vol

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GUJARAT STATE PETRONET LIMITED

PADAMLA – GODHARA GAS PIPELINE (PGPL)

TENDER DOCUMENT

FOR

LAYING OF PIPELINES, TERMINALS AND ASSOCIATEDFACILITIES

EPC CONTRACTVOLUME - IV OF V

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

CATHODIC PROTECTION)

MECON LIMITED(A Govt. of India Undertaking)

SCOPE MINAR15th Floor, North Tower

Laxmi Nagar District CentreDELHI – 110 092

November,2006

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PADAMLA – GODHARA GAS PIPELINE (PGPL)

TENDER DOCUMENT

FOR

LAYING OF PIPELINES, TERMINALS AND ASSOCIATEDFACILITIES

EPC CONTRACT (Volume-IA, IB, IC, II, III, IV & V)

TENDER NO. 05/51/23JT/GSPL/001(EPC)

MECON LIMITED(A Govt. of India Undertaking)

SCOPE MINAR15th Floor, North Tower

Laxmi Nagar District CentreDELHI – 110 092

November,2006

Gujarat State Petronet Ltd.

PADMALA – GODHARA GASPIPELINE PROJECT

Tender Document for EPC ContractsTender Doc. No.: 05/51/23JT/GSPL/001(EPC) MECON LIMITED

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MASTER TABLE OF CONTENT

Name of Project : EPC contract including Residual Engineering,Procurement, Installation, Testing andCommissioning of Pipelines, Terminals andAssociated Facilities for Padmala – Godhara PipelineProject of GSPL.

Tender Document No. : 05/51/23JT/GSPL/001(EPC)

Sl.No. Description

1) Volume-IA of V : General – Commercial(IFB, ITB, GCC, SCC – Commercial)

2) Volume-IB of V : General – Technical (Particular Jobs Specification)

3) Volume-IC of V : Price Schedule

4) Volume-II of V : Standard Technical Specification(Pipeline Laying, Piping & Mechanical)

5) Volume-III of V : Standards Technical Specification(Civil, Architectural & Structural)

6) Volume-IV of V : Standards Technical Specification(Electrical, Instrumentation, Telecommunication Works &CP Works)

7) Volume-V of V : Tender Drawings & Standard Drawings



Tender Document for EPC ContractsTender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IV of V MECON LIMITED

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CONTENTS

1.0 ELECTRICAL

Sl. No. Title Specification No.

1. SPECIFICATION FOR CABLING MEC/S/05/26/21

2. SPECIFICATION FOR EARTHING AND LIGHTNING PROTECTION MEC/S/05/26/23A

3. SPECIFICATION FOR LIGHTING FITTINGS FOR MEC/S/05/26/24AHAZARDOUS, INDOOR AND SAFE AREA

4. SPECIFICATION FOR LIGHTING MEC/S/05/26/23,R-1

5. SPECIFICATION FOR L.T. POWER DISTRIBUTION MEC/S/05/26/26BOARD

6. SPECIFICATION FOR SPLIT AIR CONDITIONING SYSTEM MEC/S/05/E9/25

7. SPECIFICATION FOR UPS SYSTEM MEC/S/05/E9/071

8. SPECIFICATION FOR DG SET MEC/S/05/E9/006

2.0 TELECOMMUNICATION


1. SPECIFICATION / PROCEDURE FOR THE MEC/S/E5/T/002 R-0TESTING OF OPTICAL FIBER CABLE

2. SPECIFICATION FOR WARNING MATS MEC/S/E5/T/042 R-1

3.0 INSTRUMENTATION


1. SPECIFICATION FOR INSTALLATION OF MEC/S/05/26/01INSTRUMENTS

2. SPECIFICATION FOR INSTRUMENT TUBING MEC/S/05/26/02

3. SPECIFICATION FOR INLET/OUTLET SECTIONS MEC/S/05/26/03& FLOW STRAIGHTNER

4. SPECIFICATION FOR INSTRUMENT TUBE FITTING MEC/S/05/26/04

5. SPECIFICATION FOR INSTRUMENT VALVES & MAINFOLDS MEC/S/05/26/05



Tender Document for EPC ContractsTender Doc. No.: 05/51/23JT/GSPL/001(EPC)

Volume-IV of V MECON LIMITED

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6. SPECIFICATION FOR JUNCTION BOXES & CABLE GLANDS MEC/S/05/26/06

7. SPECIFICATION FOR SIGNAL CABLES MEC/S/05/26/07

8. GENERAL TECHNICAL SPECIFICATION FOR INSTRUMENTATION MEC/S/05/26/08

9. TECHNICAL SPECIFICATION FOR CABLING MEC/S/05/26/21

10. TECHNICAL SPECIFICATION FOR GAS OVER OIL MEC/TS/05/E5/002

4.0 CATHODIC PROTECTION SYSTEM


1. SPECIFICATION FOR TEMPORARY CATHODIC PROTECTION MEC/PTS/05/62/016A

2. SPECIFICATION FOR PERMANENT CATHODIC PROTECTION MEC/PTS/05/62/016B

3. TECHNICAL SPECIFICATION FOR TR UNIT FOR CP SYSTEM MEC/PTS/05/E9/072

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Gujarat State Petronet Limited

SPECIFICATION FORCABLING

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

(ELECTRICAL SECTION)MECON LIMITEDDELHI 110 092


MECON LIMITEDREGD. OFF: RANCHI(JHARKHAND)

PROCESS & PIPINGDESIGN SECTION

NEW DELHI

STANDARD SPECIFICATION

TITLE CABLING SPECIFICATION NO. PAGE 1 OF 12

MEC/S/05/26/21 REVISION 0

C O N T E N T S

1.0 SCOPE

2.0 STANDARD

3.0 CABLE SPECIFICATIONS

4.0 MISCELLANEOUS MATERIALS SPECIFICATIONS

5.0 CABLE LAYING

6.0 TERMINATION

7.0 TESTING

PREPARED BY CHECKED BY APPROVED BY




NEW DELHI




1.0 SCOPE

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

2.0 STANDARDS

The work shall be carried out in the best workman like manner in conformity withthis specification, the relevant specifications, codes of practice of IndianStandards Institution, approved drawings and instructions of Engineer-in-Chargeor his authorized representative issued from time to time. In case of any conflictbetween the standards, the instruction of Engineer-in-Charge shall be binding.

3.0 CABLE SPECIFICATIONS

3.1 Power Cables

Power cables for use on 415 V system shall be of 1100 Volts grade, aluminumstranded conductor, PVC insulated, extruded PVC inner sheathed, GI Wire /flat armored and overall FRLS PVC sheathed. Power cables for 3.3 KV 6.6 KV and11 KV system shall be aluminum conductor, XLPL insulated, screened, PVCbedded galvanized steel flat armored and PVC sheathed cable. All L.T. Cablesconform to standard specification and relevant sections of IS: 1554 Part-I andH.T. Cables shall conform to IS:7098 (Part II). Unarmored cables will be usedwherever specified on the cable schedule.

3.2 Control Cables:

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

3.3 Communication cables:

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




NEW DELHI




4.0 MISCELLANEOUS MATERIALS SPECIFICATIONS

4.1 Connectors:

Cable terminations shall be made with aluminum/tinned copper crimped typesolder less lugs of M/s. Dowell’s make or approved equivalent for all aluminumconductors and stud type terminals.

4.2 Cable Identification

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

4.3 Ferrules

Ferrules shall be of approved type size to suit core size mentioned and shall beemployed to designate the various cores of control cable by the terminalnumbers to which the cores are connected for case in identification andmaintenance.

4.4 Cable Glands:

Cable glands to be supplied shall be nickel plated Brass double compression typeof approved/ reputed make. Glands for classified hazardous areas shall becertified by CMRS .

4.5 Cable Trays:

This shall be either prefabricated hot dip galvanized sheet steel trays or sitefabricated angle iron trays as specified elsewhere. Prefabricated hot dipgalvanized sheet steel cable trays shall be used for maximum support span of2000 mm unless design is approved for larger span. For requirements of largerthan 750 mm width two trays shall be run side by side. Cable trays shall besuitable for a cable weight of 50 kg/meter running length of tray. Minimumthickness of sheet steel/galvanizing shall be 2mm/86 microns respectively.

Cable trays fabricated from standard rolled sections shall use 50x50x6 /ISMC 100Sections for runners for supporting spans limited to 2000 mm/more than 2000 mmrespectively. Cross support shall be 32 x 6 mm flat/ 25x25x6 angle for width upto500 mm/ more than 500 mm respectively.




NEW DELHI




Vertical supports for both the above type of trays shall be fabricated out of ISMC100 and horizontal supports with 75 x 50 x 6 angle iron/ ISMC 75 as approved byEngineer-in-Charge.

5.0 CABLE LAYING

5.1 Cable network shall include power, control, lighting and communication cables,which shall be laid in trenches, cable trays or conduits as detailed in the relevantdrawings and cable schedules. Erection of cable trays as required shall bechecked after erection and marked in as built drawings. Cable routing given onthe layout drawings shall be checked in the field to avoid interference withstructures, heat sources, drains, piping, air-conditioning duct etc. and minoradjustments shall be done to suit the field conditions wherever deemednecessary without any extra cost.

5.2 High voltage, medium voltage and other control cables shall be separated fromeach other by adequate spacing or running through independent pipes, trenchesor cables trays, as applicable.

All communication cables (telephones, P.A.S.) RTD Cables shall run oninstrument trays/ducts/trenches. Wherever these are not available, cables shallbe taken in a separate trench with a minimum clearance of 300 mm away fromelectrical trench as per the direction of Engineer-in-Charge and Communicationcables shall cross power cables at right angles.

All cable routes shall be carefully measured and cables cut to the requiredlengths, leaving sufficient lengths for the final connection of the cable to theterminal of the equipment. The various cable lengths cut from the cable reelsshall be carefully selected to prevent undue wastage of cables. The quantityindicated in the cable schedule is only approximate. The contractor shallascertain the exact requirement of cable for a particular feeder by measuring atsite and avoiding interference with structure, foundation, pipelines or any otherworks. Before the start of cable laying, cable drum schedule; shall be preparedbe electrician contractor and get that approved by Engineer-in-Charge tominimize/avoid straight through joints required. Contractor shall work out theactual number of straight through joints required.




NEW DELHI




5.4 Cables as far as possible shall be laid in complete, uncut lengths from onetermination to the other.

5.5 Cables shall be neatly arranged in the trenches/trays in such a manner so thatcriss-crossing is avoided and final take off to the motor/switchgear is facilitated. Arrangement of cables within the trenches/trays shall be the responsibility of theContractor. Cable routing between lined cable trench and equipment/motors shallbe taken through GI pipe sleeves of adequate size. Pipe sleeves shall be laid atan angle of maximum 45o to the trench wall. In case of larger dia cables, i.e., 50mm and above, adequately sized pipe with larger bend radius shall be providedfor ease of drawing of cable or for replacement. In places where it is not possible,a smaller trench may be provided if approved by Engineer-in-Charge.

5.6 All cables will be identified close to their termination point by cable numbers asper cable schedule. Cable numbers will be punched on aluminium straps (2 mmthick) securely fastened to the cable and wrapped around it. Alternatively cabletags shall be circular in construction to which cable numbers can be convenientlypunched.

Each underground cable shall be provided with identity tags of lead securelyfastened every 30 m of its underground length with at least one tag at each endbefore the cable enters the ground. In unpaved areas, cable trenches shall beidentified by means of markers as per standard drawing. These posts shall beplaced at location of changes in the direction of cables and at intervals of notmore than 30 M and at cable joint locations.

5.7 All temporary ends of cables must be protected against dirt and moisture toprevent damage to the insulation. For this purpose, ends of all PVC insulatedcables shall be taped with an approved PVC or rubber insulating tape. Use offriction type or other fabric type tape is not permitted. Lead sheather cables shallbe plumbed with lead alloy.

5.8 RCC cable trenches shall be with removable covers .Cables shall be laid in 3 or 4tiers in these trenches as indicated on the sectional drawings. Concrete cabletrenches shall be filled with sand where specified to avoid accumulation ofhazardous gases, RCC covers of trenches in process area shall be effectivelysealed to avoid ingress of chemicals etc. Removal of concrete covers forpurpose of cable laying and reinstating them in their proper positions after thecables are laid shall be done by the electrical Contractor at no extra cost.




NEW DELHI




Cables shall be handled carefully during installation to prevent mechanical injuryto the cables. Ends of cables leaving trenches shall be coiled and provided with aprotective pipe or cover, until such times the final termination to the equipment isconnected.

5.9 Directly buried cables shall be laid underground in excavated cable trencheswhere specified in layout drawings. Trenches shall be of sufficient depth andwidth for accommodation of all cables correctly spaced and arranged with a viewof heat dissipation and economy of design.

Minimum depth of buried cable trench shall be 750 mm for low voltage and 1000mm for H.V. Cables, the depth and the width of the trench shall vary dependingupon the number of layers of cables.

Cables shall be laid in trenches at depth as shown in the drawing. Before cablesare placed, the trenches bottom shall be filled with a layer of sand. This sandshall be leveled and cables laid over it. These cables shall be covered with 150mm of sand on top of the largest diameter cable and sand shall be lightlypressed. A protective covering of 75 mm thick second class red bricks shall thenbe laid flat. The remainder of the trench shall then be back-filled with soil,rammed and leveled.

5.10 As each row of cables is laid in place and before covering with sand every cableshall be given an insulation test in the presence of Engineer-in-Charge / Owner. Any cable which proves defective shall be replaced before the next group ofcables are laid.

All wall openings / pipe sleeves shall be effectively sealed after installation ofcables to avoid seepage of water inside building/ lined trench.

Where cables rise from trenches to motor, control station, lighting panels etc., theyshall be taken in G.I. Pipes for mechanical protection upto a minimum of 300 mm

above finished ground level.

Cable ends shall be carefully pulled through the conduits, to prevent damage tothe cable. Where required, approved cable lubricant shall be used for thispurpose. Where cable enters conduit the cable should be bent in large radius. Radius shall not be less than the recommended bending radius of the cablesspecified by the manufacturer.




NEW DELHI




Following grade of the pipe fill shall be used for sizing the pipe size:

a) 1 cable in pipe - 53% fullb) 2 cables in pipe - 31% fullc) 3 or more cables - 43% fulld) Multiple cables - 40% full

After the cables are installed and all testing is complete, conduit ends abovegrade shall be plugged with a suitable weatherproof plastic compound/ `PUTTI'for sealing purpose. Alternatively G.I. Lidsor PVC bushes shall be employed forsealing purposes. The cost for the same shall be deemed to have been includedin the installation of G.I. Pipe and no separate payment shall be allowed.

5.11 Where cables pass through foundation walls or other underground structures, thenecessary ducts or openings will be provided in advance for the same. However,should it become necessary to cut holes in existing foundations or structures, theelectrical contractor shall determine their location and obtain approval of theEngineer-in-Charge before cutting is done.

5.12 At road crossing and other places where cables enter pipe sleeves adequate bedof sand shall be given so that the cables do not slack and get damaged by pipeends.

5.13 Drum number of each cable from which it is taken shall be recorded against thecable number in the cable schedule.

5.14 Cables installed above grade shall be run in trays, exposed on walls, ceilings orstructures and shall be run parallel or at right angles to beams, walls or columns.

Cables shall be so routed that they will not be subjected to heat from adjacent hotpiping or vessels.

5.15 Individual cables or small groups which run along structures/walls etc., will beclamped by means of 10 SWG GI saddles on 25x6 mm saddle bars. The costof saddle and saddle bars shall be deemed to have been included in theinstallation of cables and no separate payment shall be made on this account. Alternatively small group of cables can be taken through 100 mm slottedchannel/ISMC 100.




NEW DELHI




They shall be rightly supported on structural steel and masonry, individual or ingroups as required, if drilling of steel must be resorted to, approval must besecured and steel must be drilled where the minimum weakening of the structurewill result.

Cables shall be supported so as to prevent unsightly sagging. In generaldistance between supports shall be approximately 300 mm for cables upto 25 mmdiameter and maximum 450 mm for cables larger than 25 mm dia.

5.16 All G.I. Pipes shall be laid as per layout drawings and site requirements. Beforefabrication of various profiles of pipe by hydraulically operated bending machine(which is to be arranged by the contractor), all the burrs from the pipes shall beremoved. GI Pipes with bends shall be burried in soil/concrete in such way thatthe bends shall be totally concealed. For G.I. Pipes burried in soil, bitumencoating shall be applied on the burried lengths. Installation of G.I. Pipes shall beundertaken well before paving is completed and necessary co-ordination withpaving agency shall be the responsibility of Electrical Contractor. The open endsof pipes shall be suitably plugged with G.I. Plugs after they are laid in finalposition. G.I. Plugs shall be supplied by the Contractor at no extra cost.

5.17 Cable laid on supporting angle in cable trenches, structures, columns and verticalrun of cable trays shall be suitably clamped by means of G.I. Saddles/Clamps,whereas cable in horizontal run of cable trays shall be tied by means of nyloncords.

5.18 Supporting steel shall be painted before laying of cables. The painting shall bedone with one coat of red lead paint and two coats of approved bituminousaluminium paint unless otherwise specified.

6.0 TERMINATION

6.1 All PVC cables upto 1.1 KV grade shall be terminated at the equipments bymeans of double compression type cable glands. They shall have a screwednipple with conduit electrical threads and check nut.

All Cable entries shall be through bottom only and top entry terminations aremade only after getting approval of Engineer-in-Charge.

6.2 Power cables wherever colour coding is not available shall be identified with red,yellow and blue PVC tapes. Where copper to aluminum connections are made,necessary bimetallic washers shall be used. For trip circuit identificationadditional red ferrules shall be used only in the particular cores of control cablesat the termination points in the Switchgear/Control panels and Control Switches.




NEW DELHI




6.3 In case of control cables all cables shall be identified at both ends by theirterminal numbers by means of PVC ferrules or Self-sticking cable markers. Wirenumbers shall be as per schematic/ wiring /interconnection diagram. Biddersshall have the samples of PVC ferrules/cable markers approved before startingthe work. All unused spare cores of control cables shall be neatly bunched andferruled with cable tag at both ends.

6.4 Where threaded cable gland is screwed into threaded opening of different size,suitable galvanized threaded reducing bushing shall be used of approved type, atno extra cost. All switchgear and control panels shall have undrilled gland plate.

Contractor shall drill holes for fixing glands wherever necessary at no extra cost. Gland plate shall be of non-magnetic material/aluminium sheet in case of singlecore cables.

6.5 The cable shall be taken through glands inside the panels or any other electricalequipment such as motors. The individual cores shall then be dressed and takenalong the cable ways (if provided) or shall be fixed to the panels with polyethylenestraps. Only control cables of single strand and lighting cables may be directlyterminated on to the terminals.

In case of termination of cables at the bottom of a panel over a cable trenchhaving no access from the bottom close fit hole should be drilled in the bottomplate for all the cables in one line, then bottom plate should be split in two partsalong the centre line of holes. After installation of bottom plate and cables itshould be sealed with cold setting compound. Cables shall be clamped over theopen armoring to connect it to earth bus.

6.6 Cable leads shall be terminated at the equipment terminals, by means of crimpedtype solder less connectors as manufactured by M/s. Dowell Electro works orapproved equivalent.

Crimping shall be done by hand crimping hydraulically operated tool andconducting jelly shall be applied on the conductor. Insulation of the leads shouldbe removed immediately before the crimping. Conductor surface shall becleaned and shall not be left open.




NEW DELHI




6.7 Cable accessories for H.V. Systems

6.7.1 The 11, 6.6 and 3.3 KV cables terminations joints shall be done by skilled andexperienced jointers duly approved by the Engineer-in-Charge. Terminationincluding supplying of jointing kit shall be threaded in Contractor scope unlessspecified otherwise.

6.7.2 The termination and straight thro' joint kit. For use on high voltage system shallbe suitable for the type of cables red by the contractor or the type of cablesissued by owner for installation. The materials required for termination andstraight through joints shall be supplied in kit form. The kit shall include allinsulating and sealing materials apart from conductor fitting and consumablesitems. An installation instruction shall be included in each sheet.

