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SECTION E-2 SPECIFICATIONS FOR LIGHTNING & EARTHING PROTECTION SYSTEM E2.

01 SCOPE OF WORK: The work consists of supplying, installing, testing & commissioning of all materials and services of the complete Lightning & Earthing Protection Systems as specified herein and / or stated on the Tender Drawings (UESI-ASM-E-18, 19 & 20) and in the Bill of Quantities (BOQ). The contractor shall discuss the Earthing Pits & Main Earthing Network Grid Running Trenches layout & the related work with the Amrelis Manager Electrical / Engineer at Dhabeji Site and coordinate at site with other services for exact route, location & position of Earthing Pits & Trenches, however not deviating the essence / standards / parameters & work as per the given BOQ & tender drawings. In the case of conflict, please consult the Electrical Consultant (M/S UESI) for resolution. Principal items of work are as following:
(a)

Installation of Lightning Arresters Air Terminations along with all accessories, auxiliaries (complete in all respect) at the roof tops of Main Plant Structure, Overhead Tank & Chimney and connected with copper strip (50 x 3 mm thick) grid / meshed network employing brazed connections. All the connections & joints are brazed through CAD / Exothermic Welding using appropriate powder & mould for perfect brazing. Materials as offered by M/S Furse - U.K or imported equivalent, would be acceptable. Making grid / mesh network of Copper Strip 50 x 3 mm thick at the roof tops of Main Plant Structure, Overhead Tank & Chimney. The down coming copper strips are further extending to the corresponding Earthing Pits, through CAD / Exothermic Welding using appropriate powder & mould for perfect brazing. Materials as offered by M/S Furse - U.K or imported equivalent, would be acceptable. Making Earthing Pits, 500 x 500 x 500 mm, with a drilled / bored hole having dimensions 100 mm x 10,000 mm deep (10 Meters deep) in the centre of every Earthing Pit. The Job should be complete in all respect along with all the accessories and auxiliaries including Earthing Electrode 17.2 mm x 3000mm length, Earthing Lead - 2 X 70 sq.mm bare copper wires, G.I Perforated Pipe 38 mm (1.5) x 7000 mm length, Earthing Termination / Test Point (ETP) 300 x 50 x 10 mm thick and as per the details given in the BOQ & drawings. Page-1
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(b)

(c)

(d)

Making trench running at the ground, 500 x 500 mm deep, and burying Copper Strip, size 50 x 3 mm in the trench for connecting Earthing Pits with each other and as per given drawings. All the connections & joints are brazed through CAD / Exothermic Welding, using appropriate powder and mould for perfect brazing. Installation of Earthing Connection Points (ECPs) at appropriate locations, extending from the respective Earthing Pits Complete testing and commissioning of the installation.

(e)

(f)

If anything has been omitted or any items of work or material, usually furnished, which are necessary for the completion of the works as outlined herein before then such items of work must be and are hereby included in this section of the work. E2.02 WORK NOT INCLUDED:
(a)

Outgoing earthing connectivity of equipment onward Earthing Connection Points (ECPs), except when specifically noted otherwise. Provision of appropriate quantity & of specifications - Surge Protective Devices (SPDs). to be incorporated in the switchgear by Electrical Switchgear Consultant. Provision of appropriate quantity & of specifications Residual Current Devices for Earth Leakage Protection; to be incorporated in the switchgear by Electrical Switchgear Consultant.

