Description
VOLUME – IIIELECTRICAL, CP & CMS SYSTEM SPUR LINES OF CHAINSA – JHAJJAR PIPE LINE 0 10.11.2008 DESIGN BASIS/JOB SPECIFICATION/ STANDARD SPECIFICATION/STANDARDS/ DRAWINGS/DATASHEET REV. DATE LIST OF ATTACHMENTS FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL & CATHODIC PROTECTION) GAIL (INDIA) LTD NEW DELHI LIST OF ATTACHMENTS FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL & CATHODIC PROTECTION) DOCUMENT 0001-01-07-11-001 REV-0 Page 1 of 6 © GAIL – All rights reserved SL NO SPECIFICATION NUMBER NO OF SHEETS REVISION DOCUMENT TITLE SCOPE OF WORK 1 2 3 0001-01-04-06-003-SW2 0001-01-04-06-003-SW5 0001-01-04-06-003-SW6 SCOPE OF WORK FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL) SCOPE OF WORK FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING PIPE SCOPE OF CORROSION MONITORING SYSTEM DESIGN BASIS 4 0001-01-07-03-001 7 0 ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM SPECIFICATIONS 5 6 7 8 9 0001-01-07-02-001 0001-01-07-02-002 0001-01-07-02-005 0001-01-07-02-006 0001-01-07-02-007 10 4 12 4 5 0 0 0 0 0 JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SCADA I-O LIST SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING PIPELINE SPECIFICATION FOR CORROSION MONITORING SYSTEM DATASHEETS 10 11 12 13 14 15 16 0001-01-07-04-BC-001 0001-01-07-04-CBL-001 0001-01-07-04-CPS-001 0001-01-07-04-CPS-002 0001-01-07-04-CPS-003 0001-01-07-04-CPS-004 0001-01-07-04-EGS-001 4 4 7 6 3 3 9 0 0 0 0 0 0 0 DATA SHEET FOR BATTERY BANKS 24V DATA SHEET FOR MV-HV CABLES DATASHEET FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET FOR IMPRESSED CURRENT CP SYSTEM DATASHEET FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT DATASHEET FOR CATHODIC PROTECTION POWER SUPPLY MODULE DATASHEET FOR EMERGENCY GENERATOR DOCUMENT 0001-01-07-11-001 REV-0 Page 2 of 6 GAIL (INDIA) LTD NEW DELHI LIST OF ATTACHMENTS FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL & CATHODIC PROTECTION) © GAIL – All rights reserved SL NO 17 18 19 20 21 SPECIFICATION NUMBER 0001-01-07-04-FAS-001 0001-01-07-04-LF-001 0001-01-07-04-SB-001 0001-01-07-04-SPS-001 0001-01-07-04-UPS-001 0001-01-07-01-001 NO OF SHEETS 6 8 8 5 7 1 REVISION 0 0 0 0 0 0 DOCUMENT TITLE DATASHEET FOR FIRE ALARM SYSTEM DATASHEET FOR LIGHTING FIXTURES DATA SHEET FOR AC- DC SWITCHBOARD DATASHEET FOR SOLAR ELECTRIC POWER SYSTEM DATA SHEETFOR UPS SYSTEM SINGLE LINE DIAGRAM FOR CGS LOAD ANALYSIS 22 0001-01-07-08-001 3 0 LOAD ANALYSIS STANDARD SPECIFICATIONS 23 24 25 26 27 28 29 30 31 32 33 34 S-07-02-001 S-07-02-002 S-07-02-003 S-07-02-004 S-07-02-005 S-07-02-006 S-07-02-007 S-07-02-008 S-07-02-009 S-07-02-010 S-07-02-011 S-07-02-012 11 8 17 8 8 13 15 9 7 20 21 26 0 0 0 0 0 0 0 0 0 0 0 0 SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION FOR DC-DC CONVERTER SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION FOR INSPECTION FIELD TESTING AND COMMISSIONING OF ELECTRICAL EQUIPMENT SPECIFICATIONS FOR EARTHING INSTALLATION SPECIFICATIONS FOR CABLE INSTALLATION SPECIFICATIONS FOR LIGHTING INSTALLATION SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATION FOR CORROSION SURVEY SPECIFICATION FOR EQUIPMENT MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM DOCUMENT 0001-01-07-11-001 REV-0 Page 3 of 6 GAIL (INDIA) LTD NEW DELHI LIST OF ATTACHMENTS FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL & CATHODIC PROTECTION) © GAIL – All rights reserved SL NO 35 36 37 38 39 40 41 42 43 44 SPECIFICATION NUMBER S-07-02-013 S-07-02-014 S-07-02-015 S-07-02-016 S-07-02-018 S-07-02-019 S-07-02-020 S-07-02-021 S-07-02-022 S-07-02-024 NO OF SHEETS 17 9 11 7 25 19 16 16 8 32 REVISION 0 0 0 0 0 0 0 0 0 0 DOCUMENT TITLE SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION FOR FLAMEPROOF LIGHTING AND POWER PANELS SPECIFICATION FOR MEDIUM AND HIGH VOLTAGE CABLES AND ACCESSORIES SPECIFICATION FOR STATIONARY NICKEL CADMIUM BATTERIES SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY UNIT SPECIFICATION FOR BATTERY CHARGER SPECIFICATIONS FOR CPPSM SPECIFICATIONS FOR MEDIUM VOLTAGE MOTORS INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM INSPECTION TEST PLAN 45 46 47 S-07-06-001 S-07-06-002 S-07-06-003 3 3 4 0 0 0 INSPECTION TEST PLAN FOR BATTERY CHARGER INSPECTION AND TEST PLAN FOR MV-HV CABLES INSPECTION AND TEST PLAN FOR FIRE ALARM SYSTEM STANDARD DRAWINGS 48 49 50 51 52 S-07-01-004 S-07-01-005 S-07-01-006 S-07-01-007 S-07-01-008 1 1 1 1 1 0 0 0 0 0 TYPICAL EARTH ELECTRODE FOR EARTHING SYSTEM TYPICAL EARTH ELECTRODE IN TEST PIT TYPICAL EARTH PLATE FIXING DETAILS TYPICAL EARTH CONNECTION FOR STREET LIGHTING POLE TYPICAL EARTHING ARRANGEMENT FOR PROCESS EQUIPMENT GAIL (INDIA) LTD NEW DELHI LIST OF ATTACHMENTS FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL & CATHODIC PROTECTION) DOCUMENT 0001-01-07-11-001 REV-0 Page 4 of 6 © GAIL – All rights reserved SL NO 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 SPECIFICATION NUMBER S-07-01-009 S-07-01-010 S-07-01-011 S-07-01-012 S-07-01-013 S-07-01-014 S-07-01-014A S-07-01-014B S-07-01-014C S-07-01-015 S-07-01-016 S-07-01-017 S-07-01-018 S-07-01-019 S-07-01-020 S-07-01-021 S-07-01-022 S-07-01-023 S-07-01-024 S-07-01-025 NO OF SHEETS 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 2 1 2 1 REVISION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DOCUMENT TITLE EARTHING/ BONDING OF PIPES AND PIPE RACKS FENCE AND GATE EARTHING (TRANSFORMER YARD) EQUIPMENT EARTHING SCHEDULE TYPICAL DETAILS OF DIRECTLY BURIED EARTH ELECTRODE TYPICAL INSTALLATION OF LIGHTING FIXTURE AT GROUND LEVEL TYPICAL OPEN AREA STREET LIGHT OR FLOOD LIGHT FIXTURE MOUNTED ON WALL/COLUMN TYPICAL OPEN AREA STREET LIGHT OR FLOOD LIGHT MOUNTED ON POLE TYPICAL OPEN AREA STREET LIGHT LIGHT FIXTURE MOUNTED ON POLE TYPICAL MARSHALLING BOX DETAILS FOR LIGHTING POLE POST TOP LANTERN INSTALLED ON GATE TYPICAL INSTALLATION OF FLUORESCENT FIXTURE MOUNTING IN EXPOSED WIRING SYSTEM TYPICAL INSTALLATION OF RECESSED MOUNTED FLUORESCENT FIXTURE TYPICAL INSTALLATION OF RECESSED MOUNTED OR BELOW FALSE CEILING MOUNTED FLUORESCENT FIXTURE TYPICAL INSTALLATION DETAILS OF LIGHTING FIXTURE MOUNTING IN CONCEALED CONDUIT SYSTEM TYPICAL INSTALLATION OF LIGHTING/ POWER PANEL FLUSH MOUNTED TYPICAL INSTALLATION OF MESTEC CHANNEL SAFETY MEASURES FOR ELECTRICAL INSTALLATIONS DURING CONSTRUCTION TYPICAL INSTALLATION DETAILS OF ELECTRICAL PANELS ON FALSE FLOORING TYPICAL INSTALLATION DETAILS OF ELECTRICAL PANELS ON CABLE TRENCH PREPACKED ZINC ANODE DOCUMENT 0001-01-07-11-001 REV-0 Page 5 of 6 GAIL (INDIA) LTD NEW DELHI LIST OF ATTACHMENTS FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL & CATHODIC PROTECTION) © GAIL – All rights reserved SL NO 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 SPECIFICATION NUMBER S-07-01-026 S-07-01-027 S-07-01-028 S-07-01-029 S-07-01-030 S-07-01-031 S-07-01-032 S-07-01-033 S-07-01-034 S-07-01-035 S-07-01-036 S-07-01-037 S-07-01-038 S-07-01-039 S-07-01-040 0001-01-07-01-001 NO OF SHEETS 1 1 1 4 1 1 1 1 1 1 1 14 1 3 REVISION 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 DOCUMENT TITLE PREPACKED MAGNESIUM ANODE MAGNESIUM RIBBON ANODE TEST STATION WITH FOUNDATION DETAILS TEST STATION CONNECTION SCHEMES GALVANIC ANODE INSTALLATION ZINC RIBBON ANODE FOR CASED CROSSINGS WITH COATED/ PAINTED CASING PIPELINE GROUNDING THROUGH POLARISATION CELL AND GALVANIC ANODE. TYPICAL CONSTRUCTION DETAILS OF HIGH SILICON CAST IRON ANODE PERMANENT COPPER-COPPER SULPHATE REFERENCE CELL AND INSTALLATION DETAILS SHALLOW ANODE GROUND BED (PCP) ANODE LEAD JUNCTION BOX NOTES, LEGEND AND DETAILS FOR AREA CLASSIFICATION (ONSHORE OIL/ GAS INSTALLATIONS) MARKING OF TRENCHES FOR ELECTRIC CABLES DETAILS OF HOT DIP GALVANIZED LADDER TYPE CABLE TRAY INSTALLATION DETAILS FOR DOUBLE POLE TERMINATING STRUCTURE UPTO 33 KV SINGLE LINE DIAGRAM FOR CGS 1 0 GAIL (INDIA) LTD NEW DELHI LIST OF ATTACHMENTS FOR PIPELINE LAYING AND ASSOCIATED WORKS (ELECTRICAL & CATHODIC PROTECTION) DOCUMENT 0001-01-07-11-001 REV-0 Page 6 of 6 © GAIL – All rights reserved ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM SPUR LINES OF CHAINSA - JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM STANDARD 0001-01-07-03-001 REV-0 Page 1 of 7 © GAIL – All rights reserved CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. SITE CONDITIONS POWER SOURCE DETAILS SYSTEM VOLTAGES CONTROL BUILDING DESIGN EQUIPMENT DESIGN MONITORING AND CONTROL SIGNAL THROUGH SCADA CABLING SYSTEM EARTHING SYSTEM LIGHTING AND VENTILATION SYSTEM ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS STATUTORY APPROVALS CP SYSTEM GAIL (INDIA) LTD NEW DELHI ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM STANDARD 0001-01-07-03-001 REV-0 Page 2 of 7 © GAIL – All rights reserved This electrical design data defines the design requirements applicable for this project in addition to the Specification for Sacrificial Anode Cathodic Protection System S-0702-011, Specification For Impressed Current Cathodic Protection System S-07-02-012. (Data marked ‘* ’shall be furnished/ confirmed by client). Site Conditions A Equipment design temperature 40oC B. Soil Resistivity As per Soil Analysis report C. Min. temp. for battery sizing 5oC D. Altitude above mean sea level Less than 1000M Dry, dust storms in summer, humid / E. Weather heavy rain fall during monsoon Power Source Details: At Manned Terminals: Power generation by 24V DC Solar Panels 1 nos.415V, 50Hz,TPN AC supply from All CGS local grid to be arranged by the contractor Battery back-up of 72 hours 3. Utilisation voltage & Operating philosophy 3.1 Telecom For all stations one 24 V DC feeder SCADA to be provided. All DC-DC converters to meet the equipment requirements shall be in the scope 3.2 Instrumentation of the equipment vendor For all stations 240 V AC from Grid 3.3 Electrical System Power Supply For all stations one 24 V DC feeder to 3.4 CP system be provided. At CGS control room / telecom / SCADA room 240V,1-Ph AC grid power 3.5 Air Conditioning supply. At all locations 240 V AC grid power 3.6 Lighting/ventilation supply For all stations 24 V DC. Feeder to be 3.7 Fire detection & fire protection system provided 3.8Number/configuration of DC to DC converters for - Instrumentation power supply Not required CP power supply Single (shall be part of CPPSM) In the scope of Telecom Equipment Telecom power supply -48 V DC Vendor SCADA Power Supply 24 V DC Not required 4 Control Building Design 4.1 Building floor Level raised by Internal No (use of porta-cabins is envisaged) trenches GAIL (INDIA) LTD NEW DELHI ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM STANDARD 0001-01-07-03-001 REV-0 Page 3 of 7 © GAIL – All rights reserved Solar Array Out door 4.4 DC to DC converters 5. Battery type/back up time 72 hours backup time Entire battery capacity shall be split into two banks of 50% capacity nos. Single front 5.5 CO2 Flooding System Control & Battery Room 5 Equipment Design 5. C. it is proposed that the same shall be done through the battery charger which is fed from grid supply.Out put voltage As required .4 Fire alarm and detection system Required at all locations Required for Electrical. Single front(If applicable) -Outgoing Switch fuse feeders Fixed.2 Specific Equipment Locations A.Out put voltage Not applicable . SCADA & 4.1 Instrumentation power supply Not required . with only front access and maintenance only.Type Not applicable .1 Back up Battery Battery type shall be Nickel-cadmium with A. Battery charger (for boost charging) Electrical Room (Note:.Number/configuration Not applicable 5.For EQUALISING CHARGE/BOOST CHARGE to batteries (whenever required) at stations.3 Air Conditioning A. Shall be part of CPPSM . Battery execution Unmanned SV/IP station and manned station 5. For Telecom /SCADA Required /Instrument /Control room B.2 CP power supply : .Type Galvanically isolated between input and output.3.2 Lighting Panel Wall mounted 5. Batteries Separate room B. at each B.4.4.Number/ configuration To be decided by CP system design GAIL (INDIA) LTD NEW DELHI ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM STANDARD 0001-01-07-03-001 REV-0 Page 4 of 7 © GAIL – All rights reserved . Telecom. -Outgoing motor feeders Fixed.4. Single front -Outgoing MCB feeders Fixed.3 Back-up battery 5. For electrical room Not required 4. Single front without rear -Incomer panel : access.1 MV Switchboard/ Battery Charger/ DCDB MV Switchboard/DC Switchboard:Load break Switch/MCCB/switch-fuse contactor Fixed. Inside Buildings Cable trays / conduits Galvanized prefabricated / Site fabricated D. 5. Lighting cum Power Panel control MCCB/MCB GAIL (INDIA) LTD NEW DELHI ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM STANDARD 0001-01-07-03-001 REV-0 Page 5 of 7 © GAIL – All rights reserved . Main earthloop material GI strip D..6 Cables for Electrical System 5.6.2 Lighting . Outdoor (for stations with electric grid Manual power only) Manual B. Unpaved area RCC trench / Directly buried C. armored.1 Lighting Control Philosophy Manual A.1 Cable laying philosophy A.0 Cabling System 7.6. B. Building((for stations with electric grid power only: control building and Guard room) C.Out put voltage .5 Inverter 5.5 mm² (Copper) c) Lighting 2. Control building earth loop GI 9.0 Monitoring and control signal through SCADA Digital and analogue monitoring and control signals as required for Solar Panel power source.5. Earth electrode GI Pipe/plate C. Paved area Cable tray / RCC trench B.1 Type Not Not Not Not Not Not required applicable applicable required applicable applicable PVC insulated armoured.0 Lighting and Ventilation System 9. PVC sheathed for MV cable and XLPE insulated.Number/configuration 5. PVC sheathed for HV cable Copper up to 16 sq mm and Aluminium 5.0 Earthing System 4 separate systems (one each for Electrical general & safety earth.5.2 Conductor material for 35 sq mm and above.5 mm² (Copper) d) Number of cores for MOV cables NA 6. A. Number of earthing system Instruments + Scada / Telecom systems and lightening protection).Number/configuration 5.6. fire detection and alarm system shall be provided 7.Out put voltage .1 For Air conditioners .3 Minimum size of cable for power and control cables a) Medium voltage power cable 2. Type of cable trays And painted 8. CP system.5.5 mm² (Copper) b) Control cables 2. 7.2 of spec. Power Panels Yes for AC 9. C. Electrical room AC exhaust fan.4 of (ER F.2 Wiring Type A. ELCB at Incomer of AC Lighting cum Yes for DC. Battery room DC exhaust fan DC exhaust fan activated by thermostat B. 10. S-07-02-011 E. Type Sacrificial magnesium anode 1 Year or till commissioning of PCP B. Size of exposed area of coupon 100mm x 100mm To be decided by CP contractor based on b.1 Temporary cathodic protection Required A. Anode material (for sacrificial CP Zinc/ low potential (1. No. No. SG.7.0 Electrical Equipment for Hazardous Areas All the electrical equipment for Gas Group IIA/ IIB hazardous areas shall be of Ex-d type suitable for temp classification T3. 5.2 of spec.0 CP System 12. Buildings trays 9. SCADA/Telecom room with powered louver for exhaust fan and air inlet. S-07-02-011 c. Electrical resistance probes Probes) spec.7.0 Statutory Approval Statutory Authority for Electrical : Central Electrical Inspectorate/State Installation electrical inspectorate.3 Ventilation A. of E/R probe reading instrument One Shall be provided as per Cl. Out door Armoured cable Concealed / Surface conduits or cable B. 12. of magnet devices for operation By CP contractor of magnetic reed switch H. Polarisation coupons 07-02-011 a. Pipeline coating Three Layer Polyethylene D.5.1 of spec. Additional tests to evaluate the Shall not be conducted coating defects K. No.element D. of coupons Cl. 11.4.55 V ) Magnesium System) Shall be provided as per Cl. Protective current density As per Cl. Quantity of E/R probes Contractor based on Cl.7. S-07-02-011 1 no.1. S-0702-011 b. CPL survey Shall not be conducted during TCP GAIL (INDIA) LTD NEW DELHI ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM STANDARD 0001-01-07-03-001 REV-0 Page 6 of 7 © GAIL – All rights reserved .(iii) of spec.5.. however location to be decided by CP a. Polarisation cell Electrolytic type I. Design life whichever is later C. No. Proposed location of CP stations/ Anode Ground bed (For impressed As per Pipeline Schematic drg. Coupons GAIL (INDIA) LTD NEW DELHI ELECTRICAL DESIGN BASIS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL SYSTEM STANDARD 0001-01-07-03-001 REV-0 Page 7 of 7 © GAIL – All rights reserved . Design life of protection 35 Years C.5.7. c. of computerised test station One station readers/ portable data reader collection & storage instruments.1. Electrical resistance probes 07-02-012 (Also refer Cl.12. S-07-02-012 E. SG. S07-02-012 (Also Refer Cl. Current drainage survey Shall be carried out High silicon iron / mixed metal oxide F.2 Permanent Cathodic Protection System A. S-07-02-012 b.G above) J Polarisation cell Electrolytic type K. Chain link fencing around the ground Shall be provided bed: M. anode junction boxes and anode By Contractor ground bed cable laying L. Interval for data acquisition/ storing Once every day I Polarisation coupons Shall be provided as per Cl. Acquisition of land for anode ground bed. Type Impressed current type B. Design protection current density As per Cl.1F above) Shall be provided as per Cl. however exact locations to be a. Pipeline coating Three Layer Polyethylene D.1.7. Type of Anodes for anode ground bed titanium/ Zinc/Magnesium Shall be provided as per Cl.13 of spec.8 of spec.7.13 of spec.12. SH. of computerized test stations decided by CP sub contractor based on Cl. Proposed location of E/R probes To be decided by CP contractor during Computerised test stations/ Polarisation detail engineering based on specifications and in consultation with the GAIL.(iii) of spec.12 of spec. Current Cathodic protection system) P. No.. Computerised test stations 07-02-012 1 nos.7.12. Additional tests to be conducted for :Pearson survey /DCVG survey identifying pipe coating defects/holidays O. Close interval potential logging Shall be carried out survey: N. JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPUR LINES OF CHAINSA .JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) STANDARD 0001-01-07-02-001 REV-0 Page 1 of 10 © GAIL – All rights reserved . INSPECTION. 2. GENERAL AREA CLASSIFICATION DESCRIPTION OF REQUIREMENTS FOR CATHODIC PROTECTION AND ELECTRICAL WORKS 4.CONTENTS 1. TESTING AND COMMISSIONING DRAWINGS AND DOCUMENTS ANNEXURE-1: MAKE OF ELECTRICAL EQUIPMENT/COMPONENTS GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) STANDARD 0001-01-07-02-001 REV-0 Page 2 of 10 © GAIL – All rights reserved . 5. 3. lightning protection system and fire alarm system. testing and commissioning of the electrical works.0 1. earthing. lighting. standard specifications. 1. installation. at various locations along the SPUR LINES OF CHAINSA . In case of any conflict. design basis.1 GENERAL Introduction 1. standard drawings and National/International codes & standards. cabling layout. in conformity with these specifications. earthing and lightning protection layouts.5 The contract shall include clearing of temporary constructions. GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) STANDARD 0001-01-07-02-001 REV-0 Page 3 of 10 © GAIL – All rights reserved . taking statutory approvals and energizing the system.3 The Electrical works at each station/Terminal and all works related to temporary and permanent cathodic protection system for the pipeline shall be executed by contractor in line with scope document.1. approved drawings/ construction drawings and the instructions of the or Engineer-in-Charge from time to time.2. Fire alarm system layout.1. etc. In case of conflict between various documents.1.1.1. erection.2 The electrical portion for pipeline laying work as covered in this specification includes design. power supply system. 1. testing and commissioning of the power system as per the single line diagrams (SLDs) and description given in this document and other associated documents enclosed with this tender. supply. lighting layout.1 The intent of this specification is to define the requirements for Design. cabling. 1.JAHJJAR PIPELINE and associated installations.4 The work shall be carried out to the best workmanship like manner.2 Standards 1. waste materials and loose earth. cable schedule. supply.1. job specification.1 The work shall be performed in conformity with these specifications and code of practices of the Bureau of Indian Standards. data sheets. interconnection diagrams. etc. for each station/Terminal along the route of the pipeline. the stipulations under these specifications shall govern. viz. which might get collected in and nearby the work site during execution of work and after final completion. The contractor shall also prepare electrical layout drawings for equipment layout. following shall be order of priority:Scope document Design Basis & Single Line Diagrams Data sheets standard specifications/standard drawings Codes and standards 1. 1. engineering. (c) The regulations laid down by Electrical Inspectorate (CEA). Gas Group IIA/IIB and Temp. 2. equipments or fittings supplied by the contractor that may be discovered at the time of issue of the completion certificate. based on area classification as per IS 5572.3 Guarantee The contractor shall guarantee the installation for satisfactory operation against any defects of workmanship and materials (supplied by the contractor) for a period as specified elsewhere. class T3. shall be flameproof type. (e) The regulations laid down by the Chief Controller of Explosives.no.1.0 AREA CLASSIFICATION Electrical/Control room building at all stations shall be located in safe area.4 Site Condition The equipment offered and the installation shall be suitable for continuous operation under the site conditions mentioned in design basis doc. (d)The regulations laid down by the Factory Inspector.2 In addition.no. 1. (b)The fire insurance Regulations.5 Utilisation Voltage The utilization voltages shall be as per design basis doc. Any other regulations laid down by the Central.2. GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) STANDARD 0001-01-07-02-001 REV-0 Page 4 of 10 © GAIL – All rights reserved . 0001-01-07-03001. Indian Petroleum Rules and as shown in the respective equipment specification/ particular specification. All the electrical equipment to be located in hazardous area Zone 1 or Zone 2. or arise or come to light thereafter. Any damage or defect connected with the erection of materials. (f) The regulations laid down by Oil Industries Safety Directorate (OISD). State or Local Authorities from time to time during the execution of this contract. the work shall also conform to the requirements of the following: (a) The Indian Electricity Act and rules framed there under. 1. shall be rectified or replaced by the contractor at his own expense as deemed necessary and as per the instruction of owner or Engineer-in-Charge within the time limit specified by the owner or Engineer-inCharge. 0001-01-07-03-001. 1. 6 3. Separate Earth pits for Lightning conductor/arrestor.9 © GAIL – All rights reserved .’ ELECTRICAL WORKS Electrical works including design.3. fence and steel cage over MOV etc. FA panel.4 3.g Instrumentation cables/ Optical cable.0 3. DC lighting (in Telecom room. 3. Power Supply and Control supply is required to be provided as per OISD Guidelines. testing and commissioning of all electrical items shall be provided.2 3. All SVs installed on cathodically protected pipeline shall be earthed using 2 number of zinc anodes (20KG net weight). earth strip shall be bolted with electrode using minimum two bolts as per the requirements of OISD.. supply. The power supply shall be met from Solar system at 24V DC (Floating) output. data sheets and specifications attached elsewhere in this tender. 0001-01-07-03-001. The electrical power distribution to various electrical consumers at 24V DC shall be done from 24V DC switchboard.3 At all earth test pits. 24V DC power distribution as required for SCADA. Temporary cathodic protection(TCP) works to be done immediately upon lowering of pipeline. at each station shall also be in the scope of contractor. For Telecom a separate dedicated earth of 1 ohm to be provided by contractor. installation.5 3.1 REQUIREMENTS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL WORKS CATHODIC PROTECTION SYSTEM:The requirements of cathodic protection system have been specified in Design basis document no. Pipeline contractor shall install earth strips and terminate the earth cables to the respective Instrumentation/SCADA/Telecom equipment cabinet (both GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) STANDARD 0001-01-07-02-001 REV-0 Page 5 of 10 3. connected to electrical safety earth.7 3. Rat repellant electrical system is to be provided in all stations to avoid damage to the cables and cabling into the marshalling units/electrical equipment. Necessary DC-DC converters required for feeding telecom equipment shall be provided as part of DC switchboard. Instrument IS and Non IS.8 3. Cables (e. Earthing of main gate. electrical room). etc) coming from field shall also be terminated on this earth Signal/system earth : For Instrumentation and SCADA one dedicated earth of 1 ohm to be provided by contractor. Safety Earth (Instrumentation cabinet earth): The same shall be common earth for Instrumentation/SCADA/Telecom. TESTING AND COMMISSIONING All the equipment shall be tested and commissioned as per contract requirements. The contractor shall arrange all testing equipment necessary to carry out the tests. test value. Minimum 6 sets of drawings/ documents of the vendor-supplied equipment shall be submitted within 4 weeks of order placement. cables.1 5. A complete set of reproducible drawings for contractor-supplied equipment shall be furnished to the owner/GAIL for records. Drawings and data of Solar system power source.3 5. 24V DC Switchboards.system & safety) & cables coming from field for instrumentation/Telecom. All test certificates and the contractor shall submit field test reports after completion of work in bound volumes (6 sets).0 5. cable schedules and interconnections shall be submitted by the contractor on the hard copies as well as in soft copy usable on a WINDOWS .5 5. Storage and maintenance instructions along with necessary handling precautions shall be furnished by the contractor for equipment supplied in this tender. All tests shall be conducted in the presence of the owner/ Engineer-in-charge or his authorised representative unless he waives this requirement in writing. Final set shall be submitted in folders and shall be stamped as final drawing along with the copy of the GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) STANDARD 0001-01-07-02-001 REV-0 Page 6 of 10 4. INSPECTION. lighting fixtures.2 5. specifications. or codes shall be rejected forthwith and the contractor shall carry out modifications at his own cost. CP system shall be submitted for review by owner. Any work not conforming to the execution drawings. date of testing. Vendor catalogues and literature shall be supplied for all equipment included in the scope of Contractor. 3.10 4. The tests shall be recorded on approved Performa and certified records of the tests shall be submitted to the owner/ Engineer-in-charge.3 4.2 A display board of suitable size to be provided adjacent to all earth pit so as to display earth pit number. DRAWINGS AND DOCUMENTS Contractor shall submit all datasheets/ drawings and documents to the owner/ Engineer-in-charge.4 5.1 4.6 © GAIL – All rights reserved .4 5. As-built layouts. next due date etc. Ni-Cd batteries.0 4. prior approval from owner shall be obtained before placement of order. 5. drawing number. equipment number and revision number are marked on each drawing. vendor shall ensure that job number. see Annexure-I. For makes of items not covered therein.necessary test/ inspection certificates. GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) STANDARD 0001-01-07-02-001 REV-0 Page 7 of 10 © GAIL – All rights reserved . title.7 For list of acceptable makes of electrical equipment. Before submitting the drawings. Ltd./ Universal Cables Ltd.Engineers & Controls Pvt.Ltd. Ltd. & Chemical Products Ltd. Ltd./Havell’s India Pvt.Ltd. / Schneider Electric/ Control & Swgr./ Nicco 13OD) Corp.Amco Power Systems Ltd./ Reliance Engineers Ltd. (Item CMI Ltd. Solar System Central Electronics GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) STANDARD 0001-01-07-02-001 REV-0 Page 8 of 10 © GAIL – All rights reserved .ANNEXURE-1 1./ Mather & Fire Alarm system(Item code./ Cables-Medium Voltage-Power -PVC Nicco Corp./Cords Cable Cathodic Control Co./ Heat Shrunk technologies./ KEI Ind./ Electro Anodes for CP system (Item CodeProtection Services India (P) Ltd. Ltd.13BB) Ltd./ Cables-Control-PVC (Item CodeIndustrial Cables(I) Ltd./ KEI/ Elkay Code-13OE).Ltd. Cables-Fire alarm and comm./ Evershine Electricals/ Elkay Telelinks (P) Ltd.K./ Finolex Cables Ltd. Ltd./ Delton Cables Ltd. Bombay/ Cords Cable Ind./ Goyolene Fibres (India) Pvt./ North Eastern Cables Pvt./ Universal Cables Ltd./ Paramount Communications Ltd./ Gemscab Ind. Telelinks/ Reliance Engineers Ltd. Associated Flexibles & Wires (P) Ltd./Brooks Cable Works./ (Item Code-13OC) Radiant Cables Pvt./ Torrent Cables Ltd.Ltd.13TA) Platt Pumps Ltd./ KEI Ind./Ravin Cables Ltd./ 13EA) Scientific Metal Engineers (P) Ltd New Fire Engineers/ Honeywell Inc./ Torrent Cables Ltd./ Control & MV Switchboards (Fixed type) (Item Schematics/M. Pvt./ Polycab Wires Pvt./Bhartia Industries Ltd./ Delton Cables Ltd./ Honeywell Automation India Ltd. Ltd. Ltd. Code.Ltd./ Cable termination & Jointing Kit (Item Raychem RPG Limited/ Yamuna Gases & code-14CB) Chemical Ltd.Ltd./ Radiant Cables Pvt./ Havell’s India Pvt./HBL Nife Power 13HD) systems Ltd./CMI Ltd. Ltd. Ltd/RPG Cables ltd Associated Flexibles & Wires (P) Ltd./ CCI/ Finolex Cables Ltd./ Gemscab Ind. (FormerlyVijay Fire)/ Edward International Mahindra Engg. Nickel-Cadmium batteries (Item code./ Ravin Corporation Ltd./ PSL Ltd.Ltd./Industrial Cables(I) Ltd./ Suyog Electricals Ltd./ Polycab Wires Pvt.Ltd.1 Following is the list of approved makes for electrical equipment:- Siemens/ L&T/ GE India Industrial Pvt./ Kidde India Ltd. Pvt./L&T Areva T&D India Ltd.2 Following is the list of approved makes for electrical components:- Lighting Fixtures for non Bajaj/Crompton/Philips/Havell’s Ind Pvt. Ltd. Datar Switchgear/ Havell’s India/ Indo Asian fuse gear/ Indiana Current Control/ Standard Electricals/ Legrand India Pvt./Schneider Electric India Pvt./ Precifine Product Pvt./ L&T/ Siemens/ Electronic Automation Automatic Electric/ Meco Instruments/ Rishab Instruments/ Nippen Electricals Instruments Co. Ltd. Ltd.1. GE India Industrial Pvt.& Controls/ Kaycee/ Areva T&D India Ltd./ Controls & Switchgears Contactors./ ABB STANDARD 0001-01-07-02-001 REV-0 Page 9 of 10 Cable glands for Hazardous area. Ltd. Ltd. Ltd / Indo Asian fuse gear/Cooper Bussman (I) Pvt./ Areva T&D India Ltd./ Hot Line Switchgears & Controls./ Shri Tulsi Switchgears/ Controls & Switchgears Contactors Ltd. Ltd. Ltd. (T&D Group)/Siemens ltd./ Schneider Electric/ Bhartia Ind. Pvt. Ltd/Standard Metal Industries. (Type : Energy meters) L&T/ Siemens/ Tecknic Controls/ Bhartia Ind./ L&T/ Schneider Electric L&T/ Siemens/ GE India Industrial Pvt. Baliga/ Comet Brass Products/ Comet Industries/ Flexpro/ Flameproof Equipment / FCG Power/ FCG Flameproof Control Gears Pvt Ltd. Hazardous area (Item Code-14LB) Ltd. (T&D Group)/Jyoti ltd. Works/ Sudhir Swgrs./ABB (Bangalore) L&T/ Siemens/ Switron Devices/ Hot Line Swgrs. Ltd. Bhartia Ind. ABB (Baroda) /Easun Reyrolle/ Areva T&D India Ltd. Protection relays (Electromechanical type) Auxiliary Relays Control switches/Selector Switches MCBs MCCBs Fuses Timers Meters Push Buttons/Indicating lamps Contactors GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) © GAIL – All rights reserved ./Schneider Electricals India Pvt. Ltd./Schneider Elect./ Prompt Engg. / Reliable Electronic components Pvt.ltd. (For LED type Indicating lamp only)/Essen Deinki L&T/ Siemens/ GE India Industrial Pvt. Contractor may procure material from any of Owner approved vendor/subvendors. if required may be supplied after owner approval. USA Kirk.Fuse switch combination (Bangalore) L&T/Siemens/ Bhartia Ind./Havell’s India Pvt./ Standard Electrical Ltd. Germany/OBO Bettermann. The alternate make of components will be evaluated post order./Control & Swgrs.0 3. ABB (Bangalore)/ Control & Switchgear/ Indo Asian Fuse Gear/ L&T/ Siemens/ Schneider Electric. based on the satisfactory track record and test certificates to be furnished by the contractor.0 GAIL (INDIA) LTD NEW DELHI JOB SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) STANDARD 0001-01-07-02-001 REV-0 Page 10 of 10 © GAIL – All rights reserved . Ltd.0 Make of other equipment/components not mentioned above shall be subject to prior approval of Owner. components shall be strictly as per above vendor list. Ltd.2 Following is the list of preferred makes equipment /material for CP system:Dehn+Sohne. Contractor can offer component of makes other than specified in the tender. during order execution./ Schneider Electric/ ABB (Bangalore)/GE India Ind. Germany Platt Line/Corpro Borin. Ltd. In case alternate makes are not found acceptable. /GE India Pvt. In case of non-availability of equipment/material from above vendors. L&T/ Siemens/ Schneider Electric/ Control & Switchgear/ Indo Asian Fuse Gear Datar Switchgear/ Indo Asian Fuse Gear/ Legrand India Pvt.0 2./ Schneider lectric Heavy duty switches Earth leakage circuit breaker (ELCB) 1. alternate makes. Contactors Ltd. USA Rose corrosion. Pvt./ Havells India Pvt. 4. USA/Caproco Surge Diverters (Explosion Proof) Zinc ribbon anode Permanent reference cell Polarisation Cell E/R probes & reading meter Notes:1. Ltd. Ltd. JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI SCADA I/O LIST FOR ELECTRICAL PARAMETERS STANDARD 0001-01-07-01-002 REV-0 Page 1 of 4 Copyright GAIL – All rights reserved .SCADA I/O LIST FOR ELECTRICAL PARAMETERS SPUR LINES OF CHAINSA . SS-ST SS-STP SS-RST SAC-A1 SAC-A2 * (AS PER NO. No.-DIS BDD-B1 BTT-V SY-LC SP-F SC-F AF-F SCC-F1 DCDB-V GRID-ON FA FA-ELECT-RM FA-TEL-RM FA-F CO2-PRL AC ON CO2-LKG VENT-ON TEL-RMTEMP RELRM-T As per vendor recommend ation 4 SOLAR ARRAY CURRENT mA* BATTERY CHARGING CURRENT BATTERY DISCONNECTED BATTERY DEEP DISCHARGE BATTERY VOLTAGE LOAD CURRENT SOLAR PANEL FAULT SOLAR CONTROLLER FAULT ARRAY FAULT SOLAR SYSTEM CONTROL CIRCUIT BUS VOLTAGE OF MAIN DCDB GRID POWER AVAILABLE FIRE DETECTION ALARM FIRE DETECTION ELECTRICAL ROOM FIRE DETECTION TELECOM/SCADA FAULT IN FIRE DETECTION SYSTEM CO2 GAS RELEASED M D 1 CO2-PRL AIR CONDITIONING TELECOM/SCADA ROOM ON CO2 CYLINDER WEIGHT LOSS BY LEAKAGE 23 VENTILATION SYSTEM ON (TELECOM/SCADA) TELECOM/SCADA ROOM TEMP BATTERY ROOM/ELECTRICAL EQPT. OF SIGNAL S 1 1 1 TAG NO. DHARUHERA.0 Name of station: MANESAR. NEEMRANA (WITH SOLAR SYSTEM AS POWER SOURCE OPTION) STATION USING SOLAR SYSTEM AS POWER SOURCE A. 1 2 3 DESCRIPTION SOLAR SYSTEM START SOLAR SYSTEM STOP SOLAR SYSTEM RESET MONITORING (M) /CONTROL(C) C C C DIGITAL (D) / ANALOGUE(A) D D D NO. Signal List S.BHIWADI. OF ARRAYS) BCC BAT.1. KUSHKHERA. ROOM/TELECOMSCADA ROOM/CO2 ROOM DOOR OPEN M A * 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 M M M M M M M M M M M M M M M M M M M M M A D D A A D D D D A D D D D D D D D D A D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 GAIL (INDIA) LTD NEW DELHI SCADA I/O LIST FOR ELECTRICAL PARAMETERS STANDARD 0001-01-07-01-002 REV-0 Page 2 of 4 Copyright GAIL – All rights reserved . DESCRIPTION ANALOG SIGNAL DETAILS RANGE SAC-A1 SAC-A2* (AS PER NO.SCADA ROOM DOOR CLOSED TELECOM-SCADA ROOM DOOR OPEN BAT. Details of Analog inputs to SCADA TAG NO. ROOM/TELECOM.5V 35°C 20.DIS BDD-B1 SP-F SC-F AF-F SCC-F1 GRID-ON FA FA-ELECT RM FA-TEL-RM FA-F CO2-PRL CO2-LKG AC-ON VENT-ON RM-TEL-DO C. OF ARRAYS) BCC BATT-V SY-LC DCDB-V TELRM-T SOLAR ARRAY CURRENT BATTERY CHARGING CURRENT BATTERY VOLTAGE LOAD CURRE NT BUS VOLTAGE OF MAIN DCDB TELECOM/SCADA ROOM TEMPERATURE 0-32V 0-60°C 27.ROOM/TELECOMSCADA ROOM/CO2 ROOM DOOR OPEN STATE DESCRIPTION CONTACT CLOSE CONTACT OPEN NORMAL OPERATION BATTERY DISCONNECTED BATTERY DEEP NORMAL OPERATION DISCHARGE NORMAL OPERATION SOLAR PANEL FAULT SOLAR CONTROLLER NORMAL OPERATION FAULT ARRAY FAULT SOLAR NORMAL OPERATION SYSTEM CONTROL NORMAL OPERATION CIRCUIT FAIL NORMAL OPERATION GRID POWER AVAILABLE NORMAL OPERATION FIRE DETECTION ALARM FIRE DETECTION NORMAL OPERATION ELECTRICAL ROOM FIRE DETECTION NORMAL OPERATION TELECOM/SCADA ROOM FAULT IN FIRE NORMAL OPERATION DETECTION SYSTEM NORMAL OPERATION CO2 GAS RELEASED CO2 CYLINDER WEIGHT NORMAL OPERATION LOSS BY LEAKAGE AIR CONDITIONING NORMAL OPERATION TELECOM/SCADA ROOM ON VENTILATION SYSTEM ON NORMAL OPERATION (TELECOM/SCADA) BATTERY ROOM / ELECTRICAL EQPT.B. Contact configuration of digital inputs to SCADA TAG NO DESCRIPTION BATTERY DISCONNECTED BATTERY DEEP DISCHARGE SOLAR PANEL FAULT SOLAR CONTROLLER FAULT ARRAY FAULT SOLAR SYSTEM CONTROL CIRCUIT FAIL GRID POWER AVAILABLE FIRE DETECTION ALARM FIRE DETECTION ELECTRICAL ROOM FIRE DETECTION TELECOM/SCADA ROOM FAULT IN FIRE DETECTION SYSTEM CO2 GAS RELEASED CO2 CYLINDER WEIGHT LOSS BY LEAKAGE AIR CONDITIONING TELECOM/SCADA ROOM ON VENTILATION SYSTEM ON (TELECOM/SCADA) BATTERY ROOM/ELECTRICAL EQPT.5V 0-100A ALARM (HIGH) ALARM (LOW) GAIL (INDIA) LTD NEW DELHI SCADA I/O LIST FOR ELECTRICAL PARAMETERS STANDARD 0001-01-07-01-002 REV-0 Page 3 of 4 Copyright GAIL – All rights reserved . PSP Details of Analog inputs to SCADA DESCRIPTION PIPE TO SOIL POTENTIAL ANALOG SIGNAL DETAILS ALARM (HIGH) ALARM (LOW) (-)1. ALL ANALOGUE SIGNALS TO SCADA SHALL BE THROUGH 4-20 mA TRANSDUCERS.0 NAME OF STATION : A. PSP CPPSM V CPPSM I B. Contact configuration of digital outputs from SCADA TAG NO SS-ST SS-STP SS-RST DESCRIPTION SOLAR SYSTEM START SOLAR SYSTEM STOP SOLAR SYSTEM RESET STATE DESCRIPTION CONTACT CONTACT CLOSE OPEN SOLAR SYSTEM START SOLAR SYSTEM STOP SOLAR SYSTEM RESET NA N. 2.A. GAIL (INDIA) LTD NEW DELHI SCADA I/O LIST FOR ELECTRICAL PARAMETERS STANDARD 0001-01-07-01-002 REV-0 Page 4 of 4 Copyright GAIL – All rights reserved . Signal List S. N. VALUES SPECIFIED UNDER ANALOG SIGNAL DETAILS ARE BASED ON AVAILABLE INFORMATION .D.8 RANGE 0-(-4)V DC NOTES : 1. TAG NO. OF SIGNALS 1 1 1 TAG NO.A. ALL DIGITAL OUTPUTS FROM SCADA SHALL BE POTENTIAL FREE CONTACT. 3. No. WHICH WILL MOMENTARILY CLOSE FOR 2 SECOND FOR ACTIVATION OF CORRESPONDING DIGITAL OUTPUT COMMAND.EXACT VALUES BASED ON ORDERED EQUIPMENT SHALL BE INFORMED LATER.3V (-)0. 1 2 DESCRIPTION PSP Voltage CPPSM Output Voltage CPPSM Output Current ALL CP STATIONS MONITORING (M) /CONTROL (C) M M M DIGITAL (D) / ANALOGUE (A) A A A NO. 2. SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM (ELECTRICAL) SPUR LINES OF CHAINSA .JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 1 of 12 © GAIL – All rights reserved . 0 7.0 6.0 2.CONTENTS SECTION 1.0 4.0 9.0 8.0 TITLE SCOPE CODES AND STANDARDS SITE CONDITIONS SCOPE OF SUPPLY TECHNICAL REQUIREMENTS TESTING AND INSPECTION VENDOR DATA REQUIREMENTS CERTIFICATION PACKING AND TRANSPORTATION GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 2 of 12 © GAIL – All rights reserved .0 5.0 3. 0001-01-0703-001.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM © GAIL – All rights reserved . solar power controller.no.1 4. The exact number of solar electric power systems along with loads connected to each system and the load rating of each system shall be as indicated in the equipment data sheet.0 Any other recognised international codes or standards may be used in lieu of the above.1.1. STANDARD 0001-01-07-02-005 REV-0 Page 3 of 12 4. subject to the approval of the Company.0 4. but not be limited to the following: Photo voltaic solar panels with mounting accessories.2 3. The Solar Electric Power System shall independently meet the power requirement of continuous loads as defined in data sheet. testing and supply of the Solar Electric Power System to be installed. Battery set with stand and its accessories etc. ventilated room. ventilated battery room. manufacture.1 4. Battery Bank shall be designed to be located in closed. SCOPE OF SUPPLY The scope of supply through this specification includes.1.0 SCOPE This specification provides the minimum requirements for the design.1 CODES AND STANDARDS The equipment supplied shall comply with the requirements of the latest revision of the relevant standards of : NEC National Electrical Code NEMA NFPA API ANSI ASTM BIS IEC National Electrical Manufacturers’ Association National Fire Protection Association American Petroleum Institute American National Standards Institute American Society for Testing and Materials Bureau of Indian Standards International Electro-technical Commission 2. Each solar electric power system when installed in accordance with vendor’s instructions shall form self-sufficient power system to meet the power requirements of continuous loads. Controller panel shall be designed to be located in closed. SITE CONDITIONS The equipment offered and the installation shall be suitable for continuous operation under the site conditions mentioned in design basis doc. 2.0 2. 3 Junction boxes and Nickel/Chromium plated double compression type brass cable glands and tinned copper lugs. The load requirement per day shall be determined on the basis of load data specified in the data sheet.1. the load cycle requirements of the connected loads with the solar energy availability at site under worst weather conditions. Voltage drop in cables between solar array and solar controller and solar controller and battery.4.2 5.2 SOLAR PANELS The photovoltaic solar panel array shall consist of required number of individual solar panels. as required.1 5. Battery Bank Solar power controller The solar power system shall be self sustained type.3 4. The individual photovoltaic elements shall be connected in suitable series-parallel combinations to obtain the required voltage and current rating of a solar module. b) Operating voltage considering: Charging voltage of the battery. Flame retardant low smoke (FRLS) type interconnecting cables between solar panels and main junction boxes.1. Solar panel array shall consist of required number of panels in series-parallel combination to meet the system requirements. TECHNICAL REQUIREMENTS POWER SYSTEM Power system shall include the following equipment : Photovoltaic solar cell array (Solar panels).1. The solar panel array shall be designed based upon Isolation Data (to be gathered by contractor from metrological department) and following design conditions: i) Output current to be considered at operating point based on following operating conditions: a) Cell temperature while delivering current corresponding to Pmax point on the I-V curve at specified ambient temperature.0 5. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 4 of 12 © GAIL – All rights reserved .1 5.1. Solar panels will be mounted on steel support structure of suitable height on the control room roof top.1. Individual solar modules shall be connected in suitable series– parallel combinations to obtain the required voltage and current rating of a solar panel. as required. The photovoltaic solar cell array (solar panels) and the solar controller shall be sized to meet through battery back-up. 5.4 5. if any. such as. cable termination arrangement. the following de-rating factors shall be applied: a) b) c) d) e) f) g) h) i) j) Deterioration factor over life span or 15% whichever is higher. Negative tolerance. Unless specified otherwise width of the walkway is 1600mm. The supporting arrangement shall be such as to utilize minimum space on the control room roof top. The arrangement and material of encapsulation shall be compatible with the thermal expansion properties of the silicon cells and the module framing arrangement/ material. vertical stainless steel rods or flexible rods shall be provided to prevent bird landing on the panels. supporting structure and all other accessories shall be suitable for location in extremely corrosive. brass cable glands and all other necessary equipment and hardware. double compression.g. Battery charge/discharge efficiency or 93% whichever is lower. nickel/chromium plated. dusty environment to be encountered. negative tolerance on nominal rating of solar panels) De-rating factor of 2% or as applicable (whichever is higher) to account for panel orientation other than the specified one as per insolation data.2. Losses in field wiring and array wiring. Each panel shall be provided with a weatherproof Junction GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 5 of 12 5. Any other de-rating factor considered essential for satisfactory and guaranteed performance of Solar Power System (e. The encapsulation arrangement shall ensure complete moisture proofing for the entire life of the solar modules. After working out the output current at operating point. solar module fixing accessories. Losses in solar controller. The panel dimension and its supporting structure shall be so sized as to leave a clear walking space of minimum 750mm. The solar panels shall be able to fully charge the battery bank after “3 NO SUN DAYS” cycle from the surplus power available from the solar panel in next 14 days with 70% Depth of Discharge of battery. Losses due to line resistance cables (panel to controller). Materials used in the construction of panel frame to support the solar modules. Voltage losses in solar controller. Panel Construction The Solar modules shall have suitable encapsulation and sealing arrangements to protect the Silicon elements (Cells) from the environment. Arrangement. inter-module connections.1 © GAIL – All rights reserved . The solar module framing shall be copper free aluminium alloy. Losses due to dust deposit or 1% whichever is higher. The solar panel shall have suitable supporting arrangement complete with adjustable mounts. Losses due to module/branch mismatch or 2% whichever is higher. on the output voltage at solar controller. of cells in the battery bank shall be decided on the following basis : Geographical and climatic conditions prevalent at site. Battery suitable for 4000 or more charge-discharge cycle for 10% depth of discharge and for 1600 or more charge discharge cycle for 70% depth of discharge. if recommended by manufacturer. 5. the system voltage shall be 24 V (Nominal). AH capacity and no. Design ambient temperature-minimum and maximum site temperatures as given in Specification. if any. 70% Depth of Discharge.1 BATTERY BANK Battery Cells The battery bank shall be charged from the surplus power available from the solar panel when the sunlight is available and will supply/supplement the solar electric power from the solar panel when the sunlight is inadequate under cloudy condition and during nights. The battery shall incorporate the following features: High charging efficiency.3 5. Minimum 3 days back-up to independently feed the load plus losses. Extended life expectancy. Unless specified otherwise. Long maintenance interval/Maintenance free for VRLA battery cell. The battery shall be able to fully charge after “3 NO SUN DAYS” cycle from surplus power available from the solar panel in next 14 days with 70% depth of discharge. i) ii) iii) iv) v) vi) vii) viii) ix) x) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 6 of 12 © GAIL – All rights reserved .box with minimum IP 55 enclosure with removable gasketed front cover for termination of external cables. Back-up during low insolation periods considering the de-rated solar panel output and insolation data. Deterioration factor over the life span (Actual or 20% whichever is higher). The type of battery cells shall be as specified in equipment data sheet. The type. Suitable bypass diodes shall be provided for partial shadowing of modules. The battery cells shall be provided with flame arresting type catalytic caps or ceramic plugs. Good cycle life even for deep discharge. Large electrolyte reservoir.“Site Conditions and Climate”. The battery cells shall be low self discharge (up to 3% at 27°C per month) Ni-Cd suitable for photo voltaic application. The electrical terminals in the junction box shall be corrosion proof and anti-loosening type. Self discharge during low insolation periods considering average ambient temperature of 30°C. Weight of individual cell shall be of the order of 55 Kg.3. The cable entry shall be from top or bottom (to be decided at the time of detailed engineering) through glands and access to all inside equipments shall be from the front only. (The signal will be in the form of a normally open potential-free contact). The battery bank shall be automatically disconnected from the solar panels when the state of charge of the battery reaches 110% or maximum permissible charge level (as indicated by the battery manufacturer) and from the load when the depth of discharge reaches 70%.4. the following components/ features shall be provided in the controller as a minimum requirements: i) ii) iii) iv) v) vi) vii) viii) ix) x) A 2-Pole MCCB with shunt trip to isolate the solar panel from the solar controller/battery on receipt of 60% LEL signal from the gas detection panel. S-07-02-016. semiconductor grade fuses shall be used for diodes. Apart from required control elements. Switches mounted on the front to disconnect all alarms and indications. The controller shall be provided with low loss type. SCRs etc. The supply system shall be suitable for both negative earthed and unearthed system as required. Unless specified otherwise. Charge-discharge Ammeter. high efficiency. Ammeters to measure load current and solar array current. The provision of negative earthing shall be through an isolating link. MCCBs and MCBs shall be used for the circuit or device protection in place of fuses. Battery deep discharge alarm and indication.3. SOLAR POWER CONTROLLER Technical requirements The solar power controller shall regulate the charge of the battery and shall monitor the charging current from the solar array.1 General requirements and Performance for Ni-Cd Batteries shall be as per GAIL spec. However. The battery bank shall be automatically reconnected to the Solar Panel when the state of charge of the battery drops to 100%.5. the solar controller shall be wall mounted type with hinged and gasketed door in the front. Control circuit fail alarm and indication. Necessary transducers for providing two wire 4-20 mA signals for the following parameters : Battery voltage Solar array current GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 7 of 12 © GAIL – All rights reserved .4 5. tested and tropicalized components with overall loss of the solar controller not exceeding 10% of the rated load. Voltmeter to indicate system output voltage and Battery voltage. Power from the battery set & solar arrays shall be routed through the solar controller. An array fault indicator to indicate solar array failure.2 5. 2. All wiring shall be identified by permanent slip-on or clip-on marking sleeves on each terminating wire in addition to marking at the terminal block. Bundles of wires shall be routed neatly in vertical or horizontal planes. Panels shall be provided with necessary lifting hooks and mounting brackets/base channels. 5. battery circuit etc. Wire lugs shall be of crimping type.04 Earthing An earth bus bar of minimum 2mm x 3mm size made of electrolytic copper shall be provided. Each terminal block assembly shall have 20% spare terminals.4.5 mm2 PVC insulated copper wire of 650 volts grade. The terminal block shall have a white plastic marking strip of the length of the terminal block.4. Wiring to door mounted devices shall be with flexible wires.02 Wiring The wiring shall be done with minimum 2. Protection features to take care of faults in DCDB bus. Bus joints shall be bolted type and insulated by flame-retardant insulation tape. Battery charging current Load current Solar panel fault indicators xi) xii) xiii) Current limiting features with active elements. 5. solar controller. solar panel. The bus bars shall be electrolytic copper and shall be sleeved with 1100V grade flame retardant PVC. Unless specified otherwise. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 8 of 12 © GAIL – All rights reserved . The degree of protection of enclosure shall be IP-51 minimum. running the complete length of the solar controller. Digital Ampere hour meter. all terminal blocks shall be rated for minimum 20A at 650 volts.4. Voltage regulator shall be switching mode type.2 General Requirements 5.2.01 Panel Construction The panel shall be fabricated out of minimum 14 SWG sheet steel. Individual wires and bundles shall be secured with PVC wire ties. cable lacings or by enclosing in PVC wire trays.4. 5. All non current carrying parts shall be bonded with flexible copper wires with the earth bus. The earth bus shall have provisions at both ends for connecting it to earth grid conductor.2.2. 5.4.03 Bus Bars Bus bars shall be sufficiently sized and adequately braced for the supply conditions specified in data sheet. 4.2 6.06 Cabling All interconnecting cables between various solar panels and main JBs.1 6.3 GENERAL (FOR ALL ITEMS) A quantitative check to ensure that all items in specified quantity are present. The company reserves the right to have a representative to witness the final testing and inspection. as specified.2. All electronic circuit boards shall be tropicalised to prevent corrosion and fungus growth.2. Adequate space shall be provided for termination of external cables. All power connections in case of solar controller shall be segregated from one another and from the electronic circuits 5. All required Nickel-Chromium plated brass double compression cable glands and tinned copper lugs shall be included in the scope of supply.1. connecting JBs to solar controller.1. included in scope of supply. The tag inscription shall be in line with the equipment number list.1.6 IDENTIFICATION All solar panels. solar controller to battery shall be supplied by contractor. TESTING AND INSPECTION All tests shall be carried out as per relevant standards at Vendor’s works. Dimensional checks 6. Prior intimation of at least 20 days shall be given to enable the Company depute its representative to witness the tests.5 MATERIALS AND FINISH All materials shall be selected and finished to resist the site conditions and climate. 5.1 6.05 Segregation All electrical devices and live parts in the solar controller panel shall be segregated by means of metallic screens.4. shall be Flame Retardant Low Smoke (FRLS) type. 5.5. Testing and inspection shall include but not necessarily limited to the following: 6. A visual inspection to check workmanship and compliance with submitted drawings. solar controller and related devices and materials shall have permanent tags in contrasting colours affixed on them and lettering of at least 12 mm size.0 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 9 of 12 © GAIL – All rights reserved . Cables of sizes. batteries. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 10 of 12 © GAIL – All rights reserved .6. : + 35°C 4 Duration : 48 hrs. S. Wind Pressure equivalent to an air velocity of 5 280km/hr. 6 Rain Test as required in the mentioned standards 7 Dust Test as required in the mentioned standards Composite /Humidity Test as required in the mentioned standards 8 Test 9* Mould Growth 84 days 10* Hail Storm test Test as required in the mentioned standard Shock Test Peak Acceleration : 490m/sec 2 Duration : 11** 11msec Vendor shall submit the test procedure for owner’s review. Dry heat 85°C 3 Duration : 16 Hrs Salt mist Temp. Hot spot endurance test. Low Temp.2. of cycles :10 Duration of Exposure:30 Min. and also mention the name of the applicable standards. 6.2 i) ii) iii) The following design qualification tests shall also be conducted : Earth continuity test. shall be subjected to following tests and performance of module before and after each test shall be tabulated and furnished.2.No Test Test Details Cold Temp (-) 40°C 1 Duration : 16 Hrs Rapid Change of Temp. or The tested module exhibits any open circuits and or ground faults. or the tested module fails to pass the electrical isolation tests The entire ordered lot of modules shall be rejected.: (-)40°C High Temp:+ 85°C 2 No. module. or The tested module develops cracks or mechanical damage. Electrical isolation test. Minimum 2% of ordered modules or 1 No.2 6. Vendor shall indicate test conditions like temperature limits and duration etc.1 SOLAR PANELS Following environmental tests as per applicable IEC/IS shall be carried out on photovoltaic modules on sampling basis. In case on account of testing: i) ii) iii) iv) The overall deterioration in the performance of the tested modules after test exceed 5% of rated performance. The tests shall be carried out sequentially on each module selected for testing and the tested module shall be discarded after tests. whichever is higher. Dimension.1.2.1. Voltage & current (at P max point & operating point) of modules and arrays at 16°C.2. 60°C cell temperature.1. Solar panel sizing calculations.2.1.6 7.4 7. 28°C. VENDOR DATA REQUIREMENTS GENERAL Make.9 7.8 7. Operating & maintenance manual Hazards & safety precaution. Type test certificates. Completed data sheet.5 7.4 7. Temperature co-efficient of voltage & current.3 6. Expected life span with 20% degradation in output power. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 11 of 12 © GAIL – All rights reserved .2 7.1 7.5 7.5 7.1.3 7. of equipment.1. Routine test certificates. Detailed calculations to verify suitability of structure to withstand wind velocities of 280 km/hr.11 7.1 BATTERY : Refer GAIL Specification S-07-02-016 SOLAR CONTROLLER Tests in the following order shall be conducted for the panel : General Earth Continuity Test Functional Tests Insulation Resistance Measurement Heat Run Test Insulation Resistance Measurement Functional Test Burn out tests for 120 hrs.1 7.2.3 7.1.1 7. at 10 mW/cm2 and 100 mW/cm2 solar insolation.4 i) ii) iii) iv) v) vi) vii) 6.3. Bill of material.1. Applicable International Standards Installation.7 7. 6. Catalogues & Brochures.NOTE: Type test certificate can be accepted for the tests marked with asterisks (*).10 7. 40°C.1. Isc.3 7.1.2 7.0 7.1. weight & general arrangement drawings. SOLAR PANELS I-V characteristics (plotted on graph) indicating values of Voc. BATTERY SET : Various characteristics curves not limited to the following : i) Charging-discharging characteristics at various cell voltage & temperature. type & catalogue no. on the complete system in one assembly. Interconnection diagram for various equipment along with cable size.2.2 7. 0 PACKING AND TRANSPORTATION The offered equipments along with accessories shall be shipped to site packed in wooden crates. Any change in size of battery. State of charge V/s. Selection criteria including sizing calculation. All calculations furnished during bid stage shall be for information only.4 7. solar panel etc. Capacity V/s. Schematic & wiring diagrams.3 7. Sp. State of charge. Expected temperature at critical points for maximum load.3. SOLAR CONTROLLER Operational write up. 2. Cell voltage V/s. 9.3 Self discharge at various ambient temperatures. 8. of cycles. Depth of discharge V/s. rate of discharge. no. Items marked with asterisks (*) must be furnished along with bids. shall be done without any price implication. They shall be wrapped with polythene sheets. All other items including the above shall be submitted for Company’s approval/information during detailed engineering.0 CERTIFICATION All offered equipments or equipments of similar design manufactured by the same supplier : Shall have been type tested by an independent authority.1 7.3.2 7.4 7. NOTE: 1. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SOLAR ELECTRIC POWER SYSTEM STANDARD 0001-01-07-02-005 REV-0 Page 12 of 12 © GAIL – All rights reserved . They shall be checked during detailed engineering stage.3.4. Shall be having current certification/approval/listing by an approved agency or UL or FM.ii) iii) iv) v) vi) 7. Shall have been in continuous satisfactory service for a minimum period of two years. Recommended float charging voltage & current.4. Crates shall have skid bottom for handling. Memory effect (if any).4. before being placed in the crates to prevent damage to finish. Gravity of electrolyte.2 7. JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING OF PIPELINE STANDARD 0001-01-07-02-006 REV-0 Page 1 of 6 © GAIL – All rights reserved .SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING OF PIPELINE SPUR LINES OF CHAINSA . 0 3. Battery life therefore should be adequate to commensurate with the run time required to travel the pipe length of each segment and the drive cups should have requisite resistance to wear and tear to maintain effective sealing throughout the entire run time. The compressor should have the capacity to develop pressure upto 10KG/CM2. contractor shall use air as propelling medium for which single compressor of 900 cfm capacity shall be used.e.TECHNICAL SPECIFICATIONS 1. dent etc. e. The cleaning pigs for successive cleaning pig runs shall be selected by the contractor in such a manner that effective cleaning i. Contractor shall also keep one compressor of the same capacity mentioned above as stand by. 5kg/100km ferrous debris is achieved. PROPELLING MEDIUM Since pipeline is not commissioned. Contractor shall decide the number of Magnet cleaning pig runs and the choice of the Magnet cleaning pig for each cleaning run as suitable for the purpose to obtain internal condition adequately clean so as to obtain valid and interpretable inspection data from the Electronic Geometry pig and to safeguard Electronic Geometry pig against damage due to debris in the pipeline.0 ELECTRONIC GEOMETRY PIG RUNS The Electronic Geometry pig should be capable of recording the entire length of each segment i. This requirement is not intended to be all inclusive and use of guidelines set-forth does not relieve the contractor of his responsibility of successfully carry out all activities and to obtain reliable and valid data from the EGP tool about condition of the pipeline as defined under Scope of work. However. In case debris received is more than this amount.0 INTENT The intent of the specification is to set forth the requirements of the Electronic Geometry Survey of the pipelines to help bidder quote his unit rate price in the schedule of rates. from launcher to receiver in one single run and therefore its electronic recorder system should have requisite data storage capacity. the ferrous debris permitted with magnetic cleaning pig shall not exceed 5 Kg/100KM.0 MAGNET CLEANING PIG RUNS Prior to launching of Electronic Geometry pig. Contractor has to arrange all the facilities required for pressurising air into the pipeline and running the pigs at required speed so that valid and interpretable data by running Electronic Geometry pig is generated by using the above media 3.0 4. SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING OF PIPELINE STANDARD 0001-01-07-02-006 REV-0 Page 2 of 6 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . contractor shall complete all activities required to establish adequate cleanliness of pipeline to the satisfaction of the contractor and to verify the internal geometry of the pipeline with relation to ovality. 2. the contractor shall be required to make subsequent run(s) until at least the above limit is achieved. and difference of thickness.1 Magnetic cleaning and Electronic geometry pigging shall be carried out segment wise.1 Accuracy of defects: The best accuracy offered and guaranteed by the BIDDER for each category of defect should be clearly spelt out. buckles.D. 4. -25%of measured value Location Accuracy Axial: 0. Minimum Detection level: 2% of ID Sizing Accuracy: +0%.20 Meter The tool should be capable of negotiating minimum 3D bend and 15%reduction in Pipe ID.The measurement shall cover the entire 360o of internal pipe wall circumference using properly oriented and sufficient no of sensors. It is proposed that pig tracking would be done in a discrete manner at least 5 to 10 KM intervals on each pipeline segment at pre-selected locations. change in pipeline I. the tool should have minimum capabilities as under. The exact KM chainage of these locations shall be decided at site in consultation with the Contractor and Company. o Identification of all pipeline permanent features e. o Valves or any partially closed valves.g. The BIDDER shall detail out the complete methodology of pig tracking proposed to be deployed by him including complete technical details of the equipment and device proposed to be used for this purpose. Wherever required temporary launcher/receiver to be deployed for each segment DEFECT SIGNIFICANCE The following information/performance expected out of the Electronic Geometry pig inspection: is 5. The tool shall be capable to identify and locate the following features as a minimum o Individual Girth weld o Dent.1% from nearest Permanent Features.0 DATA ANALYSIS Bidder shall carry out the data analysis for EGP at his data analysis center.0 5. or any other out of roundness. However. SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING OF PIPELINE STANDARD 0001-01-07-02-006 REV-0 Page 3 of 6 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . 6. valves. Within pipe ± 0. ovality. The analysis shall consist minimum of following: o Defect sizing (Depth & length) for all "significant defects" (Deformation > 2% of ID). tees etc. Length of each segment shall be decided to suit site conditions and spread in consultation with Engineer-in-charge. 7.0 PIG TRACKING The movement of any type of pig put into the pipeline during Magnetic cleaning and Electronic Geometry Pigging shall be required to be monitored along the pipeline length from launcher to receiver trap. o Detailed report about running of the Electronic Geometry pig including but not limited to the operational and functional details. 8. any reporting system shall include but not limited to the following: o A detailed report in respect of each pipe segment of running each of the pre-inspection tools such as Magnet cleaning pig. relative and absolute distance. depth and axial location suitably referenced. o Velocity plot of the Electronic Geometry pig along the length of the segment.o Identification of potentially hazardous defects likely to affect structural integrity of the pipeline. However. 9. o The Contractor will transfer all the processed data generated on a CD with user-friendly operation on a compatible PC. The software should be user friendly. In case no physical verifiable defect is SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING OF PIPELINE STANDARD 0001-01-07-02-006 REV-0 Page 4 of 6 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . o Details describing the type. The above report to be submitted in four copies of bound volume. and total time required. o A detailed report in respect of each defect for which sizing has to be done indicating its length. This will have to be mutually agreed between the successful bidder and company. operating parameters. size and location of individual mechanical defects. Final processed inspection log shall also be compiled in a CD having userfriendly operation on a Compatible PC along with the operating software necessary for review/analysis of data.. their chainage and sizing. This is required to facilitate selection of significant defects. The location of each defect should be suitably listed with reference to permanent pipeline features. pig condition.0 DEFECT VERIFICATION At the discretion of the company/consultant identify at least two verification dig sites (In case SIGNIFICANT defects are detected during Electronic Geometry Pigging) for each pipeline segment jointly with GAIL from the recorded data and provide GAIL defect sheet indicating distance from the nearest pipeline feature or reference marker to facilitate location of defect in the field. girth weld no. The format and Performa of the above report shall be mutually agreed upon between the successful bidder and company. o Preliminary site report for each pipe segment for each running of Magnet cleaning. Providing all the raw and processed data along with the software package for enabling company/consultant to study the data as required. Contractor will furnish this CD and viewer as part of report.0 FINAL WORK REPORT The Bidder shall include in his offer the most appropriate reporting procedure envisaged for the subject pipeline. and Electronic Geometry pig runs stating comments/observations of each run. Contractor shall carry out necessary fabrication and modification of pipe with new pipe piece after retrieval of pig at no cost to the company in the event of pig stuck situation for reason attributable to contractor. contractor will make extra runs to get valid and physically verifiable data without any additional cost and time implication to the company. If Pig does not move from stuck up location. Technical specification of the bid document.2 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . However locating the stuck up SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING OF PIPELINE STANDARD 0001-01-07-02-006 REV-0 Page 5 of 6 10. EGP run shall be considered NOT SUCCESSFUL provided at the end of the electronic geometry Pigging run. including linear positions. the Contractor is not able to deliver valid. interpretable and physically verifiable data and which after dig site verification in the field is found in conformity with the Defect Significance mentioned at Clause No 5.1 EGP run shall be considered SUCCESSFUL provided at the end of the electronic geometry Pigging run. Also refer clause No. Technical specification of the bid document. 9. by any of suggested measure. The company has foreseen the following abnormal conditions. should such a condition arise during implementation of Project. the Contractor is able to deliver valid. TOOL FAILURE Contractor is required to get valid interpretable and verifiable data for each segment of the pipeline. 10.0 ABNORMAL SITUATIONS: The objective of this section is to write down foreseeable abnormal circumstances for taking appropriate measures.reported. In case contractor's equipment fails to perform electronic geometry inspection to generate valid data for any of the pipeline segment. The plan shall identify procedure for exactly locating the stuck up pig.0 Part II. if the bidder foresees any other abnormal condition.1 10.0 above in case no physical verifiable data are reported. However. interpretable and physically verifiable data and which after dig site verification in the field is found in non conformity with the Defect Significance mentioned at Clause No 5. STUCK-UP TOOL The bidder shall detail out a contingency plan in his bid as proposed by him in case any of the pigs get stuck up. 9.0 Part II. then EGP tool performance will be verified by detection and locational accuracy of permanent installations on the pipeline The contractor shall depute his representative to observe the verification at verification sites for proving that field log detected anomalies conform to sizing. then the pipeline section shall have to be cut for retrieval of Pig. equipment. he is free to make a mention of the same in his technical bid offer. The pipe shall be issued to contractor by company as free issue material. including support facilities required to retrieve the pig. detail procedure for retrieval of pig. V.pig and its retrieval shall always be responsibility of the contractor.0 MISMATCH OF INSPECTION RESULTS WITH ACTUAL DEFECTS DURING SITE VERIFICATION: In case of variance between the results of physical defect verification and the results reported by the contractor on the basis of Electronic Geometry Survey (after considering the tolerance as provided in the contract) segments. After modification pigging Contractor shall run Gauge pig to check internal restriction.0 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MAGNETIC CLEANING AND ELECTRONIC GEOMETRY PIGGING OF PIPELINE STANDARD 0001-01-07-02-006 REV-0 Page 6 of 6 © GAIL – All rights reserved . (In Technical Support With Analytic Gmbh) New Delhivii) M/s SPETSNEFTEGAZ.1 above. v) M/s Graffin Technologies. o Bidder should have full-fledged calibration and testing facility for Electronic Geometry Pig tool including test loop of similar size and data interpretation facilities. (Exclusively for EGP and its related cleaning process) Dubai. i) M/s ROSEN Europe B. o Bidder should have carried out satisfactory similar job of pipeline of diameter 24"or above for at least 50km length in single run and also with cumulative length of 140 km during last ten years. 11.0. Bidder should submit documentary evidence to substantiate his claim for his past experience in the form of work order/ completion certificate. bidder should satisfy the entire following technical and past experience requirement. UAE iii) M/s TDW India Limited. BID EVALUATION CRITERIA (TECHNICAL) If the bidder is not among the list of suggested vendor at clause 13. SUGGESTED VENDOR LIST Following is the list of suggested vendors who have done the similar type of jobs. ii) M/s Linscan Advanced Pipeline And Tank Services. this shall be considered as a failed run and shall be dealt as per Cl. if any. The Netherlands. Baroda vi) M/S Bhotika Pipeline Services Co. o Bidder should own the proposed 18" tool.10. o Bidder's proposed tool should be capable of inspecting minimum 2% of ID defects.Ltd. Moscow 12.0 13. Baroda iv) M/s BJ Services Company Middle East Limited. JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION MONITORING SYSTEM STANDARD 0001-01-07-02-007 REV-0 Page 1 of 9 © GAIL – All rights reserved .SPECIFICATION FOR CORROSION MONITORING SYSTEM SPUR LINES OF CHAINSA . 0 2. MARKING & SHIPMENT SPARE & ACCESSORIES DOCUMENTATION TO BE PROVIDED BY VENDOR SUGGESTED VENDOR LIST GUARANTEE GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION MONITORING SYSTEM STANDARD 0001-01-07-02-007 REV-0 Page 2 of 9 © GAIL – All rights reserved .0 9.0 10.0 3.0 8.CONTENTS 1.0 INTRODUCTION GENERAL SCOPE OF WORK SPECIFICATION INSPECTION & TESTING PAINTING.0 6.0 4.0 5.0 7. trial run.0 ER-Probes & coupons are located at Sultanpur on the 18” line to Neemrana and consists of : Corrosion probe Transmitter Corrosion Meter Corrosion Coupon ER Probe access fitting assembly 3. The probes & coupons shall be flush mounted on the pipeline. installation and testing of corrosion monitoring system to be located on Sultanpur – Neemrana Pipeline. supply of all materials. drawing. supply. testing. All materials in contact with fluid shall be in accordance with NACE Standard MR-0175. specification.0 Introduction This specification covers the minimum requirements for design.1. Each probe shall be connected to a transmitter (2 wire system) to give an o/p of 4~20 mA. erection/installation.0 Specification 4. STANDARD 0001-01-07-02-007 REV-0 Page 3 of 9 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION MONITORING SYSTEM © GAIL – All rights reserved . commissioning. This o/p will be connected to a panel mounted corrosion meters for direct digital read out of corrosion rate in the control room at each station. assembly. training the client’s personnel. standards etc enclosed with the tender document and as per direction of Engineer-in-charge. 4. General The corrosion monitoring system will be used to establish the internal corrosion profile of the pipeline using electrical resistance (ER) corrosion probes & corrosion coupons in conjunction with other inspection techniques. guaranteeing. fabrication.1 Technical Requirements The electrical resistance (ER) probes & CS corrosion coupons to be installed at the stations as mentioned above shall be retrievable from the line under pressure. fabrication.0 Scope of Work Design. 2. proportional to corrosion rate. preparation of operation manual. preparation of technical data sheet and engineering drawings and obtaining approval from GAIL for Corrosion Monitoring System as per system description. The transmitters shall be intrinsically safe certified & suitable safety barriers between transmitters & corrosion meters shall be provided by the vendor. 4-20mA output from the transmitter . Pipeline inlet pressure may vary according to pipeline pressure drop due to different flow rate. preservation at site.corrosion meter shall also be available for interfacing with DCS/ SCADA. engineering. the corrosion monitoring system shall be suitable for operation under this fluctuating pressure conditions. The manufacturer shall provide operation manual for these instruments. (Datasheet enclosed) The transmitter shall have valid intrinsically safe certificate from authorized certifying agency. acme thread outlet with hollow-plug assembly in AISI-316 along with heavy duty protective C. c) 4.Instrumentation department will have to keep provision of space for panel mounting.2. Rating 6000psi. flare weld Access fitting Assembly (non-tee). Coupon shall be supplied with hard thin film rust preventive oil. acme thread outlet with solid plug assembly in AISI-316. body carbon steel. ( datasheet enclosed). Probe life shall be at least 2 yrs.0.2. flare weld Access Fitting Assembly (non-tee). Probes shall be high-pressure retrievable type. cover complete with essential spare.2 Materials The scope of supply shall consist as minimum requirement of the following components: 4. cover complete with essential spare. Electrical department shall arrange connection of mains UPS to receiver at each location. Rating 6000 psi.3 RETRIEVER KIT complete with repair & seal kit for ER probes & coupon with holders– 1 Nos..(1+1) Nos.2. STANDARD 0001-01-07-02-007 REV-0 Page 4 of 9 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION MONITORING SYSTEM © GAIL – All rights reserved . body carbon steel.(Data sheet enclosed) Total –5 Nos Retrievable coupon holder of SS 316 – 1 Nos b) ACCESS FITTING ASSEMBLY for Corrosion Coupon – 1 Nos 2” NB. flush mounted.0.25” height. body in SS316 with element of carbon steel for installation with high-pressure hollow plug access fitting assembly.25” height. at 1-to 1. removable by solvent before installation.S.5 mpy corrosion rate. 4. Probe: (IW+IS) for each location as in 2. b) Transmitter: Transmitter 1 for each location as in 2.1 a) ER PROBE . (1 for Sultanpur – Neemrana Section) Rating 1500 psi.25” dia x 1/8” thickness with one mounting hole of ID 0. 5. along with heavy duty protective C.312”. 5.2 a) COUPONS Mild steel flush disc coupons l. Drawing enclosed as Annexure-A for connection to DCS/ SCADA. 4. ACCESS FITTING ASSEMBLY for ER Probe 2” NB.S. The probe shall be suitable for measurement of corrosion rate in the range of 0-5 mpy. for ER probe. The unit shall be suitable to provide 24VDC supply for powering the transmitter’s 4-20 mA loop through the two wire cable.01 mil o Measurement repeatability: + 1 dial division o Measurement range: 0-5 mpy. 4-20 mA signal shall also be available from the transmitter-corrosion meter for interfacing with DCS/ SCADA. operation and maintenance manual o Owner will provide 220V power supply for this unit. o The corrosion meter shall have valid intrinsically safe certificate from authorized certifying agency. 6. heavy duty field service box.4 DOCUMENTATION TO BE PROVIDED BY VENDOR All component data sheet Engineering. All items shall be properly packed and protected to avoid damage during shipment.2 8. 4.1mpy or 0. 5.0 PAINTING.3 8.Service valve kit. (Data sheet enclosed) o Resolution: ± 0. o The unit shall receive 4-20 mA signal proportional to corrosion rate from the transmitter through the same two-wire cable and provide digital display of corrosion rate through the same two-wire cable. 8. MARKING AND SHIPMENT All items shall be painted and marked as per manufacturer’s standard before shipment. 7. for all items of his work prior to shipment.1 8. extension lever. o Operating temp.0 INSPECTIONS AND TESTING The manufacturer and third party inspector shall carry out inspection and testing as per relevant codes and service requirements of this specification. essential repair and seal kit Each retriever and service valve kits shall be designed for operation on all the locations both for probe & coupon.0 SPARE AND ACCESSORIES The manufacturer shall supply required spare and accessories for 2 yrs operation. Purchasing and construction schedule Spare part list for commissioning & start-up Spare part list for 2 years operation GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION MONITORING SYSTEM STANDARD 0001-01-07-02-007 REV-0 Page 5 of 9 © GAIL – All rights reserved .0 8. complete with blanking plug. spare face-to-access fitting O-ring.2. Insurance during shipment shall be ensured by the manufacturer. Manufacturer’s third party inspector’s test certificates in printed format must be sent with the despatch paper of all supply items. : (-) 10 °C to 65°C o Complete with suitable safety barrier & two wire cable of required length between transmitter & corrosion meter.4 CORROSION METER – 1 Nos. brass hammer. 9 9. Norway Caproco-UK All the components shall be purchased from a single manufacturer.6 8. Preservation procedure for coupons. USA Cormon. 10. UK Atel.0 GUARANTEE The vendor shall guarantee for Quality.5 8.8. Integrity & standard of all monitoring instruments & accessories. The corrosion monitoring items shall be procured from one of the following vendors: Rohrback Cosasco System.7 8. USA Metal Samples.8 8. probes and other spare accessories. Manufacturer’s test certificate/ Third party Inspector Certificate.0 i) ii) iii) iv) v) vi) Operating and maintenance manual Quality control plan Intrinsically safe certificates with catalogue wherever applicable. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION MONITORING SYSTEM STANDARD 0001-01-07-02-007 REV-0 Page 6 of 9 © GAIL – All rights reserved . Italy Corrocean. As given in 4.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION MONITORING SYSTEM STANDARD 0001-01-07-02-007 REV-0 Page 7 of 9 © GAIL – All rights reserved .25” height flare weld (nontee). carbon steel SS316 Required Design temperature (oC) pressure pressure Monitoring Retriever & service valve Required kit With field transmitter and panel Type mounted corrosion meter installed in control room Nos. Probe length Type Access fittings Material Body: Hollow plug assembly: Protective cover Accessories temperature 0-55 29-65 45-92 92 11.CORROSION MONITORING SYSTEM (ER PROBE) – DATA SHEET Tag no.87 Natural Gas Retrievable ER probe SS316 carbon steel 2” flare weld Flush mounted 5mil min To be decided by vendor 2” NB. 30″-P-80-3205Line no. ACME thread outlet with hollow plug assembly. 5.) Service Type Material Body: Element: Probe End connection Probe element type Element thickness –. Wall thickness Pipe material API General Operating (oC) Operating (kg/cm2g) Design (kg/cm2g ) Flow(m3/hr. : (-10) deg.1mpy or 0. The unit shall be suitable to provide 24VDC supply for powering the transmitter’s 4-20mA loop through the two wire cable. Line no.CORROSION MONITORING SYSTEM (TRANSMITTER) – DATA SHEET Tag no. o o o o o Later Later Resolution: + 0. operation & maintenance manual. Later Later 2 wire type ER probe 4-20Ma 5’ for ER probe connection and as required for connection to corrosion meter 24 VDC from receiver unit At site near probe by bracket/ yoke support Yes (valid certificate required) Yes As given in 4. Line no. o The unit shall receive 4-20mA signal proportional to corrosion rate from the transmitter through the same two wire cable & provide digital display of corrosion rate through the same two wire cable 4-20 mA signal shall also be available from the transmitter Corrosion meter for interfacing with DCS/ SCADA. Type Input Output Cable lead Power supply Mounting Whether intrinsically safe Safety barrier between transmitter & receiver Nos. SPECIFICATION FOR CORROSION MONITORING SYSTEM STANDARD 0001-01-07-02-007 REV-0 Page 8 of 9 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . C to 65 deg. o Owner will provide 220V power supply for this unit. C Complete with suitable safety barrier & two wire cable of required length between transmitter & corrosion meter.2 CORROSION MONITORING SYSTEM (CORROSION METER) – DATA SHEET Tag no.01 mil Measurement repeatability: + 1 dial division Measurement range: 0-5 mpy Operating temp. o The corrosion meter shall have valid intrinsically safe certificate from authorised certifying agency. 25” height. Later Later o Mild Steel flush disc coupons 1. o Retrievable coupon Holder of SS 316 o Access Fitting Assembly for coupons: 2” NB.CORROSION MONITORING SYSTEM (COUPON) – DATA SHEET Tag no.25” dia x 1/8” thickness with one mounting hole of ID 0. along with heavy duty protective CS cover complete with essential spare. Rating 6000 psi. flare weld Access Fitting Assembly (non-tee). acme thread outlet with solid plug assembly in AISI-316. 5. body carbon steel. Line no. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION MONITORING SYSTEM STANDARD 0001-01-07-02-007 REV-0 Page 9 of 9 © GAIL – All rights reserved .312”. JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET BATTERY BANKS 24V 0001-01-04-BC-002 REV-0 Page 1 of 4 © GAIL – All rights reserved .DATA SHEET FOR 24 Volts DC BATTERY BANKS SPUR LINES OF CHAINSA . 0001-01-07-08-001 Contracto r Minimum AH capacities of batteries have bee indicated in Scope doc.000-01-07-08-001 Discharge duty requirements Nomina Duty cycle End cell No.0 2.BATTERY BANKS(24V) Part-I (Data to be filled in by purchaser) A Site Conditions Design ambient temp Humidity Atmosphere B 1. Double row double tier 4.: 40oC Min. of l. for each location 2 Nos. same shall be provided by vendor. Note: The end cell voltage shall conform to Battery stands formation: Accessories required with each battery set a) Hydrometer (syringe type) suitable for specific gravity reading b) Thermometer with specific gravity correction scale c) Cell testing voltmeter (3V-0-3V) complete with leads d) Rubber gloves : e) f) g) Spanner Acid-resistant jugs and funnels Wall-mounting type teak wood holder for hydrometer the values specified above. for each location GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET BATTERY BANKS 24V 0001-01-04-BC-002 REV-0 Page 2 of 4 © GAIL – All rights reserved . Design margin of 10% shall be considered in battery sizing..no.: 5oC (for battery sizing) Highly humid Highly corrosive and dusty as applicable for refineries Less than 1000 m above MSL Battery type shall be Nickel-cadmium 10 hours :# Refer Load Analysis doc.0 3. each for each location 1 No. Last1 First1 system No 28 Cd Cd 90 min min min voltage min 1. for each location 1 No. DC Item Next voltage NiLocation cells NiNext.no.DATA SHEET . Detailed calculations shall be reviewed during detail engg.In case higher AH capacities of batteries are required.0001-01-0406-003-SW2.without any time and cost implication. without any time and cost implication. for each location 2 Nos.0 Altitude Battery Type Quick charging time Max. for each location 2 Pairs for each location 2 No.16 1 24V Refer Load analysis By doc.no.0 5 2 Nos. by Vendor) BATTERY 1 2 3 4 5 6 7 8 9 10 11 12 13 13.1 13. Tag no Manufacturer's name Type and catalogue no.2 16 17 17.2 14 15 15.DATA SHEET .1 Item no. safe quick charging rate (amperes) Permissible ripple content Suggested quick charging rate (amperes) Quick charging voltage Max. of cells Nominal cell voltage Cell voltage at the end of full discharge at 10 hours/ 5 hours rate : Specific gravity of electrolyte at the end of full charging at ___ oC : Specific gravity of electrolyte at the end of full discharge at 10 hours / 5 hours rate at ___ oC : Quantity of electrolyte per cell (litres) Weight of each cell with electrolyte (kg) Quick charging current Max.1 15. quick charging voltage per cell Quick charging voltage per cell for constant voltage finishing charging Float charging voltage per cell Float charging current Float charging current range (amperes) GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET BATTERY BANKS 24V 0001-01-04-BC-002 REV-0 Page 3 of 4 © GAIL – All rights reserved .BATTERY BANKS (24V) Part .II (Guaranteed Technical Particulars . of cell Ampere hour capacity No. 3 27.2 28. 8 above : Dimensions of each battery rack Width (mm) : Depth (mm) : Height (mm) Number of battery racks GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET BATTERY BANKS 24V 0001-01-04-BC-002 REV-0 Page 4 of 4 © GAIL – All rights reserved . 8 above : 5 hour rate to end cell voltage specified at S. no.17. 8 above : 2 hour rate to end cell voltage specified at S.4 27. of electrolyte which the cells can withstand without injurious effects Continuously For short periods Type of positive plate Type of negative plate No.1 28. of -ve plates per cell Material and thickness of separators 27 27.1 21.) Max. no.2 18 19 20 21 21.1 27. no.2 22 23 Permissible ripple content AH efficiency at 10 hours/ 5 hours rate Short circuit current of the battery bank Short circuit withstand time (sec. 8 above : 30 minute rate to end cell voltage specified at S. ambient ___ oC 10 hour rate to end cell voltage specified at S. no.5 28 28. no. 8 above : 1 hour rate to end cell voltage specified at S. allowable temp.2 27.3 29 Ampere-hour capacity at min. of +ve plates per cell No. V.JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATASHEET DATASHEET FOR MV/HV CABLE 0001-01-07-04-CBL-001 REV-0 Page 1 of 4 © GAIL – All rights reserved .CABLES SPUR LINES OF CHAINSA .V/M.DATA SHEET FOR H. A Aluminum (25 mm² & above) and Copper (up to 16 mm²) Copper □ Yes / □No □ Solidly bonded (earthed at both 4. : 40oC Min.6 kV 7.1 SITE CONDITIONS Ambient temperature : SYSTEM PARAMETERS Voltage Nominal System Voltage □ 415 V □ 3.MV CABLE DATA SHEET Part 1 (Data by Purchaser) 1.35 kV/ 11 kV 11 kV/ 11 kV 12.3 kV/ 3.8 kV/ 6.A □ Yes □ No Whether installation falls under the jurisdiction of Directorate General of Mines Safety GAIL (INDIA) LTD NEW DELHI DATASHEET DATASHEET FOR MV/HV CABLE 0001-01-07-04-CBL-001 REV-0 Page 2 of 4 © GAIL – All rights reserved .2 11 kV(E) 11 kV(UE) 22 kV 33 kV E: Earthed Max. 2.35 kV / 11 kV 6.1 4.3 kV(E) □ 3.6 kV or 6.2 kV 12 kV 12 kV 24 kV 36 kV UE Un-earthed System 50 Hz ± 3 % Voltage grade 650 V/ 1100 V 1.3 kV 3.2 kV 7.9 kV/ 3.6 kV 3.6 kV(E) □ 6.3 kV 3. : 10oC Highest System Voltage 500 V 3.6 kV/ 6.3 3 i) ii) iii) 4 4. 1.3 kV(UE) □ 6.3 □ Single point bonded □N.1 2.6 kV(UE) □ □ □ □ 2.6 kV 6.2 2.7 kV/ 22 kV 19 kV/ 33 kV Frequency Single line to ground fault current / duration CONDUCTOR MATERIAL HV Power Cables MV Power Cables Control Cables SPECIFIC REQUIREMENTS Cable to be flame retardant Type of sheath and armour bonding ends) system adopted for single core cables Refer Single line diagram Aluminium / Copper N. A. = Not Applicable Please tick mark (√) against box.5 Type of cable accessories (if applicable) Drum length required (Indicate whether standard drum lengths as per specification or specific drum lengths are required) Note : N. 0001-01N. GAIL (INDIA) LTD NEW DELHI DATASHEET DATASHEET FOR MV/HV CABLE 0001-01-07-04-CBL-001 REV-0 Page 3 of 4 © GAIL – All rights reserved . By Pipeline Contractor specification 07-02-001 4.4.A.4 Make of accessories (if applicable) Refer Annexure-I enclosed with Job (Electrical) document no. 13 2.10 2.1 2.2 2.2 2 2.8 2.6 2.1 1.5 2.HV/MV CABLE DATA SHEET Part 2 (Data by Vendor/Contractor) 1 1.9 2. inner sheath and outer sheath Max.12 2. Drum length of cable : GAIL (INDIA) LTD NEW DELHI DATASHEET DATASHEET FOR MV/HV CABLE 0001-01-07-04-CBL-001 REV-0 Page 4 of 4 © GAIL – All rights reserved .7 2.11 2.14 GENERAL Name of manufacturer : Cable type / code : TECHNICAL PARTICULARS (TO BE FURNISHED SEPARATELY FOR EACH SIZE) Conductor material : Material/ thickness of semi-conducting conductor screen (for HV cables) : Thickness of insulation : Material/ thickness of semi-conducting insulation screen (for HV cables) : Thickness of inner sheath : Calculated diameter of cable under armour (as per IS:10462) : Material/ Type and size of armour : Nominal diameter of cable under outer sheath : Calculated diameter of cable under outer sheath : Thickness of outer sheath : Nominal outer diameter of cable : Tolerance on outer diameter : Type of compound for conductor insulation.3 2.4 2. JAHJJAR PIPELINE Gail (India) Ltd.DATASHEET FOR SACRIFICAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPUR LINES OF CHAINSA .0 Page 1 of 7 Copyright GAIL – All rights reserve . New Delhi DATASHEET FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET 0001-01-07-04-CPS-001 Rev . 0 Type of coating for the pipelines : Type of CP system : Design life of protection : 3 Layer Polyethylene Permanent / Temporary using sacrificial anodes Temporary CP system : 1 Year or till commissioning of PCP. S-07-02-011 Corrosion survey shall be conducted by contractor Magnesium low potential type (1.DATA SHEETSACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES PART I (PURCHASER SPECIFIED DATA) 1.55V) / magnesium high potential type (1. Readings shall be taken after every 24 hours. Shall be carried out during TCP stage interference prone areas such as lines (11KV & above) / foreign pipeline either crossing/running in parallel.0 Test stations CP at cased crossings Close interval ‘ON’/’OFF’ potential: particularly at logging survey EHV/HV transmission 9.0 6. New Delhi DATASHEET FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET 0001-01-07-04-CPS-001 Rev .0 Page 2 of 7 Copyright GAIL – All rights reserve .0 8.0 2.7.0 5.75V) (To be selected by CP contractor based on the requirements of specification) To be provided as per requirement To be provided at TCP stage for carrier pipe and casing pipe based on applicability as per Cl.S-07-02-011.0 Design protection current density : Corrosion survey data : Type of sacrificial anode : 7.0 3. 4. whichever is later As per specification no.0 Gail (India) Ltd.8 of specification no. _ _ x _ _ x _ _ mm. Type of anode installation : 11.0 12. for magnesium anodes / of pipeline and first anode 2000 mm min. Notes: i. unless otherwise specified. 11.0 11. Where sacrificial anode system is specified as temporary cathodic protection system.2. Distance between edge of Pipeline and : magnesium ribbon anode. Distance between centre line : 11. for zinc anodes 500 mm min 11. min. New Delhi DATASHEET FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET 0001-01-07-04-CPS-001 Rev .1 S.Prepacked : sub Contractor) Zinc Magnesium _ _ _ Kg _ _ _ Kg _ _ x _ _ x _ _ mm.P.0 Page 3 of 7 Copyright GAIL – All rights reserve .Size : .3.P. monitoring of the sacrificial anode cathodic protection system till the commissioning of permanent C. _ _ x _ _ x _ _ mm. No Indicative Design data for sacrificial anodes ground bed (see note ‘v’ below) To be decided by CP contractor Chainage From To Pipeline Dia M Pipeline Wall thickne ss mm Type of coating Anode material Zinc / Magnesium Anode type Solid / Ribbon Anode ground bed spacing No. contractor.0 Additional tests to be conducted Pearson survey / DCVG survey / Not required for identifying pipe coating defects/holidays Required Shall be done using sacrificial anodes Of temporary CP system 11.10.4.0 Interference detection Interference mitigation only as a part 11. Distance between individual anodes : 11.5. _ _ x _ _ x _ _ mm. Min. system shall be carried out by C.Type : . Horizontal / Vertical ___M 5000 mm min.6. Min. Details of anodes (By CP . of anodes per ground bed Nos.Net weight : .Bare : . min. Gail (India) Ltd. Contractor shall supply all instruments. etc. vi. This shall include providing cable trenches and foundations for all equipment. In cases where temporary and permanent cathodic protection works are being executed by different agencies. materials shall be from GAIL approved vendors. permanent cathodic protection works are being executed by the same agency. all test stations. v. part-II (to be filled in by the contractor)’ and submit the same for GAIL’S’s review. iii. iv.P.P. All civil works associated with the complete cathodic protection system are included in the scope of Contractor. Contractor shall fill up all the data asked for in the ‘Data sheet sacrificial anode cathodic protection system for pipelines. List of acceptable vendors: (Refer Elsewhere) The make of equipment.0 0001-01-07-04-CPS-001 Page 4 of 7 Copyright GAIL – All rights reserve . The design data for anode ground beds and anodes shall be decided by CP contractor depending on the protection current requirement of the pipeline as laid.ii. In cases where sacrificial anode CP system is specified as temporary and where both temporary. system. New Delhi DATASHEET FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET Rev . the contractual scope of work shall be referred for further details. vii. Contractor shall quote for CP system on lump sum basis. tools and tackles necessary for proper operation and maintenance of complete cathodic protection system and associated equipment. system shall be completed as part of temporary C. Gail (India) Ltd. activities of permanent CP system which are common to temporary C. min .2 Voltage grade 1. Min. . New Delhi DATASHEET FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET 0001-01-07-04-CPS-001 Rev .3 Make 2.2 Special Backfill for sacrificial anodes : 4.1 Type : 1.For non charged pipeline : 2. _ _ _ Kg min.1 Make and model number of . . min.Make : _ _ _ _ _ _ 3.0 Details of anodes 3.Pin brazing equipment : 3.Net weight : .Anode material : . min.1 Prepacked type .Size : _ _ x _ _ x _ _ mm.Bare : _ _ x _ _ x _ _ mm.Anode material : Zinc Magnesium -Net weight : _ _ _ Kg min per metre _ _ _ Kg min per metre . ____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________ 4.Cad weld Material : .3 Special Backfill for sacrificial anodes : Gail (India) Ltd.0 Page 5 of 7 Copyright GAIL – All rights reserve .Make : _ _ _ _ _ _ Zinc Magnesium _ _ _ Kg min.0 Cable to pipe connection -For charged pipeline : .0 Cables 1.Prepacked : _ _ x _ _ x _ _ mm.2 Ribbon type . _ _ x _ _ x _ _ mm. _ _ x _ _ x _ _ mm.0 Makes 4.Size : .1 Test stations : 4.DATA SHEET SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES PART-II (TO BE FILLED IN BY THE VENDOR) 1. Min. min _ _ x _ _ x _ _ mm. FORM-IA DETAILS OF SPECIFIC EXPERIENCE OF BIDDER* / HIS NOMINATED SUB-CONTRACTOR FOR SACRIFICIAL ANODE CP SYSTEM (SEPARATE SHEETS SHALL BE FILLED UP FOR EACH JOB/PROJECT HANDELED) Name of CP sub contractor: Description Dia Length Sl (For Sacrificial Of of Pipe No Anode CP Pipe Line System) Line Design and 1 Engineering experience Supply of CP 2 equipment / material Installation of 3 CP system Testing and 4 commissioning * Strike out which ever is not applicable EXPERIENCE DETAILS OF HYDROCARBON HANDLING CROSS COUNTRY PIPELINES No of Anode Name of Date of Type of Type of Ground Beds Work Order No** Commencement Project & Coating Anodes For The Owner Of Work Pipeline Name of Backup Agency Considered Date of Completion of Work Experience of Backup Agency ** Copy of the work order and completion certificate shall be attached GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR STATIONARY VALVE REGULATED LEAD ACID BATTERIES TECHNICAL NOTES 0001-01-07-04-CPS-001 REV-0 Page 6 of 7 Copyright GAIL – All rights reserved . FORM-IB DETAILS OF SPECIFIC EXPERIENCE OF BIDDER* / HIS NOMINATED SUB-CONTRACTOR FOR CP SYSTEM / BACKUP AGENCY FOR INTERFERENCE DETECTION AND MITIGATION (SEPARATE SHEETS SHALL BE FILLED UP FOR EACH JOB/PROJECT HANDELED) Name of CP sub contractor FOR CP System: Name of Backup Agency for Interference Detection And Mitigation Sl No Cause of Interference Length of Pipe Line Dia Of Pipe Line Type of Coating No of CP Stations for the Pipeline Name of Project & Owner Date of Commencement Of Work Date of Completion of Work Details of Backup Agency if Hired for CP Interference / Mitigation Survey Experience of Name of Backup Agency Agency Work Order No** 1 2 3 Cathodically protected foreign pipelines crossing/ parallel running Cathodically unprotected foreign pipelines/ structures crossing/ parallel running High voltage line AC/DC (66KV and above) crossing & parallel running 4 AC/DC electrified traction * STRIKE OUT WHICH EVER IS NOT APPLICABLE ** COPY OF WORK ORDER AND COMPLETION CERTIFICATE SHALL BE ATTACHED *** LIST OF INTEREFERENCE DETECTION. MITIGATION JOBS DONE ALONG WITH WORK ORDER AND COMPLETION CERTIFICATE SHALL BE ATTACHED GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR STATIONARY VALVE REGULATED LEAD ACID BATTERIES TECHNICAL NOTES 0001-01-07-04-CPS-001 REV-0 Page 7 of 7 Copyright GAIL – All rights reserved . JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET 0001-01-07-04-CPS-002 REV-0 Page 1 of 6 © GAIL – All rights reserved .DATA SHEET FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPUR LINES OF CHAINSA . S-07-02-012 QUANTITY OF REMARKS E/R PROBES Quantity indicated here in is tentative 2 nos.7.3 12. (One per Part) readers/Data retrieval computer of portable type for data collection. Required / Not required 100mm x 100mm To be worked out by CP sub Contractor based on Cl.12 of spec. of coupons : No.0 Pipeline coating : Type of CP system : Design life of protection : Design protection current density : Current drainage survey : 3 layer Polyethyelene coating Permanent / Temporary 35 Yrs As per specification no. only.2 10. (One per Part) Once every 24 hours interval Two Nos.0 5. 