GUJARAT STATE PETRONET LIMITED

PADAMLA – GODHARA GAS PIPELINE (PGPL)

TENDER DOCUMENT
FOR
LAYING OF PIPELINES, TERMINALS AND ASSOCIATED FACILITIES

EPC CONTRACT
VOLUME - IV OF V

TENDER NO. 05/51/23JT/GSPL/001(EPC) (TECHNICAL SPECIFICATION FOR ELECTRICAL, INSTRUMENTATION, TELECOMMUNICATION & CATHODIC PROTECTION)

MECON LIMITED
(A Govt. of India Undertaking) SCOPE MINAR th 15 Floor, North Tower Laxmi Nagar District Centre DELHI – 110 092

November,2006
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GUJARAT STATE PETRONET LIMITED
PADAMLA – GODHARA GAS PIPELINE (PGPL)

TENDER DOCUMENT
FOR
LAYING OF PIPELINES, TERMINALS AND ASSOCIATED FACILITIES

(Volume-IA, IB, IC, II, III, IV & V) TENDER NO. 05/51/23JT/GSPL/001(EPC)

EPC CONTRACT

MECON LIMITED
(A Govt. of India Undertaking) SCOPE MINAR th 15 Floor, North Tower Laxmi Nagar District Centre DELHI – 110 092

November,2006

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PADMALA – GODHARA GAS PIPELINE PROJECT
Gujarat State Petronet Ltd.
Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Tender Document for EPC Contracts

MECON LIMITED

MASTER TABLE OF CONTENT Name of Project : EPC contract including Residual Engineering, Procurement, Installation, Testing and Commissioning of Pipelines, Terminals and Associated Facilities for Padmala – Godhara Pipeline Project of GSPL. 05/51/23JT/GSPL/001(EPC)

Tender Document No.

:

Sl.No. Description 1) 2) 3) 4) 5) 6) Volume-IA of V Volume-IB of V Volume-IC of V Volume-II of V Volume-III of V Volume-IV of V : : : : : : General – Commercial (IFB, ITB, GCC, SCC – Commercial) General – Technical (Particular Jobs Specification) Price Schedule Standard Technical Specification (Pipeline Laying, Piping & Mechanical) Standards Technical Specification (Civil, Architectural & Structural) Standards Technical Specification (Electrical, Instrumentation, Telecommunication Works & CP Works) Tender Drawings & Standard Drawings

7)

Volume-V of V

:

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PADMALA – GODHARA GAS PIPELINE PROJECT
Tender Document for EPC Contracts
Gujarat State Petronet Ltd.
Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IV of V

MECON LIMITED

CONTENTS 1.0 Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 2.0 Sl. No. 1. 2. 3.0 Sl. No. 1. 2. 3. 4. 5. ELECTRICAL Title SPECIFICATION FOR CABLING SPECIFICATION FOR EARTHING AND LIGHTNING PROTECTION SPECIFICATION FOR LIGHTING FITTINGS FOR HAZARDOUS, INDOOR AND SAFE AREA SPECIFICATION FOR LIGHTING SPECIFICATION FOR L.T. POWER DISTRIBUTION BOARD SPECIFICATION FOR SPLIT AIR CONDITIONING SYSTEM SPECIFICATION FOR UPS SYSTEM SPECIFICATION FOR DG SET TELECOMMUNICATION Title SPECIFICATION / PROCEDURE FOR THE TESTING OF OPTICAL FIBER CABLE SPECIFICATION FOR WARNING MATS INSTRUMENTATION Title SPECIFICATION FOR INSTALLATION OF INSTRUMENTS SPECIFICATION FOR INSTRUMENT TUBING SPECIFICATION FOR INLET/OUTLET SECTIONS & FLOW STRAIGHTNER SPECIFICATION FOR INSTRUMENT TUBE FITTING SPECIFICATION FOR INSTRUMENT VALVES & MAINFOLDS Specification No. MEC/S/05/26/01 MEC/S/05/26/02 MEC/S/05/26/03 MEC/S/05/26/04 MEC/S/05/26/05 Specification No. MEC/S/E5/T/002 R-0 MEC/S/E5/T/042 R-1 Specification No. MEC/S/05/26/21 MEC/S/05/26/23A MEC/S/05/26/24A MEC/S/05/26/23,R-1 MEC/S/05/26/26 MEC/S/05/E9/25 MEC/S/05/E9/071 MEC/S/05/E9/006

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Page 1 of 2

PADMALA – GODHARA GAS PIPELINE PROJECT
Tender Document for EPC Contracts
Gujarat State Petronet Ltd.
Tender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IV of V

MECON LIMITED MEC/S/05/26/06 MEC/S/05/26/07

6. 7. 8. 9. 10. 4.0 Sl. No. 1. 2. 3.

SPECIFICATION FOR JUNCTION BOXES & CABLE GLANDS SPECIFICATION FOR SIGNAL CABLES

GENERAL TECHNICAL SPECIFICATION FOR INSTRUMENTATION MEC/S/05/26/08 TECHNICAL SPECIFICATION FOR CABLING TECHNICAL SPECIFICATION FOR GAS OVER OIL CATHODIC PROTECTION SYSTEM Title SPECIFICATION FOR TEMPORARY CATHODIC PROTECTION SPECIFICATION FOR PERMANENT CATHODIC PROTECTION TECHNICAL SPECIFICATION FOR TR UNIT FOR CP SYSTEM Specification No. MEC/PTS/05/62/016A MEC/PTS/05/62/016B MEC/PTS/05/E9/072 MEC/S/05/26/21 MEC/TS/05/E5/002

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Page 2 of 2

Gujarat State Petronet Limited

SPECIFICATION FOR CABLING

SPECIFICATION NO. MEC/S/05/26/21

(ELECTRICAL SECTION) MECON LIMITED DELHI 110 092
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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

CABLING

SPECIFICATION NO. MEC/S/05/26/21

PAGE 1 OF 12 REVISION 0

CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 SCOPE STANDARD CABLE SPECIFICATIONS MISCELLANEOUS MATERIALS SPECIFICATIONS CABLE LAYING TERMINATION TESTING

PREPARED BY

CHECKED BY

APPROVED BY

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

CABLING

SPECIFICATION NO. MEC/S/05/26/21

PAGE 2 OF 12 REVISION 0

1.0

SCOPE This is to define the requirements for supply, wherever applicable, the installation, testing and commissioning of the cabling system.

2.0

STANDARDS The work shall be carried out in the best workman like manner in conformity with this specification, the relevant specifications, codes of practice of Indian Standards Institution, approved drawings and instructions of Engineer-in-Charge or his authorized representative issued from time to time. In case of any conflict between the standards, the instruction of Engineer-in-Charge shall be binding.

3.0 3.1

CABLE SPECIFICATIONS Power Cables Power cables for use on 415 V system shall be of 1100 Volts grade, aluminum stranded conductor, PVC insulated, extruded PVC inner sheathed, GI Wire /flat armored and overall FRLS PVC sheathed. Power cables for 3.3 KV 6.6 KV and 11 KV system shall be aluminum conductor, XLPL insulated, screened, PVC bedded galvanized steel flat armored and PVC sheathed cable. All L.T. Cables conform to standard specification and relevant sections of IS: 1554 Part-I and H.T. Cables shall conform to IS:7098 (Part II). Unarmored cables will be used wherever specified on the cable schedule.

3.2

Control Cables: Control cables shall be 1100 Volt Grade, 2.5 mm2 copper conductor PVC insulated, extruded PVC inner sheathed, GI Wire armored and overall FRLS PVC sheathed, as per IS: 1554 Pt. I. Unarmored cables shall be used wherever specified on the cable schedule.

3.3

Communication cables: Communication cables shall comprise 1 pair unarmored, 2-pair, 5-pair and multipair armored cables of sizes as specified in the cable schedule. Minimum conductor size shall be 0.5 mm telephone system and 0.71 for plant communication system.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

CABLING

SPECIFICATION NO. MEC/S/05/26/21

PAGE 3 OF 12 REVISION 0

4.0 4.1

MISCELLANEOUS MATERIALS SPECIFICATIONS Connectors: Cable terminations shall be made with aluminum/tinned copper crimped type solder less lugs of M/s. Dowell’s make or approved equivalent for all aluminum conductors and stud type terminals.

4.2

Cable Identification Cable tags shall be of 2 mm thick, 20 mm wide aluminum strap of suitable length to contain cable number, equipment no., etc.

4.3

Ferrules Ferrules shall be of approved type size to suit core size mentioned and shall be employed to designate the various cores of control cable by the terminal numbers to which the cores are connected for case in identification and maintenance.

4.4

Cable Glands: Cable glands to be supplied shall be nickel plated Brass double compression type of approved/ reputed make. Glands for classified hazardous areas shall be certified by CMRS .

4.5

Cable Trays: This shall be either prefabricated hot dip galvanized sheet steel trays or site fabricated angle iron trays as specified elsewhere. Prefabricated hot dip galvanized sheet steel cable trays shall be used for maximum support span of 2000 mm unless design is approved for larger span. For requirements of larger than 750 mm width two trays shall be run side by side. Cable trays shall be suitable for a cable weight of 50 kg/meter running length of tray. Minimum thickness of sheet steel/galvanizing shall be 2mm/86 microns respectively. Cable trays fabricated from standard rolled sections shall use 50x50x6 /ISMC 100 Sections for runners for supporting spans limited to 2000 mm/more than 2000 mm respectively. Cross support shall be 32 x 6 mm flat/ 25x25x6 angle for width upto 500 mm/ more than 500 mm respectively.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

CABLING

SPECIFICATION NO. MEC/S/05/26/21

PAGE 4 OF 12 REVISION 0

Vertical supports for both the above type of trays shall be fabricated out of ISMC 100 and horizontal supports with 75 x 50 x 6 angle iron/ ISMC 75 as approved by Engineer-in-Charge.

5.0 5.1

CABLE LAYING Cable network shall include power, control, lighting and communication cables, which shall be laid in trenches, cable trays or conduits as detailed in the relevant drawings and cable schedules. Erection of cable trays as required shall be checked after erection and marked in as built drawings. Cable routing given on the layout drawings shall be checked in the field to avoid interference with structures, heat sources, drains, piping, air-conditioning duct etc. and minor adjustments shall be done to suit the field conditions wherever deemed necessary without any extra cost. High voltage, medium voltage and other control cables shall be separated from each other by adequate spacing or running through independent pipes, trenches or cables trays, as applicable. All communication cables (telephones, P.A.S.) RTD Cables shall run on instrument trays/ducts/trenches. Wherever these are not available, cables shall be taken in a separate trench with a minimum clearance of 300 mm away from electrical trench as per the direction of Engineer-in-Charge and Communication cables shall cross power cables at right angles. All cable routes shall be carefully measured and cables cut to the required lengths, leaving sufficient lengths for the final connection of the cable to the terminal of the equipment. The various cable lengths cut from the cable reels shall be carefully selected to prevent undue wastage of cables. The quantity indicated in the cable schedule is only approximate. The contractor shall ascertain the exact requirement of cable for a particular feeder by measuring at site and avoiding interference with structure, foundation, pipelines or any other works. Before the start of cable laying, cable drum schedule; shall be prepared be electrician contractor and get that approved by Engineer-in-Charge to minimize/avoid straight through joints required. Contractor shall work out the actual number of straight through joints required.

5.2

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

CABLING

SPECIFICATION NO. MEC/S/05/26/21

PAGE 5 OF 12 REVISION 0

5.4

Cables as far as possible shall be laid in complete, uncut lengths from one termination to the other. Cables shall be neatly arranged in the trenches/trays in such a manner so that criss-crossing is avoided and final take off to the motor/switchgear is facilitated. Arrangement of cables within the trenches/trays shall be the responsibility of the Contractor. Cable routing between lined 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 45o to the trench wall. In case of larger dia cables, i.e., 50 mm and above, adequately sized pipe with larger bend radius shall be provided for ease of drawing of cable or for replacement. In places where it is not possible, a smaller trench may be provided if approved by Engineer-in-Charge. All cables will be identified close to their termination point by cable numbers as per cable schedule. Cable numbers will be punched on aluminium straps (2 mm thick) securely fastened to the cable and wrapped around it. Alternatively cable tags shall be circular in construction to which cable numbers can be conveniently punched. Each underground cable shall be provided with identity tags of lead securely fastened every 30 m of its underground length with at least one tag at each end before the cable enters the ground. In unpaved areas, cable trenches shall be identified by means of markers as per standard drawing. These posts shall be placed at location of changes in the direction of cables and at intervals of not more than 30 M and at cable joint locations.

5.5

5.6

5.7

All temporary ends of cables must be protected against dirt and moisture to prevent damage to the insulation. For this purpose, ends of all PVC insulated cables shall be taped with an approved PVC or rubber insulating tape. Use of friction type or other fabric type tape is not permitted. Lead sheather cables shall be plumbed with lead alloy. RCC cable trenches shall be with removable covers .Cables shall be laid in 3 or 4 tiers in these trenches as indicated on the sectional drawings. Concrete cable trenches shall be filled with sand where specified to avoid accumulation of hazardous gases, RCC covers of trenches in process area shall be effectively sealed to avoid ingress of chemicals etc. Removal of concrete covers for purpose of cable laying and reinstating them in their proper positions after the cables are laid shall be done by the electrical Contractor at no extra cost.

5.8

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND) TITLE CABLING

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

SPECIFICATION NO. MEC/S/05/26/21

PAGE 6 OF 12 REVISION 0

Cables shall be handled carefully during installation to prevent mechanical injury to the cables. Ends of cables leaving trenches shall be coiled and provided with a protective pipe or cover, until such times the final termination to the equipment is connected. 5.9 Directly buried cables shall be laid underground in excavated cable trenches where specified in layout drawings. Trenches shall be of sufficient depth and width for accommodation of all cables correctly spaced and arranged with a view of heat dissipation and economy of design. Minimum depth of buried cable trench shall be 750 mm for low voltage and 1000 mm for H.V. Cables, the depth and the width of the trench shall vary depending upon the number of layers of cables. Cables shall be laid in trenches at depth as shown in the drawing. Before cables are placed, the trenches bottom shall be filled with a layer of sand. This sand shall be leveled and cables laid over it. These cables shall be covered with 150 mm of sand on top of the largest diameter cable and sand shall be lightly pressed. A protective covering of 75 mm thick second class red bricks shall then be laid flat. The remainder of the trench shall then be back-filled with soil, rammed and leveled. 5.10 As each row of cables is laid in place and before covering with sand every cable shall be given an insulation test in the presence of Engineer-in-Charge / Owner. Any cable which proves defective shall be replaced before the next group of cables are laid. All wall openings / pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water inside building/ lined trench. Where cables rise from trenches to motor, control station, lighting panels etc., they shall be taken in G.I. Pipes for mechanical protection upto a minimum of 300 mm above finished ground level. Cable ends shall be carefully pulled through the conduits, to prevent damage to the cable. Where required, approved cable lubricant shall be used for this purpose. Where cable enters conduit the cable should be bent in large radius. Radius shall not be less than the recommended bending radius of the cables specified by the manufacturer.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

CABLING

SPECIFICATION NO. MEC/S/05/26/21

PAGE 7 OF 12 REVISION 0

Following grade of the pipe fill shall be used for sizing the pipe size: a) b) c) d) 1 cable in pipe 2 cables in pipe 3 or more cables Multiple cables 53% full 31% full 43% full 40% full

After the cables are installed and all testing is complete, conduit ends above grade shall be plugged with a suitable weatherproof plastic compound/ `PUTTI' for sealing purpose. Alternatively G.I. Lidsor PVC bushes shall be employed for sealing purposes. The cost for the same shall be deemed to have been included in the installation of G.I. Pipe and no separate payment shall be allowed. 5.11 Where cables pass through foundation walls or other underground structures, the necessary ducts or openings will be provided in advance for the same. However, should it become necessary to cut holes in existing foundations or structures, the electrical contractor shall determine their location and obtain approval of the Engineer-in-Charge before cutting is done. 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. Drum number of each cable from which it is taken shall be recorded against the cable number in the cable schedule. Cables installed above grade shall be run in trays, exposed on walls, ceilings or structures and shall be run parallel or at right angles to beams, walls or columns. Cables shall be so routed that they will not be subjected to heat from adjacent hot piping or vessels. 5.15 Individual cables or small groups which run along structures/walls etc., will be clamped by means of 10 SWG GI saddles on 25x6 mm saddle bars. The cost of saddle and saddle bars shall be deemed to have been included in the installation of cables and no separate payment shall be made on this account. Alternatively small group of cables can be taken through 100 mm slotted channel/ISMC 100.

5.12

5.13

5.14

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND) TITLE CABLING

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

SPECIFICATION NO. MEC/S/05/26/21

PAGE 8 OF 12 REVISION 0

They shall be rightly supported on structural steel and masonry, individual or in groups as required, if drilling of steel must be resorted to, approval must be secured and steel must be drilled where the minimum weakening of the structure will result. Cables shall be supported so as to prevent unsightly sagging. In general distance between supports shall be approximately 300 mm for cables upto 25 mm diameter and maximum 450 mm for cables larger than 25 mm dia. 5.16 All G.I. Pipes shall be laid as per layout drawings and site requirements. Before fabrication of various profiles of pipe by hydraulically operated bending machine (which is to be arranged by the contractor), all the burrs from the pipes shall be removed. GI Pipes with bends shall be burried in soil/concrete in such way that the bends shall be totally concealed. For G.I. Pipes burried in soil, bitumen coating shall be applied on the burried 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. The open ends of pipes shall be suitably plugged with G.I. Plugs after they are laid in final position. G.I. Plugs shall be supplied by the Contractor at no extra cost. Cable laid on supporting angle in cable trenches, structures, columns and vertical run of cable trays shall be suitably clamped by means of G.I. Saddles/Clamps, whereas cable in horizontal run of cable trays shall be tied by means of nylon cords. Supporting steel shall be painted before laying of cables. The painting shall be done with one coat of red lead paint and two coats of approved bituminous aluminium paint unless otherwise specified. TERMINATION All PVC cables upto 1.1 KV grade shall be terminated at the equipments by means of double compression type cable glands. They shall have a screwed nipple with conduit electrical threads and check nut. All Cable entries shall be through bottom only and top entry terminations are made only after getting approval of Engineer-in-Charge. 6.2 Power cables wherever colour coding is not available shall be identified with red, yellow and blue PVC tapes. Where copper to aluminum connections are made, necessary bimetallic washers shall be used. For trip circuit identification additional red ferrules shall be used only in the particular cores of control cables at the termination points in the Switchgear/Control panels and Control Switches.

5.17

5.18

6.0 6.1

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

CABLING

SPECIFICATION NO. MEC/S/05/26/21

PAGE 9 OF 12 REVISION 0

6.3

In case of control cables all cables shall be identified at both ends by their terminal numbers by means of PVC ferrules or Self-sticking cable markers. Wire numbers shall be as per schematic/ wiring /inter- connection diagram. Bidders shall have the samples of PVC ferrules/cable markers approved before starting the work. All unused spare cores of control cables shall be neatly bunched and ferruled with cable tag at both ends. Where threaded cable gland is screwed into threaded opening of different size, suitable galvanized threaded reducing bushing shall be used of approved type, at no extra cost. All switchgear and control panels shall have undrilled gland plate. Contractor shall drill holes for fixing glands wherever necessary at no extra cost. Gland plate shall be of non-magnetic material/aluminium sheet in case of single core cables.

6.4

6.5

The cable shall be taken through glands inside the panels or any other electrical equipment such as motors. The individual cores shall then be dressed and taken along the cable ways (if provided) or shall be fixed to the panels with polyethylene straps. Only control cables of single strand and lighting cables may be directly terminated on to the terminals. In case of termination of cables at the bottom of a panel over a cable trench having no access from the bottom close fit hole should be drilled in the bottom plate for all the cables in one line, then bottom plate should be split in two parts along the centre line of holes. After installation of bottom plate and cables it should be sealed with cold setting compound. Cables shall be clamped over the open armoring to connect it to earth bus.

6.6

Cable leads shall be terminated at the equipment terminals, by means of crimped type solder less connectors as manufactured by M/s. Dowell Electro works or approved equivalent. Crimping shall be done by hand crimping hydraulically operated tool and conducting jelly shall be applied on the conductor. Insulation of the leads should be removed immediately before the crimping. Conductor surface shall be cleaned and shall not be left open.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

CABLING

SPECIFICATION NO. MEC/S/05/26/21

PAGE 10 OF 12 REVISION 0

6.7 6.7.1

Cable accessories for H.V. Systems The 11, 6.6 and 3.3 KV cables terminations joints shall be done by skilled and experienced jointers duly approved by the Engineer-in-Charge. Termination including supplying of jointing kit shall be threaded in Contractor scope unless specified otherwise. The termination and straight thro' joint kit. For use on high voltage system shall be suitable for the type of cables red by the contractor or the type of cables issued by owner for installation. The materials required for termination and straight through joints shall be supplied in kit form. The kit shall include all insulating and sealing materials apart from conductor fitting and consumables items. An installation instruction shall be included in each sheet. The termination 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. The terminating kits shall preferably be of the following types : a) TAPLEX' of M-seal make using non-linear resistance material fortress grading. `PUSH-ON' type of CCI make using factory - molded silicone rubber insulators. `TROPOLINK' type of CCI makes. Heat-shrinkable sleeve type of M/s. Raychem.