(b)

(c)

E2.03 GENERAL: The Lightning & Earthing Protection Systems work shall be carried out in accordance with IEC 62305 Series of Standards & Codes of practice including protection against Physical Damage to Structure & Life Hazard. As per IEC 62305 series of Lightning Protection Standards and the statistical data available with IEC, Lightning Strokes / Flashes may lead to a maximum lightning current flow from 100,000 Amperes (100 KA) to 200,000 Amperes (200 KA) and even more, and these huge quantities of lightning currents are dissipated to ground within a few micro seconds. The extent of Lightning & Earthing Protection Systems of work, specified or shown on the tender drawings, is schematic & does not indicate the exact positions of the Lightning Arrestors / Air-Terminations, Earthing Pits, Trenches, conductor / copper strips connections / joints (types) etc. etc. Page-2
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However, the contractor shall ensure that the system is complete in all respect, including all accessories & auxiliaries as intended by the specifications / BOQ & Tender Drawings. The Lightning Protection System shall comprise of: Air Terminations / Lightning Arresters & Copper Strips Mesh at the roof tops of Main Plant Structure, Overhead Tank & Chimney etc. and down coming (from roof top) copper strips that are further extending to the corresponding Earthing Pits on the ground. Materials as offered by M/S Furse U.K or imported equivalent, would be acceptable. The general earthing resistance requirements are such that the Lightning Protection Earthing System must have a resistance of less than 10 ohms, measured at a frequency, different from the power system frequency or multiple thereof. The Earthing Protection System shall comprise of: Earthing Pits (same are the part of Lightning Protection System as well) with a drilled / bored hole having solid copper Earthing electrode at the bottom of the drilled hole, Earthing leads, Earthing termination / test points (ETPs), Earthing Continuity Conductors ( Copper Strips 50 x 3 mm thick), Earthing Connection Points (ECPs) as well as Running Trenches having buried copper strips for connecting / looping Earthing Pits and all accessories & auxiliaries necessary for the satisfactory operation of the associated Electrical System. E2.04 MATERIALS:

(a)

All materials shall be in accordance with the type and manufacture described in the Bill of Quantities and/or shown on the relevant drawings. Where the Contractor desires to use material differing from those described, he shall obtain the approval of the Consultant in writing before tendering. Materials shall accord with the appropriate Pakistan and IEC Standard Specifications. The rights are reserved to inspect materials on site at reasonable times and to reject any material not complying with the specifications. The cost of any dismantling and re-erection of the installation occasioned by the removal of rejected materials shall be borne by the Contractor.

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(b)

(Items to be imported for use under this contract are listed hereunder. (Each bidder may submit his own list which may differ from the following provided the bidder can give justification for the proposed changes.) i) Copper Strips 50 x 3 mm thick, ETPs & ECPs, made of 99.9 % pure and Imported copper. Lightning Arresters Air Terminations along with all accessories, auxiliaries & complete in all respect. Materials as offered by M/S Furse U.K or imported equivalent, would be acceptable. Earthing Electrodes along with all accessories, auxiliaries & complete in all respect. Materials as offered by M/S Furse U.K or imported equivalent, would be acceptable. Brazed connections / joints through CAD / Exothermic Welding. Materials as offered by M/S Furse U.K or imported equivalent, would be acceptable. LIGHTNING & EARTHING PROTECTION SYSTEMS ITEMS MATERIAL & INSTALLATION DETAILS Air Termination (Lightning Arrestor) - 15 mm x 2000 mm Length Air Termination (Lightning Arrestor) shall comprise of copper rod 15 mm x 2000 mm Length, base, multi-point spikes - brazed on the top of the copper rod, and further including appropriate & suitable mounting arrangement over the copper strip mesh at the perlins of the roof top / ridge of the structure, perpendicular to x-axis or horizontal - axis. All the parts /sub-assemblies of the Air-Terminal must be made of 99.9 % pure copper. Moreover all the connections / joints / assemblies /sub-assemblies must be brazed through CAD / Exothermic Welding.

ii)

iii)

iv)

(c)