2 nos.0 11.1 No.1 Corrosion survey data : Integration of permanent CP with : Type of Anodes for anode ground bed : High silicon iron / mixed metal oxide titanium Electrical resistance probes : Quantity of E/R probes : S.3 11. However current measurement survey for proper current distribution shall be carried out by CP contractor.7. of computerised test station : Polarisation coupons : Size of exposed area of coupon : No. S-07-02-012 To be provided in line with requirement of Cl.2 11.0 2.1 11.0 8. DATASHEET 0001-01-07-04-CPS-002 REV-0 Page 2 of 6 10.0 4.0 Surge diverter across insulation joints GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES © GAIL – All rights reserved . Contractor shall quote unit rates for E/R probes for addition/deletion purpose in future. of magnet devices for operation 1 No. Shall be provided for marshy areas and water (E/R Probes) logged area Tentative quantity is given below. 6. Enclosed / Corrosion survey shall be conducted by contractor In the scope of the contractor / Not in the scope Temporary CP of the contractor. S-07-02-012 Shall be carried out / Need not be carried out. of computerisd test stations : Data collection interval : No.2 of spec. S-07-02-012. To be worked out by CP sub Contractor based on magnetic reed switch on criteria specified in spec.0 10.9.0 9. however exact requirement to be decided by CP contractor in line with GAIL spec.0 3.DATA SHEET IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES PART-I (PURCHASER SPECIFIED DATA) 1.2 10.0 9. per Part Required Two Nos.NO SPREAD NUMBER Section A Section B A B 9.0 7. of E/R probe reading instrument Computerised test stations : No. S-07-02-012.no. no. iii) Obtaining approval certificate from electrical inspectorate for electrical installation and carrying out any modifications as per the requirement of electrical inspectorate shall be included in contractor scope.9 of spec. anode junction boxes and anode ground bed cable laying 15 16 17 Chain link fencing around the ground Close interval potential logging survey Additional tests to be conducted for identifying pipe coating defects/ holidays Interference detection & mitigation Shall be provided / Shall not be provided. 4. integration of the permanent impressed current CP system with the sacrificial anode temporary CP system (whether provided by a different contractor or included along with the impressed current CP system) shall be the responsibility of the impressed current CP contractor whose scope shall include disconnection of sacrificial anodes wherever required. iv) All civil works associated with the complete cathodic protection system are included in scope of Contractor.0 Grounding through Polarisation cells To be provided in line with Cl. S-07-02-010. anode lead junction boxes. Shall be carried out Shall be carried out (Also refer Note (xiv) 18 19 20 Shall be done by Contractor as per Cl.13. Proposed location of CP stations/anode ground beds: By contractor Proposed location of E/R probes / Computerised test stations / Polarisation coupons: Location/quantity of E/R probes.no. The galvanic anode shall be of weight/size for design life of PCP system. S-07-02-012. The polarization cell shall be of electrolytic type of rating as per cl. No Locations of ER probes Locations of Computerised test stations Locations of polarisation coupons Notes: i) Unless otherwise specified in project specifications/data sheet.10. all test stations. the common activities shall be completed as part of temporary cathodic protection system. In cases where temporary and permanent cathodic protection works are being executed by the same agency. This shall include providing cable trenches and foundations for all equipment.1 of in conjunction with galvanic anodes as per S-07-02-012.0 of spec. the contractual scope of work shall be referred for further details. In cases where temporary and permanent cathodic protection works are being executed by different agencies. etc.7. kiosks. Polarization coupons shall be decided by CP sub contractor as per specification requirement and same shall be subject to review during detail engineering by Owner/) Sl. S-07-02-012 By Contractor 14 Acquisition of right of Use for : anode ground bed.9. GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET 0001-01-07-04-CPS-002 REV-0 Page 3 of 6 © GAIL – All rights reserved . deep well ground beds. No. ii) The permanent CP system includes certain activities. Computerised test stations.no. which are common with the temporary and permanent cathodic protection facilities.no. Contractor shall clearly bring out during bidding stage. if any. tools and tackles necessary for proper operation and maintenance of complete cathodic protection system and associated equipment. the requirement of additional CP stations/higher rated ground bed. DCVG survey shall be carried out to pin point the coating defect/holiday wherever signal loss is greater than 2db/unit distance and complete report shall be submitted to Owner/GAIL for further action. reading shall be taken at close intervals as per the direction of Engineer-in-Charge.v) vi) vii) viii) ix) x) xi) xii) Contractor shall supply all instruments. Necessary coordination with pipeline laying contractor shall also be in the scope of CP contractor. GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET 0001-01-07-04-CPS-002 REV-0 Page 4 of 6 © GAIL – All rights reserved . Vendor shall fill up all the data asked for in the ‘Data sheet Impressed current cathodic protection system for pipelines. Reference signal cables coming from permanent reference cells and pipeline shall be 1-pair X 2. The make of equipment. These cables shall not be laid in cable trench for power/anode/cathode cables. part II (to be filled in by the vendor)’ and submit the same for GAIL’S’s review. For make of equipment refer elsewhere. Anode Ground Bed shall preferably be horizontal type.5 MM2 and shall be laid in a separate cable trench. however type of anode ground bed finally selected shall be as per soil resistivity data by CP sub-contractor. Where signal loss observed is higher. materials shall be selected from GAIL approved vendors. CAT survey with ‘A’ frame shall be carried out at a regular interval of 250 meters along the route of pipeline to identify coating defects/holidays. over and above those specified in clause 19 above. 4.3 Maximum DC leakage current at 400 C at . : 3.4 Make and mode no.5 Rated no.5 Rating of reed switch : -Continuous current rating : _ _ _ A DC. of reed switch : _ _ _ Years 4.2 Material of E/R probe : 1. at _ _ _ V DC -breaking current : _ _ _ A DC.3 Size of the exposed area of the probe 1.3 Make and model no.0 Permanent reference electrodes 2. : 2. of operations over life time under maximum ratings _ _ _ Nos. 3. of E/R probe : reading instrument 2.2 Make & model no.1.2.4 Make and model no.1 Exposed area of metal : 4.1 Type : 5.5V DC across the Polarisation cell: _ _ _ mA .2 Metal type : 4.2 Ratings : GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET 0001-01-07-04-CPS-002 REV-0 Page 5 of 6 © GAIL – All rights reserved .4 50 Hz AC current rating at 400 C .2 Design life of electrode under burial condition.0V DC across the Polarisation cell: _ _ _ mA 3.1 Make and model no.Contnuous : _ _ _ A .1 Make & model no.0 Polarisation cells 3. of reed switch : operator magnet 4.DATA SHEET IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES PART-II (TO BE FILLED IN BY THE VENDOR) 1.0 E/R probes 1. at _ _ _ V DC 5.Short time : _ _ _ KA for _ _ _ sec 3.1 Type : 3.1V DC across the Polarisation cell : _ _ _ mA . of E/R probe 1.0 Surge Diverters 5.0 Polarisation Coupons 4. 0 Make of 9.1 CPTR unit : 9. 8/20 micro second wave : AC spark over voltage -50 Hz AC : -Impulse(1.5.8 Special Backfill for sacrificial anodes: GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES DATASHEET 0001-01-07-04-CPS-002 REV-0 Page 6 of 6 © GAIL – All rights reserved .1 Make and model number of .3 Test stations : 9.1 Impressed current anodes .1 Type and voltage grade -For anode tail cables : _ _ _ / _ _ _ V -For other CP cables : _ _ _ / _ _ _ V 6.0 Cables 6.2 CPPSM : 9.6 Calcined petroleum coke breeze : 9.1 5.2.2 Current.0 Anode type and make 8.4 Anode junction box : 9.For charged pipeline : .7 Permanent reference electrodes -CuCuSO4 type : -Ag-AgCl type : 9.Cad weld Material : .For non charged pipeline : 7.Type : .2 Make -For anode tail cables : -For other CP cables : 7.0 Cable to pipe connection .Make : 8.2/50 micro second) : 5.5 Cathode junction box : 9.3 Make : 6.2.2.Pin brazing equipment : 8. Sacrificial anodes make -Zinc anodes : -Zinc ribbon anodes : 9. JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT TRANSFORMER RECTIFIER UNIT DATASHEET 0001-01-07-04-CPS-003 REV-0 Page 1 of 3 © GAIL – All rights reserved .DATA SHEET IMPRESSED CURRENT TRANSFORMER RECTIFIER UNIT SPUR LINES OF CHAINSA . 2. copper-copper-sulphate half cell. All Pipe to soil potentials (PSP) measured/set values specified are w.no. 1 Phase Input power supply fault level Number of output circuits Output voltage (+ve earthed) Rated output current Pipe to soil potential setting range (Vps) Minimum set potential range (Vrs) Maximum pipeline potential range (Vpm) 25kA at power supply point One/two as required See note-2 See note-2 -0.5V -0.0V Two 40 oC Highly humid Less than 1000 m Vendor Standard By Contractor Required (Refer doc.Relative humidity . 5.I (TO BE FURNISHED BY PURCHASER) Input power supply 240 V ± 10 %.85V . 3. stop.Design ambient temperature .1V to-2. 50 Hz ± 3 %.0001-01-07-02-002 Minimum pipeline potential range (Vpm) Number of reference cells for control Site conditions . CPTR units for CP system shall be provided with micro processor based synchronisable ON/OFF current interrupter timer with GPS interface.2 17 Current Interrupter Type of current interrupter Interrupter controls Specific requirement (if any) Close loop control with PSP of reference cells in feedback loop (as per clause no.Altitude above mean sea level 12 13 14 15 Shade of final paint Commissioning at site Remote monitoring and control through SCADA for SCADA I/O) Type of Control .t. 6.1 16.7V to -1. S-07-02-013 Required Mounted in CPTR unit / Portable Type(GPS based timer interrupters for measuring OFF potentials shall be provided) Auto (operation through SCADA) and (for start.Manual 16 16.4V to -0. 4.1 of Part II of the data sheet. *Separate data shall be furnished for each rating of CPTR unit. current ratings of CPTR units and their location along the ROW of the pipe line shall be as per contractor/vendor data in S. .4 of spec. The type of indicating lamps shall be minimum 10mm dia.4 of spec.9V -1.r. NOTES : 1. reset) Manual / Manual only Galvanic Isolation required between input & output circuits. CPTR unit shall be provided with a door having transparent glass cover for viewing various parameters/indications with out opening the door. The output voltage. LED type. GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT TRANSFORMER RECTIFIER UNIT DATASHEET 0001-01-07-04-CPS-003 REV-0 Page 2 of 3 © GAIL – All rights reserved .Auto : .to -2.1 2 3 4 5 6 7 8 9 10 11 DATA SHEET CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT PART .5V -0.No. no.S-07-02-013 Constant voltage and constant current Mode (CVCC) having regulated output voltage at set value of constant voltage and constant current with current limit features (as per clause 6. 3 of spec.1 .W.Timing range * Separate data shall be furnished for each rating of CPTR unit. S-07-02-012) Closed lop PSP regulation in auto mode (refer clause 6.3 (Manual mode) * ________% 2.On .4 Timer Details .9 Sec 0. S-07-02-012) Current regulation (from 0.O.1 S.2 3.Timing Accuracy 0.1 3.4. no.3 Technical particulars of Current interrupter Type of interrupter Power supply voltage Detail of output Contractor .4 2.II (TO BE FILLED BY CONTRACTOR/VENDOR) Rating of each CPTR unit along R.Current rating : * A.2 (Manual mode) * _______ % 2.At 50% output voltage : . no. GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT TRANSFORMER RECTIFIER UNIT DATASHEET 0001-01-07-04-CPS-003 REV-0 Page 3 of 3 © GAIL – All rights reserved .99.At 10% output voltage : . no. No PART . suitable for the interruption duty.Voltage rating of coil : * V.3 of spec. S-07-02-012) Output ripple at full load current and . AC/DC _______________ _______________ _______________ .1 Guaranteed technical particulars of CPTR unit Efficiency at 10 % load at 25 % load at 50 % load at 75 % load at 100 % load Voltage regulation (from zero to100 % load variation and through out the output voltage range(Refer clause 6.1 . DC.4. S-07-02-012) * * * ± ________ mv Auto mode Manual mode * * * _______________ _______________ _______________ _______________ _______________ 2.5 3 3.4. Location along ROW CPTR unit output rating Voltage Current Installation in sub station building/ outdoor kiosk Size of incomer cable 2 2.Make .Off .3 of spec.3 of spec.99.At 100% output voltage : (refer clause 6. no.Make .2.5 V to100 % output voltage variation and through out the output current range (Refer clause 6.9 Sec _______________* _______________ Mounted CPTR unit / Portable type _______________ 3. . DATA SHEET FOR IMPRESSED CURRENT CATHODIC PROTECTION POWER SUPPLY MODULE SPUR LINES OF CHAINSA .JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT CPPSM DATASHEET NUMBER REV-0 Page 1 of 3 © GAIL – All rights reserved . 4V to -0.9V -1.Design ambient temperature . current ratings of CPTR units and their location along the ROWof the pipe line shall be as per contractor/vendor data in S. CPTR unit shall be provided with a door having transparent glass cover for viewing various parameters/indications with out 4.S. CPPSM units for CP system shall be provided with micro processor based synchronisable ON/OFF current interrupter timer with GPS interface.1 16. The type of indicating lamps shall be minimum 10mm dia. coppercopper sulphate half cell. *Separate data shall be furnished for each rating of CPTR unit.Altitude above mean sea level 12 13 14 15 Shade of final paint Commissioning at site Remote monitoring and control through SCADA 0001-01-07-02-002 for SCADA I/O LIST) Type of Control . 3. 5. stop.5V -0.t.7V to -1.I (TO BE FURNISHED BY PURCHASER) 1 2 3 4 5 6 7 8 9 10 11 Input power supply Input power supply fault level Number of output circuits Output voltage (+ve earthed) Rated output current Pipe to soil potential setting range (Vps) Minimum set potential range (Vrs) Maximum pipeline potential range (Vpm) 24VDC ±15% 10 kA at power supply point One/two as required See note-2 See note-2 -0. 6-510024).with current limit feature (as per clause 6. reset) and NOTES : 1.no.DATA SHEET CATHODIC PROTECTION POWER SUPPLY MODULE PART .4 of spec. 6. S-07-02-020 Minimum pipeline potential range (Vpm) Number of reference cells for control Site conditions .2 17 Current Interrupter Type of current interrupter Interrupter controls Specific requirement (if any) Close loop control with P. opening the door.r.to -2. The output voltage. All Pipe to soil potentials (PSP) measured/set values specified are w.1V to-2. .’ GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT CPPSM DATASHEET NUMBER REV-0 Page 2 of 3 © GAIL – All rights reserved .No.Auto : .0V Two 40 oC Highly humid Less than 1000 m Vendor Standard By Contractor Required (Refer doc.Relative humidity . Constant voltage and constant current mode (CVCC) having regulated output voltage at set value of constant voltage and constant current. S-07-02020) Required / Not Required Mounted in CPSSM unit / Portable Type (GPS based timer interrupters for measuring OFF potentials shall be provided) Auto (operation through SCADA) (for start. DC-DC converter required for galvanic isolation shall be a part of CPPSM unit. of reference cells in feedback loop (as per clause no. 6.1 of Part II of the data sheet.85V .4 of spec.Manual 16 16. 2.P.5V -0. LED type. Off .3 of spec.99.99.1 Guaranteed technical particulars of CPSSM unit Efficiency at 10 % load at 25 % load at 50 % load at 75 % load at 100 % load _______________* _______________* _______________* _______________* _______________* (Manual mode) * _______ % 2.Voltage rating of coil : * V.Timing range . No PART . DC.4.4.3 of spec.2 2. S-07-02-020) Closed lop PSP regulation in auto mode (refer clause 6.9 Sec _______________* _______________ * Separate data shall be furnished for each rating of CPSSM unit. suitable for the interruption duty.3 of spec.3 Technical particulars of Current interrupter Type of interrupter Power supply voltage Detail of output Contractor . no.2 3.At 10% output voltage : . .3 2.4 Timer Details .W.1 .Make . GAIL (INDIA) LTD NEW DELHI DATA SHEET IMPRESSED CURRENT CPPSM DATASHEET NUMBER REV-0 Page 3 of 3 © GAIL – All rights reserved . S-0702-020) Current regulation (from 0. no. no. no.2.Make . 6-51-0025) (Manual mode) * ________% ± ________ mv Auto mode * * * Manual mode * * * 3 3.5 V to100 % output voltage variation and through out the output current range (Refer clause 6.9 Sec 0.1 .5 Voltage regulation (from zero to100 % load variation and through out the output voltage range(Refer clause 6.At 100% output voltage : (refer clause 6.4 2.1 3.3 of spec.4.On .Timing Accuracy 0.O.1 S. Location along ROW CPSSM unit output rating Voltage Current Installation in sub station building/ in an out door kiosk Size of incomer cable 2 2. AC/DC _______________ _______________ *_______________ Mounted CPTR unit / Portable type _______________ 3.II (TO BE FILLED BY CONTRACTOR/VENDOR) Rating of each CPSSM unit along R. S-07-02-020) Output ripple at full load current and .Current rating : * A.At 50% output voltage : . JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET EMERGENCY GENERATOR NUMBER REV-0 Page 1 of 9 © GAIL – All rights reserved .DATA SHEET FOR EMERGENCY GENERATOR PACKAGE SPUR LINES OF CHAINSA . Vendor's scope : Sl. no. 2.Data Sheet for Emergency generator package Part-1 Scope of work (Electrical) A.3 3 4 5 6 7 8 9 Notes: 1. Items listed at sl.0 above. Fabricated steel cable trays and racks as required for cabling in the battery limits Supply Installation Testing & Commissioning Yes/No Yes/No Yes/No 2 2. Line Cubicle for CT /PT Neutral Cubicle for CTs Line side breaker in cubicle Synchronizing equipment Power and Control cabling in between the package equipment Earthing within the battery limits and connection to main earthing grid Battery & battery charger for control power requirement of the complete DG set.1. GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET EMERGENCY GENERATOR NUMBER REV-0 Page 2 of 9 © GAIL – All rights reserved . 2. no. 2.no 1 Description Emergency generator complete with brushless excitation and AVR system. 2. frame earthing connections & lubrication system. Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Spares for commissioning Spares for two years trouble-free operation.1 2.3 can also form part of Generator Control Panel listed at sl. Generator control panel with AMF system and control / metering and auxiliary equipments.2 2. ‘Yes’ indicates activity in vendor’s/contractor’s scope.2 & 2. Data Sheet-Part-2 (Data furnished by purchaser) 1 1.1 Acceptable makes for equipment / material Refer Annexure-I of Job specification ATTACHMENTS Standard specifications for Emergency Generator Set Rating & Job Requirements (furnished by Purchaser) Alternator Data a. TPN. (Including for battery charger while Generator is at standstill) b) Mains supply for auxiliaries: 415V ± 10%. Fault level : 9kA (1 sec).1 7 7. this temperature is applicable for the ambience outside acoustic enclosure ) 2 Equipment location Outdoor/ Indoor /Shed with sides open/Trolley mounted suitable for outdoor location.1 1.(1W +1 S) for each SV/IP station. g. Of units Type of driver : Painting : Colour shade : Rated output : By Pipeline Contactor Continuous 2 nos. Duty No. (Including for battery charger while Generator is at standstill) Yes/ No Not Available Not available 5 6 6.(Since DG is for temporary power supply till the commissioning of permanent power source i. Fault level : 25kA (1 sec). power as required shall be derived by the vendor within the DG package. Power supplies available from owner's system D. c. TPN. d. Self excited internal combustion engine Epoxy 631 as per IS 2 nos. e.1 4.3 Site Conditions Design ambient temperature for electrical equipment design (IS:9676) Altitude Humidity 40oC Less than 1000mm above mean sea level Highly Humid (For machines wish acoustic enclosure .2 1. Any aux.C supply for controls (excluding engine starting battery which is supplied by vendor) a) Mains supply for auxiliaries: 415V ± 10%.(1W+1S) 10kVA for each Intermediate SV/IP station DATASHEET DATA SHEET EMERGENCY GENERATOR NUMBER REV-0 Page 3 of 9 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Item No.2 Utilization voltage for auxiliaries to be supplied by vendor No auxiliary power shall be available. f.e SPV ) suitable FRP sheet over the trolley mounted DG shall also be provided. Adequate/Inadequate Ventilation 3 4 4. b. Short time parallel operation (remark-1) e. Generator line side Bus-duct/cable b. n. However.F. Breaking capacity c. Making capacity Refer Single line diagrams(Exact cable size shall be decided during detail engineering. Required/ Not required V Amp KA KA GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET EMERGENCY GENERATOR NUMBER REV-0 Page 4 of 9 © GAIL – All rights reserved . AVR may not be provided with excitation current limiter. l. rise limited to Cl-F is also acceptable) Class B As per IS:13364 Technical Particulars a. The relays for sensing grid disturbances and timely isolating the distribution system from grid shall be provided by purchaser in this case.) 50Hz ± 3% Solidly earthed 9. AVR shall be provided with excitation current limiter. Continuous parallel operation (remark-1) f.) During detail engineering. Required / Not Required h. Generator start-up time <30 seconds Remarks :In case of short time parallel operation for load transfer. Black start facility. Generator breaker rating b. Neutral side cable-type/size 7. 415V 0. Permissible voltage drop (remark-2) Brushless Required / Not Required Air cooled / Water Cooled Required / Not Required With state grid /with other Generators / both 2% g. 7. Cyclic operation between DG sets as described in job specification doc.2 Rated Terminal voltage Rated P.3 Termination Details a. i. o. 7. b. in case of continuous parallel operation with load sharing. Excitation support by PMG c. d. j. p. Type of excitation system.4 Generator breaker : a.0001-01-07-02001 shall be provided. k.h.0 kA (1 sec. Rated Frequency System neutral earthing System fault level (KA) Degree of protection : Insulation class Temp Rise limited to Maximum Transient Reactance (Xd‘) along the pipeline route. m.no. Type of cooling.) at for SV stations Minimum IP-23 Class F (Alternatively Class-H insulation with temp.8 lag (min. Line side cable -Type/size c. 3.5 Protection CTs shall be physically located inside the terminal box / cubicle as given below :1.s /P.T.B. N-CT: CT for earth fault protection in Neutral . 7. differential relay Yes / No Under voltage relay Yes / No Control requirements (Refer Clause no.T fuse failure relay Yes / No Synchroscope & cut-off O/V relay with time delay Yes / No Yes / No switch Ammeter with selector Stand by earth fault relay Yes / No Yes / No switch Voltmeter with selector Lockout relay Yes / No Yes / No switch Control supply failure relay Yes / No KWH meter Yes / No Check synchronizing relay Yes / No KW meter Yes / No Winding R. Control Function / Element LCP RCP (*) Yes / No Yes / No(refer clause 1 Gen Start/stop P.CT Requirement Ratio Class Burden Function Vk/Rct Location 5P10 15 VA protection 1 PS 10 VA differential 2 PS 10 VA REF 3 Yes/No D. D-CT: CT for Differential protection to be located just before the star point (neutral formation point).D Yes / No P.T.T.B no.4 7. 2.CT Yes/No R. control switch Yes / No Yes / No 5 Synchronizing equipment Yes / No Yes / No 6 Auto/Manual selector switch for starting Yes / No Yes / No GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET EMERGENCY GENERATOR NUMBER REV-0 Page 5 of 9 © GAIL – All rights reserved .7.B $$ Yes / No Yes / No 3 Voltage increase/decrease Yes / No Yes / No 4 Gen C.s : Current transformer for protection P. (Neutral tee off point is the tapping for earth connection provided in the neutral conductor / lead) Protection Relays / Metering : Type Required Type Required Voltage restrained O/C relay Yes / No P.D Yes / No Frequency meter Yes / No Reverse power relay Yes / No Hour run counter Yes / No Thermal overload relay Yes / No Gen.T. 4. to be located between star point and the neutral tee off point.CT Yes/No Required (as per table given below) / Not required.CT Yes/No AVR CT Yes AVR PT Yes 5P10 10VA earth fault 4 regulation Cl 1 regulation 7.F. meter Yes / No Bearing R. CT/PT for AVR N. No. to be located between earth connection and the neutral tee off point . P-CT : CT for Over Current and Short Circuit Protection .5 C. R-CT: CT for restricted earth fault protection in Neutral. to be located just before the star point (neutral formation point).7.7 also) S.7) 2 Freq increase/decrease P. 7.2 8. vibration test of alternator Special tests Transient voltage performance with Job AVR and Shop Driver a) By 100 % Load Rejection at 1 pf b) By 100 % Load Application at 0.B Yes / No Yes / No $$ Frequency increase/decrease from remote control panel shall be achievable by changeover of contacts (push button type). Emergency generator vendor shall provide necessary facility enabling the above mentioned control/monitoring functions to be transferred to the remote control panels by cables.6 Indication & alarm :. Unless otherwise specified remote control panel shall be in purchaser’s scope of supply.1 8. wave form test .2 pf Yes/No Yes/No Yes / No Yes/ No GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET EMERGENCY GENERATOR NUMBER REV-0 Page 6 of 9 © GAIL – All rights reserved . No Function LCP RCP (*) 1 Load on mains/generator Yes / No No 2 Gen C.As per vendor’s standard S. lube oil pump. other auxiliary motors. 8 8.T.3 TESTING AT WORKS 8. Vendor to ensure governor suitability for this type of control. etc. Notes : 1.B (open/close/trip) Yes / No No 3 Control supply failure Yes / No No 4 Winding temp high Yes / No No 5 Bearing temp high Yes / No No 6 Start Failure Yes / No No 7 P. fuse failure Yes / No No 8 DG ready to start (#) Yes / No No (#) DG ready to start indication shall be active only after all auxiliaries of DG set (i.) are in ready/healthy condition.7 Auto/Manual selector switch for regulation Yes / No Yes / No 8 Local/remote switches Yes / No Yes / No 9 Annunciation windows Yes / No Yes / No 10 Annunciation accept/reset P.1 Witness of Generator Control Panel functional requirements by simulation Witness of routine test as per IS:4722.e. e.1 Rating & performance details: a.F. r. Make : Temp inside acoustic enclosure : Frame designation : Rated output : Terminal voltage : Enclosure : Rated P. 9. permissible impact load : Temperature rise at full load : 25% Load 50% Load 75% Load 100% Load Amps RPM Hz Lag KVA KV _______ oC higher than design ambient Efficiency % Rated P. g. withstand time : Type of voltage regulator : Insulation class : Max. j. Armature resistance (25_c) Armature resistance (100_c) Transient time constant Td’ Sub-transient time constant Td” GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET EMERGENCY GENERATOR NUMBER REV-0 Page 7 of 9 © GAIL – All rights reserved .Part-3 Technical Data from Alternator Manufacturers 9.3 Resistances and time constants a. k. n.F. i. s.C. c. to indicate tolerances) Parameter Direct axis transient reactance Direct axis sub-transient reactance Synchronous reactance Zero sequence reactance Negative sequence reactance Abbr Xd’ Xd” Xd X0 X2 Tolerance % ± ± ± ± ± Ohm/phase Ohm/phase Sec Sec Value (pu) 9. h. l. b. d. o. m. c. f.C. : Phase/connection/no. d.2 Sl. p. b. Unity P. q. of terminals : Full load current : Speed : Rated frequency : Cooling system : Max permissible inductive loading : Steady state 3-phase S. currents : 3-phase S.no a b c d e 9.3 Reactances (Mfr.F. f. 50 Hz IP. power supply Battery a. c.4 Local control panel a.5 Remote control panel a. b. b. mm 9. 9. b. 9. c.1 D. Make : Dimension : Type : Degree of protection Weight : Colour shade : Dimension : Weight : Degree of protection : IPAlternator dimension (LxWxH) : Stator weight : Rotor weight : Total weight : Coupling : Make : Voltage/Freqency : Enclosure protection : Insulation class Starting : 415 V.C. d. Make : Model : Type : No.7 Auxillary Motors a.3 .6 Miscellaneous data a. of cells : Nominal voltage : Nominal capacity : Dimension of rack : Cell arrangement : GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET EMERGENCY GENERATOR NUMBER REV-0 Page 8 of 9 © GAIL – All rights reserved . b. b. f. c.phase .55 : 'B' DOL Direct / Through gear Box 631 as per IS IP.8 9. e. e. 9. c.8. e. e. h. c. d. d. d.9. g. c. GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET EMERGENCY GENERATOR NUMBER REV-0 Page 9 of 9 © GAIL – All rights reserved . h. d..9. b. g. e. Make : Model : Input voltage : Float voltage range : Boost voltage range : Float charge current : Boost charge current : Overall dimension LxWxH : .2 Battery charger a.8. f. DATA SHEET FIRE ALARM SYSTEM SPUR LINES OF CHAINSA .JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET FIRE ALARM SYSTEM 0001-01-07-04-FAS-001 REV-0 Page 1 of 6 © GAIL – All rights reserved . 1 1.1 1.1 1.1 1.12 1.5.5 1.8 1.3 1.2 1.5.6 1.2 1.4 1.13 1.7 1.4.1 1.2 1.16.3.12.10 1. type and model no.FIRE ALARM SYSTEM DATA SHEET Part 2 (To to be filled in by the vendor) 1 Make.1.11 1.8.15 1.1 1.1 1.9 1.3.1 1.16 1.1.2. of following items Make Type 1.2 1.14 1.2.1 Heat detectors (safe area) : (hazardous area) Ionisation type smoke detectors (safe area) (hazardous area) Photoelectric type detectors (safe area) (hazardous area) Linear beam smoke detectors 1 (safe area) Manual break glass boxes (safe area) (hazardous area) Ultra-violet flame detectors I/R detectors Heat sensing cables Detector unit for heat sensing cables Wired telephone handset Response indicators Exit signs Hooters Hooter acknowledge boxes Blinking lights Halon /CO2 release /Inhibit switches Siren Detectors where radioactive materials are used Strength of radioactive material / Model No Dimensions Less than 1 microcurie GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET FIRE ALARM SYSTEM 0001-01-07-04-FAS-001 REV-0 Page 2 of 6 © GAIL – All rights reserved .2 1. e. Siren b. b. b. :: No. : Operating voltage : Mounting : GFloor mounting/GWall mounting Dimensions (L x D x H) mm : 2. e. d.1 Conventional fire alarm system Central fire alarm panel a.) : GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET FIRE ALARM SYSTEM 0001-01-07-04-FAS-001 REV-0 Page 3 of 6 © GAIL – All rights reserved . d.4 Zonal fire alarm panel a. c. i. c. of zones Operating voltage & power Ingress protection IPe. Voltage/ phase/ frequency 2. of devices per loop(Max.3 Mimic panel(if non-integral) a. : Operating voltage & power consumption: Mounting : GFloor mounting/GWall mounting Dimensions (L x D x H) mm : Max. of zones : No.2 2. Make & model no. d. No. & Min. g. f. b. h. Starter for siren(IP-55) : Required/ Not required V/ Hz Phase/ GIntegral/Non-integral consumption : 2. Output c. c. f.2 Siren a. Make & model no. Dimensions (L x D x H) mm Mimic LED size LEDs arrangement : LEDs arrangement basis As graphic mimic of plant/unit Zone Wise/ Unit wise/ or Detector/Manual call point wise :Required/ Not required KW/ db at 1 meter (AC) DC V d. Make & model no. d.1.1 Computer aided fire alarm system Central fire alarm panel (CFAP) a.2 Video display unit (VDU) a. Make & model no. Make & model no. : Quantity : Location : Speed & size : Dimensions (L x D x H) mm GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET FIRE ALARM SYSTEM 0001-01-07-04-FAS-001 REV-0 Page 4 of 6 © GAIL – All rights reserved . h. g.2. e. e. Make & Model no. f.5 Repeat alarm panel a. e. i j. c. b. d.28 of spec. : Locations : VDU screen size VDU type/ Colour Dimensions (L x D x H) mm Graphic display/ Text only/ Multicolour 3. : Operating voltage & power consumption: Mounting : GWall mounting Dimensions (L x D x H) mm : LEDs arranged in a matrix : LEDs arranged on graphic mimic : 3 3. e.3 Printer a.3. c. c. : Memory capacity : No of inputs : No of programmable outputs : Scanning speed : Operating voltage & power consumption : Software used : Processor redundancy (Refer clause5. f. b. d. b. S-07-02-024: Ingress protection : IP Dimensions (L x D x H) mm 100% 3. c. Make & model no. d. b. c. e. c. h. i. : Operating voltage & power consumption : Display : Ingress protection : IPe. g. b.5 Repeat alarm panel a. Make & model no. b. number of loops : Max number of devices in each analogue loop : Event history storage processing : Number of programmable outputs : Scan frequency for devices : Operating voltage & power consumption : Communication protocol : Ingress protection : IPk. f. j. : Rating : Amp KVA Dimensions (L x D x H) mm : GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET FIRE ALARM SYSTEM 0001-01-07-04-FAS-001 REV-0 Page 5 of 6 © GAIL – All rights reserved . b. Dimensions (L x D x H) mm 3. d.4 Data gathering cum fire alarm panel (DGFAP) a. k. and min.3. d. g. : Type of panel : Max. Make : Type/Model No. Dimensions (L x D x H) mm 4 4.2 Charger / UPS Charger UPS a. d. Make & model no.1 Battery bank & charger details Battery DGFAP CFAP Zonal panel a. e. Make Type/model no. c. e. AH Rating : No. b. c. d. f. of cells : Voltage per cell : End cell voltage : Dimensions (L x D x H)mm 4. 2 Recommended cable size & type : a. Between CFAP & DGFAP : Between CFAP & Zonal panel : Between CFAP & repeat alarm panel : Between DGFAP & repeat alarm panel: Between zonal panel & repeat alarm panel : S/km nF/km 6. d. Per loop) : Cable capacitance(Max. b. Between DGFAP & detectors. Per loop) : GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET FIRE ALARM SYSTEM 0001-01-07-04-FAS-001 REV-0 Page 6 of 6 © GAIL – All rights reserved . manual call points : Between Zonal panel & detectors. DGFAP (Watts) Zonal fire alarm panel(Watts) The total fire alarm system (Watts): 6 6.4 Cable resistance(Max. e.1 Cables Recommended cable / wire size & type a. b. b. c.5 Power requirements a. c.3 6. manual call points : 6. JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATASHEET FOR LIGHTING FIXTURES DATASHEET 0001-01-07-04-LF-001 REV-0 Page 1 of 8 © GAIL – All rights reserved .DATA SHEET FOR LIGHTING FIXTURES SPUR LINES OF CHAINSA . 19/23 6 Crompton-CPA 1124 HSB Bajaj BJP-236 Philips TCX-398 / 236 Bajaj BJSM-02236 Crompton CMLM 24HITW Philips TCS-306/236 Bajaj-BJPMS-236. Crompton CSBW 1124 HSB Crompton CSP 42HITW Bajaj BJMP-420 Crompton CRL 42HITW/P Bajaj BJML-420 Crompton IBH-1 1 1OBC PHILIPS FXC1O1 Bajaj BJDB-100 Philips TCS 3 1/236 White Bajaj BJSM 236 Crompton CSBW 11 24H5B Philips TCS 306/236 Bajaj BJCM 236 Crompton CRFG 24H5B SFD4 2x36 W SFD5 2x36 W SFD6 2x36 W SFD9 SFD1O SFD12 4x1 8 W 4x18 W 1x60 W/ lxl00 W SFD13 2x36 W SFDI4 2x36 W GAIL (INDIA) LTD NEW DELHI DATASHEET FOR LIGHTING FIXTURES DATASHEET 0001-01-07-04-LF-001 REV-0 Page 2 of 8 © GAIL – All rights reserved . Ceiling/pendent mounting decorative fixture suitable for 2x36W fluorescent lamps with serrated Al. Similar to ND3 but with white epoxy powder coated from inside and outside with reflector. Similar to IND5 but suitable for 2x36W fluorescent lamps. Widespread minor optics decorative recess/surface mounting luminaries fined with aluminum reflector and having serrated Al. Pendent mounting decorative fixture suitable for 1x36W fluorescent lamp with opal acrylic cover Ceiling/pendant mounting fixture suitable for 2x36 W fluorescent lamps with opal acrylic translucent diffuser and high import black polystyrene end plates. Ceiling/wall mounting fixture with prismatic glass cover. Crompton-IGE 1324/ R5E24 Bajaj BJIV-236 Philips-TKC-203/136 Crompton-IGP. cross louvers suitable for 2x36 W fluorescent lamps. Wide spread minor optics with decorative finish on ends. 140 Philips-TMC 50 1/236 Crompton-IGP 1 3-24H5B Bajaj-BJIR-236 Philips-TKC 203/136 Crompton-IGE. cross louvres suitable for 2x36 W fluorescent lamps. Industrial type fixture suitable for 1x36W fluorescent lamp made of stove enamel finish MS sheet steel housing and vitreous enamelled white reflector. Similar to IND3 but suitable for 2x36W fluorescent lamps.FIXTURE TYPE ND1 DESCRIPTION Mounting rail type fixture suitable for 1 x 36 W fluorescent lamp made of stove enamel finish MS sheet steel housing. WATTAGE 1x36 W ND2 2x36 W ND3 1x36 W ND4 2x36 W ND5 1x36 W ND6 SFD3 2x36 W 1x36 W MANUFACTURERE TYPE DESIGNATION Philips-TMC 50 1/136 Crompton-IGP13 14HSB Bajaj-BJIR-136. Ceiling mounting decorative fixture suitable for 4x18 W fluorescent lamps with dished opal acrylic cover. Similar to SFD9 but with prismatic louvers. Ceiling/ pendant luminaries fined with aluminum reflector and having serrated cross louvers suitable for 2x36 W fluorescent lamps. Similar to IND1 but suitable for 2x36W fluorescent lamps.1314/ RSE14 Bajaj-BJIV-136 Philips-TKC-203/236.1314 /RPC14 Bajaj BJIE-136 Philips-TKC-203/236 Crompton-IGP 1324 /RPC24 Bajaj BJIE-236 Philips TCS-19/136 Crompton-CPA 1114 HSB Philips-TCS. cross louvres. Wide spread decorative ceiling/pendent mounting fixture made of white stove enamelled sheet steel housing and aluminum mirror optic system to achieve wide light distribution and having a serrated Al. cross louvres across the minor system for minimizing glare. bracket mounting suitable for 70 W sodium vapour lamp. Similar to RSD1 but suitable for 4x18W fluorescent lamps. Same as LB 1 but with wire guard. Recess mounting luminaries with minor system housing and dispersive anodised aluminum reflector for use in areas with strip false ceiling type suitable for 2x36W fluorescent lamp. Same as above but with 4x18 W fluorescent lamp. Recess mounting down-lighter fixture with 60/100W incandescent lamp. suitable for 125 W HPMV lamp. WATTAGE MANUFACTURERE TYPE DESIGNATION Bajaj BLSM 236 CFLP2 Crompton CRDI 236 Philips TCS 498/136 Bajaj BJPMS 136 Philips TBS-185/136 Bajaj BJMM-136 Crompton CRFA. mirror optics decorative recess mounting fixture for use in areas with strip false ceiling having a reflector made of high purity aluminum sheet and fined with serrated Al. cross louvres. suitable for 250 W HPMV lamp complete with integral ballast. Industrial high bay fixture with anodised aluminum reflector. Widespread minor optics decorative ceiling/pendent luminaries suitable for 1x36 W fluorescent lamps. Low bay sheet steel fixture. suitable for 2x36 W fluorescent lamp. suitable for 1x36 W fluorescent lamp.1 4HSB 2x36 W SFD16 1x36 W RSD1 1x36 W RSD2 2x36 W Philips TB S-90 Bajaj BJLM-236 Crompton CRFD-24H5B Philips TBS 285/236(DL) Darklite Crompton CRFD 24H5B Bajaj BJDL 236 Philips TBS 300/418M1 Crompton CRFL 42H5B Bajaj BJDL 418 Philips TBC-305/418(0) Crompton CRP 42HITW Bajaj BJMP 420 Philips DN 622 Crompton DDLV 10BC Bajaj BJDR 100 Bajaj BJDL 136 Philips TBS 185/136 (DL) Crompton CRFD 14 HSB Philips TBS-305/418 Crompton CRFD 42H5B Bajaj BJMM 420 Philips SGK-27 Bajaj BJRLB-7OSV Crompton LSA 7TH Philips SGK-27 Crompton LSA 7TH Bajaj BJRLB 7OSV/WG Bajaj BJRLB Crompton LMA 1112 1H/BC Philips HGK 27 Philips HDK225HPL250 Crompton TMB 1 325TH Bajaj BJHBT-250 DATASHEET REV-0 Page 3 of 8 RSD6 2x36 W RSD7 4X18W RSD9 4x18 W 1x60 W/ 1x100 W 1x36 W RSD10 RSD12 RSD13 4x18 W LB 1 lx7OW LB2 lx7OW LB3 lxl2SW HB1 1x250 W GAIL (INDIA) LTD NEW DELHI DATASHEET FOR LIGHTING FIXTURES 0001-01-07-04-LF-001 © GAIL – All rights reserved . Wide spread mirror optics decorative recess mounting fixture having a reflector made of high purity aluminum sheet and fined with senated Al. Medium bay fixture made of sheet steel finished with stove enamel light grey. The housing is closed with clear toughened glass fitted with a robust MS frame with anodised aluminum reflector and complete with integral control gear. Same as RSD6 but for single 36 W fluorescent lamp. Wide spread.FIXTURE TYPE SFD15 DESCRIPTION Widespread minor optics ceiling mounted luminaries with high purity aluminum reflector and serrated Al. with wide distribution mirror system. cross louvers suitable for 2x36 W compact fluorescent lamps. Recess mounting decorative fixture suitable for 4x1 8 W fluorescent lamp with dished opal acrylic cover. capacitor etc. Chemical resistance fixture suitable for 2x36 W fluorescent lamp. 1x250 W HB4 Similar to HB2 but with a gasketed front glass cover. COMPACT FLUORESCENT LAMP (CFL) Wall/ceiling mounting fixture suitable for 9W CFL with opal acrylic diffuser.124OTHIP Philips SDK-100 Bajaj BJMBT-150 Crompton SHS-1215 TH Philips SDK-100/250 Bajaj BJHB-250 Crompton SHS.FIXTURE TYPE HB2 DESCRIPTION Similar to HB1 but with 400 W HPMV lamp. Similar to CM2 but suitable for 2xlSW fluorescent lamps with reeded light stabilized clear acrylic cover (for use in indoor areas with high humidity and corrosive vapours). with minor louvers suitable for 2xllW CFL.1225TH Philips SDK-100/400 Bajaj BJHBT-400 SV Crompton SHS. Dust & Vapour proof fixture suitable for lx4OW lx4OW fluorescent lamp with glass sheet cover. 1x9 W CFL 1 CFL2 1x9 W CFL3 CFL3 (with DC choke) CFL4 2x1 1 W 2x1 1 W 2x1 1 W GAIL (INDIA) LTD NEW DELHI DATASHEET FOR LIGHTING FIXTURES DATASHEET 0001-01-07-04-LF-001 REV-0 Page 4 of 8 © GAIL – All rights reserved . 1x400 W HB5 Similar to HB1 but with 150W SON lamp.C. 1x400 W CM2 2x36 W MANUFACTURERE TYPE DESIGNATION Philips HDK225HPL400 Crompton TMB 1 34OTHIP Bajaj BJHBT-400 Philips HDK-103/250W Crompton THS-1225TH1P Bajaj BJHBT-250MV Philips HDK-103/400 Bajaj BJHBT-400MV/TE Crompton THS. with minor louvers suitable for 2x11 W CFL. fitted with anodised aluminum reflector suitable for 9W CFL. 1x250 W HB7 Similar to HB1 but with 400 W SON lamp. Similar to CM3 but with 2x36W fluorescent lamps. Similar to CFL3 but with built in D. 1x150 W HB6 Similar to HB1 but with 250W SON lamp. Ceiling mounted decorative luminaries. stove enamelled grey outside and white inside with gasketed clear acrylic cover. WATTAGE 1x400 W HB3 Similar to HB1 but with a gasketed front glass cover. choke Recess mounted decorative luminaries.1240TH Philips TMX-95/236 Crompton IFV-24H/TW Bajaj BJI-236 VP Philips TDC-10/218 Bajaj BJI-218FG Philips TDC-10/236 Crompton IFC-1124H SB Bajaj BJI-236FG Philips TPW-1 1/236 Crompton IDJ-24HITW Bajaj BJI-236 Crompton IFV 1 124H/TW Bajaj BJI-136FG Crompton TLN 91 L Philips FWN 012 (OPAL) Bajaj BJEXL 19 Philips FBS-03 Crompton DDLV9 Bajaj BJMR 19 Crompton TLE 211 Philips FCS-31/211 Bajaj BJMS 211 Contractor to select subject to approval of GAIL Engineer-in-Charge Crompton TLD 211 Philips FBS-285/211 Bajaj BJMR 211 CM3 2x18 W CM4 2x36 W CM5 CM6 Ceiling/pendent mounting drip proof and dust tight fixture suitable for 2x36 W fluorescent lamps with 2x36 W aluminum housing. Recess mounted luminaries. Single piece die-cast aluminum body street light fixture with bowl type Al. Decorative luminaries made of coloured FRP with clear acrylic cover suitable for aesthetic and decorative lighting of lawns and parks etc. with 1xGLS6OW lamp. Similar to CFL5 but in horizontal version suitable for 2x9W CFL. WATTAGE 2x1 1 W 2x9 W 2x9 W 2x9 W MANUFACTURERE TYPE DESIGNATION Contractor to select subject to approval of GAIL Engineer-in-Charge Crompton TLK 29 Bajaj BJDS 29 Crompton DDLH29 Crompton TLJ29 Bajaj BJDR29 Philips TRC-34/236 Crompton SFE-24H/TW Bajaj BJSLA-236/240 Philips TRC-33/220 Bajaj BJSLA 220 OUTDOOR TYPE FIXTURES Street lighting fixture suitable for 2x36W ST1 fluorescent lamps made of stove enamelled grey aluminum canopy and acrylic transparent cover. Similar to 5T3 but suitable for 35 W SOX low pressure sodium vapour lamp. Post top lantern suitable for 80W HPMV lamp with necessary control gear and housing attachment. ST4 ST7 ST8 ST9 ST1O Similar to 5T3 but suitable for 250W HPMV lamp. Similar to PT4 but suitable for 9W CFL. Similar to ST1 but suitable for 2x18W fluorescent ST2 lamp. Similar to 5T3 but suitable for 70W HPSV lamp. Similar to ST1O but suitable for 70W HPSV tubular lamp.FIXTURE TYPE CFL 4 (with DC choke) CFL5 CFL6 CFL7 DESCRIPTION Similar to CFL4 but with built in D. (Tntegral type). a pair of anodised ST3 aluminum reflectors and highly transparent clear acrylic sheet cover with hinge and toggle fastening. reflector and with clear acrylic cover suitable for 150 W SON tubular lamp. Similar to PT1 but suitable for 70W HPSV lamp. neoprene gaskets and integrated pre-wired ballasts etc. choke Decorative wall/ceiling mounted luminaries with opal acrylic cover suitable for 2x9W CFL.C. (Integral type). Street lighting fixture suitable for 125W HPMV lamp with cast aluminum housing stove enamelled grey outside and white inside. (Tntegral type). 2x36 W 2x18 W 1x125 W Crompton MSC-1 112 IH Bajaj BJMSD-125MV Philips HRP-48 1x250 W 1x35 W 1x70 W 1x70 W lxlSO W PT1 1x80 W PT2 1x125 W PT3 1x70 W Crompton MSNR1 125TH Bajaj BJMIP-250MV Philips XRP-5 1/35 Bajaj BJLS-35 Philips SRP-48 Crompton SSC-1 107 IHIWI Bajaj BJMSC-705V Crompton SSG-1407 TH/WT Bajaj BJMSC-705V Philips SRP 51 Bajaj BGEST 150 Crompton SSG 1515 TH Crompton MPT-1 18TL Bajaj BJPTT-8OMV Philips HRC-40/80 Crompton MPT-1 12TL Bajaj BJPTT-125 Philips HRC 40/125W Crompton SPT-71 17TL Bajaj BJPTT-70 Philips HRC-40/70W Philips NGC 100 Bajaj BJB 100 Philips FGC-100 Crompton CFBL-9 Bajaj BJBE 19 PT4 1x60 W PT5 1x9 W GAIL (INDIA) LTD NEW DELHI DATASHEET FOR LIGHTING FIXTURES DATASHEET 0001-01-07-04-LF-001 REV-0 Page 5 of 8 © GAIL – All rights reserved . Similar to CFL6 but in round shaped. Similar to PT1 but suitable for 125W HPMV lamp. Similar to FD6 but suitable for 2x250W SON tubular lamp. easy relamping facility (without disturbing the beam direction) protector scale for quick day light adjustment. Flood lighting fixture suitable for 2x400W HPMV lamps made of cast aluminum with cooling fins.12/24 DATASHEET REV-0 Page 6 of 8 FD7 2x250 W FD9 Similar to FD6 but with 2x400W SON tubular lamp. Similar to FD6 but suitable for 1x250W SON tubular lamp. Similar to BK1 but with pressed aluminum body. tropicalised gasket and BC lamp holder suitable for 100W GLS lamp. heat resistant front glass cover fixed to reflector by aluminum ring and rubber gasket. (IP-54 enclosure). Industrial well glass fixture with cast aluminum alloy mounting piece and a sheet aluminum canopy stove enamelled white inside and grey outside with heat resistant glass and wire guard suitable for upto 200W GLS/160 W MLL. 2x400 W FD10 1x250 W FD1 1 2x250 W GAIL (INDIA) LTD NEW DELHI DATASHEET FOR LIGHTING FIXTURES 0001-01-07-04-LF-001 © GAIL – All rights reserved .1 12OBC/ES Bajaj BJVW 200 Philips NDC-22 Crompton 1WV121OBC/ES/VE Bajaj VWI 125 MV Philips NDC-22 Crompton IWV 2OBL/Y Bajaj VWI 125/VE Bajaj BJEF-18(S) Philips HVF 12 Crompton FMD 14 Philips HVF 12 Bajaj BJEF-18 (5) Crompton FBD14 Philips MNT-00 1 Crompton FHD-1224 Bajaj BJEF-22CA/ BGENF 22 BK3 lx 100 W BK4 1x125 W BK5 lx 100 W FD1 Flood lighting fixture suitable for 250W HPMV lamp comprising of anodised aluminum housing and reflector with adjustable lamp holder. Similar to BK3 but enamelled reflector. white inside) and complete with prismatic front glass. Similar to BK3 but suitable for 125 W HPMV lamp with necessary control gear and housing attachment. finished stove enamelled grey outside white inside with frosted front glass fitted with tropicalised gasket and without wire guard. Similar to FD1 but suitable for 400W HPMV lamp. Similar to FD6 but with 2x250W HPSV lamp.12/24 Philips SNF-14 Bajaj BJEF-14CAT Crompton FAD-i 114 Philips SNT-00i Bajaj BJEF-22CA/ BGENF 22 Crompton FHD. Flood light fixture of cast aluminum housing and spun aluminum reflector heat resistant glass cover and adjusting facility suitable for lx250W HPSV lamp. with additional vitreous WATTAGE MANUFACTURERE TYPE DESIGNATION Crompton IBH-1110BC Bajaj BJDB-100 1x100 W BK2 lx 100 W Philips-NXC-1 1 Crompton IBH-111OBC Philips NDC-22 Crompton 1WV. (IP-54 enclosure). wire guard. 1x250 W FD2 1x400 W FD4 2x400 W FD6 1x250 W Philips SVF-12 Crompton-FBD 14 Bajaj BJEF 18 (5) Philips SNT-00l Bajaj BJEF-22 CA/BGENF 22 Crompton FHD.FIXTURE TYPE BK1 DESCRIPTION Bulk head fitting with cast aluminum alloy body having stove enamelled finish (silver grey outside.12/24 Philips SNT-001 Bajaj BJEF-22CA/ BGENF 22 Crompton FHD. anodised reflector gasketed heat resisting glass front cover. FIXTURE TYPE FD12 DESCRIPTION Similar to FD6 but suitable for ix400W SON tubular lamp. WATTAGE 1x400 W FD13 2x250 W MANUFACTURERE TYPE DESIGNATION Philips SNT-14 Bajaj BJEF-14CAT Crompton FAD-i 114 Philips SNT-00i Bajaj BJEF-22CA/ BGENF 22 Crompton FHD.12/24 Bajaj BGEMF 1505 V FD14 1x150 W AV1 1x100 W Bajaj BJAOL-i GAIL (INDIA) LTD NEW DELHI DATASHEET FOR LIGHTING FIXTURES DATASHEET 0001-01-07-04-LF-001 REV-0 Page 7 of 8 © GAIL – All rights reserved . Integrated flood lighting fixture of die-cast aluminum housing with ALGLAS reflector. Neon aviation obstruction lighting fixture complete with neon lamp. heat resistant toughened clear glass cover suitable for 150 W HPSV lamp. designed to give omni directional steady ‘ON’ red colour light. Similar to FD6 but suitable for 2x250W HPMV lamp. Same as Exe-1 but with 80W HPMV lamp and separate control gear. Same as FLP-3 but with integral control gear. Same as FLP-i but with 125W HPMV lamp and separate control gear. All 36 W fluorescent lamp can be replaced by 40W with the consultation of site engineer-in-charge. 6. Flameproof and weatherproof flood lighting fixture with 500W incandescent lamp. 3. 5. Increased safety & WP Well glass lighting fixture for use in zone-2 classified areas with 400 W HPMV lamp. Same as FLP-4 but with integral control gear. Same as Exe-3 but with integral control gear. Same as Exe-4 but with integral control gear. GAIL (INDIA) LTD NEW DELHI DATASHEET FOR LIGHTING FIXTURES DATASHEET 0001-01-07-04-LF-001 REV-0 Page 8 of 8 © GAIL – All rights reserved . 4. Flameproof & WP Well glass lighting fixture with 80 W HPMV lamp for use in TIC classified areas Flameproof & WP Well glass lighting fixture with 125 W HPMV lamp for use in TIC classified areas. Weatherproof well glass increased safety lighting fixture for use in zone-2 classified areas with 100/200W incandescent lamp. limited to 9W loss) ballast.9) type. Same as FLP-6 but with 250W HPMV lamp. Flameproof & WP Well glass lighting fixture with 200 W incandescent lamp for use in TIC classified areas. Same as Exe-1 but with 125 W HPMV lamp and separate control gear. 0. Flameproof & WP Well glass lighting fixture with 250 W HPMV lamp for use in TIC classified areas. Flameproof bulk head lighting fixture with 100W incandescent lamp. 1x 100 W / 1x200W 1x 160 W 1x80 W 1x80 W 1x125 W 1x125 W 1x250 W 1x250 W 1x500 W 1x250 W lx 100 W 1x400 W 2x36/40 W 2x20 W Lx100 W lx 160 W 1x80 W 1x80 W 1x125 W 1x125 W 1x250 W 1x150 W 1x400 W 1x200 W 1x80 W lxl25W 1x250 W NOTES: 1. All fluorescent fixtures shall be fitted with low loss type (i. All mirror optics luminaries should be epoxy powder coated. Same as FLP-i with 250W HPMV lamp and separate control gear Same as FLP5 but with integral control gear. Same as Exe-1 but with 160W blended lamp. Same as FLP-10 but for 2x20W fluorescent lamps. 2. Make of fixtures shall be embossed on the body. Same as Exe-5 but with integral control gear. Same as FLP-i but with SOW HPMV lamp and separate control gear. Same as FLP6 but with 400 W HPMV lamp. Same as Exe-1 but with 250 W HPMV lamp and separate control gear. Flameproof and weatherproof fluorescent lamp fixture suitable 2x36/40W fluorescent lamps with integrated choke box housing mounting clamps etc. Same as FLP-i but with 160W ML blended lamp.e. All fixtures shall be complete with lamps. All fluorescent/Mercury vapour! Sodium Vapour fixtures shall be high power factor (Mm.FLP-1 FLP-2 FLP-3 FLP-3a FLP-4 FLP-4a FLP-5 FLP-5a FLP-6 FLP-7 FLP-8 FLP-9 FLP-10 FLP-11 Exe-1 Exe-2 Exe-3 Exe-3a Exe-4 Exe-4a Exe-5 Exe-5a Exe-6 FLP IIC-i FLP IIC-2 FLP IIC-3 FLP IIC-4 FLAMEPROOF/INCREASED SAFETY TYPE LIGHTING FIXTURE (ZONE-i AND ii) Flameproof and weatherproof well glass lighting fixture for use in zone-i classified areas with 100/200W incandescent lamp. JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATA SHEET FOR AC/DC SWITCHBOARD DATASHEET 0001-01-07-04-SB-002 REV-0 Page 1 of 8 © GAIL – All rights reserved .DATA SHEET FOR AC/DC SWITCHBOARD SPUR LINES OF CHAINSA . 0 OPERATING CONDITIONS: 2.7 Power supply for spring charging motor 3. 10 kA for DC switchboards (However DC Switchboards shall be suitable for withstanding fault level/current as applicable for short circuit contribution of Ni-Cd batteries at a particular location) As per approved Test certificates DATASHEET 0001-01-07-04-SB-002 REV-0 Page 2 of 8 3.A.6 System making capacity GAIL (INDIA) LTD NEW DELHI DATA SHEET FOR AC/DC SWITCHBOARD © GAIL – All rights reserved . 10 kA for DC switchboards (However DC Switchboards shall be suitable for fault level/current as applicable for short circuit Ni-Cd batteries at a particular location) As per Single line diagrams Heat shrunk PVC Sleeves Min. 10 kA for DC switchboards (However DC Switchboards shall be suitable for fault level/current as applicable for short circuit Ni-Cd batteries at a particular location) Solidly earthed for AC & Floating for DC N.4 Location 1.5 System breaking capacity 40°C Highly humid Less than 1000 m Various Highly corrosive and dusty as applicable for refineries 415 V AC / 24 V DC 50 Hz ± 3% (applicable for AC switchboards) 3 (applicable for AC switchboards) Min.3 Altitude above MSL 1.2 Frequency 2.25kA for 415 V AC & Min.0 ELECTRICAL DATA: 3.DATA SHEET FOR 24V DC SWITCHBOARD PART-I (TO BE FURNISHED BY PURCHASER) 1.4 System fault level : withstanding contribution of 2.5 System earthing 2.5 Atmosphere : 2.1 Design Temp 1.2 capacity for 1 sec withstanding contribution of 3.4 Busbars Insulation 3.25kA for 415 V AC & Min.0 SITE CONDITIONS: 1.1 Voltage 2.25kA for 415 V AC & Min.2 Relative humidity 1.6 Auxiliary supply 2. Min.3 No of phases 2.1 Short circuit withstand 3.3 Busbar current rating inside panel at specified ambient 3. 0 MAKE OF EQUIPMENTS/COMPONENTS Refer Annexure-I enclosed with Job specification (Electrical) document no.9 Incoming power entry 3. fixed type suitable for flush mounting against wall with front access. 0001-01-07-02-001 or elsewhere.16 Minimum motor starter module size Minimum switchfuse module size 3. refer SLDs Vendor standard Vendor standard Integral base frame and tack welding to the channel 3.17 Floor fixing floor 4. For incoming and outgoing feeder details.11 3.8 Duty cycle of breaker 3.7 Type of Circuit breaker 3.14 Cable entry (I/C & O/G) Bus duct entry Cable gland/lugs Colour shade Exterior Feeder arrangement Not applicable Not applicable Cable as per data sheets Bottom Not applicable Included As per IS-5 Single front.12 3.13 3. Contractor shall ensure that equipment supplied can be located in available space. GAIL (INDIA) LTD NEW DELHI DATA SHEET FOR AC/DC SWITCHBOARD DATASHEET 0001-01-07-04-SB-002 REV-0 Page 3 of 8 © GAIL – All rights reserved .10 3. front maintenance only and without rear access.15 3.3. 2 Overall dimensions of MCC/contactor controlled feeder panel: Length : Depth : Height : mm mm mm 6.1 Overall dimensions of CB panel Length : Depth : Height : mm mm mm NOTE: Vendor shall furnish the dimensions of various types/ratings of CB panels separately.0 3.1.2 Overall weight and dimensions of largest shipping section: Weight : Length : Depth : Height : kg mm mm mm 7.0 2.1 Overall dimensions of each switchboard: PCC (Length*Depth*Height) : PMCC (Length*Depth*Height) : MCC (Length*Depth*Height) : ASB (Length*Depth*Height) : LDB (Length*Depth*Height) : mm mm mm mm mm 6.0 Recommended clearances for SWBD DATASHEET 0001-01-07-04-SB-002 REV-0 Page 4 of 8 GAIL (INDIA) LTD NEW DELHI DATA SHEET FOR AC/DC SWITCHBOARD © GAIL – All rights reserved . 5.0 Make : PART-II (TO BE FILLED UP BY VENDOR ALONG WITH QUOTATION) 415 V AC / 24V DC Switchboard Type / designation : Degree of protection : Overall weight of CB panel Incomer Outgoing kg kg 5.0 4. 1 12.1 If Yes.3 13.0 9.0 Clearance in air Phase to phase : Phase to earth : 11.0 Main horizontal bus bar 11.3 11.Front : Rear : Above : 8.0 17.0 15.0 16.2 11.0 12.1 11.0 Shock loading on foundation : Max size/no of PVC-insulated Al cond (AYFY) cables that can be terminated inside the panel with rear extension/ without rear extension : 10.0 18.4 12.0 Busbar current rating at design ambient (40 °C) : Main bus bar size : Main bus bar material : Main bus bar location : mm mm mm mm mm A Al/Cu Top/Bottom Vertical bus bars Busbar current rating at design ambient (40 °C) : Bus bar size : Bus bar material : Insulating material : Earth bus size/material : 1 min power frequency voltage : 1 sec short circuit withstand capacity : Peak dynamic withstand capacity : Safety shutter provided for test and drawout positions : Yes/No mm2/ Al / Cu kV kA kA Al/Cu A 19. furnish dimensions : GAIL (INDIA) LTD NEW DELHI DATA SHEET FOR AC/DC SWITCHBOARD DATASHEET 0001-01-07-04-SB-002 REV-0 Page 5 of 8 © GAIL – All rights reserved .0 14.0 Whether adaptor panel required between PCC/MCC panel : Yes/No 19.2 12. 14 21.24 21.9 21.17 21.18 21.10 21.11 21.1 21.15 21.8 21.22 21.20 21.5 21.19 21.23 21.2 21.12 21. of auxiliary contacts : Derating required for capacitor switching : Yes Yes Yes/No sec NO + NC % Yes m sec m sec W/VA W/VA W/VA Yes A at °C A kA kA kA (peak) GAIL (INDIA) LTD NEW DELHI DATA SHEET FOR AC/DC SWITCHBOARD DATASHEET 0001-01-07-04-SB-002 REV-0 Page 6 of 8 © GAIL – All rights reserved .6 21.13 21.0 CIRCUIT BREAKER ( Following data for each rating of breaker) 21.21 21.7 21.16 21.25 Make : Type designation : No of poles/phase : Nominal current rating (in free air) : In panel current rating at site conditions : Breaking capacity : Short time rating (1 sec) : Peak making current : 1 min dry withstand volt (power frequency) : Duty cycle : Total opening time : Total closing time : Power required for opening : Power required for closing : Power required for spring charging motor : Breaker is trip free : Closing mechanism : Provision of manual spring charging : Tripping mechanism : Mechanical trip PB provided : Mechanical ON/OFF indicator provided : Operation counter provided : Time taken for spring charging : No.4 21.3 21.21. permissible rated fuses : 23.7 23.22.11 22.1 22.8 22.3 23.5 23.6 22.Hold on : Closing time : Opening time : No of aux.2 22.Pick up : Coil consumption .6 Rated voltage : Rated current : AC 23 rating : Rated making capacity : Rated breaking capacity : Rated short circuit withstand current with max.2 23.10 22.15 Coil consumption .8 Mechanical life : Maximum permitted back up fuse rating : DATA SHEET FOR AC/DC SWITCHBOARD __________ __________ __________ DATASHEET 0001-01-07-04-SB-002 REV-0 Page 7 of 8 __________ __________ __________ __________ __________ GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .14 22.0 CONTACTOR ( Following data for each rating of contactor) 22.3 22.12 22.4 Make : Type designation : Rated voltage : Rated current AC-3 Duty : AC-4 Duty : 22.0 SWITCH ( Following data for each rating of switch) 23.7 22.5 22.13 22.1 23. contacts : Maximum permitted back up fuse rating : __________ __________ __________ __________ __________ __________ __________ __________ __________ _________ ops (at rated voltage) ops VA VA secs secs NO + NC 23.4 23.9 Thermal rating : Making capacity : Breaking capacity : Switching frequency : ops/hr Life Electrical : Mechanical : 22. 0 THERMAL OVERLOAD RELAY ( Following data for each type of relay) 24.0 FUSES ( Following data for each rating of fuse) 25.4 24.3 24.2 25.6 Make : Type : Setting range : Single phasing preventor : Type of operation : Maximum permitted back up fuse rating : __________ __________ __________ Intergral / Separate Direct / CT operated __________ 25.1 25.2 24.1 24.24.5 24.3 Make : Type : Current rating __________ __________ __________ GAIL (INDIA) LTD NEW DELHI DATA SHEET FOR AC/DC SWITCHBOARD DATASHEET 0001-01-07-04-SB-002 REV-0 Page 8 of 8 © GAIL – All rights reserved . DATASHEET FOR SOLAR ELECTRIC POWER SYSTEM (ELECTRICAL) SPUR LINES OF CHAINSA .JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATASHEET FOR SOLAR ELECTRIC POWER SYSTEM DATASHEET 0001-01-07-04-SPS-01 REV-0 Page 1 of 5 © GAIL – All rights reserved . 3 1.10 2.9 2.7 1.2 1.1 2.0%. -0.2 2.9 1.10 1.4 1.12 1.0 2. Of By-Pass Diodes Per Module Make And Type Of By-Pass Diodes GAIL (INDIA) LTD NEW DELHI DATASHEET FOR SOLAR ELECTRIC POWER SYSTEM DATASHEET 0001-01-07-04-SPS-01 REV-0 Page 2 of 5 03 Days Yes (30%) Photovoltaic Telecom.) Latitude Longitude Ambient Temp Insolation Data Expected Life Span Solar Panel Module Output Watts Peak No.15 2.8 2.13 1.14 1.1 1. lighting and other electrical loads 24 V DC +4%.7 2. 0001-01-0708-001 Floating Yes Grid Power Unclassified Area Refer Elsewhere Refer Elsewhere Refer Elsewhere Refer Elsewhere Refer Specification 0001-01-07-02-005 25 years for all components © GAIL – All rights reserved . 2 Wire 20 mV As per Load Analysis Document No.5 1.12 2.6 2.4 2.8 1.11 2.11 1.3 2.13 Solar System Type Application Load Voltage Ripple Output Daily Load Demand System Earthing Battery Backup Required Type Of Alternative Energy Source Available Location (Solar Panels) Wind Velocity (Max. scada.6 1.1 1.5 2. Of Bird Spikes Per Module No. Of “NO SUN DAYS” Battery Backup Required Load To Be Disconnected If Battery State Of Charge Is Low (Indicate SoC %) Pv Array Mounting Considerations Clear Space Required For Mounting The Solar Panel Array System Downtime Considerations (To Determine System Safety Factors) Solar Module Framing Material Module Dimensions /Weight Junction Box Material Of Solar Panel Material Of Bird Spikes No. 12 No.0 3.24 2.10 3. No.2 3.25 2. Temperature Rise Of Solar Cells Under Severe Working Condition Over Max.9 3.11 3.1.23 2.7 3.5 sq.18 2.22 2. Of Solar Panels Solar Controller Panel Type Enclosure Degree Of Protection Dimensions Weight Mounting Cable Entry Access Internal Wiring Minimum Size Control Bus Bar Make Country Of Origin Voltage Regulator Floor mounted From bottom From front only 2.15 2. Make Of Solar Modules Country Of Origin Weight Of Solar Module Max. flame retardant PVC sleeved IP-51 ______ mm( L) x _____ mm (W) x _____ mm (H) GAIL (INDIA) LTD NEW DELHI DATASHEET FOR SOLAR ELECTRIC POWER SYSTEM DATASHEET 0001-01-07-04-SPS-01 REV-0 Page 3 of 5 © GAIL – All rights reserved . Ambient Temperature Nominal Voltage Of Solar Array Annual Deficit Of Capacity (Ah) From Solar Array Weight Of Solar Array Dimension Of Solar Array Material Of Solar Array Junction Box Degree Of Protection Of Solar Array JB No. Of Solar Cells Per Module Solar Cell Manufacturer’s Type Ref.17 2.4 3.6 3.8 3.3 3. 1100 V grade.1 3.26 3.16 2. mm2 PVC insulated copper wire Electrolytic copper.20 2.14 2.19 2.5 3.21 2. 17 4.18 4.8 4.2 V/CELL Battery room Solar power system application Ni-Cd © GAIL – All rights reserved .13 Recommended Value Of Float/Boost charge Voltage Recommended Value Of Float/Boost Charge Current Recommended Mounting Arrangement With Minimum/Statutory Clearances Required Between Racks/Stacks & All Round Clearances In The Battery Room Internal Resistance Of Each Cell Short Circuit Current Of Battery Bank Factor For Converting Discharge Over A Period Of 168 Hours To A Standard C10 Rating Factors For Converting Discharged Ah Capacity During Deficit Month When Part Of The Load Are Fed From Solar Panel And The Rest By The Battery Battery Bank Weight Battery Accessories Provided As Per Spec. Of Cells Rating In Ah (C10) 4.11 4.2 4. Battery Self Discharge Location/Installation Site/Environment Conditions Nominal Voltage End Cell Voltage At 70% & 100% Dod No.0 Battery Bank Application Type Make Country Of Origin Model No.19 4.12 4.4 4. 000101-07-02-005 Battery Rack/Stack Make Construction Coating And Colour Shade No.10 4.21 5.20 4.3 4.6 4.7 4.1 4.0 5.2 5. Of Tiers/Stack GAIL (INDIA) LTD NEW DELHI DATASHEET FOR SOLAR ELECTRIC POWER SYSTEM DATASHEET 0001-01-07-04-SPS-01 REV-0 Page 4 of 5 1.13 4.9 4.15 4.16 4.4 4.0 4.5 4.4.1 5.14 4.3 5. 5. 5. 3. ATTACHMENTS: Specification for Solar Electric Power System-. All cables shall be in continuous lengths without intermediate joints.6 5. 6.9 5.0001-01-07-02-005 and Load Analysis Document No.2 6.5 No. Vendor shall furnish duly filled-in datasheet along with the Bids. 0001-01-07-08-001 DATASHEET FOR SOLAR ELECTRIC POWER SYSTEM DATASHEET 0001-01-07-04-SPS-01 REV-0 Page 5 of 5 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . the daily load demand given under Item 1. 4.4 6. The design load shall be finalized by the contractor based on actual load of selected equipment.1 A B C D E F G 6. Of Rows/Stack Dimensions Weight (Rack/Stack) Total Weight Of The Battery (Including Battery Rack/Stack & Batteries) Material Of Enclosure Of Battery Rack/Stack Inter-Row/Inter-Cell Connectors Number Material Miscellaneous Materials Cable Size/ Type On Solar Module Solar Module To Array Jb/Main Jb Main Jb To Solar Controller Panel Battery To Solar Controller Panel Interconnecting Cable Conductor Material Make Of Interconnecting Solar Panel Cable Whether Interconnecting Cable Between Solar Array/Module Panel & Main JB Cable Gland Type Cable Gland Quantity Whether Glands Supplied By Vendor Lugs – Type Tinned Copper YES Double compression Nickel/chromium plated brass _____ mm (L) x _____ mm (W) x _____ mm (H) NOTES: 1.8 5.0 6. 2.5 are minimum required. The contractor shall decide the final load based on the final selected equipment. The loads shall be considered as a minimum.5 5.7 5.10 A B 6. The interconnecting cables between solar panel and Main junction boxes shall be Flame retardant Low Smoke (FRLS) type.3 6. The loads as indicated are tentative. AH capacity of battery shall be selected considering design ambient of 10°C. However. DATA SHEET FOR UPS SYSTEM SPUR LINES OF CHAINSA .JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET UPS SYSTEM 0001-01-07-04-UPS-001 REV-0 Page 1 of 7 © GAIL – All rights reserved . /phases : System fault level : SITE CONDITIONS Design ambient temperature Min.1 DATA SHEET FOR UPS SYSTEM PART -I PURCHASER'S DATA RATING AND JOB REQUIREMENTS INPUT POWER SUPPLY Voltage/freq.8 3.6 3.1 1.2 3.11 3.12 Mode of operation Load p.4 3.8 pf) No. relative humidity Altitude above MSL SYSTEM REQUIREMENTS Type of inverter Rating (KVA at 0.) 2. ambient for battery sizing 40oC 10oC Highly Humid Less than 1000 m 415 V± 10%.3 Max.6 to 1 (lag) Battery type shall be Nickel-cadmium 30 minutes Double row double tier Required/Not Required IP-31 From bottom/top Epoxy paint shade 631 as per IS:5 GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET UPS SYSTEM 0001-01-07-04-UPS-001 REV-0 Page 2 of 7 © GAIL – All rights reserved .3 3 3. 0.8.2 2. 3 Ph 25kA(1 sec. (rated and variation) Type of battery Battery Backup Time Battery rack formation Fault diagnostic unit Ingress protection of enclosure Cable entry : Painting : `Parallel Redundant with bypass transformer 0.f.10 3.1 1.1 3.7 3.2 2 2. 50 Hz ± 3%. of phases Output Voltage Output frequency Transistorised 10kVA 1 Phase (Ph-N) 230V±1%(Ungrounded) 50Hz ± 1% 3.9 3.5 3. GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET UPS SYSTEM 0001-01-07-04-UPS-001 REV-0 Page 3 of 7 © GAIL – All rights reserved . Outgoing Rating Of Rating Rating Rating Feeders Feeder 5 5.4 SPECIFIC REQUIREMENTS All interconnecting cables (including associated cable glands and lugs) between all panels of UPS system are included in vendor’s scope. ACDB shall be suitable for flush mounting with front access.3 5.1 5. refer Single line diagram attached with the tender document.Of KVA Incomer Switch Fuse Item No.2 5. Owner’s Interface Normally closed (NC) potential-free contacts shall be wired upto terminal strip for connection by purchaser. No.4 ACDB For incoming and outgoing feeder details of UPS ACDB. LED shall be provided instead of conventional indicating lamps. for the following conditions: a) b) c) d) e) f) UPS MOD-1 Trouble UPS MOD-2 Trouble Charger Failure Inverter Failure Battery Discharged Battery Isolated. front maintenence type only and without any rear access. 12 Efficiency of bypass stabilizer including input transformer a) b) c) d) At 100% load At75% load At 50% load At no load GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET UPS SYSTEM 0001-01-07-04-UPS-001 REV-0 Page 4 of 7 © GAIL – All rights reserved .9 1.) Mode of operation Dynamic Response under following conditions a) b) c) d) e) 1.4 1.6 1.8 1.3 1.7 1.f.1 1.8 p.II TECHNICAL DATA FROM MANUFACTURERS 1 1.5 UPS SYSTEM Make Type designation Rating (KVA at 0.11 For 50% step load For 100% step load and unload Power supply interruption and Load Transferred to bypass line restoration: When one inverter gets faulty and load transferred to healthy inverter Maximum recovery time to reach steady state after above disturbance Type of cooling/Redundancy in cooling system Degree of ingress protection of panels Noise level Colour shade Efficiency of each rectifier and inverter module including input and output transformer a) At 100% load b) c) d) At 75% load At 50% load at no load 1.2 1.10 1.PART . 8 2.1 2.3 2.14 1.10 2.2 2.5 2.13 Overall efficiency of UPS system( ratio of output load to input power drawn from mains when all charger and inverters are on and Synchronized with bypass operating at no load) a) At 100% load b) c) d) At 75% load At 50% load At no load 1. of phases : Steady state output voltage (Nominal/Variation) : Steady state output frequency (Nominal / Variation) Output voltage adjustment range at rated load : Input voltage DC (Nominal/Range) : Frequency variation limit for inverter :phase locked with main Allowable unbalance between phases (for 3 phase only): Harmonic distortion at inverter output at rated load a) For linear load b) For nonlinear load Overloading capacity and duration Short circuit capacity and duration Output voltage and phase angles (for 3-Ph only) a) For 30% unbalance load b) c) d) For 40% unbalance load For 50% unbalance load For 100% unbalance load 2.9 2.13 Type of control circuit Load crest factor (for which UPS is designed) Max.12 2.7 Cable entry : Guaranteed dimensions (LXDXH) of UPS :system except ACDB and Battery Heat loss for the total system (KW) : INVERTER Rating (at specified ambient)/No.16 2 2.1.6 2.4 2.11 2.15 1. allowed rating of outgoing feeders for fault clearance of feeder fault by UPS with and without mains bypass supply back up (as percentage of UPS rating) a) With fast acting semiconductor fuses b) With normal HRC fuses DATASHEET DATA SHEET UPS SYSTEM 0001-01-07-04-UPS-001 REV-0 Page 5 of 7 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . 6 4.1 No.5 4.1 3.8 6.2 Current rating at specified ambient (continuous / short time) : Type of static switch : Transfer time a) b) Synchronised mode Unsynchronised mode 4 4.4 4.3 3.7 6.3 4.1 4.4 STATIC SWITCHES 3.5 6.2 4. of cells in each bank No.2 3.1 6.4 6.3 6.9 BATTERY CHARGER Current Rating Type of Charger Output voltage under float/rapid charging condition Output Voltage accuracy under specified input Maximum ripple content on DC side with battery :connected/disconnected Maximum harmonic content in input current Input transformer rating MANUAL TRANSFER DEVICES Make/Type designation Rating (continuous/short time) BATTERY Make : Type designation Type AH rating End cell voltage Nominal voltage No.2 6.3 3.2 6 6. of static switches in each UPS system 3.7 5 5.1 5. of battery banks Battery charging requirements a) b) c) Nominal Volts/cell Float Voltage/cell Rapid charging Voltage/cell GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET UPS SYSTEM 0001-01-07-04-UPS-001 REV-0 Page 6 of 7 © GAIL – All rights reserved .6 6. 1 8.4 8. of outgoing feeders/rating of each Overall dimensions(LXDXH) Maximum & minimum operating height CELL BOOSTER Make/ Type designation Voltage range Current range RELIABILITY Safety factor used for selecting the components (a) Electronic devices (b) Electrical devices MTBF/MTTR Availability factor 10.4 7.2 10.10 6. of racks and tiers with clearances : Container type No.11 6.3 10 10.1 9.6 8 8.2 7.6. no.13 7 7.1 Rapid charging time Overall rack dimensions.3 8.3 GAIL (INDIA) LTD NEW DELHI DATASHEET DATA SHEET UPS SYSTEM 0001-01-07-04-UPS-001 REV-0 Page 7 of 7 © GAIL – All rights reserved .5 9 9.2 9.2 8. of recommended air changes/hour for battery room STEP DOWN BYPASS TRANSFORMER WITH SOLID STATE VOLTAGE STABILIZER Make/Type designation Rating and voltage ratio Accuracy of Stabilizer Type of Control Type of Cooling Type of Stabilizer AC DISTRIBUTION BOARD Make /Type designation Rating of board No.5 7.1 7.12 6.3 7. 24 V SPV AND BATTERY CHARGER IN PARALLELL OPERATION HAVE BEEN CONSIDERED. VENTILATION AND GAIL (INDIA) LTD NEW DELHI SPECIFICATION SINGLE LINE DIAGRAM FOR CGS 0001-01-07-01-001 REV-0 Page 1 of 1 Copyright GAIL – All rights reserved . SCADA/TELECOM EQUIPMENT WILL BE SUPPLIED AND INSTALLED BY THE OWNER. AC DISTRIBUTION FOR LIGHTING. ANY DC-DC CONVERSION WILL BE IN THE SCOPE OF THE SCADA/TE. 5.NOTES: 1. 2.ECOM VENDOR 4. 24 V SPV POWER SOURCE + 415/220 V AC POWER SOURCE HAS BEEN CONSIDERED. 3. JAHJJAR PIPELINE GAIL (INDIA) LTD NEW DELHI STANDARD LOAD ANALYSIS DOCUMENT 0001-01-07-08-001 REV-0 Page 1 of 3 © GAIL – All rights reserved .LOAD ANALYSIS DOCUMENT SPUR LINES OF CHAINSA . Lighting / ventilation / Air conditioning load for CGS has been considered and will be fed by grid power supply. feeders from existing grid power system of the vicinity/industrial areas.Contr Room A/C . The efficiency of dual redundant DC to DC converters to be provided in SCADA/Telecom equipment is assumed as 0. Power requirement is envisaged to be met through 415/240 V. The battery charger connected to the grid power supply shall be used for boost charging of the batteries.Fire Alarm & Detection & CO2 Flooding System On Grid Power Supply:.0 (a) FOR STATIONS AT Manesar. feeder for Telecom and 1 no. Kushkhera and Neemrana.NOTES & ASSUMPTIONS:1. (a) New building/porta-cabin has been considered at above locations. GAIL (INDIA) LTD NEW DELHI STANDARD LOAD ANALYSIS DOCUMENT 0001-01-07-08-001 REV-0 Page 2 of 3 © GAIL – All rights reserved . As such indoor/outdoor lighting.Contr Building Lighting . etc.7 in power source sizing calculations. Dharuhera. 24V power source Solar Panel configuration along with battery back-up for 72 hours has been considered for meeting the power requirements at the unmanned stations.0 FOR RECEIPT TERMINAL (CGS) AT Manesar. Loads considered are following:On Power source with Battery Backup:. Fan Elect Room . air conditioning loads.Ex Fan BR .Ex.SCADA . Kushkhera and Neemrana. feeder for SCADA shall be provided at each location.Instrumentstion . Bhiwadi. Bhiwadi. 24V DC(Floating) 1 no.Telecom .Cathodic Protection . (b) (c) (d) (e) (f) 2.Area Ltg Boost charging requirement of batteries has not been considered in sizing of SPV. Dharuhera. have been considered. Any DC-DC conversion as required shall be in respective Telecom/SCADA equipment to be supplied & installed by other vendors separately. Chg Total Critical 780 100 100 Load Say 800W Solar+ Power by Power by Power Source Grid + CJPL CJPL Battery Battery Backup 72 Hrs Time Load on Grid Power Light Contr Bldg 0 0 1000 Contr Room A/C 0 0 3000 Area Ltg 0 0 2500 Battery Charger Watts Watts Watts 1.LOCATIONS LOAD Sultanpur Kh & Man ToP Manesar Dharuhera Bhiwadi Kushkhera Neemrana Load On Power Source With Battery Backup Telecom 0 0 150 Scada 0 0 130 Instt /PLC 0 0 200 Ex Fan BR 0 0 50 Ex Fan TC/SCADA 0 0 50 Room F A System 0 0 100 CP Syatem 100 100 100 Batt. 3. 150 130 200 50 50 200 100 780 Say 800W Solar+ Grid + Battery 72 Hrs 1000 3000 2500 Watts 150 130 200 50 50 250 130 200 50 50 250 130 200 50 50 200 100 880 Say 900W Solar+ Grid + Battery 72 hrs 1000 3000 2500 Watts 200 200 100 100 By Contractor 780 880 Say 800W Say 900W Solar+ Solar+ Grid + Grid + Battery Battery 72 Hrs 1000 3000 2500 By Contractor Watts 72 Hrs 1000 3000 2500 Watts ** The above loads are indicative. 2. Sizing of SPV system. 4. Battery Bank. Contractor to verify the adequacy at the design stage. Battery charger and Grid Power supply to be done by the contractor Loads not on Battery Backup STANDARD GAIL (INDIA) LTD NEW DELHI LOAD ANALYSIS DOCUMENT 0001-01-07-08-001 REV-0 Page 3 of 3 © GAIL – All rights reserved . Battery Capacity Required (Ah) for 72 hours backup AND a DESIGN MARGIN OF 10% SPV system to be sized for Critical loads + battery charging current Battery charger connected to grid supply to be sized for critical loads + battery boost charging current 5. SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION S-07-02-001 REV-0 Page 1 of 11 © GAIL – All rights reserved . ABBREVIATIONS: BIS CRCA DOL LED NO NC PVC Bureau of Indian Standard. Cold rolled cold annealed Direct on line starting Light emitting diode Normally open contact Normally open contact Polyvinyl chloride GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION S-07-02-001 REV-0 Page 2 of 11 © GAIL – All rights reserved . 0 6.0 8.0 SCOPE CODES AND STANDARDS GENERAL REQUIREMENTS SITE CONDITIONS DESIGN AND FABRICATION REQUIREMENTS EQUIPMENT SPECIFICATION INSPECTION.0 4.0 3.0 7.CONTENTS 1.0 2.0 5. TESTING AND ACCEPTANCE PACKING AND DESPATCH GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION S-07-02-001 REV-0 Page 3 of 11 © GAIL – All rights reserved . control and distribution of power to various medium voltage consumers of the package equipment such as Air conditioning plant. o IS 8623 Factory built assemblies of switchgear and control gear for voltages upto and including 1000 V AC and 1200 V C. standards issued by IEC/BS / VDE/ IEEE! NEMA or equivalent agency shall be applicable.(Part-1 to Part-5) In case of imported equipment standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards. o IS 5082 Material data for aluminium bus bars.3 2.0 2. Pressurisation plant.1 2. Air dryer plant etc CODES AND STANDARDS The equipment shall comply with the requirements of latest revision of following standards issued by BIS unless other wise specified. o IS 13703 Low voltage fuses. o IS 5578 Guide for marking of insulated conductor. o IS 13947 LV Switchgear and control gear. testing.5 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT Page 4 of 11 © GAIL – All rights reserved . The equipment shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country. In case of any contradiction between various referred standards / specifications / data sheet and statutory regulations the following order of priority shall govern: SPECIFICATION S-07-02-001 REV-0 2.Part -II particular requirements for busbar trunking systems (bus ways).4 2. fabrication. o IS 772 AC Electricity Meters o IS 248 Direct acting electrical indicating instrurhents o IS 2705 Current transformers o IS 2824 Method for determining the comparative tracking index of solid insulating materials under moist conditions o IS 3156 Voltage transformers o IS 323 1 Electrical relays for power systems protection. In case Indian standards are not available for any equipment.. o IS 6005 Code of practice of Phosphating of iron and steel.0 SCOPE This specification covers the requirement of design.2 2. packing and supply of Medium voltage fixed type switchboard in single front execution required for receipt.1. o IS 3618 Phosphate treatment of iron and steel for protection against corrosion. o IS 11353 Guide for uniform system marking and identification of conductors and apparatus terminals. SPECIFICATION S-07-02-001 REV-0 3.2 5. Switchboard enclosure shall provide a degree of protection not less than P-42 as per applicable IS. The switchboard shall be fixed type in single front execution.1 5.0 5. with complete front access for operation and maintenance. l’he switchboards shall be designed to operate under specified site conditions. All the equipment described in this specification is intended for continuous duty at the Specified ratings under the specified ambient conditions unless indicated otherwise. The switchboard shall be free standing. If not specifically mentioned a design ambient temperature of 400 C and altitude not exceeding 1000 metres above mean sea level shall be considered. humid and corrosive atmospheres.1 4. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment at least for 15 years from the date of supply. fully compartmentalised.0 3. and following requirements of this specification in addition to the general requirements as per latest editions of applicable Indian standards. No prototype equipment shall be offered. cables and bus bar.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT Page 5 of 11 © GAIL – All rights reserved . totally segregated compartments for feeders.2 Statutory regulations Data sheets Job specification This specification Codes and standards GENERAL REQUIREMENTS The offered equipment shall be brand new with state of art technology and proven field track record.1 3.3 4. Vendor shall give a notice of at least one-year to the end user of equipment and GAIL before phasing out the product/spares to enable the end user for placement of order for spares and services. suitable for flushing mounting to wall.0 4. SITE CONDITIONS The switchboards shall be suitable for installation and satisfactory operation in a pressurised substation or in substation with restricted natural air ventilation in a tropical. dust and vermin proof suitable for indoor installation. assembled in single line up.o o o o o 3. DESIGN AND FABRICATION REQUIREMENTS Medium voltage switchboard shall meet the requirements of medium voltage switchboard data sheet. metal enclosed. The switchboard shall he suitable for bottom cable entry unless specified otherwise and shall be provided with removable gland plates unless otherwise specified. The switch board shall comprise of incoming load break switch panel or air circuit breaker panel. The width shall be sufficient to accommodate the required number of cables. in any case it shall not be less than 200mm width. The final paint shade shall be as per manufacturer standard unless specified otherwise. cable termination compartment etc. zinc passivated or cadmium plated high quality steel bolts. covers and doors shall be provided with neoprene gaskets around the perimeter to make the switchboard dust and vermin proof. The switchboard shall be designed to ensure maximum safety during operation. Required number of single compression nickel plated brass cable glands and tinned copper compression type lugs for all power and control cables shall be included in the vendor’s scope of supply. fuse switch contactors feeders.5 5. and connection of cables.10 GAIL (INDIA) LTD NEW DELHI Page 6 of 11 © GAIL – All rights reserved . All joints and connections of the panel members shall be made of galvanised. The switchboard shall be sheet steel clad with the frame fabricated out of 2mm cold rolled sheet steel and doorsi’covers out of 1. rust. However. All these shall SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION S-07-02-001 REV-0 5. The under coat shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. All hardware shall be corrosion resistant. The cable alley shall he provided with a suitable hinged door. relocation of outgoing circuits and maintenance with the energised bus bar system and without taking any special precautions.6 5.7 5. grease and dirt. degreased to remove mill scale. outgoing switch fuse. secured against loosening. motor starter feeders. The switchboard shall be spray painted with two coats of final paint or powder coated.9 5. Suitable lifting hooks shall be provided and each shipping section for ease of lifting of switchboard. Fabricated structure shall be pickled and then rinsed to remove any trace of acid. nuts and washers. All openings.3 The switchgear shall be assembled out of vertical panels of uniform height not exceeding 2450 mm.8 5.4 5. inspection. control supply transformers.5.6mm cold rolled sheet steel. The switchboard shall have a separate cable alley for each vertical panel with cable tying arrangement. The switchgear shall permit maximum interchangeability and shall be extensible on either side. The maximum height of the operating handle/switches shall not exceed 1900 nmi and the minimum height not below 300 mm. having integral base frame for each vertical panel. All metal surfaces shall be thoroughly cleaned. both power and auxiliary/control bus bars. 12 5. control supply and metering SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION S-07-02-001 REV-0 5.14 5. Each vertical panel shall be provided with anti condensation heater rated for 240 V AC supply.16 5.11 Main horizontal bus bars shall be provided at the top in separate compartment. Number and rating of feeders shall be as per package vendor’s electrical load list/single line diagram. provided with a switch fuse and thermostat having variable setting range of 30-70 °C. Each outgoing feeder shall be in multitier arrangement having minimum height of individual module as defined in switchboard data sheet. All feeders shall be of modular design with height in multiple of standard unit size.be housed in independent compartments separated from each other by metallic barrier. All components including bus bars and cable termination shall be accessible only from the front side for repair and maintenance. Components requiring frequent inspection during operation shall be easily accessible.19 5. One set of vertical bus bars can be provided for feeding outgoing feeders in two panels on either side of the vertical bus bar. 5. Vertical bus bars required for connection between main bus bars and outgoing feeders shall be in separate vertical chamber. indication. Adequate space shall be provided for termination of incoming and outgoing cables. Minimum clearance between line parts. All auxiliary devices for control.13 5. Horizontal and vertical bus bars shall be sized depending upon the maximum expected current and to limit the specified maximum operating temperature at specified design ambient temperature. between live parts/neutral to ground shall be 19 mm. The components rating and type for various types of outgoing feeders such as motor feeders shall be selected based on package requirement and shown in data sheets.20 GAIL (INDIA) LTD NEW DELHI Page 7 of 11 © GAIL – All rights reserved . Adequately sized auxiliary copper bus bars running horizontally in a separate enclosure shall be provided for space heaters.15 5. Main bus bars shall be of high conductivity Electrical Grade aluminium having uniform current rating throughout their length. The maximum operating temperature of bus bars including joints at the maximum design temperature inside the panel shall not exceed 95°C under normal operating conditions. measurement and protection except the bimetallic relays shall be mounted on the front side of the respective compartment.17 5.18 5. the wiring for power. 240 V AC control supply for motor starters shall be derived from a common 415/240 V adequately sized transformer for each bus section.22 5.requirements. Each wire shall be terminated at a separate terminal.25 5. The inside the switchboards.1 GAIL (INDIA) LTD NEW DELHI Page 8 of 11 © GAIL – All rights reserved . mm. complete with necessary interlock and defeat mechanism. For modules rated above 100 Amp. All motor starting shall be DOL type unless otherwise specified.27 6. Each wire shall be identified at both ends by self-sticking wire marker tapes or PVC ferrules. Copper earth bus of 30x6 mm2 size for fault level upto 31.5 KA shall be provided throughout the length of the switchboard with provision for interconnection to earthing grid at two ends. Control supply change over switch shall be provided in case the switchboard is with two bus-sections. Yellow and Blue colour rings for easy phase identification at regular interval and at every power tap off point and designed to withstand specified short circuit currents for one second. SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION S-07-02-001 REV-0 5. signaling protection and instrument circuits shall be done with PVC insulated copper conductors having 660/1100 V grade insulation. Components of the similar modules of same sizes shall be identically located and wired.24 5. for conductors larger than lOmm2 bolt type terminals with crimping lugs shall be provided. A minimum of 10% spare terminal shall be provided on each terminal block. heavy duty/mzaor duty. Transparent shrouds shall be used on outgoing power terminals. Clamp type terminals shall be acceptable for wires upto 10 mm2 size. air break type with the operating handle mounted on the compartment door.21 All horizontal and vertical bus bars shall be insulated with heat shrink PVC sleeves of 1100 V grade and removable shrouds shall be provided for joints.5 mni2 copper conductor shall be used. For higher fuse rating control circuits.5 mm2 coppers for circuits having fuse rating 10 Amp. control. Doors and movable parts shall be earthed using flexible copper connections. Shorting links shall be provided for all CT terminals. Necessary tee-off connections shall be used for distributing auxiliary supply to each vertical panel.5 KA and 50x6 mm2 size for fault level above 31. Minimum size of control wire shall be 1. preferably copper strip connection shall be used. All bus bars shall be prominently marked with Red.0 6.23 5. All non-current carrying metallic parts of the mounted equipment shall be earthed. 5. EQUIPMENT SPECIFICATION All breaker shall be air break type All switches shall be load break.26 5. or less. 2. 5 for ammeter and voltmeter.0 and instrument safety factor less than 5. Protective current transformers shall have an accuracy class 5P and an accuracy limit factor greater than 10. Thermal overload relays shall be three elements.All switches drives other than rotary switches shall be lockable in both on and off position. o o o o o o o o GAIL (INDIA) LTD NEW DELHI 6.0 is acceptable for ammeters only for outgoing feeders. Alternately clustered LED type indicating light with minimum 8mmdiameter size shall be considered. Current transformers for metering shall have an accuracy class 1. 6. Ammeter selector switch shall have make before break feature on its contacts. The following indicating colours shall be used. Indicating lamps shall be suitable for 6. However accuracy class of 3.5 6. complete with built in 240/6V transformers. Bimetal relays shall be manually reset type with the reset push button provided on the cubicle door.0 V AC.6 6. flush mounting type and of 96 x 96 mm and 72 mm x 72 mm square pattern instruments for incomer and outgoing feeders respectively. Lamps shall be provided with translucent covers to diffuse light. All selector switches shall be rotary back-connected types having a cam operated contact mechanism with knob type handle.7 6. Accuracy class shall be 2. Ammeters for motor feeders shall have a non-linear compressed scale at the end to indicate motor starting current and red mark for the normal current.2 6.8 Close/on Red Open/off Green Fault trip : Amber Control supply on : White Push button colours shall be as follows: Stop/open/emergency : Red Start/close : Green Reset/test : Yellow/Black/White SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION S-07-02-001 REV-0 Page 9 of 11 © GAIL – All rights reserved .5 for KW/KWH meter and 1. positive acting ambient temperature compensated type with adjustable setting range and built in protection feature against single phasing.4 6. pressure fitting link type The contactors shall be air break type having AC-3 or AC-4 duty rating as per package requirement. All contactors shall be provided with 1 NO + 1 NC potential free spare auxiliary contacts wired to the terminal block for owner use. All measuring AC instruments shall be moving iron.3 All fuses shall be non-deteriorating HRC cartridge. Acceptance tests shall be as follows: A general visual check shall be carried out.9 A centrally located engraved nameplate shall be provided for the switchboard. Tests shall be carried out at the manufacturer works under his supervision and at his cost. All routine tests as specified by the applicable standards and codes shall be conducted.5. At least 10% spare feeders of each rating of outgoing feeders subject to a minimum of one feeder of each rating shall be provided in the switchboard. under various conditions of supply voltage.4 7. INSPECTION. Manual and electrical operation of switches. switchboard shall be subject to inspection by GAIL or by an agency authorised by the owner. All necessary information concerning the supply shall be furnished to GAILs inspectors. In addition.“Stop” push buttons for motor control feeders shall have stayput feature. The vendor shall also submit the guaranteed technical particulars with the bids. terminal blocks. Type tests certificates of a recognised testing organisation shall be furnished with the bids. Identification tags shall be provided inside the panels matching with those shown on circuit diagram. Each module shall have engraved nameplate-bearing data as per approved drawings.0 7.3 7. contactors. number. This shall cover measurement of overall dimensions. 6. and type of devices and their ratings as per bill of materials.1 7. location and connection of terminals.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION S-07-02-001 REV-0 Page 10 of 11 © GAIL – All rights reserved .10 7. Name plate or polyester adhesive stickers shall be provided for each equipment mounted on the switchboard. relays etc.2 7.5 7. Two weeks notice shall be given to GAIL for witnessing the final testing of the complete assembly to ensure satisfactory operation of all components. TESTING AND ACCEPTANCE In addition to the expediting/inspection activities being undertaken by th package vendor. Special warning labels shall be provided on removable covers or doors giving access to cable terminals and bus bars.5. specified tests shall be conducted to check mechanical and electrical operation and the control wiring to specification and schematic drawings. location.1 7. All motor starter feeders shall have Stop and Reset push buttons and On and Trip indication lamps. 6. The panels shall be wrapped in polyethylene sheets before being placed in wooden crates /eases to prevent damage to the finish. Relays shall preferably be tested with secondary injection test equipment. Normally all routine tests as specified in the relevant standards shall be conducted by the sub-supplier at his works. weight. Insulation resistance of the main and auxiliary circuit shall be checked. ammeter selector switch and correctness of wiring connection between them. The equipment may be stored outdoors for long periods before installation.5.7.5.5. Special precaution notations such as Fragile.4 7. Purchase number etc.3 7.5 7.7 7. Crates /cases shall have skid bottoms for handling. Operation check for every control function as per the schematic diagram by manually simulating the actual operating conditions. in addition type test if specified shall be additionally carried out and witnessed by the owner at CPRI/approved testing authority. For equipment bought from other sub-suppliers certified test reports of tests carried out at the manufacturer’s works shall be submitted. Owner’s particulars.6 7. center of gravity.8 Dry insulation test with power frequency voltage for all circuits in ‘On’ position. This side up. ammeter. The packing should be suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed 8.5. Primary injection test to check winding of current transformers. PACKING AND DESPATCH All the equipment shall be divided in to several shipping sections for protection and ease of handling during transportation .0 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MV SWITCHBOARDS FIXED TYPE FOR PACKAGE EQUIPMENT SPECIFICATION S-07-02-001 REV-0 Page 11 of 11 © GAIL – All rights reserved . shall be clearly marked on the package together with other details as per purchase order.5.The equipment shall be properly packed for transportation by ship/rail or trailer.5. SPECIFICATION FOR DC-DC CONVERTER GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR DC-DC CONVERTER SPECIFICATION S-07-02-002 REV-0 Page 1 of 8 © GAIL – All rights reserved . 8. INDICATIONS AND METERING INTERFACE WITH SCADA PAINTING INSPECTION AND TESTING PACKING AND DESPATCH GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR DC-DC CONVERTER SPECIFICATION S-07-02-002 REV-0 Page 2 of 8 © GAIL – All rights reserved .0 2. 7. 11. 10. CONTROLS. 9. 6. 5. SCOPE CODES AND STANDARDS GENERAL REQUIREMENTS SITE CONDITIONS DESIGN AND FABRICATION REQUIREMENTS PERFORMANCE REQUIREMENTS MONITORING. 4. 3.CONTENTS 1. instrumentation and CP system requiring highly reliable power supply.1 SCOPE This specification covers the requirements of design. SCADA.3 GENERAL REQUIREMENTS The offered equipment shall be brand new with state of art technology and proven field track record.1 2 2. manufacture.2 2.4 © GAIL – All rights reserved .1 3. standards issued by IEC/BS/ VDE/ IEEENEMA or equivalent agency shall be applicable. delivery to site. packing. No prototype equipment shall be offered. unless other wise specified: i) BIS specifications ii) iii) International Electrotechnical Commission (IEC) American standards institution (ANSI) 2. testing. In case of any contradiction between various referred standards / specifications / data sheet and statutory regulations the following order of priority shall govern: o Statutory regulations o Data sheets o Job specification o This specification o Codes and standards 3 3. testing and commissioning of the DC to DC converters. DC to DC converters are required for installation at remote and unattended stations of pipelines for feeding power to station loads of telecommunication.3 2. In case Indian standards are not available for any equipment. CODES AND STANDARDS: The equipment shall comply with the requirements of latest revision of following standards. Vendor shall give a notice of at least one year to the end user of equipment and GAIL before phasing out the product/spares to enable the end user for placement of order for spares and services.2 3. These DC to DC converters shall be suitable for continuous and uninterrupted operation without failure and requiring minimum maintenance (maintenance interval not less than three months) and without requiring any operator or any GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR DC-DC CONVERTER SPECIFICATION S-07-02-002 REV-0 Page 3 of 8 3.1 1. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment at least for 15 years from the date of supply.4 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country. the front of panel. 660V PVC insulated wires with stranded copper conductor of size 2.1 5. It shall be possible to operate the MCCBs/MCBs without opening the door of the converter panel. while other auxiliary devices.6/2mm thick sheet steel. The main earth connection shall be brought out to two terminals for connection to station earthing system.3 5. All instruments shall be switchboard type and back connected. The basic module of DC to DC converters shall be highly reliable. This shall ensure complete safety to personnel intending routine maintenance by opening the panel doors. so that LEDs and operating knobs/potentiometer can be directly accessed. All the equipments described in this specification are intended for continuous duty at the specified ratings under the specified ambient conditions unless indicated otherwise. that maintenance requirements can be attended from front only. indication and other . DESIGN AND FABRICATION REQUIREMENTS The converter panel shall be fabricated with 1. alarm. If not specifically mentioned a design ambient temperature of 40°C and altitude not exceeding 1000 meters above mean sea level shall be considered. Wherever required.1 SITE CONDITIONS The DC to DC converters shall be suitable for installation and satisfactory operation in a non air-conditioned room with restricted ventilation.5 mm2 shall be used for control wiring. Removable cable gland plate shall be provided for glanding of all cables. All fuses shall be provided inside the panel and shall be of link type.2 5. connectors and terminals shall be arranged. using single compression nickel plated brass cable glands. The DC to DC converter shall be designed to operate under site conditions as specified in the data sheet. The converter panel shall be wall mounted type and shall not need rear access for maintenance. All components.other attention at unattended stations.6 mm sheet steel. All live parts shall be properly shrouded. All non-current carrying metallic parts shall be earthed with copper wire. so . the front facia of DC to DC converter module shall be flushed with .5 © GAIL – All rights reserved .4 5. Alternatively the cabinet may be designed in two vertical portions with plug in modules of DC to DC converters in one portion.2 5 5. Frames shall be enclosed by using 2mm thick sheet steel and doors and covers shall be made of 1. In this type of construction. Suitable louvers shall be fitted for ventilation. The bottom vertical portion with hinged door shall accommodate MCCBs/MCBs. 4 4. housed in another portion. having proven performance record. Overall hinged door shall be provided at the front of the panel. auxiliary devices as required for the overall unit. The termination provision shall GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR DC-DC CONVERTER SPECIFICATION S-07-02-002 REV-0 Page 4 of 8 4. suitable stiffeners shall be provided. the other converter shall continue to feed the load. The . The parallel redundant DC-DC converters shall have two nos. In case of failure of any one of converter.4 6. The normal output shall be restored within 100msec.6 GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR DC-DC CONVERTER SPECIFICATION S-07-02-002 REV-0 Page 5 of 8 © GAIL – All rights reserved . 