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NEW FCCU PROJECT, HPCL, MUMBAI

Document No.
6891-0645-CP-002
Rev. No.0
(SMMS)
Page 1 of 98

JOB SPECIFICATION
FOR
CATHODIC PROTECTION SYSTEM
FOR
SEAWATER LINE
AND
UNDERGROUND VESSELS

NEW FCCU PROJECT, HPCL, MUMBAI

TECHNICAL VOLUME

0
Rev. No

28.12. 09

Date

Template No. 5-0000-0001-T1 Rev. 1

ISSUED FOR IMPLEMENTATIONS
Purpose

NB

BC

BC

Prepared by

Reviewed
by

Approved
by

Copyrights EIL – All rights reserved

NEW FCCU PROJECT, HPCL,
MUMBAI

(SMMS)

Document No.
6891-0645-CP-002
Rev. No.0
Page 2 of 98

TABLE OF CONTENTS
Section/ Subsection No.

Description

1.0

Scope Of Work

1.1

Scope Of Work For Cathodic Protection System (CP System)

1.2

Scope Of Work For CP System installation

1.3

Instruction To Bidders

1.4

Specific Requirements For CP System Works

2.0

Design Basis/ Philosophy For CP System

2.1

Codes And Standards

2.2

Scheme For CP System

2.3

Design Basis For CP System

2.4

Detailed Engineering Works To Be Performed By Contractor For
CP System

3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8

Specification For CP System Equipment and Materials
Specification for natural air cooled transformer/ rectifier unit
CP System Power distribution board (PDB)
Mixed metal oxide coated titanium tubular anode
Permanent reference cell
Mixed Metal Oxide Wire Anode
Anode, cathode & monitoring junction boxes (AJB), (CJB), (MJB)
Cables
Calcined petroleum coke breeze

3.9
3.10
3.11
3.12
3.13
4.0

Thermit welding
Materials/ equipment for operation and maintenance
Specification For Painting Corrosion protection for junction boxes,
PDB, cable markers and junction boxes support structures
Specification For Central monitoring and control system
Specification For Soil Resistivity Test
Tentative Bill of Materials (BOQ)

5.0

Mandatory Spares For Cathodic Protection System

6.0

Vendor list for CP System

7.0

Drawing List for C P System

Template No. 5-0000-0001-T2 Rev. 1

Copyrights EIL – All rights reserved

NEW FCCU PROJECT, HPCL,
MUMBAI

(SMMS)

Document No.
6891-0645-CP-002
Rev. No.0
Page 3 of 98

1.0 SCOPE OF WORK

Template No. 5-0000-0001-T2 Rev. 1

Copyrights EIL – All rights reserved

No.3 INSTRUCTION TO BIDDERS 1. 6891-0645-CP-002 Rev. 1 Copyrights EIL – All rights reserved .2 SCOPE OF WORK FOR CP SYSTEM INSTALLATION 1. HPCL. 5-0000-0001-T2 Rev. MUMBAI (SMMS) Document No.4 SPECIFIC REQUIREMENTS FOR CP SYSTEM WORKS Template No.1 DESCRIPTION SCOPE OF WORK FOR CATHODIC PROTECTION SYSTEM (CP SYSTEM) 1.NEW FCCU PROJECT.0 Page 4 of 98 CONTENTS SECTION 1.

inclusive and the use of the guidelines set forth here do not relieve the CONTRACTOR of his responsibility of providing adequate CP System. supply. consumables in his scope of supply and provide all construction tools. Detail Engineering package as per Design basis and job specifications enclosed in this bid document. 5-0000-0001-T2 Rev. One set of soft copy and hard copy of all drawing/ document to be submitted to EIL and six set of hard copy and one set of soft copy to be submitted to client for records. HPCL.2 Scope of work for Cathodic Protection (CP) System Installation Item wise works envisaged under this Contract will comprise of the following: 1. The schedule of the under ground vessels to be protected shall be as follows: Sl. Temp.x500m long in unit and offsite areas . & obtain approval from OWNER/ EIL before execution of work. fabrication / construction drawings. installation.L. layout drawings of all materials/ equipment of CP System. (mm) Design. The detail engineering package shall include. equipment and personnel necessary for the work and submit construction drawings and as built drawings including soft copies in latest version of AutoCAD and operating manuals after completion of work. MUMBAI Document No. calculation and preparation of Bill of quantities.2. 6891-0645-CP-002 Rev. which shall be proved performing to the entire satisfaction of the OWNER/ EIL. HPCL complex at MUMBAI. No. to T. design calculations. necessary technical information/ datasheets.NEW FCCU PROJECT. The contractor also need to supply all materials. Description Inside Dia (mm) T. and commissioning of impressed Current Cathodic Protection (CP) System for plant underground seawater cooling(SWS/SWR) pipeline 40” dia. The Contractor needs to keep vigilance and take all precautionary measures to prevent fire hazards during execution of job.1 Preparation and submission of Design. testing. CONTRACTOR needs to obtain approval on all layout drawings of Cathodic Template No. 1 Copyrights EIL – All rights reserved . shop/ field Testing & Inspection plan for equipment.0 Page 5 of 98 (SMMS) 1. detailed engineering. 6891-114-50-47-0405. tackles.0. Testing and commissioning procedures and formats. Name of equipment suppliers. drum s Amine Blow down 65 FCCU 2. Quality control/ Quality assurance documents etc. Installation procedures. Item No. And underground vessels within the battery limit of NEW FCCU PROJECT.L. MAHARASHTRA.0 SCOPE OF WORK 1. Rev. at HPCL MAHUL Terminal as shown in Layout drawing no. O C 200 Location T h Closed blow down FCCU 114-D-3028 1800 5500 i 1.1 The work to be performed by the contractor shall comprise of design. No. as a minimum. 1. Connection schemes and wiring diagrams. 120-D-1002 1600 5000 Drum d This document is not intended to be all.

NEW FCCU PROJECT. seek and obtain all permission related and obligatory to his part of the work.6 Liaison with other agencies. 1. Cables.2.8 After Commissioning of the CP System. MUMBAI (SMMS) Document No.0 Page 6 of 98 Protection materials/ equipment at site from OWNER/ EIL before starting the installation work. Final commissioning of installed system as per approved procedure and submission to EIL of results thereof. Supply all materials. as-built drawings. 1.7 Preparation and submission of 1 set of soft copy and 6 sets of hard copies to client and one set each soft and hard copy to EIL for records for all as built CP System package comprising of operation and maintenance manual for equipment. 5-0000-0001-T2 Rev. 1. for "Design Basis/ Philosophy for CP System". HPCL. 1. if it is found that structure to electrolyte potential achieved at some location is in the range which is below acceptable limit as per code. The intending bidders shall be deemed to have visited the site and have studied the conditions before submitting the Bids.) and submission to EIL of Test results/ certificates for approval before delivery of equipment. No.2. 1.3 INSTRUCTION TO BIDDERS 1. Junction Boxes etc. 6891-0645-CP-002 Rev. equipment and perform all erection and installation work as per approved detail-engineering package.2. 1.2. 6891-0645-CP-002. 1.2.2. Non-familiarity with the site conditions will not be considered a reason either for extra claims or for not carrying out the work in strict conformity with the drawings and specifications. site conditions and specification included therein. 1.2.3.3 Shop testing of all major contractor supplied CP equipment (T/R.9 CONTRACTOR shall give performance guarantee for CP System of underground vessels as per design basis and job specifications and operation guarantee of the material and equipment supplied by him as well as guarantee against defective workmanship for installation work carried out by him. Provision of service connection to T/R units shall be in CONTRACTOR's scope of work.1 Site Particulars It shall be the bidder's responsibility to have a thorough understanding of the reference documents. 1 Copyrights EIL – All rights reserved . subsection 2. 1.2(a) Carry out soil resistivity survey at 10 locations (locations to be decided by EIL) by wenner-4 Pin method and presentation of result to EIL (Soil chemical analysis need not be done). then a supplementary CP System need to be installed to bring the potential level at such locations within acceptable limit as mentioned vide Document No.4 Field-testing of individual components of CP System as per approved detail engineering package. Anode. Material specifications and Pre-commissioning/ Commissioning results.2 (b) Carry out detailed engineering. Template No.2.

4 Bidder to note that the time schedule for the CP System work shall be 5 months from the date of FOI/LOI.3 Bidder to note that all bought outs shall be supplied only from the list of approved vendors given elsewhere in the document. c) List of materials/ equipment and consumables to be procured from Indian market along with names of suppliers/ manufacturers and brief technical details. make of the equipment. on award of Contract. 1.4 The bidder shall prepare a separate technical proposal for this work. The work front for CP System for each location shall be given to the CP System contractor by others as and when it is ready. Information to Be Furnished By Bidder along with Technical Bid 1. However bidder may note. MUMBAI (SMMS) Document No.NEW FCCU PROJECT. Quantities approved by Owner/ EIL after detailed engineering shall be considered for installation purpose.P.3. Any work carried out or supplies effected without such approval shall stand automatically rejected and his claim for compensation for such unauthorised work shall be null and void. after award of contract they have to carry out the detailed engineering of C. No. Additional manpower if asked by EIL depending upon the exigencies of the work shall be provided by the Contractor with out any extra cost to Owner. 1 Copyrights EIL – All rights reserved . 5-0000-0001-T2 Rev. ii) The site organisation chart with Bio data of the Personnel to be deployed at site full time for the entire duration of this Project. For any item for which list of approved vendors not furnished. b) Bidders are required to confirm the supply of Tentative Bill of quantities (BOQ) for all major materials as mentioned vide section 4.0 of this document. System as per design guidelines given in this document. Template No. vendor names & obtain Client’s Consultant’s approval before placement of order on the ve ndor. This proposal shall.2 Every item of work and supply by CONTRACTOR shall be subject to Engineer-InCharge scrutiny.3. and also required to furnish drawings. 1. d) List of materials/ equipment and consumables to be procured from foreign market along with name of supplier/ manufacturer and Make. 6891-0645-CP-002 Rev. supervision and approval. HPCL.3. as a minimum include the following information: a) Two separate organisation charts to be furnished along with two different headings as follows: i) Complete organisation chart with Bio data to key personnel for the entire organisation of the Bidder. Tech. Therefore CP System contractor need to be required to mobilize and demobilize at site with man material and equipment as per the availability of the work front. documents and all other supporting evidence to enable EIL to make an objective evaluation of their bids in all respects. Bidder shall propose.3.0 Page 7 of 98 1.

3 `A' class Electrical Contractor license is essentially required as per regulations laid by electrical inspector of the state for electrical jobs. No. MUMBAI (SMMS) Document No. 1. f) To confirm necessary hot/ cold permit shall be taken by Bidder from OWNER as per safety procedures applicable at site before starting of hot/ cold wo rk inside the plant area. It shall be Bidder's responsibility to arrange access for EIL/ OWNER Personnel for such visits. All costs related with travel. In case no exceptions/ deviations are contemplated.0 Page 8 of 98 specification/ detail of equipment as per information required in Spec No. e) In case the bidder takes any deviation to the terms and conditions of the tender specifications. - Fabrication/ testing of material/ equipment to be supplied by CONTRACTOR or its tie up agency for CP system. tools.4.4. g) Quantified list along with Make/ Model/ technical data/ catalogues of the major construction equipment.NEW FCCU PROJECT. Template No. 6891-0645-CP-002 Rev. i) Bar chart giving details how Bidder plans to execute the work within the specified time schedule. boarding. The Contractor shall arrange for the same.4.4 SPECIFIC REQUIREMENTS FOR CP SYSTEM WORKS 1. the bidder must list all such exceptions/ deviations in proper formats. Any approval from electrical inspector required for the electrical installation shall be in Contractor's scope. Depending on the exigency of the work contractor may have to mobilise additional construction equipment without any extra cost & time impact. 1 Copyrights EIL – All rights reserved .1 General Clauses given under specific requirements for CP System works shall be read in conjunction with General conditions of contract and in case of any conflict. 5-0000-0001-T2 Rev. the bidder proposes to use for execution of the work.2 EIL/ OWNER shall have the right to inspect the following: - Workshop & production facilities available with CONTRACTOR or its tie up agency. 68910645-CP-002. the provisions of specific requirements for CP System works will override the provision of general conditions of contract. HPCL. the bidder must fill up the proforma with the words "NIL EXCEPTIONS AND DEVIATIONS". tackles and testing/ commissioning instruments. 1. lodging for EIL/ OWNER personnel for such visits (if any) shall be borne by EIL/ OWNER. 1.

HPCL. equipment and consumables required for the work in his scope.6 Construction Aids. Template No. 1. Packing and Handling Contractor shall be responsible for transportation of all equipment/ materials required for CP system work and unload the same at allotted area at site. 1 Copyrights EIL – All rights reserved .7 Transportation. tackles and testing equipment and appliances.4 Document No. No. special Aids. Tools and Tackles Contractor shall be solely responsible for making available for executing the work. tools. cons umables not covered in Spec. Technical specifications of major items are given in Spec. Supply of all balance materials. Equipment. The rates quoted for the execution of the Contract shall be inclusive of all Contractor supplied material and equipment. Such construction equipment shall be in first class operating condition.0.0 Page 9 of 98 Materials 1. 6891-0645-CP-002 Rev. No. 1. repaired or the equipment replaced all together by Contractor. of this document. all instruments including automatic Programmable current interrupters required for commissioning and interference testing of the system. No. Contractor needs to replace/ repair or reinstall free of cost any material/ equipment supplied or installed by him in case it fails to operate due to defective material or workmanship as per requirements of this specification within 12 (Twelve) months from the date of issue of completion certificate and acceptance of the CP System by Owner.4. machinery tools and tackles etc. The Owner/ EIL reserve the right to re-arrange such deployment depending upon the progress and priority of work in various sections at no extra cost to Owner. subsection 3.4. 6891-0645-CP-002. MUMBAI (SMMS) 1. 1.NEW FCCU PROJECT.4.1 Material Supplied By Owner No material for CP System shall be supplied by owner.5 Warranty Contractor need to provide design guarantee for the system as per codes and standards & the protection criteria mentioned in the section “Design basis” of this document. sub-section 3.4. Contractor shall replace at his own cost if any item found defective or missed before handing over the system to owner. Any discrepancies pointed out by Owner/ EIL shall be immediately got rectified.4. 6891-0645-CP-002.4. 5-0000-0001-T2 Rev.4.0 but required for completion of work as per this specification shall be entirely Contractor's responsibility. 1.2 Material Supplied By Contractor The Contractor shall procure supply all materials.4. all requisite construction Equipment. Owner/ EIL shall not in any way be responsible for providing any such equipment.

storage and erection against corrosion. HPCL. rain. rough handling in transit and storage in open during monsoon including delays in transit. MUMBAI (SMMS) Document No.4. Bidder shall be responsible for any damage to equipment/ material due to above reasons. high temperature. 1 Copyrights EIL – All rights reserved . “Vendor List for CP System".7.1 To protect all the material during period of dispatch.NEW FCCU PROJECT.0 Page 10 of 98 1. sunlight. “Tentative Bill of Materials (BOQ).8 Bidder to refer in technical volume : Document No. "Job specifications for CP System". “CP System drawing List” Template No. No. 5-0000-0001-T2 Rev. 6891-0645 -CP -002: The “Scope of Work”. incidental damage due to vermin. "Design Basis/ Philosophy for CP System".4. 1. 6891-0645-CP-002 Rev. "Mandatory Spares for CP System". humid atmosphere.

NEW FCCU PROJECT.0 DESIGN BASIS/ PHILOSOPHY FOR CP SYSTEM Template No. 6891-0645-CP-002 Rev.0 Page 11 of 98 2. 1 Copyrights EIL – All rights reserved . MUMBAI (SMMS) Document No. HPCL. 5-0000-0001-T2 Rev. No.

1 Copyrights EIL – All rights reserved . 5-0000-0001-T2 Rev. 6891-0645-CP-002 Rev.3 Design basis for CP System of underground vessels 2. Description 2. MUMBAI (SMMS) Document No.1 Codes and Standards 2. HPCL.2 Scheme for Cathodic Protection (CP) System 2.4 Detailed Engineering Works To Be Performed By Contractor For CP System of underground Vessels Template No.NEW FCCU PROJECT. No.0 Page 12 of 98 CONTENTS Section No.