6.7.3 The termination kits shall be suitable for termination of the cables to an indoorswitchgear or to a weatherproof cable box of an outdoor mounted transformermotor. The terminating kits shall preferably be of the following types :

a) TAPLEX' of M-seal make using non-linear resistance material fortressgrading.

b) `PUSH-ON' type of CCI make using factory - molded silicone rubberinsulators.

c) `TROPOLINK' type of CCI makes.

d) Heat-shrinkable sleeve type of M/s. Raychem.

For outdoor installations, weather shields/sealing ends and any other accessoriesrequired shall also form part of the kit.

6.7.4 The straight thro jointing kits shall be suitable for underground-buried installationwith uncontrolled backfill and possibility of flooding by water. The jointing kit shallbe one of the following types.

a) `TAPLEX' of M-seal make

b) `TROPOLINK' type of CCI make

c) Heat-shrinkable sleeve type of M/s. Raychem.




NEW DELHI




6.7.5 Makes of kits other than those specified in 6.7.3 and 6.7.4 may be considered,provided the Contractor furnishes type test certificates, alongwith the offer.

6.7.6 Type tests are to be carried out at manufacturer's works to prove the generalqualities and design of a given type of termination/jointing system. The type testsshall include the following tests conforming to the latest IEC 502.2, 466 and VDE0278 specifications. The Contractor along with the offer for the jointing systemconsidered shall submit the type test certificates.

a) A.C. Voltage withstand dry test for 1 minute

b) Partial discharge test - Discharge magnitude small be less than 20 p.c.

c) Impulse voltage withstand test with 10 impulses of each polarity.

d) A.C. high voltage test following load cycling test with conductortemperature at 95oC.

e) Thermal short circuit test of 250oC for 1 second.

f) DC Voltage withstand test for 30 minutes.

g) Humidity test.

h) Dynamic short circuit test.

i) Salt log test

j) Impact test

7.0 TESTING:

7.1 Before energizing, the insulation resistance of every circuit shall be measuredfrom phase to phase and from phase to ground.

7.2 Where splices or termination are required in circuits rated above 600 volts,measure insulation resistance of each length of cable before splicing and or/terminating. Repeat measurement after splices and/or terminations arecompleted.




NEW DELHI




7.3 Measure the insulation resistance of directly burried cable circuits before cabletrenches are back-filled. Repeat measurement after back- filling.

For cables upto 1.1 KV grade 1000 KV Meager and for H.V. Cables 2.5 KV/5 KVMeager shall be used.

7.4 D.C. High Voltage Test shall be conducted after installation on the following andtest results are recorded.

a) All 1000volts grade cables in which straight through joints have beenmade.

b) All cables above 1100 V grade.

For record purposes test data shall include the measure values of leakage currentversus time.

The D.C. High Voltage test shall be performed as detailed below in the presenceof the Engineer-in- Charge or his authorized representative only.

Cables shall be installed in final position with all the straight through jointscomplete. Terminations shall be kept unfinished so that motors, switchgears,transformers etc. are not subjected to test voltage.

The test voltage shall be as under:-

i) For cables 3.3 KV grade 5.4 KV DC

ii) For cables 6.6 KV grade 10.8 KV DC

iii) For cables 11 KV grade 18 KV DC

7.5 All cables shall be tested as per standard test Performa available with siteengineer.

7.6 Cable schedule and layout drawings must be marked for AS BUILT conditionsduring the installation work and shall be approved by Site Engineer.

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SPECIFICATION FOREARTHING AND LIGHTNING PROTECTION

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





NEW DELHI


TITLE EARTHING AND LIGHTINGPROTECTION

SPECIFICATION NO. PAGE 1 OF 10

MEC/S/05/26/23A REVISION 1

C O N T E N T S

1.0 SCOPE

2.0 STANDARDS

3.0 EARTHING CONDUCTOR/ELECTRODE

4.0 EARTHING NET WORK

5.0 INSTALLATION OF EARTH ELECTRODE

6.0 CONNECTION

7.0 TESTING

8.0 TEST PROFORMA





NEW DELHI





1.0 SCOPE:

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

2.0 STANDARDS:

The work shall be carried out in the best workmanlike manner in conformity withthis specification, the relevant specifications/codes of practice of Indian StandardInstitution, approved drawings and instructions of the Engineer-in-Charge or hisauthorized representative issued from time to time. In case of any conflictbetween the standards, the instructions of Engineer-in-Charge shall be binding.

3.0 CONDUCTOR ELECTRODE:

The main grid conductor shall be hot dip galvanized G.I. Flat or PVC insulatedaluminum conductor/copper conductor. Sizes for main conductors shall bemarked on the drawings. Thickness of hot dip galvanizing shall not be less than75 microns.

4.0 EARTHING NETWORK:

4.1 The earthing installation shall be done in accordance with the earthing drawings,specifications and the standard drawings of reference attached with thisdocument. The entire earthing system shall fully comply with the Indian ElectricityAct and Rules framed thereunder. The contractor shall carry out any changesdesired by the Electrical Inspector or the owner, in order to make the installationconform to the Indian Electricity Rules at no extra cost. The exact location on theequipment shall be determined in field, in consultation with theEngineer-in-Charge or his authorized representative. Any changes in themethods, routing, size of conductors etc. shall be subject to approval of theOwner/Engineer-in-Charge before execution.

Excavation and refilling of earth, necessary for laying underground earth busloops shall be the responsibility of the contractor.

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




NEW DELHI

STANDARDSPECIFICATION

TITLE EARTHING AND LIGHTING PROTECTION SPECIFICATION NO. PAGE 3 OF 10


4.4 The main earth loop shall be laid at a depth of 750 mm below grade level. Wherever cable trenches are available, the earth lead shall be laid in the trenches and shall be firmly cleated to the walls of concrete lined trenches. The earthing strip shall be protected against mechanical damage.

4.5 In process unit areas, the earthing cable shall be run along cable trays whereverspecified in the layout drawings. The earthing cable shall be suitably cleated andelectrically bonded to the cable tray at regular intervals.

4.6 Joints and tappings in the main earth loop shall be made in such a way thatreliable and good electrical connections are permanently ensured. All jointsbelow grade shall be welded and suitably protected by giving two coats ofbitumen and covering with hessian tape. All joints above ground shall be bymeans of connectors/lugs as far as practicable. Tee connectors shall be used fortapping, earth leads from the main earth loop wherever it is installed aboveground. Earthing plates shall be provided for earthing of two or more equipmentat a place from earth grid. Where aluminium cable risers are to be connected tothe underground GI earth bus, the aluminium cable riser shall be taken to thenearest earth pit and terminated through a bolted joint. If this is not practicable,then a G.I. risers shall be brought above grade and a bolted joint shall be madebetween this GI riser and the aluminium cable termination. This G.I. Riser shallbe protected applying two coats of bituminous paint/bitumen on the exposedportion.

4.7 Conduits in which cables have been installed, shall be effectively bonded andearthed. Cable armours shall be earthed at both ends.

5.0 EARTH ELECTRODES:

5.1 Earth pipe electrodes shall be installed as shown in the earthing layout drawingsand in accordance with the standard drawings of reference and IS: 3043. Theirlocation shall be marked to enable accurate location by permanent markers.

5.2 All earth electrodes shall preferably be driven to sufficient depth to reachpermanently moist soil. Electrodes shall preferably be situated in a soil which hasa fine texture and which is packed by watering and ramming as tightly aspossible. Wherever practicable, the soil shall be dug up, all lumps broken andstones removed from the immediate vicinity of the electrodes.




NEW DELHI




5.3 All earth electrodes shall be tested for earth resistance by means of standardearth test meter. The tests shall take place in dry months, preferably after aprotracted dry spell. If necessary, a number of electrodes shall be connected inparallel to reduce the earth resistance. The distance between two electrodesshall not be less than twice the length of electrode.

5.4 The electrodes shall have a clean surface, not covered by paint, enamel, greaseor other materials of poor conductivity.

5.5 The exact location and number of earth electrodes required at each location shallbe determined in the field in consultation with the owner/Engineer-in- Charge,depending on the soil strata and resistively, to meet the ohmic values prescribedin clause 5.3. Earth Electrodes shall be located avoiding interference with road,building foundation, column etc. Individual earth electrode shall be provided foreach lightning arrestor and lightning mast. The electrodes shall be so placed thatall lightning protective earths may be brought to earth electrode by a short andstraight a path as possible to minimize surge impedance.

5.6 The disconnect facility shall be provided for the individual earth pits to check their earth resistance periodically. All the earth electrodes shall be suitably numbered and this should be indicated in as built drawings.

5.7 600 x 600 x 3 mm thick copper plate earth electrode for RTU, Telecom and Instrument control panel, metering panel and UPS panel.

6.0 CONNECTION:

6.1 All electrical equipment is to be doubly earthed by connecting two points onequipment to a main earthing ring. The earthing ring will be connected via links toseveral earth electrodes. The earth grid formed shall be a closed loop as shownin the drawing with earth electrodes connected to the grid with double stripconnection. The cable armour will be earthed through the cable glands.

6.2 In hazardous areas all major process equipments shall be connected to theearthing ring by means of anti- loosening connections and all pipe lines will bebonded and earthed on entering the battery limit of the process area.

6.3 The following shall be earthed.

1. Transformer neutrals, CT/PT neutrals.


2. Neutral Grounding Resistors.




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3. Transformer Housing.

4. Lightning Arrestors.

5. All switchgear and their earth buses, bus duct.

6. Motor Frames.

7. Non-current carrying metallic parts of electrical equipment such asswitchgear, switch racks, panel boards, motor control centers, lighting,power and instrument panels, push button stations, cable trays, pipes,conduits, terminal boxes, etc.

8. All fences, gates/enclosures, housing electrical equipment

9. All steel structures, rails etc. including bonding between sections.

10. Shield Wire

11. Structural steel and Columns.

12. Loading racks.

13. Lighting Mast, poles.

14. Lighting rods (Mast).

15. Tanks and vessels containing flammable materials.

16. Rotating parts of the agitators, pumps etc. through spring loaded brushesof suitable grade.

17. Earth continuity conductor shall be provided for flanges.

Conductor size for connection to various equipments shall be as indicated onEarthing Layout Drawings.

6.4 Two distinct conductors directly connected to independent earth electrodes,which in turn, shall be connected to the earth too, shall earth system.




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The earth connection shall be properly made. A small flexible aluminum cable loops to bridge the top cover of the transformer and the tank shall be provided to avoid earth fault current passing through fastening bolts when there is a lightning surge, high voltage surge or failure of the bushings.

6.5 Each Lightning Arrestor shall be connected to a separate electrode located asclose as possible to it and within the fenced area for each set of arrestors. Thethree nos. electrodes for each set of arrestors shall be spaced about 5 metersapart so that they are all within the enclosing fence. Each of these electrodesshall be connected to the main earth grid.

6.6 The shield wire shall be connected with the main grid solidly and not throughsupporting steel structures.

6.7 All paint, scale and enamel shall be removed from the contact surface before theearthing connections are made.

6.8 All earthing connections for equipment earthing shall be preferably from the earthplate mounted above ground. In case of G.I. Earth Loop all underground "T"connections shall be of the same size as main loop however in case of PVCinsulated aluminum conductor loops underground joints shall be completelyavoided. Connections to motors from earth plate or main loop conductor broughtabove ground shall not be less than following:

Mains Grid & equipment such as : 50 x 6 mm GI FlatMain Electrical Distribution BoardSilent D. G. Set

Switch Socket DB, Lighting DB 25 x 6mm GI/16 sq. mm GI ropeUPSDB

Motors 5.5 KW to 3 KW 2.5 sq mm Cu Wire PVC

2.2 KW to 0.375 KW 2.5 sq mm Cu Wire PVC

Other equipment 2.5 sq mm Cu Wire PVC

Mechanical equipment / Vessels, 50 x 6 mm GI FlatTanks, Pipe/cable racks, structure, fencing

RTU, Telecom, UPS 25 x 6 mm copper


Field Instruments 2.5 sq mm Cu Wire PVC

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




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6.9 All hardware used for earthing installations shall be hot dip galvanized or zinc passivated. Spring washers shall be used for all earthing connections of equipment.

6.10 Lighting fixtures shall be earthed through the extra core provided in the lightingcable for this purpose.

7.0 TESTING:Earthing systems/connections shall be tested as follows:

7.1 Resistance of individual electrodes shall be measured after disconnecting it fromthe grid.

7.2 Earthing resistance of the grid shall be measured after connecting all theelectrodes to the grid. The resistance between any point on the metallic earthgrid and the general mass of earth shall not exceed 1 ohm.

7.3 The resistance to earth shall be measured at the following:

a) At each electrical system earth or system neutral earth.

b) At each earth provided for structure lightning protections.

c) At one point on each earthing system used to earth electrical equipmentenclosures.

d) At one point on each earthing system used to earth wiring systemenclosures such as metal conduits and cable sheaths or armor.

e) At one point on each fence enclosing electrical equipment.

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




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8.0 LIGHTNING PROTECTION

8.1 Lightning protection system shall generally comprise lightning finials (airterminals), roof conductors, down conductors, test links, and earthelectrodes. The number, types, materials and sizes shall be in accordancewith the Specification and IS: 2309.

8.2 Air terminals shall be mounted on top of buildings or structure as required.All air terminals shall be inter-connected with roof conductors, pipes,hands rails or any other metallic projection above the roofs shall also bebonded to the roof conductors.

8.3 Down conductors from air terminals or from roof conductors shall berouted as directly as possible to the test links on earth buses, withminimum bends.

8.4 All provisions regarding connections of conductors for equipment earthingsystem shall also apply to lightning protection system.

8.5 In corrosive atmospheres, plumbing metal for corrosion protection shallcover lightning finials or air terminals.




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TITLE EARTHING SPECIFICATION NO. PAGE 9 OF 10


9.0 TEST PROFORMA

(INSTALLATION TESTING REPORT EARTHING INSTALLATIONS)

1. Earth system data

Type of electrode :

Total number of electrodes :

Main grid size :

Material :

2. General checks Put Tick √ if O.K.; otherwise give details.

Construction of earth electrodes as perStandard.

Size of earth conductorfor various equipmentO.K. as per Standard.

Minimum distance keptbetween two electrodes.

Cleanliness and tightnessof connectors.Inspect bolted & clampedconnectors.


3. TESTS

3.1 Measured earth resistanceof each electrode in ohms

No. 1

2

3

4

5

3.2 Measurement of earth grid resistance(with all electrodes connected to grid)

a) At each electrical system :earth or system neutral earth.

b) At each point provided :for structure lightningprotection

c) At one point on each :earthing systems usedto earth electricalequipment enclosure

d) At one point on each :earthing systems usedto earth wiring systemssuch as metal conduitsetc.

e) At one point on each :fence enclosingelectrical equipment.




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TITLE EARTHING SPECIFICATION NO. PAGE 10 OF 10


4. Remarks:

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

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SPECIFICATION FORLIGHTING FITTINGS FOR HAZARDOUS

INDOOR AND SAFE AREA

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


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

C O N T E N T S

1.0 SCOPE

2.0 STANDARDS

3.0 SYSTEM

4.0 CERTIFICATION

5.0 GENERAL REQUIRMENT FOR THE FIXTURE

6.0 CONSTRUCTION

7.0 TERMINALS AND WIRING

8.0 CONTROL GEAR & LAMP HOLDERS

9.0 GUARANTEE AND INSPECTION

10.0 INFORMATION REQUIRED WITH QUOTATIONS

11.0 TEST AND INSPECTION

12.0 DRAWINGS AND DOCUMENTS

13.0 PACKING

14.0 DEVIATION

15.0 LUX LEVEL FOR CALCULATION

16.0 SPV BASED POWER SYSTEM FOR EMERGENCY LIGHTING LOAD

17.0 SPV BASED SOLAR STREET LIGHTING POLES

ANNEXURE – I DOCUMENTATION FOR LIGHTING FIXTURE



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SPECIFICATION NO. Page 1 of 12TITLE LIGHTING FITTINGS


1.0 SCOPE

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

2.0 STANDARDS

Complete lighting fixtures and other accessories shall conform to the followingIndian Standards or other relevant internationally accepted standards.

IS-2148 Specification for Flameproof Enclosures.

IS-5572 Classification of hazardous area for electrical installation.

IS-8239 Classification of maximum surface temperature of electricalequipment for use in explosive atmosphere.

IS-6381 Construction and testing of electrical apparatus with type ofprotection `e'

IS-8289 Electrical equipment with type of protection `n'.

IS-2206 Flameproof electrical lighting fittings Pt.I & II(well glass and bulkhead type, fittings using glass tubes)

IS-8224 Electric lighting fitting for division 2 areas.

IS-1913 Electric lighting fittings, general and safety requirements .3.0 SYSTEM

Unless until specified in material requisition all lighting fixtures shall be suitablefor 220 - 250 volts single phase and neutral, 50 Hz. power supply.

4.0 CERTIFICATION

All fixtures and accessories shall be tested and certified by independentauthorities for use in specified gas group location. Certification number/data andgas group/temperature classification must be indicated on the manufacturer'snameplate on each fixture.



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5.0 GENERAL REQUIREMENT FOR THE FIXTURE

5.1 Fixtures shall be complete with all the accessories including the control gear withlamp.

5.2 The control gear for fluorescent lamp fixtures shall consist of starter, electronicsballast and capacitors for power factor improvement and for correction ofstroboscopic effect.

5.3 The Control gear for mercury vapour fixtures shall consist of ballast and capacitor forpower factor improvement. The control gear for sodium vapour fixtures shallcomprise a ballast capacitor and an igniter.

5.4 The fixture housing shall be made of CRCA sheet steel / aluminum sheet or castaluminum.

5.5 Each fixture shall be provided with cable glands and a terminal block suitable for Termination of aluminum conductor upto 2.5 sq. mm sizes. Looping facility shall be Provided.

5.6 The control gearbox shall normally be mounted integrally. Non-integrally controlgearbox shall also be acceptable.

5.7 The control gearbox shall be suitable for location in the same area as the fixture andshall have the same degree of protection.

5.8 Neoprene gaskets shall be provided where necessary to prevent ingress of dust,moisture and insects inside the fixture and to make the fixture suitable for outdoorinstallation.

5.9 The fixtures shall be so designed that it shall be possible to maintain or replace thedifferent accessories without difficulty, including the replacement of the lamp.

5.10 The insulation of wiring conductor for the fixture and for the control gear box whereprovided separately shall be selected considering the maximum temperature due tothe heat generation by ballast, lamp, etc. under normal operating condition andproximity of the wiring conductor to these. Wherever necessary, heat resistant typeinsulated conductor shall be used for the wiring of the fixture and control gearbox.

5.11 The wiring between different components of the fixtures and control gearbox shall beproperly secured to avoid loosening of the connections due to vibration.

5.12 The fixture/control gearbox shall be provided with an earthing terminal.



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

5.14 Painting

5.14.1 All metal surfaces shall be made completely free from any scale and rust by suitableprocesses of degreasing and pickling. The thoroughly cleaned surfaces shall bepretreated by phosphatising and passivating.

5.14.2 Two coats of zinc chromate primers shall be applied on all metal surfaces beforeapplication of two coats of finishing paint as specified for different types of fixtures.Where epoxy paint is specified, epoxy based primers shall be used.

5.15 Supporting Arrangement

5.15.1 Fixture shall be suitable for mounting on the ceiling / structure as required. Amounting bracket shall be supplied, where necessary.

5.15.2 Sketch showing the mounting arrangement and dimension for each type of fixtureshall be furnished.

5.1 TYPE OF FIXTURE

5.1.1 All flame proof lighting fixture shall be of cast aluminum alloy (LM6).

5.1.2 Flame proof well glass fixture:- Fixture shall be suitable for HPMV lamps.- FLP Control gearbox shall consist of copper ballast, capacitor for power factor

improvement, cable gland etc.5.1.3 Indusial type fluorescent fixture shall consist of Electronics ballast, starter, capacitor for power factor improvement, cable gland etc.

5.2 INDUSTRIAL TYPE

5.2.1 Channel / Rail Mounting Fluorescent Fixture.

5.2.2 The fixtures shall be provided with CRCA sheet steel mounting channel containingall the accessories, suitably covered with CRCA sheet steel and epoxy stoveenameled.