6. The electrical isolation between input and output shall be rated for mm 500V DC. DC-DC converters which shall work in parallel redundant mode. but each capable of delivering full load. The steady state output regulation for no load to full load and with input voltage variation of +25% and -1 5%(unless specified otherwise) over nominal voltage. It shall be possible to operate the DC to DC converters with its output polarities ungrounded or any of its polarity grounded. shall be better than ± 1% of the rated output..6 6 6.1 All components and devices shall be provided with screwed nameplates. Nameplates shall be 3 ply (white/black/white) two colour laminated plastic. as specified in the data sheet/MR/tender document.3 6. The DC to DC converters shall either work in dual parallel redundant mode or single non redundant mode. The overall efficiency shall be minimum 75%. variation in voltage up to +25% and -15%. drawing repetitive peak surge currents. sharing the load in normal operation. The output of the converter shall be filtered/smoothened to provide DC output with less than 2% ripple. 5. unless specified otherwise in the data sheet. The voltage conversion/control from input to output shall be by control of duty cycle of conduction of the power semiconductor device. converters shall operate on a switching frequency above 20kHz.2 6. PERFORMANCE REQUIREMENTS DC to DC converter shall be of solid state type and shall operate on switch mode principle. irrespective of grounding of input supply. using suitable cable lugs. The output voltage dynamic response of the converter unit shall not be more than ± 10% of nominal output voltage for step loading and unloading of 50% of the rated output in case of dual redundant DC to DC converters and on 100% step loading and unloading in case of single non redundant DC to DC converters. DC-DC converters shall be suitable for the incoming supply voltage as specified in the data sheet.5 6. The DC to DC converters shall have galvanic isolation (between input supply and output supply). The output voltage shall be adjustable up to ± 5% of the nominal output voltage. requisite isolation transformer shall be provided in E the converter.be provided in the panel for terminating the power cables. The DC to DC converter shall be suitable for feeding power to loads having switch mode power supply regulators at the input. with . INDICATIONS AND METERING Each DC to DC converter module shall be provided with monitoring for the following: i) Load voltage high ii) Load voltage low iii) Thermal overload protection iv) Module. Potential free contacts for remote monitoring shall be provided for digital signals and 4-2OmA current signals corresponding to input parameter range(0. db (A) at any load from 0-100%. The potential free contact for digital monitoring shall be open to alarm state. CONTROLS. DC to DC converters shall be suitable to withstand switching surges or otherwise protective devices shall be provided. distance from the converter unit at any position shall not exceed 70 . internal component layout and component rating shall ensure high MTBF and low MTTR MONITORING.1 (a) (b) 8.8 6.Too high/Too low Following control devices.interference noise emitted by the converter shall be minimised to allow proper operation of telecom and SCADA systems in the vicinity and powered by the converter. The converter shall preferably be of natural cooled type.Fault/Fail(Module not feeding the load) v) Input fuse fail vi) Input voltage .11 7 7.9 6. Radio . The converter shall be field proven and shall be suitable for unattended operation at remote locations. connection to SCADA system: cob. INTERFACE WITH SCADA Following digital/analog monitoring signals shall be provided in DC to DC converters for remote . LED indication for module fault/fail(Module not feeding the load) Other alarm indication & control devices as per manufacturer’s requirement/standard.not faulty/not failed) DC output voltage.7 Each converter module shall be protected against output short circuit and over current. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR DC-DC CONVERTER SPECIFICATION S-07-02-002 REV-0 Page 6 of 8 6. The converter shall have input filters to minimise the AC feedback to the power supply.10 6.2 © GAIL – All rights reserved .1 7.6.2 a) b) c) 8 8. (Module . LED indications and meters for each DC to DC converter shall be provided on front of the panel: Potentiometer for adjustment of output voltage. The converter design. The noise level measured at 1 m.110% of maximum rated value of the parameter) for analog signals. DC to DC converter module feeding the load for each DC to DC converter module. All the instruments and equipment required for testing shall be arranged by vendor. grease and dirt.All functions shall be checked up for proper operation. All unpainted steel parts shall be cadmium plated or suitably treated to prevent corrosion. PAINTING The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale.0 10. Panel finish shall be free from imperfections like pin holes. 50Hz between input and output. orange peels etc. Colour of final paint shall be vendor standard. Fabricated structures shall be pickled and then rinsed to remove any trace of acid.Proper mounting of components and neatness of wiring etc.5 mm2 copper cable.3 The transducers shall have electrical isolation rated for minimum 2kV. The under surface shall be free from all imperfections before undertaking the finishing coat. The accuracy class of the 4-20 mA current transducers shall be 5% or better.Completeness of the equipment in line with specs.Dimensional checking .8. . 9. Detailed test procedures along with the facilities available at vendor’s works shall be submitted along with the bid. Alternatively.3 a) b) GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR DC-DC CONVERTER © GAIL – All rights reserved .2 10.Model number Functional testing:. The 4-20mA current transducers shall be suitable for driving load resistance of 600 ohms located up to 100 m away and connected through 0. Test certificates including test records and performance data etc. Final acceptance tests shall be carried out at manufacturer’s works under his care and expense. It shall then be spray painted with two coats of epoxy paint.1 INSPECTION AN]) TESTING The owner or his authorised representatives may visit the works during manufacture of equipment to g 8 assess the progress of work as well as to ascertain that only good quality raw materials are used for the same. SPECIFICATION S-07-02-002 REV-0 Page 7 of 8 10. Owner’s representative shall be given minimum four weeks advance notice for witnessing the final testing. Acceptance tests shall include but not be limited to the following: Visual Inspection . rust. shall be furnished by the vendor.0 10. . The finished panel shall be dried in stoving ovens in dust free atmosphere. powder coating as per manufacturer’s standard is also acceptable. The under surfaces shall be prepared by applying a coat of phosphate and a coat of zinc oxide/phosphate primer. He shall be given all assistance to carry out the inspection. The transducers shall be protected against input and output voltage surges. measurements shall be carried out to prove that the operating temperatures of various components do not exceed their design ratings with sufficient margins as per good engineering practice/established guidelines. center of gravity.c) d) 11. Type test certificates shall be submitted for ensuring compliance to other guaranteed performance parameters. weight. The packing should be suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed.0 Heat run test (full load test) shall be carried out for a minimum duration of 8 hours on all units except that in case of identical ratings for more than one unit. Owner’s particulars. The equipment may be stored outdoors for long periods before installation. PACKING AND DESPATCH The equipment shall be properly packed for transportation by ship/rail or trailer. The panels shall be wrapped in polyethylene sheets before being placed in wooden crates /cases to prevent damage to the finish. Special precaution/parameters such as “Fragile”. heat run test may be conducted only on one of the identical units. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR DC-DC CONVERTER SPECIFICATION S-07-02-002 REV-0 Page 8 of 8 © GAIL – All rights reserved . During this test. Purchase number etc. “This side up”. Crates /cases shall have skid bottoms for handling. shall be clearly marked on the package together with other details as per purchase order. SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 1 of 17 © GAIL – All rights reserved . Abbreviations: ACDB C.C CT DCDB HV MMI MV OISD PF PT UPS VRLA AC Distribution Board Carbon Tetrachloride Current Transformer DC Distribution Board High Voltage Man Machine Interface Medium Voltage Oil Industry Safety Directorate Power Factor Potential Transformer Uninterrupted Power Supply Valve Regulated Lead Acid GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 2 of 17 © GAIL – All rights reserved .T. 3.CONTENTS 1. 4. 5. SCOPE CODES AND STANDARDS INSTALLATION OF EQUIPMENT EQUIPMENT COMMISSIONING LIST OF CONSTRUCTION EQUIPMENT GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 3 of 17 © GAIL – All rights reserved . 2. Part 3: Installation. field inspection. forming part of electrical power distribution and utilisation system. testing and commissioning of electrical equipment. 3 INSTALLATION OF EQUIPMENT Prior to start of installation of the electrical equipment contractor shall verify that equipment and complete materials have been received. c) Regulations laid down by CCE/DGMS (as applicable). GAIL Installation Standards. The substation/switchgear room wherein the equipment shall be installed shall be kept clean. testing and commissioning of all electrical equipment shall be done by contractor with utmost care. installation and maintenance of switchgear and control gear . CODES AND STANDARDS The work shall be carried out in the best workmanlike manner in conformity with this specification.1 2. Part 2 Installation. o IS 1011 8(Part-3) Code of practice for selection. including Communication and Fire alarm system. b) Regulations laid down by CEA/Electrical Inspectorate. dry and free from all debris. e) Any other regulations laid down by central/state/local authorities and Insurance agencies.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable: a) Indian Electricity Act and Rules. Panel floor cutouts not in immediate use shall be suitably covered to SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 4 of 17 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Installation and maintenance of transformers. o IS-7816 Guide for testing Insulation resistance of rotating machines.1 SCOPE This specification defines the requirements for the installation. installation. layout drawings and to the following specifications/ codes of practice of Bureau of Indian Standards and OISD standards. o IS 10028(Part-2) Code of practice for selection. o OISD 147 Inspection and safe practices during electrical installations 2 2. o SP-30(BIS) National Electrical Code. d) The petroleum rules (Ministry of Industry Government of India). o OISD 137 Inspection of Electrical Equipment. Manufacturer’s instructions and the requirements given in their technical manuals shall be strictly adhered. Handling. shifting to required site location. 2 3. The lifting position mark indicated on packing casing shall be adhered to strictly. care shall be taken to observe the correct lifting arrangements and to make sure that slings are attached to the manufacturer’s designated lifting points. Contractor shall check and report to the Engineer-in-charge about any damaged item and / or missing component for getting the same replaced as per specifications. It shall be ensured that the base plate level of HV switchboard shall match with the finished floor level. The foundation pockets and the grouted bolts shall be cured for a minimum period of 48 hours. All the panels shall be assembled. nuts and bolts are all intact and tightened.avoid any mishap. base channel frame of panels supplied by the vendor shall be grouted and levelled in cement concrete. for keeping it in required vertical position. The switchboard panels shall be taken out from the packed cases and shifted one by one to its proper place.1. Steel base channels shall be welded to inserts provided in floor slab. Cross members shall be provided at the junctions of each shipping section and other places as required. ACDB.1. It shall be ensured that panel to panel coupling bolts. Roller bars may be used for shifting of panels.1. bushings.1 3. racking in and out SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 5 of 17 3. Dragging of the panels directly on floor shall be avoided. The lifting. No parts shall be subjected to undue strains or sudden stresses which could cause damage to the equipment. Use of a crane and trailer shall be made for handling of equipment. all accessories and loose items shall also be inspected by the contractor before their assembly/mounting. Alternatively when the floor is being laid.1 Switchboards and Bus Ducts The term switchboard here includes all HV / MV/ LV switchboard panels . 3. DCDB etc. charger panels. avoiding any impact to the equipment. When handling the switchboard panels. No new holes for jointing of the panels other than those recommended by the vendor shall be drilled. fit properly without any strain on any part. motor control centers. power and lighting distribution boards. While lifting the panels in packed conditions. The panels shall be preferably kept inside the packing cases till foundations are ready. The switchboards shall be lifted after ensuring that panel supports. During installation. bus bar links etc. metering and protective equipment. The switchboard panels shall be properly supported on the truck or trailer by means of ropes to avoid any chance of tilting. No gaps shall be left between the panels. utmost care shall be taken to avoid any damage to insulators. UPS panels. The switchboard panels shall be handled with care. The switchboard panels shall be installed on prepared foundations or floor cutouts. aligned and levelled. Alignment of panels shall be checked in both longitudinal and lateral directions.3 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . of high voltage equipment. reference shall be made to GAIL structural standard No. meters. Hinges of panel doors shall be lubricated to give free and noise free movement. 3. Auto transfer scheme shall be simulated and verified. S-11-01-010 (Cable Trench). or any other reason./sq. busbar chamber shall be cleaned and checked for tightness of all the components. switchboard components such as switches. Interconnection wiring between shipping sections shall be made by contractor. starters. Where specified . Contact resistance of all busbar joints and contactors shall be checked. panels cutouts provided for future use shall be filled with lean concrete. Functional scheme verification of individual feeder shall be carried out and minor wiring modifications in the panel wiring. defective components if any shall be taken out.4 After completion of erection of switchboards. All openings shall be kept completely closed to avoid ingress of any foreign particles inside the panel.operation of the breaker and all other motions shall be free from any obstruction. wiring continuity and correctness in the protection as well as measurement circuits. All the wiring connections shall also be checked. The checkered plates shall be painted with a coat of red oxide zinc chromate primer after proper surface preparation as per specifications. all the cubicles. In this regard. All loosely supplied items shall be fitted up. all uncovered portions of floor cutouts shall be covered with 6 mm thick removable checkered plates finished with floor level. During the course of scheme verification tests.T. C. the entire switchboard shall be dried.5 Where switchboard is damp or having a low IR value due to damaged insulators/ bushings/any other insulated parts. contacts shall be cleaned with C.T. Special attention shall be paid to CT circuits polarity. Insulator shall be checked for any damage. All the starters. 3. switches. The panels shall be checked for correct vertical position using pendulum weight and spirit levels . Bus bar sections or links shall he inserted and where specified. After erection of switchboard panels. Vacuum circuit breakers shall be checked for integrity o bottle seals. Suitable lifting arrangements shall be provided for checkered plates. The design of the checkered plates shall be such that the maximum allowable deflection is 1) 200 (where L is the span of the checkered plates in metres) for a live load of 500 kg.1. The same shall be replaced by component supplied by owner. The switchboard panels shall be tack welded at suitable intervals at base channel. All the moving parts shall be checked for easy and free movement. shall be insulated. Phase sequence and polarity of PTs and CTs shall be checked.C. after bringing to the notice of Engineer-in-charge. and PT.1. if required shall be done as per the directions of Engineer. chambers.up according to the instruction of the SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 6 of 17 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .in-charge. where required. 1. Wiring continuity and correctness are ensured in the protection and measurement circuits. Electrical simulation tests shall be carried out for all the protective. alarm and annunciation relays and external interfaces to ascertain proper functioning.charge All moving parts.Engineer-in-charge for the IR value to improve to a safe level for commissioning. PTs. supply for all the circuits is correct.1. incoming and outgoing cables shall be meggered.11 ii) iii) iv) v) GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . protective relays and other relays and contactors shall be tested as per manufacturers recommendations and according to the instructions of the Engineer-in.7 3.in. All the control wiring. 3. All the auxiliary contacts of breaker shall be checked-up.1. bus bars. Indicating lamps are healthy and are in correct position.1. of closing/tripping mechanism.8 3. That all the metering instruments have been checked and found in working order.1. bushings. following points shall be checked and ensured for safe energising of the switchboard: i) That the installation of equipment to be commissioned is complete in all respects with its auxiliaries and all other mounting including earthing . That the polarity test and ratio test of all the PTs and CTs is complete and phase sequence of CTs conforms to the correct vector group connections. All power and control fuses are of proper rating. Openings in floor within and outside panels have been sealed off. Pre-Commissioning Check List: Before commissioning any switchboard. Care shall be taken to protect the surrounding insulation from direct local heating during the drying up process. That all the protective relays including both conventional and microprocessor based numerical relays and thermal overload relays have been tested for secondary injection tests. racking in and racking out mechanism.1. Protection relays shall be inserted and connected and settings adjusted as required by the Engineer. spouts and shutter closing mechanism shall be checked for proper operation.10 3. Safety insulation mats of approved make and of required voltage grade shall be provided in the sub-station. cleaned and contact pressure measured. other live parts of switchgear. That the high voltage test of incoming and outgoing cables have been conducted and results are satisfactory. Polarity of D.charge.9 3.6 All the metering instruments.C. (Primary injection tests SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 7 of 17 3. All cover and door gaskets are intact to make the enclosure vermin proof. 2 Transformers Transformers on receipt at site shall be unloaded by means of crane or lifting devices of adequate capacity. The insulators shall be cleaned. Relay settings. The transformers shall be properly supported by steel ropes and stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and vibrations. Petroleum jelly shall then be applied and bolted connection made. The bus duct enclosure shall be checked for earth continuity and then earthed at two places.1. All lifting lugs shall be used to avoid unbalanced lifting and undue stresses on lugs. data logging.2. The bus duct shall be properly supported between switchgear and transformer. Value have been recorded for bus bars. bus bar bolts and nuts shall be thoroughly cleaned. Before lifting transformer. That I. Lifting jacks shall not be used under the valves or radiator tubes. Restricted Earth fault protection at full / reduced current to ensure correctness of complete wiring). At no instance the transformer shall be kept on bare ground. for active part. 3. In case when it is necessary to use jacks for lifting. the transformers shall be loaded on a suitable capacity truck or trailer. Where it is not possible to unload the transformer directly on a foundation.R. status indications.12 Bus Ducts: The bus ducts as per issued drawings will be supplied in parts and all the parts shall be assembled and the bus bar connections shall be made at site. Contact surface of bus bars.g. Lifting lugs if any provided for partial lifting (e. fault annunciations. it shall be unloaded on a properly SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 8 of 17 3. 3. While slinging.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . control wiring and potential transformers. shall not be used for lifting complete transformer. care shall be taken to avoid slings touching other parts. it shall be ensured that all cover bolts are tightened fully. Parts other than those identified for lifting of the transformer shall not be used for lifting. display of switchboard SLDs shall be verified from MMI in case the same is provided. circuit breaker. The bus duct levelling shall be checked with spirit level and pendulum weight. incoming and outgoing cables. For transporting transformers from stores to site. flexible connections etc. The opening in the wall where the bus duct enters the switchgear room shall be completely sealed to avoid rain water entry. projections provided for the purposes of jacking shall be used . All the surroundings and panels have been cleaned and temporary earth leads have been removed.vi) shall be carried out for differential protection. Expansion joints. Where required joint resistance of bus bars have been recorded and found to be satisfactory. conservator) etc. The insulators in bus ducts shall be inspected for any possible damage during transit and the defective ones shall be replaced. supplied by the manufacturer of the bus duct shall be properly connected. aligned and checked for free movement on the channels or rails. cooling fans.1. Oil samples shall be taken from each drum and tested for determination of dielectric strength.built wooden sleeper platform.2 Transformers shall be examined. All the connections for CTs bushings and other wiring shall be checked for tightness and correctness before replacing the lid or tightening all the bolts. transformer shall be fitted with all accessories such as valves. To prevent aeration of the oil. 3.charge. It shall be ensured that oil spills can not propagate along cable trenches. Oil shall be filled through a streamline oil filter using metal hose. All air vents shall be opened. bushings and other devices which are supplied in different packages shall be checked for any transit damage and cleaned thoroughly before fixing on the transformer.in.2.in. Particular attention shall be given to the following in this regard. the rate of oil flow shall be reduced when the level is almost upto the bottom of the main cover to prevent internal pressure from rupturing the pressure relief-pipe diaphragm.5 3. the transformer tank shall be filled through the bottom drain valve. fire walls and foundations laid by the civil contractor. iv) Cracked or broken bushings. Contractor shall examine the transformer base. valves. gauges. All the accessories like radiators. conservator tanks.charge. sight glass etc.1. wheels and other accessories. Normally transformers upto 1000 kVA rating shall be received duly fitted with radiator tubes. valves. If any thing adverse is noted the same shall be brought to the notice of Engineer. It is necessary to filter the oil before the transformers are filled. A transformer shall never be left without putting stoppers to the wheels. Stoppers shall be provided to the transformers immediately to prevent any movement. GAIL (INDIA) LTD NEW DELHI 3. Any sign of leakage of the barrel or of its having been opened shall be recorded and reported. oil pit. thermometers etc. iii) Loosening of bolts due to vibration in transit. conservator tanks explosion vent pipe. Topping of transformer with oil: Before topping up with oil. i) Dents on tank wall or cooling tubes. for any sign of damage in transit. In a transformer with conservator tank. While the transformers of above 1000 kVA rating may be supplied with loose accessories. It shall be ensured in oil filling operation that no air pockets are left in the tank and that no dust or moisture enters the oil. The transformers shall be levelled. All loosely supplied parts shall be assembled as per manufacturer’s instruction manuals/ drawings and documents. v) Oil leakage particularly along welds. Any discrepancy noted will be brought to the notice of Engineer. ii) Damage to protruding parts like valves. Transformers shall be placed on channels or rails over concrete foundations.6 SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 9 of 17 © GAIL – All rights reserved . with a 5 kV Megger may be a rough indication for stopping the dehydration. ii) The transformer shall be carefully monitored throughout the drying out process and all observations shall be carefully recorded. Generally a megger reading of 2 megohms / kV at 600 C temp. ii) Testing of Oil: For dielectric test. regular readings of the insulation resistance of the winding to earth and winding to winding and temperature against time shall be recorded. value versus time of both windings shall be recorded during the drying-up process. a minimum number of cycles shall be done for each transformer as found necessary by the Engineer-in-charge.2.2 3. The following work on transformers. shall be performed by the contractor if specifically called for: Before finally commissioning the transformer it may sometimes be desired to run it for a few hours on short-circuit. Normally a streamline filter shall be used for drying-up.5 Transformer Oil i) Sample of oil from the transformer shall be taken from the bottom of the tank. if required .6 3. Pre-commissioning Check List: Before commissioning of any transformer. the oil shall be tested as described in IS 335. 3.8 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION © GAIL – All rights reserved .2. During this process. shall be carried out and record maintained in accordance with IS : 10028.2. Precautions when drying i) The maximum sustained temperature to which transformer oil may be subjected shall be limited to 80 C.7.2. Drying out of the transformers.Sufficient time shall be allowed for the oil to permeate the transformers and also for the locked -up air bubbles to escape.7 3.7. Any air accumulation in the Buchholz relay shall be released. iii) Drying out shall be continued so that the insulation resistance as prescribed in the standard code of practice is attained and the value remains constant for more than 12 hours.1 3.2. Testing of radiator tubes for any leakage and rectifying these by welding / brazing. The oil shall also be tested for acidity in accordance with the methods prescribed.2. the following points shall be checked for safe energisation of the transformer: SPECIFICATION S-07-02-003 REV-0 Page 10 of 17 3. approximately equal to the impedance voltage of the transformer. However. applying a low voltage. JR. The tap setting on which the off load tap switch is locked shall be recorded. SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 11 of 17 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Tap changer limit switches are operating satisfactorily on the maximum and minimum tap positions. Generally the off-load tap switch shall be kept on nominal tap. In case transformers are idle for more than one month after dehydration.i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) That all the accessories have been fixed properly and transformer body and neutral are properly earthed. That the winding and oil temperature thermometer pockets contain oil and the winding and oil temperature settings on dial gauges are in order. annunciation and trip circuits have been checked and are in order. The mechanical parts of the on-load tap changer are lubricated. alarm and annunciation relays have been tested. Tap position mechanical indicator on the transformer and tap position indication meter on the control panel are reading the same tap positions. The transformer dehydration is over and results are satisfactory and approved by the Engineer-incharge. transformer oil has been given at least two circulations. Oil level of tap changer tank is upto the required level and oil has been tested for dielectric strength. That gaps of arcing horns for the bushings where provided are in order and earth connections for the surge diverters have been checked. On-load tap changer contact pressure and resistance is as per manufacturers recommendations. That the operation of off-load and on-load tap changers on all the tap positions is satisfactory. All the other protective relays. and floats are free. That the ratio test and winding resistance on all the tap positions is satisfactory. That the insulation resistance of all the control circuits and IR value of the transformer windings and all the incoming and outgoing cables have been checked. The explosion vent diaphragm does not have any dents. Phase sequence and connections have been checked for proper vector group. That the transformers fitted with fans for forced air cooling have been checked up for automatic starting and stopping of the fans and airdisplacement has been verified. Motor IR value has taken and found satisfactory. That the oil level. That the silica gel is in reactivated condition. Accumulation of any oil and air had been released. in the transformer conservator tank and all the bushings is upto the marked point and the oil has been tested for dielectric strength and acidity. That the simulation tests for all external interface connection alarm. That the Buchholz relay has been tested and checked up for any friction in the movement. The breather pipe is clear from any blocking and contains oil upto the proper level. That all the metering equipment have been tested and polarity test of PT’s and transformer winding is satisfactory. R. In case of lower l. H. winding temperature and oil temperature readings. i) By locking the motor so that it can not rotate and then applying such a low voltage to the stator terminals so as to pass full load current in the stator keeping the stator winding temperature below 90° C . vii) Cable end boxes for any over -heating.C. iii) Voltage and current on all the three phases.R. value becomes steady. Placing heaters or lamps around and inside after making suitable guarding and covering arrangements so as to conserve the heat. Electrical contractor shall measure the insulation resistance of motor windings.V. In this case a close watch shall be kept for any possible overheating and I.3 3. i) Blowing hot air from external source. iv) Transformer hum or abnormal noise. 3.2. i) The inrush magnetizing current and no-load current. the following method of drying has to be adopted. Observations after Commissioning: After switching on the transformer the following points shall be observed and recorded.R. ii) iii) Putting the motor in oven.2.2.V. Values vs.6 3. or if any relay flag has operated. That the setting of all the protective relays is at the desired value and D. voltage. if any. vi) Record current . During drying the temperature rise of winding shall not exceed the permissible value for the class of insulation used. A minimum value of 1 megohm for 415 V motors shall be considered a safe value. Insulation resistance of the motors shall be measured between the winding of the machine and its frame by means of a 500 / 1000 V Meggar in case of 415 V motors . Value. SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 12 of 17 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . the insulation value shall be improved by any of the following methods as directed by the Engineer-in-charge.7 In case the insulation is low. cooling air temperature. Trip supply is healthy. ii) Alarm. after consultation with Engineer-in-charge. v) Circulation of oil and leakages. and M.xiv) xv) 3.9 That all the valves in the cooling system and valve between the Buchholz relay and the conservator tank are in open position. MOTORS All the motors generally would be erected by the mechanical contractor. temperature shall be plotted and heating continued till I. Electrical contractor shall keep the motor space heater energised as per the directions of Engineer-in-charge. hourly for 24 hours. Voltage.10 3. It shall also be ensured that recommended flow and pressure of air is available to produce the required cooling effect. 3. till steady temperature is reached. Finally the motor shall be started on no-load after decoupling.14 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION © GAIL – All rights reserved . Normally the motors run in clockwise direction as viewed from the driving end with reference to the phase sequence R.9 3.12 3. the over-load settings may be reduced or time lags bypassed from protective gear to ensure rapid tripping of switchgear in event of faults. If the no load test run is found satisfactory.13 3. the ventilation and cooling system of the motor must be inspected.2. In case it is essential.11 3. or for a time as instructed by Engineer-in-charge. with half an hour readings and. and for large machines after 10 hours.2.8 It shall be ensured that the motor leads are correctly connected in the terminal box. Y. Attention shall be given to the proper running of the bearings. slip rings and brush gear shall be polished and brushes shall be fixed in their holders with clearance and pressure as recommended by the manufacturers. as indicated in the Name Plate’. and shall be allowed to run for a minimum period of 4 hours. The direction of rotation of a new motor specially of large capacity. B. Maximum temperature of winding while drying shall be 70° C to 80° C (thermometer) or 90° C to 95° C by resistance method.ii) By blasting hot air from external source. In case of motor with forced ventilation the air inlet shall be examined to ensure that it is free from moisture and any foreign material.2. SPECIFICATION S-07-02-003 REV-0 Page 13 of 17 3. the insulation resistance of the motor shall be recorded under hot and cold conditions. Before commissioning. Direction of rotation shall be checked and recorded. The control circuit shall be tested for proper functioning as per circuit diagram. stator winding and bearing temperature shall be recorded after every 1 hour during this test. The covers of all terminal boxes shall be properly fixed. A record has to be kept for drying process. In case of synchronous machines. and phase sequence of supply shall be kept in view while joining and connecting to the motor terminals. the gaskets intact. vibration or unusual noises if any.2. the motor shall be allowed to run for 8 hours and all readings shall be recorded. starting current.2. no load current.2.2. After switching off the motor. the drying process can be supplemented by blower. Heating shall be done slowly first till steady temperature of winding is reached after 4 to 5 hours. The motor control gear shall also be carefully examined. 3. The proper level of bearing oil has to be checked . All covers etc. Electrolyte if required / as applicable shall be filled as per manufacturer’s instructions. for connection to earth electrodes and to the main grid. shall be checked for tightness to ensure that the enclosure of the resistor is dust. Batteries Battery (Lead acid.1.5 3. motor exciter set and induction generators directly coupled or coupled through reduction gears shall be checked for abnormal vibration. Contractor shall check and bring to the attention of Engineer-in-charge any defect noticed in this regard. Inter row connections shall be made with the leads supplied by the manufacturer. Due care shall be taken to avoid any damage to bearing insulation wherever provided. Welding Receptacles The welding receptacles shall be erected on steel/concrete structures as per the drawings.15. rough handling during transit.4 3. In isolated places a separate support shall be fabricated and installed.2. vermin and weatherproof. 3. All the motors.15 3.2.2.6 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 14 of 17 © GAIL – All rights reserved . The resistor shall be levelled and installed. Nickel Cadmium or VRLA type as specified) shall be erected on stands and insulators supplied by the manufacturer of the batteries.1 The following work on motors.3 3. If the grease coming out is deteriorated grease shall be replaced.1. may be performed by the contractor if specifically called for. Neutral Earthing Resistor The neutral earthing resistor shall be inspected for any damage to the resistor grid and other components. complete replacement of bearing with specified grade of grease after proper cleaning of the bearing shall have to be done ‘Wherever external greasing facility exists. The condition of grease in bearings shall be checked and in case it is necessary. if any Large rated HV motors with journal type bearings are liable to get damaged from shock.1. the condition of grease may be checked by pumping some new grease of specified grade at start. The installation shall be done as per the layout drawings and manufacturer’s instructions.15. Any minor defect in a race or roller may give rise to considerable amount of vibration and noise. Earthing conductors shall be taken from the out end terminal of the resistor.2.2 3.15. First aid boxes containing ointments and medicines for immediate treatment of injuries (As prescribed by Indian Red Cross Society or equivalent).10 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION © GAIL – All rights reserved . Gang operated Isolators/outdoor Disconnectors The isolators shall be transported to site in the dismantled condition. The exact location shall be decided at site by contractor in consultation with Engineer-in-charge. All outdoor push buttons / control stations shall preferably have integral canopies for additional weather protection.7 Push Button/Control Stations The push buttons / control stations shall be installed near to the motors to be controlled. entrance to switchgear room and at other places as required by Engineer-in-charge. Danger boards (H. switchboards.3 3. Contractor shall provide the following items in substation.V.9. SPECIFICATION S-07-02-003 REV-0 Page 15 of 17 3. If control stations for hazardous areas are to be supplied by contractor. telephone set etc.8 3. Instructions of restoration of persons suffering from electric shock in English.) shown on the drawing are indicative. shall be earthed. Individual channel supports shall be installed as per GAIL standard. break glass unit. erected and levelled by him.3. as per Indian Electricity Rules: Fire buckets filled with clean dry sand and ready for immediate use for extinguishing fires and fire extinguisher (carbon dioxide. The Communication system and Fire alarm system panels and equipment shall be installed complying to manufacturer’s instructions. The contractor shall inspect. M.2 3. dry chemical extinguisher etc. The operating mechanism shall be installed on the structure and connected to the isolator poles. assemble and install the isolator on the base structure previously fabricated. The operating mechanism shall be tested by slowly bringing the isolator to the closed position and carrying out the necessary adjustment as per the manufacturer’s instructions. The earthing switches.) suitable for dealing with electric fires shall be conspicuously marked and kept. Correct type of equipment with regard to hazardous protection as specified on drawing shall be adhered to by contractor.) shall be provided on transformer gate. Hindi and local language of the district shall be affixed in a conspicuous place.9.9.1 3. The location of field station (call back station unit..4 3. The canopy shall be made of 2 mm thick galvanized sheet steel or FRP where these are not integral with the equipment. clean . tested by CMRI and approved by CCE or other applicable certifying authorities.V.9 3.9. frames and operating handle etc. these shall be of Ex(d) type. All the insulators may be also supplied loose. for installation. Pipe bending machine (hydraulic). Portable gas cutting / welding set. ladders. and gloves.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . etc. vacuum cleaners. tarpaulins. After the equipment is installed properly in accordance with drawings and specifications. Miscellaneous items such as slings. LIST OF CONSTRUCTION EQUIPMENT The contractor shall have all necessary construction equipment. 4. as required. Conduit dye set. S-07-02-004. Pipe threading machine. contractor shall carry out all pre-commissioning checks and tests as per GAIL format in the presence of Engineer-in-charge and test readings shall be recorded and furnished to BIL in triplicate.1 Equipment Commissioning Field inspection.2 5 All equipment layout drawings shall be marked by the Contractor for “AS BUILT STATUS” and two sets of copies shall be submitted to GAIL. Equipment: i) Portable grinder. Separate tool kit for each Electrician. These shall include but not be limited to the following. safety goggles.4 4. Portable electric blowers . ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) Portable welding machine. Dewatering pump sets (diesel driven). Hand crimping tool. and these shall be brought to site by contractor before the start of work. Portable drill machine suitable to take up drilling for different sizes as per requirement. Hydraulic crimping machine. SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 16 of 17 5. Safety belts. pulleys. wooden sleepers. testing and commissioning of the complete electrical installation shall be carried out as per GAIL specification no. tools and tackles and testing instruments to carry out the erection works and to commission the system as specified. Power Hacksaw. meters. Insulation tester 5000 V motor/hand driven Phase sequence indicator. both analogue and digital Portable Ammeters. Multi-meter. ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) Insulation tester 2500 V motor/hand driven.C.C. xviii) LUX METER to measure illumination levels. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR ELECTRICAL EQUIPMENT INSTALLATION SPECIFICATION S-07-02-003 REV-0 Page 17 of 17 © GAIL – All rights reserved .F. Portable Voltmeters.2 Test Instruments i) Insulation tester 1000 V hand driven. Single phase variac 3 phase variac of adequate capacity. D. Earth Resistance tester. Secondary injection testing kit. Watt-meters. Kelvin's double bridge for measurement of very low resistance.5. high -pot test kit. Tacho-meter. D. Clip on meters of different ranges. Oil filtration machine of adequate capacity. P. high -pot test kit. TESTING AND COMMISSIONING OF ELECTRICAL INSTALLATIONS GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR INSPECTION.SPECIFICATION FOR FIELD INSPECTION. FILED TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT SPECIFICATION S-07-06-004 REV-0 Page 1 of 8 © GAIL – All rights reserved . FILED TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT SPECIFICATION S-07-06-004 REV-0 Page 2 of 8 © GAIL – All rights reserved .ABBREVIATIONS: AFC CEA : CCE : DC DGMS : GI : HV : IS : MV : OISD : Approved for construction Central Electricity Authority Chief Controller of Explosives Direct current Director General Mines and Safety Galvanized Iron High Voltage Indian Standard Medium voltage Oil Industry Safety Directorate GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR INSPECTION. FILED TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT SPECIFICATION S-07-06-004 REV-0 Page 3 of 8 © GAIL – All rights reserved .CONTENTS 1.0 4.0 2.0 3.0 SCOPE CODES AND STANDARDS FIELD INSPETION. TESTING AND COMMISSIONING RECORDS GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR INSPECTION. Part 45 High voltage test Inspection of Electrical Equipment Inspection and safe practice during electrical installation 2. checking the workmanship of the installation. iii) Regulations laid down by Tariff Advisory Committee/Loss prevention council. iv) Regulations laid down by CCE/DGMS (as applicable).3 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . inspection / pre-commissioning checks and tests shall be carried out by contractor.1 3. soundness of switchgear bus connections. testing and commissioning of Electrical Equipment and Installation. CODES AND STANDARDS The field inspection. the rating of equipment. In the event of defects being found out. the same shall be rectified and the installation retested as applicable. v) The petroleum rules (Ministry of Industry Government of India). testing commissioning of electrical equipment as per Inspection Test plans. vi) Any other regulations laid down by central / state / local authorities / Insurance agencies FIELD INSPECTION. wiring properly dressed and labeled.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable: i) Indian Electricity Act and Rules. Part 43 Insulation resistance Method of Test for cables. ii) Regulations laid down by CEA / Electrical Inspectorate. sizes of cables installed.1 2. Code of practice for installation and maintenance of power cables up to & including 33 kV rating. SPECIFICATION FOR INSPECTION. Method of Test for cables. TESTING AND COMMISSIONING Contractor shall carry out complete field inspection. FILED TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT SPECIFICATION S-07-06-004 REV-0 Page 4 of 8 3. forming part of electrical power distribution and utilisation system.0 2. sealing of unused cable entries. The pre-commissioning inspection among other requirements shall include visual inspection. checking of all safety interlocks. safety clearances.0 SCOPE This specification covers the requirements for the field inspection.2 Before the completed installation or an addition to the existing installation is put into service.1. testing and commissioning of electrical equipment shall be carried out in line with this specification and the latest edition of following Indian Standards and OISD standards.0 3. conformance to the AFC document. control/interface functions as per requirement etc. and 3. SP-30(BIS) National Electrical Code IS-78 16 IS 1255 IS 10810(Part 43) IS 108 10(Part 45) OISD 137 OISD 147 Guide for testing Insulation resistance of rotating machines. (Electrical contractor shall co-ordinate with other agencies involved for the above and provide support services for checking interfaces of electrical equipment and the intended functioning) o Earth resistance measurement for each earth electrode.4 Visual inspection for soundness of bus bar connections of bus-ducts. terminal connections of equipment/motor shall be carried out. o Checking of all wired interface contacts (analog. telephone and security system shall be checked for correct operation and intended function. The contractor shall provide necessary SPECIFICATION FOR INSPECTION. bolts. control circuit interlocks for intended functioning. o Checking of safety features for correctness of operation etc. o Testing of measuring instruments for proper functioning. o Insulation test for each winding and power and control circuit o High voltage test for cables o Dielectric strength test on transformer oil. o Checking the correctness of wiring schemes. It shall be ensured that no foreign materials are present inside busduct and equipment terminal boxes. and the earthing system as a whole. A close visual inspection of electrical equipment in hazardous areas shall be made to ensure that equipment is suitable for the classified zone and gas group and correctly installed. o Testing of all types of relays/releases for required operation.5 3. o Verification of phase sequence. Fire alarm.9 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Fittings shall be operated only with specified type of a lamp or tube.3. control circuits shall be tested for correct operation under all operating combinations and proved correct before applying power to main circuits.7 3.6 3. o Lighting installation shall be tested for correct illumination levels. with all covers. After the visual inspection. FILED TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT SPECIFICATION S-07-06-004 REV-0 Page 5 of 8 3. at panel and equipment terminal chambers as applicable. inspection chambers shall be refitted with gaskets. all the covers of terminal boxes. digital input/output contacts) for DCS and ECS interface. After the above tests and inspection are completed. bolts & nuts as per equipment manufacturer’s instructions. o Earth continuity test for all circuits. with the fittings installed. nuts and hardwares intact and there is no physical damage mark seen on the enclosure Site Acceptance Test procedure for specific equipment shall be furnished by the respective equipment vendor. Plant Communication.8 3. Pre-commissioning tests shall include but not be limited to the following: o Continuity test for each winding and power and control circuits. 300V grade 1.000 200 3. Contractor shall use only calibrated measuring and test instruments and shall maintain calibration records.12.000 200 12. In addition to the equipment manufacturer’s instructions. FILED TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT SPECIFICATION S-07-06-004 REV-0 Page 6 of 8 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .000V grade 5.12 3.12. MV and Miscellaneous Switchboards The insulation resistance test values for the switchboards shall be as per following table: Minimum Insulation Rated voltage of the DC Test Voltage in resistance in MΩ Switchboard Volts 33.10 All pre-commissioning checks and tests shall be carried out as per the directions of Engineer.1 3.700/15.11 3.000 100 240V 500 10 110V 500 10 SPECIFICATION FOR INSPECTION.in-charge.600V grade 1.000V 5.000 200 6.000 200 19.700/22.300V 1.2 HV.900/3.000 200 3.000 10 1.assistance to the equipment vendor to perform Site acceptance testing to enable the equipment vendor to perform the same.000 200 415V 1.000V grade 5. tackles.000V grade 5.350/11.000 200 11.000 200 3. 3. The Insulation Resistance test values for various electrical equipment shall be as below: Cables The insulation resistance test values for cables shall be as per following table: Minimum Insulation Rated voltage of the DC Test Voltage in resistance in MΩ Cable Volts Lighting and power 250 1 circuit wiring 650/1 100V grade cables 1. All tests shall be carried out by contractor in the presence of GAIL/Owner’ s representatives The contractor shall bring to site all required tools. and testing instruments for carrying out field testing. pre-commissioning check requirements shall also be complied.600V 1.800/6.000 200 6.000V 5.000 200 8.000/33000V grade 5. 8/6.13.3.300V 1.000V 3.12.9/3.65/1.3/3.3 3.000 100 1.13 High-voltage testing 3.5 9 9 18 SPECIFICATION S-07-06-004 5 5 5 REV-0 Page 7 of 8 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR INSPECTION.500 5.000 It shall be ensured that during insulation tests.000V 5. V.3 3.000 50 415V 1. The instructions of equipment/panel manufacturer shall be followed strictly in this regard.12. high voltage test shall be conducted as per following table on all H.3 Generators and Motors 3. 3. feeder cables and also on 1100 V grade cables where straight through joints have been made.600V 1.6 Transformers The insulation resistance test values for the Transformers shall be as per following table Minimum Insulation DC Test Voltage in Rated voltage of the resistance in MΩ at 40° Volts Transformers C Upto600V 601 to 5000V 5001 to 15. Rated Voltage TEST VOLTAGE (kV) BETWEEN of Cable (kV) Duration Conductor to Any Conductor and (Minutes) U0 I U* Conductor (For Metallic Sheath! Unscreened Cables) Screen/Armour 0.000 2.7 1.1 3 3 5 1.000 10.5 3.12.C.000 80 3.000 5.4 The insulation resistance test values for the Generators and Motors shall be as per following table: DC Test Rated voltage of the Minimum Insulation resistance in Voltage in Generators and Mega ohms at 40°C Volts Motors 11.12. electronic devices and components that are liable to get damaged on applied test voltage shall be disconnected from circuit.12.000V 15001 to 35.000 120 6. FILED TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT © GAIL – All rights reserved .000 15 240V 500 12 3.000 5.1 D.6 5 9 10. 35/11 11/11 12. In any case. Before energising any equipment. It shall be ensured that the electrical inspectorate approval is available before energising the equipment RECORDS Contractor shall keep up-to-date records of all activities carried out and test results.5 60 U0: Phase Voltage Conductor to Conductor (For Unscreened Cables) 18 30 30 U* Line Voltage Duration (Minutes) 5 5 5 5 5 3. Primary injection tests shall be carried out for differential protection. Field inspection / test reports shall be submitted to GAIL / Owner by the contractor in bound volumes (triplicate copies).5 3. repair work or nature of jointing work carried out.Rated Voltage of Cable (kV) U0 I U* 6.6 6. 3.7/22 19/33 TEST VOLTAGE (kV) BETWEEN Any Conductor and Metallic Sheath! Screen/Armour 18 18 30 37. the test voltage shall not be less than the rated voltage.13. ‘COMMISSIONING CLEARANCE FORM’ as per standard format shall be duly filled in by contractor and submitted to GAIL. FILED TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT SPECIFICATION S-07-06-004 REV-0 Page 8 of 8 © GAIL – All rights reserved .13.4 3.0 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR INSPECTION.13. etc. restricted earth fault protection at full/reduced current to ensure correctness of complete wiring. DC test voltage for old cables shall be 1.2 3.13.5 times rated voltage or less depending on the age of cables. All protective relays including thermal overload relays shall be tested by secondary injection current.13.3 The cable cores must be discharged on completion of DC high voltage test and cable shall be kept earthed until it is put into service.6/6.6 4. SPECIFICATION FOR EARTHING INSTALLATION GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR EARTHING INSTALLATION SPECIFICATION S-07-02-005 REV-0 Page 1 of 8 © GAIL – All rights reserved . ABBREVIATIONS: CEA DGMS GI : IS MS OISD UPS : Central Electricity Authority Director General Mines and Safety Galvanized Iron Indian Standard Mild Steel Oil Industry Safety Directorate Uninterrupted Power Supply GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR EARTHING INSTALLATION SPECIFICATION S-07-02-005 REV-0 Page 2 of 8 © GAIL – All rights reserved . 0 4.0 Scope Codes and Standards Material Specifications Earthing Network Installation Of Earth Electrode Connection Testing GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR EARTHING INSTALLATION SPECIFICATION S-07-02-005 REV-0 Page 3 of 8 © GAIL – All rights reserved .0 7.CONTENTS 1.0 3.0 6.0 5.0 2. Code of practice for earthing Guide for control of undesirable static electricity.0 3. Any other regulations laid down by central/state/local authorities and Insurance agencies. layout drawings. ii) iii) iv) v) Regulations laid down by CEA (Eiectrical Inspectorate).1. Recommended practices on static electricity Inspection and safe practice during electrical installation. GAIL Installation Standards. 2. The main earth grid conductor shall be hot dip galvanised M. flat unless otherwise specified. the latest edition of relevant specifications. Regulations laid down by CCE/DGMS (as applicable).1 MATERIAL SPECIFICATIONS All materials and hardware to be supplied by the contractor shall be new.S.0 SCOPE This specification defines the requirements for the supply of earthing and lightning protection materials and installation of the earthing and lightning protection systems.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable: i) Indian Electricity Act and Rules. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR EARTHING INSTALLATION SPECIFICATION S-07-02-005 REV-0 Page 4 of 8 3. unused and of best quality and shall conform to the specifications given here under and to latest specifications of Bureau of Indian Standards. Sizes for main conductors shall he as indicated on the earthing layout drawing .0 2. codes of practice of Bureau of Indian Standards and OISD Standards listed below SP:30 (BIS) Special Publication-National Electrical Code IS:2309 IS:3043 IS:7689 OISD 110 OISD 147 Protection of buildings and allied structures against lightning. 3. Contractor shall bring material samples to site and get it approved by Engineer-in-charge before installation.Amount of galvanizing shall be 610 gm per sq. CODES AND STANDARDS The work shall be carried out in the best workman like manner in conformity with this specification.1 2.1.2 © GAIL – All rights reserved . The petroleum rules (Ministry of Industry Government of India). All joints below grade shall be welded and shall be suitably protected by giving two coats of bitumen and covering with hessian tape. INSTALLATION OF EARTH ELECTRODE Earth Electrode shall be installed as shown on installation standard and layout drawings. the earth conductor shall be laid in the trenches and shall be firmly cleated to the sidewall of concrete trenches using Gl clamps. Earth strip laid above ground shall be welded across straight through joints and joints shall be suitably protected by giving two coats of bitumen to avoid oxidation and insulation film formation of the strip surface. The earth plates shall be used for taking multiple earth connections to two or more equipment. nut etc.3 5. All joints at tappings above ground shall be by means of connector/lugs.metre. Earth electrodes shall be as per GAIL Standard S-07-01-004. The exact location of earth electrodes in the field shall be determined by contractor in consultation with the GAIL Engineer-in-charge. The earthing conductor shall run along one of the cable trays along a cable route. Where lined cable trenches are available. at interval of 400 mm to 500 mm and near to the termination end. lap welding with an overlapping of strip equivalent to double the width of the strip and all four sides shall be continuously welded. depending on GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR EARTHING INSTALLATION SPECIFICATION S-07-02-005 REV-0 Page 5 of 8 4. Joints and tappings in the main earth loop shall be made in such a way that reliable and good electrical connections are permanently ensured. Earth plate shall be as per GAIL Standard S-07-01-006. From each earth electrode two distinct connections shall be made to the main earth conductor.1 EARTHING NETWORK This consists of main earth conductor (grid conductor) forming a closed ring network with required number of earth electrodes connected to it to provide a common earth for electrical devices and metallic structures. The earth conductor shall be laid along cable trays/cable trench/pipe racks as indicated on the earthing layout drawing.0 4. 1 © GAIL – All rights reserved . 4. The earthing for equipment shall be tapped from the main earth conductor and not from cable tray support structure. A minimum of two bolts of adequate size shall be used for this purpose. The earthing conductor shall be suitably cleated and electrically bonded to all the other cable trays on the same cable route at a regular interval of 25 to 30 metre.2 4.0 5. The location shown on the layout drawings are indicative. When two earth strips are to be jointed by means of welding. Earth conductor when laid underground shall be at a depth of 500mm below finished grade level. Earthing strip joints at earth plate and equipment shall be through GI bolts. switchboards. not covered by paint. battery charger panels. Earth electrodes shall be located avoiding interferences with road. lighting fixtures etc. grease or other materials of poor conductivity.Static and lightning protection The following shall be earthed.5 5.Current and potential transformer secondary neutral . The electrodes shall have a clean surface. lighting/power panels. The tests shall take place in dry months. UPS. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR EARTHING INSTALLATION SPECIFICATION S-07-02-005 REV-0 Page 6 of 8 5. Individual earth electrodes shall be provided for each lightning arrestor and flood light mast.Steel structures/columns.0 6. motors. grain size and distribution.6 5. Location of earth electrodes shall be marked by permanent markers for easy identification. power sockets. column.3 5.7 5. all lumps broken and stones removed from the immediate vicinity of the electrodes and soil packed by watering and ramming as tight as possible. All earth Electrodes shall be serial numbered and also marked on ‘As Built’ drawing for future reference. shall be connected to the plant earthing system below ground by minimum two earth connections. preferably after a protracted dry spell. enamel.the soil strata and resistivity. Earthing system provided for concrete paved area by other agency where applicable.System neutral . building foundation. control stations.1 © GAIL – All rights reserved .. rail loading platforms etc. The disconnect facility shall be provided for the individual earth electrode to check its earth resistance periodically. pipelines etc The civil area drawings shall be referred for this.2 Electrodes shall preferably be located in a moist soil which has a fine texture . . The distance between two electrodes shall not be less than twice the depth of electrode.Equipment earthing for personnel safety . bus ducts. . All earth electrodes shall be tested for earth resistance by means of standard earth test meter.8 6.4 5.. welding receptacles. neutral earthing resistors.System neutral earthing . capacitors. 5. CONNECTION The earth system connections shall generally cover the following: .Metallic non-current carrying parts of all electrical apparatus such as transformers. Wherever practicable the soil shall be dug up.. spheres. Equipment/street light pole etc.4 6. 6.6 6.9 © GAIL – All rights reserved . scale and enamel shall be removed from the contact surface before the earthing connections are made. Lightning protection shall be provided for the equipment.g. Steel pipe racks in the process units and offsite area shall be earthed at every 24 metres.) Cable shields and armour Flexible earth provision for Wagon.5 6.2 All process pipelines shall be bonded and earthed at the entry and exist points of battery limit of hazardous area. (Reference installation standard S07-01-009). All medium and high voltage equipment (above 250V) shall be earthed by two separate and distinct connections with earth. The main earthing network shall be used for earthing of equipment to protect against static electricity. Plant instrument system clean earthing. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR EARTHING INSTALLATION SPECIFICATION S-07-02-005 REV-0 Page 7 of 8 6. These shall however be connected to the earthing system at two or more points as shown on layout drawing. Lightning down conductor shall be brought to earth electrode in shortest straight path as feasible to minimise surge impedance.- Cable trays and racks. Self conducting structures shall not require separate aerial rod and down conductors.8 6. lighting mast and poles Storage tanks. All paint. yard etc. vessels. columns and all other process equipment. transformer.7 6.3 6. structures and buildings as shown on layout drawing. Fence and Gate for electrical equipment (e. Truck Shield wire Conductor size for branch connection to various equipment shall be as per GAIL Installation Standards unless otherwise stated on earthing layout drawings. An independent earthing network shall be provided for lightning protection and this shall be bonded at least at two points with the main earthing network below ground. Earth continuity conductors across pipe line flanges shall not be provided as per OISD 110. UPS system clean/safety earth shall be separate from the electrical earthing system. located remote from main earth network may be earthed by means of individual earth electrode and earth conductor unless otherwise stated in job specifications. 13 6.3 Earthing resistance of the grid shall be measured after connecting all the earth electrodes to the grid.6.12 6. the value shall not be more than 1 ohm.Earthing systems/connections shall be tested as follows Resistance of individual earth electrodes shall be measured disconnecting it from the grid by using standard earth test megger. the value of 5ohms as earth resistance shall be desirable. but in no case it shall be more than 10 ohms. At one point on earthing system used to earth wiring system.2 7. At each earth provided for structure lightning protections. Earth connections shall be made through compression type cable lugs/by welded lugs. At one point on earthing system used to earth electrical equipment enclosures. However for generating stations and large subsystems. The reinforcements of sub-station building and the sub-station floor shall be connected to main earth grid.11 6. a) b) c) d) e) The resistance to earth shall be measured typically at the following points: At each electrical system earth or system neutral earth. such as metal conduits and cable sheaths or armour. o For lightning protection. All earthing layout drawings shall be marked by contractor for ‘AS BUILT STATUS’ and two sets of copies shall be submitted to GAIL.4 7.14 7. The resistance value of an earth grid to the general mass of earth shall be as follows: o For the electrical system and equipment a value that ensures the operation of the protection device in the electrical circuit but not in excess of 4 ohm. enclosures. testing and commissioning of electrical installation shall be done as per GAIL standard 6-5l-0087. Spring washers shall be used for all earthing connections and all connections adequately locked against loosening.1 7. after 6. At one point on fence enclosing electrical equipment. All hardware used for earthing installation shall be hot dip galvanised or zinc passivated. TESTING AND COMMISSIONING Field inspection. Lighting fixtures and receptacles shall be earthed through the extra core provided in the lighting circuit/cable for this purpose. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR EARTHING INSTALLATION SPECIFICATION S-07-02-005 REV-0 Page 8 of 8 7.5 © GAIL – All rights reserved .0 7.10 All earthing connections for equipment earthing shall be preferably from the earth plate mounted above ground wherever provided Equipment foundation bolts shall not be used for earthing connection. SPECIFICATION FOR CABLE INSTALLATION GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 1 of 13 © GAIL – All rights reserved . Abbreviations: BS CEA ET FLP GI MS OISD RCC SWG British Standards Central Electricity Authority Electrical Thread Flame Proof Galvanised Iron Mild Steel Oil Industry Safety Directorate Reinforced Concrete Cement Standard Wire Gauge GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 2 of 13 © GAIL – All rights reserved . 6. 2.CONTENTS 1. 5. SCOPE CODES AND STANDARDS MATERIAL SPECIFICATIONS CABLE LAYING TERMINATIONS TESTING GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 3 of 13 © GAIL – All rights reserved . 4. 3. unused and of best quality and shall conform to the latest specifications of Bureau of Indian Standards. Regulations laid down by CEA/Electrical Inspectorate.1. b. Part 43 Insulation resistance.2 In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable: a. Site fabricated angle iron trays SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 4 of 13 3 3. Code of practice for installation and maintenance of power cables upto and including 33 KV rating. (Part45) Inspection and safe practice during electrical installation Fire prevention and protection system for electrical installation 2 2. Method of Test for cables.1. Indian Electricity Act and Rules. Cable Trays: These shall be ladder type trays either prefabricated hot dip galvanised sheet steel trays or site fabricated angle iron painted trays as specified in job specification. GAIL installation standards. codes of practice of Bureau of Indian Standards and OISD standards listed below SP:30 (BIS) IS: 1255 IS:108 10 IS:10810 OISD 147 OISD 173 Special Publication National Electrical Code. The petroleum rules (Ministry of Industry Government of India). wherever applicable.2 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . e. Pre-fabricated hot dipped galvanised trays The cable trays shall comply to the requirements of relevant Indian Standards. Any other regulations laid down by central/state/local authorities and insurance agencies MATERIAL SPECIFICATIONS All materials and hardware to be supplied by the contractor shall be new. Part 45 High voltage test.1 2.1 3. testing and commissioning of cable installation. Regulations laid down by CCE!DGMS/DGFASLI (as applicable). installation. the latest edition of relevant specifications.1 3. layout drawings. c. d.1 SCOPE This specification defines the requirements for supply of materials. CODES AND STANDARDS The work shall be carried out in the best workman like manner in conformity with this specification. (Part 43) Method of Test for cables . double compression type and shall have PVC shroud for additional weather protection. substation.3 Vertical supports for both the prefabricated and site fabricated type trays shall be fabricated out of ISMC 100 and horizontal supports shall be with 65 x 65 x 6mm angle iron sections. The size of cable glands supplied shall be appropriate to the size of cable so that flame proofness of glands is retained. Indigenous FLP glands shall have valid BIS license as per the requirements of statutory authorities. PG as applicable). NPT. If required.3 Connectors: Power cable terminations shall be made with crimped type tinned copper solder less lugs which shall be suitable for the cable size mentioned in cable schedule. The cable glands for outdoor terminations shall be weather protected. suitable reducers/adopters shall be used. o Protection from exposure to sun is required. flanged on both sides for fixing on cable tray.g. Outer most tier of all vertical cable trays shall be covered with GI sheet for protection against physical damage to cables. Cable racks and trays shall be covered by removable top covers on upper most tier allowing adequate ventilation in following cases where o Mechanical damage of cables is likely to occur during maintenance in the plant.2 Cable Glands: Cable glands shall be of nickel plated brass unless otherwise specified. Cross support shall be 25 x 6 mm MS flat for tray width upto 500 mm and 32 x 6 mm flat for tray of more than 500 mm wide and spacing between two cross supports shall not exceed 250 mm. 3. control room etc). GI cover sheet shall allow adequate ventilation to the cables and shall be in standard length of 3000 mm. Entry thread of cable gland shall be compatible to the entry thread provided in the equipment (BS. o Oil or spillage of chemicals can be expected. The single compression type cable glands shall be used for indoor panels/equipment (e. Cable glands forming a part of relevant FLP enclosure shall be FLP type. 3. 3. Covers shall be complete with required GI hardware. ET. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 5 of 13 © GAIL – All rights reserved .1.Angle iron cable trays shall be fabricated from standard rolled angle iron sections of size 75x75x8 for runners for supporting spans limited to 3000 mm. tested by CMRI or any other recognized independent testing laboratory and approved by CCE/DGMS or any other statutory authority as applicable. the individual cable fixing clamps and spacers shall be of non-magnetic material. piping . When single core cables are laid in flat formation. trenches or cables trays. The Telephone. telephone and communication cables. control. Cable routing given on the cable layout drawings shall be checked in the field so as to avoid interference with structures. fire alarm and plant communication cables shall be directly buried in road berm area. These shall be laid in trenches! cable trays as detailed in the cable layout drawings. For single core cables. Street lighting cables shall be laid on the other side of road berm area 4 4.1. High voltage. Details of cable routes and cable spacing not shown in detail on these drawing shall be determined by the contractor and approved by the engineer in-charge. As a general practice. Telephone. medium voltage power and control cables shall be separated from each other by adequate spacing or by running through independent pipes. when laid in trefoil formation shall be braced by suitable clamps at a distance.1 4.. Any change in routing shall be done to suit the field conditions wherever deemed necessary. after obtaining approval of Engineer-in-charge. for ease of identification.3. fire alarm. air-conditioning duct etc. spacing of 600 mm from power and control cables but in any case such separation shall not be less than 300 mm. heat sources. cables shall be taken in a separate trench/tray with a mm. as shown on layout drawings/installation standards. drains. Cable Laying General Cable installation shall include power. Communication and Fire alarm cables shall run on instrument trays/ducts! trenches in the units. the sheath of single core cables shall be earthed at one point to keep sheath at earth potential unless otherwise stated. If straight through joints are required to be provided on single core cables. Single core cables. armour shall be earthed at one end for the cable run length as per manufacturer’s recommendation. armour shall be broken at joints as per manufacturer’s recommendations.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 6 of 13 © GAIL – All rights reserved . not exceeding 3 meters along the cable routing. Wherever these are not available.4 Ferrules: Ferrules shall be of approved type and of size to suit core size mentioned and shall be employed to designate the various cores of control cable by the terminal numbers to which the cores are connected. These cables shall cross power cables preferably at right angles. lighting. (unless otherwise specified in cable layout drawings). 4 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 7 of 13 © GAIL – All rights reserved . All cables shall be identified close to their termination point by cable tag numbers as per cable schedule. Sufficient care shall be taken while laying cables to avoid formation of twist. At road crossings overhead trays shall be installed at 7000 mm (minimum) above grade level or cables shall be routed cable tray culvert! Electrical road crossings as per layout drawings. Overhead trays shall be installed 2700 mm (minimum) above grade level.3 Cables shall be neatly arranged in the trenches / trays in such a manner that cr155-crossing is avoided and final take off to the motor / switchgear is facilitated. in order to avoid mechanical injuries to cables.2 The lengths indicated in the cables schedule are only approximate.4. In places where it is not possible. The various cable lengths cut from the cable reels shall be carefully selected to prevent undue wastage of cables.Before the start of cable laying.1. All cable routes shall be carefully measured . the contractor shall prepare cable drum schedule and get that approved by Engineer-in -charge to minimise/avoid straight through joints and then the cables cut to the required lengths. Cable tag numbers shall be punched on aluminium straps (2mm thick.1.1. Cable routing between cable trench and equipment/motors shall be taken through GI pipe sleeves of adequate size. Each underground cable shall be provided with cable tags of lead securely fastened every 30 m of its underground length with at least one tag at each end before the cable enters/leaves the ground. It is to be ensured that both the ends of GI pipe sleeves shall be sealed with approved weather proof sealing plastic compound after cabling. 20 mm wide and of enough length) securely fastened to the cable and wrapped around it. Extra loop length shall be given for feeder cables where required as per the directions of Engineer-in-charge to meet contingencies Cables shall be laid in directly buried trench or in RCC trench (underground trench) or in cable tray along pipe sleepers or in over head trays as shown on cable layout drawings. sharp bend etc. Rollers shall be used for pulling of cables. cables shall be laid in smaller branch trenches. leaving sufficient lengths for the terminations of the cable at both ends. Bending radii of pipes shall not be less than 8D. The contractor shall ascertain the exact length of cable for a particular feeder by measuring at site. Pipe sleeves shall be laid at an angle of maximum 45 to the trench wall. cable 4. Cable installation shall provide minimum cable bending radii as recommended by cable manufacturer. 4. Arrangement of cables within the trenches / trays shall be in line with cable layout drawings. In unpaved areas. 1. Where cables pass through foundation walls. However. cables shall be taken through PVC/RCC pipes.. the necessary openings shall be provided in advance for the same by another agency. ends of cables shall be taped with an approved PVC end cap or rubber insulating tape. Cables laid direct in ground Cables shall be laid underground in excavated cable trenches where specified in cable layout drawings. Every cable shall be given an insulation test in presence of Engineer-in-charge/Owner before filling the cable trench with sand Any cable which is found defective shall be replaced. 4.1.9 Wherever cable trench crosses storm water. These cable markers shall be placed at location of changes in the direction of cables and at intervals of not more than 30 m and also at cable straight through joint locations.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 8 of 13 © GAIL – All rights reserved . Cables shall be properly spaced and arranged with a view of heat dissipation and economy of design. All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water inside building/lined trench. Where cables are required to cross drains of depth more than 1200 mm.7 4. Ends of cables leaving trench shall be coiled & capped and provided with protective cover till such time the final termination to the equipment is completed. waste water channel/drain.10 4.8 4. For this purpose. 4. 4.trenches shall be identified by means of cable markers as per installation drawing.5 All temporary ends of cables must be protected against dirt and moisture to prevent damage to the insulation.6 4. Cables for road crossings shall be taken through ERC (Electrical Road Crossing) as shown in the cable layout drawings.1.1. At road crossing and other places where cables enter pipe sleeves adequate bed of sand shall be given so that the cables do not slack and get damaged by pipe ends. Maximum number of cable layers in trench shall be preferably limited to 5 layers. the electrical contractor shall determine their location and obtain approval of the Engineer-in-charge before carrying out the same. Trenches shall be of sufficient depth and width for accommodation of all cables.1. cables shall be taken over the drain on cable trays supported suitably using ISMC 150/200 sections.1. Each row of cables shall be laid in place and before covering with sand. should it become necessary to cut holes in existing structures for example floor slab etc. This sand shall be leveled and cables laid over it. Individual cable or small group of cables (upto 3 to 4 cables) which run along structures / walls etc. to prevent the sagging of cables. ceiling or structures and shall be run parallel or at right angles to beams . Each cable tray shall contain only one layer of cables as far as possible for power cables. It is to be insured by the contractor that the bottom of buried trenches shall be cleared of all rocks. However control cables may be laid in double layer in the cable trays. distance between supports shall be approximately 300 mm for cables upto 25 mm diameter and maximum 450 mm for cables larger than 25 mm dia. Concrete cables trenches shall be filled with sand in hazardous area to avoid accumulation of hazardous gases and oil.4. All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of water 4. oil drainage piping. shall be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle bars. Removal of concrete covers where required for the purpose of cable laying and reinstating them in their proper position after cables are laid shall be done by electrical contractor. A flat protective covering of 75 mm thick second class red bricks shall then be laid and the remainder of the trench shall then be back -filled with soil. Cable routing shall be planned to be away from heat sources such as hot piping.3 Cables laid in concrete trench Cables shall be laid in 3 or 4 tiers in concrete trench as shown on layout drawings. clamped on walls. gas.1 Above ground cables Cables installed above grade shall be run in cable trays. rammed and leveled. Cables shall be supported so as to prevent sagging. air-conditioning duct etc. water. Alternatively small group of cables can be taken through 100/150 mm slotted channel tray / ISMC 100. In general. RCC covers of trenches shall be effectively sealed to avoid ingress of chemical and oil in process area. The depth and the width of the trench shall vary depending upon the number of layers of cables as per GAIL installation Standards Cables shall be laid in buried trenches at depth as shown in the cable layout drawings.4.Minimum depth of cable trench shall be 750 mm for medium voltage and 900 mm for H.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 9 of 13 © GAIL – All rights reserved . These cables shall be covered with 150 mm of sand on top of the largest diameter cable and sand shall be lightly compacted. walls or columns. The trench bottom shall be filled with a layer of sand.V.4 4. 4. Cables. 4. stones and sharp objects before cables are placed. TERMINATIONS All PVC cables up to 1 100V grade shall be terminated at the equipment by means of compression type cables glands suitable for the cable size. Installation of G.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 10 of 13 © GAIL – All rights reserved .43% of pipe cross-sectional area occupied by cables. Cable ends shall be carefully pulled through conduit to prevent damage to cable. The cables shall be identified close to their termination points at both the ends of cable(cable numbers shall be punched on aluminium straps 2mm 4. bitumen coating shall be applied on the buried lengths.4.4. 3 cables in a pipe .4. pipes shall be undertaken well before paving is completed and necessary co ordination with paving agency shall be the responsibility of Electrical Contractor. 2 cables in a pipe -31% of pipe cross-sectional area occupied by cables.3 Cable laid on supporting angle in cable trenches. control station.4. Before fabrication of various profiles of pipes by hydraulically operated bending machine (which is to be arranged by the contractor) all the burrs from the pipes shall be removed.5 4. They shall have a screwed nipple with conduit electrical threads and check nut.4. Alternatively rubber bushes shall be employed for the purpose of sealing.. columns and vertical run of cable trays shall be suitably clamped by means of G.7 5 5. de-scaled and cleaned. b. After the cables are installed and all testing is complete.I. junction box etc. d. structures. 01 Pipes having bends shall be buried in soil / concrete in such a way that the bend shall be totally concealed.40% of pipe cross-sectional area occupied by cables. 1 cable in a pipe -53% of pipe cross-sectional area occupied by cables. pipes buried in soil. Final painting shall be done with two coats of approved bituminous aluminium paint unless otherwise specified. The painting shall be done with one coat of redoxide zinc chromate primer. c. they shall be taken in GI pipe for mechanical protection upto a minimum of 300 mm above grade. conduit ends above grade shall be plugged with a suitable weatherproof plastic compound/bitumen/suitable sealing compound. de-rusted.I. For G. saddles / clamps.4 4. lighting panel. 4.I. All GI Pipes shall be laid as per layout drawings and site conditions. Following guide shall be used for sizing of pipe. 4 and above cables in a pipe. The under surfaces shall be properly degreased. All cable trays (other than galvanised trays) and supporting steel structures shall be painted before laying of cables. Distance between supporting angles shall not exceed 600 mm. Where cables rise from trench to motor.6 a. whereas cables in horizontal run of cable trays shall be tied by means of nylon cords.4. Lugs shall enclose all strands of cable core.6 5. All unused spare cores of control cables shall be neatly bunched and ferruled with cable tag at both ends. Gland plate shall be of non. After fixing bottom plate. 5. Crimping of lugs to cable leads shall be done by hand crimping / hydraulically operated tool as per requirement. For trip circuit identification additional red ferrules shall be used only in the particular cores of control cables at the termination points in the Switchgear/ Control panels and Control Switches Contractor shall drill holes for fixing glands wherever necessary. yellow and blue PVC tapes. The individual cores shall then be dressed and taken along the cables ways or shall be fixed to the panels with polyethylene straps . all cores shall be identified at both ends by their terminal numbers by means of PVC ferrules suitable for core size. All unused cable entries on equipment/panels shall be plugged/sealed. In case of control cables. necessary bimetallic washers shall be used. tugs provided with the equipment vis-à-vis to the cable size indicated in cable schedule for taking corrective action. Outdoor cable termination through top of equipment shall not be permitted. uncovered cable holes/gaps shall be sealed with cold setting compound.4 5. then gland plate shall be split in two parts along the centre line of holes. Cable armour shall not be exposed after termination is complete. Suitable conducting jelly shall be applied on the conductor lead.3 5. for future use. 5. In case of termination of cables at the bottom of a panel over a cable trench having no access from the bottom close fit holes shall be drilled in the gland plate for all the cables in one line. The contractor shall bring to the notice of Engineer-in-charge any mismatch in cable glands.7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 11 of 13 © GAIL – All rights reserved . Where copper to aluminium connections are made. The cable shall be terminated at electrical equipment /switchboards through glands of proper size. by cable tag numbers.thick and securely fastened to the cable. Conductor surface shall be cleaned and shall not be left open.5 5. The cable glanding shall be done as per manufacturers instructions. wrapped around it) and also along the route at recommended intervals.magnetic material! aluminium sheet in case of single core cables. Wire numbers shall be as per schematic! wiring/inter-connection diagram.2 Power cables cores wherever colour coding is not available shall be identified with red. Cutting of strands shall not be allowed. Insulation of the leads shall be removed before crimping. All cable entries for outdoor termination shall be preferably through bottom. Damaged enclosures of hazardous area equipment shall be brought to the notice of Engineer-incharge by contractor.1 6.5 a) b) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 12 of 13 © GAIL – All rights reserved .9 5. D. High Voltage test shall be performed as detailed below in the presence of the Engineer-in-charge or his authorised representative only. Only type tested termination kits of approved make shall be used.4 6. The jointing and termination of medium voltage power cables shall be carried out by trained personnel only. No unauthorised repairs. 5.V. TESTING AND COMMISSIONING Field testing and commissioning of electrical installation shall be carried out as per GAIL specification S-07-02-004. Cables 2. insulation resistance of each length of cable shall be measured before splicing and or / terminating. the insulation resistance of every circuit shall be measured from phase to phase.5 kV / 5 kV Megger shall be used. nuts.3 6. # The location of joints shall be identified with permanent markers. modifications shall be carried out on the hazardous area equipment terminal boxes and junction boxes. the following shall be insured: # The number of joints shall be restricted to minimum as far as possible. Measurements shall be repeated after back filling. cable sealing boxes intended to be used with the apparatus shall be filled with solid setting type bituminous compound unless otherwise specified.2 6. Where required. The insulation resistance of directly buried cables shall be measured before cable trenches are backfilled.C. All cables above 1100 V grade.10 6 6. all the bolts. After completion of splices and for terminations measurements shall be repeated. # No joints shall be allowed in hazardous areas without the approval of Engineer-in. All 1100 volts grade cables in which straight through joints have been made.8 The cable joints in power and control cables shall be avoided as far as possible. The D. For cables upto 1. After termination is complete. phase to neutral and from phase/neutral to earth. High Voltage test shall be conducted on cables given below after installation. In case a joint is unavoidable.C.1 kV grade 1000 V Megger and for H. Jointing and termination of high voltage cables shall be done by skilled and experienced jointer duly approved by Engineerin-charge.charge. hard wares of terminal box shall be properly placed in its position and tightened.5.. Before energising. Where splices or terminations are required in circuits rated above 650 volts. .Cables shall be installed in final position with all the straight through joints complete. Cable schedule.6 All checks and tests shall be made as per Owner’s standard test Performa available with site engineer.7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CABLE INSTALLATION SPECIFICATION S-07-02-006 REV-0 Page 13 of 13 © GAIL – All rights reserved . such as switches. all other electrical equipment related to the cable installation. etc. In each test. During the high voltage test. instrument transformers. bus bars. cable layout drawings. Interconnection drawings shall be marked by contractor for ‘AS BUILT STATUS’ and two sets of copies shall be submitted to GAIL. 6. must be earthed and adequate clearance shall be maintained from the other equipment and framework to prevent flash-overs. the metallic sheath/screen/armour shall be connected to earth. 6. All test readings shall be recorded and submitted to GAIL in triplicate sets. SPECIFICATION FOR LIGHTING INSTALLATION GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 1 of 15 Copyright GAIL – All rights reserved . Abbreviations: BIS : CEA CMRI DG DGMS ELCB FFL FRP GI HPMV HPSV MCB : MDB MS PVC TPN Bureau of Indian Standards Central Electricity Authority Central Mining Research Institute Diesel Generator Director General Mines and Safety Earth Leakage Circuit Breaker Finished Floor Level Fibre Glass Reinforced Plastic Galvanised Iron High Pressure Mercury Vapour High Pressure Sodium Vapour Miniature Circuit Breaker Main Distribution Board Mild Steel Polyvinyl Chloride Three Phase and Neutral GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 2 of 15 Copyright GAIL – All rights reserved . CONTENTS 1 1 1 1 1 SCOPE CODES AND STANDARDS EQUIPMENT SPECIFICATIONS LIGHTING INSTALLATION TESTING AND COMMISSIONING GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 3 of 15 Copyright GAIL – All rights reserved . 1 3. The canopy shall be made of 2mm thick galvanized sheet steel or FRP where these are separate from the equipment. materials.1 2. Panels shall be indoor/outdoor type as specified. e) Any other regulations laid down by central/state/local authorities and Insurance agencies. fittings and appliances to be supplied by the contractor shall be new. All metal surfaces shall be cleaned free of rust. In the absence of any specifications for a particular item. Lighting and Power panels shall have TPN incoming feeder and single phase outgoing feeders. b) Regulations laid down by CEA/Electrical Inspectorate. c) Regulations laid down by CCE/DGMS (as applicable). installation.2 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved . Lighting circuit feeders shall be rated for 10 amps and power circuit feeders shall have current rating of I 6Amps.1. CODES AND STANDARDS The work shall be carried out in the best workmanlike manner. unused and of the best quality and shall conform to the specifications given hereunder. contractor shall bring material samples along with proven track record to site and get the same approved by Engineer-in-Charge/Owner before installation.2 3 3. Lighting and Power Panels Lighting and Power panels (general purpose panels for safe area) shall be made of 1. Indoor type panels shall have 1P42 degree of protection and shall be suitable for surface or flush mounting on wall surface as specified. These shall be manufactured in accordance with the latest revision of the specifications of Bureau of Indian Standards/International standards. power circuit feeder shall be rated for 20 amps. given a coat of red-oxide primer and finished with two coats of epoxy based paint of shade 632 of IS 5.1 SCOPE This specification defines the requirements for the supply of equipment. Panels shall be equipped with phase and neutral busbars of required SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 4 of 15 2 2. In addition to the above it shall be ensured that the installation conforms to the requirements of the following as applicable: a) Indian Electricity Act and Rules.). lighting power distribution.6mm thick sheet steel and shall be dust and vermin proof. and the relevant specifications/codes of practice of the Bureau of Indian Standards. testing and commissioning of the lighting system (lighting fixtures. in conformity with this specification GAIL Installation Standards. EQUIPMENT SPECIFICATIONS All materials. d) The petroleum rules (Ministry of Industry Government of India).In power panels for window Air conditioning units.1. Lighting and power panels located outdoor shall be 1P55 weather protected and shall also preferably have integral canopy for additional weather protection. telephone wiring etc.1 3. The panels shall be complete with requisite number of cable glands as specified. all fixtures shall be supplied complete with lamps. HPMV/HPSV lighting fixtures shall be complete with ballast.e. Lighting fixtures The types.current carrying capacity. shall be made of 2mm thick sheet steel panel. Control gears shall be integral or non-integral as specified in lighting layout drawings. Complete wiring inside the panel. dust and vermin proof similar in construction to Lighting and Power panels but with TPN MC13 incoming and TPN outgoings (MCB with ELCB units and MCB without ELCB unit as applicable) of required numbers as specified. The fixtures shall be of high power factor type i. 3. In addition.9 or more. Further. as required.1. shall be neatly bunched with PVC tape and button. A hinged door to cover the operating knobs shall be provided. Sufficient space shall be provided (200 to 250mm) between gland plate and the bottom of terminal block for easy termination. circuit rating. Also a laminated copy of the diagram shall be provided inside the panel in a suitably designed pocket. power panels/MDB is more than 35 sq. The panel shall have knock out holes or removable gland plate for the entry of incoming and outgoing conduits or cables. The incoming cable leads shall be connected to terminal block (bolted type terminals) of required size.2 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved . a circuit diagram indicating incomer details and outgoing details viz. SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 5 of 15 3.1. This terminal block shall be connected to TPN incomer unit through separate PVC insulated copper conductor wires/bus bars. Unless otherwise specified.1. Sufficient terminals shall be provided in the terminal block so as to ensure that not more than one wire (core) is connected to a terminal. The outgoing feeders shall be provided with single pole miniature circuit breakers (MCBs) for safe areas and double pole MCBs for hazardous areas. Wherever the size of incoming cable to lighting. mm a suitable cable adapter box shall be provided and attached to the panel. makes and catalogue numbers of various types of lighting fixtures shall be as given in Fixture schedule job data sheet. at least 0.3 The Main distribution board (MDB) where used. The incomer shall be with MCB and ELCB unit unless otherwise specified. Each circuit phase and neutral shall be given ferrule numbers. All MCBs shall be of M9 category as per IS 8828 and sensitivity of ELCBs shall be 100 mA unless otherwise specified.5 3. the panel shall be provided with an earth bus bar with terminal studs for connection to the third core of each outgoing circuit. Circuit number. load connected and details of the load shall be pasted inside the panel. Two external earthing studs for connection to the plant eathing grid shall be provided on the panel. starters and capacitor.4 3. Ballast for fixture shall be copper wound or electronic type. Miniature circuit breakers shall be mounted in such a way that the operating levers project outside the front bakelite cover plates for ease of operation. fixtures and fan regulators etc. In buildings such as sub-station. The receptacles and the controlling ON/OFF switch shall be mounted in the same enclosure box but these shall be in separate units to facilitate replacement by parts. 7-51-0210 and 7-51-0228) from ERW steel tubular pipes of specified section. For surface conduit wiring. switches. These shall be complete with terminal block suitable for connection of wires up to 4 sq. Conduit and Accessories Conduits for Electrical installations shall conform to IS:9537. For exhaust fans and wall mounted air circulators. Cover plate shall be fixed by cadmium plated brass screws and cup washers. shall be made of M. manufactured in accordance with IS:13947 shall be used for non hazardous areas. The sheet shall extend at least 2 cm on all sides of outlet box. Outlet boxes custom fabricated for sockets. Flush mounting type receptacles shall be used in areas where concealed wiring has been adopted and surface type shall be used in other areas.6mm thick and the minimum wall thickness of PVC conduit shall be 1. socket and switch enclosures shall be separate.3 Switches Switches. piano type switches in surface mounted box shall be provided. These sockets shall be supplied complete with plugs. 7-510202. Generally PVC conduits shall be used in concealed wiring and for surface wiring GI conduit (in plant buildings) and black enameled steel conduit (in non plant buildings) shall be used.6mm.G. Industrial Type switches (Weather protected) shall be used for outdoor areas. Workshop. The colour shall suit the shade of the walls or shall be white if the shade of the walls is not finalised.4 3. shall be flush mounting piano type unless otherwise specified. 7-51-0205. shed.7 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved . Sheet having minimum thickness of 1. maintenance shop etc.3. 