FCCU & PRU REVAMP PROJECT, MATHURA LOCATION: IOCL PANIPAT REFINERY

Tender No:TPKTI/0785/FCCU-PR/096
Page 5 of 6 Rev. 0

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DESCRIPTION

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5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 6.0 6.1 6.2 6.3 6.4 6.5 6.6

ELECTRICAL DOCUMENTS Electrical Job Specification For Mounded Bullet Engineering Design Basis For Electrical Data Sheet For MV Switchgear Standard Specification For MV Cable And Accessories

00785-000-LD-14901 01 00785-068-JSD1675-01 00785-000-JSD1650-01 00785-000-DS1654-01 00785-000-STD1621-03 A 0 0 0 0 0 0 1 0 0 0

Specification For Cable For Cathodic Protection 00785-000-STDSystem 1621-04 Standard Specification For Medium Voltage Switchgear Standard Specification For Cathodic Protection List Of Mandatory Spares (Electrical) Vendor list -Electrical Standard spec. for Electrical Heat Tracing INSTRUMENTATION DOCUMENTS Job Specification For Instrumentation Items For Mounded Bullets Mandatory Spares For Instrumentation Design Basis – Instrumentation Job specification for MOV Vendor list - Instrumentation Electrical data sheet for MOV actuators 00785-000-STD1654-01 00785-000-STD1675-01 00785-000-NM1603-01 00785-000-NM1602-01 00785-000-STD1686-01 00785-000-STD1686-01

00785-68-JSS-1514C 15 00785-000-NM1587-01 00785-000-JSD1501-01 00785-68-JSS1543-12 00785-000-NM1502-01 00785-000-DS1669-01 2 0 C 0 0

FCCU & PRU REVAMP PROJECT, MATHURA LOCATION: IOCL PANIPAT REFINERY
Tender No:TPKTI/0785/FCCU-PR/096
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Technical specification for procurement of valves Quality control plan for control valve HSE DOCUMENTS Design Basis For Fire Protection And F&G Detection System For Offsite Mounded Bullet Facility Scope Of Work For Fire Protection And F&G Detection System For Offsite Mounded Bullet Facility Layouts for fire protection system MISCELLANEOUS Site Facilities & Requirements – Mounded Bullets Deviations list format Inspection and Test Plan for Mounded Bullets Package General Quality Control Requirements

00785-000-JSS1300-0004 00785-000-ITP1541-01 00785-68-SOW1900-01 00785-068-JSD1900-01 00785-68-SOW1900-01

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00785-68-DW-19301 01 Refer Attached --

00785-071-PTC-(1)0 01 Refer Attached -0 0 0 -

00785-071-ITP2543-01 00785-19-PP-502 00785-019-PP-0308Planning, Scheduling, Monitoring and Scheduling 01 Vendor list-Mech --

Project N°

Unit

Document

Code

Serial N°

Rev.

Page

00785

068

JSD

1675

01

A

1/20

ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET

UNIT PROJECT
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

: 0068-PANIPAT NAPHTHA CRACKER : FCCU AND PRU REVAMP, MATHURA. : IOCL, PANIPAT NAPHTHA CRACKER

LOCATION

OWNER

EPCM
TECHNIP KT INDIA LTD.

INDIAN OIL CORPORATION LIMITED.

NOIDA, INDIA.

ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET

A
REV.

19.03.2012
DATE

ISSUED FOR ENQUIRY
STATUS

ABS
PREPARED BY

VV
REVIEWED BY

SM
APPROVED BY

VJK
PM

DOCUMENT REVISIONS Sections changed in last revision are identified by a line in the right margin

................................. and shall not..... 6........................... under any circumstances................................ 4 SCOPE OF WORK SUPPLY ....... Page 00785 068 JSD 1675 01 A 2/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET CONTENTS The present document or drawing is property of TECHNIP KT INDIA LTD............. 5.......... 13 JOB MATRIX........................... 1.............. 3 AREA CLASSIFICATION . 4.............................................................................. without its prior written consent...................................... 2.......... ...PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP......................... 7....................................................................... transferred........................................ directly or indirectly.......... 3 DEFINITION .. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use............................................ 3........ GENERAL ..................................... 3 SITE CONDITIONS ...................... copied........... disclosed or used.......................... be totally or partially................. 0068....... 14 CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER.................................................................................................Project N° Unit Document Code Serial N° Rev............................................................................. reproduced.................................................................................................... 5 MISCELLANEOUS WORKS.....

Project N° Unit Document Code Serial N° Rev. : : : : 47ºC 50ºC 2ºC 2ºC CLIENT UNIT PROJECT INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. transferred. DEFINITION In this document following are implied: EPCM Bidder End user TPKTI Package/system vendor IOCL 3. without its prior written consent. The contract scope also includes clearing up of temporary constructions. Page 00785 068 JSD 1675 01 A 3/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET 1. directly or indirectly. for applicable items/ clause. following order of precedence shall prevail: x x x x x x Statutory requirement IS Codes and standards This document Engineering design basis Data sheets Technical specifications In case of ambiguity. . under any circumstances. drawings attached with bid shall form the basis of electrical works for mounded bullets at Panipat Refinery. copied. 00785-000-JSD-1650-01. disclosed or used. bidder shall inform Owner/EPCM of their interpretation. No additional cost or time on account of conflicts/ambiguities shall be admissible if not notified prior to award of contract.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. For engineering design basis refer doc. The present document or drawing is property of TECHNIP KT INDIA LTD. be totally or partially. waste materials and loose earth which might get collected consequent to the execution of the work performed under this contract. 2. the owner's decision on interpretation shall be considered final if need arises during the execution. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. no. GENERAL This document along with standard specifications. In case bidder fails to convey the same prior to award. In case of any discrepancy / conflict amongst various documents. SITE CONDITIONS * * * * Maximum temperature Design maximum temperature Minimum temperature Winterizing temperature : : : 0068. reproduced. IOCL. and shall not.

Irrespective of the area classification (whether Zone-1 or 2). lighting/power panels. fittings and meters are installed in well ventilated areas or pit. transferred. all area enclosed within 16 m distance around the storage bed and pump station shall be classified as Zone-2 hazardous area.Average . where well maintained valves. Further an area from 1.Project N° Unit Document Code Serial N° Rev. junction CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. filler openings. 0068. In case of pipeline handling flammable material.Maximum : 2ºC : : : 36% @ 4º-50ºC 95% * * Dry bulb temperature Barometric pressure . Page 00785 068 JSD 1675 01 A 4/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET * * The present document or drawing is property of TECHNIP KT INDIA LTD. local control stations. the extent of Zone-2 area above ground shall be considered as 4.Average : : : : 740 mm Hg < 1000 mm * Altitude above mean sea level 4. without its prior written consent. be totally or partially. The area within 1. copied. shall also be classified as Zone-1.Minimum . All areas within the pump station shall be classified as minimum Zone-2 hazardous area. disclosed or used. welding receptacles/sockets. Petroleum Rules and Project Design Basis. In addition. all electrical equipment such as motors. AREA CLASSIFICATION The area classification shall be done in accordance with IS: 5572. oily sewer vents. Open trenches. under any circumstances. directly or indirectly. although the pit itself shall be classified as Zone-1 area. inspection hatches. . rotary or dip gauges. and shall not. the vents or drains blanked during normal operation and used only when the plant is depressurized or under shut down. process water drains. However. pits or sump below grade level within Zone-2 area shall be classified as Zone-1 area. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.Maximum . should not be regarded as an operational vent or drain or source of hazard.0 m in all directions from the possible source of hazard.0 m (extending in all directions) from vents shall be classified as Zone-2. reproduced.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. product sampling locations.5 m radius (extending in all directions) of safety vents.5 m to 3. The Mounded Storage bed shall be classified as Zone-1 hazardous area. Design minimum temperature Relative humidity . discharge orifice of fixed liquid level gauges.

and shall not. Page 00785 068 JSD 1675 01 A 5/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET boxes. SCOPE OF WORK SUPPLY Electrical works are divided into two parts herein i) Cathodic protection system ii) Balance Electricals 5.1. JBs.Project N° Unit Document Code Serial N° Rev. reproduced. etc. without its prior written consent. Cable size 1CX95 sqmm to be laid from CRJB 1 to Distribution box. All hazardous area equipment shall be tested by CMRI and approved by CCE or equivalent The present document or drawing is property of TECHNIP KT INDIA LTD. .1. Shifting of two nos. INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. earth pits to new CP system yard from existing yard for earthing of equipments.1. The TR-Units as required for new bullets shall also be installed in the same yard. shall be in bidder’s scope of work. 0068. suitable for Gas Group-IIA & IIB and Temperature Class-T3. 5. shall be flameproof type Ex’d’ as per IS:2148 with IP-55 protection.) The existing CP system yard along with all equipments like TR-units. DBs. location shall be verified and finalized by bidder in accordance with latest amendments in OISD regulations. copied. Following cables are to be laid: CLIENT UNIT PROJECT : : : Cable size 1CX95 sqmm to be laid from AJB 1B to Distribution box. under any circumstances. Vendor shall design and submit drawings for EPCM approval. testing agencies and statutory authority of country of origin. Bidder shall be required to submit the testing and approval certificates for all hazardous area equipment for Owner’s/ EPCM’s approval. Cathodic Protection Scope 5. and submitting drawings to EPCM for approval. for existing bullets (6 nos. Bidder shall visit site to get relevant information and get familiar with this shifting job. if required.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.1. The scope of work to be carried out for shifting of CP system shall include but not limited to the following: x x x x Design of CP system yard including all civil works.1. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. directly or indirectly. All flameproof equipment shall be BIS-approved. however. including foundations. lighting fixtures and accessories etc. 5. transferred. Shifting of Existing CP System for Existing Bullets (6 nos.1. Design and construction of yard.) is to be relocated and the proposed location has been indicated in equipment layout. disclosed or used. be totally or partially.

Bidder shall check the sufficiency of existing cable incomer from MC-1341 for supplying to the new power distribution board. 4000 VA.5 sqmm cable shall be single stranded copper with double insulation. The existing CP system TR-unit is of Raychem make. Total 6 nos. Serial no. Cable size 1CX95 sqmm to be laid from CRJB 6 to Distribution box. reproduced. All dismantling and re-installation works for existing CP system is in bidder’s scope.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.1. - Cable specification is given below: 1CX95 sqmm cable shall be aluminium conductor pvc insulated armoured cable with double insulation. The incoming power supply to this power distribution board shall be taken from MC-1341 in S/S-13.e. i. supply. Cable size 1CX95 sqmm to be laid from AJB 1A to Distribution box.1. without its prior written consent. Bidder to co-ordinate with CP system vendor for dismantling and re-installation work and this work shall be done under supervision of existing CP system vendor. 0068. copied.5 sqmm cable to be laid. Cable of 20CX1. new bullet is in bidder’s scope of work. . Incomers and outgoing feeders to supply to both existing as well as new CP system. adequacy CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. if damaged shall be supplied and laid by bidder free of cost.. Bidder shall consider a new power distribution board.2. x x Any other existing cable. New CP system for New Bullet (1 no. transferred. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. disclosed or used. and shall not. 5. under any circumstances.) The design.101542-07K8. installation and commissioning of a new CP system for 1 no.5 sqmm to be laid from each CRJB box to measurement junction box. feeder nos. - Cable of size 1CX35 sqmm to be laid from new earthing pits inside the yard to earthing junction box in the same yard. Bidder shall design the new CP system to work along with the existing CP system and design the CP system yard accordingly to accommodate existing as well as new equipments. to be supplied and installed by bidder in the CP system yard. The power distribution philosophy for existing CP system henceforth shall be kept unchanged. of 20CX1. be totally or partially. 1CX35 sqmm cable shall be aluminium conductor unarmoured with pvc insulation and pvc sheathing. with 2 no.Project N° Unit Document Code Serial N° Rev. 5FC and 11FC. Page 00785 068 JSD 1675 01 A 6/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET The present document or drawing is property of TECHNIP KT INDIA LTD. 20CX1. directly or indirectly. Detailed specification shall be obtained by bidder from site.

installation and commissioning of cathodic protection systems for mounded bullets in contact with soil. length etc. Test. generate and evaluate necessary information to perform complete design. 0068. reproduced. Submit to EPCM a detailed cathodic protection design and installation methods for review and approval. services.Project N° Unit Document Code Serial N° Rev. x x Review and validate correctness of information furnished by the EPCM. evaluate and mitigate stray currents generated by newly installed cathodic protection systems. disclosed or used. and if necessary supply and laying of new cables shall be in bidder’s scope of work. . procurement. Bidder shall indicate dimensions of such equipment to be placed in CP system yard (eg T/R unit) and Electrical power consumption along with bid. testing. Preparation and submission of general cathodic protection system layout. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Supply of all labor. tools. Provide documentation for system design and installation. x Supply and install permanent testing facilities and remote monitoring capabilities to monitor the cathodic protection systems using latest proven technology available at the time of system design. Furnish operation manual for system operation and maintenance. Supply of mandatory spares and commissioning spares as required. evaluate and mitigate possible interference caused by cathodic protection system on communication and low energy control systems. The design data shall include basis. be totally or partially. Bidder to provide redundant transformer / rectifier set. installation. The present document or drawing is property of TECHNIP KT INDIA LTD. supply. directly or indirectly. x x x x x x x x x Test. The scope of work for new cathodic protection system shall include but not limited to the following: x Obtain. on equipment to be protected. commissioning and documentation of the cathodic protection systems including a design site survey for collection of data. copied. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. which shall be hot standby type. supervision. installed and consumable materials. This is essential part of bid. and shall not. under any circumstances. transferred. and each and every item of expense necessary for the design. in compliance with this specification and referenced standards. equipment. calculations and drawings. Page 00785 068 JSD 1675 01 A 7/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET of cable. without its prior written consent.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.

x Any sensitivity in the proposed cathodic protection system that requires special attention. and shall not. 5. A list of the estimated number and types of cathodic protection monitoring facilities. 5FC and 11FC for CP System. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. resistance and current output of ground beds. Installation procedures. be totally or partially.3. Bidder shall consider a power distribution board in field to supply power to existing and new CP system. Calculations of current requirements. MCC-1341 feeder nos. The civil works required to install the cathodic protection system. Design documents The basic design documents shall be submitted for approval to the EPCM covering the following requirements: x x x x x Results of any site surveys and soil investigations that have been carried out. etc. . under any circumstances. copied.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. deep well head works. A complete set of design drawings. 0068. cable trenches. : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. reproduced.1. disclosed or used.Project N° Unit Document Code Serial N° Rev. security fencing. Further power distribution shall be in bidder’s scope. however. Such works include transformer/rectifier plinths. it is bidder’s responsibility to carry out successful commissioning of CP system and include any supply/work. Page 00785 068 JSD 1675 01 A 8/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET x The bidder shall include in the material schedule a list of proposed monitoring equipment (hardware and software) required to carry out regular surveys of the cathodic protection system The present document or drawing is property of TECHNIP KT INDIA LTD.1. Effort is made to define the scope of work as completely as possible. A schematic diagram of the proposed cathodic protection system. The following detailed design documents shall be submitted by Bidder to the EPCM for approval before construction starts: x x x x CLIENT UNIT PROJECT A schedule of materials including a complete set of material and equipment specifications. not included herein. The bidder shall provide load details for new CP system in his offer to EPCM. mounting details of distribution boxes and test posts. without its prior written consent. transferred. 5.2. Commissioning procedures. directly or indirectly. Power supply Owner shall provide 415 V 3 Phase Power Supply at two points in Substation-13. in his scope of work to ensure completeness of operation.

or equipment not specifically mentioned but required for completion of job. reproduced. brackets. . Wherever available. In case of using existing trench. copied. Flameproof hand-lamps and 24 V sockets (with built-in transformers). The present document or drawing is property of TECHNIP KT INDIA LTD. laying. In case of requirement of new cable trench. 0068.2.2. electrical road crossings etc. tray supports. sockets and junction boxes as required.Project N° Unit Document Code Serial N° Rev. bidder shall provide the same after carrying out site survey. directly or indirectly. termination of all power and control cabling from switchgear in substation to equipment within battery limit shall be by bidder. All supporting structures for lighting fixtures including poles. Any other electrical loads defined elsewhere in tender. 5.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. Balance Electricals The main equipment for balance electrical works for the job broadly includes.4. 5. transferred. trenches. for installing cables from substation to within the battery limit. under any circumstances.1. Inside process units. The bidder shall include training of Owner’s personnel in the operation and maintenance of the cathodic protection system with particular attention being paid to any special features of the system and troubleshooting.1. Safety The Bidder shall address in his design all safety related topics regarding the cathodic protection systems and indicate. without its prior written consent. cable tray should be covered after laying of all cables.5. supply of the following: Flameproof lighting fixtures lamps and accessories for all local lighting. clamps. making good of existing trench after laying cable is in bidder’s scope. Supply. disclosed or used. in the installation and operating documentation. but is not limited to. precommissioning. 5.1. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. etc. existing cable tray /trench shall be used by bidder. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. Training Bidder shall consider presence of Owner’s operating personnel during installation. Flameproof welding receptacles. be totally or partially. procedures to ensure safe working practices. Page 00785 068 JSD 1675 01 A 9/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET 5. commissioning and close interval potential survey of the cathodic protection system. All cable trays. The bidder shall be familiar with local safety rules and practices and implement these in his work. and shall not.

transferred. Bidder’s scope of work Bidder’s scope shall include detailed engineering. procurement. Further power distribution shall be by bidder. Detailed Engineering Sizing and selection of equipment. be totally or partially. Flameproof double compression cable glands for all equipment. metering. trouble-free operation of the complete system and equipment as covered in the tender. supervision. . Voltage Drop. efficient. control. x x 1 no. annunciation.2. b) Calculations for Lighting System. Earthing System. cables and materials including all devices for indication. Page 00785 068 JSD 1675 01 A 10/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET The present document or drawing is property of TECHNIP KT INDIA LTD. panels supplied. Tool kits for maintenance of all equipment and systems as recommended by respective manufacturers. 5. supply of all electrical equipment and materials required for the package. preparation of all layout drawings.2. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.Project N° Unit Document Code Serial N° Rev. - Commissioning spares & spares for 2 years’ normal operation for all electrical equipment.3.3. testing and commissioning of complete electrical system forming part of this tender.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. This includes but is not limited to the following: a) Overall Single Line Diagram of the facilities provided. sizing. feeders for power supply to CP system in substation-13. d) Preparation of control schematics and logic for control panels and other equipment requiring sequential or other control systems.2. installation details. lighting and earthing layout drawings including associated documents such as. operation and protection as required. 5. 1 no. disclosed or used.1. for the safe. interlocks. without its prior written consent. selection. feeder for supply to Heat Tracing shall be provided in field heat tracing DB. feeder for power supply to MOV shall be provided in Substation-13.2. under any circumstances. reproduced. Bidder shall consider a power distribution box at field to feed both existing and new CP system. AB-1351 feeder no. transportation to site. directly or indirectly. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. c) Preparation of cable tray/trench. copied. Owner’s scope x Owner shall provide two nos. 0068. and shall not. 17R-B (63 A SFU). Bidder's scope of work shall include the following: 5. installation.

and shall not. earthing and miscellaneous items and procurement of all items in Bills of Material. stability and solvency needs to be verified by the vendor before placement of order. interconnection diagrams. laying. . terminal details for equipment / devices including Electrical-Instrumentation interface details. All Power and Control cable supply. walkways. Job specifications a) Switchboards housing switch fuse feeders required for the mounted Bullet package in refinery will be supplied and installed by the owner. 5. pumps. Various electrical works covered under this contract like equipment erection. b) Bidder shall ensure that equipment supplied by them shall be provided with suitably sized terminal boxes having suitable cable entry. lighting. Installation standard drawings shall be issued to the successful Bidder.Project N° Unit Document Code Serial N° Rev. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. g) Preparation of "As Built" drawings. Page 00785 068 JSD 1675 01 A 11/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET e) Preparation of cable schedule. copied. e) Local lighting for the mounded storage. c) The complete electrical system shall conform to requisition attachments and data sheets in this tender. earthing. the sub-vendors’ current validity and range of approval as per enlistment letter. workload. without its prior written consent.2. Preparation of all Bills of Material for all electrical equipment including cable trays. shall be performed in accordance with the specifications attached with the tender. transferred. cable tray supports. prior approval from Owner/EPCM shall be required. be totally or partially.4. stairs etc. Power supply required for local CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. under any circumstances.2. Wherever required. Any other makes shall be subject to EPCM’s/Owner’s written approval. d) Makes of electrical equipment. disclosed or used. cable tray works etc. 5. panels. pump station. termination from substation to equipment within the package battery limit will be done by the Bidder. For makes of items not included in the list. shall be provided by Bidder. materials and components shall be selected out of the list attached elsewhere in the Tender. However.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. cabling. cabling. Installation. additional adapter box/JB shall be provided by the bidder. within the battery limit. testing and commissioning Installation. operating platforms. steel supports. lighting and earthing works etc. f) The present document or drawing is property of TECHNIP KT INDIA LTD.5. directly or indirectly. reproduced. testing and commissioning of all equipment and materials supplied by Bidder including complete lighting. Both normal and emergency/critical lighting circuits shall be provided. 0068.

6. and shall not. After contract award Electrical document deliverables to be submitted by Bidder for review and records shall broadly include the following: CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. Page 00785 068 JSD 1675 01 A 12/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET lighting of new bullet shall be tapped from existing lighting panels for lighting of existing bullets. disclosed or used. under any circumstances. reproduced.Project N° Unit Document Code Serial N° Rev.2. copied.2.6.6. 5. f) The present document or drawing is property of TECHNIP KT INDIA LTD. . Bidder shall obtain and evaluate necessary information to perform complete design. g) Recommended list and quantity of maintenance spares. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. f) . b) Guaranteed power consumption for rated throughput of plant.2. 0068. g) Cables shall be laid on trays above ground on cable racks/sleepers. directly or indirectly. commissioning and documentation for heat tracing system.1. . c) UPS and DC load requirements.Deviation. supply. without its prior written consent. transferred. Lamps and control gear shall be included for lighting fixtures while control switches/push buttons shall be provided for local control stations. h) Spares for two years’ normal operation of all electrical equipment and commissioning spares shall be included in the scope of supply. Heat tracing system shall conform to standard specification for heat tracing attached with the tender. d) Cable tray requirement in substation/field. e) Makes for various equipments offered. if any.2. Where unavoidable. 5. Drawing/ documents required from Bidder 5. . i) Mandatory spares shall be provided as per mandatory spares list. Heat tracing for new bullet in totality is in bidder’s scope.5M pole mounted lighting fixtures for local lighting of new bullet. testing.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. be totally or partially. Bidder to use 4. installation. a few cables may be laid in trenches subject to specific approval by owner/EPCM.Specific confirmation to scope of tender. With bids a) Load list.Specific confirmation to specifications and technical requirements of tender.

a b etc and equipment. . 0068. No. copied.3. Description After order Review Ref. without its prior written consent. shall be incorporated by the Bidder without any time or cost implication to owner. under any circumstances. and shall not. a Design calculations Load data. lighting fittings 5.2. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. 7. Any changes required by the CEA/statutory agency. Obtaining approvals and clearance for energizing the complete electrical facilities covered under this tender including approval of drawings from Central Electricity Authority/other statutory agencies. Layouts Equipment layouts.1.Project N° Unit Document Code Serial N° Rev. MISCELLANEOUS WORKS Supply and installation of all other equipment/ accessories not specifically mentioned herein but nevertheless necessary for completion of job. Correction and submission of drawings for AS-built status. 6./ Records Remarks The present document or drawing is property of TECHNIP KT INDIA LTD. Cable tray layout Earthing/Lighting layouts MTO & schedules Vendor drawings GAD. a b 6.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. 4. Data Sheets Wiring schemes. Page 00785 068 JSD 1675 01 A 13/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET Sr. a 3. equipment sizing Lighting/earthing calculations Basic design SLD Material requisitions Purchase requisitions (before * * * * * order placement) for bulk items such as cables. directly or indirectly. a b 2. 6. 1. 6. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. technical data for all electrical equipment * * * * * 6. reproduced. disclosed or used. transferred. be totally or partially.

as per requirement for the satisfactory completion of the electricals for mounded bullets. Bidder shall draw power from designated substation for all electrical consumers. co-ordination with 9 7. vendor drawings. In general.1. under any circumstances.1. 7.4.1. and shall not. catalogues. operation and maintenance manuals for all equipment/materials in Bidder's scope of supply.1.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.1 7. All 9 CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. installation. disclosed or used. Submission of test certificates.3 owner/EPCM. No.1 Engineering Description Bidder EPCM/ Owner Remarks Identification of shut down requirements and planning for hook up activities Any item not specifically mentioned in the package but required as per good engineering practice and for smooth and 9 7. JOB MATRIX Scope & Miscellaneous work as defined in clause 5. without its prior written consent. reproduced.2 safe operation of the equipment/ system/ plant shall deem to have been specified and shall be in the scope of Bidder with no additional cost and schedule implication to the Owner/EPCM Collecting necessary information about the existing system. transferred.1. copied. 7. . Area 9 7. 0068. be totally or partially. The present document or drawing is property of TECHNIP KT INDIA LTD. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Page 00785 068 JSD 1675 01 A 14/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET 6.4 areas under mounded bullets including all sheds/ buildings within plant battery limit area shall be included in Bidder’s scope.Project N° Unit Document Code Serial N° Rev. all electricals required for the 9 7.0 shall be read in conjunction with the following matrix: S. directly or indirectly.5 lighting in mounded battery limit area and power supply to CP system shall be from LDB/switchgear in designated substation.0 & 6.