Each T/R Unit shall have one outgoing positive header cable. which shall be terminated to AJB to be installed near each vessel(through inout connection). which shall be terminated. RP-0285-95 : 7361 Part I-1991 ( Formerly CP 1021-1973) : 0150. HPCL. 6891-0645-CP-002 Rev. within the battery limit of NEW FCCU PROJECT. Corrosion control in Petroleum production TPC Publication No. Regulations laid by Chief Inspector of Explosives. 2.2 Scheme for Cathodic Protection (CP) System Impressed Current Cathodic Protection (CP) System for soil side corrosion prevention of seawater line and underground vessels as given at scope of work. of India. one 250A/ 63A. Regulation laid by Factory Inspector of State. Free ends of each loop of string anode shall be terminated to AJB.. Petroleum Act. 415V. Regulations laid by Chief Electrical Inspector of State. MUMBAI (SMMS) 2. to a cathode junction box cum test station (CJB). TP circuit breaker/ Switch Fuse unit shall be allotted by OWNER at the Electrical substation-10. 5-0000-0001-T2 Rev. 1976 (Govt. protection against corrosion due to stray currents from DC installations.0 Page 13 of 98 Codes and Standards The entire work shall be performed as per the following codes/ standards. ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ ∗ NACE BS VDE : RP-0169-97. 4-wire (300/ 50 sq. the requirements of this specification shall be binding. air cooled. 400V power supply for CP System at the Electrical substation. One No. OWNER shall provide 3-Phase. Two drainage cables and two measurement cables from the vessel and seawater line shall be terminated to its CJB. piggyback connected with anode lead cable. Each TR Template No.NEW FCCU PROJECT. MAHARASHTRA. Power supply for the T/R Unit shall be drawn by contractor from the Electrical substation-10. each of anode junction boxes (AJB). Each T/R Unit shall have one out going negative header cable. indoor type. DIN : 30676 IEC/ NEC : Relevant codes Indian electricity act and rules framed there under. HPCL complex at MUMBAI. 1 Copyrights EIL – All rights reserved .5) Wherever the requirements in this specification are in conflict with any of the above standards.0 of this document. No. factory pre-packed with coke breeze for the U/G vessels and MMO tubular anode for seawater line. Fire insurance regulations. CJB cum test station (CJB) is to be installed near each vessel and seawater line for the drainage connection and potential measurement. The tentative requirement of the Bill of materials (BOQ) for each vessel and seawater line to be supplied by Contractor is furnished in the section 4. mm ) power supply cable from this circuit breaker/ Switch Fuse unit outlet to one indoor type wal mounted PDB near the T/R Unit location for distribution of power to the T/R Unit. Anodes to be considered shall be close continuous distributed type string anode of mixed metal oxide wire. CONTRACTOR need to lay one 3-phase.1 Document No. Transformer-Rectifier unit (T/R Unit) 25V/ 25A rating shall installed to energise the anode strings for both the vessels through 1 No. 4wire.

testing and commissioning of the following major materials/ equipment as per the above. Monitoring of CP System performance shall be done by installation of 4 No. 5-0000-0001-T2 Rev.0. Following guide lines shall be considered for uniform current distribution: - Separation distance of String anode from vessel to be protected shall be 0.30m Template No. The interruption device shall be solid state type without any mechanical moving parts and shall have arrangement for bypass. which shall be located near the T/R Units and have the provision of measurement of vessel/pipe to soil potential. of permanent reference cells for each vessel and 20 No.0. in the form of several loops surrounding the vessel.1 Contractor shall carryout detailed engineering. procurement. 2. Also for monitoring of vessel /pipe to soil potentials at the T/R unit. 25V/ 25A capacity. indoor plinth mounted type and shall be installed at non-classified locations inside S/S-10. Underground Cable laying in paved/ unpaved areas should be done as per enclosed drawing wherever overhead cable trays/ cable trenches are not available. The anode strings shall be laid in the sand cushion of the vessel backfill. The enclosure of T/R units shall be IP-55 as per relevant IEC/ NEC codes as per enclosed subsection 3. Interruption ON / OFF cycle should be programmable in the time ratio selectable from 0 to 999 seconds in increments of 1 second. a) The T/R units shall have programmable current interruption facility according to a schedule defined by the user. installation. Selector shall be used at the TR Unit for measurement of potential for each reference cell.mentioned basic scheme for Cathodic Protection System for the buried vessel: Transformer/ Rectifier (T/R) units : T/R unit 2 No.2.NEW FCCU PROJECT. All the reference cells to be installed and the output current / voltage of connected respective TRU are required to be part of the central monitoring system. and MJB shall be installed at one location inside the Electrical S/S-10. HPCL. The T/R Units. All Cable laying should be done on existing overhead cable trays/ cable trenches wherever possible. 1 Copyrights EIL – All rights reserved . No. air cooled. Connection of drainage cables and measurement cables to the Vessel shall be done by Thermit welding. PDB. 75V/ 75A capacity and 1 No. The reference cell cables and the measurement cables from each vessel and the seawater line shall be routed through the respective cathode junction box cum test station (CJB) to a single Monitoring Junction Box (MJB). of permanent reference cells along the seawater line route. piggyback connected with anode lead cable.0 Page 14 of 98 Unit and PDB should be located at non-classified area inside the electrical S/S-10. factory pre-packed with coke breeze. The general specifications of mixed metal oxide coated on titanium wire anode factory pre-packed with coke breeze is enclosed in SECTION 3. monitoring cables consisting of reference cell and measurement cables shall be laid between MJB and T/R unit for connection of two reference cells to each T/R Unit panel. MUMBAI (SMMS) Document No. b) Anode Beds: i) For vessel : Anodes minimum 213m length to be considered shall be close continuous distributed type string anode of mixed metal oxide wire. 6891-0645-CP-002 Rev.

shall be considered for backfilling the RCC PIT surrounding the vessel. • Sand shall be backfilled in layers of maximum 250mm loose thickness and compacted to 80% relative density with suitable vibratory compactor. CP System contractor need to Supply and backfill fine sand within the RCC pits for backfilling of the UG Vessels and CP System materials to be installed inside the RCC pit including making of 75mm PCC Cover on the pit. vi) In case desired by EIL /OWNER as an (optional) item.0 Page 15 of 98 Free ends of each anode string loop should be connected to AJB. Grading zone I/II/III/IV.0 “Tentative Bill of Materials (BOQ)” of this document need to be offered by all bidders.0 . supervisors. No. HPCL. The contractor need to execute the work as per the detailed engineering package to be prepared by them and approved by EIL/ OWNER during execution stage. The sand filling shall be done as follows: • The internal dimension of the pit for sand filling purpose need to be considered 5000mm(h)x8000mm(l)x7068(w). if bidders offer more than the minimum quantity of materials or rating of TR Units mentioned. IS Sieve Designation 1. as per IS: 383-1970. During detailed engineering stage. 5-0000-0001-T2 Rev. • Sand type conforming to fine aggregate. 1 Copyrights EIL – All rights reserved . 6891-0645-CP-002 Rev. CP Contractor need to coordinate the CP System activity with the other agency.m. technicians skilled/unskilled labour and materials/equipment required for commencing construction work for distributed anode bed for seawater line as follows: Template No. iii) Sand resistivity need to be considered for the Vessel CP System design as 200 ohm. ii) For seawater line: CONTRACTOR shall mobilize at site with engineers.ii) A trained cable jointer need perform the anode lead cable to anode string joints. In case the sand filling inside the RCC pit and making of PCC cover over the pit is done by other agency. v) The Minimum quantity of CP System materials and TR Unit ratings as mentioned in Section 4. that should be acceptable but lower than the minimum quantity of materials or rating of TR Units mentioned here should not be acceptable. MUMBAI (SMMS) Document No.30m or as decided during the detailed engineering stage. of anode lead cables from each loop shall be terminated to AJB - Vertical separation distance between each consecutive anode string shall be 0. Thus 2 No.18mm. Data collection for soil/ sand resistivity to be done as per scope of work & enclosed Specification given in SECTION 3.NEW FCCU PROJECT. iv) The vessel shall have suitable paint for the soil side corrosion protection. at factory or at field.

anode installation. including but not limited to transportation and access to the job site.0 Page 16 of 98 Site Preparation CONTRACTOR shall be solely responsible for thorough investigation as to all local conditions affecting the work. For commencing construction work. 5-0000-0001-T2 Rev.NEW FCCU PROJECT. Anodes shall be lowered in such fashion that bottom of anode is 150mm above the bottom of bore hole. ground water level & soil strata equipment machinery and material required by CONTRACTOR. 1 Copyrights EIL – All rights reserved . No. 4-Layer wrapping of total thickness 3. cable are to be installed as per the construction drawings to be prepared by Contractor and approved by EIL/OWNER prior to commenc ing any installation work at each site. Procedure for Template No. availability and quality of labour. - Top 2m of the casing pipe of 6m deep anode bed shall be coated with coaltar tape (DENSOLEN-System AS 40 Plus – C50. PVC pipe of matching ID. - One MS cap or PVC cap to be provided as top cover of the casing to prevent entry of any foreign object inside the bore hole until the permanent anodes are installed inside the casing. prior to and during performance of the work. DISTRIBUTED ANODE BED: VERTICAL Distributed vertical anode bed system of anode bed size 6" dia x 6m deep shall be installed at 15 to 20m interval along the seawater line route. The drilling of bore hole and casing of the bore hole for vertical distributed anode beds shall include the following: - MS casing pipe (bottom closed) to be considered for 6" dia for 6m deep distributed anode bed. including the availability and condition of roads. handling and storage of materials. RTU. water and electric power. Necessary work for bore holes for vertical anode beds. junction boxes. climatic conditions. the CONTRACTOR shall survey and mark at site the exact location of anode ground beds as per advise of EIL(SMMS) engineers to be present at site.TR Unit. Annular space between casing pipe and anodes as well as between casing pipe & bore hole shall be filled by pumping calcined Petroleum coke breeze in slurry form.2mm) or coal tar enamel or shrouded with 5mm W. MUMBAI (SMMS) Document No. backfilling with coke breeze and making of RCC pit for anode beds need to be done by CONTRACTOR. HPCL. To ensure that anodes are located centrally. The CONTRACTOR shall also locate with the help of a pipe locator all existing underground piping as per layout drawings in this project before starting drilling/excavation work.T. non metallic centralizer and dead weight shall be lowered centrally in each bore hole. disposal. Anode Installation: MMO tubular anode complete with anode Lead Cable. 6891-0645-CP-002 Rev. All PDB. MJB. each anode shall be fitted with a non metallic centralizer.

PVC insulated unarmored cable.0. INDO ASIAN. 5-0000-0001-T2 Rev. MUMBAI (SMMS) Document No. The Power distribution board (PDB) shall be composed of one no. if required. Wiring inside PDB shall be done using 50mm2 . 1-core. All cable glands shall be of double compression weatherproof brass.0. CJB cum test station (CJB) shall be located at Rim of the Vessel and near seawater line for the drainage connection and potential measurement. of 25 x 5mm tinned copper bus bar shall be used which should be taped by PVC tape of red. MERLIN GERIN. SIEMENS. unarmoured cable between TPN switch neutral and neutral bus whereas rest of the wiring shall be done by 25mm2 . L&T. should be engraved and stencilled using paint on RCC pit cover. 1 phase. The enclosure of AJB & CJB shall be classified type as per Area classification and relevant IEC/ NEC codes given in enclosed spec. 6891-0645-CP-002 Rev. lugs shall be long barrel heavy duty tinned copper type. copper conductor. 63A outgoing MCB for input power supply to TR Unit as well as 6No. of Anode leads for each AJB.3 phase.6A outgoing MCB for central monitoring system power supply. No. MDS. The MCCB and MCB shall be suitable for motor load application and shall be of HAGER. While deciding no. The contractor needs to execute the work as per design to be approved by EIL during the detailed engineering stage. d) Cables: Cables for CP System shall be as per in enclosed specification for cables. vide subsection 3. OR AEG make. All 10mm2 lead cables shall be terminated inside the respective Anode lead junction box. the spare cable entries should be closed with a threaded plug. ABB. All cable entries to the PDB Template No. The enclosure of shall be IP-55 as per relevant IEC/ NEC codes. 1 Copyrights EIL – All rights reserved . e) Power Distribution Board (PDB): The Power distribution board (PDB) shall be plinth mounted indoor type and shall be installed at non-classified locations near the T/R Unit. copper conductor. of cable entries and cable terminals should be kept spare at each AJB for connection of Anodes as per supplementary design. incoming MCCB and 12/3 no. All single core cables shall be used red. All cables terminations shall be through Tinned copper cable lugs of matching cable size. nickel/ cadmium plated type. vide subsection 3. Two drainage cables and two measurement cables from the Vessel and seawater line shall be terminated to each CJB. PVC insulated. at least two nos. 1-core. HPCL. In case supplementary design is not required in certain areas. 4-wire 250A/ 63A. The anode bed No.NEW FCCU PROJECT. yellow and blue colours for identification of the three phases and black colour for neutral. 4 Nos. c) Junction Boxes: Junction Boxes (AJB & CJB) for CP System shall be as per in enclosed specification for junc tion boxes.0 Page 17 of 98 backfilling of coke breeze shall be got approved by CONTRACTOR from EIL before commencing the work One MS Plate should be used as RCC pit cover. All hardware used shall be of stainless or brass material. SCHNEIDER ELECTRIC. The incoming switch shall be 3-pole and outgoing switches shall be 2-pole. yellow and blue coloured for phase connections and black coloured for neutral connection.

One gland for 300mm2 / 50mm2 . 1-phase. The shutters shall be screwed to the panel enclosure structure at the centre in addition it shall have lockable handles. Permanent reference cells shall be installed in the sand cushion surrounding the vessel at a distance of 150mm from the vessel for monitoring of CP System.0 and Drawing No. The finish coat shall be of polyamide cured epoxy in three coats to achieve total thickness of 15 mils. The enclosure of MJB shall be IP-55 as per relevant IEC/ NEC codes. HPCL. 1 Copyrights EIL – All rights reserved . Painting details of inside and outside surfaces of the PDB panel shall be as follows: After fabrications the entire enclosure shall be sand blasted to a SA2½ surface. g) Thermit Weld Connection: All cable-to. 1phase. Size of the PDB Panel enclosure shall be adequate to accommodate all components easily and shall be made of 12 SWG sheet steel.Cu. Contractor shall prepare the layout/ construction drawings for internal / external potential monitoring arrangement including wiring diagram and submit to OWNER/ EIL for approval before procurement/ installation of the same. The outgoing cables shall be 25mm2.vessel connections shall be made utilizing the exothermic weld process. only for unavoidable Template No. f) Cable to cable straight through joint : As far as possible any straight through joint shall be avoided for any cable run. No. of permanent reference cells at distance of 1m from pipeline need to be installed. For measurement of vessel and seawater line to electrolyte potentials multi-core cable (20/10-core x 2. Multi-core cable (10-core x 2. 12/3/6 glands to be provided at right side bottom of the panel for outgoing cable connections for 63A PDB. 6891-0645-CP-002 Rev.0 Page 18 of 98 panel shall be through Aluminium single compression glands. CONTRACTOR shall prepare the layout/ construction drawings and a prototype of PDB showing internal terminal arrangement and wiring arrangements and submit to OWNER/ EIL for approval before procurement/ installation of the same at site. An inorganic zinc primer shall then be sprayed to a total thickness of 3 mils. 5-0000-0001-T2 Rev. MUMBAI (SMMS) Document No. The finish coat shall be a dark grey or yellow shade as per choice of EIL/ OWNER. i) Permanent Reference cells for Vessel and seawater line : Cu/ CuSO4 Permanent reference cells shall be as per specification for permanent reference cells. For sea water line 20 No. ) to be laid between CJB and MJB.5 mm2 . however for unavoidable situations the straight through joint kit of any standard manufacturer like Raychem or equivalent make as per OWNER/ EIL approval may be considered for jointing cables.5 mm2 . 4-core incoming cable connection shall be provided at left side bottom of the panel. vide subsection 3. 3-core Aluminum conductor cables for central monitoring system power supply. Two nos. 3-core Aluminum conductor cables for TRU power input and 16mm2 . hinged front shutters shall be provided.Cu) to be laid also between MJB and T/R Unit for potential measurement at the TR Unit with the help of selector switch. Minimum 4 No. 3-phase.NEW FCCU PROJECT. of permanent reference cells surrounding each vessel need to be installed. The Thermit weld connections shall be made as per enclosed Specification vide subsection 3.0. h) Monitoring Junction Box (MJB) : MJB shall have provision for measurement of vessel and seawater line to electrolyte potentials and shall be installed near the T/R Unit.7-06-208. Permanent reference cell lead cable shall be without joint between the reference cell and MJB.

HPCL. 5-0000-0001-T2 Rev. earthing grids. 6891-0645-CP-002 Rev.28mm (Platine Bros. Hence the structures intended to be cathodically protected shall be in electrical continuity with many foreign structures within the plant complex such as RCC pavements. Bentonite. To take care of such situation CP System shall be designed & installed in two stages by providing one preliminary design and another supplementary design as follows: Template No. clamps and necessary hardware need to be supplied as required. crosses. splicer.0 Page 19 of 98 situations the straight through joint kit of any standard manufacturer like Raychem or equivalent make as per OWNER/ EIL approval may be considered for jointing cables.7mmx14. Surface area and surface condition of nearby foreign structures. USA / Yuxi Chaina make) shall be considered for carrier pipe protection inside casing pipe at one 20m long road crossing for 40” dia. j) Carrier pipe protection inside casing pipe at road crossing: Diamond shape zinc ribbon anode of dimension 12. other U/G structures. No. Relative position of anode between foreign structure and structure intended to be protected. tees. Length of Zinc ribbon anode at every location shall be 1100mm. Minimum number of Zinc ribbon anode locations shall be 12 No. For installation of permanent reference cell for seawater line at each location one 4" HDPE/PVC pipe backfilled with Gypsum. MUMBAI (SMMS) Document No. 1 Copyrights EIL – All rights reserved . ventilated and solid bottom cable tray manufactured and tested as per NEMA FG-1-1984 / ASTM E-84 / ASTM D-635 /IS-6746 standards and matching with the specifications of the existing FRP trays in the plant need to be supplied and installed on existing pipe rack by CP Contractor. Minimum number of Casing insulator locations shall be 12 No. All accessories such as bends. 6mm thick. The tray shall be 300mm width. reducers. Casing insulator & heat shrinkable end seal shall be RACI INDIA make. RCC foundations.NEW FCCU PROJECT. which are not intended to be protected. The CP current requirement therefore shall be governed by following factors: - Surface area and coating quality of structures to be protected. Sodium Sulphate special backfill material need to be installed vertically upto 2m depth by suitable drilling method as per specification & drawing & direction of Engineer-in-Charge. 2. carrier pipe.3 Design basis for CP System of Vessels & seawater line : a) No Insulating joints shall be installed to isolate any incidental structures from CP System within Battery limit. k) FRP Cable tray For laying of CP System cable along the seawater pipeline route one ultraviolet/fire resistant FRP ladder type. and 500m long supported at 3m interval. Height of the casing insulator shall be decided based on casing pipe ID.

No. These observations shall be recorded in a tabular form or graphically plotted and to be submitted to OWNER/ EIL for review. CONTRACTOR shall start installation work of CP System only after site verification and approval of locations by OWNER/ EIL at site. HPCL. etc.0 need to be installed at the suitable locations as decided by EIL. Supplementary design: After energizing CP System as per preliminary design. Junction boxes (AJB. PDB. Incase it is decided to install additional anodes then 6A capacity MMO tubular anodes vide subsection 3.). MJB and RTU shall be installed at one location in non-classified area near the Electrical S/S-10. Cell : 2. Distribution Boards. protection potential and protection span of cathode structure nearest to as well as remotest to each anode bed shall be observed until predetermined current limits of Anodes or T/R units are reached or desired protection potential levels are achieved. MJB. anode beds of various configurations. MUMBAI (SMMS) 1. to soil potential is to be taken at all test points in presence of OWNER/ EIL.NEW FCCU PROJECT. 5-0000-0001-T2 Rev.0. The power supply for the T/R Unit/ PDB shall be drawn from the identified cubical of the electrical substation. Document No. 2. Cables of various sizes. the unprotected/ under protected and over protected areas shall be identified and a supplementary design is to be made to bring all structures intended to be protected within acceptable potential limits. After completion of installation work. The locations of T/R units. The locations for installation of all CP system materials/ equipment shall be verified at site by OWNER/ EIL to check the practical feasibility of installation as well as its suitability for optimum/ effective performance as envisaged in the design.10V(Instant OFF) for impressed current system Template No. Then the system as per preliminary design shall be energised at different current levels. CJB. The quantities required for T/R units. For identification of under protected/ overprotected areas.2 above.50V(ON) or –1. For each current level.). etc. 1 Copyrights EIL – All rights reserved . The T/R Units. Cables of various sizes. and any other materials as required shall be calculated by CONTRACTOR. Power Distribution Boards. Thermit weld connections. CJB. CONTRACTOR shall carry out testing/ commissioning activities in presence of OWNER/ EIL. Junction boxes (AJB. OWNER/ EIL after review/ interpretation of the instant commissioning results or within 6 months of the polarization period of the CP System. at first natural Str. The following criteria shall be followed to determine the protection levels: - Maximum allowable vessel to soil potential with respect to Cu/ CuSO4 ref. 6891-0645-CP-002 Rev. shall be marked by CONTRACTOR in appropriate layout drawings and shall be submitted along with Detail engineering package to OWNER/ EIL for approval.0 Page 20 of 98 Preliminary design: A preliminary design shall be made based on the scheme mentioned in section 2. 3. Detailed Engineering works to be performed by CONTRACTOR are mentioned in Section 4. MJB. shall decide whether any additional anode bed or additional T/R unit is required to be installed or whether there is requirement for disconnection of some anodes/ anode beds or any other remedial measures and the contractor shall update the CP System accordingly at no additional cost and within a specified time acceptable to EIL/ OWNER. Thermit weld connections. anode beds of various configurations.