7-51-0207. with joints.5 3. Outlet boxes shall be galvanized after fabrication. Black enameled steel or GI conduit shall be of 1. industrial type metal clad socket outlets and plugs shall be provided.6mm.6 3. swaged SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 6 of 15 3.S. The type of conduit (steel/GI/PVC) shall be as specified on drawing. Lighting Poles Lighting poles shall be fabricated (as per GAIL installation standards namely 7-51-0201. D. Switches in areas where concealed wiring has been adopted. Receptacles Three pin type 5A/15A receptacles manufactured in accordance with IS: 1293 shall be used for non hazardous areas. mm Front cover plate shall be of 3mm thick backelite / PB sheet. Outlet boxes shall be provided with adequate number of knock outs on all the sides for ease of wiring either with conduits or without conduits. Outlet Boxes The outlet boxes used as point outlets shall be prefabricated type 65mm deep junction boxes. a weather protected TPN switch (at 1500mm from ground level) and a weather protected distribution board fabricated out of sheet steel shall be provided at the top of mast. rating and 12 Nos. Poles shall be coated with bituminous preservative solution on the ground portion of the outside surface.2 3. handrail. Wires Wires shall be PVC insulated and shall be of 660 Volts grade as per 1S694. The distribution board shall have cable entries from bottom. the sweep dia.1 Lighting Mast Lighting masts (Lattice tower) where used. MS flats provided at the base plate for connection to the plant earthing grid. Necessary space provision and suitable mounting arrangement shall be made on top of the tower for mounting of ballast (choke) and condensers for all the circuits and the lighting fixtures. black wire for neutral and green wire for earth shall be used (size of earth wire shall be same as for phase and neutral size).8. Ceiling fan/Exhaust fan Ceiling fans shall be of 1200mm sweep unless otherwise specified with double ball bearing and regulator. mm for ISA power socket circuits and 4 sq. and air CFM shall be as specified in job specification. mm for split A/C power socket circuits. 2.5 Sq. The pole shall have. The suspension down rod shall be sturdy mild steel rod of adequate diameter and of minimum length of 300mm with shackles suspension arrangement as per IS. SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 7 of 15 3. Wire size for air conditioning circuit feeders shall be as indicated in the panel schedule. outgoing circuits each with a 6A single pole MCB. mm for lighting.together when hot and bevelled on outside edges. They shall be complete with 2 nos. a marshalling box near the bottom to contain HRC fuses. Red/Yellow/blue wires for phases.8 3. The TPN Switch and the distribution board shall also have a canopy for additional weather protection. an earth stud and terminal block. A ladder.9 3. The TPN switch shall be suitable for looping one more lighting mast from the same incoming power supply. For exhaust fans. shall be fabricated as per VENDOR STANDARDS AND THE DESIGN MUST BE APPROVED BY GAIL.5 Sq. The distribution board shall have TP&N busbars of 30 Amps. a neutral link. Unless otherwise specified the flood lighting high masts shall be telescopic type AND MUST BE APPROVED BY GAIL BEFORE PROCUREMENT. Remainder of the outside surface shall be given one coat of redoxide primer and finished with two coats of aluminium paint.10 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved . Exhaust fans for battery room shall be with anticorrosive blades suitable for use in acidic fumes. platform. 3. Conductor shall be of stranded copper and size shall be minimum 1.8. Distribution board shall be fabricated out of 2mm thick sheet steel and shall be painted with two coats of enamel over a base coat of red oxide. The masts shall be given one coat of red oxide primer and two coats of aluminium paint. gauges. On walkways. shall be modular in design.1 4. lighting fixtures shall be located nearer to landing of stairs or ladders. platforms and other outdoor area. All outdoor lighting shall be group controlled manually or through synchronous timer or photocell. Conduits shall be laid out by the contractor to suit field conditions and as per directions of the Engineer-in-Charge.5 meters above the floor level. Frames shall be suitable for surface and flush mounting in brick! concrete wall. 4 4. panels. LIGHTING INSTALLATION General The lighting fixtures in the plant shall be fed from lighting panel.1.1.3 4. socket outlets etc. Top entries for cables shall be avoided to avoid water entry.5 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 8 of 15 Copyright GAIL – All rights reserved . un-armoured cables. or PVC insulated copper conductor wires in conduit Metsec channel as specified.2 4. Administrative buildings.1 4. flow meters.4 4. Switches and sockets shall match colors of the frame and cover plates to obtain a combination which shall match decor of the interiors of Control Room. All cable glands for outdoor terminations shall be double compression type and the gland shall be covered with PVC or rubber boot shroud. The minimum height of any lighting fixture shall be preferably not less than 2. All unused cable entries shall be plugged with suitable blanking plugs. offices rooms etc. All outdoor cable terminations to outdoor junction boxes. and to avoid objectionable shadows. All these items shall fit into the same frame with overall standard dimensions.3. shall be through bottom or from side. panel boards and other equipment to provide proper illumination. All joints of conductors in Switch boards/JBs Fittings shall be made only by means of approved mechanical connectors (nylon/PVC connectors). The lighting layouts furnished by owner will indicate approximate locations of lighting fixtures. The electrical contractor shall determine. the exact locations of each fixture in order to avoid interference with piping or other mechanical equipment and also with a view to obtain as much uniform illumination as practicable.1.1. Lighting wiring between panel and lighting fixtures shall be done with PVC insulated 3-core (phase. Wiring in the building shall be done by means of 3-core copper. conductor PVC insulated. neutral and earth) copper conductor armoured cable for hazardous areas.1. Bare twisted joints shall not be permitted any where in the wiring system. with approval of Engineer-in-Charge.11 Decorative switches and sockets Decorative lighting switches and sockets where specified. The frames shall be suitable for conduit entry from all the sides. I.12 4.4. All hardware shall be galvanised or zinc passivated. All lighting fixtures shall be provided with terminal block with required terminals suitable for connection of wire up to 2.10 4.1. receptacle : 300mm from FFL unless otherwise specified (1200 mm for process areas and industrial sheds) Lighting fixture As indicated in layout drawing Exhaust fan : In the cutout provided / as indicated in Layout drawings.1. In places where ceiling fans are provided. fixtures shall be suspended from concrete surfaces with the help of anchor fasteners.1. For location where fan points are shown. GI pipe sleeves shall be extended to 300mm above FFL. shall be of industrial metal clad type.8 4. where metal inserts are not available. may be bolted or welded to the existing steel work or metal inserts.5 sq. In case of concrete structures. Fixtures shall be firmly supported from the structures. maintenance shop etc. workshop. The terminals of switch sockets shall be suitable to receive the size of wire specified. Support clamps etc.1. fan hooks with junction box shall be provided during concreting. Circuit cables in a group shall be cleated to structure by using galvanised strip clamps or cable run in cable trays wherever trays are available.11 4. Spacers and cleats shall be of required size to accommodate the cables. are provided separately JB shall be located within a distance of 3 00mm from hook for mounting of ceiling rose. DG shed.1.1. Industrial type plug sockets with 20A MCB or rating as per job specification shall be provided at a height of 5 00mm from FFL for window AC units. Socket outlets and plugs for installation in Sub-station building.6 o o o o o 4. pipes (for protection of cables) shall be decided at site as per site convenience in consultation with Engineer-incharge. neutral and earth.1. Wiring for all outlet sockets shall be done with 3 cores of equal sizes for phase. SPECIFICATION S-07-02-007 REV-0 Page 9 of 15 4.Bs. In such cases special care shall be taken to see that anchoring is firm. Exact termination/layout of G. All cables be clamped/laid in straight run without any sag and kink. lighting fixtures shall be suspended below the level of fan to avoid shadow effect. Underground lighting cables (in paved areas) shall be taken in suitable G. The cable shall be straightened after unwinding it from the drum.7 Mounting height of equipment shall be as under Top of Switch Box 1200 mm from FFL(Finished floor level) Top of Lighting/Power Panel : 1800mm from FFL 5/15 Amp.1. mm copper conductor.1.13 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR LIGHTING INSTALLATION Copyright GAIL – All rights reserved . sleeves buried at a minimum depth of 300mm from FFL.9 4. Where fan hooks and J. 5 sq. The ends of all conduits shall be reamed and neatly bushed.4. Separate conduit shall be run for lighting and power circuits. Required number of pull boxes shall be used at intervals to facilitate easy drawing of wires. junction boxes (65mm deep) shall be used so as to rest on shuttering properly. Conduit ends shall be free from sharp edges or burrs. Conduit System Surface or concealed conduit system of wiring shall be adopted. Pull wire (GI or steel) shall be provided inside conduit for the ease of wire pulling. or similar fittings. including all accessories forming part of the conduit system.I.6mm thick G. All conduit connections shall be properly screwed and Junction box covers shall be properly fitted so as to avoid entry of concrete slurry. conduits for Normal lighting/Emergency lighting/DC critical lighting shall be separate.6 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved . Maximum number of wires permissible in a conduit shall be seven/nine for wire size of 2.l. saddle and bars shall be provided on either side. Drop conduits for switch boards shall be decided by contractor as per wall locations shown in Architectural drawings.2. shall be vertical or horizontal.1. as specified in the drawings. Conduit layout shall be decided at site as per site conditions.4 4.2 4. The contractor shall coordinate his work with SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 10 of 15 4.2. Conduits shall be laid above reinforcement.2. Further. saddle bars of required width in an approved manner at intervals of not more than 5Ocms for straight run. bends. respectively. saddles on 3mm thick G.mm.5 sqmnill. Where concealed wiring is done. At places near junction boxes.5 4. Conduit shall be of minimum 25mm dia. shall be adequately protected against rusting.1 4. conduits shall be laid in time before concreting of the slab. Switch for exhaust fan shall be located in a separate switch board along with other switches. bare threaded portion of conduit pipe shall not be exposed unless such bare threaded portion is treated with anti corrosive preservative or covered with approved plastic compound.2. Conduit connection to outlet boxes shall be by means of screwed hubs or check nuts on either side. In all cases. Pin grip type or clamp type fittings are not acceptable. Where concealed wiring is to be adopted.2 4.14 Wiring for exhaust fans shall be terminated in receptacles as specified in layout drawing and the connection from receptacle to the exhaust fan shall be by means of a flexible cord equivalent in size to the main run of wires. All exposed run of conduits on surface.3 The exposed outer surface of the conduit pipes. Only threaded type conduit fittings shall be used for metallic conduit system.2. Conduit pipes shall be fixed by 1. 4.2. Vertical conduit runs shall be made in wall before plastering is done so as to avoid chasing.8 All junction boxes. Correct type of lighting equipment (fixtures and JBs) with regard to hazardous protection as specified in the drawing.2.other agencies involved in the civil works in such a way.5mm2 copper conductor armoured cable. both the entries shall be used for looping in and looping out connection. As built conduit layout drawing shall be submitted by contractor after completion of the work.G. care shall be taken to see that proper covers are provided to prevent rusting of conduits.3 4.3. In fixtures having double cable entries. After erection. bends and other accessories shall be of the same material as that of conduit and shall have the same protective coatings. retaining its explosion and weather protections. Circuit wiring feeding hazardous areas shall be controlled by two pole switches/MCBs (for phase as well as neutral isolation). Locations of all point outlets. for mechanical and electrical continuity and shall be permanently connected to earth by means of approved type of earthing clamps. During installation. Cables shall not be routed along hand rails.7 4. box) are provided looping in and looping out connections shall be through CG box. Where required 3 or more of cables may be taken in slotted channel tray after getting the approval of Engineer-in-charge. All unused cable entries shall be sealed with suitable plugs. Circuit cables shall be firmly cleated in a group along columns! beam/ladders/side channels/platform using 1. shall be installed for the areas classified as Zone 1.3. Hazardous Area Installation Wiring in hazardous area shall be done by using minimum 2. junction boxes shall be marked with brick powder or sand so that these are easily identified after shuttering removal.4 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved . thus avoiding the use of a additional junction box.3.6mm thick GI saddles on 25x3 mm GI saddle bar at intervals of 400mm to 500mm for straight run and on either side close to bending and at both termination ends as per the directions of Engineer-in-charge. The terminations in the junction boxes and the lighting fittings shall be done avoiding possibility of loose connections due to vibrations.3 4. the entire conduit system shall be tested.2. thus minimising the use of a separate junction box. Wherever separate control gear boxes (C.2 4. 4.1 4. Zone 2 etc. SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 11 of 15 4. Where chases are made for conduit run contractor shall fill these chases or any other openings made by them after completing the work and patch the surface.3. After the terminations are made the cover of the junction boxes and the lighting fittings shall be closed properly with all bolts and hard wares in correct position. that the work of the other agencies is not hampered or delayed. 4.1 4. shall be tested by CMRI and duly approved by C.4. switches. Exact location of fixtures shall be finalised in co-ordination with air-conditioning duct diffuser layout. 4. Nagpur or DGMS Dhanbad or any other applicable statutory authority.2mm thick (Metsec channel).C.3 4. Similarly equipment such as lighting fixture. To facilitate easy maintenance ‘Looping back system’ of wiring shall be followed throughout. The entire assembly shall be fixed to the ceiling with necessary number of supports which may be by means of steel conduit or chromium plated chain link as required. Required number of j unction boxes shall be used at intervals for wire pulling and inspection. Mounting details of fixtures shall be indicated on the drawings. lighting! power panels. shall be taken in 25mm dia PVC conduit concealed in walls upto switchboards/panels. All indigenous FLP equipment shall also have valid BIS license as required by statutory authorities. The Metsec’ Channel shall run continuous in suitable sections from one end to other end of wall. All wires inside channel shall be neatly bunched by nylon tape & buttons. Lighting fixtures shall be supported from true ceiling.E. If specified on the drawings. panels layout and false ceiling grid layout. shall be installed on a suitable steel mounting frame/distance bracket. well before fire proofing is done.4 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 12 of 15 Copyright GAIL – All rights reserved . However when group of circuits are run in a single conduit the earth wire can be common.Where fire proofing column/structures are encountered. with approved colour as per the directions of Engineer-in-Charge. The complete channel shall be spray painted.3.4. shall be fixed to mild steel cold rolled sections of 50mm x 50mm and of 1.2 4. Any material/equipment specified to be supplied by contractor for installation in hazardous areas. Wiring in areas above false ceiling shall be done in Surface Conduit (25mm dia GI conduit) suitably clamped to the true ceiling. a group of fluorescent lighting fixtures which are to be mounted end to end. Each circuit shall have independent phase neutral and earth wire. junction boxes etc. receptacles etc. Building Lighting The type of wiring system shall comprise surface/concealed conduit system or cable wiring as specified on layout drawings.5 Cable glands for terminating cable on flameproof equipment shall be of double compression FLP type.4. All wires in conduit shall be colour coded as specified. all cabling shall be taken in GI pipes of required size and both ends shall be sealed. thereby avoiding direct contact with the concrete used for fire proofing. control gear box. field call stations. Accordingly supply tappings and other interconnections including for earthing are made only at fixture connector blocks or at switch boards.4 4.4. Vertical drops from true ceiling for panels. Final submission of drawings shall be in soft copies and in bound volumes together with one transparency of each document).1 Street Lighting Street lighting poles to be located on road side shall be installed at a minimum distance of 300mm from the edge of the walkway of the road (road berm). design calculations wherever required. for review by purchaser before erection work is started.4.4. cement godown. The second part is the point wiring which shall include the work necessary from tapping point in the switch box upto various fixtures or fan outlets/ceiling roses. contractor shall prepare and submit lighting layout drawings. service building.8 4.4. receptacles. 4.5 4.5mm2/2.6 4. junction boxes. Switches for light fixtures/exhaust fans in battery room shall be provided outside the Battery room.5.) Based on the above input.4. SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 13 of 15 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved . The number of points in a circuit shall not exceed ten and the load in each circuit shall be less than 1000 Watts.5mm2. layout of circuit indicating number of wires etc. type and mounting details of lighting fixtures. All drawings shall be prepared preferably in A0 and Al size. The following basic data/document for preparation of layouts will be provided to the contractor. The lighting layout drawing shall show the location. gate house. etc. workshop.. etc. Panel schedules shall be in A4 size drawings.) shall be prepared by installation contractor. two different sources or two different phases of supply shall be combined in one switchboard. number of outlets. conduit layout drawings for concealed wiring. The panel schedule shall include rating of incoming and outgoing feeders. Lighting layouts for non-plant buildings (such as ware house. The first part is the circuit wiring which includes the work necessary from lighting panel up to switch box and from switch box to another switch box. Size of wires from marshalling box upto fixture shall be 1. In no case.4.7 4. load for each outgoing circuit. i) Architectural drawings ii) Illumination level required iii) Type of lighting fixture iv) Type of wiring (concealed/surface conduit/cable wiring etc. copper conductor PVC insulated. rest room. panel schedules.5 Building conduit lighting system of wiring where measurement is done on point wiring basis generally consists of two parts. 7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 14 of 15 Copyright GAIL – All rights reserved .6. All the cables shall be neatly clamped to the structure at intervals not exceeding 25 cm. The foundation for the street lighting poles will be made by electrical contractor.2 4. Wiring from Distribution Board to each flood-light fixture shall be by means of a 3-core 2. Mast Lighting The lattice structure masts shall be installed on concrete foundations with the base plate bolted on to the anchor bolts. copper conductor PVC insulated armoured cable. 4. twin flat wire. the second coat to be given just before handing over to the owner. Alternatively the flood light high mast shall comply to specification no.Ssqmm. The masts shall be numbered as per drawings.6.2 conduit system’.5.6. One telephone socket outlet shall be provided for connection to telephone instrument.4 4.4 4.5. The poles shall be numbered as per the drawings! directions of Engineer inCharge. unless otherwise specified in job specification. Street lighting poles shall be supplied with a base plate. Conduit installation system shall comply to the requirements given in clause 4. installed on wall surface or concealed or as specified in job specification. The telephone wiring shall be done with 0.4.2 4. S-0701-014 Exact orientation of flood lighting fixtures shall be decided at site to achieve optimum utility of these fixtures. Required number of pull boxes shall be provided at interval for easy drawing of wires. Telephone Wiring Conduits for telephone wiring in buildings shall be of 1.3 4.3 Each pole shall be earthed at two points by connecting to the plant earth grid as shown on Installation standards.6. 25mm dia black enamelled steel conduit/PVC as per IS 9537. Street lighting fixture shall be mounted on steel tubular poles as per standard drawings.5.6mm thickness.6 4.63mm dia annealed copper conductor PVC insulated 660V grade. The masts shall be connected to the plant earth grid at two points The main feeder upto the distribution board of lighting mast shall be through PVC insulated armoured cable of size as specified in the respective drawing.1 4. The lattice structure shall be painted with a coat of primer and two coats of aluminium paint. phase/neutral to Earth).000 ohms. minimum and maximum illumination level shall be measured in the area and recorded. (Between phases. shall include but not be limited to the following: The insulation resistance of each circuit without the lamps (load) being in place shall be measured and it should not be less than 500. 5. Pre-commissioning checks and tests. If required load shall be balanced on the three phases.Charge in triplicate. Operation of ELCB’s shall be checked Contractor shall duly fill in all the above test results and submit the test reports to Engineer-in.2 All lighting layout drawings shall be marked by contractor for ‘AS BUILT STATUS’ Wand two sets of copies shall be submitted to GAIL. Current and voltage of all the phases shall be measured at the lighting panel busbars with all the circuits switched on with lamps. The earth continuity for all socket outlets shall be checked. It shall be ensured that switch provided for ON/OFF control of point (light/fan/socket) is only on LIVE side. A fixed relative position of the phase and neutral connections inside the socket shall be established for all sockets.1 (i) (ii) (iii) (iv) (v) (vi) TESTING AND COMMISSIONING Lighting installation shall be tested and commissioned by installation contractor as per GAIL specifications S-07-02-004. phases to neutral. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR LIGHTING INSTALLATION SPECIFICATION S-07-02-007 REV-0 Page 15 of 15 Copyright GAIL – All rights reserved .5 5. After inserting all the lamps and switching on all the circuits. SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATIONS S-07-02-008 REV-0 Page 1 of 9 © GAIL – All rights reserved . GENERAL AREA CLASSIFICATION DESCRIPTION OF REQUIREMENTS FOR CATHODIC PROTECTION AND ELECTRICAL WORKS INSPECTION.CONTENTS 1. 5. 4. 3. 2. TESTING AND COMMISSIONING DRAWINGS AND DOCUMENTS ANNEXURE-1: MAKE OF ELECTRICAL EQUIPMENT/COMPONENTS GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATIONS S-07-02-008 REV-0 Page 2 of 9 © GAIL – All rights reserved . 0 1. installation. the stipulations under these specifications shall govern.1.2 1. which might get collected in and nearby the work site during execution of work and after final completion. Standards The work shall be performed in conformity with these specifications and code of practices of the Bureau of Indian Standards. at all stations associated with Sultanpur-Neemrana pipeline The electrical portion for pipeline laying work as covered in this specification includes design.2 1. etc. In case of conflict between various documents. engineering. supply.1 GENERAL Introduction The intent of this specification is to define the requirements for Design. cabling. supply. following shall be order of priority:Scope document Design Basis & Single Line Diagrams Data sheets GAIL standard specifications/standard drawings Codes and standards 1. erection. GAIL standard specifications.4 The work shall be carried out to the best workmanship like manner. viz. lightning protection system and fire alarm system.1. design basis.1.5 1. interconnection diagrams. power supply system.1 1. etc. The contractor shall also prepare electrical layout drawings for equipment layout. for each station/Terminal along the route of the pipeline.1. testing and commissioning of the electrical works.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . The contract shall include clearing of temporary constructions. In case of any conflict. waste materials and loose earth. lighting. standard drawings and National/International codes & standards. cable schedule. earthing. approved drawings/ construction drawings and the instructions of the owner or Engineer-in-Charge from time to time. earthing and lightning protection layouts. in conformity with these specifications. cabling layout. data sheets.3 1.1. Fire alarm system layout.1. lighting layout. taking statutory approvals and energizing the system. testing and commissioning of the power system as per the single line diagrams (SLDs) and description given in this document and other associated documents enclosed with this tender. job specification.2. The Electrical works at each station/Terminal and all works related to temporary and permanent cathodic protection system for the pipeline shall be executed by contractor in line with scope document. SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATIONS S-07-02-008 REV-0 Page 3 of 9 1. 0 AREA CLASSIFICATION Electrical/Control room building at all stations shall be located in safe area. class T3.4 Site Condition The equipment offered and the installation shall be suitable for continuous operation under the site conditions mentioned in design basis doc.3 Guarantee The contractor shall guarantee the installation for satisfactory operation against any defects of workmanship and materials (supplied by the contractor) for a period as specified elsewhere. (f) The regulations laid down by Oil Industries Safety Directorate (OISD). the work shall also conform to the requirements of the following: (a) The Indian Electricity Act and rules framed there under. (d)The regulations laid down by the Factory Inspector.2. shall be rectified or replaced by the contractor at his own expense as deemed necessary and as per the instruction of owner or Engineer-in-Charge within the time limit specified by the owner or Engineer-in-Charge. 0001-01-0703-001 2. shall be flameproof type. equipments or fittings supplied by the contractor that may be discovered at the time of issue of the completion certificate.2 In addition. Indian Petroleum Rules and as shown in the respective equipment specification/ particular specification.1. (c) The regulations laid down by Electrical Inspectorate (CEA). based on area classification as per IS 5572.no. 1.5 Utilisation Voltage The utilization voltages shall be as per design basis doc. All the electrical equipment to be located in hazardous area Zone 1 or Zone 2.no. Any other regulations laid down by the Central. (b)The fire insurance Regulations.0 3. 1. Gas Group IIA/IIB and Temp. Any damage or defect connected with the erection of materials. (e) The regulations laid down by the Chief Controller of Explosives.1 REQUIREMENTS FOR CATHODIC PROTECTION SYSTEM AND ELECTRICAL WORKS CATHODIC PROTECTION SYSTEM:The requirements of cathodic protection system have been specified in SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATIONS S-07-02-008 REV-0 Page 4 of 9 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . or arise or come to light thereafter. 0001-01-07-03-001 1. 3. State or Local Authorities from time to time during the execution of this contract. TESTING AND COMMISSIONING All the equipment shall be tested and commissioned as per contract requirements. 0001-01-07-03-001. installation. The electrical power distribution to various electrical consumers at 24V DC shall be done from 24V DC switchboard.7 3. fence and steel cage over MOV etc. Cables (e.0 4. testing and commissioning of all electrical items shall be provided. DC lighting (in Telecom room. at each station shall also be in the scope of contractor. For Telecom a separate dedicated earth of 1 ohm to be provided by contractor.5 3. A display board of suitable size to be provided adjacent to all earth pit so as to display earth pit number.8 3. SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATIONS S-07-02-008 REV-0 Page 5 of 9 3.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . data sheets and specifications attached elsewhere in this tender. date of testing. INSPECTION. electrical room). 3. Safety Earth (Instrumentation cabinet earth): The same shall be common earth for Instrumentation/SCADA/Telecom. The power supply shall be met from Solar system at 24V DC (Floating) output.4 3.3 At all earth test pits.Design basis document no.g Instrumentation cables/ Optical cable.6 3. 3. 24V DC power distribution as required for SCADA. supply. Rat repellant electrical system is to be provided in all stations to avoid damage to the cables and cabling into the marshalling units/electrical equipment. earth strip shall be bolted with electrode using minimum two bolts as per the requirements of OISD. next due date etc. Earthing of main gate. All SVs installed on cathodically protected pipeline shall be earthed using 2 number of zinc anodes (20KG net weight). connected to electrical safety earth.2 ELECTRICAL WORKS Electrical works including design. Necessary DC-DC converters required for feeding telecom equipment shall be provided as part of DC switchboard.9 4. Pipeline contractor shall install earth strips and terminate the earth cables to the respective Instrumentation/SCADA/Telecom equipment cabinet (both system & safety) & cables coming from field for instrumentation/Telecom. etc) coming from field shall also be terminated on this earth Signal/system earth : For Instrumentation and SCADA one dedicated earth of 1 ohm to be provided by contractor. test value. FA panel. 5 5. see Annexure-I.2 Any work not conforming to the execution drawings. lighting fixtures. 4. The tests shall be recorded on approved Performa and certified records of the tests shall be submitted to the owner/ engineer-in-charge. CP system shall be submitted for review by owner/ GAIL.7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATIONS S-07-02-008 REV-0 Page 6 of 9 © GAIL – All rights reserved . For list of acceptable makes of electrical equipment.4 5. equipment number and revision number are marked on each drawing. Final set shall be submitted in folders and shall be stamped as final drawing along with the copy of the necessary test/ inspection certificates. Ni-Cd batteries. specifications. A complete set of reproducible drawings for contractor-supplied equipment shall be furnished to the owner for records. cable schedules and interconnections shall be submitted by the contractor on the hard copies as well as in soft copy usable on a WINDOWS 2000 PC. As-built layouts. Vendor catalogues and literature shall be supplied for all equipment included in the scope of Contractor. 24V DC Switchboards.1 5. drawing number. title. The contractor shall arrange all testing equipment necessary to carry out the tests.2 5.0 5.3 5.6 5. or codes shall be rejected forthwith and the contractor shall carry out modifications at his own cost. Drawings and data of Solar system power source. DRAWINGS AND DOCUMENTS Contractor shall submit all datasheets/ drawings and documents to the owner/ engineer-in-charge.4 5. prior approval from owner/ GAIL shall be obtained before placement of order. Minimum 6 sets of drawings/ documents of the vendor-supplied equipment shall be submitted within 4 weeks of order placement.4. Before submitting the drawings. cables. All test certificates and the contractor shall submit field test reports after completion of work in bound volumes (6 sets).2 5. vendor shall ensure that job number. Storage and maintenance instructions along with necessary handling precautions shall be furnished by the contractor for equipment supplied in this tender.3 4. For makes of items not covered therein. All tests shall be conducted in the presence of the owner/engineer-in-charge or his authorised representative unless he waives this requirement in writing. Ltd. & Chemical Products Ltd./ Radiant Cables Pvt. Ltd./ Radiant Cables Pvt./ Polycab Wires Pvt./ Control & Schematics/M.Ltd./Cords Cable Cathodic Control Co./Havell’s India Pvt.Ltd./ Reliance Engineers Ltd./ KEI/ Elkay Telelinks/ Reliance Engineers Ltd. Amco Power Systems Ltd. Ltd./ Delton Cables Ltd. Anodes for CP system Fire Alarm system Cable termination & Jointing Kit Nickel-Cadmium batteries Solar System GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATIONS S-07-02-008 REV-0 Page 7 of 9 © GAIL – All rights reserved . (Formerly-Vijay Fire)/ Edward International Mahindra Engg. Central Electronics MV Switchboards (Fixed type) Cables-Medium Voltage-Power -PVC Cables-Control-PVC Cables-Fire alarm and comm./ Universal Cables Ltd./ Torrent Cables Ltd./Ravin Cables Ltd.ANNEXURE-1 1. Ltd/RPG Cables ltd Associated Flexibles & Wires (P) Ltd. Ltd./ Electro Protection Services India (P) Ltd./Industrial Cables(I) Ltd./ Nicco Corp. Ltd. Ltd.K. Ltd./ Gemscab Ind./CMI Ltd. Ltd./ Gemscab Ind./ Polycab Wires Pvt./ Scientific Metal Engineers (P) Ltd New Fire Engineers/ Honeywell Inc./ North Eastern Cables Pvt./ Ravin Corporation Ltd.1 Following is the list of approved makes for electrical equipment:Siemens/ L&T/ GE India Industrial Pvt./ PSL Ltd.Ltd./ Paramount Communications Ltd. Ltd.Ltd.Ltd./ Delton Cables Ltd./ Nicco Corp./ Industrial Cables(I) Ltd./ Finolex Cables Ltd./ Evershine Electricals/ Elkay Telelinks (P) Ltd./HBL Nife Power systems Ltd. Pvt./ Havell’s India Pvt./ Kidde India Ltd./Bhartia Industries Ltd./ Universal Cables Ltd./ CCI/ Finolex Cables Ltd./ Torrent Cables Ltd.Ltd. CMI Ltd./ Goyolene Fibres (India) Pvt./ Heat Shrunk technologies. Bombay/ Cords Cable Ind./ KEI Ind./ Mather & Platt Pumps Ltd.Ltd.Engineers & Controls Pvt./ KEI Ind.Ltd./ Suyog Electricals Ltd./ Raychem RPG Limited/ Yamuna Gases & Chemical Ltd./Brooks Cable Works. Associated Flexibles & Wires (P) Ltd. / Schneider Electric/ Control & Swgr./ Honeywell Automation India Ltd. / Hot Line Switchgears & Controls. L&T/ Siemens/ Schneider Electric/ Control & Switchgear/ Indo Asian Fuse Gear Datar Switchgear/ Indo Asian Fuse Gear/ Legrand India Pvt./ Areva T&D India Ltd. Ltd. Ltd / Indo Asian fuse gear/Cooper Bussman (I) Pvt. Ltd ABB (Bangalore)/ Control & Switchgear/ Indo Asian Fuse Gear/ L&T/ Siemens/ Schneider Electric. Ltd.2 Following is the list of approved makes for electrical components:Bajaj/Crompton/Philips/Havell’s Ind Pvt. /GE India Pvt. Ltd. Ltd/Standard Metal Industries./ Standard Electrical Ltd./ Schneider Electric/ ABB (Bangalore)/GE India Ind./ABB (Bangalore) L&T/ Siemens/ Switron Devices/ Hot Line Swgrs./Schneider Elect./ Controls & Switchgears Contactors Ltd. Pvt. (Type : Energy meters) L&T/ Siemens/ Tecknic Controls/ Bhartia Ind./ ABB (Bangalore) L&T/Siemens/ Bhartia Ind./ L&T/ Siemens/ Electronic Automation Automatic Electric/ Meco Instruments/ Rishab Instruments/ Nippen Electricals Instruments Co. Bhartia Ind. Ltd. Pvt./ L&T/ Schneider Electric L&T/ Siemens/ GE India Industrial Pvt. Ltd. Pvt.& Controls/ Kaycee/ Areva T&D India Ltd.1./ Prompt Engg. Ltd. Contactors Ltd./Schneider Electric India Pvt./L&T Areva T&D India Ltd./ Schneider Electric Lighting Fixtures for non Hazardous area Cable glands for azardous area Protection relays (Electromechanical type) Auxiliary Relays Control switches/Selector Switches MCBs MCCBs Fuses Timers Meters Push Buttons/Indicating lamps Contactors Fuse switch combination Heavy duty switches Earth leakage circuit breaker (ELCB) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATIONS S-07-02-008 REV-0 Page 8 of 9 © GAIL – All rights reserved . Ltd. (T&D Group)/Siemens ltd./Control & Swgrs. Ltd. Baliga/ Comet Brass Products/ Comet Industries/ Flexpro/ Flameproof Equipment / FCG Power/ FCG Flameproof Control Gears Pvt Ltd. Ltd./ Precifine Product Pvt. Ltd. ABB (Baroda) /Easun Reyrolle/ Areva T&D India Ltd./ Shri Tulsi Switchgears/ Controls & Switchgears Contactors Ltd./ Schneider Electric/ Bhartia Ind./Havell’s India Pvt. Datar Switchgear/ Havell’s India/ Indo Asian fuse gear/ Indiana Current Control/ Standard Electricals/ Legrand India Pvt. Ltd. Ltd. (T&D Group)/Jyoti ltd. Ltd./Schneider Electricals India Pvt. Works/ Sudhir Swgrs.ltd. / Reliable Electronic components Pvt. GE India Industrial Pvt. (For LED type Indicating lamp only)/Essen Deinki L&T/ Siemens/ GE India Industrial Pvt./ Havells India Pvt. 0 3.2 Following is the list of preferred makes equipment /material for CP system:Dehn+Sohne. In case alternate makes are not found acceptable. Contractor can offer component of makes other than specified in the tender. if required may be supplied after GAIL approval. components shall be strictly as per above vendor list. based on the satisfactory track record and test certificates to be furnished by the contractor. USA/Caproco Surge Diverters (Explosion Proof) Zinc ribbon anode :Permanent reference cell :Polarisation Cell:E/R probes & reading meter:Notes:1. USA Kirk.0 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR PIPELINE LAYING AND TERMINAL WORKS (ELECTRICAL) SPECIFICATIONS S-07-02-008 REV-0 Page 9 of 9 © GAIL – All rights reserved .0 2. 4. alternate makes. Germany Platt Line/Corpro Borin. The alternate make of components will be evaluated post order. In case of non-availability of equipment/material from above vendors. USA Rose corrosion. Contractor may procure material from any of GAIL approved vendor/subvendors.0 Make of other equipment/components not mentioned above shall be subject to prior approval of GAIL. during order execution.1. Germany/OBO Bettermann. SPECIFICATION FOR CORROSION SURVEY GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION SURVEY SPECIFICATION S-07-02-009 REV-0 Page 1 of 7 © GAIL – All rights reserved . Abbreviations: ROU : EHV : HV : Right of Use Extra High Voltage High Voltage GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION SURVEY SPECIFICATION S-07-02-009 REV-0 Page 2 of 7 © GAIL – All rights reserved . 0 6.CONTENTS 1.0 3.0 7.0 5.0 4.0 2.0 SCOPE CODES AND STANDARDS GENERAL SOIL RESISTIVITY SURVEY TESTS ON SOIL SAMPLES ADDITIONAL DATA COLLECTION REPORT GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION SURVEY SPECIFICATION S-07-02-009 REV-0 Page 3 of 7 © GAIL – All rights reserved . conform to the requirement of latest revisions of following applicable standards: BIS specifications BS specifications and codes of practice NACE publications The work shall be carried out in compliance with all applicable local laws and regulations. GENERAL This specification defines the basic guidelines for carrying out the corrosion survey. 2. SCOPE The specification covers the requirements for corrosion survey including measurement of soil resistivity.2 © GAIL – All rights reserved . Codes and standards. which shall GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION SURVEY SPECIFICATION S-07-02-009 REV-0 Page 4 of 7 4 4. CODES AND STANDARDS Equipment and measurement techniques shall unless otherwise specified. To carryout the soil resistivity measurement Wenner’s 4 pin method or approved equal shall be used. SOIL RESISTIVITY SURVEY Unless otherwise specified the soil resistivity measurements shall be carried out at intervals of approximately 500 m along the ROU. which is intended to form a basis for design of cathodic protection system for the pipeline.1 4. This specification. Where soil resistivity is less than 100 ohm. Job specification.1. In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern: o o o o o 3 Statutory regulations. At locations where multi layer soil with large variation in resistivity/ corrosiveness is expected and /or locations specifically advised by OWNER or his representative resistivity measurements at additional depth of up to 3 m (approx) or more shall be taken. The depth of resistivity measurement at each location shall be at around 1 m and at the burial depth of the pipeline accounting for the cuttings /fillings or 2 m approximately which ever is higher. m and two successive readings differ by more than 2:1 then additional soil resistivity readings in between the two locations shall be taken. Contractor shall be responsible for providing necessary data interpretation based on corrosion survey measurements. chemical analysis of soil/water and collection of other cathodic protection related data along ROU of the pipelines. Data sheets. In general the resistivity of soil. Wherever possible / advised by OWNER or his representative.3 be surrounding the pipe. Samples shall be collected on an average at one location for every 10 km along ROU with minimum at two locations. TESTS ON SOIL SAMPLES Soil/water samples shall be collected along the ROU for analysis. shall be measured. The resistivity graph shall also indicate the resistivity at additional depths measured at various locations and depth of water table. At each location the soil samples shall be collected at I m.7 4. Hence the depth of measurement / electrode spacing may vary depending on topography and strata at the area. soil resistivity and in consultation with OWNER or his representative. The observations shall be made enclosing the soil immediately surrounding the pipeline route where ROU has been cleared but trenching has not been done.8 4. 2 m depth and at expected depth of pipeline if it is more than 2 m at the location. While recording the data reference to the nearest intersecting point shall be made. Observations shall be made enclosing the soils adjoining the trench wherever pipeline trenching has already been done. To provide visual representation of variations in the resistivity along ROU.9 4. measurements shall be made right over the centre line of pipeline route surveyed accounting for the cuttings /fillings also. At places where ROU has not yet been cleared. All measurements shall be made and recorded in metric units. 4.6 4.4. depth of water table shall be determined by resistivity observations. Care shall also be taken that the observations are not influenced by presence of other earth currents in the area especially in the vicinity of EHV/HV lines and plants using earth return in their source of power etc. Exact locations shall be decided at site depending on the type of soil.5 4.10 5 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION SURVEY SPECIFICATION S-07-02-009 REV-0 Page 5 of 7 © GAIL – All rights reserved . At places in ROU where other pipelines are already existing care shall be taken to precisely locate such pipes line and take such precautions that observations are not adversely affected by presence of such pipelines. All measurements shall be taken at right angles to the ROU unless otherwise asked by OWNER or his representative at site. values shall be plotted on semi log graph sheets.4 4. 1. Possibility of integration/isolation of CP system of the foreign service/pipeline with that of the proposed pipeline. Remedial measures existing on foreign service/pipeline to prevent interactions. Location and type (Deep well / surface) of anode ground bed.1.1.1. Where pipeline is likely to pass close to any existing ground bed (with in 100 m approx).8 6. Type of existing cathodic protection systems (impressed current / sacrificial).7 6. anode. Location of existing test stations. ADDITIONAL DATA COLLECTION The following data shall be collected with a view to generate design data for evaluation of cathodic protection interaction possibilities due to presence of other services in ROU and its vicinity: Following information regarding foreign service/pipeline in or around the ROU (for existing and those.1.3 6. bicarbonates.1.bed potential gradient survey shall be carried out SPECIFICATION FOR CORROSION SURVEY SPECIFICATION S-07-02-009 REV-0 Page 6 of 7 6.12 6. Parallel running / crossing. Rating of impressed current type of anode ground bed. Depth of laying. chlorides. Diameter and pipeline coating in case of pipeline.1 6.9 6.4 6.1.1. which may involve negotiations with owner’s of foreign services. nitrates. current.1. Types of service / pipeline and year of laying.13 6. oxygen activity.1.5 6. pipe to soil potential readings.2 6.1. Graphical representation of existing structure / pipe to soil potential records.11 6. Year of laying / commissioning.14 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .10 6.1.1 6.6 The collected soil / water samples shall be analyzed to determine presence and percentage of corrosive compounds including carbonates.1. moisture content and pH value. Location of existing CP power supply units and their output voltage.6 6.1. which are likely to come up during contract execution). to verify possible interference with the CP system of the pipeline covered under this project. prepared in connection with the work shall be submitted along with six prints by the contractor. operating voltage.7 7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR CORROSION SURVEY SPECIFICATION S-07-02-009 REV-0 Page 7 of 7 © GAIL – All rights reserved . bicarbonates. Crossing and parallel running of electrified and non-electrified traction (along with information regarding. in the vicinity of the entire pipeline route.3 Voltage rating. The report along with various drawings. Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power lines along with details of voltage.) as well as abandoned tracks near ROU having electrical continuity with the tracks in use. REPORT On completion of all the field and laboratory work an interim report incorporating results generated from surveys. phases and sheathing details of cables running parallel or crossing the ROU.4 6.5 6. 6. graphs etc. sheathing details of underground power cables along ROU or in its vicinity. Voltage rating. Any other relevant information that may be needed in designing and implementing of proper cathodic protection scheme for the proposed pipeline.6 6. shall be submitted for comments / approval. The final report incorporating comments / missing data shall be furnished for records. The report shall also highlight any adverse impact on performance of sacrificial anodes due to the percentage of corrosive compounds including carbonates. nitrates. AC/DC type etc.2 6. 6. AC/DC type etc. fabrication yards with electric welding etc. etc. chlorides present in the soil and pH value of the soil noticed during the survey. phases. additional data collected. Existing and proposed DC/AC power sources and systems using earth return path such as HVDC substations/ earthing stations. results of test carried out. SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-010 REV-0 Page 1 of 20 © GAIL – All rights reserved . AC: BS: BIS: CMRI: CP: CPPSM: CPTR: DC: HV: IS: MMO: MOV: NACE: PE: PVC: ROW: Abbreviations: Alternating Current British Standards Bureau of Indian Standards Central Mining Research Institute Cathodic Protection Cathodic Protection Power Supply Module Cathodic Protection Transformer Rectifier Direct Current High Voltage Indian Standards Mixed Metalic Oxide Motor Operated Valves National Association of Corrosion Engineers Polyethylene Polyvinyl Chloride Right of Way GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-010 REV-0 Page 2 of 20 © GAIL – All rights reserved . 7. 4. SCOPE CODES AND STANDARDS SITE CONDITIONS EQUIPMENT/MATERIAL SPECIFICATIONS EQUIPMENT FOR CLASSIFIED AREAS TESTS AND ACCEPTANCE PACKING AND DESPATCH GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-010 REV-0 Page 3 of 20 © GAIL – All rights reserved .CONTENTS 1. 3. 2. 5. 6. 2 PVC insulated (heavy duty) cables.1. 2. manufacture.3 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES © GAIL – All rights reserved . SPECIFICATION S-07-02-010 REV-0 Page 4 of 20 2. These equipment and materials shall broadly include: Sacrificial Anodes Test Stations Anodes for impressed current CP system Anode junction boxes Cathode junction boxes Permanent reference cells Electrical resistance probes Polarisation cells and surge diverters/grounding cells Polarisation coupons Computerised test stations Cables Requirement of Cathodic protection TR units (CPTR unit) and cathodic protection power supply modules (CPPSM) are covered in separate specifications. supply and testing of various equipment and materials for Cathodic Protection system for underground pipelines/structures. Corrosion Resistant High Silicon Iron Castings ASTM ASTM A518 M B418 Cast and wrought galvanic zinc anodes. ASTM B843 Magnesium Alloy Anodes for Cathodic Protection. code of practice for land and BS 7361. Part-I 2. Specification for seamless and welded Titanium and ASTM B338 Titanium alloy tubes for condensers and heat exchangers.0 2. In case of imported equipments standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards. Part-I marine applications.0 SCOPE This specification covers the requirements for the design.1 CODES AND STANDARDS All equipment and material covered in this specification shall conform to the requirements of the latest revision of following standards: IS 3043 Code of practice for earthing NACE standard Standard recommended practice Control of corrosion RP0169 on underground or submerged metallic piping system Cathodic protection. The equipment shall also confirm to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country. IS 1554. 02% max. - 3. This specification.3% max. EQUIPMENT/MATERIAL SPECIFICATIONS All equipment/material shall be brand new with state of art technology and proven field track record.3.3% max. 0.1.5 .0.05% max. 0. No prototype equipment shall be offered.Total Magnesium Anode open circuit Potential Anode consumption rate Weight (High potential type) 0.15 . 0. SPECIFICATION S-07-02-010 REV-0 Page 5 of 20 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES © GAIL – All rights reserved .1% max.5% .7% 0. Codes and standards. The anode shall be of high manganese.55 volts 7. warm and humid or dusty atmosphere.Yr. Data sheets.2. The metallurgical composition. magnesium alloy packed with special back fill.01% max.0 4. 0. a design ambient temperature 400C and an altitude not exceeding 1000 M above mean sea level shall be considered. 2.1.03% max.Each .1 4./(A. 0.6. potential and consumption rate of anode shall be as below: Composition Element Manganese Copper Silicon Zinc Aluminium Iron Nickel Calcium Other metallic elements .3 % 0.1 0. If not specifically mentioned therein. 0. Make and construction of all equipment/materials shall be subject to approval by Owners representative.9 Kg/(A.4 In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern: Statutory regulations.003% max. Balance 1. 0. 0. SITE CONDITIONS The equipment and materials shall be suitable for installation in locations having generally corrosive.3% .9Kg.5% 5. Job specification.7% 0. Service conditions shall be as specified in the project specification/data sheet. Balance 1. Weight (Low potential type) 0.) Max.02% max. Sacrificial Anodes Magnesium Anode The anode shall conform to the requirements of ASTM-B 843 standard.05% max.Yr) max.001% max.002% max.0 4.75 volts 7. 07% 0.0014% max.24Kg/(A.24Kg.002% max.1. The anode and cable terminations shall be suitable for the anticipated fault current at the SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES 4.003% max. Composition: Element Aluminium Cadmium Copper Iron Lead Others Zinc Anode open circuit Potential Anode consumption rate Weight (Type I) 0. 0.1.. Remainder 1.6 4.5m cable slack provided at each anode and test station ends.)max.Yr) max 11. Anodes of type I shall be used for seawater./(A.1. bicarbonates. nitrates. present in the soil. shall be of minimum 20 kg net weight each. 0.005% max. The other details of anodes shall be as shown in the applicable GAIL standard drawings.1 volts Weight (Type II) 0.3 11.7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION S-07-02-010 REV-0 Page 6 of 20 © GAIL – All rights reserved .005% max.005% max. as applicable without any intermediate joint in the cable and with minimum of 0. 0.1 volts ii) iii) 4. the thickness of back fill shall not be less than 50mm on all the sides of the anode.01% max. potential and consumption rate of anodes shall be as below. The anodes shall be provided with cable tail of sufficient length to reach test station/ buried junction box.5% 0. brackish water or saline electrolyte application and anode of type II shall be used for fresh water. etc. The metallurgical composition of anode.006% max.1.003% max.5 4. In any case. 0. The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates. 0.Yr.4 4. Remainder 1. 0.1% to 0.1. back fill and soil applications.2 Zinc Anode The anode shall conform to the requirements of ASTM-B 418 standard. The anodes shall be suitable for the composition/conditions of soil in which they will be installed. grounding of pipeline through polarization cell at EHV/HV line crossings or running in parallel.1. The anode (other than ribbon anode) shall be packaged with special backfill. grounding of motor operated valves on cathodically protected portion of the pipeline. etc. The type of ribbon anode inside the casing at cased crossing shall be suitable for the type of soil outside the casing. 0. The anodes for grounding of cathodically protected above ground pipelines at intermediate SV stations. pigging stations. etc.4.025-0. location of installation. The resistors shall be suitable for operation over the design life for the permanent CP system specified in the project specification/data sheet. Number of terminals and different schemes of wiring shall be as per the applicable GAIL standard drawing. At locations where solid state polarization cells are provided. the test station size shall be suitable for mounting the polarization cell inside the test station. etc. the anodes for directly grounding the pipeline shall be of the same type as the one provided for the protection of the pipeline. Distance form pipeline in meters.2 75% 20% 5% Test Stations Test stations shall be provided along the pipeline ROW for monitoring the performance of the cathodic protection system. anode/cathode junction box.1. Test station enclosure shall be made of sheet steel of at least 3 mm thickness and shall be suitable for GI pipe post mounting. 4. grid coil type. For pipelines protected by sacrificial anodes. The nameplate shall carry the following minimum information: Chainage in km. Test stations shall have weatherproof enclosure having degree of protection IP-55 and hinged lockable shutter. shall be of variable. A nameplate of anodized aluminum with black back ground and white letters shall be fixed to the inner side of the test station. i) ii) iii) iv) v) vi) GAIL (INDIA) LTD NEW DELHI The constructional features of test stations shall be as per the SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-010 REV-0 Page 7 of 20 © GAIL – All rights reserved . The resistors for control of current provided in the test stations. Test station connection scheme. The inner and outer surfaces of test stations shall be epoxy painted.8 Special Backfill The composition of special back fill for anodes shall be as below : Gypsum Bentonite Sodium Sulphate 4. Minimum twenty percent spare terminals shall be provided in each test station. Direction of product flow. /Amp. Cable to anode joint shall be reliable and long lasting for total design life of anode. Anode canisters shall be filled with petroleum coke breeze with following specification conforming to IS: 8502.3. The design life of anode under burial condition.1. For shallow anode ground bed sheet steel anode canisters of adequate size shall be provided for each anode. 0. High silicon cast iron type anodes shall be center-connected hollow type or end connected solid type. 0. Anode consumption rate shall not be more than 0.1 i) applicable GAIL standard drawings.1% max. 0.5% max. 0. Anodes for Impressed Current CP System High Silicon Cast Iron Anodes.75 % 1.0 % 0.5% max.1 ohm cm max at 150 PSI SPECIFICATION S-07-02-010 REV-0 Page 8 of 20 iii) iv) v) b) c) d) e) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES © GAIL – All rights reserved .5% max.2 kg. dust free 0.03 kg/litre min.1 % 3.m (max./M3 2.2% max. Element Silicon Manganese Carbon Chromium Copper Molybdenum Iron Weight 14./M3 to 1200 kg. 0.25 .5% max. III. Remainder ii) Surface current density rating of the anode for continuous operation shall be 15 amperes/sq.) for deep well anode ground beds. Yr.7% .) for shallow anode ground bed and 10 amperes/sq. 1 mm max. 800 kg.4.14. Grade-A type.2 .5. a) Chemical Fixed carbon content by mass: Ash by mass: Moisture by mass: Volatile matters by mass: Bulk density Real density Particle size Resistivity Composition 99% min. at the design operating current shall be in minimum the design life of the CP system specified in the project specifications/data sheet. Composition of anodes shall be as below and shall also conform to ASTM A518 M-86 Gr.3 4.m (max. 3.3 The anodes shall be provided with sheet steel canisters and coke breeze as per clause No.3. their physical and mechanical properties shall be substantiated by manufacturer’s published catalogues and backed up by type test reports. over laid with mixed oxide of noble metals (MMO coated). design life.1 (v) & (vi) above. noble metal oxide coating thickness (gm/square meter). anode centralisers and gas venting pipes shall be provided for the ground bed. anodes shall be non canistered type. at the design operating current in minimum be the design life of the CP system specified in the project specifications/data sheet. The anodes shall be centre connected sealed tubular type. Anode cable tail shall be connected/jointed to the anode and the joint insulated at the anode manufacturer’s shop before despatch of anode.3. rated current output. which shall long enough for termination on their associated anode lead junction box without intermediate joint. Each anode shall be supplied with anode lead cable connected to it. 4. shape. Each anode shall be supplied with anode tail cable connected to it. Anode supporting pipe. consumption rate. The guaranteed design parameters of anode regarding current density.3. These anodes shall be dimensionally stable.1 v) above shall be supplied along with the anodes. dimensions.2 i) ii) 4.4 i) GAIL (INDIA) LTD NEW DELHI SPECIFICATION S-07-02-010 REV-0 Page 9 of 20 © GAIL – All rights reserved . Grade I/Grade II. Each junction box shall have provision of termination of cable tails from individual anodes of the ground bed and provision of connection SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES 4. Calcined petroleum coke breeze slurry conforming to clause 4. Anode Junction Box Depending on the size and configuration of anode ground beds.4 4. Mixed Metal Oxide Coated Titanium Anode Mixed metal oxide coated titanium anodes shall be of pure titanium having substrate composition of titanium of ASTM B-338.vi) For deep well ground beds. For deep well ground beds steel pipe casing for active portion of the ground bed and non metallic pipe casing for the top inactive portion of the ground bed shall be provided. The top non metallic casing and the lower metallic pipe casing shall have threads for jointing each other. The design life of anode under burial condition. requisite main and sub anode junction boxes (where required) shall be supplied for each ground bed. 4.3. A nameplate of anodised aluminium with black back ground and white letters shall be fixed to the inner side of the junction box. 30% spare out going circuits shall be provided in each anode junction box.55. variable resistance of grid coil type and a current measurement shunt. Distance form CP station in metres.of anode cable coming form main anode junction box (in case of sectionalised ground bed) or from CP station power source.5 Ground bed current rating Ground bed resistance Connection scheme. i) The junction box shall have a bus bar with an incoming circuit for connecting to negative of the CP power source and separate out going circuits for collection of negative drainage current from each of the pipelines. ii) Junction boxes shall have sheet steel enclosure of minimum 3 mm thickness and hinged lockable shutters. Junction boxes shall have anode bus of copper with nickel/ silver plated or tinned. iv) Cathode Junction Box Where output of the CP power supply unit is connected to multiple pipelines a cathode junction box shall be supplied for providing near the pipelines at the location of connection of the negative drainage cable to the pipelines. Distance form pipeline in metres. Each outgoing circuit shall be labelled clearly to indicate the circuit/sub anode junction box to which it is connected. Terminals shall be of anti loosening type and provided with identification labels. The nameplate shall carry the following minimum information: 4. One number spare SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES ii) GAIL (INDIA) LTD NEW DELHI SPECIFICATION S-07-02-010 REV-0 Page 10 of 20 © GAIL – All rights reserved . iii) The constructional features of junction boxes shall be as per the applicable GAIL standard drawing enclosed with the data sheet for impressed current cathodic protection system for pipelines. Each out going circuits shall have isolation link. Disconnecting links shall be provided for each out going/anode circuit. The incoming circuit shall have a current measurement shunt. Junction boxes shall be weatherproof with degree of protection IP. Provision shall be made for measurement and control of individual out going circuit/anode current by providing suitable shunt and resistors of grid coil type. It shall be epoxy painted on inside and outside surface. A nameplate of anodised aluminium with black back ground and white letters shall be fixed to the inner side of the junction box. iii) Junction box shall have sheet steel enclosure of minimum 3 mm thickness and hinged lockable shutters. The inside and outside surfaces of the junction box shall be epoxy painted. at computerised test station locations and at locations of polarisation coupons along ROW. The reference cell for high resistivity areas shall be suitable for the prevailing dry soil conditions to give maximum service life. The nameplate shall carry the following minimum information: Chainage in km. Proper identification labelling shall be provided for each terminal. Silver/silver chloride type reference cells shall be supplied for marshy area locations where water table is high and chloride ion content is more than 300 ppm.outgoing circuit shall be provided.6 4. Earth electrodes shall be 100 mm dia. Direction of product flow. etc. Permanent Reference Cells High purity copper/copper sulphate reference cells or Zinc reference cells as specified in project specification/data sheets. pigging stations. Each outgoing circuit label shall clearly indicate the size and identification of the pipeline to which it is connected. The permanent reference cells shall have a minimum design life of 20 years under installed/buried condition. The reference cells shall be provided with cable tail long enough for SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES iv) 4. with proven high reliability shall be supplied for providing stable pipe to soil potential measurement reference at CP stations. and at terminals GI earth electrodes shall be supplied.7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION S-07-02-010 REV-0 Page 11 of 20 © GAIL – All rights reserved . GI Earth Electrodes For earthing of above ground cathodically unprotected pipelines at intermediate SV stations. 3000 mm long. and 13 mm thick conformity to IS 3043. Junction box shall be weatherproof with degree of protection IP-55. i) ii) iii) iv) The reference cells shall have high accuracy and stability and maintain the same over its design life. The terminals shall be of anti loosening type. Connection scheme Distance form the nearest pipeline in metres. 5 digit display.9. The instrument shall be able to directly read out the resistance of probes.8 Electrical Resistance Probe Electrical resistance probes utilising the electrical resistance technique shall be suitable for use along the pipeline at marshy areas and at interference affected locations/vulnerable locations to monitor the external corrosion activity on the pipeline. The solid state device shall have weather proof enclosure and shall be suitable for mounting inside a test station. The device shall require minimum maintenance. 4. The surge SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES GAIL (INDIA) LTD NEW DELHI SPECIFICATION S-07-02-010 REV-0 Page 12 of 20 © GAIL – All rights reserved .2 Surge Diverter The surge diverter when connected in parallel across the insulating joints shall protect the insulating joint against surges coming across it due to lightning strikes. 4. Portable E/R probe reading instrument shall be supplied by contractor.9 4. etc.2 volt shall not be more than 0. designed to simultaneously provide isolation for DC current and low resistance path for AC current. Unless other wise specified in project specification/data sheet the DC blocking voltage shall not be less than 1. The device shall have weatherproof enclosure suitable for out door mounting.5 mA. The instrument shall run on rechargeable batteries. as specified in the project specification/data sheet. The material of the E/R probe element shall be of the same alloy as that of the pipeline material. Probe shall be provided with cable leads for connecting it to CP system and required for the probe resistance measurements. The probe reading instrument shall be suitable for use in field and shall have IP 55. on the above ground portion of the pipeline. subject to minimum ratings as indicated in clause 4.connection to test station without any joint in between. The DC leakage current at 1. The surge diverter shall be of spark gap type. electrical faults.3 below.1 Polarisation Cell and Surge Diverter Polarisation Cell Polarisation cell shall be a electrolytic type or solid state device as specified in project specification/data sheets.2 volts. 4.9. The probe reading instrument shall be of digital type with 3. weatherproof enclosure.9. The device shall be suitable for continuously conducting maximum AC steady state current and short time AC short circuit current expected to flow through the pipeline under the normal operating condition/any kind of fault on the EHV/HV line at respective sites. AC fault current: (RMS symmetrical) . 100 Kilo Amp. The coupon shall have one side exposed area of 100 mm x 100 mm unless other wise specified in project specification/data sheet.Ac voltage under maximum rated AC fault current: Surge Diverter a) b) c) Type: Current. The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates.10 Polarisation Coupons The Polarisation Coupons shall be made from the material of the pipeline. the thickness of back fill shall not be less than 50mm on all the sides of the anode.Minimum rated 50 Hz steady: state current (RMS symmetrical) . Connection of coupon to pipeline shall be through a vacuum sealed magnetic reed switch housed inside the test station. surge diverters. etc. nitrates. 1KV 2.2 KV ii) iii) The polarisation cells. The magnetic reed switch shall be rated to carry and break minimum 50 mA at 50 V DC. explosion proof type.3 The minimum ratings of polarisation cells and surge diverters shall be as below unless otherwise specified in the project specification/data sheet.diverters shall be of explosion proof type. anodes. shall be adequately sized and suitable for the design life of permanent CP system.2/50 micro Second): a) b) Solid state type/Electrolytic type Rating 30Amin at 280C and min 2V DC 5 kA min for 1 cycle Less than 10 V peak to peak Spark gap. Cable connection of 10 mm2 and 4 mm2 shall be provided to the coupon for connecting it to pipeline for cathodic protection and potential measurements respectively.over AC voltage -50 Hz: -Impulse (1. connecting cables. Magnet for operation of reed switches shall be provided as specified in GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-010 REV-0 Page 13 of 20 © GAIL – All rights reserved . 4. present in the soil. bicarbonates. i) Polarisation Cell Type: Description .9. etc. 4. 8/20 micro Second wave: Spark . cable joints. In any case. The measurement range for the input ports for pipe to soil measurement shall be (+) 5 V to (–) 5 V DC. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-010 REV-0 Page 14 of 20 © GAIL – All rights reserved . The computer shall have a real time clock and shall indicate the date and time of the data collection along with the data. It shall be possible to designate a unique identification number incorporated in to the software of each computer for identification of the unit after down loading the field data from it.1 Computerised Test Station and Test Station Reader Computerised Test Stations The computer units for installing at computerised test stations shall be able to measure and record the field CP system parameters automatically at regular programmed intervals. The measurement range for the other input ports shall be decided based on the maximum value of the in put parameters measured. The field computer shall have weatherproof enclosure. as programmed. The battery provided in the computer shall be suitable for its operation including storing the measured data at field. etc. The computer shall have memory capacity suitable for storing the data measured at programmed intervals continuously for six months without down loading the data.project specification/data sheet. The computer shall have required numbers of input ports for measurement of pipe to soil DC potentials. induced AC potentials. The accuracy of the internal clock shall be +/. The test station housing the computer shall be of IP 55. The input data measurement accuracy shall be +/. In any case the number of input ports shall not be less than five.11. Unless otherwise specified in the job specification/data sheet the computers shall be programmed to collect and store all the field parameters once daily. It shall be possible to reprogram the computer for the data collection interval/set/initialize the computers at field with the help of data retrieval computer. 4.5% or better.0.11 4.1% or better.0. weather proof with locking arrangement. pipeline current. for minimum 10 years without requiring the replacement/recharging of the battery The computer shall have provision/plug in arrangement for retrieval of the stored data with a hand held data-retrieval computer. bond current. All the input measurement ports shall be protected against high voltage surges due to lightning/HV switching that may come from the pipeline. Copper bus bars. The battery provided in the data-retrieval computer shall be suitable for this operation without any replacement/recharging the same during the operation. It shall be possible to down load the data collected by the data-retrieval computer to a station computer for further analysis of the data or directly to a printer. The under surface shall be free from all imperfections before undertaking the finishing coat. field programming/setting/initializing the field computer and estimating the field computer battery capacity/life left over. weatherproof enclosure.2 The Data Retrieval Computer The data retrieval computer shall be of portable type suitable for use in field. Suitable plug arrangement shall be provided on the data-retrieval computer so that it can be plugged in to the field computer for data transfer. grease and dirt. final spray painting with two coats of epoxy based paint shall be done. 4. ii) iii) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-010 REV-0 Page 15 of 20 © GAIL – All rights reserved . when connected to the field computer. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. Panel finish shall be free from imperfections like pinholes. rust.4.12 i) Miscellaneous Requirements The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale. The data-retrieval computer shall have enough memory capacity for retrieving/down loading the data collected and stored by minimum ten field computers. runoff paint etc.11. Requisite cable lugs shall be supplied. The computer shall be suitable for retrieving/down loading the data collected by the field computer. The unit shall be provided with a carry bag suitable for carrying in field. orange peels. each having collected the field data for minimum six months continuously. interconnection copper link shall be tinned or nickel/silver coated. The lugs shall be of tinned copper. The data-retrieval computer shall have IP 55. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. Test station/junction box cabling Adequate space shall be provided inside the test station/junction box for termination of cables. All unpainted steel parts shall suitably treated to prevent rust formation. Termination shall be performed using crimped lugs. After preparation of the under surface. For impressed current CP system the size of conductor of cables shall be based on the current to be carried.13. Length of anode tail cables shall be sufficient for routing and terminating the cable inside anode junction box/buried junction box/test station as SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES i) ii) iii) 4. armoured. twisted pair with individual pair shielded and overall shielded with Aluminium backed by mylar / polyster tape.2 4. single core. The tape shield shall be helically applied with metallic side down.13. Aluminium backed by mylar / polyster tape shielded. reference cells. PVC sheathed. The size of the copper conductor of the cables shall be as below: Minimum 4 mm2 for potential measurement. The size of CPTR unit AC incomer cables shall be of minimum 4mm2 copper conductor.5 GAIL (INDIA) LTD NEW DELHI SPECIFICATION S-07-02-010 REV-0 Page 16 of 20 © GAIL – All rights reserved .4.05 mm. PVC insulated.4 4. PVC sheathed. armoured.1 Cables Cables shall be of annealed high conductivity stranded copper conductor. annealed high conductivity stranded copper conductor. unarmoured. PVC insulated. with either side 25% overlap and 100% coverage. PVC over all sheathed type. Impressed current CP anode tail cables shall be of minimum 10 mm². ground bed loop resistance and shall be minimum 35mm2 copper for positive. 650 voltage grade PE insulated. For sacrificial anode CP system the cable size shall be minimum 6 mm2 copper for anode tail cable from anode to buried junction box and 10 mm2 copper from buried junction box to test station in case of temporary CP anodes.3 4.13. 6 mm2 for current measurement and 25 mm2 for bonding/grounding. negative drainage cables and 10 mm2 copper for anode tail cables.13 4. for Owner’s approval. 650/1100V grade PVC insulated.13. Cable conductor sizes indicated above are minimum only and where necessary for proper operation of the CP system higher sized cables shall be provided. Cables for connecting various transducers from CPTR Unit/CPPSM to telemetry interface junction box shall be copper conductor. The cables for reference cells and pipeline potential measurements shall be of 4 mm2 copper conductor. PVC sheathed.13. except for reference cell. In case of sacrificial anodes for permanent CP system the size of anode tail cable from anode to test station shall be minimum 6 mm2 copper. potential measurement and impressed current CP anode tail cables. armoured. PVC sheathed conforming to IS1554 part-I. Contractor may suggest cables with alternative insulation/sheathing having proven track record for impressed current anode ground bed application. The minimum shield thickness shall be 0. PVC over all sheathed type. 1 TESTS AND ACCEPTANCE Unless other wise agreed by the Engineer-in-Charge. 6. 5. All flameproof equipment shall carry the BIS license marking as per the requirement of statutory authorities. which may reduce the performance of the anode. Indigenous equipment shall be certified by CMRI or any other recognised testing body and shall be approved by the concerned statutory authority.2 6.applicable without any intermediate joint. All necessary information concerning the supply shall be furnished to GAIL/Owner’s inspector. cable joint to anode cone. Instruments and equipment required for testing shall be arranged by the manufacturer. Final acceptance shall be subject to successful testing. cracks. all the equipment/material shall be subject to inspection by GAIL/Owner or by an agency authorised by the owner.0 EQUIPMENT FOR CLASSIFIED AREAS Equipment for hazardous area shall be flame proof type and shall meet the requirement of IS:2148 or equivalent international standard and shall be suitable for gas group IIB. Any cracks which follow the longitudinal direction of elongated anodes shall not be acceptable. Sacrificial Anodes Inspection Visual inspection shall be carried out on all the anodes regarding surface finish excessive shrinkage. temperature class T3 (2000C). SPECIFICATION S-07-02-010 REV-0 Page 17 of 20 6. All Imported equipment for hazardous area may be tested and certified by an independent certifying agency of country of equipment origin and shall be approved by the concerned statutory authority in India.0 6. Two weeks notice shall be given to GAIL/Owner for witnessing the final testing. Minimum 10% of number of anodes from each heat for conformity to dimensions and weight. Type test certificates instead of conducting the tests may be accepted where specified in the project specifications. etc. Routine tests and final acceptance tests shall be carried out at manufacturer’s works under his care and expense.3 i) a) b) c) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES © GAIL – All rights reserved . The anode surface shall be free from cracks. If the second lot of anodes also fails the test. The surface of the anodes shall be free from coatings and slag/dross inclusions etc. all the anodes of the heat shall be rejected. If the anode fails the test. The total weight of the anodes shall not have negative tolerance Recommended dimensional tolerance shall be as follows: ii) iii) Length Width/thickness ±2. The following limits shall be used.Small cracks in the transverse direction of elongated anodes and in anodes of other shapes may be accepted provided the cracks would not cause any mechanical failure during service of the anode considering that the combination of cracks and lack of bond to the anode core is detrimental. at the end for the second heat. The depression may be measured for the edges of one side. The maximum deviation from straightness shall not exceed 2%. two more anodes shall be tested. Maximum 10% of the depth of anode or 50% of the depth of the anode core whichever is less. at the beginning for the 3rd heat and so on. Destructive Testing At least one anode per heat shall be subject to close inspection by destructive testing for slag inclusions.5% ±5.0% d) One anode per heat shall be subjected to radiographic test completely to evaluate cracks. The weight tolerance of individual anode may be taken as + 5%. iv) Chemical Analysis One anode sample per heat shall be subject to chemical analysis by spectrography. etc. Sample shall be taken in the beginning for first heat. SPECIFICATION S-07-02-010 REV-0 Page 18 of 20 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES © GAIL – All rights reserved . The anode shall be free from excessive shrinkage. voids. For transverse cracks the acceptable limits shall be furnished by the bidders along with the offer. bond between the anode material and steel inserts. slag inclusion. ) Where agreed by Owner type test certificate in lieu of actual conduction of electrochemical test may be accepted. Chemical analysis Chemical analysis test and acceptance criteria shall be as per clause 6. shrinkage. The anode acceptance criteria shall be as specified in the clause except that no crack in the anode shall be acceptable unless the cracks are only superficial. The report shall also indicate the month and year of manufacture of reference cell. surface cracks & craters. cable joint.).3 i) above. inter granular attack.4. v) Electrochemical Tests One anode from the ordered lot shall be tested for Open circuit potential Consumption rate by weight loss method Visual examination of corrosion pattern (uneven consumption.3 iii) above. vi) Manufacturer’s test reports regarding reference cell calibration shall be furnished.4 6. atomic absorption/emission/photometrics etc. weight. measurements of dimension. etc. radiographic tests etc. all the anodes of the heat shall be rejected. shall be conducted as per clause 6. Vendor shall indicate specific method of spectrography for each element (e.1 i) ii) iii) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES © GAIL – All rights reserved . Impressed Current Anodes High silicon Cast Iron anode Visual inspection Visual inspection regarding surface finish. Destructive testing Destructive testing and acceptance criteria shall be as per clause 6. SPECIFICATION S-07-02-010 REV-0 Page 19 of 20 6.In case the chemical composition of the tested anode do not meet the requirements of this specification. In case of anode closed circuit potential and/or the anode consumption rate do not meet the acceptance criteria all the anodes of the heat shall be rejected. The anode open circuit potential shall lie with in (+) 10 MV and (-) 50 MV of the guaranteed value.g. The anode consumption rate shall not be less than the specified value.3 iv) above. by radiography. All the equipment shall be divided in to several sections for protection and ease of handling during transportation. voids etc. The special back fill material for the sacrificial anodes shall be tested for composition and test reports shall be submitted. particle size and resistivity and test certificate shall be furnished. The equipment shall be properly packed for transportation by ship/rail or trailer.3 7.0 PACKING & DESPATCH All equipment/material for CP system along with one set of final drawings shall be dispatched to site packed in wooden crates. The package shall be completely suitable for out door storage in areas with heavy rain/high ambient temperature unless otherwise agreed. bulk density. Special notations such as ‘Fragile’. Destructive tests shall be carried out where asked by owner based on the radiographic test results. dross inclusion. ‘This side up’. real density. The equipment may be stored out doors for long periods before installation. ‘Centre of gravity’. visual examination of corrosion pattern and the anode acceptance criteria shall be as per clause 6.iv) Electrochemical tests Electrochemical tests for anode consumption. Mixed Metal Oxide Coated Titanium Anode Contractor shall furnish list/details of the tests that will be conducted by manufacturer of anode and their acceptance criteria. etc shall be clearly marked on the package together with other details as per purchase order. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR EQUIPMENT / MATERIAL FOR CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-010 REV-0 Page 20 of 20 © GAIL – All rights reserved .4. The equipment shall be wrapped in polyethylene sheets before being placed in crates/cases to prevent damages to finish.2 6. ‘Weight’.3 v) above Spectrographic analysis The anodes from each heat shall be tested for chemical composition by spectrographic analysis and for homogeneity. Petroleum coke breeze and special back fill The petroleum coke breeze material shall be tested for chemical composition. v) 6. ‘Owners particulars’. Crates/cases shall have skid bottom for handling. ‘PO nos’.4. SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 1 of 21 © GAIL – All rights reserved . Abbreviations: AC BS BIS CP CMRI CPPSM CPTR CTE DC EHV FBE HDD HV IS MOV Micro A/mm2 NACE PE PVC ROW SV Alternating current British Standards Bureau of Indian Standards Cathodic Protection Central Mining Research Institute Cathodic Protection Power Supply Module Cathodic Protection Transformer Rectifier Coal tar enamel Direct Current Extra High Voltage Fusion bonding epoxy Horizontal Directional Drilling High Voltage Indian Standards Motor operated valve Micro-ampere per square millimeter National Association of Corrosion Engineers Polyethylene Polyvinyl Chloride Right of way Sectionalizing Valve HVDC High Voltage Direct Current GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 2 of 21 © GAIL – All rights reserved . 0 3.0 11.0 4.0 12.0 2.0 9.0 6.0 7.0 10.0 SCOPE CODES AND STANDARDS SYSTEM IMPLEMENTATION CORROSION SURVEY CATHODIC PROTECTION DESIGN PARAMETERS CATHODIC PROTECTION DESIGN CRITERIA SYSTEM DETAILS INSTALLATION FIELD TESTING AND COMMISSIONING INTERFERENCE MITIGATION SYSTEM MONITORING CLOSE INTERVAL POTENTIAL LOGGING SURVEY GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 3 of 21 © GAIL – All rights reserved .0 5.CONTENTS 1.0 8. IS:1554 Part I : PVC insulated (heavy duty) cables. NACE Standard RP-0177 : Standard Recommended Practice Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems. VDE 0150 : Protection against Corrosion due to Stray Current from DC Installations. NACE Standard RP-0286 : Standard Recommended Practice The Electrical isolation of Cathodically Protected Pipelines. This specification defines the basic guidelines to develop a suitable sacrificial anode cathodic protection system for the pipelines/structures required to be protected. 2. engineering. performance and materials to be supplied shall conform to the requirements of the latest revision of following standards as a minimum: NACE Standard RP-0 169 : Standard Recommended Practice Control of External Corrosion on Underground or Submerged Metallic Piping Systems.54276: Cathodic Protection Monitoring for Buried Pipelines. Compliance with these specifications and/or approval of any of the contractor’s documents shall in no case relieve the contractor of his contractual obligations. testing and commissioning of sacrificial anodes cathodic protection system for external surface of cross country onshore underground pipelines/structures including supplementing of corrosion survey. All data required in this regard shall be taken into consideration to develop an acceptable design and for proper engineering of the system. BS 7361 Part I : Code of Practice for Cathodic Protection for land and Marine applications. 1. SPECIFICATION S-07-02-011 REV-0 Page 4 of 21 1.2 1.1 2.3 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES © GAIL – All rights reserved .1.1 SCOPE This specification defines the requirements of design. investigation for interference/interaction problems and mitigation of the same.2 2. NACE Publication 1 OA 190: Measurement technique related to criteria for CP of Underground or Submerged Steel Piping System (as defined in NACE Standard RPO 169-83). NACE Publication No.3 2. installation. APPLICABLE CODES AND STANDARDS The system design. In case of imported equipments standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards. The equipment shall also confirm to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country. g) As built documentation. o This specification. In addition. Survey instruments shall have maximum AC and DC ground current rejection feature. b) C. e) Procedures for interference testing and mitigation. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 5 of 21 © GAIL – All rights reserved . F f) Close interval potential logging survey and system monitoring procedures.1 CORROSION SURVEY The details of corrosion survey including soil resistivity data along ROW and other data required for C. o Codes and standards. system.0 SYSTEM IMPLEMENTATION All work to be performed and supplies to be effected as a part of contract shall require specific review by owner or his authorised representative. o Job specification. Care shall be taken to ensure that the resistivity observations are not influenced by the presence of foreign pipelines/structures. d) Field testing and commissioning procedure. However.0 4. and earth currents in the vicinity of EHV/HV lines and installations using earth return in their power system etc.4 In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern: o Statutory regulations. c) Detailed engineering package. contractor shall have to generate/collect additional data as per clause 4. Major activities requiring review shall include but not be limited to the following: a) Corrosion survey data interpretation report and design basis for C.2. design if available with the Owner shall be included as part of project specification/data sheet. Wenner’ s 4-pin method or approved equal shall be used for such measurements.P. P.2 below required for completeness of the job. o Data sheets. 3. 4. verification of its veracity and adequacy shall be the entire responsibility of the contractor. system design package. P. Contractor shall also carry out soil resistivity survey at sacrificial anode ground bed locations for proper design of ground beds as specified in data sheet. ) as well as abandoned tracks near ROW having electrical continuity with the tracks in use. OWNER shall provide assistance for liaison work to the extent possible: Route and types of foreign service/pipeline in and around or crossing the right of way (including those existing and those which are likely to come up during contract execution). which may involve negotiations with owners of other services. type of protection. pressure. in the vicinity of the entire pipeline route. sheathing details of underground power cables running along ROW or in its vicinity. Graphical representation of existing structure/ pipe-to-soil potential records. rating of anode beds. Possibility of integration/isolation of CP systems. the contractor shall carry out corrosion survey along the ROW of the pipeline conforming to the specifications included in the tender document. if any. AC/DC type etc.Where specified in the project specification/data sheet. Voltage rating.e. type. location. and coating scheme used. (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) (xi) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 6 of 21 © GAIL – All rights reserved . fabrication yards with electric welding etc. and year of laying/commissioning in case of foreign pipelines. wall thickness. Crossing and parallel running of electrified and non-electrified traction (along with information regarding. Present output current and voltage readings of the CP power supply units.2 Additional Data to be Collected The following data shall be collected to generate design data for evaluation of interaction/interference possibilities due to presence of other services in ROW/in vicinity. Any other relevant information that may be needed in designing and implementing proper protection scheme for the proposed pipeline. Diameter. phases. Remedial measures existing on foreign pipelines/services to prevent interaction. 4. operating voltage. AC/DC type etc. type of cathodic protection system provided. soil cover. Information on existing and proposed DC/AC power sources and systems using earth return path such as HVDC substations/ earthing stations. Contractor shall conduct necessary potential gradient surveys for any existing anode ground beds that may interfere with the CP system of the pipelines covered under this project. Crossing or parallel running of any existing or proposed 11 KV and above AC/DC overhead power lines along with details of voltage. test station locations and their connection schemes. Details of the existing cathodic protection systems protecting the services i. a report incorporating all the results generated from surveys and details of additional data collected shall be prepared. The report shall also contain detailed interpretation of survey results and resistivity data enclosed. 35 125 m Soil resistivity less than 10ohm 125 500 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 7 of 21 © GAIL – All rights reserved .4. 75 300 m Soil resistivity 10ohm to 100 ohm. with the permanent CP system shall be designed based on permanent CP parameters. 25 90 m Soil resistivity 10ohm to 100 ohm. This report shall also include various drawings prepared in connection with the above work. Temporary Permanent m CP (μA/m2) CP (μA/m2) 40 200 Soil resistivity 10ohm to 100 ohm. following parameters shall be used for design of cathodic protection system. probable interference prone areas etc. those parts of sacrificial anode cathodic protection system.1 Protection Current Density (i) Pipe lines having coal tar enamel (CTE) coating with two / three layers of reinforcement. CP CP (μA/m2) m (μA/m2) Soil resistivity more than 100 ohm. Minimum Protection Pipeline Surrounding Current Density Soil resistivity more than 100 ohm. Where the cathodic protection system is specified for temporary protection.3 Report On completion of all fieldwork. to form design basis for the scheme of cathodic protection. CATHODIC PROTECTION DESIGN PARA1’IETERS Unless otherwise specified in the data sheet. which will be integrated. 5. The soil resistivity values shall be plotted on semi-log graph sheets.0 5. 500 2000 m Sea water 1000 5000 (ii) Pipe lines having fusion bonded epoxy coating Minimum Protection Pipeline Surrounding Current Density Temporary Permanent Soil resistivity more than 100 ohm. current drainage survey data (where included in contractor’s scope). Where this temperature exceeds 30° C.8 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 8 of 21 © GAIL – All rights reserved .3 Anode utilisation factor : 0.6 for ribbon anodes Pipeline natural potential : (-) 0. Unless otherwise specified in data sheet the design life of temporary CP shall be one year and that of permanent CP shall be 30 years.45V. Where considered necessary for satisfactory protection of pipeline the current density shall be suitably increased by contractor. At HDD (horizontal directional drilling) crossing. Safety factor for current density : 1.(iii) Pipe lines having polyethylene(PE) coating Minimum Protection Pipeline Surrounding Current Density Temporary Permanent Soil resistivity more than 100 ohm. Actual current density to be adopted shall be decided based upon soil and other environmental conditions.85 for solid anodes and 0. 5.2 5.5 5.7 5. proximity of foreign pipe lines/structures and other interference areas affecting the installation. m temporary CP for the pipeline may not be provided after obtaining specific approval from the Owner.3 5. 10 35 m Soil resistivity 10ohm to 100 ohm.1 above shall be applicable where the temperature of the fluid transported by the pipeline / the surface temperature of the buried portion of the pipeline does not exceed 300 C.6 5. Along the ROW where soil resistivity is higher than 100 ohm.4 5. the protection Current Density shall be increased suitably in consultation with the GAIL. CP CP (μA/m2) m (μA/m2) Soil resistivity more than 100 ohm. The pipe protection Current Density indicated in the clause 5. 15 50 m Soil resistivity less than 10ohm 35 125 The above current density values for temporary CP system are applicable for CP system design life up to two years. the pipe protection current density applicable for marshy area shall be considered. All flameproof equipment shall carry the BIS license marking as per the requirement of statutory authorities. Equipment requiring specialised maintenance or operation shall be avoided as far as possible Prototype equipment shall not be accepted. o Sacrificial anodes and anode ground beds o CP system at cased crossings o Test stations o Surge diverter and polarisation cell o Permanent reference cells o Electrical resistance probes o Interconnecting cables o Cables to pipe connections All equipment shall be new and procured from approved manufacturers.5 V (ON) for polyethylene coated pipe lines. Equipment offered shall be field proven.1 A positive potential swing of 100 milli-volts or more shall be considered sufficient to indicate the presence of an interaction/interference situation requiring investigation and incorporation of mitigation measures by the CONTRACTOR. 6. anode lead junction boxes etc. SYSTEM DETAILS The system shall include the following major equipment/sub-systems unless otherwise specified in project specifications.95 V (ON) and (-) 1. Indigenous equipment shall be certified by CMRI or any other recognised testing body and shall be approved by the concerned statutory authority. temperature class T3 (200°C). 7. between (-) 0. Where it is essential to install the equipment in hazardous area. All equipment including test stations. shall be located in safe non-hazardous areas.0 CATHODIC PROTECTION DESIGN CRITERIA Cathodic protection system shall be designed to meet the following criteria: The pipe to soil potential measurements shall be between (-) 0.0 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 9 of 21 © GAIL – All rights reserved . Equipment shall conform to the relevant specifications enclosed with the tender document.7 V (ON) for fusion bonded epoxy/coal tar coated pipe lines with respect to a copper/copper sulphate reference electrode. such equipment shall be flame proof type and shall meet the requirement of IS: 2148 or equivalent international standard and shall be suitable for gas group IIB.6.95 V (ON) and (-) 1. The magnesium ribbon anode shall be separated from the pipeline by at least half a meter.1. Anodes of type I as per ASTM-B 418 standard shall be used for seawater. Where magnesium anode is used for protection of polyethylene coated pipelines. shall be checked for proper operation by the contractor. Each electrically continuous section of pipeline shall be protected totally by single type of anode to avoid inter-anode circulation currents. The anodes shall be installed at sufficient depth to reach moist soil and shall be separated from the pipeline by at least 5 m and 2 m for magnesium and zinc anodes respectively. The anode connections to pipe line shall be routed through test stations. brackish water or saline electrolyte application and anode of type II as per ASTM-B 418 standard shall be used for fresh water.6 7. At high resistivity area the magnesium ribbon anodes shall be installed all along the pipeline by the side of the pipeline in the pipeline trench. m and above magnesium ribbon anodes may be provided. such that the effect of soil is minimum on the anode effectiveness and life. phosphates and nitrates. 55V) type. At high resistivity area where resistivity is of the order of 50 ohm. 7. back fill and soil applications.2 7. m and pH value is within 9. The anodes shall be laid in proper type of back fill.1. Suitability of the selected sacrificial anodes for the soil conditions with particular attention to carbonates. zinc anodes may be provided.All Imported equipment for hazardous area may be tested and certified by an independent certifying agency of country of equipment origin and shall be approved by the concerned statutory authority in India.4 7.55V) magnesium anodes may be provided. Suitable safe guards against anode passivation in prevailing soil shall be taken by the contractor. Anodes shall be installed along the pipeline at suitable intervals as per pipeline protection voltage attenuation calculations and ground bed resistance/current output of anode installations.1.8 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .1 7. m.1.5 Along ROW where soil resistivity is predominantly in the range of 10 ohm.75V) magnesium anodes may be provided. Along ROW where soil resistivity is predominantly in the range of 30 ohm-m to 50 ohm-m high potential (1 . bicarbonates. the anodes shall preferably of low potential (1.1 Anode Ground Beds Along ROW where soil resistivity predominantly remains low. 7.1.3 7.1. low potential (1 . m to 30 ohm.1.7 7. SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 10 of 21 7. ranges from 010 ohm.1. 