6.7.2

6.7.3

b)

c) d)

For outdoor installations, weather shields/sealing ends and any other accessories required shall also form part of the kit. 6.7.4 The straight thro jointing kits shall be suitable for underground-buried installation with uncontrolled backfill and possibility of flooding by water. The jointing kit shall be one of the following types. a) b) c) `TAPLEX' of M-seal make `TROPOLINK' type of CCI make Heat-shrinkable sleeve type of M/s. Raychem.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND) TITLE CABLING

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

SPECIFICATION NO. MEC/S/05/26/21

PAGE 11 OF 12 REVISION 0

6.7.5

Makes of kits other than those specified in 6.7.3 and 6.7.4 may be considered, provided the Contractor furnishes type test certificates, alongwith the offer. Type tests are to be carried out at manufacturer's works to prove the general qualities and design of a given type of termination/jointing system. The type tests shall include the following tests conforming to the latest IEC 502.2, 466 and VDE 0278 specifications. The Contractor along with the offer for the jointing system considered shall submit the type test certificates. a) b) c) d) A.C. Voltage withstand dry test for 1 minute Partial discharge test - Discharge magnitude small be less than 20 p.c. Impulse voltage withstand test with 10 impulses of each polarity. A.C. high voltage test following load cycling test with conductor temperature at 95oC. Thermal short circuit test of 250oC for 1 second. DC Voltage withstand test for 30 minutes. Humidity test. Dynamic short circuit test. Salt log test Impact test

6.7.6

e) f) g) h) i) j) 7.0 7.1

TESTING: Before energizing, the insulation resistance of every circuit shall be measured from phase to phase and from phase to ground. Where splices or termination are required in circuits rated above 600 volts, measure insulation resistance of each length of cable before splicing and or/ terminating. Repeat measurement after splices and/or terminations are completed.

7.2

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

CABLING

SPECIFICATION NO. MEC/S/05/26/21

PAGE 12 OF 12 REVISION 0

7.3

Measure the insulation resistance of directly burried cable circuits before cable trenches are back-filled. Repeat measurement after back- filling. For cables upto 1.1 KV grade 1000 KV Meager and for H.V. Cables 2.5 KV/5 KV Meager shall be used.

7.4

D.C. High Voltage Test shall be conducted after installation on the following and test results are recorded. a) All 1000volts grade cables in which straight through joints have been made. All cables above 1100 V grade.

b)

For record purposes test data shall include the measure values of leakage current versus time. The D.C. 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 all the straight through joints complete. Terminations shall be kept unfinished so that motors, switchgears, transformers etc. are not subjected to test voltage. The test voltage shall be as under:i) ii) iii) 7.5 For cables 3.3 KV grade For cables 6.6 KV grade For cables 11 KV grade 5.4 KV DC 10.8 KV DC 18 KV DC

All cables shall be tested as per standard test Performa available with site engineer. Cable schedule and layout drawings must be marked for AS BUILT conditions during the installation work and shall be approved by Site Engineer.

7.6

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Gujarat State Petronet Limited

SPECIFICATION FOR EARTHING AND LIGHTNING PROTECTION

SPECIFICATION NO. MEC/S/05/26/23A

(ELECTRICAL SECTION) MECON LIMITED DELHI 110 092

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

EARTHING AND LIGHTING PROTECTION

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 1 OF 10 REVISION 1

CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 SCOPE STANDARDS EARTHING CONDUCTOR/ELECTRODE EARTHING NET WORK INSTALLATION OF EARTH ELECTRODE CONNECTION TESTING TEST PROFORMA

PREPARED BY

CHECKED BY

APPROVED BY

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

EARTHING AND LIGHTING PROTECTION

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 2 OF 10 REVISION 1

1.0

SCOPE: The intent of this specification is to define the requirements for the supply, installation, testing, and commissioning of the Earthing System.

2.0

STANDARDS: The work shall be carried out in the best workmanlike manner in conformity with this specification, the relevant specifications/codes of practice of Indian Standard Institution, approved drawings and instructions of the Engineer-in-Charge or his authorized representative issued from time to time. In case of any conflict between the standards, the instructions of Engineer-in-Charge shall be binding.

3.0

CONDUCTOR ELECTRODE: The main grid conductor shall be hot dip galvanized G.I. Flat or PVC insulated aluminum conductor/copper conductor. Sizes for main conductors shall be marked on the drawings. Thickness of hot dip galvanizing shall not be less than 75 microns.

4.0 4.1

EARTHING NETWORK: The earthing installation shall be done in accordance with the earthing drawings, specifications and the standard drawings of reference attached with this document. The entire earthing system shall fully comply with the Indian Electricity Act and Rules framed thereunder. The contractor shall carry out any changes desired by the Electrical Inspector or the owner, in order to make the installation conform to the Indian Electricity Rules at no extra cost. The exact location on the equipment shall be determined in field, in consultation with the Engineer-in-Charge or his authorized representative. Any changes in the methods, routing, size of conductors etc. shall be subject to approval of the Owner/Engineer-in-Charge before execution. Excavation and refilling of earth, necessary for laying underground earth bus loops shall be the responsibility of the contractor.

4.3

The earth loop impedance to any point in the electrical system shall have a value which will ensure satisfactory operation of protective devices.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

EARTHING AND LIGHTING PROTECTION

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 3 OF 10 REVISION 1

4.4

The main earth loop shall be laid at a depth of 750 mm below grade level. Wherever cable trenches are available, the earth lead shall be laid in the trenches and shall be firmly cleated to the walls of concrete lined trenches. The earthing strip shall be protected against mechanical damage. In process unit areas, the earthing cable shall be run along cable trays wherever specified in the layout drawings. The earthing cable shall be suitably cleated and electrically bonded to the cable tray at regular intervals. Joints and tappings in the main earth loop shall be made in such a way that reliable and good electrical connections are permanently ensured. All joints below grade shall be welded and suitably protected by giving two coats of bitumen and covering with hessian tape. All joints above ground shall be by means of connectors/lugs as far as practicable. Tee connectors shall be used for tapping, earth leads from the main earth loop wherever it is installed above ground. Earthing plates shall be provided for earthing of two or more equipment at a place from earth grid. Where aluminium cable risers are to be connected to the underground GI earth bus, the aluminium cable riser shall be taken to the nearest earth pit and terminated through a bolted joint. If this is not practicable, then a G.I. risers shall be brought above grade and a bolted joint shall be made between this GI riser and the aluminium cable termination. This G.I. Riser shall be protected applying two coats of bituminous paint/bitumen on the exposed portion. Conduits in which cables have been installed, shall be effectively bonded and earthed. Cable armours shall be earthed at both ends. EARTH ELECTRODES: Earth pipe electrodes shall be installed as shown in the earthing layout drawings and in accordance with the standard drawings of reference and IS: 3043. Their location shall be marked to enable accurate location by permanent markers. All earth electrodes shall preferably be driven to sufficient depth to reach permanently moist soil. Electrodes shall preferably be situated in a soil which has a fine texture and which is packed by watering and ramming as tightly as possible. Wherever practicable, the soil shall be dug up, all lumps broken and stones removed from the immediate vicinity of the electrodes.

4.5

4.6

4.7

5.0 5.1

5.2

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

EARTHING AND LIGHTING PROTECTION

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 4 OF 10 REVISION 1

5.3

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. If necessary, a number of electrodes shall be connected in parallel to reduce the earth resistance. The distance between two electrodes shall not be less than twice the length of electrode. The electrodes shall have a clean surface, not covered by paint, enamel, grease or other materials of poor conductivity. The exact location and number of earth electrodes required at each location shall be determined in the field in consultation with the owner/Engineer-in- Charge, depending on the soil strata and resistively, to meet the ohmic values prescribed in clause 5.3. Earth Electrodes shall be located avoiding interference with road, building foundation, column etc. Individual earth electrode shall be provided for each lightning arrestor and lightning mast. The electrodes shall be so placed that all lightning protective earths may be brought to earth electrode by a short and straight a path as possible to minimize surge impedance. The disconnect facility shall be provided for the individual earth pits to check their earth resistance periodically. All the earth electrodes shall be suitably numbered and this should be indicated in as built drawings. 600 x 600 x 3 mm thick copper plate earth electrode for RTU, Telecom and Instrument control panel, metering panel and UPS panel. CONNECTION: All electrical equipment is to be doubly earthed by connecting two points on equipment to a main earthing ring. The earthing ring will be connected via links to several earth electrodes. The earth grid formed shall be a closed loop as shown in the drawing with earth electrodes connected to the grid with double strip connection. The cable armour will be earthed through the cable glands. In hazardous areas all major process equipments shall be connected to the earthing ring by means of anti- loosening connections and all pipe lines will be bonded and earthed on entering the battery limit of the process area. The following shall be earthed. 1. Transformer neutrals, CT/PT neutrals.

5.4

5.5

5.6

5.7

6.0 6.1

6.2

6.3

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2.

Neutral Grounding Resistors.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

EARTHING AND LIGHTING PROTECTION

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 5 OF 10 REVISION 1

3. 4. 5. 6. 7.

Transformer Housing. Lightning Arrestors. All switchgear and their earth buses, bus duct. Motor Frames. Non-current carrying metallic parts of electrical equipment such as switchgear, switch racks, panel boards, motor control centers, lighting, power and instrument panels, push button stations, cable trays, pipes, conduits, terminal boxes, etc. All fences, gates/enclosures, housing electrical equipment All steel structures, rails etc. including bonding between sections. Shield Wire Structural steel and Columns. Loading racks. Lighting Mast, poles. Lighting rods (Mast). Tanks and vessels containing flammable materials. Rotating parts of the agitators, pumps etc. through spring loaded brushes of suitable grade. Earth continuity conductor shall be provided for flanges.

8. 9. 10. 11. 12. 13. 14. 15. 16.

17.

Conductor size for connection to various equipments shall be as indicated on Earthing Layout Drawings. 6.4 Two distinct conductors directly connected to independent earth electrodes, which in turn, shall be connected to the earth too, shall earth system.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND) TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

EARTHING AND LIGHTING PROTECTION

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 6 OF 10 REVISION 1

The earth connection shall be properly made. A small flexible aluminum cable loops to bridge the top cover of the transformer and the tank shall be provided to avoid earth fault current passing through fastening bolts when there is a lightning surge, high voltage surge or failure of the bushings. 6.5 Each Lightning Arrestor shall be connected to a separate electrode located as close as possible to it and within the fenced area for each set of arrestors. The three nos. electrodes for each set of arrestors shall be spaced about 5 meters apart so that they are all within the enclosing fence. Each of these electrodes shall be connected to the main earth grid. The shield wire shall be connected with the main grid solidly and not through supporting steel structures. All paint, scale and enamel shall be removed from the contact surface before the earthing connections are made. All earthing connections for equipment earthing shall be preferably from the earth plate mounted above ground. In case of G.I. Earth Loop all underground "T" connections shall be of the same size as main loop however in case of PVC insulated aluminum conductor loops underground joints shall be completely avoided. Connections to motors from earth plate or main loop conductor brought above ground shall not be less than following: Mains Grid & equipment such as : Main Electrical Distribution Board Silent D. G. Set Switch Socket DB, Lighting DB UPSDB Motors 5.5 KW to 3 KW 2.2 KW to 0.375 KW Other equipment Mechanical equipment / Vessels, Tanks, Pipe/cable racks, structure, fencing RTU, Telecom, UPS 50 x 6 mm GI Flat

6.6

6.7

6.8

25 x 6mm GI/16 sq. mm GI rope

2.5 sq mm Cu Wire PVC 2.5 sq mm Cu Wire PVC 2.5 sq mm Cu Wire PVC 50 x 6 mm GI Flat

25 x 6 mm copper

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Field Instruments

2.5 sq mm Cu Wire PVC

Anchor bolts or fixing bolts shall not be used for earthing connection.

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\spec for earthing and lightning protection Fina-23A.doc

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

EARTHING AND LIGHTING PROTECTION

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 7 OF 10 REVISION 1

6.9

All hardware used for earthing installations shall be hot dip galvanized or zinc passivated. Spring washers shall be used for all earthing connections of equipment. Lighting fixtures shall be earthed through the extra core provided in the lighting cable for this purpose. TESTING: Earthing systems/connections shall be tested as follows: Resistance of individual electrodes shall be measured after disconnecting it from the grid. Earthing resistance of the grid shall be measured after connecting all the electrodes to the grid. The resistance between any point on the metallic earth grid and the general mass of earth shall not exceed 1 ohm. The resistance to earth shall be measured at the following: a) b) c) At each electrical system earth or system neutral earth. At each earth provided for structure lightning protections. At one point on each earthing system used to earth electrical equipment enclosures. At one point on each earthing system used to earth wiring system enclosures such as metal conduits and cable sheaths or armor. At one point on each fence enclosing electrical equipment.

6.10

7.0

7.1

7.2

7.3

d)

e)

Measurement shall be made before connection is made between the ground and the object to be grounded.

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\spec for earthing and lightning protection Fina-23A.doc

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND) TITLE

PROCESS & PIPING DESIGN SECTION NEW DELHI EARTHING AND LIGHTING PROTECTION

STANDARD SPECIFICATION

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 8 OF 10 REVISION 1

8.0

LIGHTNING PROTECTION 8.1 Lightning protection system shall generally comprise lightning finials (air terminals), roof conductors, down conductors, test links, and earth electrodes. The number, types, materials and sizes shall be in accordance with the Specification and IS: 2309. Air terminals shall be mounted on top of buildings or structure as required. All air terminals shall be inter-connected with roof conductors, pipes, hands rails or any other metallic projection above the roofs shall also be bonded to the roof conductors. Down conductors from air terminals or from roof conductors shall be routed as directly as possible to the test links on earth buses, with minimum bends. All provisions regarding connections of conductors for equipment earthing system shall also apply to lightning protection system. In corrosive atmospheres, plumbing metal for corrosion protection shall cover lightning finials or air terminals.

8.2

8.3

8.4 8.5

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

EARTHING

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 9 OF 10 REVISION 1

9.0

TEST PROFORMA (INSTALLATION TESTING REPORT EARTHING INSTALLATIONS) 1. Earth system data Type of electrode Total number of electrodes Main grid size Material 2. : : : :

General checks Put Tick √ if O.K.; otherwise give details. Construction of earth electrodes as per Standard. Size of earth conductor for various equipment O.K. as per Standard. Minimum distance kept between two electrodes. Cleanliness and tightness of connectors. Inspect bolted & clamped connectors.

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3.

TESTS 3.1 Measured earth resistance of each electrode in ohms 1 2 3 4 5 3.2 Measurement of earth grid resistance (with all electrodes connected to grid) a) At each electrical system earth or system neutral earth. At each point provided for structure lightning protection At one point on each earthing systems used to earth electrical equipment enclosure At one point on each earthing systems used to earth wiring systems such as metal conduits etc. At one point on each fence enclosing electrical equipment. :

No.

b)

:

c)

:

d)

:

e)

:

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\spec for earthing and lightning protection Fina-23A.doc

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

EARTHING

SPECIFICATION NO. MEC/S/05/26/23A

PAGE 10 OF 10 REVISION 1

4.

Remarks:

____________________________________________________________ |PROJECT: | UNIT: | |_____________________________|______________________________| |TESTED BY | WITNESSED BY | DATE | | |______________________| | | | | | | |CONTRACTOR | MECON | OWNER | | |______________________|___________|___________|______________|

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\spec for earthing and lightning protection Fina-23A.doc

Gujarat State Petronet Limited

SPECIFICATION FOR LIGHTING FITTINGS FOR HAZARDOUS INDOOR AND SAFE AREA

SPECIFICATION NO. MEC/S/05/26/24A

(ELECTRICAL SECTION) MECON LIMITED DELHI 110 092
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CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0

SCOPE STANDARDS SYSTEM CERTIFICATION GENERAL REQUIRMENT FOR THE FIXTURE CONSTRUCTION TERMINALS AND WIRING CONTROL GEAR & LAMP HOLDERS GUARANTEE AND INSPECTION INFORMATION REQUIRED WITH QUOTATIONS TEST AND INSPECTION DRAWINGS AND DOCUMENTS PACKING DEVIATION LUX LEVEL FOR CALCULATION SPV BASED POWER SYSTEM FOR EMERGENCY LIGHTING LOAD SPV BASED SOLAR STREET LIGHTING POLES DOCUMENTATION FOR LIGHTING FIXTURE

ANNEXURE – I

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 1 of 12
REVISION 0

1.0

SCOPE This specification defines the design, construction, testing and supply of lighting fixtures suitable for installation in classified hazardous, indoor and safe area in Gas Pipeline and CNG & City Gas unit. Unless specified in material requisition all fixtures shall be suitable for Gas Groups IIA & IIB as per IS 2148.

2.0

STANDARDS Complete lighting fixtures and other accessories shall conform to the following Indian Standards or other relevant internationally accepted standards. IS-2148 IS-5572 IS-8239 Specification for Flameproof Enclosures. Classification of hazardous area for electrical installation. Classification of maximum surface temperature of electrical equipment for use in explosive atmosphere. Construction and testing of electrical apparatus with type of protection `e' Electrical equipment with type of protection `n'. Flameproof electrical lighting fittings Pt.I & II(well glass and bulk head type, fittings using glass tubes) Electric lighting fitting for division 2 areas. Electric lighting fittings, general and safety requirements .

IS-6381

IS-8289 IS-2206

IS-8224 IS-1913 SYSTEM

3.0

Unless until specified in material requisition all lighting fixtures shall be suitable for 220 - 250 volts single phase and neutral, 50 Hz. power supply. 4.0 CERTIFICATION All fixtures and accessories shall be tested and certified by independent authorities for use in specified gas group location. Certification number/data and gas group/temperature classification must be indicated on the manufacturer's nameplate on each fixture.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 2 of 12
REVISION 0

5.0 5.1

GENERAL REQUIREMENT FOR THE FIXTURE Fixtures shall be complete with all the accessories including the control gear with lamp. The control gear for fluorescent lamp fixtures shall consist of starter, electronics ballast and capacitors for power factor improvement and for correction of stroboscopic effect. The Control gear for mercury vapour fixtures shall consist of ballast and capacitor for power factor improvement. The control gear for sodium vapour fixtures shall comprise a ballast capacitor and an igniter. The fixture housing shall be made of CRCA sheet steel / aluminum sheet or cast aluminum. Each fixture shall be provided with cable glands and a terminal block suitable for Termination of aluminum conductor upto 2.5 sq. mm sizes. Looping facility shall be Provided. The control gearbox shall normally be mounted integrally. Non-integrally control gearbox shall also be acceptable. The control gearbox shall be suitable for location in the same area as the fixture and shall have the same degree of protection. Neoprene gaskets shall be provided where necessary to prevent ingress of dust, moisture and insects inside the fixture and to make the fixture suitable for outdoor installation. The fixtures shall be so designed that it shall be possible to maintain or replace the different accessories without difficulty, including the replacement of the lamp. The insulation of wiring conductor for the fixture and for the control gear box where provided separately shall be selected considering the maximum temperature due to the heat generation by ballast, lamp, etc. under normal operating condition and proximity of the wiring conductor to these. Wherever necessary, heat resistant type insulated conductor shall be used for the wiring of the fixture and control gearbox. The wiring between different components of the fixtures and control gearbox shall be properly secured to avoid loosening of the connections due to vibration. The fixture/control gearbox shall be provided with an earthing terminal.

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.12

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 3 of 12
REVISION 0

5.13 5.14

The fixtures shall be designed to maximize the downward throw of luminous Painting

5.14.1 All metal surfaces shall be made completely free from any scale and rust by suitable processes of degreasing and pickling. The thoroughly cleaned surfaces shall be pretreated by phosphatising and passivating. 5.14.2 Two coats of zinc chromate primers shall be applied on all metal surfaces before application of two coats of finishing paint as specified for different types of fixtures. Where epoxy paint is specified, epoxy based primers shall be used. 5.15 Supporting Arrangement

5.15.1 Fixture shall be suitable for mounting on the ceiling / structure as required. A mounting bracket shall be supplied, where necessary. 5.15.2 Sketch showing the mounting arrangement and dimension for each type of fixture shall be furnished. 5.1 TYPE OF FIXTURE

5.1.1 5.1.2

All flame proof lighting fixture shall be of cast aluminum alloy (LM6). Flame proof well glass fixture: - Fixture shall be suitable for HPMV lamps. - FLP Control gearbox shall consist of copper ballast, capacitor for power factor improvement, cable gland etc. Indusial type fluorescent fixture shall consist of Electronics ballast, starter, capacitor for power factor improvement, cable gland etc.

5.1.3

5.2

INDUSTRIAL TYPE

5.2.1 5.2.2

Channel / Rail Mounting Fluorescent Fixture. The fixtures shall be provided with CRCA sheet steel mounting channel containing all the accessories, suitably covered with CRCA sheet steel and epoxy stove enameled. The fixture without reflector shall be with epoxy stove enamel finish. Where reflector is specified the same shall be CRCA sheet steel and vitreous enameled, white

5.2.3

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 4 of 12
REVISION 0

inside and gray outside. 5.3 5.3.1 CORROSION PROOF FLUORESCENT FIXTURE The fixtures shall be suitable for installation in an area laden with corrosive chemical dusts and vapors. The ballast, capacitor and terminal block shall be housed in a cast aluminum enclosure, which shall be made dust and vapour proof with the use of neoprene rubber gaskets. The internal connecting wires shall run inside 2 Nos. seamless aluminum pipes properly screwed and sealed on either side of the control gear housing. The end boxes shall be made of cast aluminum fixed at the ends of the seamless pipes, which shall contain the starter holder, starter and the lamp holders. The lamp holders shall be so designed that when the lamps are fitted, ingress of corrosive dust and vapour inside the lamp holders is prevented to protect lamp pins. WELL GLASS TYPE MERCURY / SODIUM VAPOUR FIXTURE The fixture housing shall be made of cast aluminum alloy in dust, vapour and weather proof execution finished in epoxy stove enamel, grey outside and white inside, provided with clear heat resistant glass which shall be fitted with neoprene gasket and 3 mm G.I. wire guard. HIGH BAY TYPE MERCURY/ SODIUM VAPOUR FIXTURE.