PDB. suitable RCC duct or PVC PIPE duct embedded in concrete at proper depth need to be prepared by Contractor. No. 1 Copyrights EIL – All rights reserved . a separate earth pit approved by OWNER / EIL may be considered by contractor. f) For continuous string/ wire anode the anode current capacity shall be considered 30mA/m. wherever plant earthing grids are not available nearby. MUMBAI (SMMS) - Document No.0 Page 21 of 98 Minimum allowable vessel to soil potential with respect to Cu/ CuSO4 ref. all multi core-monitoring cables may be laid in either electrical or instrumentation cable trays which ever is available. all cables are to be laid at the cable trays wherever possible. h) Earthing of all T/R Units.850 V (ON) or -100mV polarization shift (Off) or -300mV (ON) potential shift from initial native potential. k) The type of coating and operating temperature of each Vessel should be taken into consideration for all detail-engineering calculations. g) Identification and mitigation of interference between structures to be protected as well as between the structures to be protected and foreign structures need to be carried out by contractor as per the requirements of the codes mentioned in this document. Separate classified type CJB cum test station need to be installed at the rim wall of Vessel for potential monitoring. 6891-0645-CP-002 Rev. considerations must be given to see no T/R unit is loaded more than 75% of its rated output voltage & current capacity through out design life while feeding load to a single or group of anode beds.NEW FCCU PROJECT. and JUNCTION BOXES need to be done by connecting the same with plant earthing grids. Discretion to use any of the criteria shall solely rest with Owner/ Owner's Representative. i) To avoid cable damage in the long run. under ground cable laying should be considered only when no cable trays are available nearby. d) While deciding number of modular type 25V/ 25A and 75V/ 75A capacity T/R units. e) While making preliminary design contractor should make the entire endeavor to ensure the adequacy of the design so that the requirement of supplementary design is bare minimum. HPCL.0. j) For road crossing of CP System cables. 5-0000-0001-T2 Rev. to ensure adequate potential level of Vessels intended to be protected. All CP System cables need to be laid at power cable trays. . Template No. Contractor should get the construction drawing approved by OWNER/ EIL before execution of the work.Interference Criteria : +100mV positive shift b) Design life of Anode = 25 years (minimum) for impressed current CP System. Cell :. c) Test station/ test points as mentioned in the BOQ are to be considered for monitoring external potential of Vessels.

2 and design basis given vide item no. MUMBAI (SMMS) l) Document No. 2.0 Page 22 of 98 Wherever specific guidelines are not furnished for cathode structure current density or separation distance of anode from cathode structure and spacing between consecutive anodes. installation work procedures & fabrication/ construction drawings for following items: - CP System power distribution board (PDB): Total quantity and connection scheme showing group of T/R units to be connected with each CP System PDB and connection details between owner's switch board and each CP System PDB. Detailed Engineering Works To Be Performed By Contractor for CP System of underground Vessels and seawater line Following detailed engineering works are to be performed by contractor based on scheme given vide item no. Bill of quantity along with detailed calculations and preparation of specifications. detailed circuit diagrams and their installation drawings. - Item wise list of vendors with their reference lists for supply of materials/ equipment. m) If operating temperatures of Vessel exceed 25 deg. HPCL. Construction drawings and work procedures for anode to cable jointing and also for installation of anode strings.0 mA/m2 and the same for bare cathode/ incidental structure shall be considered 25mA/m2 .2.C. 5-0000-0001-T2 Rev. - AJB/ CJB/ MJB/RTU: Total quantity and connection Scheme showing how group of anodes. Also fabrication drawing & schematic drawing for internal terminal arrangements and installation drawings for a typical AJB/ CJB/ MJB/RTU.C.5mA/m2 /deg. - T/R unit: Total quantity. for termination anode/ cathode/ reference cell/ measurement cable connections. 1 Copyrights EIL – All rights reserved .3 of this document for CP System of underground Vessels and seawater line: - List of materials/ equipments to be procured from Indian market/ foreign market. of Anode strings and anode string to anode lead cable joint details for entire CP System and their layout arrangement drawings showing no. a current density for coated cathode structure and RCC incidental structure shall be considered 5.NEW FCCU PROJECT. of anode strings in each bullet. anode beds and vessels are to be connected with each AJB/ CJB/ MJB/RTU.4 Classified type local AJB/ CJB need to be provided near the rim of each Vessel and seawater line. protective current density shall be corrected @ 0. - Anodes: Total nos. n) 2. No. Template No. 6891-0645-CP-002 Rev. - Calculation and Preparation of Bill of Quantities for all CP system materials and equipment required.

CJB. - T/R unit wise CP System layout drawing showing how each T/R unit is connected with group of anode strings/ vessels through AJB/ CJB/ MJB. cable routes on a plot plan. - Preparation of construction drawings with soft copies before starting of installation/ procurement work. tackles etc. anode beds. anodes. anode lead cables. 6891-0645-CP-002 Rev. - Cable to vessel joint: Total quantity of joints and details of a typical joint. Template No.NEW FCCU PROJECT. as well as mo vement of personnel within the plant area. systematic manner to the best quality standards and properly documented to provide confidence that materials supplied and/ or work executed and services performed by him conform to the applicable specifications and all the requirements of contract document and work executed by him shall perform satisfactorily over the entire period of its life. No. drainage cables. - Test points: All reference cells and anode strings should be marked in a single layout drawing. HPCL. equipments.0 Page 23 of 98 Design calculations showing: - Cables: Total quantity of cables and their layout drawing for each CP Station as well as for entire CP System for +ve header cables. - Quantified list of the major construction equipment. AJB. earthing cables. -ve header cables. to ensure that the work is performed in a planned. All CP System materials/ equipment shall be marked properly for easy identification on all appropriate drawings as well as on site. 1 Copyrights EIL – All rights reserved . - Quality Assurance Plans/ Procedure The CONTRACTOR shall establish document and maintain an effective Quality Assurance system as outlined in recognized codes etc. - Details & list of vehicles proposed to be used by the CONTRACTOR during the entire construction & commissioning period for transportation of material. - Preparation of testing & commissioning procedure for CP System. Preparation of Soft & hard copies of as built drawings after completion of CP System work shall also be furnished. - Overall CP System layout drawing including all test points. including Diesel engine pump set for dewatering at cable/ pipe trench the BIDDER proposes to use for execution of the work. power supply cables and multi-core monitoring cables. MUMBAI (SMMS) Document No. and Quality Assurance Plans included in Specifications etc. 5-0000-0001-T2 Rev. - Bar chart giving details how BIDDER plans to execute the work within the specified time schedule. MJB/RTU. tools.

iii) Equipments. which shall be furnished by BIDDER along with.0 Page 24 of 98 The Quality Assurance Systems Plans/ Procedures of the CONTRACTOR shall generally cover the following aspects/ details. gauges and similar testing equipments etc. 6891-0645-CP-002 Rev. In addition. all the Quality Assurance Programs/ Plans as per specifications enclosed with the Contract shall be fully complied with by the Contractor. ii) Complete details pertaining to the responsibility authority and accountability of the Quality Assurance Organization of the CONTRACTOR at site. v) Control Procedures/ Plans for calibration and safe up-keep of instruments. i) A Quality Assurance Organogram with curriculum vitae of key personnel responsible for the Quality Assurance at site. 5-0000-0001-T2 Rev. vi) Quality audit & Maintenance/ records/ procedures etc. iv) Quality Control of processes such as Thermit welding. Template No. BIDDER shall be required to provide explanation pertaining to the details furnished by him in accordance with provisions contained in this clause and any further details. as sought for by OWNER/ EIL. HPCL. - All other information as required in individual job specifications shall be furnished by CONTRACTOR in his detail-engineering package. MUMBAI (SMMS) Document No. Installation. operation & maintenance of CP System.NEW FCCU PROJECT. No. vii) Other relevant details. anode to cable jointing etc. Quality Assurance System Plans/ Procedures of the CONTRACTOR shall be furnished in the form of a QA manual. material. his detail-engineering package. Testing and commissioning control plans for quality testing/ inspection etc. - Precautionary measures to be taken to prevent fire hazard during Thermit welding and Pin Brazing of vessel for the purpose of cable to vessel joint as well as during installation. 1 Copyrights EIL – All rights reserved . Erection.

HPCL. 6891-0645-CP-002 Rev.NEW FCCU PROJECT. MUMBAI (SMMS) Document No. 1 Copyrights EIL – All rights reserved .0 Page 25 of 98 3. 5-0000-0001-T2 Rev.0 SPECIFICATION FOR CP SYSTEM EQUIPMENT AND MATERIALS Template No. No.

No.5 MIXED METAL OXIDE WIRE ANODE 3.11 SPECIFICATION FOR PAINTING CORROSION PROTECTION FOR JUNCTION BOXES. HPCL.3 3.6 ANODE. 5-0000-0001-T2 Rev.13 Template No.10 MATERIALS/ EQUIPMENT FOR OPERATION AND MAINTENANCE 3. MUMBAI (SMMS) Document No.8 CALCINED PETROLEUM COKE BREEZE 3. 6891-0645-CP-002 Rev.NEW FCCU PROJECT.4 MIXED METAL OXIDE COATED TITANIUM TUBULAR ANODE PERMANENT REFERENCE CELL 3.7 CABLES 3.12 SPECIFICATION FOR CENTRAL MONITORING AND CONTROL SYSTEM SPECIFICATION FOR SOIL RESISTIVITY TEST 3. CABLE MARKERS AND JUNCTION BOXES SUPPORT STRUCTURES 3.2 CP SYSTEM DISTRIBUTION BOARD 3. PDB. CATHODE & MONITORING JUNCTION BOXES 3.0 Page 26 of 98 CONTENTS SECTION 3.1 DESCRIPTION SPECIFICATION FOR NATURAL AIR COOLED TRANSFORMER/ RECTIFIER UNIT 3. 1 Copyrights EIL – All rights reserved .9 THERMIT WELDING 3.

MUMBAI (SMMS) Document No.1 SPECIFICATION FOR NATURAL OIL COOLED TRANSFORMER/ RECTIFIER UNIT Template No. 6891-0645-CP-002 Rev. No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved .NEW FCCU PROJECT. HPCL.0 Page 27 of 98 3.

Lower Parel.1.NEW FCCU PROJECT. Mumbai.0 Document No. The units shall be supplied in accordance with the following specifications and data sheets.Terminal markings. No.1 TRANSFORMER RECTIFIER UNITS (T/R UNITS) The transformer rectifier units shall be a standard product of a manufacturer as follows: A) M/S Raychem RPG Ltd. Template No.Temperature -rise ( first revision) with Amendments No.1 CODES AND STANDARDS In general the T/R Unit covered by this specification shall unless otherwise specified.1 and 2 4) IS:2026 (Part III)-1981 .Essential ratings and characteristics of Semiconductor devices. IS:3700 . 6891-0645-CP-002 Rev. 5-0000-0001-T2 Rev.Insulation levels and dielectric tests (Second revision) with Amendment No. HPCL. 3. Mumbai B) Kristron Systems. 1 Copyrights EIL – All rights reserved .1 6.Power transformers 2) IS:2026 (Part I)-1977 – General (first revision) with Amendments No. (CANARA ELECTRIC). be in line with the requirements of any of the latest applicable standard of: a) Indian Standards Institution (ISI) b) International Electro technical commission (IEC) c) American Standards Institution (ANSI) d) British Standards Institution (BS) which shall include but not to the following: 1) IS: 2026 .1 to 3 3) IS:2026 (Part II)-1977. MUMBAI (SMMS) 3.1 5) IS:2026 (Part IV-1977 .0 Page 28 of 98 Specifications and Testing of Air Cooled Transformer Rectifier Units The specifications and testing procedure of transformer units are given as follows: 3. tapings and connections (first revision) with Amendment No. regularly engaged in production of cathodic protection power supplies.

1988) 8) IS:3700 (Part II)-1972 .General requirements (first revision) (with Amendment No.50.Non-linear resistor type surge arrestors (Second revision) Template No. 1 Copyrights EIL – All rights reserved .Light emitting diodes 16) IS:8828-1978 .1.Low Power signal diodes (first & revision) (Reaffirmed 1988) IS:4400 (Part II)-1967 9) IS:3700 (Part III)-1973 .0 Page 29 of 98 (SMMS) 7) IS:3700 (Part I)-1972 – General (first revision)& (Reaffirmed IS:4400 (Part I) -1967.Air-break switches.Miniature air-break circuit-breakers for AC circuits for voltages not exceeding 1000 volts(with Amendment No. 24) IS:3070 (Part I)-1985 . 18) IS:9224 (Part I)-1979 .links for the protection of Semi conductor devices 21) IS:4064 .Low power small signal transistors& IS:4400 (Part IV) – 1981 (Reaffirmed 1988) 11) IS:3700 (Part V)-1968 . MUMBAI Document No.1)Superseding IS:2208) 20) IS:9224 (Part IV)-1980 . 6891-0645-CP-002 Rev. 22) IS:4064 (Part I)-1978 .General requirements 19) IS:9224 (Part II)-1979 .Rectifier Diodes (First revision) & IS:4400 (Part III)-1968 (Reaffirmed 1988) 10) IS:3700 (Part IV)-1968 .Supplementary requirements for fuses with high breaking capacity for Industrial application(with Amendment No.NEW FCCU PROJECT. Rs.Voltage regulator & voltage reference diodes (Reaffirmed 1988)& IS:4400 (Part VIII)-1970 15) IS:3700 (Part II)-1984 . air break switch-dis connectors and fuse-combination units for voltages not exceeding 1000V AC or 1200 V DC. and Amendment No. 5-0000-0001-T2 Rev.Surge arrestors for alternating current systems.1. No.1) (Superseding IS:2607and IS:4047) 23) IS:3070 .Reverse blocking triode thyristors & IS:4400 (Part VII)-1970 (Reaffirmed 1988) 14) IS:3700 (Part VIII)-1970 . air-break dis connectors.2) 17) IS:9224 .Low voltage fuses. HPCL.Supplementary requirements for fuse.Power transistors (Reaffirmed1988) 12) IS:3700 (Part VI)-1968 – Switching transistors (Reaffirmed 1988) 13) IS:3700 (Part VII)-1970 .

Dial. scales and indexes for indicating analogue measuring instruments. 38) IS:1122-1985 .1) 35) IS: 4800 (Part V)-1968 .Direct recording electrical measuring instrument (Reaffirmed 1987) 42) IS: 3107-1974 .PVC insulated and PVC-Sheathed heavy duty cables (with Amendment No.1 to 3) (Amendment No.0 Page 30 of 98 25) IS:3070 (Part II)-1966 . 33) IS: 4800 (Part I)-1968 .Self bonding wires.Expulsion type lightening arrestors (with Amendment No.Wires with good dielectric properties under humid conditions(with Amendments No. 31) IS:3961 (Part V)-1968 .Wires for elevated temperatures (with Amendments No.acting electrical indicating instruments (first revision) (with Amendments No.1 (Reaffirmed 1977) 26) IS:11548 . 39) IS: 1248 (Part I) -1983 .PVC-insulated light duty cables.50) 28) IS:3961 .Portable multipurpose direct (Reaffirmed 1987) . 6891-0645-CP-002 Rev.Capacitor for surge protection. 32) IS:4800 . No. MUMBAI (SMMS) Document No. Rs.1 to 3) (Reaffirmed 1978) 37) IS: 4800 (Part 12)-1986 .Conductor data (with Amendments No.Recommended current ratings for cables. above 650V 27) IS:694-1977 . heat or solvent bonding enameled round copper wire with temperature index 155. 5-0000-0001-T2 Rev.1) 30) IS:3961 (Part IV)-1968 .Enameled round winding wires. HPCL.1.1 and 6) (Reaffirmed 1978) 36) IS: 4800 (Part VII)-1970 .PVC insulated cables for working voltages up to and including 1100 volts(second revision) with Amendments No.1 & 2) Template No.1.1 and 2) (Reaffirmed 1978) 34) IS: 4800 (Part-II)-1968.Direct acting indicating analogue electrical measuring instruments and their accessories: Part II Ammeters and Voltmeters (Second revision) 41) IS:6236-1971. 29) IS:3961 (Part II)-1967 . 1 Copyrights EIL – All rights reserved .Direct acting indicating analogue electrical measuring instruments and their accessories: Part-I General requirements (Second revision) 40) IS: 1248 (Part II) -1983 .Polyethylene insulated cables.Maximum overall diameters (Reaffirmed 1978) (with amendment No.NEW FCCU PROJECT.

Each diode in the bridge circuit shall be protected by a HRC fuse. 50 Hz power supply.) 44) IS: 8573-1977 . 3. 1 Copyrights EIL – All rights reserved . The transformer core and winding will be dipped in thermosetting varnish and baked.Digital electronic DC voltmeters and DC electronic analogue-to-digital convertors (with Amendment No. the requirements under this specification shall be binding.Dimensions for Panel mounted indicating & recording electrical instruments (first revision) (with Amendme nt No. Transformer varnish will meet the standards for 155 degree C operation.1.The auto transformer shall be similar to main transformer except it will have single winding and tapping for manual mode of control. The transformer winding shall withstand 2.3 RECTIFYING ELEMENTS The power rectification shall be done by Silicon diodes mounted on heat sinks of sufficient size to prevent the diode case temperature from exceeding 100o C at ambient temperature as per data sheet. 5-0000-0001-T2 Rev. core to winding insulation shall be class F type. shall be placed between the two windings and grounded to the rectifier cabinet.NEW FCCU PROJECT. Transformer winding wire insulation.2 TRANSFORMER The main transformer will be the isolation type having separate primary and secondary windings. No.1. 6891-0645-CP-002 Rev.1. MUMBAI (SMMS) Document No. 3. In rush current limiting reactor of suitable rating to be provided at input line of the main transformer to avoid possibility of abnormal tripping of MCB while closing circuit using MCB.000 volt (RMS at 50 hertz) applied for one minute between the windings and between each winding and the transformer core.4 AC INPUT The transformer rectifier units shall be designed to operate on 240 volts (+10%) AC single phase. for this purpose a visible lead should be brought out from the copper foil which shall be connected to any of the mounting stud of the transformer core.1) (Reaffirmed1991) Wherever the requirements in this specification are in conflict with any of the above standards. The diodes shall be connected in Bridge circuitry for full wave rectification. winding interlayer insulation. 3. 3. composed of heavy copper foil. Transformer full load efficiency will not be less than 95%.5 DC OUTPUT Template No. An electrostatic shield. Maximum temperature of transformer winding will not exceed 90 deg C and air temperature inside the upper cabinet will not exceed 65degC at full load current at ambient temperature of up to 45 deg C.0 Page 31 of 98 43) IS: 2419-1979 .1. The peak inverse voltage rating and current ratings of the diodes shall be as per data sheet. HPCL.1.

