VAPOUR RECOVERY SYSTEM TO COMPLY EMISSION NORMS

AT TALEGAON DEPOT

SPECIFICATIONS FOR
ELECTRICAL WORKS

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ELECTRICAL JOB SPECIFICATIONS

1.0 Scope

1.1 This specification covers major aspects of design, manufacture, supply, installation, testing
and commissioning of electrics for vapour recovery system.

1.2 The equipment shall conform to this specification, standard specifications and all other
relevant specifications attached to this tender document.

1.3 In case of conflict between requirements specified in various documents, the more stringent
one shall be followed. Owner decision shall be final and binding. The same shall be complied
without any time / cost implication to Owner.

1.4 Vendor’s scope, shall include sizing, design, engineering, manufacturing, supply, testing at
manufacturer’s works, packing and delivery at site of all the electrical equipment (flame proof in
hazardous areas) viz. motors, local control panels etc. including supply of all commissioning spares,
special tools & tackles as per the specifications and data sheets enclosed with this tender. The major
electrical equipment for Vapour Recovery Unit, interalia, includes

• Motors & Motor Starters etc.

• Local Control Panel
• Local control station (LCS) for motors away from LCP
• All power, control, space heater, signals cables from field to Substation & Control room.
• All Power cabling (including supply of cables) from Motor Control Centre (Sub-station) to Main
power distribution Unit of the Vapour recovery Unit Skid.
• All interconnecting cabling (including supply of cables) between the equipments within the package
battery limits.
• Earthing of electrical equipments within the skid and connections for bonding with main plant earth
grid
• Any other electrical equipment/component/unit not specifically mentioned above but required for
normal operation of Vapour recovery Unit.
•Vendor’s scope shall also include providing all specialized tools & tackles / instruments
required for above service.

3.0 Site Conditions

The equipments offered in the Vapour recovery system shall be suitable for continuous operation
under the following site conditions:
Design ambient temperature: 50 °C
Minimum ambient temperature: 5 °C

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Maximum ambient temperature: 46 °C
Altitude above M.S.L.: 677 M (approx)
All the equipment shall be provided with anti-corrosive epoxy paint.

4.0 Power Supply system from Owner

Medium voltage (motors): 415V ± 10 %
System frequency: 50Hz ± 3 %

5.0 Utilization Voltage

Motors rated up to 160 kW : 415V, 3 ph

Anti-condensation heaters : 240V, 1 ph

6.0 Area Classification & Equipment selection

Area classification for the package unit shall be considered as per following:

a) Area classification for the package unit shall be Zone-1, Gas group IIA/IIB, Temp. Cl. T3.

b) The minimum enclosure protection for all other equipments shall be as follows:

Equipment Type of enclosure protection

Motors / Motor Starters/Terminal Boxes: Ex (d)
Local Control panel/Local control stations: Ex (d)
Flameproof Equipments Ex (d) shall meet the requirements of IS 2148:2004 or IS/IEC 60079-
1(2001) or IS/IEC 60079-1(2007).

7.0 Equipment specification:

7.1 MV motors shall conform to the attached specifications and shall not have dual winding.

7.2 Local Control Panel/LCS

7.2.1 Local Control Panel shall be used for starting/stopping of motors. Following facilities shall
be provided as a minimum on Control panel
a) Start/Stop push buttons for motor
b) Ammeters for driver motor rated above 5.5kW
c) Selector switches
For all other control and indication requirements refer documents attached elsewhere in this
tender.

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7.2.2 Separate local control stations with start/stop P.B shall be provided for motor located away
from LCP. Local control stations shall conform to the attached specifications and the same shall
be provided with following facilities as minimum:
a) Start/Stop push buttons for motor
b) Ammeters for driver motor rated above 5.5kW
c) Selector switches (As required)

7.2.3 In case a separate electrical control panel is provided in the sub-station then Local push
button control station shall be wired directly from the electrical control panel in the substation.

7.2.4 Emergency push buttons as required for plant operation and safety etc. shall be provided

8.0 Vendor to furnish list of recommended two years spares for operation and maintenance with
unit prices for all electrical equipments. However minimum spares for motors shall include the
following:

a) Bearing DE/NDE one set

b) Terminal box cover with screws
c) Fan
d) Terminal block

9.0 Any special tools required for maintenance of motor and its auxiliary systems shall be
included in the scope of vendor.

10.0 All power and control cable sizes shall be finalized during detailed engineering. Provisions
as required in Vendor’s equipment for termination of the same shall be made accordingly
without any cost & time implications to Owner.

11.0 Vendor shall supply Cable glands and tinned copper lugs for equipments supplied by them.
Cable details of these cables shall be provided during detail engineering.

12.0 Approved Vendor List

Serial No Equipment/Component Makes

1 Motor-Induction-(MV flame Bharat Bijlee limited, Crompton Greaves ltd.,

proof) (Indigenous make) Kirloskar Electric Co ltd, Marathon Electric
Motor I ltd,