5.3.2

5.3.3

5.4 5.4.1

5.5

5.5.1 The fixtures shall be in dust and vapour proof execution with a reflector and heat Resistant glass cover and shall be provided with integral control gear. 5.5.2 The control gear and lamp holder housings shall be of cast aluminum, so designed as to achieve better heat dissipation and proper cooling of the unit. The reflector shall be made of anodized aluminum epoxy enameled outside and electrochemically brightened inside. The canopy shall be of cast aluminum having terminal block for external connection and provided with suspension hook. The canopy, control gear and lamp holder housings shall be epoxy stove enameled. STREET LIGHTING FIXTURE. The fixtures shall be suitable for fluorescent, mercury vapour or sodium vapour lamp as specified and shall be made of cast! sheet aluminum epoxy enameled housing,

5.5.3

5.5.4

5.5.5 5.6 5.6.1

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 5 of 12
REVISION 0

anodized aluminum reflector and non-yellowing type acrylic cover. 5.6.2 5.6.3 5.6.4 The fixture shall be totally enclosed type suitable for outdoor installation. Light distribution shall be cutoff, semi cutoff or non-cut off type as specified. The fixture shall be provided with side entry for the supporting pipe. The cable shall be taken inside through the supporting pipe of 25mm dia. The clamping arrangement for the supporting pipe shall be designed to suit the weight of the fixture and wind load for mounting height upto 16 M as specified in the relevant Indian Standard Specification. The clamping arrangement shall provide wide range flexibility in the use of supporting pipe by the purchaser.

5.6.5

5.6.6 Unless otherwise specified, fixture for use with mercury / Sodium vapour lamp shall be provided with arrangement of adjusting the position of lamp holder to have a cutoff or semi cut off light distribution. 5.7 5.7.1 FLOOD LIGHTING FIXTURE The fixture shall be in weatherproof execution suitable for high pressure mercury! Sodium vapors lamp and shall comprise of epoxy stove enameled, cast aluminum alloy body, a clear heat resistant flat toughened glass, an anodized mirror polished aluminum reflector and a focusing device. The fixture shall be having an arrangement for rotation on both horizontal and vertical planes and locking in any desired position. The complete unit shall be mounted on a heavy base of cast iron for fixing the fixture on a structural platform. All cast iron and MS. structural provided in the fixture shall be epoxy painted. A separate control gearbox suitable for the rating of the lamp specified shall be supplied along with the fixture. FIXTURE FOR USE IN HAZARDOUS AREA. The fixture for use in hazardous area shall be in cast aluminum enclosure that shall be epoxy stove enameled. The fixture shall have comply with relevant standard for flameproof fixtures. The fixtures shall be suitable for hazardous area for enclosure group IIA & IIB and

5.7.2

5.7.3

5.7.4 5.7.5

5.8 5.8.1

5.8.2 5.8.3

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 6 of 12
REVISION 0

temp class T3. 5.8.4 5.8.5 Flameproof fixture/Control gearbox shall be provided with flameproof cable glands. One internal earthing terminal shall be provided.

5.8.6 The vendor shall confirm that the fixtures and control gear box, where supplied separately, have been tested and certified by relevant statutory authorities for use in the hazardous area as offered by them and shall submit the relevant documents along with the offer. 5.9 ACCESSORIES BLASST 5.9.1 The ballast shall be highly inductive silicon steel laminated, copper wire wound polyester filled heavy-duty type. Capacitors

5.10

5.10.1 The capacitors shall be constant value type hermetically sealed in metal enclosure to ensure long trouble free service. 5.10.2 The value of the capacitors for power factor improvement shall be so selected that the corresponding lamp circuit power factor does not fall below 0.95 lags. 5.11 Starter

5.11.1 The starter shall be suitable for igniting fluorescent lamp having bi-metal electrodes and radio interference suppression capacitor in an enclosure of high mechanical, strength.

5.12

Lamp Holder

5.12.1 The lamp holders shall ensure proper contact with the lamp during continuous operation, preventing extinguishing of the lamp due to small vibration. 5.12.2 The material of the lamp holder shall be suitable to withstand the operating temperature without any deterioration. 5.12.3 The lamp holder for fluorescent lamp shall be spring loaded rotor type, suitable for

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 7 of 12
REVISION 0

bi-pin lamp, so designed to prevent contact with live parts of the holder after the lamp has been taken out or during insertion/removal of the lamp. 5.12.4 The lamp holder for mercury and sodium vapour lamp shall be Edison screw type. 5.13 Starter Holder

5.13.1 The starter holders used for fluorescent lamp shall ensure good electrical contact with the starter pin with strong spring action for trouble free operation. It shall be possible to insert or remove the starter with ease. 5.14 Cable Glands

5.14.1 Cable glands shall be of brass double compression type for PVC insulated armored and PVC sheathed 1.1 KV grade 3C 2.5 sq. mm YWY cable. 6.O CONSTRUCTION All fixtures shall be suitable for use in outdoor open location and shall have degree of protection for weatherproofing equal to IP-55. The body of the lighting fixture shall be of cast aluminum alloy LM-6 and should be free from frictional sparking hazard. Complete fixture body and accessories shall be suitable to withstand corrosive atmosphere. Outer metallic surface shall be treated/prepared and provided with two coats of epoxy paint. All screws, nuts, studs, clamps, supporting brackets, etc. shall be electro galvanized or zinc passivated.

All fixtures shall be provided with sheet steel vitreous enameled or approved type of reflector. Glass used for fixtures shall be clean and toughened type suitable for use under conditions involving exceptional risk of mechanical damage and shall be type `A' as per IS 2206 or the requirements stipulated by international standards. All well glass fixtures shall be provided with steel wire protecting cage-having mesh dimension not exceeding 50 mm. The fixing parts of the enclosure, which is to be opened for replacement of bulb, shall be so fastened that they can only be unfastened with special tools. All fixtures shall carry a special warning inscription in English to "Isolate supply elsewhere before opening". Three sets of special tools required for maintenance of fixtures shall be supplied free of cost along with the fixtures. The temperature rise of external surface shall not exceed the temperature Specified in the standards for the gas group to which fitting shall be suitable.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 8 of 12
REVISION 0

All fixtures and associated control gearboxes shall be provided with two 3/4" E.T. threaded entries with one approved type threaded plug to seal one of the entries. Two entries shall be used for looping of circuit wherever required. All junction boxes for looping for SPN Lighting circuits using cables up to 4 mm2 shall be minimum 100 mm dia in size. Junction boxes for looping of large threephase cable and multiple single-phase circuits shall be of minimum 300x250x100 mm. in dimension complete with flameproof cable glands as specified in material requisition. The top of all well glass lighting fixtures shall be identically drilled/threaded to Facilitate the installation on pole/column or ceiling as per the enclosed sketch Using stud/bracket supplied by others. 7.0 TERMINALS & WIRING Each terminal for external cable connections shall be suitable for termination of minimum of two number 4 mm2 aluminum conductors for circuit looping facility. All terminals shall be of non-sparking and anti- loosening design such that they do not produce any arc or spark in normal operation. Connection to current carrying parts shall be such that the contact is not appreciably impaired by temperature or by vibrations, which occur, in normal service or by shrinkage of insulating materials.

If flexible wires are used for internal wiring they should be soldered at the ends, preferable with lugs. Whereas a screw type holder is used, the center contact shall be connected to a terminal, which shall be clearly identified for connection to the live conductor. One earthing terminal shall be provided inside the connection chamber suitable for termination of minimum 4-mm2 aluminum conductors. 8.0 CONTROL GEAR AND LAMP HOLDER Lighting fixtures suitable for discharge lamps shall be complete with power factor correction capacitor, choke and starter, etc. mounted within the fixtures as integral part completely wired upto terminals. Separate control for gearbox shall be acceptable only for flood lighting fixtures and these shall be of approved flameproof construction.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 9 of 12
REVISION 0

All incandescent lamp fixtures shall have screwed type E.S. cap lamp holder.

All lighting fixtures which are not certified as flameproof construction but approved for use in Div. II area shall have approved ENCLOSED BREAK lamp holder and complete enclosure certified as having restricted breathing type construction. Mounting All well glass fixtures shall be suitable for bracket, ceiling or pole mounting as per the enclosed sketch.

All flood lighting fixtures shall be supplied with adjustable mounting arrangement both in horizontal and vertical plane. 9.0 GUARANTEE & INSPECTION All fittings shall be guaranteed for defective material/ design/ workmanship, for a period of 12 months from the date of commissioning or twenty-four months from the date of dispatch whichever is earlier. Mechanical strength of well glass shall satisfy the requirements stated in Clause 7.2.1 of IS 6381 and during inspection facilities shall be provided for impact testing of a random sample.

All fittings and accessories shall be inspected by the purchaser's representative before dispatch and minimum two weeks notice shall be given to facilitate inspection. Purchaser's representative will also be allowed to visit works during execution of order for expediting/monitoring activities. 10.0 INFORMATION REQUIRED WITH QUOTATIONS 1. Three copies of catalogues/drawings giving details of make/catalogue No./Overall Dimensions/Weight/ Material of construction and mounting details etc. Name/address of testing/certifying authority and certificate No./date for each item. Clause wise deviations to the requirements of specification/material requisition, if any. It will be assumed that offer meets all the requirements

2.

3.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 10 of 12
REVISION 0

except deviations furnished with the quotation. 4. Drawing of the complete assembly for each item offered which shall be valid for the actual material supplied if ordered.

11.0

TESTS AND INSPECTION

11.1 The following tests shall be carried out on the lighting fixtures and their accessories as per relevant IS. 11.1.1 11.1.2 11.1.3 Routine tests On each lighting fixture and its accessories On representative number of each type. Wherever specified on one lighting fixture and its Accessories of each type.

Acceptance Tests Type tests -

11.2

All the above-mentioned tests shall be carried out in the presence of purchaser’s representative. In addition, the fixtures shall be subjected to stage inspection at works and inspection at site for final acceptance. These tests and inspection shall however not absolve the Vendor from his responsibility for making good any defect, which may be noticed subsequently. DRAWINGS AND DOCUMENTS Drawings and documents as per Annexure-l shall be supplied. All drawings and documents shall have the following description written boldly. Name of Client GSPL. Name of Consultant MECON Enquiry / Order Number. PACKING The lighting fixtures shall be properly packed to safeguard against weather conditions and handling. It shall be wrapped in polythene bag with an additional wrapping of bitumen paper to make it completely waterproof before the equipment is packed in wooden crates.

11.3

12.0 12.1 12.2

13.0 13.1

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 11 of 12
REVISION 0

14.0 14.1 15.0

DEVIATIONS Deviation, if any, from this standard shall be clearly indicated in the offer with reason thereof. Lux level for lighting fixture calculation in the Specified location are as follows: (a)Control Room (b) Office Room (d) DG Room (e) Process area (f) Road area (g) Open Area 500 lux 300 lux 150 lux 150 lux 50 lux 20 lux 10 lux

(c) Electrical Room -

16.0

TYPE OF LIGHTING FIXTURE

16.1 Building Lighting: 16.1.1 16.1.2 Control Room / Office Room/Electrical Room: Surface /Recess mounted CFL type TLLE 211 M/s CG or equivalent. DG Room/Other Room: Industrial type fixture IGP 1214 HSB of M/s CG Make or equivalent. 16.2 16.2.1 Open Area: Hazardous Area (i) Well glass fixture type FLPW – 1245 (Lamp: 125 W HPMV) of M/s Baliga make or equivalent (ii) Flood light fixture type FLPW – 3690 (Lamp: 400 W HPSV) of M/s Baliga make or equivalent. 16.2.2 Safe Area (i) Street light fixture type SRP 601/150,150W HPSV of M/s Philips make or equivalent. (ii) Flood light fixture type FBD 1440, 400W of M/s CG make or equivalent.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING FITTINGS

SPECIFICATION NO. MEC/S/05/26/24A

Page 12 of 12
REVISION 0

(iii) SPV Based Solar Street lighting poles26WLPSV Lamps

17.0

SPV Based Solar Street lighting poles: No. Of Poles - 6 (Six) Nos. (Two nos.for each station) - 2 (Two) Nos. (One nos. for each Tap-off point) Supply, installation, testing, commissioning of Solar Street lighting poles (Model: MV8 of M/s Tata BP Solar India Ltd.) with aluminum paint complete with mounting bracket, control gear box, internal cable from fitting to junction box, and 26W LPSV Lamps, 12 V 150Ah battery backup providing 4 days (3 no sun shine days) autonomy with 150Wp solar array etc. including civil foundation with pipe inserts for cables and connecting work, with all material and labour as per specifications, drawings and instruction of Engineer-in-charge. Nominal height of pole shall be 6m above ground. Work to be completed in all respects.

ANNEXURE-I DOCUMENTATION FOR LIGHTING FIXTURES AND ACCESSOREIS

S.No

Documents

No. of Copies With bid Final 8 8

1. Specification Sheet 2. Technical particulars 3. Illustrative and descriptive catalogues indicating general Arrangement, light distribution, light absorption and utilization factors, starting current, full load current, power factors etc. 4. Sketch showing mounting arrangement and dimension 5. Type Test Certificate for (a) Flame proof fixtures 6. Test Certificates 7. Guarantee Certificates NOTE

1 1

1 1

8 8

1 -

8 8 8

1. All final drawing and document shall be submitted at least four weeks prior to dispatch of equipment. 2. These shall be made in sets and shall be supplied in fine plastic coated folder.

LIST OF SPARES – MANDATORY 1. Starters for fluorescent tubes. 2. Ballast of each type. Ignitor for sodium vapour lamps.

GUJARAT STATE PETRONET LIMITED

SPECIFICATION FOR LIGHTING

SPECIFICATION NO. MEC/S/05/26/22, Rev 1

(ELECTRICAL SECTION) MECON LIMITED DELHI 110 092
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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING

SPECIFICATION NO. MEC/S/05/26/22

PAGE 1 OF 10 REVISION 1

CONTENTS 1.0 2.0 3.0 4.0 4.1 4.2 4.3 4.4 4.5 5.0 SCOPE STANDARDS EQUIPMENT SPECIFICATIONS LIGHTING SYSTEM General Conduit System Hazardous Area Building Lighting Street Lighting TESTING AND COMMISSIONING

PREPARED BY

CHECKED BY

APPROVED BY

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND) TITLE LIGHTING

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

SPECIFICATION NO. MEC/S/05/26/22

PAGE 2 OF 10 REVISION 1

1.0

SCOPE The intent of this specification is to define the requirements for the supply, erection, testing and commissioning of the lighting system.

2.0 2.1

STANDARDS: The work shall be carried out in the best workmanlike manner, in conformity with this specification, the relevant specifications/ codes of practice of the Indian Standard Institution, approved drawings and instructions of the Engineer-in-Charge or his authorized representative issued from time to time. In addition to the standards mentioned in 2.1, all work shall also conform to the requirements of the following: a) b) c) Indian Electricity Act and Rules framed thereunder. Fire Insurance Regulations. Regulations laid down by the Chief Electrical Inspector of the State, State Electricity Board. Regulations laid down by the Factory Inspector of the State. Any other regulations laid down by the local authorities.

2.2

d) e) 3.0

EQUIPMENT SPECIFICATIONS All materials, fittings and appliances to be supplied by the contractor shall be of the best quality and shall conform to the specifications given hereunder. The equipment shall be manufactured in accordance with the current Indian Standards Specifications. In the absence of any specifications, Material samples shall be brought to site by Contractor and get it approved by Engineer-in-Charge or his authorized representative before installation.

3.1

Lighting and Power Panels: Power and Lighting panels shall be of 14 gauge sheet steel construction to provide general purpose indoor/outdoor type of enclosure. These shall be suitable for surface of flush mounting as specified. Outdoor lighting panels shall be weather protected (IP- 55) and shall also have necessary canopy.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING

SPECIFICATION NO. MEC/S/05/26/22

PAGE 3 OF 10 REVISION 1

Panels shall be equipped with phase and neutral bus bars of adequate capacity and isolators/miniature circuit breakers and fuses for the incoming and outgoing circuits as specified on panel schedule. All fuses shall be HRC link type and isolators shall be rotary type only. Where miniature circuit breakers are provided for incoming to the lighting power panels, the same shall be without the tripping elements. Miniature circuit breakers shall be mounted in such a way that operating levers project outside the front bakelite cover plates. A hinged door to cover the operating knob shall be provided. Each circuit phase/neutral shall be given ferrule numbers. Complete wiring inside the panel shall be neatly bunched with PVC tape & button. All cables entries shall be as marked in the schedule. Cables glands for PVC insulated armored cables of sizes as specified on panel schedule shall be provided for the incoming cables of all surface mounted panels. For the outgoing circuits of these panels cable glands or conduit entry shall be provided as specified on panel schedule. Conduit entry shall be provided for the incoming and outgoing circuits of all flush mounted panels. All metal surfaces shall be cleaned free of rust given a coat of red-oxide primers and finished with 2 coats of approved paints. 3.2 Switches Switches, manufactured in accordance with IS: 3854 shall be used. Switches in areas where concealed wiring has been adopted shall be flush mounting piano type unless otherwise specified. Electronics type fan regulator shall be used for ceiling fans. design and models of the regulator shall be same as that of switches. 3.3 Receptacles Only 5A/15A combination type receptacles manufactured in accordance with IS:1293 shall be used with the third terminal connected to the earth. All receptacles shall be provided with a switch mounted on the same enclosure but shall be a separate unit to facilitate replacement by part. Flush mounting type receptacles shall be used in areas where concealed wiring has been adopted and surface type shall be used in other areas. Outlet Boxes Outlet boxes for sockets, switches, fixtures and fan regulators etc. shall be of minimum 16 gauge or as specified in Schedule of Rates, M.S. Sheet 3" deep. Junction/Outlet boxes shall be used in roof slab where concealed wiring has been adopted. Front cover plate shall be of sheet steel in areas where surface wiring has been adopted. For concealed wiring the front cover plate shall be of Formica or approved equivalent with colour to suit the walls. Outlet boxes shall be electro-galvanized after fabrication. Cover plate shall be fixed by cadmium plated brass screw and suitable C.P. brass cup washers. Engineer-in-Charge shall approve samples of these.

3.4

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND) TITLE LIGHTING

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

SPECIFICATION NO. MEC/S/05/26/22

PAGE 4 OF 10 REVISION 1

3.5

Conduit and Fittings: Conduit shall be of minimum 16 gauge ERW or GI or Polyethylene as specified. Generally, polyethylene conduits shall be used in concealed wiring and for surface wiring GI conduit (in industrial buildings) and ERW conduit (in non industrial buildings) shall be used. Care shall be taken to see that all conduit ends have no burrs and ends are neatly reamed to avoid damage to wires. All metal conduit accessories shall be only of threaded type. Pin grip or clamp type accessories are not acceptable. Samples of these shall be furnished for approval by Engineer-in-Charge at site, before installation.

3.6

Lighting Poles: Lighting poles shall be fabricated as per drawings, from seamless pipes of specified section, with joints, swaged together when hot and bevelled on outside edges, poles shall be coated with bituminous preservative solution throughout on the inside surface and on the ground portion of the outside surface. Remainder of the outside surface shall be given one coat of red oxide primer and finished with two coats of aluminium paint. A fuseboard shall be provided inside the muff as per standard drawing at the bottom of the pole, to contain kitkat fuses, a neutral link and a grounded stud. G.I. Conduit shall be embedded in muff for incoming and outgoing cables. Foundation for lighting poles will be made by the electrical contractor and the cost for the same including supply of cement all other connected material shall be deemed to have been included in the erection of pole. MECON Standard shall be strictly followed for complete work. Lighting poles shall be numbered serially as per the direction of Engineer-in-Charge.

3.7

Wires Wires shall be PVC insulated 660/1100 Volts grade as per IS: 1554. Conductor shall be stranded copper and size shall be Min. 2.5 mm2 for lighting and Min. 6 mm2 for power socket and industrial socket for Air Conditioner circuits. Red/ Yellow/ blue wires for phases black wire for neutral and green wire for earth shall be used. Wiring in conduits without colour cooling is not acceptable. Engineer-in-Charge shall approve make and samples of this before lying.

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING

SPECIFICATION NO. MEC/S/05/26/22

PAGE 5 OF 10 REVISION 1

4.0 4.1

LIGHTING SYSTEM: General The lighting fixtures in the plant are fed from lighting panel and group controlled from local control station. Lighting wiring between panel and lighting fixtures shall be done by PVC insulated 3-core (phase, neutral and earth) armoured cable for hazardous areas. Lighting fittings in building shall be fed from lighting panels (supplied from lighting panel/ D.C.Panel). Wiring in the building shall be done by means of 3-core copper conductor PVC insulated, armoured cables, or PVC insulated copper conductor wires in conduit of 1" size/ Metsec channel as specified. All joints of conductors in Switch board/JBS/Fitting shall be made only by means of approved Mechanical connectors (nylon/ PVC connectors). Bare or twist joints are not permitted any where in the wiring system. Cost toward mechanical connectors is deemed to have been included in wiring.

4.1.1

The lighting layouts furnished by owner shall indicate approximately locations of lighting fixtures. The electrical contractor shall determine, with approval of the Engineer-in-Charge or his authorized representative. The exact locations of each fixture in order to avoid interference with piping or other mechanical equipment and also with a view to obtain as uniform illumination as practicable, and to avoid objectionable shadows. Conduit run shown on drawing are only indicative. The contractor to suit field conditions as per directions of the Engineer-In-Charge shall lay these out. On walkway, platforms and other outdoor area, lighting fixtures shall be nearer to landing of stairs or ladders, gauges, flow-meters, panel boards and other equipment requiring good illumination. In pump and compressor areas and other locations at ground level, unless otherwise called for on the drawing or directed lighting fixtures shall be mounted preferably 4 meters above level of the floor. Where this is impracticable, the minimum height of any lighting fixture shall be preferably not less than 2 1/2 meters above the floor level.