5.2.3 The fixture without reflector shall be with epoxy stove enamel finish. Where reflectoris specified the same shall be CRCA sheet steel and vitreous enameled, white



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inside and gray outside.

5.3 CORROSION PROOF FLUORESCENT FIXTURE

5.3.1 The fixtures shall be suitable for installation in an area laden with corrosive chemicaldusts and vapors.

5.3.2 The ballast, capacitor and terminal block shall be housed in a cast aluminumenclosure, which shall be made dust and vapour proof with the use of neoprenerubber gaskets. The internal connecting wires shall run inside 2 Nos. seamlessaluminum pipes properly screwed and sealed on either side of the control gearhousing. The end boxes shall be made of cast aluminum fixed at the ends of theseamless pipes, which shall contain the starter holder, starter and the lamp holders.

5.3.3 The lamp holders shall be so designed that when the lamps are fitted, ingress ofcorrosive dust and vapour inside the lamp holders is prevented to protect lamp pins.

5.4 WELL GLASS TYPE MERCURY / SODIUM VAPOUR FIXTURE

5.4.1 The fixture housing shall be made of cast aluminum alloy in dust, vapour andweather proof execution finished in epoxy stove enamel, grey outside and whiteinside, provided with clear heat resistant glass which shall be fitted with neoprenegasket and 3 mm G.I. wire guard.

5.5 HIGH BAY TYPE MERCURY/ SODIUM VAPOUR FIXTURE.

5.5.1 The fixtures shall be in dust and vapour proof execution with a reflector and heatResistant glass cover and shall be provided with integral control gear.

5.5.2 The control gear and lamp holder housings shall be of cast aluminum, so designedas to achieve better heat dissipation and proper cooling of the unit.

5.5.3 The reflector shall be made of anodized aluminum epoxy enameled outside andelectrochemically brightened inside.

5.5.4 The canopy shall be of cast aluminum having terminal block for external connectionand provided with suspension hook.

5.5.5 The canopy, control gear and lamp holder housings shall be epoxy stove enameled.

5.6 STREET LIGHTING FIXTURE.

5.6.1 The fixtures shall be suitable for fluorescent, mercury vapour or sodium vapour lampas specified and shall be made of cast! sheet aluminum epoxy enameled housing,



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anodized aluminum reflector and non-yellowing type acrylic cover.

5.6.2 The fixture shall be totally enclosed type suitable for outdoor installation.

5.6.3 Light distribution shall be cutoff, semi cutoff or non-cut off type as specified.

5.6.4 The fixture shall be provided with side entry for the supporting pipe. The cable shallbe taken inside through the supporting pipe of 25mm dia.

5.6.5 The clamping arrangement for the supporting pipe shall be designed to suit theweight of the fixture and wind load for mounting height upto 16 M as specified in therelevant Indian Standard Specification. The clamping arrangement shall providewide range flexibility in the use of supporting pipe by the purchaser.

5.6.6 Unless otherwise specified, fixture for use with mercury / Sodium vapour lamp shall beprovided with arrangement of adjusting the position of lamp holder to have a cutoff orsemi cut off light distribution.

5.7 FLOOD LIGHTING FIXTURE

5.7.1 The fixture shall be in weatherproof execution suitable for high pressure mercury!Sodium vapors lamp and shall comprise of epoxy stove enameled, cast aluminumalloy body, a clear heat resistant flat toughened glass, an anodized mirror polishedaluminum reflector and a focusing device.

5.7.2 The fixture shall be having an arrangement for rotation on both horizontal andvertical planes and locking in any desired position.

5.7.3 The complete unit shall be mounted on a heavy base of cast iron for fixing the fixtureon a structural platform.

5.7.4 All cast iron and MS. structural provided in the fixture shall be epoxy painted.

5.7.5 A separate control gearbox suitable for the rating of the lamp specified shall besupplied along with the fixture.

5.8 FIXTURE FOR USE IN HAZARDOUS AREA.

5.8.1 The fixture for use in hazardous area shall be in cast aluminum enclosure that shallbe epoxy stove enameled.

5.8.2 The fixture shall have comply with relevant standard for flameproof fixtures.

5.8.3 The fixtures shall be suitable for hazardous area for enclosure group IIA & IIB and



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temp class T3.

5.8.4 Flameproof fixture/Control gearbox shall be provided with flameproof cable glands.

5.8.5 One internal earthing terminal shall be provided.

5.8.6 The vendor shall confirm that the fixtures and control gear box, where suppliedseparately, have been tested and certified by relevant statutory authorities for use inthe hazardous area as offered by them and shall submit the relevant documents alongwith the offer.

5.9 ACCESSORIES

BLASST

5.9.1 The ballast shall be highly inductive silicon steel laminated, copper wire woundpolyester filled heavy-duty type.

5.10 Capacitors

5.10.1 The capacitors shall be constant value type hermetically sealed in metal enclosure toensure long trouble free service.

5.10.2 The value of the capacitors for power factor improvement shall be so selected thatthe corresponding lamp circuit power factor does not fall below 0.95 lags.

5.11 Starter

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

5.12 Lamp Holder

5.12.1 The lamp holders shall ensure proper contact with the lamp during continuousoperation, preventing extinguishing of the lamp due to small vibration.

5.12.2 The material of the lamp holder shall be suitable to withstand the operatingtemperature without any deterioration.

5.12.3 The lamp holder for fluorescent lamp shall be spring loaded rotor type, suitable for



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bi-pin lamp, so designed to prevent contact with live parts of the holder after thelamp has been taken out or during insertion/removal of the lamp.

5.12.4 The lamp holder for mercury and sodium vapour lamp shall be Edison screw type.

5.13 Starter Holder

5.13.1 The starter holders used for fluorescent lamp shall ensure good electrical contactwith the starter pin with strong spring action for trouble free operation. It shall bepossible to insert or remove the starter with ease.

5.14 Cable Glands

5.14.1 Cable glands shall be of brass double compression type for PVC insulated armoredand PVC sheathed 1.1 KV grade 3C 2.5 sq. mm YWY cable.

6.O CONSTRUCTION

All fixtures shall be suitable for use in outdoor open location and shall havedegree of protection for weatherproofing equal to IP-55.

The body of the lighting fixture shall be of cast aluminum alloy LM-6 and shouldbe free from frictional sparking hazard. Complete fixture body and accessoriesshall be suitable to withstand corrosive atmosphere. Outer metallic surface shallbe treated/prepared and provided with two coats of epoxy paint. All screws, nuts,studs, clamps, supporting brackets, etc. shall be electro galvanized or zincpassivated.

All fixtures shall be provided with sheet steel vitreous enameled or approved typeof reflector. Glass used for fixtures shall be clean and toughened type suitablefor use under conditions involving exceptional risk of mechanical damage andshall be type `A' as per IS 2206 or the requirements stipulated by internationalstandards. All well glass fixtures shall be provided with steel wire protectingcage-having mesh dimension not exceeding 50 mm.

The fixing parts of the enclosure, which is to be opened for replacement of bulb,shall be so fastened that they can only be unfastened with special tools. Allfixtures shall carry a special warning inscription in English to "Isolate supplyelsewhere before opening". Three sets of special tools required for maintenanceof fixtures shall be supplied free of cost along with the fixtures.

The temperature rise of external surface shall not exceed the temperature Specified in the standards for the gas group to which fitting shall be suitable.



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All fixtures and associated control gearboxes shall be provided with two 3/4" E.T.threaded entries with one approved type threaded plug to seal one of the entries.Two entries shall be used for looping of circuit wherever required.

All junction boxes for looping for SPN Lighting circuits using cables up to 4 mm2

shall be minimum 100 mm dia in size. Junction boxes for looping of large three-phase cable and multiple single-phase circuits shall be of minimum 300x250x100mm. in dimension complete with flameproof cable glands as specified in materialrequisition.

The top of all well glass lighting fixtures shall be identically drilled/threaded to Facilitate the installation on pole/column or ceiling as per the enclosed sketch Using stud/bracket supplied by others.

7.0 TERMINALS & WIRING

Each terminal for external cable connections shall be suitable for termination ofminimum of two number 4 mm2 aluminum conductors for circuit looping facility.All terminals shall be of non-sparking and anti- loosening design such that theydo not produce any arc or spark in normal operation.

Connection to current carrying parts shall be such that the contact is notappreciably impaired by temperature or by vibrations, which occur, in normalservice or by shrinkage of insulating materials.

If flexible wires are used for internal wiring they should be soldered at the ends,preferable with lugs.

Whereas a screw type holder is used, the center contact shall be connected to aterminal, which shall be clearly identified for connection to the live conductor.

One earthing terminal shall be provided inside the connection chamber suitablefor termination of minimum 4-mm2 aluminum conductors.

8.0 CONTROL GEAR AND LAMP HOLDER

Lighting fixtures suitable for discharge lamps shall be complete with power factorcorrection capacitor, choke and starter, etc. mounted within the fixtures asintegral part completely wired upto terminals. Separate control for gearbox shallbe acceptable only for flood lighting fixtures and these shall be of approvedflameproof construction.



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

All lighting fixtures which are not certified as flameproof construction but approvedfor use in Div. II area shall have approved ENCLOSED BREAK lamp holder andcomplete enclosure certified as having restricted breathing type construction.

Mounting

All well glass fixtures shall be suitable for bracket, ceiling or pole mounting as perthe enclosed sketch.

All flood lighting fixtures shall be supplied with adjustable mounting arrangementboth in horizontal and vertical plane.

9.0 GUARANTEE & INSPECTION

All fittings shall be guaranteed for defective material/ design/ workmanship, for aperiod of 12 months from the date of commissioning or twenty-four months fromthe date of dispatch whichever is earlier.

Mechanical strength of well glass shall satisfy the requirements stated in Clause7.2.1 of IS 6381 and during inspection facilities shall be provided for impacttesting of a random sample.

All fittings and accessories shall be inspected by the purchaser's representativebefore dispatch and minimum two weeks notice shall be given to facilitateinspection. Purchaser's representative will also be allowed to visit works duringexecution of order for expediting/monitoring activities.

10.0 INFORMATION REQUIRED WITH QUOTATIONS

1. Three copies of catalogues/drawings giving details of make/catalogueNo./Overall Dimensions/Weight/ Material of construction and mountingdetails etc.

2. Name/address of testing/certifying authority and certificate No./date foreach item.

3. Clause wise deviations to the requirements of specification/materialrequisition, if any. It will be assumed that offer meets all the requirements



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except deviations furnished with the quotation.

4. Drawing of the complete assembly for each item offered which shall bevalid for the actual material supplied if ordered.

11.0 TESTS AND INSPECTION

11.1 The following tests shall be carried out on the lighting fixtures and their accessoriesas per relevant IS.

11.1.1 Routine tests - On each lighting fixture and its accessories

11.1.2 Acceptance Tests - On representative number of each type.

11.1.3 Type tests - Wherever specified on one lighting fixture and itsAccessories of each type.

11.2 All the above-mentioned tests shall be carried out in the presence of purchaser’srepresentative. In addition, the fixtures shall be subjected to stage inspection atworks and inspection at site for final acceptance.

11.3 These tests and inspection shall however not absolve the Vendor from hisresponsibility for making good any defect, which may be noticed subsequently.


12.1 Drawings and documents as per Annexure-l shall be supplied.

12.2 All drawings and documents shall have the following description written boldly.

- Name of Client GSPL.

- Name of Consultant MECON

- Enquiry / Order Number.

13.0 PACKING

13.1 The lighting fixtures shall be properly packed to safeguard against weather conditionsand handling. It shall be wrapped in polythene bag with an additional wrapping ofbitumen paper to make it completely waterproof before the equipment is packed inwooden crates.



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14.0 DEVIATIONS

14.1 Deviation, if any, from this standard shall be clearly indicated in the offer with reasonthereof.

15.0 Lux level for lighting fixture calculation in the Specified location are as follows:

(a)Control Room - 500 lux(b) Office Room - 300 lux(c) Electrical Room - 150 lux(d) DG Room - 150 lux(e) Process area - 50 lux(f) Road area - 20 lux

(g) Open Area - 10 lux

16.0 TYPE OF LIGHTING FIXTURE

16.1 Building Lighting:

16.1.1 Control Room / Office Room/Electrical Room: Surface /Recess mounted CFL type TLLE 211 M/s CG or equivalent.16.1.2 DG Room/Other Room: Industrial type fixture IGP 1214 HSB of M/s CG Make or equivalent.

16.2 Open Area:

16.2.1 Hazardous Area (i) Well glass fixture type FLPW – 1245 (Lamp: 125 WHPMV) of M/s Baliga makeor equivalent

(ii) Flood light fixture type FLPW – 3690 (Lamp: 400 WHPSV) of M/s Baligamake or equivalent.

16.2.2 Safe Area (i) Street light fixture type SRP 601/150,150W HPSV ofM/s Philips make or equivalent.

(ii) Flood light fixture type FBD 1440, 400W of M/s CGmake or equivalent.



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(iii) SPV Based Solar Street lighting poles26WLPSV Lamps

17.0 SPV Based Solar Street lighting poles: - No. Of Poles - 6 (Six) Nos. (Two nos.for each station) - 2 (Two) Nos. (One nos. for each Tap-off point) Supply, installation, testing, commissioning of Solar Street lighting poles (Model:

MV8 of M/s Tata BP Solar India Ltd.) with aluminum paint complete with mountingbracket, control gear box, internal cable from fitting to junction box, and 26W LPSVLamps, 12 V 150Ah battery backup providing 4 days (3 no sun shine days) autonomywith 150Wp solar array etc. including civil foundation with pipe inserts for cables andconnecting work, with all material and labour as per specifications, drawings andinstruction of Engineer-in-charge. Nominal height of pole shall be 6m above ground.Work to be completed in all respects.

ANNEXURE-I

DOCUMENTATION FOR LIGHTING FIXTURES AND ACCESSOREIS

S.No Documents No. of Copies

With bid Final

1. Specification Sheet 1 82. Technical particulars 1 83. Illustrative and descriptive catalogues indicating general

Arrangement, light distribution, light absorption andutilization factors, starting current, full load current, power 1 8factors etc.

4. Sketch showing mounting arrangement and dimension 1 85. Type Test Certificate for

(a) Flame proof fixtures 1 86. Test Certificates - 87. Guarantee Certificates - 8

NOTE

1. All final drawing and document shall be submitted at least four weeks prior todispatch of equipment.

2. These shall be made in sets and shall be supplied in fine plastic coated folder.

LIST OF SPARES – MANDATORY

1. Starters for fluorescent tubes.

2. Ballast of each type.

Ignitor for sodium vapour lamps.

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SPECIFICATION FORLIGHTING

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





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TITLE LIGHTING SPECIFICATION NO. PAGE 1 OF 10


C O N T E N T S1.0 SCOPE

2.0 STANDARDS

3.0 EQUIPMENT SPECIFICATIONS

4.0 LIGHTING SYSTEM

4.1 General

4.2 Conduit System

4.3 Hazardous Area

4.4 Building Lighting

4.5 Street Lighting

5.0 TESTING AND COMMISSIONING





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1.0 SCOPE

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

2.0 STANDARDS:

2.1 The work shall be carried out in the best workmanlike manner, in conformity withthis specification, the relevant specifications/ codes of practice of the IndianStandard Institution, approved drawings and instructions of theEngineer-in-Charge or his authorized representative issued from time to time.

2.2 In addition to the standards mentioned in 2.1, all work shall also conform to therequirements of the following:

a) Indian Electricity Act and Rules framed thereunder.

b) Fire Insurance Regulations.

c) Regulations laid down by the Chief Electrical Inspector of the State, StateElectricity Board.

d) Regulations laid down by the Factory Inspector of the State.

e) Any other regulations laid down by the local authorities.

3.0 EQUIPMENT SPECIFICATIONS

All materials, fittings and appliances to be supplied by the contractor shall be ofthe best quality and shall conform to the specifications given hereunder. Theequipment shall be manufactured in accordance with the current IndianStandards Specifications. In the absence of any specifications, Material samplesshall be brought to site by Contractor and get it approved by Engineer-in-Chargeor his authorized representative before installation.

3.1 Lighting and Power Panels:

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




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Panels shall be equipped with phase and neutral bus bars of adequate capacityand isolators/miniature circuit breakers and fuses for the incoming and outgoingcircuits as specified on panel schedule. All fuses shall be HRC link type andisolators shall be rotary type only. Where miniature circuit breakers are providedfor incoming to the lighting power panels, the same shall be without the trippingelements. Miniature circuit breakers shall be mounted in such a way thatoperating levers project outside the front bakelite cover plates. A hinged door tocover the operating knob shall be provided. Each circuit phase/neutral shall begiven ferrule numbers. Complete wiring inside the panel shall be neatly bunchedwith PVC tape & button. All cables entries shall be as marked in the schedule. Cables glands for PVC insulated armored cables of sizes as specified on panelschedule shall be provided for the incoming cables of all surface mounted panels. For the outgoing circuits of these panels cable glands or conduit entry shall beprovided as specified on panel schedule. Conduit entry shall be provided for theincoming and outgoing circuits of all flush mounted panels. All metal surfacesshall be cleaned free of rust given a coat of red-oxide primers and finished with 2coats of approved paints.

3.2 Switches

Switches, manufactured in accordance with IS: 3854 shall be used. Switches inareas where concealed wiring has been adopted shall be flush mounting pianotype unless otherwise specified. Electronics type fan regulator shall be used forceiling fans. design and models of the regulator shall be same as that of switches.

3.3 ReceptaclesOnly 5A/15A combination type receptacles manufactured in accordance withIS:1293 shall be used with the third terminal connected to the earth. Allreceptacles shall be provided with a switch mounted on the same enclosure butshall be a separate unit to facilitate replacement by part. Flush mounting typereceptacles shall be used in areas where concealed wiring has been adopted andsurface type shall be used in other areas.

3.4 Outlet BoxesOutlet boxes for sockets, switches, fixtures and fan regulators etc. shall be ofminimum 16 gauge or as specified in Schedule of Rates, M.S. Sheet 3" deep. Junction/Outlet boxes shall be used in roof slab where concealed wiring has beenadopted. Front cover plate shall be of sheet steel in areas where surface wiringhas been adopted. For concealed wiring the front cover plate shall be of Formicaor approved equivalent with colour to suit the walls. Outlet boxes shall beelectro-galvanized after fabrication. Cover plate shall be fixed by cadmium platedbrass screw and suitable C.P. brass cup washers. Engineer-in-Charge shallapprove samples of these.




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3.5 Conduit and Fittings:

Conduit shall be of minimum 16 gauge ERW or GI or Polyethylene as specified. Generally, polyethylene conduits shall be used in concealed wiring and forsurface wiring GI conduit (in industrial buildings) and ERW conduit (in nonindustrial buildings) shall be used.

Care shall be taken to see that all conduit ends have no burrs and ends areneatly reamed to avoid damage to wires. All metal conduit accessories shall beonly of threaded type. Pin grip or clamp type accessories are not acceptable. Samples of these shall be furnished for approval by Engineer-in-Charge at site,before installation.

3.6 Lighting Poles:

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

3.7 Wires

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




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4.0 LIGHTING SYSTEM:

4.1 General

The lighting fixtures in the plant are fed from lighting panel and group controlledfrom local control station. Lighting wiring between panel and lighting fixtures shallbe done by PVC insulated 3-core (phase, neutral and earth) armoured cable forhazardous areas. Lighting fittings in building shall be fed from lighting panels(supplied from lighting panel/ D.C.Panel). Wiring in the building shall be done bymeans of 3-core copper conductor PVC insulated, armoured cables, or PVCinsulated copper conductor wires in conduit of 1" size/ Metsec channel asspecified. All joints of conductors in Switch board/JBS/Fitting shall be made onlyby means of approved Mechanical connectors (nylon/ PVC connectors). Bare ortwist joints are not permitted any where in the wiring system. Cost towardmechanical connectors is deemed to have been included in wiring.