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2 Motors (MV-Flame Proof) –
Imported
3 Push button & indication lamp
(Indigenous make)
4 Meter (Indigenous make)
5 Selector switches (Indigenous
make)
6 Contactors (Indigenous make)
7 Fuses (Indigenous make)
8 Bimetal relays (Indigenous
make)
Asea Brown Boveri limited, Ansaldo Sistemi
Industrali Spa, Fuji Electric Co ltd, Hitachi ltd,
Jeumont SA / Framatone ANP, Loher gmbh,
Siemens AG, Toshiba Corporation, Weg
Exportadora SA.
Bhartia Industries ltd, Controls & Switchgears
Contactors ltd, Essen Deinki, Hotline
Switchgear & Controls, Larsen & Toubro ltd,
Precifine Products pvt. Ltd., Siemens limited,
Shri Tulsi Switchgears pvt ltd, Schneider
Electric India pvt ltd, Teknic Controls,
Automatic Electric ltd., Areva T & D India ltd
(T&D group), MECO Instruments pvt ltd,
Nippen Electrical Instruments co., Rishabh
Instruments pvt ltd,
Areva T & D India ltd (T&D group), Hotline
Switchgear & Controls, Kaycee Industries ltd.,
Larsen & Toubro ltd, Reliable Electronic
Components pvt ltd, Siemens limited, Switron
Devices
ABB ltd (Bangalore), Bhartia Industries ltd,
Control & switch gear contactors ltd, GE India
industrial pvt. Ltd, Larsen & Toubro ltd,
Siemens ltd, Schneider electric India pvt. Ltd,
Cooper Bussman India pvt ltd, GE India
industrial pvt. Ltd, Indo Asian Fusegear ltd,
Larsen & Toubro ltd, Siemens ltd
ABB ltd (Bangalore), Bhartia Industries ltd,
Control & switch gear contactors ltd, GE India
industrial pvt. Ltd, Larsen & Toubro ltd,
Siemens ltd, Schneider electric India pvt. Ltd
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Note:-

a) Vendor may procure material from any other approved equivalent vendors. However
workload, stability and solvency need to be verified by the Vendor before placement of order.

b) Vendor shall strictly follow the list of makes for Equipments as specified above.

c) Vendor can offer components of makes other than specified above during order execution.
The alternate make of components will be evaluated post order, based on the satisfactory track
record and test certificates to be furnished by the Vendor. In case the alternate makes are not
found acceptable, components shall be strictly as per above vendor list.

d) For equipment/components other than above, vendor shall submit past track record for the
proposed sub-vendors and obtain written approval from Owner before placing order.

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STANDARD
SPECIFICATIONS FOR
MEDIUM VOLTAGE
POWER DISTRIBUTION
PANEL

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SPECIFICATION OF MOTOR CONTROL CENTRE
1.0 SCOPE:

1.1 This specification covers requirements of medium voltage switchgear comprising of

main medium Voltage Switchboard , Motor Control Centre (MCC) required to distribute
power to the plant at medium voltage.

1.2 The drawing and specifications complement each other and what is shown or called for
one shall be interpreted as being called for on both. Material, if any, which may have
been omitted but which fairly implied as being required to make a complete assembly of
switchgear as shown on the drawing and specifications shall be construed as being
required and no extra charges shall be paid for this material.

1.3 Preparing Single Line Diagram (SLD) for the electrical system required for proper
function of Vapour Recovery System and obtaining approval of owner.

2.0 CODES AND STANDARDS:

2.1 The design, manufacture and performance of equipment shall comply with all currently
applicable BS/IS/IEC, statutory regulations and safety codes in the locality where the
equipment will be installed.

2.2 Unless otherwise specified, equipment shall conform to the latest applicable
BS/IS/IEC and in particular, the following:

CODES DESCRIPTION
IS : 2147 (1962) Degree of Protection provided by enclosure for low voltage
BS : EN 60947 switchgear
IEC : 144/IEC539
IS : 13703 (1993) HRC cartridge fuse link up to 650 Volt
BS : 88
IS : 13947 (1993) Specification for low voltage switchgear and control gear.
BS 5486
IEC : 157-1
IS : 4047 Heavy duty air break switches complete unit of air break
switches and fuses.
IS : 2208 HRC Cartridge fuse link.

IS : 2516 Air Circuit Breaker.

IS : 2959 A. C. Contactor up to 1000 Volts

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IS : 375 Marking and arrangement for switchgear busbar main
connection.
IS : 2705 (1992) Specification for current Transformers
BS : 7626
IEC : 185
IS : 3156 (1992) Specification for voltage transformer
BS : 7625
IEC : 186
IS : 1248 (1993) Specification for direct acting indicating analogue electrical
BS : 89 measuring instrument and their accessories
IEC : 51

CODES DESCRIPTION
IS : 8623 (1993) Specification for factory built assemblies of switchgear and
IEC : 439 control gear (up to 1000 Volts)
IS : 8544 (1977) AC motor starter of voltage not exceeding 1000V.
IEC : 292
IS : 3231 (1965) Specification for electrical relays for power system
BS : 142 protection
IEC : 255
IS : 5578 (1984) Guide for marking of insulated conductors
BS : 5253 Specification for alternating current isolators
IEC : 129 (disconnector) and earthing switches
IS : 3427 (1997) Specification for AC Metal enclosed switchgear and control
gear for rated voltage above 1 KV & up to & including 52
KV.
IS : 11353 (1985) Guide for uniform system for making & identification of
conductors & apparatus terminals.
IS : 2607 Air break isolator for voltages at 1000 volts.

3.0 GENERAL REQUIREMENTS (FOR IP PROTECTION IP-42):

3.1 All identical equipment and corresponding parts shall be fully interchangeable.

3.2 Switchgear shall comprise of floor mounted, metal enclosed compartmentalized modular
type vertical sections suitable for indoor application.

3.3 Switchgear Panel shall be dust and vermin proof and shall be easily extensible on both
sides.

3.4 All doors, panels, removable covers shall be gasket all around preferably with neoprene
gaskets.

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3.5 Each vertical section shall comprise the following:

3.5.1 Metal enclosed bus bar compartment running horizontally throughout the length of
switchgear.

3.5.2 Individual feeder modules in multi tier formation.

3.5.3 Shrouded vertical bus bars or individual feeder connections by 650V grad stranded
PVC insulated wires/strips.

3.5.4 Vertical cable alley with doors or covers covering entire height, if specified in enclosed
data sheet.

3.5.5 Horizontal wire way for control wiring, if required.

3.5.6 Space heater, if required.

3.5.7 Sheet steel between two adjacent vertical sections except for horizontal bus bar
compartment.

3.5.8 Separate door for each feeder module.

3.6 Metal enclosed unit shall comprise rigid structural frame enclosed by 2 mm thick
cold rolled sheet steel. Doors and covers shall be of 1.6mm thick cold rolled sheet steel.
Structural frame work with foundation bolts etc. shall be provided at the bottom to mount
switchgear directly on concrete/steel channel base.