4.1.2

4.1.3

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND) TITLE LIGHTING

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

SPECIFICATION NO. MEC/S/05/26/22

PAGE 6 OF 10 REVISION 1

4.1.4

Lighting in walkways and platforms shall be not more than 2 meters above the walkways in order to permit maintenance without the use of a ladder. Socket outlets in process areas shall be approximately 1200mm above finished grade and 300mm above grade in office area. Lighting and power panel shall be mounted such that top of the panel is not more than 2000mm above finished grade. Fixtures shall be firmly supported from the structures, support clamps etc. may be bolted or welded to the existing steel work or metal inserts. In case of concrete structures, where metal inserts are not available, fixtures will be fixed to or supported from concrete surfaces with the help of anchor fastener. In such cases special care shall be taken to see that anchoring is firm. All hardware shall be galvanized or zinc passivated circuit cables shall be group cleared to structure by using galvanised strip clamps or run in cable trays wherever they are available. Spacers and cleats shall be of suitable size to accommodate the cables shall be got approved by Engineer-in-Charge before fixing from at site. For isolated structures lighting cables may be taken in underground G.I. pipes. Main runs of wiring from lighting panels and tapping to individual fixtures shall be in sizes specified/ approved. Wiring for all outlet sockets shall be done with 3 cores of equal sizes for phase, neutral and earth. The cost for cable clamps, metal spacers, anchor bolts, etc. shall be deemed to have been included in the installation of cables. Contractor shall have close watch on the lighting drawings issued to him. Any discrepancy noticed between the figure given in the drawing and the actual requirement at site, shall be immediately brought to the notice of Engineer-in-Charge by the Contractor.

4.1.5

4.1.6

4.1.7

4.1.8

4.1.9

4.1.10

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING

SPECIFICATION NO. MEC/S/05/26/22

PAGE 7 OF 10 REVISION 1

4.2 4.2.1

Conduit System: Surface or concealed conduit system of wiring shall be adopted, as specified in the drawings. Suitable pull boxes or inspection type fittings will be used to facilitate drawing of wires. Only threaded type conduit fittings shall be used. 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 with bakelite bushings. In order to minimize condensation of sweating inside the conduit system, all cables shall be properly drained and ventilated in such a manner so as to prevent entry if insects. The outer surface of the conduit pipes, including all accessories forming part of the conduit system, shall be adequately protected against rust, particularly when such system is exposed to weather. In all cases, bare threaded portion of conduit pipe shall not be allowed unless such bare threaded portion is treated with anti corrosive preservative or covered with approved plastic compound. Conduit connection to outlet boxes shall be by means of screwed hubs or check nuts on either side. Conduit pipes shall be fixed by 16 gauge G.I. Saddles on 25x6 mm G.I. Saddle bars in an approved manner at intervals of not more than 25 cms. Saddles shall be fixed on either side of couplers, bends or similar fittings, at a distance of 30 cm from the center of such fittings. The cost of saddle bars, saddles, clamps, etc. Shall be deemed to have been included in the installation of conduits. Where concealed wiring is to be adopted, conduits shall be laid in time before concreting of the slab. The Contractor shall coordinate his work with other agencies involved in the civil works in such a way, that the work of these other agencies is not hampered or delayed because of any section on his part. Vertical conduit runs shall be made either through columns or chases prepared in the walls. Contractor shall fill these chases or any other openings made by him after completing. The work and neatly finish the surface. During Installation, care shall be taken to see that adequate covers are provided to prevent rusting of conduits. If required, conduits run may be concealed in the floor for low-level receptacles and exhaust fans. As built conduit Contractor shall submit layout drawing.

4.2.2

4.2.3

4.2.4

4.2.5

4.2.6

4.2.7

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING

SPECIFICATION NO. MEC/S/05/26/22

PAGE 8 OF 10 REVISION 1

4.2.8

Wiring for exhaust fans shall be terminated in ceiling roses/receptacles and the connection from ceiling roses/ receptacles to the exhaust fan shall be by means of a flexible cord equivalent in size to the main run of wires. After erection, the entire conduits system shall be tested throughout, for mechanical and electrical continuity and shall be permanently connected to earth by means of approved type earthing clamps, in accordance with Indian Electricity Rules. Hazardous Area: Wiring in hazardous area shall be done by minimum 2.5 mm2 Copper Conductor armoured PVC cables. Correct type of lighting equipment (fixtures and JBs etc.) as specified in the drawing, shall be installed for the particular classified zone 1 (Class I Div. I) and Zone 2 (Class I Div.II) locations. The wiring in hazardous area shall be carried out by highly skilled wireman with due regard for perfect terminations. The terminations in the junction boxes and the lighting fittings shall be done so as not to work loose due to vibrations. After the terminations are made the cover of the junction boxes and the lighting fittings shall be closed to make the complete fittings weatherproof. In fixtures having double cable entries, both the entries shall be used for looping in and looping out connection. Thus avoiding the use of a separate junction box. Building Lighting: All the fluorescent lighting wirings to be supplied under this contract shall consist of chokes, starters and capacitors. The fittings shall be high power factor type and shall be supplied with white light fluorescent tubes. All the lighting fittings shall be supplied complete with cable glands wherever applicable and the cost for the glands shall be deemed to have been included in the supply of fixtures. Mounting details 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 "Metsec channel". The entire assembly will then by fixed to the ceiling with necessary number of supports as required to reduce the deflection. 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. Nylon tape & buttons shall neatly bunch all wires inside channel.

4.2.9

4.3 4.3.1

4.3.2

4.3.3

4.4 4.4.1

4.4.2

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING

SPECIFICATION NO. MEC/S/05/26/22

PAGE 9 OF 10 REVISION 1

4.4.3

Fixtures shall be firmly supported from the structures. Support clamps etc., may be bolted or welded to the existing steel works or metal inserts. In case of concrete structures minimum two numbers metallic anchor fasteners of approved size shall support fixtures. All supports shall be thoroughly cleaned and painted in an appropriate colour to suit the fixture. In case of false ceilings employing minimum tee grid system, fixtures shall be supported from true ceiling. Exact locations of fixtures shall be supported from true ceiling. Exact locations of fixtures shall be finalized in consultation with air-conditioning contractor and as indicated on Architectural drawings. Wiring above false ceilings shall not be left loose and shall be supported along the structures/ceilings. Wiring above false ceiling shall be on surface and below false ceiling it shall be concealed. To facilitate easy maintenance `Looping back system' of wiring shall be followed throughout. Accordingly supply tapping and other interconnections are made only at fixtures connector blocks or at switch boards; Intermediate junction boxes shall be used for wire pulling as inspection boxes. All wires in conduit shall be colour coded as specified in clause 3.8. Each circuit shall have independent phase neutral and earth wire. Unless otherwise specified, insulated conductors of ac supply and dc supply shall be bunched in separate conduits. Street Lighting: Street lighting poles shall be installed at a distance of 300 mm from the edge of the walkway of the road. Fixture wire from marshalling box upto fixture shall be 2.5 mm2, copper conductor PVC insulated. Main feeder upto the marshalling box shall be as per the respective drawings. Each pole shall be grounded by connecting it to the plant ground grid with 3/8" GI wire rope / GI strip as specified

4.4.4

4.4.5

4.5 4.5.1

4.5.2

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MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LIGHTING

SPECIFICATION NO. MEC/S/05/26/22

PAGE 10 OF 10 REVISION 1

4.5.3

Street lighting shall be done with HPMV 150 watt street lighting fixtures. They shall be mounted on steel tubular poles as per standard drawings. Electrical contractor will make the foundation for the street lighting poles. Street lighting poles shall be supplied with a base plate and grouted. The street lighting poles shall be painted with one coat of coat of primer and two coats of aluminum paint. The second coat of aluminum paint shall be given just before the handling over the installation to the Engineer-in- Charge. The poles shall be numbered as per drawings. Testing and Commissioning Lighting installation shall be tested as per the instruction of Engineer-in-Charge and shall include but not be limited to the following: (1) Measure the insulation resistance of each circuit without the lamps (load) being in place and it should not be less than 500,000 ohms to earth. 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. Check the earth continuity for all sockets outlets. A fixed relative position of the phase and neutral connections inside the socket shall be established for all sockets. After inserting all the lamps and switches on all the circuits minimum and maximum illumination level should be measured in the area. Ensure switch ON/OFF control for each point (light/fan/socket) is only on live side. Contractor shall duly fill in the test results and forward the test reports to Engineer-in-Charge.

5.0

(2)

(3)

(4)

(5)

(6)

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Specification for light final correction-24A-22\spec forlighting-22.doc

Gujarat State Petronet Limited

SPECIFICATION FOR L.T. POWER DISTRIBUTION BOARD

SPECIFICATION NO. MEC/S/05/26/26

(ELECTRICAL SECTION) MECON LIMITED DELHI - 110 092

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Spec for L.T.Power Distribution Board Final-26.doc

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LT POWER DISTRIBUTION BOARD

SPECIFICATION NO. MEC/S/05/26/26

PAGE 1 OF 5 REVISION 0

CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0

ELECTRICAL DESIGN INSULATION LEVEL FUNCTIONAL UNITS CONSTRUCTION FEATURES BUSBARS & CONNECTIONS EXTERNAL TERMINATIONS COMPONENTS

PREPARED BY

CHECKED BY

APPROVED BY

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Spec for L.T.Power Distribution Board Final-26.doc

MECON LIMITED REGD. OFF : RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LT POWER DISTRIBUTION BOARD

SPECIFICATION NO. MEC/S/05/26/26

PAGE 2 OF 5 REVISION

0

1.0

ELECTRICAL DESIGN Electric Power Supply • Rated main circuit voltage 415 ±10%, 50Hz ±5%, solidly grounded neutral.

2.0

INSULATION LEVEL • • Rated insulation voltage 660V One minute power frequency withstand voltage : 2.5 kV for power circuits and 2 kV for control circuits. Clearance in air of live parts : phase to phase : 25.4mm, phase to earth : 19.4mm.

2.1

Short Circuit Strength Horizontal and vertical buses with one second rating not less than the symmetrical short circuit level specified.

3.0 3.1

MADE-UP OF FOLLOWING FUNCTIONAL UNITS Incomer • • • • • • Moulded case circuit breaker Voltmeter (on line side) with 4 position selector switch Ammeter one for each phase. KWH meter. Power factor meter if specified in SLD. Indicating lamps for each phase, busbar side.

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Spec for L.T.Power Distribution Board Final-26.doc

MECON LIMITED REGD. OFF : RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LT POWER DISTRIBUTION BOARD

SPECIFICATION NO. MEC/S/05/26/26

PAGE 3 OF 5 REVISION

0

3.2

Outgoing Feeders • • • • Moulded case circuit breaker. Removable neutral link to be provided for neutral connection DOL starter feeders as specified / required. Capacitor bank to achieve power factor of 0.95 complete with contactor, push button, indication lamp etc. if specified in SLD.

4.0 4.1

CONSTRUCTION FEASTURES Mechanical Design • Non draw out type ,floor mounted, free standing design. • Sheet steel clad, front operation and maintenance type. • Minimum sheet steel thickness : Doors & covers - 1.6mm cold rolled and other members - 2.0mm • Degree of protection IP 54 • Assembled on base channel of structural steel/ frame of minimum height 50mm and 2.5mm thickness painted black. . The maximum and minimum operating height of the switches shall be 1800mm and 300mm respectively. • Earthed metallic barriers between compartments and between vertical sections. • Zinc dichromate and passivated hardware. • Transport unit not longer than 3.2 meters. • Removable lifting arrangement for each transport unit. • Extendibility on both sides. • Cable entry from bottom, 2mm thick removable and un-drilled gland plates • All built up and wired modules or vacant cubicles/ chambers shall be of size so as to accommodate standard modules.

4.2

Labels • PDB designation nameplate shall be at the centre of the board with letters not less than 2.5mm high. Panel identification/ designation number shall be on each panel at the top, both in front and rear. Warning labels "CAUTION EXTERNAL VOLTAGE" for terminal blocks where

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Spec for L.T.Power Distribution Board Final-26.doc

voltage appears from external source. Labels made of non-rusting metal or 3 ply lamicoid with engraved inscriptions

MECON LIMITED REGD. OFF : RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LT POWER DISTRIBUTION BOARD

SPECIFICATION NO. MEC/S/05/26/26

PAGE 4 OF 5 REVISION

0

• • 4.3

of white letters (minimum 3mm high) on black-ground. Label designation and size of lettering subject to approval.

Surface Treatment All metal parts of the panel to under go surface treatment that includes cleaning, chemical degreasing, pickling in acid, cold rinsing, phosphating and passivating followed by spraying with two coat of epoxy based primer & two coats of epoxy based paint of approved colour & shad.

5.0

BUSBAR & CONNECTIONS • • • • Three phase, Neutral and earth buses unless otherwise specified. Power and earth buses of EC grade aluminium alloy equivalent to E91E WP as per IS-5082 or high conductivity electrolytic grade copper as per IS-613. The bus bars shall be designed to withstand a system fault current of 1 Sec.The minimum acceptable size of bus bar shall be 250 Sq.mm (Aluminium). Heat shrinkable PVC sleeve (red, yellow, blue for phase and black for neutral).

6.0

EXTERNAL TERMINATIONS • • • Extension bus links properly spaced for terminating single cable of size 120 sq. mm and above as well as for terminating multiple cables. Crimping type tinned, heavy duty copper lugs for power and control cables. Power terminal blocks to be provided with covers.

7.0 7.1

COMPONENTS Air Break Fuse Switch Units

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Spec for L.T.Power Distribution Board Final-26.doc

• •

Air break, triple pole, switch, confirming to IS Specification HRC fuse links as per requirement

MECON LIMITED REGD. OFF : RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

LT POWER DISTRIBUTION BOARD

SPECIFICATION NO. MEC/S/05/26/26

PAGE 5 OF 5 REVISION

0

• •

Utilisation category AC23. Auxiliary contacts - 1 No & 1 NC

7.2

Power Contactor • Air break, triple pole confirming to IS Specification.

7.3

Thermal Overload Relays Triple pole, ambient temperature compensated, inverse time lag conforming to IS-8544. • Built in single phasing protection. • Setting range step-less adjustable in range 70% to 110%. Capacitor Bank Capacitor bank shall be APP type complete with discharge resistance etc.if required as per SLD. •

7.4

7.4

Auxiliary Contactors • • 4 Contacts 2 No. + 2 NC Continuous rating - 10 Amp

7.5

Indicating Instruments • • • • All meters Digital type. Accuracy class - 1.5 Ammeter with normal scale upto full load and suppressed scale for motor starting current. Voltmeter protected with HRC fuses

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Spec for L.T.Power Distribution Board Final-26.doc

KWH meter shall be 3 phase 4 wire type confirming to IS : 722 ,CT Operated with test blocks for current and voltage coil testing at site without interrupting recording.

7.6

Indicating Lamps • • Cluster LED type. Colour ON-Red; OFF - Green; CIRCUIT HEALTHY - White; FAULYT/ WARNING Amber, RED - YELLOW - BLUE for Incomer.

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Spec for L.T.Power Distribution Board Final-26.doc

Gujarat State Petronet Limited

SPECIFICATION FOR SPLIT AIR CONDITIONER SYSTEM

SPECIFICATION NO. MEC/S/05/E9/25

(ELECTRICAL SECTION) MECON LIMITED DELHI 110 092

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

SPLIT AIR CONDITIONER

SPECIFICATION NO. MEC/S/05/E9/25

Page 1 of 3
REVISION 0

1.0

SCOPE OF WORK Scope of Work includes supply installation and commissioning of latest model split Air Conditioner with remote, 4KVA automatic voltage stabilizers, automatic change over switch etc.

2.0

Number of AC Units: Sl. No. 1. 2. 3. Location No. Of 1.5 T Split AC Unit 4 Nos.

Control Room at Dispatch terminal at Padmala Control cum SCADA Room 4 Nos. at SV-1 Control Room at Receiving 4 Nos. terminal at Halol

3.0

Power Supply Voltage Voltage Frequency 230 V +/- 10% ,Single Phase 50 Hz +/- 5%

4.0

5.0

Contractor shall supply all material including 4 KVA Stabilizer, 20A Industrial type Plug Socket with 20A SP MCB, brackets, tools and tackles and any other items required for installation, testing and commissioning of the Air conditioning system. Fifty percent Air Conditioners shall run for 8 hrs. and automatically switch off and remaining Air conditioner shall automatically switch “ON” through automatic change over circuit with timer,contactor,indication lamp etc. Automatic Change over panel for Air conditioners shall be kept in electrical room .

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

SPLIT AIR CONDITIONER

SPECIFICATION NO. MEC/S/05/E9/25

Page 2 of 3
REVISION 0

Please furnish the Technical Data Sheet for Split Air Conditioner: Sl.No. 1. 2. 3. 4. 5. 6. 7. Description Manufacturer T.R. Rating Model No. Nominal Cooling Capacity Heating capacity Power supply Voltage Frequency Phase Power Consumption Running Current Performance Nominal Air Circulation Indoor Nominal Air circulation Outdoor Moisture Removal Noise Level Refrigerant type Features Air direction Auto air swing Temp. control Fan type Fan discharge Fan quality Fan motor type Fan motor –no. of speed Fan motor –quantity Compressor type Compressor model Compressor –quantity Air discharge Forced operation Soft dry operation De-humidification Plasma air purifier Unit Power Supply

KCAL/HR BTU/HR Not Applicable V Hz WATTS A CFM CFM dB 230V 50Hz 1 Phase

8.

9.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

SPLIT AIR CONDITIONER

SPECIFICATION NO. MEC/S/05/E9/25

Page 3 of 3
REVISION 0

Anti bacterial filter Electro static filter Remote control Indoor unit-width Height Depth Weight Colour Outdoor unit-width Height Depth Weight Colour

TECHNICAL SPECIFICATION FOR UPS SYSTEM, RECTIFIER, CHARGER AND BATTERY SETS

SPECIFICATION NO.: MEC/S/05/E9/071

Page 1 of 18

CONTENTS
1.0 2.0 3.0 4.0 5.0 SCOPE STANDARDS GENERAL REQUIREMENTS DRAWING AND DOCUMENTS INSPECTION

ANNEXURE-I ANNEXURE-II A, II B & II C ANNEXURE-III ANNEXURE-IV

PURCHASER'S DATA FOR UPS TECHNICAL DATA FROM MANUFACTURER PREFERRED MAKE CHECK LIST

Page 2 of 18

1.0

SCOPE The intent of this specification is to define the requirements of uninterrupted power supply system, Rectifiers, Inverter system and the associated battery sets. Tenderer's scope of work includes design, manufacture, testing, packing and delivery to site and testing & commissioning of the complete UPS system with static by-pass, solid state voltage stabilizer for by-pass supply, distribution boards and battery banks etc. as per this specification, data sheet and SOR.

2.0 2.1

STANDARDS In general the equipment covered by this specification shall unless otherwise specified be in line with the requirement of any of the latest applicable standards of a) b) c) d) Bureau of Indian Standards British Standard Institution American Standard Institution International Electro Technical Commission

2.2

Wherever the requirements in this specification are in conflict with any of the above Standards, the requirements under this specification shall be binding. GENERAL REQUIREMENTS Uninterrupted Power System Basic Particulars for Design 1. Basic Details Suitable for industrial application. The rating of the system shall be as per Schedule of Rates at 0.8 p.f. lagging at 50°C ambient. Over load rating as specified in Data sheet. Automatic selection of available phase (out of three phases) incase of outage of power supply of the phase in use for feeding incoming power supply to the UPS, if indicated in SOR/DATASHEET. Single phase voltage and frequency controlled output. Suitable protection shall be provided in the control circuit to guard against instability of phase controlled rectifier due to electrical oscillation which may be present in input supply as caused by emergency DG set. Single/ Dual/Parallel redundant system with automatic static bypass, common DC battery and solid state voltage stabilizer as per data sheet and drawing.

3.0 3.1 3.1.1

-

-

Page 3 of 18

-

-

-

-

The load shall normally be fed from the inverter. Battery shall be suitable to maintain the power supply in the event of mains failure or battery charger failure for time period as indicated in Data sheet. Static by pass switch to connect the load to the mains supply through static voltage stabilizer or hot standby UPS, as per the configuration, without interruption to the load in the event of inverter failure. AC Distribution board/ DC Distribution board as per data sheet. Space heater and panel illumination to be provided. Noise level at a distance of 1 m. from UPS panels shall not exceed 60 decible. UPS system shall be suitable for both floating output or earthing of one leg in case of single-phase system/star-point in case of threephase system. MCR with straight modbus or RS485 of UPS shall transmit the health-monitoring signal to RTU for indication at SCADA.

2.

Permissible Variations a) Mains power supply system :Voltage : Frequency :

+10%, - 20% ±5%

b)

Output of the uninterrupted power supply system while delivering a load of its rated capacity :Voltage : ±1% Frequency : ±1% Accuracy of static type voltage stabilizer for bypass supply shall be within ±2%

c)

3.

Protective Features Short circuit and overload protection DC Earth Fault

3.1.2

Transformer 1. 2. 3. Rating suitable for the application Dry type, with class 'H' insulation ± 2.5% tappings on primary side.

3.1.3 1. 2.