9 At the temporary CP anode ground bed. For the portion of the pipeline for which the CP system has been specified based on the permanent CP system parameters. At all insulating joints. The number of anodes for ground bed. 7. Where specified in the project specification/data sheet the requisite current density test/survey shall be conducted by the contractor to establish the adequacy of CP current requirement and number of anode ground beds. For sacrificial anode ground bed which is intended for permanent CP system and/or which is to be integrated with permanent CP system. Test stations shall be provided at additional locations.12 7. For temporary cathodic protection system.2.1 above. spacing of ground beds based on the applicable soil resistivity.1. Test Stations Test stations shall be provided along the pipeline ROW for monitoring the performance of the cathodic protection system at the following locations.1. contractor shall prepare a table for number of anodes required at different soil resistivities to produce the specified protection current for the specified designed life.11 7. type of coating for the pipeline shall be chosen from the table after necessary verification by the CP contractor.10 7. At vulnerable locations with drastic changes in soil resistivity. the contractor shall ascertain the requirement of the cathodic protection current density indicated in clause 5. Any deficiency in the protection system if noticed during commissioning or during monitoring shall be corrected by the CP contractor by suitably augmenting the system with additional anodes without any cost/schedule implications. At both sides of metalled road crossings. etc. if required.1. the leads of all the anodes shall be joined together in a junction box filled with epoxy and buried.2 7. the leads of all the anodes shall be brought up to the test station and shall be terminated individually. A single cable shall be routed from the junction box to test station. For permanent cathodic protection system.1 a) b) c) d) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 11 of 21 © GAIL – All rights reserved . so that distance between any two adjacent test stations does not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like forest/deserts: At the locations of anode ground beds. The number of anodes at each ground bed shall be sufficient for providing the specified pipe protection current density taking into consideration the ground bed resistance.7. size of pipeline.1. cable resistance. an indicative design data for sacrificial anodes ground bed in tabular form is given in data sheet. In the vicinity of DC networks or grounding systems and HVDC grounding systems where interference problems are suspected.2.3 7. o Test station connection scheme 7.2 At locations of surge diverters. The nameplate of test stations shall carry the following minimum information: o Chainage in km. Test stations used for sacrificial anodes shall have shunt for measurement of anode current. on both sides of major river crossings.2. At the locations of reference cell and Electrical Resistance probe installation. pipeline grounding through polarisation cells. At EHV/HV cable crossings or along routes where EHV/HV cables are running in parallel.5 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 12 of 21 © GAIL – All rights reserved . At locations of Sectionalizing Valve (SV) stations. Locations where interference is expected.e) f) g) h) i) j) k) l) m) n) o) p) 7. along the pipeline. At both sides of major river crossings. At any other locations considered necessary by OWNER or OWNER’ s representative. Test stations for bonding shall be provided with shunt and resistor as a means to monitor and control current flow between the pipeline and foreign pipelines or structures that may exist in common ROW. Test station with current measuring facility shall be provided at interference prone areas. At EHV/HV AC/DC overhead line crossings and selected locations where EHV/HV overhead line is in the vicinity of the pipeline.2. zinc and magnesium anodes.4 7. near marshy areas and minimum one for every 10 km max. At crossings of other pipelines/structures. At railway line crossings and at selected locations along lines running parallel to the pipeline. At both sides of cased crossings. provision for resistance insertion to limit the anode current output and anode-disconnecting link. The test stations shall be installed with the face of the test station facing the pipeline.2. 3.6 o Direction of product flow.5 7.wires of the probe shall be connected to pipeline through test station and terminated inside test station enabling periodic resistance measurement of the probe using a portable measuring instrument.4 7.4.3 7. Permanent Reference Cells High purity copper-copper sulphate reference cells with proven high reliability shall be provided for stable coupon to soil potential measurement at the locations of polarisation coupons. high purity zinc may be considered as an alternative to silver/silver chloride. The life of reference cells shall be minimum 10 years under burial conditions.3.3. Minimum two cables shall be provided from the pipeline at any test station.2 7. the locations of their installation and the number of portable E/R probe reading instruments shall be as specified in the project specification/data sheet. The number of E/R probes.5. Terminals and different schemes of wiring shall be provided as per the test station connection scheme. A detailed teststation schedule shall be prepared.2 7.1 7. Minimum twenty percent spare terminals shall be provided in each test station. at marshy area locations. SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 13 of 21 7.2. For marshy area in saline soils. Electrical Resistance Probe Where specified in data sheet electrical resistance probes (E/R probes) utilising the electrical resistance technique shall be provided along the pipeline at marshy areas and at vulnerable locations to monitor the external corrosion activity on the pipeline. The test station connection scheme inside the test station shall clearly indicate the type of reference cell (Cu-CuSO4/Ag-AgCl).4 7.2. The E/R probes shall be provided preferably at the bottom portion of pipeline. Surge Diverter and Polarisation Cell Surge Diverter : Explosion proof type spark gap surge diverter shall be connected across each insulating joint to protect it from high voltage surges.o Distance from pipeline in metres. The location of all the test stations shall be marked with their connection schemes and other relevant information on alignment sheets. 7.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .3. The lead.4.2.1 7.8 7. where water table is high and chloride ion concentration is more than 300 ppm. The reference cells shall be of silver/silver chloride type in place of copper/copper sulphate cells.3 7.7 7. the pipeline shall be grounded through polarization cell to the earth system of the EHV/HV tower causing the voltage induction or to a separate earthing system of zinc anodes through polarisation cell. iv) Type of polarization cell shall be as specified in data sheet.7. bicarbonates. the thickness of back fill shall not be less than 50mm on all the sides of the anode. and terminals shall be earthed with GI earth 7.6 7. etc.7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 14 of 21 © GAIL – All rights reserved .0 km where EHV/HV transmission lines run parallel within 25 m of the pipeline. as per below: o The pipeline shall be grounded through polarization cell with zinc galvanic anodes of minimum 20 kg net weight each at location where pipeline crosses EHV/HV transmission lines.2 Polarisation Cell i) Wherever the pipeline is either crossing or running in parallel with overhead EHVIHV transmission lines of voltage grade 66kV and above. pigging stations. cable termination. iii) The polarization cell shall be installed inside test station of suitable size. The MOV power supply cable armour shall be insulated (by cutting and taping with insulation tape) at MOV end to avoid armour carrying CP current. The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates. ii) Locations along pipeline where continuous induced over-voltage due to other overhead transmission lines/underground cables of voltage grade below 66kV is expected or observed during commissioning.5. o The pipeline shall be grounded at regular intervals of maximum 1.5. polarization cell and anode system shall be suitable for the design life of permanent CP system.3 The total system including cable. it is mandatory that the pipeline shall be grounded to discharge any accumulated potential/surge that may appear in case of transmission line faults. In any case. The above ground cathodically unprotected pipeline at intermediate SV stations. surge diverters/polarisation cells/anodes shall be suitable for the anticipated fault current at the location of its installation The surge diverter. 7. Motor operated valves where located on the cathodically protected portion of the pipeline shall be grounded by a zinc or magnesium anode of 20 kg net where the type of anode provided for the CP system of the pipeline is zinc or magnesium respectively.5. nitrates. present in the soil.4 7. The grounding system shall have minimum resistance to earth to restrict the pipeline voltage as per NACE/VDE criteria but shall not exceed 5 ohms. etc. The anodes shall be placed at close intervals as per design calculations with minimum one number of anodes installed between every two supports provided between carrier and casing. PVC sheathed conforming to IS. 7.electrodes. armoured. uncoated or unpainted) additional protection for carrier pipe may not be provided.8. At cased crossings where casing is painted or uncoated.2 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .9 7. mm copper conductor. The carrier pipe inside the painted or coated casing shall be protected by zinc ribbon anodes weld connected to the outer surface of bottom of carrier pipe extending up to hour hand positions of 4 and 8 O’clock. PVC insulated.8. Where casing is bare (i.P. Cables Cables shall be with annealed high conductivity.e. design parameters and design life of permanent CP system. stranded copper conductor. from test station to pipeline. additional protection for casing pipes may not be provided.10.1 7.8 7.2 7. The length of anode tail cable shall be sufficient for routing from anode to buried junction box or test station for anodes for temporary CP or permanent CP respectively. The anodes shall be sized based on the permanent CP design parameters for marshy area and design life of permanent CP system. The resistance to earth of grounding shall be limited to 5 ohms max. provided at both ends of casing. mm. Reference Cell Access Points Reference cell access points shall be provided near insulating joint locations and at SV stations.8. The cables for reference cells and pipeline potential measurements shall be of 4 sq.10 7.mm. for measurement of pipe to soil potentials.1554 Part-I except for the cables for reference cells and pipeline for potential measurement. PVC insulated. A perforated PVC pipe filled with native soil and buried at the location shall be provided for the purpose. Aluminium backed by SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 15 of 21 7.mm. for anode tail cable from anode to buried junction box or test station (in case of permanent CP anode ground bed). the casing shall be protected by sacrificial anode installations. The length of the PVC pipe shall be adequate to reach the native soil below the paving.3 7.1 CP at cased crossing At cased crossings where casing is coated. 10 sq. The anode installation shall be sized based on the permanent C . 650/1100V grade. The size of cable for bonding. where the ground is paved. The size of the copper conductor shall be 6 sq. from buried junction box to test station and 10 sq. grounding anodes and surge diverter connections shall be suitable for the maximum fault current subject to minimum 25 sq mm. polarisation cell.10. mylar/polyster tape shielded.6 8.7 8.0 8.8 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 16 of 21 © GAIL – All rights reserved .3 8.1. In case of above ground cable. For cables laid outside the station/plant area. The armour of all the cables from pipeline to test station (potential measurement. up to accessible height for protecting against the mechanical damage. to mark the route. PVC sheathed. armoured.1.1. from the finished grade.4 8.1.1. 5 m. polyethylene warning mats shall placed at a depth of 0. Cable route shall be carefully measured and cables cut to required length. Cables shall be laid in sand under brick cover and back filled with normal soil.9 m. All underground unarmoured cables including anode tail cables shall run through PE sleeves. The cables routed along the pipeline shall be carried at the top of the carrier pipe by securely strapping it at intervals with adhesive tape or equivalent as required.2 8. etc) and test station to ground bed (anode cable) shall be earthed only at test station end of the cable to avoid armour carrying CP current. PVC pipes of proper size shall be provided for all underground cables for road crossings.1 INSTALLATION Cable Laying Cables shall be laid in accordance with the layout drawings to be prepared by the contractor. Minimum half metre cable slack shall be provided near anodes.1.1.1. etc. PVC over all sheathed type. All cables inside station/plant area shall be laid at a depth of 0. 8. AC cables for CPTR units.75 M. No straight through joint shall be permitted.5 8. Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and final take-off to equipment is facilitated. reference cell cables. all unarmoured CP cables shall be laid in GI conduits of sufficiently large size. The cables for reference cells and pipeline potential measurement shall be routed in a separate trench other than the trench provided for the rest of the CP system cables. Cables outside station/plant area shall be laid at a depth of minimum 1. The cable armour shall be insulated by cutting and taping with insulation tape 8. cathode cables.1 8. pipeline and test stations to account for any settling. 1. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 17 of 21 8. Voltage test. Voltage grade.1. FIELD TESTING AND COMMISSIONING System testing at site Field tests as per the reviewed field testing and commissioning procedures prepared by the Contractor. connected and are in good working condition as required for the intended operation. Cable to pipe connections All cable connections to the new pipeline shall be made by an approved exothermic process or by pin brazing. Continuity check. i) Cables Cable No. designed based on the permanent CP design parameters. Conductor cross section. necessary tests shall be carried out to establish that all equipment. Intimation shall be given at least one week before commencing the tests.1 9.4 © GAIL – All rights reserved .2 Permanent Reference Cells The permanent reference cells shall be installed in natural soil conditions as per the recommendations of the cell manufacturer. Owner/Owner’s representative may witness all tests. equipment and instruments required for testing shall be provided by Contractor. Before the C.4 9.2 9. cable connection to charged pipelines shall be made by pin brazing. However. Insulation resistance values between each core & earth.3 8. Acceptance of the complete installation shall be contingent upon inspection and test results. Exothermic welding shall be adopted for water pipelines.0 9.8. system facilities are put into operation. The coating repair material shall be compatible with the original coating and shall prevent ingress of water along the cable surface and at the interface of coating repair with the original pipe coating.P. Ground bed Fencing Where specified in project specifications/data sheet a chain link fencing shall be provided around the location of each ground bed.1.1 ohm. the following minimum tests must be carried out and recorded. Installations in highly acidic/alkaline soil and soil contaminated by hydrocarbons shall be avoided.3 9. All tools. shall be carried out on the equipment/systems before these are put into service.1 9. Coating shall be repaired after connection of cable conductor to pipeline.1. The resistance of the cable to pipe at the connection point shall not exceed 0. devices. wiring and connection have been correctly installed. Generally. iv) Polarisation Cell Location/Identification number. v) Anode Ground Bed Location/Station Vertical/horizontal Check for actual layout and compliance with drawings.between cores. Check for proper connection. ii) Insulating joint Location. Current output of ground bed Current out put of each anode (in case of permanent CP anode ground beds) SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 18 of 21 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Rating Type Explosion proof enclosure. iii) Surge diverter Location/identification number. Pipe to soil potential of both protected and nonprotected sides of the insulating joint before and after energisation of CP system. Details of grounding provided for the polarisation cell. All cables shall be tested by 500 V megger. Type Ratings Check for wiring Check standby current drain after CP system energisation. (Current drain with respect to voltage across the cell shall be recorded). Check for healthiness. 2. The current output of each anode at permanent CP anode ground bed or the total current output of anode bed at temporary CP anode ground bed shall also be measured to ensure that it does not exceed the output current capacity of the anodes.2.2. Anode installation shall become individually operational as above.2. At the locations of cased crossings where anode installations are provided for the protection of the casing pipe. these anode installations shall be commissioned as per the procedure detailed in clause 9.2.1 Commissioning Natural potential of pipe to soil for the complete pipeline and casing pipeline at the locations of cased crossings shall be measured at all the test station locations. In case the anode output current exceeds the rated capacity.2. The anode shall be connected to pipeline in the test station and the pipe to soil potential observation shall be made after allowing sufficient time for polarisation. recorded prior to connecting anodes to pipe line and casing pipeline respectively. 9.2 9. it shall be controlled by insertion of resistance element in the anode circuit inside test station and the pipe to soil potential shall be rechecked for adequacy of protection. At locations of polarisation coupons the coupon ‘OFF’ potential shall be measured by switching off the reed switch.2 9.vi) EIR Probe Location/Identification number Checking of wiring as per schematics Resistance reading of probe Installed on top/bottom/side of the pipeline vi) vii) Reference Cell Location Type of cell Potential reading Installed on top/bottom level of pipeline 9. suitable resistance shall be inserted in the anode circuit to limit the potential.3 9.4 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 19 of 21 © GAIL – All rights reserved . In case pipe to soil potential exceeds the specified value. After connecting all the anode ground beds to pipe line. Additional anodes shall be provided where required to achieve desired level of protection and to keep the anode out put current with in the rated value. measurement of pipe to soil potentials shall be taken at each test station to ensure conformity to protection criteria. above. recorders shall preferably be used.2. Where transmission lines cross the pipeline or run in parallel within or more than 25m from the pipeline.6 10.5 In case of insufficient protection as per the CP design criteria. Resistance readings of the probe shall be taken at all the locations of electrical resistance probes.7. provision of electrical shield etc.9. investigations shall be made continuously over a period of time and if required simultaneously at different locations to find out the stray current source(s). Bonding with foreign pipeline/structure. interference due to high voltage DC line.0 10. Measurements including pipe/structure to soil potential and pipeline/structure current etc. Where foreign pipelines (unprotected or protected by independent CP system) run in parallel to the pipeline in same trench or very near to the pipeline.3 10. diodes. For measurements over longer durations. In case of fluctuating stray current.5 10. mutual interference between the pipeline and foreign pipelines/structures. AC voltage measurements shall also be made on the pipeline to find out continuous induction of voltage. depending on the type of interference. electric traction etc. HVDC groundings. as a mitigation measure shall be provided where the owner of the foreign pipeline/structure has no objection. the pipeline shall be grounded in line with clause no. INTERFERENCE MITIGATION Investigations shall be made for stray current electrolysis of the pipeline. interference on foreign pipelines/structures due to the CP of the pipeline and ground bed. and are not bonded to the pipeline then investigation shall be made for current discharge points on both the pipelines.2 10. These shall include installation of bond with variable resistor. Where bonding is SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 20 of 21 9. otherwise alternative mitigation measure shall be provided. installation of galvanic anodes for auxiliary drainage of current. In case of induced voltage being beyond safe limits. on any portion of the pipeline! casing pipeline (at cased crossings where casing is cathodically protected) Contractor shall carry out necessary additions/modifications to the provided protection in consultation with the Owner/Owner’s representative. Mitigation measures shall be provided depending on type of stray current electrolysis! interference. on the pipeline/structure being CP protected and on foreign pipelines/structures shall be made to investigate the current discharge and pickup locations. AC induction on pipeline due to 11 KV and above overhead HV/EHV line.6 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .4 10.5 above.2. adjustment/relocation (if possible) of offending interference source.1 10. the bonding resistor shall be adjusted for optimum value for minimum/no interference. the C . Contractor shall provide required mitigation measures and rectify the under/over-protected zones. Where specified in the project specification/data sheet. During this period if any deficiency! interference in protection system is noticed. identify if any. Galvanic anodes installed as a mitigation measure shall be sized for the design life specified for permanent CP. 12.0 SYSTEM MONITORING Where the CP system provided is temporary.0 CLOSE INTERVAL POTENTIAL LOGGING SURVEY Where specified in project specification/data sheet. after the backfilling has been consolidated sufficiently and CP system has stabilized. The monitoring report shall be submitted regularly to owner for his review/information. contractor shall carry out a close interval potential survey over the entire length of pipeline by computerised potential logging method and identify the under protected/over protected area. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR SACRIFICIAL ANODE CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-011 REV-0 Page 21 of 21 © GAIL – All rights reserved .provided for mitigation. which ever is less.P. additional tests for detailed identification of coating defects shall be conducted by the contractor. system shall be monitored at all test stations once in a month for healthiness/adequacy of protection till commissioning of permanent CP or for design life of temporary CP specified. 11. any major coating damage on the pipeline. the major pipeline coating defects required to be repaired. the same shall be rectified/augmented by providing additional anodes as required. During the survey the reference cell shall be calibrated minimum once in 24 hours. SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 Page 1 of 26 © GAIL – All rights reserved . Abbreviations: AC BS BIS CP CMRI CPPSM CPTR CTE DC EHV FBE HDD HV HVDC IS MOV Micro A/mm2 NACE PE PVC ROW SV Alternating current British Standards Bureau of Indian Standards Cathodic Protection Central Mining Research Institute Cathodic Protection Power Supply Module Cathodic Protection Transformer Rectifier Coal tar enamel Direct Current Extra High Voltage Fusion bonding epoxy Horizontal Directional Drilling High Voltage High Voltage Direct Current Indian Standards Motor operated valve Micro-ampere per square millimeter National Association of Corrosion Engineers Polyethylene Polyvinyl Chloride Right of way Sectionalizing Valve GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 Page 2 of 26 © GAIL – All rights reserved . 0 5.0 SCOPE CODES AND STANDARDS SYSTEM IMPLEMENTATION CORROSION SURVEY CATHODIC PROTECTION DESIGN PARAMETERS CATHODIC PROTECTION DESIGN CRITERIA SYSTEM DETAILS INSTALLATION FIELD TESTING AND COMMISSIONING INTERFERENCE MITIGATION CLOSE INTERVAL POTENTIAL SURVEY GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 Page 3 of 26 © GAIL – All rights reserved .0 4.0 2.0 3.0 9.0 11.0 6.0 7.CONTENTS 1.0 8.0 10. NACE Publication 1 OA 190: Measurement technique related to criteria for CP of Underground or Submerged Steel Piping System (as defined in NACE Standard RPO 169-83). and/or approval of any documents submitted by contractor shall in no case relieve the contractor of his contractual obligations. The equipment shall also confirm to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country. installation.1 2. investigations for interaction/interference problems and mitigation of the same.0 2.3 2.1. NACE Standard RP-0286 : Standard Recommended Practice The Electrical isolation of Cathodically Protected Pipelines.4 GAIL (INDIA) LTD NEW DELHI Page 4 of 26 © GAIL – All rights reserved . testing and commissioning of an Impressed Current Cathodic Protection System for cross. This specification provides the basic parameters to develop a suitable impressed current cathodic protection system for the pipelines/structures requiring protection. performance and materials to be supplied shall conform to the requirements of the latest revision of following standards as a minimum: NACE Standard RP-0 169 : Standard Recommended Practice Control of External Corrosion on Underground or Submerged Metallic Piping Systems. IS:1554 Part I : PVC insulated (heavy duty) cables. close interval potential logging survey. NACE Standard RP-0177 : Standard Recommended Practice Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems. In case of any contradiction between various referred standards! specifications! data sheet and statutory regulations the following order of priority shall govern: SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 1.country onshore underground pipelines/structures including supplementing of corrosion survey.2 1. All data required in this context shall be taken into consideration to develop an acceptable design and for proper engineering of the system.0 1. NACE Publication No.54276: Cathodic Protection Monitoring for Buried Pipelines. In case of imported equipments standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards.1 SCOPE This specification defines the requirements of system design. APPLICABLE CODES AND STANDARDS The system design.3 2. Compliance with these specifications. engineering. BS 7361 Part I : Code of Practice for Cathodic Protection for land and Marine applications.2 2. VDE 0150 : Protection against Corrosion due to Stray Current from DC Installations. 1. Close interval potential logging survey procedure. Where specified in the data sheet. Conceptual system design.1 Soil Resistivity Survey At Impressed Current Anode Ground Bed Plot Each selected anode bed plot shall be sub-divided into sub-plots. Survey instruments shall have maximum AC and DC ground current rejection feature.4 below required for completeness of the job. Procedures for interference testing and mitigation. i) ii) iii) iv) v) vi) vii) viii) 4.2 4. Field testing and commissioning procedures. and earth currents in the vicinity of EHV/HV lines and installations using earth return in their power system etc.1 4.2. Contractor shall carry out soil resistivity survey at anode ground bed locations for design of ground bed. Detailed engineering package. Care shall be taken to ensure that the resistivity observations are not influenced by the presence of foreign pipelines/structures. Contractor shall carry out corrosion survey along the ROW of the pipeline conforming to the specifications included in the tender document.2 To carry out soil resistivity measurement Wenner’ s 4-pin method or an equivalent method approved by Owner shall be used. Data sheets. However.0 4. In addition. Sizes of subplots shall depend upon the expected depth for soil resistivity investigations. CORROSION SURVEY General The details of corrosion survey including soil resistivity data along ROW and other data required for C. This specification. Job specification.1. P design if available with the Owner shall be included as part of project specification/data sheet. Basic engineering package. Major activities requiring review shall include but not be limited to the following: Corrosion survey data interpretation report and plot plans for land acquisition. contractor shall have to generate/collect additional data as per clause 4. 3. SYSTEM IMPLEMENTATION All work to be performed and supplies to be effected as a part of contract shall require specific review by Owner or his authorised representative. Codes and standards. Each of these sub-plots shall be investigated for resistivity data individually. As built documentation. verification of its veracity and adequacy shall be the entire responsibility of the contractor.1 4. 4.0 Statutory regulations. Sufficient SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 GAIL (INDIA) LTD NEW DELHI Page 5 of 26 © GAIL – All rights reserved . in the vicinity of the entire pipeline route. Present output current and voltage readings of the CP power supply units. along with all associated cabling up to pipeline and any other related equipment and accessories for CP station shall be demarcated on the ground. pressure. fabrication yards with electric welding etc. rating of anode beds. One or more ground bed plots may be required to be selected and surveyed at each CP station to form a suitable ground bed. type. as applicable. CP station. demarcation and size of sub-plots and number of sets of resistivity observations required for each sub-plot shall be individually decided for each ground bed plot location. Possibility of integration/isolation of CP systems. Ground plots so demarcated shall be surveyed for all other topographical and cadastral features and topo-sheets shall be developed by the CONTRACTOR. Remedial measures existing on foreign pipelines/services to prevent interaction. soil cover. and coating scheme used. etc. 4. 4.observations shall be taken at each of these sub-plots as required and desired by Owner/Owner s representative to obtain sufficient information about sub-soil stratification and. to establish the depth of water table. which shall be suitable for use in land acquisition etc. which may involve negotiations with owners of other services. Graphical representation of existing structure! pipe-to-soil potential records.4 i) ii) iii) iv) v) vi) vii) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 Page 6 of 26 © GAIL – All rights reserved . Existing and proposed DC/AC power sources and systems using earth return path such as HVDC substations! earthing stations. Topographic Surveys Cathodic protection stations consisting of anode ground bed. Additional Data to be Collected The following data shall be collected to generate design data for evaluation of interaction/ interference possibilities due to presence of other services in ROW or in its vicinity. wall thickness.3 4. Details of the existing cathodic protection systems protecting the services i.2. year of laying/commissioning in case of foreign pipelines. location. wherever °possible. if any.2.3 4.2 Number. Route and types of foreign service/pipeline in and around or crossing the right of way (including those existing and those which are likely to come up during contract execution). OWNER shall provide assistance for liaison work to the extent possible. location.e. The number of subplots at each ground bed plot shall be decided at site in consultation with Owner/Owner’s representative. Diameter. test station locations and their connection schemes. type of cathodic protection system provided. type of protection. Unless otherwise stated in the data sheets.Pipeline Surrounding Temporary CP Permanent (μA/m2) CP (μA/m2) Soil resistivity more than 100 ohm. probable interference prone areas. sheathing details of underground power cables along ROW or in its vicinity. etc. selected locations for anode ground beds. m 40 200 Soil resistivity 10ohm to 100 ohm. m 75 300 Soil resistivity 10ohm to 100 ohm. CATHODIC PROTECTION DESIGN PARAMETERS A distinctly independent impressed current cathodic protection system shall be provided to protect the external surfaces of the complete pipeline/structure installation as specified. Any other relevant information that may be needed in designing and implementing proper cathodic protection scheme for the proposed pipeline. Contractor shall conduct necessary potential gradient surveys for any existing anode ground beds that may interfere with the CP system of the pipelines covered under this project. Report On completion of all field work. AC/DC type etc.. operating voltage. phases.) as well as abandoned tracks near ROW having electrical continuity with the tracks in use.0 5. a report incorporating all the results generated from surveys and details of additional data collected shall be prepared. Voltage rating. AC/DC type etc. Soil resistivity values shall be plotted on semi-log graph sheets.1 i) Protection Current Density Range Pipe lines having coal tar enamel (CTE) coating with two/three layers of reinforcement. Minimum Protection Current Density . Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power lines along with details of voltage. to form a design basis for the scheme of cathodic protection. the following parameters shall be used for design of permanent cathodic protection system 4. The report shall also contain detailed interpretation of survey results and resistivity data. m 500 2000 Sea water 1000 5000 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 Page 7 of 26 © GAIL – All rights reserved .5 5. This report shall also include various drawings prepared in connection with the above work.viii) ix) x) xi) Crossing and parallel running of electrified and non-electrified traction (along with information regarding. 25 90 m Soil resistivity 10ohm to 100 ohm.m (max. 5.3 0. (For high silicon cast iron anode) SPECIFICATION S-07-02-012 REV-0 5.1 iv) below. proximity of foreign pipe lines/structures and other interference areas affecting the installation.6 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES Page 8 of 26 © GAIL – All rights reserved .) for shallow anode ground bed and 10 Amp.6 for end connected anode 15 Amp. the protection Current Density shall be increased suitably in consultation with the GAIL.ii) Pipe lines having fusion bonded epoxy coating Minimum Protection Current Density Pipeline Surrounding Temporary CP Permanent (μA/m2) CP (μA/m2) Soil resistivity more than 100 ohm. m Soil resistivity less than 10ohm Minimum Protection Current Density Temporary CP Permanent (μA/m2) CP (μA/m2) 10 35 15 50 35 125 iii) The above current density values for temporary CP system are applicable for CP system design life up to two years./Amp.m (max. Where considered necessary for satisfactory protection of pipeline the current density shall be suitably increased by contractor.) for deep well anode ground bed 0. At HDD (horizontal directional drilling) crossing./sq. Safety factor for current density : Anode utilisation factor (For high silicon cast iron anode) Anode surface current density(For high silicon cast iron anode for continuous operation) Anode consumption rate 1. the pipe protection current density applicable for marshy area shall be considered. m 35 125 Soil resistivity less than 10ohm 125 500 Pipe lines having polyethylene(PE) coating Pipeline Surrounding Soil resistivity more than 100 ohm.1 above shall be applicable where the temperature of the fluid transported by the pipeline! the surface temperature of the buried portion of the pipeline does not exceed 300 C. Where this temperature exceeds 30° C.5 5. Actual current density to be adopted shall be decided based upon soil and other environmental conditions. current drainage survey data.2 The pipe protection Current Density indicated in the clause 5. m Soil resistivity 10ohm to 100 ohm.yr./sq.85 for centre connected anode and 0.2 kg.3 5.4 5. Also refer to clause 7. A positive potential swing of 100 milli volts or more shall be considered sufficient to indicate the presence of an interaction/interference situation requiring investigation and incorporation of mitigation measures by the CONTRACTOR.0 i) ii) iii) 7. a minimum polarisation shift of (-) 100 milli volts may be accepted as an adequate level of cathodic protection for the pipeline with the approval of Owner.9 Pipeline natural potential (-) 0.10 For mixed metal oxide coated titanium anodes the anode utilisation factor. considering the total anode ground bed loop resistance as the sum of the resistance specified in this clause and pipe to earth resistance). unless specified otherwise Anode ground bed loop resistance 1 ohm (max. 1 8V (OFF) with respect to a copper/copper sulphate reference electrode.9V (OFF) and (-) 1.8 5. In rare circumstances. shall be as per the guaranteed values published by the manufacturer and supported by test certificates/field proven ness. SYSTEM DETAILS The system shall include the following major equipment/sub-systems unless otherwise specified in project specifications: o o o o o o o o o o CP stations . anode surface current density and anode consumption rate etc.CPTR units/cathodic protection power supply modules (CPPSM).0 GAIL (INDIA) LTD NEW DELHI Page 9 of 26 © GAIL – All rights reserved .5. Anode ground beds and anodes Anode junction box Cathode junction box Test stations Permanent reference cells Electrical resistance probes Polarisation cell and surge diverter Polarisation coupons SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 6. including anode to ground resistance.7 5. 5. anode and cathode cable resistances (The output voltage rating of the CPTR unit / CPPSM shall in minimum be adequate to drive the specified end of life cathodic protection current with safety factor.45 V Design life of CP system 30 years.). CATHODIC PROTECTION DESIGN CRITERIA Cathodic protection system shall be designed to meet the following criteria The pipe to soil potential measurements shall be between (-) 0. Equipment requiring specialised maintenance or operation shall be avoided as far as possible.Equipment offered shall be field proven. Prototype equipment shall not be accepted. anode lead junction boxes etc. 7.. the availability of nearby low resistivity areas for location of associated ground beds must be ensured while selecting the locations of CP stations. In addition. As far as possible. All Imported equipment for hazardous area may be tested and certified by an independent certifying agency of country of equipment origin and shall be approved by the concerned statutory authority in India. temperature class T3 (200°C). The same shall be verified for SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 I) II) III) IV) GAIL (INDIA) LTD NEW DELHI Page 10 of 26 © GAIL – All rights reserved . CPPSM. test stations. All equipment/materials shall conform to the relevant specifications included in the tender document. As far as possible. The proposed locations of CP stations and anode ground bed current ratings are detailed in project specifications/data sheets. Indigenous equipment shall be certified by CMRI or any other recognised testing body and shall be approved by the concerned statutory authority. All equipment including CPTR unit. locations of intermediate CP stations shall coincide with the locations of SV stations.1 Cathodic Protection Stations The number and exact locations of CP stations shall be worked out based on the corrosion survey data collected. shall be located in safe non-hazardous areas.o o o o Computerized Test Stations CP system at cased crossing Bond Stations Cables All equipment shall be new and procured from approved reputed manufacturers . Where it is essential to install the equipment in hazardous area. All flameproof equipment shall carry the BIS license marking as per the requirement of statutory authorities. such equipment shall be flameproof type and shall meet the requirement of IS: 2148 or equivalent international standard and shall be suitable for gas group IIB. the following guidelines shall be followed for selecting the locations: Number of CP stations and their selected locations shall ensure that these remain valid and are adequate for the full design life of the system after considering all foreseeable factors. testing and commissioning of cathodic protection power supply module (CPPSM) /indoor type Cathodic Protection Transformer Rectifier Unit (CPTR unit)! outdoor type CPTR unit installed in kiosk along with kiosk shall be included in contractor’s scope The CP TR units shall be provided at CP stations where reliable AC power supply is available.2 CP Transformer Rectifier Unit/CPPSM If specified in project specifications/data sheet. The minimum end of life pipe protection current requirement shall be considered as the current requirement indicated in the clause 5. Anode canisters shall be filled with petroleum coke breeze. as far as possible. The anodes installed in the ground shall be located in perennially moist strata. Ground bed shall be located electrically remote from the pipeline and foreign pipeline! other buried metallic structures. wherever possible. switchyards. building foundations. The CPTR unit/CPPSM shall be installed in non-hazardous (safe) area as specified in data sheets. The location of ground bed shall be checked and ensured for remoteness from the pipeline and other buried foreign pipelines/structures. ratings of CP stations for permanent CP system indicated in the data sheet. CPPSM shall be provided at other CP stations where reliable DC power supply instead of reliable AC power supply is available. SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 7. Anode Ground Beds Each CP station shall have an independent anode ground bed. coal tar enamel with reinforcement coated pipeline.adequacy by the contractor.0 above and adequacy of number. Unless otherwise agreed. Nearest part of the anode bed shall at least be 100 meters away from the pipeline and foreign pipeline! other buried metallic structures. Sheet steel anode canisters of adequate size shall be provided for each anode. which may be of shallow or deep well construction depending upon the data collected by the contractor. In case of deep well ground beds non-canistered anodes with petroleum coke breeze in the well surrounding the anodes shall be provided. anodes shall be of high silicon cast iron type or mixed metal oxide coated titanium anodes. the supply.0 above or 3 times the current density value measured by the current drainage survey for polyethylene coated pipeline and 4 times the current density value measured by the current drainage survey for fusion bonded epoxy. Deep well ground beds may also be used in the congested locations where availability of suitable land for spread out ground beds is restricted. electrical earthing systems. 7.3 i) ii) iii) iv) GAIL (INDIA) LTD NEW DELHI Page 11 of 26 © GAIL – All rights reserved . whichever is maximum. The requisite current drainage tests/survey shall be conducted by the contractor to establish the adequacy of CP current requirement indicated in clause 5. Horizontal ground beds shall be at right angles to the pipeline. installation. etc. anode positioning. The negative of the CP power source shall be connected to the incoming circuit of the cathode junction box. active. anode wiring. deep well gas venting. Anodes shall be supplied complete with tail cables. The depth of anodes (depth of top of anode in case of vertically laid anodes) shall not be less than 2 meter from grade level Layout of anode installation in anode bed shall be detailed out in drawings showing anode installation details. SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 vi) vii) viii) ix) 7. which shall be long enough for termination on their associated anode lead junction boxes without intermediate joints. anode grouping.5 GAIL (INDIA) LTD NEW DELHI Page 12 of 26 © GAIL – All rights reserved . deep well casing. The deep well anode ground bed details shall include the details of anodes. In case of two parallel pipelines running in the same ROW. passive portions of the ground bed. Exact lengths and termination details shall be indicated in construction drawings. which shall be further connected to the main anode junction box (where applicable). All cable tails from individual anodes shall be terminated onto the respective anode junction boxes.4 7. one or more anode junction boxes shall be provided at each ground bed. Cathode Junction Box Where output of the CP power supply unit is connected to multiple pipelines a cathode junction box shall be provided near the pipelines at the location of connection of the negative drainage cable to the pipelines. the anode ground beds of the respective pipelines shall be located on the respective sides of the pipelines. anode cable routing. Each out going circuits shall have provision for measurement and control of current. anode cable supporting. Anode Junction Box Depending on the size and configuration of anode ground beds. The main anode junction box shall be connected to the cable coming from CP power source. Potential gradient around the anode bed shall be within safety requirements with regard to interference on foreign structures and its effective boundary shall be defined. etc. Each outgoing circuit in main junction box (where applicable) and each anode circuit in junction shall have provision for measurement and control of individual circuit/anode current. The junction box shall have separate out gong circuit one for each pipeline to collect the negative drainage currents from each of the parallel pipelines.v) Each shallow anode-bed shall contain anodes with canisters positioned horizontally or vertically in the soil with suitable backfill. etc. The incoming circuit shall have a current measurement facility. 1 i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) Test Stations Test stations shall be provided along the pipeline ROW for monitoring the performance of the cathodic protection system at the following locations. At locations of sectionalizing valve (SV) stations.7. At EHV/HV AC/DC overhead line crossings and selected locations where EHV/HV overhead line is in the vicinity of the pipeline. At crossings of other pipelines/structures. if required. pipeline grounding through polarisation cells. At both sides of major river crossings. so that distance between any two adjacent test stations does not exceed 1000 meters in inhabited areas and 2000 meters in uninhabited areas like forest/deserts: At all insulating joints. At vulnerable locations with drastic changes in soil resistivity.6 7. Locations where interference is expected. zinc and magnesium anodes.6. At both sides of metalled road crossings. At locations of surge diverters. At the locations of reference cell. At any other locations considered necessary by Owner/Owner’s representative SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 GAIL (INDIA) LTD NEW DELHI Page 13 of 26 © GAIL – All rights reserved . In the vicinity of DC networks or grounding systems and HVDC grounding systems where interference problems are suspected. At EHVIHV cable crossings or along routes where EHV/HV cables are running in parallel. electrical resistance probe and polarization coupon installation. At both sides of cased crossings. At railway line crossings and at selected locations along lines running parallel to the pipeline. Test stations shall be provided at additional locations. At the location of computerised test stations. The nameplate of test stations shall carry the following minimum information: o Chainage in km.3 7.7.4 7.7.7. end point CP stations).5 Number of terminals and different schemes of wiring shall be as per the test station connection scheme. along the pipeline. 7. on both sides of major river crossings. Test stations shall be installed with the face of the test station facing the pipeline. where water table is high and chloride concentration is more than 300 ppm. high purity zinc may be considered as an alternative to silver/silver chloride. The life of the reference cells shall be minimum 10 years under the installed conditions.6. Test stations with current measuring facility shall be provided at each CP station drainage point (to measure pipeline current on any one side of pipeline from drainage point at intermediate CP station and towards protected side of the pipeline at starting.6. at interference prone areas. near marshy areas and minimum one for every 10 km max. For marshy area in saline soil.7 7. 7. The location of all the test stations shall be marked with their connection schemes and other relevant information on alignment sheets.7.6.6. Minimum two cables from the pipeline shall be provided at any test station.6. Minimum twenty percent spare terminals shall be provided in each test station. Permanent Reference Cells High purity copper/copper sulphate reference cells with proven high reliability shall be provided for stable pipe to soil potential measurement at CP stations.1 7. A detailed test-station schedule shall be prepared.7 7. polarization coupons and computerized test station locations along ROW. Silver/Silver Chloride reference cells in place of copper/copper sulphate cells shall be provided at marshy area locations.3 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 Page 14 of 26 © GAIL – All rights reserved .2 Test stations for bonding shall be provided with shunt and resistor as a means to monitor and control current flow between the pipeline and foreign pipelines or structures that may exist in common ROW. The test station connection scheme shall clearly indicate the type of the reference electrode (Cu CuSO4/Ag AgC1) at these locations.2 7.6 7.6. o Direction of product flow. o Test station connection scheme o Distance from pipeline in meter. 8.1 7. as per below: o The pipeline shall be grounded through polarization cell with zinc galvanic anodes of minimum 20kg net weight each at location where pipeline crosses EHV/HV transmission lines.9 7. Electrical Resistance Probe Where specified in project specification/data sheet electrical resistance probes (E/R probes) utilising the electrical resistance technique shall be provided along the pipeline at marshy areas and at vulnerable locations to monitor the external corrosion activity on the pipeline. Locations along pipeline where continuous induced over-voltage due to other overhead transmission lines/underground cables of voltage grade below 66kV is expected or observed during commissioning.3 7. The material of the E/R probe element shall be of the same alloy as of the pipeline material.7. the pipeline shall be grounded through polarisation cell to the earth system of the EHV/HV tower causing the voltage induction or to a separate earthing system of zinc anodes through polarisation cell.0 km where EHV/HV transmission lines run parallel within 25m of the pipeline. SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 7.8 7. it is mandatory that the pipeline shall be grounded to discharge any accumulated potential/surge that may appear in case of transmission line faults. computerised test stations. the locations of their installation and the number of portable E/R probe reading instruments shall be as specified in the project specification/data sheet.1 i) ii) iii) iv) GAIL (INDIA) LTD NEW DELHI Page 15 of 26 © GAIL – All rights reserved .9.8. Type of polarization cell shall be as specified in data sheet.2 7. The cable up to CP power source shall be routed through test stations near pipeline. The probes shall be provided preferably at the bottom portion of pipeline.4 The cable from reference cells shall be provided up to CP power source at CP Stations and up to test stations at the locations of polarization coupons.7. Polarisation cell shall be installed inside test station of suitable size. The number of E/R probes.8. o The pipeline shall be grounded at regular intervals of maximum 1. The lead-wires of the probe shall be connected to pipeline through test station and terminated inside test station enabling periodic resistance measurement of the probe using a portable probe measuring instrument. Polarisation Cell and Surge Diverter Polarisation Cell Wherever the pipeline is either crossing or running in parallel with overhead EHV/HV transmission lines of voltage grade 66 kV and above. Polarisation Coupons Where specified in the project specification/data sheet steel coupons of pipeline material shall be provided along the pipeline to monitor the adequacy of the CP system to polarize/protect coating holidays. intermediate SV stations. The surge diverter and polarisation cell system shall be suitable for the design life of permanent CP system. The protection cable hail be connected through a SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 7. bicarbonates.9. The resistance to earth of grounding shall be limited to 5 ohms max. provided during temporary CP system shall be disconnected. Motor operated valves where located on the cathodically protected portion of the pipeline shall be grounded by a zinc anode of 20 kg net. Two cables one for connection to pipeline for protection and other for potential measurement shall be provided for each coupon. cable termination. marshy areas and at other locations such that minimum one coupon is installed maximum every 10 km approximate or the maximum interval specified in the project specification/data sheet. interference prone areas. etc. Coupon shall be installed at CP station drainage points. The anodes shall be pre packed with special backfill adequately so that the performance of the anode is not affected by the carbonates. the thickness of back fill shall not be less than 50mm on all the sides of the anode.2 Surge Diverter Explosion proof spark gap surge diverter shall be provided across each insulating joint to protect it from high voltage surges. The grounding system shall have minimum resistance to earth to restrict the pipeline voltage as per NACE/VDE criteria but shall not exceed 5 ohms. along the pipe line.12 GAIL (INDIA) LTD NEW DELHI Page 16 of 26 © GAIL – All rights reserved . shall be earthed with GI earth electrodes. Coupons shall be installed at bottom 1/3 portion of the pipeline and 250 mm away from the pipe surface. present in the soil. In any case.11 7.3 7. The MOV power supply cable armour shall be insulated (by cutting and taping with insulation tape) at MOV end to avoid armour carrying CP current. The total system including cables. nitrates.4 7. at locations where the pipeline is bonded to foreign pipeline/structures. polarisation cell shall be suitable for the anticipated fault current at the location of installation. predicted cathodic protection mid points along the pipeline. if any. pigging stations. The above ground cathodically unprotected pipeline at terminals. The coupons shall be constructed from the pipeline material and shall have uncoated surface of 100 mm x 100 mm exposed to soil.5 7.9.9.10 7. anodes/surge diverters. surge diverters shall be suitable for installation in classified areas. Magnesium anodes grounding.7. etc.9. Data-retrieval computer of portable type suitable for use in field shall be provided as specified in the project specification/data sheet for programming the field computers and retrieving the data stored by the field computers. A permanent reference electrode shall be installed adjacent to the coupon in a manner so as to measure the representative potential of the coupon. SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 7. additional protection for casing pipes may not be provided.14.14 CP at Cased Crossing At cased crossings where casing is coated. design parameters and design life of permanent CP system.2 7.magnetic reed switch inside the test station to enable measurement of coupon ‘OFF’ potential. The carrier pipe inside the painted or coated casing shall be protected by zinc ribbon anodes weld connected to the outer surface of bottom of carrier pipe extending up to hour hand positions of 4 and 8 O’clock. as required.13 Computerized Test Stations Where specified in the project specification/data sheet computerized test stations shall be provided along the ROW of the pipeline for automatically monitoring and recording the pipe to soil potential. The computers shall have required number of input ports for measurement of potentials and current as applicable at the location of its installation. etc. Computers shall have real time clock and record the time of data measurement. The anodes shall be sized based on the permanent CP design parameters for marshy area and design life of permanent CP system. At cased crossings where casing is uncoated or painted. The anode installation shall be sized based on the permanent C . casing pipeline and foreign pipelines.14. etc. pipe current. of the pipeline. the casing shall be protected by sacrificial anode installations provided at both ends of casing. The computers shall be programmed to collect and store all the field parameters at intervals as specified in the project specification/data sheet.P. Each computer shall an identification number incorporated in its software. The anodes shall be placed at close intervals as per design calculations with minimum one number of anode installed between every two supports provided between carrier and casing. 7. Where casing is uncoated or unpainted additional protection for carrier may not be provided. 7.3 pipe REV-0 GAIL (INDIA) LTD NEW DELHI Page 17 of 26 © GAIL – All rights reserved . The computer with in the test station shall measure and record these parameters regularly at programmed intervals. Magnets for operation of reed switch shall be provided as specified in the project specification/data sheet.1 7.14. which shall be clearly indicated along with the data display/print out. for measurement of pipe to soil potentials. PVC insulated. for anode and cathode cables.16. mm copper conductor.7. PVC over all sheathed type. Cables Cables shall be with annealed high conductivity stranded copper conductor. The anode tail cables shall be PE insulated. coupon and pipeline potential measurements shall be of 4 sq. PVC sheathed. armoured. mm. armoured.16 7.3 7. 10 sq. The cables for connecting various transducers from CPTR unit/CPPSM to telemetry interface junction box shall be twisted pair with individual pair shielded and overall shielded with aluminium backed by mylar/polyster tape. except for the cables for anode tail. polarisation cell. reference cells and pipeline for potential measurements.16. Aluminium backed by mylar/polyster tape shielded. Cable route shall be carefully measured and cables cut to required length. PVC sheathed.1 Cable Laying i) Cables shall be laid in accordance with layout drawings to be prepared by the contractor. PVC sheathed. for anode tail cables and polarization coupon protection cables. where the ground is paved.2 7. The size of cable for bonding.0 INSTALLATION 8. PVC insulated.15 Reference Cell Access Points Reference cell access points shall be provided near insulating joint locations and at SV stations. PVC sheathed and length shall be sufficient for termination on anode lead junction box without any joint in between.5 8.1 7. Copper conductor. The cables for reference cells. mm. armoured. grounding anodes and surge diverter connections shall be suitable for the maximum fault current subject to minimum 25 sq mm. No straight through joint shall be permitted. armoured. PVC over all sheathed type. 7. unarmoured.mm. 650/1100 V grade.16. for current measurement. The cable shall be of 3 core type for single phase CPTR units and of 4 core type for 3 phase CPTR units. mm. The length of the PVC pipe shall be adequate to reach the native soil below the paving. PVC insulated.4 7. 650/1100 V grade. The size of the copper conductor shall be minimum 35 sq. 650V grade. The CPTR unit incomer cable shall be minimum 4 sq. PVC sheathed conforming to IS 1554 part-I.16. A perforated PVC pipe filled with native soil and buried at the location shall be provided for the purpose. 6 sq.16. Minimum half metre cable SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 GAIL (INDIA) LTD NEW DELHI Page 18 of 26 © GAIL – All rights reserved . For cables laid outside the station/plant area. CP station to ground bed (anode cable) and test station to pipeline shall be earthed only at CP station end and test station end respectively of the cables. anode junction box. Distant measurement cables and permanent reference cell cables routed along the pipeline shall be carried at the top of the carrier pipe by securely strapping it at intervals with adhesive tape or equivalent as required. reference cell & drainage cables etc. The cables for reference cells and pipeline potential measurement shall be routed in a separate trench other than the trench provided for the rest of the CP system cables. Cables shall be laid in sand under brick cover and back filled with normal soil. Cables outside station/plant area shall be laid at a depth of minimum 1.2 8. The resistance of the cable to pipe at the pin brazing connection point shall not exceed 0. polyethylene warning mats shall be placed at a depth of 0. AC cables for CPTR Units etc. Exothermic welding shall be adopted for water pipelines. Cable to Pipe Connections All cable connections of other than cathode drainage cables to the new pipeline shall be made by an approved exothermic process or by pin brazing. The cable armour shall be insulated (by taping with insulation tape) to avoid armour carrying CP current.9 metre from the finished grade.5 metres.75 metre.). GAIL (INDIA) LTD NEW DELHI iii) iv) v) vi) vii) viii) 8. Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and final take-off to equipment is facilitated.slack shall be provided near anodes. ii) All cables inside station/plant area shall be laid at a depth of 0.3 SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 Page 19 of 26 © GAIL – All rights reserved .1 ohm. up to accessible height for protecting against the mechanical damage. In case of above ground cables. All underground unarmoured cables including anode tail cables shall run through PE sleeves. cable connection to charged pipelines shall be made by pin brazing. Installations in highly acidic/alkaline soil and soil contaminated by hydrocarbons shall be avoided. pipeline and test stations to account for any settling. Permanent Reference Cells The permanent reference cells shall be installed in natural soil conditions as per the recommendations of the cell manufacturer. PVC pipes of proper size shall be provided for all underground cables for road crossings. to mark the route. all unarmoured CP cables shall be laid in GI conduits of sufficiently large size. However. The armour of the cables from CP station to test station (potential measurement. 1 i) ii) iii) iv) GAIL (INDIA) LTD NEW DELHI Page 20 of 26 © GAIL – All rights reserved .0 9. setting of all equipment. specifications. 8. if necessary. control and protective devices. Generally. FIELD TESTING AND COMMISSIONING System testing at site Field tests as per the reviewed field testing and commissioning procedures prepared by the Contractor. the following minimum tests must be carried out and results shall be recorded: Visual Inspection : Comparison with drawings. Owner/Owners representative may witness all tests. All tools. Field testing shall include but not be limited to the following: Contractor shall carry out pre-commissioning operations after completion of installation of the system including all pre-commissioning checks. The material of the plate shall be same as that of the material of the pipeline. equipment and instruments required for testing shall be provided by Contractor. reliability and performance tests shall be carried out by Contractor. Before the electrical facilities are put into operation. shall be carried out on the equipment/systems before these are put into service. At cathode drainage point the cable joint including the bolt. SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 9. connected and are in good working condition as required for the intended operation. a) Cables Cable No. At least one week’s intimation notice shall be given before commencing the tests. Testing : Simulation tests of equipment to determine its operational fitness. by taking apart the component parts. detailed physical inspection and. Acceptance of the complete installation shall be contingent upon inspection and test results.4 Ground Bed Fencing Where specified in project specifications/data sheet chain link fencing shall be provided around the location of each ground bed/anode lead junction box. All site tests. Pipe coating shall be repaired after connection of cable to pipeline. metal plate and the exposed portion of the pipeline shall be covered by the coating repair material against ingress of water/moisture.The cathode drainage cable shall be connected to a bolt welded to a metal plate. which is weld connected to the pipeline. necessary tests shall be carried out to establish that all equipment and devices have been correctly installed. The coating repair material shall be compatible with the original coating and shall prevent ingress of water along the cable surface and at the interface of coating repair with the original pipe coating. g) Anode Ground Bed Location/Station Check for actual layout and compliance with drawings. E/R Probe Location/Identification number Checking of wiring as per schematics Resistance reading of probe Installed on top/bottom/side of the pipeline Reference Cell Location Type of cell Potential reading Installed on top/bottom level of pipeline Insulating joint Location Pipe to soil potential of both protected and non-protected sides of the insulating joint before and after energisation of CP system. Insulation resistance values between each core & earth.b) c) d) e) f) Voltage grade. All cables shall be tested by 500 V megger. Current dissipation by each individual anode. Details of grounding provided for the polarisation cell. Resistance of each individual anode. between cores (between core and earth for single core cable). (Current drain with respect to voltage across the cell shall be recorded). Rating Type Check for healthiness. Total resistance of complete anode bed. Conductor cross section Continuity check Voltage test. h) Computerised test station Location/Identification number Checking of wiring as per schematics Checking programmed interval for collection of the field data by the computer GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 Page 21 of 26 © GAIL – All rights reserved . Surge diverter Location/identification number. Polarisation Cell Location/Identification number Rating Check for wiring Check standby current drain after CP system energisation. Mutual interference. 2 CP Commissioning Procedure A model commissioning procedure for a three stations CP system of a pipeline is given below for general guidance. at the test station nearest to the drainage point. ammeters.Type of reference cell i) Polarisation Coupons Location Exposed area/size of coupon Coupon to soil ‘ON’ and ‘OFF’ potentials Type of reference cell Magnetic reed switch rating.1 shall be energised with out put potential adjusted to achieve a maximum pipe to soil potential (PSP) as specified. The typical switching cycle of current interrupter shall be 12 seconds ‘ON’ and 3 seconds ‘OFF’ . Electrical continuity of the entire pipeline shall be verified in conformity with design. All current measuring test stations shall be calibrated and recorded using portable battery. CP station no. variable resistances. as required. Input resistance of the pipeline at all the drainage points shall be checked and recorded. Sacrificial anode where provided for the protection of the casing pipe at cased crossings shall be disconnected. Observations on either spread of protected portion of pipeline and coupons under this CP station shall be taken for PSP ‘ON’ and PSP ‘OFF’ values at each of the installed test stations (coupon to soil potential at the locations of the coupon installations). In completion of installation of anode beds and other systems as envisaged in this specification. tested and compared against the agreed specifications and procedure. Operation of magnetic reed switch with magnet 9. voltmeters. etc.The pipeline current values across the cross section of the pipeline shall also be determined at all the intended test stations influenced by this station. casing pipe to soil and coupon to soil potential values at all the test stations of the system (coupon to soil potential at the locations of the coupon installations) shall be measured with respect to Copper/Copper Sulphate half cell. Contractor shall develop detailed commissioning procedure as per this guideline. natural pipeline to soil. The pipeline shall be allowed to depolarize for at least 72 hours after switching ‘OFF’ the protection (if any) of all other pipelines in the common ROW. Before the pipelines are put on charge by switching ‘ON’ any of the CP stations. SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 i) ii) iii) iv) v) vi) vii) viii) ix) GAIL (INDIA) LTD NEW DELHI Page 22 of 26 © GAIL – All rights reserved . Anodes provided for grounding at the MOVs on cathodically protected portion of the pipeline shall be disconnected. Temporary protection facilities provided (if any) which do not form part of permanent CP shall be disconnected from the system & removed unless agreed otherwise. they shall be individually checked. 1 and 3 shall now be switched ‘OFF’. At cased crossings where casing is protected. sacrificial anodes provided for the casing shall be connected to the casing pipe. If there are appreciable differences in these observations as compared to those of earlier set. plotted. 18V (OFF). CP station no. Coupon to soil ‘OFF’ potential shall be measured at all locations of coupon installations by operation of magnetic reed switch in the test station.95V (OFF) and sites of occurrence of the most negative protective potential are not more negative than (-) 1. PSP values at each of the test stations of the existing pipelines shall be measured. xiii) Care shall be exercised to ensure that power supply remains uninterrupted during the period of commissioning. Where casing pipe protection is inadequate or the out put current of the anode is more than the designed current. a third set of observations shall be taken after 72 hours. The PSP of the coupons shall be within the PSP range specified in clause 6 of this document. the test in progress shall be repeated after allowing time for polarisation. coupon to soil observations shall again be taken 72 hours after the adjustment of potentials and the protection system shall be left in this state of operation. if advised by the Owner/Owner’s representative. A full set of pipe to soil.2 shall be switched ‘ON’ and measurement procedure as detailed in clause ix) above shall be repeated. mutual SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 xiv) xv) xvi) GAIL (INDIA) LTD NEW DELHI Page 23 of 26 © GAIL – All rights reserved . The zinc anodes for grounding of MOVs at the locations of MOVs on cathodically protected portion of the pipeline shall be reconnected to the MOVs. More sets of observations shall be taken in any of the steps specified above. Another complete set of pipe to soil and coupon to soil observations shall be taken after lines have stayed on charge for 48 hours. The casing to soil potential and anode out put current shall be measured and recorded. CP station no. In case of an interruption. 3 shall be switched ‘ON’ and measurement procedure as detailed in clause ix) above shall be repeated. in any case. The output of all CP stations shall then be so adjusted that the sites of occurrence of least negative protective potentials are not less negative than (-) O. All the three CP stations in the system shall then be simultaneously switched ‘ON’ and PSP values at the drainage points of pipeline shall be brought to a value of maximum PSP as specified and a complete set of observations shall be taken. where existing pipelines run in parallel to the new pipeline.x) xi) xii) CP station no. Similarly CP station no.1 shall now be switched ‘OFF’. All the CP stations of the system shall be switched ‘OFF’ and the pipelines shall be allowed to depolarize. Maximum drainage point protective potentials shall not be allowed to go beyond the maximum PSP values as specified. then additional anodes shall be provided as required. Such deficiencies shall include mitigation of stray current electrolysis and interference problems that may be found existing in the course of testing and commissioning. Interference situations shall also be identified and mitigated by comparing different sets of readings taken at same test stations at -different intervals of time under identical conditions where positive potential swing is 100 mV or more.1 8V (OFF) respectively even after 72 hours of operation. etc as programmed. at no extra cost or time schedule impact. At the locations of the Electrical resistance probe installations the resistance readings of the probes shall be measured using probe reader. If any deficiencies are found in the system. xxiv) The reference cell shall be calibrated minimum once in 24 hours during the commissioning. 6 of this document. then the drainage point potentials shall be adjusted depending upon anode ground bed currents in consultation with Owner/Owner’s representative. at any location on the pipeline. the same shall be rectified by the contractor. 95V (OFF) or more negative than (-) 1. xx) xxi) xxii) xxiii) If it is found during commissioning that the sites of occurrence of least negative or most negative protective potentials are less negative than (-) 0. Final records of testing and commissioning including graphical representation of final pipe to soil potential readings shall be compiled with interpretation in consultation with Owner/Owner’s representative and submitted. xix) After one month of starting the computers to collect the field data. Any deficiency found in the protection of the pipeline shall be rectified by the contractor at his own cost. xvii) Current readings at all the current measuring test stations shall be measured and recorded.interference situations between the pipelines shall be identified and necessary mitigation measures shall be provided. xviii) Where computerized test stations are provided the computer shall be initialized/started to collect and store the field data of potentials. In any case. A set of PSP observations shall also be taken during the peak of the first dry season after commissioning the system into regular operation. the protective ‘OFF’ potential values of pipeline and polarization coupons shall not exceed the PSP value range specified in Cl. to the complete satisfaction of Owner/Owner’s representative. current readings. The data shall be analyzed with the help of a station main computer. the data stored by the computers at all the computerized test stations shall be retrieved/down loaded using the field data-retrieving computer. SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 GAIL (INDIA) LTD NEW DELHI Page 24 of 26 © GAIL – All rights reserved . 9 above.0 10. and ground potential gradient etc. interference on metallic structures which lie in between pipeline and ground bed or near to ground bed. Wherever foreign pipelines which may or may not be protected by an independent CP system run in parallel to the protected pipeline. A. INTERFERENCE MITIGATION Investigations shall be made for stray current electrolysis of the pipeline. Where overhead EHV/HV transmission lines/underground electric cables cross the pipeline or run in parallel with in or more than 25m from the pipeline.1 10. Measurements including pipe/structure to soil potentials and pipe/structure currents etc. the bonding resistor shall be adjusted for optimum value for minimum/no interference. interference on foreign pipelines/structures due to the CP of the pipeline and ground bed.5 10. the pipeline shall be grounded in line with clause no. adjustment/ relocation (if possible) of offending interference source. mutual interference between the pipeline and foreign pipelines/structures.4 10. Voltage measurements shall also be made on the pipeline to find out continuous induction of voltage. investigations shall be made continuously over a period of time and if required simultaneously at different locations to find out the stray current source(s).3 10.7. In case of the induced voltage being beyond the safe limits. Otherwise alternative mitigation measures shall be provided. diodes. depending on the type of interference.xxv) The current dissipated by individual anodes shall be measured from the anode lead junction box and corrected for equal dissipation to the extent possible keeping the total ground bed current same. provision of electrical shield etc.2 10.6 GAIL (INDIA) LTD NEW DELHI Page 25 of 26 © GAIL – All rights reserved . AC induction on pipeline due to overhead EHV/HV lines. C. SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 10. Wherever bonding is provided for mitigation. These shall include installation of bond with variable resistor. on the pipeline/structure being CP protected and on foreign pipelines/structures. interference due to high voltage DC lines. shall be made to investigate the current discharge and pickup locations. Bonding with foreign pipelines/structures as a mitigation measure shall be provided where the owners of the foreign pipelines/structures have no objection. installation of galvanic anodes for auxiliary drainage of current. Galvanic anodes installed as a mitigation measure shall be adequately sized for the life specified for permanent CP system. HVDC earthing system. Mitigation measures shall be provided depending upon the type of stray current electrolysis/interference. In case of fluctuating stray currents. investigations shall be performed for current discharge points on both the pipelines. etc. either in the same trench or very near to the protected pipeline and are not bonded to it. electric traction. Recorders shall preferably be used for long time measurements. if specified in the project specification/ data sheets. Additional tests for detailed identification of coating defects shall be conducted by the contractor. required to be repaired. Contractor shall provide required mitigation measures and rectify the under/over protected zones. after the backfilling has been consolidated sufficiently and CP system has stabilized. identify if any. any major coating damage on the pipeline.11. the major pipeline coating defects. During the survey the reference cell shall be calibrated minimum once in 24 hours. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM FOR PIPELINES SPECIFICATION S-07-02-012 REV-0 Page 26 of 26 © GAIL – All rights reserved . Detailed procedures for running this survey shall be submitted for review. contractor shall carry out a close interval ‘ON’/’OFF’ potential survey over the entire length of pipeline by computerised potential logging method and identify the under protected/over protected area.0 CLOSE INTERVAL POTENTIAL SURVEY Where specified. SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 1 of 17 © GAIL – All rights reserved . Abbreviations: CPTR units: Cathodic protection transformer rectifier units MTBF : Mean time between failure MTTR : Mean time to repair PCB : Printed circuit board MOV : Metal oxide varistor PSP : Pipe to soil potential CVCC : Constant Voltage and Constant Current Mode GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 2 of 17 © GAIL – All rights reserved . 6. SCOPE CODES AND STANDARDS SITE CONDITIONS GENERAL REQUIREMENTS TECHNICAL REQUIREMENTS EQUIPMENT DESCRIPTION INSPECTION.CONTENTS 1. 2. 7. TESTING AND ACCEPTANCE PACKING AND DESPATCH GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 3 of 17 © GAIL – All rights reserved . 3. 5. 8. 4. o This specification. section-i) In case of imported equipment. (Parts-4. In case of any contradiction between various referred standards/specifications/data sheet and statutory regulations the following order of priority shall govern: o Statutory regulations. o IS: 5469 : Code of practice for the use of semiconductor junction devices. humid and dusty atmosphere.3 2.2 2. o IS: 3700 : Essential rating and characteristics of semiconductor devices (Parts-i to 11) o IS: 3715 : Letter symbols for semiconductor devices (Parts-i to 4) o IS: 4411 : Code of designation of semiconductor devices. o Job specification.1 SCOPE This specification covers the requirements for the design. o IS:7204 : Stabilised power supplies DC output. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 4 of 17 2 2. (Parts-i to 4) o IS: 6619 : Safety code for semiconductor rectifier equipment. o IS: 13703 : Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC. performance and materials to be supplied shall conform to the requirements of the latest revision of following standards: o IS: 1248 : Direct acting indicating analogue electrical measuring instruments and (Parts-i. 2. warm. standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards. (Parts-i to 4) o IS: 12021 : Control transformers for switchgear and control gear for voltages not exceeding 1000 V AC (Parts-i to 4). 8 & 9) accessories. CODES AND STANDARDS The system design. o Data sheets. o Codes and standards SITE CONDITIONS The CPTR unit shall be suitable for installation in non air-conditioned room with restricted ventilation or in outdoor kiosk (as specified in data sheet). manufacture and testing of Cathodic Protection Transformer Rectifier units (CPTR units) working on controlled rectification principle intended to supply power to cathodic protection system for underground pipelines! structures.4 3 © GAIL – All rights reserved . (Parts-i to 4) o IS: 13947 : Low voltage switchgear and control gear. The equipment shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country. in locations having generally corrosive.1 2. suitable stiffeners shall be provided. preferably.3 5 5.1. Hinged doors shall be provided at the front and back as required. If not specifically mentioned therein. All wirings shall be ferruled with PVC ferrules at both ends for ease of identification.3 GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT © GAIL – All rights reserved . 660 V grade PVC insulated BIS approved wires with stranded copper conductor of size minimum 2. a design ambient temperature of 40°C and an altitude not exceeding 1000 m above mean sea level shall be considered 4 4. Suitable power terminals shall be provided for SPECIFICATION S-07-02-013 REV-0 Page 5 of 17 4.2 5. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least 15 years from the date of supply. These hooks when removed shall not leave any hole in the panel or imperfection in the paint finish. The unit shall be natural cooled type. The CPTR unit panel shall.5 mm diameter.6 mm thick sheet steel. Clamp type terminals suitable for termination up to 10 mm2 conductor shall be provided for all control cable connection. Degree of protection for the panel shall be minimum IP-4 1.1. Suitable hooks shall be provided for lifting the panel. The front. Louvered openings with wire mesh for natural ventilation may be provided. Vendor shall give a notice of at least one year to the end user of equipment and GAIL before phasing out the product/spares to enable the end user for placement of order for spares and services.1.2 GENERAL REQUIREMENTS The offered equipment shall be brand new with state of art technology and proven field track record. maintenance and shall be suitable for mounting flushed to the wall.1 5. The Unit shall be freestanding type. Wherever required. Control wiring for electronic circuits shall be through flat ribbon cable or through copper wire of minimum 0. TECHNICAL REQUIREMENTS Fabrication and General Details CPTR unit shall be housed in sheet steel enclosure.1 4. All instruments shall be panel mounted type and back connected.1 5.Service conditions shall be as specified in the data sheet. rear walls and doors shall be made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1. not need rear access for operation. No prototype equipment shall be offered.5 mm2 shall be used for power and auxiliary wiring. All fuses shall be provided inside the panel and shall be of link type. If required the panel shall be provided with space heater to prevent moisture condensation. Minimum 20% spare terminals shall be provided.11 GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 6 of 17 © GAIL – All rights reserved . 5.8 5.9 5. The CPTR unit shall be field proven. PCB tracks shall be tinned and solder masked. Where space heater is not provided the electronic PCBs/components and other control devices shall be made immune to moisture condensation. HRC fuse and link for phase and neutral respectively.1. shall be located at a convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.1. The space heaters shall be located at the bottom of the panel and shall be provided with a manually operated switch.1. pushbuttons. 5.5 All live parts shall be properly shrouded. single compression type for indoor installations and double compression type for outdoor installations.1.1. The space heater shall have porcelain connectors.6 5. Panel shall be provided with integral base frame channel.1.1. moisture and fungal growth. Cable glands shall be of brass. nickel plated.4 5. CPTR unit shall be suitable for bottom cable entry unless otherwise specified in the data sheet and shall be supplied complete with crimping type cable termination lugs and cable glands. internal component layout and rating of component shall ensure high MTBF and low MTTR. The integral base frame of panel shall be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack welding to purchaser’s insert plate/flat/channel embedded in the floor. All the control equipment like switches. Amply dimensioned oblong holes shall be provided at the bottom of the panel for its bolting to the embedded insert plate/channel. Prototype equipment shall not be acceptable. The PCB shall be coated with suitable lacquer to make it immune to dust. The terminal blocks shall be mounted minimum 300 mm above the gland plate.7 5. Where plug in type of PCBs are used gold plated male-female connectors shall be used for the purpose. The design.power cables. The space in the terminal chamber shall be adequate for termination of required number and sizes of cables as specified in the data sheet.1. potentiometers etc. The input power factor of the unit at rated load shall be 0. This shall ensure complete safety to personnel intending routine maintenance by opening the panel doors.10 5.8 lag or better. The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate. Panel finish shall be free from imperfections like pin holes.) shall be provided with suitable nameplates. Nameplates shall be engraved out of 3-ply (black-white. grease and dirt. Hard paper or selfadhesive plastic tape nameplates shall not be acceptable. Colour shade of final paint shall be approved by the purchaser before final painting is started. orange peels. Labels shall be provided for every component on the cards.1. etc. After preparation of the under surface. All non-current carrying metallic parts of the panel and mounted equipment shall be connected to the panel earth bus. Back-engraved Perspex sheet nameplates may also be acceptable. All doors and movable parts shall be connected to the earth bus by flexible copper cables.black) lamicoid sheets or anodised aluminium. Suitable canopy shall be provided on the top of the Kiosk. etc.1. Fabricated structures shall be pickled and then rinsed to remove any trace of acid.g. lamps. Necessary ventilation arrangement with louvers and wire mesh shall be provided for proper operation of the CPTR unit. 5.1.5. rust. switches. connecting wires as well as for the terminals in the terminal strip inside the panel. 5.15 GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 7 of 17 © GAIL – All rights reserved .13 5. The kiosk shall be suitable for outdoor mounting and shall give proper protection to the CPTR unit against rain. Hinged lockable doors shall be provided at the front and back. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer.1. The kiosk shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and external surfaces. pushbuttons.12 An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminium shall be provided throughout the length of the panel. Nameplates shall be fastened by screws and not by adhesive. Provision shall be made for connecting this earth bus at two ends with the plant earth grid by means of (40x5) mm2 GI flat. meters.14 Where specified in the data sheet the CPTR unit shall be housed in an outdoor kiosk. The cable entry to the kiosk shall be from bottom through cable glands. the panel shall be spray painted with two coats of final paint or shall be powder coated. The finished panels shall be dried in stowing ovens in dust free atmosphere. The undersurface shall be made free from all imperfections before undertaking the finishing coat. All panel mounted equipments (e. Engraving shall be done with groove cutters. run off paint. PCBs. other harsh weather conditions. Painting All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale. All unpainted steel parts shall be suitably treated to prevent corrosion.1. The CPTR unit shall be suitable for 415 V AC. the unit may be suitable for 240V AC. The safety factor for transformer rating shall be minimum 125%. o Rectifier and filter o Output protections o System controls o Control.2 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Transformer shall be vacuum impregnated with epoxy varnish and baked. 1 ph power supply and the rectifier shall be full wave type and controlled type. A moulded case circuit breaker with thermal over load and short circuit release shall be provided at the input of the transformer. Single-phase transformers may be provided up to 50V. 3 phase transformers shall be provided. for single phase AC CPTR units. 6. 50A DC or less.Transformer and input controls. indication and metering Transformer and Input Controls The transformer shall be natural cooled dry type with separate primary and secondary windings.1 Rectifier and Filters The rectifier shall be made of thyristors and diodes as basic components. where the miniature circuit breaker rated for the incoming AC supply short circuit current indicated in the data sheet is available. 3-ph power supply. CPTR Units having multiple output circuits shall have separate secondary windings for each output circuit. Rectifier shall be 3 phase full wave type and controlled type.1. If these parts are moving elements. An intermediate earth screen shall be provided between primary and secondary windings.1 6. Miniature circuit breaker with thermal overload and short circuit release in place of moulded case circuit breaker may be provided. The thyristors! triad rectifier elements shall be protected against voltage surges coming from the incoming power supply SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 8 of 17 6. For CPTR units rated 50V. Alternatively. diodes shall be at least two times the actual maximum device current and minimum two times the actual maximum voltage coming across the device respectively. Beyond this rating. 50A DC output rating of the CPTR units.2 6. The current and voltage ratings of thyristors.1 6. diode rectifier of full wave type in the secondary of the transformer and triac or back to back connected thyristors in the transformer primary AC supply circuit may be provided. 6 EQUIPMENT DESCRIPTION The CPTR unit shall be complete with following main sections: o . then they shall be greased.2. 2 The thyristors/triacs shall be protected by semiconductor fuses.2. For CPTR units with multiple output circuits. short circuit current and having thermal over load. The set output voltage (Vos) shall remain constant irrespective of output current.4 6.2. Current limit feature shall be provided. 50A DC or less. then the semiconductor fuses may not be provided. The current limit (los) shall be continuously adjustable from zero to rated output current. System Controls The CPTR unit shall have two distinct modes of operation (independent for each output circuit) as below: Constant Voltage and Constant Current Mode (CVCC) In this mode the output voltage of CPTR unit shall be continuously adjustable from O. 6.3 6. if the thyristors or triacs are adequately over rated and system has enough inductance so that in case of sudden output short circuit the over current limit feature comes into action before short circuit current rises beyond the rating of the thyristors/triacs.5 6. Output Protections Two pole moulded case circuit breaker or miniature circuit breaker (if available) rated for the DC output current. The rectifier elements shall have humidity/moisture resistant finish and mounted in sufficiently sized heat sink designed to provide adequate cooling under worst conditions of operation. Required shunt zeners / MOV shall be provided across the rectifier elements for protection.3 6. SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 9 of 17 6.and from output side from the pipeline.4. For CPTR units with multiple output circuits.5V DC to the rated output voltage specified on the data sheet.2. A lightning arrestor rated for minimum 1OKA impulse current discharge capacity and rated voltage & maximum spark over voltage rating suitable to protect the CPTR unit components against lightning and switching surges shall be provided at the output. For units rated 50V. short circuit release shall be provided in the output.1 A) GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . each output circuit shall have independent rectifier and filter. This feature shall be demonstrated during testing of the unit at works.4 6. The rectifier system shall be of natural air cooled type.2. Adequate filtering shall be provided on the DC output of the rectifier to limit the ripple content in the output to less than 5% at rated output. each output circuit shall be provided with circuit breaker and lightning arrestor. The rectifier elements shall have adequate protection against high dv/dt and di/dt. to avoid hunting between the reference cells at change over conditions. In case of open circuit or short circuit of reference cell or potential being less negative than a minimum set potential (Vrs).9 V). The unit shall be designed to operate with number of reference cells connected to it (to be provided by others) as specified in data sheet. the output voltage or current of the CPTR unit shall adjust automatically to a preset value (Vas/las). The set potential shall be continuously adjustable over the range specified in data sheet. CPTR unit shall have feature to automatically select the reference cell having less negative potential than the others and use the same for auto control of the unit (e. After that the output current limit shall be maintained and output voltage shall decrease to keep the current constant. This protection shall be fast enough to protect the active devices of the unit and fast enough to act before tripping of MCCB/MCB or blowing of fuse. in feed back loop.8 V is less negative than (-) 0. The CPTR unit control shall adjust the output voltage such that the PSP as measured by reference cell always remains equal to the set potential on the unit. B) Auto PSP mode In this mode of operation the output of the CPTR unit shall operate in an external closed loop with pipe to soil potential (PSP). Irrespective of output voltage requirement the control system shall maintain the output current to the set current limit value till the voltage limit is reached. measured by reference cell.g. The set potential (Vps) shall have high long time stability and minimum temperature drift. Irrespective of output current demand the chosen value of the output voltage shall be maintained by the control system till the current limit is reached. Should fault occur in all the reference cells. (-) 0. For constant current mode of operation the output voltage shall be set at maximum and output current shall be varied through varying the setting of output current limit. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 10 of 17 © GAIL – All rights reserved . the unit shall sense these conditions as reference cell failure and shall automatically switch over to the other healthy reference cell for control. In both CVCC and auto PSP modes of operation a fast acting electronic over current limit protection shall be provided. In case of more than one reference cell being specified. Adequate hysterisis shall be provided in selecting the less negative potential reference cell. which shall be adjustable. After that the output voltage limit shall be maintained and output current shall decrease to keep the voltage constant.For constant voltage mode of operation the output current limit shall be set at maximum and output voltage setting shall be varied. each settable from 1 to 99 seconds. each output circuit shall have independent control system. When the timer is turned on the ‘ON’ timing shall start and shall close the output contactor till the end of the ‘ON’ timing. At the end of the ‘ON’ timing the ‘OFF’ timing shall start and keep the contactor open till the end of the ‘OFF’ timing.5. In case of microprocessor based system keypad with display may be provided in place of thumbwheel switches.3 6. The timing error of the timer shall be less than 5 parts per million.3 6. However the CPTR Unit shall allow grounding of positive output terminal through the anode ground bed.4 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .constant current mode of operation. The ‘ON’ and ‘OFF’ timings of the timer shall be settable by separate 2 digit thumbwheel switches. In auto PSP mode the closed loop PSP regulation for no load to full load variation with input voltage variation from maximum to minimum and PSP feedback varying over the specified range shall be within 20 mV. the current regulation for minimum to maximum output voltage and minimum to maximum variation in input voltage shall not be more than 2.5.5.5 6.5 % of rated voltage through out the range of output voltage and over the specified ambient temperature variation as specified in data sheet. The current interrupter shall have an output contactor with current rating minimum 125% of the output current rating of the CPTR unit and a digital timer to operate it. 6.4 The DC output of the CPTR unit shall be floating (ungrounded) in the Unit.5 6.4. At the end of the ‘OFF’ timing the ‘ON’ timing shall start again and close the output contactor. In CVCC.2 The unit shall continuously monitor the PSP and necessary annunciation shall be provided in case of PSP either exceeding the specified maximum limit (Vpm) or remaining lower than the specified minimum limit (Vpn).4. Current Interrupter If specified on the data sheet a current interrupter for CPTR Unit output current interruption shall be provided.6.4. The output voltage regulation for no load to full load variation with input voltage variation from maximum to minimum shall not be more than 2.5.2 6.constant voltage mode of operation. For CPTR units with multiple output circuits. in CVCC. SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 11 of 17 6. The timer shall have ‘ON’ and ‘OFF’ timings.4. This process of ‘ON’ and ‘OFF’ timing shall continue.1 6.5% through out the range of output current. 