8 approval from EPCM as necessary.7 Timely review of documents and conveying comments and approval Preparation of enquiry specifications and data sheets. Factory 7.11 7.13 7.1. disclosed or used.1.16 7. procurement of all items as involved to complete the package Obtaining statutory approvals such as CCE.17 7.1.1. reproduced. government authorities and any other agency as required for completion of work and commissioning of the plant 7.10 7. bid evaluation and obtaining 7.1.1. .15 7. directly or indirectly.9 Inspectorate. and shall not. Central Electricity Authority (CEA). installed. without its prior written consent.1.1.18 CLIENT UNIT PROJECT 9 9 9 9 Electrical load list/ consumer list Earthing design and calculations for plant Cable sizing calculations Cable tray sizing calculations Lighting calculations Selection of equipment for hazardous area CP system calculations Any other calculation not specified above but required as support of selected equipments Timely submission of calculations and : : : 9 9 9 9 9 9 9 9 9 INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER.6 documents after award of contract and obtaining comments/ approval on the same 7. transferred. Bidder EPCM/ Owner Remarks supplied.1. be totally or partially.Project N° Unit Document Code Serial N° Rev.1. 0068.1. Page 00785 068 JSD 1675 01 A 15/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. No. Preparation and submission of drawings and 7.12 7. local statutory authorities.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. tested and commissioned by bidder.1. Description other equipment necessary for smooth operation of mounded bullets shall be The present document or drawing is property of TECHNIP KT INDIA LTD. under any circumstances. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.14 7. copied. placement of order.1. Bidder shall design the system accordingly.

20.6 7.2 As built drawings/ documents as required 9 Design.21 7. Lighting scheme b.2. trays.22 Lighting fixtures.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.1. junction boxes. noncritical equipment as per Annexure-I 7. Overall earthing layout for the areas within bidder’s scope of work Area lighting layouts as required Cable schedule. Bidder EPCM/ Owner Remarks 7. pre-commissioning. commissioning of electrical equipment as a minimum but not limited to the following: MR/PR/ Vendor documents w. directly or indirectly. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Socket outlets etc. Page 00785 068 JSD 1675 01 A 16/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. earthing materials.23 7. disclosed or used.Project N° Unit Document Code Serial N° Rev. cable drum schedule MTO schedules for bulks like cables.1.1. Procurement.1. reproduced.1.20.20 7. semi-critical.20. 9 7. 0068.5 7.20. .3 7.1.1. testing. cable accessories. transferred. and shall not.1 Drawings SLD a.1.19 documents and conveying comments and approval 9 7. structural steel.4 Schematic diagrams Interconnection & terminal wiring diagrams Cable tray/ Trench/ conduit routing.2 7. procurement. 7. Earthing and Lighting layouts. under any circumstances. No.20. LCS. supply.1. copied.1 LT Switchboards x PDB for CP system : : : 9 CP system panel shall be in safe CLIENT UNIT PROJECT INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER.1.r.1. Any other SLD as required 9 9 9 9 9 9 9 9 7. be totally or partially. without its prior written consent. Supply and Installation of Electrical Equipment EPCM review of Design.t. Description support documents Timely review of calculations and support The present document or drawing is property of TECHNIP KT INDIA LTD. installation. LP/PP.20.

7. Lighting fittings FLP for outdoor areas as required Local control stations (FLP) Bulk items (cable trays. Page 00785 068 JSD 1675 01 A 17/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S.2. as required All consumables required during erection.5 7. 0068. be totally or partially. 7.7 and convenience socket outlets with plugs.2.2.4 7. supply. Panel shall be provided with The present document or drawing is property of TECHNIP KT INDIA LTD. all types of junction boxes.2. 7.2.3 7. copied. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.8 All erection hardwares materials. and shall not.2 7. transferred.3 Interface with EPCM/OWNER Interface with EPCM/ OWNER for scope as defined in cl. . if located outdoor. gauges etc.6 UPS PDB Motorised valve actuators (if any) LT power and control cables. disclosed or used.9 9 9 9 CLIENT UNIT PROJECT INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER.1 Interfacing shall include receiving all necessary information from/to EPCM/Owner for satisfactory completion of work under Bidder’s scope. 7. structural steel. reproduced. directly or indirectly.10 commissioning of Cathodic protection system 7.2. pre-commissioning and commissioning Design.3. glands lugs. installation. 5 of job specification. welding 7.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.Project N° Unit Document Code Serial N° Rev. conduits.2. without its prior written consent.2. hume pipes etc.3. GI canopy. Description Bidder EPCM/ Owner Remarks area. tools.2.2 Forwarding all inputs related to sizing and selection of equipment (under Bidder’s : : : 9 9 9 9 9 UPS system by owner/EPCM 9 9 9 7. No. earthing material. under any circumstances. testing and 7.

7. putting RCC covers etc.1 respective specifications at supplier’s shop and at site as per electrical job specification and approved QC plan 9 9 EPCM’s scope is limited to critical equipment as enclosed in Annexure-I 9 9 9 9 9 CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER.4 Enabling Works Re-routing and relocation of existing cables/ 7. 7. space and floor cut out requirement for installation of TR units. reproduced.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. disclosed or used.4. and shall not. . Proper laying of all cables (both new and old) in the existing cable trenches.Project N° Unit Document Code Serial N° Rev. be totally or partially. without its prior written consent.4. after taking out the cables laid in those trenches and backfilling with sand. testing and commissioning of rerouted/ relocated underground services.2 Installation. No. CP system load requirement etc. copied.4 Construction box culvert type road crossings wherever cable trenches enter unit area Provision of required numbers and sizes of 7. wherever 7. control and signal cables.3 made available to Bidder. transferred. Description scope) to EPCM/Owner with regard to consumer list. 7.1 trenches/ structures over/under ground. under any circumstances.5 hume pipes at the road crossings for power. cable sizes. directly or indirectly.5. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 0068. which are fouling with new construction job. testing of the electrical equipment and systems supplied as listed in the 7. feeder requirement for mounded bullet consumers to EPCM/Owner. Page 00785 068 JSD 1675 01 A 18/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. Bidder EPCM/ Owner Remarks requirement.4. 7.4. Bidder shall also forward input details of cable tray/space requirement in substation.5 Inspection & Testing Inspection. lighting load The present document or drawing is property of TECHNIP KT INDIA LTD.4.

7. be totally or partially.6 Documentation All documentation and drawings as listed 9 7. transferred.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP. Detailed testing.5 material from storage site near the equipment foundation Erection.7. machining etc.6.2 All AS-BUILT engineering drawings & documents All AS-BUILT vendor drawings & documents Erection and Commissioning Site fabrication. 7.6 commissioning of equipment as per approved installation/commissioning 9 CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. .7. directly or indirectly. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.6. without its prior written consent.6.7. under any circumstances.7. to the battery limit of mounded bullets. reproduced.5. Testing and inspection of materials on 9 7.2 commissioning procedures for EPCM/ owners review/ approval 9 7. Page 00785 068 JSD 1675 01 A 19/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S.Project N° Unit Document Code Serial N° Rev.4 receipt at site and to take remedial action for replacement of damaged items Transportation and handling of equipment/ 9 7.3 specifications to be submitted for review/ approval of EPCM/Owner 9 7.3 from substation.7.7 7. and shall not.1 elsewhere with their soft copy on CD with native file. alignment. testing and 9 7.5. Description Any other tests as required/ identified for the equipment during detail engineering QA/QC documents compiled as per Bidder 9 EPCM/ Owner 9 Remarks 7. 0068. pre-commissioning. Construction of RCC built up cable trenches 9 9 9 9 7. copied.3 7. No.2 The present document or drawing is property of TECHNIP KT INDIA LTD.7. Supply of all consumables up to handing over.4 7.6. disclosed or used.1 7.

7. drawings. transferred.9 Commissioning original equipment manufacturer’s scope 7. 0068. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.11 7.10 7. Description procedures. Filled up Performa of field activities & The present document or drawing is property of TECHNIP KT INDIA LTD. be totally or partially.7. etc.8. reproduced. without its prior written consent.1 interfacing/ enabling works not specifically covered above but required for completeness of the project 9 CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – PANIPAT NAPHTHA CRACKER. and shall not.PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.7.8 Trial runs 7. directly or indirectly. Page 00785 068 JSD 1675 01 A 20/20 ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. under any circumstances.7.Project N° Unit Document Code Serial N° Rev.12 Performance tests/ Reliability tests Handing over Training of Owner’s personnel 9 9 9 Owner/EPCM witness 7.7 recording test results for EPCM/Owner approval 9 9 Testing & commissioning shall be under 9 7.7. Bidder EPCM/ Owner Remarks 7. copied. No.7. .8 Miscellaneous Any other works/ services/ materials/ 7. disclosed or used.

directly or indirectly. disclosed or used. Page 00785 000 JSD 1650 01 00 1/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL UNIT PROJECT The present document or drawing is property of TECHNIP KT INDIA LTD. reproduced.Project N° Unit Document Code Serial N° Rev. MATHURA. 26. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. ENGINEERING DESIGN BASIS FOR ELECTRICAL 00 REV. copied.10. LOCATION OWNER EPCM TECHNIP KT INDIA LTD. and shall not. be totally or partially. : FCC UNIT : FCCU AND PRU REVAMP. MATHURA REFINERY. under any circumstances. INDIAN OIL CORPORATION LIMITED. INDIA. without its prior written consent. NOIDA.2010 DATE REVISED AND RE-ISSUED STATUS ABS PREPARED BY DYS REVIEWED BY DYS APPROVED BY CSA PM DOCUMENT REVISIONS Sections changed in last revision are identified by a line in the right margin . transferred. : IOCL.

. transferred............................................................................ Page 00785 000 JSD 1650 01 00 2/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL CONTENTS The present document or drawing is property of TECHNIP KT INDIA LTD........................................... 14................... 9........... under any circumstances......................................................................... 4 SYSTEM DETAILS .. 5. 13... 11... FCCU AND PRU REVAMP. 12............................................. reproduced............................... and shall not............................... 3 CODES AND STANDARDS ... 8................... 1.............................................................................................. 4....................... 11 AREA CLASSIFICATION AND EQUIPMENT SELECTION .......................................................................................Project N° Unit Document Code Serial N° Rev....................................... 3 SITE CONDITIONS ........ 6...................................... without its prior written consent............ 6 PERMISSIBLE VOLTAGE DROP ..... copied... 3 UNITS ............................................................................................................... FCC UNIT....................................... 14 SUBSTATION DESIGN .................... 18 EQIPMENT DESIGN ................... SCOPE ..................... MATHURA.................................................................................... 43 CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.............................................................. 38 LIGHTING SYSTEM... directly or indirectly................ 8 POWER DISTRIBUTION ............................................. 40 COMMISSIONING OF EQUIPMENT ......................... disclosed or used....................................................... 9 SYSTEM CONFIGURATION ................. 10................................................................................................................. 12 PROTECTION – METERING – CONTROL ............................................................................................. be totally or partially................................................................ 2...................... for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use........... 3........................................................................................................... ..... 16.................. 11 CONSTRUCTION POWER : DETAIL TO BE INCORPORATED .................................................. 22 EARTHING SYSTEM .... 7.............................................................. 15............................................................

MATHURA. . and shall not. drawings shall form the basis of Electrical design for developing detail engineering for revamp of FCCU for LPG yield and reliability The present document or drawing is property of TECHNIP KT INDIA LTD. transferred. SCOPE This document along with related specifications. FCCU AND PRU REVAMP. FCC UNIT. directly or indirectly. Page 00785 000 JSD 1650 01 00 3/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 1. following order of precedence shall prevail: • • • • Statutory requirement Engineering design basis Technical specifications .Project N° Unit Document Code Serial N° Rev.data sheets IS Codes and standards 2.Maximum * Dry bulb temperature : : : 36% @ 4º-50ºC 95% : : : : 47ºC 50ºC 2ºC 2ºC 2ºC 0 Design maximum ambient temperature : CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. under any circumstances.Average . copied. disclosed or used. be totally or partially. IOCL. reproduced. UNITS Following units shall be executed based on this document: • • • • • FCCU Revamp Propylene Recovery Unit (PRU) LPG Treater Offsite & Utilities (O&U) Propylene service at Marketing terminal 3. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. improvement at Mathura Refinery. SITE CONDITIONS * * * * * * Maximum temperature Minimum temperature Winterizing temperature Design minimum temperature Relative humidity . In case of any discrepancy / conflict amongst various documents. without its prior written consent.

IS 12360 (1988): . Code of practice for installation & maintenance of power cables up to & including 33kV rating.IS13234 (1992): . directly or indirectly. CODES AND STANDARDS Codes and standards as per minimum requirement shall be as follows: a) Statutory Regulations: Indian electricity act. copied.IS 5571 (2000): .IS 5572 (2009): .IS 4201 (1983): . installation and maintenance of transformers. Code of practice for selection. b) Codes and Standards .Minimum .Average * Altitude above mean sea level 4. Application guide for electrical relays for AC systems.IS 1255 (1983): Guide for short circuit calculations in three phase AC system Classification of hazardous areas having flammable gases and vapours for electrical installations Guide for selection of electrical equipment for hazardous areas. disclosed or used. reproduced. (1998) The factory act. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. . and shall not.Maximum The present document or drawing is property of TECHNIP KT INDIA LTD. FCCU AND PRU REVAMP. under any circumstances.IS 4146 (1983): . Application guide for CT.IS 3842 (2001): . MATHURA. Voltage bands for electrical installation including preferred voltages and frequencies.Project N° Unit Document Code Serial N° Rev. FCC UNIT. Application guide for VT.IS 3961 (2001): . Page 00785 000 JSD 1650 01 00 4/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL * Barometric pressure . for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. : : : : 740 mm Hg < 1000 mm . be totally or partially. Indian electricity rules. transferred. without its prior written consent. Recommended current rating for cables. The TAC rules. The petroleum rules.IS 10028 (2001): .

IS 9676 (1980): . Code of practice fro fire safety of industrial buildings – electrical generating and distributing stations. Application guide for on load tap changers.IS 3034 (1993): . Code of practice for the selection. Recommended practices – inspection & safe practices during electrical installations. . MATHURA.OISD-RP-147 (2002): Recommended practices on static electricity. Application guide for insulation co-ordination. reproduced.IS 5216 (1982): . transferred. be totally or partially. . directly or indirectly. Code of practice for the Protection of buildings and allied structures against lightning.OISD-STD-173 (2003): Fire prevention and protection system for electrical installations.IS 3043 (1987): .IS 7689 (1989): . Code of practice for fire safety of buildings . copied. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Code of practice for earthing.SP-30: Guide for control of undesirable static electricity.electrical installations. under any circumstances. . FCCU AND PRU REVAMP. without its prior written consent. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.IS 732 (1989): .IS 10118 (1982): .IS 13346 (2004): . Code of practice for interior illumination. Code of practice fro electrical wiring installations.IS 2309 (1989): . General requirements for electrical apparatus for explosive gas atmosphere.IS 13408 (1992): . installation and maintenance of switchgear and control gear.IS 6665 (1972): .IS 8478 (1977): . Page 00785 000 JSD 1650 01 00 5/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL . FCC UNIT. Reference equipments. disclosed or used. carbon processing and handling facilities ambient temperature for electrical .IS 3646 (1992): . and shall not. Code of practice for selection. installation and maintenance of electrical apparatus for use in potentially explosive atmospheres. Guide for safety procedures and practices in electrical work. Code of practice for industrial lighting.OISD-RP-110 (1999): .IS 3716 (1978): The present document or drawing is property of TECHNIP KT INDIA LTD.IS 1646 (1997): .OISD-STD-113 (2001): Classification of areas for electric installations of hydro. National Electrical Code (NEC) – BIS Publication.Project N° Unit Document Code Serial N° Rev.

reproduced.IEC 79: . Page 00785 000 JSD 1650 01 00 6/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL -OISD-RP-149 (2001): Recommended practices – design aspects for safety in electrical system. 3 wire. and shall not. gases or vapours and of hazardous locations for electrical installation on chemical process areas. 50 Hz. FCC UNIT. 6. disclosed or used. 4 wire. 50 Hz. 1phase. directly or indirectly.37 kW to up to and including 160 kW For motors less than 0. 50 Hz : 11kV and 6. without its prior written consent. welding receptacles Normal lighting : 240 V AC. 3 phase. 3 phase.NFPA 70B (1994): . practice for electrical equipment . 50 Hz.6 kV : 415 V CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. resistance earthed For 415 V distribution For motors above 160kW For motors from 0. transferred. 5. .NFPA 77 (2000): . 3 wire : 415 V. resistance earthed.6 kV.IEEE 519 – 1992: Recommended practices and requirements for harmonic control in electrical power systems Any other standards may be followed provided it is equivalent or more stringent than the available codes indicated above. 50 Hz. FCCU AND PRU REVAMP.NFPA 497 (2004): Electrical apparatus for explosive gas atmospheres Recommended maintenance National fire alarm code Static electricity Recommended practice for classification of flammable liquids. . .37 kW MOVs. solidly earthed : 6.OISD-GDN-180 (1999): Lightning protection The present document or drawing is property of TECHNIP KT INDIA LTD. MATHURA. 3 phase.Project N° Unit Document Code Serial N° Rev. 3 phase.6 kV. under any circumstances. 3 phase. 1phase. SYSTEM DETAILS In this document • HV implies MV implies Utilization voltages : Main power supply : 11 kV.NFPA 72 (2002): . 50 HZ : 415 V. be totally or partially. 3 wire. copied. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 3 wire. 50 HZ : 415 V AC : 240 V AC.

MATHURA. . disclosed or used. without its prior written consent. 240 V. 1 phase AC up to MCC level shall be derived from individual 0 module 2. be totally or partially. reproduced. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. FCC UNIT. Page 00785 000 JSD 1650 01 00 7/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL Convenience receptacle Critical lighting Control supply The present document or drawing is property of TECHNIP KT INDIA LTD. transferred. copied. and shall not. under any circumstances.6 kV and 11 kV Switchgear Instrumentation supply (Refer Instrument Design basis) Power supply for Fire Alarm system Power supply for Public address system • Emergency Power HOLD • Voltage and frequency variations : : 230 V AC UPS : 24 V DC : 240 V AC non –UPS (For non-critical load) : 230 V AC UPS : 230 V AC UPS : 11kV + 10% : 6. directly or indirectly. 220 V DC for 415 V PMCC . : 240 V AC. 2 wire 1. 1phase.Project N° Unit Document Code Serial N° Rev.6 kV + 10% : 415 V+ 10% : 240 V + 10% : 50 Hz + 5% Combined voltage and frequency variation • System fault level HOLD : + 10%. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. FCCU AND PRU REVAMP. 6. 50 HZ : 220 V DC.

copied. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.Project N° Unit Document Code Serial N° Rev.5% board located remotely Cable between HV switchboard and transformer primary (located near) Bus duct or cable between transformer secondary and HV Switchboard or PCC/PMCC d) Cable between PCC/PMCC and MCC or auxiliary switchboard. i) ii) e) MCC / Auxiliary Switchboard near PCC/PMCC MCC/Auxiliary Switchboard situated remote from PCC/PMCC Cables between HV Switchboard and HV Motor Running-3% Starting-10% f) Cable between PCC/PMCC and motor Running-5. a) b) c) Cable at System Element HV switchboard incomer with sending end Permissible Voltage Drop 2% 2% 0. . Page 00785 000 JSD 1650 01 00 8/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 6.5% CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. directly or indirectly.No. PERMISSIBLE VOLTAGE DROP The maximum voltage drops under steady state conditions at full load shall be within the limits stated in the following table: The present document or drawing is property of TECHNIP KT INDIA LTD. disclosed or used. MATHURA. reproduced.5% 2 to 2. FCCU AND PRU REVAMP. and shall not. FCC UNIT. without its prior written consent.5% Starting-10% g) Cable between MCC (situated near PCC/PMCC) and motors h) Cable between MCC (situated remote from PCC/PMCC) and motors Running-5% Starting-10% 3% 0. under any circumstances. Maximum S. transferred. be totally or partially.

3. For 6. without its prior written consent. copied. Page 00785 000 JSD 1650 01 00 9/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL Maximum S. (BHEL make. Distribution system for instrumentation supplies shall be designed accordingly. directly or indirectly. For 415 V motors starting voltage at motor terminal shall not be less than 80% of rated value. POWER DISTRIBUTION A) FCCU. under any circumstances.11 kV power supply shall be brought to new substation (mentioned as S/S 51 hereafter) for Electrical loads of FCCU revamp unit. 2. . and shall not. System Element Cable between Auxiliary Switchboard & Lighting Panel Circuit between lighting panels and lighting points DC Supply Circuit (Electrical Controls) DCDB to Control Room UPS outgoing circuit Permissible Voltage Drop 1 to 1.5% 4% 5% 2% (Note – 1) 5% (Note-1) i) j) k) l) m) Note: 1.6kV motors starting voltage at motor terminal shall not be less than 90% of rated value. typeVM12) located at TPS substation. be totally or partially. disclosed or used. one panel at each side . MATHURA. 11 kV extension panels shall be installed and integrated with 11 kV Switchgear. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. In case of any conflict between electrical design basis and instrumentation design basis. FCC UNIT. Minimum voltage available across any instrument in the field shall be as per instrumentation design basis. 7. PRU & LPG Treater 0 Two nos. The present document or drawing is property of TECHNIP KT INDIA LTD. transferred. PRU and LPG Treater Unit.No. 11 KV power Cable between TPS to proposed sub station 51 shall have one additional run of CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.Project N° Unit Document Code Serial N° Rev. the latter shall govern regarding instrumentation power supplies. FCCU AND PRU REVAMP. reproduced.

reproduced. --. Switchgear shall feed two nos.433 kV transformers.in substation 11 . and shall not.. Cooling water pump motor shall be supplied from feeder no ----of existing 6. for Load distribution of substation 51. --.6 kV switchgear in DHDS substation to receive power supply. C) Cooling Tower Cooling tower fan motors (3 nos on 415 V) shall be fed from existing PMCC in NHGU substation.Project N° Unit Document Code Serial N° Rev.6 kV transformers and two nos. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. be totally or partially. Third motor shall be supplied from existing motor feeder no. These two extension panels shall feed one no 11 kV Switchgear in Substation 51.and reconnected to 6.in substation 11. without its prior written consent.--.6 kV switchgear no. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. .of switchgear no. Required CTs. 11 kV extension panels shall be in the scope of supply for the Erection contractor. 11 kV switchgear in NHGU substation shall be extended by one panel each on both sides. copied. FCC UNIT.6 kV Switchgear and 415 V switchgear respectively. The transformers shall supply 6. Existing motor fed from feeder no. 11/0. PMCC shall be extended by one vertical panel each on both sides. Refer Overall key single line diagram 00785-000-DW-1652-01. transferred. This run shall be in addition to the runs which are calculated as per the load requirement. under any circumstances. ---and reconnected to PMCC extension panel in NHGU Substation to receive power supply. --. 11/6. This The present document or drawing is property of TECHNIP KT INDIA LTD. shall be disconnected from switchgear no. compatible to the system. One no. disclosed or used. Cooling water pump motors shall be fed from existing 6. MATHURA. protection relays etc shall be provided in existing feeders.in substation 11 shall be disconnected from switchgear no.in substation 11. Existing motor fed from feeder no.in switchgear no. one on each bus section. --. Two nos. Two nos.6 kV switchgear ---. --. Existing MCC shall be replaced with new MCC and available feeder details shall be furnished to TPKTI.of 6. FCCU AND PRU REVAMP. new CT Fan motors shall be fed from extension panels. Page 00785 000 JSD 1650 01 00 10/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL the cable in each of the two feeders. in turn . B) LPG Storage Facility Electrical loads for this facility shall be fed from New MCC 193 in LPG MCC room.-.6 kV switchgear in DHDS substation. directly or indirectly.

directly or indirectly. MATHURA.Project N° Unit Document Code Serial N° Rev. 6. disclosed or used.6 kV switchgear and 415 V PMCCs shall have two bus sections with two incomers and one bus coupler. SYSTEM CONFIGURATION System configuration for 11 kV. FCCU AND PRU REVAMP. under any circumstances. • Auto changeover shall be blocked if both incomers sense under voltage simultaneously. and restore power to the affected section. transferred. . closing of incomer and opening of bus coupler shall be through manual changeover with momentary paralleling between two incomers through synchro check relay. Once affected incomer is restored. CONSTRUCTION POWER : DETAIL TO BE INCORPORATED CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. without its prior written consent. 6. be totally or partially. bus coupler shall be closed through automatic changeover. Page 00785 000 JSD 1650 01 00 11/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL D) Marketing terminal HOLD The present document or drawing is property of TECHNIP KT INDIA LTD. E) Unloading facilities and Panipat Refinery HOLD 8. and shall not. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.6 kV and 415 V switchgears shall be as follows: • • • • 11 kV. FCC UNIT. On failure of any one incomer. reproduced. 9. copied. due to loss of power supply. In normal operation both incomers shall be ON and bus coupler OFF.

