CP Technical

FCCU & PRU REVAMP PROJECT, MATHURA LOCATION: IOCL PANIPAT REFINERY
Tender No:TPKTI/0785/FCCU-PR/096
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PART SECTION NO
DESCRIPTION
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5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 6.0 6.1 6.2 6.3 6.4 6.5 6.6
ELECTRICAL DOCUMENTS Electrical Job Specification For Mounded Bullet Engineering Design Basis For Electrical Data Sheet For MV Switchgear Standard Specification For MV Cable And Accessories
00785-000-LD-14901 01 00785-068-JSD1675-01 00785-000-JSD1650-01 00785-000-DS1654-01 00785-000-STD1621-03 A 0 0 0 0 0 0 1 0 0 0
Specification For Cable For Cathodic Protection 00785-000-STDSystem 1621-04 Standard Specification For Medium Voltage Switchgear Standard Specification For Cathodic Protection List Of Mandatory Spares (Electrical) Vendor list -Electrical Standard spec. for Electrical Heat Tracing INSTRUMENTATION DOCUMENTS Job Specification For Instrumentation Items For Mounded Bullets Mandatory Spares For Instrumentation Design Basis Instrumentation Job specification for MOV Vendor list - Instrumentation Electrical data sheet for MOV actuators 00785-000-STD1654-01 00785-000-STD1675-01 00785-000-NM1603-01 00785-000-NM1602-01 00785-000-STD1686-01 00785-000-STD1686-01
00785-68-JSS-1514C 15 00785-000-NM1587-01 00785-000-JSD1501-01 00785-68-JSS1543-12 00785-000-NM1502-01 00785-000-DS1669-01 2 0 C 0 0
FCCU & PRU REVAMP PROJECT, MATHURA LOCATION: IOCL PANIPAT REFINERY
Tender No:TPKTI/0785/FCCU-PR/096
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Technical specification for procurement of valves Quality control plan for control valve HSE DOCUMENTS Design Basis For Fire Protection And F&G Detection System For Offsite Mounded Bullet Facility Scope Of Work For Fire Protection And F&G Detection System For Offsite Mounded Bullet Facility Layouts for fire protection system MISCELLANEOUS Site Facilities & Requirements Mounded Bullets Deviations list format Inspection and Test Plan for Mounded Bullets Package General Quality Control Requirements
00785-000-JSS1300-0004 00785-000-ITP1541-01 00785-68-SOW1900-01 00785-068-JSD1900-01 00785-68-SOW1900-01
3 0 0 1
7.2 7.3 8.0 8.1 8.2 8.3 8.4 8.5 8.6
00785-68-DW-19301 01 Refer Attached --
00785-071-PTC-(1)0 01 Refer Attached -0 0 0 -
00785-071-ITP2543-01 00785-19-PP-502 00785-019-PP-0308Planning, Scheduling, Monitoring and Scheduling 01 Vendor list-Mech --
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET
UNIT PROJECT
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
: 0068-PANIPAT NAPHTHA CRACKER : FCCU AND PRU REVAMP, MATHURA. : IOCL, PANIPAT NAPHTHA CRACKER
LOCATION
OWNER
EPCM
TECHNIP KT INDIA LTD.
INDIAN OIL CORPORATION LIMITED.
NOIDA, INDIA.
A
REV.
19.03.2012
DATE
ISSUED FOR ENQUIRY

STATUS
ABS
PREPARED BY
VV
REVIEWED BY
SM
APPROVED BY
VJK
PM
DOCUMENT REVISIONS Sections changed in last revision are identified by a line in the right margin
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET CONTENTS
1. 2. 3. 4. 5. 6. 7.
GENERAL ............................................................................................................................................ 3 DEFINITION ......................................................................................................................................... 3 SITE CONDITIONS .............................................................................................................................. 3 AREA CLASSIFICATION .................................................................................................................... 4 SCOPE OF WORK SUPPLY ............................................................................................................... 5 MISCELLANEOUS WORKS.............................................................................................................. 13 JOB MATRIX...................................................................................................................................... 14
CLIENT UNIT PROJECT
: : :
INDIAN OIL CORPORATION LIMITED PANIPAT NAPHTHA CRACKER. 0068- PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET 1. GENERAL This document along with standard specifications, drawings attached with bid shall form the basis of electrical works for mounded bullets at Panipat Refinery, IOCL.
For engineering design basis refer doc. no. 00785-000-JSD-1650-01, for applicable items/ clause. The contract scope also includes clearing up of temporary constructions, waste materials and loose earth which might get collected consequent to the execution of the work performed under this contract. In case of any discrepancy / conflict amongst various documents, following order of precedence shall prevail: x x x x x x Statutory requirement IS Codes and standards This document Engineering design basis Data sheets Technical specifications
In case of ambiguity, bidder shall inform Owner/EPCM of their interpretation. In case bidder fails to convey the same prior to award, the owner's decision on interpretation shall be considered final if need arises during the execution. No additional cost or time on account of conflicts/ambiguities shall be admissible if not notified prior to award of contract.
2.
DEFINITION In this document following are implied: EPCM Bidder End user TPKTI Package/system vendor IOCL
3.
SITE CONDITIONS * * * * Maximum temperature Design maximum temperature Minimum temperature Winterizing temperature
: : : 0068- PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.
: : : :
47C 50C 2C 2C
CLIENT UNIT PROJECT
INDIAN OIL CORPORATION LIMITED PANIPAT NAPHTHA CRACKER.
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET * *

Design minimum temperature Relative humidity - Average - Maximum
2C
: : :
36% @ 4-50C 95%
* *
Dry bulb temperature Barometric pressure - Minimum - Maximum - Average
: : : : 740 mm Hg < 1000 mm
Altitude above mean sea level
4.
AREA CLASSIFICATION The area classification shall be done in accordance with IS: 5572, Petroleum Rules and Project Design Basis. The Mounded Storage bed shall be classified as Zone-1 hazardous area. All areas within the pump station shall be classified as minimum Zone-2 hazardous area. In addition, all area enclosed within 16 m distance around the storage bed and pump station shall be classified as Zone-2 hazardous area. The area within 1.5 m radius (extending in all directions) of safety vents, product sampling locations, process water drains, oily sewer vents, inspection hatches, discharge orifice of fixed liquid level gauges, rotary or dip gauges, filler openings, shall also be classified as Zone-1. Further an area from 1.5 m 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 depressurized or under shut down, should not be regarded as an operational vent or drain or source of hazard. Open trenches, pits or sump below grade level within Zone-2 area shall be classified as Zone-1 area. In case of pipeline handling flammable material, where well maintained valves, fittings and meters are installed in well ventilated areas or pit, the extent of Zone-2 area above ground shall be considered as 4.0 m in all directions from the possible source of hazard, although the pit itself shall be classified as Zone-1 area. Irrespective of the area classification (whether Zone-1 or 2), all electrical equipment such as motors, local control stations, lighting/power panels, welding receptacles/sockets, junction
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET boxes, lighting fixtures and accessories etc. shall be flameproof type Exd as per IS:2148 with IP-55 protection, suitable for Gas Group-IIA & IIB and Temperature Class-T3. All hazardous area equipment shall be tested by CMRI and approved by CCE or equivalent
testing agencies and statutory authority of country of origin. All flameproof equipment shall be BIS-approved. Bidder shall be required to submit the testing and approval certificates for all hazardous area equipment for Owners/ EPCMs approval.
5.
SCOPE OF WORK SUPPLY Electrical works are divided into two parts herein i) Cathodic protection system
ii) Balance Electricals
5.1. 5.1.1.
Cathodic Protection Scope
5.1.1.1. Shifting of Existing CP System for Existing Bullets (6 nos.) The existing CP system yard along with all equipments like TR-units, JBs, DBs, etc. for existing bullets (6 nos.) is to be relocated and the proposed location has been indicated in equipment layout, however, location shall be verified and finalized by bidder in accordance with latest amendments in OISD regulations. The TR-Units as required for new bullets shall also be installed in the same yard. Vendor shall design and submit drawings for EPCM approval. Design and construction of yard, including foundations, if required, shall be in bidders scope of work. The scope of work to be carried out for shifting of CP system shall include but not limited to the following: x x x x Design of CP system yard including all civil works, and submitting drawings to EPCM for approval. Bidder shall visit site to get relevant information and get familiar with this shifting job. Shifting of two nos. earth pits to new CP system yard from existing yard for earthing of equipments. Following cables are to be laid: CLIENT UNIT PROJECT : : :
Cable size 1CX95 sqmm to be laid from AJB 1B to Distribution box. Cable size 1CX95 sqmm to be laid from CRJB 1 to Distribution box.
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
Cable size 1CX95 sqmm to be laid from AJB 1A to Distribution box. Cable size 1CX95 sqmm to be laid from CRJB 6 to Distribution box. Cable of 20CX1.5 sqmm to be laid from each CRJB box to measurement junction box. Total 6 nos. of 20CX1.5 sqmm cable to be laid.
Cable of size 1CX35 sqmm to be laid from new earthing pits inside the yard to earthing junction box in the same yard.
Cable specification is given below: 1CX95 sqmm cable shall be aluminium conductor pvc insulated armoured cable with double insulation. 20CX1.5 sqmm cable shall be single stranded copper with double insulation. 1CX35 sqmm cable shall be aluminium conductor unarmoured with pvc insulation and pvc sheathing. Detailed specification shall be obtained by bidder from site.
x x
Any other existing cable, if damaged shall be supplied and laid by bidder free of cost. All dismantling and re-installation works for existing CP system is in bidders scope. The existing CP system TR-unit is of Raychem make, Serial no.- 101542-07K8, 4000 VA. Bidder to co-ordinate with CP system vendor for dismantling and re-installation work and this work shall be done under supervision of existing CP system vendor.
5.1.1.2. New CP system for New Bullet (1 no.) The design, supply, installation and commissioning of a new CP system for 1 no. new bullet is in bidders scope of work. Bidder shall design the new CP system to work along with the existing CP system and design the CP system yard accordingly to accommodate existing as well as new equipments. Bidder shall consider a new power distribution board, to be supplied and installed by bidder in the CP system yard, with 2 no. Incomers and outgoing feeders to supply to both existing as well as new CP system. The power distribution philosophy for existing CP system henceforth shall be kept unchanged. The incoming power supply to this power distribution board shall be taken from MC-1341 in S/S-13, feeder nos. 5FC and 11FC. Bidder shall check the sufficiency of existing cable incomer from MC-1341 for supplying to the new power distribution board, i.e. adequacy
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET of cable, length etc. and if necessary supply and laying of new cables shall be in bidders scope of work.
The scope of work for new cathodic protection system shall include but not limited to the following: x Obtain, generate and evaluate necessary information to perform complete design, supply, installation, testing, commissioning and documentation of the cathodic protection systems including a design site survey for collection of data. x x Review and validate correctness of information furnished by the EPCM, on equipment to be protected. Supply of all labor, supervision, installed and consumable materials, services, equipment, tools, and each and every item of expense necessary for the design, procurement, installation and commissioning of cathodic protection systems for mounded bullets in contact with soil, in compliance with this specification and referenced standards. x Supply and install permanent testing facilities and remote monitoring capabilities to monitor the cathodic protection systems using latest proven technology available at the time of system design. x x x x x x x x x Test, evaluate and mitigate possible interference caused by cathodic protection system on communication and low energy control systems. Test, evaluate and mitigate stray currents generated by newly installed cathodic protection systems. Provide documentation for system design and installation. Furnish operation manual for system operation and maintenance. Submit to EPCM a detailed cathodic protection design and installation methods for review and approval. The design data shall include basis, calculations and drawings. Preparation and submission of general cathodic protection system layout. Supply of mandatory spares and commissioning spares as required. Bidder shall indicate dimensions of such equipment to be placed in CP system yard (eg T/R unit) and Electrical power consumption along with bid. This is essential part of bid. Bidder to provide redundant transformer / rectifier set, which shall be hot standby type.
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET x The bidder shall include in the material schedule a list of proposed monitoring equipment (hardware and software) required to carry out regular surveys of the cathodic protection system
Effort is made to define the scope of work as completely as possible, however, it is bidders responsibility to carry out successful commissioning of CP system and include any supply/work, not included herein, in his scope of work to ensure completeness of operation.
5.1.2.
Power supply Owner shall provide 415 V 3 Phase Power Supply at two points in Substation-13, MCC-1341 feeder nos. 5FC and 11FC for CP System. Further power distribution shall be in bidders scope. Bidder shall consider a power distribution board in field to supply power to existing and new CP system. The bidder shall provide load details for new CP system in his offer to EPCM.
5.1.3.
Design documents The basic design documents shall be submitted for approval to the EPCM covering the following requirements: x x x x x Results of any site surveys and soil investigations that have been carried out. Calculations of current requirements, resistance and current output of ground beds. A schematic diagram of the proposed cathodic protection system. A list of the estimated number and types of cathodic protection monitoring facilities. The civil works required to install the cathodic protection system. Such works
include transformer/rectifier plinths, deep well head works, mounting details of distribution boxes and test posts, cable trenches, security fencing, etc. x Any sensitivity in the proposed cathodic protection system that requires special attention. The following detailed design documents shall be submitted by Bidder to the EPCM for approval before construction starts: x x x x
CLIENT UNIT PROJECT
A schedule of materials including a complete set of material and equipment specifications. A complete set of design drawings. Installation procedures. Commissioning procedures.
: : : INDIAN OIL CORPORATION LIMITED PANIPAT NAPHTHA CRACKER. 0068- PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.
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5.1.4.
Training Bidder shall consider presence of Owners operating personnel during installation, precommissioning, commissioning and close interval potential survey of the cathodic protection system. The bidder shall include training of Owners personnel in the operation and maintenance of the cathodic protection system with particular attention being paid to any special features of the system and troubleshooting.
5.1.5.
Safety The Bidder shall address in his design all safety related topics regarding the cathodic protection systems and indicate, in the installation and operating documentation, procedures to ensure safe working practices. The bidder shall be familiar with local safety rules and practices and implement these in his work.
5.2. 5.2.1.
Balance Electricals The main equipment for balance electrical works for the job broadly includes, but is not limited to, supply of the following: Flameproof lighting fixtures lamps and accessories for all local lighting. Flameproof welding receptacles, sockets and junction boxes as required. Flameproof hand-lamps and 24 V sockets (with built-in transformers). All supporting structures for lighting fixtures including poles, brackets, clamps, etc. Supply, laying, termination of all power and control cabling from switchgear in substation to equipment within battery limit shall be by bidder. All cable trays, tray supports, trenches, electrical road crossings etc. for installing cables from substation to within the battery limit. Inside process units, cable tray should be covered after laying of all cables. Wherever available, existing cable tray /trench shall be used by bidder. In case of requirement of new cable trench, bidder shall provide the same after carrying out site survey. In case of using existing trench, making good of existing trench after laying cable is in bidders scope. Any other electrical loads defined elsewhere in tender, or equipment not specifically mentioned but required for completion of job.
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
Flameproof double compression cable glands for all equipment, panels supplied. Tool kits for maintenance of all equipment and systems as recommended by respective manufacturers.
Commissioning spares & spares for 2 years normal operation for all electrical equipment.
5.2.2.
Owners scope x Owner shall provide two nos. feeders for power supply to CP system in substation-13. Bidder shall consider a power distribution box at field to feed both existing and new CP system. x x 1 no. feeder for power supply to MOV shall be provided in Substation-13, AB-1351 feeder no. 17R-B (63 A SFU). 1 no. feeder for supply to Heat Tracing shall be provided in field heat tracing DB. Further power distribution shall be by bidder.
5.2.3.
Bidders scope of work Bidders scope shall include detailed engineering, preparation of all layout drawings, sizing, selection, procurement, supply of all electrical equipment and materials required for the package, transportation to site, installation, supervision, testing and commissioning of complete electrical system forming part of this tender, for the safe, efficient, trouble-free operation of the complete system and equipment as covered in the tender. Bidder's scope of work shall include the following:
5.2.3.1. Detailed Engineering Sizing and selection of equipment, cables and materials including all devices for indication, metering, annunciation, interlocks, control, operation and protection as required. This includes but is not limited to the following: a) Overall Single Line Diagram of the facilities provided. b) Calculations for Lighting System, Earthing System, Voltage Drop. c) Preparation of cable tray/trench, lighting and earthing layout drawings including associated documents such as, installation details. d) Preparation of control schematics and logic for control panels and other equipment requiring sequential or other control systems.
CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED PANIPAT NAPHTHA CRACKER. 0068- PANIPAT NAPHTHA CRACKER FCCU AND PRU REVAMP.
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET e) Preparation of cable schedule, interconnection diagrams, terminal details for equipment / devices including Electrical-Instrumentation interface details. f)
Preparation of all Bills of Material for all electrical equipment including cable trays, cable tray supports, steel supports, lighting, earthing and miscellaneous items and procurement of all items in Bills of Material.
g) Preparation of "As Built" drawings.
5.2.4.
Installation, testing and commissioning Installation, testing and commissioning of all equipment and materials supplied by Bidder including complete lighting, earthing, cabling, cable tray works etc. within the battery limit.
5.2.5.
Job specifications a) Switchboards housing switch fuse feeders required for the mounted Bullet package in refinery will be supplied and installed by the owner. All Power and Control cable supply, laying, termination from substation to equipment within the package battery limit will be done by the Bidder. b) Bidder shall ensure that equipment supplied by them shall be provided with suitably sized terminal boxes having suitable cable entry. Wherever required, additional adapter box/JB shall be provided by the bidder. c) The complete electrical system shall conform to requisition attachments and data sheets in this tender. Various electrical works covered under this contract like equipment erection, cabling, lighting and earthing works etc. shall be performed in accordance with the specifications attached with the tender. Installation standard drawings shall be issued to the successful Bidder. d) Makes of electrical equipment, materials and components shall be selected out of the list attached elsewhere in the Tender. Any other makes shall be subject to EPCMs/Owners written approval. For makes of items not included in the list, prior approval from Owner/EPCM shall be required. However, the sub-vendors current validity and range of approval as per enlistment letter, workload, stability and solvency needs to be verified by the vendor before placement of order. e) Local lighting for the mounded storage, pump station, pumps, operating platforms, panels, walkways, stairs etc. shall be provided by Bidder. Both normal and emergency/critical lighting circuits shall be provided. Power supply required for local
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET lighting of new bullet shall be tapped from existing lighting panels for lighting of existing bullets. Bidder to use 4.5M pole mounted lighting fixtures for local lighting of new bullet. f)
Heat tracing for new bullet in totality is in bidders scope. Bidder shall obtain and evaluate necessary information to perform complete design, supply, installation, testing, commissioning and documentation for heat tracing system. Heat tracing system shall conform to standard specification for heat tracing attached with the tender.
g) Cables shall be laid on trays above ground on cable racks/sleepers. Where unavoidable, a few cables may be laid in trenches subject to specific approval by owner/EPCM. h) Spares for two years normal operation of all electrical equipment and commissioning spares shall be included in the scope of supply. Lamps and control gear shall be included for lighting fixtures while control switches/push buttons shall be provided for local control stations. i) Mandatory spares shall be provided as per mandatory spares list.
5.2.6.
Drawing/ documents required from Bidder
5.2.6.1. With bids a) Load list. b) Guaranteed power consumption for rated throughput of plant. c) UPS and DC load requirements. d) Cable tray requirement in substation/field. e) Makes for various equipments offered. f) - Specific confirmation to scope of tender. - Specific confirmation to specifications and technical requirements of tender. - Deviation, if any. g) Recommended list and quantity of maintenance spares.
5.2.6.2. After contract award Electrical document deliverables to be submitted by Bidder for review and records shall broadly include the following:
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Sr. No.
Description
After order Review Ref./

