ENGINEERING/HO Ref:ENG/34 Date:August 27,2018 Sub: Technical Specification for Earth Electrodes and Earth Enhancing Materials for Chemical Earthing System 1.0 2.0 3.0 4.0 5.0 6.0 Encl cc cc cc ae The Technical specification for the chemical earthing has been reviewed and a detail guidelines is prepared on technical specification for Earth Electrodes and Earth Enhancing Materials for Chemical Earthing System. ‘The Chemical Earthing should be provided only at those location where soil resistivity is very high, The earthing system should be designed location specific based on soil condition, for effective earthing system. The Technical Specification is carrying general arrangement drawings for two types of earth electrodes, viz. Pipe-in-Pipe Type earth electrode and Copper Bonded Earth Electrode. Selection of earth electrodes should also be done as per design. Entire Earthing system provided for Terminal/Depot/AFs should meet the standard guidelines as per IS 3043(latest revision). This circular also supersedes the technical details provided for chemical earthing under Circular Ref: ENG/20/2017 ;dtd;07.06.2011. This has approval of ED(E&PJ) and ED(HS&E) (SK Suman) (Vaneet Ban: Chief Manager(Elec.) DGMlEnge) ‘As above : All State Engineering Heads : CGM(M&l), HO ;GM(Engg), HO‘TECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES | ENG/34/CE & EARTH ENHANCING MATERIALS. FOR CHEMICAL EARTHING ‘Compan i | TECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES AND EARTH ENHANCING MATERIALS FOR CHEMICAL EARTHING SYSTEM SKS VB. 27.08.2018 PoIL 2G) DGM(Engs) Issue Date Description Prepared By Checked By _| Approved By 1‘TECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES | ENG/34/CE & EARTH ENHANCING MATERIALS FOR CHEMICAL EARTHING AMaharatna ‘Company. INDEX Clause Particulars Page No. No. 1.0 Scope 2 2.0 Standards 3-4 3.0 General Technical Requirement. 4 3.1 Earth Electrode 47 4.0 Earth enhancement material 79 5.0 Test 5.1 Type Test 9-10 52 Acceptance Test 11 5.3 Rejection 11 5.4 Routine Test. 1 6.0 Test Certificates 1 7.0 Inspection 12 8.0 Installation of Earthing System 12-14 9.0 Marking on Electrode 14 10.0 Maintenance of Earthpit 14 11.0 Frequency of Test 15 Drawing 16 7 but = &. Test certificate from NABL approved laboratory to be provided for the compound so designed. it should have better hygroscopic properties to absorb moisture. It should absorb & release the moisture in the dry weather condition and help in maintaining the moisture around the earth electrode. It should have capacity to retain more than 10% moisture at 105°C. Test certificate for the same from NABL approved laboratory shall be submitted. ‘Material shall be in granular form of size 0.1mm to 3mm and shall absorb water to the extent of @ 51%. Specific gravity of BFC material shall be between 2.5 to 2.7. Material shall be nontoxic, nonreactive, non-explosive & non-corrosive. Material shall be thermally stable between temperature range of -10°C to +60°C. Material shall not decompose or leach out with time. It shall not pollute the soil or local water table & shall meet environmental friendly requirement for landfill. It should expand & swell considerably & remove entrapped air to create strong connection between earth electrode & soil. It should diffuse in to the soll pores & create conductive roots enlarging conductive zone of the earth pit. It shall be suitable for any kind of electrode and all kinds of soils of different resistivity. It shall not require periodic charging treatment or replacement. It shall not cause burns, irritation to eye, skin etc.TECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES | ENG/34/CE @ EARTH ENHANCING MATERIALS. FOR CHEMICAL EARTHING xix) Earth Enhancement Material should be RoHS compliant. xx) Minimum quantity requirement per pit of size 5'x5'x10" shall be minimum 75Kg per pit (in case of open pit installation of earth electrode) and for 250mm bore type pit shall be minimum 50 Kg per pit. In case of Copper Bonded Rod Electrode, the bore size will be 125mm and the required Earth Enhancement Materials will be minimum. 35Kg per pit. xxi) Earth enhancement material shall be supplied in sealed, moisture proof bags. These bags shall be marked with manufacturer’s name or trade name, quantity, batch no. & date of manufacture. 