3.7 Switchgear shall be provided with removable cable gland plate, brass cable glands and
crimping type cable lugs, if specified in data sheet.

3.8 Separate labels shall be provided for switchgear modules, relays, instruments,
switches, etc. Approval for the type of label shall be taken from the owner.

3.9 Control switches, push buttons, indicating lamps, meters and relays shall be mounted on
the front door. CT, VT, shall be mounted on fixed portion. For fully draw out / semi draw
out execution, all other equipment shall be mounted on with draw able chassis with
suitable guides for easy withdrawal.

3.10 Painting shall be carried out with seven tank process consisting of emulsion cleaning,
pickling with dilute acid, washing and rinsing by water, phosphate and oven drying. One
(1) coat of stoving type zinc chromate primer and two (2) coats of synthetic enamel
paint shall be applied.

3.11 Feeder control and motor control equipment not incorporating circuit breaker control
shall be of fully draw out, semi draw out or fixed type execution as specified in data
sheet.

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3.11.1 Fully draw out type with draw able chassis - All power and control connections shall be
of plug in type.

3.11.2 Semi draw out type with draw able chassis - All power connections shall be of plug in
type. All control connections shall be of screwing type.

3.11.3 Fixed type-both power and control connections shall be of bolted/screwed type. With
draw able chassis need not be provided.

3.12 Name plate of PVC acrylic sheet having white letter in black back ground, rear engraved
type, shall be provided for all feeders. Also each component of the switchgear shall be
provided with identification labels.

3.13 A trolley for raising and lowering breakers shall be provided with panel.

3.14 All inter panel wirings and external wiring connection shall be brought to cable alley
having terminal blocks adequately numbered & mounted on rails. Provision of rails with
extra terminal shall be kept.

3.15 The switch for any of the cubical shall isolate power and control wiring together.

3.16 It is proposed to connect a PLC in future for remote start/stop of the motors being
connected in the MCC panels. As such separate potential free contact to be provides for
start/stop trip and run feedback signal for each starter in the MCC panel.

3.17 Temperature rise calculation for PCC, ESB & MCC panels shall be furnished by the
successful tenderers prior to taking up fabrication of panels.

3.18 The rated frequency withstand voltage for control circuits shall be 1.5 KV for 1 minute.

3.19 The sheet steel enclosures for LDB’S and PDB’S shall be out of 14 gauges CRCA sheet
steel as indicated in specifications and schedule.

4.0 MAIN BUS BARS:

4.1 Main bus bars shall be of uniform cross section.

4.2 Wherever aluminum to copper connections is required, suitable bimetallic

connectors/clamps shall be used / provided.

4.3 Maximum temperature of bus bars and bus connections shall not exceed 85 deg. C.

4.4 Bus bars shall be air insulated. Bus bars shall be provided with heat shrinkable
insulating sleeve and phase color coded.

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4.5 Separate support shall be provided for each bus bar. If common support is provided for
all bus bars, anti-tracking barriers shall be incorporated and approval shall be obtained
for arrangement.

4.6 The temperature rise shall be 30 Deg C over ambient of 55 Deg C as per the sheets
furnished with tender.

5.0 CIRCUIT BREAKERS:

5.1 Air break fully draw out type circuit breakers shall consist of the following :

5.1.1 Shunt trip unit shall be provided (UV coil required).

5.1.2 Spare closing and tripping unit shall be provided.

5.1.3 Mechanical OPEN/CLOSE position indicator, visible with door closed.

5.1.4 Emergency trip push button.

5.1.5 '
Red'
,'Green'Blue and '
Amber'indicating lamps.

5.2 There shall be '

Service'
,'Test'and '
fully withdrawn' position for breakers.

5.3 It shall be possible to withdraw or engage breaker only in open position.

5.4 Compartment door of breaker shall not open unless breaker is in open position.

5.5 Automatic safety shutters shall be provided to cover live contacts when carriage is
withdrawn.

5.6 Releases shall have potential free alarm contacts.

5.7 Facility shall be provided for blocking under voltage release only for testing.

5.8 Manually operated mechanism shall be of spring charging stored energy type or spring
assisted type independent of the speed at which handle is operated.

5.9 Power operated mechanism shall be of motor wound spring charging stored energy type.
Emergency manual charging facility shall also be provided.

5.10 Stored energy mechanism shall have indicators to show '

charged'and '
discharged'
conditions of spring.

5.11 Operating mechanism shall be trip free.

5.12 Circuit breaker shall have an anti-pumping feature.

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5.13 Circuit breaker shall have slow closing and opening feature, for maintenance purpose.

5.14 It shall be ensured that circuit breaker body is grounded whilst it is racked-in into the
panel.

5.15 The panel shall be provided with DC power pack of suitable voltage rating for providing
control supply for closing, tripping & alarm/signal OF Air Circuit Breaker. 230V control
supply for closing, tripping & alarm/signal shall be tapped from any phase and neutral of
panel.

6.0 AIR BREAK SWITCHES:

6.1 Switches shall withstand short circuit current of value equal to the let through current of
associated fuse for 1 second and peak short circuit current equal to cut off current of
associated fuse.

6.2 Switches of motor feeders shall be of motor duty (AC23) operated, fault make, load
break type. All other switches shall be of heavy duty type.

6.3 Switch handle shall have padlocking facility in '

OFF'position.

6.4 It shall be possible to open the door only when switch is in off position and it shall not be
possible to close switch when door is open. It should be provided with Defeat Interlock
Facility.

6.5 Depending on interlocking logic - besides electrically controlled interlock, a mechanical

interlocking shall be provided in breaker.

7.0 Moulded case circuit breaker (MCCB):

7.1 It shall comply with IEC-947.

7.2 The MCCB shall be current limiting type suitable for 50 kA fault level.

7.3 All breakers up to 250A shall have thermal magnetic release with adjustable setting for
overload, short circuit and earth fault release.