Records
Remarks
1. a b 2. a 3. 4. a
Design calculations Load data, equipment sizing Lighting/earthing calculations Basic design SLD Material requisitions Purchase requisitions (before * * * * *
order placement) for bulk items such as cables, lighting fittings
5. a b 6. 7. a b
etc and equipment. Layouts Equipment layouts, Cable tray layout Earthing/Lighting layouts MTO & schedules Vendor drawings GAD, Data Sheets Wiring schemes, technical data for all electrical equipment * * * * *
6. 6.1.
MISCELLANEOUS WORKS Supply and installation of all other equipment/ accessories not specifically mentioned herein but nevertheless necessary for completion of job.
6.2. 6.3.
Correction and submission of drawings for AS-built status. Obtaining approvals and clearance for energizing the complete electrical facilities covered under this tender including approval of drawings from Central Electricity Authority/other statutory agencies. Any changes required by the CEA/statutory agency, shall be incorporated by the Bidder without any time or cost implication to owner.
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET 6.4. Submission of test certificates, catalogues, vendor drawings, installation, operation and maintenance manuals for all equipment/materials in Bidder's scope of supply.
7.
JOB MATRIX Scope & Miscellaneous work as defined in clause 5.0 & 6.0 shall be read in conjunction with the following matrix:
S. No. 7.1 7.1.1 Engineering
Description
Bidder
EPCM/ Owner
Remarks
Identification of shut down requirements and planning for hook up activities Any item not specifically mentioned in the package but required as per good engineering practice and for smooth and
7.1.2
safe operation of the equipment/ system/ plant shall deem to have been specified and shall be in the scope of Bidder with no additional cost and schedule implication to the Owner/EPCM Collecting necessary information about the existing system, co-ordination with
7.1.3
owner/EPCM, as per requirement for the satisfactory completion of the electricals for mounded bullets. In general, all electricals required for the
7.1.4
areas under mounded bullets including all sheds/ buildings within plant battery limit area shall be included in Bidders scope. Bidder shall draw power from designated substation for all electrical consumers. Area
7.1.5
lighting in mounded battery limit area and power supply to CP system shall be from LDB/switchgear in designated substation. All
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. No. Description other equipment necessary for smooth operation of mounded bullets shall be
Bidder
EPCM/ Owner
Remarks
supplied, installed, tested and commissioned by bidder. Bidder shall design the system accordingly. Preparation and submission of drawings and 7.1.6 documents after award of contract and obtaining comments/ approval on the same 7.1.7 Timely review of documents and conveying comments and approval Preparation of enquiry specifications and data sheets, bid evaluation and obtaining 7.1.8 approval from EPCM as necessary, placement of order, procurement of all items as involved to complete the package Obtaining statutory approvals such as CCE, Central Electricity Authority (CEA), Factory 7.1.9 Inspectorate, local statutory authorities, government authorities and any other agency as required for completion of work and commissioning of the plant 7.1.10 7.1.11 7.1.12 7.1.13 7.1.14 7.1.15 7.1.16 7.1.17 7.1.18
CLIENT UNIT PROJECT
Electrical load list/ consumer list Earthing design and calculations for plant Cable sizing calculations Cable tray sizing calculations Lighting calculations Selection of equipment for hazardous area CP system calculations Any other calculation not specified above but required as support of selected equipments Timely submission of calculations and
: : :
9 9 9 9 9 9 9 9 9
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. No. Description support documents Timely review of calculations and support
Bidder
EPCM/ Owner
Remarks
7.1.19
documents and conveying comments and approval
7.1.20 7.1.20.1
Drawings SLD a. Lighting scheme b. Any other SLD as required 9 9 9 9 9 9 9 9
7.1.20.2 7.1.20.3 7.1.20.4
Schematic diagrams Interconnection & terminal wiring diagrams Cable tray/ Trench/ conduit routing, Earthing and Lighting layouts. Overall earthing layout for the areas within bidders scope of work Area lighting layouts as required Cable schedule, cable drum schedule MTO schedules for bulks like cables, trays.
7.1.20.5 7.1.20.6 7.1.21
7.1.22
Lighting fixtures, LP/PP, junction boxes, cable accessories, earthing materials, LCS, structural steel. Socket outlets etc.
7.1.23 7.2
As built drawings/ documents as required
Design, Procurement, Supply and Installation of Electrical Equipment EPCM review of Design, procurement, supply, installation, testing, pre-commissioning, commissioning of electrical equipment as a minimum but not limited to the following: MR/PR/ Vendor documents w.r.t. semi-critical, noncritical equipment as per Annexure-I
7.2.1
LT Switchboards x PDB for CP system

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CP system panel shall be in safe
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. No. Description Bidder EPCM/ Owner Remarks area. Panel shall be provided with
GI canopy, if located outdoor. 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 UPS PDB Motorised valve actuators (if any) LT power and control cables. Lighting fittings FLP for outdoor areas as required Local control stations (FLP) Bulk items (cable trays, glands lugs, welding 7.2.7 and convenience socket outlets with plugs, earthing material, structural steel, all types of junction boxes, conduits, hume pipes etc. 7.2.8 All erection hardwares materials, tools, gauges etc. as required All consumables required during erection, pre-commissioning and commissioning Design, supply, installation, testing and 7.2.10 commissioning of Cathodic protection system 7.3 Interface with EPCM/OWNER Interface with EPCM/ OWNER for scope as defined in cl. 5 of job specification. 7.3.1 Interfacing shall include receiving all necessary information from/to EPCM/Owner for satisfactory completion of work under Bidders scope. 7.3.2 Forwarding all inputs related to sizing and selection of equipment (under Bidders
: : :
9 9 9 9 9
UPS system by owner/EPCM
9 9
7.2.9
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. No. Description scope) to EPCM/Owner with regard to consumer list, cable sizes, lighting load
Bidder
EPCM/ Owner
Remarks
requirement, CP system load requirement etc. Bidder shall also forward input details of cable tray/space requirement in substation, space and floor cut out requirement for installation of TR units, feeder requirement for mounded bullet consumers to EPCM/Owner. 7.4 Enabling Works Re-routing and relocation of existing cables/ 7.4.1 trenches/ structures over/under ground, which are fouling with new construction job. 7.4.2 Installation, testing and commissioning of rerouted/ relocated underground services. Proper laying of all cables (both new and old) in the existing cable trenches, wherever 7.4.3 made available to Bidder, after taking out the cables laid in those trenches and backfilling with sand, putting RCC covers etc. 7.4.4 Construction box culvert type road crossings wherever cable trenches enter unit area Provision of required numbers and sizes of 7.4.5 hume pipes at the road crossings for power, control and signal cables. 7.5 Inspection & Testing Inspection, testing of the electrical equipment and systems supplied as listed in the 7.5.1 respective specifications at suppliers shop and at site as per electrical job specification and approved QC plan 9 9 EPCMs scope is limited to critical equipment as enclosed in Annexure-I 9 9 9 9 9
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. No. 7.5.2

Description Any other tests as required/ identified for the equipment during detail engineering QA/QC documents compiled as per
Bidder 9
EPCM/ Owner 9
Remarks
7.5.3
specifications to be submitted for review/ approval of EPCM/Owner
7.6
Documentation All documentation and drawings as listed 9
7.6.1
elsewhere with their soft copy on CD with native file. Detailed testing, pre-commissioning,
7.6.2
commissioning procedures for EPCM/ owners review/ approval
7.6.3 7.6.4 7.7 7.7.1 7.7.2
All AS-BUILT engineering drawings & documents All AS-BUILT vendor drawings & documents Erection and Commissioning Site fabrication, machining etc. Supply of all consumables up to handing over. Construction of RCC built up cable trenches
9 9 9 9
7.7.3
from substation, to the battery limit of mounded bullets. Testing and inspection of materials on
7.7.4
receipt at site and to take remedial action for replacement of damaged items Transportation and handling of equipment/
7.7.5
material from storage site near the equipment foundation Erection, alignment, testing and
7.7.6
commissioning of equipment as per approved installation/commissioning
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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. No. Description procedures, drawings, etc. Filled up Performa of field activities &
Bidder
EPCM/ Owner
Remarks
7.7.7
recording test results for EPCM/Owner approval
9 9 Testing & commissioning shall be under 9
7.7.8
Trial runs
7.7.9
Commissioning
original equipment manufacturers scope
7.7.10 7.7.11 7.7.12
Performance tests/ Reliability tests Handing over Training of Owners personnel
9 9 9
Owner/EPCM witness
7.8
Miscellaneous Any other works/ services/ materials/
7.8.1
interfacing/ enabling works not specifically covered above but required for completeness of the project
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ENGINEERING DESIGN BASIS FOR ELECTRICAL
UNIT PROJECT
: FCC UNIT : FCCU AND PRU REVAMP, MATHURA. : IOCL, MATHURA REFINERY.
LOCATION
OWNER
EPCM
NOIDA, INDIA.
00
REV.
26.10.2010
DATE
REVISED AND RE-ISSUED

STATUS
ABS
PREPARED BY
DYS
REVIEWED BY
DYS
APPROVED BY
CSA
PM
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ENGINEERING DESIGN BASIS FOR ELECTRICAL CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
SCOPE ................................................................................................................................................. 3 UNITS ................................................................................................................................................... 3 SITE CONDITIONS .............................................................................................................................. 3 CODES AND STANDARDS ................................................................................................................ 4 SYSTEM DETAILS .............................................................................................................................. 6 PERMISSIBLE VOLTAGE DROP ....................................................................................................... 8 POWER DISTRIBUTION ..................................................................................................................... 9 SYSTEM CONFIGURATION ............................................................................................................. 11 CONSTRUCTION POWER : DETAIL TO BE INCORPORATED ................................................... 11 AREA CLASSIFICATION AND EQUIPMENT SELECTION ............................................................. 12 PROTECTION METERING CONTROL ....................................................................................... 14 SUBSTATION DESIGN ..................................................................................................................... 18 EQIPMENT DESIGN .......................................................................................................................... 22 EARTHING SYSTEM ......................................................................................................................... 38 LIGHTING SYSTEM........................................................................................................................... 40 COMMISSIONING OF EQUIPMENT ................................................................................................. 43
CLIENT UNIT PROJECT
: : :
INDIAN OIL CORPORATION LIMITED MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 1. SCOPE This document along with related specifications, drawings shall form the basis of Electrical design for developing detail engineering for revamp of FCCU for LPG yield and reliability
improvement at Mathura Refinery, IOCL. In case of any discrepancy / conflict amongst various documents, following order of precedence shall prevail: Statutory requirement Engineering design basis Technical specifications ,data sheets IS Codes and standards
2.
UNITS Following units shall be executed based on this document: FCCU Revamp Propylene Recovery Unit (PRU) LPG Treater Offsite & Utilities (O&U) Propylene service at Marketing terminal
3.
SITE CONDITIONS * * * * * * Maximum temperature Minimum temperature Winterizing temperature Design minimum temperature Relative humidity - Average - Maximum * Dry bulb temperature : : : 36% @ 4-50C 95% : : : : 47C 50C 2C 2C 2C 0 Design maximum ambient temperature :
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ENGINEERING DESIGN BASIS FOR ELECTRICAL * Barometric pressure - Minimum - Maximum

: : : : 740 mm Hg < 1000 mm
- Average * Altitude above mean sea level
4.
CODES AND STANDARDS Codes and standards as per minimum requirement shall be as follows: a) Statutory Regulations: Indian electricity act. Indian electricity rules. (1998) The factory act. The petroleum rules. The TAC rules.
b) Codes and Standards - IS13234 (1992): - IS 5572 (2009): - IS 5571 (2000): - IS 12360 (1988): - IS 3961 (2001): - IS 4201 (1983): - IS 3842 (2001): - IS 4146 (1983): - IS 10028 (2001): - IS 1255 (1983): Guide for short circuit calculations in three phase AC system Classification of hazardous areas having flammable gases and vapours for electrical installations Guide for selection of electrical equipment for hazardous areas. Voltage bands for electrical installation including preferred voltages and frequencies. Recommended current rating for cables. Application guide for CT. Application guide for electrical relays for AC systems. Application guide for VT. Code of practice for selection, installation and maintenance of transformers. Code of practice for installation & maintenance of power cables up to & including 33kV rating.
CLIENT UNIT PROJECT : : : INDIAN OIL CORPORATION LIMITED MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL - IS 8478 (1977): - IS 3043 (1987): - IS 3716 (1978):
Application guide for on load tap changers. Code of practice for earthing. Application guide for insulation co-ordination. Code of practice fro electrical wiring installations. Code of practice for industrial lighting. Code of practice for interior illumination. General requirements for electrical apparatus for explosive gas atmosphere. Code of practice for the selection, installation and maintenance of electrical apparatus for use in potentially explosive atmospheres.
- IS 732 (1989): - IS 6665 (1972): - IS 3646 (1992): - IS 13346 (2004): - IS 13408 (1992):
- IS 7689 (1989): - IS 2309 (1989): - IS 1646 (1997): - IS 3034 (1993): - IS 10118 (1982): - IS 5216 (1982): - IS 9676 (1980): - SP-30:
Guide for control of undesirable static electricity. Code of practice for the Protection of buildings and allied structures against lightning. Code of practice for fire safety of buildings - electrical installations. Code of practice fro fire safety of industrial buildings electrical generating and distributing stations. Code of practice for selection, installation and maintenance of switchgear and control gear. Guide for safety procedures and practices in electrical work. Reference equipments. National Electrical Code (NEC) BIS Publication. carbon processing and handling facilities ambient temperature for electrical
- OISD-STD-113 (2001): Classification of areas for electric installations of hydro- OISD-STD-173 (2003): Fire prevention and protection system for electrical installations. - OISD-RP-110 (1999): - OISD-RP-147 (2002): Recommended practices on static electricity. Recommended practices inspection & safe practices during electrical installations.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL -OISD-RP-149 (2001): Recommended practices design aspects for safety in electrical system. - OISD-GDN-180 (1999): Lightning protection
- IEC 79: - NFPA 70B (1994): - NFPA 72 (2002): - NFPA 77 (2000): - NFPA 497 (2004):
Electrical apparatus for explosive gas atmospheres Recommended maintenance National fire alarm code Static electricity Recommended practice for classification of flammable liquids, gases or vapours and of hazardous locations for electrical installation on chemical process areas. practice for electrical equipment
- IEEE 519 1992:
Recommended
practices
and
requirements
for
harmonic control in electrical power systems Any other standards may be followed provided it is equivalent or more stringent than the available codes indicated above.
5.
SYSTEM DETAILS In this document HV implies MV implies Utilization voltages : Main power supply : 11 kV, 50 Hz, 3 phase, 3 wire, resistance earthed, 6.6 kV, 50 Hz, 3 phase, 3 wire, resistance earthed For 415 V distribution For motors above 160kW For motors from 0.37 kW to up to and including 160 kW For motors less than 0.37 kW MOVs, welding receptacles Normal lighting : 240 V AC, 1phase, 50 HZ : 415 V AC : 240 V AC, 1phase, 50 HZ : 415 V, 3 phase, 4 wire, 50 Hz, solidly earthed : 6.6 kV, 50 Hz, 3 phase, 3 wire : 415 V, 3 phase, 3 wire, 50 Hz : 11kV and 6.6 kV : 415 V
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ENGINEERING DESIGN BASIS FOR ELECTRICAL Convenience receptacle Critical lighting Control supply
: 240 V AC, 1phase, 50 HZ : 220 V DC, 2 wire 1. 240 V, 1 phase AC up to MCC level shall be derived from individual 0 module 2. 220 V DC for 415 V PMCC , 6.6 kV and 11 kV Switchgear
Instrumentation supply (Refer Instrument Design basis) Power supply for Fire Alarm system Power supply for Public address system Emergency Power HOLD Voltage and frequency variations :
: 230 V AC UPS : 24 V DC : 240 V AC non UPS (For non-critical load) : 230 V AC UPS : 230 V AC UPS
: 11kV + 10% : 6.6 kV + 10% : 415 V+ 10% : 240 V + 10% : 50 Hz + 5% Combined voltage and frequency variation System fault level HOLD : + 10%.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 6. PERMISSIBLE VOLTAGE DROP The maximum voltage drops under steady state conditions at full load shall be within the limits stated in the following table:
Maximum S.No. a) b) c) Cable at System Element HV switchboard incomer with sending end Permissible Voltage Drop 2% 2% 0.5% board located remotely Cable between HV switchboard and transformer primary (located near) Bus duct or cable between transformer secondary and HV Switchboard or PCC/PMCC d) Cable between PCC/PMCC and MCC or auxiliary switchboard; i) ii) e) MCC / Auxiliary Switchboard near PCC/PMCC MCC/Auxiliary Switchboard situated remote from PCC/PMCC Cables between HV Switchboard and HV Motor Running-3% Starting-10% f) Cable between PCC/PMCC and motor Running-5.5% Starting-10% g) Cable between MCC (situated near PCC/PMCC) and motors h) Cable between MCC (situated remote from PCC/PMCC) and motors Running-5% Starting-10% 3% 0.5% 2 to 2.5%
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ENGINEERING DESIGN BASIS FOR ELECTRICAL Maximum S.No.

System Element Cable between Auxiliary Switchboard & Lighting Panel Circuit between lighting panels and lighting points DC Supply Circuit (Electrical Controls) DCDB to Control Room UPS outgoing circuit
Permissible Voltage Drop 1 to 1.5% 4% 5% 2% (Note 1) 5% (Note-1)
i) j) k) l) m)
Note: 1. Minimum voltage available across any instrument in the field shall be as per instrumentation design basis. Distribution system for instrumentation supplies shall be designed accordingly. In case of any conflict between electrical design basis and instrumentation design basis, the latter shall govern regarding instrumentation power supplies. 2. For 415 V motors starting voltage at motor terminal shall not be less than 80% of rated value. 3. For 6.6kV motors starting voltage at motor terminal shall not be less than 90% of rated value.
7.
POWER DISTRIBUTION A) FCCU, PRU & LPG Treater 0 Two nos. 11 kV extension panels shall be installed and integrated with 11 kV Switchgear, (BHEL make, typeVM12) located at TPS substation, one panel at each side .11 kV power supply shall be brought to new substation (mentioned as S/S 51 hereafter) for Electrical loads of FCCU revamp unit, PRU and LPG Treater Unit. 11 KV power Cable between TPS to proposed sub station 51 shall have one additional run of
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ENGINEERING DESIGN BASIS FOR ELECTRICAL the cable in each of the two feeders. This run shall be in addition to the runs which are calculated as per the load requirement. These two extension panels shall feed one no 11 kV Switchgear in Substation 51. This
Switchgear shall feed two nos. 11/6.6 kV transformers and two nos. 11/0.433 kV transformers. The transformers shall supply 6.6 kV Switchgear and 415 V switchgear respectively. Refer Overall key single line diagram 00785-000-DW-1652-01, for Load distribution of substation 51. 11 kV extension panels shall be in the scope of supply for the Erection contractor. B) LPG Storage Facility Electrical loads for this facility shall be fed from New MCC 193 in LPG MCC room. Existing MCC shall be replaced with new MCC and available feeder details shall be furnished to TPKTI. C) Cooling Tower Cooling tower fan motors (3 nos on 415 V) shall be fed from existing PMCC in NHGU substation. PMCC shall be extended by one vertical panel each on both sides. Two nos. new CT Fan motors shall be fed from extension panels, one on each bus section. Third motor shall be supplied from existing motor feeder no. --- in switchgear no.--- in substation 11. Existing motor fed from feeder no. --- of switchgear no. --- in substation 11 shall be disconnected from switchgear no. ---and reconnected to PMCC extension panel in NHGU Substation to receive power supply. Two nos. Cooling water pump motors shall be fed from existing 6.6 kV switchgear in DHDS substation. Required CTs, protection relays etc shall be provided in existing feeders, compatible to the system. One no. Cooling water pump motor shall be supplied from feeder no ----of existing 6.6 kV switchgear ---- in substation 11. Existing motor fed from feeder no. --- of 6.6 kV switchgear no,.-- in substation 11 , in turn , shall be disconnected from switchgear no. --- and reconnected to 6.6 kV switchgear in DHDS substation to receive power supply. 11 kV switchgear in NHGU substation shall be extended by one panel each on both sides.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL D) Marketing terminal HOLD