4.1.1 The lighting layouts furnished by owner shall indicate approximately locations oflighting fixtures. The electrical contractor shall determine, with approval of theEngineer-in-Charge or his authorized representative. The exact locations of eachfixture in order to avoid interference with piping or other mechanical equipmentand also with a view to obtain as uniform illumination as practicable, and to avoidobjectionable shadows. Conduit run shown on drawing are only indicative. Thecontractor to suit field conditions as per directions of the Engineer-In-Charge shalllay these out.

4.1.2 On walkway, platforms and other outdoor area, lighting fixtures shall be nearer tolanding of stairs or ladders, gauges, flow-meters, panel boards and otherequipment requiring good illumination.

4.1.3 In pump and compressor areas and other locations at ground level, unlessotherwise called for on the drawing or directed lighting fixtures shall be mountedpreferably 4 meters above level of the floor. Where this is impracticable, theminimum height of any lighting fixture shall be preferably not less than 2 1/2meters above the floor level.




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4.1.4 Lighting in walkways and platforms shall be not more than 2 meters above thewalkways in order to permit maintenance without the use of a ladder.

4.1.5 Socket outlets in process areas shall be approximately 1200mm above finishedgrade and 300mm above grade in office area. Lighting and power panel shall bemounted such that top of the panel is not more than 2000mm above finishedgrade.

4.1.6 Fixtures shall be firmly supported from the structures, support clamps etc. may bebolted or welded to the existing steel work or metal inserts. In case of concretestructures, where metal inserts are not available, fixtures will be fixed to orsupported from concrete surfaces with the help of anchor fastener. In such casesspecial care shall be taken to see that anchoring is firm.

4.1.7 All hardware shall be galvanized or zinc passivated circuit cables shall be groupcleared to structure by using galvanised strip clamps or run in cable trayswherever they are available. Spacers and cleats shall be of suitable size toaccommodate the cables shall be got approved by Engineer-in-Charge beforefixing from at site. For isolated structures lighting cables may be taken inunderground G.I. pipes.

4.1.8 Main runs of wiring from lighting panels and tapping to individual fixtures shall bein sizes specified/ approved. Wiring for all outlet sockets shall be done with 3cores of equal sizes for phase, neutral and earth.

4.1.9 The cost for cable clamps, metal spacers, anchor bolts, etc. shall be deemed tohave been included in the installation of cables.

4.1.10 Contractor shall have close watch on the lighting drawings issued to him. Anydiscrepancy noticed between the figure given in the drawing and the actualrequirement at site, shall be immediately brought to the notice ofEngineer-in-Charge by the Contractor.




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4.2 Conduit System:

4.2.1 Surface or concealed conduit system of wiring shall be adopted, as specified inthe drawings. Suitable pull boxes or inspection type fittings will be used tofacilitate drawing of wires.

4.2.2 Only threaded type conduit fittings shall be used. Pin Grip type or clamp typefittings are not acceptable. Conduit ends shall be free from sharp edges or burrs. The ends of all conduits shall be reamed and neatly bushed with bakelitebushings.

4.2.3 In order to minimize condensation of sweating inside the conduit system, allcables shall be properly drained and ventilated in such a manner so as to prevententry if insects.

4.2.4 The outer surface of the conduit pipes, including all accessories forming part ofthe conduit system, shall be adequately protected against rust, particularly whensuch system is exposed to weather. In all cases, bare threaded portion ofconduit pipe shall not be allowed unless such bare threaded portion is treatedwith anti corrosive preservative or covered with approved plastic compound.

4.2.5 Conduit connection to outlet boxes shall be by means of screwed hubs or checknuts on either side.

4.2.6 Conduit pipes shall be fixed by 16 gauge G.I. Saddles on 25x6 mm G.I. Saddlebars in an approved manner at intervals of not more than 25 cms. Saddles shallbe fixed on either side of couplers, bends or similar fittings, at a distance of 30 cmfrom the center of such fittings. The cost of saddle bars, saddles, clamps, etc. Shall be deemed to have been included in the installation of conduits.

4.2.7 Where concealed wiring is to be adopted, conduits shall be laid in time beforeconcreting of the slab. The Contractor shall coordinate his work with otheragencies involved in the civil works in such a way, that the work of these otheragencies is not hampered or delayed because of any section on his part. Verticalconduit runs shall be made either through columns or chases prepared in thewalls. Contractor shall fill these chases or any other openings made by him aftercompleting. The work and neatly finish the surface. During Installation, care shallbe taken to see that adequate covers are provided to prevent rusting of conduits. If required, conduits run may be concealed in the floor for low-level receptaclesand exhaust fans. As built conduit Contractor shall submit layout drawing.




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4.2.8 Wiring for exhaust fans shall be terminated in ceiling roses/receptacles and theconnection from ceiling roses/ receptacles to the exhaust fan shall be by meansof a flexible cord equivalent in size to the main run of wires.

4.2.9 After erection, the entire conduits system shall be tested throughout, formechanical and electrical continuity and shall be permanently connected to earthby means of approved type earthing clamps, in accordance with Indian ElectricityRules.

4.3 Hazardous Area:

4.3.1 Wiring in hazardous area shall be done by minimum 2.5 mm2 Copper Conductorarmoured PVC cables.

4.3.2 Correct type of lighting equipment (fixtures and JBs etc.) as specified in thedrawing, shall be installed for the particular classified zone 1 (Class I Div. I) andZone 2 (Class I Div.II) locations.

4.3.3 The wiring in hazardous area shall be carried out by highly skilled wireman withdue regard for perfect terminations. The terminations in the junction boxes andthe lighting fittings shall be done so as not to work loose due to vibrations. Afterthe terminations are made the cover of the junction boxes and the lighting fittingsshall be closed to make the complete fittings weatherproof. In fixtures havingdouble cable entries, both the entries shall be used for looping in and looping outconnection. Thus avoiding the use of a separate junction box.

4.4 Building Lighting:

4.4.1 All the fluorescent lighting wirings to be supplied under this contract shall consistof chokes, starters and capacitors. The fittings shall be high power factor typeand shall be supplied with white light fluorescent tubes. All the lighting fittingsshall be supplied complete with cable glands wherever applicable and the cost forthe glands shall be deemed to have been included in the supply of fixtures.

4.4.2 Mounting details shall be indicated on the drawings. If specified on the drawings,a group of fluorescent lighting fixtures, which are to be mounted end to end, shallbe fixed to mild steel cold rolled sections "Metsec channel". The entire assemblywill then by fixed to the ceiling with necessary number of supports as required toreduce the deflection. The `Metsec' channel shall run continuous in suitablesections from one end to other end of wall. The complete channel shall be spraypainted, with approved colour as per the directions of Engineer-in- Charge. Nylontape & buttons shall neatly bunch all wires inside channel.




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4.4.3 Fixtures shall be firmly supported from the structures. Support clamps etc., maybe bolted or welded to the existing steel works or metal inserts. In case ofconcrete structures minimum two numbers metallic anchor fasteners of approvedsize shall support fixtures. All supports shall be thoroughly cleaned and paintedin an appropriate colour to suit the fixture.

4.4.4 In case of false ceilings employing minimum tee grid system, fixtures shall besupported from true ceiling. Exact locations of fixtures shall be supported fromtrue ceiling. Exact locations of fixtures shall be finalized in consultation withair-conditioning contractor and as indicated on Architectural drawings. Wiringabove false ceilings shall not be left loose and shall be supported along thestructures/ceilings. Wiring above false ceiling shall be on surface and below falseceiling it shall be concealed. To facilitate easy maintenance `Looping backsystem' of wiring shall be followed throughout. Accordingly supply tapping andother interconnections are made only at fixtures connector blocks or at switchboards; Intermediate junction boxes shall be used for wire pulling as inspectionboxes.

4.4.5 All wires in conduit shall be colour coded as specified in clause 3.8. Each circuitshall have independent phase neutral and earth wire. Unless otherwise specified,insulated conductors of ac supply and dc supply shall be bunched in separateconduits.

4.5 Street Lighting:

4.5.1 Street lighting poles shall be installed at a distance of 300 mm from the edge ofthe walkway of the road. Fixture wire from marshalling box upto fixture shall be2.5 mm2, copper conductor PVC insulated. Main feeder upto the marshalling boxshall be as per the respective drawings.

4.5.2 Each pole shall be grounded by connecting it to the plant ground grid with 3/8" GIwire rope / GI strip as specified




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4.5.3 Street lighting shall be done with HPMV 150 watt street lighting fixtures. Theyshall be mounted on steel tubular poles as per standard drawings. Electricalcontractor will make the foundation for the street lighting poles. Street lightingpoles shall be supplied with a base plate and grouted. The street lighting polesshall be painted with one coat of coat of primer and two coats of aluminum paint. The second coat of aluminum paint shall be given just before the handling overthe installation to the Engineer-in- Charge. The poles shall be numbered as perdrawings.

5.0 Testing and Commissioning

Lighting installation shall be tested as per the instruction of Engineer-in-Chargeand shall include but not be limited to the following:

(1) Measure the insulation resistance of each circuit without the lamps (load)being in place and it should not be less than 500,000 ohms to earth.

(2) Current and voltage of all the phases shall be measured at the lightingpanel bus bars with all the circuits switched on with lamps, if required loadshall be balanced on the three phases.

(3) Check the earth continuity for all sockets outlets. A fixed relative positionof the phase and neutral connections inside the socket shall beestablished for all sockets.

(4) After inserting all the lamps and switches on all the circuits minimum andmaximum illumination level should be measured in the area.

(5) Ensure switch ON/OFF control for each point (light/fan/socket) is only onlive side.

(6) Contractor shall duly fill in the test results and forward the test reports toEngineer-in-Charge.

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


SPECIFICATIONFOR

L.T. POWER DISTRIBUTION BOARD

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

(ELECTRICAL SECTION)MECON LIMITEDDELHI - 110 092




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TITLE LT POWER DISTRIBUTION BOARD SPECIFICATION NO. PAGE 1 OF 5


C O N T E N T S

1.0 ELECTRICAL DESIGN

2.0 INSULATION LEVEL

3.0 FUNCTIONAL UNITS

4.0 CONSTRUCTION FEATURES

5.0 BUSBARS & CONNECTIONS

6.0 EXTERNAL TERMINATIONS

7.0 COMPONENTS



MECON LIMITEDREGD. OFF : RANCHI(JHARKHAND)


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1.0 ELECTRICAL DESIGN

Electric Power Supply

• Rated main circuit voltage 415 ±10%, 50Hz ±5%, solidly grounded neutral.

2.0 INSULATION LEVEL

• Rated insulation voltage 660V

• One minute power frequency withstand voltage : 2.5 kV for power circuits and2 kV for control circuits.

• Clearance in air of live parts : phase to phase : 25.4mm, phase to earth :19.4mm.

2.1 Short Circuit Strength

Horizontal and vertical buses with one second rating not less than thesymmetrical short circuit level specified.

3.0 MADE-UP OF FOLLOWING FUNCTIONAL UNITS

3.1 Incomer

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




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TITLE SPECIFICATION NO. PAGE 3 OF 5LT POWER DISTRIBUTION BOARD

MEC/S/05/26/26 REVISION 0 3.2 Outgoing Feeders

• Moulded case circuit breaker.• Removable neutral link to be provided for neutral connection• DOL starter feeders as specified / required.• Capacitor bank to achieve power factor of 0.95 complete with contactor, push

button, indication lamp etc. if specified in SLD.

4.0 CONSTRUCTION FEASTURES4.1 Mechanical Design

• Non draw out type ,floor mounted, free standing design.• Sheet steel clad, front operation and maintenance type.• Minimum sheet steel thickness : Doors & covers - 1.6mm cold rolled and other

members - 2.0mm• Degree of protection IP 54• Assembled on base channel of structural steel/ frame of minimum height

50mm and 2.5mm thickness painted black. . The maximum and minimum operating height of the switches shall be 1800mm and 300mm respectively.

• Earthed metallic barriers between compartments and between verticalsections.

• Zinc dichromate and passivated hardware.• Transport unit not longer than 3.2 meters.• Removable lifting arrangement for each transport unit.• Extendibility on both sides.• Cable entry from bottom, 2mm thick removable and un-drilled gland plates• All built up and wired modules or vacant cubicles/ chambers shall be of size

so as to accommodate standard modules.

4.2 Labels

• PDB designation nameplate shall be at the centre of the board with letters notless than 2.5mm high. Panel identification/ designation number shall be oneach panel at the top, both in front and rear.

• Warning labels "CAUTION EXTERNAL VOLTAGE" for terminal blocks where


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



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

4.3 Surface TreatmentAll metal parts of the panel to under go surface treatment that includes cleaning,

chemical degreasing, pickling in acid, cold rinsing, phosphating andpassivating followed by spraying with two coat of epoxy based primer &two coats of epoxy based paint of approved colour & shad.

5.0 BUSBAR & CONNECTIONS

• Three phase, Neutral and earth buses unless otherwise specified.• Power and earth buses of EC grade aluminium alloy equivalent to E91E WP

as per IS-5082 or high conductivity electrolytic grade copper as per IS-613.• The bus bars shall be designed to withstand a system fault current of 1

Sec.The minimum acceptable size of bus bar shall be 250 Sq.mm(Aluminium).

• Heat shrinkable PVC sleeve (red, yellow, blue for phase and black forneutral).

6.0 EXTERNAL TERMINATIONS

• Extension bus links properly spaced for terminating single cable of size 120sq. mm and above as well as for terminating multiple cables.

• Crimping type tinned, heavy duty copper lugs for power and control cables.• Power terminal blocks to be provided with covers.

7.0 COMPONENTS

7.1 Air Break Fuse Switch Units


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



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

7.2 Power Contactor

• Air break, triple pole confirming to IS Specification.

7.3 Thermal Overload Relays

• Triple pole, ambient temperature compensated, inverse time lag conforming toIS-8544.

• Built in single phasing protection.• Setting range step-less adjustable in range 70% to 110%.

7.4 Capacitor Bank Capacitor bank shall be APP type complete with discharge resistance etc.if required as per SLD.

7.4 Auxiliary Contactors

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

7.5 Indicating Instruments

• All meters Digital type.• Accuracy class - 1.5• Ammeter with normal scale upto full load and suppressed scale for motor

starting current.• Voltmeter protected with HRC fuses


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

7.6 Indicating Lamps

• Cluster LED type.• Colour

ON-Red; OFF - Green; CIRCUIT HEALTHY - White; FAULYT/ WARNING - Amber, RED - YELLOW - BLUE for Incomer.


SPECIFICATION FORSPLIT AIR CONDITIONER SYSTEM

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




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SPECIFICATION NO. Page 1 of 3TITLE SPLIT AIR CONDITIONER

MEC/S/05/E9/25 REVISION 0

1.0 SCOPE OF WORK

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

2.0 Number of AC Units: -

Sl. No. Location No. Of 1.5 TSplit AC Unit

1. Control Room at Dispatchterminal at Padmala

4 Nos.

2. Control cum SCADA Roomat SV-1

4 Nos.

3. Control Room at Receivingterminal at Halol

4 Nos.

3.0 Power Supply Voltage

Voltage - 230 V +/- 10% ,Single PhaseFrequency - 50 Hz +/- 5%

4.0 Contractor shall supply all material including 4 KVA Stabilizer, 20A Industrial type PlugSocket with 20A SP MCB, brackets, tools and tackles and any other items required forinstallation, testing and commissioning of the Air conditioning system.

5.0 Fifty percent Air Conditioners shall run for 8 hrs. and automatically switch off andremaining Air conditioner shall automatically switch “ON” through automatic change overcircuit with timer,contactor,indication lamp etc. Automatic Change over panel for Airconditioners shall be kept in electrical room .



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Please furnish the Technical Data Sheet for Split Air Conditioner:

Sl.No. Description Unit PowerSupply

1.2.3.4.5.6.7.

8.

9.

ManufacturerT.R. RatingModel No.NominalCooling CapacityHeating capacityPower supplyVoltageFrequencyPhasePower ConsumptionRunning CurrentPerformanceNominal Air CirculationIndoorNominal Air circulationOutdoorMoisture RemovalNoise LevelRefrigerant typeFeaturesAir directionAuto air swingTemp. controlFan typeFan dischargeFan qualityFan motor typeFan motor –no. of speedFan motor –quantityCompressor typeCompressor modelCompressor –quantityAir dischargeForced operationSoft dry operationDe-humidificationPlasma air purifier

KCAL/HRBTU/HR Not Applicable

VHz

WATTSA

CFMCFM

dB

230V50Hz1 Phase



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Anti bacterial filterElectro static filterRemote controlIndoor unit-widthHeightDepthWeightColourOutdoor unit-widthHeightDepthWeightColour

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TECHNICAL SPECIFICATION

FOR

UPS SYSTEM, RECTIFIER, CHARGER AND BATTERY SETS

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

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CONTENTS

1.0 SCOPE

2.0 STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 DRAWING AND DOCUMENTS

5.0 INSPECTION

ANNEXURE-I PURCHASER'S DATA FOR UPS

ANNEXURE-II A, II B & II C TECHNICAL DATA FROM MANUFACTURER

ANNEXURE-III PREFERRED MAKE

ANNEXURE-IV CHECK LIST

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1.0 SCOPE

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

2.0 STANDARDS

2.1 In general the equipment covered by this specification shall unlessotherwise specified be in line with the requirement of any of the latestapplicable standards of

a) Bureau of Indian Standardsb) British Standard Institutionc) American Standard Institutiond) International Electro Technical Commission

2.2 Wherever the requirements in this specification are in conflict with any ofthe above Standards, the requirements under this specification shall bebinding.

3.0 GENERAL REQUIREMENTS

3.1 Uninterrupted Power System

3.1.1 Basic Particulars for Design

1. Basic Details

- Suitable for industrial application.- The rating of the system shall be as per Schedule of Rates at 0.8

p.f. lagging at 50°C ambient.- Over load rating as specified in Data sheet.- Automatic selection of available phase (out of three phases)

incase of outage of power supply of the phase in use for feedingincoming power supply to the UPS, if indicated inSOR/DATASHEET.

- Single phase voltage and frequency controlled output.- Suitable protection shall be provided in the control circuit to guard

against instability of phase controlled rectifier due to electricaloscillation which may be present in input supply as caused byemergency DG set.

- Single/ Dual/Parallel redundant system with automatic staticbypass, common DC battery and solid state voltage stabilizer asper data sheet and drawing.

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- The load shall normally be fed from the inverter.- Battery shall be suitable to maintain the power supply in the event

of mains failure or battery charger failure for time period asindicated in Data sheet.

- Static by pass switch to connect the load to the mains supplythrough static voltage stabilizer or hot standby UPS, as per theconfiguration, without interruption to the load in the event ofinverter failure.

- AC Distribution board/ DC Distribution board as per data sheet.- Space heater and panel illumination to be provided.- Noise level at a distance of 1 m. from UPS panels shall not exceed

60 decible.- UPS system shall be suitable for both floating output or earthing of

one leg in case of single-phase system/star-point in case of three-phase system.

- MCR with straight modbus or RS485 of UPS shall transmit thehealth-monitoring signal to RTU for indication at SCADA.

2. Permissible Variations

a) Mains power supply system :-Voltage : +10%, - 20%Frequency : ±5%

b) Output of the uninterrupted power supply system while delivering aload of its rated capacity :-Voltage : ±1%Frequency : ±1%

c) Accuracy of static type voltage stabilizer for bypass supply shall bewithin ±2%

3. Protective Features

- Short circuit and overload protection- DC Earth Fault

3.1.2 Transformer

1. Rating suitable for the application2. Dry type, with class 'H' insulation3. ± 2.5% tappings on primary side.

3.1.3 Rectifier/ Battery Charger

1. Switched ON through a MCCB.

2. Charger size shall be based on the maximum inverter input load current

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and recharging current (in maximum time of 10 hours after complete discharge).The rating of rectifier / charger shall be not less than the value calculatedas follows:For Ni-Cd batteries = Inverter input current + 0.2 Ah (5 hr. rating ofbattery)For VRLA batteries= Inverter input current+ 0.2 Ah (10 hr. rating ofbattery)

Rated kVA capacity of UPS X load p.f.Where inverter input current = --------------------------------------------------------- Battery charging voltage X inverter efficiency

3. With transient and surge protection circuit in input circuit to protect UPSfrom surges and voltage Spikes.

4. With necessary smoothing reactor and filters5. Automatic boost and float charging control6. Protective features :

- Maximum current limiting- Over temp. trip.- Boost charging and float charging current limiting with back up

protection against over charging.7. Indications :

- As per manufacturer’s standard.