Rectifier/ Battery Charger Switched ON through a MCCB. Charger size shall be based on the maximum inverter input load current

Page 4 of 18

and recharging current (in maximum time of 10 hours after complete discharge). The rating of rectifier / charger shall be not less than the value calculated as follows: For Ni-Cd batteries = Inverter input current + 0.2 Ah (5 hr. rating of battery) For VRLA batteries= Inverter input current+ 0.2 Ah (10 hr. rating of battery) Rated kVA capacity of UPS X load p.f. Where inverter input current = --------------------------------------------------------Battery charging voltage X inverter efficiency 3. 4. 5. 6. With transient and surge protection circuit in input circuit to protect UPS from surges and voltage Spikes. With necessary smoothing reactor and filters Automatic boost and float charging control Protective features : Maximum current limiting Over temp. trip. Boost charging and float charging current limiting with back up protection against over charging. Indications : -

7.

-

As per manufacturer’s standard.

8.

Charger shall simultaneously supply entire power necessary for inverter and to keep the battery of required capacity in fully charged condition. Provision for automatic charging in both float and boost shall be made.

3.1.4 1. 2. 3. 4. 5. 6.

Inverter With input circuit consisting of battery MCCB, battery filter and smoothing reactor. DC/DC converter for voltage control Control electronics Series reactor and parallel filter Output transformer Protection against the following: Abnormal output voltage Abnormal link voltage Over load trip Low battery voltage High transformer temperature

Page 5 of 18

7.

8.

Auxiliary supply failure Meters For output voltage For output frequency Ammeter Battery current and voltage with indication of status - "in charge" or "discharge". Static by-pass switch Static switch automatically switches the load to the reserve power supply or the mains whenever there is failure in invertor supply to the load. Retransfer of load from stabilized bypass supply to the inverter in auto as well as in manual mode. High speed fuses shall be provided for protecting the thyristors against accidental overload. Following indications & alarms shall be provided in the by-pass module. Indications Load on bypass Constructional Features

3.1.5 1. 2. 3. 4.

5. 6.

7. 8. 9. 10. 3.1.6 3.2 3.2.1

Unitized construction Free standing, floor mounted, indoor type and complete with all interconnection. Dust and vermin proof Sheet steel clad Minimum 2 mm thick for panels Minimum 1.6 mm thick for doors and side covers Units shall be self contained and serviceable The arrangement and layout shall facilitate easy and convenient supervision of the unit while running as well as quick detection of disturbances and trouble shooting. Copper earth bus bar shall run through out the length of Panels. All doors & non current carrying parts shall be suitably earthed. Dimensions of panels shall be such that it can be accommodated in existing room if indicated in MR/ SOR. The maximum and minimum operating height of the switches shall be 1800mm and 300mm respectively. Painting type and shade : Epoxy 631 of IS : 5 Enclosure and Ventilation Enclosure conforming to minimum IP-41 class. Units shall be provided with cooling fans and louvers. Battery unit Ampere-hour capacity of the battery shall be selected on the following

Page 6 of 18

basis: a) b) c) d) e) f) g)

Load power factor of 0.8 Aging factor of 0.8 Battery state of charge factor of 0.95 Minimum ambient temperature as specified in data sheet Backup time as specified in data sheet Minimum end cell voltage shall be 1.1V per cell for Ni-Cd battery & 1.85 V per cell for VRLA battery. Inverter rated KVA X Rated load p.f --------------------------------------------------------------------Inverter Efficiency * X End cell voltage X No of cell

Battery Current =

* for parallel redundant UPS at 50 % load on each inverter. 3.2.2 The type of battery (Ni-Cd/ lead acid-VRLA) shall be as per MR/ SOR/DATASHEET. Sets of Indoor Stationary batteries of type as per enclosed data sheet complete with all required accessories as applicable including but not limited to the following shall be supplied with each battery set ; a) b) c) 3.2.4 Battery stands in double row/ double tier formation as per battery manufacturer’s standard. Cell testing voltmeter complete with leads- (1 no. per set). Spanner - (1 no. per set).

3.2.3

Overall dimensions of complete battery set shall be such that it can be accommodated in existing room if indicated in data sheet. DRAWINGS AND DOCUMENTS The following documents shall be submitted alongwith the offer: a) b) List of two years operation and maintenance spare. Technical data sheet (Annex-II) and check list (Annex-IV) duly filled.

4.0 4.1

4.2

The following calculations/ dimensions shall be submitted alongwith offer: a) b) c) d) Charger sizing calculation. Battery sizing calculation. Battery cabinet size. UPS panel size including solid-state stabilizer panel.

4.3

The following drawings shall be submitted for approval within 3 weeks of award of contract. a) G.A. of panel and battery stand. b) Schematic

Page 7 of 18

c) d) 4.4

Bill of Material Wiring diagram for reference.

Final drawings, operation & maintenance manual and erection instructions shall be submitted alongwith despatch of equipments in three sets in hard copy & two sets in soft copy (CD). INSPECTION Inspection and testing of equipment shall be carried out by the owner/ consultant at the works of the contractor on final product to ensure conformity of the same with the acceptable criteria of technical specification, approval drags. and reference national/ international standards.

5.0

5.1

The contractor shall submit Quality Assurance Plan (QAP) for respective equipments within 3 weeks of award of contract. QAP shall be prepared and furnished by the contractor alongwith their internal in process quality checks. ‘Type test' including 24 hr. heat run test shall be conducted on one UPS System of each rating and ‘Acceptance test’ on the remaining. Batteries shall be tested for type and `Acceptance Test’/ Routine Test at battery manufacturer’s works and test reports shall be submitted for review and approval. Final acceptance testing alongwith the batteries shall be done at site. Site acceptance test procedure shall be submitted by the Contractor alongwith QAP.

5.2

5.3

5.4

Page 8 of 18

ANNEXURE - I PURCHASER'S DATA FOR UPS 1.0 1.1 INPUT POWER SUPPLY Voltage/freq./ phase: 415 V (±) 10 % , TPN, Automatic 3 Ph to 1 Ph. (Selection through Phase selection logic circuit), 50 Hz ± 5% 10 KA

1.2 2.0 2.1 2.2 3.0 3.1 3.2 3.3 3.4 3.5

System fault level SITE CONDITION Design Ambient/ Minimum ambient Max. Relative humidity SYSTEM REQUIREMENTS Input Power Supply to System Type of inverter Rating (KVA at 0.8 pf.) Overload capacity Mode of operation

50°C / Min. 5°C 100%

240 V (±) 10 % TPN, 50 (±) 5% Hz AC through 3 Ph to 1 Ph auto selection logic ckt. Transistorized (IGBT) or Latest proven technology 5 KVA 150% for 10 Sec., 125% for 10 min. , 110 % cont. Parallel Redundant UPS with static stabilizer and 3 Ph.Battery charger

3.6 3.7

Load p.f. Type of Battery

0.8 (with variation between 0.6 to 1.0) Ni-Cd (1.2 V) Pocket plate type

3.8

i) ii) iii) iv)

Battery end cell voltage Battery stand formation Battery back up time Derating factor

1.1 V/Cell (Ni-Cd) Two steps and Two tier
12 Hrs. (2 Banks of 6 hours each)

As per specification Minimum IP-41 From bottom

3.9 3.10

Type of enclosure Cable entry

Page 9 of 18

4.0

A.C.D.B./ D.C.D.B. DETAILS

(1) ACDB (1 No.) One number incomer DP MCB and 13 nos. out going DP MCBs with semiconductor fuses and bus bar. (2) Metering: Voltmeter, Ammeter (Digital type).

5.0 6.0

QUANTITY Drawings reference

i) 3 Sets UPS Block diagram No.MEC/TS/05/E9/071B,R -0

Page 10 of 18

ANNEXURE-II (A) TECHNICAL DATA FROM MANUFACTURER (To be filled up by the Tendered) 1.0 1.1 1.2 1.3 1.4 INVERTER Manufacturer’s Model No.(Enclose catalogue) Rating (at specified ambient) / no. of phases Applicable codes/standards Steady state output volt/freq (230 V + 1%) (50 Hz + 1%) 1.5 1.6 1.7 Input volt. Synchronization (inv. phase locked with main) in percentage Synchronization manually adjustable in steps of

1.8 1.9 1.10 1.11

Allowable unbalance between phases (for 3 Phases only) Harmonics distortion for linear & non-linear loads (not more than 4% and 15% respectively). Mode of operation Dynamic Responses at following conditions a) ± 50% step load (for parallel redundant UPS) b) ± 100% step load (for hot standby and single UPS system). c) Power supply interruption and restoration. d) Load Transferred to bypass line e) When one inv. gets faulty and load transferred to healthy inv. (for parallel redundant UPS) Recovery time to reach steady state after above disturbance (not more than 100m Sec) Overload capacity Short circuit capacity and duration (in % and m sec.) Degree of protection of the panel.

1.12 1.13 1.14 1.15

1.16

Noise Level (dB. A at 1 m) (Not more than 75 dB)

Page 11 of 18

1.17 1.18 1.19

Efficiency at 100%/75%/50% loads (not less than 80% at 100% load) Type of control circuit (Static PWM) Out put voltage & phase angle (for 3 Ph.only) a) For 30% unbalance load b) For 40% unbalance load c) For 50% unbalance load d) For 100% unbalance load Crest Factors STATIC SWITCHES Nos. of static switches in each set Current rating at specified ambient Transfer time (m sec.) a) Synchronized mode (not more than 4m Sec) b) Unsynchronized mode (not more than 20m Sec) BATTERY CHARGER Rating (Amp.) / MAKE (Enclose back up calculation). Type of charger (Basic configuration) Output volt under float/boost charging condition Volt. Accuracy under specified input (± 1%) Max. Ripple content on DC side (% RMS) (not more than 2% without battery) Max. Ripple content on AC side (% RMS) Efficiency at 100%/75%/60 of load Mode of Change over from float to boost and viceversa BATTERY Make Type (Enclose catalogue) AH rating (Enclose back up calculation) End cell volt. at specified discharge rate (V/ cell)

1.20 2.0 2.1 2.2 2.3

3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.0 4.1 4.2 4.3 4.4

Page 12 of 18

4.5 4.6 4.7 4.8

Output (Nominal) volts Nos. of battery banks Nos. of cells in each banks Battery charging requirements (V/ cell) a) b) c) Volts/Cell Float Boost

4.9 4.10 4.11 4.12 4.13 4.14 5.0 5.1 5.2

Voltage variation from fully charged battery to discharged battery (volts) Charging time( Hrs.) Max. permissible ripple content (% RMS) Overall dimension (L*W*H) Container type Accessories for battery as per specification included MANUAL TRANSFER DEVICES Rating (Amp.) Make/Type .

6.0 6.1 6.2 6.3 6.4 6.5

STEP DOWN BYPASS TRANSFORMER WITH SOLID STATE VOLTAGE STABILISER Make/type Rating and Voltage ratio Accuracy of stabilizer (not more than ± 2%) Type of control (Solid state) Type of cooling Natural

7.0 7.1 7.2 7.3

AC DISTRIBUTION BOARD/ DC DISTRIBUTION BOARD Nos. of feeder/rating Cable entry from (Bottom) Deleted

7.4

Max. rating of outgoing feeders possible for fault clearance by UPS with and without supply back up (as percentage of UPS rating) not less than 25%

Page 13 of 18

a) 8.0

With fast acting semi conducting fuses Microprocessor based

Control

9.0 10.0 11.0

Indications and Alarm METERING UPS Dimension (L x W x H) except Battery : (Including inverter, charger, rectifier, bypass stabilizer, ACDB/DCDB etc. )

12.0 12.1

OVERALL EFFICIENCY OF UPS SYSTEM Ratio of output load to input drawn from mains when inverters are on and synchronized with bypass. a) At 100% load (not less than 80% at 0.8 p.f.) b) At 75% load c) At 50% load RELIABILITY a) Safety factor used for selecting electronic components/ other electrical components (not less than 200%/ 125% respectively) b) MTBF / MTFR c) Availability factor DEGREE OF PROTECTION

13.0

14.0

15.0 16.0 17.0

Heat loss for total system (W) Spare potential free contracts (for duplicating of fault status in remote panel) to be provided. Fault status shall be compatible to hook-up with Owner’s PC through RS 232/ RS 485 interface.

Page 14 of 18

ANNEXURE-II B

TECHNICAL DATA FROM MANUFACTURER FOR BATTERY CHARGER

(To be filled up by the Tenderer)

1.0

BATTERY CHARGER FOR Ni-Cd BATTERY BANK

1.1

Rating (KW/Amp.) (Suitable for charging of battery and supply to 5 KVA load simultaneously)

1.2 1.3 1.4

Input Supply Redundancy (Parallel redundant system) MAKE

415 V +/- 10 %, TPN from DG Set.
Refer UPS Block diagram No.MEC/TS/05/E9/071B,R -0

1.5

Output volt under float/boost charging condition Volt. Accuracy under specified input.

1.6

1.7

Efficiency at 100%/75%/50 % of load

>75% at 75% load.

1.8

Mode of Change over from float to boost and vice-versa

Automatic & Manual

Page 15 of 18

ANNEXURE –IIC TECHNICAL DATA FROM MANUFACTURER FOR THE INVERTER (To be filled up by the Tenderer) 1.0 1.1 1.2 1.3 1.4 1.5 1.6 INVERTER System Rating (at specified ambient) Redundancy Manufacturer’s Model No. (Enclose catalogue) Applicable codes/standards Input volt. Steady state output volt/freq (240 V + 3%) (50 Hz + 3%) 1.7 1.8 1.9 1.10 1.11 1.12 2.0 3.0 3.1 3.2 3.3 4.0 5.0 Harmonics distortion for linear & non-linear loads (not more than 4% and 15% respectively). Overload capacity (125% for 10 min., 110% Cont.) Short circuit capacity and duration (in % and m sec.) Efficiency at 100%/75%/50% loads (not less than 80% at 100% load) Type of control circuit (Static PWM) Crest Factors ACDB Battery Type Back up time Derating factor Degree of protection of the panel. Noise Level (dB. A at 1 m) (Not more than 75 dBA) SMF Lead Acid 4 Hrs. Same as that of UPS battery IP-41 1 Incomer MCB 10A & Outgoing 5 Nos. 5A MCB 230 V +/- 10%, 1Ph. & N AC ,50 Hz +/- 5% 1.25 KVA Single

Page 16 of 18

ANNEXURE-III PREFERRED MAKES 1. 2. UPS System & Inverter System BATTERIES (Ni-Cd) Emerson / DB Power / APLAB / KELTRON / HI -REL AMCO/ HBL-NIFE

3.

CONTROL SWITCHES

ALSTOM/ SIEMENS/ KAYCEE/ L&T

4.

CONTACTOR

SIEMENS/ L&T/ BCH/ TELEMECHANIC

5.

FUSES (Semiconductor/ HRC)

ALSTOM/ SIEMENS/ L&T

6.

TERMINALS

CONNECTWELL / WAGO / PHOENIX

7.

METERS

AEP/ SIMCO/ IMP/ ALSTOM/ RISHAB

FOR ANY OTHER ITEMS, WHICH ARE NOT LISTED ABOVE, SHALL BE SUBJECT TO MECON/GSPL APPROVAL.

Page 17 of 18

ANNEXURE - IV CHECK LIST (To be filled up by tenderer ) Sl.No 1 2 3 4 5 6 7 Description Deviation from specification Charger sizing calculation enclosed Battery sizing calculation enclosed Battery catalogue enclosed UPS Panel Catalogue enclosed Confirm compliance to Block diagram Inspection for UPS and battery as per specification. Dimension for UPS Panel, rectifier and Battery Bank enclosed. Unpriced schedule enclosed Break up for two years operation & maintenance spares enclosed for UPS REMARKS Offer may be rejected if there is any deviation

8

9 10

Page 18 of 18

Gujarat State Petronet Limited

SPECIFICATION FOR DG SET

SPECIFICATION NO. MEC/S/05/E9/006

(ELECTRICAL SECTION) MECON LIMITED DELHI 110 092
D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Specification of DG Set-006\Content & Annexure.doc

TABLE OF CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0

SCOPE STANDARDS TO BE FOLLOWED SERVICE CONDITION OPERATING REQUIRMENT DIESEL ENGINE GENERATOR SYNCHRONISATION & CONTROL PANEL INSTRUMENTATION ACCESSORIES PAINTING TESTS AND INSPECTION SPARES DRAWING AND DOCUMENTS DEVIATION PACKING

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Specification of DG Set-006\Content & Annexure.doc

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 1 of 15
REVISION 0

1.0 1.1

SCOPE This specification covers the technical requirements of design, manufacture, assembly; testing at works and delivery in well packed condition of 40 KVA diesel generator set complete with Control Panel, all required accessories and control equipment to supply continuous electrical power. This specification shall be read in conjunction with specification sheet. The scope of supply shall include, but not limited to the following: a) b) Diesel engine, complete with all the required accessories and components. Generator set, for operation with the above diesel engine, complete with all the required accessories and components. Fuel oil system comprising of fuel oil tank, filter, piping; valves, fittings, etc. Air intake system comprising of air blower, air filter, etc. Lubrication oil system comprising of lube oil pump, filter, cooler, piping, valves, fittings etc. Air-cooled. Starting system complete with battery, battery charger, control system etc. All inter connecting piping, valves, fittings up to the battery limits. First fill of lubricants. A common base frame suitable for assembly of engine and alternator with accessories. Anti, vibration mounting and foundation bolts shall also be supplied. Base frame shall be designed for transportation of above items duly assembled on it. Exhaust manifold complete with silencers, asbestos lagging, metallic expansion bellows and piping as per requirement. All necessary instruments interlocks, controls with necessary annunciation and indication for monitoring and safe starting, running in parallel & independently stopping of the D.G. set their auxiliaries complete with tubing and cabling. CONTROL PANEL.

1.2 1.3

c) d) e)

f) g) h) i) j)

k)

l)

m)

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 2 of 15
REVISION 0

n)

Power and Control cable between control panel and all equipment within the battery limit including racks, earthing terminating materials etc. All safety and protective devices. All other items, not specified here but, necessary for safe, satisfactory and uninterrupted operation of D.G. set. Set of special tools and tackles required for installation and maintenance. Commissioning spares . All other services as indicated in specification sheet. Contractor shall get approval from electricity authority for DG Set. . Erection, site testing and commissioning of the D.G. set at site. Electrical Civil Work The following jobs shall be in the scope of work of the Contractor. a) All civil works such as provision of foundations, plate inserts, wall and floor cutouts, cable trenches, etc.

o) p)

q) r) s) t) 1.4 1.5

2.0 2.1

STANDARDS TO BE FOLLOWED The design, manufacture and testing of the equipment covered by this standard shall comply with the latest issue of the following codes and other relevant Indian standard specifications unless otherwise specified in the specification sheet. i) ii) BS 649 - Diesel engines for general purpose. IS- 10000 - Methods of test for internal combustion engine.

iii) ASME codes. iv) IS 4722— Rotating Electrical Machines. 2.2 Equipment designed and manufactured to other national standards shall be acceptable provided they are in no way inferior to the above-mentioned standards. The design and operation features of the equipment offered shall also comply with the

2.3

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 3 of 15
REVISION 0

provisions of latest issue of the Indian Electricity Rules and other statutory regulations. The supplier shall, wherever necessary, make suitable modification in the equipment to comply with the above. 2.4 Wherever any requirement, laid down in this specification, differs from that in Indian standard / IEC, the requirement specified here in shall prevail. SERVICE CONDITIONS Ambient Conditions These shall be as indicated in specification sheet. 3.2 System Details These shall be as indicated in specification sheet. 4.0 4.1 OPERATING REQUIREMENTS The D.G. set shall be suitable for ‘black start” operation. The equipment offered shall be suitable for operating at their rated capacity continuously under the ambient conditions and voltage and frequency variations indicated in specification sheet, without exceeding the temperature rise limits specified in relevant standards and without any detrimental effect on any part. The D.G. set shall be designed for continuous operation at full load or partial load and have the capability to run at 110% of the MCR for one hour in every 12 hours. The standby D.G. set should start manually after prolonged idle period. Under such conditions, the auxiliary power shall not be available. The starting and lubrication system shall be suitably designed to take care of these conditions and allow easy, safe and quick starting. The D.G. set loading sequence is not automatic and hence need not be defined by Owner / client. The D.C. set shall be manually controlled and started manually. DIESEL ENGINE General Design Feature The diesel engine- shall be of multistroke , multicylinder with mechanical fuel injection arrangement and complete with all the required accessories.

3.0 3.1

4.2

4.3

4.4

4.5 5.0 5.1 5.1.1

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 4 of 15
REVISION 0

5.1.2 5.1.3

The engine output shall be at least 15% greater than the power required for the loads. The engine shall be suitable for trouble free operation with high speed diesel conforming to IS: 1460. The unbalance force transmission to the foundation shall be minimum. Critical speed of the assembly shall be sufficiently higher than the rated speed of the engine. The engine shall be provided with filter and silencer mounted suitably on the engine frame and complete with necessary ducts work for air intake. The engine shall be provided with exhaust silencer, necessary ducts, and minimum 1 no. Expansion bellows and supporting arrangement from ceiling for exhausting the gases to outside. Fuel Oil System The system shall comprise of gravity fed oil tank, or otherwise as specified in specification sheet. The gravity tank shall be complete with the provision of filling up by Hand pump from the standard drums. The hand pump and associated hose pipe shall be supplied along with oil tank. The gravity fed oil tank shall be located at a height from floor and near the wall of the engine room. Suitable brackets / structure shall be provided by the vendor for this purpose. The tank shall be fabricated out of MS. plates in cylindrical construction. The capacity of the tank shall be adequate for 12 hours continuous running of the engine. It shall be complete with valves for filling and draining, vent connection, level gauge glasses, level switches for low level alarm. Cooling System The engine shall be air-cooled. Lube Oil System Proper lube oil system shall be provided for all lubricating points of the engine. Starting System The Electrical starting system shall be provided.