5.0 TESTS: 5.1 Type test: ‘The materials offered should have been successfully type tested for the tests in line with the relevant standard and technical specification. Complete set of the type test reports should be submitted. Following type tests shall be carried out on one sample; 1. MS. pipe shall be ISI marked & type tested as per IS:1239. MTC should = be: submitted (not later than 3year) 2. Material composition of Rod Electrodes shall be tested as per standard in mentioned 3.1. 3. Current carrying capacity Test shall be carried out on the electrode as per relevant IS & it shall withstand capacity rating as mentioned inthe specifications. 4, Toanalyze effect of corrosion, salt spray test as per relevant 1S 2119 shall be carried out at any NABL approved laboratory , preferably for 500hrs. or more. 5. Electrical properties test on conductive materials as specified inthe specifications. 6. Toxic Content test on Conductive materials & earth enhancement material as per standard. Ow a a va 3‘TECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES | —_ ENG/34/CE & EARTH ENHANCING MATERIALS. IndianOil FOR CHEMICAL EARTHING AMaharatna ‘Company’ 7. Copper Bus Bar shall be tested for percentage of copper as per IS :14644. 8 Exothermic weld material shall be tested as per provisions of IEEE 837. 9. Physical , chemical & electrical properties test on earth enhancement material per clause no.4 10. The copper coating on electrode should not be less than the prescribed thickness at any point, as mentioned in the specification and comply with the adherence requirement in below. (i) Length of the electrode with one end cut to a 45 degree point shall be driven between two steel clamping plates or the jaws of vise set 0.04 in (1.02mm) less than the diameter of the electrode, so as to shear off sufficient metal to expose the bond between the copper coating and electrode. Peeling of the coating by the steel plates or the jaws of the vise is acceptable, but there shall be no other evidence of separation of the coating from the metal core. (i) At room temperature, a length of the electrode is rigidly held in a clamp or vise and the free end is bent by applying a force normal to the electrode at a distance from the clamping devise equal to 40times the diameter. The magnitude of the force and the direction of application of force shall be such that the electrode is permanently bent through a 30-degree angle. While bending of the electrode there shall be no evidence of cracking of the copper coating. 11. Copper Electrode should be UL Listed. All the type tests as per the relevant standard shall be carried out free of cost before commencement of supply. IOCL or their authorized representative will be present to witness the test, if required. If the material has been type tested earlier than five years all the type tests as per relevant standard shall be carried out by the vendor in presence of purchaser’s representative free of cost. Even if the material has been type tested earlier, the purchaser reserves the right to demand repetition of one or more tests included in the list of type test on requisite number of samples (minimum two sample from every lot of minimum 50nos.) from any of the lots during the tenure of the supply, at no cost to purchaser. If the material does not withstand the type test, then the material supplied till ‘then will be liable for rejection and supplier will have to remove them at no cost to |OCL. 10 — a AAMaharatna 5.2 5.3 5.4 6.0 TECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES | ENG/34/CE & EARTH ENHANCING MATERIALS. IndianOil FOR CHEMICAL EARTHING ‘Company ACCEPTANCE TESTS: The inspecting officer will carry out the acceptance tests on the materials as specified in the relevant standard with latest amendments and & this technical specification. Following shall constitute acceptance test and shall be done on 100% sample basis for all the tests mentioned below except where otherwise indicated - 1) Physical check for earth electrode as per clause 3.1 of this specification. 