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

3.1.4 Inverter

1. With input circuit consisting of battery MCCB, battery filter and smoothingreactor.

2. DC/DC converter for voltage control3. Control electronics4. Series reactor and parallel filter5. Output transformer6. Protection against the following:

- Abnormal output voltage- Abnormal link voltage- Over load trip- Low battery voltage- High transformer temperature

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- Auxiliary supply failure7. Meters

- For output voltage- For output frequency- Ammeter- Battery current and voltage with indication of status - "in charge" or

"discharge".8. Static by-pass switch

- Static switch automatically switches the load to the reserve powersupply or the mains whenever there is failure in invertor supply tothe load.

- Retransfer of load from stabilized bypass supply to the inverter inauto as well as in manual mode.

- High speed fuses shall be provided for protecting the thyristorsagainst accidental overload.Following indications & alarms shall be provided in the by-passmodule.

Indications- Load on bypass

3.1.5 Constructional Features

1. Unitized construction2. Free standing, floor mounted, indoor type and complete with all

interconnection.3. Dust and vermin proof4. Sheet steel clad

- Minimum 2 mm thick for panels- Minimum 1.6 mm thick for doors and side covers

5. Units shall be self contained and serviceable6. The arrangement and layout shall facilitate easy and convenient

supervision of the unit while running as well as quick detection ofdisturbances and trouble shooting.

7. Copper earth bus bar shall run through out the length of Panels. All doors& non current carrying parts shall be suitably earthed.

8. Dimensions of panels shall be such that it can be accommodated inexisting room if indicated in MR/ SOR.

9. The maximum and minimum operating height of the switches shall be1800mm and 300mm respectively.

10. Painting type and shade : Epoxy 631 of IS : 5

3.1.6 Enclosure and Ventilation

- Enclosure conforming to minimum IP-41 class.- Units shall be provided with cooling fans and louvers.

3.2 Battery unit

3.2.1 Ampere-hour capacity of the battery shall be selected on the following

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basis:a) Load power factor of 0.8b) Aging factor of 0.8c) Battery state of charge factor of 0.95d) Minimum ambient temperature as specified in data sheete) Backup time as specified in data sheetf) Minimum end cell voltage shall be 1.1V per cell for Ni-Cd battery

& 1.85 V per cell for VRLA battery.g) Inverter rated KVA X Rated load p.f Battery Current = ---------------------------------------------------------------------

Inverter Efficiency * X End cell voltage X No of cell

* for parallel redundant UPS at 50 % load on each inverter.

3.2.2 The type of battery (Ni-Cd/ lead acid-VRLA) shall be as per MR/SOR/DATASHEET.

3.2.3 Sets of Indoor Stationary batteries of type as per enclosed data sheetcomplete with all required accessories as applicable including but notlimited to the following shall be supplied with each battery set ;

a) Battery stands in double row/ double tier formation as per batterymanufacturer’s standard.

b) Cell testing voltmeter complete with leads- (1 no. per set).c) Spanner - (1 no. per set).

3.2.4 Overall dimensions of complete battery set shall be such that it can beaccommodated in existing room if indicated in data sheet.


4.1 The following documents shall be submitted alongwith the offer:

a) List of two years operation and maintenance spare.b) Technical data sheet (Annex-II) and check list (Annex-IV) duly

filled.

4.2 The following calculations/ dimensions shall be submitted alongwith offer:

a) Charger sizing calculation.b) Battery sizing calculation.c) Battery cabinet size.d) UPS panel size including solid-state stabilizer panel.

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

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c) Bill of Materiald) Wiring diagram for reference.

4.4 Final drawings, operation & maintenance manual and erectioninstructions shall be submitted alongwith despatch of equipments in threesets in hard copy & two sets in soft copy (CD).

5.0 INSPECTION

Inspection and testing of equipment shall be carried out by the owner/consultant at the works of the contractor on final product to ensureconformity of the same with the acceptable criteria of technicalspecification, approval drags. and reference national/ internationalstandards.

5.1 The contractor shall submit Quality Assurance Plan (QAP) for respectiveequipments within 3 weeks of award of contract.QAP shall be prepared and furnished by the contractor alongwith theirinternal in process quality checks.

5.2 ‘Type test' including 24 hr. heat run test shall be conducted on one UPSSystem of each rating and ‘Acceptance test’ on the remaining.

5.3 Batteries shall be tested for type and `Acceptance Test’/ Routine Test atbattery manufacturer’s works and test reports shall be submitted forreview and approval.

5.4 Final acceptance testing alongwith the batteries shall be done at site. Siteacceptance test procedure shall be submitted by the Contractor alongwithQAP.

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ANNEXURE - IPURCHASER'S DATA FOR UPS

1.0 INPUT POWER SUPPLY

1.1 Voltage/freq./ phase: 415 V (±) 10 % , TPN, Automatic 3 Ph to 1 Ph.(Selection through Phase selection logic circuit), 50 Hz ± 5%

1.2 System fault level 10 KA

2.0 SITE CONDITION

2.1 Design Ambient/ Minimum ambient 50°C / Min. 5°C

2.2 Max. Relative humidity 100%

3.0 SYSTEM REQUIREMENTS

3.1 Input Power Supply to System 240 V (±) 10 % TPN, 50 (±) 5% Hz AC through 3Ph to 1 Ph auto selection logic ckt.

3.2 Type of inverter Transistorized (IGBT) or Latest proven technology

3.3 Rating (KVA at 0.8 pf.) 5 KVA

3.4 Overload capacity 150% for 10 Sec., 125% for 10 min. , 110 %cont.

3.5 Mode of operation Parallel Redundant UPS with static stabilizer and

3 Ph.Battery charger

3.6 Load p.f. 0.8 (with variation between 0.6 to 1.0)

3.7 Type of Battery Ni-Cd (1.2 V) Pocket plate type

3.8 i) Battery end cell voltage

ii) Battery stand formation

iii) Battery back up timeiv) Derating factor

1.1 V/Cell (Ni-Cd)

Two steps and Two tier

12 Hrs. (2 Banks of 6 hours each)

As per specification

3.9 Type of enclosure Minimum IP-41

3.10 Cable entry From bottom

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4.0 A.C.D.B./ D.C.D.B. DETAILS (1) ACDB (1 No.)

One number incomer DP MCB and 13 nos. outgoing DP MCBs with semiconductor fuses andbus bar.

(2) Metering: Voltmeter, Ammeter (Digital type).

5.0 QUANTITY i) 3 Sets

6.0 Drawings reference UPS Block diagram No.MEC/TS/05/E9/071B,R -0

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ANNEXURE-II (A)TECHNICAL DATA FROM MANUFACTURER

(To be filled up by the Tendered)

1.0 INVERTER

1.1 Manufacturer’s Model No.(Enclose catalogue)

1.2 Rating (at specified ambient) / no. of phases

1.3 Applicable codes/standards

1.4 Steady state output volt/freq (230 V + 1%)

(50 Hz + 1%)

1.5 Input volt.

1.6 Synchronization (inv. phase locked with main) inpercentage

1.7 Synchronization manually adjustable in steps of

1.8 Allowable unbalance between phases (for 3Phases only)

1.9 Harmonics distortion for linear & non-linear loads(not more than 4% and 15% respectively).

1.10 Mode of operation

1.11 Dynamic Responses at following conditionsa) ± 50% step load (for parallel redundant

UPS)b) ± 100% step load (for hot standby and

single UPS system).c) Power supply interruption and restoration.d) Load Transferred to bypass linee) When one inv. gets faulty and load

transferred to healthy inv. (for parallelredundant UPS)

1.12 Recovery time to reach steady state after abovedisturbance (not more than 100m Sec)

1.13 Overload capacity

1.14 Short circuit capacity and duration (in % and msec.)

1.15 Degree of protection of the panel.

1.16 Noise Level (dB. A at 1 m)

(Not more than 75 dB)

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1.17 Efficiency at 100%/75%/50% loads (not less than80% at 100% load)

1.18 Type of control circuit (Static PWM)

1.19 Out put voltage & phase angle (for 3 Ph.only)a) For 30% unbalance loadb) For 40% unbalance loadc) For 50% unbalance loadd) For 100% unbalance load

1.20 Crest Factors

2.0 STATIC SWITCHES

2.1 Nos. of static switches in each set

2.2 Current rating at specified ambient

2.3 Transfer time (m sec.)a) Synchronized mode (not more than 4m

Sec)b) Unsynchronized mode (not more than

20m Sec)

3.0 BATTERY CHARGER

3.1 Rating (Amp.) / MAKE (Enclose back upcalculation).

3.2 Type of charger (Basic configuration)

3.3 Output volt under float/boost charging condition

3.4 Volt. Accuracy under specified input (± 1%)

3.5 Max. Ripple content on DC side (% RMS) (notmore than 2% without battery)

3.6 Max. Ripple content on AC side (% RMS)

3.7 Efficiency at 100%/75%/60 of load

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

4.0 BATTERY

4.1 Make

4.2 Type (Enclose catalogue)

4.3 AH rating (Enclose back up calculation)

4.4 End cell volt. at specified discharge rate (V/ cell)

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4.5 Output (Nominal) volts

4.6 Nos. of battery banks

4.7 Nos. of cells in each banks

4.8 Battery charging requirements (V/ cell)

a) Volts/Cellb) Floatc) Boost

4.9 Voltage variation from fully charged battery todischarged battery (volts)

4.10 Charging time( Hrs.)

4.11 Max. permissible ripple content (% RMS)

4.12 Overall dimension (L*W*H)

4.13 Container type

4.14 Accessories for battery as per specificationincluded

5.0 MANUAL TRANSFER DEVICES

5.1 Rating (Amp.) .

5.2 Make/Type

6.0 STEP DOWN BYPASS TRANSFORMER WITH SOLID STATE VOLTAGESTABILISER

6.1 Make/type

6.2 Rating and Voltage ratio

6.3 Accuracy of stabilizer (not more than ± 2%)

6.4 Type of control (Solid state)

6.5 Type of cooling Natural

7.0 AC DISTRIBUTION BOARD/ DC DISTRIBUTION BOARD

7.1 Nos. of feeder/rating

7.2 Cable entry from (Bottom)

7.3 Deleted

7.4 Max. rating of outgoing feeders possible for faultclearance by UPS with and without supply backup (as percentage of UPS rating) not less than25%

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a) With fast acting semi conducting fuses

8.0 Control Microprocessor based

9.0 Indications and Alarm

10.0 METERING

11.0 UPS Dimension (L x W x H) except Battery :

(Including inverter, charger, rectifier, bypassstabilizer, ACDB/DCDB etc. )

12.0 OVERALL EFFICIENCY OF UPS SYSTEM

12.1 Ratio of output load to input drawn from mainswhen inverters are on and synchronized withbypass.a) At 100% load (not less than 80% at 0.8

p.f.)b) At 75% load c) At 50% load

13.0RELIABILITY

a) Safety factor used for selecting electroniccomponents/ other electrical components(not less than 200%/ 125% respectively)

b) MTBF / MTFRc) Availability factor

14.0 DEGREE OF PROTECTION

15.0 Heat loss for total system (W)

16.0 Spare potential free contracts (for duplicating offault status in remote panel) to be provided.

17.0 Fault status shall be compatible to hook-up withOwner’s PC through RS 232/ RS 485 interface.

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ANNEXURE-II BTECHNICAL DATA FROM MANUFACTURER FOR BATTERY CHARGER

(To be filled up by the Tenderer)

1.0 BATTERY CHARGER FOR Ni-Cd BATTERY BANK

1.1 Rating (KW/Amp.)

(Suitable for charging of battery and supply to5 KVA load simultaneously)

1.2 Input Supply 415 V +/- 10 %, TPN fromDG Set.

1.3 Redundancy (Parallel redundant system) Refer UPS Block diagramNo.MEC/TS/05/E9/071B,R -0

1.4 MAKE

1.5 Output volt under float/boost chargingcondition

1.6 Volt. Accuracy under specified input.

1.7 Efficiency at 100%/75%/50 % of load >75% at 75% load.

1.8 Mode of Change over from float to boost andvice-versa

Automatic & Manual

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ANNEXURE –IICTECHNICAL DATA FROM MANUFACTURER FOR THE INVERTER

(To be filled up by the Tenderer)

1.0 INVERTER System

1.1 Rating (at specified ambient) 1.25 KVA

1.2 Redundancy Single

1.3 Manufacturer’s Model No. (Enclose catalogue)

1.4 Applicable codes/standards

1.5 Input volt. 230 V +/- 10%, 1Ph. & N AC ,50Hz +/- 5%

1.6 Steady state output volt/freq (240 V + 3%)

(50 Hz + 3%)

1.7 Harmonics distortion for linear & non-linear loads(not more than 4% and 15% respectively).

1.8 Overload capacity (125% for 10 min., 110%Cont.)

1.9 Short circuit capacity and duration (in % and msec.)

1.10 Efficiency at 100%/75%/50% loads (not less than80% at 100% load)

1.11 Type of control circuit (Static PWM)

1.12 Crest Factors

2.0 ACDB 1 Incomer MCB 10A & Outgoing5 Nos. 5A MCB

3.0 Battery

3.1 Type SMF Lead Acid

3.2 Back up time 4 Hrs.

3.3 Derating factor Same as that of UPS battery

4.0 Degree of protection of the panel. IP-41

5.0 Noise Level (dB. A at 1 m)

(Not more than 75 dBA)

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ANNEXURE-IIIPREFERRED MAKES

1. UPS System & InverterSystem

Emerson / DB Power / APLAB / KELTRON / HI-REL

2. BATTERIES (Ni-Cd) AMCO/ HBL-NIFE

3. CONTROL SWITCHES ALSTOM/ SIEMENS/ KAYCEE/ L&T

4. CONTACTOR SIEMENS/ L&T/ BCH/ TELEMECHANIC

5. FUSES

(Semiconductor/ HRC)

ALSTOM/ SIEMENS/ L&T

6. TERMINALS CONNECTWELL / WAGO / PHOENIX

7. METERS AEP/ SIMCO/ IMP/ ALSTOM/ RISHAB

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

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ANNEXURE - IV

CHECK LIST (To be filled up by tenderer )

Sl.No Description REMARKS

1 Deviation from specification Offer may be rejected if thereis any deviation

2 Charger sizing calculation enclosed

3 Battery sizing calculation enclosed

4 Battery catalogue enclosed

5 UPS Panel Catalogue enclosed

6 Confirm compliance to Block diagram

7 Inspection for UPS and battery as perspecification.

8 Dimension for UPS Panel, rectifier andBattery Bank enclosed.

9 Unpriced schedule enclosed

10 Break up for two years operation &maintenance spares enclosed for UPS

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


SPECIFICATION FORDG SET

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



TABLE OF CONTENTS

1.0 SCOPE

2.0 STANDARDS TO BE FOLLOWED

3.0 SERVICE CONDITION

4.0 OPERATING REQUIRMENT

5.0 DIESEL ENGINE

6.0 GENERATOR

7.0 SYNCHRONISATION & CONTROL PANEL

8.0 INSTRUMENTATION

9.0 ACCESSORIES

10.0 PAINTING


12.0 SPARES


14.0 DEVIATION

15.0 PACKING



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SPECIFICATION NO. Page 1 of 15TITLE DIESEL GENERATOR SET


1.0 SCOPE

1.1 This specification covers the technical requirements of design, manufacture, assembly; testingat works and delivery in well packed condition of 40 KVA diesel generator set complete withControl Panel, all required accessories and control equipment to supply continuous electricalpower.

1.2 This specification shall be read in conjunction with specification sheet.

1.3 The scope of supply shall include, but not limited to the following:

a) Diesel engine, complete with all the required accessories and components.

b) Generator set, for operation with the above diesel engine, complete with all the requiredaccessories and components.

c) Fuel oil system comprising of fuel oil tank, filter, piping; valves, fittings, etc.

d) Air intake system comprising of air blower, air filter, etc.

e) Lubrication oil system comprising of lube oil pump, filter, cooler, piping, valves, fittingsetc.

f) Air-cooled.

g) Starting system complete with battery, battery charger, control system etc.

h) All inter connecting piping, valves, fittings up to the battery limits.

i) First fill of lubricants.

j) A common base frame suitable for assembly of engine and alternator with accessories.Anti, vibration mounting and foundation bolts shall also be supplied. Base frame shall bedesigned for transportation of above items duly assembled on it.

k) Exhaust manifold complete with silencers, asbestos lagging, metallic expansion bellowsand piping as per requirement.

l) All necessary instruments interlocks, controls with necessary annunciation and indicationfor monitoring and safe starting, running in parallel & independently stopping of the D.G.set their auxiliaries complete with tubing and cabling.

m) CONTROL PANEL.



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n) Power and Control cable between control panel and all equipment within the battery limitincluding racks, earthing terminating materials etc.

o) All safety and protective devices.

p) All other items, not specified here but, necessary for safe, satisfactory and uninterruptedoperation of D.G. set.

q) Set of special tools and tackles required for installation and maintenance.

r) Commissioning spares .

s) All other services as indicated in specification sheet.

t) Contractor shall get approval from electricity authority for DG Set. .

1.4 Erection, site testing and commissioning of the D.G. set at site.

1.5 Electrical Civil Work

The following jobs shall be in the scope of work of the Contractor.

a) All civil works such as provision of foundations, plate inserts, wall and floor cutouts,cable trenches, etc.

2.0 STANDARDS TO BE FOLLOWED

2.1 The design, manufacture and testing of the equipment covered by this standard shall complywith the latest issue of the following codes and other relevant Indian standard specificationsunless otherwise specified in the specification sheet.

i) BS 649 - Diesel engines for general purpose.

ii) IS- 10000 - Methods of test for internal combustion engine.

iii) ASME codes.

iv) IS 4722— Rotating Electrical Machines.

2.2 Equipment designed and manufactured to other national standards shall be acceptable providedthey are in no way inferior to the above-mentioned standards.

2.3 The design and operation features of the equipment offered shall also comply with the



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provisions of latest issue of the Indian Electricity Rules and other statutory regulations. Thesupplier shall, wherever necessary, make suitable modification in the equipment to complywith the above.

2.4 Wherever any requirement, laid down in this specification, differs from that in Indianstandard / IEC, the requirement specified here in shall prevail.

3.0 SERVICE CONDITIONS

3.1 Ambient Conditions

These shall be as indicated in specification sheet.

3.2 System Details

These shall be as indicated in specification sheet.

4.0 OPERATING REQUIREMENTS

4.1 The D.G. set shall be suitable for ‘black start” operation. The equipment offered shall besuitable for operating at their rated capacity continuously under the ambient conditions andvoltage and frequency variations indicated in specification sheet, without exceeding thetemperature rise limits specified in relevant standards and without any detrimental effect onany part.

4.2 The D.G. set shall be designed for continuous operation at full load or partial load and havethe capability to run at 110% of the MCR for one hour in every 12 hours.

4.3 The standby D.G. set should start manually after prolonged idle period. Under suchconditions, the auxiliary power shall not be available. The starting and lubrication systemshall be suitably designed to take care of these conditions and allow easy, safe and quickstarting.

4.4 The D.G. set loading sequence is not automatic and hence need not be defined by Owner /client.

4.5 The D.C. set shall be manually controlled and started manually.

5.0 DIESEL ENGINE

5.1 General Design Feature

5.1.1 The diesel engine- shall be of multistroke , multicylinder with mechanical fuel injectionarrangement and complete with all the required accessories.



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5.1.2 The engine output shall be at least 15% greater than the power required for the loads.

5.1.3 The engine shall be suitable for trouble free operation with high speed diesel conforming toIS: 1460.

5.1.4 The unbalance force transmission to the foundation shall be minimum. Critical speed of theassembly shall be sufficiently higher than the rated speed of the engine.

5.1.5 The engine shall be provided with filter and silencer mounted suitably on the engine frameand complete with necessary ducts work for air intake.