Equipment Zone – 1 Gas Group IIA. transferred. be totally or partially.Project N° Unit Document Code Serial N° Rev. 10. IIB Ex-e/Ex-n (refer note2) Ex-e/Ex-n (refer note2) Ex-d Ex-d Ex-d Ex-d Ex-nR Ex-nR Ex-n Ex-d Ex-d Ex-d Ex-d Ex-d Gas Group IIC Ex-e/Ex-n (refer note2) Ex-e/Ex-n (refer note2) Ex-d Ex-d Ex-d Ex-d Ex-nR Ex-nR Ex-n Ex-d Ex-d Ex-d Ex-d Ex-d MV Motors HV Motors Push Button Station Motor Starter (for MOV etc) Plug & Socket Welding Receptacle Lighting Fixtures Ex-d Ex-d/Ex-p Ex-d Ex-d Ex-d Ex-d i) Lighting Fitting and control Ex-d gear box ii) Control Gear Box Junction Boxes Hand Lamps i) Light fitting ii) Transformer Unit iii) Plug & Socket Break glass unit (Fire Alarm System) Lighting panel / power panel Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. under any circumstances. Page 00785 000 JSD 1650 01 00 12/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 10. copied. without its prior written consent.1. . MATHURA. disclosed or used. IIB Gas Group IIC Ex-d Ex-d/Ex-p Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Zone – 2 Gas Group IIA. and shall not. reproduced. FCC UNIT. AREA CLASSIFICATION AND EQUIPMENT SELECTION The electrical equipment for hazardous areas shall be selected as per IS-5571 and petroleum rules. directly or indirectly. The MINIMUM requirement is summarized below: The present document or drawing is property of TECHNIP KT INDIA LTD. FCCU AND PRU REVAMP. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

and shall not. copied. transferred. Irrespective of the area classification (whether Zone-1 or Zone-2). All electric motors for vertical oil sump pumps shall be flameproof type. FCCU AND PRU REVAMP. disclosed or used. e. Else EX-d or Ex-p motors shall be offered. Building such as compressor sheds inside the process area shall be designed to allow adequate ventilation to allow area classification as Zone-2. All electrical equipment installed in Analyzer shelter shall be flameproof type suitable for Gas Group IIA. As additional safety features. In case of Ex-e/Ex-n motors. explosion protection. c. all lighting fixtures within the storage areas shall be flameproof type. IIC irrespective of the area being classified as Zone1 or Zone-2. b. All other electrical equipment shall be suitable for Zone-1 or Zone-2 area depending on extent of CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. . all motors and lighting fittings within the pump house (station) associated with storage area and within the loading/unloading gantries shall be of flameproof type. the following requirements for electrical equipment shall be followed: a.2. without its prior written consent. reproduced. in the shed shall be flameproof type. The electrical equipment for hazardous areas shall generally be suitable for gas group IIA/IIB and temperature classification T3 as applicable to the selected type of The present document or drawing is property of TECHNIP KT INDIA LTD. h. risk analysis shall be carried out as per IS-6381:2004 and IEC 60079-7(2001). for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. All emergency / critical lighting fixtures and associated junction boxes in hazardous areas (whether Zone-1 and Zone-2) shall be flameproof type. EOT crane etc. under any circumstances. MATHURA. directly or indirectly. the gas group to be considered shall be IIC. All electric motors for agitators / mixers and metering pumps handling flammable material shall be flameproof type irrespective of the area being classified as Zone-2 or Zone-1. 10. 2. In case of hydrogen or hydrocarbon mixtures having more than 30% volume hydrogen. IIB. Even though fired heaters in process units are not considered for area classification. d. Irrespective of the area classification (whether Zone-1 or Zone-2). be totally or partially. FCC UNIT. f.Project N° Unit Document Code Serial N° Rev. Page 00785 000 JSD 1650 01 00 13/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL Note: 1. g. considering operational and maintenance conditions. Lighting equipment. all electrical equipments associated with fired heaters in process units shall as a minimum be suitable for installation in Zone-2 area.

for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. MATHURA. Ex-n motors with prestart ventilation provision or Ex-d or Ex-p motors shall be used in Zone-2 areas for application having average starting frequency more than 1 per week. j. Else. k. where rating of motor is more than 100kW. directly or indirectly. l. Elevators.1. 11. transferred. . MOV actuators. without its prior written consent. For Ex-n and Ex-e motors. and shall not. disclosed or used. PROTECTION – METERING – CONTROL Protection devices for power distribution system shall be as indicated below: Transformer Motor Feeder Feeder Second L. Pressurized motors may be provided in case Ex-d motors are not available. EOT cranes. under any circumstances. The present document or drawing is property of TECHNIP KT INDIA LTD. FCC UNIT. reproduced. 0 Relay Number HV Yes 51 51N 51G ID MTL current relay IDMTL backup fault-relay earth- Yes Yes earth.g. Ex-d motors shall be used in Zone-2 areas for HV motors for centrifugal compressors. FCCU AND PRU REVAMP. Ex-d motors shall be provided. Page 00785 000 JSD 1650 01 00 14/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL hazard. i.Project N° Unit Document Code Serial N° Rev. copied. Ex-p motors shall be used for large rating motors where either Ex-n or Ex-d motors are not available.6kV OverYes Yes Yes --Outgoing Feeder HV MV PCC/ PMCC Yes (4) Yes (4) No Yes (7) No Yes Incomer MV PCC/ PMCC Yes (4) Yes (4) No 11. Ex-d motors shall be used in Zone-2 areas for motors having frequent start/ stop requirements e.433 voltage KV) 6.V ary winding winding HV < 0. the appropriate risk assessment factors shall be worked out taking operational and maintenance conditions. All motors for hazardous area Zone-1 shall preferably be flameproof type. m. be totally or partially.Yes (6) fault-relay (secondary Yes neutral) Motor protection relay No Yes -- No No Yes No No No CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.

V ary winding winding HV < 0. transferred. Page 00785 000 JSD 1650 01 00 15/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL Transformer Motor Feeder Feeder Second L. reproduced. 49. and shall not.433 voltage KV) 6.Project N° Unit Document Code Serial N° Rev. directly or indirectly. be totally or partially. . copied. MATHURA. without its prior written consent. 50L/R) 64R instantaneous earth-fault No Yes -No No No Yes restricted 50 50N 87 relay (secondary side) instantaneous over-current relay earth-fault relay protection relay 86 tripping relay 95 63 trip auxiliary circuit relay Yes Yes Yes No Yes Yes Yes --Yes (2) Yes Yes -Yes ----No (13) ---Yes --Yes (5) Yes (8) Yes Yes Yes (5) Yes (8) No No Yes (3) Yes Yes No No No No Yes No No No No Yes Yes Yes No No No No Yes Yes (13) No instantaneous Yes (6) (1) Yes Yes Yes differential Yes supervision relay (transformer) PT Fuse monitoring (Block U/V trip) 27. FCCU AND PRU REVAMP. 46.2 25 Cable protection Feeder management relay CLIENT UNIT PROJECT : : : under voltage check relay with timer synchronization relay differential INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. disclosed or used.6kV rotor Outgoing Feeder HV MV PCC/ PMCC Incomer MV PCC/ PMCC Relay Number The present document or drawing is property of TECHNIP KT INDIA LTD. FCC UNIT. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 50N. HV with locked feature (50. under any circumstances.

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ENGINEERING DESIGN BASIS FOR ELECTRICAL Notes: (1) (2)
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

For transformers rated 5 MVA and above For motors rated 1500 KW and above For critical / long feeders and plant feeders connected to main power generation and distribution bus. DC supply shall be extended to remote substation implemented. 0

(3) (4) (5) (6) (7) (8)

Wherever auto transfer feature is provided proper logics as discussed above to be Instantaneous earth fault 50N shall be provided only for transformer with delta primary. For motor feeders rated 75 kW and above. For switchgears having bus transfer scheme, where continuous or momentary paralleling is envisaged, check synchronizing relay shall be integrated with overall paralleling scheme.

(9)

The bus tie feeders in HV switchboards shall be provided with 51, 51N, 86 and 95 relays. All HV switchboards will have bus differential protection with C.T circuit supervision. There shall be overlapping of zones such that no blind spots are left in the system. For this CT location must be checked before finalizing the vendor drawings. 0

(10) HV and MV breaker controlled motor feeders or contactor feeders with DC control supply, shall be provided with timers for delayed tripping on bus under voltage while the under voltage relay shall be common for the bus. Under voltage relay will sense all three phases and tripping shall be blocked in case of P.T fuse failure. (11) All HV switchboards shall have two sources of DC supply for redundancy. supply to the switchboard. (13) Trip circuit supervision shall be provided as part of numerical relay in switchgear. (14) Numerical relays shall be comprehensive units with all protection, metering and control and communicable with existing ECS system in the refinery. (15) 2 nos. of Master Trip (86) relays shall be considered for all breaker controlled motors. One self reset type (flag hand reset) for process trip, another manual reset for electrical trip. Both relay actuation shall be recorded through numerical motor protection relay.
CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.

0

(12) One No. DC supply supervision relay (80) shall be provided for each incoming DC

0

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ENGINEERING DESIGN BASIS FOR ELECTRICAL (16) Motors below 30 kW shall be provided with ELCB .Motors above 30 kw shall be provided with suitable earth leakage relay with CBCT. (17) deleted
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

(18) Under frequency load shedding relays to be provided in each HV switchboard. At least six stages of under frequency settings are to be provided. Manual load shedding command from TPS should also operate the load shedding relays. For tripping individual feeders self reset type VAJ relays to be envisaged. 0

11.2.

The metering devices in HV and MV Switchboards shall be as below: Feeder Type HV Incomer HV Bus Tie HV Transformer HV Bus P. T HV Feeder HV Motor X X X Plant X X X X A(3 X X X V(3 X Hz X PF X KW KWH X X Hour Run KVAR KVAH KVA

phase) phase)

PCC/PMCC Incomer PCC PMCC
CLIENT UNIT PROJECT : : :

X / X

X -

-

X -

-

X -

-

-

-

-

INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.

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ENGINEERING DESIGN BASIS FOR ELECTRICAL Bus Tie PCC P.T
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

Bus

X X X X

X X -

-

-

-

X X

-

-

-

-

ACB outgoing MV Motor (> 75kW) MCC/ASB Incomer MCCB/SFU Outgoing (> 250A) LDB Incomer 1) 2)

X

X

-

-

-

-

-

-

-

-

Ammeter shall be provided at field for motors rated 30 kW and above. Comprehensive metering shall be part of numerical relay, wherever numerical relay is provided. Separate microprocessor based energy meter connected to metering C.T will be provided .Metering data shall be communicable to ECS system through numerical relay/ intelligent energy meter. 0

12. A)

SUBSTATION DESIGN FCCU, PRU and LPG Treater One new substation shall be designed for FCCU, PRU and LPG treater. This substation shall be located adjacent to substation 39. 1) This substation shall house 11 kV switchgear, 6.6 kV switchgear, 415 V PMCC/MCC, auxiliary switchboard, Main lighting distribution board, lighting transformer, DC battery charger, VFDs, DCDB, RTU panels, NGR, 11/6.6 kV and 11/0.433 kV distribution transformers as required. 2) Substation shall be maintained at a positive pressure through pressurization system in the switchgear rooms. It is to be ensured that the inlet air of the pressurized system shall be free from

CLIENT UNIT PROJECT

: : :

INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.

Project N° Unit Document Code Serial N° Rev. Pressurisation duct arrangement shall take into due consideration MV bus duct layout. reproduced. The present document or drawing is property of TECHNIP KT INDIA LTD. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Name. FCCU AND PRU REVAMP. address and telephone number of nearest doctor shall be mentioned in it. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. directly or indirectly. MATHURA. and shall not. Positive pressure of 2 mm of Hg shall be maintained inside the substation. without its prior written consent. . Substation building shall be preferably without any columns within the switchgear room to ensure optimum space utilization. The cable cellar shall have a minimum clear height of 2. FCC UNIT. 11) Switchgear room shall be provided with the following minimum equipment: a. The battery rooms shall be provided with exhaust fans and louvered opening in opposite wall/door. Framed laminated shock treatment chart. 6) Substation wall adjacent to the transformer bays shall be either 355 mm thick brick wall or 230 mm thick RCC wall. conforming to IE rules. A separate entry for operating personnel and also an emergency door opening outwards shall be provided in the substation. under any circumstances. be totally or partially. first aid boxes and other safety equipment as per statutory requirements. The cable cellar floor shall be 500 mm above the approach road level and shall be paved and cemented. 8) VFD’s . 0 9) Substation lighting shall be controlled by push button stations located at the entrance. 3) Sub-station floor shall be raised above grade level and the space below the switchgear room shall be utilized as cable cellar. supports etc. Rubber mats of required voltage rating shall be provided around all the switchboards and panels. where Switchboards are installed suitably sloped ramp for transition between the floor and the switchgear bottom plate shall be provided to allow easy installation and removal of any draw out devices. Floor of the battery room and walls up to 1. copied. along with necessary flameproof exhaust fan and other electrical fittings and switches and water connection with sink. transferred. Light fittings in this room shall be chemical resistant and flameproof type. UPS (if any). in English and local language.0 m with rolling shutter shall be provided for entry of equipment. Page 00785 000 JSD 1650 01 00 19/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL moisture and hazardous mixtures. 4) An entry of 3. will be installed in air conditioned environment.5 m and shall house all cable trays. 7) Battery bank shall be located in a separate adequately ventilated room in the substation building.0 m height shall have acid/alkaline resistant protective material coating/tiling. disclosed or used. 5) In the Substation Room. The roof shall be given adequate water proofing treatment to ensure that rain water does not seep into the substation. 10) Substation shall have fire fighting equipment. Chargers .

Where oil capacity CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. f.5 m high removable chain link fence with a lockable gate at the open side. c. 100 A outlet shall be provided for oil filtration and other maintenance. earthing rod. disclosed or used. FCC UNIT. without its prior written consent. LT megger (2 nos. HT megger m. o. copied. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. g. and shall not. Page 00785 000 JSD 1650 01 00 20/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL b. i. l.Project N° Unit Document Code Serial N° Rev. be totally or partially. complete with rechargeable battery. Easily accessible first aid box containing ointments and medicines for treatment of electrical burns. d. Each bay shall be provided with 2. transferred. directly or indirectly. Self contained portable hand lamp. Earthing truck (for both circuit and bus). Caution notices shall be provided for all energized electrical equipment. Fire extinguishers and round bottom fire buckets filled with clean dry sand shall be provided in each transformer yard. Discharge rod (2 nos. FCCU AND PRU REVAMP.) n. 12) Oil filled distribution transformers shall be located in bays adjacent to the substation building. One no. Tools for working on HT Panels and LT panels (if required) . e. j. Laser temperature measurement guns (2 nos. Breaker handling trolley (2 nos. 14) Oil immersed transformer with oil capacity exceeding 2000 litres shall be provided with a soak pit of sufficient capacity to accommodate entire volume of oil. Height of the bay shall be decided so as to facilitate maintenance and easy removal of equipment and requirements of natural ventilation. under any circumstances. Round bottom fire buckets filled with clean dry sand. MATHURA. 13) In every transformer bay one no. Framed single line diagram (AC and DC). Adequate number and size of CO2 fire extinguishers and dry chemical powder suitable for dealing with fire. The present document or drawing is property of TECHNIP KT INDIA LTD.) p. Transformer bays shall have well drained floor. Partition walls between transformer bays and the end wall of the last bay shall be of fireproof type and shall extend at least 600 mm above the height of the equipment. Minimum 1000 mm clearance shall be provided all round the transformer.) 0 k. h. surfaced with gravel or other suitable material. conforming to IE rules.) Supply of above equipment shall be in the scope of Erection contractor. Portable battery operated emergency light. reproduced.

together with cable cellar and panels shall have provision for 20% future expansion. be totally or partially. single/double tier . without its prior written consent. disclosed or used. copied. Page 00785 000 JSD 1650 01 00 21/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL of transformers exceeds 9000 litres. reproduced. FCCU AND PRU REVAMP. directly or indirectly. through suitable drain pipes of 150 mm or 200 mm in diameter. FCC UNIT. annunciation / 2500 mm control panel. Space for two adjacent panels for future extension on each side of switchboard shall be maintained. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.Double row. Following minimum clearances around various equipments shall be maintained: Front clearance for HV switchboard Front clearance for all other switchboards / panels Between front to front of different switchboard / panels Rear clearance for panels having maintenance access from front only 2500 mm 2000 mm 3000 mm Less than 200mm or more than 800mm 0 Rear clearance for panels requiring maintenance from 1500 mm rear Side clearance between two boards or from nearest 1500 mm obstruction (but not less than twice the width of each panel) All-round clearance Battery rack to wall clearance for Single row. Substation. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. PMCC and MCCs panels can be extended in either side for minimum 2 no panels on either side in future. .Project N° Unit Document Code Serial N° Rev.Double row. Minimum vertical clearance above the top of highest equipment shall be minimum 1500 mm measured from bottom of roof slab and minimum 500 mm measured from the bottom of the lowest roof beam. and shall not. MATHURA. transferred. single tier . The present document or drawing is property of TECHNIP KT INDIA LTD. double tier Between battery racks Front clearance for wall mounted equipment 1000 mm 100 mm ( increase to 300 -400 mm)) 100 mm( increase to 300 -400 750)) mm 750 mm 1000 mm Head room clearance below bus ducts or any other 2000 mm overhead equipment Front clearance for operation station. provision shall be made to drain away the oil to a separate waste oil tank/pit located away. 15) The substation building shall be sized to take care of present and future needs and to maintain the adequate clearances between equipment for ease of maintenance. 16) The sub station shall be designed such that all new HT panels. under any circumstances.

Incoming power shall be taken from existing substation only. FCCU AND PRU REVAMP. transferred. 2) HV extension panel breaker rating shall be suitably rated for total electrical load down stream. For distribution details refer clause 7. reproduced. EPCM contractor shall extend existing substation and provide new panel for Propylene service. DHDS and Substation 11. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Existing MCC shall be replaced with new MCC and existing feeder details shall be furnished to TPKTI. 0 C) Cooling Tower Cooling tower electrical loads shall be supplied from NHGU substation. under any circumstances. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. All cables shall have FRLS outer sheath. without its prior written consent. type VM12) shall be provided in TPS substation.6 kV Switchgear shall be provided in New substation 59.Project N° Unit Document Code Serial N° Rev. If space /supply feeders are not available. 18) 19) B) Cable cellar shall be provided with exhaust fans for adequate ventilation. FCC UNIT. copied. . 11 kV and 6. and shall not. and similarly for outdoor equipment entry point.1. E) Unloading facilities at Panipat refinery HOLD 13. The present document or drawing is property of TECHNIP KT INDIA LTD.c. MATHURA. 0 13. No new substation is envisaged. directly or indirectly. Fire barriers shall be installed at substation building cable entry points. disclosed or used. Page 00785 000 JSD 1650 01 00 22/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 17) Fire proofing of cables shall be done for 1 m length at indoor equipment entry point. EQIPMENT DESIGN HV Switchboard/ HV Extension panel 1) HV extension panel on either side of 11 kV switchgear 7A/8A (BHEL make. 11KV board to be extended on both sides by 1 feeder each in NHGU substation. be totally or partially. Transformer bay shall have clear approach road for movement of crane / Hydra. D) Marketing Terminal (HOLD) Existing substation shall be utilized for this facility. LPG Storage facility Electrical loads for this facility shall be fed from New MCC 193 in LPG MCC room.

2 times rated peak line to earth voltage. rods. circuit breaker only. 0 7) All breakers shall be horizontal isolation draw out type VCB.T. tripping. 16) Rating of CBs / contactors used in motor feeders shall be 125% of maximum continuous rated current of motor. Trolley shall have SERVICE.D values less than 20 pc and window type CTs are to be used for high ratings. 0 0 14) Auto changeover circuit supervision and remote and local indication shall be provided 0 . under any circumstances.Project N° Unit Document Code Serial N° Rev.6 kV Switchgears and Line PTs and bus PTs shall be in separate compartments and shall not be part of incomer breaker or outgoing feeder breakers. FCCU AND PRU REVAMP. 13) All breaker contacts shall be silver plated. 5) Short circuit rating for 6. All protection CTs except class PS shall be of minimum 5P10 class. disclosed or used. 12) All panels shall have peeping infra-red window at the rear for thermo graphy. breaker lifting trolleys shall be provided. MATHURA. The TEST position shall be within the cubicle. each having locking facility. and shall not. be totally or partially. 11) 11 kV and 6. Direct contact of breakers. 18) Earthing trolleys. These positions shall have limit switches with auxiliary contacts for interlock. copied. maintenance and replacement. A flexible duty interlocked plug and socket arrangement with scrapping earth terminals shall be used for auxiliary supply. TEST and ISOLATION positions. FCC UNIT. 17) Normal and standby loads shall be evenly distributed on both bus sections. Page 00785 000 JSD 1650 01 00 23/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 3) HT switchgear. Surge arrestors shall be of adequate rating and located near the cable termination after bus differential C. PTs shall be easily accessible for testing. closing etc. Surge arrestors shall be provided for this purpose.kA for 3 sec. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. All CTs shall have P. directly or indirectly. Normal and standby loads shall be fed from different bus sections. 15) For VCBs. master trip relays etc shall be used for interlocking. over voltage due to motor switching shall be limited to 2. 4) Short circuit rating for 11 kV Extension panel and switchgear shall be 40kA for 3 sec. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. 6) Each vertical section shall consist of 1 no. without its prior written consent. transferred. 10) Contact multiplication shall preferably be avoided. CB shall be operable in SERVICE and TEST positions with the cubicle door closed. 9) Interlock of upstream breaker shall be taken in closing and tripping circuits of incomers. The present document or drawing is property of TECHNIP KT INDIA LTD. 8) All protection and metering CTs. reproduced. fed from transformers shall be rated for at least equal to the continuous rating of transformer considering site ambient conditions. for the same.6kV switchgear shall be ---.

The present document or drawing is property of TECHNIP KT INDIA LTD. 13. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. with off circuit tap changer having range of plus ±5% in steps of 2. Page 00785 000 JSD 1650 01 00 24/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 19) Marshalling cabinet shall be provided for DCS / PLC interfacing in the switchgear itself. MATHURA. PT secondary shall be 110VAC.e. 20) Spare outgoing feeders shall be provided in HV Switchgears (not extension panels). ONAN cooled. 24) Provision for 20% spare feeders to be kept. breaker / bus / cable compartments shall also be provided with metal barrier sheets.9 kV transformer shall be: Primary – through cables Secondary – through cables 2) Power connection for 11/0. copied. under any circumstances.9 kV b) 11/0. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. suitable for outdoor use. FCC UNIT. 22) Failure of DC control supply shall not trip any breaker.433 kV transformer shall be: Primary – through cables Secondary – through bus duct 3) Distribution transformers shall be three-phase. . During outage of one transformer.5%. FCCU AND PRU REVAMP. transferred.2. reproduced. with minimum of 2 spare feeders( one on each side of panel). 0785-000-1652-01. refer Standard specification of HT Switchgear doc no. and shall not. other healthy transformer shall be loaded to 80% of rated capacity. 21) HT switchgear shall be metal clad only. boltless design.Project N° Unit Document Code Serial N° Rev. For all other design requirement. At least one number of each rating and type or 20% whichever is more shall be provided as spare on each bus section. disclosed or used. 4) Transformer rating shall suit 20% spare capacity with 100% load as basis. each transformer shall be loaded to 40% of rated capacity.433 kV 1) Power connection for 11/6. Terminal block shall have provision for termination of armoured multicore copper cables. During normal operation. i. oil immersed. be totally or partially. double wound type. 23) CT secondary shall be 1A for both metering and protection. All the three compartments. Transformers Distribution transformers shall be with following turn ratio a) 11/6. directly or indirectly. without its prior written consent.

be totally or partially. Due consideration shall be given to the starting current of large motors. 9) Lighting transformers shall be ANAN type.Project N° Unit Document Code Serial N° Rev. 0785-000-1641-02. transferred. 7) Distribution transformers shall be of low loss type.5 MVA The present document or drawing is property of TECHNIP KT INDIA LTD. 0785-000-1641-03. and shall not be less than 99. 6) Transformer rating and impedance shall be selected in order to limit short circuit current to values within the current rating and rupturing capacity of switchgear and also to permit the DOL starting of the largest motor without exceeding the permissible voltage drop limit. refer Standard specification of Distribution Transformer doc no. FCC UNIT. However. 13. 8) Distribution Transformers shall be supplied with required accessories. without its prior written consent. under any circumstances. 2) Separate feeders shall be provided in the switchboard for each load/motor. Transformer sizing shall take care of minimum 8 hours maximum demand. reproduced. refer Standard specification of Dry Transformer doc no. FCCU AND PRU REVAMP. Maximum efficiency shall occur at about 40-50% of ONAN rating. For design requirement. Number of such distribution transformers shall be decided based upon the total load requirement. and shall not. 1) Starters for the motors in general shall be provided in PCC/MCC located in substation. . For list of accessories and other design requirement. Page 00785 000 JSD 1650 01 00 25/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 5) The maximum rating shall be 2 MVA. maximum can be considered as special case. with provision for 20% future requirement. starters (suitable for classified area) shall be provided by the package vendor in the field near the motors . disclosed or used. However in special cases like MOVs & EOT cranes etc. MV Switchboard Switchboard Rating shall be at least equal to maximum demand under any circuit configuration. as an exception maximum two numbers welding receptacles may be connected to one power feeder. directly or indirectly. 4) Motors rated upto and including 55 kW shall be fed from MCC and provided with DOL starter.5%. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. MATHURA. 3) Motors rated 30 kW and above shall be provided with a CT in MCC for connection of an ammeter in the local control station. copied.3. Transformer of rating up to 2.

in case number of motors is not many for one unit/switchgear. disclosed or used. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. transferred. 13) PMCCs shall be suitable for bus duct top entry. 6) However. 20) Wherever motors are fed from existing switchgears. MCCs shall be suitable for bottom cable entry. shall be provided in switchgear. 17) Local/remote selector switch shall be mounted at field. . 15) ACBs shall be provided with minimum 4 NO +4 NC spare auxiliary contacts wired up to terminal box. may be fed from same PMCC. Under voltage tripping in PMCC shall be inhibited if voltage dip is transient or if it occurs on both incomers simultaneously. Page 00785 000 JSD 1650 01 00 26/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 5) Motors above 55 kW and upto and including 160 kW shall be fed from PMCC and provided with ACB and motor protection relay. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. 10) All breakers in PMCC shall be provided with suitable numerical relays communicable with Existing ECS system in the refinery. 21) For all other design requirement. 16) Contactors shall be air break type with 3 main contacts and 3 NO+3 NC contacts. reproduced. if required by process. in case of space constraint. FCC UNIT. No switch fuse feeders shall be used in PMCC. refer Standard specification for MV switchgear/distribution board doc no. subject to prior discussion and concurrence with OWNER.Project N° Unit Document Code Serial N° Rev. double front MCCs may be provided after prior discussion with OWNER. under any circumstances. 14) MCCs shall preferably be single front. 12) MCCs shall have mechanical interlock and manual changeover facility between incomers and bus coupler. 11) PMCCs shall have auto changeover facility. and shall not. be totally or partially. without its prior written consent. FCCU AND PRU REVAMP. directly or indirectly. cables for interface with DCS/PLC shall be taken to control room from individual feeders directly. However. MATHURA. 9) All PMCC feeders shall be with ACBs. 00785-000-STD-1654-01and single line diagrams of individual switchgear. all motors The present document or drawing is property of TECHNIP KT INDIA LTD. 7) Minimum rating of ACB incomers for MCC shall be 800A 8) Motor feeders shall be provided with IEC type-2 co-ordination. 19) Separate Marshalling cabinet shall be provided in the new Substation for switchgear and DCS/PLC interface requirements. copied. 18) Reacceleration facility.