HPCL.6 DC OUTPUT ADJUSTMENTS The DC output control shall be available in any of the following modes. The SCR's of the transformer rectifiers will be controlled by commands from electronic circuit cards.NEW FCCU PROJECT. 2 nos. 5-0000-0001-T2 Rev. For feed back PSP reference.2 AUTO MODE: Unit shall have CONSTANT OUTPUT CURRENT/ VOLTAGE CONTROL (AVCC MODE) in AUTO MODE as per Data Sheet. The output of the main transformer shall be rectified for DC load supply. These Template No.1. Silicon controlled Rectifiers (SCR's) shall be used in the Primary Circuit of main Transformer for close loop control of the output voltage in auto mode.6. i) CONSTANT CURRENT AND VOLTAGE CONTROL (AVCC MODE) Constant current control feature shall be achieved by automatically adjusting T/R unit output voltage between 0 to 110% rated voltage through close loop control using T/R unit output current as feed back taken from the shunt inside the T/R unit so that T/R unit output current of any value between 0 to 110% rated current does not vary more than +1.1. 3.1 MANUAL MODE Output voltage at 23 equal steps up to 110% rated voltage shall be available by means of coarse and fine tap changing switches for rated input supply voltage and 110% rated output current. MUMBAI (SMMS) Document No.0 Page 32 of 98 The transformer rectifier shall be designed to operate continuously at 110% rated output current and 110% rated output voltage at input supply voltage 240v (+10%) without exceeding specified hot spot temperature limit and without damaging any components. 3. with the help of a selector switch. Tapping for output voltage control shall be taken from a separate auto transformer. 1 Copyrights EIL – All rights reserved .1. 6891-0645-CP-002 Rev. 3.6. Continuous ly adjustable potentiometer to be used for setting T/R unit output current/ PSP. Cu/ CuSO4 ref. No.04% of the set potential.0A of set value when there is a change input supply voltage of +10% or change in load resistance over a specified range decided by the ratio of output voltage & current rating of the T/R unit. cells to be used one operating and other standby to be selected manually with the help of a selector switch. to cause change in output current of T/R unit so that PSP as measured by external reference cell always remains constant and does not vary more than +0. The controlled output voltage of the auto transformer shall be fed to main transformer input. ii) CONSTANT PIPE TO SOIL POTENTIAL CONTROL (NOT APPLICABLE FOR THIS PROJECT) Constant Pipe to soil potential (PSP) control feature shall be achieved by automatically adjusting T/R unit output voltage between 0 to 110% rated voltage through close loop control using PSP as feed back taken from external reference cell.

1. HRC fuse of suitable rating should be connected before MCB so that AC input current is limited to max. The trip point will be unaffected by ambient temperature. In addition to above MCB.10 VOLTAGE SURGE PROTECTION Template No. Separate PCB shall be used for main auto mode control and the backup control. Complete printed circuit boards will be sealed with a circuit card sealant to prevent atmospheric corrosion and fungus contamination. In addition to above electronic current limiting feature HRC fuse of suitable ratings to be used at positive and negative terminals as well as one double pole MCB of suitable rating to be connected after HRC fuse at the out put to disconnect T/R unit quickly in case of over loads in the output circuit or for ease of isolating T/R Unit from the circuit when it is desired to keep the T/R Unit in standby mode. 10% excess rated input current as per data sheet. 3. The limits of the two switches shall be algebraically additive and shall give equal steps of 3A each up to 110% rated current. The current limit for backup control is to be set by two limit switches marked "coarse" and "fine". 6891-0645-CP-002 Rev.6. 5-0000-0001-T2 Rev. MUMBAI (SMMS) Document No.1. 3. The printed circuit board contact pads will be chromium plated to provide easy conduction and to eliminate contact corrosion.8 INPUT OVERLOAD PROTECTION Protection from overloads on the input will be provided by Miniature circuit breakers of suitable rating on the input side. 3.NEW FCCU PROJECT. One scale calibrated in Ampere shall be provided with each limit switches so that current limit can be set by operator at any desired value in 3A step. The trip handles of individual poles of circuit breaker will be mechanically linked so that all lines are opened when an overload occurs. 1 Copyrights EIL – All rights reserved . In any circumstances even in case of short circuit the T/R unit output current should not exceed the current limit set by the backup control. HPCL.9 OUTPUT OVERLOAD PROTECTION Protection from overload on the output in auto mode for T/R unit having either constant current control or constant pipe to soil potential control will be provided by another close loop SCR control circuitry giving automatic constant current control same as mentioned vide 3.7 DC OUTPUT RIPPLE The filter circuit shall be designed in such a manner that ripple factor does not exceed 5% at rated load both in Auto and manual mode. 3.1.1.1. No. Circuit elements in the control cards shall be derated properly and proper heat dissipation arrangements shall be made in the PCB so that they function properly for full load operation of T/R unit at ambient temperature as per data sheet.2 (i) except that it will act as back up control to ma in auto mode control.0 Page 33 of 98 cards shall be the plug-in type Printed Circuit Board (PCB) mounted on the front panel of the rectifier for easy field replacement.

14 ANNUNCIATION Each transformer rectifier shall be supplied with a continuous signal light which will go out at loss of A. HPCL.NEW FCCU PROJECT. 5-0000-0001-T2 Rev.5mm (minimum). 6891-0645-CP-002 Rev. All meters shall be rectangular in shape and accurate to within 2% at full load at ambient temp.11 COOLING The transformer/ rectifier will be air cooled completely enclosed IP55 construction.12 INPUT AND OUTPUT TERMINALS DC terminals made of tinned plated copper shall be located convenient to the cable entrance. current and Structure to electrolyte Potential measurement meter with selector switch for selection of different Structure to electrolyte Potential measurement meter. Digit size should be 12. 3. All meters shall be electronic digital type with LED display arrangement and should be able to indicate the current and voltage ranges as per data sheet up to a resolution of one decimal place for DC Ammeter & Voltmeter and 3 decimal places for Potential measurement meter. Three negative and three positive output terminals shall be provided. The temperature of the transformer winding shall not be more than 90 OC and maximum air temperature of the upper cabinet should not be more than 65 OC for ambient temperature of up to 45 OC. 3.C. 3. All AC & DC voltmeters shall be provided with separate fuse and toggle switch where as all Ammeters shall be provided with only toggle switch.1.1. This R-C circuitry will be rated as recommended by the manufacturer of the SCR/ Diodes so that they will conduct heavily before the peak inverse voltage ratings of the SCR/ Diodes are reached. 1 Copyrights EIL – All rights reserved . MUMBAI (SMMS) Document No. The terminals shall be suitable for cable sizes as per data sheet. No.13 METERS The transformer rectifier units shall be equipped with separate continuous reading voltmeter and ammeter for the D. input voltage. AC terminals shall be insulated to withstand 2000 volts 50Hz to the enclosure. They shall be temperature compensated to vary no more than 1% per 10% temperature changes.1. 3. shall be shielded to prevent accidental contact and shall be sized to take cable sizes as per data sheet.C output and the A. In addition. In addition to this each T/R unit should give annunciation for Auto and manual mode of operation by continuous signal light. T/R unit should also indicate the Template No.C input.0 Page 34 of 98 Each silicon controlled rectifier (SCR) and Diodes shall be protected from voltage surges by means of R-C circuitry. as per data sheet. lighting arrestors and zener Barrier type or MOV type surge Diverters shall be provided in the AC input and DC output circuit of the Transformer rectifier as per data sheet.1.

C DC control/ monitoring cables. one earthing terminal shall be made for earthing Template No. Lifting lugs of size suitable for lifting complete transformer rectifier unit when full of oil to be welded at the 8mm thick bottom plate of upper cabinet. The enclosure shall be supplied with an engraved warning level with the words "DANGER". Auto-transformer. DC choke. One holder for 60 watt filament lamp connection shall be provided at a strategic point inside the cabinet to facilitate proper illumination during operation and maintenance. After fabrication the entire enclosure shall be sand blasted to a SA 2 1/2 surface. MUMBAI (SMMS) Document No. 6891-0645-CP-002 Rev. The upper compartment shall contain the SCRs. A Plexiglas viewing window shall be provided at the front shutter to allow the meters to be read without opening the front shutter. Both the compartments shall be completely enclosed type having IP55 construction.C cable entries. Accessibility shall be provided by hinged and removable front and back shutters. lower cabinet shall be 10 SWG(3. • • • Steel channel under the base for plinth mounting. No.16 ENCLOSURE EARTHING All normally dead metallic parts shall be electrically continuous. Protective devices. The finish coat shall be a dark grey shade of polyamide cured epoxy in three coats to achieve total thickness of 15 mils. and shall be provided with a Plexiglas viewing window.1. One 240V.NEW FCCU PROJECT. The transformer rectifier shall be provided with the following accessories.25mm) W.1.67mm) W. 3.0 Page 35 of 98 failure of each fuse in bridge rectifier and two DC output fuses by an independent LED for each. one of them A. Gland plate should be provided against each junction box for fixing single compression cable glands for A. Lower compartment shall contain main transformer.15 ENCLOSURES "The enclosure of T/R unit shall be plinth mounted type having two compartments. The enclosure shall have a frame work made of minimum 50mmx50mmx3mm angle iron. earthing terminals shall be suitable for 35mm square cable connection. A detachable sun/ rain shade to be provided of suitable size. 5A Socket shall be provided at a strategic point inside the cabinet to facilitate connection of soldering iron during maintenance. Necessary fins for the cooling purpose shall be provided at lower compartment.) thick steel plate. Size of enclosure shall be minimum 1700(H) x 700(W) x 550mm (D) or higher size than this. cable entries and other for D. 5-0000-0001-T2 Rev.C.T. 3. 1 Copyrights EIL – All rights reserved . the upper cabinet body shall be made of minimum 12SWG (2. An inorganic zinc primer shall then be sprayed to a total thickness of 3 mils. Diodes. Locatable control cabinet with viewing window to IP55 as a minimum. sheet steel.T sheet steel and bottom plate of lower and upper compartment shall be 8mm(min. indicating meters. HPCL. Two junction boxes shall be provided at both sides of the upper compartment. One drawing pocket shall be made at inner side of the front shutter. Electronic control circuits/ control cords etc.

MUMBAI (SMMS) Document No. Provision shall also be made adjacent to each gland plate for cable gland earthing connection. ii) Terminal blocks shall be arranged and positioned to afford easy access for carrying out external cable termination. No. Template No.1. Each post shall be fitted with double nuts and washers. 5-0000-0001-T2 Rev. viii) Cable terminal arrangements for power and control cables may be integrated provided that a barrier separates the two. Direction of cable entry shall be from below. Cable glands & cable lugs shall be in the scope of supply for CP system installation contractor. cell to be provided for T/R unit panel for connection to VSP meter. ref. iv) Three positive and three negative post type D. one no. 3. ix) Auxiliary wiring shall have copper conductors of the manufacturer's standard sizing (subject to Buyer’s approval). inspection and maintenance.1 Cable Terminations i) Cable glanding and terminating facilities and terminals shall be suitable for the specified cable type and conductor size. measurement cables and a selector switch for permanent ref.magnetic metal panel or gland plate and provision made for bonding and earthing any armour and/ or concentric ground conductors.NEW FCCU PROJECT. 6891-0645-CP-002 Rev. vii) Termination of single core cables shall be through a non. 1 Copyrights EIL – All rights reserved . The earth connection points shall be protected against corrosion. HPCL. It shall not be necessary to scrape the paint away in order to make an effective earth connection. testing. x) Suitable terminals for two nos.0 Page 36 of 98 connection to power supply earthing and two earthing terminals shall be made for earthing connection to the local earthing pits.C output terminals shall be provided for the T/R Unit. vi) A terminal box or chamber with undrilled gland plate or entry panel of sufficient dimensions to terminate the specified incoming and outgoing cables shall be provided. iii) All terminal blocks shall be shrouded or provided with transparent covers. Pinch screw type terminals are not acceptable. v) Terminals for different voltages shall be separated by partitions.16. There shall be ample clear space allowed between the terminal block and the gland plate for the spreading and termination of external conductors. cell cables. Consideration and provision shall be taken by the manufacturer on the equipment design for the use of cables with aluminum conductors.

rating Weight in Kg of T/R unit Model number Serial number Year of Manufacture 3. 133A (RMS on state current) H. Ripple and Hum at rated output: Not more than 5% N.8 lagging J. Filtering circuit: L. HPCL. Manufacturer's name AC input voltage and current rating AC frequency Phase Output DC volts and Amps. c. AC input voltage : 240 Volts +10% 50 Hz single phase B. Zener Diodes of voltage unit rating 300V RMS.Diodes: 150A (Max. No. Full load power factor: 0. Surge Diverters i) For diodes/ SCR's : R-C circuitry of rating as advised by manufacturer of SCR/ Diodes ii) For input of T/R unit : 2 nos. DC output current : 75A G. a. d. KVA rating of transformer : 7.) C.6 KW(Max.1. AC input Current : 33A(Max.17 NAME PLATE A permanently stamped stainless steel metal plate shall be attached to outside of the case with the following information. 75A T/R UNIT A.NEW FCCU PROJECT. e. Minimum conductor size shall be 1. 3. i. Average forward current) .0mm2 (current density shall not be more than 3A/mm2 for copper conductor).7KVA E.Transformer alone: More than 95% . 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved . Template No. Spark over voltage 800V (Peak). Conductors shall be fitted with sleeve ferrules bearing the same identification as the terminal to which they are connected. f. Full load efficiency . iii) For output of T/R : 2 nos. MUMBAI (SMMS) Document No. 6891-0645-CP-002 Rev. spark over voltage 1000V (Peak).0 Page 37 of 98 Wiring shall be crimped using self-insulated compression type terminal blocks which shall be suitably identified. RIR Type A6 FMR 80 or equivalent MOV type surge diverters. j. DC output voltage : 50V F.18 DATA SHEET OF 50V. Zener Diodes of voltage rating 300V RMS.) D. Peak Inverse Voltage Diodes/ SCR's : 1200V (PIV) L. h. RIR Type A6 FMR 100 BB or equivalent MOV type surge diverters. Insulation level: 2KV K.SCR : 85A (Average on state current).Transformer Rectifier Assembly: More than 75% I.C filter M. DC power output : 4. Current rating . b.1.

Max. P. in the live line of all lamps. Protection : MCB suitable for motor load having thermal over load and magnetic short circuit Protection for input current in addition to separate HRC fuse protection for each Diode. 1 Copyrights EIL – All rights reserved . 6891-0645-CP-002 Rev. each at the input and output of the T/R unit of voltage rating 280V RMS. Lightening arrestor: 2 nos. Corrosion voltmeter.1.1. 1 No. Q. DC voltmeter 0-60V. 5-0000-0001-T2 Rev.T-2.5KV (Peak). 3-core.5KV @1.1. HRC fuse at out put and input terminals.5KA. Enclosure: Per sec. Monitoring cable : 6mm2 . glass cartridge fuse. Enclosure painting : As per sec. 3 nos (Monitoring cable to be used in case permanent ref. Max. auxiliary power lines to control circuit and voltmeter circuits. 1-core. DC Ammeter 0-80A 1 No. 1. Cable entry: Through double compression Aluminum gland of following sizes of cables. X. MUMBAI (SMMS) Document No.3. Cooling : Air cooled S. LAMCO L. Max. HPCL. Power supply cable : 25mm2 . Gland plates are to be provided at the junction boxes located at both side of upper compartment: +ve and .ve header : 95mm2 /50mm2 1-core. Construction : Plinth mounted indoor type. impulse current discharge capacity 4/10 micro second impulse current wave 10KA(Peak). cell is used for monitoring pipe/ structure to soil potential ) V. Y. Meters/ Instruments: As per Sec. 1 No. AC Ammeter 0-50A 1 No.13. Schematic: Supplier to furnish for EIL approval schematic wiring diagram and fabrication drawing prior to fabrication of T/R units.15 W.0 Page 38 of 98 O.1.18.NEW FCCU PROJECT.15 U.3. 10M ohm input resistance. Fabrication.8 or equivalent make. 8/20 micro second impulse current wave 2. T. 1 No.2/ 50 micro Seconds impulse spark over voltage 2. No. 3. discharge residual voltage at 5KA. Ambient temp : 45 deg C Template No. Spare parts & Additional features: Supply as per Sec. AC voltmeter 0-300V 1 No. 4nos. 3. 0-5000 mV. R.

input voltage single phase A.1. AC input voltage single phase AC input current DC power output KVA rating of transformer DC output voltage DC output current : : : : : : 240 volts +10% 50HZ 5A (max.21 Testing of T/R units All T/R units shall be tested by contractor and inspected by EIL/ Owner before dispatch. E. C.output current : : : : : : 240 volts +10% 50 Hz 50A (max.1. C. 3.NEW FCCU PROJECT.1.1.Input Current D. 25V T/R UNIT A. F.8 KW (Max. 75V T/R UNIT A. D. No.C. F. 1 Copyrights EIL – All rights reserved .18.0 Page 39 of 98 Z.output voltage D. testing shall be conducted in accordance with codes and standards enclosed in this document.0KW (max. 3.C.) 625W (max.C. D. HPCL. E. as per routine tests done by manufacturer and additional tests as mentioned below: Template No.20 (a) DATA SHEET OF 25A. C. MUMBAI (SMMS) Document No.20 DATA SHEET OF 50A.) KVA rating of transformer : 5 KVA DC output voltage : 50V DC output current : 50A Current rating SCR: 50A (Average on state current). A. AC input voltage single phase : 240 volts +10% 50HZ AC input current : 30A (max.1. Type of control required in Auto mode: Constant current control and constant voltage control (AVCC MODE) 3. B.C.5 KVA 25V 25A Rest same as 3.3KVA 75V 75A Rest same as 3.) 6. 50V T/R UNIT A. B.19 DATA SHEET OF 75A. B.18 except in item(S) where DC Voltmeter rating shall be 0-80V in place of 0-60V.Power output KVA rating of transformer D. 3. E.1.18 except in item(s) where DC Ammeter rating shall be 0-60A in place of 0-80A. 6891-0645-CP-002 Rev. 133A (RMS on state current) Rest same as 3. D.C. G. 5-0000-0001-T2 Rev.1. F.) 11.) DC power output : 3.) 2.