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Roof top Copper Strips (50 x 3 mm thick) Mesh / Grid Network The roof-top copper strips (50 x 3 mm thick) mesh / grid network shall connect the Air Terminations / Lightning Arrestors with each Page-4
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other and further provide various diversified current carrying paths for the lightning strokes / flashes (carrying huge lightning currents ) to reach the earthing electrodes / (earthing pits), to be dissipated in the earth mass. Air Terminals & the copper strip mesh at the perimeter of the roof-top shall be as close to the edges of the roof top / ridge structure, as practically possible. Moreover, Air-Terminals and the copper strip mesh, shall be installed on the perlins supporting the roof top, as the roof-top by itself, is just covered by 1 mm thick sheet which is not strong enough to hold Air-Terminals & the mesh. c-3 Down-Coming Copper Strips 50 x 3 mm thick (from roof-top) & extending to Earthing Pits for Lightning Protection System. The down-coming copper strips (50 x 3 mm thick) from the roof-top for Lightning Protection System & further extending to the corresponding Earthing Pits, shall be brazed through CAD / Exothermic Welding with the Steel structure (pillars) at 3 locations: top, middle and bottom ( bottom above PVC insulation) and further shall be saddled at each running meter. While running & connecting the down-coming copper strips with the items of the Lightning & Earthing Protection System, sharp bends / corners / turnings must be avoided using appropriate round bends / corners / turnings. The "Down coming copper strips" from the roof top of the "Main Plant Structure", O/H Water Tank, Chimney, must be insulated at least "100 KV, 1.2/50 micro seconds impulse wave insulation" using 3 mm thick PVC / Polyethylene Insulation up to a height of 2500 mm (2.5 meters) from finished floor level, to reduce touch potential threats for personnel.

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Earthing Pit 500 x 500 x 500 mm deep Earthing pits having size: 500 X 500 X 500 mm deep (inside dimensions), shall be a cement concrete chamber, provided with a drilled / bored hole in the centre of the pit, having dimensions: 100 mm x 10,000 mm (10 meter) deep (in line with the Soil Resistivity Report provided by M/S Amreli Steels & as per its Page-5
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recommendations for good conductivity), for carrying Earthing Electrode at the bottom of the bored/drilled hole. All Copper items / parts should be made of 99.9% Pure & imported copper. Earthing Pit work / job should be completed in all respect including all accessories, auxiliaries and as per Drawings: UESI-ASM-E-18, 19 & 20. The top of the Earthing Pit must be flushed with the finished floor level, where available & applicable, covered by a medium duty Cast Iron Cover & painted by "corrosion resistive" (anti-corrosive) paint, matching the Finished Flooring color. The earthing pit includes earthing electrode whose top-end, is connected / brazed through CAD / Exothermic welding by 2 x 70 sq. mm bare copper conductor wire to be connected with the Earthing Termination / Test Point (ETP), by using appropriate copper lugs to make removable connections of the earthing electrode for testing purposes. The 2 x 70 sq. mm bare copper conductor wire, (Earthing Lead) are further enclosed in a 38 mm (1.5 inch) x 7000 mm Length of Galvanized Iron Perforated Pipe, having cover on its top & a "T- connection" to extend copper wires to ETP, as shown in the drawing. The remaining space in the drilled / bored hole, inside & around the perforated G.I Pipe and around Earthing Electrode, must be filled by "sweet earth" and solidly compacted by watering to provide the least possible resistive path in the ground / earth. To reduce "Step Potential" threats for personnel, "GRAVEL" at the surface must be used, 150 mm deep and with a distance of 3000 mm around each Earthing Pit.

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Solid Copper Earthing Electrode - 17.2 mm x 3000 mm Length Sloid Copper Earthing Electrode, rod type, having dimensions: 17.2 mm x 3000 mm Length, made of 99.9% pure & imported copper, with all accessories, auxiliaries & complete in all respect to be used as mentioned in item E-01 of BOQ relating to Earthing Pit. (Drwg: UESI- ASM-E-19).

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Earthing Lead 70 sq. mm Bare Copper Conductor Wire The earthing lead: 70 sq. mm bare copper conductor wire, shall connect the top end of the earthing electrode through brazed CAD / Exothermic Welding to the Earthing Termination / Test Point (ETP) via appropriate size of copper lugs to make the connections removable at ETP side, for testing purposes.