Vertical motors shall have thrust bearings. 13. 3) Only standard output (kW) ratings of motors shall be used. non-inflammable and flame retarding type. under any circumstances. 4) Sleeve or anti friction type bearings shall be used. 13. corrosion proof joint less stainless steel grids. transferred.4. . 00785-000-STD-1653-09. 2) The bus bar material shall be electrolytic aluminium / copper. The present document or drawing is property of TECHNIP KT INDIA LTD. refer Standard specification for MV Bus duct doc no. NGR Neutral Grounding Resistor (NGR) shall be housed in a sheet metal enclosure and shall be naturally ventilated. without its prior written consent. The resistor shall be of unbreakable. 5) Material shall be same as that used for switchgear bus bars. copied. 6) Terminal box of HT motors shall be Phase insulated / Phase separated / Phase segregated / Pressurized with elastimold connector and shall withstand specified 0 CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. 4) Outdoor bus duct shall be weather proof IP55 and shall be provided with suitable seal and canopy. 6) Space heater with auto cut-off shall be provided at suitable location. 3) Bus insulators shall be non-hygroscopic. The grids shall be in punched form. MATHURA.6. 2) Motors rated 1500 kW and above shall be provided with soft start facility. Page 00785 000 JSD 1650 01 00 27/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 13. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. be totally or partially. 7) Continuous earthing strips of proper sizes shall be provided on the two sides of the bus duct.5. FCC UNIT. 5) HT motors shall have 6 nos duplex RTDs for winding temperature detection. The NGRs shall be rated to withstand the fault current for 10 seconds. reproduced.Project N° Unit Document Code Serial N° Rev. disclosed or used. FCCU AND PRU REVAMP. maximum rated with possible exception of crane and hoist motors. insulation class F with temp rise limited to class B. for connection with the earthing grid. Motors 1) All motors shall be IP 55. directly or indirectly. Dual dial type temperature indicator without contacts for bearings shall also be provided. and shall not. Motors shall be continuous. 2 nos bearing temperature detectors with suitable scanners (with provision of alarm and trip output). MV Bus Duct 1) MV bus duct shall be non phase segregated type. 8) For all other design requirement.

22) U/V protection provided for motor as well as transfer scheme shall be comprehensive and sense all three-phase voltages. Ammeter shall be provided for space heater circuit on switchgear. 12) Winding and bearing temperature alarm and trip shall be provided for HT motors. 10) Motors rated 75 kW and above shall have space heaters. 18) Instantaneous earth fault tripping shall be provided in motor feeders with residual connection and variable stabilising resistor. 11) Difference between starting time of motors at 80% voltage and hot thermal withstand time at 100% voltage shall be minimum 3 sec. Insulation for these motors shall be designed for 140% of rated insulation level. FCCU AND PRU REVAMP. The under voltage protection shall operate only on under voltage of all three phases and shall be blocked on tripping of PT MCB. reproduced. copied. 8) Starting current shall be limited to 600% on DOL. 14) All motor terminal boxes shall be on the right hand side of the motor viewed from driving end. directly or indirectly. transferred. A separate neutral terminal box shall be provided for making star connection. if so required by process. without its prior written consent.Project N° Unit Document Code Serial N° Rev. Page 00785 000 JSD 1650 01 00 28/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL short circuit current for 0. Minimum 10% additional RTD points shall be provided.25 sec. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. 9) Reacceleration of motors. The present document or drawing is property of TECHNIP KT INDIA LTD. MATHURA. Reduced voltage starting by soft starter may be used if starting voltage drop limits cannot be maintained by DOL starting method. 7) Motors shall be capable of 20% over speed. under any circumstances. 19) Auto start schemes shall be designed in instrument PLC. be totally or partially. shall be provided for interruption in normal power supply up to 5 seconds. 15) Terminal box of the motor shall be suitable for rotation by 90o. FCC UNIT. The under voltage input to the relay for motors shall be derived from bus PT. and shall accommodate CTs for differential protection. 17) Surge suppressor shall be provided in VCB operated motor feeders. disclosed or used. and shall not. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 21) Numerical relays for motors shall have RTD and BTD support feature and the RTDs and BTDs of the motors may be hooked up to the respective numerical relay for alarm / trip provision. . 13) EEx-d gr IIC motors with top terminal box shall be provided with extended shaft. 20) Voting logic shall be provided in auto start schemes of motors. 16) All outdoor motors shall be provided with canopy.

PRU and LPG treater UPS power for instrument load. 25) For Excitation Panel of Synchronous Motors Single Phase Bridge to be considered. FCCU AND PRU REVAMP. 26) All motors to have canopies. reproduced. Another DC system shall be CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. 0 0 . 24) All breaker operated motors shall be provided with TNC switch at the local control station.Project N° Unit Document Code Serial N° Rev. directly or indirectly. PRU and LPG treater 1) Two nos.7. UPS System A) FCCU. The same is required for Reliability Improvement ( So That Single Phase UPS SUPPLY CAN BE GIVEN TO BRIDGE).8. B) LPG Storage Facility HOLD C) Cooling Tower HOLD D) Marketing Terminal HOLD E) Unloading facilities at Panipat refinery HOLD 13. separate 220 V DC system with battery bank. Page 00785 000 JSD 1650 01 00 29/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 23) Under voltage relay contact multiplication shall be provided through self reset relay. There shall be no UPS power DB in field. MATHURA. if required. 13. without its prior written consent. and shall not. charger and DC distribution board shall be provided in new Substation. transferred. The present document or drawing is property of TECHNIP KT INDIA LTD. New UPS Power distribution board shall be provided. be totally or partially. Fire alarm system. Public address system and for any other requirement shall be obtained from existing UPS system located in Main control room of refinery. One DC system shall be utilized for switchgear control supply and Owner’s future requirement. disclosed or used. FCC UNIT. copied. under any circumstances. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Battery charger and DCDB A) FCCU.

15) Incoming supply to battery chargers shall be through either circuit breakers or switch fuse units. shall be obtained from LPG MCC room -----. 14) DCDBs shall be provided with semiconductor fuses for fast isolation. 0 3) Each battery bank. 10) One summary fault contact shall be provided for remote alarm. be totally or partially.Project N° Unit Document Code Serial N° Rev. 11) DCDB shall have three incomers and one bus coupler. under any circumstances. copied. and not through contactors. 12) DCDB incoming and outgoing cables shall be copper cables. FCC UNIT. 9) Rating of charger shall be suitable for trickle / boost charging of batteries and to feed the DC loads. 7) All electrical equipment inside battery room shall be flameproof. and shall not. 17) Boost charging alarm and critical battery charger alarms shall be provided at manned location / control room. transferred. The present document or drawing is property of TECHNIP KT INDIA LTD. --- CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. B) LPG Storage facility DC supply. charger & DCDB shall have at least 25% spare capacity to meet future requirements. Page 00785 000 JSD 1650 01 00 30/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL utilized for critical lighting. 16) DC ground fault scheme shall be provided in the DC systems. 4) Each DCDB shall be provided with at least 20% spare feeders. 0 13) Battery charger shall be provided with ripple overshoot annunciation. reproduced. with 25% spare capacity. FCCU AND PRU REVAMP. . 18) Autostart facility for chargers to be provided to avoid manual start of chargers during system under-voltage conditions. refer standard specification of DC battery and charger. DCDB no. Both chargers shall have configuration of 2 Float cum-boost chargers with common battery bank. directly or indirectly.00785000-STD-1672-01. if required. MATHURA. 5) Minimum battery backup shall be as follows: a) 2 hours for switchgear b) 30 minutes for DC critical lighting 6) Isolator shall be provided near battery. 2) Batteries shall be vented Ni-Cd type. 8) Charger shall have dual parallel redundant modules of float and boost charging units. without its prior written consent. For all other requirement. disclosed or used. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

--E) Unloading facilities at Panipat Refinery DC supply. DCDB no. . call station shall be provided in new substation ---. shall be obtained from NHGU substation -----. Communication System 1) Stand alone Plant communication system shall be provided for FCCU revamp. rotating beacon shall be provided. --The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not. 2) Suitable surface treatment (blast cleaned to SA 2 ½ surface finish) with Polyurethane / Poly-Urea coating shall be provided over mounded bullet. disclosed or used. 13. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Required number of Field call stations shall be provided in plant unit. MATHURA. One no. if required. without its prior written consent. 5) The vendor shall have the necessary application equipment like plural component airless spray equipment and blast cleaning equipment and all suitable inspection instruments. 4) Where it is not possible to achieve required dB above surrounding noise level. reproduced. --13. copied. Page 00785 000 JSD 1650 01 00 31/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL C) Cooling Tower DC supply. directly or indirectly. if required. be totally or partially. shall be obtained from existing substation -----. 3) Thorough electrical isolation of CP system shall be ensured. if required. 3) Speakers shall produce a sound level at least 10 dB above ambient noise level. Master call station and exchange shall be located at Main control room.10. DCDB no. transferred. D) Marketing Terminal DC supply. The vendor shall submit the completion/ performance certificate for the job done in past 5 years. 4) This job shall be executed as supply and apply basis with necessary guarantees. under any circumstances. 2) Integration with existing communication system shall not be provided. shall be obtained from existing substation -----. FCCU AND PRU REVAMP. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Corrosion Protection 1) Sacrificial anode cathodic protection system shall be provided for mounded bullets for corrosion protection. DCDB no. PRU and LPG Treater unit. FCC UNIT.9.Project N° Unit Document Code Serial N° Rev.

9) The system shall have facility for manual / auto recording of conversation. under any circumstances. 0 13. and shall not. Page 00785 000 JSD 1650 01 00 32/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 5) It shall be possible to communicate between two field stations without the interference of MCS / operator. PRU and LPG treater units. The present document or drawing is property of TECHNIP KT INDIA LTD. For other requirements. 0 . refer Standard specification for Public Address system 00756-000-STD1630-02. be totally or partially.11. FCC UNIT. 10) The system shall have at least 30% spare capacity after meeting all requirements of the process units. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. disclosed or used. 8) The system shall have features like status monitoring. PRU and LPG treater units. desk mounted sets shall be provided in FCCU Revamp. of Flameproof telephone terminal boxes with crone type connector shall be provided at field for hooking up with existing EPABX located at -------. Required no. Telephone System Adequate number of flameproof telephones shall be provided in FCCU Revamp. transferred. 00785-000-DW-1665-04. refer Standard specification for Telephone system 00756-000STD-1630-03.13. copied. without its prior written consent. 13. For other requirements.Project N° Unit Document Code Serial N° Rev. directly or indirectly. of handheld walkie talkie sets and 5 nos. MATHURA. 6) System shall have battery backup of 8 hours in case of power failure. Fire detection and Alarm system 1) Stand-alone Fire alarm system shall be provided for the following areas: • • • CLIENT UNIT PROJECT Substations ( substation nos -----------------) Existing Control room New control room : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. and also to have direct communication with MCS. Telephone arrangement shall be as per telephone block diagram no. FCCU AND PRU REVAMP. 13. reproduced. 11) Plant communication system shall have Interlock with Fire alarm system. fault diagnostics and report generation. 7) The central exchange shall have redundant CPU. Walkie Talkie system 15 nos.12. and shall be able to broadcast pre-recorded messages.

PRU. 2) FA system loops from above areas shall be hooked to Central Fire Alarm Panel in fire 3) Fire alarm system shall be analogue addressable type. 9) Interlock shall be provided between new substation fire alarm system and pressurization system (Pressurisation blowers to trip sensing fire or gas release in Substation). dry cured XLPE insulated. insulation screened. 13. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Required RTU shall be provided in the substation for this purpose. be totally or partially. 0 5) Fire resistant armoured pink colour cables shall be used for the system. MATHURA. Integration with existing system shall not be required. FRLS PVC inner sheathed armoured & FRLS PVC outer sheathed. if required.15.Project N° Unit Document Code Serial N° Rev. Fibre optic cable shall be used for long distance. LPG Treater plant units LPG storage control building. reproduced. Switchgears in new substation 59 shall hook up to existing Honeywell ECS system. without its prior written consent. Cables 1) In general. FCC UNIT. shall be considered. all HV cables shall be with stranded aluminium conductor. 7) Detectors shall be provided inside substation. and shall not. directly or indirectly. 4) Repeater panel . copied. 6) Detectors and manual call points shall be connected in separate loops. FCCU AND PRU REVAMP. refer Standard specification for Fire Alarm STD-1630-01. disclosed or used. 8) The system shall have 30% spare loop capacity for future expansion. If existing system is not adequate for accommodating the additional I/ Os. FCCU revamp. The screen for the HV cables shall withstand earth fault current for one 0 system 00756-000- CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. For other requirements. additional card may be installed in the system. exit and generally at a travel distance of 30 m. ECS system Existing BHEL Max-DNA ECS system shall be utilised for extension panels of 11 kV Switchgear 7A/8A in TPS substation. also between new control room AC system and fire alarm system. under any circumstances. Page 00785 000 JSD 1650 01 00 33/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL • • The present document or drawing is property of TECHNIP KT INDIA LTD. . Linear heat sensing cables shall be used in cable trays in cable cellar. MCPs shall be mounted at entry. control room and cable cellar. transferred. 13. 10) Response indicators shall be provided for detectors located in hidden locations such as control room / substation.14.

. transferred. MATHURA. Control cables shall be twisted pair or shielded wherever electromagnetic / electrostatic interference is anticipated. minimum 2. All HV cables shall be designed for fault levels as mentioned elsewhere in the document. FRLS PVC inner sheathed. 2) Fault level with stand time for HV cables shall be as follows: The present document or drawing is property of TECHNIP KT INDIA LTD. 7) All multicore / muItipair control cables shall have minimum 20% spare cores.5 mm2 copper conductors shall be used.Project N° Unit Document Code Serial N° Rev.5 mm2 stranded copper conductor. 10) HT cables shall be unearthed grade. screened. and shall not. without its prior written consent. 9) For Plant communication and fire alarm system PVC insulated. 4) The control cables shall be 1. directly or indirectly. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. mm.5 sec for Plant feeder 1 sec for Incoming feeder 3) Generally all LV power cables shall be 1. 8) The telephone cable shall be single / multipair.5 sq. FRLS PVC inner sheathed. For lighting inside the building minimum 1. mm for each core.8 mm dia copper conductor. Copper conductor shall be used for sizes up to and including 10 sq. size of copper conductor shall be limited to 630 sq. 20% spare cores shall be provided in each communication cable. mm. armoured and overall PVC sheathed FRLS type with 0. 6) All power and control cables shall be in single continuous lengths (except for long feeder where the length of such feeder is above the manufacturing range of approved cable manufacturers). armoured & FRLS PVC outer sheathed. 5) Lighting cable shall be 1. armoured & FRLS PVC outer sheathed. 12) For HT cables. armoured and overall PVC sheathed FRLS cable with 1. disclosed or used.1 kV grade . PVC insulated. be totally or partially. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. FCC UNIT.25 sec for outgoing feeder 0. FRLS PVC inner sheathed. armoured & FRLS PVC outer sheathed. 20% spare cores shall be provided in each communication cable. mm stranded copper conductor. In no case any joint shall be located in hazardous area. PVC insulated. PVC insulated.1 kV grade with 2. • • • 0. FCCU AND PRU REVAMP.1 kV grade with stranded aluminium / copper conductor. under any circumstances. Page 00785 000 JSD 1650 01 00 34/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL second. reproduced. with proper colour coding. PVC insulated wire shall be used in conduit system (for circuit and point wiring). 11) Size of aluminium conductor shall be limited to 300 sq. and for higher sizes aluminium conductor shall be used. PVC insulated. copied.5mm2 copper conductor.

240V single phase with earth connection. . disclosed or used. copied. 2) Adequate number of 3 phase welding receptacles shall be provided at suitable locations to ensure accessibility with a 50 meters length of trailing cable to any point in the process area. These shall be rated for 16A. under any circumstances. These shall be rated for 63A suitable for 415V. Stop push button shall generally have stay put feature except in the case of critical drives such as lube oil pump etc. MATHURA.Project N° Unit Document Code Serial N° Rev. and shall not. etc. FCCU AND PRU REVAMP. dust proof. corrosion resistant. Cable glands shall be flameproof double compression type nickel plated brass at process unit end. Page 00785 000 JSD 1650 01 00 35/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 13) Tinned copper lugs and double compression type nickel plated brass cable glands shall be used for cable termination. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. 1 phase sockets for lamps and portable tools. Canopy shall be provided for all control stations.). 3) Adequate number of three-pin. be totally or partially. directly or indirectly. FCC UNIT.16. the process/utility lines is to be separately covered in that portion to avoid future spillage into/onto cable trenches or trays in the event of leakage. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 13. 2) The LCS enclosure shall have suitable protection for site conditions (such as flameproof. The present document or drawing is property of TECHNIP KT INDIA LTD. shall be provided at suitable locations to ensure accessibility with a 15 meters length of cable to all manholes of process equipments. Convenience and welding receptacle 1) The enclosure shall have suitable protection for site conditions specified (explosion proof.17. dust proof. weatherproof. without its prior written consent. weather proof. transferred. Local control station 1) Each motor shall be provided with a local control station (LCS) in the field. corrosion resistant etc. Ammeter (for motors rated 30 kW and above). 3 phase system with a scraping earth connection. 13. 14) Wherever inside unit cable trenches or trays are crossed by existing or new process/utility lines .). as required. reproduced. 4) One number control switch station with start / stop push button shall be provided at ground level in addition to the push button on operating platform for air fin fan coolers. 24 V Hand lamps and portable tools shall be earthed through flexible cords. 3) The LCS shall include the following equipment as per individual process requirement: (a) (b) (c) Start/stop push button or breaker control switch (spring return to normal).

without its prior written consent. be totally or partially. energy efficient fluorescent mirror optic New Substation compressor room height more than 6 m Process areas 1 X 80 W HPMV or 1 X 125 W HPMV well glass fittings for all areas Transformer bay HPMV / fluorescent lighting fittings etc 2 X 36 W f( 5 star) fluorescent with mounting 1 X 250 W HPMV medium bay or high bay 0 All Fixtures shall be suitable for classified area (safe or hazardous). as required 2) Energy efficient lighting fixture shall be used. 13. FCC UNIT.Project N° Unit Document Code Serial N° Rev. shall be marked on the cover of all field receptacles for easy isolation. PRU. 0 CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. . Following types of fixtures shall be used for the specified areas. transferred. New Control room Fitting suitable for 2 X 36 W ( 5 star) . Lighting 1) Lighting shall be provided for the following: • • • • new substation ---. Page 00785 000 JSD 1650 01 00 36/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 4) 240/24V transformers shall be provided in a separate flameproof socket outlet. copied. LPG Treater LPG storage area. 24 V. FCCU revamp. DB/pane. 5) Required number of industrial type socket outlets (20A) shall be provided in substations. Location of critical lights shall be determined in consultation with Process group. 7) Source cubicle tag no. directly or indirectly. 415 V shall be preferably supplied from power The present document or drawing is property of TECHNIP KT INDIA LTD. disclosed or used. Emergency lighting – HOLD 3) Critical lights shall be provided for entry points & escapes routes as required. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 6) All power receptacles like 240 V. and shall not. if required Modified area of main control room. under any circumstances. MATHURA. additional lighting.18. FCCU AND PRU REVAMP. Critical lighting shall be fed from 220 V DC supply. reproduced.

refer Overall cable tray/trench/route layout drg no. transferred. 3) Outside substation. and shall not. wherever available. 6) Wherever pipe rack is not available.Project N° Unit Document Code Serial N° Rev. Care shall be taken to give sufficient space in the trench to give required bending radius for the cable and spare loop. This shall be decided as per site requirement and shall be reflected in cable tray /cable routing layout. 4) Cable trays shall be of GI type. control cables. new cable trays shall be The present document or drawing is property of TECHNIP KT INDIA LTD. without its prior written consent. reproduced. existing cable routing/cable tray/trench shall be utilised to the extent possible for cable laying. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. 2) Inside new substation---. Main cable trays shall be of ladder type. control cables may be laid in three layers. Minimum 30% spare space shall be kept for future use while designing. shall in general be run through sand filled RCC trenches with removable covers / overhead cable trays wherever provision on pipe rack for cable tray supports is available. Cable laying philosophy 1) Wherever. However. directly or indirectly. in case of inadequate space in existing cable trays. be totally or partially. Separate trays shall be provided for AC and DC signal / control circuits.7 m above grade (Except Road /unit Entrances /crane crossings). existing substation is used. signal cables shall be laid in separate GI cable trays inside the cable cellar. copied. Page 00785 000 JSD 1650 01 00 37/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 13. FCCU AND PRU REVAMP. disclosed or used. cables shall be laid in existing cable tray/trench. 10) GI conduits shall be used between trenches and field equipment like motors. 8) Cables in offsite and utilities or interconnecting cables in unpaved area shall be directly buried or laid in overhead cable tray. under any circumstances. 00785-000-DW-1624-01. provided for FCCU revamp project. Necessary supports shall be provided for the same. 7) Cables inside process units. control stations etc.19. RCC trenches shall be used for routing the cables from the substation to the process units. However. 9) Underground road crossing shall be through cable culvert and above ground road crossing shall be overhead cable bridge. FCC UNIT. For cable routing details. cable tray support shall be sized to ensure lowest tray level to be minimum 2. 5) Power Cables in cable trays shall be laid in single layer. . MATHURA. HV cables shall be laid in trench. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Small branch trays (of sizes 150 mm and below) shall be of perforated type. MV power cables. The RCC trenches shall be designed keeping provision of future requirement and without affecting the cable capacity rating.

in addition to self-load and wind forces. refer table below: 2) The minimum size of main earthing loop (MEL) around the substation shall CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. glands shall be flameproof. MATHURA. 75 kg concentrated load at center span shall be considered. Pipes laid for mechanical protection shall be sealed at both ends. be totally or partially. under any circumstances. The present document or drawing is property of TECHNIP KT INDIA LTD. In hazardous area. .Project N° Unit Document Code Serial N° Rev. These trenches shall be sealed against ingress of liquids and gases. EARTHING SYSTEM 1) Earthing system shall in general cover the following Equipment earthing for personal safety System neutral earthing Static and lightning protection be 75 x 10 mm GI. and shall not. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. copied. transferred. disclosed or used. directly or indirectly. FCCU AND PRU REVAMP. control room etc shall be provided with fire barrier and it shall have minimum three hours rating. Fire barriers shall also be provided below the opening of all HT and LT switchboards in substations. 16) Parallel / duplicate feeder cables shall be laid separately as far as possible. 12) The top of cable trenches before entering the substation shall be maximum 1 m above the ground level. or these trenches shall be connected to nearest storm water drain. For tray system design. FCC UNIT. 17) All cable trays and accessories shall preferably be prefabricated. hot dip galvanized. 14) Fire proofing / painting for all power cables on 3 m length of cable at motor end and load end in the field and panel end in the substation shall be provided. For connection up to individual equipment. All cut-outs shall be properly sealed by a sealing compound. without its prior written consent. All structural steel design shall be as per Indian Standards. 13) All entry and exit openings for cables crossing in substation. following guidelines for design shall be considered. 18) Tinned copper cable lugs and double compression nickel brass type cable gland shall be used for cable termination. 15) Fire protection for cables shall be provided as per IS12459. reproduced. a) Support span b) Cable load : : 3000mm 75kg/linear meter In addition to this. 14. Page 00785 000 JSD 1650 01 00 38/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 11) Concrete lined trenches shall have suitable drainage arrangement to avoid water collection.