main transformer between Primary and secondary. load resistance : 1.1.1 ohm for 75A T/R Output current and voltage shall be recorded for each of above conditions (i) to (iv). 75% and 100% rated output current both in Auto and manual mode of operation.21. Thermocouple instrument shall be used for measurement of temperature.65ohm for 50A T/R & 1.65ohm for 50A T/R & 1. filter choke.1. Set back up control 75A & 50A for 75A & 50A T/R unit respectively.) shall be decided by EIL and owner. load resistance 1. Efficiency test of Transformer alone after isolating rectifier at 100% rated output current.1ohm for 75A T/R iii) Input voltage 207 VAC. 3.21. Auto transformer. load resistance 1. Possible using main Auto control for T/R Unit having constant current control.1.1.10 Auto mode over load protection test: Set back up control at 40 Amp and increase current from zero to max.1 ohm for 75A T/R ii)Input voltage 253 VAC.65ohm for 50A T/R & 1. Diodes and SCR's. temp rise to be conducted for main transformer.5 Heat run test for max.9 Calibration test for all Ammeters and volt meters. duration for Auto transformer. 3.8 Polarity test in Auto and manual mode of operation of T/R unit. load resistance: 1.1 ohm for 75A T/R. Number of T/R units to be considered for Heat run tests and actual duration for which test to be conducted up to 72 hours (max. load resistance 0 ohm (short circuit across +ve and -ve terminal of T/R unit). 6891-0645-CP-002 Rev.1. load resistance: 1. The sensors shall be clamped at different locations inside the closed T/R unit cubical and the cable of the sensors shall be connected to temperature indicator through a selector switch outside the T/R unit cubical during heat run test.21.3 Output voltage and current test in Manual mode for each voltage setting using coarse and fine tap switches for the following conditions. i) Input voltage 240VAC. primary and earth. 1 Copyrights EIL – All rights reserved .1 Efficiency test of Transformer Rectifier Assembly at 25%. primary and earth. load resistance 1. 3. 3.6 Insulation resistance test using 500V megger for Auto transformer and Main transformer between primary and secondary. No.21. HPCL. 3. Template No.21.1.21. i) Input voltage 240V AC.1. 3. MUMBAI (SMMS) Document No.65ohm for 50A T/R & 1. 3.1 ohm for 75A T/R ii) Input voltage 253 VAC.21.1. iv) Input voltage 207VAC.65 ohm for 50A T/R & 1.1. 50%. secondary and earth.21.0 Page 40 of 98 3.2 No load output voltage test in Manual mode for each voltage setting using coarse and fine tap switches at rated input voltage of 240V AC.1 ohm for 75A T/R iii) Input voltage 253 VAC. 3. 3. secondary and earth. 5-0000-0001-T2 Rev.65ohm for 50A T/R & 1.4 Output voltage test at rated output current setting in Auto mode for the following conditions.7 Dielectric strength test using 2KV for 1 min. at 50A output current for 50A T/R Unit & 75A current for 75A T/R unit for 48 to 72 hours continuous operation.NEW FCCU PROJECT.21.1.21.

ii) D.12 Ripple factor test T/R unit shall be operated at full load both in Auto and Manual mode. Peak to Peak ripple wave from shall be limited within 7.C Current Regulation against variation in Load Voltage Keeping the AC input voltage at 240 V constant . 264 V.05 volt in CRO screen for 50 volt TR unit & 10. In each case ripple voltage to be checked on a cathode ray oscilloscope (CRO).C Voltage with variation of output load current at three different values ensuring that each output load current.11.1 D.1.21. 5-0000-0001-T2 Rev. 3.C voltage at 48 V and observe for any variation of D.21. 3.21. of output current with variation of AC input voltage at the steps keeping the output load constant: 216V. 6891-0645-CP-002 Rev. feed back signal to be varied from min. No. set the output D.1. taking care voltage limit set value is not exceeded.11 Constant voltage test for control circuitory. Repeat the above at 24 V and finally at 12 V set output Voltage. if any.NEW FCCU PROJECT. set the output D. HPCL.1 i) Constant Current Test D. current limit set value is not exceeded . half cell signal.1.C current at 75 A and observe for any variation of DC current with variation of output load voltage at three different values ensuring that at each output load voltage.13 Annunciation check: Template No. 3.10. 3. For each input supply voltage the reference voltage. MUMBAI (SMMS) Document No.0 Page 41 of 98 In case of Auto PSP control T/R unit ref. set potential of T/R unit using battery & rheostat in place of ref.21. 240 V.1. 1 Copyrights EIL – All rights reserved . +ve DC and -ve DC voltages of Auto mode control circuit to be checked whether they are constant.575 volt for 75 volt TR unit.C Voltage Regulation against variation in Load Current Keeping the AC input Voltage at 220 V constant. Repeat the above at 50A and finally at 25A set output current. Supply voltage of T/R unit to be applied 240V 184V and 276V.21. current during the test should not exceed more than 40A in both cases. 3. to max.1.C Current Regulation against variation in AC Input Put the unit in constant current mode and set the output current at 75 A by the help of current setting potentiome ter and observe the variation in.

Note change in the T/R output current. No.5V and again bring back to 1.21. 3. Increase feed back signal from 1. manual mode operation and auto mode operation.5V and again back to 1. 3.0V. HPCL.0V to 1.15 Power consumption test for diode: 75A T/R Unit: Forward voltage drop of each diode at 75A T/R unit output current: D1= D2= D3= D4= Power consumption: D1= D2= D3= D4= Voltage drop and power consumption should not be more than specified value mentioned in diode manufacturers’ catalogue.0 Page 42 of 98 Annunciation checks to be done for power on. 50A T/R Unit: Conduct above test for 50A T/R unit at output current of 50A. 5-0000-0001-T2 Rev.21.21. Switch on T/R unit & note T/R out put current. Note change in the T/R output current.NEW FCCU PROJECT. 25A T/R Unit: Conduct above test for 25A T/R unit at output current of 25A.0V.1. 1 Copyrights EIL – All rights reserved .16 Power consumption test for filter choke: 75A T/R Unit: a) b) Voltage drop across choke at 75A T/R Unit output current = Power consumption of choke at 75A T/R unit output current = Template No.0V to 0. MUMBAI (SMMS) Document No.1. 3.0V. ii) Conduct similar test as item (i) above with decrease of feed back signed from 1.1.14 Auto mode constant PSP operation test: (Not applicable for this project) Connect one battery with variable rheostat in place of reference cell feed back signal and conduct the following test: i) Make both T/R units set potential & feed back signal from battery 1. 6891-0645-CP-002 Rev.

4 Schematic and wiring diagram of T/R unit circuitory giving Auto/ Manual Mode of control including circuit details of all control cards. including installation/ foundation arrangement details.C.1.22.2 Front view and typical sections of T/R unit panel with arrangement of equipment.16 given above in addition the following observations: - Sl. No. 3. 5-0000-0001-T2 Rev.1 Fabrication drawings and data sheet of T/R unit giving dimensions.22.21.1.20. c) Number used in ferrules of cable leads are matching with schematic/ wiring diagram of T/R unit furnished.23 INSTRUCTION BOOK Template No. No.22.1 to 3. control. 1 Copyrights EIL – All rights reserved . rating. 3. protection and metering. MUMBAI (SMMS) Document No.1. Visual inspection details of T/R unit stating: a) All components of T/R unit are as per specification b) All items are labeled properly for identification purpose.1. Approved drawings after incorporation of comments (if any from EIL/ OWNER shall be furnished in 6 copies alongwith reproducible during the delivery of T/R units: 3.1. Painting details of enclosure.20.17 Test certificate/ documents in 6 copies are to be furnished by vendor before despatch of T/R unit to site.1. 6891-0645-CP-002 Rev. weight.1. The test certificate shall contain results for the tests from 3.3 ratings.1. 3.1. HPCL. 3.S sheet steel used for T/R unit enclosure. of T/R unit D.22 DRAWINGS/ DOCUMENTS Following drawings/ documents shall be furnished by vendor within 15 days from award of contract for approval of the same by EIL/ OWNER before starting of fabrication.22.NEW FCCU PROJECT. Data sheet of all accessories and circuit element of T/R unit including 3. output rating of T/R unit External dimensions of T/R unit Weight of T/R unit Thickness of M.0 Page 43 of 98 50A T/R Unit: a) b) Voltage drop across choke at 50A T/R unit output current = Power consumption of choke at 50A T/R unit output current = 3.

NEW FCCU PROJECT. 3. 6891-0645-CP-002 Rev. testing commissioning and safe operation and maintenance. Description of the operation of the T/R unit.1. Procedures for testing and adjusting the T/R unit: The complete procedure for testing and adjusting the T/R unit during plant operation. Instruction for the installation. the inspection procedure and cleaning procedures. The procedure for the removal and replacement of all parts listed as spares shall be given. 5.1 The instruction book in 10 copies shall be presented in such manner as to enable it to be used by personnel who are unfamiliar with the operation and maintenance of the T/R unit. Detailed description of T/R unit This description shall include the technical characteristics. The instruction book to be furnished along with supply of T/R unit.2 CONTENTS The instruction book shall contain - A description of the T/R unit. 6.23. 7.0 Page 44 of 98 3. 5-0000-0001-T2 Rev. Template No. Maintenance Instructions: This section shall be divided into two parts: a) Preventive maintenance which shall indicate the periodic inspection required. HPCL. MUMBAI (SMMS) Document No. concise and in a logical sequence. accessories and spare parts.23. using schematic diagram. This description shall be clear. and item wise the components. 1 Copyrights EIL – All rights reserved . physical and mechanical limitations.1. No. General description giving brief description of the T/R and its use. Spare parts The instruction books shall give all the necessary details so as to procure all the spare parts from the manufacture or from open market. wiring diagram and fabrication drawing. 3. The information shall be presented as follows: 1. b) Break down maintenance which shall include instruction for trouble shooting of the electrical circuits. periodic maintenance and overhaul shall be covered. 4. Index of contents 2.

1 Copyrights EIL – All rights reserved .1.1. 3. The interruption device shall be solid state type without any mechanical moving parts and shall have arrangement for bypass. Necessary terminals are to be provided at suitable locations of the T/R unit panel for easy termination of onward wiring by others for remote monitoring purpose. 6891-0645-CP-002 Rev. it should identify the fuse failed with the help of an independent LED for each fuse for local visual alarm/ indication.21. • T/R UNIT INTERRUPTION The T/R units shall have programmable current interruption facility according to a schedule defined by the user. - COVERING OF THE INSTRUCTION BOOKS: The instruction book shall be presented in a stiff covered binder with the following information printed on the cover: - the client’s name the location of the installation the name of the installation the title of the instruction book. Interruption ON / OFF cycle should be programmable in the time ratio selectable from 0 to 999 seconds in increments of 1 second. The interrupter clock of TR Unit should accept external time synchronization signal from the central monitoring system having GPS synchronized current interrupter for measurement and recording of interrupted OFF potential recording in synchronization with other T/R units. HPCL.0 Page 45 of 98 8. MUMBAI (SMMS) Document No.0 in this document need to be supplied common for all the T/R Units. • FUSE FAIL ANNUNCIATION: T/R unit should be provided with Fuse fail Indicator.24 Following additional features are to be provided with T/R Unit: Each T/R Unit should be provided with two transducers for providing 4-20 mA output signals for RTU interface for remote monitoring of T/R Unit output voltage and current. The Fuse fail indicator should sense the failure signals from each Fuse in series with diode in the bridge rectifier circuit as well as each fuse in DC output circuit. • MANDATORY SPARE PARTS One set of Mandatory spare parts as mentioned at subsection 5. Each instruction book shall be accompanied with one set of final approved Drawing/ documents as listed vide item 3. No. 5-0000-0001-T2 Rev.NEW FCCU PROJECT. Template No.

5-0000-0001-T2 Rev.NEW FCCU PROJECT. HPCL. 1 Copyrights EIL – All rights reserved . MUMBAI (SMMS) Document No. 6891-0645-CP-002 Rev.0 Page 46 of 98 3.2 SPECIFICATION FOR C P SYSTEM POWER DISTRIBUTION BOARD (PDB) Template No. No.

incoming MCCB and 12/3 no. 4core incoming cable connection shall be provided at left side bottom of the panel. Template No. of 25 x 5 mm tinned copper bus bar shall be used which should be taped by PVC tape of red. The shutters shall be screwed to the pane l enclosure structure at the centre in addition it shall have lockable handles.0 Page 47 of 98 3. Painting details of inside and outside surfaces of the PDB panel shall be as follows: After fabrications the entire enclosure shall be sand blasted to a SA2½ surface. Size of the PDB Panel enclosure shall be adequate to accommodate all components easily and shall be made of 12 SWG sheet steel. PVC insulated. All single core cables shall be used red. L&T. All cable entries to the PDB panel shall be through Aluminium single compression glands. The incoming switch shall be 3-pole and outgoing switches shall be 2pole. The finish coat shall be a dark grey or yellow shade as per choice of EIL/ OWNER. Two nos. yellow and blue colors for identification of the three phases and black color for neutral. Wiring inside PDB shall be done using 50mm2 . 3-phase. ABB OR AEG make. 4-wire 250A/63A. MUMBAI (SMMS) Document No.2 Power Distribution Board (PDB): The Power distribution board (PDB) shall be plinth mounted out door type and shall be installed at non-classified locations near a single or group of T/R Unit under a sun/ rain shed. The MCCB and MCB shall be suitable for motor load application and shall be of HAGER. 1-phase. The finish coat shall be of polyamide cured epoxy in three coats to achieve total thickness of 15 mils. 1 phase. One gland for 300mm2 / 50mm2 . The enclosure of shall be IP-55 as per relevant IEC/ NEC codes. MDS. 4 Nos.6A outgoing MCB for central monitoring system power supply. PVC insulated unarmored cable.3 phase. hinged front shutters shall be provided. 1-phase. An inorganic zinc primer shall then be sprayed to a total thickness of 3 mils. MERLIN GERIN. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved . 63A outgoing MCB for input power supply to TR Unit as well as 6No. HPCL. 12/3/6 glands to be provided at right side bottom of the panel for outgoing cable connections for 63A PDB. 1-core. copper conductor. 3-core Aluminum conductor cables for cent ral monitoring system power supply. SIEMENS. SCHNEIDER ELECTRIC. 1-core. The outgoing cables shall be 25mm2. 3-core Aluminum conductor cables for TRU power input and 16mm2 . All cables terminations shall be through Tinned copper cable lugs of matching cable size. No. copper conductor. CONTRACTOR shall prepare the layout/ construction drawings and a prototype of PDB showing internal terminal arrangement and wiring arrangements and submit to OWNER/ EIL for approval before procurement/ installation of the same at site. yellow and blue colored for phase connections and black colored for neutral connection. The Power distribution board (PDB) shall be composed of one no. 6891-0645-CP-002 Rev.NEW FCCU PROJECT. INDO ASIAN. unarmored cable between TPN switch neutral and neutral bus whereas rest of the wiring shall be done by 25mm2 .

3 SPECIFICATION FOR MIXED METAL OXIDE COATED TITANIUM TUBULAR ANODE FOR CP SYSTEM Template No. 6891-0645-CP-002 Rev. HPCL.NEW FCCU PROJECT. 5-0000-0001-T2 Rev. MUMBAI (SMMS) Document No. No. 1 Copyrights EIL – All rights reserved .0 Page 48 of 98 3.

Template No. Anode consumption rate (Kg/A. ASTM B 338 overlayed with mixed oxide of noble metals. Anode Material Titanium seamless tube of Grade 1/2. 0. Anode weight 0.(ITALY).3.3.3. per anode. No. 7.1 Anodes Mixed Metal oxide coated Titanium tube anodes shall be dimensionally stable and will be supplied with anode lead cable connected to it.No. Anode design life 25 years 6. 5.0 Document No.1. Vendor to furnish details. 3. M/S CERANODE. M/S MAGNETOCHEMIE. 6 gms/m2 (at 100 A/m2 for 25 years design life) Optimum Recommended anode current density (A/m2 ) 9. (USA). INDIA). (GOA.yr. manufacture and testing of anodes suitable for underground application.0 Page 49 of 98 Scope Mixed Metal Oxide Coated Titanium single tubular anodes shall be of standard manufacturer such as M/S TITANOR COMPONENTS LTD. Description Details 1. 5-0000-0001-T2 Rev.yr) at 100 A/m2 Current density Metal Oxide coating thickness weight (gm/M2) 2 mg/A. Anode Type Dimensionally stable Anode (DSA) 2. (USA)..). (U. 8. for use in Impressed current Cathodic Protection system.4mm OD.9mm W. 1 Copyrights EIL – All rights reserved . MUMBAI (SMMS) 3. HPCL. M/S ACTEL LTD.1.T 3. (HOLLAND). Anode Shape & Dimension Hollow Tubular 750mm long x 25.2 ANODE DATA SHEET S.7-0. M/S MATCOR (USA). 3. i) With Carbonaceous backfill in soil ii) Without backfill in soil iii) Fresh water Rated current output 100A/M2 Vendor to furnish Vendor to furnish 6 Amps 10.. 6891-0645-CP-002 Rev.NEW FCCU PROJECT.M/S ORANZIO DE NORA.41 kg + 5% 4.1.K. M/S ELTECH SYSTEMS CORPORATION. Anode Centralizer for 8" NB casing pipe 1 Nos. This specification covers the requirements for the design.

with a double insulation system. shall be KYNAR/ HALAR insulated.3. 12.1. 10mm2 stranded copper conductor. The secondary insulation shall be 0. 7 strands. Anodes with cables shall be delivered to site only after OWNER/ PMC’s approval of the test results which are to furnished by anode manufacturer for each anode. Mechanical & Physical Properties: i) Electrical Resistivity (ohm Cm) of Metal Oxide ii) Contact resistance of anode to cable Pull out strength Anode fabrication Anode to cable connection details Anode to cable joint insulation details Dead Weight for Anode Document No.4 QA/ QC for Anodes Following prototype and routine tests are to be conducted by anode manufacturer. The primary insulation shall be 0.20 inch thickirradiated cross. Fabrication details of the joint including sealing arrangement and test procedure of the joint shall be furnished by vendor or EIL's approval before making the joints.) 200 kg(min) or breaking strength of cable Vendor to furnish details Vendor to furnish details Vendor to furnish details Each anode to be supplied with a dead weight. 1. Anode to Lead cable jointing and insulation shall be done by using straight through jointing kit which is to be provided by anode manufacturer. No.1. Wire Anode to Lead cable jointing and insulation shall be done at manufacturer’s work shop or at field by a trained cable jointer Anode to cable jointing and insulation shall be done by anode manufacturer at his shop. unarmoured. HPCL.9 milli ohms (max. single core.0 Page 50 of 98 10-5 Ohm Cm 0.NEW FCCU PROJECT. 3. 3. 5-0000-0001-T2 Rev.1 Anode to Cable connection Anode lead cable conductor shall be crimped with tubular anode at the center of anode or at the ends and shall be sealed to prevent ingress of water at the joint.linked polyvinylidene floride (PVDF) 1100 Volt grade.3.065 inch thick high molecular weight polyethelene (HMWPE) sheathing jacket over the primary insulation.3. MUMBAI (SMMS) 11.3. Detailed procedure for conducting the following tests shall be furnished by manufacturer for OWNER/ PMC’s approval before commencing tests. Template No. 3. Details of the same to be furnished by vendor Note: All information to be furnished by vendor as per data sheet shall be furnished with his offer. 1 Copyrights EIL – All rights reserved . 6891-0645-CP-002 Rev.3 Anode Lead Cable Anode lead cables to be connected between each anode string and AJB.