5.1.6 The engine shall be provided with exhaust silencer, necessary ducts, and minimum 1 no.Expansion bellows and supporting arrangement from ceiling for exhausting the gases tooutside.

5.2 Fuel Oil System

5.2.1 The system shall comprise of gravity fed oil tank, or otherwise as specified in specificationsheet.

52.2 The gravity tank shall be complete with the provision of filling up by Hand pump from thestandard drums. The hand pump and associated hose pipe shall be supplied along with oiltank.

5.2.3 The gravity fed oil tank shall be located at a height from floor and near the wall of the engineroom. Suitable brackets / structure shall be provided by the vendor for this purpose. The tankshall be fabricated out of MS. plates in cylindrical construction. The capacity of the tankshall be adequate for 12 hours continuous running of the engine. It shall be complete withvalves for filling and draining, vent connection, level gauge glasses, level switches for lowlevel alarm.

5.3 Cooling System

5.3.1 The engine shall be air-cooled.

5.4 Lube Oil System

5.4.1 Proper lube oil system shall be provided for all lubricating points of the engine.

5.5 Starting System

5.5.1 The Electrical starting system shall be provided.



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5.5.2 Local manual starting scheme shall be provided.

5.5.3 The starting system shall be such that the D.C. set shall start come upto rated speed and beready to accept full load within the period as indicated in specification sheet.

5.5.4 The electric starling system shall comprise of starter motor, battery, battery charger,necessary cabling, required instruments and accessories.

5.5.5 The sealed lead acid battery shall be heavy duty type and suitable for 20 successive startingattempts of the engine without draining. The charger shall have both float / boost chargingfacilities. The battery shall be complete with suitable stand and other required accessories.

5.6 Governing System

5.6.1 The speed governing system of the diesel engine shall satisfy the following requirements:

• Steady state speed regulation shall be adjustable between 0 to 5% manually.

• Steady state speed regulation once fixed, shall not vary beyond +0.5%.

• Transient & peed regulation shall not exceed 4.5% of rated speed. Momentary underspeed and over speed shall not exceed 2% and 8% respectively.

• Recovery time shall be within 3 seconds.

5.6.2 The governor system shall be mechanical type and provided with adequate scheme to controlthe speed in the event of failure of power to the governor.

5.6.3 A mechanical over speed trip device shall be provided to operate at 110% of rated speed.

5.6.4 An engine mounted emergency push button shall be provided to trip the engine in case ofemergency.

6.0 GENERATOR

6.1 General Design Features

6.1.1 The generator shall be directly coupled to the engine.

6.1.2 The ingress protection class of the enclosure shall be IP21 as per IS : 4691.

6.1.3 The generator and its accessories shall be capable of withstanding electrical, mechanical andthermal stresses while meeting the performance requirements.



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6.1.4 The generator shall be synchronous AC. generator, star connected and shall have C.M.R. ofspecified output at 0.8 lag p.f. at rated voltage and frequency.

6.2 Winging And Insulation

6.2.1 The stator and rotor coils shall be made out of electrolytic grade copper conductors.Successive coils shall be connected by accessible and well brazed joints

6.2.2 The coils shall be class F or H insulated and treated with tropical and fungicidal treatments.

6.2.3 The windings shall be dried, properly impregnated with suitable varnish to withstand the siteconditions and properly baked. At least two additional impregnations and baking shall beapplied to the assembled coil making a total of three impregnations and backings. Finally thewindings shall be painted with special anti acid and antalkali paints to withstand the sitecondition.

6.2.4 The leading wire between the windings and the outside terminals shall be through bushings.

6.3 Performance Requirement

6.3.1 The generator and the diesel engine shall match properly to deliver the rated load under thespecified ambient and system conditions.

6.3.2 The specified rating of the D.G. set indicated are net electrical power output required forowner’s use and does not include the power required by the auxiliaries of the diesel set. Theactual output rating of the generator to be offered by vendor shall take into account the powerrequirement of the auxiliaries, 15% extra margin.

6.3.3 The generator shall have an overload capacity of 10% for 1 hour in any consecutive period of12 hours after having attained the thermal equilibrium corresponding to the rated load. Theterminal voltage shall be equal to the rated value. At the time of switching ‘ON’ the emergencyloads, restarting or reaccelerating of squirrel cage motors shall be required, in addition toswitching ‘ON’ of the lighting loads, which will be six times the rated load at power factor of0.35 lagging. The generator and its accessories shall be capable of supplying this load at theabove mentioned low power factor. Limitations, if any, shall be clearly indicated by the vendor.

6.3.4 Largest Motor Starting Requirement

The D.G. set shall be designed such that it can start squirrel cage induction motor ofspecified rating by D.O.L. starting method when already loaded up to 70% of its rated load.The voltage dip at the generator terminal shall not exceed 10% of its rated voltage during theentire starting period which will not exceed 5 seconds.



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6.3.5 The short circuit ratio, of the generator at rated KVA and rated voltage shall not be less than0.5.

6.3.6 The generator shall withstand 20% over speed for 2 minutes without any damage to any part.

6.3.7 The generator shall be capable of withstanding the three-phase short circuit at its terminalswhile operating at its voltage without sustaining any damage.

6.4 Excitation System

6.4.1 The generator shall be provided with static brush less excitation system comprising of shaftdriven rotor exciter, thyristor and other associated items.

6.4.2 The capacity of the system shall be adequate to meet the performance and largest motorstarting requirement of the generator.

6.5 Voltage Regulator

6.5.1 The generator shall have electronic automatic voltage regulators to be mounted on the controlpanel. The regulator system shall be suitable to meet the following requirements.

• Allow the generator to meet the performance requirements.

• Both auto and manual control.

• Prevent automatic rise of field voltage in the event of excitation supply failure.

• Transfer to manual mode in the event of control circuit failure in auto mode.

• Operated by the output current and voltage of the generator.

6.6 Terminal Boxes

6.6.1 All the terminal boxes shall have lP-21 degree of protection.

6.6.2 The power and control terminal boxes shall be separate. All the six leads of the generatorstator shall be taken out, three to one side and three to the other side to separate powerterminal boxes.

6.6.3 The power terminal box shall be spacious and have adequate clearance between the terminalsand the cable gland for proper termination of required nos. of aluminum cables,

6.6.4 The power terminal boxes shall be provided with tinned copper sockets suitable for crimping.



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6.6.5 The control terminal boxes shall be provided with pressure type terminal blocks.

6.6.6 All terminal boxes shall be complete with heavy-duty double compression type aluminumcable glands suitable for the cable sizes required.

7.0 CONTROL PANEL

7.1 Requirements

a) The control panel shall comprise of control & instrument section power & protectionsection and distribution section for satisfactory and trouble free operation of the set. Eachsection shall be a complete panel.

b) The control and instrument panel shall house the following:

• All the required controlling elements for the engine, generator and exciter control,for both manual and automatic operations.

• Panel mounted instrument.• The required protective devices for the engine.• The audiovisual annunciation system indicating abnormal operating conditions.

• Control switches and indicating lamps.• Automatic voltage regulator.• All other items, as required.

c) The power and protection panel shall house the following:

• MCCB, Contractor for local operation and provided with in-built protective relays,C.T.s Ammeters, Voltmeters, KWH meters, Frequency meters, ON/OFF/Tripindicating lamps, control switches etc. for the control of generator.

• Outgoing Feeder shall have MCCB.

d) The distribution panel shall house the following:

• Necessary feeder circuit outlets complete with MCCB, contractors, overloaddevices, ON/OFF/Trip indicating lamps, Ammeters etc. for the D.G. set auxiliaries,if required.

• D.C. battery charging equipment required for the start up and control of the D.G.set. The charger shall be complete with float and boost charging arrangement bothin auto and manual mode.



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7.2 General Design Features

7.2.1 The panels shall be free standing, floor mounting, identical, metal clad cubicle type inconstruction and placed side by side to form a compact assembly in dust / damp and verminproof type equivalent to lP-52 as per 15:2147.

7.2.2 The thickness of sheet steel members shall not be less than 2/1.6 mm for cold rolled steel.Suitable reinforcement, wherever necessary, shall be provided. The base channel shall bemore than 3 mm thick.

7.2.3 The door hings shall be concealed type. All threaded screws in the removable parts shall beprovided with retaining rings.

7.2.4 All the components shall be accessible for checking and taking off without the necessity ofremoving the adjacent ones. Their mounting shall be accessible and ensure the necessarydegree of safety.

7.2.5 The relays, meters, switches and lamps shall be flush mounted type. Their minimummounting height shall be 300 mm from the base of the panel.

7.2.6 The bus bars shall be for three phase and neutral and made of electrolytic copper oraluminum of required cross section and PVC sleeved. These shall be amply sized to carry therated continuous current under the specified ambient temperature without exceeding the totaltemperature of 850C. The thermal rating of the bus bars shall be designed to withstand thesystem fault current for one second without exceeding the temperature of 2500C for barecopper.

7.2.7 The clearances and creep age distance shall not be lower the values specified below:

i) Minimum clearance between two live conductors —20 mm.

ii) Minimum clearance between live parts and accidentally dangerous part —20 mm.

iii) Minimum creep age distance —28 mm.

7.3 Control Wiring

7.3.1 The panel shall be completely factory wired and ready for external connections.

7.3.2 The wiring shall be carried out with flexible stranded PVC insulated copper conductor cablesfor 1100 volts grade.

The size of wires shall be as follows:



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C.T. Circuit —2.5 sq. mm. CopperV.T. & Control circuits— 1.5 sq. mm. Copper.

7.3.3 All wiring shall be marked in accordance with lS:375. Numbered Ferrules reading from theterminals outwards shall be provided at both ends of all wiring for easy identification. Theseshall be interlocking type plastic ferrules.

7.4 Circuit Breakers

7.4.1 The circuit breakers shall generally comply with the requirements of IS:2516, having P2category, capable of carrying the specified current at the site conditions and making/breakingof the system fault current.

7.4.2 Type test certificates from an independent testing authority shall be furnished along with theoffer, for each circuit breaker rating, which shall clearly prove the capability of circuitbreakers and include the short circuit tests, temperature rise test, electrical overload tests andendurance test (both electrical and mechanical).

7.4.3 The circuit breakers shall be provided with motor wound spring closing mechanism andelectrically and mechanically trip free and have anti pumping features.

7.4.4 The circuit breakers shall have three positions for service, test and isolated with the cubicledoor closed, and position indicators provided to indicate the positions of the breaker Stoppersshall be provided to prevent excessive movement of the breaker shall have monitoring switchhaving 1 NO. + 1 NC contacts.

7.4.5 Provision shall be made for testing the circuit breaker in test position.

7.4.6 Automatic safety shutters shall be provided to screen the cable and the bus bars spouts whenthe circuit breaker is withdrawn from the cubicle.

7.4.7 The circuit breakers shall be provided with an emergency manual trip device, mechanical‘ON’, ‘OFF’ and ‘ISOLATED’ position indicators and operation counter.

7.4.8 Mechanical safety interlock shall be provided for safe operation movement of the breaker.

7.4.9 The closing coil and other associated auxiliary relays shall operate satisfactorily at allvoltages between 85 to 110% of the rated control voltage. The tripping coil and otherassociated relays shall operate satisfactorily at all voltages between 70 to 110% of the ratedcontrol voltage.

7.5 Control Fuses

The fuses shall be of non-deteriorating HRC cartridge link type and conform to IS:2208.



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They shall be suitable for the load and the service required in the circuit.

7.5 Current Transformers

7.6.1 C.T.’s shall be cast resin, accuracy class 1 as per 15:2705, for metering.

7.6.2 All the C.T.’s shall be provided with terminals and shorting links. One of the terminals of theC.T.’s shall be earthed. The polarity of the C.T.s shall be clearly marked.

7.7 Voltage Transformer

The V.T. shall be cast resin insulated having secondary terminal voltage of 110V andaccuracy class of shall be 1 as per 15:3155 and provided with primary / secondary fuses.

7.8 Relays

All protective relays shall be provided in draw out and dust proof cases and shall be flushmounted type. They shall be fully tropicalised. Relays shall be of make and type as approved.

The following protective relays shall be provided.

i) IDMTL over current and Residual earth fault.ii) IDMTL standby earth fault.iii) Over voltage or Under voltage.iv) Hand reset tripping relay.

7.9 Instruments And Metering

7.9.1 All instruments shall be flush mounting type with square face of 96 Sq.mm. They shall betropicalised and dust tight. Make and type of instruments shall be as approved.

7.9.2 Marking of the scale shall be black on white background and suitable for direct reading.

7.9.3 Zero adjusters shall be provided for operation from the front of the cases.

7.9.4 All indicating instruments shall be moving iron spring-controlled type of class 1.5 accuracyas per IS: 1248.

7.9.5 The KWH meter shall be as per IS: 732 and provided with test blocks for current and voltagecoils for testing them at site without interrupting their recording while in service.



NEW DELHI




7.9.6 The following instruments shall be provided.

i) Voltmeterii) Ammeter -iii) Frequency meteriv) KW meterv) KWH meter

7.10 Signal Lamps

LED type signal lamps shall be provided to indicate the various circuit conditions and theseshall be placed at suitable height. The colour of the lamps for various functions shall be asfollows:

Red - Circuit breaker ‘ON’Green - Circuit breaker ‘OFF’White - Trip circuit healthyAmber - Alarm and auto trip faultBlue - Non trip fault

7.11 Name Plate

7.11.1 The panel shall have a large name plate on the top to indicate is name and designation. Eachfeeder shall be provided with name plates. Each panel shall have name plates both in frontand back.

7.11.2 All control switches, push buttons, lamps etc. shall have function identification labels.

7.12 Cable Termination

Necessary cable glands and lugs for power and control cables shall be provided.

7.13 MCCB - Moulded Case Circuit Breaker

a) MCCB shall confirm to relevant ISS/International standard.b) MCCB shall have Trip free mechanism.c) Under Voltage Trip mechanism.d) Short Circuit and O/C, Circuit mechanism.



NEW DELHI




8.0 INSTRUMENTATION

8.1 The instrumentation requirement shall include field / panel mounted instruments, pushbuttons, lamps, audio-visual alarm system and other accessories as required.

8.2 The provision required in the control panel board shall include the followings:

• Fuel oil day tank level indicator.• Audio-visual alarm system for:

a) Low lube oil pressureb) All shutdown conditionc) Other abnormal conditions, as required

• Shutdown system for:

a) Minimum lube oil pressureb) Failure of engine to start after a preset timec) Other faults, as required

• Engine control system complete with:

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

8.3 The field mounted instruments shall include the followings:

a) Pressure gauge for lube oil.b) Fuel oil day tank low level indicator.c) Other items, as required.

8.4 The supply shall be complete with all instrument erection materials with 10% extra provision.

8.5 All instruments shall be suitable for site maximum ambient temperature. All electrical andelectronic instruments shall be tropicalised and fungus proof.



NEW DELHI




9.0 ACCESSORIES

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

10.0 PAINTING

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


11.1 All routine tests as per relevant standards shall be carried out in the presence of purchaser’srepresentative.

11.2 The D.G. set shall be tested for output, general performance, overloads and other testssufficient to prove the correctness of the design both at works and at site.

11.3 In addition, the equipment shall be subjected to stage inspection during process ofmanufacture at works and site inspection.

11.4 These inspections shall, however, not absolve the vendor free from his responsibility formaking good any defect, which may be noticed subsequently.

12.0 SPARES

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


Drawings and documents as per Annexure-II shall be supplied. All drawings and documentsshall have the following descriptions written boldly.

Name of client Name of consultant Project / Plant name Order no. Description of equipment.



NEW DELHI




14.0 DEVIATIONS

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

15.0 PACKING

15.1 The equipment shall be properly packed before dispatch to avoid damage during transport,storage and handling.

15.2 The equipment shall be wrapped in polythene to make it water proof Bags of silica gel shallbe kept inside to absorb moisture present during transport and storage. An additionalwrapping with bitumen paper shall also be provided before the equipment is packed inwooden crates.

15.3 A sign indicating the position of the equipment placed during transport and storage shall beclearly marked. Also proper arrangement shall be provided to handle the equipment.

Note: One nos. DG Set each for Dispatch terminal at Padmala, SV-1/ Tap-off- 2, and Receiving terminal at Halol.

Total DG Set = 3 Nos.


ANNEXURE -I

1. LIST OF SPARES — MANDATORY

The spare parts as listed below shall be quoted for the D.G. set along with the offerwith item wise unit prices:

1. Rings of various types and sizes.

2. Bearings of various types and sizes.

3. Caskets of various sizes and types.

4. Lube oil filters.

5. Fuses of all ratings.

2. LIST OF SPARES — FOR 2 YEARS OPERATION

A. MOULDED CASE CIRCUIT BREAKER (OF EACH RATING)i) Complete Breaker Assembly

B. SWITCHES (OF EACH RATING)i) Assembled switch in open executionii) FUSES Single pole moving blade assemblyiii) Single pole base assembly

C. FUSES (OF EACH RATING)i) Fuse linksii) Fuse fittings

D. CONTROL SWITCHESi) Trip – Neutral – Close Switchii) Local Remote Selector Switchiii) Heater Switchiv) Thermostatv) Ammeter Selector Switchvi) Voltmeter Selector Switchvii) Push Buttonviii) Push Button elementix) Push Button Actuator of each type

E. CONTRACTOR (OF EACH RATING)

i) Contractor with Auxiliary Contractsii) Operating Coiliii) Auxiliary Contact Block


F. INDICATING LAMPS

i) Indicating lamps globes of each colourii) Indicating lamp fittingsiii) Indicating lamp bulbs

G. METERSi) Ammeterii) Voltmeter

H. PROTECTIVE RELAYSi) Relaysii) Thermal overload relay of each type

NOTE: All spare parts shall be identical to the parts used in the distribution boards.


ANNEXURE — II

DOCUMENTATION FOR D.G. SET

Sl.No.

Description WithBidNo. ofcopies

After Order

For Review FinalNo. of Copies No. of copies

1. Specification Sheet 1 6 82. Technical Particulars 1 6 83. General arrangement and foundation

drg. For all the equipment- 6 8

4. Civil scope drawings - 6 85. Earthing Layout - 6 86. Terminal arrangement drg. And

interconnection- 6 8

7. Sectional view of D.G. set - - 88. Illustrative and descriptive literature. - - 89. Catalogue for bought out accessories - - 810. Installation, operation &

maintenance manual- - 8

11. Type test certificates for engine,alternator and circuit breaker

- - 8

12. Guarantee certificate - - 813. Spare parts list with identification - - 814. GA, schematic and wiring diagram

of synchronization & control panel.- 6 8

* * *

MECON LIMITED DELHI

SPECIFICATION / PROCEDURE FOR OPTICAL

FIBER CABLE TESTING

SPECIFICATION No. : MEC / S / 05 / E5 / T / 002 ELECT. & INST. SECTION Rev. 0 Page 1 of 2

SPECIFICATION/ PROCEDURE

FOR

OPTICAL FIBRE CABLE TESTING

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

MECON LIMITED DELHI - 110 092

0 06.06.2005 Sudhir Rakesh Shukla Pankaj Shrivastava

Revision Date Prepared by Checked by Approved by

MECON LIMITED DELHI


FIBER CABLE TESTING


INDEX

1. TEST PROCEDURE 1.1 FIBRE LENGTH MEASUREMENT 1.1.1 Test Description 1.1.2 Test Equipment 1.1.3 Procedure 1.2 INSERTION LOSS MEASUREMENT 1.2.1 Test Description 1.2.2 Tools and Equipment required 1.2.3 Procedure Appendices : Appendix – 1 (A & B) : Test Format : Fibre Length Measurement Appendix – 2 (A & B) : Test Format : Insertion Loss Measurement

MECON LIMITED DELHI


FIBER CABLE TESTING


TEST PROCEDURE The Optical Fibre cable will be tested for its continuity and average loss in dB/km. The link will be tested and recorded in the format given in Appendix-1 & 2. 1.1 Fibre Length Measurement 1.1.1 Test Description

This test will check the continuity of the fibre from station to station and record the length of fibre. Average loss per kilometer of fibre length shown in dB/km shall be recorded for information only. Testing will be done from both ends and average will be calculated (for both 1310 nm and 1550 nm).