Project N° Unit Document Code Serial N° Rev. 4) MEL for FCC revamp. existing earth grid shall be used. This shall be kept galvanically isolated from the system and safety earthing. PLC. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. PRU and LPG treater unit shall be connected to existing refinery earth grid at minimum two points: New Substation---shall have separate earthing grid. FCC UNIT. shall be provided with clean earth. 5) DCS. disclosed or used. 30 KW & Motors above 37 kW including HT motors Building columns Pipe racks. copied. vessels & heat exchangers Small equipments & instruments Lighting. including electronic relays. 7) Value of earth resistance for system earthing shall not exceed 1 Ohm. strip / G. MATHURA. they shall however be connected to the earthing system at minimum two points at the base. the value of 5 ohms as earth resistance shall be desirable but in no case it shall be more than 10 ohms. wire 8 SWG solid wire 10 mm (3/8”) wire rope 16 mm (5/8”) wire rope 40 X 5 strip 10 mm (3/8”) wire rope 8 SWG solid wire 10 mm (3/8”) wire rope GI strip. under any circumstances. directly or indirectly. As calculated GI strip. An independent earthing network shall be provided for lightning protection and this shall be bonded with the main earthing network only at the buried electrode.I.7 KW Motors 5. Earth pits shall be constructed up to 300 mm above ground level and shall be covered by removable slabs. extension panels are provided panel earthing conductor shall be connected to existing earth grid. 8) For lightning protection. Page 00785 000 JSD 1650 01 00 39/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL Type of equipment Motors upto 3.As calculated 8 SWG solid wire 10 mm (3/8”) wire rope 16 mm (5/8”) wire rope The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not. wire rope / G. 6) Self-conducting structures may not be provided with aerial rod and down conductors. reproduced.I. be totally or partially. Wherever. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. power & instruments panels Main earth bus/LT & HT SW gear interconnections/ transformer Sub-stations Push button station Street light poles Lighting transformers 3) All earth electrodes shall be GI pipe electrodes. without its prior written consent. transferred.5 KW to welding receptacles Bare G. and other electronic instruments. All other areas. provided with earth pits. FCCU AND PRU REVAMP.I. .

under any circumstances. without its prior written consent. Earth continuity shall be ensured across all flanges. transferred.Project N° Unit Document Code Serial N° Rev. 11) Above ground local earth grid of minimum 50 X 6 mm size shall be provided for all indoor areas. welded to the main cable tray support. 17) Lightning Protection shall be provided for all buildings including Compressor house as per IS . The horizontal air terminations and down conductors shall be of 20 x 3 mm2 GI Strip. 15) Cadmium coated nuts and bolts shall be used at tapping points where welding is not envisaged. LIGHTING SYSTEM Emergency Lighting – HOLD 1) Areas requiring DC critical lighting shall be as following: CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. FCCU AND PRU REVAMP. 12) Dedicated single earthing strip shall be laid along cable trays. The present document or drawing is property of TECHNIP KT INDIA LTD. 20) All earth pits shall be marked with earth pit number for easy identification. screens and armour of all multicore cables shall be earthed at both equipment and switchgear ends. 14) At least two nos. . of earth strips of adequate size shall be tapped from the main earth grid and taken to the top of all tall structures. metallic tag is also to be fastened with the earth electrode inside the pit as a permanent identification. In addition. Page 00785 000 JSD 1650 01 00 40/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 9) All utility / process pipelines shall be bonded to a common conductor by means of earth bars or pipe clamps. platforms. reproduced. No welding and drilled holes are to be left without galvanization. 18) Proper wrapping and coating shall be given to the underground welded earthing joints to avoid any corrosion. MATHURA. 16) In plant area all stair cases. and shall be connected to the earthing grid at every 20 m interval. 15. copied. railings. 13) Metallic sheaths. 21) Separate earthing shall be provided for transformer neutral. and a ring shall be made at the highest point. 19) Earth electrodes shall be galvanized after fabrication. and shall not.2309. directly or indirectly. Steel pipe racks shall be earthed at every 25 m. be totally or partially. monkey ladders shall be earthed at least at two points. This shall be connected to the main earth grid at minimum two points. FCC UNIT. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 10) Underground earthing strips to be provided with 50% corrosion allowance. disclosed or used.

fixtures. disclosed or used. Page 00785 000 JSD 1650 01 00 41/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL The present document or drawing is property of TECHNIP KT INDIA LTD. FCC UNIT. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. copied. junction boxes etc. Mounting height of control gear box shall not be more than 2 m in height from operating level. local lighting panels may be fed from existing system. 10) All outdoor lighting shall be automatically controlled by means of photoelectric cell / synchronous timers with manual overriding control. . 2) Critical (DC) lighting shall be normally “OFF” and during failure of normal power supply. LPG treater units. and shall not. All chemical-handling facilities shall be provided with chemical resistant fixtures. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 8) Lighting and power panels shall be fed from LDB through 433/433 V. be totally or partially. PRU . 4) Non–integral type lighting fixtures shall be used.Project N° Unit Document Code Serial N° Rev. 7) Lighting system for FCCU revamp. for small lighting loads.95) shall be provided with fixtures as applicable.5%. MCBs shall not be loaded beyond 80% of rated capacity. Keeping in view the restrike time lag and ‘to avoid complete darkness in case of a voltage dip/black out condition necessary incandescent lamps may be judiciously distributed throughout the plant area. lighting and power panels. MATHURA. 3) HPMV lamps shall generally be used for plant lighting. without its prior written consent.6). lighting transformer need not be provided. lighting distribution boards (LDBs). 5) DC critical lighting shall employ incandescent lamps. 6) Tall structures shall have aviation obstruction lighting as per statutory requirements. 9) For other areas (excluding areas mentioned vide cl. New control room New sub station Process units under EPCM contractors scope battery bank shall feed the critical lighting system. new substation and new control room. Dynll.15. FCCU AND PRU REVAMP. shall consist of lighting transformers for reduction of fault level. dry type lighting transformer having taps up to + 7. Fluorescent lamps with electronic ballast shall be used for indoor lighting for substation and control room. under any circumstances. Safe area street and area lighting may employ sodium vapour lamps. All ballasts shall be with copper winding and capacitor for power factor improvement (to 0. directly or indirectly. reproduced. Normally about 8-10 fixtures or maximum 1000 W shall be wired in each circuit. These panels shall be provided with MCB + ELCB as incomer and MCBs for outgoing feeders. transferred. Also. Minimum of 25% of feeders in each lighting panel shall be left as spares.

The masts shall be provided with motorized racking mechanism for lowering and hoisting lantern carriage. provided with MCB + ELCB as incomer and Miniature Circuits Breakers (MCBs) for outgoing feeders control and protection of lighting cirucitrs.Compressor Area 200 70 150 500 150 Lux 10 100 60 20 60 14) Lighting design shall conform to relevant International Codes and Standards. directly or indirectly. In case of oil mine installations. pipe racks.8 shall be assumed for lighting illumination level calculations for normal areas. 13) Lighting Lux Levels Lighting system design shall be based on average illumination levels as specified below: Area . separators etc. under any circumstances. without its prior written consent. MATHURA.Roads .7. .Main operation platforms and access stairs . be totally or partially.5%. Dynll. A maintenance factor of 0. These panels shall be secondary side voltage shall be 240 V between phases. .Process area. FCCU AND PRU REVAMP. However for dusty areas. cooling tower. Page 00785 000 JSD 1650 01 00 42/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL 11) Telescopic tubular high masts shall be provided for illumination of offsite&utility / general area.Ordinary platforms .Control Room . disclosed or used. transferred. reproduced.Switchgear room .Battery room . dry type lighting transformer having taps upto + 7. Normally about 8-10 fixtures shall be wired in each circuit. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. In areas having less lighting load.Pump house. A minimum of 25% of miniature circuit breakers of each board shall be left as spares. IES Hand Book and shall take into consideration the requirements from point of view of safety and ease in operation and maintenance. The armoured CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. 12) Lighting and power panels shall be fed from LDB through 433/433 V. Sheds . and shall not. lighting transformer can be avoided. MCBs shall not be loaded beyond 80% of rated capacity. The present document or drawing is property of TECHNIP KT INDIA LTD. FCC UNIT. copied. 15) Wiring for lighting and convenience outlets in outdoor areas shall be carried out with PVC armoured cables run along the column / platforms and structures. maintenance factor shall be 0. heat exchanger heater.Cable cellar .Project N° Unit Document Code Serial N° Rev.

COMMISSIONING OF EQUIPMENT OEM shall provide commission assistance at site as per requirement for following Equipment. Ex(e) or Ex(n) equipment and through flameproof glands for Ex(d) equipment. 19) Battery room shall have fixtures mounted on wall in order to facilitate easy replacement of fused lamps. disclosed or used. HT SWITCHGEAR. HT SWITCHGEAR 3. 17) Substation ---cable cellar lighting shall be by armoured cables.Project N° Unit Document Code Serial N° Rev. VFD 6. 16. be totally or partially. PCC&MCC FOR RELAY COMMUNICATION & CONFIGURATION 4. 1 BATTERY BANK AND BATTERY CHARGER 2. ECS 10. HT MOTORS(SYNCHRONOUS)& ITS EXCITATION PANEL 8. concealed conduit wiring shall be used below the false ceiling and surface conduit wiring above the false ceiling. stairs shall be installed in such a way that re-lamping can be done without the use of ladders. . PLANT PAGING SYSTEM 11 WALKIE TALKIE CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Switches controlling the lighting fixtures and exhaust fan shall be installed outside the battery room. 18) For new control room with false ceiling. Substation lighting shall be done by surface conduit wiring. copied. under any circumstances. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. walkways. FCC UNIT. FIRE ALARM SYSTEM 9. without its prior written consent. 20) Locally mounted lighting fixtures on platforms. 16) Two pole isolation devices shall be used for controlling fixtures in hazardous areas to The present document or drawing is property of TECHNIP KT INDIA LTD. EOT 7. FCCU AND PRU REVAMP. HIGH MAST 5. transferred. Page 00785 000 JSD 1650 01 00 43/43 ENGINEERING DESIGN BASIS FOR ELECTRICAL cable shall enter lighting fixture / JB through double compression gland for safe area. MATHURA. reproduced. and shall not. directly or indirectly. isolate phase as well as neutral.

transferred. be totally or partially. OWNER EPCM TECHNIP KT INDIA LTD. DATA SHEET FOR MV SWITCHGEAR 02 01 00 REV.08. and shall not. NOIDA. disclosed or used. MATHURA REFINERY. reproduced. under any circumstances.2010 DATE ISSUED FOR DESIGN REISSUED FOR REVIEW ISSUED FOR REVIEW STATUS ABS VV ABS PREPARED BY VV DYS DYS REVIEWED BY DYS DYS DYS APPROVED BY VJK VJK CSA PM DOCUMENT REVISIONS Sections changed in last revision are identified by a line in the right margin . 18.Project N° Unit Document Code Serial N° Rev.2011 11. INDIA. MATHURA. DATA SHEET FOR MV SWITCHGEAR UNIT PROJECT LOCATION : FCC UNIT : FCCU AND PRU REVAMP. without its prior written consent.08.11. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.2011 01. INDIAN OIL CORPORATION LIMITED. Page 00785 000 DS 1654 01 02 1/5 The present document or drawing is property of TECHNIP KT INDIA LTD. copied. : IOCL. directly or indirectly.

0 1 2 GENERAL MV Switch Board Tag no. 0 7 8 5 UNIT 0 0 D S DOC. CODE 1 6 5 4 SERIAL REV No. MATHURA FCCU AND PRU REVAMP. SITE CONDITIONS Temp.which may be double front./ Min. Std. 3427. MATHURA IOCL. Fixed / drawout type Yes Yes / No Required / Not required 34 Feeder arrangement 35 36 37 38 39 40 41 42 43 Feeder type Space heater with thermostat & switch fuse in each panel Safety shutters for test & drawout positions Heat run test Bus bars Main & Vertical busbar material Main & vertical busbar Insulation Main busbar location Earth busbar material Aluminium Heat shrunk PVC sleeved Top / Bottom Copper / Aluminium ./ Design °C Relative Humidity Altitude Above MSL Environment OPERATING CONDITIONS Rated voltage with variation Rated Frequency Number of Phases System fault level System breaking capacity System making capacity System Earthing Control circuit power supply Aux. 3231. Power supply for spring charge motor Aux. Quantity Ref. 50 KA ______KA (peak) Solidly earthed 240V AC SPN for _______ / 220VDC for _______ 240V AC SPN for _______ / 220VDC for _______ 240V AC SPN Metal Enclosed IP-54 Yes / No Yes / No Cable for ______switch boards / Busduct for ______switch boards Top / bottom Top / bottom Top Glossy white 631 as per IS:5 Integral base frame suitable for tack welding or bolting Single front for breaker feeders & other feeders except for LPG PMCC. Max. 8623 47 °C / 2 °C / 50 °C 95% less than 1000M Highly corrosive & Humid 415V AC ±10% 50 Hz ± 5% Three phase + Neutral 50 KA for 1 sec. MATHURA REFINERY PROJECT No. Power supply for Panel space heater DATA BY PURCHASER (Shall be separately furnished for each board) Switch Board Type of Switch Board Degree of protection Adaptor panel between switch board Dummy panel to maintain 6000mm centre line distance between the two incomers for busduct entry Incoming power connection Incoming cable entry Outgoing cable entry Busduct entry Interior final colour shade Exterior final colour shade Floor fixing IS:2147.2 OF 5 DATA SHEET FOR MV SWITCHGEAR TECHNIP KT India CLIENT : PROJECT : LOCATION : 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 INDIAN OIL CORPORATION LIMITED.

1. MATHURA FCCU AND PRU REVAMP. Metering & relays Protections & metering required Protection relay type (except thermal overload relay) Rating & spare aux. MATHURA REFINERY PROJECT No.0 / 10VA 1 Star + 1 Open Delta Digital type / Analogue type 64x64 / 72x72 / 96x96 mm 1 / 1. contacts in contactor controlled feeder Contactor duty Suitable for capacitor switching 10A / 1 NO + 1 NC AC23 Air Circuit Breaker O-0.0 / 10VA CL 1. 0 1 2 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 DATA BY PURCHASER (Contd. contacts in switches Switches duty Circuit breaker Type of circuit breaker Duty cycle of breaker Rating & spare aux.3 OF 5 DATA SHEET FOR MV SWITCHGEAR TECHNIP KT India CLIENT : PROJECT : LOCATION : INDIAN OIL CORPORATION LIMITED.5 / 2. MATHURA IOCL. contacts in over load relay Single phase prevention feature in thermal O/L relay Protection CT accuracy class / burden Metering CT accuracy class / burden PT accuracy class / burden Type of secondary winding of potential transformer Measuring instrument type Minimum size of meters Accuracy class of measuring instruments Control wiring Material & size Connectivity with remote system (SCADA / ECS) Type of connections with SCADA / ECS / DCS Communication protocol Relay connection type As per single line diagram of respective switch board Microprocessor based communicable type / Electro-mechanical 10A / 1 NO + 1 NC Yes 5P20 / 10VA CL 1. contacts in ACB control feeder Anti pumping feature in ACB Breaker trip free Provision for manual spring charging of breaker Trip PB for mechanical trip Mechanical on / off indicator operation counter Suitable for capacitor switching Contactors Rating & spare aux. 0 7 8 5 UNIT 0 0 D S DOC. CODE 1 6 5 4 SERIAL REV No.5 Copper.3min-CO-3min-CO 10A / 8 NO + 8 NC Yes Yes Yes Required / not required Required / not required Yes / No Yes / No 10A / 2 NO + 2 NC AC3 Yes / No Included Included Double / Single compression nickel plated brass cable glands 63 Cables and cable glands 64 Cable glands & Lugs for incoming & outgoing cables 65 Type of cable glands 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 Protection.) Switches Rating & spare aux.5 sq mm Yes / No 1 Main + 1 Redundant RS485 serial link output Modbus RTU Daisy Chain / Star topology .

MATHURA REFINERY PROJECT No. CODE 1 6 5 4 SERIAL REV No. MATHURA FCCU AND PRU REVAMP. for capacitor switching in % Contactors Contactor rating in Amps Contactor make Contactor type Thermal rating Making capacity Breaking capacity Electrical life in no.Hold on Closing time in sec. Derating reqd. of operations Coil consumption in VA . Switches) Circuit breakers 800A 1250A 1600A Circuit breaker rating (Amps) Circuit breaker make Circuit breaker Type No.Pick up Coil consumption in VA .C. Total closing time in sec. opening time in sec.4 OF 5 DATA SHEET FOR MV SWITCHGEAR TECHNIP KT India CLIENT : PROJECT : LOCATION : INDIAN OIL CORPORATION LIMITED. for capacitor switching in % 2500A 3200A 4000A ____VA ____VA ____VA Switches Switch rating in Amps Switch make Switch type Rated making capacity Rated breaking capacity Rated S. 0 7 8 5 UNIT 0 0 D S DOC. 0 1 2 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 DATA BY SWBD MANUFACTURER (Vendor to furnish data for each rating of ACB's. withstand current with max. MATHURA IOCL. of operations at rated voltage Mechanical life in no. Power required for opening in VA Power required for closing in VA ____VA Power required for spring charging motor ____VA ____VA Time taken for spring charging in sec. of operations 32A 63A 125A 250A 400A 630A . Contactors. Derating reqd. Breaker closing mechanism Breaker tripping mechanism Total opening time in sec. poles / phase Nominal current rating (In free air) Current rating at site cond. permissible rated fuses 125 Mechanical life in no. (Inside panel) Breaking capacity % DC component Peak making current Short circuit withstand capacity for 1 sec.

5 OF 5

DATA SHEET FOR MV SWITCHGEAR TECHNIP KT India CLIENT : PROJECT : LOCATION : INDIAN OIL CORPORATION LIMITED, MATHURA FCCU AND PRU REVAMP, MATHURA IOCL, MATHURA REFINERY PROJECT No. 0 7 8 5 UNIT 0 0 D S DOC. CODE 1 6 5 4 SERIAL REV No. 0 1 2

126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147

DATA BY SWBD MANUFACTURER (Contd.) Bus bars Main busbar current rating inside panel Main busbar size Main busbar clearance in air Phase to phase in mm Phase to neutral in mm Phase to earth in mm Vertical busbar rating Vertical busbar size Earth bus size Switch Board details Switch board manufacturer Manufacturer's type / designation Overall dimensions of switch board (LxDxH) Total weight of switch board Heat loss of switch board Recommended clearances for switch board Front in mm Rear in mm Above in mm Shock loading on foundation

PCC

EPMCC

MCC

ASB

MLDB

ELDB

mm

mm

mm

mm

mm

mm

_____Kg

_____Kg

_____Kg

_____Kg

_____Kg

_____Kg

2 1 0 Rev.

18.08.2011 1.08.2011 11.11.2010 Date

ISSUED FOR DESIGN REISSUED FOR REVIEW ISSUED FOR REVIEW Status

ABS VV ABS Prepared By

VV DYS DYS Checked By

DYS DYS DYS Approved By

Project N°

Unit

Document

Code

Serial N°

Rev.

Page

00785

000

STD

1621

03

0

1/8

STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES

UNIT PROJECT
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

: FCC UNIT : FCCU AND PRU REVAMP, MATHURA. : IOCL, MATHURA REFINERY.

LOCATION

OWNER

EPCM
TECHNIP KT INDIA LTD.

INDIAN OIL CORPORATION LIMITED.

NOIDA, INDIA.

STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES

0
REV.

18.10.2010
DATE

ISSUED FOR DESIGN
STATUS

VV
PREPARED BY

DYS
REVIEWED BY

DYS
APPROVED BY

CSA
PM

DOCUMENT REVISIONS Sections changed in last revision are identified by a line in the right margin

Project N°

Unit

Document

Code

Serial N°

Rev.

Page

00785

0

STD

1621

03

0

2/8

STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES

The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

CONTENTS

Sr.No 1.0 2.0 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.0 5.0 6.0 7.0 8.0 9.0 Scope .............................................................. …………… Codes and standard ......................................... …………… General construction and material of construction.…………. PVC insulated FRLS cables ............................. ………….. Conductor .......................................................... …………. Insulation ................................. …… ........................……. Filler and inner sheath .................. …… ...................……. Armouring ........................................... …… .............……. Outer sheath ............................................ …… .......…….. Dimension / thickness of materials ................. ……............ Core identification ........................................... ……............ Identification of cables ...................................... ………….. Information required with the bid ......................... ………… Cables drums ................................................... ………….. Cable quantity ................................................. …….......... Inspection and tests ............................................ …………

Page 3 3 4 4 4 4 4 5 5 5 5 6 6 6 7 7

CLIENT UNIT PROJECT

: : :

INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.

IS:3975 (1988) Mild steel wire. without its prior written consent. MATHURA. Page 00785 0 STD 1621 03 0 3/8 STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES 1. and shall not. Methods of test for cables: Part 58 Oxygen Index test Methods of test for cables: Part 61 Flame retardant test Methods of test for cables: Part 62 Flame retardant test for bunched cables Test methods for insulation & sheaths of electric cables.2 In case of any contradiction between various referred standards/ CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. SCOPE This specification covers the basic requirements for design. IS:10418 (1982) IS:10462(Part1)1983 IS:10810(Pt 58) IS:10810(Pt 61) IS:10810(Pt 62) IEC:60540 & 60540A IEC:230 (1966) IEC:60332 (3 parts) IEC:811 (5 parts) Drums for Electric cables. Fictitious calculation method for determination of dimensions of protective coverings of cables. IS:6474 (1984) Specification for Polyethylene insulation and sheath of electric cables. manufacture.1 The cables & accessories shall also confirm to the provisions of the Indian Electricity Rules and other statutory regulations in force in the country. 2. control. (IOCL). for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Test methods for insulating and sheathing materials of electric cables. directly or indirectly.Project N° Unit Document Code Serial N° Rev. Test on electric cables under fire conditions. Mathura Refinery. Mathura.1KV for power. copied.0 The present document or drawing is property of TECHNIP KT INDIA LTD. reproduced. IS:1885 (Part 32)1993 Electro Technical Vocabulary-Electric Cables. IS:3961 (Part 4) Recommended current ratings for Polyethylene 1968 insulated cables. purpose to be used in FCCU and PRU Revamp project of M/s Indian Oil Corporation Ltd. The relevant standards are: IS: 613 (1984) Copper rods and bars for electrical purposes. FCCU AND PRU REVAMP. be totally or partially. . disclosed or used. 2. manufacture and performance of PVC insulated cables shall conform to the applicable Indian. lighting. IS:2633 (1986) Method of testing uniformity of coating on Zinc coated articles. inspection and testing at vendor’s works. 2. Impulse tests on cables and their accessories. transferred. under any circumstances. IS:5831 (1984) Specification for PVC insulation and sheath of electric cables. FCC UNIT.0 CODES AND STANDARDS The design. formed wires and tapes for armouring of cables. IEC Standards. of PVC insulated cables up to 1.

with Copper/Aluminium Conductor. and shall not. 3. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. armoured and overall FRLS PVC sheathed. CLIENT UNIT PROJECT .0 Statutory regulations Data sheets Unit Specifications This Specification Codes & Standards General construction and material of construction The cables shall be suitable for laying trays. 3. be totally or partially. The outer sheath of PVC cables shall possess flame propagation properties meeting requirements as per IS-10810 (Part-62) category AF.2 Conductor The conductor shall be of plain aluminium or high conductivity annealed copper wires complying with relevant Indian standards. 3. under any circumstances. 650/1100V grade. trenches. inner sheathed.Project N° Unit Document Code Serial N° Rev. reproduced. 3. Sequential marking of the length of the cable in the meters shall be provided at every one meter. the following order of priority shall be given: The present document or drawing is property of TECHNIP KT INDIA LTD. transferred. PVC insulated.2mm up to overall diameter up to 60mm and +/3mm for above 60mm. Page 00785 0 STD 1621 03 0 4/8 STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES specifications/ data sheets and statutory regulations. directly or indirectly. FCC UNIT. The conductors of size above 6mm2 shall be stranded. or : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. without its prior written consent. FCCU AND PRU REVAMP. disclosed or used.3 Insulation The insulation shall be of polyvinyl chloride (PVC) compound applied over the conductor by extrusion and shall conform to the requirements of Type “A” insulation as per IS: 5831. copied. The embossing or engraving shall be legible or indelible.4 Filler and inner sheath (1) The filler and inner sheath shall be of the following: (a) Unvulcanized rubber. All cables covered in this specification shall be FRLS unless otherwise specified in the data sheet. The overall diameter of the cables shall be as per manufacturer’s data sheet subject to a maximum tolerance of +/. 3.1 PVC insulated FRLS cables All power and control cables shall be heavy-duty type. ducts and conduits and for underground buried installation with possibility of flooding by water & chemicals. MATHURA.

4.0 Core identification Cores of cable shall be identified by colour coding of PVC insulation as per IS:1554 (Part 1) CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. copied. FCCU AND PRU REVAMP. FCC UNIT. be totally or partially. The joints in armour wires or strips shall be made by brazing or welding and any surface irregularities shall be removed. Page 00785 0 STD 1621 03 0 5/8 STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES (2) The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not. under any circumstances.5 Armouring (1) Armouring shall be one of the following: (a) Galvanized round steel wire (b) Galvanized steel strip Where the cable diameter below armour does not exceed 13mm. transferred. The outer sheath shall be applied by extrusion over the armouring. (3) 3. C. In addition suitable chemicals shall be added to the PVC compound of the outer sheath to protect the cable against rodent and termite attack.6 Outer sheath (1) (2) The outer sheath shall be poly-vinyl chloride (PVC) compound conforming to the requirements of Type ST1/ST2 compound as per IS: 5831 and shall be of FRLS type only. the armour shall consist of galvanized round steel wires. (3) (4) (b) Thermoplastic materials Unvulcanized rubber or thermoplastic material used shall not be harder than PVC used for insulation and outer sheath. inner sheath. (2) (3) 3. Outer sheath of all PVC cables shall be black in colour and the minimum value of oxygen index shall be 29 at 27 ± 2 deg. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. disclosed or used. reproduced.7 Dimension / thickness of materials The thickness of insulation. The inner sheath shall be applied by extrusion method such that it fits closely on the laid-up cores and shall be possible to remove without damaging the insulation. outer sheath and dimension of wire/strips used for armouring shall be as per relevant standards. MATHURA.Project N° Unit Document Code Serial N° Rev. directly or indirectly. . 3. the armour shall consist of either galvanized round steel wires or galvanized steel strips. Single core cables shall have no inner sheath. Where the diameter below armouring is greater than 13mm. without its prior written consent.