2 Anode Lead cables (Routine tests) Routine & type test certificates of cable manufacturer to be furnished for anode lead cable as per IEC 502-1983 or relevant IS code. 6891-0645-CP-002 Rev. /batch No.3. Anode/ cable identification No. 3. 6 copies of typed test reports showing test results should be submitted to OWNER/PMC for approval. 5-0000-0001-T2 Rev.4 Prototype Test First anode to cable joint shall be subjected to accelerated aging test & destructive test to determine pull out strength of cable to anode joint as well as effectiveness of the joint insulation. 3. Negative tolerance will not be accepted.1. - Type and make of Heat shrink cap along with its grade and properties.3 Anode to Cable joint test (Routine tests) Each anode to cable joint shall be tested for its electrical contact resistance & its value in ohms shall be recorded.4. 3.4.4.3.1 Dimensional check (Routine tests) Dimension & weight of all anodes to be checked & recorded.1.1.1.3. 1 Copyrights EIL – All rights reserved .3. shall be mentioned in test results against each test result.3. - Procedure for making the joint Template No.0 Page 51 of 98 3.1.4.5 Anode Fabrication Manufacturers/ supplier shall furnish detailed dimensioned fabrication drawing of anode as well as details of anode to cable connection and its insulation sealing to OWNER/ PMC for approval.4 Test Reports After conducting each test.3. 3. - Name of Manufacturer of joint sealing material along with Physical & Chemical Properties. Any delivery made to site before getting OWNER/ EIL approval of test reports shall be at manufacturer risk & cost.NEW FCCU PROJECT. 3. Cable length and identification tag to be verified by measurement. MUMBAI (SMMS) Document No.4. Manufacture of anodes shall be commenced after obtaining approval and inspection of a prototype joint by OWNER/ PMC at anode manufacturer's works. Anode Manufacturer shall furnish following information for OWNER/ PMC approval before commencement of Anode to cable joint. HPCL.4.1. No.

NEW FCCU PROJECT, HPCL,
MUMBAI

(SMMS)

Document No.
6891-0645-CP-002
Rev. No.0
Page 52 of 98

3.4 SPECIFICATIONS FOR PERMANENT REFERENCE CELL

Template No. 5-0000-0001-T2 Rev. 1

Copyrights EIL – All rights reserved

NEW FCCU PROJECT, HPCL,
MUMBAI

(SMMS)

Document No.
6891-0645-CP-002
Rev. No.0
Page 53 of 98

3.4.0 SPECIFICATIONS FOR PERMANENT REFERENCE HALF CELL
a.

Type of ref. half cell :Cu/ CuSO4 type.

b.

Backfill material:
Gypsum powder
Bentonite powder
Sodium Sulphate

c.

75%
20%
05%

Body : Impact resistance PVC Sch. 80, 2" dia x 16" long

d.
Each reference shall be supplied in cotton bag of chemical backfill having overall
size 8" dia x 16" long and complete with 25 M (minimum) cable as per specification.
However, contractor to measure the actual length of measurement cable required at site
during detailed engineering stage and cut the required length from cable drum so as to
avoid cable-to-cable joint.
e.

Location of half cell: 150 mm from Bullet/ Vessel structure

f.

Design life

: 15 years

g.

Stability

: ±10 mv with 3 Micro- A load.

h.

Make : BORIN (USA) make, or PERMACELL/ HARCO (USA) make,
M.C.MILLER, USA make, CORRTECH (ZULU), AES, BARODA
suitable for 15-40 degC temperature application in sand.

I.

Measurement Cable: 6mm2 , stranded Cu conductor, Single core, screened/
armoured, PVC insulated and sheathed , 1100 V grade .
Reference Cell Cable: 6mm2 , stranded Cu conductor, Single core, screened/
armoured, PVC insulated and sheathed , 1100 V grade .

CONTRACTOR SHALL GET HIS ELECTRODE APPROVED BEFORE
PLACEMENT OF ORDER. NECESSARY TEST CERTIFICATES FROM
MANUFACTURER GIVING CALIBRATION TEST, RESULTS, AND DATE OF
MANUFACTURE SHALL BE FURNISHED DURING DELIVERY. Any delivery
effected without prior approval of owner will be at suppliers risk & cost.

Template No. 5-0000-0001-T2 Rev. 1

Copyrights EIL – All rights reserved

NEW FCCU PROJECT, HPCL,
MUMBAI

(SMMS)

Document No.
6891-0645-CP-002
Rev. No.0
Page 54 of 98

3.5 SPECIFICATION FOR MIXED METAL OXIDE WIRE ANODE

Template No. 5-0000-0001-T2 Rev. 1

Copyrights EIL – All rights reserved

3. Anode Shape & Dimension Vendor to furnish 3.NEW FCCU PROJECT.0 Page 55 of 98 3. Template No.step and water proof.yr. MUMBAI (SMMS) Document No. No. 8.) 12.5. 11.0 MIXED METAL OXIDE WIRE ANODE Factory coke backfilled fabric jacketed Mixed Metal Oxide wire anodes shall be a standard product of the manufacturer regularly engaged in the production of such anodes for use in impressed current Cathodic Protection system. HPCL. Current output capacity 50mA/m (Minimum) 10. Anode Data Sheet 1. The make / model of MMO wire anode to be supplied shall be either “MATCOR Make SPL™-FBR-16” or Covalence / Tyco Make (Anodeflex-3000-01) or or CerAnode Model PBL-15-66/50-CS. Each wire anode shall be supplied with anode lead cable piggy back connected to it i. Anode fabrication Vendor to furnish details 7. Anode Type Dimensionally stable Anode(DSA) 2.5. 5-0000-0001-T2 Rev.1.1 Anodes Mixed Metal oxide anodes shall be dimensionally stable.) 100A/m2 10-5 Ohm Cm Copyrights EIL – All rights reserved .(min) 9. Mechanical & Physical Properties Electrical Resistivity (ohm Cm) of Metal Oxide Contact resistance of anode to cable 0. there will be connection between the Primary anode and the internal header cable at a every 3m (max) distance. Anode weight Anode substrate Material Vendor to furnish Vendor to furnish 5. 4. The connection shall be multi.9 mili ohms (max. . 1 6gms/m2(min.e.1. 6891-0645-CP-002 Rev. Anode design life 25 years 6. Anode consumption rate to be considered at 100 A/M2 C density Metal Oxide coating thickness ( ) weight (gm/M2 ) Anode node current density with Carbonaceous backfill in soil/ sand 2 mg/A.

15. Template No. Vendor to furnish Detailed Fabrication drawing 1kg/AYear (min. heavy duty. Splice kit details Vendor to furnish 24. permeable.) 1. single core. 7 strands. Vendor to furnish Note: All information is required to be furnished by vendor as per data sheet and shall be furnished with his detail engineering package. 10mm2 stranded copper conductor.1. 1 Copyrights EIL – All rights reserved . The jacket shall be made of acid resistant inorganic fabric material. Jointing of anode lead cable with internal anode header cable and its insulation shall be done by using standard jointing kit which is to be provided by anode manufacturer. MUMBAI (SMMS) 13. 20 21. 22. The primary insulation shall be 0. 10 bars. Coke breeze resistivity Anode jacket shall be continuous. with a double insulation system. The secondary insulation shall be 0. However. Document No. 19.1 Kg/m ( min.04 inc h thick irradiated cross-linked poly vinylidene floride (PVDF) 1100 Volt grade. 16. 26.3 ANODE HEADER AND LEAD CABLE Anode internal header cable and anode lead cable in between each anode string and AJB shall be KYNAR/ HALAR insulated. Vendor to furnish details for adhesive seam bond strength of jacket. 14.) 99% (min.065 inch thick high molecular weight polyethylene (HMWPE) sheathing jacket over the primary insulation. 6891-0645-CP-002 Rev.0 Page 56 of 98 Overall OD of anode sting with calcined petroleum coke breeze and its fabric jacket enclosure Weight of calcined petroleum coke breeze Vendor to furnish details Spacing between consecutive anode string to anode internal header cable joints Anode lead cable piggyback connection arrangement to MMO wire anode and its sealing / insulation details for a typical joint. suitable for field handling and direct burial in sand. 17. 5-0000-0001-T2 Rev. No. unarmored. Maximum permissible potential attenuation within the anode Design Life 1% 25 years Sand Resistivity Dry sand Wet sand 20. 3.NEW FCCU PROJECT. Consumption rate of coke breeze to be considered Coke breeze fixed carbon content 3m (max.) 0.) As per manufacturer’s splice kit connection procedure.5.05 to 15 ohm-cm at 23°C. End seal kit details 23. HPCL.000 ohm-cm 500 ohm-cm 25.

4. 3. 5-0000-0001-T2 Rev.1.1.5.NEW FCCU PROJECT. All the tests should be conducted in presence of EIL/ OWNER. 3. 3.3. 6 copies of typed test reports showing test results should be submitted to EIL/ Owner for approval.1.5. Cable length and identification tag to be verified by measurement.1 Anode to Cable connection Vendor should furnish a fabrication including sealing arrangement drg. 3.1. HPCL. 1 Copyrights EIL – All rights reserved .5. which are to be furnished by anode manufacturer for each anode.4 QA/ QC for Anodes Following prototype and routine tests are to be conducted by anode manufacturer. MUMBAI (SMMS) Document No. 3.4. Detailed procedure for conducting the following tests shall be furnished by manufacturer for EIL/ Owner's approval before commencing tests.5.0 Page 57 of 98 preference will be given for direct termination of the anode header cable to AJB without any joint in between with internal anode header cable and anode lead cable. Template No.1. Anodes with cables shall be delivered to site only after EIL/ Owner's approval of the test results.4.1. Wire Anode to anode header cable jointing incase unavoidable.4.5.4.1.4 Test Reports After conducting each test.2 Anode Lead cables (Routine tests) Routine & type test certificates of cable manufacturer to be furnished for anode lead cable as per IEC 502-1983. shall be mentioned in test results against each test result. Any delivery made to site before getting EIL/ Owner's approval of test reports shall be at manufacturer risk & cost. 3. 6891-0645-CP-002 Rev. shall be done at factory or site by a trained cable jointer.1 Dimensional check (Routine tests) Dimension & weight of all anodes to be checked & recorded.5.4 Prototype Test First anode string shall be subjected to destructive test to determine pull out strength of cable to anode joint as well as effectiveness of the joint insulation and coke breeze backfilling.5. of the joint and get the prototype joint approved by EIL/ OWNER. No.3 Anode to Cable joint test (Routine tests) Each anode to cable joint shall be tested for its electrical contact resistance & its value in ohms shall be recorded. / batch No. 3. Anode/ cable identification No.

- Name of Manufacturer of Epoxy Resin & hardener along with its grade & properties in case resin splicing kit is used for joint insulation. 5-0000-0001-T2 Rev.. Vendor (Anode Manufacturer/ supplier) shall furnish following information for approval before commencement of Anode to cable joint. 1 Copyrights EIL – All rights reserved .1.NEW FCCU PROJECT. MUMBAI (SMMS) 3. Template No. No.5. HPCL. Manufacture/ assembling of anode to cable connection shall be commenced after obtaining approval and inspection of a prototype joint by EIL/ OWNER. Type and make of Heat shrink cap and dielectric sealing compound along with its grade and properties in case the same is used. 6891-0645-CP-002 Rev. Procedure for making the entire joint Procedure for accelerated ageing test of the string anode.0 Page 58 of 98 Anode Fabrication Manufacturers/ supplier shall furnish detailed dimensioned fabrication drawing of anode as well as details of cable connection and its insulation sealing to EIL/ Owner for approval.4.5 Document No.

5-0000-0001-T2 Rev.NEW FCCU PROJECT.0 Page 59 of 98 3. 6891-0645-CP-002 Rev. No. HPCL.6 JOB SPECIFICATION FOR ANODE. MUMBAI (SMMS) Document No. CATHODE & MONITORING JUNCTION BOXES FOR CP SYSTEM Template No. 1 Copyrights EIL – All rights reserved .

as per IS 5571. BOMBAY BALIGA LIGHTING. reference cell cables and measurement cables from each bullet shall terminate in its respective cathode junction box cum test station.NEW FCCU PROJECT. The terminals shall be made of cadmium plated steel or stainless steel stud nut and washers of M-10 size for termination of anode and cathode lead cables and M-4 size for termination of reference cell and measurement cables. Typical Details of the junction boxes are shown vide enclosed drawing nos.6. Template No. 2148 & 8289 and relevant IEC/ NEC standards. 1 Copyrights EIL – All rights reserved . These junction boxes will have provision for independent current measurement of each anode output. 6891-CP-D-204 & 6891-CP-D-205.0 Specifications for Anode & Cathode Junction Boxes D-204 & 6891-CP-D-205 ) Document No. DRG. For classified areas. nuts and clamps to be used for mounting the junction box with back plate/ structures shall be MS electro-galvanised or Cadmium plated. The enclosure of the junction box shall be made of cast aluminium. 5-0000-0001-T2 Rev. HPCL. Junction box enclosure shall be of type "Exd" protection Zone 2/ Group IIA/ IIB application. Each CJB shall be connected to the negative terminal of the T/R unit through loop in loop out arrangement for return of drainage current from multiple bullets to the T/R unit. NOS.mentioned reference cell cables and measurement cables from each CJB shall be terminated into a single Monitoring junction box (MJB).1. This will be accomplished by means of individual shunts for each anode circuit.6891 -CP- All classified type AJB/ CJB shall be any of the following make : A) B) C) D) FLAME PROOF EQUIPMENT PVT. Class: T-6. One earthing terminal shall be provided for earthing the junction box.(FEPL). Drainage cable. Enclosure need to be certified by CMRI. bolt and washers. One CJB shall be provided for each bullet and shall be installed at one end along the longitudinal axis of the bullet. BOMBAY FLEXPRO ELECTRICALS. Shutter should be provided with closed cell neoprene sealing gaskets. CHENNAI CEAG FLAME PROOF CONTROL GEARS. The terminal board shall be of 10mm WT Phenolic laminated sheet on which all terminals and shunts are to be mounted. GUJARAT 3. The shutter of the junction box shall be screwed to the body of junction box by using MS electro galvanised/ Cadmium plated nut. Cathode junction box cum test station (CJB) will be required for bonding multiple mounded bullets at drain point as well as for measurement of potential for each bullet. The external bolt.0 Page 60 of 98 (REF. All cable entries shall be through Aluminium double comprehension glands. The cable glands shall be FLP double compression type made of Aluminium. All the above. 6891-0645-CP-002 Rev. NAVSARI. The enclosure of CJB shall be structure/ wall mounted type.1. Temp.1 Anode Junction Boxes and Cathode Junction Box cum test station shall be suitable for Classified Area applications An anode lead junction box (AJB) will be provided to feed T/R Unit output current to anode strings. LTD. MUMBAI (SMMS) 3. No. 5572.6.

3 Proper fitting of cables at cable glands It is essential that all cables should fit tight at cable glands. HPCL. plated. Template No. 1 Copyrights EIL – All rights reserved .6. No.1. nuts and clamps to be used for mounting the junction box with back plate/ structures shall be MS electro-galvanised or Cadmium. MUMBAI (SMMS) Document No. The external bolt. Shutter should be provided with closed cell neoprene sealing gaskets.1.6. The terminal board shall be of 8mm thick Phenolic laminated sheet on which all terminals shall be made of stainless steel stud.6.12. All cable entries shall be through Aluminum double compression glands.1. For this purpose vendor need to make openings for glands at junction box or cast/ procure cable glands as per cable samples to be procured for CP System. 3. The terminal arrangement shall be such that bottom row is utilised for termination of measurement cables from each bullet and upper rows one each is allotted for the reference cell cable termination from each bullet. 3.6. 5-0000-0001-T2 Rev. 6891-0645-CP-002 Rev.67) W.0 Page 61 of 98 3. Shutter should be provided with closed cell neoprene sealing gaskets. 3.1. The enclosure for the MJB shall be of IP-55 construction made of 12SWG (2.2 Monitoring Junction Boxes for non Classified Areas: Monitoring junction boxes (MJB) will be installed near the T/R Unit and shall be required for monitoring potentials of multiple bullets.T. The enclosure shall be structure/ wall mounted type having removable hinged front shutter with one handle and flush type locking arrangement. After inspection and approval of prototype the mass production shall be started. sheet steel. nut and double spring washers of M-4 size for reference cell/ measurement cables.5 Inspection & Testing Fabrication drawing showing internal terminal arrangement of each type of junction box to be submitted by vendor to OWNER/ PMC to obtain approval for a Prototype construction.4 Painting Enclosures of all non classified type anode and Cathode junction boxes shall be surface finished with paint as per guidelines outlined in Section3.NEW FCCU PROJECT. Calibration test for shunts for each junction box to be inspected by OWNER/ PMC before despatch. hence total number of rows shall be one more than the total number of bullets.

7 SPECIFICATION FOR CABLES FOR CP SYSTEM Template No.0 Page 62 of 98 3. MUMBAI (SMMS) Document No. 5-0000-0001-T2 Rev.NEW FCCU PROJECT. HPCL. No. 1 Copyrights EIL – All rights reserved . 6891-0645-CP-002 Rev.

The secondary insulation shall be 0. 6622.065 inch thick high molecular weight polyethylene (HMWPE) sheathing jacket over the primary insulation. MUMBAI (SMMS) Document No. 1 Copyrights EIL – All rights reserved . 7 strands.04 inch thick irradiated cross-linked poly vinylidene floride (PVDF) 1100 Volt grade.0 SCOPE Cables manufacturer for all CP System cables sha ll be • • • • • • • • • • • • • • VICTOR CABLES FORT GLOSTER CABLES UNIVERSAL CABLES NETCO CABLE FINOLEX CABLES ASIAN CABLES RADIANT CABLES CCI CABLES SUYOG ELECTRICALS LIMITED (INDIA). No. 3.1. 5-0000-0001-T2 Rev. single core.1 CODES AND STANDARDS In general the cables covered by this specification shall unless otherwise specified be in the line with the requirements of any of the latest applicable standard of: a) b) c) d) e) a) IS: 7098 (Part I) -1988 IS: 3961 (Part IV)-1968 IS: 3961 (Part II)-1967 BS 5467. unarmored. The primary insulation shall be 0.7. 3. Wherever the requirements in this specification are in conflict with any of the above standard.7. 60502. HPCL. 3. with a double insulation system. the requirements under this specification shall be binding. 6346.2 ANODE LEAD CABLE Anode lead cables shall be KYNAR/ HALAR insulated.7. 10mm2 stranded copper conductor. regularly engaged in production of similar cables. 6891-0645-CP-002 Rev.1. YUXI (CHINA). -VE HEADER CABLE Template No. rating.7. MATCOR (USA). 5467. Relevant NEC/ JIS/ JEC standards. This specification covers requirements for type. NIXUS(USA).1. manufacture and testing of the cables to be used for impressed current type cathodic protection system.3 +VE.1. TRINITY CABLES (UK) ICON CABLES (INDIA). 6485 IEC 502/83.NEW FCCU PROJECT.0 Page 63 of 98 3.