7.4 Breakers with rating above 250A shall have static release with step less setting for
overload short circuit and earth protection.

7.5 The breaker shall be suitable for line load reversibility or horizontal and vertical mounting
without any derating.

7.6 The terminal of the MCCBs shall be suitable for copper/aluminum conductor cables.

7.7 Pad locking facility in OFF position.

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7.8 It shall be possible to open the door only when MCCB is in OFF position and it shall not
be possible to close MCCB when door is open.

7.9 It should be provided with door Interlock defeat facility only for testing purpose.

7.10 Auxiliary contacts for ON, Off and trip shall be provided.

8.0 MOTOR STARTERS:

8.1 Contactors

MCCBs shall be motor protection type with thermal and magnetic release. MPCB and contactor
combination shall conform to Type-2 co-ordination conforming to IEC-947. Contactor shall be air
break, double break single throw, and electromagnetic type. Main contacts shall be of silver
faced copper.
Minimum two NO and two NC auxiliary contacts shall be provided for each power contactor.
Minimum rating of power contactor shall be 25A & AC3 duty. All Contactors in Star Delta shall be
of equal rating.

For motors related to one product one of the motors will be provided with VFD to control speed
based on flow requirement. Other motors will be provided with Soft starters. Automation system
will automatically sequence motor start / stop and motor will VFD application based on flow
requirement. The logic for the same will be built in automation system.

Requirement of DOL / Star – Delta / VFD / Soft starter type of feeder is as per approved SLD.
No implication will be allowed on account of this.

9.0 THERMAL OVERLOAD RELAY:

9.1 Starters shall be complete with three elements, ambient temperature compensated, time
lagged; thermal overload relays with adjustable settings and shall have built in single
phasing preventer.

9.2 Thermal O/L relays shall be of hand-reset type. Hand reset push button separate from
stop push button shall be brought out in front of compartment door.

10.0 INSTRUMENT TRANSFORMERS:

10.1 CT and VT shall conform to the requirements of IS:2705(1992)/ BS7626//IEC185 and IS:
3156(1992)/BS:7625/BS 7625/IEC186 respectively. The rating specified are
indicative only and it shall be Contractor'
s responsibility to ensure that the ratings are
adequate for relays/meters application considering lead resistance etc.

10.2 CT/VTs shall be of cast resin type only.

10.3 Facility shall be provided for short circuiting and earthing the CT and terminal blocks.

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10.4 VT shall be provided with adequately rated primary and secondary fuse.

11 INSTRUMENTS:

11.1 Indicating instruments shall be of 96mm square size suitable for flush mounting.

11.2 Watt hour and KVar hour meters shall be suitable for 3 phase, 4 wire system,
suitable for semi flush mounting.

11.3 All digital meters shall be provided with MODBUS RS – 485 based communication
facility.

12 ELAYS:

12.1 Relays shall be suitable for flush mounting with connections from rear. Protective relays
shall be in draw out case. Only relay operation / trip indication to be provided on door.

12.2 Protective and tripping relays and timers shall be provided with hand reset flags.

13 MISCELLANEOUS ACCESSORIES:

13.1 Breaker control switch shall be :

- Spring return to neutral type with pistol grip handle.
- Provided with lost motion and sequencing device.
- Lockable in neutral position

13.2 Indicating lamps shall be of cluster LED type with suitable series resistor and
translucent lamp covers. Cluster type LED lamp shall have diameter of 22.5mm.

13.3 Push buttons shall be momentary contact type rated for 1A at 500V AC. The colour of
push buttons shall be as follows:

Start - Green
Stop - Red
Others - as per system requirement

14 INTERNAL WIRING:

14.1 All wiring inside switchgear shall be carried out with 650V grade PVC insulated copper
wires. Minimum size of conductor for control wiring shall be 2.5mm2.

Power connections for and above 63A shall be carried out with PVC insulated copper
links.

14.2 All wiring shall be terminated on terminal blocks with crimping type cable lugs of
appropriate type.

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14.3 Ferrules shall be provided on each wire. Control circuit shall incorporate a 2A DP MCB
for cutting of the supply.

15 TERMINAL BLOCKS:

15.1 Separate terminal blocks for power and control circuits shall be of 650V grade stud type.

15.2 Terminal blocks of different voltage groups shall be segregated and suitably labelled.

15.3 Terminals shall be numbered as per wiring diagrams.

15.4 Minimum 20% or min. 4 Nos. Spare terminals shall be provided.

16 EARTHING:

16.1 Copper earthing bus (in copper lugs) extending throughout the length of switchgear
shall be provided.

16.2 The earth bus bar shall be of sufficient cross section to carry safely momentary short
circuit and short time current for 1 sec.

16.3 All non-current carrying metal parts shall be effectively bonded to the earth bus.

16.4 All doors shall be bonded to earth, wherever electrical switchgear is mounted on door.

17 TESTS:

17.1 Contractor shall test switchgear as per BS/IS/IEC with all components assembled and
fully wired.

17.2 Following routine tests shall be carried out on all components and assembled switchgear
and as per relevant standards.

17.2.1 Mechanical and Electrical Operation test by stimulating site condition.

17.2.2 High voltage test (2.5 KV for one minute).

17.2.3 Test for verification of calibration of releases.

17.2.4 Insulation resistance test

17.2.5 Three (3) copies of routine and type test certificates along duly certified by the approved
third party agency shall be submitted for Owner’s approval before dispatch of switchgear.

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STANDARD
SPECIFICATION FOR
FLAMEPROOF POWER
PANELS

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CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 SITE CONDITIONS

4.0 CERTIFICATION

5.0 GENERAL REQUIREMENTS

6.0 COMPONENT SPECIFICATION

7.0 TESTING AND ACCEPTANCE

8.0 PACKING AND DESPATCH

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1.0 SCOPE

The intent of this specification is to define the requirement for the design, manufacture,
shop testing, packing and delivery of flameproof lighting and power panels.
2.0 CODES AND STANDARDS

2.1 The equipment shall comply with the latest edition of the following Indian / International
standards. Wherever Indian Standards are not available, relevant IEC / British Standards
shall be applicable.