The cables shall be wound on drums of suitable barrel diameter. (2) Manufacturer’s name or trade mark. The drum length shall be as per cable drum schedule. current carrying capacities and de-rating factors. with the take-off and fully protected against mechanical damage. brand name or trademark. under any circumstances. and shall not. free from defects and wooden preservatives shall be applied to the entire drum. The present document or drawing is property of TECHNIP KT INDIA LTD. (3) Year of manufacture. (2) (3) (4) CLIENT UNIT PROJECT . The vendor shall indicate in the offer. The wood used for construction of the drum shall be properly seasoned.0 Identification of Cables The cables shall be clearly and permanently marked with following information throughout the length. disclosed or used.0 Information required with the bid Vendor shall furnish technical particulars / description and performance details of all cables. the maximum length of cable. The actual length supplied on each drum shall be within tolerance limit of +5%. (b) Nominal cross sectional area of conductor (c) Number of cores. Page 00785 0 STD 1621 03 0 6/8 STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES 5. transferred. FCCU AND PRU REVAMP.Project N° Unit Document Code Serial N° Rev. for all conditions of cable laying. The following information shall be stencilled on each drum. copied. (d) Type of cable and voltage grade. All ferrous parts shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit or storage. (e) Cable code (f) Length of cable on the drum. securely battened. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. be totally or partially. (4) Cross sectional area of conductor and no of cores. : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. (a) Name of manufacturer. reproduced. which can be accommodated on one drum. Also. The cut ends of cable shall be sealed by means of non-hygroscopic sealing material to avoid ingress of water during transit or storage.0 Cable Drums (1) Cables shall be supplied in non-returnable wooden drums of heavy construction. FCC UNIT. PVC /Rubber end caps shall be supplied free of cost for each drum with a minimum of eight per thousand metre length. 6. 7. directly or indirectly. (1) Voltage grade. without its prior written consent. MATHURA.

directly or indirectly. (2) (3) (4) (5) (6) CLIENT UNIT PROJECT . However. be totally or partially. Routine tests shall be witnessed by a representative of Owner / EPCM Contractor. and shall not. (g) (h) (i) (j) (k) (l) (m) (n) Number of lengths on drum (if more than one). Country of manufacture Year of manufacture. then same shall be supplied. The unit rate quoted by bidder shall be valid in the event of addition / deletion of cable quantity. Test certificates for type test shall be furnished with quotation. The retention value of tensile strength & ultimate elongation value after the test shall be minimum 60% of the tensile strength and elongation value before the test. acceptance tests.0 Inspection and tests (1) Inspection and testing shall be carried out in accordance with relevant standards. MATHURA. Offer with short / non-standard lengths are liable for rejection. 8. gross weight. The test for resistance to Ultraviolet radiation: This test shall be carried out as per DIN 53387 or ASTM-G-53 on outer sheath.Project N° Unit Document Code Serial N° Rev. This format shall give minimum acceptable value as per relevant standards. Direction of rotation of drum (by means of an arrow). regarding the date of inspection to enable him or his representative to witness the tests. The inspector shall have free access to the manufacturer’s works for stage inspection and he will have the power to reject any material which appears to him to be of unsuitable description or of unsatisfactory quality. Drum number. under any circumstances. 9. The test requirement for PVC insulation & sheath of cables shall be as per latest revision of IS: 5831. FCCU AND PRU REVAMP.standard drum lengths are specified in the data sheet. type tests & additional type tests for improved fire performance shall be carried out as listed in IS-7098 (Part2). Vendor shall submit blank formats where in the test results/readings are to be entered. overall tolerance for each size of cable shall be limited to +/ . transferred. A tolerance of +/. disclosed or used. Page 00785 0 STD 1621 03 0 7/8 STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES The present document or drawing is property of TECHNIP KT INDIA LTD. The vendor shall give at least 2 weeks prior notice to the purchaser. Job number. If non.0 Cable quantity The bidder shall quote unit rates for all types of cables as indicated in the requisition. All routine tests. without its prior written consent. The test certificates with respect to this test (not older than 1 year) : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.3% shall be permissible for each drum.2%. Reference standard Approx. Vendor shall quote unit rate for witnessing such type test. FCC UNIT. reproduced. copied. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

In case test certificates are not available. Sampling for this test is to carried out one for each order. under any circumstances. provided the outer sheath remains the same. FCCU AND PRU REVAMP. before dispatch clearance of cables. test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory. (7) Acceptance tests as per IS-1554 Part-1 and IS-7098 Part-2 and the following special tests to be performed on the cables as per the sampling plan. test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory.5m above the bottom edge of the burner at the front of the ladder. clearance of cables. and shall not. In case test certificates are not available. Sampling for this test is to carried out one for each order Dielectric Retention test: The dielectric strength of the cable insulation tested in accordance with NEMA WC-5 at 75 ± 1o C shall not be less than 50% original dielectric strength. Sampling to be done for every offered lot / size as per sampling plan Flammability Test: The test shall be carried out on finished cable as per IS-10810 (part 61 & 62). MATHURA. be totally or partially. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Sampling for this test is to carried out one for each order Oxygen Index Test: The test shall be carried out as per ASTM D2863 or applicable Indian Standard specifications. from recognized testing laboratory to be furnished for review by PMC before dispatch clearance of cables. before dispatch clearance of cables. Test for rodent & termite repulsion property: The vendor shall furnish details to analyze the property by chemical method. FCC UNIT. before dispatch clearance of cables. Sampling to be done for every offered lot/ size as per the sampling plan. provided the outer sheath remains the same. Sampling for this test is to carried out one for each order. Part-62: The maximum extent of charred portion measured on the test sample should not have reached a height exceeding 2. directly or indirectly. clearance of cables. This tests are to be witnessed by PMC/ Owner before the dispatch of cables: a) Accelerated Water absorption test for insulation as per NEMA –WC-5 (For PVC insulated cables) and as per NEMA WC-7 (For XLPE insulated cables). .Project N° Unit Document Code Serial N° Rev. Test certificates with respect to this test (not older than one year) from recognized testing laboratory to be furnished for review by PMC before dispatch. (8) (9) (10) (11) CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. copied. disclosed or used. Page 00785 0 STD 1621 03 0 8/8 STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES The present document or drawing is property of TECHNIP KT INDIA LTD. without its prior written consent. Test certificates with respect to this test (not older than one year) from recognized testing laboratory to be furnished for review by PMC before dispatch. The acceptance criteria for tests conducted shall be as under: Part-61: The cable meets the specifications if there is no visible damage on the test specimen within 300 mm from its upper end. reproduced. test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory. transferred. In case test certificates are not available.

be totally or partially. LOCATION OWNER EPCM TECHNIP KT INDIA LTD. copied. and shall not. disclosed or used. MATHURA. without its prior written consent. MATHURA REFINERY. INDIAN OIL CORPORATION LIMITED. Page 00785 000 STD 1621 04 00 1/4 SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM UNIT PROJECT The present document or drawing is property of TECHNIP KT INDIA LTD.Project N° Unit Document Code Serial N° Rev. transferred. reproduced.11.2010 DATE ISSUED FOR DESIGN STATUS ABS PREPARED BY DYS REVIEWED BY DYS APPROVED BY CSA PM DOCUMENT REVISIONS Sections changed in last revision are identified by a line in the right margin . SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM 00 REV. : IOCL. NOIDA. 03. : FCC UNIT : FCCU AND PRU REVAMP. directly or indirectly. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. under any circumstances. INDIA.

.......... 3 +VE AND –VE HEADER CABLE .......................................... 3 EARTHING CABLE .......... disclosed or used............................................................................................................................................................... copied........................... The present document or drawing is property of TECHNIP KT INDIA LTD............. 4..................................... 4 CABLE IDENTIFICATION ......................... 9................. 10...................................... CLIENT UNIT PROJECT SCOPE : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY........................... reproduced.................................................................................. 1..........................................................Project N° Unit Document Code Serial N° Rev........................................................................ 3 ANODE LEAD CABLE ................................... without its prior written consent............................. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use........................... FCC UNIT... 4 MEASUREMENT CABLE AND PERMANENT REFERENCE CELL ............................. 4 INSPECTION........... and shall not.............. 4 2...... MATHURA........ 7... 4 CABLE DRUMS ....................................................... Page 00785 000 STD 1621 04 00 2/4 SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM CONTENTS 1........... ............................................ 5..................... 6................... transferred................ be totally or partially.................................................................. SCOPE ............................................................................................................. 3.. 11................. 3 DRAINAGE CABLE .............................................. 2 CODES AND STANDARDS ... 8................. FCCU AND PRU REVAMP... 3 POWER SUPPLY CABLE ( BETWEEN PCC & T/R UNIT) .............. directly or indirectly........................ under any circumstances......

The secondary insulation shall be PVC sheathing jacket over the primary insulation. The present document or drawing is property of TECHNIP KT INDIA LTD. +VE and –VE HEADER CABLE +ve header and -ve header cable shall be 95mm2. MATHURA. with a double insulation system. The primary insulation shall be 1100 volt grade cross linked Polythylene (XLPE). of cable shall be 9. single core. copied. Page 00785 000 STD 1621 04 00 3/4 SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM Cables mentioned here shall be a standard product of a manufacture regularly engaged in production of power cables. This specification covers requirements for type.Project N° Unit Document Code Serial N° Rev. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. disclosed or used. Approx. transferred. single core. Aluminium wire armoured. 3. 3-core. 6. manufacture and testing of the cables for cathodic protection system. stranded Aluminium conductor. ANODE LEAD CABLE Anode lead cables shall be 10mm2 stranded copper conductor. Aluminium wire armoured. . PVC insulated and sheathed 1100 grade cable. without its prior written consent. FCC UNIT.6mm 4. 5. FCCU AND PRU REVAMP. stranded Copper conductor. Aluminium wire armoured. the requirements under this specification shall be binding. 2. unarmoured. and shall not. reproduced.3961 (Part IV)-1968 c) IS: 3961 (Part-Ill)-1967 Where ever the requirements in this specification are in conflict with any of the above standard. be totally or partially. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. CODES AND STANDARDS In general the cable covered by this specification shall unless otherwise specified be in the line with the requirements of any of the latest applicable standard of: a) IS: 7098 (Part I)-1988 b) IS. PVC insulated and PVC sheathed 1100V grade cable. under any circumstances. single core. POWER SUPPLY CABLE ( Between PCC & T/R Unit) Power supply cable between Power source and T/R unit shall be stranded Aluminium conductor. DRAINAGE CABLE Drainage cables shall be 50mm2. rating. over all dia. directly or indirectly. PVC insulated and sheathed 1100V grade cable.

EARTHING CABLE Earthing cable shall be 35 mm2 stranded Copper conductor. transferred.Project N° Unit Document Code Serial N° Rev. 1100V grade. armoured. PVC insulated 1100V grade cable. CABLE DRUMS All cables to be supplied in wooden drums. MEASUREMENT CABLE AND PERMANENT REFERENCE CELL CABLE BETWEEN CJB CUM TEST STATION AND MJB The measurement cable & reference cell cable shall be 6mm2. under any circumstances. unarmoured. 11. Page 00785 000 STD 1621 04 00 4/4 SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM 7.SYSTEM CABLES" should be printed using black colour at one meter interval throughout the length of the cable. CABLE IDENTIFICATION For easy identification of cable. 10. FCC UNIT. 9. FCCU AND PRU REVAMP.P. copied. directly or indirectly. stranded copper conductor. . MATHURA. be totally or partially. INSPECTION All cables along with manufacturer's test certificate as per IS standards shall be inspected by OWNER at the vendor's shop before dispatch. where ever cable lengths are more than 600m. reproduced. and shall not. 8. the over sheath of the cable should have yellow colour and "C. without its prior written consent. The present document or drawing is property of TECHNIP KT INDIA LTD. Minimum 15 days notice to be furnished by vendor for this purpose. disclosed or used. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. single core. 1-core. PVC insulated and sheathed. Cable lengths in each cable drum shall be 600m (min).

INDIA. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. under any circumstances.2010 DATE ISSUED FOR DESIGN STATUS ABS PREPARED BY DYS REVIEWED BY DYS APPROVED BY CSA PM DOCUMENT REVISIONS Sections changed in last revision are identified by a line in the right margin .Project N° Unit Document Code Serial N° Rev. without its prior written consent. transferred. disclosed or used. be totally or partially. Page 00785 000 STD 1675 01 00 1/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION UNIT PROJECT The present document or drawing is property of TECHNIP KT INDIA LTD. reproduced. INDIAN OIL CORPORATION LIMITED. directly or indirectly. and shall not. : FCC UNIT : FCCU AND PRU REVAMP. copied.11. NOIDA. STANDARD SPECIFICATION FOR CATHODIC PROTECTION 00 REV. MATHURA REFINERY. LOCATION OWNER EPCM TECHNIP KT INDIA LTD. 11. MATHURA. : IOCL.

...................................... 11............... 36 CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY............. 5.......................................................... 3 DEFINITION ........................ 15 SPECIAL FACILITIES ..........Project N° Unit Document Code Serial N° Rev..................... 4 DOCUMENT REVIEW......................... 34 HANDLING............................................ 4................................................................................................................... 1............................ disclosed or used........................................ INTRODUCTION .............. be totally or partially................................................................................................................... FCCU AND PRU REVAMP................................................................... without its prior written consent.................... 10............................... 5 DESIGN BASIS ............... MATHURA........ ........ 32 MATERIAL SCHEDULES....................... under any circumstances.......................................... FCC UNIT.......... 7.................................................................................... copied..................................... 3.................... 8.. transferred............. 8 EQUIPMET AND MATERIALS ................................................. and shall not.......... directly or indirectly...................................................................... 6............................................. reproduced...... Page 00785 000 STD 1675 01 00 2/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION CONTENTS The present document or drawing is property of TECHNIP KT INDIA LTD................ 10 SYSTEMS ENGINEERING AND INSTALLATION.... 3 CODES AND STANDARDS .. 2................................................................................................................... for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use..... 9.................................................................................. 5 SITE SURVEY ...

Surface Bed .The voltage difference between a buried (or immersed) metallic surface and the electrolyte which is measured with reference to an electrode (such as copper/copper sulfate and silver/silver chloride electrodes) in contact with the electrolyte. and shall not. Structure . CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. FCCU AND PRU REVAMP. INTRODUCTION This specification covers the minimum requirements for cathodic protection of the The present document or drawing is property of TECHNIP KT INDIA LTD. disclosed or used. without its prior written consent. Structure-To-Electrolyte Potential . Page 00785 000 STD 1675 01 00 3/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 1. MATHURA. . Cathodic protection system is utilized for corrosion control of ferrous metals in contact with soil. wire or cable type anode placed parallel to the pipe run. following steel items: • • • • Buried steel piping Buried tanks Bottom surfaces of on-grade storage tanks in contact with soil. under any circumstances. copied. be totally or partially. 2. wire or cable type anode in a coil or grid form in a plane parallel to the tank bottom at a specified depth under the tank bottom.Project N° Unit Document Code Serial N° Rev. Shallow Bed . Interior surfaces of water boxes and tanks which are in contact with water.One or more anodes installed vertically at a depth of 5 to 15 meters below the earth’s surface. directly or indirectly.The surface to which cathodic protection is being applied. reproduced. below grade.When used in the matters related to pipe. Parallel Bed . transferred. (Bidder shall ensure there is no interference with RCC piles. DEFINITION Deep Well/ Deep Ground Bed . A foreign structure means a surface to which cathodic protection is being provided unintentionally. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. FCC UNIT.One or more anodes installed vertically at a depth of 15 meters or more below the earth’s surface in a drilled hole.Moist soil and water in contact with the structure.) Electrolyte . When used in the matters related to tank bottoms.One or more anodes installed horizontally or vertically at a depth of 5 meters or less. buried concrete and water.

FCC UNIT. copied. and Maintenance of Impressed Current Deep Ground Beds.Part .P of Steel Structures IS 5571(1971): Guide for selection of electrical equipment for hazardous areas Indian Electricity act Petroleum Act. cathodic protection system shall conform to the following standards as a minimum.Degree of protection provided by enclosures for low voltage switchgear & control gear National Association of Corrosion Engineers (NACE) NACE RP0169 NACE RP0177 NACE RP0193 NACE RP0286 NACE RP0572 Control of External Corrosion on Underground or Submerged Metallic Piping Systems. Page 00785 000 STD 1675 01 00 4/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 3. without its prior written consent. IS 8062 .Part I & II PVC Insulated Cable IS 7098: . MATHURA. Operation. 1976 British Standard Institute B7361 Steel Structures VDE: 0150. be totally or partially. under any circumstances.I (1976): Code of Practice for C.Part I for Cross-linked polyethylene insulated PVC sheathed cable IS 2148 (1981): .Flame Proof enclosures for Electrical apparatus IS 2147:1962: . Design.P of CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. reproduced. Installation. . National Electrical Code NEC NFPA-70 (ANSI-C1) National Electrical Code Part-I 1991 Code of Practice for C.Project N° Unit Document Code Serial N° Rev. directly or indirectly. The present document or drawing is property of TECHNIP KT INDIA LTD. CODES AND STANDARDS Unless otherwise specified. transferred. FCCU AND PRU REVAMP. disclosed or used. Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems External Cathodic Protection of On-Grade Metallic Storage Tank Bottoms The Electrical Isolation of Cathodically Protected Pipelines. Protection against corrosion due to stray current DC installation IS 3043: -Code for Practice for Earthing IS1554: . and shall not. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

1. RP0193. directly or indirectly. mesh. tubular. and shall not. RP0177. • All design. Sacrificial anode systems shall be considered secondary or supplementary to the primary impressed current systems. The design life of the cathodic protection system shall correspond to the following. MATHURA. such as NACE RP0169. installation. • Equipment. FCC UNIT.0 of this Specification. without its prior written consent. installation. Piping: On-grade tank bottoms: Buried tanks: Tank internals: Reference electrodes: • 20 years 30 years 30 years 20 years 20 years For soil applications. transferred. the primary type of cathodic protection system shall be impressed current using mixed metal oxide (MMO) anodes consisting of oxides of iridium. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. RP0286 and RP0572. DESIGN BASIS General Basis The design of cathodic protection systems shall be based on the following and other factors which are identified in the bidder’s pre-design survey: • System designs and installations shall comply with applicable sections of the industry standards referenced in Section 3. 5. Such comments The present document or drawing is property of TECHNIP KT INDIA LTD. testing and commissioning practices shall conform to the codes and standards listed in this document. under any circumstances. materials. shall not be construed as permission to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing. reproduced. The MMO anodes shall be canister. be totally or partially. FCCU AND PRU REVAMP. rod. Page 00785 000 STD 1675 01 00 5/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 4. tantalum and titanium on titanium base. equipment and materials shall be suitable for continuous operation under site conditions during the stated design life of the cathodic protection system and shall be compatible with the environmental conditions of the project. DOCUMENT REVIEW Comments made by Contractor /Owner on drawing submittal shall not relieve bidder of any responsibility in meeting the requirements of the specifications. ribbon type or a combination thereof.Project N° Unit Document Code Serial N° Rev. disclosed or used. copied. design. other requirements stated in this document and all relevant project drawings. 5. wire. . for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

Project N° Unit Document Code Serial N° Rev. reproduced. FCCU AND PRU REVAMP. The anode shape.2. TABLE 1 SCHEDULE OF CATHODIC PROTECTION SYSTEMS MMO . Page 00785 000 STD 1675 01 00 6/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 5. directly or indirectly. transferred. Schedule of cathodic protection systems The cathodic protection systems shall comply with Table 1. under any circumstances. and shall not. copied. disclosed or used. construction. without its prior written consent. contractor. . FCC UNIT. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. be totally or partially. MATHURA. or prepackage d storage MMO wire HDPE SURFACES IN CONTACT WITH WATER Water tank internals Water box internals Platinized niobium None None Horizontal (Parallel bed) loops None Surface horizontal Surface vertical Bentonite within plant boundaries casings crossings boundaries without casing) New on-grade with tank bottoms (coated and uncoated) membranes within On the pipe None Coke breeze Carbon steel piping within MMO wire plant boundaries Coke breeze CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. type and method of connection shall be approved by the purchaser/EPC The present document or drawing is property of TECHNIP KT INDIA LTD.mixed metal oxide (iridium/tantalum/titanium oxide) on titanium base ITEM TO BE ANODE MATERIAL ANODE TYPE BED BACKFILL PROTECTED SURFACES IN CONTACT WITH SOIL Buried tanks MMO wire Surface Vertical Surface horizontal Surface vertical Parallel to pipe Carbon steel piping at Zinc ribbon isolated Pipe road crossings at (with road Magnesium plant cast.

under any circumstances.00 In case of any change in calculation procedure. vendor shall take prior approval from contractor/ owner. directly or indirectly. Surfaces in contact with soil Surfaces in fresh water Surfaces in saline water 22 mA/ m2 30 mA/ m2 65 mA/m2 Surfaces in contact with concrete 20 mA/ m2 Defective Surface Area (DS. On-grade storage tank bottoms: 5% of the bottom surface plus 100% of the weld zone area (= total weld joint length.05 Surfaces coated with 3-layer system (pipe surfaces) = 0. = DS*i + S*i*CF = Total requirement current requirement. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.e. mA/m2 = Total surface area of the Structure in contact with the electrolyte.15 meters of zone width).Project N° Unit Document Code Serial N° Rev. bare surfaces) = Current density adjustment factor for coated area = Current density. FCC UNIT. reproduced. meters x 0. be totally or partially. MATHURA. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. . Page 00785 000 STD 1675 01 00 7/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 5.20 Surfaces coated with polyethylene and polypropylene = 0. Water box interiors: 1% of the total boxed area. Current requirements Total current requirements shall be calculated using the following formula: I The present document or drawing is property of TECHNIP KT INDIA LTD. coal tar urethanes = 0. disclosed or used. without its prior written consent. m2 DS CF i S Where. Tank internals (water tanks): 1% of the total floor and shell area Tank internals: hydrocarbon services (in cases where water accumulates on the floor): 1% of the floor area plus 1% of the first course of the shell area. liquid epoxy and coal tar epoxy. and shall not. Current Density Adjustment Factor For Coated Areas (CF) Surfaces coated with fusion bonded epoxy.3. transferred. copied. FCCU AND PRU REVAMP.05 Surfaces coated with other coatings = 1. mA = Surface area considered to have defective coating (i. % of the Surface Considered To Be Defective) Buried pipe and tank surfaces: 1% of the total exterior surface. I Current Density (i) The following minimum current densities (based on bare surfaces) shall be used as basis for current requirement calculations and shall be increased by 25% per 10°C rise in temperature of the electrolyte above 30°C.

PERFORMANCE CRITERIA The installed system shall provide the levels of cathodic protection specified in Table 2. . directly or indirectly. 2. be totally or partially. FCCU AND PRU REVAMP. Cu/CuSO4 reference may be used for buried piping when testing with portable reference electrodes. Page 00785 000 STD 1675 01 00 8/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 5. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. and shall not. The present document or drawing is property of TECHNIP KT INDIA LTD. a predesign site survey shall be carried out. SITE SURVEY After locations of new buried refinery structures are determined. disclosed or used. Possible interference sources such as high voltage transmission lines. reproduced. Ag/AgCl reference electrodes shall be used for permanent installations in soil and seawater. the survey results shall be adjusted to obtain a realistic design basis. TABLE 2 Cathodic Protection Potentials INSTANT “OFF” POTENTIALS. without its prior written consent. mV REFERENCE ELECTRODE Cu/CuSO4(1) Steel in soil(3) Steel in water NOTES: 1. FCC UNIT. The field survey shall evaluate the following: • • • • General terrain.Project N° Unit Document Code Serial N° Rev. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Soil electrical resistivity and chemistry testing of the site. Effects of existing cathodic protection system on new systems or vice versa. manmade stray currents or adjacent buried metallic structures or piping. If the area to be surveyed is affected by seasonal changes.4. -950 to 1150 -950 to 1100 Ag/AgCl(2) -900 to 1100 -900 to 1050 6. transferred. under any circumstances. copied. MATHURA.

Otherwise. and shall not. and readings shall be taken whenever there are visual changes in soil characteristics. All other information that is considered relevant to the design of a cathodic protection system. to test the ground bed resistance for deep wells. if possible. A single anode may be lowered down the hole with a long lead which is connected to a buried structure in series with a battery and an ammeter. disclosed or used. Page 00785 000 STD 1675 01 00 9/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 6. General Terrain The survey shall include general information of the terrain including: • The present document or drawing is property of TECHNIP KT INDIA LTD. reproduced. other pipelines).1. For each type of soil. transferred. This shall be repeated until the readings meet the 2:1 ratio criteria. If water is encountered. copied. without its prior written consent. Soil resistivity shall be estimated by inputting the anode dimensions and anode resistance in the Dwight formula for single vertical anode.Project N° Unit Document Code Serial N° Rev. a profile of current output and anode resistance with depth can be developed. directly or indirectly. readings should be taken in at least two different locations. the hole may be allowed to fill with ground water. FCCU AND PRU REVAMP. At each location a minimum of two measurements shall be carried out. Type of terrain and vegetation. . • • • 6. The site shall be marked off in a rectangular grid and readings shall be taken at each grid intersection.1. FCC UNIT. under any circumstances. If two successive readings differ by a ratio greater than 2:1. an additional reading shall be obtained at the midpoint between the previous two readings. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.2. be totally or partially. Soil Resistivity Measurements Surface and Shallow Beds The number of measurements shall be determined locally using the following minimum spacing.2. overhead power lines. By measuring the current output at known power source voltage at intervals as the test anode is lowered.2. 6.2. Water drainage and channels. Deep Well Ground Beds Holes (or wells) drilled during geotechnical survey shall be used first. Visible relevant features and crossings (main roads. MATHURA. it may be filled with local water. 6. pilot holes shall be drilled to estimated depths indicated to be favorable from tests done for shallow beds. If hole is dry. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.