2. stranded Copper conductor. screened and armored cable (between MJB & CJB).ve header cables shall be 95mm2. 6891-0645-CP-002 Rev.6 POWER SUPPLY CABLE (between Power Source & PDB). Aluminium wire armored. single run of 20-core. HMWPE insulated and sheathed 1100V grade cable. HMWPE insulated and sheathed. HMWPE insulated and sheathed. screened and armored cable.1.1. HMWPE insulated and sheathed. HMWPE insulation of each core shall be Numbered or colour coded for easy identification of each core.NEW FCCU PROJECT. MUMBAI (SMMS) Document No.8 REFERENCE CELL / MEASUREMENT CABLE BETWEEN REFERENCE CELL / VESSEL/SEAWATER LINE TO CJB Instrumentation cable.7 EARTHING CABLE Earthing cable shall be 35 mm2 . stranded copper conductor.4 DRAINAGE CABLE Drainage cables shall be 50mm2. single core. 1-core. HPCL.5 POWER SUPPLY CABLE (Between PDB & T/R Unit) Power supply cable between Power source or C. 3.0 Page 64 of 98 +ve header and .7. stranded copper conductor. 3. System DB and T/R unit shall be 25mm2. stranded copper conductor. single run of 10-core (between MJB & TRU). 3. 3. HMWPE insulated and sheathed 1100V grade cable.1.11 REFERENCE CELL / MEASUREMENT CABLE BETWEEN TRU & RTU Template No.7. 4-core.10 REFERENCE CELL / MEASUREMENT CABLE BETWEEN MJB & RTU Instrumentation cable. screened and armored cable.5mm2. stranded Aluminium conductor. 3-core. HMWPE insulated & sheathed 1100 V grade cable.P. 1-core unarmored.5mm2. 3. System DB shall be 300mm2 /50mm2. 4mm2. stranded Aluminium conductor.1. 3.1.9 REFERENCE CELL / MEASUREMENT CABLE BETWEEN CJB TO MJB & MJB TO TRU Instrumentation cable. Aluminium wire armored.7. PVC insulated and PVC sheathed 1100V grade cable. single core. HMWPE insulated and sheathed 1100V grade cable. 1 Copyrights EIL – All rights reserved . two run of 20-core.7.7.7. 5-0000-0001-T2 Rev. HMWPE insulation of each core shall be Numbered or colour coded for easy identification of each core. HMWPE insulation of each core shall be Numbered or colour coded for easy identification of each core. Aluminium wire armored.P.1.1. Aluminium wire armored. stranded Aluminium conductor. stranded Aluminium conductor.1. No. Power supply cable between Power source & C.7. 2. 3.7. 3.

13 POWER SUPPLY CABLE BETWEEN PDB TO RTU FOR CENTRAL MONITORING Power supply cable between PDB to RTU for central monitoring shall be 16mm2.) wherever cable lengths are more than 600m. 5-0000-0001-T2 Rev. 3. each pair twisted and Laid. In case of any doubt OWNER/ EIL may insist vendor to conduct the tests as per IS standards in presence of OWNER/ EIL at vendor’s work shop or some third party reputed laboratory approved by OWNER/ EIL at no extra cost.14 CABLE DRUMS All cables to be supplied in wooden drums. Numbered or color coded. 3-core. 6891-0645-CP-002 Rev. Template No.0 Page 65 of 98 Instrumentation cable. 3. HMWPE insulated and sheathed.3mm and armored with one layer of GI wire cable or fibreoptic cable.1.7.5mm2. screened and armoured cable.16 CABLE IDENTIFICATION For easy identification of cable. 3.7. 1 Copyrights EIL – All rights reserved . stranded Aluminum conductor. HPCL.1. HMWPE insulated and sheathed. HMWPE insulated and sheathed 1100V grade cable.15 INSPECTION All cables along with manufacturer's test certificate as per IS standards shall be inspected by OWNER/ EIL at the vendor's shop before dispatch. Minimum 15 days advance notice to be furnished by vendor for this purpose. HMWPE insulation of each core shall be Numbered or colour coded for easy identification of each core. the over sheath of the cable should have yellow colour and "CP SYSTEM CABLES" should be printed using black colour at one meter interval throughout the length of the cable. Cable lengths in each cable drum shall be 600m (min. Aluminium wire armored.7. stranded copper conductor. solid copper conductor. 0. MUMBAI (SMMS) Document No. 3.1. 2. 5-Pair.1.5mm2. 3.NEW FCCU PROJECT.1. No.7.7. screened with Poly Aluminium tape of 0.12 COMMUNICATION CABLE BETWEEN RTU & CENTRAL MONITORING PC Telephone cable. single run of 24-core.

NEW FCCU PROJECT, HPCL,
MUMBAI

(SMMS)

Document No.
6891-0645-CP-002
Rev. No.0
Page 66 of 98

3.8 JOB SPECIFICATION FOR CALCINED PETROLEUM COKE BREEZE
FOR CP SYSTEM

Template No. 5-0000-0001-T2 Rev. 1

Copyrights EIL – All rights reserved

NEW FCCU PROJECT, HPCL,
MUMBAI

(SMMS)

3.8

Document No.
6891-0645-CP-002
Rev. No.0
Page 67 of 98

SPECIFICATION FOR CALCINED PETROLEUM COKE BREEZE
Calcined Petroleum Coke Breeze shall conform to the following specifications as per IS:
8502-1977, Grade A :
A

Chemical Composition:
Moisture (on Dry Basis)
Fixed Carbon

0.1
0.2
99.0

(% by mass)

B

Bulk density

800 Kg/m3 to 1200 Kg/m3

C

Real density

2.03

D

Particle Size

1.00mm(max.), Dust free

E

Resistivity

0.1 ohm cm. at 150 PSI.

(% by mass)

gm/cc

3.8.1 Test Certificates
Test Certificate shall be furnished for the following:
1.
2.
3.
4.
5.
6.

Make of coke breeze
Batch no.
Chemical composition
Bulk density and Real density
Particle size analysis
Resistivity ( ohm-Cm.) at 150 psi compaction

Make: LORESCO Flex fillTM (USA), LORESCO SC.3R (USA), Goa Carbon (Goa), India
Carbon (Calcutta), Petrocarbon & Chemical Company (Haldia)
Any delivery affected without prior approval of test certificate by EIL/ owner will be at
suppliers risk & cost.

Template No. 5-0000-0001-T2 Rev. 1

Copyrights EIL – All rights reserved

NEW FCCU PROJECT, HPCL,
MUMBAI

(SMMS)

Document No.
6891-0645-CP-002
Rev. No.0
Page 68 of 98

3.9 JOB SPECIFICATION
FOR
THERMIT WELDING FOR CP SYSTEM

Template No. 5-0000-0001-T2 Rev. 1

Copyrights EIL – All rights reserved

Each thermit weld connection will basically require the following equipment of ERICO make: - Thermit weld mold vertical/ horizontal Thermit weld metal Thermit weld cap Steel disc. MUMBAI (SMMS) 3. Copper sleeve Flint Igniter Mold Cleaner Mold Packing Coaltar enamel/ two part epoxy resin for encapsulation of the joint. All thermit weld connections shall be encapsulated with thermit weld cap and flood coating of coaltar enamel. The thermit weld connections shall be made as per enclosed Drawing. HPCL. Template No.0 Page 69 of 98 Thermit Weld Connection: All cable-to-pipe connections shall be made utilizing the exothermic weld process. No. 6891-0645-CP-002 Rev. 5-0000-0001-T2 Rev.1 Document No. 1 Copyrights EIL – All rights reserved .NEW FCCU PROJECT.9.

NEW FCCU PROJECT. HPCL.10 MATERIALS/ EQUIPMENT FOR OPERATION AND MAINTENANCE OF CP SYSTEM Template No.0 Page 70 of 98 3. No. 6891-0645-CP-002 Rev. MUMBAI (SMMS) Document No. 1 Copyrights EIL – All rights reserved . 5-0000-0001-T2 Rev.

1 DC Clipon ammeter in milliamp. range current measurement of Megger (USA) make.0 Document No. Template No.10. No.0 8 Nos. HPCL.NEW FCCU PROJECT. Digital Multimeter having minimum input resistance 10 Mohm. Copyrights EIL – All rights reserved . Waco (India) make.1. 3.. MUMBAI (SMMS) 3. MOTWANE (India) . complete with leads and leather case of BECKMANN.No. Reference electrodes: Portable Copper/ Copper sulphate type having PVC SCH 40 body with transparent window and threaded ceramic porous plug of MC Miller/ Tinker Rasor/ BORIN (USA)/ PERMACELL/ HARCO (USA). 6891-0645-CP-002 Rev.C temperature application in sand. 2. S.0 1 No. Quantity Description 1. Corrtech (Ahmedabad). Lutron (India) make. / micro amp. AES or equivalent make suitable for 15-40 deg. FLUKE. RISABH (India) or equivalent make. 5-0000-0001-T2 Rev.0 Page 71 of 98 Materials/ Equipment for Operation and Maintenance of CP System Following materials/ equipment shall be supplied by the CP System Contractor for operation and maintenance of CP system for all UG Vessels.0 1No.

HPCL. CABLE MARKERS AND JUNCTION BOXES SUPPORT STRUCTURES Template No. MUMBAI (SMMS) Document No.0 Page 72 of 98 3. 1 Copyrights EIL – All rights reserved . 5-0000-0001-T2 Rev. No. 6891-0645-CP-002 Rev. PDB.NEW FCCU PROJECT.11 SPECIFICATION FOR PAINTING CORROSION PROTECTION FOR JUNCTION BOXES.

NEW FCCU PROJECT. MUMBAI (SMMS) Document No. 6891-0645-CP-002 Rev. Colour of top coat shall be yellow or grey as per choice of EIL/ OWNER.1.11. i) Surface preparation Grit/ shot Blasted to SA2 1/2 as per Swedish standard SIS 055900 ii) Galvanizing Hot dip or spray galvanized to achieve a minimum zinc thickness of 150µm.1.11. Name of Paint manufacturer and product should be approved by EIL prior to application. Primer & Paint application procedure shall be standard airless spray and as per paint manufacturer's procedure. iii) Primer Application Etch Primer with 10 µ DFT based on Polyvinyl Butyral resin + 1 coat of epoxy zinc phosphate primer @40 µ DFT/ coat iv) Paint Application 1 Coat of 2 Pack high build epoxy with Polyamide hardener cure @100 µ DFT/coat followed by 1 Top coat of Acrylic Polyurethane finish paint @40 µ DFT/coat. Colour of paint shall be yellow. HPCL. 3.0 Page 73 of 98 3. 5-0000-0001-T2 Rev. Cable markers and junction Boxes support structures All junction Boxes in Non-classified area. PDB. No. PDB and their support structures. 1 Copyrights EIL – All rights reserved . MS channels for T/R mounting if any. cable marker Posts shall be galvanized & painted in following manner.1 MS covers for shallow vertical Beds shall be painted with 2 coats of synthetic enamel paint of Asian Paint/ Berger or equivalent make.0 Corrosion Protection for Junction boxes. Template No.

6891-0645-CP-002 Rev. No.NEW FCCU PROJECT.0 Page 74 of 98 3. MUMBAI (SMMS) Document No.12 CENTRAL MONITORING & CONTROL SYSTEM Template No. HPCL. 1 Copyrights EIL – All rights reserved . 5-0000-0001-T2 Rev.

CP System sub-contractor should design. This output shall be used to turn the rectifier OFF and ON for depolarised and instant "OFF" readings. real time clock. MUMBAI (SMMS) 1. RTU/PLC shall be provided with 1 analogue output that can be used for controlling the various modes of the TR unit for remote control. digital outputs and analogue outputs to be processed by each RTU/PLC system is to be designed by vendor for review / approval by EIL/OWNER. battery backup and communication ports or equivalent PLC-SCADA system. The system should also have inbuilt mechanisms to reduce / nullify induced AC interference voltages. All CP System parameters shall be monitored and controlled from central control room using suitable soft ware. 4 analogue signals from permanent reference cells at each vessel and 20 analogue signals from permanent reference cells located at seawater line. 6891-0645-CP-002 Rev. 5-0000-0001-T2 Rev. No. The digital input/ output channels shall be optically isolated.0 Page 75 of 98 Computerized Central monitoring and Control is required for the CP System. HPCL. digital inputs. 1 Copyrights EIL – All rights reserved . Thus considering few spares minimum analogue inputs. For this purpose. The communication link between the RTU/PLC and Central monitoring and Control station should be cost effective GSM based wireless technology RS485 / telephone / fibreoptic / ethernet communication whichever is decided by EIL/ OWNER as the communication network. keypad.Duo processor Genuine Windows Vista/XP operating system with License 2GB DDR2 NECC Dual Channel SDRAM at 667 MHz Template No. memory. The RTU/PLC should be capable of generating alarms when the parameter limits are violated and it should communicate the alarm data in real time and should not wait for the monitoring software query. 4 analogue output signals and 4 digital output signals for each TR Units. Further. the T/R unit & permanent reference cells should be connected to Remote Terminal Unit (RTU) consisting of microprocessor based CPS controller with alphanumeric LCD display. The RTU/PLC Unit shall also be provided with 1 No.0 Document No. The RTU/PLC should include a GPS based time synchronization unit for measurement of true OFF potential readings. digital output for switching operation for TR Unit. Single or multiple RTU/PLC system may be provided for monitoring and control of all TR unit and Tank/Bullet/Vessel. procure and install the requisite communication system and the cables required for this purpose. 5 digital input signals. The rectifier sha ll have in-built facility to accept these signals and interrupt its output supply. In addition to this some digital and analog (input / output) signal should also be kept as spare capacity. RTU/PLC system shall be capable to process minimum 3 analogue input signals.NEW FCCU PROJECT. Central monitoring and Control station computer to be provided by the CP System subcontractor shall consist of standalone computer suitable for CP monitoring application with following minimum specifications: • • • Intel Core 2 .

. Allen-Bradley. No. Reference Electrode Voltages.NEW FCCU PROJECT. 1 Copyrights EIL – All rights reserved . Siemens. 6 USB Port MS SQL Server 2000 A3 Laser jet printer (HP make) Inbuilt UPS system which can operate up to 30 minutes on full load in case of power failure Other standard accessories CP System sub-contractor shall also provide necessary Software for Remote Monitoring & Control as well as for printing of CP reports. The T/R Unit Output DC Voltage. Alarms are to be extended to RMCP Panel through RTU/PLC units by any of the cost effective communication network such as RS485 / fibreoptic / ethernet communication whichever is decided by EIL/ OWNER as the communication network for data downloading and remote monitoring & control from master control room. HPCL. (Ahmadabad) or M/S Raychem RPG Ltd. The Remote Monitoring & Control Panel (RMCP) shall have a Data Acquisition and Control Hardware operating in Real Time on PC having minimum specification mentioned in item 3.1 REMOTE MONITORING & CONTROLLING CENTRAL CONTROL SYSTEM: The software and hardware for the proposed SCADA system shall have a proven track record of minimum three years of successful operation in the field of CP monitoring and shall be procured from the existing system supplier M/S CIMCON Software (India) Pvt. KRISTRON SYSTEMS MUMBAI or equivalent make subject to approval by EIL/ OWNER.12.SOFTWARE: Template No. 6891-0645-CP-002 Rev. SIEMENS.0 A Front End Processor (FEP) is also required that will be responsible for managing the entire communication traffic between the RMCP and RTU/PLC. Ltd.0 Page 76 of 98 320 GB SATA II HDD AT 7200 rpm 24in Flat Panel LCD Colour Monitor CD Rom Intel Integrated 10/ 100 Ethernet Network Card 1 Serial. 5-0000-0001-T2 Rev. 1 Parallel. DC Current. Each T/R Unit shall accept set point signals for DC Voltage and DC Current from Remote Monitoring & Controlling Panel and accordingly shall control its output from 0 to 100%. The unit shall maintain the data flow even in the event that the RMCP computer is not operative. SCHNEIDER ELECTRIC. 1. The software should be compatible to Windows format and MS SQL Server or Oracle database (10g) with proper License should be used. Mumbai. • REMOTE MONITORING SYSTEM . MUMBAI (SMMS) • • • • • • • • • Document No.

• 16 – bit high Resolution 5 • Input Over voltage protection: +/. • Accuracy +/. 6891-0645-CP-002 Rev. nodes for management information system for access and reporting for the management. 1 As per manufacturer 17 X 2 LCD with backlight 17 key Membrane • Micro controller based design on 12MHz frequency • 32 Kbytes of Program memory • 64 Kbytes of Data memory ( Non-volatile) • 256 Kbytes of additional Data memory • Real Time Clock ( +/. MUMBAI (SMMS) Document No.1 bit LSB. No.5 V DC. • Remote Terminal Unit – specifications : 1 Model Number: 2 Local display 3 Local Keypad 4 CPU 6 Memory retention Analog Inputs • Input Range: 0 . 5-0000-0001-T2 Rev. 10 years without external power to RTU VENDOR TO FURNISH Copyrights EIL – All rights reserved . The Monitoring software shall be user friendly. Windows Vista / XP compatible.30 V DC Continuous. 0 . Supervisory and Operator.NEW FCCU PROJECT. The monitoring software should be capable of generating Email. as and when signals go outside programmed set points and during RTU/PLC failure and TR Unit input power failure. and should allow easy data transfer to other windows based applications or custom applications having ODBC compliant database. It should generate customized reports as decided by EIL/ OWNER.10 V DC.1 minute accuracy over one month) . the software shall send an SMS to the concerned person to enable him to take the corrective action to ensure that system is restored to normal at the earliest. SMS based notification & visual alarm. It should have provisions to accommodate future need of addition of new TRs or storage Tanks as may be required from time to time. The software shall allow configuration of mobile numbers of the OWNERS employees who are responsible for maintenance and in the event of any malfunctioning of the CP system. Data security should be ensured through three different types of Access Levels namely Expert. Template No. • Watch dog timer which provides a reset signal to the CPU if not toggled due to any hardware or software failure to ensure fail safe operation.in graphic package to display graphical representation of the process on-screen with embedded buttons for switching ON/ OFF TR units. The Software shall have built.0 Page 77 of 98 The Remote Monitoring and Control System shall monitor and control all process parameters of Cathodic protection system. The software shall be compatible for interfacing of the available CP System monitoring data on LAN at 10 No. HPCL.