E)
Unloading facilities and Panipat Refinery HOLD
8.
SYSTEM CONFIGURATION System configuration for 11 kV, 6.6 kV and 415 V switchgears shall be as follows: 11 kV, 6.6 kV switchgear and 415 V PMCCs shall have two bus sections with two incomers and one bus coupler. In normal operation both incomers shall be ON and bus coupler OFF. On failure of any one incomer, due to loss of power supply, bus coupler shall be closed through automatic changeover, and restore power to the affected section. Once affected incomer is restored, closing of incomer and opening of bus coupler shall be through manual changeover with momentary paralleling between two incomers through synchro check relay. Auto changeover shall be blocked if both incomers sense under voltage simultaneously.
9.
CONSTRUCTION POWER
: DETAIL TO BE INCORPORATED
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 10. AREA CLASSIFICATION AND EQUIPMENT SELECTION The electrical equipment for hazardous areas shall be selected as per IS-5571 and petroleum rules. The MINIMUM requirement is summarized below:
10.1.
Equipment
Zone 1 Gas Group IIA, IIB Gas Group IIC Ex-d Ex-d/Ex-p Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d
Zone 2 Gas Group IIA, IIB Ex-e/Ex-n (refer note2) Ex-e/Ex-n (refer note2) Ex-d Ex-d Ex-d Ex-d Ex-nR Ex-nR Ex-n Ex-d Ex-d Ex-d Ex-d Ex-d Gas Group IIC Ex-e/Ex-n (refer note2) Ex-e/Ex-n (refer note2) Ex-d Ex-d Ex-d Ex-d Ex-nR Ex-nR Ex-n Ex-d Ex-d Ex-d Ex-d Ex-d
MV Motors HV Motors Push Button Station Motor Starter (for MOV etc) Plug & Socket Welding Receptacle Lighting Fixtures
Ex-d Ex-d/Ex-p Ex-d Ex-d Ex-d Ex-d
i) Lighting Fitting and control Ex-d gear box ii) Control Gear Box Junction Boxes Hand Lamps i) Light fitting ii) Transformer Unit iii) Plug & Socket Break glass unit (Fire Alarm System) Lighting panel / power panel Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d Ex-d
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ENGINEERING DESIGN BASIS FOR ELECTRICAL Note: 1. The electrical equipment for hazardous areas shall generally be suitable for gas group IIA/IIB and temperature classification T3 as applicable to the selected type of
explosion protection. In case of hydrogen or hydrocarbon mixtures having more than 30% volume hydrogen, the gas group to be considered shall be IIC. 2. In case of Ex-e/Ex-n motors, risk analysis shall be carried out as per IS-6381:2004 and IEC 60079-7(2001), considering operational and maintenance conditions. Else EX-d or Ex-p motors shall be offered. 10.2. As additional safety features, the following requirements for electrical equipment shall be followed: a. All electric motors for agitators / mixers and metering pumps handling flammable material shall be flameproof type irrespective of the area being classified as Zone-2 or Zone-1. b. c. d. All electric motors for vertical oil sump pumps shall be flameproof type. Irrespective of the area classification (whether Zone-1 or Zone-2), all lighting fixtures within the storage areas shall be flameproof type. Irrespective of the area classification (whether Zone-1 or Zone-2), all motors and lighting fittings within the pump house (station) associated with storage area and within the loading/unloading gantries shall be of flameproof type. e. f. All emergency / critical lighting fixtures and associated junction boxes in hazardous areas (whether Zone-1 and Zone-2) shall be flameproof type. Even though fired heaters in process units are not considered for area classification, all electrical equipments associated with fired heaters in process units shall as a minimum be suitable for installation in Zone-2 area. g. All electrical equipment installed in Analyzer shelter shall be flameproof type suitable for Gas Group IIA, IIB, IIC irrespective of the area being classified as Zone1 or Zone-2. h. Building such as compressor sheds inside the process area shall be designed to allow adequate ventilation to allow area classification as Zone-2. Lighting equipment, EOT crane etc. in the shed shall be flameproof type. All other electrical equipment shall be suitable for Zone-1 or Zone-2 area depending on extent of
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ENGINEERING DESIGN BASIS FOR ELECTRICAL hazard. Ex-d motors shall be used in Zone-2 areas for HV motors for centrifugal compressors. i.
All motors for hazardous area Zone-1 shall preferably be flameproof type. Pressurized motors may be provided in case Ex-d motors are not available. Ex-d motors shall be used in Zone-2 areas for motors having frequent start/ stop requirements e.g. EOT cranes, Elevators, MOV actuators. Ex-n motors with prestart ventilation provision or Ex-d or Ex-p motors shall be used in Zone-2 areas for application having average starting frequency more than 1 per week, where rating of motor is more than 100kW.
j. k.
l. m.
Ex-p motors shall be used for large rating motors where either Ex-n or Ex-d motors are not available. For Ex-n and Ex-e motors, the appropriate risk assessment factors shall be worked out taking operational and maintenance conditions. Else, Ex-d motors shall be provided.
11.
PROTECTION METERING CONTROL Protection devices for power distribution system shall be as indicated below: Transformer Motor Feeder Feeder Second L.V ary winding winding HV < 0.433 voltage KV) 6.6kV OverYes Yes Yes --Outgoing Feeder HV MV PCC/ PMCC Yes (4) Yes (4) No Yes (7) No Yes Incomer MV PCC/ PMCC Yes (4) Yes (4) No
11.1.
Relay Number
HV Yes
51 51N 51G
ID
MTL
current relay IDMTL backup fault-relay earth-
Yes Yes
earth- Yes (6)
fault-relay (secondary Yes neutral) Motor protection relay No
Yes
--
No
No
Yes
No
No
No
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ENGINEERING DESIGN BASIS FOR ELECTRICAL Transformer Motor Feeder Feeder Second L.V ary winding winding HV < 0.433 voltage KV) 6.6kV rotor Outgoing Feeder HV MV PCC/ PMCC Incomer MV PCC/ PMCC
Relay Number
HV
with
locked
feature (50, 50N, 46, 49, 50L/R) 64R instantaneous earth-fault No Yes -No No No Yes restricted 50 50N 87
relay (secondary side) instantaneous over-current relay earth-fault relay protection relay 86 tripping relay 95 63 trip auxiliary circuit relay Yes Yes Yes No Yes Yes Yes --Yes (2) Yes Yes -Yes ----No (13) ---Yes --Yes (5) Yes (8) Yes Yes Yes (5) Yes (8) No No Yes (3) Yes Yes No No No No Yes No No No No Yes Yes Yes No No No No Yes Yes (13) No
instantaneous Yes (6) (1) Yes Yes Yes differential Yes
supervision relay (transformer) PT Fuse monitoring (Block U/V trip) 27,2 25 Cable protection Feeder management relay
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under
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relay with timer synchronization relay differential
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ENGINEERING DESIGN BASIS FOR ELECTRICAL Notes: (1) (2)

For transformers rated 5 MVA and above For motors rated 1500 KW and above For critical / long feeders and plant feeders connected to main power generation and distribution bus. DC supply shall be extended to remote substation implemented. 0
(3) (4) (5) (6) (7) (8)
Wherever auto transfer feature is provided proper logics as discussed above to be Instantaneous earth fault 50N shall be provided only for transformer with delta primary. For motor feeders rated 75 kW and above. For switchgears having bus transfer scheme, where continuous or momentary paralleling is envisaged, check synchronizing relay shall be integrated with overall paralleling scheme.
(9)
The bus tie feeders in HV switchboards shall be provided with 51, 51N, 86 and 95 relays. All HV switchboards will have bus differential protection with C.T circuit supervision. There shall be overlapping of zones such that no blind spots are left in the system. For this CT location must be checked before finalizing the vendor drawings. 0
(10) HV and MV breaker controlled motor feeders or contactor feeders with DC control supply, shall be provided with timers for delayed tripping on bus under voltage while the under voltage relay shall be common for the bus. Under voltage relay will sense all three phases and tripping shall be blocked in case of P.T fuse failure. (11) All HV switchboards shall have two sources of DC supply for redundancy. supply to the switchboard. (13) Trip circuit supervision shall be provided as part of numerical relay in switchgear. (14) Numerical relays shall be comprehensive units with all protection, metering and control and communicable with existing ECS system in the refinery. (15) 2 nos. of Master Trip (86) relays shall be considered for all breaker controlled motors. One self reset type (flag hand reset) for process trip, another manual reset for electrical trip. Both relay actuation shall be recorded through numerical motor protection relay.
(12) One No. DC supply supervision relay (80) shall be provided for each incoming DC
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ENGINEERING DESIGN BASIS FOR ELECTRICAL (16) Motors below 30 kW shall be provided with ELCB .Motors above 30 kw shall be provided with suitable earth leakage relay with CBCT. (17) deleted
(18) Under frequency load shedding relays to be provided in each HV switchboard. At least six stages of under frequency settings are to be provided. Manual load shedding command from TPS should also operate the load shedding relays. For tripping individual feeders self reset type VAJ relays to be envisaged. 0
11.2.
The metering devices in HV and MV Switchboards shall be as below: Feeder Type HV Incomer HV Bus Tie HV Transformer HV Bus P. T HV Feeder HV Motor X X X Plant X X X X A(3 X X X V(3 X Hz X PF X KW KWH X X Hour Run KVAR KVAH KVA
phase) phase)
PCC/PMCC Incomer PCC PMCC

X / X
X -
X -
X -
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ENGINEERING DESIGN BASIS FOR ELECTRICAL Bus Tie PCC P.T