10 6. The input power supply and the rating of the output contactor shall be as specified on the data sheet.5. The controls shall be housed in a lockable cover. Terminals shall be provided in the CPTR unit for taking power supply to the current interrupter. On pressing this pushbutton during operation of the timer. A link shall be provided for shorting the output terminals provided in CPTR unit whenever the current interrupter is not connected. each output circuit shall have independent current interrupter.6 6.Timer power’ ON’ /‘OFF’ .6.5.Timer reset . the timer shall get reset and upon release of the button the timer shall restart with ‘ON’ timing. for current interruption test.11 GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT © GAIL – All rights reserved . b) Indications(LED) Timer power ‘ON’ ‘ON’ timing ‘OFF’ timing 6. then the CPTR unit shall have provision! terminals for connection of input power supply and output contacts of external current interrupter. A timer-reset push button shall be provided.5.9 6. The following controls and indications shall be provided for current interrupter.5 Whenever the timer is switched on it shall always start with ON ‘timing’. The power required for operation of the timer and contactor shall be derived from the main power supply to the CPTR unit. SPECIFICATION S-07-02-013 REV-0 Page 12 of 17 6. The interrupter unit shall have terminals for input power supply and terminals of the output contactor.Thumb wheel switch for ‘ON’ timing .5.8 The output contact of the current interrupter contactor shall be wired in the positive DC output of the CPTR unit. Where the current interrupter is not specified with CPTR unit or is specified as portable type external to the CPTR unit. If specified in the data sheet the current interrupter shall be an independent unit of portable type.5.7 6. so that normally they are not accessible. A link shall be provided for shorting these terminals whenever the current interrupter is not in use.5.Thumb wheel switch for ‘OFF’ timing In case of microprocessor based system keypad with display may be provided in place of thumbwheel switches. For CPTR units with multiple output circuits. a) Controls .5. The indications shall be mounted on the door. Thumb wheel switch for ‘OFF’ timing TR unit shall have following indicating lights (lamps or min. 1.6. e) Selector switch for selecting indication of PSP set and PSP actual for all the reference cells. b) Controls for current interrupter: .3 6.‘OFF’ timing It shall be possible to switch-off all the indication lamps by a single switch.Timer power ‘ON’ . In case of LED indication lights this facility may not be provided. c) Auto/C VCC mode selector switch. Vps and los settings.Timer reset .1.‘ON’ timing . b) ON /OFF control for output through MCCB/MCB. d) Reference cell faulty (number of lamps same as number of reference cells). d) Digital meters for measuring Vrs.4 GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT © GAIL – All rights reserved . e) Pipeline over protected.Thumb wheel switch for ‘ON’ timing .6.2 6.5 accuracy shall be provided on the CPTR unit: a) Digital meter for output voltage b) Digital meter for output current c) Digital voltmeter to measure PSP set (Vps) and PSP actual for all the reference cells. a) ON/OFF control for input through MCCB/MCB. Vpm.Timer power ‘ON’ / ‘OFF’ . Following meters having minimum Cl.6.5 accuracy.6. Following controls shall be provided inside the module at user accessible common location: a) Potentiometer for Vrs. d) Potentiometers for Vos. Vpn and Vas/las settings.O. Vpn and Vas/las settings. e) Meters for input voltage and current SPECIFICATION S-07-02-013 REV-0 Page 13 of 17 6. Indication and Metering Following controls shall be provided on CPTR unit front door. 5 mm dia LEDs): a) CPTR unit ON/OFF b) Unit in auto/CVCC (2 lamps) c) Reference cell controlling the closed loop control of the CPTR unit (number of lamps same as number of reference cells). f) Pipeline under protected g) Indications for current interrupter: . The meter shall have range from -4 V to 0 V and shall have cl.6 6. Vpm.1 Controls. It shall be possible to switch-off all the digital meters preferably by a single switch. Instruments and equipments required for testing shall be arranged by manufacturer. (Contact close in auto condition) o System in CVCC mode.CPTR unit output current The transducers shall have electrical isolation between input and output. TESTS AND ACCEPTANCE During manufacture. (Contact open on alarm condition) o System in auto-mode.PSP (-4V to OV) .5. CPTR unit shall incorporate provision for remote monitoring of the unit through SCADA system as below: a) Potential free contacts for the following: o All the reference cells failed.. indication and metering. each output circuit shall have independent controls.5 mm2 copper conductor cable. 7. 50Hz for minimum 1 minute. SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 14 of 17 7. The accuracy class of the transducer shall be 0. 6.1 For units having multiple outputs. the equipment shall be subjected to inspection by owner or his authorised representative to assess the progress of the work as well as to ascertain that only quality raw materials are used for the same. Final acceptance test shall be carried out at manufacturer’s works under his care and expense. o Checking of all settings.2. 6.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . (Contact open on alarm condition) o Pipeline under protected.. o All labels provided. The transducers shall be protected against input and output voltage surges. Visual Inspection This shall includeo Completeness of the equipment in line with specification.. The transducer shall be suitable for driving up to 600 ohms load impedance located up to 500 m away and wired with 0.6 7. Acceptance tests shall include but not be limited to the tests listed below.6. He shall be given all assistance to carryout the inspection.5 If specified in data sheet. Test certificates indicating test results shall be furnished by the manufacturer.6. (Contact close in CVCC mode) b) 4 to 20 mA electrically isolated signal for the following: .2 7. Owner’s representative shall be given minimum 2 weeks prior notice for witnessing the tests. (Contact open on alarm condition) o Pipeline overprotected.CPTR unit output voltage . The isolation insulation shall withstand 2kv. due to malfunction or failure of the unit to fulfill the performance requirements of the specification. Constant voltage operation During the test. D.C. 7. test voltages may be applied instead of A. All other CPTR units shall be energized under partial load or zero load current condition through out the test period.2. current.m. The verification of operation of the control functions.C. current limit shall be set to rated output current. measurement of output voltage.4 Functional tests Functional tests as below shall be performed on each CPTR unit. 7.3 Heat run test All CPTR units shall be subjected to a heat run test performed at rated voltage for period not less than 16 hours prior to execution of functional tests. SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 15 of 17 7.C.o Dimensional checking. power factor.4.g.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .2 Insulation tests The voltage specified in the table below shall be applied the circuits indicated: Control electronics Power electronics Withstand voltage <60V Un1 To earth 700V D. o Proper mounting of components and neatness of wiring etc. test voltages to be applied shall be 2 times the above-mentioned A. any electronic component of the unit is required to be replaced e. 2xUn1 + 1000V To control electronics 2xUn1 + 1000V To power electronics 2xUn1 + 1000V To auxiliary circuits 2xUn2 + 1000V 2xUn1 + 1000V for one minute to Auxiliary circuits Un2 2xUn2 + 1000V 2xUn2 + 1000V 2xUn1 + 1000V - (Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits respectively). ripple in the output.s) values.2. input AC voltage. The magnitude of D. o Model number. Insulation resistance test shall be conducted before and after heat run test. Performance testing shall be carried out for various output voltage settings and load varying from zero to maximum. CVCC mode operation testing a. (r.2. then the load test shall be repeated at rated current following which functional tests shall be carried out. current. If during execution of functional tests.C.2. 7.C. At least one CPTR unit of each rating shall be loaded to its rated output through out 16 hour test period. ripple in the output. The unit shall go to current limit mode and shall not damage any active component of the unit. current. The settings on Vas/Jas shall be varied and the output voltage/current shall be observed. 7.4. under protection. Performance testing shall be carried out for various output current limit settings and load resistance varied to achieve output voltage from minimum to maximum. The closed loop performance and regulation shall be checked with the PSP set voltage varied from O. reference cell failure and reference cell selection logic in auto PSP mode shall be verified by connecting variable external voltage sources to reference cell inputs of the CPTR unit. current. The verification of operation of the control functions. Constant current operation During the test.2.2V.3 The unit shall be checked for operation of the current limit by over loading the unit in both CVCC and auto PSP modes of operation. The number of external voltage sources shall be same as number of reference cell inputs specified for the CPTR unit.2. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 16 of 17 © GAIL – All rights reserved . The output voltage/current of the unit shall go to the value set on the potentiometer Vas/las provided inside the CPTR UNIT. evaluation of output current regulation of the unit shall be carried out during the testing. measurement of output voltage. The switch connected in the output shall be shorted quickly. Operation of sensors for pipeline over protection. input AC voltage. 7.85V to 1. For Units where semiconductor fuses are not provided for protection of the thyristors/triacs. Disconnecting the reference cell feed back connection in the above set up shall simulate the reference cell failed condition. The output voltage and the output current limit settings of the unit shall be set to the maximum rated values.evaluation of output voltage regulation and efficiency of the unit shall be carried out during the testing.2 Auto PSP mode operation Suitable set up shall be arranged for output loading and reference cell feed back.4. power factor. the protection of same shall be tested as below: A switch rated for making and carrying CPTR unit output short circuit current shall be connected to the output terminals of the unit. b. voltage limit shall be set to rated output voltage. ..e. Crates shall have skid bottom for handling. etc. P. The equipment may be stored outdoors for long periods before erection. Nos.4 8 The current interrupter shall be tested for time interval settings and specified operation. ‘Weight’ etc. The packing shall be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature.4. The panels shall be wrapped in polythene sheets before being placed in crates to prevent damage to finish. PACKING AND DESPATCH The equipment shall be properly packed for selected mode of transportation i.2. ‘Center of gravity’. ‘This side up’.7. GAIL (INDIA) LTD NEW DELHI SPECIFICATIONS FOR CATHODIC PROTECTION TRANSFORMER RECTIFIER UNIT SPECIFICATION S-07-02-013 REV-0 Page 17 of 17 © GAIL – All rights reserved . by ship/rail or trailer.O. Special notations such as ‘Fragile’. shall be clearly marked on the package together with Tag nos. SPECIFICATION FOR FLAMEPROOF LIGHTING AND POWER PANELS GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS SPECIFICATION S-07-02-014 REV-0 Page 1 of 9 © GAIL – All rights reserved . ABBREVIATIONS: GI MCB ELCB PVC FRP CIMFR CCE FM IEC LCIE PESO UL Galvanised Iron Miniature Circuit Breaker Earth Leakage Circuit Breaker Poly Vinyl Chloride Fibre Reinforced Plastic Central Institute of Mines and Fuel Research (formerly CMRI) Chief Controller of Explosives Factory Mutual Research Corporation International Electrotechnical Commission Laboratoire Central des Industries Electriques Petroleum and Explosives Safety Organization Underwriters Laboratory GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS SPECIFICATION S-07-02-014 REV-0 Page 2 of 9 © GAIL – All rights reserved . 0 4.0 8.0 5. TESTING AND ACCEPTANCE PACKING AND DESPATCH GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS SPECIFICATION S-07-02-014 REV-0 Page 3 of 9 © GAIL – All rights reserved .0 9.0 SCOPE CODES AND STANDARDS GENERAL REQUIREMENTS SITE CONDITIONS POWER SUPPLY CERTIFICATION TECHNICAL REQUIREMENTS INSPECTION.0 7.0 6.0 3.CONTENTS 1.0 2. 0 2. IS-8828 : Specifications for Circuit breakers for Over current protection for household and similar installations IS-12640 : Residual current operated circuit breakers. In case Indian standards are not available for any equipment. SPECIFICATION S-07-02-014 REV-0 Page 4 of 9 2.3 2.V. IS-13947 (Parts 1 & 5) L. the following order of decreasing priority shall govern: Statutory regulations Data sheets Job specification This specification Codes and standards. In case of any contradiction between various referred standards! specifications! data sheet and statutory regulations. installation and maintenance of electrical apparatus for use in potentially explosive atmospheres (other than mining applications or explosives processing and manufacture).2 2.1. IS-1248 (Parts 1 & 2) Direct acting indicating analogue measuring instruments and their accessories. CODES AND STANDARDS The equipment shall comply with the requirements of latest revision of the following standards issued by BIS (Bureau of Indian Standards).5 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS © GAIL – All rights reserved . unless otherwise specified: IS-5 Colours for ready mixed paints and enamels. IS-13346 : General requirements for electrical apparatus for explosive gas atmosphere.0 SCOPE This specification covers the requirements of design. Imported equipment shall conform to the international standards such as IEC / BS / VDE / NEMA or equivalent. manufacture. testing.13408 (Part-1) : Code of practice for the selection. IS. The equipment shall also conform to the provisions of Indian Electricity Rules and other statutory regulations currently in force in the country. Switchgear and Controlgear. standards issued by IEC / BS / VDE / NEMA or equivalent agency shall be applicable. packing and supply of flameproof Lighting and Power panels! accessories suitable for installation in locations handling flammable liquids and gases. IS-2 148 : Flameproof enclosures for electrical apparatus.1 2.4 2. IS-5571 : Guide for selection of electrical equipment for hazardous areas. which shall isolate both poles. The lighting and power panels shall be designed to operate under site conditions as specified in the data sheet. three phase and neutral (TPN) incoming supply and outgoing circuits for 240V.1 4.0 5.3.1 5. SITE CONDITIONS The equipment shall be suitable for installation and satisfactory operation in classified hazardous locations in tropical.0 GENERAL REQUIREMENTS The offered equipment shall be brand new with state of art technology and proven field track record.1 7.1 5.2. CERTIFICATION The equipment shall have test certificates issued by recognised independent test house (CIMFR / CPRI / ERTL / BASEEFA / LCIE / UL / FM or equivalent). the following additional requirements shall apply: The phase-to-phase voltage shall not exceed 125 volts (where electric lighting is used in underground mine)! 250 volts (where electric lighting is used in open cast mine or surface of a mine). No prototype equipment shall be offered.1.0 3. TECHNICAL REQUIREMENTS Construction The enclosures of the lighting and power panels shall be made of cast light metal alloy and shall be free from frictional sparking hazard. All indigenous flameproof equipment shall have valid BIS license and marking as required by statutory authorities. The panels shall have three phase. with the neutral or the midpoint of the lighting system connected with earth. The magnesium SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS SPECIFICATION S-07-02-014 REV-0 Page 5 of 9 5.2 5. humid and corrosive atmosphere as prevalent in refineries. lighting and power panels shall be suitable for 415V.2 5.2.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .0 7. All indigenous equipment shall conform to Indian standards and shall be certified by Indian testing agencies. POWER SUPPLY Unless otherwise specified. single phase and neutral (SPN). If not specifically mentioned therein. Outgoing circuits shall be controlled by 2-pole MCBs.2. without neutral.3 6. a design ambient temperature of 400 C and an altitude not exceeding 1 000m above mean sea level shall be considered. 3-wire system. For projects falling under the jurisdiction of DGMS. 50Hz. petrochemical and fertilizer plants. All equipment (indigenous & imported) shall also have valid statutory approvals as applicable for the specified location. Earth leakage protection shall be provided for all outgoing circuits.0 7. neutral and earth. The enclosures shall be sized to facilitate easy maintenance and heat dissipation. bolts.1.5 10mm2 Conductor mm2 & 2 2. unless otherwise specified. shall be made of stainless steel SS-304.1.1. The separate canopy shall be made of at least 14 SWG (2mm) galvanised sheet steel or FRP. All the non-current carrying metallic parts of the panel shall be inherently bonded together.7.3 7.1. where the enclosure has been certified without integral canopy.7 7. The enclosures shall be treated and prepared for painting with two coats of epoxy paint with final colour shade (both internal and external) as below: Flame proof (Gas group IIA/IIB) Dark admiralty grey shade 632 of IS-S Flame proof (Gas group IIC) Light yellow shade 355 of IS-S A warning inscription “Isolate power supply elsewhere before opening” shall be provided on each enclosure. The panels shall be suitable for use in outdoor open locations and shall have IP-55 degree of protection. a separate canopy can be accepted.1. They shall preferably be provided with integral canopy.1. However. The lighting and power panels shall be provided with gaskets made of noninflammable and self-extinguishing material. Each lighting and power panel shall be provided with two earthing studs with lugs on the exterior of the panel enclosure suitable for termination of 10 mm dia GI wire rope. The temperature of external surfaces shall be limited to 200°C.2 content in the alloy shall be as per IS-13 346. The warning plate shall be of nickel plated brass or stainless steel. All accessories like nuts.5 mm & Up to Upto35 Upto70 Size 10 mm2 mm2 2 mm mm2 Gland to 40 mm 60 mm 100 mm 150 mm terminal distance 7. The warning inscription shall be embossed on the enclosure or a separate warning plate with above inscription shall be fixed to the enclosure with screws.5 7.1.8 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS SPECIFICATION S-07-02-014 REV-0 Page 6 of 9 © GAIL – All rights reserved .6 7. The terminal block enclosures shall be adequately sized to properly terminate the cables by taking into account the required bending radii of cable cores and shall have the following minimum gland to terminal distances: Above Above 35 Up to Above 2. Each outgoing feeder shall be provided with distinct terminals for phase. The canopy shall be suitable for providing protection against rain from top and two sides.4 7. washers etc. the outgoing feeders shall be provided with double pole 1OA MCBs having overload and short-circuit releases.4 7.1.1. In case the standard details given above are embossed on the enclosures. for plugging the unused cable entries. with date. test certificate no.11 7. with date and agency (PESO / CCE / DGFASLI / DGMS). The nameplates shall be engraved on 3 ply black white black lamicold sheets using square cutters. BIS license number and date. applicable gas group etc. One no.2. Nameplates shall also be provided for each incoming and outgoing feeder.6 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS SPECIFICATION S-07-02-014 REV-0 Page 7 of 9 © GAIL – All rights reserved . A nameplate indicating TAG NO. all MCBs (except isolators) and ELCBs shall be with 9kA (M9 category) interrupting capacity. 7. Busbars shall be colour coded for identification of phases and neutral.1. shall be provided on each panel.2 7. Unless otherwise specified. Unless otherwise specified. Flameproof nickel plated brass sealing plugs shall be supplied. Unless otherwise specified. the same need not be repeated on the name plate.2. Black engraved perspex sheet nameplate shall also be acceptable. Component Specification Busbars in the lighting and power panels shall be made of high conductivity copper. Separate nameplate shall also be provided to indicate the details of testing agency (CIMFR or equivalent). statutory approval no.10 7.2 7. Nameplates shall be fixed by screws and shall not be pasted.9 The panels shall be provided with suitably sized cable entries at the bottom! sides.3 7. The quantity of sealing plugs shall be equal to 20% of the total number of outgoing cable entries. The operating knobs (ON / OFF / RESET) shall be provided with a suitable rack and pinion arrangement for operating them smoothly from outside. 4 pole ELCB. The ELCB shall be hand reset type. for incoming and outgoing cables.7.1 7.2. Panels shall be complete with double compression type nickel plated brass flameproof cable glands.2. 4 pole 40A MCB isolator (without overload and short-circuit release) and one no.5 7. The holes provided on these lugs shall be of oblong type. door mounted reset push button shall be provided.2. and shall be supported by non-hygroscopic insulators.2. ELCBs shall have a maximum sensitivity of 3OmA. The panels shall have external fixing lugs for mounting on wall or column. the incomer shall have one no. The certificates and BIS license must be valid at the time of despatch. PVC insulated copper conductor wires.4 8. Type test certificates from CIMFR or equivalent test house. Manufacturer shall furnish all necessary information concerning the supply to GAIL’s inspector.3 7. All internal wiring in lighting and power panels shall employ adequately sized.4. Test certificates of bought out components shall be shown to the inspection agency on demand during inspection. If required. 7.1 Terminals & Wiring The panels shall be provided with sufficient number of terminals.3.4. Wherever lugs are required for cable termination. the equipment shall be subjected to inspection by GAIL or by an agency authorised by the owner. if specified! agreed in Inspection Test Plan. Unless otherwise specified.2 8. colour coded for phase.6 8. All equipments shall be subjected to various acceptance tests as per standards but not limited to the following: General visual inspection Dimensional inspection Verification of mechanical and electrical operations Dielectric tests Routine pressure test as per IS-2 148 Any other routine and acceptance test as per applicable standards.4. Type tests shall be carried out if specified in data sheet! job specification. Terminals shall be suitable for termination of solid conductors upto 6 mm2 and stranded conductors above 6 mm2.3 8.4.7.4.1 8.5 mm2 INSPECTION.1 8.2 8. neutral and earth. the terminals for termination of incoming and outgoing external cables shall be suitable for termination of upto 70 mm2 and 6 mm2 copper conductor respectively.0 8.5 8.3.5 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS SPECIFICATION S-07-02-014 REV-0 Page 8 of 9 © GAIL – All rights reserved . All routine! acceptance tests shall be carried out at manufacturer’s works under his care and expense. BIS license and original drawings referred in type test certificates shall be shown to the inspection agency on demand during inspection. with minimum conductor sizes as below: Incomer : 16 mm2 Outgoing : 2. 660V grade. applicable PESO/ CCE / DGFASLI / DGMS approval certificates. tinned copper type lugs shall be provided.4.3 8. TESTING AND ACCEPTANCE During fabrication.4 8.2 8. additional terminal with shorting link may be used. More than 2 wires per terminal shall not be permitted. i. shall be clearly marked on the packages together with other details as per purchase order. The equipment may be stored in a covered shed for long periods before installation. The packing should be suitable for such storage. ‘P0 no. ‘Owner’s particulars’.’ etc.9. by ship! rail or trailer and shall be wrapped in polythene sheets before being placed in crates! cases to prevent damage to finish. Special notations such as ‘Fragile’.. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FLAME PROOF LIGHTING AND POWER PANELS SPECIFICATION S-07-02-014 REV-0 Page 9 of 9 © GAIL – All rights reserved . The crates! cases shall have skid bottom for handling. ‘Center of gravity’. The equipment shall be properly packed for the selected mode of transportation.0 PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation. ‘Weight’.e. ‘This side up’. SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES SPECIFICATION S-07-02-015 REV-0 Page 1 of 11 © GAIL – All rights reserved . Abbreviations: ASTM: BIS: IEC: IS: NEMA PVC XLPE HR PVC FR American Society for Testing and Materials Bureau of Indian Standards International Electrotechnical Commission Indian Standards National Electrical Manufacturers Association Polyvinyl Chloride Crosslinked Polyethylene Heat Resistant Polyvinyl Chloride Flame Retardant GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES SPECIFICATION S-07-02-015 REV-0 Page 2 of 11 © GAIL – All rights reserved . 6. SCOPE STANDARDS GENERAL CONSTRUCTION CABLES ACCESSORIES INSPECTION. 3. TESTING AND ACCEPTANCE PACKING AND DESPATCH GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES SPECIFICATION S-07-02-015 REV-0 Page 3 of 11 © GAIL – All rights reserved .CONTENTS 1. 4. 5. 2. Thermoplastic insulated wire and cable for transmission and distribution of electrical energy Cross-linked thermosetting polyethylene insulated wire and cable for transmission and distribution of electrical energy SPECIFICATION S-07-02-015 REV-0 Page 4 of 11 2. 2. Drums for electric cables Fictitious calculation method for determination of Dimensions of protective coverings of cables: Part . strips and tapes for armouring of cables Methods of test for cables: Mass of zinc coating on steel armour.2 PVC Insulated and PVC sheathed heavy-duty cables. Tests on electric cables under fire conditions Extruded solid dielectric insulated power cables for rated Voltages from 1 kV.I Electrometric and thermoplastic insulated cables. SCOPE This specification along with data sheets covers requirements for design. Specification for zinc Recommended current ratings for cables: Part . testing at works and supply of Flame Retardant PVC/XLPE cables and cable jointing I terminating accessories for medium and high voltage systems.upto30kV. STANDARDS The cables and cables jointing & terminating accessories shall comply with the latest edition of the following standards as applicable: IS: 1554 IS: 7098 IS: 8130 IS: 5831 IS: 3975 IS 108 10(Part 41) IS: 209 IS: 3961(Part 2) IS: 10418 IS: 10462 (Pt-I) IS: 10810 (Pt -58) IS: 10810 (Pt 61) IS: 10810 (Pt 62) IS: 13573 IEC: 60332-3 IEC: 60502 IEC 60540 & 60540A ASTM: D2863 ICEA S-61-402 NEMA-WC5 ICEA S-66-524 NEMA-WC7 PVC insulated (heavy duty) electric cables Cross-linked polyethylene insulated PVC sheathed Conductors for insulated electric cables and flexible cords PVC insulation and sheath of electric cables Mild steel wires.6 KV up to and including 33 KV.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES © GAIL – All rights reserved . manufacture. Test methods for insulation and sheaths of electric Cables Standard method of test for flammability of plastics using oxygen index method.1. Oxygen Index test Flame Retardant test Fire resistance test for bunched cables Joints and terminations for polymeric cables for working Voltages from 6. 4 3.3 3. and conduits and for underground-buried installation with uncontrolled backfill and possibility of flooding by water and chemicals.5 3. The cables used in installations under the jurisdiction of Director General of Mines and Safety (DGMS) shall be of copper conductor only. ends of the cables shall be properly sealed with caps to avoid ingress of water during transportation and storage. The overall diameter of the cables shall be strictly as per the values declared by the manufacturer in the technical information subject to a maximum tolerance of ±2 mm up to overall diameter of 60mm and ±3mm for beyond 60mm. the following order of priority shall govern: o Statutory Regulations o Data Sheets o Job Specifications o This Specification o Codes and Standards GENERAL CONSTRUCTION The cables shall be suitable for laying in trays. The word” Mining Cable” SPECIFICATION S-07-02-015 REV-0 Page 5 of 11 2. The embossing /engraving shall be legible and indelible. Sequential marking of the length of the cable in metres shall be provided on the outer sheath at every one metre. In addition. All cables covered in this specification shall be flame retardant (FR) unless specified otherwise in the data sheet. as applicable. Outer sheath of all PVC and XLPE cables shall be black in colour and the minimum value of oxygen index shall be 29 at 27 ± 2 C.1 3. trenches.7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES © GAIL – All rights reserved .2. and shall have valid DGMS approvals for the specified locations. In addition suitable chemicals shall be added into the PVC compound of the outer sheath to protect the cable against rodent and termite attack.2 3. PVC / Rubber end caps shall be supplied free of cost for each drum with a minimum of eight per thousand metre length.3 3 3.6 3.2 The cables and accessories shall also conform to the provisions of Indian Electricity Rules and other statutory regulations. In case of any contradiction between various referred standard/ specification/data sheet and statutory regulations. ducts. The outer sheath of PVC and XLPE cables shall possess flame propagation properties meeting requirements as per IS-l0810 (Part-62) category AF. Cables with reduced neutral conductor shall have sizes as per Table I of IS 1554 (Part-I). Control cables having 6 cores and above shall be identified with prominent and indelible Arabic numerals on the outer surface of the insulation.2 3. For mining cables. If armouring is specified for multicore cables in the data sheet. If armouring is specified for single core cables in the data sheet.4 3.8.8. The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC conforming to the requirements of Type ST-I PVC compound as per IS: 5831.shall be embossed /engraved on the cable outer sheath as per the applicable Indian Standards 3. The minimum and average thickness of outer sheath for SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES SPECIFICATION S-07-02-015 REV-0 Page 6 of 11 3.8 3.1554 (Part -1).1 PVC cables All power/control cables for use on medium voltage systems shall be heavyduty type. PVC insulated. the same shall be with 114 grade hard drawn aluminium round wire of 2. The thickness of insulation and the tolerance on thickness of insulation shall be as per Table 2 of IS: 1554 (Part-l). armoured and overall PVC sheathed unless specified otherwise in data sheet The conductors shall be solid for conductor of nominal area up to and including 6mm2 and stranded beyond 6mm2.8.8. Conductors of nominal area less than 16 mm2 shall be circular only.8.8.5 3. The outer sheath for the cables shall be applied by extrusion and shall be of PVC compound conforming to the requirements of type ST-I compound as per IS: 5831. The core insulation shall be with PVC compound applied over the conductor by extrusion and shall conform to the requirements of type ‘A’ compound as per IS: 5831. 650/1100 V grade with aluminium / copper conductor. inner-sheathed. Single core cables shall have no inner sheath. Requirement and methods of tests for armour material and uniformity of galvanisation shall be as per IS 3975 and IS -10810 (Part 41). Colour of the numbers shall contrast with the colour of insulation with a spacing of maximum 50 mm between two consecutive numbers. The dimensions of Armour shall be as per method (b) of IS . Conductors of nominal area 16 mm2 and above may be circular or shaped as per IS 8130.6 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .3 3.5 mm diameter. The minimum thickness of inner sheath shall be as per IS: 1554 (Part-I). the same shall be by single round galvanised steel wires where the calculated diameter below armouring does not exceed 13 mm and by galvanised steel strips where this dimension is greater than 13 mm. Colour coding for cables up to 5 cores shall be as per Indian standard. the size and type of armour shall be such that the combined conductance of armour shall be equivalent to 75 percent of the conductance of the largest conductor of the cable. In case of single core cables.3 3.7 If heat resisting PVC cables are specified in the data sheet. Conductor insulation -Type C b.2 3. The conductors shall be stranded and compacted circular for all cables. armoured and overall PVC sheathed.9. Inner sheath -Type ST 2 c.5 The insulation screen shall consist of non-metallic extruded semi-conducting compound in combination with a non-magnetic metallic copper screen.9. Unless specified otherwise.9. The conductors shall be provided with non-metallic extruded semi conducting screen.8. 3.6 kV and above shall be provided with both conductor screening and insulation screening. XLPE insulation and insulation screen shall all be extruded in one operation by ‘Triple Extrusion’ process to ensure perfect bonding between the layers.7 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . It shall conform to Table-I of IS: 7098 (Part -2).9 3. The core insulation shall be with cross linked compound dry cured. sheathed. The extruded inner sheath shall be of uniform thickness. the following shall be the requirements: It shall be possible to continuously operate the cable at a maximum conductor temperature of 85oC. there shall be extruded inner sheath between insulation metallic screen and armouring.9.8 ! 6.1 3. The core identification shall be by coloured strips or by printed numerals. All cables rated 3. The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the requirements of type ST 2 compound of IS: 5831. Outer sheath -Type ST 2 XLPE Cables Power cables for 3. SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES SPECIFICATION S-07-02-015 REV-0 Page 7 of 11 3. It shall shall withstand all mechanical and thermal stresses transient operating conditions.unarmoured cables and minimum thickness of outer sheath for armoured cables shall be as per IS: 1554 (Part -1).9.9. applied by extrusion. the copper screen for all the three cores together shall be capable of carrying the single line to ground fault current value and the duration specified in the data sheet. The conductor screen.4 3. PVC compounds used for HR PVC cables shall be as follows: a. XLPE insulated.3 KV up to and including 33 KV systems shall be Aluminium! copper conductor. polyethylene insulating be free from voids and under steady state and the properties given in 3.6 3.9. 6 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .5 4. For outdoor terminations.3 4. weather shields / sealing ends and any other accessories required shall also form part of the kit. These SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES SPECIFICATION S-07-02-015 REV-0 Page 8 of 11 3.1 4.9.9. Jointing Kits The straight through jointing kits shall be suitable for installation on overhead trays. with shelf life extending to more than 5 years. The contents of the accessories kit including all consumable shall be suitable for storage without deterioration at a temperature of 45°C. insulating and sealing materials apart from conductor fittings and consumable items .3.9.8 For multicore cables. the same shall be with H4 grade hard drawn aluminium round wire of 2. inner sheath shall be governed by values given in IS: 7098 Part -2 Where specified. The accessories shall be supplied in kit form. The outer sheath of the cables shall be applied by extrusion over the armouring and shall be of PVC compound conforming to the requirements of Type ST 2 compound of IS: 5831. Each component of the kit shall carry the manufacturer’s mark of origin. The terminating kits shall be from one of the makes / types mentioned in the data sheet.7098 (Part-2).9 3.An installation instruction sheet shall also be included in each kit.9. 1100 V grade power cables shall also be XLPE insulated and shall meet the requirement specified in IS-7098 (Part-1). If armouring is specified for single core cables in the data sheet.10 3. and ducts and for underground burial with uncontrolled backfill and possibility of flooding by water and chemicals. concrete lined trenches. The kit shall include all stress grading.11 4 4.2 4.4 4. Terminating Kits The terminating kits shall be suitable for termination of the cables to an indoor switchgear or to a weatherproof cable box of an outdoor mounted transformer I motor. CABLE ACCESSORIES The termination and straight through jointing kits for use on the systems shall be suitable for the type of cables offered as per this specification. the armouring shall be by galvanized steel strips as per method (b) of IS.5 mm diameter. The minimum and average thickness of outer sheath for unarmoured cables and minimum thickness of outer sheath for armoured cables shall be as per 15: 7098 (Part-2) The thickness of the insulation. 1.1.1 5. SPECIFICATION S-07-02-015 REV-0 Page 9 of 11 5. which appears to him to be of unsuitable description or of unsatisfactory quality. acceptance and special tests as detailed below. test is to be conducted by vendor at his own cost in any recognised test laboratory or in house testing laboratory. The test requirements for PVC insulation and sheath of cables shall be as per latest revision of IS: 5831. Test for Resistance to Ultra Violet Radiation: This test shall be carried out as per DIN 53387 or ASTM-G-53 on outer sheath. before despatch clearance of cables. GAIL/ Owner reserves the right to witness all tests with sufficient advance notice from vendor. the cables shall be subjected to type. testing and approval by GAIL I owner. Sampling for this test is to be done randomly once for each order.4 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES © GAIL – All rights reserved . The test reports for all cables shall be got approved from the Engineer before despatch of the cables.shall have protection against any mechanical damage and suitably designed to be protected against rodent and termite attack. The jointing kits shall be from one of the makes / types mentioned in the data sheet.3 5. The cables shall be tested and inspected at the manufacturer’s works. provided outer• sheath remains same. and IS: 7098 (Part-2) on PVC and XLPE insulated cables respectively. to examination.1. Manufacturer shall furnish all necessary information concerning the supply to GAIL I owner’s inspectors. both before and after manufacture. In case test certificates are not available. acceptance tests. Test certificates with respect to this test (not older than one year) from recognised testing laboratory to be furnished for review by GAIL before despatch clearance of cables. The retention value of tensile strength and ultimate elongation after the test shall be minimum 60 % of tensile strength and ultimate elongation before the test. regarding the date of testing to enable him or his representative to witness the tests.2 5. type tests and additional type tests for improved fire performance shall be carried out as listed in IS: 1554 (Part-I). The inspector shall have free access to the manufacturer’s works for the purpose of inspecting the process of manufacture in all its stages and he will have the power to reject any material.1 Cables After completion of manufacture of cables and prior to despatch. The inner sheath similar to that provided for cables shall be provided as part of straight through joint. The vendor shall give at least 2 weeks advance notice to the purchaser. routine. All routine tests. All the materials employed in the manufacture of the cable shall be subjected.1. 5. Cable Accessories Type tests should have been carried out to prove the general qualities and design of a given type of termination / jointing system as per IS-13573. Sampling to be done for every offered lot / size as per sampling plan.1. These tests are required to be witnessed by GAIL before despatch of cables. before despatch clearance of cables.7 (for XLPE insulated cables).WC . Flammability Test: The test shall be carried out on finished cable as per IS . Test for rodent and termite repulsion property: The vendors shall furnish the test details to analyse the property by chemical method. Accelerated water absorption test for insulation as per NEMA . Sampling for this test is to be done randomly and once for each order.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES SPECIFICATION S-07-02-015 REV-0 Page 10 of 11 © GAIL – All rights reserved . (For PVC insulated cables). before despatch clearance of cables. Test certificates with respect to this test (not older than one year) from recognised testing laboratory to be furnished for review by GAIL before despatch clearance of cables. test is to be conducted by vendor at his own cost in any recognized test laboratory or in house testing laboratory. Sampling for this test is to be done randomly once for each order. provided type of insulation remains same. In case test certificates are not available. Dielectric Retention Test: The dielectric strength of the cable insulation tested in accordance with NEMA WC . The type test certificates from independent testing laboratory shall be submitted before despatch. c. Oxygen Index Test: The test shall be carried out as per ASTM D2863 or applicable Indian Standard specifications. test is to be conducted by vendor at his own cost in any recognized test laboratory or in house testing laboratory. Sampling to be done for every offered lot/size as per sampling plan. Acceptance tests as per IS-1554 (Part-I) and IS-7098 (Part-2) and the following special tests to be performed on the cables as per sampling plan. e.10810 (part 61 & 62).5 a. provided outer sheath remains same.5 at 75 ± 10 C shall not be less than 50 % of the original dielectric strength. this test (not older than one year) from recognised testing laboratory to be furnished for review by GAIL before despatch clearance of cables. Sampling for these tests is to be done randomly once for each order.5.5.5 m above the bottom edge of the burner at the front of the ladder. In case test certificates are not available. The acceptance criteria for tests conducted shall be as under: Part-61-The cable meets the requirement if there is no visible damage on the test specimen within 300 mm from its upper end Part-62-The maximum extent of the charred portion measured on the test sample should not have reached a height exceeding 2. b. Test certificates with respect to. d. (For PVC insulated cables) and as per NEMA WC . 5. If nonstandard drum lengths are specified in the data sheet. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM & HIGH VOLTAGE CABLES & ACCESSORIES SPECIFICATION S-07-02-015 REV-0 Page 11 of 11 © GAIL – All rights reserved . Unless otherwise specified. Cables shall be supplied in drum lengths as follows: MV Cables Multicore Power cables up to 6 mm2 : 1000 m Multicore Power cables from 10mm2 up to 300 mm2 : 500 m Single Core Power cables up to 630 mm2 1000 m Control cables up to 61 cores : 1000 m HV power cables . securely battened. sound and free from defects. cable code.. gross weight etc.6 6.Above 11 kV(E) Grade and up to 33kV(E) Three Core cables up to 300 mm2 grade : Single Core cables up to 400 mm2 : Single Core cables above 400 mm2 and up to 1000 mm2 : 500 m 1000 m 6. Offers with short / non-standard lengths are liable for rejection. However overall tolerance on each size of cable shall be limited to ± 2%. voltage grade of cable.2 6. necessary information such as project title.3 Grade 350 m 1000 m 500 m A tolerance of plus or minus 3 % shall be permissible for each drum. shall be printed. BIS certification mark. drum no.1 PACKING AND DESPATCH Cables shall be despatched in non-returnable wooden or steel drums of suitable barrel diameter. the same shall be supplied. length of cable in metres. type size. Wood preservatives shall be applied to the entire drum. On the flange of the drum. Ferrous parts used shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit or storage. An arrow shall be printed on the drum with suitable instructions to show the direction of rotation of the drum. The wood used for construction of the drum shall be properly seasoned. with the take-off end fully protected against mechanical damage. manufacturer’s name.Up to 11 kV(E) Grade Three Core cables up to 400 mm2 : Single Core cables up to 400 mm2 : Single Core cables above 400 mm2 and up to 630 mm2 : 750 m HV power cables . SPECIFICATION FOR STATIONARY NICKEL CADMIUM BATTERIES GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR NICKEL CADMIUM BATTERIES SPECIFICATION S-07-02-016 REV-0 Page 1 of 7 © GAIL – All rights reserved . Abbreviations: AC Ah BS DC IEC IEEE IS MSL NEMA P0 PVC UPS VDE V Alternating current Ampere-hour British Standard Direct current International Electrotechnical Commission Institute of Electrical & Electronics Engineers Indian Standard Mean Sea Level National Electrical Manufacturers Association Purchase Order Polyvinyl Chloride Uninterrupted Power Supply Verband der Elektrotechnik. Elektronik und Information technique Volt GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR NICKEL CADMIUM BATTERIES SPECIFICATION S-07-02-016 REV-0 Page 2 of 7 © GAIL – All rights reserved . 0 7.0 2.0 4.0 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR NICKEL CADMIUM BATTERIES SPECIFICATION S-07-02-016 REV-0 Page 3 of 7 © GAIL – All rights reserved .0 SCOPE CODES AND STANDARDS GENERAL REQUIREMENTS SITE CONDITIONS TECHNICAL REQUIREMENTS PERFORMANCE INSPECTION. TESTING AND ACCEPTANCE PACKING AND DESPATCH 5.0 8.0 3.0 6.CONTENTS 1. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least 10 years from the date of supply. No prototype equipment shall be offered. Data sheets. In case of any contradiction between various referred standards/specifications/data sheets and statutory regulations. the following order of priority shall govern: Statutory regulations. 2.5 3 3. This specification. IS-10918 Specification for Vented type Nickel Cadmium batteries In case of imported equipment.3 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR NICKEL CADMIUM BATTERIES SPECIFICATION S-07-02-016 REV-0 Page 4 of 7 © GAIL – All rights reserved .4 2.2 3. 2.1 3. Manufacture and testing requirements of stationary Nickel Cadmium batteries for DC power system /AC UPS application. The equipment shall also conform to the provisions of Indian Electricity Rules and other statutory regulations currently in force in the country. GENERAL REQUIREMENTS The offered equipment shall be brand new with state of the art technology and proven field track record. CODES AND STANDARDS The equipment shall comply with the requirements of the latest revision of the following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified. standards issued by IEC/ BS/ VDE/ IEEE! NEMA or equivalent agency shall be applicable.2 2. Job specification. standards of the country of origin shall be applicable if these standards are equivalent or more stringent than the applicable Indian standards. Codes and standards.1. In case Indian standards are not available for any equipment. SCOPE The intent of this specification is to define the design.3 2.1 2. Vendor shall give a notice of at least one year to the end user of equipment and GAIL before phasing out the product/ spares to enable the end user to place order for spares and services. Battery assembly shall be supplied dry and uncharged. If not specifically mentioned therein.0 V/cell. Service conditions shall be as specified in the data sheets/job specification. unless other wise specified. Discharge duty cycle c. End cell voltage d.5 5.8 e. Design margin of 10%. Capacity rating factor Number of cells and end cell voltage shall be decided by the vendor on the basis of maximum permissible voltage to the load when batteries are float charged while feeding the load and minimum DC system voltage. unless other wise specified. Ageing factor of 0. a design ambient temperature of 40°C and an altitude not exceeding l000m above MSL shall be considered. The battery shall be suitable for being boost charged to fully charged condition from fully discharged condition within 10 hours.6 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR NICKEL CADMIUM BATTERIES © GAIL – All rights reserved .4 5. if not defined in the data sheet f.3 5. However the number of cells and end cell voltage shall be as per the data sheet. Type of plate construction for batteries shall be as per the data sheet. petrochemical and gas processing plants. TECHNICAL REQUIREMENTS The Nickel Cadmium cell/battery shall be suitable for float duty operation with a constant voltage permanently applied to its terminals which is sufficient to maintain it in a state close to full charge and shall be designed to supply load in the event of normal power supply failure. Ampere hour of the battery shall be selected based on the following: a. The standard rated ampere hour capacity of the cell/ battery shall be at a reference temperature of 27°C.2 5. Dry electrolyte and required quantity of electrolyte liquid with 10% extra shall be delivered with the battery in suitable non returnable sealed containers. unless otherwise specified. Minimum site ambient temperature of 10°C or as defined in the data sheet b.1 5. constant current discharge at 5 hours rate (C5) and an end cell voltage of 1.4 SITE CONDITIONS Stationary Nickel Cadmium battery shall be suitable for operating satisfactorily in humid and corrosive atmosphere found in refineries. with a minimum temperature of 10°C for battery sizing. SPECIFICATION S-07-02-016 REV-0 Page 5 of 7 5 5. metallurgical plants and other industrial plants. 12 6 7 SPECIFICATION FOR NICKEL CADMIUM BATTERIES SPECIFICATION S-07-02-016 REV-0 Page 6 of 7 © GAIL – All rights reserved . The cell container shall be translucent/transparent. to assess the progress of work. c. Inter cell. These shall be of tin plated copper/flexible insulated copper cable. Lugs for cable termination. PERFORMANCE Nickel Cadmium batteries shall have been type tested to meet the performance requirements for each design and Ah rating of cells as per Indian Standard IS10918. as required. GAIL/owner’ s representative shall be given free access in the works from time to time for stage wise inspection and progress reporting. The terminals shall be suitable for short circuit current and specified discharge current without damage to the cell as a result of terminal heating. Four GAIL (INDIA) LTD NEW DELHI 5. b. shocks and vibrations. d. Battery stand in formation as per data sheet. e. The construction of the arrestor shall be such that hydrogen burning on the external surface of the arrestor shall not propagate back into the cell to cause explosion. Other accessories and their quantity as per data sheet. inter row and inter bank connectors and end take offs. INSPECTION.11 5. Stationary Nickel Cadmium cells shall be designed to withstand the mechanical stresses encountered during normal transportation and handling.5. Flame arrestor shall be mounted on the cell so that all the vented gases diffuse through the arrestor to the outside environment.7 Each cell shall have a separate container. Stand insulator.10 5. TESTING AND ACCEPTANCE Batteries shall be subject to inspection by GAIL/owner or by an agency authorised by the owner. The manufacturer shall furnish all the necessary information concerning the supply to GAIL/owner’ s representative.8 5. Nominal voltage Name of manufacturer/model reference Rated capacity in ampere hours (Ah) with End Cell Voltage Voltage for float operation at 27°C with tolerance of ±1 % Month and year of manufacture Polarity Marking Each set of battery shall be supplied with all the accessories. The cell container shall be of high strength alkali resistant material and designed to withstand mechanical stresses. but not limited to the following: a. Mild steel stand pretreated and epoxy painted /PVC coated. including. Cell number plates.9 5. The following information shall be permanently marked on the cell. The terminal posts shall be of nickel plated steel. iv) Marking and packing. ‘Centre of gravity’. ‘This side up’. 8 PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment may be stored outdoors for long periods before installation. C) Type test i) ii) iii) iv) v) vi) Verification of constructional requirement. iii) Dimension. unless otherwise agreed. ii) Polarity and absence of short circuit. iv) Test for voltage during discharge. ‘Weight’. ‘P0 nos. Crates/cases shall have skid bottom for handling. mass and layout. The packing shall be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature. ‘Owner’s particulars’. Air pressure test. v) Internal resistance test. if Battery duty cycle test to meet the load cycle requirement shall also be performed at site after installation as part of commissioning unless otherwise defined in the data sheet. Special notations such as ‘Fragile’. The equipment shall be wrapped in polythene sheets before being placed in crates/cases to prevent damage to finish. shall be clearly marked on the package together with other details as per purchase order. Test for voltage during discharge. Test for Ah capacity.’ etc. Following tests shall be carried out as a minimum for each Ah rating of cells/battery: A) Routine test i) Physical examination test. iii) Test for Ah capacity. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR NICKEL CADMIUM BATTERIES SPECIFICATION S-07-02-016 REV-0 Page 7 of 7 © GAIL – All rights reserved . Ampere hour and Watt-hour efficiency test. The equipment shall be properly packed for transportation by ship/rail or trailer.. ii) Verification of dimensions.weeks advance notice shall be given to witness the final routine tests and other tests as agreed upon. Test for charge retention/loss of capacity specified in the data sheet. B) Acceptance test i) Marking and packing. SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY UNIT GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 1 of 25 © GAIL – All rights reserved . TESTING AND ACCEPTANCE SITE ACCEPTANCE TESTS PACK[NG AND DESPATCH GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 2 of 25 © GAIL – All rights reserved .CONTENTS 1 2 3 4 5 6 7 8 SCOPE CODES AND STANDARDS GENERAL REQUIREMENIS SITE CONDITIONS TECHNICAL REQUIREMENTS INSPECTION. CODES AND STANDARDS The equipment shall comply with the requirements of latest revision of the following standards issued by BIS (Bureau of Indian standards I unless other wise specified: IS.3 2. The equipment shall also conform to the provisions of Indian Electricity rules and other statutory’ regulations currently in force in the country./ BS / VDE/IFEE/NEMA or equivalent agency shall he applicable. testing. packing and despatch of static Uninterrupted Power Supply (UPS) system.5 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 3 of 25 © GAIL – All rights reserved . manufacture.2 2.4 2. 13703 (Part Ito 4) IS: 13947 (Part-4/ Sec-I) In case of imported equipments standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards. the following order of priority shall govern: o Statutory regulations o Data sheets o Job specification o This specification o Codes and standards 2 2. In case Indian standards are not aailab1e for any equipment. In case of any contradiction between various referred standards/specifications’ data sheet and statutory regulations. standards issued by IEC.1 SCOPE The scope of this specification is to define the requirements of design. 5 IS: 1248 15:2147 IS 3700 (Part I to 11) IS: 3715 (Part I to 4 IS:4411 IS: 5001 (Part I & 2) IS:54b9 (Part 1 to 3) IS 7204 (Part I to 4) IS: 12021 IS: 133 14 IS.1 2. engineering and manufacturing of the complete system to fully meet the intent and requirements of this specification and enclosed data sheets. isolating and protection devices and all other equipment! accessories required for completeness of the system whether specifically mentioned herein or not. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment at least for 15 ‘years from the date of supply. but necessary for completeness and satisfactory performance of the system. SPECIFICATION S-07-02-018 REV-0 Page 4 of 25 3. manual by pass switch. Components shall be capable of withstanding the thermal and dynamic stresses resulting from internal and external short circuits and switching surges etc.2 GENERAL REQUIREMENTS The offered equipment shall he brand new with state of art technology and proven field track record. AC distribution hoard. monitoring and safeguarding function in continuously operating petrochemical process units. static inverters. The UPS system shall be suitable to feed all loads connected to the output which are primarily instruments. Selection.3 3.3 3. controlling. utility and other miscellaneous industrial plains.7 3. petroleum refineries. No prototype equipment shall he offered. voltage stabilizer in bypass. DIDC (DCS). Vendor shall give a notice of at least one year to the end user of equipment and GAIL before phasing out the product/spares to enable the end user for placement of order for spares and services The UPS system shall he an integrated system comprising static rectifiers. battery. The inverter shall he transistorized (IGBT) type or with the latest proven technology. static switches. sizing and suitability of all equipment and components used for UPS system shall he vendor’s responsibility. The UPS shall he single phase or three phase system as indicated in the data sheets. The design of the UPS shall he such as to minimise the risk of short circuits and shall ensure human and operational safety The vendor shall he responsible for design.6 3. disc drives and other SMPS equipment leading to high crest factor of the load.9 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY © GAIL – All rights reserved .1 3.5 3.8 3. gas processing facilities. computers. All components shall he of a high quality and reliability that satisfy with the requirements of a secure AC power to ital equipment with respect to performance.4 3. 3. UPS system shall be designed to operate satisfactorily while deriving the input power from an emergency diesel generator set UPS system shall also operate satisfactorily on input power supply having. If not specified therein the UPS shall he suitable for the following input power supply.10 4 The batteries shall meet the requirement of battery Data Sheet! battery specifications attached with the hid document SITE CONDITIONS The U PS system shall be suitable for installation and satisfactory operation in a closed substation with restricted natural air ventilation in tropical. One feeder shall feed the rectifier(s) while other shall supply power to stabilized bypass supply UPS Configuration and Operational requirements The UPS system shall have one of the following basic configurations as specified in data sheet and drawings: Single UPS with Bypass (Refer Sketch 1) In UPS system having this configuration a single rectifier and inverter shall be provided.1. If not specifically mentioned therein. value of the harmonic content to the r.2 5. 5 5. Total Harmonic Distortion is the ratio in percentage of r.m. value of the fundamental component of alternating quantity.s.2 The incoming power supply to UPS will he provided by 2 Nos. o the ratio of negative to the positive sequence components not exceeding 5% and o total harmonic distortion of not more than 5%. design ambient temperature of 40C and altitude not exceeding 100CM above MSL shall he considered for the UPS TECHNICAL REQUIREMENTS Input power supply The UPS shall he suitable for input power supply as defined in the data sheet. the SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 5 of 25 5.1 5. humid and corrosive atmosphere.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Voltage 230/415V ± 10% Frequency : 50 Hz ± 5% In addition to above variations. Under normal conditions when AC mains power is available.2.1 5. feeders. the input voltage may be subject to transient variations comprising voltage dip to 20% of normal voltage during motor start-up and voltage interruption during short circuit as well as frequency variations due to large motor start up.1.m.s. The UPS system shall he designed to operate under site conditions as specified in the data sheet. Under normal conditions. the load shall he automatically transferred to stabilized bypass supply and retransfer of load from stabilized bypass supply to the inverter shall be possible in auto as well as in manual mode. In case of failure in one rectifier. In case both the inverters develop a fault. the faulty unit shall automatically get disconnected and the entire load shall be fed from the other inverter. the arrangement of rectifiers/inverters and the operating philosophy is same as described in Cl.2 Parallel Redundant UPS with bypass (Refer Sketch 2) In UPS system having this configuration two sets of rectifiers and inverters shall he provided. In case of AC input power failure or battery charger failure. Each rectifier shall be equipped with On Line automatic as well as manual charging facility. The charger shall be designed for simultaneously feeding complete inverter load and for float/rapid charging the battery to its rated capacity. Retransfer of load from stabilized bypass supply to the inverter shall he possible in auto as well as in manual mode. Normally both inverters will he synchronised with each other and with stabilized bypass supply. when AC mains power is available. 5. Charger shall be equipped with on-line automatic as well as manual charging facility.2. except that only one inverter shall be operating at one time The other inverter shall not be sharing the load but shall be synchronised with the running inverter and stabilized bypass supply and remain ready to accept the load in case of fault in the running inverter.3 Hot stand-by Redundant UPS with bypass In UPS s stem having this configuration. In case of incoming supply failure or failure of both rectifiers the battery shall feed the inverters without any interruption. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 6 of 25 © GAIL – All rights reserved .rectifier shall simultaneously feed power to inverter as well as for float/rapid charging of the battery The AC supply to loads shall he fed from inverter output. Each rectifier shall he designed for simultaneously feeding complete inverter load and float/rapid charging of the battery to its rated capacity. the other rectifier shall feed the complete load and the battery without any interruption. Both inverters shall operate in parallel and share the load equally When a disturbance/fault occurs in any one of the inverters. in case of any fault in the inverter. 5. the complete load shall he transferred to stabilized bypass supply through the static switches and retransfer of load from stabilized bypass supply to the Inverter shall be possible in auto as well as in manual mode.2.2. both the rectifiers shall operate in parallel and supply DC power for float/rapid charging the battery and simultaneously to inverters.5. the battery shall supply power to . ‘‘ inserter without any interruption.2 above. 5. All rectifiers shall also have a double wound transformer at its input.3. The performance of UPS system shall not get affected or in any way be degraded by the use of portable radio transmitter receiver in the vicinity of the UPS system and or UPS room.3. UPS Design and Performance Requirements Incoming AC supply shall he converted to DC through three phase full wave controlled rectifiers 1 he rectifiers shall operate according to the constant voltage current limiting principle and shall incorporate a “Soft Start” feature to gradually accept load on initial energising. The rectifier section of the UPS system shall be capable of precise regulation to prevent damage to the battery. For ease of maintenance. The production of radio frequency interference voltage shall not exceed the value of suppression grade N as defined in VDE0875.3 5.3.3 5.2.7 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY © GAIL – All rights reserved .2 5. The UPS system shall be designed to draw power from mains supply at a minimum power factor of 0. it shall he possible to isolate inverters and static switches from load through manually operated make before break switches.5 5. combination of breakers with the control scheme having make before break logic may be provided which ensures momentary parallelling before tripping of selected breaker. In case of larger rating UPS. The UPS system including the stabilised by-pass shall he galvanically isolated from input power I .3.85 while working at rated load in normal operating UPS configuration SPECIFICATION S-07-02-018 REV-0 Page 7 of 25 5.4 5.3. the facility for uninterrupted manual transfer in either direction through static switches shall also be provided.1 5. The output voltage of rectifier’s DC bus without the battery shall be stabilised to within ± 1% of set value during load variation between 0 to l00 of the rectifiers and specified mains input supply voltage variation. supply system by providing double wound transformers. dry type suitable for location inside the panel. An RFI filter shall be provided. Transient/surge protection circuit shall be provided in the input circuit to rectifiers to protect the UPS from surges & voltage spikes.3.3.2. where it is not possible to provide one power switch with make before break feature. All transformers shall he natural air cooled. Suitable protection shall be provided in the control circuits to guard against instability of phase controlled rectifiers due to electrical oscillations which may be present in the input supply as caused by emergency DG set.4 5.6 5.5 In all UPS configurations. 11 The rectifiers/chargers shall he designed to completely charge the Lead acid and Nickel cadmium batteries in a maximum time of 10 hours after complete discharge. the charging shall he transferred from rapid to float mode after a preset time adjustable through 024 hours timer as back up protection against over charging The rectifiers shall be sized based on the maximum inverter input load when inverter is delivering its rated output at 0. The inverters may be disconnected during initial charging of the battery.5. Minimum end cell voltage for lead acid/VRLA battery 1 . The DC load imposed by the inverters shall be considered under the most severe operating conditions where only one rectifier is operating but the UPS load is equally shared by’ all the inverters. 5.0 V per cell for Ni-Cd battery g. of cells 5.95 d. Minimum ambient temperature as specified in Data sheet. a.3.f.9 5.3. lagging and recharge the battery to nominal rated capacity of the battery. Load Power Factor of 0.8 b. Battery state of charge factor of 0.8 Back up time of 30 minutes in case of mains power failure unless specified otherwise in data sheet f. BatteryCur rent Inverter rated kVA * Rated load p.14 Ah (10 hr. Battery charger for VRLA battery shall he sized to provide boost charging of the battery up to 90% of rated Ampere hours within a duration of 24 hours and to 100% within 4 days. e. Facilities shall be provided to initiate battery rapid charge operation by manual & automatic means. Facility for initial charging of batteries shall also be provided.85 V per cell and 1.10 Aging factor of 0.8 The UPS shall be provided with automatic sequence and power walk in circuit(s) with time delay of upto 15 sec. c. In addition to above. For battery sizing. Rating of the battery) SPECIFICATION S-07-02-018 REV-0 Page 8 of 25 5.8 p. such that the rectifiers and inverters can start operating automatically when incoming AC power is restored allowing the UPS to he loaded automatically.3. The rating of each rectifier shall he not less than the value calculated as follows: For Lead Acid Batteries = inverter input current + 0. An auto charging sequence should be provided for the rapid and float charging based on current sensing.12 - GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY © GAIL – All rights reserved .3. the following factors shall he considered unless specified otherwise in the data sheet. f Inverter efficiency * Rated end cell voltage * No.3. 15 5. value of the harmonic content to the r.3. controlled and limited to set value automatically irrespective of the inverter input current. o Load current waveform having a relative harmonic content varying between zero and 50%. For VRLA Batteries = Inverter input current + 0.2Ah ( 10 hr.14 5.- For Nickel. Ripple content at the DC link shall not exceed 2% even with battery disconnected. Battery D. link shall be provided with a sensitive earth leakage protection. The inverter output voltage and frequency shall not exceed the operational tolerances. Rating of the battery) Where Inverter InputCurre nt RatedkVAcapacity of UPS*Load p. A separate current limit circuit shall also he provided for adjustment of battery current.m.m.5 and individual harmonics not exceeding the following values 3rd harmonic . the latter waveform having a crest factor not exceeding 2. f Battery chargingvoltage * Inverter efficiency 5.3. The battery may be taken out of service for maintenance.7 lagging to unity.e. Subsequent to a discharge cycle when battery is connected to rectifier.s. relative harmonic content rms value of fundamental component of current or voltage 2 1 rms value of total waveform of current or voltage 5.13 The DC rectifiers shall sense the battery charging current and adjust the DC bus voltage to maintain the charging current to preset level.Cadmium Batteries Rating of the battery) = Inverter input current +0. The inverter shall be of the current limiting type (short circuit proof) and have nominal output voltage and frequency as specified in the data sheet.3.s value of the total non-sinusoidal periodic waveform i. the battery current shall he monitored.3. during which period it shall be possible for the inverter to continue operation by drawing power from the rectifier.C.20 Ah (5 hr.34% of fundamental 5th harmonic 33% of fundamental 7th harmonic 1 8% of fundamental 9th harmonic 7% of fundamental 11th harmonic 10% of fundamental The Relative harmonic content is the ratio of the r. as measured at the output terminals of the unit during the following conditions of UPS loading: o Load variations between 0-100% of’ the rated output of UPS o Load power factor over the range of 0. The rectifiers shall be protected against reverse battery connection at DC link voltage bus.16 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 9 of 25 © GAIL – All rights reserved . 18 5.8 p.7 lag to 1. The inverters shall he ‘phase locked’ to the stabilized bypass power supply as long as stabilized bypass supply frequency remain within ± 4% of nominal. The overall efficiency of the UPS system shall not be less than 80% at rated load and 0. and not exceeding 15% under the rion4inear load conditions .3. During variations in mains frequency exceeding these limits.22 5.19 5.23 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .3.7 lag to 1 0. This adjustment shall he possible to be made when the inverter is in operation. When bypass supply frequency variation exceeds the above limits.20 5. The UPS shall have capacity to deliver a minimum overload of 125% for 10 minutes and 150% for 10 sec. The phase angle disturbance shall he less than 120 ± 3% in case of 3 phase inverter. the inverter shall revert to internal frequency control. It shall be possible to vary the inverter output voltage steplessly within ± 5% of the specified output voltage.21 5. 1 Sec.3. 5. Facility shall also be provided for adjustment of range of synchronising frequency. the UPS system output voltage variation shall not exceed ± 10% and complete recovery to normal steady state shall be within 0.3.3.f.3. The steady state output voltage and frequency (free running) variation of inverters shall not exceed ± 1% from the set value for specified input power supply conditions from no load to full load condition and load power factor variation from 0.3. The above requirement shall be complied for following transient disturbances : o 100% step load and unload (For single UPS and hot stand by UPS o 50% step load (for parallel redundant UPS o Momentary interruption in power supply SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 10 of 25 5. UPS shall be provided with current limit circuit to avoid excessive loading beyond its permissible overload withstand capability.DC input voltages over the range corresponding to battery rapid charge and battery discharge operation during the specified discharge times.0. The UPS system shall he able to operate satisfactorily on rated loads (in kVA) with power factors in the range of 0. Unless otherwise specified. specified above. the inverters shall be de-linked from mains. Free running frequency tolerance limit shall not exceed ± 1 % .17 The inverter shall control the output voltage of the UPS such as to maintain synchronism with the mains bypass voltage during variations in mains frequency up to the limits specified. The UPS output voltage waveform shall be sinusoidal with a relative harmonic content not exceeding 5% under linear load conditions. 3.26 5. The type of Voltage stabilizer in stabilized bypass supply shall he as indicated in data sheet . The load transfer devices shall comprise of continuously’ rated static elements in both inverter and stabilized bypass supply. SPECIFICATION S-07-02-018 REV-0 Page 11 of 25 5.28 5.30 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY © GAIL – All rights reserved . Facility shall be provided to manually and automatically initiate transfer of the load from inverters to the stabilized bypass supply and from stabilized bypass supply to the inverters. UPS system shall he suitable both for floating output or earthing of one leg star point in case of single phase! three phase system respectively.3. The stabilized bypass supply shall have a continuous current rating equivalent to the rated output of the UPS unit and be capable of conducting a current ten times the rated output for the duration more than the fault clearing time of the type of fuse provided.27 5. The short time rating of all the static switches shall be at least 10 times the rated output for the duration more than the fault clearing time of the type of fuse provided. 5. the maximum output voltage and angle variation between the phases should nor exceed 6% and S degrees respectively even under the condition of 100% unbalanced loading of the S phase output. Under voltage and over voltage sensing levels to initiate transfer shall be adjustable.o Load transfer to stabilized bypass supply o Complete load transfer to other healthy inverter when one of the to parallel inverters develop a fault.3.3. The maximum transfer time between inverters and bypass supply shall not exceed 4 msec and 20 msec in synchronous and asynchronous mode respectively.29 5.3.24 For 3 phase UPS system.3. The stabilized bypass supply shall he designed to regulate the output voltage within 2% of the rated voltage over complete range of load from no load to full load and fir specified input supply voltage variation.25 5. The criteria for load transfer: A) Load transfer from inverter to the stabilized bypass supply shall he as follows: a) The load transfer shall only he possible when o the stabilised bypass output voltage is within ± 5 % of rated UPS output voltage and o the mains bypass frequency is within ± 4%.3. Adequately rated static switches in required number & configuration shall be provided in the Inverter(s) output and stabilized bypass supply to ensure positive isolation of faulty inverter section such that the other inverter and bypass circuits do not feed into the fault leading to under voltage / trip. Parallelling of breaker! switch! contactor poles to achieve the required current rating is not acceptable. 5.3.31 All breakers shall he adequately rated for continuous rating as well as breaking capacity as applicable. breakers. OR o the inverter output current exceeds its tolerable limits. All other electrical components such as transformers. then the retransfer of load to the invertors shall he inhibited following four automatic transfers of load to stablised by pass within a period of 5 minutes.3. shall he rated for at least 125% of the maximum required rating. diodes and other electronic devices of UPS shall be protected with high speed semiconductor fuses 12t coordination between fuse and semi-conducting power devices shall be ensured. shall he rated under operating conditions for approximately 200% of the maximum current carried by the device. reactors. All the thyristors. B) Retransfer of load from stablised bypass supply to the inverter shall he as follows: a) The load transfer shall he possible when o The inverter output voltage is within ± 5% of nominal output voltage a. and inverter output and o stablised bypass supply are synchronised Retransfer of load from stabilised by pass to the inverter shall be done manually only unless otherwise specified in the data sheet If automatic retransfer of load to the inverter is specified in the data sheet. No electronic device shall he subjected to PIV greater than 50% of its rated value. contactors. 5.32 5. diodes etc. All output isolating device shall be double pole type. power transistors.b) Auto-transfer of the load from inverter to stabilized bypass supply shall be initiated when: o the inverter output voltage drops below 95 % of nominal output voltage under steady state condition and/or if the inverter output voltage falls below 90% of the nominal value tinder transient conditions. transistors (IGBTs). for more than 5 sec. switches.3.33 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 12 of 25 © GAIL – All rights reserved . busbars etc. All electronic power devices including thyristors. OR o The inverter output voltage exceeds 105% of the nominal output voltage under steady state condition and/or if the inverter output voltage reaches 110% of the nominal value under transient conditions. Forced ventilation of panel. normal & redundant fans shall run together.3. Hinged doors shall he provided at the front and 5. The frames shall he fabricated by using minimum 2mm thick CRCA sheet steel while the doors and covers shall he made from 1. the load connected to the healthy circuits shall not get affected The fault clearing time shall be less 2 than 4 msec. The power supply for the fans shall be tapped from the inverter output.4. in normal operation. Monitoring points shall be provided on each of the PCB’s and the PCB shall be firmly clamped in position so that vibration or long usage do not result in loose contacts.6mm thick CRCA sheet steel. Failure 7 of each PCB shall he indicated by visual alarms. fitted with suitable louvers for ventilation and cooling fans as required. Visual fault diagnostics shall preferably identify faults upto various sections in the card. All PCBs shall be provided with a transparent epoxy coating for environmental protection and trivialization.3.36 5. Wherever required suitable stiffeners shall he provided. The fans shall be arranged to facilitate removal of faulty fan for maintenance without requiring system shutdown.4 5.37 5. However. Each inverter shall he designed to clear a fault in any of the branch circuits upto a maximum rating of 25% of the system capacity without the assistance of the stabilized bypass supply.3. They shall he suitably located away from heat sources. the rating of the UPS as specified in the data sheet shall he the net output of UPS after deducting power consumption for fans etc. ACDB and cell booster enclosures shall be fabricated from structural CRCA sheet steel. The frames shall incorporate guides for PCB’s to facilitate correct insertion of PCB’s and shall allow access to the wiring side of the connectors All PCBs shall be placed in a manner to avoid replacement of a PCB by a wrong spare PCB.35 5. However in case of non-operation of 50% of running fans the UPS output shall not be affected.3.3. stabilized bypass supply and static switch sections shall he suitably housed in sheet steel panels complete with all interconnections. Maximum noise level from UPS system at 1 metre distance. The panels shall he free standing.5.38 5. under rated load with all normal cooling fans shall not exceed 75 dBA Construction Rectifier/charger and inverter. if provided. All electronic control and monitoring printed circuit cards shall be installed in standardized electronic equipment frames and shall he fitted with suitable means for easy removal.34 The outgoing circuits of ACDB shall be protected by semiconductor fuses.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 13 of 25 © GAIL – All rights reserved . shall be supplemented by 100% redundant fans. In case of any fault in branch circuits. UPS panels. All wires shall he ferruled and terminals shall be numbered.4. 1.4. Analogue instruments’ scale shall have red mark indicating maximum permissible operating rating Separate test terminals shall he provided for measuring and testing of the equipment to check the performance. square (Analogue type) of reputed make.4.3 5. Bus bars shall be colour coded and live parts shall be shrouded to ensure complete safety to personnel intending routine inspection by opening the panel doors.5 mm2 size wire SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 14 of 25 5.6 5. Bolted type terminals suitable for cable lugs shall be provided for wire size above this.back with dust tight gaskets. Inside the panels.2 Power cables shall be with aluminum / copper conductors and control cables shall he with copper conductors All the cable connections shall be from bottom and front of the panel.5 5. The minimum size of earth bus shall be 25 x 3 mm2 copper (or equivalent aluminium). The control switches shall he rotary type. All instruments shall he analogue/digital. MCCBs and load break power switches shall be mounted inside the panel. All the equipment inside the panel and on the doors shall have suitable name plate and device tag numbers as per the schematic diagram. The enclosure shall provide minimum lP-31 degree of protection. the controls connections shall be done with 660V grade PVC insulated wires having stranded copper conductors. Clamp type terminals shall be used for connection of all wires upto 10 mm2. Copper conductor PVC insulated cables or wires of 660V grade shall he used for power circuits rated less than 100 Amp. Inter panel sheet steel barriers shall he provided. A removable bolted gland plate shall be provided along with single compression type nickel plated brass cable glands for external cable connections. mounted on the door and shall be externally operable. A suitably sized earth bus shall he provided at the bottom of the panels including ACDB running through the panels line up with provision for earth connection at both ends to purchasers main earth grid.4.7 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . switchboard type. 5. Tinned copper lugs for all external connections shall be provided with the panels Bus bars shall be used in all power circuits which are rated above 100 Amp. The maximum and minimum operating height of the switches shall be 1800 mm and 300 mm respectively. if not specified otherwise in the data sheer.4. All panels shall be of same height so as to form a panel lineup which shall have good aesthetic appearance . An 11W CFL lamp controlled through a door switch shall be provided for illumination in each panel.4. hack connected.4 5. 72 x 72 mm. if nor specified otherwise in the data sheet. All potential free metallic parts of various equipment shall he earthed suitably to ensure safety. 2.2 x Ah of cell (10 hr. runoff paint. All metal surfaces shall he thoroughly cleaned and dc-greased to remove mill scale..14 x Ah of cell (10 hr.AC/ DC power ON. 12.2 x Ah of cell ( 5 hr.8 shall normally he used for circuits with control fuse rating of 10 Amp.9 5.5.5. It shall be suitable for charging not only the new cells before being introduced to the battery hank hut also any treatment to he given to the individual weak cells.4.4. Cell booster shall be suitable for 240 V ± 10% 50 Hz ± 3% SPN input power supply. Suitable interlock shall be provided so as to ensure that the variac’ controlled rectifier is at its minimum position while switching on the cell booster. Cell booster shall be portable type with wheels. Cell Booster Cell booster shall he suitable for charging one to six cells within a time duration as specified at Cl. After preparation of the under-surface. Each cell booster shall be supplied with 5 m long flexible copper conductor. Rating of the cell) Cell booster shall have heavy duty switch fuse or MCCB on AC incomer and DC output. indicating lamp for . orange peels. DC ammeter and voltmeter. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer.5 mm dia. Rating of the cell) o For VRLA battery = 0.5 5.12V for Lead Acid and Nickel Cadmium batteries respectively.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 15 of 25 © GAIL – All rights reserved . rust. Cell booster output voltage shall be in the range of 0 -18 V and 0 . or less. The output voltage and current of cell booster shall have manual control using a suitably rated variac or a full wave controlled rectifier bridge. Quantity of such boosters shall he as defined in the MR.4. Cell booster shall be sized as under: o For Lead Acid battery 0.5.10 5. etc. Panel finish shall be free from imperfections like pinholes. All control wiring shall preferably be enclosed in plastic channels or otherwise neatly hunched together. Rating of the cell) o For Ni-Cd battery 0.5 mm2 size wire shall he used. grease and dirt Fabricated structures shall be pickled and then rinsed to remove any trace of acid. For control circuit having fuse of 16 Amps. Each wire shall be identified at both ends by PVC ferrules. Ferruling of wires shall be as per relevant IS. PVC insulated and braided cable for AC incomer power supply and DC output connection to the battery. AC voltmeter. Control wiring for electronic circuits shall he through flat ribbon cable or through copper wire minimum of 0. 5. The vendor shall furnish the painting procedure along with the bids.3. The under-surface shall he made tree from all imperfections before undertaking the finished coat. the panels shall be spray painted with two coats of epoxy based final paint or shall he powder-coated. Spray painted finished panels shall be dried in stoving ovens in a dust-free atmosphere. 1.7 5. Metering.7.1 5.C. fixed type with compartmentalised construction unless otherwise indicated in the data sheet. An illuminated one line diagram indicating operational status shall he provided on the front of the panel. following schedule shall be followed for alarm. Any additional devices/features considered necessary for reliable operation and maintenance shall also be included in various panels and same shall he highlighted separately .(For all the three phases) c) D.1. All outgoing switches shall he air insulated load break type.7. audio-visual alarm shall he provided Parameters! information indicated shall he available in LCD panel or by other means directly or indirectly. Inverters a) AC voltage at each inverter output (AC voltages for 3 phase inverter) b) AC current at each inverter output (AC currents for 3 phase inverter) c) Frequency meter at each inverter output Stabilized bypass supply a) Frequency meter for incoming supply. b) Voltmeter with selector switch for incoming supply.C.1 5. Cable glands shall he of brass and single compression type and cable lugs shall be of tinned copper. Fuses on outgoing feeders shall he fast acting semiconductor type and cable entry shall he from bottom. Metering Rectifier a) Incoming line voltages (For all the three phases). It shall he possible to operate the switches without opening the doors.6 A. voltage at each rectifier output.1. Suitable supports shall he provided for supporting incoming and outgoing cables.7.1. indication and annunciation. Distribution Board Sheet steel enclosed AC distribution hoard shall he provided as part of the complete UPS package It shall accommodate AC feeders as indicated in the data sheet. The gland plate of the distribution board shall be non-magnetic type where single core cables are used as specified in the data sheet. Alarm. ACDB Following shall be provided for each of the ACDB incomers SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 16 of 25 5.2 5. control. Control.7. indications. Vertical cable alley of minimum 200mm width with suitable supports shall be provided for the termination of outgoing cables. Switches shall be provided with door interlock. d) Battery current. c) Ammeter with selector switch for incoming supply. b) Input line currents.4 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .5.7. Indication and Metering Requirements If not specified otherwise in the data sheets.3 5. The distribution board shall he floor mounted. Controls a) All the switches for starting.2 5.3. b) Primary input circuit breakers for feeding chargers.3 5. b) Ammeter (ammeter selector switch shall also he provided for 3 phase inverter).7. ma be provided in place of lamps subject to their having at least equal illurninance).7.1 5. Clustered/Jumbo LED’s of minimum 10mm dia.4 5. Audio-Visual Alarm ( separately for each circuit) a) Mains failure b) Battery charger failure c) Battery fault d) Inverter temperature high e) Low voltage from inverter f) Load on bypass g) Inverter overloaded h) All power Fuse Failures Two nos changeover contacts shall be wired to the terminal strip. bypass line and dc bus from battery including backup protection.7.2.7.7.7. Load on bypass.Voltmeter (voltmeter selector switch shall also he provided for 3 phase inverter).2. Rectifiers (for each rectifier) a) Rectifier output ‘ON b) Battery on float charge c) Battery on rapid charge Inverters (for each inverter) a) DC input ‘ON b) Load on inverter c) Inverter synchronised with mains. c) Inverter ON/OFF switch (to initiate inverter operation) SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 17 of 25 5.7. c) Power factor meter a) 5.Rectifier b) AC mains ON Bypass.1 5. Mains/Bypass a) AC mains ‘ON .4 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .2 Indications (All indication lamps shall he provided with series resistors.2. shut down and testing sequence.3 5. 1 no for common remote alarm of UPS fault in owners panel and 1 no for load on bypass supply annunciation.7.2. d) Static switch transfer test Push Button. 5.g. In addition to the above.3 5. between main and redundant units (e. 5. o Changeover time in case of inverter to stabilized bypass supply and from one inverter to other inverter. currents. Following design consideration shall be taken into account to ensure maximum availability of the system. frequency as a minimum under the following conditions o UPS power source changeover from mains to battery.4 5. Series-parallel combination of smaller devices to achieve required rating shall not he acceptable.8. o Changeover from inverter to stabilized bypass supply and vice versa o Changeover from one inverter to other inverter. There shall he no common device. testing and commissioning of 2 the equipment for ensuring high system reliability.9 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 18 of 25 © GAIL – All rights reserved . o Type of failure incident along with diagnostic report. each UPS set shall have provision for adding microprocessor based ON line fault diagnostic unit.8. master oscillators etc.8. any other feature which vendor feels may he useful shall he provided and highlighted separately. design. It shall be possible to take out any individual power circuit for maintenance without affecting the total UPS supply. o UPS power source changeover from battery to mains. Fault Diagnostic Unit If specified in the data sheet. The software shall be provided on a CD ROM.1 5.) in order to ensure that the failure of the same does not cause shutdown of more than one unit. input/output voltages. This shall supervise the UPS operation continuously.8. Vendors shall offer their nearest higher standard size that will meet the requirement of the specified UPS rating. Fault Diagnostic unit shall he compatible to hook up with owners PC through RS232/RS385 interface. manufacture. It shall identify and locate faults immediately so that corrective action can he taken. The fault diagnostic unit shall have provision for automatic print out facilities for time.2 5. o UPS failure.8 Reliability All necessary care shall he taken in selection. If any additional equipment (e. The unit on test shall withstand the specified voltage for 1 minute.1 INSPECTION . the equipment shall he subjected to inspection by Owner or by an agency authorised by the Owner. In the case of AC power frequency voltage test. the value of DC voltage shall he equal to the crest value of the test voltage specified in the table Vp 2 Vp is the highest crest voltage to be Test Voltage (AC r.C.1 Insulation tests Insulation tests shall be performed as per IEC 60146-1. The tests certificates indicating test results shall he furnished. the same are also to he included in the vendors scope.-I The insulation tests shall be carried out using an AC power frequency voltage or by using DC Voltage at the choice of the vendor. but not exceeding 100Hz of the full value starting at a maximum of 0. the test voltage at the frequency available in the test facility or at the rated frequency. adaptor cards etc.3 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . All tests shall be witnessed by owner or its authorised representative and 4 weeks prior notice shall he given before the date of commencement of tests. input failure test SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 19 of 25 6.2 6.2.u.2 Interconnection cable check The interconnection cable are to he checked for correct wiring.g. Manufacturer shall furnish all necessary information concerning the supply to Owners inspector. Following system acceptance tests shall be conducted on each UPS system: 6. In case the DC voltage is used for the test.TESTING AND ACCEPTANCE During fabrication.2. 6 6. Tests shall be carried out at manufacturers works under his care and expense UPS system shall be tested in accordance with applicable standards.2.) are required for connecting this unit with UPS system as well as with owners PC.m.s Value) expected between any pair of terminals ≤60 V 500 V ≤125 V 1000 V ≤250 V 1500 V ≤500 V 2000 V 6. bin connector. The following acceptance tests shall he performed on each UPS system as a minimum.5 p. insulation and quality of the terminations A. 6. DC link voltage. input return test The test is performed by closing ac.The test is performed with the test battery and carried out by tripping ac. phase current and input power. output power and current. Rectifier measurement shall comprise of o Input voltage.C.2. voltage. voltage and at no load.C. Following parameters of rectifiers and inverters are to measured Measurement shall be carried out in the rectifier float charge mode and in rapid charge mode. frequency and waveform distortion. output active power and frequency at no load.C. 50% load and 100% of rectifier full load. Output voltage and frequency ‘variations are to he checked for specified limits. Measurement shall comprise of o Input voltage.7 and 0. incoming circuit breakers or is simulated by energising rectifiers and bypass supply.4 A. output voltage and current.7 SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 20 of 25 © GAIL – All rights reserved . output voltage. input current.8 p.2. Inverter measurement shall also be at no load. GAIL (INDIA) LTD NEW DELHI 6. incoming circuit breakers or by switching off rectifiers and bypass supply at the same time.5 6. output distortion.f.2.6 6. input active power. o Ripple current at the DC link bus shall he recorded after isolating the test battery. output current.2. 50% load and 100% load at 0. Simulation of parallel redundant UPS fault The test is applicable for UPS with parallel redundant configuration Fault of rectifier or inverter are to be simulated and output transients are to he recorded. frequency.C input voltages corresponding to battery float charge operation as well as rated inverter maximum and minimum input D. o Output voltage. input current. Proper operation of rectifiers starting and voltage and frequency variations of output are to be checked. 50% load and 100% load of inverter rated output current and shall he repeated for inverter D. o D. Regulation test This test shall be carried out by measuring input voltage. Measurement shall he at nominal ac. Transfer test Transients shall he measured during load transfer from inverter to bypass supply caused by simulated fault and load retransfer after clearing the fault. 13 Auxiliary equipment and control circuit tests The correct functioning of all measuring instruments.2. The temperature of all UPS panels are also to be recorded.8 power factor with temperature rise measurement The test is required to he performed by connecting resistive load or resistive and inductive load to the UPS system output.11 6. UPS system in this test shall undergo a complete fill load test for 32 hours at 0. Steady state temperature of rectifier transformer. a) Output voltage and frequency and correct operation of meters. In case of failure of any component during testing. shall he recorded during the lest.2. b) Operation of all control switches and other means to put UPS system into operation. The functioning of auxiliary devices such as lighting.9 6. for 50%. c) Functioning of protective and warning devices Burn-in test for Printed circuit boards PCBs and other electronic components sub assemblies shall undergo a burnin test for 96 hours at 50o C at a voltage varied between the maximum and minimum supply voltage. Current division in parallel UPS Load sharing between UPS units shall he measured with a dummy load under parallel redundant UPS configuration Light load test The test is to verify that all functions of the UPS system operate properly.8 UPS efficiency This shall he determined by the measurement of the active power input and output at rated p.10 6. The load applied is limited to some percentage of rated load The following points are to he checked. the by pass section shall he subjected to full load test. the tests shall be repeated after replacement of the faulty component. indications.6. 6. inverter set.2.2.2. annunciation etc.8 power factor. 75% and 100% load. static switch etc.2. The load shall be placed outside the test room to avoid influences of its heat upon UPS ventilation. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 21 of 25 © GAIL – All rights reserved . DC choke. Continuous full load test at 0. protection devices and controls are to he verified. rectifier set. should he checked. Out of these 32 hours. each inverter section shall he subjected to full load test for 8 hours both invertors sections operating in parallel shall be subjected to full load test for 8 hours and the for remaining 8 hours. cooling fans.f. alarms.12 6. Short circuit fuse test Fuse tripping capability of the UPS system is to be tested by short circuiting the UPS system output via a specified rating of fuse.15 6.2.21 6. Values of output voltage and output current are to he recorded.20 6. Short circuit current capability test Specified short circuit current capability is to be tested by application of a short circuit to UPS output if necessary via a suitable fuse.2.2. 50% load and 100% load conditions. The specified voltage and phase angle variation may he checked for compliance with specified values.2. Output voltage unbalance (For 3 phase UPS only) Output voltage unbalance shall he checked under symmetrical load conditions and unbalance load conditions.22 6. Output over Voltage Operation of output over voltage protection is to he checked.19 6.14 Synchronisation test Frequency variation limits of inverter is to he tested by feeding bypass supply incoming line by variable frequency generator and inverter synchronisation limit is to he checked as specified. Harmonic components Harmonic components of output voltage are to be recorded at no load.18 6.2.6.17 6. Harmonic voltages caused by UPS system components in the AC.2. Unbalanced load test (For 3 phase UPS only) Unbalance load at specified limits is applied to the UPS system. Phase angle variation may he measured for phase to phase and phase to neutral voltages Overload capability test Specified values of short time overload are to he applied for specified time interval.23 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 22 of 25 © GAIL – All rights reserved . incomer side shall he recorded at site 6. Dynamic Response test Output recording at different loads and operating condition to he done.16 6.2. The voltage unbalance is the ratio of highest phase voltage minus lowest phase voltage to the average value. The test is carried out at an appropriate UPS load under normal operation. Phase to phase and phase to neutral output voltage are to be observed.2.2.2. Restart Manual restart to he tested after complete shut down of UPS system. Short circuit current is to be recorded. 