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Earthing Termination / Test Point (ETP) SIZE: 300 x 50 x 10 mm Thick The Earthing Termination / Test Point (ETP), having dimensions: 300 x 50 x 10 mm thick, made of 99.9% pure & imported copper, to be installed in each earthing pit upon 2 x insulator supports. ETP shall provide connectivity to 2 x earthing lead through appropriate copper lugs, 2 x copper strips 50 x 3 mm thick, brazed through CAD / Exothermic welding to connect Earthing Connection Point (ECP) & further 2 x copper strips 50 x 3 mm thick, brazed through CAD / Exothermic welding, being the running Earth Continuity Copper Strips (ECC) as per the given tender drawings.

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Earthing Continuity Copper Strips (ECC) 50 x 3 mm thick Earthing Continuity Copper Strips (ECC), having dimensions 50 x 3 mm thick, buried in a Running Trench, connecting / looping Earthing Pits through Earthing Termination / Test Point (ETP) & further connecting Earthing Connection Point (ECP) as per the given tender drawings. While running & connecting ECCs with the items of the Lightning & Earthing Protection System, sharp bends / corners / turnings must be avoided using appropriate round bends / corners / turnings.

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Earthing Connection Point (ECP) SIZE: 400 x 100 x 10 mm Thick Earthing Connections Point (ECP), having dimensions: 400 x 100 x 10 mm thick, shall be provided & installed at suitable & appropriate locations to cater the requirements of "Earthing Connnectivity". The Earthing Connection Points (ECPs) should be made of 99.9 % pure & imported copper, having 14 outgoing connection holes of appropriate diameter for earthing connectivity. ECP should be installed / brazed with the structure / facility, at suitable / appropriate locations, 300 mm above the finished floor level. ECP Page-7
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should be connected / Brazed by 2 x Copper Strips, having dimensions 50 x 3 mm thick, to Earthing Termination / Test Point(ETP) of each Earthing Pit for Structure (SP) & Electronic eqp. Pit (EP). The connections of the 2 x copper strips, (50 x 3 mm) at both the ends of ECP & ETP, are the brazed connections through CAD / Exothermic Welding. ECP should be complete in all respect including all the accessories & auxiliaries & as per drawing UESI-ASM-E-19.

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Running Trench of size 500 x 500 mm deep running between Earthing Pits for Main Earthing Network Grid Connectivity as per given drawings. Main Earthing Network Grid of Copper Strips, 50 x 3 mm thick, connecting / looping Earthing Pits as per given drawings, shall be buried at least 500 mm below the natural ground level, in a running trench of size 500 x 500 mm deep, filled by sweet earth & compacted by watering.

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All The Connections / Joints Brazed Through CAD / Exothermic Welding Except For Removable Connections All the connections / joints of the copper strips, connections of copper Strips between ETPs & ECPs, metallic / steel structure with the earting grid / mesh, lightning grid / mesh, lightning down-coming copper strips, lightning arresters / Air - Terminals, earthing pits, earthing electrodes, etc. shall be Brazed through CAD / Exothermic Welding as per IEC - 62305 Standards and practices, except for the "removable connections" for testing purposes, using appropriate "powder" and "mould" for perfect brazing: using materials as offered by M/S Furse - U.K or imported equivalent. The details of the joints & their corresponding moulds & powders required, as offered by M/S Furse U.K, are described in the BOQ.

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3 mm thick PVC / Polyethylene Insulation on Lightning- Protection down-coming Copper Strips to reduce "Touch Potential" threat To reduce "Touch Potential" threats for personnel, the "down coming copper strips" (having size 50 x 3 mm thick) of Lightning Protection Page-8
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System, from the roof top Tank, Chimney, shall be seconds impulse wave Polyethylene Insulation up the finished Floor Level.

of the "Main Plant Structure", O/H Water insulated at least "100 KV, 1.2/50 micro insulation" using 3 mm thick PVC / to a height of 2500 mm (2.5 meters) from

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