Bus
X X X X
X X -
X X
ACB outgoing MV Motor (> 75kW) MCC/ASB Incomer MCCB/SFU Outgoing (> 250A) LDB Incomer 1) 2)
Ammeter shall be provided at field for motors rated 30 kW and above. Comprehensive metering shall be part of numerical relay, wherever numerical relay is provided. Separate microprocessor based energy meter connected to metering C.T will be provided .Metering data shall be communicable to ECS system through numerical relay/ intelligent energy meter. 0
12. A)
SUBSTATION DESIGN FCCU, PRU and LPG Treater One new substation shall be designed for FCCU, PRU and LPG treater. This substation shall be located adjacent to substation 39. 1) This substation shall house 11 kV switchgear, 6.6 kV switchgear, 415 V PMCC/MCC, auxiliary switchboard, Main lighting distribution board, lighting transformer, DC battery charger, VFDs, DCDB, RTU panels, NGR, 11/6.6 kV and 11/0.433 kV distribution transformers as required. 2) Substation shall be maintained at a positive pressure through pressurization system in the switchgear rooms. It is to be ensured that the inlet air of the pressurized system shall be free from
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ENGINEERING DESIGN BASIS FOR ELECTRICAL moisture and hazardous mixtures. Positive pressure of 2 mm of Hg shall be maintained inside the substation. Pressurisation duct arrangement shall take into due consideration MV bus duct layout.
3) Sub-station floor shall be raised above grade level and the space below the switchgear room shall be utilized as cable cellar. The cable cellar floor shall be 500 mm above the approach road level and shall be paved and cemented. The cable cellar shall have a minimum clear height of 2.5 m and shall house all cable trays, supports etc. The roof shall be given adequate water proofing treatment to ensure that rain water does not seep into the substation. 4) An entry of 3.0 m with rolling shutter shall be provided for entry of equipment. A separate entry for operating personnel and also an emergency door opening outwards shall be provided in the substation. 5) In the Substation Room, where Switchboards are installed suitably sloped ramp for transition between the floor and the switchgear bottom plate shall be provided to allow easy installation and removal of any draw out devices. 6) Substation wall adjacent to the transformer bays shall be either 355 mm thick brick wall or 230 mm thick RCC wall. Substation building shall be preferably without any columns within the switchgear room to ensure optimum space utilization. 7) Battery bank shall be located in a separate adequately ventilated room in the substation building, along with necessary flameproof exhaust fan and other electrical fittings and switches and water connection with sink. Floor of the battery room and walls up to 1.0 m height shall have acid/alkaline resistant protective material coating/tiling. Light fittings in this room shall be chemical resistant and flameproof type. The battery rooms shall be provided with exhaust fans and louvered opening in opposite wall/door. 8) VFDs , Chargers , UPS (if any), will be installed in air conditioned environment. 0 9) Substation lighting shall be controlled by push button stations located at the entrance. 10) Substation shall have fire fighting equipment, first aid boxes and other safety equipment as per statutory requirements. Rubber mats of required voltage rating shall be provided around all the switchboards and panels. 11) Switchgear room shall be provided with the following minimum equipment: a. Framed laminated shock treatment chart, conforming to IE rules, in English and local language. Name, address and telephone number of nearest doctor shall be mentioned in it.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL b. Easily accessible first aid box containing ointments and medicines for treatment of electrical burns, conforming to IE rules. c. Self contained portable hand lamp, complete with rechargeable battery.
d. Portable battery operated emergency light. e. Adequate number and size of CO2 fire extinguishers and dry chemical powder suitable for dealing with fire. f. Round bottom fire buckets filled with clean dry sand. g. Framed single line diagram (AC and DC). h. One no. earthing rod. i. j. l. Earthing truck (for both circuit and bus). Caution notices shall be provided for all energized electrical equipment. LT megger (2 nos.) 0
k. HT megger m. Discharge rod (2 nos.) n. Breaker handling trolley (2 nos.) p. Laser temperature measurement guns (2 nos.) Supply of above equipment shall be in the scope of Erection contractor. 12) Oil filled distribution transformers shall be located in bays adjacent to the substation building. Transformer bays shall have well drained floor, surfaced with gravel or other suitable material. Each bay shall be provided with 2.5 m high removable chain link fence with a lockable gate at the open side. Partition walls between transformer bays and the end wall of the last bay shall be of fireproof type and shall extend at least 600 mm above the height of the equipment. Height of the bay shall be decided so as to facilitate maintenance and easy removal of equipment and requirements of natural ventilation. Minimum 1000 mm clearance shall be provided all round the transformer. Fire extinguishers and round bottom fire buckets filled with clean dry sand shall be provided in each transformer yard. 13) In every transformer bay one no. 100 A outlet shall be provided for oil filtration and other maintenance. 14) Oil immersed transformer with oil capacity exceeding 2000 litres shall be provided with a soak pit of sufficient capacity to accommodate entire volume of oil. Where oil capacity
o. Tools for working on HT Panels and LT panels (if required)
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ENGINEERING DESIGN BASIS FOR ELECTRICAL of transformers exceeds 9000 litres, provision shall be made to drain away the oil to a separate waste oil tank/pit located away, through suitable drain pipes of 150 mm or 200 mm in diameter.
15) The substation building shall be sized to take care of present and future needs and to maintain the adequate clearances between equipment for ease of maintenance. Space for two adjacent panels for future extension on each side of switchboard shall be maintained. 16) The sub station shall be designed such that all new HT panels, PMCC and MCCs panels can be extended in either side for minimum 2 no panels on either side in future. Following minimum clearances around various equipments shall be maintained: Front clearance for HV switchboard Front clearance for all other switchboards / panels Between front to front of different switchboard / panels Rear clearance for panels having maintenance access from front only 2500 mm 2000 mm 3000 mm Less than 200mm or more than 800mm 0
Rear clearance for panels requiring maintenance from 1500 mm rear Side clearance between two boards or from nearest 1500 mm obstruction (but not less than twice the width of each panel) All-round clearance Battery rack to wall clearance for Single row, single/double tier - Double row, single tier - Double row, double tier Between battery racks Front clearance for wall mounted equipment 1000 mm 100 mm ( increase to 300 -400 mm)) 100 mm( increase to 300 -400 750)) mm 750 mm 1000 mm
Head room clearance below bus ducts or any other 2000 mm overhead equipment Front clearance for operation station, annunciation / 2500 mm control panel. Minimum vertical clearance above the top of highest equipment shall be minimum 1500 mm measured from bottom of roof slab and minimum 500 mm measured from the bottom of the lowest roof beam. Substation, together with cable cellar and panels shall have provision for 20% future expansion.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 17) Fire proofing of cables shall be done for 1 m length at indoor equipment entry point, and similarly for outdoor equipment entry point. Fire barriers shall be installed at substation building cable entry points. All cables shall have FRLS outer sheath.
18) 19) B)
Cable cellar shall be provided with exhaust fans for adequate ventilation. Transformer bay shall have clear approach road for movement of crane / Hydra. LPG Storage facility Electrical loads for this facility shall be fed from New MCC 193 in LPG MCC room. Existing MCC shall be replaced with new MCC and existing feeder details shall be furnished to TPKTI. 0
C)
Cooling Tower Cooling tower electrical loads shall be supplied from NHGU substation, DHDS and Substation 11. For distribution details refer clause 7.c. No new substation is envisaged.
D)
Marketing Terminal (HOLD) Existing substation shall be utilized for this facility. If space /supply feeders are not available, EPCM contractor shall extend existing substation and provide new panel for Propylene service. Incoming power shall be taken from existing substation only.
E)
Unloading facilities at Panipat refinery HOLD
13.
EQIPMENT DESIGN HV Switchboard/ HV Extension panel 1) HV extension panel on either side of 11 kV switchgear 7A/8A (BHEL make, type VM12) shall be provided in TPS substation. 11 kV and 6.6 kV Switchgear shall be provided in New substation 59. 11KV board to be extended on both sides by 1 feeder each in NHGU substation. 2) HV extension panel breaker rating shall be suitably rated for total electrical load down stream. 0
13.1.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 3) HT switchgear, fed from transformers shall be rated for at least equal to the continuous rating of transformer considering site ambient conditions. 4) Short circuit rating for 11 kV Extension panel and switchgear shall be 40kA for 3 sec.
5) Short circuit rating for 6.6kV switchgear shall be ---- kA for 3 sec. 6) Each vertical section shall consist of 1 no. circuit breaker only.
7) All breakers shall be horizontal isolation draw out type VCB. Trolley shall have SERVICE, TEST and ISOLATION positions, each having locking facility. These positions shall have limit switches with auxiliary contacts for interlock. CB shall be operable in SERVICE and TEST positions with the cubicle door closed. The TEST position shall be within the cubicle. A flexible duty interlocked plug and socket arrangement with scrapping earth terminals shall be used for auxiliary supply. 8) All protection and metering CTs, PTs shall be easily accessible for testing, maintenance and replacement. All protection CTs except class PS shall be of minimum 5P10 class. All CTs shall have P.D values less than 20 pc and window type CTs are to be used for high ratings. 9) Interlock of upstream breaker shall be taken in closing and tripping circuits of incomers. 10) Contact multiplication shall preferably be avoided. Direct contact of breakers, master trip relays etc shall be used for interlocking, tripping, closing etc. 11) 11 kV and 6.6 kV Switchgears and Line PTs and bus PTs shall be in separate compartments and shall not be part of incomer breaker or outgoing feeder breakers. 12) All panels shall have peeping infra-red window at the rear for thermo graphy. 13) All breaker contacts shall be silver plated. for the same. 15) For VCBs, over voltage due to motor switching shall be limited to 2.2 times rated peak line to earth voltage. Surge arrestors shall be provided for this purpose. Surge arrestors shall be of adequate rating and located near the cable termination after bus differential C.T. 16) Rating of CBs / contactors used in motor feeders shall be 125% of maximum continuous rated current of motor. 17) Normal and standby loads shall be evenly distributed on both bus sections. Normal and standby loads shall be fed from different bus sections. 18) Earthing trolleys, rods, breaker lifting trolleys shall be provided.
14) Auto changeover circuit supervision and remote and local indication shall be provided
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 19) Marshalling cabinet shall be provided for DCS / PLC interfacing in the switchgear itself. Terminal block shall have provision for termination of armoured multicore copper cables.
20) Spare outgoing feeders shall be provided in HV Switchgears (not extension panels). At least one number of each rating and type or 20% whichever is more shall be provided as spare on each bus section. All the three compartments, i.e. breaker / bus / cable compartments shall also be provided with metal barrier sheets. 21) HT switchgear shall be metal clad only. 22) Failure of DC control supply shall not trip any breaker. 23) CT secondary shall be 1A for both metering and protection. PT secondary shall be 110VAC. For all other design requirement, refer Standard specification of HT Switchgear doc no. 0785-000-1652-01. 24) Provision for 20% spare feeders to be kept, with minimum of 2 spare feeders( one on each side of panel). 13.2. Transformers Distribution transformers shall be with following turn ratio a) 11/6.9 kV b) 11/0.433 kV 1) Power connection for 11/6.9 kV transformer shall be: Primary through cables Secondary through cables 2) Power connection for 11/0.433 kV transformer shall be: Primary through cables Secondary through bus duct 3) Distribution transformers shall be three-phase, oil immersed, double wound type, ONAN cooled, suitable for outdoor use, with off circuit tap changer having range of plus 5% in steps of 2.5%, boltless design. 4) Transformer rating shall suit 20% spare capacity with 100% load as basis. During normal operation, each transformer shall be loaded to 40% of rated capacity. During outage of one transformer, other healthy transformer shall be loaded to 80% of rated capacity.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 5) The maximum rating shall be 2 MVA. Number of such distribution transformers shall be decided based upon the total load requirement. Due consideration shall be given to the starting current of large motors. Transformer of rating up to 2.5 MVA
maximum can be considered as special case. 6) Transformer rating and impedance shall be selected in order to limit short circuit current to values within the current rating and rupturing capacity of switchgear and also to permit the DOL starting of the largest motor without exceeding the permissible voltage drop limit. Transformer sizing shall take care of minimum 8 hours maximum demand. 7) Distribution transformers shall be of low loss type. Maximum efficiency shall occur at about 40-50% of ONAN rating, and shall not be less than 99.5%. 8) Distribution Transformers shall be supplied with required accessories. For list of accessories and other design requirement, refer Standard specification of Distribution Transformer doc no. 0785-000-1641-02. 9) Lighting transformers shall be ANAN type. For design requirement, refer Standard specification of Dry Transformer doc no. 0785-000-1641-03.
13.3.
MV Switchboard Switchboard Rating shall be at least equal to maximum demand under any circuit configuration, with provision for 20% future requirement. 1) Starters for the motors in general shall be provided in PCC/MCC located in substation. However in special cases like MOVs & EOT cranes etc. starters (suitable for classified area) shall be provided by the package vendor in the field near the motors . 2) Separate feeders shall be provided in the switchboard for each load/motor. However, as an exception maximum two numbers welding receptacles may be connected to one power feeder. 3) Motors rated 30 kW and above shall be provided with a CT in MCC for connection of an ammeter in the local control station. 4) Motors rated upto and including 55 kW shall be fed from MCC and provided with DOL starter.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 5) Motors above 55 kW and upto and including 160 kW shall be fed from PMCC and provided with ACB and motor protection relay. 6) However, in case number of motors is not many for one unit/switchgear, all motors
may be fed from same PMCC, subject to prior discussion and concurrence with OWNER. 7) Minimum rating of ACB incomers for MCC shall be 800A 8) Motor feeders shall be provided with IEC type-2 co-ordination. 9) All PMCC feeders shall be with ACBs. No switch fuse feeders shall be used in PMCC. 10) All breakers in PMCC shall be provided with suitable numerical relays communicable with Existing ECS system in the refinery. 11) PMCCs shall have auto changeover facility. Under voltage tripping in PMCC shall be inhibited if voltage dip is transient or if it occurs on both incomers simultaneously. 12) MCCs shall have mechanical interlock and manual changeover facility between incomers and bus coupler. 13) PMCCs shall be suitable for bus duct top entry. MCCs shall be suitable for bottom cable entry. 14) MCCs shall preferably be single front. However, in case of space constraint, double front MCCs may be provided after prior discussion with OWNER. 15) ACBs shall be provided with minimum 4 NO +4 NC spare auxiliary contacts wired up to terminal box. 16) Contactors shall be air break type with 3 main contacts and 3 NO+3 NC contacts. 17) Local/remote selector switch shall be mounted at field. 18) Reacceleration facility, if required by process, shall be provided in switchgear. 19) Separate Marshalling cabinet shall be provided in the new Substation for switchgear and DCS/PLC interface requirements. 20) Wherever motors are fed from existing switchgears, cables for interface with DCS/PLC shall be taken to control room from individual feeders directly. 21) For all other design requirement, refer Standard specification for MV switchgear/distribution board doc no. 00785-000-STD-1654-01and single line diagrams of individual switchgear.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 13.4. MV Bus Duct 1) MV bus duct shall be non phase segregated type. 2) The bus bar material shall be electrolytic aluminium / copper.
3) Bus insulators shall be non-hygroscopic, non-inflammable and flame retarding type. 4) Outdoor bus duct shall be weather proof IP55 and shall be provided with suitable seal and canopy. 5) Material shall be same as that used for switchgear bus bars. 6) Space heater with auto cut-off shall be provided at suitable location. 7) Continuous earthing strips of proper sizes shall be provided on the two sides of the bus duct, for connection with the earthing grid. 8) For all other design requirement, refer Standard specification for MV Bus duct doc no. 00785-000-STD-1653-09. 13.5. NGR Neutral Grounding Resistor (NGR) shall be housed in a sheet metal enclosure and shall be naturally ventilated. The resistor shall be of unbreakable, corrosion proof joint less stainless steel grids. The grids shall be in punched form. The NGRs shall be rated to withstand the fault current for 10 seconds. 13.6. Motors 1) All motors shall be IP 55, insulation class F with temp rise limited to class B. 2) Motors rated 1500 kW and above shall be provided with soft start facility. 3) Only standard output (kW) ratings of motors shall be used. Motors shall be continuous, maximum rated with possible exception of crane and hoist motors. 4) Sleeve or anti friction type bearings shall be used. Vertical motors shall have thrust bearings. 5) HT motors shall have 6 nos duplex RTDs for winding temperature detection, 2 nos bearing temperature detectors with suitable scanners (with provision of alarm and trip output). Dual dial type temperature indicator without contacts for bearings shall also be provided. 6) Terminal box of HT motors shall be Phase insulated / Phase separated / Phase segregated / Pressurized with elastimold connector and shall withstand specified 0
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ENGINEERING DESIGN BASIS FOR ELECTRICAL short circuit current for 0.25 sec. A separate neutral terminal box shall be provided for making star connection, and shall accommodate CTs for differential protection. 7) Motors shall be capable of 20% over speed.
8) Starting current shall be limited to 600% on DOL. Reduced voltage starting by soft starter may be used if starting voltage drop limits cannot be maintained by DOL starting method. 9) Reacceleration of motors, if so required by process, shall be provided for interruption in normal power supply up to 5 seconds. Insulation for these motors shall be designed for 140% of rated insulation level. 10) Motors rated 75 kW and above shall have space heaters. Ammeter shall be provided for space heater circuit on switchgear. 11) Difference between starting time of motors at 80% voltage and hot thermal withstand time at 100% voltage shall be minimum 3 sec. 12) Winding and bearing temperature alarm and trip shall be provided for HT motors. Minimum 10% additional RTD points shall be provided. 13) EEx-d gr IIC motors with top terminal box shall be provided with extended shaft. 14) All motor terminal boxes shall be on the right hand side of the motor viewed from driving end. 15) Terminal box of the motor shall be suitable for rotation by 90o. 16) All outdoor motors shall be provided with canopy. 17) Surge suppressor shall be provided in VCB operated motor feeders. 18) Instantaneous earth fault tripping shall be provided in motor feeders with residual connection and variable stabilising resistor. 19) Auto start schemes shall be designed in instrument PLC. 20) Voting logic shall be provided in auto start schemes of motors. 21) Numerical relays for motors shall have RTD and BTD support feature and the RTDs and BTDs of the motors may be hooked up to the respective numerical relay for alarm / trip provision. 22) U/V protection provided for motor as well as transfer scheme shall be comprehensive and sense all three-phase voltages. The under voltage protection shall operate only on under voltage of all three phases and shall be blocked on tripping of PT MCB. The under voltage input to the relay for motors shall be derived from bus PT.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 23) Under voltage relay contact multiplication shall be provided through self reset relay. 24) All breaker operated motors shall be provided with TNC switch at the local control station.
25) For Excitation Panel of Synchronous Motors Single Phase Bridge to be considered. The same is required for Reliability Improvement ( So That Single Phase UPS SUPPLY CAN BE GIVEN TO BRIDGE). 26) All motors to have canopies. 13.7. UPS System A) FCCU, PRU and LPG treater UPS power for instrument load, Fire alarm system, Public address system and for any other requirement shall be obtained from existing UPS system located in Main control room of refinery. New UPS Power distribution board shall be provided, if required. There shall be no UPS power DB in field. B) LPG Storage Facility HOLD C) Cooling Tower HOLD D) Marketing Terminal HOLD E) Unloading facilities at Panipat refinery HOLD 13.8. Battery charger and DCDB A) FCCU, PRU and LPG treater 1) Two nos. separate 220 V DC system with battery bank, charger and DC distribution board shall be provided in new Substation. One DC system shall be utilized for switchgear control supply and Owners future requirement. Another DC system shall be
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ENGINEERING DESIGN BASIS FOR ELECTRICAL utilized for critical lighting. Both chargers shall have configuration of 2 Float cum-boost chargers with common battery bank. 2) Batteries shall be vented Ni-Cd type.
3) Each battery bank, charger & DCDB shall have at least 25% spare capacity to meet future requirements. 4) Each DCDB shall be provided with at least 20% spare feeders. 5) Minimum battery backup shall be as follows: a) 2 hours for switchgear b) 30 minutes for DC critical lighting 6) Isolator shall be provided near battery. 7) All electrical equipment inside battery room shall be flameproof. 8) Charger shall have dual parallel redundant modules of float and boost charging units. 9) Rating of charger shall be suitable for trickle / boost charging of batteries and to feed the DC loads, with 25% spare capacity. 10) One summary fault contact shall be provided for remote alarm. 11) DCDB shall have three incomers and one bus coupler. 12) DCDB incoming and outgoing cables shall be copper cables. 0
13) Battery charger shall be provided with ripple overshoot annunciation. 14) DCDBs shall be provided with semiconductor fuses for fast isolation. 15) Incoming supply to battery chargers shall be through either circuit breakers or switch fuse units, and not through contactors. 16) DC ground fault scheme shall be provided in the DC systems. 17) Boost charging alarm and critical battery charger alarms shall be provided at manned location / control room. 18) Autostart facility for chargers to be provided to avoid manual start of chargers during system under-voltage conditions. For all other requirement, refer standard specification of DC battery and charger.00785000-STD-1672-01. B) LPG Storage facility DC supply, if required, shall be obtained from LPG MCC room -----, DCDB no. ---
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ENGINEERING DESIGN BASIS FOR ELECTRICAL C) Cooling Tower DC supply, if required, shall be obtained from NHGU substation -----, DCDB no. --The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
D) Marketing Terminal DC supply, if required, shall be obtained from existing substation -----, DCDB no. --E) Unloading facilities at Panipat Refinery DC supply, if required, shall be obtained from existing substation -----, DCDB no. --13.9. Corrosion Protection 1) Sacrificial anode cathodic protection system shall be provided for mounded bullets for corrosion protection. 2) Suitable surface treatment (blast cleaned to SA 2 surface finish) with Polyurethane / Poly-Urea coating shall be provided over mounded bullet. 3) Thorough electrical isolation of CP system shall be ensured. 4) This job shall be executed as supply and apply basis with necessary guarantees. The vendor shall submit the completion/ performance certificate for the job done in past 5 years. 5) The vendor shall have the necessary application equipment like plural component airless spray equipment and blast cleaning equipment and all suitable inspection instruments.
13.10. Communication System 1) Stand alone Plant communication system shall be provided for FCCU revamp, PRU and LPG Treater unit. Required number of Field call stations shall be provided in plant unit. One no. call station shall be provided in new substation ---. Master call station and exchange shall be located at Main control room. 2) Integration with existing communication system shall not be provided. 3) Speakers shall produce a sound level at least 10 dB above ambient noise level. 4) Where it is not possible to achieve required dB above surrounding noise level, rotating beacon shall be provided.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 5) It shall be possible to communicate between two field stations without the interference of MCS / operator, and also to have direct communication with MCS. 6) System shall have battery backup of 8 hours in case of power failure.
7) The central exchange shall have redundant CPU. 8) The system shall have features like status monitoring, fault diagnostics and report generation. 9) The system shall have facility for manual / auto recording of conversation, and shall be able to broadcast pre-recorded messages. 10) The system shall have at least 30% spare capacity after meeting all requirements of the process units. 11) Plant communication system shall have Interlock with Fire alarm system. For other requirements, refer Standard specification for Public Address system 00756-000-STD1630-02. 13.11. Telephone System Adequate number of flameproof telephones shall be provided in FCCU Revamp, PRU and LPG treater units. Telephone arrangement shall be as per telephone block diagram no. 00785-000-DW-1665-04. Required no. of Flameproof telephone terminal boxes with crone type connector shall be provided at field for hooking up with existing EPABX located at -------. For other requirements, refer Standard specification for Telephone system 00756-000STD-1630-03. 13.12. Walkie Talkie system 15 nos. of handheld walkie talkie sets and 5 nos. desk mounted sets shall be provided in FCCU Revamp, PRU and LPG treater units. 0
13.13. Fire detection and Alarm system 1) Stand-alone Fire alarm system shall be provided for the following areas:
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Substations ( substation nos -----------------) Existing Control room New control room
: : : INDIAN OIL CORPORATION LIMITED MATHURA REFINERY. FCC UNIT. FCCU AND PRU REVAMP, MATHURA.
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FCCU revamp, PRU, LPG Treater plant units LPG storage control building. Integration with existing system shall not be required. Fibre optic cable shall be used for long distance.
2) FA system loops from above areas shall be hooked to Central Fire Alarm Panel in fire
3) Fire alarm system shall be analogue addressable type. 4) Repeater panel , if required, shall be considered. 0 5) Fire resistant armoured pink colour cables shall be used for the system. 6) Detectors and manual call points shall be connected in separate loops. MCPs shall be mounted at entry, exit and generally at a travel distance of 30 m. 7) Detectors shall be provided inside substation, control room and cable cellar. Linear heat sensing cables shall be used in cable trays in cable cellar. 8) The system shall have 30% spare loop capacity for future expansion. 9) Interlock shall be provided between new substation fire alarm system and pressurization system (Pressurisation blowers to trip sensing fire or gas release in Substation), also between new control room AC system and fire alarm system. 10) Response indicators shall be provided for detectors located in hidden locations such as control room / substation. For other requirements, refer Standard specification for Fire Alarm STD-1630-01. 13.14. ECS system Existing BHEL Max-DNA ECS system shall be utilised for extension panels of 11 kV Switchgear 7A/8A in TPS substation. If existing system is not adequate for accommodating the additional I/ Os, additional card may be installed in the system. Switchgears in new substation 59 shall hook up to existing Honeywell ECS system. Required RTU shall be provided in the substation for this purpose. 13.15. Cables 1) In general, all HV cables shall be with stranded aluminium conductor, dry cured XLPE insulated, insulation screened, FRLS PVC inner sheathed armoured & FRLS PVC outer sheathed. The screen for the HV cables shall withstand earth fault current for one 0 system 00756-000-
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ENGINEERING DESIGN BASIS FOR ELECTRICAL second. All HV cables shall be designed for fault levels as mentioned elsewhere in the document. 2) Fault level with stand time for HV cables shall be as follows:
0.25 sec for outgoing feeder 0.5 sec for Plant feeder 1 sec for Incoming feeder
3) Generally all LV power cables shall be 1.1 kV grade with stranded aluminium / copper conductor, PVC insulated, FRLS PVC inner sheathed, armoured & FRLS PVC outer sheathed. Copper conductor shall be used for sizes up to and including 10 sq. mm, and for higher sizes aluminium conductor shall be used. 4) The control cables shall be 1.1 kV grade with 2.5 sq. mm stranded copper conductor, PVC insulated, FRLS PVC inner sheathed, armoured & FRLS PVC outer sheathed. Control cables shall be twisted pair or shielded wherever electromagnetic / electrostatic interference is anticipated. 5) Lighting cable shall be 1.1 kV grade , minimum 2.5 mm2 stranded copper conductor, PVC insulated, FRLS PVC inner sheathed, armoured & FRLS PVC outer sheathed. For lighting inside the building minimum 1.5mm2 copper conductor, PVC insulated wire shall be used in conduit system (for circuit and point wiring), with proper colour coding. 6) All power and control cables shall be in single continuous lengths (except for long feeder where the length of such feeder is above the manufacturing range of approved cable manufacturers). In no case any joint shall be located in hazardous area. 7) All multicore / muItipair control cables shall have minimum 20% spare cores. 8) The telephone cable shall be single / multipair, PVC insulated, screened, armoured and overall PVC sheathed FRLS type with 0.8 mm dia copper conductor. 20% spare cores shall be provided in each communication cable. 9) For Plant communication and fire alarm system PVC insulated, armoured and overall PVC sheathed FRLS cable with 1.5 mm2 copper conductors shall be used. 20% spare cores shall be provided in each communication cable. 10) HT cables shall be unearthed grade. 11) Size of aluminium conductor shall be limited to 300 sq. mm for each core. 12) For HT cables, size of copper conductor shall be limited to 630 sq. mm.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 13) Tinned copper lugs and double compression type nickel plated brass cable glands shall be used for cable termination. Cable glands shall be flameproof double compression type nickel plated brass at process unit end.
14) Wherever inside unit cable trenches or trays are crossed by existing or new process/utility lines , the process/utility lines is to be separately covered in that portion to avoid future spillage into/onto cable trenches or trays in the event of leakage. 13.16. Local control station 1) Each motor shall be provided with a local control station (LCS) in the field. 2) The LCS enclosure shall have suitable protection for site conditions (such as flameproof, weather proof, dust proof, corrosion resistant, etc.). Canopy shall be provided for all control stations. 3) The LCS shall include the following equipment as per individual process requirement: (a) (b) (c) Start/stop push button or breaker control switch (spring return to normal). Ammeter (for motors rated 30 kW and above). Stop push button shall generally have stay put feature except in the case of critical drives such as lube oil pump etc. 4) One number control switch station with start / stop push button shall be provided at ground level in addition to the push button on operating platform for air fin fan coolers.
13.17. Convenience and welding receptacle 1) The enclosure shall have suitable protection for site conditions specified (explosion proof, weatherproof, dust proof, corrosion resistant etc.). 2) Adequate number of 3 phase welding receptacles shall be provided at suitable locations to ensure accessibility with a 50 meters length of trailing cable to any point in the process area. These shall be rated for 63A suitable for 415V, 3 phase system with a scraping earth connection. 3) Adequate number of three-pin, 1 phase sockets for lamps and portable tools, as required, shall be provided at suitable locations to ensure accessibility with a 15 meters length of cable to all manholes of process equipments. These shall be rated for 16A, 240V single phase with earth connection. 24 V Hand lamps and portable tools shall be earthed through flexible cords.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 4) 240/24V transformers shall be provided in a separate flameproof socket outlet. 5) Required number of industrial type socket outlets (20A) shall be provided in substations. 6) All power receptacles like 240 V, 24 V, 415 V shall be preferably supplied from power
DB/pane. 7) Source cubicle tag no. shall be marked on the cover of all field receptacles for easy isolation.
13.18. Lighting 1) Lighting shall be provided for the following: new substation ---, FCCU revamp, PRU, LPG Treater LPG storage area, additional lighting, if required Modified area of main control room, as required
2) Energy efficient lighting fixture shall be used. Following types of fixtures shall be used for the specified areas. New Control room Fitting suitable for 2 X 36 W ( 5 star) , energy efficient fluorescent mirror optic New Substation compressor room height more than 6 m Process areas 1 X 80 W HPMV or 1 X 125 W HPMV well glass fittings for all areas Transformer bay HPMV / fluorescent lighting fittings etc 2 X 36 W f( 5 star) fluorescent with mounting 1 X 250 W HPMV medium bay or high bay 0
All Fixtures shall be suitable for classified area (safe or hazardous). Emergency lighting HOLD 3) Critical lights shall be provided for entry points & escapes routes as required. Location of critical lights shall be determined in consultation with Process group. Critical lighting shall be fed from 220 V DC supply. 0
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 13.19. Cable laying philosophy 1) Wherever, existing substation is used, cables shall be laid in existing cable tray/trench. However, in case of inadequate space in existing cable trays, new cable trays shall be
provided for FCCU revamp project. This shall be decided as per site requirement and shall be reflected in cable tray /cable routing layout. 2) Inside new substation---, HV cables shall be laid in trench. MV power cables, control cables, signal cables shall be laid in separate GI cable trays inside the cable cellar. RCC trenches shall be used for routing the cables from the substation to the process units. The RCC trenches shall be designed keeping provision of future requirement and without affecting the cable capacity rating. 3) Outside substation, existing cable routing/cable tray/trench shall be utilised to the extent possible for cable laying. For cable routing details, refer Overall cable tray/trench/route layout drg no. 00785-000-DW-1624-01. 4) Cable trays shall be of GI type. Main cable trays shall be of ladder type. Small branch trays (of sizes 150 mm and below) shall be of perforated type. Minimum 30% spare space shall be kept for future use while designing. 5) Power Cables in cable trays shall be laid in single layer. However, control cables may be laid in three layers. Separate trays shall be provided for AC and DC signal / control circuits. 6) Wherever pipe rack is not available, cable tray support shall be sized to ensure lowest tray level to be minimum 2.7 m above grade (Except Road /unit Entrances /crane crossings). 7) Cables inside process units, shall in general be run through sand filled RCC trenches with removable covers / overhead cable trays wherever provision on pipe rack for cable tray supports is available. 8) Cables in offsite and utilities or interconnecting cables in unpaved area shall be directly buried or laid in overhead cable tray. 9) Underground road crossing shall be through cable culvert and above ground road crossing shall be overhead cable bridge, wherever available. 10) GI conduits shall be used between trenches and field equipment like motors, control stations etc. Necessary supports shall be provided for the same. Care shall be taken to give sufficient space in the trench to give required bending radius for the cable and spare loop.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 11) Concrete lined trenches shall have suitable drainage arrangement to avoid water collection, or these trenches shall be connected to nearest storm water drain. These trenches shall be sealed against ingress of liquids and gases.
12) The top of cable trenches before entering the substation shall be maximum 1 m above the ground level. All cut-outs shall be properly sealed by a sealing compound. Pipes laid for mechanical protection shall be sealed at both ends. 13) All entry and exit openings for cables crossing in substation, control room etc shall be provided with fire barrier and it shall have minimum three hours rating. 14) Fire proofing / painting for all power cables on 3 m length of cable at motor end and load end in the field and panel end in the substation shall be provided. Fire barriers shall also be provided below the opening of all HT and LT switchboards in substations. 15) Fire protection for cables shall be provided as per IS12459. 16) Parallel / duplicate feeder cables shall be laid separately as far as possible. 17) All cable trays and accessories shall preferably be prefabricated, hot dip galvanized. For tray system design, in addition to self-load and wind forces, following guidelines for design shall be considered. a) Support span b) Cable load : : 3000mm 75kg/linear meter
In addition to this, 75 kg concentrated load at center span shall be considered. All structural steel design shall be as per Indian Standards. 18) Tinned copper cable lugs and double compression nickel brass type cable gland shall be used for cable termination. In hazardous area, glands shall be flameproof.
14.
EARTHING SYSTEM 1) Earthing system shall in general cover the following Equipment earthing for personal safety System neutral earthing Static and lightning protection be 75 x 10 mm GI. For connection up to individual equipment, refer table below:
2) The minimum size of main earthing loop (MEL) around the substation shall
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ENGINEERING DESIGN BASIS FOR ELECTRICAL Type of equipment Motors upto 3.7 KW Motors 5.5 KW to welding receptacles Bare G.I. strip / G.I. wire rope / G.I. wire 8 SWG solid wire 10 mm (3/8) wire rope 16 mm (5/8) wire rope 40 X 5 strip 10 mm (3/8) wire rope 8 SWG solid wire 10 mm (3/8) wire rope GI strip, As calculated GI strip,As calculated 8 SWG solid wire 10 mm (3/8) wire rope 16 mm (5/8) wire rope
30
KW
&
Motors above 37 kW including HT motors Building columns Pipe racks, vessels & heat exchangers Small equipments & instruments Lighting, power & instruments panels Main earth bus/LT & HT SW gear interconnections/ transformer
Sub-stations Push button station Street light poles Lighting transformers
3) All earth electrodes shall be GI pipe electrodes, provided with earth pits. Earth pits shall be constructed up to 300 mm above ground level and shall be covered by removable slabs. 4) MEL for FCC revamp, PRU and LPG treater unit shall be connected to existing refinery earth grid at minimum two points: New Substation---shall have separate earthing grid. All other areas, existing earth grid shall be used. Wherever, extension panels are provided panel earthing conductor shall be connected to existing earth grid. 5) DCS, PLC, and other electronic instruments, including electronic relays, shall be provided with clean earth. This shall be kept galvanically isolated from the system and safety earthing. 6) Self-conducting structures may not be provided with aerial rod and down conductors, they shall however be connected to the earthing system at minimum two points at the base. An independent earthing network shall be provided for lightning protection and this shall be bonded with the main earthing network only at the buried electrode. 7) Value of earth resistance for system earthing shall not exceed 1 Ohm. 8) For lightning protection, the value of 5 ohms as earth resistance shall be desirable but in no case it shall be more than 10 ohms.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 9) All utility / process pipelines shall be bonded to a common conductor by means of earth bars or pipe clamps. Steel pipe racks shall be earthed at every 25 m. Earth continuity shall be ensured across all flanges.
10) Underground earthing strips to be provided with 50% corrosion allowance. 11) Above ground local earth grid of minimum 50 X 6 mm size shall be provided for all indoor areas. This shall be connected to the main earth grid at minimum two points. 12) Dedicated single earthing strip shall be laid along cable trays, welded to the main cable tray support, and shall be connected to the earthing grid at every 20 m interval. 13) Metallic sheaths, screens and armour of all multicore cables shall be earthed at both equipment and switchgear ends. 14) At least two nos. of earth strips of adequate size shall be tapped from the main earth grid and taken to the top of all tall structures, platforms, and a ring shall be made at the highest point. 15) Cadmium coated nuts and bolts shall be used at tapping points where welding is not envisaged. 16) In plant area all stair cases, railings, monkey ladders shall be earthed at least at two points. 17) Lightning Protection shall be provided for all buildings including Compressor house as per IS - 2309. The horizontal air terminations and down conductors shall be of 20 x 3 mm2 GI Strip. 18) Proper wrapping and coating shall be given to the underground welded earthing joints to avoid any corrosion. 19) Earth electrodes shall be galvanized after fabrication. No welding and drilled holes are to be left without galvanization. 20) All earth pits shall be marked with earth pit number for easy identification. In addition, metallic tag is also to be fastened with the earth electrode inside the pit as a permanent identification. 21) Separate earthing shall be provided for transformer neutral.
15.
LIGHTING SYSTEM Emergency Lighting HOLD 1) Areas requiring DC critical lighting shall be as following:
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ENGINEERING DESIGN BASIS FOR ELECTRICAL The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.
New control room New sub station Process units under EPCM contractors scope battery bank shall feed the critical lighting system.
2) Critical (DC) lighting shall be normally OFF and during failure of normal power supply; 3) HPMV lamps shall generally be used for plant lighting. Keeping in view the restrike time lag and to avoid complete darkness in case of a voltage dip/black out condition necessary incandescent lamps may be judiciously distributed throughout the plant area. Fluorescent lamps with electronic ballast shall be used for indoor lighting for substation and control room. Safe area street and area lighting may employ sodium vapour lamps. All chemical-handling facilities shall be provided with chemical resistant fixtures. 4) Nonintegral type lighting fixtures shall be used. Mounting height of control gear box shall not be more than 2 m in height from operating level. 5) DC critical lighting shall employ incandescent lamps. All ballasts shall be with copper winding and capacitor for power factor improvement (to 0.95) shall be provided with fixtures as applicable. 6) Tall structures shall have aviation obstruction lighting as per statutory requirements. 7) Lighting system for FCCU revamp, PRU , LPG treater units, new substation and new control room, shall consist of lighting transformers for reduction of fault level, lighting distribution boards (LDBs), lighting and power panels, fixtures, junction boxes etc. 8) Lighting and power panels shall be fed from LDB through 433/433 V, Dynll, dry type lighting transformer having taps up to + 7.5%. These panels shall be provided with MCB + ELCB as incomer and MCBs for outgoing feeders. MCBs shall not be loaded beyond 80% of rated capacity. Minimum of 25% of feeders in each lighting panel shall be left as spares. Normally about 8-10 fixtures or maximum 1000 W shall be wired in each circuit. 9) For other areas (excluding areas mentioned vide cl.15.6), local lighting panels may be fed from existing system. Also, for small lighting loads, lighting transformer need not be provided. 10) All outdoor lighting shall be automatically controlled by means of photoelectric cell / synchronous timers with manual overriding control.
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ENGINEERING DESIGN BASIS FOR ELECTRICAL 11) Telescopic tubular high masts shall be provided for illumination of offsite&utility / general area. The masts shall be provided with motorized racking mechanism for lowering and hoisting lantern carriage.
12) Lighting and power panels shall be fed from LDB through 433/433 V, Dynll, dry type lighting transformer having taps upto + 7.5%. In case of oil mine installations, These panels shall be secondary side voltage shall be 240 V between phases.
provided with MCB + ELCB as incomer and Miniature Circuits Breakers (MCBs) for outgoing feeders control and protection of lighting cirucitrs. MCBs shall not be loaded beyond 80% of rated capacity. A minimum of 25% of miniature circuit breakers of each board shall be left as spares. Normally about 8-10 fixtures shall be wired in each circuit. In areas having less lighting load, lighting transformer can be avoided. 13) Lighting Lux Levels Lighting system design shall be based on average illumination levels as specified below: Area - Roads - Pump house, Sheds - Main operation platforms and access stairs - Ordinary platforms - Process area, pipe racks, heat exchanger heater, cooling tower, separators etc. - Switchgear room - Cable cellar - Battery room - Control Room - Compressor Area 200 70 150 500 150 Lux 10 100 60 20 60
14) Lighting design shall conform to relevant International Codes and Standards, IES Hand Book and shall take into consideration the requirements from point of view of safety and ease in operation and maintenance. A maintenance factor of 0.8 shall be assumed for lighting illumination level calculations for normal areas. maintenance factor shall be 0.7. 15) Wiring for lighting and convenience outlets in outdoor areas shall be carried out with PVC armoured cables run along the column / platforms and structures. The armoured
However for dusty areas,
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ENGINEERING DESIGN BASIS FOR ELECTRICAL cable shall enter lighting fixture / JB through double compression gland for safe area, Ex(e) or Ex(n) equipment and through flameproof glands for Ex(d) equipment. 16) Two pole isolation devices shall be used for controlling fixtures in hazardous areas to
isolate phase as well as neutral. 17) Substation ---cable cellar lighting shall be by armoured cables. Substation lighting shall be done by surface conduit wiring. 18) For new control room with false ceiling, concealed conduit wiring shall be used below the false ceiling and surface conduit wiring above the false ceiling. 19) Battery room shall have fixtures mounted on wall in order to facilitate easy replacement of fused lamps. Switches controlling the lighting fixtures and exhaust fan shall be installed outside the battery room. 20) Locally mounted lighting fixtures on platforms, walkways, stairs shall be installed in such a way that re-lamping can be done without the use of ladders.
16.
COMMISSIONING OF EQUIPMENT OEM shall provide commission assistance at site as per requirement for following Equipment. 1 BATTERY BANK AND BATTERY CHARGER 2. HT SWITCHGEAR 3. HT SWITCHGEAR, PCC&MCC FOR RELAY COMMUNICATION & CONFIGURATION 4. HIGH MAST 5. VFD 6. EOT 7. HT MOTORS(SYNCHRONOUS)& ITS EXCITATION PANEL 8. FIRE ALARM SYSTEM 9. ECS 10. PLANT PAGING SYSTEM 11 WALKIE TALKIE
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DATA SHEET FOR MV SWITCHGEAR
UNIT PROJECT LOCATION
OWNER
EPCM
NOIDA, INDIA.
DATA SHEET FOR MV SWITCHGEAR
02 01 00
REV.
18.08.2011 01.08.2011 11.11.2010