IS : 2148 Flameproof enclosure of Electrical Apparatus

IS : 5571 Guide for selection of electrical equipment for hazardous areas.
IS : 8828 Specifications for miniature air break circuit breakers for voltages not
exceeding 1000 volts.
IS : 12640 Residual current operated circuit breakers.
IS : 13346 General requirements for electrical apparatus for explosive gas
atmospheres.
IS : 13947 L.V. Switchgear and controlgear.
IEC : 79 Electrical apparatus for explosive gas atamosphere.
(Applicable Parts)
The equipment shall also conform to the provisions of Indian electricity and other
statutory regulations as applicable.
2.2 Wherever the requirements in this specification are in conflict with any of the above
standards, the requirements under this specification shall be binding.

3.0 SITE CONDITIONS

The flameproof lighting and power panels shall be suitable for installation and
satisfactory operation in classified hazardous location in tropical, humid and corrosive
atmosphere as prevalent in Refineries / Petrochemical and Fertilizer plants or as specified
in the material requisition.
4.0 CERTIFICATION

All flameproof lighting and power panels shall be of a type already tested by CMRI
(Dhanbad) and approved by CCE/DGMS/DGFASLI (as required) for use in specified gas
group locations. BIS marking on the equipment is mandatory. Equivalent testing and
certification of the country of origin may also be acceptable for imported equipment.
However, these shall have valid CCE approval. Type test and approval certificates for
each type of lighting and power panels shall be furnished alongwith the offer.
5.0 GENERAL REQUIREMENTS

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5.1 Unless otherwise specified in the material requisition, all lighting and power panels shall
be flameproof type, suitable for gas group IIA & IIB as per IS:2148 and surface
temperature class T3 as per IS:13346.

5.2 The lighting and power panels shall have house the bus bars and other components in a
cast aluminium LM6 alloy, which shall be free from frictional sparking hazard.

5.3 Unless otherwise specified in material requisition all lighting and power panels shall be
suitable for 415V, 50HZ, three phase and neutral (TPN) incoming supply and outgoing
circuits for 240V, single phase and neutral (SPN).

For lighting and power panels falling under the jurisdiction of DGMS, the following
additional requirements shall apply.
The phase-to-phase voltage shall not exceed 250 volts.
The panels shall have 250V/144V, three phase, 3-wire system, without neutral.
Outgoing circuits shall be controlled by 2-pole MCBs. Earth leakage protection
shall also provide isolation in both poles.

5.4 Lighting and power panels shall be suitable for installation in outdoor areas and shall
have, at least, IP-55 degree of ingress protection.

5.5 Lighting and power panels shall be supplied with suitably sized cable entries, with ET
threads, for incoming and outgoing cables. Panels shall be complete with double
compression type nickel plated brass flameproof cable glands and crimping type tinned
copper lug. Number and size of cable glands for the lighting and power panels shall be as
required depending upon the number of incoming and outgoing cables.

5.6 Cable entry for all lighting and power panels shall be from the bottom only. Cable entry
size shall be decided by the vendor based on the cable sizes to be furnished post-order, by
owner.

5.7 Gaskets used in lighting and power panels shall be neoprene.

5.8 All internal wiring in lighting and power panels shall employ adequately sized, 660V
grade , PVC insulated copper conductor wires, colour coded for phase, neutral and earth,
with minimum conductor sizes as below:

Incomer : 10 mm2

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Outgoing : 2.5 mm2
5.9 Each outgoing feeder shall be provided with distinct terminals for phase, neutral and
earth. Sufficient terminals shall be provided such that not more than one outgoing wire is
connected to any terminal. 20% spare terminals shall also be provided on each terminal
block.

5.10 All the non current carrying metallic parts of the panel shall be inherently bonded
together. Earthing terminal of the outgoing circuits shall be bonded to the main housing.
Each lighting and power panel shall be provided with two earthing studs of 10mm
diameter, on the exterior of the panel enclosure for external earth connection.

5.11 Lighting and power panels shall be suitable for mounting on wall / column. All hardware
used shall be cadmium plated or zinc passivated.

5.12 All metal surfaces shall be thoroughly cleaned, degreased and made free from rust, before
the primer coat is applied. The under surface shall be made free from all imperfections
before undertaking the finishing coat. The final paint for the panel exterior shall consist
of two coats of epoxy based paint. Interior of the panels shall be given synthetic enamel
finish. Final paint of the exterior shall be dark grey, shade 632 as per IS:5, and of the
interior shall be glossy site.

5.13 A warning inscription “Isolate elsewhere before opening” shall be embossed, fixed with
screws or riveted on the top cover of the lighting and power panels.

5.14 Nameplate of each lighting and power panel shall carry the details of BIS license number,
CMRI test / CCE and DGFASLI approval certificate numbers, date of certification,
applicable gas group etc. a, alongwith the panel tag number. Panel tag numbers and final
cable sizes shall be informed to the successful bidder. Name plates shall be provided for
each incoming and outgoing feeder. Nameplate shall engraved on 3 ply black-white-black
lamicold sheets. Back engraved Perspex sheet nameplate shall also be acceptable.
Nameplates shall be fixed by screws by screw or rivers and shall not be pasted.

5.15 Requisite sets of special tools and tackles, such as Allen keys etc., recommended fort the
maintenance of the panels, shall form a part of the vendor’s scope of supply.

6.0 COMPONENT SPECIFICATION

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6.1 Incoming, outgoing cables shall be terminated in respective cable termination
compartments, which shall be distinct from incoming and outgoing feeder compartments.
Various compartments, if interconnected, shall employ certified flameproof bushings for
such interconnection, Flameproof sealing bushings shall be filled with epoxy or other
permissible sealing compound, after interconnecting wires are installed, so that no flame
propagation is possible between the two adjacent compartments.