Cable data. with numbering system in accordance with project equipment tag numbering system. Cable to anode connection including sealing materials and methods. transferred. directly or indirectly. The plates shall also have tag numbers. EQUIPMENT AND MATERIALS All equipment and materials for permanent installation shall be compatible with the environmental conditions of project. be totally or partially. MATHURA. permanent reference electrodes etc.Project N° Unit Document Code Serial N° Rev. attenuation rating of the anode. For water tank and water box services. FCC UNIT. and shall not. sulfate reducing bacteria and redox potentials. tantalum and titanium oxides) on titanium base. The tag numbers shall be marked on as-built drawings and referred to in all cathodic protection documentation. without its prior written consent.1.3. sulfates. platinum etc. copied. under any circumstances. Electrical properties of the anode including internal resistance. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Impressed current anodes Impressed current anodes for services other than water tanks and boxes shall be mixed metal oxides (iridium. at least be carried out when there are visual changes in soil characteristics. FCCU AND PRU REVAMP. current rating and consumption data.) Anode core data including dimensional data. sulfides. Anode shape and dimensional data. The number of tests should be determined locally but measurements should The present document or drawing is property of TECHNIP KT INDIA LTD. Any other information that will effect Owner’s approval. test stations.000 amps per square meter at consumption rates not exceeding 80 milligrams/amp-yr. disclosed or used.) shall have identification plates with information identifying their purpose. reproduced. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. chlorides. . All equipment (transformer rectifiers. 7. 7. Bidder shall submit the following information for product approval: • • • • • • • Composition of anode coating (mixed metal oxides. Chemical Properties of Soil Tests shall include pH. junction boxes. Page 00785 000 STD 1675 01 00 10/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 6. the impressed current anodes shall be platinized niobium anode with copper core capable of delivering 1.

transferred.001% max Balance Cd Cu Fe Pb Zn Al Cu Fe Mn Ni Mg Magnesium anodes shall be of the following composition: Others 0.77% 0.2.03% max 0. under any circumstances. dimensions.10 ohm-cm 99.005% max 0. Page 00785 000 STD 1675 01 00 11/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 7.Project N° Unit Document Code Serial N° Rev. without its prior written consent. FCC UNIT. FCCU AND PRU REVAMP. Each anode shall be clearly marked with the type of material (trade name).0014% max 0. shall consist of a mixture of Gypsum (75%). disclosed or used. when specified. 0.01% 0.02% max 0.50-1.002% max 0. 7. Full documentation (type. batch or charge number and anode weight (without backfill).003% max 0. shall be metallurgical coke breeze with the following properties: Maximum resistivity: Fixed carbon: Ash: CLIENT UNIT PROJECT : : : 0.3. directly or indirectly. chemical analysis and performance data of the anodes) shall be submitted by the bidder for review. Backfill materials for impressed current beds in soil Carbonaceous backfill. weight. reproduced. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Type II with the following composition: Al The present document or drawing is property of TECHNIP KT INDIA LTD. Backfill materials for pre-packaged sacrificial anodes Backfill for sacrificial anodes. be totally or partially. Backfill is not required for ribbon type anode installed directly on the structure. Bentonite clay (20%) and sodium sulfate (5%).3% 0.4. . other than ribbon type. copied. MATHURA. 7.30% max Cast anodes shall be factory prepackaged with backfill. and shall not.003% max remainder 0.1% INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Sacrificial anode Zinc anodes shall be ASTM B-418.

Transformer/rectifiers shall be mounted on concrete plinths and all units supplied for specific functions shall be by the same Bidders and shall be interchangeable on their plinth mountings. 415±10% V-AC. disclosed or used.5. ripple current shall not exceed 5% of the DC output current between 5% and 100% of the rated current output. Cables For cables refer standard specification no. Rectifier stations and other associated equipment shall be installed in nonhazardous areas wherever practical. The output rms. copied. All necessary hardware shall be furnished. 00785-000-STD-1621-04. Rectifiers shall be of a special design for cathodic protection service and should be 3 phase units. 0% 0% 1 185 kgs/m3 1.Project N° Unit Document Code Serial N° Rev. The current rating of the diodes shall be more than 1. 50±5% Hz if available or single phase. Transformer/rectifiers shall not be installed in series or in parallel in the same cathodic protection circuit. directly or indirectly. A step less (continuous) adjustment shall be used. FCC UNIT. Transformers/rectifiers shall comply with relevant IS/IEC standards.6. Transformers/ Rectifiers Transformers/rectifier stations shall be equipped with an alarm system which automatically signals when there is current interruption. reproduced.0 mm maximum. Automatic potential control shall be provided. and shall not. Particle size: 7. under any circumstances. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. and with a remote monitoring system.25 times the maximum current rating of the rectifier and have a minimum peak inverse voltage of . The rectifier shall be constructed silicon diodes so arranged as to provide full wave rectification. 1200V. bolts and contact hardware shall be of copper. connectors. FCCU AND PRU REVAMP. without its prior written consent. The output voltage shall be adjustable from zero to the maximum rated output when on load. dust free. Page 00785 000 STD 1675 01 00 12/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Moisture: Volatiles: Bulk density: The present document or drawing is property of TECHNIP KT INDIA LTD. 7. be totally or partially. Locking devices shall be used at all bolts and screw connections. All terminals. MATHURA. The maximum T/R output voltage shall be 75 volts. brass or bronze. transferred.

A sight glass and thermometer shall be provided. so that no damage occurs under normal handling.Project N° Unit Document Code Serial N° Rev. The enclosure shall have a minimum degree of protection IP 54. reproduced. Page 00785 000 STD 1675 01 00 13/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION The transformer/rectifier shall be provided with an isolator or Molded Case Circuit Breaker (MCCB) on its incoming circuit and. where applicable. The cabinet and its component parts shall be of sufficient strength and rigidity. Transformer/rectifiers shall be installed in a non-hazardous area wherever practical. current and permanent reference electrode potential. piping. The measuring accuracy shall be better than 2% of full scale. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Transformer/rectifiers shall be suitable to operate under the prevailing service conditions. and shall not. AC and DC cables shall be physically separated by an insulating panel. MATHURA. directly or indirectly. The cathodic protection system in the plant shall be designed so that a synchronous switching can be achieved from a central monitoring switching board. Additionally. A built-in current interrupter unit is required. During normal operation. without its prior written consent. disclosed or used. The transformer/rectifier shall be provided with approximately 76 mm diameter meters or similarly sized square pattern meters to read the output voltage. be totally or partially. If this is not possible. switched off. FCCU AND PRU REVAMP. tank or plant area system is cathodically protected by more than one transformer/rectifier. The current interrupter unit shall be electronic and shall be capable of switching the full output current on ON/OFF sequence infinitely variable and adjustable from 0 to 99 seconds independently for ON/OFF periods. transferred. all transformer/rectifier interrupter units shall be provided with a facility for synchronous switching. If a pipeline. on its AC subcircuits. Incoming cables of oil cooled transformer/rectifiers shall be terminated in separate non oil filled cable boxes and penetration into the tank shall be via bushings above oil level. the built-in current interrupter shall be bypassed and synchronous switching. copied. the construction of the rectifier units shall fulfill the requirements of the hazardous area classification applicable for the site. AC sub-circuits and negative DC output circuits. FCC UNIT. The polarity of the DC terminals and AC supply terminals shall be clearly marked.6 mm steel. The rectifier cabinet shall be of not less than 2. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. The bidder shall obtain the required information on area classification from the Owner. The transformer/rectifier shall be capable of withstanding a short circuit of up to 15 seconds duration at the output terminals without damage to any of its devices. . All weight bearing components shall be constructed from coated angle steel. under any circumstances. suitably sized fuses shall be installed on the transformer/rectifier’s phase The present document or drawing is property of TECHNIP KT INDIA LTD.

8. reproduced. be totally or partially. terminals. weight of the oil and weight of the unit plus oil. Flush Fink test station shall be used. Surge arrestors across the output terminals of DC voltage sources • • • • A rating plate indicating Manufacturer’s name. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. rectifier material. If test stations are required to be installed underground. date of purchase shall be provided. the station shall be flush (with grade) type such as FlushFink. from resistors. An oil drain with a valve. complete with spare desiccant cartridge.g. An earthing terminal. under any circumstances. FCCU AND PRU REVAMP. directly or indirectly. Lifting lugs of suitable size and location to facilitate lifting of the unit when full of oil. . copied. FCC UNIT. An oil tank breather provided with silica get cartridge and breather seal. without its prior written consent. DC rating. MATHURA. Page 00785 000 STD 1675 01 00 14/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Each transformer/rectifier shall have: • • The present document or drawing is property of TECHNIP KT INDIA LTD. maximum operating temperature of the unit. disclosed or used. Big Fink test station with upright post shall be used in all areas except areas directly in the traffic path. model number.7. Anode terminal boxes shall provide sufficient room for control and test equipment and dissipation of heat. The boxes shall be provided with hinged doors giving access to all internal components. meters and hardware as indicated by the bidders’s detailed design. 7. transferred. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. e. Anode terminal boxes Anode terminal boxes shall be of stainless steel type 316L and with minimum degree of protection IP 54 . AC rating. In such areas.Project N° Unit Document Code Serial N° Rev. grid coil resistors. manufacturing date. and shall not. They shall be provided with a 6 mm thick phenolic panel with appropriate shunts. Test stations Test posts shall provide sufficient room for the termination of test cables and for the installation of bonding cables and/or resistors. project purchase order number. equipment identification number. The junction box shall be provided with one or more 75 mm diameter conduit hub and conduit for cables. If installed in traffic areas. 7. Test post head shall be orange color. An oil filling hole with screw cap. they shall have adequate water drainage facilities and they shall be provided with a closure to avoid ingress of dirt.

The station shall be dimensionally stable up to 70°C and resistant to ultraviolet light. FCC UNIT.7 meters. 8. Test station shall be Ex’d’ type. The present document or drawing is property of TECHNIP KT INDIA LTD. disclosed or used. Education and experience data (known as CV or resume) of vendor’s Corrosion Engineer/Specialist shall be forwarded to the PMC/Owner for approval before work commences. Corrosion protection for tank bottoms shall consist of the following (descriptions of items under the tank plates starting from the tank plate) : • • • • • Coating on the soil side (underside) of the tank floor plate in compliance to specifications. The station shall be designed to reduce shock hazard. stray current analysis. copied. MATHURA. clean. FCCU AND PRU REVAMP. and shall not. chloride free foundation fill material A cathodic protection system consisting of anodes and reference electrodes.1. A HDPE or other plastic liner shall be installed approximately 450 to 550 mm below the tank plates. Tank bottoms The design and installation of cathodic protection system shall comply with the requirements of NACE RP0193. SYSTEMS ENGINEERING AND INSTALLATION Qualifications for design personnel All work consisting of site survey. system selection. • Foundation fill material. CLIENT UNIT PROJECT . for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. zone 2. A layer of 300 to 350 mm thick dry.2. 8. The liner shall have chemical resistance to any fluid leak from the tank floor plate. without its prior written consent. Terminals shall be completely accessible with leads located under the cover. Cable entry shall be at the bottom through protective tubes. system design. chloride free foundation fill material. 8. Page 00785 000 STD 1675 01 00 15/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Test stations shall be provided with lockable access doors or caps. reproduced. A layer of 150 to 200 mm thick.Project N° Unit Document Code Serial N° Rev. clean. class T3. under any circumstances. Terminal board shall be easily removable for adding or deleting cables. be totally or partially. transferred. or have external insulated contacts fitted to allow easy connection of test clips for regular monitoring. installation and commissioning shall be under direct supervision of vendor’s. : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. dry. gas group IIA/ IIB/ IIC. Maximum height shall be 2 meters with no component requiring adjustment or monitoring higher than 1. directly or indirectly.

reproduced. The drawing shall also show the installation date and maximum current rating of the anode materials. copied. Reference electrodes shall be placed close to the bottom and away from the anode loops. shall be laminated and securely attached to the inside of the anode terminal box. All design calculations for the anode assembly with its power feed points and header cable connections locations shall be performed by the anode assembly manufacturer. Anode loop length and loop diameter calculations shall be performed by the Vendor and verified by the contractor. disclosed or used. and shall not. transferred. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Leads from all reference cells and two test cables from the tank plate shall be routed to one test station. The present document or drawing is property of TECHNIP KT INDIA LTD. a minimum of three permanent reference electrodes shall be installed in the middle of the tank bottom area in a triangular pattern whose center is the center of the tank bottom. FCCU AND PRU REVAMP. be totally or partially. under any circumstances. Each cable shall be clearly tagged with anode loop number starting with #1 for the loop in the center. The distance between the reference electrodes shall not exceed 15 meters subject to a minimum of one reference electrode in each quadrant. header cable resistance and anode geometry shall be optimized to maintain variation of current distribution below 10% at any point on the linear cathodic protection system. directly or indirectly. A copy of the drawing showing reference electrodes. reduced to reasonable size. Page 00785 000 STD 1675 01 00 16/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Anodes shall be titanium wire with mixed metal oxide coating installed in the form of horizontal circular loops with cables from both ends exiting through the foundation wall. Cables from each anode loop shall be brought outside the tank foundation ring and connected to the terminals in the anode terminal box.Project N° Unit Document Code Serial N° Rev. The spacing between the anode loops shall be calculated to provide uniform current density to the tank plates. A copy of the drawing showing anode loops. Reference electrodes shall be installed along the circumference of an imaginary circle whose radius is 86% of the tank radius from the center point of the tank bottom. . for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Each tank shall have one anode terminal box. All anodes shall be powered with a dedicated transformer rectifier to each tank or a rectifier dedicated to a group of adjacent tanks. Anode resistance. FCC UNIT. Also. MATHURA. Tanks shall have grounding protectors installed at each electrically isolated joint. Reference cells shall be numbered starting with #1 for the center reference electrode followed by the reference electrodes located clockwise from the location of the test station. without its prior written consent.

copied.Project N° Unit Document Code Serial N° Rev. directly or indirectly. The system shall be free of shorts and perform at the electrical potentials specified in the cathodic protection criteria. Diameter of the anode loops Placement of the reference electrodes. Quality of the coating on the soil side of the tank plates.3. During installation of the cathodic protection system. MATHURA. FCCU AND PRU REVAMP. the system shall be checked for electrical shorts and performance. and shall not. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. shall be laminated and securely placed within the test station for reference. under any circumstances. for performance after tank floor plate placement and before starting the shell fabrication. FCC UNIT. Reference electrodes. and overall anode assembly. The cathodic protection system shall be energized using temporary power and checked The present document or drawing is property of TECHNIP KT INDIA LTD. appropriate quality checks of the following items shall be performed and documentation shall be maintained by the vendor. . 8. Placement of grounding cells and appropriated checks recommended by the manufacturer of grounding cells. • • • • • • • Liner and lining fabrication. After the tank plates are welded. cable connections. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. the following items shall be checked: • • • • • • Thickness of the sand layers. be totally or partially. disclosed or used. corrosion protection of anode to cable connections. Sufficient slack in the cables. Quality of the sand. Before starting the cathodic protection installation. Zero electrical resistance at the anode to cable connections. without its prior written consent. Anode materials. Buried tanks The design and installation of cathodic protection system shall comply with the requirements of NACE RP0169. Page 00785 000 STD 1675 01 00 17/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION reduced to a reasonable size. Depths of the anode loops and reference electrodes. transferred. reproduced.

Positive header cable shall enter the tank interior from the roof from which individual cable to the anodes shall be routed inside the ceiling space of the tank to the hand holes. gasketed covers. All cables inside the tank shall be resistant to the tank interior atmosphere. Tanks containing flammable fluids shall have grounding cells installed at each isolation The present document or drawing is property of TECHNIP KT INDIA LTD. 8. Levels of cathodic protection shall be similar to those described for buried piping. FCC UNIT. directly or indirectly.6 mm diameter wire. All wiring on the outside of the tank shall be installed in rigid steel conduit. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. transferred. replaced or inspected without entering the tank. Underwater splices of cables are not permitted. Each anode circuit shall also have grid coil resistor to permit balancing of current output from the anodes. Cables on the tank roof shall be run in galvanized and painted conduit.Project N° Unit Document Code Serial N° Rev. The permanent reference electrode shall be IR-free silver/silver chloride reference electrode. without its prior written consent. and shall not. All damages to the internal coating caused by cutting and welding operations shall be repaired . All hand holes shall have removable. Anodes shall be metallurgically bonded platinum coating on niobium substrate 1. Hand holes and mounting devices shall be provided in the roof adjacent to each anode suspension so that the anodes can be removed. Tank internals All welding and cutting of tank surfaces necessary for installation of internal cathodic protection equipment shall be completed before application of internal and external coatings when practical. disclosed or used. Junction boxes shall be provided on tank roof for each anode to anode header cable connection. MATHURA. under any circumstances.4. Connections between the positive lead wire and the conductors from the anodes shall be mechanically secure. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. FCCU AND PRU REVAMP. electrically conductive and shall be sealed to prevent moisture penetration. Page 00785 000 STD 1675 01 00 18/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Buried tanks shall be protected with impressed current cathodic protection system using vertical anodes. copied. The feeder cable to the anode shall be properly and permanently secured at the hand holes and shall be designed to easily disconnect the anode for repair or replacement. reproduced. joint. . be totally or partially. Junction boxes shall also house shunts to permit current measurements.

for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. FCCU AND PRU REVAMP. Page 00785 000 STD 1675 01 00 19/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Anodes shall be supported by a metallic stranded rope of 3 mm minimum diameter with PVC sheathing. The anode system shall have lowest possible circuit resistance. Anodes shall not be self-supporting. distribution. The anode assembly shall consist of full length anodes on the outer ring to protect the shell surface. 8. Automatic controls shall be installed to adjust the output of the rectifiers based on potential readings of the permanent reference electrodes. reproduced. The straight line spacing between reference electrodes shall not exceed 10 meters and the minimum number of reference electrodes per tank shall be two.1. disclosed or used. FCC UNIT. Reference electrodes shall be located approximately at equal distance from the anodes and close to the intersection of floor and shell. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. . MATHURA. without its prior written consent. directly or indirectly. 8. Voltage attenuation shall be less than 10% at the anode end opposite from the anode to positive cable connection. and shall not. Horizontally suspended anodes shall be used to protect the floor surface. Installation shall not require emptying. be totally or partially.Project N° Unit Document Code Serial N° Rev. wall penetrations below the high water line or the use of pressure fittings.5. The system shall be also automatically adjustable for all variables except IR drop error. Unless otherwise approved by the Owner. Piping without casing buried under roads: Piping which is geographically remote or isolated from impressed current cathodic protection systems shall be protected with zinc ribbons. copied. under any circumstances. transferred.5. Appropriate ballast weights shall be installed to keep the anodes stationary while the fluid is moving inside the tank. The anodes shall be supported from the roof in a vertical position for optimum current The present document or drawing is property of TECHNIP KT INDIA LTD. the distance between the anode surface and the tank surface shall not be less than one meter. The anode system shall be designed to prevent electrical shorting to the tank. The anode system shall provide and maintain an uniform distribution of current without exceeding the potential limits stated in the cathodic protection criteria. A magnet secured to a reference electrode cell shall be used to maintain the 10 mm distance from tank surface. Buried piping system The design and installation of cathodic protection system shall comply with the requirements of NACE RP0169.

If the pipe support is conductive. . location and the first above ground pipe support or connection to aboveground equipment. Pipe casings: The use of pipe casings is not recommended. Casings shall be dried. without its prior written consent. disclosed or used. under any circumstances. The electrical isolation shall be between the road The present document or drawing is property of TECHNIP KT INDIA LTD. Cathodic protection shall be provided to the carrier pipe inside the casing. The surfaces on the soil side shall be protected with magnesium anodes with anode to structure connections located abovegrade in a test station.Project N° Unit Document Code Serial N° Rev. the design of the casing should be such as to cause minimal interference with or shielding of cathodic protection to the carrier pipe. if their use is mandatory. Cathodic protection system for casing shall be completely separate from the cathodic protection system of the piping. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.5. reproduced.3. FCCU AND PRU REVAMP. electrical isolation shall be approved in writing by the Contractor and Company. The seal between the casing and carrier piping shall be moisture tight. sealed using nonmetallic end seals and provided with vent pipes at both ends. Zinc ribbons shall be attached to the carrier pipe via a cable in a test post. However. FCC UNIT. In addition to the electrical insulators at the casing ends. each pipe support inside the casing shall be electrically nonconductive. and shall not. noncreep glass reinforced nylon pressure plates to improve insulation between the casing and the carrier piping. by installing zinc ribbon anodes together with a reference electrode. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. be totally or partially. directly or indirectly. Page 00785 000 STD 1675 01 00 20/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION A test station shall be installed to monitor the potential of the piping. 8. transferred.2.5. 8. MATHURA. Link-Seals shall be supplied with high strength. Buried piping shall be electrically isolated on both sides of road by using dielectric joints (couplings. Piping inside casings: Piping inside casing shall be electrically isolated from the casing using insulators such as LinkSeals which shall be installed at not more than 150 mm from each end regardless of the size of the casing or the carrier pipe. copied. flanges or unions). The number of supports shall be as recommended by the Manufacturer of the insulator and approved by the Contractor and Owner.

.6. reproduced. water. be totally or partially. The plant area shall be divided into geographical areas for cathodic protection circuits. such as at road crossings or isolated areas. On short pipeline sections. FCC UNIT. and shall not. For localized (hot-spot) protection to supplement impressed current systems. the vendor shall submit a description of technical options to the contractor.500 ohm-cm and magnesium anodes if the soil resistivity is less than 3.5.4. The use of a sacrificial anode system may be considered. Each geographical area shall be serviced by one dedicated cathodic protection system. MATHURA. shall be protected with impressed current cathodic protection system. if pipeline isolation cannot be immediately installed. These geographical areas shall be of reasonable size to troubleshoot any system related problems.000 ohm-cm. the vendor shall show by measurement and calculation that: • • The resistivity of the soil is sufficiently low to allow successful application of sacrificial anodes. For temporary protection of existing pipelines. If the resistivity is more than 3. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Plant piping: Plant piping. If cathodic protection by sacrificial anodes is selected. directly or indirectly. FCCU AND PRU REVAMP. if the following conditions are met: • • • • • If the pipeline (section) runs in low resistivity soil. for economic reasons For temporary protection on newly laid pipelines.000 ohm-cm. a cathodic protection area shall be an area separated from other cathodic protection areas by roads. disclosed or used. under any circumstances. 8. transferred. The selected type of anode is capable of continuously supplying the maximum current demand. zinc anodes may be used provided the soil resistivity is less than 1.Project N° Unit Document Code Serial N° Rev. swamps or marshes. other than at road crossing either remote or isolated. Where possible. Page 00785 000 STD 1675 01 00 21/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 8. The present document or drawing is property of TECHNIP KT INDIA LTD. copied. Current drain point connection to the pipe shall be on the buried section of the piping. without its prior written consent. Sacrificial anode beds Where the impressed current system is not economically feasible. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.

7. under any circumstances. Its resistance to earth allows the maximum predicted current demand to be met at 80% or less of the voltage capacity of the DC source during the design life of the system. Page 00785 000 STD 1675 01 00 22/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION • The total mass of anode material is sufficient to supply the required current during the design life of the system. • The risk of causing harmful interference on other buried structures is minimized. FCCU AND PRU REVAMP. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Deep Well Beds The selection of the location and the type of groundbed shall be based on and take full account of local conditions such as: • • • • • • Soil conditions and resistivity at various depths.Project N° Unit Document Code Serial N° Rev. reproduced.7. Sacrificial anode cables shall be connected to the pipeline via a bondbox and shunts to allow anode current monitoring.1. Impressed current anode beds The design and installation of deepwell beds systems shall comply with the requirements of NACE RP0572. 8. For magnesium anodes. copied. it is allowed to install a resistor in the anode circuit to limit the protection levels to within the protection criteria. disclosed or used. Risk of shielding (especially for parallel pipelines). be totally or partially. Risk of damage by excavation (surface groundbeds). and shall not. Impressed current cathodic protection systems shall be powered by transformer / rectifier units fed by an AC power supply. transferred. directly or indirectly. output. MATHURA. The anodes shall be buried in low resistivity chemical backfill to obtain the required The present document or drawing is property of TECHNIP KT INDIA LTD. . without its prior written consent. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Available terrain (for surface groundbeds). The ground bed of an impressed current cathodic protection system shall be designed such that: • • Its mass and quality are sufficient to last for the design life of the system. Groundwater levels and resistivity. Strong seasonal changes in surface soil conditions. FCC UNIT. 8.

completion of the borehole and the method of installation of the anodes and backfill. plastic casing shall be used. Casings for deepwells The borehole design and construction shall be such that undesirable transfer between water bearing formations and pollution of underlying strata from the surface (e. copied. tank farms) is prevented. Geotextile shall be used to avoid blockage of the vent pipe by coke backfill. 8. Where more than one ground bed is installed per a transformer rectifier.Project N° Unit Document Code Serial N° Rev. FCCU AND PRU REVAMP. Ground bed markers shall be installed at each end of each ground bed.7. Page 00785 000 STD 1675 01 00 23/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Deepwell ground beds should be used: • The present document or drawing is property of TECHNIP KT INDIA LTD. The vendor shall specify in his detailed design the method of drilling the deepwell. If the soil conditions at the required depth are suitable to meet the project requirements. • • • The vendor shall include in his basic design a calculation of the ground bed resistance based on the most accurate soil resistivity data available. transferred. disclosed or used. MATHURA. Venting of deep well beds Deepwell ground beds shall be provided with adequate venting pipes to prevent gas blocking of the well.2.3. reproduced. FCC UNIT. and shall not. If there is a risk of shielding by other pipelines or buried structures. If the available space is limited.7. If there is a risk of stray currents on adjacent installations. .4. without its prior written consent. cables shall be routed from each ground bed to a anode junction box. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. under any circumstances. Shallow Ground bed and Surface Beds The anodes or the highest point of the carbonaceous backfill shall be not less than one meter below ground level. be totally or partially. using established methods and formulae. To achieve such isolation. establishing the resistivity of the soil at depth.g. directly or indirectly. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. 8..7. Vent pipe material shall be chlorine resistant. Metal casings may be used at the surface for stabilizing the borehole and in the active section of the groundbed. Casing at depth shall be electrically isolated from metal casing and structures at the surface. 8.