DATE
ISSUED FOR DESIGN REISSUED FOR REVIEW ISSUED FOR REVIEW

STATUS
ABS VV ABS
PREPARED BY
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REVIEWED BY
DYS DYS DYS

APPROVED BY
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DATA SHEET FOR MV SWITCHGEAR TECHNIP KT India CLIENT : PROJECT : LOCATION : 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 INDIAN OIL CORPORATION LIMITED, MATHURA FCCU AND PRU REVAMP, MATHURA IOCL, MATHURA REFINERY PROJECT No. 0 7 8 5 UNIT 0 0 D S DOC. CODE 1 6 5 4 SERIAL REV No. 0 1 2
GENERAL MV Switch Board Tag no. Quantity Ref. Std. SITE CONDITIONS Temp. Max./ Min./ Design C Relative Humidity Altitude Above MSL Environment OPERATING CONDITIONS Rated voltage with variation Rated Frequency Number of Phases System fault level System breaking capacity System making capacity System Earthing Control circuit power supply Aux. Power supply for spring charge motor Aux. Power supply for Panel space heater DATA BY PURCHASER (Shall be separately furnished for each board) Switch Board Type of Switch Board Degree of protection Adaptor panel between switch board Dummy panel to maintain 6000mm centre line distance between the two incomers for busduct entry Incoming power connection Incoming cable entry Outgoing cable entry Busduct entry Interior final colour shade Exterior final colour shade Floor fixing
IS:2147, 3231, 3427, 8623
47 C / 2 C / 50 C 95% less than 1000M Highly corrosive & Humid
415V AC 10% 50 Hz 5% Three phase + Neutral 50 KA for 1 sec. 50 KA ______KA (peak) Solidly earthed 240V AC SPN for _______ / 220VDC for _______ 240V AC SPN for _______ / 220VDC for _______ 240V AC SPN
Metal Enclosed IP-54 Yes / No Yes / No Cable for ______switch boards / Busduct for ______switch boards Top / bottom Top / bottom Top Glossy white 631 as per IS:5 Integral base frame suitable for tack welding or bolting Single front for breaker feeders & other feeders except for LPG PMCC,which may be double front. Fixed / drawout type Yes Yes / No Required / Not required
34 Feeder arrangement 35 36 37 38 39 40 41 42 43 Feeder type Space heater with thermostat & switch fuse in each panel Safety shutters for test & drawout positions Heat run test Bus bars Main & Vertical busbar material Main & vertical busbar Insulation Main busbar location Earth busbar material
Aluminium Heat shrunk PVC sleeved Top / Bottom Copper / Aluminium
3 OF 5
DATA SHEET FOR MV SWITCHGEAR TECHNIP KT India CLIENT : PROJECT : LOCATION : INDIAN OIL CORPORATION LIMITED, MATHURA FCCU AND PRU REVAMP, MATHURA IOCL, MATHURA REFINERY PROJECT No. 0 7 8 5 UNIT 0 0 D S DOC. CODE 1 6 5 4 SERIAL REV No. 0 1 2
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
DATA BY PURCHASER (Contd.) Switches Rating & spare aux. contacts in switches Switches duty Circuit breaker Type of circuit breaker Duty cycle of breaker Rating & spare aux. contacts in ACB control feeder Anti pumping feature in ACB Breaker trip free Provision for manual spring charging of breaker Trip PB for mechanical trip Mechanical on / off indicator operation counter Suitable for capacitor switching Contactors Rating & spare aux. contacts in contactor controlled feeder Contactor duty Suitable for capacitor switching
10A / 1 NO + 1 NC AC23
Air Circuit Breaker O-0.3min-CO-3min-CO 10A / 8 NO + 8 NC Yes Yes Yes Required / not required Required / not required Yes / No Yes / No
10A / 2 NO + 2 NC AC3 Yes / No Included Included Double / Single compression nickel plated brass cable glands
63 Cables and cable glands 64 Cable glands & Lugs for incoming & outgoing cables 65 Type of cable glands 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 Protection, Metering & relays Protections & metering required Protection relay type (except thermal overload relay) Rating & spare aux. contacts in over load relay Single phase prevention feature in thermal O/L relay Protection CT accuracy class / burden Metering CT accuracy class / burden PT accuracy class / burden Type of secondary winding of potential transformer Measuring instrument type Minimum size of meters Accuracy class of measuring instruments Control wiring Material & size Connectivity with remote system (SCADA / ECS) Type of connections with SCADA / ECS / DCS Communication protocol Relay connection type
As per single line diagram of respective switch board Microprocessor based communicable type / Electro-mechanical 10A / 1 NO + 1 NC Yes 5P20 / 10VA CL 1.0 / 10VA CL 1.0 / 10VA 1 Star + 1 Open Delta Digital type / Analogue type 64x64 / 72x72 / 96x96 mm 1 / 1.5 Copper, 1.5 / 2.5 sq mm Yes / No 1 Main + 1 Redundant RS485 serial link output Modbus RTU Daisy Chain / Star topology
4 OF 5
83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124
DATA BY SWBD MANUFACTURER (Vendor to furnish data for each rating of ACB's, Contactors, Switches) Circuit breakers 800A 1250A 1600A Circuit breaker rating (Amps) Circuit breaker make Circuit breaker Type No. poles / phase Nominal current rating (In free air) Current rating at site cond. (Inside panel) Breaking capacity % DC component Peak making current Short circuit withstand capacity for 1 sec. Breaker closing mechanism Breaker tripping mechanism Total opening time in sec. Total closing time in sec. Power required for opening in VA Power required for closing in VA ____VA Power required for spring charging motor ____VA ____VA Time taken for spring charging in sec. Derating reqd. for capacitor switching in % Contactors Contactor rating in Amps Contactor make Contactor type Thermal rating Making capacity Breaking capacity Electrical life in no. of operations at rated voltage Mechanical life in no. of operations Coil consumption in VA - Pick up Coil consumption in VA - Hold on Closing time in sec. opening time in sec. Derating reqd. for capacitor switching in %
2500A
3200A
4000A
____VA
____VA
____VA
Switches Switch rating in Amps Switch make Switch type Rated making capacity Rated breaking capacity Rated S.C. withstand current with max. permissible rated fuses 125 Mechanical life in no. of operations
32A
63A
125A
250A
400A
630A
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126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147
DATA BY SWBD MANUFACTURER (Contd.) Bus bars Main busbar current rating inside panel Main busbar size Main busbar clearance in air Phase to phase in mm Phase to neutral in mm Phase to earth in mm Vertical busbar rating Vertical busbar size Earth bus size Switch Board details Switch board manufacturer Manufacturer's type / designation Overall dimensions of switch board (LxDxH) Total weight of switch board Heat loss of switch board Recommended clearances for switch board Front in mm Rear in mm Above in mm Shock loading on foundation
PCC
EPMCC
MCC
ASB
MLDB
ELDB
mm
mm
mm
mm
mm
mm
_____Kg
_____Kg
_____Kg
_____Kg
_____Kg
_____Kg
2 1 0 Rev.
18.08.2011 1.08.2011 11.11.2010 Date
ISSUED FOR DESIGN REISSUED FOR REVIEW ISSUED FOR REVIEW Status
ABS VV ABS Prepared By
VV DYS DYS Checked By
DYS DYS DYS Approved By
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STANDARD SPECIFICATION FOR MV CABLE AND ACCESSORIES
UNIT PROJECT
LOCATION
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NOIDA, INDIA.
0
REV.
18.10.2010
DATE
ISSUED FOR DESIGN