5.1.4

5.1.5

5.1.6

5.2 5.2.1

52.2

5.2.3

5.3 5.3.1 5.4 5.4.1 5.5 5.5.1

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 5 of 15
REVISION 0

5.5.2 5.5.3

Local manual starting scheme shall be provided. The starting system shall be such that the D.C. set shall start come upto rated speed and be ready to accept full load within the period as indicated in specification sheet. The electric starling system shall comprise of starter motor, battery, battery charger, necessary cabling, required instruments and accessories. The sealed lead acid battery shall be heavy duty type and suitable for 20 successive starting attempts of the engine without draining. The charger shall have both float / boost charging facilities. The battery shall be complete with suitable stand and other required accessories. Governing System The speed governing system of the diesel engine shall satisfy the following requirements: • • • Steady state speed regulation shall be adjustable between 0 to 5% manually. Steady state speed regulation once fixed, shall not vary beyond +0.5%. Transient & peed regulation shall not exceed 4.5% of rated speed. Momentary under speed and over speed shall not exceed 2% and 8% respectively. Recovery time shall be within 3 seconds.

5.5.4

5.5.5

5.6 5.6.1

• 5.6.2

The governor system shall be mechanical type and provided with adequate scheme to control the speed in the event of failure of power to the governor. A mechanical over speed trip device shall be provided to operate at 110% of rated speed. An engine mounted emergency push button shall be provided to trip the engine in case of emergency. GENERATOR General Design Features The generator shall be directly coupled to the engine. The ingress protection class of the enclosure shall be IP21 as per IS : 4691. The generator and its accessories shall be capable of withstanding electrical, mechanical and thermal stresses while meeting the performance requirements.

5.6.3 5.6.4

6.0 6.1 6.1.1 6.1.2 6.1.3

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 6 of 15
REVISION 0

6.1.4

The generator shall be synchronous AC. generator, star connected and shall have C.M.R. of specified output at 0.8 lag p.f. at rated voltage and frequency. Winging And Insulation The stator and rotor coils shall be made out of electrolytic grade copper conductors. Successive coils shall be connected by accessible and well brazed joints The coils shall be class F or H insulated and treated with tropical and fungicidal treatments. The windings shall be dried, properly impregnated with suitable varnish to withstand the site conditions and properly baked. At least two additional impregnations and baking shall be applied to the assembled coil making a total of three impregnations and backings. Finally the windings shall be painted with special anti acid and antalkali paints to withstand the site condition. The leading wire between the windings and the outside terminals shall be through bushings.

6.2 6.2.1

6.2.2 6.2.3

6.2.4

6.3 6.3.1

Performance Requirement The generator and the diesel engine shall match properly to deliver the rated load under the specified ambient and system conditions. The specified rating of the D.G. set indicated are net electrical power output required for owner’s use and does not include the power required by the auxiliaries of the diesel set. The actual output rating of the generator to be offered by vendor shall take into account the power requirement of the auxiliaries, 15% extra margin. The generator shall have an overload capacity of 10% for 1 hour in any consecutive period of 12 hours after having attained the thermal equilibrium corresponding to the rated load. The terminal voltage shall be equal to the rated value. At the time of switching ‘ON’ the emergency loads, restarting or reaccelerating of squirrel cage motors shall be required, in addition to switching ‘ON’ of the lighting loads, which will be six times the rated load at power factor of 0.35 lagging. The generator and its accessories shall be capable of supplying this load at the above mentioned low power factor. Limitations, if any, shall be clearly indicated by the vendor. Largest Motor Starting Requirement The D.G. set shall be designed such that it can start squirrel cage induction motor of specified rating by D.O.L. starting method when already loaded up to 70% of its rated load. The voltage dip at the generator terminal shall not exceed 10% of its rated voltage during the entire starting period which will not exceed 5 seconds.

6.3.2

6.3.3

6.3.4

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 7 of 15
REVISION 0

6.3.5

The short circuit ratio, of the generator at rated KVA and rated voltage shall not be less than 0.5. The generator shall withstand 20% over speed for 2 minutes without any damage to any part. The generator shall be capable of withstanding the three-phase short circuit at its terminals while operating at its voltage without sustaining any damage. Excitation System The generator shall be provided with static brush less excitation system comprising of shaft driven rotor exciter, thyristor and other associated items. The capacity of the system shall be adequate to meet the performance and largest motor starting requirement of the generator. Voltage Regulator The generator shall have electronic automatic voltage regulators to be mounted on the control panel. The regulator system shall be suitable to meet the following requirements. • • • • • Allow the generator to meet the performance requirements. Both auto and manual control. Prevent automatic rise of field voltage in the event of excitation supply failure. Transfer to manual mode in the event of control circuit failure in auto mode. Operated by the output current and voltage of the generator.

6.3.6 6.3.7

6.4 6.4.1

6.4.2

6.5 6.5.1

6.6 6.6.1 6.6.2

Terminal Boxes All the terminal boxes shall have lP-21 degree of protection. The power and control terminal boxes shall be separate. All the six leads of the generator stator shall be taken out, three to one side and three to the other side to separate power terminal boxes. The power terminal box shall be spacious and have adequate clearance between the terminals and the cable gland for proper termination of required nos. of aluminum cables, The power terminal boxes shall be provided with tinned copper sockets suitable for crimping.

6.6.3

6.6.4

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 8 of 15
REVISION 0

6.6.5 6.6.6

The control terminal boxes shall be provided with pressure type terminal blocks. All terminal boxes shall be complete with heavy-duty double compression type aluminum cable glands suitable for the cable sizes required. CONTROL PANEL

7.0

7.1

Requirements a) The control panel shall comprise of control & instrument section power & protection section and distribution section for satisfactory and trouble free operation of the set. Each section shall be a complete panel. The control and instrument panel shall house the following: • • • • • • • c) All the required controlling elements for the engine, generator and exciter control, for both manual and automatic operations. Panel mounted instrument. The required protective devices for the engine. The audiovisual annunciation system indicating abnormal operating conditions. Control switches and indicating lamps. Automatic voltage regulator. All other items, as required.

b)

The power and protection panel shall house the following: • MCCB, Contractor for local operation and provided with in-built protective relays, C.T.s Ammeters, Voltmeters, KWH meters, Frequency meters, ON/OFF/Trip indicating lamps, control switches etc. for the control of generator. Outgoing Feeder shall have MCCB.

• d)

The distribution panel shall house the following: • Necessary feeder circuit outlets complete with MCCB, contractors, overload devices, ON/OFF/Trip indicating lamps, Ammeters etc. for the D.G. set auxiliaries, if required. D.C. battery charging equipment required for the start up and control of the D.G. set. The charger shall be complete with float and boost charging arrangement both in auto and manual mode.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 9 of 15
REVISION 0

7.2 7.2.1

General Design Features The panels shall be free standing, floor mounting, identical, metal clad cubicle type in construction and placed side by side to form a compact assembly in dust / damp and vermin proof type equivalent to lP-52 as per 15:2147. The thickness of sheet steel members shall not be less than 2/1.6 mm for cold rolled steel. Suitable reinforcement, wherever necessary, shall be provided. The base channel shall be more than 3 mm thick. The door hings shall be concealed type. All threaded screws in the removable parts shall be provided with retaining rings. All the components shall be accessible for checking and taking off without the necessity of removing the adjacent ones. Their mounting shall be accessible and ensure the necessary degree of safety. The relays, meters, switches and lamps shall be flush mounted type. Their minimum mounting height shall be 300 mm from the base of the panel. The bus bars shall be for three phase and neutral and made of electrolytic copper or aluminum of required cross section and PVC sleeved. These shall be amply sized to carry the rated continuous current under the specified ambient temperature without exceeding the total temperature of 850C. The thermal rating of the bus bars shall be designed to withstand the system fault current for one second without exceeding the temperature of 2500C for bare copper. The clearances and creep age distance shall not be lower the values specified below: i) ii) Minimum clearance between two live conductors —20 mm. Minimum clearance between live parts and accidentally dangerous part —20 mm.

7.2.2

7.2.3

7.2.4

7.2.5

7.2.6

7.2.7

iii) Minimum creep age distance —28 mm. 7.3 7.3.1 7.3.2 Control Wiring The panel shall be completely factory wired and ready for external connections. The wiring shall be carried out with flexible stranded PVC insulated copper conductor cables for 1100 volts grade. The size of wires shall be as follows:

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 10 of 15
REVISION 0

C.T. Circuit —2.5 sq. mm. Copper V.T. & Control circuits— 1.5 sq. mm. Copper. 7.3.3 All wiring shall be marked in accordance with lS:375. Numbered Ferrules reading from the terminals outwards shall be provided at both ends of all wiring for easy identification. These shall be interlocking type plastic ferrules. Circuit Breakers The circuit breakers shall generally comply with the requirements of IS:2516, having P2 category, capable of carrying the specified current at the site conditions and making/breaking of the system fault current. Type test certificates from an independent testing authority shall be furnished along with the offer, for each circuit breaker rating, which shall clearly prove the capability of circuit breakers and include the short circuit tests, temperature rise test, electrical overload tests and endurance test (both electrical and mechanical). The circuit breakers shall be provided with motor wound spring closing mechanism and electrically and mechanically trip free and have anti pumping features. The circuit breakers shall have three positions for service, test and isolated with the cubicle door closed, and position indicators provided to indicate the positions of the breaker Stoppers shall be provided to prevent excessive movement of the breaker shall have monitoring switch having 1 NO. + 1 NC contacts. Provision shall be made for testing the circuit breaker in test position. Automatic safety shutters shall be provided to screen the cable and the bus bars spouts when the circuit breaker is withdrawn from the cubicle. The circuit breakers shall be provided with an emergency manual trip device, mechanical ‘ON’, ‘OFF’ and ‘ISOLATED’ position indicators and operation counter. Mechanical safety interlock shall be provided for safe operation movement of the breaker. The closing coil and other associated auxiliary relays shall operate satisfactorily at all voltages between 85 to 110% of the rated control voltage. The tripping coil and other associated relays shall operate satisfactorily at all voltages between 70 to 110% of the rated control voltage. Control Fuses The fuses shall be of non-deteriorating HRC cartridge link type and conform to IS:2208.

7.4 7.4.1

7.4.2

7.4.3

7.4.4

7.4.5 7.4.6

7.4.7

7.4.8 7.4.9

7.5

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 11 of 15
REVISION 0

They shall be suitable for the load and the service required in the circuit. 7.5 7.6.1 7.6.2 Current Transformers C.T.’s shall be cast resin, accuracy class 1 as per 15:2705, for metering. All the C.T.’s shall be provided with terminals and shorting links. One of the terminals of the C.T.’s shall be earthed. The polarity of the C.T.s shall be clearly marked. Voltage Transformer The V.T. shall be cast resin insulated having secondary terminal voltage of 110V and accuracy class of shall be 1 as per 15:3155 and provided with primary / secondary fuses.

7.7

7.8

Relays All protective relays shall be provided in draw out and dust proof cases and shall be flush mounted type. They shall be fully tropicalised. Relays shall be of make and type as approved. The following protective relays shall be provided. i) ii) iii) iv) IDMTL over current and Residual earth fault. IDMTL standby earth fault. Over voltage or Under voltage. Hand reset tripping relay.

7.9 7.9.1

Instruments And Metering All instruments shall be flush mounting type with square face of 96 Sq.mm. They shall be tropicalised and dust tight. Make and type of instruments shall be as approved. Marking of the scale shall be black on white background and suitable for direct reading. Zero adjusters shall be provided for operation from the front of the cases. All indicating instruments shall be moving iron spring-controlled type of class 1.5 accuracy as per IS: 1248. The KWH meter shall be as per IS: 732 and provided with test blocks for current and voltage coils for testing them at site without interrupting their recording while in service.

7.9.2 7.9.3 7.9.4

7.9.5

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 12 of 15
REVISION 0

7.9.6

The following instruments shall be provided. i) ii) iii) iv) v) Voltmeter Ammeter Frequency meter KW meter KWH meter

-

7.10

Signal Lamps LED type signal lamps shall be provided to indicate the various circuit conditions and these shall be placed at suitable height. The colour of the lamps for various functions shall be as follows: Red Green White Amber Blue Circuit breaker ‘ON’ Circuit breaker ‘OFF’ Trip circuit healthy Alarm and auto trip fault Non trip fault

7.11 7.11.1

Name Plate The panel shall have a large name plate on the top to indicate is name and designation. Each feeder shall be provided with name plates. Each panel shall have name plates both in front and back.

7.11.2 All control switches, push buttons, lamps etc. shall have function identification labels. 7.12 Cable Termination Necessary cable glands and lugs for power and control cables shall be provided. 7.13 MCCB - Moulded Case Circuit Breaker a) b) c) d) MCCB shall confirm to relevant ISS/International standard. MCCB shall have Trip free mechanism. Under Voltage Trip mechanism. Short Circuit and O/C, Circuit mechanism.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 13 of 15
REVISION 0

8.0 8.1

INSTRUMENTATION The instrumentation requirement shall include field / panel mounted instruments, push buttons, lamps, audio-visual alarm system and other accessories as required. The provision required in the control panel board shall include the followings: • • Fuel oil day tank level indicator. Audio-visual alarm system for: a) b) c) • Low lube oil pressure All shutdown condition Other abnormal conditions, as required

8.2

Shutdown system for: a) b) c) Minimum lube oil pressure Failure of engine to start after a preset time Other faults, as required

Engine control system complete with: a) b) c) d) e) f) g) h) i) Auto / manual switch. Push buttons and other control equipment for manual start. Equipment and circuitry for pre-start priming, if required. Equipment and circuitry for repeated attempt to start. Indicating lamps for fail to start. Audiovisual alarm as specified and required. Instrumentation as specified and required. Operation hour counter. All other items, as required.

8.3

The field mounted instruments shall include the followings: a) b) c) Pressure gauge for lube oil. Fuel oil day tank low level indicator. Other items, as required.

8.4 8.5

The supply shall be complete with all instrument erection materials with 10% extra provision. All instruments shall be suitable for site maximum ambient temperature. All electrical and electronic instruments shall be tropicalised and fungus proof.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 14 of 15
REVISION 0

9.0

ACCESSORIES The D.G. set shall be complete with all required accessories, whether indicated or not, to make the installation complete in all respects and to ensure its safe and proper operation.

10.0

PAINTING The enclosures, after suitable pre-treatment, shall be painted with two coats of anti rust paint followed by two coats of anti-corrosive epoxy based paints.

11.0 11.1

TESTS AND INSPECTION All routine tests as per relevant standards shall be carried out in the presence of purchaser’s representative. The D.G. set shall be tested for output, general performance, overloads and other tests sufficient to prove the correctness of the design both at works and at site. In addition, the equipment shall be subjected to stage inspection during process of manufacture at works and site inspection. These inspections shall, however, not absolve the vendor free from his responsibility for making good any defect, which may be noticed subsequently.

11.2

11.3

11.4

12.0

SPARES Item wise unit prices for spare parts with recommended quantity shall be quoted along with main equipment. The spares quoted shall include, in addition to, the items listed in Annexure-l, any other spares considered to be necessary.

13.0

DRAWING AND DOCUMENTS Drawings and documents as per Annexure-II shall be supplied. All drawings and documents shall have the following descriptions written boldly. Name of client Name of consultant Project / Plant name Order no. Description of equipment.

MECON LIMITED REGD. OFF: RANCHI (JHARKHAND)

PROCESS & PIPING DESIGN SECTION NEW DELHI

STANDARD SPECIFICATION

TITLE

DIESEL GENERATOR SET

SPECIFICATION NO. MEC/S/05/E9/006

Page 15 of 15
REVISION 0

14.0

DEVIATIONS Deviations, if any, from this standard shall be clearly indicated in the offer with reasoning. Encircling it and the revised data shall be indicated besides the same, if any, from the data indicated in specifications sheet shall show deviations, clearly.

15.0 15.1

PACKING The equipment shall be properly packed before dispatch to avoid damage during transport, storage and handling. The equipment shall be wrapped in polythene to make it water proof Bags of silica gel shall be kept inside to absorb moisture present during transport and storage. An additional wrapping with bitumen paper shall also be provided before the equipment is packed in wooden crates. A sign indicating the position of the equipment placed during transport and storage shall be clearly marked. Also proper arrangement shall be provided to handle the equipment.

15.2

15.3

Note: One nos. DG Set each for Dispatch terminal at Padmala, SV-1/ Tap-off2, and Receiving terminal at Halol. Total DG Set = 3 Nos.

ANNEXURE -I 1. LIST OF SPARES — MANDATORY The spare parts as listed below shall be quoted for the D.G. set along with the offer with item wise unit prices: 1. 2. 3. 4. 5. 2. Rings of various types and sizes. Bearings of various types and sizes. Caskets of various sizes and types. Lube oil filters. Fuses of all ratings.

LIST OF SPARES — FOR 2 YEARS OPERATION A. MOULDED CASE CIRCUIT BREAKER (OF EACH RATING) i) Complete Breaker Assembly SWITCHES (OF EACH RATING) i) Assembled switch in open execution ii) FUSES Single pole moving blade assembly iii) Single pole base assembly FUSES (OF EACH RATING) i) Fuse links ii) Fuse fittings CONTROL SWITCHES i) Trip – Neutral – Close Switch ii) Local Remote Selector Switch iii) Heater Switch iv) Thermostat v) Ammeter Selector Switch vi) Voltmeter Selector Switch vii) Push Button viii) Push Button element ix) Push Button Actuator of each type CONTRACTOR (OF EACH RATING) i) ii) iii) Contractor with Auxiliary Contracts Operating Coil Auxiliary Contact Block

B.

C.

D.

E.

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Specification of DG Set-006\Content & Annexure.doc

F.

INDICATING LAMPS i) ii) iii) Indicating lamps globes of each colour Indicating lamp fittings Indicating lamp bulbs

G.

METERS i) Ammeter ii) Voltmeter PROTECTIVE RELAYS i) Relays ii) Thermal overload relay of each type All spare parts shall be identical to the parts used in the distribution boards.

H.

NOTE:

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Specification of DG Set-006\Content & Annexure.doc

ANNEXURE — II DOCUMENTATION FOR D.G. SET

Sl. No.

