTALLATION
IJ LOCATION
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No : P-65
INSPECTION REPORT FOR PERMANENT REFERENCE CELL
INSTALLATION
OWNER: DATE:
CONTRACTOR: CONSULTANT:
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Format No P-66
INSPECTION REPORT FOR POLARIZATION COUPON
INSTALLATION
REMARKS:
CONTRACTOR EIL
SIGN SIGN
NAME NAME
DATE DATE
Abbreviations:
IS Indian Standard
CONTENTS
1.0 SCOPE 4
2.0 REFERENCES 4
1.0 SCOPE
This standard covers the method of identification of the piping materials by coloring using
paints in order to avoid mix-up between materials of different metallurgy but similar in
physical appearance.
2.0 REFERENCES
The following Code shall be referred to as and when required for resolution of colour shades.
i. Materials shall be painted with one colour or combination of colours as set out in this
specification.
ii. Paints used for colour coding shall be of quality so as to last for at least 5 years.
vi. Special items like bellows, strainer, steam traps, valves do not require colour
identification as these items are tagged with their identification.
vii. Discrimination colour shall be marked on the inner and outer surface of pipes &
fittings.
ü. The identification colour on gaskets shall be painted on the peripheral face of each
gasket (refer Annexure-1).
iv. Width of colour band shall be a minimum of 12 mm for less than 3 inch size
components and 25mm for 3 inch and larger sizes, unless otherwise specified.
Shall be not less than 4 inch (100 mm) at both ends of pipes and shall start 2
inch (50mm) from pipe ends.
Shall be about 2 inch (50 mm) at any one end of fittings.
vi. Paints containing chlorine, chlorides, sulphur, lead, zinc or any contents detrimental to
materials are not acceptable. The contractor shall satisfy and produce documents/carry
out tests as required by the owner/EIL.
vii. A query shall be raised with EIL for materials not covered by this specification.
TABLE - 1
NOTE: * The Colours are based on RAL K5 Classic Edition 2006 by RAL, Deutsches institut,
incorporated for international jobs.
11
Salmon Pink
Salmon Pink
"c3
r-.
a)
t>.1)
Dove Grey
cz)
c),
No Paint
541Maroon
Maroon
None
(1)
0 0 0 0 (1.)
Z Z Z Z (21
1
1.,
0
0 0
az .LD
591/217
591/217
106/415
r..) C)
.--,
-1- ,--,
591
kr) ....... O
O C) c.)
1I i i 11
87
I ----- O O rel en
i 1 ■C) ,--, ,--, 00 00
A182 Fl o
Flange/Blind
Flan e
O
czt O
o . Q •2
in (--) (1) •
C) oo s-,
,—, ---., 0 0 0 -0
1I
e
11
1 1il 1I
1 1,I •
- (.1-i •-4•-■ czt
czt v) • •-•
"C:3 o ^c, .
A-234 Gr WPB/WPBW-NONIBR1
•■•-,
A-234 Gr WPBW-NONIBR
C • ,C1).
A-234Gr WPB/WPBW-IBR
c
i "C,g - Cv3 5
cc cl T=1, cu
,u +A
,SZ>
A-420WPL6
,•C+
A-234Gr WPB(N)
• ci)
&NORMALISED
1A-420WPL6W
c?,,4
IA-234WP1W
1.) Ov) 0
L.> "10 ,c)
A-234WP 1
(1)
cc)
czt O eD
ci)
'/) . 1") "è.,
0 .•c)
I I I I °
c.) cll P-4
I I I I
I I I I cll c„)
•^. r+-■•' bo
,c,
c/D
(1)
Stainless steel
t/i O
API 5LGr B — Seamless
IS1239/IS3589Gr 410
)
.
(Normalized)
0:1 ,-ti
A106 Gr B
A106Gr B
o.
1A333Gr 6
:5 r,4 czs
FormatNo. 8-00-0001-F7 Rev. 0
Z
„
kr, kr, OO
. en
en c) 0 u.4
.d .< •-
•- •-
12
coH
—• c'., ,__, ,. . „1, ,,, .1- C) ,-,
..... cf-)
-..
kn \ C) li."--- 00 01 —,
1
6-82-0003Rev.1
Paae 8 of12
Olc;,
©
1.0
1:::ii
;«I
0
a.>
0
0
L)
U
Elbows, Reducers, Tee's Flange/Blind Flange
ts..
C3
0
z
c:;
m 31 z
7)•. z
Caps
.d-
A335Gr P 11 A-234WP11 A 182 F11 27 276 Lincoln Green II
(^4
\ ,0
C X.1
S
C"--
A691Gr 1.25 Cr CL.42 A-234WP11W Lincoln Green
(EFW)
1•••••4
.--.1
(;)
el
15 A335Gr P12 A-234WP12 A182 F 12 Sky Blue
7
,
e
1
i
C)
.-1
A-234WP12W Sky Blue
;
91
Ln
C•11
<
en
Cs1
(.5
rn
A-234 WP22 A182F22 14 217 Sea Green
e
e
r."..