STATUS
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PREPARED BY
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CONTENTS
Sr.No 1.0 2.0 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.0 5.0 6.0 7.0 8.0 9.0 Scope .............................................................. Codes and standard ......................................... General construction and material of construction.. PVC insulated FRLS cables ............................. .. Conductor .......................................................... . Insulation ................................. ......................... Filler and inner sheath .................. .................... Armouring ........................................... .............. Outer sheath ............................................ ......... Dimension / thickness of materials ................. ............ Core identification ........................................... ............ Identification of cables ...................................... .. Information required with the bid ......................... Cables drums ................................................... .. Cable quantity ................................................. .......... Inspection and tests ............................................
Page 3 3 4 4 4 4 4 5 5 5 5 6 6 6 7 7
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1.0
SCOPE
This specification covers the basic requirements for design, manufacture, inspection and testing at vendors works, of PVC insulated cables up to 1.1KV for power, control, lighting, purpose to be used in FCCU and PRU Revamp project of M/s Indian Oil Corporation Ltd. (IOCL), Mathura Refinery, Mathura. 2.0 CODES AND STANDARDS The design, manufacture and performance of PVC insulated cables shall conform to the applicable Indian, IEC Standards. The relevant standards are: IS: 613 (1984) Copper rods and bars for electrical purposes. IS:1885 (Part 32)1993 Electro Technical Vocabulary-Electric Cables. IS:2633 (1986) Method of testing uniformity of coating on Zinc coated articles. IS:3961 (Part 4) Recommended current ratings for Polyethylene 1968 insulated cables. IS:3975 (1988) Mild steel wire, formed wires and tapes for armouring of cables. IS:5831 (1984) Specification for PVC insulation and sheath of electric cables. IS:6474 (1984) Specification for Polyethylene insulation and sheath of electric cables.
IS:10418 (1982) IS:10462(Part1)1983 IS:10810(Pt 58) IS:10810(Pt 61) IS:10810(Pt 62) IEC:60540 & 60540A IEC:230 (1966) IEC:60332 (3 parts) IEC:811 (5 parts) Drums for Electric cables. Fictitious calculation method for determination of dimensions of protective coverings of cables. Methods of test for cables: Part 58 Oxygen Index test Methods of test for cables: Part 61 Flame retardant test Methods of test for cables: Part 62 Flame retardant test for bunched cables Test methods for insulation & sheaths of electric cables. Impulse tests on cables and their accessories. Test on electric cables under fire conditions. Test methods for insulating and sheathing materials of electric cables.
2.1 The cables & accessories shall also confirm to the provisions of the Indian Electricity Rules and other statutory regulations in force in the country. 2.2 In case of any contradiction between various referred standards/
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specifications/ data sheets and statutory regulations, the following order of priority shall be given:
3.0
Statutory regulations Data sheets Unit Specifications This Specification Codes & Standards
General construction and material of construction The cables shall be suitable for laying trays, trenches, ducts and conduits and for underground buried installation with possibility of flooding by water & chemicals. Sequential marking of the length of the cable in the meters shall be provided at every one meter. The embossing or engraving shall be legible or indelible. The overall diameter of the cables shall be as per manufacturers data sheet subject to a maximum tolerance of +/- 2mm up to overall diameter up to 60mm and +/3mm for above 60mm.
3.1
PVC insulated FRLS cables All power and control cables shall be heavy-duty type, 650/1100V grade, with Copper/Aluminium Conductor, PVC insulated, inner sheathed, armoured and overall FRLS PVC sheathed. All cables covered in this specification shall be FRLS unless otherwise specified in the data sheet. The outer sheath of PVC cables shall possess flame propagation properties meeting requirements as per IS-10810 (Part-62) category AF.
3.2
Conductor The conductor shall be of plain aluminium or high conductivity annealed copper wires complying with relevant Indian standards. The conductors of size above 6mm2 shall be stranded.
3.3
Insulation The insulation shall be of polyvinyl chloride (PVC) compound applied over the conductor by extrusion and shall conform to the requirements of Type A insulation as per IS: 5831.
3.4 Filler and inner sheath (1) The filler and inner sheath shall be of the following: (a) Unvulcanized rubber, or
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(b) Thermoplastic materials Unvulcanized rubber or thermoplastic material used shall not be harder than PVC used for insulation and outer sheath. The inner sheath shall be applied by extrusion method such that it fits closely on the laid-up cores and shall be possible to remove without damaging the insulation. Single core cables shall have no inner sheath.
3.5 Armouring (1) Armouring shall be one of the following: (a) Galvanized round steel wire (b) Galvanized steel strip Where the cable diameter below armour does not exceed 13mm, the armour shall consist of galvanized round steel wires. Where the diameter below armouring is greater than 13mm, the armour shall consist of either galvanized round steel wires or galvanized steel strips. The joints in armour wires or strips shall be made by brazing or welding and any surface irregularities shall be removed.
(2)
(3)
3.6 Outer sheath (1) (2) The outer sheath shall be poly-vinyl chloride (PVC) compound conforming to the requirements of Type ST1/ST2 compound as per IS: 5831 and shall be of FRLS type only. Outer sheath of all PVC cables shall be black in colour and the minimum value of oxygen index shall be 29 at 27 2 deg. C. In addition suitable chemicals shall be added to the PVC compound of the outer sheath to protect the cable against rodent and termite attack. The outer sheath shall be applied by extrusion over the armouring.
(3)
3.7 Dimension / thickness of materials The thickness of insulation, inner sheath, outer sheath and dimension of wire/strips used for armouring shall be as per relevant standards. 4.0 Core identification Cores of cable shall be identified by colour coding of PVC insulation as per IS:1554 (Part 1)
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5.0
Identification of Cables The cables shall be clearly and permanently marked with following information throughout the length. (1) Voltage grade. (2) Manufacturers name or trade mark. (3) Year of manufacture. (4) Cross sectional area of conductor and no of cores.
6.0
Information required with the bid Vendor shall furnish technical particulars / description and performance details of all cables, current carrying capacities and de-rating factors, for all conditions of cable laying.
7.0
Cable Drums (1) Cables shall be supplied in non-returnable wooden drums of heavy construction. The wood used for construction of the drum shall be properly seasoned, free from defects and wooden preservatives shall be applied to the entire drum. All ferrous parts shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit or storage. The vendor shall indicate in the offer, the maximum length of cable, which can be accommodated on one drum. The actual length supplied on each drum shall be within tolerance limit of +5%. The drum length shall be as per cable drum schedule. The cables shall be wound on drums of suitable barrel diameter, securely battened, with the take-off and fully protected against mechanical damage. The cut ends of cable shall be sealed by means of non-hygroscopic sealing material to avoid ingress of water during transit or storage. Also, PVC /Rubber end caps shall be supplied free of cost for each drum with a minimum of eight per thousand metre length. The following information shall be stencilled on each drum. (a) Name of manufacturer, brand name or trademark. (b) Nominal cross sectional area of conductor (c) Number of cores. (d) Type of cable and voltage grade. (e) Cable code (f) Length of cable on the drum.
(2)
(3)
(4)
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(g) (h) (i) (j) (k) (l) (m) (n)
Number of lengths on drum (if more than one). Drum number. Direction of rotation of drum (by means of an arrow). Reference standard Approx. gross weight. Job number. Country of manufacture Year of manufacture. A tolerance of +/- 3% shall be permissible for each drum. However, overall tolerance for each size of cable shall be limited to +/ - 2%. Offer with short / non-standard lengths are liable for rejection. If non- standard drum lengths are specified in the data sheet, then same shall be supplied.
8.0
Cable quantity The bidder shall quote unit rates for all types of cables as indicated in the requisition. The unit rate quoted by bidder shall be valid in the event of addition / deletion of cable quantity.
9.0
Inspection and tests (1) Inspection and testing shall be carried out in accordance with relevant standards. Routine tests shall be witnessed by a representative of Owner / EPCM Contractor. Test certificates for type test shall be furnished with quotation. Vendor shall quote unit rate for witnessing such type test. Vendor shall submit blank formats where in the test results/readings are to be entered. This format shall give minimum acceptable value as per relevant standards. The inspector shall have free access to the manufacturers works for stage inspection and he will have the power to reject any material which appears to him to be of unsuitable description or of unsatisfactory quality. The vendor shall give at least 2 weeks prior notice to the purchaser, regarding the date of inspection to enable him or his representative to witness the tests. All routine tests, acceptance tests, type tests & additional type tests for improved fire performance shall be carried out as listed in IS-7098 (Part2). The test requirement for PVC insulation & sheath of cables shall be as per latest revision of IS: 5831. The test for resistance to Ultraviolet radiation: This test shall be carried out as per DIN 53387 or ASTM-G-53 on outer sheath. The retention value of tensile strength & ultimate elongation value after the test shall be minimum 60% of the tensile strength and elongation value before the test. The test certificates with respect to this test (not older than 1 year)
(2) (3)
(4) (5) (6)
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from recognized testing laboratory to be furnished for review by PMC before dispatch clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order, provided the outer sheath remains the same. (7) Acceptance tests as per IS-1554 Part-1 and IS-7098 Part-2 and the following special tests to be performed on the cables as per the sampling plan. This tests are to be witnessed by PMC/ Owner before the dispatch of cables: a) Accelerated Water absorption test for insulation as per NEMA WC-5 (For PVC insulated cables) and as per NEMA WC-7 (For XLPE insulated cables). Test certificates with respect to this test (not older than one year) from recognized testing laboratory to be furnished for review by PMC before dispatch, clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order Dielectric Retention test: The dielectric strength of the cable insulation tested in accordance with NEMA WC-5 at 75 1o C shall not be less than 50% original dielectric strength. Test certificates with respect to this test (not older than one year) from recognized testing laboratory to be furnished for review by PMC before dispatch, clearance of cables. In case test certificates are not available, test is to be conducted by vendor at his own cost in any recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables. Sampling for this test is to carried out one for each order Oxygen Index Test: The test shall be carried out as per ASTM D2863 or applicable Indian Standard specifications. Sampling to be done for every offered lot / size as per sampling plan Flammability Test: The test shall be carried out on finished cable as per IS-10810 (part 61 & 62). Sampling for this test is to carried out one for each order, provided the outer sheath remains the same. The acceptance criteria for tests conducted shall be as under: Part-61: The cable meets the specifications if there is no visible damage on the test specimen within 300 mm from its upper end. Part-62: The maximum extent of charred portion measured on the test sample should not have reached a height exceeding 2.5m above the bottom edge of the burner at the front of the ladder. Test for rodent & termite repulsion property: The vendor shall furnish details to analyze the property by chemical method. Sampling to be done for every offered lot/ size as per the sampling plan.
(8)
(9)
(10)
(11)
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SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM
UNIT PROJECT
LOCATION
OWNER
EPCM
NOIDA, INDIA.
SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM
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SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM CONTENTS

1.
SCOPE ................................................................................................................................................. 2 CODES AND STANDARDS ................................................................................................................ 3 ANODE LEAD CABLE ........................................................................................................................ 3 +VE AND VE HEADER CABLE ........................................................................................................ 3 DRAINAGE CABLE ............................................................................................................................. 3 POWER SUPPLY CABLE ( BETWEEN PCC & T/R UNIT) ................................................................ 3 EARTHING CABLE ............................................................................................................................. 4 MEASUREMENT CABLE AND PERMANENT REFERENCE CELL ................................................. 4 CABLE DRUMS ................................................................................................................................... 4 INSPECTION........................................................................................................................................ 4 CABLE IDENTIFICATION ................................................................................................................... 4
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
1.
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SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM Cables mentioned here shall be a standard product of a manufacture regularly engaged in production of power cables. This specification covers requirements for type, rating, manufacture and testing of the cables for cathodic protection system.
2.
CODES AND STANDARDS In general the cable covered by this specification shall unless otherwise specified be in the line with the requirements of any of the latest applicable standard of: a) IS: 7098 (Part I)-1988 b) IS.3961 (Part IV)-1968 c) IS: 3961 (Part-Ill)-1967 Where ever the requirements in this specification are in conflict with any of the above standard, the requirements under this specification shall be binding.
3.
ANODE LEAD CABLE Anode lead cables shall be 10mm2 stranded copper conductor, single core, unarmoured, with a double insulation system. The primary insulation shall be 1100 volt grade cross linked Polythylene (XLPE). The secondary insulation shall be PVC sheathing jacket over the primary insulation. Approx. over all dia. of cable shall be 9.6mm
4.
+VE and VE HEADER CABLE +ve header and -ve header cable shall be 95mm2, stranded Aluminium conductor, single core, Aluminium wire armoured, PVC insulated and PVC sheathed 1100V grade cable.
5.
DRAINAGE CABLE Drainage cables shall be 50mm2, stranded Copper conductor, single core, Aluminium wire armoured, PVC insulated and sheathed 1100V grade cable.
6.
POWER SUPPLY CABLE ( Between PCC & T/R Unit) Power supply cable between Power source and T/R unit shall be stranded Aluminium conductor, 3-core, Aluminium wire armoured, PVC insulated and sheathed 1100 grade cable.
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SPECIFICATION FOR CABLE FOR CATHODIC PROTECTION SYSTEM 7. EARTHING CABLE Earthing cable shall be 35 mm2 stranded Copper conductor, 1-core, unarmoured, PVC insulated 1100V grade cable.
8.
MEASUREMENT CABLE AND PERMANENT REFERENCE CELL CABLE BETWEEN CJB CUM TEST STATION AND MJB The measurement cable & reference cell cable shall be 6mm2, stranded copper conductor, single core, armoured, PVC insulated and sheathed, 1100V grade.
9.
CABLE DRUMS All cables to be supplied in wooden drums. Cable lengths in each cable drum shall be 600m (min), where ever cable lengths are more than 600m.
10.
INSPECTION All cables along with manufacturer's test certificate as per IS standards shall be inspected by OWNER at the vendor's shop before dispatch. Minimum 15 days notice to be furnished by vendor for this purpose.
11.
CABLE IDENTIFICATION For easy identification of cable, the over sheath of the cable should have yellow colour and "C.P.SYSTEM CABLES" should be printed using black colour at one meter interval throughout the length of the cable.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION
UNIT PROJECT
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NOIDA, INDIA.
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CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
INTRODUCTION .................................................................................................................................. 3 DEFINITION ......................................................................................................................................... 3 CODES AND STANDARDS ................................................................................................................ 4 DOCUMENT REVIEW.......................................................................................................................... 5 DESIGN BASIS .................................................................................................................................... 5 SITE SURVEY ...................................................................................................................................... 8 EQUIPMET AND MATERIALS .......................................................................................................... 10 SYSTEMS ENGINEERING AND INSTALLATION............................................................................ 15 SPECIAL FACILITIES ....................................................................................................................... 32 MATERIAL SCHEDULES.................................................................................................................. 34 HANDLING......................................................................................................................................... 36
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 1. INTRODUCTION This specification covers the minimum requirements for cathodic protection of the
following steel items: Buried steel piping Buried tanks Bottom surfaces of on-grade storage tanks in contact with soil. Interior surfaces of water boxes and tanks which are in contact with water.
Cathodic protection system is utilized for corrosion control of ferrous metals in contact with soil, buried concrete and water.
2.
DEFINITION Deep Well/ Deep Ground Bed - One or more anodes installed vertically at a depth of 15 meters or more below the earths surface in a drilled hole. (Bidder shall ensure there is no interference with RCC piles.) Electrolyte - Moist soil and water in contact with the structure. Parallel Bed - When used in the matters related to pipe, wire or cable type anode placed parallel to the pipe run. When used in the matters related to tank bottoms, wire or cable type anode in a coil or grid form in a plane parallel to the tank bottom at a specified depth under the tank bottom. Shallow Bed - One or more anodes installed vertically at a depth of 5 to 15 meters below the earths surface. Structure - The surface to which cathodic protection is being applied. A foreign structure means a surface to which cathodic protection is being provided unintentionally. Structure-To-Electrolyte Potential - The voltage difference between a buried (or immersed) metallic surface and the electrolyte which is measured with reference to an electrode (such as copper/copper sulfate and silver/silver chloride electrodes) in contact with the electrolyte. Surface Bed - One or more anodes installed horizontally or vertically at a depth of 5 meters or less, below grade.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 3. CODES AND STANDARDS Unless otherwise specified, cathodic protection system shall conform to the following standards as a minimum.
IS 8062 - Part - I (1976): Code of Practice for C.P of Steel Structures IS 5571(1971): Guide for selection of electrical equipment for hazardous areas Indian Electricity act Petroleum Act, 1976 British Standard Institute B7361 Steel Structures VDE: 0150, Protection against corrosion due to stray current DC installation IS 3043: -Code for Practice for Earthing IS1554: - Part I & II PVC Insulated Cable IS 7098: - Part I for Cross-linked polyethylene insulated PVC sheathed cable IS 2148 (1981): - Flame Proof enclosures for Electrical apparatus IS 2147:1962: - Degree of protection provided by enclosures for low voltage switchgear & control gear National Association of Corrosion Engineers (NACE) NACE RP0169 NACE RP0177 NACE RP0193 NACE RP0286 NACE RP0572 Control of External Corrosion on Underground or Submerged Metallic Piping Systems. Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems External Cathodic Protection of On-Grade Metallic Storage Tank Bottoms The Electrical Isolation of Cathodically Protected Pipelines. Design, Installation, Operation, and Maintenance of Impressed Current Deep Ground Beds. National Electrical Code NEC NFPA-70 (ANSI-C1) National Electrical Code Part-I 1991 Code of Practice for C.P of
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 4. DOCUMENT REVIEW Comments made by Contractor /Owner on drawing submittal shall not relieve bidder of any responsibility in meeting the requirements of the specifications. Such comments
shall not be construed as permission to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing. 5. 5.1. DESIGN BASIS General Basis The design of cathodic protection systems shall be based on the following and other factors which are identified in the bidders pre-design survey: System designs and installations shall comply with applicable sections of the industry standards referenced in Section 3.0 of this Specification, such as NACE RP0169, RP0177, RP0193, RP0286 and RP0572. Equipment, materials, design, installation, testing and commissioning practices shall conform to the codes and standards listed in this document, other requirements stated in this document and all relevant project drawings. All design, installation, equipment and materials shall be suitable for continuous operation under site conditions during the stated design life of the cathodic protection system and shall be compatible with the environmental conditions of the project. The design life of the cathodic protection system shall correspond to the following. Piping: On-grade tank bottoms: Buried tanks: Tank internals: Reference electrodes: 20 years 30 years 30 years 20 years 20 years
For soil applications, the primary type of cathodic protection system shall be impressed current using mixed metal oxide (MMO) anodes consisting of oxides of iridium, tantalum and titanium on titanium base. The MMO anodes shall be canister, wire, mesh, rod, tubular, ribbon type or a combination thereof. Sacrificial anode systems shall be considered secondary or supplementary to the primary impressed current systems.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 5.2. Schedule of cathodic protection systems The cathodic protection systems shall comply with Table 1. The anode shape, construction, type and method of connection shall be approved by the purchaser/EPC
contractor. TABLE 1 SCHEDULE OF CATHODIC PROTECTION SYSTEMS MMO - mixed metal oxide (iridium/tantalum/titanium oxide) on titanium base ITEM TO BE ANODE MATERIAL ANODE TYPE BED BACKFILL PROTECTED
SURFACES IN CONTACT WITH SOIL Buried tanks MMO wire Surface Vertical Surface horizontal Surface vertical Parallel to pipe Carbon steel piping at Zinc ribbon isolated Pipe road crossings at (with road Magnesium plant cast, or prepackage d storage MMO wire HDPE SURFACES IN CONTACT WITH WATER Water tank internals Water box internals Platinized niobium None None Horizontal (Parallel bed) loops None Surface horizontal Surface vertical Bentonite within plant boundaries casings crossings boundaries without casing) New on-grade with tank bottoms (coated and uncoated) membranes within On the pipe None Coke breeze Carbon steel piping within MMO wire plant boundaries Coke breeze
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 5.3. Current requirements Total current requirements shall be calculated using the following formula: I
= DS*i + S*i*CF = Total requirement current requirement, mA = Surface area considered to have defective coating (i.e. bare surfaces) = Current density adjustment factor for coated area = Current density, mA/m2 = Total surface area of the Structure in contact with the electrolyte, m2 DS CF i S
Where, I
Current Density (i) The following minimum current densities (based on bare surfaces) shall be used as basis for current requirement calculations and shall be increased by 25% per 10C rise in temperature of the electrolyte above 30C. Surfaces in contact with soil Surfaces in fresh water Surfaces in saline water 22 mA/ m2 30 mA/ m2 65 mA/m2 Surfaces in contact with concrete 20 mA/ m2
Defective Surface Area (DS, % of the Surface Considered To Be Defective) Buried pipe and tank surfaces: 1% of the total exterior surface. On-grade storage tank bottoms: 5% of the bottom surface plus 100% of the weld zone area (= total weld joint length, meters x 0.15 meters of zone width). Tank internals (water tanks): 1% of the total floor and shell area Tank internals: hydrocarbon services (in cases where water accumulates on the floor): 1% of the floor area plus 1% of the first course of the shell area. Water box interiors: 1% of the total boxed area. Current Density Adjustment Factor For Coated Areas (CF) Surfaces coated with fusion bonded epoxy, liquid epoxy and coal tar epoxy, coal tar urethanes = 0.20 Surfaces coated with polyethylene and polypropylene = 0.05 Surfaces coated with 3-layer system (pipe surfaces) = 0.05 Surfaces coated with other coatings = 1.00 In case of any change in calculation procedure, vendor shall take prior approval from contractor/ owner.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 5.4. PERFORMANCE CRITERIA The installed system shall provide the levels of cathodic protection specified in Table 2.
TABLE 2 Cathodic Protection Potentials INSTANT OFF POTENTIALS, mV REFERENCE ELECTRODE Cu/CuSO4(1) Steel in soil(3) Steel in water NOTES: 1. Cu/CuSO4 reference may be used for buried piping when testing with portable reference electrodes. 2. Ag/AgCl reference electrodes shall be used for permanent installations in soil and seawater. -950 to 1150 -950 to 1100 Ag/AgCl(2) -900 to 1100 -900 to 1050
6.
SITE SURVEY After locations of new buried refinery structures are determined, a predesign site survey shall be carried out. The field survey shall evaluate the following: General terrain. Soil electrical resistivity and chemistry testing of the site. Possible interference sources such as high voltage transmission lines, manmade stray currents or adjacent buried metallic structures or piping. Effects of existing cathodic protection system on new systems or vice versa. If the area to be surveyed is affected by seasonal changes, the survey results shall be adjusted to obtain a realistic design basis.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 6.1. General Terrain The survey shall include general information of the terrain including:
Type of terrain and vegetation, Visible relevant features and crossings (main roads, overhead power lines, other pipelines), Water drainage and channels, All other information that is considered relevant to the design of a cathodic protection system.
6.2. 6.2.1.
Soil Resistivity Measurements Surface and Shallow Beds The number of measurements shall be determined locally using the following minimum spacing, and readings shall be taken whenever there are visual changes in soil characteristics. The site shall be marked off in a rectangular grid and readings shall be taken at each grid intersection. If two successive readings differ by a ratio greater than 2:1, an additional reading shall be obtained at the midpoint between the previous two readings. This shall be repeated until the readings meet the 2:1 ratio criteria. For each type of soil, readings should be taken in at least two different locations. At each location a minimum of two measurements shall be carried out.
6.2.2.
Deep Well Ground Beds Holes (or wells) drilled during geotechnical survey shall be used first, if possible, to test the ground bed resistance for deep wells. Otherwise, pilot holes shall be drilled to estimated depths indicated to be favorable from tests done for shallow beds. If water is encountered, the hole may be allowed to fill with ground water. If hole is dry, it may be filled with local water. A single anode may be lowered down the hole with a long lead which is connected to a buried structure in series with a battery and an ammeter. By measuring the current output at known power source voltage at intervals as the test anode is lowered, a profile of current output and anode resistance with depth can be developed. Soil resistivity shall be estimated by inputting the anode dimensions and anode resistance in the Dwight formula for single vertical anode.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 6.3. Chemical Properties of Soil Tests shall include pH, chlorides, sulfides, sulfates, sulfate reducing bacteria and redox potentials. The number of tests should be determined locally but measurements should
at least be carried out when there are visual changes in soil characteristics.
7.
EQUIPMENT AND MATERIALS All equipment and materials for permanent installation shall be compatible with the environmental conditions of project. All equipment (transformer rectifiers, junction boxes, test stations, permanent reference electrodes etc.) shall have identification plates with information identifying their purpose. The plates shall also have tag numbers, with numbering system in accordance with project equipment tag numbering system. The tag numbers shall be marked on as-built drawings and referred to in all cathodic protection documentation.
7.1.
Impressed current anodes Impressed current anodes for services other than water tanks and boxes shall be mixed metal oxides (iridium, tantalum and titanium oxides) on titanium base. For water tank and water box services, the impressed current anodes shall be platinized niobium anode with copper core capable of delivering 1,000 amps per square meter at consumption rates not exceeding 80 milligrams/amp-yr. Bidder shall submit the following information for product approval: Composition of anode coating (mixed metal oxides, platinum etc.) Anode core data including dimensional data. Anode shape and dimensional data. Electrical properties of the anode including internal resistance, attenuation rating of the anode, current rating and consumption data. Cable data. Cable to anode connection including sealing materials and methods. Any other information that will effect Owners approval.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 7.2. Sacrificial anode Zinc anodes shall be ASTM B-418, Type II with the following composition: Al
0.005% max 0.003% max 0.002% max 0.0014% max 0.003% max remainder 0.01% 0.02% max 0.03% max 0.50-1.3% 0.001% max Balance
Cd Cu Fe Pb Zn Al Cu Fe Mn Ni Mg
Magnesium anodes shall be of the following composition:
Others 0.30% max Cast anodes shall be factory prepackaged with backfill. Each anode shall be clearly marked with the type of material (trade name), batch or charge number and anode weight (without backfill). Full documentation (type, weight, dimensions, chemical analysis and performance data of the anodes) shall be submitted by the bidder for review. 7.3. Backfill materials for pre-packaged sacrificial anodes Backfill for sacrificial anodes, other than ribbon type, shall consist of a mixture of Gypsum (75%), Bentonite clay (20%) and sodium sulfate (5%). Backfill is not required for ribbon type anode installed directly on the structure. 7.4. Backfill materials for impressed current beds in soil Carbonaceous backfill, when specified, shall be metallurgical coke breeze with the following properties: Maximum resistivity: Fixed carbon: Ash:
0.10 ohm-cm
99.77% 0.1%
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Moisture: Volatiles: Bulk density:

0% 0% 1 185 kgs/m3 1.0 mm maximum, dust free.
Particle size: 7.5. Cables
For cables refer standard specification no. 00785-000-STD-1621-04. 7.6. Transformers/ Rectifiers Transformers/rectifier stations shall be equipped with an alarm system which automatically signals when there is current interruption, and with a remote monitoring system. Rectifier stations and other associated equipment shall be installed in nonhazardous areas wherever practical. Transformers/rectifiers shall comply with relevant IS/IEC standards. Rectifiers shall be of a special design for cathodic protection service and should be 3 phase units, 41510% V-AC, 505% Hz if available or single phase. Transformer/rectifiers shall be mounted on concrete plinths and all units supplied for specific functions shall be by the same Bidders and shall be interchangeable on their plinth mountings. All necessary hardware shall be furnished. All terminals, connectors, bolts and contact hardware shall be of copper, brass or bronze. Locking devices shall be used at all bolts and screw connections. The maximum T/R output voltage shall be 75 volts. The output voltage shall be adjustable from zero to the maximum rated output when on load. A step less (continuous) adjustment shall be used. Automatic potential control shall be provided. Transformer/rectifiers shall not be installed in series or in parallel in the same cathodic protection circuit. The rectifier shall be constructed silicon diodes so arranged as to provide full wave rectification. 1200V. The output rms. ripple current shall not exceed 5% of the DC output current between 5% and 100% of the rated current output.
The current rating of the diodes shall be more than 1.25 times the
maximum current rating of the rectifier and have a minimum peak inverse voltage of
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION The transformer/rectifier shall be provided with an isolator or Molded Case Circuit Breaker (MCCB) on its incoming circuit and, where applicable, on its AC subcircuits. Additionally, suitably sized fuses shall be installed on the transformer/rectifiers phase
AC sub-circuits and negative DC output circuits. The transformer/rectifier shall be capable of withstanding a short circuit of up to 15 seconds duration at the output terminals without damage to any of its devices. The transformer/rectifier shall be provided with approximately 76 mm diameter meters or similarly sized square pattern meters to read the output voltage, current and permanent reference electrode potential. The measuring accuracy shall be better than 2% of full scale. The polarity of the DC terminals and AC supply terminals shall be clearly marked. AC and DC cables shall be physically separated by an insulating panel. A built-in current interrupter unit is required. The current interrupter unit shall be electronic and shall be capable of switching the full output current on ON/OFF sequence infinitely variable and adjustable from 0 to 99 seconds independently for ON/OFF periods. If a pipeline, piping, tank or plant area system is cathodically protected by more than one transformer/rectifier, all transformer/rectifier interrupter units shall be provided with a facility for synchronous switching. The cathodic protection system in the plant shall be designed so that a synchronous switching can be achieved from a central monitoring switching board. During normal operation, the built-in current interrupter shall be bypassed and synchronous switching, switched off. Incoming cables of oil cooled transformer/rectifiers shall be terminated in separate non oil filled cable boxes and penetration into the tank shall be via bushings above oil level. A sight glass and thermometer shall be provided. Transformer/rectifiers shall be installed in a non-hazardous area wherever practical. If this is not possible, the construction of the rectifier units shall fulfill the requirements of the hazardous area classification applicable for the site. The bidder shall obtain the required information on area classification from the Owner. The enclosure shall have a minimum degree of protection IP 54. Transformer/rectifiers shall be suitable to operate under the prevailing service conditions. The rectifier cabinet shall be of not less than 2.6 mm steel. All weight bearing components shall be constructed from coated angle steel. The cabinet and its component parts shall be of sufficient strength and rigidity, so that no damage occurs under normal handling.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Each transformer/rectifier shall have:

Lifting lugs of suitable size and location to facilitate lifting of the unit when full of oil. An oil filling hole with screw cap. An oil drain with a valve. An oil tank breather provided with silica get cartridge and breather seal, complete with spare desiccant cartridge. An earthing terminal. Surge arrestors across the output terminals of DC voltage sources
A rating plate indicating Manufacturers name, model number, manufacturing date, AC rating, DC rating, rectifier material, maximum operating temperature of the unit, weight of the oil and weight of the unit plus oil, project purchase order number, equipment identification number, date of purchase shall be provided. 7.7. Anode terminal boxes Anode terminal boxes shall be of stainless steel type 316L and with minimum degree of protection IP 54 . They shall be provided with a 6 mm thick phenolic panel with appropriate shunts, grid coil resistors, terminals, meters and hardware as indicated by the bidderss detailed design. The junction box shall be provided with one or more 75 mm diameter conduit hub and conduit for cables. Anode terminal boxes shall provide sufficient room for control and test equipment and dissipation of heat, e.g. from resistors. The boxes shall be provided with hinged doors giving access to all internal components. 7.8. Test stations Test posts shall provide sufficient room for the termination of test cables and for the installation of bonding cables and/or resistors. Test post head shall be orange color. Big Fink test station with upright post shall be used in all areas except areas directly in the traffic path. In such areas, Flush Fink test station shall be used. If test stations are required to be installed underground, they shall have adequate water drainage facilities and they shall be provided with a closure to avoid ingress of dirt. If installed in traffic areas, the station shall be flush (with grade) type such as FlushFink.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Test stations shall be provided with lockable access doors or caps, or have external insulated contacts fitted to allow easy connection of test clips for regular monitoring. Cable entry shall be at the bottom through protective tubes.
Terminal board shall be easily removable for adding or deleting cables. The station shall be dimensionally stable up to 70C and resistant to ultraviolet light. Terminals shall be completely accessible with leads located under the cover. The station shall be designed to reduce shock hazard. Maximum height shall be 2 meters with no component requiring adjustment or monitoring higher than 1.7 meters. Test station shall be Exd type, zone 2, gas group IIA/ IIB/ IIC, class T3.
8. 8.1.
SYSTEMS ENGINEERING AND INSTALLATION Qualifications for design personnel All work consisting of site survey, stray current analysis, system selection, system design, installation and commissioning shall be under direct supervision of vendors. Education and experience data (known as CV or resume) of vendors Corrosion Engineer/Specialist shall be forwarded to the PMC/Owner for approval before work commences.
8.2.
Tank bottoms The design and installation of cathodic protection system shall comply with the requirements of NACE RP0193. Corrosion protection for tank bottoms shall consist of the following (descriptions of items under the tank plates starting from the tank plate) : Coating on the soil side (underside) of the tank floor plate in compliance to specifications. A layer of 300 to 350 mm thick dry, clean, chloride free foundation fill material A cathodic protection system consisting of anodes and reference electrodes. A layer of 150 to 200 mm thick, dry, clean, chloride free foundation fill material. A HDPE or other plastic liner shall be installed approximately 450 to 550 mm below the tank plates. The liner shall have chemical resistance to any fluid leak from the tank floor plate. Foundation fill material.
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Anodes shall be titanium wire with mixed metal oxide coating installed in the form of horizontal circular loops with cables from both ends exiting through the foundation wall.
The spacing between the anode loops shall be calculated to provide uniform current density to the tank plates. All design calculations for the anode assembly with its power feed points and header cable connections locations shall be performed by the anode assembly manufacturer. Anode resistance, header cable resistance and anode geometry shall be optimized to maintain variation of current distribution below 10% at any point on the linear cathodic protection system. Anode loop length and loop diameter calculations shall be performed by the Vendor and verified by the contractor. Tanks shall have grounding protectors installed at each electrically isolated joint. Each tank shall have one anode terminal box. Cables from each anode loop shall be brought outside the tank foundation ring and connected to the terminals in the anode terminal box. Each cable shall be clearly tagged with anode loop number starting with #1 for the loop in the center. A copy of the drawing showing anode loops, reduced to reasonable size, shall be laminated and securely attached to the inside of the anode terminal box. The drawing shall also show the installation date and maximum current rating of the anode materials. All anodes shall be powered with a dedicated transformer rectifier to each tank or a rectifier dedicated to a group of adjacent tanks. Reference electrodes shall be installed along the circumference of an imaginary circle whose radius is 86% of the tank radius from the center point of the tank bottom. The distance between the reference electrodes shall not exceed 15 meters subject to a minimum of one reference electrode in each quadrant. Also, a minimum of three permanent reference electrodes shall be installed in the middle of the tank bottom area in a triangular pattern whose center is the center of the tank bottom. Reference electrodes shall be placed close to the bottom and away from the anode loops. Leads from all reference cells and two test cables from the tank plate shall be routed to one test station. Reference cells shall be numbered starting with #1 for the center reference electrode followed by the reference electrodes located clockwise from the location of the test station. A copy of the drawing showing reference electrodes,
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION reduced to a reasonable size, shall be laminated and securely placed within the test station for reference. The cathodic protection system shall be energized using temporary power and checked
for performance after tank floor plate placement and before starting the shell fabrication. The system shall be free of shorts and perform at the electrical potentials specified in the cathodic protection criteria. Before starting the cathodic protection installation, appropriate quality checks of the following items shall be performed and documentation shall be maintained by the vendor. Liner and lining fabrication. Quality of the sand. Quality of the coating on the soil side of the tank plates. Anode materials, cable connections, corrosion protection of anode to cable connections, and overall anode assembly. Reference electrodes. Sufficient slack in the cables. Zero electrical resistance at the anode to cable connections.
During installation of the cathodic protection system, the following items shall be checked: Thickness of the sand layers. Diameter of the anode loops Placement of the reference electrodes. Depths of the anode loops and reference electrodes. After the tank plates are welded, the system shall be checked for electrical shorts and performance. Placement of grounding cells and appropriated checks recommended by the manufacturer of grounding cells. 8.3. Buried tanks The design and installation of cathodic protection system shall comply with the requirements of NACE RP0169.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Buried tanks shall be protected with impressed current cathodic protection system using vertical anodes. Tanks containing flammable fluids shall have grounding cells installed at each isolation
joint. Levels of cathodic protection shall be similar to those described for buried piping. 8.4. Tank internals All welding and cutting of tank surfaces necessary for installation of internal cathodic protection equipment shall be completed before application of internal and external coatings when practical. All damages to the internal coating caused by cutting and welding operations shall be repaired . Anodes shall be metallurgically bonded platinum coating on niobium substrate 1.6 mm diameter wire. The permanent reference electrode shall be IR-free silver/silver chloride reference electrode. All cables inside the tank shall be resistant to the tank interior atmosphere. All wiring on the outside of the tank shall be installed in rigid steel conduit. Underwater splices of cables are not permitted. Connections between the positive lead wire and the conductors from the anodes shall be mechanically secure, electrically conductive and shall be sealed to prevent moisture penetration. Hand holes and mounting devices shall be provided in the roof adjacent to each anode suspension so that the anodes can be removed, replaced or inspected without entering the tank. All hand holes shall have removable, gasketed covers. Cables on the tank roof shall be run in galvanized and painted conduit. Junction boxes shall be provided on tank roof for each anode to anode header cable connection. Junction boxes shall also house shunts to permit current measurements. Each anode circuit shall also have grid coil resistor to permit balancing of current output from the anodes. Positive header cable shall enter the tank interior from the roof from which individual cable to the anodes shall be routed inside the ceiling space of the tank to the hand holes. The feeder cable to the anode shall be properly and permanently secured at the hand holes and shall be designed to easily disconnect the anode for repair or replacement.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Anodes shall be supported by a metallic stranded rope of 3 mm minimum diameter with PVC sheathing. Anodes shall not be self-supporting. The anodes shall be supported from the roof in a vertical position for optimum current
distribution. Installation shall not require emptying, wall penetrations below the high water line or the use of pressure fittings. The anode assembly shall consist of full length anodes on the outer ring to protect the shell surface. Horizontally suspended anodes shall be used to protect the floor surface. Appropriate ballast weights shall be installed to keep the anodes stationary while the fluid is moving inside the tank. Unless otherwise approved by the Owner, the distance between the anode surface and the tank surface shall not be less than one meter. The anode system shall be designed to prevent electrical shorting to the tank. The anode system shall provide and maintain an uniform distribution of current without exceeding the potential limits stated in the cathodic protection criteria. The anode system shall have lowest possible circuit resistance. Voltage attenuation shall be less than 10% at the anode end opposite from the anode to positive cable connection. Reference electrodes shall be located approximately at equal distance from the anodes and close to the intersection of floor and shell. A magnet secured to a reference electrode cell shall be used to maintain the 10 mm distance from tank surface. The straight line spacing between reference electrodes shall not exceed 10 meters and the minimum number of reference electrodes per tank shall be two. Automatic controls shall be installed to adjust the output of the rectifiers based on potential readings of the permanent reference electrodes. The system shall be also automatically adjustable for all variables except IR drop error. 8.5. Buried piping system The design and installation of cathodic protection system shall comply with the requirements of NACE RP0169. 8.5.1. Piping without casing buried under roads: Piping which is geographically remote or isolated from impressed current cathodic protection systems shall be protected with zinc ribbons.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION A test station shall be installed to monitor the potential of the piping. Buried piping shall be electrically isolated on both sides of road by using dielectric joints (couplings, flanges or unions). The electrical isolation shall be between the road
location and the first above ground pipe support or connection to aboveground equipment. 8.5.2. Piping inside casings: Piping inside casing shall be electrically isolated from the casing using insulators such as LinkSeals which shall be installed at not more than 150 mm from each end regardless of the size of the casing or the carrier pipe. In addition to the electrical insulators at the casing ends, each pipe support inside the casing shall be electrically nonconductive. If the pipe support is conductive, electrical isolation shall be approved in writing by the Contractor and Company. The number of supports shall be as recommended by the Manufacturer of the insulator and approved by the Contractor and Owner. Cathodic protection shall be provided to the carrier pipe inside the casing, by installing zinc ribbon anodes together with a reference electrode. Zinc ribbons shall be attached to the carrier pipe via a cable in a test post. Link-Seals shall be supplied with high strength, noncreep glass reinforced nylon pressure plates to improve insulation between the casing and the carrier piping. The seal between the casing and carrier piping shall be moisture tight. 8.5.3. Pipe casings: The use of pipe casings is not recommended. However, if their use is mandatory, the design of the casing should be such as to cause minimal interference with or shielding of cathodic protection to the carrier pipe. Casings shall be dried, sealed using nonmetallic end seals and provided with vent pipes at both ends. Cathodic protection system for casing shall be completely separate from the cathodic protection system of the piping. The surfaces on the soil side shall be protected with magnesium anodes with anode to structure connections located abovegrade in a test station.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 8.5.4. Plant piping: Plant piping, other than at road crossing either remote or isolated, shall be protected with impressed current cathodic protection system.
Current drain point connection to the pipe shall be on the buried section of the piping. The plant area shall be divided into geographical areas for cathodic protection circuits. These geographical areas shall be of reasonable size to troubleshoot any system related problems. Each geographical area shall be serviced by one dedicated cathodic protection system. Where possible, a cathodic protection area shall be an area separated from other cathodic protection areas by roads. 8.6. Sacrificial anode beds Where the impressed current system is not economically feasible, such as at road crossings or isolated areas, zinc anodes may be used provided the soil resistivity is less than 1,500 ohm-cm and magnesium anodes if the soil resistivity is less than 3,000 ohm-cm. If the resistivity is more than 3,000 ohm-cm, the vendor shall submit a description of technical options to the contractor. The use of a sacrificial anode system may be considered, if the following conditions are met: If the pipeline (section) runs in low resistivity soil, water, swamps or marshes. On short pipeline sections, for economic reasons For temporary protection on newly laid pipelines. For temporary protection of existing pipelines, if pipeline isolation cannot be immediately installed. For localized (hot-spot) protection to supplement impressed current systems.
If cathodic protection by sacrificial anodes is selected, the vendor shall show by measurement and calculation that: The resistivity of the soil is sufficiently low to allow successful application of sacrificial anodes. The selected type of anode is capable of continuously supplying the maximum current demand.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION The total mass of anode material is sufficient to supply the required current during the design life of the system. The anodes shall be buried in low resistivity chemical backfill to obtain the required
output. Sacrificial anode cables shall be connected to the pipeline via a bondbox and shunts to allow anode current monitoring. For magnesium anodes, it is allowed to install a resistor in the anode circuit to limit the protection levels to within the protection criteria. 8.7. Impressed current anode beds The design and installation of deepwell beds systems shall comply with the requirements of NACE RP0572. Impressed current cathodic protection systems shall be powered by transformer / rectifier units fed by an AC power supply. The ground bed of an impressed current cathodic protection system shall be designed such that: Its mass and quality are sufficient to last for the design life of the system. Its resistance to earth allows the maximum predicted current demand to be met at 80% or less of the voltage capacity of the DC source during the design life of the system. The risk of causing harmful interference on other buried structures is minimized.
8.7.1. Deep Well Beds
The selection of the location and the type of groundbed shall be based on and take full account of local conditions such as: Soil conditions and resistivity at various depths. Groundwater levels and resistivity. Strong seasonal changes in surface soil conditions. Available terrain (for surface groundbeds). Risk of shielding (especially for parallel pipelines). Risk of damage by excavation (surface groundbeds).
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Deepwell ground beds should be used:
If the soil conditions at the required depth are suitable to meet the project requirements. If there is a risk of shielding by other pipelines or buried structures. If the available space is limited. If there is a risk of stray currents on adjacent installations.
The vendor shall include in his basic design a calculation of the ground bed resistance based on the most accurate soil resistivity data available, using established methods and formulae. The vendor shall specify in his detailed design the method of drilling the deepwell, establishing the resistivity of the soil at depth, completion of the borehole and the method of installation of the anodes and backfill. 8.7.2. Casings for deepwells The borehole design and construction shall be such that undesirable transfer between water bearing formations and pollution of underlying strata from the surface (e.g., tank farms) is prevented. Metal casings may be used at the surface for stabilizing the borehole and in the active section of the groundbed. Casing at depth shall be electrically isolated from metal casing and structures at the surface. To achieve such isolation, plastic casing shall be used. 8.7.3. Venting of deep well beds Deepwell ground beds shall be provided with adequate venting pipes to prevent gas blocking of the well. Vent pipe material shall be chlorine resistant. Geotextile shall be used to avoid blockage of the vent pipe by coke backfill. 8.7.4. Shallow Ground bed and Surface Beds The anodes or the highest point of the carbonaceous backfill shall be not less than one meter below ground level. Ground bed markers shall be installed at each end of each ground bed. Where more than one ground bed is installed per a transformer rectifier, cables shall be routed from each ground bed to a anode junction box.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION The junction box shall contain grid coil resistors, shunts in each circuit and an ammeter with selector switch to measure current flow in each circuit. Each vertical anode shall have gravel vent and anode marker.
8.8.
Connection of cables Cable routes shall be clearly marked using cable markers. These shall be installed at approximately 25 meter intervals and at every change of direction of the cable route. Markers to indicate CP cable and include arrow to indicate the direction of cable run. Cable markers at the sacrificial anode locations shall also include markings to indicate the location of the sacrificial anodes. All cables shall be laid without coils or kinks, buried in sand at a depth of at least 0.75 m, provided with cable protection tiles and warning tape installed 250 mm above the cable. All buried cables shall be of one continuous length without splices. Cable to cable connections should be made aboveground inside test stations to reduce the risk of damage and to allow monitoring. Impressed current anode cable connections shall be insulated using epoxy resin and/or heat shrinkable insulation sleeves. The cables shall be connected to the positive feeder cable inside an aboveground junction box to enable current monitoring. The cables of sacrificial anodes shall be connected to the pipe via an aboveground distribution box to allow current monitoring and disconnection.
8.8.1. General
8.8.2. Connection Methods The vendor shall include in the design detailed procedures of processes to be used for cable connections. Welders shall be fully qualified for the applicable welding process. Cable connections shall be designed to ensure adequate mechanical strength and electrical continuity and to prevent damage to the structure. Connections shall be made to surfaces which are thoroughly cleaned to the bare metal. Cleaning shall be accomplished by grinders without reducing wall thickness lower than the project requirements. Superficial wire brushing is not acceptable. Welding of cable connections shall not be carried out on bends or within 200 mm from welds.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION All below and above ground electrical connections shall be fully encapsulated with a coating Belzona 1121 before backfilling. Coating repair at cable connections shall comply with Project coating specification requirements as applicable.
The following guideline for the selection of cable connections shall be followed: All underground connections to carbon steel surfaces (STRUCTURES and other surfaces) shall be done by using Cad-welding process only. All aboveground connections to carbon steel STRUCTURES shall be done by using Cad-welding process only. All other connections shall be done by bolted connections.
Bolted Connections: Bolted connection consists of a stud welded to the surface requiring connection, a cable terminal with brazed or crimped lug, washer and double nuts. Stud material shall be similar to the structure material. Where a stud can not be welded directly to the structure, a metal plate, 50x50 mm minimum, provided with a welded M10 threaded stud bolt, shall be welded to the structure. The plate shall be made of material similar to the structure. The cables shall be connected to the threaded stud bolt using crimped or brazed cable lugs, double nuts and serrated washers. Stud welding may be done using an electrical (resistance welding) or mechanical (friction welding) process which shall be approved by the contractor and owner. The stud material and consumable shall be compatible with the structure material. The process shall not influence the structure material properties to fall outside the original specifications. The size of threaded studs shall be 8 mm or more to suit the cable size. The cables shall be connected to the stud using crimped or brazed cable lugs, nuts and serrated washers. The pin-brazing process shall use specially designed cable lugs and brazing pins to braze the cables to the structure and shall be approved by the contractor and owner. The brazing materials shall be compatible with the structure material. Penetration of copper and/or other brazing metals into the structure shall not be deeper than 1 mm and the hardness shall remain inside the original structure requirements.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Cad welding: Cad welding materials and charges shall be approved by the contractor and owner. The vendor is solely responsible to verify the compatibility of the Cad-weld materials and
charges with the structure and submit the supporting data to contractor and owner. Cad-welding process shall be such that copper penetration into the pipeline material shall not be deeper than 1 mm and that the hardness shall meet the original structure requirements. Cad-weld charges shall not be greater than CA15 for steel pipe and cable cores shall not be heavier than 16 mm2. If heavier cables need to be attached, the core shall be separated into smaller strands of less than 16 mm2 each and welded separately. Cad-welds shall be visually inspected and gently impact tested with a hammer. The welds shall also be tested for electrical resistance using an electrical multimeter, and shall have zero resistance. Any weld which does not meet these requirements shall be discarded and the cable shall be rewelded. Where Cadwelding is not possible, e.g. for safety reasons and only in exceptional cases, the VENDOR may design glued electrical connections using metal plates bonded with electrically conductive epoxy resin. This method shall not be used for current carrying cables (drain cables or bond cables). The materials to be used and the installation procedure shall be approved by the contractor and owner. 8.9. Electrical earthing Electrical safety earthing of the plant structures and equipment shall be made compatible with the cathodic protection system. Subject to owners approval, grounding protectors such as Cathodic Isolator shall be installed between the protected structure and the plant earthing at locations where plant earthing has adverse impact on the cathodic protection system. The grounding protector must be of solid state construction, non-electrolytic and maintenance free. It shall protect the structure, cathodic protection systems and personnel against AC fault currents, lightning, AC induction and power switching surge currents.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 8.10. Electrical continuity Bonding cables shall be installed to maintain electrical continuity at locations such as nonwelded joints, mechanical joints, flanges, couplings, and locations where there is no
electrical continuity within the piping system to be cathodically protected. 8.11. 8.11.1. Electrical isolation General Cathodically protected surfaces shall be electrically isolated from other plant, foreign structures and earthing systems in accordance with NACE RP0169 and RP0286 using isolating joints. All isolation materials shall be resistant to the product/service inside the pipe. Isolating joints/flanges shall never be buried. They shall be installed above ground. Common, metal pipe supports shall be avoided or electrically isolated from the pipelines. Safety or instrument earthing shall be compatible with the cathodic protection system. Isolating joints and flanges should be painted or striped in a contrasting color for easy identification. The color should be consistent in one area. The paint shall be compatible with the pipeline/tank coating. Paints containing metallic pigments (such as zinc or aluminum) shall not be used for top coating on isolating joints/flanges.
8.11.2.
Isolating Joints The design, materials, dimensions and construction of the isolating joints shall meet the design requirements of the pipeline. Isolating joints shall be internally coated by the manufacturer over their full length using an amine cured epoxy coating, applied on a blast cleaned surface (Sa 2 1/2, ISO 85011). A length of 50 mm at each end shall be left uncoated to allow welding. All sealing and isolation materials shall be resistant to the product transported. The isolating joints shall withstand a voltage of 1500 volt AC, 50 Hz, across the joint for 5 minutes without bridging or reduction in electrical resistance. The electrical resistance across the joint shall be more than 1 mega ohm (106 Ohm) measured at 1000 V DC in dry air.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION If the product transported by the pipeline is dry gas, dry crude oil, or oil products, the overall length of the isolating joint shall be at least one meter. If the product transported by the pipeline is an electrolyte, or it may be anticipated that it
may contain an electrolyte at any time during the life of the pipeline, the following rule applies: If the resistivity of the electrolyte is higher than 100 ohm-cm, or the volume occupied by the electrolyte is less than 5% of the pipeline volume, the overall length of the isolating joint shall be four times the pipe diameter (with a minimum of one meter). If the resistivity of the electrolyte is below 100 ohm-cm, and the volume of electrolyte is more than 5% of the pipeline volume, isolating spools shall be used. Isolating spools shall be used if required by the rules above. The length of an isolating spool shall be determined by the following formula: L = (400/) x D Where: l = length of spool (cm) = electrolyte resistivity (Ohm-cm) d = nominal pipe diameter (cm) Isolating spools may be manufactured out of nonconductive composite pipe material (GRE) or as an internally coated or lined steel spool with isolating joints or flanges at both ends, depending on pipeline service, pressure and temperature. The resistance across isolating joints shall be measured immediately before welding into the pipeline. The minimum resistance shall be 1 mega ohm (106 ohm).
8.11.3.
Insulating Flanges If the use of isolating joints is not possible, electrical isolation should be provided using insulated flanges. Flanges and insulation kits shall meet the design requirements of the pipeline. Insulating gaskets for raised face or full face flanges should be the neoprene coated phenolic resin type. Bolts shall be insulated using full length phenolic or composite sleeves and phenolic resin insulating washers and steel washers at both sides.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Insulating flanges should be assembled and tested before being welded into the pipeline. A voltage of 1500 volt DC shall be applied across the flange assemble for one minute without causing breakdown of the insulation or flash over. Subsequently the
resistance across the assembled flange shall be measured and shall be more than 1 mega ohm (106 ohm). On existing flanges, the bolt-to-pipe resistance shall be measured and the overall effectiveness of the isolated flange determined after cathodic protection has been applied, This can effectively been done by measuring the current through the attached pipe using a Swain-type current clamp/meter. Insulated flanges shall be protected against ingress of dirt and moisture by the application of flange protectors except when used in sour service conditions. 8.12. Stray currents The vendor shall carry out a survey for stray currents generated by the newly installed cathodic protection systems. Stray currents generated by the newly installed cathodic protection systems shall be eliminated at the source by suitable insulation or other means. shall be designed and installed. 8.13. Installation of junction boxes and test stations The contractor shall clearly indicate the type of test post, bond box and distribution box for each application in the detailed design: Distribution boxes shall be of stainless steel type 316L painted and weatherproofed. Bond boxes, e.g. for cased crossings, shall be of GRP/polyester material with the minimum degree of protection IP65. Boxes shall be of lockable type, UV resistant, high impact resistant and complete with neoprene gasket and stainless steel type 316 captive screws. Sufficient number of test stations shall be installed to locally or remotely monitor the system performance: If this is not economically feasible other measures such as installation of a current drainage system
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Anode output - Individual anode circuits shall be provided with shunts and grid coil resistors to measure and adjust anode current outputs. Sacrificial anode cables shall be connected to the pipeline via a bondbox and shunts to allow anode current
monitoring. For magnesium anodes, a resistor shall be installed in the anode circuit to limit the protection levels to within the protection criteria. At the drain points, each negative connection to the pipe/tank shall be provided with current measurement facilities. For single pipes, the ammeter built into the current source may suffice. Where multiple negative connections are installed, separate shunts and blocking diodes shall be provided complete with ammeter and selector switch installed in a distribution box. At the drain point, a potential monitoring station shall be installed using a separate test cable connected to the pipe/tank for measurement of the drain point potential. Structure to electrolyte potentials Tank bottoms: Reference electrodes shall be installed along the circumference of an imaginary circle whose radius is 86% of the tank radius from the center point of the tank bottom. The distance between the reference electrodes shall not exceed 15 meters subject to a minimum of four reference electrodes in each quadrant. Also, a minimum of three permanent reference electrodes shall be installed in the middle of the tank bottom area in a triangular pattern whose center is the center of the tank bottom. Reference electrodes shall be placed above the HDPE membrane, close to the bottom and away from the anode loops. Plant piping: Reference electrodes shall be placed along piping systems at distances not exceeding 100 meters but not less than 2 reference electrodes for each service (fuel gas, fire water, oily water etc.). The total quantity and placement of the reference electrodes shall be such that the potentials give a reasonably accurate picture of the cathodic protection. Reference electrodes near the anode beds shall not be considered in the number of reference electrodes dedicated to the measurement of piping structure to electrolyte potentials.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Current drain/pickup - Test stations shall be installed at locations such as road crossings to monitor the casing and carrier piping. If casings at road crossings, etc. are longer than 10 meters, a test facility shall be installed at both ends of the
casing. Shorter casings shall be provided with a test facility at one end only. In each test facility, two test cable shall be connected to the protected pipe and, if a steel casing is used, two test cable shall be connected to the casing. Both cables shall be terminated in one test post and shall be identified by color coding or stainless steel tags. Cathodic interference - Test stations shall be installed at the crossings of protected and foreign structures. At crossings with foreign structures, a bonding facility shall be provided, consisting of two separate cables attached to each individual pipeline, terminating in a test post with suitable facilities to install direct or resistive bonds. The cables to each structure shall be identified by stainless steel tags. Electrical continuity - Anode terminal boxes and test stations shall be installed for bonding current carrying cables (including bonds between pipelines/ structures or across isolation joints). These test stations shall be located outside hazardous areas. If this is not possible, a box approved for the relevant area classification shall be used Electrical isolation- Each isolating joint and isolating flange shall be provided with test facilities. At all isolating joints/flanges, two cables shall be connected to each side of the joint or flange. All cables shall be separately terminated in one test post with suitable facilities to install direct or resistive bonds. The cables to each side of the isolating joint shall be identified by stainless steel tags. The contractor shall clearly indicate the type of test station and its purpose in the detailed design.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 8.14. Remote monitoring and system control Vendor shall submit for contractors and owners approval, details of a fully operational computerized remote monitoring and system control facility which shall be supplied and
installed by the vendor. Remote monitoring equipment shall be installed at all transformer/rectifiers and include output voltage, output current, drain point potential and low voltage/high current alarms. Remote monitoring at each transformer/rectifier shall include a minimum of four reference electrodes distributed around the area of influence of each transformer rectifier. If specified the system shall be suitable to perform the following tasks from control room: Measurement and adjustment of rectifiers inputs and outputs. Measurement and adjustment of impressed current anode outputs Measurement of structure-to-electrolyte potentials.
In addition to the above tasks, the following reports shall be automatically generated at user selected frequency: Current status of rectifiers and anodes.
Structure to electrolyte potentials of all or selected items.
Vendor shall supply and install all the hardware and software for the Remote monitoring and System control.
9. 9.1.
SPECIAL FACILITIES Temporary CP systems In the case that the installation of the permanent cathodic protection system cannot be finalized before the pipe/tank is buried, or if specified by the contractor, a temporary cathodic protection system shall be installed. Such a system shall be designed in the same way as a permanent cathodic protection system with the exception that material quantities and quality shall be adequate to cover a lifetime equal to the time of the pipeline, tank, concrete structure construction until the expected commissioning of the
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION permanent cathodic protection system. Anode connections shall be constructed such that they can easily be connected/ disconnected and coating repaired during and/or after commissioning of the permanent system.
The temporary system shall have a
minimum design life of at least 12 months. For temporary cathodic protection system to be used for protection during construction before AC power is available, other DC sources may be used such as batteries. The permanent monitoring facilities connected to the pipeline/tank shall be constructed simultaneously with the pipeline/tank to allow monitoring of the performance of the temporary system. 9.2. Designs near high voltage power lines If the pipeline runs in the vicinity of high voltage power lines, the vendor shall investigate whether high AC voltages can be present on the pipeline by induction or otherwise and whether devices need to be installed for protection of the pipeline and personnel. The vendor shall show (by calculation or otherwise) that no harmful voltages can be present or design additional facilities to prevent excessive voltages. Such facilities may consist of dedicated pipeline earthing and/or the installation of polarization cells. 9.3. Designs in areas of lightning activity The vendor shall install suitable lightning protection to protect the pipeline/tank isolation and cathodic protection equipment. This shall consist of suitably rated surge arrestors. Surge arrestors shall be mounted across isolating joints/flanges. Surge arrestors required to prevent elevated voltages due to faults in adjacent electrical power systems or lightning shall be of the spark gap type and shall be designed such that: The impulse breakdown voltage of the arrestor is lower than that of the isolating joint across which they are mounted. The spark gap is capable of discharging the expected lightning currents without sustaining damage. The spark gaps are fully encapsulated to prevent sparks in open atmosphere and to protect the spark gaps from moisture.
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION 10. MATERIAL SCHEDULES This schedule shall include the descriptions and quantities of all materials to install the cathodic protection system.
The vendor shall also include in the material schedule a list of proposed monitoring equipment (hardware and software) required to carry out regular surveys of the cathodic protection system. The vendor shall also include a list of proposed tools and spare parts required for maintenance of the system during the first 5 years of operation. 10.1. Installation procedures Full construction details and installation procedures of the cathodic protection system shall be submitted to the contractor and owner for review and approval. These shall include: Written procedures for the installation of DC voltage sources, ground beds, cables, test facilities and all civil works, procedures for cable connections to the structures. A time schedule for the installation of the system, where required in relation to the construction schedule of the structures. Written procedures of all tests required to demonstrate the specified quality of installation. All relevant construction drawings including but not limited to plot plans, locations of cathodic protection stations and test facilities, cable routing, single line schematics, wiring diagrams, groundbed construction and civil works. Written procedures to ensure safe working practices during the installation and operation of the cathodic protection system. The installation of the cathodic protection system shall start only after approval of the installation procedures by the contractor and owner.
10.2.
Pre-commissioning, Testing and Inspection The vendor shall perform all pre-commissioning tests in the presence of the owner to confirm satisfactory installation and operation of all equipment. Such tests shall include trial operation of power sources to their maximum capacity and measurement and
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION checking of all cathodic protection circuits to confirm satisfactory connection and identification. Test shall include resistance to earth tests of ground bed anodes and zinc earthing electrodes, calibration checks of permanent reference electrodes, testing of
isolation joints and insulated flanges. Vendor shall document the results of all tests for inclusion in the commissioning manual. Commissioning Procedures Commissioning procedures are required to prove that the installed cathodic protection system is in accordance with the design. The system shall be considered satisfactory when the cathodic protection criteria is met at test stations and any other accessible points of the structure to be protected where owner requires tests to conform effectiveness of CP system. The commissioning procedures document shall include as a minimum: 10.3. Procedures for the testing of pipeline/tank isolation Procedures for natural potential surveys Procedures for energizing and de-energizing cathodic protection hardware. Procedures for full ON - instant OFF potential surveys Procedures for interference testing and interference mitigation. Requirements for polarization of pipeline. Procedures for interference testing if applicable. A time schedule for the commissioning of the system, where applicable in conjunction with the construction or commissioning schedule of pipeline. Procedures for isolating structures. Procedures for testing and adjustment of structure to electrolyte potential.
Cathodic protection manual A cathodic protection manual is required to ensure that the as-built cathodic protection system is fully documented and that operating and maintenance procedures are available for the future operator. This document shall contain: A description of the system and system components and their purpose.
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Pre-commissioning results The commissioning report which shall include copies of the relevant as-built drawings marked up to show the location (with reference number) of all test locations used during commissioning.
As-built drawings. Vendors documentation for equipment and materials installed. A schedule of all monitoring facilities. Potential criteria for the systems. Monitoring schedules and requirements for monitoring equipment. Monitoring procedures for each of the types of monitoring facilities installed on the pipeline, tank and steel in concrete. Guidelines for the safe operation of the cathodic protection system. Method statements, test procedures and test plans General guidelines for trouble shooting before cathodic protection specialists are called for assistance.
11. 11.1.
HANDLING Packaging and Shipping Preparation for shipment shall be in accordance with the vendors standards and as noted herein. Vendor shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers. Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the job site. Preparation for shipment and packing will be subject to inspection and rejection by Owners/ Contractors inspectors. All costs occasioned by such rejection shall be to the account of the vendor. Equipment shall be packed, securely anchored, and skid mounted when required. Bracing, supports, and rigging connections shall be provided to prevent damage during transit, lifting, or unloading. All temporary bracing/supports shall be marked "REMOVE BEFORE EQUIPMENT COMMISSIONING AND START-UP."
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STANDARD SPECIFICATION FOR CATHODIC PROTECTION Separate, loose, and spare parts shall be completely boxed. Pieces of equipment and spare parts shall be identified by item number and service and marked with Contractor's order number, tag number, and weight, both inside and outside of each
individual package or container. A bill of material shall be enclosed in each package or container of parts. One complete set of the installation, operation, and maintenance instructions shall be packed in the boxes or crates with equipment. This is in addition to the number called for in the Purchase Order. 11.2. Preservation and storage Equipment and materials shall be protected to withstand ocean transit and extended period of storage at the jobsite for a minimum period of 18 months. Equipment shall be protected to safeguard against all adverse environments, such as: humidity, moisture, rain, dust, dirt, sand, mud, salt air, salt spray, and seawater.
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CP Technical

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

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

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

6.7 6.8 7.0 7.1

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

7.2 7.3 8.0 8.1 8.2 8.3 8.4 8.5 8.6

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

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

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

ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET

INDIAN OIL CORPORATION LIMITED.

ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET

ISSUED FOR ENQUIRY

ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET CONTENTS

CLIENT UNIT PROJECT

CLIENT UNIT PROJECT

INDIAN OIL CORPORATION LIMITED PANIPAT NAPHTHA CRACKER.

ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET * *

Design minimum temperature Relative humidity - Average - Maximum

36% @ 4-50C 95%

Dry bulb temperature Barometric pressure - Minimum - Maximum - Average

: : : : 740 mm Hg < 1000 mm

Altitude above mean sea level

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ii) Balance Electricals

Cathodic Protection Scope

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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET

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g) Preparation of "As Built" drawings.

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Drawing/ documents required from Bidder

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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET

After order Review Ref./

order placement) for bulk items such as cables, lighting fittings

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S. No. 7.1 7.1.1 Engineering

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documents and conveying comments and approval

Drawings SLD a. Lighting scheme b. Any other SLD as required 9 9 9 9 9 9 9 9

7.1.20.2 7.1.20.3 7.1.20.4

7.1.20.5 7.1.20.6 7.1.21

As built drawings/ documents as required

LT Switchboards x PDB for CP system

CP system panel shall be in safe

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UPS system by owner/EPCM

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ELECTRICAL JOB SPECIFICATION FOR MOUNDED BULLET S. No. 7.5.2

specifications to be submitted for review/ approval of EPCM/Owner

Documentation All documentation and drawings as listed 9

commissioning procedures for EPCM/ owners review/ approval

7.6.3 7.6.4 7.7 7.7.1 7.7.2

commissioning of equipment as per approved installation/commissioning

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recording test results for EPCM/Owner approval

9 9 Testing & commissioning shall be under 9

original equipment manufacturers scope

7.7.10 7.7.11 7.7.12