6.2 Busbars in the lighting and power panels shall be made of high conductivity copper, and
shall be supported by non-hygroscopic insulators. Busbars shall be colour coded for
identification of phases and neutral. Individual compartments shall have separate
inspection covers secured by bolts which shall be openable only with special tools.

6.3 Incomer shall have MCB(40A min.) and ELCB combination (where specifically
indicated in MR). MCBs provided for incoming supply isolation shall be with 4-poles
and shall not have over-load and short-circuit releases. ELCBs shall have a maximum
sensitivity of 30 mA.

6.4 The outgoing feeders shall be with MCBs. MCBs provided for the outgoing shall be rated
16A / 10A, as specified in the material requisition. MCBs provided in the outgoing
circuits shall be or double pole type and shall be provided with overload and short-circuit
releases. MCBs shall be with 9 kA (M9 category) interrupting capacity. All incomer and
outgoing MCBs shall have mechanical ON / OFF indication.

6.5 Stud / clamp type terminals shall be provided in an independent cable terminal
termination compartment for connection of cables. Terminals shall be anti-loosening,
anti-vibration type and shall be suitable for termination of 2.5 mm2 copper conductor,
unless specified otherwise, in the material requisition.

6.6 Flameproof nickel plated brass sealing plugs shall be supplied, for plugging the unused
cable entries. The quantity of sealing plugs shall be equal to 20% of the total number of
outgoing cable entries.

6.7 The offered panels shall be exactly in conformity with the configuration tested by CMRI
and approved by CCE/DGMS/DGFASLI.

7.0 TESTING AND ACCEPTANCE

7.1 Routine and acceptance tests shall be conducted on the lightning and power panels,
accordingly to the relevant Indian Standards, at the manufacturer’s works under his care

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and expense. An advance four weeks notice shall be given to the owner to enable him or
his authorized representative to witness the tests. During the course of manufacture, the
owner or his authorized representative shall be free to visit the works and assess the
progress of work. The manufacturer shall render all assistance to the purchase or his
representative for doing the same.
7.2 Main acceptance tests shall be as follows:-

a) General visual inspection

b) Dimensional inspection
c) Verification of mechanical and electrical operations
d) Dielectric tests.
e) Insulation resistance test before and after high voltage test.

Owner’s representative may verify or check the test reports / drawings certified by
CMRI, as well as, test reports of sub-vendors, where applicable.

8.0 PACKING AND DESPATCH

8.1 Cable entries shall suitably plugged before packing.

8.2 The lighting and power panels shall be shipped to site packed in wooden crates. Lighting
and power panels shall be wrapped in polyethylene sheets before packing in crates to
prevent damage the finish. The crates shall be provided with skid bottom for ease of
handling. Special notations such as, ‘Fragile’. This side up’, ‘Centre of gravity’. ‘Weight’
etc., shall be clearly marked on the package together with Tag number, PO number etc.

8.3 The equipment may be stored outdoors for long periods before erection. The packing
shall be completely suitable for outdoor storage in areas where heavy rain and ambient
temperature are encountered.

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STANDARD
SPECIFICATONS FOR
FLAMEPROOF CONTROL
STATIONS

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CONTENTS
1. SCOPE

2. CODES AND STANDARDS

3. SITE CONDITIONS

4. CERTIFICATION

5. GENERAL REQUIREMENTS

6. COMPONENT SPECIFICATION

7. TESTING AND ACCEPTANCE

8. PACKING AND DESPATCH

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1. SCOPE

The intent of this specification is to define the requirement for the design, manufacture,
shop testing, packing and delivery of flameproof control stations.
2. CODES AND STANDARDS

2.1 The equipment shall comply with the latest edition of the following Indian / International
standards. Wherever Indian Standards are not available, relevant IEC / British Standards
shall be applicable.

IS : 2148 Flameproof enclosure of Electrical Apparatus

IS : 5571 Guide for selection of electrical equipment for hazardous areas.
IS : 13947 L.V. Switchgear and Controlgear.
IS : 13346 General requirements for electrical apparatus for explosive gas
atmospheres.
IEC : 79 Electrical apparatus for explosive gas atamosphere.
(Applicable Parts)

The equipment offered shall also conform to rules and regulations of Fire Insurance
Authority.
2.2 Wherever the requirements in this specification are in conflict with any of the above
standards, the requirements under this specification shall be binding.

3. SITE CONDITIONS

The equipment shall be suitable for installation and satisfactory operation in classified
hazardous location in tropical, humid and corrosive atmosphere as prevalent in Refineries
/ Petrochemical and Fertilizer plants or as specified in the material requisition.
If not specifically mentioned therein, a design ambient of 40o C and an altitude not
exceeding 100 m above mean sea level shall be considered.

4. CERTIFICATION

All control stations shall be of a type already tested by CMRI (Dhanbad) and approved
by CCE/DGMS/DGFASLI (as required) for use in specified gas group locations. BIS
Marking is mandatory . Equivalent testing and certification of the country of origin may
also be acceptable for imported equipment. Type test certificates for each type of control
station shall be furnished alongwith the offer.
5. GENERAL REQUIREMENTS

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5.1 Unless otherwise specified in the material requisition, all control stations shall be
flameproof type, suitable for gas group IIA & IIB as per IS:2148 and surface class T3 as
per IS:13346.

5.2 The control stations shall have housing of cast aluminium LM6 alloy and shall be free
from frictional sparking hazard.

5.3 Unless otherwise specified in material requisition all control stations shall be suitable for
240V AC as well as for 110V/220V DC control supply.

5.4 It shall be suitable for installation in outdoor areas and provided with IP-55 degree of
protection. Unless otherwise specified in the material requisition, all control stations shall
also be provided with canopy for additional protection against rain. The canopy shall be
made of atleast 14 SWG (2mm) galvanized sheet steel.