2. Audible noise test The audible noise is required to be measured at 1 meter distance from UPS system in at least 4 to 5 locations and its value shall be within permissible limit. UPS output transients are to he measured. It shall he Vendor’s responsibility to arrange necessary instruments and tools as required by their commissioning engineer for these tests. Crates /cases shall have skid bottoms for handling. The equipment may he stored outdoors for long periods before installation.” etc.2. Special notations such as “Fragile”. If tests show that certain requirements of the specifications are not met. The equipment shall be properly packed for transportation by ship/rail or trailer. shall be clearly marked on the package together with other details as per purchase order. 8 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 23 of 25 © GAIL – All rights reserved . The equipment shall be wrapped in polyethylene sheets before being placed in wooden crates ‘cases to prevent damage to the finish. An earth fault is also to be applied to the battery terminal and UPS system output transient shall he measured. PACKING AND DESPATCH All the equipment shall he divided in to several shipping sections for protection and ease of handling during transportation.6. “weight”. The detailed test schedule and test procedure shall be formulated in line with above. vendor shall make necessary corrections to the equipment so that it satisfies all the requirements before acceptance is made. “PO nos. along with the test procedures. allowable tolerance for each test result. vendor shall get approval on the test procedures. Final acceptance testing along with the batteries shall be done at site. “Owner’s particulars”. 6. Before giving call for the witness of the tests. “This side up”.25 7 SITE ACCEPTANCE TESTS Vendor shall furnish Site Acceptance Tests procedure to be followed.24 Earth fault test An earth fault is to he applied to the output terminal of UPS system. Vendor shall also indicate the max. “center of gravity” . The packing shall be suitable for outdoor storage iii areas with heavy rains and high ambient temperature unless otherwise agreed. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 24 of 25 © GAIL – All rights reserved . GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY SPECIFICATION S-07-02-018 REV-0 Page 25 of 25 © GAIL – All rights reserved . SPECIFICATION FOR BATTERY CHARGER GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 1 of 19 © GAIL – All rights reserved . 0 2.0 3.CONTENTS 1.0 SCOPE CODES AND STANDARDS GENERAL REQUIREMENTS SITE CONDITIONS TECHNICAL REQUIREMENTS INSPECTION.0 7.0 5. TESTING AND ACCEPTANCE PACKING AND DESPATCH GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 2 of 19 © GAIL – All rights reserved .0 6.0 4. IS 13703 Low voltage fuses for voltages not exceeding 1000VAC or 1500VDC.1 SCOPE This specification covers the design.9) IS 3700 Essential rating and characteristics of semi-conductor devices. In case of any contradiction between various referred standards/ specifications / data sheets and statutory regulations.4 2. In case Indian standards are not available for any equipment. IS 1248 Direct acting indicating analogue electrical measuring instruments and accessories.2 2. 2) IS 5469 Code of practice for the use of semi-conductor junction devices. (Parts-1 to 11) IS 3715 Letter symbols for semi-conductor devices.5) IEC 60146 Semiconductor converters. (Parts-1 to 4) IS 4411 Code of designation of semi-conductor devices.3. unless otherwise specified: IS 5 Colours for ready mixed paints and enamels. (Parts-1 to 4) IS 12021 Control transformers for switchgear and control-gear for voltages not exceeding 1000VAC.3 2. manufacture. IS 7204 Stabilised power supplies dc output. The equipment shall also conform to the provisions of Indian Electricity Rules and other statutory regulations currently in force in the country. (Parts-i.2. standards issued by IEC / BS / VDE/ IEEE / NEMA or equivalent agency shall be applicable. (Parts-i.5 © GAIL – All rights reserved . packing and supply to site of Battery Chargers and Distribution Boards. (Parts-I to 3) IS 6619 Safety code for semiconductor rectifier equipment. testing at manufacturer’s works. In case of imported equipment. CODES AND STANDARDS The equipment shall comply with the requirements of latest revision of the following standards issued by BIS (Bureau of Indian Standards). (Parts-1.1 2.4. IS 5001 Guide for preparation of drawings for semi-conductor devices and integrated circuits. the following order of decreasing priority shall govern: o Statutory regulations o data sheets o Job specifications o This specification GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 3 of 19 2 2. (Parts-1 to 4) IS 13947 Low voltage switchgear and control gear.8. the standards of the country of origin shall be applicable if these standards are equivalent or more stringent than the applicable Indian standards. No prototype equipment shall be offered. petrochemical and gas processing facilities and other industrial plants.5 3. The vendor shall be responsible for design. monitoring and safeguarding functions in continuously operating process units and utility installations of petroleum refineries.4 3. The design of the equipment shall be such as to minimise the risk of short circuits and shall ensure personnel and operational safety.2 GENERAL REQUIREMENTS The offered equipment shall be brand new with state of the art technology and a proven field track record. but necessary for completeness and satisfactory performance of the system. All equipment and components shall be of excellent quality and reliability for providing secure DC power required for vital equipment performance. 3 3. controlling.7 4 © GAIL – All rights reserved . Components shall be capable of withstanding the thermal and dynamic stresses resulting from internal and external short circuits and circuit switching operations etc.1 3. The Battery Charger equipment shall be properly coordinated with the selected Battery to ensure complete compatibility. If not specifically mentioned therein. The Battery Chargers shall be designed to operate under site conditions as specified in the data sheet. The Battery shall meet the requirements of data sheets and specifications attached with the Material Requisition) Bid document. engineering and manufacturing of the complete system to fully meet the intent and requirements of this specification and attached data sheets. humid and corrosive atmosphere. Vendor shall give a notice of at least one year to the end user of equipment before phasing out the product! spares to enable the end user to place order for spares and services. design ambient temperature of GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 4 of 19 3. DC Distribution Board.o Codes and standards. The Battery Charger system shall be an integrated system comprising of static rectifiers.6 3.3 3. SITE CONDITIONS The Battery Chargers shall be suitable for installation and satisfactory operation in a pressurised or non-pressurised substation with restricted natural air ventilation in a tropical. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least 15 years from the date of supply. isolating and protection devices and all other equipment! accessories required for completeness of the system whether specifically mentioned herein or not. Both chargers shall be of identical design and rating.1. Battery Chargers for VRLA battery shall be sized to provide quick charging of the battery up to 90% of rated Ampere-hours within a duration of 24 hours and to 100% within 4 days. Online float charging of the battery assembly while feeding the complete DC load. the input voltage may be subject to transient variations comprising of voltage dips up to 20% of normal voltage during motor start-up. One feeder shall supply power to each rectifier. b.2.2 5.1 TECHNICAL REQUIREMENTS Input Power Supply The Battery Chargers shall be suitable for input power supply as defined in the data sheet. The Battery Chargers shall operate satisfactorily with a total harmonic distortion of up to 5% in the input power supply. Each charger shall be sized for the most stringent of the following duty conditions.2 Ah(C10) of battery (for VRLA battery) = 0. whichever is higher: a. unless specified otherwise.1 5.1.15 x Average DC load + float charging current GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 5 of 19 © GAIL – All rights reserved . voltage interruptions during short circuits as well as frequency variations due to large motor start-up.40°C and altitude not exceeding 1000 m above MSL shall be considered for all equipment. The battery to be connected to the chargers shall be of Nickel Cadmium! flooded electrolyte Lead Acid VRLA type as indicated in the data sheet.1 5. Battery Chargers for flooded Lead Acid and Nickel Cadmium batteries shall be sized to provide quick charging of the battery within a duration of 10 hours. Battery Charger Design Basis The Battery Charger system shall have two chargers (Charger-1 & Charger-2).2. The charger shall be sized as under: Charger rating in Amps. battery) o o the battery assembly. The charger shall be = 0.1 The incoming power supply to the Battery Charger system shall be provided by 2 independent feeders. 5. = 1. Offline quick charging of sized as under: o Charger rating in Amps.14 Ah(C10) of battery (for Lead Acid = 0. The Battery Chargers shall also be designed to operate satisfactorily while drawing input power from an emergency diesel generator set. If not specified therein.1. 5 5.2 5.2 Ah(C5) of battery (for Ni-Cd battery). they shall be suitable for the following input power supply: Voltage : 415V ± 10% Frequency : 50Hz ± 5% In addition to the above variations. when battery is connected to charger under float mode. if required. 4 nos. controlled rectifier bridge with protective devices.1. All SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 6 of 19 5.1. transistors. controlled and limited to set value automatically irrespective of the value of load current. complete with protection to limit the ripple content at the output. a redundant air cooling fan shall be provided for each service.9 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .) connected to 80% tap of the battery bank shall be provided to maintain continuity in the DC supply to the load.components during execution of the order without any claim for extra price or time. the battery current shall be monitored. Fast acting semiconductor fuses shall be provided for protection against internal short circuits.1. Under this condition. Initial charging of the uncharged battery assembly to fully charged condition. Filter circuits consisting of smoothing choke and condenser.1.5 5. diodes etc.2. Subsequent to a discharge cycle and completion of quick charging.1. Silicon blocking diodes (mm. Internal cooling of the charger unit shall preferably be by natural ventilation.(Average DC load Area under the battery duty cycle! battery duty cycle duration).2 5. sizing and suitability of all components used for various applications shall be vendor’s responsibility and the rating of components shall be increased. Protection against reverse battery connection and DC earth fault relay for earth leakage protection shall be provided. Silicon blocking diodes shall be provided in the charger output circuit to prevent back-feed from battery into the charger and filters. Selection.2. c.2. The charger components shall be capable of delivering their rated output with one forced air cooling fan out of service. the chargers shall be protected by rapid shutdown of the semi-conducting power devices. If forced air cooling is necessary.2.2. loss of ventilation alarm / trip with override facilities shall be provided. shall be rated under operating conditions for at least 150% of the maximum current carried by the device.6 5. 5. The high speed semiconductor fuses used for rectifier protection shall be complete with trip indication.2.3 Each charger shall have a 3 phase full wave.2. All electronic power devices including thyristors. In case of chargers with forced cooling. to suit associated .2.1.7 5. Independent current limits shall be provided for charger load current and battery charging current.1.1.8 5. In case of external short circuits. shall be provided. maximum continuous temperature of components shall not exceed the permissible limits.4 5. 85 lag while sharing the rated load in normal operating configuration.16 5.2.limited so as not to cause undue harmful effects on other sensitive equipment operating on the same supply bus.2.1.1. The transformer shall be natural air cooled.11 5.13 5. dry type suitable for location inside a panel. switches. No electronic device shall experience a Ply greater than 50% of its rated value. reactors.17 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 7 of 19 © GAIL – All rights reserved .14 5. for this purpose. The Chargers shall be designed to draw power from mains supply at a minimum power factor of 0. 5.2.1. The production of radio frequency interference voltages shall not exceed the value of suppression grade N’ as defined in VDE-0875. Parallelling of breaker! switch! contactor poles to achieve the required current rating is not acceptable.15 5. I. Suitable protection shall be provided in the control circuits to guard against the instability of the controlled rectifiers due to electrical oscillations which may be present in the input supply as caused by an emergency DG set.electrical components such as transformers. All DC contactors must have a tested! published DC rating equal to or exceeding the most stringent current carrying and breaking requirements while considering adequate design margins.2.2. Suitable filters! harmonic traps shall be provided. Each charger shall be galvanically isolated from the input power supply by providing a double wound transformer at its input.2. as required.1. The performance of the Battery Charger system shall not get affected or in any way be degraded by the use of portable radio transmitter receivers in the vicinity of the chargers. However. All output isolating devices shall be double pole type. An R . The DC contactors shall be operated with a DC control supply using ON! OFF selector switches and not push buttons.1. 5. a high impedance earth fault relay shall be provided for the protection of the battery.2.1. busbars etc.10 The DC system shall be unearthed.1. contactors.1. All breakers shall be adequately rated for the required continuous rating and breaking capacity as applicable.2. Transient! surge protection devices shall be provided in the input circuit of chargers to protect them against surges & voltage spikes. The chargers shall be designed to ensure that the harmonic component in the input currents are . unless mentioned otherwise in the data sheet. filter shall be provided to suppress the radio frequency interference to permissible limits. shall be rated for at least 125% of the maximum required rating. F.12 5. 19 5.1. The process of changeover from float to quick charging and reverting from quick to float charging shall be selectable in Automatic or Manual mode by means of an Auto! Manual selector switch. the battery charger shall initially charge the battery under constant current mode followed by constant voltage (finishing charging) mode or as per the . d. In Manual mode. A backup synchronous or digital timer shall also be provided for initiating the changeover to float mode by default after SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 8 of 19 b. the changeover from quick to float charging shall also be automatic based on current sensing. c.1 a.2 5. When quick charging mode is selected. 121 co-ordination between fuse and semi-conducting power devices shall be ensured.2. Changeover from constant current to constant voltage . both changeover from float to quick charging and from quick to float charging shall be performed manually using push buttons.2.1. diodes and other power electronic devices shall be protected with high speed semiconductor fuses. Similarly.5.2. including: o Filter capacitor fuse failure of either charger o DC output switch OFF of either charger o DC output fuse blown of either charger. Faulty charger shall automatically get disconnected from the healthy system.2. In Automatic mode. Vendor shall specifically ensure that the charger output voltage does not exceed the recommended limits of operation under any conditions of internal! external fault or operation. battery manufacturer’s recommendation. Other specific current! voltage limits during normal charging! operation of the chargers shall also he incorporated in the design of the chargers. the other charger shall float charge the battery while feeding the complete DC load. the changeover from float to quick charging shall be initiated through a current sensor. (finishing charging) mode shall be fully automatic. In case of AC mains failure. Operation and Performance Operation (refer block schematic diagram on last page) Normal operation requires that the battery assembly shall be float charged simultaneously by both Chargers-1 & 2 while feeding the DC load.18 All the thyristors. The Battery Chargers shall be specifically designed to limit float and quick charging voltages to the battery to limits recommended by the battery manufacturer. Output voltage shall be limited to maximum +10% of nominal system voltage when the battery is float charged while feeding the load. However in case of failure of either of the chargers. 5..2. the battery shall continue to supply the load. set at a preset value. GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . the chargers thus operating in parallel and equally sharing the total load. The chargers shall have facility for manual mode of operation in the event of failure of controller under closed loop control. Under constant current boost charging condition.2 a) c) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER © GAIL – All rights reserved . SPECIFICATION S-07-02-019 REV-0 Page 9 of 19 f. The selection shall be done through Auto! Manual selector switch. and load variation of 10 to 100% at any temperature up to the design ambient temperature specified in the data sheet. However. g. the variation in output voltage can be up to ±2% for chargers with rated output voltage up to 24V.2. b) The output voltage dynamic response of the charger unit with battery disconnected shall not vary more than ±10% of nominal output voltage in the event of step load of up to 50% of the rated output.a preset time period. Interlock shall be provided to ensure that when either of the chargers is selected in quick charging mode. Performance Both chargers shall be of solid state design. 5. Facility for Initial charging of the uncharged battery shall also be provided.2. constant voltage and current limit type. h. the DC output current shall be maintained within ±2% of set value. when battery is being quick charged by the other charger. In the event of failure of the charger feeding the load. shall be equal to or less than 2% of the nominal output voltage. continuity in DC supply shall be maintained from the battery to the load through 80% tap of the battery bank followed by full battery supplying the load through contactor C-2 (refer block diagram on last page). On/ Off push buttons etc. it will be disconnected from both the DC load and the other charger operating under float charging mode. i. The timer range shall be 0 to 24 hours or the nearest available as per manufacturer’s standard range. Energisation of contactor for DC critical lighting shall be initiated by means of an AC mains failure relay complete with Auto/ Manual selector switch. The output voltage shall be restored to a value within the steady state limits within 250 msec. e. The output voltage shall be stabilised to within ±1 % of set value in float charging mode for mains steady state voltage and frequency variation of ± 10% and ± 5% respectively. Voltage feedback shall generally be derived from charger output while current feedback from the DC ammeter. The maximum allowable RMS ripple voltage. with battery disconnected. Potentiometers under quick mode for voltage and current adjustment e. Potentiometers under float mode for voltage and current adjustment d. Panel Metering and Indication These shall include but are not limited to the following: a.d) The maximum noise level from the chargers measured at 1 metre distance in any position. Push buttons for float! quick charging mode selection c. at any load between 0.2. Lamps (1) Chargers-1 & 2 o AC power ON (1 lamp for each phase) o Float charger ON o Quick charger ON o Charger fault. (2) Charger-2 o AC input Voltmeter with selector switch o AC input Ammeter with selector switch o DC output Voltmeter o DC output Ammeter.2.100% with all normal cooling fans running shall not exceed 75 dB(A).4 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 10 of 19 © GAIL – All rights reserved . (2) DC Distribution Board 5.3 5. b. Controls Controls shall include but not be limited to the following: a. Others as required. ON! OFF control switch for AC supply to charger (push buttons are not acceptable) b. Meters (1) Charger-1 o AC input Voltmeter with selector switch o AC input Ammeter with selector switch o DC output Voltmeter o DC output Ammeter o DC Voltmeter with selector switch (battery voltage) o DC Ammeter (battery) o DC Earth Leakage Ammeter (mA).2. Auto! Manual selector switch to select mode of operation f.2. (3) DC Distribution Board o DC Voltmeter o DC Ammeter. Facility for bypassing the audio alarm on each charger shall also be provided. Components shall be properly mounted without undue stress.2. PCBs shall preferably be wave soldered. The PCBs shall be firmly clamped in position so that vibration or continued usage do not result in loose contacts.6 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Printed Circuit Boards (PCBs) PCBs used in the chargers shall be made of glass epoxy material. acknowledge. All PCBs shall be fitted in a manner to avoid replacement of a PCB by SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 11 of 19 5. All indicating lamps shall be provided with series resistors. bends.2. test and reset push buttons and hooter shall be provided on each charger for the following annunciations. twists etc. torsion. The rack shall have PCB guides which shall allow the insertion of PCBs smoothly without requiring undue force.5 Annunciation Static type audio-visual annunciator with annunciation windows. Plug-in PCBs shall preferably be mounted in a standard rack and shall be suitable for easy replacement. required for this purpose shall be provided in the chargers. They shall be located away from heat sources. Charger-1 and Charger-2 shall be wired to terminal block for remote annunciation. One summary alarm potential-free contact each for Battery. The rack shall be mounted on hinged pivots to enable it to be turned for access to the back side terminals. o DC under voltage o DC over voltage o DC earth leakage o AC incoming power supply failure o AC input fuse blown-off o Thyristor/ diode failure o DC output fuse blown-off o DC battery fuse blown-off o Filter Capacitor fuse blown-off o Load on Battery (using current direction sensing with time delay) o Battery under-voltage / Disconnected during discharge (using zero current sensing) o cubicle fan failure! cubicle temperature high (for chargers with forced cooling). including DC under voltage relay and current sensors. Copper strips! prints on PCBs shall have smooth edges free from hair line cuts and shall be provided with tin coating.2.2. Any additional relays! components. Clustered/ Jumbo LEDs of minimum 10mm diameter may be provided in place of lamps subject to their having at least equal illuminance. Industrial grade components shall be used in the PCBs and electronic circuits.o C power ON o Outgoing feeder ON (for each outgoing feeder). 5. All PCBs shall be provided with a transparent epoxy coating on both sides for environmental! anti-fungus protection and tropicalisation. 3.3 5. All panels shall be of the same height so as to form a panel lineup which shall have good aesthetic appearance. All the equipment inside the panel and on the doors shall have suitable nameplates and device tag numbers as per the schematic diagram. The DCDB shall accommodate outgoing feeders as specified in the data sheet.6 mm thick CRCA sheet steel.2.2. Unless specified otherwise in the data sheet. refer to block schematic diagram on last page.2. Visual fault diagnostics shall preferably identify faults up to various sections in the card. Wherever required. 5. even if not specifically mentioned. suitable stiffeners shall be provided. Interpanel sheet steel barriers shall be provided. SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 12 of 19 5. the DCDB shall be compartmentalised with each outgoing feeder housed in a separate compartment. Cable alley of minimum 200mm width with suitable supports shall be provided for the termination of cables for each vertical arrangement of outgoing feeders in DCDB.1 Vendor shall provide adequate protection to the system.3. Chargers-1 & 2 shall be installed side by side whereas DCDB may be located separately and interconnected to the charger through cables. The PCBs shall be provided with visual light emitting diode (LED) status indications. The frames shall be fabricated by using minimum 2mm thick CRCA sheet steel while the doors and covers shall be made from minimum 1. Bus bars shall be colour coded and live parts shall be shrouded to ensure complete safety to personnel intending routine inspection by opening the panel doors. The panels shall be provided with suitable louvers for ventilation backed by wire mesh.a wrong spare card. The charger panels and DC distribution board shall be provided with minimum IP-31 degree of ingress protection as per IS-13947 (Part-1).8 5. Each panel shall be provided with an 11W CFL light with a door operated switch and a thermostatically controlled MCB protected space heater.3. All wires shall be ferruled and terminals shall be numbered. Construction of Chargers! Distribution Board Each Battery Charger and DC distribution board shall be housed in a separate free standing cubicle.3. DCDB and Cell Booster enclosures shall be fabricated from structural! CRCA sheet steel. They must be suitable for use in a tropical climate.2.2 The Chargers. For other equipment! component details. monitoring points! test connections and setting potentiometers in a readily accessible location which is visible without removing the PCBs.3 5. Hinged doors shall be provided at the front and back as required.7 5.4 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . 5. Vendor shall ensure that all equipment! components such as incomer switches. power cables shall be with aluminum! copper conductors and control cables shall be with copper conductors. All power and control switches shall be rotary! cam operated type. are suitably located on the charger and distribution board door such that they can be operated without opening the front door. shall necessarily be installed on the front panel door as specified above. All power switches shall be air insulated load break type.3. copper strip connections shall preferably be used for currents exceeding 100A.5 The DCDB incomer and main busbars shall be rated based on the maximum load current considering an additional 10% design margin for contingencies. Analogue instrument scales shall have a red mark indicating maximum permissible operating rating. meters etc.3. All fuses shall be link type and shall be located inside the panel.5 mm2 size wire shall be used. moisture proof and tropicalised.6 5.control wiring shall be enclosed in PVC channels or otherwise neatly bunched together. However. or more.7 5. The insulation for all equipment where provided shall be heat resistant. MCCBs. annunciator windows etc. annunciators. PVC insulated. Diazed fuses shall not be accepted. All cable connections shall be from the bottom of the panel. All . voltage control switches. Ferruling of wires shall be as per relevant IS. For control circuits with fuse of 16 Amps. However. outgoing DC switches.3.3.5 mm2 size shall normally be used for control circuits with fuse rating of 10 Amps. push buttons.5. DC outgoing switches and MCCBs may be installed within the panel provided that they are operable after opening the front panel door. Wires of 1. In case of difficulty in installation on the charger front panel door.5mm diameter. push buttons. Each wire shall be suitably identified at both ends by PVC ferrules. the AC incoming power switches. For all cabling external to panels.9 5. charger mode selector switches. all other selector! control switches. Accuracy class of all meters shall be 1 %.3. BIS marked wires having stranded copper conductors.3. All instruments shall be switchboard type. back connected and 72 x 72 mm square size.8 5. 2. The busbar voltage shall 2 be higher than the recommended boost voltage for the system. or less. The rating shall be selected from standard available ratings and shall be adequate for the expected short circuit current. All power and control wiring connections within the panels shall be carried out with 660V grade. Control wiring for electronic circuits / components shall be through flat ribbon cable or copper wire of minimum 0.10 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Digital meters capable of displaying different parameters can be considered subject to Owner’s approval. indicating lamps. indicating lamps. unless specified otherwise in SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 13 of 19 5. Power switches shall be provided with a door interlock. 4 Cell Booster Cell booster shall be suitable for charging one to six cells within the time duration specified at Cl.1.18V and 042V for Lead Acid and Nickel Cadmium batteries respectively. Cell booster output voltage shall be in the range of 0. Separate test terminals shall he provided for measuring and testing the equipment to check performance. orange peels. Lettering shall be of minimum 6 mm height and edges shall be bevelled at 450 The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale. All potential free metallic parts of equipment shall be suitably earthed to ensure safety. All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust corrosion. Removable bolted undrilled gland plates shall be provided along with single compression type nickel plated brass cable glands for all external cable connections. Cell booster shall be suitable for 240 V ± 10%. A suitably sized earth bus shall be provided at the bottom of the panels running through the panel lineup with provision for earth connections at both ends to owner’s main earth grid. 50 Hz ± 5% SPN input power supply. Cell booster shall he sized as under: For Lead Acid battery = 0.12 5. unless specified otherwise. Panel finish shall be free from imperfections like pinholes. The minimum size of earth bus shall be 25 x 6 mm2 copper (or equivalent aluminium). Nameplates shall be 3 ply white-black-white 2 colour laminated plastic type.13 5.3. grease and dirt.1.14 x AH(CI0 of cell GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 14 of 19 5. 5. The finished panels shall be dried in stoving ovens in dust free atmosphere. After preparation of the under-surface. All panels shall be supplied complete with tinned copper cable termination lugs.3.3. The under-surface shall be prepared by applying a coat of phosphate paint and a coat of zinc oxide! phosphate primer. The under-surface shall be free from all imperfections before undertaking the finishing coat.11 All potential free metallic parts shall be earthed using soft drawn copper conductor wire. Colour of final paint shall be shade 631 as per IS 5. All components! devices! feeders shall be provided with screwed nameplates. It shall be suitable for charging not only new cells before being introduced to the battery bank but also for any treatment to be given to individual weak cells. The maximum height of the operating handles! switches shall not exceed 1800 mm and the minimum height shall not be below 300 mm.3. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. rust. the panels shall be either spray painted with two coats of epoxy paint or epoxy powder coated to a uniform thickness suitable for rugged industrial use. 5. Bolted type terminals suitable for cable lugs shall be provided for wire sizes above this. Clamp type terminals shall be used for connection of wires up to 10 mm2.14 © GAIL – All rights reserved .the data sheet. run off paint etc. 5.2. 5.3 5. A lithe components used shall be time tested and standardised. An industrial type 3 pin ISA plug shall be provided on AC incoming cable end and lugs shall be provided on DC outgoing cable end. the equipment shall be subjected to inspection by LIL / Owner or by an agency authorised by the Owner. Vendor shall indicate the maximum allowable tolerance against each GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 15 of 19 5. Detailed test schedule and procedures shall be formulated by the vendor and submitted for Owner’s approval.1 6. The following design considerations shall be taken into account to ensure maximum availability of the system: There shall be no common device between the two units.2 x AH(C5) of cell. Vendor shall state the safety factors used in selecting such items as semi-conductors. Cell booster shall be portable type with wheels.4 6 6.2 x AH(C10) of cell For Ni-Cd battery = 0.5 Reliability All necessary care shall be taken in selection. Series-parallel combination of smaller devices to achieve specified rating shall not be acceptable. DC voltmeter and indicating lamps for AC! DC power ON. 5.5.2 5.For VRLA battery 0. Each cell booster shall be supplied with 5 m long flexible copper conductor. the failure of which could cause shutdown of more than one charger. Each Battery Charger/ DCDB/ Cell Booster shall be tested in accordance with applicable standards. DC ammeter. transformers etc. Cell booster shall have a heavy duty switch fuse or MCCB on both AC incomer and DC output sides. PVC insulated braided cables for both AC incoming power supply and DC output connection to the battery.5. that the variac! controlled rectifier is at its minimum position while switching on the cell booster. The output voltage and current of cell booster shall be manually controlled using a suitably rated variac or a full wave controlled rectifier bridge.2 © GAIL – All rights reserved . manufacture. Tests shall be carried out at manufacturer’s works under his care and expense. It shall be possible to attend to any individual power circuit for maintenance without affecting the total DC supply. TESTING AND ACCEPTANCE During fabrication. electrolytic capacitors. along with AC voltmeter. Manufacturer shall furnish all necessary information concerning the supply to Owner’s inspector. testing and commissioning of the equipment for ensuring high system reliability. INSPECTION.5. design. The following acceptance tests shall be performed on each Battery Charger and DCDB as a minimum.1 5. Suitable interlock shall be provided so as to ensure . In case of failure of any component during testing.s Value) 500 V 1000 V 1500 V 2000 V Printed Circuit Boards PCBs and other electronic circuits shall undergo a burn-in test for 96 hours at 50°C at a voltage varied between the maximum and minimum supply voltage. the test voltage at the frequency available in the test facility or at the rated frequency. In case the equipment fails to meet any requirements of the specifications. Test certificates indicating the test results shall he submitted to owner. The other charger of the set shall be energized under zero load current condition throughout the test period.2. of the full value starting at a maximum of 0. The temperature of electronic power devices shall be measured and the device junction temperature shall be calculated. the tests shall be repeated after replacement of the faulty component. each of the two chargers of each Battery Charger set shall be subjected to a Heat Run test performed at rated load and voltage for a period not less than 8 hours.u. and the equipment shall be retested before acceptance.2 Test Voltage (AC r. but not exceeding 100 Hz. Vp 2 Vp is the highest crest voltage to be expected between any pair of terminals ≤60 V ≤125 V ≤250 V ≤500 V 6.2.5 p. shall be increased to the full value shown in the following table in not less than 10 seconds continuously or in maximum steps of 0.test parameter in line with applicable standards. 6.05 p.3 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . The insulation tests shall be carried out using an AC power frequency voltage or a DC voltage at the choice of the manufacturer.1 Insulation Tests Insulation tests shall be performed as per IEC 60146-1-1. The calculated value shall be at least SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 16 of 19 6.m.u. In the case of AC power frequency voltage test. The unit on test shall withstand the specified voltage for 1 minute.2. All tests shall be witnessed by owner or his authorised representative and 4 weeks prior notice shall be given before the date of commencement of tests. necessary modifications! corrections shall be made by the vendor to ensure compliance to the specifications. Heat Run Test Prior to execution of functional tests. In case DC voltage is used for the test. the value of DC voltage shall be equal to the crest value of the test voltage specified in the table. protections and controls mentioned in the specification shall be verified. Measurements shall include DC output voltage and current.4. Audible Noise Test Audible noise shall be measured around each charger at 1 meter distance in at least 4 to 5 positions and its value shall be within the permissible limits. 50% and 100% of rated output current. Measurements at 100% rated load current shall be repeated at 90% and 1 10% of nominal AC supply voltage. Charger Testing at Constant Output Current Limit Measurements shall be carried out both in the float charging and quick charging mode. due to charger malfunction or failure of the unit to fulfill the performance requirements of the specification. measurements shall be carried out when the charger is operating under DC current limiting conditions with DC output voltage between zero and set value corresponding to constant voltage operation.10-20°C lesser than the maximum rated junction temperature of the device with proper ambient temperature correction applied.2.2.2. Measurements shall include input AC phase voltage.4. Vendor shall furnish a Site Acceptance Test (SAT) procedure for SPECIFICATION S-07-02-019 REV-0 Page 17 of 19 6.4.6 6. then the heat run test shall be repeated at rated current following which functional tests shall be carried out.4. DCDB and Cell Boosters shall be tested at site along with the battery. shall be checked. Charger Efficiency This shall be determined by measurement of the active power input and output at 50%. 75% and 100% load.3 6. current and power and DC output voltage. Auxiliary Equipment and Control Circuit Tests The correct functioning of all measuring instruments.2. Parallel Operation Parallel operation of both chargers. indications. In each mode.2. current and output voltage ripple.4 Functional Tests Functional tests shall be performed on each charger. Charger Testing at Constant Output Voltage Measurements shall be carried out in the float charging mode and in the quick charging mode. if during execution of functional tests. 6.g.2 6. frequency.1 6.4.3 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER © GAIL – All rights reserved .5 6.2. an electronic component of the charger is required to be replaced. measurements shall be carried out at nominal AC input voltage and at zero. Site Acceptance Test The Battery Chargers. In each mode. sharing of the load and automatic isolation of faulty charger .4 6.2. e.4. alarms. ’ etc.. ‘Weight’. shall be clearly and indelibly marked on the packages together with other details as per purchase order. The equipment shall be properly packed for transportation by ship! rail or trailer. ‘This side up’. ‘Owner’s particulars’. It shall be wrapped in polythene sheets before being placed in crates! cases to prevent damage to finish. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 18 of 19 © GAIL – All rights reserved . Special notations such as ‘Fragile’. ‘P0 no.owner’s approval and all tests shall be performed as per the approved SAT procedure. 7 PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed. ‘Center of gravity’. The crates! cases shall have skid bottoms for handling. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR BATTERY CHARGER SPECIFICATION S-07-02-019 REV-0 Page 19 of 19 © GAIL – All rights reserved . SPECIFICATION FOR CATHODIC PROTECTION POWER SUPPLY MODULE (CPPSM) GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 1 of 16 © GAIL – All rights reserved . ABBREVIATIONS: CPPSM MTBF MTTR PCB : MOV PSP CVCC : Cathodic protection power supply module Mean time between failure Mean time to repair Printed circuit board Metal oxide varistor Pipe to soil potential Constant Voltage and Constant Current Mode GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 2 of 16 © GAIL – All rights reserved . 0 2.0 8.0 SCOPE CODESAND STANDARDS SITE CONDITIONS GENERAL REQUIREMENTS TECHNICAL REQUIREMENTS EQUIPMENT DESCRIPTION INSPECTION.0 6.0 4.CONTENTS 1.0 7.0 5. TESTING AND ACCEPTANCE PACKING AND DESPATCH GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 3 of 16 © GAIL – All rights reserved .0 3. 2. Data sheets Job specification This specification.0 2. The equipment shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country.1 2.0 SCOPE This specification covers the requirements for the design.4 o o o o o 3. SITE CONDITIONS The CPPSM shall be suitable for installation in non air-conditioned room with restricted ventilation or in outdoor kiosk (as specified in data sheet). IS 7204 Stabilised power supplies DC output.(Parts I to IV) IS 6619 Safety code for semiconductor rectifier equipment.1. standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian standards. Codes and standards. performance and materials to be supplied shall conform to the requirements of the latest revision of following standards: IS: 1248 Direct acting indicating analogue electrical measuring instruments and (Parts-i. humid and dusty atmosphere. (Parts-i to 4) IS 13947 Low voltage switchgear and control gear. (Parts-i to 4) IS 12021 Control transformers for switchgear and control gear for voltages not exceeding 1000 V AC. (Parts-i to 4) IS 13703 Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC. manufacture and testing of Cathodic Protection Power Supply Module (CPPSM) working on controlled switch mode principle intended to supply power to cathodic protection system for underground pipelines! structures. If not specifically GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 4 of 16 2. IS 5469 Code of practice for the use of semiconductor junction devices.2 2. section-i) In case of imported equipment. Service conditions shall be as specified in the data sheet. CODES AND STANDARDS The system design.3 2. IS 3700 Essential rating and characteristics of semiconductor devices (Parts-i to ii) IS 3715 Letter symbols for semiconductor devices (Parts-i to 4) IS 4411 Code of designation of semiconductor devices. In case of any contradiction between various referred standards / specifications / data sheet and statutory regulations the following order of priority shall govern: Statutory regulations. 8 & 9) accessories. (Parts-4. warm. in locations having generally corrosive.0 © GAIL – All rights reserved . not need rear access for operation.1 4. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least 15 years from the date of supply.0 4. The front. a design ambient temperature of 40°C and an altitude not exceeding 1000 m above mean sea level shall be considered. SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 5 of 16 4.1 5. All fuses shall be provided inside the panel and shall be of link type. Hinged doors shall be provided at the front and back as required. 660 V grade PVC insulated BIS approved wires with stranded copper conductor of size minimum 2. Control wiring for electronic circuits shall be through flat ribbon cable or through copper wire of minimum 0.5 mm2 shall be used for power and auxiliary wiring.1. The CPPSM panel shall. Louvered openings with wire mesh for natural ventilation may be provided.3 5. Wherever required.1 5. Suitable hooks shall be provided for lifting the panel. Degree of protection for the panel shall be minimum TP-4 1. TECHNICAL REQUIREMENTS Fabrication and General Details CPPSM shall be housed in sheet steel enclosure. Minimum 20% spare terminals shall be provided. The terminal blocks shall be mounted minimum 300 mm above the gland plate.2 5. preferably. The unit shall be natural cooled type. Clamp type terminals suitable for termination up to 10 mm2 conductor shall be provided for all control cable connection. maintenance and shall be suitable for mounting flushed to the wall.5 mm diameter.1. These hooks when removed shall not leave any hole in the panel or imperfection in the paint finish.6 mm thick sheet steel.3 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved .0 5. The Unit shall be freestanding type. All instruments shall be panel mounted type and back connected.2 GENERAL REQUIREMENTS The offered equipment shall be brand new with state of art technology and proven field track record. 4. All wirings shall be ferruled with PVC ferrules at both ends for ease of identification. rear walls and doors shall be made by using minimum 2 mm thick sheet steel and side walls shall be made of minimum 1.mentioned therein. Suitable power terminals shall be provided for power cables. suitable stiffeners shall be provided. Vendor shall give a notice of at least one year to the end user of equipment and GAIL before phasing out the product/spares to enable the end user for placement of order for spares and services.1. No prototype equipment shall be offered. 4 5. potentiometers etc. Amply dimensioned oblong holes shall be provided at the bottom of the panel for its bolting to the embedded insert plate/channel. The space in the terminal chamber shall be adequate for termination of required number and sizes of cables as specified in the data sheet. If required the panel shall be provided with space heater to prevent moisture condensation. The space heaters shall be located at the bottom of the panel and shall be provided with a manually operated switch and HRC fuse.10 5. Where plug in type of PCBs are used gold plated male-female connectors shall be used for the purpose. All non-current carrying metallic parts of the panel and mounted equipment shall be connected to the panel earth bus.11 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . the electronic PCB5/components and other control devices shall be made immune to moisture condensation. PCB tracks shall be tinned and solder masked.1. This shall ensure complete safety to personnel intending routine maintenance by opening the panel doors. Cable glands shall be of brass. shall be located at a convenient height of minimum 300 mm and maximum 1800 mm from the bottom of the panel.6 5.8 5.1. nickel plated.9 5. single compression type for indoor installations and double compression type for outdoor installations. Layout of panel components shall enable easy access to the components for maintenance.5. moisture and fungal growth. Where space heater is not provided. CPPSM shall be suitable for bottom cable entry unless otherwise specified in the data sheet and shall be supplied complete with crimping type tinned copper lugs and cable glands. Prototype equipment shall not be acceptable. The design.1. The integral base frame of panel shall be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack welding to purchaser’s insert plate/flat/channel embedded in the floor.1. The PCB shall be coated with suitable lacquer to make it immune to dust.1. The printed circuit boards (PCBs) shall be of copper clad glass epoxy laminate.1. All the control equipment like switches. push buttons.7 5. Panel shall be provided with integral base frame channel.1. internal component layout and rating of component shall ensure high MTBF and low MTTR. The CPPSM shall be field proven.1. The space heater shall have porcelain-insulated connectors. Provision shall be made for connecting this earth bus at two ends with the plant earth grid by means of (40x5) mm2 GI flat. An earth bus bar of minimum (25 x 3) mm2 copper or equivalent aluminium shall be provided throughout the length of the panel. All doors SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 6 of 16 5.5 All live parts shall be properly shrouded. etc.1. run off paint. lamps. GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 7 of 16 5. PCBs. Hard paper or selfadhesive plastic tape nameplates shall not be acceptable. meters. Back-engraved perspex sheet nameplates may also be acceptable. rust. the panel shall be spray painted with two coats of final paint or shall be powder coated. The finished panels shall be dried in stowing ovens in dust free atmosphere. then they shall be greased. All unpainted steel parts shall be cadmium plated or suitably treated to prevent corrosion.black) lamicoid sheets or anodised aluminium. The undersurface shall be made free from all imperfections before undertaking the finishing coat. Painting All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. After preparation of the under surface. 5.13 Where specified in the data sheet the CPPSM shall be housed in an outdoor kiosk. orange peels. Panel finish shall be free from imperfections like pin holes. Suitable canopy shall be provided on the top of the kiosk.) shall be provided with suitable nameplates. Colour shade of final paint shall be approved by the purchaser before final painting is started. 5. Nameplates shall be engraved out of 3-ply (black-white. Necessary ventilation arrangement with louvers and wire mesh shall be provided for proper operation of the CPPSM. The kiosk shall be suitable for outdoor mounting and shall give proper protection to the CPPSM against rain.1.14 © GAIL – All rights reserved . indications and positions of the control switches on the CPPSM can be seen without opening the door of the kiosk. other harsh weather conditions. The cable entry to the kiosk shall be from bottom through cable glands. Acrylic transparent glass window shall be provided on the front door of the kiosk so that the meters.1. Engraving shall be done with groove cutters. connecting wires as well as for the terminals in the terminal strip inside the panel. Labels shall be provided for every component on the cards. etc.12 All panel mounted equipments (e. Hinged lockable doors shall be provided at the front and back. The kiosk shall be made of sheet steel of minimum 3 mm thick and epoxy painted on both internal and external surfaces. switches. push-buttons. If these parts are moving elements.g. grease and dirt. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer.and movable parts shall be connected to the earth bus by flexible copper cables. Nameplates shall be fastened by screws and not by adhesive. 6.0 EQUIPMENT DESCRIPTION The CPPSM shall be complete with following main sections: o Input controls. o Power converter and filters. o Output protections o System controls o Current interrupter o Control, indication and metering Input Controls A moulded case circuit breaker with thermal over load and short circuit release (rated for the input power supply short circuit current) shall be provided at the input for power supply control. Power Converter and Filters The CPPSM shall convert and control the input DC power supply voltage/current into variable DC output voltage/current through switching power semiconductor devices (Thyristor/power transistor/power MOSFET, etc.). The variation in the output voltage/current shall be achieved through control of duty cycle of conduction of the switching power semiconductor devices. The current and voltage ratings of the power semiconductor devices shall be at least two times the maximum device current and mm. two times the maximum voltage coming across it respectively. The voltage rating of the power semi-conductor devices shall be co-coordinated with the breakdown voltage of lightning arrestor provided at the output so that the power semiconductor devices are protected from any voltage surge coming from the pipeline. Shunt zeners / MOV shall be provided across the power semiconductor devices for protection. The power semiconductor devices shall have humidity/moisture resistant finish and mounted in sufficiently sized heat sink designed to provide adequate cooling under worst conditions of operation. The power semiconductor devices shall have adequate protection against high dv/dt and di/dt. Where specified in the data sheet, the converter shall electrically isolate the input power to CPPSM from its output so that the grounding of the positive output of the CPPSM through anode ground bed shall not affect the grounding system of the input power supply. Alternatively, a separate DC to DC converter having electrical isolation between input and output power supply shall be provided at the input of the CPPSM. The power semiconductor devices shall be protected by semiconductor fuses or the system shall have instantaneous short circuit-current limit feature to protect the devices against output short circuits. An adjustable output over current limit feature shall be provided. SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 8 of 16 6.1 6.1.1 6.2 6.2.1 6.2.2 6.2.3 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved 6.2.4 6.2.5 6.2.6 6.2.7 6.3 Filter shall be provided in the input power supply circuit to minimise the AC injected into the DC input power supply system. Adequate filtering shall be provided on the DC output of the converter to limit the ripple content in the output to less than 5% at rated output. The converter system shall be of natural air cooled type. For CPPSMs with multiple output circuits, each output circuit shall have independent output converter and output filters. Output Protections Two pole moulded case circuit breaker or miniature circuit breaker rated for the DC output current, short circuit current and having thermal over load, short circuit release shall be provided in the output. A lightning arrestor rated for minimum 1 OKA impulse current discharge capacity and rated voltage & max. spark over voltage rating suitable to protect the CPPSM components against lightning and switching surges shall be provided at the output. For CPPSMs with multiple output circuits, each output circuit shall have independent protections. System Controls The CPPSM shall have two distinct modes of operation (independent for each output circuit) as below: a) Constant Voltage - Constant Current Mode (CVCC) In this mode the output voltage (Vos) of CPPSM shall be continuously adjustable from O.5V DC to the rated output voltage specified on the data sheet. Current limit feature shall be provided in this mode of operation. The current limit (los) shall be continuously adjustable from zero to rated output current. For constant voltage mode of operation the output current limit shall be set at maximum and output voltage setting shall be varied. Irrespective of output current demand the chosen value of the output voltage shall be maintained by the control system till the current limit is reached. After that the output current limit shall be maintained and output voltage shall decrease to keep the current constant. For constant current mode of operation the output voltage shall be set at maximum and output current shall be varied through varying the setting of output current limit. Irrespective of output voltage requirement the control system shall maintain the output current to the set current limit value till the voltage limit is reached. After that the output voltage limit shall be maintained and output current shall decrease to keep the voltage constant. 6.4 6.4.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 9 of 16 © GAIL – All rights reserved b) Auto PSP Mode In this mode of operation the output of the CPPSM shall operate in an external closed loop with pipe-to -soil potential (PSP) in feed back loop. The CPPSM control shall adjust the output voltage such that the PSP as measured by reference cell always remains equal to the set potential on the unit. The set potential (Vps) shall have high long time stability and minimum temperature drift. The set potential shall be continuously adjustable over the range specified in data sheet. An adjustable over current limit shall be provided to limit the maximum output current. The unit shall be designed to operate with the number of reference cells connected to it (to be provided by others) as specified in data sheet. In case of more than one reference cell being specified, CPPSM shall have feature to automatically select the reference cell having less negative potential than the others and use the same for auto control of the unit (e.g. (-) 0.8 V is less negative than (-) 0.9 V). Adequate hysterisis shall be provided in selecting the less negative potential reference cell, to avoid hunting between the reference cells at change over conditions. In case of open circuit or short circuit of the reference cell or potential being less negative than a minimum set potential (Vrs), for the controlling reference cell, the unit shall sense these conditions as reference cell failure and shall automatically switch over to the other healthy reference cell for control. Should fault occur in all the reference cells, the output voltage or current of the CPPSM shall adjust automatically to a preset value (Vas/las), which shall be adjustable. In both CVCC and auto PSP modes of operation the electronic over current limit shall be fast enough to protect the active devices of the unit and fast enough to act before tripping of MCCB/MCB or blowing of fuse. 6.4.2 The unit shall continuously monitor the PSP and necessary annunciation shall be provided in case of PSP either exceeding the specified maximum limit (Vpm ) or remaining lower than the specified minimum limit (Vpn). The output voltage regulation for no load to full load variation with input voltage variation from maximum to minimum shall not be more than 2.5 % of rated voltage through out the range of output voltage and over the specified ambient temperature variation as specified in data sheet, in CVCCconstant voltage mode of operation. In auto PSP mode the closed loop PSP regulation for no load to full load variation with input voltage variation from maximum to minimum shall be within 20 mV through out the PSP setting range specified. In CVCC- constant current mode of operation, the current regulation for minimum to maximum output voltage and minimum to maximum variation in GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 10 of 16 6.4.3 © GAIL – All rights reserved input voltage, shall not be more than 2.5% through out the range of output current. 6.4.4 6.4.5 6.5 6.5.1 6.5.2 The output of the unit shall be ungrounded and shall allow grounding of positive terminal of the output through the anode ground bed. For CPPSMs with multiple output circuits, each output circuit shall have independent control system. Current Interrupter If specified on the data sheet a current interrupter for CPPSM output current interruption shall be provided. The current interrupter shall have an output contactor with current rating minimum 125% of the output current rating of the CPPSM and a digital timer to operate it. The timer shall have ‘ON’ and ‘OFF’ timings. When the timer is turned on the ‘ON’ timing shall start and shall close the output contactor till the end of the ‘ON’ timing. At the end of the ‘ON’ timing the ‘OFF’ timing shall start and keep the contactor open till the end of the ‘OFF’ timing. At the end of the ‘OFF’ timing the ‘ON’ timing shall start again. This process of ‘ON’ and ‘OFF’ timing shall continue. The ‘ON’ and ‘OFF’ timings of the timer shall be settable by separate 2 digit thumbwheel switches, each settable from 1 to 99 seconds. The timing error of the timer’ shall be less than 5 parts per million. In case of microprocessor based system keypad with display may be provided in place of thumbwheel switches. Whenever the timer is switched on it shall always start with ON ‘timing’. A timer-reset push button shall be provided. On pressing this push-button during operation of the timer, the timer shall get reset and upon release of the button, the timer shall restart with ‘ON’ timing. The power required for operation of the timer and contactor shall be derived from the main power supply to the CPPSM. The following controls and indications shall be provided for current interrupter. The controls shall be housed in a lockable cover, so that normally they are not accessible. The indications shall be mounted on the door. a) Controls - Timer power ‘ON’ / ‘OFF’ - - Timer reset - - Thumb wheel switch for ‘ON’ timing - - Thumb wheel switch for ‘OFF’ timing SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 11 of 16 6.5.3 6.5.4 6.5.5 6.5.6 6.5.7 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved b) In case of microprocessor based system, keypad with display may be provided in place of thumbwheel switches. Indications (LED) - Timer power ‘ON’ - ‘ON’ timing - ‘OFF’ timing 6.5.8 The output contact of the current interrupter contactor shall be wired in the positive DC output of the CPPSM. A link shall be provided for shorting these terminals whenever the current interrupter is not in use. If specified in the data sheet the current interrupter shall be an independent unit of portable type. The interrupter unit shall have terminals for input power supply and terminals of the contactor in the timer output. The input power supply and the rating of the timer output contactor shall be as specified on the data sheet. Where the current interrupter is not specified with CPPSM or is specified as portable type external to the CPPSM, then the CPPSM shall have provision for connection of input power supply terminals and output contacts of external current interrupter for current interruption test. A link shall be provided for shorting the output terminals provided in CPPSM for current interruption, whenever the current interrupter is not connected. For CPPSMs with multiple output circuits, each output circuit shall have independent current interrupter. Controls, Indication and Metering Following controls shall be provided on CPPSM front door. a) ON/OFF control for input through MCCB. b) ON 10FF control for output through MCCB/MCB. c) Auto/CVCC mode selector switch. d) Potentiometers for Vos, Vps and los settings. e) Selector switch for selecting indication of PSP set and PSP actual for all the reference cells. Following controls shall be provided inside the module at user accessible common location: a) Potentiometer for Vrs, Vpm, Vpn and Vas/las settings. b) Controls for current interrupter: o Timer power ’ON’/’OFF’ o Timer reset o Thumb wheel switch for ‘ON’ timing o Thumb wheel switch for ‘OFF’ timing 6.5.9 6.5.10 6.5.11 6.6 6.6.1 6.6.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 12 of 16 © GAIL – All rights reserved 6.6.3 CPPSM shall have following indicating lights (lamps or minimum 5 mm dia LEDs): a) CPPSM ON/OFF b) Unit in auto/CVCC (2 lamps) c) Reference cell controlling the closed ioop control of the CPPSM (number of lamps same as number of reference cells). d) Reference cell faulty (number of lamps same as number of reference cells). e) Pipeline over protected. f) Pipeline under protected g) Indications for current interrupter: o Timer power ‘ON’ o ‘ON’ timing o ‘OFF’ timing It shall be possible to switch-off all the indication lamps by a single switch. In case of LED indication lights this facility may not be provided. 6.6.4 Following meters having mm ci. 1.5 accuracy shall be provided on the CPPSM: a) Digital meter for output voltage b) Digital meter for output current c) Digital voltmeter to measure PSP set (Vps) and PSP actual for all the reference cells. The meter shall have range from (-) 4 V to 0 V and shall have cl. 0.5 accuracy. d) Digital meters for measuring Vrs, Vpm, Vpn and Vas/las settings. e) Meters for input voltage and current It shall be possible to switch-off all the digital meters preferably by a single switch. If specified in data sheet, CPPSM shall incorporate provision for remote monitoring of the unit through SCADA system as below: a) Potential free contacts for the following: - All the reference cells failed. (Contact open on alarm condition) - - Pipeline overprotected. (Contact open on alarm condition) - - Pipeline under protected. (Contact open on alarm condition) - - System in auto-mode. (Contact close in auto condition) - - System in CVCC mode. (Contact close in CVCC mode) b) 4 to 20 mA electrically isolated signal for the following: - PSP (-4V to OV) - CPPSM output voltage - - CPPSM output current The transducers shall have electrical isolation between input and output. The isolation insulation shall withstand 2 kV, 50 Hz for minimum 1 minute. The 6.6.5 GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 13 of 16 © GAIL – All rights reserved accuracy class of the transducer shall be 0.5. The transducers shall be protected against input and output voltage surges. The transducer shall be suitable for driving upto 600 ohms load impedance located upto 500 m away and wired with 0.5 mm2 copper conductor cable. The transducers shall be suitable for minimum 125% continuous over load in the input voltage/current parameter. 6.6.6 . 7.0 7.1 For units having multiple outputs, each output circuit shall have independent controls, indication and metering TESTS AND ACCEPTANCE During fabrication, the equipment shall be subjected to inspection by owner or his authorised representative to assess the progress of the work as well as to ascertain that only quality raw materials are used for the same. He shall be given all assistance to carryout the inspection. Final acceptance test shall be carried out at manufacturer’s works under his care and expense. Instruments and equipments required for testing shall be arranged by manufacturer. Owner’s representative shall be given minimum 2 weeks prior notice for witnessing the tests. Test certificates indicating test results shall be furnished by the manufacturer. Acceptance tests shall include but not be limited to the tests listed below. Visual Inspection This shall includeo Completeness of the equipment in line with specification. o Checking of all settings. o All labels provided and satisfactory. o Dimensional checking. o Proper mounting of components and neatness of wiring etc. o Model number. Insulation Tests The voltage specified in the table below the circuits indicated: Withstand Voltage Control electronics voltage <60V To Earth 700V D.C. To Control Devices To power electronics To auxiliary circuits GAIL (INDIA) LTD NEW DELHI 7.2 7.2.1 7.2.2 shall be applied for one minute to Power electronics Un1 2xUn1 + 1000V 2xUn1 + 1000V 2xUn1 + 1000V Auxiliary circuits Un2 2xUn2 + 1000V 2xUn2 + 1000V 2xUn1 + 1000V REV-0 Page 14 of 16 2xUn1 + 1000V 2xUn1 + 1000V SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 © GAIL – All rights reserved (Un1 and Un2 are nominal voltage rating of power electronics and auxiliary circuits respectively). D.C. test voltages may be applied instead of A.C. The magnitude of D.C. test voltages to be applied shall be 2 times the above-mentioned A.C. (r.m.s) Values. Insulation resistance test shall be conducted before and after heat run test. 7.2.3 Heat run Test All CPPSMs shall be subjected to a heat run test performed at rated voltage for period not less than 16 hours prior to execution of functional tests. At least one CPPSM of each rating shall be loaded to its rated output through out 16 hour test period. All other CPPSMs shall be energized under partial load or zero load current condition through out the test period. 7.2.4 Functional tests Functional tests as below shall be performed on each CPPSM. If during execution of functional tests, any electronic component of the unit is required to be replaced e.g. due to malfunction or failure of the unit to fulfill the performance requirements of the specification, then the load test shall be repeated at rated current following which functional tests shall be carried out. CVCC mode operation testing Constant voltage operation During the test, current limit shall be set to rated output current. Performance testing shall be carried out for various output voltage settings and load varying from zero to maximum. The verification of operation of the control functions, measurement of output voltage, current, input voltage, current, ripple in the output, input, evaluation of output voltage regulation and efficiency of the unit shall be carried out during the testing. Constant current operation During the test, voltage limit shall be set to rated output voltage. Performance testing shall be carried out for various output current limit settings and load resistance varied to achieve output voltage from minimum to maximum. The verification of operation of the control functions, measurement of output voltage, current, input voltage, current, ripple in the output, input, evaluation of output current regulation of the unit shall be carried out during the testing. Auto PSP mode operation Suitable set-up shall be arranged for output loading and reference cell feed back. The closed loop performance and regulation shall be checked with the PSP set voltage varied from O.85V to 1.2V. SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 15 of 16 7.2.4.1 a) b) 7.2.4.2 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved Disconnecting the reference cell feed back connection in the above set up shall simulate the reference cell failed condition. The output voltage/current of the unit shall go to the value set on the potentiometer Vas/las provided inside the CPPSM. The settings on Vas/las shall be varied and the output voltage/current shall be observed. 7.2.4.3 Operation of sensors for pipeline over protection, under protection, reference cell failure and reference cell selection logic in auto PSP mode shall be verified by connecting variable external voltage sources to reference cell inputs of the CPPSM. The number of external voltage sources shall be same as number of reference cell inputs specified for the CPPSM. The unit shall be checked for operation of the current limit by over loading the unit in both CVCC and auto PSP modes of operation. For Units where semiconductor fuses are not provided for protection of the power semiconductor device, the protection of same shall be tested as below: A switch rated for making and carrying CPPSM output short circuit current shall be connected to the output terminals of the unit. The output voltage and the output current limit settings of the unit shall be set to the maximum rated values. The switch connected in the output shall be shorted quickly. The unit shall go to current limit mode and shall not damage any active component of the unit. 7.2.4.5 8.0 The current interrupter shall be tested for time interval settings and specified operation. PACKING ANB DESPATCH The equipment shall be properly packed for selected mode of transportation i.e. by ship/rail or trailer. The panels shall be wrapped in polythene sheets before being placed in crates to prevent damage to finish. Crates shall have skid bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’ etc., shall be clearly marked on the package together with Tag nos., P.O. Nos. etc. The equipment may be stored outdoors for long periods before erection. The packing shall be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature. 7.2.4.4 GAIL (INDIA) LTD NEW DELHI SPECIFICATION SPECIFICATION FOR CPPSM S-07-02-020 REV-0 Page 16 of 16 © GAIL – All rights reserved SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 1 of 16 Copyright GAIL – All rights reserved Abbreviations: BIS BS CIMFR CT FM FRP IEEE IS LCIE NEMA P0 PVC RPM UL VDE Bureau of Indian Standard British Standards Central Institute of Mines and Fuel Research Current Transformer Factory Mutual Fiber Reinforced Polyester Institute of Electrical & Electronics Engineers Indian Standard Laboratoire Central des Industries Electriques National Electrical Manufacturers Association Purchase Order Poly Vinyl Chloride Revolutions per Minute Underwriter’s Laboratories Verband Deutscher Elektrotechniker GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 2 of 16 Copyright GAIL – All rights reserved . CONTENTS 1.0 3.0 4.0 SCOPE .0 CODES AND STANDARDS GENEAL REQUIREMENTS OPERATING CONDITIONS PERFORMANCE CONSTRUCTION DETAILS MISCELLANEOUS ACCESSORIES NOISE LEVEL MOTOR VIBRATION CRITICAL SPEEDS PAINTING INSPECTION AND TESTING CERTIFICATION PACKING AND DESPATCH 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 3 of 16 Copyright GAIL – All rights reserved 1.0 SCOPE This specification covers the design, manufacture, testing, packing and supply of three phase medium voltage squirrel cage induction motors. CODES AND STANDARDS The squirrel cage induction motors and their components shall comply with the latest editions of following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified: IS - 5 Colours for ready mixed paints and enamels. IS 325 Three phase induction motors. IS 1076 Preferred numbers. IS 1231 Dimensions of three phase foot mounted induction motors. IS 1271 Thermal evaluation and classification of electrical insulation. IS 2148 Flame proof enclosures of electrical apparatus. IS 2223 Dimensions of flange mounted AC Induction motors. IS 2253 Designation for type of construction and mounting arrangement of rotating electrical machines. IS 2254 Dimensions of vertical shaft motors for pumps. IS 2968 Dimensions of slide rails for electric motors. IS 4029 Guide for testing three phase induction motors. IS 4691 Degrees of protection provided by enclosure for rotating electrical machinery. IS 4722 Rotating electrical machines. IS 4728 Terminal marking and direction of rotation for rotating electrical machinery. IS 4889 Method of determination of efficiency of rotating electrical machines. IS 6362 Designation of methods of cooling of rotating electrical machines. IS 6381 Construction and testing of electric apparatus with type of protection ‘e’. IS 7389 Pressurized enclosure of electrical equipment for use in hazardous area. IS 7816 Guide for testing insulation resistance of rotating machines. IS 8223 Dimensions and output series for rotating electrical machines. IS 8289 Electrical equipment with type of protection ‘n’. IS 8789 Values of performance characteristics for three phase induction motors. IS 9283 Motors for submersible pump sets. IS 9628 Three phase induction motors with type of protection ‘n’. IS 12065 Permissible limits of noise level for rotating electrical machines. IS 12075 Mechanical vibration of rotating Electrical Machines with shaft heights 56 mm and higher measurement, evaluation and limits of vibration severity. SPECIFICATION S-07-02-021 REV-0 Page 4 of 16 2.0 2.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS Copyright GAIL – All rights reserved IS 12802 Temperature rise measurement of rotating electrical machines. IS 12824 Type of duty and classes of rating assigned to rotating electrical machines. IS 13529 Guide on effects of unbalanced voltages on the performance of three phase cage induction motors. IS 13555 Guide for selection and application of three phase induction motors for different types of driven equipment. IS 14568 Dimensions and output series for rotating electrical machines, frame numbers 355 to 1000 and flange numbers 1180 to 2360. 2.2 In case of imported motors, standards of the country of origin shall be applicable if these standards are equivalent or stringent than the applicable Indian Standards. The motors shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country. In case Indian Standards are not available, standards issued by IEC/ BS/ VDE/ IEEE/ NEMA or equivalent agency shall be applicable. In case of any contradiction between various referred standards! specifications! data sheets and statutory regulations, the following order of priority shall govern: o Statutory regulations o Data sheets o Job specifications o This specification o Codes and standards GENERAL REQUIREMENTS The offered equipment shall be brand new with state of the art technology and proven field track record. No prototype equipment shall be offered. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment at least for 15 years from the date of supply. Vendor shall give a notice of at least one year to the end user of equipment and GAIL before phasing out the product/spares to ensure the end user for placement of order for spares and services. 2.3 2.4 2.5 3.0 3.1 3.2 3.3 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 5 of 16 Copyright GAIL – All rights reserved 4.0 4.1 OPERATING CONDITIONS Ambient Conditions: Motors shall be suitable for operating satisfactorily in humid and corrosive atmosphere found in refineries, petrochemical, fertilizer and metallurgical plants. Service conditions shall be as specified in the motor data sheet. If not specifically mentioned therein, a design ambient temperature of 40°C and an altitude not exceeding 1000 meters above mean sea level shall be taken into consideration. Frequency and Voltage Variations : Unless otherwise agreed, motors shall be designed for continuous operation at rated output under the following conditions: The terminal voltage differing from its rated value by not more than ± 6 % or The frequency differing from its rated value by not more the ± 3 % or Any combination of (a) and (b) Starting Unless otherwise specified, motors shall be designed for direct-on-line starting. Motors shall be designed for re-acceleration under full load after a momentary loss of voltage with the residual voltage being 100% and is in phase opposition to the applied voltage. Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds under cold conditions and 8 seconds under hot conditions. The starting time of the motor shall be less than the hot thermal withstand time (time tE in case of increased safety i.e. Ex-e motors) to permit application of conventional bimetal relays or thermal release against locked rotor and overload conditions. Unless otherwise specified, all motors shall be suitable for starting under specified load conditions with 75 % of the rated voltage at the motor terminals. Motors shall be designed to allow the minimum number of consecutive starts indicated in Table below: Direction of Rotation : Motors shall be suitable for either direction of rotation. In case unidirectional fan is provided for motors, direction of rotation for which the motor is designed shall be permanently indicated by means of an SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 6 of 16 4.2 a) b) c) 4.3 a) b) c) d) e) 4.4 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved arrow. Directional arrow should be manufactured from corrosion resistant material. When a motor is provided with bi-directional fans, a double-headed arrow should be provided. Normally, clockwise rotation is desired as observed from the driving (coupling) end, when the terminals ABC are connected to a power supply giving a terminal phase sequence in the order ABC. Counter-clockwise rotation of the motor shall be obtained by connecting the power supply to terminals so that the phase sequence corresponds to the reversed alphabetical sequence of the terminal letters. Ample space shall be provided at the terminal box for interchanging any two external leads for obtaining the reverse phase sequence. Starts No. of consecutive start-ups with initial temp. of the motor at ambient level (cold) No. of consecutive start-ups with initial temp. of the motor at full load operating level (hot). 5.0 5.1 5.2 5.3 PERFORMANCE Motors shall be rated for continuous duty (S1), unless otherwise specified. Unless otherwise specified, the starting current (as % rated current) shall not exceed 600% subject to tolerance. In particular cases, when the starting current is to be limited, care shall be taken such that the design values of torque meets the load requirement while at the same time complying to clause 4.3 above of this specification. In particular cases, when the starting with reduced voltage is specified, care shall be taken such that the design values of torque meets the load requirement while at the same time complying to clause 4.3 above of this specification. Starting torque and minimum torque of the motor shall be compatible with the speed torque curve of the driven equipment under specified starting and operating conditions. For heavy duty drives such as blowers, crushers etc. high starting torque motors shall be provided. In case where characteristics of driven equipment are not available while selecting the motor, minimum starting torque shall be 110% of rated value for motors up to 75 kW and shall be 90% of rated value for motors above 75 kW. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 7 of 16 Minimum no. of consecutive starts 3 2 5.4 5.5 Copyright GAIL – All rights reserved 5.6 The pull out torque at the rated voltage shall be not less than 175 percent of the rated load torque with no negative tolerance. Unless otherwise agreed, the pull out torque shall not exceed 300 percent of the rated load torque in case of motors driving equipment with pulsating loads (e.g. reciprocating compressors) the minimum value of pull out torque at 75 percent of the rated voltage shall be more than the peak value of pulsating torque and the current pulsation shall be limited to 40%. The minimum values for performance characteristics of motors rated up to and including 37 kW shall be as per IS-8789 TABLE-ito1 TABLE-8 The minimum value for product of efficiency and power factors of 2 pole, 4pole, and 6-pole motors rated above 37 kW shall be as given in Table below. Rated output (minimum) 45 kW 55 kW 75 kW 90 kW 110kW 125 kW 160kW 180kW 200 kW Product of efficiency & power factor at rated load 2-Pole 0.82 0.82 0.82 0.82 0.86 0.86 0.86 0.86 0.86 4- Pole 0.80 0.80 0.80 0.80 0.80 0.80 0.81 0.83 0.83 6-Pole 0.79 0.79 0.80 0.80 0.80 0.80 0.80 0.80 0.80 5.7 Efficiency and power-factor figures for motors having synchronous speeds of 750 RPM and below, shall be as agreed between the purchaser and the manufacturer. 6.0 6.1 CONSTRUCTIONAL DETAILS Windings 6.1.1 Unless otherwise specified in the motor data sheet, motors shall be provided with class ‘B’ insulation as a minimum. In case of motors with class ‘F’ insulation, the permissible temperature rise above the specified ambient temperature shall be limited to those specified in the applicable Indian standards for class ‘B’ insulation. 6.1.2 The winding shall be tropicalised. The windings shall preferably be vacuum impregnated. Alternately the windings shall be suitably varnished, baked and treated with epoxy gel for operating satisfactorily in humid and corrosive atmospheres. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 8 of 16 Copyright GAIL – All rights reserved 6.1.3 Windings shall be adequately braced to prevent any relative movement during operation. In this respect, particular care shall be taken for the stator windings for direct-on-line starting squirrel cage motors. Insulation shall be provided between coils of different phases that lie together. Core laminations must be capable of withstanding burnout for rewind at 400°C without damage or loosening. 6.1.4 In case of motors driving equipment with pulsating loads, special care shall be taken for the joints of rotor bars and end rings to avoid premature failures due to induced fatigue stresses. 6.1.5 The windings shall be connected in delta. However, for motors rated 2.2 kW and below, star connection may be accepted. In case of motors with stardelta starting, the motor windings shall be fully insulated for delta connection. 6.1.6 The ends of the windings shall be brought out into a terminal box. These shall be terminated by means of terminals mounted on an insulating base made of non-hygroscopic and nonflammable material. 6.1.7 All motors shall be with six terminals and suitable links to connect them in star or in delta except for motors rated up to and including 2.2 kW which may be accepted with three terminals. 6.1.8 All terminals shall be thoroughly insulated from the frame with material resistant to tracking. 6.1.9 Anti-loosening, anti-vibration type of terminals shall be provided in case of increased safety (Type Ex e) and non-sparking (Type Ex n) motors. 6.2 Terminal Box and Cable Entries 6.2.1 Unless otherwise agreed, the terminal box shall be located on the right hand side as viewed from the driving (coupling) end. However, as a special case, terminal box located on top may also be accepted, particularly for hazardous area motors, in case manufacturer has only TOP mounted terminal box design which is duly tested/certified by CIMFR and approved by PESO/CCE for installation in hazardous area.. The terminal box design shall allow rotation in steps of 900 to facilitate cable entry from any direction. 6.2.2 The terminal box shall be of robust construction and large enough to facilitate easy connection of the cables. The terminal box shall be with necessary clearances, creepage distances between live parts and between live parts to earth considering air insulation and without any compound filling. Terminal box cover shall be provided with handles to facilitate easy SPECIFICATION S-07-02-021 REV-0 Page 9 of 16 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS Copyright GAIL – All rights reserved removal. However, for terminal box covers weighing less than 5 kg., terminal box covers without handles can be accepted. 6.2.3 An adequately sized earth terminal shall be provided in the motor terminal box for termination of the fourth core of specified cables. 6.2.4 The terminal box shall be provided entries for suitable cable glands corresponding to the size of the specified cable. Crimp type tinned Cu lugs and nickel-plated brass (or aluminum if specifically required), double compression type cable glands shall be supplied along with the motors for the specified cable sizes for power and space heater cables. 6.2.5 Equipment and accessories provided shall conform to the hazardous area classification and the environmental conditions as specified in the motor data sheet. 6.2.6 Unless otherwise specified, the terminals, cable lugs, terminal box, cable entries and cable glands shall be suitable for the cables sizes as specified below in Table for 2 pole, 4 pole or 6 pole motors: Motor rating up to and including 2.2 kW and below 3.7kw 5.5kw 7.5kw 9.3kW 11.0kW 15.0kW 18.5kW 22.0kw 30.0kW 37.0kw 45.0kw 55.0kw 75.0kw 90.0kw 110.0kW 125.0 kW/132 kW 150.0kW 160.0kW 180.0kw 200.0kw Size of phase conductor (mm2) 4 Al.! 2.5 Cu 6A1./ 4Cu 10Al/ 6Cu 16Al/6Cu 25 Al/ 10Cu 25 Al./ 16Cu 35Al 50A1 50A1 70A1 95A1 95A1 120A1 185 Al 2x95Al 2x120Al 2x150 Al 2xl85Al 2x185Al 2x240Al 2x300Al 6.2.7 Cable sizes for motors having synchronous speeds 750 RPM and below shall be as agreed between the purchaser and manufacturer. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 10 of 16 Copyright GAIL – All rights reserved 6.2.8 Cables used are of 650/1100 V grade aluminum conductor, PVC insulated, PVC extruded inner sheath, armoured with overall PVC sheath. However for cables up to & including 16 mm2 cross-section, cables used may be with copper or aluminum conductor as indicated in the motor data sheet. 6.2.9 The terminal box shall be capable of withstanding internal short circuit conditions without danger to personnel or plant from the emission of hot gases or flame or due to excessive distortion or damage to the terminal enclosure. 6.2.10 Appropriate phase markings as per IS shall be provided inside the terminal box. The marking shall be non-removable and indelible. 6.3 Motor Casing and Type of Enclosure 6.3.1 Motors for use in safe areas shall be industrial type meeting the specified ambient conditions, starting and operating requirements. 6.3.2 Motors for use in hazardous areas (Zone-I or Zone-2) shall have type of protection Ex d or Ex e or Ex n as specified in the motor data sheet and shall meet the requirements of applicable Indian standards. 6.3.3 The minimum degree of motor enclosures including terminal boxes and bearing housing shall be P-55 as per IS. 6.3.4 Motors for outdoor use shall be suitable for installation and satisfactory operation without any protective shelter or canopy. Motor casing shall be provided with a suitable drain for removal of condensed moisture except in case of flameproof motors (Type Ex d). 6.3.5 Vertical motors with downward shaft shall be provided with suitable canopies covering the motor fully. Vertical motors with upward shaft e.g. on fin-fan coolers, shall be adequately protected, (such as cowls/canopies) against ingress of water into the enclosure or the bearing housing even when standing still for long periods of time. Motors designed to handle external thrust from the driven equipment shall be supplied with a thrust bearing at the non-driving end. 6.3.6 All internal and external metallic parts, which may come into contact with cooling air, shall be of corrosion resistant material or appropriately treated to resist the corrosive agents, which may be present in the atmosphere. Screws and bolts shall be of rust proof material or protected against corrosion. Unless otherwise agreed, motors shall have standard frame sizes for various output ratings as stipulated in IS. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 11 of 16 Copyright GAIL – All rights reserved 6.4 Bearing and Lubrication 6.4.1 Motors shall have grease lubricated ball or roller bearings. In all cases, the bearings shall be chosen to provide a minimum L- 10 rating life of 5 years, (40, 000 hours) at rated operating conditions (The L-l 0 rating life is the number of hours at constant speed that 90% of a group of identical bearings will complete or exceed before the first evidence of failure). 6.4.2 Unless otherwise specified, the bearings shall be adequate to absorb axial thrust produced by the motor itself or due to shaft expansion. 6.4.3 Vertical motors shall be provided with thrust bearings suitable for the load imposed by the driven equipment. 6.4.4 In cases such as pumps for hot liquids where the driven equipment operates at high temperatures, bearings shall be cooled by a shaft-mounted fan. This shall ensure efficient ventilation of the bearing and disperse the heat transmitted from the driven equipment by conduction or convection. 6.4.5 Bearings shall be capable of grease injection from outside without removal of covers with motors in the running conditions. The bearing boxes shall be provided with necessary features to prevent loss of grease or entry of dust / moisture e.g. labyrinth seal. Where grease nipples are provided, these shall be associated, where necessary, with appropriately located relief devices, which ensure passage of grease through the bearings. 6.4.6 Pre-lubricated sealed bearings may be considered provided a full guarantee is given for 4 to 5 years of trouble-free service without the necessity of relubrication. 6.5 Cooling System All motors shall be self ventilated, fan cooled. Fans shall be corrosion resistant or appropriately protected. They shall be suitable for motor rotation in either direction without affecting the performance of the motor. If this is not possible for large outputs, it shall be possible to reverse the fan without affecting the balancing of the motor. For motors operating in hazardous area, the fans shall be of an anti-static non-sparking material. Rotor The rotor shall be of squirrel cage type, dynamically balanced to provide a low vibration level and long service life for the bearings. The accepted values of peak to peak vibration amplitudes for a motor at rated voltage and speed on a machined surface bedplate with the motor leveled and with a half-key or coupling fitted shall not exceed those given in IS. Die cast aluminum rotors for motors in hazardous areas may be accepted provided the same are type tested and approved by competent authorities. SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 12 of 16 6.6 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved to a separate terminal box which shall be of the same specification and grade of protection as the main terminal box. The size of each earth stud shall be as given below in Table: Motor Rating Up to and including 7. 7. all motors rated above 22 kW shall be provided with 240 V anti-condensation heaters. The heater leads shall be brought out. preferably. Earth Terminals Two earth terminals located preferably on diametrically opposite sides shall be provided for each motor. Motor shaft shall be sized to withstand 10 times the rated design torque.0 7. SPECIFICATION S-07-02-021 REV-0 Page 13 of 16 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS Copyright GAIL – All rights reserved . sized and located so as to prevent condensation of moisture during shutdown periods. A warning label with indelible red inscription shall be provided on the motor to indicate that the heater supply shall be isolated before carrying out any work on the motor.6.3. shall be provided with lifting hooks of adequate capacity.5 kW Upto 30 kW Above37kW Stud size 6 mm 10mm 12mm 6. Lifting Hooks All motors weighing more than 30 kg.9 Necessary nuts and spring washers shall be provided for earth connection. An additional earth terminal shall be provided inside the terminal box as stated in 6.2).1 or Zone . such heaters shall conform to the provisions of applicable Indian Standards and temperature classification specified in the motor data sheet.8 6.2 Name Plates A stainless steel name plate manufactured from series 300 stainless steel and having information as per IS shall be provided on each motor.1 MISCELLANEOUS ACCESSORIES Anti-Condensation Heaters Unless otherwise stated.2.7 Shaft Extension Motors shall be provided with a single shaft extension with key-way and full key. For motors installed in hazardous atmospheres (Zone . The heaters shall permanently remain ‘ON’ when the motor is not in service and as such shall not cause damage to the windings. 7. 0 NOISE LEVEL The permissible noise level shall not exceed the stipulations laid down in IS. All external surfaces of the motor and its canopy shall be given a coat of epoxy-based paint.3 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 14 of 16 Copyright GAIL – All rights reserved . 12.2 Type tests. Witness of acceptance test shall be applicable for motors rated above 11 kW. In case of motors rated up to 11 kW. if specified. All tests shall be carried out at manufacturer’s shop under his care and expense.In addition to the motor rating plate. all the routine tests and other acceptance tests shall be witnessed by the GAIL I Owner’s Inspector.0 CRITICAL SPEEDS The first actual critical speed of stiff rotors shall not be lower than 125 % of the synchronous speed. For flexible rotors this shall be between 60 % and 80 % of the synchronous speed.0 PAINTING Internal and external parts of the casing and all metal parts including the canopy likely to come in contact with the surrounding air shall be protected with anti-acid paint that will resist the specified environment conditions. a separate number plate for motor tag number shall be fixed in a readily visible position. 8. This number shall be as per the motor data sheets.0 10. 12.0 INSPECTION AND TESTING 12. Additional information as stipulated in applicable standards shall be included in the nameplate for motors meant for use in hazardous atmospheres. 12. The manufacturer shall give prior notice of minimum 4 weeks to the Inspector for witnessing the tests. 11. 9. routine test records shall be provided as part of final documentation. Paint shade shall be 632 as per Indian Standard-IS-S. The manufacturer shall provide all necessary information concerning the supply to GAIL/Owner’s Inspector.1 During manufacturing of motors. the second actual critical speed shall be above 125 % of the synchronous speed. MOTOR VIBRATIONS Motor vibrations shall be with-in the limits of IS. unless otherwise specified for the driven equipment. unless otherwise specified in the motor data sheet. the motors shall be subject to inspection by GAIL/ Owner’s Inspector or by an agency authorised by the Owner. full load torque and pull out torque Measurement of efficiency and p.6 a) b) c) d) e) f) g) h) 12. In special cases where the type tests are asked to be carried out. In no case.5 Tests certificates duly signed by the GAIL I Owner’s Inspector shall be a part of final documentation. nameplate details. The manufacturer shall periodically carry out the following type tests as per applicable Indian Standards for all the frame sizes and ratings of motors: Full load test and measurement of voltage. current & power input Reduced voltage starting & running Tests on the Ex d enclosures as per IS GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 15 of 16 Copyright GAIL – All rights reserved .12. speed. terminal box location and cable gland sizes Measurement of shaft center height dimensions Measurement of clearances in the terminal box Verification of type of terminals (for Ex-e & Ex-n motors) Verification of direction of rotation Measurement of winding resistance Insulation resistance test (before & after high voltage test) High voltage test No load test and measurement of voltage. motor sub-assembly and complete motor assembly to the Inspector before offering the motors for final inspection and testing. starting current.f. Routine tests not limited to the following shall form part of acceptance testing: General visual checks. 12.4 12.7 a) b) c) d) e) f) g) h) i) j) k) l) The manufacturer shall carry out routine tests as per applicable Indian Standards on all the motors. power & slip Measurement of starting torque. 75% and 50% load Temperature rise test Momentary overload test Measurement of vibration Measurement of noise level Over speed test The above tests must be witnessed and approved by reputed inspection agencies. at 100%. mounting. The manufacturer shall maintain test records and submit to the Owner's Inspector at the time of final inspection & testing. The manufacturer shall submit all internal test records of the tests carried out by him on the bought-out items. the test records shall be more than 5 year old. current. GAIL/Owner’s Inspector shall witness these. current & power input Locked rotor test at reduced voltage and measurement of voltage. ‘Owner’s particulars’. Crates/cases shall have skid bottom for handling.8 a) b) c) d) 12.0 CERTIFICATION The hazardous area motors and associated equipment shall have test certificates issued by recognised independent test house (CIMFR/Basefa/LCIE/UL/FM or equivalent). The packing shall be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature. ‘This side up’. ‘Weight’.12. All motors (indigenous & imported) shall also have valid statutory approvals as applicable for the specified location. Special notations such as ‘Fragile’. shall be clearly marked on the package together with other details as per purchaser order. All indigenous flameproof motors shall have valid BIS license & marking as required by statutory authorities. 14. it shall not absolve the Vendor from liability regarding the proper functioning of the motors coupled to the driven equipment at site. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION S-07-02-021 REV-0 Page 16 of 16 Copyright GAIL – All rights reserved . ‘Center of gravity’.’ etc. ‘PO Nos. 13. Ex n motors shall be supplied with manufacturer’s certificate of conformity to IS 9628 or equivalent international standard and Indian statutory approval.0 PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation. All indigenous motors shall conform to Indian Standards and shall be certified by Indian testing agencies.9 The manufacturer shall submit the following certificates for verification by the GAIL/Owner’s Inspector: Test certificate for degree of protection of enclosure Test certificates issued by the recognised independent test house for hazardous area motors Approval certificates issued by Statutory Authorities for hazardous area motors BIS license and marking as required by Statutory Authorities for Ex d motors Though the motors shall be accepted on the basis of the satisfactory result of the testing at the shop. The equipment may be stored outdoors for long periods before installation. unless otherwise agreed. The equipment shall be properly packed for transportation by ship/rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases to prevent damage to the finish. INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS GAIL (INDIA) LTD NEW DELHI INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS STANDARD S-07-02-022 REV-0 Page 1 of 8 © GAIL – All rights reserved . PURPOSE 2. SCOPE 3. ATTACHMENTS GAIL (INDIA) LTD NEW DELHI INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS STANDARD S-07-02-022 REV-0 Page 2 of 8 © GAIL – All rights reserved .CONTENTS 1. DETAILS 4. 