Description

With Bid No. of copies

After Order

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Specification Sheet Technical Particulars General arrangement and foundation drg. For all the equipment Civil scope drawings Earthing Layout Terminal arrangement drg. And interconnection Sectional view of D.G. set Illustrative and descriptive literature. Catalogue for bought out accessories Installation, operation & maintenance manual Type test certificates for engine, alternator and circuit breaker Guarantee certificate Spare parts list with identification GA, schematic and wiring diagram of synchronization & control panel. * *

1 1 -

For Review No. of Copies 6 6 6 6 6 6 6

Final No. of copies 8 8 8 8 8 8 8 8 8 8 8 8 8 8

*

D:\old data\Vijyant\GSPL\Tender\Const\Vol IV of V\Standard specification-ELEC\Specification of DG Set-006\Content & Annexure.doc

MECON LIMITED DELHI
ELECT. & INST. SECTION

SPECIFICATION / PROCEDURE FOR OPTICAL FIBER CABLE TESTING
SPECIFICATION No. : MEC / S / 05 / E5 / T / 002 Rev. 0 Page 1 of 2

SPECIFICATION/ PROCEDURE FOR OPTICAL FIBRE CABLE TESTING

Specification No.: MEC/S/05/E5/T/002

MECON LIMITED DELHI - 110 092
0 Revision 06.06.2005 Date Sudhir Prepared by Rakesh Shukla Checked by Pankaj Shrivastava Approved by

MECON LIMITED DELHI
ELECT. & INST. SECTION

SPECIFICATION / PROCEDURE FOR OPTICAL FIBER CABLE TESTING
SPECIFICATION No. : MEC / S / 05 / E5 / T / 002 Rev. 0 Page 2 of 2

INDEX

1. 1.1 1.1.1 1.1.2 1.1.3 1.2 1.2.1 1.2.2 1.2.3

TEST PROCEDURE FIBRE LENGTH MEASUREMENT Test Description Test Equipment Procedure INSERTION LOSS MEASUREMENT Test Description Tools and Equipment required Procedure

Appendices :

Appendix – 1 (A & B) : Appendix – 2 (A & B) :

Test Format : Fibre Length Measurement Test Format : Insertion Loss Measurement

MECON LIMITED DELHI
ELECT. & INST. SECTION

SPECIFICATION / PROCEDURE FOR OPTICAL FIBER CABLE TESTING
SPECIFICATION No. : MEC / S / 05 / E5 / T / 002 Rev. 0 Page 1 of 2

TEST PROCEDURE The Optical Fibre cable will be tested for its continuity and average loss in dB/km. The link will be tested and recorded in the format given in Appendix-1 & 2. 1.1 1.1.1 Fibre Length Measurement Test Description This test will check the continuity of the fibre from station to station and record the length of fibre. Average loss per kilometer of fibre length shown in dB/km shall be recorded for information only. Testing will be done from both ends and average will be calculated (for both 1310 nm and 1550 nm). 1.1.2 Test Equipment 1. 2. 1.1.3 Optical Time Domain Reflectometer (OTDR) Patchcords, pigtails

Procedure • • • • • • • • • Power on the OTDR and make the settings as required for the top under test. Splice a pigtail to one of the fibres Connect the OTDR with pigtail Make the laser ON and observe the trace till it gets settled up to the end of the trace. Store the results in the hard disk/floppy disk with proper identification of the fibre under test. Record the results in format Repeat the procedure for the Opposite direction. Test Formats are provided in Appendix-1 (A & B) Repeat above steps for each fibre

1.2 Insertion Loss Measurement 1.2.1 Test Description During the insertion loss measurement, light is launched (LASER) in the fibre by using a LASER source from one end at the other end by using an Optical Power meter the received is measured. Fibre loss is calculated by subtracting the receive power from the transmit power. This test also determines the fibre termination continuity on end to end basis as the measurement is done on both the ends of a link. Tools and Equipment required 1. 2. Power meter working on 1310 nm and 1550 nm Laser source working on 1310 nm and 1550 nm

1.2.2

MECON LIMITED DELHI
ELECT. & INST. SECTION

SPECIFICATION / PROCEDURE FOR OPTICAL FIBER CABLE TESTING
SPECIFICATION No. : MEC / S / 05 / E5 / T / 002 Rev. 0 Page 2 of 2

3. 1.2.3

Patchcords (10 mtrs)

Procedure • • One power meter, one laser source and one unit of optical talk set are required at each end. At location A, switch ON the laser source, set it to operating wavelength of 1310 nm and connect it to the power meter (set at 1310 nm) by patch cord and record the laser power transmitted. Record it in the test sheet. Cut the patch cords, laser source & power meter remaining connected to the 2 halves of the patch cord (i.e. 2 pig tails). Splice each of the pigtails to two ends of the same fibre under test. Record the power received in test sheet To establish communication between two stations A & B, connect the Optical talk set to one of the fibre (for example fibre No. 24) at both the stations. When that particular fibre is next for testing connects the talk set to one on which testing is complete (for example fibre No.1). Confirm on the talk set that the power received is recorded. Repeats the test for 1550nm. Connect the source to next connector at Location A and Power Location B. Meter at

• • • •

• • • • • • •

Repeat the same procedure with source at Location B and Power Meter at Location A. Continue the above process till all fibres are tested Average loss of each fibre should be less than the average loss estimated. Test formats are provided in Appendix-2 (A & B)

MECON LIMITED DELHI
ELECT. & INST. SECTION

SPECIFICATION / PROCEDURE FOR OPTICAL FIBER CABLE TESTING
SPECIFICATION No. : MEC / S / 05 / E5 / T / 002 Rev. 0 Page 1 of 4

Date Location A Location B Wavelength Equipment used
Tube No./ color

FIBRE LENGTH MEASUREMENT : _____________________ : _____________________ : _____________________ : 1310 nm : _____________________
Fibre Length (m)

Appendix-1 A

Fibre No./ Color

Optical loss dB/km From A From B

1. Blue 2. Orange 3. Green 4. Brown 5. Slate 6. White 7. Red 8. Black 9. Yellow 10. Violet 11. Pink 12. Aqua

1. Blue 2. Orange 3. Green 4. Brown 5. Slate 6. White 7. Red 8. Black 9. Yellow 10. Violet 11. Pink 12. Aqua 13. Blue 14. Orange 15. Green 16. Brown 17. Slate 18. White 19. Red 20. Black 21. Yellow 22. Violet 23. Pink 24. Aqua

Cable loss (average of above) : __________________________ km (ALL LOSSES MEASURED IN dB/km) Signature & date (Tested & handed over by Cable laying vendor for HDD) Signature & date Witnessed by Client/MECON representative (s) Signature & date (Witnessed & Taken over by Main Line cable laying vendor)

MECON LIMITED DELHI
ELECT. & INST. SECTION

SPECIFICATION / PROCEDURE FOR OPTICAL FIBER CABLE TESTING
SPECIFICATION No. : MEC / S / 05 / E5 / T / 002 Rev. 0 Page 2 of 4

Date Location A Location B Wavelength Equipment used
Tube No./ color

FIBRE LENGTH MEASUREMENT : _____________________ : _____________________ : _____________________ : 1550 nm : _____________________
Fibre Length (m)

Appendix-1 B

Fibre No./ Color

Optical loss dB/km From A From B

1. Blue 2. Orange 3. Green 4. Brown 5. Slate 6. White 7. Red 8. Black 9. Yellow 10. Violet 11. Pink 12. Aqua

1. Blue 2. Orange 3. Green 4. Brown 5. Slate 6. White 7. Red 8. Black 9. Yellow 10. Violet 11. Pink 12. Aqua 13. Blue 14. Orange 15. Green 16. Brown 17. Slate 18. White 19. Red 20. Black 21. Yellow 22. Violet 23. Pink 24. Aqua

Cable loss (average of above) : __________________________ km (ALL LOSSES MEASURED IN dB/km) Signature & date (Tested & handed over by Cable laying vendor for HDD) Signature & date Witnessed by Client/MECON representative (s) Signature & date (Witnessed & Taken over by Main Line cable laying vendor)

MECON LIMITED DELHI
ELECT. & INST. SECTION

SPECIFICATION / PROCEDURE FOR OPTICAL FIBER CABLE TESTING
SPECIFICATION No. : MEC / S / 05 / E5 / T / 002 Rev. 0 Page 3 of 4

Date : ___________________ Location A : ___________________Location B : __________________ Wavelength : 1310 nm Equipment used : ___________________ Cable Length from Appendix 1A : _________ km Number of Splices (including Pigtails-N : ________________ Number of connectors-C : ___________________ Average IL = 0.38L + 0.1N + 0.5C : _________ (estimated)
Tube No./ color Fibre No./ Color A-B Power Transmitted at A Power IL (A-B) received at B B-A Power Transmitted at B Power IL (B-A) received at A Average IL

INSERTION LOSS MEASUREMENT

Appendix-2 A

1. Blue 2. Orange 3. Green 4. Brown 5. Slate 6. White 7. Red 8. Black 9. Yellow 10. Violet 11. Pink 12. Aqua

1. Blue 2. Orange 3. Green 4. Brown 5. Slate 6. White 7. Red 8. Black 9. Yellow 10. Violet 11. Pink 12. Aqua 13. Blue 14. Orange 15. Green 16. Brown 17. Slate 18. White 19. Red 20. Black 21. Yellow 22. Violet 23. Pink 24. Aqua

(ALL LOSSES MEASURED IN dB/km) Signature & date (Tested & handed over by Cable laying vendor for HDD) Signature & date Witnessed by Client/MECON representative (s) Signature & date (Witnessed & Taken over by Main Line cable laying vendor)

MECON LIMITED DELHI
ELECT. & INST. SECTION

SPECIFICATION / PROCEDURE FOR OPTICAL FIBER CABLE TESTING
SPECIFICATION No. : MEC / S / 05 / E5 / T / 002 Rev. 0 Page 4 of 4

Date : ___________________ Location A : ___________________Location B : __________________ Wavelength : 1550 nm Equipment used : ___________________ Cable Length from Appendix 1A : _________ km Number of Splices (including Pigtails-N : ________________ Number of connectors-C : ___________________ Average IL = 0.22L + 0.1N + 0.5C : _________ (estimated)
Tube No./ color Fibre No./ Color A-B Power Transmitted at A Power IL (A-B) received at B B-A Power Transmitted at B Power IL (B-A) received at A Average IL

INSERTION LOSS MEASUREMENT

Appendix-2 B

1. Blue 2. Orange 3. Green 4. Brown 5. Slate 6. White 7. Red 8. Black 9. Yellow 10. Violet 11. Pink 12. Aqua

1. Blue 2. Orange 3. Green 4. Brown 5. Slate 6. White 7. Red 8. Black 9. Yellow 10. Violet 11. Pink 12. Aqua 13. Blue 14. Orange 15. Green 16. Brown 17. Slate 18. White 19. Red 20. Black 21. Yellow 22. Violet 23. Pink 24. Aqua

(ALL LOSSES MEASURED IN dB/km) Signature & date (Tested & handed over by Cable laying vendor for HDD) Signature & date Witnessed by Client/MECON representative (s) Signature & date (Witnessed & Taken over by Main Line cable laying vendor)

MECON LIMITED Delhi

Electrical & Instrumentation Section

TECHNICAL SPECIFICATION FOR WARNING MATS (For OFC & TELECOM HDPE Duct) REV-1 Page 1 of 4

TECHNICAL SPECIFICATION NO. : MEC/TS/05/E5/T/042

TECHNICAL SPECIFICATION OF WARNING MATS (FOR OFC & TELECOM HDPE DUCT ) Technical Specification No. : MEC / TS / 05 / E5 / T / 042

MECON LIMITED
DELHI - 110 092

1 Revision

28.06.2006 Date

Sudhir

Rakesh Shukla

Pankaj Shrivastava

Prepared by

Checked by

Approved by

MECON LIMITED Delhi

Electrical & Instrumentation Section

TECHNICAL SPECIFICATION FOR WARNING MATS (For OFC & TELECOM HDPE Duct) REV-1 Page 2 of 4

TECHNICAL SPECIFICATION NO. : MEC/TS/05/E5/T/042

SPECIFICATION FOR THE WARNING MATS Purpose : For using as a warning sign for Under Ground OFC & HDPE Telecom Duct along with Natural Gas Pipeline 150mm 0.25mm thick The material Polyethylene shall be of high density

Width Thickness Material of the Mat

: : :

Colour of the Mat Art Work

: :

Golden Yellow with letters in Red A sample piece of 30mm wide and 200mm long of every batch shall be checked by immersing in 20% solution of Ammonium Sulphide for period of 2 weeks at a temperature of 15°C for colour intactness of the strip. Copy of Art work is enclosed at Page 3 The Art work shall be printed in English and local language alternatively at every 1 mtr distance Minimum 1.8 kg/cm2 Minimum 125% 0.25 mm thick warning mat shall be supplied as 500 mtrs. each bundle. Minimum following test has to be done with each batch of warning mat Tensile Strength test Elongation test Impact Strength test Color fastness test Heat Stability test Print Stability test

Mechanical Properties of Mat Tensile Strength Elongation at Break Bundle Length : : :

Tests

:

MECON LIMITED Delhi

Electrical & Instrumentation Section

TECHNICAL SPECIFICATION FOR WARNING MATS (For OFC & TELECOM HDPE Duct) REV-1 Page 3 of 4

TECHNICAL SPECIFICATION NO. : MEC/TS/05/E5/T/042

Oxidation Induction test ESCR test Melt Flow Rate test Test Certificates : Vendor has to submit the all test certificates to Purchaser The manufacturer has to submit the QAP before commencement of production. Inspection of the material will be done at vendor ‘s works by Client / MECON Representative. Vendor has to submit all test reports before inspection call. Any test failed during the inspection for the offered lot ,the total lot will be rejected. Vendor shall submit all test reports and final inspection reports along with the supply of materials.

Inspection

:

Documentation

:

WARNING
OPTICAL FIBRE CABLE ALONG WITH HIGHLY INFLAMMABLE GAS PIPELINE BELOW (CLIENT’S NAME)

CLIENT’S LOGO

BEFORE EXCAVATING OR IN EMERGENCY PLEASE CONTACT PHONE NOs. …………………………….

ELECTRICAL & INSTRUMENTATION SECTION MECON LIMITED DELHI - 110 092

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS SPECIFICATION NO.: MEC/S/05/26/01

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 1 of 19

SPECIFICATION NO. : MEC/S/05/26/01

CONTENTS

1.0 2.0 3.0 4.0 5.0

SCOPE STANDARDS OF MATERIALS INSTALLATION OF INSTRUMENTS TESTING CALIBRATION OF INSTRUMENTS

PREPARED BY

CHECKED BY

APPROVED BY

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 2 of 19

SPECIFICATION NO. : MEC/S/05/26/01

INSTALLATION, TESTING AND CALIBRATION OF INSTRUMENTATION AND CONTROL SYSTEM 1.0 1.1 1.2 1.3 SCOPE The purpose of this specification is to define the general requirements for the installation, installation materials, testing and calibration of instruments and control system. The work shall be carried out in accordance with the codes, standards and recommended practice listed in this specification and in accordance with local `Statutory regulations'. For installation of instruments and control system, of the new material where quality is of the prescribed standards and which is in every way fit for its intended purpose shall be used. Unless otherwise specified all the materials shall be indicated in this specification except where it is not compatible with fluids being handled. In such cases the selection of the material shall be approved by MECON. Only the best trade practices shall be used. All the work shall be carried out in a neat, workman like manner and to the satisfaction of MECON. STANDARDS OF MATERIALS Instrument process piping/tubing upto and including the first block valve and `in-line' instrument equipment shall conform to the line class or vessel rating concerned instrument piping or tubing after the first lock valve may use alternate materials consistent with service conditions. In general they shall conform to the following specification as a minimum. Stainless tubes shall be fully annealed and cold drawn seam less as per ASTM A 269 TP316 with size 1/2"OD x 0.65" WT (wall thickness). Monel tubing shall be fully annealed seamless as per ASTM B165 with size 1/2"OD x 0.35"WT. Carbon steel pipe shall be 1/2" seamless and shall be as per ASTM A106 Gr B min of sch 80 & dimensions as per ANSI B36.10. Seamless stainless steel pipes shall be as per ASTM A 312 Gr TP 316L Sch 80S, dimensions as per ANSI B 36.19.

1.4

1.5 2.0 2.1

2.1.1 2.1.2 2.1.3

2.1.4

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 3 of 19

SPECIFICATION NO. : MEC/S/05/26/01

2.1.5 2.2 2.2.1 2.2.2 2.3

Instrument air supply piping from the main instrument air header shall be galvanised heavy class pipes to IS 1239. Individual pneumatic signal and air supply tubing shall conform to the following specifications. Stainless tubes shall be used in general and shall be fully annealed and cold drawn seamless as per ASTM A269 TP 316 with 6mmOD x 1mmWT. Copper tubing where specified shall be seamless 6mmOD x 1.0mmWT soft annealed as per ASTM 868.74a Cd No. 122 (DHP) sheathed with PVC 1.0mm thick coloured Black. All fittings shall be as a minimum of 100 rating except for tube fittings. The fittings shall have threading as per B2.1 and socketweld connections as per B 16.11. These shall conform to the following specifications in general. Tube fittings shall be flare type compression fittings Swagelok or equilvalent make double ferrule and pressure seat type. All tube fittings in impulse lines shall be rated to 5000 PSIG at 38 C.
o

2.3.1

2.3.2 2.4

Carbon steel pipe fittings shall be forged as per ASTM A105 stainless steel pipe fittings shall be as per ASTM –182 GrF 316L. Valve shall have normally Globe body and shall be fabricated out of Bar-stock and rated to min. of 1500. These shall be screwed bonnet type with 13% GSS trim and plug shall be integral with the stem. Face to face dimensions shall be approx. 80mm. End connections shall be socketweld to ANSI 16.11 and threaded to B2.1. Multibore tubing shall have a maximum 19 single polyethylene tubes, 6mmODx1mm numbered for easy identification. The bundle shall be marked with inner and outer fire resistance PVC sheath. They shall carry a pair of telephone wire 0.6mm diameter flexible. Single pair and multi pair extension cables for Thermocules shall be matched and calibrated in accordance with ISA MC 96.1. Conductor size shall be AWG for single pair and 20 A for Multipair. The cable shall be armcured, each twisted pair shall be individually shielded with aluminium Mylar tape and a tinned copper drain wire. The wires and the cable shall be colour coded as per ISA recommended practices.

2.5

2.6

2.7

Instrument Electrical cables shall conform to the following specifications:

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 4 of 19

SPECIFICATION NO. : MEC/S/05/26/01

2.7.1

Instrument electronic signal cables single pair/ Multipair shall have copper conductor, twisted in pair and individually shielded with Aluminium Mylar tape with drain wire. In multipair cables, each pair shall be armoured with inner and cut PVC sheath. Minimum 2 conductor size shall be 1.5 mm . Control Cables for control signal, alarms actuating devices and solenoid valves of the 2 interlock and shutdown valves shall generally be 1.5 mm copper conductor, armcured with inner and cut PVC sheath. All power supply cables shall have copper/Aluminium conductor depending upon the conductor size. The cables shall be armoured with inner and cut PVC sheath. The cables 2 shall be sized adequately . Minimum conductor size shall be 2.5 mm . 2-core armcured cable shall be used for illuminator on level gauges. The material and construction of all electrical cables shall conform to IS- 1554 part I or appropriate equivalent code and standard. INSTALLATION OF INSTRUMENTS Instrument Mounting No instrument shall be installed in such a way that it bends for support on the impulse piping or electrical connection on it. Pressure gauges and temperature indicator shall normally be mounted directly on line. However direct on line mounting shall be avoided where vibrations are likely to be present. Local mounted instruments shall be mounted on brackets, panels or placed on a suitable pedestal. Transmitters shall be mounted on 2” pipe supports where practical. Instruments to be mounted on steel columns, masonary structure etc. These shall not be mounted on heating equipments, pipelines and structures. Blind transmitters shall be mounted at 130mm above graded platform. Local controllers, indicating transmitters and indicating instruments shall be mounted at approximately 1500 mm. All the instruments shall be accessible from grade, ladder or platform etc. Pressures gauges and other local indicating instruments shall be readable from grade or operating level and if used for manual control shall be visible from the related valve. All the instruments shall be located such that they dont impede the process operation.

2.7.2

2.7.3

2.7.4 2.7.5 3.0 3.1 3.1.1 3.1.2

3.1.3

3.1.4

3.1.5

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 5 of 19

SPECIFICATION NO. : MEC/S/05/26/01

3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.1.11 3.1.12 3.1.13 3.1.14 3.1.15

Local mounted instruments which are not available in weather proof housing shall be mounted inside a weather proof case. Items such as pilot valves, solenoid valves etc. shall be located local to its point of application or near to the device being actuated by them. For blind transmitters output meters shall be mounted on instrument supports. Filter regulators shall be mounted on the instrument supports below pneumatic transmitter or on the control valve yoke. Instruments or instrument lines shall not be supported on hand rails, in general. The use of process piping to support instrument lines shall be avoided as far as possible. The instrument impule piping shall be kept as short as possible. Instruments and impulse lines shall be protected against mechanical damage. In case of capillary tube instruments, capillary tube is to be supported and protected against mechanical damage. Orifice meters shall not be installed on the top of orifice fittings. On horizontal lines orifice pressure taps shall be located as follows: a) b) On top for air and gas service Horizontal for liquid and condensible vapour service.

3.2 3.2.1 3.2.1.1 3.2.1.2

Instrument Piping & Tubing. Impulse Piping/tubing The primary instrument block valves for all instruments shall be as per piping specifications. 3-Valve manifold in general shall be integral type. For pressure gauges, 2-valve manifolds shall also be acceptable instead of isolation valve, drain valve and pipe fittings.

3.2.1.3

Differential or static pressure sensing lines shall not exceed 6 Mtrs (20 feet) in general for direct connected or locally mounted instruments.

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 6 of 19

SPECIFICATION NO. : MEC/S/05/26/01

3.2.1.4

All impulse lines shall be run with a slope not less than 1 in 12 except where otherwise specified. Direction of slope is to be downward from the process for liquid service and upward from the process for gas service. Tubing shall be joined by compression fittings. Piping shall be joined by pipe fittings/flanges as per the piping specifications. All instruments pipes and tubes shall run in horizontal and vertical planes only and shall run with minimum number of changes in direction, consistent with good engineering practices and neat appearance. Tubing shall be bent with correct size tube bender as far as possible to avoid use of fittings. Hot bending shall be totally avoided. Tube cutter shall always be used to cut tubings. The use of short lengths of tubings in long runs shall be avoided in order to avoid the fittings.

3.2.1.5 3.2.1.6 3.2.1.7

3.2.1.8

3.2.1.9 3.2.1.10 3.2.1.11 3.2.1.12 3.2.1.13 3.2.1.14 3.2.1.15 3.2.2 3.2.2.1

All tubing shall run in such a manner as to give the maximum protection against mechanical damage. Tubing runs shall be grouped together and clamped. Tubing shall be arranged so that the unions can be tightened without distorting lines. Instrument tubing or piping shall not run on trays intended for cables and shall not share the same transit. No pipe or tube shall be left with mechanical strain on them. A mechanical ferrule seater shall be used on tubing for 140 kg/cm (2000 psi) or more. Pipe bushings shall not be used. Pipe plugs shall be fabricated out of bar stock and shall have hex-head. Air/Signal Tubing Signal Transmission tubes shall be laid on perforated trays prefabricated out of min 2.5 mm. thick steel plate. The width of the tray shall be selected as per the number of tubes to be laid.
2

3.2.2.2 Where tubing is run in permanent enclosures, it should be ensured that entry and exit of such enclosures is clean and smooth.

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MECON LIMITED Delhi

ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 7 of 19

SPECIFICATION NO. : MEC/S/05/26/01

3.2.2.3

Tubing run in permanent enclosures shall not have joints, except at special junctions boxes provided for this purpose.

3.2.2.4 Where permanent enclosures are left with space for instrument tubing to be laid at some later date, a galvanised pull wire of adequate size shall be left in the tray. 3.2.2.5 Where the length of transmission tubing exceeds 60 mtrs (200ft) necessity of installing signal booster relays shall be considered.

3.2.2.6 In case of `Skidded' equipment or vessels with instrumentation, where off- skid alarms shutdown or control functions are provided the signal tubes shall be terminated on the control bulk head near the skid boundary. 3.2.3 All threaded pipe joints shall be joined after applying teflon tape. It should be applied in a manner to ensure that the tape does not spill over the end of the male fitting. No other pipe joining compound shall be used except on high temperature service where graphite sealing compounds shall be used. All reasonable precautions shall be taken to prevent foreign materials entering pipe lines or tubing before and during erection. Pipes and tubes installed but not connected, shall have the ends clad in approved fashion to prevent the entry of foreign material. For a period upto one week adhevise tape may be used, for longer periods, caps or plugs shall be used. Piping/Tubing supports Piping and tubing shall be adequately supported and fixed at a distance not exceeding that in the following table: Table ----------------------------------------------------------------------------------------------------Single tubing/Piping Max. distance between supports ----------------------------------------------------------------------------------------------------3/8" OD or less Continuous 1/2" to 3/4" Nom. size 3/4" to 1" Nom. size 2 meters (6ft.) 3 meters (9ft.)