5.5 Each control station shall be provided with 2 Nos. Cable entries and shall be supplied
alongwith 1 No. suitably sized flameproof Nickel plated brass cable gland and 1 No.
Flameproof brass sealing plug.

5.6 Cable entry for all control stations shall be from the bottom. Entry size either be ¾” ET
or 1” depending on the overall diameter of cable which shall be informed to successful
bidder.

5.7 All control stations shall be provided with Neoprene gaskets.

5.8 All internal wiring shall be done with min. 2.5 mm2 copper conductor wires.

5.9 Sufficient terminal shall be provided such that not more than one outgoing wire is
connected to any terminal. 20% spare terminals shall also be provided with a min. of two
Terminals.

5.10 All control stations shall be provided with two Earthing studs on the external surface of
the enclosures suitable for connection of 8 SWG GI wire connection.

5.11 Control stations shall have external fixing lugs for mounting on wall or column. The
holes provided on these lugs shall be of oblong type. All mounting accessories like nuts,
bolts, washers, screws etc. shall be of cadmium plated.

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5.12 All metal surfaces shall be thoroughly cleaned and a primer coat is applied. The under
surface shall be made free from all imperfections before undertaking the finishing coat.
The equipment shall be given a final paint finish with two coats of epoxy based final
paint. Unless otherwise specified, final paint shade shall be 632 as per IS:5.

5.13 The warning inscription “Isolate elsewhere before opening” shall be embossed on the top
cover of the control station.

5.14 A nameplate including certificate No., date, gas etc. shall be provided for each control
station. The nameplate details indicating the equipment operated shall be supplied to the
successful bidder. Nameplates shall be engraved on 3 ply black lamicold sheets using
square cutters. Black engraved Perspex sheet nameplate shall also be acceptable
Nameplates shall be fixed by screws and shall not be pasted.

6. COMPONENT SPECIFICATION

Push buttons for start and stop shall be of green and red colour respectively. Each push
button unit shall have one normally open and one normally closed contact and all units
shall be identical and interchangeable. Stop push button shall be mushroom type with
stay put feature and lockable in pressed position. Additional NO/NC contacts shall be
provided if specified in the MR.

All selector switches shall have minimum two poles and three positions for
Auto/Off/Manual or Local-Off-Remote and six terminal shall be provided for each
selector switch, unless otherwise stated.

All ammeters shall be of moving iron type having an accuracy class of 1.5 and suitable
for 1 ampere CT secondary. Unless otherwise specified, min. size of ammeter shall either
be 72 mm x 72 mm or min. 65 mm dia. 80 % of the scale length shall cover 100% of the
CT primary current uniformly and the balance 20% of the scale shall cover 100-600 % of
the CT primary. A red mark corresponding to the full load current of the motor shall be
provided on the ammeter dial. The ammeter front glass shall be toughened (type ‘A’
glass). Primary ratings of C.T.s shall be given to successful bidder.

Control stations for circuit breaker control shall have a pistol grip handle and shall be
three position rotary control switch. Three positions shall be START – NEUTRAL –
STOP with spring return to neutral both from start and stop positions. Three positions of

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switch shall be indelibly marked on the control station. Each control switch shall have
minimum three ways or as specified in the material requisition.

All contacts shall be rated for min. 5 Amps at 240 V AC, 0.25 p.f. or 1 Amps, 220 V DC.

Indicating lamp(s), if specified in the MR shall have translucent cover preferably flush
with the front surface.

7. TESTING AND ACCEPTANCE

The control stations shall be tested according to the relevant Indian Standards at
manufacturer’s works under his care and expense. Four weeks advance notice shall be
given to the purchaser to enable him or his authorized representative to witness the tests.
During the course of manufacture the purchaser or his authorized representative shall be
free to visit the works and assess the progress of work and the manufacturer shall render
him all possible assistance to do so.
Main acceptance tests shall be as follows:-
f) General visual inspection
g) Dimensional inspection
h) Verification of mechanical and electrical operations
i) Dielectric tests.

Purchaser’s representative may verify or check the test reports of sub-vendor where
applicable.
8. PACKING AND DESPATCH

The equipment shall be shipped to site packed in wooden crates. They shall be wrapped
in polyethylene sheets before being placed in crates to prevent damage the finish. The
crates shall have skid bottoms for handling.

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STANDARD
SPECIFICATION FOR
FLAMEPROOF
EQUIPMENTS

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CONTENTS

1. SCOPE

2. CODES AND STANDARDS

3. SITE CONDITIONS

4. CERTIFICATION

5. GENERAL REQUIREMENTS

6. EQUIPMENT DETAILS

7. TESTS AND ACCEPTANCE

8. PACKING AND DESPATCH

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1. SCOPE

The intent of this specification is to define the requirements for the design, manufacture,
shop testing, packing and delivery of flameproof and weatherproof plugs, sockets and
hand lamps.

2. CODES AND STANDARDS

2.1 The equipment shall comply with the latest edition of the following Indian / International
Standards. Wherever Indian Standards are not available relevant IEC / British Standards
shall be applicable.

IS : 2148 : Flameproof enclosures for electrical apparatus.

IS : 13346 : General requirements for electrical apparatus for explosive gas

atmospheres.

IS : 13947 : LV Switchgear and controlgear.

IS : 5572 : Classification of hazardous areas (other than mines) for electrical

Part – 1 installation – Areas having flammable gases & vapours.

(Applicable parts)

IEC : 309 : Plugs, socket outlets, connectors and appliance inlets for use in
Part - 3 explosive gas atmosphere.

2.2 Wherever the requirements in this specification are in conflict with any of the above
standards, the requirements under this specification shall be binding.

3 SITE CONDITIONS

The equipment shall be suitable for installation and satisfactory operation in classified
hazardous locations in tropical, humid and corrosive atmosphere as prevalent in
Refineries / Petrochemical and fertilizer plants or as specified in the material requisition.