1. The schedule shall be based on project schedule as per contract and shall be updated and resubmitted to GAIL Project Manager every month. DETAILS Documents to be submitted to GAIL by contractor during the design and engineering phase shall include Engineering designs. the contractor shall specifically confirm whether all the comments are incorporated or otherwise with necessary justification.1 a) b) 2. 3. While resubmitting the drawings/documents. and finally selected equipment manufacturers.1 Contractor shall submit six copies of engineering drawings/documents to GAIL Project Manager.3. Documents under Review Category GAIL (INDIA) LTD NEW DELHI INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS STANDARD S-07-02-022 REV-0 Page 3 of 8 © GAIL – All rights reserved .1 3.3 3. PURPOSE This document describes the procedures to he followed lbr routing and review of turnkey contractor’s documents to ensure quality during design and engineering phase.1. The Review and Record categories shall be marked on the schedule by the contractor based on guidelines given in the bid package. SCOPE This procedure is applicable to contractor’s engineering documents and to the documents generated by his sub-contractors.2. The updated drawing schedule shall also include schedule of resubmission of drawings/documents after review. Vendor drawings and documents generated by Contractor’s subvendors/subcontractors/packagers and/or finally selected equipment manufacturers. drawings and documents generated by the Contractor or his sub-contractor for engineering. Suggested format for such a schedule is given in S-07-02-022-F1.3.3. 2. review/records is included in hid package. Engineering drawings and documents Contractor shall prepare and submit to owner/GAIL a detailed disciplinewise drawing schedule fir the drawings/documents to be generated by contractor or his sub contractor for Engineering indicating submission schedule for each drawing/document. Extent of Engineering Review Broad discipline-wise requirement of contractor’s documents for GAIL’S’s .2 3. packagers.2 3. INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS STANDARD S-07-02-022 REV-0 Page 4 of 8 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . However. Any error/deficiency noticed during execution/installation shall be promptly corrected by the contractor. (b) Proceed with engineering/construction as per comments marked.4 Identification of vendor drawings for owner’s review shall be completed by the contractor in consultation with the owner. Work may proceed. 3.3 3.2 Documents under Records Category Documents under this category are meant for GAIL records. No Document Details For Owner’s Review Yes/No For Contractor’s Review 3. 4.4. Contractor shall also provide a copy of updated drawing schedule to GAIL site-in. if any.1 Vendor drawings and documents While preparing the purchase requisition. All such drawings/documents shall he categorized as below S. (a) No comments. All necessary engineering drawings and documents as required by GAIL site-in-charge to ensure quality during execution/installation shall be provided by the contractor. comments. Contractor shall maintain at site one set of drawings/documents (under review category) bearing signatures of GAIL along with the review code for reference by owner’s site-in-charge.4.3.Following review codes shall he used for engineering drawings/documents.3. Submit revised drawing.3. Contractor may communicate his comments to vendor with a provision. Resubmit for review after incorporating comments.4 3. contractor shall include a list of all drawings and documents to he submitted by his subcontractor/packager/equipment manufacturer.charge every month. Review by GAIL shall not absolve the contractor of his contractual obligations. 3. irrespective of whether comments from GAIL were received or not during the drawing submission stage.2 All vendor drawings shall he first received and reviewed by contractor. (c) Document does not conform to contract specifications as marked.3. shall he communicated to contractor. ATITACHMENTS Format No.7 3. S-07-02-022-F2 shall be used for the purpose.4.4. 3. a) No comments. c) Document does not conform to contract specifications as marked.4. b) For equipment manufacture and supply through Owner’s Procurement In-charge. Contractor shall submit six copies of vendor drawings/documents to GAIL Project Manager.5 4 INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS STANDARD S-07-02-022 REV-0 Page 5 of 8 © GAIL – All rights reserved . However. S-07-02-022-F2 Waiver and deviation Permit.6 Contractor shall provide copies of Purchase Requisition bearing owner’s signature as well as the copies of vendor drawings. shall he communicated. Following review codes shall he used fir vendor drawings/documents. Submit revised drawing. submitted to GAIL Project Manager along with the certified and updated drawing schedule.3 Contractor shall submit vendor drawings/documents to GAIL only after ensuring that the documents meet the contract requirements. Additionally one set of all as-built documents/vendor drawings in bound volumes and/or in the form of electronic files on specified media shall be .4. Enclosed Format No.4. 3.6 As Built Documentation As built documents/vendor drawings shall he provided by the contractor to owner as per contract. c) For construction activities through Owner’s site-in-charge.5 3. if any. reviewed by GAIL to the inspector for shop testing/inspection of various equipment/materials. Resubmit for review after incorporating comments. Work may proceed b) Proceed with fabrication/manufacture as per comments marked. 3.. GAIL (INDIA) LTD NEW DELHI 3. Waiver and Deviation All waiver/deviations after contract award shall be routed as below a) For design and engineering through Owner’s Project Manager. S-07-02-022-F1 Typical Drawing Document Schedule. comments. All such documents shall include contractor’s comments and his approval signature/stamp. Documents under Record Category shall be retained by Owner for records.4 3.that any further comments by owner shall he communicated subsequently for incorporation. No Title Category Review / Record Rev I Sch Review Date Code Actual Review Issue Date Date Rev 2 Sch Review Date Code Actual Review Issue Date Date GAIL (INDIA) LTD NEW DELHI INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS STANDARD S-07-02-022 REV-0 Page 6 of 8 © GAIL – All rights reserved .Typical Drawing Document Schedule Discipline ______________________ Rev 0 Sch Review Date Code Actual Review Issue Date Date S-07-02-022-F1 S No Drg. /Doc. WAIVER/DEVIATION PERMIT (Strike out whichever is not applicable) S-07-02-022-F2 Project: ________________________________ Job No: ________________________________ Originator Ref: _______________________ Order/Contract No ____________________ Originator: Vendor/Consultant/Contractor: ____________________________________ Requirement as per specification Description of Waiver / deviation Sought TO BE FILLED BY THE ORIGINATOR Why is the waiver required? Contractual implication if waiver/deviation is granted o o Time taken shall be Cost of Item shall be More More Less Less No Change No Change o Performance requirement shall be Satisfactory Unsatisfactory Under the present constraints requested waiver/deviation is most optimum for the project and does not involve any security and safety hazard. on time/cost implications (To be filled by the department responsible for conveying to the originator) Signature & Seal Vendor/Consultant/Contractor Date: ___________________ Signature _________________________ Name:____________________________ GAIL (INDIA) LTD NEW DELHI INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS STANDARD S-07-02-022 REV-0 Page 7 of 8 © GAIL – All rights reserved . if any. Date: ___________________ Decision on waiver/deviation with remarks. S-07-02-022-F2 Opinion from Consultant’s Supervisor/Inspector (Specific if post facto approval is required) Date :___________________ Signature: _______________________ Name: __________________________ Department: ______________________ Forwarded to _________________________ by Head of Consultant Establishment (Project Manager) Date:__________________ Forwarded to _________________________ (Target Resolution Div/Deptt/Group) Signature: _______________________ Name: __________________________ Date:__________________ Signature: _______________________ (Project Manager) Name: __________________________ Disposition by Target Resolution Div/Deptt/Group Date:__________________ Signature: _______________________ Name: __________________________ FINAL DECISION OF PROJECT MANAGER ALONGWITH OVERALL REVIEW Date:__________________ DECISION OF ACCEPTING AUTHORITY (IF REQUIRED) Signature: _______________________ Name: __________________________ Date:__________________ Signature: _______________________ Name: __________________________ GAIL (INDIA) LTD NEW DELHI INSTRUCTIONS TO TURNKEY CONTRACTORS FOR ROUTING AND REVIEW OF DOCUMENTS STANDARD S-07-02-022 REV-0 Page 8 of 8 © GAIL – All rights reserved . SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 1 of 32 © GAIL – All rights reserved . Abbreviations: BIS BASEEFA CCE CFAP CMRI CPU DGFAP ERTL FAT FDD FM FRP FO GUI HAB HDD ISDN ITULED LPC LIFO MCP MMI MR Ni-Cd PO RF SAT SOE TAC UL UPS VRLA WP ZFAP Bureau of Indian Standards British Approvals Service for Electrical Equipment in Flammable Atmosphere Chief Controller of Explosives Central Fire Alarm Panel Central Mining Research Institute Central Processing Unit Data Gathering cum Fire Alarm Panel Electronic Regional Test Laboratory Factory Acceptance Tests Floppy Disk Drive Factory Mutual Fibre Reinforced Plastic Fibre Optic Graphic User Interface Hooter acknowledgement box (to mute hooters) Hard Disk Drive Integrated Service Digital Network T International Telecommunication Union. BGU) Man Machine interface Material Requisition Nickel Cadmium (battery) Purchase Order Radio Frequency Site Acceptance Tests Sequence Of Event Tariff Advisory Committee Under Writers Laboratory Uninterrupted Power Supply Valve Regulated Lead Acid (battery) Weather Proof Zonal Fire Alarm Panel GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 2 of 32 © GAIL – All rights reserved .(Telecom) Light Emitting Diode Loss Prevention Council Last in First Out Manual call point (break glass unit. 17. 2. 12.CONTENTS 1. 6. 7. 4. REPEATER) CABLE AND CABLE ACCESSORIES AUTOMATIC FIRE DETECTORS AND ACCESSORIES FIELD DEVICES FOR HAZARDOUS AREA ENGINEERING REQUIREMENTS INSPECTION. 5. 16. 11. TESTING AND ACCEPTANCE PACKING AND DESPATCH INSTALLATION AND COMMISSIONING TRAINING GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 3 of 32 © GAIL – All rights reserved . SCOPE CODES AND STANDARDS GENERAL REQUIREMENTS DEFINITIONS SYSTEM AND SITE CONDITIONS FIRE ALARM SYSTEM DESCRIPTION CONVENTIONAL FIRE ALARM SYSTEM MICROPROCESSOR BASED FIRE ALARM SYSTEM INTEGRATION WITH VARIOUS PLANT SYSTEMS PANEL CONSTRUCTION (CFAP. ZFAP. 9. 18. 10. 14. 8. DGFAP. 15. 3. 13. the following order of decreasing priority shall govern: o Statutory regulations o Data sheets o Job specifications o This specification o Codes and standards The fire alarm system and the components used shall conform to the latest edition of the following and also the other Indian and International Standards as applicable. o IS —513 Specification for cold rolled low carbon steel sheets and strips o lS2 148 Flameproof enclosures for electrical apparatus o IS 1646 Code of practice for fire safety of buildings (general): Electrical Installations SPECIFICATION S-07-02-024 REV-0 Page 4 of 32 1. design.1 2.3 2. This specification covers the requirements for selection. detectors.2 2.1. as applicable. 2. CFAP and associated equipments detailed hereunder and in Project data sheets! drawings. In case of imported equipment.2 2. the standards of the country of origin shall be applicable if these standards are equivalent or more stringent than the applicable Indian standards. standards issued by IEC! BS/ VDE! IEEE! NEMA/NFPA or equivalent agency shall be applicable. The Integrated Fire Alarm System shall be conventional or micro processor based analog addressable system comprising of MCP. 1. manufacture. testing at vendor’s works. In case Indian standards are not available for any equipment. and engineering. In case of any contradiction between various referred standards! specifications! data sheets and statutory regulations. o IS-5 Colours for ready Mixed Paint & Enamels.4. testing at site and commissioning of the system. supply. installation. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved .1 SCOPE The intent of this specification is to define the functional and design requirements for an Integrated Fire Alarm System for industrial plants and buildings. conventional or microprocessor based Fire Alarm panels. CODES AND STANDARDS The system and equipment shall comply with relevant BIS (Bureau of Indian Standards) and other Indian/ International standards. The equipment shall also conform to the special requirement! provisions of applicable statutory regulations currently in force in the country. The spares shall be available ex-stock with the vendor. SPECIFICATION S-07-02-024 REV-0 Page 5 of 32 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved . No prototype equipment shall be offered.o IS 2175 Specification for heat sensitive fire detectors for use in automatic fire alarm system o IS 2189 Code of practice for selection. o BS 5839 Specifications for manual call points.1 3.2 GENERAL REQUIREMENTS The offered equipment shall be brand new with state of the art technology and a proven field track record. Part 2 o BS-EN EMC 5008 1-1 (Electromagnetic compatibility test) o BS-EN EMC 50082-i (Electromagnetic compatibility test) 3. 3. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment for at least 15 years from the date of supply. installation and maintenance of automatic fire detection and alarm system. o IS 3034 Code of practice for fire safety of Industrial buildings: Electrical generating and distributing stations o IS 3700 Essential ratings and characteristics of semi conducting devices (Applicable parts) o IS 3826 Connectors for frequencies below 3 kHz General requirements Part-I and tests IS 5469 Code of practice for the use of semi-conductor junction devices (Applicable parts) o IS 5780 Specification for Intrinsically safe electrical apparatus and circuits o IS 11360 Specification for smoke detectors for use in automatic electrical fire alarm system. o IS 12459 Code of practice for fire safety in cable runs o IS 13346 General requirements for electrical apparatus for explosive gas atmosphere o IS-14154 Electrical apparatus with protection of enclosure for use in the presence of Part 2 combustible dust NFPA 72 National Fire Alarm code Vol 4 o LPC Loss prevention council recommendations. 1 4. shall be included as a part of the offered system. All indigenous equipment shall conform to Indian standards and shall be certified by Indian testing agencies.numeric LCD displays along with LED displays for fire! fault conditions. I/O cards for interface with other Purchaser’s equipment. and shall freely and readily supply all technical information as and when called for. It functions as fire alarm panel located centrally to population of fire detectors distributed over an area for optimizing and limiting the loop lengths. It also includes loop cards (for field devices). All equipment and accessories required for completeness of the system. All indigenous flameproof equipment shall have valid ISI license and marking as required by statutory authority. BASEEFA.3. It is electronic for conventional and microprocessor based for addressable system. Equipments to be located in hazardous areas shall have test certificates issued by recognized independent test house such as CMRI. DEFINITIONS CFAP: It is a fire alarm panel located in fire station or in disaster management control rooms. The system integrator shall coordinate with the manufacturers of various bought-out items associated with the system. ERTL. plant’s public address system etc. It has mimic for geographical display of alarms either on panel or as graphic displays on MMI.5 3. 3. It has alpha.4 3. DGFAP: It is a Microprocessor based fire alarm panel. designed for use with addressable fire alarm system. All equipment (indigenous & imported) shall also have valid statutory approvals as applicable for the specified location. The vendor shall be responsible for design. UL. CFAP is designed to gather information from distributed fire alarm panels provided in the plant! buildings and have features such as provision to activate plant-wide sirens.6 3. exit sign and hooters. as required.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 6 of 32 © GAIL – All rights reserved .7 4 4. engineering and manufacturing of the complete system and equipment to fully meet the intent and requirements of this specification and attached data sheets. whether specifically mentioned or not but considered essential for satisfactory performance.3 Vendor shall give a notice of at least one year to the end user of equipment and E1L before phasing out the product! spares to enable the end user to place order for spares and services. FM or equivalent. have interface with telephone exchange. ZFAP. This has functionality similar to what is provided for DGFAP. exit signs. cable requirement. FIELD DEVICES Devices such as detectors. INTEGRATED FIRE ALARM SYSTEM: It signifies a comprehensive fire alarm system comprising all the distributed fire alarm panels (DGFAP. pager system and public address system. or likely to be present in quantities such as to require special protection for the construction. 4. screened cable. This has LEDs for fire! fault annunciations.5 4. air conditioning etc. DATA HIGH WAY This term is meant to define the communication path between DGFAPs. REPEATER PANEL: It is similar to distributed fire alarm panels (DGFAP/ ZFAP) but will not have Zone card! Loop card for field devices.3 ZFAP: It is a fire alarm panel for conventional fire alarm system. communication hardware. SYSTEM ARCHITECTURE System architecture is line diagram defining the connectivity of DGFAPs. It shall provide interfaces with fire protection system and other systems like pressurization systems. are termed as field devices.6 4. I-lAB for individual buildings shall be provided at its exit. MCP.7 4. It provides audio! visual alarm building/plant-wide having provisions for connectivity with telephone exchange.9 4. repeater panels etc) having integration with CFAP for fire monitoring of total plant! building. communication protocol.8 4.4.4 4. repeater and CFAP. HAZARDOUS AREA An area in which an explosive gas! dust atmosphere is present. siren etc. hooters.10 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 7 of 32 © GAIL – All rights reserved . installation and use of electrical apparatus. CFAP and other network components in microprocessor based fire alarm system. This also specifies various system requirements such as redundancy. HAB This term is defined as Hooter Acknowledgement Box. These are provided at manned locations and are configured to acquire information about the fire! fault of selected zones from DGFAP! ZFAP and annunciate. workstation and programming tools. Physical media for Data highway can be fibre optic (FO) cable or twisted pair copper conductor. 5. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 8 of 32 © GAIL – All rights reserved . Power supply for fire alarm panels shall have battery back up as per IS-2189. A suitable power distribution to various equipment and sub system shall be included in vendor’s scope. SITE CONDITIONS The offered equipment shall be capable of operating continuously and maintaining its guaranteed performance at the site ambient conditions indicated in data sheet. fire alarm panels along with associated hardware shall be suitable for installation and operation in a closed building! room with restricted ventilation. INPUT POWER SUPPLY Unless stated otherwise. in the event of mains failure. etc.1 5.plant buildings. purchaser shall provide one point power supply to each fire alarm panel (ZFAP/DGFAP/CFAP! repeater panel). for the panels. Suitable and adequately rated battery charger shall be supplied as a part of back up battery system. 6.) 5. if absolutely necessary.1. shall be clearly highlighted by the vendor in the offer. shall be automatic. Batteries shall be Ni-Cd / VRLA type as specified in data sheets. 6.2.1.2.5 SYSTEM AND SITE CONDITIONS All equipment shall be designed to operate with power supply and site conditions as specified below: 5. The system shall be designed to detect incipient fires and generate audio! visual alarm in case of fire. (The full load alarm condition is defined as operation of all panel/field audio and visual alarm and the alarm load of 25 percent of total zones besides other normal operation loads. Any specific requirements for air conditioned! dust free environment.1 FIRE ALARM SYSTEM DESCRIPTION GENERAL Fire alarm system under this specification is envisaged to provide fire monitoring in industrial plants! chemical plants! plant and non. Unless specified otherwise. Battery AR rating shall be determined on the basis of maintaining the system in normal operation for a period of not less than 48 hours (quiescent condition) and successive full load alarm condition of period not less than 30 mm after the failure of normal mains supply.1. The switch over from mains to back up. details of which are indicated in data sheet. These panels shall continuously monitor the state of these devices. CFAP shall have provision for automatic and manual actuation of plant-wide siren as per operator’s choice. optica’ or ionization type detectors shall be used. Interface with other systems such as telephone exchange! plant’s public address system! Pager system shall be provided for communication required for disaster management. The connectivity shall be achieved using data high way or dedicated cable connection from each fire alarm panel to CFAP. an audio! visual alarm shall be initiated identifying the zone where fire is detected. Detectors and MCP at these buildings and plants shall be connected to DGFAP! ZFAP. For integrated fire alarm system where plant-wide large numbers of fire alarm panels are envisaged. The plant! building shall be divided into fire monitoring zones. Automatic fire detectors shall work on the principle of sensing of smoke. if specified. 6. Panels shall continuously monitor the health of the cabling and in case of short circuit or open circuit fault alarm shall be actuated. On sensing fire condition. Further. Conventional fire alarm system shall generally comprise but not be limited to the following equipment used in conjunction with conventional automatic fire alarm detectors and manual call points as a minimum. Depending on type of smoke. Detectors shall generally be provided in plant! non-plant buildings. If defined. In addition facility shall be provided to actuate siren! hooter. shall be relayed to repeater panel provided in buildings like control rooms! administrative buildings to provide zone wise annunciation. CFAP with! without mimic (as per data sheet) GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 9 of 32 6.2. these panels shall be integrated to CFAP. i.1 © GAIL – All rights reserved . panels shall provide required output for interfacing with the Purchaser’s systems such as air conditioning system or pressurization system or fire protection systems. Manual Call Point shall be provided at exit doors of the buildings and at exit route of industrial plants.2 CONVENTIONAL / ADDRESSABLE FIRE ALARM SYSTEMS Fire alarm system shall be conventional fire alarm system or microprocessor based fire alarm system as specified in data sheet. which shall be located in fire station or in administrative control room of the building as per the job requirements. Conventional fire alarm system shall have conventional field equipment and Microprocessor based system shall have addressable type field devices.The system shall consist of automatic fire detectors and manual call point or break glass unit. heat or infrared rays. Alarms. Number of detectors and break glass unit shall be decided as per guidelines given in applicable codes and standards. Fire alarm panels shall also have powered outputs for switching on exit signs and hooters as specified in data sheet. Mimic at CFAP shall be provided for fire! fault annunciation on geographical location in addition to the text! LED. switches. The design of common facility and hardware shall be provided for required future extension of zones. processor and power supply vii. 6. ZFAPs Repeater Fire Alarm Panel Plant-wide Sirens and starters Hooters. vi.1. Dual redundant copper! FO cable data highway complete with dual redundant architecture for communication hardware including communication port.2. Short circuit detection iii. 7. Panel design and component selections shall be done for future extension up to 10% of specified zones or one zone whichever is maximum in each panel. v.g. i. Earth faults iv. Power supply failure e.ii. ii.1 7. exit sign and flAB in buildings v. CFAP consisting of computer based graphic workstation and engineering station. exit sign and flAB in buildings Interface with Purchaser’s systems Any other hardware as required to render system complete Microprocessor based fire alarm system shall generally comprise but not be limited to the following equipments used in conjunction with addressable automatic detectors and addressable MCP as a minimum. Any other hardware! Software required for rendering system complete As specified in data sheet.1. vii. i. Following self-diagnostic features may be considered as minimum. Interface with Purchaser’s systems vi. Open loop detection ii. iii.2. Hooters.1 7.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved . main incoming supply fail v. Multi loop DGFAPs iii. low battery voltage. Each PCB shall have LED for annunciating card failure. iv. Plant-wide sirens and starters iv. CONVENTIONAL FIRE ALARM SYSTEM DESIGN FEATURES The system shall be modular and shall facilitate future extension ! modification.3 7. the system shall be provided with siren!s to be located at a suitable Iocation!s in the plant and it shall be actuated manually and automatically as selected by operator from CFAP! DGFAP located at fire station! other buildings. PCBs shall have watchdog feature for self-diagnostic. System faults (PCB failure) SPECIFICATION S-07-02-024 REV-0 Page 10 of 32 6.2. Fault LED OFF Flasher OFF.1. If zone is protected with clean agent! CO2 system.5 7. and functional tests etc through common “Test” push button. Scheme for FIRE/FAULT annunciation shall be as per the following. If required noise filters shall be provided at fire alarm panel. The circuit shall be so designed that silencing of the current alarm by ACCEPT push button shall not prevent annunciation of subsequent fire alarm received from any other location Signal-to noise ratio shall be high to avoid spurious actuation due to noise induced in the field wiring because of proximity with power cables.5 mm2 multi-core. Fire LED steady ON 7. unscreened.1. Cables for field devices shall be multicore copper conductor. armoured cable. Battery/ Charger status. armoured. System condition AUDIO VISUAL NORMAL FIRE Accept Reset FAULT Accept Reset OFF ON (tone 1) OFF OFF ON (tone 2) OFF Flasher OFF Flasher OFF Flasher ON.8 7. Detectors and MCPs in a ioop shall be wired through I .1.10 Flasher OFF.1. Battery backup ON. Copper conductors. Fault LED Steady ON OFF.6 7.1.7 7. Fire LED Steady ON Flasher steady. NC contact of field devices shall be considered as healthy condition and NO as fire condition. PVC insulated.1. LEDs shall be provided for fire! fault visual annunciation on the panel front. hooters. LED shall also be provided for Power supply healthy. flasher circuit.9 7. the detectors and MCPs of the zone shall be wired in cross-zones by providing minimum two loops in a zone.7. 1 NO+ I NC contact of output relays shall be wired to terminal block for interface with Purchaser’s other equipment. Fault LED Steady ON OFF.4 7. The last device in each loop shall be provided with end of line resistor of suitable value as per circuit design to facilitate cable open circuit and short circuit detection. Limiting distance from fire alarm panel to last detector/MCP shall not be less than 2 km or as specified in data sheet whichever is maximum.e.3 Logic of operation shall be built on ‘Fail safe” feature i.1. Fault LED OFF SPECIFICATION S-07-02-024 REV-0 Page 11 of 32 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved . copper conductor cable.1. It shall be possible to test lamps. 220V DC or 2A. input power supply from purchaser shall either be 240V or 110 V. Circuit shall be designed to provide annunciation if any detector in a zone senses fire.10 Depending on the size Repeat Fire Alarm panel may be floor mounting type or wall mounting type. ZFAP shall be free.4.10.1 of this specification.1. Test and Reset Push Buttons.2. ZFAP shall have required interface hardware where integration with CFAP/ repeater panel is envisaged as per data sheet.standing. Fire and fault annunciation for each Zone or group of zones at ZFAP shall be repeated at CFAP. ZFAP shall be located indoor in safe area. Annunciation scheme shall be as per 7. Input power supply and battery backup for ZFAP shall be as per data sheet and as per clause 5.4 7.1.11 7.1. Annunciation scheme at CFAP shall be provided as per the clause 7..2 7.2. It shall monitor fire! fault condition of the zone. Annunciation scheme shall be as per clause 7.2.1. Fire! fault annunciation of ZFAP shall be repeated to repeater panel. It shall be possible to select supply either 240V or 110 V at site without modifying or adding additional equipment in the panel.2. Where required.5 7.1.5A.7. CENTRAL FIRE ALARM PANEL CFAP shall be located in fire station in plants or in building control room.2. floor mounting vertical panel consisting of audio/visual annunciation with Alarm Accept. Auto/Manual control of hooters provided in buildings.3 7.1 7.3. REPEAT ALARM PANEL-CONVENTIONAL Repeat fire alarm panel shall be similar to ZFAP except providing zones for detector loops. 240V AC.10 Audio! Visual indication and annunciation shall be as per clause 7.6 7. Provision to actuate siren shall be provided if specified in data sheet. 50Hz.2 7.8. Output contacts (1NO+1NC) shall be provided for interface with Purchaser’s systems as per clause 9 of this specification.2. The rating of output contact shall be 0.4 7.3. Detectors! MCP! heat sensing cables etc shall he connected zone wise in a loop.1 Fire alarm panels including repeater panels and CFAP shall be certified! approved by applicable approving agency of country of origin as required.2 7. ZONAL FIRE ALARM PANEL ZFAP shall consist number of zones as specified in data sheet. SPECIFICATION S-07-02-024 REV-0 Page 12 of 32 7.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved .3 7. 1 phase. Open loop detection ii. Mimic panel shall be powered by CFAP. Unless otherwise specified in the data sheet.7. All fire alarm panels including repeater panel shall be networked through data high way.1. MICROPROCESSOR BASED FIRE ALARM SYSTEM DESIGN FEATURE Unless otherwise specified Microprocessor based system shall be analog addressable type.4. parameterization of addressable field devices.4 8 8. Panel design and component selections shall be done for future extension up to 10% of specified zones or one zone whichever is maximum in each panel. Input supply and battery backup for CFAP and MIMIC shall be as per data sheet and as per clause 5. The system shall be integrated as per ‘system architecture’ indicated in data sheets.2 8. Each PCB shall have LED for annunciating card failure.g. Short circuit detection iii. PCBs shall have watchdog feature for self-diagnostic. The design of common facility and hardware shall be provided for required future extension of zones. When separate mimic panel is specified. it shall either be wall mounting or freestanding floor mounted type. The system supplied shall not pose any limitation for future expansion by way of networking of fire alarm panels. Two LEDs shall be provided for each zone on mimic panel for display of fire alarm.3 8. System faults (PCB failure) SPECIFICATION S-07-02-024 REV-0 Page 13 of 32 7. i. Power supply failure e.2 CFAP shall be in vertical panel construction or desk type construction having controls such as Accept.4. Mimic shall form an integral part of the CFAP and shall be located at the top of the panel. main incoming supply fail v.1 8.1 of this specification. CFAP shall have mimic to display geographical location of fire. Test and Reset Push Buttons. data transfer.1. Earth faults iv.1 8. Microprocessor based fire alarm system shall be designed to use state of the art technology.4 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved .1. low battery voltage. Mimic made out of plastic stickers shall not be acceptable. The system shall be modular and shall facilitate future extension! modification.3 7.1.4. Following self-diagnostic features may be considered as minimum. Auto/Manual control of siren etc. graphic displays etc. 10 8. SPECIFICATION S-07-02-024 REV-0 Page 14 of 32 8. network switches! hubs etc including power supply system as required to suit the length of data highway.1. Whether specified or not. If required noise filters shall be provided at fire alarm panel.12 8. repeaters.1. screened and unarmoured and shall be laid in conduits while cable laid outdoor in plant shall be twisted pair. Unless other wise specified. Any fault in Analog detector addressable loop and data highway shall not impair communication i. screened and armoured.6 Unless specified otherwise in data sheet. Unless otherwise specified in data sheet.1.8 8.8. The logic for zone protected with clean agent system! CO2.11 8.1.1.1.9 8.e.5 i) ii) iii) iv) v) vi) 8.7 8. the minimum number of detectors! MCP/ addressable devices in a signal loop shall be 60.1.1. Fire alarm logic shall be programmable type. repeater Panels. fault tolerant type as per NFPA 72. Signal-to noise ratio shall be high to avoid spurious actuation due to noise induced in the field wiring because of proximity with power cables. The loop cabling for wiring detectors and MCPs shall be class A.13 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved . The logic shall be so programmed that silencing of the current alarm by ACCEPT push button shall not prevent annunciation of subsequent fire alarm received from any other location. fire alarm cables laid in buildings shall be twisted pair. shall be programmed to provide output for actuation after ensuring that there is no false alarm. Dual redundant at processor level (communication processor and I/O card processor) Dual redundant communication port Dual redundant data highway cable Dual redundant microprocessor at CFAP Dual redundant work station/MMI (engineering station operator’s station) Dual redundant power supply card at all fire alarm panels (but with single source of battery backup) Data highway shall be Fibre optic or twisted pair shielded copper cable as specified in data sheets. CFAP and other system components connected on fire alarm system data highway. Similarly logic to switch ON the exit sign and sound the hooters shall be programmable type. The communication shall be peer to peer between various DGFAPs. Communication! flow of analog signal shall be possible from either end of the loop.1. data highway shall include all necessary hardware such as modem. system architecture shall have minimum redundancy indicated below however not limited to the same. After Programming.1. Fault LED Steady ON OFF.1.18 All field devices such as detectors and MCPs shall be addressable type. due care shall be taken care in design to avoid signal distortion and thus the mal-operation due to cable capacitance and inductance.15 8.16 8. DGFAP and repeater panel shall have backlit alphanumeric LCD display to provide addresses. . In addition LEDs shall be provided for fire/ fault visual annunciation. status of each field device. All events shall be time stamped. hooters and exit sign may also be connected in addressable loop. Fault LED OFF Flasher OFF. Fire LED steady ON 8. System condition NORMAL FIRE Accept Reset FAULT Accept Reset AUDIO OFF ON (tone 1) OFF OFF ON (tone 2) OFF Flasher OFF Flasher OFF Flasher ON. If available in vendor’s design. As far as possible. To optimize length. LED shall also be provided for Power supply healthy.1. Any of the two should be possible to configure as engineering station for programming off line.1. Fire station shall be provided with dual redundant PC with monitor for operator’s workstation and for engineering station. If unavoidable.1. Fault isolators shall be provided to minimize outage of number of detectors) MCPs in case of loop cable fault.19 8. Software access for either Zone programming or access to plant! building graphic on monitor shall be password protected.1.Ssqmrn copper. The allowable signal loop length shall not be less than 2 km. Scheme for FIRE / FAULT annunciation shall be as per the following.20 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . the engineering station will be connected to network as online operator’s workstation. circuit design for loop shall allow the use of spur connection. The event shall be stored in LIFO structure. For hazardous area flame proof equipment shall be used. System shall provide adequate EEPROM size to store minimum of 10 events fire! fault. For viewing status of SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 15 of 32 8. Battery! Charger status.8. Battery backup ON.14 Unless otherwise specified in data sheet. Fire LED Steady ON Flasher steady. Programming shall also allow activating Siren from the keyboard in manual mode as per operator’s choice. conductor size of loop cable shall be 1 .1.17 VISUAL Flasher OFF. Fault LED OFF 8. the use of intrinsically safe field devices in hazardous area should be avoided. Fault LED Steady ON OFF. DGFAP shall have real time clock for event time stamping. 2. DGFAP shall have serial port for communication to data highway.2 8. fire and fault status password protection shall not be given.1 8.5 8.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved . Number of loops shall be basic part of main PCB and should not be extended by providing external electronic devices. These panels shall be similar to DGFAP and shall be connected to data highway through serial communication.3.1 .3 8.6 8.1 7. 8.2. DGFAP shall work as stand alone intelligent panel monitoring fire in the zones connected to it. DATA GATHERING CUM FIRE ALARM PANEL (DGFAP) DGFAP shall have basic design features as per clause 8.2.2. The protocol of communication shall preferably be open protocol.2.2 8.1 above.g. It should be possible to communicate all the information to CFAPI FA system workstation located with fire marshal.2.2. Panels shall have programming facility to inhibit the display of information that is not required in a particular repeater panel. DGFAPs shall have output relays to provide interface with Purchaser’s system defined in clause 9 as minimum. It shall be possible to interface with existing fire alarm system consisting of conventional zone detectors and MCPs with end of line resistor as a part of retrofitting.21 Fire alarm panels including repeater panels and CFAP shall be certified! approved by an international approving agency! approving agency of country of origin as applicable. LCD display and annunciation scheme shall be as per clause 8. SPECIFICATION S-07-02-024 REV-0 Page 16 of 32 8. Number of signal loops in each DGFAP shall be as defined in the data sheet.3 8. It shall be possible to change the reference value of detector sensitivity either manually or automatically as required during the operation to avoid false alarms prior to detector maintenance. REPEAT ALARM PANEL These panels shall be required for repeat of alarm in building! plant control rooms. In the event of non-availability of data highway.4 8. It shall be possible to configure DGFAP to access data of any other DGFAP and display as per the operation requirement to be finalized during engineering! commissioning.various field devices e.7 8.1. the changed parameters shall be down loaded to other PC to work in synchronism as normal operation.2 8. It shall be possible to actuate plant-wide siren in auto! manual mode. which shall be finalized with end user during implementation. Unless specified otherwise. Application software shall be installed in PC as GUI. The navigation between various graphic pages shall be user friendly.4. Engineering workstation shall be used for programming off-line.4. Battery backup shall be sized as per criteria given under 5. Siren starters shall be hardwired to DGFAP. It shall monitor the status of each addressable field device indirectly from the DGFAPs connected on data highway. Auto!Manual selection shall be provided at operator’s workstation. The minimum requirements for the PC and other peripherals shall be as stated below: o Industrial type Latest generation PC o 1 .44 MB Floppy drive o CD-ROM o Mouse and keyboard o 21 Inch coloured monitor with flat screen o SOE dot matrix printer o Engineering laser jet coloured printer with 8 PPM SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 17 of 32 8.4. vendor may supply CFAP similar to DGFAP along with PC based monitoring station. adequately rated UPS with bypass shall be provided for PC based monitoring station.6 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Alternatively.4. manual actuation shall be done from keyboard of workstation. This station shall also have two printers connected to PCs working as SOE printer and engineering printer. Only normal supply shall be made available at one point by Purchaser at the location of central fire alarm panel.4. CFAP shall have all the features and facilities of the DGFAPs. The actuation signal under manual mode selection shall be communicated serially to DGFAP to which siren starter is connected.1.1 8.3 8. After programming. The screen shall have defined area to display the latest fire or fault alarm and shall also have facility to pop up the graphic displaying the location of fire event.8.5 8. Unless stated otherwise. The graphic shall include geographical location of various plant areas including location of addressable detectors and MCPs. SOE printer shall be high-speed dot matrix printer and engineering printer shall be laser printer.4 8.4.4 CFAP/ PC BASED MONITORING STATION OR WORK STATION Based on vendor’s system design CFAP shall include network PC based monitoring station directly connected to data highway with other peripherals such as network switches! controller (HUB). Auto actuation shall be through software logic. Unless other wise specified. Access for programming and access for controls from keyboard shall be password protected. iii. petrochemical complex or the large multistory building. Selector switches for primary or secondary clean agent/CO2 supply for each protected area.7 It shall be possible to provide multilevel access of fire alarm system. iv. The actual release of clean agent! C02 shall however be delayed by 30sec after the alarm. high speed. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 18 of 32 © GAIL – All rights reserved . ii.2 INTEGRATION WITH VARIOUS PLANT SYSTEMS Fire Alarm System shall have required hardware to have interface with following plant systems as specified in data sheet. 8. Plant data network ISDN telephone exchange and pager system Fire suppression system ZFAP as a minimum shall be provided with the following interface with fire suppression system unless specified otherwise. 8. Shutdown signals to various air-handling units relative to the zone of fire. Public Alarm Announcement system Paging and plant intercom systems. v. 9. alarms. Firewater pumps start push buttons. 9 9. number of field devices as required for any large plant like refinery. vi.8 Printer i. Read only access shall not require password protection.4. viii. iii. vii. i. Manual push button for discharge of clean agent/CO2 in each protected area.Application software supporting graphics with no limitation on number of graphics. v. Deluge valve activation push buttons. Printer options shall include both graphic laser printer and dot-matrix event text printer. ii. iv. events. ii.1 i. and shall be microprocessor controlled. Printer used in the system shall provide real time records of the system events and provide system reports on demand. Clean agent/CO 2 Discharge inhibit push button for each protected area.4. deluge valve test push buttons and deluge valve activated status lamps. Automatic signal for release of clean agent/CO2 release for protected area and RELEASE audio! Visual alarm for evacuation. read only (RO) letter quality dotmatrix type 132 characters wide and 96 character set. Firewater pumps running indications. The levels of password protection shall be agreed with plant operators at the time of commissioning of system. DGFAP. instruments and indicating lamps mounted on the panel front shall be flush mounting type. Routine calibration.4 10. humid and dusty environment.2.2 10.5mm dia.1 PANEL CONSTRUCTION (CFAP.10 10. PCBs for identical functions shall be interchangeable.1 10.6mm CRCA sheets. such that only field termination shall be required at site before it is energized. Cable entry shall be from bottom unless otherwise specified in the data sheet. Control wiring for electronic circuits shall be through ribbon cable or through copper wire minimum of 0. adjustments. External cabling shall preferably be done from the rear.3.1. The external cabling shall not be terminated directly on the base connector of PCBs but shall be terminated on separate terminal block. 10. These shall be protected with anti fungus treatment.3 10.2. 1. programming and operation shall be accessible from the front of the panel without opening the door. Further connection to PCBs shall be as per manufacturer’s standard.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 19 of 32 © GAIL – All rights reserved .2 10. EQUIPMENT MOUNTING All apparatus. Control connections shall be done with 660V grade PVC insulated wires having stranded copper conductors. Doors shall be provided with pistol grip handle with lock.3 10. display screen.1 10. Panels shall be supplied completely pre-wired. ZFAP. floor mounting type unless specified otherwise and shall be fabricated out of minimum 2mm thick CRCA sheets and doors shall be fabricated out of minimum 1. PCBs shall be plug in type having pin/edge connectors.3. Lamps shall be provided inside the panel to provide adequate light for maintenance of equipments.2. WIRING AND TERMINALS Wiring within the panel shall be laid in slotted plastic raceways enclosed with cover. Terminal strip shall be provided for incoming I outgoing cables. PCBs shall be suitable for use in tropical. Power supply system including battery bank shall be mounted inside the panel. The panel shall be naturally ventilated in IP-41 enclosure protection as minimum.2. REPEATER) All fire alarm Panels shall be free standing.5mm2 size of wire shall normally be used for circuits with control fuse rating of I OA or less. 5.5 10. Hard paper or self-adhesive plastic tape nameplates shall not be acceptable.2 10.1 10. mounted on rails. Fabricated structures shall be pickled and then rinsed to remove any trace of acid.3 10. Engraving shall be done with square groove cutters. connecting wires as well as for the terminals in the terminal strip inside the panel.5mm2 cross section conductors.6. Two numbers earth lugs shall be provided outside the panel.2 10. as a minimum 2.mounted equipment shall be earthed. run-off paint etc. The undersurface shall be made free from all imperfections before undertaking the finishing coat.3 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved . Moving elements shall be greased.5. copper or equivalent aluminum shall be provided throughout the length of the panel.3.6. Labels shall be provided for every component on the cards. PAINTING All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale. rust. NAME PLATES / WARNING PLATES All nameplates for panel shall be engraved out of 3 ply (black-white.4 10.5.1 10. Panel finish shall be free from imperfections Like pinholes.6 10. All noncurrent carrying metallic parts of the panel. Clamp type terminals shall be of spring-loaded. EARTHING A common earth bar of minimum 25 x 3 mm. stacking type.6. Wiring diagram shall be pasted inside the panel door as required for termination and maintenance. The colour shade of final paint shall be as approved by the purchaser. orange peels.1 10.3 Cables shall be terminated on terminal blocks. Flexible jumpers shall connect all doors and movable parts to the earth bus.4. grease and dirt. At least 20 % spare terminals shall be provided in each panel for termination of spare cores of cables. Terminals shall be sized to accept. the panel shall be powder coated.black) lam icoid sheets or anodized aluminum. The finished panels shall be dried in dust free atmosphere.10. Special warning plates shall be provided on all removable covers or doors giving access to energized metallic parts above 24 volts. All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust-corrosion. Back-engraved Perspex sheet nameplates will also be acceptable. After preparation of the undersurface. SPECIFICATION S-07-02-024 REV-0 Page 20 of 32 10. Not more than one conductor shall be terminated on the outgoing side of each terminal. 1 CABLE AND CABLE ACCESSORIES Unless otherwise specified. Incoming power supply cables from purchaser’s switchgear to Fire Alarm Panels All other cables as required for fire alarm system including the supply.) iii.1.4 11. Loop! Zone cables from FA panel to JB (Vendor shall provide JBs in each building for signal loop cabling. DATA HIGHWAY CABLES Unless specified otherwise. Cable from purchaser’s switchgear to siren starter and siren starter to siren. Bidder.3 11.4. hooters and also supply. vi. Fibre Optic cables. number of pairs. cables for hooter/exit signs etc giving details such as type of cables. if supplied. number of fibres! connectors etc. FR type PVC outer sheathed as the minimum requirement. Cables from JB to fire alarm panel is included in purchaser’s scope while cable from JB to detectors and all other field devices shall be included in vendor’s scope. Exit sign and hooter cables from FA panel to JB (Vendor shall provide separate JB for exit sign and hooter. inductance and capacitance data. shall be of adequate size. purchaser shall supply and lay only the following cables. Copper cables. laying and termination of cables and accessories within buildings from JBs to detectors! MCPs. overall screened. armoured. size of cable. shall furnish detailed specifications for loop/zone cables.1 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . All interface cables from fire alarm panels to purchaser’s system. termination of data high way cables. Though the supply and installation of field cabling is excluded from vendor’s scope but terminations of all cables (supplied by both vendor! purchaser) at both ends shall be in vendor’s scope. Signal Loop! Zone Cables from outdoor field devices to the fire alarm panel except for buildings. exist signs. data highway cables. i. twisted pair. ii.) iv. PVC insulated. v.2 11. as a part of integration and selection of fire alarm equipment.11 11. vendor shall supply Copper cable? FO type data highway cable to suit system design and equipment specification. if supplied. high way accessories etc as required for successful commissioning shall be in vendor’s scope. shall be armoured. SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 21 of 32 11. Cables from JB to fire alarm panel is included in Purchaser’s scope while JB to exit sign and hooter is included in vendor’s scope. overall FR PVC outer sheathed and shall be as per ITU-T recommendation as a minimum. PVC inner sheathed. laying. Mounting base shall be identical for all type of detectors except special application detectors such as linear beam detectors etc.5. irrespective of whether installation is to be performed by vendor or not.2 Vendor shall supply and install all hardware and cabling accessories as per data high way design including modems. End of line resistor shall be provided at the last detector in the zone. repeaters etc as part of the FA system.3 12.1 12.3 12 12.1 11.2 12. whereas those for indoor application shall be single compression type.5 11. Modems! repeaters shall be powered by the supply provided for DGFAPs ! CFAP.5.1 12.1.4. Gl junction box! conduit box etc.1.2 11.5.1. Detectors shall be supplied with mounting bases. Multicolour LEDs provided on the detectors shall indicate Normal and Alarm state. CABLE GLANDS I ACCESSORIES All cable glands/ lugs/ connectors as required for the equipment shall be included in vendor’s scope and shall be supplied along with the system.11. Detectors shall be suitable for storage at ambient condition specified in data sheet. Detectors for microprocessor shall be addressable type. Essential features of detectors are indicated as below. for installation as well as cable connection. shall also be included in vendor’s scope.1. All the cable glands for outdoor application shall be weatherproof. fire resistant polycarbonate and shall be suitable for either surface or recess mounting. Detectors. nickelplated brass and double compression type.4 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . Where installation is included in vendor’s scope. Detector housing (body and cover) shall be made up of damage resistant. weatherproof and nickelplated brass double compression type. AUTOMATIC FIRE DETECTORS AND ACCESSORIES GENERAL SPECIFICATIONS Detectors for conventional fire alarm system shall be conventional type. equipment such as GI conduits. shall be such that the strength of the Radio Active material shall not exceed 1 micro curie or as per latest standard whichever is less. which employ Radio Active source. Detector base shall be mounted on Junction boxes having terminals for cable termination. Detectors shall be plug-in type and shall have twist lock action fitting. SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 22 of 32 11. Cable glands for hazardous area equipments shall be flameproof. However.1. UL! FM! equivalent international approving agency as applicable.12.6 12.2. All detectors shall be suitable for operation at DC power supply extended from fire alarm panel. All addressable detectors shall have selectable settings for pre-alarm and alarm and preferably have the facility to set the sensitivity and address from the fire alarm panel. T.9 12.1. if there is a gradual increase in the analogue reading.). It shall be possible to generate maintenance reports from the fire alarm panel. Each device shall have its own address module. The addressable detectors shall be continuously monitored to measure changes in their sensitivity due to the environment (dirt. Commonly used field devices are listed below. For the addressable detectors two-wire operation shall be possible. a maintenance alert shall be generated by the fire alarm panel. The specification given shall be considered as the minimum requirements.1. dust. The rate of rise element shall be carefully calibrated to ignore any normal fluctuation in temperature. temperature.1 12.Tapping shall not be permitted in the case of such wiring. humidity etc. The analogue reading sent by the detectors shall be sensed and if there is a rapid increase.2.1.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 23 of 32 © GAIL – All rights reserved .6 wiring as per NFPA72).1.12 12. an alarm shall be generated.2 12.5 12.1. All detectors must have insect screen to prevent entry and cause false alarm. but to respond quickly when the temperature rise is 9°C or more per minute. These detectors shall give an advance indication to the panel regarding the need for maintenance. All addressable detectors shall be suitable for installation using fault tolerant wiring (class-A. All field devices shall be from the latest generation in the manufacturer’s range of products. HEAT DETECTORS Heat detectors shall use negative temperature coefficient thermisters for sensing and for reference.7 All detectors shall be on the approved list of LPC.1. 12.8 12. The detector shall be designed to give a response that depends on both absolute temperature and rate of rise in temperature. Manual call points / break glass boxes for microprocessor based fire alarm system shall be addressable type.10 12.11 12.1. style . Its performance shall not be affected by an air current of 5 rn/sec.2.5. smoke detectors operating on laser diode principle shall be offered. Photo film.12. polyester. smoke guard! baffle shall be used. leather etc. The detector shall not be actuated by artificial lights.3. humidity. working on ionization principle and shall preferably be of dual chamber and dual source type. paper.1 12. The detector shall be protected against dust accumulation! ingress.5 12. UV flame detectors shall respond to ultraviolet rays of a flame.3. PHOTO ELECTRIC / OPTICAL SMOKE DETECTOR Photo electric optical smoke detectors shall work on the principle of light scattering utilizing a light emitting diode.4 12.3. nylon. 12.3 12. Where specified. The detector shall be self-restoring type ensuring repeated use and easy maintenance.5. ammonia processing paper. sunlight incident through a windowpane or welding arc. The detector shall be able to sense incipient fire by detecting the presence of visible and invisible products of combustion like wood.4 12. acrylic.3 The fixed temperature feature should be entirely independent of the rate of rise element.4 12. IONIZATION SMOKE DETECTOR Ionization smoke detector shall be solid-state type.5 12. Teflon. It shall have insect resistant screen to prevent nuisance alarms.3. foam.2. The operating temperature of fixed temperature element should be factory set at 57° C ± 5° C. painted sheets. Where air velocity is expected to be higher. pressure or permissible voltage variation.1 12. UV FLAME DETECTOR UV flame detectors shall work on the principle of a vacuum photodiode tube to detect the UV radiation that is produced by a flame.3.2 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 24 of 32 © GAIL – All rights reserved . It shall have an inbuilt arrangement such that puffs of smoke or hot air pockets do not inadvertently trigger the alarm. bakelite.2 12. thermocol.3 12. PVC. False alarm check circuit shall be incorporated to prevent false alarm due to intermittent flash or lightning. cloth. nylon. The sensitivity of the detector shall not vary with change in ambient temperature. 9.8 12.9 12. be powered from the loop signal itself.12. if external power supply is required the same shall be explicitly stated by the vendor. 19 mm knockouts SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 25 of 32 12. Alternately the break glass unit may be made of die cast aluminum alloy such as LM6.3 12. It shall consist of four copper conductors. Where specified combination UV-IR detector shall be used. Linear beam detector shall consist of separate transmitter and receiver. MANUAL CALL POINT (MCP)/ BREAK GLASS UNIT (BGU) Manual break glass unit shall be fabricated out of 14-gauge cold rolled sheet steel. each covered with a colour coded. External mechanical protection shall be provided over the sensor cables. The detector shall be completely solid-state type.6. The cores shall be twisted together and protected by an outer sheath of high temperature. preferably.9.2 12. which shall be covered under common power supply for the fire alarm panel and devices connected with it. The break glass unit shall have a minimum dimension of lOOxlOOx8Omm.1 12.6 12.2 GAIL (INDIA) LTD NEW DELHI © GAIL – All rights reserved . The detector shall. The box shall be fabricated in such a way it can be mounted flush to the wall or on the surface without any modification.1 12. The detector should not react to extremely glaring artificial light or direct sunlight. 1k detectors shall react to the infrared rays of aflame. Two nos.6. LINEAR BEAM DETECTOR Linear beam detector shall work on the principle of obscuration of infrared light beam by particles of smoke.6. Linear beam detector shall be suitable for application in high roofed locations such as warehouses etc.7.7.1 12. HEAT SENSING CABLES Heat sensing cable shall be analogue type. Vendor shall provide control unit for each 100 m length of the sensor cable. It shall have IP-55 enclosure and weatherproof construction suitable for outdoor installation.7 12. flame retardant PVC insulation. It should be sensitive enough to detect smoky fires in which flame is hardly recognizable.8. The sensitivity shall be such as to enable operation at 30% to 50% obscuration. However. negative temperature coefficient material.1 IR DETECTORS 1k detectors shall work on the principle of a single wavelength infrared flame detector using one of several different photocell types to detect the infrared emissions in a single wave length band that are produced by a flame.2 12. 2 12. shall be painted in white letters or riveted on the enclosure by a steel nameplate. The glass shall cover at least 30cm2 area and shall have a thickness not exceeding 2mm.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 26 of 32 © GAIL – All rights reserved . The glass will be broken in case of fire with the hammer provided with the BGU. Each box shall have a distinct identification number boldly painted on it. 12.6 12.5mm2 copper conductor. LEDs shall be red in colour with 5mm dia.3 12.11 12. Response indicator shall be provided where the detector is located either above false ceiling or below false floor or where detectors are not directly visible.9. Exit signs suspended from the ceiling shall have text! direction printed on both the side of exit sign.shall be provided at the bottom of the box to facilitate cable / conduit entry.10.1 12. the BGU shall have a suitably wired telephone hand set to facilitate communication between the BGU and the central annunciation panel. Hazardous area Break Glass Units shall meet the requirement of clause 13 of this specification. Use of Response indicators in addressable system is not envisaged unless otherwise specified in data sheet. The enclosure shall be painted with fire red colour (shade 536 of TS-5) epoxy painting and an inscription Break Glass in case of Fire”.4 The box shall have a push button element kept in pressed condition by a glass sheet fitted in the front of the box.10 12.5 12. duly chained to the box with stainless steel chain shall be provided with each box for breaking the glass.9.11. 12.10. the LED shall glow steadily. response indicators shall be provided suitable for wall! ceiling mounting. If specified in the data sheet.9. EXIT SIGNS Exit signs shall be fabricated out of 1. The response indicators shall be connected to the detectors directly and shall be complete with terminal blocks suitable to accept cables with up to 1. RESPONSE INDICATOR If specified in the data sheet. the LED shall flicker. Telephone hand set mounted on hook switch shall be housed in a separate lockable weatherproof break glass window enclosure. as a minimum. A suitable nickel-plated brass hammer. This shall be suitable for wall mounting or suspension from ceiling. In the normal state of detector. but in the event the detector goes into alarm condition.6mm thick cold rolled sheet steel.9. 3 12.12.12.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved .11.13. the hooter shall raise pulsating audio alarm and the lamp shall start flashing.4 12. The unit shall be powered from the fire alarm panel and operate on DC power.2 12. The unit shall be fabricated out of 2mm thick cold rolled sheet steel suitable for wall mounting. HOOTERS The unit shall consist of solid-state circuitry on a printed circuit board.14 12.1 12.14. In the event a signal for clean agent!C02 release is given. Release switches shall have inscription: ”PULL TO RELEASE CLEAN AGENT CO2” And inhibit switches shall have inscription: “PULL TO INHIBIT CLEAN AGENT / CO2”. a loudspeaker and a flashing lamp housed in a weatherproof dust tight. HAB shall be provided at exit doors of buildings to mute the hooters after evacuation. Where specified in data sheet.13.11. wall! ceiling mounting type enclosure. self-luminous exit sign shall be provided. This shall consist of pull type release and inhibit switches clean agent! CO2. Switches shall be pulled to release or inhibit clean agent! CO2. Flashing Lights (Beacon) .12 12. The hooter shall. CLEAN AGENT / CO2 RELEASE AND INHIBIT SWITCHES This unit is required to be provided at the exit of the protected buildings! rooms.The unit shall consist of solid-state circuitry on a printed circuit board and a red-capped incandescent lamp and audio unit housed in a dust tight.3 12. Exit sign shall operate on DC power supply The exit sign shall be either in red letters on white background or white letters on green background.2 Fire exit shall be displayed by means of 5mm dia LEDs or backlit text.1 12. Flashing lights shall be installed in the enclosed areas where clean agent! CO2 is to be released.12. have 102 db (A) output measured at 1-meter distance. It shall derive power from the DGFAP! ZFAP and shall operate on DC supply.2 12. wall mounting type enclosure. at least. this unit is integrated with DGFAP/ ZFAP. If specified. It shall be powered from the fire alarm panel.11. In the event of fire. the lamp shall start blinking with a warning sound enabling operating personnel to evacuate the area. The audio unit (hooter) shall have 102 db (A) output measured at 1-meter distance.12. SPECIFICATION S-07-02-024 REV-0 Page 27 of 32 12. Normally not more than 10 detectors shall be connected to one zener barrier.3 12.4 12. It shall be possible to wire the fault isolator at any point in the detector loop.15.1 12.16.15. intrinsically safe (Ex ‘i’) detectors and MCPs. SIRENS Sirens shall be industrial type with minimum 2. Zener barriers shall be provided. However vendor shall indicate maximum number of detectors! MCPs that can be connected to one Zener barrier without compromising on working of loop! zone.16 12. Fault isolator modules shall be housed in a enclosure having lP-55 degree of protection as a minimum.15. On occurrence of a fault (short circuit). screened cable. if specified in the data sheet. Vendor shall also indicate the maximum loop length from zener barrier considering 1.3 12.16.15 12.16. FAULT ISOLATOR Fault isolator shall be installed.e. 12. zener barrier shall be located at DGFAP itself else it shall be located in safe area nearest to the detector! MCP. These shall be located in unclassified! non-hazardous areas. 5km diametrical range) against the wind direction.2 12. Fault isolator shall be designed to provide short circuit protection to an addressable detector loop. On rectification of the fault.5 12.2 12.17 12. In case loop length permits. Wherever zener barriers are provided in safe area outside the Zonal panel or DGFAP.16.5 km unidirectional range (i. The fault isolator shall have the capability to continuously check the faulted side of the loop to determine if the fault still exists. the isolator shall automatically reset itself.12. If located in hazardous area.5 mm2 copper conductor.4 12. these shall be housed in their own enclosure with IP-55 degree of protection as a minimum.17. the isolator shall cut power to all devices installed between the two isolators minimizing the outage of all the detectors in a loop.1 ZENER BARRIER Preferably flameproof(Ex ‘d’) equipment that does not require the use of Zener barrier shall be used. When necessary.15.1 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 28 of 32 © GAIL – All rights reserved . it shall also be tested and approved for use in area classification defined in the data sheet.16. For three-phase siren. hooters etc for use in hazardous area. Unless otherwise specified. if specified in the data sheet shall have flame proof enclosure conforming to IS 2148. to meet the audibility requirement for the above range. approval agency.17.3 13.6 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 29 of 32 © GAIL – All rights reserved . The vendor shall possess valid test certificate issued by a recognized independent test house such as CMRI! BASEEFA! UL/ FM or Equivalent for the offered equipment. Starter shall be DOL and shall be housed in a separate 1P55 enclosure suitable for installation indoor! outdoor. All equipment for hazardous area installation shall be complete with flame proof. All equipment (indigenous or imported) shall have valid statutory approval as applicable for the specified hazardous location from CCE or any other applicable statutory authority. The nameplate shall be riveted! fixed with screws and not pasted. FIELD DEVICES FOR HAZARDOUS AREA Hazardous area is classified as Zone 1/Zone 2. wall-mounting type three-phase DOL starter shall be supplied. In case above information are embossed on the enclosure. at least be 132db(A) at 1 meter. A separate name plate shall also be provided on each equipment to indicate details of testing agency. 3 ph. Starter shall be mounted indoor in a building where siren is located. 12.12.3 13 13. statutory approval number with date. test certificate number with date.2 13. Equipment that are tested / certified by a recognized test laboratory of country of origin shall only be offered. Beacons. the same need not be repeated. Sirens shall be housed in weatherproof enclosure. The supply to the siren starter shall be provided by purchaser from Normal or Emergency power source as defined in the data sheet. BIS license number with date. fault isolators. which cannot have flameproof construction.1 13. applicable gas group.5. temperature class T3 (200 °C) as specified in data sheet. The field devices shall be suitable for installation in hazardous area as per specified area classification. AC supply. All indigenous flameproof equipment shall also have valid BIS license and corresponding marking as required by statutory authority. Equipment. Sirens shall operate at 415 V. gas group hA! IIB or lIC.2 The decibel level of the siren shall.5 13. weather proof cable glands as specified in clause 11. MCPs.17. Field devices such as detectors. shall be intrinsically safe in design and shall be used with Zener barriers located in safe area.4 13. temperature class etc. redundancy. annunciation. CONVENTIONAL FIRE ALARM SYSTEM For conventional fire alarm system. field equipments.A. which shall be submitted and got SPECIFICATION S-07-02-024 REV-0 Page 30 of 32 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM © GAIL – All rights reserved . siren.1. protocols.1 ii. drawings of various equipment. text messages etc shall be available on the fire alarm panel. siren starter etc. cable schedules. siren! siren starter etc. On this basis. 14. battery chargers. batteries. The design and engineering shall include sizing and selection of various equipment such as fire alarm panels. field equipments. The parameterization facilities of various field devices along with the geographic mimic. ii) The design and engineering shall include sizing and selection of various equipment such as fire alarm panels. Addressable Fire Alarm System i) Vendor shall develop a system architecture based on purchaser’s requirement showing details of various network elements such as DGFAP.14 Engineering Requirements Unless specified other wise. equipment installation drawings etc as minimum. The layout engineering for buildings shall include the drawings showing location of MCP/ Detector and other field devices. equipment installation drawings etc. i. interconnection diagram. including preparation of G. TESTING AND ACCEPTANCE All the equipment shall be tested to the defined specifications as per mutually agreed test plan! FAT procedure.A. as minimum. Work station. batteries. cabling requirement and protocol selection etc. including preparation of G. interconnection diagram. networking hardware. vendor shall design entire fire alarm system including design of system architecture with details of integration. The layout engineering for buildings shall include the drawings showing location of MCP/ Detector and other field devices.1 INSPECTION. 14. data highway etc. CFAP. drawings of various equipment. battery chargers. vendor shall prepare detailed drawing giving various system component details. cable schedules.1. purchaser shall provide typical block diagram.2 iii) iv) 15 15. Vendor’s scope shall also include basic design and preparation of layouts for fire alarm system for plant! buildings as specified in the data sheet! purchase documents. including the maximum permissible loop length and length of data highway. Vendor shall provide all necessary assistance and information concerning the supply to GAIL/Purchaser’ s inspectors. All equipment and systems shall be tested at site as per the approved SAT procedure SAT shall be conducted by vendor after the entire fire alarm system is installed and inter connected by cables. and acceptance tests specified by applicable codes and standards. ‘Center of gravity’. vendor shall produce original of all the type test certificates. by ship/rail or trailer.7 15. The equipment shall be properly packed for selected mode of transportation i. etc. PACKING AND DESPATCH All the equipment shall be divided into several sections for protection and ease of handling during transportation..8 16 © GAIL – All rights reserved . ‘This side up’.5 15. Special notations such as ‘Fragile &. Vendor shall rectify deficiencies noticed during SAT with no commercial implication to Purchaser including replacement of system components and supply of new component for making system successfully operational.3 15. test and approval certificates for hazardous area equipment from testing and approving authority and any other certificates as required from statutory authority for the review of inspectors. At the time of inspection. GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 31 of 32 15. the routine and acceptance tests shall be conducted at the respective equipment manufacturer’s works. shall be clearly marked on the package together with Tag nos. FAT shall include simulation of operational field conditions and test for functional adequacy. The panels shall be wrapped in polythene sheets before being placed in crates to prevent damage to finish. 15.4 15. shall be performed on the complete system.2 During manufacture. Vendor shall submit a SAT procedure for GAIL/ Purchaser’s approval. These tests shall establish the operational correctness of the system.6 15. Tests shall be carried out at the vendor’s works under his care and expense and Purchaser shall be informed at least 4 weeks in advance regarding this. GAIL/ Purchaser’s inspectors shall witness all the tests. Purchase order Nos. For bought out items.. ‘Weight’ etc. Besides all routine.e. the equipment shall be subject to inspection as per attached inspection plan to assess the progress of work and to ascertain that the quality controls are being maintained.approved from Purchaser at least one month before inspection. Crates shall have skid bottom for handling. The packing shall be completely suitable for outdoor storage in areas with heavy rains! high ambient temperature. Only the cabling specifically excluded from vendor’s scope shall be installed by others. for the successful commissioning of the system shall be arranged by the vendor. Commissioning of the complete system is to be carried out by vendor in all cases irrespective of whether the installation was performed by vendor or not. vendor shall arrange all necessary manpower and equipment required for the same. comprehensive training to Purchaser’s personnel on various operation and maintenance aspects of the Fire Alarm system as agreed during ordering 18 GAIL (INDIA) LTD NEW DELHI SPECIFICATION FOR FIRE DETECTION AND ALARM SYSTEM SPECIFICATION S-07-02-024 REV-0 Page 32 of 32 © GAIL – All rights reserved . All tools.The equipment may be stored outdoors for long periods before erection. free of cost. termination at panels for purchaser’s cables shall be done by the vendor. test equipment etc. 17 INSTALLATION AND COMMISSIONING Where installation of the system is included in the scope of the vendor. TRAINING The vendor shall provide. However. INSPECTION TEST PLAN FOR BATTERY CHARGERS GAIL (INDIA) LTD NEW DELHI SPECIFICATION REV-0 Page 1 of 3 INSPECTION TEST PLAN FOR BATTERY CHARGER S-07-06-001 Copyright GAIL – All rights reserved . Relays. MCCBs. Indicating Instruments. a Dimension check including operational height. power. SCOPE: This Inspection Test Plan covers the minimum testing requirements of Battery Chargers . Bus size. frequency. current.0 INSPECTION AND TEST REQUIREMENTS: STAGE 1 Incoming Material like Fabricated items. 2) 2) Job specifications I approved documents.Distribution Boards and Cell boosters. current and output voltage ripple at nominal AC input voftage at zero. Temperature rise for critical components would be recorded during this test. Tag plates. QUANTUM OF CHECK SCOPE OF INSPECTION Sub Vendor VENDOR GAIL 1. Identification and location of components etc. Contactors. Switches. operational checks etc as applicable 100% Supplier’s TC I Vendor’s Test Records - W W 2 3 Burn-in Test for 96 hours at 50 C ACCEPTANCE TESTS: • Visual check including layout. Clearances etc. • Full Load test for 16 hours with minimum 8hrs for each Charger. Paint shade. Electronic components. etc PCBs & Electronic components sub assemblies Battery Charger Assembly CHARACTERISTICS RECORD Visual. 50% and 100% of rated output current. Dimensional. • Charger testing at constant output voltage in float and boost charge mode. Measurement shall be o 100% Vendor’s Test Records - W W 100% Vendor’s Test Records Inspection Witness Record - W W GAIL (INDIA) LTD NEW DELHI SPECIFICATION REV-0 Page 2 of 3 INSPECTION TEST PLAN FOR BATTERY CHARGER S-07-06-001 Copyright GAIL – All rights reserved . DC output voltage. a Bill of material! Make of Components. PCBs.1. 2 REFERENCE DOCUMENTS: 1) Standard specification S-07-02-019 and standards referred there in. including measurement of AC phase voltage. Bus marking. C Distribution Board Visual. • Insulation resistance before and after HV test for power. 4 D. W – Witness R – Review 2. control and auxiliary circuits. Vendor to submit these reports before offering items for inspection SPECIFICATION REV-0 Page 3 of 3 GAIL (INDIA) LTD NEW DELHI INSPECTION TEST PLAN FOR BATTERY CHARGER S-07-06-001 Copyright GAIL – All rights reserved . Cell Booster Visual. Distribution Board. Feeder Tag Plates. IR and HV test 100% Vendor’s Test Records Inspection Witness Record - W W 5 6 Cell Booster Battery Charger. protection 100% Inspection W W and controls as per requirement. Vendor’s Test • Proper functioning of all measuring Records I instruments. Witness • Parallel operation of both chargers Record including load sharing and automatic isolation of faulty charger. control and main circuits.repeated at 100% full load current at 90% and 110% of nominal AC supply voltage. • Audible noise test. IR & HV Test Internal Test Reports 100% 100% Vendor’s Test Records Inspection Witness Record Vendor’s Test Records Inspection Witness Record Vendor’s Test Records - W W - W W - - R Notes: 1. Dimensions. • Charger testing under constant output current limiting condition in float and boost mode. Feeder Tag plates. Dimensions. alarms. including measurement of DC output voltage and current with DC output voltage varying between zero and set value corresponding to constant voltage operation. Functional Test. indications. • High voltage withstand test for power. • Dynamic Response test for step load up to 50% of rated output. Vendor’s Test Functional checks. • Charger Efficiency and Voltage regulation test. INSPECTION AND TEST PLAN FOR MEDIUM AND HIGH VOLTAGE CABLES & ACCESSORIES GAIL (INDIA) LTD NEW DELHI INSPECTION AND TEST PLAN FOR MV/HV CABLES AND ACCESSORIES SPECIFICATION S-07-06-002 REV-0 Page 1 of 3 Copyright GAIL – All rights reserved . dip test P W 3. Finished Cable CHARACTERISTICS QUANTUM OF CHECK RECORD Material Test Certificates/ supplier’s Test Records/ Third Party Lab Supplier’s Test Records Supplier’s Test Records 1. Ends Capping. manufacturer’s name). Drum details. Physical and Chemical Properties. Galvanized Armour. Marking on outer sheath (such as Incremental Length. Dimensions.0 SCOPE: This Inspection and Test Plan covers the minimum testing requirements of PVC. sheath. Conductor Resistance Insulation resistance / Volume resistivity High Voltage tests Partial Discharge(for XLPE) Hot_Set_(for_XLPE_insulation) Tests on Conductor as applicable Tests on PVC/XLPE Insulation & Sheath* Armour Galvanization . High Voltage Partial Discharge (for XLPE only) Dimension checks — overall dia. Voltage grade. Visual. SCOPE OF INSPECTION SUB SUPPLIER GAIL/TPIA SUPPLIER P P/R R 2.1. Colour coding. over/under armour. XLPE. Finished Cable P W/R 4. 100% 100% for Drum details and Sample drums for balance details 100% 2.0 INSPECTION AND TEST REQUIREMENTS: Sl No STAGE/ACTIVITY Incoming raw material like Copper. REFERENCE DOCUMENTS: P0/PR / Standards referred there in /Job specifications / Approved documents. XLPE insulated cables and cable jointing/terminating accessories for high and medium voltage systems. etc. Routine Checks: Conductor Resistance. Finished Cable (Acceptance tests) As per sampling plan Inspection Test Records - P W GAIL (INDIA) LTD NEW DELHI INSPECTION AND TEST PLAN FOR MV/HV CABLES AND ACCESSORIES SPECIFICATION S-07-06-002 REV-0 Page 2 of 3 Copyright GAIL – All rights reserved .0 3. PVC. etc. Aluminum. thickness of insulation. copper screen dimension. Size. Purity. P — Perform. H.. This document describes generally the requirements pertaining to all types of the item. RT. DT.Hold (Do not proceed without approval). Type tests on PVC insulation and Sheath High Voltage test (Water Immersion) Finished Cable (Type Dielectric power factor tests as function of voltage. more stringent conditions shall be applicable. Inspection test records 6. In ease of conflict between purchase specification. Inspection Engineer shall decide the option to be exercised for the particular stage and supplier 1 Supplier’s in house procedures may be accepted in case TPt/GAIL is satisfied with adequacy of procedures to comply with Purchase Order/Specifications requirements. Sample Supplier’s Test Records R 7. 7098 shall be carried out by supplier and test reports shall be reviewed by GAIL.Heat treatment.Radiography Testing. Random -10% (min. PQR Procedure Qualification Record. ITP Inspection and Test Plan. .NDTNot Destructive Testing. NOTES (As applicable): Wherever W/R or HJW is indicated.) of each size and type of Bulk item. temperature. Heat shock and Shrinkage tests on insulation & sheath (One sample/Lot) shall be witnessed by GAIL. HT. WPQ.Volume resistivity. all other tests as per IS-583l. Requirements specific to P0 and the item are only applicable. WPS. Legends: CCE or CCOE-Chief Controller of Explosives.Destructive Testing. # * Sample Supplier’s Test Records P R In case TC (not older than one year) from independent test lab is available & type of compound used is same then the same may be accepted.l no. In case of non availability of suitable procedures. TC-Test Certificate TPI or TPIA. Acceptance Norms for all the activities shall be as per P0/PR/ Standards referred there in] Job specifications/Approved documents GAIL (INDIA) LTD NEW DELHI INSPECTION AND TEST PLAN FOR MV/HV CABLES AND ACCESSORIES SPECIFICATION S-07-06-002 REV-0 Page 3 of 3 Copyright GAIL – All rights reserved . PR-Purchase Requisition. P0. R-Review.Purchase Order. PESO-Petroleum and Explosives safety Organisation.Vendor Data Requirements.Welding Procedure Specification. Acceptance and Type test reports before offering items for inspection to GAIL.Welders Performance Qualification. QAP-Quality Assurance Plan. fresh procedures may be qualified under TPI/GAIL witness. tests **) (XLPE cables) Heating cycle test (XLPE Cables) Impulse withstand test (XLPE cables) Visual Dimensions Cable accessories Type tests** as per IS 13573 1 sample/size/lot 1 sample /order 1 sample/order 1 sample/ order 1 sample/size lot 1 sample! lot 1 or 2 drums per lot 5. Hot deformation. RW-Random witness. IBR-Indian Boiler Regulations. ** Supplier to submit Routine. contract documents and ITP. WWitness (Give due notice.Third Party Inspection Agency. Insulation resistance Tensile and elongation (without ageing) Flammability test as per IS 10810 part 61 Flammability test as per IS 10810 part 62 Accelerated water absorption test as per NEMA(Electrical method) # Finished Cable (Special tests) Test for resistance to Ultra Violet Radiation # Oxygen Index Rodent & Termite repulsion check Drum length !surface finish check by re-winding Dielectric Retention. work may proceed after scheduled date). VDR. INSPECTION AND TEST PLAN FOR FIRE DETECTION AND ALARM SYSTEM GAIL (INDIA) LTD NEW DELHI SPECIFICATION INSPECTION AND TEST PLAN FOR FIRE ALARM SYSTEM S-07-06-003 REV-0 Page 1 of 4 Copyright GAIL – All rights reserved . Manual call points.. Fire detectors. Statutory body certification. REFERENCE DOCUMENTS: P0/PR / Standards referred there in /Job specifications / Approved documents. Annunciators. Sirens. PCBs CHARACTERISTICS QUANTUM OF CHECK RECORD SCOPE OF INSPECTION SUB GAIL/TPI SUPPLIER SUPPLIER A 1. linear beam type and optical type detectors. layout.1. IR. Burn-In Test of PCBs for 96 hrs at 50 deg C ACCEPTANCE TESTS: o Visual check including GA. Push Buttons.t data sheets. PCBs. Switches. 100% Supplier’s Test Records R 3 Conventional Fire Alarm System consisting Central. Dimensional.0 1. Ionization type. Operational checks as applicable. UV. Check of specifications of all types of detectors w. Flashing Lights. Matching of detectors with given specifications. Zonal and Repeater Fire Alarm Panels (Final Inspection) 100% Inspection Witness Record - P H/W GAIL (INDIA) LTD NEW DELHI SPECIFICATION INSPECTION AND TEST PLAN FOR FIRE ALARM SYSTEM S-07-06-003 REV-0 Page 2 of 4 Copyright GAIL – All rights reserved .r. Mimic lamps by simulating fire. battery charger.0 Sl No 1. Temp detectors. Lamps. Zener Barriers. Data Gathering Fire Alarm Panels(DGFAP) and central fire alarm panels(conventional or computer based). Tag plates. 100% Sub supplier’s TC / Supplier’s Test Records P W/R R 2. etc o Bill of material/Make of components check o Quality of lacquering and Inter changeability of PCBs o Verification of cable termination arrangement. Short Circuit/fault Isolator. Visual. Make of Items. Paint shade.0 SCOPE: This Inspection and Test Plan covers the minimum testing requirements of automatic and manual Fire Alarm System incorporating detectors. etc. INSPECTION AND TEST REQUIREMENTS: STAGE/ACTIVITY Incoming Material like Fabricated items. Exit Signs. Panel gasketing.r.t different type of detectors. etc. cable fault conditions w. Relays. o Operation check of scheme. Release and Inhibit switches. Battery.Mimic layout. Identification and location of components . layout. Siren.r. Panel gasketing.t different type of Repeat Fire Alarm Panel.t data sheets. R.4 Check of detector operation w.r. C parameters given in data sheet for the cable) o Operation checks of scheme.r. gathering Fire alarm Panel (DGFAP) and cable fault conditions w. o Simulation of all Alarms o Auto & Manual release operation o Fail safe operation o Verification of Battery type and Capacity o Operation check for Break glass assembly o Operation check on applicable accessories like Exit Signs.r. Paint shade.r. Check of specifications for Zener barriers . (Final Inspection) detectors. R. Keyboards. Short circuit/fault isolator o Provision of cable glands and earthing ACCEPTANCE TESTS: o Visual check including GA.t loop impedance ( L. Beacon Lamps. mimic lamps w. o Simulation of all Alarms o Auto & Manual release operation o GAIL (INDIA) LTD NEW DELHI 100% Inspection Witness Record - P H/W SPECIFICATION INSPECTION AND TEST PLAN FOR FIRE ALARM SYSTEM S-07-06-003 REV-0 Page 3 of 4 Copyright GAIL – All rights reserved . Check of specifications of all types of detectors w. Printers etc o Bill of material/make of Component check o Verification of cable termination arrangement Computer aided Fire Alarm System in DGFAP panels consisting of Central Fire Alarm Panel.r.t loop impedance ( L. Release and inhibit switches. Data o Operation check of scheme by simulating fire.t different type of release and inhibit switch thro’ output relays. Tag plates. C parameters given in data sheet for the cable) o Operation checks of scheme w. interfacing with suppression/clean agent systems. Identification and location of components . o Check of detector operation w.VDU.t different type of release and inhibit switch. work may proceed after scheduled date). PESO-Petroleum and Explosives safety Organisation. PQR.Purchase Order. In case of conflict between purchase specification.NDT. VDR. 2.Fail safe operation Redundancy checks Check of functions. Wherever W/R or HJW is indicated. 3. PRPurchase Requisition. IBR-Indian Boiler Regulations. SPECIFICATION INSPECTION AND TEST PLAN FOR FIRE ALARM SYSTEM S-07-06-003 REV-0 Page 4 of 4 GAIL (INDIA) LTD NEW DELHI Copyright GAIL – All rights reserved .) of each size and type of Bulk item.Vendor Data Requirements. This document describes generally the requirements pertaining to all types of the item. Random -10% (mm. etc. 2. Supervisor level access on monitor. 2. (for Flameproof type items only) o Valid BIS license( for indigenous flameproof equipment) * . UL. more stringent conditions shall be applicable. commands .Supplier to submit these certificates before offering items for inspection to GAIL o o o Samples Certificates from Statutory bodies R R Legends: CCE or CCOE-Chief Controller of Explosives. fresh procedures may be qualified under TPI / GAIL witness. RTRadiography Testing.Hold (Do not proceed without approval). R-Review. HT. DT.Not Destructive Testing. QAP-Quality Assurance Plan. Detectors and other accessories Fire Alarm system & Accessories o Certificate of Statutory approval authority like CCOE/PESO.Heat treatment. Beacon Lamps. Requirements specific to P0 and the item are only applicable.Welders Performance Qualification.Third Party Inspection Agency. CMRI etc. operator level access. Release and inhibit switches.Destructive Testing. contract documents and ITP. Short circuit/fault isolator Submission of Certificates* o Certificate of Statutory testing authority like FM.Witness (Give due notice. ITP-Inspection and Test Plan. NOTES (As applicable): 1. TPIJGAIL Inspection Engineer shall decide the option to be exercised for the particular stage and supplier. W. Graphics o CFAP communication with all devices o Changing Address of detectors o Verification of Battery type and Capacity o Operation check on applicable accessories like Exit Signs. for DGFAP. UL. . P — Perform. P0. Acceptance Norms for all the activities shall be as per P0/PR/STANDARDS referred there in /Job Specification /Approved Documents.Procedure Qualification Record. H. WPS. Supplier’s in house procedures may be accepted in case TPI I GAIL is satisfied with adequacy of procedures to comply with Purchase Order/Specifications requirements. 1 no. Siren. BASEEFA. DGFASLI.Welding Procedure Specification. In case of non Availability of suitable procedures. WPQ. TC-Test Certificate TPI or TPIA. RW-Random witness. .reports. GAIL (INDIA) LTD NEW DELHI Typical Electrode for Earthing System STANDARD REV-0 Page S-07-01-004 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Typical Earth Electrode in Test Pit S-07-01-005 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Typical Earth Plate Fixing Details S-07-01-006 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Typical Earth Connection for Lighting Pole S-07-01-007 . GAIL (INDIA) LTD NEW DELHI Typical Earthing Arrangement for Process Equipment STANDARD REV-0 Page 1 OF 1 S-07-01-008 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 2 Earthing/Bonding of Pipes & Pipe Racks S-07-01-009 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 2 OF 2 Earthing/Bonding of Pipes & Pipe Racks S-07-01-009 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Fence & Gate Earthing (Transformer Yard) S-07-01-010 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Equipment Earthing Schedule S-07-01-011 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Typical Details of Direct Buried Earth Electrode S-07-01-012 . GAIL (INDIA) LTD NEW DELHI Typical Installation of Lighting Fixture at Ground level STANDARD REV-0 Page 1 OF 1 S-07-01-013 . GAIL (INDIA) LTD NEW DELHI Typical Installation Of Open Area Flood Light Fixture Mounted On Wall/Column STANDARD REV-0 Page 1 OF 1 S-07-01-014 GAIL (INDIA) LTD NEW DELHI Typical Installation Of Open Area Flood Light Fixture Mounted On Pole STANDARD REV-0 Page 1 OF 2 S-07-01-014A GAIL (INDIA) LTD NEW DELHI Typical Installation Of Open Area Flood Light Fixture Mounted On Pole STANDARD REV-0 Page 2 OF 2 S-07-01-014A GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 2 Typical Installation of Street Lighting Fixture S-07-01-014B GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 2 OF 2 Typical Installation of Street Lighting Fixture S-07-01-014B GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 2 Typical Marshalling Box Detail for Lighting Pole S-07-01-014C GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Post Top Lantern Installed on Gate S-07-01-015 GAIL (INDIA) LTD NEW DELHI Typical Installation of Fluorescent Fixture Mounting in Exposed Wiring System STANDARD REV-0 Page 1 OF 1 S-07-01-016 GAIL (INDIA) LTD NEW DELHI Typical Installation of Recessed Mounted Fluorescent Fixture STANDARD REV-0 Page 1 OF 1 S-07-01-017 GAIL (INDIA) LTD NEW DELHI Typical Installation Of Recessed Mounted Or Below False Ceiling Mounted Fluorescent Fixture STANDARD REV-0 Page 1 OF 1 S-07-01-018 GAIL (INDIA) LTD NEW DELHI Typical Installation Of Lighting Fixture Mounting In Concealed Conduit System STANDARD REV-0 Page 1 OF 1 S-07-01-019 . GAIL (INDIA) LTD NEW DELHI Typical Installation Of Lighting Panel Flush Mounted STANDARD REV-0 Page 1 OF 1 S-07-01-020 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Typical Installation of METSEC Channel S-07-01-021 . GAIL (INDIA) LTD NEW DELHI Safety Measures for Electrical Installations During Construction STANDARD REV-0 Page 1 OF 2 S-07-01-022 . GAIL (INDIA) LTD NEW DELHI Safety Measures for Electrical Installations During Construction STANDARD REV-0 Page 2 OF 2 S-07-01-022 . GAIL (INDIA) LTD NEW DELHI Typical Installation Details of Electrical Panels on False Flooring STANDARD REV-0 Page 1 OF 3 S-07-01-023 . GAIL (INDIA) LTD NEW DELHI Typical Installation Details of Electrical Panels on Cable Trench STANDARD REV-0 Page 1 OF 2 S-07-01-024 . GAIL (INDIA) LTD NEW DELHI Typical Installation Details of Electrical Panels on Cable Trench STANDARD REV-0 Page 2 OF 2 S-07-01-024 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Prepacked Zinc Anode S-07-01-025 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Prepacked Magnesium Anode S-07-01-026 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Magnesium Ribbon Anode S-07-01-027 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Test Station With Foundation Details S-07-01-028 .0 AN ADDITIONAL 100 MM OF M15 GRADE CONCRETE SHALL BE PLACED OVER THE BASE PLATE FIXING THE FOUNDATION BOLTS.9. GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 4 Test Station Connection Schemes S-07-01-029 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 2 OF 4 Test Station Connection Schemes S-07-01-029 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 3 OF 4 Test Station Connection Schemes S-07-01-029 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 3 OF 4 Test Station Connection Schemes S-07-01-029 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Galvanic Anode Installation S-07-01-030 . GAIL (INDIA) LTD NEW DELHI Zinc Ribbon Anode for Cased Crossing With Coated/Painted Casing STANDARD REV-0 Page 1 OF 1 S-07-01-031 GAIL (INDIA) LTD NEW DELHI Pipeline Grounding Through Polarization Cell and Galvanic Anode STANDARD REV-0 Page 1 OF 1 S-07-01-032 GAIL (INDIA) LTD NEW DELHI Typical Construction Details of High Silicon Cast Iron Anode STANDARD REV-0 Page 1 OF 1 S-07-01-033 GAIL (INDIA) LTD NEW DELHI Permanent Copper-Copper Sulphate Reference Cell and Installation Details STANDARD REV-0 Page 1 OF 1 S-07-01-034 GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Shallow Anode Ground Bed (PCP) S-07-01-035 GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Shallow Anode Ground Bed (PCP) S-07-01-035 GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Anode Lead Junction Box S-07-01-036 NOTES: 1. ALL DIMENSIONS ARE IN METERS UNLESS OTHERWISE MENTIONED. 2. THE AREA CLASSIFICATION CONFORMS TO THE LATEST ISSUE OF IS 5572, INDIAN PETROLEUM RULES, OISD STD 113, OIL MINES REGULATIONS/DGMS GUIDELINES (FOR PROJECTS UNDER GGMS JURISDICTION) AND RECOMMENDATIONS OF PROCESS LISENCOR. 3. AREA WITHIN 1.50M (EXTENDING IN ALL DIRECTIONS) OF SAFETY VENTS, PRODUCT SAMPLING LOCATIONS, PROXESS WATER DRAINS, OILY SEWER VENTS, INSPECTION HATCHES, DISCHARGE ORIFICE OF FIXED LIQUID LEVEL GAUGES, ROTARY OR DIP GAUGES, FILLER OPENINGS, SHALL BE CLASSIFIED AS ZONE 1. FURTHER AN AREA FROM 1.5M TO 3.0 M (EXTENDING IN ALL DIRECTIONS) FROM VENTS SHALL BE CLASSIFIED AS ZONE 2. HOWEVER THE VENTS OR DRAINS BLANKED DURING NORMAL OPERATION AND USED ONLY WHEN THE PLANT IS DEPRESSURISED OR UNDER SHUTDOWN, SHOULD NOT BE REGARDED AS AN OPERATIONAL VENT OR DRAIN OR SOURCE OF HAZARD. 4. OPEN TRENCHES, PITS OR SUMP BELOW GRADE WITHIN ZONE 2 AREA SHALL BE CLASSIFIED AS ZONE 1 AREA. 5. IN CASE OF PIPELINE HANDLING FLAMMABLE MATERIAL, WHERE WELL MAINTAINED VALVES, FITTINGS AND METERS ARE INSTALLED IN VENTILATED AREAS OR PIT, THE EXTENT OF ZONE 2 AREA ABOVE GROUND SHALL BE CONSIDERED AS 4.0M IN ALL DIRECTIONSFROM THE POSSIBLE SOURCE OF HAZARD, ALTHOUGH THE PIT ITSELF SHALL BE CLASSIFIED AS ZONE 1 AREA. 6. GAS GROUPS ARE AS PER IS 9570. 7. ROADS FULLY/PARTIALLY COVERED UNDER HAZARDOUS AREA SHALL BE BARRICADED FOR VEHICULAR MOVEMENT. GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 1 OF 13 S-07-01-036 GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 2 OF 13 S-07-01-036 GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 3 OF 13 S-07-01-036 GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 4 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 5 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 6 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 7 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 8 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 9 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 10 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 11 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 12 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI Notes Legends and Details for Area Classification in Onshore Oil/Gas Installation STANDARD REV-0 Page 13 OF 13 S-07-01-036 . GAIL (INDIA) LTD NEW DELHI STANDARD REV-0 Page 1 OF 1 Marking of Trenches for Electric Cables S-07-01-038 . GAIL (INDIA) LTD NEW DELHI Details of Hot Dip Galvanized Ladder Type Cable Tray STANDARD REV-0 Page 1 OF 3 S-07-01-039 . GAIL (INDIA) LTD NEW DELHI Details of Hot Dip Galvanized Ladder Type Cable Tray STANDARD REV-0 Page 2 OF 3 S-07-01-039 . GAIL (INDIA) LTD NEW DELHI Details of Hot Dip Galvanized Ladder Type Cable Tray STANDARD REV-0 Page 3 OF 3 S-07-01-039 . GAIL (INDIA) LTD NEW DELHI Installation Details for Double Pole Terminating Structure upto 33 kV STANDARD REV-0 Page 1 OF 1 S-07-01-040 . SCADA/TELECOM EQUIPMENT WILL BE SUPPLIED AND INSTALLED BY THE OWNER.NOTES: 1. ANY DC-DC CONVERSION WILL BE IN THE SCOPE OF THE SCADA/TE. 24 V SPV AND BATTERY CHARGER IN PARALLELL OPERATION HAVE BEEN CONSIDERED. 24 V SPV POWER SOURCE + 415/220 V AC POWER SOURCE HAS BEEN CONSIDERED. AC DISTRIBUTION FOR LIGHTING. 3. 5.ECOM VENDOR 4. 2. VENTILATION AND GAIL (INDIA) LTD NEW DELHI SPECIFICATION SINGLE LINE DIAGRAM FOR CGS 0001-01-07-01-001 REV-0 Page 1 of 1 Copyright GAIL – All rights reserved .
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