2) Physical check for bus bar as per clause no. 3.1.3 3) Earth Enhancement material as per clause no. (xix) & (xx) 3) Chemical Composition Test on crystalline conductive material used in earth electrode & Earth enhancement material (BFC)shall_ be checked. REJECTION : In case any component tested and inspected in accordance with this specification fails to pass the tests or comply with the requirement of the specification, another two ‘component from the same lot shall be inspected in accordance with the specification and if one of them also fails to pass the test, the whole lot of that component shall be rejected subject to the discretion of the purchaser or its nominee. ROUTINE TESTS: All the material offered shall be subjected to the routine tests at the manufacturer's works as specified in the relevant standards & this specification. Certificate against the same shall be submitted, Any additional requirement for tests if required should be conducted at no extra cost. ‘TEST CERTIFICATES: Detailed type test reports of the offered material for the tests as per relevant IS std, /international standard and this specification shall be furnished. All these Type Tests shall be carried out at laboratories that are accredited by the National Accreditation Board of Testing and Calibration Laboratories (NABL) of Government of India. - ene” At| TECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES ENG/34/CE a f EARTH ENHANCING MATERIALS. IndianOil FOR CHEMICAL EARTHING AMaharatna ‘Company : : 7.0 INSPECTION: 8.0 12 ‘The purchaser or his nominee shall have right of free access to the works of the manufacturer & to be present at all reasonable times and shall be given facilities by the manufacturer to inspect the manufacturing process at any stage of manufacture. He shall have the right to reject whole or part of any work or material that does not conform to the terms of the specifications. All the reasonable/complete facilities considered necessary for the inspection by the inspecting authorities shall be supplied by the manufacturer free of cost. In case any component tested & inspected in accordance with this specification fail to pass the requirements of the specifications, another two samples shall be selected from the same lot & inspected/ tested in accordance with the specifications. If one of the additional sample fail to pass the test, complete lot shall be rejected. For all grass route terminal/depot/AFS projects the test specified above to be ensured including sampling and testing independently through NABL lab. For ROs and existing terminals/depot/AFs (where additional EPs are required), the type test report with routine test report can be submitted for acceptance. DETAILED SPECIFICATION FOR INSTALLATION OF EARTHING SYSTEM: General arrangement for earth system & earth electrode shall be as per the drawing attached, Procedure to be adopted for construction of earth electrode shall be as follows; CONSTRUCTION OF UNIT EARTH AND EARTH MAT 1. Make 5ft x 5ft x 10ft. earth pit. If it is not possible to make such a pit due to hard rocky soil or any other reasons, 250mm bore upto 10 ft. deep shall be made using earth auger or any other method. Where the Copper Bonded Rod electrode to be provided as per design, the bore size of 125mm diameter to be provided. 2. Sleeve the soil and remove the gravels and stones. If soil quality is good (without murrum & rocks) then add some quantity of earth enhancement material in the soil for using as backfill. 3. Insert the electrode at the centre of the earth pit and arrange to keep it vertical in the pit. 4, Arrange for adequate quantity of water supply for the pit. (Approx. 600 litres).‘TECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES | ENG/34/CE & EARTH ENHANCING MATERIALS. FOR CHEMICAL EARTHING AMaharatna ‘Company peEeeHeH 5. Fill the pit with the backfill material and keep on adding the earth enhancement material surrounding the electrode and simultaneously watering the pit. 6. With asteel bar or pipe keep on peeking the soil and stirring intermittently for removing the air pockets and proper settlement _of the pit. 7. Procedure to be repeated till completion of the filling of the earth pit along with the packing materials and sufficient watering & adequate —_ ramming. 