If not specifically mentioned therein, a design ambient temperature of 40o C and an

altitude not exceeding 1000 m above mean sea level shall be considered.

4 CERRIFICATION

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All offered equipment shall be of a type already tested by CMRI (Dhanbad) and approved
by CCE/DGMS/DGFASLI (as required) for use in specified gas group locations. BIS
marking is mandatory. Equivalent testing and certification of the country of origin may
be acceptable for imported equipment. Type test certificates for each type of offered
equipment shall be furnished alongwith the offer.

5 GENERAL REQUIREMENTS

5.1 The equipment shall be suitable for installation in outdoor areas and provided with a
degree of protection IP 55.

5.2 Unless otherwise stated in the material requisition the equipment shall be suitable for gas
groups IIA & IIB as per IS: 2148 and surface temperature Class T3 as per IS : 13346.

5.3 The name plates shall be provided on the equipment as per IS: 13346.

5.4 The equipment shall be finished with two coats of epoxy base final paint. Unless
otherwise specified final paint shade shall be 632 as per IS : 5.

5.5 The equipment shall be of cast aluminium LM-6 alloy and shall be free from frictional
sparking hazard.

5.6 Selection, sizing and suitability of all components used for various applications shall be
vendor’s responsibility and rating of the components shall be increased if required to suit
associated components.

5.7 All equipment shall have bottom cable entry unless otherwise specified and shall be
supplied with flameproof and weatherproof double compression brass cable glands.

5.8 The gaskets provided in the equipment shall be of synthetic rubber and all the hardware
shall be cadmium plated.

5.9 The equipment shall be provided with set of special tools if required and necessary
accessories for safe operation.

6 EQUIPMENT DETAILS

6.1 Socket Outlets & Plugs

6.1.1 Flameproof sockets shall be provided with a switch a mechanical interlock so as to break
the electrical circuit before the plug is completely withdrawn and make the circuit after
the plug is fully inserted.

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6.1.2 In order to prevent accidental removal of plug from socket, the engagement and
disengagement shall be by two separate and distinct movement & positions.

6.1.3 415 V, 63 A, three phase flameproof plug and socket meant for welding receptacle / any
other three phase auxiliary loads shall be provided with either 6 pins (3P+E) or 5 pins
(3P+N+E) as specified in the material requisition.

6.1.4 4 pin socket shall be provided with 63 A, three pole heavy duty switch whereas 5 pin
socket shall be provided with four pole (TPN) heavy duty switch.

6.1.5 Both 24 V and 240 V, 15 A single phase flameproof plug and socket shall be provided
with 3 pins (2P+E).

6.1.6 Provision shall be made so that it shall not be possible to insert 24 V plug on to a 240 V
socket.

6.1.7 Each outlet shall be provided with either a spring loaded hinged cover, or with a cap
connected through metallic chain, to close the outlet when not in service.

6.1.8 All internal power wiring shall be done with 660 V-grade PVC-insulated copper wires of
suitable size.

6.1.9 Stud type terminals of suitable size shall be provided for all outgoing and incoming
cables.

6.1.10 All sockets shall be suitable for two cables entries with looping facility and shall be
provided with two flameproof double compression brass cable glands and onw
flameproof brass sealing plug per socket to seal the unused cable entry.

6.1.11 24 V socket outlet unit shall be provide with built in 240 V / 24 V transformer. The
transformer shall be designed for 100 VA rating on continuous basis. HRC fuses shall be
provided on primary and secondary side of the transformer. The transformer shall have an
earthed screen between primary and secondary winding. The socket outlet unit with built
in transformer, switch, fuse, internal wiring shall be flameproof as a complete assembly.

6.1.12 All units shall be provided with one internal & two external earthing terminals.

6.1.13 Scraping earth connection shall be provided between the plug and socket. Earth pin of
plug shall first engage with earth pin of switch socket.

6.1.14 The plug assembly shall be mechanically rugged, light and shall not unduly stress the
socket or its own pins when fitted on to the socket.

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6.1.15 Each socket outlet unit shall have suitable mounting frame / bracket to facilitate
installation on vertical surface of wall / structure.

6.2 24 Volt Hand Lamps

6.2.1 The lamp holder of the hand lamp shall be suitable for 6 W, 24 V, 50 Hz, lamp with ES
cap.

6.2.2 The metal casting of the hand lamp shall be corrosion resistant Aluminium alloy LM 6.

6.2.3 Suitable handle for carrying hand lamp and a stand type guard suspension hook shall be
provided.

6.2.4 The well glass provided shall be clear, suitably for use under conditions involving
exceptional risk of mechanical damage. Mechanical strength of well glass shall satisfy
requirement of IS: 2206 (for type A glass).

6.2.5 Hand lamp shall be provided with a galvanized steel wire protective cage having mesh
dimension not exceeding 50 mm.

6.2.6 Each hand lamp shall be supplied complete with 50 m length of 3x1.5 mm2 copper
conductor, PVC insulated, metal braided flexible cable duly terminated in the hand lamp
while the loose end shall be used for termination in 24V plug.

7 TESTS AND ACCEPTANCE

During fabrication, the equipment shall be subjected to inspection by OWNER’S

REPRESENTATIVE / Owner or by an agency authorized by the owner. Manufacturer
shall furnish all necessary information concerning the supply to OWNER’S
REPRESENTATIVE / Owner’s inspector. Tests shall be carried out at manufacturer’s
works under his care and expense. 4 weeks’ prior notice shall be given before date of
commencement of tests for witnessing by OWNER’S REPRESENTATIVE / Owner’s
authorized representative. All equipment shall be routine tested as per relevant standards
and certified test results shall be furnished.

8 PACKING AND DESPATCH

The equipment shall be shipped to site packed in wooden crates. They shall be wrapped
in polyethylene sheets before placed in crates to prevent damage to the finish. The crates
shall have skid bottoms for handling.

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