1.1.2 Test Equipment

1. Optical Time Domain Reflectometer (OTDR) 2. Patchcords, pigtails

1.1.3 Procedure

• Power on the OTDR and make the settings as required for the top under test. • Splice a pigtail to one of the fibres • Connect the OTDR with pigtail • Make the laser ON and observe the trace till it gets settled up to the end of the

trace. • Store the results in the hard disk/floppy disk with proper identification of the

fibre under test. • Record the results in format • Repeat the procedure for the Opposite direction. • Test Formats are provided in Appendix-1 (A & B) • Repeat above steps for each fibre

1.2 Insertion Loss Measurement 1.2.1 Test Description

During the insertion loss measurement, light is launched (LASER) in the fibre by using a LASER source from one end at the other end by using an Optical Power meter the received is measured. Fibre loss is calculated by subtracting the receive power from the transmit power. This test also determines the fibre termination continuity on end to end basis as the measurement is done on both the ends of a link.

1.2.2 Tools and Equipment required

1. Power meter working on 1310 nm and 1550 nm 2. Laser source working on 1310 nm and 1550 nm

MECON LIMITED DELHI


FIBER CABLE TESTING


3. Patchcords (10 mtrs)

1.2.3 Procedure

• One power meter, one laser source and one unit of optical talk set are required at

each end. • At location A, switch ON the laser source, set it to operating wavelength of 1310

nm and connect it to the power meter (set at 1310 nm) by patch cord and record the laser power transmitted. Record it in the test sheet.

• Cut the patch cords, laser source & power meter remaining connected to the 2

halves of the patch cord (i.e. 2 pig tails). • Splice each of the pigtails to two ends of the same fibre under test. • Record the power received in test sheet • To establish communication between two stations A & B, connect the Optical

talk set to one of the fibre (for example fibre No. 24) at both the stations. When that particular fibre is next for testing connects the talk set to one on which testing is complete (for example fibre No.1).

• Confirm on the talk set that the power received is recorded. • Repeats the test for 1550nm. • Connect the source to next connector at Location A and Power Meter at

Location B. • Repeat the same procedure with source at Location B and Power Meter at

Location A. • Continue the above process till all fibres are tested • Average loss of each fibre should be less than the average loss estimated.

• Test formats are provided in Appendix-2 (A & B)

MECON LIMITED DELHI


FIBER CABLE TESTING


Appendix-1 A

FIBRE LENGTH MEASUREMENT Date : _____________________ Location A : _____________________ Location B : _____________________ Wavelength : 1310 nm Equipment used : _____________________

Tube Fibre Fibre Length Optical loss dB/km No./ color No./ Color (m) From A From B

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

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

MECON LIMITED DELHI


FIBER CABLE TESTING


Appendix-1 B

FIBRE LENGTH MEASUREMENT Date : _____________________ Location A : _____________________ Location B : _____________________ Wavelength : 1550 nm Equipment used : _____________________

Tube Fibre Fibre Length Optical loss dB/km No./ color No./ Color (m) From A From B

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

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

MECON LIMITED DELHI


FIBER CABLE TESTING


Appendix-2 A

INSERTION LOSS MEASUREMENT Date : ___________________ Location A : ___________________Location B : __________________ Wavelength : 1310 nm Equipment used : ___________________ Cable Length from Appendix 1A : _________ km Number of Splices (including Pigtails-N : ________________ Number of connectors-C : ___________________ Average IL = 0.38L + 0.1N + 0.5C : _________ (estimated)

A-B B-A Average Power Transmitted at A Power Transmitted at B

Tube No./ color

Fibre No./ Color

Power received at B

IL (A-B) Power received at A

IL (B-A) IL

1. Blue 1. Blue 2. Orange 2. Orange 3. Green 4. Brown 3. Green 5. Slate 6. White 4. Brown 7. Red 8. Black 5. Slate 9. Yellow 10. Violet 6. White 11. Pink 12. Aqua 7. Red 13. Blue 14. Orange 8. Black 15. Green 16. Brown 9. Yellow 17. Slate 18. White 10. Violet 19. Red 20. Black 11. Pink 21. Yellow 22. Violet 12. Aqua 23. Pink 24. Aqua (ALL LOSSES MEASURED IN dB/km) Signature & date Signature & date (Tested & handed over by (Witnessed & Taken over by Cable laying vendor for HDD) Main Line cable laying vendor) Signature & date Witnessed by Client/MECON representative (s)

MECON LIMITED DELHI


FIBER CABLE TESTING


Appendix-2 B

INSERTION LOSS MEASUREMENT Date : ___________________ Location A : ___________________Location B : __________________ Wavelength : 1550 nm Equipment used : ___________________ Cable Length from Appendix 1A : _________ km Number of Splices (including Pigtails-N : ________________ Number of connectors-C : ___________________ Average IL = 0.22L + 0.1N + 0.5C : _________ (estimated)

A-B B-A Average Power Transmitted at A Power Transmitted at B

Tube No./ color

Fibre No./ Color

Power received at B

IL (A-B) Power received at A

IL (B-A) IL

1. Blue 1. Blue 2. Orange 2. Orange 3. Green 4. Brown 3. Green 5. Slate 6. White 4. Brown 7. Red 8. Black 5. Slate 9. Yellow 10. Violet 6. White 11. Pink 12. Aqua 7. Red 13. Blue 14. Orange 8. Black 15. Green 16. Brown 9. Yellow 17. Slate 18. White 10. Violet 19. Red 20. Black 11. Pink 21. Yellow 22. Violet 12. Aqua 23. Pink 24. Aqua (ALL LOSSES MEASURED IN dB/km) Signature & date Signature & date (Tested & handed over by (Witnessed & Taken over by Cable laying vendor for HDD) Main Line cable laying vendor) Signature & date Witnessed by Client/MECON representative (s)

MECON LIMITEDDelhi Electrical &

Instrumentation Section

TECHNICAL SPECIFICATIONFOR

WARNING MATS(For OFC & TELECOM HDPE Duct)

TECHNICAL SPECIFICATION NO. : MEC/TS/05/E5/T/042 REV-1 Page 1 of 4

TECHNICAL SPECIFICATIONOF

WARNING MATS(FOR OFC & TELECOM HDPE DUCT )

Technical Specification No. :MEC / TS / 05 / E5 / T / 042

MECON LIMITEDDELHI - 110 092

1 28.06.2006 Sudhir Rakesh Shukla Pankaj Shrivastava

Revision Date Prepared by Checked by Approved by






SPECIFICATION FOR THE WARNING MATS

Purpose : For using as a warning sign for Under GroundOFC & HDPE Telecom Duct along with NaturalGas Pipeline

Width : 150mm

Thickness : 0.25mm thick

Material of the Mat : The material shall be of high densityPolyethylene

Colour of the Mat : Golden Yellow with letters in Red

Art Work : A sample piece of 30mm wide and 200mm longof every batch shall be checked by immersing in20% solution of Ammonium Sulphide for periodof 2 weeks at a temperature of 15°C for colourintactness of the strip. Copy of Art work isenclosed at Page 3The Art work shall be printed in Englishand local language alternatively at every 1mtr distance

Mechanical Properties of Mat

Tensile Strength : Minimum 1.8 kg/cm2

Elongation at Break : Minimum 125%

Bundle Length : 0.25 mm thick warning mat shall be supplied as500 mtrs. each bundle.

Tests : Minimum following test has to be done witheach batch of warning mat

Tensile Strength test Elongation test Impact Strength test Color fastness test Heat Stability test Print Stability test






Oxidation Induction test ESCR test Melt Flow Rate test

Test Certificates : Vendor has to submit the all test certificates toPurchaser

Inspection : The manufacturer has to submit the QAP beforecommencement of production. Inspection of thematerial will be done at vendor ‘s works byClient / MECON Representative. Vendor has tosubmit all test reports before inspection call. Anytest failed during the inspection for the offeredlot ,the total lot will be rejected.

Documentation : Vendor shall submit all test reports and finalinspection reports along with the supply ofmaterials.

WARNING

OPTICAL FIBRE CABLE ALONG WITHHIGHLY INFLAMMABLE GAS PIPELINE BELOW

(CLIENT’S NAME)

BEFORE EXCAVATING OR IN EMERGENCYPLEASE CONTACT

PHONE NOs. …………………………….

CLIENT’S LOGO

Document4

ELECTRICAL & INSTRUMENTATION SECTIONMECON LIMITEDDELHI - 110 092

SPECIFICATION

FOR

INSTALLATION OF INSTRUMENTS

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

MECON LIMITEDDelhi

ELECTRICAL &INSTRUMENTATION

SECTIONDELHI

SPECIFICATIONFOR

INSTALLATION OFINSTRUMENTS

SPECIFICATION NO. : MEC/S/05/26/01 REV-0 Page 1 of 19

Document4

C O N T E N T S

1.0 SCOPE

2.0 STANDARDS OF MATERIALS

3.0 INSTALLATION OF INSTRUMENTS

4.0 TESTING

5.0 CALIBRATION OF INSTRUMENTS


MECON LIMITEDDelhi


SECTIONDELHI

SPECIFICATIONFOR



Document4

INSTALLATION, TESTING AND CALIBRATION OFINSTRUMENTATION AND CONTROL SYSTEM

1.0 SCOPE

1.1 The purpose of this specification is to define the general requirements for the installation,installation materials, testing and calibration of instruments and control system.

1.2 The work shall be carried out in accordance with the codes, standards and recommendedpractice listed in this specification and in accordance with local `Statutory regulations'.

1.3 For installation of instruments and control system, of the new material where quality is ofthe prescribed standards and which is in every way fit for its intended purpose shall beused.

1.4 Unless otherwise specified all the materials shall be indicated in this specification exceptwhere it is not compatible with fluids being handled. In such cases the selection of thematerial shall be approved by MECON.

1.5 Only the best trade practices shall be used. All the work shall be carried out in a neat,workman like manner and to the satisfaction of MECON.

2.0 STANDARDS OF MATERIALS

2.1 Instrument process piping/tubing upto and including the first block valve and `in-line'instrument equipment shall conform to the line class or vessel rating concernedinstrument piping or tubing after the first lock valve may use alternate materialsconsistent with service conditions. In general they shall conform to the followingspecification as a minimum.

2.1.1 Stainless tubes shall be fully annealed and cold drawn seam less as per ASTM A 269TP316 with size 1/2"OD x 0.65" WT (wall thickness).

2.1.2 Monel tubing shall be fully annealed seamless as per ASTM B165 with size 1/2"OD x0.35"WT.

2.1.3 Carbon steel pipe shall be 1/2" seamless and shall be as per ASTM A106 Gr B min of sch80 & dimensions as per ANSI B36.10.

2.1.4 Seamless stainless steel pipes shall be as per ASTM A 312 Gr TP 316L Sch 80S,dimensions as per ANSI B 36.19.

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SPECIFICATIONFOR



Document4

2.1.5 Instrument air supply piping from the main instrument air header shall be galvanisedheavy class pipes to IS 1239.

2.2 Individual pneumatic signal and air supply tubing shall conform to the followingspecifications.

2.2.1 Stainless tubes shall be used in general and shall be fully annealed and cold drawnseamless as per ASTM A269 TP 316 with 6mmOD x 1mmWT.

2.2.2 Copper tubing where specified shall be seamless 6mmOD x 1.0mmWT soft annealed asper ASTM 868.74a Cd No. 122 (DHP) sheathed with PVC 1.0mm thick coloured Black.

2.3 All fittings shall be as a minimum of 100 rating except for tube fittings. The fittings shallhave threading as per B2.1 and socketweld connections as per B 16.11. These shallconform to the following specifications in general.

2.3.1 Tube fittings shall be flare type compression fittings Swagelok or equilvalent make doubleferrule and pressure seat type.

All tube fittings in impulse lines shall be rated to 5000 PSIG at 38oC.

2.3.2 Carbon steel pipe fittings shall be forged as per ASTM A105 stainless steel pipe fittingsshall be as per ASTM –182 GrF 316L.

2.4 Valve shall have normally Globe body and shall be fabricated out of Bar-stock and ratedto min. of 1500. These shall be screwed bonnet type with 13% GSS trim and plug shallbe integral with the stem. Face to face dimensions shall be approx. 80mm. Endconnections shall be socketweld to ANSI 16.11 and threaded to B2.1.

2.5 Multibore tubing shall have a maximum 19 single polyethylene tubes, 6mmODx1mmnumbered for easy identification. The bundle shall be marked with inner and outer fireresistance PVC sheath. They shall carry a pair of telephone wire 0.6mm diameterflexible.

2.6 Single pair and multi pair extension cables for Thermocules shall be matched and calibrated in accordance with ISA MC 96.1. Conductor size shall be AWG for single pairand 20 A for Multipair.

The cable shall be armcured, each twisted pair shall be individually shielded withaluminium Mylar tape and a tinned copper drain wire. The wires and the cable shall becolour coded as per ISA recommended practices.

2.7 Instrument Electrical cables shall conform to the following specifications:

MECON LIMITEDDelhi


SECTIONDELHI

SPECIFICATIONFOR



Document4

2.7.1 Instrument electronic signal cables single pair/ Multipair shall have copper conductor,twisted in pair and individually shielded with Aluminium Mylar tape with drain wire. Inmultipair cables, each pair shall be armoured with inner and cut PVC sheath. Minimumconductor size shall be 1.5 mm2.

2.7.2 Control Cables for control signal, alarms actuating devices and solenoid valves of theinterlock and shutdown valves shall generally be 1.5 mm2 copper conductor, armcuredwith inner and cut PVC sheath.

2.7.3 All power supply cables shall have copper/Aluminium conductor depending upon theconductor size. The cables shall be armoured with inner and cut PVC sheath. The cablesshall be sized adequately . Minimum conductor size shall be 2.5 mm2.

2.7.4 2-core armcured cable shall be used for illuminator on level gauges.

2.7.5 The material and construction of all electrical cables shall conform to IS- 1554 part I or appropriate equivalent code and standard.

3.0 INSTALLATION OF INSTRUMENTS

3.1 Instrument Mounting

3.1.1 No instrument shall be installed in such a way that it bends for support on the impulsepiping or electrical connection on it.

3.1.2 Pressure gauges and temperature indicator shall normally be mounted directly on line. However direct on line mounting shall be avoided where vibrations are likely to bepresent.

3.1.3 Local mounted instruments shall be mounted on brackets, panels or placed on a suitablepedestal. Transmitters shall be mounted on 2” pipe supports where practical. Instruments to be mounted on steel columns, masonary structure etc. These shall not bemounted on heating equipments, pipelines and structures.

3.1.4 Blind transmitters shall be mounted at 130mm above graded platform. Local controllers, indicating transmitters and indicating instruments shall be mounted at approximately1500 mm.

3.1.5 All the instruments shall be accessible from grade, ladder or platform etc. Pressuresgauges and other local indicating instruments shall be readable from grade or operatinglevel and if used for manual control shall be visible from the related valve.

All the instruments shall be located such that they dont impede the process operation.

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SECTIONDELHI

SPECIFICATIONFOR



Document4

3.1.6 Local mounted instruments which are not available in weather proof housing shall bemounted inside a weather proof case.

3.1.7 Items such as pilot valves, solenoid valves etc. shall be located local to its point ofapplication or near to the device being actuated by them.

3.1.8 For blind transmitters output meters shall be mounted on instrument supports.

3.1.9 Filter regulators shall be mounted on the instrument supports below pneumatictransmitter or on the control valve yoke.

3.1.10 Instruments or instrument lines shall not be supported on hand rails, in general.

3.1.11 The use of process piping to support instrument lines shall be avoided as far as possible.

3.1.12 The instrument impule piping shall be kept as short as possible.

3.1.13 Instruments and impulse lines shall be protected against mechanical damage.

3.1.14 In case of capillary tube instruments, capillary tube is to be supported and protectedagainst mechanical damage.

3.1.15 Orifice meters shall not be installed on the top of orifice fittings. On horizontal linesorifice pressure taps shall be located as follows:

a) On top for air and gas serviceb) Horizontal for liquid and condensible vapour service.

3.2 Instrument Piping & Tubing.

3.2.1 Impulse Piping/tubing

3.2.1.1 The primary instrument block valves for all instruments shall be as per pipingspecifications.

3.2.1.2 3-Valve manifold in general shall be integral type.

For pressure gauges, 2-valve manifolds shall also be acceptable instead of isolationvalve, drain valve and pipe fittings.

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

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3.2.1.4 All impulse lines shall be run with a slope not less than 1 in 12 except where otherwisespecified. Direction of slope is to be downward from the process for liquid service andupward from the process for gas service.

3.2.1.5 Tubing shall be joined by compression fittings.

3.2.1.6 Piping shall be joined by pipe fittings/flanges as per the piping specifications.

3.2.1.7 All instruments pipes and tubes shall run in horizontal and vertical planes only and shallrun with minimum number of changes in direction, consistent with good engineeringpractices and neat appearance.

3.2.1.8 Tubing shall be bent with correct size tube bender as far as possible to avoid use offittings. Hot bending shall be totally avoided.

Tube cutter shall always be used to cut tubings. The use of short lengths of tubings inlong runs shall be avoided in order to avoid the fittings.

3.2.1.9 All tubing shall run in such a manner as to give the maximum protection againstmechanical damage. Tubing runs shall be grouped together and clamped.

3.2.1.10 Tubing shall be arranged so that the unions can be tightened without distorting lines.

3.2.1.11 Instrument tubing or piping shall not run on trays intended for cables and shall not sharethe same transit.

3.2.1.12 No pipe or tube shall be left with mechanical strain on them.

3.2.1.13 A mechanical ferrule seater shall be used on tubing for 140 kg/cm2 (2000 psi) or more.

3.2.1.14 Pipe bushings shall not be used.

3.2.1.15 Pipe plugs shall be fabricated out of bar stock and shall have hex-head.

3.2.2 Air/Signal Tubing

3.2.2.1 Signal Transmission tubes shall be laid on perforated trays prefabricated out of min 2.5mm. thick steel plate. The width of the tray shall be selected as per the number of tubesto be laid.

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

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

3.2.2.4 Where permanent enclosures are left with space for instrument tubing to be laid at some laterdate, a galvanised pull wire of adequate size shall be left in the tray.

3.2.2.5 Where the length of transmission tubing exceeds 60 mtrs (200ft) necessity of installingsignal booster relays shall be considered.

3.2.2.6 In case of `Skidded' equipment or vessels with instrumentation, where off- skid alarms shutdownor control functions are provided the signal tubes shall be terminated on the control bulkhead near the skid boundary.

3.2.3 All threaded pipe joints shall be joined after applying teflon tape. It should be applied ina manner to ensure that the tape does not spill over the end of the male fitting. Noother pipe joining compound shall be used except on high temperature service wheregraphite sealing compounds shall be used.

3.2.4 All reasonable precautions shall be taken to prevent foreign materials entering pipe linesor tubing before and during erection.

3.2.5 Pipes and tubes installed but not connected, shall have the ends clad in approvedfashion to prevent the entry of foreign material. For a period upto one week adhevisetape may be used, for longer periods, caps or plugs shall be used.

3.2.6 Piping/Tubing supports

3.2.6.1 Piping and tubing shall be adequately supported and fixed at a distance not exceedingthat in the following table:

Table -----------------------------------------------------------------------------------------------------Single tubing/Piping Max. distance between supports-----------------------------------------------------------------------------------------------------3/8" OD or less Continuous

1/2" to 3/4" Nom. size 2 meters (6ft.)

3/4" to 1" Nom. size 3 meters (9ft.)

Multitube bundle 3 meters (9ft.)---------- -------------------------------------------------------------------------------------------

3.2.6.2 All field mounted instrument air tubing shall be supported with galvanised steel angles or channels of minimum 1/8" thickness fabricated to present neat appearance.

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3.2.6.3 All instruments tubing supports shall be galvanised prior to installation

3.2.6.4 Trays shall be properly supported either from any rigid steel structure or concretemember. In case of non-availability of above, a suitable support shall be fabricated.