The cables shall be connected to the positive feeder cable inside an aboveground junction box to enable current monitoring. All cables shall be laid without coils or kinks. provided with cable protection tiles and warning tape installed 250 mm above the cable. These shall be installed at approximately 25 meter intervals and at every change of direction of the cable route. . transferred. Superficial wire brushing is not acceptable. 8. FCCU AND PRU REVAMP. Connections shall be made to surfaces which are thoroughly cleaned to the bare metal. be totally or partially. The present document or drawing is property of TECHNIP KT INDIA LTD. Page 00785 000 STD 1675 01 00 24/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION The junction box shall contain grid coil resistors. directly or indirectly. 8. Cleaning shall be accomplished by grinders without reducing wall thickness lower than the project requirements. shunts in each circuit and an ammeter with selector switch to measure current flow in each circuit. Impressed current anode cable connections shall be insulated using epoxy resin and/or heat shrinkable insulation sleeves. under any circumstances. Connection of cables Cable routes shall be clearly marked using cable markers. Cable markers at the sacrificial anode locations shall also include markings to indicate the location of the sacrificial anodes. Welding of cable connections shall not be carried out on bends or within 200 mm from welds.75 m. The cables of sacrificial anodes shall be connected to the pipe via an aboveground distribution box to allow current monitoring and disconnection. disclosed or used.8. without its prior written consent. FCC UNIT. MATHURA. buried in sand at a depth of at least 0. Cable to cable connections should be made aboveground inside test stations to reduce the risk of damage and to allow monitoring. Connection Methods The vendor shall include in the design detailed procedures of processes to be used for cable connections. reproduced. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.8.2. All buried cables shall be of one continuous length without splices. General 8. copied.Project N° Unit Document Code Serial N° Rev. Welders shall be fully qualified for the applicable welding process. and shall not. Markers to indicate CP cable and include arrow to indicate the direction of cable run. Cable connections shall be designed to ensure adequate mechanical strength and electrical continuity and to prevent damage to the structure. Each vertical anode shall have gravel vent and anode marker. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.1.8.

for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 50x50 mm minimum. transferred. The following guideline for the selection of cable connections shall be followed: • • • All underground connections to carbon steel surfaces (STRUCTURES and other surfaces) shall be done by using Cad-welding process only. The plate shall be made of material similar to the structure. FCC UNIT. washer and double nuts. FCCU AND PRU REVAMP. nuts and serrated washers. be totally or partially. a cable terminal with brazed or crimped lug. All other connections shall be done by bolted connections. Page 00785 000 STD 1675 01 00 25/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION All below and above ground electrical connections shall be fully encapsulated with a coating Belzona 1121 before backfilling. The cables shall be connected to the threaded stud bolt using crimped or brazed cable lugs. provided with a welded M10 threaded stud bolt. Bolted Connections: Bolted connection consists of a stud welded to the surface requiring connection. and shall not. The process shall not influence the structure material properties to fall outside the original specifications. Stud material shall be similar to the structure material. double nuts and serrated washers. shall be welded to the structure. The stud material and consumable shall be compatible with the structure material. Stud welding may be done using an electrical (resistance welding) or mechanical (friction welding) process which shall be approved by the contractor and owner. All aboveground connections to carbon steel STRUCTURES shall be done by using Cad-welding process only. Coating repair at cable connections shall comply with Project coating specification requirements as applicable. Penetration of copper and/or other brazing metals into the structure shall not be deeper than 1 mm and the hardness shall remain inside the original structure requirements. under any circumstances. copied. The pin-brazing process shall use specially designed cable lugs and brazing pins to braze the cables to the structure and shall be approved by the contractor and owner. MATHURA. The cables shall be connected to the stud using crimped or brazed cable lugs. The present document or drawing is property of TECHNIP KT INDIA LTD. directly or indirectly. without its prior written consent. disclosed or used. a metal plate. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. The brazing materials shall be compatible with the structure material. . The size of threaded studs shall be 8 mm or more to suit the cable size. reproduced.Project N° Unit Document Code Serial N° Rev. Where a stud can not be welded directly to the structure.

the VENDOR may design glued electrical connections using metal plates bonded with electrically conductive epoxy resin. the core shall be separated into smaller strands of less than 16 mm2 each and welded separately. Subject to owner’s approval. be totally or partially. cathodic protection systems and personnel against AC fault currents. This method shall not be used for current carrying cables (drain cables or bond cables). for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. The vendor is solely responsible to verify the compatibility of the Cad-weld materials and The present document or drawing is property of TECHNIP KT INDIA LTD. FCC UNIT. e. It shall protect the structure. without its prior written consent. MATHURA. grounding protectors such as Cathodic Isolator shall be installed between the protected structure and the plant earthing at locations where plant earthing has adverse impact on the cathodic protection system. Electrical earthing Electrical safety earthing of the plant structures and equipment shall be made compatible with the cathodic protection system. The materials to be used and the installation procedure shall be approved by the contractor and owner. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.g. FCCU AND PRU REVAMP. for safety reasons and only in exceptional cases. reproduced. Cad-welding process shall be such that copper penetration into the pipeline material shall not be deeper than 1 mm and that the hardness shall meet the original structure requirements. AC induction and power switching surge currents. and shall have zero resistance. Cad-welds shall be visually inspected and gently impact tested with a hammer. transferred.9. . under any circumstances. Any weld which does not meet these requirements shall be discarded and the cable shall be rewelded. lightning. Page 00785 000 STD 1675 01 00 26/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Cad welding: Cad welding materials and charges shall be approved by the contractor and owner. copied. Cad-weld charges shall not be greater than CA15 for steel pipe and cable cores shall not be heavier than 16 mm2.Project N° Unit Document Code Serial N° Rev. non-electrolytic and maintenance free. directly or indirectly. The grounding protector must be of solid state construction. The welds shall also be tested for electrical resistance using an electrical multimeter. Where Cadwelding is not possible. disclosed or used. and shall not. If heavier cables need to be attached. 8. charges with the structure and submit the supporting data to contractor and owner.

Page 00785 000 STD 1675 01 00 27/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 8. The color should be consistent in one area. Common. be totally or partially. directly or indirectly. couplings. MATHURA. dimensions and construction of the isolating joints shall meet the design requirements of the pipeline. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. and locations where there is no The present document or drawing is property of TECHNIP KT INDIA LTD. Isolating Joints The design. 8. ISO 85011). materials. A length of 50 mm at each end shall be left uncoated to allow welding.11. without its prior written consent. They shall be installed above ground. 8. foreign structures and earthing systems in accordance with NACE RP0169 and RP0286 using isolating joints. applied on a blast cleaned surface (Sa 2 1/2.10. Isolating joints and flanges should be painted or striped in a contrasting color for easy identification. The electrical resistance across the joint shall be more than 1 mega ohm (106 Ohm) measured at 1000 V DC in dry air.11. 50 Hz. The paint shall be compatible with the pipeline/tank coating. Electrical isolation General Cathodically protected surfaces shall be electrically isolated from other plant. Paints containing metallic pigments (such as zinc or aluminum) shall not be used for top coating on isolating joints/flanges. flanges. reproduced. mechanical joints. under any circumstances.2.Project N° Unit Document Code Serial N° Rev.1. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Isolating joints shall be internally coated by the manufacturer over their full length using an amine cured epoxy coating. disclosed or used. FCC UNIT. All sealing and isolation materials shall be resistant to the product transported. FCCU AND PRU REVAMP. Isolating joints/flanges shall never be buried. Electrical continuity Bonding cables shall be installed to maintain electrical continuity at locations such as nonwelded joints. metal pipe supports shall be avoided or electrically isolated from the pipelines. . 8. copied. Safety or instrument earthing shall be compatible with the cathodic protection system. The isolating joints shall withstand a voltage of 1500 volt AC.11. transferred. and shall not. electrical continuity within the piping system to be cathodically protected. across the joint for 5 minutes without bridging or reduction in electrical resistance. All isolation materials shall be resistant to the product/service inside the pipe.

be totally or partially. disclosed or used. The resistance across isolating joints shall be measured immediately before welding into the pipeline. the overall length of the isolating joint shall be at least one meter. and shall not. directly or indirectly. The minimum resistance shall be 1 mega ohm (106 ohm). depending on pipeline service. may contain an electrolyte at any time during the life of the pipeline. the following rule applies: • If the resistivity of the electrolyte is higher than 100 ohm-cm. isolating spools shall be used.11. and the volume of electrolyte is more than 5% of the pipeline volume. copied.3. If the product transported by the pipeline is an electrolyte. the overall length of the isolating joint shall be four times the pipe diameter (with a minimum of one meter). FCCU AND PRU REVAMP. or oil products. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. or it may be anticipated that it The present document or drawing is property of TECHNIP KT INDIA LTD. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. • If the resistivity of the electrolyte is below 100 ohm-cm. Bolts shall be insulated using full length phenolic or composite sleeves and phenolic resin insulating washers and steel washers at both sides. Insulating gaskets for raised face or full face flanges should be the neoprene coated phenolic resin type. Insulating Flanges If the use of isolating joints is not possible. FCC UNIT. Flanges and insulation kits shall meet the design requirements of the pipeline. reproduced. under any circumstances. Isolating spools shall be used if required by the rules above. without its prior written consent.Project N° Unit Document Code Serial N° Rev. electrical isolation should be provided using insulated flanges. Page 00785 000 STD 1675 01 00 28/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION If the product transported by the pipeline is dry gas. MATHURA. 8. pressure and temperature. transferred. or the volume occupied by the electrolyte is less than 5% of the pipeline volume. The length of an isolating spool shall be determined by the following formula: L = (400/ρ) x D Where: l = length of spool (cm) ρ = electrolyte resistivity (Ohm-cm) d = nominal pipe diameter (cm) Isolating spools may be manufactured out of nonconductive composite pipe material (GRE) or as an internally coated or lined steel spool with isolating joints or flanges at both ends. dry crude oil. .

under any circumstances. be totally or partially. FCC UNIT. Installation of junction boxes and test stations The contractor shall clearly indicate the type of test post. UV resistant. transferred. shall be designed and installed. bond box and distribution box for each application in the detailed design: − − Distribution boxes shall be of stainless steel type 316L painted and weatherproofed. Insulated flanges shall be protected against ingress of dirt and moisture by the application of flange protectors except when used in sour service conditions. and shall not. . copied. without its prior written consent.12. Bond boxes.g. 8. MATHURA. Boxes shall be of lockable type. disclosed or used. Subsequently the The present document or drawing is property of TECHNIP KT INDIA LTD.Project N° Unit Document Code Serial N° Rev. This can effectively been done by measuring the current through the attached pipe using a “Swain-type” current clamp/meter. Sufficient number of test stations shall be installed to locally or remotely monitor the system performance: If this is not economically feasible other measures such as installation of a current drainage system CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. shall be of GRP/polyester material with the minimum degree of protection IP65. for cased crossings. directly or indirectly. Stray currents generated by the newly installed cathodic protection systems shall be eliminated at the source by suitable insulation or other means. Stray currents The vendor shall carry out a survey for stray currents generated by the newly installed cathodic protection systems. high impact resistant and complete with neoprene gasket and stainless steel type 316 captive screws. A voltage of 1500 volt DC shall be applied across the flange assemble for one minute without causing breakdown of the insulation or flash over. Page 00785 000 STD 1675 01 00 29/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Insulating flanges should be assembled and tested before being welded into the pipeline. FCCU AND PRU REVAMP. On existing flanges. resistance across the assembled flange shall be measured and shall be more than 1 mega ohm (106 ohm). reproduced.13. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. the bolt-to-pipe resistance shall be measured and the overall effectiveness of the isolated flange determined after cathodic protection has been applied. e. 8.

FCCU AND PRU REVAMP. FCC UNIT. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Also. a potential monitoring station shall be installed using a separate test cable connected to the pipe/tank for measurement of the drain point potential. oily water etc. a minimum of three permanent reference electrodes shall be installed in the middle of the tank bottom area in a triangular pattern whose center is the center of the tank bottom. reproduced. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. For magnesium anodes. a resistor shall be installed in the anode circuit to limit the protection levels to within the protection criteria. Sacrificial anode cables shall be connected to the pipeline via a bondbox and shunts to allow anode current The present document or drawing is property of TECHNIP KT INDIA LTD. At the drain points. . The distance between the reference electrodes shall not exceed 15 meters subject to a minimum of four reference electrodes in each quadrant. • Structure to electrolyte potentials − Tank bottoms: Reference electrodes shall be installed along the circumference of an imaginary circle whose radius is 86% of the tank radius from the center point of the tank bottom. copied. close to the bottom and away from the anode loops. under any circumstances. monitoring.Individual anode circuits shall be provided with shunts and grid coil resistors to measure and adjust anode current outputs. At the drain point. The total quantity and placement of the reference electrodes shall be such that the potentials give a reasonably accurate picture of the cathodic protection. directly or indirectly. Where multiple negative connections are installed.). separate shunts and blocking diodes shall be provided complete with ammeter and selector switch installed in a distribution box. Page 00785 000 STD 1675 01 00 30/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION • Anode output . each negative connection to the pipe/tank shall be provided with current measurement facilities. the ammeter built into the current source may suffice. For single pipes. and shall not. transferred. Reference electrodes shall be placed above the HDPE membrane. disclosed or used. − Plant piping: Reference electrodes shall be placed along piping systems at distances not exceeding 100 meters but not less than 2 reference electrodes for each service (fuel gas. Reference electrodes near the anode beds shall not be considered in the number of reference electrodes dedicated to the measurement of piping structure to electrolyte potentials. fire water. MATHURA. be totally or partially.Project N° Unit Document Code Serial N° Rev. without its prior written consent.

FCC UNIT. The cables to each side of the isolating joint shall be identified by stainless steel tags. a test facility shall be installed at both ends of the The present document or drawing is property of TECHNIP KT INDIA LTD.Project N° Unit Document Code Serial N° Rev. FCCU AND PRU REVAMP. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. MATHURA.Anode terminal boxes and test stations shall be installed for bonding current carrying cables (including bonds between pipelines/ structures or across isolation joints). consisting of two separate cables attached to each individual pipeline. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY.Each isolating joint and isolating flange shall be provided with test facilities. without its prior written consent.Test stations shall be installed at the crossings of protected and foreign structures. Page 00785 000 STD 1675 01 00 31/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION • Current drain/pickup . a bonding facility shall be provided. and shall not. reproduced. . disclosed or used. transferred. directly or indirectly.Test stations shall be installed at locations such as road crossings to monitor the casing and carrier piping. two cables shall be connected to each side of the joint or flange. At crossings with foreign structures. etc. In each test facility. Both cables shall be terminated in one test post and shall be identified by color coding or stainless steel tags. • Cathodic interference . if a steel casing is used. copied. are longer than 10 meters. under any circumstances. • Electrical continuity . a box approved for the relevant area classification shall be used • Electrical isolation. At all isolating joints/flanges. two test cable shall be connected to the casing. Shorter casings shall be provided with a test facility at one end only. be totally or partially. These test stations shall be located outside hazardous areas. two test cable shall be connected to the protected pipe and. All cables shall be separately terminated in one test post with suitable facilities to install direct or resistive bonds. The cables to each structure shall be identified by stainless steel tags. If this is not possible. If casings at road crossings. casing. The contractor shall clearly indicate the type of test station and its purpose in the detailed design. terminating in a test post with suitable facilities to install direct or resistive bonds.

14. and shall not. SPECIAL FACILITIES Temporary CP systems In the case that the installation of the permanent cathodic protection system cannot be finalized before the pipe/tank is buried. without its prior written consent. be totally or partially. tank. output current. drain point potential and low voltage/high current alarms. Remote monitoring at each transformer/rectifier shall include a minimum of four reference electrodes distributed around the area of influence of each transformer rectifier. MATHURA. Measurement and adjustment of impressed current anode outputs Measurement of structure-to-electrolyte potentials. FCC UNIT. In addition to the above tasks. Remote monitoring equipment shall be installed at all transformer/rectifiers and include output voltage. details of a fully operational computerized remote monitoring and system control facility which shall be supplied and The present document or drawing is property of TECHNIP KT INDIA LTD. . concrete structure construction until the expected commissioning of the CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. If specified the system shall be suitable to perform the following tasks from control room: • • • Measurement and adjustment of rectifiers’ inputs and outputs. FCCU AND PRU REVAMP. under any circumstances. 9. Such a system shall be designed in the same way as a permanent cathodic protection system with the exception that material quantities and quality shall be adequate to cover a lifetime equal to the time of the pipeline. copied. or if specified by the contractor. disclosed or used. Remote monitoring and system control Vendor shall submit for contractor’s and owner’s approval.1. reproduced. installed by the vendor. Page 00785 000 STD 1675 01 00 32/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 8. directly or indirectly. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. Vendor shall supply and install all the hardware and software for the Remote monitoring and System control. a temporary cathodic protection system shall be installed. Structure to electrolyte potentials of all or selected items. 9. the following reports shall be automatically generated at user selected frequency: • • Current status of rectifiers and anodes.Project N° Unit Document Code Serial N° Rev. transferred.

The spark gaps are fully encapsulated to prevent sparks in open atmosphere and to protect the spark gaps from moisture. The temporary system shall have a minimum design life of at least 12 months. disclosed or used. Surge arrestors required to prevent elevated voltages due to faults in adjacent electrical power systems or lightning shall be of the spark gap type and shall be designed such that: • • • The impulse breakdown voltage of the arrestor is lower than that of the isolating joint across which they are mounted. transferred. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Surge arrestors shall be mounted across isolating joints/flanges. The permanent monitoring facilities connected to the pipeline/tank shall be constructed simultaneously with the pipeline/tank to allow monitoring of the performance of the temporary system. This shall consist of suitably rated surge arrestors.2. copied. other DC sources may be used such as batteries. Designs in areas of lightning activity The vendor shall install suitable lightning protection to protect the pipeline/tank isolation and cathodic protection equipment. FCC UNIT. For temporary cathodic protection system to be used for protection during construction before AC power is available. under any circumstances. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. 9. Designs near high voltage power lines If the pipeline runs in the vicinity of high voltage power lines. The vendor shall show (by calculation or otherwise) that no harmful voltages can be present or design additional facilities to prevent excessive voltages. directly or indirectly. The present document or drawing is property of TECHNIP KT INDIA LTD. without its prior written consent. The spark gap is capable of discharging the expected lightning currents without sustaining damage. . be totally or partially. Page 00785 000 STD 1675 01 00 33/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION permanent cathodic protection system. reproduced.Project N° Unit Document Code Serial N° Rev. 9. FCCU AND PRU REVAMP. and shall not. the vendor shall investigate whether high AC voltages can be present on the pipeline by induction or otherwise and whether devices need to be installed for protection of the pipeline and personnel. Such facilities may consist of dedicated pipeline earthing and/or the installation of polarization cells. Anode connections shall be constructed such that they can easily be connected/ disconnected and coating repaired during and/or after commissioning of the permanent system. MATHURA.3.

without its prior written consent. locations of cathodic protection stations and test facilities. • • • A time schedule for the installation of the system. Testing and Inspection The vendor shall perform all pre-commissioning tests in the presence of the owner to confirm satisfactory installation and operation of all equipment. under any circumstances. These shall include: • Written procedures for the installation of DC voltage sources. cables. wiring diagrams. disclosed or used. cable routing. be totally or partially. . FCC UNIT. FCCU AND PRU REVAMP. The vendor shall also include in the material schedule a list of proposed monitoring equipment (hardware and software) required to carry out regular surveys of the cathodic protection system. directly or indirectly. Such tests shall include trial operation of power sources to their maximum capacity and measurement and CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. transferred. 10.Project N° Unit Document Code Serial N° Rev. The installation of the cathodic protection system shall start only after approval of the installation procedures by the contractor and owner. Pre-commissioning. test facilities and all civil works. Page 00785 000 STD 1675 01 00 34/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION 10. single line schematics. where required in relation to the construction schedule of the structures. The present document or drawing is property of TECHNIP KT INDIA LTD. Written procedures of all tests required to demonstrate the specified quality of installation.2. MATERIAL SCHEDULES This schedule shall include the descriptions and quantities of all materials to install the cathodic protection system. Installation procedures Full construction details and installation procedures of the cathodic protection system shall be submitted to the contractor and owner for review and approval. and shall not. 10. reproduced. procedures for cable connections to the structures. • Written procedures to ensure safe working practices during the installation and operation of the cathodic protection system. The vendor shall also include a list of proposed tools and spare parts required for maintenance of the system during the first 5 years of operation. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. copied. All relevant construction drawings including but not limited to plot plans.1. ground beds. groundbed construction and civil works. MATHURA.

Page 00785 000 STD 1675 01 00 35/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION checking of all cathodic protection circuits to confirm satisfactory connection and identification. FCC UNIT. testing of The present document or drawing is property of TECHNIP KT INDIA LTD. under any circumstances. copied. Commissioning Procedures Commissioning procedures are required to prove that the installed cathodic protection system is in accordance with the design. This document shall contain: • A description of the system and system components and their purpose. Test shall include resistance to earth tests of ground bed anodes and zinc earthing electrodes.Project N° Unit Document Code Serial N° Rev.3. calibration checks of permanent reference electrodes. A time schedule for the commissioning of the system.instant OFF potential surveys Procedures for interference testing and interference mitigation. be totally or partially. Procedures for the testing of pipeline/tank isolation Procedures for natural potential surveys Procedures for energizing and de-energizing cathodic protection hardware. Procedures for full ON . where applicable in conjunction with the construction or commissioning schedule of pipeline. reproduced. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. MATHURA. : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. Procedures for isolating structures. CLIENT UNIT PROJECT . Procedures for interference testing if applicable. transferred. FCCU AND PRU REVAMP. and shall not. The system shall be considered satisfactory when the cathodic protection criteria is met at test stations and any other accessible points of the structure to be protected where owner requires tests to conform effectiveness of CP system. directly or indirectly. Vendor shall document the results of all tests for inclusion in the commissioning manual. disclosed or used. Procedures for testing and adjustment of structure to electrolyte potential. isolation joints and insulated flanges. Cathodic protection manual A cathodic protection manual is required to ensure that the as-built cathodic protection system is fully documented and that operating and maintenance procedures are available for the future operator. Requirements for polarization of pipeline. without its prior written consent. The commissioning procedures document shall include as a minimum: • • • • • • • • • • 10.

Bracing. Vendor’s documentation for equipment and materials installed. MATHURA. 11. transferred. directly or indirectly. FCCU AND PRU REVAMP. . HANDLING Packaging and Shipping Preparation for shipment shall be in accordance with the vendor’s standards and as noted herein. Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the job site. Monitoring procedures for each of the types of monitoring facilities installed on the pipeline. Potential criteria for the systems. and to provide equipment at the destination in ex-works condition when handled by commercial carriers. Page 00785 000 STD 1675 01 00 36/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION • • The present document or drawing is property of TECHNIP KT INDIA LTD. Pre-commissioning results The commissioning report which shall include copies of the relevant as-built drawings marked up to show the location (with reference number) of all test locations used during commissioning. test procedures and test plans General guidelines for trouble shooting before cathodic protection specialists are called for assistance. • • • • • • • • • As-built drawings.1. without its prior written consent." CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. and rigging connections shall be provided to prevent damage during transit. Vendor shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application. disclosed or used. Guidelines for the safe operation of the cathodic protection system. or unloading. under any circumstances. All costs occasioned by such rejection shall be to the account of the vendor. tank and steel in concrete. be totally or partially. Equipment shall be packed. and skid mounted when required. A schedule of all monitoring facilities. Preparation for shipment and packing will be subject to inspection and rejection by Owner’s/ Contractor’s inspectors. 11. Method statements. and shall not.Project N° Unit Document Code Serial N° Rev. All temporary bracing/supports shall be marked "REMOVE BEFORE EQUIPMENT COMMISSIONING AND START-UP. supports. Monitoring schedules and requirements for monitoring equipment. lifting. copied. FCC UNIT. reproduced. securely anchored. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

Page 00785 000 STD 1675 01 00 37/37 STANDARD SPECIFICATION FOR CATHODIC PROTECTION Separate. for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use. be totally or partially. and weight. dirt. and maintenance instructions shall be packed in the boxes or crates with equipment. transferred. This is in addition to the number called for in the Purchase Order. Equipment shall be protected to safeguard against all adverse environments. individual package or container. mud. directly or indirectly. reproduced.Project N° Unit Document Code Serial N° Rev. Pieces of equipment and spare parts shall be identified by item number and service and marked with Contractor's order number. Preservation and storage Equipment and materials shall be protected to withstand ocean transit and extended period of storage at the jobsite for a minimum period of 18 months.2. both inside and outside of each The present document or drawing is property of TECHNIP KT INDIA LTD. tag number. and shall not. dust. salt spray. disclosed or used. rain. and spare parts shall be completely boxed. loose. FCC UNIT. salt air. MATHURA. sand. One complete set of the installation. CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED – MATHURA REFINERY. A bill of material shall be enclosed in each package or container of parts. without its prior written consent. copied. such as: humidity. FCCU AND PRU REVAMP. operation. under any circumstances. and seawater. 11. . moisture.