3.2.4 3.2.5

3.2.6 3.2.6.1

Multitube bundle 3 meters (9ft.) ---------- ------------------------------------------------------------------------------------------3.2.6.2 All field mounted instrument air tubing shall be supported with galvanised steel angles or channels of minimum 1/8" thickness fabricated to present neat appearance.

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ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 8 of 19

SPECIFICATION NO. : MEC/S/05/26/01

3.2.6.3 All instruments tubing supports shall be galvanised prior to installation 3.2.6.4 3.3 3.3.1 3.3.2 Trays shall be properly supported either from any rigid steel structure or concrete member. In case of non-availability of above, a suitable support shall be fabricated. Instrument Air Supply Distribution Piping material for instrument main and branched air headers upto the isolation valve at each take-off from main or branch header shall conform to piping specification. The air header size shall be established in accordance with the table below, unless 2 otherwise specified, for a header pressure of 4 to 8.5 kg/cm Table – 2 ----------------------------------------------------------------------------------------------------Max number of users Nominal pipe size ----------------------------------------------------------------------------------------------------upto 5 1/2" upto 10 3/4" upto 25 1" upto 80 1-1/2" upto 150 2" upto 500 3" ----------------------------------------------------------------------------------------------------3.2.3 All take off for branch lines are to be from the top of the main header with block valves equal in size to the branch line. All low point shall have a 1/2" valve installed as a drain and blow down point. A minimum size of ½”" pipe shall be run to the instrument with a ½” valve for each user. Tubing from the isolation valve to the instrument shall be 6.0 mm. Union shall be provided at convenient location in the air header. Filter regulator shall be provided for individual field mounted consumer and shall be complete with an output gauge. In case of skid mounted equipments or vessels which incorporate instrumentation requiring pneumatic supply, on skid supply piping shall terminate at the skid boundary location and size of the supply connections shall be noted on the vendor approval drawings.

3.3.4

3.2.5 3.3.6 3.3.7

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ELECTRICAL & INSTRUMENTATION SECTION DELHI

SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 9 of 19

SPECIFICATION NO. : MEC/S/05/26/01

3.4 3.4.1

Installation of multitude and Multicore cables. Multicore/Multitube cables shall generally be installed on trays or ducts and properly clamped. At bends minimum radius shall be maintained as per cable manufacturers standards. All cables shall be rigidly supported on structural steel and masonary. Drilling of steel member should normally be avoided. However, if the drilling of steel must be resorted to, it must be drilled where minimum of weakening of structure will result cables shall be support at every 500 mm. At every vertical drop these shall be clamped at more frequent intervals max of 300 mm. Directly buried cables shall be laid underground in excavated cable trenches. Trenches shall have sufficient depth and width to accommodate all cables correctly spaced and arranged with a view of heat dissipation and economy of design construction of trenches laying of cables and filling up of trenches shall be as per relevant standard. Each underground cable shall be provided with identifying tag of load securely fastened every 30 M of its underground length with at least one tag at each end before the cable enters the ground. Before cables are placed, the trench bottom shall be filled with a layer of sand. The cables shall be covered with 150 mm of sand on the top of the largest dia cable tube and sand shall be lightly pressed. A protective covering of 75 mm thick second class red bricks shall be laid flat and the balance portion of the trench shall be filled with soil, compacted and levelled.

3.4.2

3.4.3

3.4.4

3.4.5

At each road crossing and other places where cables enter pipe sleeves, adequate bed of sand shall be given so that the cables don’t slack and get damaged by pipe ends after back filling. At the entry into concrete blocks loops shall be provided at either end to prevent any damage to cable. The cable entry to control room shall be suitably filled and sealed after laying of cables so as to achieve a positive sealing against the entry of gas/water. All wiring, tubing, cables, junctions boxes and auxiliary equivalent shall be suitably identified as per applicable codes and practices. All pipings and tubing shall be tagged with slip-on or clip on wire marker at both ends. Jointing of cables are generally not permitted. Cables shall be cut after the exact site measurements at the cable drums shall be so selected before cutting the lengths as to avoid any unnecessary wastage.

3.4.6 3.4.7 3.4.8

3.4.9

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 10 of 19

SPECIFICATION NO. : MEC/S/05/26/01

3.4.10

Low signal cables like alarms, analysers cables, special cables for turbine meter, thermocouple compensating cables etc. shall be layed separated from power supply cables in ducts/trenches/trays. Electric signal lines for electronic transmitters to receive and to final control element shall be continuously shielded with the shield grounded at the same point as the signal circuit generally at the control instrument. Separate junction boxes shall be used for intrinsically sage cables. Different intrinsically safe system e.g., systems having different rounds shall not be run in the same multicore cable, in general. Recommended minimum separation distance between twisted pair signal leads and AC Power Lines. ----------------------------------------------------------------------------------------------------AC Power Cable Minimum Distance to Signal Lead ----------------------------------------------------------------------------------------------------Voltage (Volts) Current (Am) in (cm) 0 to 125 125 to 250 250 to 440 0 to 10 0 to 50 0 to 200 12" (30) 15" (38) 18" (46)

3.4.11

3.4.12 3.4.13

5KV & Up 200 Amp. & Up24" (61) ----------------------------------------------------------------------------------------------------Different intrinsically safe circuits e.g., circuits having different voltage levels, of the same intrinsically safe system shall not be run in the same cable unless each conductor insulation is at least 0.25mm or no hazard can result from interconnection. 3.4.14 The physical separation of power and signal cables shall be as per API 550 Part I Section VII. Cable in intrinsically safe circuits shall preferably be not run in the same tray where-on intrinsically safe circuits cables are being run. If these are being run in the same tray, a metallic earthed separately shall be provided. For temperature controllers, single pair thermocouple extension cable or cable for resistance thermometer, shall be layed directly from the element to the transducer in the control room without intermediate terminal blocks.

3.4.15

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 11 of 19

SPECIFICATION NO. : MEC/S/05/26/01

3.4.16

In case of skid mounted equipment or equipment which incorporate skid instrumentation like alarms, shutdown or control function shall terminate signals or control junction box near skid boundary for connection of off skid equipment. No wire shall be terminated or left with mechanical strain within any conductor. Splices shall be made only at terminals, in instruments or approval equipment/ junction boxes using lugs and screwed connections. No intermediate splices shall be made in cable trays or in conduct. Number of junction boxes in any cable path shall be limited to only one. Installation of Zener barriers Zener barriers shall be installed in the circuit to make the system intrinsically safe provided: a) There is no energy storage system in excess to the minimum permitted by the barrier design on the hazardous side of the barrier. The same shall be met by taking intrinsically safe transmitters and selecting the cable electrical parameters like inductance L/R ratio & capacitance in accordance with the maximum parameters given in barrier specifications. No power source exceeding the voltage rating of Zener barrier shall be connected on safe side of the Zener barrier. No outside power source including other intrinsically safe circuits shall be connected to the hazardous side of the barrier.

3.4.17 3.4.18

3.5 3.5.1

b) c) 3.5.2 3.5.3

Zener barriers shall be located as close as possible to the field wiring entry point in the control room. Single barrier are bolted directly to copper bus bar and multiple barriers on the barrier mounting plates. Copper bus or barriers mounting plates shall be isolated from the panel frame. The signal ground system for intrinsically safe system shall be separate from power ground system and shall be connected to the signal ground reference point. The maximum resistance allocable between the farthest point on intrinsically safe barrier ground bus and signal ground reference point shall be less than 1 ohm. Field wires shall directly terminate at the barriers and not through terminals. Installation of Analyser / Gas Chromatograph Installation of all analyser shall be in general, as per APIP 550 Part II. intermediate

3.5.4

3.5.5 3.6 3.6.1

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 12 of 19

SPECIFICATION NO. : MEC/S/05/26/01

3.6.2 3.6.3

The analyser housing at its classifications.

installation shall meet all safety requirements as per --

Sampled process fluid, if not returned to the process shall be disposed to a safe location. Piping shall be provided so that vapors can be vented to a safe location and liquids shall be drained in a clean and orderly fashion to a safe place. Toxic vapors shall not be vented to atmosphere. Analyser shall be located as near to the sampling point as possible. Analyser equipment must be protected from the following: a) b) c) d) e) hot equipment severe ambient temperature changes shock Mechanical damage Vibration

3.6.4 3.6.5

3.6.6

If a separate vent for the analyser is used, the location of that vent shall be in area of minimum air Turbulence. If the vent of different analysers are vented into a common vent, a back pressure regulator shall be used. Vent piping shall be designed to prevent condensate from accumulation in low point and obstruct a free vent flow. Ducts, Trays and Supports. Main cable duct shall be of bottom open type with flat/angle --- construction with side sheet and top cover of 3.2 mm thickness. The ducts and trays shall be properly supported at regular intervals. Wherever insert plates are not available, support on concrete structure or ceiling shall be fixed with a minimum of 10 mm expansion bolts Angle supports for ducts shall be fabricated from minimum of 40 mm angle. All supports shall be neatly cut with hacksaw only and not with gas cutting. Free ends of angle supports shall not have sharp ends and shall be properly rounded off. Ducts and supports shall be painted with one coat of Red oxide Zinc chromate primer conforming to to IS-2074 after cleaning to remove scale and then painted with 2 coats of final enamel paint as given below: a) b) Duct - Dark admirately Grey as per IS0632. Supports - Black.

3.6.7 3.7 3.7.1 3.7.2

3.7.3 3.7.4

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 13 of 19

SPECIFICATION NO. : MEC/S/05/26/01

3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.9 3.9.1 3.9.2

Instrument Steam Tracing Steam for Tracking of instruments shall be taken from main steam header take of valve through carbon steel pipes supported at regular intervals. Steam tracing around individual instrument shall be by copper tube of 1/8" diameter. Piping or tubing for steam tracing shall be installed in such a way as to avoid condensate pockets. After steam tracing, the line is connected to drain funnel through steam trap. Identification of Lines and Instruments All site mounted instruments, junction boxes, air headers, tubing and wiring terminations shall be labelled or tagged. Instruments shall be furnished with stainless steel name tags containing Tag no., manufacturers name, model no. serial number. This tag number shall be approximately 3"x1" size and shall be attached to the instruments with -- gauge stainless steel wire. Unused cable entries in junction boxes and field instruments are to be plugged. TESTING Instrument Impulse piping/Tubing All process impulse lines shall be disconnected both from the instrument and vessel/piping end and flushed with water. After thorough flushing the impulse lines shall be isolated from the instruments and pressurised hydraulically to 1.5 times the maximum working pressure corrected for ambient temperature. They shall then be isolated from the pressure source and the pressure reading on a test pressure gauge shall not fall at a rate exceeding one psig/hour. In case no isolation valve is provided near the instrument, impulse piping/tubing shall be pressurised along with the instrument to the maximum pressure of scale in case of pressure transmitter and max. operating pressure in case of differential pressure instrument with equalising valve open.

3.9.3 4.0 4.1 4.1.1 4.1.2

4.1.3

In special conditions where hydro- testing is not permissible due to service requirements, testing shall be carried out by using compressed air/nitrogen.

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 14 of 19

SPECIFICATION NO. : MEC/S/05/26/01

4.1.4 4.2 4.2.1 4.2.2

The external displacer type instruments and cage type level switches shall be tested to 1.5 times the operating pressure using air/nitrogen after thorough flushing. Instrument Air lines/signal tubing. Instrument air lines/signal tubing shall not be hydrostatically tested. Instrument air tubing shall be disconnected upstream of all filter regulators and blown 2 down to remove water, slag and mill scale, from lines at 7.0 kg/cm G for fifteen minutes. Air filter shall be taken in line and tubing shall be disconnected at instrument end, and blown for 3 minutes to remove traces of dirt.

4.2.3

Testing of instrument air shall be carried out with instrument air at 7 kg/cm G upto the upstream of the filter regulator after thorough flushing. All lines shall be checked with soap solution and bubbler unit for possible leak at joints. All signal tubing shall be checked with 1.5 kg/cm after proper flushing. After pressuring, source shall be cut off and rate of fall in pressure shall be less than IPSL for each 100 feet of tubing for a test period of 2 minutes as per instrument society of American RP 7.1 `Pneumatic Control Circuit Pressure Test' Cables All wiring shall be checked to ensure that it is correctly connected and properly grounded. All cables shall be checked for continuity proper connection and insulation testing. Insulation test shall be carried out on all wiring with a certified megger after disconnecting the cables at both ends.
2

2

4.2.4

4.3 4.3.1 4.3.2

4.4 4.5

All the results of the above mentioned testing shall be recorded and submitted for check. All the in line instruments like orifice plates, turbine meters, Rotameters, Target meters, vortex meters, control valves, safety valves etc. shall be removed and spool pieces shall be provided prior to the flushing of the lines. CALIBRATION OF INSTRUMENTS All instruments shall be calibrated strictly as per manufacturers instructions prior to the installation. In addition to calibration of instruments, setting of safety devices like process switches, safety valves etc. and simulation testing of all interlock and shutdown system shall be carried out.

5.0 5.1

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 15 of 19

SPECIFICATION NO. : MEC/S/05/26/01

5.2

In general, all tests shall simulate, as closely as possible, design process condition by the use of manometers, potentiometers, deadweight testers, test pressure gauges etc. Pour point callibration shall refer to the input signal to an instrument equivalent to 0,25,50,75,100% of instrument range upscale (rising) and 75,50,25,0% of instrument (downscale) (falling). All instruments unless otherwise noted shall be calibrated in upscale and downscale direction and if necessary, adjusted until their accuracies conform to those limits state by the manufacturer. Upon completion of these tests, the instruments shall be drained, completely.

5.3 5.3.1

Temperature Instruments Temperature Gauges Filled type and Bi metallic dial type Thermometers shall be four point bench checked for proper operation and calibration using a temperature bath prior to installation. Temperature Elements and Temperature Transmitters. Temperature Elements and Transmitter shall be four point bench calibrated using a temperature bath precision meter or precision gauge prior to installation.

5.3.2

5.4 5.4.1 5.4.1.1

Pressure Instruments Pressure Gauges Direct connected bourdan type pressure gauges shall be dead weight tested or tested against a test gauges prior to installation.

5.4.1.2 Receiver type pressure gauges shall be four point calibrated using a precision gauge and precision air regulator. 5.4.1.3 Pressure and Differential Pressure Transmitters. Pressure and differential pressure transmitters shall be four point calibrated using a hydraulic or dead weight tester or a precision pneumatic calibrator prior to the installation. A precision output meter or gauge shall be used to monitor the output. Orifice plates shall be checked visually for the name plate and for an upstream sharp edge. Bore dia. Shall be checked for compliance with the specification. Differential pressure type of flow instruments shall be four point callibrated using precision pneumatic callibrator or a manometer and precision regulator. A precision output meter or gauge shall be used to monitor the output of the transmitter.

5.5.1

5.5.2

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 16 of 19

SPECIFICATION NO. : MEC/S/05/26/01

5.5.3

a) b) c)

Rotameters shall be installed as received. A check shall be made to confirm that shipping stops have been removed and float has been installed. Where rotameters have transmitting mechanism, the float shall be raised and lowered mechanically and output shall be checked. Vendor calibration data/ curve shall be checked. A check shall be conducted with plumb for a vertical installation.

5.5.4 5.5.5 5.6 5.6.1

Turbine meters, Annubar, positive displacement meters, vortex meter, ultrasonic flow meter, etc. shall be installed as received. Target meters shall be checked for calibration using calibration weights. Output shall be monitered using precision output meter. Level Instruments Level Gauge Glasses Gauge glasses shall be installed as received installation of illuminators, frost protectors and other accessories shall be checked.

5.6.2

Displacer Type, Level Transmitter Displacer type level transmitter shall be checked by raising and lowering mechanically the displacement and checking the pilot or transmitter action. Check transmitter with out put gauge or meter for smooth and full output change. A check shall be conducted with plumb for a vertical installation.

5.6.3

Differential pressure type level transmitter Defferential pressure type level transmitter shall be calibrated with pneumatic calibrater at four points prior to installation. A precision meter or gauge shall be used to monitor the output of the transmitter. Tank level gauges a) Tank level gauges shall be checked by raising and lowering mechanically the displacer and checking the indicator on the gauge board. b) Check for proper liquid seal prior to installation in case of liquid seal tank gauges. c) In case of servo type gauges, the displacer is hoisted from the tank into the calibration chamber. Control Valves, shutdown valves and self actuated valves All diaphragm and piston operated control valve shall be stroked pneumatically using a pressure regulator and pressure gauge against the spring range specified on the name plate of the valve.

5.6.4

5.7 5.7.1

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 17 of 19

SPECIFICATION NO. : MEC/S/05/26/01

5.7.2 5.7.3

Mechanical seating and travel of the valve stem shall be checked against the side indicator and the name plate Valve positioner shall be calibrated with the control valve in accordance with the name plate data and specifications with the help of pneumatic calibrator or gauge with precision regulator. Zero position or fully close position of the valve shall be a live zero i.e., the plug shall be just off the seat at the minimum setting. Volume bottles, where used shall be checked for proper filling. The signal line shall be bled to zero pressure and failure action shall be confirmed. Control valve accessories such as handwheels, boosters, relays etc. shall be checked operationally. Declutchable handwheel shall be operable both with and without an air signal to the diaphragm. Self actuated control valves shall be installed as received, checking inlet and outlet points and name plate data. Regulators with external pressure connections shall be inspected for proper installation. Butterfly shall be checked carefully to see that the vane moves freely into the upstream and down stream piping. Proper vane movement to stroke shall be confirmed. All control valves and regulators shall be removed from the line prior to flushing and during hydrotesting. Safety Relief Valves Safety relief valves shall be installed as received after carefully checking the name plate data. Pilots, if used, shall be checked carefully for installation on the proper safety valve. Valves, which are installed in such a manner as to permit on line testing, shall be pressure tested after installation to determine proper operation and setting. Compressed air or nitrogen shall be used for testing of safety relief valves. Switches Level Switches shall be actuated mechanically for switch operation but shall not be calibrated for level setting. Pressure switches shall be calibrated using hydorlic or dead weight tester or precision air regulator and gauge. The setting/trip point shall be checked using a continuity tester.

5.7.4 5.7.5

5.7.6

5.7.7 5.7.8

5.8 5.8.1 5.8.2

5.9 5.9.1 5.9.2

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 18 of 19

SPECIFICATION NO. : MEC/S/05/26/01

5.9.3 5.10 5.10.1 5.10.1.1 5.10.1.2 5.10.1.3 5.10.2 5.10.2.1 5.10.2.2 5.10.3.1 5.10.4.1

Temperature switches shall be calibrated using a temperature both prior to installation and set to the required alarm/ trip point using a continuity tester. Receiver Instruments Receiver Indicator/Recorders Pneumatic indicators/ Recorders shall be calibrated using pneumatic calibrator/ precision pressure regulator and gauge. Electronics indicators/ Recorders shall be calibrated using a current generator and a precision meter. Chart drive assembly shall be checked for proper operation. Controllers Proper balancing of the controller shall be checked as per the manufacturers catalogues. Controllers shall be checked for manual and Auto operation and Transfer. The transfer from manual to Auto and vice versa shall be bumpless and smooth. Manual loader station Output of the manual loader shall be checked with a precision meter. Multipoint Temperature Recorders Each point shall be calibrated using a temperature simulator/ decade box for RTD / voltage generator and precision meter for the thermocouples.

5.10.4.2 5.10.5 5.10.6

Point synchronisation shall be checked. Pneumatic receiver switches shall be calibrated using precision air regulator and gauge. The setting/alarm/trip point shall be checked using continuity tester. Trip Amplifiers Trip amplifiers shall be calibrated using a temperature simulators or voltage generator and precision meter for thermocouple or Resistance box for RTDs. The required setting/ alarm point/ trip poing shall be checked using a continuity tester. Receiver Switch module Receiver switch modules shall be calibrated using a current source and a precision meter. The required setting/alarm/trip point shall be checked using a continuity tester.

5.10.7

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SPECIFICATION FOR INSTALLATION OF INSTRUMENTS REV-0 Page 19 of 19

SPECIFICATION NO. : MEC/S/05/26/01

5.10.8 5.10.8.1 5.10.8.2 5.10.9 5.10.9.1 5.10.9.2 5.11 5.11.1 5.11.2 5.12 5.12.1 5.13 5.14 5.15

Alarm and Annunciator system Alarm and annunciator system shall be checked for visual and Audio alarm operation using dummy signals. Full alarm sequence of each alarm point shall be checked. Each point shall be checked for proper engraving. Shutdown System Operation of final actuating elements shall be checked for proper operation using dummy signals. All timers, push buttons and switches shall also be checked for their proper operation. Analytical Instruments Check the full analyser system including sample handling system for leakage. Check the full sample handling system for its proper operation. Calibrate and check completely all analysers using zero and span samples as per vendor catalogues. Flow computer / Volume corrector Corrected flow values shall be checked for various D.C. inputs and pressure and temperature variations for upscale and downscale ranges. The list of test and callibration instruments with tracability certificates shall be submitted to MECON for approval before carrying out the tests / callibration of instruments at site. The formats / description of tests / callibration of all instruments shall be submitted to MECON for approval. Daily / weekly reports shall be submitted during execution of work at site.

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