3.3 Instrument Air Supply Distribution

3.3.1 Piping material for instrument main and branched air headers upto the isolation valve ateach take-off from main or branch header shall conform to piping specification.

3.3.2 The air header size shall be established in accordance with the table below, unlessotherwise specified, for a header pressure of 4 to 8.5 kg/cm2

Table – 2-----------------------------------------------------------------------------------------------------Max number of users Nominal pipe size-----------------------------------------------------------------------------------------------------upto 5 1/2"upto 10 3/4"upto 25 1"upto 80 1-1/2"upto 150 2"upto 500 3"-----------------------------------------------------------------------------------------------------

3.2.3 All take off for branch lines are to be from the top of the main header with block valvesequal in size to the branch line. All low point shall have a 1/2" valve installed as a drainand blow down point.

3.3.4 A minimum size of ½”" pipe shall be run to the instrument with a ½” valve for eachuser. Tubing from the isolation valve to the instrument shall be 6.0 mm.

3.2.5 Union shall be provided at convenient location in the air header.

3.3.6 Filter regulator shall be provided for individual field mounted consumer and shall becomplete with an output gauge.

3.3.7 In case of skid mounted equipments or vessels which incorporate instrumentationrequiring pneumatic supply, on skid supply piping shall terminate at the skid boundarylocation and size of the supply connections shall be noted on the vendor approvaldrawings.

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3.4 Installation of multitude and Multicore cables.

3.4.1 Multicore/Multitube cables shall generally be installed on trays or ducts and properlyclamped. At bends minimum radius shall be maintained as per cable manufacturersstandards.

3.4.2 All cables shall be rigidly supported on structural steel and masonary. Drilling of steelmember should normally be avoided. However, if the drilling of steel must be resortedto, it must be drilled where minimum of weakening of structure will result cables shall besupport at every 500 mm. At every vertical drop these shall be clamped at morefrequent intervals max of 300 mm.

3.4.3 Directly buried cables shall be laid underground in excavated cable trenches. Trenchesshall have sufficient depth and width to accommodate all cables correctly spaced andarranged with a view of heat dissipation and economy of design construction of trencheslaying of cables and filling up of trenches shall be as per relevant standard.

3.4.4 Each underground cable shall be provided with identifying tag of load securely fastenedevery 30 M of its underground length with at least one tag at each end before the cableenters the ground.

Before cables are placed, the trench bottom shall be filled with a layer of sand. Thecables shall be covered with 150 mm of sand on the top of the largest dia cable tube andsand shall be lightly pressed. A protective covering of 75 mm thick second class redbricks shall be laid flat and the balance portion of the trench shall be filled with soil,compacted and levelled.

3.4.5 At each road crossing and other places where cables enter pipe sleeves, adequate bed ofsand shall be given so that the cables don’t slack and get damaged by pipe ends afterback filling.

3.4.6 At the entry into concrete blocks loops shall be provided at either end to prevent anydamage to cable.

3.4.7 The cable entry to control room shall be suitably filled and sealed after laying of cables soas to achieve a positive sealing against the entry of gas/water.

3.4.8 All wiring, tubing, cables, junctions boxes and auxiliary equivalent shall be suitablyidentified as per applicable codes and practices. All pipings and tubing shall be taggedwith slip-on or clip on wire marker at both ends.

3.4.9 Jointing of cables are generally not permitted. Cables shall be cut after the exact sitemeasurements at the cable drums shall be so selected before cutting the lengths as toavoid any unnecessary wastage.

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3.4.10 Low signal cables like alarms, analysers cables, special cables for turbine meter,thermocouple compensating cables etc. shall be layed separated from power supplycables in ducts/trenches/trays.

3.4.11 Electric signal lines for electronic transmitters to receive and to final control element shallbe continuously shielded with the shield grounded at the same point as the signal circuitgenerally at the control instrument.

3.4.12 Separate junction boxes shall be used for intrinsically sage cables.

3.4.13 Different intrinsically safe system e.g., systems having different rounds shall not be run inthe same multicore cable, in general.

Recommended minimum separation distance between twisted pair signal leads and ACPower Lines.

-----------------------------------------------------------------------------------------------------AC Power Cable Minimum Distance to

Signal Lead-----------------------------------------------------------------------------------------------------Voltage (Volts) Current (Am) in (cm)

0 to 125 0 to 10 12" (30)

125 to 250 0 to 50 15" (38)

250 to 440 0 to 200 18" (46)

5KV & Up 200 Amp. & Up24" (61)-----------------------------------------------------------------------------------------------------

Different intrinsically safe circuits e.g., circuits having different voltage levels, of the sameintrinsically safe system shall not be run in the same cable unless each conductorinsulation is at least 0.25mm or no hazard can result from interconnection.

3.4.14 The physical separation of power and signal cables shall be as per API 550 Part I SectionVII. Cable in intrinsically safe circuits shall preferably be not run in the same tray where--on intrinsically safe circuits cables are being run. If these are being run in the same tray,a metallic earthed separately shall be provided.

3.4.15 For temperature controllers, single pair thermocouple extension cable or cable forresistance thermometer, shall be layed directly from the element to the transducer in thecontrol room without intermediate terminal blocks.

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3.4.16 In case of skid mounted equipment or equipment which incorporate skid instrumentationlike alarms, shutdown or control function shall terminate signals or control junction boxnear skid boundary for connection of off skid equipment.

3.4.17 No wire shall be terminated or left with mechanical strain within any conductor.

3.4.18 Splices shall be made only at terminals, in instruments or approval equipment/ junctionboxes using lugs and screwed connections. No intermediate splices shall be made incable trays or in conduct. Number of junction boxes in any cable path shall be limited toonly one.

3.5 Installation of Zener barriers

3.5.1 Zener barriers shall be installed in the circuit to make the system intrinsically safeprovided:

a) There is no energy storage system in excess to the minimum permitted by thebarrier design on the hazardous side of the barrier. The same shall be met bytaking intrinsically safe transmitters and selecting the cable electrical parameterslike inductance L/R ratio & capacitance in accordance with the maximumparameters given in barrier specifications.

b) No power source exceeding the voltage rating of Zener barrier shall beconnected on safe side of the Zener barrier.

c) No outside power source including other intrinsically safe circuits shall beconnected to the hazardous side of the barrier.

3.5.2 Zener barriers shall be located as close as possible to the field wiring entry point in thecontrol room.

3.5.3 Single barrier are bolted directly to copper bus bar and multiple barriers on the barriermounting plates. Copper bus or barriers mounting plates shall be isolated from the panelframe.

3.5.4 The signal ground system for intrinsically safe system shall be separate from powerground system and shall be connected to the signal ground reference point. Themaximum resistance allocable between the farthest point on intrinsically safe barrierground bus and signal ground reference point shall be less than 1 ohm.

3.5.5 Field wires shall directly terminate at the barriers and not through intermediateterminals.

3.6 Installation of Analyser / Gas Chromatograph

3.6.1 Installation of all analyser shall be in general, as per APIP 550 Part II.

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3.6.2 The analyser housing at its installation shall meet all safety requirements as per --classifications.

3.6.3 Sampled process fluid, if not returned to the process shall be disposed to a safe location. Piping shall be provided so that vapors can be vented to a safe location and liquids shallbe drained in a clean and orderly fashion to a safe place. Toxic vapors shall not bevented to atmosphere.

3.6.4 Analyser shall be located as near to the sampling point as possible.

3.6.5 Analyser equipment must be protected from the following:

a) hot equipmentb) severe ambient temperature changesc) shockd) Mechanical damagee) Vibration

3.6.6 If a separate vent for the analyser is used, the location of that vent shall be in area ofminimum air Turbulence. If the vent of different analysers are vented into a commonvent, a back pressure regulator shall be used.

3.6.7 Vent piping shall be designed to prevent condensate from accumulation in low point andobstruct a free vent flow.

3.7 Ducts, Trays and Supports.

3.7.1 Main cable duct shall be of bottom open type with flat/angle --- construction with sidesheet and top cover of 3.2 mm thickness.

3.7.2 The ducts and trays shall be properly supported at regular intervals. Wherever insertplates are not available, support on concrete structure or ceiling shall be fixed with aminimum of 10 mm expansion bolts Angle supports for ducts shall be fabricated fromminimum of 40 mm angle.

3.7.3 All supports shall be neatly cut with hacksaw only and not with gas cutting. Free ends ofangle supports shall not have sharp ends and shall be properly rounded off.

3.7.4 Ducts and supports shall be painted with one coat of Red oxide Zinc chromate primerconforming to to IS-2074 after cleaning to remove scale and then painted with 2 coats offinal enamel paint as given below:

a) Duct - Dark admirately Grey as per IS0632.b) Supports - Black.

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3.8 Instrument Steam Tracing

3.8.1 Steam for Tracking of instruments shall be taken from main steam header take of valvethrough carbon steel pipes supported at regular intervals.

3.8.2 Steam tracing around individual instrument shall be by copper tube of 1/8" diameter.

3.8.3 Piping or tubing for steam tracing shall be installed in such a way as to avoid condensatepockets.

3.8.4 After steam tracing, the line is connected to drain funnel through steam trap.

3.9 Identification of Lines and Instruments

3.9.1 All site mounted instruments, junction boxes, air headers, tubing and wiring terminationsshall be labelled or tagged.

3.9.2 Instruments shall be furnished with stainless steel name tags containing Tag no.,manufacturers name, model no. serial number. This tag number shall be approximately3"x1" size and shall be attached to the instruments with -- gauge stainless steel wire.

3.9.3 Unused cable entries in junction boxes and field instruments are to be plugged.

4.0 TESTING

4.1 Instrument Impulse piping/Tubing

4.1.1 All process impulse lines shall be disconnected both from the instrument andvessel/piping end and flushed with water.

4.1.2 After thorough flushing the impulse lines shall be isolated from the instruments andpressurised hydraulically to 1.5 times the maximum working pressure corrected forambient temperature. They shall then be isolated from the pressure source and thepressure reading on a test pressure gauge shall not fall at a rate exceeding onepsig/hour.

In case no isolation valve is provided near the instrument, impulse piping/tubing shall bepressurised along with the instrument to the maximum pressure of scale in case ofpressure transmitter and max. operating pressure in case of differential pressureinstrument with equalising valve open.

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

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4.1.4 The external displacer type instruments and cage type level switches shall be tested to1.5 times the operating pressure using air/nitrogen after thorough flushing.

4.2 Instrument Air lines/signal tubing.

4.2.1 Instrument air lines/signal tubing shall not be hydrostatically tested.

4.2.2 Instrument air tubing shall be disconnected upstream of all filter regulators and blowndown to remove water, slag and mill scale, from lines at 7.0 kg/cm2 G for fifteen minutes.

Air filter shall be taken in line and tubing shall be disconnected at instrument end, andblown for 3 minutes to remove traces of dirt.

4.2.3 Testing of instrument air shall be carried out with instrument air at 7 kg/cm2G upto theupstream of the filter regulator after thorough flushing. All lines shall be checked withsoap solution and bubbler unit for possible leak at joints.

4.2.4 All signal tubing shall be checked with 1.5 kg/cm2 after proper flushing. After pressuring,source shall be cut off and rate of fall in pressure shall be less than IPSL for each 100feet of tubing for a test period of 2 minutes as per instrument society of American RP 7.1`Pneumatic Control Circuit Pressure Test'

4.3 Cables

4.3.1 All wiring shall be checked to ensure that it is correctly connected and properly grounded.

4.3.2 All cables shall be checked for continuity proper connection and insulation testing.

Insulation test shall be carried out on all wiring with a certified megger afterdisconnecting the cables at both ends.

4.4 All the results of the above mentioned testing shall be recorded and submitted for check.

4.5 All the in line instruments like orifice plates, turbine meters, Rotameters, Target meters,vortex meters, control valves, safety valves etc. shall be removed and spool pieces shallbe provided prior to the flushing of the lines.

5.0 CALIBRATION OF INSTRUMENTS

5.1 All instruments shall be calibrated strictly as per manufacturers instructions prior to theinstallation. In addition to calibration of instruments, setting of safety devices likeprocess switches, safety valves etc. and simulation testing of all interlock and shutdownsystem shall be carried out.

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5.2 In general, all tests shall simulate, as closely as possible, design process condition by theuse of manometers, potentiometers, deadweight testers, test pressure gauges etc. Pourpoint callibration shall refer to the input signal to an instrument equivalent to0,25,50,75,100% of instrument range upscale (rising) and 75,50,25,0% of instrument(downscale) (falling).

All instruments unless otherwise noted shall be calibrated in upscale and downscaledirection and if necessary, adjusted until their accuracies conform to those limits state bythe manufacturer.

Upon completion of these tests, the instruments shall be drained, completely.

5.3 Temperature Instruments

5.3.1 Temperature Gauges Filled type and Bi metallic dial type Thermometers shall be fourpoint bench checked for proper operation and calibration using a temperature bath priorto installation.

5.3.2 Temperature Elements and Temperature Transmitters.

Temperature Elements and Transmitter shall be four point bench calibrated using atemperature bath precision meter or precision gauge prior to installation.

5.4 Pressure Instruments

5.4.1 Pressure Gauges

5.4.1.1 Direct connected bourdan type pressure gauges shall be dead weight tested or testedagainst a test gauges prior to installation.

5.4.1.2 Receiver type pressure gauges shall be four point calibrated using a precision gauge andprecision air regulator.

5.4.1.3 Pressure and Differential Pressure Transmitters.Pressure and differential pressure transmitters shall be four point calibrated using ahydraulic or dead weight tester or a precision pneumatic calibrator prior to theinstallation. A precision output meter or gauge shall be used to monitor the output.

5.5.1 Orifice plates shall be checked visually for the name plate and for an upstream sharpedge. Bore dia. Shall be checked for compliance with the specification.

5.5.2 Differential pressure type of flow instruments shall be four point callibrated usingprecision pneumatic callibrator or a manometer and precision regulator. A precisionoutput meter or gauge shall be used to monitor the output of the transmitter.

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5.5.3 a) Rotameters shall be installed as received. A check shall be made to confirm thatshipping stops have been removed and float has been installed.

b) Where rotameters have transmitting mechanism, the float shall be raised andlowered mechanically and output shall be checked. Vendor calibration data/curve shall be checked.

c) A check shall be conducted with plumb for a vertical installation.

5.5.4 Turbine meters, Annubar, positive displacement meters, vortex meter, ultrasonic flowmeter, etc. shall be installed as received.

5.5.5 Target meters shall be checked for calibration using calibration weights. Output shall bemonitered using precision output meter.

5.6 Level Instruments

5.6.1 Level Gauge Glasses

Gauge glasses shall be installed as received installation of illuminators, frost protectorsand other accessories shall be checked.

5.6.2 Displacer Type, Level Transmitter

- Displacer type level transmitter shall be checked by raising and loweringmechanically the displacement and checking the pilot or transmitter action. Check transmitter with out put gauge or meter for smooth and full output change.

- A check shall be conducted with plumb for a vertical installation.

5.6.3 Differential pressure type level transmitter Defferential pressure type level transmittershall be calibrated with pneumatic calibrater at four points prior to installation. Aprecision meter or gauge shall be used to monitor the output of the transmitter.

5.6.4 Tank level gaugesa) Tank level gauges shall be checked by raising and lowering mechanically the

displacer and checking the indicator on the gauge board.b) Check for proper liquid seal prior to installation in case of liquid seal tank gauges.c) In case of servo type gauges, the displacer is hoisted from the tank into the

calibration chamber.

5.7 Control Valves, shutdown valves and self actuated valves

5.7.1 All diaphragm and piston operated control valve shall be stroked pneumatically using apressure regulator and pressure gauge against the spring range specified on the nameplate of the valve.

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5.7.2 Mechanical seating and travel of the valve stem shall be checked against the sideindicator and the name plate

5.7.3 Valve positioner shall be calibrated with the control valve in accordance with the nameplate data and specifications with the help of pneumatic calibrator or gauge withprecision regulator. Zero position or fully close position of the valve shall be a live zeroi.e., the plug shall be just off the seat at the minimum setting.

5.7.4 Volume bottles, where used shall be checked for proper filling. The signal line shall bebled to zero pressure and failure action shall be confirmed.

5.7.5 Control valve accessories such as handwheels, boosters, relays etc. shall be checkedoperationally. Declutchable handwheel shall be operable both with and without an airsignal to the diaphragm.

5.7.6 Self actuated control valves shall be installed as received, checking inlet and outlet pointsand name plate data. Regulators with external pressure connections shall be inspectedfor proper installation.

5.7.7 Butterfly shall be checked carefully to see that the vane moves freely into the upstreamand down stream piping. Proper vane movement to stroke shall be confirmed.

5.7.8 All control valves and regulators shall be removed from the line prior to flushing andduring hydrotesting.

5.8 Safety Relief Valves

5.8.1 Safety relief valves shall be installed as received after carefully checking the name platedata. Pilots, if used, shall be checked carefully for installation on the proper safety valve.

5.8.2 Valves, which are installed in such a manner as to permit on line testing, shall bepressure tested after installation to determine proper operation and setting. Compressedair or nitrogen shall be used for testing of safety relief valves.

5.9 Switches

5.9.1 Level Switches shall be actuated mechanically for switch operation but shall not becalibrated for level setting.

5.9.2 Pressure switches shall be calibrated using hydorlic or dead weight tester or precision airregulator and gauge. The setting/trip point shall be checked using a continuity tester.

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5.9.3 Temperature switches shall be calibrated using a temperature both prior to installationand set to the required alarm/ trip point using a continuity tester.

5.10 Receiver Instruments

5.10.1 Receiver Indicator/Recorders

5.10.1.1 Pneumatic indicators/ Recorders shall be calibrated using pneumatic calibrator/ precisionpressure regulator and gauge.

5.10.1.2 Electronics indicators/ Recorders shall be calibrated using a current generator and aprecision meter.

5.10.1.3 Chart drive assembly shall be checked for proper operation.

5.10.2 Controllers

5.10.2.1 Proper balancing of the controller shall be checked as per the manufacturers catalogues.

5.10.2.2 Controllers shall be checked for manual and Auto operation and Transfer. The transferfrom manual to Auto and vice versa shall be bumpless and smooth.

5.10.3.1 Manual loader station Output of the manual loader shall be checked with a precisionmeter.

5.10.4.1 Multipoint Temperature Recorders

Each point shall be calibrated using a temperature simulator/ decade box for RTD /voltage generator and precision meter for the thermocouples.

5.10.4.2 Point synchronisation shall be checked.

5.10.5 Pneumatic receiver switches shall be calibrated using precision air regulator and gauge. The setting/alarm/trip point shall be checked using continuity tester.

5.10.6 Trip Amplifiers Trip amplifiers shall be calibrated using a temperature simulators orvoltage generator and precision meter for thermocouple or Resistance box for RTDs. Therequired setting/ alarm point/ trip poing shall be checked using a continuity tester.

5.10.7 Receiver Switch module Receiver switch modules shall be calibrated using a currentsource and a precision meter. The required setting/alarm/trip point shall be checkedusing a continuity tester.

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5.10.8 Alarm and Annunciator system

5.10.8.1 Alarm and annunciator system shall be checked for visual and Audio alarm operationusing dummy signals. Full alarm sequence of each alarm point shall be checked.

5.10.8.2 Each point shall be checked for proper engraving.

5.10.9 Shutdown System

5.10.9.1 Operation of final actuating elements shall be checked for proper operation using dummysignals.

5.10.9.2 All timers, push buttons and switches shall also be checked for their proper operation.

5.11 Analytical Instruments

5.11.1 Check the full analyser system including sample handling system for leakage.

5.11.2 Check the full sample handling system for its proper operation. Calibrate and checkcompletely all analysers using zero and span samples as per vendor catalogues.

5.12 Flow computer / Volume corrector

5.12.1 Corrected flow values shall be checked for various D.C. inputs and pressure andtemperature variations for upscale and downscale ranges.

5.13 The list of test and callibration instruments with tracability certificates shall be submittedto MECON for approval before carrying out the tests / callibration of instruments at site.

5.14 The formats / description of tests / callibration of all instruments shall be submitted toMECON for approval.

5.15 Daily / weekly reports shall be submitted during execution of work at site.

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