C•1
d-
,,
A691Gr 2.25Cr CL.42 A234WP22W Sea Green
(EFW)
‘••0
•—■
'4D
C, Navy Blue
S
A335Gr P5 A-234WP5 A 182 F5
e
e
e
1/4.0
,--,
'4:)
C)
CT
Lr)
01
en
en
<
c5
II 18 A-234WP9 A182F9 104 DarkViolet
e
e
r---
CT
'4:›
<3.■
ii>
d•
r.....
d'
,'
e
I
d-
ir....
li-1
,.,
.'t
A-234WP91W Chocolate
E-1
Format No. 8-00-0001-F7Rev. 0 Copyright EIL — All rights reserved
STANDARDSPECIFICATION No.
u_
O
z
z
o u-
o
po
•< o
<o
z
6-82-0003Rev.1
c) o o_
•w oo<
LT. (3. 1.2
z
G.
-
!".
c5
c.)
z
ASTM DESIGNATION COLOURSHADES
COLOUR (ISC) NO.
cT
.±::
C0
0
r4
rn
rn
c,
A 193 GR B7 Canary Yellow
CT
rn
z
,_,
CD
cf-)
0,
A194GR2 H Canary Yellow
■
,--
r2a)
0
0
d-
kr)
,=,,
v-,
A307GRB India Brown
L.,-
\.0
z
,...,
kr)
d-
-1
A 307 GR B India Brown
C\I
•■-■
0
0
rit
r--
r-
C\1
A193 GRB 16 Lincoln Green
C■1
z
0
I--
+,
r-
c\1
A194GR4 Lincoln Green
,C--,r
d-
--1
kr)
--,
0:1
A320GRL7 Chocolate
GC)
;_4-4
CT
d-
s
d-
rn
A 320GRB8 Light Purple Brown
,_,
Z
CT
d-
d-
s
rn
A194GR8 Light Purple Brown
cu
;-T-4
(4-4
r=4
cct
c>
•
cl
0
ao)
0
•
▪
cz$
ftS
czt
c/)
czt
cC
c.)
c.)
4c-4
cu 0
• a)
cu (I)
a)
a)
a)
a)
O
O
o
0
0
0
H
O cr,
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All rights reserved
STANDARDSPECIFICATION No.
6-82-0003Rev.1
CL
o
INDIAN STD.
z•
:,.,
C/)
C4
E--,
d
P.
<
[-.
›.
ASTMDESIGNATION/DESCRIPTION COLOURSHADES
COLOUR (ISC) NO.
C'
C■
,r
■D
,--.
c>
,--,
7
0
CompressedFibre BS7531GR.X (FULLFACE) Dove Gray
(Ring &FullFace)
1
BS7531GR.X (RING) None
"c
c, ,,
Z
o
4
CD
-■-■
,z)
■D
,--1
c0
(.7
SS304SPRWND+Grafoil Filler
.
•a., o
v, 3
7, d
-_
■
•:1-
.1-
v)
o
O
en
00
W SS 304 H +GrafoilFiller
r=1.
r:Z
o
o
.1-
.1"
,--1
C---
4".
c,
M
SS304+Grafoil Filler
'
r:Ej
.5,
9
kr■
,—,
•ci-
-
■D
v-,
SS304+Teflon Filler
`
—
In
.:I-
m
00
g
SS304LSPRWND+Grafoil Filler
c.5
,f)
CN
—
00
Ir--
P-)'
,-)
,.5
C sl
a
o
.,5
■0
C■1
r"--
C--
2ed
o
c..)
CN
<0
C7■
Cn
en
•
>.
O S
C;)
•—.
o
ANNEXURE-1
X77-7.-M-71777-77-777777777-777714
EIBOW TEE
CAP COUPL1NG
10 BE COLOUREO AS SkCIFIE0
Name
Date: Signature:
Name:
Date: Signature:
Distribution After Resolution:
RCM/ Area Coordinator /QA Mgr:
Format No. EIL -1641-1924 Rev1 Copyrights EIL – All rights reserved
Name:
Date: Signature:
Distribution After Resolution:
: RCM/ Area Coordinator /QA Mgr:
Format No. EIL -1641-1924 Rev1 Copyrights EIL – All rights reserved
CONSTRUCTION DIVISION
Bidder must furnish answers/clarifications/confirmations of all the following queries and submit
along with offer.
SL. BIDDER'S
COMMENT/QUERY
NO. CONFIRMATION/ANSWER
1. Bidder to confirm that requirement of Health, Safety and
Environment (HSE) as per specification 6-82-0001 are
taken into consideration.