6891-0645-CP-002 Rev. • Local LED status. HPCL. MUMBAI (SMMS) 7 8 9 10 11 12 13 14 15 16 17 18 19 Digital Inputs (I/p failure+ mode+ PSP+ 1 over PROTECTION + 1 Under protection+ O/P Failure) • 24 VDC inputs • Isolation: 2500 Vrms optical isolation • Input Current per channel: 7 mA @ 24 VDC • Local LED status. 1 Document No. Analog Outputs • Range: 4 –20 mA • 12-bit Resolution. • Over Voltage protection • EMI / EMC protection. • Contact rating 230 V AC @ 5 amps / 200 V DC @ 2 amps • On /off delay times 3 msec. Flow chart based Copyrights EIL – All rights reserved . 5-0000-0001-T2 Rev.0 Page 78 of 98 VENDOR TO FURNISH VENDOR TO FURNISH VENDOR TO FURNISH Through 12V dc / 100mA o/p for external 12 Vdc relay 230V AC. Digital Outputs • SSR outputs relays • 2500 Vrms optical Isolation.NEW FCCU PROJECT. No. Rectifier Switching Power Supply Power Consumption Battery Backup Communication Communication Ports Mounting Enclosure Operating Temperature range Humidity 20 Compliance 21 Protection 22 Programming language Template No. 50 Hz (can withstand a voltage fluctuation from 170 V to 270 V) Less than 7 Watt (typical) 4 AH supports all operations for 2 hours without external power RS485 / fibreoptic / ethernet 3 numbers(minimum) Wall / Pole mounting ABS / Steel / IP65 / NEMA 4 (suitable to be offered) 0 to 55 deg C 95% condensing IEC – 60068-2-1 / IEC – 60068-2-2 / IEC – 60068-2-30 / IEC – 60068-2-78 / IEC-68-2-6 /IS 9000 Part VIII / IEC-68-2-27 / IEC-61000-4-2 /IEC-61000-4-3 / IEC-61000-4-4 / IEC-61000-4-5 CISPR22 • Short Circuit Protection • Surge Protection using Metal oxide resistors.

HPCL.NEW FCCU PROJECT. A report shall be generated at 1 second logging interval by normal report generator so special marks for proper interruption cycle operation. At any time. Alarm Reports: This particular report shall give all information about the alarms. an exception report shall be available.2 Document No. The version of SQL shall be SQL 2000. 1 Copyrights EIL – All rights reserved . which did no t call. Following security features shall be provided in the server software • Roles  Fixed Server Roles  Fixed Database Roles  User-Defined Roles  Application Roles • Granting and Denying Permissions to Users and Roles • Ownership Chains • Cross-database ownership chaining • Use of Security Identifiers Template No. This shall be used to show the monthly readings for each site. Report information shall be compatible with standard spread sheet programs. All above reports of different type should be available in graphical presentation.3 DATA BASE SECURITY Database shall be in the form of SQL Server. MUMBAI (SMMS) 1. 6891-0645-CP-002 Rev. This report shall show the Remote Monitoring system.0 Page 79 of 98 Reports The software should generate reports. Scalling and calibration of analogue channel can be done by use of SCANET Editor Software. and the systems that should have called but did not. 1. on screen and printer. A single page report yearly report for each remote monitoring. which occurred in any abnormal conditions. The reports shall highlight readings outside limits and systems. which can be viewed as well as printed as listed below: i) ii) iv) v) vi) vii) viii) ix) A monthly report showing readings from every system. 5-0000-0001-T2 Rev. No. which called because of abnormal conditions.

4 • Group Creation • User Creation • User Group Allocation • Password Aging Period • Maximum Failure Attempts • Failure Notifications • Enable . 5-0000-0001-T2 Rev. MUMBAI (SMMS) • Object Level Security Implementation • Several levels of auditing of both events and states • Support for SSL implementation • Remote Administration .Disable Account Status • Template Based security setttings • e-Signature • Audit Trail • Access Level Based on the operation • Access Security Based on Object / User • Roles and Reasons • Audit Trail Query Builder • Password Masking • Automatic Application Lock out have DESIGN REVIEW: CP System sub-contractor should prepare detailed engineering package for central monitoring and control system along with schematic drawings and equipment/materials list including make/model of the same and get the same approved by EIL/OWNER before procurement/execution. 6891-0645-CP-002 Rev. No.0 Page 80 of 98 Over and above the above features. Template No. HPCL.NEW FCCU PROJECT. 1. the software supplied by the vendor shall following essential futures to access the database.Secured Terminal Services Document No. 1 Copyrights EIL – All rights reserved .

Template No. For this purpose CP System sub-contractor should furnish notice to EIL/OWNER minimum 15 days before the date of inspection. 1 Copyrights EIL – All rights reserved . HPCL.5 Document No. MUMBAI (SMMS) 1. No.NEW FCCU PROJECT. 5-0000-0001-T2 Rev. 6891-0645-CP-002 Rev.0 Page 81 of 98 INSPECTION The prototype inspection along with simulation tests shall be done at specialist agency's office / workshop by EIL/OWNER before the dispatch of the equipment and materials at site.

5-0000-0001-T2 Rev. MUMBAI (SMMS) Document No. 6891-0645-CP-002 Rev. 1 Copyrights EIL – All rights reserved . No.NEW FCCU PROJECT. HPCL.0 Page 82 of 98 3.13 SPECIFICATION FOR SOIL RESISTIVITY TEST Template No.

HPCL. 4-pin OBJECTIVE The objective of the tests given by Para 1. be in line with the requirements of BS CP 1021. the requirements under this specification shall be binding. 3. 4. for this purpose limited watering may be required at the electrode penetration points wherever soil is dry or less compact.0 SOIL RESISTIVITY TEST In general soil resistivity tests covered by this specification shall unless otherwise specified. While inserting electrodes in soil for taking soil resistivity care should be taken to make good contact of electrodes with the soil.NEW FCCU PROJECT.0 Soil resistivity upto 6m depth to be measured insitu using Wenner's method in offsite/unit areas. ? = 2pAR where. 1 Copyrights EIL – All rights reserved . 6891-0645-CP-002 Rev.0 Document No. 3.P. & 6m depth for distributed anode beds. Wherever the requirements in this specification are in conflict with the above standard. 4m. The depth of penetration of electrodes should not exceed 1/10th of the electrode spacing. The calibration certificate must be furnished to ENGINEER-IN-CHARGE for approval of the meter before use of the same for soil resistivity test at site. ? A R = = = Soil resistivity in ohm -cm Inter electrode spacing in cm Resistance observed from soil resistivity meter in ohm. 5-0000-0001-T2 Rev.1 SOIL RESISTIVITY TEST BY WENNER 4-PIN METHOD Soil resistivity by Wenner 4-Pin method to be conducted at 4 anode bed locations as per instructions of EIL. at each location soil resistivity readings to be taken for 2m. MUMBAI (SMMS) 1.0 REPORT PREPARATION Template No. System for prevention of external corrosion of underground metallic structure and piping within a plant complex. 3.0 Page 83 of 98 SCOPE The scope of this standard is to conduct the following tests within a plant complex: • 2. No.2 CALIBRATION OF SOIL RESISTIVITY METER Soil resistivity meter should be calibrated at a reputed laboratory before use.0 is to assess the corrosiveness of the soil & to decide suitable locations for anode beds for C.

6891-0645-CP-002 Rev. Template No. MUMBAI (SMMS) Document No. HPCL. No.NEW FCCU PROJECT. The soil resistivity is to be expressed in ohm-cm. 1 Copyrights EIL – All rights reserved . Six copies each of soil resistivity report to be furnished to OWNER/EIL for record. 5-0000-0001-T2 Rev.0 Page 84 of 98 All soil resistivity readings shall be typed and presented in a tabular form giving coordinates and other location reference of each test locations & depth of each reading.

6891-0645-CP-002 Rev.0 TENTATIVE BILL OF MATERIALS (BOQ) Template No.NEW FCCU PROJECT. 5-0000-0001-T2 Rev. No.0 Page 85 of 98 4. MUMBAI (SMMS) Document No. HPCL. 1 Copyrights EIL – All rights reserved .

Cu Drainage cable. As reqd.5 mm2.0 Page 86 of 98 Tentative BOQ for CP System : Tentative of bill of quantities to be supplied by Contractor shall be as follows : 1) For Vessel No. Mtrs. Mtrs. 1 1 Cables: • 95mm2 X 1-core. : At FCCU (Closed blow down drum) S. • 35mm2 X 1-core.0 Description of Item Indoor type. Nos. As reqd. 114-D-3028. air cooled Transformer Rectifier Unit (T/R Unit) of rating 25V/25A complete with its accessories and auxiliaries • • 3. 2 2 Template No.No. As reqd. No. Mtrs. Al power supply cable.0 Mixed metal oxide coated wire anode factory pre packed with coke breeze Cable splice kit for anode lead cable to anode string joints (In case MMO anode header cable is not directly terminated to AJB) Unit No. 14 Junction Boxes: • Anode Junction Boxes for classified areas • Cathode Junction Boxes cum test station for classified areas No.0 2. Mtrs.5mm2 X 10-core. Cu Monitoring cable • 2. Mtrs. 6891-0645-CP-002 Rev. As reqd. Mtrs. Mtrs. As reqd. • 25mm2 X 3-core. Cu or fibreoptic cable. Cu Monitoring cable • 2. Al power supply cable.0 5. As reqd. As reqd. 5-Pair. Mtrs. • 16mm2 X 3-core. Mtrs. Quantity 1 (Common for vessel 114-D3028 & 120-D-1002) 119 (7 loops) No. Mtrs. As reqd. 24-core. Thermit Weld Connection: • For 50mm2 cable • For 4mm2 cable Nos. As reqd.5 mm2 . Al +ve and -ve header • 50mm2 X 1-core. As reqd. As reqd. As reqd. Mtrs. As reqd. Mtrs. Mtrs. HPCL. Al earthing cable.NEW FCCU PROJECT. 1 Copyrights EIL – All rights reserved . • 4mm2 X 1-core. Al power supply cable. Mtrs. No. • 10mm2 X 1-core Cu anode lead cable. MUMBAI (SMMS) Document No. • 50mm2 X 4-core. 1. Cu Monitoring cable Communication Cable considering RS485 or Ethernet CAT-5 cable 0. Cu Measurement cable • 2. 20-core.5 mm2 . As reqd.0 4. Mtrs. 5-0000-0001-T2 Rev.

5 mm2 .0 4. Mtrs. No. Cu Monitoring cable • 2. Cu Drainage cable. 1.NEW FCCU PROJECT. No.0 5.5 mm2 . Mtrs.5mm2 X 10-core. Mtrs. Mtrs. 5-Pair. 2 2 Template No. Cu or fibreoptic cable. As reqd. Al power supply cable. Nos. Mtrs. As reqd. As reqd. air cooled Transformer Rectifier Unit (T/R Unit) of rating 25V/25A complete with its accessories and auxiliaries • • 3. As reqd. HPCL. 5-0000-0001-T2 Rev.0 i) Cu/ CuSO4 type Painting of CP System equipment Document No. As reqd. Al power supply cable. Mtrs. • 4mm2 X 1-core. Cu Monitoring cable • 2. • 10mm2 X 1-core Cu anode lead cable.5 mm2 . Al power supply cable. Mtrs. 20-core. Al +ve and -ve header • 50mm2 X 1-core.0 Description of Item Indoor type. 24-core.0 2. Mtrs. As reqd. As reqd. As reqd. 1 1 Cables: • 95mm2 X 1-core. Cu Monitoring cable Communication Cable considering RS485 or Ethernet CAT-5 cable 0. • 16mm2 X 3-core.0 Page 87 of 98 No. • 35mm2 X 1-core. As reqd. 6891-0645-CP-002 Rev. Mtrs. 12 Junction Boxes: • Anode Junction Boxes for classified areas • Cathode Junction Boxes cum test station for classified areas No.0 Mixed metal oxide coated wire anode factory pre packed with coke breeze Cable splice kit for anode lead cable to anode string joints (In case MMO anode header cable is not directly terminated to AJB) Unit No. 4 Lot. Mtrs. As reqd.0 Permanent reference cells: 7. Mtrs. 1 Copyrights EIL – All rights reserved . Mtrs. As reqd. 120-D-1002: At FCCU (Amine blow down drum) Sl No. As reqd. • 25mm2 X 3-core. MUMBAI (SMMS) 6. Quantity 1 (Common for vessel 114-D3028 & 120-D-1002) 94 (6 loops) No. Cu Measurement cable • 2. Al earthing cable. 2) For Vessel No. As reqd. Mtrs. As reqd. Mtrs. Thermit Weld Connection: • For 50mm2 cable • For 4mm2 cable Nos. • 50mm2 X 4-core. Mtrs. As mentioned in spec.

Unit No. specifications and direction of Engineer.0 7. As reqd. As reqd. Mtrs. As reqd. Mtrs. As reqd.5 mm2 . Al power supply cable.6A Capacity MMO Tubular Anode in each vertical type distributed Anode bed including dead weight.in-Charge. 4 As mentioned in spec. 1 Mtrs. Al power supply cable.0 Page 88 of 98 No.0 3. Cu or fibreoptic cable.5 mm2.5mm2 X 10-core. Junction Boxes: • Anode Junction Boxes for classified areas • Cathode Junction Boxes cum test station for classified areas • Monitoring Junction Boxes for nonclassified areas Cables: • 95mm2 X 1-core. Al earthing cable. HPCL. 1. drilling of 6m deep borehole. No. Cu Measurement cable • 2. • 35mm2 X 1-core. Cu Monitoring cable • 2.0 5. 1 Copyrights EIL – All rights reserved . 5-0000-0001-T2 Rev. As reqd. Cu Monitoring cable Communication Cable considering RS485 or Ethernet CAT-5 cable 0. Lot. Cu Monitoring cable • 2. casing pipe as per drawings.0 2. Al +ve and -ve header • 50mm2 X 1-core. As reqd. Mtrs. Cu Drainage cable. 26 No. lowering 6” dia. • 4mm2 X 1-core. anode to leade cable jointing. • 25mm2 X 3-core. As reqd. air cooled Transformer Rectifier Unit (T/R Unit) of rating 75V/75A complete with its accessories and auxiliaries Supply and Installation of 1 No. Mtrs. As reqd. • 10mm2 X 1-core Cu anode lead cable. Mtrs. Mtrs. 2 2 No. Mtrs. Mtrs. Mtrs. MS casing pipe bore hole and backfilling coke breeze inside the 6” dia. No. Mtrs. As reqd.NEW FCCU PROJECT. MUMBAI (SMMS) 6.5 mm2 . 20-core. As reqd. No. Mtrs. 5-Pair. As reqd. 6891-0645-CP-002 Rev. Mtrs. As reqd.0 Permanent reference cells: i) Cu/ CuSO4 type Painting of CP System equipment Document No. Mtrs. As reqd. • 16mm2 X 3-core. Quantity 2 3) For sea water line Sl No.0 Description of Item Indoor type. • 50mm2 X 4-core. 24-core. Thermit Weld Connection: Template No. As reqd.0 4. Al power supply cable.

synchronized switching on /off of TR UNITS & on /off potential monitoring of Permanent reference Cells as per specification and direction of the Engineer. 1 As mentioned in spec. 20 As mentioned in spec.NEW FCCU PROJECT. 4. Nos. As mentioned in spec. 1 Quantity As mentioned in spec. 4 4 No.0 Operation Spares for CP System Lot.0 CP System power distribution board (63A) No. 1) Common for both the Vessel No. One Lot Template No. No.0 Supply and installation of computerized Central Monitoring system for Cathodic Protection system including SCADA soft ware / hardware and supply of Central Monitoring PC of P4 grade along with accessories as per specification for Central Monitoring of TR Unit output. 3. HPCL.0 Page 89 of 98 Nos. 114-D-3028 & 120-D-1002 & sea water pipeline Sl No.0 Description of Item Instruments for operation and maintenance of CP System Unit One Lot 2.0 • For 50mm2 cable • For 4mm2 cable Permanent reference cells: i) Cu/ CuSO4 type Painting of CP System equipment Document No. 6891-0645-CP-002 Rev. Lot.0 7. 1. 5-0000-0001-T2 Rev. MUMBAI (SMMS) 6.In Charge. Copyrights EIL – All rights reserved .

0 Page 90 of 98 5. No. MUMBAI (SMMS) Document No.0 MANDATORY SPARES FOR CATHODIC PROTECTION SYSTEM Template No.NEW FCCU PROJECT. 1 Copyrights EIL – All rights reserved . 6891-0645-CP-002 Rev. 5-0000-0001-T2 Rev. HPCL.

Ameter Nos. set. 10 - SCR's Nos. 20 - A. 4 - Diodes Nos. 4 - A. 10 - Auto Manual Mode selector switch Nos. 3 - Filter circuit capacitor Nos.C.Fuses for output side Nos. HPCL. 4 - A. 5 - Toggle switches - Assorted Glass cartridge fuses Template No. 1 Nos.C. 5 - Electronic Control Cards each type Nos. 5 - Control transformer Nos.Voltmeter Nos. 10 - R.fuses for input side Nos.C. MUMBAI (SMMS) Document No.Circuit breaker(MCB) Nos. 20 - HRC fuse for Diodes Nos. 10 - D. 4 - D.C.NEW FCCU PROJECT.0 Page 91 of 98 5. 5-0000-0001-T2 Rev.C.Ammeter Nos. 10 - Fine voltage control switch Nos.C.C. 5 - Coarse voltage control switch Nos.Lightening arrestor Nos. No. Surge Diverter Nos. 10 - Fine current control switch Nos.C. 6891-0645-CP-002 Rev. 20 - D.0 The Bidder shall supply the following spares for all three T/R unit : - D.C. 5 - A. 10 - Coarse current control switch Nos. 10 - Signal light assembly for annunciation Nos.Voltmeter Nos. 5 50 Copyrights EIL – All rights reserved .

MUMBAI (SMMS) Template No. No.0 Page 96 of 98 Copyrights EIL – All rights reserved .NEW FCCU PROJECT. 6891-0645-CP-002 Rev. HPCL. 5-0000-0001-T2 Rev. 1 Document No.

0 Page 97 of 98 DRAWING LIST FOR C P SYSTEM Copyrights EIL – All rights reserved .0 Template No. 1 Document No. MUMBAI (SMMS) 7.NEW FCCU PROJECT. HPCL. 5-0000-0001-T2 Rev. 6891-0645-CP-002 Rev. No.

12. 6891-0645-CP-002 Rev. MUMBAI Document No. HPCL. Power Distribution Board Lay out arrangement for equipment under shelter SLG of LT Power Supply (2SHT) PDB Cabinet Layout Monitoring Junction Box (MJB) Marker post details Distributed Vertical Anode Bed details for one Anode Template No. Title Drawing No. 5-0000-0001-T2 Rev. 7. 8.NEW FCCU PROJECT. 10. No. Anode Lead Junction Box details CJB cum test station details Cable to Pipe joint details by Thermit Welding Underground Cable Installation details Installation details of Junction box support structure. 1. 6. 11.0 Page 98 of 98 (SMMS) CONTENTS A) CP System drawings : Sl. 5. 1 Rev 6891-CP-D-204 6891-CP-D-205 7-06-208 7-06-209 0 0 A A 6891-0642-D-212 0 6891-06-42-D-227 0 6891-0642-012 0 6891-0642-101 7-06-250 6891-0642-05 7-06-215 0 0 0 A 7-06-230 0 Copyrights EIL – All rights reserved . 4. 9. 2. No. 3.