8 The pit shall be very compactly rammed and watering for 2-3 days and addition of soil if required be done. 9. Make trench of 600mm (Depth) x 300mm wide for connecting the earth pit to nearest point of connection. 10. Construct inspection chamber with cover for the installation. 11. Measure the earth resistance as per IS-3043-1987 code of practice. Earth resistance value shall be less than 2 ohm in nonrocky/non- sandy surface by single electrode installation 12. ‘The bidder shall install earthing material required for the system and individual equipment earthing. All work such as cutting, bending, supporting, soldering, coating, drilling, brazing, clamping, bolting and connecting into structures, pipes, equipment frames terminals, rails or other devices shall be in the bidder’s scope of work. The bidder shall also carryout the excavation and trenching work involved. The bidder shall also back-fill and reinstates the trenches after installation of earthing conductors. 13. Metallic frames of all electrical equipments shall be earthed by two separate and distinct connections with earthing system. 14, Neutral connection shall never be used for the equipments earthing. 15. Aseparate earth electrode pit shall be provided adjacent to structures supporting lightning arrester. Earth connections shall be as short and as straight as practicable. 16. On completion of the installation, continuity of all conductors and joint shall be tested. 13 oS al | | | eye | IndianOil i AMaharatna B. 1. 3. 9.0 C= \ S & EARTH ENHANCING MATERIALS. | | TECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES | ENG/34/CE | FOR CHEMICAL EARTHING Compan: CONSTRUCTION OF RING EARTH BY PROVIDING MULTIPLE EARTH PITS : Whenever it is not possible to achieve required earth resistance with one earth electrode/pit due to difficult/rocky soil conditions, provision of ring earth consisting of more than one earth pits shall be done. The number of pits required shall be decided based on the resistance achieved. This shall be based on design and site specific requirement. The distance between two successive earth electrodes shall be minimum 3mtrs/length of electrode whichever is higher and minimum upto twice the length of earth electrode. These pits shall then be interlinked using minimum 50x6 mm Gl strip (size of conductor should be designed to site specific) to form a loop using exothermic welding or with help of at least two number of stainless steel nut bolts. Welded joint to be painted with bituminous paint to avoid corrosion. ‘The interconnecting strip shall be buried no less than 600mm below the ground level. This interconnecting strip shall also be covered with earth enhancing compound. MARKING ON ELECTRODE : The marking shall be clear, distinct and visible to the naked eye from a distance of about ‘Imter; the size of marking shall be of minimum 25mm. Following information shall be legible and indelibly marked on the packed sets; a) Specification no. b) Name of manufacturer ) Batch no. & Date of manufacture d) Current carrying capacity 10.0 MAINTENANCE OF EARTH MAR for chemical earthing is similar to one for earthing pits provided using 100mm GI for normal soil condition, i.e. by pouring water into the pit and immediate vicinity of the electrode(minimum upto 2m radius beyond electrode position). Artificial treatment as mentioned under clause no.8.8 of IS 3043 should be adopted for further enhancement. {\. 14 ae aa aaaTECHNICAL SPECIFICATIONS FOR EARTH ELECTRODES | ENG/34/CE & EARTH ENHANCING MATERIALS IndianOil FOR CHEMICAL EARTHING AMaharatna ‘Company ~ 11.0 FREQUENCY OF TEST : Earth Resistance Test for individual electrode should be carried out once in a year. However, this frequency can be increased or decreased as per local prevailing site condition, but should never be less than once in two years. Fall of Potential Method as mentioned under IS 3043 should be followed for measurement. aa 15TECHENICAL SPECIFICATION FOR EARTH ELECTRODES oo \ a=] Eg ae | perenne a fear eayon lr rpscinss ——yY. rss Pe Det —~yY DETAIL 'A’ + + OO} + ae + View Y-Y TERMINAL BLOCK DETAILS (SCALE : NTS) GENERAL ARRANGEMENT DRAWING FOR PIPE - IN PIPE ELECTRODE ale =TECHENICAL SPECIFICATION FOR EARTH ELECTRODES . Bammes iw — eo ee a [eco foo View Y-Y TERMINAL BLOCK DETAILS (SCALE : NTS) GENERAL ARRANGEMENT DRAWING FOR COPPER ELECTRODE ale 4h \v A